8cab & Covering Parts System - ENGLISG-G9165

Service Manual of G9165 Grader
SERVICE MANUAL
8 Cab & Covering Parts System
Service Manual for G9165 Grader
CONTENTS
8 Cab & Covering Parts System ............................................................................. 8-1
81 Overview of Cab .................................................................................................. 8-1
811 Cab Exterior Description ............................................................................. 8-1
812 Cab Interior Description .............................................................................. 8-3
82 A/C System Description .................................................................................... 8-14
821 Function and Location of Components ..................................................... 8-14
822 System Description .................................................................................... 8-15
83 Disassembly and Assembly Of Cab Assembly ................................................. 8-17
831 Disassembly of Cab Assembly .................................................................. 8-17
832 Assembly of Cab Assembly ...................................................................... 8-23
833 Replacement of Seat .................................................................................. 8-29
834 Disassembly and Assembly of Operation Box .......................................... 8-30
84 Disassembly and Assembly of Engine Hood .................................................... 8-32
841 Disassembly of Engine Hood .................................................................... 8-32
842 Assembly of Engine Hood......................................................................... 8-35
85 Disassembly and Assembly of A/C System ...................................................... 8-39
851 Disassembly of Evaporator Assembly ...................................................... 8-39
852 Assembly of Evaporator Assembly ........................................................... 8-41
853 Replacement of Evaporator Components .................................................. 8-44
854 Replacement of Condenser Fan ................................................................. 8-51
855 Replacement of Receiver-drier .................................................................. 8-53
856 Replacement of Compressor Components ................................................ 8-54
857 Draining and Filling of Refrigerant ........................................................... 8-56
86 Common Faults Diagnosis and Troubleshooting for A/C System .................... 8-60
861 Regular Inspection Items ........................................................................... 8-60
862 Analysis of Cooling Failure....................................................................... 8-61
863 Analysis of Insufficient Cooling ............................................................... 8-62
864 Analysis of Heating Failure ....................................................................... 8-62
865 Analysis of Other Faults ............................................................................ 8-62
8 Cab
&
Covering
Parts System
81 Overview of Cab
The G9165 cab is a specially designed grader cab by
SDLG.
811 Cab Exterior Description

1.
The cab is designed with FOPS&ROPS

function. ROPS and FOPS are used to prevent
heavy, falling objects from causing injury to
the operator, and protecting operators in case
of a roll over. ROPS does not only support the
load when the machine is rolling over, but also
absorbs the impact energy as well.
Fig. 8-1
1 Cab
2.
The G9165 cab is fixed on the rear frame using

4 dampers, which decreases the external
vibration effectively so as to improve the ride
comfort.
1
Fig. 8-2
1 Damper
8-1

3.
The ROPS (Roll Over Protection System)

includes a heavy duty bolt (ROPS bolt) and a
permanently installed gasket (ROPS gasket).
The ROPS bolt is used to connect the cab and
frame. In the circumstance of rolling over, the
ROPS can prevent the cab from detaching the
machine.
ATTENTION
If they are damaged due to falling things or
1
Fig. 8-3
1 ROPS bolt
machine rolling over, the intensity will
reduce, and they cannot satisfy the normal
2 ROPS gasket
protecting function. In this case, please

contact
with
Lingong
Construction
Machinery Co., Ltd. or its designated

dealers to consult repair method. It is
definitely
not
allowed
to
repair
it
arbitrarily.
The operators are protected effectively only
when they properly utilize the operator seat
safety belts. The operator must always use
the seat safety belt when operating the
machine. It is recommended that regular
inspection of the operator seat safety belt be
performed, and if any damage is found, the
operator seat safety belt must be replaced.
It is also recommended that the operator
seat safety belt be replaced every three
years, even if no damage is observed.
Never drill or weld inside or outside the
ROPS in order to avoid damaging or
reducing the effectiveness of the protective
structure.
WARNING
If ROPS structure is damaged due to
8-2

plastic deformation or failure, then the
ROPS
structure
must
be
replaced
immediately, please contact with the nearest

SDLG designated dealer for support.
812 Cab Interior Description

The control handles and instrument panel are
located in front of cab, and the gear shift control
handle is on the right-hand side. Simple operation,
in line with people's operating habits.
1.
Starting switch
This switch is used for starting or stopping
(shut-down) of the engine. The ON position is
also used to turn on the machine electrical
system.
a) PRE position
This position is used to turn on the engine
pre-heating cold start system.
1
Fig. 8-4
1 Starting switch
b) OFF position
Insert or remove the key in this position.
Turn the key to this position to shut down
the engine.
c) ON position
This position is used to turn on the electric
system of the machine. The key will
remain in this position when the engine is
running.
d) ST position
This is the engine-start position. Turn the
key to this position to engage the engine
starting motor.
Once the engine is started, immediately
release the key to let it return to the ON
position by spring force.
8-3

2.
CD player/Radio control panel (Optional)

The control panel is located on the right part
on the cab ceiling, for operation method please
reference CD Player/Radio Control Panel
Operation Manual.
1
Fig. 8-5
1 CD player
3.
Gear shift control

Gear shift mechanism is electro-hydraulically
controlled, 6 forward gears on the left side and
3 backward gears on the right side. Besides,
negative control is available only when
transmission box is in gear I. When traveling
downhill, you should select a suitable gear to
keep the engine speed bigger than 1200r/min,
Fig. 8-6
to guarantee lubrication of the machine.
ATTENTION
The gears should be selected successively, do
not skip any gears when shifting. Do not pull
or push the handle rashly and fiercely.
4.
Rocker switches
Turn signal lamp switch and front

headlamp switch are located in the front of
cab, below the steering wheel.
1
2
Fig. 8-7
1 Turn signal lamp switch
2 Front headlamp switch
8-4
Warning light switch

Press down the bottom end, all the turning
signal lamps will be on, which is used for
1
Fig. 8-8
1 Warning light switch
emergency to send alarm signals warn the

passing pedestrian and vehicles. Press
down the top end, all the turning signal
lamps will be off.
The switch is located on the right-hand
side.
Working light switch

Press down the top end, only front
working lights on top of the cab will be on.
Press down the bottom end, both the front
Fig. 8-9
1 Working light switch
and the rear working lights will be on.

