SG16-3

Motor Grader

Unsafe use of the machine may cause

serious accidents or even casualties. Operation
or maintenance personnel shall read this manual
carefully before operating the machine. This
manual shall be placed near the machine for
convenient and timely reference, and all persons
concerned with the machine shall read this
manual regularly.

Shantui Construction Machinery Co., Ltd.

The People's Republic of China
Address: Shantui International Business Park, No.58,
G327 Highway, Jining City, Shandong Province
Postcode: 272073
Url: www.shantui.com
 Tips
Training
If you are a green hand, in order to ensure your safety and the other’s, please operate the machine after
receiving professional training from Shantui or its dealers.
Safety
Please operate the machine after reading through the manual and successfully mastering the driving
method. See Chapter 1 for the detailed safety precautions.
Inspection
Please check the vehicle condition, weather condition and ambient condition before driving. Operate the
machine only when all the requirements are met.
Note
Please operate the machine according to the working condition of the construction site.

Tips I
Tips II
 Preface
SG16-3 are 118 kW (160 hp) motor graders.
Various aspects such as the structure, performance, driving operation, maintenance, troubleshooting,
transportation and storage of the motor grader are elaborated in the manual to provide basic knowledge
for the management and operation personnel to use the machine efficiently, economically and
completely.
The rules and guidelines in the manual are very useful for you to operate the machine safely and
efficiently. Make sure to read and obey the precautions in the manual when conducting the operation
and maintenance so as to avoid any accident or serious casualty caused by illegal operation and
maintenance.

Warning

The operation and maintenance personnel must pay attention to the following items before the
operation and maintenance:
• Make sure to read through and understand the manual before operation and maintenance.
• Carefully read and completely master the safety notices in the manual and the safety labels
adhered to the machine.
• Place the manual at the specified storage place and periodically read it.
• Please contact with Shantui or its dealer if the manual is lost or stained to be unreadable.
Please deliver the manual together with machine to the new user if you want to sale or lease the
machine.
Storage Place of Operation and Maintenance Manual

The operation and maintenance manual shall be

stored in the information box on the left rear side of
the cab as shown in the right figure.
As for all the information related to the use,
maintenance, service and troubleshooting of the
engine, please refer to the User’s Manual for
Engine for more details besides this manual.
Please remember that all the content related to
human & machine safety and important technical
requirements shall be marked with the symbol of

or ★.

Preface III
About Warranty
The warranty within the warranty period specified by Shantui only covers the malfunction caused by
material or manufacturing process defects. Shantui will take no responsibility for the malfunction or
damage due to irrational use or negligence in the view of Shantui, which includes but not limited to the
following: operation without sufficient coolant or lubricating oil; excessive oil supply; over-speed running;
insufficient maintenance of the cooling and lubricating system; irregular storage, starting, preheating,
running-in or shutdown operation; unauthorized engine maintenance; and the damage caused by using
unspecified fuel and lubricating oil or the fuel and lubricating oil mixed with water, mud or other dirt.
As for the malfunction truly caused by material or manufacturing process defects, Shantui will take no
responsibility for all the incidental expenses such as the shutdown expense and penalty, and the related
business expense as well as the loss due to the maintenance.

Tips IV
Running-in of New Vehicle
The new vehicle has undergone elaborated commissioning before leaving the factory, but it still needs to
be operated carefully during the first 100 service hours to achieve the best running-in of various parts.
If the new vehicle is in unreasonable overload at the initial service stage, the potential function of the
vehicle will deteriorate early and the service life will be shortened. Therefore, make sure to operate the
new vehicle carefully according to the following requirements:
1. Complete the inspection before staring the vehicle;
2. Idle the engine for 5 min after the engine starting and make sure its normal warming to enter into the
working mode;
3. Avoid heavy load or high speed operation;
4. Don’t start the vehicle in a hurry, speed up hastily, conduct unnecessary emergency brake or take a
sudden turn.
5. Observe and adjust the vehicle at any time to ensure its normal state.
6. The engine oil shall be changed for the first time after 50 working hours. Lubrication oil of
transmission case and rear axle assembly shall be changed after 100 working hours to improve reliability
of transmission components, reduce wear and prolong service life.
7. Maintain the vehicle according to the Maintenance Table for the First 250 Service Hours and the
following content after 250 service hours:
★ Maintenance Table for the First 250 Service Hours;
★ Operating time indicated by the hour meter;
★ Check whether dirt exists inside the filter core when replacing it and find out the reason
before the replacement if dirt accumulation is very serious.

Preface V
Safety Signs and Instructions
In order to help you operate the vehicle safely, labels of safety precautions are included in the manual
and attached onto the vehicle to provide the description of involved potential dangers and the method to
avoid such dangers.
The following signs and instructions indicate the possibility of causing personal injury or potential danger,
and are used to indicate the potential danger level in the manual and on the labels of the machine.

Danger
The danger may result in death or serious injury if it is not avoided.
Warning
The potential danger may result in death or injury if it is not avoided.
Caution
The potential danger may result in relatively low or moderate injury if if it is not avoided.
An Example to Use Safety Signs and Instructions

Warning

Make sure to place the working element on the ground before leaving the cab seat, or else
accidentally touching of the handle may cause serious injury or death.

Tips VI
 Contents
Tips ............................................................................................................................................................................. I
Preface ..................................................................................................................................................................... III
About Warranty................................................................................................................................................ IV
Running-in of New Vehicle .............................................................................................................................. V
Safety Signs and Instructions........................................................................................................................... VI
Contents .................................................................................................................................................................. VII
Chapter 1 Safety ........................................................................................................................................................ 1
1.1 Safety Labels ......................................................................................................................................... 1
1.1.1 Diagram of Safety Label Positions ............................................................................................ 1
1.1.2 Safety Labels ............................................................................................................................. 2
1.2 Safety Rules ........................................................................................................................................... 6
1.2.1 Safety Principle .......................................................................................................................... 6
1.2.2 Safety Device ............................................................................................................................. 6
1.2.3 Clothes and Personal Protective Equipment .............................................................................. 6
1.2.4 Unauthorized Modification ........................................................................................................ 6
1.2.5 Locking Before Leaving the Cab Seat ....................................................................................... 7
1.2.6 Precautions for Accumulator Application .................................................................................. 7
1.2.7 Getting on and off the Vehicle ................................................................................................... 7
1.2.8 Fire Prevention........................................................................................................................... 8
1.2.9 Safety Measures for Operation Under High Temperature ......................................................... 9
1.2.10 Prevention of Asbestos Dust ...................................................................................................... 9
1.2.11 Prevention of Crush or Cut Wound ............................................................................................ 9
1.2.12 Fire Extinguisher and First Aid Kit (with the First Aid Kit Self-prepared) ............................. 10
1.2.13 Precautions for Optional Parts ................................................................................................. 10
1.2.14 Precautions for Accessories ..................................................................................................... 10
1.3 Safety Specifications ........................................................................................................................... 10
1.3.1 Before Engine Startup .............................................................................................................. 10
1.3.2 Operation of Motor Grader .......................................................................................................11
1.3.3 Safe Operation ......................................................................................................................... 15
1.3.4 Transportation .......................................................................................................................... 16
1.3.5 Battery...................................................................................................................................... 17
1.3.6 Towing ..................................................................................................................................... 18
1.3.7 Preparations Before Maintenance ............................................................................................ 19
1.3.8 During the Maintenance........................................................................................................... 20
Chapter II Operation ................................................................................................................................................ 27
2.1 Operation Devices ............................................................................................................................... 27
2.1.1 General Layout of Operation Devices ..................................................................................... 27
2.1.2 Functions of Operation Devices............................................................................................... 28
2.1.3 Combination Instrument and Functions ................................................................................... 30
2.1.4 Other Devices .......................................................................................................................... 32
2.2 Driving ................................................................................................................................................. 37
2.2.1 Prestart Inspection.................................................................................................................... 37
2.2.2 Driving Method and Procedure ................................................................................................ 39
2.2.3 Operation for Driving .............................................................................................................. 40
2.2.4 Steering .................................................................................................................................... 40
2.2.5 Braking .................................................................................................................................... 40
2.2.6 Vehicle Stop ............................................................................................................................. 40
2.2.7 Engine Stop .............................................................................................................................. 40
2.2.8 Driving in Special Climatic Environment ................................................................................ 41
2.2.9 Gradient ................................................................................................................................... 41
2.2.10 NoticesS ................................................................................................................................... 41
2.2.11 Driving on Water...................................................................................................................... 42
2.2.12 Driving in the Desert................................................................................................................ 42
2.3 Working ............................................................................................................................................... 42
2.3.1 Operation of the Blade ............................................................................................................. 42
2.3.2 Front Wheel Lean .................................................................................................................... 42
2.3.3 Levelling .................................................................................................................................. 42
2.3.4 Ditching ................................................................................................................................... 43
Content VII
 2.3.5 Scrapping ................................................................................................................................. 44
2.3.6 Blade Adjustment ..................................................................................................................... 44
2.3.7 Method for Extending the Vehicle Life.................................................................................... 44
2.3.8 Operation Points ...................................................................................................................... 44
2.3.9 Front Dozer (optional) ............................................................................................................. 45
2.3.10 Rear Scarifier (optional) .......................................................................................................... 45
2.4 Transportation and Storage .................................................................................................................. 45
2.4.1 Transportation .......................................................................................................................... 45
2.4.2 Storage ..................................................................................................................................... 47
2.4.3 Traction .................................................................................................................................... 49
Chapter III Structure and Principle .......................................................................................................................... 51
3.1 Purpose and Main Technical Parameters ............................................................................................. 51
3.1.1 Purpose .................................................................................................................................... 51
3.1.2 Product Model and Name ........................................................................................................ 52
3.1.3 Outline Drawing Fig. 3-1 Motor Grader .................................................................................. 52
3.1.4 Overall Dimensions ................................................................................................................. 52
3.1.5 Main Specifications and Technical Parameters........................................................................ 53
3.1.6 Drive System Diagram............................................................................................................. 56
3.2 Engine .................................................................................................................................................. 56
3.2.1 Cummins Engine...................................................................................................................... 56
3.3 Torque Converter ................................................................................................................................. 58
3.4 Transmission ........................................................................................................................................ 59
3.5 Rear Axle ............................................................................................................................................. 67
3.5.1 Structure and Principle............................................................................................................. 67
3.5.2 Adjustment of Rear Drive axle ................................................................................................ 69
3.6 Tandem ................................................................................................................................................ 70
3.6.1 Structure ................................................................................................................................... 70
3.6.2 Wheel Brake ............................................................................................................................ 70
3.6.3 Adjustment of Wheel Brake..................................................................................................... 70
3.6.4 Adjustment of Jincheng Tandem Chain ................................................................................... 71
3.6.5 Lubrication and maintenance .............................................................................................. 72
3.7 Front Axle ............................................................................................................................................ 73
3.7.1 Structure Diagram of Front Axle(The first structure) .............................................................. 73
3.7.2 Structure Diagram of Front Axle(The second structure).......................................................... 73
3.7.3 Adjustment of Front Wheel Toe-in .......................................................................................... 74
3.7.4 Lubrication and Adjustment of Front Hub Bearing (Fig. 3-19) ............................................... 74
3.8 Tyre ...................................................................................................................................................... 75
3.8.1 Tyre Maintenance .................................................................................................................... 75
3.8.2 Tyre Pressure............................................................................................................................ 75
3.8.3 Tightening and Replacement of Wheels .................................................................................. 75
3.8.4 Direction of Tyre Tread ............................................................................................................ 76
3.9 Working Hydraulic System .................................................................................................................. 76
3.9.1 Introduction.............................................................................................................................. 76
3.9.2 Hydraulic Schematic ................................................................................................................ 77
3.9.3 Working Principle .................................................................................................................... 77
3.10 Hydraulic Oil Tank .............................................................................................................................. 78
3.11 Steering Hydraulic System .................................................................................................................. 78
3.11.1 Introduction.............................................................................................................................. 78
3.11.2 Hydraulic Schematic ................................................................................................................ 79
3.12 Service Brake (Foot Brake) Hydraulic System .................................................................................... 80
3.12.1 Introduction.............................................................................................................................. 80
3.12.2 Hydraulic Schematic ................................................................................................................ 81
3.13 Electrical System ..................................................................................................................................... 81
3.13.1 Electrical Schematic (Cummins Engine) ..................................................................................... 81
Chapter IV Service and Maintenance ...................................................................................................................... 85
4.1 Service and Maintenance ..................................................................................................................... 85
4.1.1 Maintenance Table ................................................................................................................... 86
4.1.2 Daily Maintenance ................................................................................................................... 89
4.1.3 Maintenance under Special Conditions.................................................................................... 90

Content VIII
 4.1.4 Maintenance of first 50h .......................................................................................................... 91
4.1.5 Maintenance per 50h................................................................................................................ 91
4.1.6 Maintenance of First 100h ....................................................................................................... 95
4.1.6 Maintenance of First 100h ....................................................................................................... 95
4.1.7 Maintenance per 250h .............................................................................................................. 97
4.1.8 Maintenance per 500h .............................................................................................................. 98
4.1.9 Maintenance per 1000h ............................................................................................................ 99
4.1.10 Maintenance per 2000h .......................................................................................................... 101
4.1.11 Maintenance per 3000h .......................................................................................................... 101
4.1.12 Maintenance of air filter ........................................................................................................ 102
4.1.13 Maintenance of air conditioner .............................................................................................. 103
4.1.14 Normal Maintenance Materials.............................................................................................. 104
4.1.15 Adjustment of various parts ................................................................................................... 105
4.1.16 Standard Tightening Force of Bolts and Nuts ........................................................................ 106
4.2 Malfunctions and Troubleshooting .................................................................................................... 106
4.2.1 Power train ............................................................................................................................. 106
4.2.2 Electrical System ................................................................................................................... 107
4.2.3 Hydraulic System ................................................................................................................... 108
4.2.4 Brake System ......................................................................................................................... 108
4.2.5 Operating System ................................................................................................................... 109
4.2.6 Steering System ..................................................................................................................... 109
4.3 Disassembly and Assembly Matters ...................................................................................................110
4.3.1 Disassembly ............................................................................................................................110
4.3.2 Assembly ................................................................................................................................110
4.3.3 Disassembly and Assembly of Bearing...................................................................................110
4.3.4 Installation of Oil Seal ............................................................................................................ 111
4.4 Attached Table .................................................................................................................................... 111
4.4.1 Lubrication Chart of Motor Grader......................................................................................... 111
4.4.2 Type and Dosage of Fuel, Coolant and Lubricating Oil .........................................................114

Content IX
 Chapter 1 Safety
1.1 Safety Labels
The following warning signs and safety labels are applicable to the vehicle.
• Make sure to know the location and content of label.
• Make sure the cleaning of label. Don’t use organic solvent or gasoline to clean the label so as to
avoid label falling.
• Besides the warning signs and safety labels, there are other labels as well. Use the same method to
treat them.
• Please replace it with a new one if the label is damaged, missing or unreadable. Please refer to the
manual or look at the actual label for the detailed part number and order it from the Shantui dealer.
1.1.1 Diagram of Safety Label Positions

No. Name No. Name

Warning label (take care during machine Warning label (inaccessible
1 9
operation) dangerous area)
Safety and usage of duty oil tank Warning label (inaccessible
2 10
dangerous area)
Warning label (take care during machine Caution label (precautions for getting
3 11
transportation) on and off the vehicle)
Warning label (pay attention to the power Caution label (never violate operation
4 12
switch) requirements)
5 Water tank and radiator labels 13 Warning label (easily crushed area)
Caution label (take care to prevent fire Warning label (fasten the safety belt
6 14
hazards) during operation)
Chapter 1 Safety 1
 )
Warning label (Take care of high Warning label (take care during
7 15
temperature) reversing)
Warning label (take care during engine Warning label (storage battery)
8 16
running )
17 Label (battery cable)
1.1.2 Safety Labels

(1) Precautions for starting, shutdown and

leaving the cab seat (09654-00100) Warning

Please obey the following rules when starting or

shutting down the machine or leaving the cab seat:
• Push the gear lever to the neutral position and
lock it with a safety control lever if any safety
mechanism exists.
• Lock the brake.
• Make sure to lock its control lever when
descending the implement to the ground.

(2) a. Beware of high-temperature oil. (09965-00100)

Caution

• Be sure to stop the engine when opening the oil tank

cap.
• Don’t open the cap when the oil temperature is high.
The hot oil will eject if the cap is open.
• Please slowly loosen the oil tank cap to release all the
internal pressure.
• Don’t loosen the oil plug if the oil temperature is high.
• Replace the oil in the duty oil tank and the filter core
after the first 250 service hours and replace them for
every 1000 service hours later.
• Descend the implement to the ground and stop the
engine when replacing the filter core.

b. Daily inspection before running (09652-01100)

Drain the water in the oil tank before the daily running.

(3) Lock the locking plate during (4) Make sure to close the power switch
transportation between sites (222-90-00016). (222-90-00017).

Warning
Warning

1. In order to ensure the

safety, fix the fixed plate and 1. Make sure to turn off
the pull rod relatively with a bolt the battery switch to cut
to avoid the swinging of tyres off the power supply when
when transporting the repairing the electrical
complete machine or replacing system or using electric
the front wheels. welding.
2. Loosen the bolt and place 2. Make sure to turn off
it in the toolbox during normal the battery switch to cut
working. off the power supply when
the machine is standby for
a long time.

Chapter 1 Safety 2
(5) a. Beware of high-temperature cooling water (09668-00100 and 09650-01101).

Warning

Don’t open the water tank cap in case

of high water temperature to prevent
hot water from injection due to internal
pressure.

Caution

• Check the cooling water from the water filler and ensure the
water level above the filter screen before the daily running.
• Be sure to idle the engine for 5 to 10 min after replacing and
filling the cooling water to ensure the water fills with the cooling
system before the engine running. And then start the running
after checking and verifying the water level is above the filter
screen.
• Don’t remove the filter screen when filling water or antifreeze.

b. It is strictly forbidden to add water

directly into the water tank.

Caution

Proper use of the antifreeze coolant

will reduce the corrosion of the
machine. Don’t use any other coolant
except the antifreeze coolant in the
water tank.

(6) Pay attention to fire prevention

(09666-00100).

Caution

Frequently check the engine and locations with

fire hazard possibility and clear away
combustible accumulation such as branches
and leaves to avoid operation interference and
fire hazard.

(7) Beware of over-high engine surface temperature (replace the label 09817-00880).
The label below indicates that touching hot parts such as the engine, motor or silencer which is running
or just finishes running may lead to the danger of scalding. Therefore, don’t touch them when they are at
high temperature.s

Chapter 1 Safety 3
(8) Take care during engine running (replace the label 09667-00100).

Caution

Obey the following rules during the engine running:

• Don’t open the side cover plate of the engine.
• Don’t approach the fan and fan belt.

(9) Don’t approach the running machine. (10) No entrance.

Warning Warning

• Keep away from

• Easily crushed area
this area when the
engine is running Keep away from this
or the cutting area during the
engine running.
head is off the
ground.

(11) Precautions for getting on and off the machine.

Chapter 1 Safety 4
 Caution

• Get on and off the

machine in order
with the handrail
and steps.

(12) Illegal operation is forbidden. (13) Easily crushed area

Caution Warning

Shovel slewing with load is forbidden. • Easily crushed

area
Don’t stand
between two
wheels when
the engine is
running.

(14) Precautions when operating the machine.

Warning

• Fasten the
safety belt
when
operating
the
machine.

(15) Caution label for reversing (09802-11000).

Warning

In order to prevent fatal accident, please operate the machine and

its auxiliary device as per the following requirements:
• Sound the horn to warn the people around.
• Make sure that nobody is in the machine or around it.
• Please arrange a monitor when the vision is blocked.
Make sure to obey the rules above even if the machine is
equipped with reversing alarm device or rear-view mirror.

(16) Storage battery label (09664-01000) (17) Battery cable label (09808-01000)

Chapter 1 Safety 5
 Warning Warning
Explosive gases
The cigarette, flame and spark may cause battery
explosion. Please pay attention to protect your eyes and
face from injury due to the battery. Be sure not to charge the Improper use of the auxiliary cable and battery
battery, use the auxiliary cable or adjust the cable wire
without correct guidance or training. cable may cause explosion and serious personal
Tighten and level the cowl.
The poisonous gas may cause serious burn.
Sulfuric acid included, please avoid contacting it with skin,
injury.
eyes or clothes.
Immediately flush the contact surface with clear water and
• Please use the auxiliary cable and battery
go to see a doctor in case of an accident.
Place it out of the reach of children.
cable according to the regulations in the
instruction manual.

1.2 Safety Rules

1.2.1 Safety Principle
• Only the personnel who has the motor vehicle driving license of motor grader and is completely
familiar with its operation can drive the motor grader. Drunk and tired personnel are not allowed to
operate the motor grader. And it is absolutely forbidden to operate the malfunctional or overloaded
machine.
• Strictly obey the safety requirements, preventive measures and instrucitons to operate and maintain
the machine.
• Ensure all the related personnel understand all the gestures and signals and then use the method
when working with other operation personnel or the personnel responsible for the traffic guidance of
the construction site.
• Immediately stop the vehicle and overhaul it if any abnormal phenomenon of mechine running
occurs. Don’t perform any operation until the abnormal phenomenon is solved.
• Obey all the related regulations.
• The machine shall be operated under the specified altitude. The power of the machine will decrease
with the increase of altitude. Part damage will quicken if the machine is used over the specified
altitude for a long time.
1.2.2 Safety Device
• Make sure all the shields and covers in correct positions and keep the intactness of all parts.
• Properly use the safety devices such as seat belt and so on.
• Never remove any safety device and make sure the safety device in good working condition.
• Improper use of safety device may cause serious personal injury or death.
1.2.3 Clothes and Personal Protective Equipment
• It is forbidden to wear loose clothes and jewelries as well as have
long & loose hair for they may be hooked by the control lever and
the moving part and cause serious injury accordingly.
• It is forbidden to wear clothes stained with oil so as to prevent
fire.
• Make sure to wear the helmet, safety glasses, mask, gloves and
safety shoes when operating and maintaining the machine. Be
sure to wear safety glasses, rigid helmet and thick gloves if your
work may contact with the splashing sweepings and other fine particles. Make sure to check
whether there is someone near the machine when beating the dowel with a hammer and clean the
filter core of the air filter with compressed air.
1.2.4 Unauthorized Modification
• Any modification unauthorized by Shantui may cause danger. Please consult with Shantui before
modifying the machine. Shantui will take no responsibility for any injury or damage due to
unauthorized modification.

Chapter 1 Safety 6
1.2.5 Locking Before Leaving the Cab Seat
• Make sure that all the control levers are in the neutral or “0” position and the parking brake handle is
pulled up to the brake position when the driver leaves the seat.
• Make sure to descend the implement to the ground completely, place the manual brake at the brake
posistion, turn off the engine and lock the devices such as the guard door and cab door when
leaving the machine. Carry the key with you.
1.2.6 Precautions for Accumulator Application
The high pressure nitrogen contained in the accumulator belongs to dangerous articles. Therefore, make
sure to read the following requirements and take care to use the accumulator.
• Check the accumulator before filling nitrogen into it. It is forbiddent to fill gas into the accumulator
when its steel impression mark is imcomplete or unreadable or the shell defect cannot ensure the
safety use.
• It is forbidden to fill oxygen, compressed air or other inflammable gas except from the nitrogen into
the accumulator in case of explosion.
• Be sure to fix the accumulator securely to the support. Don’t fix the accumulator through welding
method.
• Make sure not to drill any hole on the accumulator or carry any open fire and heat source to get
close to it.
• Don’t weld any boss on the accumulator.
• The accumulator belongs to high pressure container and shall be replaced or maintained by
professional personnel. Before removing the accumulator, release all the pressure oil, let out the
nitrogen in the cachet with a special gas-filled tool and then remove various parts.
• Make sure to release the gas before discarding the accumulator.
1.2.7 Getting on and off the Vehicle
• Face the vehicle and keep the three-point-contact (both feet and one hand or both hands and one
foot) among the body, handrail and the staircase to ensure the safety when getting on and off the
vehicle.
• It is forbidden to get on or off the vehicle when it is moving, or else accidental injury may occur.
• Make sure not to hold any control lever when getting on and off the vehicle.
• Check the handrail and the staircase when getting on and off the vehicle. Wipe off any grease or
sludge on the handrail or the staircase. Repair all the damaged parts of the handrail or the staircase
timely and tighten all loose bolts.
• Don’t get onto the cab from the back of the machine or get off the vehicle from the tyre next to the
cab.
• Don’t get on and off the vehicle with tools or other items. Lift the required tools or items to the
operating platform with a rope.
• The load of the dashboard shall be no more than 200 kg.

