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Operation and Maintenance Manual for CLG418 Motor Grader 2008.10 000 Important Safety Notices Most accidents concernin

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Operation and Maintenance Manual for CLG418 Motor Grader

2008.10 000

Important Safety Notices Most accidents concerning the operation, maintenance and repair occur due to disregard of basic safety rules or protective measures. Accidents can be avoided if the potential dangers are noticed beforehand. Therefore, the personnel concerned should familiarize themselves with the potential dangers of accidents and obtain necessary training and skills in troubleshooting with tools. Improper operation, lubrication, maintenance and repair can cause danger and even death. No operation, lubrication, maintenance and repair can be done on this machine until the content of this manual concerning operation, lubrication, maintenance and repair are carefully read and fully understood. Both this manual and this machine contain the safety notices and warnings. Disregard of these warnings may lead to death. All the dangers are marked with the safety warning symbol

followed by such signal terms as

“Danger”, “Warning” and “Caution”. Danger: The term refers to imminent dangers that will cause serious injuries or even death if not avoided. Warning: The term refers to potential dangers that may cause serious injuries or even death if not avoided. Caution: The term refers to potential dangers that may cause minor or moderate injuries if not avoided. Of the safety warning signs, the “Warning” sign is shown as follows: Warning

This safety warning symbol means: Notice! Cautious! Your safety is involved! Under the warning board, texts or graphics are used to explain the content of the danger. For those operations that may cause damage to the machine, the “Caution” or “Warning” labels are attached to this machine and described in this manual. It is impossible for Liugong Machinery Co., Ltd. to expect each dangerous working environment. Therefore, warnings in this manual and on this machine cannot cover each and every aspect. While using a tool, a procedure, a working method or an operation technique other than those recommended by Liugong, make sure that the safety of yourself and others are guaranteed and the operation, lubrication, maintenance and repair procedures selected do not damage or endanger this machine or make it suffer unsafe conditions. The descriptions, numbers and illustrations in this manual are based on the latest information available at the time of publication. This manual may not reflect the changes in the details of this machine caused by its constant design improvement. For the latest information of this machine or the information related to this manual, please contact Liugong or its distributors.

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Operation and Maintenance Manual for CLG418 Motor Grader–Contents

2008.10 000

Contents PREFACE.........................................................................................................................................7 PRODUCTS INTRODUCTION.........................................................................................................8 SAFETY REGULATIONS..............................................................................................................10 SAFETY LABELS AND THEIR ADHERENT POSITIONS.........................................................................11 GENERAL SAFETY NOTICES...........................................................................................................17 PROTECTION AGAINST CRUSHING OR CUTTING..............................................................................21 BURN PROTECTION.......................................................................................................................22 FIRE AND EXPLOSION PROTECTION...............................................................................................23 FIRE EXTINGUISHER AND FIRST-AID KIT.........................................................................................24 TYRES..........................................................................................................................................24 PROTECTION AGAINST INJURY OF THUNDER...................................................................................25 NOTICES FOR ACCESSORIES.........................................................................................................25 OPERATION SAFETY NOTICES........................................................................................................26 Mounting On/Off the Machine.................................................................................................26 Check before Engine Start......................................................................................................26 Engine Start.............................................................................................................................27 Before the Machine Operation................................................................................................28 Machine Operation..................................................................................................................28 Stop the Engine.......................................................................................................................31 Park the Machine....................................................................................................................31 LOWER THE WORKING DEVICES WHILE THE ENGINE IS STALLING...................................................32 INNER SPACE OF THE CAB............................................................................................................32 LOCKING DEVICE OF STEERING BOGIE..........................................................................................32 TABLE FOR REGULAR REPLACEMENT OF SAFETY CRITICAL PARTS.................................................32 PURPOSE AND MAIN TECHNICAL PARAMETERS...................................................................33 PURPOSE.....................................................................................................................................34 MAIN TECHNICAL PARAMETERS.....................................................................................................35 OPERATION MANUAL..................................................................................................................42 BEFORE OPERATING MACHINE......................................................................................................43 Safety for Getting On/off Machine...........................................................................................43 Daily Check.............................................................................................................................43 OPERATING DEVICE, INSTRUMENT & METER OF MACHINE..............................................................44 Negative Pole Switch of Storage Battery................................................................................44 Start Switch.............................................................................................................................45 Function Panel........................................................................................................................47 OTHER CONTROL DEVICES...........................................................................................................63 Steering Wheel........................................................................................................................64 Steering Combination Switch..................................................................................................64 2

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Cigarette Lighter......................................................................................................................64 Accelerator Pedal....................................................................................................................65 Traveling Brake Pedal.............................................................................................................65 Adjusting Rod of Steering Column..........................................................................................65 Lockpin Pedal..........................................................................................................................66 Engine Water Temperature Adjustable System (Optional)......................................................66 Electric Warming A/C System (Optional)................................................................................69 OTHERS.......................................................................................................................................71 Seat.........................................................................................................................................71 Safety Belt...............................................................................................................................73 Audio System..........................................................................................................................74 Lamps......................................................................................................................................78 Door Lock................................................................................................................................80 Positioning Lock......................................................................................................................80 Rearview Mirror.......................................................................................................................81 Overturned Engine Hood........................................................................................................81 Automatic Reverse Alarm System..........................................................................................82 Small Tool Box.........................................................................................................................82 STARTING OF ENGINE....................................................................................................................83 Check Before Starting Engine.................................................................................................83 Starting of Engine....................................................................................................................83 OPERATION TECHNOLOGY.............................................................................................................85 Operation Information.............................................................................................................85 Traveling of Machine...............................................................................................................85 Steering of Machine................................................................................................................87 Braking of Machine.................................................................................................................87 Operation of Downslope..........................................................................................................87 Operation of Machine..............................................................................................................88 SPECIAL APPLICATIONS.................................................................................................................90 Application of Tiltable Front Wheel.........................................................................................90 Application of Articulation........................................................................................................91 Side Slope Scraping................................................................................................................92 Ditching...................................................................................................................................93 Removing Snow......................................................................................................................94 OPERATION UNDER ABNORMAL CONDITION....................................................................................95 Operation under Extremely Cold Condition............................................................................95 Operation under Extremely Hot Condition..............................................................................95 Operation at Dusty and Desert Area.......................................................................................96 Operation under Rainy or Moist Condition..............................................................................96 Operation in Areas with Danger of Salt Corrosion..................................................................96 Operation at High Altitude Area...............................................................................................96 3

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PARKING OF MACHINE...................................................................................................................97 Getting Off the Machine..........................................................................................................97 Parking of Machine.................................................................................................................97 TRANSPORTATION OF MACHINE..................................................................................................................98 Shipping of Machine................................................................................................................98 Driving Machine on Road (with Relevant License)...............................................................100 Hoisting of Machine...............................................................................................................100 TRAILING OF MACHINE................................................................................................................101 Trailing of Machine with Malfunction.....................................................................................101 Trailing When the Engine is Running....................................................................................102 MAINTENANCE MANUAL..........................................................................................................103 RUN-IN OF NEW MOTOR GRADER................................................................................................104 REGULAR MAINTENANCE.............................................................................................................105 GENERAL SPECIFICATION OF TORQUE.........................................................................................109 AIR CHARGING DATA OF TYRE.....................................................................................................110 PRESSURE RELEASE...................................................................................................................110 TECHNICAL SPECIFICATION OF LUBRICATING OIL..........................................................................111 Changing Interval and Adding Capacity of Lubricating Oil....................................................111 Technical Specification of Oil.................................................................................................112 PATROL CHECK...........................................................................................................................112 MAINTENANCE OF COOLING SYSTEM...........................................................................................113 Check of Coolant Level.........................................................................................................113 Check for Concentration of Anti-freezing Fluid......................................................................114 Check for Concentration of Coolant Additive........................................................................115 Add of Coolant.......................................................................................................................115 Change of Coolant................................................................................................................116 MAINTENANCE FOR AIR FILTER OF ENGINE...................................................................................118 Clean of Air Filter...................................................................................................................118 Replacement of Safety Filter Core of Air Filter......................................................................120 MAINTENANCE OF FUEL SYSTEM OF ENGINE...............................................................................121 Check of Fuel Level..............................................................................................................121 Add of Fuel............................................................................................................................121 Rinse of Fuel Tank................................................................................................................122 Removal of Water and Impurity from Fuel............................................................................123 Replacement of Fuel Filter....................................................................................................124 Replacement of Fuel Preilter.................................................................................................125 Heating of Fuel......................................................................................................................125 MAINTENANCE OF ENGINE OIL.....................................................................................................126 Check of Engine Oil Level.....................................................................................................126 Change of Engine Oil............................................................................................................127 Replacement of Engine Oil Filter..........................................................................................128 4

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MAINTENANCE OF GEARBOX.......................................................................................................129 Check of Oil Level of Gearbox..............................................................................................129 Change of Gearbox Oil.........................................................................................................131 Replacement of Secondary Filter of Gearbox Oil.................................................................133 MAINTENANCE OF DRIVING AXLE.................................................................................................135 Oil Level of Driving Axle–Check............................................................................................135 Oil of Driving Axle–Replacement..........................................................................................135 MAINTENANCE OF TANDEM..........................................................................................................136 Checking the Oil Level of Tandem........................................................................................136 Replacement of Tandem Oil..................................................................................................136 MAINTENANCE OF HYDRAULIC SYSTEM........................................................................................137 Checking the Level of Hydraulic Oil......................................................................................137 Regular Replacement of Hydraulic Oil..................................................................................137 MAINTENANCE OF WORKING DEVICE...........................................................................................139 Oil Level of Worm-gear Case–Check....................................................................................139 Worm-gear Case–Oil Replacement......................................................................................139 Adjustment of Circle Clearance.............................................................................................140 Circle–Lubrication.................................................................................................................140 MAINTENANCE OF ACCUMULATOR................................................................................................141 Checking the Pressure of Precharged Nitrogen of Accumulator...........................................141 Pressure Relief of Accumulator.............................................................................................142 Charge of Accumulator..........................................................................................................142 MAINTENANCE OF BRAKE SYSTEM...............................................................................................143 Inspection of the Performance of Parking Brake..................................................................143 Inspection of the Performance of Service Brake...................................................................144 MAINTENANCE OF LUBRICATION SYSTEM.....................................................................................144 Schematic Diagram & Time Interval of Lubrication...............................................................144 MAINTENANCE OF STORAGE BATTERY.........................................................................................146 Cleaning of Storage Battery..................................................................................................147 Installation of Storage Battery...............................................................................................147 Charge of Storage Battery....................................................................................................148 Maintenance of Storage Battery During Stock of Machine...................................................150 Reject of Storage Battery......................................................................................................150 MAINTENANCE OF AIR CONDITIONING SYSTEM.............................................................................150 Inspection of Air Conditioner.................................................................................................150 Checking the Cooling Medium in Storage Tank of Air Conditioner.......................................151 Checking the Tension of Compressor Belt of Air Conditioner...............................................152 Cab Air Filter–Cleaning/Replacement...................................................................................152 OTHER MAINTENANCE.................................................................................................................153 Main Cutting Edge and Side Cutter Board of Moldboard–Check/Replacement...................153 Guide and Bushing of Moldboard–Check/Replacement.......................................................155 5

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Piston Rod of Moldboard Sideshift Oil Cylinder–Fixing........................................................156 Gear Sleeve of Rear Scarifier–Check/Replacement.............................................................156 Check Clearance of Engine Valve.........................................................................................157 Check the Air Intake System of Engine.................................................................................158 Check Driving Belt of Engine................................................................................................158 Check Tension Pulley Bearing and Fan Shaft Shell of Engine.............................................158 Check the Shock Absorber of Engine...................................................................................158 Check and Replacement of Fuse..........................................................................................158 Test of Reversing Alarm........................................................................................................159 Check of Seatbelt..................................................................................................................159 Cleaning Solution Addition of Window..................................................................................159 Check/Replacement of Window Wiper.................................................................................160 Welding Repair......................................................................................................................160 Fuel Heating System of Engine (Optional)............................................................................161 Worm-Gear Box (Optional)...................................................................................................164 Moldboard and Angular Device (Optional)............................................................................165 Lubrication (Optional)............................................................................................................167

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Preface The Manual should be stored with folder in the cab or the place for storing files behind the seat. The Manual covers the information concerning safety protection, operation instructions, transport, lubrication and maintenance. The details shown in some photos or figures or the optional components shown in the Manual may differ from your machine. For facilitating the explanation, it is possible that the cover plate and protective cover have been dismantled. All of the nouns about the directions in this Manual such as the “front, rear, left, right” are defined on the basis of the advance direction of the walking machine. The alteration contents which are continuously changing and improving about the design of the products are not included in this Manual. For any question of the machine or the Manual, please contact the agency of Liugong for the latest information.

Safety The Safety Regulation covers the basic safety notices and lists the warning signs and their meanings & their positions. Before operating on this machine or conducting the lubrication, maintenance or repairing, you must carefully read and understand the safety notices shown in the Safety Regulations.

Operation This chapter involves the information about instruments, switches, operating devices, working devices/gear control levers, transport and traction. It is the guidance for fresh operators and the reference for experienced operators. It should be taken at hand for further reading and learning. The photos and figures provide the guidance for operator to inspect, start, operate and shut down the machine according to the accurate procedures. The Manual just provides the basic operating instructions. So, the operator’s skills will be improved along with his acquaintance with the machine and its performance.

Maintenance The maintenance chapter is the guideline for maintaining the machine. The stepwise captions are classified according to the maintenance cycles. The maintenance items without specific cycle are listed below the title of “Other Maintenance”, while for the items under “Regular Maintenance”, the latter detailed specifications should be referred to.

Maintenance Cycle The maintenance cycle is determined by hour schedule. If the maintenance plan made by 7

Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations

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calendar (day, week and month) is more convenient and approaches the working hour schedule, it can replace the working hour schedule. The maintenance recommended must be carried out within the maintenance cycles hereinbefore, whichever comes first. Under the extremely bad, dusty or damp working conditions, the lubrication maintenance is needed more frequently than the requirement specified in the “Regular Maintenance”. The maintenance items listed in the former requirements should be repeated during the current maintenance. For example, when carrying out the maintenance items within 500 work hours or 3 months, the maintenance items for every 250 work hours or every 1 month, that for 50 work hours or every week, and that for every 10 work hours or each day also should be done.

Products Introduction

CLG418 Right Side

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Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations

CLG418 Left Side

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2008.10 000

Bulldozer

Front axle

Bidirectional hydraulic lock

Bulldozer oil cylinder

Moldboard Front frame

Bidirectional hydraulic lock

Worm-gear box

Swing oil cylinder

Multi-way valve

Control console

10 Bidirectional hydraulic lock

Slewing hydraulic motor

Slewing joint

Brake accumulator of rear axle

Working pump

Hydraulic Cab oil shaft tank Pump transmission

Angle changing oil cylinder

Scarifier

Rear axle, Tandem

Tyre

Safety valve

Battery box

Scarifier oil cylinder

Articulation steering oil cylinder

Heat radiation pump

Radiator assembly

Parking brake accumulator High-pressure filter

Air filter Diesel tank

Priority valve Blade lifting oil cylinder

Engine

Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations 2008.10 000

Schematic Diagram of Main Components

Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations

2008.10 000

Safety Regulations

Warning: Please read and be familiar with all of the safety regulations, otherwise serious fatal accident may occur. The safety notices for optional parts and accessories are also included in this chapter.

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Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations

Direction B

Direction A

Direction C

Safety Labels and Their Adherent Positions

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Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations

2008.10 000

There are some safety labels on the machine. This chapter will show you the adherent positions and hidden trouble descriptions of these safety labels. Please take some time to be familiar with these safety labels. Make sure that you are able to read all of the safety labels. If the words or graphics of those safety labels could not be read clearly, please replace them or clean them with cloth or suds. Do not clean the safety labels with detergent or gasoline. If the safety labels are damaged, lost or still can not be read after cleaning, they should be replaced. If one part with safety label needs replacing, a new label should be adhered on the newly-replaced part. 1. Warning board: The safety support (at the swinging arm of the front frame) should be used when you repairing the hoist working devices

74A0451

2.

Hoisting point sign (on the front frame)

74A0083

3.

Warning: No Entry! (on the front frame)

74A0419

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Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations

4.

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Warning (in the cab)

74A0417

5.

Warning: Please read the operator’s manual. (in the cab)

74A0415

6.

Warning: (in the cab)

74A0444

7.

Label for hydraulic oil filler: (on the hydraulic oil tank) 74A0482

8.

Schematic diagram of complete machine lubrication (on the fixed cover) 74A0831

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Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations

9.

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Warning: Keep away from the machine. (on the counterweight) 74A0418

10. Warning: Keep your hands away from the rotating fan (on the radiator support)

74A0416

11. Warning: Storage battery (on the battery box)

74A0443

12. Label of fuel tank: (on the top of the engine hood) 74A0552

13. Parking brake button: (on the right side control box in the cab) 74A0501

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14. Label of the accelerator. (on the right side control box in the cab) 74A1386

15. Label for lubrication (on the working device) 74A1548

16. Warning: Don’t allow the lifting oil cylinder swing beyond the nonworking range (in the cab)

74A1656

17. Warning: Avoid the swing seat hitting with the oil cylinder in the working. (on the swing seat) 74A1807

18. Warning: Avoid the oil cylinder hitting with the swing seat in the operation. (on the left lifting oil cylinder)

74A1809

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19. Label for operation: Press the control lever before adjusting the control console. (on the control console of cab)

74A1972

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Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations

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General Safety Notices  Only the operators who have been trained and have obtained relevant qualifications can be allowed to operate and maintain this machine.

 Hang a warning board of “No Operation” on the startup switch or control lever before maintenance or repair.

 Don’t wear loose clothes, jewelry or have long hair. They may be caught or involved into the control system or the moving parts, resulting in the serious injury or death.

 Please wear the safety helmet and safety glasses made of hard materials, safety shoes, face mask and gloves when you operate or maintain the machine.

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Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations

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 Never wear moist gloves or cloth to handle the electrical devices, or the electric shock may occur.  Ensure all of the protective plates and cover plates are fixed on the machine.  Ensure there is no chip, oil stain, tool and other irrelevant sundries on the machine; especially on the dash board, passage and the staircase.  All of the sundries should be put in place, such as the lunch box and the tools.  Prevent any foreign matter into the system components when checking the opened oil tank or water tank. Before taking down their covers, make sure your jacket pockets are empty, and move the wrench and nuts carefully.

 Understand the gesture signals used on site and their sources, and only take the signals from one people.  Never store the maintenance solution into the glass container.  The relevant laws and rules should be obeyed when you deal with such substances as lubricating oil, fuel oil, coolant, solvent, filter, storage battery and some other harmful substances.  Be cautious when using the detergent. Do not use the flammable materials as the detergent, such as the diesel oil or gasoline, which may induce the danger of fire.

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 Everything that needs repairing should be reported in time.  Anyone without the permission is not allowed to stay on or around the machine.

Compressed Air  The compressed air may result in the injury to human body. Please do wear the face mask, protection cloths and safety shoes when using the compressed air to clean the machine. The maximum pressure of compressed air should be lower than 0.2MPa.

High-Pressure Liquid Warning: Avoid the scald by high-pressure oil. Check whether the system pressure is released when you repair or replace pipes of hydraulic system. The hydraulic oil under high pressure will result in serious harm to you skin. More details about the pressure release are showed in “Pressure Release” in “Maintenance Manual”. Never make the repairing or replacement before the complete release of the system pressure.  Be cautious when disassembling the hydraulic pipelines or joints. The released high-pressure oil may result in the whisking of the hose when the oil is spouting out.  Please wear the safety glasses and leather gloves when checking the leakage. Always use the board or paper board other than naked hand to check the leakage.

 Even the leakage of the pressure liquid as small as pin hole could penetrate into the muscles and result in the personal casualty. If hitting by the jetting high-pressure oil, you should immediately contact with doctor for treatment. 20

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Well Dealing with the Spilt Liquid  The liquids split in checking, maintaining, testing, adjusting and repairing should be placed with containers.  Prepare a proper container for liquid collection before opening any liquid chamber or disassembling any parts with liquid.  All of the local laws and regulations should be obeyed when dealing with the waste liquid.

Notices for Operating Accumulator Accumulator contains the high-pressure nitrogen and is dangerous. Therefore, please read the requirements hereinafter and use the accumulator properly.  Check the accumulator before charging it with nitrogen. If the accumulator is found without the nameplate, the words on it drop off and its category can’t be recognized, its stamping mark is incomplete or can’t be recognized, or the shell is defective and can’t be used safely, it is forbidden to fill the accumulator with gas.  Only nitrogen is allowed to be filled into the accumulator. Oxygen, compressed air or other flammable gases are forbidden in case of explosion.  Always charge the accumulator with nitrogen slowly to avoid the outburst of rubber bag.  The accumulator should be mounted upward & vertically. It should be fixed steadily onto the support other than by welding method.  Don’t drill any hole on the accumulator. Don’t approach the accumulator with any naked fire and keep any heat source away from the accumulator.  Any welding work is forbidden on the accumulator.  The accumulator is a high-pressure container. It should be replaced and repaired by professional.  The gas inside should be released before the abandonment of the accumulator.

Asbestos It is bad for health to inhale the dust of asbestos. Our product is designed without the asbestos. Liugong Machinery Co., Ltd. recommends to use the original Liugong spare parts. If you need to deal with the materials with the asbestos, please obey the following regulations:  The compressed gas is prohibited to use for cleaning. Use water to sink the dust.  Use the dust collector with high filtration efficiency.  Do not grind the substance containing asbestos dust.  If possible, operate the machine in the uptake.  Obey the relevant environmental laws and regulations when you deal with the asbestos.  Take shower after touching the asbestos.  If necessary, use effectual protection mask. 21

Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations

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Protection against Crushing or Cutting  Do not put your hand, arm or any other parts of body between removable components, such as the working devices and oil cylinder, the machine and working devices.  Hold up the devices and wedge the tyres correctly when you work under the devices or vehicle. Do not hold up the working devices by using the hydraulic oil cylinder. The working device would drop off if the control mechanism moves or hydraulic pipeline leaks.

 If it is necessary to dismount the protective cover during the maintenance, it must be well mounted after the maintenance.  Keep away from any revolving or moving part.

 Ensure there is no sundry between engine fan blades. The tools and sundries dropped or pushed into the fan blades would be threw out or cut by the fan blades.  Unless otherwise specified, any adjustment is prohibited when the machine is operating or the engine is working.

 Do not use the twist or worn wire rope. Wear gloves when using or carrying it.  Ensure nobody stays around when extruding the bayonet lock by force. Please wear protection glasses to avoid injury to your eyes.  Prevent the bursting chips from making injury to others when knocking an object with hammer. 23

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Burn Protection Coolant  Under the working status, the engine coolant is of high temperature and pressure, and there is hot water in the radiator and the pipelines to the radiator. Any touch with such liquids may result in severe burn.

 Shut down the engine and cool the water filler cover till it can be opened by hands when checking the liquid level.  Release pressure by turning on the water filler cover of the cooling system slowly.  Don’t touch the alkali in the coolant by hand, eye or mouth, for the alkali may result in the injury to human body.

Oil  The hot oil and hot parts would result in the injury to human body. Do not let them contact the skin.  Under the working temperature, the hydraulic oil tank is hot and is stressed.  Shut down the engine and cool the oil filler cover till it can be opened by hands when turning on the water filler cover of the hydraulic oil tank.  Release pressure by turning on the oil filler cover of the hydraulic oil tank slowly.  The system pressure should be released before disassembling all the pipes, adapters and relevant parts.

Storage Battery  The explosion would be induced by the smoke from the storage battery.  No smoking when checking the electrolyte level of the storage battery.  The electrolyte is acidic; do not let them contact your skin or eye.  Wear protection glasses and safety gloves when checking the storage battery.

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Fire and Explosion Protection  All fuel oils, most lubricating oils and some miscible liquids of coolants are flammable.  The leakage of the fuel oil to the hot surface or electrical elements may result in fire.  No smoking when oiling, or staying in the oiling area or places for storing flammable substances.

