Common Trouble-Shooting Method of Motor Grader

Common Trouble-shooting
Method of Motor Grader
SANY Heavy Industry Co.,Ltd. Quality Changes the World

Common Trouble-shooting Method of Motor Grader
SANY Heavy Industry Co.,Ltd. 2/33 Quality Changes the World

Trouble-shooting method & process

Check the oil filling pressure, if oil filling pressure is not below 2.8MPa when engine
is at idle speed, then replace the braking pressure relay of the changing valve.
(attention: the setting send-out-signal pressure of pressure relay is 2.2MPa, so the
adjustment for pressure relay must be operated by specialized device). If oil filling
pressure is below 2.8MPa when engine is at idle speed (measuring when port G is
plugged up), then work as the following trouble-shooting process of plunger pump
and motor failure:
(1) Preparation
1) Suspending the 4 wheels of the rear axle
2) Preparing oil pressure gauge for
traveling oil pressure and oil filling pressure.
3) Preparing plug and dismantle tools.

(2) Checking process

1) Checking travelling plunger pump
Block up the high pressure port A & B by plug (according to figure 1 or 2), shift to
automatic forward or reverse gear position. When oil filling pressure is below 2.8MPa
and changed according to the engine revolution, check the oil filling relief valve. If
oil filling valve works in normal condition, that means the internal of the plunger
pump is damaged and the plunger pump must be replaced. If oil filling pump works
in normal condition, then check the travelling pressure, if forward or reverse
travelling pressure can reach to 400bar, that means there're problems with high
pressure relief valve on forward or reverse side, and check the high pressure relief
valve on that side. If forward and reverse travelling pressure are below 400bar, then
check the pressure of port Ps, whose max pressure is oil filling pressure and min
pressure is roughly 6bar. And when engine revolution reached to 1000rpm, its
pressure should be roughly 10bar. If pressure of port Ps is abnormal, then check
valve DA. If pressure of port Ps is normal, then check the pressure cut-off valve.

Fig. 1 pipeline connecting type 1 Fig. 2 pipeline connecting type 2

2) Check travelling plunger motor

Plunger motor can be checked only when plunger pump works in normal condition.
When check the plunger motor, speed displayed on the text display can not be over
15km/h, otherwise plunger pump and motor will be damaged easily. Block up the
high pressure port A & B of one plunger motor connecting to plunger pump.
Connect another plunger motor with plunger pump and engage the gear. If oil filling
pressure is normal and the vehicle travels normally in every gear position, that
means motor works in normal condition. If oil filling pressure is normal and vehicle
can't travel in any gear position, but text display shows there is a certain speed
(must be motor measuring speed), that means spline gear of the plunger motor
output axle has been worn. If oil filling pressure is low and rise and fall in a wide
range, then check the flush valve. If the flush valve works in normal condition, that
means the plunger motor has been damaged.

2. Traveling Motor Output Axle Spline Wear

Failure phenomenon:
Traction of the motor grader decreases obviously during the operating
and travelling. And the top speed can only reach to about 10km/h
(31.6km/h normally), and accompanied by impact phenomenon.
Further check shows:
(1) After the engine started, indicator of right motor speed sensor input
port l0.1 is lighted constantly, and indicator of skid adjustment output
port Q0.5 is lighted.
(2) Vehicle can run after engaged the gear and pressed the throttle pedal.
Indicator of left motor speed sensor input port l0.0 is normal and
travelling pressure could be up to 40MPa.

Malfunction analysis:
The vehicle can't run until the indicator of Q0.5 is lighted and there's impact
phenomenon during the travelling. That is caused by the difference between the
revolution of l0.0 and l0.1, which lead to the anti-skid control to operate. On condition
that there's output from port Q0.5, pressure adjustment valve on the right side will cut
off the flow, load will be increased, travelling pressure will be raised and most oil will be
flowed to left motor which actuates the machine alone, but speed and traction can't
reach the designed value. So the preliminary diagnosis is the right speed revolution
failed or right motor failed.
The vehicle can't run when indicator of Q0.5 is not lighted and indicator of right motor
speed revolution sensor input port I0.1 is lighted constantly. That means load of right
motor is very light so that system can't build up pressure, and vehicle can't travel. That
could be diagnosed as right motor failure.

Trouble-shooting method and process
(1) The indicator of input port l0.1 is lighted constantly means there's problem
with sensor or circuit. Because the speed sensor will only affect the auto gear
and anti-skid control, so disconnect the input port l0.0 and l0.1 of the sensors
on both sides (at this moment Q0.5 indicator turn off, anti-skid won't run
because port l0.0 and port l0.1 are disconnected) and resolve the electricity
system and hydraulic system failure in manual gear position.
(2) The vehicle can't travel after the gear is engaged and patrol pedal is pressed
and measured traveling pressure is up to 40MPa, which means hydraulic
system is in normal condition. It is doubted that there's problem with
electricity controlling circuit.
(3) Check working current of travelling pump and the solenoid of bypass valve
by multi-meter, and the working current is in normal condition.
(4) There is the same condition after port l0.0 is connected.

