Guide Steering System Service Manual

Service Manual of RS8160 Road Roller
SERVICE MANUAL
6 Steering System
Service Manual for G9180 Grader
CONTENTS
6 Steering System ................................................................................................... 6-1
61 General................................................................................................................. 6-1
611 Location of Steering System Components .................................................. 6-2
612 Steering System Principle Description ........................................................ 6-3
62 Description, Disassembly and Assembly of Main Components ......................... 6-6
621 Steering Pump.............................................................................................. 6-6
622 Priority Valve ............................................................................................ 6-11
623 Steering Gear ............................................................................................. 6-12
624 Steering Control Mechanism Assembly .................................................... 6-18
625 Front Axle .................................................................................................. 6-19
626 Steering Cylinder ....................................................................................... 6-38
63 Pressure Measurement of Steering Hydraulic System ...................................... 6-39
64 Deflation of Steering Hydraulic System ........................................................... 6-40
65 Diagnosis and Solutions for Common Faults of Steering System .................... 6-41
Steering System
61 General
G9180 grader is equipped with full hydraulic steering system. The system has the advantages of
compact structure, high sensitivity, good stability, flexible and easy operation, shock absorption and
free of extra lubricating device. Besides, manual steering is available when steering power source
(pressure oil) is cut off.
Fig. 6-1 Principle diagram of steering system

1 Steering cylinder
2 Steering gear
3 Priority valve
Working hydraulic system

6-1
4 Steering pump
Brake hydraulic system
6-2
1 Steering pump
2 Priority valve
Fig. 6-2 Location of steering system

3 Steering gear
4 Steering cylinder
5 Pressure measuring port
611 Location of Steering System Components
612 Steering System Principle Description

The principle of hydraulic steering system is illustrated in Fig. 6-1. Steering system and the left
multitandem valve share the same high-pressure gear pump, the pump absorbs oil from hydraulic
tank, pressure oil enters the priority valve through port P, then the oil flows into steering gear from
port CF of priority valve. When turning the steering wheel, steering gear will send pressure oil into
steering cylinder to carry out front-wheel steering.
When the steering gear is in neutral position
Steering gear
Priority valve
Filter
Steering
pump
Oil tank
Fig. 6-3 Oil line when steering gear is in neutral position

As shown in Fig. 6-3, if the engine flames out, the pump will stop supplying; the control spring of
priority valve will force the spool to move right to connect port CF. After the engine is started,
hydraulic oil in the tank flows into priority valve through steering pump, the priority valve will
allocate oil to steering gear through port CF. The pressure oil in CF port will also act on both ends of
the priority valve, and the oil in the left end will flow back to the radiator through the orifice in
steering gear and port LS, pressure loss will be formed in this case. Resultant force of the spring and
pressure oil in the left end is smaller than the force produced by the pressure oil in the right end, the
spool will move to left, opening degree of port EF will increase, while that of port CF will decrease,
at this point, oil flow in CF oil line is very small and most oil will be sent to working hydraulic
6-3

system. When working system is not working, the pressure oil will return to hydraulic oil tank
through neutral position of multitandem valve.
When steering
When relative angular displacement is produced between the valve spool and valve bush of steering
gear, the variable orifice in steering gear will communicate with metering motor, and the passage to
the radiator will closed in the meantime. This change will result in pressure rise of oil in left end of
priority valve, and force the spool to find a new equilibrium position. If increase the rotating speed of
steering wheel, in the moment of change, the value of flow in the steering gear is less than the product
of steering wheel rotating speed and steering gear displacement, and rotating speed of valve bush
driven by metering mechanism is lower than rotating speed of spool driven by steering wheel, so
angular displacement of spool to valve bush increases and opening degree of variable orifice
increases. At this point, larger flow is needed to produce the same differential pressure as the one
before the change between two ends of the variable orifice to force the priority valve spool to move
right. So CF port opening degree of priority valve increases with the increase the increase of steering
wheel rotating speed. Finally, the flow valve in the steering gear will equal to the product of steering
wheel rotating speed and steering gear displacement.
Steering gear
Priority valve
Filter
Steering pump
Oil tank
Figure 6-4 Oil line when steering
6-4

