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Agrison TX930LX Operation Manual

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Summary of Contents for Agrison TX930LX

  • Page 1 Agri ison TX920L – TX930LX Wheel L Loader Range peration Manual peration Manual...

  • Page 2: Table Of Contents

    Content INTRODUCTION OF NON ROAD SERIES DIESEL ENGINE ......1 PREFACE ................ 2 NOTICE FOR USERS............3 CHAPTER1 MAIN TECHNICAL SPECIFICATIONS AND PARAMETERS OF 90, 92, 95, 100, 102 SERIES DIESEL ENGINE ..........5 MAIN TECHNICAL SPECIFICATIONS .................... 5 (II) MAIN TECHNICAL DATA ............................21 TIGHTENING TORQUE OF MAIN BOLTS ........
  • Page 3 (III) C ........................28 OOLANT LUID (IV) S ....................30 TARTUP OF IESEL NGINE (V) R ..................35 UNNING IN OF IESEL NGINE (VI) P RECAUTIONS DURING PERATION OF IESEL NGINE ..........36 (VII) S ............38 HUTDOWN AND NSPECTION OF IESEL NGINE (VIII) S...
  • Page 4 (VIII) R ................58 EGULAR ECHNICAL AINTENANCE CHAPTER 4 COMMON FAULT ANALYSIS AND ELIMINATION APPROACHES FOR DIESEL ENGINE ........62 (I) D ................62 IFFICULT TARTUP OF IESEL NGINE (II) U ........65 NSTABLE INIMUM LOAD TEADY PEED PEED (III) U ................
  • Page 5 (XIII) M ......................82 ALFUNCTIONED TARTER (XIV) M ................ 83 ALFUNCTIONED HARGING YNAMO (XV) M ................84 ALFUNCTIONED OMPRESSOR (XVI) F ........88 AULT IAGNOSIS OF URBOCHARGER ON IESEL NGINE (XVII) M ALFUNCTIONED OWER TEERING ..............91 CHAPTER 5 PRESERVATION OF DIESEL ENGINE ......

  • Page 6: Introduction Of Non Road Series Diesel Engine

    Introduction of Non road Series Diesel Engine “Agrison” 90, 92, 95, 100, 102GB Series of diesel engine are designed. The advanced technology developed for diesel engines for non-road diesel machinery products .This series diesel engine has excellent power and economic indexes, high reliability and durability and mainly applicable for engineering and agricultural machinery, marine main and auxiliary engines, and small generating unit..

  • Page 7: Preface

    Preface Thanks for your choosing “Agrison” diesel engine. The Instruction is prepared for your understanding its operation and maintenance. For the sake of safety of person and property, please read it carefully before using. The mark “ ” in the Instruction shows that personal injury or other damages may be caused, please obey the instruction strictly.

  • Page 8: Notice For Users

    Notice for Users In order to guarantee the safety of person and property, please read the Instruction carefully before using and operate and maintain diesel engine according to the regulations in the Instruction strictly. Diesel engine’s startup, running-in, operation, shutdown shall be carried out properly according to the Instruction, wherein the new engine or that after overhaul must run in before using, through which the surfaces of moving parts of the engine can reach good matching so as to avoid abnormal abrasion and damage.
  • Page 9 When the running-in period comes to an end, please carry out maintenance in the near franchised service station as required by enclosed “Engine Service Manual”. For the details of 3-Rs (Return, Replacement and Repair at no charge) for Agrison engines, please refer to the “Engine Service Manual”.

