Shandong Huafengdongli 4102 series User manual

HUAFENGDONGLI

4102

Series

Diesel

Engine

Operation

And

Maintenance

Manual

Shandong Weichai Huafeng Power Co.,Ltd

Preface

HUAFENGDONGU brand 4102 series diesel engine is afour -stroke, water -cooled,

inline

and

direct injecting combustion chamber

type,

high -speed diesel engine. 4102

series

is bore -enlarged

from

series.

1980s our company adopted the comet Vcombustion

system and diesel design technique

Ricardo Consulting Engineers Company and have made

great improvement

design. This type diesel engine possesses perfonnances of high power,

economy

and

liability, and reaching aadvanced level among the same kinds products all over

the world.

The National Science Congress prized HUAFENGDONGU brand 4102 series diesel en-

gine and it is easy to adapt. According to the different application, through being changed for

some

its parts accordingly,

can

l1sed

to match with middle tractors, engineering

ma-

chinery, middle vehicles, generating

sets,

irrigating machinery and agricultural machinery

and

00.

4102 series is developed from 495 series, main

parts

are

reinforced, Electrical

system, Inlet system, Exhaust system, Cooling system have improved, and the output range

is enlarged. ZH4102 is developed from K4102. It adopts the direct injecting combustion

chamber,

and improved its economy further.

The

model, its make -up role

and

the meaning

of the symbol for every type is as follows:

(J)

102

0--0

00:

Distinguish symbol, Expressed with number sequence

Version symbol, expressed with number sequence

Application feature symbol, expressed with alphabet

alphabet: for conunon

use;

for tractor;

for engineering machinery; Q: for vehi-

cle;

for generating

set;

for marine

use;

for power take -off

unit;

for trans-

porting vehicle use.

Con3truction feature symbol, expressed with alphabet; no alphabet: for

natural

aspirated

model;

for turbocharged model.

@:Cylinder

bore

(mm)

Cylinder

number

(J): Cylinder expanded

(ZH:

Direct injecting combustion chamber)

period maximally, reduce the cost

usage, we compiled this manual on the basis of the "

Nation Rated 495 Diesel Engine Manual"

and

the ch8nge and improvement

products to in-

troduce the operation and maintenance knowledge to the customers.

This operation manual mainly introduces common usage type. For the products is chan-

ging and improving continually tthere may

some slight difference between

the

products

and

that described in this manual

and

the users are advised to notice it

kindly.

The manual is complied

Yu Caihong, Wei Yunfeng, Zhao

Ruian,

Wang Jinghai, and

Sun Chuanhai. Advised

Peiyan, Chen

ling,

and

finally examined

and

approved by

Huaiq(ng.

For the limit of the compilers, there may

some mistakes in the

manual,

you find

any,

please point out so that we can be corrected.

The

compiler

November

2005

Attention

The diesel engine operators must familiarize themselves

with

this manual as well as engine

comstruction and strictly'follow the procedures

operation and maintenance especially the

regulations for safety opera -lion described in this manual.

Before operating an engine

full load,the

hours

mnning in should

carried out as

specified in the manual.'

Increase its speed gradually after stating acold engine, never let it ron

highs speed ab-

ruptly, and dontstop the engine instantly while its cooling water is still hot,also donflet

the engine running long time without load.

the ambient temperature falls below +

S'C

,drain

the cooling water out

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

forbid -den.

Never run the diesel engine without and air cleaner so as to prevent the unfiltered air from

entering the cylinders.

6. The engine must

filled with specified grade fuel and lubri -cating

oil,

and aspecial and

clean container for each oil should be used. The fuel oil should

settled for

hours and

fil -tered before using.

7. The inspection and repair of the components in electrical sys -tern must

carried out by

the person who 'has a

good

knowledge of electricity.

The working environment of the diesel engine should

well ventilated to avoid being pol-

luted by waste gas or smoke.

The power rating

and

amending of the diesel engine is ac -cording to GB6072. 1 - 2000

the first section of reciprocating internal combustion 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 technical requirement

for

low

and middle level powered diesel engine in JB/T889S

-1999

and Q/WHFOO2 -

2005 495 series diesel engine enterprise standard.

