Post on 03-Feb-2016
description
transcript
Service Manual of RS8160 Road Roller
SERVICE MANUAL
7 Frames, Wheels & Working Devices
Service Manual for G9165 Grader
I
CONTENTS
7 Frames, Wheels & Working Devices .................................................................. 7-1
71 General ................................................................................................................. 7-1
711 Overview of Frames .................................................................................... 7-1
712 Overview of Working Devices .................................................................... 7-3
72 Disassembly and Assembly of Front Bulldozing Plate ....................................... 7-8
721 Disassembly of Front Bulldozing Plate ....................................................... 7-8
722 Assembly of Front Bulldozing Plate ........................................................... 7-9
73 Disassembly and Assembly of Frame Junction ................................................. 7-10
731 Disassembly of Upper Frame Junction ..................................................... 7-10
732 Disassembly of Lower Frame Junction ..................................................... 7-13
733 Assembly of Upper Frame Junction .......................................................... 7-14
734 Assembly of Lower Frame Junction ......................................................... 7-16
74 Disassembly and Assembly of Front and Rear Wheels .................................... 7-18
741 Disassembly of Rear Wheels ..................................................................... 7-18
742 Assembly of Rear Wheels ......................................................................... 7-19
743 Disassembly of Front Wheels .................................................................... 7-20
744 Assembly of Front Wheels ........................................................................ 7-22
75 Disassembly and Assembly of Middle Working Devices ................................. 7-23
751 Disassembly of Shovel Blades .................................................................. 7-23
752 Assembly of Shovel Blades ....................................................................... 7-26
753 Disassembly of Middle Scarifier ............................................................... 7-28
754 Assembly of Middle Scarifier ................................................................... 7-30
755 Disassembly of Rotary Gear Ring ............................................................. 7-31
756 Assembly of Rotary Gear Ring ................................................................. 7-36
76 Disassembly and Assembly of Middle Working Devices ................................. 7-42
761 Disassembly of Rear Scarifier ................................................................... 7-42
762 Assembly of Rear Scarifier ....................................................................... 7-45
77 Diagnosis and Elimination of Common faults .................................................. 7-46
Service Manual for G9165 Grader
7-1
7 Frames, Wheels &
Working Devices
71 General
711 Overview of Frames
1 2 3
Two kinds of frame are commonly used,
namely unitary frame and articulated frame.
Articulated frame consists of front frame, rear
frame and master pins.
G9165 has adopted articulated frame.
The front frame is mainly used to support the
working devices and cab.
The rear frame is installed with engine, torque
converter-transmission box assembly, fuel tank,
hydraulic oil tank and drive axle.
The front frame is installed on front frame, it
Fig. 7-1
1 Front frame
2 Master pin
3 Rear frame
Service Manual for G9165 Grader
7-2
can provide broad view for the operator, which
is beneficial for observing working state of the
shovel blades to improve the operation
accuracy. The master pin is used to connect
front frame and rear frame.
Front frame
The front frame is of box-type double-section
structure, it is welded together by four steel
plates. The front frame has advantages of good
manufacturability, integrated modular design,
and easy to be assembled with accessories like
front bulldozing plate and middle scarifier.
Rear frame
The rear frame is welded together by box-type
beams. It has advantages of integrated modular
design, high reliability and easy to be
assembled with accessory device like rear
scarifier. The accessory device is connected
with transmission system, so the impact load
only acts on the rear frame and will not affect
the transmission system.
Fig. 7-2
Fig. 7-3
Service Manual for G9165 Grader
7-3
712 Overview of Working Devices
Working device of G9165 grader have adopted
modular design, the basic model is free of
front counterweight and rear counterweight.
And accessories, such as front bulldozing plate,
middle scarifier and rear scarifier, can be
assembled easily and quickly according to
operational requirements.
Front bulldozing plate
The bulldozing plate is installed on front end
of the grader, it is mainly used for material
paving operations and trimming of road where
the shovel blades cannot reach.
If the bulldozing plate is not needed in the
operation, you can remove it, clean it and its
accessories thoroughly, coat the fitting surface
with grease and put it in dry room for storing
(or take moistureproof measures).
If the bulldozing plate is going to be stored for
long term, please coat the fitting surface with
grease and coat the other areas with paint.
Weight of the bulldozing plate: 1160kg
ATTENTION
During travel, the bulldozing plate should
be lifted up according to the road condition.