When steering load exceeds the rated value or the steering cylinder reaches its stroke end
When steering load exceeds the rated value or steering cylinder reaches its stroke end and if you
keep turning the steering wheel, the oil cannot flow in to the cylinder. At this point, loading pressure
skyrockets, while differential pressure between two ends of variable orifice reduces sharply. When
steering oil line pressure exceeds the setting valve of steering safety valve, this valve will open to
work. Pressure loss produced when pressure oil flows through variable orifice, and this differential
pressure pass to two ends of priority valve spool to force the spool to move left, which result in
decrease of CF port opening degree, and decrease of EF port opening degree, in this way, the
pressure of oil in steering line will reduce.
Steering when engine flames out
When engine is not working, the metering mechanism can work as an oil pump, it can supply
pressure oil to the steering cylinders. Under this circumstance, the oil in oil return chamber of
steering cylinder will return to upstream of the variable orifice through the check valve inside the
steering gear.
The grader adopts dynamic signal load sensing non-reactive steering gear. Features of the
steering system are:
1.
Good compensation for steering load change.
2.
The steering hydraulic system and working hydraulic system are designed without interference
to each other.
3.
The main circuit always takes supplying pressure oil to steering system as first priority.
4.
Only small flow goes through steering gear when steering wheel is in neutral position, which is
energy-saving. The main circuit always takes supplying pressure oil to steering system as first
priority, the steering operation is reliable.
5.
Neutral position pressure characteristic is not subject to displacement, flow amplifying function
is available.
6.
Compared static signal steering gear, starting performance in cold climates is improved, as well
as reliability and stability of the system.
6-5
62 Description, Disassembly and Assembly of Main Components

621 Steering Pump
The steering pump is double pump. The pump is connected with transmission box output port, and
it transmits input mechanical energy from transmission box into oil pressure energy, and outputs
pressure oil flow into the system. Its the power source of steering system.
Technical parameters
Nominal
32/16ml/r
displacement
Steering pump: 25MPa
Nominal pressure
Brake pump: 20MPa
Max. pressure
Fig. 6-5 Steering pump
1 Oil outlet of brake pump
4 Brake pump
2 Oil outlet of steering pump

5 Steering pump
Steering pump: 31.5MPa

Brake pump: 25MPa
3 Oil absorption port
Fault diagnosis of steering pump (working pump)

Table 6-1
S/N
1
2
3
4
Fault phenomenon
Causes
Oil in hydraulic tank reduces,

while oil in transmission box Damaged oil seal.
increases.
Oil in hydraulic tank increases,
while oil in transmission box Damaged oil seal.
reduces.
Measure the pressure and

replace oil seal ring or the
pump.
Measure the pressure and
replace oil seal ring or the
pump.
Oil leaking from pump body Damaged O-ring or Replace the O-ring or fasten
the bolt.
junction surface.
loose bolt.
Oil leakage of pump body
Pump body crack.
Excessive wear of
spline shaft.
Excessive wear of side
Abnormal sound produced by plate.
steering pump.
Out of tolerance of
spine shaft.
Bearing failure.
Elimination method
Insufficient output flow result in Excessive wear of side

plate or gear.
slow motion.
6-6
Check and replace the pump.

Replace the spline shaft or
the pump.
Replace the side plate or the
pump.
Replace the spline shaft or
the pump.
Replace the bearing or the
pump.
Replace the relevant parts or
the pump.
Disassembly of working pump
ATTENTION
1.
Before disassembling the steering pump, please park the machine in maintenance position
properly. Refer to Page 10 in Safety & Environment.
2.
When dismantling the hydraulic pipeline, do not screw off the nut connecting to the oil
port rashly. Loosen the nut gradually until the oil spills out so as to prevent the oil splash
due to incomplete pressure relief.
3.
During dismantling the steering system, necessary protective measures should be taken
for each pipeline and oil port to prevent debris like dust from entering the steering
system.
4.
During dismantling the steering system, please collect the remnant hydraulic oil with
appropriate vessel when disconnecting a pipe, and pour the collected oil into a dedicated
hydraulic oil recycling bin after the maintenance work.
5.
When assembling, be sure to replace the seal with a new one, related standards of
tightening torque in this manual must be strictly followed.
1.
Connect a hose to the oil drain valve on the

bottom of hydraulic tank, and put a clean
vessel under the other end of the hose. Open
the drain valve of the tank to drain the
hydraulic oil out. (Open the filling cap of the
tank to accelerate the draining speed)
ATTENTION
1
Cover up the discharged oil to avoid
Fig. 6-6
1 Oil drain valve
2 Hose
contamination.
6-7

2.
Remove the fixing bolts of the cover plate,

take down the bolts and cover plate.
Cover plate
Fig. 6-7
1 Cover plate
2 Cover plate
3.
Remove the fixing bolts of steering pump oil

absorption steel pipe, take down the bolts and
fission flange, and then remove the steel pipe
and O-shape ring.
1
Fig. 6-8
1 Oil absorption steel pipe
4.
Disconnect the oil outlet rubber hose of

steering pump, and the oil outlet rubber hose
of brake pump.
Fig. 6-9
6-8

5.
Remove the connecting bolts of steering pump

and transmission box, take down the bolts and
gaskets.
6.
Hang the pump with lifting rope, and then use

a copper bar to knock it gently, take down the
pump and the sealing gasket.
Steering pump
7.
1
Remove the fixing screws of the two straight

joints (on the two oil outlet ports), and then
Fig. 6-10
1 Bolt
take down the fission flanges and straight

