1repair & maintenance_englisg-g9165

Service Manual of G9165 Grader

1 Repair & Maintenance

SERVICE MANUAL

Service Manual for G9165 Grader

I

CONTENTS

1 Repair & Maintenance ......................................................................................... 1-1

11 Oil, Coolant and Others ....................................................................................... 1-1

111 Fuel .............................................................................................................. 1-1

112 Coolant ......................................................................................................... 1-2

113 Lubricant ...................................................................................................... 1-2

114 Storage of Oil and Fuel ................................................................................ 1-3

115 Filters ........................................................................................................... 1-3

12 Selection of Oils .................................................................................................. 1-4

121 Oil Application ............................................................................................ 1-4

122 Notes for Oil Application ............................................................................ 1-5

13 Maintenance ......................................................................................................... 1-6

131 Precautions before Maintenance.................................................................. 1-6

132 Periodic Maintenance ................................................................................ 1-10

133 Maintenance & Repair ............................................................................... 1-16


1-1

1 Repair &

Maintenance

11 Oil, Coolant and Others

ATTENTION

Change oil as soon as the oil is deteriorated

or is mixed with many impurities.

Add the specified volume of oil. Either too

much or too little oil may cause problems.

Clean or replace the relevant filters when

changing oil.

111 Fuel

The fuel pump is a precision instrument. If the

fuel mixes with water or dirt, the fuel pump

will not work normally.

Never let impurities or contaminants enter the

system when changing fuel filters or adding

fuel.

Strictly choose the fuel type according to

recommendations in this manual.

The fuel may be frozen at low temperatures

(particularly temperatures lower than 5°F

(-15°C)). So it may be necessary to change the

kind or blend of fuel according to the ambient

temperatures. Refer to Table 1-1 in this

chapter for details.

Always fill up the fuel tank after operating to

prevent water, which is condensed by the


1-2

moisture in the air, from entering the fuel tank.

If the engine fails to prime with fuel or the

filters have been just replaced, purge the air in

the fuel inlet system.

112 Coolant

In order to keep sediment from blocking the

radiator and affecting the thermal performance,

use high quality glycol type antifreeze mixed

at the proper proportion with distilled water;

do not use straight water as coolant.

If the engine is overheating, the engine should

be cooled down first, then topped off with

coolant

Coolant should be added to the specified level,

if the coolant level is too low, it will result in

engine overheating and corrosion problems of

cooling system.

Antifreeze is combustible, stay away from

open flame when filling it.

It is required to choose the kind or type of

antifreeze according to the ambient

temperatures. Refer to Table 1-1 in this

chapter for details.

113 Lubricant

Lubricant can help to prevent the wear of

fitting surface and noise.

The connectors (pipe joint, connecting set) that

are not involved in this manual are only for

overhauling and not need to add lubricant. But

be sure to fill the lubricant if some parts are

difficult to operate after a long time using.

Clean the spilled lubricant after filling.


1-3

114 Storage of Oil and Fuel

Prevent water, dirt, or other impurities from

mixing with the oil.

Follow the rule, first in - first out, to maintain

oil quality during long-term storage.

115 Filters

Filters are extremely important safety

components. They can prevent impurities in

the fuel from entering important equipment

and causing problems. Replace filters at

shorter intervals when the machine works in a

severe environment.

Never try to clean paper filter elements and

use them again. Always replace them with a

new one.

When replacing the oil filters, check whether

there are some metallic particles adhering to

the old filter. If some metal particles are found,

investigate and repair.

Never open the packaging of new filters until

they are ready to be used.

Always use authentic filters.


1-4

12 Selection of Oils

121 Oil Application

Use the oil in strict accordance with the rules

about specified brand and quantity. (Refer to

Table 1-1).

Clean the oiler or container before filling the

fuel, hydraulic oil, grease and clean the filling

ports to prevent water, sludge and debris

entering into the oil.

Except for the grease, use a filter for filling.

Fill grease until there is grease squeezing out

of the filling point. And wipe the spilled

grease.

