Operational Manual PowerLink 4D2 3CG Escn CMP-TL OCR
Operational Manual PowerLink 4D2 3CG Escn CMP-TL OCR
Operational Manual PowerLink 4D2 3CG Escn CMP-TL OCR
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.
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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 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.
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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
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
Usage type ....... ..... ........................... .. ........ .... .............................. ... .. ............ ............ .. ....... .Generators
Model .... ... .. .. ... .... ...................... .... ....... ..... ............ ... .... ........... ... .................. .. .......... ............. 4D2.3CG
Type .......................... ln-line, water co~led , 4-stroke, direct injection ffi-shaped combustion chamber
Compression ratio ............. ... ........ ....................... ...... .................. ... : ... ........ ............... 18: 1
Rated speed (r/min) .... .. ............... .... ................................ ....... .............. ........... 1500 / 1800
Max. torque speed (r/min) ............................ ... .. .. ... ............... ............... ....... .. ........... ...... NA
Min. fuel consumption at full load (g/kW· h) ..................... .. .. .... ...................................... S240
Min. steady idle speed (r/min) ............ ... ............. ....... ..... ............. ................................ S650
Noise dB (A) ........ ... ............ .. ......... .... ............... ..... ........... ........................................ S105
Cooling system ...... ... ... ........................ .............................. closed cycle, torced water cooling
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,
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1.3 Main Characteristic Data
(For 4D2.3CG)
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Chapter 2 Operation of the Diesel Engine
• 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 .
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
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
medium speed .
5) The engine should be shut down and checked when any abnormal phenomenon happens during
the operation.
1. Oil
Use CD grade oil.
Use different oil for different ambient temperature.
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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
Hexagon wrench
Spanner handle
Valve clearance gauge
Assembling and dismantling tool for spin-on filter
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)
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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
Maintenance records:
Signa ture/ Signaturel
Work time Date Worktime Date
stamp stamp
50
125 250
375 500
625 750
875 ......
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
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 @
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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.
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.
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.
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.
"'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.
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.
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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.
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
Rocker Number 1 2 3 4 5 6 7 8
Cylinder Number 1 2 3 4
lntake 1 2 3 4 5 6 7 ·8
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.
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.
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.
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Chapter 5 Sketch Maps for Five Main Systems of the Diesel Engine
1
Fuel tank
1
Low pressure pipe
1
Leak-off tube 1
Fuel filter
- 1
1
Fuel injection pump 1
1
1
lnjectors 1
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
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5.3 Cooling System
Radiator
Water pump
Water passage
Outside of the
Cylinder head
cylinder head
Thermostat
2 3 4 5 6
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Chapter 6 Engine Trouble Shooting
Air trapped in fuel system __ Check fuel piping and release trapped
air with hand delivery pump
•
Fault in delivery pump Check fuel supply pipe and repair
delivery pump
'•
Fault in injector
-4
test stand
•
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
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6.2 Abnormal oil pressure
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
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'
Contact POWERLINK
service station
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6.3 High exhaust smoke
Contact POWERLINK
service station
Pistan rings worn or stuck, oil ___ ~ Clean or change piston rings
entering combustion chamber '--·- - - - - - - - - - - - - - - - - - - '
Contact POWERLINK
station
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6.5 High white exhaust smoke
Contact POWERLINK
service station
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6.6 lnsufficient power
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Fuel filter or filter screen of
fuel supply pump chocked
- - l~______C_le_a_n_o_r_re_p_la_c_e_ _ _ _ _~
Contact POWERLINK
service station
30 23
6. 7 Abnormal noise
'
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
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~~~~~~~~~~~
ir
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6.1 O High oil consumption
•
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
•
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
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
•
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
•
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)
35
28
Appendix 2 Specification of Main Auxiliaries (For 4D2.3CG)
Rotor JZX1420 BQ
Model
Flow Rate L/min 23 (2456 r/min) 4QF180T
Voltage V 12 Voltage V 14
lnjector WaterPump
Model PF68S4
Opening
20.3-20.8 Flow Rate L/min 70 (2600 r/min)
Pressure Mpa
36 29
Routine Maintenance Diagram
37
10
Common Maintenance and Repair Parts (optional)
5 CLEANER,AIR H99Y1-00311X 5
9 BEARING,MAIN NA385B-01033 5
12 THERMOSTAT NA385B-43002 1
13 BUSHING NB485B 4
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:
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.