  • Page 10: Chapter1 Main Technical Specifications And Parameters Of

    Chapter1 Main Technical Specifications and Parameters of 90、 92、 95、 100、102 Series Diesel Engine Parameters listed in the book based standard environment (atmospheric pressure: 100Kpa, inlet temperature 298, dry air pressure 99Kpa, water vapor partial pressure 1Kpa, relative humidity 30%) in the value under the condition;...
  • Page 11 ≤ 238 g/kW·h Min. Fuel Consumption Rate Crankshaft Rotating Direction Clockwise (from the front view of diesel engine) Lubricating Way Pressure & splash combined Cooling Way Forced circulating water cooled Oil Capacity（L） 6±0.2/7±0.2 230±20 Net Mass kg...
  • Page 12 Model No. 4100GB 4100GB-2 Model in-line four-cylinder, direct injection, water cooling, four-stroke, natural aspirated Total Piston Displacement L Bore×Stroke（mm） 100×105 100×115 Rated Power/Speed 46/2400 50/2400 45/2600 45/2650 52/2600 52/2800 53/2600 50/2400 kW/r/min Max.NetPower/Speed kW/r/min 44/2400 47/2400 42/2600 43/2650 45/2600 50/2800 50/2600 48/2400 Max.
  • Page 13 4102G 4102GB 4102TB 4102GB 4102GB Model No. in-line four-cylinder, direct injection, water cooling, four-stroke, natural aspirated Model 102×115 Bore×Stroke（mm） Total Piston Displacement Rated Power/Speed 52/2200 48/2300 48/2400 50/2400 51/2400 52/2400 55/2400 58/2400 46/2600 48/2600 55/2600 56/2600 55/2650 60/2800 kW/r/min Max.NetPower/Speed 50/2200 45/2300 45/2400 48/2400 48/2400 50/2400 52/2400 55/2400 44/2600 45/2600 52/2600 55/2600 52/2650 57/2800 kW/r/min 212-235...
  • Page 14 Model No. YN27GB1 YN30GB1 YN33GB1 YN33GB Model in-line four-cylinder, direct injection, water cooling, four-stroke, natural aspirated Bore×Stroke（mm） 90×105 95×105 100×105 Total Piston Displacement Rated Power/Speed 40/2600 45/2600 50/2600 48/2400 50/2400 52/2600 58.8/3200 kW/r/min Max.NetPower/Speed 37/2600 42/2600 47/2600 45/2400 48/2400 50/2600 55/3200 kW/r/min Max.
  • Page 15 Lubricating Way Pressure & splash combined Cooling Way Forced circulating water cooled Oil Capacity（L） 6±0.2/7±0.2 6.8±0.2/9.5±0.2 230±20 340±20 Net Mass kg (kg)
  • Page 16 Model No. YN36GB1 YN36GB2 YN36 YN38GB1 YN38GB2 Model in-line four-cylinder, direct injection, water cooling, four-stroke, natural aspirated Bore×Stroke（mm） 100×115 102×115 Total Piston Displacement L Rated Power/Speed 55/2600 50/2200 60KW/2600 65/2800 60/2600 62/2600 57/2600 kW/r/min Max.NetPower/Speed 52/2600 48/2200 58/2600 61.5/2800 57/2600 60/2600 55/2600 kW/r/min...
  • Page 17 Cooling Way Forced circulating water cooled Oil Capacity（L） 6.8±0.2/9.5±0.2 340±20 Net Mass kg (kg)
  • Page 18 Turbocharged Diesel Engine Model No. YN27GBZ YN27GBZ1 YN27GBZ2 YN30GBZ YN30GBZ1 Model in-line four-cylinder, direct injection, water cooling, four-stroke, turbocharged Bore×Stroke（mm） 90×105 95×105 Total Piston Displacement L Rated Power/Speed 60/2400 50/2600 52/2600 60/2600 60/2400 50/2600 62/2400 62/2600 65/2600 68/2600 kW/r/min Max.NetPower/Speed 57/2400 47/2600 49/2600 57/2600 57/2400 47/2600...
  • Page 19 Oil Capacity（L） 6±0.2/7±0.2 240±20 Net Mass kg (kg)
  • Page 20 Model No. YN38GBZ YN38GBZ1 YN38GBZ2 Model in-line four-cylinder, direct injection, water cooling, four-stroke, turbocharged Bore×Stroke（mm） 102×115 Total Piston Displacement L Rated Power/Speed 63/2600 58/2400 65/2400 75/2400 kW/r/min Max.NetPower/Speed 60/2600 55/2400 61/2400 71/2400 kW/r/min Max. Torque/Speed 260-360/1800-2200 N·m/r/min Cylinders Working Sequence 1-3-4-2 Min.Idling Stabilized Speed 800 ±20...
  • Page 21 Oil Capacity（L） 6.8±0.2/9.5±0.2 350±20 Net Mass kg (kg)
  • Page 22 YN4A08 YN4A08 YN4A075-3 YN4A06 YN4A062-3 YN4B092- YN4B0 Model No. YN4A075-31 8-30 5-30 2-30 85-30 in-line four-cylinder, direct injection, water cooling, four-stroke, turbocharged、Electric-EGR Model Bore×Stroke（mm） 90×105 92×105 Total Piston Displacement L Rated Power/Speed 65/2600 63/2400 55/2400 45/2400 45/2600 55/2600 68/2600 63/2400 kW/r/min Max.NetPower/Speed 62/2600...
  • Page 23 Cooling Way Forced circulating water cooled Oil Capacity（L） 6±0.2/7±0.2 240±20 Net Mass kg (kg)
  • Page 24 YN4C082- YN4C0 YN4C075- YN4D08 YN4E102-3 YN4E09 YN4E088-3 Model No. YN4E106-30 75-30 8-30 5-30 in-line four-cylinder, direct injection, water cooling, four-stroke, turbocharged、Electric-EGR Model 100× Bore×Stroke（mm） 100×105 102×115 Total Piston Displacement L Rated Power/Speed 60/2600 55/2400 55/2600 65/2600 78/2600 75/2400 70/2600 65/2400 kW/r/min Max.NetPower/Speed 57/2600...
  • Page 25 Cooling Way Forced circulating water cooled Oil Capacity（L） 6.8±0.2/9.5±0.2 350±20 Net Mass kg (kg)

