Service Manual of G9190

G9190 Grader Service Manual
880×1230 mm 16# 18pieces

1st Edition in 2014. 3 1st Print
SHANDONG LINGONG CONSTRUCTION

MACHINERY CO.，LTD
Address: Linyi Economic Development Zone

Tel: 86-0539-8785688
Fax: 86-0539-8785698
Postal code：276023
Website：www.sdlg.cn
Services Tel：8008607999 4006587999 0539-8785800
Services Fax：86-0539-8785671
Service Manual of G9190 Grader
Contents
Safety and Environment ..................................................................................................................................... 1
0 Overview .................................................................................................................................................... 0-1
1 Repair and Maintenance ...................................................................................................................... 1-1
11 Oil, Coolant, and Others ...................................................................................................................... 1-1
12 Choice of Fuel/Oil ............................................................................................................................... 1-4
13 Repair .................................................................................................................................................. 1-8
2 Engine system ........................................................................................................................................... 2-1
21 Overview ............................................................................................................................................. 2-1
22 Lubrication System.............................................................................................................................. 2-8
23 Fuel Supply System ....................................................................................................................... 2-10
24 Cooling System ................................................................................................................................. 2-13
25 Intake and Exhaust System ................................................................................................................ 2-16
26 Disassembly and Assembly of Engine .............................................................................................. 2-18
27 Disassembly and Assembly of Fuel Tank .......................................................................................... 2-37
28 Disassembly and Assembly of Radiator ............................................................................................ 2-41
29 Common Malfunctions and Troubleshooting of Engine ................................................................... 2-45
3 Electrical and information system ............................................................................................................ 3-1
31 Electrical system introduction ............................................................................................................. 3-1
32 Electrical principles and failure analysis ........................................................................................... 3-18
33 Grader harness layout ........................................................................................................................ 3-62
4 Powertrain .................................................................................................................................................... 4-1
41 Hydraulic torque converter-gearbox assembly .................................................................................... 4-2
42 Drive shaft assembly ......................................................................................................................... 4-23
43 Drive axle and balance box assembly................................................................................................ 4-27
44 Common faults of grader powertrain and troubleshooting ................................................................ 4-35
5 Braking system ....................................................................................................................................... 5-1
51 Service Parking System ....................................................................................................................... 5-1
52 Parking brake..................................................................................................................................... 5-19
I
53 Troubleshooting of braking system .................................................................................................... 5-22
6 Steering system ......................................................................................................................................... 6-1
61 System Overview ................................................................................................................................ 6-1
62 Description and Disassembly/Installation of Main Units ..................................................................... 6-6
63 Pressure Measuring Point and Criterion of Steering System ............................................................. 6-42
64 Bleeding Air from Steering System ................................................................................................... 6-43
65 Steering system troubleshooting guide............................................................................................... 6-44
7 Frame, Wheels, and Working Device ........................................................................................................... 7-1
71 Overview of Frame and Working Device ............................................................................................. 7-1
72 Disassembly and Assembly of Front Mouldboard ............................................................................. 7-10
73 Disassembly and Assembly of Frame Joint........................................................................................ 7-13
74 Disassembly and Assembly of Front and Rear Wheels ...................................................................... 7-21
75 Disassembly and Assembly of Middle Working Device .................................................................... 7-27
76 Disassembly and Assembly of Rear Ripper ....................................................................................... 7-45
77 Common Malfunction Causes and Troubleshooting .......................................................................... 7-50
8 Cab and Covering Parts System ................................................................................................................ 8-1
81Overview of Cab ................................................................................................................................... 8-1
82 Description of A/C System................................................................................................................. 8-16
83 Disassembly and Assembly of Cab Assembly ................................................................................... 8-20
84 Disassembly and Assembly of Engine Hood ..................................................................................... 8-33
85 Disassembly and Assembly of A/C System ....................................................................................... 8-38
86 Diagnosis and Troubleshooting for Common Malfunctions of A/C System ...................................... 8-59
9 Working Hydraulic System ....................................................................................................................... 9-1
91 System Overview ................................................................................................................................. 9-1
92 Principle and Disassembly/Assembly of Main Units ......................................................................... 9-11
93 Pressure Measuring Point and Criterion of Working Hydraulic System ............................................ 9-71
94 Air Bleeding of Hydraulic System ..................................................................................................... 9-72
95 Malfunction Diagnosis of Working Hydraulic System ...................................................................... 9-73
II
Contents
Safety and Environment ................................................................................................................ 1
Preface ...........................................................................................................................................1
Safety is related to everyone .........................................................................................................1
Guidelines......................................................................................................................................3
Electromagnetic environment compatibility ............................................................................3
Cab rollover protection structure (ROPS) ................................................................................3
Noise limitation ........................................................................................................................4
Safety during Handling of Machine ..............................................................................................5
Some Simple Safety Rules .......................................................................................................6
Before Operations ....................................................................................................................7
Seat belt ....................................................................................................................................8
During running of engine .........................................................................................................9
In event of rollover danger .....................................................................................................10
Falling object..........................................................................................................................10
Towing and tow-start .............................................................................................................10
Safety rules during repair and maintenance ................................................................................ 11
Before any repair or maintenance work: ................................................................................ 11
Maintenance position .............................................................................................................12
Operation Safety of Tires ............................................................................................................14
Air inflation ............................................................................................................................14
Installation of tire and wheel rim ...........................................................................................15
Repair of tires and wheel rims ...............................................................................................15
Operation Safety of Battery.........................................................................................................16
Battery Charging ....................................................................................................................17
Start with Booster Battery ......................................................................................................18
Handling Safety of Oils ...............................................................................................................19
Operation Safety of A/C Refrigerant ...........................................................................................20
Personal protection devices ....................................................................................................21
Measures in event of accident: ...............................................................................................22
I
Operation Safety of Accumulator ............................................................................................... 23

Safety of Hydraulic System ...................................................................................................... 24
Relief of pressure (Release of pressure) ................................................................................ 25
Fire Prevention Measure ............................................................................................................. 26
Cleanliness ............................................................................................................................. 27
Electric system....................................................................................................................... 28
Welding and Grinding ........................................................................................................... 28
Checking after Fire Accident or High Temperature.................................................................... 29
Health Hazard of Paints, Plastics, and Rubbers .......................................................................... 30
Working on painted surfaces ................................................................................................. 30
Rubbers and plastics .............................................................................................................. 31
Fluororubber .......................................................................................................................... 32
Environment ............................................................................................................................... 34
Waste Treatment .................................................................................................................... 34
Engine oil and fluids .............................................................................................................. 35
Chemicals .............................................................................................................................. 36
Rubbers and plastics .............................................................................................................. 36
Electronic units ...................................................................................................................... 36
Works in contaminated environment..................................................................................... 37
Decontamination after leakage/splashing .............................................................................. 37
Decontamination after accidents ........................................................................................... 37
II
Safety and
Environment
Preface
This manual is one part of the entire
Maintenance Manual of G9190 Grader. Please
carefully read the contents of this part.
Warning:
Make sure to firstly read the section “Safety”
in the manual before the operations.
Safety is related to everyone

Always abide by the instructions of the
Operation and Maintenance Manual of G9190
Grader attached in the machine. This manual is
supplemental with the Operation and
Maintenance Manual of G9190 Grader.
SDLG designs and manufactures safe and
efficient machines. However, our endeavors will
come to naught if the operator of our machines
fails to carefully read or abide by the safety
instructions, such as climbing up or down the
slip machine parts without use of ladder,
grasping the hoses instead of handrail, or use
incorrect tools not intended for the specific
operation.
To maintain the safe and effective functions of
the machine, make sure to always use
1
appropriate spare parts designed especially for
this machine (genuine parts from Shandong
Lingong Construction Machinery Co., Ltd.). Our
company (Shandong Lingong Construction
Machinery Co., Ltd.) will not be liable for the
damages of machine nor provide warranty
compensation arising from the use of spare parts
other than the genuine parts from Shandong
Lingong Construction Machinery Co., Ltd.).
The working personnel shall bear the safety
consciousness and fulfill the maintenances of
machine, in order to ensure safety and
effectiveness and bring in profit. If failing to
abide by the safety operation instructions or pay
attention to the “warnings” in this manual, the
operator shall ensure that own operation method
is safe and reliable. Otherwise, there is a danger
of accident or even danger leading to injury
accident.
Warning Symbol:
This symbol appears along with the specific
key points and warning texts in this manual
and is intended for “Warning! Please be
alerted of your life safety!”.
2
Guidelines
Electromagnetic environment
compatibility
The electric devices on this machine will
probably cause interference on other electric
devices under certain conditions or will be
interfered by external electromagnetic wave to
cause safety problems.
Our machines have passed the special tests of
electromagnetic wave interference. All other
electric devices installed on this machine must
pass the electromagnetic interference tests.
Cab rollover protection structure

(ROPS)
It’s prohibited to conduct any unauthorized
modification on the rollover protection structure
(ROPS), such as the reduction of roof height,
drilling, welding on fire extinguisher bracket and
radio antenna bracket or other device. The
similar unauthorized modification will probably
impair the strength of rollover protection
structure (ROPS) and forfeit the conformity
certificate. The rollover protection structure
(ROPS) has passed the following test and met
the requirements of ISO 3471. The roof of the
cab has passed the strength test and met the
falling object protection structure (FOPS)
3
requirements of ISO 3449.
All modification plans to the weight carrying
structure of cab must be consulted with
Shandong Lingong Construction Machinery Co.,
Ltd. in advance, in order to ensure that the
qualified performances of the machine will not
be impaired. One important point is that all
personnel within your organization, including the
management personnel, shall fully understand
the relevant regulations of the rollover protection
structure (ROPS). If anyone within your
company finds out a modified machine without
permission, your company should notify the
customer and manufacturer in written of which
machine and what type of modification.
Noise limitation
For the noise level load regulations at the driver
seat, the vibration value of the driver seat is
1.22m/s2 for the light-duty operator and
1.25m/s2 for heavy-duty operator.
It’s prohibited to modify or disassemble any
material influencing the noise level, such as the
sound insulation, sound reduction, and sound
absorbing materials. In addition, it’s prohibited
to cut hole/opening in the cab or engine
compartment, or it will increase the noise within
the cab.
4
Safety during Handling of

Machine
Shandong Lingong Construction
Machinery Co., Ltd. is only liable for the
following conditions:
• This machine is used and maintained •
correctly as per the instructions in Repair
Manual of G9190 Grader and the
Operation and Maintenance Manual of
G9190 Grader.
• The specified maintenances and checking
are fulfilled at specified intervals.
• The lubrication instructions of the
machine specified in the manual are abode
by.
• No safety seal is ever opened by
non-authorized personnel.
• All maintenance and repair works are
fulfilled as per the manners specified by
our company (SDLG).
• Only the genuine parts/accessories or
additional devices meeting the
requirements of our company (SDLG) are
used.
Warning:
The driver of the machine must
sufficiently understand and master the
contents of Operation and Maintenance
5
Manual of G9190 Grader before the
operations of the machine.
It’s of great importance for the driver to
carefully read and abide by the
instructions of Operation and
Maintenance Manual of G9190 Grader.
It will lead to serious injury accidents if
the machine is driven by non-trained
personnel.
It’s prohibited to operate the machine
without Operation and Maintenance
Manual of G9190 Grader
Understand the warning labels, symbols,
and instructions on the machine before
using the machine.
Some Simple Safety Rules

• All malfunctions or problems impairing the
safety shall be resolved as soon as possible.
• Always wear the protective helmet, goggles,
gloves, protective boots, and other safety
equipment required for your works.
• Avoid standing in the front or rear side of
the machine while the engine is running.
• While cleaning the outer side of the
windows, always use long-shank rubber
window scraper or brush, in order to prevent
unnecessary climbing up or down the
6
machine.
• Keep clean the foot plate surfaces,
maintenance site, handrails, and anti-slip
protective parts, without any engine oil,
diesel, sludge, or ice/snow, and ensure the
timely repair and replacement when such
parts are damaged or lost.
• Periodically check all anti-slip protective
parts for secure fixing. If not, take fixing
measure or replace.
• Always face towards the machine and use
the foot plates and handrails to climb up or
down the machine. Always ensure 3-point
contact, namely two hands + one foot or two
feet + one hand. Do not jump up or down the
machine.
Figure 1 Access of Machine Before Operations
Some important rules are as below:
• Implement all safety checking measures
described in the Operation and Maintenance
Manual of G9190 Grader.
Warning:
Do not drive the machine whenever you
feel tired or are influenced by alcohol,
medicine, or other drugs.
• Before starting the engine indoors, ensure
the sufficient ventilation. This machine is
fitted with one diesel engine and its exhaust
7
gas is harmful to your health. Therefore,
ensure the sufficient ventilation. In event of
insufficient ventilation, run the engine only
when it’s absolutely necessary.
• Before operations or conducting any repair
or maintenance works on the machine, read
all nameplates and instructions on the
machine and the instructions in the
Operation and Maintenance Manual of
G9190 Grader. Every label contains
important information related to safety,
treatment method, and repair and
Figure 2 Reading Operation and maintenance.

Maintenance Manual of G9190 Grader • Fasten the seat belt in all operations.
before Operations of Machine
• Always sit in the driver seat to start the
engine.
• All functions must be intact and effective,
namely all malfunctions probably leading to
accidents are resolved, before putting the
machine into operation.
• It’s absolutely prohibited to use the machine
without ventilation device for a long period
nor operate within an completely enclosed
cab without turning on the fan (in order to
prevent hypoxia).
Seat belt
• If it’s necessary to clean the seat belt, use
mild soapy water, air dry under fully
8
stretched state, and then retract the seat belt.
Ensure the correct installation of the seal
belt.
• If the seat belt is worn or is subject to force
application during the accident of machine,
immediately replace the seat belt.
• It’s absolutely to modify the seat belt or its
mounting parts.
• The seat belt is designed for one adult and
not intended for use by multiple persons.

Figure 3 Fastening Seat Belt during All
• The seat belt shall always be under retracted
Operations
state when it’s not in use.
During running of engine
• Pay attention to the warning lamps. In event
of red warning lamp, immediately take
measures or pay more attention. Please refer
to the instructions in section “Instruments”
of Operation and Maintenance Manual of
G9190 Grader.
• Before leaving the machine, make sure to
place the control levers and handles to
neutral position. Shift the gearshift control

Figure 4 Placing Control Lever at lever to neutral gear.
Neutral Position
Warning:
Risks of serious injuries.
• Do not stand near the frame joint, unless it’s
already locked by the frame joint lock.
• Before leaving the machine with machine
9
unattended, stop the engine.
In event of rollover danger

• This cab features the protection function for
operator and conforms to the standard of
rollover protection structure (ROPS). Please
refer to the Guidelines - Cab Rollover
Protection Structure for further descriptions.
The precondition for the protection is that
the seat belt is fastened by the operator.
Therefore, hold tightly the steering wheel in
event of rollover of this machine.
Warning:
Do not jump off the machine.
Falling object
• The structural sizes of this cab meet the
requirements of cab falling object protection
structure (FOPS).
Towing and tow-start

• Towing
If the grader is being towed, shift the
gearshift control lever to neutral gear (N). If
possible, run the engine so that the steering
and brake assist device are still functional. If
the grader is being towed by wire rope, it’s
prohibited for anyone to stay between the
tractor and the grader.
• Tow-start
10
Because of the torque converter, it’s
impossible to start the grader by towing, as
the tow-start will damage the transmission.
Safety rules during repair and

maintenance
This part includes the general safety rules during
checking and maintenance.
Other rules, consultation, and warning texts are
provided in Operation and Maintenance of
G9190 Grader.
Before any repair or maintenance work:
It’s really dangerous to implement any repair or
maintenance work incorrectly.
Ensure that you have sufficient knowledge,
correct information, appropriate tools, and
complete equipment to correctly fulfill the repair
and maintenance works.
• If someone is to take over your repair works,
ensure that the detailed work progress
(namely how much has been fulfilled and
how much is to be fulfilled) is provided.
• While cleaning the machine with high
pressure water, do not point the nozzle
directly to the anti-slip surface with anti-slip
coating or labels affixed on the machine.
Warning:
Only use the special foot plate surfaces to
11
walk on the machine or climb up or down
the machine. Please refer to Operation
and Maintenance Manual of G9190
Grader.
• While working on the machine, do not wear
loose articles that will be probably clamped
on the machine, such as headscarf and
jewelry, in order to prevent personal
injuries.
• Always wear the protective helmet, goggles,

Figure 5 Wearing Labor Protective
gloves, protective boots, and other safety
Devices
equipment required for your works.
• Always keep the engine stopped during the
repair or maintenance of the machine, unless
otherwise specified on the signal symbols
and nameplate on this machine or in this
publication.
• Stop the engine before opening the engine
hood, radiator water tank, or similar part.
Ensure that there is no tool or article that
will probably cause damage left on the
machine.
• Keep the engine hood closed during the
running of the engine and the working of the
machine.
Maintenance position
1. Park the machine on a horizontal and solid
surface and place it at maintenance position,
12
as shown in the figure below.
2. Lowe the working devices (blade and
mouldboard) onto the ground.
Figure 6 Maintenance Position of

3. Stop the engine, withdraw the ignition key,
Grader
and pull up tightly the handbrake.
4. Affix the warning flag and fix the articulated
steering mechanism of grader.
5. Securely support the working devices if it’s
necessary to hang them in the air.

No Operation
6. It’s prohibited to tighten the connectors in
the system when the hydraulic system
contains pressure.
Figure 7 Affixing of Warning Flag
7. Block the rolling of wheels, such as use of
wedges.
8. Turn off the battery cutoff switch.
9. Cool down the machine
Warning
• If the pressure is not relieved before the

opening of the system, the oil will spray
13
out under high pressure to cause serious

personal injuries. Relieve the pressure
from pressurized pipeline and oil tank, in
order to prevent the safety accidents.
• If it’s necessary to operate on the machine
before it’s cooled down, pay special
attention to hot fluids and machine parts,
in order to prevent scalding.
Operation Safety of Tires

Warning:
It will probably cause explosion and lead
to serious injuries while inflating the tires
installed on wheel rims.
Air inflation
• Do not stand on one side of the tire while
inflating a tire installed on the wheel rim.
During the air inflation, use one air cock
capable of automatic locking and one long
enough hose to keep you out of the danger
zone.
Figure 8 No Standing Near Tire during • While inflating the tire, ensure that no one is
Air Inflating
standing within the danger zone.
• Make sure to check the tire pressure when
the machine is under unloaded condition.
• If the pressure of one tire installed on the
machine is less than 80% of the normal
pressure and it’s suspected that the wheel
rim or tire is damaged, disassemble the tire
14
for air inflation.
Installation of tire and wheel rim

• Handle the tire only by trained technicians.
• If one tire clearly mismatches with one
wheel rim, do not install the tire onto the
wheel rim.
• Do not assemble the wheel rim parts of
different sizes together nor use damaged or
failed parts.
• Special cautions shall be taken while using
the repaired wheel parts. Any failed or
incorrect welding, heating, or fusion will
probably impair the strength of parts and
cause future malfunction.
• While installing tire on wheel rim, use the
lubricant recommended by the tire
manufacturer.
Repair of tires and wheel rims

• It’s prohibited to cut, weld or heat the wheel
parts by any means.
• Take cautions while using the wheel edge
breaker and hydraulic jack. Keep out of the
danger zone while disassembling foreign
material from the tire. It’s really dangerous
while loosening the wheel edge breaker as it
will probably cause serious personal injuries
or death.
15
Operation Safety of Battery

The battery contains sulfuric acid, which is of
corrosivity to the human bodies and machine
parts. In addition, the battery will release
hydrogen under loaded condition (as power
supply) or during discharging. The hydrogen
combines with the oxygen in the air to form
explosive air mixture.
During all works related to the machine battery,
the combination of explosive air mixture and
corrosive sulfuric acid will greatly increase the
danger of accident.
Therefore, during the operations of the battery,

Figure 9 Corrosive Sulfuric Acid carefully read and abide by the following rules.
Warning:
Danger of serious corrosion!
Caution:
• The battery will release explosive gas. Do
not smoke near the battery.
• While disassembling the battery, firstly
cut off the grounding wire. To reduce the
Figure 10 No Open Fire danger of fire accident due to fire spark,
finally connect the grounding wire during
the installation of battery.
• It’s absolutely prohibited to tilt
excessively a battery towards any
direction. Otherwise, the battery
16
electrolyte will probably leak out.
• Do not connect in series an excessively
discharged battery with a fully charged
battery, or there is a danger of explosion.
• Do not touch the wiring posts of battery
with any metal object (such as tool, ring,
and watch). Otherwise, there is a danger
of fire accident and personal injury.
• While working near the battery, cover the
top of the battery with a cloth or other
non-conductive material.
• Always install the caps of battery wiring
posts.
• The battery contains substances harmful
to the health and environment. Therefore,
the scrapped battery must be disposed as
per the relevant local/national
regulations. Please refer to the
environment-friendly treatment methods.
Battery Charging
The explosive hydroxide is formed during the
charging of the battery. A short-circuit, open fire,
or spark near the battery will cause powerful
explosion. Before disconnecting the charging
clamps, firstly cut off the charging current. Keep
well ventilated, especially when the battery is
being charged in an enclosed space.
17
Warning:
Danger of serious corrosion!
The battery electrolyte contains corrosive
sulfuric acid. If the electrolyte is splashed onto
exposed skin, flush away immediately. Use
soapy water and a great amount of clean water to
clean the affected area. If the electrolyte is
splashed into eyes or any other sensitive body
part, flush with a great amount of clean water
and seek for medical treatment immediately.
Start with Booster Battery

To start with booster battery pack, make sure to
abide by the following items:
Caution:
• Check and ensure that the booster battery
pack or any other power supply has same
battery with the machine battery.
• If a fully charged battery is connected
with a depleted battery, the battery will
explode due to current surge. As the
battery contains sulfuric acid, it will cause
personal injuries.
Abide by the following steps:
1. Open the engine hood.
2. Open the battery cover.
3. Turn off the battery cutoff switch.
4. Do not disconnect the cables of machine
18
battery.
5. Disassemble the caps from battery posts.
6. Connect the positive cable from the booster
battery or other power supply to the positive
wiring post of the left battery.
7. Connect the negative cable from the booster
battery to the engine cylinder block.
8. Turn on the battery cutoff switch.
9. Use the ignition switch within cab to start
the engine.
10. To charge by alternator, disassemble the
jumper cable from the grounding point and
negative post of booster battery and then
disassemble the jumper cable between the
positive wiring posts.
11. Restore the machine.
Caution:
If the alternator fails to charge, stop the
machine by switch and check for cause.
Handling Safety of Oils

Warning:
Danger of scalding! Please wear
protective gloves.
• While replacing the hydraulic oil, engine oil,
or drive oil of the grader, bear in mind that
the oil is really hot and will probably cause
burn/scalding.
19
• The engine oil, hydraulic oil, diesel, and fuel
in the grader is of corrosivity to the mucous
membrane, such as eyes, throat, and skin.
Therefore, pay special attention to keep
these sensitive body parts away from engine
oil.
• While vacuumizing or draining engine oil or
fuel, take measures to avoid unnecessary
splashing. In the place impossible to collect
oil with a container, use a suction pump or
connect a hose as safety measure. The
careless drainage of engine oil or fuel is not
only harmful to the environment, but also
leads to fire accident.
The scrapped oils shall be disposed by
authorized disposal company. Please refer to the
environment-friendly treatment methods.
Operation Safety of A/C Refrigerant
Whenever it’s necessary to break up the A/C
system, the repair works and further works shall
be fulfilled by the personnel with special
qualification. Many countries also require special
training and officially authoritative approval.
Please understand and abide by the national
administration rules.
Caution:
The refrigerant will increase the
20
greenhouse effect. Do not intentionally
drain it to open air.
Personal protection devices

When there is a danger of skin contact with
refrigerant, please use tight goggles and
protective gloves and protect other naked skin
(there is a danger of cold injury). The incorrect
treatment will cause serious personal injuries and
environment hazard by the refrigerant R134a.
Therefore, pay special cautions during the
Figure 11 Wearing Goggles and Gloves operation of A/C unit. To prevent the injury for
in event of Contact Danger with
the personnel who might come into contact with
Refrigerant
refrigerant, the following rules will be of great
help.
Warning:
• The gases are smell-free and odor-free
and will seriously damage the lung even
under low concentration.
• Danger of cold injury! Please use
protective gloves.
• The fluid refrigerant will cause cold
injury.
• The low concentration gas refrigerant will
have certain influence, especially on the
nerve system.
• High concentration gas refrigerant has an
anesthetic effect.
21
• The A/C unit is of high pressure and the
refrigerant will leak unintentionally. Do
not disconnect the hose or disassemble the
filler port cap from the compressor.
• If the leakage is suspected, please contact
a person authorized by the service station
for troubleshooting and repair.
• The smoking, welding, and other open
fire are prohibited in the working site for
handling of refrigerant. The refrigerant
gas will combust and generate a toxic gas
and the inhalation of such gas is really
dangerous. The gas generated during the
heating of the refrigeration has a pungent
odor under high concentration.
Measures in event of accident:

Inhalation of refrigerant gas
Upon suspicion of escaped gas, please leave the
suspected area, attempt to seek for fresh air, and
transfer the affected personnel out of the danger
area. A small amount of refrigerant vapor will
have certain influence, especially on the nerve
system. A great amount of refrigerant vapor will
have anesthetic effect. Under serious conditions,
seek for medical treatment immediately.
Skin irritation
In event of cold injury, flush with warm water
for a long period. If the unprotected skin comes
22
into contact with a great amount of fluid
refrigerant, carefully keep warm the injured area
with warm water or cloth. If the symptom is
sustained, seek for medical treatment
immediately.
Splashing into eyes
Flush the eyes with warm water, till the irritation
feeling disappears. Seek for medical treatment
immediately.
Operation Safety of Accumulator

Warning:
• The operations shall be fulfilled only by
professional repair personnel.
• If the pressure is not relieved before the
personal injuries.
Relieve the system pressure before
disassembling the accumulator from the
machine.
Some accumulators contain pressure, namely the
so-called pre-charged pressure, even when they
are disassembled from the machine. Therefore,
take cautions during the handling of accumulator
or operations on the accumulator.
The pre-charged pressure must be lowered to
barometric pressure before taking any measure
on the accumulator.
23
Avoid the exposure of accumulator under high
pressure and avoid the brutal handling.
The scrapped accumulator must be pressure
relieved before the crushing, in order to prevent
explosion.
Warning:
The scrapped accumulator without
perforation probably still contains high
pressure and shall be handled with care
always.
Safety of Hydraulic System

The hydraulic system in the grader is running at
extremely high pressure. To prevent serous
personal injuries, it’s of great importance to
repair the system in a correct way, namely all
personnel relevant to the machine shall be
extremely careful during the operations and pay
close attention to all defects.
To prevent accidents, please abide by the
following regulations:
• Do not adjust the pressure limiting valve to a
pressure higher than the level recommended
by the manufacturer.
• Any expanded hydraulic hose (for instance:
at the joint) indicates the immediate rupture
of the hose and shall be replaced as soon as

possible. Pay attention to the leakage of
24
hydraulic hoses and connections and repair
before the rupture of parts.
Warning:
If the pressure is not relieved before the
personal injuries.
Relief of pressure (Release of

pressure)
The system contains accumulated pressure after
the engine is stopped. Before loosening or
opening any hose connector or plug in hydraulic
system or brake system, make sure to relieve the
residual pressure in the system by pressure relief.
When the engine is stopped, depress the brake
valve repeatedly to relieve the pressure of
accumulator.
• All pressurized oil tank/container shall be
opened with care, in order to relieve any
residual pressure.
• Check the leakage of pipe connectors and

tightening state of connections only after the
pressure of the system is completely
relieved.
• Use steel plate or hard paper board, instead
of hand, to check for leakage.
25
Fire Prevention Measure

Overview
• The fire extinguisher fitted on the machine
must be maintained at functional state and is
located on the left rear side of the cab.
• Even only there is a low fire, whenever the
actual condition permits, bear in mind your
personal safety and take the following
measures:
1. Start the machine and drive away from
fire or hazardous site.
2. Rotate the ignition key to position “0”

Figure 12 Fire Extinguisher
to stop the engine.
3. Leave the cab.
4. Turn off the battery switch.
5. Start the fire extinguishing and when
necessary call the fire department.
• The fire and smoking are prohibited in the
vicinity of the machine while adding fuel to
the machine or the fuel system is opened to
come into contact with air.
• The diesel is an inflammable substance and

Figure 13 No Smoking during
Refueling can’t be used for cleaning the machine. Use
qualified detergent to clean the machine.
• Some detergents will probably cause fire or
skin irritation. Avoid the inhalation of
detergent vapor.
26
Cleanliness
The cleanliness is the decisive factor for safe and
reliable operations of all machine systems.
Therefore, keep clean the repair and maintenance
site. The engine oil and water will wet the
ground and ladder. It will easily cause danger if
the electric system contaminated with engine oil
or water comes into contact with tools. The oily
clothing or the clothing contaminated by
lubricating grease is the hazardous substance
leading to serious fire accident.
• Please daily check to ensure that the
machine and devices are free of dust and oil
dirt, such as the slide plate on the bottom of
body. This can reduce the potential hazard
for fire accident and help the detection of
malfunctioned or loosened part easily.
• Special cautions shall be taken while using
high pressure water for cleaning, as the
electronic units and cable insulations will be
damaged under relative moderate pressure
and water temperature. Please properly
protect the cables.
• During the working in the environment with
fire danger, such as the lumber mill or waste
disposal plant, pay special attention to
maintaining the cleanliness. The appropriate
devices (such as muffling baffle, radiator
27
shield, and high power air pre-cleaner) must
be installed during working under such
environment, in order to prevent the danger
of spontaneous combustion due to
accumulated materials.
Electric system
• Check the cables for presence of scratch and
ensure that the cables are not damaged in
that way. This is especially important for the
wires without fuse.
• If the wires without fuse are ever broken,
make sure to check whether the wires are
reconnected and ensure that the connection
mode can greatly reduce the scratching
danger for the wires. Keep the wires without
fuse away from engine oil or fuel hose.
• While installing any optional device, ensure
that all wires are connected via fuse and the
arrangement and fixing mode of wires can
guard the wires against being scratched.
Welding and Grinding

During any electric welding works, the fire
extinguisher must be easily accessible.
• The welding and grinding works can be
conducted only in the clean portions of the
machine and are prohibited in the portions
containing inflammable fluid, such as the oil
28
tank and hydraulic pipe. Special cautions
shall be taken when it’s necessary to conduct
welding and grinding at such portions.
• When it’s necessary to weld at the painted
surfaces, firstly remove the paint. The
welding on painted surface will not only
generate gas harmful to health, but also
cause poor welding and even malfunction,
which will finally lead to accident.
• Use personal protective devices. Whenever
the actual condition permits, use an exhaust
fan to exhaust the toxic gas generated during
the welding and grinding.
Checking after Fire Accident or

High Temperature
• As a preventative measure, the seal rings
shall be always treated as fluororubber. In
addition, please refer to the section
“Fluororubber”.
Warning:
Avoid the splashing of water while
cleaning the machine burnt by fie.
Therefore, do not use high pressure water
for cleaning.
• Whenever it’s possible to come into contact
with melted polymer, do not touch the burnt
unit or part directly with hand. Firstly clean
29
with a great amount of lime water (one
calcium hydroxide solvent or suspension
liquid, namely hydrated lime).
• Use thick protective gloves made of rubber
and wear goggles to protect your eyes.
• If your skin probably comes into contact
with burnt fluororubber, please seek for
medical treatment. The skin shall be treated
with hydrofluoric acid burn cream or similar
medicine. The symptoms will probably
appear after several hours from the contact
of burnt fluororubber.
• Scrap the protective gloves, cloth, and other
objects probably coming into contact with
burnt fluororubber.
• Keep well ventilation during operations.
• If the eyes are irritated, flush with a great
amount of clean water immediately for at
least 15min and then seek for medical
treatment.
Health Hazard of Paints, Plastics,

and Rubbers
Working on painted surfaces
It’s absolutely prohibited to use flame to weld or
cut on painted surfaces. All paints will
decompose when being heated to generate a
great amount of different substances and the
30
repeated exposure in such environment will be
very harmful to your health.
Make sure to take the following safety measures:
• Use sand paper to grind away an area of at
least 10cm (4 inch) in radius around the
welding point or cutting point (please use
the respirator) on the painted surface. If the
paint can’t be ground away by sand paper,
take other measures, such as paint remover.
Caution:
If the paint is removed by paint remover,
use an exhaust fan and wear the
respirator and protective gloves.
• The grinding machine with high speed
grinding disc can heat up the painted surface
and shall be used only along with the use of
an exhaust fan. In addition, wear the mask or
other respirator.
Rubbers and plastics

Warning:
The rubbers and plastics will release
substances harmful to the health and
environment when being heated. Make
sure to abide by the following safety rules:
• If no heat insulation measure is taken in
advance, do not weld or cut by flame gun
near the polyester material (plastic or
31
rubber).
• Do not burn the polymeric materials while
scraping them.
• Handle with care the machine after the fire
or high temperature accident.
• Always were gloves, goggles, and mask, or
other respirator.
Fluororubber
Warning:
• There is a danger of serious corrosion!
• When the hydrofluoric rubber is being
heated, even only at approximate 320ºC
(610ºF), it means the accumulation of
hydrofluoric gas and the inhalation of
such gas will seriously corrode the
respiratory tract.
Some seals are designed to resist high
temperature (namely the seals in the engine,
transmission, axle, brake, hydraulic motor, and
pump) and manufactured by fluororubber, which
will generate hydrogen fluoride and hydrofluoric
acid when being heated to high temperature.
The hydrofluoric acid is of strong acidity and
corrosivity. It can’t be flushed or cleaned from
skin and will cause extremely serious burns and
corrosion injuries, which require long time for
recovery. As general principles, the injured

tissues must be removed by surgery.
32
The hydrofluoric acid will remain on the
machine parts for a long time (several years)
after fire accident.
If one machine or one machine part is subject to
fire accident or other strong heat, it can be
handled only by trained repair personnel.
The high strength rubber gloves and effective
protective goggles shall be used for all
operations on the machine after fire accident.
Warning:
The combustion of painted parts and
plastic/rubber parts will cause harm to
health.
Decontamination.
For the portions exposed to high temperature, if
it’s suspected that the parts affected are made of
fluororubber, make sure to thoroughly flush with
a great amount of lime water (one calcium
hydroxide solvent or suspension liquid, namely
water mixed with hydrated lime), in order to
remove the toxic substances. At completion of

the decontamination works, make sure to clean
the gloves in the lime water and then scrap.
If the machine is exposed to fire accident or
other high temperature source, the safety
measures in the following checklist must be

abode by unconditionally in all cases: Checking
after Fire Accident or High Temperature.
33
Environment
For the future environment protection, the entire
world is facing with the huge challenges of
environment issues and the water cleanliness,
weather variation, and use of chemicals have
become the most important issues. The machines
from Shandong Lingong Construction
Machinery Co., Ltd. played own significant role
against these challenges and made own
contribution to the more environment-friendly
development and the cautious utilization of
natural resources.
Waste Treatment
Abide by the following steps during the
treatment of wastes.
• Recycling: It’s the best way from an
environmental protection perspective.
• Material recycling: It’s a good environment
protection means to use recycled material in
new products.
• Energy recovery: It's a good alternative
method to burn the non-recyclable
inflammable material as fuel.
• Disposal: This method can be used for
hazardous wastes. The disposal must be

Figure 14 Recycling
conducted in special sites.
• Burial: It’s a bad method from an
34
environmental protection perspective and
shall be avoided whenever possible.
• Storage: It's a temporary measure to treat the
wastes until appropriate treatment
technology is developed.
Always choose a method most appropriate to the
environment protection, whenever a possibility is
available, such as the use of biochemical engine
oil.
Always abide by the national and local
environmental protection regulations.
All wastes shall be submitted to the waste
treatment firms authorized by authority for
treatment.
Engine oil and fluids

The non-reusable engine oil or fluids (such as
coolant) shall be collected by sealed containers
and submitted to the disposal department for
disposal.
Filters
The engine oil and fuel filters shall be fully
drained, placed in sealed containers, and
submitted to the disposal department for
disposal.
Refrigerant
The refrigerant contains substances influencing
the greenhouse effect and can’t be exhausted into
35
open air. The repair personnel for treatment of
refrigerant must understand the relevant local
laws and regulations as well as the international
regulations. It’s recommended that the repair
personnel for all repair works of the A/C must be
trained. Many countries require that such works
can be fulfilled only by those with certificate
released by authority.
Engine oil and fuel
While draining the engine oil and fuel, take
appropriate measure to prevent unnecessary
splashing. In the place impossible to use
drainage container, please use pump or hose.
Chemicals
The chemicals, paints, sealants, and detergents
shall be treated or disposed by recycling
department.
Rubbers and plastics

The rubber and plastic parts shall not be burned
directly. Please submit to the recycling
department.
The tires shall be treated as per special
regulations.
Electronic units
The electric units and electronic wastes, such as
circuit boards and bulbs, shall be submitted to
the recycling department for disposal.
36
Works in contaminated environment

The machine working in contaminated
environment/healthily harmful site shall be fitted
with special device suitable for such
environment.
After the working in the contaminated
environment with asbestos or other toxic dust,
the used cab and engine air filters must be placed
in sealed plastic bag (the packaging bag of new
filter) and submitted to disposal department for
treatment.
Decontamination after
leakage/splashing
Use appropriate absorbing material to collect the
leaked engine oil or fuel, such as water
absorbing pad.
Avoid the leaked engine oil/fuel from draining
into sewage along with rainwater/flood.
The contaminated soil and ground materials must
be removed and collected in appropriate
containers.
The collected soil and absorbing materials shall
be submitted to disposal department for
treatment.
Decontamination after accidents

Whenever possible, seal the leakages on the
machine.
37
Use water drainage railing to isolate the leakage
site.
Add absorbing materials, such as water
absorbing sands or wood chips.
Block the leakage fluid from draining into
sewage or drain along with rainwater/flood.
Collect the absorbing materials and floating soil,
place in sealed containers, and submit to disposal
department.
38
Contents
0 General ............................................................................................................. 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
I
0 General
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
0-1
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
0-2
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
0-3
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
0-4
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.
0-5
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

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
0-6
Table 0-3 Engine

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
0-7
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
0-8
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

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
0-9
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
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
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
0-10
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
0-11
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
0-12
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
0-13
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
0-14
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
0-15
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.
0-16
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
0-17
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.
0-18
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
0-19
Contents
1 Repair and Maintenance .................................................................................... 1-1
11 Oil, Coolant, and Others .................................................................................. 1-1
111 Fuel ............................................................................................................ 1-1
112 Coolant ...................................................................................................... 1-2
113 Lubricating Oil .......................................................................................... 1-3
114 Storage of Fuel/Oil .................................................................................... 1-3
115 Filter .......................................................................................................... 1-3
12 Choice of Fuel/Oil ........................................................................................... 1-4
121 Fuel/Oil ..................................................................................................... 1-4
122 Precautions for Use of Fuel/Oil ................................................................ 1-6
13 Repair .............................................................................................................. 1-8
131 Precautions before Repair ......................................................................... 1-8
132 Periodical Maintenance .......................................................................... 1-12
133 Maintenance and Repair ......................................................................... 1-19
I
II
1 Repair and Maintenance
11 Oil, Coolant, and Others

Caution:
● As the grader is working under harsh
conditions (high temperature and high
pressure) and the ambient environment is
full of dust, the oil will get deteriorated
easily. Upon detection of oil deterioration
or excessive impurities in oil, timely
replace the oil.
● Add oil as per the specified amount. The
insufficient or excessive oil added will lead
to occurrence of malfunction.
● At the replacement of oil, clean or replace
related oil filter.
111 Fuel
● The fuel pump is a high precision device. If
the fuel contains water or impurity, the fuel
pump can’t work normally.
● Extreme caution shall be taken during the
replacement or refueling to guard against the
ingress of impurities.
● Use the fuel strictly as per the grades
specified in this manual.
1-1
● The fuel will solidify under low temperature
(especially below -15ºC). Therefore, replace
the fuel depending on the ambient
temperature. Please refer to “Fuel/Oil
Reference Table 1-1” in this chapter.
● To prevent the ingress of water condensate
from airborne vapor into the fuel tank, top up
the fuel at completion of working.
● In event of suction failure of fuel at time of
start or after replacement of fuel filter, firstly
completely bleed the air from the circuit.
112 Coolant
● To prevent formation of water scale from
blocking the radiator or influencing the heat
radiation performance, make sure to use the
antifreeze specified by SDLG as the engine
coolant throughout the year. It’s prohibited to
use water as coolant.
● If the engine is overheated, wait for the
engine to cool down before adding coolant.
● Add the coolant to the specified level. The
under-low coolant level will lead to engine
overheating and corrosion of cooling system.
● The antifreeze is an inflammable substance.
Keep away from open fire while adding
antifreeze.
● While adding the antifreeze, choose the
1-2
model of antifreeze depending on the ambient
conditions. Please refer to the “Fuel/Oil
Reference Table 1-1” in this chapter for
details.
113 Lubricating Oil

● The lubricating oil can effectively reduce the
wear and noise of the junction surfaces.
● The connectors (such as joints and
connecting sleeves) not covered by this
manual are to be treated at the time of
overhaul and it’s unnecessary to add
lubricating oil. If certain portion is under
inflexible use due to over-long usage time,
please add the lubricating oil.
● While adding lubricating oil, wipe clean the
overflowed lubricating oil.
114 Storage of Fuel/Oil

● Guard against ingress of water, dirt, and other
impurity.
● To guarantee quality of oil under long-term
storage, abide by the principle of “first in and
first out” (the oil with longest storage time,
but still within shelf life, shall be firstly
used).
115 Filter
● The filter is an important safety part that can
1-3
prevent the ingress of impurities contained in
the oil into important portions to cause
machine malfunction. The filter shall be
periodically replaced. Under relatively harsh
working environment, shorten the
replacement interval of the filter.
● The paper filter can’t be cleaned after use and
shall be replaced with new filter element.
● While replacing with new filter, check the
used filter for presence of metal particles. If
yes, please contact the repair personnel.
● Do not unpack the new filter before use.
● Use genuine filter parts.
12 Choice of Fuel/Oil
121 Fuel/Oil
● Use the fuel/oil as per specified trademarks
and amounts. Please refer to Fuel/Oil
Reference Table 1-2 for details.
● While adding fuel and oil and lubricating
grease for hydraulic oil, clean the fueler/oiler
and container and wipe clean the adding
portion to prevent the ingress of water, dirt,
and impurity into fuel/oil.
● Make sure to use filter to add all types of
fuel/oil, except the lubricating grease.
● While adding the lubricating grease, add till
the lubricating grease overflows from gap of
1-4
the adding portion and wipe away the
overflowed lubricating grease.
● While replacing with new oil, drain the used
oil when the machine is still hot after
working. Add the cleaning oil and run the
engine under unloaded condition for several
minutes. After the engine is stopped, fully
drain the cleaning oil from all portions, add
clean new oil, run the engine at low speed,
and add new oil to the required level. The
fuel tank shall be periodically cleaned.
● In different seasons, replace the types of
working oil and lubricating oil as per the
actual conditions and working requirements.
Refer to “Fuel/Oil Reference Table 1-1” in
this chapter.
● While adding fuel/oil or checking the fuel/oil
amount, make sure to park the grader on a
horizontal place. Add the fuel/oil as per the
dipstick or indicator.
1-5
Fuel/Oil Reference Table 1-1

Standard fuel/oil Applied Amount
Type Season
Recommended type and specification portion (L)
Ambient temperature ≥4℃ 0# ordinary

diesel (GB252)
Ambient temperature ≥-5℃ -10#
ordinary diesel (GB252)
Engine fuel Fuel tank 152
Delo 400 LE Synthetic 15W/40 (GB Diesel engine
Engine oil All year 22
11122) oil sump
L-HV46 low temperature hydraulic oil Hydraulic oil
Hydraulic oil All year 210
(GB 11118.1) tank
Heavy duty automotive gear oil (GL-5) Rear axle and
Gear oil All year 28+23×2
85W/90 (GB13895) balance box
Transmission
Diesel engine oil CH-4 15W-40
lubricating All year Transmission 28
(DeloGlod)
oil
Nov. 1 ~
next Feb. 28 2# universal lithium-based lubricating
Lubricating or 29 (for grease (GB/T 7324) All Add as
grease leap year) articulations necessary
Remaining 3# universal lithium-based lubricating
period grease (GB/T 7324)
-35# glycol engine coolant NB/SH/T
Antifreeze All year Water tank 43
0521
122 Precautions for Use of Fuel/Oil
● The diesel in the fuel tank must be timely
refueled, in order to prevent empty suction.
Check the fuel tank for presence of
contamination and sediment once a month
and at the same time clean the fuel filter.
1-6
● The diesel engine oil must be replaced
periodically, as the mechanical impurities in
the oil will be increased along with the time.
The causes for increased impurities include
the product from oxidation and wear of parts,
combustion residue in cylinders, and ingress
of dust from outside.
● The oil will become black and the physical
and chemical indicators will deteriorate when
the percentage of these impurities hits
0.4~0.5%.
● Periodically check the cleanliness of
hydraulic oil.
Method: Take several drops of oil from the
oil tank and drip onto a 200-mesh filter paper.
If a light yellow circle appears on the filter
paper, it indicates that the filter paper can be
used further. If the yellow circle on the filter
paper is clearly visible, with a black center, it
indicates that the oil is already contaminated
and needs to be replaced.
● The oil filter must be used to add new oil and
it’s prohibited to add the oil directly or use
the mixture from several types of hydraulic
oil. At the replacement of oil, make sure to
thoroughly drain the used oil.
1-7
13 Repair
131 Precautions before Repair

Park the vehicle at repair position 1 (Refer to
page 8 of Environment and Safety)
● Repair on a solid and level ground.
● Place all control levers to neutral positions.
● Pull up the parking brake handle.
● Place stop blocks in the front and rear of the
wheels.
● Lock the front and rear frames with frame
locking levers.
Hanging of warning signs
At the time of repair, place a warning sign near
the start button, in order to prevent the start of
engine by other person.
Preparation of parts
Use the repair parts designated by our company
for repair and replacement.
Preparation of fuel/oil
Choose the fuel/oil designated by this manual,
depending on the ambient temperature.
Use of specified fuel/oil
Keep clean the fuel/oil tank. Use specified
fuel/oil.
Keeping clean the machine
Keep clean the entire machine, especially the oil
filling portions such as lubricating oil cup and
1-8
filler port, against the ingress of impurities.
Paying attention to high temperature oil and
coolant
It’s really dangerous to drain the high
temperature oil or coolant or take out the oil
filter when the engine is just stopped. Make sure
to wait for the engine to cool down. The
appropriate temperature for oil drainage is
generally 20~40ºC. If the actual temperature is
less than above range, heat up to the above range
before drainage.
Checking of oil and filter
After replacement of oil or filter, check the
drained oil and replaced filter. Upon detection of
a great amount of metal particles or other
impurities therein, please contact the repair
personnel.
Fuel strainer
Do not take away the fuel strainer during
refueling.
Replacement of oil
Replace the oil in a clean place, in order to guard
the oil against contamination during
replacement.
Welding instruction
● Turn off the engine start switch and
disconnect the battery cables.
● Disconnect all ECUs.
1-9
● The welding region shall be within 1m reach
from the grounding cable.
● Avoid the welding near the seal rings and
bearings.
● It's prohibited to weld the pipeline or oil tank
containing oil.
Fire protection
Clean the parts with non-flammable detergent or
light oil. Keep away from sparks and smoke.
Seals
During the replacement of O-ring or seal gasket,
clean the sealing surfaces and install new
O-rings or seal gasket to correct positions.
Checking of frame
After the long-term handling of rocks, check the
frame for presence of damage and check the
connecting bolts and nuts for presence of
looseness and damage.
Precautions for washing of vehicle
● Wash the vehicle after the engine is
sufficiently cooled down.
● It’s prohibited to splash water to the
electronic units.
Checking under rainy or snowy environment
After working under rainy or snowy
environment, wash the grader as soon as possible
and lubricate the specified parts and add oil for
rusting prevention.
Dusty environment
1-10
Pay attention to the following issues during

working under dusty environment:
● Frequently check and clean air cleaner to
prevent blockage.
● Frequently clean radiator to prevent
blockage.
● Frequently clean and replace fuel filter.
● Clean the electric devices, especially the
starter motor and alternator, in order to
prevent accumulated dust from impairing the
heat dissipation.
● Please refer to the attached Operation and
Maintenance Manual of Diesel Engine for
detailed replacement and maintenance of air
cleaner.
Avoiding use of oil mixture
It’s prohibited to use the mixture from oils of
different trademarks. If the oil only available is
different from the oil in use, fully replace the oil
in use and thoroughly clean the oil container.
1-11
132 Periodical Maintenance

The location of the periodical maintenance is
shown in the figure.
Lubrication Diagram
Front wheel tilting rod Front wheel bearing
Front axle bearing
Tilting cylinder bearing
Front wheel tilting

knuckle
Traction frame
articulation cap
Steering cylinder bearing
Swing bearing
Swing cylinder bearing
Swing cylinder bearing
Lifting cylinder bearing
Oscillating cylinder
bearing
Blade extraction cylinder
bearing Transmission filler
port
Blade angle change cylinder
bearing
Hydraulic system oil
Articulation cylinder bearing filter
Articulation bearing Transmission oil filter
Transmission oil level gauge Hydraulic oil tank filler

port
Hydraulic oil tank level

gauge Rear axle filler port
Drive shaft
Balance box filler port
Engine oil filler port
Engine oil dipstick
Rear axle an balance box oil

level gauge
● A new vehicle must be run in within the

Figure 1-1
initial 50 hours. Within the run-in period,
choose good roads whenever possible.
● When the engine is started, avoid the sudden
acceleration, warm up on the spot, and wait
1-12
for the engine coolant temperature to reach
more than 50ºC before vehicle startup.
● During the traveling, do not climb a slope by
depressing the accelerator pedal fiercely and
avoid emergency braking and long-term use
of brake.
● Fulfill the maintenance works as per the
specified requirements before, during, and
after the run-in of grader.
● Do not operate the grader under full power
within the first 50~100h. Within the second
50~100h, it’s acceptable to operate the grader
under full power, provided that the operation
time is not too long.
● Check the engine oil level twice a day (every
10 hours) within the first 200 working hours.
● While adding grease to the drive shaft, use
low pressure, in order to prevent forced
injection or excessive addition. Add the
grease, till the new grease outflows.
● While working under dusty condition,
frequently clean the water tank and all fins of
oil radiator at a number higher than that
specified in the lubrication diagram.
Important! Frequently check the oil level.
● The periodical maintenance is classified into
every 10h, every 50h, every 100h, every
200h, every 500h, every 1000h, every 1500h,
1-13
and every 2000h.
Every 10h Maintenance
● Clean the grader: Remove the dust and sand
burning from the surfaces of grader and
remove the dust and oil dirt from the surfaces
of engine, hydraulic units, and various parts.
Take cautions to prevent getting the dirt into
the filler ports and air cleaner.
● Check the connection and tightening states of
the grader parts and especially check the
connecting bolts between frame and rear axle
and the connecting bolts of drive wheel rims
for presence of looseness and breakage.
Tighten or replace the loosened or broken
bolts.
● Check and resolve the oil leaks at any portion
of the grader.
● Check the hydraulic oil level and add new oil
as per the specified requirements to the
specified level.
Caution:
The grader shall pass the 50h run-in before

being placed for official operation. The 50h
run-in shall be fulfilled as per the relevant
specification in Operation and Maintenance
Manual of Diesel Engine. At completion of
run-in, conduct the maintenance as per the
following requirements:
1-14
● Fulfill the every 10h maintenance items.
● Check the tire pressure and check the wheel
nuts (700~800Nm, check with torque
wrench).
● Check the hydraulic oil level and add
hydraulic oil to specified level.
● Check the rear axle and hydraulic system for
presence of leakage and resolve (if any). Add
hydraulic oil to the specified level.
● Fulfill the every 10h and every 50h
maintenance items.
● Replace the rear axle lubricating oil.
● Fully drain the used oil under the hot state of
the machine and then add new lubricating oil.
● Check the intake system and exhaust system
and ensure the secure connection of the
connectors. When necessary, clean intake and
exhaust pipelines.
● Check the parking brake system and adjust
when necessary.
● Check the steering mechanism for presence
of loose connection, including the slotted nut
of steering rod, and tighten (if any).
● Check the guide gap of blade and adjust
when necessary.
● Tighten the wheel nuts.
● Check the chain tension of balance box and
1-15
tighten if loosened.
● Fulfill the every 10h, every 50h, and every
100h maintenance items.
● Check the oil levels for various portions of
rear axle or add oil.
● Blow away the accumulated dust from inside
of alternator with compressed air, check all
portions for presence of abnormality, and
resolve the abnormality (if any).
● Check the guide gap of swing frame and
adjust when necessary.
● Fulfill the every 10h, every 50h, every 100h,
and every 200h maintenance items.
● Replace the transmission fine filter.
● Check the switches and electric circuits for
operation and monitoring devices for normal
functioning. Immediately repair any damaged
one.
● Check the drive shafts between transmission
and rear axle and between engine and
working pump and the universal joint drive
shaft for presence of excessive gap.
every 200h, and every 500h maintenance
items.
1-16
● Replace the hydraulic oil filter element.
● Check the wear state of the fan drive shaft
bearings and belt tensioner bearings.
● Special maintenance must be taken for the
engine if the ambient temperature is less than
5ºC.
1． Make sure to use winter fuel and pay
special attention to the water content in
the fuel, in order to prevent blocking the
fuel line.
2． The cooling system must use the
antifreeze specified by SDLG as the
engine coolant throughout the year. It’s
prohibited to use water as coolant.
3． It’s better not to park the grader outdoors
in cold seasons and regions, or it’s
necessary to heat up the coolant for body
warm-up at the time of start.

every 200h, every 500h, and every 1000h
maintenance items.
● Replace the lubricating grease in the front
axle housing and adjust the gap of front
wheel bearings.
● Check the pinion axial gap of the rear axle
main drive. If >0.05, readjust the gap.
1-17
every 200h, every 500h, every 1000h, and
every 1500h maintenance items.
● Clean the cooling system
● Clean the engine oil cooler.
● Check the internal water seal of the water
pump and add new lubricating grease.
The above maintenance requirements are the
basic requirements under normal working
conditions. Under harsh working conditions, the
user shall shorten the maintenance interval and
increase the maintenance number depending on
the actual needs. Fulfill the maintenance and
service of diesel engine as per the requirements
in the Operation and Maintenance Manual of
Diesel Engine.
1-18
133 Maintenance and Repair

Drainage of transmission oil
1 3
Conduct the checking and repair after the
machine is cooled down.
1. Disassemble the oil drainage plug and drain
oil into a container. After full drainage of oil,
reinstall the plug.
2
Figure 1-2
1 Dipstick
2 Drainage plug
3 Filler port
2. Clean the oil drainage plug, apply a layer of

、
sealant, and tighten.
1
Figure 1-3
1 Drainage plug
1-19
3. Add the oil through the oil filler port, shift
the transmission to neutral gear, and start and
run at low speed (approximate 1000r/min).
1 2
Figure 1-4
1 Filler port
2 Dipstick
4. At 40ºC, the oil level shall be between the
middle mark and lower mark "Cold”.
5. At 80ºC, the oil level shall be between the
middle mark and upper mark "Hot”.
6. Loosen the oil dipstick counter-clockwise,
withdraw, and wipe clean. Then, insert the oil
dipstick into the dipstick tube, tighten to
place, and withdraw (for at least 2 times).
1
Figure 1-5
1 Dipstick
1-20
Replacement of transmission oil filter
1. Drain the oil and take out the filter.
2. Install new filter and tighten as per the
requirements and instructions of the filter.
1
Figure 1-6
1 Filter
Cleaning of transmission suction filter screen

1. Disassemble the cover and clean the suction
filter screen. Check and ensure that no part is
damaged.
2. Install a new washer between cover and
transmission.
3. Reinstall the suction filter.
1
Figure 1-7
1 Location of suction filter
1-21
Drainage and adding of drive axle oil
Wear the protective equipment and guard against
scalding as the oil is not completely cooled
down.
2 4
1. Take out the oil drainage plug, fully drain the
oil into a container, and then reinstall the
plug.
2. Check and clean the oil drainage plug,
reinstall, and tighten.
3. Add new oil to the axle body through filler
port to the specified level and reinstall and
tighten the filler plug.
Capacity: Approximate 28L.
4. The required oil amount can be controlled by

1 3
taking the lower marking line of oil level port
Figure 1-8
1 Oil level port as the benchmarking. A small amount of
2 Filler port
3 Drainage plug overflowed oil is allowed. The lower limit of
4 Breather cap the oil level is 8mm below the lower marking
line of the oil level port.
Drainage and filling of balance box oil
1. Screw off the oil drainage plugs (two for
each balance box) on the bottom of balance
box and fully drain the oil into a container.
2. Check and clean the plugs, replace with new
seal rings, and install and tighten the plugs.
1
Figure 1-9
1 Drainage plug
1-22
12
3. Screw off the breather cap and add new oil
through filler port to the lower marking line
of the filler port (namely maximum oil level).
4. Install and tighten the breather cap. Capacity:
Approximate 23L for each balance box.
5. Place the axle at horizontal position while
adding the oil.

