Huafengdongli R4100D2 User manual

HUAFENGDONGLI
R Series Diesel Engine
OPERATION AND MAINTENAN ANUAL
Shandong Weichai Huafeng Power Co., Ltd

Preface
Rseries diesel engine is afour ~troke ,vertical, water-cooled,inline and direct injec-
ting combustion chamber type,high-speed diesel engine. Thjs series diesel engine is
specially designed for our country by Ricardo Consulting Engineers Co.
of Britain,
and manufactured and developed firstly by Ricardo Consulting Engineers
Co. cooper-
ated with Shandong Weichai Huafeng Power
Co. ,Ltd. It's a new generation prod-
uct instead
of the same type diesel engine in our country. This type diesel engine
possesses performances
of high power,economy and easy starting,under the envi-
ronment
with temperature higher than -lOOC ,the dieael engine can be easily started
without preheating. The first overhaul period is 8000hrs. Its reliability and service life
achieved aadvancde level among the same kind products all over the world.
Rseries diesel engine covers 8types as: both four-cylinder and six-cylinder with bore
of lOOmm,both four-cylinder and six-cylinder with bore of l05mm,and every style
has two models of matural aspirated and superchareged. RIOS series is bore -en-
larged from Rl00 series,besides piston,piston ring,piston pin,cylinder liner,cylinder
liner seal ring and injection pump,
all other parts can be exchanged between both
two types of diesel engine.
Rseries diesel engine features easy adaptation to meet the various needs of
matched equipments,according to the requirement of users. It can be furnished with
hydraulic pump for Ifting and steering purposes, air compressor and vacuum pump
for breaking purposes and full power take-off from the front end
of the crankshaft.
Through being changed for some
of its parts accordingly, it can be used to match
with truck,tractor,small power generating station,engineering machinery,agricultru-
al machinery,irrigation machinery,drilling machinery and so on. The output range of
various version of Rseries diesel engine is 35 KW -125 KW ,its rated speed is 1500r/
min
-2800r/min. The moder,its make-up rule and the meaning of the symbol for ev-
ery type is as follows:
R6100 Z D 1 2
(1)@@ @@@ (j)
CD: distinguish symbol,Expressed with number sequence
~: Version symbol,expressed with number sequence
@: application featrue symbol,expressed with alphabet
no alphabet:for common usage;T: for tractor; G:for engineering machinery;
Q:
for vehicle;D:for generating set;
C:for marine usage;P:for power take-off unit
@: construction feature symbol,expressed with alphabet;no alphabet:for natural #85-
pirated model;
Z:for turbocharged model.
(S):cylingder bore( mm)
@:cylinder number
(J):series symbol;stand for imported from RICARDO
This operating manual mainly introduces common usage type. For various versions;

only show their different features. As technology progresses and usage expands,the
aengine wi'l be modified
and improved from time to time,therefor the product s'up-
plied hereafter may be slightly different from that described in this manual and the
users are kindly advised to notice it.
Being obtained
as the accidental test result, the characteristic c.urves in the manual
are only supplied for reference.' And the picture in the manual cant be the accord-
ance
of check upon delivery.
/
The manual is compiled by Wang Jinghai, Zhao Ruian, Yang Lin, Sun Chuanhai,
Wang Luhai,
Dou Yuxiang, Jiang Bo, Yu Caihong, Liu Taicheng, Zhuang Longping,
Wei Zhiyou,
Du Zhijun, advised by Li Peiyan, Chen Ling, Hao Sixian, and finally ex-
amined and approved by
Chen Ling. For the limit of the compilers, there may be
mistakes
in the manual, if you find any, please point out so that they can be correc-
ted. Also, it will be appreciated if you give your suggestions about our products.
The compilers
June,
2005.