  • Page 26: (Ii) Main Technical Data

    (II) Main Technical Data Valve Clearance Table 2 Cold 0.30～0.35mm Intake state Valve 0.25～0.30mm state Cold 0.35～0.40mm state Exhaust Valve 0.30～0.35mm state Temperature and Pressure Ranges of Diesel Engine under Normal Situation Table 3 Leaving Water ≤ 95℃ Temperature 196～588 kPa Oil Pressure Oil Pressure at Min.

  • Page 27: Tightening Torque Of Main Bolts

    3. Tightening Torque of Main Bolts Table 4 490、 495 （YN27、 YN30） Series 4100、4102（YN33、YN36、YN38） Model No. Diesel Engine Series Diesel Engine Bolts for Cylinder 130~160N·m（13~16kgf·m） 160~200N·m（16~20kgf·m） Head Bolts for Main 140~170N·m（14~17kgf·m） 200~240N·m（20~24kgf·m） Bearing Bolts for 100~130N·m（10~13kgf·m） 100~140N·m（10~14kgf·m） Connecting Rod 100~130N·m（10~13kgf·m） 100~140N·m（10~14kgf·m）...

  • Page 28: Tightening Torque Of General Bolts And Nuts (For Reference)

    4. Tightening Torque of General Bolts and Nuts (For Reference) Table 5 Nominal Diameter of Bolt mm Strength Class of Bolt Tightening Torque N.m 12~15 25~31 44~54 69~88 108~137 147~186 206~265 14~18 29~39 49~64 83~98 127~157 176~216 245~314 9~12 22~29 44~58 76~102 121~162...
  • Page 29 5. Recommended Value of Tightening Torque of Screw Plug Table 6 Thread Size NPT1/8 NPT1/4 NPT3/8 NPT1/2 NPT3/4 NPT1 Tightening 8～14 24～34 47～68 68～95 88～102 Torque N.m...

  • Page 30: Chapter2 Operation Of Diesel Engine

    Chapter2 Operation of Diesel Engine (I) Fuel In order to guarantee the reliability of supply system, the clean diesel produced by regular oil company in the country and in conformity with the state’s standard must be used; in case of automatic filing, the fuel vessel must be clean and used exclusively;...
  • Page 31 Notice: 1. Too much collecting water in the water-filtering cup at the lower part of oil-water separator will cause the engine not to be started, which will be eliminated in time. 2. Be sure not to operate till the fuel tank is completely empty; otherwise it may lead to air entering in the fuel pipeline causing abnormal supply and power cutoff.

  • Page 32: (Ii) Lubricating Oil

    (II) Lubricating Oil Diesel engine shall use the diesel at CD level or above. The viscosity number of selected oil is related to ambient temperature. When the temperature is low, high viscosity will increase startup resistance and the engine can not reach starting speed easily so that the startup is difficult.

  • Page 33: (Iii) Coolant Fluid

    (III) Coolant Fluid Diesel engine shall use antifreeze coolant fluid (which may use alcohol and glycerin mixture or glycol). It has the necessary performance of antifreeze, anticorrosion, antiscale and increasing boiling point. If there is no antifreeze fluid, clean soft water, such as river water, rain water, shall be used, which has poor mineral composition and little scale deposit after heated so that the cooling system will not be clogged easily and affect heat dissipation.
  • Page 34 5. Do not add hard water, such as well water, tap water; once the coolant fluid is found to have any suspended or deposited matter, or has been stunk, it is demonstrated that it has been reacted chemically and deteriorated and malfunctioned; at this time, the cooling system should be cleaned in time and the coolant fluid should be replaced completely.