3
Figure 1-10
1 Filler port
2 Breather cap
3 Oil level port
Tension of balance box chain
1. Disassemble two covers of balance box.
1
Figure 1-11
1 Cover
2. Support the balance box till the wheels are
off the ground.
1
Figure 1-12
1 Balance box
1-23
3. The elongation of the chain is increased
when the chain is under the stretch. If the sag
on the loose side of the chain is higher than
18mm, it’s necessary to re-tension the chain.
Caution:
There are two chains in each balance box and
two chains need to be checked together. The
tension of chains shall be conducted only by
Figure 1-13
professionals.
The tension of chains is achieved by rotating the
eccentric bearing cap. The tension procedure is
as below:
3.1. Support the balance box till the wheels are
off the ground and then drain the oil.
1
Figure 1-14
1 Drainage plug
1-24
3.2. Disassemble the rear wheels.
1
Figure 1-15
1 Rear wheel
3.3. Disassemble the brake drum.
1
Figure 1-16
1 Brake drum
3.4. Take out the oil cup, replace with one M10
bolt at the original place, and rotate into
the threaded hole of chain wheel shaft for
5~8 turns.
Caution:
This bolt can prevent the chain wheel and
shaft subassembly from sliding out of the
tapered roller bearings.
1
Figure 1-17
1 Oil cup
1-25
3.5. Disassemble the bolts from the connecting
plate.
1
Figure 1-18
1 Connecting plate
3.6. Disassemble the bolts from the bearing
block.
3.7. Rotate the connecting plate and bearing
block for a same hole distance in same
direction, till the chains are appropriately
tensioned.
Caution:
1
Figure 1-19 Before disassembling the connecting plate and
1 Bearing block bearing block, add marks to their original
positions for identification purpose, in order
to ensure relative consistency of adjusted
positions. While rotating the connecting plate
and bearing block, take special cautions to
prevent damaging the O-rings.
3.8. After the adjustment, install the
disassembled parts in turn.
3.9. Add oil to the balance box and reinstall
the covers.
3.10. Properly adjust the brake system and bleed
the air from system for future use.
1-26
Replacement of hydraulic oil

1. Lower the blade onto ground and lift the
mouldboard to the top end.
1
Figure 1-20
1 Mouldboard
2. Stop the engine and operate the control lever
to lower the mouldboard onto the ground.
Figure 1-21
1 4
3. Screw off the oil drainage valve on the
bottom of the oil tank to drain the oil into a
container. After the oil is fully drained, close
the oil drainage valve.
4. Open the oil return filter cover and add
specified hydraulic oil, till the oil level
reaches the middle position of the oil leveler.
5. Install the oil return filter cover.
6. Start the engine and operate the control
levers for all working devices for

2 3
reciprocating movements at large travel, in
Figure 1-22
1 Return filter order to fully fill the hydraulic system with
2 Level gauge
3 Drainage valve hydraulic oil and bleed the air from the
4 Breather valve
1-27
hydraulic system.
7. Place all working devices onto the ground,
stop the engine, and bleed air from oil tank.
8. If necessary, add oil through oil return filter
till the oil level reaches the middle position
of oil leveler.
Capacity: Approximate 210L, when the oil level
is at the oil leveler.
Caution:
1. Pay special attention to the sealing
performance of filter port and when
necessary replace seal ring. To prevent
damaging the fine thread of filter cover,
take cautions during the installation.
2. Replace the oil after the specified working

1 2 hours are reached. In addition, the oil
Figure 1-23
1 Return flange must be replaced under two special
2 Suction flange conditions, namely after repair and under
serious contamination. Sample a drop of
oil and drip onto a filter paper or blotting
paper. If a clear black spot emerges near
the oil drop after several hours, the
failure to replace oil will damage the
hydraulic system.
1-28
Replacement or repair of working pump and
steering pump
1. Open the oil drainage valve of hydraulic oil
tank to drain the oil.
2. Replace or repair the working pump and
steering pump.
3. After the repair, close the oil drainage valve
and add oil to specified level.
Figure 1-24
Replacement of oil return filter element

1. Disassemble the oil return filter cover.
2. Take out the entire filter element.
3. Replace with new filter element and reinstall
properly.
Caution:
1 While reinstalling the entire filter into the oil

Figure 1-25 tank, take cautions not to damage the seal ring
1 Return filter cover
of seat and carefully tighten the oil return filter
cover.
1-29
Cleaning of fuel tank

1. Use kerosene to carefully clean the fuel tank
cover and filter screen.
2. Loosen the oil drainage plug on the bottom
of fuel tank for several turns and store the
several liters of fuel drained in a container.
After the drainage, re-tighten the plug and

1 notice the normal sealing.
Figure 1-26
1 Drainage plug Caution:
The cleaning of fuel tank shall be conducted
at the certain amount of fuel (approximate
1/4) in the fuel tank. Before cleaning the fuel
tank, park the grader for a period, in order to
help accumulation of sediments contained in
the fuel tank.
Refueling of fuel tank

1. No smoking or open fire is allowed during
1
refueling and the engine must be stopped.
2. To prevent the condensation of water vapor,
top up the fuel tank at all times.
3. Open the fuel filler cap.
4. After the refueling, immediately install the
cap to guard the fuel against contamination.

1 2
Figure 1-27
1 Filler port
2 Filter assembly
1-30
Drainage of Engine Oil
1. Conduct the checking and repair after the
2. Place an empty container beneath the engine
and screw off the oil drainage plug.
1
Figure 1-28
1 Drainage plug
Adjustment of engine valve clearance
1. Place the machine to maintenance position
1. (Refer to page 8 of Safety and
Environment)
2. Stop the engine for 30min. The oil
temperature shall be less than 80ºC.

1
Figure 1-29
1 Maintenance position
3. Disassemble the engine to the state shown in
the figure.
4. Use a rotation tool to rotate the engine to the
valve overlapping position on the cylinder 1.
(The cylinder 1 is on the same side of the
flywheel)
The overlap refers to the state that the exhaust
valve is about to open and the intake valve is

1 about to close. At this position, no push rod of
Figure 1-30
1 Flywheel corresponding cylinder can be rotated manually.
1-31
5. Use a feeler gauge to check the valve
clearance. The insertion of feeler gauge shall
have a feeling of slight friction.
Correct valve clearance:
0.3±0.05mm for intake valves
0.5±0.05mm for exhaust valves
1 2
6. Loosen the nuts and use a screwdriver to
rotate the bolts.
7. Tighten the nuts to obtain correct valve
clearance.
3
Figure 1-31
1 Adjustment bolt
2 Nut
3 Valve
8. Starting from the cylinder 1, the valves are
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, and 12 in turn.
9. Adjust the valves 3, 6, 7, 10, 11, and 12 in
turn. At completion of adjustment, add a
mark.
Figure 1-32
1-32
10. Rotate the crankshaft for 360º, till the valves
of cylinder 6 are overlapped. Adjust the
clearance of valves 1, 2, 4, 5, 8, and 9 in
turn.
11. Install the valve chamber cover (If
necessary, replace the washer).

Figure 1-33
Caution:
The valve clearance will increase by 0.1mm
after replacement of cylinder gasket each
time. Readjust the valve clearance after
50~150 working hours.
12. Reinstall the engine.
Replacement of engine fuel filter

1. Disassemble the fuel filter with a filter
wrench.
2. Apply new engine oil to new filter seal.
Tighten as per the instructions on the filter.
3. After replacement, bleed the air from fuel
system.
1 2 3 Replacement of engine oil filter

Figure 1-34
1 Fuel strainer
2 Fuel fine filter machine is cooled down.
3 Engine oil filter
1. Replace the engine oil filter. Apply new
engine oil onto new filter.
2. Tighten the filter as per the requirements.
1-33
Replacement of engine air cleaner

1. When the resistance alarm indicates red or
the resistance alarm indicator lights up,
make sure to maintain or replace the main
filter element.
2. During the maintenance of the main filter
element, it’s unnecessary to take out the

1
Figure 1-35 safety filter element, as no maintenance is
1 Air cleaner required for the safety filter element.
3. When the main filter element is ever
maintained for three times or the resistance
alarm indicates red or the alarm indicator is
still on after the maintenance, it’s necessary
to replace both main filter element and
safety filter element.
Adding of engine oil
Add oil as per the specified requirements to a
level between the upper and lower markings of
oil dipstick.
Filling amount: 22L
1
Figure 1-36
1 Oil filler port
1-34
1
Figure 1-37
1 Oil dipstick
Checking of engine drive belt

1. Use a measuring apparatus to check the belt
tension.
2. Check the belt for presence of wear. If yes,
replace the belt.
1
Figure 1-38
1 Drive belt
1-35
Adjustment of parking brake

Caution:
During the adjustment of parking brake,
pull up the parking brake handle to the
maximum position, namely reaching the
maximum braking torque.

1
1. Loosen the lock nut for several turns.
2. Remove the pin.
3. Separate the connecting fork from the brake
handle and rotate for several turns.
4. Place the connecting fork on the brake
handle and install and tighten the pin.
5. Install the lock nut.

2 3 6. Firstly it’s necessary to adjust the flexible
Figure 1-39
1 Lock nut shaft to the critical tension state, but any
2 Brake rod braking symptom is disallowed. During the
3 Pin
assembly, tighten the back nut on the flexible
shaft end in such manner that the deflection
of the flexible shaft is less than 3mm under
the application of 30N force. Next, pull the
handle to neutral position and then return to
neutral position. Repeat for three times and
retighten the back nut on the flexible shaft
end in such manner that the deflection of
flexible shaft is less than 3mm under the
application of 30N force.
1-36
Lubrication and adjustment of front wheel

bearings
1. Support the front axle and disassemble the
front wheels.
1
Figure 1-40
1 After disassembly of front wheel
2. Disassemble the hexagon socket bolts.
1
Figure 1-41
1 Hexagon socket bolt
3. Disassemble the end cap.
Figure 1-42
1-37
4. Disassemble the wheel hub with a puller.
1 2
Figure 1-43
1 Puller
2 Wheel hub
5. Clean the wheel hub, steering knuckle shaft,
bearings, and cap and replace with new seal
rings.
6. Add new lubricating grease, install the wheel
hub, and check the bearing clearance.
7. Re-fix the end cap with bolts and tighten the
1 2 hexagon socket bolts in crossed manner in

Figure 1-44 turn.
1 V-shaped seal ring
2 Seal ring 8. The wheel hubs shall be capable of free
rotation without jumping. During the
checking, the wheel hubs shall be free of
vibration clearance.
Caution:
The maintenance of front wheel bearings shall
be fulfilled only by professionals.

9. Capacity of lubricating grease: Approximate
1-38
280g for each wheel.
Lubricating grease: Universal lithium-based

lubricating grease EP2 GB 7324.
Adjustment of blade
If the blade of the grader is under excessive
swing, the wearing plate and the bushing need to
be replaced. Replace the wearing plate and the
bushing in pairs. The wear extent can be reduced
by timely eliminating the roughness on the guide
rails and the files can be used for polishing.
1. Replace the bushing.
● Place the blade on two pieces of wood.
● Disassemble the baffle plate.
● Disassemble the blade slide and then
disassemble the bushing.
● Install new bushing and tighten the baffle
plate.
1 2
Figure 1-45
1 Baffle plate
2 Bushing
1-39
2. Replace the wearing plate.
● Place the blade on two pieces of wood.
● Loosen the fastening bolts.
● Disassemble the worn plate, replace with
new wearing plate, and tighten with bolts.
1
Figure 1-46
1 Wearing plate
Adjustment of blade swing gear ring

1. Axial adjustment of rotary frame
● Loosen the back nut and fastening nut
beneath the clamping plate and take out the
guide plate of rotary gear ring.
● Adjust the quantity of washers and ensure
that the axial gap between the bottom of
swing frame and the wearing cast nylon is

1 2
Figure 1-47 1~2mm by inspecting with feel gauge.
1 Clamping plate
● Tighten the fastening nuts to 755±45N.m
2 Guide plate
and then tighten the lock back nut.
● Ensure that the gap meets the requirement
and reinstall the guide plate.
1-40
2. Radial adjustment of rotary frame
● Loosen the nuts and bolts and adjust the
guide plate.
● Tighten all nuts to 755±45N.m.
● Conduct the rotary test. The rotary ring must
be capable of 360ºfree rotation.
1
Figure 1-48
1 Guide plate
Maintenance of wheels
1. Daily check the tires for presence of cut,
cracking, or sharp object that probably
penetrates the tire cover and immediately
remove all foreign materials.
2. Guard the tires against the corrosion of fuel,
engine oil, and lubricating grease.
3. The inflation valves must be installed with
mesh caps to guard against ingress of dirt.
4. The leaking valve core shall be replaced with
new one.
5. Periodically check the tire pressure, the
under-low or over-high tire pressure will lead
to excessive or unilateral wear.
6. Tire pressure:
0.2MPa for front wheels and 0.25MPa for
rear wheels.
1-41
Replacement of tire
● Place the machine to maintenance position
1. (Refer to page 8 of Safety and
Environment)
● Before the replacement of wheel, tightly pull
up the parking brake.

1
Figure 1-49 ● To replace the rear wheels, it’s acceptable to
1 Maintenance position
elevate one side of the grader by the blade.
Therefore, place the angle end of the blade
in the front of the balance box wheel to be
elevated and then use the lifting cylinder on
the same side of the wheel to be elevated to
elevate the grader.
● The front wheels can be elevated by
supporting the mouldboard or blade onto the
ground.
● Before the disassembly of wheels, make
sure to securely support the grader.
● Loosen the nuts of wheel rims and
disassemble the wheels.
Caution:
● During the disassembly and installation of
wheels, make sure not to damage the threads
of wheel rim bolts.
● After the wheels are installed, tighten the

1
Figure 1-50 wheel rim nuts in crossed manner.
1 Wheel
● Within 100 working hours after the
1-42
replacement of each wheel, frequently check
and re-tighten the wheel rim nuts. The
specified tightening torque is 700~800N.m.
Direction of tire tread
● Pay attention to the direction of tire tread
during the installation of tire. It’s
recommended to install the tires of drive
wheels with the tread facing towards the
direction shown in the figure, in order to
obtain maximum traction force in the
forward traveling direction.

1
Figure 1-51
1 Tread of rear tire
● While installing the non-drive front wheels,
the tread direction shall be reverse to the
rear wheels.
1
Figure 1-52
1 Tread of front tire
1-43
Maintenance of battery
This grader adopts two maintenance-free
batteries 6-QW-70B in series connection. If the
batteries are under storage for a long period
(more than 6 months), it’s necessary to check the
power state. During the use, frequently check the
tightening state of the batteries to guard against
1 looseness.
Figure 1-53
1 Battery
1. Checking of battery power
● Observe the power state via charge
indicator: Light green indicates full power
and dark black indicates low power.
● Upon detection of white charge indicator,
probably there is air bubble in the charge

1
Figure 1-54 indicator. Lightly vibrate the battery to drive
1 Charge indicator away the air bubble. If the charge indicator
is still in white after vibration, replace the
battery.
2. Disassembly and installation of battery
● Disconnect the negative cable (-) firstly and
then disconnect the positive cable (+) during
the disassembly.
● Connect the positive cable firstly and then
connect the negative cable during the
installation.
1-44
● The batteries must be secured on the grader
and correctly connected to the charging
circuits of the electric system. Apply a small
amount of Vaseline to the wiring poles of
the batteries.
Long-term parking of grader

1. If the grader is to be left unused for a long
period, thoroughly clean and lubricate the
machine, apply lubricating grease to the
finish machined surfaces, and apply a thick
layer of acid-free grease (Vaseline) to the
piston rods and whenever possible wrap the
piston rods with papers.
2. It’s better to park the grader under shed or
indoors, in order to guard the tires against
sunlight and moisture. The tire pressure must
be checked frequently.
3. If the grader is parked outdoors or on an
uneven ground, it’s better to cushion the
grader with wood bars to lighten the load of
tires, relieve the tire pressure by 50%, and
cover the tires against direct sunlight
exposure.
4. To prevent rusting, the fuel tank shall be full
of fuel. Whenever the condition permits, add
the anticorrosive (10% of total fuel amount).
5. It’s reasonable to periodically run the grader.
1-45
Start the machine once every two weeks to
warm up the machine. When possible, drive
the grader for a short distance. If the machine
is supported by wood bars, run all gears of
the gear transmission system once to warm
up the machine.
6. When the machine is parked for more than 4
weeks, take out the batteries from the
machine and store in a dry and anti-freezing
place. Charge the batteries once a month.
Restoring grader to working state
If the grader is not used for approximate one
year, replace the hydraulic oil, the oils for
transmission, rear axle drive case, and balance
box, as well as the engine oil before the reuse.
1. Restore the machine from the repair position.
2. Thoroughly clean the piston rods and add
lubricating oil to all oil cups.
3. Start the machine for warm-up.
4. Walk around the machine to check and
ensure there is no leakage.
5. Check the display screen for presence of any
warning about low oil level.
6. Check the battery electrolyte amount and tire
pressure.
● Warm up the grader and check for presence
of low oil level information in the system.
1-46
Before the further warm-up, add more hydraulic
oil in the related system and increase the engine
speed to approximate 1800rpm, till the engine
and transmission reach the working temperature
of 50–90°C (122–194°F).
Checking of transmission oil level
When the machine is at working temperature and
the engine is running at low idling speed, the
transmission oil level shall be within the rated
range of the oil dipstick.
1
Figure 1-55
1 Dipstick
Checking of hydraulic oil level
Observe the oil level via the circular oil pointer
on the back of the hydraulic oil tank.
1
Figure 1-56
1 Circular oil pointer
1-47
Checking of engine oil level
The oil level shall be between the maximum and
minimum markings of the oil dipstick.
1
Figure 1-57
1 Oil dipstick
Checking of coolant level

1. Add water through the water filler port so
that the water flows into the water tank from
the lower water chamber through water
refilling pipe.
2. Do not add the water too fast. It takes

1 2
Figure 1-58 approximate 20min to top up the water tank
1 Expansion water tank
for the first time.
2 Coolant filler port
3. After topping up the water tank, start the
engine and idle for warm-up. Then, check the
water level of the water tank via the water
filler port. If the water level is lower than the
baffle plate, add more water to ensure normal
use.
4. It’s prohibited to start the engine without
topping up the water tank.
Warning:
It’s prohibited to open the filler cap before the
system is cooled down, in order to guard
yourself against harm by high pressure hot
gas.
1-48
Checking of battery, cables, and connectors

● Coming into contact with the battery
electrolyte will lead to serious chemical
burn.
● Always wear the personal protective gloves,
goggles, and protective clothing while
handling the battery.

1 1. Open the battery covers. Open the cover on
Figure 1-59
1 Battery one side of the machine at one time.
2. Check and clean the cable connectors and
battery poles/studs and apply lubricating
grease, such as Vaseline, onto the outer
surfaces as anti-corrosive.
3. Check the fluid level. It indicates normal if
the battery charge indicator is in green.
Cleaning of radiator
1. Open the engine hood and disassemble the
grille guard.
2. Along the driving direction of the machine,
use compressed air to blow clean the fins of
radiator.
3. Install the grille guard.
Caution:
The improper handling will probably damage
1 the radiator fins.
Figure 1-60
1 Radiator
1-49
Cleaning of condenser
1. If the A/C is equipped.
2. Disassemble the cover and use compressed
air to blow clean the condenser from the
outside.
3. Install the cover.
1
Figure 1-61
1 Condenser
1-50
Contents
2 Engine system .............................................................................................. 2-1
21 Overview ......................................................................................................... 2-1
211 Engine Description.................................................................................... 2-1

212 Engine Identification ................................................................................ 2-1
213 Composition and Meaning of Product Model .......................................... 2-2
214 Numbering of Cylinders ........................................................................... 2-2
215 Principle of Engine ................................................................................... 2-3
216 Engine Block............................................................................................. 2-4
217 Cylinder Head and Cylinder Gasket ......................................................... 2-5
218 Technical Specification of Engine ............................................................ 2-7
22 Lubrication System ......................................................................................... 2-8
221 Lubricating Oil Line ................................................................................. 2-9

23 Fuel Supply System ....................................................................................... 2-10
231 Low Pressure Fuel Line .......................................................................... 2-11

232 High Pressure Fuel Line ......................................................................... 2-12
233 Return of Fuel ......................................................................................... 2-12
24 Cooling System ............................................................................................. 2-13
241 Function of Cooling System ................................................................... 2-14

242 Thermostat .............................................................................................. 2-15
25 Intake and Exhaust System ........................................................................... 2-16
251 Intake System.......................................................................................... 2-16

252 Exhaust System ....................................................................................... 2-17
253 Turbocharger ........................................................................................... 2-17
26 Disassembly and Assembly of Engine .......................................................... 2-18
261 Disassembly of Engine ........................................................................... 2-18

262 Assembly of Engine ................................................................................ 2-28

27 Disassembly and Assembly of Fuel Tank ..................................................... 2-37
271 Disassembly of Fuel Tank ....................................................................... 2-37

272 Assembly of Fuel Tank ........................................................................... 2-39
28 Disassembly and Assembly of Radiator ........................................................ 2-41
281 Disassembly of Radiator ......................................................................... 2-41

282 Assembly of Radiator.............................................................................. 2-43
29 Common Malfunctions and Troubleshooting of Engine ............................... 2-45
291 Start failure of engine.............................................................................. 2-45

292 Low engine power................................................................................... 2-45
293 Abnormal exhaust gas (black, white, or blue smoke) ............................. 2-46
294 Over-high or under-low lubricating oil pressure .................................... 2-47
295 High consumption of lubricating oil ....................................................... 2-48
296 High coolant temperature........................................................................ 2-49
2 Engine system
21 Overview
211 Engine Description
The Deutz engine is fitted.
The Deutz products feature high torque, easy
cold start and full load running, low volume,
light weight, easy matching with complete
vehicle, and low consumption, emission, noise,
and vibration. The fuel supply system of Deutz
1013 series engine adopts the monoblock high
pressure pump corresponding to individual
cylinder. The engine oil pump is of rotor type
and is installed in the engine front cover and
driven directly by crankshaft. The engine oil
pump rotor is installed onto the crankshaft by
three non-uniformly distributed keys. The pump
displacement is controlled by the tooth width of

Engine serial number engine oil pump rotor and is (75L/min) for
6-cylinder engine.
Figure 1 Overall Engine
212 Engine Identification
The engine serial number is stamped on the
nameplate located on the cylinder block.
The model name and serial number of the engine
must be indicated at the ordering of spare parts.
2-1
213 Composition and Meaning of

Product Model
B F 6 M 10 13-20 T2-1582
Ordering number
T2=Euro-II
20=10 × horsepower
13=Piston travel (cm)
10=Product serial number
M=Water-cooled model (L=Air-cooled model)
6=Number of cylinders
F=High speed four-stroke model
B=Turbocharged model
214 Numbering of Cylinders
The cylinders are numbered in sequence from
the flywheel. Sequence of ignition device:
1-5-3-6-2-4. Observed from the flywheel, the
engine is rotating in counter-clockwise direction.
Figure 2 Locations of Cylinders
2-2
215 Principle of Engine
This engine is a four-stroke diesel engine, of
which each working cycle is composed of intake,
compression, power, and exhaust strokes. During
the intake process, the diesel engine inhales fresh
air. The intake process is completed after the
piston reaches the bottom dead center. Next, the
piston moves upward to start the compression
stroke. In such case, the fresh air is compressed
by the piston and its temperature rises. When the
piston approaches the top dead center, the diesel
is sprayed into combustion chamber in atomized
state by the fuel injector to form mixture with
high temperature air, which is rapidly ignited for
combustion to drive the downward movement of
piston for start of power stroke. The power
stroke is completed when the piston reaches the
bottom dead center. Under the action of inertia,
the piston moves upward to the top dead center
to exhaust the combusted gas and complete the
exhaust stroke.
One working cycle of the diesel engine is
completed.
2-3
216 Engine Block
It’s built through best optimized design via finite
element method. The low pressure fuel is
supplied by the fuel supply pipe cast or installed
on the cylinder block.
Figure 3 Engine Cylinder Block

1. Cylinder block Advantage: It realizes more reasonable layout of
2. Main bearing bolt
3. Locating pin complete unit, eliminates leakage, and can heat
4. Screw plug
the fuel in advance. The design of cylinder block
5. Sealing gasket
6. Screw plug takes the easy repair and maintenance into
7. Screw plug
sufficient consideration so that all external
8. Screw plug
9. Bushing accessories, except the starter and turbocharger,
10. Bushing
11. Water jacket plug are arranged on the same side of the engine.
13. Screw plug
14. Guide bushing
23. Guide bushing
24. Screw plug
2-4
217 Cylinder Head and Cylinder

Gasket
The cylinder head is an integral structure cast
from gray cast iron. The cylinder head is fixed
onto the cylinder block by 18 bolts (for
4-cylinder engines) or 26 bolts (for 6-cylinder
engines).
Figure 4 Cylinder Head

1. Cylinder head 2. Water jacket plug
3. Screw plug 4. Sealing gasket
5. Rocker arm plug 6. Valve spring
locking plate 7. Spring seat 8. Valve
spring 9. O-ring 10. Valve guide pipe
11. Intake valve seat 12. Intake valve The cylinder head bolts must be tightened as per
13. Exhaust valve 14. Exhaust valve
seat specified sequence, in order to ensure the
uniform force application on the cylinder head.
Tightening Torque:
First step 30Nm
Second step 80Nm
Figure 5 Tightening Sequence of Bolts Third step 90º
2-5
Cylinder gasket: The DEUTZ diesel engine
adopts the asbestos-free cylinder gasket, which is
harmless to the human body. The cylinder gasket
is divided into three types (to guarantee the
compression ratio) and is identified by number
Figure 6 Cylinder Gasket of holes.
Height difference between cylinder block

Hole No. Thickness of cylinder gasket S
plane and piston crown
Table 1 Specification of Cylinder
Gaskets
2-6
218 Technical Specification of Engine

Model BF6M1013EC Number of cylinders 6
Inline, water-cooled,
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
Table 2
2-7
22 Lubrication System
Fan end
PO is the opening pressure for various pressure
valves.
Engine oil
filter
Engine oil
radiator
Figure 7 Pressure Lubrication
Route Diagram
1. Oil sump
2. Engine oil radiator bypass valve
3. Engine oil filter bypass valve
4. Engine oil collector
5. Engine oil pump
6. Turbocharger
7. Main oil passage pressure limiting
valve
This engine is fitted with piston cooling nozzles
to pray oil to the lower portion of the piston, in
order to maintain a stable working temperature.
2-8
221 Lubricating Oil Line
Figure 8 Lubrication Oil Line

1. Oil sump
2. Engine oil collector pipeline 12. Push rod, for supply of lubricating oil to
3. Lubricating oil pump rocker arm
4. Lubricating oil cooler 13. Rocker arm
4.1 Heat exchanger bypass valve 14. Return to oil sump
4.2 Cutoff valve (relief valve) 15. Turbocharger oil inlet pipe
4.3 Lubricating oil alternative filter 16. Turbocharger
4.5 Oil pressure sensor 17. Oil pipe to air compressor or hydraulic pump
5. Main oil pipe 18. Air compressor
6. Crankcase bearing (main bearing) 19. Hydraulic pump
7. Connecting rod bearing 20. Air compressor or hydraulic pump return
8. Camshaft bearing pipe
9. Pipeline to piston nozzle 21. Pipeline to differential gear (2x)
10. Piston cooling nozzle 22. Balance shaft
11. Tappet with rocker arm pulse 23. Turbocharger oil return pipeline, to
lubrication crankcase
2-9
23 Fuel Supply System
Figure 9 Fuel System

1. Fuel tank 7. Fuel injection pump
2. Fuel line to diesel pump 8. Fuel line to fuel injector
3. Diesel pump 9. Fuel injector
4. Fuel line to diesel filter 10. Fuel return pipe
5. Diesel filter 11. Fuel pipe bolt with pressure control valve
6. Fuel line to fuel injection pump 12. Fuel line of fuel return tank
2-10
231 Low Pressure Fuel Line
The fuel flows out from fuel tank 1 and flows
into the diesel filter 5 for filtration through diesel
pump 3. Next, the filtered fuel flows into the fuel
injection pump 7 through fuel inlet pipe of fuel
injection pump, of which a part of fuel flows into
high pressure fuel line, namely high pressure fuel
pipe - fuel injector - cylinder, for combustion
and the remaining large proportion of fuel flows
into the return chamber within the cylinder block
through the fuel injection pump to form low
pressure fuel line. The pressure of low pressure
fuel line is 5bar. The pressure stability in the low
pressure fuel line is of vital importance for the
engine power output. In event of insufficient
engine power output, firstly measure the fuel
pressure.
The control valve 10 controls the pressure of low
pressure fuel line. The main cause for the fuel
leakage (cavitation erosion) of fuel injector is the
insufficient pressure of low pressure fuel line.
Make sure to timely replace and clean the diesel
filter.
2-11
232 High Pressure Fuel Line
The fuel in the low pressure fuel chamber flows
from the fuel injection pump 7 to fuel injectors
through a really short high pressure fuel pipe.
When the pressure reaches 220bar, the fuel
injector 9 opens to inject the fuel into the
combustion chamber.
233 Return of Fuel
As the fuel supply amount of the fuel delivery
pump is more than 10 times of the fuel amount
of the fuel injection pump, a great amount of
remaining fuel returns to the diesel tank through
pressure control valve 10 and return pipe 11. A
small amount of leaking diesel from the working
clearance of fuel injector also returns to the
diesel tank via return pipe. This is intended to
cool the combustion and achieve automatic air
bleeding by utilizing a great amount of return
fuel for fully bleeding air from fuel line.
2-12
24 Cooling System
The coolant pump sucks in low temperature
water from the external radiator through
thermostat. The coolant firstly flows into water
jacket within cylinder block for cooling of
cylinder sleeve through engine oil radiator, then
flows into the water jacket for cooling of
cylinder head through water passage, and finally
returns to the radiator.
Figure 10 Cooling System

1. Thermostat cap 8. Pipeline from radiator to engine
2. Coolant pump (water pump) 9. Breather pipe from cylinder head to
3. Lubricating oil cooler compensation water tank
4. Cooling of cylinder 10. Compensation water tank
5. Cooling of cylinder head 11. Pipeline from radiator to thermostat cap
6. Pipeline from heat exchanger to 12. Coolant compensation pipeline
engine 13. Coolant pipeline from heater
7. Radiator 14. Coolant pipeline to heater
2-13
241 Function of Cooling System
During the running the engine, the combustion of
fuel and the friction between moving parts
generate a great amount of heat so that the parts
are strongly heated, especially the parts in direct
contact with the combustion gas are under very
high temperature. Without appropriate cooling,
the normal working of the engine can’t be
guaranteed. The cooling system is functioned to
maintain the running of engine under the most
appropriate temperature.
The 1013 series engines are of water-cooled
engine. Water is functioned as the heat transfer
medium to transfer the heat to the air. This is to
utilize a small amount of water under continual
recirculation to absorb excessive heat within the
engine water jacket and then flow to the radiator
for heat dissipation. As the temperature
difference between inlet and outlet of water
jacket is relatively low, the lower portion of the
cylinder will not get over-cooled. In addition, the
easily adjustable cooling strength of the
water-cooling system can maintain the normal
temperature of the engine. In addition, the
system can preheat the engine with hot water to
ease the start in winter.
2-14
242 Thermostat
The thermostat is functioned to change the
recirculation strength of the water (route and
flow rate) depending on the engine load and
water temperature. In addition, it can shorten the
hot start time of engine and reduce the fuel
consumption and wear of engine parts.
2-15
25 Intake and Exhaust System

251 Intake System
Sucked in through the air cleaner, the air flows to
the turbocharger. After flowing out from the
turbocharger, the air is cooled in the air cooler.
The air flows through the preheater before
finally reaching the cylinder through intake
manifold and intake valve. When the driver
rotates the starter key to position 1, the heater is
activated if the engine coolant temperature is too
low. The preheating is completed after the
engine is started. After the engine is started, the
additional preheating and after-heating will be
activated if required. The preheating and

Figure 11 Intake and Exhaust System
after-heating times are controlled by the engine
1. Air Cleaner
2. Turbocharger control system. The advantages include easier
3. Turbocharged air cooler
start and less white smoke in exhaust gas. When
4. Preheater
5. Intake manifold, with the preheating coiled tube is working, the
turbocharged air temperature and
pressure sensor preheating symbol on the information panel will
light up.
2-16
252 Exhaust System
The exhaust gas enters the exhaust manifold
through exhaust valve and then flows into the
muffler through turbocharger. After flowing
through the muffler, the exhaust gas is exhausted
through the exhaust pipe.
253 Turbocharger
Figure 12 Exhaust System
The turbocharger is driven by exhaust gas and
1. Exhaust manifold
2. Turbocharger the exhaust gas flows through the turbine
3. Muffler
housing on its way to the muffler.
The exhaust gas drives the rotation of turbine
rotor within the turbine housing. The compressor
rotor and the turbine rotor are on one same shaft.
The compressor rotor is located within the
housing between the air cleaner and engine
intake manifold.
The rotating compressor rotor sucks the air from
the air cleaner. The turbocharger is fitted with
one exhaust gas bypass valve. The exhaust
Figure 13 Turbocharger bypass valve is controlled by the turbocharged

Red = Exhaust gas air pressure. It’s allowed that a small amount of
Blue = Air from air cleaner
1. Turbine housing exhaust gas bypasses through the turbine rotor
2. Compressor housing
under high engine speed (high turbocharged air
3. Exhaust valve
pressure).
2-17
26 Disassembly and Assembly of

Engine
261 Disassembly of Engine
The following procedure can be referenced for
the replacement of engine or the disassembly of
engine part from the complete machine for
internal checking and repair.
1 Start the machine, drive to the maintenance
position, push down the parking brake on the
control box, turn off the power supply of the
machine, stop the engine, and block the tires
with wood wedges.
Conduct the following operations after the
machine is cooled down. During the
disassembly, wrap all pipe connectors to guard
against the ingress of foreign materials into the
pipeline.
2 Drain the coolant.
1
Figure 1-1
1. Water drainage valve
2-18
3 Disassemble the engine hood. Refer to 8-30
Disassembly of Engine Hood.
Engine hood
1
Figure 1-2
1 Engine hood
4 Disassemble the hydraulic oil tank bracket.
Refer to 9-19 Disassembly of Hydraulic Oil
Tank.
Hydraulic oil tank bracket
1
Figure 1-3
1 Hydraulic oil tank bracket 5 Disassemble the engine breather pipe.
1
Figure 1-4
1 Breather pipe
2-19
6 Disassemble the water refilling pipe between
expansion water tank and engine and the engine
water inlet and outlet pipes.
1 2 3
1 2 3
Figure 1-5
1 Water outlet pipe
2 Water refilling pipe
3 Water inlet pipe
7 Disassemble the air inlet and outlet pipes and
brackets between the engine to the air-cooling
radiator.
1 2 3
Figure 1-6
1 Air outlet pipe
2 Bracket
3 Air inlet pipe
8 Disassemble the turbocharger air inlet pipe.
1
Figure 1-7
1 Turbocharger air inlet pipe
2-20
9 Disassemble the heater water inlet pipe.
1
Figure 1-8
1 Heater water inlet pipe
10 Disassemble the heater water return pipe.
1
Figure 1-9
1 A/C water pipe
11 Disassemble the A/C compressor-condenser
pipe and evaporator-compressor pipe.
1 2
Figure 1-10
1 Compressor-condenser pipe
2 Evaporator-compressor pipe
2-21
12 Disassemble the fuel inlet pipe.
1 2
Figure 1-11
1 Fuel inlet pipe
2 Fuel strainer
13 Disassemble the fuel return pipe.
1
Figure 1-12
1 Fuel return pipe
14 Disconnect the electronic control connector of
monoblock pump.
1
Figure 1-13
1 Monoblock pump
2-22
15 Disassemble the fuel temperature sensor.
1
Figure 1-14
1 Fuel temperature sensor
16 Disconnect the connector of engine oil
pressure sensor.
1 2
Figure 1-15
1 Harness connector
2 Engine oil pressure sensor
17 Disconnect the intake pressure and
temperature sensor.
1
Figure 1-16
1 Intake pressure and temperature sensor
2-23
18. Disconnect the coolant temperature sensor.
1 2
Figure 1-17
1 Coolant temperature sensor
2 Instrument display connector
19 Disconnect the cam position sensor.
1
Figure 1-18
1 Cam position sensor
20 Disconnect the crankshaft speed sensor.
1
Figure 1-19
1 Crankshaft speed sensor port
2-24
21 Disconnect the preheater harness.
1
Figure 1-20
1 Preheater harness port
22 Disconnect the alternator harness.
1
Figure 1-21
1 Alternator
23 Disassemble the A/C compressor harness.
1
Figure 1-22
1 A/C compressor harness
2-25
24 Disconnect the starter connector.
1 2
Figure 1-23
1 Starter connector
2 Starter relay connector
25 Securely lift the engine.
Engine
1
Figure 1-24
1 Engine
26 Disassemble the observation window.
1
Figure 1-25
1 Observation window
2-26
27 Disassemble the stud.
1
Figure 1-26
1 Stud
28 Disassemble the connecting bolts.
1 2
Figure 1-27
1 Bolt
2 Torque converter
29 Disassemble the engine fastening bolts.
1
Figure 1-28
1 Fastening bolts
2-27
30 Lower the engine.
Engine 680kg
1
Figure 1-29
1 Engine
262 Assembly of Engine

1 Hoist the engine.
Engine 680kg
★If the stud is loosened, the engine can’t be
assembled by pliers. Instead, tighten two nuts
relatively and use a wrench to rotate the outer nut
for tightening.
1
Figure 1-30
1 Engine
2 Connect the engine with transmission and
torque converter assembly.
1) Apply one film of sealant to the end face of
the transmission, disassemble the top cover
of torque converter, connect the torque
converter with engine by bolts and washers,
and connect the torque converter with the
engine flywheel by nuts.

1
Figure 1-31
1 Torque converter
2-28
★ Tighten all bolts as per the tightening
method of circular grouped bolts. While
connecting the central ring, guard against the
ingress of foreign material into torque
converter.
2) At completion of checking, reinstall and
tighten the window cover on the top of the
torque converter. Apply AT272 sealant
along the perimeter of the window.
AT272
3 Tighten the fastening bolts.
120-200N
1
Figure 1-31
1 Fastening bolts
4 Connect the starter harness.
1
Figure 1-32
1 Starter
2-29
5 Connect the A/C compressor harness.
1
Figure 1-33
1 A/C compressor
6 Connect the alternator harness.
1
Figure 1-34
1 Alternator
7 Connect the preheater harness.
1
Figure 1-35
1 Preheater connector
2-30
8 Connect the crankshaft speed sensor harness.
1
Figure 1-36
1 Crankshaft speed sensor port
9 Connect the cam position sensor.
1
Figure 1-37
1 Cam position sensor
10 Connect the coolant temperature sensor

harness.
1
Figure 1-38
1 Coolant temperature sensor
2-31
11. Connect the intake temperature and pressure

sensor.
1
Figure 1-39
1 Intake temperature and pressure sensor
12 Connect the engine oil pressure sensor

harness.
1
Figure 1-40
1 Engine oil pressure sensor
13 Connect the fuel temperature sensor.
1
Figure 1-41
1 Fuel temperature sensor
2-32
14 Connect the monoblock pump harness.
1
Figure 1-42
1 Monoblock pump
15 Connect and tighten the fuel return pipe.
1
Figure 1-43
1 Fuel return pipe
16 Connect the inlet pipe of fuel strainer.
1 2
Figure 1-44
1 Fuel inlet pipe
2 Fuel strainer
2-33
17 Connect the A/C compressor-condenser pipe

and evaporator-compressor pipe.
1 2
Figure 1-45
1 Compressor-condenser pipe
2 Evaporator-compressor pipe
18 Connect the heater water return pipe.
1
Figure 1-46
1 A/C water pipe
19 Connect the heater water inlet pipe.
1
Figure 1-47
1 Heater water outlet pipe
2-34
20 Connect the turbocharger air inlet pipe.
1
Figure 1-48
1 Turbocharger air inlet pipe
21 Connect the inlet and outlet pipes and
brackets between engine and air-cooling radiator.
1 2 3
Figure 1-49
1 Air inlet pipe 2 Bracket 3 Air outlet
pipe
22 Connect the water inlet and outlet pipes and
oil refilling pipe between engine and radiator.
1 2 3
Figure 1-50
1 Water outlet pipe
3 Water inlet pipe
2-35
23 Connect the breather pipe.
1
Figure 1-51
1 Breather pipe
24 Install the hydraulic oil tank bracket. Refer to
9-23 Assembly of Hydraulic Oil Tank.
Hydraulic oil tank bracket
1
Figure 1-52
1 Hydraulic oil tank bracket
25 Install the engine hood. Refer to 8-33
Assembly of Engine Hood.
Engine hood
1
Figure 1-53
1 Engine hood
2-36
26. Add the coolant.
Coolant 43L glycol coolant
1
Figure 1-54
1 Expansion tank
Fuel Tank
271 Disassembly of Fuel Tank
1. Disassemble the fuel level sensor.
1
Figure 2-1
1 Fuel level sensor
2 Disassemble the fuel outlet pipe.
1
Figure 2-2
1Fuel outlet pipe
2-37
3 Disassemble the fuel return pipe.
1
Figure 2-3
1 Fuel return pipe
4 Disassemble the fastening bolts.
Before disassembling the fastening bolts,
securely hoist by overhead traveling crane to
prevent falloff.
1
Figure 2-4
1 Fastening bolts
5 Hoist away the fuel tank.
Fuel tank 176kg
1
Figure 2-5
1 Fuel tank
2-38
272 Assembly of Fuel Tank

1 Clean the surfaces of fuel tank.
1
Figure 2-6
1 Fuel tank
2 Hoist and assemble the fuel tank.
Fuel tank 176kg
1
Figure 2-7
1 Fuel tank
3 Tighten the fastening bolts.
376-502N
1
Figure 2-8
1 Fastening bolts
2-39
4 Install the fuel return pipe.
1
Figure 2-9
1 Fuel return pipe
5 Install the fuel outlet pipe.
Figure
1 Fuel inlet pipe
1
Figure 2-10
1 Fuel outlet pipe
6 Connect the fuel level sensor.
1
Figure 2-11
1 Fuel level sensor
2-40

Radiator
281 Disassembly of Radiator
1 Drain the coolant.
1
Figure 3-1
1 Water drainage valve
2 Disassemble the air inlet pipe, breather pipe,
and water inlet pipe.
1 2 3
Figure 3-2
1 Air inlet pipe
2 Breather pipe
3 Water inlet pipe
3 Disassemble the water filling pipe, water outlet
pipe, and air outlet pipe.
1 2 3
Figure 3-3
2 Water outlet pipe
3 Air outlet pipe
2-41
4 Disassemble the hydraulic oil inlet and outlet
pipes and the drive oil inlet and outlet pipes
(located on two sides of radiator).
1 2
Figure 3-4
1 Hydraulic oil pipe
2 Drive oil pipe
5 Disassemble the fastening bolts.
Before disassembling the fastening bolts,
securely hoist the radiator by overhead
traveling crane to prevent rollover.
1
Figure 3-5
1 Fastening bolts
6 Hoist away the radiator.
Radiator
1
Figure 3-6
1 Radiator
2-42
282 Assembly of Radiator

1 Clean the surfaces of radiator and hoist the
radiator to the frame.
1
Figure 3-7
1 Radiator
2 Tighten the bolts.
70-100N
1
Figure 3-8
1 Fastening bolts
3 Install the hydraulic oil pipes and drive oil
pipes (located on two sides).
1 2
Figure 3-9
1 Hydraulic oil pipe
2 Drive oil pipe
2-43
4 Install the air outlet pipe, water filling pipe,
and water outlet pipe.
1 2 3
Figure 3-10
1 Air outlet pipe
3 Water outlet pipe
5 Install the air inlet pipe, breather pipe, and
water inlet pipe.
1 2 3
Figure 3-11
1 Air inlet pipe
2 Breather pipe
3 Water inlet pipe
6. Add the coolant.
43L Glycol coolant
1
Figure 3-12
1 Expansion tank
2-44
29 Common Malfunctions and Troubleshooting of Engine

291 Start failure of engine
Factors of starter system
1 Low battery power
Solution: Carefully check the battery power and charge or replace.
2 Damage of starter motor.
Solution: Repair or replace starter motor.
Factors of fuel supply system
1 Air content in fuel system.
Solution: Dredge the fuel line, tighten all connectors, and bleed air.
2 Blockage of fuel line system.
Solution: Dredge the fuel line, tighten all connectors, and bleed air.
3 Dirty diesel filter element.
Solution: Replace filter element.
4 Serious wear of plunger/outlet valve.
Solution: Repair fuel injection pump by professionals.
5 Damage of low pressure fuel delivery pump.
Solution: Replace fuel delivery pump.
Adjustment factors
1 Dislocation of fuel injection advance angle
Solution: Adjust the fuel injection advance angle.
2 Change of valve clearance.
Solution: Check and adjust valve clearance.
3 Low start fuel amount.
Solution: Check fuel injection pump by professionals.
292 Low engine power
1 Blockage of diesel filter or fuel delivery pump pipe connector filter screen.
2-45
Solution: Clean or replace.
2 Insufficient pressure or poor atomization of fuel injector.
Solution: Check and repair fuel injector or replace fuel injector nozzle coupling.
3 Excessive wear of fuel injector high precision coupling.
Solution: Adjust fuel supply amount or check and repair plunger coupling.
4 Air content in fuel system.
Solution: Bleed air from fuel system.
5 Incorrect fuel injection advance angle.
Solution: Adjust as per the requirements.
6 Non-uniform fuel supply amount among cylinders.
Solution: Adjust fuel supply amount for various cylinders.
7 Hindered air cleaner.
Solution: Clean or replace cleaner element.
293 Abnormal exhaust gas (black, white, or blue smoke)
Blue smoke from diesel engine
1 Over-high oil level in engine oil sump.
Solution: Drain excessive lubricating oil till the oil level is within the specified marking on the
oil dipstick.
2 Unsealed closing or burning at opening position of fuel injector needle valve, leading to
ingress of diesel into oil sump
Solution: Clean and calibrate fuel injector or replace needle valve coupling.
3 Damage of fuel injection pump (P pump) plunger sleeve seal ring or poor sealing between
plunger sleeve and pump body, leading to ingress of fuel into oil sump along lubricating oil line
Solution: Replace seal ring.
4 Damage of valve oil seal or out-of-tolerance of clearance between valve and guide pipe,
leading to ingress of engine oil into combustion chamber during intake stroke
Solution: Replace malfunctioned valve, guide pipe, and oil seal (The oil seal must be replaced
2-46
once being disassembled. If the clearance meets the requirement after the replacement with new
valve, it’s acceptable not to replace the guide pipe).
5 Damage of turbocharger seal ring, leading to ingress of lubricating oil into combustion
chamber for combustion along intake passage
Solution: Repair or replace.
White smoke from diesel engine
1 Water content in fuel system.
Solution: Clean the fuel tank and filter and use qualified diesel.
2. Wear of cylinder valves.
Solution: Replace worn parts.
3. Poor fuel atomization of fuel injector and combustion failure of diesel drips within
combustion chamber
Solution: Calibrate fuel injector and fuel supply advance angle.
Black smoke from diesel engine
1. Over-high exhaust backpressure or blocked exhaust pipeline.
Solution: Reduce the bends of exhaust pipe and remove dust from muffler.
2 Delay of fuel injection.
Solution: Adjust the fuel injection advance angle.
3 Poor working or damage of fuel injector.
Solution: Disassemble for cleaning and checking.
4. Poor quality or incorrect trademark of diesel.
Solution: Replace the diesel.
5. Serious wear of cylinder sleeve and piston subassembly.
Solution: Replace worn parts.
294 Over-high or under-low lubricating oil pressure

Over-high engine oil pressure
1 Abnormal engine oil pressure indicator.
Solution: Replace indicator.
2-47
2. Over-high engine oil viscosity.
Solution: Select the engine oil of specified trademark and take preheating measure at start of
engine in winter.
3. Under-low clearance of pressure lubrication portions or blockage of engine oil fine filter.
Solution: Adjust the clearance of lubrication portions and clean or replace engine oil filter.
4. Improper adjustment of pressure limiting valve.
Solution: Readjust the spring force of pressure limiting valve to drop the engine oil pressure to
specified value.
Under-low engine oil pressure
1 Wear of engine oil pump or damage of sealing gasket.
Solution: Repair engine oil pump and replace sealing gasket.
2 Reduced suction amount of oil pump.
Solution: Check the oil amount, add oil, and clean engine oil pump strainer.
3 High leakage amount of engine oil.
Solution: Check the lubrication pipeline for presence of rupture and check the fitting gap of
bearings at crankshaft and camshaft as per requirements.
4 Blockage of engine oil filter or cooler.
Solution: Check and clean the engine oil filter and cooler.
5 Under-low engine oil viscosity.
Solution: Choose the engine oil of appropriate trademark as per the requirements.
6 Improper adjustment of pressure limiting valve.
Solution: Clean pressure limiting valve and adjust or replace spring.
7 Under-low indication of engine oil pressure
Solution: Check and replace engine oil pressure sensor and engine oil pressure gauge.
295 High consumption of lubricating oil

1 Improper choice of engine oil viscosity.
Solution: Choose appropriate lubricating oil.
2 Over-high vacuum pressure of combustion chamber, leading to penetration of engine oil into
2-48
combustion chamber.
Solution: Check the cause of over-high vacuum pressure and adjust accordingly.
3 Change of speed and running mode.
Solution: The test proved that the engine oil consumption is increased significantly along with
the increasing of the speed. Run the engine as per the specified requirements.
296 High coolant temperature

1 Improper choice of coolant or insufficient amount.
Solution: Choose appropriate coolant and add to appropriate level.
2 Blockage of water radiator.
Solution: Use a thin steel plate to carefully put back the radiator fins to original positions and
restore the straight shapes of radiator fins and then clean with compressed air or water gun.
3 Incorrect indication of water temperature gauge or warning lamp.
Solution: Measure the temperature at the water temperature sensor with a surface thermometer
and observe whether the indication of the water temperature gauge is consistent with the actual
temperature.
4 Under-low speed of fan and deformed or reversely installed blades.
Solution: The loose rubber belt of fan will lead to slip and cause under-low fan speed and
deteriorated blowing effect. Upon detection of loose rubber belt, adjust accordingly. If its
rubber layer is aged or damaged or its fiber layer is broken, replace the belt. If the fan blades
are deformed, replace.
5 Malfunction of cooling water pump.
Solution: Replace the water pump.
6 Malfunction of thermostat.
Solution: Replace the thermostat.
7. Damage of cylinder gasket.
Solution: Replace the cylinder gasket.
8 Overloaded running of diesel engine.
Solution: Reduce the engine load.
2-49
Contents
3 Electrical and information system ..................................................................... 3-1
31 Electrical system introduction ......................................................................... 3-1
311 Precautions of electrical system................................................................ 3-1
312 Electrical system introduction .................................................................. 3-2
313 Alternator introduction.............................................................................. 3-4
314 Main power switch ................................................................................... 3-5
315 Electrical control system introduction ...................................................... 3-6
316.Battery ..................................................................................................... 3-14
32 Electrical principles and failure analysis....................................................... 3-18
321 Battery failure and solutions ................................................................... 3-18
322 Alternator failure and precautions .......................................................... 3-19
323 Starter motor principles and troubleshooting ......................................... 3-21
324 Low-temperature auxiliary starter system .............................................. 3-25
325 Overview of completed grader circuits .................................................. 3-26
326 Completed grader circuit learning and diagnosis ................................... 3-31
33Grader harness layout ..................................................................................... 3-62

3 Electrical and information system

31 Electrical system introduction
311 Precautions of electrical system
Any modification of electrical system is prohibited without the authorization of our
company.
Any modification could impair the function of machines or even lead to severe personal
casualty and damage to machine.
Any incaution during operation of electrical system could lead to severe personal
casualty and damage to machine.
Before operating the electrical system, carefully observe the following descriptions and the
relevant introductions.
Before working on the electrical system, take down all metallic goods such as wrist
watch, ring or bracelet.
Battery
1. Before repairing the electrical system, use the fully charged or functional battery.
2. Before installing the battery, ensure the battery poles are correctly connected.
3. The capacity of battery to be replaced should be equal to that of battery replacing it. As the
charging current to reach a certain voltage varies depending on the battery service life years,
these batteries should have the same durable years.
Alternator
1. Before testing the alternator or regulator, check whether the battery or wire is well insulated,
loosened or rusted. Check the belt of alternator.
2. With generator working, never cut off its cable, otherwise that could damage to the
alternator and regulator.
3. Safety connection should be done to prevent against any spark and voltage transient. If the
cable is disconnected, that will damage to the alternator and regulator.
4. If the outlet of alternator is connected to the chassis, that could damage to the alternator and
3-1
regulator.
Electrical elements
Caution! The electronic elements are very sensitive and easily damaged due to
electromagnetism and static electricity from tools and human bodies. Therefore, observe the
following introductions before working on the electronic elements:
1. When some electronic element is being powered, any disconnection to this unit is
prohibited, otherwise, that could damage to the electronic elements.
2. Before maintaining the electrical system, use a tool to contact each metallic part connected
to the frame to release the static on this tool.
3. Never contact the plugs of electronic elements.
4. As servicing the electrical system, do not touch the circuit board. If have to, grasp the edge
of circuit board.
5. Never touch single electrical element.
6. To replace an element, ensure the ground wire is safely connected.
Welding
1. Disconnect the battery poles to prevent against the possible explosion.
2. Before any welding on the complete machine or engine, unplug the engine ECU and
transmission ECU to prevent against any damage to the control unit.
3. The spark during welding could directly fall on the rubber hose, wire or pressure pipe,
possibly leading to sudden breakage or damaging to the insulation of wire. Therefore, use
the fire damper to shield the spark.
312 Electrical system introduction

Electrical system includes: battery, starter motor, alternator, instrument, switch, lamp, A/C
circuit and other equipments.
The complete machine has voltage of DC 24V, including two 12V batteries in series located at
the rear side of cab. Negative ground and single-wire system are adopted. For the relationship and
working principals of electrical equipments, carefully read the electrical system schematic.
3-2
Power supply switch is located at the left side of battery. Turning the switch to could turn
off the power supply of the completed machine; turning the switch to could turn on the power
supply of the completed machine. To store the vehicle for long term, turn off the power supply of
the completed machine. The relays and fuses are mainly located in the distribution box at the back
of driver’s seat and could be seen by uncovering the distribution box. The relays in the distribution
box are interchangeable.
The joints of parts should be marked in the manner of CN+ digit + letter, differing from other
connection. A stands for plug and B stands for slot. Taking I-ECU for example, there are two
connectors: CN6 and CN7, CN6-A meaning plug and CN6-B meaning the corresponding slot.
3-3
313 Alternator introduction

Current: 70A; charging voltage: 28V;
integrated with build-in charger.
The function of alternator: at engine idling, it
could not only power all electrical systems except
for the starter, but also charges the battery. The
regulator, as the voltage-regulating device, could
automatically regulate the output voltage of
alternator as the engine rpm varies to maintain it

Fig.3-1 Alternator terminals steady.
Rotational direction of alternator: viewing
Circuit schematic from the drive end, clockwise.
Ambient temperature of generator :﹣40℃
D + connected to the ~85℃

charging indicator system
This alternator works with battery in the
parallel way, and should not run without loads.
Fig. 3-2 Alternator circuit schematic Appropriate fuse should be installed between
the output end of generator and loads (including
battery).
Rated working rpm: 6000r/min;
Max working rpm: 12000r/min;
3-4
Output feature curve Performance parameters:
Cold status: U＝27V n＝1600r/min
I≥37A ( reference value)

Cold state
U＝27V n＝6000r/min
Hot state
I≥80A (reference value)
Hot status: U＝27V n＝1600r/min
I≥30A
U＝27V n＝6000r/min I≥70A
Fig.3-3 Alternator output feature curve Voltage regulating value: n＝6000r/min
I＝35A
U＝28±0.3V
RPM features: n＝2000 ~10000r/min
I＝7A ｜△ U｜≤0.5V
Load features: n＝6000r/min
I＝7 ~60A ｜△ U｜≤0.8V
Temperature compensation coefficient:
0 ~-10mv/℃
314 Main power switch

If the machine is not in use, power switch
could be used to disconnect the electrical system
from the battery. The power switch is located at
the left side of rear frame and battery switch is
connected to the negative pole (24V) and battery.
Working ambient temperature:

Fig. 3-4 Power switch
﹣ 40℃~+75℃ and relative humidity: no
more than 90%.
3-5
315 Electrical control system

introduction
Electronic control unit of G9190 grader
includes engine control unit (E-ECU) and
instrument control unit (I-ECU). E-ECU could
monitor the engine running state. Any failure
monitored by the E-ECU could be transmitted to
the instrument panel.
Engine control unit (E-ECU)

E-ECU, at the rear side of cab or inside of
trim panel (for positions, shown in fig.3-4),
includes the software controlling the engine
functions and receives the information sent by the
engine own sensors.
Main technical features of ECU:
Working temperature: -40℃~+85℃
Rated voltage: 24VDC;
Working range of voltage: 16~32VDC;
Before any welding on the complete machine
or engine, unplug the engine ECU to prevent
against any damage to the control unit.