 Clean and screw up all of the electrode terminals. Check whether any wire is loose or worn. Screw up the loose power supply and repair or replace the worn wires before starting the machine.  Store fuel oil and lubricating oil in the containers with corresponding marks in case they are used by non-working personnel.  Store the oily finishing cloth and other flammable materials into the containers with protection and place them in a safe area.  Do not take electric welding or torch cutoff on the pipelines with flammable liquid. Clean with the flammable liquid before the electric welding or torch cutoff.  Clear the flammable materials away from the machine, such as fuel oil, lubricating oil or other sundries.  Do not operate the machine nearby the naked fire.  Lighting with naked fire is prohibited during the operation and maintenance of machine.  Ensure the storage battery is far away from the naked fire or sparks. No smoking in the charging place for storage battery.  Contact the positive (+) cable to the positive (+) terminal of the storage battery connected with the startup motor, and contact the negative pole (-) of the outer power supply to the negative pole (-) of the starter when using the jumper to start up the machine. If the starter is without the negative terminal, contact it onto the housing of the engine.  Do not charge the frozen storage battery to avoid the explosion.

Ether (Warning: Do not use ether to start up the machine)

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 Any try by using ether to start up the engine may result in the severe damage to the engine or the personal casualty.

Pipelines, Pipes and Hoses  Do not bend or hammer the high-pressure pipelines; do not install pipes/hoses bent or broken improperly onto the machine.  Any loose or broken pipe/hose of fuel oil, lubricating hydraulic circuit and hydraulic system should be repaired in time. The leakage may result in fire. For any repair or replacement, please contact authorized distributor of Liugong Machinery Co., Ltd.  Make replacement in case of one of the following problems: Any damage or leakage of the joints. Any abrasion or rupture of the hoses and any exposure of the reinforced steel wires. Any local knurl of the hoses. Any obvious twisting or deviation of the hoses. Reinforced steel wires tumbled into the outer shell of hoses. Any misalignment of the end joints.  Ensure all of the pipe clamps, guard boards and heat-proof covers are installed correctly to avoid shocking or overheating caused by the friction with other parts.  Naked fire is prohibited when dissembling the connecting pipelines of the A/C compressor. Otherwise, it may release toxic gas and result in poisoning.

Fire Extinguisher and First-aid Kit  Fire extinguisher should be prepared and you should read the instructions and understand how to use it.  First-aid kit should be prepared in the working area. It should be checked on time and replenished some medicals if necessary.  Understand the treatment in case of fire or injury.  Prepare the telephone numbers of certain persons, such as doctor, emergency centre and fire station, for emergency use. Affix those numbers to the specified place and ensure all the personnel are familiar with those numbers and the correct contact method.  Check and maintain the fire extinguisher regularly. Abide by the recommended usage on the panel.

Tyres  The special equipment and technologies are required for the maintenance, dismantlement, repair and installation of tyres and wheels. Therefore, you should have them maintained or repaired by a tyre service shop.

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 The explosion of pneumatic tyre may be resulted from the heating or burning gas inside the tyre. In general, it is mainly resulted from the expansion or burning of the heated gas in case of heating or electric welding on the wheel rim, outer flame or too frequent braking.  The explosion of tyre is much more powerful than the bleeding. It may force the tyre, wheel rim and driving parts to fly 500m far away. The explosion and chips may result in casualties and property damage.  Do not stay close to the heated tyres. Keep a minimum distance (at least 15m). Stay away from the shaded area as showed in the figure.

 It is recommended to charge the tyre with dry nitrogen (N 2). If the tyre was charged with air, the nitrogen is recommended to adjust the air pressure because the nitrogen can mix with the atmospheric gas. The tyre with nitrogen would reduce the possibility of explosion, and that is because the nitrogen is incombustible. Similarly, the nitrogen can protect the tyres from being oxidized, and prevent the rubber aging and corrosion of the parts of wheel rim.

Protection against Injury of Thunder  Do not try to climb on or step down the machine when the thunder happens nearby the machine.  In case of the thunder, stay in the cab if you are just in the cab or stay away from the machine if you are on the ground.

Notices for Accessories  Please read the Instructions, Manuals of the accessories and the information related to the accessories in the manuals when installing and using the spare accessories.  Don’t use the accessories without permission by Liugong Machinery Co., Ltd. or the 27

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authorized distributor. The safety problems brought by the using of accessories without permission may be adverse to the normal operation of machine and shorten the service life.  Liugong Machinery Co., Ltd. shall not bear any responsibility for injury, accident or machine damage brought by the using of accessories without permission.

Operation Safety Notices Mounting On/Off the Machine   

   

Before mounting on or off the machine, clear the oil or the mud off the handle or the stairs. Replace the damaged parts and fasten the loose bolts. Mount on or off the machine only where there are stairs or handles. To mount on or off the machine, face the machine with the hand(s) holding the handle and the foot (feet) stepping on the stairs, that is, three parts of the body should touch the machine (two feet and one hand or two hands and one foot).

Jumping off the machine is forbidden. Mounting on or off the machine while it is running is forbidden. While mounting on or off the machine, do not use any operating lever as an armrest. While mounting on or off the machine, do not carry tools or other articles. Hoist the tools to be used onto the operating platform with ropes.

Check before Engine Start  





Before starting the engine, make sure that nobody is around the machine. Adjust the operator’s seat to a proper position and check the seat belt and the securing device of the belt for damage. The seat belt should be replaced if it has been used for three years. Check the bumpers on the machine for locking the front and rear frames and ensure they are securely locked in the “loose” position.

Make sure that the lighting system of the machine works properly and there is sufficient lighting in the workplace. 28

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Engine Start 

If any operating lever is attached with the warning label “Do not operate”, the engine should not be started.



Before starting the engine, make sure that the hydraulic operating lever is in the “Hold” position while the gear lever is in the neutral position.



To start the engine, blow the horn to warn.

Hoot! Hoot!



Do not start the machine before making sure that the operator has already been seated and fastened the seat belt securely.



Start the engine only in the cab. Starting the engine by short-circuiting the start motor is forbidden, for starting the system through a bypass may damage the electrical system of the machine.



If it is necessary to start or repair the machine in a closed or poorly ventilated place, the doors and the windows should be opened to ensure sufficient ventilation and to prevent gas 29

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poisoning. If sufficient ventilation is still impossible to achieve, install a fan.

Before the Machine Operation 

Nobody else should be on or around the machine. The seat belt should be fastened.



Ensure that all the windows, the lamp shades and the rear-view mirrors are clean and secure the open or closed doors and windows.



Adjust the rear-view mirror to provide the best sight for the operator on the seat.



Clear away all the obstacles in the driving path of the machine. Be aware of high-voltage lines, ditches and other dangers.



Ensure that the horn, the reversing alarm (if any) and other alarms of the machine work properly.

Machine Operation 

It is necessary to know the maximum extent and range of your machine.



The driver should drive the machine while being seated with the seat belt fastened. The operating levers should be operated only when the engine is running.



Before driving the machine, the driver should ensure that nobody will get hurt.



Unless an extra seat with the seat belt and the Roll-over Protective Structure (ROPS) are equipped, nobody should be driven. 30

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Before formally starting the work, drive the machine slowly to an open space and check all the operating levers and protective devices for proper functioning.



If any item of repair (noise, vibration, smell, incorrect instrument display, gas leakage, oil leakage, etc.) for the machine is found during its operation, such item(s) should be reported immediately.



While driving the machine, lift all the working devices as high as possible. The moldboard should be kept within the width of the motor grader to ensure that the tyre does not touch the moldboard when the machine is turning.



Avoid working on the fringe of a cliff, under a dam or a heap, on a road without enough support or at a place with overhung articles to prevent falling.



While working continuously after the rain, bear in mind that the environment condition has changed and more caution should be taken.



While working in the snow or clearing the snow, extra caution should be taken, for even a gentle slope may cause sideslip. If snow has been pushed to the side of the motor grader, take extra care of the obstacles buried under the snow. 31

Operation and Maintenance Manual for CLG418 Motor Grader–Safety Regulations





   





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Avoid any situation that can cause the machine to roll over. The machine may roll over while working on the hills, banks or slopes. It may also roll over while crossing the ditches, heaps or other unexpected obstacles. While on a slope, the machine should move up and down in a straight way without turning or crabsidling on the slope to avoid rollover.

If the machine starts to sideslip downward on the slope, stop working immediately and drive the machine down the slope. While driving down the slope, shift the gear to the neutral position and keep control of the motor grader without depressing the brake pedal. Be sure to know the rated workload of the machine. If the workload is exceeded during the operation, not only the machine will be damaged, but also unexpected accidents will occur. This machine can undertake only specified jobs. Performing other jobs outside its range of use will damage it. See Usages and Main Technical Performances and Parameters for its specified jobs. Take extra caution while working by the high voltage lines. If the machine may touch cables while operating on a worksite, the power company concerned should be consulted before the operation is started to check whether any action is possible under the existing laws and regulations. To transport the machine, make sure that the trailing device has enough strength. The trailer can be connected only with the draw bar and the hinged point. Straddling the steel wire or similar devices between the trailer and the trailed machine is forbidden.

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Before transporting the machine, make sure that nobody is between the machine and the trailer. The traction frame or the traction pin of the traction equipment should be connected with the draw bar of the machine center to center.

Stop the engine 

Do not stop the engine immediately after the machine has worked with load, otherwise the engine will deteriorate more quickly and its life will reduce.



After parking the machine, keep the engine running for five minutes to allow it cool gradually.

Park the Machine 

Park the machine on an even ground and then lower the working devices to the ground where there should be no danger of falling stones or landslides. If the level of the ground is low, there should be no danger of floods either.



If it is necessary to park the machine on a slope, place wedge blocks under the wheels to prevent the machine from moving. Then lower the working devices to the ground.



Apply the service brake to stop the machine. Shift the gear lever to the “Neutral” position.



Apply the parking brake.



Turn the battery circuit breaker to the OFF position to prevent the battery from discharging due to short circuit, current leaking from some components or damage.



To leave the machine, lower such working devices as the moldboard, the front bulldozer and the rear scarifier (if equipped) completely to the ground. Then lock the operating levers with the locking device, stop the engine and apply the parking brake. Finally lock all the devices with the keys, remove the keys and take them along.

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Lower the Working Devices while the Engine Is Stalling 

Before lowering the working devices, make sure that nobody is around the machine.

Note: If the machine is equipped with the electro-hydraulic operating levers, the starting switch for the engine should be in the ON position in order to lower the working devices. After the working devices have been lowered, the starting switch for the engine should be switched to the OFF position. 

Move all the operating levers to the “Lower” position to lower the working devices to the ground or onto the trailer. After the levers have been released, they will return to the “Hold” position.

Inner Space of the Cab This machine of Liugong is equipped with a cab comforting to the industrial standards “SAE J154” and “ISO 3411”, which set out the requirements for the space of the cab. Any modifications to the cab should not occupy the specified space. The added radio, fire extinguisher and other devices should be so installed to keep the specified space intact. Any articles brought into the cab should not occupy the specified space. Dinner boxes or other loose goods should be secured. When the machine is driving on uneven grounds or when it is rolled over, these goods should not cause the danger of shock.

Locking Device of Steering Bogie To hoist or transport the machine or to do maintenance work around the hinged point, connect the locking device of the steering bogie. To operate the machine, disconnect the locking device of the steering bogie. Reference: For more details about the locking device of the steering bogie, see the section “Locking Device of Steering Bogie” under the Chapter “Operation” in the operation and maintenance manual.

Table for Regular Replacement of Safety Critical Parts No.

Critical parts that need replacing regularly

Quantity

Replacement period

1

Filter core of hydraulic tank

2

Every year or 2,000 hours (whichever is the sooner)

2

Fuel pipe

3

Every other year or

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3

Steering cylinder seals

2

4

Hose assembly

9

5

Brake hose

9

6

Braking oil cylinder seals

7

Accumulator

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4,000 hours (whichever is the sooner)

1 group 3

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Every three years or 6,000 hours (whichever is the sooner)

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Purpose and Main Technical Parameters

Caution

The content of this chapter means a lot in correctly using, maintaining and repairing this machine.

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Purpose This motor grader is a kind of construction machinery mainly used to level off pavement and to refinish embankment section, which is applicable to leveling works on road, square, etc. As this motor grader is ordinary construction machinery, it is inapplicable under flammable, explosive, high-dust conditions or the environment with poison gas.

Working Environmental Requirements 1.

Elevation: ≤3,048m

2.

Ambient temperature: -15℃~40℃ (no auxiliary cold start device attached)

3.

Wading depth: ≤430mm

Forbidden Operations 1.

Over load usage.

Caution: The preventive measures in respect of operation, maintenance and safety operation regulations noted in this Manual is only applicable to this machine being used according to the stated purposes. If this machine is used beyond the usage range stated in this Manual, Liugong Machinery Co. Ltd. shall take no safety responsibility, which will be assumed by the consumers. The forbidden operations must not be conducted in any case.

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Main Technical Parameters Overall Specifications Curb weight---------------------------------------------------------------------------------------------------15,500kg Front wheels--------------------------------------------------------------------------------------------------4,400kg Rear wheels--------------------------------------------------------------------------------------------------11,100kg Maximum traction force (wheelspin)-----------------------------------------------------------------------86kN Moldboard cutting pressure-----------------------------------------------------------------------------≥7,800kg Minimum turning radius----------------------------------------------------------------------------------7,800mm

Engine System Diesel engine ------------------------------------------------------------- Dongfeng Cummins 6CTA8.3-C215 Rated power------------------------------------------------------------------------------------------------------160KW Rated REV------------------------------------------------------------------------------------------------------2,200rpm Number of cylinders------------------------------------------------------------------------------in-line six-cylinder Cylinder bore × Stroke-----------------------------------------------------------------------------------114×135mm Displacement of piston--------------------------------------------------------------------------------------------8.3L Peak torque---------------------------------------------------------------------------------------908N.m/1,500r/min Torque reserve-------------------------------------------------------------------------------------------------------30% Specific fuel consumption under calibrated working condition (base test) --------------------228g/kw.h Fuel----------------------------------------------------------------------------------No. 0 or No.-35 light diesel fuel Fan diameter----------------------------------------------------------------------------------------------------762mm

Drive System Torque converter Model---------------------------------------------------------------------------------------------------------ZF 6WG200 Type----------------------------------------------------------------------------single stage turbine, three elements Torque ratio-------------------------------------------------------------------------------------------------------2.15 Cooling method------------------------------------------------------------------------air cooling pressure cycled Transmission Model------------------------------------------------------------------------------------------------------ZF 6WG200 Type-------------------------------------------------------------------------------------------- fixed shaft power shift 38

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Gears------------------------------------------------------------------------ 6 forward speeds, 3 reverse speeds Transmission oil pump (gear pump) Working pressure-----------------------------------------------------------------------------------------1.6~1.8MPa Top travel speed at each gear Forward gear VI --------------------------------------------------------------------------------------------≥40.3km/h

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Forward gear V--------------------------------------------------------------------------------------------≥26.1km/h Forward gear IV--------------------------------------------------------------------------------------------≥20.7km/h Forward gear III--------------------------------------------------------------------------------------------≥12km/h Forward gear II--------------------------------------------------------------------------------------------≥10km/h Forward gear I--------------------------------------------------------------------------------------------≥5.8km/h Reverse gear I-----------------------------------------------------------------------------------------------≥5.8km/h Reverse gear II------------------------------------------------------------------------------------------------≥12km/h Reverse gear III--------------------------------------------------------------------------------------------≥26.1km/h

Differential & final drive Type of main drive -----------------------------------------------------------------spiral bevel gear first reducer Type of wheel reducer----------------------------------straight toothed cylindrical gear planetary reducer

Driving axle and tyre Type-----------------------------------------------------------------------------------------------------four-wheel drive Tyre----------------------------------------------------------------------------------------------------------------17.5–25 Tyre pressure------------------------------------------------------------------------------------------0.275±0.01MPa

Brake System Brake pump-------------------------------------------------------------------------------------- Permco gear pump Service brake (operating by foot) --------------------------------------------------- full hydraulic shoe brake Oil pressure of brake -------------------------------------------------------------------------------------10±0.3MPa Open pressure of prefill valve-----------------------------------------------------------------------12.3±0.35MPa Switch-off pressure of prefill valve-------------------------------------------------------------------15±0.35MPa Alarm pressure of low pressure of service brake------------------------------------------------------11.5MPa Pre-charged pressure of accumulator---------------------------------------------------------------------9.2MPa Parking brake and emergency brake-----------------------manual electric control caliper disc brake Oil pressure of system------------------------------------------------------------------------------------------15MPa Alarm pressure of low pressure of parking brake-------------------------------------------------------3.5MPa Pre-charged pressure of accumulator---------------------------------------------------------------------9.2MPa

Steering Hydraulic Pressure System Type----------------------------------------------------------------------------------------load sensor steering gear Number of steering cylinders-- inside diameter × stroke------------------------------------2-φ25×258mm Working pressure of system-----------------------------------------------------------------------------15~17MPa Steering angle---------------------------------------------------------------------- 451 each for left and right

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Working Hydraulic Pressure System Working pump------------------------------------------------------------------------------------Permco gear pump

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Multiple-way valve-------------------------------------------------------------------------------------------------husco Maximum flow---------------------------------------------------------------------------------------132L/2,300r/min Top working pressure of system-----------------------------------------------------------------------------18MPa

Moldboard Length × height × thickness--------------------------------------------------------------------3,960×610×19mm Maximum ground clearance of moldboard----------------------------------------------------------------450mm Maximum cutting depth of moldboard----------------------------------------------------------------------550mm

Electric System Voltage of system ---------------------------------------------------------------------------------------------------24V Storage battery----------------------------------------------------------------------------------------2—6-QW-120T Voltage of bulb ----------------------------------------------------------------------------------------------------24V Start of diesel engine ------------------------------------------------------------------------------24V electric start

Fuel Capacity Fuel-------------------------------------------------------------------------------------------------------------------230L Hydraulic oil----------------------------------------------------------------------------------------------------------186L Crankcase of diesel engine----22L (actual capacity of fuel charge depends on the scale of oil level) Transmission case system-----45L (actual capacity of fuel charge depends on the scale of oil level) Turbine case, rear axle and tandem ------------------------------------85L (actual capacity of fuel charge depends on the scale of oil level)

Air Conditioning System Warm air Working medium-----------------------------------------------------------------------------------coolant of engine Heating capacity ------------------------------------------------------------------------------------------5,000Kcal/h Cool air Working medium---------------------------------------------------------------------------------------------------R12A Cooling capacity-------------------------------------------------------------------------------------------4,000Kcal/h Voltage of --------------------------------------------------------------------------------------------------24V

42

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Operation and Maintenance Manual for CLG418 Motor Grader–Operation Manual

Ground clearance

Outline Dimensional Drawing of Product (Standard)

Cutting depth

Side reaching distance of moldboard 1639 Tianjing Hengzheng 1553

Side reaching distance of moldboard

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Ground clearance

Outline Dimensional Drawing of Product (with Optional Front Bulldozer)

Cutting depth

Side reaching distance of moldboard

Tianjing Hengzheng 1553

Side reaching distance of moldboard

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Ground clearance

Outline Dimensional Drawing of Product (with Optional Rear Scarifier)

Cutting depth

Side reaching distance of moldboard Tianjing Hengzheng 1553

Side reaching distance of moldboard

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Outline Dimensional Drawing of Product (with Optional

Ground clearance

Front Bulldozer and Rear Scarifier)

Cutting depth

Side reaching distance of moldboard

Tianjing Hengzheng 1553

Side reaching distance of moldboard

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Operation Manual

Caution: Before operating the machine, please seriously read and master this manual so as to operate the machine accurately. Accurate operation plays a significant role in safety guarantee, gain of high work efficiency and service life of machine.

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Before Operating Machine Safety for Getting On/off Machine 

Before getting on/off the machine, check the armrest or ladder and wipe them clean at once when there is any oil mark, lubricant or mud on them. Besides, repair the broken parts and tight the loose bolts.



Don’t jump on/off the machine or get on/off the machine when it is moving.



When getting on/off the machine, face it, hold the armrest, step the ladder and contact the machine with 3 points (both feet and one hand or both hands and one foot) to keep the body stable.



Don’t hold any control lever when getting on/off the machine.



Don’t climb up/down the machine when taking tools or other articles. Lift the required tools to operating platform with rope.

Daily Check To prolong the service life of machine, thoroughly check the machine around before getting on it and starting the engine. Check the circumstance and bottom of machine for loose of bolts, circulated waste, leakage of hydraulic oil or coolant and broken/wearing parts. Check the condition of working equipment and hydraulic elements. Check all levels of oil, coolant and fuel oil. For details of daily check, please refer to the maintenance schedule–maintenance/10 work hours or daily maintenance in “Maintenance Manual” of operation and maintenance manual.

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Operating Device, Instrument & Meter of Machine Negative Pole Switch of Storage Battery The negative pole switch of storage battery is installed at the left rear of rear frame which could be seen by opening the side door of battery case of motor grader.

indicates the negative pole switch is turned on:

Turn the handle for negative pole switch clockwise to “ON” position before starting the machine. When the negative pole switch is on, the handle for switch should point to position “I” on switch panel. indicates the negative pole switch is turned off:

For cutting off the power supply of electrical system of complete machine, turn the handle for negative pole switch anti-clockwise to “OFF” position. When the negative pole switch is off, the 49

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handle for switch should point to position “O” on switch panel. The negative pole switch is different from start switch. When the negative pole switch is turned off, the electrical system of complete machine is also cut off. However, when start switch is turned off, the storage battery will still connect with electrical system of complete machine so that part of electrical parts could still operate.

Caution: Turn off the negative pole switch when the machine stops for more than 3 hours. Warning: Don’t turn off the negative pole switch of storage battery when the engine is running. Or else, the electrical system of complete machine will be damaged.

Start Switch

Start switch

(1)

(3)

(2)

(4)

Start switch

The start switch is located on control panel of right side of seat. There are four positions located clockwise on it: (1)

AU (auxiliary position)-------this position is out of use now.

(2)

OFF (off position)-------when this position is applied, circuits other than emergency stop 50

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switch which could control the turn lamps are cut off and the engine will also stop. (3)

ON (on position)-------the position which is achieved by inserting and turning the key of start switch clockwise. When this position is applied, the electrical system of complete machine is electrified so as to operate normally.

(4)

START (start position)-------turn the key of start switch to this position to start the engine, and then loose the key to let the start switch return “ON” position automatically.

Caution: Make sure the negative pole switch of storage battery is on and the gearshift lever is on middle position before starting machine.

Gearshift control handle

Warning When the engine fails to start, turn the start switch to “OFF” position to re-start it, or else, the start switch will be damaged! The time for each start should be no more than 30s; the interval between 2 starts should be at least 2min, and the number of continuous starts can’t exceed 3; after starting continuously for 3 times, continue to start after waiting for 3min, or else, the service life of storage battery will be reduced and the starting motor may be damaged!

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Function Panel

A B

B

C

A

Central function panel

B

Operation control handle

C

Right function panel

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Central Function Panel

A

D B

C

A.

Engine Water Thermometer It is available to indicate the temperature of cooling water of engine. When the pointer points to the red area, stop the machine and check engine fan, belt and water level of radiator.

Warning When the pointer points to the red area, stop the machine on a safe place which is facilitate for overhaul and check radiator fan, belt and level of water tank of engine. Continue to travel or operate after troubleshooting. When checking radiator fan, belt and level of water tank of engine, take action to prevent burn caused by high temperature and keep away from the movable parts to avoid being clipped! B.

Gearbox Oil Thermometer

It is available to indicate the working oil temperature of gearbox. When the pointer points to the red area, it indicates the oil temperature is too high. Then the alarm indicator lamp of 53

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gearbox will flash so that the machine should be stopped to be checked for trouble cause.

