Vous êtes sur la page 1sur 52

Service Manual of G9165 Grader

SERVICE MANUAL

2 Engine System

Service Manual for G9165 Grader

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

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.

Fig. 2-1 Engine


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.

Service Manual for G9165 Grader


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.
Fig. 2-2 Engine characteristics curves

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. Thats the whole
working circle of the diesel engine.
2

Service Manual for G9165 Grader

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.

Fig. 2-3 Engine block

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
Fig. 2-4 Valve mechanism

wear the tappet evenly, reduce sliding speed and


increase reliability.

Service Manual for G9165 Grader


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.
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

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
Inline, water-cooled,
turbo charged and
intercooled

Cylinder quantity

Cylinder bore/stroke (mm)

105/130

Rated fuel consumption


(g/kWh)

210

Rated speed (r/min) 2200

Max. torque (Nm)

680

Displacement (L)

Emission standard

China II
GB20891-2007

Type
Rated power (kW)

129

6.75

Service Manual for G9165 Grader

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.
Water outlet pipe

Engine oil cooler

Fan

Radiator

Thermostat

Cylinder cover

Pump
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
Full closed
Full open
Fig. 2-7 Working states of thermostat

automatically.

can

be

During

adjusted
major

to

80~95oC

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.
5

Service Manual for G9165 Grader

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

4 Engine oil strainer

5 Engine oil pump

3 Bypass valve of engine oil filter

6 Turbocharger
6

7Pressure-limiting valve

Service Manual for G9165 Grader


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
Fig. 2-9 Engine oil filter

element of the engine oil filter replaceable, which


can lower the maintenance cost for the user.

Service Manual for G9165 Grader

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
injection
pump
Fuel
fine
filter

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
8

Service Manual for G9165 Grader


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

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
Fig. 2-11 Intake & exhaust system

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
Fig. 2-12 Turbocharger
RedExhaust
BlueFiltered air
1 Turbine housing
2 Compressor housing
3 Waste gate

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.
10

Service Manual for G9165 Grader

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

1) Generator

2 Drain coolant

2) Starting enrichment device

3 Engine hood
4 Engine-related wiring
harnesses
5 Engine throttle control
wire

3) Electric flameout device

6 Intercooler air inlet pipe


7 Intercooler air exit pipe
8 Radiator water inlet pipe
Engine
assembly

9 Radiator water outlet pipe


10 A/C water inlet pipe
11 A/C water outlet pipe
12 A/C hose
13 Fuel inlet pipe
14 Fuel return pipe
15 Engine oil drain pipe
16 Transmission box
17 Fixing bolts
18 Lift down the engine

11

4) Engine oil pressure switch


5) Ground wire

6) Engine water temperature


sensor
7) Starter motor
8) A/C compressor

Service Manual for G9165 Grader


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

1
Fig. 2-13
1 Water drain valve
3.

Remove engine hood.


Refer to Section 841 in this manual for
removal of engine hood.

1
Fig. 2-14
1 Engine hood

12

Service Manual for G9165 Grader


4.

Disconnect

the

engine

related

wiring

harnesses.
1) Disconnect the generator wiring harness.

1
Fig. 2-15
1 Generator wiring harness
2) Disconnect the wiring harness of starting
enrichment device.

1
Fig. 2-16
1 Wiring harness of starting enrichment
device
3) Disconnect the wiring harness of electric
flameout device.

1
Fig. 2-17
1 Electric flameout device
13

Service Manual for G9165 Grader


4) Disconnect the engine oil pressure switch
wiring harness.

1
Fig. 2-18
1 Engine oil pressure switch
5) Disconnect the ground wire.

1
Fig. 2-19
1 Ground wire
6) Disconnect the water temperature sensor
wiring harness.

1
Fig. 2-20
1 Water temperature sensor

14

Service Manual for G9165 Grader


7) Disconnect the starter motor wiring
harness.

1
Fig. 2-21
1 Starter motor
8) Disconnect the A/C compressor wiring
harness.

1
Fig. 2-22
1 A/C compressor wiring harness
5.

1
Fig. 2-23
1 Engine throttle pull rod

15

Disconnect the engine throttle control wire.

