Dingsheng Tiangong PY180H Operating Manual Download Page 1

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GRADER PY180H

Operating Manual

Product name: Grader
Product specification: PY180H

Add：No.5 Haitai North ＆ South Street，Huayuan Industry Zone of
Tianjin New Technology Industry Zone China

Postal code： 300384
Tel：0086-22-58396099
Fax：0086-22-58396090

The People's Republic of China

Ding Sheng Tian Gong Construction Machinery Stock Co., Ltd

Summary of Contents for PY180H

Page 1: ...ication PY180H Add No 5 Haitai North South Street Huayuan Industry Zone of Tianjin New Technology Industry Zone China Postal code 300384 Tel 0086 22 58396099 Fax 0086 22 58396090 The People s Republic of China Ding Sheng Tian Gong Construction Machinery Stock Co Ltd ...

Page 2: ...short of rules shall be forbidden Report any abnormal phenomenon to higher level and the higher level department shall take measures accordingly Refuse unapproved personnel to get on the machine or enter the working site Forbid operating against rules such as lateral drag repairing on inclined or uneven road surface and working under lifted heavy etc Once the operator take notice of possibility of...

Page 3: ...4 13 Wheels and tyres 5 4 14 Front and rear frames 5 4 15 Driver s cab 5 4 16 Electrical system 5 5 Layout and equipments 6 6 Description 7 6 1 Grader 7 6 1 1 Engine 8 6 1 2 Hydrodynamic torque converter transmission 8 6 1 3 Traveling braking Foot braking hydraulic system 9 6 1 4 Hydraulic operating system and hydraulic steering system 10 6 1 5 Electrical devices 15 7 Operation instruction 16 7 1 ...

Page 4: ... wheel bearing 56 8 9 Work device Blade 57 8 10 Tyres 59 8 11 Fasten and change wheel 60 8 12 Steering 61 8 13 Hydraulic operating system 61 8 14 Transmission shaft 61 8 15 Electrical device of grader 61 8 16 Notes to store the grader 62 9 Fault analysis and troubleshooting 63 10 Front axle drive unit 72 10 1 hydraulic system of front axle drive 72 10 2 Front driving axle 73 10 3 Operating instruc...

Page 5: ...ection are very important for the brake system and steering system especially We will provide technical service for any necessary repairs upon the sales of the grader GB T 14782 93 Technical item of Motor Grader 1 1 Warranty clause We observe the contact and carry out guarantee of repair replacement and refund of substandard products and supply mating parts after the sales of engineering machinery...

Page 6: ...rson is forbidden to enter the working area 14 The operating device shall be fallen to the ground or fixed in case of down time or not used 15 Only when setting the grader to the ground or fixing the grader can the diver leave and set the control device to their original positions 16 The drive must have the hand brake engaged and all assistant safety devices locked before leaving the driver s cab ...

Page 7: ... machine 4 1 Dimensions Fig 1 Tyre 17 5 25 Fig 1 4 2 Working weight Unit kg Complete machine Front axle Rear axle 15400 4600 10800 4 3 Engine Type 6CTA8 3 C215 Bore stroke 114 135mm Total displacement of the pistons 8 27L Rated power 160kW ...

Page 8: ...ype tandem box oscillating angle 15 heavy duty roller chains drive 4 7 Speed Forward km h Reverse km h 1st 2nd 3rd 4th 5th 6th 1st 2nd 3rd 5 23 7 94 11 84 17 85 25 40 5 23 11 84 25 4 8 Brake system 4 8 1 Service brake foot brake Pipe system Brake system consists of one circuit hydraulic pump and accumulator Brake Pliers disc brakes are assembled on rear wheels 4 on two front wheels 2 on two rear w...

