Installation and Maintenance Manual Foreword ---------------------------------------------------------------------------------------- 20-2 Safety Notes ------------------------------------------------------------------------------------ 20-4 Description of Hanging Up ------------------------------------------------------------------- 20-6 Tightening Torque ------------------------------------------------------------------------------ 20-8 Engine Specification and Maintenance ------------------------
Foreword Synopsis This manual is being as a assistant information for improving the maintenance quality for maintainer and help understanding this type of product and it also provides correct maintenance method and judgment criteria. The users should correctly understand each part of contents shown in this manual and finish maintenance by using of this manual. This manual mainly contains the necessary technical information during maintenance.
How to Read this Manual As a maintenance guide, each item indicated in this manual avoid as possible the repeated similar type of information. So it is need to retrieve simultaneous the information shown in other parts during maintenance period. Supplement and Renew You should contact with our subsidiaries for the supplements or other change to obtain the latest maintenance information.
Safety Notes Safety Hints Safety Caution Notes: Correct maintenance is the important factor of safe operation. We specially recommend our company’s maintenance technology in terms of high efficiency and safety, which detailed describe in this manual. It is need to use the special tools provided by our company during maintenance period. To avoid unnecessary injuries, ▲ symbols indicated in this manual mean the safety hints. All items indicated such symbols should be conducted carefully.
disassemble or assemble. 10. Remove the dirt or oil stains from the ascending and descending area on the stair or vehicle. Ascend and descend the vehicle by using of handrail, stair or steps. If there is no handrail, stair or steps to ascend and descend, please don’t jump onto or jump from the vehicle. Notes during operation 11. Please loose slowly them when disassemble cartridge cap, discharging oil plug or pressure testing screw plug to avoid the oil sprout out.
Description of Hanging Up Hanging Up The heavier components with more than 25 kg should be lifted with electric hoist or other lifting tools. Please check the contents below if the components can’t be removed from the vehicle. 1) Check if the connecting bolts have been dismantled completely. 2) Check if there are some other components or covers interfere with them, which affect the disassembly.
2) The rope should be in the middle of the hook. The rope in the edge of hook is very dangerous, which can cause the rope to slide and result in the accident when lifting. The lifting strength is maximum when the rope in the middle of the hook. 3) Hanging up the heavy with single rope is prohibited. Use two or more ropes wound on the heavy symmetrically when hanging up.
Tightening Torque Tightening torque of horn type connecting nut (Use the torque wrench) Screw Diameter Subtense Width Tightening Torque mm mm Nm kgm 14 18 22 24 30 33 36 42 19 24 27 32 36 41 46 55 24. 5±4.9 49±19.6 78.5±19.6 137.3±29.4 176.5±29.4 196.1±49 245.2±49 294.2±49 2.5±0.
Engine Specification and Maintenance Major parameters ----------------------------------------------------------------------------Change of Engine Oil and Engine Oil Cartridge ----------------------------------------Change of Fuel Cartridge -------------------------------------------------------------------Exhaust of Fuel System ---------------------------------------------------------------------Maintenance of Air Filter Element---------------------------------------------------------Lubricant and Recommen
Major Parameters MAJOR PARAMETERS Contents HG190 model Engine Cummins 6CTA8.3-C190 Rated power 142kW (190 hp) Max torque 860Nm/1,400rpm Transmission Power Train Power shift (ZF Technology), 6 Forward / 3Reverse Gears Max speed 49.2/30.0 km/h Service brake Foot operated, hydraulically actuated on four tandem wheels Parking brake flexible shaft control actuated inner-expanding drum brake Pump flow Hydraulic 99 L/min Max system pressure 17.
Change of Engine Oil and Engine Oil Cartridge ★ ★ The engine oil will become dirt and the engine oil additive will reduce after the engine is used. The content of pollutant is in direct proportion to the total loss of fuel and engine oil. The period of changing the engine oil, in any case, should not exceed 8000 km, 250 hours or above three months for the engine under normal operation. Change the engine oil and engine oil cartridge to remove the impurities suspended inside the engine oil.
★ When mount the engine oil cartridge, after the sealing ring has contacted, then tight 3/4～1 circle. Over tight the cartridge will cause the screw to distort or damage the sealing ring of cartridge. Check and clean the discharging oil screw plug and sealing surface, and install the discharging oil screw plug. Fill the clean engine oil into the engine until reach proper height of oil level. The capacity of the entire lubricating system, including the cartridge, is 27 L.
After stop the machine, flow the engine oil into the oil stray from the top components about in 5 minutes, and then check the height of oil level. If necessary, refill the engine oil to the level where the “H” mark of dipstick is shown. Change of Fuel Cartridge Clean the around head of the fuel cartridge. Dismantle the cartridge. Clean the surface of washer on he head of cartridge. Change the O sealing ring.
Exhaust of Fuel System Loose the exhaust screws Press the plug of oil transit pump until the oil flowing from the connecting area has no air. Loose the connecting nut on the oil sprayer and drive the diesel by using of starting motor to exhaust the air inside the high-pressure oil pipes and tight the connecting nut. Start the diesel. Exhaust the air inside high-pressure oil pipe for one time until the diesel runs smoothly.
Maintenance of Air Filter Element ★ The diesel used for engineering machinery always working in the badly condition that the dust content in the air is very high. So it is require high filtering efficiency of air filter elements and high sealing of the air inlet system.
The disassembly of cyclone paper air filter 1) Loose the clamp (7) and remove the coarse filter (4). Loose the clamp (8) and remove the cover and butterfly nut (9) and remove the paper main filter element (2) and safety filter element (1). 2) Conduct the maintenance as the method abovementioned. 3) The assembly of air filter is conducted as per the reverse sequence. ★ Avoid damaging the filter element when dismantle the filter element.