Middle scarifier
The middle scarifier is installed in the middle
area of G9165 grader. It is mainly used for
removing bulk rocks and stumps, it can also be
used to break the asphalt pavement.
Weight of the middle scarifier: 850kg
ATTENTION
Before starting the machine, lift the scarifier
1
Fig. 7-4
1 Front bulldozing plate
1
Fig. 7-5
1 Middle scarifier
Service Manual for G9165 Grader
7-4
up at first. Remove the scarifier if the
scarifier isn’t needed and store the teeth of
scarifier properly.
Shovel blades
The shovel blades are installed in the middle
area of G9165 grader, they are used to scrape
the soil and flatten the working plane.
The blade is driven by single oil cylinder,
over-positioning is avoided.
Radian of the blade is optimized to ensure
good trafficability and mobility and high
productivity.
Swing cylinder angle is small, thus the shovel
blade can move smoothly and flexibly when
changing the cutting angle.
Shovel blade ground clearance: 445mm
Shovel blade cutting depth: 787mm
Shovel blade tilt angle: 47° forward
5° backward
ATTENTION
During driving, the shovel blades should be
lifted up according to the road condition.
Up/down of shovel blade
Right and left lifting cylinder act on the ball
head on left and right side of connecting rack
respectively, by extending or retracting the
cylinder piston, the left and right side of
connecting rack can be lifted or lowered,
thereby height of the left and right blades can
be adjusted, which can make the height and
inclination of the ground meet the
requirements.
1 2
Fig. 7-7
1 Left blade lifting cylinder
2 Right blade lifting cylinder
1
Fig. 7-6
1 Shovel blade
Service Manual for G9165 Grader
7-5
Rotating of shovel blade
The horizontal deflection angle is the angle
between shovel blade body and longitudinal
axis of the grader in horizontal plane.
The rotary frame together with the blade body
can achieve 360° rotation in the horizontal
plane. A certain deflection angle exists
between blade and grader travel direction, so
that the scraped soil can be discharged from
the two sides and the grader can work
continuously.
Sidesway of shovel blade
The side protrusion length is the length of the
outside part of the side-extended shovel blade.
Blades can extend to both sides along the
length of the blade under the action of the
sidesway cylinder so as to increase the
operation width of grader.
Side-swing of shovel blade
When the blades are fully extended to both
sides and the operation width is still not
enough, you can side-swing the connecting
rack, rotary frame and the blades together left
and right to increase the operation range.
1
Fig. 7-8
1 Blade rotating cylinder
1
Fig. 7-9
1 Blade sidesway cylinder
1 2
Fig. 7-10
1 Locking cylinder
2 Side-swing cylinder
Service Manual for G9165 Grader
7-6
Side overturning of shovel blade
The side overturning angle is the inclined
angle of the side-overturned shovel blade in
the vertical plane.
Side overturning of shovel blade is used to
scrape side slope, under the joint action of left
and right lifting cylinders, the blades can edge
on left side and right side of grader and form a
certain angle to the ground, the maximum side
overturning angle of blade is 90°.
Adjusting of cutting angle
The cutting angle is the angle between the
shovel blade and the ground.
Under the action of blade tilt cylinder, the
blade body can tilt between forward 47° and
backward 5°, so as to get different cutting
angle of blade and to be used for different
working condition.
Rear scarifier
The rear scarifier is installed in the rear area of
G9165 grader. It is mainly used for removing
bulk rocks and stumps, it can also be used to
break the asphalt pavement to help the blades
to transfer the soil and material.
Weight of the rear scarifier: 1350kg
Rear scarifier is designed with five teeth,
generally three of them are used to operate on
hard ground. The teeth should be used
symmetrically, for example, use one middle
tooth or 2 outside teeth only, or use the three
teeth together.
Fig. 7-11
1
Fig. 7-12
1 Tilt cylinder
1
Fig. 7-13
1 Rear scarifier
Service Manual for G9165 Grader
7-7
Adjusting of rear scarifier
Running position: Retract the teeth and lift the
scarifier up completely;
Position for loosening soil: stretch the teeth out
and put them on the ground;
Cutting position: Use the cylinder to press
down the scarifier completely.
Loosening soil
Required number of teeth, cutting depth and
traveling speed depend on the hardness of the
ground.
Put the teeth of the scarifier on the ground;
Drive the grader forward, lower the scarifier to
insert the teeth into the earth.