When replacing oil, drain the contaminated oil

out after operation. Fill cleaning oil and keep

the engine running idly for several minutes to

clean all the parts. And then fill the new oil

and keep the engine running at low speed.

Finally, fill the oil to the specified level. The

fuel tank should be cleaned regularly.

In different seasons, replace the oil or grease

according to the actual situation. Refer to

Table 1-1 in this chapter for details.

When filling oil or checking the oil level, put

the grader in a horizontal position. Apart from

the oil dipsticks and other pointers, the oil

level should be in the middle part of the oil

window, such as the drive axle, balance tank,

turbine box.


1-5

Table 1-1 Oil selection table

Kinds of

Fluids Season Recommended Types And Standards

Application

point Qty.

Fuel

Ambient temperature≥4oC 0# common

diesel oil GB252

Ambient temperature≥-5oC -10# common

diesel oil GB252

Ambient temperature≥-14oC -20#

common diesel oil GB252

Ambient temperature≥-29oC -35#

common diesel oil GB252

Fuel tank 170L

Engine oil Full year CH-4 15W-40 Engine oil pan 16L

Hydraulic oil Full year Anti-grinding hydraulic oil L-HM46 Hydraulic oil

tank 132L

Gear oil Full year Heavy load vehicle gear oil(GL-5) 85W/90

GB 13895

Rear axle and

balancing boxes 28+23×2L

Transmission

oil Full year Diesel engine oil CH-4 15W-40 (Delo Gold)

Transmission

box 28L

Grease General lithium based grease EP2 GB

7324

All articulated

points ——

Antifreeze Full year -35# ethylene glycol-based engine coolant

NB/SH/T0521 Water tank 24L

122 Notes for Oil Application

Diesel oil in the fuel tank must be added

timely to prevent cavitation. Check whether

the fuel tank is contaminated, whether there is

sediment, and clean the oil filter every mouth.

The engine oil must be changed regularly

because the mechanical impurities in the oil

will increase over time, main causes are:

oxidation after wear, residual ballast in the

cylinder after combustion, and the dust from

outside.

When the impurity content reaches 0.4~0.5%,

oil begins to become black, physical and

chemical index will deteriorate. Replace the oil


1-6

in hot state.

Check the cleanliness of hydraulic oil

regularly. Method: Take a few drops of oil

from the tank and drops the oil on the filter

paper (240mesh). If the paper presents a light

yellow circle, it proves that the oil can

continue to use; If the yellow circle on paper is

obvious, and the center is black, it proves the

oil is polluted and need to be replaced.

Fill the new oil through the oil filter, and do

not fill the oil directly into the fuel tank. Never

allow several brands of hydraulic oil mixed to

use. The crude oil must be cleaned when

replacing the oil.

13 Maintenance

131 Precautions before Maintenance

Put the machine in maintenance position (refer

to in Safety & Environment).

Perform the maintenance on hard and level

ground.

Set all control levers/handles to the Neutral

position.

Pull up the parking brake handle to set the

loader in the parking brake state.

Wedge the tires with blocks.

Lock the front and rear frames with frame

locking bars.

Use warning tags

Hang a do-not-start-engine tag near the ignition


1-7

switch before performing maintenance or repairs to

prevent inadvertent engine or machine movements.

Use genuine parts

It is highly recommended to use only genuine parts

specified by the manufacturer.

Use high quality and premium specification oils

and fuels

Use oils and fuels specified in this manual and

according to local ambient temperatures and

machine use conditions.

Use clean fluid containers for oils and fuels

Keep containers of oils and fuels clean and make

certain to use specified oils and fuels.

Keep the machine clean

Always keep the machine clean. Keep grease

fittings, pipe joints, oil level gauges, and fluid fill

caps/openings clean to prevent foreign materials

from entering these systems.

Pay attention to high-temperature oil and

coolant

It is very dangerous to drain hot oils or engine

coolant, or to remove the filters immediately after

the engine stops. Make sure the engine is cooled

down to ambient temperature. Always drain oils

when they are at temperatures of approximately

68~104°F (20~40°C), as this will ensure complete

system drainage. If the oil temperatures are lower

than this temperature, it is recommended to warm

it up to this temperature before draining it.

