GENSET ENGINE

GENSET DIESEL ENGINE

4D2.3CG
OPERATIONAL MANUAL
PARTS LIST

TECHNICAL DOCUMENT so

www.powerlinkworld.com

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 FOREWORD
Thank you for purchasing our diesel engine .
This manual contains information for the correct operation and maintenance of your
engine.lt also contains important safety and installation information or troubleshoo-
ting guidelines. Please always keep this manua l w ith the equipment for handy use.
Please operate this equipment after throughly reviewing and understanding the con-
tents of this manual.

POWERLINK reserves the right to modify the characteristics of its products at any
time in order to incorporate the latest technological developments . The information
contained in this document may therefore be changed without notice.
Without express written permission from us, any part of this manual can not be repr-
oduced in any form or by any means.

Copyright 2012 POWERLINK

& SAFETY SYMBOL

This symbol , the industry's " Safety Alert Symbol", is used th roughout th is manu al an d
on labels on the mach ine itself to warn of the possiblity of personal injury. Read these
instructions carefully. lt is essential that you read the instructions and safety regulatio•
ns before you attempt to assemble or use this unit.

lt indicates a hazardous situation which, if not avoided,

&DANGER WILL result in serious injury or even death.

lt indicates a hazardous situation which, if not avoided,

&WARNING COULD result in serious injury or even death.

lt indicates a hazardous situation wh ich, if not avoided ,

&cAUTION COULD result in minor or moderate injury.

lt indicates potential hazards which can cause injury.

NOTE lt indicates additional information which is important to

a procedure ..

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& Safety Rules
Be sure to keep sparks , flames and Be sure to properly dispose of old
lighted tobacco away from flamma- oil or other fluids . Use an approv-
ble and combustible materials like ed container. Please be environm-
battery gases and engine fuels . Al- entally safe .
ways have an approved fire extinguisher within
easy reach.

Be su e th at all tools and working

areas are properly maintained and
read y for use. Keep work surfaces
-P±,-
~

·->~"'{<'
Be su re that your workshop or wo-
rk area is properly ventilated and
well lit.
clean and free of debris that could
get into machine components and cause dam-
age .
1 Be sure to wear protective eye w-
ear and other protective clothing if
the situation warrants it.

Be s re a fas eners intended f- Be aware of potential crushing ha-

... ~ o e e use (i. e., cotter pins zards such as moving parts, free
#O"\ a d self-locking nuts) are not reu- swinging or unsecured componen-
---~ sed. These components may fail ts when lifting or placing loads. Al-
if they are used a second time. ways wear approved steel-toed shoes.

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 Table of contents
Chapter 1 General Description of Diesel Engine ................................................................. 1
1.1 Overall Dimensions of Diesel Engine .................................................... .......... .. ............... 1
1.2 Engine Technical Performance Data ................................................................................ 2
1.3 Main Characteristic Data ............................. ... .... .. ........... ......... ........ ...... .......................... 3
Chapter 2 Operation of the Diesel Engine .................. .. ................................ .. .... .. ..... ....... .4
2.1 Preparation for the first Operation of the Diesel Engine ........................ .. ...... .. .... .. ............ .4
2.2 Starting of the diesel engine ....... .. ........................ .... ...................................... .................. 5
2.3 Operation of the diesel engine .... .................................................... ...................... ............. 5
2.4 Shutting down of the diesel engine ....... ... ...................................... .... ....................... ......... 6
2.5 Precaution during Engine Operation ........................................ .. ........................................ 6
2.6 Working Media.-........................................... ... ...... .. .................. ............ ... ..... ... .. ......... .... .... 6
Chapter 3 Technical Maintenance of the Diesel Engine ................... .......... .. ........... ............. 8
3.1 Maintenance Tools .. ........................................ ......... .......... ........................... ... ................. 8
3.2 Maintenance Periods ............ ......... .. ......... ........ ....................... .... ... .. ....... .. ... ...... .... :......... 8
3.3 Technical maintenance in winter .. ........................ ............................................ ....... ........ 1O
3.4 Storage of the Engine ....................................... ....................... ......... ......................... ... , .. 1O
Chapter 4 Adjustment of the diesel engine ......... ......... ... ....... .... ..... .. ........ ......... ... .. .......... 11
4.1 Tightening Sequence of Cylinder Head Bolts ................................. .... ............................. 11
4.2 Checking and Adjustment of Driving Belt.. ..... : ..... ... ............... ........ ............... .......... ... .. .. .. 11
4.3 Notes about Thermostat ...... .. .. ...... .. ....... ...... ... ..... ... ........... ..... .. .... .. ... ...... ...... ................. 12
4.4 Adjustment of Starting Motor ............................. ............................ .. .... .. ......... .. .. ......... .... 12
4.5 Adjustment of Generator .......... ..... .................... ..... .. ... ............................. ........ .. ..... .... ..... 12
4.6 Expelling Air from Fuel System ........................... ................... .... ......... .............. ............... 12
4. 7 Maintenance of Air Filter ....................................................... .... ..... ......... .. ....................... 14
4.8 Draining Out Coolant ..... ... .. ... .. ...... ......... .......... .. ...... ... ............................ ... ..................... 14
4.9 Renew Spin-on Fuel Filter ......... .................... .................................................................. 14
4.10 Renew Oil Filter ............................................................................................................. 14
4.11 Adjustment of Valve Clearances .... ........................................................ ... ................... .. 15
4.12 Adjustment of lnjection Timing .............................................. ......................................... 16
4.13 Adjustment of lnjector .... .. .. ......................... ............. ......... ..................... ............. ........... 16
4.14 Adjustment of lnjection Pump ........ ... ............ ........... .... .. .... ....... .. .................. .. .. .. ... .... ... . 16
Chapter 5 Sketch Maps for Five Main Systems of the Diesel Eng ine .. ..... ... ................ .......... .17
5.1 Fuel System ................. .. ... .... .. ... .. ... ... ............... .. .. ... ........ ..... ... ...... ... ... ..... ....... ... ..... ........ 17
5.2 Lubricating System ... .. .. ... .. ... .. .... ...................................... ... .. ....... .... ................ ............... 17
5.3 Cooling System ................ ....... ..................................................... ................................... 18
5.4 Electric System ......... .. ... ..... .. .. ... .............................................................................. ........ 18
Chapter 6 Engine Trouble Shooting ..................................... .... .. ........... ........ ... .. .......... .. 19
6.1 Engine fails to start ....... .. .. ... ................. .. .................... ....... ......................... .... .... ....... ... .. . 19
6.2 Abnormal oil pressure ...................... ..... ....... ..... ...... ....... ... ... ....... ................ ..................... 20
6.3 High exhaust smoke ...... ... .............................. ... ........ .. ... ............ .. .... ....... ....... ................. 21
6.4 Blue Exhaust Smoke .. ... .. ... ...... ...... ......... .. .... ... ........ ..... .. ..... ... ..... .. .. ............................. ..21
6.5 High white exhaust smoke ...................................................... ............................. .. ..... ..... 22
6.6 lnsufficient power .. ..... .................. ... .................... ............... ...... ..................... ....... ......... .23
6.7 Abnormal noise ..... .. ..................... ... ..................................................... .... .. ... .. ...... .. ....... 24
6.8 Severe Vibration .... .......................................................................... ............... ... ...... ........ 25
6.9 Engine over-heated ................ .. ..................... ... .. .. .. .... ............. .. .. .. ......... ....... .... .. .... ........ 25
6.1 O High oil consumption ............ .. .. ... ................. ... ....... .. ........... .............. ... ..... ....... ........ .... .26
6.11 Speed going up out of control ........... ....... ... .. ..................... ...... ............................. ...... ... 26
6.12 Engine shutting down automatically ...... .............. ............. .... ......... .......... ..... ........ ...... .. .27
6.13 Rising oil level ........... .. .. ... ... .. .. ......................... ............. .. .......... ... ... ... .... ........... ......... .... 27
Appendix 1 Outsourcing Parts list (For 4D2.3CG) ........... .. .. .. ....... .. .... ... ............... .......... ....... 28
Appendix 2 Specification of Main Auxiliaries (For 4D2.3CG) .............................. ...... .. .. ......... 29

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Chapter 1 General Description of Diesel Engine

1.1 Overall Dimensions of Diesel Engine

4D2.3CG

758.9
Front view (with fan ) lntake side view

545
Exhaust side view Rear view

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1.2 Engine Technical Performance Data

Technical data for 4D2.3CG

Usage type ....... ..... ........................... .. ........ .... .............................. ... .. ............ ............ .. ....... .Generators

Model .... ... .. .. ... .... ...................... .... ....... ..... ............ ... .... ........... ... .................. .. .......... ............. 4D2.3CG

Type .......................... ln-line, water co~led , 4-stroke, direct injection ffi-shaped combustion chamber

No. of cylinders- bore- stroke (mm) .................................................................................. .... 4-85-100

Total displacement (L) ............................. .... .............................. .................................................. 2.27

Firing arder ..... ... ......................... ......................................................................... 1-3-4-2

Compression ratio ............. ... ........ ....................... ...... .................. ... : ... ........ ............... 18: 1

Rated speed (r/min) .... .. ............... .... ................................ ....... .............. ........... 1500 / 1800

Rated power (KW) ..................................................................... 17 (1500rpm) / 20 (1800rpm)

Max. torque (N ·m) .......... .............. ........................................................... .................... NA

Max. torque speed (r/min) ............................ ... .. .. ... ............... ............... ....... .. ........... ...... NA

Maximum mean effective pressure (k Pa) .................................................................... ~661.4

Min. fuel consumption at full load (g/kW· h) ..................... .. .. .... ...................................... S240

Oil consumption (g/kW· h) ..... .......... ... ...................................................................... s1 .63

Min. steady idle speed (r/min) ............ ... ............. ....... ..... ............. ................................ S650

Direction of crank rotation viewed from flywheel end ........................................ counterclockwise

Noise dB (A) ........ ... ............ .. ......... .... ............... ..... ........... ........................................ S105

Cooling system ...... ... ... ........................ .............................. closed cycle, torced water cooling

Lubrication system ................................................. ............ ............. pressured and splashed

Starting device .............................................................................................electric motor

Net weight (kg) ................... .. .......... ........ ........... ...................................................... S262

Overall dimension length*width*height (mm) ........................................ ......... 758.9*545*603.3

Note: The rated power is the power at standard condition that mea ns the atmospheric pressure is 1

x 10 5 Pa (750mmHg), ambient temperature is 25 t:', relative humidity is 30% without air filter,

muffler or cooling fan.