ATTENTION
Before turning or reversing the machine, lift
the scarifier up at first. When parking the
machine, be sure to lower the scarifier to
the ground.
Remove the scarifier if the scarifier isn’t
needed and store it properly.
You should check whether the tooth handle
of the scarifier is damaged, cracked or
bended periodically. Do not use a faulty
tooth handle.
Front counterweight
The front bulldozing plate can be used as front
counterweight to balance the rear scarifier.
Weight of the front counterweight: 452kg
1
Fig. 7-14
1 Front counterweight
Service Manual for G9165 Grader
7-8
72 Disassembly and Assembly of
Front Bulldozing Plate
721 Disassembly of Front Bulldozing
Plate
1. Park the machine on solid and flat ground.
2. Put blocks under front and back of rear tires to
prevent the grader moving.
3. Use a copper bar to remove the connecting
pins of front bulldozing plate and the
connecting arm, and the connecting pins of
front bulldozing plate and the lifting support.
1
Fig. 7-15
1 Grader
1
Fig. 7-16
1 Wood block
1.
1 2 3
Fig. 7-17
1 Connecting pin 2 Connecting arm
3 Lifting support
2.
Service Manual for G9165 Grader
7-9
4. Use lifting rope to detach and lift the
bulldozing plate away and put it in suitable
place.
1160Kg
ATTENTION
Incorrect detaching method may result in
personal injury or damage the machine.
Be careful when detaching the bulldozing
plate, do not operate fiercely, and do not
bump against the fitting surfaces.
Rated hoisting weight of the lifting
appliance should be greater than the weight
of bulldozing plate. Nobody is allowed to
stand or walk under the lifted bulldozing
plate. Make sure is lifting rope is reliable
before lifting.
722 Assembly of Front Bulldozing
Plate
1. Prepare some lubricating oil and necessary
assembling tools, be well prepared.
2. Coat the connecting pins with lubricating oil,
lift the bulldozing plate and align the pin holes
for assembling.
3. Use copper bar to install the connecting pins.
1
Fig. 7-18
1 Bulldozing plate
3.
1 2
Fig. 7-19
1 Connecting arm
2 Lifting support
4.
Service Manual for G9165 Grader
7-10
4. Start the machine and check the function of
front bulldozing plate.
73 Disassembly and Assembly of
Frame Junction
731 Disassembly of Upper Frame
Junction
1. Park the machine on solid and flat ground.
2. Operate the control handles repeatedly to
unload the hydraulic system.
Fig. 7-20
5.
Fig. 7-21
Fig. 7-22
Service Manual for G9165 Grader
7-11
3. Turn off the battery power switch.
4. Put blocks under front and back of rear tires to
prevent the grader moving.
5. Remove the lock ring and fixing bolt of the
steering cylinder front connecting pin. Then
use a copper bar to remove the connecting pin.
1
Fig. 7-23
1 Power switch
1
Fig. 7-24
1 Wood block
6.
1 2
Fig. 7-25
1 Connecting pin
2 Steering cylinder
7.
Service Manual for G9165 Grader
7-12
6. Disconnect the rubber hoses from the valve,
and use protective caps to seal all the oil ports.
Make sure all other forms of connection are
disconnected before removing the master pin
of front frame and rear frame.
7. Place bracket under front and rear frames to
support them properly.
8. Remove the extraction pipe and oil cup.
9. Remove the fixing bolt of the upper master pin.
Take down the base plate.
1 2
Fig. 7-26
1 Front frame 2 Rear frame
8.
1
Fig. 7-27
1 Extraction pipe
9.
1
Fig. 7-28
1 Base plate
10.
Service Manual for G9165 Grader
7-13
10. Remove the fixing bolts of the upper locating
plate. Take down the plate.
11. Remove the spacer ring, take down the O-ring
and knock to remove the knuckle bearing.
732 Disassembly of Lower Frame
Junction
1. Remove the fixing bolt of the lower master pin.
Take down the base plate.
1 2 3
Fig. 7-29
1 Upper locating plate
2 Upper master pin
3 Knuckle bearing
11.
1
Fig. 7-30
1 Base plate
12.
Service Manual for G9165 Grader
7-14
2. Remove the lining, and take down the spacer
bush.
3. Remove the fixing bolts of the lower locating
plate. Take down the plate.
4. Remove the locating sleeve, take down the
O-ring and knock to remove the knuckle
bearing.