  • Page 35: (Iv) Startup Of Diesel Engine

    (IV) Startup of Diesel Engine Preparation and Inspection before First Startup: Upper mark 1. Fill lubricating oil into oil pan till reaching upper mark on dipstick. 2. Add coolant fluid till reaching water tank filler, and stand 4 to 5 minutes to remove the air inside ,then cover the filler cap.
  • Page 36 Preparation and Inspection before Daily Startup: 1. Stop vehicle at flat ground with parking brake. 2. Pull out dipstick 3. Wipe it with clean cloth, then insert it again down to the bottom. 4. Pull out the dipstick again and check the oil level. 5.
  • Page 37 Starting procedure of cold engine (ambient temp. is higher than 0℃): 1. Switch on with the key and check each electrical instrument for normal indication. “ON”. 2. Turn the ignition key to 3. Press the accelerator to the half extent and start the diesel engine. 4.
  • Page 38 Starting procedure of hot engine 1. Switch on with the key and check each electrical instrument for normal indication. 2. Turn the ignition key to “ON”. 3. It should loosen the ignition key after starting the diesel engine . Notice: When lubricating oil or oil filter is replaced or diesel engine is not used for long time (more than 1 week), oil pump shall be in oil-break before startup and vehicle is empty load condition;...
  • Page 39 Warming up and inspection after startup: 1. Diesel engine shall be idling for 3～5min after startup for warming up, but cold engine shall be prevented from idling for long time. 2. The followings shall be checked during warming up: Oil pressure (the alarm light thereof is off after warming up). Charging state of dynamo (the indicator light thereof is off during warming up).

  • Page 40: (V) Running-In Of Diesel Engine

    80% of rated speed. Do not let the engine idle for a long time, after the end of the run, after running to be "forced to go together maintenance" (see Chapter III, seventh). Recommended to the Agrison Power technical service stations of were " compulsory running-in maintenance."...

  • Page 41: (Vi) Precautions During Operation Of Diesel Engine

    4. Diesel engine with the harvest units to throttle the half open walking 5 hours of operation 5.Before the harvester works continuously，the lubricating oil pressure should reach 2kgf/cm2，water temperature raise to 60℃.After that the harvester begin to keep a slow speed with small feed quantity，and increase the load gradually to the rated feed quantity.
  • Page 42 The engine and related parts has any abnormal sound, which shows that it runs abnormally or the moving part has abnormal friction; thus the engine should be shut down for inspection. 4. Exhaust Smoke Color Volume of white or black smoke rose from the engine, which shows the combustion inside is abnormal and the engine should be shut down for inspection.

  • Page 43: (Vii) Shutdown And Inspection Of Diesel Engine

    (VII) Shutdown and Inspection of Diesel Engine 1. Before the engine has been shut down,it should make sure the gear has been positioned in neutral and the vehicle has been in the empty load condition. 2. Diesel engine shall be operated at low speed for 3-5 minutes before shutdown so as to be cooled down completely, during which the engine shall be checked for leakage of water, oil and gas and abnormal sound.
  • Page 44 prevent from being scalded. 4. It is necessary to ensure the effective ventilation when diesel engine is used, because it will exhaust harmful gas and soot. 5. The influence of waste gas, exhaust smoke and noise on surrounding environment, personnel and articles has to be taken into account when diesel engine is working.

  • Page 45: Chapter 3 Regular Inspection And Technical Maintenance

    Chapter 3 Regular Inspection and Technical Maintenance AS the condition of most of Non road engine is very scurviness . The service life of engine is depended on time and mode of use. If no attention is paid to decreased performance of engine, the vehicle’s performance will be reduced.
  • Page 46 Notice: If frequent drainage is required, please drain the water in fuel tank at the service station of Agrison Power to get rid of water. Replacement of Diesel Filter Replacement Cycle The replacement cycle for the diesel filter: Under the condition of guarantee fuel to clean every 12 months or the cumulative work 320 hours.
  • Page 47 tightened. Exhaust the gas in fuel pipes. Start up engine and check for the leakage. Exhaust in Fuel System Air entering into the fuel system will lead to difficult startup of engine and other failures. If the fuel tank is emptied during maintenance, please exhaust the gas in the fuel system after refilling of fuel.
  • Page 48 exhausting in the system is required, pump fuel with manual pump and then tighten the nut on manual lever. The joint of fuel suction pipe is set at the bottom of the transfer pump; and inside the joint bolt, there is a small sieve which is arranged at the front portion of the fuel passage impeding most of impurities.

