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ENGINE SYSTEM MOTOR GRADER G9165
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Service Manual of G9165 Grader
2 Engine System
SERVICE MANUAL
Service Manual for G9165 Grader
I
CONTENTS
2 Engine System ..................................................................................................... 2-1
21 General ................................................................................................................. 2-1
211 Engine Functions ......................................................................................... 2-1
212 Main Function Bodies of Engine ................................................................. 2-3
213 Engine Technical Parameters ...................................................................... 2-4
22 Cooling System .................................................................................................... 2-5
241 Overview of Cooling System ...................................................................... 2-5
23 Lubrication System .............................................................................................. 2-6
231 Overview of Fuel System ............................................................................ 2-6
24 Fuel Supply System ............................................................................................. 2-8
241 Overview of Fuel System ............................................................................ 2-8
25 Intake & Exhaust System .................................................................................. 2-10
251 Overview of Intake & Exhaust System ..................................................... 2-10
26 Disassembly & Assembly of Engine System .................................................... 2-11
261 Disassembly of Engine .............................................................................. 2-11
262 Assembly of Engine .................................................................................. 2-21
263 Disassembly and Assembly of Fuel Tank ................................................. 2-30
264 Disassembly and Assembly Of Radiator ................................................... 2-35
27 Diagnosis and Troubleshooting of Engine Common Problems ........................ 2-43
271 Engine Fails to Start .................................................................................. 2-43
272 Engine Power is not Sufficient .................................................................. 2-43
273 Exhaust Exceptions (Black Smoke, White Smoke, Blue Smoke) ............ 2-44
274 Engine Oil Pressure is Too High or Too Low ........................................... 2-45
275 Large Consumption of Engine Oil ............................................................ 2-46
276 High Coolant Temperature ........................................................................ 2-46
Service Manual for G9165 Grader
1
2 Engine System
21 General
211 Engine Functions
G9165 grader is applied with WEICHAI DEUTZ
WP6 engine.
The engine is in-line, 6-cylinder, water-cooled,
direct injection, 4-stroke, turbocharged diesel
engine. The engine meets China II emission
standard (non-road machinery). Features of
DEUTZ products are: compact structure, high
reliability, excellent dynamic property and
economical efficiency and convenient maintenance,
which can perfectly satisfy the working requests of
the grader.
Engine identification
The serial number is printed on nameplate, which is
located on the engine cylinder block.
You must indicate the engine type and serial
number when ordering spare parts.
Fig. 2-1 Engine
Service Manual for G9165 Grader
2
Engine characteristics curves
The engine speed characteristic curves show how
the effective power P and torque M vary with
engine speed n continuously.
Engine working principle
The diesel engine is designed with four strokes,
every working cycle consists four processes, i.e.
intake, compression, power and exhaust.
Specifically speaking, during air intake, engine
inhales fresh air continuously until the piston
approaches the bottom dead center (BDC),
marking the end of intake. Then, the compression
stroke begins as the piston starts moving upwards,
during which the fresh air is compressed by the
piston and its temperature rises. When the piston
approaches TDC, the diesel is atomized and then
injected into combustion chamber via injector,
where it is mixed with high temperature gas (i.e.
gas mixture is formed) and combusts automatically
and quickly. When the pressure generated from
self-combustion forces the piston to move
downwards, the power stroke begins, which will be
ended as the piston gets close to BDC. Following
this, the exhaust stoke starts as the piston moves
upwards by the force of inertia, and when it
approaches TDC, all remaining waste gas resulted
from mixture combustion is discharged, marking
the end of exhaust stroke. That’s the whole
working circle of the diesel engine.
Fig. 2-2 Engine characteristics curves
Service Manual for G9165 Grader
3
212 Main Function Bodies of Engine
High gantry type block
------Crankcase sealing surface is lower than
crankshaft axis.
------Enhanced the stiffness of the bottom half
engine block.
Wet-type cylinder sleeve
------The cylinder sleeve outside surface contacts
with the coolant directly.
------Excellent cooling performance, can avoid
cavitation effectively.