733 Assembly of Upper Frame
Junction
1. Clean the to-be assembled components and
parts thoroughly, make sure there is no
impurities, and no bump and scratch damage.
2. Clean up the master pin holes.
1 2 3
Fig. 7-31
1 Spacer bush
2 Lower master pin 3 Lining
13.
1
Fig. 7-32
1 Master pin hole
14.
Fig. 7-33
15.
Service Manual for G9165 Grader
7-15
3. Press-fit the spacer ring and O-ring, then
install the upper locating plate.
4. Tighten the fixing bolts of upper locating
plate.
5. Align the upper mater pin holes, lubricate the
pin holes and knuckle bearing hole with EP2
lubricating grease.
6. Press-fit the upper master pin, then install the
pin fixing bolt and base plate.
The bolt should be coated with thread locking
sealant.
Tightening torque: 339Nm
7. Install the extraction pipe and oil cup.
1 2 3
Fig. 7-34
1 Upper locating plate
2 Upper master pin
3 Knuckle bearing
16.
1 2
Fig. 7-35
1 Base plate 2 Bolt
17.
1
Fig. 7-36
1 Extraction pipe
18.
Service Manual for G9165 Grader
7-16
734 Assembly of Lower Frame
Junction
1. Press-fit the knuckle bearing, then install the
lower locating plate tighten the fixing bolts.
2. Align the lower mater pin holes.
3. Press-fit the lower master pin, then install the
spacer bush and lining.
4. Install base plate and tighten the pin fixing
bolt.
1 2
Fig. 7-37
1 Lower locating plate
2 Lining 3 Spacer bush
19.
1
1
Fig. 7-38
1 Base plate
20.
Service Manual for G9165 Grader
7-17
5. Install the extraction pipe and oil cup.
6. Connect the hydraulic pipes.
7. Install the steering cylinder front connecting
pin and nylon spacer.
8. Install the lock ring and fixing bolt of the
steering cylinder front connecting pin.
Lubricate the pin.
9. Check hydraulic oil level, add if insufficient.
10. Start the engine and check for oil leakage.
11. Turn the front frame to the extreme position,
and then deflate the hydraulic system.
12. Add grease to the knuckle bearings again.
1
Fig. 7-39
1 Extraction pipe
21.
1
Fig. 7-40
1 Hydraulic oil pipe
22.
1 2 3
Fig. 7-41
1 Connecting pin
2 Steering cylinder
3 Frame locking bar
23.
Service Manual for G9165 Grader
7-18
74 Disassembly and Assembly of
Front and Rear Wheels
741 Disassembly of Rear Wheels
1. Put the machine in maintenance position.
Refer to Page 10 in Safety & Environment.
2. Operate the control handle keep the shovel
blade close to the to-be removed wheel. Then
operate the blade lifting cylinder on the same
side to jack up the wheel.
3. Install tire forklift tools, and fix the wheel.
4. Use pneumatic impact wrench to remove
wheel nuts.
ATTENTION
Do not damage the thread when removing
the nuts. Tighten the wheel nuts crosswise
and diagonally when installing the wheel.
1
Fig. 7-42
1 Grader
1
Fig. 7-43
1 Wheel forklift tool
1
Fig. 7-44
1 Rear wheel
Service Manual for G9165 Grader
7-19
5. Remove the wheel and put it in suitable place.
742 Assembly of Rear Wheels
1. Clean up fitting surfaces between rim and hub.
Ensure the hub thread is clean and free of
damage.
2. Install the wheel.
Use tire forklift tools to place wheel in position.
Install four uniformly-spaced tire wheel nuts
diagonally and tighten them orderly.
ATTENTION
Tighten the nuts clockwise and evenly (take
several tightening steps to prevent tilting
the wheel).
1
Fig. 7-45
1 Bracket
1
Fig. 7-46
1 Hub
1
Fig. 7-47
1 Rear wheel
Service Manual for G9165 Grader
7-20
3. Remove tire forklift tool.
4. Install and tighten rest wheel nuts.
Tightening torque: 700~800Nm
5. Recover the machine.
6. Check the machine functions.
743 Disassembly of Front Wheels
1. Put the machine in maintenance position.
Refer to Page 10 in Safety & Environment.
2. Use the bulldozing plate to jack up the front
wheel.
3. Put blocks under front and back of rear tires to
prevent the grader moving.
