You are on page 1of 48

Service Manual of G9165 Grader

SERVICE MANUAL

3 Electrical & Information
System

Service Manual for G9165 Grader

CONTENTS
3 Electrical & Information System ......................................................................... 3-1
31 Description of Electrical System ......................................................................... 3-1
311 Working Precautions for Electrical System ................................................ 3-1
312 Electrical System Description ..................................................................... 3-4
32 Power Supply and Starting System ..................................................................... 3-5
321 Battery.......................................................................................................... 3-6
322 Power Switch ............................................................................................. 3-13
323 Staring Switch............................................................................................ 3-13
324 Generator/Alternator.................................................................................. 3-14
325 Starter Motor.............................................................................................. 3-17
33 Instrument Monitoring System .......................................................................... 3-21
331 Instrument Panel ........................................................................................ 3-21
332 Sensors ....................................................................................................... 3-24
34 Lighting System ................................................................................................. 3-26
341 Front Combination Lamp Circuit .............................................................. 3-26
342 Front and Rear Lamp Circuit ..................................................................... 3-27
35 Reverse Alarm System & Electric Horn System .............................................. 3-29
351 Reverse Alarm System .............................................................................. 3-29
352 Electric Horn System ................................................................................. 3-30
36 Wiper and Cleaning System .............................................................................. 3-31
37 Shovel Blade Floating ....................................................................................... 3-33
38 Wiring Harness Routing .................................................................................... 3-34
39 Fault Inspection and Diagnosis ......................................................................... 3-39
391 Basic Method to Fault Inspection and Diagnosis ...................................... 3-39
392 Common Fault Diagnosis and Troubleshooting........................................ 3-42

I

make sure that the battery polarity connection is correct. the carelessness can lead to serious personal injury and grader damage. Power switch 1. Modification can impact the grader function. always turn off the power switch before any of the following situations occurs!  Grader will stop working for a long time  Operator will leave the grader for a long time  Oil stain on the grader will be removed  Grader will be subject to welding  Fastening the battery circuit 3-1 . rings and others metal objects from your arms. 3. Battery 1. 2. During electrical system operation. Before operating the electrical system. always observe the following descriptions and the relevant descriptions carefully. if the power switch is not turned off. always use the fully charged or fully featured battery. While replacing the battery. While installing the battery. make sure that the capacity of the new battery is equal to that of the replaced one. and even lead to serious personal injury and grader damage. which can lead to accidental fire or other grader damages! Therefore. While troubleshooting the electrical system. remove your wrist watch. Before start working on electrical system. many parts in the circuit are still charged.Service Manual for G9165 Grader 3 Electrical & Information System 31 Description of Electrical System 311 Working Precautions for Electrical System No modification to electrical system modification is allowed without the permission of our company. After the engine flames out.

bundle it up or replace it immediately. Compressed air and fluid can result in personal injury! If a pressure switch has to be replaced during maintenance.g. 5. 3. Bundle up the wiring harness and conductor properly and avoid any forcible wiring harness folding and bending. Keep the wiring harness and conductor as far away from hot parts as possible (e. 2. Otherwise. Keep the wiring harness and conductor as far away from oil and water as possible. and even fire on complete grader. 3. Prevent the wiring harness and conductor against frication with sharp metal edges. pay special attention to prevent oil and water from entering into the connector. Connect the connector properly: While connecting the connectors (especially when the connectors are relatively concentrated). CAUTION: While removing the 3-2 . always apply fuses of the same specification. and fix the wiring harness to a proper location that is free from wear.Service Manual for G9165 Grader  Maintaining or replacing the battery  When a fire or other accident occurs Fuse 1. 2. which can lead to many unpredictable faults. please hold the connector body and press its lock latches to separate the connector in two directions. engine block). always observe the lock latch for snap-fit. While overhauling the waterproof connector. please observe the letter identifications of connectors carefully in case of wrong connection. Therefore. Pressure switch 1. please make sure to release the pressure. While connecting the connector. please use SDLG accessories as far as possible. Wiring harness or conductor 1. While separating the connector. Only as a last resort should the accessories be purchased from market with great caution! Inferior fuses can result in immeasurable damage to the grader. the connector cannot be connected again unless they are cleaned and dried. The blade fuse and flat plate fuse adopted by this product must strictly conform to the relevant specifications in QC/T 420 Fuse-links for motor vehicles. To replace the fuse. Keep the wiring harness and conductor as far away from the moving parts as possible in case of snap break and wear. 4. 6. Connector 1. if a fuse has to be replaced during maintenance. Use of copper wire for emergency is not allowed. Do not hold the conductor and pull the connector out forcibly. When the wiring harness or conductor is found to be worn.

so these pipes should be covered. otherwise the machine will not start and move. If necessary.Service Manual for G9165 Grader pressure switch. wires or pressure pipe. Keep the integrity of the circuit when conducting relevant electrical operation. The high-temperature and high-pressure oil or water can result in personal injury! To replace the sensor. switch. use a tool to contact a metal mechanical part connected to the frame to discharge the static electricity from the tool. While replacing the element. After the repair is completed. Before maintaining the electrical system. fuse. 6. Electrical element The electrical equipment is sensitive and can be easily damaged by the electromagnetism or the static electricity from the tool or human body. etc. wear the goggle and gloves. the connection to this element should not be disconnected. Do not touch any individual electrical element. only hold the circuit board edge. 5. Therefore. the electrical element can be damaged. Disconnect the terminals of battery to prevent explosion of battery. When a certain electrical element is electrified. control device. Otherwise. 4. do not touch the circuit board. wire insulation may be damaged. make sure that the ground wire is safely connected. For welding. shut down the engine first. 2. Do not touch the plug pin on the electrical element. 3. Welding 1. be sure to install the wire connectors of the computer control panel. the following instructions should be observed: 1. 3-3 . electrical device and conductor. and wait until the engine and transmission housings are sufficiently cooled down. 2. ATTENTION Any complete circuit should consist of power supply. sparks may fall directly on rubber hoses. Sensor 1. While maintaining the electrical system. while doing the relevant electrical element operation. 3. and these pipes may suddenly rupture.

lamps. Machine system voltage is DC 24V. containing two batteries 12V in series. switches. located in the left side of the rear frame. As to the relationship and working principle between electrical equipment. 3-4 . Relays and fuses are mainly located in the distribution box behind operator's seat. you can see the relays in distribution boxes can be interchanged. please carefully read the electrical system circuit diagram. Power switch is located near the battery. and the line applies single system. when the switch turns to " " position. the vehicle power is turned on. When the switch turns to " " position. AC generator. after the cover of distribution box is removed. the vehicle power is off. For parking vehicles for a long term. starter motor.Service Manual for G9165 Grader 312 Electrical System Description Electrical system includes battery. turn off the power switch. A/C circuits and other electrical equipment. Negative pole is grounded. gauges.