Engine block assembly mainly consists of engine
block, cylinder sleeves, gear housing rear oil seal
cap, flywheel shell and oil pan. The engine block
applies high-position water inflow, which can
improve the cooling speed of the piston and
cylinder sleeve.
Valve mechanism
The valve mechanism comprises camshaft, tappet,
pushrod, rocker arm, intake and exhaust valve,
valve spring, cylinder cover and cylinder cover
shield.
The camshaft adopts unitary structure, independent
lubricating oil channel is designed for each journal.
Tappet is a flat bottom cylindrical part that made of
alloy steel. There is bias between its center and
cam symcenter, which can produce rotational
motion when the tappet moving up and down to
wear the tappet evenly, reduce sliding speed and
increase reliability.
Fig. 2-3 Engine block
Fig. 2-4 Valve mechanism
Service Manual for G9165 Grader
4
Crankshaft mechanism
The crankshaft mechanism comprises crankshaft,
connecting rod, piston, flywheel, damper and
crankshaft pulley.
Crankshaft is used to convert the forces from
piston and connecting rod into torques, so as to
drive transmission system of vehicle, engine valve
train, and other auxiliary devices.
Be sure to heat the timing gear to 250oC when
installing it, and note that a locating pin on the
crankshaft is used to position it.
213 Engine Technical Parameters
Refer to Table 2-1 for engine technical parameters.
Table 2-1 Engine technical parameters
Items Parameters Items Parameters
Model WP6G175E21 Cylinder quantity 6
Type Inline, water-cooled,
turbo charged and
intercooled
Cylinder bore/stroke (mm) 105/130
Rated power (kW) 129 Rated fuel consumption
(g/kWh) ≤210
Rated speed (r/min) 2200 Max. torque (Nm) 680
Displacement (L) 6.75 Emission standard China II
GB20891-2007
Fig. 2-5 Crankshaft mechanism
1 Torque damper
2 Piston pin 3 Piston pin snap ring
4 Piston 5 Piston ring
6 Connecting rod
7 Main bearing shell
8 Flywheel
9 Connecting rod bearing shell
10 Thrust plate
11 Crankshaft
Service Manual for G9165 Grader
5
22 Cooling System
241 Overview of Cooling System
Cooling system is used to maintain the diesel
engine runs continuously at a suitable temperature,
and the forced circulation cooling is the best way
to guarantee that the required operation
temperature is set up in the shortest time. The
cooling system of this diesel engine mainly
consists of water pump, thermostat, water tank
(radiator), fan, expansion water tank, pipes and
heating system.
Rad
iato
r Fan
Thermostat
Pump
Engin
e oil
coole
r
Water outlet pipe
Cylinder cover
Diesel engine block
Fig. 2-6 Cooling system
When the coolant temperature is lower than the set
value, the partial or all coolant water will bypass to
water pump directly under the control of
thermostat. Thereby, regardless of the load
condition of the diesel engine, the coolant
temperature can be adjusted to 80~95oC
automatically. During major circulation, the
coolant will flow through the radiator for cooling;
and during minor circulation, the coolant will flow
directly into the water pump to warm up the diesel
engine. The head-on wind and air absorbed by the
fan can carry the heat from radiator away to
maintain a stable working temperature of 85~95oC.
Full closed Full open
Fig. 2-7 Working states of thermostat
Service Manual for G9165 Grader
6
23 Lubrication System
231 Overview of Fuel System
Lubrication system consists of engine oil pump, oil
filter, engine oil cooler, engine oil pan, oil strainer,
etc.
PO represents opening pressure of each valve.
The engine is also equipped with piston cooling
nozzle to keep working temperature stable by
spraying oil to the bottom side of the piston.
In the lubrication system, pressure lubrication is
provided for main bearing, connecting rod bearing,
cam bearing, rocker arm bearing, injection pump
and turbocharger; while splashing lubrication is
applied for connecting rod small end, gear train,
piston and cylinder sleeve.