When the switch is in middle position, the
lights will be off.
Shovel blade light switch

Press down the bottom end, the blade light
on the front frame and the light on bottom
of cab will not be on. Press down the top
Fig. 8-10
1 Shovel blade light switch
end, they will be off.
Rear working light switch

Press down the bottom end, the rear
working light on the rear hood will be on.
Press down the top end, it will be off.
Fig. 8-11
1 Rear working light switch
Backlight switch
Press the bottom end and backlight will be
on; Press the top end, it will be off.
1
Fig. 8-12
1 Backlight switch
8-5
Mute switch
Press the bottom end of the switch, the
audible alarm will stop.
1
Fig. 8-13
1 Mute switch
Locking cylinder switch

This switch is an auto-reset switch. Push
bottom end and the lock cylinder retracts,
release the switch the cylinder will stop
Fig. 8-14
1 Locking cylinder switch
retracting and be fixed at current position.

Push top end and the locking cylinder
extends, release the switch the cylinder
will stop extending and be fixed in current
position.
Reserved position for fan heater switch

Press the bottom end of the switch, the fan
heater will start to work, Press the top end,
fan heater will stop.
Fig. 8-15
1 Reserved position for fan heater
switch
Rotating beacon switch

The switch is located in right-top of cab.
Press down the bottom end of the switch,
and the beacon on the top of the cab will
be on. Press down the top end, the beacon
will go off.
1
Fig. 8-16
1 Rotating beacon switch
8-6
Windshield washer switch

This switch is an auto-reset switch. Push
bottom end and the washer spray works on
the front windshield. Push top end and the
washer spray works on the rear windshield.
Release the switch, it will reset to original
1
Fig. 8-17
1 Windshield washer switch
position.
Front windshield wiper switch

Push bottom end of the switch and the
wiper begins to work. Push the top end of
the switch and the wiper stops working.
There are 2 positions between ON and
OFF that give two different working
Fig. 8-18
1 Front windshield wiper switch
speeds.
5.
Temperature control switches
Fan control switch

System switch controls the speed of
evaporator fan. It is divided into high,
neutral, and low grade power so that you
can properly select wind, and start/stop
1
2
Fig. 8-19
1 Fan control switch
2 Fresh air switch
3 Cooling change switch
A/C.
Fresh air switch

Control
the
fresh
air
actuator
and
circulation of inside and outside air.
Cooling change switch

Rotate the switch clockwise to start cooling
system
and
choose
capacity.
Cooling
Start the engine.
8-7
proper
cooling

Turn on the power/fan control switch and
turn the temperature switch to the
"COOL" position. A light should indicate
cooling system is operating.
Adjust the fan control to a desired speed.
When the cab temperature reaches a
desired level, adjust the temperature
switch counterclockwise until the light
goes out indicating that the cooling system
has cycled off. When the cab temperature
goes above the temperature switch setting,
the light will come on and the cooling
system is engaged until it reaches the
appropriate cab temperature setting.
Heating
First, set cooling change switch to "O" or
"OFF" position.
Start the engine and open the cab heat
exchanger water valves.
Set the fan control to the desired air flow.
6.
Cab light switch

This switch is located in the center of cab light.
Push it to ON position, the cab light will be
on. Push it to OFF position to turn it off.
1
Fig. 8-20
1 Cab light switch
8-8

7.
Parking brake control handle

This handle is located at left side of operators
seat. Pull it up to engage parking brake and put
it down to release the brake.
Fig. 8-21
8.
Cigarette lighter
Insert the lighter and press it down, it will be
locked automatically. At this point, electric
heating piece of the lighter is contacting the
lighter socket, and then it starts to heat heating
wire. When the wire is heated to red color, the
snap spring is subject to strong heat and begins
to shift form to pop up the lighter. Then you
can use the lighter to light the cigarette, and
Fig. 8-22
1 Cigarette lighter
insert it back after that.
9.
Tilt angle of steering wheel adjusting handle

Adjusting angle of steering wheel is 19.
Control the handle on the right side of
instrument desk to tilt the steering wheel to the
desired position.
1
Fig. 8-23
1 Tilt angle of steering wheel
adjusting handle
8-9

10. Instrument desk inclination adjusting pedal
The instrument desk is locked by gas spring,
step the pedal to remove the lock, at this point,
the instrument desk can be tilted, hold the
steering wheel to adjust instrument desk to
desired position and release pedal to lock it.
Adjusting range is 70~90.
1
Fig. 8-24
1 Instrument desk inclination adjusting
pedal
11. Steering wheel and horn button

The steering wheel and steering control unit
are connected. Turning the steering wheel
clockwise, the machine turns right, turning the
steering wheel counter-clockwise, the machine
turns left. Press the button in the middle of the
1
Fig. 8-25
1 Horn button
steering wheel and the horn will sound.
2
2 Steering wheel
12. Safety hammer

In case of an emergency, the hammer hanged
in the left-rear side of the cab can be used to
break the window and flee the cab.
1
Fig. 8-26
1 Safety hammer
8-10

13. Working device control handles
As shown in the left figures, there are five
control handles on both sides of steel wheel,
which are used to control the two multitandem
valves on front of cab respectively, to perform
the following actions:
1
2
Fig. 8-27
1 From left to right, the handles are used
to control up/down of rear scarifier,
shovel blade tilt angle, hinge steering,
up/down of bulldozing plate
2 From left to right, the handles are used
to control up/down of left shovel blade,
sidesway of shovel blade, rotation of
shovel blade, swing of shovel blade, tilt
of front wheels, up/down of right shovel
blade
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 end of blade can be adjusted,
which can make the height and inclination
of the ground meet the requirements.
Shovel blade rotating

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

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
8-11

blades together left and right to increase
the operation range.
Side overturning of shovel blade

Side overturning of blade is used to scrape
side slope, under the joint action of left
and right lifting cylinder, 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 shovel blade cutting angle

