Wechai Power engines 495 Service Manual
HUAFENGDONGLI
495
Series
OPERATION
Diesel
AND
Engine
MAINTENANCE
MANUAL
Shandong
Weichai
Huafeng
Power
Co.,
Ltd
Preface'
HUAFENGDONGLI brand
- cooled., swirl combustion chamber, four - cylinder diesel engine.
company adopted the comet V combustion system
Ricardo Consulting Engineers Company
sign. Thus, the power, economy
same kind products
HUAFENGDONGLI brand
ence Congress
parts are changed accordingly. It
neering machinery, middle - sized vehicles, generating sets, irrigating machines
agricultural products process machines etc.
495
series diesel engineis26.5 -51". 5KW, 'and its rated speedis1500
Model
the o.utput range
direct injecting combustion chamber,
el, its make -
ZH
K 4
(J)
K4100isdeveloped'from Model
4
100
100
4
95
@@
and
has
up
rule
D D
D D
D D
@@~
495
series diesel engineisa four - stroke, vertical, water
In
1980', our
and
diesel design ·technique of
and
have make great improvementinde-
and
tiability reached a advanced level among the
all
over the world.
495
series diesel engine was prized by the National Sci-
its
easy to adapt. According to the different application, some
canbematched with
The
495
through cylinder expansion.
been enlarged.
and
the meaning of the symbol for every typeisas
ZH4100isdeveloped from
and
improved its economy further.
middle.:...
output range of various version of
sized tractors, engi-
-2800r/min.
As
K4100.
It adopts the"
The
follows:
D-D
D-D
D-D
CD
a result,
~nd
mod-
CD:
distinguish symbol, Expressed with number sequence
~:
Version symbol., expressed with number sequence
@:
application featrue symbol,expressed with alphabet
no
alphabet:for common use; T:for tractor; G:for engineering machinery;Q:for
vehicle;D:for generating
C:for marine use; P:for power
@:
construction feature symbol,expressed with alphabet;noalphabet:for natural
pirated model;
Z:for
turbocharged model.
@:cylingder bore(
@:cylinder number
(J):
cylinder expanded
In
order to keep the diesel engineingood conditioninmost time
antee period
basis of the
provement of the products to introduce the operation
mm)
(ZH:
maxim~lIy,
II
National Rated
set;
take~ff
'Direct injecting combustion chamber)
reduce the cost of usage,
495
Diesel Engine Manual"
unit; Y:
for.
transporting vehicle use.
we
compiled this manualonthe
and
,prolong
and
the change
maintenance. knowledge to
as-
the guar-
and
im-
the customers.
This operation manual mainly introduces common usage type.
changing and improving continually, there maybesome slight difference. between
and
the produces
kindly.
The
rrtanualiscompliedbyZhao
.'
Yang
Lin,LiZhiyong, advised'byLiPeiyan,
proved byLiHuaiqing.
For
the limit of the compilers, -there maybe-mistakesinthe manual, if you
plea'se
you give
kindly point out
us
that describedinthis
·so
that they
your- suggestions about our .products.
manua'i
Ruian, Wang Jinghai
can
be
arid the. users are advised to notice it
Chen
Ling,
corrected. Also, it will, be appreciated if
,Sun.
and
For
the products
Chuanhai,
finally examined
The'
Yu
compiler
May,
Caihong,
and
fil1d
2006
is
ap-
any,
Attention
1..The diesel engine operators must familiarize themselves with
as
well
as
this manual
and
construction
and
maintenance especially' the regulations for safety
tion described
2.
Before operating
should
3.
Increase its 'speed gradually after stating a cold engine, never
let it
insta.ntly while its cooling water
engine running long time without load.
4. If the ambient temperature falls below +5°C,drain the cooling
water out of the radiator, the lubricating
diesel engine itself completely after stopping the engine. Continuous keeping the water
den. .
be
carried out
run
at highs speed abruptly,
strictly follow· the .procedures of operation
in
this manual.
an
engine
engine at full load,the
as
specified
in
the
in
the manual. .
and
don't
is
still hot,also do'n't let ti
oil
cooler should
60
hours running
stop the engine
oil
cooler
and
be
0tJera-
in
Ie
the
forbid-
5. Never
.prevent the unfiltered air from entering the cylinders.
6.
The engine
eating oil,
'be used.' The fuel
tered before' using.
7.
The inspection
tem' must
knowledge,of electricity.
8.
The working environment of the diesel engine should
ventilated to avoid being polluted by waste gas or smoke.
9.
The power rating
cording to
internal
rating
engine
10.
