2L-50

DIESEL ENGINE
USER'S I\4ANUAL

tqro ilra rp'' I

A tr {\ta

t JIANGSU JIANGHUAI ENGINE CO., LTD.

I

I
 Contents
-dcr:.le

PART I SERYICE IIISTRUCTIOI{

Chaptsr I The Main poins of Usage & applicarion Range

Chapter2 PrincipalTechnical'specifications
; : '
Chapter 3 Engine installation

Chapter 4 Service Instruction and Engine Adjusiment

Chapter 5 Fitting clearance and wear limits of the main moving pars

Chapter 6 Maintenance of the Engine

Chapter 7 Troubles and their Elimination

Chapter 8 Seal and Prese'rvation of the Engine

PART II PARTS WTTH ILLUSTRATIONS

Cylinder head lntake and Exhaust pipe Assembly

Cylinder block Assembly

CamshaftAssembly

Crankshaft -fl ywheel Assembly

Piston connecting Rod Assembly

Fuel System Assembly

Cooling System

Lubrication System Assemb ly

Appendix I spare parts supplied with the engine

Appendix tr tools srryplied with the engine

 Attention

ir i: --': :. :r-.:t: .rt dle'el engrri' i, o:" n,;;:rnallv and reliablv. tlie reuLrlations
- r:J.
br-l,tri .l::---'- --:

. . .., .- . ::
, :.,
.--.'-: .:: -:ibr-
: :- .., :.Jbe

:-'--, , -, .-l -, . i .:.)-,-lhe engine

.-: :,., :;l'.iLations.

: , . - -1.: i:.-l l- -r, :: ..:-: , - --::. -ile::IinS $ithOut Watef iS
..,:i:.::-':-.
{i.lne operators rnust gat hrl-rlr.1. -" n: pr-crples and strlctures of the
engine. and stick to majniarn re;.:.:- . i i. .-.:i :llr,i be Liisnrissed as soon as it
is iiiscovere<i. avoid opcralirg .;-.. : : - -:
7. Don't toucli high-tenrp.r-.-...- - -. . - ,: - ' ,': .:C!. :ine etc.)and
nmning parts (such as ;lr:i- .. - . - -'- :..: .:rr.'i -should
prevent hres.

I
F-_

Chapter 1 The Main points of Usage &

applicatiol Range
Cqred *.ift fte same type of diesel enghes, its has the advantage of high
psEr. wI| dimercimC hw fuel and oil consumption, easy to start, high reliability,
i( e- h is &e pdect engine of agriculftral irrigation, generating sets and small type
mdrc s€rs if it get proper trmsformatioa-
ln
order to make the diesel engine work normally aad reliably, the regulations
belov should be followed.
1. Equip the machine with the rated output specified in the name plate, avoid
il-srload.ing, over speeding or long - term operation under low load and low speed.
2. use tfoe fue1 and lubrication specified in this manual, the fuel and oii should be
Frified (filtered and precipitated) before being used and the lube - oil should be
*mged:egularly
3. check the installing and connecting bolts aad the fastening bolts ofthe engine
irefregulatl srengthen them when loosen.
,*. Clean the air fllter, fuei fi1ter, oil filter periodically according
to regulations.
-i. The cooling water must be clean and soft water, operating without water is
fffbidden-
6. The operators must get familiar with the working principles and structures of
fte engine, and stick to maintain regularly. The defects should be dismissed as soon as it
is dscoverd avoid operating defective engine.
7. The location screws of fuel injection pump have been adjusted fastened and
sealed *ith plum bum , do not dismantle or adjust them an one will.
 Cleapter 2 Principai fechnieal Speeiiications

2L-50 SPECIFI{]ATIOT

Fou-Stroke. Water-Cooled. !'ertical, Direct Iniection

Spare Torque coefficient >15%

(g'(k\\'.ir
Oil Consumption < 1.63

Idle Speed(rpmt <750+30

Maximums Smok: FSli <4.5

Cooling merLrr Forced water cooling

!llcctric

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p-*p T-J
{4}-aJ E.6* 3 b*r e2%\ r|"
ftohJGI.
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 Principai Technical Specifica{ions
\1r )l)al 2L-50
t\ Pii \.ERTICAL WATER _ COOLED
FOUR- STROKE
ll :l i (l\lBi-lsl la,)r'i DIRECT INJECTION
'. - '. I i r: li (-rF (.'tri 1l\ I-)i: ::, 2
i- 1 i,l\Di,ii EOR t: 11Omn
.r!: i.tir \,
_\TIti)KI: 112nm
.. i)lS'1'()N i)hiPl ,\Cil).ItlrT 2.13 LITERS
, :: :i::(,r\. Ii.j.j I0 18.5:1

)212o/o
: r ,, ,4i)il_il INTAKE VALVE 0.35mm
EXHAUST VA-L!'E O.4OMM

3'CABETORET.D.C
::. C.{ BEFORE B.D,C
5:. C.,\-{TTERB.D.C
t. CABEFOREB.D.C

: : '. 4:i::- La 2.1xld LPa

: :-,,' a i.D', \\Ciri)-'\).[,LE 14+l'CA

j . ar ;. j,i r._r.1); BQ2OOO PUMP

.- . :L Dlr,\ii:TFR 9mm

i\ ii, Ol: Fl-Ei- l\.ll:{-lttll LONG_SHAPE MULII HOLEVALVE

Tl?E KBAL-P145
I \ i,L r-)i' ST^,ll1t.r, t,ii il.rl QDJi52TD
l\ PE Ot' ilI(,il'.lii'l:, CF\ERilt)lr. 2JF200(14V), JF11(14V, 350W)
iril aji,TarF. J081 1A OR J 0810
,it_ t.{P,\aiTY 7.5 LITERS