Fan side
Engine oil filter
Engine oil
radiator
Fig. 2-8 Route diagram of force-feed lubrication
1 Oil pan 2 Bypass valve of engine oil radiator 3 Bypass valve of engine oil filter
4 Engine oil strainer 5 Engine oil pump 6 Turbocharger 7Pressure-limiting valve
Service Manual for G9165 Grader
7
The engine oil cooler, is connected to the cooling
water circuit in series. In this way, the cooling
ability and reliability of the cooler is greatly
improved. Meanwhile, the engine oil filter, safety
valve and pressure limiting valve adopt integration
design, the engine appearance is improved. Filter
element of the engine oil filter replaceable, which
can lower the maintenance cost for the user.
Fig. 2-9 Engine oil filter
Service Manual for G9165 Grader
8
24 Fuel Supply System
241 Overview of Fuel System
The fuel system of this diesel engine consists of
such major parts as injection pump, fuel injectors
and regulator together with such auxiliary devices
as fuel tank, fuel delivery pump, fuel pre-filter, fuel
filter and high/low pressure fuel pipes.
Injector
Fuel
fine
filter
Fuel
injection
pump
Fuel
dilivery
pump
Oil-water
separator
Fuel tank
Fig. 2-10 Fuel system
Low pressure circuit
Firstly, through the pre-filter, the water and large
grained impurities in the fuel absorbed by fuel
delivery pump will be removed, then the pumped
fuel will be sent to the fuel injection pump through
the fuel filter. After being pressurized and metered
in the injection pump, some of the fuel will be
injected into combustion chamber through the fuel
injector. The redundant fuel will flow back to feel
Service Manual for G9165 Grader
9
tank through the fuel return pipe to form fuel return
circuit.
Stabilized pressure in low pressure circuit is vitally
important for engine power output. If the situation
of under-capacity of engine occurs, check the fuel
pressure first. The major cause to oil leak
(cavitation) of injector is insufficient pressure of
low pressure circuit, so ensure the cleanness of fuel
filter and replace it if necessary.
High pressure circuit
The fuel in injection pump enters into the injector
via a short high-pressure oil pipe, once the pressure
rises up to set value, the injector will start to work
to inject fuel into the combustion chamber.
Fuel return
Since the oil supply rate of fuel pump is more than
ten times greater than the capacity of injector, a lot
of excess fuel will return back to fuel tank via the
pressure control valve, leaked fuel from injector
during working gap returns to fuel tank too.
Service Manual for G9165 Grader
10
25 Intake & Exhaust System
251 Overview of Intake & Exhaust
System
Intake system
Air is absorbed in through air filter, and then flows
into turbocharger. After being pressurized and
heated by the turbocharger, the air will flow into
intake manifold. Under the control of engine valve
mechanism, the intake valves will open
periodically to let fresh air flow into the cylinders
according to the working cycle and ignition order.
Finally, the fuel and fresh will combust in the
combustion chamber.
For diesel engine, the intake air must be clean and
sufficient, and a filter is designed in the system to
guarantee that. The filter should be chosen
according to engine power and working condition.
Exhaust system
Firstly, the exhaust gas flows into exhaust manifold
through the exhaust valve; then enters into the
silencer through turbocharger, discharge into the
environment through exhaust pipes at last.
Turbocharger
The turbocharger is driven by exhaust gas, the
exhaust gas flows through the turbine casing on its
way to silencer. Exhaust airflow drives the turbine
rotor in the turbine casing. The compressor rotor
and turbine rotor locate on the same shaft, the
former located in the housing that connected
between air filter and intake manifold. When
compressor rotor rotates, it will absorb air from the
air filter, and the air will be compressed in
compressor and forced into engine cylinders.
Fig. 2-11 Intake & exhaust system
Fig. 2-12 Turbocharger
Red—Exhaust
Blue—Filtered air
1 Turbine housing
2 Compressor housing
3 Waste gate
Service Manual for G9165 Grader
11
26 Disassembly & Assembly of Engine System
261 Disassembly of Engine
In the case of replacement or overhaul of the engine, the following steps can be followed to remove
the engine from the whole machine.
