Agrison TX920L Operation Manual Download Page 7

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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.

The instruction marked with “Notice” in the Instruction shows that personal injury or

slight damages on gadget may be caused, please follow the operation procedure carefully.

Summary of Contents for TX920L

Page 1: ...Agri TX930LX Wheel L Op Op ison TX920L Loader Range peration Manual peration Manual ...

Page 2: ...CAL SPECIFICATIONS AND PARAMETERS OF 90 92 95 100 102 SERIES DIESEL ENGINE 5 I MAIN TECHNICAL SPECIFICATIONS 5 II MAIN TECHNICAL DATA 21 3 TIGHTENING TORQUE OF MAIN BOLTS 22 4 TIGHTENING TORQUE OF GENERAL BOLTS AND NUTS FOR REFERENCE 23 CHAPTER2 OPERATION OF DIESEL ENGINE 25 I FUEL 25 II LUBRICATING OIL 27 ...

Page 3: ...IESEL ENGINE 36 VII SHUTDOWN AND INSPECTION OF DIESEL ENGINE 38 VIII SECURITY WARNING 38 CHAPTER 3 REGULAR INSPECTION AND TECHNICAL MAINTENANCE 40 I FUEL SUPPLY SYSTEM 40 II LUBRICATING SYSTEM 44 III COOLING SYSTEM 47 IV AIR INTAKE SYSTEM 50 V BATTERY 51 VI AIR COMPRESSOR 52 VII USAGE AND TECHNICAL MAINTENANCE IN WINTER 54 ...

Page 4: ...SPEED 65 III UNSTABLE SPEED OF DIESEL DNGINE 67 IV UNDERPOWER OF DIESEL ENGINE 68 V SUDDEN DECREASED SPEED OR SHUTDOWN OF DIESEL ENGINE 70 VI ABNORMAL SMOKE EXHAUST 71 VII OVERHEATED DIESEL ENGINE 73 VIII ABNORMAL SOUND DURING OPERATION OF DIESEL ENGINE 74 IX EXCESSIVE LUBRICATING OIL CONSUMPTION 75 X EXCESSIVE FUEL CONSUMPTION 77 XI MALFUNCTIONED LUBRICATING SYSTEM 78 XII MALFUNCTIONED COOLING SY...

Page 5: ...G DYNAMO 83 XV MALFUNCTIONED AIR COMPRESSOR 84 XVI FAULT DIAGNOSIS OF TURBOCHARGER ON DIESEL ENGINE 88 XVII MALFUNCTIONED POWER STEERING PUMP 91 CHAPTER 5 PRESERVATION OF DIESEL ENGINE 95 CHAPTER 6 LIFTING INSTALLATION AND DEPRESERVATION OF DIESEL ENGINE 97 ...

Page 6: ...llation of vehicles units To ensure the normal use of the diesel engine this specification describes the knowledge of non road diesel machinery technical parameters structure performance and other aspects while providing the use maintenance and fault analysis of technical information and other aspects The data and description offered in the Instruction shall be based on current products solely Ple...

Page 7: ...ety 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 The instruction marked with Notice in the Instruction shows that personal injury or slight damages on gadget may be caused please follow the operation procedure carefully ...

Page 8: ... specification Strictly prohibit running in at idle speed at original place 3 Operators shall pay attention to the safety warning marks Do not close to the area with safety warning during the operation of diesel engine 4 In order to prolong the life of starter and battery the continuous starting time of starter shall not exceed 15 seconds If restart is required turn the ignition key to OFF and res...

Page 9: ...unning in period comes to an end please carry out maintenance in the near franchised service station as required by enclosed Engine Service Manual 8 For the details of 3 Rs Return Replacement and Repair at no charge for Agrison engines please refer to the Engine Service Manual 9 Please keep Conformity Certificate of engine and Engine Service Manual well ...

Page 10: ...I Main Technical Specifications Natural Aspirated Diesel Engine Table 1 Model No 490G 490GB 490T 495T 495GB Model in line four cylinder direct injection water cooling four stroke natural aspirated Total Piston Displacement L 2 7 3 0 Bore Stroke mm 90 105 95 105 Rated Power Speed kW r min 39 2650 39 2650 33 2600 39 2650 36 8 2400 38 2400 42 2650 45 2650 42 2800 Max NetPower Speed kW r min 37 2650 3...