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1.3 Main Characteristic Data

(For 4D2.3CG)

1. Timing (in terms of crankshan angle)

lntake valve open: 12ºbefore top dead center.

lntake valve clase: 38ºafter bottom dead center

Exhaust valve open: 50ºbefore bottom dead center.

Exhaust valve clase: 14 ºafter top dead center.

Cold valve clearance: intake valve 0.28-0.33mm, exhaust valve 0.28-0.33mm.

2. lnjection advance angle: 16-18ºCA.

3. Temperature and pressure requirements:

1 ) Exhaust temperature:~823k (550ºC) .

2 ) Oil temperature: ~368k (95ºC).

3 ) Cooing water temperature: 343-368k (70-95ºC) .

4 ) Oil pressure at the main oil gallery: 0.2-0.44Mpa.

4. Tightening torques for /he main bolts in N-m:

Cylinder head bolt: 120-140.

Main bearing bolt: 120-140.

Connecting rod bolt: 88-93.

Flywheel bolt: 110-130.

5. Oíl capacity in /he oíl sumpz5.5L.

6. Overa// Dimensions of Diesel Engine

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Chapter 2 Operation of the Diesel Engine

2.1 Preparation for the first Operation of the Diesel Engine

1) Fill the oil

Generally, there's no oil filled in the engine when it is off the line. Customer should fill the oíl by
himself before operating the engine. When filling oil, please open the cover of the oil filling port on
the cowl of the cylinder head first, take out the oil gauge, then fill the oil and check the oil level with
the gauge. Check the oil level again after 3 minutes. Oil capacity: make sure the lubricating oil level
in the oil sump should be between the upper mark and lower mark on the oil gauge when the
lubricating system is filled full oil.
.&Note: Only clean oil can be filed into engine, make sure no any deposit in the filled oil. Fuel
injection pump assembly also needs to be filled with oil. The lubricating oil in the pump case should
be between the upper mark and lower mark on the injection pump oil gauge.
2) Fill diesel fuel
.Users can choose the corresponding diesel fuel for summer or winter according to the temperatures
in their local places. The position of the fuel pipe joint position is on the lower part of the injection
pump. Before filling into the engine, the diesel fuel should be keep still for more than 72 hours to
clear out the water and impurities.
3) Fill coolant
• Open the cap and the drain cock
• Fill the coolant to the mark of filler
• Glose the drain cock when the coolant flows out
• Screw on the cap
4) Other preparing work before starting the engine
Check whether all engine mounting fasteners are in good condition and whether the control handles
such as throttle, shut down handle and etc can operate smoothly.
• Revolve the crankshaft several turns to check whether all moving parts can move smoothly.
• Check oil sump and injection pump for the oil level.
• Check whether the radiator is full of cooling water and there is no leakage at the joints.
• Check whether the fuel is sufficient, fuel ~upply is unblocked and there is no leakage at the joints
of fuel pipes. Check if the fuel cock at the fuel tank has been turned open.
• Check whether the battery has been fully charged and all joints between electric equipments are
in good condition.

• Check all fixing fasteners for various components (injection pump, fuel supply pump, fuel filter,
water pump, fan, generator and its bracket, v-belt of fan, electric starting motor, oil filter, water
radiator, etc.)
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• Check all joints between air filter, intake rubber pipe and intake pipe for secure air tightness.
• Check if power take off clutch is released.

- - Upper limit
· - - - Lower limit

The oil level shall be between the upper and lower marked line .

.2.2 Starting of the diesel engine

1) Put the speed control lever at its middle speed position.

2) Loose the vent screw on the fuel filter, press the hand fuel supply pump several times to release
the air trapped in the fuel system . For a new engine oran engine having stood by for a long period,
where a lot of air may have been existed in the fuel system , it may be necessary to loose the vent
screw on the injection pump and to press the fuel supply pump repeatedly till all the trapped air is
released. lf the engine has been operated frequently , this work may be omitted according to the
actual situation.
3 ) Press the start button to start the engine. lf it fails to start, the button should be released and
restart it after waiting for two or three minutes. lf the engine still fails to start after three consecutive
attempts, the trouble cause should be found out and dealt with accordingly before starting it again.
4 ) The starting button should be released immediately after starting. Watch the speedometer and
adjust the speed control lever. Run the engine at 600-850rpm idle speed to see if the engine is
working normally. Pay special attention to the oil pressure, which should be higher than 0.05MPa.
Then, speed up the engine gradually to 1800 to 2000 rpm at idle load to warm it up.

2.3 Operation of the diesel engine

1) The engine should not take load to work until the water temperature reaches 50 ºC and oil
temperature reaches 40ºC. And the rated load should not be taken until the water temperature goes
up to BOºC .
2) Load and speed should be increased and decreased smoothly. Generally speaking, it is not
allowed to be changed abruptly.
3) During the operation of the engine, constantly watch the readings of the gauges on the control
board to see whether they show normal values. Pay attention to exhaust smoke and its running
sound. lf any abnormal thing is found, shut down the engine and check it.

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2.4 Shutting down of the diesel engine

1) Before shutting down the engine, gradually reduce its load and speed. Run the engine at idle
speed until the water temperature cools down to 70 ºC. Then operate the shut- down lever to shut

down the engine.

2) When ambient temperature goes below 5ºC in the winter and the water temperature goes below
60ºC after shutting down the engine , open the drain cocks on the cylinder block and the radiator to
drain the cooling water to avoid freezing and damaging the engine(if anti-freezing fluid has been
added , it will not be necessary to do so) .

2.5 Precaution during Engine Operation

1) Operation and maintenance of the engine should be done according to the manual.

2) A new engine oran overhauled engine should not work at full load and high speed. lt should take
a running- in period of 50 hours with light load (:550% of load) and low speed (:52000rpm) before
going to its normal operation.
3) Fuel should keep clean . lt is recommended to keep the fuel still for one week or more to let the

impurities settle down or filter the fuel with silk cloth.

4) Keep a normal water temperatu re (70 ºC-95 ºC). The oil pressure should be 0.2-0.4MPa at

medium speed .
5) The engine should be shut down and checked when any abnormal phenomenon happens during
the operation.

2.6 Working Media

1. Oil
Use CD grade oil.
Use different oil for different ambient temperature.

SAEgrade Temperature range SAEgrade Temperature range

20 -10---30 ºC 5W/30 -40---35ºC

30 -10---35º C 10W/30 -30---35ºC

40 -5---40º C 15W/40 -20---40ºC

5W -40---1 OºC 20W/40 -15---40ºC

10W -30--- 15ºC 20/20W -10---35ºC

5W/20 -40---1 0ºC

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2. Diesel fuel
Customers can choose the light diesel fuel according to the actual ambient temperatures at their
local places.
3. Coolant
Special coolant is needed for sorne vehicles. In that case, use coolant according to the requirement
of the vehicles. For general purposes, use cooling water which meets certain requirements.
Cooling water: it's good to be rain water, tap water or clean river water. lt's not good to use well
water because there are so many minerals in the water which will form scale deposited in the
cooling system which is harmful to cooling effect and may damage the engine. lt may need to add
antifreeze into the cooling system to prevent water freezing in cold winter. The most common
antifreeze is glycol water solution or alcohol.
Filling coolant and precautions:
• Fill cooling water up to the mark at the filler.
• Pay attention to clase the drain cock after water draining from it.
• Tighten filler cap.
• Start the engine, run it until it reaches normal working temperature and the thermostat opens
and the water pipe of the majar circuit apparently grows warmer.
• Shut down the engine after the initial operation . Let the engine cool down and check the water
level.
& Caution: Be careful of not getting burnt when you open the filler cap while the water
temperature is still high.

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Chapter 3 Technical Maintenance of the Diesel Engine

3.1 Maintenance Tools

Hexagon wrench
Spanner handle
Valve clearance gauge
Assembling and dismantling tool for spin-on filter

3.2 Maintenance Periods

These maintenance periods are suitable for general situation, if maintenance is required for the
vehicles (cars, forklifts, tractors and so on) the shorter maintenance period is applied. When the
engine operation should meet local regulations, the maintenance periods and procedures should be
modified to ensure right operation.
• Note: Sorne maintenance periods should be shortened if the engine is worked in dusty
environment or other rigorous conditions.
Engine maintenances are classified as follows:
1 . Daily maintenance
2 . Grade 1 maintenance (After 50 hours or 2500km)
3 . Grade 2 maintenance (After 250 hours or 12500km)
4 . Grade 3 maintenance (After 1000 hours or 50000km)

lnterval Maintenance ltems

1 . Check the oil sump, air filter and the oil level in the injection pump. lf the oil
level rises, find out the cause and deal with it; if the oil is not sufficient
enough , fill the oil to the specified value.
2 . Check the cooling water level in the water tank and fill it if the cooling water
is not sufficient enough . When the temperature goes below 5 ºC, all
cooling water shall be drained out after the engine being shutting down (if
Dai/y
there is no any antifreeze) .
Maintenance
3 . Check and fix bolts and nuts to eliminate any leakages phenomena .
4 . Use the compressed_air to eliminate the dust on the cartridge of air filter
when working on the occasions with much dust.
5 . Clean the mud, deposited dust and smear outside of the engine.
6 . Pay attention to the sound when the engine is running. Watch the exhaust
smoke and deal with the caused troubles and abnormal situations.

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 1 . Same as the Daily Maintenance.
2 . Clean deposited dust on the cartridge of air filter and dust bin. Renew the oil
in the air filter.
3 . Check and adjust the tightness of fan belt.
Grade 1
4 . Fill the grease lubricant to the water pump bearing (except the
Maintenance
shaft-connecting water pump).
5 . Check every parts of engine make an adjustment if necessary.
6 . Start the engine to check its operation condition after finishing the
maintenance and deal with the caused troubles and abnormal situations.
1 . Same as Grade 1 Maintenance.
2 . Renew the oil, clean the oil sump and oil filter.
3 . Clean the oil filter, and replace the cartridge of filter.
4 . Renew the oil in injection pump and air compressor.
5 . Clean the diesel oil box, screen filter of supply pump and pipe. Use the
Grade 2
clean diesel oil to clean the cartridge.
Maintenance
6 . Use the compressed air to blow out the deposited dust in the generator.
Check all the parts and deal with the troubles on the abnormal parts.
7 . Adjust the valve clearance and check the valve spring.
9 . Check the opening pressure of injector and the atomization quality. Adjust
them if necessary.
1 . Same as Grade 2 Maintenance.
2 . Clean the cooling system, and wipe off the furring.
3 . Clean the oil cooler.
4 . Replace the cartridge of air filter and the cartridge of diesel oil filter.
5 .Dismantle the cylinder head. Check the leak tightness of valve and clean the
deposited carbon.
Grade 3 6 . Check cylinder head bolts, tightening torques of connecting rod and main
Maintenance bearing bolts.
7 . Check water pump (except the shaft-connecting bearing water pump).
Renew the grease lubricant and replace the water seal if necessary.
8 . Check the generator and starting motor. Fill the grease lubricant.
9 . Check the injection pump, adjust the advance timing, and adjust the
injection pump according to the real situation.
1O . Check the air compressor, grind the valve and clean the deposited carbon.