Page 9: ...are driven by hydraulic motor there are two types of structures tooth ring or rolling disc 4 13 Wheels and tyres Rims 14 00 1 5 25 TB Standard tyres on all 6 wheels 17 5 25 PR12 4 14 Front and rear frames Construction Front frame steel beam structure its section is pressed into U sleeve welded like box Rear fame solid beams welded in two sides 4 15 Driver s cab Structure Weld structure of the stee...

Page 10: ... accessories 1 Front frame 2 Rear frame 3 Articulation center 4 Engine cover 5 Splash guard 6 Driver s cab 7 Driver s seat 8 Air conditioner optional 9 Mark plate 10 Instrument plate 11 Removable console Engine and accessories 12 6 cylinder diesel engine 13 Air filter 14 Exhaust system 15 Fuel tank Gear box axle wheel 16 Driving shaft 17 Torque converter transmission 18 Gear change lever ...

Page 11: ...ke pedal 49 Brake 50 Relief pressure valve of the accumulator 51 Hand brake disc brake Electrical devices 52 Batteries left side of the engine 53 Head lights 54 Tail lights 55 Indicators instruments switches and cables Not shown in figure 6 Description 6 1 Grader The engine and transmission are mounted on the rear frame The work devices are mounted on the front frame The additional front bulldozin...

Page 12: ... should be 80 110 when at normal work and it is allowed to reach 120 at moment The transmission has 6 multi disk clutches controlled by hydraulic which can engage and disengage under the load reach the power shift The transmission gear is a constant engagement drive Its construction and principal can be seen in the following attached figures The speed ratio of the transmission as follows Forward R...

Page 13: ...ngine Note The transmission oil must be changed after operation of the first 100 hours and later every 1000 hours or at least once a year The oil filter also should be changed with oil changing Please notice that the used filter could not be assembled again even no apparent damage found Note When the engine is shut down and the main machine is dragged this transmission require that the traction di...

Page 14: ...n The double direction hydraulic lock 16 mounted on the returning lines for titling and lifting the blade can guard against moving due to their own weight and the load to insure safety running and operating accuracy of the blade Because of the supplying oil in the equal flow double lift cylinders for up and down operation in the simultaneous and same speed to raise operating performance of the gra...

Page 15: ...ring and braking 3 Return oil cooler 4 Sealed type oil tank 5 Filter valve 6 Return oil filter 7 Steering safety valve 8 Hydraulic steering gear 9 Pressure limiting valve 10 Braking valve 11 Accumulator 12 Brake 13 Safety valve 20Mpa 14 Operating valve left 15 Operating valve right 16 Bidirectional hydraulic lock 17 Hydraulic lock ...

Page 16: ...12 A3 电气接线图 ...

Page 17: ...ector 18 插接器 Connector 19 插接器 Connector 20 插接器 Connector 21 插接器 Connector 22 插接器 Connector 23 插接器 Connector 24 插接器 Connector 25 制动压力开关 Brake pressure switch 26 电源开关 Power switch 27 起动机 Starter 28 插座 Socket 29 制动灯开关 Brake light switch 30 发电机 Alternator 31 回油滤油器 Oil filter for oil return 32 吸油滤油器 Oil filter for oil intaking 33 左组合后灯 Left combined tail lamp 34 测试插头 Test plug 35 变矩油温传感器 Torque changin...

Page 18: ... 63 等候灯 Waiting lamp 64 停止灯 Stopping lamp 65 充电继电器 Charging relay 66 作业灯开关 Working light switch 67 后照灯开关 Light switch for rear lighting 68 顶灯开关 Overhead light switch 69 仪表示宽灯开关 Instrument view side switch 70 熔断器 Fuse 71 中速控制开关 1 Intermediate speed control switch 1 72 中速确认开关 Intermediate speed conform switch 73 中速调整开关双向自动复位 Intermediate speed adjust switch Both way auto reset 74 中速控制开关 2 Intermedi...

