1Repair & Maintenance_ENGLISG-G9165

Service Manual of G9165 Grader

SERVICE MANUAL

1 Repair & Maintenance Maintenance

Service Manual for G9165 Grader

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 122 Notes for Oil Application Application .................. ............................ ................... ................... ................... ................... .................... ..........1-5 13 Maintenance ......................................................................................................... 1-6 131 Precautions before Maintenance................ Maintenance.......................... ................... ................... ................... ................... ............ .. 1-6 132 Periodic Maintenance ................................................................................ 1-10 133 Maintenance & Repair.................... .............................. ................... ................... ................... ................... ................... ........... ..1-16

I

Service Manual for G9165 Grader

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

1-1

Service Manual for G9165 Grader

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.

 1-2

Clean the spilled lubricant after filling.

Service Manual for G9165 Grader

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. 

1-3

Always use authentic filters.

Service Manual for G9165 Grader

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.

1-4

Service Manual for G9165 Grader

Table 1-1 Oil selection table Kinds of Application Season Recommended Types And Standards Fluids  point o Ambient temperature≥4 C 0# common diesel oil GB252 Ambient temperature≥-5oC -10# common diesel oil GB252 Fuel Fuel tank Ambient temperature≥-14oC -20# common diesel oil GB252 Ambient temperature≥-29oC -35# common diesel oil GB252 Engine oil

Full year CH-4 15W-40

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

Gear oil

Full year

Antifreeze

16L

Hydraulic tank

132L

oil

Heavy load vehicle gear oil(GL-5) 85W/90 Rear axle and 28+23×2L GB 13895  balancing boxes

General lithium based grease EP2 7324

Full year

170L

Engine oil pan

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

Grease

Qty.

GB All articulated  points

-35# ethylene glycol-based engine coolant  NB/SH/T0521

Water tank

28L

——

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

1-5

Service Manual for G9165 Grader

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 Page 10 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 1-6

Service Manual for G9165 Grader

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. 1-7

Service Manual for G9165 Grader 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 1-8

Service Manual for G9165 Grader 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.

1-9

Service Manual for G9165 Grader

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.

 1-10

Avoid emergency brake or using the brake for

Service Manual for G9165 Grader

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 da y (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

1-11

Service Manual for G9165 Grader

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.

Every 50 hour maintenance

ATTENTION Before putting a new grader into operation, a running-in period of 50 hour is required. Follow the instructions in Operation and M aintenance M anual of Di esel Engi ne  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.

Every 100 hour maintenance 

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.

 1-12

Check whether the connection of steering

Service Manual for G9165 Grader

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.

Every 250 hour maintenance 

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.

1-13

Service Manual for G9165 Grader

Every 500 hour maintenance 

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)

Every 1000 hour maintenance 

Complete the tasks of the 10 hour, 50 hour 100 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.

1-14

Service Manual for G9165 Grader 

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.

Every 2000 hour maintenance 

Complete the tasks of the 10 hour, 50 hour 100 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.

Every 3000 hour maintenance 

Complete the tasks of the 10 hour, 50 hour 100 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 1-15

Service Manual for G9165 Grader 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 1

3

Overhaul the machine after it is cooled. 1.

Remove the oil drain plug to discharge the transmission oil into a clean vessel.

2 Fig. 1-2 1 Oil dipstick 3 Oil filling port

2 Oil drain plug

2.

Clean the oil drain plug, coat it with sealant and retighten it.

1 Fig. 1-3 1 Oil drain plug

1-16

Service Manual for G9165 Grader

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).

1

2

Fig. 1-4 1 Oil filling port

2 Oil dipstick

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).

1 Fig. 1-5 1 Oil dipstick

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 Fig. 1-6 1 Transmission oil filter

1-17

Service Manual for G9165 Grader 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.

1 Fig. 1-7 1 Oil absorption filter screen location

Draining and filling of drive axle oil

2

4

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. 1-8 1 Oil level hole 3 Oil drain plug

2 2 Oil filling port 4 Vent cap

1-18

Service Manual for G9165 Grader 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.

1 Fig. 1-9 1 Oil drain plug 12

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.

3 Fig. 1-10 1 Oil filling port 3 Oil level hole

2 Vent cap

Tensioning of balancing box chain

1.