Turn on the power switch.Service Manual for G9165 Grader 32 Power Supply and Starting System Starting switch Power relay 1 Power relay 2 P-ST Fuse TML (Start interlock) Flameout relay Flameout solenoid valve Fuse Starting enrichment Excitation resistor Battery Charging indicator signal Tachometer signal Gear selector Generator Power switch Fuse Starter motor assembly Positive end Control end Fig. Current of storage battery also passes through fuse 30A to flameout valve relay. terminal B and BR will be connected. and fuse block → #121 wire → connector CN4 → #121 wire → connector CN59 →contact point B of starting switch. Turn on the starting switch (turn the starting switch to ON). and the voltage of two batteries (connected in series with 24V rated voltage) will pass through #56a conductor → fuse 60A→ #56 wire → connector CN24 → #56 wire → connector CN5 → #56 wire. and current will pass through #28 wire → connector CN60 → #28 wire → 3-5 . and all the way to the power relay. 3-1 Power supply and starting system Principle description: 1. 2.

current passes through #22 wire → connector CN2 → #22 wire → flameout relay coil → #2e wire → connector CN23. The other path goes through connector CN23 to power on starter motor. 3-6 . 3.Service Manual for G9165 Grader connector CN23 → the holding coil of flameout solenoid valve will be electrified.h Reserve capacity: 230min Low-temperature starting current: 850A Fig. can absorb the overvoltage in the circuit at any time. then the coil of power relay will be electrified. At this point. The battery can be a reversible DC power supply connected to the generator in parallel to power on the electrical devices. The battery can supply large starting current to the starter motor in a short time to start the engine. 3-2 Storage battery wiring Main battery functions in a circuit: 1. thus protect the electrical parts from breakdown. 3. the voltage will pass through #2 wire → fuse block → the complete grader electrical load. and the #76 wire and gear selector will be electrified. so will #121. R1 and R2 will be connected. 2. The voltage will pass through #60 wire → connector CN2 → start interlock relay. The battery. A single battery can supply 200A~600A starting current to the starter motor in a short time (5~10s). Turn the starting switch to START. #28 #60 and #92 conductors. the #59 wire will output electrical signal to electrify the start interlock coil and pull in its contact. BR. also equivalent to a large capacitor. and the contact will be closed. the current will pass through the power relay. flameout magnetic valve will be electrified and the fuel passage open. 321 Battery The complete grader applies two water-free and maintenance-free lead acid batteries. if gear selector is in neutral. contact points B. Main parameters (single battery) Rated voltage: 12V Rated capacity of 20h: 120A. #56 wire and #2 wire will be electrified.

3-4 Principle of battery eye 1 Green 2 Black 3 White 4 Battery cover 6 Optical SOC indicator 7 Small green ball 3-7 5 Sight glass .Service Manual for G9165 Grader Features of maintenance-free battery The maintenance-free battery.  White: The battery will be scrapped.electricity is sufficient and the battery can work normally. Fig. 3-3 Battery eye Fig. also known as MF battery.lack of electricity is heavy and supplementary charge is required. An electrolyte densitometer is installed inside the maintenance-free battery. The sight glass of the densitometer can display in the following three colors:  Green: The electricity amount is above 65% . which can automatically display the electricity condition of battery and the electrolyte level.  Black: The electricity amount is below 65% . means that maintenance operations such as filling distilled water. checking electrolyte level and electrolyte concentration are not required during the period of normal use.

0±0. ★ATTENTION The battery should be charged in a well-ventilated area. During the constant voltage charging. the following methods are recommended for charging: At room temperature. and charge the battery for 16~24h at a constant voltage of 16. and pay attention to the electricity safety. out-of-service for more than 6 months since the delivery) or the battery status indicator turns black because the battery is over discharged due to the grader charging system failure or other misoperation.1V. connect the battery positive and negative to DC generator output positive and negative respectively. if the battery temperature exceeds 45°C or the charging current exceeds 25A. the voltage should be lowered appropriately and the charging time extended.Service Manual for G9165 Grader Charging specifications for battery If the battery is stored for a long time (for example. 3-8 .

5V and under 1 Over discharge (battery eye displays black) 1 Short circuit (battery eye mostly displays green) 1 Open circuit (battery eye mostly displays green) Voltage Load test Charge Replace Replace Green range Normal - Yellow range Undercharge Charge Undercharge Charge Short circuit or open circuit Replace Red range Fig.Service Manual for G9165 Grader Battery open-circuit voltage inspection Inspection content Diagnosis Solution 12.5V and above. 3-5 Storage battery tester 3-9 .4~11V. Battery eye displays green Normal Load test 12. Battery eye displays black Undercharge Charge 10.

2. Adjust charging voltage to 13. idle traveling Engine transmission belt is loose or circuit failure. 1. Battery eye displays black. High voltage regulator set value. Battery eye displays white. Negative wire is not disconnected for long term parking.8~14. Battery voltage is under 12V. 2. Recharging too long.6~29V). Battery box is deformed. 1. 3. and battery eye displays green. 3. Difficult to start. 1. Start too many time in a short distance. 2. Lead powder on polar plate is easy to fall off. 3.5V (charging voltage for two batteries in series should be 27. Overloaded battery. Adjust the electrical system Recharge the battery. Adjust electrical configuration of the grader. Replace the battery. 4. 2. Short circuit 2. 5. Overuse. Recharge voltage exceeds 16. . 1. 2. Test the battery with tester and the pointer is in yellow or red range. 7. There is acid mist on battery box. Electrical load is greater than charge level. Battery inner polar plate turns white Battery voltage is about 10. the lighting is poor. Short circuit of machine electrical system. 2. Undercharge 3. 2. Battery voltage is under 11V. 3. 2. Over discharge 2. Electrical appliance is not turned off when the machine is not in use. Low voltage regulator set value. 4. Adjust charging voltage (Refer to above-mentioned requirements). Charging circuit failure. 1. 4. overcharge or high temperature that results in polar plate short circuit. 6. Overcharge 3.5V. 2.2V. Manufacturing defect in battery. 1. 3. 1. 1. 3-10 Solution 1. Self-discharge is huge 1. Replace the battery if necessary. Idle traveling or traveling at night. 3. Replace the battery. Recharge the battery. Erosion of battery connector.Service Manual for G9165 Grader Diagnosis and troubleshooting of storage battery common faults Fault Phenomenon Causes 1.