Lubricant and Recommended Specification of Fuel Lubricant for diesel It is better to use the CD Class 15W/40 diesel oil produced by China Petrochemical General Company or use the APICC/CD Class 15W-40 thickened engine oil of America Petroleum Association. The sulphate content in the oil should not exceed 1.85%. Attention: When the ambient temperature is keeping below -5℃, use the light weight CD Class 5W-30 engine oil will facilitate the start.
The commissioning of the tension of pulley of belt of fan Check the tension of belt of fan Apply force of 6 kg into the middle area between the pulley wheel of fan and pulley wheel of alternator to check tension. Measuring Process 1. Apply force of 6 kg into the middle point between the alternator and pulley wheel of fan, press the V type belt and measure the deflection dimension of V type belt with ruler. Adjustment Process 1. Loose the bolt (1) of alternator and bolt (2) of the adjusting plate. 2.
Transmission System 1.
General Description 1. Engine 4. Rear Transmission Shaft 2. Connecting Plate 5. Rear Transaxle The power of engine (1) transmits to torque converter and power gearshift gearbox inside the hydrodynamic transmission (3) through the connecting plate (2). It will realize the speed at each shift of FORWARD/REVERSE through the selection of clutch to adapt the exterior load. 20-20 3. Torque Converter 6.
Transmission System 1.Engine 2. Connecting Plate The power of engine (1) was transmitted to torque converter via the flywheel, connecting plate (2) of flywheel and elastic connecting plate. The torque converter takes the oil as medium. The torque converter will convert the transmitted torque based on the variation of load, and then the torque was transmitted to the driving gear of gearbox.
Pipeline of Hydrodynamic Transmission Transmission pump (inside the transmission gear) sucks the oil from the transmission gear (1) via the filter. The oil from transmission pump was transmitted to control valve of transmission gear via transmission oil filter (6). Then the oil was cooled by the radiator (4), and the cooled oil will cool and lubricate the transmission gear. 20-22 1. 2. 3. 4. 5. 6. 7.
Hydraulic Oil Pipe Diagram of Gearbox (The engine is under flameout status) 20-23
Hydraulic Diagram of Gearbox 1. Gearbox 10. Main Control Pressure Valve 19. Shift Valve 2. Coarse Filter 11. Reset Valve 20. Shift Valve 3. Transmission Pump 12. Regulator Valve 21. KV Clutch 4. Oil Filter 13. Solenoid Valve (M3) 22. KR Clutch 5. 14. Solenoid Valve (M1) 23. K4 Clutch 15. Solenoid Valve (M4) 24. K3 Clutch 16. Solenoid Valve (M2) 25. K2 Clutch 17. Shift Valve 26. K1 Clutch 18. Shift Valve 27. One Way Valve Lubrication Device of Gearbox 6. Oil Cooler 7.
Torque Converter 1. Pump Casing 4. Pump Wheel 7. Transmission Oil Pump 2. Turbine 5. Driving Gear 8. Turbine Shaft 20-25 3. Guide Wheel 6. Pump Wheel Axle 9.
Power Channel The torque converter is mounted between the engine and gearbox. The power from engine was transmitted to pump casing (1) via flywheel, connecting plate of flywheel and elastic connecting plate. The pump casing (1) and pump wheel (4) are connected and fixed by using of bolt and the pump casing (1) and pump wheel axle are connected by spine, which will rotate depend directly on the running of engine.
Gearbox 1. 2. 3. 4. SG6 Shift Selector Shift Solenoid Cable Gearbox Output Cable of Power Supply General Description The gearbox is mounted in the back of torque converter. The power from converter enters into the gearbox through the driving gear of gearbox. 20-27 The gearbox use the combination of clutches of FORWARD/REVERSE and four speed clutches to shift of forward one～six shift or reverse one～three shift and transmit the power to the output shaft.
1. Converter 4. Reverse Clutch Gear 7. Output Gear 10. 3rd Clutch Gear 13. Reverse Clutch (KR) 2. Driving Gear 5. 4th Clutch Gear 8. 1st Clutch (K1) 11. 2nd Clutch (K2) 14. Forward Clutch (KV) 20-28 3. Forward Clutch Gear 6. 4th Clutch (K4) 9. 2nd Clutch Gear 12.
Clutch 1. Lubricant Channel 4. Drum Wheel (Clutch Case) 7. Gear 10. Piston 13. Washer 2. Gear 5. Reset Spring 8. Auxiliary Shaft 11. Clutch Cylinder Block 14. Lubricant Opening 20-29 3. Discharging Oil Steel Ball 6. Bearing Plate 9. Friction disc 12.
The Operation of Clutch When engaged: The oil flows into the clutch cylinder block from the control valve of gearbox via the oil hole inside the shaft to push the piston (10). The main and auxiliary friction disc are engaged when pushing the piston, which make the clutch case (4) and clutch gear to form one integer to transmit the power. When disengaged: The oil pressure applied into the piston (10) is reduced when the control valve of gearbox cut the oil supplied to the clutch.
Forward 1st Shift Input Output Operation When conduct the operation of forwarding 1st shift, KV and K1 clutches are engaged. The power transmitted from torque converter to driving gear was transmitted to the output shaft. The main and auxiliary friction discs inside the KV shift and K1 shift clutches are compacted by the oil pressure applied into their cylinder block via the piston.
Forward No.2 Shift Input Out put Out put Operation When conduct the operation of forwarding No.2 shift, K4 and K1 clutches are engaged. The power transmitted from torque converter to driving gear was transmitted to the output shaft. The main and auxiliary friction discs inside the K4 shift and K1 shift clutches are compacted by the oil pressure applied into their cylinder block via the piston.
Forward No.3 Shift Input Output Output Operation When conduct the operation of forwarding No.3 shift, KV and K2 clutches are engaged. The power transmitted from torque converter to driving gear is transmitted to the output shaft. The main and auxiliary friction discs inside the KV shift and K2 shift clutches are compacted by the oil pressure applied into their cylinder block via the piston.
