Auto Grader Lubrication Card

Contents

Introduction

1 Purpose and classification

1.1 Classification of auto graders

1.2 Auto Grader Operating Tools

1.3 Operating mode

1.4 Mechanical type motor grader transmission

2 Types and periodicity of grader maintenance

2.2 Daily Maintenance (ETO)

2.3 First maintenance of TO-

2.4 Second maintenance of TO-

2.5 Seasonal maintenance of STR

2.6 Transition to autumn-winter operation season

2.7 General Storage Provisions

2.7.1 Requirements for short-term storage

2.7.2 Long-term storage requirements

2.7.3 Storage of storage batteries

2.8 Automatic grader slinging and transportation

3 Lubrication card

3.1 Grader lubrication card

2.3 Lubricant equivalents

4 General operating instructions

5 Maintenance safety measures

List of literature

Introduction

The continuous increase in the intensity of road traffic, as well as the increasing need for the construction of new industrial and transport facilities, requires increased productivity in construction and improved performance of roads and other embankments for engineering purposes. The high values ​ ​ of these indicators for such structures are largely determined by the thoroughness of planning work during their layer-by-layer construction, as well as the productivity of profiling machines. The indicators of "evenness" of clothes and coatings of roads, airfields and the upper structure of railway embankments depend on this. Therefore, the operation of profiling structural layers in the general process of construction is quite important and responsible. Therefore, it is necessary to strive to improve the design of profiling and planning machines, in particular, auto graders.

1 Purpose and classification

Auto graders have been widely used in road construction: for planning road foundations during the construction of an earthen bed; erecting a roadbed from side reserves in flat and slightly crossed terrain (with an embankment height of up to 0.5-0.75 m); layer-by-layer leveling of soil in embankments during operation of excavating machines; for arrangement of drainage channels; slopes, shoulders, cuts and embankments; movement of soil and road construction materials, repair and maintenance of dirt and gravel roads; during railway, land reclamation, irrigation and hydraulic construction, as well as for cleaning roads and areas from snow.

For auto graders, the operating mode is characterized by low speeds (3-4.5 km/h). Idle mileage is carried out at speeds up to 15 km/h, and transport speeds reach 30-45 km/h. Auto graders, as a rule, work on a capture 1-2 km long (determined by the front of work). Trailed graders are divided into light, medium and heavy. Light graders have a dump 2500-3000 mm long, medium 3000-3500, heavy 3500-4500 mm; by weight - light 2.6 tons, average 2.96 tons, heavy 4 tons or more; control - with manual, mechanical and hydraulic drive; for running equipment - with metal wheels and with rubber tires .

1.2 Auto Grader Operating Tools

The main working body of the auto grader is the dump. Additional equipment includes bulldozer dump, bricklayer, snow cleaner, dump extension, slant.

Dump of motor grader is made of sheet steel bent along radius and is installed on traction frame. Lower knife is fixed on bolts in lower part, and side knives are fixed on sides of dump. The dump can be moved in the guides by means of a hydraulic cylinder, which is attached to one of the two ball pins, depending on which side the dump is to be removed. For the energy intensity of the cutting process and the efficiency of the motor grader, the installation angles of the dump are important.

Grip angle a is formed between longitudinal axis of dump and longitudinal axis of motor grader. The gripping angle determines the width of the road bed grip, speed, and energy intensity when cutting and moving soil along the road. When cutting the soil with a dump, the grip angle (3545 °), which is optimal from the point of view of energy intensity, is taken.

The angle of inclination p (angle of cutting) determines the transverse inclination of the dump to the ground surface and is set using the mechanism for lifting and lowering the dump by setting each end of the dump to the desired height (with cutting not more than 1520 °, and with finishing work - 18 °).

The cutting angle y is formed between the front plane of the knife and the surface of the ground. The cutting angle is determined by the type of work and soil properties (when cutting soil Y = 30 °, when planning Y = 60T70 °). For accurate and fast installation of the dump at the necessary angles, it is recommended to use special devices, for example, the angular meter proposed by N. A. Rozov. All measurements are made when the auto grader stops completely. Roller dumps are used in auto graders.

In the standard dump for rollers, windows are cut. The surface of the rollers copies the surface of the dump. Roller attachment units, reduction gear and hydraulic motor of roller rotation drive are located on rear side of dump and do not create additional resistances.

Studies have shown that soil resistance to roller dump movement is significantly reduced due to replacement of sliding friction along the dump by rolling friction of roller bearings, as well as due to forced drive of rollers.