3. 1. 2. Open circuit 3. . Negative and positive are inversely connected when charging. Replace the battery. Rack of fusion or short circuit in battery. Battery voltage is negative. Low electrolyte level. 2. Battery is overcharged Vent hole is blocked. 4. Unable to charge or electrolyte rise when recharging. The color of positive and negative polar plate is opposite. Inverse charge 2. 3-11 Replace the battery.Service Manual for G9165 Grader 1. 1. Battery voltage is 0V when discharging. Manufacturing defect in battery. Battery burst Battery container burst and acid splashing out. Replace the battery. Battery voltage is unstable.

Service Manual for G9165 Grader Fault diagnosis process for maintenance-free battery 3-12 .

the complete grader will not be electrified. or removing the battery wire. Before connecting the battery wire or retightening its connector. R1. the battery negative will be connected to the frame. please note to turn off the power switch in case of electric leakage or other accidents! 2.Service Manual for G9165 Grader 322 Power Switch The power switch controls the battery negative and frame (ground) for connection and disconnection. see the table below: TML B BR R1 R2 C P-ST OFF HEAT ON START 3-13 ACC . BR. the battery negative will be disconnected from the frame and the circuit will fail to form a loop. When the grader stops working. please always turn off this switch for the sake of safety! 4. Turn on the power switch. If the complete grader circuit fires or the engine does not flame out after the electric lock is turned off. and turn on the electric lock. For the function gears of starting switch. thus cannot be started. Before welding the complete grader. the complete grader electrical load will be electrified. C and ACC. even if the electric lock is turned on. turn off the power switch. or other accidents occur. 323 Staring Switch This power switch has six pins B. R2. Fig. please always turn off this switch. please turn off the power switch immediately! 3. Main parameters Voltage: 24VDC Continuous current for main contact point: ≤200A Transient current (5s): 1200A Working temperature: -40oC~120oC Duty rating: Current≤200A Continuous working Current≤1200A Conduction time is 5s. 3-6 Power switch WARNING 1.

Service Manual for G9165 Grader Method to determine the starting switch for damage: Disconnect the #121. pin BR and pin R1. pin B and pin BR. pin R2 and pin C. belt pulley. When the switch is in ON. the current will generate a magnetic field. At any moment. and set the digital multimeter to 200Ω resistance to check the switch as per the function gears (When the switch is in HEAT. #28. after starting. only the positive diode connected to the one-phase winding with the highest electric potential is 3-14 . otherwise. 3-7 Generator/alternator Working principle of generator The generator consists of rotor. #60 and #92 conductors from the starting switch. The excitation winding is generally wound around the rotor. pin R1 and pin ACC. charging indicator signal. is a supporting element for the diesel engine and powers on the electrical devices of the complete grader. D+: Input direct current. excitation. 2. B+: Generator positive. a simple sinusoidal electromotive force with the same three-phase frequency and amplitude. stator. and the rectifier is generally a six pipe bridge type full wave rectifier. fan. The unilateral conductivity of silicon diode can be applied to rectify. connected to battery positive. front/rear end cover and electric brush etc. Fig. Driven by the generator. pin B and pin BR. the power is supplied by the battery. 324 Generator/Alternator The generator. and 120º included phase difference will generate. When the switch is in START. When the DCV is applied to both ends of the excitation winding. Due to the effect of rotating magnetic field on the stator three-phase symmetrical windings. the stator is connected in delta shape. connected to storage battery in parallel. the magnetic field will rotate as with the rotor. pin B and pin BR. the switch is faulty. pin BR and pin ACC. If the connection is normal. remove the starting switch from the grader. and it should be repaired or replaced. the power will be supplied by the generator which charges the storage battery in the meantime. Before the grader gets started. pin C and pin ACC). make the generator work W: Tachometer signal. 1. the switch works well. pin BR and pin R2.

The generator terminal voltage is proportional to the generator speed: The variation range of engine speed is wide. Moreover. 4. 3. similarly. Fig. The filter capacitor is mainly used to filter out the spike pulse and high-frequency interference sent out by the generator. Turn on the electric lock. 3-15 . and the six diodes will be electrified in turn. measure the generator terminal voltage (with red probe connected to generator D+. The voltage regulator controls the connection and disconnection of switch tube to change the excitation current. and black probe to ground). only the negative diode connected to the one-phase winding with the lowest electric potential is electrified. thus a stable pulsating DC voltage can be obtained on both ends of the load. therefore. check the generator drive belt for looseness. the reading should be approximately 28V). check the generator ground for reliability at regular interval. start the grader. and record the reading of multimeter (this reading is actually the battery terminal voltage. and record the reading of multimeter (if the generator works normally. measure the generator terminal voltage again. a voltage regulator should always be set. Turn off the electric lock. and use a wrench to check the generator terminal for correct. secure and reliable connection. Set the multimeter to 200V DCV to do inspection. 2. and generally below 26V). Troubleshooting If the generator fails to generate electricity or the generating voltage is too low: firstly. the terminal voltage will vary greatly too.Service Manual for G9165 Grader electrified. 3-8 Working principle of generator Method to determine the generator for normal generation and troubleshooting 1. and the requirements for a constant voltage on electrical device of grader will fail to be met. which directly acts on the field’s strength to stabilize the generator voltage. As a result. repeat this cycle all over again. 5.

Generator fails to charge The main causes include generator fault. If the terminal is electrified. 3. If it is higher than the standard value. Remove the wire connection from the generator field terminals. If the terminal is electrified. set the multimeter to DCV (25V) with the red probe connected to the generator armature terminal post and the black probe to the generator housing. Start the generator and run it at a moderate speed. then the charging voltage is too high. slip ring. if the terminal is not electrified. and that the battery has faults. the starter runs weakly and even fails to drive the engine to run. Too high charging voltage If the generator voltage is too high. too loose belt. and check or replace the regulator.Service Manual for G9165 Grader Common fault diagnosis to generator and troubleshooting 1. it shows the charging voltage is too low. If it is lower than the standard value. 3-16 . it indicates that the generator output power can meet the requirements of the ignition system and the powered devices. If it is normal. rotor and stator or replace the generator. set the multimeter to DCV to measure the voltage at both ends of the battery or generator. generator inside fault or battery fault. the electric lock and the wire connecting the electric lock and the regulator can be open circuited etc. First of all. the charging indicator lamp flashes or the ammeter swings around the zero. a new electronic regulator should be replaced. check the fan belt for slippage due to loose tension. If there is no electricity. Then. readjust as required. turn on the electric lock switch. and measure the voltage on both ends of the battery or the generator. if the engine flames out. the wire connecting the regulator and the generator can be open circuited. Method: Disconnect the battery ground wire when the engine runs at a moderate or above speed. it indicates that both the battery and generator has fault. In this case. if the terminal is not electrified. go on checking the generator and battery for fault. Do further check to the components such as generator electric brush. if the engine runs normally. the regulator may be faulty. the generator may be faulty. check the regulator live wire terminal. The possible cause can be the unusual or faulty regulator operating voltage. regulator fault or electrical circuit fault etc. If there is electricity. 2. and use the multimeter (DC test lamp) to check the terminal. If too loose. and the water consumption in battery electrolyte can be too quick which may result from the unusual or faulty regulator operating voltage. Too low charging voltage When the engine is working. check the regulator field terminal. the bulb is easy to be burned out when the engine runs.