The manufacturing of the diesel engine
common techn'ical requirement for
powered diesel engine
run
the diesel engine without
m·ust
and
be
GB6072.
combu?tion engine: standard basic condition, the
and
testing method of power, fuel consumption
oil
consumption.
be
filled with specified grade fuel
a special
and
carried out by the person
and
clean container for each
oil
should
repair of the components
and
amending of the diesel engine
1 -
2000
be
the first section of reciprocating
in
JB/T8895
and
air cleaner so
settled for
low.
-1999
72
hours
in
electrical sys-
who
is
and
has
according to 'the
middle level
and
Q/WCG094
and
·Iubri-
oil
should
and
a good
be
is
as
well
to
fil-
ac-
and
- 2004 495 series diesel
11.
The
No.
of production license of this series diesel engine
is:
12.
XK06'
00279.
The
'position of safety warning marks:
(1)
- 205 - 00160, XK06 - 205 - 00161,
Theres a guard
cylinder cover which
the diesel engine.
(2)
Theres a guard against fire mark at the
(3)
ThereSa guard against twinning mark
ifold.
),
There's a flywheel rotating direction mark
(4
wheel housing.
en-gine
aga.inst
is
enterprise standard.
XK06~
burning mark at'the
end
- 205
of the
-.
beside the exhaust manifold of
oil
filler.
on
the inlet man-
on
the fly-
Contents
1"
Longitudinal sectional drawing for
Cross sectional drawing f9r
2"
Outline drawing for 495, 495G,
3"
Outline drawing for
4
,,·Outline
5"
Outline drawing for
6"
Outline drawing for 495GI0,
7"Outline drawing for
8"
Outline drawing for 4950 diesel engine (Fig.
9"Outline drawing for 49501, 495Yl
10"Outline drawing for
11" Outline drawing for 495D,
drawing for
.......................................................................................................
495T
diesel engine (Fig.
495Gl,
495G3
495Gll
diesel engine (Fig.
495Y-l,
495
diesel engine (Fig.
495
diesel engine (Fig.
K4100
diesel engine (Fig.
3)
495G9, K4100Gl diesel engine (Fig.
5)
495G14
diesel engine (Fig.
495Dl,
diesel engine (Fig.
-1,
495G6
495Y4
diesel engine (Fig. 10)
495D2,
7)
8)
diesel engine (Fig.
K4100D
la)
Ib)
.....................•........
2)
6)
diesel engine (Fig. 11) .
...
···············
~.................
4)
9)
•...........
..·..
1
2
3
4
5
6
7
8
9
10
·11
12
12"Outline drawing for
12)
13"Outline drawing of
14"Load characteristic curve for 1500,1800, 2000r/min diesel engine (Fig. 14) ...
....................
15
"Load characteristic curve for 1500, 1800r/ min turbocharged diesel engine (Fig.
15)
16"Speed adjusted characteristic curve for 1600, 2000r/min diesel engine used for
tractors (Fig. 16)
17
"Speed
used for engineering machines (Fig. 17)
18"Speed
diesel engine used for engineering machines (Fig. 18)
19"Total output test curve for 2000, 2800r/min diesel engine used for vehicles (Fig.
19)
and
speed adjusted characteristic curve for 2000, 2400r/min diesel engine
and
speed adjusted characteristic curve for 2400r/min Model
CHAPTER
1.
Main technical specification
2.
Range
for various
495ZD
495P
-
I.
Main Technical specification and data for the
-1,
495ZDl
diesel engine (Fig. 13)
-1,
495ZD2,
495ZD3
diesel engine~Fig.
~
diesel engine
temperatu~e
and
pressure
13
14
15
16
17
18
ZH4100
19
20
21
3. Tightening torque of main bolts
4..Main adjusting data
5.
Matched-clearances and wear limit of
6.
Matched clearances
7.
Ma.in
adjusting.data ofZH4100 diesel engine
and
wear limit of K4100,
495
main parts
ZH4100
main parts
CHAPTER
II.
Main
structure and replacing and repairing
method
1.
Cylinder block assembly
2.
cylinder block
3.
Piston and connecting
4.
Crankshaft and flywheel assembly
5.
Intake and exhaust system and turbocharger
6.
Fuel
system
7.
Lubricating system
8.
Cooling system
9.'Electric system
10.
Transmission system
11.
Power take out equipment
12.
The main changed parts of
13.
The main changed parts of
CHAPTER
1.
Transportation and installation
2.
Fuel, oil and cooling water
3.
Preparati.on before starting
4.
Starting
5.
Running
;6.,
Stopping
7.
Safe and technical operation rule
and,
related assembly
rod
III.
Operation
asse-mbty
K4100
ZH4100
diesel engine
diesel engine
of
of
diesel engine 31
diesel engine
44
CHAPTER
1.