Traction frame is made in the form of welded structure of box section. In the front part of the motor grader, by means of a ball pivot attached with a finger, the traction frame is connected to the head of the main frame of the motor grader by means of a support and studs. Lubricant fitting serves for lubrication of hinge. In the rear part the traction frame is suspended from the main frame by two lifting tractors and one extension rod. Lifting rods are connected to external ball pins, and extension rod - to internal pin. On the plane there installed is a reduction gear for rotation of the dump, the gear of which is engaged with the outer toothed rim of the full-turn circle. Shoes are installed on gaskets and attach turning circle to traction frame. Bolts attach front movable shoe. A dump is installed on the brackets. Such a design of the traction frame and the turning wheel provides a 360 ° rotation of the dump.

Additional working tools of the motor grader are: a bricklayer (ripper) used for loosening dense soils and bricklaying gravel-and-gravel coatings during road repair, bulldozer equipment and a snow cleaner.

The ripper-bricker can be installed in the rear part of the dump or in the front part of the motor grader and controlled using special hydraulic cylinders. In the same way, working equipment of bulldozer and snow cleaner is installed on the front bracket of the main frame sill beam.

2 Types and periodicity of grader maintenance

To maintain the auto grader in the state of technical readiness for operation, prevent faults and premature wear of parts, the following types and periodicity of maintenance are established:

• daily maintenance (ETO) - every shift or after 10 hours;

• first service (TO-1) - after 125 motor hours;

• second service (TO-2) - in 500 motor hours;

• seasonal maintenance (STO) - during the transition to spring-summer and autumn-winter operating seasons, when the ambient air temperature is set to not lower than or not higher than 5 ° С, respectively;

• maintenance under special operating conditions.

Deviations of actual periodicity from set for TO1, TO-2 by 10% are allowed. About maintenance (except for ETO) the corresponding entry must be made in the auto grader logbook. Types, periodicity and list of engine maintenance works are given in engine operating manual.

2.1 Maintenance under special operating conditions

During maintenance in desert conditions:

1. Pay special attention to ensuring the tightness of the engine suction system;

2. check the ventilation holes of transmission sapons, bridges, reduction gears, fuel tank, accumulators every 50 hours;

3. refuelling of the motor grader should be carried out in conditions protected from wind and dust (under tarpaulin, tent, etc.).

In conditions where the ambient air temperature is above 5 ° C all year round, i.e. it is not necessary to use the pre-start heater of the engine, it is recommended to remove it from the motor grader by plugging the outlets of the fuel and water systems.

When operating under conditions of negative temperature, the normal thermal mode of the engine should be maintained by installing an insulation cover.

2.2 Daily Maintenance (ETO)

If necessary, clean the grader of dirt. Inspect attachment of components, including: attachment to engine frame, suspension of bridges and cockpit; attachment of wheels. The presence of fasteners on the components is mandatory, the washers must be tightly compressed. Check the condition of the tyres and remove the stuck items. The pressure in all tyres shall be the same. Stuck sharp objects are not allowed. Tyres are rejected in case of cuts with cord violation or wear of grousers. Check condition of dump knives (dumps). If the knife is worn out, reinstall it or replace it. Do not wear knives to the front sheet of the dump. Check tightness of fuel, lubrication, cooling and heating systems of the engine, pneumatic and hydraulic systems; tightness of transmission unit, bridges. On the surfaces of assembly units and parts, small darkening from oils (without drop separation) is allowed. Pressure drop in pneumatic system is not more than 0.015 MPa (0.15 kgf/cm2) for 15 min at non-operating engine. Use the auto grader spares kit for troubleshooting. Check presence of fuel, oil, cooling and working liquids, and at ambient air temperature below plus 5 ° С - presence of alcohol in the fuse against freezing. It is forbidden to leave if the measuring rulers show the lower level in the tanks. At ambient temperature below plus 5 ° C, alcohol replacement is weekly. Drain condensate from the pneumatic system receiver. Keep the drain valves open until the condensate disappears in the air jet. Check engine operation by hearing, check readings of instrumentation in the cockpit. Check the clogging of the air cleaner by the clogging indicator, when the indicator operates, clean the air cleaner. If the indicator is faulty, clean the air cleaner when operating under the following conditions :

1. normal dust content - in 250 motor hours;

2. increased dust content - in 2030 motor hours.