joints.
Assembly of steering pump

1.
Install the two straight joints to the two oil

outlet ports of the double pump with screws
and fission flange respectively.
2.
Install the double pump to the transmission

box with M1235 nuts, gaskets and sealing
gasket.
Steering pump
ATTENTION
1
Be sure to tighten the studs first.
Fig. 6-11
1 Bolt
3.
Put an O-ring in the O-ring groove of each

straight joint. Connect the oil outlet rubber
hose of steering pump, and the oil outlet
rubber
hose
of
brake
pump
to
the
corresponding straight joint with four M1030

and a fission flange respectively.
Fig. 6-12
6-9

4.
Put O-ring in the O-ring groove of the pump

oil absorption steel pipe joint. Fix the pipe on
the oil absorption port with four M1035 and a
fission flange.
1
Fig. 6-13
1 Oil absorption steel pipe
5.
Install the cover plate.

Cover plate
Fig. 6-14
1 Cover plate
2 Cover plate
6.
1
Fig. 6-15
1 Oil filling port
6-10
Fill hydraulic oil to specified level.
622 Priority Valve

The priority valve is a constant differential reducing component. Regardless of the changes of
loading pressure and oil supply, the priority valve can maintain almost the same pressure
differential between two ends of variable orifice, which can ensure the flow valve in the steering
gear always equal to the product of steering wheel rotating speed and steering gear displacement.
Port P of priority valve is connected with steering pump oil outlet hose, port CF is connected with
port P of steering gear, port EF is connected with port P of the left multitandem valve, and port LS
is connected with port LS of steering gear.
Nominal flow rate
Opening pressure of safety
valve
Dynamic signal introcontrol,
control pressure
Fig. 6-16 Priority valve oil ports
Fig. 6-17 Priority valve

6-11
150L/min
140Bar
8.6Bar
623 Steering Gear

The grader adopts dynamic signal load sensing non-reactive steering gear.
Port P of steering gear is connected with port CF of priority valve, port L and port R is connected
with steering cylinder respectively, and oil in port T flows into oil tank through radiator. Port LS of
steering gear is connected with port LS of priority valve.
Displacement
SAE involute
spline
320ml/r
Max. inlet pressure
17.2MPa
Max. continuous backpressure
2.1MPa
Max. system temperature
93oC
Steering torque
2.8~4.0Nm
Connection type
Fig. 6-18 Steering gear

The steering gear and steering cylinder constitute a
position control system. The displacement of the steering
cylinder piston rod is proportional to the angular
displacement of the steering gear valve element. The
cycloid motor inside the steering gear is a metering
mechanism (it can work as an oil pump when engine is
not working), and it converts the volume of oil
distributed to the steering cylinder into the angular
displacement of the steering gear valve bush. The relative
angular displacement of valve sleeve to the valve element
determines the opening area of the oil-distributing
window. The higher the steering wheel speed, the bigger
the relative angular displacement, and so is the opening
area of the oil-distributing window. When the steering
Fig. 6-19 Internal oil line of steering

gear
1 Bi-directional overload valve
2 Bi-directional oil refill valve
3 Inlet check valve
wheel stops rotating, the relative angular displacement is

zero and the oil-distributing window shuts itself down to achieve feedback control. The return spring
makes the valve sleeve go over the dead zone and align with the valve element.
Function of combination valve inside the steering gear

Inlet check valve: The check valve will be open when oil flows into steering gear. It is used to
6-12

prevent external impact at low steering speed; it can also prevent high pressure oil from flowing back,
which will lead to shake of steering wheel. If the oil flows inversely, the valve closes.
Bi-directional overload valve: When the steering cylinder is influenced by external shock, pressure
of oil in the cylinder will rise and if it gets to setting value of overload valve (20MPa), the valve will
open to load off to protect the cylinder.
Bi-directional oil refill valve: When overload valve is open and in order to avoid cavitation
phenomenon, the oil refill valve will open and absorb oil from returning port of combination valve, to
supplement pressure oil to cylinder left chamber or right chamber timely.
Precautions when maintaining steering gear

1.
Make sure all parts and components are clean to prevent dirt from entering steering gear or
hydraulic system.
2.
Keep the oil ports and pipe joints clean, and never use thread seal tape to replace seal rings for
sealing.
3.
Make sure the oil ports of steering gear combination valve and oil ports of steering gear are
correct connection relationship.
4.
Avoid exerting axial force on the steering gear input end when assembling.
5.
Deflate the steering gear after assembling.
6.
Never dismantle the steering gear arbitrary, unless you are sure that the steering gear is faulty.
7.
Never dismantle the combination valve arbitrary, pressure adjustment of the combination valve
must be verified by tests.
8.
Make sure all parts and components are clean when disassembling and assembling steering gear,
and beware of collisions.
9.
When disassembling and assembling, the valve element and valve bush assembly should be
removed or installed vertically, to avoid falling out of pin(s) inside.
10. Align the mark points when assembling the universal driving shaft and rotor.
11. Do not forget to install the steel ball of check valve and pin(s).
Disassembly of steering gear
ATTENTION
1.
Before disassembling the steering gear, please park the machine in maintenance position
properly. Refer to Page 10 in Safety & Environment.
2.
When dismantling the hydraulic pipeline, do not screw off the nut connecting to the oil
port rashly. Loosen the nut gradually until the oil spills out so as to prevent the oil splash
due to incomplete pressure relief.
6-13

