Reviving a Champion D560 Motor Grader After a Decade of Dormancy

[MikePhua]

Champion’s Legacy in Road Machinery
Champion Road Machinery, founded in Canada in the early 20th century, built its reputation on robust, operator-friendly motor graders. The D560 model, part of the D500–D600 series, was designed for municipal and contractor use, offering mechanical simplicity and hydraulic control in a mid-weight frame. These machines were widely adopted across North America for road maintenance, ditch shaping, and light construction. Though Champion was eventually absorbed into Volvo Construction Equipment in the late 1990s, many of its graders remain in service today, prized for their rebuildability and straightforward mechanics.
Initial Startup and Fluid Contamination
A recently acquired D560, left idle for nearly ten years, surprisingly fired up with minimal effort. However, early signs of trouble emerged during transport. The clutch and torque converter fluid appeared milky—an indicator of water contamination. Hydraulic fluid in the steering gearbox showed similar symptoms. While the engine oil remained clean, the presence of moisture in other systems suggested prolonged exposure to condensation or failed seals.
Operators should be aware that milky hydraulic or transmission fluid can lead to:
• Reduced lubrication and increased wear
• Corrosion of internal components
• Foaming and erratic pressure behavior
• Seal degradation and pump cavitation
Immediate flushing and replacement are essential. In this case, the transmission was drained and yielded only half a gallon—far below the expected five-gallon capacity. Both drain plugs showed fuzzy metallic residue, likely from gear wear, but no catastrophic damage. A mixture of Marvel Mystery Oil and 10W hydraulic fluid was used to flush the gearbox before refilling.
Transmission and Shift Linkage Inspection
The D560 is equipped with a 9135 transmission, a rugged unit common to mid-century graders. Transmission fluid access was eventually located via a side plug, and a filter screen near the suction hose was pulled for inspection—clean. However, the inline filter was clogged and replaced.
The shift lever box, mounted below the cab, showed signs of stiff movement due to old grease and grime. Disassembly and cleaning were planned to restore smooth gear selection. No special tools are required, but care should be taken to avoid damaging detents or spring-loaded linkages.
Circle Drive Actuator and Hydraulic Leaks
The circle drive actuator, responsible for rotating the moldboard, was leaking hydraulic fluid from the top. Beneath the grime, the actuator likely contains worn O-rings or seals. Disassembly is straightforward but requires cleaning and inspection of the gear-driven timing mechanism. A key point of failure is the gear beneath the actuator, which includes a grease fitting. If neglected, wear in this gear can disrupt piston timing and cause the circle to jam.
Additional wear points include:
• Circle gear backlash due to worn wear plates
• Out-of-round circle housing causing uneven rotation
• Misalignment between timing gear and rotational pistons
Regular greasing and inspection of these components can prevent costly repairs and maintain grading precision.
Front End Damage and Sheet Metal Replacement
During its previous life, the grader suffered a brake failure and rolled backward into a tree, damaging the radiator and front hood sections. The radiator was retrofitted, but the hood remains partially missing, leaving the engine exposed. While this doesn’t affect function, it compromises protection and aesthetics.
Finding replacement sheet metal for vintage Champion machines is difficult. Jade Equipment, a known supplier, was unable to assist. Operators seeking parts should consider:
• Contacting regional salvage yards with older fleets
• Networking with municipal shops that retired similar models
• Fabricating custom panels using original dimensions
• Searching for donor machines in rural equipment auctions
A better-fitting radiator may also be sourced from compatible models or retrofitted with modern cooling units, provided mounting brackets and hose routing are adapted.
Anecdote from Manitoba
A grader operator in Manitoba recalled rebuilding a D600 with similar issues. After discovering water in the transmission and hydraulic systems, he replaced all seals and flushed the system with kerosene before refilling. The machine went on to serve another 15 years in gravel road maintenance. His advice: “If it’s been sitting, assume everything’s wet and dirty—and clean it like you’re going to sell it tomorrow.”
Recommendations for Rehabilitation
To restore a long-idle Champion grader:
• Drain and flush all fluids, including transmission, hydraulics, and differential
• Inspect and clean filter screens and inline filters
• Disassemble and lubricate shift linkages and actuator gears
• Replace worn seals and O-rings in hydraulic components
• Check moldboard circle gear for backlash and wear
• Source sheet metal from salvage or fabricate replacements
• Test steering and brake systems under load before field use
Documenting each step and photographing assemblies before disassembly can aid future maintenance and parts sourcing.
Conclusion
Reviving a Champion D560 after a decade of neglect is a testament to the durability of mid-century road machinery. With methodical inspection, fluid replacement, and mechanical care, these graders can return to service and perform reliably for years. While parts may be scarce, ingenuity and field knowledge remain the most valuable tools in any rehabilitation project. In the world of legacy iron, every bolt turned is a step toward preservation and performance.