2.3 First maintenance of TO-1

Wash the auto grader and perform ETO operations. Hot water jet pressure must be 0.4... 0.6 MPa (4... 6 kgf/cm2). Lubricate according to lubrication table. Syringe until lubricant appears from the joints. Check the clearance between the belt and the parking brake drum. Provide clearance of 0.5... 1 mm between the tape and the drum. Check the gaps between the push-down cams and the clutch thrust ring, check the clearance between the release clutch disc and the brake disc. The clearance between the cams and the thrust ring shall be within 0... 0.2 mm at a size of 21 mm between the release clutch disc and the brake disc (adjust the clearance of 0... 0.2 mm and the size of 21 mm together with the servomechanism). Check tyre pressure. Pressure must be 0.23 - 0.28 MPa (2.3 - 2.8 kgf/cm2). Check by pressure gauge. Check the plays in the joints of the steering rods. Plays in push-pull rods hinges are not allowed. Tighten the wheels attachment nuts. Tightening torque 400450 Nm (4045 kg/cm2). Check oil level in crankcase, add if necessary. Oil level below 10 - 15 mm from test hole is not allowed. Clean and wash the ventilation holes of transmission sapons, hydraulic system tank, bridges, dump rotation reducer, fuel tank plugs. Holes and grids must be clean. Drain fuel sludge from fuel tank and coarse filter. Drain from the tank 2... 3 l, and from the filter 0.1... 0.2 l fuel. Check electrolyte level in accumulators, as well as condition of terminals, vents, plugs. Lubricate contact parts of terminals and wire tips with technical vaseline. The electrolyte level shall be 10... 15 mm above the safety shield. Drain the operating fluid from the hydraulic system filter, wash the filter housing, replace the filtering element. Perform the operation in one TO-1.

2.4 Second maintenance of TO-2

Perform TO-1 operations. Check and adjust clearances in engagement of auto grader turning wheel. Lateral gap in engagement up to 6 mm. Measure convergence of front wheels (convergence of wheels is 1.52.5 mm). Lubricate according to lubrication table. Syringe until lubricant leaves the joints. Check electrolyte density and degree of battery charging. If necessary, charge them. Electrolyte density in summer 1.25 g/cm3; in winter 1.29 g/cm3. The battery, discharged by more than 25% in winter and more than 50% in summer, should be charged.

2.6 Transition to autumn-winter operation season

Clean the spark plug and the prestart preheater burner of the engine. The presence of coke is not allowed.

Rinse and replace solenoid valve filters and prestart preheater nozzles if necessary. Disconnect solenoid valve with nozzle and electric heater from the burner. Remove the filter cases, wash the filters in acetone or gasoline and blow them with compressed air. Set everything in its place. Check the heater operation, adjust fuel flow if necessary.

Note:

• In areas where one of the operating seasons (spring-summer or autumn-winter) is predominant according to climatic conditions, oil replacement in the transmission and hydraulic system should be carried out in 1000 motor hours with the next TO-2.

2.7 General Storage Provisions

Autograder is stored:

• interschange - break in use up to 10 days;

• short-term - from 10 days to 2 months;

• long - more than 2 months.

The motor grader must be stored in closed rooms or under a canopy. It is allowed to store on open equipped sites during mandatory preservation, sealing and removal of components requiring storage. It is not allowed to store the motor grader and its components in rooms containing (emitting) dust, impurities of aggressive vapors or gases. During inter-exchange storage, it is allowed to store the motor grader at sites and points of inter-exchange storage or directly at work sites.

2.7.1 Requirements for short-term storage

The motor grader must be put into short-term storage no later than 10 days after the completion of work. The motor grader is placed for short-term storage in complete, i.e. without removing assembly units and parts from it.

In preparation for short-term storage, it is necessary to:

1. clean the motor grader of dust, dirt and oil leaks;

2. perform engine preservation in accordance with instructions of operation manual;

3. tightly close all holes and slots through which atmospheric precipitation can enter the internal cavities of the motor grader;

4. open drain valves to provide free outlet of cooling liquid from the cooling system and condensate;

5. switch off the batteries, the electrolyte level and density must be brought to the norm (in cases of storage of the motor grader at low temperatures or more than 1 month, the batteries must be removed and put into storage);

6. apply PVK lubricant GOST 1953787 on the surfaces of the working elements of the motor grader, rods of hydraulic cylinders, splined joints, gearboxes, a turning wheel, as well as on external mating machined surfaces;

7. wrap with paraffined paper and bind sapunas on crankcase and plugs of filler necks with twine;

8. wrap air purifiers with polyethylene film and bind them with twine;

9. restore the places of paint damage;

10. close and seal the cowl and cockpit doors;

11. install an auto grader on the supports, between the tyres and the supporting surface there should be a clearance of 8... 10 cm.

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