- Li. r:iT I ER c0708

:i-iEl'ilNG lOIl{lUE FOR PRINCIPAT- BLILTS
CYLIi\-DER HEAD BOLT 140-160N.m
CONNECTLNG ROD BOLT 120.-140N.m
L[dD,iBE.{RING BOLT 180-1200N.m
FLYWHEEL BOLT 120-140N.m
 Chapter 3 Engine instaliaticn
Power output of2L-50 is efftried through bolts offlywheel side connecting the fl)Theel lriih
equipped machiire. Diesel engine should be locared properiy and installed finnl;; with ie equipped
machine. The corresponding base or assembling surface irame foe diesel engine contteeting pa.r
must be flat smocthly . The specific disposition of installarion lioles ol 2L-50 t"vpe is
iialiirrirld ir.ir,i1
li irt iltsei it,rrille ctii i-:3 s:111ls1,3,1..rtti,. ::;lr..t:!!.i,tili, r.t;iilti.:.: :.- t:.',:.
:,:Lrt::Ir:IIII

i ir:ti,:ri-J trt'i ir,i- i;t\ii irii ,:t .i nal Eirgiti.;

\-i jurlnr;nt:

: - : r- r::t r:. -.-:t:_: ttt,. :.- :..: :. .: :-,-:,t: jl illa iujl llippl.i S\Slell
: ..: pr.,ior:t ilu lt:: ci;it: tit-:eLiill lr,:: - : .

) i: 1- \{ r.l' lr.ri i .-. . i:.:

'\ ,,r. \11 ., l:: r.,i..... :

l),,ri
Viscc,sin ir dit-lcir-iti lirr r-1r; ! :r,l!..i ul;icr lr,rr
Ii),lLi-:r.r, 1l::.uurr'.i.r; _ :.(r:..,r.
{}:llie clhiriranii .if i,--r rt:i.,t.. I _ :- :-: -t-.t:tiiitncti,l|xonki
beucakti:e<jaldtlti:llietl:l;ttt -::::: ii,.a:--:.:-t \j-::ttl. -,:-:;;J31.!19-rijsh,tir1.ib:
-.;.'.1,J f. iir,.1,.'lnr,r : .. -_
. i .il H{- 1"1 i: suiubl;- ilrr ieirlii:iirirr, riro.. t l5'l
i:l oil 11[-]1 is loi tenil,-cnrur. lr:rt\i..!t 0'L alil l: i
;, (lrl iJ(- i :: ibr t.rnpl:rtuic l.cr':r 11 il
: - , ,:l \\ liai
- : '.:: tlt.-:. li ll: i(i]i ,-tiai . :titit as rail iralel 0f ri\,ef 1..:rlar lii.:,:l : : :: : ,. 1

- : r :: . .::i:;. . -:..1 :,.,....1rine lrilrld ba ilJla! ir:i-. tr : : ra;tid

.::t,riid ie iirrti
ii.-; l

b. l-;: : : - ::. .,il:r,\ itnal the coii:plt:lirr

rrlndiiiorl :ri1oil,a r-

.:. lt-itn ln ll;;, :.-: - : , : -.:i.: il .

,l Lhcck drc oil i.,..: .,. :::. :i| ritc ilo :rrrkeii liilt.s.
r \'laki s|ra 1i.,a Ldl.::. : .:: ,. : , t,i rh:ck iltt!.r ilar. .ioit:is ii; rihiclt

thir: .i,'lrl.i:rot b. iiraii_1.

F-:

in order.
2; sraring the Engine
After finishing preparation all'r'e msationed "check again ti1l to be sure ready for staring
and

r heu do as follou s.

Setthethrorileiqrdi:uth:a.lodle>peedposition.tumonthepowerswitchofStaltingmotor
ro
.-sa3r1"
- bU the tfune n,lsa noi be more thm l0 seco*ds . or the safiing motor would be destoyed .

rle e4:re srro''ed. nrm fte prow* stit'ir o -o- '

2. Eryine stoPPiag
1) Nomal stopping
and the
a. Before stopping engine , the load and the speed should.be decreased gradually
agine should be let run at idle speed for 2 to 5 minutes ' At last , stop it '

In winter u'hen the ambient temp€ratue is below 0 C , the water in the cylinder
must be
b. ,
drainedoffcompletelyinordertoavoidtheengirrebeingdestr.oyedbefreezing,whichshouldbe
don: after the c1'linder temperatue has decreased below 40C
I I Errcrgenc.v Stopping in case of Rain-way
place
I\-bee 6e engine speed increased out of control ' in another words , running away takes '
rir sryrng L.'r{le DiL{ be pirlled directly . If fail to sop the engine rhe following emergency
'
meas:es :hcrld bc ra\c at onct :

r trr-= Se wting nrs of ihe higtr-pressure fuel injection piPe to cut offthe fuel supply '

b. BlocltiefuakePiPe.
c. ftilloutftefuelPiPe.'
-1. points for attenlion
at lower speed
. 1) Newly-produced or over-hauled diesel engine must do running for 60 hours
practice '
(behs 2000rpm) and lowerftelow 20kW) and then it can be put into normal
2) After being started , the engine must run for 2 to 5 minutes at no load , then run as nomal '

3) Check the oil pressure whether in normal condition , if no pressure

' stop ihe engine

immediately and check lubricaiing system completely '

4)overloadshoulribecontrolledwhentheengiaeisinopelation.long-timeofoverloadis
prohibited.
emission smoke
5) Observed the color of exhaust smoke and the sound of ruming , nonnal
shouldbeverylightornocolol.Ifthesnokeandsoundoftheenginegetabnormal'theengine
should be stopped and checked .