Chapter 1 Safety 7
1.2.8 Fire Prevention

• Fuel, oil and antifreeze coolant are inflammables and

easy to cause a fire.
• Keep the liquid away from the source of ignition.
• Shutdown the engine, make sure not to smoke or get
close to the open fire when filling oil.
• Fill the fuel or lubricating oil at the well-ventilated place.
• Tighten the fuel tank cap and the duty oil tank cap
securely.
• Don’t conduct electric welding or flame cutting to the
pipeline with flammable liquid. Clean up the pipeline with
non-inflammable liquid before the electric welding or
flame cutting.
• Clean up the inflammble materials accumulated on the
machine and make sure no existence of tarpaulin or
other inflammables.
• Don’t let the exhaust port of the silencer close to the
place for inflammables such as withered grass, old
paper and so on when operating the machine. Or else, a
fire may occur.
• Make sure to keep the fireworks away from the storage
battery for explosive gas will produce near the battery.
• Don’t use a open fire (a match or a lighter) to check the
dark place.

Chapter 1 Safety 8
1.2.9 Safety Measures for Operation Under High
Temperature
• The engine coolant, oil and hydralic oil are all at high
temperature and pressure state when the operation has
just been stopped. At this time, taking down the cap to
drain oil or water or to replace the filter may cause
serious scalding. Make sure to conduct such operations
according to the operation specificaitons when the
temperature is down.
• Make sure to turn off the engine, cool down the water
and oil, slowly loosen the cap and release the internal
high pressure gas before taking down the cap in order to
prevent the splashing of hot water and oil. (Use your
hand to get close to the surface of the radiator or the
duty oil tank to check the air temperature when the water
and oil temperature is down. Don’t touch the radiator
and the duty oil tank.)

1.2.10 Prevention of Asbestos Dust

Breathing asbestos dust is harmful to human health. Make
sure to obey the following rules when treating the materials
with asbestos fiber:
• Don’t use compressed air to clean the dirt.
• Clean the dirt with water to prevent dust flying.
• Try to operate the machine out of the wind.
• Wear a gas mask if necessary.

1.2.11 Prevention of Crush or Cut Wound

• Don’t stretch your hands, arms or other part of the body into or between the moving parts (such as
between implement and cylinder, body and implement, two tyres, front and rear frame connections
and so on). When the machine is working, the space around the shovel may increase or decrease.
Don’t approach it, or else serious accidents or personnal injury may occur.
• Properly support the equipment or the accessories when working under the machine. Don’t use the
cylinder as the support.
• Unless otherwise specified, no modification can be made when the machine is running or the engine
is working.
• Keep away from all the rotating and moving parts.
• Make sure that no debris exists in the fan blade of the engine fan.

Chapter 1 Safety 9
1.2.12 Fire Extinguisher and First Aid Kit (with the First
Aid Kit Self-prepared)
• Provide the fire extinguisher and master its applicaiton
method. Place it at the specified location.
• Don’t remove the fire extinguisher privately. Immediately
use the fire extinguisher to avoid the property loss when
a fire occurs.
• The storage box shall be equipped with a first aid kit.
• Escape from a fire according to the following method:
Turn off the starting switch, stop the machine and get out
of the machine through handrail and staircase.
• Make sure to know the telephone number of the
emergency contact person.

1.2.13 Precautions for Optional Parts

• Please first read the user’s manual and the related content in the manual when installing and using
the optional part.
• Don’t use the optional part unauthorized by Shantui or the dealer. Using unauthorized optional part
may cause a safety problem and affect the normal operation and service life of the machine.
• Shantui shall take no responsibility for any injury, accident or mechanical malfunction caused by
using unauthorized optional part.
1.2.14 Precautions for Accessories
• Timely replace the cutting edge of the motor grader shovel and the tyres for they are easily worn.
1.3 Safety Specifications
1.3.1 Before Engine Startup
★ Field Safety
• Before starting the engine, check whether there is anything abnormal in the vicinity to possibly
cause a hazard.
• Check the terrain and ground condition, select the optimal and safest the operation method, and
avoid the construction carried out in the area where falling objects usually appear.
• When working on the road, assign the special personnel to command the traffic and set the
barricades for the purpose of ensuring the safety of traffic and pedestrians.
• When carrying out the construction in the place where water pipes, gas pipelines and high-voltage
cables are laid underground, contact the relevant authorities to locate these pipes and lines and try
not to damage them.
• It is not recommended to work underground or in a poorly ventilated environment.
• Before passing the riverway, marsh or sandy bank, firstly check the ground condition, water depth
and water flow rate. Never have the allowable water depth exceeded nor have the drive axle
housing bottom contacted with water. After passing it, clean and check the parts which are filled with
lubricating oil. (For the allowable water depth, see Chapter 3, Structure and Principles).
★ Fire Prevention
• Completely remove the inflammables (such as wood scraps, leaves and paper scraps) accumulated
on the engine box body to avoid a possible fire hazard.
• Check whether the fuel, lubricating oil and hydraulic systems are leaky. Repair the leakage, if any.
Remove all excessive oil, fuel or other inflammable fluids.
• Ensure that a reliable fire extinguisher is available.
• Never operate the machine near a naked fire.
Chapter 1 Safety 10
★ Checks before Startup
• Always perform the routine service and maintenance. If any abnormality is found, immediately
report it to the management personnel and start the machine after the repair.
• Check whether the locking plates of front and rear framework have been unlocked.
• Check whether the coolant level, fuel level, transmission oil level and the oil level in the engine oil
pan are normal, and check whether the air cleaner is clogged.
• Check whether the front axle locking mechanism has been unlocked.
• Check whether the master power switch (battery switch) is turned on.
★ In the Cab
• Check whether all instruments are working normally and the control lever is set to the PARK
position.
• Do not place the parts and tools around the operator seat. As the motor grader may vibrate during
the driving or operation, they may affect the operation, or cause damage to the parts, or move the
control lever to misact and incur an accident.
• Keep the cab floor, control lever, pedal and armrest free of oil, lubricating grease, snow or other dirty
matters.
• Check whether the safety belt, buckle ring and parts are damaged or worn, and replace the
damaged parts. Always tie the safety belt when driving the motor grader. Replace the safety belt
immediately after it has been used for 3 years.
• Never take any inflammable or explosive dangerous objects into the cab.
• Never smoke in the cab.
★ Ventilation for Closed Space
• When you have to start the engine in a closed space, you shall ensure the sufficient ventilation,
since the excessive engine exhaust gas are lethal.
★ Precautions for Rearview Mirrors, Windows and Lamps
• Wipe all windows and lamps to ensure a clear visual field.
• Use the acetaldehyde cleaning solution rather than the formaldehyde cleaning solution, as the latter
may stimulate your eyes.
• Adjust the side rearview mirror to ensure that you have a good visual field when operating on the
operator seat. Immediately replace the damaged rearview mirrors, if any.
• Ensure that the ceiling lamp and working lamps function normally.
1.3.2 Operation of Motor Grader
★ During Engine Startup
• Check the function of brakes and steering gears every day before driving the motor grader.
• Perform a walk-around check before entering the cab to ensure that there is nobody or other
obstruct nearby.
• Only after properly sitting on the seat can you start the engine.
• Never have anyone other than the operator entering the cab or other parts of the motor grader.
• Only start the engine in the cab. Never short the motor circuit to start the engine.
• For the engine startup, the startup time shall not be longer than 20 s after the key has been turned
to the START position. The interval between two startups shall not be less than 2 min.
• The gear selector must be set to the NEUTRAL position.
★ Checks during Reversing
Before operating the motor grader or implement, perform the following items:

Chapter 1 Safety 11
• Sound the siren to warn the surrounding persons.
• Ensure that there is no other person around the motor grader, especially its rear.
• If necessary, assign the special personnel to check the safety, especially during the reversing of
motor grader.
• For the dangerous area or poor visual field, assign the special personnel to command the field
traffic.
• Never have any person entering the driving route of mode grader.
• Follow the above items, even though the motor grader is equipped with the reversing alarm and
rearview mirror.
★ Safety Check
• Before starting the engine or operating the motor grader, ensure that the control lever is set to the
NEUTRAL position.
★ Checks after Startup
• Check whether there is abnormal noise or vibration when the engine runs. The presence of
abnormal noise or vibration means that the motor grader may be malfunctioning and this shall be
immediately reported to the management personnel. Operate the motor grader after the repair
instead.
• Follow the operation instruction to test whether the brake valve and throttle function normally and
whether the motor grader can be steered left and right freely at a low speed.
• Before driving the motor grader, ensure that the hand brake is disengaged.
★ Precautions during Driving
• Before driving the motor grader, sound the horn to signal and ensure the safety.
• Before driving the motor grader, move or retract the blade into the range of wheels with care to
prevent the blade from scraping the frame, ladder, wheels and steering center link.
• Neither look around nor be absent-minded, as a tiny inadvertence may incur a serious hazard.
Rather, notice the driving direction and the surrounding working personnel, and sound the horn to
signal the emergency if a hazard occurs.
• Never drive the motor grader with the cab doors opened (except the fixed doors).
• Never use the motor grader to transport the personnel.
• During the driving, keep the blade as high as possible (just not to contact the framework).
• For the rough road, drive the motor grader at a low speed and stably steer it to avoid the abrupt turn.
• When driving the motor grader, never use the mobile phone.
• Follow the traffic rules on the regular roads. Never cause any obstruct to the road. In particular,
rapidly pass the crossing.
• Drive the motor grader sideward on the road. Be careful to give the way to other vehicles and keep
the proper distances with them.
• If any abnormal noise or smoke is found, immediately stop the motor grader, diagnose the cause
and eliminate the malfunction.
• If the engine or control lever functions abnormally during the driving, immediately stop the motor
grader and perform the repair.
★ Prohibitions on Overspeed Driving
• Be familiar with the performance of motor grader, and determine the appropriate driving speed
according to the actual condition of operation field. Meanwhile, identify the running route and
operation method of motor grader, and inform the relevant working personnel of them.
• Drive the motor grader at a low speed to keep it always controllable.
• When driving the motor grader on the rough or smooth road, avoid high-speed running, adjustive
Chapter 1 Safety 12
 turn and abrupt braking.
• For the untidy zone, or the rough road, or the road with scattered objects, the steering wheel
sometimes may be difficult to control and accordingly cause an overturn accident. Therefore, slow
down the motor grader when passing these places.
• Never turn the motor grader at a high speed.
★ Safe Driving under Severe Environment
• When operating or driving the motor under the severe environment, pay additional attention to
safety, and never work solely at a dangerous place. Perform an advance investigation on the road
condition, the bridge strength and the terrain and geology of operation field to avoid the possible
hazard.
• When driving the motor in the soft or damp zone, notice the wheel sinking or brake effect.
• Notice the possible overturn of motor grader, since the soil stacked on the ground or near the
ditches is soft and may be collapsed under the gravity or vibration of motor grader.
• Avoid driving the motor grader to approach the suspended objects or deep gullies, as the weight or
vibration of motor grader may collapse them to cause the equipment overturn and personnel
casualty.
★ Safe Driving on Slopes
• During the driving on a slope, crabbing or turning the motor grader may risk an overturn, and such a
dangerous operation shall be forbidden. Rather, drive the motor uphill and downhill at a low speed
with the slope gradient less than 20°.
• Carefully control the motor grader and never abruptly brake it during the driving on a slope, since
the gravity of motor grader moves to the rear wheel or front wheels.
• Avoid turning the motor grader on the slope. Only when the motor reaches the even ground can it be
turned. When performing the work on the embankment or slope, slow down the motor grader and
turn it with a narrow angle.
• For the downslope, always engage the gear and drive the motor grader at a low speed. Never shift
the gear when driving on the downslope. If the motor grader speed is over its gear speed, depress
the brake pedal to slow down the motor grader.
• During the driving on the hill, embankment or slope, keep the blade approaching the ground with a
distance of 20~30 cm between them. In case of an emergency, rapidly lower the blade to the ground
so as to stop the motor grader or prevent the overturn.
• If the engine shuts down on the slope, immediately depress the brake pedal, lower the blade, apply
the parking brake, and wedge the wheels by some massive objects.
★ Precautions during Operation
• Nobody is allowed to stand on any place of motor grader except for the control console.
• Never reverse the motor grader when the blade is working.
• Never perform the work with the motor grader at the traveling speed (high speed).
• Never have any person entering the operation area when the motor grader is working.
• Lower the implements to ground or fix them during operation interval or non-service period.

Warning

• Never abruptly accelerate or decelerate the motor grader. The abrupt braking may cause the
personal injury!
• When driving the motor grader, shift the gears in sequence. Never control the motor grader
by the skipping gear shifting, which is very dangerous!
★ Operation with Loads
• When moving or rotating the blade, always be careful to prevent it from scraping the frame, ladder,
Chapter 1 Safety 13
 wheels and steering center link.
• Never slew the blade with loads.
• Before turning or reversing the motor grader, raise the scarifier.
• Raise the dozer when it is not used.
• Never abruptly stop or lower the implements, or else they and the hydraulic system may be
damaged.
★ Assurance of Good Visual Field
• For the place in front with a poor visual field or the narrow road crossing, slow down the motor
grader, resume the driving after a brief stop, and, if necessary, sound the horn to warn other
vehicles or get guided by the special personnel. Avoid the irrational operation.
• When working in the dark environment, use the working lamp and ceiling lamp, and install the
lighting devices in the working site.
• Since the distance and ground height are apt to be misjudged at night, keep the motor grader
running at a speed suitable for the lighting.
• For the poor visual field in a foggy, snowy or rainy day, stop the work, if possible, and just resume it
after the weather turns fine. If it is impossible to stop the work, try to drive the motor grader by
deceleration, and meanwhile have no body entering the working range, or get guided by the special
personnel.
★ Attention to Obstructs
• When turning or driving the motor grader at an obstructive place, be careful to prevent the motor
grader from colliding with those obstructs.
• When turning or driving the motor grader at a narrow place, notice the surrounding environment,
slow down the motor grader, and identify whether there are obstructs nearby.
★ No Approach to High-voltage Cables
• Before the construction, notify the local power authority to take the necessary measures. Only carry
out the construction after the approval of local power authority. Never drive and operate the motor
grader near the cables, as they may cause the electric shock hazard which can result in the serious
property loss and personal injury. If it is compulsory to carry out the construction near the cables,
follow the requirements below:
• Notify the local power authority to take the necessary measures prior to the construction, and carry
out the construction after its approval.
Cable Voltage Safe Distance
• The construction near the high-voltage cables may risk an
electric shock to cause the serious fire hazard and personal 100-200 V >2m
injury. Therefore, always keep a certain safe distance between 6,600 V >2m
the motor grader and the cables (see the right table). 22,000 V >3m
66,000 V >4m
• Before operating the motor grader, carefully understand the 154,000 V >5m
safe operation specifications established by the local power 187,000 V >6m
authority. 275,000 V >7m
• Wear the rubber shoes and gloves to tackle any possible 500,000 V > 11 m
emergency. Put a rubber cushion on the operator seat. Be
careful to prevent the exposed portions of your body from
contacting the chassis.
• When the motor is too close to the cables, assign a signalman
to give off an alarm.

• When the motor grader is working near the high-voltage cables, have nobody approaching it. If the
motor grade has to approach or contact the cables, the operator must be in the cab to prevent the
electric shock and shall not leave the cab until the power supply is surely cut off. Keep anyone away
from the motor grader.

Chapter 1 Safety 14
★ Traction
Towing the motor grader unable to travel by the improper methods or inappropriate steel wire ropes can
cause the personal injury or death. Therefore, the following precautions shall be observed.
• Operate according to the traction instruction given in this manual. Other improper traction methods
may cause some hazards.
• Select the proper steel wire ropes which are free of broken strands, twists and abrasions; wear the
leather gloves when contacting the steel wire ropes by your hands.
• When preparing for the traction together with other workers, use the agreed signals prior to the
operation.
• If the engine of the defective motor grader can not start or there is a malfunction in the braking
system, contact the manufacturer for repair.
• It is dangerous to tow a motor grader on the slope. Select a place with a gradient as flat as possible
to tow the motor grader.
• If the defective motor grader is towed by another motor grader, the steer wire ropes used shall be
strong enough to support the weight of defective motor grader. When connecting the motor grader
to be towed, have nobody going between the towing and the towed motor graders.
• Never stand on the towing ropes or steel wire ropes with your feet apart from each other.
1.3.3 Safe Operation
★ Maintenance of Good Operation Habits
• When operating the motor grader, always sit on the seat, tie the safe belt, check the safety
protection device of claim belt, and ensure that the motor grader is constantly controllable.
• Accurately operate the control lever of implements to avoid the possible misoperation.
• Carefully observe the working status of motor grader. Immediately stop the motor grader and report
for repair, if any malfunction occurs. Never repair the parts when the motor grader is working.
• Never overload the working motor grader. It is extremely dangerous to carry out the operation
beyond the performance of motor grader. Therefore, identify the conditions of working road first of
all to avoid the overload. SHANTUI will bear no responsibility for any damage caused to the motor
grader or personnel by the overload operation.
• Slowly move the motor grader, and adjust the blading angle and depth of blade according to the
working conditions, as the motor grader working with loads may be unstable.
• When operating the motor grader, be careful to prevent the blade from colliding with the hard
objects which may damage it. Nobody shall stand under the front framework, lest the blade may
cause the personal injury when working.
• When reversing the motor grader, carefully and clearly observe the surroundings behind the motor
grader.
★ Attention to Surroundings
• Keep any irrelevant person out of the operation range. Since the implements are moving parts,
some dangerous factors may exist around them (i.e. at the bottom, in the front and rear, and on the
left and right). Never enter their operation ranges until the motor grader is shut down.
★ No Approach to Dangerous Places
• A fire hazard is apt to occur when the gas discharged from the silencer is jetted to the inflammable
materials or the exhaust pipe approaches the inflammable materials. Therefore, special attention
shall be paid to the places where the hazardous materials (such as grease, paper, sear grass and
chemicals) or inflammable materials are present.
★ Parking of Motor Grader
• When leaving the motor grader, completely lower the implements to the ground, apply the hand
brake to lock all auxiliary safety devices, shut down the engine, use the key to lock the devices such
as cab and hood, and set the battery switch to the OFF position.
Chapter 1 Safety 15
• Take along the key.
• Park the motor grader on the even road, if possible.
• When parking the motor grader on the slope, conform to the gradient and put the wedges under the
tyres.
★ Precautions for Frigid Zones
• After the operation, thoroughly remove the water, snow or silt which adheres to the wires, wire
connectors, switches or sensors and their covering parts. Or else, the moisture inside the water,
snow or silt will freeze to fail the motor grader during the next operation and possibly cause an
unexpected malfunction.
• Warm up the motor grader completely. If the motor grader is not completely warmed up before you
operate the control levers, its response will be slow and may accordingly cause an unexpected
accident.
• Operate the control levers to circulate and heat the hydraulic oil in the hydraulic system (by raising
the system pressure to the set value, then releasing the pressure, and finally returning the hydraulic
oil to the hydraulic oil tank). This can ensure the quick motor grader response and prevent the motor
grader failure.
• If the battery electrolyte is frozen, neither charge the battery nor start the engine by another power
supply. In this case, charging the battery or starting the engine by another power supply is
dangerous and may ignite the battery.
• When charging the battery or starting the engine by another power supply, you shall melt the battery
electrolyte prior to the startup and check for leakage.
1.3.4 Transportation
★ Loading and Unloading
• Special attention shall be paid, since hazards are always potential when you load/unload the motor
grader. When loading/unloading the motor grader, both run the engine and drive the vehicle at a low
speed.
• Load/unload the motor grader on the hard and flat ground, and keep a safe distance from the
roadside.
• Always use the cushion blocks to pad the wheels and ramp plates of trailer prior to
loading/unloading.
• The ramp plate used shall have enough strength, length and width to constitute the ramp providing
a safety gradient. The angle between the ramp plate and the ground shall not be wider than 15°,
and the distance between the ramp plates shall be corresponding to the wheel track of motor
grader.
• Ensure that two ramp plates are firmly placed and fixed on the same plane.
• Keep the ramp plate surface clean and free of grease, ice or other scattered objects. Remove the
dirty objects from the tyres of motor grader.
• Never operate the steering wheel and framework steering control lever on the ramp plates. If
necessary, remove the ramp plates, calibrate the direction and then mount the motor grader again.
• After loading the motor grader, lock the hinged framework by the locking plate, lower the blade to
the ground, wedge the motor grader tyres, strictly bind the motor grader, and ensure that the front
axle locking mechanism is locked.
★ Conveying
• When conveying the motor grader by the trailer, comply with the national and regional specifications
on the lengths, widths and heights of relevant goods, and follow all applicable laws.
• When determining the conveying route, consider the length, width and height of goods to prevent
the inconformity with the restrictions.
• When passing the bridge or the structure in the private land, firstly check whether it has the enough
strength to support the weight of the motor grader. When driving the motor grader on the public
Chapter 1 Safety 16
 roads, you shall meet and follow the relevant rules.
• If you want to convey the motor grader by other means, please contact SHANTUI or its authorized
agents.
1.3.5 Battery
• The battery electrolyte contains sulphuric acid, which will quickly burn the skin and cloth in case of
splash. If the sulphuric acid is splashed on your body, immediately wash clean with water.
• The acid can lead to blindness if splashed into eyes. So if it occurs, immediately flush with a large
quantity of clean water and see a doctor.
• If accidently drunk, immediately drink a large quantity of water or milk, eggs or vegetable oil and
then see a doctor.
• Wear safety glasses or goggles and rubber gloves, etc. when handling the battery.
• This battery is of maintenance-free type, without the need to fill electrolyte, so it’s possible to
determine the conditions of the battery just by watching the color of the sightglass above it. It
indicates that the battery is in normal status when the color is green, in low power status when it is
black and shall be charged and doesn't work properly when it becomes white and shall be replaced
immediately.
• The battery may generate hydrogen, which is very explosive and easily ignited by small sparks or
flames. So never keep the ignated cigarettes or open flames close to the battery.

• Stop the engine and turn the ignition switch and battery
switch to OFF position before handling the battery.
• Avoid short circuit between the battery positive (+) and
negative (-) terminals due to accidental contact of metal
objects such as tools.

• Connect the positive (+) terminal first when installing the battery and disconnect the negative (-)
terminal (at one side of ground wire ) first when removing the battery.
• Determine the positive (+) and negative (-) terminals first and then tighten them tightly with nuts
when removing or installing the battery.
• Use cloth to wipe when cleaning the top surface of the battery. Never use gasoline, solvent, any
other organic solvent or cleaner.
• Neither charge the battery or start the engine by other power supply if the battery electrolyte has
been freezed, which is dangerous and may result in a fire. It's required to melt the electrolyte and
check for any leakage before starting during charging process or when starting the engine with other
power supply.
• Remove the battery from the machine before charging.
• Turn the battery to OFF position to prevent from current flowing when repairing electrical system or
welding on the machine.
• Tighten the electrodes reliably, because loosen electrodes may lead to sparks, thus resulting in
explosion.

Chapter 1 Safety 17
★ Charge of battery
There will be explosive risk if the battery is handled incorrectly when it is charged. Therefore, it's required
to follow the battery operating instructions and the related maintenance procedures in the manual and
comply with the following notes.
• Charge in a well-ventilated place and take off the top cover of the battery to spread hydrogen and
prevent explosion.
• Set the voltage of the charger to one that corresponds to the voltage of the battery charged.
Incorrectly voltage setting will result in overheat and a fire to the charger, thus bringing an explosion.
• Connect the positive (+) charging clamp of the charger to the positive (+) terminal of the battery and
the negative (-) charging chuck to the negative (-) terminal of the battery and then be sure to tighten
the two terminals firmly.
• Fast charge the battery and set the value below its rated capacity if its charging rate is lower than
1/10. Excessive current may lead to leakage or evaporation of the electrolyte, which may result in a
fire or explosion.
★ Starting with charging cable

Incorrect

• Wear safety glasses or goggles when starting with charging cable.