Fig. 3-5 Engine control unit E-ECU
To unplug the ECU, the ECU must be
outage.
Main functions:
1. Auxiliary control at cold startup
ECU controls the auxiliary devices for cold
startup according to the circumstances, bettering
3-6
the cold-start performance of engine.
2. Idling control
At low temperature, speed up engine idling
to quickly raise the engine temperature. The
idling control functions at 0℃ or below, raising
rpm by 100-150 rpm.
3. Engine rpm limit
ECU could limit the engine max. rpm and
control the high idling.
4. PTO function
PTO could control engine to idle at a speed
higher than the idling speed. In addition, this
speed could be regulated by a switch.
ECU control is realized by the closed loop.
With this function activated, brake pedal not
depressed down, vehicle speed as 0, the engine
rpm can be regulated by the S+ and R- switch
until the needed one. The rated speed is 100
rpm/s and is controlled by pressing the -/+ button.
5. Multimode fuel-efficient switch
Use the switch (full load or no load) to save
fuel.
6. Smart diagnosis
In case of any failures, the failure indicator
will timely give the warning.
K-line diagnosis: with K line and diagnostic
tools to read and eliminate the failures stored in
3-7
ECU.
Joint calibration of ECU is done by CAN.
7. Emergency function
In case of tachometer failures, max.
allowable rpm should drop.
Engine could automatically raise rpm.
In case of intake pressure sensor failures,
reduce the power.
If the intake temperature exceeds the up
limit, reduce the power.
Instrument control unit (I-ECU)

I-ECU could receive the signal sent from the
sensors and other control units and then visually
display the machine running states by the aid of
LCD, instrument and indicators etc.
I-ECU only receives the signal and visually
displays it, rather than transmitting it. In addition,
I-ECU does not control other units.
Instrument display of start-up process
Self-inspection: after the power is tuned on,
pointers of instrument point to the max. value,
then return back to zero and then point to the
correct value. In addition, the instrument enters
Fig. 3-6 Instrument control unit I-ECU the normal working state after all indicators being
ON for 1.5s.
After the instrument is outage, pointers will
automatically return to zero.
3-8
Work description: the working hour meter
displays the software revision No. as soon as it is
powered on and the accumulated working hours
as soon as it works normally.
After engine is started, the instrument
displays an hourglass symbol and refreshes it
every 6min. The timing data will be stored once
every one minute.
3-9
Instrument control unit (I-ECU) symbols

Name Symbol Name Symbol
Engine tachometer Fuel level gauge
Oil temperature Engine coolant

gauge of torque temperature gauge
converter
Turn indicator Central warning

indicator
Low-braking-pressur Low-fuel-level
e warning lamp warning lamp
Parking brake Safety lock

indicator lamp
High-beam indicator Low-transmission-

oil warning lamp
Engine malfunction Preheater indicator

indicator lamp
Air filter clogging Mute indicator

indicator
3-10
Instrument panel functions

a. Instruments
Function Introduction Signal
Engine tachometer Range: 0-3000; red zone: 2500-3000 Collecting
Unit: n/min the W
signals of
Working hour meter Range: 99999.9; alternator
When engine speed more than or equal to 400n/min,
timing begins.
Throbbing once every 6min; memory working once
every 1min
Speedometer Range: 999.9 Unit: km/h Speed
sensor.
Engine coolant Range: 40-120℃; red zone: 103-120℃; alarming point : Sensor
temperature gauge 105℃
Oil temperature Range: 40-140℃; red zone: 120-140℃ Sensor
gauge of torque
converter
Fuel level gauge Range: 0-1/8-1/4-3/8-1/2-5/8-3/4-7/8-1; red zone: 0-1/8 Sensor
Braking pressure Sensor

Reserved
gauge
3-11
B. Warning
Function Introduction Color Signal
1. Before startup, after switch is turned on, warning

symbol is constantly ON; after switch is turned off,
warning symbol goes out.
Low-oil pressure 2. After startup, when pressure is low, the switch is Red Grounded
warning turned on, warning symbol flashes and buzzer sounds;
after switch is turned off, warning symbol goes out.
3. At the moment of engine startup and flameout,
indicator is not lit.
After the ignition key is turned to ON, if the pressure is low,
Low-braking-pressu
switch will be turned on, warning symbol will flash and buzzer Red Grounded
re warning
will sound.
1. Before startup, whether the switch is turned on or off,
the warning symbol is OFF.
Low-transmission-oi 2. After startup, when pressure is low, the switch is Red Grounded
l warning turned on (delays for 10s to determine the truth of
signal), warning symbol flashes and buzzer sounds;
after switch is turned off, warning symbol goes out.
High-coolant If coolant temperature is more than105℃, warning symbol
Red Sensor
temperature warning flashes and buzzer sounds.
With the ignition key turned to ON, this indicator is constantly
Battery charging ON. W
Red
indicator warning When engine speed more than or equal to 400n/min, this terminal
indicator goes out.
Oil-water separator With the ignition key turned to ON, oil-water separator switch is
Yellow Grounded
warning turned on, and warning symbol is ON.
Fuel strainer With the ignition key turned to ON, when the strainer switch is
Yellow Grounded
warning clogged, and warning symbol is ON.
Hydraulic oil If the hydraulic oil temperature is more than set value, warning
Red Grounded
temperature warning symbol flashes and buzzer sounds.
Low-fuel-level When fuel level is less than or equal to 1/8, the warning signal
Red Sensor
warning will flash.
Engine failure In case of engine failures, warning symbol flashes and buzzer
Yellow Grounded
warning sounds.
With the ignition key turned to ON, if the air cleaner resistance
Air cleaner clogging
is high, the switch will be turned on and warning symbol Yellow Grounded
warning
flashes.
With the ignition key turned to ON, when the moisture content
Transmission oil
in the transmission oil is more than set value, the switch will be Yellow Grounded
filter warning
turned on, lighting the warning symbol.
Before startup, oil pressure and charging indicator are ON and
Central warning this indicator does not flash.
Red
indicator Any one of warning conditions mentioned above is met, this
lamp will flash
3-12
c. Indicating:
Function Introduction Color Signal
Gears: F, N, R, 1, 2, 3, 4 Neutral gear –N , Forward- F, Backward-R Power
Green
supply
Power cutoff indicating After the transmission power is cut off, this Power
Red
symbol will glow. supply
During engine preheating, the indicator will Power
Preheating Yellow
go on. supply
With warning indicator or left turn switch Power
Left turn indicating Green
turned on, this symbol will glow. supply
With warning indicator or right turn switch Power
Right turn indicating Green
turned on, this symbol will glow. supply
High-beam is on and then this symbol will Power
High-beam indicating Blue
glow. supply
After the solenoid valve locks the hydraulic
Power
Safely locking indicating oil pipeline of working equipments, this Red
supply
symbol will glow.
After the mute indicator is turned on, audible Grounde
Mute indicator Yellow
warning will stop and indicator will glow. d
With the manual brake not released, indicator Grounde
Manual brake indicating Red
symbol will flash. d
If seat belt is not buckled, the symbol will Grounde
Seatbelt indicating Red
glow. d
d. Others:
Function Introduction
Instrument backlight After the background lamp switch is turned on, this symbol will glow.
Buzzer Intermittent buzzer: 1.0 ~1.2Hz, 85db
Connector 20pin: molex 0039281203; 22pin: molex 0039281223
5v power supply could power the speedometer through the pins. Max.
5V power supply output
Current output: 500mA; self-recovery fuse installed inside.
Software Software version: VEr 1.0
3-13
316. Battery
Water-free and maintenance-free lead-acid battery is installed on G9190 grader.
Main technical features:

Rated voltage: 12V
Rated capacity of 20h: 70A.h
Reserved capacity: 115min
Starting current at low temperature: 535A
Overall dimension(mm): 260*173*203
Overall height (mm) : 225
Overall weight: 18.8KG
Net weight of lead: 9.7KG
Precautions
As the sulfuric acid in the electrolyte could generates the hydrogen and oxygen during
charging, any handling error could lead to burn or fire. Therefore, do observe the followings:
1. As the sulfuric acid in the electrolyte is strongly corrosive, keep it away from children,
wear goggles and rubber gloves to handle the electrolyte. Once the sulfuric acid is
splashed into your eyes or onto your skin, immediately flush them with lots of clean
water, if needed, go to the hospital.
2. Before working on the battery, switch off the engine.
3. Before installation, connect the battery positive pole to the positive pole of engine, and
then connect the battery negative pole to the negative pole of engine. Before removing
the battery, first disconnect the negative wire (-).If the electrolyte approaches the “Lower
level”, refill it with distilled water until it reaches below the “Upper level”.
4. Do not reversely or horizontally place the battery. Keep the battery away from
mechanical beat or heavy weight.
5. As hydrogen and oxygen generated in charging could explode in case of open fire or
clogging in vent, battery should be kept away from the open fire and should be
3-14
prevented against any short circuit due to contact with metallic goods (such as tools).
6. Use a rag rather than the gasoline, solvent, other organic solvent or detergent to clean the
top surface of battery. The battery casing is inflammable and should be kept away from
the open fire.
7. Battery should be stored in clean, well ventilated, 5 ~25℃ ambient, and kept away from
the thermal source by 2m at least and should not be exposed to sunshine.
Too high temperature will greatly impair the battery performance. At room temperature, the
battery can be stored for 6 months without any charging. The battery stored for more than 6
months can still be available after being recharged.
If you do not use the battery already installed on vehicle for a long time (generally 15 days),
please remove it from the vehicle, and then store it at the dry and well ventilated site. Please
charge the battery every 3-6months (depending on whether the indicator becomes black).
8. Before replacing the battery, use the rubber pad to protect the battery, fixing plate to
secure it. At last, install the safe guard.
9. A liquid densimeter, installed on the top of battery, is used to observe the charging state
of battery, where green means the battery is at good state and is not needed of charging,
dark color means the battery is needed to be charged. If the electrolyte level already
drops to the level lower than build-in small densimeter, the center point will change to
full dark color or white, indicating the battery can not normally work and is needed to be
replaced.
10. Frequently check the discharging state of battery, timely recharge it if 50% is discharged
in summer or 25% is discharged in winter.
Battery charging specifications
1. Ensure the battery poles are clean and charging circuit is well connected.
2. Charger positive pole should connect to the positive pole of battery and the negative pole of
charger to the negative pole of battery. Never charge the battery in the serial way (24V).
3. It is suggested to charge the battery by using constant-voltage 16V and 25A (up limit) until
3-15
the densimeter changes to the green. Max. charging voltage should not exceed the 16.2V,
otherwise, lots of water will be electrolyzed, electrolyte level dropping and densimeter
becoming white. That means the battery can not be used.
4. If the battery can not be charged by the constant-voltage way, refer to the constant-current
methods shown as follows:
4.1. Charging current: 1/8 ~1/10 of rated capacity. At the last phase, charging voltage should
reach but not exceed the 16V (if less than 16V, after the charging is over, the densimeter
is still black). If charger can not guarantee that the charging voltage is less than 16V, the
voltage at the battery end should be manually monitored once every 1hour. Otherwise,
that could lead to lack of water due to over-voltage charging, shortening the useful life
and even losing efficiency.
4.2 The relationship between charging time and voltage before charging
Charging duration Charging duration
Battery voltage /V Battery voltage /V
/h /h
12.55 ~12.45 2 11.80 ~11.65 8
12.45 ~12.35 3 11.65 ~11.50 9
12.35 ~12.20 4 11.50 ~11.30 10
12.20 ~12.05 5 11.30 ~11.00 12
12.05 ~11.95 6 11.00 or below 14
11.95 ~11.80 7
4.3. After charging is over, check the battery liquid densimeter color, where green means the
battery is fully charged. In case of black, check whether the charging connection is well
fastened, whether the connecting point is clean or whether the charging voltage reaches
16V at the last phase. After 24h, measure the voltage and refer to the relationship above to
recharge it.
4.4 If the densimeter is white, maybe there are bubbles inside, then shack it to eliminate the
bubbles. After that, if it is still white, replace the battery.
4.5. For the battery with voltage less than 11V, maybe the battery can not be charged at the
initial stage, because the battery is severely lack of electricity, the density of sulfuric acid
3-16
is close to that of the pure water and resistance of battery is very high. In such case, reduce
the charging current or replace it with charger with higher power. As battery is charged,
the sulfuric acid density will rise and charging current will gradually restore to the normal.
4.6. During charging, if the battery sprays a lot of sulfuric acid, stop charging to find out the
cause.
4.7 During charging, if the battery temperature exceeds the 45℃, stop charging until the battery
temperature drops to the room temperature. Then recharge it by the way of current
dropping to the half.
4.8. During charging, the densimeter should be checked once every hour, where the green
means the battery is fully charged and charging should be over.
4.9. After the charging is over and battery is tested qualified, it is suggested to coat the
terminals with the grease or vaseline to prevent against the electric corrosion.
3-17
32 Electrical principles and failure analysis

321 Battery failure and solutions
Battery voltage test
Use the voltage meter or multimeter to measure the battery voltage so as to judge its technical
status.
Firstly turn on the starting switch. When the engine is not started, the terminal voltage range of
battery of the 24V electrical system displayed by the voltage meter should be 22.8 ~25.2V. If the
voltage is too low, that indicates the battery is severely lack of electricity or short circuited. After
the starting switch is turned on and within 3~5S of engine startup, the voltage meter should display
the 18~22V. If less than 18V, it indicates the battery needs to be repaired or replaced; if higher than
22V, it indicates the battery is good and can still work.
Failure Phenomenon Possible cause Troubleshooting
Outside Damaged Pole corroded or loosened, casing Repair or replace it
failures cracked or electrolyte leaked. as case may be.
Vulcanization 1. White, hard and 1. Insufficient charging has lasted for For battery with
of pole plate not-soluble coarse lead long time. slight
occurs. sulfate are accumulated 2. After discharging, the battery is not vulcanization,
on the pole surface. charged timely. adopt the method
2. Battery charging capacity of equalizing
3. Frequently charge it or completely
is poor; voltage rises very charging to handle
discharge it at small current.
fast during charging to it: current: 1/40 of
4. Electrolyte is impure or rated capacity;
2.9V/cell (normally:
self-discharging is severe. duration: 20-30h;
2.7V/cell)
5. Inside of battery is short circuited or repeatedly and
3. During discharging,
lots of water accumulated on the fully charging and
voltage drops very fast to
surface of battery, leading to discharging it.
1.8 V/ cell for 1-2h, with
leakage of electricity. Replace the battery
capacity obviously less
6. Inside of battery, the electrolyte with severe
than others.
level is low, making the exposed vulcanization.
part of pole plate vulcanized.
Battery Battery can not be charged, 1. Pole is damaged or cracked. Replace it
open-circuited without current displaying. In 2. Rosin joint
the severe case, arcing may
happen inside of battery.
Battery short 1. Low voltage 1. Short circuited due to damage of Replace it
-circuited 2. Insufficient capacity partition or leakage of lead.
3. After charging, the 2. Electrolyte impure; impurity
voltage is still less than crystallization, leading to short
the normal value. circuit; active materials on the pole
plate severely coming off; the cast
accumulating on the bottom of cell,
leading to short circuit.
3-18
322 Alternator failure and precautions

Maintenance and
Failure Phenomenon Cause
precautions
Short circuits are 1. Dipping paint of stator is not
divided into well handled; the insulation
phase-to-phase paint could not fill up the slot, Regular
short one, loosening the wires. maintenance; timely
Stator
winding turn-to-turn one 2. Due to the lack of lubricant in replace the severely
short-circuited and bearing or erosion, radical loosened bearings.
or winding-to-winding clearance of bearing rises, Timely repair or
open-circuited one, wherein the deflecting the rotator shaft. replace the casing if
former two can be Then the rotator may hit the the outer race of
inspected from the stator, raising the stator winding bearing and bearing
outside, appearing temperature and leading to local casing wears.
the burnt color or short circuit or mechanical open
discolor. circuit.
1. Alternator overloads for long
time due to unreasonable
configurations, leading to stator
burnt.
Stator core Alternator is stuck 2. The screws on the front/rear Timely tighten the
damaged or scratched. end covers are not tightened, loosened screws.
damaging to the stator due to
scratch.
3. Damaged insulation causes
short circuit.
1. Lead of
windings is not 1、 Windings and ring are not well Replace the brush with
properly welded with each other. 50% or more wear and
welded or cut 2、 Clearance between the ring and invalid spring; replace
off. the ring with runout
Rotator rotator shaft becomes widened;
more than 0.05mm or
windings have 2. Brush wears the lead is cut off.
severely or is severely burnt surface;
open circuit. 3、 Ring is not well connected to
loosened. grind the ring by
the contact surface of brush, lathing it and then use
3. Brush is broken leading to the alternator unable the ethyl alcohol to
or stuck. to generate the magnetic field. wipe the ring surface.
4. Ring is burnt.
1. Voltage regulator is damaged,
Rectifier Output voltage of leading to the diode breakdown. Do not install
assembly alternator is too
high-power electrical
short-circuited low; or the voltage 2. The positive or negative
working voltage /current is too equipments to the
or can not be
high, leading to the diode grader.
open-circuited outputted.
breakdown.
3-19
Alternator unable to be charged
At engine normally running, if the charging indicator glows or the ampere meter points to the
negative direction, it indicates the alternator can not work normally, accordingly the battery can not
be charged, mainly because the alternator, regulator or electrical system fails.
Disconnect the terminal connecting to the magnetic field of alternator. Turn on the electric lock
switch, then use the multimeter (DC test lamp) to check the terminal. If there is electricity, it shows
the generator fails. Further check the brush, ring, rotator and stator or replace the alternator. If there
is no electricity, check the terminal of regulator magnetic field. If this terminal is live, the circuit
from the regulator to the alternator is opened; if there is no power on terminal, please check the
terminal of live wire of regulator. If this terminal is live, the regulator fails, then check or replace
the regulator; if there is no power on terminal, the circuit from the electric lock to regulator or
electric lock circuit is opened.
Charging voltage too low
With engine running, if the charging indicator flashes or pointer of ampere meter swings
leftward or rightward surrounding the zero, starter running is powerless or can not drive the engine,
maybe the working voltage of regulator is lack of regulation or fails, regulator belt is too loose or
inside alternator or battery fails.
Firstly use the AC voltage gear of multimeter to measure the voltages of battery and alternator.
If the measured voltage is less than the standard value, it shows the charging voltage is too low.
Then check for the fan belt tension. If too loose, readjust it according to the standard. If the
measured voltage is normal, check whether the alternator or battery fails by the way shown below:
with engine running at intermediate speed or more, disconnect the battery ground wire, then if the
engine could run normally, that indicates the output power of alternator could meet the
requirements of ignition system or other equipments and battery fails. If the battery ground wire is
disconnected, the engine stops running, that shows both the battery and alternator fail.
Charging voltage too high
If the alternator voltage is too high, charging indicator will easily be burnt during engine
3-20
running and the water in the electrolyte will consume rapidly, mainly because the working voltage
of regulator is not properly adjusted or the regulator fails.
Start the alternator and then have it run at mid speed, and shift the multimeter to the DC voltage
gear (25V). Then connect its red pen to the armature of alternator and black pen to the casing of
generator. Then measure the voltage of battery or alternator. If the measured voltage is higher than
the standard, it shows the charging voltage is too high, replace with a new electronic regulator.
323 Starter motor principles and

troubleshooting
Overview
Starter motor is a device converting the
electric energy of battery to the mechanical energy
so as to start the starter. Starter motor consists of
DC motor, drive mechanism (engaging
mechanism) and control mechanism
(electromagnetic switch) etc. The function of DC

Control end
motor is to convert the electric energy to the
mechanical energy, generating the electromagnetic
torque. The function of powertrain mechanism: to

Fig. 3-7 Starter circuit
start engine, it transmits the electromagnetic
torque to the flywheel, drives and then starts
engine. After the engine is started up, the drive
gear of starter motor will automatically slip to
prevent the engine from driving the armature of
motor and eventually it disengages the flywheel
gear. Control device could control the circuit ON
3-21
or OFF from motor to battery and disengagement

Screw
or engagement between the powertrain mechanism
and flywheel.
Control circuit of starter motor
The control device is controlled by ignition
key via starting interlock relay. SG-6-gear selector
could send the signal to the starting interlock relay
to limiting the engine be started only with
transmission shifted to neutral gear, and
accordingly improving the safety of machine.
Fig. 3-8 Outside terminals of starter
Use and protection of starter motor

Not much maintenance is needed for the starter motor, however, lack of basic maintenance
could cause a lot of troubles to the operator.
Precautions:
1. Voltage dropping at the starter motor negative pole or the positive pole due to any reason could
impair the starting performance. Leading to difficult or unable startup. Therefore, firstly, ensure
the all poles in the battery circuits are clean and secure to reduce the resistance; secondly, as
casings of most starter motors are grounded, check whether the engine housing is well
connected to the negative pole of battery; thirdly, the battery cable section area, materials should
meet the requirements, moreover, the overall length of cable should be as short as possible to
reduce the wire resistance.
2. The dust covers and sealing gaskets of starter motor should be properly installed to prevent the
transmission lubricant and dust from getting in the inside of starter motor.
3. As soon as the engine is started, the starter motor should stop running to reduce the motor wear
and battery power consumption. In addition, starter motor long-time running could not only
3-22
raise the temperature of DC motor windings but also over discharge the battery, shortening the
useful life. Generally, the starting time should not exceed 5s. If the engine is not started, wait for
15s for a second startup; if the engine can not be started for three consecutive times,
troubleshoot it and try again.
4. Before startup, shut down all electrical equipments irrelevant to engine starting, at the same
time, shift the transmission to the neutral gear to increase the starting capacity of starter motor
and to reduce the engine resistance torque.
5. If the too-low ambient temperature leads to difficult startup, before starting up, sufficiently
preheat the engine to reduce the engine oil viscosity so as to reduce the engine resistance torque.
Common failures and solutions of starter motor

Starter unable to work
After the ignition key is turned to ON, if the starter cannot work, the possible causes are: starter
relay or the starting switch is open circuited. After troubleshooting, if the starter cannot run, the
inside of starter fails and the possible causes: coil in the electromagnetic switch of starter fails, the
starting switch is burnt or is not properly connected, motor brush, commutator and armature or field
is open circuited.
Starter powerless
Although the starter could drive the crankshaft of engine to run, the running rpm of crankshaft
is low, leading to difficult startup. That indicates the load-bearing capacity drops and actual
output power reduces, and the possible causes are: battery lacks of electricity; battery terminals
are loosened or corroded; starting switch or the commutator is burnt; the brush wears excessively
or the spring is powerless; the motor armature or electromagnetic windings are short circuited;
too tightened engine assembly or low ambient temperature could raise the starting resistance
torque.
Starter unable to stop
Release the starting switch of power supply and the starter cannot stop running, then the
possible causes are: starting switch fails; starter relay fails or the starting switch is stuck.
3-23
Starter idling
Although the starter is running, the engine crankshaft cannot rotate, and the possible causes are:
single-direction clutch slips; forks are not appropriately adjusted or are stuck; the pushing force of
drive gears is insufficient; gears impact with each other or wear successfully; the fork shaft is lost
etc. The problems can be solved by replacing the clutch.
Noisy starting
In case of rhythmic knocking sound during startup, the possible causes are: the holding coil in
the electromagnetic switch is open circuited; starter relay is damaged; battery lacks of electricity or
the contact between poles is poor; in case of continuous rubbing or howling noise, the possible
causes are: bearings are worn; armature is bent or rotator is out of round, and that could lead to
armature impacting with the casing, commutator is burnt or the brush is not appropriately connected
etc.
3-24
324 Low-temperature auxiliary

starter system
Principles
G9190 grader adopts cylinder-to-cylinder
preheating: use the glow plug to heat the air
entering each cylinder.
Electric-controlled glow plug has perfect
functions: after the power starting switch is
Thermal shrinkage hose

started, turn this switch to the preheating
position, lighting the preheater indicator. E-ECU
could control the preheater relay to be closed at
set time, powering and then heating the glow
图 3-9 预热塞 plug. After preheating for 15s, turn the voltage
starting switch to the starting position, powering
the starter relay and then having the starter work.
At last the engine could be smoothly started at
low temperature.
Inspection of Low-temperature
auxiliary starter system
Fig. 3-9 Preheater Use the Ω gear of multimeter to measure
whether the influx wire of glow plug is
connected to the engine cylinder. Apply the
battery voltage equal to that of the electrical
system on the glow plug, the current is higher at
the beginning and will drop after 15s when the
temperature reaches 180 ~220℃.
3-25
325 Overview of completed grader circuits

Composition of electrical circuits
1. Circuits of power supply
Consisting of battery, alternator, regulator and indicators, as well as the protective elements
2. Starter circuits
It consists of starter, relay, starting switch, preheater and its control circuit, as well as the
protective elements.
3. Circuits of lighting and signaling devices
Consisting of headlamp, turn lamp, brake lamp, reverse lamp, scraper lamp and their relays
and switches
4. Circuits of instruments
It consists of instrument indicator, sensor, all kinds of warning lamps and controllers etc.
5. Circuits of auxiliary devices
It consists of all kinds of electrical devices aiming to enhancing the grader safety and
comfort etc., including the wiper, cleaner, A/C system, cigar lighter and radio etc.
Analysis of circuits
Analysis method: firstly analyze the each-element circuit and then assembly circuits, namely
sequence of “from part to whole”. To study some circuits, firstly learn the working principles and
working nature, then apply the relative connecting principles to analyze and master the circuits.
The concrete method is that: along with the current flowing direction, analyze the circuit from
the power supply to the electrical elements; the reverse direction is also available. If you want to
find out the unfamiliar circuits, the latter is more convenient.
Refer to the principles of “Breaking up the whole into parts and Closed loop” to learn the
circuits. That could be very easy to locate the wire connecting the two parts and could be helpful
to find out the circuit failures and solve them.
Features of electrical circuits:
1. Grader electrical system adopts single-wire system. To analyze the circuit principles, check
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along the circuit from the electrical elements to the electrical switch and protective elements
and to the power supply positive pole. As the circuits are closed, the electrical system must be
grounded. Therefore, do not neglect the failures due to poor grounding.
2. Grader has two power supplies, namely the alternator and battery are connected in parallel,
with electrical protector installed between them.
3. All electrical devices are also connected in parallel and controlled by the relevant switch in the
manner of controlling the power supply wire and controlling the ground wire.
4. In order to prevent against any damage to the circuits or electrical devices due to short circuit or
grounding, each circuit is equipped with a protector.
Grader circuit failure diagnosis and solutions

Common failures of electrical system: short circuit, open circuit, grounding, poor connection
and control device failures etc.
Inspection of circuits
Taking the grader technical maintenance or driver-found failures into the considerations, check
the outside surfaces of the whole electrical circuits, mainly including:
1. Secure: each electrical part and wire should be reliably fixed; casings and parts should be intact;
2. Connection and clean: each plug should be firmly installed; grounding points should be tight;
each contact point should be free of rust, oil, or burn; the wire surface should be free of oil stain,
dirt or dust.
3. Insulation and shielding: the insulation of wire should be free of damage or aging; any exposed
parts should be wrapped by the adhesive tape; the shielding layer of wire should be free of crack
or scratch.
4. Fuses and relays: each fuse and relay should be reliably installed; wire should be appropriately
connected; the fuse and relay selection should be reasonable and meet the circuit rated value.
5. Switches: each switch and button should act smoothly, without any stuck or failure.
Instrument and detector
Use the instrument and special detector such as the voltage meter or DC lamp to check the
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electrical system so as to locate the failures. In addition, scratching fire is prohibited.
1. Inspection by measuring voltage
Measure the voltage of related parts to judge the technical status of starter system and
power supply system. That could be regarded as the one of daily maintenance of grader and
also has import significance in correct operation of electrical system and timely solving the
failures.
1.1、 Measurement the voltage of battery: keep the headlamp ON for 30s to remove the
float electricity of battery, then turn off the headlamp and measure the voltage of
battery. The measured voltage should be 24.5V or more.
1.2、 Measurement of starting voltage to judge the battery, starter and connection state:
turn the ignition key to the Start gear to start engine, within 15s the battery voltage
should reach 19.5V or more. If less than this value, the battery terminals may be
corroded or poorly connected; battery over discharging or fails; starter motor fails.
1.3、 Measure the voltage to judge the state of alternator regulator: start engine and have
it run at 2000r/min, then measure the voltage of alternator or battery. The
measurement voltage value should be within 27.4 ~29.5V. In such case, it is normal
that the current reading of voltage meter on the vehicle is higher than that before
startup; if the reading exceeds 30V, the regulator fails. To make the result more
accurate, turn on the headlamp or the auxiliary electrical system, if the reading of
voltage meter on vehicle is less than 27V, maybe the drive belt is loose; contact
points of wire are corroded or loosened; regulator or alternator fails.
2. Measurement of voltage drop
This method is suitable for the inspection of wire, battery and joints. Although ohmmeter could
measure the circuit resistance, it has low voltage and current, unable to reflect the actual conditions.
Therefore, it is more reasonable that the voltage drop is measured as the current passes by. Select
the voltage meter with range of 0-3V and accuracy of 1.0 grade or more, then energize the circuit to
be measured. The measured result should be that the voltage drop of common circuits is 0.1V and
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starting circuit 1V at most.
3. Test of leakage of battery electricity
This test could judge the grounding or poor insulation etc. Turn off all electrical devices,
measure the current between the negative pole and grounding point. The measured current
value should not exceed 30mA or 300mA for the grader equipped with electric control system,
otherwise it indicates battery leakage. The possible causes: electric leakage at the switch or
wire; alternator diode short-circuited or high leaked electricity; regulator or electronic control
device fails; or the switch fails.
4. Inspection of short /open circuits
4.1. Inspection of open circuit: connect the tester lamp or special tools between the circuit
connector and grounding point, then turn on the relevant lamp, if the lamp does not glow,
this circuit must be opened.
4.2. Inspection of short circuit: any short circuit could burn the fuse. Before replacing the
fuse, find out the cause by adopting the following methods:
A ohmmeter: connect one pen to the grounding point and connect the other to the fuse , if the
displayed resistance is zero or little, short circuit must happen. Then sequentially disconnect the
electrical devices controlled by this fuse, if the displayed resistance gradually increase, this device
must be short-circuited.
B buzzer: in case of short circuit, the buzzer will sound. Then sequentially disconnect the
relative devices, if the buzzer mutes, this device must be short-circuited. (grader electrical devices
are connected in parallel.)
C interrupter and magnetic flux meter: connect the interrupter to the both ends of fuse, check
the pulsed magnetic field of wire to be tested along with magnetic flux meter, where the pointer of
magnetic flux meter stays still is the short-circuited point.
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Main power supply Main power supply
Fuse
Starting switch
Terminal
Position
SG-6S gear selector

Starting
Starting interlock
interlock
ECU power supply
relay
Preheater Preheater relay
Shuihanbao relay
Electric
pump
Starter motor
Fuse
Power supply switch
Positive pole Control

Alternator
shaft shaft
Fig. 3-10 Power system circuit diagram
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326 Completed grader circuit introduction and diagnosis

Circuits of power supply system
1、 After the power supply is turned off, the voltage of battery goes through 56a wire→60A
fuse→56 wire→ connector CN24→56wire→connector CN5→5A
fuse→121wire→connector CN4→connector CN59→121wire→starting switch.
2、 After the starting switch is turned to ON, the terminals B and BR of starting switch are
connected. Wires 121 and 28 are passable. It can be reviewed that the current goes through
the BR terminals, No. 28 wire and then the connector CN60, then is divided into three ways.
The first way: the current goes to the Shuihanbao relay through the connector CN23 and No.
28 wire. Then the Shuihanbao relay is powered, followed by the electric pump that could
pump oil.
The second way: the current goes to the main power supply relay through the connector CN4
and No.28 wire, then the relay is turned on, energizing the No.56 and 2 wires and then the
fuse of No.2 wire.
The third way: the current goes to the No.24 connector of E-ECU through the connector CN9
and No.28 wire. E-ECU after being energized will refer to the ambient temperature to judge
whether the preheating is needed. If the ambient temperature is low, No.61 connector of
E-ECU will send a current signal to energize the preheater relay through the No.61 wire,
connectors CN9 and CN23, having the preheater work.
3、 If the transmission is shifted to neutral gear, SG-6S gear selector will power the No.11 wire.
Then the starting interlock relay is energized via the connector CN2. At this time, turn the
starting switch to the START, turning on the terminals of B, Br and R2. The current flows to
the No.30 terminal of starting interlock relay via the No.60 wire, connectors CN59 and CN2.
Before that, since the starting interlock relay has already be turned on, the current flows out
from the No.87 terminal of starting interlock relay to the starter motor assembly through the
connecter CN2, No, 22 and connector CN23. Then the starter motor assembly begins to work.
After the grader engine is started, the alternator driven by the drive belt begins to generate
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the electricity.
4、 After the engine is started, the driver should release the starting switch that then could
automatically reset to ON gear, disconnecting the No.61 wire and starting interlock relay. At
last, the starter motor stops working.
5、 Turning the starting switch to OFF could disconnect the No. 28 wire. Then the engine control
unit could not receive the signal from starting switch, controlling engine to be switched off.
6、 At last, switch off the power supply.
Main components and maintenance:

Starting switch
1、 Starting switch, also called as the electric lock, could be used to control the functions of
power ON, OFF, Start or Flameout etc.
Starting switch has the six pins: B, BR, R1, R2, C and ACC and each pin has different
functions. The grader wiring method is shown in fig. 3-9.
2、 Methods for judging whether the electric lock is damaged: Disconnect the wire from the
electric lock, remove the lock from the vehicle and then shift the multimeter to the 200Ω
gear to check whether the electric lock is conductible. If conductible, the lock is good; if
not, the lock fails, repair or replace it.
Fuse
Fuse, as a protective element, features simple structure, convenient use and low cost etc. The
fuse should be connected in the protective circuit in series. In case of the protective circuit is
overloaded or short circuited, the fuse will be blown, functioning as protective role.
Use the same-specification fuse to replace it. It is not allowed to use the copper wire in
emergency. The color and specifications of fuses are shown as follows:
Specification Color Specification Color
5A Orange 15A Blue
7.4A Brown 20A Yellow
10A Red 30A Green
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Relay
If a certain current goes through the relay coil, the coil will generate the electromagnetic field,
actuating the contact points of relay. When the coil is out of electricity, the two contact points will
separate.
Method for judging whether the relay is damaged or not: use the ohm gear of multimeter to
measure the resistance, the measured value between the pins 85 and 86 should be relative high and
the measured resistance between the pins 30 and 87 could be infinite. Pin 86 is connected to the
positive and negative poles of DC 24V power supply. The pins 30 and 87 should be conductible.
As the relay-type diode is equipped inside of relay, the No.85 terminal should be grounded.
Whereas the ground wire can not be connected to the No.86 terminal, otherwise the relay can not
work normally.
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Common failures, reasons and solutions of main circuits

Failure Phenomenon Cause Solutions
1、 Main power switch is 1、 Turn on the main
not turned on. power switch.
2、 Main power switch is 2、 Replace the main
damaged. power switch
3、 Battery severely lacks 3、 Recharge or replace
When the electric of electricity. battery
lock is closed, the 4、 60A and 10A fuses are 4、 Carefully find out
sound of power blown. the circuit failures and
Completed
relay actuating can then replace the fuse.
vehicle
not be heard and 5、 Electric lock is 5、 Replace the electric
powerless
whole electrical damaged. lock
system is 6、 Relay of power supply 6、 Replace the power
powerless. is damaged. supply relay
7、 The binding post of 7、 Check and then
battery is loosened. tighten the cable
connection point.
8、 Harness connector is 8、 Recheck the relative
loosened. connectors.
1、 Gearshift lever is not 1、 Shift to N gear.
shifted to neutral gear.
2、 The control unit of 2、 Ask professionals for
Turn the electric
gearshift fails, unable to help.
Engine lock to the Start,
output the N-gear signal
unable to be but the whole
to the starting control
started vehicle has no
wire.
response.
3、 Starting interlock relay
fails. 3、 Replace the starting
interlock relay.
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After 1、 Electric lock is stuck or 1、 Replace the electric lock
engine is fails.
started, the The electric lock 2、 The contact points of 2、 Replace the start relay
starter does not return starter relay are burnt.
motor can back. 3、 The contact points of 3、 Repair or replace the
not stop starter motor control starter motor
running. unit are burnt.
of electricity. battery
2、 The terminals of battery 2、 Grind, clean or tighten
are severely corroded, the battery terminals.
oxygenized or loosened.
3、 Starter control circuit 3、 Find out the causes;
fails, for example: repair or replace the
Turn the electric
circuit is opened or not failed elements.
lock to Start, but
Starter well connected; the
the starter motor
motor electric lock or starter
has no response or
unable to relay is damaged
starter motor runs
rotate or 4、 The control unit of 4、 Check whether the
slowly, therefore
powerless starter motor fails. suction coil or the holding
the engine can not
coil is short-circuited,
be started.
open-circuited or
grounded; check whether
the contact points or
terminals are burnt; if so,
repair or replace it.
5、 The DC motor of starter 5、 Check the starter motor.
fails.
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1、 Check whether the
one-way clutch slips.
2、 Check whether the drive
gear or the flywheel is
Turn the electric damaged.
lock to Start, then
Starter 3、 Check the drive gear,
the starter motor The drive mechanism of
motor flywheel or armature
runs at high speed, starter fails.
idling bushing is worn.
but the engine
rotates slowly. 4、 Check whether the fork
is broken or separated.
5、 Refer to the actual
conditions to repair or
replace the starter motor.
of electricity or fails. battery
2、 The terminals of battery 2、 Grind, clean or tighten
are severely corroded, the battery terminals.
oxygenized or loosened.
3、 The holding coil of 3、 Repair or replace the
starter fails. starter motor
4、 The relay of starting 4、 Replace the start relay
control circuit is not
Drive gear After the electric conductible; the voltage
of starter lock is turned to of this relay is slightly
motor hits Start, drive gear of higher.
the starter motor hits 5、 The clearance between
flywheel. the flywheel. 5、 The latter three items
the drive gear and limit
belong to the inside
ring is slightly widened.
failures of starter motor,
6、 The drive gear, therefore, find out the
flywheel, armature causes, repair or replace
bushing are severely the starter motor.
worn.
7、 Starter drive spring is
too soft or fractured; the
fork is out of the
position.
1、 Diesel pipe is bent, 1、 Smooth the diesel
Grader could start
Engine leading to the difficult pipeline.
and after a while
automatic fuel supply
automatically
flameout 2、 Flameout control 2、 Check the flameout
stalls.
system failure occurs. control circuit.
3-36
Instrument system
Instrument monitoring – sensor system introduction
G9190 grader instrument monitoring- sensor system consists of stepwise combine instrument,
engine coolant sensor, engine oil pressure switch, rear-wheel-speed sensor, torque converter oil
temperature sensor, transmission pressure sensor, fuel level sensor, air filter clogging pressure
switch, low braking pressure warning switch etc.
Oil Water
Speedo temperature temperature Fuel
meter gauge gauge gauge
Warning
lamp Instrument controller
Coolant temperature signal
Oil temperature signal
Battery power supply

Speedometer
Fuel signal
Power
Engine coolant temperature

sensor
Rear-wheel speed sensor
Engine oil pressure switch
Air filter clogging pressure switch

Low braking pressure
warning switch
Torque converter oil temperature

sensor
Excitation
resistance
Transmission oil
pressure sensor
发电机
Alternator
Fuel level
sensor
Fig. 3-11 Instrument system –sensor system schematic
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Main components and

maintenance:
Sensor system related instrument panel
shown in fig. 3-10 consists of speedometer, oil
temperature gauge, coolant temperature
gauge, fuel level gauge, low braking pressure
warning indicator, low oil pressure warning
indicator, low transmission oil warning lamp
and air cleaner clogging indicator etc.
Low braking pressure warning

switch
30s after the G9190 grader engine is
started, the low pressure warning lamp of
service brake should not flash; if it flashes,
stop engine for troubleshooting, as failing to
braking vehicle could lead to possible

Fig.3-12. Low braking pressure warning accidents.
switch
Low braking pressure warning switch of
service brake is installed on the prefill valve
connected to the energy accumulator.
Temperature sensor
G9190 grader has been equipped with two
temperature sensors, controlling the engine
Fig.3-13 Engine coolant temperature coolant and torque converter oil temperature.
sensor
These temperature sensors belong to the
thermistor sensors, namely, the temperature
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rises, so does the conductivity. Therefore the
resistance drops gradually.
Fig.3-14 Torque converter oil

temperature sensor
Transmission oil pressure warning
switch
G9190 Transmission oil pressure warning
switch located on the speed-change valve of
transmission could monitor the drive oil
pressure. When the oil pressure drops to
1.1Mpa, the contact points actuate, lighting
the transmission oil pressure warning
indicator and giving the buzzing.
Fig.3-15. Transmission oil pressure

warning switch
3-39
Fuel level sensor

Actually, G9190 grader fuel level sensor
located on the fuel tank is a sliding resistor. As
the oil level rises, the resistance drops.
Fig.3-16 Fuel level sensor

Engine oil pressure switch
The warning point of G9190 grader engine
oil pressure switch is 0.7bar. One end of this
switch is connected to the pin 52 of ECU and
other to ground. When the oil pressure is less
than set value, the warning happens and engine
enters into protective state.
Fig.3-17 Engine oil pressure switch
Rpm sensor.
G9190 grader rpm sensor located on the
transmission belongs to the hall effect sensor,
where the red wire of this sensor is connected
to the 24V power supply, the yellow one is the
signal wire outputting the signal to the
tachometer on the instrument and the blue one

Fig.3-18 Engine tachometer sensor
is grounded.
3-40
Common failures and solutions

Temperature gauges could not indicate
normally.
Remove the sensing wire at the
temperature sensors (respectively No.15 wire
of torque converter oil temperature sensor and
No.14 wire of engine coolant temperature
sensor shown in the schematic). If the sensor
is grounded, instrument could display the
max. value; if the sensor is open circuited, the
instrument could display the min. value,
indicating the instrument and wire are good
and the sensor is damaged. Then replace the
damaged sensor. Otherwise, check the wire, if
good, the instrument must have failed.
Fuel level gauge could not indicate normally
Remove the sensing wire at the fuel level
sensor (respectively No.19 wire of fuel level
sensor in the schematic). If the sensor is
grounded, instrument could display the max.
value; if the sensor is open circuited, the
instrument could display the min. value,
indicating the instrument and wire are good and
the sensor is damaged. Then replace the
damaged sensor. Otherwise, check the wire, if
good, the instrument must be failed.
3-41
Lighting circuits
Circuits of front and rear working lamps and rear lamp
If the rocker switch of front/rear work lamps is turned to II gear, the terminals 1 and 3 are
connected and the terminals 2 and 4 are connected. Then, the current flows through F14 fuse, No.39
wire and connector CN1 and then is divided into two ways respectively through the terminals 2 and
4 and terminals 3 and 1 of rocker switch:
Rocker switch of rear

lamp
Terminal
Rocker switch of front/rear work Position
lamp OFF
Terminal
Position
OFF
Front-left lamp
Front-right lamp
Rear-left lamp
Rear-right lamp
Rear lamp
Fig. 3-19 Circuits of front and rear working lamps and rear lamp
3-42
One way: the divided circuit flows to the headlamp relay through the No.74 wire and CN1,
energizing the relay coil and actuating the contact points of relay. Pin 30 of relay is connected to the
pin 87. The current runs to the front-left and front-right lamps sequentially through the F14 fuse,
No.39 wire, pin 30 of headlamp relay, pin 87 of headlamp relay, No. 34 wire, connectors CN1 and
CN15, lighting the front-left and front-right lamps.
The other way: the divided circuit flows to the rear lamp relay through the No.75 wire and
CN2, energizing the relay coil and actuating the contact points of relay. Pin 30 of relay is connected
to the pin 87. The current runs to the rear-left and rear-right lamps sequentially through the F15 fuse,
No.47 wire, pin 30 of headlamp relay, pin 87 of headlamp relay, No. 71 wire, connectors CN1 and
CN15, lighting the rear-left and rear-right lamps.
After the rocker switch of front and rear work lamps is turned to I gear, its terminals 4 and 8 are
connected. Then the current goes to the headlamp relay sequentially through the F14 fuse, No.39
wire, connector CN1, terminals 4 and 8 of rocker switch, No.74 wire and connector CN1,
energizing the relay coil and actuating the relay contact points. Pin 30 of relay is connected to the
pin 87. The current runs to the front-left and front-right lamps sequentially through the F14 fuse,
No.39 wire, pin 30 of headlamp relay, pin 87 of headlamp relay, No. 34 wire, connector CN1 and
CN15, front-left and front-right lamps.
If the rocker switch of rear lamps is turned to I gear, the terminals 2 and 6 are connected and
the terminals 1 and 5 are connected. The current runs to the rear lamp relays sequentially through
the F13 fuse, No. 45 wire, connector CN1, terminals 6 and 2, terminals of 5 and 1 of rocker switch,
No.79 wire and connector CN1, energizing the relay coil and actuating the relay contact points, pin
30 and pin 87 of relay. Current goes to the rear lamps sequentially through the F13 fuse, No. 45
wire, rear lamp electromagnetic relay, connector CN1, No.4 wire, connectors CN23, CN16 and
CN17.
3-43
Common failures: lamps can not be ON. Take the front-left lamp as an example. For other
lamps, refer to the following methods:
1、 Check whether the bulb is black, if so, it is burnt and replace it.
2、 Unplug the front-left lamp, turn on the rocker switch of front and rear work lamps, then use
the ampere meter to measure the circuit between No.34 and No.0 wires. If there is current,
the circuit is good and then check whether the front-left lamp plug is firmly connected; if so,
it shows that the inside circuits of front-left lamp is loosened or the bulb is damaged.
If there is no current, refer to the following steps for inspection:
2.1 Check whether the 10A fuse of F14 is blown.
2.2 Check whether the connectors CN15 and CN1 are reliable or the circuit is reliable.
2.3 Check whether the rocker switch of front and rear work lamps is reliable.
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Rocker switch of scraper lamp
Terminal
Position
Scraper
OFF
Scraper
Scraper
Left lamp
Right lamp
Fig. 3-20 Schematic of scraper lamp circuit and side lamp circuit
After the rocker switch of scraper lamps is turned to I gear, its terminals 1 and 5 are connected
and terminals 2 and 6 are connected. Then the current goes to the scraper lamp relay sequentially
through the F6 fuse, No.42 wire, connector CN2, terminals 6 and 2 of rocker switch, terminals 5
and 1 and No.74a wire, energizing the relay coil and actuating the relay contact points. Relay pin 30
is connected to its pin 87. The current goes to the scraper lamp sequentially through the F6 fuse,
No.42 wire, pin 30 of scraper lamp relay, pin 87, No. 34a wire and connectors CN26 and CN27,
lighting the scraper lamp. After that, this current goes from connectors CN23, CN25, CN28 and
CN29 to the left and right side lamps.
3-45
Common failures: lamps can not be ON. Take the left lamp as example. For other lamps, refer
to the following methods:
1、 Check whether the bulb is black, if so, it is burnt and replace it.
2、 Unplug the left lamp, turn on the rocker switch of scraper lamps, then use the ampere
meter to measure the circuit between No.34a and No.0 wires. If there is current, the circuit
is good and then check whether the left lamp plug is firmly connected; if so, it shows the
inside circuits of left lamp is loosened or the bulb is damaged.
If there is no current, refer to the following steps for inspection:
2.1 Check whether the 15A fuse of F6 is blown.
2.2 Check whether the connectors CN25, CN23 and CN2 are reliable or the harness is
reliable.
2.3 Check whether the rocker switch of scraper lamps is reliable.
Rocker switch of warning lamp Flasher

Terminal
Position
OFF
Left combine lamp

Left tail lamp Right tail lamp
Right combine lamp
Fig. 3-21 Schematic of warning lamp circuit

After the rocker switch of warning lamps is turned to I gear, its terminals 1 and 5 are connected
and terminals 2 and 6 are connected. Then the current goes to terminals 6 and 2 and terminals 5 and
1 of rocker switch sequentially through the F13 fuse, No.21 wire, flasher and connector CN4 and
then is divided into two ways: one way of current goes to the left turn indicator, left tail lamp and
3-46
left combine lamp through the No.6 wire and the other goes to the right turn indicator, right tail
lamp and right combine lamp through the No. 7 wire, realizing the warning function and lighting
the corresponding lamps.
Common failures: lamps can not be ON. Refer to the methods fro diagnosing the work lamps
for others.
Heater and A/C-circuits
If the rocker switch of heater is turned to I gear, the terminals 3 and 5 are connected and the
terminals 4 and 6 are connected. Then the current flows to the heater sequentially through the F5,
connector CN6, No.36 wire, rocker switch and NO.53 wire.
If the rocker switch of heater is turned to II gear, the terminals 1 and 3 are connected and the
terminals 2 and 4 are connected. Then the current flows to the heater sequentially through the F5,
connector CN6, No.36 wire, rocker switch and No.53a wire.
If the rocker switch of heater is turned to I gear, the terminals 1 and 5 are connected and the
terminals 2 and 6 are connected. Then the current flows to the heater vent sequentially through the
F5, connector CN6, No.36 wire, rocker switch and N0.51 wire.
Failure diagnosis
1、 Check whether the circuit is well connected and whether the connector is loosened.
2、 Check whether the heater is normal.
3、 Check whether the rocker switch is damaged.
Heater vent Rocker switch of heater vent A/C Rocker switch of heater
Terminal Terminal
Position Heater Position
OFF OFF
Fig. 3-22 Schematic of heater circuit

3-47
Wiper
If the rocker switch of sprayer is shifted to I gear, the terminals 1 and 3 are connected and the
terminals 2 and 4 are connected. Then the current goes to the rear sprayer motor sequentially
through the fuse F9, connector CN4, No. 37 wire, rocker switch and No. 23 wire, actuating the rear
sprayer motor.
If the rocker switch of sprayer is shifted to the II gear, the terminals 3 and 7 are connected
and the terminals 4 and 8 are connected. Then the current goes to the front sprayer motor
sequentially through the fuse F9, connector CN4, No. 37 wire, rocker switch and No. 23a wire,
actuating the front sprayer motor.
If the rocker switch of front wiper 1 is shifted to I gear, the terminals 3 and 5 are connected
and terminal 4 and 6 are connected. Then the current goes to the front wiper 1 motor sequentially
through the fuse F9, connector CN4, No. 37 wire, its rocker switch and No. 25 wire. At the same
time, No. 37 wire is directly connected to the wiper motor, able to actuate the wiper.
If the rocker switch of front wiper 1 is shifted to II gear, the terminals 1 and 3 are connected
and terminal 2 and 4 are connected. Then the current goes to the front wiper 1 motor sequentially
through the fuse F9, connector CN4, No. 37 wire, its rocker switch and No. 26 wire. At the same
time, No. 37 wire is directly connected to the wiper motor, able to actuate the wiper. The working
principles of other wipers are similar to that above.
Failures and solutions of wiper
Wiper motor does not work: check whether the F9 is blown, whether the connector is
loosened or harness is worn or whether the wiper motor is short-circuited or open-circuited.
The sprayer does not work: check whether the alternator could rotate normally and pump
water or whether the water pipeline is cut off (for example, the water pipeline is fractured or tightly
clamped). Check whether the sprayer is clogged.
3-48
Rocker switch of
Rocker switch of rear
Sprayer sprayer Sprayer
wiper Rear wiper
motor Terminal
motor
Position Terminal
Position
OFF OFF
Background indicator
Black
Red
Black
White
Blue
Rocker switch of front Rocker switch of front Rocker switch of front
wiper 3 wiper 2 wiper 1
Terminal Terminal Terminal
Position Position Position
OFF OFF OFF
Front
wiper 1
Red
Black
White
Blue
Black
Front
wiper 2
Red
Black
White
Blue
Black
Front
wiper 3
Red
Black
White
Blue
Black
Fig. 3-23 Schematic of wiper circuit
3-49
Warning system
Warning system consists of reverse warning system and electric horn system.
Reverse warning system
Reverse warning system is used to alert the surrounding persons as the G9190 grader is
reversing, with the working principles shown in fig. 3-22.
Reverse relay
Reverse buzzer
SG-6 gear selector
Fig. 3-24 Reverse warning system
Turning on the electric lock could power the reverse warning fuse 10A (F12), with its voltage at
24V. After you shift to the R gear, the control unit could send the 24V to the reverse relay through
the No. 58 wire of connector CN3, actuating the contact points of relay. Then the No. 9 wire is
powered and the reverse buzzer sounds.
The installation position of reverse buzzer is shown in fig. 3-23.
3-50
Fig. 3-25 Reverse buzzer
Common failures and solutions of reverse warning system

1. After the electric lock is turned on and R gear is engaged, the reverse buzzer does not sound:
1.1. Check whether the fuse F12 of 10A reverse warning system is blown.
1.2. Measure the No. 58 voltage respectively at the connector CN3 and reverse relay. If the
wire at the connector CN3 is not conductible, check the SG-6 gear selector. If the No.
58 wire of CN3 could be conductible but the No. 58 wire of relay could not, No. 58
wire is cut off due to the connector loosened or harness worn.
1.3. Check whether the reverse relay is damaged.
1.4. If no problem is found through the above steps, check whether the connectors of No. 9
wire are loosened or whether the No.9 wire voltage at the CN31 is normal. If so, reverse
buzzer must have been damaged, and then replace it. If there is not voltage at the CN31,
the No. 9 wire connectors are loosened or the harness is worn.
2. After the electric lock is turned on and whichever gear is engaged, the reverse buzzer sounds
always.
Contact points of reverse relays 87 and 87a are blown, always powering the No. 9 wire.
3-51
Scraper-lock cylinder electric system

Scraper floating electrical system (optional module of G9190 grader)
Left floating rocker switch of Right floating rocker switch of

scraper scraper
Terminal Terminal
Position Position
OFF OFF
Left
铲刀浮动电磁阀
Right
Scraper floating
solenoid valve
Fig. 3-26 Schematic of scraper floating
The working principle of scraper floating electrical system: after the electric lock is turned on,
the No. 42 wire at CN3 is powered. If you press down the left or right floating rocker switch, 24V
voltage could be sent to the No. 186 and No. 187 wires, energizing the scraper floating solenoid
valve and then controlling the oil-line direction in this valve. At last the automatic leveling of
scraper is realized. (Please refer to the hydraulic section.)
Failures and solutions of scraper floating system
1、 Check whether the 10A F6 fuse is blown.
2、 Check whether each connector is well connected. Check whether the No. 42 wire at the
connector CN3 is energized. After the rocker switch is turned on, check whether the No. 186
wire and No. 187 wire at the connector CN50 are powered. If powered, this circuit is normal; if
not, check whether the joint of connector is good or the harness is damaged.
3-52
3、 Check whether the solenoid valve is damaged.
4、 Check whether the rocker switch is damaged.
If no problem is found through the above steps, the harness may be worn or short-circuited. Then
check whether the relative harness is good.
Lock cylinder electric system
Safe Rocker switch of lock cylinder

Lock
Terminal
Position
OFF
Approach switch 红
Solenoid valve of lock

cylinder
Fig. 3-27 Schematic of lock cylinder electrical system
If the pin of lock cylinder is not completely fixed into its slot, the safe lock indicator will
glow, altering the operator about that. When the approach switch at the pin at the front end of lock
cylinder reaches the sensing range, the switch will be turned off, having the safe lock lamp OFF to
indicate that the pin is completely fixed.
3-53
Fig.3-28 Approach switch
Turning on the rocker switch of lock cylinder could power the No. 85 and No. 86 wires through
the fuse F12. Then the solenoid valve begins to work, controlling the related valve pipeline.
Common failure repair

1 Check whether the 10A fuses F6 and F12 are blown.
2. Check whether each connector is well connected or whether the circuit is damaged.
3. Check whether the approach switch is damaged.
4. Check whether the rocker switch of lock cylinder is damaged.
5. Check whether the lock solenoid valve is damaged.
3-54
Auxiliary electrical system (electric horn, fan, radio and cigar lighter)
G9190 grader auxiliary electrical system consists of electric horn, fan, radio and cigar lighter.
(Horn)
Horn
Radio
Horn button
Fan
Horn assembly
Cigar
lighter
Fig. 3-29 Schematic of auxiliary electrical circuit
Failures and solutions of fan

2、 Check whether each connector is well connected.
3、 Check the harness is damaged.
4、 If on problem is found through above steps and No. 36 wire at fan is powered, but when you
press down the fan button, it could not normally work. In such case, replace the fan. Otherwise,
sequentially check whether the fuse, connector or harness is damaged.
3-55
Failures and solutions of electric horn

3、 Check whether the harness is damaged.
4、 Check whether the horn button is damaged.
5、 If the horn can not work after being pressed, check whether the No. 153 wire of horn is
powered. If so, the horn is damaged, so replace it. If not, sequentially check whether the
connector is firmly connected or whether the harness is damaged.
Failures and solutions of radio

4、 If the radio can not work after being turn on, check whether the No. 21 wire at radio is powered.
If so, the radio is damaged, so replace it. If not, sequentially check whether the connector is
firmly connected or the harness is damaged.
Failures and solutions of cigar lighter

4、 If the cigar lighter can not work normally, check whether the No. 77 of cigar lighter is powered.
If so, the cigar lighter is damaged. If not, sequentially check whether the connector is firmly
connected or the harness is damaged.
3-56
Engine control unit
ECU power supply
Ignition switch
Preheater indicator
Yellow failure indicator