and the contact disc will disconnect. the 24V terminal voltage for the battery will pass through the starting relay contact to the starter motor. then normal torque will be generated to drive the crankshaft rotating. DC motor. After the engagement. the core under the influence of spring force will reset to the original position. the corresponding two magnetic fields will be in opposite directions. 3-17 . 3-9 Starter motor When the complete grader gets started (the electric lock is turned to START). the current of holding coil and pull-in coil will flow in an opposite direction. at the moment the driver releases the key of electric lock. therefore. the electromagnetic forces acting on the core will offset each other. At this time. thus. the contact disc will trigger the two main contact terminals of motor to be connected and the battery strong current will pass through the armature winding and excitation winding of the starter. making the engine get started. consequently the starter motor will stop running. the current of pull-in coil passing through the excitation winding and the armature winding will generate certain electromagnetic torque. the pinion gear. during its slow rotation. Fig. In this case. shifter fork and driving gear.Service Manual for G9165 Grader 325 Starter Motor The starter motor is a supporting element for the diesel engine and mainly consists of magnetic switch. thus realizing the engine start. The DC motor can convert the battery’s electric energy to mechanical energy and the driving gear can drive the engine flywheel. the drive pinion will exit from disengagement. will engage with the ring gear. After the engine gets started successfully. then the pull-in coil and holding coil will be connected to drive the pinion gear engaging with the flywheel gear.

the battery can subject to over-discharge. Therefore. 3-10 Use and maintenance of starter motor The operator does not have to do too much maintenance to the starter motor. 3. keep all the terminal posts in the battery circuit clean. Precautions: 1.Service Manual for G9165 Grader Fig. the starter motor should stop running immediately to reduce wear and battery electric energy consumption caused by the unnecessary running of starter motor. eliminate the fault and then restart. Moreover. engage the grader to N to increase the starting ability of the starter motor and decrease the engine’s drag torque. the temperature of the inside DC motor winding can increase too high and make the motor get burned out. stop for 15s and then try to start again. each start should not exceed 5s. first of all. 5. the section area of the cable and the materials in battery circuit should meet the requirements. If the engine cannot get started at a time. turn off all the electrical devices irrelevant to the starting. 2. thus affecting the battery life span. and connect them firmly to reduce the contact resistance. if the basic maintenance cannot be met. After the engine starts. if the starter motor keeps running for too long. and the cable overall length should be as short as possible to reduce the conductor resistance. thirdly. The voltage drop of starter motor positive or negative cable from any cause can degrade the starting performance. The starter motor sealing elements such as dust cover and gasket should be installed properly in case that the transmission lubricating oil and dust enters into the starter motor. thus resulting in hard start and even start failure. the operator may encounter great trouble. 3-18 . find out the cause. meanwhile. In general. 4. However. warm up the engine fully before the start to reduce the viscosity of the engine lubricating oil and decrease the engine’s drag torque. meanwhile. Before the start. secondly. If hard starting is caused by too low ambient temperature. If the engine fails to start for 3successive times. check whether the engine housing and battery negative ground are in good conditions because most of the starter motor housing are grounded.

Starter fails to work If the starter cannot work after it is powered on. If there is no voltage. too much wear of electric brush or lack of spring. the starting relay and starting switch may be turned off. inverter. however. 2. poor contact. motor switch ablation. negative switch and ground wire for reliable connection. Otherwise. electric lock or magnetic switch. Starter underpower The starter can drive the engine crankshaft to rotate. Starter idling 3-19 . starting relay fault or motor switch bonding. poor contact caused by oxidation corrosion. and local short circuit in motor armature and field winding. and too large starting drag torque caused by too tight engine assembly or too low ambient temperature. and motor electric brush. The possible causes can be battery feeding. start interlock relay and battery etc. While turning the electric lock to START. then the starter motor may have internal faults. if the starter still cannot work after the above-mentioned fault is eliminated. G9165 grader has start interlock function. or the connecting wire is open-circuited. the motor switch ablation. the running speed is too low and the engine cannot start smoothly. In this case. Starter cannot stop If the starter cannot stop working after the power starting switch is released. Troubleshooting: 1. and the starter motor runs itself. Check whether the transmission control lever is turned to neutral position. detect the conductor voltage at the magnetic switch of starter motor. the possible causes can be the power starting switch fault. indicating the decrease of loading capacity and the actual output power. the possible causes can be the fault in the magnetic coil of the starter magnetic switch. or replace the magnetic switch or the starter motor. armature and magnetic field open circuit. Troubleshooting: Grind the contact point and the moving contact disc again. Cause analysis: This fault generally results from contact point burnout of starting relay. Check the storage battery connection. 2) Symptom: During the start.Service Manual for G9165 Grader Common fault diagnosis to starter motor 1) Symptom: Turn on the negative switch. it can be concluded that the start failure is caused by the fault inside the starter motor. the starter motor does not have any reaction. and it will not get started unless the transmission neutral switch detects a signal. inverter ablation. looseness of battery connection terminal. check the electric lock.

or inverter ablation and electric brush poor contact etc. the possible causes can be the one-way clutch slippage. the possible causes can be the open circuit in magnetic switch holding coil. fork mechanism malfunction or seizure. The fault can be eliminated as long as the clutch is replaced. if the friction or whistling is constant. armature shaft bend and rotor out-of-round. starting relay damage. 3-20 . the possible causes can be motor sweep chamber caused by bearing wear. insufficient push-out by driving gear. too much gear teeth collision or wear.. Too large starting noise If rhythmic crash is produced during the start.Service Manual for G9165 Grader If the starter runs but the engine crankshaft cannot rotate. battery electricity shortage or poor pole contact etc. and fork shaft loss etc.

