2Engine System ENGLISG-G9165

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.

9


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 Red—Exhaust Blue —Filtered 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


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

3) Electric flameout device

4 Engine-related wiring harnesses 5 Engine throttle control wire

4) Engine oil pressure switch

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

5) Ground wire

6) Engine water temperature sensor 7) Starter motor 8) A/C compressor


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 awa y. 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


4.

Disconnect

the

engine

related

wiring

harnesses. 1)

Disconnect the generator wiring harness.

2)

Disconnect the wiring harness of starting

1 Fig. 2-15 1 Generator wiring harness

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


4)

Disconnect the engine oil pressure switch wiring harness.

1 Fig. 2-18 1 Engine oil pressure switch 5)

Disconnect the ground wire.

6)

Disconnect the water temperature sensor

1 Fig. 2-19 1 Ground wire

wiring harness.

1 Fig. 2-20 1 Water temperature sensor

14


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.


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


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


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

1

2

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


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


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

1 Fig. 2-36 1 Engine

20


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

Engine assembly

1) Generator

4) Engine oil pressure switch 5) Engine water temperature sensor 6) Ground wire

6 Radiator water inlet pipe

7) Starter motor

7 Radiator water outlet pipe

8) A/C compressor

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


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


22


4.

Connect the engine related wiring harnesses. 1)

Connect the generator wiring harness.

2)

Connect the wiring harness of starting

1 Fig. 2-40 1 Generator wiring harness

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


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)

1 Fig. 2-45 1 Ground wire

24

Connect the ground wire.


7)

Connect the starter motor wiring harness.

8)

Connect

1 Fig. 2-46 1 Starter motor the

A/C

compressor

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.

wiring


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


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.


27


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


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


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


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.


31


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


32


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


6.

1 Fig. 2-73 1 Fuel filling port

34

Add fuel.


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.


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. 2-78 1 Vent pipe

2 2 Water inlet pipe

36


6.

Disconnect the radiator water outlet pipe and water refill pipe.

1

2

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.

1

2

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.

1

2

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


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.

1

2

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


4.

Connect the transmission oil outlet pipe and hydraulic oil outlet pipe to the radiator.

1

2

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

Connect the radiator water inlet pipe and vent pipe.

1

2

Fig. 2-89 1 Vent pipe

2 Water inlet 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 40


7.

Connect the intercooler air inlet pipe.

8.

Connect the intercooler air exit pipe.

9.

Install the engine rear cover.



1 Fig. 2-93 1 Engine rear cover

41


10. Fill coolant.

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

42


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 professionall y.

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. 43


Solution: Regulate oil supply or troubleshoot plunger and bar rel 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 wit hin 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 44


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 t he 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. 45

2Engine System ENGLISG-G9165

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