2Engine System ENGLISG-G9165

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


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


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


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


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


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


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


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


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


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.


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


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


12

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


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


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


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


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

Fig. 2-26


1

Fig. 2-25



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



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


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

Fig. 2-34

1 Transmission box

1

Fig. 2-35

1 Fixing bolt


20

18. Lift down the engine and put it on suitable

support.

1

Fig. 2-36

1 Engine


21

262 Assembly of Engine

Refer to the following steps to recover the engine.

4 Engine-related wiring harnesses

5 Engine throttle control wire





Engine

assembly


10 A/C hose

13 Fuel inlet pipe

14 Fuel return 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


2 Transmission box

3 Fixing bolts

1 Lift and assemble the

engine

8) A/C compressor

16 Engine hood

17 Coolant


22

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


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


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


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


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

Fig. 2-50


1

Fig. 2-51



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 2

Fig. 2-53

1 Compressor to condenser pipe

2 Evaporator to compressor pipe

1

Fig. 2-54



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

Fig. 2-56

1 Fuel inlet pipe

1

Fig. 2-57

1 Fuel return pipe


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

Fig. 2-60

1 Coolant filling port


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


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


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


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


34

6. Add fuel.

1

Fig. 2-73

1 Fuel filling port


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


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

Fig. 2-77


1 2

Fig. 2-78

1 Vent pipe 2 Water inlet pipe


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


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


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


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


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

Fig. 2-92


1

Fig. 2-93

1 Engine rear cover


42

10. Fill coolant.

1

Fig. 2-94

1 Coolant filling port (expansion

water tank)


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.


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


45

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.


46

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.

2Engine System ENGLISG-G9165

Documents

disassembly of engine

engine power

engine functions g9165

engine oil pressure

turbocharged diesel

engine technical parameters

overview of fuel system

lubrication system