Page 19: ... in figure Jk 406 起动开关挡位图 Jk 406 Gear figure of starting switch Conecta velocidad B BR 10A ACC 10A C 20A R1 50A R2 50A III X X X 0 X I X X X II X X X X 6 1 5 Electrical devices A Electrical connection diagram Fig 10 B Fuse description 1 10A Oil cut off valve 2 10A Starting relay 3 10A Instrument 4 10A Front and rear wipers overhead light 5 15A Rear working light 6 15A Front working light 7 5A Char...

Page 20: ...yre pressure is in accordance with regulations and requirement e Whether the battery sulfuric acid level has been charged fully f Check liquid levels Engine Transmission Rear axle Tandem box Blade rotating turbine box Hydraulic oil tank After starting the engine The working brake pressure signal lamp cannot light check the function of the brake and steering systems After the machine has worked for...

Page 21: ...gauge 11 Water temperature gauge 12 Control lever for front bulldozing plate 13 Control lever for front wheel lean 14 Blade outgoing control lever 15 Control lever for blade to scrape 16 Control lever for lifting right blade 17 pedal of assistant vehicle ladder 18 Control device for hand brake 19 Main power switch 20 Scarifier indicator 21 Brake pedal 22 Accelerator pedal 23 Six gang switch 24 Con...

Page 22: ... means the battery is charging 3 Water temperature gauge Fig 11 11 Measuring range 50 115 Indicates the cooling water temperature of engine Under normal condition the water temperature shall be below 90 4 Timer Fig 11 29 Accumulated range 0 9999 9h Accumulated operating time of engine 5 Transmission control pressure gauge Fig 11 7 Measuring range 0 2 5MPa When the oil temperature of transmission i...

Page 23: ...oting 3 Indicator lamp for brake red Fig 12 11 The indicator lamp lights in case of service brake 4 Indicator lamp for hydraulic oil filter red Fig 12 4 The indicator lamp lights when the engine is running which means that the oil filters are blocked Clean or replace the filter element 5 Indicator lamp for far light blue Fig 12 5 The indicator lamp lights when the front light is switched to far li...

Page 24: ...h for front window 6 Wiper switch for rear window 7 3 5 Comprehensive switch Fig 14 Fig 14 Control lever position 1 Switch off 2 Big head of head lamp 3 Switch off 4 Left turning 5 Right turning 6 Horn 7 Small head of head lamp 7 3 6 Accelerating pedal Fig 11 21 This pedal can be used to control the engine speed 7 3 7 Brake pedal Fig 11 22 ...

Page 25: ...steering wheel in the Driver s cab is adjustable the driver can operate the steering wheel comfortably in proper position a Pull up the lifting lever Fig 11 31 on the right side of moving console slowly b Move the steering wheel up and down to get a proper position Adjust according to individual conditions c Release the lifting lever and fix the operating console 7 4 Driver s cab 7 4 1 Driver s ca...

Page 26: ...ight of seat cushion and backrest c The lever 3 can be used to move the position of entire driver s seat frontward and backwards The driver s seat shall be set with the lever 3 after adjustment d Weight adjustment The carrying capacity of seat can be adjusted by the use of hand wheel 4 the adjusting range 60 130Kgf Fig 17 7 5 Operation of operating device In driver s cab the adjustment and determi...

Page 27: ...el lean 3 Hydraulic cylinder for blade shift 4 Hydraulic cylinder for cutting angle adjustment 5 Hydraulic motor for rotary gear ring 6 Hydraulic cylinder for blade swing 8 Hydraulic cylinder for blade lift lower left 9 Hydraulic cylinder for blade lift lower right 10 Hydraulic cylinder for frame articulation 11 Hydraulic cylinder for back ripper lift lower 7 5 1 Control device Fig 19 1 Blade lowe...

Page 28: ...eating on the driver seat Fig 20 The following steps can be used to fix the swing frame on positions 1 2 3 4 5 and 6 shown in Fig 21 a If turn from horizontal position 3 to 1 or 2 operate according to the directions 2 14 and 19 shown in Fig 19 to retract swing cylinders completely b If turn from horizontal position 3 to 4 or 6 operate according to the directions 1 13 and 20 shown in Fig 19 to exte...