Inspect the oil and filters

After any systems oils are changed or filters are

replaced, inspect the oil and filters. If large

amounts of metallic particles or impurities are

found, investigate and repair.


1-8

Retain the fuel fill strainer

Do not remove the fuel strainer while fueling.

Practice clean oil changing

Change oil in a dust-free place to keep impurities

and contaminants out of the oil.

Welding guide

Turn off the starting switch of the engine, and

the main battery switch, and remove the

battery cables from their terminals.

Disconnect all ECU connections.

Keep the distance between the grounding cable

line and welding area no more than 39in (1m).

Avoid welding near seal rings and bearings.

Never weld any pipe or take that has fuel or oil

in them.

Fire prevention

When cleaning any parts or components, use

non-flammable cleaners or light oil. Keep sparks

and cigarette lighters away from them.

Seals

When replacing O-rings or gaskets, clean the

sealing faces first, and make sure the O-rings and

gaskets are in the correct assembly position.

Inspect the front and rear frames

After a long period of operation, check for damage

of the undercarriage, frames, center joint, and for

loose or damaged bolts and nuts.

Precautions to use while washing the machine

Do not wash the machine with a hot or warm

engine. Let it cool down.

Do not allow water to spray on any electrical

components.

Machine cleaning after inclement weather


1-9

operations

Clean the machine immediately after working in

rain and snow. Lubricate and coat anti-rust oil to

components.

Environments with airborne contaminants

Do the following when the machine works in

conditions with airborne dust or chemicals:

Inspect and clean air filter frequently to avoid

restricted inlet air.

Clean the radiator frequently to avoid

blockages and overheating.

Clean and replace fuel filter frequently.

Clean the electric components, especially the

starting motor and alternator to avoid

accumulation of dust affecting dissipation of

heat.

Refer to the accompanying Maintenance

Manual for Diesel Engine for maintenance

and replacement of air filter.

Avoid using mixed oil

Never use oil mixed from different brands. If using

a different kind of oil from the one previously used,

drain the oil from the machine, and fill with the

new brand oil completely.


1-10

132 Periodic Maintenance

Fig. 1-1

A new machine must have a running-in period

of 50h. And you should choose good road for

the running-in period.

After starting the engine, avoid accelerating

suddenly; start operation when the water

temperature gets to 50oC. When driving, do

not accelerate to climb the slope.

Avoid emergency brake or using the brake for


1-11

a long time.

You should properly carry out the maintenance

tasks before, during and after run-in period.

Do not operate the grader in full power in the

first 50~100h period. It is allowed to operate

the grader in full power in the second 50~100h

period, but the time could not be too long.

In the first 200 working hours, you should

check the engine oil level twice a day (10h).

When filling the grease to the transmission

shaft, inject the grease with low pressure rather

than high pressure to avoid too much overflow.

Fill until there is grease squeezed out of the

fitting area.

When working in dusty environment, you

should clean the water tank and radiator fins

frequently, be sure to shorten the maintenance

cycle and increase the maintenance times

according to real conditions.

Important! Check the oil level often.

Periodic maintenance is divided into every 10 hour

maintenance, every 50 hour maintenance, every

100 hour maintenance, every 250 hour

maintenance, every 500 hour maintenance, every

1000 hour maintenance, every 2000 hour

maintenance, and every 3000 hour maintenance.

Every 10 hour maintenance

Clean the grader: Clean the dust and ash on the

surface of grader; Clean the dust and oil on the

surface of parts and hydraulic components. Do

not let dirt enter oil filling port and air filter.

Check the connection and fixing of the parts of

grader. Check whether the connecting bolts

between frame and rear axle and hub are loose


1-12

or broken. Fix or replace the loose or broken

parts.

Check the grader for leaking phenomenon and

eliminate the problem.

Check hydraulic oil level and add specified

new oil if necessary.


ATTENTION

Before putting a new grader into operation,

a running-in period of 50 hour is required.

Follow the instructions in Operation and

Maintenance Manual of Diesel Engine to

perform the running-in. After the

running-in period, maintain the machine as

per the instruction s below:

Complete the tasks of the 10 hour periodic

maintenance indicated above.