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C. Alarm Unit of Monitoring System The alarms of monitoring system are classified to be 2 levels according to relative importance of inspection items:  First Level Alarm: lamps of item flash. Including turn indicator lamp, charge indicator lamp and upper beam indicator lamp of headlamp.  Second Level Alarm: lamps of item flash and buzzer sounds. Including traveling brake low-pressure alarm lamp, emergency brake low-pressure alarm lamp, engine oil pressure alarm indicator lamp and gearshift oil pressure alarm lamp.

3、1

1、2

6、7 4、5 1. Turn indicator lamp (green) When the machine turns left, the left turn indicator lamp is on and the front/rear left turn lamps are on simultaneously. When the machine turns right, the right turn indicator lamp is on and the front/rear right turn lamps are on simultaneously.

2.

Traveling brake low-pressure alarm lamp (red)

This item is second level alarm. When the traveling brake hydraulic oil pressure is too low, indicator lamp of this item will flash to alarm and the buzzer will sound to alarm. Then stop the machine at once to find out trouble cause.

3.

Emergency brake low-pressure alarm lamp (yellow)

This item is second level alarm. When the emergency brake hydraulic oil pressure is too low, indicator lamp of this item will flash to alarm and the buzzer will sound to alarm. Then stop the machine at once to find out trouble cause. 4.

Charge indicator lamp (yellow) The charge indicator lamp indicates if the generator charges the battery. When the start switch is turned to “ON” position, this lamp will be on, and when engine is started, it will be off. 55

Operation and Maintenance Manual for CLG418 Motor Grader–Operation Manual

5.

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Headlamp upper beam indicator lamp (green)

When the green indicator lamp is on, it means the working condition of headlamp is upper beam.

6.

Engine oil pressure alarm indicator lamp (yellow) This item is second level alarm. When the engine oil pressure is too low, indicator lamp of this item will flash to alarm and the buzzer will sound to alarm. Then stop the machine at once to find out trouble cause.

7.

Gearshift oil pressure alarm lamp (yellow)

This item is second level alarm. When the gearshift oil pressure is too low, indicator lamp of this item will flash to alarm and the buzzer will sound to alarm. Then stop the machine at once to find out trouble cause.

D. Seesaw switch 1.

2.

3.

Headlamp switch: control the left/right headlamps to be on/off simultaneously.

Small lamp switch: control the small lamp to be on/off.

Working lamp switch: control the two working lamps on cab roof to be on/off simultaneously.

4.

Rear headlamp switch: control the left/right rear headlamps to be on/off simultaneously.

5.

Front ceiling lamp switch: the switch which controls the front ceiling lamp.

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Operation control handle The control handle for operating cylinder is installed on the both sides of steering wheel and used to control the operation of operating cylinder.

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Handles 1 and 2 control the fall and lift of left side of moldboard

Fall of left side of moldboard–Push the handle forward to make left moldboard

fall. When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position. Holding–When releasing the handle at “Fall” or “Lift” position, it will return to holding position. 58

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Then the moldboard will stay at the selected position.

Lift of left side of moldboard–Pull the handle backward to lift the left moldboard lift.

When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position.

Handles 3 and 4 control the fall and lift of scarifier (Optional)

Scarifier fall–Push the handle forward could make the scarifier fall. When releasing the handle, it will return to holding position. Then the scarifier will stay at the selected position. Holding–When releasing the handle, it will return to holding position. Then the scarifier will stay at the selected position.

Scarifier lift–Pull the handle backward to make scarifier lift. When releasing the handle, it will return to holding position. Then the scarifier will stay at the selected position.

Handles 5 and 6 control the leftward and rightward moldboard sideshift

Leftward moldboard sideshift–Pushing the handle forward could cause the leftward sideshift of moldboard. When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position. Holding–When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position.

Rightward moldboard sideshift–Pulling the handle backward could cause the

rightward sideshift of moldboard. When releasing the handle, it will return to holding position. Then the moldboard will return to the selected position.

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Handles 7 and 8 control the decrease and increase of moldboard angle

Decrease moldboard angle–Push the handle forward to decrease moldboard angle.

When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position. Holding–When releasing the handle, it will return to holding position.

Increase moldboard angle–Pull the handle backward to increase moldboard angle.

When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position.

Handles 9 and 10 control the clockwise and anti-clockwise rotation of

moldboard

Rotate moldboard anti-clockwise–Push the handle forward to rotate the

moldboard anti-clockwise. When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position. Holding–When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position.

Rotate moldboard clockwise–Pull the handle backward to rate the moldboard clockwise. When releasing the handle, it will return to holding position. Then the moldboard will return to the selected position.

Caution: Prevent the frame ladder, wheel and trapezoidal pull rod from being damaged by moldboard during operation.

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Handles 11 and 12 control the leftward and rightward sideshift of moldboard

Leftward sideshift of moldboard–Push the handle forward to make moldboard

move leftward. When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position. Holding–Whenever the handle is released, it will return to holding position.

Rightward sideshift of moldboard–Pull the handle backward to make moldboard

move rightward. When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position.

Handles 13 and 14 control the leftward and rightward articulation steering of

wheel

Left articulation–push the handle forward to make the back of machine move

lefttward. When releasing handle (17), it will return to holding position. Then the machine will stay at the selected position. Holding–When releasing the handle, it will return to holding position. Then the machine will stay at the selected position.

Right articulation–Pull the handle backward to make the back of machine move

rightward. When releasing the handle, it will return to holding position. Then the machine will stay at the selected position.

Caution: Prevent pulling the right articulation steering to the maximum position during operation.

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Handles 15 and 16 control the leftward and rightward lean of wheel

Leftward lean of wheel–Push the handle forward to make wheels lean

leftward. When releasing the handle, it will return to holding position. Then the wheels will stay at the selected position. Holding–When releasing the handle, it will return to holding position. Then the wheels will stay at the selected position.

Rightward lean of wheel–pull the handle backward to make wheels lean

rightward. When releasing the handle, it will return to holding position. Then the wheels will stay at the selected position.

Caution: Try your best to avoid the simultaneous operation of wheel lean turn and steering wheel turn. If the front wheels need lean to the limit position and turn at the same time, lean the front wheels to limit position at first, and then control steering wheel to turn. The reverse operation order will be easy to cause damage of steering oil cylinder.

Handle 17 and 18 control the fall and lift of bulldozer (Optional)

Fall of bulldozer–Push the handle forward to make bulldozer fall. When releasing

the handle, it will return to holding position. Then the bulldozer will stay at the selected position. Holding–When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position.

Lift of bulldozer–Pull the handle backward to lift bulldozer. When releasing the

handle, it will return to holding position. Then the bulldozer will stay at the selected position.

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Handle 19 and 20 control the fall and lift of right moldboard

Fall of right moldboard–Push the handle forward will make the right moldboard fall. When releasing the handle, it will return to holding position. Then the moldboard will stay at the selected position. Holding–When releasing the handle from fall or lift position, it will return to holding position. Then the moldboard will stay at the selected position.

Lift of right moldboard–pull the handle backward to lift the right moldboard. When releasing the handle from fall or lift position, it will return to holding position. Then the moldboard will stay at the selected position.

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Right Function Panel The right function panel is located at the right side of driver seat and consists of engine hand throttle, gearshift control handle, parking brake button, fuel level gauge, voltmeter, work hour meter, start switch, A/C control panel and a group of seesaw switches. 2

1 1.

4

3

6

5 1

9 1

7

8

Engine Hand Throttle When the engine throttle can’t move, press the button on the top of engine hand throttle handle, pull the handle backward and then the engine speed increases.

2.

Gearshift Control Handle Handle

Shifting the handle forward/backward could make the vehicle travel forward (the handle is at “V” position)/backward (the handle is at “R” position); the middle position is neutral (the handle is at “N” position). The figures 1, 2, 3, 4, 5 and 6 in above figure indicate different positions of forward gear, and figures 1, 2 and 3 indicates the different positions of reverse gear. Neutral/Start Interlock Protection Function The electrical system of complete vehicle has neutral/start interlock protection function, namely only when gearshift control handle is set at neutral, the engine could be started. This function could prevent the accident caused by sudden action of vehicle when it is starting.

Caution: When the gearshift control system has any trouble, please don’t disassemble it by yourself. If it is unable to eliminate the trouble, please contact our appointed service station or after service company for 64

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maintenance.

3.

Parking Brake Button

Parking brake button (hand brake) is on the right function panel. When pressing it, the parking brake engages and the brake is applied; when pulling it up, the parking brake releases and the brake is relieved. Parking brake is also used as emergency brake. In the case of emergency during operation of machine, manually press parking brake button to apply emergency brake. If the gearbox is at gear 1 or gear 2 at that time, it will apply neutral automatically.

Caution: Unless the traveling brake fails to work, the parking brake can’t be engaged during traveling. Using the parking brake as traveling brake in normal operation will cause severe damage of brake system. 4.

Voltmeter

The voltmeter indicates the voltage condition of complete machine power. The normal power voltage is about 26V. When the voltage is less than 24V or more than 30V, the voltage alarm indicator lamp will flash to alarm.

Caution: When alarm for low voltage or high voltage is detected, please stop the machine on a safe place which is facilitate for maintenance and check it. 5.

Fuel Level Gauge

Fuel level gauge indicates the fuel level of complete machine. The fuel level achieves the maximum when fuel level gauge indicates “1” and achieves the maximum when the gauge indicates “0”. When the indication of fuel level is less than “0.2”, it is time to refill fuel.

6.

Work Hour Meter It indicates the work hour of complete machine in hour. The range of work hour meter is 09999.99 hour(s). When the start switch is on and the instrument assembly is electrified to work, the work hour meter begins to time at the same time.

7.

Start Switch See section “Start Switch” of Equipment and Instrument & Meter of Machine for details. 65

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A/C Control Panel

(1)

(2)

(3)

(4)

(5)

(1) Power switch; (2) Wind speed switch; (3) Display screen; (4).Cool-heat change-over switch; (5)Temperature control switch. (1) Power switch: A/C system will be turned on/off when pressing the switch upward/downward. (2) Wind speed switch: the wind speed of A/C system will increase/decrease when pressing the switch upward/downward. There are 3 gears. Low-speed position: the fan provides a constant wind volume and the blowing speed is set at low-speed mode. Medium position: the fan provides a constant wind volume and the blowing speed is set at medium-speed mode. High-speed position: the fan provides a constant wind volume and the blowing speed is set at high-speed mode. (3) Display screen: the display screen shows the condition (cooling or heating) of A/C system, set temperature, current temperature, etc. (4) Cool-heat change-over switch: pressing upward/downward the switch will set the A/C system at heating/cooling mode. (5) Temperature control switch: pressing upward/downward the switch will increase/decrease the set temperature.

Caution: When A/C switch is turned on, no matter which condition (cold or warm) the room temperature adjusting rod is set at, the compressor of A/C is always working. For saving energy, when heating mode is applied, the A/C could be turned off. Warm Water Valve of A/C System The heating function of A/C system is realized by way of heat release when engine coolant gets through the evaporator of A/C system. Install a manual warm water valve on water intake pipe. Manual Warm Water Valve Manual valve (water return)

Manual valve (fetch water)

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When heating is required, open the manual warm water valve at first (the handle has the same strike as the pipeline). When repairing A/C system with troubles, close the manual warm water valve at first (the handle is vertical to the strike of pipeline) so as to avoid leakage of engine coolant. When replacing engine coolant, open the warm water valve and solenoid water valve so as to replace the coolant in evaporator and assure the accurate level of engine coolant.

Warning: If no antifreeze coolant is filled in engine coolant when the ambient temperature is below 0℃ and the engine doesn’t work, drain the water tank of engine, open warm water valve and solenoid valve at the same time and drain the coolant in evaporator, or else, the piping of radiator will be cracked due to excessive low temperature! 9.

Seesaw Switch (1)

(1)

(2 )

(3 )

(4 )

Parking lamp switch

When the parking lamp switch is engaged, all of the left/right turn indicator lamps will be on (7 (5 (6 at the same time, which could be for emergency stop in the case of ) used as ) alarm ) emergency.

(2)

Front windscreen wiper switch

This switch controls the front windscreen wiper to be turned on/off.

(3)

Water spray switch

Press the control switch of sprinkler, and then the injector works and spray water to front windscreen. After being released, the switch will return automatically and the sprinkler stops spraying water. The water tank of sprinkler is installed at the left lower place of cab. Water tank of sprinkler

Warning Frequently check if the water in water tank of sprinkler is used up to avoid poor driving sight due to there is no water could be used to clean the windscreen. When the ambient temperature is below 0℃, drain the water tank of sprinkler 67

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or refill coolant in water tank, or else, sprinkler will fails to work as it is frozen or even been broken!!!

(4)

Rear windscreen wiper switch

The rear windscreen wiper switch has 3 positions: stop, low-speed and high-speed. The wiper could return automatically when “stop” is applied. (5)

Forced lubrication switch One lubrication cycle could be started at any time when this switch is pressed. This condition is only for the time when electric switch lock is electrified by power supply. This switch has a latch which makes the switch stay at the electrification position. For turning off the switch, this latch must be pressed down.

Forced lubrication switch is turned on

(6)

Rotation signal lamp switch

The rotation signal lamp switch controls the rotation signal lamp on left rear part of cab roof to be on or off.

(7)

Buzzer mute switch

The buzzer mute switch controls the sound of alarm buzzer to be sound or mute.

Warning: Don’t turn on buzzer mute switch to set the buzzer to be mute during normal operation or traveling, or else, there would be potential danger!

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Other Control Devices

1

3

2

5

6 7

1. 2. 3. 4. 5. 6. 7.

4

Steering wheel Steering combination switch Cigarette lighter Accelerator pedal Parking brake pedal Adjusting rod of steering column Lockpin pedal

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Steering Wheel

The steering wheel adopted by this machine is normal. It is in the cab and connected with full hydraulic steering gear. After being turned, the steering wheel can’t return automatically and its steering angle will stay the same. Thus, after the turn of machine finishes, turn the steering wheel anti-clockwise to make the machine travel smoothly.

Steering Combination Switch For turning left, pull the steering combination switch downward. Then the left turn indicator lamp flashes and the front/rear left turn lamps flash at the same time; For turning right, push the steering combination switch upward. Then the right turn indicator lamp flashes and the front/rear right turn lamps flash at the same time; Pull the steering combination switch to medium position to make the turn indicator lamp go out.

Steering combination switch Cigarette lighter

Cigarette Lighter One cigarette lighter is installed on the central control panel below steering gear in the machine. After being pressed, the cigarette lighter will be electrified to heat. After heating, the electricity will be cut off automatically and the cigarette lighter will popup. Then it could be pulled out.

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Accelerator Pedal

The accelerator pedal is located at right front of driver seat. Press the accelerator pedal to increase the fuel supply volume of diesel engine; release it to decrease the engine speed.

Traveling Brake Pedal

Traveling brake pedal is located at the right front of driver seat. Press the traveling brake pedal to carry out stop by wheel rim brake of front/rear driving axles. The brake lamp is on at the same time. Release the traveling brake pedal to release traveling brake.

Adjusting Rod of Steering Column

Adjusting rod

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The inclination angle of steering gear of this machine could be adjusted forward/backward/upward/downward within certain range to meet different operation customs of drivers. The adjusting method is as follows: 

Step the adjusting rod downward and loose the steering gear.



Keep the foot staying at adjusting rod and adjust the steering wheel forward/backward/ or upward/downward to proper position.



Release adjusting rod and tight the steering gear.

Lockpin Pedal

When the moldboard is scraping the side slope and swinging around the rocker, lock it to required working position by stepping the lockpin pedal.

Engine Water Temperature Adjustable System (Optional) 1.Description of label position: The sticking position is as follows: 1.1 74A2061 is adhered to the left of panel platform of control console. The specific position is shown as the figure.

1

2

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1) Label 74A2061 2) Panel of control console 1.2 74A2067 is adhered to the right upper corner of panel of right control box. The specific position is shown as the figure.

1

2

3

1) 2)

Panel of right control box Adjusting knob for engine water temperature Adjusting knob for engine water temperature (namely adjusting knob for fan speed). When adjusting the gears from gear I to gear IV, the fan speed will increase step by step, namely the engine water temperature will change from high to low step by step. 3) Label 74A2067 2. Instructions for Replacement of Engine Water Temperature Adjusting Knob: 2.1 Instructions for disassembly and installation: Remove the old knob according to the follow method: 2.1.1 First remove the screw 1 right above the knob with cross screwdriver. The specific operation is shown as the figure:

1

1) 2)

2

Cross screwdriver Screw 1

2.1.2 Remove the screw and take off the knob handle 2 and white indicator plate 3.

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1) Knob handle 2 2) Indicator plate 3 2.1.3 Remove the lower screws 4 (2 screws) with cross screwdriver, take off the cover plate 5 of switch, and then the knob could be removed from the whole control box panel as the figure shows:

1

2

3

1) Screw 4 2) Cover plate 5 of switch 3) Switch body 6 2.1.4 Remove the right control box panel in figure 1 with screwdriver and pulled out the connector (connected with control box) of knob in figure 2. At this time, the whole old knob is removed. Then connect the new knob connector with connector of control box properly.

Figure (1)

Figure (2)

2.1.5 Properly connect the connector, repeat the operations of 2.1.1 and 2.1.2, remove the switch cover plate 5 of new knob and put the switch body 6 through the mounting hole (knob) to connect it with switch cover plate 5 by screw 4 so as to block the knob on right control box panel. Then fix the whole switch on right control box panel with screw, properly mount the indicator plate 3 and knob handle 2 and fix them with screw 1; at last fix the cover plate of 74

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control box to complete the replacement of knob switch.

Fixing hole of knob switch 2.1.6 Stick the label 74A2067

Electric Warming A/C System (Optional) 1.

Operation of A/C Control System The panel of right control box is divided to 2 parts: A/C control panel and electric warming switch 1.1 Position and symbol description of A/C control panel

Fig. 3-1 A/C control panel

1

2

3

4

5

1. Power switch 2. Wind speed switch 3. Display screen 4. Cool-heat change-over switch 5. Temperature control switch. 1.2 Position and symbol description of electric warming switch

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Fig. 3-2 Electric warming switch

6 2. Instructions for A/C System Operation 1. Power switch: position 1 shown in fig. 3-1. A/C system will be turned on/off when pressing the switch upward/downward. 2. Wind speed switch: position 2 shown in fig. 3-1. The wind speed of A/C system will increase/decrease when pressing the switch upward/downward. There are 3 gears. 3. Display screen: position 3 shown in fig. 3-1. The display screen shows the condition (cooling or heating) of A/C system, set temperature, current temperature, etc. 4. Cool-heat change-over switch: position 4 shown in fig. 3-1. Pressing upward/downward the switch will set the A/C system at heating/cooling mode. 5. Temperature control switch: position 5 shown in fig. 3-1. Pressing upward/downward the switch will increase/decrease the set temperature. 6. Electric warming switch: position shown in fig. 3-2. There are 4 uniform switches whose functions are the same. One switch corresponds to one electric heat wire. The more switches you pressed, the better warming effect could be felt.

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Others Seat

Caution: The driver’s seat provided with the machine is in accordance with the corresponding grade of ISO7096. The driver’s seat with the function of suspension shock absorption can be adjusted forward and backward and in the height direction as well. The backrest angle and the head cushion height can also be adjusted to suit different drivers and various working situations. Seat adjustment, which enables the foot to reach the total excursion of the pedal, should be carried out when the driver is seated against backrest. A.

Forward and backward adjustment (-60mm~60mm)

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Tilting angle adjustment of armrest (0~90°, the reference direction is horizontal)

Caution: The armrest of the seat cannot be seated, as its maximum bearing capacity is 50kg. C.

Height adjustment of the front part of the seat (0~60mm)

D.

Height adjustment of the rear part of the seat (0~60mm)

E.

Bipolar adjustment of the head cushion height (0~40mm and 40mm~80mm)

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Angle adjustment of head cushion (0~10°)

G. Tilting angle adjustment of backrest (0~45°, the reference direction is vertical)

H.

Non-telescopic safety belt

I.

Weight stiffness adjustment (50kg~120kg)

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Safety Belt Caution: The machine is equipped with safety belt before it is transported to the destination from Liugong. The safety belt and its mounting instructions are in accordance with the ISO6683 standard during the mounting. The safety belt set on the machine is non automatic telescopic. Tie the safety belt before operating the machine. Check the wear and tightness of the safety belt before using it. Replace it if necessary. Consult the Liugong agency about replacement information of safety belt. Adjust the length of the safety belt before using it to ensure its safeguard function and the comfort for the driver. Adjust the height of the belt by moving the position of the locking tongue at the safety belt. The locking device of the safety belt is on the right rear side of the seat. Insert the locking tongue of the belt into the opening of the locking device and the locking device will be jammed. Press down the red button beside the opening of the locking device, and the locking tongue will jet out from the locking device. Check if the locking device of the safety belt can be locked and released normally before using the belt.

Audio System Audio system, set inside the cab, is composed of mainframe, loudspeaker and antenna. mainframe loudspeaker’s position

Left loudspeaker

1 2 3

6

7

4

8

5

9 81

10

Right loudspeaker

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①power/mute ②audio effect ③play ④disc/tape cassette ⑤forward/rewind ⑥volume ⑦preset ⑧LCD display ⑨preset ⑩radio combined key

Audio system

Power\mute key

Press this key to turn on the audio and press it down for 2 seconds to cut off the power. Press the key temporarily to mute the player. Press once more to cancel the mute state.

Volume control Press “VOLUME + ” key and the volume will increase gradually. Press “VOLUME–” and the volume will reduce gradually.

Caution: Select proper volume to avoid traffic accident. Audio effect

(1)Audio mode select Press “SOUND” key once and the screen will display “ROCK”. Select and self-define the sound mode by pressing the volume key. 

BASS-TRE–Self-define base and top sound mode



FLAT–Original audio mode



JAZZ–Jazz music mode



VOCAL–Speech mode



POP–Pop music mode



CLASSIC–Classic music mode



ROCK–Rock music mode

(2)Volume balance of the left and right loudspeaker Press “SOUND” key twice and the screen with display “BAL”. Adjust the volume balance of left and right loudspeaker by pressing the volume key. 

7--–Left loudspeaker reaches the highest volume while right loudspeaker the lowest.

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-0-–The volume of left and right loudspeaker is well balanced.



--7–Right loudspeaker reaches the highest volume while Left loudspeaker the lowest.

(3)Audio frequency adjustment Press “SOUND” key three times and the screen will display “FADER”. Adjust the audio frequency by pressing the volume key. 

--7--–Highest



-0-–Original audio



7 –Lowest audio

audio

(4)High and low volume mode selection Press “SOUND” key four times and the screen will display “LOUD”. Select volume mode by pressing the volume key. 

OFF–Cancel volume mode



HI–High volume mode



MID–Middle volume mode



LOW–Low volume mode

Reception of Radio

Band selection

Press “BAND” key to select the band.

Automatic search



Press “” key to enter the low-frequency automatic search status,and press “” to enter the high-frequency automatic search status.



Continue to press these two keys to search for other station.

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Manual search (if frequency of the required station is known)



Press “” key or “” key for about 2 seconds to enter manual search status.



Press “” key to enter low-frequency station search status, and press “ ” key to enter high-frequency station search status.



The system will return to the last operation status automatically if no search action is conducted within 5 seconds.

Station storage

6 stations can be stored by adjusting the preset key (1~6). 

Manual storage Turn the radio to required station. Select a preset key and press it down for 2 seconds to store the present station.



Automatic storage In the status of reception, 6 stations of FM band and 6 stations of MW (AM) band can be stored. When any new station is stored automatically, the former station will be automatically replaced.

Press down “AST” key

to enter automatic station storage setting status.

Play of Audio Cassette

Play

Insert the tape into the audio cassette with the opening facing right and start playing.

Play stop

Press down “▲” key to stop playing and part of the tape recedes. 84

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Reverse play

Press “” key and “” key at the same time, and the other side of the tape will start playing.