1 Preparation
2 Drain coolant
3 Engine hood
4 Engine-related wiring harnesses
5 Engine throttle control wire
6 Intercooler air inlet pipe
7 Intercooler air exit pipe
8 Radiator water inlet pipe
9 Radiator water outlet pipeEngine
assembly10 A/C water inlet pipe
12 A/C hose
13 Fuel inlet pipe
14 Fuel return pipe
15 Engine oil drain pipe
1) Generator
2) Starting enrichment device
3) Electric flameout device
4) Engine oil pressure switch
5) Ground wire
6) Engine water temperature sensor
7) Starter motor
11 A/C water outlet pipe
16 Transmission box
17 Fixing bolts
18 Lift down the engine
8) A/C compressor
Service Manual for G9165 Grader
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1. Drive the grader to the maintenance location,
engage the parking brake and turn the electric
lock key counterclockwise to shut down the
engine. Wedge the tires with wood blocks.
ATTENTION
The following operations should be done
only after the grader is cooled down. During
removal, all exposed pipe joints should be
wrapped properly to avoid intrusion of
foreign matters.
2. Drain the coolant and lift the radiator away.
Coolant
3. Remove engine hood.
Refer to Section 841 in this manual for
removal of engine hood.
1
Fig. 2-13
1 Water drain valve
1
Fig. 2-14
1 Engine hood
Service Manual for G9165 Grader
13
4. Disconnect the engine related wiring
harnesses.
1) Disconnect the generator wiring harness.
2) Disconnect the wiring harness of starting
enrichment device.
3) Disconnect the wiring harness of electric
flameout device.
1
Fig. 2-15
1 Generator wiring harness
1
Fig. 2-16
1 Wiring harness of starting enrichment
device
1
Fig. 2-17
1 Electric flameout device
Service Manual for G9165 Grader
14
4) Disconnect the engine oil pressure switch
wiring harness.
5) Disconnect the ground wire.
6) Disconnect the water temperature sensor
wiring harness.
1
Fig. 2-18
1 Engine oil pressure switch
1
Fig. 2-19
1 Ground wire
1
Fig. 2-20
1 Water temperature sensor
Service Manual for G9165 Grader
15
7) Disconnect the starter motor wiring
harness.
8) Disconnect the A/C compressor wiring
harness.
5. Disconnect the engine throttle control wire.
1
Fig. 2-21
1 Starter motor
1
Fig. 2-22
1 A/C compressor wiring harness
1
Fig. 2-23
1 Engine throttle pull rod
Service Manual for G9165 Grader
16
6. Disconnect the intercooler air inlet pipe.
7. Disconnect the intercooler air exit pipe.
8. Disconnect the radiator water inlet pipe.
1
Fig. 2-24
1 Intercooler air inlet pipe
1
Fig. 2-26
1 Radiator water inlet pipe
1
Fig. 2-25
1 Intercooler air exit pipe
Service Manual for G9165 Grader
17
9. Disconnect the radiator water outlet pipe.
10. Disconnect the A/C water inlet pipe.
11. Disconnect the A/C water outlet pipe.
1
Fig. 2-27
1 Radiator water outlet pipe
1
Fig. 2-28
1 A/C water inlet pipe
1
Fig. 2-29
1 A/C water outlet pipe
Service Manual for G9165 Grader
18
12. Disconnect the compressor to condenser pipe
and evaporator to compressor pipe.
13. Disconnect the fuel inlet pipe.
14. Disconnect the fuel return pipe.
1 2
Fig. 2-30
1 Compressor to condenser pipe
2 Evaporator to compressor pipe
1
Fig. 2-31
1 Fuel inlet pipe
1
Fig. 2-32
1 Fuel return pipe
Service Manual for G9165 Grader
19
15. Disconnect the engine oil drain pipe.
16. Hang the engine with lifting rope and remove
the connecting bolts of engine and
transmission box.
17. Remove the engine fixing bolts.
1
Fig. 2-33
1 Engine oil drain pipe
1
Fig. 2-34
1 Transmission box
1
Fig. 2-35
1 Fixing bolt
Service Manual for G9165 Grader
20
18. Lift down the engine and put it on suitable
support.
1
Fig. 2-36
1 Engine
Service Manual for G9165 Grader
21
262 Assembly of Engine
Refer to the following steps to recover the engine.