(5) That indicator of Q0.5 is lighted and vehicle can run after port l0.1 is
connected. Apparently it looks weird that as we know, Q0.5 is used to control
anti-skid, why is this Q0.5 port energized could the vehicle run?
(6) It is discovered via computer online monitoring that even gear hasn't been
engaged, there is a revolution signal into port l0.1 which is various with the
changing of throttle, and there's no revolution signal into port l0.0. When
vehicle is travelling, revolution signal of port l0.1 is much higher than that of
port l0.0, but the vehicle is still travelling in straight line. That could be
diagnosed that right motor is rotary with no load, and most likely the spline has
been damaged which connects the motor and tandem.
(7) It is found that the spline has been damaged which connects the motor and
tandem after disassembling the motor.
(8) It is in normal condition after the damaged parts were replaced.

3. Failure of Traveling Motor Proportional Solenoid
Failure phenomenon:
Travelling speed of motor grader can't be raised, and the top speed in
manual gear 4 and automatic gear position can only reach roughly to over
10km/h
When the two motor's displacement were adjusted to minimum as gear
position demands, if the displacement of the motor on one side is still at
max. displacement status instead of adjusted to min. value, while the
other motor displacement is adjusted to min, then the failure will occur as
mentioned. This failure maybe caused by the following possibilities:
(1) There's no control signal for proportional solenoid at the failed side.
(2) proportional solenoid at failed side has been damaged.

Trouble-shooting method and process
On the condition that electricity control signal is in normal condition, cut off the left
(right) side proportional solenoid control signal, then check vehicle speed. If the speed
is the same as before, which means right (left) side proportional solenoid works in
normal condition. That if vehicle speed can only reach roughly 6km/h (gear I
engaged), which means right (left) side proportional solenoid has been damaged.
When there's only one speed sensor been damaged, the temporary solution is to
connect the 2 sensor in parallel, by this way, both l0.0 and l0.1 will receive revolution
signal and the motor grader will run in normal condition.

4. Failure of Travelling Motor Speed Sensor

Failure phenomenon:
Motor grader speed can't be raised with heavy impact during travelling and
there's huge difference between the speed displayed on the display and
the actual speed, further more the speed fluctuated in a wide range.
As a result of the damage of one side's rev speed sensor, output pulse
signal disappears from time to time. PLC can not received the proper pulse
signal from this side, so the calculated speed of PLC has huge difference
from actual. And the PLC might also misunderstand this signal as skid,
thus shut off the circuit of the other side's motor and cause the impact.

Trouble-shooting Method And Process:

Cut off anti-skid solenoid control signal of the pressure adjusting
valve, then disconnect the left (right) motor revolution sensor, that
if the vehicle speed displayed on the text display during travelling
statue is nil or lower than actual speed or fluctuated in wide range,
which means right (left) motor rev speed sensor failed. That if the
speed displayed on the text display ranges from 0-15.8km/h, half
of the reality speed, which means right (left) motor rev speed
sensor works in normal condition.

5. Failure of Travelling Pump Switch Solenoid
Failure phenomenon:
Motor grader can not run in any forward gear position, but it can run in
each reverse gear position and the speed is normal.
Failure should have occurred in forward control system because the
reverse function is normal.
1. There is no output from reverse control port Q0.7 of PLC
2. Relay K4 failed or there's problem in circuit.
3. Reverse switch solenoid Y6 failed.
4. Reverse side's high pressure relief valve failed, system pressure can't be
built.
5. Swash plate of travelling plunger pump can't swing in motor grader
forward moving direction.

Trouble-shooting Method and Process:

When engage the reverse gear, there will be output from port Q0.7
of the PLC, then measure Y6, there's 24 voltage. That means
there's no problem with relay K4 and circuit.
Exchange Y5 & Y6, that forward function is in normal condition and
reverse function is abnormal, which means Y6 failed. Motor grader
travel normally after Y6 is replaced.

6. Failure of bypass solenoid change valve

Failure phenomenon:
Motor grader can't run in any gear position, speed displayed on the text
display is nil, input and output of the PLC is in normal condition, the
travelling oil pressure is roughly 3MPa.
That solenoid valve's control signal is incorrect or the solenoid is failed,
results in that bypass solenoid can't changing to close the bypass circuit
after gear is engaged, and the traveling plunger pump's port A & B is
connected and to connect. Therefore, the motor grader can't travel.
Trouble-shooting method and process:
Check the bypass solenoid change valve's control signal, if it is in normal
condition then check the valve or clean the valve spool.