Forward and reverse

Press “” key or “” key to conduct the forward and backward play, the direction of which is subject to the play direction of the tape. Indicator lamp shows the play direction

action



Forward





Reverse





Forward





Reverse



key

After the operation of forward and backward play, the audio will turn to playback automatically. Press the other “” key or “” key which is not pressed down to stop the operation of forward or backward play and the audio will return to normal playback. Automatic reverse side play After the play of one side of the tape finishes, the other side will start to play automatically.

Caution: The dust accumulated at the magnetic head after long term use will affect the play effectiveness. Clean the magnetic head with clean tape periodically. (Once or twice a month)

Warning This sound system will be damaged if wet with water. Therefore, take care not to spray water onto it when washing the machine. It is easily damaged by a loose tape. Therefore, do not use tape C-120 to avoid damage. When taking out the tape after turning off the audio, do not put the tape at magnetic place to prevent the tape from being erased. Keep metal pieces such as iron or screwdriver away from the playback head. 85

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When the machine is running with high-power output for a long time, the temperature of the frame may add up to about 70℃. Therefore, do not touch the frame.

Lamps The lamps of the machine consist of front combination lamps (left and right respectively), rear combination lamps (left and right respectively) and room lamps. Front combination lamps include front overhead lamp, front small lamp, headlamp, front steering lamp and front working lamp.

1 2

3 4 5 ①front overhead lamp ②front small lamp ③headlamp ④front steering lamp ⑤front working lamp Rear combination lamps include rear overhead lamp, rear small lamp, rear steering lamp, night travel lamp, brake lamp and working lamp.

6 7

9 8 ⑥ rear overhead lamp ⑦ rear steering lamp ⑧ brake lamp ⑨ rear small lamp

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Indoor lamp

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Door Lock

The key to opening the door is the same with the key to opening the left and right door. At the moment, insert the key, turn it clockwise to 180°and take it out. Hold the door lock, press the lock downward with the thumb, and pull the door outward to open the door. The lock can not be pressed down when the door is locked. To lock the door, first close the door, then insert the key and turn it anti-clockwise to 180°and take it out.

Positioning Lock When the left and right doors are opened to 180°, the positioning lock on the door will touch the locker outside the cab and be jammed so as to fix the door at this position. The pull rod of the positioning lock is in the middle of the door. When the positioning lock is locked, pull the pull rod downward, then the positioning lock will be released and the door will be closed.

Positioning lock

Locker

Pull rod

Warning: For the sake of security, make sure the left and right doors are closed when the driver is operating the machine. 88

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Rearview Mirror There is a rearview mirror respectively on the top, left and right side of the cab. Adjust the mirror before operating the machine to ensure the driver a good rear view.

Rearview mirror adjustment: Screw down the bolt that connects the bearer of the rearview mirror and the cab and turn the bearer to adjust the relative mirror position to the cab; Screw down the bolt that connects the rearview and the bearer and turn the rearview mirror to adjust the tip range of the mirror; Screw up the bolt after the above adjustment is finished.

Overturned Engine Hood The electric hoist device of overturned engine hood, set on the right rear part of the machine, is composed of hoist actuator and hoist control box, which is located in the battery box on the right side of the machine.

Hoist switch

Hoist control box

When opening the engine hood to carry out maintenance, open the cover of right side battery box first and then you can see the hoist control box. The hoist switch set on the control box panel is inching switch. The hoist actuator will drive the engine hood to hoist when the hoist switch is pulled upward. The hoist actuator will drive the engine hood to descend when the hoist switch is pulled downward. Release the hoist switch and it will reset automatically. The hoist actuator will keep the engine hood at the selected position.

Caution: When the engine hood hoists or descends to extreme position, the electric mechanism will crack with a sound of “clapping”, which shows that the clutch of the electric mechanism skids. Release the switch timely and it will return to the neutral position automatically to avoid damage to the electric 89

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mechanism. No standing behind the engine hood when the hood is in reardump and return status!!!

Automatic Reverse Alarm System

Automatic reverse alarm system, set at the rear part of the machine, will sound automatically during operation of the gearshift control handle to reverse the machine.

Warning: As the automatic reverse alarm system is close to the radiator, stop the engine to cool down the radiator before adjusting the reverse alarm system.

Small Tool Box A small tool box used for storing common tools is set on the left side of the driver’s seat.

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Starting of Engine Check Before Starting Engine 

Check the liquid level of engine radiator.



Check the oil level of engine.



Check the oil level of hydraulic oil tank.



Check the oil level of transmission system.



Check the sealing status of each oil tube, water tube and fuel tube.



Make sure the tyre air pressure is normal.



Check if the storage battery has damaged wire or loose connector.



Check the throttle pedal standard.



Adjust the articulation steering, that is, keep the front wheel and rear wheel in a straight line.



Check the front wheel lean and adjust it vertical.

Starting of Engine Caution: Before starting the engine, make sure no one else except the operator is on the motor grader or works near the motor grader. Keep the motor grader under control of the operator all the time. 

Switch on the negative switch. When the negative switch is engaged, the switch handle will point to the “I” position on the switch panel.



Climb up and down the ladder according to the relevant safety regulations.

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Adjust the driver’s seat to a proper position.



Close the left and right door of the cab.



Check if the safety belt is normal and well tied.



Check if the gearshift control handle is set in neutral position. If not, pull it to the neutral position.

Caution: The machine has the function of neutral/start interlock protection. Namely, the engine can be started only when the gearshift control system is set at the neutral position so as to avoid accident caused by abrupt action during start-up of the engine. 

Turn the fan switch and the air conditioner switch of the air conditioning system to the position of “OFF” (shut down).



Insert the key into electric lock and turn it clockwise for a grid to the position of “ON” to electrify the machine and sound the horn, announcing that the machine is about to start and 92

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others should not get close to it.



Step down the throttle pedal slightly and continue to turn the key clockwise a grid to the “START” gear to engage the diesel start motor. In normal conditions, the engine will start working in 10 seconds. At this time, release the start electric lock to let it return to its original position.

Caution: The time to start the motor each time should not exceed 30 seconds; an interval of at least 2 minutes should be reserved between every two starts and it is not allowed to start the motor for more than consecutive 3 times; restart the motor after 3 minutes if consecutive 3 starts are unsuccessful. Otherwise, the service life of storage battery will be reduced and the motor may be damaged. 

    

Full load operation is allowed when the machine is being warmed for at least 5 minutes with idle speed (650~750rpm) after started. If the hydraulic system is slow in action, more preheating time is needed. Preheat the hydraulic oil in severe cold weather. Move all the control devices and preheat the oil repeatedly through hydraulic oil tank and hydraulic oil tube. During low speed operation, listen if the engine works normally and if the gearbox has abnormal sound. Check if each instrument works well and if the illuminating device, indicator lamp, horn, screen wiper and the brake lamp work normally. Check if the travel brake and the brake parking system work normally. If there is no obstacle around the machine, turn the steering wheel slowly and check if the machine has the action of left and right steering.

Operation Technology Operation Information 

   

During operation of machine, comply with the following basic instructions: In case of any casualties, make sure there isn’t any other person on the machine or working near the machine with exception of the operator. Always keep the machine under the control of operator. Devices such as moldboard and bulldozer shall be lifted high enough to keep away from obstacles. Before releasing parking brake button, press on the service braking pedal to prevent the machine from moving. Keep a good field of vision and best stability of traveling machine. Lower down the speed of engine when climbing over a hill and turning. 93

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Warning: The falling objects may lead to casualty. Clear off any suspension and roll the materials carefully.

Traveling of Machine  

Operate the control handle of operating cylinder, and lift devices such as moldboard and bulldozer high enough to keep away from obstacles and travel on a flat ground. Press on the service braking pedal and pull out parking brake button at the same time to release parking brake. Release the service braking pedal slowly, and observe whether the machine is moving.

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Pull out parking brake button

Caution: If the machine is moving, press on service braking pedal immediately and press the parking brake button to carry out braking. Then check if there is any malfunction of shifting control system of this machine. 

Select the traveling direction and speed by adjusting the position of gearshift control handle.

Caution: This machine can be started only when it is engaged to forward gear 1, forward gear 2 or reverse gear 1, reverse gear 2. 

Drive the machine to a flat, open place and rotate the steering wheel to check if the machine can carry out left/right pivot steering.



Check the service braking performance. Travel with a speed of forward gear 1 or forward gear 2. First release the accelerator pedal, and then slowly press on the service braking pedal, the machine shall slow down obviously and stop.

Caution: If the machine doesn’t slow down obviously after pressing on the service braking pedal, please press the parking brake button immediately to carry out emergency brake, so as to ensure safety by forcing the machine to stop. 

Check for the engagement of each gear. Respectively engage each gear to check the response of shifting. This machine is equipped with manual electro-hydraulic-powered shifting control system. The shifting of each gear shall comply with the following rules:

Starting Speed-limit Rule The highest speed of the starting of machine is limited to gear 2. After starting, the machine can be engaged to gear 3 or gear 4 only if the traveling speed is up to the limit. Although engaged to gear 3 or gear 4, the machine is still traveling at a speed of gear 2.

Gearshift Rule When changing traveling direction, the speed is required to be less than 10km/h. The forward gear 1 and gear 2 can be directly engaged to the correspondent reverse gear at any time (F1〈=〉R1 and F2〈=〉R2). As for forward gear 3 and gear 4, the shifting procedure of shifting system is: shift to gear 2 at the current traveling direction, and engage to gear 2 at the opposite direction after a while. In this way, the gear may be shifted to the preset gear.

Caution: During the operation of shifting, release the accelerator pedal first before operating the gearshift control handle for gear shift, so as to protect the gearshift clutch. 95

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Steering of Machine For left turning, pull the steering combination switch frontward; for right turning, pull the steering combination switch backwards. (As shown in the following figure), by that time, the correspondent turn lamps at the front/rear part of the machine and the correspondent turning indicator lamps on the instrument assembly will be lit up, indicating to the vehicles and passers-by around that this machine is about to conduct operation of steering . Left turning

Combination witch

Right turning

Rotating the steering wheel, the operation of steering will be carried out immediately. The faster the rotating speed of steering wheel is, the machine will steer faster. When the steering is finished, rotate the steering wheel in the opposite direction to make the machine travel in a straight direction. Turn the combination switch to the neutral position, the turn lamps and turning indicator lamps will be off immediately. When conducting steering at a high traveling speed, in order to ensure the safety of traveling, the accelerator pedal must be released before the operation of steering, if necessary, use service brake to slow down the traveling speed of machine.

Warning: It is forbidden to conduct steering on a slope. Drive the machine to a flat ground for carrying out these operations.

Braking of Machine For the braking of machine, release the accelerator pedal first, and then slowly press on the brake pedal to conduct service braking.

Warning: When the machine is traveling at a high speed, unless the presence of emergency, don’t press the brake pedal down to the bottom suddenly in case of safety incidents and damage of machine due to sudden braking.

Operation of Downslope To avoid interruption of engine lubricating resulting in inadequate lubrication, the working grade of motor grader shall not exceed the following degree. It is because the poor lubrication may lead to accidents of engine. 96

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Longitudinal Slope

Left or right

Frontward

Backwards

20 degree

25 degree

25 degree

Before downslope, please chose a suitable gear, and don’t shift gear during the downslope traveling. In most cases, the upslope and downslope gears are the same. Keep a sufficiently low downslope speed. During downslope traveling, if the machine speed increases, use the service brake to control the traveling speed of machine. When the machine is traveling at a high speed, the utilization of service brake will make the brake and driving axle overheated, bringing serious abrasion or damage to the brake.

Operation of Machine 1.

Preparation Before Operation Before operation, use this machine to flatten the worksite, eliminate the bumps, fill the pits, and weed the slippery ground surface. Clear off the large and sharp stones on the worksite to prevent the tyre from scratch. 2. Adjustment of Moldboard The operation of swing oil cylinder may give the moldboard various operating positions to meet the needs of operation. The moldboard can extend and retract from left and right side, and rotate at any angle and slew at 360 degrees.

Caution: When moving moldboard, don’t damage the frame ladder, wheel and trapezoidal rod. 3.

Adjustment of Tilting Angle of Moldboard Cutting Edge This motor grader is equipped with hydraulic angular device. Operation of control handle in the cab will enable the moldboard cutting edge to change the extension and retraction of oil cylinder, so as to realize the adjustment of tilting angle of moldboard cutting edge to meet the needs of operation.

Through the adjustment of tilting angle of moldboard cutting edge, the accuracy of moving material and flattening will be ensured, so as to achieve the best effect.

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Fig. a indicates that the moldboard cutting edge forms an acute angle with the ground. This position is used for digging and moving the wet soil, ditching and pushing the mound aside. Fig. b indicates that the moldboard cutting edge forms a middle-size angle with the ground. This position is used for flattening and pushing the loose soil aside. Fig. c indicates that the moldboard cutting edge nearly forms a right angle with the ground. This position is used for maintenance of gravel surface and improvement of flattened surface. Operation of Rear Scarifier (Optional) If this machine is equipped with rear scarifier, there will be a rear scarifier lifting indicator (as shown in the figure) under the steering wheel which will indicate the lifting state of scarifier. There are five teeth on the rear scarifier. Generally, three teeth are used on the hard ground and each of them shall be in symmetry during utilization. For example: use the middle tooth or the two lateral teeth, or use these three teeth together.

Rear scarifier lifting indicator

Traveling position: take off spring pin 1 and pull out the axis pin 2, so that each tooth will be located at the preset position. Then push the axis pin and insert the spring pin. Thus, the teeth will be retracted inwards, and the scarifier will be completely lifted. Scarifying position: the motor grader is in a horizontal status and the teeth are extracted out on the ground. Scarifying: put the scarifier on scarifying position, press the scarifier down by operating control handle and fix it at one position. Drive the motor grader frontward and lower down the rear scarifier at the same time, so as to put it down into the earth. The operation rod controls the lifting of rear scarifier while the hardness of soil determines the amount of teeth used by scarifier, the depth down into the earth and the traveling speed.

Traveling Position

Scarifying position

Scarifying

Caution: Before steering and reversing of motor grader, the rear scarifier shall be lifted 5.

Operation of Bulldozer (Optional) The control level is in charge of the bulldozer (lifting and falling). The bulldozer is connected 99

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to the front frame by high strength bolt. See section of Operating Control Handle for details.

Special Applications Application of Tiltable Front Wheel The tiltable front wheel has a special effect in helping to keep the machine traveling under the control of operator.

Application of Tiltable Front Wheel in Steering When traveling on level surface, start the motor grader and keep it engaged at gear 1. When the wheel is vertical, the left turning or right turning can be realized by quickly tilt the front wheel, instead of operating the steering wheel. The characteristic of tilting of the front wheel enables independent steering. When steering at 90° or turning around along the Y lane, cooperate with steering wheel to make steering much more easier. When turning right, quickly tilt the front wheel rightwards.

Application of Tiltable Front Wheel in Operation During the operation, a lateral component force will be formed, guiding the front end of the machine to the load. Therefore, the operation of tiltable front wheel will make up with the lateral component force to keep the machine traveling on a straight line. If the front end turns right, tilt the front wheel leftwards to keep the machine on a straight line. For example: when the materials move leftwards, the front end of machine will turn right. In that case, tilt the front wheel leftwards to keep the front end stable, as shown in the following figure.

No matter the machine is on a level surface, a slope or in a ditch, the simple rule for tilting of front wheel is: when the front end is inclined to stray away from the straight line, tilt the front wheel in the opposite direction to come over this inclination and keep the machine on a straight line.

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first and then operate the steering wheel for steering. If operate the steering wheel before tilting the front wheel, it is likely to damage the steering oil cylinder.

Application of Articulation When being used on level road, the articulation has two obvious advantages: the first one is that it can resist to the lateral component force as the tilting of front wheel; the second one is that it will make the operation of machine much easier. Normally, during the excavation of moldboard, a lateral component force of tractive force will be generated, guiding the front end of motor grader to the load. The articulation can be used to neutralize this inclination and keep the machine traveling on a straight line. If the front end turns right, articulate the rear components leftwards to keep the machine on a straight line. No matter the machine is on a level surface, a slope or in a ditch, the simple rule for articulation is: when the front end is inclined to stray away from the straight line, articulate the rear components in the opposite direction to come over this inclination and keep the machine on a straight line.

Application of articulation during operation When traveling on level surface, start the motor grader and keep it engaged to gear 1. When the rear components are in the neutral position, the left turning or right turning can be realized by quickly articulate the rear components, instead of operating the steering wheel. The articulation may also be used with tiltable front wheel together to further reduce turning radius. When using tiltable front wheel and articulation for steering, articulate rightwards if tilt rightwards and turn the machine rightwards. If the machine needs to turn left, conduct operation in the reverse way.

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The machine turns right when only articulation is used.

Turns right when using articulation, steering wheel and tiltable front wheel.

Side Slope Scraping Rocker

Right lifting cylinder

Left lifting cylinder Swing oil cylinder

The left and right lifting cylinders are fixed at the rotary table assembly of drawbar, and the rocker indicator is located facing the cab. Thus, without leaving cab, the operator can use three control valves together to change the moldboard from normal flat position to the desired position as position 1, 2, 3, 4, 5, and 6 as shown in the following figure. During the operation of scraping side slope, carefully comply with the following procedures: (1) Start the motor grader when it is on flat position. (2) First, put the moldboard flat on the ground and keep it sufficiently touching the earth. Besides, make sure there isn’t any interference between the moldboard and components such as frame ladder, wheel and trapezoidal rod. (3) Always move the moldboard leftwards/rightwards. (4) Put the moldboard cutting edge on the ground stably, and put the moldboard at the outside of frame by operating the control handle which controls the clockwise and anti-clockwise rotation of moldboard. (5) Put the moldboard on the ground, press on the lock-pin pedal at the left lower side of 102

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steering wheel with left foot, and slightly operate the left/right lifting cylinder and swing oil cylinder in turn, to make one side of the moldboard touch the ground and the rocker rotate around the beam, so as to put the moldboard at the required position for operation. (6) When the rocker rotate to certain position, release the lock-pin pedal with left foot and insert it into any hole of the 6 long holes on the rocker (the position of hole various depending on the requirement of operation).

Caution: Don’t release the lock-pin pedal before aligning the lock-pin of rocker with the pinhole.

Lockpin pedal

Caution: When operating the left/right lifting cylinder, the end of piston rod shall not be higher than the oil cylinder barrel, otherwise the oil cylinder may be damaged. Warning: During side slope scraping, the maximum allowable tilting angle is 90°. The tilting angle of moldboard shall not exceed 90°; otherwise the oil cylinder may be damaged. For the sake of safety operation, it is suggested to conduct side slope scraping at right side.

Ditching When the moldboard cutting edge forms a certain angle, the furthest end frontward is called “toe” and the other end is called “heel”.

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Marked Depth The mark post of ditching line shall be marked according to the plan. The marked depth shall be shallow so that the straight ditching line will be done easier. This will help you with a precise straight line when you continue to dig a deeper ditch. For effective ditching, the cutter board shall be located by an angle of 45°; meanwhile the ‘toe’ of moldboard cutting edge shall be right behind the front wheel. The angle formed by the moldboard cutting edge shall be sufficient to finish the required digging depth, and the lifted ‘heel’ of moldboard cutting edge shall be able to form a mound inside and outside of rear wheel. Note: The top of front wheel shall be inclined toward the ditch. Times of Addition After marking the preliminary ditching line, try best to calculate the remaining depth of ditch. The pressure towards the “toe” of moldboard cutting edge shall be appropriate and the motor grader shall be stably operated with an ideal gear. Remember that the mound must be piled inside or outside of the rear wheel. Treatment of Mound After each digging, the soil shall be piled up or pushed forward to the middle part of road and kept away from operation. Don’t try to operate on the soft or loose mound which has been digged before, otherwise the tractive force will be lowered resulting in uneven pit. To save time, leave all the soil digged out before away from the pits. Reparation of Side Slope After ditching, the side slope shall be inclined. Locate the rotary table and moldboard cutting edge with the “heel” at the bottom of slope so that the soil will flow to the inside wheel of the right rear tandem box as shown in the figure. The “toe” of moldboard cutting edge shall be put frontward, facing the right front wheel. The top of front wheel shall be inclined to the slope. (This is an exception of the normal rules) Refining Back Slope If the ditch requires a flat V-type bottom (as shown in Fig.78 A), it is necessary to refine the back slope and get rid of the soil on the side slope. If it requires a flat-bottomed ditch, it is necessary to finish the remaining part of this section. Flattening Bottomed Ditch (1) It is necessary to dig another V-type ditch at the back slope of the first V-type ditch, (see 1 in Fig.79) (see profiles). Locate the moldboard cutting edge and move the soil to the top part of road. (2) When digging a flat-bottomed ditch, the moldboard cutting edge shall extend at maximum to make its whole length in the ditch. The “toe” is at the base plane of side slope 104

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while the “heel” is at the base plane of inside slope. This kind of operation will move the soil to the back slope. Removing Soil from Shoulder As requirement, conduct final finishing at the inside slope for one or two times to move the soil to the road and the outside of rear wheel. By that time, the hub is finished. Meanwhile, piled up the remaining soil or scatter it to the center of road.

Removing Snow This machine is not equipped with special snow blade for removing snow. If it is required to remove snow with moldboard, pay attention to the road condition all the time to prevent damaging the machine. During removing snow, it is suggested to: operate from the center of road first, and clear a way out before pushing the snow with one side of the moldboard for a wider way. When operate on a slope, the front wheel shall be inclined to the snow slope to achieve the best effect. As the condition of whether and transportation will probably make the fallen snow turn into thick ice, it is better to adjust the tilting angle of moldboard cutting edge to remove snow. Making the moldboard cutting edge basically from a right angle with the ground will highly enhance the efficiency of cutting ice.

Operation under Abnormal Condition Operation under Extremely Cold Condition Caution: If the ambient temperature is too low, it will be difficult to start the engine, and the radiator may be frozen.  

Use fuel, hydraulic oil and lubricating oil with low stickiness. See Specifications of Oil of this Operation and Maintenance Manual for the specific grade of oil. The coolant must be added with anti-freeze fluid. The precautions for using anti-freeze fluid are: don’t use anti-freeze fluid containing methanol, ethanol and propanol; never use any anti-leakage agent, no matter using independently or with anti-freeze fluid together; don’t mix the anti-freeze fluid with different grade together.

Warning: The anti-freeze fluid should be kept away from open fire, and don’t smoke while filling anti-freeze fluid. 



The precautions for using battery are: when the ambient temperature is lowered down, the capacity of battery will also be lowered down. If the charging rate of battery is too low and the electrolyte may be frozen, it is better to keep the charging rate close to 100% and keep the battery warm, thus it is easier to start the engine on the next day; at extremely cold area, use battery resistant to extremely cold. The precautions after finishing the daily work are: completely clear off the mud, water and snow on the machine. Prevent the sealing performance from being damaged due to the mud, water or snow entering the sealing; to prevent the vehicle from being frozen on the ground, park the vehicle at dry hard ground or wooden board; to prevent the capacity of battery from 105

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being lowered down, cover the battery and move it to a warm place, and install it before operation on the next day.

Caution: After finishing the daily work, clear off the mud, water or snow sticking on the machine, otherwise the operation of the next day will be affected by freezing. 

Precautions when the cold whether is finished: when it turns warm, all the fuel, hydraulic oil and lubricating oil should be changed with those with half-stickiness. See Specifications of Oil of this Operation and Maintenance Manual for the specific grade of oil.

Operation under Extremely Hot Condition The operation of machine under high temperature may leave the machine overheated. Monitor the temperature of engine and transmission. As long as it is necessary, stop the operation and give the machine a cooling period.  Frequently conduct inspection and maintenance for fan and radiator.  The level of coolant shall comply with the specification (keep within 10mm, calculating from the top of radiator). Check if there is any foreign substance such as dust, sand or insect. If there is, clear it off in time to prevent plugging the cooling line.  At extremely high temperature, it is easier for the cooling system to form corrosion of scale. Change anti-freeze agent regularly, and the preservative agent shall keep a good anticorrosive performance.  If necessary, wash the cooling system regularly to keep it clean. Avoid using water with high alkalinity in case of speeding up the formation of scale and corrosion.  If the machine is about to be shut down for several days, remove the battery and keep it at a cool place.  Don’t leave the machine in the sunshine for a long time. The feasible way is trying to park the machine at a shady place. If the shady place is not available, cover the parked machine with canvas to keep the engine compartment, transmission and hydraulic device from dust.

