1repair & Maintenance - ENGLISG-G9165
1repair & Maintenance - ENGLISG-G9165
1repair & Maintenance - ENGLISG-G9165
SERVICE MANUAL
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
111 Fuel
1-1
112 Coolant
according
to
the
ambient
113 Lubricant
1-2
115 Filters
Filters
are
extremely
important
safety
1-3
12 Selection of Oils
121 Oil Application
1-4
Full year
Antifreeze
16L
Hydraulic
tank
132L
oil
Full year
170L
Transmission
Transmission
Full year Diesel engine oil CH-4 15W-40 (Delo Gold)
oil
box
Grease
Qty.
GB All articulated
points
Water tank
28L
24L
1-5
Check
the
cleanliness
of
hydraulic
oil
13 Maintenance
131 Precautions before Maintenance
Put the machine in maintenance position (refer
to Page 10 in Safety & Environment).
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
Clean
the
radiator
frequently
to
avoid
motor
and
alternator
to
avoid
1-9
Fig. 1-1
1-10
hour
maintenance,
every
250
hour
hour
maintenance,
every
2000
hour
1-11
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
1-12
1-13
1-14
2
Fig. 1-2
1 Oil dipstick
3 Oil filling port
1
Fig. 1-3
1 Oil drain plug
1-16
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
2.
1
Fig. 1-6
1 Transmission oil filter
1-17
2.
3.
1
Fig. 1-7
1 Oil absorption filter screen location
2.
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.
1
Fig. 1-8
1 Oil level hole
3 Oil drain plug
2
2 Oil filling port
4 Vent cap
1-18
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.
5.
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
1
Fig. 1-12
1 Balancing box
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.
1
Fig. 1-14
1 Oil drain plug
1-20
1
Fig. 1-15
1 Rear wheel
3.3 Remove the drum brake.
1
Fig. 1-16
1 Drum brake
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
1
Fig. 1-18
1 Connecting plate
ATTENTION
Before disassembling the connecting plate
and bearing seat, you should mark their
1
Fig. 1-19
1 Bearing seat
1-22
Fig. 1-20
Fig. 1-21
1 Return oil filter
3 Oil drain valve
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
1
Fig. 1-23
1 Steering pump
2
2 Working pump
ATTENTION
When installing the filter assembly, you
1
Fig. 1-24
1 Return oil filter cap
1-24
ATTENTION
Fig. 1-25
1 Oil drain plug
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
1
Fig. 1-27
1 Oil draining port
Replacement of fuel filters
1.
2.
tighten
them
according
to
the
1
2
Fig. 1-28
1 Coarse fuel filter (pre-filter)
2 Fine fuel filter
Replacement of engine air filter
1.
2.
3.
1
Fig. 1-29
1 Air filter
1
2
Fig. 1-30
1 Engine oil filling port
2 Engine oil dipstick
Transmission belt checking
1.
2.
1
Fig. 1-31
1 Belt
1-27
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
1
2
Fig. 1-35
1 V-shape seal ring
2 Seal ring
ATTENTION
Maintaining of the front wheel bearing can
only be performed by professionals.
Lubricating grease: about 280g for
each wheel
Lubricating
grease:
common
lithium
1
Fig. 1-36
1 Clamp plate
1~2mm.
2 Guide plate
1-29
1
Fig. 1-37
1 Guide plate
Maintenance of tires
1.
2.
3.
4.
5.
6.
1-30
storage
batteries,
the
two
Fig. 1-38
1 Storage battery
When
negative
disassembling,
wire
(-)
disconnect
first,
and
the
then
Fig. 1-39
1 Battery eye
1-31
box
reaches
working
1
Fig. 1-40
1 Oil dipstick
1-33
1
Fig. 1-41
1 Engine oil dipstick
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
2.
3.
ATTENTION
If not being dealt properly, the fins of
1
Fig. 1-43
1 Radiator
Cleaning of condenser
1.
2.
1
Fig. 1-43
1 Condenser
1-35