3.
During dismantling the steering system, necessary protective measures should be taken
for each pipeline and oil port to prevent debris like dust from entering the steering
system.
4.
During dismantling the steering system, please collect the remnant hydraulic oil with
appropriate vessel when disconnecting a pipe, and pour the collected oil into a dedicated
hydraulic oil recycling bin after the maintenance work.
5.
When assembling, be sure to replace the seal with a new one, related standards of
tightening torque in this manual must be strictly followed.
1.
Remove the fixing bolts of the left and right

guard plates, take down the guard plates.
1
Fig. 6-20
1 Left guard plate
2.
Remove the fixing bolts of the top guard plate,

take down the guard plate.
1
Fig. 6-21
1 Top guard plate
6-14

3.
Remove the beam.
4.
Disconnect the oil pipes from steering gear.
1
Fig. 6-22
1 Beam
ATTENTION
Mark the oil pipes properly to prevent
confusion.
1
Fig. 6-23
1 Pipe
5.
Remove the connecting bolts of steering

column holder and cab.
6.

column holder and steering gear support.
1
Fig. 6-24
1 Bolt
3 Pin
34
2 Steering column holder

4 Steering gear support
6-15

7.

column and steering gear. Take down the
steering gear.
8.
1
Fig. 6-25
1 Bolt
Remove the straight joints.
2 Straight joint
Assembly of steering gear

1.
Install the straight joints to the corresponding

oil ports.
2.
Connect steering column and steering gear

with four M1025 bolts and gaskets.
1
2 3
4
Fig. 6-26
1 Steering column
2 Bolt
3 Gasket
3.
Install the pin to connect the steering column

holder and steering gear support.
4.
Install the steering column holder to cab with

four M1025 bolts and gaskets.
1
2
3
Fig. 6-27
1 Bolt
3 Pin
6-16

5.
Connect the oil pipes to the corresponding oil

ports of steering gear.
Fig. 6-28
6.
Install the beam fixing bolts.
7.
Install the top guard plate.
1
Fig. 6-29
1 Beam
1
Fig. 6-30
1 Bolt
2
2 Top guard plate
6-17

8.
Install the left and right guard plates.
1
Fig. 6-31
1 Left guard plate
624 Steering Control Mechanism Assembly
Fig. 6-32
1 Steering wheel
2 Steering column
3 Nut
4 Gasket
5 Pressing plate
6 Protective cover
8 Cotter pin
9 Gasket
10 Bolt
12 Pin
6-18
625 Front Axle

Front axle bracket
Fig. 6-33 Front axle assembly

1 Front axle
2 Gasket
8 V-shape seal ring
3 Bolt
9 Swing shaft
5 Rim
6 Oil cup
7 Lock washer
10 Bolt
11 Gasket
12 Support
Fig. 6-34 Front axle

1 Left steering frame
2 Left steering knuckle
3 Retainer ring
6 Front wheel tilt cylinder
7 Oil cup
10 Knuckle bearing
11 Bolt
12 Gasket
15 Composite bearing
16 Cotter
17 Front axle frame
19 Composite bearing
20 Articulated shaft
24 Screw
26 Screw
27 Cover plate
32 Gasket
33 Gasket
25 Gasket
31 Right steering knuckle
4 Shaft
8 Connecting rod
6-19
13 Support
21 Support
28 Screw
34 Gasket
5 Retainer ring
9 Retainer ring
18 Lock washer
22 Gasket
23 Bolt
29 Gasket
30 Pin
35 Right steering frame

36 Wheel axle
37 V-shape seal ring
38 Seal ring
39 Screw
41 O-ring
42 Nut
43 Lock washer
44 Gasket
45 Tapered roller bearing
46 Screw
47 Screw
48 Hub
49 Gasket
50 Lining
51 Nut 52 Right swivel head
54 Cotter
55 Left swivel head
53 Lock nut
58 Bolt
59 Pull rod 60 Shaft
64 Plate
65 Right steering cylinder
61 Pin
56 Clamp
62 Plain radial bearing

66 Bolt
40 Hub cover
57 Nut
63 Retainer ring
68 Support 69 Left steering cylinder

The front axle assembly of grader is different from common axle. Apart from having steering
function, it also has front-wheel wide-angle tilting function and horizontal swing function. Because
of the design, the grader can balance itself during working, and the working accuracy is improved.
Under special working condition, it can increase adhesive force of the front wheels, which is
beneficial for the grader to satisfy all kinds of working conditions.
Maintenance of front wheel bearing must be conducted by specialized person in accordance with
specific procedures. Non-specialized person is not allowed to disassemble the front axle.
Disassembly of front axle assembly

