7frames, Wheels & Working Devices - ENGLISG-G9165

Service Manual of RS8160 Road Roller
SERVICE MANUAL
7 Frames, Wheels & Working

Devices
Service Manual for G9165 Grader
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
7 Frames, Wheels &

Working Devices
71 General
711 Overview of Frames
Fig. 7-1
1 Front frame
Two kinds of frame are commonly used,

namely unitary frame and articulated frame.
2 Master pin
Articulated frame consists of front frame, rear
3 Rear frame
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.
7-1
The front frame is installed on front frame, it

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
Fig. 7-2
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
Fig. 7-3
only acts on the rear frame and will not affect

the transmission system.
7-2
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.
1
Fig. 7-4
1 Front bulldozing plate
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
Fig. 7-5
1 Middle scarifier
Before starting the machine, lift the scarifier

7-3

up at first. Remove the scarifier if the
scarifier isnt 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.
1
Fig. 7-6
1 Shovel blade
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: 47forward
5backward
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
1
2
Fig. 7-7
1 Left blade lifting cylinder
2 Right blade lifting cylinder
requirements.
7-4
of
the
ground
meet
the
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
Fig. 7-8
1 Blade rotating cylinder
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.
1
Fig. 7-9
1 Blade sidesway cylinder
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
2
Fig. 7-10
1 Locking cylinder
2 Side-swing cylinder
7-5
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
Fig. 7-11
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.
1
Fig. 7-12
1 Tilt cylinder
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
Fig. 7-13
1 Rear scarifier
symmetrically, for example, use one middle

tooth or 2 outside teeth only, or use the three
teeth together.
7-6
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 isnt
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
7-7
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
1
Fig. 7-15
1 Grader
prevent the grader moving.
1
Fig. 7-16
1 Wood block
1.
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
2
3
Fig. 7-17
1 Connecting pin
2 Connecting arm
3 Lifting support
7-8
2.

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
1
bump against the fitting surfaces.
Fig. 7-18
1 Bulldozing plate
Rated
3.
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.
1
2
Fig. 7-19
1 Connecting arm
2 Lifting support
4.
7-9
Use copper bar to install the connecting pins.

4.
Start the machine and check the function of

front bulldozing plate.
Fig. 7-20
5.

Frame Junction
731 Disassembly
of Upper Frame
Junction
1.
Park the machine on solid and flat ground.
2.
Operate the control handles repeatedly to
Fig. 7-21
unload the hydraulic system.
Fig. 7-22
7-10

3.
Turn off the battery power switch.
4.
1
Fig. 7-23
1 Power switch
1
Fig. 7-24
1 Wood block
6.
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. 7-25
1 Connecting pin
2 Steering cylinder
7.
7-11

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.
1
Fig. 7-26
1 Front frame
2
2 Rear frame
8.
8.
Remove the extraction pipe and oil cup.
9.
9.
Remove the fixing bolt of the upper master pin.
1
Fig. 7-27
1 Extraction pipe
Take down the base plate.
1
Fig. 7-28
1 Base plate
10.
7-12

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.
1
2
3
Fig. 7-29
1 Upper locating plate
2 Upper master pin
3 Knuckle bearing
11.
732 Disassembly of Lower Frame

Junction
1.
Remove the fixing bolt of the lower master pin.

Take down the base plate.
1
Fig. 7-30
1 Base plate
12.
7-13

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.
Fig. 7-31
1 Spacer bush
2 Lower master pin
3 Lining
13. Assembly
733
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.
1
Fig. 7-32
1 Master pin hole
14.
Fig. 7-33
15.
7-14
Clean up the master pin holes.

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.
1
2
3
Fig. 7-34
1 Upper locating plate
2 Upper master pin
3 Knuckle bearing
16. Press-fit the upper master pin, then install the
6.
pin fixing bolt and base plate.
The bolt should be coated with thread locking
sealant.
Tightening torque: 339Nm
1
2
Fig. 7-35
1 Base plate
2 Bolt
17.
7. Install the extraction pipe and oil cup.
1
Fig. 7-36
1 Extraction pipe
18.
7-15
734 Assembly
of
Lower
Frame
Junction
1
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.
Fig. 7-37
1 Lower locating plate
2 Lining
3 Spacer bush
19.
4.
Install base plate and tighten the pin fixing

bolt.
1
Fig. 7-38
1 Base plate
20.
7-16

5.
Install the extraction pipe and oil cup.
1
Fig. 7-39
1 Extraction pipe
21.
6. Connect the hydraulic pipes.
1
Fig. 7-40
1 Hydraulic oil pipe
22.
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.
1
2
Fig. 7-41
1 Connecting pin
2 Steering cylinder
3 Frame locking bar
12. Add grease to the knuckle bearings again.
23.
7-17