4. AdjustmentofEngine
l) Adjustment of value clearance
be at T.D.C of
Talie the cylinder iread-cover down and tum flywheel to make the flrsi cylinder
thecompressionstroke.Loosingtheadjustmentnutandsiipafeelergaugebetweentherockerm
and the value to a just value to arljust value clearance (0.35mm thick
for lhe inlet value and 0.'l0mm
rest cylindes
for the exhaust value) . Do as the same for adjusting the value clearance ofttte
.

2)
Adjusting ofFuei Supply Advance Angle
Dismantle the high pressure fuel injection pipe of the first cylinder , then
tum the flyrvheel
pay attention to the level of the fuel . Stop fuming right way as soon as the level of the
slowly and
fuel begins to rise .

AadthenmeasureafclengthbetweentheT.D.Clineintheflywhrel'ssurfaceandthelineinthe
box offlywheel . It will get the fuel supply advance angle to let the arc-lengfi be divided be 3.07.
Ifthe angle is bigger than 2l degrees (crankshaft angle ) or less ihm 19 degrees . ir should be
adjusted . Tum the fuel pump towrds cylinder block wili make the angle bigger md against c,vlfuder
block will make it smaller.

Chapter 5 Fitting Wear limits of the V{ain Moving Parts

i.lU

Piston skirt 0.40

cylinder set hole
--!1.
l 1 st piston
ring I ] 020
Piston ring groove
6 2st piston r-ing 0.05-0.085 0. 1E
Piston rir.rg gioove
7 oii ring 0.0.1-0.072 0.18
Piston ring groor e

8 in process of geff mesh 0.40

clearance
9 cylinder liner protruding Aom 0.01 8-0. 1 12 0.t5
top surface of cyiinder block
10 !
Crankshaft neck 0.06-0.12 0.25
Rear bush

12 ; Axial cl€a'oe of cam<}at 0.0?{.1?5 0-50

li
li
IJ \-. :--.,- 0 2t)
\ali;:--
 Chapter 6 Maintenance of the Engine
i. Diesel Engine
1) Operating-mdltenanr=
a) Check rlie cil kr ei il tk oil sump to keep the level between the marked lines, approaclring
the rryper one-
b) Check oil iet'el in injection purrp, and fill more if necessary.
c) Check cooling *'ater in the radiator *'hether it is sufiicient refill it ifnecessary.
d) Check thoroughly a:nd the leakage of oil or u'ater or air should be forbidden
e) Check all corurectors and joints and keep them in nomal condition.
f) Clean the dirt on the surface ofthe engine.
l'i \,[ahtenmce after i00 Hous Operating
\lhen rie engine is operating for 100 hours, maintenance as follo*'ing should be done, besides
&e -C$efi.tsng maintenaDce".
a; Ci:s &e ur:ir prs of rhe oil filter. Replace the paper oil filter wtridge if it is wom oul
,br Ctae r-i ;r;31 ,sa"iCge md replace ir if messa4'.
.-, Chat:!e tai"x :1lirk iml corer bo16 and iighm it'o regulated position.
d7 Ccert r:l- c{Ersa =;:C;< i: if necessa-r.
er Cbcct ik esim of$e &it-ne betr
t-l Ckan fre actmulared cafto in fu exhast pipe.
gi AIi lmits including pars, assemblies wiich were dismande from ile engine for the
mqrarnce 5fiqfld be reset carefully- After ensuring correct positions and specified clearances, start
tbe enehe and get rid of afly houble which appears. The engine shouid be proved perfect in
paforrmnce before it is put into normal operation.
3) Maintenance after 500 Hours Operating
After the engine has been operating for 500 horus, not only the "maintenance after 100.hours
operation", but also the following procedurs should be done.
a) Check the injection pressure of the fuel injectors and the spray chmcteristics. Dismantle the
fuel injectors and make needle vaius clean ifnecessar;'.
b) Check the fuel supply advane angle and adjust it ifit is required.