• Don’t allow the two machines to contact when starting with the battery of another machine.
• Be sure to connect the positive cable first when using charging cable and remove the negative
ground wire when removing.
• Sparks will be generated if any tool contacts the positive terminal and chassis simultaneously, which
is very dangerous. So be sure to operate carefully.
• Make sure reliable coupling when couple the ground wire to the frame of the vehicle to be started.
• Pay attention not to allow the clamps of the charging cable to contact with each other or the
machine when removing the cable.
1.3.6 Towing
★ Fasten the towing pin with a cable when towing
• Incorrect towing method will result in personnel injury or machine damage.
• Be sure to use a cable with enough strength when towing the vehicle with other vehicle.
• Place the control lever to Neutral position and, if possible, allow the engine running thus to make the
steering and brake still effective.
• Never tow the vehicle on a slope.
• Don't use curled and twisted cable.
• Don't stride over or get close to the towing cable.
Chapter 1 Safety 18
• Don't allow any person to get into the area between the towing vehicle and the towed vehicle when
coupling the vehicle to be towed.
• The vehicle shall not be towed with a towing speed higher than 10 km/h for a distance over 10 km.
1.3.7 Preparations Before Maintenance
★ Warning labels
• Serious personnel injury or death will be resulted if other personnel start the engine or operates the
control lever when the maintenance personnel is maintaining the machine or refuelling.
• Label a warning label on the control lever in the cab to remind others that you are overhauling the
machine. And provide other warning labels around the machine if necessary.
★ Appropriate tools
• Only use the tools with reliable quality. Using damaged, poor, defective or makeshift tools may
cause injuries to you.
★ General knowledge
• The personnel irrelevant to the maintenance and repair work being performed shall not enter into
the working area. Appoint special personnel to watch if necessary.
• Repair the vehicle according to the specified procedures, or seek for help from the technical service
personnel of the Shantui Construction Machinery Co., Ltd. if you don’t know how to do.
• Predetermine the working commander and prepare working procedures for step-by-step work when
repairing the vehicle or assembling and removing the components.
• Wear work cloths with tightening sleeves and trouser legs as well as safety glasses.
• Keep clean and tidy around the working place, free from scattered oilcloth and lubricating oil
(lubricant), etc. to prevent fire and personnel falls.
• Paste a label with words “No Operation” or other similar warning labels on the starting switch and
instrument panel before maintaining to prevent the personnel injuries or death resulted from others’
starting the engine or operating the control lever.
• Fix the front and rear frames with a connecting rod before inspecting and servicing the vehicle.
★ Replace safety-critical components periodically
• Periodically replace the safety-critical and easily aged components.
Periodic Replacement Table for Key Parts
No. Key Parts to Be Replaced Periodically Qty. Replacement Period
Every year or every 2000 h
1 Return oil filter element of hydraulic oil tank 1
(Whichever comes first)
2 Oil filter of hydraulic oil tank 1
3 Oil filter screen of fuel tank 1
4 Fuel pipe (fuel tank – diesel prefilter) 1
5 Fuel pipe (diesel prefilter - fuel delivery pump) 1
6 Fuel pipe (fuel delivery pump – diesel filter) 1
7 Fuel pipe (diesel filter – high-pressure pump) 1
Every two years or every 4000
8 Fuel return pipe 1
h
9 Hose (torque converter - radiator) 1
(Whichever comes first)
10 Hose (radiator - torque converter) 1
11 Front wheel steering cylinder seal 2
12 Rack steering cylinder seal 2
13 Hose (oil pump - prefill valve) 1
14 Hose (prefill valve – foot brake valve) 1
15 Hose (foot brake valve – brake rigid tube) 2
• Be sure to replace in case of any defectiveness even though it’s not the time to replace.
• Be sure to replace the sealing elements such as O-ring and sealing gasket when replacing the
Chapter 1 Safety 19
 hose.
• Contact the Shantui Construction Machinery Co., Ltd. or its designated dealer for the replacement
of safety-critical parts.
★ Stop the engine before inspection and maintenance
• Be sure to stop the vehicle on the solid and leveling ground and pull out of the key before the
inspection and maintenance. Otherwise others may start the engine or operate the control lever
when you are maintaining, thus resulting in injuries to you.
• Lock the front and rear racks with steering hinged locks.
• Allow the front axle locking mechanism under locking status and turn off the battery switch.
• Be sure to place the hand brake to Brake position and operate by two persons with one seated on
the driver seat to turn off the engine immediately if needed while taking special care to avoid injuries
to the maintainer resulted from incorrect operation of control lever if it’s required to maintain with the
engine running, such as cleaning the inside of the radiator.
• The maintenance personnel shall pay special attention not to contact the moving components to
prevent from being hooked.
1.3.8 During the Maintenance
★ Personnel
• Only trained personnel who gets relevant qualification can maintain and service. It's required to take
some safety measures when grinding, welding and using the removers.
★ Accessories

• Place the parts removed from the machine in a safety place to make sure they won’t drop and falling
down. Failure to do this will lead to serious injuries. Hang up a label with words “No Entry” around
the accessories to prevent unapproved personnel from getting close.
• All non-staff are not allowed to get close to the machine or accessories.
★Keep the vehicle clean

• Keep the vehicle clean and tidy whenever. Clean the

machine before carrying out overhaul and maintenance,
which can not only make sure that the dirt won’t enter into
the machine but also the maintenance proceeds safely.
• Don’t use water or steam to wash the sensors, plugs or
cab inside. Water entering into the electrical system may
result in a danger under which the machine cannot move
or moves suddenly.

• Make sure the cleaness when performing overhaul and maintenance, otherwise it will be difficult to
find the faults. During the overhaul and maintenance period, the dirt or sludge on the machine may
be splashed into eyes and easily result in personnel slippage and injuries.
• Never use gasoline or other flammable substance as cleaner to wash the machine.
• Wear non-slip shoes to prevent slippage on wet surface when washing the machine and wear
protective cloth when flushing the machine with high-pressure water.
Chapter 1 Safety 20
• Be sure to wear protective cloth and safety glasses when sweeping the filter elements with
compressed air.
★ Anti-explosion
• Use the lighting device with anti-explosive function when inspecting the fuel, lubricating oil and
battery electrolyte. Failure to do this will bring explosive hazard.
• There will be injury hazard if working in dark place without lighting, so it’s required to install
appropriate lighting facilities.
• Don’t use lighters or open flames for lighting even in dark places. There will be fire hazard, because
the gas emitted from the battery may generate explosion if it contacts fire.
★ When working under the machine

• Place the implements on the ground or the lowest position

when maintaining the machine or servicing under the
machine.
• It’s prohibited to work under the vehicle without safety
support or with poor support.
• Fix the tyres with wedges.
• It’s very dangerous when working under the machine if the
tyres are supported only with implements to lift them off
the ground.

★ When working on the top of the machine

• When maintaining on the top of the machine, make sure the foothold is clean and free from
obstacles while noting that there shall be no scattered lubricating oil or lubricant and tools around
and noting the steps when walking to prevent from falling off.
• Never jump from the machine. Face the machine and use a ladder and handrail when getting in and
out the machine while keeping three points (two feet and one hand or two hands and one foot)
contact all the time.
• Use protective equipment if necessary.
• It’s not allowed to stand on the top of the engine hood because it is smooth and dangerous.
• Don’t stand on the top of the tyres because it is smooth and dangerous.
★ When the engine is running
Don’t maintain when the engine is running to avoid injuries. If it’s required to maintain with the engine
running, comply with the following notes.
• Arrange one worker seated on the driver seat and prepare to turn off the engine at any time. All the
workers must keep contact with others.
• Don’t touch the high temperature components such as tail pipe and muffler to avoid scald.
• When the working points are close to rotating parts, there will be an involvement hazard, so be sure
to take special care.
• Don’t touch any control lever. If it’s required to operate the control lever, send a signal to other
workers in order to warn them to go to safety place.
• Never allow any tools or any part of your body to contact with the fan leaf or fan belt. Failure to do
this may result in serious injuries.
• Don’t blindly adjust the components you don’t know.
★ Don’t allow foreign materials into the machine
• Pay attention not to allow any foreign materials (such as nuts, bolts, cotton yarn or tools) falling into
the machine when opening the access panel or overhauling the oil filler of the oil tank. Such items
falling into the machine inside will lead to machine damage, misoperation and other faults. Be sure
Chapter 1 Safety 21
 to take out from the machine if any foreign materials fall into the machine.
• Don’t take any unnecessary tools and parts in your pockets when performing the overhaul.
★ Heavy objects
• Be sure to wear protective glasses, safety helmet and other protective cloth and place a copper bar
between the hammer and the part to be hammered when using a hammer.
• Hammering the hard parts (such as pins or bearings) with the hammer may get the fragment into
eyes, thus causing injuries.
• Carefully use the tools and heavy objects to prevent falling off.
★ Welding repairs
• The welding work shall be carried out by a qualified welder in the place equipped with appropriate
equipment. Never allow the personnel without welder certificate to operate because welding will
generate gases, which may result in a fire and electric shock when working.
• Disconnect the battery terminals and turn off the battery switch to prevent battery explosion.
• Disconnect the harness connector at the gear lever (at the right lower side of the cab); after the
repair, be sure to connect it according to the requirements, otherwise the vehicle will fail to work.
• Remove the paint on the area to be welded to prevent the generation of harmful gases.
• Flammable steam and sparks will be generated if welding on the hydraulic equipment or pipeline or
the areas very close to them, which will bring a fire hazard. Therefore, such situations shall be
avoided.
• If the sparks splashed from welding may directly fall on the rubber hoses, cables or pressure
pipelines, these pipes may burst suddenly and the insulation cover of the wires will be damaged, so
it’s required to cover them with fire dampers.
• Pay special attention when welding in the area close to tyres because the tyres may explode.
• Wear protective cloth when welding.
• The welding sites shall be well-ventilated.
• Remove all flammable materials and provide fire extinguisher in the working sites.
• Don’t carry out the modification that affects the performance, safety and strength of the vehicle and
implement in the sites.
★ Principles for fuel and oil filling
• The engine must be shut down when refuelling. It’s forbidden to smoke and get close to open flames
during the refueling process.
• Be sure to timely remove the leaked fuel and oil to avoid slipping.
• Be sure to tighten the oil filler cap.
• Never wash the components with fuel.
• Be sure to refill in a well-ventilated place.

• The model and type of the oil and water used by the machine depends on the working conditions
and air temperature, which shall be selected according to the table “Category and Quantity of Fuel,
Coolant and Lubricating Oil”.

Chapter 1 Safety 22
• Avoid persons and pets contacting with the coolant
because it is poisonous. Middle part

• Use “soft water” as cooling water as far as possible and

never use sewage as cooling water.
• Be sure to timely remove or replace various filters.
• Check the coolant, fuel, lubricating oil, working oil, etc. at
any time and add according to the requirements to ensure
the normal operation of the vehicle.

★ Quantity of radiator antifreeze

• When checking the quantity of the coolant, stop the engine, allow it and radiator to cool and then
check the quantity of the antifreeze.
• Slowly loosen the cover to release internal pressure before removing it.
★ Usage of lighting
• Be sure to use explosion-proof light when checking the fuel, oil and coolant. Failure to do this will
result in explosive hazard.

★ Notes on battery maintenance

• It's forbidden to smoke and use open flames when working on the battery.
• Don’t allow the battery medium to contact with skins and cloth. In case of injuries due to electrolyte,
flush with water and then see a doctor at once.
• Don’t allow metal objects (such as tools, ring and watch) to contact with the electrodes of the battery,
which will result in short circuit and fire hazards.
• Turn off the battery switch and cut off the power when repairing the electrical system or welding.

• Dispose the old battery according to environmental protection requirements.

• Never allow smoke and flames getting close to the battery and maintain and use the battery strictly
complying with the product specifications because there will be explosive gas generated near the
battery.
★ Overhaul of hydraulic system
• Place the scraper knife on the ground, cool the hydraulic oil and release all system pressures in the
hydraulic system before overhauling the hydraulic system.
• Don’t bend or hammer high pressure pipelines and install the abnormally bent or damaged rigid pipe
or hose to the machine.
• Timely repair or replace loose or damaged fuel and lubricating oil pipes, rigid pipes and hoses of the

Chapter 1 Safety 23
 hydraulic system. Because leakage may result in a fire.
• Carefully check the pipelines, rigid pipes and hoses and tighten all connectors as per the specified
torque. Use plate or paperboard instead of naked hands to check for leakage. Even pin-hole sized
pressure liquid leakage may penetrate muscle, thus leading to personnel injuries or death. If the
liquid gets on the skins and results in injuries, immediately go to the hospital and ask a professional
doctor to treat.
• Replace if the connector is damaged or leaked, the hose outer layer is wore or cut, the reinforced
steel wire is exposed, locally upheaved, obviously twisted or pressed incorrectly, the steel wire in
the reinforced layer is inserted into the outer layer and the end connector mismatches.
• Make sure all pipe clamps, guard boards and heat-proof covers are correctly installed to avoid
overheat resulted from vibration or friction with other parts.
• Select a suitable container to store the liquid when replacing the oil for hydraulic system, filters and
other parts. The liquid waste disposal shall be in accordance with the local environmental protection
laws and regulations.
★ Disposal of high pressure hose
• Don’t bend or hammer the high pressure hoses with rigid objects and use bent or cracked hoses
and rigid pipes. Failure to do this will lead to explosive hazard when using them.
• Timely tighten the loose connectors and replace the ruptured oil pipes to prevent oil leakage.
Because oil leakage may lead to a fire.
★ Notes on disposal of high pressure oil
• Never forget that pressure exists in the oil pipelines of implements all the time.
• Don’t refill, drain the oil or carry out maintenance and inspection before releasing the internal
pressure.
• It is very dangerous If the high pressure oil is leaked from a small hole and gets on your skins or is
splashed into your eyes, so be sure to wear safety goggles and thick gloves and stop the leakage
with thick paperboard or small wooden blocks.

• If you are hurt by the high pressure oil, immediately contact the doctor and get timely treatment.
★ Notes for maintenance under high temperature and high pressure
• Just after stopping the working, the engine coolant and oils in all parts are under high temperature
and high pressure status. Under such conditions, opening the covers to drain oil and water or
replacing filters may result in scalds or other injuries. Therefore, it’s required to check and maintain
according to the procedures given in the manual after the temperature decreases.

• Turn off the engine, allow the water to cool and slowly loosen the cover when opening it to release
the pressure in order to prevent the hot water from splashing. When checking whether the water
temperature decreases, it’s possible to place your hands close to the front of the radiator to check
the air temperature. Pay attention not to touch the radiator.

Chapter 1 Safety 24
• Turn off the engine, allow the oil to cool and slowly loosen the cover when opening it to release the
pressure in order to prevent the hot oil from splashing. When checking whether the oil temperature
decreases, it’s possible to place your hands close to the front of the hydraulic oil and torque
converter oil radiators to check the air temperature. Pay attention not to touch the radiator.
• Don’t touch the engine body or muffler, tail pipes and electrical elements when the engine is hot to
avoid scalds.
• Don’t remove the engine oil temperature sensor, water temperature sensor, torque converter sensor
and A/C water pipes when the engine is hot to avoid scalds.
• Avoid the coolant contacting with your skin and eyes because it contains alkaline substances.
• Select a suitable container to store the liquid when replacing the coolant, engine oil, transmission oil
as well as filters and other parts. The liquid waste shall be disposed according to the local
environmental protection laws and regulations.
• Prevent the refrigerant from splashing onto your skin and thus resulting in frostbite when removing
the connecting pipelines of the A/C compressor.
★ Rotating fans and belts
• Don’t get close to rotating components to prevent getting caught in.

• There will be cut-off or knock-up hazards if your body or tools contact with the fan blades, so never
contact with any rotating parts.
★ Maintenance of tyres
• Burst of tyres and wheel rim parts will lead to serious casualty accidents.
• The installation of tyres needs specialized knowledges and tools. It’s preferred to assemble the
tyres in a special factory if necessary.
• Make sure the tyre pressure is correct and no more than the specified maximum.
• Check the tyres for correct pressure, cut marks and ballooning, the wheel rims for damage and the
bolts and nuts for missing everyday. It’s not allowed to drive a vehicle with damaged tyres.
★ Wastess
• Don’t pour the waste oil into sewers or rivers.
• Be sure to put the oil drained from the machine into a container and never pour it on the ground.
• Observe relevant laws and regulations when disposing the oil, fuel, refrigerant fluid, solvent, filters,
battery and other poisonous (harmful) substances.

• Don't discard the battery and dump the acid liquor at will when the battery cannot be used any
longer due to electrode ageing. Failure to do this may hurt yourself or other people, livestock around
and pollute the surrounding environment. So, the used battery shall be sent to Waste Recycling
Chapter 1 Safety 25
 Department for disposal.

Chapter 1 Safety 26
 Chapter II Operation
2.1 Operation Devices
2.1.1 General Layout of Operation Devices
1) For positions and names of parts of operation devices and combination instruments in the SG18-3
motor grader, see Figures 2-1, 2-2 and 2-3.

Combination instrument and steering wheel Gear lever Throttle control lever

Fig. 2-1

Implement control
lever

Fig. 2-2

Brake pedal Foot throttle pedal

Brake handle

Fig. 2-3

Chapter II Operation 27
 2.1.2 Functions of Operation Devices

1) Throttle Control Lever and Accelerator Pedal ① ②

(see Fig. 2-4)
The lever is to control the engine speed and output
power.
① Idle speed position
② High speed position
2) Gear Shift (see Fig. 2-5)
The control lever is to control the forward traveling and
reverse of vehicle, and driving speed. The middle Fig 2-4
position is N (neutral) position (see Fig. 2-5).

The control lever is operated to the left to achieve Forward Reverse Neutral
forward gear 1, and forward to achieve gears 2, 3, 4, 5
and 6.
The control lever is operated to the right to achieve the
reverse gear 1, and backward to achieve gears 2 and 3.
The gear shift shall be performed in sequence, and it is
not allowed to skip gears.

Fig.2-5

Caution

When the vehicle is stopped for a while, make sure to set the gear lever to “N” (neutral).
3) Steering Control (Fig. 2-6)
The steering wheel is to control the front wheel to turn left and right, and allows for turn with a small
radius.
The turn with a large radius can be achieved by operating the frame steering control lever. Push the
lever forward to turn left and pull the lever backward to turn right.

Front-wheel steering Brake pedal Throttle pedal

Frame steering control lever

Fig. 2-7
Fig. 2-6

4) Brake Pedal (see Fig. 2-7)

The brake pedal acts on the wheel brakes of 4 rear wheels via the hydraulic system.

28 Chapter II Operation
If the pedal is depressed, the vehicle will stop.

Caution

Do not hold your foot on the pedal if not required.

5) Throttle Pedal (see Fig. 2-7)
The pedal is to control the engine speed and output power, linked with throttle control lever.

6) Hand Brake (see Fig. 2-8) Release position

Braking position
It is used for parking braking, controlling the brake
on the transmission output shaft.
Hold the hand brake lever, with your thumb
pressing on the cylindrical pin on top of the lever to
pull up the hand brake lever to the highest position.
Then, release your thumb and the vehicle is
braked.

Fig. 2-8

Caution

• To start the vehicle, lay down the hand brake lever A ( free position).
• To prevent sliding of a stopped vehicle, pull the hand brake lever A up to lock the vehicle.
7) Control Lever of Implement (see Fig. 2-9)
As shown by the symbol on the control lever, operating a control lever can control corresponding action
of implement by means of hydraulic drive.

Frame articulation steering control

Scarifier lift control Blade tilt control

Blade slewing control Blade lift control

Chapter II Operation 29
 Blade sideshift control Front wheel lean controlFront dozer control

Blade lift control Blade reclining control

Fig. 2-9

2.1.3 Combination Instrument and Functions

1) Functions (see Fig. 2-10A/B)
The combination instrument of The first structure grader includes the engine oil pressure gauge, water
thermometer, voltmeter, hour meter, and transmission oil thermometer.
The combination instrument of The second structure includes the engine oil pressure gauge, water
thermometer, voltmeter, hour meter, transmission oil thermometer and Tachometer and hour meter,
generally for monitoring the working state of machine.

Caution

Always check the instruments during the operation to confirm if the parts work properly.

Fig. 2-10A
Fig 2-10B
2)Engine Oil Pressure Gauge (see Fig. 2-11)
It indicates the engine oil pressure, with the range of 0 ~1 MPa.
When the engine is running normally, the oil pressure shall not
be lower than 0.1 MPa or higher than 0.5 MPa.
The engine shall be preheated, as the pressure may be higher
during the cold start, so as to keep the instrument indication
within the normal range before operation.

Fig.2-11

30 Chapter II Operation
3) Voltmeter (see Fig. 2-12)
Before the machine operation, if the voltmeter indication is
higher than 24 V, it means the battery voltage is normal;
otherwise, the battery voltage is low and may lead to difficult
startup. If the engine can’t be started, the battery shall be
recharged.
During the normal operation of machine, the voltmeter indication
is about 28 V. If the voltage is lower than 27 V or higher than
29.5 V, identify the cause and do troubleshooting before
operation. Fig. 2-12

4) Water Thermometer(see Fig. 2-13)

It indicates the engine coolant temperature. During the normal
operation of machine, the indication is lower than 108℃. If it is
exceeded, it means the coolant temperature is above 100℃. In
such case, the engine speed shall be reduced to make the
indication return to normal; stop the vehicle and check the
coolant level if necessary.

Fig.2-13

5) Hour Meter (see Fig. 2-14)

It records the engine running time as a basis for regular
maintenance and malfunction occurrence time, with the
indication range of 0~99999.9 h.

Fig. 2-14

6) Oil Thermometer (see Fig. 2-15)

It indicates the working oil temperature of torque converter.
During the normal operation of machine, the indication is below
110℃. If the value is exceeded, it means the oil temperature is
high, and when it reaches 120℃, it means the oil has reached
critical temperature and needs close attention; if the indication
exceeds 120℃, the engine speed shall be reduced to make the
indication return to normal, and the vehicle shall be stopped for a
check if necessary.
The normal working temperature of torque converter is Fig. 2-15
80℃-110℃, allowing an instantaneous rise to 120℃.

Chapter II Operation 31
7) Tachometer and hour meter (see figure 2-14)
It indicates engine speed within 0～3000r/min.
It records running hours of engine, reminding the driver of
regular maintenance and indicating occurrence time (0-99999.9
hours).

2.1.4 Other Devices Fig 2-16

1) Starter Switch (Fig. 2-17)

Fig. 2-17

OFF: If the ignition key is inserted or removed, the circuits in this position will be broken.
ON: If the key is turned to right to this position, the circuit is connected.
START: (Fig. 2-17) If the gear lever is set to netural, and the key is clockwise turned to START,
the starter motor will drive the engine. The key shall be released immediately after the
start and the switch will automatically return to ON.
STOP: If the starter switch is turned to OFF and anticlockwise turned to S, the engine will be
stopped.

2) Horn Button
The horn button is in the middle of steering wheel. If it is pushed,
the horn will sound.
3) Fuse Box (Fig. 2-19A/B)
The fuse is to prevent overload or short-circuit of electrical
system. A fuse shall be cleaned or replaced in case of rust. Horn button

Fig. 2-18

★ The fuse of the same capacity shall be used for replacement.

The starter switch shall be turned off for fuse replacement.
Fuse arrangement and current capacity of electric appliance

32 Chapter II Operation
 Wiring Diagram of Fuse Box
To power supply

14 13 12 11 10 9 8 7 6 5 4 3 2 1

A/C power supply

Horn

Working lamp switch

Flasher

lamp
Charge
supply
Instrument

Key switch
switch
switch
TRear lamp

Front lamp

indicator

power
Fig. 2-19A
Fuse Box
No. Fuse Capacity Circuit
1
○ 30A Starter switch
2
○ 20A Instrument power supply
3
○ 20A Electric control transmission
4
○ 20A Brake control
5
○ 30A Front lamp, main working lamp
6
○ 30A Wiper etc.
7
○ 20A Rear lamp, auxiliary working lamp
8
○ 20A Preheating controller
9
○ 15A Horn power supply
1○0 10A Hand brake power supply
1
○1 25A A/C power supply
1○2 20A Cab power supply
1○3 20A Cab power supply
1○4 20A Cab power supply

Chapter II Operation 33
 Fig 2-19B(The second structure)
Fuse Box
No. Fuse Capacity Circuit
1 30A Starter switch
2 20A Instrument power supply
3 20A Gear selector
4 15A Flasher
5 20A Brak control
6 20A Tail lamp switch
7 30A Tail lamp, auxiliary work lamp
8 15A Horn power supply
9 20A Hand brake power supply
10 20A 前灯开关
11 25A A/C power supply
12 20A Cab power supply
13 20A Cab power supply
14 20A Cab power supply

4) Combined Indicator Lamp (Fig. 2-20)

○
1 ○
2 ○
3 ○
4
• Left and right turn signal indicator lamps
①, ④
If the left turn switch is turned on, the left turn
indicator lamp ①will be on.
If the right turn switch is turned on, the right turn
indicator lamp ④ will be on.
• Low pressure warning lamp ②
It indicates the brake fluid pressure. If the lamp is
on, it means the brake fluid pressure is low and
braking capacity is decreased or braking can’t be ○
5 ○
6
applied. In such case, stop the vehicle for check or
wait until the system pressure reaches the
specified value before operation. Fig 2-20

• Charge indicator lamp ③

It indicates the working state of generator. When
the generator works, it will be off; if the generator
doesn’t work, it will be on.
• Hand brake indicator lamp ⑤
The lamp ⑤ will be on if the hand brake lever is
pulled up, and off when the hand brake lever is
released.
• Oil pressure indicator lamp ⑥
If the oil pressure is below 0.08 MPa, the lamp ⑥
will be on.

34 Chapter II Operation
 ○
1 ○
2 ○
3 ○
4
Fig. 2-21

5) Rear Lamp Switch ① (Fig. 2-21)

It controls the rear lamp.
6) Front Lamp & Instrument Lamp Switch ②
(Fig. 2-21)
It controls the front lamp and instrument lamp.
7) Working Lamp Switch ③ (Fig. 2-21)
It controls the main and auxiliary working lamps.
Set the switch at neutral and the working lamps will
be off; push it forward and the main working lamp
will be on; pull it backward and the auxiliary
working lamp will be on.
8) Pull Pin Switch ④ (Fig. 2-21) Fig. 2-22
○
1
It controls the pull pin electromagnetic valve.
9) Battery Switch ⑤ (Fig. 2-22)
It controls the battery and electrical circuit on / off.