1.
Put the machine in maintenance position.
2.
Start the engine, and operate the control handle

of the shovel blade rotary cylinder until the
blades are perpendicular to the front frame.
And then operate the control handle of the
shovel blade lifting cylinder to lower the
blades to the prepared wood support. Shut
down the engine.
ATTENTION
1
Fig. 6-35
1 Shovel blade
Before
performing
the
following
maintenance work, you must prop up the

shovel blades. Otherwise the grader may tip
over and cause personnel injury.
6-20

Removal of front wheel
1.
Loosen the fixing bolts of front wheels. Start

the engine and operate the control handle of
the shovel blade lifting cylinder to lower the
blades, in this case, the front end of grader is
elevated. Put reliable support under the front
end of the grader and operate the control
handle of the shovel blade lifting cylinder to
lift the blades, to let the front end of the grader
fall on the support slowly. Shut down the
Fig. 6-36
1 Bolt
engine.
2.
Remove the fixing bolts of front wheels, take

down the bolts and gaskets. Remove the
wheels.
Removal of front wheel hub

1.
Hang the hub with lifting appliance, remove

the fixing bolts of the hub cover, take down
the bolts and hub cover.
Hub
1
Fig. 6-37
1 Hub cover
2
2 Inside hexagon bolt
2.
1
Fig. 6-38
1 Hub cover
2 O-ring
6-21
Remove the O-ring from the hub cover.

3.
Remove the outside lock nut, and then take

down the lock nut, lock washer, and the lock
nut and gasket under the washer.
1
2 3
4
5
Fig. 6-39
1 Hub
2 Gasket
4 Lock washer
3 Lock nut
5 Lock nut
4.
Use special tool to remove the hub.
ATTENTION
In the process of removing the hub, the
tapered roller bearing may fall off at any
moment.
Structurally, middle part of the wheel axle
is lower, so do not knock to remove the hub,
to avoid damaging the tapered roller
bearing.
1
Fig. 6-40
Fig. 6-41
6-22

5.
Use special tool to remove the tapered roller

bearing. Take down the V-shape seal ring and
O-ring.
Fig. 6-42
2 V-shape seal ring
3 O-ring
Removal of drag link

1.
Hang the drag link with lifting appliance, and

then remove the cotter pin.
2.
Screw off the slotted nut, and take down the

nut and gasket.
1
Fig. 6-43
1 Cotter pin
3 Gasket
2 Slotted nut
4 Drag link
6-23

3.
Use copper bar to knock the swivel head off

(knock from bottom).
4.
Do the same to the swivel head on the other

end, and then lift down the drag link.
1
Fig. 6-44
1 Swivel head
5.
Remove the fixing bolt of the clamp, take

down the clamp and separate the swivel head
and drag link.
1
Fig. 6-45
1 Clamp
Removal of steering cylinder
1.
Disconnect the oil pipes from the steering

cylinder.
1
Fig. 6-46
1 Oil pipe
6-24

2.
Remove the fixing bolt of the steering cylinder

piston-side connecting pin, take down the bolt,
gasket and the bottom support. Then use a
copper bar to remove the pin.
1
Fig. 6-47
1 Bolt
3.
Remove the cotter pin from the slotted nut, and

then screw off the slotted nut. Take down the
nut and gasket.
1
Fig. 6-48
1 Slotted nut
4.
Use a copper bar to knock the swivel head off

the steering frame.
5.
Lift down the steering cylinder. Remove the

connecting bolt of the swivel head and steering
cylinder piston rod, and take down the swivel
head.
1
Fig. 6-49
1 Bolt
6-25

Removal of wheel axle
1.
Remove the connecting bolts of the wheel axle

and steering frame, and then take down the
wheel axle.
Wheel axle
1
Fig. 6-50
1 Bolt
Removal of steering frame
1.
Remove the fixing bolts of the cover plate,

take down the bolts and cover plate.
1
Fig. 6-51
1 Cover plate
2
2 Bolt
2.
Remove the inside hexagon bolt, take down

the bolt and gasket.
1
Fig. 6-52
6-26

3.
Remove the pin.
4.
Use the same method to disconnect the other

end connection, lift the steering frame away.
Steering frame
1
Fig. 6-53
1 Pin
Removal of front wheel tilt cylinder
1.
Hang the tilt cylinder with lifting appliance.
2.
Disconnect the oil pipes from the tilt cylinder.
3.
Remove the fixing bolt of the tilt cylinder
Fig. 6-54
1 Tilt cylinder rod-side connecting hose
2 Tilt cylinder piston-side rubber hose
piston-side connecting pin, take down the bolt

and gasket. Then use special tool to remove
the pin.
1
Fig. 6-55
1 Bolt
6-27

4.
Use snap ring plier to remove the snap ring of

tilt cylinder rod-side connecting pin. Then use
a copper bar to remove the pin. Lift the tilt
cylinder away.
Front wheel tilt cylinder
1
Fig. 6-56
1 Snap ring
Removal of connecting rod
1.
Use snap ring plier to remove the snap ring on

both ends of the pin.
2.
Use the same method to remove the snap rings

on the other end of the connecting rod. Hang
the connecting rod away with lifting appliance.
Connecting rod
1
Fig. 6-57
1 Snap ring
3.
Use snap ring plier to remove the snap ring.

