Weichai 495 Series Diesel Engines Manual (EN)

HUAFENGDONGLI 495 Series Diesel Engine OPERATION AND MAINTENANCE MANUAL Shandong Weichai Huafeng Power Co., Ltd

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Preface' HUAFENGDONGLI brand 495 series diesel engine is a four - stroke, vertical, water - cooled., swirl combustion chamber, four - cylinder diesel engine. In 1980', our company adopted the comet V combustion system and diesel design ·technique of Ricardo Consulting Engineers Company and have make great improvement in de- sign. Thus, the power, economy and tiability reached a advanced level among the same kind products all over the world. HUAFENGDONGLI brand 495 series diesel engine was prized by the National Sci- ence Congress and its easy to adapt. According to the different application, some parts are changed accordingly. It can be matched with middle.:...

sized tractors, engi- neering machinery, middle - sized vehicles, generating sets, irrigating machines ~nd agricultural products process machines etc. The output range of various version of 495 series diesel engine is 26.5 -51". 5KW, 'and its rated speed is 1500 -2800r/min. Model K4100 is developed'from Model 495 through cylinder expansion. As a result, the o.utput range has been enlarged. ZH4100 is developed from K4100. It adopts the" direct injecting combustion chamber, and improved its economy further. The mod- el, its make - up rule and the meaning of the symbol for every type is as follows: ZH 4 100 D D D-D K 4 100 D D D-D 4 95 D D D-D (J) @@ @@~ CD 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 C: for marine use; P: for power take~ff unit; Y: for. transporting vehicle use. @: construction feature symbol, expressed with alphabet; no alphabet: for natural as- vehicle; D:for generating set; pirated model; Z:for turbocharged model. @:cylinder number (J): cylinder expanded (ZH:

'Direct injecting combustion chamber) @:cylingder bore( mm) In order to keep the diesel engine in good condition in most time ,prolong the guar- antee period maxim~lIy, reduce the cost of usage, we compiled this manual on the basis of the II National Rated 495 Diesel Engine Manual" and the change and im- provement of the products to introduce the operation and maintenance. knowledge to

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the customers. This operation manual mainly introduces common usage type. For the products is changing and improving continually, there may be some slight difference. between the produces and that described in this manua'i arid the. users are advised to notice it kindly. The rrtanual is complied by Zhao Ruian, Wang Jinghai ,Sun. Chuanhai, Yu Caihong, .' Yang Lin, Li Zhiyong, advised'by Li Peiyan, Chen Ling, and finally examined and ap- proved by Li Huaiqing. plea'se kindly point out ·so that they can be corrected. Also, it will, be appreciated if For the limit of the compilers, -there may be -mistakes in the manual, if you fil1d any, you give us your- suggestions about our .products.

The' compiler May, 2006

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Attention 1 .. The diesel engine operators must familiarize themselves with this manual as well as engine construction and strictly follow· the .procedures of operation and maintenance especially' the regulations for safety 0tJera- tion described in this manual. 2. Before operating an engine at full load, the 60 hours running in should be carried out as specified in the manual. . 3. Increase its 'speed gradually after stating a cold engine, never let it run at highs speed abruptly, and don't stop the engine insta.ntly while its cooling water is still hot, also do'n't let ti Ie 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 oil cooler and the diesel engine itself completely after stopping the engine. Con- tinuous keeping the water in the oil cooler should be forbid- den. . 5. Never run the diesel engine without and air cleaner so as to .prevent the unfiltered air from entering the cylinders. 6. The engine m·ust be filled with specified grade fuel and ·Iubri- eating oil, and a special and clean container for each oil should 'be used.' The fuel oil should be settled for 72 hours and fil- tered before' using. 7.

The inspection and repair of the components in electrical sys- tem' must be carried out by the person who has a good knowledge, of electricity. 8. The working environment of the diesel engine should be well ventilated to avoid being polluted by waste gas or smoke. 9. The power rating and amending of the diesel engine is ac- cording to GB6072. 1 - 2000 the first section of reciprocating internal combu?tion engine: standard basic condition, the rating and testing method of power, fuel consumption and engine oil consumption. 10. The manufacturing of the diesel engine is according to 'the common techn'ical requirement for low. and middle level powered diesel engine in JB/T8895 -1999 and Q/WCG094

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