10) Adjustment of Drivers Seat (Fig. 2-23)

Forward/backward adjustment: Lift the control
lever “1” and move the seat forward or backward to
the required position. After the adjustment, the
control lever shall be repositioned.
Upward/downward adjustment: Lift the handle “2”
with both hands to lift or lower the seat. Two
handles 2 are set symmetrically, one for each side.
Backrest angle adjustment: Lift the handle “4” to
properly adjust the backrest angle and release it
after adjustment.
Seat hardness adjustment: Clockwise or anticlock
wise rotate the handle “3” to harden or soften the
seat. The optimal comfort can be achieved by
adjustment depending on the weight. Fig. 2-23

Chapter II Operation 35
★ The damping capacity of operator’s seat
shall comply with ISO7096.
Seat belt
Check if the safety bracket and belt are
normal before fastening the seat belt.
Fasten the seat belt using the following methods:
1. Adjust the seat by following the above steps:
Check the belt for twist.
2. Sit in the seat, hold the buckle (2) and insert the Fig. 2-24
plug (3) into the buckle (2). Move the seat belt to
check if it is fastened (Fig. 2-24).
3. To remove the belt, lift the cusp of buckle lever
and unfasten the belt.
Fasten the belt along but not wrap the operator’s
body. The belt length can be adjusted at both sides
of the buckle and plug, and the buckle shall be at
the center in front of the operator’s body.
The belt length shall be adjusted as follows. (Fig. Fig. 2-25
2-25)
1) To shorten the belt, pull its free end at any side
of the buckle or plug.
2) To lengthen the belt, make it at right angle to the
buckle or plug and pull it.

11) A/C (Figures 2-26~2-28)

1. Start the engine.

Air outlet Air volume knob A/C switch/temperature adjustment knob

Fig. 2-26
2. Open the air outlet and operate the Air volume switch to start the fan. The switch has 3 gears and 4
positions from left to right to allow the gradual evaporator fan speed rise and adjustable air volume.
3. Turn on the A/C switch to MAX COLD. Then, the compressor starts to work and the system begins
refrigeration. When the temperature is appropriate, turn the switch back to adjust the temperature
depending on the operator’s need.
4. Heating
Start the engine for 10 min for water temperature rise, and then open the water pipe valve and adjust the
air volume switch to supply warm air.
5. Precautions for Use:

36 Chapter II Operation
⑴ Do not keep the temperature adjustment knob to MAX COLD and the air volume switch at LOW.
Otherwise, the evaporator may frost.
⑵ Try to protect the stopped vehicle from sunshine in summer.
⑶ When using the A/C, close the doors and windows; during refrigeration, shut off the valves of heat
source; during heating, do not open the refrigerating system.
⑷ No refrigeration is required in winter, but the compressor shall be run once (about 1 min) every week
to maintain the A/C in normal working state.
⑸ During heating, the water temperature shall be above 80℃.
⑹ In case that the principle is not fully understood and reliable protective measures are not available,
do not open the A/C system pipeline to avoid accidents.

Compressor Fluid reservoir

window

Fluid reservoir

Fig. 2-27
Fig. 2-28

★ If there are bubbles in the fluid reservoir window, or the refrigerating effect is not obvious,
turn to professional maintenance staff for treatment.
12) Fire Extinguisher
The machine is furnished with a fire extinguisher. Perform according to safety rules in case of a fire.
2.2 Driving
Warning

Prior to machine overhaul, install the articulation lock, apply the hand brake, turn off
the power and battery switches, lock the front axle locking mechanism and turn off the
engine, and place the machine on the level ground.
Before going into this section, read and comprehend the chapter “Safety”.
Warning

Perform the following daily inspection before starting the motor grader to ensure safety. Strictly obey the
safety rules to ensure personal and machine safety.
2.2.1 Prestart Inspection
★ Form the habit of prestart inspection, and do not act reckless and carelessly, as this is
conducive to personal and machine safety.
1) Check for oil and water leaks.
Check the vehicle by walking around it to see if there is oil or water leak. Take special care to the high
pressure hose connector, hydraulic cylinder, transmission, rear and front axles, tandem and tyre. Repair
the leaks if any.
2) Check the bolt and nut.
Check the tightness of bolts and nuts at positions apt to get loose, especially those of the air filter and
rim, and tighten them if necessary.

Chapter II Operation 37
3) Check the circuit.
Check if the battery voltage is normal, the starting circuit of diesel engine is loose, the wire is damaged
or short circuited, the terminal is loose and rusted, and if the battery switch is turned on.
4) Check if the machine is damaged or has missing parts, and timely make repair.
5) Check if the machine is properly maintained.
Check if the lubrication points are adequately lubricated. If the motor grader has been stopped for a long
time, before reusing it, check if the lubricating oil of parts is deteriorated, and drain out the waste oil and
use new oil if it can’t be used, and perform lubrication as per the lubrication schedule.
6) Check the coolant level (Fig. 2-29).

Fig. 2-29

Remove the radiator cap (1) (Fig. 2-29) to check if the coolant is at the specified level, and add coolant if
necessary.
The coolant shall be added after engine stop. Fill the radiator tank with coolant (until the coolant
overflows) and then start the engine. Recheck the coolant level after the engine idles for 5 min, and add
coolant if necessary. In case of abnormal decrease, check for leak and fix it timely.
Warning

Before removing the radiator tank cap, make sure the machine is stopped and cool down. Slowly
loosen the radiator tank cap to release the internal pressure before opening it, so as to avoid
personal injuries due to splashing.
7) Check the oil level in oil pan.
When the engine stops, take out the oil gauge to check the oil level. When the engine is running idly,
confirm the oil pressure gauge has normal indication and then take out the oil gauge to check the oil
level. If it is necessary to add oil, open the oil filler. The oil type depends on the ambient temperature, as
detailed in "Type and Quantity of Fuel, Coolant and Lubricating Oil”. When checking the oil level, the
vehicle shall be on the level ground. For oil filling, the level shall not be above “H” mark.
8) Check the fuel level.
For SG18-3, check the fuel level via the observation window A (see Fig. 2-30).
For SG18D-3, check the fuel level via the fuel gauge (see Fig. 2-16) or observation window A (see Fig.
2-30).

Fig. 2-30 Fig. 2-31

At the end of each day, refueling shall be made, with oil passing through the filtration screen. Before
operation, add sufficient fuel to prevent the air from entering the fuel pipeline.
38 Chapter II Operation
Maximum volume of fuel tank: 320 L Regular volume: 280L
Avoid fuel overflow during refueling, so as to prevent fires.
Discharge the impurities in fuel tank (Fig. 2-31): Loosen the valve at the bottom of fuel tank to drain out
the water and sediments.
9) Check the oil level of transmission
Check the oil level with oil gauge, and add oil with filtration screen if required. The type of lubricating oil
depends on the ambient temperature, as detailed in “Type and Quantity of Fuel, Coolant and Lubricating
Oil”.
The inspection shall be performed with the engine idling at 1000 r/min.
10) Check the oil level in hydraulic oil reservoir
Check the oil level via the observation window, and add oil to the upper middle position of oil level gauge.
11) Check the oil level of rotation worm-gear box
Check the oil level of worm-gear box, and open the oil filler plug to add oil to the middle position of oil
level gauge if required.
12) Check the front axle locking mechanism
Check if the front axle locking mechanism is released, and release it if locked.

①
② Fig. 2-32

2.2.2 Driving Method and Procedure

1) Check the prestart positions of control levers.
①—hand brake lever, ②—gear lever, ③—throttle control lever.
Adjust the operator’s seat to enable the operator to lean against the backrest to fully depress the brake
pedal.
2) Set the gear lever to neutral.
3) Place the blade on the ground.
4) Start the engine.
Pull the throttle control lever away from the idle speed position, and slightly increase the throttle opening.
Turn the ignition key to START. When the engine is started, release the ignition key to make it
automatically return to ON. If the engine is not started, restart it after 2 min, and the key shall not remain
at “START” more than 20 s. To start the engine without sufficient fuel, top it up and fill the fuel filter
core with fuel, discharge the air from fuel system and start the engine.
5) Inspection After Engine Start
The following inspection shall be done after engine start:
• Keep the engine idling until the oil pressure falls within the normal range.
• Pull the throttle control level to make the engine idle at medium speed for about 5 min.
• The engine shall not run at idle or high speed more than 20 min. If idling is required, apply loads at
Chapter II Operation 39
 times or increase the engine speed to the medium range.
• After the engine temperature rises, check if the instruments are normal.
• Make the engine keep on running with low load to keep the water temperature normal.
• Check if the exhaust gas has normal color and if there is abnormal sound or vibration.
• If the oil pressure is not within the normal range, immediately stop the engine and identify the
malfunction cause.
2.2.3 Operation for Driving
Check if the surroundings are safe before driving.
1) Operate the blade control lever to lift and rotate it to the inside of body.
2) Depress the brake pedal, set the hand brake lever to the free position and release the brake pedal.
3) Set the gear lever to the forward 1st gear to start up the vehicle.
4) Operate the throttle control lever to accelerate the engine
• It is forbidden to drive at high speed on the slope or poor road;
• Before driving down a slope, select an appropriate gear and do not shift gear during the process.
• It is forbidden to overtake when driving down a slope and the brake pedal can be applied to slow
down.
5) Gear Shift
The gear shift shall be performed in sequence, and the applications of gears are as follows:
Gear 1, 2: for working, climbing and rough road
Gear 3, 4, 5, 6: for level road and high-speed traveling
The throttle opening can't be increased during the gear shift to avoid great impact to drive system.
To improve the operator’s comfort and maximize the life of power element, brake application is required
during gear shift.
It is unnecessary to stop the vehicle and depress the brake pedal when shifting gear in driving. To shift
up, release the throttle pedal while operating the gear lever, and then depress the throttle pedal; to shift
down, release the throttle pedal and slow down before shifting.
2.2.4 Steering
The vehicle can make a turn by rotating the steering wheel to the required direction.
For steering in a limited space, the articulation steering can be used together.
It is not allowed to turn when driving at high speed.
Do not turn on a slope, as it may lead to machine rollover.
2.2.5 Braking
Do not keep your foot on the brake pedal, unless absolutely necessary.
Do not depress the pedal repeatedly, unless absolutely necessary.
When driving down a slope, use the engine as a brake and do not shift gear or set the gear lever to
neutral.
2.2.6 Vehicle Stop
Push the throttle control lever to the idle speed position and reduce the engine speed. Set the gear lever
to neutral (N).
Depress the brake pedal and stop the vehicle; pull up the hand brake lever to the locking position,
release the brake pedal and operate the blade lift lever to the “Fall” position to lower it to the ground.
2.2.7 Engine Stop
Make the engine idle for 5 min to allow it to cool down. Turn the ignition key to OFF to stop the engine
40 Chapter II Operation
and then remove the key. The engine life will be shortened greatly when abruptly stopped without cooling,
which is not allowed except in emergencies.
2.2.8 Driving in Special Climatic Environment
Precautions for cold climate:
1) Low temperature will cause difficult engine start, freezing of coolant and adversely affect the vehicle,
therefore, appropriate measures shall be taken, and correct oil and coolant shall be used as per
“Type and Quantity of Fuel, Coolant and Lubricating Oil”.
2) For the temperature below 0℃, to prevent the coolant being frozen, the antifreeze can be used
depending on the lowest temperature. Reference can be made to “Engine Maintenance: Clean the
Inside of Cooling System” for the mix proportion of water and antifreeze and application method.

Caution

• The water without antifreeze shall be drained out in winter to prevent the machine parts
being damaged due to frost crack. Caution: Remember to drain out the water from the oil
cooler, etc.
• Use standard antifreeze and do not prepare the antifreeze coolant with methanol or ethanol,
as this will cause engine malfunction.
• Caution for fires, as the antifreeze coolant is flammable.
• When the temperature drops, the battery capacity will decrease, leading to charge reduction
and freezing of electrolyte. If the battery has its charge level remaining near 100% and
insulated, it can resist low temperature.
3) Thoroughly clean the cooling system before adding the prepared antifreeze coolant.
4) Especially remove the snow or water on hydraulic cylinder piston rod, as the frozen snow or water
will damage the cylinder oil seal.
■ The table below shows the relation between the specific gravity of fluid and charge rate:
Fluid Temperature
20℃ 0℃ -10℃ -20℃
Charge Rate
100% 1.28 1.29 1.30 1.31
90% 1.26 1.27 1.28 1.29
80% 1.24 1.25 1.26 1.27
75% 1.23 1.24 1.25 1.26
2.2.9 Gradient
To prevent the engine lacking lubrication, the working gradient of motor grade shall not exceed the
values below, as poor lubrication may lead to engine malfunction.
Cross Slope Longitudinal Slope
Left or right Forward Backward
Allowable angle 20° 25° 25°
2.2.10 NoticesS
1) Except under exceptional circumstances, the vehicle shall not be parked on a slope. If required,
park it along the slope and apply hand brake.
2) The vehicle shall not run on the cross slope with an angle exceeding 20° and longitudinal slope
exceeding 25°.

Caution

• Straightly drive at low speed on a slope instead of running transversely or turning.

• Do not shift gear or go through obstacles when driving on a slope.
• When driving on a slope, the fuel tank shall enough fuel, otherwise the vehicle will ncline and
Chapter II Operation 41
 the engine may stop due to lack of fuel, which will impair the braking effect.
3) To start up the vehicle on an abrupt slope, depress the brake pedal, and set the gear lever to gear 1
while slowly releasing the brake pedal.
4) To drive down a slope, set the gear lever to the low speed gear and use the engine as a brake. If
dangers happen due to engine over-speed, the brake pedal can be applied to slow down.
2.2.11 Driving on Water
For driving on water, check the water depth and underwater soil property to prevent accidents due to
deep water and loaded soil subsidence, and the water level shall not exceed 500 mm.
2.2.12 Driving in the Desert
For driving in the desert or other dusty places, the vehicle shall be tightly sealed and the air filter shall be
kept clean.
2.3 Working
The blade cutting angle, slewing angle and operation method shall be rationally selected depending on
the job object, which is important to prolong the vehicle life, relieve the operator's fatigue and improve
the working efficiency.
2.3.1 Operation of the Blade
As shown by the symbols on the control levers, operating the control levers can control blade adjustment
to meet various working needs. (Refer to 2.1.2 “Functions of Operation Devices”)
It is forbidden to operate the blade to rotate under load.

Caution

2.3.2 Front Wheel Lean

Operate the front wheel lean control lever to control the front wheel to lean left and right to achieve the
following:
1) Smaller turning radius; higher sideslip resistance of tyre on the level ground.
2) Good adhesion between the wheel and ground even on a slope.
2.3.3 Levelling
The levelling is applicable for road construction, subgrade trimming, site levelling, ditch backfill and
paving of road materials.
During the operation, it is necessary to properly adjust the blade angle according to the engineering
requirement and soil condition, and advance at gear 1 to lower and insert the blade into the soil, and
always adjust the cutting depth, plane angle and driving direction depending on the load and terrain to
make the scooped soil move sideway along the blade face and fall on one side of motor grader or
between two wheels. It is important to note that the rib shall not lie on the track of rear wheel, or else the
tractive force of motor grader will be affected, resulting in uneven road section.
When filling the ditch, make the blade tilt to its side toward the ditch and lay down the soil in the ditch so
as to ensure driving safety. To reverse the machine, make the blade rotate to 180° to improve the
working efficiency. For levelling or laying the gravels at the final stage of shoveling, adjust the blade to be
at 90° to the longitudinal axis and advance at gear 1, and adjust the blade height, cut less soil, make the
most of cut soil move forward and less overfill both sides. For the overflowed soil, lower the blade to the
ground to spread out the soil at high driving speed. On the tortuous operating line, the operator shall
seize the direction or apply the all-wheel steering for flexible operation.

42 Chapter II Operation
 Fig. 2-33 Fig. 2-34
2.3.4 Ditching
The operation is applicable for road side ditches and site drains. During the operation, the blade is tilted
to allow one end to work. The ditching includes calibration, deepening and trimming. Before ditching,
remove the obstacles, make rough levelling, and loosen the soil if necessary and mark the centre line of
ditch.
1) Calibration
The calibration has a great influence on the overall operation quality, especially on the ditch direction.
During the operation, align the shoveling end of blade with the outer edge of front wheel, lean the front
wheel toward the inside of ditch appropriately and the leave the blade end in the ditch, at a distance of
15-30 cm from the outer edge of ditch. Drive the motor grader forward at gear 1 and lower the front end
of blade with the cutting depth generally not exceeding 10 cm. The rear end shall be about 40 cm above
the ground and the cut soil shall fall in the middle of blade, between two wheels. Take care to control the
driving direction and make the motor grader advance along the marked line to ensure correct ditch
position.
2) Deepening
The deepening is to shovel and move the soil, following the calibration. Each shoveling shall move
inwards properly to leave a wide enough step which shall be equal to or greater than the width of each
shoveling to make each shoveling match with the design line of side slope. During the operation,
advance at gear 1, lower the front end of blade and lift the rear end, and the correct position of blade
shall be such that the rib formed after each shoveling is inside the rear wheel to ensure the motor grader
runs stably. The cutting depth shall be timely adjusted as per the variation of cutting resistance, but not
adjusted too much each time so as to avoid generating waves and affecting the subsequent operation.
Each cutting depth and width shall be consistent wherever possible, and the final shoveling must reach
the full depth and width of ditch. The soil shall be moved once or twice after each shoveling, and the soil
moving shall be performed based on the soil condition and rib size to stretch the blade at a distance of
10-20 cm from the rib and keep the formed rib after soil moving fall on the outside of rear wheel. Besides,
during each shoveling and soil moving, to ensure the machine stability and control the driving direction,
the front wheel shall be leaned toward the inside of ditch appropriately.
3) Trimming
It is to trim the outside slope after ditching to full depth. The operation shall be based on the terrain
condition, and make the motor grader cross over the ditch to shovel the soil to the outer edge of ditch or
cut inside the ditch with the rear end of blade, then clear up the soil. If limited by the terrain, the blade
side can be tilted toward one side of motor grader to make the machine run along the ditch and shovel
the soil within the ditch, and then remove it.

Chapter II Operation 43
2.3.5 Scrapping

Fig. 2-35

It is to scrap and trim the side slope with an angle of 25°-70° and height of 3-4 m. Before scrapping,
adjust the blade to one side of motor grader by sideshifting and tilting the blade, keep the upper end of
blade forward and advance at gear 1, and lower the blade for shoveling. During the process, adjust the
scrapping height by rotating the turning circles or moving the blade to lift the blade so as to adjust the
scrapping gradient. To improve the operation stability, the front wheel shall be leaned toward the side
slope.
To improve the working efficiency, it is preferable to use two motor graders for concurrent operation, with
one machine (leading and inclining the blade) for subgrade surface leveling, and the other for side slope
scrapping.

Caution

It is forbidden to drive at high speed on rough road.

It is always forbidden to accelerate or decelerate abruptly.
2.3.6 Blade Adjustment
As shown by the symbols on the control levers, operating the control levers can control the blade
adjustment to meet various working needs.
Caution: It is forbidden to operate the blade to rotate under load.
2.3.7 Method for Extending the Vehicle Life
The vehicle life largely depends on the maintenance and operation methods. Therefore, the followings
shall be kept in mind:
1) Apply different working modes based on the operation condition.
2) During the operation, minimize the tyre slip. If it occurs, reduce the load until it disappears.
3) Try to avoid abrupt startup, acceleration and unnecessary high-speed driving, abrupt braking and
turning.
4) Before operation, remove the stones and other obstacles from the working site.
2.3.8 Operation Points
The motor grader is competent for foundation clearing, fine levelling, scrapping, reshaping, mixed paving,
collection and compaction, snow removal.
1) The articulation steering greatly reduces the turning radius and makes the motor grader perform more
flexibly in above operations. The motor grader can take the “crab walk” to allow the blade to stretch
beyond the rear wheel, so as to prevent the rear wheel running on the leveled ground. The articulation
steering also endows the motor grader with self-relief capacity under difficult conditions.
2) The following devices help to expand the machine use if equipped:
Rear scarifier, dozer and front and rear counterweights

44 Chapter II Operation
3) The key factor to achieve the optimal efficiency of motor grader is correct blade slewing angle and
cutting angle. The greater slewing angle is recommended to make the working length per centimeter
have high spading pressure. During the shoveling, smaller cutting angle can reduce the cutting
resistance while larger angle can improve the leveling accuracy and mixing effect.
4) The front wheel shall lean toward one side where materials flow out. When working on a slope, keep
the front wheel vertical and achieve good adhesion via the front wheel lean.
5) During the leveling, the blade can be stretched out by operating the sideshift device without changing
its working height.
6) The motor grader is not applicable to work underground or in poorly ventilated places.
2.3.9 Front Dozer (optional)
The dozer can be lifted and lowered by operating the front dozer lift control lever.

Caution

The dozer shall be lifted when not in use.

2.3.10 Rear Scarifier (optional)
The rear scarifier has five teeth, and only three of them are used when on hard road, with each being
required to be applied symmetrically.
The scarifier has two positions, namely the working position and vehicle traveling position; remove the
elastic pin, pull out the axis pin, retract the scarifier teeth inwards and fully lift the scarifer to achieve the
vehicle traveling position; remove the elastic pin, lead the teeth outwards to achieve the working position;
operate the scarifier lift control lever to lower it to the ground and drive the machine towards while
lowering the scarifier for working.

Caution

The scarifier shall be lifted before the motor grader turns and reverses.
2.4 Transportation and Storage
2.4.1 Transportation
The motor grader is generally self propelled or transported by other vehicles.
During the transportation, comprehend and obey the road rules, laws of road tranport vehicles and
vehicle restriction regulations.
When driving across bridges and tunnels, measure the weight limited by the bridge and the spacial size
of tunnel.
1) Self-propelling Transportation
1. Limit for traveling distance: Generally not exceeding 100 km.
2. Limit for traveling clearance: 30~50 m.
2) Trailer Transportation
1. Limit for loading gauge: Distance from the ground to the top of motor grader not exceeding 4.5 m.
2. Loading method: The motor grader is generally self-loaded, or lifted under special cases.
Self-loading
It is preferable to errect a platform, and abserve the following regulations if a ladder is used. (Fig. 2–36).
a. The trailer shall be on the flat ground, in the braking state, with the tyres secured with square timber
blocks. The trailer shall have a 10-m space behind the ladder for adjusting the direction of motor grader.
b. The ladder shall have sufficient width, length and strength, capable of resisting the safe loading. It can
be supported by square timbers for reinforcement if necessary.
c. The ladder shall be set right and the motor grader shall be driven slowly onto the trailer under the
Chapter II Operation 45
instructions of the commander.
d. The vehicle shall be located in an appropriate position on the trailer. When the machine stops, pull up
the hand brake lever, fix the front and rear frames with the articulation locks, lock the front axle locking
mechanism, wedge the wheels and fix the draw hook and lifting hook to the trailer with ropes to prevent
accidents due to slipping on the way.

Caution

Do not adjust the traveling direction when climbing. If required, drive back to the ground and
adjust it.
e. Lower the blade and set the levers to the following positions:
• Set the throttle control lever to the low speed position and remove the ignition key.
• Set the gear lever to neutral.
• Set the blade control lever to the middle position.
• Set the hand brake lever to the locking position.

Caution

• If the blade head is wider than the trailer, rotate the blade to between front and rear wheels.
• For long-distance water transportation, take anti-corrosion measures and apply antirust oil
to the exposed cylinder piston rod, etc.

Fig. 2-36
Lifting method
The lifting shall be performed with the lifting hook on the front and rear frames (see Fig. 2-37).
Precautions for lifting:
• Turn off the engine, lock the cab door and guard door with the key and remove the key.
• Lock the front and rear frames together with the locking bar to prevent them swinging.
• Lock the front axle locking mechanism and fix the front axle.
• Fit the ropes only through the lifting hooks for lifting!
• The front and rear frames have two symmetrical lifting hooks which shall be put on simultaneously
for lifting. It is not allowed to hang them on one side or crosswise, as this may lead to rollover.
• Requirements for spreader: A lifting eye must have four slings of equal length, to ensure four
shackles bear force simultaneously to keep the machine remain level after lifting.
• Pay special attention to the allowable limit of spreader, as the lifting will be dangerous if the limit is
exceeded.
• After lifting and during transportation, the motor grader shall be properly fixed, and the tyres shall be
wedged and fixed with ropes. The administrative rules for transportation load weight, width and
length shall be observed.

Caution

• Be careful with the vehicle handling.

• No pedestrian or vehicle is allowed to stay under the lifted vehicle during lifting.
46 Chapter II Operation
• Avoid damaging the hydraulic pipe.

