XCMG Motor Grader GR165 Trouble shooting

Power System

Sr, No.

Trouble Symptom

Cause

Remedy

1

Engine keeps running but the machine cannot move.

1. Gears not being engaged.

2. Hand brake is not released.

3. Oil level of the transmission system is too low.

4. Oil pressure of the gear-shifting box is too low.

5. There is some thing wrong with the torque converter.

6. The clutch or transmission part of the gear-shifting box gets broken.

1. Engage the or check if the gear engaged is correct or not.

2. Release the hand brake when air pressure being up to regulated value.

3. Refill with new oil.

4. Please see Trouble No.2.

5. Change the torque converter.

6. Check and repair the gear-shifting box.

2

Oil pressure of gear-shifting system is too low.

1. There is something wrong with main safety valve.

2. Serious oil leakage from clutch oil sealing.

3. Oil leakage from oil pipelines.

4. Failure with oil pump.

5. Oil filters being blocked.

1. Check and repair the control valve of gear-shifting.

2. Replace the new sealing ring and sealing seat.

3. Fasten the fittings for pipelines.

4. Replace the oil pump.

5. Replace the oil filter.

3

Gears or certain gear could not be engaged.

1. Low oil pressure for gear-shifting system.

2. Oil pipelines being blocked.

3. Serious oil leakage from clutch oil sealing.

4. Hand brake not being released.

5 、 There is something wrong with gear-shifting control handle or electrical switch for gear-shifting.

1. See Trouble No.2.

2. Clean or replace oil pipelines.

3. See Trouble No.2

4. Release the hand brake.

5. Replace gear-shifting control handle or electrical switch for gear-shifting.

4

Not enough driving power.

1. Not sufficient oil level or oil leakage from transmission system.

2. Too low oil pressure for gear-shifting system.

3. Improper adjustment for braking system. Braking wrench or hand brake not being completely released.

4. Torque converter oil temperature being too high.

5. Diesel edging working abnormally.

1. Refill with new oil after checking and repairing.

2. See Trouble No.2.

3. Check and Adjust gear-shifting system.

4. See Trouble No.5.

5. Check and repair diesel engine.

5

The overheating of torque converter and the transmission

1. The transmission system has insufficient or excessive oil.

2. The clutch slips.

3. The oil is too dirty or deteriorated.

4. The water tank and oil radiator are blocked or damaged.

5. The long continuous operation time or overload operation.

1. Check the oil level and adjust according to requirements.

2. Repair the clutch, correct the transmission pressure.

3. Change the liquid oil.

4. Clean regularly, replace when damaged.

5. Temporarily stop for cooling down, avoid overload.

6

Gear in disorder

1. The shift control handle is damaged.

2. The variable speed control electric control box is damaged.

1. Repair or replace the control handle.

2. Replace the electric control box.

Steering System

Sr, No.

Trouble Symptom

Cause

Remedy

1

Engine keeps running but the machine cannot move.

1. Oil temperature being too low.

2. Wrong connection for oil pipelines of pilot-control oil circuit.

3. Oil pipelines of pilot-control oil circuit being blocked.

4. Over flow valve in pilot-control oil pressure being too low.

5. The mounting bolts on fully-hydraulic steering mechanism being fastened too tight.

6. Oil from oil pump is too low.

1. Try to operate it again after oil temperature warming up.

2. Re-connect the oil pipelines correctly as required.

3. Clean the oil pipelines of pilot-control oil circuit.

4. Adjust the over flow valve pressure, as required.

5. Turn the bolts to make them get loose a little bit

6. Check and repair or replace the oil pump.

2

The steering wheel can still rotate after the machine steers to its max. Limitation.

There is something wrong with steering limitation mechanism.

Check and make repairing for steering limitation mechanism.

3

When steering resistant force is low, steering is all right, but when resistant.

1. Safety valve in pilot-control engage oil pressure being too low.

2. Safety valve core is stagnant or filter inside is too low.

1. Adjust the safety valve pressure as required.

2. Remove stagnant reason or exchange subassembly of safety valve.

4

When turning the machine, the machine doesn ’ t make steering.

1. Safety valve in pilot-control is lock.

2. Shrapnel of fully-hydraulic steering mechanism is break.

1. Remove stagnant reason or exchange subassembly of safety valve.

2. Check and repair the overflow valve of main oil circuit.

5

The machine makes steering by itself even without being operated by the operator.

1. Valve cover of fully-hydraulic steering mechanism is lock

2. Shrapnel of fully-hydraulic steering mechanism is break.

1. Clean out eye winker in valve.

2. Exchange the shrapnel.

6

Loud sound from steering pump, and steering cylinder piston moving slowly.

1. There is air inside the steering oil circuit.

2. The steering pump gets worn down, with insufficient oil flow.

3. Oil viscosity being thin.

4. Insufficient hydraulic oil level.

5. Pressure for overflow valve of main oil circuit is adjusted too low.

6. Serious oil leakage from steering cylinder.

1. Check the sealing status of inhales oil circuit and exhaust.

2. Check, repair or replace the steering pump.

3. Change the hydraulic oil, as required.

4. Replenish with new oil, as instructed.

5. Re-adjust the pressure for overflow valve.

6. Check and repair the hydraulic cylinder or replace the sealing ring.

Braking System

Sr, No.

Trouble Symptom

Cause

Remedy

1

There is not enough power or failure.

1. There is still air inside the braking hydraulic pipelines.

2. Oil circuit is walled up.

3. Too much clearance between the braking drum and braking discs.

4. There is oil on the braking discs.

5. Oil from oil pump is too low.

6. Pressure for sufficient liquid valve is low.

1. Bleeding air.

2. Clean out and dredge oil circuit.

3. Adjust clearance as require.

4. Clean out oil dirt and remove leakage trouble.

5. Check repair or replace oil pump.

6. Check repair or replace sufficient liquid valve.

2

The braking device can ’ t be disengaged soundly.