Operation at Dusty and Desert Area There are dust at almost every place of operation. But when operating at dusty and desert area, some extra precautions must be taken:  Keep the cooling fin and cooling area clean. If possible, frequently blow it with compressed air.

Caution: When using compressed air, wear anti-dust glasses.  



During conducting maintenance of fuel system, do pay attention to keep the fuel tank away from dust and sands. Frequently and regularly conduct maintenance towards air cleaner, check the air cleaner service indicator everyday, and keep the dust cap and dust gauze clean so as to keep the engine accessories and engine compartment away from dust and sands as much as possible. Conduct lubricating and maintenance according to the lubricating figure on the machine. Before filling lubricant, clean all lubricating parts. If there is sand at the lubricating part, it will speed up the abrasion of accessories. 106

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Try to keep away from sands and dust. The machine should be parked under shed, or be covered by canvas, so as to prevent damaging the machine by sands and dust.

Operation under Rainy or Moist Condition  

The procedure for operation under rainy or moist condition is the same as that of operation under extremely hot condition. Protect all exposed surface which is coated with preservative and lubricant. Especially pay attention to the damaged and un-coated surface. Protect the area with cracked paint or chip scratch as soon as possible to prevent corrosion.

Operation in Areas with Danger of Salt Corrosion Salt water and salt water spray have a great influence of corrosion. Thus when operating in areas with danger of salt corrosion, the following precautions should be complied with:  When the machine is exposed in salt water, wipe the machine and wash it with clean water.  Coat anticorrosive lubricating oil on all exposed surface. Especially pay attention to the surface with damaged paint film.  All paint surfaces are in good overhaul status.  Conduct lubrication to the machine according to the lubricating figure on the machine.

Operation at High Altitude Area  

Before operation, adjust the mixing ratio of engine fuel and air according to the relevant engine manual. Check if the engine is overheated. Properly seal the pressure cap to ensure the coolant pressure in the system.

Parking of Machine Getting Off the Machine 

When walking down from the machine, use ladder and rail, face the machine and use both hands. Before getting off, make sure there isn’t any crumb and sundries.



Check if there are any sundries in the engine compartment. Clear off all crumbs and scrip in case of fire.



Clear off all flammable debris to reduce the possibility of fire. Besides, depose this debris properly.



Turn the negative switch of battery to O position.



Install all covers and anti-destruction protective lock.

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Parking of Machine Short Term Parking 

Drive the machine to a flat place.



Use service brake to stop the machine.



Press the parking brake button to conduct parking brake.



Get all operation devices down on the ground and slightly press downwards.



Run the engine at idle speed for 5 minutes to let each accessory cooled evenly.



Turn each switch to neutral position or “OFF” position.



Close left and right door, and get down from the rail according to relevant rules.



Turn the negative switch of battery to shut-down status, i.e. the handle of switch pointing the “O” position on the switch panel.



If the machine is not added with anti-freeze fluid, after parking in winter, open all engine drain valves in time to discharge all coolant in the evaporator of cooling system and air conditioning system so as to prevent the machine components from being frozen. If the machine is added with anti-freeze fluid, carry out according to the instruction of anti-freeze fluid grade.



Lock all equipment, take off the key and take it along.

Caution: Park the machine at a flat ground. If the machine must be parked on a slope, use a wedge block to prop the wheel to prevent the machine from moving. Long Term Parking A. Before Storage 

The ambient temperature for storage of machine is -15℃~40℃.



Wash and dry each part of the machine, and put it in a dry warehouse. If the machine can only stored in the open air, cover it with canvas.



According to the recommended oil in the “oil standard” of maintenance part, full-fill the fuel tank, fill lubricating grease to each moving axis pin and drive shaft, and replace the hydraulic oil.



Coat the exposed part of piston rod of hydraulic oil cylinder with a thin layer of grease.



Remove the battery from the machine, and store it separately.



If the temperature will possibly be lower than 0℃, add anti-freeze fluid in the engine cooling water, and make sure the anti-freeze fluid can arrive at the engine body or evaporator of air 108

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conditioning system. Or completely drain the water in cooling system. Notice that the water in the evaporator of air conditioning system should also be discharged. 

Fix the front and rear frame with frame locking device.

B. During Storage 

Start the vehicle once a month to run each system, and fill lubricating grease to each moving axis pin and drive shaft so that each moving part will be lubricated, and charge the battery at the same time.



Before starting the vehicle, wipe off the grease on the piston rod of hydraulic oil cylinder. After finishing the operation, coat a thin layer of grease.



Coat the corrodible part with rust inhibitor.

Warning: If using rust inhibitor in doors, open the door and window to keep ventilated and discharge the poisonous gas. C. Before Reuse 

Replace the lubricating oil of engine, transmission and driving axle, and the hydraulic oil, brake fluid and anti-freeze fluid.



Add lubricating grease to all moving axis pins and drive shafts.



Before starting the machine, wipe off the grease on the piston rod of hydraulic oil cylinder.

Caution: If the anti-corrosion treatment is not conducted to the machine monthly, please consult the contractor of Liugong.

Transportation of Machine Shipping of Machine Before shipping, investigate the height, width and allowable load of the passage of transportation line. The total height, width and weight after putting this machine on the transport vehicle shall not exceed that of relevant regulation. Before loading, clear off the ice, snow and other slippery material on the platform and transport vehicle. It will prevent slipping during loading and keep the machine from moving during transportation.

Caution: During shipping, comply with the state and regional rules and regulations regarding shipping height, width, length and weight. If the machine is delivered to a cold place, make sure there is appropriate anti-freeze fluid in the cooling system. 

Before shipping, underlay the wheel of trailer or truck with wedge block. (It is trailer shown in 109

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the figure).



After the machine is located on the trailer or truck, don’t conduct steering during transportation.



After parking, fix the front and rear frame with frame locking device.



Lower all operation devices on the floor of transport vehicle, and put the gearshift control handle at neutral position.



Switch the handle of priority isolating valve to “OFF” position.



Press the parking brake button to engage the parking brake.



Flame out the engine, turn all switches to neutral position or “OFF” position, and pull out the starting switch key.



Close and lock all doors and pull out the key.



Turn the negative switch of power to the off position.



When transporting machine with truck or trailer, underlay the wheel with wedge block and fix the machine with steel wire to prevent the machine from moving during transportation.



Cover the exhaust hatch to prevent the turbocharger from rotating as a windmill, otherwise the turbocharger may be damaged.

Driving Machine on Road (with Relevant License) 

Before driving machine on road, consult the tyre agent for suggestions of tyre pressure and speed limit.



When traveling for a long distance, take a break for 30 minutes after driving every 40km (or after driving every 1 hour) to cool the tyre. 110

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Charge the tyre to appropriate pressure. Refer to “tyre charging information” of Operation and Maintenance Manual for the information of tyre charging.



When driving machine on road at medium speed, comply with all regulations regarding speed limit.

Hoisting of Machine Warning: The incorrect hoisting and fixing of machine will lead to moving with load and casualty. Frame locking device must be installed before hoisting. 

Refer to section of “Main technical parameters” for the weight of machine. Check the maximum load capacity of crane and stringer to ensure the safety of hoisting.



The 4 stringers of hanger shall obtain the same length to ensure that the 4 hoisting hooks are stressed evenly during hoisting.



There are hoisting point marks like this on the front and rear frame of machine.

Hoisting ring



Hoisting ring

Before hoisting, fix the front and rear frame with frame locking device to prevent the machine from moving.

Locking device

Pin

Caution: To connect the frame locking device, the machine must directly face the front. 

The hanger should be fixed firmly to the hoisting ring with mark on the machine.

Warning: The incorrect hoisting will lead to deviation of machine resulting in casualty and losses.

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Trailing of Machine Trailing of Machine with Malfunction Warning

The incorrect trailing of machine with malfunction may lead to casualty. Before releasing brake, use wedge to underlay the wheel to prevent the machine from freely rolling. The brake malfunction may lead to casualty. Before trailing the machine to reparation site, make sure necessary maintenance and adjustment have been conducted. When trailing a machine with malfunction for no more than 10km, carry out trailing according to these trailing instructions. When trailing a machine, the speed shall not exceed 2km/h. Trail the machine to a convenient place for maintenance. For trailing a machine for long distance, transport the machine with a trailer. The trailing machine shall be equipped with protective device to protect the driver when the trailing cable or drawbar is broken. There shouldn’t be any person on the trailed machine, with exception of a driver controlling steering and/or brake. Before trailing, make sure the trailing cable or drawbar has enough strength to pull the machine. The strength of trailing cable or drawbar is at least 1.5 times of that of the trailed machine, so as to pull the machine from mud or slope. Don’t use chain for trailing. The chain link may possibly be broken, resulting in casualty. Use a cable with loop or steel rope with end-ring as a trailing tool. Assign an observer at the safety position. If the cable begins to break or loose, the observer should stop the trailing procedure. If the trailing machine moves while the trailed machine doesn’t move, stop trailing. Keep the trailing cable at a minimum angle which is less than 30° with right ahead. The fast moving of machine will make the trailing cable or drawbar overloaded, resulting in breakage of trailing cable or drawbar. The constant moving of machine is better for trailing. Normally, the size of trailer shall be the same as that of the trailed machine. Make sure the trailer has enough brake ability, weight and power so as to control the uphill distance and traveling distance of the two machines. To supply enough control and break force, it may be required to connect a larger machine on the machine with malfunction to prevent the latter one from getting out of control and rolling. Any loaded trailed machine must be equipped with a brake system which can be controlled in the 112

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cab. It is impossible for this manual to point out all requirements in different situation. For detailed information regarding trailing machine with malfunction, please consult contractor of Liugong.

Trailing When the Engine is Running When the engine is running, trailing for short-distance under certain circumstances may be conducted. By that time, the drive system and steering system must be operable, and the machine can only be trailed for short distance, e.g. pull the machine out from puddle or pull it over the road. The driver on the trailed machine must operate the machine according to the direction of trailing cable, put the gearshift control handle at the neutral position, and lift all operation devices. Besides, please strictly comply with all instructions summarized under this title.

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Maintenance Manual

Caution: Please carefully read and understand the contents of the manual, so that you can correctly maintain the machine. Proper maintenance is of great significance for the safety and the extension of the service life of the machine.

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Run-in of New Motor Grader Run-in of new motor grader plays an important role for extending the service life of machine, eliminating the hidden danger and preventing the occurrence of a major accidence. After the purchase of the machine, users should conduct the operation and maintenance for the machine according to the provisions for the run-in of new vehicle in the manual, and then the machine can be used properly.

Requirements for Run-in of New Motor Grader 

The run-in term of new motor grader is 100 hours.



Every time when starting up, run it at idle speed for 5 minutes. Machine should start at stably low speed and small accelerator and then gradually increase the speed.



During the run-in process, each of the forward gears I, II, III, IV, V, VI and reverse gears I, II, III should be running-in uniformly.



Except for the emergency, it is necessary to avoid the sudden start, acceleration, steering and braking.



During the run-in period, scraping the loose material is appropriate and the work should not be too hasty. The workload should not exceed 70% of the rated value and running speed should not exceed the 70% of the maximum rated value.



Attention should be paid to the lubrication of machine; change or add the lubricating oil and grease according to the specified cycle.



Attention should be frequently paid to the gearbox, torque converter, front and rear axles, hub, parking brake and middle bearing shaft as well as the temperature of hydraulic oil, engine coolant and engine oil, and if the overheating is found, it is necessary to find out the cause and eliminate it.



Check the fastening situation of the bolts and nuts of all parts.

Following work should be done after 8-hour run-in of new motor grader 

Take a comprehensive examination for the fastening situation of bolts and nuts of all parts, particularly the bolt of diesel engine cylinder head, bolt of exhaust pipe, fixing bolt of front and rear axles, nut of wheel rim, connecting bolt of transmission shaft, fixing bolt of diesel engine and gearbox, and bolt at the articulated place between the front and rear frames.



Check the degree of tightness for the fan belt, generator belt, air-conditioning compressor belt.



Check the oil level of gearbox, driving axle and diesel engine.



Check the hydraulic and brake system for leakage.



Check the connection of all controlling pull rods and throttle pull rods.



Check the temperature and connection of all parts of electrical system, power supply of generator, lighting and turn signal lamp.

Caution: All kinds of oil level should be checked according to the relative operational procedures. Following work should be done after the finish of run-in of new motor grader 115

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Take a comprehensive examination for the fastening situation of bolts and nuts of all parts, particularly the bolt of diesel engine cylinder head, bolt of exhaust pipe, fixing bolt of front and rear axles, nut of wheel rim, connecting bolt of transmission shaft, fixing bolt of diesel engine and gearbox, and bolt at the articulated place between the front and rear frames.



Check the degree of tightness for the fan belt, generator belt, air-conditioning compressor belt.



Check the tightness of hydraulic system and brake system.



Change the transmission oil of gearbox and the lubricating oil of driving axle.



Replace the secondary filter of gearbox oil and clean the primary filter of gearbox oil.



Clean the oil-return filter core of hydraulic oil tank.

Caution: The transmission oil of gearbox, lubricating oil of driving axle and secondary filter of gearbox oil should be replaced according to the relevant operational procedures.

Regular Maintenance Caution: it is necessary to read and understand all the safety information, warnings and instructions prior to any operation or maintenance. Liugong Machinery Co., Ltd. requires that the maintenance work should be done using the first due cycle between the time-table and calendar (day, week, month, etc.).Under the extremely harsh, dusty or humid work environment, the lubrication and maintenance more frequent than specified in the “regular maintenance” are necessary. When taking the maintenance, maintenance items listed in the original requirements should be repeated. For example, the maintenance items listed in “per 250 work hours or a month”, “per 50 work hours or a week” and “per 10 work hours or a day” should be carried out when taking the maintenance items listed in the “500 hours or 3 months”

Maintenance per 10 work hours or a day 

Check the storage battery and the switch of it.



Check the engine oil level.



Check the coolant level.



Check the hydraulic oil level.



Check the fuel level.



Remove the fuel in the prefilter and engine and the water and impurity inside the diesel primary filter.



Patrol check. (See the “patrol check” of “important maintenance procedure” for details)



Check the engine fan and driving belt visually. 116

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Check the operating conditions of the lamp and instrument.



Check the tyre air pressure and the damage of it.



Check the operating conditions of reverse alarm.



Add the lubricating grease into all the transmission shafts according to the instructions of complete-machine diagram posted on the machine.

Maintenance per 50 work hours or a week First, conduct the above-mentioned check and maintenance items 

Check the oil level of gearbox.



After first 50 work hours, it is necessary to check the gab between the brake shoe and brake drum of parking brake, and replace it if improper. Afterwards, check it per 250 work hours.



Screw down the linking bolts of all transmission shafts.



For the motor grader equipped with the air conditioner, clean the filter screens of air-return and new-air ports of air conditioner evaporator; check the degree of tightness of transmission belt of compressor and check the condenser for the oil pollution, dirt and other debris which affect the heat emission of condenser.



Keep the binding post of storage battery clean and paint with vaseline to prevent the corrosion of acid mist on the post.



Check the lubricated state of all lubrication points and add the lubricating grease to the lubricating points according to the lubrication diagram of complete machine posted on the machine.



After the first 50 work hours, check the pre-charging pressure of nitrogen in the accumulator.

Maintenance per 100 work hours or 2 weeks First, conduct the above-mentioned check and maintenance items 

After the first 100 work hours, change the gearbox oil, and change it once every 1 ,000 work hours afterwards. Even if the number of work hours is less than the specified value, the gearbox oil should be changed once a year at least. Every time when replacing the gearbox oil, the secondary filter of gearbox should also be replaced.



After the first 100 work hours, replace the driving axle, tandem and the gear oil of worm-gear box, and afterwards the driving axle, tandem and the gear oil of worm-gear box should be replaced once every 1,000 work hours. Even if the number of work hours is less than the specified value, the gear oil of driving axle should be changed once a year at least.



Clean the engine cylinder head and the radiator set.



Rinse the oil filling filter screen of fuel tank.



After the first 100 work hours, check the pre-charging pressure of nitrogen in the accumulator.

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First, conduct the above-mentioned check and maintenance items 

Check the fastening toque of the fixed bolt of wheel rim.



Check the fastening torques of the mounting bolts of gearbox and engine.



Check the operational device, the stress welding seam of front and rear frames and the fixed bolt for the crack and looseness.



Check the oil levels of driving axle, tandem and worm-gear box.



Check the blockage alarm lamp of air filter and the lamp goes on. The core of air filter should be cleaned or replaced.



Check the air intake system of the engine.



Change the engine oil and replace the oil filter.



Replace the filter of engine coolant.



After the first 250 work hours, clean the oil-return filter core of hydraulic system. Afterwards the oil-return filter core of hydraulic system should be replaced once every 1,000 work hours.



Check the driving belt of engine, air conditioner compressor belt for the tension and damage.



The machine equipped with the air conditioner should be checked with whether the refrigerant inside the reservoir is sufficient.



For the machine equipped with the air conditioner, it is necessary to clean the air filters inside and outside cab.



Detect the service brake and parking brake.



After the first 250 work hours, check the pre-charging pressure of nitrogen in the accumulator.

Maintenance per 500 work hours or 3 months First, conduct the above-mentioned check and maintenance items 

Check the concentrations of anti-freezing fluid and coolant additive.



Replace the fuel prefilter and the fuel primary filter and secondary filter on the engine.



Fasten the connecting bolt between the driving axle and frame.



Check the fixed bolt of the articulated pin of frame for looseness.



After the first 500 work hours, check the pre-charging pressure of nitrogen in the accumulator. Afterwards check the pre-charging pressure of nitrogen in the accumulator once every 1,000 work hours.

Maintenance per 1,000 work hours or 6 months First, conduct the above-mentioned check and maintenance items 

Adjust the valve clearance of engine. 118

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Check the tension pulley bearing and fan shaft housing of engine.



Change the gearbox oil and replace the oil filter of gearbox.



Change the gear oil of driving axle, tandem and worm-gear box.



Replace the oil-return filter core of hydraulic system.



Rinse the fuel tank.



Screw down all the fixed bolts of storage battery and clean the top of storage battery.



Check the pre-charging pressure of nitrogen in the accumulator.



For the machine equipped with the air conditioner, it is necessary to replace the air filter outside the cab.

Maintenance per 2,000 work hours or a year First, conduct the above-mentioned check and maintenance items 

Change the hydraulic oil, rinse the oil tank and the oil absorption filter screen and check the oil suction pipe.



Check the operational situation of service brake and parking brake systems and remove and check the friction plate for the friction state.



Check the tightness of distribution valve and operational oil cylinder by measuring the natural settlement of oil cylinder.



For the cab equipped with the air conditioner, it is necessary to check whether the cooling pipe and water pipe of air-conditioning system are broken, worn out or dipped in the oil pollution and check the pipe connector and pipe clamp for the looseness.



For the machine equipped with the air conditioner, it is necessary to replace the air filter inside the cab.



Check the steering system for the flexibility.



Change the engine coolant, rinse the cooling system of engine and replace the engine coolant filter.

Maintenance per 6,000 work hours 

Check the shock absorber of crankshaft belt pulley of engine and replace it if necessary.



Clean and repair or replace the engine nozzle.



Clean and calibrate the fuel pump.



Check the fan hub and repair or replace it if necessary.



Overhaul the turbocharger. 119

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General Specification of Torque Unless the special statement is available, the bolts used by the machine should be screwed down according to the torques in the following table. 

Metric standard thread torque Thread Size



Standard Torque lbf•ft (N•m) Intensity of grade 8.8

Intensity of grade 10.9

M6

7.7±1.1 (10.5±1.5)

M8

19±2.9 (26±4)

M10

38±5 (52±7)

53±4 (72±6)

M12

66±9 (90±12)

89±7 (120±10)

M14

107±15 (145±20)

144±11 (195±15)

M16

166±26 (225±35)

225±18 (305±25)

M18

229±33 (310±45)

306±26 (415±35)

M20

302±37 (410±50)

443±37 (600±50)

M22

443±59 (600±80)

590±52 (800±70)

M24

561±74 (760±100)

752±74 (1,020±100)

M27

811±111 (1,100±150)

1,106±74 (1,500±100)

M30

1,106±148 (1,500±200)

1,364±11 (1,850±150)

M33

1,512±221 (2,050±300)

2,139±295 (2,900±400)

M36

1,955±258 (2,650±350)

2,286±184 (3,100±250)

British standard thread torque

Thread Size

Standard Torque lbf•ft (N•m)

1/4

9±3 (12±4)

5/16

18±5 (25±7)

3/8

33±5 (45±7)

7/16

52±11 (70±15)

1/2

74±11 (100±15)

9/16

110±15 (150±20)

5/8

148±18 (200±25)

3/4

266±37 (360±50)

7/8

420±59 (570±80)

1

645±74 (875±100) 121

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Air Charging Data of Tyre Liugong proposed that tyre should be charged with dry nitrogen and the tyre pressure should be adjusted, which is for all the machines equipped with the rubber tyre. Nitrogen is an inert gas and will not support the combustion in the tyre. The use of nitrogen (N2) will not only reduce the risk of explosion, and also contribute to the prevention of oxidation and rubber aging as well as the corrosion of wheel rim parts. Tyre life can reach at least 4 years.

Warning The operators using the air charging equipment should be trained properly, because using the incorrect air charging technology will lead to the casualties. Set the pressure of air charging equipment of tyre not higher than the recommended tyre pressure 140KPa (20 psi). The check and adjustment of the air charging pressure of tyre should be conducted after the fully cooling of tyre and notify all other staff to leave the dangerous zone (around the tire). Nitrogen charging pressure is the same as the air charging pressure. Liugong advised that the air charging pressure should be determined according to the actual operating conditions of tyre. The air charging pressure of tyre shown in the table is the value at the normal temperature 17.5-25

MPa

psi

0.275±0.01

40±1.5

When the motor grader is traveling in the cold temperature, the tyre pressure will change greatly. The tyre which is charged sufficiently in the normal temperatures will be in a shortage of air pressure in the cold temperature. The rather low tyre pressure will shorten the service life.

Pressure Release Warning

Hydraulic oil circuit has always been under the state of pressure, so when checking or replacing the pipe or hose, the circuit pressure should be released. If the pressure is not released, high-pressure oil will be emitted which would cause the serious personal injury. After turning off the engine, parts, oil and the cooling water inside the radiator are still in the high temperature, which would cause the serious burns. At the beginning of the operation, wait for the temperature to fall. When removing the oil filling cover and the water-filling cover of radiator, oil or water will blow out, so it is necessary to slowly rotate the cover prior to the removal of cover to release internal pressure. 123

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Operation method of Pressure Release: 1.

Park the machine on the level and solid ground. And lower all the devices down to the ground.

2.

Within 15 seconds after the shutdown, turn the starting switch to the ON gear and operate the control lever towards all direction fully (operational device and running device) to release the internal pressure of operational device.

3.

Slowly unscrew the oil filling cover A at the top of the hydraulic tank or water-filling cover B of the radiator to release the internal pressure.

A B

4.

The remaining pressure inside the hydraulic device can be released by unscrewing the fastening nuts between the hydraulic pipeline and then screw down them again. At the same time, be sure to collect the remaining oil inside the operational device.

5.

Pressure release of the accumulator; see the “Maintenance of Accumulator” for details.

Technical Specification of Lubricating Oil Changing Interval and Adding Capacity of Lubricating Oil Caution: When carrying out the check, maintenance, test and adjustment to the motor grader, it is necessary to be prepared to use a suitable container to collect the liquid before removing any hydraulic oil circuit or disassembling any part containing the liquid. And dispose of all liquid in accordance with the local laws and regulations.