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3.3 Technical maintenance in winter

c. Please pay special attention to maintenance of the engine when the temperature is below 5 ºC.

1. Oil and fuel for winter application should be used. Closely watch water content in the fuel to avoid

fuel pipes being plugged.

2. lt's better to fill antifreeze in the cooling system: Or the cooling water should be drained out when
the water temperature goes below 40-50ºC after the engine is shut down.
3. lt's better not to park the vehicle in the open air in the cold season or cold regions. Otherwise,
when start the engine, it is necessary to heat up the cooling water and warm up the engine first and
use the air heater. lf you get these jobs done, the engine can be started in cold regions ..

Maintenance records:
Signa ture/ Signaturel
Work time Date Worktime Date
stamp stamp

50
125 250

375 500

625 750

875 ......

3.4 Storage of the Engine

1) lf the engine will not be used for a long time, the oil, cooling water and fuel should be drained out
while the engine is still warm and clean the oil sump and screen filter.
2) Do relevant technical maintenance.
3) Dismantle the intake and exhaust manifolds. Fill every cylinder with 200g clean oil which is
dehydrate treated through inlet and exhaust ports, and turn the crankshaft to make the oil uniformly
adhere on the surfaces of the parts such as valves, cylinder liners and pistons.
4) Wipe away any oil, water traces and dust off the engine surfaces. Smear anticorrosion oil on the

components which are not painted. Don't smear rubber and plastic parts.
5) Outlets of water pipes, intake and exhaust manifolds and muffler should be plugged by wood
plugs or wrapped with plastic film.

6) The engine should be stored in a dry anél clean place with good ventilation. lt's prohibited to put
chemicals near the engine.

Note: In this way the engine can be well stored for three months. Beyond this period, the above
procedures should be repeated.

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Chapter 4 Adjustment of the diesel engine

4.1 Tightening Sequence of Cylinder Head Bolts

The cylinder head is fixed on the cylinder block with cylinder head bolts. When tightening these bolts,
torque wrench should be used and the specified tightening torque value should be reached step by
step following the tightening sequence shown in the figure. lt the cylinder head has been dismantled
and remounted , the engine should be shut down and the cylinder head bolts should be re-tightened
to the specified tightening torque as well as the valve clearances should be e-adjusted after the
engine is warmed up in its first running.

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® CD @

9 2 7

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4.2 Checking and Adjustment of Driving Belt

1) Check the whole belt and renew the broken belt.

2) Engine should work 15 minutes after the new belt is installed, then check the tightening ot belt.
3) Driving belt should be kept under a certain tension status . Normally when exerting a force ot 29 -
49N at the middle part ot the belt a depressed distance not exceeding 1O-15mm is recommended.
Too tight belt will lead to excessive wear ot bearings in generator, tan and water pump. Too loose
belt will lead to drop ot speeds ot accessories. As a consequence, voltage trom generator, air tlow
trom tan and/or water tlow from water pump will drop and normal tunction ot the engine will be
affected.
4) Adjust tension ot belt:
• Loosen two fixing bolts.
• Turn the generator to the right or left to adjust the tension ot belt until it reaches an appropriate
val u e.
• Tighten the two bolts.

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4.3 Notes about Thermostat

Note: it's prohibited to operate an engine without a thermostat. When the temperature of the coolant
through the thermostat reaches about 70ºC , the thermostat valve should open, and it should fully
open when the temperature reaches 85ºC.
When checking the thermostat, if necessary, thermostat may be put into water and heat it up
gradually, and then check the open temperature and fully open temperature of thermostat valve to
see whether they are in the range specified above.

4.4 Adjustment of Starting Motor

The voltage of starting motor is 12V, power is 2.5kW. lt is electro-magnetically controlled and
mechanically driving. When starting an engine , put on the main switch and press down the start
push button , and the engine will start to work. lf it fails to start, wait till the starting pinion returns to its
original position and stands still befare trying the second time.
1. Befare using the starting motor, check the engine, starting system circuit and the charging
situati on of the battery.
2. Normally, engine can start in just one attempt. The time used to start the engine each time should
not exceed 1O seconds. The time interval between 2 consecutive tries should be longer than 1
minute. lt's prohibited to restart the motor while the engine and motor are still moving, otherwise
severe crash will happen between pinion and ring gear. After the engine start to work, loase the
push button at once and let the pinion return to its original position.
3. lf the engine still fails to start after several attempts, do not try again befare the trouble has been
got rid of.

4.5 Adjustment of Generator

1. Don't disconnect the wire from its terminal when the engine is running.
2. Not be confused with the polarities.

3. Use compressed air to clean out dust from inside the generator after long time operation.

4.6 Expelling Air from Fuel System

When the eng ine is working , air ca n enter the system under the fallowing circu msta nces:
1. Drain out fuel from the fuel tank when the en gine is still working .
2. Low pressure fuel pipe or return pipe is broken ora joint have not been tightly fi xed. Once the air
enters the fuel system , it should be expelled befare the engine begins to work.
Take steps as fallows :

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1. Open vent plug of fuel filter, and operate the hand delivery pump till there is no air in the ·fuel
flowing out the vent hole. Tighten the vent plug again.
2. Open vent plug of injection pump, and operate the hand delivery pump till there is no air in the fuel
flowing out the vent plug. Tighten the vent plug again.

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4. 7 Maintenance of Air Filter

1. The intake air quality is closely related to the working environment and the size of air filter. lf there
is too much dust, relevant measurements should be taken.
2. The maintenance periods should be adjusted according to the actual situation.
3. Relevant detail clean method and maintenance periods should be taken according to the
requirement of the vehicle.

4.8 Draining Out Coolant

"'Note: The coolant should not be drained when the engine is still hot and the system is still
pressurized. lt's very dangerous to drain the coolant under high temperature and high pressure.
1. Make sure that the vehicle or the machine is standing horizontally.
2. Open the filling cap of the radiator.
3. Puta container under the drain cock. Open the drain cock by the side of the cylinder block to drain
out coolant.
4. Open the drain plug at the radiator bottom to drain out water in the radiator. lf the radiator does
not have a drain plug , just dismantle the hose from the bottom of the radiator.
5. Clean the cooling system with clean water.

4.9 Renew Spin-on Fuel Filter

1. Clean the surface of the fuel filter.

2. Loase drain device at the filter bottom. Drain water /fuel into a container.
3. Dismantle the filter with special spanner shown or sorne other similar tools.
4. Threaded adaptar should be tightly fixed with the filter cover. Be sure to keep the inside of filter
clean.
5. Smear the sealing of the new fuel filter with a little clean fuel. Tightly fix the new filter on to the
filter cover.
6. Expel the air in the fuel filter.

4.1 O Renew Oil Filter

1. Put a pan under the oil filter to collect the oil draining out.
2. Dismantle the oil filter with special spanner or other similar tools. Make sure that the adaptar is
tightly fixed in the filter cover.
3. Clean the filter cover.
4. Fill clean lubricating oil into the new filter.
14 21
5. Smear the sealing of filter with clean lubricating oil.
6. When installing the new filter, after turning tight by hand it can be further screwed in by only 3/4
turn. Much care should be taken when using the spanner to avoid damaging the sealing .
7. Make su re there is lubricating oil in the oil sump.
8. Operate the engine and check if there is leakage from the filter. After the engine stops for a while,
check the oil level with the oil gauge, fill more lubricating oil if necessary.

4.11 Adjustment of Valve Clearances

After repairing or technical maintenance, valve clearances of the engine should be checked and
adjusted.
The method of adjusting valve clearances is as follows: ·
1. Take off the cylinder head cover, check and fasten the bolts which hold the rocker: bracket.
2. Turn round the crankshaft until the first piston is at its top dead center when the mark at the
observing window on the flywheel housing is ,just in line with the "O"mark on the flywheel , or the
indicating pin on the gear housing cover is just pointing to the "O" mark on the V belt pulley.
3. Measure the intake and exhaust valve clearances of the first cylinder with a feeler gauge. Adjust
them to 0.35mm and 0.45mm respectively in cold state. Then turn the crankshaft for 180ºCA to
adjust the other cylinders valve clearances.
Adjustment done as follows:
• Take off the cylinder head cover.
• Shut down the engine and wait for 30 minutes before adjusting valve clearances. Oil temperature
should be below 80 ºC.
• Using the feeler gauge to check the valve clearances between@ and @.
Adjust the valve clearances in following steps : 1. Loosen nut ©.
2. Turn bolt ® with a screwdriver and tighten nut © to get correct valve clearances.
3. Check and adjust other valve clearances.
4. lnstall cylinder head cover.
Adjust the valves marked ~ in the table.

Cylinder Number 1 2 3 4

Va/ve Exhaust lntake Exhaust lntake Exhaust lntake Exhaust lntake

Rocker Number 1 2 3 4 5 6 7 8

Compression TDC ofNo. 1 ..

~ ~ ~ ~
Cylinder

Cylinder Number 1 2 3 4

Va/ve Exhaust lntake Exhaust lntake Exhaust lntake Exhaust lntake

lntake 1 2 3 4 5 6 7 ·8

Compressing TDC ofNo.4

~ ~ ~ ~
Cy/inder
22 15
4.12 Adjustment of lnjection Timing

In order to get the lowest fuel consumption rate and good performance, it's necessary to adjust the
injection timing.
The method of adjusting injection timing is as follows:
1. Release the air trapped in the fuel system. Repeatedly turn the crankshaft to and fro to fill up the
injection pump with fuel. Dismantle No.1 high pressure pipe. Blow away the fuel in the delivery valve
adapter. Slowly turn round the crankshaft clockwise and watch the fuel in the adaptar. Stop the
crankshaft as soon as the first sign of the fuel moving up is discovered.
2. Check if the mark at the observing window on the flywheel housing or the indicating pin on the
gear housing cover points to the right timing marks on the flywheel and V belt pulley respectively.
3. lf the injection advancing angle is not right, loose three M8 nuts that fix the injection pump on the
gear housing . Turn the injection pump off the cylinder block if the angle is too big or otherwise if too
small.