Page 29: ...ator When operating the control lever in driver s cab the cutting angle can be adjusted to suit all working conditions 7 5 5 Scarifier Note The scarifier can work by the use of 1 6 teeth the earth can be scarified while rotating the blade a Set the scarifier teeth at working position 1 Move the safety spring Fig 22 1 and pull out the lever Fig 22 2 2 Push the safety lever Fig 22 2 into after setti...

Page 30: ...ack scarifying indicator Fig 11 20 This indicator is mounted on the left side of driver s seat the pointer 2 indicates the height of teeth on measuring scale 1 Fig 23 b Tooth adjustment The tooth can have two positions as shown in the figure below 1 Take off spring pin Fig 24 1 2 Pull out the pin shaft Fig 24 2 each tooth can be placed on the predetermined position and then drive the pin shaft in ...

Page 31: ...he middle position 3 Deep ripper Fig 26 press the ripper completely by use of oil cylinder Fig 24 d Scarifying The control lever See 7 5 1 controls the lifting and lowering of the back scarifier the number of teeth depth and driving speed are dependant on the tyre of ground being cut 1 Drop the ripper until the teeth lower onto the ground 2 Drive the grader forwards and at the same time lower the ...

Page 32: ... indicator Note This indicator is mounted on the front left lamp holder Fig 27 Fig 27 1 The Pointer 1 on indicator 2 indicates the position of bulldozing plate Left mark point The bulldozing plate if lifted completely Middle mark point The bulldozing plate is close to the ground Right mark point Maximum cutting depth of the bulldozing plate 7 5 8 Front wheel lean The control of the front wheel lea...

Page 33: ...tarter knob as soon as the engine runs Do not keep the starter running continuously for more than 15 seconds Note In order to protect the battery the time interval of 1 2min shall be remained for each starting e As soon as the engine runs smoothly the engine speed shall be reduced At the same time the gauge is light and the indicator is off Note Pay attention to avoid running at high speed when th...

Page 34: ... Instrument display during running a Indicator lamp The indicator lamp for battery charge red The indicator lamp for brake service pressure red The indicator lamp for hydraulic oil filter red Above indicator lamps are off b The following instruments must be observed Note If one of the indicator lamps mentions above lights and unusual conditions happen in the pressure gauge of the transmission the ...

Page 35: ... 7 6 8 Preparation before driving Before driving on the road the following instructions shall be followed 1 Clean the heavy dirt on the grader 2 Check the brake steering system tyres and lights 3 Set articulated steering Front and rear wheels must be in line See Fig 29 4 Check front wheel lean and set front wheel vertically 5 Bring the blade in traveling position and lift it as high as possible 6 ...

Page 36: ... then lower the bulldozing plate b Stop the wheels and fix the grader firmly 7 6 15 Working slope of the grader In order to avoid interrupted or insufficient lubrication of engine the working slope of the grader shall not exceed the following values because bad lubrication of engine may give rise to danger Transversal slope Longitudinal slope Left or right Forward Backward Permissible angle 20 25 ...

Page 37: ...ncreases the leveling and mixing effect 5 The front wheel should be leaned towards the side from which the material is running off When working on slopes the front wheel can be set vertically to give better traction with the aid of the wheel lean 6 By acting the blade side shift the blade can be moved out during grading without the changing the operating height 7 The grader should not be used unde...

Page 38: ... be carried out carefully and then clean the machine Oil change can only to be carried out with the engine under working temperatures All oil change shall be carried out at the correct intervals at least once a year b Clean all grease nipples before greasing Fill up with grease until fresh grease emerges c Clean all oil nipples and draining plugs before doing oil change Use a fine mesh for filling...

Page 39: ...35 A3 润滑图 ...