1
Fig. 7-48
1 Wheel forklift tool
1
Fig. 7-49
1 Grader
1
Fig. 7-50
1 Wood block
24.
Service Manual for G9165 Grader
7-21
4. Install tire forklift tools, and fix the wheel.
5. Remove the wheel nuts and wheel.
ATTENTION
Do not damage the thread when removing
the nuts. Tighten the wheel nuts crosswise
and diagonally when installing the wheel.
6. Put the wheel in suitable place.
1
Fig. 7-51
1 Wheel forklift tool
1
Fig. 7-52
1 Hub
1
Fig. 7-53
1 Bracket
Service Manual for G9165 Grader
7-22
744 Assembly of Front Wheels
1. Clean up fitting surfaces between rim and hub.
Ensure the hub thread is clean and free of
damage.
2. Install the wheel.
Use tire forklift tools to place wheel in position.
Install four uniformly-spaced tire wheel nuts
diagonally and tighten them orderly.
ATTENTION
Tighten the nuts clockwise and evenly (take
several tightening steps to prevent tilting
the wheel).
3. Remove tire forklift tool.
4. Install and tighten rest wheel nuts.
Tightening torque: 700~800Nm
5. Recover the machine.
6. Check the machine functions.
1
Fig. 7-55
1 Wheel forklift tool
1
Fig. 7-54
1 Hub
Service Manual for G9165 Grader
7-23
75 Disassembly and Assembly of
Middle Working Devices
751 Disassembly of Shovel Blades
1. Start the machine, drive it to flat, spacious and
solid ground, and stop the machine after
adjusting.
2. Operate the control handles repeatedly to
unload the hydraulic system. Then set all
control handles in neutral position and pull up
the parking brake handle.
3. Shut down the engine and put blocks under
front and back of the tires to prevent the grader
moving.
Fig. 7-57
1
Fig. 7-58
1 Wood block
25.
1
Fig. 7-56
1 Grader
Service Manual for G9165 Grader
7-24
4. Hang the shovel blade with lifting rope to
prevent it falling off and damaging your foot
or the ground after removing the connecting
pin.
5. Disconnect the oil pipes of blade sidesway
cylinder, use a container to collect the oil and
take measures to protect the exposed oil ports.
6. Use a copper bar to remove the connecting pin
of blade tilt cylinder, disconnect the cylinder
from shovel blade.
1
Fig. 7-59
1 Shovel blade
26.
1
Fig. 7-60
1 Blade sidesway cylinder
27.
1 2
Fig. 7-61
1 Blade tilt cylinder
2 Connecting pin
28.
Service Manual for G9165 Grader
7-25
7. Take down the connecting pin and protect the
cylinder from getting scratched.
8. Remove the fixing bolts of the locking block,
take down the block.
9. Remove the fixing bolts of the cover plate,
take down the plate.
1
Fig. 7-62
1 Connecting pin
29.
1
Fig. 7-63
1 Locking block
30.
1
Fig. 7-64
1 Cover plate
31.
Service Manual for G9165 Grader
7-26
10. Use a copper bar to remove the lining.
11. Lift the shovel blade away and put it in
suitable place.
752 Assembly of Shovel Blades
1. Clean up the rotary gear ring fitting areas and
inject some lubricating oil into the mounting
holes.
1
Fig. 7-65
1 Lining
32.
1
Fig. 7-66
1 Shovel blade
33.
1
Fig. 7-67
1 Rotary gear ring
34.
Service Manual for G9165 Grader
7-27
2. Coat the lining and wear-resisting plate with
lubricating oil.
3. Lift and connect the shovel blade to the rotary
gear ring.
4. Use a copper bar to install the lining. Fix the
cover plate on the lining with bolts and tighten
the bolts.
5. Install the fixing bolts of the locking block, fix
the lining.
1
Fig. 7-68
1 Lining
35.
1
Fig. 7-69
1 Lining
36.
1
Fig. 7-70
1 Locking block
37.
Service Manual for G9165 Grader
7-28
6. Use a copper bar to install the connecting pin
of blade tilt cylinder, to connect the cylinder
and shovel blade.
7. Use grease gun to inject some grease into the
pin joint.
8. Clean up the sdiesway cylinder pipe joints and
connect the oil pipes.
753 Disassembly of Middle Scarifier
1. Start the machine, drive it to flat, spacious and
solid ground, and stop the machine after
adjusting.