4.13 Adjustment of lnjector

The test and adjustment of injector should be done on the test stand. The purpose is to adjust the
injector pressure and watch the atomization quality and deal with the troubles.
The steps for the adjustment of injector:
1 )Push the handle of the hand pump to raise the fuel pressure to 18MPa; Gradually push the handle
to further raise to 20.3 to 20 .8MPa; watch the nozzle tip to see if there is any fuel leakage or dripping.
Check, wash, or lap the nozzle precision couple if necessary.
2 ) Take down injector screw cap, tighten or loasen adjusting screw to get the injector pressure to
20 .3 - 20.8Mpa. Fix the screw cap and check again.
3 ) Watch the atomization quality. Do the atomization test ata speed of every 1 second each . The
fuel atomization should be fine and even. No splashed fuel should be seen and uneven or deflected
spray is not allowed. Clear cut sound should be heard when the injection stops. Generally, abnormal
injection is caused by sluggish movement of the nozzle needle valve, fuel dripping is caused by
damaging of sealing surfaces, branching of spray is caused by carbon deposit at nozzle tip or
thermal deformation.

4.14 Adjustment of lnjection Pump

lnjection pump has been checked and adjusted befare being released off the line. lf there is need to
re-adjust, it should be done on a special testing machine by a professional mechanic.

16 23
Chapter 5 Sketch Maps for Five Main Systems of the Diesel Engine

5.1 Fuel System

1
Fuel tank

1
Low pressure pipe
1
Leak-off tube 1

Fuel filter

- 1
1
Fuel injection pump 1
1

High pressure pipes

1
lnjectors 1

5.2 Lubricating System

1-Strainer 2-0il Sump 3-0il Pump 4-Connecting Rod Bearings 5-0il Filter
6-Gear Train 7-0il Pressure Gauge 8-Valve Rocker Arms 9- Push Rods and Tappets
10- Valve Rocker Arm Shaft 11-Valves 12-Camshaft 13-0il Galleries 14-Cra nkshaft

24 17
5.3 Cooling System

Radiator

Water pump

Water passage

Outside of the
Cylinder head
cylinder head

Front of the cylinder head

Thermostat

Flow chart of the cooling system

5.4 Electric System

2 3 4 5 6

1-Battery 2-Starting Moor 3-Wire 4-Preheating Plugs 5-Starting and Preheating

Switch 6-Amperemeter 7-Main Switch 8-Regulator 9- Generator

18 25
Chapter 6 Engine Trouble Shooting

6.1 Engine fails to start

Cause of trouble Remedies

Fault in charging generator - -4 Charge or replace the generator

Fault in starting motor -4 Check and fasten connections

Air trapped in fuel system __ Check fuel piping and release trapped
air with hand delivery pump

Fuel filter blocked -4 Clean or replace fuel filter

•
Fault in delivery pump Check fuel supply pipe and repair
delivery pump

'•
Fault in injector

Valve clearance is too small

___ Dismantle the injector and adjust it on

-4
test stand

Adjust and lap the valve

•
Gas leak through cylinder
- - 4 Replace the gasket and fasten bolts 1
head gasket

•
Fault in pisten ring -1~ ___R_e_n_ew_,_cl_e_a_n_a_n_d_a_d_ju_s_t_ _~
•
Low temperature and too high >--- Pre-warm the engine and use
oil viscosity specified oil
+
Faults in injection timing -1~ ____C_h_e_c_k_a_n_d_a_d_ju_s_t_ _ _ __.

'
Contact POWERLINK
service station

26 19
6.2 Abnormal oil pressure

Cause of trouble Remedies

Low oil level and oil viscosity ---i Fill or replace the oil

•
Broken oil pipeline, leakage at
pipe connection, damaged oil ~
---i Weld or replace
pressure gauge

Ir

Broken pressure regulating

spring
- ---i Replace

Too big bearing clearance - - - -1 Check and repair

11

Loose screw plug ---i Check and repair

Fault in pressure regulating

valve. Oil return passage
blocked
~
---i Check and adjust

Too low ambient temperature ~

- - - Pre-warm the engine and ues specified oil
or too high oil viscosity

'

No oil reaches rocker arm, oil

passage blocked in cylinder ~
---i Clean and make the oil passage through
head or in rocker arm bracket

'

Contact POWERLINK
service station

20 27
6.3 High exhaust smoke

Cause of trouble Remedies

Nozzle chocked by carbon

deposit or seized needle ._ - - - - - -i Check, repair, or replace faulty parts
valve

To heavy load - - - - - -i Adjust the load within specified range

Too late injection timing - - - - - -i Adjust the injection timing

lncorrect valve clearance or ,_ Check valve clearance, valve sealing

valve leak band and valve spring force and
eliminate all troubles.

Uneven injection - - - - - -1Adjust injection quantity of every cylinderl

lntake pipe an.d air filter are _

blocked -1~ ___ c_i_e_an_o_r_c_ha_n_g_e_a_ir_fi_lt_e_r_ _~

Contact POWERLINK
service station

6.4 Blue Exhaust Smoke

Cause of trouble Remedies

Pistan rings worn or stuck, oil ___ ~ Clean or change piston rings
entering combustion chamber '--·- - - - - - - - - - - - - - - - - - - '

L__~~º-i_ll_e_ve_l_to_o~h-·1g_h~~----'~ ~._______D_r_a_in_o_u_t_e_x_c_e_s_si_v_e_o_il_ _ _ ___.

¡
Wrong installation of rings --l The side marked with "up" should tace upward 1

Contact POWERLINK
station

28 21
6.5 High white exhaust smoke

Cause of trouble Remedies

Too small advance angle

- - - '~~~~-A_d_ju_s_t_t_h_e_a_d_v_a_n_ce~a_n_g_le~~~----'

Too low injection pressure,

- Check, adjust repair or change faulty nozzle
poor atomization or nozzle
dripping