7. Parking Braking Changing Valve Failure
Failure phenomenon:
Motor grader parking braking pressure alarms (alarm pressure is 2.2MPa), and it
can run in any gear position.
Parking braking oil pressure comes from oil filling pressure ， the following aspects
should be taken into consideration according to schematic diagram:
1. Oil filling pressure is not adequate, pressure switch can't be engaged, port l1.5
is at low level, indicator alarms;
2. Pressure relay failed, false alarm;
3. That parking braking change valve can't change and no pressure oil actuate the
parking brake, which leads to vehicle break down.
4. Motor grader can't travel, braking pressure indicator alarms.
5. A serious leakage from piston of parking brake, which leads to braking pressure
can't be built and braking can't be released.

Trouble-shooting method and process:

1. Measure the oil filling pressure, the pressure is 30bar, ok;
2. Pull out pressure relay, it still can't travel and travelling
pressure reach to 40MPa. That means the oil pressure is built in
the oil circuit;
3. More, release the parking brake in manual mode, then motor
grader can travel normally, and check the brake and find it is ok;
4. Stop the vehicle and check braking change valve, if the valve
spool is clamping stagnation, after cleaning the spool, the failure
is gone.

8. Motor grader can't steer

Failure phenomenon:
After start the motor grader engine, the steering wheel could steer, but the
swing cylinder has no movement, and the front wheel couldn't be steered.
It maybe caused by the following reasons:
1. The swing safety relief valve of steering failed, which results in that
pressure oil directly flow back to the oil tank.
2. That manual servo valve is blocked, which results in that pressure oil
couldn't flow into swing cylinder.
Trouble shooting method & process:
The problem could be solved after replace the diverter.

9. Tilting of wheels when diverting
Failure phenomenon:
After start the motor grader engine, swing the steering wheel in place,
then the front wheel will tilt to this side when it divert to this side.
Commonly it is caused by
the failure of two-way balance valve.
Such as the setting relief pressure is
too low, valve spool is blocked and etc.
The problem could be solved after replace
the two-way balance valve of the front
famework.

10. Driven gear teeth in the gear box is broken
Failure phenomenon:
After the motor grader has been used for a period of time, the drive gear
teeth of the worm-gear case is broken off at the root section, there is
obvious extrusion marks on the root section of each drive gear tooth.
The material of the drive gear provided by OEM in the worm-gear case
doesn't meet the design requirement, material required is 42CrMo, and it
maybe 40Cr in reality, that causes the fatigue strength of the drive gear
isn't strong enough. Turning gear ring has a certain ovality, teeth length of
the gear ring is irregular with taper; that teeth of some sections is thicker
than those of other sections, which will cause teeth sticking and broken off
with heavy loads when driven gear turns to this section.

Fig. 3


(1) Adjust turning gear ring of shovel blade
Notes: if radius run-out is over 3mm, axial clearance is over
2.5mm, the slider of turning gear ring must be adjusted.
1) axial adjustment of slider through clearance gauge
 Use clearance gauge to measure the axial clearance between
gear ring (shown in 1 of Fig.3) and 4 slider (shown in 2 of
Fig.3), to insure the clearance is between 0.5-0.8mm (shown in
3 of Fig.3)
 Loose the nut (shown in 4 of Fig.3), take away 4 slider gasket,
make the clearance meet the requirement, and then mount the
slider.

2) radial adjustment of turning gear ring
Loose nut (shown in 4 of Fig.3) and nut (shown in 5 of Fig.3),
screw the bolt (shown in 6 of Fig.3), adjust the slider to ensure
the clearance range from 0.3-0.5mm through which the short
axle of turning gear ring could pass
Screw up all nuts, the tightening torque of the nut (shown in 4
of Fig.3) is 590Nm. And then test it to ensure the turning gear
ring could swing freely ranging from 0-360 degree
(2) Replace the slider
After replace the slider, adjust the radial and axial clearance
between 4 sliders and turning gear ring according to the
adjustment method of shovel blade turning gear ring.

11. Brake failure or bad braking efficiency
Failure phenomenon:
During traveling period, loose the throttle pedal of the grader, press the
brake pedal, after that the brake doesn't work or the braking efficiency
is bad.
Malfunction reason is that there is no positive pressure or the positive
pressure is lower between brake lining and the friction surface of the
brake drum, the leakage of oil reduces friction coefficient, so the
frictional force is reduced, thus the braking torque is reduced too.
The malfunction mentioned is caused by the following reasons:
(1) Oil leakage from braking pipe connector
(2) there is air in the braking hydraulic oil pipe

(3) The brake lining worn so that the clearance between the brake drum and the brake
lining is too large.
(4) There is oil leakage from branch braking pump of the brake, thus piston thrust is low.
(5) That seal ring of the bearing end cover is damaged and there is gear oil leakage from
tandem, which reduces the friction coefficient between brake lining and brake drum.