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.
14. Operators seat
Weight adjustment
The weight adjustment handle is in the
front middle of the seat bottom area. Turn
the handle counterclockwise to reduce the
damping stiffness and turn the handle
clockwise
to
increase
the
damping
stiffness.
Fore-and-aft adjustment
The seat slide handle is on the front
1
2
3
Fig. 8-28
1 Fore-and-aft adjustment handle
2 Weight adjustment handle
3 Backrest angle adjustment handle
bottom
side
of the
seat.
Pull
the
fore-and-aft handle and move the seat

forward or backward to the desired
position. It will lock automatically after
releasing the handle.
Backrest angle adjustment

Pull the backrest angle adjustment handle
upward to release the backrest and allow
8-12

for adjustment fore and aft until the
backrest
angle
is
comfortable.
The
backrest angle is locked by releasing the

handle.
Height adjustment
There are three positions for the height of
seat. The operator can adjust according to
the need. When adjusting, grasp the base
under the seat by two hands and pull it up,
and the seat will touch the clamp. When a
snap sound is heard, release the seat. The
seat will be fixed in this position. Adjust
the position of seat to the highest position,
and then press down. The seat will fall to
the lowest position.
Headrest height adjustment

Set the headrest of the seat by using two
hands. Pull up or push down to adjust the
height of the headrest.
15. Operator's seat safety belt

If there is safety belt, be sure to check it before
operation, and replace it if necessary. Please
fasten your seatbelts for your own safety
before operation.
16. Rear view mirrors
Rear view mirrors are located on the left and
right sides on top of the cab. Before starting
work, adjust the angle of the all rear view
mirrors for safe operation.
Fig. 8-29
8-13
82 A/C System Description

821 Function
and
Location
of
Components
The grader A/C system is composed of compressor,
evaporator
assembly,
condenser
assembly,
receiver-drier (fluid reservoir) and rubber cooling

hose. The compressor is driven through belt by the
grader engine. The panel switch controls the
temperature and air volume. Besides, it allows a
great quantity of air to get in and out, featuring
with a high efficiency of cooling and automatic
1
Fig. 8-30
1 Compressor
control of cab temperature.

1.
The A/C compressor, just like the heart of the

A/C cooling system, maintains the refrigerant
circulation in the cooling system, by inhaling
low-temperature and low-pressure refrigerant
vapor from the evaporator, then compressing it
into
high-temperature
and
high-pressure
refrigerant vapor, and finally delivering the

refrigerant vapor to condenser.
2.
The condenser is a heat exchanger that held

together by pipes and cooling fins. Its function
is to cool and condense the high-temperature
and high-pressure refrigerant vapor into
high-pressure refrigerant liquid.
3.
The receiver-drier is use to reserve refrigerant,

remove water from the refrigerant, filter
1
Fig. 8-31
1 Condenser
2 Receiver-drier
impurities and measure refrigerant quantity.

4.
The function of expansion valve is to atomize

the liquid refrigerant from receiver-drier into
low-temperature, low-pressure and vaporous
refrigerant. It can also adjust the refrigerant
flow aquatically according to cooling load.
8-14

5.
The
evaporator
is
used
to
gasify
the
low-temperature, low-pressure and vaporous

refrigerant by absorbing heat of the air in the
cab, so as to cool the cab. The cooling
performance of the A/C depends on heat
absorption capacity of the condenser.
Fig. 8-32
822 System Description

This grader A/C system mainly consists of heater system, cooling system, ventilation system and
pressure control system.
This grader cooling system cools the air inside or fresh air from the outside to lower the temperature
in the grader.
The operating instructions are as follows:
1.
Start the engine;
2.
Turn on the fan control switch, then rotate the cooling change switch to COOL, and the
indicator lamp will be on, which indicates cooling is started;
3.
Rotate the fan control switch, and you can select high, middle and low gears to enjoy three
different modes of air flowing;
4.
When the temperature is down to the required temperature, anti-clockwise rotate the cooling
change switch slowly until the indicator lamp is off and the compressor stops running, in which
case, the temperature in the cab is the set temperature. With any higher internal temperature
than that, the indicator lamp will be on, the compressor will start automatically, and the system
will start cooling; and with any lower internal temperature than that, the indicator lamp will be
off, and the system will stop working;
5.
When the A/C is turned on, dot rotate the cooling change switch to COOL, and rotate the fan
control switch to a low gear at the same time in case the evaporator frosts, which may affect the
cooling effect.
The grader heater system brings the coolant in the diesel engine into the heater radiator depending
on the heat of coolant, blows the heated air into the vehicle through a blower, and thus to increase
the internal temperature.
The heater system should be operated as follows:
8-15

1.
Rotate the cooling change switch to O or OFF position before use;
2.
Start the engine and open the cab heat exchanger water valves;
3.
Turn on the fan control switch, select the gear, and adjust to required air flow.
This grader ventilation system includes natural ventilation and forced ventilation. The natural
ventilation is the result of the air pressure outside while the grader is running; the forced ventilation
utilizes a blower to force fresh air outside into the cab.
This grader pressure system is controlled by a high/low-pressure switch, and in the event of
abnormal A/C system pressure including little or no refrigerant and excessively high pressure,
disconnect the compressor to protect the A/C system.
ATTENTION
Turn off the heat exchanger water valves when cooling in summer, and turn off the
cooling change switch when heating in winter.
Refrigerating fluid for A/C system of G9165 grader is R-134a (Freon-free environmental
refrigerant). It features high heat absorptivity, easy to liquefy, non-inflammable and non-explosive,
stable chemical contents, non-toxic and non-corrosive.
Fig. 8-33
8-16
83 Disassembly and Assembly Of

Cab Assembly
831 Disassembly of Cab Assembly
1.
Before removal of cab, use a lifting rope to

hang the cab, hoist the cab properly until the
lifting rope is neither loose nor too tight.
2.
Disconnect the connection between cab and

multitandem valve.
Fig. 8-34
3.
Disconnect the connection between steering

gear and cab.
1
Fig. 8-35
1 Steering gear
8-17

4.
Disconnect the connection between foot brake

valve and cab.
1
Fig. 8-36
1 Foot brake valve
5.
Disconnect the connection between A/C hoses

and evaporator.
ATTENTION
The refrigerant shall be drained firstly in
this procedure.
Fig. 8-37
6.
1
Fig. 8-38
1 Pull the yellow part upward, and then
unplug the connector
8-18
Disconnect the rear frame wire harnesses.