Failure joint Oil pressure warning switch input 31
Failure joint Brake switch signal input
Preheater relay
SAE J1939 Shielded wire
SAE J1939 Shielded wire
Positive pole of power supply 2d
K line
Positive pole of power supply 2d
Main relay E43
Negative pole of power supply 0
CAN Shielded wire
Negative pole of small signal 0
Full loaded
Fuel-efficient switch
No load
Accelerator pedal Fuel temperature sensor signal E47

sensor pedal
Accelerator Intake pressure/temperature sensor power supply E12
sensor Intake temperature signal E48
Sensor grounded Intake pressure signal E49
Sensor signal Intake pressure sensor grounded E9

Sensor power supply
Coolant temperature sensor signal E46
Sensor power supply
Coolant sensor grounded E18
Sensor signal
Sensor grounded Camshaft position sensor power supply E33
Accelerator pedal sensor Camshaft position sensor signal E32
2 pedal
Accelerator Camshaft position sensor grounded E35
Oil pressure sensor power supply E11

sensor 2 Oil pressure sensor signal E70
Oil pressure sensor grounded E8
Crankshaft sensor power supply E31
Crankshaft sensor signal E13
Crankshaft sensor grounded E29
High end +
1st cylinder monoblock
缸单体泵
Low end -
1pump
High end +
缸单体泵
2ndcylinder
2pumpmonoblock Low end -
High end +
3rd cylinder monoblock

缸单体泵
3pump Low end -
Power Supply
Power Supply
Power Supply
Power Supply
Temperature signal
High end +
Pressure signal
Ground
Signal
Ground
Ground
Signal
4 缸单体泵
Signal
Ground
Signal
Ground
Signal
Ground
4th cylinder monoblock Low end -
pump
High end +
5 缸单体泵
5th cylinder monoblock Low end -
Crankshaft position/rpm
Camshaft position sensor
Fuel temperature sensor

Intake pressure and
temperature sensor
Coolant temperature
pump
Oil pressure sensor
High end +
6 缸单体泵
sensor
Low end -
sensor
6th cylinder monoblock

pump
Fig. 3-30 Schematic of engine control unit (E-ECU)
3-57
Engine control unit (E-ECU) pin definition

E-ECU E-EC
Name of signal Name of signal
pin U pin
Negative pole of power
1 50 Fuel-efficient switch
supply
2 51 SAE J1939 shielded wire
supply
3 52 Oil pressure warning switch input
supply
Positive pole of power
4 56 Remote Stop switch
supply
Positive pole of power
5 57 Brake pedal switch
supply
Accelerator pedal position
7 59 PTO Resume - switch
sensor 2 grounded
Oil pressure sensor
8 60 PTO Set + switch
grounded
Intake temperature sensor and
9 pressure (TMAP) sensor 61 Heater relay.
grounded
10 63 Common failure indicator
sensor 2 grounded
Oil pressure sensor power
11 64 Exhaust brake /engine brake indicator
supply
Intake temperature and pressure Accelerator pedal position sensor 1 signal
12 66
sensor power supply input
Crankshaft position/tachometer Accelerator pedal position sensor 2 signal
13 67
sensor signal input input
15 70 Oil pressure sensor signal input
sensor 1 power supply
17 72 PTO ON/OFF switch
sensor 1 grounded
Coolant temperature /fuel
18 73 Clutch pedal switch
temperature sensor grounded
Wheel-speed signal Cruise set/accelerator switch
22 74
(instrument output) input (optional)
24 Ignition switch input 75 Cruise recover switch (optional)
26 SAE J1939 - 76 Cruise ON/OFF switch (optional)
3-58
E-ECU E-EC
Name of signal Name of signal
pin U pin
Cruise set/decelerator switch
27 SAE J1939 - 77
(optional)
Crankshaft rpm/ position
29 78 Neutral-gear switch
sensor grounded
Wheel-speed signal
28 79 Exhaust brake switch
grounded
Crankshaft rpm / position
31 80 Remote Stop switch grounded
sensor power supply
32 81 Small signal grounded
signal input
Camshaft position sensor Low end of 1st cylinder monoblock
33 98
power supply pump
Camshaft position sensor High end of 3rd cylinder monoblock
35 99
grounded pump
High end of 1st cylinder monoblock
37 CAN + 100
pump
High end of 2ndcylinder monoblock
38 CAN - 101
pump
High end of 4th cylinder monoblock
39 CAN shielded wire 102
pump
High end of 6th cylinder monoblock
40 K line 103
pump
Low end of 6th cylinder monoblock
42 Exhausting braking valve 105
pump
Low end of 3rd cylinder monoblock
43 Main relay 106
pump
Low end of 2nd cylinder monoblock
44 Preheater indicator 108
pump
Coolant temperature sensor High end of 5th cylinder monoblock
46 110
signal input pump
Fuel temperature sensor Low end of 4th cylinder monoblock
47 111
signal input pump
Intake temperature and pressure Low end of 5th cylinder monoblock
48 112
sensor temperature signal input pump
Intake temperature and pressure
49
sensor pressure signal input
3-59
121 119 113 106
116 114 89 82
Fig. 3-31 ECU connector pin 40
121 119 113 106
116 114 89 82
Fig. 3-32 ECU connector pin 81
Fig. 3-33 Engine harness auxiliary connectors and completed machine harness connectors
3-60
S/N Terminal Description

1 ECU46 Coolant temperature sensor signal
2 ECU29 Crankshaft tachometer/ position sensor grounded
3 ECU11 Oil pressure sensor power supply
Coolant temperature sensor, fuel temperature sensor,
4 ECU18 multi-state switch grounded
5 ECU13 Crankshaft rpm sensor signal
6 ECU8 Oil pressure sensor grounded
7 ECU47 Fuel temperature sensor signal
8 E31 Crankshaft rpm / position sensor power supply
Intake temperature sensor and pressure (TMAP)
9 E9 sensor grounded
10 E70 Oil pressure sensor signal
11 E33 Camshaft position sensor power supply
12 E48 sensor signal
14 E35 Camshaft position sensor grounded
Intake temperature and pressure (TMAP) sensor
15 E12 power supply
17 E32 Camshaft position sensor signal
18 E49 sensor signal
3-61
Electronic control sys
stem of enggine
Composiition of electtronic controol system
Generallyy, an electric
c control sysstem consistts of sensor,,
ECU and d electric control
c fuel system (ac ctuator andd
electric control unit pump), which are connected d
through harness.
h
Sen
nsor Electronic control unit Electric control fuel systeem (electric
(EC
CU) control unit pump/high -pressure
mmon rail systtem)
com
Sensor
Magne
etoelectric/hall speed senso
or
Temperatture sensor
Intake air Fuel Co

oolant
Cranksh
haft speed Camshaft speed
s temp
perature
temperature temperatuure
se
ensor sensoor se
ensor
sensor sensorr
Pressu
ure sensor
Accelerator pedal posiition sensor
Intake a
air Oil prressure Heeadlamp presssure
pressuree se
ensor sen
nsor (inside EC
CU)
sensorr (opttional)
ure sensor
1. Pressu
Function of the intak ke pressuree sensor: de etect the airr
pressure in the inttake pipe aafter the tu urbocharger,,
determine the intake air amount in combinattion with the e
intake aiir temperatu ure, which iis used for oil amountt
correction to limit the
e injection aamount at a lower boostt
pressure and avoid soot
s generaation. Functio
on of the oill
pressure sensor (opttional): mon itor oil press
sure, stop att
low oil pressure
p and protect thhe engine. Function off
atmospheric pressu ure sensor:: detect th he externall
25
atmospheric pressurre, which iss used for correction
c off
de oil volume
high crud e. When drivving at high altitude, the
e
superchaarger can bee protected by reducing g the powerr
of the engine.
2. Tempe
erature Sens
sor
Function of the intak
ke pressuree sensor: de
etect the airr
pressure in the inttake pipe aafter the tuurbocharger,,
determine the intake air amount in combinattion with the
e
intake aiir temperatu
ure, which iis used for oil amountt
correction.
Function of the fuel temperaturre sensor: measure
m the
e
fuel temperature foor the correection of fu
uel injection
n
quantity.
Function of coolantt temperatuure sensor: detect the e
engine coolant
c temp
perature, whhich is usedd to protectt
the enginne when the engine teemperature is too high,,
and to optimize the injection quuantity and timing
t when
n
the cold start
s and am
mbient tempeerature are too
t low.
3. Speed
d sensor
The camshaft sensor provides a
T
t dead center position during
top Function of camshafft speed sennsor: determ
mine the top
p
s
starting
dead cen nter of one cylinder coompression and can bee
used as s the backu up functionn of cranksshaft speedd
sensor.
Function of cranksh
haft speed sensor: dettermine the e
engine speed and th
he position of each cylinder of the
e
engine, which can be used as a back kup for the e
camshaftt sensor.
With the cranks

W shaft
s
sensor, it takes 15
s
seconds to find the
u
upper point position.
4 Accelerrator pedal
Function of the accelerator pedal stroke position n
sensor: transmit the e driver's eexpectation for vehicle e
accelerattion to the electronic
e coontrol unit (E
ECU), whichh
determines the basic c fuel injectiion quantityy and torque
e
demand according to t this signaal. On the construction
c n
machinerry vehicles, it may be rreplaced by other typess
of hand throttles,
t etc
c.
Electronic control unit (ECU)

Functions of electron
nic control u nit (ECU)
26
1. Startin
ng control
For an engine, in ord
der to ensurre the startin
ng reliabilityy
and smoke emission n requiremennts, the inje
ection timing g
and starrting torque
e must be set accord ding to the e
following methods:
Injection timing =f (rrotational sppeed, injection quantity,,
emperature))
coolant te
Starting torque
t =f (sp
peed, coolannt temperature, starting
g
time)
The startt control fun
nction is acttivated until the engine
e
speed exxceeds the start
s end speeed and enters the idle e
speed co ontrol. Onlyy then can the driver operate
o the
e
engine. Starting
S andd stopping sspeed is dettermined byy
coolant te
emperature and atmosppheric press sure.
2. Low id
dle speed co
ontrol
When the engine en nters the idlle speed coontrol stage,,
the idle speed controller funnctions to control the e
n of the engine. Idle speeed controller is a pure
operation e
PID controller, whic
ch keeps tthe engine idle speed d
constant.
Idle speeed is related to cooolant tempe erature, forr
example,, idle spee ed at low eengine tem mperature iss
higher th
han that at high
h temperaature. In addition, if the
e
accelerattor pedal fails, the idle sspeed will be increasedd
to maintaain a minimmum speed at which a driver can n
drive the vehicle to th
he service sstation.
3. Driving
g control
Torque control:
c n torque conntrol is used
when d, the valuee
from the accelerator pedal is intterpreted as the driver'ss
expectatiion of the wheel output torque acco ording to the
e
current engine
e speed. The conttrol mode is similar to a
two-pole mechanicall governor.
Expected d torque =f (acceleratoor pedal pos sition value,,
engine speed) Speed control: W When speed control is in n
effect, the
t value from the acceleratorr pedal iss
interprete
ed as the e driver's expected speed
s andd
operates at a certain set speedd. This conttrol mode iss
o a full-progrram mechannical governo
similar to or.
Expectedd value off rotational speed =ff (value off
accelerattor pedal)
4. Torque
e limitation
The max ximum torqu ue emitted by the eng gine can bee
limited in the followin
ng ways: Sm moke limit: th
he maximum m
torque lim
mit is relatedd to the intaake air volum
me, and thee
air presssure and air temperaturre determine e the intake
e
air volum
me. Limited byb intake air volume
Maximum m torque prrevents thee engine fro
om emittingg
black sm
moke. Engine protectionn: under any condition,,
once the
e coolant tem
mperature eexceeds the upper limit,,
the maxiimum torquee must be rreduced accordingly too
prevent the
t engine frrom overheaating.
27
Emergency torque limit: when the ECU diagnoses a
serious failure of the electronic control system, the
engine will reduce the maximum torque, forcing the
driver to go to the maintenance station to correct the
error.
The following error types may cause this function to
occur: Accelerator pedal sensor failure/speed signal
failure/solenoid valve drive failure
5. Fuel injection timing adjustment: The adjustment of
fuel injection timing is to meet the requirements of
emission regulations and fuel economy, while takes into
account cold start and low noise. The adjustment of
injection timing is related to engine performance and
additional correction.
Injection timing =f (rotational speed, injection quantity,
cooling temperature, intake pressure, atmospheric
pressure)
6. Fuel temperature compensation. With the increase of
temperature, engine performance decreases.
The reason is that the decrease of fuel density and
viscosity and increase of the leakage of fuel injection
pump. The influence of temperature on fuel injection
quantity is balanced by measured fuel temperature and
corresponding adjustment and control compensation.
7. Uniformity of each cylinder
The uniformity function of each cylinder is used to
compensate for the fuel injection quantity difference
caused by the manufacturing tolerance of the fuel
injection pump. After replacing the ECU or the unit
pump, the unit pump compensation code shall be
written.
8. Cold start assistant control. In a low temperature
environment, in order to improve the cold start
performance of the engine, the electronic control unit
will determine whether intake air preheating is required
and the preheating time according to the current engine
temperature, which is realized by controlling the intake
air preheating relay.
9. The engine protection function is used to protect the
engine under certain limit conditions. If the coolant
temperature is too high and the oil pressure is too low,
the power of the engine will be reduced, even the
engine will be shut down, thus achieving the purpose of
protecting the engine.
10. Engine exhaust braking. Once the ECU detects the
demand signal from the exhaust brake switch, it
determines whether to start the exhaust brake function
according to the current engine speed. If the exhaust
brake function is activated, the fuel system will
immediately stop fuel injection at the same time. If the
driver steps on the accelerator pedal to accelerate at
this moment, he/she will automatically withdraw from
the exhaust brake, even if the exhaust brake switch is
closed.
28
11. Maxim mum speed limit. The m maximum sp peed controll
function sets the maximum
m ddriving speeed limit to
o
prevent drivers from m speeding. The maxim mum speed d
limit is prreset by the electronic ccontrol syste
em.
12. Cruis
se function
The vehicle runs att a constannt speed an nd does nott
need thee driver to control
c the aaccelerator pedal, thuss
reducing the labor in
ntensity of thhe driver and improving
g
ng comfort. The driver can adjust the vehicle
the drivin e
speed through the crruise controll switch.
13. Comm
munication interface
i
ISO inteerface: ISO communica cation interface adoptss
ISO9141 (K-line) sta andard seriaal data com mmunication n
mode, which can rea alize data exxchange witth electronicc
control unit. It include
es the follow
wing function
ns:
Exchange of diagnos stic data (errror informatiion, clearing
g
of error list)/program
mming of coontrol syste em (reading g
and proggramming of relevant paarameters)/re ealization off
engine test functtion/reading of meas sured and d
ed values
calculate
CAN interface: CAN adopts SAE J1939 9 standard,,
which is a high-speed serial com
mmunication mode. Thiss
communication mode is mainly used betwe een differentt
c control units. It inncludes the
electronic e followingg
functions
s:
Exchange of data/readout of measured parameterr
values and
a calcula
ated valuess/injection limit/engine
e
braking opera
ation/perform
mance reduction
n
n/input of default vaalues or performance
operation p e
characteristic quantitties
Composiition of electtronic controol fuel system

m
Fuel fiilter
Overflow
O valve
Fuel d
delivery
puump Electric control
unitt pump
Primary fuel filter
Camshaft Intake air Oil

O pressure
speed te
emperature and sensor
Harness sensor pressure sensor
Fuel
teemperature
sensor
Fuel tankk
Crankshaft Accelerator Cooling wateer

Electrric control unit speed pedal position temperaturee
sensor sensor sensor
29
Electric control EG
GR Exhausst Gas Re
ecirculation))
ystem
control sy
Coolant Control un
nit For diesel engines, the main exhaust po ollutants are
e
EGR co
ooler NOx (nittrogen oxides) and PMM (particulaate matter)..
EGR valve
Compareed with T2, the NOx value of T3 T emission n
standard is reduced from 6g/kW
Wh to 4g/kWWh, and the e
e remains un
PM value nchanged att 0.3 g/kWh
Air intake
The formmation mechanism of NO Ox is that nitrogen
n and
d
oxygen in the inta ake air reaact chemica ally at high h
Cylinder top temperatture. The hig gher the tem
mperature in the cylinderr
that gene erates NOx, the higher tthe concentration of O2 2
remaining after com mbustion, thee higher thee generated d
Top of cylin
nder NOx. On nce NOx is generated,
g it cannot bee eliminatedd
by itself. SCR technology is gennerally used d in medium m
and heavy vehicle engines, a nd ammoniia (urea) iss
used for catalytic redduction of N
NOx. In the construction
c n
machinerry industry, EGR tecchnology is s generallyy
adopted in T3 stage. The enngine exha aust gas iss
introduceed into the intake pipe oof the engin
ne to reduce e
the conc centration of
o oxygen tthat can pa articipate in
n
combustiion. In addiition, the heeat capacity y of carbon n
dioxide, water,
w nitrog
gen and the like in the exhaust
e gass
is higher and more e heat cann be absorrbed during g
combustiion to reduc ce the com bustion temmperature in n
the cylindder, thus reducing the ggeneration of NOx and d
reaching T3 emission standard.
Electronic control sys

stem identifification
ECTEK E-ECU+ Bosch seensor + unit pump
p
configura
ation
Name Part Numbe

er Remarkks
ECU 3601115-20
3 81/A（ECTEK）
D04199447 or F04199447/
F A
Crankshaft position sensor Magnetooelectric (un
niversal)
(Bosch)
Camshaft p
position senssor D04194021 (Bosch) Magnetooelectric
Intake air p
pressure tem
mperature
D04194078 (Bosch)
sensor
Water tempera
ature/fuel D04199809 or 3602160-55D
3 D
Universaal
temperaturre sensor (Bosch)
D04215774 (Bosch) or
o Connectctors are diifferent and
d
Oil pressurre sensor
3602185B48
3 8D/A (Sensa
ata) not univversal.
Unit pump Random typ
pe (hengyan
ng)
30
Engine control
c unit E-ECU
E
Taking signal (data) acquisiition as input, afterr
on, analysis
calculatio s and judgm ment, deterrmination off
countermmeasure, coontrol instrucctions are issued,
i and
d
actuatorss are commaanded to woork as output.
E-ECU possition
E-ECU pin diagram
31
E-ECU pin description (part of pins
s are not use
ed)
Definitio
n of
ECU Signal name Tyype
connecti
on pin
1 Negative electrode G
Ground
Ground
Ground
32
4 Positive electrode Battery + 24V
5 Positive electrode Battery + 24V
7 Grounding of accelerator pedal position sensor 2 Ground
8 Grounding of oil pressure sensor Ground
9 Grounding of intake air temperature and pressure (TMAP) sensor Ground
10 Power supply of accelerator pedal position sensor 2 +5V
11 Power supply of oil pressure sensor +5V
Power supply of intake air temperature and pressure (TMAP)
12 +5V
sensor
Hall effect frequency
13 Crankshaft position/speed sensor signal input
signal
15 Power supply of accelerator pedal position sensor 1 +5V
17 Grounding of accelerator pedal position sensor 1 Ground
Grounding for water temperature sensor and fuel temperature
18 Ground
sensor
20 EGR motor+
22 Speed signal (instrument output) input Frequency signal
23 EGR motor-
24 Ignition switch input Key
Connect diagnostic
26 SAE J1939 -
instrument
Connect diagnostic
27 SAE J1939 +
instrument
28 Power supply of EGR position sensor (grounding)
29 Grounding of crankshaft speed/position sensor Ground
30 Power supply of EGR position sensor (5V)
31 Power supply of crankshaft speed/position sensor +5V
Hall effect frequency
32 Signal input of cam position sensor
signal
33 Power supply of cam position sensor +5V
35 Grounding of cam position sensor Ground
37 CAN + CAN communication
38 CAN - CAN communication
39 CAN shielded wire Shielded wire
40 K line Communication line
42 Exhaust brake valve 1A low end On/Off drive
43 Main relay 1A low end On/Off drive
44 Preheat indicator 1A low end On/Off drive
46 Signal input of water temperature sensor Analog quantity
47 Signal input of fuel temperature sensor Analog quantity
Signal input of intake air temperature and pressure (TMAP)
48 Analog quantity
sensor temperature
49 Signal input of intake air temperature and pressure (TMAP) Analog quantity
33
sensor pressure
50 Multi-load fuel saving switch Analog quantity
51 SAE J1939 shielded wire Shielded wire
52 Oil pressure alarm switch input Low potential switch
56 Remote shutdown switch Low level switch
57 Brake pedal switch Low potential switch
59 PTO Resume –switch High potential switch
60 PTO Set + switch High potential switch
3.5A high-end On/Off
61 Heating relay
drive
63 General fault indicator 1A low end On/Off drive
64 Exhaust brake/engine brake indicator 1A low end On/Off drive
66 Signal input of accelerator pedal position sensor 1 Analog quantity
67 Signal input of accelerator pedal position sensor 2 Analog quantity
68 EGR position signal
70 Signal input of oil pressure sensor Analog quantity
72 PTO ON/OFF switch High potential switch
73 Clutch pedal switch High potential switch
74 Cruise setting/acceleration switch (optional) High potential switch
75 Cruise recovery switch (optional) High potential switch
76 Cruise ON/OFF switch (optional) High potential switch
77 Cruise setting/deceleration switch (optional) High potential switch
78 Neutral switch High potential switch
79 Exhaust brake switch High potential switch
80 Remote shutdown switch ground Ground
81 Small signal ground Ground
1-cylinder unit pump 6-cylinder machine low end
98 Low-end PWM drive
3-cylinder unit pump 6-cylinder machine high-end
99 High-end PWM drive
101 2-cylinder unit pump 6-cylinder machine high-end High-end PWM drive
102 4-cylinder unit pump 6-cylinder machine high-end High-end PWM drive
108 2-cylinder unit pump 6-cylinder machine low end Low-end PWM drive
34
5-cylinder unit
u pump 6--cylinder ma
achine high-e
end
110 H igh-end PW
WM drive
3-cylinder unit
achine high-e
end
111 4-cylinder unit
achine low end Loow-end PWM drive
5-cylinder unit
achine low end
112 Loow-end PWM drive
3-cylinder unit
achine low end
Coolant level
l sensorr/fuel temperrature senso
or
Note: In the testing mentioneed below, thet plug-in
n
sensor, ECU harn ness, relay,, etc. are all placed d
under thhe OFF po osition of EECU key door.
d When n
measuring voltage, the key do oor is placed in the ONN
position again, which is not em
mphasized later.
The coo olant/fuel te
emperature sensor provides an n
engine co
oolant/fuel temperature signal to the ECU, and
d
the senssitive elemeent is a theermistor with negative
e
temperatture coefficient. The fuuel temperature sensorr
uses the water temperature senssor as the same part.
Temperaturre sensor
Sensor signal
Fuel tem
mperature sensor
Sensor ground
Coolant te
temperature sensorr
Sensor signal
Mapping o
of sensor re
esistance an
nd tempera
ature:
Temperaturre (℃) (-20) (0) （20） 40 600 80 100 120

Maximum R
Resistance Value
V (Ω) 168300
0 6230 2650 1230 6220 330 190 120
Minimum R
Resistance Value
V (Ω) 141000
0 5470 2350 1120 5770 310 180 110
1.1 Sens
sor inspection
Unplug thet sensor, measure thhe resistanc
ce between n
the two pins of the temperrature sens sor with a
multimete er, and judg
ge whether the sensor is faulty byy
comparin ng the mea asured valuue with the parameterr
table in th
he above table.
1.2 Sens
sor power su
upply inspecction
Pull off the sensor, place thee key door in the ON N
position, and measurre whether tthe voltage between
b the
e
35
two pins at the harneess end is 5VV. If not, che
eck whetherr
the wire is
i broken an nd whether tthe sensor signal wire iss
short-circ
cuited to gro
ound.
Intake airr pressure te

emperature sensor
The intake air press sure tempe rature sens sor providess
the ECU U with the e informatioon of the intake airr
temperatture and th he intake aair pressure e after thee
engine iss intercooled
d. The pressuure sensitive
e element iss
of silicon diaphragm type and thee temperatu ure sensitive
e
element is of thermisstor type witth negative temperature
t e
coefficiennt.
Sensor powe
wer supply
Sensor g round
Temperature ssignal
Pressuree signal Intake air presssure/temperature sensor
Sensor ground
Sen
nsor parame
eters
Temperaturre Sensor Resistance (Ω) Temperature Sensor

S Resisstance (Ω)
Standarrd Maxim
mum Minim
mum Standard
S Maximum Minimum
Value Value Value
e Value
V Value Value
-40 48150 51000 45299
9 50 850
8 900 818
-30 26850 28439 25346
6 60 610
6 646 588
-20 15610 16534 14781
1 70 120
1 127 115
-10 9430 9988 8954 80 330
3 349 319
0 5890 6238 5608 90 250
2 264 242
10 3790 4014 3617 100 190
1 201 184
20 2510 2658 2401 110 140
1 148 135
30 1720 1821 1649 120 110
1 116 106
40 1200 1271 1152 130 90
9 95 87
36
Signal off output end when U=5V
V, T=25℃
Standard
pressure -50 0 50 100 150 2200 300
(kpa)
Absolute
pressure 50 100 150 200 250 3300 400
(kpa)
Output
0.5 1.07 1.64
4 2.2
21 2.27 33.36 4.5
voltage (V)
2.2 Temp
perature resistance insppection
When thhe ECU is powered ooff, unplug the engine e
harness of the intake
e air pressuure temperatture sensor,,
measure the resistance betw ween the temperature
t e
signal line and th he ground wire (blac ck) with a
er, and chec
multimete ck the parammeter table to determine
e
whether the
t sensor is faulty.
2.3 Pow wer supply inspection
i oof temperatture sensorr
signal line
The engine harness s is disconn ected from the sensor,,
and the multimeterr measuress whether the t voltagee
between the tempera ature signal line and gro
ound is 5V. Iff
not, checck the wire for broken circuit and the sensorr
signal wire for short circuit
c to groound.
er supply ins
2.4 Powe spection of inntake pressure sensor
The eng gine harness s is normallly connecte ed with thee
sensor, and
a measure e whether thhe power sup pply voltage
e
between the power supply of the intak ke pressure e
sensor and the ground wire is 5V V. If not, che
eck the wire
e
for broke en circuit an
nd the sensoor signal wiire for shortt
circuit to ground.
2.5 Inspe
ection of sign
nal line of inntake pressu
ure sensor
The engiine wiring harness is noormally connected withh
the sensor. Measuree the voltagee between the signal off
e pressure sensor
the intake s and the ground wire. Underr
different intake preessures, w whether it meets the e
pressure and signal voltage paraameter table
e. When thee
37
engine is
s not started, the intakke pressure is 100kPa,,
and the correspondin
c ng signal lin e voltage is 1.07V.
Cranksha
aft speed/ca
amshaft speeed sensor
Cranks
shaft speed/position
n sensor
Sensor pow
wer supply
Sensor signal
Sensor ground
g

Sensor pow
wer supply
Sensorr signal
Sensor ground
The crannkshaft spee

ed sensor iis installed at the frontt
end of the engine.
The ECU U is provide ed with the instantaneo ous rotating g
speed of the engin ne by meassuring the upperu toothh
signal on
n the flywheel of the enngine, so as to be used d
for accurrately timing
g and controolling the oill quantity off
the engin
ne.
Bosch magnetoelec
m ctric crankshhaft sensor installation
n
clearance
e: 0.6± 0.1m
mm
The cam mshaft speedd sensor is innstalled at the

t rear end
d
of the engine; the po
ower turns unnder the pum mp.
The camshaft sig gnal sensoor together with the e
cranksha aft speed se
ensor providdes the EC CU with the
e
correct to
op dead cen
nter signal off one cylinde
er.
The cam mshaft gear plane has ssignal pins, 4+1 pin forr
4-cylinde
er machine and
a 6+1 pin for 6-cylinde er machine.
Bosch magnetoelec
m ctric camshhaft sensor installation
n
e: 0.3~1.2mm
clearance
Detectionn of cranksshaft speed sensor and camshaftt
position sensor: Th he camshafft position sensor
s and
d
crankshaaft speed seensor belonng to signal generation n
sensors. The detec ction mainlyy depends on whetherr
they can send out signals
s correectly and whether
w theirr
signals are
a synchronous. In ordder to make e the signall
phase off the sensor correct, the mechanical installation n
accuracyy of the sens
sor and the ggap between n the sensorr
and the signal dis sk must bee ensured within the e
technicall requiremen
nts. If condi tions permitt, the signall
oscillosco
ope can be e used to see wheth her the two o
signals are
a synchronous. The following fig gure showss
the synchhronous wav veform of a 6-cylinder engine.
e
38
Crankshaft speed ssensor signal
Top dead ceenter of cylinder 1
Signal of the camshaft position senssor
Camshaft rotating angle
Sensor re
esistance measurement
m t
Measure the resistan nce betweenn pin 1 and pin 2 of the e
sensor respectively. The resistance value off
cranksha aft/camshaft position seensor is aboout 860Ω. Iff
the resisstance value
e is too smaall, the electromagneticc
coil inside
e the sensor may be shoort-circuited
d. These twoo
sensors are magnettoelectric seensors with permanentt
magnets inside. If the
ey are takenn down and stored, theyy
should beb stored on n iron shelvves instead of wooden n
shelves to avoid demagnetiza
d ation. In ad ddition, the
e
sensors are easy to o absorb ironn filings and
d should be e
cleaned in time to avoid
a affecti ng the accu
uracy of thee
sensors.
If the tw wo sensors fail at the ssame time, the engine e
cannot ig gnite. If only the camshaaft position sensor
s fails,,
the ECU will automatically judgee the cylinder sequence..
When sta arting, it may feel the enngine starts s slowly withh
slight jitte
er, but the enngine will reesume normal operation n
after starrting. If only the crankshhaft speed sensor
s fails,,
the ignition will not be b affected,, but the sta ability of the
e
engine during norma al operation w will be reduc
ced.
sure sensor
Oil press
The oil pressure sensor proovides the engine oill
pressure value to th he ECU, annd the ECU determiness
the operation cond dition of thhe lubricatiion systemm
g to the oil pressure
according p valuue, and perfforms powerr
reduction
n and shuttdown proteection on the engine e
according
g to the fault condition.
39
Oil pressure
p sensor
Sensor power su
upply
Sensor sign
nal
Sensor ground
Power
supply
Output
Ground
Oil pressure s
sensor (rela
ative pressu
ure)
Pressure (b
bar) Ambien
nt Temperature
-30℃
℃～0℃ 0℃～80℃ and 1100℃～125℃
Voltage U（V）
P<0 0.3～0.6 0.3～0..7
0 0.4～0.6 0.3～0..7
2 1.2～1.4 1.1～1..5
4 2.0～2.2 1.9～2..3
6 2.8～3.0 2.7～3..1
8 3.6～3.8 3.5～3..9
10 4.4～4.6 4.3～4..7
p>10 4.4～4.7 4.3～4..7
4.1 Sens
sor power su
upply inspecction
Unplug the sensor harness cconnector, and use a
multimete er to measu
ure the voltaage between pin 1 and d
pin 3 of the harness connector too see if it is about 5V. Iff
not, pleaase check the harness for broken circuit and d
short circ
cuit.
4.2 Inspe
ection of pressure signaal line
Use a diaagnostic apparatus to rread the pre
essure value e
and volta
age value of the oil presssure sensorr, and checkk
whether there is any deviation between th he pressure e
and electtricity.
121-pin vehicle
v ECU
U internal ssensor comm
mon source
e
(power supply module)
40
5.1 V_A5
5V1: accelerrator pedal ssensor 1(pin
n15).
5.2V_A5V V2: intake air pressurre temperatture sensorr
(pin12), exhaust
e air pressure diffference sen
nsor (pin14,,
temporarrily not equip
pped with thhis sensor)
5.3. V_AA5V3: accellerator pedaal sensor 2(pin10),
2 oill
pressure sensor (pin11), GR pposition sensor (pin30)..
e sensors arre the samee power sup
the three pply module e
inside EC
CU. If the above
a sensoor power su upply failure
e
occurs, it is necessa
ary to checkk whether each
e sensorr
problem is caused byy a wiring prroblem in turn.
EGR valve
EGR position senso
or
Powe er supply of EGR
R
posittion sensor (5V) Power supply of the e
EGR valve position sensor (5V)
Powe er supply of EGR R motor -
posittion sensor (grounding)
E
EGR position signal Grounding off the
position sensorr
EGR motor EGR valve

v
EGR motor (-) motor +
Signal of the po
osition
sensor
EGR motor (+)
6.1 Powwer supply inspection oof EGR valve position

n
sensor
Disconneect the EGR connector, and use a multimeter
m to
o
measure whether the t voltagee between the powerr
supply off the position
n sensor at tthe harness s end (pin 1))
and the ground
g wire (pin 3) is 5V
V. If not, che
eck whetherr
the harne
ess is broken circuit andd short-circuuit.
6.2 Discconnect the e EGR coonnector, and a use a
multimete
er to measure whetheer the voltag ge between n
the EGR valve motorr +(6 legs) aand the moto or (2 legs) att
the harn
ness end is s 24V. If noot, check whether
w the
e
harness is broken cirrcuit and shoort-circuit.
Unit pum
mp
The resis e unit pump is 0.5Ω
stance of the
Engine harness
h
41
Engine
6 5 4 3 2 1
1 0 9 8 7
1 6 1 5 1 4 1 3 1 2 1 1
2 0 1 9 1 8 1 7
2 6 2 1
2 5 2 4 2 3 2 2
Connect the wiring harness

attachment interface of the
whole vehicle Transition interface
Fault code
Description SPN FMI
Missing in crankshaft sensor signal 190 12
Error in crankshaft sensor signal 190 11
Missing in camshaft sensor signal 636 12
Error in camshaft sensor signal 636 11
Overlarge deviation in camshaft cylinder detection signal 190 7
Seizing of +key of multifunctional switch 520237 11
Seizing of - key of multifunctional switch 520238 11
Multi-function switch RES key is jammed 520239 11
Atmospheric pressure sensor APS is high 108 3
Atmospheric pressure sensor APS is low 108 4
Boost pressure sensor BPS is high 102 3
Boost pressure sensor BPS is low 102 4
Fault of reasonability of boost pressure sensor 102 2
High physical value of boost pressure sensor 102 15
Low physical value of boost pressure sensor 102 17
Boost temperature sensor IATS is high 105 3
Boost temperature sensor IATS is low 105 4
High physical value of intake air temperature sensor 105 15
Low physical value of intake air temperature sensor 105 17
Unreasonable static value of intake air temperature
105 12
sensor signal
Cooling water temperature sensor CTS is high 110 3
Cooling water temperature sensor CTS is low 110 4
Cooling water temperature sensor CTS is not reasonable 110 2
High physical value of coolant temperature sensor 110 15
Low physical value of coolant temperature sensor 110 17
Dynamic test of coolant temperature sensor 520198 2
42
Test of absolute value of coolant temperature sensor 520198 2
Fuel temperature sensor FTS is high 174 3
Fuel temperature sensor FTS is low 174 4
High physical value of fuel temperature sensor 174 15
Low physical value of fuel temperature sensor 174 17
Accelerator 1 signal ACCPED is high 91 3
Accelerator 1 signal ACCPED is low 91 4
Accelerator signal ACCPED is not reasonable 91 2
Accelerator 2 signal ACCPED is high 29 3
Accelerator 2 signal ACCPED is low 29 4
High engine speed 533 15
Ambient temperature sensor ETS is high 171 3
Ambient temperature sensor ETS is low 171 4
Oil pressure sensor OPS is high 100 3
Oil pressure sensor OPS is low 100 4
Fault of low reasonability of oil pressure 100 17
Fault of high reasonability of oil pressure 100 2
Oil temperature sensor OPS is high 175 3
Oil temperature sensor OPS is low 175 4
Fault of oil temperature reasonability 175 2
Unreasonable oil temperature beyond maximum value 175 15
Rail pressure sensor SRC is high 157 3
Rail pressure sensor SRC is low 157 4
Rail pressure sensor is not reasonable 157 2
Rail pressure sensor offset test too large 157 15
Rail pressure sensor offset test is too small 157 17
Air flow sensor SRC is high 132 3
Air flow sensor SRC is low 132 4
Overhigh physical value of air flow 132 15
Too-low physical value of air flow 132 17
Air flow sensor OffsetDrift is high 132 2
Air flow sensor OffsetDrift is low 132 2
Air flow sensor SetyDrift is high 132 2
Air flow sensor SetyDrift is low 132 2
IdleMode_AFSCD_facIdlAdjValUW overrun 132 2
lodeMode_AFSCD_facLdAdjValUW overrun 132 2
Air flow sensor signal error 132 12
Air flow sensor temperature SRC is high 172 3
Air flow sensor temperature SRC is low 172 4
Air flow sensor temperature cycle SRC is high 520193 3
Air flow sensor temperature cycle SRC is low 520193 4
43
High physical value of air flow sensor temperature 172 15
Low physical value of air flow sensor temperature 172 17
Fault of on-off reasonability of clutch 598 2
Fault of reasonability of speed sensor signal 84 12
Overranging in speed 84 0
Fault of high speed sensor signal cycle 84 3
Fault of low speed sensor signal cycle 84 4
DOCPOC differential pressure sensor SRC is high 4767 3
DOCPOC differential pressure sensor SRC is low 4767 4
DOCPOC congestion 4767 12
DOCPOC removal 4767 11
DOCPOC static pressure difference is too large 4767 15
DOCPOC static pressure difference is too small 4767 17
EGR position largely offsets from last learning value 2791 13
EGR position control positive deviation is too large 2791 20
EGR position control positive deviation is too small 2791 21
EGR valve is stuck in open state 2791 20
EGR valve is stuck in close state 2791 21
EGR position sensor SRC is high 2791 3
EGR position sensor SRC is low 2791 4
EGR position sensor physical value is high 2791 15
EGR position sensor physical value is low 2791 17
Over high cooling water temperature 110 15
Open circuit of starting motor driver 677 5
Short circuit of starting motor driver 677 3
Fault of failure to judgment of reasonability of brake pedal
597 12
signal
Fault of failure to judgment of the reasonability of the
91 12
accelerator pedal and brake pedal signal
Open circuit of water-in-oil indicator light 520192 5
Short circuit of water-in-oil indicator light 520192 3
Multi-state switch SRC is high 520245 3
Multi-state switch SRC is low 520245 4
Short circuit of injection driver of the first cylinder 651 3
Open circuit of injection driver of the first cylinder 651 5
Unreasonable injection drive of the first cylinder 651 2
Short circuit of injection driver of the second cylinder 652 3
Open circuit of injection driver of the second cylinder 652 5
Unreasonable injection drive of the second cylinder 652 2
Short circuit of injection driver of the third cylinder 653 3
Open circuit of injection driver of the third cylinder 653 5
Unreasonable injection drive of the third cylinder 653 2
44
Short circuit of injection driver of the fourth cylinder 654 3
Open circuit of injection driver of the fourth cylinder 654 5
Unreasonable injection drive of the fourth cylinder 654 2
Short circuit of injection driver of the fifth cylinder 655 3
Open circuit of injection driver of the fifth cylinder 655 5
Unreasonable injection drive of the fifth cylinder 655 2
Short circuit of injection driver of the sixth cylinder 656 3
Open circuit of injection driver of the sixth cylinder 656 5
Unreasonable injection drive of the sixth cylinder 656 2
The starting point of cylinder 1 is not reasonable 651 12
Fire in cylinder 1 1323 3
Multifunction switch OFF key is jammed 520240 11
Remote throttle 1 signal ACCPED is high 520243 3
Remote throttle 1 signal ACCPED is low 520243 4
Remote throttle signal ACCPED is not reasonable 520243 2
Remote throttle 2 signal ACCPED is high 520244 3
Remote throttle 2 signal ACCPED is low 520244 4
Injection times are limited by power supply system
520225 16
capacity
Injection times are limited by high-pressure pump capacity 520225 15
Injection times are limited by system capacity 520225 11
Limited by engine oil mass 520226 14
OBD fault oil mass limit 1 520227 14
Main relay control terminal short circuit 2634 3
Main relay control terminal open circuit 2634 5
The controlled end of the main relay is stuck 2634 12
The controlled end of the main relay is open circuit 2634 12
Short circuit of air conditioner relay 1351 3
45
Open circuit of air conditioner relay 1351 5
Short circuit of exhaust brake valve 1074 3
Open circuit of exhaust brake valve 1074 5
Short circuit of exhaust brake indicator light 520190 3
Open circuit of exhaust brake indicator light 520190 5
Short circuit of intake heating relay 729 3
Open circuit of intake heating relay 729 5
Short circuit of intake heating indicator light 520191 3
Open circuit of intake heating indicator light 520191 5
OBD fault lamp short circuit 520194 3
OBD fault lamp broken circuit 520194 5
Svs lamp short circuit 624 3
Svs lamp broken circuit 624 5
EGR motor power failure 520195 12
EGR motor short circuit to power supply 520195 3
EGR motor short circuit to ground 520195 4
EGR motor open circuit 520195 5
EGR motor overheating 520195 2
Pneumatic EGR failure 520196 12
EGR flow is too large 520197 15
EGR flow is too small 520197 17
EGR valve NOx limit 1 Out of Limit 520199 15
EGR valve NOx limit 2 Out of Limit 520199 16
Positive deviation of rail pressure control exceeds upper
523613 16
limit
Negative deviation of rail pressure control is lower than
523613 17
lower limit
The oil quantity of high pressure oil pump is too low 523613 7
Rail pressure is too low 523613 4
Rail pressure is too high 523613 3
VCV valve inappropriate opening at idle speed 523613 2
OverRun pump flow failure 523613 12
Pump flow failure 523613 12
Rail pressure drive open circuit 523615 5
Rail pressure drive short circuit to ground 523615 4
Rail pressure drive overload 523615 3
Rail pressure drive overheat 523615 12
VCV valve current feedback signal SRC is high 523615 16
VCV valve current feedback signal SRC is low 523615 18
VCV valve virtual connection 523615 7
PRV open 523470 0
PRV impact request 523470 0
46
PRV impact failure 523470 7
PRV opening too many times 523470 10
PRV opening time too long 523470 11
The opening time and times of PRV exceeded 523470 12
Excessive deviation of boost pressure 1192 15
Too small deviation of boost pressure 1192 17
Overhigh rotational speed of fan 1639 3
Too-low rotational speed of fan 1639 4
Overhigh engine temperature 520200 16
Opening circuit of fan driver 1071 5
Short circuit of fan driver to ground 1071 4
Overload of fan driver 1071 12
Overheating of fan driver 1071 2
Short circuit of fan driver 1071 3
Short circuit of the high-speed fan driver 1071 3
Opening circuit of high-speed fan driver 1071 4
Short circuit of low-speed fan driver 1071 3
Opening circuit of low-speed fan driver 1071 4
Monitoring fault of rail pressure positive deviation based
523613 20
on speed
Fault of excessive pressure drop rate in Overrun state 523613 20
No pass for self-inspection of water-in-oil sensor 97 12
Detect that water is contained in oil 97 11
Open-circuit fault of fuel oil heating driver 520231 5
Short-circuit fault of fuel oil heating driver 520231 3
MCU temperature sensor SRC is high 520201 3
MCU temperature sensor SRC is low 520201 4
MCU temperature is high 520201 15
MCU temperature is low 520201 17
EEPROM has too many Sectors not available 630 2
EEPROM erase error 630 12
EEPROM programming error 630 4
AD reference voltage is too high 520202 3
AD reference voltage is too low 520202 4
CAN0_BusOff 520203 12
CAN1_BusOff 520204 12
Receiving message 1 Overtime 520205 12
47
DCU Type 1 fault 520216 11
5VLDO#1 Fault of power supply module 520221 12
12VLDO power supply module failure 520224 12
High battery voltage 168 3
Low battery voltage 168 4
DCDC short circuit 520232 3
DCDC open circuit 520232 5
PIC communication failure 520233 12
Reset caused by clock error 520234 12
Reset caused by watchdog 520235 12
Access at illegal address 520236 12
Troubleshooting
SPN190 FMI 11/12
Fault Description SPN FMI

Missing in crankshaft sensor signal 190 12
Error in crankshaft sensor signal 190 11
1. The installation clearance between the crankshaft sensor and the target wheel is 0.3-2.0mm, which
shall be adjusted.
2. Check the 3harnesses between the sensor and ECU for broken circuit, short circuit, short circuit to
ground, repair or replace the harness.
3. Check whether the voltage between pin 1 and pin 3 of harness end or the ground of carriage is 5V.
The 121-pin crankshaft sensor and the intake pressure temperature sensor share the same source. It is
necessary to check whether the power supply of the intake pressure temperature sensor is
short-circuited to ground at the same time, and repair it if any.
4. Ignition of the engine, measure whether the voltage between pin 2 and pin 3 is 2.0-2.2V.
SPN636 FMI 11/12

48
Missing in camshaft sensor signal 636 12
Error in camshaft sensor signal 636 11
1. The installation clearance between the camshaft sensor and the target wheel is 0.3-2.0mm, which
shall be adjusted.
2. Check the 3 harnesses between the sensor and ECU for broken circuit, short circuit, short circuit to
ground, repair or replace the harness if necessary.
3. Check whether the voltage between pin 1 and pin 3 of harness end or the ground of carriage is 5V.
The 121-pin camshaft sensor shares the same source with Accelerator Pedal Sensor 1 and the fuel
temperature sensor. It is necessary to check whether the power supplies of Accelerator Pedal Sensor 1
and the fuel temperature are short-circuited to ground at the same time, and repair it if any.
4. Ignition of the engine, measure whether the voltage between pin 2 and pin 3 is 0.5-1.0V.
SPN108 FMI 3/4

High APS of the atmospheric
108 3
pressure sensor
Low APS of the atmospheric
108 4
pressure sensor
1. The system uses an alternative value of 100kp.
2. ECU is built in, replace ECU.
SPN102 FMI 2/3/4/15/17

SPN105 FMI 3/4

High BPS of the boost pressure
102 3
sensor
Low BPS of the boost pressure
102 4
sensor
Reasonability fault of the boost
102 2
pressure sensor
High physical value of the boost
102 15
pressure sensor
Low physical value of the boost
102 17
pressure sensor
High IATS of the boost temperature
105 3
sensor
Low IATS of the boost temperature
105 4
sensor
1. Definition of sensor pins: 1- ground, 2- temperature signal, 3- power supply, 4- pressure signal.
2. When the sensor connector is disconnected, whether the voltage between pin 3 and pin 1 and pin 2
and pin 1 is 5V, if not, check the wiring harness and check whether the crankshaft sensor power supply
is short-circuited to ground (common source).
3. When the sensor connector is disconnected, measure the resistance between pin 1 and pin 2 of air
temperature sensor, 2375-2492Ω/20℃;
1113-1185Ω/40℃, or replace the sensor.
49
4. Measure the voltage between pin 4 and pin 1 under standard atmospheric pressure,
1.223V; 150kPa, 3.189V. If the voltage does not change when the pressure changes, replace the sensor.
SPN110 FMI 2/3/4/15/17

SPN520198 FMI 2

High CTS of the cooling water
110 3
temperature sensor
Low CTS of the cooling water
110 4
temperature sensor
Unreasonable CTS of the cooling
110 2
water temperature sensor
High physical value of the coolant
110 15
temperature sensor
Low physical value of the coolant
110 17
temperature sensor
Dynamic test of the coolant
520198 2
temperature sensor
Absolute value test of the coolant
520198 2
temperature sensor
1. When the connector is disconnected, check whether the voltage between the two terminals at the
harness end is 5V. If not, check whether the harness is open circuit and short circuit to ground.
2. Measure the resistance of temperature sensor, 3280-3770Ω/20℃; 1374-1556 Ω/40℃.
SPN174 FMI 3/4/15/17/

High FTS of the fuel temperature
174 3
sensor
Low FTS of the fuel temperature
174 4
sensor
High physical value of the fuel
174 15
temperature sensor
Low physical value of the fuel
174 17
temperature sensor
1. When the connector is disconnected, check whether the voltage between the two terminals at the
harness end is 5V. If not, check whether the harness is open circuit and short circuit to ground.
2. Measure the temperature sensor resistance, 3280-3770ohms/20℃; 1374-1556 ohms /40℃.
SPN91 FMI 2/3/4

SPN29 FMI 3/4

High ACCPED of Accelerator 1 91 3
50
signals
Low ACCPED of Accelerator 1
91 4
signals
Unreasonable ACCPED of
91 2
Accelerator signal
High ACCPED of Accelerator 2
29 3
signals
Low ACCPED of Accelerator 2
29 4
signals
1. When the connector is disconnected, check whether the voltage between the sensor power supply at
the harness end and ground is 5V, and if not, check whether the harness is broken circuit and
short-circuit.
2. And check the power supply module a throttle 1(15), camshaft (33), fuel temperature (34); power
supply module b throttle 2(10), oil pressure (11), EGR position (30). Whether the corresponding sensors
and circuits have failed.
3. Whether the output voltage ratio of the diagnostic apparatus monitoring pedal 1 and pedal 2 sensor is
2:1, and if not, replace the pedal.
SPN100 FMI 2/3/4/17/

High OPS of the oil pressure sensor 100 3
Low OPS of the oil pressure sensor 100 4
Low reasonability of the oil pressure 100 17
High reasonability of the oil pressure 100 2
1. The multimeter measures whether the voltage between the power supply (red) and the ground
(black)is 5V. If not, check whether the harness is broken circuit or short-circuit. Remove the sensor and
measure whether the power supply is 5V. If yes, the sensor is damaged internally.
2. Measure the signal line voltage. When flameout, 0.5V/0Mpa; at idle speed, 1.14-2.3V/160-450kPa; at
high idle speed, 2.06-3V/390-650kPa, or replace the sensor.
SPN2791 FMI 3/4
Fault description SPN FMI

High SRC of the EGR position
2791 3
sensor
Low SRC of the EGR position
2791 4
sensor
1. Check whether the voltage between connectors E30 and E28 at harness end is 5V. If not, check the
harness for broken circuit and short circuit. In addition, it is necessary to check whether the common
source sensor and its circuit are faulty. V3- accelerator pedal 2, oil pressure, EGR position sensor are
the same power supply module.
SPN651 FMI3/5
SPN652 FMI3/5
SPN653 FMI3/5
SPN654 FMI3/5
SPN655 FMI3/5
51
SPN656 FMI3/5

Short circuit of injection driver of the
651 3
first cylinder
Open circuit of injection driver of the
651 5
first cylinder
652 3
second cylinder
652 5
second cylinder
653 3
third cylinder
653 5
third cylinder
654 3
fourth cylinder
654 5
fourth cylinder
655 3
fifth cylinder
655 5
fifth cylinder
656 3
sixth cylinder
656 5
sixth cylinder
Check the harness of the unit pump. The resistance of the unit pump is 0.5Ω.
SPN168 FMI 3/4

High battery voltage 168 3
Low battery voltage 168 4
1. The normal operating battery voltage range of ECU is 9-32V.
2. The multimeter checks whether the battery harness and pins are short-circuited with ground or other
lines. At this time, the signal voltage shall be less than the limit value.
52
33. Grader harness layout
Fig. 3-34 Power supply circuits
Fig. 3-35 Front frame harness
3-62
13
12 1
2
3
11
4
10
9
8
Fig. 3-36 Rear frame harness layout

1 Connected to 2 Connected to 3 Connected to 4 Connected to the
negative pole air filter starter transmission
of battery warning switch pressure switch
5 Connected to 6 Connected to 7 Connected to 8 Connected to
rear vehicle fuel level left side of Shuihanbao
body harness sensor engine
9 Connected to 10 Connected to 1 Connected to 12 Connected to
transmission speed sensor. 1 the brake tail front frame
and coolant lamp switch harness
temperature
sensor
3-63
Gearbox pressure switch Joint of rear cover
Hole No. Wire No.Hole No. Wire No.
Hole No. AMP 2 core (hole end) harness
Wire No.
Jacket
Terminal
Water Seal
Fuel level sensor
To starting motor
Hole No. Wire No. Hole No. Wire No. Hole No. Wire No. Hole No. Wire No.
Torque converter oil
temperature sensor
Connected to the
positive pole of Hole No. Wire No.
Alternator wire
battery
Hole No. Wire No.
Instrument harness Rear-wheel-speed
joint sensor
Hole No.
Connected to air filter Wire No.
clogging switch Connected to the

coolant Engine oil
Hole No. Wire No. temperature pressure switch
Fuse socket
sensor
Fuse
Excitation
3-64
Brake tail lamp switch resistance
Fuse socket
Hole No.
Wire No.
Fuse Hole No.
Fuse Wire No.
Fig. 3-37 Rear frame harness layout

Connected to the
preheater relay Connected to relay
Front frame harness

joint
Connected to the
electric pump
Reverse buzzer
Wire Name Sectional area Color

No.: (mm2)
0 Earth wire 5 Black
0c Earth wire 1.25 Black
2a/2b Alternator charging wire 1.25 Red
2c Engine ECU power supply wire 2.0 Red
4 High beam wire of rear lamp 1.25 White
6 Right turn lamp wire 0.85 White
7 Left turn lamp wire 0.85 White
8 Brake switch wire 0.85 White
9 Reverse signal wire 0.85 White
10 High beam wire of headlamp 1.25 White
11 Low beam wire of headlamp 1.25 White
13 Hand brake switch indicator 0.85 White
wire
14 Engine coolant temperature 0.85 White
sensor wire
15 Torque converter oil temperature 0.85 White
signal wire
17 Transmission pressure signal 0.85 White
wire
19 Fuel signal wire 0.85 White
20 Charging warning lamp wire 0.85 Red
22 Starting signal wire 0.85 White
28 Battery relay coil positive 0.85 Red
pole wire
30 Rocker switch backlight, 0.85 White
clearance lamp wires
31 Engine oil pressure warning wire 0.85 White
32 Braking pressure switch wire 0.85 White
34a Scraper lamp wire 1.25 White
40 Reverse /horn power supply wire 1.25 Red
42 Lock-cylinder approach-switch 0.85 Red
power-supply wire
56/56a Main-power-supply-wire 5.0 Red
3-65
positive pole
61 Preheater indicator wire 0.85 White
65 Approach-switch (lock cylinder) 0.85 White
signal wire
73 Alternator W-end signal wire 0.85 White
80 Instrument-panel power-supply 0.85 White
wire
81 Wheel-speed signal wire 0.85 White
85 Lock-cylinder 0.85 White
lock-solenoid-valve wire
unlock-solenoid-valve wire
125 Vehicle-speed sensor 5V power 0.85 Red
supply wire
153 Horn power supply wire 1.25 White
3-66
Front/rear
work lamp Hole No. Wire No.
Front/rear
work lamp A/C
Rear lamp\ Heater vent \
Background
Background
Heater
Background
Background
Background
Background
lamp
\
lamp
lamp
lamp
lamp
lamp
Heater vent
Heater
Cigar lighter
ECU harness connector
Fig.3-38 Instrument panel harness

with 81 pins
Connected to the
gear selector
Connected to
the cab
Diode
Background
Background
Background
Background
Background
assembly
lamp
lamp
lamp
lamp
lamp
Warning lamp Scraper lamp Background Mute Lock cylinder Hole No. Wire No. Hole No. Wire No.
3-67
switch lamp switch
Shielding: MG640352 schematic
Work Hole No. Wire No. Hole No. Wire No. Hole No. Wire No. Hole No. Wire No.
Using the thermal
lamp shrinkage pipe Hole No. Wire No. Hole No. Wire No.
Hole No. Wire No.
Connected to the
rear wiper
Diameter of
No.0 diameter:1.25mm
2 Joint of central controller
Work Hole No. Wire No. Hole No. Wire No.Hole No. Wire No.
lamp Reserved power supply
joint
Hole No. Wire No.
Joint of cab harness
Hole No. Wire No. Hole No. Wire No.
Connected to the Hole No. Wire No.Hole No. Wire No.Hole No. Wire No.Hole No. Wire No.
instrument panel Rear frame joint
Background
Background
lamp
lamp
Horn
button

No.: (mm2)
0c Sensor/instrument earth wire 1.25 Black
2 PTO power supply wire 1.25 Red
2c Engine ECU power supply wire 2.0 Red
4 High beam wire of rear lamp 1.25 White
6 Right turn lamp wire 0.85 White
7 Left turn lamp wire 0.85 White
8 Brake switch wire 0.85 White
8a Gear selector brake signal wire 0.85 White
9 Reverse signal wire 0.85 White
10 High beam wire of headlamp 1.25 White
11 Low beam wire of headlamp 1.25 White
12 Horn button wire 0.85 White
13 Hand brake switch indicator 0.85 White
wire
14 Engine coolant temperature 0.85 White
sensor wire
15 Torque converter oil temperature 0.85 White
signal wire
17 Transmission pressure signal 0.85 White
wire
19 Fuel signal wire 0.85 White
21 Fuse box top wire /instrument 0.85 Red
panel power supply wire
22 Starting signal wire 0.85 White
23 Front-sprayer-motor control wire 0.85 White
23a Rear-sprayer-motor control wire 0.85 White
24 Front-wiper reset wire 0.85 White
24a Rear-wiper reset wire 0.85 White
25 Front-wiper low-speed wire 0.85 White
25a Front-wiper low-speed wire 1.25 White
26 Front-wiper high-speed wire 1.25 White
3-68