2. Operate the control handles repeatedly to
unload the hydraulic system. Then set all
control handles in neutral position and pull up
the parking brake handle.
3. Hang the middle scarifier with lifting rope to
prevent it falling off.
1 2
Fig. 7-71
1 Blade tilt cylinder
2 Connecting pin
38.
Fig. 7-73
1
Fig. 7-72
1 Grader
Service Manual for G9165 Grader
7-29
4. Screw off the connecting bolts and remove the
left and right welded pull rods.
5. Knock to remove the left and right welded
connecting pins, and remove the left and right
connecting arms.
6. Lift the middle scarifier away and put it in
suitable place.
ATTENTION
Incorrect detaching method may result in
personal injury or damage the machine.
Be careful when detaching the middle
scarifier, do not operate fiercely, and do not
bump against the fitting surfaces.
Rated hoisting weight of the lifting
appliance should be greater than the weight
of middle scarifier. Nobody is allowed to
stand or walk under the lifted middle
scarifier. Make sure is lifting rope is reliable
before lifting.
1
Fig. 7-74
1 Left welded pull rod
1 2
Fig. 7-75
1 Left connecting arm
2 Left welded connecting pin
Service Manual for G9165 Grader
7-30
754 Assembly of Middle Scarifier
1. Lift the middle scarifier to the right position
for assembling.
2. Install the left and right connecting arms, and
knock-in the welded connecting pins.
3. Install the left and right welded pull rods. And
tighten the connecting bolts.
4. Start the machine and check the functions.
1 2
Fig. 7-76
1 Welded connecting pin
2 Left connecting arm
1
Fig. 7-77
1 Left welded pull rod
1
Fig. 7-78
1 Middle scarifier
Service Manual for G9165 Grader
7-31
755 Disassembly of Rotary Gear Ring
1. Start the machine, drive it to flat, spacious and
solid ground, and stop the machine after
adjusting.
2. Operate the control handles repeatedly to
unload the hydraulic system. Then set all
control handles in neutral position and pull up
the parking brake handle.
3. Shut down the engine and put blocks under
front and back of the tires to prevent the grader
moving.
Fig. 7-80
1
Fig. 7-81
1 Wood block
39.
1
Fig. 7-79
1 Grader
Service Manual for G9165 Grader
7-32
4. Hang the rotary gear ring with lifting rope to
prevent it falling off.
5. Remove the connecting bolts of clamping plate,
and take down the clamping plate and guide
plate.
6. Remove the three guide plates and clamping
plates orderly. Lift down the rotary gear ring.
1
Fig. 7-82
1 Rotary gear ring
40.
1 2
Fig. 7-83
1 Clamping plate 2 Guide plate
41.
1
Fig. 7-84
1 Rotary gear ring
42.
Service Manual for G9165 Grader
7-33
7. Disconnect the oil pipes and take measures to
protect the exposed pipe joints.
8. Hang the front end and rear end of the
connecting rack with lifting rope.
9. Remove the locking cylinder.
The locking cylinder is used to position the
swing frame. A rocker switch on the
instrument panel is used to lock/unlock it.
Operate the swing frame to the desired
position, when the lug is aligned to the one
of the indicating holes (the swing frame is
aligned to the connecting rod locating hole),
press the rocker switch at this point, the
swing frame will be locked, and the
indicator light on the instrument panel will
be on.
The position of swing frame is easy to
control in the cab by one man.
1
Fig. 7-85
1 Pipe joint
43.
1 2 3
Fig. 7-86
1 Rotary gear ring
2 Connecting rack 3 Ball head
44.
1 2
Fig. 7-87
1 Locking cylinder
2 Indicating hole
3 Position the swing frame
45.
2
Service Manual for G9165 Grader
7-34
10. Press the rocker switch
11. Remove the connecting bolts of left swing
cylinder.
12. Remove the connecting bolts of the right
swing cylinder. Take down the cylinder.
1
Fig. 7-88
1 Rocker switch for locking cylinder
46.
1 2
Fig. 7-89
1 Swing cylinder 2 Bolt
47.
Fig. 7-90
48.
Service Manual for G9165 Grader
7-35
13. Remove the bolts on both sides of the swing
frame. Take down the swing frame.
14. Loosen the connecting bolts of shovel blade
lifting cylinder piston rod, to disconnect the
connection between blade lifting cylinder and
connecting rack.
15. Remove the connecting bolts of the ball head
support and connecting rack.