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.
Fig. 7-42
1 Grader
3.
Install tire forklift tools, and fix the wheel.
4.
Use pneumatic impact wrench to remove
1
Fig. 7-43
1 Wheel forklift tool
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. 7-44
1 Rear wheel
7-18

5.
Remove the wheel and put it in suitable place.
1
Fig. 7-45
1 Bracket
742 Assembly of Rear Wheels

1.
Clean up fitting surfaces between rim and hub.

Ensure the hub thread is clean and free of
damage.
1
Fig. 7-46
1 Hub
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. 7-47
1 Rear wheel
7-19

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. 7-48
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.
1
Fig. 7-49
1 Grader
3.

1
Fig. 7-50
1 Wood block
24.
7-20

4.
Install tire forklift tools, and fix the wheel.
1
Fig. 7-51
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.
1
Fig. 7-52
1 Hub
6.
1
Fig. 7-53
1 Bracket
7-21
Put the wheel in suitable place.
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.
1
ATTENTION
Fig. 7-54
1 Hub
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.

5.
Recover the machine.
6.
Check the machine functions.
1
Fig. 7-55
7-22

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.
1
Fig. 7-56
1 Grader
2.

unload the hydraulic system. Then set all
control handles in neutral position and pull up
the parking brake handle.
Fig. 7-57
3.
Shut down the engine and put blocks under

front and back of the tires to prevent the grader
moving.
1
Fig. 7-58
1 Wood block
25.
7-23

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.
1
Fig. 7-59
1 Shovel blade
26.
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.
1
Fig. 7-60
1 Blade sidesway cylinder
27.
6. Use a copper bar to remove the connecting pin
of blade tilt cylinder, disconnect the cylinder
from shovel blade.
1
2
Fig. 7-61
1 Blade tilt cylinder
2 Connecting pin
28.
7-24

7. Take down the connecting pin and protect the
cylinder from getting scratched.
1
Fig. 7-62
1 Connecting pin
29.
8. Remove the fixing bolts of the locking block,
take down the block.
1
Fig. 7-63
1 Locking block
30.
9. Remove the fixing bolts of the cover plate,
take down the plate.
1
Fig. 7-64
1 Cover plate
31.
7-25

10. Use a copper bar to remove the lining.
1
Fig. 7-65
1 Lining
32.
11. Lift the shovel blade away and put it in
suitable place.
1
Fig. 7-66
1 Shovel blade
33.
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. 7-67
1 Rotary gear ring
34.
7-26

2. Coat the lining and wear-resisting plate with
lubricating oil.
3. Lift and connect the shovel blade to the rotary
gear ring.
1
Fig. 7-68
1 Lining
35.
4. Use a copper bar to install the lining. Fix the
cover plate on the lining with bolts and tighten
the bolts.
1
Fig. 7-69
1 Lining
36.
5. Install the fixing bolts of the locking block, fix
the lining.
1
Fig. 7-70
1 Locking block
37.
7-27

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.
1
2
Fig. 7-71
1 Blade tilt cylinder
2 Connecting pin
38.
753 Disassembly of Middle Scarifier

1.

adjusting.
1
Fig. 7-72
1 Grader
2.

Fig. 7-73
3.
Hang the middle scarifier with lifting rope to

prevent it falling off.
7-28

4.
Screw off the connecting bolts and remove the

left and right welded pull rods.
1
Fig. 7-74
1 Left welded pull rod
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
1
2
Fig. 7-75
1 Left connecting arm
2 Left welded connecting pin
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

of middle scarifier. Nobody is allowed to
stand or walk under the lifted middle
scarifier. Make sure is lifting rope is reliable
before lifting.
7-29
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.
Fig. 7-76
1 Welded connecting pin
2 Left connecting arm
3.
Install the left and right welded pull rods. And

tighten the connecting bolts.
1
Fig. 7-77
1 Left welded pull rod
4.
1
Fig. 7-78
1 Middle scarifier
7-30
Start the machine and check the functions.
755 Disassembly of Rotary Gear Ring

1.

adjusting.
1
Fig. 7-79
1 Grader
2.