Generator terminal W Speedometer Range: 99999. unit: km/h.9. Unit: n/min. When engine speed ≥400n/min. Red range: 0-1/8 Sensor Brake air pressure gauge Reserved position Sensor 3-21 Signal source . red area: 2500~3000. Working hour meter Range: 99999.Service Manual for G9165 Grader 33 Instrument Monitoring System 331 Instrument Panel Fig. Red area: 103~120oC. 3-11 Instrument panel Gauges Name Function description Engine tachometer Range: 0~3000. the memory storage data every 1 minute. red area: 120~140oC Sensor Fuel level gauge Range: 0~1/8-1/4~3/8~1/2~5/8~3/4~7/8~1. alarm set point: 105oC Sensor Torque converter oil temperature gauge Range: 40~140oC. timing.9. Flashing every 6 minutes. Speed sensor Engine water temperature gauge Range: 40~120oC.

light Red Sensor Charging indicator light Red Terminal W Name Function description 1. Red Ground Turn ignition key to ON. turn off the switch. this indicator will flash and temperature alarm buzzer will ring. Red Ground Low fuel level alarm light When the fuel level is lower than 1/8. Ground Turn ignition key to ON. At the moment of starting up or flaming out. Turn ignition key to ON. turn off the switch. this red indicator light will flash. this indicator will be off. if the engine speed≥400n/min. After starting. this indicator will be on if Yellow course filter is blocked. oil pressure Oil-water separator alarm light Fuel filter restriction alarm light Turn ignition key to ON. this indicator will be on if Yellow oil-water separator switch is connected. Low brake pressure alarm light 1. After starting. this indicator will be off. this indicator will flash and buzzer will ring. this indicator will be off.Service Manual for G9165 Grader Alarm lights Color Signal source Before starting. if engine oil pressure is low and the switch is on. this indicator will not be lightened. this indicator is normally on. Ground Air filter restriction alarm light Turn ignition key to ON. this indicator is normally off no matter the switch is on or off. 3. Low gear shifting 2. turn off the switch and this indicator is normally off. Red Sensor Engine failure alarm light This indicator will flash and buzzer will ring if there is Yellow engine failure. this indicator will flash if Yellow filtration resistance is high and the switch is connected. this indicator will flash and buzzer will ring. Red Ground High coolant If water temperature≥105oC. this indicator will flash and buzzer will ring if the pressure is low and the switch is turned on. if oil pressure is low and the switch is on (delay 10s to determine whether the signal is true). Ground 3-22 . Ground High hydraulic oil temperature alarm light This indicator will flash and buzzer will ring if there is the hydraulic oil temperature exceeds the set value. turn on the switch and this indicator is normally on. Red Ground Before starting. Low engine oil pressure alarm light 2.

Green Power source Right steering indicator This indicator will flash if alarm light or right steering switch is turned on.Service Manual for G9165 Grader Turn ignition key to ON. Red Ground 3-23 . If water content in oil is bigger Transmission oil than set value. signal is power source. reverse-R. 2. Central alarm light Before starting. Otherwise. Green Power source Red Power source Power cut-off indicator This indicator light will be on if the power is cut-off. and audible alarm (buzzer) will Yellow stop. either light mentioned above is not lightened will lead to alarm of central indicator. Red Ground Safety belt indicator This indicator will be on if safety belt is not buckled up. N. 4 Neutral-N. this indicator will be on. connect the switch and this indicator will Yellow filter alarm light be on. Blue Power source Safety lock indicator This indicator will be on if hydraulic circuit is locked up by electromagnetic valve. gear indicator Equipped with KD function. Ground Red Indicator lights F. Preheating indicator This indicator will be on if the engine preheater is Yellow working. 3. this indicator will be on. Red Power source Mute indicator Turn on mute switch. Power source Left steering indicator This indicator will flash if alarm light or left steering switch is turned on. this indicator wouldn’t alarm if both low engine oil pressure indicator and charging indicator are lightened. Green Power source High beam indicator If front combination light is lightened in high beam form. R. 1. Ground Parking (hand) brake indicator This indicator will be on if parking brake is not relieved. forward-F.

The temperature sensor is a thermistor whose resistance will decrease if the temperature rises.Service Manual for G9165 Grader Low brake pressure alarm switch Oil Water Air temperature temperature Fuel level pressure Working Tachometer Speedometer gauge gauge gauge gauge hour meter Engine water temperature sensor Engine oil pressure switch Torque Rear wheel converter oil speed sensor temperature sensor Fuel level sensor Transmission box pressure sensor Fig. Overhaul when temperature gauge indication is abnormal: 3-24 . 3-12 Instrument monitoring system 332 Sensors Temperature sensor (Engine water temperature) G9165 is equipped with temperature sensor to monitor the engine water temperature.

Otherwise. If the wires are in good conditions. Fuel level sensor The fuel level sensor is actually a discrete slide resistor. then. The sensor is installed on the fuel tank. Replace the sensor. then it shows that the instrument and wires are in good conditions but the sensor is damaged. check the wires. 3-13 Fuel level sensor 3-25 . Troubleshoot abnormal indication by fuel level sensor: Remove the sensing wire (#19 conductor) from the fuel level sensor. low brake air pressure alarm switch and low engine oil pressure alarm switch). it shows that the instrument and wires are in good conditions but the sensor is damaged. As with the increase of fuel level. Fig. the pressure switch can trigger the alarm or send out control signal. the instrument itself may be faulty. reading when the sensing line is suspended. or it displays the min. When the tested pressure reaches the rated value. Working principle: When the tested pressure exceeds the rated value. If the instrument displays full range when the sensing line is grounded. the resistance will decrease. reading when the sensing line is suspended. displacement will occur to the free end of the flexible components. the instrument may be faulty. If the wires are in good conditions. The complete grader is equipped with two pressure switches (i. Pressure switch The pressure switch is a simple pressure control device.08MPa. or it displays the min. If the instrument displays full range when the sensing line is grounded. Push the switch directly or after the comparison to change the on-off state of the switch so as to control the tested pressure.e. when the brake pressure is lower than 11.5MPa or the engine oil pressure is lower than 0.Service Manual for G9165 Grader Remove the sensing line (engine water temperature corresponds to #14 conductor) from the temperature sensor. Replace the sensor. Otherwise. check the wires. the alarm indicator lamp will flash and audible alarm will sound.

and the current will flow to the rocker switch via #35 conductor and meanwhile to the contact points of front combination lamp high/low beam relay via #35 conductor.Service Manual for G9165 Grader 34 Lighting System 341 Front Combination Lamp Circuit Front headlamp high/low beam rocker switch Pin (Front headlamp (Front headlamp low beam) high beam) Steering lamp rocker switch Pin Position Position OFF OFF Front-right combination lamp Warning light rocker switch Small lamp Right steering Pin Position Headlamp OFF Front-left combination lamp Small lamp Left steering Headlamp Flasher Fig. #49 and #50 conductors will not be electrified. to close the contact point. If it turns black. and the coils of front combination lamp high/low beam relay will also be electrified. Common troubleshooting to front combination lamp 1. the bulb may be damaged. and it should be replaced. When the combination switch is turned off. #49 or #50 conductors will be electrified (24V). fuse F16 (10A) will be electrified (24V). 3-26 . alarm light and steering lamps Turn on the electric lock. Check the bulb for blackening. the front headlamps (high beam or low beam) will be electrified (24V) and they will work in corresponding positions at the same time. when the switch is turned on. and front and rear headlamps will not work. 3-14 Circuit diagram of front combination lamp.