Check the tire pressure, check the wheel nuts.

Check hydraulic oil level and fill hydraulic oil

to specified level.

Check if there is leakage in the hydraulic

system, remove the problem if so, and fill

hydraulic oil to specified level.


Complete the tasks of the 10 hour and 50 hour

periodic maintenance indicated above.

Check the intake system and exhaust system,

and ensure the connectors are connected firmly.

Clean the intake and exhaust pipes if

necessary.

Check the parking brake system and adjust it if

necessary.

Check whether the connection of steering


1-13

mechanism is loose, including nuts of steering

linkage, tighten them.

Tighten wheel nuts.

In addition, do the extra maintenance in the

first 100 hour as follows:

Replace the gear oil in rear axle. Drain all the

oil radically after warming up the grader and

then fill the new oil. (Do this maintenance

every 1000h thereafter)

Clean transmission box oil pan, oil absorption

strainer therein, and filter elements in torque

converter-transmission box oil line, replace the

transmission oil. (Do this maintenance every

500h thereafter)

Check the guide clearance of blade and adjust

it if necessary.

Tighten the wheel nuts.

Check the tension of chain of balancing box. If

it is loose, tighten it.


Complete the tasks of the 10 hour, 50 hour and

100 hour periodic maintenance indicated

above.

Check the oil level of main drive and

balancing box, add if necessary.

Remove the dust inside the generator with

compressed air and check whether the parts are

normal, and eliminate the problem if not.

Check the guide clearance of rotary frame and

adjust it if necessary.

Replace the fuel filter element.

Replace the air filter element.


1-14


Complete the tasks of the 10 hour, 50 hour 100

hour and 250 hour periodic maintenance

indicated above.

Clean transmission box oil pan, oil absorption

strainer therein, and filter elements in torque

converter-transmission box oil line, replace the

transmission oil.

Check whether the circuits of switches and

control monitoring device are normal. Repair

if damaged.

Check whether the clearance of transmission

box to rear axle transmission shaft, engine to

working pump transmission shaft and the

cardan shaft are oversized.

Replace the fuel pre-filter element.

In addition, do the extra maintenance in the first

500 hour as follows:

Replace hydraulic oil filter elements. (Do this

maintenance every 1000h thereafter)

Replace the filters in brake system. (Do this

maintenance every 1000h thereafter)



hour, 250 hour and 500 hour periodic

maintenance indicated above.

Replace hydraulic oil. Replace hydraulic oil

return filter element. Clean the oil absorption

strainer.

Replace the filters in brake system.

Replace the rear axle oil. Warm up the

machine and empty the axle, and fill new

lubricating oil into the axle.


1-15

Check whether the bearing of fan transmission

shaft and the tension wheel of belt are worn

seriously.

Engine should be maintained specially if the

ambient temperature is lower than 5°C.

Choose fuel that applicable to winter and

pay attention the water content in the fuel

in case of blockage of fuel circuit.

Be sure to use antifreeze (coolant)

specified by SDLG all year round. Use

water as coolant is strictly forbidden.

In cold season and areas, it is better not to

park the grader in an open area. Otherwise,

you need to preheat the engine before

starting.



hour, 250 hour, 500 hour and 1000 hour

periodic maintenance indicated above.

Replace the antifreeze, replace it every 2000

working hours or once a year, whichever comes

first.



hour, 250 hour, 500 hour, 1000 hour and 2000

hour periodic maintenance indicated above.

Clean the cooling system.

Clean the engine oil cooler.

Check the water seal in water pump, fill

grease.

The maintenance principles listed above are the

basic requirements. If the working condition is

very severe, please shorten the maintenance


1-16

cycle and increase the maintenance times

according to the real conditions. Maintain the

diesel engine according to requirements in

operation and maintenance manual of diesel

engine strictly

133 Maintenance & Repair

Draining of transmission box oil

Overhaul the machine after it is cooled.

1. Remove the oil drain plug to discharge the

transmission oil into a clean vessel.

2. Clean the oil drain plug, coat it with sealant

and retighten it.