7.
Disconnect the cab right-side wiring harnesses.
8.
Disconnect the wiring harness under the hand
Fig. 8-39
(parking) brake handle (on the bottom of cab).
1
Fig. 8-40
1 Wiring harness connector
9.
Disconnect the windshield washer motor

wiring harness and the water pipe(s).
Fig. 8-41
8-19

10. Disconnect the transmission control wiring
harnesses.
Fig. 8-42
11. Disconnect the engine throttle control wire.
1
Fig. 8-43
1 Engine throttle control wire
12. Disconnect the cab interior trim wiring

harness.
Fig. 8-44
8-20

13. Disconnect the fan heater water pipes.
Fig. 8-45
14. Remove the rack(s).
1
Fig. 8-46
1 Rack
15. Disconnect the hand (parking) brake.
Fig. 8-47
8-21

16. Remove the ROPS bolt.
Fig. 8-48
17. Remove the cab (damper) fixing bolts.
1
Fig. 8-49
1 Fixing bolt
18. Lift down the cab.
Fig. 8-50
8-22
832 Assembly of Cab Assembly

1.
As shown, connect the lifting device, lift the

cab and put it onto the rear frame. Do not let
the cab hurt the pipeline of the rear frame.
ATTENTION
Hook the cab lifting eye with the lifting rope
to lift the cab horizontally and align it with
Fig. 8-51
the mounting holes. Do not press down on

the hydraulic rubber hoses and wiring
harness connectors. Ensure that the cab is
smoothly lowered down in the course of
descending.
2.
Install the cab (damper) fixing nuts.
3.
Install the ROPS bolt.
1
Fig. 8-52
1 Fixing nut
1
Fig. 8-53
1 Bolt
8-23

4.
Connect the wiring harness under the hand

(parking) brake handle (on the bottom of cab).
1
Fig. 8-54
5.
Connect the windshield washer motor wiring

harness and the water pipe(s).
Fig. 8-55
6.
Connect the transmission control wiring

harnesses.
Fig. 8-56
8-24

7.
Fix the multitandem valve on the support with

bolts.
Fig. 8-57
8.
Connect the lower connecting rods to the

multitandem valve orderly.
Fig. 8-58
9.
1
Fig. 8-59
1 Steering gear
8-25
Connect the steering gear oil pipes.

10. Connect the foot brake valve pipes.
1
Fig. 8-60
1 Foot brake valve
11. Connect the rear frame wire harnesses.
1
Fig. 8-61
12. Connect the cab interior trim wiring harness.
Fig. 8-62
8-26

13. Connect the cab right-side wiring harnesses.
Fig. 8-63
14. Connect the A/C hoses to the evaporator.
Fig. 8-64
15. Connect the fan heater water pipes.
Fig. 8-65
8-27

16. Connect the hand (parking) brake.
Fig. 8-66
17. Connect the engine throttle control wire.
1
Fig. 8-67
1 Engine throttle control wire
18. Install the rack(s).
Fig. 8-68
8-28
833 Replacement of Seat

1.
Remove the bolts under the seat bracket.
2.
Take the seat out of the cab.
3.
Replace with new seat and install the bolts.
Fig. 8-69
Fig. 8-70
Fig. 8-71
8-29
834 Disassembly and Assembly of

Operation Box
1.
Remove the cover plate fixing bolts.
2.
Remove the shell plate fixing bolts.
3.
Take down cover plate and shell plate.
4.
Install cover plate and shell plate.
Fig. 8-72
Fig. 8-73
Fig. 8-74
8-30

5.
Install the shell plate fixing bolts, but do not

tighten them.
Fig. 8-75
6.
Install the cover plate fixing bolts. Tighten all

the bolts.
Fig. 8-76
8-31

Engine Hood
841 Disassembly of Engine Hood
1.
Remove the rear cover side plate(s).
2.
Disconnect the rear cover wiring harnesses.
3.
Remove the connecting bolts of rear cover and
Fig. 8-77
1
Fig. 8-78
frame.
1
Fig. 8-79
1 Bolt
8-32

4.
Remove the connecting bolts of engine hood

and rear cover.
1
Fig. 8-80
1 Bolt
5.
Lift down the rear cover.
6.
Remove the connecting bolts of engine hood
Fig. 8-81
and expansion water tank.
Fig. 8-82
1 Bolt
8-33

7.
Remove the connecting bolts of air filter cover

and engine hood.
Fig. 8-83
1 Air filter cover
2 Bolt
8.
Remove the fixing bolts of hydraulic oil tank

cover plate on both sides.
1
Fig. 8-84
1 Cover plate
9.
1
Fig. 8-85
1 Link
2
2 Bolt
8-34
Remove the link connecting bolts.

10. Remove the power switch.
1
Fig. 8-86
1 Power switch
11. Remove the engine hood fixing bolts.
12. Lift down the engine hood.
1
Fig. 8-87
1 Bolt
842 Assembly of Engine Hood

1.
Lift up the engine hood. Align the bolt holes

and put it down.
2.
Install and tighten the engine hood fixing

bolts.
1
Fig. 8-88
1 Bolt
8-35

3.
Install the power switch.
4.
Fix the expansion water tank on engine hood
1
Fig. 8-89
1 Power switch
1
with bolts.
Fig. 8-90
1 Bolt
5.
Fig. 8-91
1 Air filter cover
2 Bolt
8-36
Fix air filter cover on engine hood with bolts.
6.
Install the link with bolts.
7.
Lift and assemble hydraulic oil tank cover
Fig. 8-92
1 Link
2 Bolt
plate(s), tighten the fixing bolts.
1
Fig. 8-93
1 Cover plate
8.
Lift and assemble rear cover, tighten the fixing

bolts.
Fig. 8-94
8-37

9.
Connect the wiring harnesses.
1
Fig. 8-95
10. Install the rear cover side plate(s).
1
Fig. 8-96
1 Side plate
8-38

A/C System
Start the engine and drive the grader to smooth and
spacious ground. Fix the front of the front tires and
back of the rear tires with blocks. Keep the bucket
flat on the ground, and shut down the engine.
851 Disassembly
of
Evaporator
Assembly
1.
Drain engine coolant (about 28L), contain it

with clean vessel.
2.
Open the lockpin of the A/C hood assembly.
ATTENTION
Avoid directly contacting the refrigerant.
The removal and refitting of the climate
unit shall be conducted in a well-ventilated
area.
1
Fig. 8-97
1 Lockpin
3.
1
2
Fig. 8-98
1 Fresh air filter module
2 Return air filter module
8-39
Remove the filters.