connect them again. 3-15 Circuit diagram of front and rear lamps Turn on the electric lock. The current will pass through #47 and #39 conductors to electrify front lamp relay and 3-27 . Check the connector for reliable connection and wiring harness for wear. set the dimmer switch respectively to high beam and low beam positions. 4. Otherwise. the internal wiring of front combination lamp may get loosened or the bulb may be damaged.Service Manual for G9165 Grader 2. so will #47 and #39 conductors. If the voltage is 0V. Remove the connector. check the connector for reliable connection. Check the combination switch. In case of loose connection. 3. Check fuse F16 for blowout. fuse F14 and F15 will be electrified (24V). If the voltage is 24V. 342 Front and Rear Lamp Circuit Front/rear lamp rocker switch Pin (Front lamp) (Rear lamp) Rear headlamp rocker switch Pin Position Position (Rear headlamp) OFF OFF Left-front lamp Right-front lamp Left-rear lamp Right-rear lamp Rear headlamp Rear headlamp Fig. check as the steps below. and use the multimeter DCV to detect the voltage of #49 and #50 conductors at the connector. 5.

The current will pass to rear headlamp rocker switch. the current will pass through #74 and #75 conductors to electrify font lamp and rear lamp relay coils. the current will pass through #74 conductor to electrify font lamp relay coil. fuse F13 will be electrified (24V). #4 conductor will be electrified and the rear headlamps will be on.Service Manual for G9165 Grader rear lamp relay. When the rocker switch is turned on. the current will pass through #79 conductor to electrify rear headlamp lamp relay coil. Meanwhile. When the rocker switch is turned to position “II”. so will #45 conductor. #34 conductor and #71 conductor will be electrified and the left and right front lamps and rear lamps will be on. and relay contact will be closed. 3-28 . the front/rear lamp rocker switch will be powered on. When the rocker switch is turned to position “I”. and relay contact will be closed. and relay contacts will be closed. #34 conductor will be electrified and the left and right front lamps will be on.

Common faults analysis Turn on the electric lock and engage a reverse gear. and reverse relay coil and #9 conductor will be electrified. and the buzzer will ring. Engage to a reverse gear. Check F12 fuse for blowout. 2. Check the connector and conductor for firm and reliable connection. 3-16 Reverse alarm system & Electric horn system 351 Reverse Alarm System Turn on the electric lock. and F12 fuse (#48 conductor) will be electrified (24V). if the reverse alarm does not buzz: 1.Service Manual for G9165 Grader 35 Reverse Alarm System & Electric Horn System (Reverse) (Horn) Reverse buzzer Horn button Reverse switch Horn assembly Fig. the reverse switch will be connected. #9 conductor open circuit 3-29 .

it can be concluded that the electric horn is damaged). engage the switch to REVERSE. if there is no voltage. 4. Turn on the electric lock. Under normal condition. and they are. caused by #9 conductor and certain power wire short circuit. the buzzer keeps buzzing regardless of the gears. and the electric horn will keep buzzing. If the above-mentioned problems do not occur. the alarm can be damaged and it should be replaced. the connector may get loose or wiring harness may be worn in general. 2. when the electric horn switch is pressed down. horn relay will be electrified. 3-30 . press down the electric horn switch. release the switch and the buzzing will stop.Service Manual for G9165 Grader in the middle generally results from connector looseness or wiring harness wear. and the two corresponding conductors will be connected. 3. Common faults troubleshooting Turn on the electric lock and press down the electric horn switch. 3. fuse F17 and #40 conductor will be electrified (24V). such events generally result from the adhesion of reverse switch contact. but electric horn fails to alarm: 1. please check the voltage of #9 conductor. #12 wire will be grounded. Check whether the electric horn switch (button in the middle of steering wheel) works normally. Check the reverse switch for damage. 352 Electric Horn System Turn on the electric lock. Check the connector for looseness and wiring harness for wear. in rare occasions. Check F17 fuse for blowout. If it is in good condition. If the electric horn does not sound. If the voltage is normal (24V). 4. Check the electric horn for damage (Connect the two terminal posts of electric horn to the 24V power and the ground respectively.

the spray (washer) switch (i. auto reset rocker switch) will be turned on. 3-17 Wiper and cleaning system Working principle of cleaner Turn on the electric lock. 3-31 . then the water in the reservoir can be pumped to the nozzle (installed below the cab windshield) and sprayed to the windshield.Service Manual for G9165 Grader 36 Wiper and Cleaning System Rear wiper Rear wiper rocker switch Sprayer motor Sprayer motor Sprayer rocker switch Pin Pin Position White Blue Black Red Black Position OFF OFF Front wiper 3 rocker switch Front wiper 2 rocker switchFront wiper 1 rocker switch Pin Pin Pin Position Position Position OFF OFF OFF Front wiper 1 Red Black White Blue Black Front wiper 2 Red Black White Blue Black Front wiper 3 Red Black White Blue Black Fig. and the injection motor (installed to the water reservoir) will be electrified to work by #37 conductor.e. the F9 wiper fuse will be electrified (24V).

#37 conductor will be electrified (24V). connected to the ground at the original position. White: The other armature brush lead for low gear armature. Blue: The other electric brush lead for high gear armature. Gear II: High speed gear. Check the connector for looseness and wiring harness for wear. Common faults troubleshooting Wiper motor fails to work 1. Check the wiper switch for damage. 3-32 . 2.Service Manual for G9165 Grader Working principle of wiper The wiper motor is a permanent magnet motor. Sprayer nozzle fails to spray water out 1. The five conductors outside the wiper motor are as shown: Red: Power wire. 2. Gear I: Low speed gear. Black: Reset wire. pin 37 connected to pin 26. Check the waterway for disconnection (water pipe breaks or is over-tightened). Check the F9 wiper fuse for blowout. After the electric lock is turned on. 4. Observe whether the motor is running and pumping water. 3. OFF: Pin 24 is connected to pin 25 to ensure that the wiper can always stay in the original position. Check the armature of wiper motor for short circuit or open circuit. pin 37 connected to pin 25. Check the nozzle for blockage. 3.

3-33 . 3-18 Shovel blade floating system Turn on the electric lock. the F6 fuse and #42 conductor will be electrified.Service Manual for G9165 Grader 37 Shovel Blade Floating Left shovel blade floating switch Right shovel blade floating switch Pin Position Pin Position OFF OFF Shovel blade floating solenoid valve Right floating Shovel blade floating solenoid valve Left floating Fig. and you can operate the rocker switch to control the blade solenoid valves.