  • Page 49: (Ii) Lubricating System

    Stop the engine. Cut off the power and wait at least 10 to 15 minutes. Loosen the filter with special wrench. (Depending on the specification of the engine, a special cap wrench is required. If there is any question, please consult to Agrison service station.) Then screw off the filter by hand.
  • Page 50 Wipe the mounting surface of the filter clean. Include new filter with rubber gasket which is dipped with oil fully. Screw on the filter by hand till the hand can not play the role, and then tighten it with wrench. Loosen drain screw on oil pan with wrench to drain off the oil;...
  • Page 51 Oiling capacity (Approx): Unit：Liter Table 10 Integrated oil pan Welded oil pan Oil filter replaced Oil filter not replaced Note: The recommended lubricating oil is used (Refer to the section of “Lubricating Oil” in Chapter 2 for details) with the filling capacity is different based on the oil temperature and oil draining time. The above vales are for reference only and the oil level must be checked with dipstick after replacement of oil.

  • Page 52: (Iii) Cooling System

    (III) Cooling System 1. Inspection and Adjustment Requirement of Belt Check the belt for cracks, cilia, wearing or attachment of oil. Replace it if necessary. The belt is not allowed to contact the bottom of the groove. Check and adjust the tightness of the belt. Loose belt will lead to excessive temperature of the water in the engine or tight belt to wearing or breaking of belt.
  • Page 53 Belt Deviation： Unit：mm Table 11 f new belt Driving belt Deviation of used belt Deviation o Deviation after Limit adjustment 12～13 8～9 7～8 Fan belt 98N（10kg） Pressure applied 2.Engine cooling fluid When the engine is in operation, sufficient coolant fluid inside the cooling system is required to guarantee normal work;...
  • Page 54 Replacement Procedure of Coolant Fluid in Engine Open both drain plug and radiator cap. Open the drain valve on the engine block. Tighten the water switch on the block after drainage of coolant fluid. Fill water into the radiator Keep the engine at the speed of 1600-2000rpm for about 1 minutes to vent air. Shut down and repeat the step 2 to 4 two to three times.

  • Page 55: (Iv) Air Intake System

    (IV) Air Intake System The status of air intake system will affect the life and performance of the engine and the air compressor to a great extent. It is recommended to use one air filter for both air compressor and the engine and clean and maintain it frequently.

  • Page 56: (V) Battery

    (V) Battery 1. The surface of battery shall be kept clean and dry. Any corrosive liquid shall be washed away with alkaline water. 2. The joint of battery shall be ensured clean and firm. 3. The negative terminal of battery shall be cut off (or the master supply switch be cut off) if the vehicle is not used in 30 days or longer so as to prevent from electric leakage.

  • Page 57: (Vi) Air Compressor

    (VI) Air Compressor Air compressor is the pressure gas source for braking. Its performance will affect the safety of driving. In order to guarantee the compressor to work reliably, the followings shall be obeyed. 1. Do not increase the pressure setting of the pressure adjusting valve on air cylinder at discretion. 2.
  • Page 58 Clean away dirts on the sheet and seat of the inlet valve by gasoline or diluting Remove the four agent. bolts on the top of the cylinder head. Exhausting Exhausting valve valve seat sheet （Back） Clean away dirts on the sheet and Pressing plate for seat exhausting...