Page 11: ... Rate 238 g kW h 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 Net Mass kg 230 20 ...

Page 12: ...x NetPower Speed kW r min 44 2400 47 2400 42 2600 43 2650 45 2600 50 2800 50 2600 48 2400 Max Torque Speed N m r min 185 224 1600 2000 234 250 1700 2000 Cylinders Working Sequence 1 3 4 2 Min Idling Stabilized Speed 800 850r min Min Fuel Consumption Rate 238 g kW h Crankshaft Rotating Direction Clockwise from the front view of diesel engine Lubricating Way Pressure splash combined Cooling Way Forc...

Page 13: ...etPower Speed kW r min 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 Max Torque Speed N m r min 212 235 1700 2 000 250 265 1 600 1800 212 235 1700 2000 Cylinders Working Sequence 1 3 4 2 Min Idling Stabilized Speed 800 850 Min Fuel Consumption Rate 238 Crankshaft Rotating Direction Clockwise from the front view of diesel engine Lubr...

Page 14: ... min 40 2600 45 2600 50 2600 48 2400 50 2400 52 2600 58 8 3200 Max NetPower Speed kW r min 37 2600 42 2600 47 2600 45 2400 48 2400 50 2600 55 3200 Max Torque Speed N m r min 160 170 1600 1800 181 190 1600 1800 203 215 1600 1800 210 225 1600 2000 Cylinders Working Sequence 1 3 4 2 Min Idling Stabilized Speed 780 820 800 850 Min Fuel Consumption Rate 225 Crankshaft Rotating Direction Clockwise from ...

Page 15: ...10 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 Net Mass kg kg 230 20 340 20 ...

Page 16: ...0 2200 60KW 2600 65 2800 60 2600 62 2600 57 2600 Max NetPower Speed kW r min 52 2600 48 2200 58 2600 61 5 2800 57 2600 60 2600 55 2600 Max Torque Speed N m r min 215 240 1600 1800 240 255 1600 1800 230 255 1600 1800 Cylinders Working Sequence 1 3 4 2 Min Idling Stabilized Speed 800 850 Min Fuel Consumption Rate g Kw h 225 Crankshaft Rotating Direction Clockwise from the front view of diesel engine...

Page 17: ...12 Cooling Way Forced circulating water cooled Oil Capacity L 6 8 0 2 9 5 0 2 Net Mass kg kg 340 20 ...

Page 18: ...0 60 2400 50 2600 62 2400 62 2600 65 2600 68 2600 Max NetPower Speed kW r min 57 2400 47 2600 49 2600 57 2600 57 2400 47 2600 60 2400 60 2600 62 2600 65 2600 Max Torque Speed N m r min 213 237 1800 2200 230 255 1600 1800 Cylinders Working Sequence 1 3 4 2 Min Idling Stabilized Speed 800 20 Min Fuel Consumption Rate g Kw h 225 Crankshaft Rotating Direction Clockwise from the front view of diesel en...

Page 19: ...14 Oil Capacity L 6 0 2 7 0 2 Net Mass kg kg 240 20 ...

Page 20: ...2600 58 2400 65 2400 75 2400 Max NetPower Speed kW r min 60 2600 55 2400 61 2400 71 2400 Max Torque Speed N m r min 260 360 1800 2200 Cylinders Working Sequence 1 3 4 2 Min Idling Stabilized Speed r min 800 20 Min Fuel Consumption Rate g Kw h 225 Crankshaft Rotating Direction Clockwise from the front view of diesel engine Lubricating Way Pressure splash combined Cooling Way Forced circulating wate...

Page 21: ...16 Oil Capacity L 6 8 0 2 9 5 0 2 Net Mass kg kg 350 20 ...

Page 22: ... 2400 45 2400 45 2600 55 2600 68 2600 63 2400 Max NetPower Speed kW r min 62 2600 60 2400 52 2400 42 2400 42 2600 52 2600 65 2600 60 2400 Max Torque Speed N m r min 270 1600 1 950 280 1600 1 800 245 1600 180 0 205 1600 1 800 195 1600 195 0 230 1600 1800 285 1600 19 50 280 1600 1 800 Cylinders Working Sequence 1 3 4 2 Min Idling Stabilized Speed r min 800 20 Min Fuel Consumption Rate g Kw h 225 Cra...