4.
Disconnect the wiring harness connector of the

temperature control panel and fresh air door
motor.
1
2
Fig. 8-99
1 Filter cap
2 Air door wiring harness
5.
Disconnect
the
evaporator-control
panel
wiring harness connector and the evaporator

power wiring harness connector.
1
2
3
Fig. 8-100
1 Power wiring harness connector
2 Evaporator-control panel wiring harness
connector
3 Temperature control panel
6.
Disconnect the hose clamps of engine fan

heater water pipes.
7.
Remove the connecting bolts of the evaporator

and cab.
1
Fig. 8-101
1 Hose clamp
2 Bolt
8-40

8.
Remove the 2 connecting bolts of cab interior

trim panel and evaporator assembly.
Fig. 8-102
1 Interior trim panel
2 Bolt hole
9.
Take down the evaporator assembly and put it

in suitable place.
1
Fig. 8-103
1 Evaporator assembly
852 Assembly
of
Evaporator
Assembly
1.
Install the evaporator assembly.
2.
Connect the rubber hoses at the air vent of the

evaporator and air inlet of the cab.
ATTENTION
Keep
the
unobstructed.
1
Fig. 8-104
1 Evaporator assembly
8-41
air
vent
and
air
inlet

3.
Install the hose clamps of engine fan heater

water pipes.
4.
Install the connecting bolts of the evaporator

and cab.
Fig. 8-105
1 Hose clamp
2 Bolt
5.
Disconnect
the
evaporator-control
panel
wiring harness connector.

6.
Connect the evaporator power wiring harness

connector.
1
2
3
Fig. 8-106
1 Power wiring harness connector
2 Evaporator-control panel wiring harness
connector
3 Temperature control panel
7.
Install the 2 connecting bolts of cab interior

trim panel and evaporator assembly.
Fig. 8-107
1 Interior trim panel
2 Bolt hole
8-42

8.
Connect the wiring harness connector of the

motor.
9.
Install the filter cap.
1
2
Fig. 8-108
1 Filter cap
10. Close the lockpin of the A/C hood assembly.
11. Fill refrigerant.
12. Recover the machine.
1
Fig. 8-109
1 Lockpin
8-43
853 Replacement
of
Evaporator
Components
ATTENTION
The evaporator parts to be replaced should
be supplied with the same model and by the
same manufacturer, and do self-inspect to
make sure whether the replaceable parts
meet
all
the
technical
requirements.
Considering that there is nitrogen in the

A/C components and the system should be
free from impurities and moisture, connect
the pipeline immediately once you take off
the cap. If the pipeline is open, cover the
spout plug, or wrap it with a multilayer
plastic cloth instead.
Replacement of heater core

1.
Remove the evaporator assembly from the

grader, and put it on a platform.
2.
Remove the fixing plate installed on the right

side of the evaporator.
Fig. 8-110
1 Evaporator
2 Fixing plate
3.
Remove all the clamps, and dismantle the

housing.
1
Fig. 8-111
1 Clamp
8-44

4.
Take out the heater core and replace it.
5.
Refit the housing, and fix all the clamps.
ATTENTION
Check whether the fan has been installed in
the right place.
6.
Refit the heating system.
Fig. 8-112
1 Heater core
Replacement of blower
1.

2.

Fig. 8-113
1 Evaporator
2 Fixing plate
3.

housing.
1
Fig. 8-114
1 Clamp
8-45

4.
Disconnect the wiring harness connector, take

out the blower and replace it.
5.
Refit the housing, and fix all the clamps.
ATTENTION
Check whether the fan has been installed in
a right place.
6.
Refit the heating system.
1
Fig. 8-115
1 Blower
Replacement of expansion valve
WARNING
Please wear protective gloves to avoid
getting hurt by the oil.
1.
Completely drain the refrigerant out from the

system.
2.
Remove the filter and filter cap. Disconnect

the
wiring
harness
connector
of
the

1
2
Fig. 8-116
1 Filter cap
motor.
3.
Remove the fixing plate on the right upper side

of the evaporator. Disconnect the pressure
sensor connector.
Fig. 8-117
1 Fixing plate
2 Pressure sensor connector
8-46

4.
Disconnect the pipes from the expansion valve,

and remove the expansion valve. Block the
joint.
5.
Take down the plug and install a new

expansion valve.
ATTENTION
Make sure the inner cavity of the expansion
valve is clean, and lubricate the sealing ring
1
with compressor oil.
Fig. 8-118
1 Expansion valve
6.
Connect the expansion valve pipes.
7.
Connect the pressure sensor connector.
8.
Install the fixing plate.
9.
Fill the refrigerant into the system with a

vacuum pump.
Fig. 8-119
1 Fixing plate
2 Pressure sensor connector
10. Install the filter cap. Connect the wiring

harness connector of the temperature control
panel and fresh air door motor.
11. Recover the grader.
1
2
Fig. 8-120
1 Filter cap
8-47
Replacement of temperature sensor

1.

2.

Fig. 8-121
1 Evaporator
2 Fixing plate
3.

housing.
1
Fig. 8-122
1 Clamp
4.
Pull out the temperature sensor joint, which is

located
between
the
heater
core
and
refrigerator core. Replace the sensor with new

one.
1
Fig. 8-123
1 Heater core
2 Refrigerator core
8-48

5.
Refit the evaporator housing and install the

fixing plate.
1
Fig. 8-124
1 Fixing plate
6.
Install the filter cap. Connect the wiring

7.
Close the lockpin of the A/C hood assembly.
8.
Recover the machine.
1
2
Fig. 8-125
1 Filter cap
Replacement of evaporator
WARNING
Please wear protective gloves to avoid
getting hurt by the oil.
1.
Open the cover of evaporator assembly.
2.
Completely drain the refrigerant out from the

system.
1
2
Fig. 8-126
1 Filter cap
3.
Remove the filter and filter cap.
4.
Disconnect the wiring harness connector of the

motor.
8-49

5.
Remove the fixing plate on the right upper side

of the evaporator.
6.
Disconnect the pressure sensor connector.
7.
Fig. 8-127
1 Fixing plate
housing. Take out the evaporator and put it

aside.
8.
Loosen
the
bolts
and
install
the
new
of
the
evaporator.
ATTENTION
Make
sure
the
inner
cavity
evaporator is clean, and lubricate the

