Chapter 2: Maintenance and repairing a motor grader

2.1 Introduction
A motor grader is a piece of heavy machinery used to create a smooth, wide, flat surface.
Traditionally, the grader is used for road maintenance its main function is to flatten surfaces
before the application of asphalt. Presently, these machines are also commonly used for fine
grading, spreading, and earthmoving. They can be used for clearing debris and brush, as well
as for snow removal. A variety of attachments convert the motor grader into a more versatile
machine, enabling the machine to do things such as dig shallow holes. The attachment of an
elevating conveyor enables the machine to take loose material from the trailing end of its
blade, elevate it, and cast it into a hauling unit.

Fig 2.1: Komatsu motor grader

In generally motor graders need regular maintenance schedule because of its heavy use. In
motor graders work done was measured by hours. So these maintenance were done based on
hours.

2.2 Parts of a motor grader

Fig. 2.2: Parts of a motor grader (Outer)

Fig. 2.3: Parts of a motor grader (outer 2)

Fig. 2.4: Parts of a motor grader (Inner)

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

Steering wheel
Accelerator leaver
Accelerator paddle
Break paddle
Clutch paddle
Hand break leaver

7. Decompression leaver
8. Turn signal switch leaver
9. Gear shift leaver
10. High-low leaver
11. Gear shift leaver
12. Forward-Reversed leaver
13. Hydraulic control leavers

2.3 Maintenance of a motor grader

As above mentioned motor graders needed regular maintenance and those maintenance are
based on working hours. Those maintenance were divided in to 10 hour, 100 hour, 300 hour,
600 hour, 1200 hour maintenance.

2.3.1 Every 10 working hours or daily maintenance

1. Walk around checks
Hydraulic system-Check for leakages, worn hoses and damaged lines
Electrical System-Check for loose connections and open circuits
Scarifier-Check for wear and damage
Tires-Check for wear, cuts or gouges
Blade-Check for wear and damage
Engine compartments-Check for oil and fuel leaks
Clutch and transmission-Check for leakages
Cooling system-Check for worn hoses, leakages and thrash build up
Operation-Check for noise and vibration

2.

Check oil level in engine crank case

Fig.
2.5: Oil filter of a motor grader

Prefect oil level should be between full and add marks on gauge (1)
If there is not enough engine oil , it was added to the oil filter (2)
Oil level was checked after 5 minutes of engine stopped

3. coolant level in radiator was checked

Fig. 2.6: Radiator

cap and radiator inlet

Coolant should be up to bottom of the filter.

If there is lack of coolant water was added to the radiator inlet(2)

4. Oil level in the hydraulic tank was checked

Fig. 2.6: Hydraulic

tank of motor grader (6)

Oil level should be between full and add in the oil gauge provided
If there is lack of hydraulic oil, it was added to the oil filter

5. Steering wheel play was checked

Fig. 2.7: Motor grader steering wheel

Motor grader steering wheel should be checked for the play of the
wheel
Standard play should between 10 to 12cm (about 4 inches) when
measured at wheel rim

6. Blade attachments of motor grader was checked

Fig. 2.8: Blade attachment of motor grader

Scarifire and blade was checked for wear and damages

Sacrifire teeth (1) or blade cutting edges were replaced if it worn or
damaged

7. Tyres and rims were checked

Fig. 2.9: Tyre set of a motor grader

Tyre set was checked for damages, were and the fitting nuts of the
wheel were checked

2.3.2 Every 100 working hours or monthly maintenance

1. Oil level in the clutch and flywheel was checked
There as a special gauge in the clutch to check the oil level.
In generally oil level should be between full and add marks on the
gauge
Oil was added to the oil reservoir
2. Electrolyte level in the battery was checked
Electrolyte liquid should be above 1cm (3/8 inches) above the cell
plates
Distilled water was poured if it is necessary
3. Moisture and sediment was drained from fuel filter

Moisture and sediment was collected in the fuel filter because of the
impurity of diesel and the machine exposed to the rain
To clean the oil filter first the oil supply line was closed and then the air
plug was loosen.
Then the drain plug was removed and let the moisture and sediment to
go out.
Then the oil filter and the drain plug was cleaned and attached to their
positions

4. Blade, circle and guide plates were lubricated

Fig. 2.10: Blade (1),

Circle
(2), Guide plate (3) of motor grader

Sliding surfaces of the blade, circle and guide plate was cleaned and gear
oil was applied to those surfaces.

5. Adjust fan belt tension was checked

Generally the deflection should be 2 to 2.5 cm(3/4 to 1 inch)

6. Clutch pump drive belt tension was checked and adjusted

7. Air master was checked for air and oil leakages
8. Clutch booster was checked for oil leakages

Fig. 2.11: Clutch booster

2.3.3 Every 300 working hours or 3 month maintenance

1. Oil level of the transmission gear case was checked

Fig. 2.12: Transmission gear oil gauge (1)

2. Oil level in rear axle gear case was checked

Fig. 2.13: Gear case of motor grader

Level plug was removed and the oil level was checked
Oil level should be at the bottom of the plug opening

3. Oil level in the tandem drive gear case was checked

4. Oil level in the circle reverse worm gear case was checked

Fig. 2.14:

Circle reverse
worm gear case

5. Oil level in reverse reduction gear case was checked

6. Fuel feed pump per filter was washed
7. Crank case oil and filter was changed

First the engine was warm up

Then the drain plug was removed and allow oil to drain
The bolt at the center of the filter case was removed and the filter element
was taken out from the case
New elements were placed and the case was cleaned
Oil filter was filled with 19 liters of oil
Engine was run in low speed and the oil level was checked
Oil was added if it is needed

8. Air cleaner element was cleaned

9. Wheel nuts were checked and retightened
10. Air master was lubricated
11. Steering wheel shaft joints were lubricated
12. Drawbar ball joint was lubricated
13. Hydraulic control levers were lubricated
14. Clutch pump bearings were lubricated

2.3.4 Every 600 working hours or 6 month maintenance

1. Fuel filter element was changed

2. Hydraulic filter element was changed

3. Steering wheel intermediate shaft bearing was lubricated
4. Circle reverse universal joints were lubricated
5. Transmission gearshift lever was lubricated
6. Hydraulic pump universal joints were lubricated

Fig. 2.15: Hydraulic pump universal joints (1 & 2)

7. Shear pin flange was lubricated

Fig. 2.16: Shear pin flange (1)

2.3.5 Every 1200 working hours or 12 month maintenance

1. Engine cylinder head bolts were retightened and the valve clearance was adjusted

2. Oil in the flywheel clutch case was changed

3. Oil in transmission gear case was changed
4. Oil in the rear axle gear case was changed
5. Oil in the tandem drive gear case was changed
6. Oil in the hydraulic tank was changed
7. Cooling system was flushed and coolant was changed
8. Air cleaner element was changed
9. Steering wheel shaft and spline shaft was lubricated
10. Ball joints of the attachment was lubricated
11. Circle to draw bar clearance and circle to guide shoe clearance was checked