Escolar Documentos
Profissional Documentos
Cultura Documentos
SERVICE MANUAL
2 Engine System
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
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
excellent
dynamic
property
and
intake,
compression,
power
and
exhaust.
forces
the
piston
to
move
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
Parameters
Items
Parameters
Model
WP6G175E21
Inline, water-cooled,
turbo charged and
intercooled
Cylinder quantity
105/130
210
680
Displacement (L)
Emission standard
China II
GB20891-2007
Type
Rated power (kW)
129
6.75
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
Fan
Radiator
Thermostat
Cylinder cover
Pump
Diesel engine block
control
of
automatically.
can
be
During
adjusted
major
to
80~95oC
circulation,
the
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
6 Turbocharger
6
7Pressure-limiting valve
Injector
Fuel
injection
pump
Fuel
fine
filter
Fuel
dilivery
pump
Oil-water
separator
Fuel tank
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.
the
intake
valves
will
open
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
1 Preparation
1) Generator
2 Drain coolant
3 Engine hood
4 Engine-related wiring
harnesses
5 Engine throttle control
wire
11
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.
1
Fig. 2-13
1 Water drain valve
3.
1
Fig. 2-14
1 Engine hood
12
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
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
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
7.
8.
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
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
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
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
1
Fig. 2-36
1 Engine
20
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
21
7) Starter motor
8) A/C compressor
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.
1
Fig. 2-38
1 Transmission box
3.
1
Fig. 2-39
1 Fixing bolt
22
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
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
1
Fig. 2-45
1 Ground wire
24
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
7.
8.
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
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
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
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
ATTENTION
Considering
that
the
fuel
is
highly
1
Fig. 2-61
1 Oil drain plug
3.
1
Fig. 2-62
1 Fuel sensor connector
1
Fig. 2-63
1 Reverse buzzer
30
1
Fig. 2-64
1 Fuel inlet pipe
5.
1
Fig. 2-65
1 Fuel return pipe
6.
ATTENTION
Hang the fuel tank with lifting appliance to
prevent falling.
1
Fig. 2-66
1 Fixing bolt
31
1
Fig. 2-67
1 Fuel tank
Assembly of fuel tank
1.
1
Fig. 2-68
1 Fuel tank
2.
1
Fig. 2-69
1 Fixing bolt
32
4.
5.
1
Fig. 2-70
1 Fuel return pipe
1
Fig. 2-71
1 Fuel inlet pipe
1
Fig. 2-72
1 Reverse buzzer
33
1
Fig. 2-73
1 Fuel filling port
34
Add fuel.
ATTENTION
Before removing the fixing bolts, you should
hang the radiator with lifting appliance to
prevent falling.
In
the
process
of
disassembling,
the
1
Fig. 2-74
1 Water drain valve
2.
1
Fig. 2-75
1 Engine rear cover
35
4.
5.
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
Fig. 2-79
1 Water refill pipe
2 Water outlet pipe
7.
Fig. 2-80
1 Hydraulic oil inlet pipe
2 Transmission oil inlet pipe
8.
Fig. 2-81
1 Hydraulic oil outlet pipe
2 Transmission oil outlet pipe
37
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
1
Fig. 2-85
1 Fixing bolt
2.
3.
1
Fig. 2-86
1 Radiator wind deflector
Fig. 2-87
1 Hydraulic oil inlet pipe
2 Transmission oil inlet pipe
39
Fig. 2-88
1 Hydraulic oil outlet pipe
2 Transmission oil outlet pipe
5.
Fig. 2-89
1 Vent pipe
Fig. 2-90
1 Water refill pipe
2 Water outlet pipe
40
8.
9.
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
1
Fig. 2-94
1 Coolant filling port (expansion
water tank)
42
Adjustment factors
Blockage of fuel filter or fuel supply pump oil inlet pipe connector filter screen.
Solution: Clean or replace it/them.
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.
Bad atomization of injected fuel, the fuel fails to burn in the combustion champ.
Solution: Adjust the injector and fuel supply advance angle.
Too little gap in force-feed lubricating positions or blocked engine oil filter.
Solution: Adjust the gap, clean or replace the filter.
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.
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 thermostat.
Solution: Replace the thermostat.