Too low water temperature - - - -1 lncrease water temperature

~~~~~~~~~~~~~~~~------'

Water entering combustion - Check cylinder head gasket

chamber

Contact POWERLINK
service station

22 29
6.6 lnsufficient power

Cause of trouble Remedies

A_ir_fi_lte_r~c_h_o_c_ke_d______~ - -
.___ _ ~.__ _ _ _ _C_le_a_n_o_r_c_h_a_ng_e_1t_ _ _ _ ___J

'
Fuel filter or filter screen of
fuel supply pump chocked
- - l~______C_le_a_n_o_r_re_p_la_c_e_ _ _ _ _~

Uneven injection - - ~._______A_d_j_us_t_to_m_a_ke_e_ve_n_ _ _ _ ___J

Low compression pressure or

- - -.__I_C_h_e_c_k_a_nd_re_p_a_ir_in_je_c_ti_o_n_p_u_m_p_e_le_m_e_n_ts_~
poor atomization

lncorrect injection timing - - ~.______A_d~j_us_t_a_s_s~p_e_ci_fie_d_ _ _ _ _~

· t· t Adjust fuel delivery quantity and repair broken

1nJec ion pump e1emen s worn - - - - parts

The distorted and loosed

governor spring fails to reach - - - ~.___A_d_ju_s_ta_n_d_r_e_p_la_ce_th_e_g_o_v_e_rn_o_r_sp_r_in_g_ ___J

the rated speed

Air enters fuel system - - ~,_______E_lim_in_a_te_t_h_e_a_ir_ _ _ _ ___,

Check valve clearance, valve spring force, valve

Valve leakage - - - guide wear and valve sealing condition; change
faulty parts or lap valve with its seat if necessary

Low compression pressure - - - ~~_ _ _ _ _ _S_ee_ite_m_6_.1_ _ _ _ _ _~

lncorrect valve timing - - -._l_ _ _C_h_a_ng_e_ca_m_sh_a_ft_i_f_ne_c_e_s_sa_ry

_ _ ___,

Loosed cylinder head bolts - - l.____T_i_g_ht_e_n_w_it_h_s_;_p_e_ci_fi_ed_to_rq.....:...u_e_ _ ___,

Gas leak through injector hole Change copper washer, clean injector
sleeve, evenly tighten injector fixing nuts

Contact POWERLINK
service station

30 23
6. 7 Abnormal noise

Cause of trouble Remedies

Too big injection advancing angle
resulting in rhythmic metallic - _ _ _ - ~L~~~~R_e_-_ad_j_u_st_i_n_je_c_ti_o_n_ti_m_i_ng~~~~-
knocking sound
t
- - - - -LI~~C_le_a_n_._re_p_a_i_ro_r_c_h_a_n_g_e_n_e_e_d_le~va_l_v_e~~
Nozzle dripping or seized needle
valve
t
Too big valve clearance resulting in
clear rhythmic knocking sound
1-
- -LI~~~~-A_d_ju_s_t_v_a_lv_e_c_le_a_r_a_n_c~e~~~~

'
Pistan and valve impinging
resulting in rumbling even
rhythmic knocking sound. When
your finger lightly touches screws
-
lncrease valve clearance, decrease
connecting rod bearing, clearance or change
connecting rod bushing
on top of cylinder head cover a
beat of pistan impinging can be felt
t
Pistan and cylinder head impinging - - - - - Replace with the thicker cylinder head gasket
resulting in powerful knocking

'
Broken valve spring, bent push rod
or worn tappet resulting in light
knocking sound from valve
mechanism
, 1-
Change faulty parts and re-adjust valve
clearance

•
Sound resulting from too big
clearance between pistan and -
I ~~~C_h_a_n_g_e~pi_s_to_n_o_r_c_y_li_nd_e_r_l_in_e~~~-
- - - - -L
cylinder liner. lts intensity will
decrease as the engine warms up

'
Sound resulting from too big clearance
in connecting rod bearing . A heavy
knocking sound can be heard if engine
speed drops suddenly
-
- - - - -LI~~~C_h_a_n_ge~c_o_n_ne_c_t_in_g_r_o_d_b_e_a_ri_n_g~~~

+
Sound resulting form too big clearance
between pistan pin and connecting
rod bushing. A light and sharp sound ~
____ -Ll~~~~-C_h_a_n_g_in_g~ro_d~bu_s_h_in_g~~~~~
can be heard especially during idle
speed

'
Sound resulting from too big clearance
in crankshaft thrust bearing. An
impinging sound of crankshaft axially
1- ~ ___ -Ll~~-C_h_a_n_g_e_c_r_a_n_ks_h_a_ft_t_h_ru_s_t_b_e_a_ri_ng~~~
moving to and fro can be heard

'
Contact POWERLINK service station

24 31
6.8 Severe Vibration

Cause of trouble Remedies

Great differences between working Check and adjust the fuel delivery,
conditions of different cylinders
such as bad atomization, leakage
- repair the nozzle,and check the
compression ratio in each cylinder
and compression ratio and so on

t
Water or air enters diesel füel Diesel fuel should be deposited;
eliminate the air
t
lncorrect mounting of engine, loase
mounting fixing bolts
- - - - - ~L~C~h_ec_k~an_d~ti_gh_t_e_n_f_ix_in_g_b_o_lt_s~~

•
Knockl.ng i·nsi'de cylinder
!
L _ _ _ _ _ Check injection timint g. Don'tdtake
load until engine ge s warme up
L_~~~~--..~~~~~-' L~~~~~~~~~~~

Contact POWERLINK service

station

6.9 Engine over-heated

Cause of trouble Remedies

Inferior combustion dueto over

loading, worn critica! parts or -
Find out the cause of trouble;
wrong adjustment repair or re-adjust accordingly

ir

Faulty cooling system dueto

damaged water pump, thermostat
or tan, heavy sea le deposited in
engine water jacket or radiator,
broken cylinder head gaskets and
SO Oíl
Find out the cause of trouble
- respectively and deal with
accordingly

Contact POWERLINK service

station

32 25
6.1 O High oil consumption

Cause of trouble Remedies

L - __ _ L_o_w_o_il_v_is_c_os_i_ty_ ___,~ - - - - - -i Use oil with right viscosity as specified
t
Worn pistan and cylinder
liner, pistan oil hole blocked
>--
-4>-____R_e_p_la_c_e_;_c_le_a_n_o_i_l~ho_l_e_ _ _~

•
Stuck ring or inversely >--
- - - - - -4~_____ C_l_e_a_n_o_r_re_p_l_a_ce_ _ _ _
fitted compression ring __J

i
Oil leak through front or
rear crankshaft seal, oil
sump seal or cylinder head - - - - - - -4~__C_he_c_k_a_nd_re_p_l_a_ce_re_l_a_te_d_p_a_rt_s_ __J

rear cover gasket

•
Too high oil temperature Reduce oil temperature; check
resulting in evaporation and - and adjust limiting pressure valve
severe splash of oíl pump

•
Contact POWERLINK
service station

6.11 Speed going up out of control

Cause of trouble Remedies

Governor fly-ball holder

seized at low speed position
>---
- - - - - i>-______R_e_p_a_ir_ _ _ _ _ __J

t
Governor control lever locked
at high speed position
>---
- - - - - i Repair the governor and the tension rod 1

t
Governor arm gets out from
the shifting yoke
>---
---- - 1~ ______R_e_p_a_ir_ _ ___ __J

t
Great amount of oil enters
combustion chamber
>--- - - -i Reduce the oil as mentioned above

t
Contact POWERLINK service
station

26 33
6.12 Engine shutting down automatically

Cause of trouble Remedies

Seized pistan or crankshaft journal - - - - - ~,__ _ _ _ _R_e_p_a_ir_ _ _ ______.

•
Air trapped in fuel system causing Release trapped air, repair
chocked fuel passage, or faulty fuel ,__ fuel supply pump or clean up
supply pump or chocked fuel filter fuel filter

'
Seized delivery valve of injection
pump or governor fly-ball holder, or -
broken plunger spring
- - - - - 1.____R_e_p_a_ir_o_r_r_e_p_la_c_e_ __..
t
Contact POWERLINK service station

6.13 Rising oil level

Cause of trouble Remedies

Broken water seal on ,__
- - - - - - - - - ~.__ _C_h_a_ng_e_w_a_te_r_s_e_a_I_~
cylinder liner

•
Water leak through faulty ~ - - - - ~ Change cylinder head gasket 1
cylinder head gasket

•
Water leak through faulty
cylinder block or cylinder - - - ~,____C_h_e_c_k_a_n_d_r_e_p_a_ir_ __.
he ad

t
Seized injector - - ~~___C_h_e_c_k_a_n_d_r_e_p_a_
i r _ _ _,

•
Contact POWERLINK
service station

34
27
Appendix 1 Outsourcing Parts list (For 4D2.3CG)

No. Part Manufacturer

YIZHENG SHUANG HUAN PISTON RING CO.,LTD

1 pistan ring
NANJING FEIYAN PISTON RING CO.,LTD

2 pistan SHANDONG BINZHOU BOHAI PISTON CO.,LTD

main bearing, cannecting

HANGZHOU XINDA SLIDING BEARING CO.,LTD.
3
rod bearing SHIJIAZHUANG DIAMONDBUSH BEARING CO.,LTD

4 intake and exhaust valve HANGZHOU VALVE CO.,L TD

HENAN ZHONGYUAN ENGINE FITTINGS STOCS

5 cylinder liner
CO.,LTD

HANGZHOU CYLINDER PAD CO.,LTD

6 cylinder head gasket
ZIANGSHAN CYLINDER PAD CO.,;TD

front and rear ail seals af

7 SHANGHAI SHEEN FLUOROPLASTIC SEALS CO.,L TD
crankshaft

main bearing , cylinder

8 TAIZHOU HUADA MACHI NE CO.,LTD
h_
ead, cannecting rod balts

ANHUI WUHU XINDA POWDERMTALLURGY

9 camshaft bushing
CO.,LTD

10 injectar WEIFU HIGH-TECHNOLOGY CO.,LTD

SHANGHAI RIXIN AUTOMOBILE FITTING