Page 23: ...18 Cooling Way Forced circulating water cooled Oil Capacity L 6 0 2 7 0 2 Net Mass kg kg 240 20 ...

Page 24: ...400 55 2600 65 2600 78 2600 75 2400 70 2600 65 2400 Max NetPower Speed kW r min 57 2600 52 2400 52 2600 62 2600 74 2600 72 2400 67 2600 62 2400 Max Torque Speed N m r min 255 1600 195 0 255 1600 1 800 230 1600 1 950 285 1600 1 950 350 1600 1950 350 1600 180 0 320 1600 1 950 320 1600 180 0 Cylinders Working Sequence 1 3 4 2 Min Idling Stabilized Speed r min 800 20 Min Fuel Consumption Rate g Kw h 2...

Page 25: ...20 Cooling Way Forced circulating water cooled Oil Capacity L 6 8 0 2 9 5 0 2 Net Mass kg kg 350 20 ...

Page 26: ...ate 0 30 0 35mm Hot state 0 25 0 30mm Exhaust Valve Cold state 0 35 0 40mm Hot state 0 30 0 35mm 2 Temperature and Pressure Ranges of Diesel Engine under Normal Situation Table 3 Leaving Water Temperature 95 Oil Pressure 196 588 kPa Oil Pressure at Min No load Speed 49 kPa ...

Page 27: ...N m 13 16kgf m 160 200N m 16 20kgf m Bolts for Main Bearing 140 170N m 14 17kgf m 200 240N m 20 24kgf m Bolts for Connecting Rod 100 130N m 10 13kgf m 100 140N m 10 14kgf m Bolts for Flywheel 100 130N m 10 13kgf m 100 140N m 10 14kgf m Bolts for Clutch Housing 70 100N m 7 10kgf m 70 110N m 7 11kgf m Bolts for Crankshaft Pulley 140 170N m 14 17kgf m 200 230N m 20 23kgf m ...

Page 28: ... 14 16 18 20 Tightening Torque N m 5 6 5 7 12 15 25 31 44 54 69 88 108 137 147 186 206 265 6 6 6 8 14 18 29 39 49 64 83 98 127 157 176 216 245 314 8 8 9 12 22 29 44 58 76 102 121 162 189 252 260 347 369 492 10 9 13 14 29 35 64 76 108 127 176 206 274 323 372 441 529 637 12 9 15 20 37 50 74 88 128 171 204 273 319 425 489 565 622 830 ...

Page 29: ...24 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 Torque N m 8 14 24 34 47 68 68 95 88 102 ...

Page 30: ...temperature is low the wax in the diesel is separated resulting in increased viscosity and blocking the pipeline which will cause difficult startup and black smoke On the contrary if the diesel for winter is used in summer high temperature will result in decreased viscosity causing bad lubrication in supply system which may damage injection pump and injector moreover lead to delayed ignition causi...

Page 31: ...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 Please fill diesel in the regular service station The failure of engine caused by inferior diesel will make you lose the interest of quality assurance ...

Page 32: ...up is difficult Therefore proper brand of lubricating oil shall be used based on different ambient temperature in different seasons and at different regions Table 8 Ambient Temp Lubricating Oil Brand Corresponding SAE Number 10 15W 40 CD level 15W 40 CD level 20 5 10W 30 CD level 10W 30 CD level 20 5W 30 CD level 5W 30 CD level Notice 1 It is not allowed to use different brands of oil from differe...

Page 33: ...pay attention to the continuity of the usage Please notice that coolant fluid has not only the function of antifreeze but also the roles of anticorrosion antiboiling and antiscale 2 Select coolant fluid with different freezing point based on the air temperature of the region the diesel engine to be used The freezing point shall be10 lower than the min temperature of this region at least so as to a...

Page 34: ...at this time the cooling system should be cleaned in time and the coolant fluid should be replaced completely 6 Glycol coolant fluid is poisonous which shall be prevented from being contacted or inhaled in case of skin contact wash with water immediately and completely furthermore anticorrosive additive of nitrite in this coolant fluid has carcinogenicity so that the waste is not allowed to poured...