Then remove the connecting pin(s).
1
Fig. 6-58
1 Snap ring
6-28

Removal of steering knuckle
1.
Remove the fixing bolt of steering knuckle and

front axle bracket connecting pin, take down
the bolt and gasket. Use special tool to remove
the connecting pin, and lift the steering
knuckle away.
Steering knuckle
1
Fig. 6-59
1 Bolt
Removal of front axle bracket
1.
Remove the fixing bolt of front axle bracket

and frame connecting pin, take down the bolt
and gasket.
2.
Use special tool to remove the connecting pin,

and lift the front axle bracket away.
Front axle bracket
1
Fig. 6-60
1 Bolt
6-29
Assembly of front axle assembly

Assembly of front axle bracket
1.
Hang the front axle bracket with lifting

appliance, align it to the frame for assembling,
and then install the pin to connect them.
Front axle bracket
2.
Install the pin fixing bolt and gasket.
1
Fig. 6-61
1 Bolt
Assembly of steering knuckle

1.
Hang the
steering knuckle
with
lifting
appliance, align it to the front axle bracket for

assembling, and then install the pin to connect
them.
Steering knuckle
2.
1
Fig. 6-62
1 Bolt
6-30
Install the pin fixing bolt and gasket.

Assembly of connecting rod
1.
Preassemble the two connecting pins to the

steering knuckle first, and install the snap
rings.
2.
Install the knuckle bearing to the pin, and fix it

with snap ring.
3.
Hang the connecting rod with lifting appliance,

align it to the steering knuckle for assembling,
1
Fig. 6-63
1 Pin
connect them with the two preassembled pins,
and install the snap rings.

2 Snap ring
Connecting rod
Assembly of front wheel tilt cylinder
1.
Lift the tilt cylinder to suitable position for

assembling.
Front wheel tilt cylinder
2.
Install the cylinder piston-side connecting pin,

and fix the pin with bolt and gasket.
1
Fig. 6-64
1 Bolt
3.
Install the cylinder rod-side connecting pin and

fix the pin with snap ring.
1
Fig. 6-65
1 Snap ring
6-31

4.
Connect the piston-side and rod-side rubber

hoses.
1
2
3
Fig. 6-66
1 Tilt cylinder rod-side connecting hose
2 Tilt cylinder piston-side rubber hose
Assembly of steering frame
1.
Hang the steering frame with lifting appliance,

align it to the steering knuckle for assembling,
and then install the pin to connect them.
Steering frame
1
Fig. 6-67
1 Pin
2.
1
2
Fig. 6-68
2 Gasket
6-32
Install the inside hexagon bolt.

3.
Install the fixing bolts of the cover plate.
Fig. 6-69
1 Cover plate
2 Bolt
Assembly of wheel axle
1.
Use lifting appliance to lift the wheel axle to

suitable position for assembling. Then install
the connecting bolts of the wheel axle and
steering frame.
Wheel axle
1
Fig. 6-70
1 Bolt
Assembly of steering cylinder
1.
Connect the steering cylinder to the swivel

head with bolt.
2.
Use lifting appliance to lift the steering

cylinder assembly to suitable position for
assembling. Then connect the swivel head to
the steering frame.
1
Fig. 6-71
1 Bolt
6-33

3.
Tighten the slotted nut to fix the swivel head.

Then install the cotter to fix the nut.
1
Fig. 6-72
1 Slotted nut
4.
Install the fixing bolt of the steering cylinder

piston-side connecting pin.
1
Fig. 6-73
1 Bolt
5.
1
Fig. 6-74
1 Oil pipe
6-34
Connect the oil pipes to the steering cylinder.

Assembly of drag link
1.
Install the clamp to connect the swivel head

and drag link.
1
Fig. 6-75
1 Clamp
2.
Use lifting appliance to lift the drag link to

suitable position for assembling. Then connect
the swivel head to the steering frame.
1
Fig. 6-76
1 Drag link
3.
Tighten the slotted nut to fix the swivel head.