Service Manual for G9165 Grader


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. 2-25
1 Intercooler air exit pipe

1
Fig. 2-26
1 Radiator water inlet pipe

16

Service Manual for G9165 Grader


9.

Disconnect the radiator water outlet pipe.

1
Fig. 2-27
1 Radiator water outlet pipe
10. Disconnect the A/C water inlet pipe.

1
Fig. 2-28
1 A/C water inlet pipe
11. Disconnect the A/C water outlet pipe.

1
Fig. 2-29
1 A/C water outlet pipe

17

Service Manual for G9165 Grader


12. Disconnect the compressor to condenser pipe
and evaporator to compressor pipe.

Fig. 2-30
1 Compressor to condenser pipe
2 Evaporator to compressor pipe
13. Disconnect the fuel inlet pipe.

1
Fig. 2-31
1 Fuel inlet pipe
14. Disconnect the fuel return pipe.

1
Fig. 2-32
1 Fuel return pipe
18

Service Manual for G9165 Grader


15. Disconnect the engine oil drain pipe.

1
Fig. 2-33
1 Engine oil drain pipe
16. Hang the engine with lifting rope and remove
the

connecting

bolts

of

transmission box.

1
Fig. 2-34
1 Transmission box
17. Remove the engine fixing bolts.

1
Fig. 2-35
1 Fixing bolt

19

engine

and

Service Manual for G9165 Grader


18. Lift down the engine and put it on suitable
support.

1
Fig. 2-36
1 Engine

20

Service Manual for G9165 Grader

262 Assembly of Engine


Refer to the following steps to recover the engine.

1 Lift and assemble the


engine
2 Transmission box

2) Starting enrichment device


3) Electric flameout device

3 Fixing bolts
4 Engine-related wiring
harnesses
5 Engine throttle control
wire
6 Radiator water inlet pipe
7 Radiator water outlet pipe
Engine
assembly

1) Generator

8 A/C water inlet pipe


9 A/C water outlet pipe
10 A/C hose
11 Intercooler air inlet pipe
12 Intercooler air exit pipe
13 Fuel inlet pipe
14 Fuel return pipe
15 Engine oil drain pipe
16 Engine hood
17 Coolant

21

4) Engine oil pressure switch


5) Engine water temperature
sensor
6) Ground wire

7) Starter motor
8) A/C compressor

Service Manual for G9165 Grader


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.

1
Fig. 2-37
1 Engine
2.

Connect the engine and transmission box with


bolts.

1
Fig. 2-38
1 Transmission box
3.

Tigjhten the engine fixing bolts.


120~200Nm

1
Fig. 2-39
1 Fixing bolt

22

Service Manual for G9165 Grader


4.

Connect the engine related wiring harnesses.


1) Connect the generator wiring harness.

1
Fig. 2-40
1 Generator wiring harness
2) Connect the wiring harness of starting
enrichment device.

1
Fig. 2-41
1 Wiring harness of starting enrichment
device
3) Connect the wiring harness of electric
flameout device.

1
Fig. 2-42
1 Electric flameout device
23

Service Manual for G9165 Grader


4) Connect the engine oil pressure switch
wiring harness.

1
Fig. 2-43
1 Engine oil pressure switch
5) Connect the water temperature sensor
wiring harness.

1
Fig. 2-44
1 Water temperature sensor

6) Connect the ground wire.

1
Fig. 2-45
1 Ground wire

24

Service Manual for G9165 Grader


7) Connect the starter motor wiring harness.

1
Fig. 2-46
1 Starter motor
8) Connect the A/C compressor wiring
harness.

1
Fig. 2-47
1 A/C compressor wiring harness
5.

1
Fig. 2-48
1 Engine throttle pull rod

25

Connect the engine throttle control wire.

Service Manual for G9165 Grader


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

26

Service Manual for G9165 Grader


9.

Connect the A/C water outlet pipe.

1
Fig. 2-52
1 A/C water outlet pipe
10. Connect the compressor to condenser pipe and
evaporator to compressor pipe.
16~20Nm

1
2
Fig. 2-53
1 Compressor to condenser pipe
2 Evaporator to compressor pipe
11. Connect the intercooler air inlet pipe.