Fig. 2-37 Lifting Diagram

2.4.2 Storage
1) Before Storage
If the machine is expected to be stored for a long time, the following measures must be taken for less
maintenance before reusing.
• After cleaning the parts, store the machine in a dry location instead of outdoors. If the machine has
to be stored outdoors due to limited conditions, it is preferable to support it with bolsters to reduce
tyre load. Reduce tyre pressure by 50% and cover it with canvas to avoid exposure to sunshine
(especially the tyres).
• Before storage, add sufficient fuel and lubricating oil, and replace the oil.
• Apply a thin layer of grease to the metal surface (cylinder piston rod).
• If the machine is to be not used for a long time, turn off the battery switch; if the machine is to be out
of use for more than 4 weeks, remove the battery and place it in a dry and ventilated place, and
recharge it monthly.
• If the ambient temperature drops below 0℃, fill the radiator tank with antifreeze coolant.
• Install the articulated locking bar of front and rear frames, and lock the front axle locking
mechanism.
• The control levers and pedals are set as follows:
★ The gear lever is set to neutral.
★ The throttle control lever is set to the low speed position.
★ The blade control lever is set to the middle position.
★ The brake pedal is set to the free position.
★ The hand brake lever is set to the locking position.
2) During Storage
Daily storage
• Store the vehicle on flat ground and keep its blade horizontally grounded. The storage place shall
be indoor and dry wherever possible to avoid scale. The vehicle shall be covered with a piece of
cloth if stored outdoors.
• Turn the ignition switch to “OFF”, and remove the key and properly keep it.
Chapter II Operation 47
• After removing the key, operate the control lever of implement slowly for 2-3 times to release the
residual pressure of cylinder and hose, and then set the control lever to the middle position.
• Set the gear lever to neutral and pull up the parking brake lever.
• Connect the front and rear frames with the safety lock bar, and lock the front axle locking
mechanism.
• All positions with a lock shall be locked, and the key shall be removed and properly kept.
• In winter or cold weather (temperature below 0℃), add antifreeze coolant to the cooling water; for
vehicles not using antifreeze coolant, the cooling water shall be drained out to prevent the vehicle
being damaged by cooling water freezing.
Long-term storage
The machine storage may last more than (long-term) or less than 2 months (short-term). The motor
grader shall be stored in a sheltered, ventilated and dry place without corrosive substance and gas.
Before storage, the exposed and readily corrodible parts (e.g. piston rod and shaft) shall be coated with
grease, and the machine shall be applied with wax for rust prevention before long-term storage.
Out of use for a month:
In addition to the precautions for “Daily storage”, the following measures shall be taken:
The vehicle shall be driven weekly, and the implement shall be operated for ready use.
Out of use for more than a month:
In addition to the precautions for “Daily storage”, the following measures shall be taken:
• Check the lubrication points of all parts, and apply grease for protection.
• Park the vehicle on elevated hard road wherever possible to avoid the rain erosion.
• Remove the battery.
The battery shall be kept in a dry place, even when the vehicle is parked in an indoor area with summer
heat or moist. Recharge the battery monthly.
• Cover the vehicle with a piece of cloth when it is stored in a damp place (air breather, air filter).
• Adjust the tyre pressure to the standard pressure and check the tyre wear.
To remove the tyre load, it is advisable to lift the vehicle, or levitation is preferable. If it is impossible to lift
it, check the tyre pressure once every two weeks to maintain appropriate pressure.
• Regularly operate the motor grader.
A weekly inspection restoring the vehicle to the operable state shall be performed. Start the engine,
warm it up and make the vehicle to run forward and backward. If the frame is on the bolsters, make the
machine operate in all gears to heat it. Before activating the implement, wipe out the grease on piston
rod, and apply a layer of antirust grease after operation.

Caution

If the antifreeze is applied indoors, the windows and doors shall be opened for ventilation to
discharge the toxic gas.
★ When operating the implement, remove the grease from the cylinder piston rod.
3) Use After Long-term Storage
• Remove the covering guarding against damp.
• Wipe out the antirust grease on exposed parts.
• Drain out the oil of engine crankcase, transmission and drive axle, clean them and use new oil.
• Discharge the inclusions and water in the working oil tank and fuel tank.
• Remove the engine cylinder head and add an appropriate amount of lubricating oil to the rocker arm
shaft.
48 Chapter II Operation
• Add coolant to the specified level.
• Charge and refit he removed battery, and connect it to the cable.
• Check the tyre pressure.
• Conduct pre-job inspection.
• Conduct warm-up operation.
• Grease the articulated positions.
If the motor grader is not provided with weekly rust prevention in storage, consult SHANTUI or its agent,
and take the following measures before use.
(1) Remove the oil pan and the oil drain plugs of other oil tanks to drain out the mixed water.
(2) Remove the cylinder head, lubricate the valves and rock arm, and check the valve action.
(3) To discharge the air of hydraulic system and make the engine run at low speed, the following
methods shall be applied:
Operate each cylinder in circles for 4-5 times, and set the piston to 100 mm from the stroke end.
Then operate each cylinder in circles for 3-4 times until the stroke end is reached.
★ If the engine initially runs at high speed or the piston runs to the stroke end, the mixed air may
damage the piston spacer, etc.
(4) Start the engine and preheat it for operation until the normal temperature is reached.
(5) Check the oil quantity of engine, transmission, rear axle, tandem, worm-gear box and hydraulic oil
reservoir.
If the motor grader is not in use for a year or above, the hydraulic oil, oil of transmission, rear axle,
tandem and blade rotation worm-gear box as well as the engine oil shall be replaced.
(6) Observe the color of upper observation hole of battery to judge the battery condition.
(7) Check the tyre pressure.
4) Precautions for Tyre Storage
(1) Basically, the tyres shall be stored in the warehouse, and no entry is allowed without permission. If it
is necessary to store them outdoors, erect fences around them and put up a sign indicating “No
Entry”.
(2) The storage place shall be dry and clean, as the moisture will accelerate the softening of rubber,
and dust or oil will cause corrosion. The tyres shall be sheltered from the light and heat wherever
possible, and ventilation shall be avoided. The tyres shall be covered with canvas, plastic cloth or
other dust cloth. Incorrect storage will seriously affect the tyre quality and service life.
(3) Sit the tyres vertically on the level ground and wedge them to prevent falling due to unauthorized
touch. If the tyre is laid with its side touching the ground, it will be flattened and the quality will
decline.
2.4.3 Traction
1) Lift the traction pin of tail counterweight and fit the drag rope, then lower the traction pin in position.
Precautions for traction:
• The drag rope shall be fit through reliably.
• The braking device of towed vehicle shall be able to act normally; otherwise, the traction shall not be
performed!
• If the failed vehicle is towed on poor road, further serious damage will be caused.
• The traction is not for long distance movement but for towing the vehicle to a repair site.
• If the vehicle fails, consult your SHANTUI dealer for traction procedure.
2) The machine can’t be towed except in emergencies, and the steps below shall be followed:
Chapter II Operation 49
• If the brake can’t be applied, place stops under the wheels to avoid abrupt movement.
• For traction, release the hand brake, and maintain the traveling speed within 10 km/h and traction
distance not more than 10 km. The vehicle shall be towed to the nearest repair site wherever
possible. The motor grader can’t be towed except in emergencies, and for long distance movement,
a special trailer shall be used.
3) Check if the drag rope or traction pin has sufficient strength to resist the weight of towed vehicle. If
the vehicle has to travel on muddy road or up a slope, two drag ropes or traction pin capable of
resisting the weight 1.5 times that of machine shall be used.

50 Chapter II Operation
 Chapter III Structure and Principle

3.1 Purpose and Main Technical Parameters

3.1.1 Purpose

This machine is mainly used for large-area ground grading and ditching, slope scraping,
bulldozing, scarification and snow removal on roads, airports, farms, etc. It is necessary for
national defense construction, mine construction, urban and rural road construction, water
conservancy construction, farmland improvement, etc.

1) This machine has the following features:

• Articulated frame, providing small turning radius and high flexibility by cooperation with the
front wheel steering.

• Hydromechanical drive, making the engine power be utilized fully to increase the torque and
the tractive force of the whole machine, and also allowing automatic stepless speed change
according to the outside resistance change to protect the drive parts and engine.

• Electro-hydraulic control power shift transmission, having 6 forward gears and 3 reverse
gears.

• International famous hydraulic parts, ensuring reliable operation.

• Full hydraulic control blade motion

• Three-section rear drive axle, equipped with a NO-SPIN differential.

• Reasonably arranged adjustable control console, seat, control handle and instruments,
allowing convenient use and better driving comfort.

• Luxurious and beautiful cab, providing open visual field, having good sealing performance
and equipped with an A/C.

• Optional front dozer and rear scarifier.

2) Working environment:

• Altitude: ≤3000 m

• Ambient temperature: -25℃~45℃

• Fording depth: ≤500 mm

This motor grader is an ordinary construction machine and is not applicable to flammable,
explosive, dusty or toxic gas environment.

3) Forbidden operation:

• Overload.

• Blade rotation with load.

Chapter II Operation 51
• High-speed traveling on rough road.

• Sudden acceleration or deceleration.

3.1.2 Product Model and Name

SG16-3 motor grader

3.1.3 Outline Drawing Fig. 3-1 Motor Grader

1. Front axle 2. Couterweight 3. Front frame 4. Blade lift cylinder 5. Blade tilt cylinder

6. Cab 7. Implement control 8. Gear shifting control 9. Throttle control 10. Driver’s seat

11. Fuel tank 12. Working oil tank 13. Engine hood 14. Tandem and wheel installation

15. Mudguard 16. Toolbox 17. Main frame 18. Implement

19. Steering articulated cylinder 20. Reclining cylinder

3.1.4 Overall Dimensions

8726

52 Chapter II Operation
 Fig. 3-2

Fig. 3-3

3.1.5 Main Specifications and Technical Parameters

1) Engine

Model: Cummins 6BTAA5.9-C160

Type:In-line, water-cooled, four-stroke, direct injection, turbocharged and intercooled diesel

engine

Number of cylinders - bore × stroke: 6-102×120

Rated power: 118kW

Rated speed: 2200 rpm

Max. torque / speed at max. torque: 670/1500 N.m/rpm

Torque reserve coefficient: 1.25

Min. fuel consumption: ≤236g/kW.h

Smoke density: ≤1 BSU

Cold start performance (w/o preheating): -10°

2) Gears and speeds

Forward gear: Cummins engine

Gear I 5.4 km/h

Gear II 8.4 km/h

Gear III 13.4 km/h

Gear IV 20.3 km/h

Chapter II Operation 53
Gear V 29.8 km/h

Gear VI 39.6 km/h

Reverse gear:

Gear I 5.4 km/h

Gear II 13.4 km/h

Gear III 29.8 km/h

3) Implement

Blade length 3660 mm (optional 3965 mm)

Blade height 635 mm

Max. blade lifting height 440 mm

Max. blade cutting depth 500 mm

Blade slewing angle 360°

Blade cutting angle adjustment range 44°~91°

4) Other performance parameters

Track width 2155 mm

Wheelbase 6260 mm

Max. tractive force 86 kN (ξ=0.8)

Min. ground clearance 430 mm

Gradeability 20°

Min. turning radius 7.8 m

Working hydraulic system pressure 16 MPa

Brake oil pressure 10 MPa

Operating weight 15400 kg

5) Drive system

Torque converter Type Single-stage single-phase and three-element

torque converter

Transmission Type Fixed shaft power shift

Control mode Electro-hydraulic control

Number of gears 6 forward gears and 3 reverse gears

Universal joint Double-cross constant velocity universal joint

54 Chapter II Operation
Rear axle Type 3-section grader drive axle equipped with a
“no-spin” differential

Tandem Type Oscillating tandem, oscillating angle ±15°,

heavy-duty roller chain drive

Wheel caliper disc brake

6) Traveling system

Tyre Model 17.5-25PR14

Rim Model 14.00/1.5-25(TB)

7) Power output

Position - Transmission power-take-off mouth

Rotation speed - 2200 r/min

Rotation direction - Clockwise (viewed from the vehicle rear end)

8) Hydraulic system

Working oil pressure-------------- 16 MPa

Oil pump type ---------------------- Gear pump

Working pump output ------------ 123 L/min (engine speed 2200r/min)

Blade lift cylinder bore x rod ---------------------------------- φ80×φ50 (double-acting)

Blade tilt cylinder bore x rod ---------------------------------- φ80×φ50 (double-acting)

Blade reclining cylinder bore x rod -------------------------- φ70×φ35 (double-acting)

Blade sideshift cylinder bore x rod -------------------------- φ80×φ50 (double-acting)

Frame steering cylinder bore x rod ------------------------- φ80×φ50 (double-acting)

Front wheel steering cylinder bore x rod ------------------ φ63×φ35 (double-acting)

Front wheel tilt cylinder bore x rod -------------------------- φ80×φ50 (double-acting)

Chapter II Operation 55
3.1.6 Drive System Diagram

Fig. 3-4 Drive system

1. Engine 2. Transmission 3. Tandem 4. Rear axle 5. Drive shaft

6. Working double pump 7. Steering and brake pump

3.2 Engine
3.2.1 Cummins Engine

Outline Drawing (Fig. 3-5)

56 Chapter II Operation
Fig. 3-5

Chapter II Operation 57
Main Performance Parameters

Model Cummins 6BTAA5.9-C180

Number of cylinders - bore × stroke 6-102×120
Piston displacement (L) 5.9
Working order 1-5-3-6-2-4
Rated speed (r/min) 2200
Rated power (kW) 132
(HP) 180
Max. torque (N.m) / speed (r/min) 670/1500
Max. idle speed (r/min) 2460
Min. idle speed (r/min) 800
Min. fuel consumption (g/kWh) 205
Generator 24V 70A
Starting mode 24V 6 kW

Performance Curve (Fig. 3-6)

Torque (N.m)

Power (kW)
consumption
fuel
(g/kW.h)
Specific

Engine Speed (rpm)

Fig. 3-6

3.3 Torque Converter

The torque converter is a three-element torque converter, with a circulating circle diameter of
φ320 and a torque ratio of K0=2.5 in case of stalling. The torque converter impeller spring disc is
directly connected to the engine flywheel. The torque converter control oil circuit inlet pressure is
0.85 MPa and the outlet pressure is 0.5 MPa. The oil temperature during normal working is
80℃-110℃, with an allowed instantaneous temperature rise to 120℃.

58 Chapter II Operation
Working Diagram (Fig. 3-7):

Tp = Impeller torque

Tt = Turbine torque

Tr = Guide wheel torque

Impeller Turbine

Engine

Transmission

At starting
Vehicle stop

In the midway

Engine
Under lockup
Engine

Fig. 3-7

3.4 Transmission
The transmission and torque converter are integrated to form a whole.

The transmission used in this machine is a multi-gear power shift transmission controlled by an
electro-hydraulic control valve based on hydraulic pressure. It provides 6 forward gears and 3
reverse gears.

The transmission has 6 hydraulic control wet type multi-plate friction clutches. They can be
engaged / disengaged with load (no power cut off) to realize power shift. The gears of
transmission are of constant-mesh type. The structure and principle are illustrated on the following
pages.

Gear Ratio

Forward Reverse
Gear 1 Gear 2 Gear 3 Gear 4 Gear 5 Gear 6 Gear 1 Gear 2 Gear 3
5.9 3.775 2.304 1.475 0.964 0.617 5.9 2.304 0.964

The transmission is equipped with two double pumps driven by the torque converter impeller. The
Chapter II Operation 59
transmission output shaft is connected to the drive shaft at its rear end to transmit the power to the
rear axle. The output shift is connected to the parking brake at its front end.

The transmission is under electro-hydraulic control. The gear selector is installed at the right of
operator’s seat. When the gear selector is operated manually, the solenoid valves connected with
the gear selector control the hydraulic slide valve to realize gear shift. Such operation shall be
conducted in turn. Never bypass any gear for gear shift. In addition, this transmission
allows reverse operation only at gear 1. When driving down a slope, set the transmission at an
appropriate gear so that the engine speed is not less than 1200 r/min to meet the lubrication and
cooling demands of transmission parts.

The working pump (gear pump) used for supplying oil to the torque converter and controls is
installed in the transmission and driven by the impeller, with an output of 35 L/1000 r/min and an
working pressure of 1.3-1.7 MPa. A buffer structure is set in the control valve to regulate the
pressure drop / rise during gear shift, reducing the gear shift impact and ensuring smooth gear
shift. In addition, a neutral protection device is set in the transmission circuit so that the engine
can be started only when the transmission is set at N, preventing misoperation.

The electro-hydraulic control transmission has no pressure cut-off valve. The pressure ON/OFF is
controlled by a pressure switch installed under the brake pedal.

For this transmission assembly, SAE15W-40 hydraulic oil is used. The first oil charge is 28 L. For
oil level check, the oil level shall be located between the upper mark (80℃) and lower mark (40℃)
with the engine under idling state and transmission temperature normal. If the oil level is checked
with the engine not started, it will be higher than the upper mark.

The oil shall be replaced after the first 100 h of transmission operation. Afterwards, the oil shall be
replaced every 1000 h of transmission operation or every year, whichever comes first. The oil filter
shall be replaced each time the oil is replaced.

Caution: The oil filter shall be replaced each time the oil is replaced even if it seems to
have no damage.

When the machine is towed with the engine stopped, the towing speed shall not exceed 10 km/h
and the towing distance shall not exceed 10 km for the reason of this transmission.

60 Chapter II Operation
Outline Drawing (Fig. 3-8):

1. Torque converter housing

2. Torque converter

3. Tachometer interface

4. Nameplate

5. Oil-drain hole

6. Output flange

7. Transmission mounting screw hole

8. Power-take-off mouth

9. Vent cap
Fig. 3-80
10. Secondary filter

11. Electro-hydraulic control valve

Structure Diagram (Fig. 3-9)

Chapter II Operation 61
 Fig. 3-9

1. Torque converter (impeller housing, impeller, turbine, guide wheel) 2. Secondary filter

3. Working pump 4. Power-take-off mouth 5. Reverse and gearshift clutch

6. Lubricating oil circuit interface 7. Clutch pressure oil circuit interface 8. Piston seat

9. Piston 10. Friction plate 11. Clutch housing

12. Supporting shaft 13. Tachometer shaft 14. Output shaft

15. Box

Schematic Diagram (Fig. 3-10):

62 Chapter II Operation
 Torque converter

To steering pump Engine flywheel

To working pump

Parking brake

图 Fig.
3-123-10

Forward Reverse
Gear Gear Gear Gear Gear Gear Gear Gear Gear Gear
1 2 3 4 5 6 1 2 3
Kv ○ ○ ○
Kr ○ ○ ○
K1 ○ ○ ○
Clutch
K2 ○ ○ ○
K3 ○ ○ ○
K4 ○ ○ ○
1 ○ ○ ○ ○ ○ ○ ○ ○ ○
Gear
2 ○ ○ ○ ○ ○ ○

Chapter II Operation 63
 3 ○ ○ ○
4 ○ ○ ○ ○
5 ○ ○ ○ ○ ○ ○
6 ○ ○
7 ○ ○ ○
8 ○ ○ ○ ○ ○ ○
9 ○ ○ ○ ○ ○ ○ ○ ○ ○
10 ○ ○ ○
11 ○ ○ ○
12 ○ ○ ○
13 ○ ○ ○ ○ ○ ○ ○ ○ ○

Structure of Electro-hydraulic Control Valve (Fig. 3-11):

control valve
Pressure

Return valve
Working pressure valve

Gearshift valve 3
Gearshift valve 4

Gearshift valve 1

Fig. 3-11

64 Chapter II Operation
 Neutral position

Control pressure
Torque converter
valve Gear valve
bypass valve

Electric Schematic (Fig. 3-13):

Return valve
Pressure control Gear valve
valve

Torque converter
One-way valve Gear valve
Torque converter pressure

compensation valve
Hydraulic Schematic (Fig. 3-12): (color printing)

Fig. 3-12
Filter
Cooler
Safety valve Gear valve

Oil pump
Control pressure
Lubrication Control oil pressure after throttling
Oil pool Torque converter inlet pressure
Torque converter outlet pressure
Lubrication pressure
Oil return pool
Oil suction pool

Chapter II Operation 65
 Gear selector
Break point
6-pole CA socket
GND Transmi

66 Chapter II Operation
Electromagnet ssion

Electromagnet

Cable connection
Electromagnet
Positive (+)
assembly
3
GND
Electromagnet
DC blocking
Power supply system
4
coil

Fig. 3-13
To positive (+)
Starter circuit Starter circuit (AS)

Reverse lamp
(AS)
Electromagnet connected (RF)
Disconnect the positive circuit of reverse Connected for

clutch under control of brake switch 0.4 s at the

Contact switch
thepressed
instant of gear
Output
Forward gear Reverse gear Neutral gear
shift
Spee

d Downshift

To:
interlock

Plug Socket
Contact pressed 8-pin AMP
8-pin AMP
Flat plug
Socket
Notices:

• If welding is required for troubleshooting, disconnect the harness connector on the

gear selector at the right of operator’s seat at first. Otherwise, the gear selector may be
burnt by the surge current at the time of welding.

• After welding, the battery switch shall be turned off.

• During installation or removal of engine and transmission assembly or lifting of

transmission, take care to avoid falling of torque converter.

• The gear selector shall not be opened by non-professional personnel. The harness
connector connected to the gear selector shall not be removed or installed with power
on. Before such operation, the power shall be cut off.

• After repair, connect the gear selector harness connector and turn on the battery
switch as required. Otherwise, the machine start and traveling will be impossible.

3.5 Rear Axle

The rear axle structure is illustrated in Fig. 3-14and Fig. 3-15. The rear axle is a 3-section split
drive axle, with the main drive at the middle section and a planetary rear axle supporting device at
each of the two end sections. The three sections are connected firmly with hexagon socket head
cap screws. This 3-section split axle allows easy and convenient axle housing machining and
manufacturing, and convenient assembly, installation and service. The rear axle is rigidly
connected with the frame.

3.5.1 Structure and Principle

It is composed of a main drive and two rear axle supporting devices (planetary reducers) at both
ends. The main drive comprises a spiral bevel gear pair and a NO-SPIN differential, with a speed
ratio of i1=3.091. The rear axle supporting device is a planetary reducer with a speed ratio of
i2=4.2. Hence, the total speed ratio of rear axle is i=i1*i2=12.982..

The No-spin differential is also known as jaw freewheel differential. As shown in Fig. 3-16, the left
and right differential housings are connected to the driven gear of main drive with bolts. The
driving ring is fixed between two differential housings and rotates together with the differential
housings. The driving ring has many radial power transmission teeth (inverted trapezoidal section,
small angle) along the circle on both sides. The corresponding left and right driven rings also have
similar power transmission teeth on the inner side. The purpose of inverted trapezoidal section is
to prevent automatic separation of driven rings from the driving ring during torque transmission.
The conical spring is used to make the driving ring and driven rings engaged. Each of the two
spline sleeves has splines inside and outside. The outside spline is connected with the driven ring.
When the grader travels straightly, the driving ring drives the left and right driven rings, spline
sleeves and half axles to rotate through the power transmission teeth on both sides. At this time,
the torque transmitted from the main drive to the driving ring is allocated to the left and right half
axles according to the resistance of left and right driving gears. When the machine turns or one
side of wheels rotate more rapid as they are suspended or trapped in mud or snow, the torque of
driving ring can be transmitted to the other side of wheels (rotating more slowly) completely or

Chapter II Operation 67
mostly. Unlike the common conical planetary gear differential, for the No-spin differential, the
torque can be allocated to the left and right half axle gears equally even if the planetary gear
rotates around its axis (differential working, internal friction resisting torque≈0), which is the
advantage of No-spin differential.

The planetary reducer (rear axle supporting device) is unlike the common loader wheel planetary
reducer (NGW type). As shown in the figure, the planet carrier and axle body are fixed, the half
axle gear (sun gear) is the driving input end, and the ring gear, ring gear support and duplex
sprocketsprocket shaft are connected to form the driven input end.

Spiral bevel driven gear Clamp nut Spiral bevel driving gear Adjusting ring

Pressure cover

Locking nut

Adjusting screw

Fig. 3- 14 Main Drive

Ring gear support Planet carrier

Check Ring
Small tapered roller bearing Round nut

gasket gear
Duplex sprocket Housing

Pinion shaft (sun

gear, half axle)

Planet shaft
Big tapered roller
Oil seal Check gasket
bearing Planet
Needle bearing

gear

Fig. 3-15 Supporting Device

Follow the specified requirements when removing or installing the final drive. Ensure the meshing
surface is close to the small end in the tooth length direction and the meshing area is not less than
half of the tooth length and at the middle in the tooth height direction by smear test.
68 Chapter II Operation
The planetary reducer is secured by means of “nut + check gasket + locking nut”, as shown in Fig.
3-16. For adjustment, tighten the round nut to 400-440 N.m and rotate the duplex sprocket shaft to
make the two bearings at the correct positions. Then, loosen the round nut slightly and apply a
tangential force F=55N.m at the duplex sprocket shaft bolt. At this time, the duplex sprocket shaft
shall be rotated freely. Then, mount the check gasket and fit the claw into the locking groove on
the nut, and then tighten the other locking nut to 400-440 N.m to make the axial clearance be
0.1-0.2 mm.

To replace the needle in the planet of planetary reducer, group the needles and ensure the
following conditions are met: the diameter difference between the needles in the same group shall
not be more than 0.005 mm; the needle cylindricity shall be 0.003 mm; the radial clearance
between needle, gear inner hole and planet shaft shall be 0.015-0.030 mm.

3.5.2 Adjustment of Rear Drive axle

(1) Rear axle

a. The axial negative clearance of two bearings before running-in is 0.01-0.03. The preload of
two bearings is adjusted by increasing or reducing the ring thickness,

b. The axial negative clearance of two bearings after running-in is 0.005-0.01.

c. The normal backlash of gear pair is 0.2--0.4. It is adjusted through adjusting gasket.

d. The tightening torque of shouldered nut is 650 Nm; that of bolt is 280 Nm; that of bolt
connected with the main drive housing is 110 Nm; that of screw is 70 Nm.

e. The clearance between the slide block and gear is 0.2.