2

Fig. 1-2

1 Oil dipstick 2 Oil drain plug

3 Oil filling port

1 3

1

Fig. 1-3

1 Oil drain plug


1-17

3. After filling new oil into the transmission box,

put the transmission lever (gear selector) in the

neutral “N” position, start engine and let the

engine run idly for several minutes (about

1000rpm).

4. Loosen the oil dipstick clockwise and remove

the oil dipstick. Clean it. Insert the oil dipstick

and tighten it. Then take it out to read the oil

level (do this at least twice).

When the oil temperature is 104°F (40°C), oil

level should be between bottom scale and

middle scale (ZONE COLD).

When the oil temperature is 176°F (80°C), oil

level should be between highest scale and

middle scale (ZONE HOT).

Replacement of transmission oil filter

Overhaul the machine after it is cooled.

1. Drain the oil out and then remove the filter.

2. Install new filter and tighten it according to the

instructions described in the related manual.

1 2

Fig. 1-4

1 Oil filling port 2 Oil dipstick

1

Fig. 1-5

1 Oil dipstick

1

Fig. 1-6

1 Transmission oil filter


1-18

Clean the oil absorption filter screen of

transmission box

1. Remove the cover and clean the internal parts.

Check and ensure the parts are not damaged.

2. Install a new gasket between cover and

transmission box

3. Reassemble the absorption screen.

Draining and filling of drive axle oil

Wear protective equipment to prevent burns

caused by uncooled engine oil.

1. Remove the oil drain plug to discharge the

transmission oil into a clean vessel.

2. Clean the oil drain plug and retighten it.

3. Fill new oil into the axle via the oil filling port

to specified level. Install and tighten the oil

filler plug.

Axle oil: approx. 28L

4. The oil level can be checked via the oil level

hole, a bit of spilled oil is allowed. The lower

limit is about 8mm to the edge of the hole.

1

Fig. 1-7

1 Oil absorption filter screen location

1 2

Fig. 1-8

1 Oil level hole 2 Oil filling port

3 Oil drain plug 4 Vent cap

2 4


1-19

Draining and filling of balancing box oil

1. Screw off the oil drain plugs on bottom of the

balancing box (each balancing box has two

oil drain plugs)

2. Clean the plugs, and install each plug with

new seal ring. Tighten the plugs.

3. Remove the vent cap and fill new oil into the

balancing box via the oil filling port to the

bottom edge of the oil level hole (the oil is

about to overflow from the hole). The volume

of each balancing box is about 23L.

4. Install and tighten the vent cap.

5. Keep the axle in horizontal position when

filling.

Tensioning of balancing box chain

1. Remove the two cover plates.

1

Fig. 1-9

1 Oil drain plug

3

Fig. 1-10

1 Oil filling port 2 Vent cap

3 Oil level hole

1 2

1

Fig. 1-11

1 Cover plate


1-20

2. Lift up the balancing box assembly and

support it.

3. When the train is pulled, its elongation will

increase. If the sag of the loose side of chain

is greater than 18mm, the chain needs to be

re-tensioned.

ATTENTION

There are two chains in each balancing box,

the two chains need to be inspected

together. Tensioning of the chains can only

be performed by professionals.

Tensioning of the chain is realized by rotating the

eccentric bearing cap. As per the steps below:

3.1 Support the balancing box assembly to keep

the wheels off ground. Empty the balancing

box.

1

Fig. 1-12

1 Balancing box

Fig. 1-13

1

Fig. 1-14

1 Oil drain plug


1-21

3.2 Remove the rear wheel.

3.3 Remove the drum brake.

3.4 Remove the oil cup, and install a M10 bolt to

the hole instead, screw the bolt into the hole

for about 5~8 circles.

ATTENTION

The bolt is used to prevent the chain wheel

and shaft module from slipping away from

the tapered roller bearing.

1

Fig. 1-15

1 Rear wheel

1

Fig. 1-16

1 Drum brake

1

Fig. 1-17

1 Oil cup


1-22

3.5 Remove the fixing bolts of the connecting

plate.