  • Page 59: (Vii) Usage And Technical Maintenance In Winter

    (VII) Usage and Technical Maintenance in Winter When the temperature is below 5 ℃ i n w i nt er ,t he diesel may be frozen due to low temperature of diesel engine body and large viscosity of lubricating oil, which results in difficult startup of the engine. Hence it had better be carried out comprehensive technical maintenance once before entering into winter and the followings shall be noticed in usage: 1.
  • Page 60 2. Coolant Fluid When the temperature decreases below 5℃, t he w at er i n t he cool i ng syst em sha l l be drai ned af t er shutdown. In order to avoid draining and filling water repeatedly, we recommend to use antifreeze coolant fluid (refer to the section of “Coolant Fluid”...
  • Page 61 Cold startup requires current consumption to a larger extent, thus comparing to normal temperature, more time is needed for recharge after startup. The electrolyte of undercharged battery has low specific density so that it is easy to be iced up and damaged.
  • Page 62 off fuel and let the engine rotate in the empty load condition.And it make every active part rotate easily to minish the viscosity of lubricating.Finally preheat engine and start engine.
  • Page 63 (VIII) Regular Technical Maintenance Regular maintenance is important and rational use of the diesel engine project, in order to make the diesel engine to maintain a good technical condition, long-term reliable work for you, it must be carefully technical maintenance according to specifications. When maintenance, pay special attention to cleaning the parts, when dismantling parts reinstall, should be cleaned and ensure the correct installation, and then start checking whether functioning properly.
  • Page 64 2、Check the coolant fluid of water tank;add properly in case of shortage. 3 、 Check the battery electrolyte fluid level, it should be maintained above the plate 10~15 mm, should add distilled water shortage. 4、Check oil tank for shortage and add properly if required. 5 、...

  • Page 65: Maintenance

    6.Clean away the dirts on the radiating surface of charge air cooler and the surface of water tank. 7. Use compressed air to clean air filter. 8.Clean the air compressor (a pump) with independent air filter element. 9. put engine oil. 10.
  • Page 66 2.Replace the element of air filter.  The third level Technical Maintenance： Accomplish “The first level Technical Maintenance”， the followings must be done:： 1.Replace the element of diesel filter. 2.Replace the element of air filter.

  • Page 67: Diesel Engine

    Chapter 4 Common Fault Analysis and Elimination Approaches for Diesel Engine Notice: All fault eliminations are proposed to be disposed in the service station authorized by A g r i s o n ; otherwise you may not be entitled to enjoy the “Three Commitments”. (I) Difficult Startup of Diesel Engine Fault Characteristics &...
  • Page 68 injector, adjust the injection pressure; or f） injector disgorges no or minor amount replace the injector assembly. of fuel, has low injection pressure, or g） Replace the injection pump, spring or matching has bad atomization; the pressure adjusting spring thereof is damaged; part for the piston.
  • Page 69 exceed the specified limits. e） Replace the cylinder liner and the piston. 3. Diesel has large viscosity and is difficult Heat the cooling water and use proper diesel. to be atomized due to too low temperature, even clogs fuel pipe. 4.

  • Page 70: (Idle Speed )

    (II) Unstable Minimum No-load Steady Speed (Idle Speed) Fault Characteristics & Causes Elimination Approaches 1. The minimum no-load steady speed (idle speed) 1. Go to Agrison technical service station to is low. check fuel system. 2. High-speed and idle-speed accelerator handle 2.
  • Page 71 the specified limits. position; e) Replace the cylinder liner and the piston. 9. Gear mark is wrong. 9. Adjust gear timing marks. 10. Internal sieve of bolt is clogged. 10. Clean the sieve. 11. Oil pump does not work properly. 11.

  • Page 72: N O - Load Steady Speed Diesel Dngine

    (III) Unstable Speed of Diesel Dngine Fault Characteristics & Causes Elimination Approaches 1. Fuel pipe a) Air exists in supply system. a) Exhaust the air in the fuel system and tighten the connections of the fuel pipe； b) Excessive water content is included in fuel. b) Replace the fuel；...
  • Page 73 (IV) Underpower of Diesel Engine Fault Characteristics & Causes Elimination Approaches 1. Clean the element or replace it if 1. Element of air filter is clogged. necessary. 2. Clean away the oil stain inside the cooler 2. Intercooler is too dirty. as well as impurities and dust outside.
  • Page 74 12. Refer to Item 8 in (II) “unstable idle 12. Compression pressure in cylinder is insufficient. speed”. 13. Injection timing is improper. 13. Adjust the gear to align the mark. 14. Injection pump works improperly. 14. Adjust or replace the pump. 15.

  • Page 75: Diesel Engine

    (V) Sudden Decreased Speed or Shutdown of Diesel Engine Fault Characteristics & Causes Elimination Approaches 1. Fuel system a）Loosen vented screw to exhaust the air. a) Air is entrained in low-pressure fuel pipeline. b) Water is mixed in fuel. b) Screw off the drain plug of oil-water separator under coarse filter to drain the c) Filter is clogged by impurities.