1
Fig. 7-91
1 Swing frame
49.
1
Fig. 7-92
1 Shovel blade lifting cylinder piston
rod head
50.
1 2
Fig. 7-93
1 Ball head support
2 Connecting rack
51.
Service Manual for G9165 Grader
7-36
16. Lift the connecting rack away and put it in
suitable place.
756 Assembly of Rotary Gear Ring
1. Replace the wear-resisting plates with new
ones.
1
Fig. 7-94
1 Ball head support
52.
1
Fig. 7-95
1 Connecting rack
53.
1
Fig. 7-96
1 Wear-resisting plate
Service Manual for G9165 Grader
7-37
2. Hang the rotary gear ring with lifting rope and
place it on the connecting rack.
3. Tighten the connecting bolts of the clamping
plate and guide plate.
Loosen the back nut and fastening nut on
bottom of the clamping plate, change the
quantity of adjusting gaskets.
Use a feeler gauge to measure the axial
clearance between rotary frame and
wear-resisting nylon plate, which should be
within 1~2mm.
Tighten the back nut and fastening nut.
Tightening torque: 755±45Nm
4. Install the three guide plates and clamping
plates orderly.
Fig. 7-97
1
Fig. 7-98
1 Clamping plate
1
Fig. 7-99
1 Guide plate
Service Manual for G9165 Grader
7-38
5. Hang and turn over the connecting rack and
rotary gear ring assembly.
6. Align the bolt holes of connecting rack and
ball head support.
7. Install and tighten the connecting bolts.
1
Fig. 7-100
1 Connecting rack
1 2
Fig. 7-101
1 Connecting rack
2 Ball head support
1
Fig. 7-102
1 Connecting bolt
Service Manual for G9165 Grader
7-39
8. Install and rotary cylinders and connect the oil
pipes.
Installation method:
Keep the left rotary cylinder and the
actuating arm in the same line, the piston
rod of the rotary cylinder is retracted at
this point.
Keep the right rotary cylinder
perpendicular to the actuating arm, as
shown in Fig. 7-104.
Loosen the lock nut and oil pipe of rotary
valve, and rotate the valve element until
the small hole on the valve element is
aligned to the oil port. Then keep the
rotary valve element still and tighten the
lock nut.
1
Fig. 7-103
1 Rotary cylinder
Fig. 7-104
Service Manual for G9165 Grader
7-40
9. Install the swing frame and tighten the
fastening bolts.
10. Install the locking cylinder and connect the oil
pipes.
11. Install the swing cylinder, tighten the
fastening bolts and connect the oil pipes.
1
Fig. 7-105
1 Swing frame
54.
1
Fig. 7-106
1 Locking cylinder
55.
1
Fig. 7-107
1 Swing cylinder
56.
Service Manual for G9165 Grader
7-41
12. Install the left and right shovel blade lifting
cylinders and connect the oil pipes.
13. Start the machine and check the functions.
Check for oil leakage.
1
Fig. 7-108
1 Lifting cylinder
57.
Fig. 7-109
58.
Service Manual for G9165 Grader
7-42
76 Disassembly and Assembly of
Middle Working Devices
761 Disassembly of Rear Scarifier
1. Start the machine, drive it to flat, spacious and
solid ground, and stop the machine after
adjusting. Lower the bulldozing plate to the
ground.
2. Operate the control handle to lower the rear
scarifier to the prepared backing plate.
3. Operate the control handles repeatedly to
unload the hydraulic system. Then set all
control handles in neutral position and pull up
the parking brake handle.
Fig. 7-112
1
Fig. 7-110
1 Grader
1
Fig. 7-111
1 Rear scarifier
Service Manual for G9165 Grader
7-43
4. Shut down the engine and put blocks under
front and back of the tires to prevent the grader
moving.
5. Use a copper bar to remove the connecting
pins. Remove the left and right connecting
boxes.
6. Disconnect the cylinder oil pipes, and take
measures to protect the exposed pipe joints.
Use a copper bar to remove the lower
connecting pins.
1
Fig. 7-113
1 Wood block
59. 1
60.
2 3
Fig. 7-114
1 Upper connecting pin
2 Left connecting box 3 Rear scarifier
61.
1 2
Fig. 7-115
1 Lower connecting pin
2 Connecting box
62.
Service Manual for G9165 Grader
7-44
7. Lift the rear scarifier away and put it in
suitable place.