According to the malfunction analysis mentioned above, if the traveling brake pressure of
the hydraulic system is normal, check the following items step by step:
(1) Check each brake pipe connector, fasten the connector
where oil leakage happens or replace the seals.
(2) Exhaust the air in the traveling brake hydraulic oil
pipeline according to the following process (shown in Fig.4)
Fig.4 exhausting air in braking system

1)Take away the rubber cap of exhaust bolt ①
2)Connect one end of rubber pipe ② to exhaust bolt ①, put the other end to
a clean container ③.
3) Loose the exhaust bolt ① for half cycle, and press the brake pedal. Fasten
the exhaust bolt and loose the pedal until there is oil flow out and no air is
exhausted from exhaust port .
4) If the brake problem is still no solved after mentioned process is done,
adjust the clearance between lining and brake drum, check the degree of wear
of brake lining. brake lining should
be replaced if the thickness left is below 3mm.
Clearance adjustment of brake is as following
(shown in Fig.5)
Fig 5. brake clearance adjustment

a. Fasten adjustable bolt according to the direction shown in figure, until
the brake lining contacts with brake drum.
b. Loose adjustable bolt for about 30 degree according to the direction
shown in fig, at this moment, the clearance between lining and drum is
roughly 0.75mm.
c. Use the same way to adjust the clearance of the other lining and brake
drum.
Notice:
 Do no fasten the bolt too tight or the cam will be damaged.
 Brake lining on both sides should be replaced at the same time to avoid
imbalance of braking force.
 4 brake should be adjusted at the same time when replaceing some
parts related to brake shoe; the two brake shoe of the same brake
should be adjusted at the same time too.

12. Oil leakage from parking brake
Failure phenomenon:
Oil leaks out from A, B, C section of parking brake. (shown in
Fig. 6)
(1) If oil leaks out from A, that means seal ring 7 or O-ring 12 is
damaged, and the oil leaking is hydraulic oil.
(2) If oil leaks out from B, that means O-ring 12 is damaged,
and the oil leaking is gear oil.
(3) If oil leaks out from C, that means seal paper washer is
damaged, and the oil leaking is gear oil.

Fig 6. Parking brake structure


(1) As for A section's oil leakage, dismantle cover 10, nut 11, cover 8 by turns,
clean up the oil in inner chamber of gland16 and on end face of piston 13, and
then start engine, operate the parking brake for some times, obverse the oil
leakage condition. If oil leaks out from the fitting surface between gland 16 and
piston 13, that means seal ring 7 failed; if oil leaks out from the fitting surface
between piston 13 and piston rod 2, that means O-ring 12 failed; if leakage is
not obvious, it is still difficult to figure out whether seal ring 7 failed or O-ring 12
failed, and the further examination is needed. Loose bolt 14 and disassemble
parking brake, take out piston 13, check the failure condition of seal ring 6 and
O-ring 7s' sealing surface, and replace the failed one. Check the fitting surface
between each parts with sealing parts, clean up the burr and foreign matter
which will damage sealing parts before assembly.

(2) If oil leaks out from B section, replace O-ring 17, clean up burr
and foreign matter which will damage O-ring before assembly.
(3) If oil leaks out from C section, loose bolt 14 and 5,
disassemble brake including brake outer drum 18, replace the seal
paper washer between brake outer drum 18 and tandem 4. When
replacing paper washer, we should remove the old paper washer,
and coat seal gum onto the new paper washer.

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Common Trouble-Shooting Method of Motor Grader

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Common Trouble-Shooting Method of Motor Grader

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Common Trouble-shooting

Method of Motor Grader

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Trouble-shooting method & process

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(2) Checking process

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Fig. 1 pipeline connecting type 1 Fig. 2 pipeline connecting type 2

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2) Check travelling plunger motor

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2. Traveling Motor Output Axle Spline Wear

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(4) There is the same condition after port l0.0 is connected.

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4. Failure of Travelling Motor Speed Sensor

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Trouble-shooting Method And Process:

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Trouble-shooting Method and Process:

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6. Failure of bypass solenoid change valve

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Trouble-shooting method and process:

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8. Motor grader can't steer

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Trouble shooting method & process:

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Trouble shooting method & process:

Fig.4 exhausting air in braking system

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Fig 5. brake clearance adjustment

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Fig 6. Parking brake structure

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Trouble shooting method & process:

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