Service Manual for G9165 Grader 38 Wiring Harness Routing Rear frame wiring harnesses To front frame wiring harness To battery “+” To starter motor To speed sensor To brake taillight switch To transmission box To transmission box pressure switch Oil temperature sensor To water temperature sensor To engine oil pressure switch To rear cover wiring harness To generaotr To fuel level sensor Fig. 3-19 Sketch map for rear frame wiring harness routing 3-34 .

To starter motor Plug No. Fuse To front frame wiring harness port Wire No. Wire No. To instrument desk wiring harness port Plug No. 3-20 Rear frame wiring harnesses Wire No. Reverse buzzer Fig. To water temperature sensor Wire No.25 White 6 Right steering lamp wire 0. Rear wheel speed senssor Generator wiring Excitation resistor wiring Plug No. To flameout solenoid valve Plug No. Plug No.25 Black 5 Red 2a/2b Generator charging wire 4 Rear cover work light wiring 1. Plug No. Wire No. Wire No.85 White 9 Reverse buzzer & reverse lamp wiring 0.Service Manual for G9165 Grader To battery “+” To rear cover wiring harness port Fuel level sensor Transmission box oil pressure switch Plug No.85 White 8 Brake lamp wiring 0. Plug No.85 White 3-35 .85 White 7 Left steering lamp wire 0. Engine oil pressure switch Brake taillight switch Plug No. Wire No. Torque converter oil temperature sensor Plug No. Name Sectional area (mm2) Color 0 Ground wire 5 Black 0c Ground wire 1. Wire No. Wire No. Wire No. Wire No.

85 White 22 Electric lock to starting relay wiring 0.85 White 19 Fuel level sensor wire 0.85 Red 81 Speed sensor signal wire 0.85 White 15 Torque converter oil temperature sensor wire 0.85 Red 5 Red 56/56a Battery relay positive wiring 65 Signal wire of lock cylinder probity switch 0.85 White 20 Generator charging alarm wire 0.25 White 13 Hand brake indicator light wiring 0.85 Red 29 Power wire of flameout relay holding coil 1.85 White 86 Unlocking solenoid (lock cylinder) valve wiring 0.85 Red 42 Power wire of lock cylinder probity switch 0.85 White 14 Engine water temperature sensor wire 0.85 White 34a Shovel blade work light wiring 1.85 White 32 Low brake pressure alarm lamp wiring 0.0 Red 3-36 .25 White 40 Power wire of reversing light and brake light 0.85 Red 80 Instrument panel power wire 0.25 White 2e Power wire of flameout valve pull-in coil 2.85 Red 28 Battery relay coil positive wire 0.85 White 18 Signal wire of brake air pressure gauge 0.Service Manual for G9165 Grader 10 Front headlamp high beam wire 1.25 White 30 Wire of width lamp and backlight 0.85 Red 153 Horn power wire 1.85 White 73 Working hour meter wiring 0.85 White 31 Engine oil pressure alarm signal wire 0.85 White 85 Locking solenoid (lock cylinder) valve wiring 0.85 White 17 Transmission box oil pressure sensor wire 0.25 White 11 Front headlamp low beam wire 1.85 White 125 Power wire (5V) of speed sensor 0.

Service Manual for G9165 Grader Front frame wiring harnesses To rear frame wiring harness To low brake pressure alarm switch To blade light Proximity switch To lock cylinder solenoid valve Fig.25 White 12 Horn button wiring 0.85 White 85 Locking solenoid (lock cylinder) valve wiring 0.25 White 11 Front headlamp low beam wire 1. Name Sectional area (mm2) Color 2 Black 0 Ground wire 6 Right steering lamp wire 0.25 White 42 Power wire of proximity switch 0.85 White 7 Left steering lamp wire 0.85 White 30 Wire of width lamp and backlight 0.85 White 34a Shovel blade light wiring 1.85 White 13 Hand brake switch light wiring 0.85 White 32 Low brake pressure alarm lamp wiring 0. 3-21 Sketch map for rear frame wiring harness routing Wire No.85 White 86 Unlocking solenoid (lock cylinder) valve wiring 0.85 White 153 Electric horn control wire 1.85 White 10 Front headlamp high beam wire 1.85 Red 65 Signal wire of lock cylinder probity switch 0.25 White 3-37 .

Wire No. Low brake pressure alarm switch To lock cylinder To lock cylinder Plug No.Service Manual for G9165 Grader Front-left combination lamp Front-right combination lamp To horn Plug No. Wire No. Plug No. Hand brake indicator switch To rear frame wiring harness port Wire No. To horn To ground Work Proximity switch (lock cylinder) light Work light Plug No. Fig. Wire No. 3-22 Front frame wiring harnesses 3-38 .

the ground point should be firm. Inspection of the electrical circuit condition When doing technical maintenance to the grader or the driver finds out any fault. protector etc. 3. 4. oil stain and ablation. check the appearance of the entire grader electrical circuit. Fixation: All electrical components and wires should be fixed reliably. In other words. For the specific method: you can search from the power to electrical devices along the flow direction of operating current or from the electrical devices to power against the flow direction of operating current. mainly including: 1. and the housing and components should be in good conditions. The electrical diagram can be read and understood with the principle of breaking up the whole into parts and the principle of closed circuit. Connection and cleaning: The connectors should be connected firmly. To form a loop. The electrical devices are connected in parallel and controlled by relevant switches via controlling the power wire and the ground wire. the contact point should be free from rust. therefore. There are two power supplies on the loader. the electrical devices have to be grounded. you should get familiar with its working principle. dirt and dust. search from the electrical device.Service Manual for G9165 Grader 39 Fault Inspection and Diagnosis 391 Basic Method to Fault Inspection and Diagnosis Circuit analysis The circuit analysis method is studying the circuits of various parts from part to whole gradually. 2. It is helpful to circuit troubleshooting if the conductor can be easily found out from two connected devices. the generator and the battery are connected in parallel with circuit protector set in between. The electrical circuit diagram features the following: 1. and to the power positive. through the circuit switch. and the wire surface should be free from oil stain. The electrical devices for the grader apply the single-wire system. To study a certain circuit. While analyzing the circuit principle. analyze and take grasp of the circuit depending on its nature of work and applying the relevant connecting principles. 2. 3-39 . along the circuit. the faults caused by poor electrical element ground should not be ignored while searching for the fault. The circuit protectors are installed in all electrical circuits to avoid circuit damage or electrical device damage caused by short circuit or ground. It is more convenient to search the unfamiliar circuits in the latter one.