Changing Interval and Adding Capacity of Oil Type

Changing Interval

Adding Capacity

Engine crankcase

250

22L

Gearbox system

1,000

45L

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Hydraulic oil

2,000

186L

Fuel tank

Per day

230 L

Rear axle, tandem and worm-gear box

1,000

80L

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Technical Specification of Oil Type

Name Summer oil

Lubricating grease

★Molybdenum

Applicable Position Winter oil

disulfide

lithium-base For roller bearing, sliding bearing, axis pins of

lubricating grease No.2

operational device, steering cylinder and frame, swing bracket of rear axle, spine of transmission shaft, universal joint and water pump shaft etc.

Torque

★Mobil Black King 1300 or engine oil of For torque converter and power gear-shift gearbox

converter oil

the levels higher than SAE15W-40 CF

Hydraulic oil

★HM46

anti-wear

hydraulic oil Engine oil

HV46 anti-wear

For the hydraulic system, brake system and steering

hydraulic oil

hydraulic system of operational device

★Oil of the levels Oil of the levels more For diesel engine more

than

SAE/CF-4

than SAE/CF-4 5W-30

15W-30 Engine North Fuel

Light diesel No.0

South

Gear oil

Light diesel No.0

Light diesel No.-35 For diesel engine Light diesel No.0

★SAE85W-90 GL-5 Heavy-load vehicle Driving axle, tandem and worm-gear box gear oil

Notes: The ones marked with ★ are the oil added before leaving the factory

Caution: 1. 2.

3. 4.

The oil of the same specification but different brands can not be mixed. If for any reason, it is necessary to use an oil of different brand, please rinse the system first. If the motor grader has been used in the low-temperature and cold areas for long term, the HV46 low-temperature anti-wear hydraulic oil should be selected as the hydraulic oil, and the ATF220 or DEXRON-III or Donax TC transmission oil should be used for the gearbox. It is necessary to replace a variety of lubricating oil, and even if the oil is very clean, it may degenerate if placed for a long period of time. The fuel should be selected based on the local minimum temperature when using the machine.

Patrol Check Caution: Closely observe the machine for leakage. If the leakage is found, it is necessary to find the source of leakage and repair it. If you suspect or find the leakage, be sure to frequently check the change of level.   

Check the hoses of cooling system and hydraulic system for the leakage and repair or replace it timely if necessary. Check the engine chamber and remove the accumulated debris from the engine chamber and on the radiator. Check the engine for any visible damage to the parts. 126

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Check the tyre for damage. Check the integrity of valve cap. Check the driving axle, tandem, worm-gear box and gearbox for the leakage and repair the leaking point if any. Check the hydraulic oil tank, all the hoses and tubes for the leakage. At the meantime check all the blanking plugs, sealers, connectors and nozzle for the leakage. Repair the leaking points and replace the hoses if necessary.



Check all the operational devices and connecting rods for the wear and damage.



Be sure that all the doors, overhaul covers and guard boards are solid. Overhaul the overhaul doors, overhaul covers and guard boards for the damage.



Check the ladder, walkway and armrest. Remove all the debris. Repair any damage or replace the damaged parts.



Check the roll-over protective structure (ROPS) for the visible damage and contact the Liugong agency for repair.



Check all the lighting lamps and replace the damaged bulb and glass.



Check the cab and keep the cab clean.



Check the instrument and indicator lamp on the instrument panel for the damage and replace any damaged part.



Check the seat belt, snap and mounting fastener and replace any worn or damaged part.



Adjust the rear-view mirror and check the window to ensure that visual field is not affected and rinse the window if necessary.

Maintenance of Cooling System Check of Coolant Level Warning

Operating coolant is of the higher pressure and temperature. The hot coolant can cause the serious burns, so if it is necessary to shut down the engine and wait for the radiator to cool down before opening the cover, and then slowly unscrew the water-filling cover in order to release the internal pressure. The engine coolant is mainly composed of the cooling water, anti-freezing fluid and additive and located in the radiator at the rear of the machine.

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Checking Method of Coolant Level: 1.

It is necessary to slowly unscrew the water-filling cover of the radiator to release the pressure after the engine coolant temperature dropped to 50℃ below so as to avoild the burns by the high-temperature steam or coolant sprayed out. Water-filling port of water radiator

2.

Check whether the coolant level is within 1 cm under the water-filling port, and add the coolant if necessary. Check the seal of water-filling cover of water radiator and replace it if damaged. Screw down the water-filling cover of water radiator.

3. 4.

Caution: If the coolant should be added every day, it is necessary to check the engine’s cooling system for leakage. If the leakage is found, it is necessary to eliminate the leakage and add the anti-freezing fluid to the appropriate level.

Check for Concentration of Anti-freezing Fluid When adding the coolant to the new motor grader or the engine of which cooling system is rinsed, first it is necessary to choose the concentration of the anti-freezing fluid inside the coolant in accordance with local minimum temperature (under normal circumstances, the freezing point of the coolant should be 10℃ above less than the minimum temperature of the area) and calculate the required amount of the anti-freezing fluid based on the total volume of the cooling system of engine, and then mix the anti-freezing fluid with the softened water to add into the cooling system. The total volume of the cooling system of the machine is about 45 liters (the actually added amount should be determined by checking whether the coolant level is within 1 cm under the water-filling port and add the coolant if necessary). The brand and performance of the anti-freezing fluid recommended by Liugong Machinery Co., Ltd. are as follows: Applicable Minimum Ambient Shell Anti-freezing Fluid (Concentrated-OAT)

Mobil Anti-freezing Agent

Temperature

(Percentage)

(Concentrated) (Percentage)

-45℃

55%

——

-30℃

47%

47%

-15℃

30%

33%

0℃

0

0

When replacing the anti-freezing fluid, please choose the high-quality anti-freezing fluid and add it under its instructions.

Caution: 1. Anti-freezing fluid is a flammable material, do not close to the 129

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open flame. 2. Be sure not to use the water independently as the coolant. It is prohibited to add the tap water or mineral water to the cooling system instead of the softened water. Otherwise it may lead to the corrosion of the whole cooling system.

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Check for Concentration of Coolant Additive Coolant should contain the additive (SCA). Additive can prevent the rust, scaling, pitting and corrosion of the engine parts contacting with the coolant. The concentration of coolant additive should be maintained at around 3%. Anti-freezing fluid already contains the additive, but the additive would be consumed during the use of engine, so it is necessary to check the concentration of additive once per 500 work hours or 6 months and add the additive regularly by replacing the coolant filter. Refer to the “Operation and Maintenance Manual of Engine” for the further detailed provisions about the testing method for concentration of additive and the supplement of additive.

Add of Coolant Warning

Operating coolant is of the higher pressure and temperature. The hot coolant can cause the serious burns, so if it is necessary to shut down the engine and wait for the radiator to cool down before opening the cover, and then slowly unscrew the water-filling cover in order to release the internal pressure. Coolant-adding steps are as follows: 1.

It is necessary to mix the water and anti-freezing fluid completely according to the selected ratio of coolant in advance.

2.

Switch on the negative switch of power supply; insert the key into the starting switch and turn it clockwise to “ON” gear to switch on the power supply of complete vehicle.

3.

Turn the inverter switch of air-conditioning system to the heater gear.

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4.

Turn the manual valve in the water-in pipe of engine to the access position.

Manual hot-water valve (water intake)

5.

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Manual hot-water valve (water return)

Open the water-filling cover of water radiator to add the coolant slowly until the level is within the 1 cm under the water-filling cover of water radiator and remain stable for 10 minutes.

Caution: With the injection of coolant, it is important to exhaust the air from the cooling system pipeline of engine. 6.

Keep the water-filling cover of water radiator open, start the engine to run at the low idle speed for 5 minutes first and run at the high idle speed for 5 minutes, and make the coolant temperature reach 80℃ above.

7.

Re-check the coolant level and, if necessary, add the coolant until the level is within 1 cm under the water-filling cover of water radiator.

8.

Check the seal of water-filling cover of water radiator and replace it if damaged. Warning

Do not add the cold coolant to the high-temperature engine; otherwise it could lead to the damage to the engine body. It is necessary to add the coolant after the engine temperature is below 50℃ . Liugong Machinery Co., Ltd. will not hold responsibility for the losses due to the decline in the concentration of anti-freezing fluid as a result of the leakage of coolant caused by the improper operation of user.

Change of Coolant Warning

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liquid before removing any hydraulic oil circuit or disassembling any part containing the liquid. And dispose of all liquid in accordance with the local laws and regulations. Operating coolant is of the higher pressure and temperature. The hot coolant can cause the serious burns, so if it is necessary to shut down the engine and wait for the radiator to cool down before opening the cover, and then slowly unscrew the water-filling cover in order to release the internal pressure. It is necessary to change the coolant inside the cooling system and rinse the cooling system once every 2,000 work hours or a year (whichever comes first). Before it, if the coolant was contaminated, engine was overheated or bubble appeared in the radiator, it is necessary to rinse the cooling system.

Operational steps of rinsing the cooling system are as follows: 1.

Switch on the negative switch of power supply; insert the key into the starting switch and turn it clockwise to “ON” gear to switch on the power supply of complete vehicle; turn the inverter switch of air-conditioning system to the heater gear.

2.

Turn the manual valve in the water-in pipe of engine to the access position. Manual hotwater valve (water intake)

3.

Manual hotwater valve (water return)

Open water-discharging valve at the bottom of the water radiator to discharge the coolant of engine and use the container to receive it.

Discharge valve

4.

After discharging the engine coolant, close the discharge valve at the bottom of the water radiator.

5.

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them. Check the water radiator for leakage, damage and the accumulation of filth and clean and repair it according to the needs. 6.

Add the clean water to the cooling system of engine and appropriate amount of special cleaning fluid of the cooling system of engine (the concentration of cleaning fluid should be determined in accordance with the User’s Guide).

Caution: 1. With the injection of coolant, it is important to exhaust the air from the cooling system pipeline of engine. 2. Throughout the cleaning process of cooling system, do not cover the water-filling port of the water radiator when the engine is running. 7.

Keep the water-filling cover of water radiator open, start the engine and run the engine for 5 minutes again when the coolant temperature reaches 80℃ above.

8.

Shut down the engine to discharge the cleaning fluid.

9.

Add the clean water into the cooling system of engine to normal level and keep unchanged for 10 minutes. Keep the water-filling cover of water radiator open, start the engine and run the engine for 5 minutes again when the coolant temperature reaches 80℃ above.

10. Shut down the engine to discharge the water inside the cooling system. If the discharged water is still dirty, it is necessary to rinse the system until the discharged water gets clean. 11. Replace the coolant filter and turn off all the discharge valves. And then add the new coolant in accordance with the aforementioned operational procedures of “Add of Coolant”.

Caution: Engine coolant is toxic and can not drink, please dispose of it in accordance with the relevant local law.

Maintenance for Air Filter of Engine Air filter is located under the rear hood of motor grader.

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Clean of Air Filter Caution: 1. The air filter should be maintained if the blockage alarm lamp of air filter goes on. 2. When maintaining the air filter, it is necessary to shut down the engine to prevent the damage to engine.

1.

Shut down the engine and open the engine hood.

2.

Open the cover of air filter.

3.

Radially pull out the main filter core.

4.

Clean the inner wall of air filter shell.

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When cleaning the main filter core, use the compressed air with the pressure not more than 300KPa to wash out outwards from the inside of main filter core along the crease and then wash out repeatedly from the inside and outside of the main filter core respectively along the crease.

Clean of Main Filter Core

Caution: It is prohibited to beat when cleaning the main filter core; otherwise it may cause the damage to engine. 6.

After cleaning the main filter core, it should be check with lamp, and if the small holes or particles and the damage to washer or seal are found, it is necessary to replace the main filter core. Check of Main Filter Core

7.

Mount the clean main filter core inside the air filter shell and ensure the uniform contact of end position of main filter core.

8.

Clean and mount the air filter cover and ensure the uniform contact between the packing plate of inner cover of air filter and the air filter shell.

9.

After cleaning the main filter core, start the engine; if the blockage alarm lamp of air filter still flashes or still emits the black smoke, it is necessary to replace with a new safety filter core.

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cleaned for 6 times, it still should be replace once a year. When replacing the main filter core, the safety filter core should be replaced at the same time.

Replacement of Safety Filter Core of Air Filter Safety filter core

Caution: The safety filter core can only be replaced with new one and not be cleaned for using again. 1.

Shut down the engine and open the engine hood.

2.

Open the cover of air filter.

3.

Remove the main filter core.

4.

Remove the safety filter core.

5.

Clean the inner wall of air filter.

6.

Mount the new safety filter core and ensure the uniform contact and good seal of seal ring on the end surface of the safety filter core.

7.

Mount the main filter core and the cover of air filter.

Caution: 1. When replacing the main filter core, the safety filter core should be replaced at the same time. 2. After cleaning the main filter core, start the engine; if the blockage alarm lamp of air filter still flashes or still emits the black smoke, it is necessary to replace with a new safety filter core.

Maintenance of Fuel System of Engine Check of Fuel Level The fuel level gauge of this machine is located on the functional panel at the right of seat.

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Fuel level gauge indicates the fuel level of the complete machine and when the fuel gauge indicates “1/1”, the fuel level is the highest and when it indicates “0”, the fuel level is the lowest. When the fuel gauge indicates the 2nd lattice at the left, it is necessary to add the fuel timely.

Add of Fuel The fuel tank of the motor grader is located at the central rear of the complete machine with the volume of 230 liters.

1.

The filler of diesel tank is located at the top of engine hood. Filler

2.

When opening the cover of filler, first erect the locking plate of the cover, and rotate the cover anti-clockwise to the next locking position, and then move the cover outwards.

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Take off the cover of filler and then add the fuel.

Caution: Do not take off the filter screen of filler when adding the fuel.

Rinse of Fuel Tank

Caution: When carrying out the check, maintenance, test and adjustment to the motor grader, it is necessary to be prepared to use a suitable container to collect the liquid before removing any hydraulic oil circuit or disassembling any part containing the liquid. And dispose of all liquid in accordance with the local laws and regulations. The fuel tank is located in the central rear of the complete machine and the filter screen of filler and fuel tank should be rinsed regularly.

Fuel tank could be rinsed according to the following methods: 1.

Remove the blind flange in the front of fuel tank and rinse the inner surface of fuel tank with the clean fuel. Rinse of fuel tank

Blind flange

Oil drain screw plug

2.

Unscrew the oil drain screw plug under the fuel tank to drain the fuel.

3.

Rinse it repeatedly until the drained fuel is clean. 139

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Removal of Water and Impurity from Fuel In case of the water and impurity in the fuel, fuel pump and nozzle will be unable to operate normally and the abrasion will speed up. Measures should be taken to eliminate the water and impurity from the fuel. Methods are as follows: 1.

If the conditions allow, the fuel should get through with 24-hour precipitation before being added into the fuel tank.

2.

Before the refueling, unscrew the oil drain screw plug at the bottom of the fuel tank once a week to discharge the water and impurity.

3.

Everyday, after the end of the work, fill the fuel tank fully and exhaust the wet air from the fuel tank.

4.

After filling the fuel tank fully, the engine should be started after 5-10 minutes in order to make the water and impurity in the fuel deposit at the bottom of the fuel tank.

5.

After the operation everyday, unscrew the oil drain plug at the bottom of fuel pre-filter, fuel filter (primary filter, secondary filter) to discharge the water and impurity.

Fuel filter Fuel pre-filter

Caution: Do not wait for adding the fuel until the fuel of tank run out, this will lead to the shutdown of the engine and the fuel at the bottom of the fuel tank contains more water and impurities will affect the normal operation of the engine.

Replacement of Fuel Filter Caution: Do not inject the fuel before mounting the fuel filter. Fuel pollution will accelerate the wear and tear of the fuel system parts. 1. First of all, clean the surrounding areas of filters (primary filter, secondary filter) and the mounting seat. 2.

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Take off the packing plate ① on the thread joint of the mounting seat. Clean the sealing surface of mounting seat with fiber-free cloth. Clean of sealing surface of mounting seat

4.

Mount a new packing plate on the thread joint of the mounting seat of filter; supply a layer of engine oil on the sealing surface of the filter; fill the filter with the clean fuel. Prepare for new filter

5.

Mount the filter to the mounting seat with hands and tighten it for 1/2 to 3/4 laps when the packing plate of filter contacts the mounting seat. It is prohibited to tighten it mechanically to avoid the damage to the filter. Mount of filter

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Replacement of Fuel Prefilter 1.

First of all, clean the surrounding areas of prefilter and the mounting seat.

2.

Remove the prefilter from the mounting seat and clean the sealing surface of mounting seat with fiber-free cloth.

3.

Remove the transparent water cup from the lower part of fuel prefilter.

4.

Clean the water cup and then mount it to the new fuel prefilter.

5.

Fill the fuel prefilter with the fuel and apply a layer of engine oil on the packing plate, and then mount it to the mounting seat.

Heating of Fuel If the fuel should be heated due to the lower temperature, fuel temperature should not exceed 35℃ , otherwise engine power would be lost.

Maintenance of Engine Oil Check of Engine Oil Level

Caution: Excessive or insufficient engine oil will cause the damage to the engine. 1.

Drive the motor grader to the flat ground, shut down the engine and implement the parking brake.

2.

After shutting down the engine, wait 10 minutes for the engine oil inside the crankcase flowing back to the engine oil disc.

3.

Open the engine hood and the filler and oil level gauge are all located at the right side of engine.

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Filler

Oil level gauge

4.

Unscrew and pull out the oil level gauge, wipe the oil level gauge with a clean cloth, re-insert the engine oil level gauge to the end, and then pull it out for checking that the oil level should be between the “L” scale and “H” scale of the oil level gauge. Reasonable oil level range

5.

If the oil level is below the “L” scale, please add the oil; if the oil level is over the “H” scale, please unscrew the oil drain screw plug at the bottom of the engine oil disc to discharge a part of the engine oil.

Change of Engine Oil

Caution: When carrying out the check, maintenance, test and adjustment to the motor grader, it is necessary to be prepared to use a suitable container to collect the liquid before removing any hydraulic oil circuit or disassembling any part containing the liquid. And dispose of all liquid in accordance with the local laws and regulations. 1.

Park the motor grader on a flat ground and run the engine until the water temperature reaches 60℃ .

2.

Shut down the engine and implement the parking brake.

3.

Oil drain bolt of engine oil is located at the left side of rear frame. Release the oil drain port of engine oil to discharge the oil into the proper container.

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Oil drain port

4.

Screw down the oil drain bolt. And then add the clean engine oil from the filler to the “H” scale of oil level gauge. Run the engine at the idle speed and check the engine oil filter and oil drain bolt for leakage.

5.

Shut down the engine, wait 10 minutes for the engine oil flowing back to the engine oil disc and re-check the engine oil level, and if the engine oil is insufficient, please add the engine oil to the “H” scale of engine oil level gauge. Check of Engine Oil Level

Caution: When opening the electric lock but not starting the engine, engine oil pressure alarm and buzzer will give an alarm until the engine is started successfully and engine oil pressure gets into the normally operating scope. If the alarm continues give an alarm, please shut down the engine immediately and check whether the engine oil level is at the right position in order to avoid the damage to the engine.

Replacement of Engine Oil Filter 1.

Clean the surrounding area of the mounting seat of the oil filter.

2.

Remove the engine oil filter with the belt spanner.

3.

Clean the contacting surface of packing plate on the mounting seat with a clean cloth. If the oil O-type seal ring is stuck on the mounting seat, remove it. Clean of mounting seat 144

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Mount a new O-type seal ring, fill the engine oil filter with the clean oil and supply a layer of clean engine oil on the surface of the packing plate. Mount of new engine oil filter

Caution: Before the mount, fill the engine oil filter with the clean oil. In case of mounting an empty oil filter, engine will break down due to the lack of lubricating oil.

5.

Mount the oil filter to the mounting seat, tighten it by hand until the surface of the packing plate of oil filter contacts with the mounting seat, and then use the belt spanner to screw down the oil filter to the required value.

Caution: Excessively mechanical tighten may cause the damage to the thread or the seal of core of the engine oil filter.

Maintenance of Gearbox Check of Oil Level of Gearbox Caution: When checking the oil level, it is necessary to park the motor grader on the flat ground, place the gear-control handle at the neutral gear and press down the button of parking brake to implement the parking brake. Mount the fixed bumper of the frame to prevent the movement and rotation of the 145

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machine. Gearbox is located under the fuel tank, the filler of gearbox is located between the radiator and fuel tank and the oil gauge for checking the oil level is mounted inside the oil filling pipe. Filler of gearbox

Caution: 1. When checking the oil level of gearbox, it is necessary to check the cold oil level and hot oil level respectively. 2. Too high or low oil level of gearbox may lead to the damage to the gearbox, so the oil level of gearbox should be remained in the correct position.

Gearbox oil level should be checked as follows: 1.

Park the motor grader on the flat ground.

2.

Place the gear control handle at the neutral gear “N” and press down the button of parking brake to implement the parking brake in order to prevent the motion of machine.

3.

It is necessary to check the cold oil level when the engine is running idly and the oil temperature does not exceed 40℃ l by unscrewing the oil level gauge anti-clockwise to take off it and wipe out oil on it with a clean cloth and insert it into the oil filling pipe till the end, and then pull out the oil level gauge. At this time the oil level should be within the “COLD” oil zone of the oil level gauge (see the following figure).

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Zone “COLD”

4.

When the oil temperature reaches the operating value (80℃ ~90℃ ), check the hot oil level. Take off the oil level gauge and wipe out oil on it with a clean cloth and insert it into the oil filling pipe till the end, and then pull it out. At this time the oil level should be within the “HOT” oil zone of the oil level gauge (see the above figure). If the oil level is over the “HOT” zone, discharge a part of the gearbox oil through the oil drain screw plug at the bottom of the gearbox.

Zone “HOT”

5.

After the check, insert the oil level gauge into the oil filling pipe of gearbox, and then rotate it clockwise to screw down the oil level gauge.

Caution: When checking the oil level of gearbox, changing the gearbox oil and replacing the oil filter of gearbox, be sure to keep clean to prevent the filth from entering the gearbox system so as to avoid the damage to the gearbox. When checking the hot oil level of the gearbox, the operation methods to rapidly increase the oil temperature are as follows: 1.

Park the motor grader on the flat ground and it is necessary to ensure that there is a bodylength space in the front and rear of the machine and there are no people around the machine.

2.

Place the gear control handle to the neutral gear “N” and pull up the button for parking brake to release the parking brake.

3.

Step on the service brake pedal to the end.

4.

Place the gear control handle to the forward 6th gear, at this time, the torque converter is in the stall working condition and the oil temperature of gearbox will rise rapidly. 147

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When the oil temperature of gearbox reaches above 80℃ , place the gear control handle to the neutral gear and pull up the electromagnetic valve switch of parking brake. At this point the hot oil level of gearbox can be checked.

Change of Gearbox Oil After the first 100 work hours, it is necessary to change the gearbox oil, and change it once every 1,000 work hours afterwards. Change the gearbox oil once a year at least.

Caution: When carrying out the check, maintenance, test and adjustment to the motor grader, it is necessary to be prepared to use a suitable container to collect the liquid before removing any hydraulic oil circuit or disassembling any part containing the liquid. And dispose of all liquid in accordance with the local laws and regulations. The gearbox oil should be changed according to the following steps: 1.

Park the motor grader on the flat ground, place the gear control handle at the neutral gear and press down the button of parking brake to prevent the movement and rotation of machine.

2.

Start the engine and run it at idle speed and shut down the engine when the oil temperature of gearbox reaches the operating value (80℃ ~90℃ ).

3.

Screw off the oil drain screw plug ① receive it with a container.

at the lower rear of gearbox to discharge the oil and

1. Oil drain screw plug 2. Primary filter of gearbox 3. Oil suction pipe

Caution: At this time oil temperature of gearbox is still high, so it is necessary to wear the protective equipment and operate carefully so as not to cause physical harm. 4.