(2) No-spin differential

The torque for separating the driving ring from driven rings is 103 Nm. Ensure free separation and
engagement in forward and reverse directions.

(3) Rear axle supporting device

a. The tightening torque of round nut is 350 Nm-400 Nm.

b. The axial clearance of bearing is 0.1--0.2.

c. The tightening torques of screw and bolt are 180 Nm and 830 Nm respectively.

Chapter II Operation 69
3.6 Tandem

7 6

31 5 4 3 2 1

Fig. 3-16

3.6.1 Structure

The tandem is fitted at the position (1) and positioned axially with the cover (3) and bearing (2).
The tightening torque of the bolt (4) is 120 Nm.

The rear axle main drive transmits power into the tandem through the half axle and drives the
sprocket shaft (5) and brake drum (6) to rotate through the chain.

1) Jincheng tandem drive ratio: i=1.389

2) Meritor tandem drive ratio: i=1.414

The rated working pressure of wheel brake is 10 MPa and the maximum working pressure is, 15
MPa. (Fig. 3-16)

3.6.2 Wheel Brake

(1) Structure and characteristics

The wheel brake is a hydraulic caliper disc brake. It is characterized by large braking moment,
high braking speed, good cooling effect and convenient service. The brake mainly comprises
caliper, piston and friction plate. It is fixed on the hub of tandem,

(2) Working principle

For braking, the high-pressure oil passes through the brake pipeline and caliper inlet and then
enters the piston chamber. Under the effect of pressure, the pistons at both sides move to center
and the friction plate is pushed to clamp the brake hub rotating together with the output sprocket
shaft to generate a friction resisting moment. Then, braking is realized. The working route is as
follows: high-pressure oil→ piston movement → pushing the friction plate → clamping the brake
hub.

3.6.3 Adjustment of Wheel Brake

Check the wear of friction plate. To ensure free engagement and disengagement of brake, the
70 Chapter II Operation
friction plate shall be replaced immediately when it is worn to (original groove depth: about 6 mm).

Check the bolt tightness. Axial movement of axis pin may be caused in case of bolt looseness.
Ensure the distance between the inside end surfaces of two axis pins is not less than 31 mm.

Replace the friction plate according to the following steps (Fig. 3-17):

(1) Jack up the tandem to lift the wheels off the ground;

(2) Remove the wheel ②;

(3) Loosen the brake pipeline and remove the brake ③;

(4) Remove the axis pin fastening bolt ④ and pull the axis pin ⑤ outwards until the friction plate
can be removed;

(5) Remove the worn friction plate and replace it;

(6) Reset the axis pin ⑤;

(7) Install the axis pin fastening bolt ④ and tighten it.

(8) Install the brake ③ and connect the brake pipeline;

(9) Install the wheel ② and remove the tandem support;

(10) Adjust the brake system and bleed it for use.

4
3
5

8
9
13

14 10 6 7 12 1

Fig. 3-17

3.6.4 Adjustment of Jincheng Tandem Chain

Check the chain tension after the tandem works with the machine for 100 h. If necessary, tension
it. Afterwards, check the chain tension every 500 h of working. If necessary, tension it.

Note: Each tandem has two chains and both of them shall be checked each time.

Chapter II Operation 71
1) Check the chain tension (Fig. 3-19).

(1) Remove the two tandem cover plates (1).

(2) Jack up the tandem to lift the wheels off the ground;

(3) The chain is stretched after being tensioned. If the sag of slack chain edge is more than 18 mm,
retension the chain.

The chain is tensioned by rotating the eccentric bearing seat.

The chain shall be tensioned by professional personnel.

2) Retension the chain according to the following steps:

(1) Jack up the tandem to lift the wheels off the ground and drain the oil;

(2) Remove the wheel ②.

(3) Loosen the brake pipeline;

(4) Remove the plug ⑥; mount an NM12x35 bolt to the original position and screw it into the
center screw holes on front and rear sprocket shafts.

Note: This bolt can prevent the front and rear sprocket shaft welding parts from sliding
out from the tapered roller bearing (12).
○

(5) Remove the bolt ⑨ on hub ⑧ and the bolt ⑩ on bearing cap ⑦.

(6) Rotate the hub ⑧ and bearing cap ⑦ by the same pitch in the same direction until the chain is
tensioned properly.

Caution: Before removing the hub ⑧ and bearing cap ⑦, mark the original positions for
identification to ensure identical positions after adjustment.

Take care when rotating the hub ⑧ and bearing cap ⑦ to avoid damaging the O-rings (13)
○
and (14).
○

(7) Re-install ⑦ and ⑧ with hexagon bolts ⑨ and ⑩ and tighten the bolts crosswise oppositely.

(8) Remove the bolt on bearing cap ⑦ and install the plug ⑥.

(9) Connect the brake pipeline.

(1) Install the wheel ②.

(2) Fill the tandem with oil and re-install the cover plate ①.

(3) Adjust the brake system and bleed it for use.

3.6.5 Lubrication and maintenance

Fill Meritor rear axle and equilibrium box with gear oil: SAE 85W/90 (turn to SAE 140W/90 in case
environment temperature is above 50℃). Fill the rear axle case with 28L oil and fill the equilibrium box to
the middle position of service hole. Check the oil level regularly and replenish in case the level is low.

72 Chapter II Operation
Lubricate each lubrication location of equilibrium box in time. Wash air vent caps of rear axle and
equilibrium box regularly to ensure unimpeded ventilation.

Note: Change oil for rear axle assembly after the first 100 hours. After that, change oil per 100
hours.

Fill Jincheng rear axle and equilibrium box with gear oil: SAE 85W/90 (turn to SAE 140W/90 in case
environment temperature is above 50℃). Fill the rear axle case with 25L oil and fill the equilibrium box to
the middle position of service hole. Check the oil level regularly and replenish in case the level is low.
Lubricate each lubrication location of equilibrium box in time. Wash air vent caps of rear axle and
equilibrium box regularly to ensure unimpeded ventilation.

Note: Change oil for rear axle assembly after the first 100 hours. After that, change oil per 100
hours.

3.7 Front Axle

3.7.1 Structure Diagram of Front Axle(The first structure)

Fig. 3-18A

1-Front hub 2-Left steering knuckle 3-Connecting base 4-Center link

5-Track rod 6-Shaft 7-Axle frame 8-Connecting plate 9-Right steering knuckle

3.7.2 Structure Diagram of Front Axle(The second structure)

Chapter II Operation 73
 Fig. 3-18B

1- Front hub 2- Left steering knuckle 3- Center link 4- Track rod 5- Shaft

6- Axle frame 7-Spherical hinge 8- Right steering knuckle 9- Right steering knuckle

3.7.3 Adjustment of Front Wheel Toe-in

The front wheel toe-in refers to the difference between front distance and rear distance between
two front wheels or the included angle between the front wheel center line and the longitudinal
center line. The front wheel toe-in is used to ensure the vehicle rideability and reduce tyre wear.
When the front wheels roll, the inertia force will make the tyres deflect inwards naturally. If the
toe-in is appropriate, the deflection of tyres in rolling can be offset so as to reduce the inside and
outside tyre wear.

Note: 1) The first structure front axle adjustment dimension A (Fig. 3-18A) 1251 mm, making the
front wheel toe-in be 5-10 mm.

2) The second structure front axle adjustment dimension A (Fig. 3-18B) 1540 mm, making the
front wheel toe-in be 5-10 mm.

3.7.4 Lubrication and Adjustment of Front Hub Bearing (Fig. 3-19)

Note: The front hub bearing shall be maintained by professional personnel only.

Required quantity of lubricating grease: about

280 g per wheel

Lubricating grease: No. 2 lithium-based

lubricating grease

(1) Jack up the front axle and remove the front

wheels.

(2) Check the clearance of hub ①.

(3) Loosen the hexagon bolt ② and hexagon

socket head cap bolt ③.

(4) Remove the cap ④.

(5) Count the adjusting gaskets ⑤.

(6) Remove the hub ① with tools and clean

Fig. 3-19
the hub steering shaft joint, bearing and
cap. In case of damage, replace the seal
ring on new cap and the bearing.

(7) Apply new lubricating grease.

(8) Install the hub.

(9) Check the bearing clearance. If necessary, remove one adjusting gasket ⑤.
74 Chapter II Operation
(10) Re-install the cap ④ with bolts. Tighten the hexagon socket head cap bolt ③ to 78 Nm and
the hexagon bolt ② to 250 Nm. The hexagon socket head cap bolts shall be tightened
crosswise oppositely.

(11) The hub ① shall be rotated easily without vibration. Check that the hub has no vibration
clearance.

3.8 Tyre
Note: The six tyres shall have the same specification.

3.8.1 Tyre Maintenance

(1) Check the tyres for cutting, cracks and foreign objects every day. In case of any foreign object,
remove it.

(2) Protect the tyres against erosion by fuel, oil and lubricating grease.

(3) The inflation valve shall be equipped with a screen cap.

(4) Replace the leaky valve core if any.

(5) Regularly check the tyre pressure. Low or high tyre pressure will cause fast wear or one-side
wear.

Note: The tyre pressure determines tyre efficiency and life. The following specified tyre
pressure applies to cold tyres (at the beginning). In traveling, the tyre temperature
will rise due to tyre deflection and consequently the tyre pressure will also rise.
However, such pressure rise is protective, so do not correct the pressure, for
example, by deflating the tyre.

3.8.2 Tyre Pressure

Tyre Size Ply Front Tyre Rear Tyre

17.5~25 14 0.26~0.28 0.26~0.28

3.8.3 Tightening and Replacement of Wheels

(1) Tightening of wheels

Check the rim bolts and nuts for looseness every day within the first 100 h of working. Afterwards,
tighten them to 700-800 N.m every 50 h of working.

(2) Pull up the hand brake lever before wheel replacement.

Loosen the rim nuts for one circle before jacking up the grader.

For rear wheel replacement, jack up one side of the grader by hydraulic pressure. For this
purpose, set the blade end corner just before the tandem wheel to be jacked up and then jack up
the grader by using the lift cylinder at the same side with the wheel to be replaced.

Supporting the moldboard or blade against the ground can jack up the grader.

Stably support the grader before wheel removal.

Chapter II Operation 75
Remove the rim nuts and then remove the wheel.

Caution: During wheel removal and installation, never damage the rim nut thread. After
installing the wheel, tighten the rim nuts crosswise symmetrically.
Tighten the rim nuts to 700-800 Nm every day within 100 working hours after
wheel replacement.

3.8.4 Direction of Tyre Tread

For tyre installation, pay attention to the direction of tyre tread. The driving wheel（Optional L-2A）
shall be installed with the tyre tread toward the forward direction as shown in Fig. 3-20 so that the
maximum tractive force can be obtained in the traveling direction (indicated by the arrow).

Fig. 3-20

The non-driving front wheel shall be installed with the tyre tread in the direction opposite to that of
rear wheel.

Note: Under some special working conditions, different tyre tread directions may be adopted. It is
recommended to follow the tyre manufacturer’s instructions.

3.9 Working Hydraulic System

3.9.1 Introduction

This system is a constant-displacement double pump dual-circuit system (Fig. 3-21). It is

composed of an enclosed oil tank, a dual gear pump, two multi-way change valves, hydraulic
cylinder, hydraulic motor and pipeline. The double pump is installed at the transmission output
end, so it always runs together with the engine. The hydraulic control system can work as long as
the engine runs.

The multi-way change valves and the double pump constitute a separate hydraulic system having
a working pressure of 16 MPa and an output of Q=123.2 L/min (when the engine speed is 2200).

The left and right lift cylinders are supplied with oil by two circuits having the same flow, so these
two cylinders can basically operate synchronically and at the same speed, making the grader

76 Chapter II Operation
work more precisely.

3.9.2 Hydraulic Schematic

Fig. 3-21

1. Hydraulic oil tank 2. Double pump 3. Multi-way change valve

4. Two-way hydraulic lock 5. Blade lift cylinder 6. Blade tilt cylinder

7. Balance valve 8. Rotary motor 9. Rotary joint

10. Blade sideshift cylinder 11. Hydraulic lock 12. Reclining cylinder

13. Front wheel tilt cylinder

The system pressure is controlled by the internal pressure valve of multi-way change valve (Fig.
3-25, the pilot overflow valve pressure value is 16 MPa).

3.9.3 Working Principle

For the hydraulic circuit, oil is sucked from port P1 of double pump ② and then flows into the oil
tank ① after passing through the multi-way change valve, oil return pipe and oil return filter ⑧.

The two-way hydraulic lock ④ installed on blade tilt cylinder, hydraulic lock 11
○ installed on front
wheel tilt cylinder and the balance valve ⑦ installed on blade lift cylinder can prevent
displacement caused by equipment weight and load and consequently ensure the traveling safety

Chapter II Operation 77
and blade working precision.

The blade is rotated by the big ring gear which is driven by the turbine worm under the action of
hydraulic motor. The valve plate flow distribution adopted in JZK cycloidal hydraulic motor ○ 8
allows automatic compensation for flow distribution surface wear and consequently keeps the
motor running efficiently.

The high-pressure oil flows into the motor through the oil inlet and, after passing through the flow
distribution pressure plate, flow distribution universal driving shaft and flow distribution supporting
plate, drives the rotor to rotate to generate a mechanical torque. The torque is transmitted from
the output shaft to the worm and worm drive to drive the pinion and big ring gear so as to realize
blade rotation.

3.10 Hydraulic Oil Tank

The hydraulic oil tank is shared by the working hydraulic system and steering hydraulic system.

The hydraulic oil tank is used for oil storage and cooling as well as separation of air and impurities
from the oil.

The hydraulic oil tank is an open type oil tank. When the hydraulic system works, the oil level in
the tank fluctuates. Air is discharged during upward oil level movement and air is sucked during
downward movement. To purify the oil in tank, an air filter is installed vertically on the oil tank
cover plate to filter the sucked air. In addition, the air filter is also used as the oil filler to filter out
the dirty particles in oil. Furthermore, when the hydraulic system works, the air filter can keep the
pressure in oil tank balanced with the barometric pressure to avoid possible pump cavitation.

The hydraulic oil tank is equipped with an oil suction filter and an oil return filter. The oil suction
filter can protect the pump against suction of large contamination particles. When the filter core is
blocked by pollutants to a vacuum pressure of -0.02 MPa, the bypass valve at the upper end of
filter core will be opened automatically to ensure normal pump working. The oil return filter can
remove the metal particles generated by element wear and rubber pollutants generated by seals
in the hydraulic system to keep the oil returning to the oil tank clean. When the oil return pressure
reaches 0.35 MPa due to filter core blockage by pollutants or low oil temperature, the bypass
valve at the lower end of filter core will be opened automatically to ensure normal working of oil
filter and hydraulic system.

To clean or replace the filter core, remove the screw on the mounting flange and pull up the
mounting flange.

An oil level gauge is installed on the outside of the oil tank. It can indicate the oil level clearly. The
oil level shall be kept at the middle of the oil level gauge. To replace the hydraulic oil, open the
oil-drain valve at the bottom of the oil tank to discharge the waste oil and clean the oil tank.

3.11 Steering Hydraulic System

3.11.1 Introduction

The front wheel steering system is a full hydraulic steering device. This system is composed of full
hydraulic steering gear, FKC valve block and oil cylinder.

78 Chapter II Operation
The first structure working principle: When the engine is running, the steering pump ⑨ sucks oil
from the oil tank ① and the oil from the pump flows into the steering gear valve block and controls
the steering cylinder motion (left / right turn) through the steering wheel (Fig. 3-22A).

The second structure working principle: When the engine is running, the pump sucks oil from the oil
tank and the oil from the pump flows into the steering gear valve block with prefill valve, and
controls the steering cylinder motion (left / right turn) through the steering wheel (Fig. 3-22B).

The two hydraulic locks installed on the frame steering cylinder and front wheel tilt cylinder are
used for stabilization in the frame steering and front wheel lean oil circuits to eliminate the swing of
front wheels and frame during machine traveling.

3.11.2 Hydraulic Schematic

To brake system

Fig. 3-22A(The first structure)

1. Working oil tank 2. Multi-way change valve 3. Double pump 4. Oil return filter

5. Steering gear assembly 6. Front wheel steering cylinder 7. Frame steering cylinder

8. Front wheel tilt cylinder 9. Double pump 10. Oil filter 11. Hydraulic lock 12. Oil cooler

Chapter II Operation 79
 图 3-22B（The second structure）
1、Working oil tank 2. Multi-way change valve 3. Double pump 4、oil suction filter
5、Oil return filter 6、Steering gear assembly 7、Oil cooler 8、Frame steering cylinder
9、Hydraulic lock 10、Front wheel tilt cylinder 11、Front wheel steering cylinder
12、prefill valve

3.12 Service Brake (Foot Brake) Hydraulic System

3.12.1 Introduction

The foot brake is a single-circuit hydraulic system. It acts on the four rear wheels of the grader.
When the engine is running, the brake pump ⑧ sucks oil from the oil tank ⑩ and the oil from the
pump flows to the two accumulators (4) through the prefill valve (6) and then to the wheel brake
through the brake valve. For the two accumulators, oil is filled when the pressure is lower than 123
bar and oil is cut off when the pressure is 150 bar.

The oil filling of accumulator (4) only needs a short period. After that, the prefill valve will make the
oil return to the working oil tank.

When the brake valve (2) is pressed, the pressure oil in the accumulator circuit will flow to the
brake slave cylinder (13) which makes the brake shoe of wheel brake (12) act. In addition, the
approach switch installed under the brake pedal is connected, making the brake relay work and
the brake lamp on.

At the mini type measuring joint (5), a special pressure gauge is used to measure the brake

80 Chapter II Operation
system pressure.

3.12.2 Hydraulic Schematic

Pull pin pipeline system oil return

To pull pin pipeline system

To hydraulic pipeline of steering system

Fig. 3-23

1. Working brake pressure switch (min. brake pressure 10 MPa) 2. Brake valve

3. Brake lamp switch 4. Hydraulic accumulator (1.0 L each) 5. Mini type measuring joint

6. Prefill valve 7. Brake slave cylinder 8. Double pump 9. Primary filter

10. Hydraulic oil tank 11. Bleeder plug 12. Wheel brake

3.13 Electrical System

3.13.1 Electrical Schematic (Cummins Engine)

Chapter II Operation 81
 Fig 3-24

82 Chapter IV Service and Maintenance

 14. Fuse 15. Starter switch 16. Charge indicator lamp 17. Flasher
18. Brake pressure switch 19. Hand brake approach switch 20. Brake fluid pressure switch 21.
Battery relay 22. Starter relay 23. Hour meter 24. Oil pressure gauge
25. Rheostat type oil temperature gauge 26. Water thermometer 27. Voltmeter
28. Reverse relay 29. Brake relay 30. Brake lamp relay 31. Front lamp switch
32. Working lamp switch 33. Rear lamp switch 34. Pull pin switch 35. Horn
36. Remote controller 37. Battery 38. Combined relay 39. Stop relay
40. Oil pressure indicator lamp 41.Electric control transmission 42. Left turn indicator lamp
43. Right turn indicator lamp 44. Combined switch 45. Hand brake relay
46. High-/low-pressure witch 47. Starter 48. Stop electromagnet 49. Enriching valve 50.
Generator 51. Oil pressure sensor 52. Torque converter oil temperature sensor 53. Water
temperature sensor 54. Reverse alarm 55. Left rear combined lamp
56. Right rear combined lamp 57. Left front combined lamp 58. Right front combined lamp 59. Left
main working lamp 60. Right main working lamp 61. Left auxiliary working lamp
62. Right auxiliary working lamp 63. Left rear lamp 64. Right rear lamp
65. Pull pin solenoid valve 66. Hand brake indicator lamp
67. Horn switch 68. Brake fluid pressure warming lamp 69. A/C fan
70. A/C fan 71. Compressor 72. Power switch

Chapter IV Service and Maintenance 83

84 Chapter IV Service and Maintenance
 Chapter IV Service and Maintenance
4.1 Service and Maintenance
Precautions:
The service and maintenance of vehicles play a significant role for prolonging the service life,
guaranteeing the safety of human and machine, improving the efficiency and increasing the economic
efficiency.
In addition to the relevant requirements referred in "Safety Tips", driving and maintenance personnel
shall also comply with the following.
Service and maintenance staff shall first be familiar with the machine structure, performance, removal
and installation procedures, technical requirements, precautions, etc., and then engage in the service
and maintenance works. The aimless engagement is not allowed. For the items difficult for service and
maintenance, if not very sure, you’d best consult the manufacturer or your local service provider. Routine
maintenance shall be usually conducted before starting the vehicle and after the completion of daily
work.

Park the vehicle on the level ground before the

maintenance, put down the blade, lock the hand
brake, lock the front and rear frames with
articulation lock (Fig. 4-1), adjust the front axle tyre
vertically, lock the locking plate of front axle and
then conduct the maintenance. When the
maintenance is conduct without stopping the
engine, two persons shall cooperate, of which one
person sits in the cab, and the other carries out the
maintenance. Be careful not to touch the moving
parts. Before the maintenance, clean and wash the
surrounding of the positions to be repaired,
especially the oil port, filter, nozzle and box body
cover to prevent the dust from entering the oil. Fig. 4-1

Caution

• Motor grader is equipped with the articulation steering mechanism, so the front and rear
frames shall be locked;
• Front axle of motor grader is equipped with the locking mechanism, so the front axle shall be
locked;
• Do not process the electrical system in the rain;
• When checking or filling the cooling water, prevent the scalding due to the hot water;
• After replacing the oil filter core or particulate filter, exhaust the air from oil circuit;
• Do not take out the filter screen of filler, and then fill the oil;
Remember that the high pressure exists in the hydraulic circuit, and first relieve the pressure
before filling or draining the oil or checking and maintaining the machine. Release the pressure
as follows:
• Lower the blade to the ground, stop the engine, turn the control lever of hydraulic system
continuously to each position 2-3 times, and then slowly release the filler cap or pipe joint;
• Before the service and maintenance for electrical system, turn off the power switch to cut off the
main power supply (storage battery), and cover the battery with insulating material;
• Before changing the oil, run the vehicle to rise the temperature to 30 ~ 40 ℃ and then drain the oil;
• Do use the clean oil and grease. Do not check or change the oil in dusty places, otherwise the dust
may be mixed into the oil;

Chapter IV Service and Maintenance 85

• Overhaul the tandem, rear axle, etc., and prevent the spanners, nuts, etc. from falling into the box
body to cause the trouble;
• Keep the oil away from the fire source, and do not use a torch instead of lamp;
• When replacing the O-ring, liner or other seals, strictly clean the part surfaces and carefully install
them.
1) Precautions for fuel system
The service life of diesel engine depends on the cleanliness of fuel.
Keep the engine clean and dry, otherwise it will damage the injection elements of engine.
Galvanized iron barrel is not suitable for storing fuel.
Before extracting the fuel from barrel, leave the barrel for a longer period of time.
Do not let the oil-suction tube stir up the sediment at the bottom of barrel.
Do not suck the fuel at the bottom of barrel.
The fuel at the bottom of barrel is not suitable for the engine and may be only used for cleaning
2) Precautions for hydraulic system
During the maintenance of hydraulic system, the cleaning is essential. Ensure that no dirt or impurity
enters the system.
If the oil level is found to drop every day, check all the pipelines and hydraulic elements for leakage.
Do not place the hydraulic oil barrel outdoor. Weather changes may cause the water to infiltrate through
the oil port.
Fill the hydraulic oil with the filtering devices, because the filtered hydraulic oil may prolong the service
life of filter.
Before unscrewing the joint and opening the oil tank cover, clean them and surrounding surfaces to
prevent the dirts from entering.
Do not open the filler of hydraulic oil reservoir, and close it to prevent the dirts from entering.
3) Precautions for cooling system
Preparing and checking the cooling agent are crucial for the water-cooled engine, otherwise the engine
may fail due to the corrosion, cavity and icing.
Always check the cooling system. In addition to the coolant level, check the concentration of the coolant
in the cooling system.
4) For the routine maintenance of engine, see Use and Maintenance Manual of Engine.
Running-in Instructions
Conduct the following maintenance works when the new engine or overhauled engine is put into use:
Engine oil level shall be checked daily before the engine runs about 250h.
According to the load conditions, the fuel consumption of engine may return to normal level after about
100-250h.
In 250h of operation, carry out the maintenance according to the contents of first 250h.
4.1.1 Maintenance Table
No. Items Content
For service and maintenance of engine, see Service and maintenance Manual of Engine
Check before starting
1 Check for the oil and water leakage Check it
Check the bolts and nuts, especially the
2 Check and tighten them
rim nuts
3 Check the circuit Check and tighten it
4 Check the coolant level Check and fill it

86 Chapter IV Service and Maintenance

5 Check the oil level of oil pan Check and fill it
6 Check the fuel level Check and fill it
Check and inflate it to make it in line with
7 Check the tyre for pressure and damage requirement and remove the attachments on the
tyre
8 Discharge the impurities in oil tank Discharge the water and sediment
9 Check the dust indicator Check and clean the air filter core
10 Check the brake system Check and adjust it
11 Check the steering system Check and adjust it
Maintenance of first 50h
Check the fastening bolt of engine oil
1 tank Check and tighten it