4 Engine-related wiring harnesses
5 Engine throttle control wire
11 Intercooler air inlet pipe
12 Intercooler air exit pipe
6 Radiator water inlet pipe
7 Radiator water outlet pipe
Engine
assembly
8 A/C water inlet pipe
10 A/C hose
13 Fuel inlet pipe
14 Fuel return pipe
15 Engine oil drain pipe
1) Generator
2) Starting enrichment device
3) Electric flameout device
4) Engine oil pressure switch
6) Ground wire
5) Engine water temperature
sensor
7) Starter motor
9 A/C water outlet pipe
2 Transmission box
3 Fixing bolts
1 Lift and assemble the
engine
8) A/C compressor
16 Engine hood
17 Coolant
Service Manual for G9165 Grader
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1. Lift and assemble the engine.
Engine: 636kg
ATTENTION
If the stud is loose, do not use a
plier/wrench to tighten it directly. You can
install two nuts to the stud first, tighten the
nuts against each other, and then use a
wrench to tighten the stud by clamping the
nuts.
2. Connect the engine and transmission box with
bolts.
3. Tigjhten the engine fixing bolts.
120~200Nm
1
Fig. 2-37
1 Engine
1
Fig. 2-38
1 Transmission box
1
Fig. 2-39
1 Fixing bolt
Service Manual for G9165 Grader
23
4. Connect the engine related wiring harnesses.
1) Connect the generator wiring harness.
2) Connect the wiring harness of starting
enrichment device.
3) Connect the wiring harness of electric
flameout device.
1
Fig. 2-40
1 Generator wiring harness
1
Fig. 2-41
1 Wiring harness of starting enrichment
device
1
Fig. 2-42
1 Electric flameout device
Service Manual for G9165 Grader
24
4) Connect the engine oil pressure switch
wiring harness.
5) Connect the water temperature sensor
wiring harness.
6) Connect the ground wire.
1
Fig. 2-43
1 Engine oil pressure switch
1
Fig. 2-44
1 Water temperature sensor
1
Fig. 2-45
1 Ground wire
Service Manual for G9165 Grader
25
7) Connect the starter motor wiring harness.
8) Connect the A/C compressor wiring
harness.
5. Connect the engine throttle control wire.
1
Fig. 2-46
1 Starter motor
1
Fig. 2-47
1 A/C compressor wiring harness
1
Fig. 2-48
1 Engine throttle pull rod
Service Manual for G9165 Grader
26
6. Connect the radiator water inlet pipe.
7. Connect the radiator water outlet pipe.
8. Connect the A/C water inlet pipe.
1
Fig. 2-49
1 Radiator water inlet pipe
1
Fig. 2-50
1 Radiator water outlet pipe
1
Fig. 2-51
1 A/C water inlet pipe
Service Manual for G9165 Grader
27
9. Connect the A/C water outlet pipe.
10. Connect the compressor to condenser pipe and
evaporator to compressor pipe.
16~20Nm
11. Connect the intercooler air inlet pipe.
1
Fig. 2-52
1 A/C water outlet pipe
1 2
Fig. 2-53
1 Compressor to condenser pipe
2 Evaporator to compressor pipe
1
Fig. 2-54
1 Intercooler air inlet pipe
Service Manual for G9165 Grader
28
12. Connect the intercooler air exit pipe.
13. Connect the fuel inlet pipe.
14. Connect the fuel return pipe.
1
Fig. 2-55
1 Intercooler air exit pipe
1
Fig. 2-56
1 Fuel inlet pipe
1
Fig. 2-57
1 Fuel return pipe
Service Manual for G9165 Grader
29
15. Connect the engine oil drain pipe.
16. Lift and install the engine hood.
17. Lift and assemble the radiator. Fill the radiator
with coolant.
ATTENTION
Fill glycol type coolant into the expansion
tank, and then start the grader. After a
while, fill more glycol type coolant until the
specified level is reached.