3.6 Remove the fixing bolts of the bearing seat.

3.7 Rotate the connecting plate and bearing seat

in the same direction for the same angle until

the sag of the loose side is about 11.5mm.

ATTENTION

Before disassembling the connecting plate

and bearing seat, you should mark their

positions. During rotating the connecting

plate and bearing seat, be careful to avoid

damaging the O-rings.

3.8 After the adjusting, install the removed parts

orderly.

3.9 Fill oil into the balancing box and reassemble

the cover plates.

3.10 Adjust and deflate the brake system.

1

Fig. 1-18

1 Connecting plate

1

Fig. 1-19

1 Bearing seat


1-23

Replacement of hydraulic oil

1. Lower the shovel blades to the ground and

raise the front bulldozing plate to the highest

position.

2. Shut down the engine, and operate the control

handle to lower the front bulldozing plate to

the ground.

3. Place an oil collection container under the

drain valve; Open the drain valve to discharge

the hydraulic oil into the container. Close the

valve after all oil is discharged.

4. Open the return oil filter cap and fill specified

hydraulic oil into the tank until the oil level

pointer points at the middle position.

5. Install the filter cap.

6. Start the engine and operate the control

handles repeatedly to fill the hydraulic system

with oil and bleed the air out

7. Lower all working devices to the ground, shut

down the engine and deflate the hydraulic oil

tank.

8. Check the oil level via a round oil level pointer

and add when necessary.

Hydraulic oil: 132L

ATTENTION

Special attention should be paid to the

sealing of the filter mouth, and the seal

ring should be replaced when necessary. To

prevent damaging the fine thread on filter

cap, be careful when installing the cap.

The hydraulic oil should be replaced

periodically. Additionally, during repairing

or working in dusty environment, let one

Fig. 1-20

1 4

2 3

Fig. 1-21

1 Return oil filter 2 Oil level pointer

3 Oil drain valve 4 Air filter

1 2

Fig. 1-22

1 Oil return flange

2 Oil absorption flange


1-24

drop of the hydraulic oil fall on a filter

paper or blotting paper, if an obvious black

spot appears a few hours later, then the oil

must be replaced to avoid damaging the

hydraulic system.

Replacement or repair of working/steering

pump

1. Open the oil drain valve on bottom of

hydraulic oil tank to discharge the oil.

2. Replace or repair the working/steering pump.

3. Close the oil drain valve and fill hydraulic oil

to specified level after the replacement or

repair.

Replacement of return oil filter element

1. Remove the filter cap.

2. Take out the entire filter element.

3. Replace the filter element with a new one and

assemble it.

ATTENTION

When installing the filter assembly, you

must be careful to avoid damaging the seal

ring. Tighten the filter cap slowly and

carefully.

1 2

Fig. 1-23

1 Steering pump 2 Working pump

1

Fig. 1-24

1 Return oil filter cap


1-25

Cleaning of fuel tank

1. Use kerosene to clean the fuel tank caps and

filter screens carefully.

2. Loosen the oil drain plug on the bottom of

fuel tank to discharge the kerosene into a

container. Retighten the plug after the

draining, and pay attention to check whether

the seal is normal.

ATTENTION

The fuel tank should be cleaned with

specified volume of kerosene (about a

quarter of the fuel tank volume). Before

the cleaning, you should keep the grader

running for a while to let the sediments in

the fuel tank gather.

Fuel filling

1. There should be no smoking or open flame

near the fueling site, and the engine must be

stopped.

2. To avoid condensation of water vapor in the

air, be sure to fill up the fuel tank.

3. Remove the filler cap.

4. Install the filler cap immediately after the

filling to prevent contamination.

1

Fig. 1-25

1 Oil drain plug

1 2

Fig. 1-26

1 Fuel filler 2 Fuel filter assembly


1-26

Engine oil draining

1. Do the maintenance after the machine is

cooled.

2. Place the empty container under the engine

and remove the oil drain plug.

Replacement of fuel filters

1. Remove the filters with filter wrench.

2. Coat the new filter seals with new engine oil.

And tighten them according to the

requirements described in the filter manual.