Forward No.4 Shift Input Output Output Operation When conduct the operation of forwarding No.4 shift, K4 and K2 clutches are engaged. The power transmitted from torque converter to driving gear is transmitted to the output shaft. The main and auxiliary friction discs inside the K4 shift and K2 shift clutches are compacted by the oil pressure applied into their cylinder block via the piston.
Forward No.5 Shift Input Output Output Operation When conduct the operation of forwarding No.5 shift, KV and K3 clutches are engaged. The power transmitted from torque converter to driving gear was transmitted to the output shaft. The main and auxiliary friction discs inside the KV shift and K3 shift clutches are compacted by the oil pressure applied into their cylinder block via the piston.
Forward No.6 Shift Input Output Operation When conduct the operation of forwarding No.6 shift, K4 and K3 clutches are engaged. The power transmitted from torque converter to driving gear was transmitted to the output shaft. The main and auxiliary friction discs inside the K4 shift and K3 shift clutches are compacted by the oil pressure applied into their cylinder block via the piston.
Reverse No.1 Shift Input Output Output Operation When conduct the operation of reversing No.1 shift, KR and K1 clutches are engaged. The power transmitted from torque converter to driving gear is transmitted to the output shaft. The main and auxiliary friction discs inside the KR shift and K1 shift clutches are compacted by the oil pressure applied into their cylinder block via the piston.
Reverse No.2 Shift Input Output Operation When conduct the operation of reversing No.2 shift, KR and K2 clutches are engaged. The power transmitted from torque converter to driving gear is transmitted to the output shaft. The main and auxiliary friction discs inside the KR shift and K2 clutches are compacted by the oil pressure applied into their cylinder block via the piston.
Reverse No.3 Shift Input Output Operation When conduct the operation of reversing No.3 shift, KR and K3 clutches are engaged. The power transmitted from torque converter to driving gear is transmitted to the output shaft. The main and auxiliary friction discs inside the KR and K3 clutches are compacted by the oil pressure applied into their cylinder block via the piston.
Control Valve of Gearbox 1. Control Valve of Gearbox 15. To Connection of Oil Radiator 2. Gearbox 16. From To Connection of Oil Radiator 53. Pressure Test Port of Forward Clutch (KV) 55. Pressure Test Port of Reverse Clutch (KR) 56. Pressure Test Port of 1st Clutch (K1) 57. Pressure Test Port of 2nd Clutch (K2) 58. Pressure Test Port of 3rd Clutch (K3) 60. Pressure Test Port of 4th Clutch (K4) 63. Temperature Port of Torque Converter Outlet 65.
1. Solenoid Valve (M1) 2. Solenoid Valve (M2) 3. Solenoid Valve (M3) 4. Solenoid Valve (M4) 5. Shift Valve 6. Regulator Valve 7. Main Pressure Control Valve 8. Accumulator 20-41 9. Quick Return Valve 10. Shift Valve 11. Shift Valve 12.
Gearbox Solenoid Valve Function When operate the transmission manipulator handle to conduct forward and reverse each shift, the electric signal is sent to the four solenoid valves mounted on the gearbox control valve to control the slid valve of each shift according to the open and close solenoid From combination. Oil pump Operation 1.
Main Pressure Control Valve Function The main pressure control valve regulates the oil pressure flowed to the clutch loop and solenoid valve loop and distributes the oil flow between the clutch loop and torque converter. Operation 1. The oil comes from the oil pump enters into the main pressure control valve, the oil will pass through the port A and port B and flow to the shift valve when the oil pressure is lower than the specified pressure of main pressure control valve (1). 2.
Quick Return Valve and Regulator Valve General: The purpose of quick return valve is to make the regulator valve smoothly increase the pressure of clutch. Quickly reset to transmit the pressure inside the accumulator to apply into the pressure regulator valve. When the gearbox switches the shift, the loop will be drained instantaneously. The regulator valve is mainly composed of pressure regulator valve and accumulator. When shift operation changes the speed, the clutch is compacted by the piston.
Rear Transaxle Anti-slid Differential 1. Transaxle Housing 2. Cover 3. Main Screw Bevel Gear 4. Joint 5. Bolt 6. Washer 7. Chain Wheel 8. Anti-slid Device 9. Shim 10. Shim 11. Large Bevel Gear 12. Oil Pipe 13. Vent Valve 14. Oil Level Plug 15. Drain Plug 16. Swing Frame 17.Bearing 18.Bearing 19.Flange 20.Transaxle Case 21.
The power passes through engine → Joint → gearbox, then passes through the main screw bevel gear (3) and large bevel gear at proper angle, then transmit to drive differential case (19) and (20). When the differential case (19), (20) was driven, the cross (8) is moved and drive halfshaft (13) and (12). Use the bolt (5) to adjust the preload of main screw bevel gear (3).
Working Principle of Differential Device 1. Straightly Drive: The left and right driven clutches (6) and (7) engage with cross (5) and middle engaging wheel (16). The power is transmitted to cross through main screw bevel gear and transmitted to left and right wheels through the side wheel to keep the same speed of left and right wheels.
Balanced Housing 1. 2. 3. 4. 5. 6. 7. 8. Bearing 9. Balance Housing 10. Cover 11. Refill Port 12. Cover 13. Drain Plug 14.
Transmission System 2.
Rear Transaxle Serial No. 1 2 3 Inspection Items Requirements Action Preload of main screw Starting torque: 8.8～11.8 Nꞏm bevel gear bearing Turn the main screw bevel gear and Preload of large screw matching gear, adjust bearing, bevel gear bearing measuring the starting torque 9.6～ Adjustment 13.4 Nꞏm Tooth clearance between Tolerance Repair Limit the large screw bevel gear 0.25～0.33 1.