No.: (mm2)
28 Battery relay coil wire 0.85 Red
30 Rocker switch background lamp, 0.85 White
31 Engine oil pressure warning wire 0.85 White
32 Braking pressure switch wire 0.85 White
33 Flasher signal output wire 1.25 White
34 Headlamp wire 2.0 White
34a Scraper lamp wire 1.25 White
35 Headlight power supply wire 1.25 Red
36 A/C and heater power 3.0 Red
supply wire
37 Wiper power supply wire 2.0 Red
38 Reserved cold startup power 1.25 Red
supply wire
39 Headlight power supply wire 0.85 Red
40 Reverse /horn power supply wire 1.25 Red
41 Radio power supply wire 1.25 Red
42 Lock-cylinder approach-switch 0.85 Red
power-supply wire
43 Timing meter power-supply wire 0.85 Red
45 Rear lamp switch wire 0.85 Red
46 Brake solenoid valve power 0.85 Red
supply wire
47 Rear lamp switch wire 0.85 Red
48 Lock-cylinder switch 0.85 Red
power-supply wire
49 High beam wire of front 0.85 White
combine lamp
50 Low beam signal wire of front 0.85 White
combine lamp
53 Heater low-speed wire 1.25 White
53a Heater high-speed wire 1.25 White
56 Main power supply wire 5.0 Red
58 Reverse-gear output wire 0.85 White
3-69

No.: (mm2)
59 Starting interlock output wire 0.85 White
60 Starting interlock signal 0.85 White
wire
61 Preheater indicator wire 0.85 White
65 Approach-switch (lock cylinder) 0.85 White
signal wire
71 Rear lamp wire 1.25 White
73 Alternator W-end signal wire 0.85 White
74 Headlamp signal wire 0.85 White
74a Scraper signal wire 0.85 White
75 Rear lamp signal wire 0.85 White
77 Cigar lighter power supply 1.25 White
wire
79 Rear lamp signal wire 1.25 White
80 Instrument-panel power-supply 0.85 White
wire
81 Wheel-speed signal wire 0.85 White
85 Lock-cylinder solenoid-valve 0.85 White
wire
unlock-solenoid-valve wire
99 Mute switch wire 0.85 Red
121 Electric lock power supply wire 1.25 Red
125 vehicle-speed sensor 5V power 0.85 Red
supply wire
153 Horn power supply wire 1.25 White
158 Engine malfunction indicator 0.85 White
wire
159 Air filter clogging signal wire 0.85 White
186 Scraper left floating signal wire 0.85 White
187 Scraper right floating signal wire 0.85 White
E59 PTO Resume – switch 0.75 White
E60 PTO Set + switch 0.75 White
E72 PTO ON/OFF switch 0.75 White
3-70
Connected to engine ECU
Hole No. wire No. Hole No. wire No.
Connected to instrument
panel harness
Engine diagnosis joint
Fuel-efficient switch
Rocker switch socket
schematic
Fig. 3-39 E-ECU harness
3-71
Connected to wiper motor 3
Hole No. Wire No.
Connected to the right horn
Connected to front Connected to top
work lamp (front-right) warning lamp
Fig. 3-40 Cab harness

Connected to
Connected to
rear lamp
rear lamp
Ceiling lamp (rear-right)
(rear-left)
Radio connector
Connected to instrument panel harness
3-72
Front wiper 3 Front wiper 1 Front wiper 2
Background
Background
Background
lamp
lamp
lamp
Connected to fan
Connected to front
work lamp (front-left)
Connected to
left horn
Hole No. Wire No.
Connected to wiper motor 2
Connected to Hole No. Wire No. Hole No. Wire No.
Hole No. Wire No.
Background
Background
Background
wiper motor 1
lamp
lamp
lamp
Sprayer Rear wiper Warning lamp
on top
Wire No.: Name Sectional area Color

(mm2)
21 Fuse box top wire /instrument 0.85 Red
panel power supply wire
23a Rear-sprayer-motor control wire 0.85 White
24/24b/24c Front-wiper reset wire 0.85 White
24a Rear-wiper reset wire 0.85 White
25/25b/25c Front-wiper low-speed wire 0.85 White
25a Front-wiper low-speed wire 1.25 White
26/26b/26c Front-wiper high-speed wire 1.25 White
30 Rocker switch background lamp, 0.85 White
34 Headlamp wire 2.0 White
36 A/C and heater power 3.0 Red
supply wire
37 Wiper power supply wire 2.0 Red
41 Radio power supply wire 1.25 Red
71 Rear lamp wire 1.25 White
72 Warning lamp signal wire 0.85 White
76 Sprayer power-supply wire 1.25 White
L+ Left horn signal + 0.85 White
L— Left horn signal - 0.85 White
R+ Right horn signal + 0.85 White
R— Right horn signal - 0.85 White
3-73
Content
4 Transmission System............................................................................................................... 4-1
41 Hydraulic torque converter-gearbox assembly ..................................................................... 4-2

411 Gearbox introduction ..................................................................................................... 4-2
412 Mechanical principles of gears of gearbox .................................................................... 4-4
413 Gearbox control system ................................................................................................. 4-4
414 Operating and maintenance of gearbox ......................................................................... 4-8
415 Removal and installation of gearbox ........................................................................... 4-10
416 Precautions ................................................................................................................... 4-24
42 Drive shaft assembly........................................................................................................... 4-25
421 Drive shaft introduction ............................................................................................... 4-25
422 Removal and installation of drive shaft assembly ....................................................... 4-28
43 Drive axle and balance box assembly................................................................................. 4-30
431 Grader drive axle introduction..................................................................................... 4-30
432 Main reducing gear and differential assembly ............................................................ 4-31
433 Hub reduction gear assembly ...................................................................................... 4-32
434 Balance box assembly ................................................................................................. 4-32
435 Removal and installation of drive axle and balance box assembly ............................. 4-33
436 Operation maintenance and repair of drive axle.......................................................... 4-38
44 Common faults of grader powertrain and troubleshooting ................................................. 4-41
441 Common faults of gearbox .......................................................................................... 4-41
442 Common faults of drive axle ....................................................................................... 4-42
Ⅰ
4-2
4 Transmission System
The Transmission System of SDLG G9190 grader mainly consists of gearbox, drive shaft,
drive axle, etc. The powertrain schematic diagram is shown in figure 4-1.
Fig. 4-1 G9190 grader Powertrain schematic diagram
1. Engine 5. Drive shaft
2. Hydraulic torque converter+gearbox 6. Left working pump
3. Balance box 7. Right working pump
4. Drive axle
4-1
41 Hydraulic torque converter-gearbox assembly

411. Gearbox introduction
The SDLG G9190 grader adopts the 6WG180 gearbox assembly which can realize speed
switching between 6 forward gears and 3 reverse gears to adapt to the complicated working
conditions of the grader.
The torque converter is a single-step single-phase three-element structure without the lockup
clutch (figure 4-2). The diameter of circulating circles is φ320, the torque ratio is 1.94, and the
torque converter impeller is connected with the engine flywheel via the spring plate and transition
plate. The control pressure of gearbox is 1.3~1.8Mpa. The inlet pressure of torque converter is
0.25~1.0Mpa, the outlet pressure is 0.25~0.4Mpa, and the oil temperature is at 80℃~110℃ during
normal operation, maximally 120℃.
Turbine
Impeller
Engine
Gearbox
Guide wheel
Fig. 4-2 Hydraulic torque converter
The gearbox is fixed-shaft electro-hydraulic control power shift gearbox which can realize
gear up and down operations via the clutch with wet friction plate without disconnecting the power
and can engage and disengage under load to realize power shift. The gears of gearbox are of
normally engaged drive.
4-2
Fig. 4-3 6WG180 hydraulic torque converter and gearbox

1. Solenoid valve M4 2. Solenoid valve M3 3. Solenoid valve M2 4. Solenoid valve M1
5. Oil temperature 6. Oil outlet of torque 7. Oil suction pipe of 8. Hydraulic torque
sensor port converter gearbox converter
9. Variable-speed 10. Clutch (3 groups in 11. Parking brake 12. Vehicle speed
pump total) sensor
13. KV pressure 14. KR pressure 15. K4 pressure 16. K3 pressure
measuring port measuring port measuring port measuring port
17. Control oil 18. K1 pressure 19. K2 pressure
pressure measuring measuring port measuring port
port
4-3
412 Mechanical principles of gears of gearbox

The actuating mechanism in the gearbox consists of 6 clutches, which are K1, K2, K3, K4,
KV and KR respectively and the KR is reverse clutch. Different gears can be realized through the
combinations, and there are must two clutches working simultaneously at each gear, see figure 4-4
for the working principles of the gearbox.
Fig. 4-4 Drive principle of gearbox
The gear combinations and drive ratio are shown in the table below:
Table 4-1
Forward gear Reverse gear
Gear I II III IV V VI I II III
Drive ratio 5.986 3.42 2.594 1.48 1.178 0.672 5.986 2.594 1.178
Gear
KV+K1 K4+K1 KV+K2 K4+K2 KV+K3 K4+K3 KR+K1 KR+K2 KR+K3
combination
Vehicle
speed 4.8 8.4 11 18.6 23 38 4.8 11 23
(km/h)
413 Gearbox control system
The shift control of gearbox is electro-hydraulic control, the shift selector is installed at the
right side of driver’s seat (as shown in figure 4-5), the hydraulic slide valves are controlled by the
4-4
shift selector and the solenoid valves are connected with the shift selector to realize shift control in
sequence. Do not control the gears in a manner of skipping some gear. The gear pump used for
supplying oil for the torque converter and control valve is installed in the gearbox and is directly
driven by the engine through the PTO shaft, and the flow is Q=35L/min. The hydrodynamic drive
oil enters the variable-speed control valve after the suction oil filter and pressure control valve in
the oil line, and the control pressure of gearbox is 1.3~1.8Mpa. The function of the pressure control
valve is to adjust the pressure rising characteristic of clutch cylinder during shifting to reduce the
shifting impact and improve the shifting quality.
Reverse gear
Neutral gear
Forward gear
Fig. 4-5 Gear selector
The power on/off of solenoid valves at different gears are shown in the table below:
Table 4-2
4-5
4-1
414 Operating and maintenance of gearbox
The gearbox assembly adopts the SAE 15W-40 diesel oil for lubrication, and the initial oil
filling amount is 28L approximately, the oil filling port and dipstick of gearbox are at the left
front side of the rear frame.
Oil filling port of gearbox

+
Gearbox dipstick
Fig. 4-7
Fig. 4-8 Gearbox dipstick
Gearbox oil level inspection method:
● Park the grader on the level ground;
● Place the shift lever of gearbox at the neutral position “N”;
● The gearbox is within the working temperature scope;
● Engine idle speed, about 1000r/min;
● Unscrew the dipstick counterclockwise, take it out and clean;
● Insert the dipstick into the oil pipe and tighten it, take it out again when it is in
place (at least 2 times);
● If the temperature is at 40°C, the oil level shall be between lower scale “cold” and
middle scale;
● If the temperature is at 80°C, the oil level shall be between upper scale “cold” and
middle scale.
If the oil amount reaches the oil level when the vehicle is cold, it can guarantee sufficient
circulation flow for the gearbox and torque converter but cannot meet the oil requirements of the
4-8
whole system, the final standards for deciding the oil amount is the oil level when the vehicle is hot.
If the oil level is checked when the engine is not started, the oil level shall be above the lower scale
(figure 4-8). The oil must be changed after the initial 100h operation of gearbox, and change the oil
every 1000h afterwards, at least once a year, and the filter shall be replaced every time the oil is
changed.
Tightening method of filter: coat a thin layer of oil on the seal ring, tighten until it contacts
with the tank surface, then tighten 1/3~1/2 circle by hands or a special tool. During daily work,
check whether the bypass valve of filter is at the open mode.
4-9
415 Removal and installation of gearbox
Caution
Remove the gearbox after cooling down.
During removal, all pipe joints shall be
wrapped up and protected to prevent
impurities from entering the pipes.
Removal of gearbox
1. Wedge the tyres of grader with wooden wedges.
1
Fig. 4-9
1. Wooden wedge
2. Remove the cab and covering parts system. Refer
to 8-17 and 8-29.
Cab
Engine hood
1 2
Fig. 4-10
1. Engine hood
2. Cab
4-10
3. Remove the speed change valve and control the
oil pressure sensor。
Caution
After removing the oil pressure sensor,
protect the oil port well and keep the oil
pressure sensor properly.
1
Fig. 4-11
1. Oil pressure sensor
4. Remove the hydraulic oil tank assembly. Refer to
9-17.
Hydraulic oil tank assembly
1
Fig. 4-12
1. Hydraulic oil tank assembly
5. Drain the gearbox oil.

Caution
During daily maintenance, drain the oil from

the special oil drainage port. When removing
the gearbox, the oil can be drained from the oil
drainage port, or directly remove the oil filling
pipe to drain the oil.
1 2
Fig. 4-13
1. Oil filling pipe
2. Hose clamp
4-11
6. Disconnect solenoid valve control line of speed
change control valve.
1 2
Fig. 4-14
1. Speed change control valve
2. Solenoid valve control line
7. Remove the hydrodynamic drive oil temperature
sensor.
Caution
After removing the oil temperature sensor,
protect the oil port and keep the oil temperature
1 sensor properly.
Fig. 4-15
1. Oil temperature sensor
8. Remove the vehicle speed sensor.
1
Fig. 4-16
1. Vehicle speed sensor
4-12
9. Disconnect the oil pipe from gearbox to radiator.
1
Fig. 4-17
1. Oil pipe from gearbox to radiator
10. Disconnect the oil pipe from radiator to gearbox.
1
Fig. 4-18
1. Oil pipe from radiator to gearbox
11. Remove the connecting bolts of drive shaft and
gearbox.
1 2
Fig. 4-19
1. Bolt
2. Drive shaft assembly
4-13
12. Remove the oil inlet/outlet pipes of working
pump and steering pump.
Caution
When removing the oil pipes, take off the oil
pipes slowly to prevent oil from splashing. All oil
ports must be well protected to prevent impurities
from entering.
1 2
Fig. 4-20
1. Working pump
2. Oil pipe
13. Remove the parking brake cable.
1
Fig. 4-21
1. Parking brake cable
14. Remove the gearbox cover plate.
1 2
Fig. 4-22
1. Cover plate
2. Bolt
4-14
15. Remove the bolts connecting torque converter
housing and connecting plate.
1 2
Fig. 4-23
1. Connecting plate
2. Bolt
16. Remove the connecting bolts of torque converter
housing and engine flywheel housing.
Caution
Before removing the connecting bolts of
engine and gearbox, the engine must be
1 supported on the frame to prevent it from

Fig. 4-24
falling, and then carry out the removal.
1. Bolt
17. Remove the set bolts of gearbox bracket.
1
Fig. 4-25
1. Bolt
4-15
18. Remove the gearbox.
Lift the gearbox slightly via the lifting device,
make sure that the gearbox is separated from the
frame and there is no squeezing or pulling of the oil
pipes and wires before lifting the gearbox.
Gearbox assembly
1 2
Fig. 4-26
1. Gearbox assembly
2. Lifting device
Caution
When lifting the gearbox, perform slowly and
keep the gearbox balance to avoid the torque
converter dropping and hurting people.
Fig. 4-27
4-16
Installation of gearbox
1. Connect the lifting device to the gearbox.
2. Lift the gearbox in place.
Gearbox assembly
Caution
Lift the gearbox stably to avoid the torque
converter dropping.
1 2 Operate carefully and pay special attention to

Fig. 4-28
the cables and hydraulic hoses on the
1. Gearbox assembly
2. Lifting device machine; otherwise, there may be risk of
damages due to clamping or squeezing.
3. Install the two upper connecting bolts
between the engine and the gearbox.
4. Install and tighten the connecting bolts
between the engine and the gearbox.
1 2 3
Fig. 4-29
1. Gearbox housing
2. Bolt
3. Engine housing
4-17
5. Tighten the gearbox support to the frame
from the sides. Remove the lifting device.
1
Fig. 4-30
1. Bolt
6. Install the connecting bolts between gearbox
torque converter housing and connecting
plate.
1 2 3
Fig. 4-31
1. Connecting plate
2. Bolt
3. Torque converter housing
7. Install the gearbox cover plate.
1 2
Fig. 4-32
1. Bolt
2. Cover plate
4-18
8. Install the oil return pipe from radiator to
gearbox.
Caution
Before installing the oil pipes, the oil ports

must be completely cleaned.
1
Fig. 4-33
1. Oil pipe from radiator to gearbox
9. Install the oil outlet pipe from gearbox to
radiator.
1
Fig. 4-34
1. Oil pipe from gearbox to radiator
10. Connect the oil inlet/outlet pipes of working
pump and steering pump.
Caution
Before connecting the oil pipes, the oil ports
must be completely cleaned to prevent
impurities from entering the pipes.
1 2
Fig. 4-35
1. Working pump
2. Oil pipe
4-19
11. Connect the drive shaft to the gearbox.
Torque: 110~130N·m
Coat the 272 thread fastening glue

on the bolts.
1 2
Fig. 4-36
1. Bolt
12. Install the parking brake cable.
1
Fig. 4-37
1. Parking brake cable
13. Install the oil filling pipe of gearbox.
1 2
Fig. 4-38
1. Oil filling pipe
2. Hose clamp
4-20
14. Install the speed sensor.
1
Fig. 4-39
1. Speed sensor
15. Install the oil temperature sensor.

Caution
When installing the sensor, the thread must
be wrapped up by the thread seal tape to
avoid oil leakage.
1
Fig. 4-40
1. Oil temperature sensor
16. Connect the solenoid valve control line of
speed change control valve.
1 2
Fig. 4-41
1. Speed change control valve
2. Solenoid valve control line
4-21
17. Install the hydraulic oil tank assembly.
1
Fig. 4-42
1. Hydraulic oil tank assembly
18. Install the variable-speed control oil pressure
sensor.
1
Fig. 4-43
1. Oil pressure sensor
19. Install the cab and covering parts system.
1 2
Fig. 4-44
1. Engine hood
2. Cab
4-22
20. Fill the gearbox oil.
Fill 15W-40 diesel oil to the gearbox, the

theoretical filling amount is 28L, observe the
filling amount via the middle scale of the dipstick
when filling.
1
Fig. 4-45
1. Oil filling port of gearbox
4-23
416 Precautions
1. The maintenance, removal and check of gearbox shall be carried out under the guidance or
by professionals.
2. When removing the gearbox, pay attention that the torque converter is not axially positioned,
protect the torque converter against dropping when lifting the gearbox.
3. When the grader starts or is running normally, the parking brake must be released. Due to the
high output torque ratio of torque converter, even if in normal operating conditions, the
grader can easily overcome the braking torque of parking brake and run forcibly without
awareness of the driver. The result will be that the oil temperature of torque converter will
rise sharply, causing brake overheating, smoking or even burnt. The parking brake can be
used as the emergent brake.
4. When electric welding is carried out on the main machine, the cable of gear selector must be
disconnected to avoid accidental Overcurrent which may damage the internal circuit.
5. When the engine is stopped and the main machine is pulled, the gearbox requires that the
pulling speed shall not exceed 10km/h and the pulling distance shall not exceed 10km.
6. When draining the oil, the oil in the gearbox, torque converter and radiator shall be
completed drained to avoid secondary contamination of oil quality. Usage of unclean or
nonconforming oil will cause serious fault of gearbox.
4-24
42 Drive shaft assembly

421 Drive shaft introduction
1. Structure and function of universal gearing
The drive shaft is a universal gearing installed between the gearbox and drive axle, it usually
consists of the universal joint assembly and the drive shaft (people usually call the universal
gearing as drive shaft assembly). As the working conditions of grader are very complicated, the
axis of gearbox output shaft and the axis of drive axle input shaft cannot coincide; besides, during
the grader operation, the roads and the working site are not flat, the relative positions of the two
axes always change. Rigid connection of gearbox output shaft and drive axle input shaft is
improper, and the universal gearing composed of two cross spider universal joints and one drive
shaft must be used. The function of the universal gearing is to solve the problem of nonaxiality of
gearbox and drive axle to adapt to the change requirements of included angle between the gearbox
and the drive axle, so as to transmit the power of gearbox to the drive axle.
The SDLG G9190 grader adopts the drive shaft assembly, of which the rated working torque
is 4100N·m, the deviation of central lines of the cross spider universal joints at the two ends of the
drive shaft assembly is within 3°, the lubricant is ZL-2 lithium base grease, the working tilt angle
of universal joint is ≥20°, to adapt to the complicated working conditions of grader.
1. Universal joint 2. Hex head bolt 3. Drive shaft
Fig. 4-46 Drive shaft assembly
2．Universal joint
(1) Structure of universal joint
The universal joint is the most complicated part in the drive shaft assembly and can be
4-25
divided into common (non-constant angular velocity) universal joint and constant angular velocity
universal joint according to the velocity features; according to rigidity, the universal joint can be
divided into rigid universal joint and flexible universal joint. The universal joints used on universal
gearing of grader are common cross spider rigid universal joints.
The common cross spider rigid universal joint consists of cross spider, roller bearing, oil
seal and oil cup. To reduce the friction loss and increase the drive efficiency, the roller bearing is
installed between the journal and the sleeve of cross spider, and the sleeve is fixed on the universal
joint fork to protect the bearing against dropping from the universal joint fork under the action of
centrifugal. To lubricate the bearing, the lubricating oil way is drilled through in the cross spider
and groove is processed on the end surface of the cross spider, so that the grease can be filled into
the oil cup and reach the working surface of the roller bearing.
(2) Drive features of cross spider universal joint
The cross spider universal joint has the feature of non-constant velocity drive. The
“non-constant velocity drive” means that when the driving shaft rotates at constant angular
velocity, the rotational speed of driven shaft will varies, i.e. the non-constant velocity feature of
single cross spider universal joint during drive with included angle. It should be noted that
“non-constant angular velocity of drive” means that the angular velocity of driven shaft in a cycle
is non-constant”. When the drive shaft finishes a circle, the driven shaft also rotates a circle, so,
their average rotation velocities are same.
The non-constant velocity feature of common cross spider universal joint makes the driven
shaft and drive parts which it connected with to cause torsional vibration, thus generating additional
alternating and affecting the parts’ life. The method of “constant velocity universal drive” is thus
developed: from non-constant velocity of cross spider universal joint associating the between two
shafts (gearbox output shaft and drive axle input shaft). If double cross spider universal joint drive
is adopted, the non-constant velocity of one cross spider universal joint may be offset by the
non-constant velocity of the other cross spider universal joint to release the constant drive between
the two shafts.
(3) Structure and features of drive shaft
4-26
The drive shaft is an important part of the universal gearing, usually for connection
between the gearbox and the drive axle. The drive shaft generally consists of the pipe sleeve fork
assembly, universal joint fork and spline shaft assembly. During running of grader, the relative
positions between the gearbox and the drive axle always change. In order to avoid movement
interference, the slide spline connecting part composed of the slide fork and the spline shaft is
arranged in the drive shaft to realize the change of drive shaft length. To reduce the wear, the oil
cup, oil seal and spline jacket filled with grease is installed on the drive shaft to ensure the
lubrication of spline shaft in the pipe sleeve fork and prevent moisture and dust from entering the
sliding spline.
4-27
422 Removal and installation of drive
shaft assembly
Caution
In case of faults, replace the drive shaft as a
whole. It is prohibited to use the drive shaft
assembly with any deformation, scrapping or
cracks.
Fix the tyres of grade via the wooden wedges
before removing the drive shaft.
Place the hand brake at the braking position.
Removal of drive shaft assembly
1. Wedge the tyres of grader with wooden
1 wedges.
1 wooden wedge
1
Fig. 4-47
1. Wooden wedge
2. Remove the connecting bolts of drive shaft
and gearbox.
and drive axle.

Caution
When removing the bolts, support the drive

1 shaft to prevent it from dropping.
Fig. 4-48
1. Bolt
4-28
Installation of drive shaft assembly
1. Install the connecting bolts of drive shaft and
drive axle.
Torque: 110~130N·m
Coat the 272 thread fastening glue on
the bolt.
2. Install the connecting bolts of drive shaft and

1
gearbox.
Fig. 4-49
1. Bolt Torque: 110~130N·m
Coat the 272 thread fastening glue on
the bolt.
Caution
Before installing the drive shaft, check
whether the drive shaft universal joint is
normal or stretch axially. In case of any fault,
please replace the drive shaft immediately.
4-29
43 Drive axle and balance box assembly

431 Grader drive axle introduction
As a major part of the chassis powertrain, the main function of grader drive axle is to increase
the torque transmitted by the engine and distribute the torque to left and right drive wheels so that
the two wheels have differential function. Meanwhile, the drive axle bears all action force
transmitted from the road surface and frame.
The rear drive assembly of G9190 grader adopts the 3-section type grader drive axle, the
driving drive axle is equipped with a no-spin slide limit differential, pendulum type balance box, the
pendulum angle is ±15°, heavy roller chain drive, and hub drum brake. Final ratio is 3.7, the hub
reduction ratio is 3.26, the balance box reduction ratio is 1.474, and the total reduction ratio is
17.779. The GL-5 85W-90 gear oil is used as the lubrication oil, the connection of balance box
assembly and hub reduction gear assembly and the balance box assembly are lubricated via the
grease.
The drive axle and balance box assembly schematic diagram is shown below:
1 2 3 4
Fig. 4-50
1. Balance box assembly 2. Main drive assembly
3. Differential assembly 4. Hub reduction gear assembly
4-30
The power transmission route is:
Drive shaft
Left pinion Left sprocket Drive chain Left drive
Left planet
shaft shaft wheel
carrier
Main
reducing gear
Right pinion Right planet Right Drive chain Right drive

Differential shaft carrier sprocket shaft wheel
432 Main reducing gear and differential assembly
The main reducing gear assembly consists of main driving pair, differential and input flange.
The differential is no-spin type. When the vehicle is in nonlinear driving, the outer wheel rotates
faster than the inner wheel under the ground dragging, the outer driven ring separates from the
driving ring and generates rotation relative to the driving ring. The central ring is limited by the
inner driven ring engaging tooth and rotates synchronously with the driving ring, rotation
movement of the outer driven ring and central ring is generated, the outer driven ring tooth rises
along the central ring tooth surface until the central ring and the driving ring separate from each
other, so that the outer driven ring will be under the ground dragging other than the driving ring and
performs fast differential rotation. At this moment, the moving ring hung on the outer driven ring
will rise along with the outer driven ring, the lug reaches the support surface of central ring and
prevents the outer driven ring from dropping under the force of conical spring and engaging the
outer driven ring and driving ring. The moving ring keeps the separation state and eliminates the
friction loss and noise caused by contact between teeth of the driving and driven ring, the inner
driven ring and the driving ring will engage to transmit the torque normally. During straight driving,
the ground drag force for driving the outer driven ring to rotate fast disappears, the outer driven ring
will drop fast under the force of conical spring and engage with the driving ring, and the torque
transmitted by the driving ring will be recovered. When the wheel at one side is on icy or wet road
or is off the ground, the wheel at the other side can transmit the original 100% torque, so that the
vehicle has excellent off-road performance. The change-over and performance are automatic, the
driver does not need to operate, and the performance is better than common bevel gear differential.
4-31
433 Hub reduction gear assembly
The hub reduction gear assembly adopts the cylindrical gear planetary drive, the power of
differential will be input to the sun gear from the axle shaft spline, the planet carrier is fixed and
drives the double-row sprocket shaft via the gear ring output, the power will be transmitted to the
double-row sprocket in the balance box.
434 Balance box assembly
The G9190 grader adopts the drum brake balance boxes, one at each side of the rear frame,
the two pendulum balance boxes are driven by serial heavy chains and supported on the supporting
device housing of rear axle via a copper bush in the middle of the box, while the horizontal
positioning is realized by the double-row spherical roller bearing on the outer cover plate in the
middle of the box, with the forward/backward pendulum angle is 15°. The whole machine is good
in off-road performance and the road levelling operation precision is improved. As the sprocket
shaft is a simple support beam structure, the support rigidity is good and can meet the requirements
for different working conditions of grader.
In the balance box, the double-row sprocket transmits the power to the front/rear drive
sprocket via the roller chain and then to each wheel, so as to realize the forward/reverse running
operation of the grader. The tensioning and adjustment of roller chain are realized via the rotation of
eccentric bearing block. (Refer to Operation maintenance and repair of drive axle in section 436 for
the specific adjusting method.)
4-32
435 Removal and installation of drive
axle and balance box assembly
Caution
Before removing the drive axle, park the
grader on level ground. It is prohibited to
carry out the removal and installation
operations when the grader is parked on
slopes or uneven grounds.
Do not carry out the removal operations
immediately after using the machine; only
perform the removal after the drive axle is
cooled down.
During removal, the joints shall be well
protected to prevent impurities from entering
the oil cavity.
Removal of drive axle
1. Fix the grader tyres via the wooden wedges.
1
Fig. 4-51
1. Wooden wedge
4-33
2. Disconnect the brake fluid pipes at the two
sides of the balance box.
3. Disconnect the pipe from drive axle to
breather.
1
Fig. 4-52
1. Brake fluid pipe
and axle.
1
Fig. 4-53
1. Bolt
5. Remove the 8 set bolts of axle via the high
torque pneumatic wrench.
1
Fig. 4-54
1. Axle fixing bolt
4-34
6. Lift the frame from tail part via the lifting
device.
Rear frame
7. Remove the wooden wedges of rear axle
wheels and push out the rear axle assembly
together with the wheels.
8. Support the rear frame via the support.
Caution
1 Before this step, recheck the front wheel
Fig. 4-55
1. Rear frame fixing and make sure that the front wheels
are reliably fixed via the wooden wedges to
prevent the frame moving forwarding during
lifting, and the running tonnage must be
sufficient.
4-35
Installation of drive axle
Caution
During installation, protect the meshing
surface and fitting end faces and keep the
cleanliness to avoid collision and impurities;
Plane sealant must be coated on the fitting
end faces and thread fastening glue must be
coated on the bolts;
During installation, the bolts must be
tightened as per the torque if required.
Installation of drive axle
1. Lift the rear frame via the lifting device.
Rear frame
Caution
Every time before lifting the rear frame, the
front wheels must be checked for reliable
fixing.
1
Fig. 4-56
1. Rear frame
4-36
2. Installation of drive axle.
Push the drive axle assembly into the lower part
of rear frame, lower the rear frame slowly, align the
bolt holes and install the axle bolts.
Torque: 940~1120N·m
1 2
Fig. 4-57
1. Rear axle assembly
2. Bolt
3. Connect the drive shaft.
Torque: 110~130N·m
1 2
Fig. 4-58
2. Bolt
4. Connect the brake fluid pipes at left and right
sides of the balance box.
5. Connect the vent pipe of drive axle.
1
Fig. 4-59
1. Brake fluid pipe
4-37
436 Operation maintenance and repair of drive axle
During operation of drive axle, the normal function of each part depends greatly on the proper
operation, maintenance and repair. Some basic knowledge will be provided in this manual for users’
reference to properly operate, maintain and simply repair the vehicle by themselves to keep the
vehicle in good technical conditions, prolong the service life, and better realize the product
functions.
1. Connection of rim and axle
The rim nuts are M22x1.5, and the tightening torque is 700~800N·m, and shall be
tightened in group symmetrically and evenly. During normal operation, frequently check the
nuts for looseness and retighten timely. If the spherical rim nuts are adopted, check whether the
nut sphere fits the rim ball socket, please ensure the fitting and the reliable connection.
2. Lubrication
2.1 Types of lubrication oil GL-5 85W/90 gear oil
2.2 Oil filling position and amount
The oil filling position of main reducing gear and hub reduction gear assembly is above
the main reducing gear, with independent oil filling pipe, and the oil holes at two sides of
left/right balance box assembly are oil filling holes for balance boxes respectively, and the axle
shall be at horizontal position during filling.
Recommended oil filling amount: fill about 28L oil for the main reducing gear hub
reduction gear assembly and 23L oil for the balance box assembly.
During site repair, fill the oil by taking the lower generatrix of axle oil level hole as the
standard, a little oil overflow is allowable, and the lower limit of oil level is 8mm under the
lower generatrix of oil level hole.
2.3 Add grease at the connection of balance box assembly and hub reduction gear assembly
and the oil nipples of balance box assembly.
3. Operation and maintenance
3.1 Always remove the oil stain, mud and dust, especially the breather plug shall be kept
smooth. Check all parts for tightness, particularly the main reducing gear, hub reduction
4-38
gear and rim bolts, and tighten timely in case of looseness.
3.2 Frequently check for oil leakage and repair and eliminate timely. Check the lubrication oil
level of main reducing gear, hub reduction gear and left/right balance box, add if
insufficient to keep the required oil level and ensure the normal running. Initial lubrication
oil change: after first month or operating for initial 100h; change interval: when work
every 6 months or 1000h.
3.3 The connecting position of balance box assembly and hub reduction gear assembly and
the oil nipples of balance box assembly shall be greased after operating for 3 months.
4. Repair precautions
4.1 When removing or installing the main reducing gear, the gear engaging area shall be
checked by coloring. It is required that on the tooth length direction of the engaging area
close to the small end, the engaging mark shall be ≥1/2 of the tooth length, and the height
shall be at the middle of tooth height.
4.2 The hub reduction gear assembly adopts the locking form of “slotted nut + fastening bolt”.
During installation, by using the adjusting ring, the axial clearance of bearing and hub
reduction gear housing shall be at 0.05~0.15mm, and when tightening the slotted nut by the
torque of 500~600N·m, the double-row sprocket shaft shall be able to rotate freely. Install the
fastening bolt and tighten by the torque of 60~70N·m. Tighten the two fastening bolts
alternately and evenly.
4.3 When replacing the roller needles in the planet gear of hub reduction gear, all roller
needles shall be grouped and matched to make the diameter difference in the same group
no greater than 0.005mm, the cylindricity of roller needle shall be 0.003mm; and the
radial clearance between the roller needles, inner hole of gear and planet gear shaft shall
be 0.015~0.030mm.
4.4 During repair or replacement of the axle shaft of the hub reduction gear, the clearance
between the adjusting pillar and the stop block shall be 1~2mm.
4.5 The rated working pressure of brake is 10Mpa and the maximum working pressure is
15Mpa. Mineral oil shall be used for the brake.
4-39
4.6 After the grader works for 100h with the main machine, carry out the initial check for
chain tension and tension it if necessary. Later, check when works for every 500h.
4.6.1 Check the chain tension
Remove the two cover plates of balance boxes, support the balance boxes to make the
wheels leave the ground. If the sag of loose side of chain exceeds 18mm, the chain shall be
tensioned.
4.6.2 Steps for tensioning the chain
a. Support the balance box to make the wheels off ground, drain the oil;
b. Remove the wheels, brake drum and brake shoe, etc.
c. Remove the bolts on the connecting plate and the bolts on the eccentric bearing block;
d. Rotate the connecting plate and eccentric bearing block by same hole pitch at the same
direction until the sag of loose side of the chain is about 11.5mm.
e. After adjustment, install the removed parts in sequence.
Note: Before removing the connecting plate and the eccentric bearing block, make a mark
at the original position, so that the position after adjustment will be consistent.
4.7 During repair, the original sealant position shall be cleaned via solvent. After drying, coat
a 1mm layer of 598 Plane sealant; the bolts shall be clean and be coated with 262
thread-locking adhesive at the thread end, and tighten by the required tightening torque.
4.8 All seals shall be replaced after removal and shall not be used again.
4.9 Check the thickness of friction plate through the observation hole of brake, and the brake
shoe must be replaced when the friction plate is worn to 3mm.
4-40
44 Common faults of grader powertrain and troubleshooting

441 Common faults of gearbox
1. The Variable-speed oil pressure is too low
Possible cause: (1) The gearbox oil level is Troubleshooting: (1) Fill gearbox oil to
too low; specified level;
(2) The filter is clogged; (2) Replace the filter;
(3) The control pressure valve (3) Clean the valve core or
is stuck; replace if necessary;
(4) Variable-speed pump fault; (4) Replace the
Variable-speed pump.
2. Low oil level at some gear position
Possible cause: (1) The gear valve is stuck; Troubleshooting: (1) Clean the valve core and
replace it if necessary;
(2) Internal leakage of gear (2) Replace the gear clutch;
clutch;
(3) Seal damage; (3) Replace the seal.
3. Engagement failure
Possible cause: (1) Insufficient oil in the Troubleshooting: (1) Add the oil;
gearbox;
(2) Great internal leakage of (2) Replace the oil pump;
oil pump, the efficiency is
low;
(3) The gear solenoid valve (3) Tighten or replace the
wire is loosened or damaged; harness.
4. Overheating of torque converter and gearbox
Possible cause: (1) The oil radiator is blocked Troubleshooting: (1) Eliminate the blockage or
or damaged; replace the oil radiator;
(2) The oil level of gearbox is (2) Add oil to the gearbox to
too low; the specified level;
(3) Drive at high/low gear for (3) Change the driving
too long time; method, such as drive at
different gear positions;
(4) Fault of torque converter (4) Replace the torque
safety valve; converter safety valve;
(5) Oil deterioration (5) Change the
hydrodynamic drive oil;
(6) Clutch slip (6) Check and repair the
clutch.
4-41
5. Disordered gears
Possible cause: (1) The signal of electrically Troubleshooting: (1) check the gear signal
control handle is wrong; according to table 4-2;
(2) Open circuit of solenoid (2) Check or replace the
valve or the valve is burnt; solenoid valve;
(3) The gear valve core of (3) Remove, check and clean
control valve is stuck; the gear valve;
(4) Sintering of the gear (4) Remove, check and
clutch; replace the clutch.
442 Common faults of drive axle

1. Abnormal sound of balance box, high noise
Possible cause: (1) Improper tension of roller Troubleshooting: (1) Adjust the roller chain
chain; tension;
(2) Roller chain fault; (2) Replace the roller chain.
2. The drive axle temperature is too high
Possible cause: (1) Insufficient drive axle oil Troubleshooting: (1) Fill or change the drive
or oil deterioration axle oil;
(2) Too small main drive (2) Adjust the main drive
clearance; clearance.
3. Abnormal sound of drive axle
Possible cause: (1) Excessive main drive Troubleshooting: (1) Adjust the main drive
clearance; clearance.
4-42
Maintenance Manual of G9190 Grader
Contents
5 Brake system .......................................................................................................................... 5-1
51 Service Parking System ........................................................................................................ 5-1
511 Structure and working principle .................................................................................... 5-1
512 Technical data of elements ............................................................................................ 5-3
513 Assembly and disassembly of one-way braking valve.................................................. 5-9
514 Assembly and disassembly of accumulator ................................................................ 5-10
515 Assembly and disassembly of prefill .......................................................................... 5-13
516 Replace the brake shoe ................................................................................................ 5-15
52 Parking brake...................................................................................................................... 5-19
521 Principle of parking bake ............................................................................................ 5-19
522 Assembly and disassembly of parking brake handle .................................................. 5-20
53 Troubleshooting of braking system .................................................................................... 5-22
531 Trouble of service brake ............................................................................................. 5-22
532 Common troubles with parking brake ......................................................................... 5-24
I
5 Brake system
Braking system of grader is composed of service braking system and parking braking
system. The service brake is used to reduce or stop a running grader while the parking brake is used
to park a stopped grader on various road conditions (including parking on a slope).
51 Service Parking System

As a hydraulic power braking system, the G9190
grader service brake is a drum brake, featuring of
steady braking, safe and reliable, simple
structure and easy maintenance (dual circuit
braking system is optional for it is of high
reliability that while one circuit fails the other
one still works).
511 Structure and working principle

A gear cylinder supplies the service braking
system with oil. The oil cylindered out comes
into an accumulator via a prefill. The oil in the
accumulator or from the valve comes into the
cylinder of brake on the wheel in 2 ways;
meanwhile, the brake light is activated as its
switched is pressed down. The braking valve
cuts off oil when the brake pedal is released and
the cylinder and oil tank are connected at the
same time, then oil returns to the cylinder and
the light goes off.
The prefill enables the cylinder to supply oil to
accumulator with priority at any time. Whenever
5-1
the engine runs the 2 accumulators are full of oil
and the braking system is ready to work.
The valve works on the 4 rear wheel brakes with
the help from hydraulic system. Braking pressure
is determined by pressure on the valve.
Fig. 5-1 Service braking system

1 Braking cylinder 2 Filter 3 Hydraulic oil tank
4 Joint 5 Prefill 6 Oil return block
7 Braking valve 8 Accumulator 9 Pressure switch
10 Brake coupling 11 RH brake 12 LH brake
5-2
512 Technical data of elements

Prefill
It keeps proper pressure for the 2 accumulators.
In case the pressure of the accumulator is lower
than 12.4MPa, the valve charges the accumulator
till the pressure rises to 18 MPa.
1 2 3 4 5
Fig. 5-2 Prefill
1 Mouth O 2 Mouth T
3 Mouth A 4 Mouth P
5 Warning switch for low pressure
Prefill module can be replaced by dual circuit
braking system.
1 2 3 4 5 6 .
Fig. 5-3 Prefill
1 Warning switch for low pressure
2 Mouth A1
3 Mouth P 4 Mouth A2
5 Mouth O 6 Mouth T
5-3
Braking valve
The valve is mainly composed of valve body,
upper channel, inlet mouth and moving block.
When it is required to activate braking, press
down the block and the channel will be
unblocked the inlet mouth with the outlet mouth.
When it is required to inactivate braking, just
release the block to cut off the inlet mouth from
the outlet mouth.
1 2 3 4
Fig. 5-4 Braking valve
1 Mouth A1 2 Mouth A2
3 Oil inlet mouth P
4 Oil outlet mouth T
Braking valve module can be replaced by dual
circuit braking system.
1 2 3 4 5 6
Fig. 5-5 Serially connected pedal valve
1 Mouth T1 2 Mouth T2
3 Mouth A1 4 Mouth A2
5 Mouth P1 6 Mouth P2
5-4
Capsule accumulator
It is used to store pressure oil for braking. It stores
pressed liquid and a capsule with pre-set pressure in a
sealed case and absorbs or releases the liquid for
braking. When the braking cylinder is working, it
stores energy by delivering pressure oil into the
accumulator via the prefill. At this point, air in the

1 capsule is compressed, so the liquid pressure is same
Fig. 5-6
1 Accumulator with the pressure in the capsule, storing energy. Only
nitrogen is allowed to be charged into the capsule.
The accumulator is stored with enough pressure oil.
In case of any system trouble, the pressure oil can
carry out braking for 6 times.
In case the accumulator is lower than 11.5MPa, the
warning switch for low pressure will power on the
indicator on the cab instrument panel. At the point,
you have to stop to check the trouble.
1
Fig. 5-7
1 Low pressure indicator
5-5
How to charge the accumulator?
1. Stop the vehicle and operate the service

Charge with Nitrogen
brake for several times to release high
pressure oil in the accumulator as much as
possible, then slowly release the air plug on
the oil outlet at the bottom of the
accumulator to drain left pressure in the
accumulator.
2. Remove protection cap of air prefill from the
top of the accumulator.
3. Connect the end of charging facility with
pressure meter with prefill on the top of the
accumulator and connect the other end with
nitrogen tank.
4. Switch on the nitrogen tank. Whenever the
pressure meter of the charging facility

Charging Releasing indicates the pressure is stable, slowly
switch on the charging facility to charge the
accumulator with nitrogen.

Fig. 5-8 Principles of accumulator
5. The pressure may be reached instantly and
the tank shall be switched off in such case.
Check the indicator if the pressure reaches
the required value; if no, charge again; if the
pressure is high, release some nitrogen via
the air plug to proper value.
6. As soon as the pressure reaches the required
value, switch off the tank and then the
charging facility.
5-6
7. Take off the charging facility.
8. If the accumulator leaks, (it can be checked
by applying oil on the head. In case of any
bubble, it indicates the accumulator leaks),
gently knock the prefill inside the
accumulator with a hammer or a screw
driver to let it down forward and return
quickly to let the sealing face contact
completely.
9. Install the protection cap.
Brake assembly
It is made up by brake and drum.
Press down the brake pedal and the pressure oil from
the accumulator or from the prefill comes into wheel
brake and brake cylinder in two ways. The cylinder
pushes the shoe to expand forward to rub with inside
wall of the drum to exert braking.
1 2
Fig. 5-9
1 Brake
2 Drum
5-7
The brake is mainly made up by base plate, wheel
cylinder, shoe assembly and other accessories.
The brake adopts a kind of wheel cylinder that can
adjust clearance smartly. When the frication lining is
worn, the cylinder can adjust clearance between the
frication lining and the drum smartly.
1 2 3 4
Fig. 5-10 Brake assembly
1 Wheel cylinder
2 Shoe assembly
3 Base plate
4 Back spring
Release air in braking system
Air in the hydraulic system shall be released in
such cases: hydraulic oil is changed; pipe joints
are loose or after repair.
The job shall be done by two persons. All
locations on the wheel brakes are involved.
Please follow below steps to operate:
1. Remove the rubber cap from release plug;
2. Connect one end of the hose with the release
plug and put the other end into a clean
container;
1 2 3. Screw off the release bolt for half round and
Fig. 5-11
press down the brake pedal. Screw on the
1 Container 2 Hose
bolt and release the pedal as soon as oil
comes out from the release hole.
Caution:
It takes just a second for the oil to come
out from the hole; therefore you shall be a
skillful operator.
4. In addition, follow the same steps for other
brakes.
5-8
513 Assembly and disassembly of

one-way braking valve
Disassemble the one-way braking valve
1. Press down braking pedal for several times
to clear the braking system.
2. Remove oil hose from mouth A, T and P.
Caution:
During the disassembly process, do not remove
all connecting nuts from the mouths but loose

1 2 3 4
Fig. 5-12 them a little till oil comes out; otherwise oil
1 Mouth T
may spill out.
2 Mouth P
3 Straight joint During the disassembly process of hydraulic
4 Mouth A
pipes, protect all pipes and mouths against
dust or other foreign matters.
All the pipes shall be marked for easy
identification.
3. Remove the straight joints of the 4 mouths.
4. Remove the 3 connecting bolts of braking
valve and cab.
5. Take out the braking valve from the cab.
1
Fig. 5-13
1 Bolt
5-9
Assembly of one-way braking valve
1. Install the 3 connecting bolts of braking valve
and cab.
1
Fig. 5-14
1 Bolt
2. Install the straight joints of the 4 mouths.
Tightening torque: 58±3N.m
3. Connect oil hose with mouth T, P and A.
Tightening torque:45±4.5N.m
1 2 3 4
Fig. 5-15
1 Mouth T 2 Mouth P
3 Straight joint 4 Mouth A

accumulator
Disassembly of accumulator
1. Remove the 6 bolts connecting the outside
wall with the frame.
1 2
Fig. 5-16
1 Outside wall
2 Bolt
5-10
2. Press down the brake pedal for several times
to clear the braking system; remove the oil
hose at the bottom of the accumulator.
Caution:
During the disassembly process, do not remove
all connecting nuts from the mouths but loose
them a little till oil comes out; otherwise oil

1 2
Fig. 5-17 may spill out.
1 Accumulator
2 Oil hose During the disassembly process, protect all
pipes and mouths against dust or other foreign
matters.
3. Remove the U-shape bolt fixing the
accumulator. Remove bolts, gasket, nuts and
washer from the U-shape bolt to take out the
accumulator and remove the straight joint.
Caution:
The accumulator is pressed even it is removed
from the machine. This is called pre-charged

1 2 3
Fig. 5-18 pressure. Do careful when handling with the
1 U-shape bolt 2 Gasket
3 Accumulator accumulator.
5-11
Assembly of the accumulator
1. Fix the accumulator to the bracket with
U-shape bolt, gasket, nuts and washer.
1 2 3
Fig. 5-19
1 U-shape bolt 2 Gasket
3 Accumulator
2. Install the straight joint and connect the oil
hose.
Straight joint tightening torque:
310±31N.m
Oil hose tightening torque:
70±7N.m
1 2
Fig. 5-20
1 Accumulator
2 Oil hose
3. Connect the outside wall with the frame
1 2
Fig. 5-21
1 Outside wall
2 Bolt
5-12

prefill
Disassembly of prefill
1. Remove bolts connecting the outside wall
with the frame.
1 2
Fig. 5-22
1 Outside wall
2 Bolt
2. Remove oil hose connecting mouth O with
oil tank;
3. Remove oil hose connecting mouth P with
high pressure filter oil outlet;
4. Remove tee fitting from mouth A;
5. Remove tee fitting from mouth T;
1 2 3
Fig. 5-23
1 Oil hose from mouth O to oil tank
2 Mouth P
3 Tee fitting on mouth T
4 Tee fitting on mouth A
5-13
6. Remove the fixing bolts of the outside wall
to take down the prefill;
1
Fig. 5-24
1 Bolt
Assembly of prefill
1. Install the outside fixing bolts of the prefill;
1
Fig. 5-25
1 Bolt
2. Connect the tee fitting with mouth A and
mouth T.
3. Connect mouth P and high pressure filter
with an oil inlet hose.
Tightening torque:70±7N.m
4. Connect mouth O and oil tank with an oil
hose.
1 2 3
Tightening torque:110±10N.m
Fig. 5-26
1 Oil hose from mouth O to oil tank
2 Tee fitting on mouth T
3 Tee fitting on mouth A
5-14
5. Install the 6 bolts to connect the outside wall
with the frame.
1 2
Fig. 5-27
1 Outside wall 2 Bolt
516 Replace the brake shoe

1. Remove the rear tires, Refer to 7-18.
1
Fig. 5-28
1 Tire
2. Remove the brake drum.
1
Fig. 5-29
1 Brake drum
5-15
3. Remove the end cover.
1
Fig. 5-30
1 End cover
4. Remove the spline hub.
1
Fig. 5-31
1 Spline hub
5. Remove the back spring.
Caution:
Be gentle when removing the spring and
take necessary action to protect it.
1
Fig. 5-32
1 Back spring
5-16
6. Replace the brake shoe.
1
Fig. 5-33
1 Brake shoe
7. Use a new brake shoe and then install the
back spring.
Caution:
All target brake linings shall match well
with the brake drum so as to ensure
required contact face; besides, brake

1
lining on the opposite side shall also be
Fig. 5-34
1 Back spring replaced to ensure equal braking.
8. Install the spline hub.
1
Fig. 5-35
1 Spline hub
5-17
9. Install the end cover.
1
Fig. 5-36
1 End cover
10. Install the brake drum.
1
Fig. 5-37
1 Brake shoe
11. Install the tire.
Tightening torque: 700～800N.m
12. Recover the machine.
1
Fig. 5-38
1 Tire
5-18
52 Parking brake
521 Principle of parking bake
It is used to stop a stopped vehicle from sliding
by blocking the output shaft of transmission. The
parking braking system is mainly composed of
brake handle, parking brake, orifice plate, etc.
The manual brake operation system is composed
of manual brake, handle and brake cable. When
the driver pull up the handle, the rod swings,
enabling the cam on the head of the rod to rotate,
so as to expand the brake shoes (frication disc) to
1 2 3
Fig. 5-39 Illustration of parking brake hold down upon the inner ring of the brake drum
1 Release position of parking brake rotating along with the transmission. In this way,
2 Parking brake position
the stopped vehicle is prohibited from sliding.
3 Parking brake assembly
When the parking brake is activated, the
indicator flashes.
The manual braking system has few troubles;
however, it may also troubled in case of proper
maintenance, such as sliding braking, worn
frication disc, cracked brake drum, failure in
traveling after the grader is released from
braking. The sliding braking is mainly caused by
seriously worn frication disc. Early worn of
frication disc is caused by oil on the disc or the
disc is expanded due to moisture. If the grade
1 fails in traveling after if is released from braking,
Fig. 5-40
1 Manual brake indicator it may caused by expanded disc; therefore, the
disc shall be kept clean and dry.
5-19

parking brake handle
Disassembly and assembly of parking brake
handle
1. Remove the screws fixing the handle beside
the driver’s seat.
1 2
Fig. 5-41
1 Screw
2 Parking brake handle
2. Screw out the end of handle cable and screw
off the adjusting nut of brake assembly and
take down the assembly from the bracket.
3. Remove the pin shaft and split pin with a
pliers.
4. Take out the handle from the cab.
1 2
Fig. 5-42
1 Adjusting nut
2 Pin shaft, split pin
5-20
Assembly of parking brake handle
1. Install the handle into the cab, place the
handle to its lower limit (non-braking
position) and then connect the cable with the
hand brake.
1 2
Fig. 5-43
1 Screw
2 Lower limit of handle
2. Connect the cable and hand brake with the
pin shaft and split pin and fix the cable onto
the bracket.
Caution:
The cable shall be adjusted to critically
tensioned but unable to brake. Tighten the
nuts on the back of the cable to ensure its
deflection is less than 3mm against force of
30N; then pull the handle to the middle

1 2
position and then back to the original
Fig. 5-44
1 Adjusting nut position; repeat this for 3 times; then
2 Pin shaft, split pin
re-tighten the nuts on the back of the cable to
ensure its deflection is less than 3mm against
force of 30N.
5-21
53 Troubleshooting of braking system

Common troubles of full hydraulic braking system are: powerless foot braking; parking
brake can not be released; powerless parking brake; accumulator charging failure; long-time
accumulator charging; no inching braking’ low pressure warning light is on; braking light is not
on, etc.
531 Trouble of service brake

Table 5-1
1 Release the air. Use the nozzle on the
1 Air exists in the
rear tire to release the air.
brake pipeline;
2 Examine the braking valve. Check if
2 Brake valve
the Max. braking pressure at the
troubled;
outlet of the valve is the required
3 Leakage in the pressure; otherwise, adjust the valve
brake pipeline; or replace it;
4 Prefill failure; 3 Examine if the pipeline and joints
Foot braking 5 Accumulator leak; if the joint is loose, tighten it; if
1 damaged; the sealing ring is damaged, replace
powerless
6 Frication disc of it;
wheel brake is worn 4 Replace the prefill;
to the limit; 5 Examine the accumulator;
7 Brake cylinder too 6 Replace the frication disc of wheel
old or does not brake;
work at all;
7 Examine the cylinder pressure and
8 There is oil on the flow;
brake shoe;
8 Wash and clean the brake shoe;
1 Pressure in the
High charging capsule of the
frequency of 1 Check the pressure
2 accumulator is too
brake liquid low; 2 Replace the failed prefill
prefill
2 Prefill failure
1 No oil in the tank or
oil level is too low;
2 The cylinder is too 1 Check the oil level;
Accumulator old or does not
liquid 2 Check the cylinder pressure or flow;
3 work at all;
charging 3 Release the air;
failure 3 Air exists in
accumulator oil 4 Replace the failed prefill;
tank;
4 Prefill failure;
5-22
1 The cylinder is too

old to convey all
It takes too flow or pressure or 1 Check the cylinder pressure or flow;
long time to does not work at all; 2 Replace the failed prefill;
4
charge the 2 Prefill failure; 3 Disassemble the capsule to check it
accumulator 3 The capsule is or replace it;
broken and nitrogen
comes out from it;
1 The light is broken;
2 The system is
5
Brake light is troubled during the 1 Examine the light
not on machine’s operation 2 Stop the machine to check
and oil pressure
comes down;
1 System oil pressure
is low because the
Low pressure machine is started 1 Just waits for a moment. The warning
warning light for just a second; will be disabled as long as the
6 pressure rises to required value;
of service 2 The oil pressure
brake is on comes down 2 Stop the machine to check;
because of system
trouble;
1 The brake pipeline 1 Check if the brake pipeline and joint
leaks; leak; if the joint is loose, tighten it; if
2 Parameter of the sealing ring is damaged, replace
The low nitrogen charging it;
pressure runs out of normal 2 Release the pressure completely
warns when values; charging before measuring it: press down the
7
the brake pressure is too high brake pedal for several times after the
pedal is or too low, or even engine is shut down, then measure
pressed down the accumulator the nitrogen charging pressure with
sealing failure, accumulator charging meter;
resulting in nitrogen
leakage;
Check if the pressure at the outlet of
No inching
8 Braking valve failure braking valve is normal; if it higher than
braking
required one, replace the valve;
Run-out when Try to maintain the 4 tire of same
9 Different tire pressure
braking pressure
5-23
532 Common troubles with parking brake

Table 5-2
1 Large clearance
between brake
drum and brake
shoe, leading to
1 Re-adjust as required
Parking brake small contact
1 face; 2 Wash and clean the brake shoe;
failure
2 There is oil on 3 Adjust the travel of handle pin shaft
the brake shoe;
3 Powerless brake
shoe
Parking brake Examine if the lever is bent, stuck or if the
Parking brake
handle fault spring is broken; if everything is ok,
2 lever can not
examine if the fan-shaped gear’ teeth are
be fixed
sliding.
5-24
Contents
6 Steering system......................................................................................................................................... 6-1
61 System Overview .................................................................................................................................... 6-1
611 Location of Steering System .......................................................................................................... 6-2
612 Principle Description of Steering System ....................................................................................... 6-3
62 Description and Disassembly/Installation of Main Units .................................................................... 6-6
621 Steering Pump ................................................................................................................................ 6-6
622 Priority Valve ................................................................................................................................ 6-12
623 Steering Gear ................................................................................................................................ 6-14
624 Steering Control Assembly ........................................................................................................... 6-21
625 Front Axle ..................................................................................................................................... 6-22
626 Steering Cylinder .......................................................................................................................... 6-42
63 Pressure Measuring Point and Criterion of Steering System ........................................................... 6-42
64 Bleeding Air from Steering System ..................................................................................................... 6-43
65 Steering system troubleshooting guide ............................................................................................... 6-44
Ⅰ
3
6 Steering system
61 System Overview
The steering system of this machine adopts fully hydraulic power steering, featuring the
advantages of compact structure, high flexibility, good stability, flexible and labor-saving operations,
absorption of road impact, and non-necessity of additional lubrication devices. In addition, at the
interruption of power oil source, this machine can still realize the manual steering.
Figure 6-1 Schematic Diagram of Steering System