Check the fixing clip of suction and drain

2 pipes on the cylinder head Check and tighten it

3 Check the engine for loose parts Check and tighten it

4 Check the gap of valve Check and adjust it
5 Engine oil and filter Replace Engine oil and filter
Maintenance per 50h
Lubrication (Check the following positions and add the grease)
Connecting bearing between front axle
2
and front frame
Tilt cylinder of front axle Axis pin : 1 Joint bearing : 1
Front wheel steering knuckle 4
Front hub 2
Tilt joint of front wheel 2
Steering joint of front wheel 2
Steering cylinder Axis pin : 2 Joint bearing : 2
Spherical hinge of drawbar 1
1
Slewing joint 1
Lift cylinder articulation 6
Tilt cylinder articulation 2
Reclining cylinder Axis pin : 2 Joint bearing : 2
Rocker 6
Front and rear frame articulations 2
Framework articulation cylinder Axis pin : 2 Joint bearing : 2
Drive shaft 2
MERITOR 12
Rear axle assembly
JINCHENG 2
2 Complete machine Clean the exposed surface
Check the nuts and bolts for looseness, Check and tighten them and replace the
3
and check the worn parts excessively worn parts
4 Check the solution of storage battery Check and fill it
Check the tyre pressure and check the Check and inflate it, and tighten the nut (fastening
5
rim nut torque: 700-800Nm)
Check securing nut of rear axle and main
6 Check and tighten (tighten torque is 810-900Nm)
frame
Maintenance of first 100h (first overhaul )
1 Engine oil filter core Clean it
2 Engine diesel oil filter core Clean it
3 Air filter Clean the filter core and dust collector
4 Check the fan belt for tensity Check and adjust it
5 Check the idle speed of engine Check and adjust it
6 Check the hand brake Check and adjust it
7 Check the oil tank, oil pump, cylinder, Check and replace the seal
Chapter IV Service and Maintenance 87
 pipeline, hose and joint for tightness
8 Check the working system for pressure Check and adjust it
Check the steering mechanism fastener
9 Check and tighten it
for connection
10 Check the steering system for pressure Check and adjust it
11 Check the blade guide gap Check and adjust it
12 Check the rim nut Check and tighten it
13 Check the tandem chain for tensity Check and tighten it
14 Torque converter transmission Change the oil
15 Slewing worm-gear box of blade Change the oil
16 Screen of transmission oil filter Clean it
Hydraulic oil tank oil-return filter core and
17 Replace it
oil-suction filter core
18 Rear axle and tandem Replace it
Maintenance per 250h
1 Fan belt tensity Check and adjust it
2 Fuel filter core Replace it
Transfer pump screen and pipeline of
3 Clean it
fuel tank
Check the oil tank, oil pump, cylinder,
4 Check and replace the seal
pipeline, hose and joint for tightness
Check the steering mechanism fastener
5 for connection, including the nuts of Check and tighten it
steering rod
Check and adjust it, and replace the damaged
6 Check the hand brake
brake gasket
7 Lubricating oil of rear axle and tandem Change it
8 Storage battery and terminal Measure and fill the coated Vaseline on the joint
Maintenance per 500h
1 Transmission filter core Clean it
2 Check the liner of wheel brake Check and replace it
3 Check the tandem chain for tensity Check and adjust it
4 Drive shaft Check and adjust it
Maintenance per 1000h
1 Torque converter transmission Change the oil
2 Slewing worm-gear box of blade Change the oil
3 Rear axle and tandem Change the oil
4 Diesel tank filter Clean it
Check the blade guide gap and slewing
5 Check and adjust it
ring for guide gap
6 Working oil tank and filter Change the oil and clean it
Vent ports of transmission and torque
7 Clean it
converter
Maintenance per 2000h
1 Lubricating grease in the hub Replace it
2 Front wheel bearing gap Check and adjust it
Check the main drive pinion of rear axle
3 Check and adjust it
for axial gap
4 Check the rim weld and stressed position Check and repair it
5 Torque converter transmission Change the oil
Maintenance per 3000h
Check the main drive pinion of rear axle
1 Check and adjust it
for axial gap
2 Tool angle and blade Replace them
3 Torque converter transmission Overhaul and change the oil
4 Front axle Overhaul and change the oil
5 Tandem Remove and check it
88 Chapter IV Service and Maintenance
 6 Axial gap of main drive pinion of rear axle Adjust it if more than 0.05
Unscheduled maintenance items

Change anti-freezing solution Twice per year (spring and autumn) or after 1,000 hours

Inspect and clean the air filter or change the air

Irregular maintenance
filter

Inspect and adjust the tires Adjust at any time

Inspect tire pressure Replenish at any time

Oil level of equilibrium box of rear axle Check at any time

Oil level of transmission case Check at any time

Oil level of service oil Check at any time

Oil level of engine oil Check at any time

Oil level of worm gear case Check at any time

4.1.2 Daily Maintenance

Level gage
Check the oil and water leakage. After the vehicle
runs, check for the traces of oil and water leakage,
especially the joint of high-pressure hose,
hydraulic cylinder, radiator, etc.; If the leakage is
found, analyze the reasons for leakage and timely
repair it.
1) Check the bolts and nuts of part for the
tightness; tighten the loose bolts and tyre rim nuts
especially of the air filter, muffler, front axle、rear Fig.4-2
axle、main frame, etc.
2) Check the electrical system and see if each
line is normal.
3) Check and fill the antifreeze coolant:

Open the back door of left engine cover, and observe if the antifreeze coolant level gage (as shown in
Fig. 4-2) is at the middle of gage, and if not, fill the antifreeze coolant through the water filler to the
middle of gage; turn off the engine when filling the antifreeze coolant.
After filling the antifreeze coolant, idle the engine for about 5 min, and then check the water volume, and
if it is not at the middle of level gage, fill the antifreeze coolant again.
★ If you shall fill more antifreeze coolant than usual, you shall check the cooling system for
leakage.
If the temperature of antifreeze coolant is higher, do not open the cap to prevent the ejection
of hot liquid. After the temperature drops, slowly open the cover to allow the pressure of liquid to
decrease, and then open it.
4) Check the fuel
(1) For SG18-3 motor grader (as shown in Fig.4-3), after the operation ends, check the oil volume
through the observation window A, remove the filler cap B and fill the oil through the oil port to make sure
that the fuel is full.

Chapter IV Service and Maintenance 89

(2) For SG18D-3 motor grader, check the fuel volume through fuel gage to ensure that the fuel is full.

Fig.4-3

★ When working on a slope, you shall ensure that there is sufficient fuel in the tank to avoid
the air in the fuel pipeline.
★ When filling the fuel, do not let the fuel flow out, otherwise, it may cause a fire
5) Check the oil volume of engine oil pan
Check the oil volume with dipstick, and if the oil is insufficient, fill the oil through the filler. When the
engine is off, check the oil volume with the side of dipstick with the scale.
6) Check the transmission oil volume
★ The model of used lubricating oil depends on the ambient temperature. Please select it
according to the Table of Fuel, Cooling Water and Lubricating Oil.
★ When checking the oil level, control the engine at the idling conditions (about 1000r/min),
and check the oil level when the transmission is at the required temperature.
When the oil temperature is 40℃, the oil level shall be between the middle line and lower line of dipstick;
when the oil temperature is 80℃, the oil level shall be between the middle line and upper line.
7) Removal of water and sediment in the fuel tank
Open the switch at the bottom of fuel tank to remove the sediment and water at the bottom as well as the
fuel.
8) Check the dust indicator
When the air filter is clogged, the red piston of dust indicator moves to the repair line, and the air filter
shall be cleaned. After the maintenance, press the button, and the red piston returns.
For the cleaning method, see Check the Air Filter.
9) Check the brake system
According to the maintenance system, check the pump, cylinder, valve, pipeline and joint of hydraulic
brake system for sealing, and timely rectify the leakage.
10) Check the steering system
Regularly check the functions of steering system. In case of the malfunctions of hydraulic steering
system, you shall stop working and notify the Sales and Service Department of manufacturer or
professionals for repair.
(1) According to the maintenance system, check the pump, cylinder, valve, pipeline and joint of hydraulic
steering system for sealing, and timely rectify the leakage.
(2) Check if the nuts and bolts of steering rod and steering cylinder are properly installed, and tighten
them if necessary.
4.1.3 Maintenance under Special Conditions
When the motor grader is working on the materials which are dusty and easy to block the filter and
radiator, shut down the machine for 15min after it works 1h in order to extend the life of machine. Clean
the dust inside the air filter, remove the subsidiary materials on the radiator, and then continue the work.
90 Chapter IV Service and Maintenance
4.1.4 Maintenance of first 50h
First 50h later, conduct the following maintenances for the engine:
(1) First change the engine oil
(2) Replace the oil filter
(3) Tighten the fastening bolts of engine oil chamber
(4) Tighten the fixing clip of suction and drain pipes on the cylinder head
(5) Tighten the loose parts of engine
For replacement and maintenance methods, see Use and Maintenance Manual of Engine.
4.1.5 Maintenance per 50h
1) Tighten the drive shaft and rim nut;
2) Clean the exposed surface of complete machine and moving surface, and add the grease at each
lubricating point.
(1) Fill the grease into the nozzle as shown in the figure: Front axle
and connecting shaft 2 of front frame (Fig. 4-4)
(2) Tilt cylinder 2 of front axle (Fig.4-5)

(3) Steering knuckle 4 of front wheel (Fig. 4-6)

(4) Front hub 2 (Fig.4-7)
图 4-4

Fig.4-5 Fig.4-6

(5) Tilt joint 2 of front wheel (Fig. 4-8)

Fig.4-7 Fig.4-8 Fig.4-9

(6) Steering cylinder 2 (Fig.4-9)

(7) Steering rod 2 (Fig 4-10)

Chapter IV Service and Maintenance 91

 Fig 4-10
(8) Drawbar spherical hinge 1 (Fig.4-12)

Fig.4-12 Fig.4-13

(9) Slewing joint 1 (Fig.4-13)

(10) Lift cylinder articulation 6 (Fig.4-14)

Fig.4-14
(11) Tilt cylinder articulation 2 (Fig.4-15)

Fig.4-15 Fig.4-16
(12) Reclining cylinder 4 (Fig.4-16)

92 Chapter IV Service and Maintenance

 Fig.4-17

(13) Rocker 6 (Fig.4-17)

(14) Front and rear frame articulation 4 (Fig.4-18)

Fig.4-19

(15) Frame articulation cylinder 4 (Fig.4-19)

Fig.4-20
(16) Drive shaft 2 (Fig.4-20)

(17) rear axle assembly 2

Chapter IV Service and Maintenance 93

 Fig 4-21
○
1 ○
2

（18） Tilt cylinder 2 of front axle (Fig.4-5)

（19） Steering knuckle 6 of front wheel （Fig 4-22）

图 4-21 图 4-22

（20） Front dirve motors 4 (Fig.4-23）

（21） Tilt rod 2 (Fig.4-24)
（22） Steering cylinder 2 (Fig.4-25)

图 4-23 图 4-24 图 4-25

（23） Steering rod 2 (Fig 4-26)
（24） Reclining cylinder 2 (Fig.4-27)

94 Chapter IV Service and Maintenance

 图 2-26 图 2-27

4.1.6 Maintenance of First 100h

2. JINCHENG rear axle assembly 2 (Fig.4-22)

(18) Rear axle assembly

4.1.6 Maintenance of First 100h
First 100h later, conduct the following maintenances for the engine:
1) For the maintenance of engine, see Use and Maintenance Manual of Engine.
★ For the parts removed due to the maintenance, you shall ensure the correct positioning, and
then start the engine to check its functions and eliminate the existing malfunctions and
irregularities (this work shall be performed for following maintenance).
2) First change the oil of slewing worm-gear box of blade.
(1) Check the oil volume
• Slewing worm-gear box of blade shall be horizontal.
• The oil level (max oil level) shall be located in the middle of observation hole. Fill the oil from the
filler if necessary.
(2) Change the oil
Tilt the swing blade to the drain plug in order to speed up the oil drain, and support the blade on the
ground. Remove the drain plug and let the oil flow into the container, while unscrewing the filler plug to
let the oil flow as soon as possible. Clean the drain plug, replace the sealing ring, install and tighten the
plug. Manipulate the blade lift cylinder, and level the blade. Fill the new oil through the oil port to the
middle position of observation window, clean the plug, replace the sealing ring, install the plug and
tighten it .
When the level is at the middle position of observation window, the capacity of worm-gear box is 2.5L.
3) Check the oil level of transmission and change the oil
(1) Check the oil level
• Park the vehicle on a flat place
• Shift lever of transmission at the neutral position "N"
• Transmission within the working temperature range
• Engine idling
• Counterclockwise loosen the dipstick, take it out and clean it.
• Insert the dipstick into the oil level pipe and tighten it in place, and then take it out (at least twice)
• When the oil temperature is about 40 ℃, oil level shall be between the lower scale and middle scale
• When the oil temperature is about 80 ℃, oil level shall be between the upper scale and middle scale
Check the oil level under cold status only to ensure that the transmission and torque converter have the
sufficient circulation flow, and finally the oil level shall be equal to that under hot status.
(2) Change the oil and filling volume
Change the oil first when the machine runs for 100h. Thereafter, change the oil once at least every
1000h or every year. （whichever comes the first）
Change the oil according to the following requirements:
• Park the vehicle on a flat ground, and when the transmission is at operating temperature, remove
the drain plug and sealing ring to drain the oil.
Chapter IV Service and Maintenance 95
Note: When draining the oil, not only drain the transmission oil, and also the oil of torque
converter and radiator.
• Clean the drain plug and housing sealing surface, and install them along with new sealing ring.
• Fill the specified oil products.
You shall use the clean transmission oil and filter!
In any case, it shall be consistent with the marks on the dipstick!
• Start the engine and idle it
• Place the control lever of transmission at neutral position "N"
• Fill the oil to upper part of lower scale of dipstick
• Park the vehicle at a safe place
• Select the all gears once
• Check the oil level again, and re-fill the oil if necessary.
4) Replace the transmission oil filter
When changing the oil, replace the oil filter. Do not use the damaged oil filter!
Clean the surrounding of transmission oil filter, unscrew the oil filter, replace with a new oil filter and
tighten it. Be careful not to let dirts and impurities get into the oil circuit.
Install the oil filter according to the following requirements:
• Coat the sealing ring with a thin layer of oil.
• Press the fine filter until it contacts with the sealing surface, and then tighten it about 1/3 to 1/2 turn.
• Fill the oil
• Start the engine.
• Check the transmission oil level when the engine is idling and transmission oil is at working
temperature.
• Check if it is tightened. If necessary, manually tighten it again.
When installing the oil filter, you shall avoid the external force. Do not use a damaged oil filter.
5) Replace the hydraulic oil suction and return filter core.
Remove the bolts, cover and filter core on the oil tank. Clean the inside of the removed part and filter,
and install a new filter core. Fill the specified volume of hydraulic oil through the oil port (F). The type of
used lubricating oil depends on the ambient temperature, and you shall refer to the table, Type and
Volume of Fuel, Coolant and Lubricating Oil.
Be careful to install the oil-suction filter and oil-return filter at the correct position so as to avoid
the damage to pump.
6) Hand brake
Test the hand brake by pulling up the lever to the fourth tooth socket to reach the full brake force. With
the normal pulling force, if the handle exceeds the sixth tooth socket, you shall adjust the hand brake:
Unscrew the locking nuts a few turns, remove the pin, tighten the clamp lever several turns, adjust the
mounting distance of flexible shaft, install the pin and then tighten the fastening screws.
When using the hand brake, before the clamp lever hits the upper baffle, replace the lining of
hand brake. Otherwise, the clamp lever will not move before the brake force is reached.
Unscrew the bolts, and remove the pressure plate. Take out the baffle and loosen the clamp lever until
the brake lining falls out. Replace the brake lining, push the baffle and fix it with pressure plate, and
tighten the bolts with the locking agent with the torque of 23-25Nm.
7) Blade guide gap
See the Adjust the Blade in the chapter (4.1.15)
96 Chapter IV Service and Maintenance
8) Adjust the tandem chain
Check tension of chain of equilibrium box after 100 working hours. If the chain is loose and droops for
over 18mm, then the chain shall be tightened. After that, inspect the tension per 500 working hours.

Note: Each tandem has two chains and both of them shall be checked each time.
9) Change oil of equilibrium box
Oil of equilibrium box shall be changed for the first time when the machine has reached the first 100
hours. After that, change the oil per 1,000 hours or per year (whichever comes the first)!
Screw off the drain plug and drain the oil to a container. Wash the plug, replace with a new sealing ring,
screw on the plug and tighten it. Screw off air cap and fill with fresh oil to the middle position of oil level
indicator. Fill each equilibrium Jincheng box with about 38L fresh oil. Screw on the air cap.
10) Change oil of rear axle assembly
Oil of rear axle assembly shall be changed for the first time when the machine has reached the first 100
hours. After that, change the oil per 1,000 hours or per year (whichever comes the first)!
Drain lubrication oil from final drive case (when the engine is warm).
Screw off oil filler (inspection) plug of final drive case to fill with fresh oil till it overflows from the service
hole. Keep the oil still for 1 hour and then replenish. Screw on the plug (about 25L oil for Jincheng rear
axle).
Refer to operation manual of rear axle and equilibrium box in case of special region.
4.1.7 Maintenance per 250h
Maintenance per 50h shall be carried out simultaneously.
1) Check the connection of steering mechanism fastener, including the nuts of steering rod, and tighten it
if necessary.
2) Change the tandem oil
Loosen the drain plug, inject the oil into the container, clean the plug, replace with a new sealing ring,
and then install and tighten the drain plug, unscrew the vent cap, fill the new oil to the middle of oil level
indicator. Fill about 23L for each Meritor tandem; Fill about 23L for each Jincheng tandem;install and
tighten the vent cap.
3) Change the oil of rear axle
(1) Check the oil volume
Unscrew the filler plug of main transmission on the axle housing. The level shall reach the plug port, and
fill it if necessary.
(2) Change the oil
Drain the lubricating oil through the drain port of main transmission (under the hot status).
Unscrew the filler plug of main transmission (check), inject the new oil until the oil spills from the port,
and then tighten the filler plug.
4) Adjust the fan belt
Press it down for 10mm as standard with 60N force along the arrow direction as shown in Fig.4-21,
otherwise adjust it and check the belt for damage. If the readjustment is unavailable or the scratch and
crack appear due to the stretched belt, replace two belts at the same time. After the new belt is installed,
check and adjust it after it runs 1h. V-belt shall not contact with the bottom of V-groove.

Chapter IV Service and Maintenance 97

 Belt pulley of Belt pulley of fan
Generator generator

Belt pulley of crankshaft

Belt pulley of crankshaft

Fig.4-28 (Viewed from operator seat)

5) Drive belt of water pump (Fig.4-28)

Water pump and fan share a belt pulley which shall be checked and
adjusted according to the same method with the drive belt of fan.
6) Drain the water and impurities in the fuel tank (Fig.4-29):
Open the side cover, loosen the valve at the bottom of fuel tank,
and drain the water and impurities in the fuel tank.
4.1.8 Maintenance per 500h
Maintenance per 50h and 250h shall be carried out simultaneously. Fig.4-29
1) Fuel filter

Close the valve at the bottom of fuel tank (see Fig.4-29), and remove the filter cartridge with the spanner.
Inject the clean fuel to the new cartridge, and coat the sealing gasket with a small amount of oil. Install
the cartridge and manually tighten it until the sealing gasket contacts the filter seat, and then tighten it to
1/2 to 3/4 turn (not overtighten).
2) Fan belt
Check the V-belt, and replace it in case of the following conditions:
When the V-belt contacts with the bottom of belt pulley; when the V-belt is worn, and its surface is less
than the outer diameter of belt pulley;
When the V-belt has cracks and peeling; For the replacement procedure, see Adjust the Fan Belt.
3) Hub wheel brake
Check the thickness of brake lining according to the maintenance requirements, and replace with the
new brake lining if the thickness is less than 3mm.
1) Replace the brake lining
Brake lining shall be updated by professionals.
New brake lining shall be grinded and trimmed with brake drum to ensure the necessary contact area.
Also, the lining of opposite wheel shall be replaced at the same time to avoid imbalance in the brake
force.
2) Adjust the brake
Note: When replacing the brake with linings, adjust four wheels of tandem.
If the gap between the brake shoe and brake drum is not less than 1.0 mm, adjust it. Two brake shoes of
a brake shall be always adjusted together and the order does not matter. Adjustment shall be carried out
by two people, and one person turns the wheel, while the other adjusts the brake.
Raise a side of motor grader with the blade supporting the ground. Support the tandem, and release the
hand brake. Rotate the wheel and adjust it with a 22mm spanner (see Fig.4-31) according to the
"tightening“ direction as shown in Fig.4-30 until the wheel is locked (two brake shoes contact with brake
drum).
98 Chapter IV Service and Maintenance
 Unscrew Unscrew

Tighten Tighten

Fig.4-30 Fig.4-31
Note: Do not exert too much force on the adjustment bolt ①, otherwise the convex plate welded
inside may bear the excessive force.
Unscrew the adjusting bolt ① (Fig.4-30) for about 30° according to the "releasing" direction, so that the
gap between two brake shoes and brake drum may expand to 0.45-0.55mm. Adjust another brake, and
rotate the adjustment bolt ① at reverse direction.
4) Caliper disc brake
Replace the friction plate if the wear limit is reached. Replace all damaged oil seals and dust rings.
(1) Check
If the wear limit is reached, the friction plate shall be replaced.
Replace all damaged oil seals and dust rings..
Clean the clamp (with mineral oil), check the piston hole for nicks, scratches, corrosion, etc., and replace
it if it is severely damaged.
If the axis pin is so worn that it can not guide the friction plate, it shall be replaced.
Check the rubber parts for aging, and replace it if so.
(2) Assemblage
Clean all the parts with mineral oil, and the tightening torque is 60Nm.
(3) Test of brake performance
Brake performance is critical to the safety and efficiency. After the repair, it is still necessary to check if
the brake performance is still in good condition. Take the brake distance as the indicator of brake. In
case of the straight and dry cement road, when the traveling speed is 30 km/h, the brake distance is not
greater than 13m.
5) Maintenance of drive shaft
In case of the obvious gap between the cross shaft of drive shaft and fork sleeve, it is necessary to
replace the drive shaft. Do not remove the assembled counterweight. The damage of counterweight may
lead to the unstable operation and it will be prematurely worn.
6) Maintenance of engine shall be referred to engine operation and service manual
★ Make sure the parts removed for maintenance shall be replaced in right positions. Start up the
engine to inspect its operation performance and remove any existing fault or anything that is abnormal
(this shall be performed for maintenance of each level).