1. The braking valve bar being in wrong position, the piston being blocked, and the spring mal-functioning or being broken.

2. Oil circuit is blocked or oil circle is difficulty.

3. Clearance between the braking drum and braking discs is too few.

1. Check, repair or change the braking valve.

2. Clean out and dredge oil circuit

3. Adjust.

3

Parking brake is failure.

1. There is oil dirt on the parking brake mechanism.

2. Empty journey of the parking brake is too large.

1. Clean out oil dirt.

2. Adjust.

Electrical System

Sr, No.

Trouble Symptom

Cause

Remedy

1

After the key switch was turned to “ Start-up ’ , the engine motor could not run.

1. The pilot wire connection for starting-up electrical circuit gets loose or disconnected.

2. Poor electrical contact with starting relay, or wire coil gets burnt.

3. Chief switch of power supply not open up.

4. Key switch not open up.

5. Fuse getting broken.

6. Starting motor winding get broken.

7. Seriously insufficient electrolyte with the battery.

1. Fasten the pilot wire.

2. Polish the contact point or replace the electrical relay.

3. Open the Chief switch of power supply.

4. Open the key switch.

5. Replace the fuse.

6. Replace or repair it.

7. Recharge the battery.

2

Wrong display of gauges.

1. The wire connection gets loose or disconnected.

2. The sensor being broken.

3. Gauges being broken.

1. Fasten the wire connection.

2. Replace the sensor.

3. Replace the gauges.

3

The bulbs don ’ t light.

1. The fuse is broken.

2. The bulb is broken.

3. The wire connection gets disconnected.

1. Replace the fuse.

2. Change the bulb.

3. Fasten the wire connection.

4

The generator doesn ’ t work, or its current is too little or too much.

1. The generator doesn ’ t work, or its current is too little or too much.

2. The pulley belt gets too loose.

3. The regulator or the generator being broken.

1. Re-tighten the wire connection.

2. Adjust the tension of the pulley belt.

3. Replace the generator.

Hydraulic system

Sr, No.

Trouble Symptom

Cause

Remedy

1

Power of the mechanism is insufficient or even no power completely.

1. The pump serious worn out and serious inner leakage.

2. The oil temperature is too high, oil viscosity being thin.

3. Oil leaks from the pipeline system.

4. The over flow valve work abnormally or being blocked, the string abate.

1. Replace the working pump.

2. Debase oil temperature.

3. Find the oil leaking position and eliminate it.

4. Repair overflow valve and string.

2

Oil flux is too low.

1. Oil line is too low, cannot absorb oil.

2. Temperature too low, oil viscosity being thick, cannot absorb oil.

3. Serious inner leakage.

1. Stop machine, refill oil as require.

2. Increase oil temperature.

3. Repair or replace.

3

The working hydraulic oil gets mixed with gearbox oil.

Shaft gland fails for power oil pump

Replace the sealing ring.

4

Pump is found with abnormal noise and vibration.

1. Air get access into pump, and the oil level is too low.

2. The oil temperature is too low, or oil viscosity is too much high, or the pump pumps in air.

3. Something wrong with the pump.

1. Fill in more oil, or bleed out air.

2. Warm up oil temperature.

3. Repair or make replacement.

5

It is hard or heavy to operate the control joysticks.

1. The control valve is blocked.

2. The spring doesn ’ t function.

1. Clean.

2. Replace.

6

Cylinder performance is  not stable.

1. Air is built up inside cylinder.

2. Piston rings got broken.

1. Check and bleed out air.

2. Replace the sealing.

7

Too much oil temperature.

1. Too long time working, with being overloaded.

2. System pressure is too high.

3. Insufficient oil level inside oil tank.

4. Too high ambient temperature.

5. Too much internal leakage.

1. Stop working for a while.

2. Adjust to desired pressure.

3. Fill in oil.

4. Stop the machine, and let it cool down.

5. Check relative working mechanism.

8

When suctioning oil, vacuum exists.

1. Oil level being over low.

2. The oil suction tubes got blocked.

3. Air got access into oil suction tubes.

4. The hydraulic oil viscosity being too high.

5. Too serious oil leakage from gear pump.

6. Oil viscosity being too high during cold weather.

1. Replenish oil to required level.

2. Clean or replace to eliminate blockage.

3. Check and exhaust the air.

4. Change oil.

5. Repair or replace.

6. Keep close watch after the machine being started up.

Working Mechanism

Sr, No.

Trouble Symptom

Cause

Remedy

1

Working mechanism doesn ’ t work.

1. Cylinder got broken.

2. The safety valve being blocked or with leakage.

1. Replace the pump.

2. Repair.

2

The working mechanism could not be maintained at desired position.

1. The sealing rings in cylinder got damaged, resulting internal leakage.

The locking valves are out of order.

1. Replace the sealing ring.

2. Repair.

3

The blade vibrates when it is under working.

1. Too much clearance inside of blade sliding track.

2. Too much clearance on the slewing bearing.

1. Make proper adjustment.

2. Make proper adjustment.

4

The blade could not slew.

1. The driving motor and turbo box got broken.

2. The sliding track of slewing bearing got jammed.

1. Make replacement.

2. Make proper adjustment, and eliminate the blockage.

5

The blade could not perform side extending.

1. The guiding mechanism of blade got blocked.

2. The center slewing bearing has oil leakage.

1. Cleaning.

2. Repair.

1.

When the clutch is slipping

2.

When the clutch does not slip