Balanced Housing Serial No. Inspection Items 1 Preload bearing of 2 The extension chains (10 knots) Requirements hub of Action Rotation torque: 11.5～16.5 Nꞏm Standard Dimension Repair Limit 317.5 322.
Steering System 1.
Steering Pipeline The grader adopts the hydraulic control 1. Steering Wheel steering system. The pressure oil is enters 2. Steering Gear into cylinder (3) through the steering gear (2) 3. Steering Cylinder when the steering wheel turning and the working hydraulic oil is also used to steering system.
Steering Principle Diagram 1. Hydraulic Oil Tank 2. Hydraulic Steering Pump 3. Hydraulic Oil Filter 4. Main Force Loader 5. Steering Gear 6. Steering Cylinder 7. Dividing Valve A. To Hydraulic Oil Loop B.
Steering Gear 1. Rotor Assembly 2. Interactive Shaft 3. Valve Cartridge 4. Valve Sleeve 5. Pawl Pin 6. Spring Lamination 20-55 7. Roller Bearing 8. Check Valve 9.
Operation When doesn’t turn the steering wheel: When the steering wheel doesn’t turn, the spring lamination makes the valve cartridge and valve sleeve stop at the central position 2. slot hole 3.core of slot of valve cartridge that its pawl pin was fixed. In such case, the oil ports that 4. front inlet of steering cylinder connecting valve sleeve with steering 6. core 5.
When the steering wheel turning (turn left) When the steering wheel turns left, the turning bring the match of spline, cause the steering shaft also turns left. Because the valve sleeve is connected with valve cartridge by using of spring laminations, the valve cartridge compact the spring laminations, bring about the turning angle difference between the valve sleeve and valve cartridge, which make all holes in the valve sleeve are all connected with slots of valve cartridge.
Connect the manual pump oil port to valve sleeve oil port The connecting diagram of manual pump oil port (seven holes) to valve sleeve oil hole (12 holes) is illustrated. When the steering wheel turns right side, the oil holes a, c, e, g, i and k are connected with pump through the valve cartridge slot. In the same way, the oil holes b, d, f, h, j and l are connected with steering cylinder.
As abovementioned, the manual pump The other function of manual pump is oil ports that under oil output status are regulating the output oil during operation connect to the valve sleeve oil ports that period.
Front Axle Inward Incline: 5.0 ± 1.0 mm Outward Incline: 0° Main Pin Incline Angle: 0° 1. 2. 3. 4. 5. Steering Cylinder Link Rod Front Axle Incline Cylinder Incline Rod 20-60 6. Support 7. Central Vertical Shaft 8. Hub Nut 9. Hub Axle 10.
Function of Front Axle 1. Steering Please see “Steering System”. 2. Reduce the angle of scraper blade and the variation of ascend and descend displacement The front axle is installed in the center of frame, so it can swing 16 degrees. As the swing of balanced housing, when front wheel gets across one object or falls into one pit, the front axle can limit the ascend and descend displacement variation of scraper blade to minimum. Please see the figure.
The calibration of front wheel The two front wheels make the vehicle to turn. Use the special method to assemble the wheel to make the steering easy, stable and accurate. Such special assemble is called as calibration, which has great influence on the operation of steering wheel. 1. Outward Incline When assemble front wheel, the distance between the tops of the two wheels is far than the distance between the bottoms of the two wheels. Such incline is called as outward incline. 2.
Steering Cylinder 1. Sleeve 7. Nut 13. O Ring 2. Retainer Ring 8. Bearing Ring 14. Bearing Ring 3. Cylinder Head 9. Piston Sealing Ring 15. Dustproof Seal 4. Cylinder Body 10. Oil Cup 16. Retainer Ring 5. Piston Rod 11. O Ring 17. Oil Cup 6. Piston 12.
Tire 1. 2. 3. 4. 5. 6. Tire Inner Tire Side Ring Lock Ring Air Inlet Spoke Tire Size Air Pressure 20-64 17.5-25-12PR L-3 3.
Structure 1. 2. 3. 4. 5. Engineering machinery use different types of tires, which extensively apply into various environments. So, unlike the car tire, the tires of engineering machinery are various. In the nowadays that the engineering machineries are extensively applied, the service life and cost of tire produced by engineering machinery tire manufacturer will relevant to the engineering efficiency factor.
1. Tread Traction and Adhesion Tire tread is the outer layer of tire, and its The adhesion will increase through the main purpose is to protect the interior wear reduction in the contact pressure of ground. and ablation to minimum. The contact area (1) Try to reduce air pressure between the tread and ground is rim, and such (2) Use the wider tire, if possible part is made of different types and slots to (3) If the load is given, try to increase the suit to the different environment the tire uses.
Dimensions of tire and spoke Tire’s Dimensions The dimensions of tire include the tire width (in inch), inner diameter (in inch), tire layers indicating with dimensions and the three values connecting together by using of “-” symbol. e.g. 13.00 – 24 – 12PR (Narrow Base Tire) Width Inner Diameter Layers 17.5 – 25 – 12PR (Normal Tire) Dimensions of Spokes The dimensions include the spoke diameter indicated in inch and spoke’s type and the spoke width indicated in inch. e.g. 8.
Steering System 2.
Standard Value Table for Judgment Item Condition Unit Standard Allowable Value Value Travel Steering angle of steering wheel Circle 5-5.8 Incline Rod mm 55-65 mm 65-75 Hinge Bar At end of travel Manipulation Force Steering Wheel Engine idle rotate with low speed Incline Rod Hinge Bar N Max. value before arriving the Max. 30 Max. 50 Max. 36 Max. 51 Max. 30 Max. 345 termination of travel Wheel Tire Radial Eccentricity mm Max. 7.0 Max. 7.0 Air Pressure MPa 0.30 0.30±0.