Then install the cotter to fix the nut.
1
Fig. 6-77
1 Cotter pin
3 Gasket
3
2 Slotted nut
6-35

Assembly of front wheel hub
1.
Install the tapered roller bearing and seals to

the hub.
ATTENTION
A refrigerated bearing is easier to be
assembled.
Fig. 6-78
2 V-shape seal ring
3 O-ring
2.
Use lifting appliance to lift the hub to suitable

position for assembling. Then install the hub to
wheel axle.
Hub
3.
1
Fig. 6-79
6-36
Install the outside tapered roller bearing.

4.
Install the gasket, lock nut, lock washer and

the outside lock nut orderly.
1
2 3
4
5
Fig. 6-80
1 Hub
2 Gasket
4 Lock washer
3 Lock nut
5 Lock nut
5.
Install the O-ring from the hub cover. Then

install the hub cover to wheel hub.
1
Fig. 6-81
1 Hub cover
2 O-ring
6.
Install and tighten the fixing bolts of the hub

cover.
1
Fig. 6-82
1 Hub cover
2
6-37

Assembly of front wheel
1.
Use bolts and nuts to fix the wheel on hub.

Wheel
1
Fig. 6-83
1 Bolt
626 Steering Cylinder

Single-rod double-acting hydraulic cylinder
Cylinder diameter
63mm
Piston rod diameter
45mm
Piston stroke
340mm
Fig. 6-84 Steering cylinder
6-38
63 Pressure Measurement of Steering Hydraulic System

Pressure measuring tools
Pressure gauge with measuring range of 0~25MPa
Pressure measuring points
Quick pressure measuring joints on steering cylinder (Specification of thread on the port M162)
Steering system pressure measuring point
Fig. 6-85 Steering system pressure measuring point

Pressure measuring method
1.
Connect the pressure gauge to the pressure measuring joint.
2.
Start the engine and turn the steering wheel to the extreme position to build pressure.
3.
Read and record the reading on pressure gauge.
Standard working hydraulic system pressure

Set pressure of steering system: 1403.5Bar.
6-39
64 Deflation of Steering Hydraulic System

After replacing steering pump, steering gear, priority valve, steering cylinder and the hydraulic
pipes in steering circuit, air bleeding must be done by performing the following steps:
1.
Park the loader in maintenance position properly, lower the front bulldozing plate to the ground
and jack up the front wheel (off ground), and then open the filling cap of hydraulic oil tank.
2.
Start and run the engine idly, turn the steering wheel gently to let steering cylinders stretch out
and draw back (about 50~60mm, from the bottom of the stroke) for 2~3 times.
3.
After the hydraulic oil is fully circulated, turn the steering wheel left and right within a narrow
range for several times. Be sure not to let the steering cylinder gets to its stroke end.
4.
Keep the engine run at high speed, turn the steering wheel gently to let steering cylinders
stretch out and draw back in full stroke for 3~5 times to drain the air in the circuit out.
5.
After air bleeding, set the machine and working device in standard position (the steering wheel
should be in neutral position; front frame and rear frame should be in the same line; the front
bulldozing plate should be lower to ground and be 90o to the frame; the scarifier should be
lowered close to the ground). Then check the oil level and tighten the filling cap.
6.
Stop the engine, check and ensure there is no leakage in hydraulic circuit.
6-40
65 Diagnosis and Solutions for Common Faults of Steering System

Table 6-2 Fault phenomenon and elimination methods
1.
1.
The built-in check valve of steering gear is damaged and the

inlet is blocked.
2.
Steering gear failure, the check valve steel ball is jammed and
couldnt reset.
3.
Priority valve LS pipe is twisted together or too long, the

damping hole is blocked or oil leakage.
4.
The steering column is damaged and requires larger driving

torque.
5.
Interference between steering column and steering gear

connecting part, extra axial or radial force is formed and acts
on steering gear valve element after assembling.
6.
Low set pressure of priority valve relief valve, or the main

valve element is stuck, or the damping hole is blocked.
7.
Low set pressure of safety valve of steering gear combination

valves.
8.
Oil return filter is blocked.
9.
The pump is severely worn, whose volume efficiency, output

pressure and flow rate can no longer meet system requirement.
Steering hard
10. Somewhere in the steering circuit is blocked that results in

severe throttle.
11. Main valve element of priority valve is jammed or the main
spring rigidity is reduced.
12. Interference in front axle steering mechanism.
2.
Vehicle snaking
1.
Check for cavitation phenomenon.
2.
The pump oil absorption steel pipe or pipe joint has air leakage
problem.
3.
Low oil level in hydraulic oil tank.
4.
Steering cylinder connecting pin is loose or the piston rod is

distorted.
5.
Steering cylinder has severe internal leakage problem.
6.
The bi-directional overload valve or bi-directional refill valve

has oil leakage problem
6-41
3.
4.
Vehicle off tracking
Self-steering
steering wheel
neutral.
1.
Check whether the connecting rod of steering cylinder is loose.
2.
Internal leakage of steering cylinder.
3.
There is large pressure differential between the two tires.
4.
Leakage in one side of bi-directional oil compensation valve or

bi-directional overload valve.
5.
Oil contains too much air.
1.
Check the connecting rod of steering cylinder is loose.
when 2.
is in
3.
4.
5.
6.
7.
8.
9.
Transient steering is not 1.

flexible after the machine
is just started.
Internal leakage of steering cylinder.