11 ail filter
MANUFACTURE CO., LTD

SHANGHAI RIXIN AUTOMOBILE FITTING

12 Fuel filter ..
MANUFACTURE CO ., LTD

35
28
Appendix 2 Specification of Main Auxiliaries (For 4D2.3CG)

Lubricating Oíl Pump lnjection Pump

Rotor JZX1420 BQ
Model
Flow Rate L/min 23 (2456 r/min) 4QF180T

Starting Motor Charging altemator

Model QDJ1309-K Model JFW817

Power kW 2.5 Power kW 750

Voltage V 12 Voltage V 14

lnjector WaterPump

Model PF68S4

Nozzle Hole Model Centrifuga!

0.28
Diameter mm

Opening
20.3-20.8 Flow Rate L/min 70 (2600 r/min)
Pressure Mpa

Fue/Filler Oíl Filler

Model HECX7085 Model JX85100-D

- -

36 29
 Routine Maintenance Diagram

37
10
 Common Maintenance and Repair Parts (optional)

POWERLINK also provides spare parts

such as filters, water-oil separators, oil
filters or any other part if necessary.

The following lists are optional by the needs of customers.

Minor Repair / 1000 hrs optional

No. Part Name Part No. Q'ty Remark
1 FILTER,FUEL, ASSEMBLY 490B-24000A 1

2 CORE CARTRIDGE,LUB 485B(NA485B) 5

3 CORE FILTER,FUEL 490 5

4 WATER FUEL SEPERATER WS165XS 5

5 CLEANER，AIR H99Y1-00311X 5

6 BELT,V RIBBED AV15*970 1

7 GASKET,VALVE COVER NA485B-11004 1

8 BEARING,CRANKSHAFT THRUS NA385B-01022 2

9 BEARING,MAIN NA385B-01033 5

10 BEARING,CONNECTING ROD NA385B-04006 4

11 NOZZLE TIP F019123009-2YB 4

12 THERMOSTAT NA385B-43002 1

13 BUSHING NB485B 4

14 STOP SOLENOID 1751ES-12 1

38
11
39
GENSET DIESEL ENGINE
4D2.3CG

PARTS LIST 8
o

www.powerlinkworld.com
40
41
 FOREWORD
Thank you for purchasing our diesel engine and this parts list covers the parts of
your machine.

When ording parts or requesting service information, you will always be asked to offer
the following details:

1. Model, Product ID and Serial number.

2. Parts number and Description.
3. Quantity required.

Power link has endeavored to deliver the highest degree of accuracy possible. However,
continuous improvement of our products is a Power link policy. Therefore, product spe-
cifications are subject to change without notice.Further changes of de~ign will be reflec-
ted in the next edition.

Without express written permission from us, any part of this list can notbe reproduced in
any form or by any means.

Copyright 2012 POWERLINK

& SAFETY SYMBOL

This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and
on labels on the machine itself to warn of the possiblity of personal injury. Read these
instructions carefully. lt is essential that your read the instructions and safety regulati-
ons before you attempt to assemble or use this unit.

lt indicates a hazardous situation which, if not avoided,

&DANGER WILL result in serious injury or even death.

lt indicates a hazardous situation which, if not avoided,

&WARNING COULD result in serious injury or even death.

lt indicates a hazardous situation which, if not avoided,

&cAUTION COULD result in minor or moderate injury.

lt indicates potential hazards which can cause injury.

NOTE lt indicates additional information which is important to

a procedure.

42
43
 & Safety Rules

Be sure to keep sparks, flames and

lighted tobacco away from flamma-
ble and combustible materials like
battery gases and engine fuels. Al-
ways have an approved fire extinguisher within
easy reach.

Be sure that ali tools and working

areas are properly maintained and
ready for use. Keep work surfaces
clean and free of debris that could
get into machine components and cause dam-
age.

Be sure any forklift, overhead cra-

ne or other lifting or supporting de-
vice is fully capable of supporting
and stabilizing the weight to be lift-
ed. Use only chains or straps that are in good
condition and of ample capacity.

Be sure that fasteners intended f-

or one time use (i. e. , cotter pins
and self-locking nuts) are not reu-
sed . These components may fail
if they are used a second time.

Be sure to properly dispose of old

oil or other fluids. Use an approv-
ed container. Please be environm-
entally safe .

.-. Be su re that your workshop or wo-

·±·
-.-,'-"
//
1 1-....
1 \ .....
rk area is properly ventilated and
well lit.

Be sure to wear protective eye w-

& ear and other protective clothing if

the situation warrants it.

Be aware of potential crushing ha-

zards such as moving parts, free
swinging or unsecured componen-
ts when lifting or placing loads. Al-
ways wear approved steel-toed shoes.

44
 Contents

;f]Lf*,~~toJZ Cylinder block assembly · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · ·· · · · ·· · · · · ·· · · · · · · · 1

f=\.ffiIW..&Jfcf=\.;f]L;f1;J Cylinder cover and timing mechanism · · · · · · · · · · · · · · · · · .. · · · · .. · · · · · · · · · · · · · · · · · 5

BE$Ji;ff~.IH4 Crank haft and connecting rod components ·· · · ·· ·· · · .. ·· · ·· · · ·· ·· .. . · · · · · ·· ·· · ·· · 8
iE Btfü~1t"?#J * ,~,Jjjt Timing gear train assembly · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10
f=\.ffirw_a,~,Jjjt Cylinder head cover assembly ·· · · · · · · · · ·· · · · · · · · · · ·· · ·· · · ·· · · · ·· · · · · · .. ·· · · · · · · .. ·· 14 ~
<t-tp*&f. Cooling system · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 16

~~yffi*&f. Fuel ystem · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · 19

1if1ffl*&f. Lubricating ystem · · · · · · · ·· · ·· ·· · · · · .. · ··· ·· · · · · ··· ·· · ·· · · · · · · · ··· ··· ·· · · ·· ··· · ·· ·· · · · · · · · ··· 21
;fJL rm~ mff ,
~ 7#1 it!, ;fJLEz. JE it!, 'jj:_ it!, :fJL ,~,jjjt · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 24
Oil filter, taiting motorand charging generator assembly

45
 ifJL1*j~fkJJJt Cylinder block assembly

C0
.q-
1
/

} Q.1)
I
I

(O
I
N

mo

• 1 .
46
 fJL{*,g,J]J: Cylinder block assembly

ff % 1~
~-
% !g f$ ff
No. Part No. Name
*
Q'ty Remarks

1 NA385B-01005 f=(für~ Cylinder liner 4

2 490B-01006 f=( für~H 7l< !!! Cylinder liner water seal 8

3 NA385B-01002 l=F für~iE:t~fi Cylinder head bolt(long) 14

Washer for cylinder head
4 NA385B-01044 f=( ffir~~ifim !!! bolt
18

5 NA485B-01004 l=FffiI~mJt Cylinder head gasket 1

6 GBff93-1987 s!f!•ml!I 8 Spring washer 8 15

7 GBff5783-2000 /<~§*!t~if.i M8xl6 Bolt M8x16 2

8 NA485B-34007 ¡E;f& Fixed plate 1

9 GBff62-2000 ~%t~-BJ: M6 Nut M6 1

10 GBff97 · 1-45 f mi!! 6-140HV Washer 6-140HV 4

Upper cover,air intake
11 490B-34005 íl~ !N:H _t~ 1
de vice
12 490B-34009 o ~i~U&it !!! 0-ring 1

13 ?Jt IXXJ Filter net 1

Lower body ,air intake
14 490B-34006 íl~P_&~r{* 1
de vice
15 NA385B-34003 ~íl~P_&1f Right air intake pipe 1

16 GBff65 - 2000 3ftl~H*~,,~n Screw M6x45

M6x45 1

17 NA485B-34004-l tr:íl~fl& it Left air intake pipe 1

18 A385B-34002 ttff~~;f,& Cover plate 1

19 NA385B-34001 ttff~~ mJt Cover gasket 1

20 NA485B-Ol 101 m1* Cylinder block 1

..
21 NA385B-Ol 103 8 !ffi$EB*t~ Cam haft bush 1

22 NA385B- 01034 3:$áili(_t) Main bearing,upper half 5

23 NA385B-01033 3:$áili( ) Main bearing.lower half 5

24 NA385B-Ol 104 3:$ái7f\~ Main bearing cover 4

. 2 .
47
 tJLf*Jg,,nX: Cylinder block assembly

rf % 1~ % ~ fJ\ ~it ~ ff
No. Part No. Name Q'ty Remarks

25 NA385B-Ol 105 ± $fijjft~Jt:ir&: ~ Washer for main bearing 10

26 NA385B-Ol 106 . ±$EH7tt~~Jt:i Bolt for man bearing

cover IO

27 ZBT32003-88 f!9[%~Jt 14 Bowl plug 14 3

28 GBtr5782-2000 /"JFJ*~Jfi M8x45 Bolt M8x45 1

29 490B-01039 ~J~ R% Plug R% 1

30 ZBT32003-88 f!9[%~Jt 30 Bowl plug 30 8

31 NB485B- l 5001- 3 bt ~;fJL fil¡~~ Front bracket,engine 2

32 GBtr898-1988 ~*t~t:i Bolt

6
GM10-M10x25-8.8 GMIO-M10x25 -8.8
33 GBtr93-1987 5'-•r&:~ 10 Spring washer 10 26

34 GBtr6170-86 /\JFJt~-BJ: MIO Nut MIO 6

35 NA385B-01107 fü±$ffiltt~ Rear main bearing cap 1

Cramkshaft thrust bearing
36 NA385B-OI022 Bil $E81l:Jt Jt Cf) (lower)
2

NA385B-OI026 ¡tt¡ $EH_

l1Jt Jt (_t) Cramkshaft thrust beaiing
37 2
(upper)