Testing Tools List Serial No. Test Items Tools Range 0-250 N 1 Steering Wheel Manipulation Force Pull-push Weight 2 Steering Wheel Manipulation Demonstration Disc Ruler 3 Tire Radial Eccentricity Measuring Gauge 4 Tire Expansion Pressure Tire Pressure Meter 5 Outward Incline Angle Outward Incline Angle Meter 2m 0.
Check Steering Wheel Special Tools Serial No. 1 2 Part Description Push-and-pull Balance Tape Quantity 1 1 Steering Wheel Neutral Travel When the travel of steering wheel is over the standard value, or steering wheel produces vibration, or the steering wheel bumps hands, please reassemble (replace) the steering gear assembly. Manipulation Force Use the push-and-pull balance A to measure the manipulation force of steering wheel.
Check Tire Radial Eccentricity Special Tool Standard Measuring Gauge Serial No. Part Description Quantity A Standard Measuring Gauge 1 Tire Air Pressure Meter 1 Inspection of Front Wheel 1) Start the engine and make the front wheel (1) off ground by using of the scraper blade as the jack. 2) Raise the rear wheel end of machine and put the lower part of the machine on a support. 3) Use the standard gauge A to measure the tire eccentricity through rotating tire by hand.
Check Inward Incline Angle Special Tool Serial No. Part Description Quantity 1 Round Tape 1 Inspection: 1. Make the steering rod and incline rod of front wheel lie in the middle position and stop the grader on the flat ground. ★ When parking the vehicle, drives the whole machine along the forward direction for sever meters and then stop it. 2. Measure with tape the height from the tire tread (ground) to the center of axle. 3.
Steering System 3.
Front Axle 20-75
Unit: mm No. Items to be inspected Clearance 1 between incline pin and incline rod sleeve 3 4 5 6 7 pin and sleeve between incline pin and sleeve Clearance between axle end pin and sleeve Clearance between ball joint and sleeve Clearance between support and sleeve Preload of hub bearing Tolerance Standard Value 50 Clearance between main Clearance Requirement 55 45 45 Standard Allowable Clearance Axle Hole Clearance -0.025 +0.142 0.125- -0.064 +0.080 0.206 -0.030 +0.174 0.
Steering Cylinder No. Items to be inspected Requirement Tolerance Standard 1 Clearance between piston Clearance 2 Value 35 between cylinder pin axle and 35 sleeve Clearance 3 between cylinder rod sleeve and installation pin 5 Tightening torque of torque of Clearance Axle Hole Clearance -0.080 +0.132 0.086- -0.142 +0.006 0.274 -0.025 0 0.013- -0.064 -0.012 0.064 -0.06 +0.02 0.06- -0.09 0 0.
Brake System 1.
Brake Pipeline 1. Brake Pedal 4. Parking Brake Rod 2. Brake Booster 5. Parking Brake 3.
Brake Circuit 1. Hydraulic Oil Tank 2. Hydraulic Pressure and Steering Pump 3. Hydraulic Oil Filter 4. Booster 5. Steering Control Valve 6. Steering Cylinder A. To hydraulic Circuit B.
Booster This booster is the hydraulic operation 1. Unloading Valve booster. Depress the brake pedal, the oil 2. Slid Valve comes from steering pump applies into 3. Boot booster piston (6) and the hydraulic force 4. Master Piston in the piston (7) will increase. 5. Shell 6. Booster Piston 7. Piston 8.
Release the Brake The slid valve (2) doesn’t act when the brake pedal isn’t depressed. The oil comes from oil pump enters into booster through steering circuit. The oil enters into booster via “a” point and flows into A chamber and is drained.
Brake Operation Depress the brake pedal, the slid valve Depress foot brake, the slid valve (2) (2) move to right and “a” is blocked and pushes booster piston (6) and “a” point is the pressure of B chamber is increased. closed. When the pressure of B chamber When the pressure of B chamber is increased to 20 kg/cm2, the overflow increases, the booster piston is moved to valve (1) is open and the oil is drained.
Wheel Cylinder Brake Drum Brake 1. Return Spring 5. Sleeve Pad 2. Fixed Pin 6. Regulator 3. Wheel Cylinder 7. Brake Drum 4.
Parking Brake 1. Connecting Rod 2. Anchor Plate 3. Brake Drum 4. Return Spring 5. Regulator 6. Operation Rod 7. Soft Axle 8. Connecting Rod 9. Brake Drum 10. Brake Hoof Parking brake is inner expansion type brake applies into the counter shaft of gearbox.
Brake System 2.
Standard Value Table for Judgment Item Condition Unit Standard Allowable Value Value 160±5 160±15 10±5 10±10 Pedal Brake (Foot Brake) Height Neutral Travel Travel Operation Force Brake Property Engine’s Rotation Speed: Stop mm Engine’s Rotation Speed: Low Speed mm 80±10 80±20 N Max. 450 Max. 650 m Max. 13 Max. 13 N Max. 300 Max.
Check Brake Pedal Special Tools Serial No. A B Part Number Common Use Tools Part Description Tape Vernier caliper 1. Height Adjustment Measure with tape the distance from bottom plate to center of fixed bolt of pedal (1). Adjust the height from pedal brake bolt (20 to fixed pedal. 2. Adjustment of Neutral Travel Measure with tape A along the action direction of pedal. ★ The engine should be flameout when conducting the measurement. Adjust fork rod and connecting rod until the standard value is reached.
3. Travel ▲ Confirm the shift operation rod is in the middle position and pull parking brake operation rod up forwardly. Start engine, depress pedal (1), and measure with tape A the distance from center of installing bolt of pedal to the bottom frame plane. ★ Conduct the measurement when the engine is idle. ★ If the travel is over standard value when the pedal is depressed or the brake efficiency is bad, please refer to “Brake Drum Adjustment”.