Page 35: ...he filler cap 3 Fill clean diesel into the tank check the pipeline thereof for free flowing and exhaust the air inside 4 Check the connections between battery and electrical system for the correctness and firmness 5 Check the pipelines and joint faces for oil and water leakage 6 Check the belt for its tensioning force and any abnormal Upper mark Lower mark Attention When oil level is measured The ...

Page 36: ...m whether it is between upper and lower mark on the dipstick if it is below the lower mark add the oil required Notice 1 The oil level check shall be carried out after shutdown for 15 20min 2 Check the water tank coolant is enough and add properly if required 3 Check oil tank for shortage and add properly if required 4 Check the pipelines and joint faces for oil and water leakage 5 Confirm the par...

Page 37: ... and check each electrical instrument for normal indication 2 Turn the ignition key to ON 3 Press the accelerator to the half extent and start the diesel engine 4 Take the foot off the accelerator pedal slowly after startup 5 It should loosen the ignition key after starting the diesel engine ...

Page 38: ...hould 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 drive crankshaft with starter for about 10 15s and prelubricate turbocharger then start the engine ...

Page 39: ...ng up Charging state of dynamo the indicator light thereof is off during warming up Pay attention to abnormal sound of engine if any abnormal sound is heard check the engine immediately and eliminate the fault in time The color of the engine exhaust The color of exhaust Burning state of the engine Remark Colorless or Slight blue smoke Normal The ideal combustion state Black smoke Abnormal The unsa...

Page 40: ...r 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 1 Diesel is not allowed in the case of cooling fluid boil work and do not work in the long term water temperature is too high or too low 2 Diesel engine is not allowed to run at idle for more than 10min The user of harvester...

Page 41: ...unction 1 Oil Pressure During operation of diesel engine the alarm light of oil pressure is twinkled repeatedly which shows the oil pressure is relatively low and the engine should be shut down for inspection 2 Coolant Temperature The indication of water thermometer exceeds100 or the indicator light thereof is on which shows the engine is overheated and it should be run at the speed lower than 100...

Page 42: ...ust 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 Notice 1 Do not stop overheated engine in a second 2 Diesel engine is not allowed to work under overload for long time 3 Strictly prohibit adding cold water into engine immediately in case of high temperature and water shortage ...

Page 43: ...ture is below 0 t he drai nage val ves ofengi ne bl ock and w at er t ank shall be opened after shutdown to drain the cooling water fully and prevent the block water pump and radiator from frost damage If antifreeze fluid at proper temperature is used the drainage is not required VIII Security Warning 1 When diesel engine is running do not contact fan belt pulley belt and other exposed area of rot...

Page 44: ...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: ...is chapter I Fuel Supply System The pump and nozzle for injection is precise parts so that the water content or impurities in the fuel will cause the pump piston or injector to be damaged and make the filter dirty or clogged Thus unclean fuel will reduce the service life of the pump and the injector Please carry out regular inspection according to the following 1 Drainage of Oil water Separator or...

Page 46: ...t the service station of Agrison Power to get rid of water 2 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 If the impurities such as fuel and water cut is large it should shorten the cycle Replacement Procedure Screw off the diesel filter with proper tool Wip...

Page 47: ...the fuel transfer pump up and dow n w i t h force till no bubbles could be seen in the fuel exhausted from the bleed screw Tighten the bleed screw and press t he t ransf er pump up and dow n w i t h f orce t il l l t he resi st ance i s f el tt o increase suddenly If the engine is not operated stably after startup the accelerator handle could be pulled two or three times Notice 1 The piston type f...

Page 48: ...ided to diesel engine is single or double grade spin on filter with bleed screw on the top The filter element shall be replaced regularly The interior shall be prevented from dirty when in maintenance especially the seal at every portion shall be noticed when in assembling In order to guarantee diesel engine to get clean fuel automobile accessory manufacturers or users are required to add one stag...

Page 49: ...ilter clogged Replace it immediately regardless of the specified maintenance cycle 1 Replacement Cycle Lubricating oil 6 months or the accumulative work 100 hours Oil filter 6 months or the accumulative work 100 hours 2 Replacement Procedure for Lubricating Oil The vehicle or the temperature of the engine is in normal use Stop vehicle on horizontal plane with parking brake Stop the engine Cut off ...