38 GBtr97·1-1985 ~f&:~ 8-140HV Washer 8-l 40HV 13

39 NA385B-01073 mrffi?IB rg~ m tt Oil filter gasket 1

40 NA385B- 01014 1J~;J<.R~t#rg Linking tube of drain cork 1

41 485-01100 1J~;J<.R~fü314 Drain cork 1

42 490B-01078 rffiff1~~~ 303 Transrucer oil pressure 303 1

43 NA385B-01025 fürffiit~mtt Rear oil seal cap gasket 1

44 NA385B-01024 fürffiit~ Rear oil seal cap 1

..
45 NA385B-13004 IS$t;%f&:Jt Housing pad 1

46 rffi if.:f. 85 X l I0x 12 Oil seal 85xl10xl2 1

47 GBtr5783-86 /\JFJ~~Jfi M8x25 Bolt M8x25 8

48 NA385B-Ol 108 f!9[%~Jt Bowl plug 1

. 3 .
48
 fJL1*Jg._)jjt Cylinder block assembly

ff% ~
1-t %
~·
ff¡\ ff
No. Part No. Name
*
Q'ty Remarks

49 NA85B-01109 8~~Fo*t~ Rear camshaft bush 2

50 NA385B-01013 f=\. ffir~Ji: 1iz ~ Cylinder head pin bush 2

51 NA385B-01003 f=\. ffir~m: t~ifi Cylinder head bolt(short) 4

..

. 4 .
49
 )

3
)lr
Fl
~~
~
~
)lr
~
&j:
2
n
'""-<
~
~·
::i
2 o...
('D
1-oj

CJ
o
<
' ,l~
('D
1-oj

pj
14 30 ::i
o...

~
.-;-
~ ·
a
~·
::i
30 Q'q

a
('D
CJ
~
... . 33
§
~·
35 \/)

a
lll

50
 ~ffir.W..&Wc~f!L;f1J Cylinder cover and timing mechanism

ff % 1~ ~ ~
%
~- * ff
No. Part No. Name Q'ty Remarks

1 NA385B-03202 1=\.flf*W3t~ V al ve rocker arm seat 5

2 NA385B-03210 1=\.fltfüWfü14 V al ve rocker arm assembly 8

3 NA385B-03203 4: n tffiW $EB si!!• Valve rocker arm spring 4

4 NA385B-03206 $EH~ Bush 3

5 GBtr6170-2000 /" JfJ t" -BJ: M8 Nu t M8 5

6 GBm9-2000 r*J /\ jfj mi t± tqfü ~ JE:t" Screw M8x37 5

$J M8x37
Adj usting nut for valve
7 NA385B-03205 1=\. 1'1 fBJ ~iJJ ~ t"-BJ: ele aran ce
8
Adjusting screw for val ve
8 NA385B-03201 1=\. 1'1 fBJ ~iJJ ~ t" $J ele aran ce
8

9 GBtr93-1987 s••m~ s Spring washer 8 39

10 GBtr5782-2000 /\ifJ~t"fi M8x60 Bolt M8x60 5

11 GBtr5782-2000 /\JfJ~~iti M8x45 Bolt M8x45 5

12 ZBT32003-88 ~%~Jt 12 Bowl plug 12 2

13 NA485B-03204 tfüW$EB Rocker arm shaft 1

14 GBtr5783-2000 /\JfJ~t"fi M8x20 Bolt M8x20 8

15 NA385B-03009 ffi 1l= Hoisting ring 1

16 GBtr5782-2000 /\jfj~!l¡,";fi M8x55 Bolt M8x55 2

17 NA385B-03003 1=11:1=\.ifmJt Gasket exhaust manifold 4

18 NA385B-03102 1=\.fl~if Valve guide 8

19 GBtr5782-2000 /\JfJ~t"ti M8x75 Bolt M8x75 4

20 NA385B-03006 1=\. fl lJJi~ .. Split valve lock 16

21 NA385B-03007 1=\. ns••-.t~ Val ve spring upper seat 8

22 NA385B-03004 1=\. fl)'Hi!! jt Valve s pring 8

23 NA385B-03005 l=f' n r*l s•• Valve spring 8

24 GBtr6175-2000 1 ID!/\ jfj ~i-BJ: 1 type nut 8

. 6 .
51
 ~ffir.W..&WC~fJLifíg Cylinder cover and timing mechanism

ff % 1-t -'% !g ~ ~ji ff

No. Part No. Name
*
Q'ty Remarks
:x~~t;u
25 GBtr899-1988 Stud GM8-M8x50-8 .8 8
GM8-M8x50-8.8
26 ZBT32003-88 ~%~Jt 26 Bowl plug 26 4

27 NA385B-03010 ffil1= (A) Hoisting ring (A) 1

28 GBtr6170-2000 / " 1§ t; -BJ: M8 Nut M8 1

29 NA485B-03111 ~%~Jt 55 Bowl plug 55 1

30 GBtr5783-2000 /\J§~t;;f.i M8x25 Bolt M8x25 7

31 GBtr97 · 1-1985 f-m~ 8-140HV Flat washer 8-140HV 6

32 NA485B-03016 Jitf=(~mJt Gasket,intake manifold 1

33 NA385B-03108 1-fFl=(l'l ~ Intake valve seat 4

34 NA385B-03015 1-fFl=(fl Exhaust valve 4

35 NA385B-03107 Jitf=(fl~ Intake valve 4

36 NA385B-03014 Jitf=(fl Intake valve 4

37 NA485B-031O1 f=(ffirw Cylinder Head 1

38 GBtr923-1988 w%t;-BJ: M8 Nut M8 5

39 JB982-77 ~-ª-~*itm~ 8 Se&l ring 8 5

40 ZBT32003-88 ~%~Jt 10 Bowl plug 10 4

41 ZBT32003-88 ~%~Jt 20 Bowl plug 20 8

42 490B-03109 ~t!Bff~~ Sleeve pipe 4

..

. 7 .
52
 fiH$B:Jji;ff~ll 14 Crankshaft and connecting rod components

I,
o
.,...

~-\-.
o:'.) _ ____,,

. 8 . 53
 El±J$EBJiiff~J3.14 Crankshaft and connecting rod components

ff % 1~ % !g f¡\ !J&:I ff
No. Part No. Name
*
Q'ty Remarks

1 NA385B-05008 ~iYJJT\ Starting pawl 1

2 NA385B-05007 ~iYJJRm~ Washer for starting pawl 1

3 NA485B-05006 El±! ~El* tffi Crankshaft pulley 1

4 GB1096-79 í)l Cl0x63 Key Cl0x63 1

5 NB385B-04205 :ii ff t'--BJ: Nut for connecting rod 8

6 NB385B-04212 :iitfw Connecting rod cap 4

7 NA385B-04005 :iiff~]L Connecting rod bearing 8

8 NB485B-05004 El±!~ Crankshaft 1

9 NB385B-04202 :iiff*t~ Connecting rod bush 4

10 NA385B-04004 $~~~ Piston pin 4

11 GB!f893 · 1-1986 tLJ=t.B~:t'.ít-3 ~ 28 Elastic retainer 28 8

12 NA385B-04002 ~-:iim~fíF Compression ring(top) 4

Compression ring
13 NA385B-04003 ~=:iim~fíF (second)
4

14 NA385B-04100 rrnfíF Oil ring 4

15 NB385B-04001 $~ Piston 4

16 NB385B-04203 :ii ;ff~/";ji Connecting rod bolt 8

17 NB385B-042 l l :iiff Connecting rod 4

..

. 9 .
54
 Timing gear train assembl y

. 10 .
55
 iEBtw$t1{Zili*'~'JJX: Timing gear train assembly

ff % 1~ % ~ ~ ~fl ff
No. Part No. Name
*
Q'ty Remarks

1 GBtr5782-2000 /,fiH*t"fi M8x35 Bolt M8x35 4

2 GBtr5782-2000 /\fiH*t"fi M8x80 Bolt M8x80 2

3 GBff93- l 987 5!¡! ~m 111 s Spring washer 8 32

4 GBff97· l-1985 f-mll! 8- l 40HV Washer 8-l 40HV 30

5 NA385B-16001 iEBtfü~1i[~ Gear chamber cover 1

6 GBtr5782-2000 /\fiH*t"fi M8x45 Bolt M8x45 2

G~r chamber cover
7 NA385B-16002 iEBtfü~1i[~mJt 1
gasket
8 GBtr5782-2000 /\fiH*!l!lti M8x50 Bolt M8x50 3
Timing gear for injection
9 NA385B-02003 l!Jitr83*iEBtfü~ pump
1
Clamping plate for
10 NA385B-02012 iEBt·tfifü~lli;t& 1
timing idle gear
11 NA385B-02006 iEBt·tfifü~ Timing idle gear 1

12 NA385B-02015 fJL183*.:EZ))Jfü~ Active gear for oíl pump 1

13 NA385B-16003 iEBtfü~1i[ Gear chamber 1

Timing gear for
14 NA385B-02007 liB $83iE at& !t~ crankshaft 1

15 GBff898-1988 xJl*t"U M8x25-8.8 Stud M8x25-8.8 3

16 GBff6170-2000 /\fi§t"-BJ: M8 Hexagon-headed nut M8 3

17 NA385B-16009 iEBtfü~1i[mJt Gear chamber gasket 1

18 NA385B-16005 1J!1Wff~ Adancer cover 1

19 NA385B-16006 1J!1WH~mh" Adancer cover gasket 1

20 183itI 52x72xl2 Oíl ·seal 52x72x12 1

..
21 NA385B-02005 iEBt·tfifü~ft~ Timing idle gear bush 1

22 GBtr5783-2000 /\fiH*t"fi M8x20 Bolt M8x20 6

23 NA385B-02004 iEBt·tfifü~$83 Timing idle gear 1

24 NA385B-02008 8 ~$83 l[J1H& Camshaft plate 1

. 11 .
56
ff % 1-t % .1I; f$ ~~ ff
No. Part No. Name
*
Q'ty Remarks

25 GBff5782-2000 /\~*!t";fi M8x75 Bolt M8x75 2

26 GBff93-1987 5!iíffrti:ml 10 Spring washer 1O 1

1 Type hexagon-he11ded
27 GBff6170-2000 1 IDU" ~ t"-Bt M10 nut MIO
1

28 NA385B-16012 t~ft Po in ter 1

29 GBff5782-2000 /"~*!t";fi M8x60 Bolt M8x60 1

30 GBff5782-2000 /"~*!t";fi M8x65 Bolt M8x65 2

31 GBff5782-2000 /"~*!t";fi M8x30 Bolt M8x30 2

32 GBff5783-2000 /\~*!t";fi Bolt M12x30 1

M12x30
33 GBff93-1987 5!iíffrti:ml 12 Spring washer 12 1
Clamping plate for
34 NA385B-0201 l 8 ~~iEBt-fü~ ffiif,& camshaft timing gear
1

35 NA385B-02009 8~~iEBt-fü~ V amshaft timing gear 1

36 G Bff5782-2000 /"~*~J;fi M8x25 Bolt M8x25 4

37 GBff5782-2000 /\~*t"fi Bolt M10x80 1

Mlüx80
38 NA385B-53002 1E i:E!,~ i:E!, Vl.5z~ Generator bracket 1

39 GBff5783-2000 /"~*!t";fi M8x16 Bolt M8x16 1

lnj ection pump flange
40 NA385B-1601 l UJltri±!JfU! ~ rt1: Jt gasket
1

41 NA385B-02016 UJltrB:IJí[iEBt-fü~~Jét1<1! Timing gear for injection 1

pump
42 NA385B-06002 1=c f11Mt1 V al ve tappet 8

43 NA485B-06001 8~~ Camshaft 1

44 GBff1096-1988 .3f-tt e10x25 Flat key C 10x25 1

..
45 NA3 85 B-06003 1=cf11iff V al ve push rod 1

46 NA485B-08001-2 :f:lp1=c1f Exhaust manifold 1

47 NA485B-08002 :f:lp1=c,g,1f*tm Exhaust manifold gasket 1

48 GBff898-1988 X~*t"tt GMIO-Mlüx Stud

2
lx25-8.8 GM10-Mlüxlx25-8.8

. 12 .
57
 1E.Btfü~1~$J*)~,Jjjt Timing gear train assemhly

ff % 1~ ~ ~
%
~- * ff
No. Part No. Name Q'ty Remarks

49 GBtr6171-2000 /'\ JfJ 1~ -Et Nut Ml0xl-H62 2

Ml0xl-H62
50 GBtr6173-2000 /\:fifJ•t~-Bt Nut Ml0xl-H62 2
Ml0xl-H62
51 NA485B-09002 :ilt'=C.~ Intake tube 1

52 NB485B-54000 ~
.:.X.. f=(jjo ttt.:H
,,,, Air heater 1

53 NA385B-09004 :iltÉ:ti~*tm lntake connecting tube gasket 2

54 NA3 85B-09003-6 :ilt'=C.ti~ lntake connecting tube 1

55 NA385B-14000 ~É:~~m-=H
:.:c.~ !'..\ FJ ~
,~, mt , Air cleaner assembly 1

..

58
. 13 .
 Cylinder head cover assembly

. 14 . 59
 Cyli~der head cover assemhly

1~