4. Operation Force Special Tool Serial No. Part Description Quantity 1 Tape 1 Depress the pressure meter with foot to measure its maximum operation force. ★ Conduct measurement when the engine is under idle speed. Exhaust of Brake Pipeline ★ The exhaust operation should be conducted by two persons, one refills the brake fluid and the other exhausts air. ★ Prepare some extra brake fluid to prevent the brake fluid from using out during operation. ▲ The engine should be stopped when exhaust the air.
Check Parking Brake Operation Rod Special Tools Serial No. Part Number A Common Use Tools B Part Description Tape Pressure Meter Travel Inspection Measure with tape the travel distance from top to bottom of parking operation rod. Travel Adjustment ▲ The engine should be stopped when conduct adjustment. 1.
Brake System 3.
Wheel Rim Brake Drum Brake Unit: mm Serial Items to be No. inspected 1 2 Wear of Lining Inner surface wear of brake drum Judgment Action Clearance between the rivet head and lining surface: Max. 0.5 Standard Dimension Repairing Limit 438.2 441.2 Change lining Replace the brake drum Over tolerance of 3 roughness of inner surface of brake Repairing limit: 0.
Booster No. Items to be inspected Judgment Tolerance Standard 1 2 Clearance between booster casing and piston Clearance between piston and cylinder Dimension 76.2 38.1 Clearance Limit Hole Clearance -0.2 +0.074 0.200- -0.25 0 0.324 -0.050 +0.068 0.050- 0.089 0 0.151 0.35 0.20 Repairing Limit Free Installed Installed Free Installed Length Length Load Length Load 123 73 40 kg - 33 kg 4 Selector Spring 41 36 11.8 kg - 9 kg 5 Overflow Spring 48.5 42.5 11.
Hydraulic System 1.
Hydraulic Pipeline The hydraulic control part of operation work 1. Left Control Valve (4 ways) equipment is composed of hydraulic oil tank 2. Right Control Valve (4 ways) (3), oil pump (4), distributing valve (5) and 3. Hydraulic Oil Tank high-pressure pipeline. The control valve, oil 4. Hydraulic Oil Pump cylinder and hydraulic motor are connected 5. Distributing Valve together with high-pressure pipeline.
Scraper Blade Lifting Control Pipeline 1. Left Control Valve (4 ways) 2. Right Control Valve (4 ways) 3. Left Hydraulic Control Check Valve (For Lifting) 4. Right Hydraulic Control Check Valve (For Lifting) 5.
Scraper Blade Side Moving Control Pipeline 1. Left Control Valve (4 ways) 2. Rotary Joint 3.
Traction Frame Side Swing Control Pipeline 1. Right Control Valve (4 ways) 2. Traction Frame Side Swing Cylinder 3.
Front Wheel Incline Control Pipeline 1. Right Control Valve (4 ways) 2. Hydraulic-control Check Valve (For Front Wheel Incline) 3.
Hinge Control Pipeline 1. Rear Frame 2. Right Control Valve (4 Ways) 3. Hydraulic-control Check Valve 4. Hinge Cylinder Turning Control Pipeline 1. Right Control Valve (4 Ways) 2.
Power Incline Control Pipeline 1. Left Control Valve (4 Ways) 2. Hydraulic-control Check Valve (For Power Incline) 3. Rotary Joint 4. Power Incline Cylinder Front Scarifier Control Pipeline (Optional) 1. Right Control Valve 2. Hydraulic-control Check Valve (For Front Scarifier) 3.
Rear Ripper Control Pipeline (Optional) 1. Left Control Valve 2. Rear Ripper Cylinder 3.
Hydraulic Operation The angular regulating handle in the control board can adjust the angle between control board and baseboard, and the control board can be leaned towards the seat except for in vertical position. So, the operator will obtain comfortable operation under stand and seating status. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
20-105
Oil Pump Theoretic Exhaust Volume: 25 ml/r 45 ml/r Maximum Pressure: 20 MPa 17.5 MPa 1. Retainer Ring 2. Oil Seal 3. Flange for Installation 4. Driven Gear 5. Pump Body 6. Middle Connecting Plate 7. Pump Body 8. Cover 9. Washer 10. Sleeve 11. Sealing Parts 12. Connector 13.
Turning Motor 1. Bottom Cover 2. Stator Bushing 3. Drive Shaft 4. Valve Plate 5. Check Valve 6. Output Shaft 7. Flange 8. Stator 9. Screw Rod 10.
Control Valve Left Control Valve 1. Turning Control Valve 2. Power Incline Control Valve 3. Scraper Blade Side Moving Control Valve 4. Scraper Blade Lifting (Left) Control Valve 5. Rear Ripper Control Valve (Optional) 6. Overflow Valve A. Oil Inlet B.
Right Control Valve 1. Scarifier Control Valve (Optional) 2. Scraper Blade Lifting (Right) Control Valve 3. Front Incline Control Valve 4. Traction Frame Side Swing Control Valve 5. Hinge Control Valve 6. Overflow Valve A. Oil Inlet B.
Distributing Valve 1. Valve Body 2. Screw Plug 3. O Ring 4. Valve Sleeve 5. Spring Oil enters A chamber from oil pump and is distributed at constant speed. One strand of oil flows to B1 chamber and C1 chamber; another strand of oil flows to B2 chamber and C2 chamber and these oil will flow to master control valve, respectively.
Hydraulic-control Check Valve (For left and right lifting, hinge, front wheel incline and traction frame side swing) 1. Check Valve 2. Piston 3. Valve Body 4. Screw Plug 5. Screw Plug 6. Check Valve Operation When operate the control valve, oil enters A1 chamber from oil pump and check valve (6) is opened and oil flows to B1 chamber. When the pressure is produced, oil pushes piston (2) from throttle E and opens the check valve (1).