3. Deflate fuel system after the replacement.

Replacement of engine air filter

1. Maintain or replace the main filter when the

filter is blocked and the alarm is triggered.

2. When maintaining the main filter element, it is

not necessary to remove the safety filter

element, because the safety filter element is

maintenance-free.

3. If the main filter element has been maintained

3 times or the alarm indicator is still on after

the maintaining, the main filter element and

safety filter element should be replaced at the

same time.

1

Fig. 1-27

1 Oil draining port

1 2

Fig. 1-28

1 Coarse fuel filter (pre-filter)

2 Fine fuel filter

1

Fig. 1-29

1 Air filter


1-27

Engine oil filling

Fill the engine oil to the specified level. Oil level

should be between “MAX” mark and “MIN” mark

on the oil dipstick.

Engine oil: 16L

Transmission belt checking

1. Use a gauge to check tensioning condition of

belt.

2. Check whether the belt is worn, and replace it

if necessary.

1 2

Fig. 1-30

1 Engine oil filling port

2 Engine oil dipstick

1

Fig. 1-31

1 Belt


1-28

Lubrication and adjustment of front wheel

bearing

1. Jack up the front axle and remove the front

wheel(s).

2. Remove the inside hexagonal bolts, and take

down the end cover.

3. Use a puller to remove the hub.

1

Fig. 1-32

1 Front wheel

1

Fig. 1-33

1 Inside hexagonal bolt

1 2

Fig. 1-34

1 Puller 2 Hub


1-29

4. Rinse the hub, front wheel spindle, bearing

and end cover, replace the seal rings with new

ones.

5. Fill lubricating grease, install the hub and

check the bearing clearance.

6. Install the end cover fixing bolts, tighten the

inside hexagon bolts orderly and crosswise.

7. Check and make sure that the hub can rotate

freely and smoothly, without runout and

vibration.

ATTENTION

Maintaining of the front wheel bearing can

only be performed by professionals.

Lubricating grease: about 280g for

each wheel

Lubricating grease: common lithium

lubricating grease EP2 GB 7324

Adjusting of shovel blade rotary gear ring

1. Axial adjustment of rotary frame

Loosen the lock nuts and fixing nuts on

bottom of clamp plate. Take down the

rotary gear ring guide plate.

Change the number of adjusting gaskets

and use a feeler gauge to ensure the axial

clearance between the bottom of rotary

frame and wear-resisting nylon is within

1~2mm.

Tighten the fixing nuts to 755±45Nm,

and tighten the lock nuts.

Assemble the guide plate.

1 2

Fig. 1-35

1 V-shape seal ring

2 Seal ring

1 2

Fig. 1-36

1 Clamp plate 2 Guide plate


1-30

2. Radial adjustment of rotary frame

Loosen the nuts and bolts to adjust the

guide plate.

Tighten the nuts to 755±45Nm.

Perform turning trial, and make sure the

rotary ring can turn 360 degrees freely.

Maintenance of tires

1. Check the tires daily for cut, crack and

penetration of sharps things, and remove all

foreign matters immediately.

2. Prevent the tires from being corroded by fuel,

engine oil and lubricating grease.

3. The inflation valve must be installed with

mesh cap to avoid intrusion of impurities.

4. Leaking valve elements should be replaced

with new ones.

5. Check the tire pressure periodically, too high

or too low pressure will cause severe wear or

unilateral wear.

6. Inflation pressure for front tire is 0.21MPa,

while that for rear tire is 0.25MPa.

1

Fig. 1-37

1 Guide plate


1-31

Maintenance of storage battery

G9165 grader is equipped with two 6-QW-70B

maintenance-free storage batteries, the two

batteries are connected in series. You must check

the electric quantity of the battery after long-term

storage (more than 6 months). You should also

check the fixation state of the batteries constantly

to prevent looseness.

1. Inspection of battery electric quantity

The “battery eye” can be used to determine

the battery electric quantity: Check the

color of “battery eye”, if the “battery eye”

indicates green, it means the battery is fully

charged; if the “battery eye” indicates

black, then the battery power is low.