Page 50: ...prevent from mixing foreign matters After filling cover carefully and then check the oil level after 5 10 minutes When start up the engine check the filter and the screw on oil pan for leakage and then adjust as required When shut down the engine check the oil level after several minutes and fill if required Notice Be careful that hand is to be scalded by hot oil 1 Check the oil level frequently L...

Page 51: ...eplaced 7 9 5 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: ...st 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 Press down the belt pulley of water pump and the belt at the middle of the engine to check the deviation When the deviation of fan belt is more than the specified value or after replacement of fan belt the tightness of the fan belt shall be adjusted Ref...

Page 53: ...forbidden to use hard water containing large amount of alkali or mineral matters in the cooling system Notice If the cooling system requires frequent supplement of coolant fluid please make a check in maintenance service center The antifreeze coolant fluid is poisonous so that it shall be stored in the marked container carefully and prevented from being contacted by children Driving belt Deviation...

Page 54: ...rainage 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 Add coolant fluid into the radiator to specified level Carry out the proportion of antifreeze fluid and water in accordance with the description attached to the container for antifreeze fluid ...

Page 55: ...insufficient air intake of engine and air compressor leading to decreased power of the engine and then to engine failure finally In addition damaged filter element will cause abraded cylinder and air valve mechanism of engine and air compressor leading to increased oil consumption and decreased output of the engine and then to shortened service life of both machines finally For the air filter for ...

Page 56: ...t used in 30 days or longer so as to prevent from electric leakage Notice Do not let the battery near to fireworks or electric spark since the hydrogen released during the reaction of battery would explode Do not let battery fluid contact skin eyes textile or paintwork After touch the battery by hand do not rub eyes with this hand and clean it completely Once the acid fluid contacts eyes skin or c...

Page 57: ...he four bolts on the top of the cylinder head and take down the head and the valve seat plate to clean away impurities and dirts on the sealing face of the valve seat by gasoline or diluting agent Take down the inlet valve sheet from two locating pins and clean away impurities and dirts on the sheet by gasoline or diluting agent Take down the valve sheet from the head remove the two screws on the ...

Page 58: ...this reservoir however providing that the oil consumption of the engine is normal it is normal Clean away dirts on the sheet and seat of the inlet valve by gasoline or diluting agent Remove the four bolts on the top of the cylinder head Exhausting valve sheet Inlet valve seat Inlet valve sheet Exhausting valve seat Back Clean away dirts on the sheet and seat of the exhausting valve by gasoline or ...

Page 59: ...ice of the fuel Select proper fuel as appropriate Refer to the section of Fuel in Chapter 2 for details Please go to service station to make sure you use the right fuel 2 The supply of fuel and eliminate water Pay attention to the supply of fuel Pay attention to loose the drain plug of the fuel tank to exhaust the deposited water content before startup Notice 1 If the liquid surface of Fuel tank i...

Page 60: ...rious deposits Please use antifreeze as the proper proportion recommended by related manufacturer 3 Lubricating Oil When the temperature decreases the viscosity of the oil increases resulting in difficult startup of the engine and the viscosity affects the stability of the engine to a large extent hence it is very important to select lubricating oil with appropriate viscosity based on the temperat...

Page 61: ...in Winter Below the temperature of 0 the engine should fix preheating equipment to start the engine easily The followings shall be paid attention to in starting the engine 1 Before starting the engine the engine should preheat 2 Press the accelerator to the full extent and start the diesel engine 3 If start the engine fail unsuccessfully for the first time wait for 30 seconds to let the batteries ...

Page 62: ...57 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: ...roperly Technical maintenance are classified as follows 一 Routine maintenance work 8 to 10 hours 二 The first compulsory running in maintenance 3 months or the cumulative work 50 hours 三 The first level Technical Maintenance 6 months or the cumulative work 100 hours 四 The second level Technical Maintenance 12 months or the cumulative work 300 hours 五 The third level Technical Maintenance 18 months ...

Page 64: ... on the radiating surface of of water tank The first compulsory running in maintenance 1 Check the level and leakage of the coolant fluid all joints of the water pipes for coolant fluid shall have no leakage 2 Check the battery Verify positive and negative posts to be connected firmly and reliably and installed properly and observe the surrounding of battery to confirm whether the electrolyte leak...