c) Check the sealing condition of iniet and exiaust values. If it's necessary', the sealing 1ip of
the values shouid be remedies or polished.
d) Retighten the com€ctor bolts, the main bearing - cover bolts and the flywheel bolts'
e) Retighten cyiinder head bolts and adjust value clearance as regulation.
f) Replace the lube. Oil in ihe fuel injection pump.
g) Clean cooling system. (fili 10% solution of HCI into the water jacket, after remaining it for
20 minutes or so. drain it off. and wash the waterjacket with water repeaiedly.l
h) Check cranksha.ft seal and replace it if it is wom out.
i) Ciem oil passage.
j) Make a rvhole check for the engine and do some adjustment ifnecessary-
2. Fuel Injection Pump
Combustion system is the heart of diesel engine. In order io prolong the life of the engine ald
msure good performance, it is necessary to perfom perfect maintmm€ rtork for the fuel injection
pump.
1) MaintenancePrinciple
a) OperatingMaintenance
Fuel injection pump and its connecting units should be kept clean and firm to assure normal
working performance. Check the fuel pipes to prevent them from blocking. Refill fuel into tlre tank
and oil inro the injection pump in time.
b) Maintenance after 500 Hours Operating
Replace the oil in the injection pump completely when the engine is ruming for 5(S houri.
c) Mahtenmce after 2000 Houm Operating or ir Case of abnomal \\b*irg Pa-'ornance.
\kke a s hole - ch*k for the fsg! injatioa pump ard ::vs :ri :!= ,-i d Fti Replace the
f,on - l,{j: FL= i:- mesa;-.:
]r Ca*ir
al Ki€p ft€ fiEl srrypliing sltu ct€atr aJ H fh= ! g$od
b) Useftereguluedfirl-
c) The firel must be precipitated md filtaed ompia{'befue pouing into the fuel tank.
d) Do not dismande the fuel injection pump if nct ln:tssary-
e) After the engine being wom by the usen, oil in fte injection pmp ard governor must be
drained offcompletely and refill fresh oil before it is ptr into normal operation.
f) Keep pmper amount and viscosity of oil in the govemor when diesei engine is in normal
operation.
3) Supplements
For accessories, starting motor and generating rts. etc. naintenance worlr should be perfomed
according to their operation manual.
 Chapter 7 Troubles and their Elimination

as regulated or preheat the oil

i nrain a"a replace fuel, clean fuel pipe and fuel

lat'.'
- : ::..e uith reguiated brand offtiel
--.: ii,,r!lr s\ Slelr E;<harist air alrj check the fuel pipe comecting
:rut for ieak:ige

-ir fuel pipe destroyed or leak in ttre connecting Repair or replace them

Clean injector nozle and adjust fuel injecting

it si*r regula:ed oil

1J,:Si l:

. :rr Check the tightening torque of nut on the

r r -jli irlror;rh cvlindei head gasket
cylinder head, replace it if the gmket in bad
condition
_ , = ittn oiii
1;-;S

3) the gaps of the rings lined on the same Separate the gaps spacing 120' one another

direction
4) piston rings being shrck or broken Clean wjfi diesel t'uei or rcpiace it thern

5) leak in valves Check the sealing condition ofvalves and seats,

1) voltage ofbattery too low

B. Low
Prollablc causes Solr,ing

1. problems of fuel supPlY sYstem

1) fuel pump precise coupler wom out Replace theil

2) speed govemhg spring defomed Replace it

3) uneven distribution offuel Adiust injccting punP
4) fuel supptying insufrcient because of Check and make the fuel cook open, clean or
choking olfuel passages or fuel filier cartage replace fuel frlter, adjust quantity of fuel
supplying

10
 -l

2. speed insuffrcient Adjust the govemor handle tt-r make tire speed
rise
3. fuel suppiy advance angle rn,-o::ct Adjust it as regulated
4. cooling s\.stem out olorder Check the problem out and set rid ol ir

1) fuel tank empty

- :.-::-: :::t ,:-: t..:: ,- ! I :. ::: .. .,ii:rimp. oil passage.

aa1--:a:ii-.i:l:l:. ::i:11..:-:::a-l:::::-:, - j :;:t-ir:::ta:;tndOfthetn
lubrication si.tcn
3. piston clogged in the cylinder Repair or replace it
4. valve stuck ' Clean it
5. engine or,er load suddeni

D. Abnomal exhaust
Piobable cau::s
1. Black smoke

l) load too heavy Relieve the load if the equipment unit is in

suitable, replace it
2) spraying abnormal Repair or replace the nozzle coupLei
3) arr charge insuffrcient Check and make the irrtake passage clean
4) the timing of valves' shutting or opening Conect it
incorrect
Adjust it

Dmin the needless oil off

It:i:: t: a - , ::,: -:.,, .t: t::::r :.: I :::iS. Or make the
tla.ti.r:-. : ... :-r:.urh.r
direction

-11 the ciearance .:: i ::- r : ' :: : ::!ilt or the cvlinder

'niq

_1. \\'hire Smoke

l)waterinfuel Clean fte fuel tank and fuel filter, replace the
: firels'irhnomal fuel
3) l\'ater in cylinder Chek tie c-vlinder - sleeve, gaskei, cylinder -
I

heacl cover, and replace try cfthcm iinecessatl

3) the needle valve clogged or the injection Clean or replace the noule or adjust the
pressue very low iliection pressure

4) the en_eine temperature ioo lo* When the engine temperatue rises. this
phenomenon will disappear

l. the govemor out oforder

'
i

F. Supplerrents

a1 e.fibilorving conditioo takes place, the engine should be stopped at once

::r::rle:auses Solvine
l.
Make the movrng part's siip in good condition

Replace the spilnu

: - : : :::::l:: i'i pUnP CamShafi tOO big Adjust it

- - : :.:::lsaPPeaiing Check the water pipes, water passage and water

pumD, set rid ofthe faults which are found

Check the lubrication svstem

 Chapter I Seal and Preservation of tlie Engine
l. Diesel Engine
If engine is cur of operation 1or long time. the foilcu'ing presenation methcds should be
l'ullosed to avoi,l corio.r.,n u .ro.toil.
1. Drain the ilcl and lube oi1 au,ar.
2. Remove the dust and oil stain on the surface.
3. Draia the oil filter and clem it.
4. Dismmtle the oil filter and cleen ir.
5. Disrmtle the frel filrumdclro it-
6. Cire $esart i:,
;. Hear ?tg kmd IIC - t ti e
=d iI' C * *e :s :m rne{ess oil). Fill 1Kg
raEiess Gl itrto crdnk case. mgte tbe ergine so *s -.fu rd .Gld iE sp4ed upon mobile parts,
tha drain rlr or-i.