Screw off the oil drain screw plug at the lower of the oil radiator of torque converter to discharge the oil and receive it with a container and then screw off the air release screw plug at the top of the oil radiator of torque converter to speed up the oil drain. Oil radiator of torque converter

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Filler

Air release port

Oil radiator of torque converter

Caution: When draining the oil, it is necessary not only to drain the gearbox oil and also the oil of torque converter and radiator. 5.

Replace the oil secondary filters of gearbox.

Oil secondary filter of gearbox

6.

Remove the oil suction pipe ① at the right rear of gearbox to take off the primary filter ① . Rinse and dry it with the clean compressed air or fuel.

7.

Remove the iron dust attached on the oil drain screw plug with the magnet and remove the iron dust of inner wall by stretching the magnet through the mounting port of secondary filter into the oil disc of gearbox.

8.

Mount the primary filter, oil suction pipe, oil drain screw plug, oil drain screw plug under the radiator of torque converter and its sealing pieces.

9.

Unscrew the oil filling screw plug in the top of radiator of the torque converter and add the clean gearbox oil from the filler of the radiator of torque converter, and then screw down the air release screw plug and oil filling screw plug after the radiator is full of the gearbox oil.

10. Take out the oil level gauge of gearbox and add the clean gearbox oil from the oil filling pipe 149

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of gearbox until the oil level reaches above the “HOT” zone.

11. Start the engine and run it at the idle speed, at the same time check the oil level and add the gearbox oil repeatedly until the oil level reaches above the “COLD” zone of oil level gauge. During this process, the gearbox is likely to produce a slight abnormal sound, which is caused by the lack of gearbox oil, and adding the oil to the specified level will eliminate the abnormal sound.

12. When the gearbox oil reaches the operating temperature (80℃ ~90 ℃ ), check the oil level once again, and the oil level should be within the “HOT” zone of oil level gauge. In case of the oil shortage, please add the oil; in case of excessive oil, please drain some of the oil.

Zone “HOT”

13. Insert the oil level gauge and tighten it clockwise.

Caution: Before changing the gearbox oil, be sure to cover the parking brake to avoid the friction plate of parking brake stained with the oil to reduce the brake performance.

Replacement of Secondary Filter of Gearbox Oil The secondary filter of gearbox oil is located at the right top of the gearbox and should be replaced when changing the gearbox oil.

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Oil secondary filter of gearbox

1.

Clean the surrounding area of secondary filter of gearbox.

2.

Remove the secondary filter from the mounting seat with the belt spanner.

3.

Clean the sealing surface of mounting seat with a clean cloth.

4.

Apply a layer of gearbox oil on the packing plate of new secondary filter.

5.

Tighten the secondary filter on the mounting seat until the packing plate of secondary filter contacts with the sealing surface of the mounting seat and then screw it down for 1/3 to 1/2 laps by hand.

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Maintenance of Driving Axle Oil Level of Driving Axle–Check Caution: take care when unscrewing the plug to take oil in or out driving axle, in case of hot oil splash. 6. Drive the machine to a flat field and park it horizontally! Clean all the filling parts up before check! 7. Put the shifting control handle in neutral gear, and press down the parking brake button in case of vehicle moving. 8. Observe the oil scale in the middle of driving axle, and you shall find the oil level in the middle of oil scale, otherwise the oil volume is not enough. Filler

Oil scale

Oil drain hole

Oil of Driving Axle–Replacement Caution: 1. During the check, maintenance, test and adjustment of machine, when removing any hydraulic circuits or taking down any parts containing liquids, you must prepare a proper container to collect the liquids and then dispose all the liquids according to the local code and regulation. 2. It should be conducted to drain oil after driving for a time so as to fully suspend the precipitated impurity in the axle housing. 1 2 3

Put the shifting control handle in neutral gear, and draw up the parking brake button. If the vehicle stops on a slope, the wheels must be wedged. Unscrew the drain plug in the middle of rear driving axle to drain the oil, and collect the oil in a container.

Warning: as the oil temperature maybe high, you should wear safety appliances and operate carefully, in case of body injuries. 4

Screw up the drain plug in the middle of rear driving axle. 152

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Filling in clean gear oil through the filler of rear driving axle until the oil level is in the middle of oil scale. After ten minutes, if the oil level keeps the same, you can screw up the choke plug of the filler of rear driving axle.

Maintenance of Tandem Checking the Oil Level of Tandem Drive the machine to a flat field. Observe the oil scales separately in the middle of left and right wheels, and you should find the oil level in the middle of oil scale, otherwise the oil volume is not enough.

Oil scale

Replacement of Tandem Oil 1.

Put the shifting control handle in neutral gear, and press down the parking brake.

2.

If the vehicle stops on a slope, the wheels must be wedged.

3.

Unscrew the drain plug at the inner side of tandem to drain the oil, and collect the oil in a container.

Drain plug

4.

Screw up the drain plug after the oil is completely discharged.

5.

Filling in the clean gear oil through the filler of tandem until the oil level is in the middle of oil scale.

6.

After ten minutes, if the oil level keeps the same, you can screw up the choke plug of the filler of rear driving axle. 153

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Filler

Maintenance of Hydraulic System Checking the Level of Hydraulic Oil Caution: when checking the level of hydraulic oil, you should park the vehicle in a flat field, put the working devices like moldboard on the ground and ensure to align the front and rear frames without angle. Filler of hydraulic oil tank

Hydraulic oil tank

Liquid level meter

The hydraulic oil tank locates at the back of cab. At the left side of hydraulic oil tank is a liquid level meter to indicate the level of hydraulic oil. At this moment, the level of hydraulic oil should be at 2/3 scale of liquid level meter.

Regular Replacement of Hydraulic Oil Warning 1. During the check, maintenance, test and adjustment of machine, when removing any hydraulic circuits or taking down any parts containing 154

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liquids, you must prepare a proper container to collect the liquids and then dispose of all the liquids according to the local code and regulation. 2. During the operation of replacing the oil, you should be very careful of the cleanliness of hydraulic oil and do not let any dirt into the hydraulic system. 3. If the hydraulic oil is seriously polluted and goes bad (like the color turns black) because of bad working condition, please replace the hydraulic oil in time. 1 Drive the machine to a flat field, press down the parking brake button, and fit on the fixed bumper of frame. 2 Start the engine and run it for 10 minutes at idle speed, during when repeat the movements like raising and declining the boom and tipping the moldboard forward and backward. 3 At last, lift the boom to the top position, tip the moldboard backward to the biggest position, and then shut down the engine. 4 First shift the switch of shut-off valve of oil guide to the “OFF” gear. 5 Clean the oil drain hole beneath the hydraulic oil tank, unscrew the drain plug to discharge the hydraulic oil, and collect it with container. Meanwhile open the filler cap with lock of hydraulic oil tank to speed up oil discharging process. Oil drain hole of hydraulic oil tank Filler cap of hydraulic oil tank

Warning: as the oil temperature maybe high, you should wear safety appliances and operate carefully, in case of body injuries. 6 Take apart the oil-in pipe of hydraulic oil radiator, and drain the residual hydraulic oil of the radiator. 7 Take down the top cover of oil return filter of hydraulic oil from hydraulic oil tank, take off the oil return filter core and replace it with a new one. Open the filler cap and take off the filter screen of filler to clean. Oil return filter

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8

Take down the flange cover of cleaning mouth of oil tank beneath the filler, wash the bottom and four walls of the hydraulic oil tank with fuel, and dry it with clean cloth at last. 9 Mount the drain plug of hydraulic oil tank, oil return filter and top cover, filter screen of filler, flange cover of cleaning mouth of oil tank and hydraulic oil radiator well. 10 Fill in clean hydraulic oil through the filler of hydraulic oil tank to make the oil level reach the upper scale of liquid level meter of hydraulic oil, and then screw up the filler cap. 11 Remove the fixed bumper of frame and start the engine. First shift the switch of shut-off valve of oil guide to the “ON” gear. And then operate the control handle of leading valve to conduct the movements of raising and declining the boom, tipping the moldboard forward and backward, and turning left and right to the largest angle for 2~3 times, in order to fill the oil tank and oil pipe with hydraulic oil. Afterwards run the engine at idle speed for 5 minutes to exhaust the air in the system. 12 Shut down the engine, open the filler cap of hydraulic oil tank, and add clean hydraulic oil until the level of hydraulic oil reaching the 2/3 scale of liquid level meter of hydraulic oil tank.

Maintenance of Working Device Oil Level of Worm-gear Case–Check 1.

Put the worm-gear case horizontally.

2.

Observe the oil level indicator, and the oil level must in the middle of observing hole.

3.

Add oil through filler (plug 2) first, if necessary.

4.

Normally, you should check the oil level after 50h’s continuous work of the machine. Plug 2

Oil level indicator Plug 1

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Worm-gear Case–Oil Replacement 1.

In order to speed up oil discharging, swing the moldboard to lean at the drain plug (plug 1) side and bear the moldboard on the ground.

2.

Take off plug 1, and then you can drain the oil. If taking off plug 2 at the same time, you can pick up the draining speed and make the oil discharged completely.

3.

Clean plug 1, and exchange a new sealing ring. Mount the sealing ring at the worm-gear case (plug 1) and screw it up.

4.

Lift and decline the oil cylinder with moldboard to put the worm-gear case horizontal again.

5.

Fill the oil again through the filler (plug 2) to make the oil in the middle of the observing hole of oil level indicator. The oil volume is about 2.5L. Grease is 85W/90 GL-5 (in summer) or 80W/90 GL-5 (in winter). Clean plug 2, and exchange a new sealing ring. Mount the sealing ring at (plug 2) and screw it up.

6. 7.

Guarantee to replace oil at once each year.

Adjustment of Circle Clearance 5.

In order to ensure reliable working requirements, when assembling the working devices, you can choose the adjusting gasket with proper thickness which is mounted between traction frame and circle, and adjust the assembling clearance to 0.2~0.5 mm. The abrasion limit during work should be no more than 1mm. The worn-out gasket should be replaced in time.

6.

After 500h of overall work, you should check the abrasion situation of adjusting gasket and the clearance between traction frame and circle.

Adjusting gasket

Circle–Lubrication 7.

The lubricating grease filled by the factory is 3# lithium base lubricating grease. When the machine is working at low temperature, you can fill 2# lithium base lubricating grease. If it falls short of the working condition, you can change for proper lubricating oil.

8.

If you find abnormal sound at the turning part or continuous increase of turning drive power during usage, you shall find out the reason, and remove and check it, if necessary.

9.

Fill lubricating grease for circle, driving gear and each ball socket after every 100h’s work or after every two weeks. 157

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Lubricating points of circle (3 points)

Lubricating points of driving gear

Lubricating points of spherical articulation

Maintenance of Accumulator The accumulators (3) used by the brake system of this machine are mounted at the right side of frame, beneath the cab. Accumulator I is used for parking and emergency brake circuit. Accumulator II, III which beneath accumulator I are used for service brake circuit.

Accumulator cover

Accumulator III

Accumulator II

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Nitrogen

of

Accumulator Caution: 1. Accumulator should be checked by the pressure of precharged nitrogen of accumulator according to the stated cycle of “periodical maintenance”, to ensure the normal work of service brake system and parking brake system. 2. Check of the pressure of precharged nitrogen of accumulator should be conducted with special tools and by specially trained people. The operation steps are as follows: 1

2

Stop the machine in a flat and clear field with working devices like moldboard horizontal on the ground. Put the shifting control handle in neutral gear, and shut down the engine. Then turn the start switch clockwise to the first gear, and electrify it. Releasing the pressure of accumulator: stamp on the brake pedal continuously for 20 times or so, and then continuously press down and pull up parking brake button for 20 times or so, in order to discharge the hydraulic oil in the accumulator. Afterwards slowly loose the drain plug at the oil-out opening beneath the accumulator to drain the remained hydraulic oil in the accumulator. Protecting cap charge valve

of

Drain plug

Caution: don’t splash the hydraulic oil on the people during operation. 3 4

Remove the protecting cap of charge valve from the upper end of accumulator. Connect the charging tool with the end of nitrogen cylinder and block it by plug. Connect the other end of pressure gauge with the charge valve at the upper end of accumulator.

④ ③ ② ① 1. connecting to the charge valve of accumulator 2. release port 3. switch 4. connecting to nitrogen cylinder 159

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Turn on the switch of charging tool, and the thimble of it will push the charge valve of accumulator open. At this moment the indicating needle of pressure gauge shall indicate the reading. When the indicating needle becomes stable, whose reading is the pressure of precharged nitrogen in accumulator. The value should conform with: Accumulator I——9.2MPa; Accumulator II, III——9.2MPa If the pressure is too low, the nitrogen should be complemented. Turn off the switch of charging tool, and then remove it from the accumulator and mount the protecting cap of charge valve.

Pressure Relief of Accumulator If the pressure of precharged nitrogen is above the respecting value, you can decompress it to the required pressure value by the air releasing end cap. It is suggested to slowly decompress it. It will need several minutes after depression to read the effective pressure value.

Charge of Accumulator Caution: 1. If the pressure of precharged nitrogen of accumulator is insufficient, it should be complemented in time, otherwise it will affect the normal usage of brake system. 2. Check of the pressure of precharged nitrogen of accumulator should be conducted with special tools and by specially trained people. The operation steps are as follows: 1. 2.

3.

4.

5.

Connect the end of charging tool with pressure gauge to the charge valve at the upper end of accumulator, and the other end with nitrogen cylinder. Slowly open the valve on the nitrogen cylinder. Wait until the pressure reading of pressure gauge becomes stable, and then slowly turn on the switch of charging tool. At this moment, the charge valve inside accumulator will be pushed open and the air charging starts. Keep charging until the pressure indicated by pressure gauge is a little higher than the required one, and then close the valve. Pressure can be reached in a short time. You should turn off the switch of nitrogen cylinder, and check whether the pressure reaches or not after the pressure gauge is stable. If not, recharge it. If the pressure is too high, it may be depressed to the suitable value by bleeding the air through the air releasing end cap of charging tool. When the pressure is charged enough, first turn off the switch of nitrogen cylinder, and then turn off the switch of charging tool. Take off the charging tool. Check whether the charge valve is leaking by suds. If there is air bubble, it is leaking. Slightly knock on the charge valve inside accumulator by hammer or small screwdriver to make it first drop a little and then return rapidly. It is al right when the sealing faces completely touch together. Screw up the protecting cap of charge valve of accumulator again.

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Warning During the operation of removing the protecting cap of charge valve, it is forbidden to turn the steering wheel. Make sure the engine is shut down, in case of body injuries. The accumulator can only be charged fully with nitrogen by charging tool. Oxygen, compressed air or other flammable gas are prohibited to charged, in case of explosion.

Maintenance of Brake System Inspection of the Performance of Parking Brake Caution: the performance of parking brake should be checked constantly to ensure the parking safety and the brake ability of emergency brake. 6. 7. 8.

9.

Adjust the air pressure of tyre to the prescribed value. Lift the working devices like moldboard. Start engine, and drive the machine up to the slope of 15% (angle is 8.5°). The pavement should be even and dry. Step down the pedal of service brake and stop the machine stable. Put the shifting control handle in neutral gear, and then shut down the engine.

Press down the parking brake button, and slowly loose the pedal of service brake. Check whether the machine is in the same position.

Warning: if the machine moves during inspection, it may cause body injuries.

Inspection of the Performance of Service Brake Caution: in order to ensure the safety and accuracy, the inspection of the 161

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performance of brake system can only be conducted by professional people. Non-professional people are forbidden to conduct this inspection. Caution: before inspecting the performance of service brake, you should guarantee the normal work of service brake system so as to use parking brake to conduct emergency brake. Drive the machine at the speed of 30 km/h on even and dry road. Step down the pedal of service brake completely. When the machine stops, first put the shifting control handle in neutral gear and press down switch of electromagnetic valve of parking brake, and then loose the pedal of service brake. Check the brake distance, which should be no more than 13m.

Warning: if the machine moves during inspection, it may cause body injuries.

Maintenance of Lubrication System Schematic Diagram & Time Interval of Lubrication As this machine has no centralized lubricating device, lubricating grease should be filled according to the schematic diagram and time interval of lubrication, in order to ensure the normal work of every part in the machine. The lubrication system drawing is struck at the left side of engine hood, near the cab.

Oil Time interval of filling lubricating grease

No. 3 lithium base grease Time interval of lubricating the lubrication points 38, 39, 40, 41, 42, 43 is every 20h or 2 days. Time interval of lubricating other lubrication points is every 50h or 1 week.

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Maintenance of Storage Battery Storage battery locates at the left rear side of machine. Safety warning sign

When operating the storage battery, you must obey the requirements of the safety warning signs struck near storage battery and on the top cover of storage battery.

Dangerous sign area

warning

Indication of magic eye state

Safety warning sign area

Warning Absolutely don’t put the lit cigarette or naked flame near to the storage battery. When touch the storage battery during work, you shall wear safety glasses and rubber gloves. It is required to pull on protective garment additionally. Before conducting the work related with storage battery, shut down the engine.

Magic eye

Magic eye

Instruction of the charge state of storage battery: Densimeter (also called gravimeter, hereinafter referred to as magic eye) of charge state is attached to on the top cover of storage battery, when the light is sufficient, you can visually check 163

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the charge state of storage battery by naked eyes. Green magic eye–the charge state of storage battery exceeds 65%, and the storage battery is normal. Black magic eye–the charge state of storage battery is under 65%, and it needs to be charged. Transparent and bright magic eye–the storage battery is scrapped and needs to be exchanged. When the housing of storage battery is broken or leaks acid liquid, or end post is broken, or when the magic eye is transparent and bright, you should find out the reason and then exchange the storage battery.

Cleaning of Storage Battery Open the cover of storage battery case at the left of the machine, clean the ends and surface of storage battery with clean cloth, smear the terminal of storage battery with Vaseline, and then ensure the cable of storage battery is mounted firmly. Nut of press plate

Terminal of storage battery Terminal of storage battery

Terminal of storage battery (with the sleeve unplugged)

Caution: 1. After a period of time, the press plate of storage battery will be loosened by the vibration during the operation of machine. In order to avert looseness of storage battery, you shall constantly check whether the nut in the center of press plate is screwed tight. If it is loose, please screw it up. 2. After a period of time, the connection between the terminal of storage battery and the cable connectors will be loosened by the vibration during the operation of machine. In order to avert the possible looseness, you shall constantly check whether the connection between the terminal of storage battery and the cable connectors is loose or not.

Installation of Storage Battery The storage battery with green densimeter can be mounted firmly and reliably in the stated parts of vehicle and put into use. 10. Make the cathode switch of storage battery in closed state. Turn the start switch (also called electric switch lock) to the “OFF” position and pull the key out. 11. Clean the ends and surface of storage battery with clean cloth. Absolutely don’t use gasoline or any other organic solvent or cleanser. 12. When connecting the wire, first connect the anode of storage battery with that of engine, and then connect the cathode of storage battery with that of engine. 13. Screw the nuts firm and tight. 164

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14. Put through the cathode switch of storage battery, insert the key and start the electric switch lock.

Warning: you must identify the positive (+) end and the negative (-) end separately. Wrong installation will result in serious damage of pile head.

Charge of Storage Battery 15. Reason why storage battery is lack of electricity.  Abnormal usage like turning on the electric appliances for too long with the machine not started.  The situations like long time driving of machine, heavy current of electrical leakage of machine, or mounting additional electric appliances, cause the complete discharge of battery.  Frequent starting of machine.  Malfunctions of charging system of machine like useless engine or other electronic components, too low setting of the charging voltage of engine voltage regulator, or loose drive belt of engine, can make abnormal charge of battery, cause the battery lack of electricity and the magic eye of storage battery black, and even the fail of starting the machine. 

The stock time of storage battery is over 6 months.

The storage battery with electricity shortage caused by the above reasons can be back to normal by correctly and timely replenishing. 16. Check the appearance of battery before charging. 

The storage battery with broken housing of storage battery with or which leaks acid liquid can not be replenished. Find out the reason and then exchange it.



Battery with broken end post can not be replenished. Find out the reason and then exchange it.



The storage battery with whitish magic eye needs to be exchanged instead of replenished.



Before replenishing, clean the end post and remove the superficial oxide skin.

17. Precautions of Charging 

Wear safety glasses.



Keep a good ventilation of circumstance during charging. Charge it under normal temperature.



Smoking is forbidden in case of the introduction of tinder.



When connecting the wire after charging, first connect the wire of anode; when disconnecting the wire before charging, first disconnect the wire of cathode.

18. Operations of Charging the Storage Battery 

Ensure that the end post of storage battery is clean and that the connection of charging circuit is good.



The anode of charger is connected with that of storage battery. The cathode of charger is 165

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connected with that of storage battery. Be sure not to charge the battery in series (24V). 

It is suggested to use constant voltage of 16.0V (the maximum voltage can not exceed 16.2V. The excess of this limit can cause many water electrolyzed, leading declined liquid level, whitish magic eye and broken battery). Charge the storage battery with current limiting 25A charger until the magic eye turns green, which means the battery is fully charged.



If there is no condition to charge with constant voltage, you can use the following normative constant current:

(1) Select 1/8~1/10A charging current with rated capacity (it is12~15A for 37B0108 battery, and 10~12A for 37B0077 battery). The voltage at the final stage of charging should reach but not exceed 16V (the voltage at the final stage below 16V is easy to cause the magic eye black after the battery is filled.) If the charger can not guarantee that the charging voltage will be limited below 16V, the voltage of storage battery must be monitored every hour by people, otherwise it will affect the service life of storage battery or even make it inefficacy, because of water loss caused by over voltage. (2) The corresponding relationship of charge time and voltage of storage battery before charging is listed as follows (For your information, the small the charging current, the longer the charging time). Battery voltage Charge time 12.55~12.45V 2h 12.45~12.35V 3h 12.35~12.20V 4h 12.20~12.05V 5h 12.05~11.95V 6h 11.95~11.80V 7h 11.80~11.65V 8h 11.65~11.50V 9h 11.50~11.30V 10h 11.30~11.00V 12h Below 11.00V 14h (3) Check the color of magic eye after charging. If the magic eye is green, it means the storage battery is fully charged. If the magic eye is black, check whether the charging wire is connected firmly and whether the connecting points are clean, or whether the voltage at the final stage reaches 16V. Check the voltage after 24h’s laying, and then continue to charge it according to the relationship of charge time and voltage of storage battery. (4) If the magic eye is whitish after charging, it may be caused by the air bubbles in the magic eye. You can slightly shake the battery to remove the air bubbles. If it is still whitish after shaking, it means the electrolyte is lost and the storage battery is scrapped which needs to be exchanged.  As to the storage battery with the voltage lower than 11.0V, the electricity may not be charged into the storage battery at the early stage of charging. Because the sulphuric acid proportion of storage battery with serious electricity shortage is close to pure water, the internal resistance of storage battery is very big. At this time, you can decrease the charge current or change another charger with bigger power, or you can charge with another storage battery connected in parallel. With the charging of the storage battery, the sulphuric acid proportion in it will raise, and then the charge current can be gradually back to normal.  During charging, if lot of acid spouts from the exhaust hole of storage battery, you should 166

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stop charging at once and find out the reason. During charging, if the temperature of storage battery exceeds 45 degree, you should stop charging, and wait until it drops to room temperature and then continue to charge it with the charge current halved. During charging, check the state of magic eye every hour. If the magic eye is green, it means the storage battery is fully charged. It is suggested to smear Vaseline on the end post of storage battery after the charge and qualification testing, in case of electrolytic corrosion.

Warning If the treatment of storage battery is incorrect during charging, the storage battery may explode. When the housing of storage battery is broken or leaks acid liquid, or end post is broken, or when the magic eye is transparent and bright, you should find out the reason and then exchange the storage battery. Keep ventilation during charging. Smoking is forbidden in case of spark and naked flame.