Hydraulic-control Check Valve (with safety valve) (For front scarifier (optional)) 1. 2. 3. 4. 5. The hydraulic-control check valve with safety valve is mainly prevent the pressure variation of hydraulic cylinder and protect hydraulic cylinder from occurring abnormal pressure due to the foreign force. When the scraper plate is lifted to max. position, the traction frame is moved to end.
Hydraulic-control Check Valve (For power incline, rear ripper (optional), front scraper blade (optional)) 1. 2. 3. 4. 5. The hydraulic-control check valve with safety valve is mainly prevent the pressure variation of hydraulic cylinder and protect hydraulic cylinder from occurring abnormal pressure due to the foreign force.
Rear Ripper Oil Cylinder (Optional) 1. Cylinder Head 2. Cylinder Body 3. Piston 4. Bearing Ring 5. Locking Nut 6. Piston Ring 7. Sealing Ring 8. Bearing Ring 9. Dustproof Ring 10.
Hydraulic System 2.
▲ Exhaust the air in the hydraulic circuit When replace the hydraulic pump or replace the hard pipe and hose near the pump, or replace the hard pipe and hose of the working system or steering system, exhaust the air in the working system and steering system according to the following methods: (1) Open the cap of oil refill hole on the hydraulic oil tank; (2) Start the engine; (3) Make the engine running under idle speed, and extend and retract all cylinders of working system and steering system starting f
Troubleshooting (Turning Motor) Fault Motor doesn’t run The rotation speed of motor is different with the setting value Cause 1. Dust or the oil is too dirty, radial load of shaft and shaft sleeve is too large and motor is clogged. 2. No pressure. Troubleshooting 1. Turn the motor and test the oil pressure. 3. Motor internal leak. 1. The oil of motor is not enough. 3. Exchange the motor 1.
Hydraulic System 3.
Hydraulic Oil Cylinder Items to be inspected Judgment Standard Dimension Scraper blade lifting Scraper blade side moving Traction frame side swing 50 45 Front wheel incline 35 Hinge turning 45 Power incline turning 40 Scarifier (optional) 50 Rear (optional) 50 ripper Scraper blade lifting Clearance between piston rod support and sleeve 2 50 Scraper blade side moving Traction frame side swing Standard Clearance -0.080 -0.142 +0.164 +0.007 0.087～ 0.036 -0.080 -0.142 -0.080 -0.142 -0.
Items to be inspected No. Judgment Tolerance Standard Dimension Scraper blade lifting Scraper blade side moving Traction frame side swing 45 40 40 Hinge 45 Power incline turning 40 Scarifier (optional) 50 Rear ripper (optional) 75 Clearance Hole Clearance -0.080 +0.062 0.087～ -0.142 0 0.204 -0.025 +0.142 0.105～ -0.064 +0.080 0.206 - - - -0.025 +0.142 0.105～ -0.064 +0.080 0.206 -0.025 +0.142 0.105～ -0.064 +0.080 0.206 -0.025 0 0.013～ -0.064 -0.012 0.064 -0.
Work Equipments 1.
Traction Frame and Lifter Traction frame is important equipment for supporting turning gear ring and scraper blade. When the ball joint (8) is worn, the shim (9) is used to adjust the clearance at connecting area to ensure the clearance is not too much. When rotate the guide frames (11) and (14) and make them contact with turning gear ring at (a) and (b) points. The shim (12) and (13) as well as adjusting bolt are used to adjust the clearance of connecting elements. 1. Traction Frame 2.
The oil cylinder is mounted on lifter to move the scraper blade device. Connecting frames (5) and (7) are mounted guide plate that is welding on front frame. The connecting frame can be turned when remove the control pin at the left side of instrument column. There are 3 holes that pins can insert into to prevent turning. Holes (d) and (c) are used to scrape the gradient to left or to right for scraper. Hole (e) is used more frequent than other holes.
Lifter Connecting Frame Control The connecting frame of lifter is fixed on the 1. Pin guide plate on the support of front frame lifter 2. Soft Shaft through pin. When conduct scraping gradient 3. Pedal operation, depress the pedal (3) and remove pin and turn the connecting frame of lifter.
Scraper Blade The adjusting frame (6) is used to adjust the cutting angle of scraper blade. When the scraper blade is move to edge, the sliding frame is corresponds with the sleeve of sliding elements. When the clearance between the sliding frame and sliding elements is too much and the operation accuracy cannot be obtained, change the sliding frame.
Turning Gear The turning gear is driven by motor through 1. Connector 2. Pinion the splineway on the worm shaft (7). 3. Shaft The connector (1) and gear (2) is connected 4. Housing through the safety pin (9). If abnormal torque 5. Worm Wheel is transmitted from the scraper blade, the 6. Screw Plug 7. Worm safety pin (9) will be sheared to prevent the 8. Drain Plug scraper blade system from cracking due to 9. Safety Pin overload. 10. Bearing 11.
Frame The front frame can turn 26° to left or to right 1. Frame (the turning limit block is located on left and 2. Press Cover right sides of frame) through the hinge oil cylinder. When conduct moving operation, leaving the mud operation or operate on the corner, the hinge structure is benefit to reduce the turning radius. In additionally, the operation view is good due to the front frame is an integer.
Front Scarifier (Optional) When remove the bolt (5) between holes (a) 1. Scarifier Oil Cylinder and (b) on the support (8), the cutting angle 2. Arm of teeth, lifting height and cutting depth of 3. Scarifier Oil Cylinder Arm scarifier can be changed. 4. Rod 5. Bolt 6. Tooth 7. Wedge Block 8.
Rear Ripper (Optional) The lifting height and digging depth of ripper are adjusted through the hydraulic oil cylinder (1). The tooth tip cuts into the ground by using of the load produced by the self-weight of ripper, so the rear ripper can conduct difficult digging operations that common ripper cannot operate. Two kinds of teeth tips are used respectively to: short teeth suits to heavy load digging and long teeth suits to common operation. 1. 2. 3. 4. 5. 6.