8. Fill a little mormt of *.aterless oil into inrzte rege mtate tte engine so as to make the oil
cover piston tops, cylinder liners and valve sealilg dr:rs S tte shaust valve at close state to
sepamte the liners &0m outside.

9. Add 0.2Kg induskial Vaseline into the remainftr warerless oi1, heat and mix them till melt
completely, that is the mixed oil.
10. Dismantle the cylinder head cover. stain a bnrsh with the mixed oil to brush rocker arms and
other parts.
I l. Install all the parts and make ihe cover rf tre mgine clean and rrL.
l2.Pack the parts of the intake a:rd exharxr ppe *ell ri* oiled paper to avoid pollutants
entering.
13. Finall1,, paini the rest mired oil evanly m fu ryaiated exposed pare (eg. Flyrvheel) of the
engine.
14. Oi1 - brushing is forbidden on rubber and plastic parts.
15. The engine should be put in a weli - ventilated clean and dry place, placement ofchemicals
(eg. Fertilizer, pesticide) is forbidden there.
Caution: Maintenance as above can keep 3 months, repeat it ifover 3 months.
iI. Fuel Injection Pump
h order tc prevent &e fuel pump Som eroding dming long - term preseruation, the pump
shouldbe saled
Drain ib€ ffiL\&r iaei- fiiling in antirut oil fix the pump on e testing platform, connecting
the pipes aod lei mtkr= cil i- ti rq *e * rifr me speed 500rpn to (Bdp the altimst oil follow
over the surface of all partt iE3 e.:: ie c,l n f,e .-zeo-.haft ca- atd place protection caps upon
the frrel intake md ex.haus: dcre rls

!-,
t-

Fig.1 Intake and Exhaust pipe Asseurbli'

 Intake and Erhaust pipe Assembly (Fig.1)
Ser No. +-frnl+ZtT Name of parts lE€ PartsNo. Qr)'
1 iEits tr+ Adding oil hole cover JD2110.1-2.1 1

1 *B4EE Nas NutM8 GB,T923- I 988

3 +48 Washer TY395IT.1.2-8
4 &,&4tr Rubber rvasher TY395IT.1.2-7 3

5fiffiEf?e cylnderheadbonnet 'xD3:.1.-l 1

4
9 8

10 .',=: \\:t:;,r';! i,- ---.,-1001 8

11 fiFttr Exhaustpipe _.rtr_::.10.:-1NB 1

t2 flF-r.E4,h" Exhaust pipe gasket T\'2100IL1-2(]NB z

13 triH4H Intake pipe gasker 2JD32.l-1a I

14 E'iH',i? i5 Intake corinectine prpe 2JD,r2.10.1-1 I

l5 [?+t N48 x 25 Bo]t ]v{E >i t5 cB,,T5lS3-20t)0 4

15

I
T

Fig.2 Cylinder head Assembh

 C.viinder head Assembly (Fig.2)
Ser No. +t'1+Zt8 Name ofparts KE Parts No. Qtv
I {EH+EJA+ Rockshaft plug TY295.t.2-2 l
2 lirEl 10 Check ring 16 GBIT 894.1-198tr 2

3 itit-s+ll Rockshaft 2JD32.1.2-1 1

1 J*'Siiit I Rockshali cauier I TY295. I- i0 2

5 f'Ei#FE$"qfT Screw .lD;190 1-2? 1

6 i$H}fe Rocker arm bush sl95-03005 4

lllffiH htakevalverockerarm T1'35-l r-2-i i 2

i.llFlHtr*igi sl95{Lrflb_r -+
rr'ahe clea'ace adju*iag scrcr
4
ir

11 2

2 1

f li:iir,i R,-r'i::::i ::- -i -i9:iT 1 -1-l 1

4 4El to Gasket 1o GB T97.r-2002 3

5 4BE utO NutMlO GB,rT6170-2000 3

r., :t;
6 liiji$ {ls Iu Rciks:.: - -:, -i 1

1',7 tEHffi-{,EETffiI] TY495'l-ll J

The canier ofrockshaft lires scres-
l8 2

19 i",l;ne+4jifi i. . :::: ::.: : ... :- -: 3

,1iiliFriif;ry',] a :::::::,::
20 li :.- :'l : 8

21 Sllf+Fffi Valve cap t\:J:,-j -.1

22 Silfli* Valvecollects iDll,-r:.\ l-

23 ftl]i+€tr Spring seat cover JD2105A. t -26

24 -1llt5$€ -Valvesprirg(outer) TYt95 1-1

25 5ll4'18ff valve sprhg(imer) w295.1-3 I 4

26 o28 Waterplug @28 TY295.1.1-5 2

^*
=.i \alvezuidestem JD2102Q.l.l{a : 4
==
:: l
t9 4
,1
30
3t Ilit..:r.- :::.i.i-l 2

32 1

33 I: \ir - GB T57E3-200(r 6

3,+ .itFrli ::.-. : : JDI102Q.1.1-8A I

35 T\-195t.1 -7a l

2iD32.1.1,1 I

t1
: - , .,: \.::l: t::-: : E ? Parts No Otv

,*tr WaterPlug TY495Q.1.1-4 2

JD2105A.l.l -3 2
flFillB Exhaustvalveseat
2JD35 -4 2
39 flF-1il Exhaust valve I

40 ' €r1llE lntake valve seat JD2105A 1.i-2 2

2
4l : Eill Intake valve 2JD35.1-3
2
42 ft1Y'tr Stifled water jacket TY49sQ.1.1-4