1
sealing ring with compressor oil.
Fig. 8-128
1 Evaporator
9.
Connect the pressure sensor connector.
10. Assemble the evaporator housing.
11. Install the fixing plate.
Fig. 8-129
1 Fixing plate
8-50

12. Install the filter cap. Connect the wiring
1
2
Fig. 8-130
1 Filter cap
13. Fill the refrigerant into the system with a
vacuum pump.
1
Fig. 8-131
1 Filing hose
854 Replacement of Condenser Fan

1.
Remove the peripheral bolts of condenser

cover.
2.
Unplug the plug of fan motor, remove

condenser cover and fan and put them on
cushion.
1
Fig. 8-132
1 Bolt
8-51

3.
Loose the 4 connecting bolts of condenser fan.
ATTENTION
Pay attention to the nuts inside.
4.
After replacing with a new fan, fasten the four

connecting bolts.
ATTENTION
When assembling the new fan, put the fan
wiring harness on the upper right position.
1
Fig. 8-133
1 Condenser fan bolt
2 Fan wiring harness
5.
Assemble condenser cover and fan to the

condenser.
6.
8-52
Recover machine.
855 Replacement of Receiver-drier

1.
Drain the refrigerant.
2.
Remove the steam storage pipe that connected

with the receiver-drier. Protecting the steam
storage pipe connector well is required.
3.
Remove the upper bolts that connecting

condenser and receiver-drier. Protecting the
condenser pipe connector well is required.
4.
1
2
Fig. 8-134
1 Steam storage pipe
2 Receiver-drier
3 Condenser pipe
Remove the bottom bolts that connecting

condenser and condenser pipe. Protecting the
condenser pipe connector well is required.
5.
Loose
the
fixing
bolts
connecting
receiver-drier support and condenser. Remove

the receiver-drier.
6.
Replace with a new receiver-drier and connect

it with steam storage pipe and condenser pipe.
Before connecting pipes, it is forbidden to
remove the plug cap. It can only be opened in
the last stage of installation.
7.
Install the receiver-drier fixing bolts.
8.
Fill refrigerant.
9.
Recover the machine and check A/C system.
Fig. 8-135
1 Fixing bolt of receiver-drier support
2 Condenser pipe
8-53
856 Replacement
of
Compressor
Components
ATTENTION
The evaporator parts to be replaced should
be supplied with the same model and by the
same manufacturer, and do self-inspection
to check whether the replaceable parts meet
all the technical requirements.
Considering that there is nitrogen in each
A/C components and the system should be
free from impurities and moisture, connect
the pipeline immediately once you take off
the cap. If the pipeline is open, cover the
spout plug, or wrap it with a multilayer
plastic cloth instead.
Replacement of compressor belt
1.
Put the machine in the maintenance position.
2.
Open the engine hood.
3.
Loose the connecting bolts and adjusting

screws, and then remove the belt.
4.
Install a new belt, adjust the tension, tighten

and adjust
the belt properly with
the
connecting bolt. If the belt goes down for

1
Fig. 8-136
1 Belt
10-12mm after being applied with the force of
about 10kg, the belt is adjusted properly. After
2 Adjusting screw
that, tighten the compressor.

5.
Recover the machine and test-run the A/C

system.
8-54

Replacement of compressor
1.
Open the engine hood.
2.
Drain the refrigerant completely out of the

system.
3.
Release the belt tension, and remove the belt.

Pull out the clutch wiring harness plug.
4.
Separate the compressor to condenser pipe and

evaporator to compressor pipe from the
compressor, put them aside for fixation, and
Fig. 8-137
1 Compressor to condenser pipe
2 Evaporator to compressor pipe
protect the condenser pipe connector well.

5.
Loose and remove the fixing bolts of

compressor, then take down the compressor.
6.
Drain the compressor oil into a calibrated

breaker (volume of the breaker should be no
less than 250ml).
ATTENTION
Pay attention to compressor oil.
The leaked compressor oil should disposed
in an environmentally friendly way
1
7.
Fig. 8-138
1 Belt
Replace the compressor with a new one

(pre-filled with 240ml compressor oil). Drain
the compressor oil completely out of the new
compressor.
8.
Fill the old compressor oil (obtained by step 6)

into the new compressor.
9.
Install the new compressor with the connecting

bolt, yet without tightening.
10. Pull off the plugs from the refrigerant pipe and
compressor, install the refrigerant pipe and a
new O-ring on the compressor, and lubricate
the O-ring with compressor oil.
11. Insert the connector, and install the refrigerant
pipe clamp.
8-55

12. Refit the belt onto the compressor, adjust the
compressor location so that the compressor
clutch belt groove and the engine belt groove
are on the same plane, and then adjust the belt
moderately.
13. Add the refrigerant into the A/C system again.
1
Fig. 8-139
1 Filling hose
857 Draining
and
Filling
of
Refrigerant
Refrigerant draining
Instruments:
1.
Refrigerant device
Vacuum pump
Adaptor
AC leak detector
Hose
Platform scale
Put the refrigerant container on the platform

scale.
Make sure the volume of the refrigerant
container is big enough to contain the
refrigerant.
Weight the refrigerant, weight of refrigerant =
weight of refrigerant and container weight of
refrigerant container.
1
Fig 8-140
1 Drain hose
Read the capacity of container from the

container.
2.
Make sure there is no pressure in the recovery

device.
3.
Connect the red draining hose of the

recovery device to the refrigerant container.
8-56

Connect blue absorption hose to low
pressure connector of the machine.
Drain
4.
Open the red hose valve on the refrigerant

container.
Open the valve on the refrigerant container.
Open the draining valve on the recovery
device.
Rotate the central controller to recovery
position.
Start the recovery device through the switch,
start draining.
Open the blue hose valve through the lower
Open absorption valve
5.
When the weight no longer increases, check

whether the pressure is lower than the vacuum
degree displayed on the pressure gauge.
6.
Fig 8-141
1 Scale displayer
2 Absorption
3 Central controller
4 Draining
5 Refrigerant container valve
6 Red hose valve
7 Refrigerant container
8 Platform scale
Close the absorption valve.