1 Fig. 1-11 1 Cover plate 1-19

Remove the two cover plates.

Service Manual for G9165 Grader

2.

Lift up the balancing box assembly and support it.

1 Fig. 1-12 1 Balancing box

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

Fig. 1-13

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. 1-14 1 Oil drain plug

1-20

Service Manual for G9165 Grader

3.2 Remove the rear wheel.

1 Fig. 1-15 1 Rear wheel 3.3 Remove the drum brake.

1 Fig. 1-16 1 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. 1-17 1 Oil cup

1-21

Service Manual for G9165 Grader

3.5 Remove the fixing bolts of the connecting  plate.

1 Fig. 1-18 1 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

1

positions. During rotating the connecting

Fig. 1-19 1 Bearing seat

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

1-22

Adjust and deflate the brake system.

Service Manual for G9165 Grader Replacement of hydraulic oil

1.

Lower the shovel blades to the ground and raise the front bulldozing plate to the highest  position.

2.

Fig. 1-20

Shut down the engine, and operate the control handle to lower the front bulldozing plate to the ground.

3. 1

4

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

2

7.

3

Fig. 1-21 1 Return oil filter 3 Oil drain valve

Lower all working devices to the ground, shut down the engine and deflate the hydraulic oil

2 Oil level pointer 4 Air filter

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

1 2 Fig. 1-22 1 Oil return flange 2 Oil absorption flange

periodically. Additionally, during repairing or working in dusty environment, let one 1-23

Service Manual for G9165 Grader 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.

1 Fig. 1-23 1 Steering pump

2 2 Working pump

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

1 Fig. 1-24 1 Return oil filter cap

must be careful to avoid damaging the seal ring. Tighten the filter cap slowly and carefully.

1-24

Service Manual for G9165 Grader 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

1

The fuel tank should be cleaned with

Fig. 1-25 1 Oil drain plug

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. 1-26 1 Fuel filler

2 2 Fuel filter assembly

1-25

Service Manual for G9165 Grader 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.

1 Fig. 1-27 1 Oil draining port 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.

1 2 Fig. 1-28 1 Coarse fuel filter (pre-filter) 2 Fine fuel filter 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. 1

If the main filter element has been maintained 3 times or the alarm indicator is still on after

Fig. 1-29 1 Air filter

the maintaining, the main filter element and safety filter element should be replaced at the same time. 1-26

Service Manual for G9165 Grader 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

1 2 Fig. 1-30 1 Engine oil filling port 2 Engine oil dipstick 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 Fig. 1-31 1 Belt

1-27

Service Manual for G9165 Grader Lubrication and adjustment of front wheel bearing

1.

Jack up the front axle and remove the front wheel(s).

1 Fig. 1-32 1 Front wheel 2.

Remove the inside hexagonal bolts, and take down the end cover.

1 Fig. 1-33 1 Inside hexagonal bolt 3.

1 Fig. 1-34 1 Puller

2

2 Hub

1-28

Use a puller to remove the hub.

Service Manual for G9165 Grader

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.

1 2 Fig. 1-35 1 V-shape seal ring 2 Seal ring

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

1 Fig. 1-36 1 Clamp plate

frame and wear-resisting nylon is within

2

1~2mm. 2 Guide plate



Tighten the fixing nuts to 755±45Nm, and tighten the lock nuts.



1-29

Assemble the guide plate.

Service Manual for G9165 Grader

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.

1 Fig. 1-37 1 Guide plate

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.

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Service Manual for G9165 Grader 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.



1

If the “ battery eye” turn white, then there “ battery eye”,

might be bubbles in

Fig. 1-38 1 Storage battery

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,

negative

wire

(-)

disconnect first,

and

the then

disconnect the positive wire (+). 

When assembling, connect the positive wire (+) first, and then connect the negative wire (-).

1



Fig. 1-39 1 Battery eye

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.

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Service Manual for G9165 Grader 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. 1-32

Recover the machine in the maintenance

Service Manual for G9165 Grader

 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 (122~194oF). 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

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Service Manual for G9165 Grader Engine oil level checking

Oil level should be between “MAX” mark and “MIN” mark on the oil dipstick.

1 Fig. 1-41 1 Engine 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.

1 2 Fig. 1-42 1 Expansion water tank 2 Coolant filling port

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.

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