Page 40: ...ng of lift cylinder 铰接油缸轴承 Bearing of articulated cylinder 铰接轴承 Articulated bearing 变速箱油位 Oil level of transmission 变速箱后桥十字轴 Transmission centrepiece of rear axle 油冷却器散热片 Oil cooler radiator fin 变速箱及液压系统 Transmission and hydraulic system 平衡箱油位观察玻璃 Inspection glass of oil level of tandem box 发动机加油滤筒 Filtering cartridge of engine filling 后桥油位观察玻璃 Inspection glass of oil level of rear axle 发动机油标尺 E...

Page 41: ...le 液压油加油过滤器 Filling strainer of hydraulic oil 液压油箱加油口 Oil filler of hydraulic tank Symbol description Oil cup W Oil filling and filter R Clean F Grease O Check oil level S Bilateral symmetry Fig 30 Lubrication chart of PY180H grader ...

Page 42: ...ion Change oil for transmission of torque converter Change oil for rear axle Change oil for tandem box Replace filter element of transmission Clean oil suction filter screen of transmission Replace return oil filter element of hydraulic oil 500h Change oil for hydraulic tank 8 2 4 Lubricating oil and grease Classification Lubricating grease Oil cup and oil filling place of lubricating grease No 2 ...

Page 43: ... two oil filters can be seen if open the machine enclosure on right side of the engine the oil filler and three engine oil scale One located on the oil sump and the rest on speed regulator and ejection pump a Check engine oil level Note Generally the oil consumption of engine oil is very high so the oil level shall be checked twice daily during running in period about 200h check the oil level once...

Page 44: ...container to assist draining unscrewing the screw thread of oil filler Fig 31 2 Close it only after oil is drained off Fig 31 2 Clean drain plug Fig 31 1 and use a new sealing ring to refit and retighten 3 Fill fresh oil at the oil filter Fig 31 2 into axles until the middle of the oil level indicator Fig 31 3 is reached 4 Rescrew on screw plug and tighten Capacity Approximate 28L oil level is req...

Page 45: ... 1 2 then fill oil if necessary 8 3 5 Turbine box of blade rotating Note Check oil level and change oil according to the lubrication chart 8 2 a Change oil 1 In order to accelerate the drainage of oil swing the grader blade It is inclined towards the oil drain plug Fig 34 1 and put the blade on the ground 2 Remove the oil drain plug Fig 34 1 and drain oil into a proper container Remove the plug Fi...

Page 46: ...c operating and steering systems Fig 35 Note The hydraulic tank is located at the left side of the engine cover Check oil level and change oil and oil filter according to the lubrication chart Item 8 2 a Bleeding of oil tank Note Before opening the tank Filling cover or tank valve air in the tank must be bled 1 Loosen the fastener and remove the cover 2 Remove the rubber cap on the exhaust valve F...

Page 47: ...36 2 on the bottom of the oil tank by a few turns and let oil drain into a container Screw the nut if oil is drained off Attached note Connect the nut with flexible tube Fig 36 2 to control draining oil Fig 36 Fig 37 5 Fasten the nut Fig 36 2 6 Open the filter Fig 37 3 and fill up specified hydraulic oil and the oil level shall reach the middle of the observing glass Fig 38 4 7 Refit the filter co...

Page 48: ...stener and take off the cover plate 2 Bleed air from oil tank 3 Unscrew filter cover 4 Remove complete filter element Fig 39 2 and pressure cover Fig 39 3 5 Pull out the split pin Fig 40 4 and unscrew the castle nut Fig 40 5 Remove spring seat Fig 40 6 and pressure spring Fig 40 7 and filter element Fig 40 8 from the base Fig 40 9 6 Clean magnet Fig 40 10 and base Fig 40 9 7 Reassemble new filter ...