1. Steering cylinder 2. Steering gear 3. Priority valve 4. Steering pump
①Working hydraulic system ②Brake hydraulic system.
6-1
611 Location of Steering System
6-2
Figure 6-2 Location of Steering System

1. Steering pump 2. Priority valve 3. Steering gear 4. Steering cylinder
5. Pressure measuring port
612 Principle Description of Steering System

The principle of the steering hydraulic system is shown in the figure above. The steering
system shares the high pressure left gear pump with the left multi-way valve. The gear pump sucks
the oil from the hydraulic tank and the oil flows into the port P of priority valve through gear pump
and into the steering gear through port CF of priority valve. When the steering wheel is rotating, the
steering gear conveys the pressure oil into steering cylinder along the rotation direction of steering
wheel to drive the steering of the front wheels as per the required direction.
When the steering gear is at neutral position
If the engine is stopped, the oil pump will not output oil and the control spring of the priority
valve will move rightward the valve core to connect the oil line CF. After the engine is started, the
hydraulic oil flows into the priority from the hydraulic oil tank through steering pump and the
priority valve distributes the oil to the steering gear connected with port CF. A pressure drop is
generated when the oil flows through the neutral position throttling orifice of steering gear. The
pressure on two ends of steering gear neutral position throttling orifice is transmitted to two ends of
priority valve core so that the hydraulic force generated is balanced with the spring force and
hydraulic force to position the valve core at a balanced position. As the hydraulic resistance of the
steering gear neutral position throttling orifice is high, it only requires a very small flow to generate
the pressure difference enough to drive the leftward movement of priority valve core. The valve
core is driven leftward further to increase the opening of port EF and reduce the opening of port CF.
in such case, the oil flow through the oil line CF is really low and a majority of oil converges to the
working system through port EF. When the working system is not working, the system is unloaded
at the neutral position in the multi-way valve.
6-3
Steering gear
Priority valve
Main safety
valve
Filter
Steering
pump
Oil tank
Figure 6-3 Oil Line with Steering Gear at Neutral Position

During steering
A relative angular displacement is generated between the valve core and valve sleeve of the
steering gear. When the angular displacement reaches certain value, the neutral position throttling
orifice is completely closed. A pressure drop is generated when the oil flows through the variable
throttling orifice of the steering gear (This pressure drop is relatively smaller than that at the neutral
position throttling orifice of steering gear). The pressure on two sides of the variable throttling
orifice of the steering gear is transmitted to two sides of the priority valve core so that the valve
core is driven to seed for new balance position. If the rotation speed of the steering wheel is
increased, at the instant of speed change, the flow rate through the steering gear is less than the
product from the rotation speed of steering wheel and the displacement of steering gear and the
rotation speed of the valve sleeve driven by metering device is less than the speed of valve core
driven by the steering wheel so that the angular displacement of the valve core with respect to the
valve sleeve is increased and the opening extent of the variable throttling orifice is increased. In
such case, only the higher flow can generate the same pressure difference before the change of
rotation speed on two sides of the variable throttling orifice to drive the leftward movement of the
6-4
priority valve core. Therefore, the opening extent of the valve port within the priority valve that is
leading to the oil line CF is increased along with the increased rotation speed of the steering wheel.
Finally, the oil supply amount from the priority valve to the steering gear equals to the product from
the rotation speed of the steering wheel and the displacement of steering gear.
Steering gear
Priority valve
Main safety
Filter valve
Oil tank
Figure 6-4 Oil Line during Steering
When the steering load exceeds rated value or the steering cylinder reaches end of travel
When the steering cylinder reaches the end of travel, the oil can’t flow to the steering cylinder
if the steering wheel is rotated further. In such case, the load pressure rises rapidly and the pressure
difference between two ends of the variable throttling orifice is reduced rapidly. When the steering
oil line pressure exceeds the regulated value of the steering safety valve, this valve opens. A
pressure drop is generated when the pressure oil flows through the throttling orifice. This pressure
drop is transmitted to two ends of the priority valve core to drive the leftward movement of the
valve core so that the valve port to the oil line CF is turned down and the valve port to the oil line
EF is turned up to reduce the pressure of the steering oil line.
During steering with engine stopped
6-5
The metering device is functioned as oil pump to output pressure oil and drive the piston of
steering cylinder. The oil outputted from the return chamber of cylinder returns to the upstream of
variable throttling orifice through the check valve within steering gear.
The steering gear fitted on this machine is a dynamic signal load-sensing no-response steering gear,
which features as below:
1. Good pressure compensation for change of steering load.
2. Mutually independent steering circuit and working circuit.
3. Preferential guarantee of main flow for steering circuit.
4. Energy-saving (as only a really small amount of oil flows through steering gear when the
steering gear is at neutral position) and reliable steering (as the pressure and flow are
preferentially guaranteed for the steering circuit).
5. Capability of flow amplification, as the neutral position pressure characteristic is
exempted from the influence of the displacement.
6. In addition, compared with static signal, the dynamic signal improves the start
performance under cold weather and promotes the reliability and stability for the best
system performances.
62 Description and Disassembly/Installation of Main Units
621 Steering Pump

The steering pump is a duplex pump installed on the transmission. Driven by the engine
through the transfer case gears on the transmission, it supplies pressure oil source to the entire
steering system and brake system.
6-6
1 2 Technical Specification
Nominal displacement 32/16ml/r
Rated pressure
25MPa for steering pump
20MPa for brake pump
Maximum pressure
31.5MPa for steering pump
25MPa for brake pump
3 4 5
Figure 6-5 Steering Pump
1. Brake pump oil outlet port 2. Steering pump oil outlet port 3. Oil suction port
4. Brake pump 5. Steering pump
Malfunction diagnosis of steering pump
Table 6-1
No. Malfunction Symptom Malfunction cause Troubleshooting
Damage of oil seal Measure pressure and
Reduced hydraulic oil and increased
1 replace oil seal or working
transmission oil
pump
Damage of oil seal Measure pressure and
Increased hydraulic oil and reduced
2 replace oil seal or working
transmission oil
pump
Oil leakage at junction surface of pump Damage of O-ring or Replace O-ring or tighten
3
body looseness of bolts bolts
Cracking of pump body Measure pressure and
4 Oil leakage of pump body
replace steering pump
Excessive wear of spline Replace spline shaft or
shaft steering pump
Excessive wear of side plate Replace side plate or
steering pump
5 Noise of steering pump Out-of-tolerance of spline Replace spline shaft or
shaft, interfering with the steering pump
shaft
Damage of bearing Replace bearing or steering
pump
Insufficient flow of steering pump, Excessive wear of gear or Replace corresponding part
6
leading to slow movement of cylinder side plate or steering pump
6-7
Disassembly of steering pump
Caution
1. Before the disassembly or installation of the steering pump, please park the grader at
a correct maintenance position (Refer to page 8 of Safety and Environment).
2. During the disassembly of oil pipes, instead of screwing off all bolts hastily, slightly
loosen the bolts till the oil overflows, in order to prevent the splashing of oil due to
incomplete unloading of oil.
3. During the disassembly of hydraulic system, it’s necessary to take necessary
protection measures for all pipelines and oil ports to guard against the ingress of foreign
material (such as dust) into the hydraulic system.
4. During the disassembly of hydraulic system, use an appropriate container to load the
residual oil overflowed during the disassembly of pipelines. At completion of the
repair, pour the hydraulic oil collected into the special hydraulic oil recycling tank.
5. At the time of assembly, please make sure to replace with new seals and strictly
tighten to the torque specified in the relevant standard in page 0~7 of this
maintenance manual.
1. Connect one end of one hose to the oil
drainage valve on the bottom of hydraulic
oil tank, connect another end to a clean
container, and open oil drainage valve to
drain the hydraulic oil. (Opening the oil
filler cap can speed up the drainage of
1 2 hydraulic oil).
Figure 6-6 Caution

1. Oil drainage valve
2. Hose Cover the oil drained to prevent
contamination.
6-8
2. Disassemble the fastening bolts of the

cover plate, as shown in the figure,
and take out the bolts and cover plate.
Cover plate
1 2
Figure 6-7
1. Cover plate
2. Cover plate
3. Disassemble the fastening screws between
steering pump oil suction pipe and steering
pump, take out the screws and split flange,
and then take out the oil suction pipe and
O-ring
Figure 6-8
1. Steering pump oil suction pipe
4. Disconnect the steering pump oil outlet hose
and brake pump oil outlet hose.
1 2
Figure 6-9
1. Steering pump oil outlet hose
2. Brake pump oil outlet hose
6-9
5. Disassemble the fastening bolts of steering
pump and transmission-torque converter
assembly power takeoff port and take out the
bolts and washers.
6. Hoist the steering pump with hoisting slings
and use a copper bar to lightly knock the
1 gear pump towards the outer side to take out

Figure 6-10
1. Bolt the steering pump and sealing gasket.
Steering Pump
7. Disassemble the fastening straight
connectors and screws of two oil outlet ports
of the steering pump and take out the
screws, split flange, and straight connector.
Assembly of Steering Pump
1. Use screws and split flange to fasten two
straight connectors to corresponding oil
ports of the steering pump.
2. Use M12×35 nuts, washers, and sealing
gasket to install the steering pump to the end
1 face of the transmission.

Figure 6-11 Steering Pump
1. Bolt
Caution
Make sure to tighten the studs.
6-10
3. Install the O-ring to the pipe connector
O-ring slot of the steering pump oil outlet
hose and brake pump oil outlet hose and use
four M10×30 screws and split flange to
tighten to the end face of working pump oil
outlet port.
1 2
Figure 6-12
1. Steering pump oil outlet hose
4. Install O-ring to the pipe connector O-ring
slot of the steering pump oil suction pipe
and use four M10×35 screws and split
flange to tighten to the end face of steering
pump oil suction port.
1
Figure 6-13
1. Steering pump oil suction pipe
5. Use bolts to install the cover plate to
corresponding position.
Cover plate
1 2
Figure 6-14
1. Cover plate
2. Cover plate
6-11
6. Add hydraulic oil to the specified level.
Figure 6-15
1. Oil filler port
622 Priority Valve

The priority valve is a fixed difference pressure reducing unit. No matter how the load pressure
and oil pump output change, the priority valve can basically maintain unchanged the pressure
difference between two ends of variable throttling orifice within the steering gear, in order to
guarantee that the flow supplied to the steering gear always equals to the product from the rotation
speed of steering wheel and the displacement of steering gear.
The port P of priority valve is connected with the oil outlet hose of steering pump, the port CF
is connected with port P of steering gear, the port EF is connected with the port P of left multi-way
valve, and the port LS is connected with the port LS of steering gear.
6-12
LS T
P
Technical Specification
Nominal flow 150L/min
Safety valve opening pressure 140bar
Control pressure, dynamic signal internal control 8.6bar
EF CF
Figure 6-16 Oil Port Description of Priority Valve
Figure 6-17 Priority Valve
6-13
623 Steering Gear

This machine adopts dynamic signal load-sensing non-response steering gear.
The port P of steering gear is connected with port CF of priority valve, the ports L and R are
connected with steering cylinder respectively, and the oil at the port T flows to the radiator for heat
dissipation and then returns to oil tank. The port LS is connected with port LS of priority valve.
L LS R
Connection mode SAE involute spline
Displacement 320ml/r
Maximum inlet pressure 17.2MPa
Maximum continuous backpressure 2.1MPa
Maximum system temperature 93ºC
Steering moment 2.8~4.0N.m
T P
Figure 6-18 Steering Gear
The steering gear works with steering cylinder to form a position system and the displacement
of steering cylinder piston rod is in direct proportion to the angular displacement of the steering
gear valve core. The gerotor motor within the steering gear is a metering device (functioned as oil
pump during steering with engine stopped). It converts the oil volume distributed to the steering
cylinder into angular displacement of the steering gear valve sleeve so that the angular displacement
of valve sleeve with respect to the valve core determines the opening area of the oil distribution
window. The higher the rotation speed of the steering wheel is, the higher the relative angular
displacement is and the higher the opening area of the oil distribution window is. When the steering
wheel stops rotation, the relative angular displacement is zero and the oil distribution window is
closed automatically to realize feedback control. The return spring drives the valve sleeve over the
dead zone to align with the valve core.
6-14
3
Figure 6-19 Internal Oil Line of Steering Gear
1. Two-way overload valve 2. Two-way refilling valve 3. Inlet check valve
Function of steering gear internal combination valve
Inlet check valve: The check valve opens when the oil flows into the steering gear. At low
speed, the inlet check valve can prevent the jitter of steering wheel arising from the reflux of the
high pressure oil under the impact of external load.
Two-way overload valve: When the internal pressure of the steering cylinder rises under the
external impact to the pressure setting of overload valve (20MPa), the overload valve opens to drain
the oil for overload protection of the steering cylinder.
Two-way refilling valve: When the steering cylinder generates instantaneous vacuum pressure
under the external impact, the refilling valve opens immediately to refill oil to the left or right oil
chamber of the steering cylinder, in order to prevent the cavitation of cylinder. When the two-way
refilling valve opens, generally the two-way overload valve is overloaded.
Precautions for installation and repair of steering gear
1) Keep all parts clean, in order to prevent ingress of dirt into the steering gear or hydraulic
system.
2) Keep oil pipe connectors clean. Do not use Teflon tape to substitute the seal rings for
sealing purpose.
3) Ensure the correct installation of oil ports for steering gear valve blocks and steering
gear.
6-15
4) During the installation of steering gear, make sure to prevent the application of axial
force onto the input end of the steering gear.
5) Bleed the air from the load port of steering gear.
6) Do not disassemble the inside of steering gear, unless it’s absolute sure that the steering
gear is malfunctioned.
7) Do not disassemble the combination valve block at will. The pressure of the combination
valve block must be adjusted by testing unit.
8) Keep all parts clean and prevent collision during the disassembly and installation of
steering gear.
9) During the disassembly and installation of the valve core and valve sleeve pair, pay
special caution to take out and install vertically, in order to prevent the flyout of the
shifting pin.
10) Pay attention to the alignment of markings during the assembly of coupling shaft and
rotor.
11) Never forget the installation of check valve ball and shifting pin or incorrectly install the
bolt.
Disassembly of steering gear
Caution
1. Before the disassembly or installation of the steering gear, please park the grader at
2. During the disassembly of oil pipes, instead of screwing off all bolts hastily, slightly
loosen the bolts till the oil overflows, in order to prevent the splashing of oil due to
incomplete unloading of oil.
3. During the disassembly of hydraulic system, it’s necessary to take necessary
protection measures for all pipelines and oil ports to guard against the ingress of
foreign material (such as dust) into the hydraulic system.
4. During the disassembly of hydraulic system, use an appropriate container to load
the residual oil overflowed during the disassembly of pipelines. At completion of the
repair, pour the hydraulic oil collected into the special hydraulic oil recycling tank.
6-16
5. At the time of assembly, please make sure to replace with new seals and strictly
tighten to the torque specified in the relevant standard in page 0~7 of this
maintenance manual.
1. Disassemble the fastening bolts of left and
right guard plates and take out the bolts and
left and right guard plates.
1
Figure 6-20
1. Left and right guard plates
2. Disassemble the fastening bolts of upper
side plate and take out the bolts and plate.
1
Figure 6-21
1. Plate
3. Disassemble the crossbeam.
1
Figure 6-22
1. Crossbeam
6-17
4. Disconnect all hoses from the steering gear.
Caution
Mark the oil pipes appropriately, in order to
prevent confusion during assembly.
1
Figure 6-23
1. Hose
5. Disconnect the connecting bolts between
steering column bracket and cab and take
out the bolts and washers.
6. Disconnect the connecting bolts between
steering column bracket and steering gear
fixing bracket.
1 2 3 4
Figure 6-24
1. Bolt
2. Steering column bracket
3. Pin
4. Steering gear fixing bracket
7. Disconnect the fastening bolts between
steering column and steering gear, take out
the bolts and washers, and then take out the
steering gear and steering gear fixing
bracket.
8. Disassemble all connectors of steering gear.

1 2
Figure 6-25
1. Bolt
2. Connector
6-18
Assembly of steering gear 1. Install the straight connectors to
corresponding oil ports of steering gear.
2. Use four M10×25 bolts and washers to
connect the steering column with steering
gear.
1 2 3 4
Figure 6-26
1. Steering column
2. Bolt
3. Washer
4. Steering gear fixing bracket
3. Install the connecting pins between steering
column bracket and steering gear fixing
bracket.
4. Use four M10×25 bolts and washers to
install the steering column bracket to
corresponding position of the cab.
1 2 3
Figure 6-27
1. Bolt
2. Steering column bracket
3. Pin
6-19
5. Connect all connecting oil pipes of steering
gear to corresponding oil ports.
Figure 6-28
6. Install the fastening bolts of steering gear
crossbeam.
1
Figure 6-29
1. Crossbeam
7. Install the cover plate.
1 2
Figure 6-30
1. Bolt
2. Plate
6-20
8. Install the left and right guard plates.
1
Figure 6-31
624 Steering Control Assembly
Figure 6-32
1. Steering wheel 2. Steering column 3. Nut 4. Washer 5. Pressure plate
6. Protective cover 7. Steering column bracket 8. Split pin 9. Washer 10. Bolt
11. Steering gear fixing bracket 12. Pin
6-21
625 Front Axle

Differing from common axles, the front axle assembly of grader features high angle tilting and
horizontal swing functions of the front wheels in addition to the steering function. It can realize the
automatic adjustment of balance to achieve higher working accuracy of the grader and can increase
the adhesion of front wheels under special working conditions to improve adaptability of grader to
different working conditions.
The maintenance of the front wheel bearings must be fulfilled by professionals as per specified
procedure and non-professionals are prohibited for disassembly of the front wheel bearings without
consent.
Figure 6-33 Front Axle Assembly

1. Front axle 2. Washer 3. Bolt 4. Front axle (for wheel rims with inner tube) 5. Tire
6. Oil cup 7. Lock washer 8. V-shaped seal ring 9. Swing shaft 10. Bolt
11. Washer 12. Support
6-22
Figure 6-34 Front Axle

1. Left bogie 2. Left steering knuckle 3. Retainer 4. Shaft 5. Retainer ring
6. Front wheel tilting cylinder 7. Oil cup 8. Connecting rod 9. Retainer ring
10. Knuckle bearing 11. Bolt 12. Washer 13. Support 14. Hinged shaft
15. Composite bearing 16. Split pin 17. Front axle frame 18. Lock washer
19. Composite bearing 20. Hinged shaft 21. Support 22. Washer 23. Bolt 24. Screw
25. Washer 26. Screw 27. Cover plate 28. Screw 29. Washer 30. Pin
31. Right steering knuckle 32. Gasket 33. Gasket 34. Washer 35. Right bogie
36. Wheel shaft 37. V-shaped seal ring 38. Seal ring 39. Screw 40. Wheel hub cap
41. O-ring 42. Nut 43. Stop washer 44. Gasket 45. Tapered roller bearing
46. Screw 47. Screw 48. Wheel hub 49. Washer 50. Bushing
51. Nut 52. Right-handed ball joint 53. Lock nut 54. Split pin 55. Left-handed ball joint
56. Clamp 57. Nut 58. Bolt 59. Tie rod 60. Shaft 61. Pin
62. Radial spherical plain bearing 63. Retainer ring 64. Spacer
65. Front wheel steering cylinder, right 66. Bolt 67. Hinged shaft 68. Support
69. Front wheel steering cylinder, left
6-23
Disassembly of front axle
1. Park the grader at a correct place.
2. Star the engine, control the blade swing
cylinder to swing the blade to form a 90º
angle against the front frame, control the
blade lifting cylinder to lower the blade onto
the support wood blocks prepared in
advance, and then stop the engine.

1 Caution
Figure 6-35
1. Blade
Before the repair works as below, please
make sure to support the blade, or the grader
will probably roll over to cause personal
injuries.
Disassembly of tires
1. Loosen the fastening bolts of front wheels.
Start the engine and operate the blade lifting
cylinder to lower the blade, so as to tilt up
the front end of grader. Place reliable
support devices at the front protruding
position of grader, operate the blade lifting
cylinder to lift the blade so that the front end

1
Figure 6-36 of the grader is supported on the support
1. Bolt
devices, and then stop the engine.
2. Disassemble the fastening bolts of front
wheel and take out the bolts and washers.
Then, take out the tires and wheel rims.
6-24
Disassembly of wheel hubs
1. Hoist the wheel hub with lifting device,
disassemble the fastening bolts of wheel hub
cap, and take out the bolts and wheel hub
cap.
Wheel hub
1 2
Figure 6-37
1. Wheel hub cap
2. Hexagon socket bolt
2. Take out the O-ring from the wheel hub cap.
Figure 6-38 1 2
1. Wheel hub cap
2. O-ring
3. Disassemble the lock nut and then take out
the lock nut, stop washer, and the lock nut
and washer beneath the stop washer in turn.
1 2 3 4 5
Figure 6-39
1. Hub 2. Gasket
3. Lock nut 4. Stop washer
5. Lock nut
6-25
4. Use special tools to take out the wheel hub
from the wheel shaft.
Caution
During the disassembly of the wheel hub, the
tapered roller bearing on the front end of
wheel hub will probably fall off at any time.
The structure of wheel shaft is high on two

Figure 6-40 1
1. Tapered roller bearing sides and low in the middle. Do not
disassemble the wheel hub by knocking
method, in order to prevent damaging the
inner tapered roller bearing due to
non-uniform application of force.
Figure 6-41
6-26
5. Use special tools to disassemble the tapered
roller bearing and then take out the V-shaped
seal ring and seal ring.
1 2 3
Figure 6-42
1. Tapered roller bearing
2. V-shaped seal ring
3. Seal ring
Disassembly of drag link
1. Hoist the drag link with lifting device. Then,
take out the split pin from the slotted nut.
2. Screw off the slotted nut and take out the nut
and washer.
1 2 3 4
Figure 6-43
1. Split pin
2. Slotted nut
3. Gasket
4. Drag link
6-27
3. Use copper bar to knock from lower side to
take out the rotary head.
4. 4. Take out the rotary head on the other
side as per same method and then hoist out
the drag link.
Figure 6-44 1
1. Rotary head
5. Disassemble the fastening bolts of
connecting pipe clamp between drag link and
rotary head, take out the pipe clamp, and
disconnect the rotary head from drag link.
Figure 6-45
1. Pipe clamp
Disassembly of steering cylinder
1. Disconnect the connecting oil pipes from the
steering cylinder.
1
Figure 6-46
1. Hose
6-28
connecting pin at the end of steering cylinder
rodless chamber, take out the bolts, washers,
and support beneath, and use copper bar to
disassemble the connecting pin.
1
Figure 6-47
1. Bolt
3. Take out the split pin of slotted nut between
the steering cylinder piston rod end rotary
head and the bogie and screw off the slotted
nut between rotary head and bogie. Take out
the slotted nut and washer.
Figure 6-48
1. Slotted nut
4. Use copper bar to take out rotary head from
the bogie.
5. Hoist out the steering cylinder. Disassemble
the connecting bolts between rotary head and
steering cylinder piston rod and take out the
rotary head from the steering cylinder.
1
Figure 6-49
1. Bolt
6-29
Disassembly of wheel shaft
1. Disassemble the connecting bolts between
wheel shaft and bogie and take out the wheel
shaft.
Wheel shaft
1
Figure 6-50
1. Bolt
Disassembly of bogie
1. Disassemble the fastening bolts of cover
plate and take out the bolts and cover plate.
1 2
Figure 6-51
1. Bolt
2. Cover plate
2. Disassemble the hexagon socket bolts and
take out the bolts and washers.
Figure 6-52
6-30
3. Take out the pin.
4. Disassemble the lower end joint as per the
same method and hoist away from the bogie.
Bogie
1
Figure 6-53
1. Pin
Disassembly of front wheel tilting cylinder
1. Hoist the front wheel tilting cylinder with
lifting device.
2. Disconnect the connecting hose from the
front wheel tilting cylinder.
1 2
Figure 6-54
1. Rod chamber connecting hose of
front wheel tilting cylinder
2. Rodless chamber connecting hose
of front wheel tilting cylinder
3. Disassemble the fastening bolts of the
connecting pin of front wheel tilting cylinder
rodless chamber, take out the bolts and
washers, and use special tools to disassemble
the pin.
1
Figure 6-55
1. Bolt
6-31
4. Use circlip pliers to take out the fastening
circlip from the piston rod end of the front
wheel tilting cylinder, knock the piston rod
end of front wheel tilting cylinder from the
shaft, and hoist it away from tilting cylinder
with lifting device.
Front wheel tilting cylinder

1
Figure 6-56
1. Circlip
Disassembly of connecting rod
1. Use circlip pliers to disassemble the
fastening circlip between the connecting rod
and steering knuckle and knock the
connecting rod off from the shaft.
2. Disconnect the other end of connecting rod
from the steering knuckle as per same
method and hoist the connecting rod away

1
with lifting device.
Figure 6-57
Connecting rod
1. Circlip
3. Use circlip pliers to take out the fastening
circlip of the shaft and take out the shaft.
1
Figure 6-58
1. Circlip
6-32
Disassembly of steering knuckle
connecting pin between bogie and front axle
frame and take out the bolts and washers.
Use special tool to take out the pin and hoist
it away from steering knuckle with lifting
device.
Steering knuckle
1
Figure 6-59 Disassembly of front axle frame
1. Bolt
connecting pin between frame and front axle
frame and take out the bolts and washers.
2. Use special tool to take out the pin and hoist
it away from the front axle frame with lifting
device.
Figure 6-60 1
Steering knuckle
1. Bolt
Assembly of steering axle

Assembly of front axle frame
1. Hoist the front axle frame with lifting device,
align the connectors of front axle frame and
frame, and install the fastening pin.
Front axle frame
2. Install the fastening bolts and washers of pin.
1
Figure 6-61
1. Bolt
6-33
Assembly of steering knuckle
1. Hoist the steering knuckle with lifting
device, align the connectors of steering
knuckle and front axle frame, and install the
fastening pin.
Steering knuckle
2. Install the fastening bolts and washers of pin.
1
Figure 6-62
1. Bolt
Assembly of connecting rod
1. Install the shaft onto the steering knuckle
from one side of the steering knuckle and
install the fastening circlips on two sides.
2. Install the knuckle bearing onto the shaft and
fix with circlips.
3. Hoist the connecting rod to an appropriate
position with lifting device, connect the
1 2
connecting rod to the designated position on
Figure 6-63 the shaft, and install the fastening circlip.
1. Shaft
Connecting rod
2. Circlip
Assembly of front wheel tilting cylinder
1. Hoist the cylinder to an appropriate position
with the lifting device.

Front wheel tilting cylinder
2. Install the fastening pin on the rodless
chamber end of the tilting cylinder and fix
with bolts and washers.

Figure 6-64 1
1. Bolt
6-34
3. Install the circlip on the piston rod end of the
tilting cylinder.
1
Figure 6-65
1. Circlip
4. Install the connecting hoses of rod and
rodless chambers.
1 2
Figure 6-66
1. Rod chamber connecting hose of
front wheel tilting cylinder
2. Rodless chamber connecting hose
of front wheel tilting cylinder Assembly of Bogie
1. Hoist the bogie with lifting device, align the
connectors of bogie and steering knuckle,
and install the fastening pin.

Bogie
1
Figure 6-67
1. Pin
6-35
2. Install the hexagon socket bolts.
1 2
Figure 6-68
2. Washer
3. Install the fastening bolts of cover plate.
1 2
Figure 6-69
1. Bolt
2. Cover plate Assembly of wheel shaft
1. Hoist the wheel shaft to an appropriate
position with lifting device and then install
the connecting bolts between wheel shaft and
bogie.
Wheel shaft
1
Figure 6-70
1. Bolt
6-36
Assembly of steering cylinder
1. Use bolts to connect the steering cylinder
with rotary head.
2. Use lifting device to hoist the steering
cylinder to an appropriate position and then
connect the rotary head to the bogie.
1 2
Figure 6-71
1. Rotary head
2. Bolt
3. Screw on the slotted nut of rotary head and
fix with split pin.
1
Figure 6-72
1. Slotted nut
4. Install the fastening bolt of connecting pin at
the rodless chamber end of steering cylinder.
1
Figure 6-73
1. Bolt
6-37
5. Connect the connecting hoses on the steering
cylinder
1
Figure 6-74
1. Hose
Assembly of drag link
1. Use drag ling to connect the drag link with
the rotary head.
Figure 6-75
1. Pipe clamp
2. Use lifting device to hoist the drag link to an
appropriate position. Then, install the rotary
head onto the bogie.
1
Figure 6-76
1. Drag link
6-38
3. Screw on the slotted nut of rotary head and
fix with split pin.
1 2 3
Figure 6-77
1. Split pin
2. Slotted nut
3. Gasket
Assembly of wheel hub
1. Install the tapered roller bearing and seal ring
onto the wheel hub.
Caution
During the replacement of bearing, cool down
the bearing to ease the assembly.
1 2 3
Figure 6-78
2. V-shaped seal ring
3. Seal ring
6-39
2. Use lifting device to hoist the wheel hub to
an appropriate position and then install wheel
hub to the wheel shaft.
Wheel hub
3. Install the outer tapered roller bearing of the
wheel hub.
1
Figure 6-79
4. Install the gasket, lock nut, stop washer, and
lock nut in turn.
1 2 3 4 5
Figure 6-80
1. Hub
2. Gasket
3. Lock nut
4. Stop washer
5. Lock nut
5. Install the O-ring onto the wheel hub cap and
install the wheel hub cap onto the wheel hub.
1 2
Figure 6-81
1. Wheel hub cap
2. O-ring
6-40
6. Install the fastening bolts of wheel hub cap.
1 2
Figure 6-82
1. Wheel hub cap
Assembly of tires
1. Use bolts and washers to fix the tire onto the
wheel hub.
Tires
1
Figure 6-83
1. Bolt
6-41
626 Steering Cylinder

Single-rod double-acting piston cylinder
Cylinder bore 63mm
Rod diameter 45mm
Stroke 340 mm
Rated pressure 21MPa
Figure 6-84 Steering Cylinder
63 Pressure Measuring Point and Criterion of Steering System

Pressure measuring tool
Pressure gauge with measuring range at 0~25MPa
Pressure measuring point
The pressure measuring point (with M16×2 thread) is located on the rapid pressure measuring
connector of the steering cylinder.
Pressure measuring point of steering system
Figure 6-85 Pressure Measuring Point of Steering System
Pressure measuring method
1. Connect the pressure gauge to the pressure measuring connector of the steering cylinder.
2. Start the engine and rotate the steering wheel to the limit position for building of pressure.
3. Read the value of the pressure gauge.
Pressure measurement criterion
The regulated pressure of the steering system is 140±3.5 Bar.
6-42
64 Bleeding Air from Steering System

At the replacement of steering pump, steering gear, priority valve, steering cylinder, and
hydraulic oil pipe in the steering circuit, make sure to bleed the air from the steering system as per
the following method:
1. Lowe the mouldboard, elevate the front frame till the front wheels are off the ground, and
then open the filler cap on the hydraulic oil tank.
2. Start the engine. Idle run the engine and extend and retract the cylinder of steering system
from the bottom of the travel repeatedly for 2~3 times (approximate 50~60mm).
3. Run the engine at high speed and extend and retract the cylinder of steering system in full
travel for 3~5 times to bleed the air from the pipeline.
4. After bleeding the air, set the machine and working devices to standard positions (Park the
machine with wheels in linear direction, adjust the front and rear frames in one same line,
place the mouldboard onto the ground with a 90ºangle against the frame, and lower the
ripper near the ground) and then check the oil amount and tighten the filler cap.
5. Stop the engine and check for presence of leakage in pipes and hoses.
6-43
65 Steering system troubleshooting guide

Table 6-2
1. Damage of check valve at steering gear inlet, leading to
blockage of steering gear inlet.
2. Blockage and return failure of steering check valve steel ball

due to breakdown of steering gear
3. Blockage or oil leakage of damping hole due to kinked or

over-long priority valve LS pipe.
4. Damage of steering column and over-high rotating torque.
5. Interference at joint between steering column and steering

gear, generating axial or radial force onto the steering gear
valve core after assembly.
6. Under-low pressure of priority valve relief valve, stagnation

1. Heavy steering of main valve core, or blockage of damping hole.
7. Under-low pressure of safety valve in steering gear

combination valve block.
8. Blockage of oil return filter.
9. Serious wear or damage of pump, leading to low volume

efficiency and failure to meet system pressure and flow needs.
10. Blockage in steering system pipeline, leading to serious

throttling and heavy steering.
11. Stagnation of priority valve main valve core by foreign

material or reduced elasticity of main spring.
12. Interference of front axle steering mechanism.
1. Check for presence of cavitation.
2. Ingress of air in oil suction pipe and at joint.
3. Low oil tank level.

2. S-shaped traveling of
grader 4. Loose pin or bent rod of cylinder.
5. Internal leakage of cylinder.
6. Leakage of two-way overload valve or two-way refilling

valve.
6-44
1. Check the cylinder connecting rod for presence of looseness.
2. Internal leakage of cylinder.
3. High pressure difference between two sides of tires.

3. Off-tracking of grader
4. Unilateral leakage of two-way overload valve or two-way oil
refilling valve.
5. Air content in oil.
1. Check the cylinder connecting rod for presence of looseness.

4. Synchronized 2. Internal leakage of cylinder.
movement of steering
wheels at slow rotation 3. Unilateral leakage of two-way overload valve or two-way oil
of steering wheel refilling valve.
5. Temporary non-flexible 1. High temperature difference between steering gear units and
steering at start system oil after long-term non-working.
1. Air content in system
2. Loose cylinder pin.
3. Thermal impact.
6. Inaccurate steering
4. Stagnation of priority valve main valve core.
5. Leakage of cylinder.
6. Low pump efficiency, leading to unstable pressure.
7. Creepage of steering
1. Air content in system
cylinder
8. No pressure feeling or 1. Falloff of nut between steering column and steering wheel.
no movement of
2. Falloff of coupling between steering column mandrel and
steering wheels at free
steering gear valve core.
rotation of steering
wheel 3. Under-low oil tank level.
9. No movement or slow 1. Serious leakage of two-way overload valve or two-way

movement of steering refilling valve.
wheels at easy rotation
of steering wheel 2. Serious leakage of cylinder piston.
6-45
1. Loose nuts of steering wheel.
2. Worn or damaged joint between steering column and steering

gear.

10. Idle travel of steering
wheel 4. Leakage of two-way overload valve and two-way refilling
valve.
5. Over-high worn gap or damage at joint between cylinder and

steering connecting rod.
6. Leakage of cylinder.
1. Tight or interfered joint between steering column and steering

gear.
11. Poor return or 2. Poor return due to high oil return backpressure.
follow-up rotation 3. Return failure due to ingress of high contamination particles
between valve core and valve sleeve.
4. Damage or low elasticity of steering gear spring plate.
1. Ingress of large and solid contamination particles between

stator and rotor.
12. Damage of steering 2. Serious grinding damage.
gear units.
3. Breakage of shifting pin.
4. Thermal impact (at 50ºC temperature difference).
1. Error of assembly relation. At the rework and reinstallation,

13. Vibration or align the spline tooth of coupling shaft shifting pin slot with
autogiration of steering the inner spline tooth of the rotor ring gear.
wheel 2. When the oil pumped is connected to the port R or L, the
steering gear will rotate around its axis like a motor.
14. Opposite rotation

direction between
1. Reversed connection of ports R and L.
steering wheels and
steering wheel
15. Bounce of steering

2. Damage of check valve at steering gear inlet.
wheel
6-46
Contents
7 Frame, Wheels, and Working Device ................................................................................... 7-1
71 Overview of Frame and Working Device ............................................................................. 7-1
711 Overview of Frame ....................................................................................................... 7-1
712 Overview of Working Device ....................................................................................... 7-3
72 Disassembly and Assembly of Front Mouldboard ............................................................. 7-10
721 Disassembly of Front Mouldboard ............................................................................. 7-10
722 Installation of Front Mouldboard ................................................................................ 7-12
73 Disassembly and Assembly of Frame Joint........................................................................ 7-13
731 Disassembly at Joint of Upper Frame ......................................................................... 7-13
732 Disassembly at Joint of Lower Frame......................................................................... 7-16
733 Installation at Joint of Upper Frame ........................................................................... 7-17
734 Installation at Joint of Lower Frame ........................................................................... 7-19
74 Disassembly and Assembly of Front and Rear Wheels ...................................................... 7-21
741 Disassembly of Rear Wheels ...................................................................................... 7-21
742 Installation of Rear Wheels ......................................................................................... 7-23
743 Disassembly of Front Wheels ..................................................................................... 7-24
744 Installation of Front Wheels ........................................................................................ 7-26
75 Disassembly and Assembly of Middle Working Device .................................................... 7-27
751 Disassembly of Blade.................................................................................................. 7-27
752 Installation of Blade .................................................................................................... 7-31
753 Disassembly of Middle Ripper ................................................................................... 7-32
754 Installation of Middle Ripper ...................................................................................... 7-34
755 Disassembly of Rotary Ring Gear .............................................................................. 7-35
756 Installation of Rotary Ring Gear ................................................................................. 7-41
76 Disassembly and Assembly of Rear Ripper ....................................................................... 7-45
761 Disassembly of Rear Ripper ....................................................................................... 7-45
762 Installation of Rear Ripper .......................................................................................... 7-49
I
77 Common Malfunction Causes and Troubleshooting .......................................................... 7-50
II
7 Frame, Wheels, and

Working Device
71 Overview of Frame and Working
Device
711 Overview of Frame
1 2 3
Figure 7-1 ● The frame is classified into integral frame
1 Front frame
2 Articulation pin and articulated frame. The articulated frame
3 Rear frame
is mainly composed of the front frame, rear
frame, and articulation pin.
● This machine adopts articulated frame.
● The front frame is mainly functioned to carry
the working device and cab.
● The engine, transmission and torque
converter assembly, fuel tank, hydraulic oil
7-1
tank, and drive axle are fixed at
corresponding support points of the rear
frame.
● The cab of this machine is arranged on the
front frame, with good visibility and easy
operations, and helps observe the states on
two sides of the blade during the turning,
crab walk, or corner leveling and promote the
working accuracy. The articulation pin is
functioned to connect the front and rear
frames.
Front frame
● The front frame is a two-segment boxed
structure welded together from four steel

Figure 7-2
plates, featuring good manufacturability,
integrated modular design, and easy
assembly of attachments including front and
rear rippers.
Rear frame
● The rear frame adopts frame structure welded
from boxed beams, featuring integrated
modular design and easy assembly of
attachments including rear ripper. As the

Figure 7-3
attachments are not connected with the drive
system, the impact load is only transmitted to
the rear frame, featuring high reliability.
7-2
712 Overview of Working Device

● The working device of grader adopts
modular design. No front or rear ballast is
required for the basic model. Depending on
the actual needs, the attachments such as
front blade, middle ripper, and rear ripper can
be installed easily and rapidly.
Front mouldboard
● The front mouldboard is installed in the front

of the G9190 grader for pavement, backfill,
and unloading of bulk material and handling
of road corners inaccessible by the blade.
Finishing.
1
Figure 7-4 ● When the front mouldboard is not required
1. Front mouldboard
during the working, disassemble the
mouldboard, thoroughly clean the
mouldboard and its parts, apply lubricating

grease to the machined surfaces, and
preserve in a dry indoor place or store with
moisture-proof measure.
● If it's not to be used for a long period, apply
lubricating grease onto the machined fitting
surfaces and paint other surfaces for
protection purpose.
Attachment weight: 1160kg

Caution:
During the driving, lift the mouldboard as
appropriate, instead of placing it too low.
7-3
Middle ripper
● The middle ripper is installed in the middle of
the G9190 grader for moving away large rocks and
stubs as well as destructing the road asphalt.

Caution:
Make sure to lift the middle ripper before the

1
Figure 7-5 start of machine. If the ripper is not to be used for
1. Middle ripper
a long period, disassemble the tooth holders or
unload the middle ripper.
Blade
● The blade is installed in the middle of G9190
grader for scraping soil and leveling working
surface.
● The blade part adopts single cylinder
structure to prevent the bending of blade
extraction cylinder due to redundant
positioning under the application of force.
● The optimized blade curvature enables the
materials to have good throughput capacity
1
Figure 7-6 and flow capacity, promoting the production
1. Blade efficiency.
● With small angle of oscillating cylinder, at
the change of blade cutting angle, the blade
moves more stable, featuring high flexibility.
Ground clearance of blade: 445mm
Cutting depth of blade: 787mm
Tilting angle of blade: 47ºforward
7-4
5ºbackward
Caution:
During the driving, lift the blade as appropriate,

instead of placing it too low.
● Lifting of blade
The left and right blade lifting cylinders are
acting on the ball joints on the left and right sides
of the connecting frame respectively. Through
the extension and retraction of the cylinder
pistons, the left and right sides of the connecting
frame are lifted or lowered respectively to adjust
the left and right heights of the blade so that the
leveled surface meets the required leveling or
gradient requirement.
1 2
Figure 7-7
1. Right lifting cylinder
2. Left lifting cylinder
● Swing of blade
The horizontal deflection angle refers to the
angle formed by the blade body and grader
longitudinal axis within the horizontal plane.
The rotary frame can, along with the blade body,
realize the rotation of any angle within 360º. The
direction of blade can form certain deflection
1 angle against the traveling direction of the grader

Figure 7-8
so that the soil scraped by the blade during
1. Swing cylinder
working can timely be moved to two sides of the
grader, in order to guarantee the continuous
7-5
working performance of grader.
● Lateral extension of blade
The lateral extension amount of the blade refers
to the amount of the blade extended leftward or
rightward.
Under the action of the blade extraction cylinder,
the blade body can extend towards two sides
along its length direction, in order to increase the
1 working width of the grader.

Figure 7-9
1. Blade extraction cylinder
● Lateral sway of blade
If the required width can’t be met after the blade
is extended to the limit position, laterally sway
the connecting frame, rotary frame, and blade
together towards the left or right side of the
grader to increase the working scope.
1 2
Figure 7-10
1. Locking cylinder
2. Oscillating cylinder
7-6
● Side turning of blade

The inclination angle refers to the inclination
angle within the vertical plane when the blade is
vertically erected.
The side turning of the blade is intended to
realize the scraping of the side slope. Under the
joint action of the left and right lifting cylinders
and blade oscillating cylinder, the blade can be
1
vertically erected on the left or right side of the
Figure 7-11
1. Tilting angle cylinder grader, with certain angle against the ground.
The left/right maximum side turning angle of the
blade is up to 90º.
● Adjustment of blade angle
The blade angle refers to angle of blade plane
against the ground.
Under the action of blade tilting angle cylinder,
the blade body can tilt forward for up to 47ºand
backward by up to 5º, in order to achieve
different cutting angle of the blade and adapt to
needs under different working conditions.
7-7
Rear ripper
● The ripper is installed on the rear of the
G9190 grader for moving away large rocks
and stubs as well as destructing the road
asphalt to help the transfer of soil and
material by the blade.

● The rear riper has 5 teeth, of which generally
3 teeth are working on the solid ground. The
1
Figure 7-12 teeth shall be used symmetrically, for
1. Rear ripper instance: one middle tooth, or two outer tooth
or three middle teeth.
● Adjustment of rear ripper
1. Traveling position: Retract inward the teeth
and fully lift the ripper.
2. Ripping position: Extend the teeth onto the
ground.
3. Deep ripping position: Fully depress the
ripper by the cylinder.
● Ripping
1. The number of ripping teeth, ripping depth,
and traveling speed depend on the hardness
of the soil.
2. Lower the ripping teeth onto the ground.
3. Drive forward the grader and at the same
time lower the rear ripper to plug into the
ground.
7-8
● Function of front ballast: When the rear

ripper is installed, the front frame can be
functioned as the front ballast of ripper, if the
front frame is not fitted with front
mouldboard.
Front ballast weight: 452kg
1
Caution:
Figure 7-13
1. Front ballast ● When the machine is started, always lift
the ripper before making a turn or backing up
the machine. When the machine is parked
after working, make sure to lower the ripper
onto the ground.
● If the ripper is not to be used for a long
period, take out and correctly preserve the
ripper.
● Frequently check the tooth holders of the
ripper for presence of damage, such as
cracking or bending, and do not use damaged
tooth holder.
7-9

Front Mouldboard
721 Disassembly of Front
Mouldboard
1. Park the machine on a solid and level road.
1
Figure 7-14
1. Maintenance position
2. Place stop blocks in the front and rear of the
rear wheels to prevent the forward or
backward movement of the rear frame.
1
Figure 7-15
1. Stop block
7-10
3. Use a copper bar to disassemble the pin
between the connecting arm and lifting
bracket.
1 2 3
Figure 7-16
1. Pin
2. Connecting arm
3. Lifting bracket
4. Disassemble the mouldboard and place at an

appropriate position with lifting slings.
1160Kg
Caution:
1. The incorrect disassembly or assembly will

probably cause personal injuries or
damage the machine.
2. Take cautions during the disassembly and
assembly of the mouldboard. Do not
1 disassemble or assemble with brutal force
Figure 7-17
1. Mouldboard or knock the installation fitting surfaces.
3. The rated lifting capacity of the lifting
equipment shall be higher than the weight
of mouldboard. All personnel are
prohibited to access the area beneath the
mouldboard being lifted. Ensure that the
lifting slings are securely fixed before the
lifting.
7-11
722 Installation of Front Mouldboard

1. Prepare an appropriate amount of lubricating
oil and necessary assembly tools and fulfill
the pre-installation preparations.
2. Apply lubricating oil onto the pin and hoist
the mouldboard to the aligned position of
pin hole.
1 2 3. Use a copper bar to knock in the pin
Figure 7-18
1. Connecting arm between the connecting arm and lifting
2. Lifting bracket bracket.
4. Start the machine and check the
mouldboard.
Figure 7-19
7-12

Frame Joint
731 Disassembly at Joint of Upper
Frame
1. Park the machine on a solid and level road.
Figure 7-20
2. Move the control lever back and forth
repeatedly to release the hydraulic oil
pressure.
Figure 7-21
3. Turn off the battery power switch.
1
Figure 7-22
1. Power switch
7-13
4. Place stop blocks in the front and rear of the
rear wheels to prevent the forward or
backward movement of the rear frame.
1
Figure 7-23
1. Stop block
5. Disassemble the locking ring and bolt from
the front pin of the steering cylinder and use
a copper bar to knock out the pin.
1 2
Figure 7-24
1 Pin
2 Steering Cylinder
6. Disconnect the hoses from the control valve
and protect all ports. Ensure that all
connections of all types are disconnected,
except the pin between the front and rear
frames.
7. Place supports in the front of rear frame and
1 2 beneath the front frame and properly fix the

Figure 7-25
front and rear frames.
1. Front frame
2. Rear frame
7-14
8. Disassemble the oil port outlet pipes and oil
cups.
1
Figure 7-26
1. Oil port outlet pipe
9. Disassemble the bolts of upper articulation
pin and take out the cushion plate.
1
Figure 7-27
1. Cushion plate
10. Disassemble the bolts of upper locating plate
and take out the upper locating plate.
11. Disassemble the spacer ring, take out the
O-ring, and knock out the knuckle bearing.
1 2 3
Figure 7-28
1. Upper locating plate
2. Upper articulation pin
3. Knuckle bearing
7-15
732 Disassembly at Joint of Lower

Frame
1. Disassemble the bolts of lower articulation
pin and take out the cushion plate.
1
Figure 7-29
1. Cushion plate
2. Disassemble the bushing and take out the
spacer sleeve.
3. Disassemble the bolts of lower locating plate
and take out the lower locating plate.
4. Disassemble the locating sleeve, take out the
O-ring, and knock out the knuckle bearing.
1 2 3
Figure 7-30
1. Spacer sleeve
2. Lower articulation pin
3. Bushing
7-16
733 Installation at Joint of Upper

Frame
1. Before the assembly, keep all parts clean,
without any foreign material or knocking
damage or scratch.
2. Thoroughly clean the pin holes of both front
and rear frames.
1
Figure 7-31
1. Pin hole
Figure 7-32
7-17
3. Press in the spacer ring and O-ring and
install the upper locating plate.
4. Tighten the bolts of upper locating plate.
5. Align the positions of upper pin and use EP2
lubricating grease to lubricate the upper
bearing pin and knuckle bearing.
3 4 5
Figure 7-33
1. Upper locating plate
2. Upper articulation pin
3. Knuckle bearing
6. Press in the bearing pin and install the bolts
and cushion plate.
7. Apply thread sealant while installing the
bolts.
Tightening torque: 339N.m
1 2
Figure 7-34
1. Cushion plate
2. Bolt
7-18
8. Install the oil port outlet pipe and oil cup.
1
Figure 7-35
734 Installation at Joint of Lower

1 Frame
1. Press in the knuckle bearing, install the
lower locating plate, and tighten the bolts.
2. Accurately align two frames at the position
of lower pin.
3. Press in the lower pin and install the spacer
sleeve and bushing.
2 3
Figure 7-36
1. Lower locating plate
2. Bushing
3. Spacer sleeve
7-19
4. Tighten the cushion plate with bolts and fix
the pin.
1
Figure 7-37
1. Cushion plate
5. Install the oil port outlet pipe and oil cup.
1
Figure 7-38
6. Connect the hydraulic pipeline at the frame
articulation.
1
Figure 7-39
1.Front and rear frame hydraulic pipeline
7-20
7. Install the steering cylinder front pin and
nylon washer.
8. Install the locking ring and lock bolts and
lubricate the cylinder pin.
9. Check the hydraulic oil level and add to
specified level.
10. Start the engine and check for presence of
1 2 3 oil leakage.
Figure 7-40
11. Carefully turn the machine to the fully
1. Cylinder pin
2 .Steering Cylinder locking positions in two directions, in order
3. Locking rod
to bleed the air from the hydraulic system.
12. Add lubricating grease to lubricate the upper
and lower knuckle bearings once again.

Front and Rear Wheels
741 Disassembly of Rear Wheels
1. Park the machine to maintenance position 1
(Refer to page 8 of Safety and Environment
for details).
2. Elevate one side of the grader by the blade.
Therefore, place the angle end of the blade

1
Figure 7-41 in the front of the balance box wheel to be
1.Maintenance position
elevated and then use the lifting cylinder on
the same side of the wheel to be elevated to
elevate the grader.
7-21
3. Install the wheel lifting fork and fix the
wheel.
1
Figure 7-42
1. Wheel lifting fork
4. Use a pneumatic wrench to disassemble the
wheel nuts and wheel.
Caution:
During the disassembly and assembly of
wheels, make sure not to damage the
threads of wheel rim bolts. After the

1
wheels are installed, tighten the wheel rim
Figure 7-43
1.Rear wheel nuts in crossed manner.
7-22
5. Disassemble the wheel and place in a safe
and appropriate position.
1
Figure 7-44
1. Bracket
742 Installation of Rear Wheels
1. Clean the contact surfaces of the wheel rim
and wheel hub. Keep clean the threads on
the wheel hub, without any damage.
1
Figure 7-45
1. Hub
2. Install the wheel and install four wheel nuts
in uniformly distributed manner. Directly
tighten the nuts.
Caution:
Clockwise tighten the nuts. Screw in several
turns each time, in order to prevent tilting the

1
wheel.
Figure 7-46
1.Rear wheel
7-23
3. Disassemble the wheel lifting fork.
4. Install the remaining wheel nuts.

Tightening torque: 700~800N.m
6. Check functions.
1
Figure 7-47
743 Disassembly of Front Wheels
1. Park the machine to maintenance position 1
(Refer to page 8 of Safety and Environment
for details).
2. Elevate the front wheels by supporting the

1 mouldboard onto the ground.
Figure 7-48
3. Before the disassembly of wheels, make sure
to securely support the grader and block the
movement of rear wheels.
1
Figure 7-49
1. Stop block
7-24
4. Install the wheel lifting fork and fix the
wheel.
1
Figure 7-50
5. Disassemble the wheel nuts and wheel.
Caution:
During the disassembly and assembly of
wheels, make sure not to damage the
threads of wheel rim bolts. After the wheels
are installed, tighten the wheel rim nuts in
1 crossed manner.
Figure 7-51
1. Hub
7-25
6. Place in a safe and appropriate position.
1
Figure 7-52
1. Bracket
744 Installation of Front Wheels
1. Clean the contact surfaces of the wheel rim
and wheel hub. Keep clean the threads on
the wheel hub, without any damage.
2. Install the wheel and install four wheel nuts
in uniformly distributed manner. Directly
tighten the nuts.

Caution:
1 Clockwise tighten the nuts. Screw in several

Figure 7-53
1. Hub turns each time, in order to prevent tilting the
wheel.
7-26
3. Disassemble the wheel lifting fork.
4. Install the remaining wheel nuts.
Tightening torque: 700~800N.m
6. Check functions.
1
Figure 7-54

Middle Working Device
751 Disassembly of Blade
1 Start the machine, drive to a level, spacious,
and solid ground, set straightly, and stop the
machine.
1
Figure 7-55
2 Operate the control lever back and forth
repeatedly to relieve the hydraulic oil
pressure, then shift all control levers to
neutral positions, and pull up the parking

Figure 7-56
brake handle.
7-27
3 Stop the engine and use stop blocks to
wedge the tires of grader.
1
Figure 7-57
1. Stop block
4 Hoist the blade with lifting slings, in order to
prevent injuring the feet or damaging the
ground after the disassembly of pin.
1
Figure 7-58
1. Blade
5 Disconnect the hoses of blade extraction
cylinder, accommodate the oil, and properly
protect the pipe connectors.
1
Figure 7-59
1. Blade extraction cylinder
7-28
6 Use a copper bar to knock out the pin of
inclination angle cylinder and disconnect the
cylinder from the blade.
1 2
Figure 7-60
1. Tilting angle cylinder
2. Tilting angle cylinder pin
7 Take out the pin and properly protect the
cylinder to prevent scratching the piston rod.
1
Figure 7-61
1. Pin
8 Disassemble the fastening bolts of locking
block and take out the locking block.
1
Figure 7-62
1. Locking block
7-29
9 Disassemble the fastening bolts of bushing
and take out the cover plate.
1
Figure 7-63
1. Cover plate
10 Use a copper bar to knock out the bushing.
1
Figure 7-64
1. Bushing
11 Hoist out the blade with lifting slings and
place in a safe and appropriate position.
1
Figure 7-65
1. Blade
7-30
752 Installation of Blade
1. Remove dirt from two end bores of the
lower bushing of rotary ring gear and apply
an appropriate amount of lubricating oil to
the bores.
1
Figure 7-66
1. Rotary ring gear
2. Apply lubricating oil to the bushing and
wearing plate.
3. Hoist the blade assembly to an appropriate
position beneath the rotary ring gear and
connect it to the rotary ring gear.
1
Figure 7-67
1. Bushing
4. Use a copper bar to knock in the bushing
and tighten the bushing cover plate bolts.
1
Figure 7-68
1. Bushing
7-31
5. Tighten the fastening bolts of locking block
to fix the bushing.
1
Figure 7-69
1. Locking block
6. Use a copper bar to knock in the titling angle
cylinder pin, install the cylinder, and connect
the cylinder and blade.
7. Use a grease gun to inject an appropriate
amount of grease to the pin of tilting angle
cylinder.
1 2 8. Clean the pipe connector of lateral extending

Figure 7-70
cylinder and properly connect the hoses.
1. Tilting angle cylinder
2. Tilting angle cylinder pin
753 Disassembly of Middle Ripper
1. Start the machine, drive to a level, spacious,
machine.
1
Figure 7-71
7-32
2. Move the control lever back and forth
repeatedly to release the hydraulic oil
pressure.
3. Hoist the ripper with lifting slings to prevent

Figure 7-72
falloff during disassembly.
4. Screw off the connecting bolts and
disassemble the left and right welded tie
rods.
1
Figure 7-73
1. Left welded tie rod
1. Knock off the left and right welded pins and
disassemble the left and right connecting
arms.
2. Hoist the middle ripper and place at a safe
and appropriate position.