Leakage in one side of bi-directional oil compensation valve or
The machine is off work for too long, large temperature
differential between steering gear components and hydraulic
oil.
1.
Too much air in the steering system.
2.
Steering cylinder pin is loose.
3.
Heat shock.
4.
Main valve element of priority valve is jammed.
5.
Oil leakage in steering cylinder.
6.
Low efficiency of steering pump results in unstable pressure.
1.
Too much air in the steering system.
Steering is inaccurate.
Steering
creeping
cylinder
1.
Steering wheel can be
turned freely, but there is 2.
no force feeling or the
machine fails to steer.
3.
Nuts of steering wheel and steering column fall off.
Steering wheel can be 1.

turned easily, but the
machine doesnt steer or
2.
steers slowly.
Severe leakage in bi-directional oil compensation valve or

The connection between steering column central spindle and

steering gear valve element is failed.
Low hydraulic oil level.
Severe internal leakage of steering cylinder.
6-42

1.
Nut of steering wheel is loose.
2.
The connection between steering column and steering gear is

severely worn or damaged.
10. Idle motion of steering 3.

wheel.
4.

Leakage in bi-directional oil
compensation
valve
or
5.
The steering cylinder linkage is damaged or worn (big gap).
6.
Leakage of steering cylinder.
1.
The connection between steering column and steering gear is

too tight or interference exists.
2.
11. Bad return or dragging
turning of steering wheel 3.
Too large return backpressure results in bad return.

Big contamination particle enters into the gap between valve
bush and valve element that results in unable to return.
4.
Steering gear spring sheet is damaged or with small rigidity.
1.
Big and hard contamination particle enters into the gap between
stator and rotor.
12. Components of steering 2.

gear is damaged
3.
Severe grind damage.

Pull pin cracked
4.
Heat shock. (50oC differential)
Wrong assembly relationship. For reassembly, corresponding

spline tooth in universal driving shaft pull pin groove should be
aligned to rotor internal spline tooth concave.
Connect the oil inlet pipe to port R or port L, and the steering
gear will self-rotate as the motor.
13. Steering wheel trembles

or self-rotation
14. Steering wheel and the

machine
turning
in 1.
opposite direction
Pipe of port L and port R are inversely connected.
15. Steering wheel rebound
The built-in check valve of steering gear is damaged
1.
6-43

Guide Steering System Service Manual

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Guide Steering System Service Manual

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Service Manual of RS8160 Road Roller

Service Manual for G9180 Grader

Service Manual for G9180 Grader

Fig. 6-1 Principle diagram of steering system

Working hydraulic system

Brake hydraulic system

Fig. 6-2 Location of steering system

5 Pressure measuring port

Service Manual for G9180 Grader

611 Location of Steering System Components

Service Manual for G9180 Grader

612 Steering System Principle Description

Fig. 6-3 Oil line when steering gear is in neutral position

Service Manual for G9180 Grader

Figure 6-4 Oil line when steering

Service Manual for G9180 Grader

Good compensation for steering load change.

Service Manual for G9180 Grader

62 Description, Disassembly and Assembly of Main Components

2 Oil outlet of steering pump

Steering pump: 31.5MPa

3 Oil absorption port

Fault diagnosis of steering pump (working pump)

Oil in hydraulic tank reduces,

Measure the pressure and

Pump body crack.

Insufficient output flow result in Excessive wear of side

Check and replace the pump.

Service Manual for G9180 Grader

Disassembly of working pump

Connect a hose to the oil drain valve on the

Cover up the discharged oil to avoid

Service Manual for G9180 Grader

Remove the fixing bolts of the cover plate,

Remove the fixing bolts of steering pump oil

Disconnect the oil outlet rubber hose of

Service Manual for G9180 Grader

Remove the connecting bolts of steering pump

Hang the pump with lifting rope, and then use

Remove the fixing screws of the two straight

take down the fission flanges and straight

Assembly of steering pump

Install the two straight joints to the two oil

Install the double pump to the transmission

Be sure to tighten the studs first.

Put an O-ring in the O-ring groove of each

corresponding straight joint with four M1030

Service Manual for G9180 Grader

Put O-ring in the O-ring groove of the pump

Install the cover plate.

Fill hydraulic oil to specified level.

Service Manual for G9180 Grader

622 Priority Valve

Fig. 6-16 Priority valve oil ports

Fig. 6-17 Priority valve

Service Manual for G9180 Grader

623 Steering Gear

Max. inlet pressure

Max. continuous backpressure

Max. system temperature

Fig. 6-18 Steering gear

Fig. 6-19 Internal oil line of steering