Page 49: ...k down occurred and unusual conditions Hydraulic system Check for sealing condition Visual inspection Electrical system Check the line and joint Visual inspection Wheel and tyre Check tyre pressure and make it conform to the requirement of 8 10 2 Check the tyre for damage and remove the foreign body Brake system Check the function of hand brake Daily maintenance 10 operating hours Steering system ...

Page 50: ...e their correct positions when reassembling Then start the engine check its running condition and eliminate all faults and abnormal phenomenon This work shall be conducted in the following different stage maintenance Brake system Check the hand brake adjust if necessary Hydraulic operating and steering systems Check the oil tank oil pump oil cylinder pipe and hose as well as joint for sealing cond...

Page 51: ...ering lever Tighten it if necessary Check operating pressure Brake system Check the hand brake adjust it if necessary Replace the damaged braking pad After every 250 operating hours Working Mechanism Check the play of blade guide and the play of turning circle guide Adjust if necessary Engine Carry out the maintenance items specified by different stage maintenance Torque converter transmission Rep...

Page 52: ... to the using condition the air prefilter shall be disassembled to remove dusts with compressed air or water after operating for 100 150 hours then reassemble after the air prefilter becomes dried completely b Air filter 1 When the blocked alarm indicates from green to red conduct maintenance to main filter element 2 The filter element must be replaced after cleaning for 5 times 3 The main filter ...

Page 53: ...fill up the tank open the cab Fig 48 2 and make sue that the filter screen Fig 48 3 is in the filling oil hole d After filing up close the cap immediately Always keep tank closed to avoid contamination of the fuel 3 Clean the fuel tank a The tank cap Fig 48 2 and the filter screen Fig 48 3 should be thoroughly cleaned with kerosene from time to time b Unscrew the screw cap on the bottom side of th...

Page 54: ...e type of fixed clamp The brake disk is combined with the wheel hub turning with the wheels By the transition plate the clamp is fixed on shaft connected plate See Fig 9 10 When braking hydraulic oil is entered into each piston cylinder to make the piston I push the friction disk 2 and press brake disk 3 so as to produce braking torque After releasing hake by elastic sc were worn he tolerance incr...

Page 55: ...tion discs of ht assembly for wear extent Replace if the rear limit which is mentioned above has been reached 2 Replace if there is any damage on oil seal and dust proof ring 3 Clean the clamp Use mineral oil 4 Inspect the piston hole for scratches and corrosions Replace the clamp if there is any heavy damage 5 Inspect the piston for scratches and corrosions Replace if there is any serious damage ...

Page 56: ...ust be run in and rounded off with brake drum to insure necessary contact area additionally in order to avoid unbalanced braking force the brake lining shall be replaced together with that of opposite wheel Adjust foot brake Fig 55 Note When replacing the brake with brake lining all four wheel of the tandem box shall be adjusted Both brake shoes of one brake shall be adjusted together the adjustin...

Page 57: ...ance between both brake shoes and brake drum will be released to about 0 75mm 5 Adjust the other brake take notice that the rotating direction of adjusting bolt Fig 56 1 is reverse 8 6 2 Air release of hydraulic brake system Fig 50 Fig 51 Note After changing oil for hydraulic tank joints in pipeline become loosened or damaged the air in hydraulic system must be released While the engine is running...

Page 58: ...rest brake wheel cylinders as specified 8 6 3 Hand brake Fig 52 Note The hand brake is adjusted by pulling the handle upwards to the 4th socket of tooth the full braking force Fig 51 can be reached If the handle can be puller up with normal force over the 6th socket of tooth of the detent the hand brake must be readjusted a Adjust hand brake 1 Loosen the fastening nut Fig 52 1 for some turns 2 Rem...

Page 59: ...th cover plates of tandem box 2 Support the tandem box and make the wheel leave from ground 3 When the chains are tensioned they increase in elongation If the chain touches with tandem box the chains shall be retightened The chain can be tensioned by turning the eccentric bearing cover Only professional staff can tension the chain a Retighten the chain 1 Support the tandem box and make the wheel l...