Warning:
1 2 1. The incorrect disassembly or assembly will

Figure 7-74
probably cause personal injuries or
1. Right connecting arm
2. Welded pin damage the machine.
2. Take cautions during the disassembly and
assembly of the middle ripper. Do not
disassemble or assemble with brutal force
or knock the installation fitting surfaces.
7-33
3. The rated lifting capacity of the lifting
equipment shall be higher than the weight
of middle ripper. All personnel are
prohibited to access the area beneath the
middle ripper being lifted. Ensure that the
lifting slings are securely fixed before the
lifting.
754 Installation of Middle Ripper

1. Hoist the middle ripper to an appropriate
position beneath the front frame.
2. Install the left and right connecting arms and
knock the welded pins.
1 2
Figure 7-75
1. Welded pin
2. Left connecting arm
3. Install the left and right welded tie rods and
tighten the connecting bolts.
1
Figure 7-76
1. Left welded tie rod
7-34
4. Start the machine and check the functions.
1
Figure 7-77
1. Middle ripper
755 Disassembly of Rotary Ring Gear
machine.
1
Figure 7-78
2. Operate the control lever back and forth

Figure 7-79
brake handle.
3. Stop the engine and use stop blocks to
1
Figure 7-80
1. Stop block
7-35
4. Hoist the rotary ring gear with lifting slings
to prevent sudden falloff.
1
Figure 7-81
1. Rotary ring gear
5. Disassemble the connecting bolts of
clamping plate and take out the clamping
plate and guide plate.
1 2
Figure 7-82
1. Clamping plate
2. Guide plate
6. Disassemble three guide plates in turn and
hoist down the rotary ring gear.
1
Figure 7-83
1. Rotary ring gear
7-36
7. Disconnect the upper oil pipe of coupling
frame and properly protect the pipe
connector.
1
Figure 7-84
1. Pipe connector
8. Hoist the front and rear of the coupling
frame with lifting slings.
1 2 3
Figure 7-85
1. Rotary ring gear
2. Coupling frame
3. Ball joint
2 9. Disassemble the locking cylinder.
● The swing bracket adopts the locking
cylinder for positioning purpose. To change
the side turning angle of the cylinder, press
the right button of the cab to unlock.
● Operate the swing bracket to the required
position. When the indication hole is aligned
1 3 with the eye plate indication edge, it

Figure 7-86
indicates that the swing bracket is aligned
1. Locking cylinder
2. Indication hole with the connecting rod locating bore. Press
3. Locating swing bracket
7-37
the lock button. It indicates that it’s locked
when the indicator lamp on the operating
board shows locked.
● The swing bracket can be operated by the
driver within the cab, featuring easy position
operations.
10. Press the lock button of the cab.
1
Figure 7-87
1. Lock button
11. Disassemble the connecting bolts of left
oscillating cylinder.
1 2
Figure 7-88
2. Bolt
7-38
12. Loosen the connecting bolts of right
oscillating cylinder and disassemble the
cylinder.
Figure 7-89
13. Loosen the bolts on two sides of the swing
bracket and take out the swing bracket.
1
Figure 7-90
1. Swing bracket
14. Loosen the bolts on the piston rod head of
the blade lifting cylinder and disconnect the
cylinder from the coupling frame.
1
Figure 7-91
1. Lifting cylinder piston rod head
7-39
15. oosen the bolts of ball joint bracket in the
front of the coupling frame and disconnect
from the front frame.
1 2
Figure 7-92
1. Ball joint bracket
2. Coupling frame
1
Figure 7-93
16. Hoist the coupling frame to a safe and
appropriate position.
1
Figure 7-94
1. Coupling frame
7-40
756 Installation of Rotary Ring Gear
1. Replace with new wearing plate.
1
Figure 7-95
1. Wearing plate
2. Hoist the rotary ring gear with lifting slings
and place on the coupling frame.
Figure 7-96
3. Tighten the connecting bolts between
clamping plate and guide plate.
● Loose the back nut and fastening nut beneath
the clamping plat and adjust the number of
washers.
● Check the axial gap between the bottom of
1 rotary frame and the wearing cast nylon with a

Figure 7-97
feeler gauge.
1. Clamping plate
Gap: 1~2mm
7-41
● Tighten the fastening nut and the lock back
nut.
4. Install three clamping plates and guide
plates in turn.
1
Figure 7-98
1. Guide plate
5. Hoist and overturn the coupling frame and
rotary ring gear.
1
Figure 7-99
1. Coupling frame
6. Align the bolt holes of coupling frame and
ball joint.
1 2
Figure 7-100
1. Coupling frame
7-42
7. Tighten the connecting bolts of coupling
frame and ball joint bracket.
1
Figure 7-101
1. Connecting bolt
8. Install the swing cylinder and connect the
hoses.
1
Figure 7-102
1. Swing cylinder
Installation method:
● Adjust the left swing cylinder to be linear
with the swing drive arm and retract the left

Upper projection
of rotary bracket
swing cylinder.
Left cylinder
Right cylinder
● Adjust the right drive arm to form an
approximate 90ºagainst the line between the

Figure 7-103
right drive arm and the rear pivot of the right
swing cylinder.
● Loosen the nuts and oil pipes of rotary valve,
rotate the rotary valve core to align the
7-43
orifices of rotary valve core with the oil port,
and then tighten the lock nut of rotary valve
while maintaining the position of the rotary
valve core.
9. Install the swing bracket and tighten the
fastening bolts on two sides.
1
Figure 7-104
1. Swing bracket
10. Install the lock cylinder and connect the
cylinder hoses.
1
Figure 7-105
1. Locking cylinder
11. Install the oscillating cylinder, tighten the
fastening bolts, and connect the cylinder
hoses.
1
Figure 7-106
7-44
12. Install the left and right lifting cylinders and
connect the cylinder hoses
1
Figure 7-107
1. Lifting cylinder
13. Start the machine, check the functions, and
check for presence of leakage.
Figure 7-108

Rear Ripper
761 Disassembly of Rear Ripper
and solid ground, set straightly, stop the
machine, and lower the mouldboard onto the
ground.
1
Figure 7-109
7-45
2. Operate the machine to steadily lower the
rear ripper onto the cushion plate.
1
Figure 7-110
1. Rear ripper
3. Operate the control lever back and forth
Figure 7-111 brake handle.
4. Stop the engine and use stop blocks to
1
Figure 7-112
1. Stop block
7-46
5. Knock out the pin and disassemble the left
and right connecting boxes.
1 2
Figure 7-113
1. Upper pin
2. Left connecting box
3. Rear ripper
6. Disconnect the hoses of cylinder and
properly protect the hose connectors. Knock
out the lower pin.
1 2
Figure 7-114
1. Lower pin
2. Connecting box
7. Hoist the rear ripper to a safe and
appropriate position.
1
Figure 7-115
1. Rear ripper
7-47
8. The ripper tooth sleeve is a wearing part. To
replace the ripper tooth sleeve, hammer one
end of the fixing pin with high force to
knock out the fixing pin and spring sleeve
and take out the ripper tooth sleeve.
9. To assemble the ripper tooth, attach the
ripper tooth sleeve to the ripper tooth angle,
buckle the fixing pin and spring sleeve
together, and knock into the fitting hole with
tool, till the protrusion length of the fixing

1 2 3 4
Figure 7-116 pin is basically same between two end faces.
1. Ripper tooth
2. Spring sleeve
3. Fixing pin Caution:
4. Ripper tooth sleeve
● The incorrect disassembly or assembly will
probably cause personal injuries or damage
the machine.
● Take cautions during the disassembly and
assembly of the ripper. Do not disassemble or
assemble with brutal force or knock the
installation fitting surfaces.
● The rated lifting capacity of the lifting
equipment shall be higher than the weight of
ripper. All personnel are prohibited to access
the area beneath the ripper being lifted.
Ensure that the lifting slings are securely
fixed before the lifting.
7-48
762 Installation of Rear Ripper

1. Prepare an appropriate amount of lubricating
oil and necessary assembly tools and fulfill
the pre-installation preparations. To ease the
assembly beneath the grader, it’s better to
assemble the rear ripper in the place with
trench.
2. Disassemble the foot plate on two sides of
1 the drive axle, replace the washers, and
Figure 7-117
tighten the original bolts.
1. Foot plate
Tightening torque: 180～210N.m
3. Knock in the pin and connect the cylinder.

4. Use a grease gun to inject an appropriate
amount of grease to the pin joint.
5. Fix the hoses and install the left and right
connecting boxes.
6. Hoist the rear ripper and knock in the pin.
Figure 7-118
7. Start the machine and check the functions.
1
Figure 7-119
1. Rear ripper
7-49
77 Common Malfunction Causes and Troubleshooting

The state of the working device directly determines the working efficiency and progress of the
machine. The analysis of several common malfunctions during the working are listed in the table
7-1 as below.
Table 7-1
Malfunction Malfunction cause Troubleshooting
Bypass of oil line due to damage of swing
Replace swing cylinder seals
cylinder seals
Automatic rotation of
blade rotary frame under Wear of multi-way valve rotary valve group Replace rotary valve group of multi-way valve
load Abnormal wear of rotary valve core Replace rotary valve
Pipeline leakage Replace corresponding pipeline
Remove the foreign materials from swing
Stagnation of swing mechanism mechanism and adjust the gap of rotary frame
as per requirements
Damage of rotary valve drive shaft, damage
Replace rotary valve drive shaft and rotary
of rotary valve gear, or sliding between rotary
valve gear
valve drive shaft and rotary valve gear
Damage of rotary drive gear Replace rotary drive gear
Damage at joint between rotary drive arm and
Replace rotary drive arm or rotary drive gear
rotary gear spline
Rotation failure or
non-flexible rotation of Error continuity relation of oil line between Readjust relative position of rotary valve core
blade rotary frame rotary valve and swing cylinder and swing cylinder as per requirements.
Insufficient oil in hydraulic oil tank Add oil to specified level
Damage of seals in left and right swing
Replace seals
cylinders
Incorrect regulated pressure of multi-way
Reset
valve
Failure of multi-way valve for maintaining
Replace multi-way valve safety valve
required pressure
Wear or under-low gap of guide cast nylon Replace guide cast nylon or adjust gap
Inconsistent rotation
direction of blade rotary
Error position of rotary valve core Adjust the rotary valve core and adjust for 180º
frame against indicated
direction of control lever
Unidirectional rotation of Readjust relative position of rotary valve core
Error adjustment of rotary valve core
blade rotary frame and cylinder
High axial and radial gaps of rotary frame Adjust axial and radial gaps of rotary frame
Damage of guide sleeve of bushing of blade Replace guide sleeve or bushing of tilting
tilting angle bracket angle bracket
Vibration of blade during
working Abnormal wear or breakage of blade upper
Replace wearing plate.
slide cast nylon plate
Replace the cylinder seals or corresponding
Internal leakage of blade tilting angle cylinder
multi-way valve group
Failure of blade lifting cylinder balance valve
Falloff of working device Replace balance valve
due to damage or stagnation
7-50
Contesnts
8 Cab and Covering Parts System ...................................................................................................... 8-1
81 Overview of Cab ...................................................................................................................................... 8-1
811 Exterior Description of Cab............................................................................................................... 8-1
812 Description of Cab Upholstery .......................................................................................................... 8-3
82 Description of A/C System .................................................................................................................... 8-16
821 Locations and Functions of Parts .................................................................................................... 8-16
822 System Description.......................................................................................................................... 8-17
83 Disassembly and Assembly of Cab Assembly ............................................................................... 8-20
831 Disassembly of Cab Assembly ........................................................................................................ 8-20
832 Assembly of Cab Assembly ............................................................................................................. 8-25
833 Replacement of Seat ........................................................................................................................ 8-31
834 Disassembly and Assembly of Operating Cabinet........................................................................... 8-31
84 Disassembly and Assembly of Engine Hood ................................................................................. 8-33
841 Disassembly of Engine Hood .......................................................................................................... 8-33
842 Assembly of Engine Hood ............................................................................................................... 8-35
85 Disassembly and Assembly of A/C System ................................................................................... 8-38
851 Disassembly of Ventilation System ................................................................................................. 8-38
852 Assembly of Ventilation System ...................................................................................................... 8-41
853 Replacement of Evaporator Parts .................................................................................................... 8-43
854 Replacement of Condenser Fan ....................................................................................................... 8-51
855 Replacement of Fluid Reservoir ...................................................................................................... 8-51
856 Replacement of Compressor Par ..................................................................................................... 8-52
857Drainage and Adding of Refrigerant ................................................................................................ 8-55
86 Diagnosis and Troubleshooting for Common Malfunctions of A/C System .............................. 8-59
861 Periodical Checking Items ............................................................................................................... 8-59
862 Analysis of Refrigeration Failure Malfunction ................................................................................ 8-61
863 Analysis of Insufficient Refrigeration Output ................................................................................. 8-62
I
864 Analysis of Heating Failure Malfunction ......................................................................................... 8-62
865 Analysis of Other Malfunctions ....................................................................................................... 8-63
II
8 Cab and Covering

Parts System
81 Overview of Cab
G9190 cab is a grader cab specially designed by
SDLG.
811 Exterior Description of Cab

1. The G9190 cab features falling object protective
1 structure and rollover protection structure
Figure 8-1
1. Cab (FOPS&ROPS). It can protect the operation
personnel in event of falling heavy object above or
rollover of the machine.
2. G9190 cab is fixed on the front frame by four
absorbers, which can effectively attenuate the
vibration from the outside and improve the driving
comfort.
1
Figure 8-2
1. Shock absorber
8-1
3. The parts of rollover protection structure (ROPS)

include one heavy bolt (ROPS bolt) and
permanently installed washer (ROPS washer). The
cab and frame are connected by ROPS bolt. In
event of rollover accident of the machine, the
ROPS parts can prevent the cab from separating
from the machine.
Caution:
1 2 If the ROPS&FOPS structure is damaged by falling
Figure 8-3
1. ROPS bolt object or due to rollover, its strength will be
2. ROPS washer impaired and can’t meet the normal protection
function. In such case, please contact Shandong
Lingong Construction Machinery Co., Ltd. or its
designated dealer to obtain new ROPS&FOPS
structure. The repair by self is absolutely
prohibited.
Make sure to fasten the seat belt during the
operations of the machine, in order to enable the
ROPS & FOPS structure for effective protection.
Replace the seat belt once every three years, even
no abnormality is detected.
It’s prohibited to drill hole or conduct electric
welding inside or outside of the ROPS cab, in order
to prevent damaging or impairing the strength of
ROPS cab.
Warning
If the rollover protection structure (ROPS) is

deformed or damaged due to certain cause or
accident, make sure to replace with new rollover
protection structure (ROPS). Please contact your
8-2
nearest SDLG dealer to obtain new ROPS

structure.
812 Description of Cab Upholstery

The control levers and instruments are located in the
front and the gear control lever is located on the right
side, which conform to the people’s driving habits and
greatly reduce the operation difficulty of the grader.
1. Starter switch
1 This switch is functioned to turn on or off the electric
Figure 8-4
1. Starter switch system of complete machine and start the engine.
• Position PRE
This is the engine preheating position of the cold start
system.
• Position OFF
At this position the key can be inserted or withdrawn.
Rotate the key to this position to turn off the circuit.
• Position ON
Turn on the electric system of the complete machine.
Please keep the key at position ON during the running
of the engine.
• Position ST
This is the position to start the engine. Hold the key at
this position at the instant of the engine start.
After the engine is started, the key will automatically return to
position ON upon release of the key.
8-3
2. CD player/radio control panel (if equipped)
This control panel is located on the right front side of
the cab roof. Please refer to the Operation and
Installation Manual of CD Player/Radio for operation
1 methods.
Figure 8-5
1. CD player/radio control panel
3. Gear control lever
The gearshift operation adopts electro-hydraulic
control. The gear control lever is located on the right
side, including 6 drive gears on the left, neutral gear in
the middle, and 3 reverse gears on the right. In

Figure 8-6
addition, this transmission can realize the reversed
control only at 1st gear. During the downslope
traveling, operate the corresponding gear in such
manner that the engine speed is no less than
1200r/min, in order to meet the lubrication
requirements for all transmission portions.

Caution:
The gearshift shall be conducted gradually one by
one. Do not jump the gear or operate with excessive
force or brutally.
8-4
4. Rocker switch
• The turn lamp and headlamp switches are located
in the front, beneath the steering wheel.
1 2
Figure 8-7
1. Turn signal lamp switch
2. Headlamp switch
• Warning lamp switch
Depress the lower end of switch to flash all turn signal
1 lamps, in order to send warning lighting and alert other

Figure 8-8 vehicles and pedestrians in event of emergency.
1. Warning lamp switch
Depress the upper end of switch to stop the flashing of
turn signal lamps.
This switch is located on the right side.
• Multi-state switch (power selection switch)
This switch is functioned to select the
running of engine under different power

1
curves, in order to effectively utilize the
Figure 8-9
1. Multi-state switch engine power and achieve best performance
and combustion efficiency.
2 - High power curve
1 - Medium power curve
0 - Low power curve
8-5
• PTO switch (automatic cruise switch)
This switch is functioned to run the engine at
1 a preset speed higher than idling speed.

Figure 8-10
1. PTO switch
• PTO S+/R- switch (automatic cruise speed
regulation switch)
1 This switch is an automatic reset switch to adjust the

Figure 8-11 preset speed of automatic cruise switch. When the
1. PTO S+/R- switch
speed is increased to preset value, release the S+ end
to maintain this speed. The R- end can be used to
reduce the engine speed during cruise control.
• Working lamp switch
Depress the upper end of switch to turn on the
1 headlamp on the top of cab. Depress the lower end of

Figure 8-12 switch to turn on both headlamp on the top of cab and
1. Working lamp switch
the rear lamp. Operate the switch to middle position
to turn off the lamps.
• Blade lamp switch
Depress the lower end of switch to turn on the blade
1 lamp on the front frame and depress the upper end of

Figure 8-13 switch to turn off the blade lamp.
1. Blade lamp switch
• Rear working lamp switch
Depress the lower end of switch to turn on the rear
1 lamp on the rear cover of machine and depress the

Figure 8-14 upper end of switch to turn off the rear lamp.
1. Rear working lamp switch
8-6
• Backlight switch
Depress the lower end of switch to turn on the
backlight of instrument panel and rocker switches and

1
depress the upper end of switch to turn off.
Figure 8-15
1. Backlight switch
• Mute switch
Depress the lower end of switch to stop the sound
alarm of the instrument panel.

1
Figure 8-16
1. Mute switch
• Locking cylinder switch
This switch is an automatic reset switch. Depress and
1 hold the lower end of switch to retract the locking

Figure 8-17 cylinder. Once released, the locking cylinder stays
1. Locking cylinder switch
firmly at the current position. Depress and hold the
upper end of switch to extend the locking cylinder.
Once released, the locking cylinder stays firmly at the
current position.
• Reserved switch of heater
Depress the lower end of switch to start the running
of heater and depress the upper end of switch to stop

1
the running of heater.
Figure 8-18
1. Reserved switch of heater
8-7
• Top warning lamp switch
This switch is located on the right top of the cab. Depress
the lower end of switch to flash the top warning lamp of the
cab. Depress the upper end of switch to turn off the top
1
Figure 8-19 warning lamp.
1. Top warning lamp switch
• Rear wiper switch
Depress the lower end of switch to run the wiper and
depress the upper end to stop the wiper. Two working
speed (high speed and low speed) can be obtained by
1 the different extends the lower end is depressed.

Figure 8-20
1. Front wiper switch
• Washer switch
• This switch is an automatic reset switch. Depress
the lower end of switch to run the washer motor.
The water is sprayed out from the wiper spray
1 nozzle to clean the front windscreen of cab. Once

Figure 8-20
released, the switch will automatically reset to
1. Washer switch
stop the water spray. Depress the upper end of
switch to run the washer motor. The water is
sprayed out from the wiper spray nozzle to clean
the window glasses of cab. Once released, the
switch will automatically reset to stop the water
spray.
8-8
• Front wiper switch
Depress the lower end of switch to run the wiper and
depress the upper end to stop the wiper. Two working
speed (high speed and low speed) can be obtained by
1 the different extends the lower end is depressed.

Figure 8-21
1. Front wiper switch
5. Temperature control switch
• Fan speed switch:
This switch is the system switch (power switch) and
also controls the speed of evaporator fan (high speed,
medium speed, and low speed), in order to select

1 2 3
appropriate air output and turn on/off the A/C system.
Figure 8-22
1. Fan speed switch: • Fresh air selection switch:
2. Fresh air selection switch
This switch controls the running of fresh air actuator,
3. Refrigeration start switch
in order to control the internal/external air
recirculation.
• Refrigeration start switch:
Rotate clockwise to turn on refrigeration system and
adjust the refrigeration output.
• Refrigeration
Start the engine. Turn on the fan speed switch. In such
case, it can be felt that the system has started the air
output mode. Then, rotate the refrigeration start switch
to refrigeration position. In such case, the refrigeration
indicator lamp lights up to indicate that the system is
under refrigeration state.
Rotate the fan speed switch to select different position,
in order to achieve different levels of air output (high
8-9
speed, medium speed, and low speed).
When the desired temperature is reached, rotate the
refrigeration start switch slowly counter-clockwise, till
the indicator lamp goes out.
• Heating
Before the use, firstly turn off the refrigeration start
switch.
Start the engine and open the hot water valve.
Turn on the fan speed switch and select appropriate
position to adjust to the required level.
6. Roof lamp switch
This switch is located in the center of cab roof. Push to
position “ON” to turn on roof lamp and push to
position “OFF” to turn off.
1
Figure 8-23
1. Roof lamp switch
7. Parking brake handle
It’s located in the left side. When the loader stops
working, pull up the parking brake handle to guard
against the movement of machine due to inclined road

Figure 8-24
or external force.
8-10
8. Cigarette lighter
The cigarette lighter is located on the right
side, slightly towards the rear end.
When the cigarette lighter is inserted and pushed
down to lock, the electric heating unit of the
cigarette lighter comes into contact with the
cigarette lighter socket to start the heating. When
1 the electric heating wire of the cigarette lighter

Figure 8-25 reaches the preset temperature, the snap ring will
1. Cigarette lighter
be deformed under the action of high temperature
to pop out the cigarette lighter. In such case, pick
up the cigarette lighter to light a cigar and insert it
back.
9. Steering wheel tilting angle adjustment handle
The adjustable angle of steering is 19º. Adjust by
operating the handle on the right side of the
handle stand the tilting angle of steering wheel to
the desired position and then tighten the handle.
1
Figure 8-26
1. Steering wheel tilting angle adjustment
handle
10. Instrument desk angle adjusting pedal
Step on the pedal at the lower part of console to
release the lock of air spring, the console can be
tilting adjusted, hold the steering wheel and push it
to the required position. Release the pedal, the
console can be fixed at the position under the

1 action of air spring, and the angle can be adjusted
Figure 8-27
1. Instrument panel angle adjustment pedal to 70°~90°.
8-11
11. Steering wheel and horn button
The steering wheel is located on the straight front
of the cab. Rotate the steering wheel to realize the
steering of front wheels. When necessary, press
the middle button of the steering wheel to sound
the horn and release to stop the sounding.

1 2
Figure 8-28
1. Horn button
2. Steering wheel
12. Safety hammer
In event of emergency, use the hammer hung on
the left rear side of the cab to break the glass and
escape from the cab.
1
Figure 8-29
1. Safety hammer
13. Working device control levers
The working device is operated in such manner
that five control levers located on each side of the
steering wheel control the related valve groups of
two multi-way reversing valves in the front of the

1 2
cab to realize the connections with oil lines of
Figure 8-30
1. Lifting/lowering of rear ripper, adjustment different pressures and fulfill different actions:
of blade tilting angle, articulated steering,
• Lifting of blade
and lifting/lowering of mouldboard (from
left to right). Operate the blade lifting control levers to control
2. Left lifting/lowering of blade, lateral
extension of blade, swing of blade, the left and right cylinders to adjust the left and
oscillating of blade, tilting of front wheels, right heights of the blade so that the leveled
and right lifting/lowering of blade (from left
to right) ground meets the horizontal or gradient
requirements.
8-12
• Swing of blade
By operating the blade swing lever, it can achieve
the rotation at any angle within 360º scope of
horizontal plane so that the blade forms a certain
deflection angle against the traveling direction of
the grader and the soil scraped by the blade during
working can timely be moved to two sides of the
grader, in order to guarantee the continuous
working performance.
• Lateral extension of blade
Under the action of the lateral extension cylinder,
the blade body can extend towards two sides
along its length direction, in order to increase the
working width of the grader.
• Lateral sway of blade
If the required width can’t be met after the blade
is extended to the limit position, laterally sway the
connecting frame, rotary frame, and blade
together towards the left or right side of the grader
to increase the working scope.
• Side turning of blade
The side turning of the blade is intended to realize
the scraping of the side slope. Under the joint
action of the left and right lifting cylinders and
blade oscillating cylinder, the blade can be
vertically erected on the left or right side of the
grader, with certain angle against the ground. The
left/right maximum side turning angle of the blade
8-13
is up to 90º.
• Adjustment of blade angle
Under the action of blade tilting angle cylinder,
the blade body can tilt forward for up to 47ºand
backward by up to 5º, in order to achieve different
cutting angle of the blade and adapt to needs
under different working conditions.
14. Seats
• Weight capacity adjustment
The weight capacity adjustment handle is located
in the center beneath the seat. Rotate the handle
counter-clockwise to reduce the shock absorption
rigidity and rotate clockwise to increase the shock
absorption rigidity. The operator can rotate the
shock absorption rigidity adjustment handle
depending on own weight until feeling

1 2 3
Figure 8-31 comfortable.
1. Longitudinal adjustment handle
• Longitudinal adjustment
2. Weight capacity adjustment handle
3. Backrest adjustment handle The longitudinal adjustment handle is located in
the front of the left lower side of the seat. Lift the
longitudinal adjustment handle with hand and
adjust the seat longitudinally to achieve ideal
position. Release the handle to lock the seat
automatically.
• Backrest angle adjustment
Lift the backrest angle adjustment handle, pull the
backrest to an appropriate backrest angle, and
release the handle to lock the backrest angle.
8-14
• Height adjustment
The seat has three different heights at three
different positions and the operator can adjust
depending on own needs. At the time of
adjustment, hold the base beneath the seat cushion
with both hands and pull up with force stably. The
seat can reach a height position during upward
movement and a “click" sound can be heard. In
such case, release the hands to fix the seat at such
position. After the seat is adjusted to highest
position, pull upward with force and then push
down to lower the seat to lowest position.
• Headrest height adjustment
Hold the seat headrest with both hands and pull up
or push down with force stably to adjust the seat
headrest height.
15. Seat belt
If equipped with seat belt, please check the seat
belt before the checking and judge the necessity of
replacement. Please fasten the seat belt during
operations.
16. Rearview mirror
There is one rearview mirror on each side in the
rear of the cab. Please properly adjust the
rearview mirrors before the operations, in order to
ensure good visibility.
8-15
82 Description of A/C System

821 Locations and Functions of Parts
The A/C system of grader is composed of
compressor, evaporator assembly, condenser

Figure 8-32
assembly, fluid reservoir, and refrigeration hoses.
The compressor is driven by the engine via belt.
The panel switch controls the temperature and air
output. It features high air output, fast
refrigeration effect, and automatic control of cab
temperature.
1. The compressor is the heart of the A/C
refrigeration system and is functioned to
maintain the recirculation of refrigerant
within the refrigeration system, suck in the
low temperature and low pressure refrigerant
vapor from the evaporator, compress to high
temperature and high pressure refrigerant
vapor, and convey the refrigerant to the
condenser.
2. The condenser is a heat exchanger composed
of pipes and radiator fins. It's functioned to
cool down the high temperature and high
pressure refrigerant vapor outputted by the
compressor, in order to condense to high
pressure fluid refrigerant.

1
Figure 8-33
1. Compressor
8-16
3. The storage and drying tank is functioned to
store the refrigerant, remove water content
from refrigerant, filter the impurities, and
check the amount of refrigerant.
4. The expansion valve is functioned to spray out
through the expansion valve orifices the fluid

1 2
Figure 8-34 refrigerant outputted by the fluid reservoir, in
1. Condenser
2. Storage & drying tank order to form low temperature and low
pressure atomized gas refrigerant. Depending
on the refrigeration load, it can automatically
adjust the flow of refrigerant.
5. The evaporator is functioned to evaporate
through heat absorption the low temperature
and low pressure atomized gas refrigerant
sprayed by the expansion valve and cool
down the hot airflow flowing through the
radiator, in order to cool down the cab. Its

Figure 8-35 heat absorption capacity determines the
refrigeration performance of the A/C.
822 System Description

The A/C system of grader is mainly composed of
heating system, refrigeration system, ventilation
system, and pressure control system.
The refrigeration system of the grader is
functioned to cool down the interior air or the
fresh air from the outside, in order to reduce the
interior temperature. Its operation description is as
below:
8-17
1. Start the engine.
2. Turn on the power/fan speed switch and rotate
the temperature control switch to position
“COOL”. The indicator lamp lights up to
indicate the start of refrigeration.
3. Rotate the fan speed switch to high, medium,
or low position to obtain three different air
outputs.
4. When the desired temperature is reached,
rotate the temperature control switch
counter-clockwise slowly, till the indicator
lamp goes out and the compressor stops
working. In such case, the temperature within
the cab is the preset temperature. When the
interior temperature is higher than this
temperature, the indicator lamp lights up and
compressor starts automatically to start the
refrigeration. When the interior temperature is
less than this temperature, the indicator lamp
goes out and the system stops running.
5. During the operations of the A/C, do not rotate
the temperature control switch to position
“COOL” and at the same time rotate the fan
speed switch to low speed, in order to prevent
the frost formation of evaporator from
impairing the refrigeration effect.
The heating system of grader utilizes the heat of
coolant, introduces the coolant of the diesel
8-18
engine into the heating radiator, and blows the
heated air into the machine by fan, in order to
increase the interior temperature.
Operation description of heating system:
1. Before use, rotate the temperature control
switch to position “O” or “OFF”.
2. Start the engine and open the hot water valve.
3. Turn on the fan speed switch and select
appropriate position to adjust to the required
level.
The ventilation system of grader is classified into
natural ventilation and forced ventilation. The
natural ventilation utilizes the outside wind
pressure generated during the traveling of grader
to realize ventilation. The forced ventilation
utilizes the fan to forcibly blow the outside air
into the cab.
The pressure control system of grader is
controlled by the high and low pressure switch. In
event of abnormal pressure of A/C system, such
as insufficient or no refrigerant or over-high
pressure, it’s functioned to turn off the
compressor, in order to protect the A/C system.

Caution:
Please close the hot water valve during
refrigeration in summer and turn off the
temperature control switch during heating in
winter.
8-19
The A/C system of grader adopts R-134a
refrigerant (Freon-free environment-friendly
refrigerant), featuring strong heat absorption,
easy liquefaction, no explosion or combustion,
stable chemical composition, no deterioration,
non-toxic, and no corrosion.
Expansion
valve Low pressure
fluid state
Low pressure gas

Drying state
filter High pressure gas

state
Level
High pressure
glass Liquid fluid state
reservoir
Evaporator Drying
filter
Compressor Compressor
Condenser
Figure 8-36

Cab Assembly
831 Disassembly of Cab Assembly
1. Before the disassembly of cab, hoist the cab
with lifting slings, till the lifting slings are not
loose, but do not hoist too tight.
2. Disconnect the multi-way valve from the cab.
8-20
3. Disconnect the steering gear from the cab.
Figure 8-37
4. Disconnect the brake valve from the cab.
Figure 8-38
5. Disconnect the A/C pipes from the evaporator.
Caution
It’s necessary to firstly drain the refrigerant.
Figure 8-39
8-21
6. Disconnect the rear frame harness from the
rear of cab.
Figure 8-40
7. Disconnect the harness on the right side of the
cab.
1
Figure 8-41
1. Shift upward the yellow part and apply
force towards the outer side.
8. Disconnect the harness beneath the handbrake
handle (bottom of the cab).
Figure 8-42
8-22
9. Disconnect the motor harness and washing
fluid hose at the washer fluid reservoir.
Figure 8-43
10. Disconnect the cab harness from the gear
operating harness connecting socket.
Figure 8-44
11. Disconnect the interior trim harness from the
inside of cab.
Figure 8-45
12. Disconnect the pipeline of heating system.
Figure 8-46
8-23
13. Disassemble the stand.
Figure 8-47
14. Disconnect the handbrake.
Figure 8-48
15. Disassemble the ROPS bolt.
Figure 8-49
16. Disassemble the fastening bolts of cab.
Figure 8-50
8-24
17. Hoist out the cab.
Figure 8-5
832 Assembly of Cab Assembly
1. As shown in the figure, connect the lifting
equipment, hoist the cab, and carefully lower
on the rear frame. Do not press the rear frame
pipelines.
Figure 8-52 Caution:
Attach the lifting slings to the lifting eyes of the
cab, pay attention to hoist horizontally, and
align with the mounting holes. Do not apply
pressure onto the hydraulic hoses and harness
connectors. Make sure to guarantee the
stability of cab while lowering the cab.
Figure 8-53
2. Install the nuts of shock absorbers.
Figure 8-54
8-25
3. Install the ROPS bolt.
Figure 8-55
4. Connect the harness beneath the handbrake
handle (bottom of the cab).
Figure 8-56
5. Connect the motor harness and washing fluid
hose at the washer fluid reservoir.
Figure 8-57
6. Connect the cab harness with the gear
operating harness connecting socket.
Figure 8-58
8-26
7. Fix the multi-way valve on the bracket.
Figure 8-59
8. Connect lower tie rods to the multi-way valve
in sequence.
Figure 8-60
9. Connect the pipelines of steering gear.
Figure 8-61
10. Connect the pipeline of brake valve.
Figure 8-62
8-27
11. Connect the rear harness of cab.
Figure 8-63
12. Connect the rear frame harness to the interior
trim harness.
Figure 8-64
13. Connect the harness on the right side of the
cab.
Figure 8-65
8-28
14. Connect the A/C pipelines.
Figure 8-66
15. Connect the heating system pipelines.
Figure 8-67
16. Connect the handbrake.
Figure 8-68
8-29
17. Install the stand.
Figure 8-69
8-30
833 Replacement of Seat

1. Disassemble the bolts beneath the seat bracket.
Figure 8-70
2. Move the seat out of the cab.
Figure 8-71
3. Replace with new seat and install bolts.

Figure 8-72
Operating Cabinet
1. Disassemble the front and rear bolts of cover
plate.
Figure 8-73
8-31
2. Disassemble the bolts from the front and left of
the outer panel.
Figure 8-74
3. Take out the cover plate and outer panel .
4. Install the cover plate and outer panel.
Figure 8-75
5. Attach the outer panel bolts, but do not tighten.
Figure 8-76
6. Attach the cover plate bolts and tighten all
bolts.
Figure 8-77
8-32

Engine Hood
841 Disassembly of Engine Hood
1. Disassemble the rear side panel.
Figure 8-78
2. Disconnect the rear cover harness.
Figure 8-79
3. Disassemble the connecting bolts between rear
cover and frame.
Figure 8-80
8-33
4. Disassemble the connecting bolts between the
upper portion of engine hood and upper
portion of rear cover.
Figure 8-81
5. Hoist out the rear cover.
Figure 8-82
6. Disconnect the engine hood from expansion
water tank.
Figure 8-83
7. Disconnect the muffler from exhaust pipeline.
Figure 8-84
8. Disassemble the fastening bolts of engine
hood.
Figure 8-85
8-34
9. Hoist out the engine hood.
Figure 8-86
10. Disassemble the bolts from two sides of
hydraulic oil tank cover plates.
Figure 8-87
11. Hoist out the cover plate.
Figure 8-88
842 Assembly of Engine Hood
1. Hoist the engine hood, align the threaded
holes, and lower the engine hood.
Figure 8-89
8-35
2. Tighten the fastening bolts of engine hood.
Figure 8-90
3. Fix the expansion water tank to the engine
hood.
Figure 8-91
4. Properly connect the exhaust pipeline.
Figure 8-92
5. Hoist the hydraulic oil tank cover plate to the
installation position and tighten the bolts.
Figure 8-93
8-36
6. Hoist the rear cover to the installation position
and tighten the bolts.
Figure 8-94
7. Connect the harness.
Figure 8-95
8. Install the rear cover side plate.
Figure 8-96
8-37

A/C System
Start the machine, drive to a level and spacious
ground, place the wood wedges in the front of
front wheels and in the rear of rear wheels to
block the wheels, lower the bucket horizontally
onto the ground, and stop the engine.
851 Disassembly of Ventilation
System
1. Drain the engine coolant (approximate 28L)
into a clean container.
2. Open the lock pin of A/C cover assembly.
Caution
Conduct the disassembly and assembly in a

1 well ventilated place and avoid the direct
Figure 8-97
contact with refrigerant.
1. Lock pin
3. Disassemble the filter.
1 2
Figure 8-98
1. Fresh air filter screen subassembly
2. Return air filter screen subassembly
8-38
4. Disconnect the thermostat panel from the fresh
air vent motor harness.
1 2
Figure 8-99
1. Filter cap
2. Air vent motor harness
5. Disconnect the thermostat panel from the
evaporator assembly harness and disconnect
the evaporator power harness.
1 2 3
Figure 8-100
1. Power harness
2. Thermostat panel harness
3. Thermostat panel
8-39
6. Disconnect the hoop between the engine
heater water pipe and evaporator.
7. Disassemble the connecting bolts between
evaporator and cab.
1 2
Figure 8-101
1. Hoop
2. Bolt
8. Disassemble two connecting bolts within the
right interior trim panel of cab from the
evaporator assembly.
1 2
Figure 8-102
1. Interior trim panel
2. Bolt hole
9. Disassemble the evaporator assembly and
place in an appropriate position.
1
Figure 8-103
1. Evaporator assembly
8-40
852 Assembly of Ventilation System

1. Install the evaporator assembly.
2. Connect the evaporator air outlet hose and
cab air inlet hose.

Caution
Ensure the correct directions of air inlet and outlet and
1 keep them non-blocked.

Figure 8-104
1. Evaporator assembly
3. Install the hoop between the engine heater
water pipe and evaporator.
4. Install the connecting bolts between
evaporator and cab.
1 2
Figure 8-105
1. Hoop
2. Bolt
5. Connect the thermostat panel and fresh air
vent motor harness.
6. Connect the evaporator power harness.
1 2 3
Figure 8-106
1. Power harness
2. Thermostat panel harness
3. Thermostat panel
8-41
7. Connect the connecting bolts within the cab
interior trim panel with the evaporator
assembly. .
1 2
Figure 8-107
1. Interior trim panel
2. Bolt hole
8. Connect the thermostat panel and fresh air
vent motor harness.
9. Tighten the filter cap with bolts.
1 2
Figure 8-108
1. Filter cap
10. Close the lock pin of A/C cover assembly.
11. Add the coolant.
1
Figure 8-109
1. Lock pin
8-42
853 Replacement of Evaporator Parts

Caution
The replacement evaporator parts shall be the
products of same model from same
manufacturer. Check to ensure that the
replacement parts conform to all technical
requirements. The A/C parts contain nitrogen.
To prevent the ingress of dirt or moisture into
the system, remove the cap and immediately
connect the pipeline. When the pipeline is
opened, attach the plug. If not available, wrap
with multiple layers of plastic cloth.
Replacement of heat exchanger
1. Disassemble the evaporator from the machine
and place on a platform. Refer to the
Disassembly and Assembly of Ventilation

1 2 System.
Figure 8-110
1. Evaporator 2. Disassemble the fixing plate installed on the
2. Fixing plate right side of the evaporator.
3. Disassemble all clamps and break up the
housing.
1
Figure 8-111
1. Clamp
8-43
4. Take out the heat exchanger and replace with
new one.
5. Reinstall the housing and fix all clamps.
Caution
Check and ensure that the fan is installed in
correct position.
1 6. Reinstall the ventilation system.
Figure 8-112
1. Heat exchanger
Replacement of fan
System.
2. Disassemble the fixing plate installed on the

1 2
Figure 8-113 right side of the evaporator.
1. Evaporator
2. Fixing plate
3. Disassemble all clamps from the evaporator
housing
1
Figure 8-114
1. Clamp
8-44
4. Disconnect the harness, take out the fan, and
replace with new one.
5. Reinstall the housing and fix all clamps.

Caution
Check and ensure that the fan is installed in
correct position.
1 6. Reinstall the ventilation system.
Figure 8-115
1. Fan
Replacement of expansion valve
Warning
The refrigerant will cause damages. Guard the
unprotected skin against direct contact with
refrigerant. Please wear the protective gloves.
1. Fully drain the refrigerant from the system.
Refer to the Drainage of Refrigerant.
2. Disassemble the filter cap and filter and
disconnect the thermostat panel and fresh air
1 2 vent motor harness.

Figure 8-116
1. Filter cap
3. Disassemble the filter cap and evaporator
right fixing plate.
1 2
Figure 8-117
1. Fixing plate
2. Pressure sensor connector
8-45
4. Disconnect the pipeline from the expansion
valve, disassemble the expansion valve, and
plug the connectors.
5. Take out the plugs and install new expansion
valve.
Caution
1 Keep clean the internal chambers of expansion

Figure 8-118
1. Expansion valve valve and lubricate the seal rings with
compressor oil.
6. Connect the expansion valve pipeline.
7. Insert the pressure sensor connector.
8. Install the fixing plate.
9. Add refrigerant.
1 2
Figure 8-119
1. Fixing plate
2. Pressure sensor connector
10. Install the filter cap and air vent motor
harness.
1 2
Figure 8-120
1. Filter cap
8-46
Replacement of temperature sensor
System.
1 2
2. Disassemble the fixing plate installed on the
Figure 8-121
1. Evaporator right side of the evaporator.
2. Fixing plate
3. Disassemble the clamps of evaporator
assembly and break up the housing.
1
Figure 8-122
1. Clamp
4. Unplug the temperature sensor connector
located between the heating filter element and
refrigeration filter element.
1 2
Figure 8-123
1. Temperature sensor connector
8-47
5. Install the evaporator assembly housing and
right fixing plate.
1
Figure 8-124
1. Fixing plate
6. Install the filter cap and air vent motor
harness.
7. Close the lock pin of A/C cover.
1 2
Figure 8-125
1. Filter cap
Replacement of evaporator
Warning
The refrigerant will cause damages. Guard the
unprotected skin against direct contact with
refrigerant. Please wear the protective gloves.
1. Open the evaporator assembly cover.
2. Fully drain the refrigerant from the system.
Refer to the Drainage of Refrigerant (page
8-62).
1 2 3. Disassemble the filter and filter cap.

Figure 8-126
4. Disconnect the air vent motor and thermostat
1. Filter cap
2. Air vent motor harness panel harness.
8-48
5. Disassemble the fixing plate located on the
right side of the evaporator.
6. Unplug the temperature sensor.
1
Figure 8-127
1. Fixing plate
7. Disassemble the housing clamps, take out the
evaporator, and move it aside.
1
Figure 8-128
1. Evaporator
8. Loosen the bolts and install new evaporator.
Caution
Keep clean the internal chambers of
evaporator and lubricate the seal rings with
compressor oil.
9. Insert the temperature sensor.

1
Figure 8-129 10. Install the evaporator housing.
1. Fixing plate
11. Install the right fixing plate of evaporator.
8-49
12. Install the filter cap, filter, and air vent motor
harness.
1 2
Figure 8-130
1. Filter cap
13. Add refrigerant.
1
Figure 8-131
1. Filling hose
8-50
854 Replacement of Condenser Fan

1. Disassemble the peripheral bolts of condenser
cap.
2. Unplug the fan motor connector, disassemble
the condenser cover along with the fan, and
place on a pad.
1
3. Loosen four connecting bolts of condenser fan.
Figure 8-132
1. Bolt (8 pieces) Caution
Pay attention to the middle nuts.

4. Tighten four connecting bolts after
replacement with new fan.
Caution:
While installing new fan, place the fan harness

into the socket.
5. Install the condenser cover along with the fan
1 2
Figure 8-133 onto the condenser.
1. Condenser fan bolt 6. Restore the machine.
2. Fan harness
855 Replacement of Fluid Reservoir
1. Drain the refrigerant.
2. Disassemble the fluid reservoir-evaporator
pipe from the fluid reservoir and properly
protect the ports of fluid reservoir-compressor
pipe.
3. Disassemble the upper condenser pipe from

1 2 3
Figure 8-134 the fluid reservoir and properly protect the
1. Fluid reservoir - evaporator pipe ports of condenser pipe.
2. Fluid reservoir
3. Condenser pipe
8-51
4. Disassemble the lower condenser pipe from
the fluid reservoir and properly protect the
ports of condenser pipe.
5. Loosen the fastening bolts between fluid
reservoir bracket and the condenser and take
out the fluid reservoir.
1 2 6. After the replacement with new fluid

Figure 8-135 reservoir, connect the fluid
1. Bolt
2. Condenser pipe reservoir-evaporator pipe and the condenser
pipe. It’s prohibited to remove the plugs until
immediately before the connection of pipes.
7. Install the fastening bolts of fluid reservoir.
8. Add refrigerant
856 Replacement of Compressor

Parts
Caution
The replacement evaporator parts shall be the
products of same model from same
manufacturer. Check to ensure that the
replacement parts conform to all technical
requirements.
The A/C parts contain nitrogen. To prevent the
ingress of dirt or moisture into the system,
remove the cap and immediately connect the
pipeline. When the pipeline is opened, attach
the plug. If not available, wrap with multiple
layers of plastic cloth.

Replacement of compressor belt
8-52
1. Place the machine to maintenance position.
3. Loosen the connecting bolts and adjustment
screw and take out the belt.
4. Install new belt, adjust the belt tension, tighten
with connecting bolts, and adjust to
1 2 appropriate belt tension in such manner that

Figure 8-136 the belt deflection is 10~12mm when an
1. Belt
2. Adjustment screw approximate 10kg force is applied onto the
belt. After the adjustment, tighten the
compressor.
5. Restore the machine and test run the A/C
system.
Replacement of compressor
2. Drain the refrigerant from the system.
3. Release the belt tension and then disassemble
the belt. Unplug the clutch harness connector.
4. Loosen the compressor-condenser pipe and
the evaporator-compressor pipe from the
compressor, move aside and properly fix the

1 2
Figure 8-137 pipes, and properly protect the ports of
1. Compressor-condenser pipe condenser pipe. 。
2. Evaporator-compressor pipe
5. Loosen and disassemble the fastening bolts of
compressor and disassemble the compressor.
6. Drain excessive compressor oil into a
graduated flask with minimum volume at
250ml.
8-53
Caution
Dispose the leaking compressor oil in an
environmental-friendly manner.
7. Replace with new compressor. A new
compressor is prefilled with approximate
240ml compressor oil. Drain fully all
compressor oil from new compressor.
8. Add the compressor oil of same amount with
that drained from the used compressor into
the new compressor.

1 9. Use connecting bolts to install new
Figure 8-138
compressor, but do not tighten the bolts.
1. Belt
10. Unplug the plugs from the refrigerant pipe
and compressor, install refrigerant pipe and
new O-ring on the compressor, and lubricate
the O-ring with compressor oil.
11. Insert the connector and then install the
refrigerant pipe clamp.
12. Reinstall the belt onto compressor, adjust its
position till the clutch belt groove of the
compressor is within one same plane with the
engine belt groove, and adjust to appropriate
1
belt tension.
Figure 8-139 13. Re-add the refrigerant.
1. Filling hose
8-54
857 Drainage and Adding of

Refrigerant
Drainage of refrigerant
Tools
Refrigerant device Vacuum pump
Adapter AC leak tester
Hose Platform scale
1. Place the refrigerant cylinder on the platform

1
scale.
Figure 8-140
1. Drainage hose Ensure that the refrigerant cylinder for drainage of
refrigerant is large enough.

1 2 3 4
Weigh the refrigerant cylinder. The weight of
refrigerant cylinder after the drainage - weight of
refrigerant cylinder before the drainage = weight
of refrigerant.
Read the amount of refrigerant cylinder capable of
being filled from the refrigerant cylinder.
2. Ensure that the recovery device is free of
pressure.
3. Connect the red hose at the position
“Drainage” of recovery device to the
refrigerant cylinder.
Connect the blue hose at the position “Suction” to
the low pressure connector of the machine
compressor.
5 6 7 8
Figure 141
1. Platform scale display unit
2. Suction
8-55
3. Central controller Drainage

4. Drainage
5. Refrigerant cylinder valve 4. Open the red hose valve on the refrigerant
6. Red hose valve cylinder.
7. Refrigerant cylinder
Open the valve on the refrigerant cylinder.
8. Platform scale
Open the valve “Drainage” on the recovery
device.
Rotate the central controller to “Recovery”.
Start the recovery device by switch to start the
drainage.
Open the blue hose valve by the low pressure
connector of the machine.
Open the valve “suction”.
5. When the weight is increased no more, check
whether the pressure is lower than the
vacuum pressure indicated on the pressure
gauge.
6. Close the valve “Suction”.
Close the blue hose valve by the low pressure
connector of the machine.
Rotate the central controller to “Automatic
Cleaning” so that the reading of blue pressure
gauge drops to vacuum pressure.
Close the recovery device by switch.
Close the refrigerant cylinder valve.
Close the valve “Drainage”.
7. Disconnect the recovery device from the
machine.
Vacuumization of vacuum pump and adding of
refrigerant
8-56
Tools
Refrigerant device
Adapter
Vacuum air bleeding
1. Close all valves on the pressure gauge cabinet.
2. Connect the red hose to the high pressure
connector of machine.
Open the hose valve by machine connector.
3. Connect the blue hose to the low pressure
Open the hose valve by machine connector.

1 2
Figure 8-142 4. Connect the yellow hose to the refrigerant
1. Red hose
2. Blue hose cylinder.
Overturn the refrigerant cylinder on the platform
scale.
Check the refrigerant cylinder for presence of
refrigerant. The weight of refrigerant cylinder -
refrigerant cylinder = amount of refrigerant.
5. Open two green valves on the pressure gauge
cabinet.
Start the vacuum pump.
6. Open the blue and red valves on the pressure
gauge cabinet.
Start the vacuum pump. Run the vacuum pump for
at least 50min.
8-57
7. When the correct pressure is reached, close
two green valves and the red and blue valves
on the pressure gauge cabinet.
Stop the vacuum pump.
Disconnect the hoses from the machine.
Adding
8. Connect the adapter to the low pressure
1 2 3 4 connector of the machine and add the oil of

Figure 143 the same amount with that consumed by the
1. Refrigerant cylinder
2. Platform scale system.
3. Vacuum gauge
Disassemble the adapter.
4. Vacuum pump
9. Connect the red hose to the high pressure
Connect the blue hose to the low pressure
10. Press the TARA on the display unit of scale
(reset the scale).
Open the valve on the refrigerant cylinder.