  • Page 76: Exhaust

    (VI) Abnormal Smoke Exhaust Fault Characteristics & Causes Elimination Approaches 1. White smoke rises. a) Water penetration exists in cylinder. a) Check and eliminate the fault. b) Water is included in fuel. b) Replace the fuel. c) Fuel has too bad atomization. c) Clean or replace the injector.
  • Page 77 mark. g) Intercooler is too dirty. g) Clean away impurities and dust on the outside surface of the intercooler.

  • Page 78: Engine

    (VII) Overheated Diesel Engine Fault Characteristics & Causes Elimination Approaches 1. Cooling water in the tank is insufficient or 1. Fill up or replace the cooling water in the tank. contaminated. 2. Get rid of the scale, foreign matters in the pipes 2.

  • Page 79: Diesel Engine

    (VIII) Abnormal Sound during Operation of Diesel Engine Fault Characteristics & Causes Elimination Approaches 1. Fuel injection is too early; there is rhythmed and clear 1. Adjust the advance angle of fuel supply. metallic rapping in cylinder. 2. Fuel injection is delayed too much; there is dull and 2.

  • Page 80: Ound During Operation Of Oil Consumption

    knock can be heard at cylinder head cover. 8. Top of piston bumps cylinder head or valve so that 8. Adjust the valve clearance, valve timing metallic rapping can be heard near the cylinder head in or replace the head gasket. case of low speed.
  • Page 81 Fault Characteristics & Causes Elimination Approaches 1. Lubricating oil is too much or splashed 1. Drain some oil. excessively. 2. Oil leaks at drain bolt, oil filter, cylinder head, oil 2. Tighten the bolt, replace the gasket, replace pan gasket, cylinder head cover gasket, front and the end cap or plug.

  • Page 82: Onsumption

    (X) Excessive Fuel Consumption Fault Characteristics & Causes Elimination Approaches 1. Air filter is clogged. 1. Clean or replace the filter element. 2. Get rid of impurities and dust on outside surface of 2. Intercooler is too dirty. the intercooler. 3.

  • Page 83: Ubricating System

    (XI) Malfunctioned Lubricating System...
  • Page 84 Fault Characteristics & Causes Elimination Approaches 1. Oil pressure is too low. a) Oil pan is short of oil. a) Oil to the marking line on the dipstick. b) Oil passage is clogged. b) Clean the oil passage and blow off by compressed air.
  • Page 85 8. Connecting rod bearing and main bearing are 8. Replace the connecting rod bearing and the worn. main bearing. 9. Oil pressure gauge is damaged. 9. Replace the pressure gauge.

  • Page 86: Ooling System

    (XII) Malfunctioned Cooling System Fault Characteristics & Causes Elimination Approaches 1. Water temperature is too high. a) Cooling water is insufficient. a) Fill up cooling water into the tank. b) Spring of radiator cap is soft. b) Replace the spring. c) Belt of water pump is loose or damaged.

  • Page 87: S Tarter

    (XIII) Malfunctioned Starter Fault Characteristics & Causes Elimination Approaches 1. Starter does not work. a) Connection has poor contact. a) Clean and tighten the contact. b) Battery is undercharged. b) Charge up the battery. c) Electric brush has poor contact. c) Clean the commutator surface.

  • Page 88: C Harging D Ynamo

    (XIV) Malfunctioned Charging Dynamo Fault Characteristics & Causes Elimination Approaches charged completely; undercharged; unstable charging current a) Replace in time if damaged. a) Measure diode or IC regulator one by one with multimeter after opening the back cover b) Replace in time if damaged. of dynamo.
  • Page 89 (XV) Malfunctioned Air Compressor Fault Characteristics & Causes Elimination Approaches a) Check the relief valve components, clean or 1. No inflating replace failure ones. a) Relief valve of air compressor is seized. b) Take down and check the cylinder head, check b) Valve sheet is deformed or broken.
  • Page 90 excessively or broken. head gasket. e) Bolt on cylinder head is loose and head f) Replace the pipe or joint. gasket is washed out causing air leakage. f) Pipe between air compressor and air tank is broken or air leaks from the joint thereof. 3.
  • Page 91 oil inlet of air compressor). i) Replace with qualified lubricating oil. 4. There is abnormal sound in air compressor. a) Check and replace the connecting rod bearing a) Connecting rod bearing and bushing, or main and bushing, main shaft bearing; tighten the bolt on bearing is worn seriously or damaged, and bolt connecting rod.
  • Page 92 seal. c) Check or replace packing plate; tighten joint bolts c) Leakage occurs at junction face; joint on oil for oil inlet and return. inlet or return pipe is loose. d) Check and readjust the belt tensity. d) Belt is fixed tightly causing abrasion on main bearing shell.