Close the blue hose valve through the low
Rotate the central controller to auto clean;
the blue pressure gauge falls to vacuum degree
again.
Close the recovery device.
Close refrigerant container valve.
Close draining valve.
7.
Disconnect the recovery device from the

machine.
8-57
Refrigerant filling, including vacuum

pumping
Vacuum exhaust
1.
Close all of the valves on the pressure gauge

box.
2.
Connect the red hose to the high pressure

connector on the machine.
Open the hose valve through the machine
connector.
3.
Connect the blue hose to the low pressure

connector on the machine.
Open the hose valve through the machine
1
Fig 8-142
1 Red hose
connector.
2
4.
2 Blue hose
Connect the yellow hose to the refrigerant

container.
Place the refrigerant container upside down on
the platform scale.
Check whether there is refrigerant in the
container. Weight of refrigerant = weight of
refrigerant
and
container
weight
of
refrigerant container.
5.
Open the two green valves on the pressure

gauge box.
Start the vacuum pump.
6.
Open the blue and red valves on the pressure

gauge box.
Start the vacuum gauge.
Keep the vacuum pump working at least for 50
2
3
4
Fig 8-143 Pressure gauge box
1 Vacuum gauge
2 Refrigerant container
3 Platform Scale
4 Vacuum pump
minutes.
7.
When reached the right pressure, close the two

green valves, red valve and blue one on the
pressure gauge box.
Close the vacuum pump.
8-58

Disconnect the hoses from the machine.
Filling
8.
Connect the adaptor to the low pressure

connector of the machine, and fill in the same
volume of oil consumed by system.
Remove the adaptor.
9.
Connect the red hose to the high pressure

connector of the machine.
Connect the blue hose to the low pressure
connector of the machine.
10. Press the TARA (reset the scale) on the scale
1
Fig 8-144
1 Adapter
displayer.
Open the yellow valve on the pressure gauge
box.
11. Open the blue valve, start filling.
12. Under the condition of opening AC power,
start the engine. Run the engine at the speed of
1000rpm.
13. When the platform scale shows the right
weight of the refrigerant, close the refrigerant
valve (refer to the information on the inside of
1
Fig 8-145
1 Red hose
the machine hatch).
Close the yellow valve on the pressure gauge

2 Blue hose
box.
14. Close the hose valve through the machine
connector.
Close all of the valves on the pressure gauge
box.
15. Open the red and blue valves through the
machine connectors and check the pressure at
the speed of 1800rpm.
16. Disconnect the red and blue hoses from the
machine.
8-59
86 Common Faults Diagnosis and Troubleshooting for A/C System

To inspect faults and troubleshoot the A/C system, determine the cause of malfunction definitely
according to the abnormal phenomenon of A/C running, and then take measures. The common
faults of A/C system include system cooling failure, insufficient cooling capacity, heating failure
and etc.
861 Regular Inspection Items

The grader A/C system which works in a rather severe environment may be damaged regardless of
whether it is working or not, so it's better to enhance the routine maintenance.
Frequently inspect all the pipeline connects of A/C system, the compressor fixing bracket and the
compressor belt which should be tensioned properly, observe the cooling system hoses which
should be free of wear, inspect the A/C system wiring harness, and keep condenser surface clean.
Table 8-1 Table of regular inspection items
Inspection items
Interval
Inspection content
Daily
Poor fastness, with gap.
Pipeline assembly
Connecting bolt
Loose connection, looseness of nut

and bolt.
Loose connection, looseness and
falling off of nut and bolt.
Condenser
assembly
A/C fan control
switch
Refrigerant
leakage
Yearly
Looseness and bend.

Belt
Half a year
Degradation, wear, bruise and

cracking.
Noise, off-flavor or abnormal

heating.
Cooling fin falls down.
Foreign materials clogging.
Start inspection, air volume and

switch control.
Change-over function.
Leakage in pipeline joints.
Leakage inside the components.
8-60

Refrigerant
quantity
Noise
Temperature
difference of
receiver-drier
Inspect the refrigerant quantity.

Compressor.
Condenser blower and evaporator
blower.
Surfaces that have temperature
difference are interfered with
foreign materials.
862 Analysis of Cooling Failure

Table 8-2 Analysis table of cooling failure
The evaporator
blower runs.
Inspect whether the blower

The compressor connector falls off, the ground is
fails to work.
normal, and the blower gets
damaged.
The
condenser
blower fails to
run.
Inspect whether the temperature
The compressor control switch gets damaged, the
works.
relay pulls in, the relay connector
is loose.
Inspect whether the clutch is
The
condenser The compressor
damaged, the connector falls off,
blower runs.
fails to work.
and the belt is loose or slips.
Cooling
failure
The evaporator
blower fails to
run.
The
condenser
Test whether the speed control switch malfunctions,
blower runs, and
the blower wire is disconnected, and the blower
the compressor
ground wire in good condition.
works as well.
The
condenser
Test whether the fuses are blown and the relay works
blower fails to
normally, and inspect connecting wiring harness for
run, neither the
looseness.
compressor.
Both
the
evaporator blower If the machine is not occupied for a long term,
The compressor
and
condenser R134a leakage occurs, inspect with a pressure
is normal.
blower
work gauge, and confirm whether there is R134a.
normally.
8-61
863 Analysis of Insufficient Cooling

Table 8-3 Analysis table of insufficient cooling
Insufficient
cooling
capacity
The
compressor
is normal.
The liquid receiver inlet and outlet are

Both the evaporator reversely connected.
blower and condenser
Inspect whether the expansion valve is
blower work normally,
blocked by ice or dirt, and replace the liquid
so do the evaporator
receiver.
and condenser.
Replace the R134a.
The
blower
runs Inspect whether the condenser surface has
normally, so do the been
blocked
by
the
incrustation
others.
accumulated.
864 Analysis of Heating Failure

Table 8-4 Analysis table of heating failure
Heating
failure
Inspect whether the solenoid valve pulls in.