Page 65: ...r in the water filtering cup at the lower part of diesel filter which will be eliminated in time 13 Check the condition of engine idle relaxedly press the accelerator pay attention to abnormal sound of engine 14 Slightly refueling door when the water temperature rise whether the fannormal start work listening with ears The first level Technical Maintenance Besides don t replace the element of oil ...

Page 66: ...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: ...l tank is free of oil or it is switched off c Air is entrained in fuel pipe and injection pump d Water is mixed in fuel or fuel passage or filter is clogged e Pump for fuel transfer or injection does not supply oil or advance angle of fuel supply is improper a Select proper fuel brand b Add fuel to the tank or switch it on c exhaust the air in fuel system then tighten the pipe joints Replace the f...

Page 68: ...ce the injection pump spring or matching part for the piston 2 Cylinder pressure is insufficient a Valve clearance is too small b Air leaks from valve c Air leaks from junction of cylinder head and gasket d Piston ring is worn coked or the openings are overlapped e Abrasions of cylinder liner and piston a Adjust the valve clearance b In case of reduced elasticity of the valve spring replace the sp...

Page 69: ...ch of starter malfunctioned d Gear of starter can not be engaged to ring gear of flywheel e Electric brush of starter and commutator has poor contact f Preheating device malfunctioned or preheating time is short a Charge or provide with battery conforming to the requirement b Tighten the connections of the electric appliance system c Repair the electromagnetic switch of the starter or replace the ...

Page 70: ...5 Tighten the connecting nut 6 High speed and idle speed accelerator handle have wrong positions 6 Adjust the positions of the accelerator handles 7 Valve clearance is too large 7 Adjust the valve clearance 8 Cylinder pressure is insufficient a Valve clearance is too small b Air leaks from valve c Air leaks from junction of cylinder head and gasket d Piston ring is worn coked or the openings are o...

Page 71: ...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 Replace the pump ...

Page 72: ... Speed governor works improperly Adjust and calibrate the speed governor 3 Cylinder head gasket performs bad sealing Check the bolts and the gasket of the cylinder head Tighten the bolts or replace the gasket 4 Cylinders supply oil differently a Injection pump has different oil supplies from the cylinders b Injector performs badly or the matching parts are seized c Piston spring for injection pump...

Page 73: ...ir leaks from exhaust manifold or main pipe 5 Tighten the connecting screws or replace 6 Air exists in fuel pipeline 6 Exhaust the air and tighten the connections of the pipe 7 Oil reserve in the tank is insufficient and the oil used is of poor quality 7 Fill up fuel to the tank select the fuel in accordance with the requirement 8 Injection pump piston or delivery valve seat thereof malfunctioned ...

Page 74: ...2 Refer to Item 8 in II unstable idle 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 Turbocharging pressure is insufficient 15 Adjust or replace the turbocharger ...

Page 75: ... pipeline b Water is mixed in fuel c Filter is clogged by impurities a Loosen vented screw to exhaust the air b Screw off the drain plug of oil water separator under coarse filter to drain the water inside c Regularly replace the filter element 2 Fuel injection nozzle is seized 2 Replace the injector 3 Injector pump works improperly 3 Adjust or replace the pump ...

Page 76: ...t or replace piston ring b Replace the valve c Replace the oil seal 3 Black smoke rises a Diesel engine is under overload b Fuel supply is delayed too much c Fuel supply is excessive d Air filter and exhaust pipe is clogged e Valve clearance is improper valve is sealed incompletely f Timing for fuel injection is improper a Reduce the load b Adjust the advance angle of fuel supply c Adjust injectio...

Page 77: ...72 g Intercooler is too dirty mark g Clean away impurities and dust on the outside surface of the intercooler ...

Page 78: ... scale foreign matters in the pipes for free flowing 3 Water pump belt is loose 3 Adjust the tensity of the belt 4 Water pump works improperly 4 Repair or replace the water pump 5 Temperature saver malfunctioned 5 Repair or replace the temperature saver 6 Lubricating oil is of poor quality 6 Replace the lubricating oil 7 Water thermometer malfunctioned 7 Replace the water thermometer 8 Diesel engi...