42
43
& Safety Rules
·±·
-.-,'-"
//
1 1-....
1 \ .....
rk area is properly ventilated and
well lit.
44
Contents
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
. 2 .
47
tJLf*Jg,,nX: Cylinder block assembly
rf % 1~ % ~ fJ\ ~it ~ ff
No. Part No. Name Q'ty Remarks
. 3 .
48
fJL1*Jg._)jjt Cylinder block assembly
ff% ~
1-t %
~·
ff¡\ ff
No. Part No. Name
*
Q'ty Remarks
..
. 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
. 6 .
51
~ffir.W..&WC~fJLifíg Cylinder cover and timing mechanism
..
. 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
15 NB385B-04001 $~ Piston 4
..
. 9 .
54
Timing gear train assembl y
. 10 .
55
iEBtw$t1{Zili*'~'JJX: Timing gear train assembly
ff % 1~ % ~ ~ ~fl ff
No. Part No. Name
*
Q'ty Remarks
. 11 .
56
ff % 1-t % .1I; f$ ~~ ff
No. Part No. Name
*
Q'ty Remarks
. 12 .
57
1E.Btfü~1~$J*)~,Jjjt Timing gear train assemhly
ff % 1~ ~ ~
%
~- * ff
No. Part No. Name Q'ty Remarks
52 NB485B-54000 ~
.:.X.. f=(jjo ttt.:H
,,,, Air heater 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
4 NA485B-11004 *
4:. ffir_W_!l tt lm Seal ring,cylinder head cov.er 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
7 NA385B-43010-1 lJ 1Ill.H %
-++-is -=I=" Thermostat housing 1
Thermostat housing
8 NA385B-43005 11 rlfrH'iEm J=l gasket
1
16 NA385B-43007 **
~
l:j iJ-Ylfr H:ftiíJC~ Jt~ Rubber hose 1
. 17 .
62
{~!P*m Cooling system
~
~- ~
ff:% 1-t % !g ff
No. Part No. Narne Q'ty Remarks
27 GBtr276-1994 $E8wlVJ~~B~-~Ll
jj( 60202 rPJ;L'Jsj( Ba11 beanng
· 60202 2
. 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
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~ $~ ~ nx:
' c.,1~
1
Jll;\
. 22 .
67
~fj *
nt m Lubricating system
ff % 1~ !g ~
%
~- * ff
No. Part No. Name Q'ty Remarks
..
. 23 .
68
fJL1á3i,&1~ff "~$J~tJLbZ.JE~.bti:E!.fJLg,~ Oil filter "starting motor
and charging generator assembly
.. 6
. 24 .
69
fJL1ffiy~~~ff ,®$J ~fJLAJE~jtE:§JJL,~~tBJG Oil filter ,starting motor
and charging generator assembly
ff % 1~ i; ~
%
~· * ff
No. Part No. Name Q'ty Remark
Adjusting lever for
1 495B-53001 'JXfttJL~~ generator 1
..
. 25 .
70
4 6
HCI OA4P
~¡
111 L1
8
L2 04Wl.S
A 102
103
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u
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lf IZ.5
n. Gr u
1 YGt5
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A
'Gr 1.1
..
N
1 8 31 Gr t5 1Gr1.15
1 PE
,. ,, lS WY 2.S
"
llAI llAI llAI
~"i"w1I Z5 2' 7 Gr 1.15
31• Al t5
1 1 PV 46 Gr l .7S ·12Gr1.lS
22
1 45 Gr 1.lS ,4 Gr 0.15
~
L
l 1 Zl 125
J ®11214
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B 21 22 14 n B
41 211 221 231
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CT 1
1
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INPUT
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'- '- '-
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•
CHG ALT +VE :; ! l'PU
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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
® LAHP •2¡
<D A1 TO ENGINE CONNECTOA
~
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