Working day maintenance
2.
First grade .technique mainenance
3.
Second grade technique maintenance
4.
Third grade technique maintenance
5.
Technique mauntenanceonwinter working
CHAPTER
N.
Technical maintenance
V.
TroublE.?
and remedy method
of
diesel engine
49
51
1.
Start failures
2.
Unsteady running
3.
Outputisinstfficient of drops suddenly
4. Abnormal noise during engine iperation
5.
Abnormal exhaust smoke
6.
Insufficient
7.
Oil
temperature too high.
8.
The
temperature of used cooling water too high
9.
Troubleinthe injection pump
10.
Insufficient fuel supply of the fuel delivery pump
11. Injector
12. Governorintrouble
13.
Engine stops suddenly
14. Charged dynamo out of order
15.
Starting motorbein
16.
Governorintrouble
17. Turbochargerintrouble
18.
Air compressorintrouble
19.
Clutchintrouble
oil
in
trouble
pressure
trouble
APPENDIX:
The
wearing
in
of
the
diesel
engine
64"
Fig.laLongitudinal sectional drawing for
495
diesel engine
• 1 •
· 2 ·
Fig.
1b Cross sectional drawing for 495 diesel engine
10°
27°
40°
_-..-
_____
27°
10°
-
~a
~
['
z
['
~
•
694
~Q
Cit
:c
~
N
•
{:
~
:c
\0
;;
•
o
00
00
445
Fig.2 Outline drawing for 495, 495G,
K4100
-+10-4--
diesel engine
18.5
± 0.5
• 3 •
893
212
158
60
N
N
N
0
~
320
420
182
152
90
~~
N
N
~
S
~
~
00
~
0
N
N
99
I"
Z
l"'-
"l:t
•
~o
t-
oo
:x:
-...0
0'\
N
•
36
30
79
Fig.3 Outline drawing for 495T diesel engine
8-M12
12-MIOeven
Thread
distributed
depth
605
825
20
22.5°
445
50 20
9-MJ2
Thread
depth
316
268
19
90
Fig.4 Outline drawing for 495Gl , 495G9, K4100Gl diesel engine
* The air cleaner, exhaust manifold & oil gauge
are the same
as
thoseof495
(see
Fig.
2)
of
495G9
· 5 ·
212
615
844
158
242
189
o
~
00
182
60
90
30 79
N
N
N
12-.12.5
Il-M12 even
Thread
0
~
distributed
depth
N
N
0
'I")
~
25
4
r
36
436( ± 0.03)
218
± 0.03
± 0.05
466
Fig.5 Outline drawing for
495G3
diesel engine
874
605
50 20
9-M12
Thread
8-M12
Thread
depth
depth
316
268
19
445
22.5
0
22.5
0
Fig.6 Outline drawing for 495GIO, 495G14 diesel engine
*
The
length dimension of 495G14
is
the same
as
495Gl
(see
Fig.
4)
± 0.5
90
• 7 •
The
the
connecting
diesel
engine
836
969
dimension
of
32
The
the
253
connecting
clutch
shell
228
dimension
of
4-M14
· 8 ·
836
Fig.7 Outline drawing for
495Gll
114
diesel engine
120
694
318
6-M8
Thread
depth
16
9-MJ2
445
Fig.8 Outline drawing for 4950 diesel engine
6
(
00
:c
~
":t
•
90
+:
0.5
·
9·
675
4
The
~he
installing
diesel
engine
846
848
949
dimension
of
32
The
connecting
the
clutch
2-
13
dimension
shell
Fig.9 Outline drawing for 49501 , 495Yl - 1, 495G6 diesel engine
* The exhaust manifold height
* * The inlet & exhaust manifold and air cleaner
are the same
107of495Yl - 1is255
as
495G2
of
495G6
of
•10•
The
the
installing
diesel
engine
dimension
of
The
the
connecting
clutch
shell
dimension
of
786
32
Fig.10Outline drawing for 495Y
-1
, 495Y4 diesel engine
·11·
318
694
6-4>
•
36~i
Both
12
•
even
III
distributed
sides
Fig.ll
22.5° 22.5°
445
Note:
The
dimensioninthe bracketsisthe length of 41000
Outline drawing for
4950,49501,49502,
K41000 diesel engine
686
9-\1'2
V)
00
N
6-.36~(;il(,
even
distributed
Both sides
27':
445
Fig.12Outline drawing for 495ZD
495ZD2, 495ZD3
diesel engine
-1
, 495ZDl-1,
..................
1--
6
~
•
·13•
§o
":f
~
Q5
~
•
O£:6
OPlt
· 14 ·
00
rr.
Fig.13Outline drawing of
495P
diesel engine
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