1
Fig. 2-54
1 Intercooler air inlet pipe

27

Service Manual for G9165 Grader


12. Connect the intercooler air exit pipe.

1
Fig. 2-55
1 Intercooler air exit pipe
13. Connect the fuel inlet pipe.

1
Fig. 2-56
1 Fuel inlet pipe
14. Connect the fuel return pipe.

1
Fig. 2-57
1 Fuel return pipe

28

Service Manual for G9165 Grader


15. Connect the engine oil drain pipe.

1
Fig. 2-58
1 Engine oil drain pipe
16. Lift and install the engine hood.

1
Fig. 2-59
1 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. 2-60
1 Coolant filling port

29

Service Manual for G9165 Grader

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

1
Fig. 2-61
1 Oil drain plug

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. 2-62
1 Fuel sensor connector

1
Fig. 2-63
1 Reverse buzzer
30

Service Manual for G9165 Grader


4.

Disconnect the fuel inlet pipe from the fuel


tank.

1
Fig. 2-64
1 Fuel inlet pipe
5.

Disconnect the fuel return pipe from the fuel


tank.

1
Fig. 2-65
1 Fuel return pipe
6.

Remove the fuel tank fixing bolts.

ATTENTION
Hang the fuel tank with lifting appliance to
prevent falling.

1
Fig. 2-66
1 Fixing bolt

31

Service Manual for G9165 Grader


7.

Lift down the fuel tank and clean it.

1
Fig. 2-67
1 Fuel tank
Assembly of fuel tank
1.

Lift and put the fuel tank on the frame for


assembling.

1
Fig. 2-68
1 Fuel tank
2.

Tighten the fuel tank fixing bolts.


320~480Nm

1
Fig. 2-69
1 Fixing bolt

32

Service Manual for G9165 Grader


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. 2-70
1 Fuel return pipe

1
Fig. 2-71
1 Fuel inlet pipe

1
Fig. 2-72
1 Reverse buzzer

33

Service Manual for G9165 Grader


6.

1
Fig. 2-73
1 Fuel filling port

34

Add fuel.

Service Manual for G9165 Grader

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

1
Fig. 2-74
1 Water drain valve
2.

1
Fig. 2-75
1 Engine rear cover

35

Remove the engine rear cover.

Service Manual for G9165 Grader


3.

Disconnect the intercooler air inlet pipe.

4.

Disconnect the intercooler air exit pipe.

5.

Disconnect the radiator water inlet pipe and

1
Fig. 2-76
1 Intercooler air inlet pipe

1
Fig. 2-77
1 Intercooler air exit pipe

vent pipe.

1
Fig. 2-78
1 Vent pipe

2
2 Water inlet pipe
36

Service Manual for G9165 Grader


6.

Disconnect the radiator water outlet pipe and


water refill pipe.

Fig. 2-79
1 Water refill pipe
2 Water outlet pipe
7.

Disconnect the transmission oil inlet pipe and


hydraulic oil inlet pipe from the radiator.

Fig. 2-80
1 Hydraulic oil inlet pipe
2 Transmission oil inlet pipe
8.

Disconnect the transmission oil outlet pipe and


hydraulic oil outlet pipe from the radiator.

Fig. 2-81
1 Hydraulic oil outlet pipe
2 Transmission oil outlet pipe
37

Service Manual for G9165 Grader


9.

Remove the radiator wind deflector.

1
Fig. 2-82
1 Radiator wind deflector
10. Remove the radiator fixing bolts.

ATTENTION
Hang the radiator with lifting appliance to
prevent falling.

1
Fig. 2-83
1 Fixing bolt
11. Lift the radiator away.

1
Fig. 2-84
1 Radiator

38

Service Manual for G9165 Grader


Assembly of radiator
1.

Lift and put the radiator on the rear frame,


install and tighten the fixing bolts.

1
Fig. 2-85
1 Fixing bolt
2.

Install the wind deflector.

3.

Connect the transmission oil inlet pipe and

1
Fig. 2-86
1 Radiator wind deflector

hydraulic oil inlet pipe to the radiator.

