1repair & Maintenance - ENGLISG-G9165

Service Manual of G9165 Grader
SERVICE MANUAL
1 Repair & 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 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 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 5F
(-15C)). 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

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.
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.
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

Table 1-1 Oil selection table
Kinds of
Application
Season
Recommended Types And Standards
Fluids
point
Ambient temperature4oC
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+232L
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

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

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
68~104F (20~40C), 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

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

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
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

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
1-11

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.
1-12
Check whether the connection of steering

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.
1-13
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.
1-14
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 5C.
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
1-15

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
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

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 104F (40C), oil
level should be between bottom scale and
middle scale (ZONE COLD).
When the oil temperature is 176F (80C), 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

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
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

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. Remove the two cover plates.
1
Fig. 1-11
1 Cover plate
1-19

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

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

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.

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
Fig. 1-20
handle to lower the front bulldozing plate to

the ground.
3. Place an oil collection container under the
1
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
Fig. 1-21
1 Return oil filter
3 Oil drain valve
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

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

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
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

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

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

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. Use a puller to remove the hub.
1
Fig. 1-34
1 Puller
2 Hub
1-28

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
1
2
Fig. 1-35
1 V-shape seal ring
2 Seal ring
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
1~2mm.
2 Guide plate
Tighten the fixing nuts to 75545Nm,

and tighten the lock nuts.
1-29
Assemble the guide plate.

2. Radial adjustment of rotary frame
Loosen the nuts and bolts to adjust the

guide plate.
Tighten the nuts to 75545Nm.
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.
1-30

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

wire (+) first, and then connect the negative
wire (-).
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.
1-31

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
1-32

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
1-33

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.
1-34

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
1
radiator may get damaged.
Fig. 1-43
1 Radiator
Cleaning of condenser
1.
Remove the cover hood, and clean the

condenser with compressed air from outside.
2.
1
Fig. 1-43
1 Condenser
1-35
Install the cover hood.

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Service Manual of G9165 Grader

1 Repair & Maintenance

Service Manual for G9165 Grader

Service Manual for G9165 Grader

Change oil as soon as the oil is deteriorated

Add the specified volume of oil. Either too

Clean or replace the relevant filters when

The fuel pump is a precision instrument. If the

Never let impurities or contaminants enter the

Strictly choose the fuel type according to

The fuel may be frozen at low temperatures

Always fill up the fuel tank after operating to

Service Manual for G9165 Grader

If the engine fails to prime with fuel or the

In order to keep sediment from blocking the

If the engine is overheating, the engine should

Coolant should be added to the specified level,

Antifreeze is combustible, stay away from

It is required to choose the kind or type of

temperatures. Refer to Table 1-1 in this

Lubricant can help to prevent the wear of

The connectors (pipe joint, connecting set) that

Clean the spilled lubricant after filling.

Service Manual for G9165 Grader

114 Storage of Oil and Fuel

Prevent water, dirt, or other impurities from

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

components. They can prevent impurities in

Never try to clean paper filter elements and

When replacing the oil filters, check whether

Never open the packaging of new filters until

Always use authentic filters.

Service Manual for G9165 Grader

Use the oil in strict accordance with the rules

Clean the oiler or container before filling the

Except for the grease, use a filter for filling.

Fill grease until there is grease squeezing out

When replacing oil, drain the contaminated oil

In different seasons, replace the oil or grease

When filling oil or checking the oil level, put

Service Manual for G9165 Grader

Full year CH-4 15W-40

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

Heavy load vehicle gear oil(GL-5) 85W/90 Rear axle and

General lithium based grease EP2

Engine oil pan

-35# ethylene glycol-based engine coolant

122 Notes for Oil Application

Diesel oil in the fuel tank must be added

The engine oil must be changed regularly

When the impurity content reaches 0.4~0.5%,

Service Manual for G9165 Grader

regularly. Method: Take a few drops of oil

Fill the new oil through the oil filter, and do

Perform the maintenance on hard and level

Set all control levers/handles to the Neutral

Pull up the parking brake handle to set the

Wedge the tires with blocks.

Lock the front and rear frames with frame

Use warning tags

Service Manual for G9165 Grader

Service Manual for G9165 Grader