4.1.9 Maintenance per 1000h

Maintenance per 50h, 250h and 500h shall be carried out simultaneously.
1) Cooling fin of water tank
Loosen the bolts of water tank grille, and open it. Blow off the dirt, dust or leaves on the cooling fin of
water tank with compressed air. Steam or water may also be used instead of compressed air. Check the
Chapter IV Service and Maintenance 99
rubber hoses of water tank for cracks or brittle, and replace it if necessary. Check if the rubber hose
clamp is loose.
2) Corrosion preventor (water filter core)
Close the inlet and outlet valves of corrosion preventor. Rotate it counterclockwise with a filter spanner to
remove the cartridge of corrosion preventor.
Apply a small amount of oil on the sealing surface, and replace with a new element. Screw down the
element 1/2 to 3/4 turn after the sealing surface contacts with the cover (Do not overtighten it). After the
replacement, open the valve.
Be sure to use the genuine oil filter specified by Shantui.
3) Working oil tank and filter
Open the drain valve at the bottom of oil tank, and drain the oil into the special container. After the
draining, close the drain valve. Remove the bolts, cover and filter core on the oil tank. Clean the inside of
removed part and filter, and then assemble them. Fill the specified volume of hydraulic oil through the oil
filler (F) (see the Maintenance of first 100h). The type of used lubricating oil depends on the ambient
temperature. Please see the table, Type and Volume of Fuel, Coolant and Lubricating Oil.
Be sure to use the genuine oil filter specified by Shantui.
4) Vent cap
Remove the vent cap, and wash off the dust accumulated inside with the diesel oil.
a. Tandem 2
b. Transmission 1
c. Rear axle 1
5) Worm gear case for blade slewing
Incline the blade to drain plug to speed up oil drainage and lay down the blade on ground. Remove the
drain plug to enable the oil to return to a container. Screw off the plug to speed up drainage. Wash the
plug, replace with a new sealing ring, screw on the plug and tighten it. Operate the hoist cylinder of blade
to lay the blade on horizontal level. Fill with fresh oil from oil filler to middle position of service hole. Wash
the plug, replace with a new sealing ring, screw on the plug and tighten it.
Volume of worm gear case is 2.5L when the oil level reaches the middle of service hole.
6) Change oil of equilibrium box
Screw off the drain plug and drain the oil to a container. Wash the plug, replace with a new sealing ring,
screw on the plug and tighten it. Screw off air cap and fill with fresh oil to the middle position of oil level
indicator. Fill each equilibrium Jincheng box with about 38L fresh oil. Screw on the air cap.
7) Change oil of rear axle
Drain lubrication oil from final drive case (when the engine is warm).
Screw off oil filler (inspection) plug of final drive case to fill with fresh oil till it overflows from the service
hole. Keep the oil still for 1 hour and then replenish. Screw on the plug (about 25L oil for Merito rear
axle).
8) Change oil of transmission case
Change oil in accordance with following requirements:
 Park the machine on even ground. When the transmission case stays at working temperature,
remove the drain plug and sealing ring to drain off oil.
Note: Do drain off the oil from the transmission case and drain off oil from torque converter and
radiator.
 Wipe clean the drain plug and sealing face of the housing. Replace the drain plug with a new
sealing ring.
 Fill oil as specified

100 Chapter IV Service and Maintenance

Do use clean transmission case oil and filter!
Always fill oil to the specified scale on the dipstick!
 Start up the engine and run it idly;
 Shift the lever of transmission case to “N”;
 Fill oil to above the lower scale of dipstick;
 Pull up the parking brake handle;
 Shift to each speed gear for once;
 Check the oil level and fill with oil if it is necessary;
9) Change oil of oil filter of transmission case
The filter shall be changed each time when changing oil. Never use a damaged filter.
Clean the area around the filter; screw off the filter and replace it with a new one; oil and foreign matter shall not
get into the oil channel;
Install the filter following below steps:
 Apply oil on sealing ring;
 Press the fine filter till it contacts with the sealing face on the top of transmission case; tighten the filter for
1/3 to 1/2 round.
 Fill with fresh oil;
 Start up the engine;
 Idly run the engine and check oil level of transmission case when it stays at working temperature;
 Check if the filter is tightened with hand; tighten it if it is necessary;
Protect the filter when installing it and never use a damaged filter.
4.1.10 Maintenance per 2000h
Maintenance per 50h, 250h, 500h and 1000h shall be carried out simultaneously.
1) Brake pedal
2) Turbocharger
The soot or sludge adhered to the pump wheel of turbocharger may affect the working performance and
even damage the turbocharger. Please contact your local dealer of Shantui for necessary check or
cleaning. Do not use a wire brush or similar item to prevent the damage to the pump wheel surface.
3) Valve gap
Please contact your local dealer of Shantui to check the valve gap, because it requires the special tools.
4) Lubricate and adjust front wheel hub bearing (see 3.7.4 for details)
Note: maintenance of front wheel hub bearing shall only be performed by specialized personnel.
4.1.11 Maintenance per 3000h
Maintenance per 50h, 250h, 500h, 1000h and 2000h shall be carried out simultaneously.
1) Water pump
Check the belt pulley for looseness, grease or water leakage. If so, please contact your local dealer of
Shantui for repair or replacement.
2) Fan belt pulley and tensioner pulley
Check the wheels for looseness and grease leakage. If so, please contact your local dealer of Shantui
for repair or replacement.

Chapter IV Service and Maintenance 101

4.1.12 Maintenance of air filter

Always check and maintain the air filter as necessary (Fig.4-32).

1) Check:
Regularly check the dust indicator of air filter. If the red mark on the dust
indicator has risen to the check port, the air filter core shall be cleaned.
Stop the engine while cleaning.
2) Clean or replace the outer filter core:
Remove the wing nut ① and outer filter core (Fig.4-33 and 4-34) and clean
the inside of air filter casing. Clean and check the outer filter core (for Fig.4-32
cleaning methods, see Cleaning Method of Outer Filter Core). Once the
outer filter core is cleaned, a word piece on the inner core plate shall be torn
off (Fig.4-34). Install the cleaned outer filter core element. Replace the
damaged sealing gasket ② or wing nut ① (Fig.4-33). Check the mounting
nuts of internal filter core for looseness, and tighten the loosened nuts.

Plate Word piece

Fig.4-33 Fig.4-34

3) Replace the inner filter core (when outer filter core is cleaned six times or inner filter core is damaged)
First remove the outer filter core, and then remove the inner filter core. Cover the air inlet, Clean the
inside of air filter casing, and take off the inlet cap. Install the new inner filter core on the joint, and then
tighten it with nuts. Install the outer filter core.

Caution

• Replace the filter core which is cleaned six times and used for more than one year, and also
replace the inner filter core.
• Do not clean or replace the air filter core when the engine is running.
★ Do not use the cleaned inner filter core.
4) Cleaning methods of outer filter core
Clean it with compressed air.
Blow the inside of filter core directly along the folds with the dry compressed air (less than 0.7Mpa).
Directly blow the folds from the outside, and then repeatedly blow the inside. Finally, check if the filter
core is clean.

Caution

When using the compressed air, wear the goggles and other safety items.
When checking the inside with the lighting, in case of the holes or thin portion, replace the outer filter
core. (Fig.4-35)

102 Chapter IV Service and Maintenance

If the outer filter core can be used, keep it at the dry place after remove the
dusts.
When cleaning the outer filter core, you can not beat or hit it by other
objects.
Do not use the outer filter core with the uneven folds, deformation or
damaged sealing gasket.

Fig.4-35

4.1.13 Maintenance of air conditioner

Air Air Knob A/C

outlet switch/Refrigerating
capacity knob

Reservoir window

Reservoir

Fig.4-36
★ Clean the condenser
Dusty condenser may result in the great decrease of cooling performance of air conditioner. Under the
excessively dusty environment, you need to clean the condenser several times a day.
Do not clean the condenser with the hot water or steam. Heat will cause the extremely high pressure,
which will lead to the damage or explosion of air conditioning system. Remove the fastening screws of
condenser, and clean the front and rear cooling fins of condenser with the compressed air or cold water.
★ Check the refrigerant level
Start the engine and turn on the air conditioner (Fig.4-36). Turn on the knob of cab evaporator, and
select refrigeration temperature.
Open the air outlet. The temperature shall be below the actual room temperature, so the compressor will
Chapter IV Service and Maintenance 103
work.
★ Check the reservoir
Check the window of reservoir for air bubbles, and if so, the refrigerant is insufficient, and you shall
inform the service department. Fill the refrigerant, and if necessary, check the air conditioning system for
leakage. Annually before the start of construction season, the reservoir shall be replaced by the
maintenance department.
According to the provisions of pressure vessels, all pressure vessels shall be regularly checked by
professionals. Reservoir shall be check twice annually. Check the pressure vessels with the special
attention paid to the corrosion and mechanical performance. If the pressure vessels are not in the
normal status, they shall be replaced to prevent the possible injury to the operator.
4.1.14 Normal Maintenance Materials
Operation
Number of part Name Qty Oil grade
hours
Initial 3937743 Engine oil filter 1 pc
50 hours 3931063 Fuel filter 1 pc
0750 131 053 Filter of transmission case 1 pc Refer to Types and
Application Amount of
AF26549 (outer) Fuel, Lubrication Oil
Initial Air filter element 1 pc
AF26550 (inner) and Coolant
100 hours
222-60-09001 Returned oil filter element 1 pc
222-60-10001 Oil suction filter element 1 pc
3931063 Fuel filter element 1 pc
3930942 Oil-water separator 1 pc Refer to Types and
Application Amount of
500 hours 3937743 Engine oil filter element 1 pc Fuel, Lubrication Oil
AF26549 (outer) and Coolant
Air filter element 1 pc
AF26550 (inner)
3931063 Fuel filter element 1 pc
3930942 Oil-water separator 1 pc
3937743 Engine oil filter element 1 pc
Refer to Types and
AF26549 (outer) Application Amount of
1000 hours Air filter element 1 pc
AF26550 (inner) Fuel, Lubrication Oil
and Coolant
0750 131 053 Filter of transmission case 1 pc
222-60-09001 Returned oil filter element 1 pc
222-60-10001 Oil suction filter element 1 pc

104 Chapter IV Service and Maintenance

4.1.15 Adjustment of various parts

Fan belt
By reference to Fig.4-23 and according to 4.1.7,
when its value is not in the standard range, it shall
be adjusted. Replace two belts at the same time.
Adjustment of blade
If the motor grader blade moves too much, it is
necessary to replace guide plates and bushings in
pair and trim it with a file to timely eliminate the
wear.
(1) Replace bushing (Fig.4-37)
Fig.4-37
a. Place the blade on two woods.
b. Remove the baffle ②.

c. Slide and remove the blade, and then remove the bushing ①
d. Install the new bushing, and tighten the guides.
(2) Replace the guide plate (Fig.4-38)
a. Place the blade on two woods.
b. Unscrew the fastening bolt ①
c. Remove the guide plate ②
d. Install a new guide plate and tighten it with bolts.
(3) Adjust the slewing ring gear of blade (Fig.4-39)
Description: If the radial runout exceeds 3mm, and axial gap is more than 2.5mm, you shall adjust the
slewing ring and guide plate.
a. Axial adjustment of guide plate
① Measure the axial gap between the ring gear ① and four guide plates ② with a feeler.
② Unscrew the nut ④, and then remove the adjustment gasket ③ of four guide plates to make the gap
as required, and re-install the guide plates.
b. Radial adjustment of slewing ring
① Loosen the nut ④ and nut ⑤, twist the bolt ⑥, and adjust the guide plate.
② Tighten all nuts, and tightening torque of nut ④ is 590Nm.
③ For the test, the slewing ring shall freely rotate 360°

Fig.4-38 Fig.4-39

Chapter IV Service and Maintenance 105

4.1.16 Standard Tightening Force of Bolts and Nuts

Caution

• If the bolts, nuts or other parts which shall be tightened are not in accordance with the
specified tightening torque, the parts will come loose and be damaged, which will result in
the damage to machine and operating malfunctions.
• Tighten the parts with the attention paying to the torque
Torque table
Unless otherwise instructed, tighten the metric nuts and bolts according to the tightening torques listed in
the following table. To replace the nuts or bolts, you shall use the genuine accessories of Shantui with
the same size.

Diamete Width of Tightening torque

r of bolt end
thread surface Target value Scope

Tighten the hydraulic hose according to the tightening torques in the following table

Width of Tightening torque

end
Common surface
threaded Target value Scope
part No.
(a)

4.2 Malfunctions and Troubleshooting

4.2.1 Power train
Malfunction Cause Remedy
See the Engine Use and Maintenance Instructions for the engine common malfunctions.
1. Gear not engaged 1. Apply a gear or check the gear
Diesel engine 2. Hand brake not released accuracy
runs but the 3. Insufficient drive system oil 2. Release the hand brake
complete 4. Low transmission oil pressure 3. Add oil as specified
vehicle does 5. Torque converter faulty 4. See malfunction 2
not move 6. Transmission clutch or transmission 5. Replace the torque converter
component damaged 6. Repair the transmission
Low 1. Main safety valve faulty 1. Repair the transmission control
transmission 2. Severe oil leakage of clutch oil seal valve
106 Chapter IV Service and Maintenance
 oil pressure 3. Pipe oil leakage 2. Replace the oil seal and oil seal
4. Oil pump malfunctions seat
5. Filter blocked 3. Screw down the pipe connector
4. Replace the oil pump
5. Replace the filter
1. Low transmission oil pressure 1. See malfunction 2
2. Pipe blocked 2. Clear or replace the pipe
Unable to
3. Severe oil leakage of clutch oil seal 3. See malfunction 2
apply a gear
4. Hand brake not released 4. Release the hand brake
or certain gear
5. Gear lever or electric control box 5. Replace the lever or electric
malfunctions control box
1. Insufficient transmission system oil or
oil leakage
1. Add new oil after repairing
2. Low transmission oil pressure
2. See malfunction 2
Insufficient 3. Improper brake adjustment; incomplete
3. Check and regulate
driving force disengagement of brake shoe or hand
4. See malfunction 5
brake
5. Repair the diesel engine
4. High torque converter oil temperature
5. Diesel engine working abnormally
1. Check the oil level and make
adjustment as required
1. Insufficient or excessive transmission
2. Repair the clutch, and correct the
system oil
shift pressure
2 . Clutch slips
3. Replace the oil
Too hot torque 3. Oil is too dirty or deteriorated
4. Wash it periodically; replace it
converter and 4. Water tank and oil heat radiator
when damaged
transmission blocked or damaged
5. Stop to cool off; avoid overload
5. Long continuous work or overloaded
6. Inform the service department of
6. Torque converter valve faulty
our company
7. In high gear or low gear for too long
7. Change the driving way, e.g. drive
in different gears
1. Gear lever damaged
1. Repair or replace the lever
Gear mixing 2. Gear shifting electric control box
2. Replace the electric control box
damaged
1. Low oil level
Abnormal
2. Oil leakage or blockage of pump and 1. Add oil
pressure at
cooling system 2. Repair, clean
torque
3. Filter blocked 3. Repair, clean
converter
4. Outlet pressure valve stuck or 4. Repair, clean
outlet
damaged
Low control
pressure at 1. Low oil level 1. Add oil
each gear of 2. Control pump faulty 2. Repair or replace it
the 3. Control pressure valve faulty 3. Readjust the pressure or repair
transmission
Low control
Clutch seal, piston ring or friction plate is
pressure at Replace it with new one
severely worn
certain gear
4.2.2 Electrical System
Malfunction Cause Remedy
1． Poor contact of starting circuit wire 1． Repair and handle it
2． Poor contact of starting relay contact or 2． Polish the contact or replace the
Engine does coil burnt relay
not work after
3． Power main switch not closed 3． Repair or replace it
switching to
start position 4． Starting switch faulty 4． Replace it
5． Fuse broken 5． Replace the fuse
6． Starter motor winding damaged 6． Replace it or repair it
Chapter IV Service and Maintenance 107
 7． Storage battery severe power-lack 7． Recharge it
Incorrect 1． Wire loose, fallen off 1． Press down the wiring terminal
instrument 2． Sensor broken 2． Replace the sensor
indication 3． Instrument broken 3． Replace the instrument
1． Fuse broken 1． Replace the fuse
Light is off 2． Filament burnt 2． Replace the bulb
3． Connecting wire fallen off 3． Press down the wiring terminal
Generator
does not work 1． Generator wire loose 1． Tighten the wire again
or recharging 2． Belt loose 2． Adjust the belt
current is too 3． Regulator or generator broken 3． Replace the complete generator
low/high
4.2.3 Hydraulic System
Malfunction Cause Remedy
1. Oil pump worn or damaged 1. Replace the oil pump
Low flow or 2. Filter blocked 2. Clean or replace it
abnormal 3. Low oil level 3. Add oil
pressure 4. Improper valve adjustment 4. Make adjustment as required
5. Hydraulic system oil line blocked 5. Clean out
1. Connector loosen
Oil leakage
2. Sealing ring damaged
Ineffective
1. Hydraulic motor connector oil leakage 1. Replace the seal
shovel blade
2. Parts of hydraulic motor worn 2. Replace the hydraulic motor
rotation
Working
hydraulic oil
mixing with
Faulty oil seal of the working oil pump Replace the oil seal
the
transmission
oil
Abnormal 1. Air entered; low oil level
1. Add oil, discharge the air
sound and 2. Cold oil, high in viscosity or pump
2. Preheat it
vibration of starving
3. Repair and replace it
pump 3. Pump faulty
Big control 1. Control valve blocked by dirt 1. Clean out
force 2. Spring fails 2. Replace it
Unreliable 1. Air trapped in cylinder 1. Check it; discharge the air
cylinder action 2. Piston sealing damaged 2. Replace the sealing ring
1. Continuous long and heavy work 1. Reduce the work load
2. Excessive system pressure 2. Regulate to specified pressure
High oil
3. Insufficient oil in cylinder 3. Add oil
temperature
4. High ambient temperature 4. Stop and cool off
5. Big internal leakage 5. Check the related elements
1. Add oil to the specified oil level
1. Low oil level
2. Wash or replace it to eliminate the
2. Oil suction pipe blocked
Vacuum blockage
3. Air in working oil pump suction pipe
occurs in oil 3. Repair or replace it
4. High hydraulic oil viscosity
suction 4. Change oil
5. Gear pump severe leakage
5. Repair or replace it
6. Cold weather causing high oil viscosity
6. Observe after running
4.2.4 Brake System
Malfunction Cause Remedy
1. Oil leakage of brake oil line 1. Eliminate the oil leakage
Weak brake
2. Air mixed in brake oil 2. Discharge air through the slave
or brake
3. Oil line blocked pump nozzle
failure
4. Big clearance between shoe and brake 3. Wash and clear the oil line
108 Chapter IV Service and Maintenance
 drum 4. Regulate it
5. Oil stain on brake shoe facing 5. Clean off the oil stain
6. Low accumulator pressure 6. Check the pressure (nitrogen)
1. Oil line blocked causing difficult oil 1. Wash and clear the oil line
return 2. Repair or replace the brake valve
Brake can not
2. Brake valve rod stuck and return spring 3. Regulate it
be released
failure or breakage
3. Brake strap clearance too small
Parking brake 1. Oil stain on parking brake surface 1. Clean the oil stain
failure 2. Too big idle stroke of parking brake 2. Regulate it
4.2.5 Operating System
Malfunction Cause Remedy
Operating
1． Oil cylinder damaged 1． Repair it
device
control failure 2． Safety valve stuck and leaky 2． Replace the pump
Operating
device can 1． Cylinder piston sealing ring damaged;
1． Replace the sealing ring
not stay at the internal leakage
determined 2． Repair it
2． Lock valve failure
position
Shovel blade 1． Too big blade slideway fit clearance
1． Regulate it
vibrates 2． Too big slewing circle supporting
during work 2． Regulate it
clearance
1． Driving motor or worm-gear case 1． Replace it
Shovel blade
damaged 2． Regulate it to eliminate the
can not slew
2． Slewing support slideway stuck stagnation
Shovel blade
can not 1． Shovel blade guiding device blocked 1． Wash it
stretch 2． Central turning connector leaks oil 2． Repair it
laterally
4.2.6 Steering System
Malfunction Cause Remedy
1． Low oil temperature 1. Start after increasing the
2． Wrong control oil line connection temperature
3． Control oil line blocked 2. Connect pipe line as specified
3. Wash the control pipe
Hard steering 4． Low pressure of safety valve in
4. Readjust the safety valve pressure
priority valve
5. Unscrew the bolt
5． Too tight bolt of the hydraulic 6. Repair or replace the oil pump
steering gear measuring motor
6． Insufficient oil pump oil supply
Steering wheel
can still be
turned after the Limit mechanism faulty Repair the limit mechanism
vehicle reaching
its limit
Turn normally
when the
1． Low regulating pressure of safety
steering 1. Readjust the safety valve pressure
valve in priority valve
resistance is 2. Eliminate the stagnation cause or
small; and turn 2． Safety valve core stuck or poor replace the safety valve assembly
slowly when the internal infiltration leakage
resistance is big
Vehicle does not 1. Eliminate the stagnation cause or
1． Stuck safety valve in priority valve
turn when replace the safety valve assembly
turning the 2． Main oil line overflow valve faulty 2. Repair the main oil line overflow

Chapter IV Service and Maintenance 109

 steering wheel valve
1． Full hydraulic steering gear valve
Steering wheel 1． Eliminate the foreign matter in the
sleeve stuck
turns valve
automatically 2． Full hydraulic steering gear spring
2． Replace the spring blade
broken
1． Check the oil suction pipe sealing
1． Air in steering oil line
and discharge the air
2． Steering pump worn, insufficient
2． Repair or replace the steering
flow
Steering pump pump
3． Insufficient oil viscosity
noisy; steering 3． Change oil as specified
cylinder piston 4． Insufficient hydraulic oil
4． Add oil as specified
moves slowly 5． Low regulating pressure of main oil
5． Regulate the overflow valve
line overflow valve
pressure as specified
6． Internal leakage of big steering
6． Repair the oil cylinder or replace
cylinder
the seal
4.3 Disassembly and Assembly Matters
4.3.1 Disassembly
1) Before disassembling any components of the motor grader, carefully read the user’s guide, to fully
understand the removed components. Mastering the structure and purpose of each component is
an important factor of completing the overhaul work smoothly.
2) Pay great attention to the direction and position of each part when removing. Mark the identification
sign if necessary. Meanwhile pay attention to the order of removing the parts from motor grader, to
ensure the correct installation of the parts.
3) Use the special tools according to the specifications of operation sequence. If there are no special
tools, use similar tools. If the general tools may cause some damage to the related parts, the special
tools shall be used.
4) The parts with taper or tight fit shall be firmly installed on the original position. If finding these parts
are loose, check its wear status.
5) The parts removed shall be cleaned up and placed together orderly, and take actions to protect
them from dust accumulation. Use two kinds of cleaning fluid: one for washing the foul, and the
other for cleaning.

Caution

Filter and breathing cover are the parts which shall be specially washed.
4.3.2 Assembly
1) All parts shall be clean before assembly. The replaced spare parts are generally coated with antirust
agent, so first scrub it.
2) In most instances, the installation of bearing, bushing and oil seal shall use the special installation
tools. It is a bad habit to directly hammer them into the installation position, instead a block or soft
metal shall be filled up to deliver the impact force.
3) The spring washer, plain washer, tongued washer and split pin are very important parts. But due to
their small sizes, they are apt to be omitted when assembling. When installing the fasteners such as
bolts and nuts, check the locking method of these parts for meeting the specification.
4) Use torque wrench at the place where the torque limit is specified. When fixing the cover or the
similar parts (such as valve body, etc.) having bolts, screw down the bolts symmetrically and
gradually, to distribute the pressure evenly.
5) The match mark is not the identification sign of matching part, but a method indicating accurate
alignment as far as possible, so do not mistake.
4.3.3 Disassembly and Assembly of Bearing
1) The dust is harmful for all bearings. It is the common reason of bearing noise and quickening
110 Chapter IV Service and Maintenance
 lubricating oil degeneration. When replacing the bearing, remove the packaging of bearing only
when all works of installation are completed.
2) Use gasoline as the washing fluid of bearing. If compressed air is available, use kerosene and
diesel to wash, and then blow off the dust with compressed air.
3) When installing the bearing, the position shall be correct, and the bearing shall be placed closely
with the shoulder or bearing race, to reduce excessive clearance of two faces.
4.3.4 Installation of Oil Seal
1) When installing the oil seal, the oil seal lip of blocking oil and gear oil shall face inward (the side of
blocked oil), to improve anti-oil performance. The oil seal lip of blocking grease shall face outward,
because after adding new grease, the used grease is easy to be extruded.
2) Keep the bearing close with the shoulder or bearing race.
3) Before installing the oil seal, apply a layer of lithium base grease on the lip, otherwise, due to the
friction of dry friction in the initial stage of working, the oil seal may be scratched.
4) When installing the oil seal, use a conduit to make the oil seal slip into the seat (see Fig. 4-40A); if
there is no such conduit, use a brass sheet to make a conduit temporarily (see Fig. 4-40 B).
5) The correct way of pressing oil seal into the seat (see Fig. 4-40 C): use a proper tool to make the
pressure applied on the oil seal end face evenly, the diameter of its tool shall be 0.5~1 mm smaller
than the bore, and its free end shall have the shape fitting hammering.

Fig. 4-40A, B and C Oil Seal Installation

4.4 Attached Table
4.4.1 Lubrication Chart of Motor Grader
1. Lubrication Chart(The first structure)

Chapter IV Service and Maintenance 111

2. Lubrication Chart(The second structure)

112 Chapter IV Service and Maintenance

Chapter IV Service and Maintenance 113
4.4.2 Type and Dosage of Fuel, Coolant and Lubricating Oil
Rated
Ambient Temperature and Applicable Oil Dosage
Part (L)
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 ℃
280
-10~-30 # light
Engine fuel diesel
tank
0＃light diesel

Q.S. (add
SAE5W-30 according
Engine oil
to the oil
pan
SAE15W-40 dipstick
scale)

SAE5W-30 28
Transmission
*SAE15W-40

HO-15
Hydraulic oil
110
reservoir
*HV46H

SAE75W-90
Turbine case 2.5
SAE85W-90

SAE85W-90 Jincheng
Rear axle
Rear axle 25 L
Meritor
Rear axle
28 L
SAE75W-90 Jincheng
SAE85W-90 Tandem
38 L/side
Tandem
Meritor
Tandem
23 L/side
Other
lubrication 2 # and 3 # lithium base grease Q.S.
parts
Engine
Q.S.
coolant Soft water＋antifreeze
Notes:
1. The oil product labeled * is the substitute of the product in its column and can be used in case of no
such oil product in the corresponding column.
2. The lubricating oil grade for the Dongfeng Cummins Engine is CH-4 level or above, and for other
engine oil grade selection, please refer to the engine maintenance manual.
3. When the ambient temperature is under -20℃, the oil of engine oil pan is replaced with SAE5W-30.
4. When filling the oil, first extract the filtration screen from the oil filler, clean it up with clean diesel, put
it back to the oil filler, then fill the oil, and use the oil product which is fully subsided.
5. The adding amount of oil and grease shall meet the requirements, not too much or too little.
6. The tools of adding oil and water shall be clean, and shall be stored in the box or cabinet covered
114 Chapter IV Service and Maintenance
 tightly after using.
7. When draining the oil, preheat the oil to 30~40℃.
SAE oil grade is the international universal oil grade.

Chapter IV Service and Maintenance 115