Fig. 7-80
3.

moving.
1
Fig. 7-81
1 Wood block
39.
7-31

4.
Hang the rotary gear ring with lifting rope to

prevent it falling off.
1
Fig. 7-82
1 Rotary gear ring
40.
5. Remove the connecting bolts of clamping plate,
and take down the clamping plate and guide
plate.
1
Fig. 7-83
1 Clamping plate
2
2 Guide plate
41.
6. Remove the three guide plates and clamping
plates orderly. Lift down the rotary gear ring.
1
Fig. 7-84
1 Rotary gear ring
42.
7-32

7.
Disconnect the oil pipes and take measures to

protect the exposed pipe joints.
1
Fig. 7-85
1 Pipe joint
43.
8. Hang the front end and rear end of the
connecting rack with lifting rope.
1
2
Fig. 7-86
1 Rotary gear ring
2 Connecting rack
3 Ball head
9.
44. 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
1
2
Fig. 7-87
1 Locking cylinder
2 Indicating hole
3 Position the swing frame
indicator light on the instrument panel will

be on.
The position of swing frame is easy to
45. control in the cab by one man.
7-33

10. Press the rocker switch
1
Fig. 7-88
1 Rocker switch for locking cylinder
46.
11. Remove the connecting bolts of left swing
cylinder.
1
2
Fig. 7-89
1 Swing cylinder
2 Bolt
47.
12. Remove the connecting bolts of the right
swing cylinder. Take down the cylinder.
Fig. 7-90
48.
7-34

13. Remove the bolts on both sides of the swing
frame. Take down the swing frame.
1
Fig. 7-91
1 Swing frame
49.
14. Loosen the connecting bolts of shovel blade
lifting cylinder piston rod, to disconnect the
connection between blade lifting cylinder and
connecting rack.
1
Fig. 7-92
1 Shovel blade lifting cylinder piston
rod head
50.
15. Remove the connecting bolts of the ball head
support and connecting rack.
Fig. 7-93
1 Ball head support
2 Connecting rack
51.
7-35
1
Fig. 7-94
1 Ball head support
52.
16. Lift the connecting rack away and put it in
suitable place.
1
Fig. 7-95
1 Connecting rack
53.
756 Assembly of Rotary Gear Ring

1.
Replace the wear-resisting plates with new

ones.
1
Fig. 7-96
1 Wear-resisting plate
7-36

2.
Hang the rotary gear ring with lifting rope and

place it on the connecting rack.
Fig. 7-97
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
1
Fig. 7-98
1 Clamping plate
within 1~2mm.
Tighten the back nut and fastening nut.
Tightening torque: 75545Nm
4.
Install the three guide plates and clamping

plates orderly.
1
Fig. 7-99
1 Guide plate
7-37

5.
Hang and turn over the connecting rack and

rotary gear ring assembly.
1
Fig. 7-100
1 Connecting rack
6.
Align the bolt holes of connecting rack and

ball head support.
Fig. 7-101
1 Connecting rack
2 Ball head support
7.
1
Fig. 7-102
1 Connecting bolt
7-38
Install and tighten the connecting bolts.

8.
Install and rotary cylinders and connect the oil

pipes.
1
Fig. 7-103
1 Rotary cylinder
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.
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.
7-39

9. Install the swing frame and tighten the
fastening bolts.
1
Fig. 7-105
1 Swing frame
54.
10. Install the locking cylinder and connect the oil
pipes.
1
Fig. 7-106
1 Locking cylinder
55.
11. Install
the
swing
cylinder,
tighten
fastening bolts and connect the oil pipes.
1
Fig. 7-107
1 Swing cylinder
56.
7-40
the

12. Install the left and right shovel blade lifting
cylinders and connect the oil pipes.
1
Fig. 7-108
1 Lifting cylinder
57.
13. Start the machine and check the functions.
Check for oil leakage.
Fig. 7-109
58.
7-41

Middle Working Devices
761 Disassembly of Rear Scarifier
1.

adjusting. Lower the bulldozing plate to the
ground.
1
Fig. 7-110
1 Grader
2.
Operate the control handle to lower the rear

scarifier to the prepared backing plate.
1
Fig. 7-111
1 Rear scarifier
3.

Fig. 7-112
7-42

4.

moving.
1
Fig. 7-113
1 Wood block
1
59.
5. Use a copper bar to remove the connecting
60.
pins. Remove the left and right connecting
boxes.
2
3
Fig. 7-114
1 Upper connecting pin
2 Left connecting box
3 Rear scarifier
61.
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.
Fig. 7-115
1 Lower connecting pin
2 Connecting box
7-43
62.