  • Page 93: Iagnosis Of T Urbocharger On D Iesel E Ngine

    (XVI) Fault Diagnosis of Turbocharger on Diesel Engine Besides diesel engine faults is disposed in accordance with fault analysis and elimination approaches recommended in the Instruction, the working situation of turbocharger shall be checked and evaluated to judge the errors thereof. Turbocharged diesel engine has the common faults as follows: 1.
  • Page 94 Issues On-Engine Fault Diagnosis Table Possible Causes Elimination Approaches Clean or replace the filter √ √ √ √ √ Air filter is too dirty. element. Air leaks from pipeline between Tighten the fasteners or √ air filter and gas compressor. replace the sealing parts.
  • Page 95 Clear away foreign Inlet duct of gas compressor is √ √ √ √ √ √ √ matters or replace the impeded. damaged parts. Clear away foreign Outlet duct of gas compressor √ √ √ matters or replace the is impeded. damaged parts.
  • Page 96 Crankcase breather of diesel Clear away foreign √ √ √ √ engine is impeded. matters or replace. As the case may be, Center housing of turbocharger replace lubricating oil and √ √ √ √ has dirt retention or coking. the oil filter element, or replace the turbocharger.
  • Page 97 disassemble it. If replace the power steering pump only, the trouble may not be solved, even new troubles may occur. Therefore carry out fault diagnosis at first, and then eliminate it once find out the reason. A power steering pump having been in normal operation is unlikely to have defect on its own in the future service.
  • Page 98 Fault Characteristics & Causes Elimination Approaches 1. The pump neither sucks oil nor has pressure (the actuating mechanism does not a) Dismantle and clean the filter and the pipe; or work). replace the fluid. a） The filter or the suction pipe is clogged. b) Check and tighten related threaded connecting b）...
  • Page 99 the compensating groove on oil distribution b） Check and get rid of the blockage in the disc is clogged. compensating groove. c） The suction pipe has too large resistance, c） Check and get rid of the blockage. even clogged. d） Check and replace the worn parts inside the d）...
  • Page 100 Chapter 5 Preservation of Diesel Engine Never used diesel engine or diesel powered vehicle, if long-term storage is required, shall be disposed in advance in accordance with the following requirements: 1. Drain the lubricating oil off. 2. Open water drain valve to drain the coolant fluid off inside the diesel engine. 3.
  • Page 101 cleaning. 2. Open water drain valve to drain the coolant fluid off inside the diesel engine. 3. Drain the diesel off inside the fuel tank and the pipeline thereof. 4. Get rid of the dust on the element of air filter (paper type). 5.
  • Page 102 Chapter 6 Lifting, Installation and Depreservation of Diesel Engine When lift diesel engine in packing case, hitch the lower four corners of the packing case with wire cable. Diesel engine unpacked has two lugs at both sides of the cylinder head for lifting. When diesel engine unpacked is placed, the oil pan is prohibited from landing.
  • Page 103 Addenda The list of vulnerable parts Number Name Main liner Crankshaft thrust sheet Cylinder head gasket Cylinder liner Water seal ring Piston Piston ring Piston pin Bearing of connecting rod shaft Front Oil seal Back Oil seal...
  • Page 104 Addenda Packing list Serial Sort Apellation Amount Unit Remark number Diesel engine Qualification Document with diesel engine Inside of packaging Operation instruction Serving enchiridion Packing list Remarks： 1.This list is only applicable to the common type. Spare parts for special customer requirements models or random accessories, Add in the box under the contract.
  • Page 105 Agrison 2098 Hume Highway Campbellfield Victoria Australia 3061 P: 1300 651 830 Fax: 1300 854 830 Intl: + 61 3 9357 8867 contact@agrison.com.au www.agrison.com.au *All rights reserved.

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