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 opera-
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 acold engine,never
let it run at highs speed abruptly,and don't stop the engine
instantly while its cooling
water is still hot, also don't let the
engine running long
time without load.
4. If the ambient temperature falls below + SOC ,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 must be filled with specified grade fuel and lubri-
\eating oil,and aspecial
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 agood
knowledge
of electricity.
8. If the water pump is without oil filler, its a??? bearing wa-
.
ter pump, and needntadd lub oil to it.
9. Be sure to use water -cooling diesel engine. Please refer to
P.43 for details.
10. The working environment of the diesel engine should be
well ventilated to avoid being polluted by waste gas or
smoke.
11. The power rati~g and amending of the diesel engine is ac-
cording to GB6072.1"-2000 the first section of reciprocating
internal combustion engine:
sta"ndard basic condition, the

rating and testing method of power, fuel consumption and
engine oil consumption.
12. The manufacturing of the diesel engine is according to the
common technical requirement for low
and middle level
powered diesel engine
in JB/T8895 ~ 1999 and Q/WCGOOS
-2002R series diesel engine enterprise standard.
13. The No. of production license of this series diesel engine
is:
XK06 - 205 -00160, XK06 -205 -00161, XK06 -205 --
00279.
14. The position of safety warning marks:
(1) Theres aguard against burning mark at the end of the
cylinder cover which
is beside the exhaust manifold of the
diesel engine.
(2) There~ aguard against fire mark at the ail filler.
(3) Theresaguard against twinning mark on the inlet man-
ifold.
( 4) There's aflywheel rotating direction mark on the fly-
wheel housing.

Contents
1. Longitudinal sectional drawing for R4100, R410S diesel engine( Fig.la) .•....•.• 1
Cross sectional drawing for R4100, R4l05 diesel engine(
Fig. 1 b) 2
2. Longitudinal sectional drawing for R6100, R610S diesel engine(Fig. 2a) 3
Cross sectional drawing for R6100, R610S diesel engine( Fig. 2b) 4
3. Speed and speed adjusted characteristic curve for Model R410S, R410SZ
diesel engine( Fig. 3) 5
4. Speed and speed adjusted characteristic curve for Model R610S, R610SZ
diesel engine( Fig. 4) 6
5. Speed adjusted characteristic curve for Model R4105T and R410STI
diesel engine for tractor usinn(Fig.
S) u ••••••••••••••••••••••••••••••• 7
6. Speed and speed adjusted characteristic curve for Model R410SG diesel engine
used for engineering machine (Fig.
6) ......................•...........•..•............. 8
7. Speed and speed adjusted characteristic curve for Model R6105G, R610SGt,
R610SZG and R610SZGl diesel engine used for engineering machine (Fig. 7) ···9
8. Load characteristic curve for Model R6100ZDl and R6100ZD2 diesel engine for
generating sets (Fig..
8) · · ····..· ·..· ....•...... ~ · 10
9. Propellant characteristic curve for Model R4105C, R410SCl, R610SC and R6105Cl
marine diesel engine (Fig.
9) 11
10. Load characteristic curve for Model R41OSP, R410SZP and R610SP diesel engine
for generating unit(
Fig. to) 12
CHAPTER I. Main Technical Specifications and Data for the
diesel engine 13
§1Main techincal specifications
§2Range for various temperature and pressure
§3Tightening torque of main bolts
§4Main adjusting data
§5Matxhed clearances and wear limit of main parts
CHAPTER II. Main structure of diesel engine .......•................ 28
§1Cylinder head assembly
§2Cylinder block and relatea assemoly
§3Camshaft assembly
§4Piston and connecting rod assembly
§5crankshaft and flywheel assembly