1
Fig. 2-59
1 Engine hood
1
Fig. 2-58
1 Engine oil drain pipe
1
Fig. 2-60
1 Coolant filling port
Service Manual for G9165 Grader
30
263 Disassembly and Assembly of
Fuel Tank
Disassembly of fuel tank
1. Loosen the screw plug at the bottom of the fuel
tank and then drain out the fuel to a clean
container, and then cover the container
properly to avoid intrusion of foreign matters.
ATTENTION
Considering that the fuel is highly
combustible, any open flame is strictly
prohibited, the maintenance should be done
at a position far away from fire source, and
such flame as spark produced by collision
shall be avoided.
2. Disconnect the fuel level sensor.
3. Disconnect the reverse buzzer wiring harness.
1
Fig. 2-61
1 Oil drain plug
1
Fig. 2-62
1 Fuel sensor connector
1
Fig. 2-63
1 Reverse buzzer
Service Manual for G9165 Grader
31
4. Disconnect the fuel inlet pipe from the fuel
tank.
5. Disconnect the fuel return pipe from the fuel
tank.
6. Remove the fuel tank fixing bolts.
ATTENTION
Hang the fuel tank with lifting appliance to
prevent falling.
1
Fig. 2-64
1 Fuel inlet pipe
1
Fig. 2-65
1 Fuel return pipe
1
Fig. 2-66
1 Fixing bolt
Service Manual for G9165 Grader
32
7. Lift down the fuel tank and clean it.
Assembly of fuel tank
1. Lift and put the fuel tank on the frame for
assembling.
2. Tighten the fuel tank fixing bolts.
320~480Nm
1
Fig. 2-67
1 Fuel tank
1
Fig. 2-68
1 Fuel tank
1
Fig. 2-69
1 Fixing bolt
Service Manual for G9165 Grader
33
3. Connect the fuel return pipe to the fuel tank.
4. Connect the fuel inlet pipe to the fuel tank.
5. Connect the reverse buzzer wiring harness.
1
Fig. 2-72
1 Reverse buzzer
1
Fig. 2-71
1 Fuel inlet pipe
1
Fig. 2-70
1 Fuel return pipe
Service Manual for G9165 Grader
34
6. Add fuel.
1
Fig. 2-73
1 Fuel filling port
Service Manual for G9165 Grader
35
264 Disassembly and Assembly Of
Radiator
Disassembly of radiator
ATTENTION
Before removing the fixing bolts, you should
hang the radiator with lifting appliance to
prevent falling.
In the process of disassembling, the
disconnected oil pipe joins should be
properly protected to prevent intrusion of
foreign matters.
1. Open the drain valve to drain coolant.
Coolant
2. Remove the engine rear cover.
1
Fig. 2-74
1 Water drain valve
1
Fig. 2-75
1 Engine rear cover
Service Manual for G9165 Grader
36
3. Disconnect the intercooler air inlet pipe.
4. Disconnect the intercooler air exit pipe.
5. Disconnect the radiator water inlet pipe and
vent pipe.
1
Fig. 2-76
1 Intercooler air inlet pipe
1
Fig. 2-77
1 Intercooler air exit pipe
1 2
Fig. 2-78
1 Vent pipe 2 Water inlet pipe
Service Manual for G9165 Grader
37
6. Disconnect the radiator water outlet pipe and
water refill pipe.
7. Disconnect the transmission oil inlet pipe and
hydraulic oil inlet pipe from the radiator.
8. Disconnect the transmission oil outlet pipe and
hydraulic oil outlet pipe from the radiator.
1 2
Fig. 2-79
1 Water refill pipe
2 Water outlet pipe
1 2
Fig. 2-80
1 Hydraulic oil inlet pipe
2 Transmission oil inlet pipe
1 2
Fig. 2-81
1 Hydraulic oil outlet pipe
2 Transmission oil outlet pipe
Service Manual for G9165 Grader
38
9. Remove the radiator wind deflector.
10. Remove the radiator fixing bolts.
ATTENTION
Hang the radiator with lifting appliance to
prevent falling.