Page 60: ...brake 10 Assemble wheels 11 Fill oil up for tandem box and reassemble cover plate 12 Adjust the brake system and drain air for system for use 8 8 Lubrication and adjustment of front wheel bearing Note The maintenance of the front wheel bearing must be carried out by professional staff Lubricating grease consumption Approx 280g Lubricating grease No 2 Extreme Pressure Lithium Lubricating Grease 1 J...

Page 61: ... socket head cap screw Fig 54 3 of 78Nm and hexagon bolt Fig 54 2 of 250Nm according to specified moment of force The hexagon socket head cap screw shall be screwed face to face crosswise orderly 11 The wheel hub Fig 54 1 shall be turned easily and without jounce When checking the wheel hub should not have a screw crosswise 8 9 Work device Blade Description If the action of the wheel blade is too ...

Page 62: ... the tightening bolt Fig 56 1 3 Disassemble the guide plate Fig 56 2 4 Install new guide plate and tighten with fastening bolt 8 9 3 Fasten the piston rob of the blade shift cylinder Fig 57 In our factory after the piston rob locks the grooved nut Fig 57 2 two taper washers Fig 57 3 can be turned manually Note When repairing or changing the cylinder fasten the piston rob in the same way Fig 57 1 8...

Page 63: ...orque of nut is 590Nm Fig 58 4 3 Conduct test the turning circle must be able to turn by 360º 8 10 Tyres Note On all 6 wheels the tyre with the same size shall be mounted 8 10 1 Tyre maintenance a Check the tyre for incised wound crack or sharp objects on the surface and immediately all foreign bodies b The tyre must be free from fuel oil oil and grease c The gas charging valve must be equipped wi...

Page 64: ...ed up hydraulically With this purpose the blade can be turned in such a manner that the blade tip is located in front of the tandem wheels which have to be lifted Then jack up the grader with the lift cylinder on the side where the wheel to be changed Use bulldozing plate and blade to bear against to support the front wheel The grader must be supported firmly before disassembling the wheels Unscre...

Page 65: ...lief valves in the entire hydraulic system are set to the correct operating pressure and these settings are sealed If find any faults the operating pressure would be readjusted by our service personnel If the seals are opened during the guarantee period in the event of damage resulted from excessive pressure settings the guarantee will be ineffective 8 14 Transmission shaft The transmission shaft ...

Page 66: ...erminals with acid free lubricating grease Battery shall be kept clean and dry 8 16 Notes to store the grader 8 16 1 Place the grader 1 If the grader is stored for long time clean and lubricate completely Grease is coated on finished surface and a thick layer of no acid grease Vaseline is coated on piston levers and packed by a paper bands as far as possible 2 It is best to put the grader in the c...

Page 67: ...nly undertaken by our Sales Service Dept or done in our factory to ensure the structure strength It is unallowed to weld on the bridge and strictly forbidden to connect the earth wire of the welding appliance to the bridge Fault symptom analysis of causes and trouble shooting Faults Possible causes Remedies 1 Problem in fuel system a Air in the fuel system b Fuel system blocked c No oil supply or ...

Page 68: ... oil supply of each cylinder a Uneven oil supply of each cylinder of oil injection pump b Poor injection of oil injector or coupling part clipped c Piston spring of oil injection pump broken Bleed air Check water content of fuel Check and repair Check and adjust the speed regulator Check cylinder bolts if necessary replace washer of cylinder cap and check height of top surface on bulgy body of the...

Page 69: ...te oil injection 3 Gas cylinder sends impact sound after starting the diesel engine because of too big clearance between piston and gas cylinder this sound is decreased with diesel engine running warm 4 Sound is low and sharp it is more obvious especially when idling as a result of too much clearance between piston pin and pinhole 5 Sound of collision of parts of machine can be heard when rotation...

