Agrison TX930LX User manual

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TX930LX Wheel
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Manual
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Manual

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
(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

(III) COOLANT FLUID .....................................................................................................................28
(IV) STARTUP OF DIESEL ENGINE................................................................................................30
(V) RUNNING-IN OF DIESEL ENGINE ..........................................................................................35
(VI) PRECAUTIONS DURING OPERATION OF DIESEL 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

(VIII) REGULAR TECHNICAL MAINTENANCE...........................................................................58
CHAPTER 4 COMMON FAULT ANALYSIS AND ELIMINATION
APPROACHES FOR DIESEL ENGINE........................................ 62
(I) DIFFICULT STARTUP OF DIESEL ENGINE...............................................................................62
(II) UNSTABLE MINIMUM NO-LOAD STEADY SPEED (IDLE 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 SYSTEM...............................................................................81

(XIII) MALFUNCTIONED STARTER..............................................................................................................82
(XIV) MALFUNCTIONED CHARGING 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

1
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.. As required by users, by modification of part of
components (such as adjusting injection pump, replacing clutch housing, oil pan, air outlet
and inlet pipe, engine support, electric appliance system), it can meet the different
requirements of performance and installation 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. Please pay attention, due to continuous improvement of our products and
for the purpose of satisfaction of different users, the in-kind product shall prevail if any
discrepancy existed in the Instruction.
With diesel engine factory service manual, random tools and spare parts, the user can
randomly enumeration tools and spare parts list.
Before you use, please read this manual seriously , using strictly according to the
provisions of this specification, maintenance and repair of diesel engine.

2
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.

3
Notice for Users
1. 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.
2. 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. Its service life, reliability and economics shall depend on
the quality of initial running-in to the great extent, please run it in strictly according to the
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 restart after 2
minutes.
5. Do not remove air filter during operation. The air filter shall be cleaned as required. The upper
and lower gasket rings for filter element shall be fit up for sealing in re-installation. When the filter
is connected with hose, clamp shall be used to prevent the hose from loosing due to shake of
diesel engine. Strictly prohibit not-filtered dusty air from entering into cylinder.
6. Oil supply system is the important system of diesel engine. The parts and components thereof

4
shall not be removed or adjusted without permission, which shall be carried out in the technical
service station authorized by Agrison Power.
7. 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”.
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.

5
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; another particular value changes due to continuous product and product
kind prevail.
(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
37/2650
30/2600
36/2650
34/2400
35/2400
40/2650
42/2650
40/2800
Max. Torque/Speed
N·m/r/min
156-170/1700-1900 181-195/1700-1900
Cylinders Working Sequence
1—3—4—2
Min. Idling Stabilized Speed
800-850r/min

6
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
Forced circulating water cooled
Oil Capacity
（
L
）
6
±
0.2/7
±
0.2
Net Mass kg
230±20

7
Model No.
4100GB
4100GB-2
Model
in-line four-cylinder, direct injection, water cooling, four-stroke, natural aspirated
Total Piston Displacement L
3.3
3.6
Bore×Stroke（mm）100×105 100×115
Rated Power/Speed
kW/r/min
46/2400 50/2400 45/2600 45/2650 52/2600 52/2800 53/2600 50/2400
Max.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
Forced circulating water cooled
Oil Capacity（L）6.8±0.2/9.5±0.2
Net Mass kg
340±20

Model No.
4102GB
4102TB 4102GB 4102G
B-1
4102GB
Model
in-line four-cylinder, direct injection, water cooling, four-stroke, natural aspirated
Bore×Stroke（mm）102×115
Total Piston Displacement
L
3.8
Rated Power/Speed
kW/r/min
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
Max.NetPower/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)
Lubricating Way
Pressure & splash combined
Cooling Way
Forced circulating water cooled
Oil Capa
8
（L）
city
6.8±0.2/9.5±0.2
Net Mass kg (kg)
340±20

9
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
L
2.7 3.0 3.3
Rated Power/Speed
kW/r/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 the front view of diesel engine)

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

1
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
3.6
3.8
Rated Power/Speed
kW/r/min
55/2600 50/2200 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)
Lubricating Way
Pressure & splash combined

12
Cooling Way
Forced circulating water cooled
Oil Capacity（L）6.8±0.2/9.5±0.2
Net Mass kg (kg)
340±20

1
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
2.7
3.0
Rated Power/Speed
kW/r/min
60/2400 50/2600
52/2600
60/2600 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 engine)
Lubricating Way
Pressure & splash combined
Cooling Way
Forced circulating water cooled

14
Oil Capacity（L）6±0.2/7±0.2
Net Mass kg (kg)
240±20

1
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
3.8
Rated Power/Speed
kW/r/min
63/2600 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 water cooled