If the “battery eye” turn white, then there

might be bubbles in “battery eye”,

waggle the battery gently to drive the

bubble away. If the “battery eye” still

indicates “white” after waggling, then the

battery should be replaced.

2. Disassembly and assembly of storage battery

When disassembling, disconnect the

negative wire (-) first, and then

disconnect the positive wire (+).

When assembling, connect the positive

wire (+) first, and then connect the negative

wire (-).

The battery must be fixed on the grader

firmly, and connected to electrical system

correctly. Coat the terminals with some

Vaseline to prevent electric erosion.

1

Fig. 1-38

1 Storage battery

1

Fig. 1-39

1 Battery eye


1-32

Long-term storage of the grader

1. If the grader is going to be stored for long

time, you should clean and lubricate it

thoroughly. Coat the fine finished surfaces

with lubricating grease and coat the piston

rods with a thick layer of Vaseline, and warp

them up as far as possible.

2. It is better to park the grader in a shed or

house, to prevent the tires from exposing to

strong sun light and moisture, and you must

check the tire pressure regularly.

3. If the grader is going to be parked in the open

air or on uneven ground, it is better to jack up

the machine with wood block to deload the

tires, and then reduce the tire pressure by half.

In the meantime, cover the tires to avoid direct

sun light exposure.

4. To avoid corrosion, the fuel tank should be

filled up with fuel, add preservative (10% of

the total fuel quantity) if the conditions permit.

5. It is reasonable to run the grader periodically.

Run the grader every other week to warm it up,

if possible, jack the machine up to engage the

transmission gears.

6. If the grader is going to be stored for more

than four weeks, you should remove the

batteries and put them in dry and warm place,

and charge them every month.

Reset the grader back to working state

If the grader is out of work for about a year, you

should replace the hydraulic oil, transmission box

oil, axle oil, balancing box oil and engine oil

before putting it into operation again.

1. Recover the machine in the maintenance


1-33

position.

2. Rinse the piston rods thoroughly, and inject

all grease cups with lubricating grease.

3. Preheat and start the engine.

4. Walk around the machine to make sure that

there is no leakage.

5. Check the display screen for any warnings

regarding low oil level.

6. Check the battery electrolyte level and tire

pressure.

Preheat the grader and check the display

screen for any warnings regarding low oil

level.

Before you continue to preheat the

machine, add more hydraulic oil into the

hydraulic oil tank. And speed up the

engine to 1800rpm until the engine and

transmission box reaches working

temperature 50~90oC (122~194

oF).

Transmission oil level checking

When the machine is at working temperature and

the engine runs at idle status, the oil level of

transmission oil should be in the rated range

marked on the oil dipstick.

1

Fig. 1-40

1 Oil dipstick


1-34

Engine oil level checking

Oil level should be between “MAX” mark and

“MIN” mark on the oil dipstick.

Coolant level checking

1. Fill water through the coolant filling port, the

water will flow into the water tank through the

refill pipe.

2. Do not fill the water too fast, it takes about

20min to fill up the water tank for the first

time.

3. When the expansion water tank is filled up

with water, start the engine and run it idly,

check the water level through the water filling

port, and fill more water if the level is below

the baffle plate.

WARNING

It is forbidden to open the filler cap when

the system is not cooled to avoid human

injury caused by high-pressure steam.

1

Fig. 1-41

1 Engine oil dipstick

1 2

Fig. 1-42

1 Expansion water tank

2 Coolant filling port


1-35

Cleaning of radiator

1. Open the engine hood and remove the grille

shield device.

2. Clean the fins of radiator and condenser with

compressed air along the moving direction of

the machine.

3. Install the grid shield device.

ATTENTION

If not being dealt properly, the fins of

radiator may get damaged.

Cleaning of condenser

1. Remove the cover hood, and clean the

condenser with compressed air from outside.

2. Install the cover hood.

1

Fig. 1-43

1 Radiator

1

Fig. 1-43

1 Condenser

1repair & maintenance_englisg-g9165

Documents

fuel filters

fuel type

fuel pump

fuel tank

blend of fuel

fuel mixes

fuel inlet system

oil application