*,3t4 l,ls x zs BoltM8 x 25 GB, T-i78,r-2000 4

5 +t,:*+n,i+ + 4C Radiator oole bracket TY395IT.1 3-8NB 1

GB,',T57E2-2000 2

-16 '8tr e Gasket 8

(iBiT97. i -2002 12

:- -=1i Front coverplate TY3 1008.1-18 1

i ::.'t i:llferaruie llltll":l-"1 :-'-. NJ-12 1

i
- : .1 , i-:-rl-l(100
2

t2
il
I
Fig.3 CylinderblockAssembly

t9

r
 Cylinder block Assembly(Fig. 3)
[1]5 Parts No. Qry
iD2110B.2-16 i

21D35T.2-7 2

l::ig 2iD35T.2-8 4
,1 -'.:. a-
"i::J:::i:
Plug TY495.2.1-10 1

r-ftffitrij€ Rear camshaft bush JD4102.2.1-3 1

5 'E&H o12 OrientationPin@l2 TY295.2.1-6 4

: i afilg Cvlinder 2JD35T.2.1 -1 I

1
r PILig TY195.2.1-9
\\:t:r-dtatnitlg cork TY395rT.2.3 1

rv495.2.1-4 2
I
1

.-): ::, l: l

-. ?.:.::::::: :::.:ai -Ja-iiil'l

JD-1102.2.1- 1 1

' | .= .,_ B.L-SpirAi0l laCOIlaS JD1102.2.3 1

-
'11. l0 BoltMEX20 GB,rT5783 -2000 6

:
=a.=
E \\rasher E GBlT93- I 987 6

Date 2JD32.2-29 1

2X6 Rii et 2X6 GB,T867- 19u6 4

20
I
{i

Fig.4 CllinderblockAssembly

21
 Cylinder block AssemblY(Fig.a)

E€'Parts No. oh
Ser No. +'n6t+Zt)\Name of Pafis

1 r:s
AHtt tlts
goi15'{[ x 25 GB1T5783-2000 2

l,
1 HEflfE+ Altemator support TY2951.2-19 1

HYdraulic PumP gasket TY295IT.1 6-12a 1

3 &EF4H
Gear case cover gasket TY295r.2-9 1
4 ff+t€ffi4
5 ff+tBffi G'q,l"j!I" TY395I.2-3
( r/[ )ilI Bcaring 20i cB Tl;6- I ie: 2
6
GBi T I 096-200i I
1 # 10x16 KeY 10X16
T\'295rT. 6-5a
E i{n,tsfl+fi shaft of lift PumP I 1

2
9 &E'f,,4+atfr1;t11 Hvdraulic pump gear II T-r'1951T.1 6-4a

aiB'T276- 199,1 2
10 *ei4 10d Bearingi06

11 tsE 30 cryripfg GB',TE94.1-1986 2

I

i2 :AE=€4:&ft I Hydraulic PumP gear I TY-295IT.16-3a

TY2951T.16-2a l
13
'l:li:lf.-:j-:r I
f i:-:i:1.:1 SI":rii
1-.E T -_16_'r i 1
l5
r:-.:r-.. Or1 seal SG{rl '
:0}l ll .rB Tlf , -1 , , 1
16
=
1,1 . -- ,}8 OrientationPin @8 TY295.2.1-5

18 a+;i4E 8 Washer 8 GB/T9l-19Si 6

2
t9 .?il: M8x75 Bolt M8x75 G81T5782-2001r

.,.,i:: +i#if#ili$,f TY395I.2-3 I I

20 Cover of geai case gaskel
t
t1 frftEffiffffitE Cover of gear case TY2951T.2-3i)c

Cover of gear case gasket TY295l',f. I 6-9a 1

)) ff?tEffiffi.4,+
TY2951T.1 6-10a 1
23 ff+tEffi,ifi. Cover of gear case

24 ffitt x:_s
l,rs Bolr\'18 x 25 GB rT5i 8l-1000 4

25 ss
Lrqtt l,ls x Bolt M8 X :5 GBiT5732-200t) 18

4
26 iHit vsx2,o Bolt M8x2o GBiT5783-2000

Cover of airPumP hole TY295IT.2-1 5ZYa 1

21 ':,f,[Il#ttl
li .iETL;1i{,[]+l Cover of air pump hole - T\'395.2- 1,1 1

22
l

Fig.5 CylinderblockAssembly

23
 Cylinder block Assernbly(Fig.5)

Ser No. 4-frI4+2ffi Nme of parts l!? Parts No Qti'

j
1 17c+4i' Fll,wheel box gasket JDI i02Q.2-2a

b,. 2 ffi& rratzx:s BoltM12x35 GB,1T5783-2000 1

3 EaEfi'LBH Start generator gasket TY295rr.2-23 l

4 t fi4t6i 12 \vasher il GB/Tg3-1987

.,
5 !.fltt M8 x ?o Bolt N18 x lo tiB i-r:-l' '