11. Lift the radiator away.
1
Fig. 2-82
1 Radiator wind deflector
1
Fig. 2-83
1 Fixing bolt
1
Fig. 2-84
1 Radiator
Service Manual for G9165 Grader
39
Assembly of radiator
1. Lift and put the radiator on the rear frame,
install and tighten the fixing bolts.
2. Install the wind deflector.
3. Connect the transmission oil inlet pipe and
hydraulic oil inlet pipe to the radiator.
1
Fig. 2-85
1 Fixing bolt
1
Fig. 2-86
1 Radiator wind deflector
1 2
Fig. 2-87
1 Hydraulic oil inlet pipe
2 Transmission oil inlet pipe
Service Manual for G9165 Grader
40
4. Connect the transmission oil outlet pipe and
hydraulic oil outlet pipe to the radiator.
5. Connect the radiator water inlet pipe and vent
pipe.
6. Connect the radiator water outlet pipe and
water refill pipe.
1 2
Fig. 2-90
1 Water refill pipe
2 Water outlet pipe
1 2
Fig. 2-89
1 Vent pipe 2 Water inlet pipe
1 2
Fig. 2-88
1 Hydraulic oil outlet pipe
2 Transmission oil outlet pipe
Service Manual for G9165 Grader
41
7. Connect the intercooler air inlet pipe.
8. Connect the intercooler air exit pipe.
9. Install the engine rear cover.
1
Fig. 2-91
1 Intercooler air inlet pipe
1
Fig. 2-92
1 Intercooler air exit pipe
1
Fig. 2-93
1 Engine rear cover
Service Manual for G9165 Grader
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10. Fill coolant.
1
Fig. 2-94
1 Coolant filling port (expansion
water tank)
Service Manual for G9165 Grader
43
27 Diagnosis and Troubleshooting of Engine Common Problems
271 Engine Fails to Start
Caused by starting system
1 Power shortage of storage battery.
Solution: Check the battery carefully, recharge or replace it.
2 Damaged starting motor.
Solution: Repair or replace the motor.
Caused by oil supply system
1 There is air in the oil system.
Solution: Unchoke the oil circuit (such as blow with high pressure air), tighten all joints and
discharge air.
2 Blockage of oil system.
Solution: Unchoke the oil circuit (such as blow with high pressure air), tighten all joints and
discharge air.
3 The diesel filter element is particularly dirty.
Solution: Replace the filter element.
4 Serious wear damage of plunger/delivery valve.
Solution: Repair the fuel supply pump professionally.
5 Damaged low pressure fuel supply pump.
Solution: Replace the fuel supply pump.
Adjustment factors
1 Dislocated of fuel injection advance angle.
Solution: Adjust the fuel injection advance angle.
2 Change of valve clearance.
Solution: Check and adjust valve clearance.
3 Oil shortage when starting
Solution: Check the fuel supply pump professionally.
272 Engine Power is not Sufficient
1 Blockage of fuel filter or fuel supply pump oil inlet pipe connector filter screen.
Solution: Clean or replace it/them.
2 Low injection pressure or bad atomization.
Solution: Troubleshoot the injector or replace inject nozzle matching parts.
3 Serious wear damage of precise inject nozzle matching parts.
Service Manual for G9165 Grader
44
Solution: Regulate oil supply or troubleshoot plunger and barrel assembly.
4 Air infiltrate into the fuel system.
Solution: Discharge air of the fuel system.
5 Incorrect fuel injection advance angle.
Solution: Adjust the angle according provisions.
6 Nonuniform oil supply of each cylinder.
Solution: Adjust oil supply.
7 Blockage of air filter.
Solution: Clean or replace the filter element.
273 Exhaust Exceptions (Black Smoke, White Smoke, Blue Smoke)
The engine gives off blue smoke
1 High engine oil level of engine pan.
Solution: Drain redundant engine oil, and make sure the oil level is within specified range.
2 Diesel flows into oil pan due to oil-fuel injector needle-valve untightly closed or stucked in
open position.
Solution: Clean and adjust the injector or replace the needle valve matching parts.
3 Damaged fuel supply pump plunger bushing sealing ring (P pump), or bad sealing between
plunger bushing and pump body, the fuel flows into oil pan along engine oil passage.