Work Equipments 2.
Judgment Standard Table Items Operation Rod Moving Scraper blade right lifting Scraper blade left lifting Scraper blade side moving Traction frame side moving Turning Power Incline Front scraper blade Rear ripper Operation Force Scraper blade left & right lifting Scraper blade side moving Traction frame side moving Turning Power Incline Front scraper blade Rear ripper Operation Speed 1. Scraper blade lifting speed (Ascending) (Descending) 3.
6. Rear ripper lifting speed (Ascending) (Descending) Hydraulic Sedimentation 1. Scraper blade oil cylinder extend 3. Rear ripper oil cylinder extend 4. Rear ripper oil cylinder retract Setting pressure of master overflow valve Right valve Left valve 20-132 mm/10 min. 2. Scraper blade oil cylinder retract 220 170 198 153 200 150 180 135 Max. 10 Max. 20 Max. 20 Max. 40 Max. 10 Max. 20 Max. 30 Max. 50 mm/sec 7.
Adjustment Tools List Serial No. Test Items Tools Range 1 Hydraulic pressure Pressure meter 0-40 MPa 2 Oil temperature Thermosensor -50℃-120℃ 3 Engine’s speed Tachometer Digital Readout 4 Operation Push-and-pull 0-250 N balance 0-500 N Tape 2m force of work equipment operation rod 5 Test travel ▲ When finish test, adjustment or maintenance, stop the machine on the flat ground, set the safety lock on the frame, and put the scraper blade on the ground and then flameout the engine.
Check Operation Rod Special Tools Serial No. A B Description Tape Push-and-pull Balance Quantity 1 1 Travel Use the steel tape to measure the operation length at the center of handle of rod (1). Conduct the measurement when the ★ engine is stop. ★ The travel of work equipment operation rod is determined by the travel of slid valve of control valve, however, the centering position of handle is adjusted by individual rod.
Check Hydraulic Oil Temperature Special Tools Serial No. A Description Thermosensor Quantity 1 1. Remove the cap of hydraulic oil tank and remove filter. Please slowly loose when remove the cap to release the pressure in the hydraulic oil tank. 2. Insert the thermosensor into oil hole and measure the oil temperature with main body of thermosensor A. Check Hydraulic Oil Pressure Serial Description Quantity No.
Adjust the hydraulic oil pressure ★ Adjust according to the steps below if the hydraulic oil pressure can’t reach to standard value (20 MPa) 1. Remove cover (3), loose nut (4), and turn adjusting screw (5) to adjust the pressure of interior spring (6). ★ Clockwise turn for increasing oil pressure. ★ Counterclockwise turn for decreasing oil pressure. 2. After finish the adjustment, repeat commissioning and check if it has reached the standard value.
Hydraulic Sedimentation Special Tool Serial No. A Description Tape Quantity 1 1. Scraper blade oil cylinder extends 1) Start engine after test the pressure and increase the hydraulic oil temperature to such range of 40±5℃. 2) Put the bottom edge of scraper blade on the ground and push oil cylinder to leave the front wheel from the ground for 300 mm. 3) Stop engine for 10 minutes and use the disc tape to measure shrink value of oil cylinder and piston rod. 2.
Work Equipments 3.
Traction Frame and Lifter Unit: mm No. Items to be inspected Judgment hinge joint Clearance between gear ring and traction frame Dimension 120 Clearance Limit Axle Hole Clearance -0.120 +0.180 0.120 -0.297 0 0.447 Standard Clearance Clearance Limit 1.5 1.0-2.
Unit: mm No. Items to be inspected Judgment Tolerance Standard 4 between support and sleeve 75 Wear of Lifter Axial Clearance of Clearance -0.030 +0.22 0.190 -0.076 +0.16 0.296 0.6 side Clearance Limit 0.8-1.3 2.0 Tolerance Standard Dimension incline cylinder bottom side support and sleeve Change 45 Standard Axle Hole Clearance -0.080 +0.062 0.080- -0.142 0 0.204 20-140 Clearanc e Limit 0.
Scraper Blade Unit: mm 1 Clearance between scraper side moving cylinder shaft and regulator Judgment Standard Dimension 120 Tolerance Axle Hole -0.025 -0.064 +0.142 +0.080 Standard Clearanc e 0.1050.206 Wear of cutting edge 3 Wear of side blade 4 Wear of Guide Repairing Limit: Height: 364 Thickness: 21 5 Wear of Guide Block of Scraper Blade Repairing Limit: Height: 14 Thickness: 33 1.
Turning Gear Unit: mm No. Items to be inspected Judgment Tolerance Standard 1 3 shaft and sleeve 4 65 Clearance between worm shaft and sleeve Clearance between pinion and shearing pin Clearance -0.030 +0.057 0.0440- -0.076 +0.010 0.117 +0.035 +0.226 0.034- +0.035 +0.069 0.221 0 +0.080 0- -0.021 0 0.101 connector and shearing Gear clearance between worm and turbine Clearance between pinion and friction plate Pinion’s wear 30 0 +0.080 0- -0.021 0 0.101 0.5 0.5 1.0 1.
Front Scarifier (Optional) Unit: mm No. Items to be inspected Judgment 1 Value and sleeve 110 Hole Clearance -0.036 +0.207 0.025- -0.090 +0.120 0.
Rear Ripper (Optional) Unit: mm No. Items to be inspected Judgment Tolerance Standard Clearance between pin and sleeve Value 50 Limit Hole Clearance -0.025 +0.039 0.025- -0.064 0 0.103 290 20-144 Repairing Limit 150 Replace Clearance 0.
Electrical Circuit Diagram(HG190) 20-145