0 a+fiiill-d 8 washer 8 GBrT93-1987

U,!i-dLl#tE. Cover of obsenation hole T\-295.I.2-17A I

I !'l-rll Main bearing tile(upper) tD495B.2-416 3

9 Ti+HE Main bearing tile(lower) .rDrl95B.2-5,r8 J

i # ,tr I- Upper thrust piece of crankshaft JD2115.2-25 2

11 TtGH(A) .rD2115.2-26 1

Lox'er thns piece of crmkshaft(imer)

w49s.2-25 1

:.ID1: f :. l-- I
, --. : ;a i.l lllarn beanng cap bolt w295.2.1-8 6
'-
: #l,frffiffi{*BFl oil filter assemblY JXSs 100A I

6 ,= i+: M8 x 30 Bolt Ir48 x 30 GB/T5783-2000 2

tl-'jBiHiH#* Oil clarifier gaskei TY295.2-22 1

il1ditrX.rAA'{+ oi1 level dipstick JD2102Q.2.2.17"C I

l9 ++"dtdH{H]t \4ain bearing cap boh DGW-.{O1-01 8

2A 4E io Washer 10 GBi93- r 987 8

21 n,+tH Flpvheel box JD2105ts.2-1A I

22 (+tH{H++ Flyrvheel box bolt TY395i.2-4: 10

21
t

Camshaft Assembly(Fi g. 6)

25
 Camshaft Assernbly(Fig. 6)

Ser Nc. '{*lul+Zf4 Name of parts I! rj- parrs No. Qtv

I &+tr8rt+i5.i.E+ Camshaft gear Screw TY295.3-1 4 1

2 e*ffiffftEffi. Camshaft gear hold do'*n TY2951.3-i3A 1

3 &+tffiff* Camshaftgear TY2 100ll.3-,+ 1

1 ffi toxi6 Key 10x16 GB{1096-2003 11

5 wt+ Tappet T\'l9i:-l: I

5 '1ll+'tlt+ Valr,e push rod JD2115.3--1 I
7 lflC+fr Camshaft 2JD32.3- 1 I

8 *+t+filtl&H Thrust piece TY295.3-5 I

9 qq& M8 x 16 Bolt M8 x 16 G81T5783-2000 2

0 EEE M8X4O Bolt M8X4O GB T5782-2000 3

F€48 8 Elastic washer 8 GB Tq3-1987 8

trlEfi+tEE Idle geahold dom JIl4 r 02.3-9 I

: j - .: -i : ::'l: -.iisn JD4102.3-8 1

li l=lffii+: Idle gru JD4102.3-6 1

ryi+-EP:ffi Idle shaft ,IDi11r: -:-- 1

E.fif, EA** Flangejointoftuelpump T1-195r 3-11 1

:.:;A7r'i:i*t Fuel injection pump gear TY2100n.3- 10 I

t! i4 frl& f6l l0 Elastic washer 10 GB1T93-1987 3

tRt/+) Ml0x25 go11 141$x25 GB/T5783-2000 1

L9

26
 .. -rl \
'..+
fnb,
{s
? 1\ 'i
\J .iI
kt ^h
\-t-al

Fig.7 Crankshaft-flywheel Assembly

,,1
 Crankshaft -flyw,heel Assembly(Fig. 7)

-t: J::ir \o. ()tv

---- r' rl -
--:l: -l-:-
J T\ -+95.+.t-9
Busi, :-_l - -

trffiff+t Crankshaft gear T\'lerI Ll.,'a.\

fiE 8x7x28 Kev8x7x28 cts,'109ii-2003
#t:=+€ 8x18 Keii8x18 GBiT1096-10r)3
#E Crankshaft
: r: : flrirltrciboii 7Y295.4.2-3 8

1D2102.4.2.15H I

rlifE w495.4.2-2 l

GB Tl'6-1994 1

:8
 I
I

l\)

/.-=:_
/-\
f1
\ /-='\ ,'
- v

Fig.8 Piston connecting RodAssembly

29
 Piston connecting Rod Assembly(Fig.8)

- ; ..... 0."

•
"arne of oarts ~ Qty
I
1 iHf1'~.ff~ c~ rod 5mll\ bushmg :JD35TA 12-2 2
,
! 2 illff* C«mectiDg rod assembly ::JD35T-U .2-l -
, 3 ilm1llK Connectingrod bearing shell ./D4102.4.1~ 4
4 i!lf~ Connecting rod cap 2JD35T.4.1.2-3 2
5 i!m~n Connecting rod bolt JD2115.4.1.2-4 4
~t"l1!il37 Cir clip 37 GB/T894.1-1986 4
! 7 , iiS£ffj Piston pin JDLlI05.4.l-3 2
I I
I 8 ! g£ Piston JD2110A.I-4 2
I 9 i ~ij1E1f~il!iJ.t Oil scraper ring I JD21IOA.l.l 2
I 10 i~-i]!'=1.Jf Compressionring (2) JD2110A.l-2 2

i 11 i~-i!!'=1.P; Compressionring (1) JD2110.4.1-1 I 2 I

30
'.