Page 79: ...ton pin and pin hole thereof is too large The sound is soft and sharp which will be clearer at idle especially 4 Replace the parts to guarantee the specified clearance 5 Clearance between main bearing and connecting rod bearing is too large so that clash of machine members can be heard when the speed of diesel engine is decreased suddenly The sound is heavy and strong when the speed is low 5 Repla...

Page 80: ...can be heard near the cylinder head in case of low speed 8 Adjust the valve clearance valve timing or replace the head gasket 9 Gear clearance is too large due to wearing so that clash can be heard at gear box when speed is decreased suddenly 9 Replace the gear as appropriate IX Excessive Lubricating Oil Consumption ...

Page 81: ... gasket end caps and plugs 2 Tighten the bolt replace the gasket replace the end cap or plug 3 Spill port of oil control piston ring is clogged by coke 3 Get rid of the coke at the spill port 4 The oil is of poor quality 4 Replace the oil 5 Piston ring is worn or clamped 5 Replace the piston ring 6 Clearance between cylinder liner and piston is too large 6 Replace the cylinder liner or the piston ...

Page 82: ...id of the dirt in the exhaust pipe 6 Min no load steady speed is too high 6 Adjust the min no load steady speed to specified value 7 Fuel is of poor quality 7 Use specified fuel 8 Advance angle of fuel supply is improper 8 Adjust the advance angle 9 Injector spray is of poor quality 9 Adjust the opening pressure of fuel injector check and clean the nozzle or replace it 10 Valve clearance is improp...

Page 83: ...78 XI Malfunctioned Lubricating System ...

Page 84: ...the oil filter or replace the filter element d Reduce the load replace the oil and lower the oil temperature 2 The oil is of poor quality 2 Replace with the oil in conformity with the requirement 3 Spill valve of oil filter is sticking or has excessive oil return 3 Repair or replace the oil filter 4 Oil pump screen is clogged 4 Clean the screen 5 Oil pump gear is worn or the end clearance is too l...

Page 85: ...80 8 Connecting rod bearing and main bearing are worn 8 Replace the connecting rod bearing and the main bearing 9 Oil pressure gauge is damaged 9 Replace the pressure gauge ...

Page 86: ...ting tube of radiator is loose or broken a Fill up cooling water into the tank b Replace the spring c Tighten or replace the belt d Replace the temperature saver e Repair or replace the water pump f Clean the cooling water passage to get rid of the scale g Clean the pipeline of radiator for clearing h Repair or replace the radiator i Replace the gasket or packing plate j Tighten or replace the con...

Page 87: ... Bearing bushing is worn b Electric brush has poor contact c Commutator is dirty or singed d End terminal is desoldered e Poor contact f Switch has poor contact g Battery is undercharged or has small capacity a Replace the bearing bushing b Clean the commutator surface c Clean the oil stain and polish with fine sand cloth d Weld the terminal firmly e Clean and tighten the contact f Repair the swit...

Page 88: ...ver of dynamo b Check body and base of vacuum pump for any crack and matching face between pump core and main shaft spline of dynamo and internal working face for serious abrasion and scratch c Vacuum pump blade is worn seriously on the width d Oil leaks a Replace in time if damaged b Replace in time if damaged c Replace in time once any damage is found the width of the blade must not be less than...

Page 89: ...head clean up the valve base plate and valve sheet d Check whether any part is missed and confirm the parts are all in place 2 Air pressure is insufficient a Driving belt of air compressor is too loose causing skid b Oil water separator or air filter is clogged c Air compressor s cylinder block piston and piston ring are worn causing air leakage d Valve sheet of air compressor performs incomplete ...

Page 90: ...ely e Dirt is not drained from air tank frequently f Air compressor is operated too long g Pressure in crankcase of engine is too high h Oil pressure in engine is too high i Lubricating oil is deteriorated a Check and replace the filter check and eliminate the twist and deformation of suction pipe b Check and eliminate the bent twist and deformation of oil return pipe c Check and replace the pisto...

Page 91: ... knock f There is foreign matter on top of piston a Check and replace the connecting rod bearing and bushing main shaft bearing tighten the bolt on connecting rod b Check and replace the drive or driven pulley and adjust the belt tensity c Check and replace the broken clogged inlet pipe for lubricating oil d Check and tighten the fixing bolt e Tighten the loose nut on gear replace the malfunctione...