8. The tooth sleeve is vulnerable part. When
disassembling it, you can use a copper bar to
knock one end of the steady pin to remove the
pin and elastic sleeve, and then take down the
tooth sleeve.
9. When assembling the sacrifice tooth, fit the
tooth and tooth sleeve first. The use a copper
bar to knock the steady pin and elastic sleeve
into the mounting hole.
ATTENTION
Incorrect detaching method may result in
personal injury or damage the machine.
Be careful when detaching the scarifier, do
not operate fiercely, and do not bump
against the fitting surfaces.
Rated hoisting weight of the lifting
appliance should be greater than the weight
of the scarifier. Nobody is allowed to stand
or walk under the lifted scarifier. Make
sure is lifting rope is reliable before lifting.
1
Fig. 7-116
1 Rear scarifier
63.
1 2 3 4
Fig. 7-117
1 Scarifier tooth 2 Elastic sleeve
3 Steady pin
4 Scarifier tooth sleeve
64.
Service Manual for G9165 Grader
7-45
762 Assembly of Rear Scarifier
1. Prepare some lubricating oil and necessary
assembling tools, be well prepared. Since the
scarifier needs to be assembled to the bottom
of the grader, a ditch nearby will be better.
2. Remove the left and right foot treadles. Install
the connecting bolts (with gaskets) back to
their original positions and tighten them.
Tightening torque: 180~210Nm
3. Knock to assemble the pin to connect the oil
cylinder.
4. Use grease gun to inject some grease into the
pin joint.
5. Connect and fix the oil pipes, and install the
left and right connecting boxes.
6. Lift and assemble the rear scarifier, and install
the connecting pin.
7. Start the machine and check the functions.
1
Fig. 7-118
1 Foot treadle
Fig. 7-119
1
Fig. 7-120
1 Rear scarifier
Service Manual for G9165 Grader
7-46
77 Diagnosis and Elimination of Common faults
The quality of working devices directly affects working efficiency of the machine. Table 7-1
presents some common faults in daily operation.
Table 7-1
Fault phenomenon Possible causes Elimination methods
Self-motion of
shovel blade rotary
frame under load
Seal of rotary cylinder is damaged
and result in bypass of oil line Replace the seal
Wear of rotary valve group in
multitandem valve Replace the rotary valve group
Abnormal wear of rotary valve
element Replace the rotary valve
Oil pipe or pipe joint has leakage
problem Replace the pipe
Shovel blade rotary
frame cannot rotate
or cannot rotate
smoothly
Clamping stagnation of rotary
mechanism
Clean up the rotary mechanism and
adjust the rotary frame clearance
according to related requirements
Drive shaft of rotary valve is
damaged, gear of rotary valve is
damaged, sliding occurs between
drive shaft of rotary valve and gear
of rotary valve
Replace the drive shaft or gear
Rotary drive gear is damaged Replace the gear
Spline connection of rotary
actuating arm and rotary gear is
damaged
Replace the actuating arm or gear
The oil lines between rotary valve
and rotary cylinder is wrongly
connected
Adjust the position of rotary valve
element according to related
requirements
Low oil level in hydraulic oil tank Add oil to specified level
Seal of rotary cylinder is damaged Replace the seal
Set pressure of multitandem valve
is incorrect Reset
The multitandem valve cannot
maintain required pressure
Replace the safety valve of
multitandem valve
The wear-resisting nylon plate is
severely worn or with too small
clearance
Replace the wear-resisting nylon
plate or adjust the clearance
Turning direction of
shovel blade rotary
frame is not
inconsistent with
the indicated
direction of the
control handle
Position of rotary valve element is
wrong
Adjust the position of rotary valve
element by rotating 180°
Service Manual for G9165 Grader
7-47
Shovel blade rotary
frame can only
rotate in one
direction
Position of rotary valve element is
wrong
Adjust the position of rotary valve
element according to related
requirements
The shovel blade
vibrates during
working
Axial and radial clearance of rotary
frame is too large Adjust
The guide sleeve or lining of
shovel blade tilt cylinder support is
damaged
Replace the guide sleeve or lining
The wear-resisting nylon plate is
severely worn or broken
Replace the wear-resisting nylon
plate
Shovel blade tilt cylinder has
severe internal leakage problem Replace the cylinder seals
The working device
falling down
unexpectedly
Shovel blade lifting cylinder
balance valve is damaged or stuck,
and result in failure
Replace the balance valve