Fig. 2-87
1 Hydraulic oil inlet pipe
2 Transmission oil inlet pipe
39

Service Manual for G9165 Grader


4.

Connect the transmission oil outlet pipe and


hydraulic oil outlet pipe to the radiator.

Fig. 2-88
1 Hydraulic oil outlet pipe
2 Transmission oil outlet pipe
5.

Connect the radiator water inlet pipe and vent


pipe.

Fig. 2-89
1 Vent pipe

2 Water inlet pipe


6.

Connect the radiator water outlet pipe and


water refill pipe.

Fig. 2-90
1 Water refill pipe
2 Water outlet pipe
40

Service Manual for G9165 Grader


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

41

Service Manual for G9165 Grader


10. Fill coolant.

1
Fig. 2-94
1 Coolant filling port (expansion
water tank)

42

Service Manual for G9165 Grader

27 Diagnosis and Troubleshooting of Engine Common Problems


271 Engine Fails to Start

Caused by starting system

Power shortage of storage battery.


Solution: Check the battery carefully, recharge or replace it.

Damaged starting motor.


Solution: Repair or replace the motor.

Caused by oil supply system

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.

Blockage of oil system.


Solution: Unchoke the oil circuit (such as blow with high pressure air), tighten all joints and
discharge air.

The diesel filter element is particularly dirty.


Solution: Replace the filter element.

Serious wear damage of plunger/delivery valve.


Solution: Repair the fuel supply pump professionally.

Damaged low pressure fuel supply pump.


Solution: Replace the fuel supply pump.

Adjustment factors

Dislocated of fuel injection advance angle.


Solution: Adjust the fuel injection advance angle.

Change of valve clearance.


Solution: Check and adjust valve clearance.

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.

Low injection pressure or bad atomization.


Solution: Troubleshoot the injector or replace inject nozzle matching parts.

Serious wear damage of precise inject nozzle matching parts.


43

Service Manual for G9165 Grader


Solution: Regulate oil supply or troubleshoot plunger and barrel assembly.
4

Air infiltrate into the fuel system.


Solution: Discharge air of the fuel system.

Incorrect fuel injection advance angle.


Solution: Adjust the angle according provisions.

Nonuniform oil supply of each cylinder.


Solution: Adjust oil supply.

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

High engine oil level of engine pan.


Solution: Drain redundant engine oil, and make sure the oil level is within specified range.

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.

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.

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).

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

There is moisture in the fuel system.


Solution: Clean the fuel tank and filter, and use qualified diesel oil.

Abrasion of cylinder valve.


Solution: Replace it.

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


44

Service Manual for G9165 Grader


1

Exhaust back pressure is too high or exhaust pipeline is blocked.


Solution: Reduce bend positions of pipeline; dust out the silencer.

The injection lags


Solution: Adjust fuel injection advance angle.

The injector doesnt work normal or being damaged.


Solution: Dismantle, clean and check.

Poor quality of diesel or wrong brand.


Solution: Replace the diesel.

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

Malfunctioned engine oil display device.


Solution: Replace the display device.

High viscosity of engine oil


Solution: Choose specified brand engine oil, and take preheating action when starting the
machine in winter.

Too little gap in force-feed lubricating positions or blocked engine oil filter.
Solution: Adjust the gap, clean or replace the filter.

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

Abrasions of engine oil pump or damaged sealing gasket.


Solution: Repair the pump and replace the gasket.

The absorbed oil reduces


Solution: Check oil capacity, add engine oil and clean the absorption filter.

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.

Blockage of engine oil filter or cooler.


Solution: Check and clean engine oil filter and cooler.

Low viscosity of engine oil


Solution: Choose specified brand engine oil.
45

Service Manual for G9165 Grader


6

Misadjusted pressure restrict valve.


Solution: Clean the valve; readjust or replace the spring.

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.

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.

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.

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.

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.

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.

Malfunction of cooling-water pump.


Solution: Replace the pump.

Malfunction of thermostat.
Solution: Replace the thermostat.

Damaged cylinder cover gaskets.


Solution: Replace them.

Overloaded operation of diesel engine.


Solution: Lower the load of engine.
46