15

Ii

Fig.9 Oil pan System Assembly

31

 Oil pan System Assembly (Fig.9)

Name of pans ffI~ Parts '\0.
Lpper oil pump body JD2l15.5-1
Outer rotor 10':115-5-2
InJRrT(I[or ) ID2115.5.1-1
I 4 ~ Pin GB T; ; 9-CO{lO I I

! 5 ~m O.O5~O.08 Gastet 005 - 0.08 n-3-1:"5-5 Ii

! 6 fJl.illJ*Tf* Loweroil JlUIIIP body mcii5.~ !

r--?'
r--
tn.iffl*t#~ Oil pump gear
TY395.5-3 i I i
I 8 *JL~tIJjHrtl Oil pump shaft JD2115.5.1-2 I I I

! 9 fl~!I'il4X65X 16 Key 4X6.5X16 IGBITl 098-2003 I 1

I,

I 10 t'3ll<t 14 Cir clip 14

GBiT894.1-1986 + 1 "1

I
~

11 I U11.;lt~.L\hX Respirator becomes always

2JD32.73a ~I

t
I-­
]2 "f~~ 8 Washer 8
~97.1-2002 19

! 13 ~1'<~~ 8 Elastic washer 8

GB/T93-1987 19

14 • ~~ \f8X25 Bolt M8X2j

Oil sump gasket
,- f'- Oil pan -
: 1- S',a.£relm Oil drain plug washer i JD3100Q.7-3
I

~':ii2jUf Oil drain plug

! JD3100Q.7-2 I

19 i ~~ M8X 150 Bolt M8XljO

I GB!I5782-2000 18

32

•
...

Fig .10 Cooling System

33

 Cooling System(Fig .10)

~Jl1lf~;g¥J; I ~ '% Parts '-;0

l
SerNo. Name of parts
<\.~fi M8X4-5------~------+-------~--'--'-----1
Bolt \18 X 45 , GBTS'82-2000

2
mil!! 8 Washer 8 ! GB T93-198'
Fan TY39SI.l2-lSa
Fan cushion n'2951T 12-18H
~U1 \A12 GB T61,0-21X1O
------
Elastic washer 1 2 G BT93-j 98­
7
. .>fmll!! 12 Washer 12
GM7,1-2002 I

! 8
**&:*$0; Water pump pulley TY495,12-5 I

9
R\.J)jiJ&:w 17X lOX 1041 Fan Beetl7 X 10 X 1041
HG4-401-74 I

10
i :131m 40 Circlip 40
GB/T893.l-1986 1

II
' !i<5i¥: 60203 Bearing 60203
GB/T278-1989 2

;
12
~i¥:~~ Bearing sleeve TY295.12-12 1

13
~ 5': 16 Key 5X 16
GBITl 096-2003
1

14
*~~ Water pump shaft
TY495.12-4 I

, 15
~;o-8 Washer 8
GB,'r97. 1-2002
1

..
I 16
"i~~ Water thrower
295-14006
I

F
i!~ M8X25 Doh M8X25
GBrT5783-2000 2

18

**~ Waterpurnp
TY495.12-1 1

19
~ Spring seat TY295.12-9 2

20
,*ttj$~ Water seal spring TY295.12-8 2

21
I *t-Hj\i'~ Water seal assembly TY295.l2-1O 1

22
tll!'::z7Kt-t Rubber water seal TY295.12-7 I

! 23
**pj$0; Water pump wheel TY495.12-3 1

24
r*lfmJt Lower water tube gasket TY495,12-7 I
I

25

26

27

r7.k.If
ij\fi M8 X25
7.k.*t":Jt
Lower water tube
Bolt M8X25
Water pump gasket
TY2951T.12-6
GBrT5783-2000
TY295.12-13
=+-1
2

28
7.k.*~ Water pump seat TY495.12-2 1

i 29
7.k.*l'l'mJt Water pump seat gasket TY295.12-14 1

34

•
'1l
I
­ \
\

I. \
\
\
\
\
\

/>9
. \
\

12

, ..
I.
Fig.II Fuel SystemAssembly

35
 Fuel SystemAssembly (Fig.I I)

Qty
KBAL-PI45 2
IT2'J5IT.15.6LT 1
.lD4110 l~ ,
'"
~

4 i ",,!liilll~,gJ£ High pressure pipe assanbIy(l) 2JD35.15.1 I

5 ",,!liilll~,~.J£ High pressure pipeassembly(2) 21D35.l5.2 I
6 ! ~tJi*.~.J£ Fuel injection pump assembly BQ2000 1
- 1~;m~il'fi1! Fuel filter assembly C0506 1
8 ~jf~1I! 10 Elastic washer 10 GB!f93-1987 2

.....
9 -"'-~1Il 10 Washer 10 GBIT97.1-2002 2
10 JI!'f MHlX20 Bolt M1OX20 GB!f5783-2000 2

n
• 5*_ ~~~iB~~.,* TY295Ll5.4G I I
T!3II>fer-pumpand Fuel-filter vitta
4~~.iejH~i!II'i'!' gI£ IT295Ll5.5G I
12
Fud ijber-Fuel injection pump vitta
13 i.1IIl*~Jt Fuel injection pump gasket 1D2115.2-21 I

36

 Appendix 1

Spare Parts Supplied with the engine

No. Name I---Q-u-a-nt-it-, - - ­

y

Piston ring ::set

.2 I Connecting rod bearing I set

I
I Radiater fan strap
I ,

Appendix (I
••
Tools Supplied with the Engine

I,

Name
N°'1 '"
I ."\.

--'-----------+---~
.2
I Valveremover

,Feeler gauge (0.35,0.45)

­

...

37
 ........

\
.

.... ---
JtANGSU JIANGHUAI ENGINE CO. , LTD.
PEOPLE'S REPUBLIC OF CHINA
AOb: NO.!18 XIWANG AVENUE(SOUTH),ECONOMIC & TECHNICAL
DEVELOPMENT ZONE,YANCHENG,JIANGSU,CHINA
TEL:+86-515-88881660 .
FAX:+86-515-88881660
Http://www.jd.dongyin.com
E-mail:jiangdong@dongyin.com

38