§6Transmission system
§7Intake and exhaust system
§8Fuel system
§9 Lubricating system
§10 Cooling system
§ 11 Electric system
§ 12 Air compressor assembly
§ 13 Clutch assembly
CHAPTER m. Operation of diesel engine 54
§1Transportation,installation,storage and preservation
§2Fuer,oil and cooling water
§3Preparation before starting
§4Starting
§5Running
§6 Stopping
§7The wearing in of the diesel engine
§8Safe and technical operationg rule
CHAPTER N.Technical maintenance of diesel engine 61
§1Working day maintenance
§2First grade technique mainenance
§,3 Second grade technique maintenance
§4Third grade technique maintenance
§5Technique mauntenance on winter working
CHAPTER V. Trouble and remedy method 63
§1Start failures
§2Unsteady running
§3 Output is instfficient of drops suddenly
§4Abnormal noise during engine iperation
§5Abnormal exhaust smoke
§6Insufficient oil pressure
§7 Oil temperature too high
§8The temperature of used cooling water too high
§9 Trouble in the injection pump
§ 10 Insufficient fuel supply of the fuel delivery pump
§ 11 Injector in trouble

§ 12 Governor in trouble
§ 13 Engine stops suddenly
§ 14 Charged dynamo out of order
§ 15 Starting motor be in trouble
§ 16 Governor in trouble
§ 17 Turbocharger in trouble
§ 18 Air compressor in trouble
§ 19 Clutch in trouble
CHAPTER VI. Installation instruction for diesel engine
generating set 76

.Fig. la Longitudinal sectional drawing for R4100, R4105 die~el engine
• 1 •

~-=-
\\
~~~--1:I-..L.-'~--~ ~AlIIIJ/'r'7"7""'7'/.L.-J
Fig.lb.Crcss sectional drawing for R4100,R4105 diesel engine
· 2 ·

Fig.2a longitudinal s~ctional drawing for R6100,R6105 diesel engine
· 3 •

· 4 ·
Fig.2b Cross sectional draw~ng for R6100, R610S diesel engine

Me
N.m
350
300
250
200
ge
g/kW.h
240
230
220
210
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kW
70
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1200 1400 1600
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'1 r/ TTl in
Fig. 3Speed and speed adujsted cha.racteristic curve for
Model R4105, R410SZ .diesel engine
• 5 •

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350
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g/kW.h
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kW
110
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1200
1400
1600
1800
2000 2200 2400 n
r/min
• 6 ·
Fig.4 Speed and speed adjusted characteristi~ curve for
Model R6105, R6105Z diesel engine

nr/min
2200
2000
1800
1600
1400
1200
ge
g/kW.h
280
270
260
250
240
230
220
210
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280
240
200
160
120
80
40
10
20 30 40
Pe kW
Fig. 5Speed and speed adjusted characteristic curve fo~
Model R4105T and R410STl diesel engine used for tractors
· 7 ·

Me
275
250
225
200
glkW· h
240
230
220
210
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kW
60
50
40
30
20
1000
1300
1600
1900
2200
2500 2800 n
r/min
· 8 ·
Fig. 6 ~peed and speed adjusted characteristic curve for
Model R4105G diesel engine used for engineering machine

Me
N·ro
500
450
400
375
350
L
g/kW. h
240
230
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110
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T/min
Fig. 7Speed and speed adjusted ~haracteristic curve for Model R6105G, R6105Gl,
R6105ZG and R6105ZGl diesel engine used for engineering machine

ge
g/kW.h
360
340
320
300
280
260
240
220
~
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\\1500r/min
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Pe kW
Fig. 8 Load characteristic curve for. Model R6100ZDl and R6100ZD2
diesel engine for generating sets
•10 •

Pc
kW
70
50
40
30
20
10
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320
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1000 1200 1400 1600 1800 2000 nr/min
Fig. 9Propellant characteristic curve for Mo~el R4105C, R4105CI,
R610SC and R610SCI marine diesel engine
• II •

ge
g/kW.h
380
360
340
320
300
280
260
240
220
\
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10 20 30 40 50
60
70
Pe kW
Fig. 10 Load characteristic curve for Model R4105P, R4.105ZP and
R610SP diesel engine for stationary power using
• 12 •