Page 92: ...ice causing air compressor to work constantly b Air brake system leaks seriously causing air compressor to work constantly c Moving parts have insufficient oil supply and cylinder scoring occurs a Check relief valve components when inlet unloading and clear away or replace the failure parts with seizure check unloading valve when outlet unloading and clean repair or replace the failure parts with ...

Page 93: ...d definitely do not disassemble it If replace the turbocharger 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 turbocharger having been in normal operation is unlikely to have defect on its own in the future service If the impeller of the turbocharger can rotate freely not scratching the in...

Page 94: ...ine Possible Causes Elimination Approaches Air filter is too dirty Clean or replace the filter element Air leaks from pipeline between air filter and gas compressor Tighten the fasteners or replace the sealing parts Air leaks pipe between gas compressor and inlet duct of diesel engine Replace the sealing parts or tighten the fasteners Intercooler is too dirty Clean the intercooler Air leaks from j...

Page 95: ...ace the sealing parts or tighten the fasteners Air leaks from joint face between diesel engine s exhaust manifold and cylinder head Replace the sealing parts or tighten the fasteners Exhaust pipe of diesel engine is impeded Clear away foreign matters Air leaks from joint face at fuel gas outlet of turbine Replace the sealing parts or tighten the fasteners Muffler or tail pipe is impeded Clear away...

Page 96: ...lter element Impeller of gas compressor is worn or damaged Clean air intake system or replace the turbocharger Turbocharger s bearing bearing hole or shaft diameter is worn Replace the turbocharger Oil number is improper Use lubricating oil as specified XVII Malfunctioned Power Steering Pump Power steering pump has the common faults as follows 1 abnormal sound 2 hard steering Any of these faults m...

Page 97: ... abnormal sound it need not be anxious to determine that its operation is in trouble The experience shows that most of the faults thereof are related to improper use of vehicle Therefore it is recommended to check tyre pressure hydraulic pipeline driving system fluid level inside and screen of the reservoir pipe joints and power steering fluid on vehicle at first After the diagnosis is finished th...

Page 98: ...pipe or replace the fluid b Check and tighten related threaded connecting part or replace the sealing part to prevent air invasion strictly c Check the related worn parts and grind d Replace with the fluid having low viscosity e Fill the fluid to the specified level 2 Oil leaks from the junction of oil port a The joint is loose or the sealing part is damaged a Tighten the threaded connecting part ...

Page 99: ...c is clogged c The suction pipe has too large resistance even clogged d The pump is worn increasingly b Check and get rid of the blockage in the compensating groove c Check and get rid of the blockage d Check and replace the worn parts inside the pump ...

Page 100: ...as plastic products and parts shall not be applied with the oil 5 The air filter or air inlet and the orifice of exhaust pipe shall be packed well with oiled paper to prevent dust and dirt from invasion 6 The diesel engine or the vehicle shall be placed in the room with good ventilation dry and clean conditions and free of intense magnetic field temperature 30 60 humidity 0 80 It is strictly prohi...

Page 101: ...t outside the diesel engine apply antirust oil add butter into drier oil and mix thoroughly after melting on the unpainted parts and components Rubber products as well as plastic products and parts shall not be applied with the oil 7 The air filter or air inlet and the orifice of exhaust pipe shall be packed well with oiled paper to prevent dust and dirt from invasion 8 The diesel engine or the ve...

Page 102: ...ary work It shall be fixed in the workshop with the characteristics of rain proof moisture proof good ventilation little dust and spaciousness Diesel engine with oil seal had to be removed antirust oil before using Continuously inject hot water into the cooling system to preheat the engine Open the oil drain plug to drain the lubricating oil inside Turn the crankshaft or drive it with starting dyn...

Page 103: ...rable parts Number Name 1 Main liner 2 Crankshaft thrust sheet 3 Cylinder head gasket 4 Cylinder liner 5 Water seal ring 6 Piston 7 Piston ring 8 Piston pin 9 Rod 10 Bearing of connecting rod shaft 11 Front Oil seal 12 Back Oil seal ...

Page 104: ...ration instruction 1 4 Serving enchiridion 1 5 Packing list 1 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 2 Please check the box at the time If discrepancies are to supply contracts signed with manufacturers of related supporting state prevail ...

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Agrison TX920L, Operation Manual

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