l=l
ff:-% 7 ~ ~ t:t• ~ ff
No. Part No. Name Q'ty Remarks

1 NA485B-11100 4:.ffiI_WllWmW14 Cylinder Head Cover 1

2 NB485BPG-11 009 ~AA! lndentification marker 1

3 GB827-86 t~M!f9PlJ 2x5 Rivet 2x5 4

4 NA485B-11004 *
4:. ffir_W_!l tt lm Seal ring,cylinder head cov.er 1

5 NA485B-11010 :iffi é"®; Pipe 1

1...§

6 490B-11013A tarrn o _W Oil filer cap 1

7 490B-11014 tarrn o _W~!m Oil filer cap washer 1

. 15 .
60
~

O\

33

9 6 -u

"""... --
, 44

10
2 3
' ~
'-.~\ª 42
43 42
29
1
30

41 27
,..... '1 40
~
~~
28
27 ~
,... .1
~
2 3 ~
11
13 n
o
o........
20 .. .
~
Cfq
1~¡
fJ)
"-<
fJ)
.-+
C'D
a

2
17

\ 61
 i~!p *m Cooling system

ff % 1~ ~
~-
% i; ff
No. Part No. Name
*
Q'ty Remarks

1 GBtr5783-2000 /\J§ ::~d!~ M8x20 Bolt M8x20 2

2 GBtr93-1987 s!i!•m111 8 Spring washer 8 14

3 GBtr97· 1-1985 f-mlll 8-140HV Washer 8-140HV 10

4 NA385B-43001 1J rlfrH iiif. Thermostat cover 1

5 NA385B-43003 11 rlfrH w. mJ=l Thermostat cover gasket 1

6 NA385B-43002 1Jylfrff(1052A ID!) Theimostat (1052A) 1

7 NA385B-43010-1 lJ 1Ill.H %
-++-is -=I=" Thermostat housing 1
Thermostat housing
8 NA385B-43005 11 rlfrH'iEm J=l gasket
1

9 490B-430008 t"~ NPT3/8 Plug NPT3/8 1

10 GBtr5782-2000 /\ 1§ ~ ~!~ M8x45 Bolt M8x45 1

11 GBtr5782-2000 /\J§~t"~ M8x40 Bolt M8x40 1

12 490B-01014 f}l}X{JJL@] Jj( ti~ Union 1

13 GBtr5782-2000 /\ JfJ ~ t"~ M8x35 Bolt M8x35 2

14 NA385B-43012 Jj(~ti~ Union 1

15 ZBT32005 · 1-86 :XJUfi,XJH'. J:\'.; :f,f f¡fil 26 Hose clamp 26 1

16 NA385B-43007 **
~
l:j iJ-Ylfr H:ftiíJC~ Jt~ Rubber hose 1

17 GBtr5783-2000 /\JfJ~~!~ M8x16 Bolt M8x16 4

18 NA385B-41003 Jxtm ffiAffi. Clamping plate for fan 1

19 F400-28-52-7 Jxtm ,~,Jtlt Fan assembl y 1

20 HG4-401-74 JxtmJ&w Fan belt 15x9x970 1

15x9x970
..
21 NA385B-41002 JxtmElw~ Fan pulley 1

22 GBtr6170-2000 /" JfJ t"-BJ- M10 Nut MIO 1

23 GBtr93-1987 s!i! •m 111 1o Spring washer 1O 1

24 GBtr97 · 1-1985 f-mlll 10-140HV Flat washer 10-140HV 1

. 17 .
62
 {~!P*m Cooling system

~
~- ~
ff:% 1-t % !g ff
No. Part No. Narne Q'ty Remarks

25 NA385B-42001 7k*Elw~f.9: Fan pulley hub 1

26 GBtr893 · 1-1986 :tLms•·t1:t~mi 35 Elastie retainer internal 35 1

27 GBtr276-1994 $E8wlVJ~~B~-~Ll
jj( 60202 rPJ;L'Jsj( Ba11 beanng
· 60202 2

28 NA385B-42003 $ffi jj(mi~ Bearing spacer sleeve 1

Woodruff key
29 GBtr1099-1979 -*IÑ!it 4x6.55x16 4x6.5x16 1

30 NA385B-42002 7k*$E8 Waster pump shaft 1

~~J:\:ff Yí11B;tf
31 GBtrl 153-1979 Oil cap 90º,M8xl 1
90º ,M8xl
32 NA3 85B-42004-1 7k*nf* Water pump housing 1
Water pump housing
33 NA3 85B-42005 **mlt gasket
1

34 NA3 85B-42009 7j(i-t IF-12 Water seal IF -12 1

35 NA385B-42008 **ºt~ Water pump impeller 1

Linking plate, water
36 NA385B-42006 **~*t~if& pump 1

37 NA385B-42007 **~*t~1&mJt Linking plate gasket 1

38 GBtr68-1985 1ft!tfL~t~n Flat head cap screw

M6xl2 M6x12 2

39 GBtr5782-2000 /<M~~Jti M8x50 Bolt M8x50 4

40 NA385B-43204 **nf* Switch housing 1

41 490B-43201 3f~t~ ~ Screw plug 1

42 GBtr848-1985 1J\mml 10-140HV Small washer 10-140HV 2

43 490B-43203 *Hlll Seal ring 1

44 490B-43202 ff~t~ti Bolt 1

..
45 GBtr119-1986 l~ 3x60 Pin 3x60 1

. 18 .
63
 ~~1Eá*~ Fuel system

,.,.~
,.,. / /1
--.i

12
11

. 19 .
64
 ~9&11B-*m Fuel system

ff % 1~ % ~ fYJ\
~- ~ ff
No. Part No. Name Q'ty Remark

1 A490B-25100 ll]jtrm:ff p rm ~$14 lnjector leak-off pipe 1

2 A490B-22000 llJjt rm :ff Fuel inj ector 1

3 NC485B-23100 m-ffiI~ffirE8~$14 :stlcyl~der high pressure 1

ue tu

4 NC485B-23200 m=ffiI~ffirE8~$14 ¡n1 cy~nder high pressure

ue tu 1

5 NC485B- 23300 m=ffiI~ffirE8~$14 t~~l ~~~der high pressure 1

6 NC485B- 23400 mimffiI~ffirE8~$14 i~~l ~:l~der high pressur~ 1

7 498B-25002 @Jrm~ Oil return tube 1

8 A498B-2 l 000-1 ll]jtrm:ff ,~,mt Fuel inj ection pump 1

High-pressure pipe clamp
9 490B-23500 ~ &rm~---F~$14 parts 1

10 490B-25200
tIB 1W:ff~ ll]jt1ES *:itHm Filter to the fuel pump inlet
1
~$14 pipe parts
11 490B- 25400 $0urE8** rm ~:t~=* Oil tube connector 1

12 490B-25300
$Ou rm *~ tm 1~ :ff$0urm Fuel supply tube from supply
1
~$14 pump to fuel filter
175 lES- Flameout electromagnetic
13 ~~;k Jt!. iítt ~~ ,~,pX: 1
12ETUC3B1Sl valve assembly
14 490B-24000 ~ rmtm m:ff Diesel filter 1
/

..

. 20 .
65
rJEJ i1t-* Y-f. Lubricating system

33

66 . 21 .
 ~i] r1t *m Luhricating system

ff % 1-t % 1S ~~ a
No. Part No. Name
fefF
*
Q'ty Remarks

1 NB485B-32000
m1'm~ $~ ~ nx:
' c.,1~
1
Jll;\

Oil filter JX0810 1

JX0810 "'

2 NA485B-07200 tJL1ffiif~R $1!f Oil lever stick 1

3 NA485B-07002 1m~ñmJ=t Oil sump gakset 1

4 NB485B-07100 1m~ñ~!f-t~ift31!f Oil sump 1

5 GB!f97 · 1-1985 .+mll! 8-140HV Flat washer 8- l 40HV 26

6 GB!f93-1987 s!ií1tm111 8 Spring washer 8 26

7 GB!f5782-2000 /"J§*!l~fi M8xl6 Bolt M8xl6 26

8 JB982-77 füitW!tmlll 20 Sealring 20 1

9 JB2343-79 /\j§ *~'~!l~~ Magnetic plug

1
M20xl.5 M20xl.5
10 GBtr5782-2000 /\J§*!l~fi M6x55 Bolt M6x55 1

11 NA385B-31006 ~& ffi ~~ ~ Pressure-limited valve 1

12 GB!f93-1987 s!ií1tm111 6 Spring washer 6 5

13 NA385B-31005 ~&ffis!iíJi Pressure-limited spring 1

14 GBtr5783-2000 /\J§*!l~fi M6x30 Bolt M6x30 1

15 GB!f308-1989 Wjf}j( 10 Steel hall 10 1

16 GB!f6172-2000 /\J§•t~ilt MIO Thin nut MlO 1

17 GBtr859-1987 ~ID!s!ií1tm111 10 Spring washer 1O 1

18 GBtr848-1985 mll! 10-140HV Washer 10-140HV 1

19 GB!f1099-1979 * lfilliJt 3x5X13 Wooddruff key 3x5xl3 1

20 NA385B-31007 t!L1ffi*-&~ Oil pump gear 1

..
21 GB!f5782-2000 /\ J§ * !l~fi M6x50 Bolt M6x50 3

22 NA385B-31001 tJL1ffi*f* Oil pump housing 1

23 NA385B-3l101 ;fJL1ffi*~ Shaft oil pump 1

24 NA385B-31102 i*J~r lnner rotor 1

. 22 .
67
 ~fj *
nt m Lubricating system

ff % 1~ !g ~
%
~- * ff
No. Part No. Name Q'ty Remarks

25 490B-31203 ~tHf1í Pin 1

26 NA385B- 31004 ~r~-T Outer rotor 1

27 NA385B-31002 fJlrEl3*~ Oíl pump cover 1

28 NA385B-31 003 mM*mJt Oíl pump gasket 1

29 GBffl 19 · 1-2000 ~Hff1í B4x12 Pin B4x12 2

30 GBff5783-2000 /" 1§ :~dJ;f.i M8x 16 Bolt M8x16 1

31 GBff93-1987 5tJtm~ s Spring washer 8 1

32 NB485B-35200 11& rE13~$14 Oíl inlet pipe 1

33 GBff5782-2000 1\J§:*t~fi M6x40 Bolt M6x40 2

34 GBff93-1987 5tJtm~ 6 Spring washer 6 2

35 GBff97 · 1-1985 ~ft1:~6 Plain washer 6 2

36 NB485B-35001 ~ =:- mJt Gasket 1

..

. 23 .
68
 fJL1á3i,&1~ff "~$J~tJLbZ.JE~.bti:E!.fJLg,~ Oil filter "starting motor
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ff % 1~ i; ~
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No. Part No. Name Q'ty Remark
Adjusting lever for
1 495B-53001 'JXfttJL~~ generator 1

2 GB!f97.1-1985 :s¡z.~~ 8 Washer 8 1

3 GB!f93-1987 s!iíJHt':~ s Spring washer 8 1

4 GB!f5783-2000 /,<~~*t~f.i M8x25 Bolt M8x25 1

5 GB!f5782-2000 /,J§*t~f.i M10x80 Bolt M10x80 1

6 JFZl 72-WX-XCDI 'N_ft;f}L Gengerator 1

7 GB!f97.1-1985 1JZ-m~ 10-140HV Washer 10-140HV 1

8 GB!f93-1987 s!iíJt=m~ 10 Spring washer 1

9 GB!f6170-2000 /\J§t~-BJ: 10 Nut 10 1

10 QDJ1309K-P jfQ i)}J ft tJL Starting motor 1

..

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70
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Apellation 1 The connecting diagram of PLC-920 controller far diesel Gen-set ltem Name Date ltem Na me Date

t~-~
GEN-SET HO(J[L , GHP17PXU _&u
P~¡n
FUSE To REHOTE ST ART CONNECTOR Designer 2019 14/03/18 Checked
ENGINE PIOOEL ' 402.lCG
CONTRDllER HQIJEl, PLC-'21
m A
F 1 VOLTAGE• UJ.VllP
®
fERQUt:NCY• i!liZ
POWER TERltNAL (i) 1 TO ATS COIHCTOR
1 Proofread 1 1 1 Approved Po••' lly•t • m •
HOTOA Rl'P• lf!!rp11
FLU LOAO C~RENT • llA
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<D A1 TO ENGINE CONNECTOA
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PAHEl.LAl'P SWITCH
1 Drg.No 1 064005-10000194 78 1 Sheet 1 111 Edition 4.0

71 7
72
 A

06.2012

http://www.powerlinkworld .com
Specification may change without prior notice. For more info.,
contact Power Link or your local distributors please.
©2012 POWERLINK

73