7.
Lift the rear scarifier away and put it in

suitable place.
1
Fig. 7-116
1 Rear scarifier
63.
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
1
2 3
4
Fig. 7-117
1 Scarifier tooth
2 Elastic sleeve
3 Steady pin
4 Scarifier tooth sleeve
Be careful when detaching the scarifier, do

not operate fiercely, and do not bump
against the fitting surfaces.
64. Rated hoisting weight of the lifting
of the scarifier. Nobody is allowed to stand
or walk under the lifted scarifier. Make
sure is lifting rope is reliable before lifting.
7-44
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.
1
Fig. 7-118
1 Foot treadle
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.
Fig. 7-119
7.
1
Fig. 7-120
1 Rear scarifier
7-45
Start the machine and check the functions.
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
Self-motion
of
shovel blade rotary
frame under load
Seal of rotary cylinder is damaged

and result in bypass of oil line
Wear of rotary valve group in
multitandem valve
Abnormal wear of rotary valve
element
Oil pipe or pipe joint has leakage
problem
Clamping stagnation
mechanism
Shovel blade rotary

frame cannot rotate
or cannot rotate
smoothly
Elimination methods
of rotary
Replace the rotary valve group

Replace the rotary valve
Replace the pipe
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
The oil lines between rotary valve
and rotary cylinder is wrongly
connected
Replace the actuating arm or gear

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
The multitandem valve cannot
maintain required pressure
The wear-resisting nylon plate is
severely worn or with too small
clearance
Turning direction of
shovel blade rotary
frame
is
not
inconsistent
with
the
indicated
direction of the
control handle
Replace the seal
Position of rotary valve element is

wrong
7-46
Reset
Replace the safety
multitandem valve
valve
of
Replace the wear-resisting nylon

plate or adjust the clearance

element by rotating 180

Shovel blade rotary
frame can only
rotate
in
one
direction
The shovel blade

vibrates
during
working
The working device

falling
down
unexpectedly
Position of rotary valve element is

wrong
Axial and radial clearance of rotary
frame is too large
The guide sleeve or lining of
shovel blade tilt cylinder support is
damaged
The wear-resisting nylon plate is
severely worn or broken
Shovel blade tilt cylinder has
severe internal leakage problem
Shovel blade lifting cylinder
balance valve is damaged or stuck,
and result in failure
7-47

element according to related
requirements
Adjust
Replace the guide sleeve or lining
Replace the wear-resisting nylon
plate
Replace the cylinder seals
Replace the balance valve

7frames, Wheels & Working Devices - ENGLISG-G9165

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Service Manual of RS8160 Road Roller

7 Frames, Wheels & Working

Service Manual for G9165 Grader

Service Manual for G9165 Grader

7 Frames, Wheels &

Two kinds of frame are commonly used,

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

The rear frame is installed with engine, torque

The front frame is installed on front frame, it

Service Manual for G9165 Grader

The front frame is of box-type double-section

front bulldozing plate and middle scarifier.

The rear frame is welded together by box-type

only acts on the rear frame and will not affect

Service Manual for G9165 Grader

712 Overview of Working Devices

Working device of G9165 grader have adopted

Front bulldozing plate

The bulldozing plate is installed on front end

If the bulldozing plate is not needed in the

If the bulldozing plate is going to be stored for

The middle scarifier is installed in the middle

Before starting the machine, lift the scarifier

Service Manual for G9165 Grader

The shovel blades are installed in the middle

The blade is driven by single oil cylinder,

Radian of the blade is optimized to ensure

Swing cylinder angle is small, thus the shovel

Up/down of shovel blade

Service Manual for G9165 Grader

Rotating of shovel blade

that the scraped soil can be discharged from

the two sides and the grader can work

Sidesway of shovel blade

Side-swing of shovel blade

Service Manual for G9165 Grader

Side overturning of shovel blade

certain angle to the ground, the maximum side

Adjusting of cutting angle

The rear scarifier is installed in the rear area of

Rear scarifier is designed with five teeth,

hard ground. The teeth should be used

symmetrically, for example, use one middle

Service Manual for G9165 Grader

Adjusting of rear scarifier

The front bulldozing plate can be used as front

Service Manual for G9165 Grader

72 Disassembly and Assembly of

Park the machine on solid and flat ground.

Put blocks under front and back of rear tires to

Use a copper bar to remove the connecting

Service Manual for G9165 Grader

Use lifting rope to detach and lift the

bump against the fitting surfaces.

appliance should be greater than the weight

722 Assembly of Front Bulldozing

Prepare some lubricating oil and necessary

Coat the connecting pins with lubricating oil,

Use copper bar to install the connecting pins.

Service Manual for G9165 Grader