The evaporator blower
Inspect whether the other valves of heater pipeline are not
runs normally.
switched on yet.
Inspect whether the speed control switch malfunctions, the
The evaporator blower blower wire is disconnected, and the blower ground wire
fails to work.
in good condition. Inspect whether the fuse is blown and
connecting wiring harness is loose.
865 Analysis of Other Faults

Table 8-5 Analysis table of other faults
S/N
Symptoms
Causes
Troubleshooting
The system performs cooling normally

at the beginning, and the insufficient
cooling capacity occurs after a while;
bubble can be observed from the sight
glass of liquid receiver; the high/low
pressure gauge readings are low.
Mostly driving on the

rough road, the vibration
results in connector
looseness
and
then
leaking occurs.
Detect the leak with a

leak
detector,
and
screw up the loose parts
carefully.
The system fails to carry out cooling,

with hot air from the vent, and no
temperature difference between the
expansion valve inlet and outlet after
testing by hand, and the low pressure
gauge readings are low.
Improper operation may

be the cause. The
Replace the expansion
expansion valve thermal
valve, and renew the
bulb is worn and leaking,
R134a.
which turns off the
valve.
8-62
The air out of the vent is not cool, and

the compressor temperature increases.
The low pressure gauge pointer goes
down rapidly, and gets close to 0,
while the high pressure gauge reading
remains high.
Impurities get into the

system, and block the
expansion valve strainer,
resulting in thin frost and
perspiring
on
the
expansion valve.
Intermittently starting
the cooling system may
resolve the instant
problem when the
blockage is not serious.
Or
remove
the
expansion valve and
clean it with alcohol
and renew the R134a
for the draining system.
The cooling capacity is insufficient, so

The orifice in the
that the evaporator gets frosted; the
expansion valve makes
high/low pressure gauge readings
no difference.
are low.
Drain
the
system,
replace the expansion
R134a.
After the system runs for a while, the

cooling capacity decreases gradually,
the high pressure gauge reading goes
up and the low pressure gauge reading
is less than 0.4Mpa.
The drying agent in the

receiver is saturate, and
the expansion valve
throttle is clogged by ice.
Drain
the
system,
replace the expansion
R134a.
The temperature control

After the cooling system is turned on,
switch is not connected
only air instead of cool air comes out,
well or the compressor
with the high/low pressure gauge
electromagnetic clutch
unchanged.
coil is damaged.
Inspect whether the

temperature
control
switch is damaged with
a multimeter; replace
the
compressor
electromagnetic clutch.
The temperature control

switch is turned on with
small opening angle, so
that the compressor stops
running, resulting in
insufficient
cooling
capacity.
Inspect the temperature

control switch, which
should be turned to the
maximum cooling
The
compressor
electromagnetic
clutch acts frequently, the engaged
time is short, with poor cooling effect,
and the high/low pressure gauge
readings are normal.
Precautions for troubleshooting cooling system:

1.
While troubleshooting the system, wear protective glasses and protective mask as many as
possible so as to avoid any direct contact with the refrigerant, which may cause frostbite,
and once any large amount of refrigerant contacts the human body, please wash with cold
water immediately.
2.
The cooling system should be repaired at a well-ventilated place because the refrigerant is
colorless, tasteless, and even leads to personnel suffocation due to anoxia.
3.
The refrigerant exposed to open flame will produce toxic phosgene, so keep away from any
8-63

fire sources.
4.
To avoid any risk of explosion, soldering or cleaning with hot steam is not allowed around
the A/C pipeline or its parts.
5.
During the replacement of system parts, make sure that the system connectors and system
inner cavities are clean. Meanwhile, replenish the refrigerator oil in accordance with the
standards shown in the table 8-6.
Table 8-6 Refrigerant capacity

Part name
Supplementary capacity/mL
Evaporator
40~50
Condenser
40~50
System connecting hoses
30~40
Receiver-drier
15~25
6.
After replacement of A/C parts, the pipeline joints, while being connected, should be
tightened to the specified tightening torque, which is shown in the table 8-7.
Table 8-7 Tightening torque

Thread dimensions
Tightening torque
5/8-18UNF, M161.5
16~20Nm
3/4-16 UNF, M221.5
20~25Nm
7/8-14 UNF, M241.5
30~35Nm
8-64

8cab & Covering Parts System - ENGLISG-G9165

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Service Manual of G9165 Grader

8 Cab & Covering Parts System

Service Manual for G9165 Grader

Service Manual for G9165 Grader

811 Cab Exterior Description

The cab is designed with FOPS&ROPS

absorbs the impact energy as well.

The G9165 cab is fixed on the rear frame using

Service Manual for G9165 Grader

The ROPS (Roll Over Protection System)

machine rolling over, the intensity will

reduce, and they cannot satisfy the normal

protecting function. In this case, please

Machinery Co., Ltd. or its designated

Service Manual for G9165 Grader

immediately, please contact with the nearest

812 Cab Interior Description

Service Manual for G9165 Grader

CD player/Radio control panel (Optional)

Gear shift control

to guarantee lubrication of the machine.

Turn signal lamp switch and front

Service Manual for G9165 Grader

Warning light switch

emergency to send alarm signals warn the

Working light switch

Press down the bottom end, both the front

and the rear working lights will be on.

Shovel blade light switch

of cab will not be on. Press down the top

end, they will be off.

Rear working light switch

Press down the top end, it will be off.

Service Manual for G9165 Grader

Locking cylinder switch

release the switch the cylinder will stop

retracting and be fixed at current position.

Reserved position for fan heater switch

fan heater will stop.

Rotating beacon switch

Service Manual for G9165 Grader

Windshield washer switch

Front windshield wiper switch

OFF that give two different working

Temperature control switches

Fan control switch

Fresh air switch

circulation of inside and outside air.

Cooling change switch

Service Manual for G9165 Grader

Cab light switch

Service Manual for G9165 Grader

Parking brake control handle

can use the lighter to light the cigarette, and

insert it back after that.

Tilt angle of steering wheel adjusting handle

Service Manual for G9165 Grader

11. Steering wheel and horn button

steering wheel and the horn will sound.

12. Safety hammer

Service Manual for G9165 Grader

Up/down of shovel blade

Shovel blade rotating