or the battery may be over discharged or faulty. Test battery electricity leakage 3-40 . In general. 2. and the voltage on both ends of the battery should be higher than 9. 4. Select a voltmeter with range of 0~3V and precision more than 1. keep the headlamp on for about 30s. The circuit resistance can be measured by ohmmeter. Therefore. 5.5V. and that of the starting circuit should be no higher than 1V. it is not allowed to apply clashing method to check the circuit. Insulation and shielding: The wire insulating layer should be free from damage and aging. it is more reasonable to determine the conductor and the contact point state by measuring the voltage drop when the normal current is through. the circuit voltage drop is 0. Measure circuit voltage drop The voltage drop test method can be used to test the conductors. To measure the battery voltage.5V within 15s. 1. As one of the daily maintenance items for grader. If it is lower than this value. Measure the voltage between the battery positive and negative. and the selected fuses and relays should be complete and meet the rated values of the circuit. Test voltage The technical conditions for the starting and power system can be determined via measuring the voltage of the relevant parts. While the electrical elements are applied in the circuit. and then turn off the headlamp. Turn the electric lock to START to run the engine. and it should be higher than 12.Service Manual for G9165 Grader 3. But the voltmeter and the DC lamp can be used.0 grade.1V. 3. or the starter motor may have fault. the low voltage and the current cannot indicate actual condition. starter and connecting wire state. Measure the starting voltage to determine the battery. the connector of the battery cable may be corroded or connected poorly. Instrument detection Use the instrument or special detector to check the electrical circuits accurately to determine the faulty part and eliminate it. the wire connection should contact well. remove the floating electricity from the battery surface. Fuse and relay: The fuses and relays should be installed firmly. however. battery cables and connectors. it is of great importance to the correct application of electrical system and the timely troubleshooting etc. and the wire shielding layer should be free from breakage and scratch. the exposed area should be covered by adhesive tape. Switch operating condition: The switches and buttons should move smoothly without any stagnation or failure. and shift the circuit to working state.

Check open circuit and short circuit Check open circuit: Use the test lamp or special tool to check for open circuit. Check short circuit: When a short circuit occurs. Disconnect the electrical devices controlled by the fuse one by one. which. Turn off all switches to electrical equipment and measure the current between the battery negative and the ground. Disconnect the controlled electrical devices one by one. The commonly used methods are as follow: Method A: Ohmmeter: Connect one probe to ground point and the other to the fuse connection. The place where the pointer does not move is the short circuit point. 3-41 . in general. Otherwise. should not exceed 30 mA. The current of the grader with ECS should be no more than 300 mA. or faulty regulator or ECU. or short circuit in the generator diode or too large leakage current. connect the test lamp or special tool between the circuit connector and the ground. Method B: Buzzer: When short circuit occurs. The causes should be found out before the replacement of the fuse. the buzzer will sound. if the buzzer does not sound. 4. and hold the gaussmeter to test the pulse magnetic field near the conductors along the circuit. (Grader electrical devices are connected in parallel) Method C: Check with circuit interrupter and fluxmeter (gaussmeter): Connect the circuit interrupter to both ends of the fuse. if the lamp is not on.Service Manual for G9165 Grader The battery electricity leakage test can determine faults such as ground and insulation damage. there is open circuit. then short circuit occurs in the device. and the short circuit occurs if the resistance is zero or very small. Turn on the corresponding switch. the fuse (fuse wire) can be burned out. if the resistance increases. the battery leaks electricity. short circuit occurs in the devices. The possible causes can be electricity leakage from circuit switch/conductor or poor insulation. or faulty switch.

Turn on the main power switch 2. but the is faulty and cannot handling entire grader does not output neutral signal to 3. Electric lock is damaged 6. Check the circuit carefully. and replace the fuse 5. The contact point of motor starter motor control is sintered 3-42 . Power relay is damaged 7. Starting relay contact 2. Recharge or replace the battery 4. The transmission control lever is not engaged to NEUTRAL 1. Ask professionals for to START. Replace electric lock 2. Main power switch is not turned on 2. Replace start interlock response starting control circuit relay 3. Transmission control unit 2. Start interlock relay is faulty After starting. the power relay pull-in Entire grader cannot be heard and out of power the entire grader’s electrical load is powerless Start failure Cause Troubleshooting 1. Battery circuit connectors are loosened 8. Wiring harness connectors are loosened 1.Service Manual for G9165 Grader 392 Common Fault Diagnosis and Troubleshooting Fault name Symptom When turning on the electric lock. Master power switch is damaged 3. 80A and 10A fuses blow out 5. Check and connect the relevant connectors again 1. Replace the power relay 7. Engage to NEUTRAL Turn the electric lock 2. Check and tighten the cable connections 8. Replace the electric lock 6. The electric lock is stuck and in failure 1. Replace the main power switch 3. Repair or replace starter 3. Battery is heavily lack of electricity 4. Electric lock cannot starter motor return to original works position continuously 1. find out the cause. Replace starting relay point is sintered 3.

Polish. open circuit. Handle or replace the starter motor depending on actual situation . Find out the cause. Check the starter motor Turn electric lock to Starter motor START. ground. Starting control circuit cannot rotate motor does not faulty element faults such as open circuit or rotates response or rotates 4. Check the pull-in coil or or poor connection. weakly slowly. Check driving gear. starting relay damage etc. resulting in holding coil for short electric lock damage. or Turn the electric lock to 3. Starter motor DC motor replace them faults 5. clean and tighten 2. the starter the circuit or replace the 3. Battery circuit wiring the battery connecting terminal is seriously circuit oxidized and corroded. Check the fork for breakage or disengagement 5. and engine start failure circuit. Recharge or replace the 1. Check all the one-way clutches for slippage 2. Faults of starter motor point and wiring terminal control for ablation. flywheel ring gear and armature shaft bush for serious wear 4.Service Manual for G9165 Grader 1. the starter Starter motor transmission motor runs at high run idling mechanism is faulty speed but engine runs slowly 3-43 1. Battery is heavily lack of battery electricity 2. repair loosely connected Starter motor START. and the contact 4. Check driving gear or flywheel ring gear for damage 3. handle or 5.

and the fork disengages from original position etc. The last three causes are starter motor inside faults. Battery is lack of electricity or faulty 2. Auto flame out Grader can start. Check flameout control circuit . Repair or replace the starter motor 4. clean and tighten the battery connecting circuit 3. Battery circuit wiring terminal is oxidized. and flames out fuel supply is unsmooth automatically in a short 2. The cut-off voltage for Starter motor Turn electric lock to relevant relays in driving gear START.Service Manual for G9165 Grader 1. Polish. corroded or connected loosely 3. flywheel ring gear and armature shaft bush are seriously worn 7. Recharge or replace the battery 2. but it 1. Replace the starting relay 5. Clearance between collision collision driving gear and stop ring is too large 6. Isolator spring is too soft or broken. Flameout control circuit time is faulty 3-44 1. Straighten out the fuel supply pipeline 2. Repair and replace the starter motor after the specific cause is found out 1. and the starter starting control circuit is and flywheel motor driving gear and too high has gear flywheel has gear 5. Driving gear. Starter motor holding coil is faulty 4. Diesel pipe is bent.