Solution: Replace the sealing ring.
4 Damaged valve oil seal or excessive clearance between the valve and tube.
Solution: Replace all faulted valves, pipes and oil seal (the oil seal must be replaced once being
disassembled; if the clearance meets the requirements after the valve is replaced, you can spare
the tube).
5 Damaged sealing ring of turbocharger, engine oil burns after enters into the combustion
chamber along air inlet passage.
Solution: Repair or replace.
The engine gives off white smoke
1 There is moisture in the fuel system.
Solution: Clean the fuel tank and filter, and use qualified diesel oil.
2 Abrasion of cylinder valve.
Solution: Replace it.
3 Bad atomization of injected fuel, the fuel fails to burn in the combustion champ.
Solution: Adjust the injector and fuel supply advance angle.
The engine gives off black smoke
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1 Exhaust back pressure is too high or exhaust pipeline is blocked.
Solution: Reduce bend positions of pipeline; dust out the silencer.
2 The injection lags
Solution: Adjust fuel injection advance angle.
3 The injector doesn’t work normal or being damaged.
Solution: Dismantle, clean and check.
4 Poor quality of diesel or wrong brand.
Solution: Replace the diesel.
5 Severe wear of cylinder sleeve and piston group.
Solution: Replace worn parts
274 Engine Oil Pressure is Too High or Too Low
Engine oil pressure is too high
1 Malfunctioned engine oil display device.
Solution: Replace the display device.
2 High viscosity of engine oil
Solution: Choose specified brand engine oil, and take preheating action when starting the
machine in winter.
3 Too little gap in force-feed lubricating positions or blocked engine oil filter.
Solution: Adjust the gap, clean or replace the filter.
4 Misadjusted pressure restrict valve.
Solution: Readjust the spring force of the valve, so the engine oil pressure can drop to specified
value.
Engine oil pressure is too low
1 Abrasions of engine oil pump or damaged sealing gasket.
Solution: Repair the pump and replace the gasket.
2 The absorbed oil reduces
Solution: Check oil capacity, add engine oil and clean the absorption filter.
3 Large engine oil leakage.
Solution: Check whether the lubricating pipe is broken; check and adjust the fitting clearance of
bearings in crankshaft and camshaft as required.
4 Blockage of engine oil filter or cooler.
Solution: Check and clean engine oil filter and cooler.
5 Low viscosity of engine oil
Solution: Choose specified brand engine oil.
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6 Misadjusted pressure restrict valve.
Solution: Clean the valve; readjust or replace the spring.
7 Low displaced engine oil pressure.
Solution: Check and replace engine oil pressure sensor and pressure gauge.
275 Large Consumption of Engine Oil
1 Improper engine oil viscosity.
Solution: Choose proper engine oil.
2 High negative pressure in combustion chamber, result in engine oil spraying up to the chamber.
Solution: Examine the reason for high negative pressure and fix it.
3 Change of rotating speed and operating mode.
Solution: Test showed that with the increase of rotating speed, engine oil consumption rises
obviously, operate the engine according to the rules.
276 High Coolant Temperature
1 Improper selection of coolant or shortage of cooling water.
Solution: Choose suitable coolant and add to specified level.
2 Blockage of water radiator.
Solution: Put the radiating fins back to their original positions with stalloy carefully, after they
return to flat shape, clean them with compressed air or water gun.
3 Wrong indication of water thermometer or warning light.
Solution: Use the water thermometer to measure the temperature of water temperature sensor
area, see whether the measured temperature is consistent with actual value.
4 Low rotating speed of fan, the blades are deformed or installed backwards.
Solution: Loosened rubber belt will lead to slipping, which result in low rotating speed of fan.
Adjust the belt if necessary; if the rubber layer aged, damaged or fractured, replace it. If the
blades are deformed, replace them.
5 Malfunction of cooling-water pump.
Solution: Replace the pump.
6 Malfunction of thermostat.
Solution: Replace the thermostat.
7 Damaged cylinder cover gaskets.
Solution: Replace them.
8 Overloaded operation of diesel engine.
Solution: Lower the load of engine.