Page 70: ...normal load is light grey and only changed to be deep grey even under temporary great load When the fume drained from the diesel engine is blue white or black it is regarded as abnormal Blue fume indicates burning of engine oil white fume indicates existence of water or failure of fine droplets of diesel to burn black fume indicates too 1 Emitting Blue fume a Too much engine oil piston ring instal...

Page 71: ...d repair Check and repair 1 8 Too high temperature of cooling water 1 Water temperature gauge or temperature sensing plug does not work 2 Deficiency in water 3 Blockage caused by too much incrustation in engine water passage Radiating fin of radiator or copper tube stained 4 Engine overloaded Check and replace Fill in cooling water bleed air adjust belt tension and check the water pump clearance C...

Page 72: ... and repair Replace parts 1 11 Fault in fuel injector 1 Decrease in oil injection or cannot inject oil a There existing air in oil circuit b Needle valve and valve body are snapped c Needle valve and valve body are matched too loosely d Oil supply system leaks oil seriously e Oil supply of injection pump is irregular 2 Low injection pressure a Adjusting screw is loose b Camber of spring 3 High inj...

Page 73: ...l c Plunger spring of oil pump and delivery valve spring are broken 2 Can not reach idle speed a Operating arm has not been put to bottom b Tooth ring and adjusting toothed bar have been clipped 3 Idle car a Camber of adjusting spring because of long use b Extending and retracting distances of flyball are inconsistent c Wearing clearance of floating lever 4 Propeller racing a Rotating speed is too...

Page 74: ...Poor contact of switch g Battery undercharged or the capacity too small h Clutch slipping 3 Difficulty in gear return Switch contact piece fused and firmly adhered Clean and tighten the contact point Charge or replace battery Clean the surface of commutator Repair Change the sleeve Clean the contact surface of commutator Remove oil stain and use crocus cloth to polish the surface Re weld Clean and...

Page 75: ... system Tighten joints or replace sealing piece 4 Hydraulic steering 4 1 Hydraulic steering gear or steering pump damaged Notify the Sales Service Dept of our company 4 2 Front wheel wobbled Steering cylinder or lever bearing worn Replace bearing or corresponding ball pivot 5 Working device 5 1Working device understeers or fails to remain in the selected position Too low oil level in oil tank Pist...

Page 76: ...ntroduction to PY180 series graders has been made here we will not describe The contents relating to the front axle drive unit are introduced in this chapter The front axle drive unit is mainly composed of hydraulic system of front axle drive and front driving axle 10 1 hydraulic system of front axle drive The drive unit of front axle adopts hydrostatic system as power source Please refer to schem...

Page 77: ... has three driving types as follows full axle drive only rear axle drive and only front axle drive The full axle drive means front and rear axles drive at the same time which can only be used to Gear 1 and 2 of forward gear 1 and neutral gear of reverse When the control lever of transmission is at the other gears even the switch for front axle drive is at open position the front axle drive will no...

Page 78: ...ure 制动压力 Brake pressure Fig 61 1 Indicator lamp of front axle drive 2 Switch of front axle drive 2 3 Switch of front axle drive 1 4 Switch of full axle drive Front axle drive After switching off Pressing No 2 switch of front axle drive and No 3 switch of front axle drive and when the transmission is at neutral gear the front axle drive will work the front axle is under driving state rear axle is u...

Page 79: ...l axle drive and when the transmission is on gear 1 and 2 of forward and gear 1 of reverse the front axle drive will work the front and rear axles are under driving state the indicator lamp of No 1 front axle drive lights Fig 62 Schematic diagram of front axle drive ...

Page 80: ...ior to using front axle drive the pressure value shall be within 2 5bars 10 5 Fault analysis and troubleshooting Please refer to Chapter 9 for fault analysis and troubleshooting Additionally when the front axle drive turns from driving state to free wheel state and long vibration and towing phenomenon happens to front wheel motor the pressure value at MC point of control valve shall be checked thi...

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