1
Open the yellow valve on the pressure gauge
Figure 8-144
1. Adapter cabinet.
11. Open blue valve and start the adding.
12. Start the engine when the AC power supply is
turned on. Run the engine at 1000rpm.
13. When the correct refrigerant amount is
displayed on the platform scale, close the
refrigerant cylinder valve (Refer to the
information on the inner side of the machine
port).
8-58
Close the yellow valve on the pressure gauge
cabinet.
14. Close the hose valve by machine connector.
Close all valves on the pressure gauge cabinet.
15. Open the red and blue hose valves by
machine connector and check the pressure at

1 2 1800rpm.
Figure 8-145
1. Red hose 16. Disconnect the red and blue hoses from the
2. Blue hose machine.
86 Diagnosis and Troubleshooting for Common Malfunctions of A/C

System
During the malfunction checking and repair of A/C system, make sure to find out the cause for
abnormal working based on the running abnormality of A/C and then take corresponding measures.
The common malfunctions of A/C system include the refrigeration failure, insufficient refrigeration
output, and heating failure.
861 Periodical Checking Items

The A/C system of loader is working under harsh environment and will be probably damaged, no
matter it’s running or not. Therefore, make sure to enhance the maintenance works at ordinary
times.
Frequently check the pipeline connectors of the A/C system, check the compressor fixing bracket,
and check the compressor belt for appropriate tension. In addition, pay attention to observe the
hoses of refrigeration system for presence of wear, check the harnesses of A/C system, and keep
clean the surfaces of the condenser.
8-59
Table 8-1 Table of Periodical Checking Items

Checking time
Checking item Checking description
Daily Half year Yearly
Poor retaining, with gap ▲ ▲
Pipeline assembly Loose connection and loose nuts and
▲ ▲
bolts
Loose connection and loose or fallen
Connecting bolt ▲ ▲
nuts and bolts
Looseness and bending ▲ ▲
Deterioration, wear, damage, and
Belt ▲ ▲
cracking
Noise, with abnormal smell or heating ▲
Condenser Bent radiator fins ▲
assembly Blockage by foreign material ▲ ▲ ▲
Start checking, fan speed, and switch
A/C fan speed ▲ ▲
control
switch
Switching function ▲ ▲
Leakage of Leakage at pipeline connection ▲ ▲
refrigerant. Internal leakage of parts ▲
Refrigerant amount Check the refrigerant amount ▲ ▲
Compressor ▲
Noise
Condenser fan and evaporator fan ▲
Temperature
difference of The surface with temperature difference
▲
storage and drying indicates blockage by foreign material.
tank
8-60
862 Analysis of Refrigeration Failure Malfunction
Table 8-2 Analysis Table of Refrigeration Failure Malfunction

Check the fan connector
Failure of for falloff and good
compressor grounding and check fan
for damage.
No rotation of
Check temperature
condenser fan
control switch for
Rotation of Running of
damage, check relay for
evaporator fan compressor
actuation, and check relay
connectors for looseness
Check clutch for damage,
Rotation of Failure of check wiring connectors
condenser fan compressor for falloff, and check belt
Refrigeration
for looseness and slip.
failure
Rotation of
Check fan speed switch for failure, check
condenser fan
fan wires for open-circuit, and check fan
and running of
for good grounding wire.
No rotation of compressor
evaporator fan No rotation of
Check fuse for burnout, check relay for
condenser fan
normal functioning, and check for loose
and failure of
wiring.
compressor
Normal running There is leakage of R134a in system due
Normal
of evaporator fan to non-running for a long period. Check
running of
and condenser with high and low pressure gauge to
compressor
fan determine the presence of R134a.
8-61
863 Analysis of Insufficient Refrigeration Output

Table 8-3 Analysis Table of Insufficient Refrigeration Output Malfunction
Normal running Reversely connected inlet and outlet of
of evaporator fan fluid reservoir
and condenser Check expansion valve for presence of ice
fan and normal blockage or dirt and replace fluid
Insufficient Normal
functioning of reservoir.
refrigeration running of
evaporator and
output compressor Replace R134a.
condenser
Normal running
Check whether the condenser surfaces are
of fan and all
blocked by deposited dirt
others
864 Analysis of Heating Failure Malfunction

Table 8-4 Analysis Table of Heating Failure Malfunction
Normal running of Check solenoid valve for actuation. Check whether there
evaporator fan is any other valve not opened in heating pipeline.
Heating
Check fan speed switch for failure, check fan wires for
failure Working failure of
open-circuit, and check fan for good grounding wire.
evaporator fan
Check fuse for burnout and check for loose wiring.
8-62
865 Analysis of Other Malfunctions

Table 8-5 Analysis Table of Other Malfunction Items
Phenomenon Cause Troubleshooting
The refrigeration performance is good at
the beginning. After one period, the The connectors are loosed Find out the leakage point
refrigeration output is insufficient, there are due to vibration after with leak tester and
1
air bubbles in the observation port of fluid frequent traveling on rough carefully tighten the
reservoir, and the reading is low on both roads, leading to leakage. loosened point.
high pressure and low pressure gauges.
No refrigeration of A/C system, hot air
Improper use. The sensing
output from air vents, no temperature
bulb of expansion valve is Replace expansion valve
2 difference by hand touch between inlet and
worn to cause leakage and and refill R134a.
outlet of expansion valve, and very low
close valve orifice.
reading on low pressure gauge
Intermittently turn on the
refrigeration system to
The system contains eliminate the instant
The air output at air vents is not cool and
impurities, the expansion blockage, provided the
the compressor temperature is increased.
valve filter screen is blocked, blockage is not serious.
3 The pointer of low pressure gauge drops
and there is thin frost or Alternatively, disassemble
rapidly to near 0 and the reading on high
condensate at expansion the expansion valve, clean
pressure gauge is too high.
valve. it with alcohol, fully drain
the system, and refill
R134a.
The refrigeration output is insufficient, the
The throttling orifices within Fully drain the system,
evaporator is frosted, and the reading is too
4 expansion valve are not replace expansion valve,
low on both high pressure and low pressure
functioning. and refill R134a.
gauges.
After one-period running of the system, the The desiccant within fluid
refrigeration output is reduced gradually, reservoir is saturated and the Fully drain the system,
5 the reading of high pressure gauge is too throttling orifices of the replace fluid reservoir, and
high, and the reading of low pressure gauge expansion are blocked by refill R134a.
is less than 0.4MPa. ice.
Use a multimeter to check
After the refrigeration system is turned on, Poor contact of temperature
the temperature control
there is only output of air, but no cool air, control switch or damage of
6 switch for damage and
and the readings of high pressure and low compressor electromagnetic
replace compressor
pressure gauges are still. clutch coil.
electromagnetic clutch.
The opening extent of
The compressor electromagnetic clutch acts
temperature control switch is
frequently, with short actuation time, the Check the temperature
too small, leading to
7 interior temperature is not reduced, and the control switch and turn to
automatic stop of compressor
readings of high pressure and low pressure the coolest position.
and insufficient refrigeration
gauges are normal.
output.
8-63
Please pay attention during the checking and repair or refrigeration system:
1. During the checking and repair, wear the protective goggles or mask whenever possible.
Avoid the direct contact with refrigerant, or it will cause cold injury to human body. In
event of contact with a great amount of refrigerant, flush with cool water immediately.
2. The repair of refrigeration system shall be conducted in a well ventilated area, as the
refrigerant is a colorless and odorless substance and can cause suffocation due to hypoxia.
3. The refrigerant will generate toxic phosgene while coming into contact with open fire.
Keep away from fire source.
4. To prevent explosion danger, do not conduct welding in the vicinity of A/C pipelines or
parts or clean with hot steam.
5. At the replacement of system parts, keep clean the system connectors and chambers. At
the replacement of system parts, add the refrigerant oil as per the criterion shown in
Table 8-7.
Table 8-7 Amount of Refrigerant Oil

Part Name Adding amount/mL
Evaporator 40～50
Condenser 40～50
System connecting hoses 30～40
Fluid reservoir 15～25
6. After the replacement of A/C parts, tighten the pipeline connectors to the specified tightening
torque, as shown in Table 8-8.
Table 8-8 Tightening Torque

Thread size Tightening torque
5/8-18UNF、M16×1.5 16～20N·m
3/4-16UNF、M22×1.5 20～25N·m
7/8-14UNF、M24×1.5 30～35N·m
8-64
Contents
9 Working Hydraulic System.................................................................................................................... 9-1
91 System Overview .................................................................................................................................... 9-1
911 Description of System Principle ......................................................................................................... 9-3
92 Principle and Disassembly/Assembly of Main Units ...........................................................................9-11
921 Working Pump ..................................................................................................................................9-11
922 Hydraulic Oil Tank .......................................................................................................................... 9-18
923 Multi-Way Valve ............................................................................................................................. 9-28
924 Rotary Control Valve ....................................................................................................................... 9-37
925 Central Rotary Joint......................................................................................................................... 9-45
926 Hydraulic Cylinder .......................................................................................................................... 9-55
927 Other Hydraulic Units ..................................................................................................................... 9-67
93 Pressure Measuring Point and Criterion of Working Hydraulic System ......................................... 9-71
94 Air Bleeding of Hydraulic System ........................................................................................................ 9-72
95 Malfunction Diagnosis of Working Hydraulic System ....................................................................... 9-73

9 Working Hydraulic System

91 System Overview
The working hydraulic system of this machine is a fixed displacement dual-pump and dual-circuit
open-type system and is composed of one enclosed oil tank, two high pressure gear pumps, two
multi-way reversing valves and hydraulic cylinders, and rotary valves, and related pipelines. The
system pressure is controlled by the internal pressure valve of the multi-way valve. The system
pressure setting is 21MPa. The hydraulic locks installed on the front wheel tilting cylinder and the
front and rear frame articulation cylinder and the balance valves on the blade oscillating cylinder
and blade lifting cylinder can prevent the displacement arising from the own weight and the load of
the machine and guarantee the traveling safety of the machine and working accuracy of the blade.
The working device of the grader is powered by two high pressure gear pumps installed at the
power takeoff port of the transmission. The left main pump supplies high pressure oil to the left
multi-way valve and right main pump supplies high pressure oil to the right multi-way valve to
realize the stable scraping and accurate working adjustment of grader and at the same time prevent
the working malfunction of entire machine due to malfunction of individual pump.
The swing of blade is achieved in such manner that the rotary valve + dual-cylinder oscillate to
drive the pinion engaged with rotary ring gear to drive the rotation of entire rotary gear ring.
Hydrauli
c oil tank
Radiator Working
pump
Multi-wa Multi-wa
y valve y valve
Working
devices
Figure 9-1 Flow Route of Hydraulic Oil
9-1
9-2
Figure 9-2 Schematic Diagram of Working Hydraulic System

1. Oscillating of blade 2. Articulated steering 3. Tilting of front wheels 4. Mouldboard 5. Lifting of blade 6. Swing
cylinder 7. Change of blade angle 8. Extraction of blade 9. Ripper 10. Lifting of blade
I. Steering hydraulic system II. Brake hydraulic system III. Central swing joint IV. Rotary control valve
911 Description of System Principle

Left/right lifting and lowering of blade
The blade lifting cylinders are controlled by left and right multi-way valves respectively, for which
the oil is supplied by two constant flow circuits. Therefore, two blade lifting cylinders can basically
synchronize at same speed, which promotes the working accuracy of the grader. The balance valves
installed on the cylinders can effectively prevent the displacement arising from the own weight and
the load of the machine and guarantee the traveling safety of the machine and working accuracy of
the blade.
Figure 9-3 Left/Right Lifting/Lowering of Blades
1. Right blade lifting cylinder 2. Left blade lifting cylinder 3. Right multi-way valve
4. Left multi-way valve 5. Balance valve
Oscillation of blade
The blade oscillating cylinder is powered by the 5th valve group of the right multi-way valve.
Refer to page 9-62 for relevant descriptions of the balance valves.
9-3
Figure 9-4 Oscillation of Blade
1. Blade oscillating cylinder 2. Right multi-way valve 3. Balance valve
Change of blade angle and lateral extension of blade
The blade tilting angle cylinder and the blade extraction cylinder are powered by the 4 th and 3rd
valve groups of the left multi-way valve respectively and are connected through the central rotary
joint of the working device. The rotary joint prevents the hydraulic pipelines of two cylinders from
being intertwined during the swing of the blade.
Please refer to page 9-42 for relevant descriptions of the central rotary joint.
Figure 9-5 Change of Blade Angle and Lateral Extension of Blade
1. Left multi-way valve 2. Central rotary joint 3. Blade angle cylinder 4. Blade extraction cylinder
9-4
Titling of front wheels
The front wheel tilting cylinder is powered by the 3rd valve group of right multi-way valve. The
hydraulic lock is functioned for stabilization in the front wheel tilting circuit, in order to eliminate
the shimmy of front wheels and front frame during the traveling of the machine.
Refer to page 9-62 for related descriptions of hydraulic lock.
Figure 9-6 Tilting of Front Wheels
1. Hydraulic lock 2. Front wheel tilting cylinder 3. Right multi-way valve
Articulated steering
The articulated steering cylinder is powered by the 4th valve group of right multi-way valve. The
balance valves are functioned for stabilization in the articulation of front and rear frames and during
working, in order to eliminate the torsion of front and rear frames due to offset load during traveling
or working of machine.
Refer to page 9-62 for relevant descriptions of the balance valves.
9-5
Figure 9-7 Articulated Steering
1. Right multi-way valve 2. Balance valve 3. Articulated steering cylinder
Swing of blade
The hydraulic oil for the swing control of blade is supplied by the 5th valve group of left multi-way
valve and is distributed to two swing cylinders via rotary control valve. Two hardened pinions
driven by the swing cylinders drive the rotation of rotary ring gear to realize the swing of blade.
The swing structure of this machine is different from the motor + worm reducer adopted by other
manufacturers both home and abroad and adopts dual-cylinder swing drive mechanism. To enable
the continuous swing of the swing frame, the drive cranks of the left and right swing cylinders are
arranged in a spacing of 90º. Two hardened pinions drive the swing of the swing frame and the
valve core of the rotary control valve is driven by the rotary valve gear to swing, in order to provide
appropriate connected oil lines to two cylinders and guarantee the continuous swing.
Refer to page XX for related description of crossed relief valve.
Refer to page 9-38 for related description of rotary control valve.
9-6
Figure 9-8 Swing of Blade
1. Left multi-way valve 2. Rotary control valve 3. Swing cylinder 4. Crossed relief valve
Lifting/lowering of mouldboard (optional module)
The mouldboard cylinder is powered by the 2nd valve group of the right multi-way valve. This
attachment is an optional module and is not available in standard model. If the mouldboard is not
fitted, the corresponding oil ports of the multi-way valve are sealed by screw plugs.
Figure 9-9 Lifting/Lowering of Mouldboard
1. Right multi-way valve 2. Mouldboard cylinder
9-7
Lifting/lowering of rear ripper (optional module)
The rear ripper cylinder is powered by 2nd valve group of left multi-way valve. This attachment is
an optional module and is not available in standard model. If the ripper is not fitted, the
corresponding oil ports of the multi-way valve are sealed by screw plugs.
Figure 9-10 Lifting/Lowering of Rear Ripper
1. Left multi-way valve 2. Ripper cylinder
Lifting/lowering of middle ripper (optional module)
The middle ripper cylinder is powered by 2nd valve group of right multi-way valve. This attachment
is an optional module and is not available in standard model. If the ripper is not fitted, the
corresponding oil ports of the multi-way valve are sealed by screw plugs.
9-8
Figure 9-11 Lifting/Lowering of Middle Ripper
1. Right multi-way valve 2. Middle ripper cylinder
Locking cylinder
The locking cylinder is powered by refilling valve port A of brake hydraulic system. The oil flows
into the electromagnetic reversing valve and the rocker switch within the cab controls the reversing
of the solenoid valve to realize the extension and retraction of locking cylinder piston rod.
Res
erv
ed
Figure 9-12 Locking Cylinder
1. Locking cylinder 2. Electromagnetic reversing valve 3. Locking cylinder action switch
9-9
Floating of blade (Replaceable module)
The floating function of the blade is to realize the floating function of blade by replacing the
balance valve in the standard model with floating balance valve and controlling via duplex solenoid
valve the connection/disconnection of oil flow from port A of refilling valve to floating port of
floating balance valve. The floating functions of the left and right blade lifting cylinders are
controlled by two rocker switches in the cab respectively.
Refer to page 9-63 for related description of duplex solenoid valve.
Refer to page 9-62 for related description of floating balance valve.
4
1
2
6
7 8
Figure 9-13 Floating of Blade
1. Right blade lifting cylinder 2. Left blade lifting cylinder 3. Floating balance valve
4. Oil return block 5. Duplex solenoid valve 6. Refilling valve
7. Right cylinder floating switch 8. Left cylinder floating switch
9-10
92. Principle and Disassembly/Assembly of Main Units
921 Working Pump

Nominal displacement 32ml/r
Rated/maximum pressure 25/31.5Mpa
Rated/maximum speed 2200/2500 r/min
Capacity efficiency ≥0.92
Number of teeth 14
Figure 9-14 Working Pump
Principle of working pump
When the upper gear of the working pump is rotate in the direction shown in the figure, the volume
of the oil suction chambers is increased to form vacuum pressure so that the oil in the oil tank is
sucked into the oil suction chamber through oil suction pipe of the pump to fill the gaps of teeth
under the action of the barometric pressure. The volume of oil compression chamber is reduced to
press the oil into pressure oil line.
Oil Oil inlet

outlet
Figure 9-15 Principle of Working Pump
9-11
Composition of working pump
Figure 9-16 Composition of Working Pump

1. Retainer ring 2. Retainer ring 3. Rolling bearing 4. Rotary shaft lip seal
5. Front cover 6. Bearing 7. Rectangular seal ring 8. Gasket
9. Lugged retainer ring 10. Lugged seal 11. Side plate 12. Drive gear shaft
13. Driven gear shaft 14. Rivet 15. Nameplate 16. Rear cover 17. Bolt
Malfunction diagnosis of working pump
Table 9-1
Measure pressure and
Reduced hydraulic oil and
1 Damage of oil seal replace oil seal or working
increased transmission oil
pump
Increased hydraulic oil and
2 Damage of oil seal replace oil seal or working
reduced transmission oil
pump
Oil leakage at junction surface Damage of O-ring or Replace O-ring or tighten
3
of pump body looseness of bolts bolts
4 Oil leakage of pump body Cracking of pump body
replace working pump
9-12
Table 9-1 Continued

Excessive wear of spline Replace spline shaft or
shaft working pump
Excessive wear of side Replace side plate or
plate working pump
Abnormal noise of working
5 Out-of-tolerance of spline
pump Replace spline shaft or
shaft, interfering with the
working pump
shaft
Replace bearing or
Damage of bearing
working pump
Insufficient flow of working
Excessive wear of gear or Replace corresponding
6 pump, leading to slow
side plate part or working pump
movement of cylinder
Disassembly of working pump

Caution
1. Before the disassembly or installation of the working pump, please park the grader at an
appropriate maintenance position (Refer to page 8 of Safety and Environment).
2. During the disassembly of oil pipes, instead of screwing off all bolts hastily, slightly loosen
the bolts till the oil overflows, in order to prevent the splashing of oil due to incomplete
unloading of oil.
3. During the disassembly of hydraulic system, it’s necessary to take necessary protection
measures for all pipelines and oil ports to guard against the ingress of foreign material
(such as dust) into the hydraulic system.
residual oil overflowed during the disassembly of pipelines. At completion of the repair,
pour the hydraulic oil collected into the special hydraulic oil recycling tank.
5. At the time of assembly, please make sure to replace with new seals and strictly tighten to
the torque specified in the relevant standard in page 0~7 of this maintenance manual.
9-13

1 2 filler cap can speed up the drainage of
Figure 9-17 hydraulic oil).
1. Oil drainage valve
2. Hose  Caution
Cover the oil drained to prevent
contamination.
2. Disassemble the fastening bolts of the cover
plate, as shown in the figure, and take out
the bolts and cover plate.
Cover plate
Figure 9-18
1. Cover plate
2. Cover plate
working pump oil suction pipe and working
pump, take out the screws and split flange,
and then take out the oil suction pipe and
O-ring.
Figure 9-19
1. Working pump oil suction pipe
9-14
4. Disconnect the working pump oil outlet
hose from straight connector.
Figure 9-20
1. Connecting straight connector of working
pump oil outlet hose
5. Take out the connecting straight connector
of working pump oil outlet hose and
O-ring.
1 2
Figure 9-21
1. Working pump oil outlet hose
2. O-ring
6. Screw off the fastening nuts between
working pump and power takeoff port of
transmission and torque converter assembly
and take out the nuts and washers.
7. Hoist the working pump with lifting slings
and use a copper bar to lightly knock the

1 2 gear pump towards the outer side to take
Figure 9-22
out the working pump and sealing gasket.
1. Nut
2. Sealing gasket Working pump
9-15
8. Disassemble the fastening screws of
working pump straight connector and take
out the screws, split flange, and straight
connector.
Assembly of working pump
1. Use four screws and split flange to connect
the straight connector to the oil outlet port
of working pump.
2. Use four M12 bolts and washers and sealing
gasket to install the working pump to the
end face of the transmission.

1 2
Figure 9-23 Working pump
1. Bolt
2. Sealing gasket
3. Connect the working pump oil outlet hose to
straight connector.
1
Figure 9-24
1. Connecting straight connector of working
pump oil outlet hose
9-16
4. Install O-ring to the pipe connector O-ring
slot of the working pump oil suction pipe
and use four M10×30 screws and split
flange to tighten to the end face of working
pump oil suction port.
Figure 9-25
1. Working pump oil suction pipe
5. Use bolts to install the cover plate to
corresponding position.
Cover plate
1 2
Figure 9-26
1. Cover plate
2. Cover plate
Figure 9-27
1. Oil filler port
9-17
922 Hydraulic Oil Tank

It's functioned to supply oil to entire hydraulic system. In this machine, it’s also functioned to
supply oil to the brake system. The oil return filter is fitted in the oil tank to remove the impurities
from hydraulic system and maintain the cleanliness of the hydraulic oil.
Figure 9-28 Composition of Hydraulic System
1. Bolt 2. Washer 3. Oil filler filter element 4. Round oil leveler 5. Tank body 6. Bolt 7. Thick washer
8. Washer 9. Nut 10. Oil drainage connector 11. Ball valve 12. Oil drainage connector 13. O-ring
14. Oil return flange 15. Ring magnet 16. O-ring 17. Oil suction flange 18. Washer 19. Bolt
20. Sealing gasket 21. Oil suction filter element assembly 22. O-ring 23. Screw plug 24. Breather filter
25. Oil return filter 26. Bolt
9-18
The hydraulic oil tank is fitted with following units:
1. Breather filter: Due to thermal expansion and shrinkage of hydraulic oil within the oil tank, the
hydraulic oil tank must be connected with the open air. The breather filter is the medium to the
open air. It’s dehumidifying and dedusting design keeps clean and dry the air into the machine
and effectively guarantees the cleanliness of hydraulic oil.
2. Oil level gauge: It’s functioned to observe the oil amount in the oil tank.
3. Oil return filter: It’s functioned to filter the contaminants from the oil. When the filter element
contains excessive contaminants to cause over-high pressure difference of filtered oil, the
bypass valve in the filter opens so that the oil flows through the bypass valve to guarantee
normal working of hydraulic system. At the same time, the pressure difference relay sends
signal and the indicator lamp in the cab lights up for alarm. In such case, replace the filter
element immediately.
Oil suction filter Oil filler filter element Oil return filter
element assembly
9-19
Breather filter Level gauge
Procedure for replacement of hydraulic oil:
1. Lower the blade onto ground and lift the mouldboard to the top end.
2. Stop the engine and operate the control lever to lower the mouldboard onto the ground.
3. Screw off the oil drainage plug on the bottom of oil tank to fully drain the oil into a container
and then tighten the plug.
4. Open the oil return filter cover and add specified hydraulic oil, till the oil level reaches the
middle position of the oil level gauge.
5. Install the oil return filter cover.
6. Start the engine and operate the control levers for all working devices for reciprocating
movements at large travel, in order to fully fill the hydraulic system with hydraulic oil and
bleed the air from the hydraulic system.
7. Place all working devices onto the ground, stop the engine, and bleed air from oil tank.
8. If necessary, add oil through oil return filter till the oil level reaches the middle position of oil
leveler.
 Caution
Pay special attention to the sealing performance of filter port and when necessary replace seal
ring. To prevent damaging the fine thread of filter cover, take cautions during the installation.
9-20
Disassembly of hydraulic oil tank

 Caution
1. Before the disassembly or installation of the hydraulic oil tank, please park the grader at
unloading of oil.
1. Operate the control lever to lower the blade
onto the ground, lift the mouldboard to the
top end, stop the engine, and operate the
control lever to lower the mouldboard onto
the ground.
Figure 9-29
filler cap can speed up the drainage of
hydraulic oil).
1 2  Caution
Figure 9-30 Cover the oil drained to prevent
1. Oil drainage valve contamination.
2. Hose
9-21
3. Disassemble the engine hood. (Refer to part
Disassembly and Assembly of Engine
Hood)
Engine hood
1 2
Figure 9-31
1. Engine Hood
2. Cover plate
4. Disassemble the fastening bolts of oil tank
left and right guard plates and use lifting
slings to hoist out the oil tank left and right
guard plats.
Left and right guard plates of oil tank
1
Figure 9-32
1. Left and right guard plates of oil tank
5. Dissemble the oil tank front guard plate.
Oil tank front guard plate
1
Figure 9-33
1. Front guard plate of oil tank
9-22
6. Disassemble the fixing plates on two sides
of oil tank and take out the fixing plates,
bolts, and washers.
1
Figure 9-34
1. Fixing plate
7. Disconnect the oil outlet hose of brake
pump from the high pressure filter.
1 2
Figure 9-35
2. 2 High Pressure Filter
3 4
8. Disconnect all oil return pipes from
hydraulic oil tank.
1 2
Figure 9-36
1. Oil return hose of high pressure filter safety
valve port T
2. Oil return hose of oil return block port T
3. Connecting pipe of refilling valve port O
4. Oil outlet hose of priority valve port T
9-23
Figure 9-37
1. Radiator oil return hose
9. Disassemble the fixing clamps of the
hydraulic oil tank outlet hose and hydraulic
pump inlet pipe.
1 2 3
Figure 9-38
1. Working pump oil inlet pipe
2. Hydraulic oil tank outlet hose
3. Steering pump oil inlet pipe
10. Disassemble the fastening bolts of tank
body and bracket and hoist out the tank
body.
Hydraulic oil tank
Figure 9-39
1. Bolt
9-24
Assembly of hydraulic oil tank

1. Hoist the hydraulic oil tank to
corresponding position of the machine
body and install the fastening bolts of
hydraulic oil tank and frame.
Hydraulic oil tank

1
Figure 9-40
1. Bolt
2. Install the fixing clamps of the hydraulic oil
tank outlet hose and hydraulic pump inlet
pipe.
1 2 3
Figure 9-41
1. Working pump oil inlet pipe
2. Hydraulic oil tank outlet hose
3. Steering pump oil inlet pipe
3. Install all oil return pipes of oil tank to
corresponding oil ports of hydraulic oil
tank.
 Caution
Mark the oil pipes appropriately, in
order to prevent confusion during

1 2 3 4
Figure 9-42 assembly.

1. Oil return hose of high pressure filter safety
valve port T
2. Oil return hose of oil return block port T
3. Connecting pipe of refilling valve port O
4. Oil outlet hose of priority valve port T
9-25
Figure 9-43
1. Radiator oil return hose
4. Install the brake pump oil outlet hose to
corresponding oil port of high pressure
filter.
1 2
Figure 9-44
2 High Pressure Filter
5. Use bolts and washers to install four fixing
plates on the left and right sides.
Figure 9-45
1. Fixing plate
9-26
6. Install the fastening bolts of oil tank front
guard plate.
Figure 9-46
1. Front guard plate of oil tank
7. Install the fastening bolts of left and right
guard plates of oil tank.
Figure 9-47
1. Left and right guard plates of oil tank
8. Install the engine hood. (Refer to the part
Installation of Engine Hood)
1 2
Figure 9-48
1. Engine Hood
2. Cover plate
9-27
Figure 9-49
1. Oil filler port
923 Multi-Way Valve

The multi-way valve is classified into left and right multi-way valves. Each multi-way valve is
mainly composed of valve body, 5 slide valves in series connection, check valve, and relief valve.
Operate the control lever to extend or retract the valve core of multi-way valve to realize
corresponding actions.
Figure 9-50 Hydraulic Schematic Diagram of Multi-Way Valve
Oil inlet check valve: It’s functioned to prevent the reflux of oil, in order to prevent the nodding of
cylinder.
Main relief valve: It’s a pilot cartridge valve. By increasing or reducing the initial spring
compression amount on the pilot valve core, the regulation pressure of the main relief valve can be
increased or reduced. The regulated pressure is 210bar.
The actions achievable by the various slide valves of the multi-way valve are shown in the figure
below.
9-28
Right multi-way valve Left multi-way valve
Figure 9-51 Multi-Way Valve

1. Lifting/lowering of blade 2. Mouldboard 3. Tilting of front wheels 4. Articulated steering
5. Oscillating of blade 6. Swing cylinder 7. Change of blade angle 8. Extraction of blade
9. Ripper 10. Lifting/lowering of blade
Composition structure of multi-way valve
Figure 9-52 Structure of Right Multi-Way Valve

1. Valve core end cap 2. End cap nut 3. Valve core end cap fastening screw 4. Spring seat 5. Spring
6. Working valve block subassembly 7. Plain washer - Sealing 8. Dust ring 9. O-ring
10. Valve core subassembly 11. Valve body 12. Sealing subassembly 13. Working valve block subassembly
14. O-ring 15. Spring 16. Check valve core 17. End cap nut 18. Oil inlet valve block subassembly
19. Oil outlet valve block subassembly 20. Nut 21. Fastening screw 22. Fastening screw 23. Nut
24. Relief valve subassembly 25. Plug subassembly 26. Valve core subassembly 27. Valve core
9-29
Figure 9-53 Structure of Left Multi-Way Valve
1. Valve core end cap 2. End cap nut 3. Valve core end cap fastening screw 4. Spring seat 5. Spring
6. Working valve block subassembly 7. Plain washer - Sealing 8. Dust ring 9. O-ring
10. Valve core subassembly 11. Valve body 12. Sealing subassembly 13. Working valve block subassembly
14. O-ring 15. Spring 16. Check valve core 17. End cap nut 18. Oil inlet valve block subassembly
19. Oil outlet valve block subassembly 20. Nut 21. Fastening screw 22. Fastening screw 23. Nut
24. Relief valve subassembly 25. Plug subassembly 26. Valve core subassembly 27. Valve core
Malfunction diagnosis of multi-way valve
Table 9-2
Malfunction
No. Malfunction cause Solution
Symptom
Under-low regulated pressure of
Adjust safety valve pressure
safety valve
Blockage of safety valve slide valve Disassemble, clean and reassembly
Insufficient
1 working Damage of pressure regulation
Replace with new one
pressure spring
Replace pipeline or adjust pressure of
Excessive pressure loss of system
relief valve within allowable pressure
pipeline
range
Insufficient Insufficient system oil supply Check oil source
2 working Over-high oil temperature and
flow Take measure to cool down oil
reduced viscosity
9-30
Malfunction
No. Malfunction cause Solution
Symptom
Poor choice of oil Replace oil
Excessive fitting gap between slide Replace the slide valve as per
valve and valve body reasonable gap
Damage or deformation of reset
Replace with new one
3 Reset failure spring
Non-coaxiality of reset parts Reassemble to ensure coaxiality
Damage of seal ring Replace with new one
Over-high oil temperature and
Take measure to cool down oil
reduced viscosity
External Poor sealing of oil port mounting Check tightening and sealing state of
4 flange surface corresponding parts
leakage
Blockage of fastening screws or
loose back nut of pressure
Tighten related parts
regulation screw for various
junction surfaces
Disassembly of multi-way valve
 Caution
1. Before the disassembly or installation of the multi-way valve, please park the grader at a
correct maintenance position (Refer to page 8 of Safety and Environment).
unloading of oil.
9-31
1. Disassemble the fastening bolts of guard
plate and take out the bolts and plate.
Figure 9-54
2. Disassemble the fastening bolts of plate and
take out the bolts and plate.
Figure 9-55
1. Plate
3. Disassemble the fastening bolts for control
tie rod and multi-way valve tie rod and take
out the bolts, nuts, and washers.
1 2 3
Figure 9-56
1. Multi-way valve tie rod
2. Control tie rod
3. Bolt
9-32
4. Disconnect all oil pipes from the multi-way
valve.
 Caution
1 assembly.
Figure 9-57
1. Oil pipe
5. Disassemble the fastening nuts between the
multi-way valve rear plate and frame and
hoist out the multi-way valve.
Multi-way valve
1 2
Figure 9-58
1. Multi-way valve rear plate
2. Nut
6. Disassemble all pipe connectors from
multi-way valve.
Figure 9-59
1. Pipe connector
9-33
7. Disassemble the pin of multi-way valve tie
rod.
1 2 3
Figure 9-60
2. Pin
3. Pin
multi-way valve and rear plate.
Figure 9-61
1. Screw
Assembly of multi-way valve
1. Install the fastening screws between
multi-way valve and rear plate.
Figure 9-62
1. Screw
9-34
2. Install the pin of multi-way valve tie rod.
1 2 3
Figure 9-63
2. Pin
3. Pin
3. Connect the pipe connectors to the
corresponding oil ports of multi-way valve.
Figure 9-64
1. Pipe connector
4. Use four M10 nuts to install the multi-way
valve to corresponding position in the front
of cab.
Multi-way valve
1 2
Figure 9-65
1. Multi-way valve rear plate
2. Nut
9-35
5. Install the oil pipes to corresponding oil
ports of multi-way valve.
Figure 9-66
1. Hose
6. Use bolts to connect the multi-way tie rod
with control tie rod.
1 2 3
Figure 9-67
2. Control tie rod
3. Bolt
7. Use M6×20 bolts and washers to fix the
upper guard plate in the front of the cab.
1 2
Figure 9-68
1. Bolt
2. Plate
9-36
8. Use M6×20 bolts and washers to fix the left
and right guard plates in the front of the
cab.
Figure 9-69
924 Rotary Control Valve

The rotary control valve is located in the top of the connecting frame and is one main unit of the
blade swing mechanism. It’s functioned to provide appropriate connected oil lines to two blade
swing cylinders continuously, in order to guarantee the continuous swing.
Figure 9-70 Rotary Control Valve
9-37
Figure 9-71 Hydraulic Schematic Diagram of Rotary Control Valve
Description of blade swing action
During the swing, the port AA of the rotary
valve is always connected with the chamber A
within the rotary valve and the port BB of rotary
valve is always connected with the chamber B of
rotary valve.
At the initial position of assembly or repair and
replacement, the left swing cylinder fully

Figure 9-72
retracts to be in linear state with the swing drive
arm so that it can’t provide the drive force and
the right swing cylinder is in the middle of its
stroke to form 90ºangle with swing drive arm
and provide maximum drive force. The pressure
oil of port AA flows into the rod chamber of
right swing cylinder through rotary valve and
the port BB is connected with the rodless
9-38
chamber of right swing cylinder through rotary
valve so that, under the action of hydraulic oil,
the right swing cylinder retracts and the pinion
driven by the drive arm drives the swing frame
for counter-clockwise swing. At the same time,
the valve core of the rotary valve is driven by
the rotary valve gear for synchronous swing.
The rotation of rotary valve core drives the
pressure oil from the chamber AA to the rodless
chamber of left swing cylinder and the rod
chamber of right swing cylinder so that the left
swing cylinder extends and the right swing
cylinder retracts to jointly drive the swing frame

Figure 9-73
for further counter-clockwise swing.
When the left swing cylinder forms a 90ºangle
with drive arm, the right swing cylinder is in
linear state with the drive arm. At this very
moment, only the left swing cylinder drives the
swing frame for further counter-clockwise
swing. In such case, the pressure oil of chamber

Figure 9-74
AA flows into the rodless chamber of left swing
cylinder, the BB is connected with the rod
chamber of left swing cylinder via rotary valve,
and the rod chamber and rodless chamber of the
right swing cylinder are connected.
9-39
with drive arm, the left swing cylinder is in
moment, only the right swing cylinder drives the

Figure 9-75
AA flows into the rodless chamber of right
swing cylinder, the BB is connected with the rod
chamber of right swing cylinder via rotary valve,
left swing cylinder are connected.
with the drive arm, the pressure oil of AA flows
into the rod chamber of left swing cylinder and
the rodless chamber of right swing cylinder via
rotary valve and the BB is connected with the
rodless chamber of left swing cylinder and the

Figure 9-76
rod chamber of right swing cylinder via rotary
valve so that the left swing cylinder retracts and
the right swing cylinder extends under the action
of hydraulic oil to drive via the drive arm the
pinion, which drives the swing frame for further
counter-clockwise rotation.
9-40
with drive arm, the right swing cylinder is in
moment, only the left swing cylinder drives the
AA flows into the rod chamber of left swing

Figure 9-77
cylinder, the BB is connected with the rodless
chamber of left swing cylinder via rotary valve,
right swing cylinder are connected.
Vice versa.
Disassembly of rotary control valve
 Caution
1. Before the disassembly or installation of the rotary control valve, please park the grader
at a correct maintenance position (Refer to page 8 of Safety and Environment).
unloading of oil.
9-41
1. Disconnect all oil pipes from the rotary
control valve.
 Caution
assembly.
Figure 9-78
1. Pipe connector 2. Oil pipe
2. Screw off three fastening bolts of rotary
control valve and take out the bolts and
washers.
Figure 9-79
1. Bolt
3. Take out the rotary control valve from the
frame.
Figure 9-80
4. Take out the drive shaft, sleeve, and the
spacers between rotary control valve and
frame.
Figure 9-81
1. Spacer 2 . Drive Shaft
9-42
5. Use a fixture to fix the rotary control valve
in the position shown in the figure and
disconnect all connectors from the rotary
control valve.
Figure 9-82
1. Connector
2. Rotary control valve
Assembly of rotary control valve
1. Use a fixture to fix the rotary control valve
in the position shown in the figure and
connect all connectors with the rotary
control valve.
Figure 9-83
1. Connector
2. 2 Rotary Control Valve
9-43
2. Install the spacers to the position shown in
the figure, with the quantity same with that
before disassembly. Install the drive shaft
and sleeve.
Figure 9-84
1. Spacer
2. Drive Shaft
3. Install the rotary control valve to
corresponding position of the frame.
Figure 9-85
4. Install the fastening bolts of rotary control
valve.
Figure 9-86
1. Bolt
9-44
5. Connect all oil pipes to the corresponding
oil ports of rotary control valve.
Figure 9-87
1. Connector
2. Oil pipe
925 Central Rotary Joint

The central rotary joint is located in the top center of the swing frame and is functioned to guarantee
that the hydraulic pipelines of two cylinders are not intertwined during the swing of the blade.
Technical
Specification
To multi-way Rotation torque
valve oil port 7B
30~60N.m
To rodless chamber of blade
angle cylinder To multi-way The installation of
valve oil port 7A
rotary joint shall be
To rodless chamber of blade
lateral extension cylinder
free of carrying of
To rod chamber of blade
angle cylinder To multi-way valve oil port 8B
external force to
ensure relatively free
To multi-way valve oil port 8A
rotation.
To rod chamber of blade

lateral extension cylinder
Figure 9-88
9-45
a, b - Change of blade tilting angle c, d - Lateral extension of blade
Figure 9-89 Hydraulic Schematic Diagram of Central Rotary Joint
1 Screw plug
2 O-ring
3 Rotary shaft
4 Water seal
5 Wearing ring
6 Rotary seal ring
7 Rotary body
8 Water seal
9 Baffle plate
10 Washer
11 Bolt
Figure 9-90 Composition of Central Rotary Joint
9-46
Disassembly of central rotary joint

 Caution
1. Before the disassembly or installation of the central rotary joint, please park the grader
at a correct maintenance position (Refer to page 8 of Safety and Environment).
unloading of oil.
9-47
1. Disconnect the connecting oil pipes of
blade oscillating cylinder rod and rodless
chambers.
1 2
Figure 9-91
1. Connecting hose of blade oscillating
cylinder rodless chamber
2. Disassemble fastening nuts of four cover
plates and take out the nuts and washers.
Figure 9-92
1. Nut
3. Lightly support the cover plates.

 Caution
Do not support with excessive force.
There are two connecting oil pipes
beneath the cover plate.
Figure 9-93
1. Cover plate
9-48
4. Disconnect two oil pipes beneath the cover
plates and take out the cover plates.

 Caution
assembly.
1 2
Figure 9-94
5. Disconnect four connecting oil pipes from
central rotary joint.

 Caution
assembly.
1 2 3 4
Figure 9-95
1. Connecting hose of multi-way valve port 8B
2. Connecting hose of multi-way valve port 8A
6. Disassemble the fastening nuts of plate.
1 2
Figure 9-96
1. Plate
2. Nut
9-49
Figure 9-97
1. Nut
7. Disassemble four fastening bolts of hose
clamp.
Figure 9-98
1. Pipe clamp
8. Disassemble four connecting oil pipes
beneath the central rotary joint.

 Caution
assembly.
1 2 3 4
Figure 9-99
1. Connecting hose of blade angle cylinder rod
chamber
2. Connecting hose of blade lateral extension
cylinder rod chamber
3. Connecting hose of blade angle cylinder
rodless chamber
9-50
9. Disassemble four straight connectors from
the central rotary joint.
Figure 9-100
1. Straight connector
10. Screw off six fastening nuts from central
rotary joint, take out the nuts and washers,
and take out the central rotary joint and six
bolts from the top.
Figure 9-101
1. Nut
Assembly of central rotary joint

1. Use six M12 bolts and nuts to install the
central rotary joint to corresponding
position of frame along the direction shown
in the figure.
Figure 9-102
1. Nut
9-51
2. Install the straight connectors to the central
rotary joint.
Figure 9-103
1. Straight connector
3. Connect four oil pipes to corresponding oil
ports of central rotary joint.
1 2 3 4
Figure 9-104
1. Connecting hose of blade angle cylinder rod
chamber
3. Connecting hose of blade angle cylinder
rodless chamber
4. Use bolts, nuts, and washers to install the
connecting plate beneath the central rotary
joint.
1 2
Figure 9-105
1. Nut
2. Plate
9-52
Figure 9-106
1. Nut
5. Use M10×20 bolts and hose clamps to fix
the connecting hoses of central rotary joint
onto the connecting plate.
Figure 9-107
1. Hose clamp
6. Install four oil hoses above the central
rotary joint.
1 2 3 4
Figure 9-108
9-53
1 2
Figure 9-109
7. Use nuts and washers to fix the cover plates
to designated positions.
Figure 9-110
1. Nut
8. Connect two hoses above the cover plates.
1 2
Figure 9-111
9-54
926 Hydraulic Cylinder
Figure 9-112 Structure of Hydraulic Cylinder
1. Piston fastening nut 2. Piston seal 3. Piston 4. Cylinder barrel 5. Pressure cap
6. Wearing ring 7. O-ring 8. Support ring 9. Seal ring for shaft 10. Dust ring
11. Piston rod 12. Cylinder head nut 13. Plain washer
The parameters of the cylinders adopted for the working hydraulic system of this machine are
shown in the table below.
Table 9-3 Unit: mm

Name SDLG code Cylinder bore Piston rod diameter Stroke
Articulated steering
4120004770 115 50 303
cylinder
Blade lifting cylinder 4120004769 90 50 1379.5
Blade oscillating
4120004768 90 50 693.5
cylinder
Locking cylinder 4120004765 80 60 63.5
Swing cylinder 4120004766 80 35 279.5
Blade extraction
4120004767 90 50 1346
cylinder
Blade angle cylinder 4120004771 100 50 260.5
Front wheel tilting
4120004762 100 50 169
cylinder
Precautions for disassembly of hydraulic cylinder
(1) Make sure to relieve the pressure of the hydraulic circuit before the disassembly of hydraulic
cylinder. Otherwise, while disassembling the connecting pipes of the hydraulic cylinder, the
high pressure hydraulic oil in the circuit will spray out at high speed along the connecting pipe,
9-55
which will probably cause personal injuries. Before the disassembly, firstly loosen the
adjustment handle or pressure regulation screw of the relief valve to relieve the pressure of
hydraulic circuit and then stop the power source to stop the running of entire hydraulic system.
In such case, the connecting pipes can be loosened. To prevent the residual pressure in the
circuit, slowly loosen the pipe connector. When one half of the connector threads is loosened,
shake the oil pipes and observe the presence of overflowed pressure oil at the connector before
the further disassembly.
(2) The hydraulic cylinder is the power actuator in the hydraulic system. Therefore, before
disassembling the hydraulic cylinder from the machine, make sure to properly support the
connected parts with appropriate supports, in order to prevent causing personal injuries or
damaging the machine. Before the disassembly, start the machine, operate the hydraulic
cylinder to the position appropriate for disassembly, relieve the pressure, and stop the machine
for disassembly.
(3) Observe whether the cylinder is fitted with hydraulic lock at the disassembly of the hydraulic
cylinder. If yes, firstly disassemble the hydraulic lock, otherwise the hydraulic cylinder will
contain a pressure locked by the hydraulic lock, which will not only bring about difficulties to
the disassembly, but also easily cause personal injuries and machine damage. At the
disassembly of hydraulic lock, wrap the connection with several layers of clean cotton cloth
and then loosen the screw, in order to prevent spray-out of high pressure oil.
(4) At the disassembly of hydraulic cylinder, firstly understand the main structure of hydraulic
cylinder and do not disassembly blindly. Due to different sizes, structures, and applications of
the hydraulic cylinders, the disassembly sequences and methods are different. Before the
disassembly, please disassembly with reference to the structure diagram of hydraulic cylinder
on the Parts Catalog provided by our company. If not available, judge the internal structure of
hydraulic cylinder by the external shape, structure, and application of the hydraulic cylinder
and establish corresponding disassembly sequence.
(5) Generally, drain the hydraulic oil from both chambers of the hydraulic cylinder before the
disassembly of hydraulic cylinder and then disassemble the end caps and withdraw the piston
9-56
rod and piston. At the disassembly of parts, it’s prohibited to hammer with high force. If
absolutely necessary, cushion with a red copper bar to prevent damaging the parts. For some
parts requiring use of special tools, the special tools must be used. Do not hammer or pry with
high force. The end caps tightened with fine thread shall be loosened uniformly by special
wrench with high force after being shaken loosely. It’s permissible to shake the deformation
resistant connection portions with a copper bar and it’s prohibited to impact with high force.
For the purpose of looseness prevention, some portions tightened by bolts are applied with
thread sealant at the time of assembly and are difficult to be disassembled. The forced
disassembly will probably break the bolts. Heat up the exposed parts of bolts for the sealant to
come off and become ineffective before the disassembly.
(6) At the time of disassembly, prevent damaging the piston rod end thread, oil port thread, piston
rod surfaces, and cylinder sleeve inner walls. To prevent bending or deformation of slim parts
such as piston rod, support with cushion woods uniformly at time of placement. At the
disassembly of seals, prevent using sharp tools, in order to prevent damaging seals. For the
seals difficult to be disassembled, immerse into boiling water and wait for them to become soft
before disassembly. Before and after the disassembly, take all measures possible to prevent the
parts of hydraulic cylinder from being contaminated by surrounding dust and impurities. For
instance, at the time of disassembly, operate in a clean environment whenever possible. After
the disassembly, cover all parts with plastic cloth, instead of cotton cloth or other working
cloth.
(7) Check carefully all parts and seals disassembled for presence of damage or aging and
determine the necessity of replacement. For the hydraulic cylinder with internal or external
leakage during use, if there is no scuffing on the piston rod or the cylinder barrel, the leakage is
basically caused by the worn or aged seals. If the cylinder barrel is ever impacted, use an
inside diameter micrometer to measure the inside diameter of cylinder barrel for presence of
deformation. For the cylinder barrels, piston rods, and other motion parts, pay special attention
to observe for presence of knocking damage and scuffing and determine the necessity of
replacement depending on the damage extent and the actual dimensions of hydraulic cylinder.
9-57
If no replacement is required, grind the ridges in the surrounding area of damaged location
with fine oil stone and polish smoothly with metallographic abrasive paper.
Precautions for assembly of hydraulic cylinder
(1) All parts shall be thoroughly cleaned and air dried before the assembly. The parts to be applied
with sealant shall be cleaned with special detergent or, alternatively, the acetone. The
preliminary solidifying time for the sealant is generally 20min. Tighten the parts to the
required torque within 20min.
(2) Correctly install the sealing devices for all locations. While installing the O-rings, do not
stretch to the extent of compression set or install by rolling, or it will probably distort the
O-rings and cause oil leakage. While installing the Y-shaped, V-shaped, and multistep seals,
pay attention to the installation direction, in order to prevent the reverse installation from
causing oil leakage. For Y-shaped seals, the lips shall face towards the pressurized oil chamber.
In addition, differentiate the Y-shaped seals for shaft and for holes, in order to prevent
installation error. The V-shaped seals are composed of support ring, seal ring, and compression
ring in different shapes. When the compression ring is pressed tightly against the seal ring, the
support ring can cause deformation of seal ring for sealing purpose. At the time of installation,
face the opening of seal ring towards the pressurized oil chamber. The adjustment of
compression ring shall be based on the extent of no oil leakage. Do not press too tightly, in
order to prevent over-high sealing resistance. The steps of the multistep seals shall face
towards the pressurized oil chamber. If the sealing devices are fitted with the sliding surfaces,
apply an appropriate amount of hydraulic oil onto the sealing devices during assembly. All
O-rings and dust rings disassembled must be replaced with new ones.
(3) The bolts and lock nuts for the pressure carrying parts of the hydraulic cylinder are of one-time
parts and can’t be reused. Do not replace the pressure carrying parts at will. Only use the
genuine parts. If not available, replace with corresponding products based on the carrying
pressure. There are requirements of tightening torques and sequences for most fastening or
connecting bolts of parts, such as lock nuts and fastening bolts, and the tightening angle is
even specified for some fastening or connecting bolts. Therefore, use special wrench or torque
9-58
wrench to tighten to the required torque at the time of tightening. The bolts on one same part
shall be tightened symmetrically with same tightening torque, in order to prevent breakage of
bolts due to non-uniform application of force. While tightening the bolts on piston rod or slim
parts, pay attention to cushion the piston rod or slim parts uniformly with cushion woods, in
order to prevent bending deformation during tightening.
(4) Some piston seals are swollen after being installed into the piston seal grooves and will be
easily cut during assembly with cylinder barrel. Use a tapered bushing to tension the seals. If
not available, lathe one tapered bushing based on the dimensions of piston and cylinder barrel.
Generally, its taper is 30ºand its small end dimension is the inside diameter of cylinder barrel.
After the piston is assembled with the piston rod, manage to measure whether their coaxiality
and straightness in full length meet the requirements.
(5) Apply an appropriate amount of hydraulic oil to all slide parts for lubrication at the time of
assembly. The fine thread parts in large sizes can be applied with grease at the time of
assembly. In event of tight thread fit or ever burnt thread during disassembly, lubricate with
molybdenum disulfide grease.
(6) At completion of the repair and assembly of hydraulic cylinder, make sure to conduct the
pressure leakage test before reuse. For the hydraulic cylinder with hydraulic lock, do not install
the hydraulic lock during the pressure leakage test. During the test, firstly operate the hydraulic
cylinder at low pressure back and forth for several times to bleed the air. Observe for presence
of stagnation feeling and non-uniform resistance during the movement of the piston
subassembly. During the pressure test, slowly increase the pressure and carefully observe for
presence of leakage.
9-59
Disassembly of hydraulic cylinder
1. Find out an appropriate container and drain
the residual hydraulic oil from hydraulic
cylinder.
Figure 9-113
1 2. Fix the hydraulic cylinder on a bench vice
in the manner shown in the figure.
Figure 9-114
1. Cylinder barrel
3. Screw off the cylinder head nuts with a
cylinder wrench.
Figure 9-115
1. Cylinder head nut
9-60
4. Take out the pressure cap from the cylinder
barrel.
Figure 9-116
1. Pressure cap
5. Lightly take out the piston rod and piston
from the cylinder barrel.
1 2
Figure 9-117
1. Piston rod
2. Piston
6. Take out the cylinder barrel from the bench
vice and fix the piston rod onto the bench
vice in the manner shown in the figure.
Figure 9-118
1. Piston rod
9-61
7. Disassemble the fastening bolts of piston
and piston rod and take out the bolts and
washers.
Figure 9-119
1. Bolt
8. Take out the piston.
Figure 9-120
1. Piston
9. Take out the seals from the piston
Figure 9-121
1. Piston seal
9-62
10. Take out the pressure cap from the piston
rod.
1 2
Figure 9-122
1. Pressure cap
2. Piston
11. Take out the O-ring and support ring from
the pressure cap.
1 2
Figure 9-123
1. O-ring
2. Support ring
12. Take out the dust ring, wearing ring, and
seal ring for shaft from the inner ring of the
pressure cap.
1 2 3
Figure 9-124
1. Dust ring
2. Wearing ring
3. Seal ring for shaft
9-63
13. Take out the cylinder head nuts.
Figure 9-125
Assembly of hydraulic cylinder
1. Fix the piston rod onto a bench vice and
install the cylinder head nuts onto the
piston rod.
Figure 9-126
2. Install the dust ring, wearing ring, and seal
ring for shaft on the pressure cap.
1 2 3
Figure 9-127
1. Dust ring
2. Wearing ring
3. Seal ring for shaft
9-64
3. Install the O-ring and support ring on the
outer ring of pressure cap.
Figure 9-128
1. O-ring
2. Support ring
4. Install the pressure cap onto the piston rod.
1 2
Figure 9-129
1. Pressure cap
2. Piston rod
5. Install the seals on the piston.
1 2
Figure 9-130
1. Piston
2. Seal
9-65
6. Install the piston onto the piston rod.
Figure 9-131
1. Piston rod
7 Install the fastening bolts and plain washers
of the piston and piston rod.
1 2
Figure 9-132
1. Bolt
2. Plain washer
8. Take out the piston rod from the bench
vice, fix the cylinder barrel onto a bench
vice, and install the piston rod into the
cylinder barrel.
1 2 3
Figure 9-133
1. Piston rod
2. Piston
3. Cylinder barrel
9-66
9. Tighten the cylinder head nuts with a
cylinder wrench.
Figure 9-134
927 Other Hydraulic Units

Hydraulic lock
The hydraulic lock is composed of two hydraulic control units. When the reversing valve is at
neutral position and there is a certain external load, the hydraulic lock can maintain stationary the
position of cylinder.
The hydraulic lock is fitted in the articulation steering circuit, front wheel tilting circuit, and ripper
lifting circuit of this machine.
C1 C2 Technical Specification
Rated pressure 240bar
Rated flow 57L/min
Opening pressure 2.1bar
V1 V2 Pilot ratio 4:1
Figure 9-135
Balance valve
The balance valve can automatically change the resistance coefficient based on the variation of
system working condition (pressure difference) to effectively control the flow at a fixed value
within a certain pressure difference range.
The balance valve is fitted in the blade oscillating circuit and left and right blade lifting circuits of
this machine.
9-67
A1 B1 Technical Specification
Proportion between control pressure and
Area 4:1
Pressure setting 240bar
Flow 70L/min
A B
Maximum working pressure 350bar
Figure 9-136
Floating balance valve
In addition to the fulfillment of balance valve function, the floating balance valve is also fitted with
a floating function. When the pressure oil is applied onto the oil control port D, the left and right
check valves within the balance valve open and both rodless and rod chambers of the blade lifting
cylinder are connected with the oil return line. In such case, the blade lifting cylinder is at free
floating state under the application of working device weight and own weight.
V1
D Technical Specification
V2
Rated flow 60L/min
Pressure regulation range 140—350 Bar
C1
C2
Figure 9-137
9-68
Figure 9-138
Duplex solenoid valve
The turn-on/turn-off of the solenoid valve realizes the connection/disconnection of the oil control
line between the refilling valve and the floating balance valve.
Rated flow 11L/min
Voltage 24V
Figure 9-139
9-69
Port A2 to right blade floating

balance valve
Port A1 to left blade floating

balance valve
Port T to oil return block
Port P to refilling valve
Figure 9-140
Crossed relief valve
Maximum flow 25L/min
Figure 9-141
Figure 9-142
9-70
93 Pressure Measuring Point and Criterion of Working Hydraulic System

Pressure measuring tool
Pressure gauge with measuring range at 0~25MPa
Pressure measuring point
Oil inlet of multi-way valve
Pressure
measuring point
Figure 9-143
Pressure measuring method
Lift the cylinder to build the system pressure.
Pressure criterion
214.1±3.5 Bar
9-71
94 Air Bleeding of Hydraulic System
The oil in the hydraulic system has very low compressibility, of which the influence can be omitted
under general conditions. However, the low pressure air features high compressibility and is
approximate 10000 times of the oil. Therefore, the influence is really high even only a small amount
of air is contained in the system. The air dissolved in the oil will escape from the oil at low pressure
to form air bubbles and cause cavitation. In the high pressure zone, under the action of the pressure
oil, the air bubbles will be crushed and compressed rapidly to generate noise in the system. In
addition, the air will discharge a great amount of heat when being compressed abruptly, which will
lead to partial overheating and damage of both hydraulic units and hydraulic oil. The air features
high compressibility and will cause creepage of hydraulic units, impair the working stability, and
sometimes even lead to vibration, which will influence the normal working of the system. The
mixing of a great amount of air bubbles in the oil will easily cause deterioration and lower the life
of the oil. Therefore, make sure to guard against the ingress of air into the hydraulic system and
bleed the air from the hydraulic system after the replacement of hydraulic pump, hydraulic cylinder,
and hydraulic pipes, connectors, and valves.
For this machine, bleed the air from the working hydraulic system as per the method below:
1. Open the filler cap on the hydraulic oil tank.
2. Start the engine. Idle run the engine and extend and retract all cylinders of working hydraulic
system and steering system from the bottom of the travel repeatedly for 2~3 times
(approximate 50~60mm).
3. Run the engine at high speed and extend and retract all cylinders of working hydraulic system
and steering system in full travel for 3~5 times to bleed the air from the pipeline.
4. After bleeding the air, set the machine and working devices to standard positions (Park the
machine with wheels in linear direction, adjust the front and rear frames in one same line,
place the mouldboard onto the ground with a 90ºangle against the frame, and lower the ripper
near the ground) and then check the oil amount and tighten the filler cap.
5. Stop the engine and check for presence of leakage in pipes and hoses.
9-72
Precautions for air bleeding
1. While bleeding air from the steering cylinders, lower the mouldboard to elevate the front frame,
till the front wheels are off the ground.
2. While bleeding air from the hydraulic system (including swing, lateral extension, and tilting of
mouldboard), lift the mouldboard.
3. While bleeding the air for the traction frame side turning system, slightly lower the
mouldboard.
4. While bleeding the air from the articulated steering system, shift the transmission to neutral
gear.
5. When the mouldboard is lifting and the ripper cylinder is extending, the machine is already off
the ground. Take special cautions for fulfillment of this operation.
95 Malfunction Diagnosis of Working Hydraulic System
Table 9-4
Serious wear and internal Replace hydraulic pump
leakage of hydraulic pump
Reduced oil viscosity due to Refer to treatment method for
over-high oil temperature over-high oil temperature
Insufficient system
1 pressure or completely no Oil leakage of pipeline Find out leaking location and
pressure system resolve
Abnormal working or Repair or replace relief valve
blockage of relief valve
Failure of spring Replace spring
Oil suction failure due to Stop machine and add
under-low oil level in hydraulic oil to the specified
hydraulic oil tank level.
Suction failure of hydraulic Increase hydraulic oil
2 Low system flow pump due to over-high temperature
hydraulic oil viscosity under
low temperature
Serious internal leakage Repair or replace internal
leakage unit
9-73
Table 9-4 Continued

Mixing between hydraulic Failure of hydraulic pump Replace hydraulic pump oil
3
oil and hydraulic drive oil shaft seal seal
Air ingress in hydraulic Bleed air from hydraulic
system system as per requirements
Abnormal noise and
Under-low oil level in Add hydraulic oil to the
4 vibration of hydraulic
hydraulic oil tank specified level.
pump
Malfunction of hydraulic Repair or replace hydraulic
pump pump
Blockage of multi-way valve Clean multi-way valve core
core by dirt
5 Heavy operations
Failure of multi-way valve Replace multi-way valve
spring spring
Air content in the hydraulic Bleed the air as pre
Action failure of cylinder requirements
6
hydraulic cylinder
Damage of piston seal Replace piston seal
Long-term continuous Pause the operation
working under loaded
condition
Over-high system pressure Adjust to specified pressure
7 Over-high oil temperature Insufficient oil amount in oil Add hydraulic oil to the
tank specified level.
Over-high ambient Stop the machine for cooling
temperature
High internal leakage Check and repair related units
9-74

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Service Manual of G9190

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G9190 Grader Service Manual

880×1230 mm 16# 18pieces

SHANDONG LINGONG CONSTRUCTION

Address: Linyi Economic Development Zone

0 Overview .................................................................................................................................................... 0-1

1 Repair and Maintenance ...................................................................................................................... 1-1

11 Oil, Coolant, and Others ...................................................................................................................... 1-1

12 Choice of Fuel/Oil ............................................................................................................................... 1-4

13 Repair .................................................................................................................................................. 1-8

2 Engine system ........................................................................................................................................... 2-1

21 Overview ............................................................................................................................................. 2-1

22 Lubrication System.............................................................................................................................. 2-8

23 Fuel Supply System ....................................................................................................................... 2-10

24 Cooling System ................................................................................................................................. 2-13

25 Intake and Exhaust System ................................................................................................................ 2-16

26 Disassembly and Assembly of Engine .............................................................................................. 2-18

27 Disassembly and Assembly of Fuel Tank .......................................................................................... 2-37

28 Disassembly and Assembly of Radiator ............................................................................................ 2-41

29 Common Malfunctions and Troubleshooting of Engine ................................................................... 2-45

3 Electrical and information system ............................................................................................................ 3-1

31 Electrical system introduction ............................................................................................................. 3-1

32 Electrical principles and failure analysis ........................................................................................... 3-18

33 Grader harness layout ........................................................................................................................ 3-62

4 Powertrain .................................................................................................................................................... 4-1

41 Hydraulic torque converter-gearbox assembly .................................................................................... 4-2

42 Drive shaft assembly ......................................................................................................................... 4-23

43 Drive axle and balance box assembly................................................................................................ 4-27

44 Common faults of grader powertrain and troubleshooting ................................................................ 4-35

5 Braking system ....................................................................................................................................... 5-1

51 Service Parking System ....................................................................................................................... 5-1

52 Parking brake..................................................................................................................................... 5-19

53 Troubleshooting of braking system .................................................................................................... 5-22

6 Steering system ......................................................................................................................................... 6-1

61 System Overview ................................................................................................................................ 6-1

62 Description and Disassembly/Installation of Main Units ..................................................................... 6-6

63 Pressure Measuring Point and Criterion of Steering System ............................................................. 6-42

64 Bleeding Air from Steering System ................................................................................................... 6-43

65 Steering system troubleshooting guide............................................................................................... 6-44

7 Frame, Wheels, and Working Device ........................................................................................................... 7-1

71 Overview of Frame and Working Device ............................................................................................. 7-1

72 Disassembly and Assembly of Front Mouldboard ............................................................................. 7-10

73 Disassembly and Assembly of Frame Joint........................................................................................ 7-13

74 Disassembly and Assembly of Front and Rear Wheels ...................................................................... 7-21

75 Disassembly and Assembly of Middle Working Device .................................................................... 7-27

76 Disassembly and Assembly of Rear Ripper ....................................................................................... 7-45

77 Common Malfunction Causes and Troubleshooting .......................................................................... 7-50

8 Cab and Covering Parts System ................................................................................................................ 8-1

81Overview of Cab ................................................................................................................................... 8-1

82 Description of A/C System................................................................................................................. 8-16

83 Disassembly and Assembly of Cab Assembly ................................................................................... 8-20

84 Disassembly and Assembly of Engine Hood ..................................................................................... 8-33

85 Disassembly and Assembly of A/C System ....................................................................................... 8-38

9 Working Hydraulic System ....................................................................................................................... 9-1

91 System Overview ................................................................................................................................. 9-1

92 Principle and Disassembly/Assembly of Main Units ......................................................................... 9-11

94 Air Bleeding of Hydraulic System ..................................................................................................... 9-72

95 Malfunction Diagnosis of Working Hydraulic System ...................................................................... 9-73

Operation Safety of Accumulator ............................................................................................... 23

Maintenance Manual of G9190 Grader. Please

carefully read the contents of this part.

Make sure to firstly read the section “Safety”

in the manual before the operations.

Safety is related to everyone

Operation and Maintenance Manual of G9190