Maintenance of Storage Battery during Stock of Machine  

 



If the machine is going to be stocked over 15 days, the cathode wire of storage battery should be disconnected. Check the charge state of storage battery every other 3 month. Storage battery with the voltage over 12.40V is the one with normal charge. Storage battery with the voltage under 12.40V is the one lack of electricity. Must replenish the storage battery when it is lack of electricity. Replenishment should be done complying with the charging procedure. For the vehicle that does not disconnect the wire of storage battery, check the voltage state of the storage battery once every month. Storage battery with the voltage under 12.40V should be replenished complying with the charging procedure. For the storage battery on vehicle that is stocked over 1 year, if it is not replenished complying with the charging procedure, then it must be scrapped and replaced.

Reject of Storage Battery Although the storage battery used for machine is watering-free and maintenance-free, whose inner structure can effectively prevent the acidic materials inside from polluting the environment, yet when it is scrapped, the polar plate containing lead, acidic materials and plastic encloser will cause pollution to the environment of varying degrees, for the broken of exterior structure or for other reasons. Therefore, the waste storage battery is not allowed to be littered. Please send the waste storage battery to be dealt with to professional processing station of battery or recycle bin here (if any) set up by the storage battery manufacturer.

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Maintenance of Air Conditioning System Inspection of Air Conditioner Warning: the refrigerant gas of air conditioner inbreathed through the lit cigarette or other smoking methods, or the smog given off by the flame touching the refrigerant of air conditioner, will cause casualty. Smoking is forbidden during the maintenance of air conditioner or at the place possibly having refrigerant gas. 1 2

Start engine and run it at high idle speed. Turn on the switch of air conditioner and adjust it in cooling mode, and then control the blowing speed in high speed mode by adjusting the wind speed switch.

3 4

Let the air conditioning system run stably for 2 minutes. Open the rear hood, and touch the air intake pipe and the exhaust pipe to check the refrigerant in the system. If there is refrigerant in the system, the exhaust pipe is warmer than the air intake pipe. If there is not any refrigerant or there is a very few refrigerant in the system, the cooling effect will be very poor. Air intake pipe

Exhaust pipe

Checking the Cooling Medium in Storage Tank of Air Conditioner When opening the air conditioner, check whether the cooling medium is sufficient or not by observing whether the cooling medium in the storage tank has air bubbles or not through the liquid glass on the storage tank. If there are lots of air bubbles, the cooling medium is insufficient; 168

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if there is a thimbleful of air bubbles or no air bubbles, the cooling medium is sufficient.

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Liquid glass

Liquid glass

Storage tank

Checking

the

Tension

of

Compressor

Belt

of

Air

Conditioner Rate of tension of compressor belt of air conditioner: if vertically adding a load W=1.3kg to the point of belt at the middle of two points of contact made by the belt and two belt pulleys (the belt pulley of compressor of air conditioner and the belt pulley of engine), the flexivity produced by belt should be 4±1mm. See the following drawing.

If the belt has no tension, that is, the flexivity produced by belt is over 4±1mm, when vertically adding a load W=1.3kg to the point of belt at the middle of two points of contact made by the belt and two belt pulleys (the belt pulley of compressor of air conditioner and the belt pulley of engine), the belt should be exchanged. If the belt fluffs or has breaches, it needs to be exchanged.

Cab Air Filter–Cleaning/Replacement Cab Air Filter Cab air filter is composed by exterior air filter and interior air filter. The chocking-up degree of filter completely lies on the working circumstance of machine.

Caution: 1. Cab air filter is only used to filter the dust from the air but not the poison gas! 2. If the exterior air filter is chocked up, it may cause the 170

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decrease of fresh wind in cab. The normal interval of cleaning air filter is 200h. The cleanness of air filter can be properly prolonged or shortened according to the quantity of dust in the working condition. Exchange the exterior air filter every other 1,000 hour. Please choose the air filter complying with ISO10263-2.

Caution: 1. if you operate the machine under dusty condition, the cab air filter should be constantly cleaned. 2. If the body will be hit by compressed air or high pressure water, or if there will be danger to cause serious damages when compressed air or high pressure water is used to blow away the dust or dirt, you must wear goggles, dirt shroud or other safety appliances. Cleaning of Exterior Air Filter: 1 Remove the fixed bolt of air filter housing at the right rear part of cab, and then take off air filter housing ① and exterior air filter ①. 2 Clean the air filter with compressed air. If the air filter is oily or too dirty, use neutral medium to wash. After washing in water, completely dry it before using again.

Caution: if the chocking-up problem of air filter can not be solved by air blowing or water washing, or if the air filter is broken, you should change a new one. 3

Put the cleaned air filter ① into the groove of air filter housing ①, and then mount it together with the air filter housing, and screw the bolt tight.

Other Maintenance Main Cutting Edge and Side Cutter Board of Moldboard –

Check/Replacement Warning: the falling of moldboard will cause injury for personnel, and underlay the moldboard well before replacing the main cutting edge or side cutter board.

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The main cutting edge 2 and side cutter board 1 may be of damage or excessive abrasion. If needed, replace the cutting edge 2 and side cutter 1. 4 Put the wedge block under moldboard, lower the moldboard on wedge block and do not underlay the moldboard too high. Underlay the moldboard with sufficient wedge blocks to remove the main cutting edge 2 and side cutter board 1 conveniently. 5 Remove the bolt, main cutting edge 2 and side cutter board 1. 6 Clean all interfaces. 7 Install new main cutting edge 2 and side cutter board 1. 8 Tighten the bolt to specified torque. 9 Lift the moldboard to take off the wedge block.

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Guide and Bushing of Moldboard–Check/Replacement If the moldboard seriously shakes forward and backward when operating, replace the guide and bushing. When replacing the guide and bushing, replace them together. If the toughness of guide rail can be eliminated in time, the abrasion degree of bushing will be reduced and file will be used to finish the guide rail. Replace the Bushing

Bushing Baffle

10 Stop the machine in wide and flat place steadily, and conduct the parking brake to ensure the machine will not move when repairing. Place the wedge block under moldboard and lower the moldboard on wedge block. 11 Screw off the bolt on fastening baffle, and remove the baffle. 12 Remove the moldboard by sliding it and then remove the bushing. 13 Clean all interfaces. 14 Install new bushing and install the moldboard well. 15 Tighten the bolt on fastening baffle to specified torque. 16 Lift the moldboard to take off the wedge block. Replace the Guide

Bolt

Guide

17 Stop the machine in wide and flat place steadily, and conduct the parking brake to ensure the machine will not move when repairing. Place the wedge block under moldboard and lower the moldboard on wedge block. 173

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18 Screw off the bolt on fastening baffle, and remove the baffle. 19 Clean all interfaces. 20 Install new guide. 21 Tighten the bolt on fastening baffle to specified torque. 22 Lift the moldboard to take off the wedge block.

Piston Rod of Moldboard Sideshift Oil Cylinder–Fixing The two conical washers can be rotated with hand after the slotted nut has been locked by the piston rod. Use the same method to fix piston rod when repairing or replacing the oil cylinder.

Piston rod of oil cylinder

Conical washer

Slotted nut

Conical washer

Gear Sleeve of Rear Scarifier–Check/Replacement Check the gear sleeve of scarifier, if the gear sleeve is damaged or badly worn, please replace it in time. WARNING The falling of scarifier will cause injury to personnel. Underlay the scarifier well before replacing gear sleeve. When knocking the connecting pin between gear body and gear sleeve with strength, the connecting pin may depart outward and injure other people. Ensure that there is no person nearby when operating the pin. In order to prevent eyes from being injured, please wear safety-guard glasses when knocking the pin. 23 Underlay the rear scarifier well at a proper height when removing the gear sleeve. 24 Remove the pin from the side of snap ring of gear sleeve and then remove the gear sleeve and snap ring.

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25 Clean the gear body, pin and snap ring and install snap ring to the slot at side of gear body. 26 Re-install the gear sleeve. 27 Drive the pin into snap ring, gear body and gear sleeve from the side of snap ring. 28 If the replacement of other gear sleeves is needed, please repeat step 2 to step 5. 29 Lift the rear scarifier, move off the pad and lower the scarifier to the ground. Roll Over Protection Structure (ROPS)–Check (Optional) WARNING

Do not try to straighten the ROPS structure and do not repair ROPS structure by welding the stiffening plate to this structure. If there is crack in welding line, casting and other metal parts of ROPS, please contact Liugong agent.

30 The external ROPS of this machine is connected with the two end faces of front frame by two bolt holes on the two pillar. 31 Check the ROPS to see if there are looseness or any other damaged bolts, and replace any damaged bolt.

Caution: better to use original parts and tighten according to specified torque. Coat the bolt thread of all ROPS with lubricating oil before the bolt is installed into ROPS. Otherwise, incorrect bolt torque will appear. 32 When operating the machine on rough surface, resultantly, if there is noise from ROPS, please check the mounting seat of ROPS.

Check Clearance of Engine Valve Cautions: the adjustment of clearance of engine valve should be conducted by professionally trained personnel and special tools should also be used. Please refer to Manual of Engine Operation and Maintenance for details of adjustment of clearance for engine valve. 176

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Check the Air Intake System of Engine Mainly check if there are cracked hose, loose clamp or puncture in this item, and tighten or replace parts according to needs to confirm there is no leakage of air intake system.

Check Driving Belt of Engine Visually check the driving belt of engine to see if there is crack on crossed surface. If there is vertical (length direction of belt) crack or small fallen-off material, the belt should be replaced. Please refer to Manual of Engine Operation and Maintenance for replacement steps.

Check Tension Pulley Bearing and Fan Shaft Shell of Engine Check if the tension pulley bearing and the tension pulley can rotate freely. Check shaft shell of fan and it can rotate without shaking or excessive end clearance.

Check the Shock Absorber of Engine Please refer to Manual of Engine Operation and Maintenance for details.

Check and Replacement of Fuse The fuse box is located at cab. The fuse is used for protecting electrical system and preventing damage when the circuit is over-loaded. If the fuse wire is broken, replace the fuse. If the new fuse wire is broken again, check the circuit, and repair the circuit if needed. See the following table about color of strip-type fusible device (fuse) for each specification: BX2011C-5A

Orange

BX2011C-7.5A

Brown

BX2011C-10A

Red

BX2011C-15A

Blue

BX2011C-20A

Yellow

BX2011C-30A

Green

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Cautions: replace the fuse only with the same type and specification; otherwise, the circuit will be damaged. If the fuse needs to be replaced frequently, there may be circuit malfunction and please contact Liugong agent.

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Test of Reversing Alarm Turn the start switch of engine to “ON” gear to conduct the test. Place the control handle of transmission at backward position, at the very moment, the reversing alarm should start to buzz. The reversing alarm will stop buzzing until the control handle of transmission is placed at neutral or forward position.

Check of Seatbelt Before using the belt, drivers should check abrasion and firmness degree of belt, and please replace it if necessary. Adjust the length of belt before using to ensure that the belt is of safety control function and of certain comfort. The length of belt can be adjusted by moving the lock tongue position of belt. Regardless of seatbelt appearance, replace the belt every three years. There is a date label on each belt and this label can be used to confirm the service life of seatbelt. Please consult Liugong agent for replacement of seatbelt.

Cleaning Solution Addition of Window The sprinkler tank is located at the right of rear frame in lower part of cab; cleaning solution is added via water filler of sprinkler tank.

Water filler of sprinkler tank

WARNING

Frequently check if the water in sprinkler tank is run out to prevent the field of vision from being affected due to lack of water of sprinkler to clean the window.

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When ambient temperature is lower than 0°C, drain off or add anti-freezing fluid to the sprinkler tank. Otherwise, the sprinkler will not work due to freezing, or even the sprinkler will be damaged by frost!!!

Check/Replacement of Window Wiper

Check front upper and lower part of wiper blade 1 of windscreen wiper, and please check wiper blade of rear window 2 wiper if the wiper is also installed to rear window of the machine. If there is stripe on windscreen left by wiper blade, please replace the wiper blade. Similarly, if there is stripe on rear window left by wiper blade of rear window, please replace the wiper blade.

Welding Repair Comply with correct welding operation procedures to prevent the electrical parts and bearing from being damaged. When the welding is carried out on motor grader or engine with electrical parts, comply with the following operation procedures: 1

Stop the machine on level ground.

2

Close the electrical lock and shut off the engine.

3

Press down parking brake button to conduct the parking brake.

33 Switch off the negative switch of storage battery and cut off the connection between storage battery and frame. 34 In order to prevent crystal display instrument in cab and EST control unit of ZF transmission being damaged, be sure to pull out all connectors connecting instrument and harness of the motor grader and connector for control unit of ZF transmission before welding! 35 If there are other electrical parts on your machine, such as loudspeaker, in order to prevent possible losses, be sure to cut off all connectors connecting electrical parts and the harness of motor grader before welding. 36 In order to prevent harmful gas, clean the paint in place that needs to be welded. 37 Firmly clamp the ground cable of welder with parts that need to be welded, and it will be much better if the grounding position is neat to welding parts. Check and confirm that the circuit from ground cable to welding parts will not go through any of the following parts: Bearing Hydraulic oil cylinder 180

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Controller Inner circuit of other electrical components Doing this is to reduce possible damage of following parts: Bearing Hydraulic parts Electrical components Other possible parts on the machine 38 Be sure to keep combustibles away from the welding site. Protect any cable well. Do not let any spark and welding slag splash the cable when welding, otherwise, it will cause fire disaster and unnecessary losses and injures. 39 Weld with normal safety operation procedure for welding.

WARNING

Using grounding point of electrical parts on machine as the grounding point of welder is forbidden!!! If the welding will be conducted near the grounding point of electrical appliance, cut off the grounding point of this electrical appliance. And confirm that the welding loop of welder do not go through the electrical appliance before welding. Otherwise, these electrical parts will be damaged or even fire disaster will appear! Voltage above 200V is forbidden to use continuously. The distance between welding area and grounding cable should be less than 1 m. The seal ring and bearing should not be located at the place between welding area and grounding cable. Be sure not to weld pipes with fuel, engine oil and hydraulic oil and not weld sealed or poorly ventilated vessel.

Fuel Heating System of Engine (Optional) 1. Overall Structure of Fuel Heater

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Overall structure Fig.1

1. Electric control box 2. Rubber plug 3. Ignition plug 4. Release valve 5. Water-in temperature sensor 6. Relief resistance 7. Water-out temperature sensor 8. Water outlet 9. Flame temperature sensor 10. Pump and motor 11. Water inlet 12. Drain plug 13. Main bracket 14. Pump bracket 15. Oil-in hose of electromagnetic valve 16. Electromagnetic valve 17. Oil-return hose of electromagnetic valve 18. Oil-out hose of electromagnetic valve 19. End cover

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1. Electric control box 2. Rubber plug 3. Ignition plug 4. Release valve temperature sensor 6. Relief resistance 7. Water-out temperature sensor 9. Flame temperature sensor 10. Pump and motor 11. Water inlet

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5. Water-in 8. Water outlet

12. Drain plug 13. Main

bracket 14. Pump bracket 15. Oil-in hose of electromagnetic valve 16. Electromagnetic valve 17. Oil-return hose of electromagnetic valve 18. Oil-out hose of electromagnetic valve 19. End cover 2. Operating Method 2.1 The following figure shows the positions of the buttons of engine fuel heating system

2.2 Button symbols and operating instruction of each button

1 4

2

5 6

3

1. Pump (power) switch 2. Power indicator light (green) 3. Heating switch  4. Burning indicator light (green) 5. Malfunction indicator light (yellow) 6. Preheating indicator light (red) 2.2.1 The outline of standard control panel is shown in the figure above. 2.2.2 First open all the water-in and water-out ball valves of the fuel heater when using the heater; close the water-in and water-out ball valves of the heater during a long term of non-use. 2.2.3 First turn on the water pump switch 1. The heater water pump starts working with power indicator light 2 (green light) on the control panel on. 2.2.4 Then turn on heating switch 3. The heater is now in the preheating condition with preheating indicator light 6 (red light) on. 2.2.5 About 2 minutes later the heater will be in the condition of normal burning with burning indicator light 4 (green light) on and preheating indicator light 6 (red light) off. 2.2.6 When the water-out temperature in the heater reaches 85±5 ℃, the machine will automatically stop operating and heating, with burning indicator light 4 (green light) off and the pump working normally. 2.2.7 When the water-in temperature in the heater is lower than 65±5 ℃, the machine will start automatically (with red light on) and be in the condition of preheating and ignition. After the burning is normal, burning indicator light 4 (green light) will be on. The heater will be in the 183

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circular working condition as analogized in turn. 2.2.8 To stop the machine, first turn off heating switch 3, and then turn off water pump switch 1. This machine is set with relay program to protect the basic machine, i.e. when the basic machine is shut down, the water pump and main motor will stop after 3 minutes’ continuous operation. Therefore, don’t cut the general power supply until burning indicator light 4 is off. 2.2.9 Modes of malfunctions: When there is an ignition malfunction or the short or broken circuits of the water-in and water-out sensors, malfunction indicator light 5 (yellow light) will be normally on with preheating indicator light 6 and burning indicator light 4 off, and the fuel heater can not work normally. When there is a malfunction of one of the water-in and water-out sensors, malfunction indicator light 5 (yellow light) will blink with the frequency of 1 Hz and the fuel heater can work normally. When both of the water-in and water-out sensors fail, malfunction indicator light 5 (yellow light) will blink with the frequency of 0.5 Hz while preheating indicator light 6 and burning indicator light 4 will be off, and the fuel heater can not work normally. After doing troubleshooting, just restart the machine using the methods mentioned above (If heating medium is refilled, restart the machine after operating by the method of exhaust). 3. Repair and Maintenance: In winter, the heater should be removed from the vehicle, and then it should be cleaned, inspected and filled with lubricating grease before being used. Usually the heater needn’t to be overhauled during one heating season. When obvious thermal efficiency drop, ignition difficulty and other malfunctions are found, find out the reasons and do troubleshooting. 3.1 After the heater has been operated for a period of time (according to the service condition), unscrew the heater plug to clean up the accumulated charcoal. If the heating cord is burnt out, remove the heater plug and replace it with a new one. 3.2 In the case of a large amount of accumulated charcoal which would reduce the thermal efficiency, clean up the accumulated charcoal on the in-wall heat conduction strip of the water sleeve body and in the combustion chamber. 3.3 Keep the oil tank, oil tubes and oil filter clean and smooth. Periodically wash those devices according to the practical situation. 3.4 Use the coolant appropriate to the surrounding temperature as cooling medium for the circular system of the heater. 3.5 Periodically check the heater pump according to the service condition. Once there are malfunctions such as linkage of sealing surface or operating difficulty at the start, check and repair those malfunctions in time. 3.6 Maintain the electric control box, electromagnetic valve and other electrical elements of the heater by the methods used in the maintenance of general electric appliance with low voltage. All the performance parameters of the automatic controller are seriously adjusted by the manufacturer and mustn’t be changed by the users without permit. 3.7 In normal case, the motor of the heater needn’t to be repaired after 2,000h utilization. When abnormal operation which is caused by a long period of utilization or other reasons occurs, check and repair the motor. Check the states of carbon brush abrasion and axle lubrication. If necessary, fill the lubricating grease or replace the carbon brush. Caution: 1. When filling coolant medium into the circular system, open the water pump switch of the heater and press the release valve on the water-in pipe of the heater body momentarily to 184

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release the air in the system. When pressing the release valve, if powerful liquid jets out from the exhaust hole, the air is entirely released. If necessary, start the engine and reinforce the system circulation to favor the exhaust. The coolant medium filled into the circular system must be anti-freezing fluid which can achieve the requirements of surrounding temperature for vehicle utilization. Don’t use petrol for this machine.

Worm-Gear Box (Optional) 1

Check of Oil Level (1) Set level the worm-gear box. (2) Make sure that the oil level is in the mid position of the observation hole while observing from the oil level indicator. (3) Oil should be first added through oil fill hole (plug 2) if necessary. (4) Check the oil level after 50h continuous operation in general. Oil level indicator

Plug 2

Plug 1

Fig.1 Worm-gear box 2

Replacement of Oil (1) Swing the moldboard to make it incline to one side of oil discharge plug (plug 1) to speed up the oil draining and set it against the ground. (2) Just remove oil discharge plug 1 to discharge the oil. To speed up the oil discharging, take off plug 2 at the same time. All the oil should be drained out. (3) Clean up plug 1 and replace its seal ring with the new, then mount and screw down plug 1 on the position of worm-gear box (plug 1). (4) Adjust the lifting oil cylinder with moldboard and set level the worm-gear box over again. (5) Fill with oil again from the filler hole (plug 2) to have the oil level in the mid position of the observation hole of oil level indicator. The oil volume is about 2.5L. Choose the oil grease with the type of 85W/90 GL-5 (in summer) or 80W/90 GL-5 (in winter). (6) Clean up plug 2, replace the seal ring with the new, and then mount and screw down the plug on the position of (plug 2). (7) Ensure at least one oil replacement annually.

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Operation and Maintenance Manual for CLG418 Motor Grader–Maintenance Manual

2008.10 000

Moldboard and Angular Device (Optional) Moldboard and angular device are indispensable parts of working device. Different positions of the moldboard can be achieved by controlling the swinging oil cylinder to fit the demands of various working conditions. The moldboard can be side shifted and retracted from the left and right sides. It can be rotated in all angles and in 360°. However, when rotating or moving the moldboard, be careful not to damage the parts such as the frame, the ladder, the wheels and the steering pull rod, etc. The adjustment of the rotation shovel angle can be achieved by controlling the tilting oil cylinder with the hydraulic angular device. Bigger rotation shovel angle that can produce higher shoveling pressure should be adopted to achieve the optimal efficiency of the motor grader. During the shoveling, a smaller shovel angle may reduce the cutting force while a bigger shovel angle may enhance the precision of smoothness and the mixing effect. Repair and Maintenance If the moldboard of the motor grader shakes (being loose) greatly, the guide and bushing should be replaced in pairs. Cleaning the roughness and unsmoothness on the guide rail in time can reduce the abrasion grade. The guide rail can be trimmed by a file. (1) Replacement of moldboard bearing bushing

Baffle

Bushing

Fig.2 Moldboard bearing bushing a. Put the moldboard on two wood blocks b. Remove the baffle c. Remove the moldboard by sliding it, and then remove the bushing d. Replace it with a new bushing and fasten the baffle e. Replace both of the two bushings at the same time rather than replacing only one of them (2) Replacement of guide

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Operation and Maintenance Manual for CLG418 Motor Grader–Maintenance Manual

2008.10 000

Guide

Bolt

Fig.3 Guide of moldboard a. Put the moldboard on two wood blocks b. Unscrew the fastening bolts c. Remove the guide d. Replace it with a new one, and screw the fastening bolts e. Replace both of the two bushings at the same time rather than replacing only one of them (3) Fix the piston rod of the moldboard sideshift oil cylinder The two conical washers can be rotated with hand after the slotted nut has been locked by the piston rod. Use the same method to fix piston rod when repairing or replacing the oil cylinder.

Piston rod of oil cylinder

Conical washer Slotted nut

Conical washer Fig.4 Piston rod adjustment of moldboard sideshift oil cylinder

Lubrication (Optional) 3# lithium lubricating grease is filled to the product when the latter one is delivered into the market. 2# lithium lubricating grease can be filled to the product which is working at low temperature. Lubricating (1) The left and right bushings should be filledpoint with lubricating grease once after every 50 hours’ ppoint or week’s operation. (Refer to the following figure) 187

Operation and Maintenance Manual for CLG418 Motor Grader–Maintenance Manual

2008.10 000

Fig.5 Lubricating point of moldboard bearing bushing (1) The circle, driving gear and each ball socket should be filled with lubricating grease once after every 100 hours’ or 2 weeks’ operation. (Refer to the following figure) Lubricating total)

point

(3

in

Fig.6 Lubricating point of circle

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Operation and Maintenance Manual for CLG418 Motor Grader–Maintenance Manual

2008.10 000

Lubricating point

Fig.7 Lubricating point of driving gear

Lubricating point

Fig.8 Lubricating point of ball socket

189