11. The

No.

of production license of this series diesel engine

is:XK06

-205

-OO524,XK06

205

-002790

12. The position

safety warning marks:

(1 ) Theresguard against burning mark at the end of the cylinder cover which is beside

the exhaust manifold of the diesel engine.

(2 )Theresaguard against fire mark

the oil filler.

( 3 ) Theresaguard against

twinning

mark

the

inlet

man

-ifold.

680

828.5

9-M12

depth

320

600

(".J

OutlinG

.dra:wift.f;

for

1:111020

dioool

onlY-no

• 1 •

g/kW

450

420

390

360

330

300

270

240

\1500r/min

1800r/min

\\vV

\\\

2000r/min

\ \

.IV

""'II

r---.....

-............

r-----..

---

"""'--

r-----..

I'----

· 2 ·

Load

characteristic

curve

for

1500,

1800

~r/min

diesel engine

4102 Main Technical Specifications

4102

K4102 K4102G K4102P

ZH4102D

Type

Four strokes, Water Cooling,

Inline,

Swirl

combustion chamber

2Cylinder

No.

-Bore *Stroke 4 -

-102

x115

(mm)

3Total Displacement of Piston

3.76

(L)

4Pressure Ratio

19:

5Firing Order

1-3-4-2

6Air Intake Mode Naturally Aspirated

Output I

Speed 44/2000 36.3/1500 46.6/2400 44/2000 36.3/1500

Rated

(kW/r/min)

7Working

Condition 12h Output I

Speed 4012000

33/1500

40/2000

33/1500

(

kW/r/min)

8Highest Idling Speed

~2160

~1575

~2640

~2160

~1575

(r/miD)

9Lowest Idling Stable Speed

~550

(

r/min)

10 Max

Torque/Speed

219/1500

213/1680 219/1500

(N.

mlr/min)

Average

Effective

650

702

620

650

702

I---

Pressure(Kpa)

Fuel

Rated Consumption Rate

~258.4

~266.6

~258.4

I---

Working

(glkW.

Condition Oil Consumption

-Rate{

glkW.

~2.04

14 Exhaust

temperature(

)

=::;;600

15 Crankshaft Rotating Direction

Anti

-clockwise

(Facing

to the power output

end)

16 Cooling Mode Forced Water Cooling

17 Lubricating Mode Compound type with pressure

and

splash

Startin2

Mode

Electric

startin2

Net

Mass{

kg)

320 380

340

450

380

• 3 •

Various temperature and pressure range

Oil temperature

Outlet cooling water temperature

Oil

pressure

Fuel injection pressure

~lOO'C

(the

Engine)

~95CC

(naturally

aspirated)

E:98CC

(the

Engine)

=690CC

(naturally

aspirated)

0.20

-0.

40MPa

~O.

5MPa,when

idling

speed

+1.0MPa

Main

bolts tightening

torque

Cylinder head bolt

Main

bearing bolt

Flywheel tightening bolt

Connecting

rod

bolt

Gear

case

bolt

Flywheel housing bolt

160

-180N.

(Direct

injecting:190 -

210)

160

-180N_

100

-120N.

100

-120N.

-40N.

-60N.

Main adjusting data

Valve lash(cold

state)

Air intake &exhaust valve

Valve timing:

Air intake valve open

Exhaust valve open

Compression clearance

Fuel delivery advance

angle:

1500 -1600r/min

1800 -2000r/min

2400r/min

· 4 ·

0.35

-0.

45mm

12°:i:

3·

before top

dead

center

36·±

after bottom

dead

center

0±

3·

before bottom

dead

center

120±

after top

dead

center

-1.

2mm

150±20before top

dead

center

17°±2° before top

dead

center

Matched clearances

and

wear limit of main

parts

Matched parts Standard size Matched clearance Wear limit

o .

1Crankshaft main journal neck Shaft.

CP75·

019

070

154

0.30

and main hearing Hole

75:g:~

Crankshaft

thrust ring

and

Axial clearance

0.50

crankshaft

0.080

-0.230

Crankshaft &connecting

rod

Shaft

<1>65

0.019

0.050

-0.

112

0.30

3journal

neck

and

connecting

bearing

Hole

<Il

:g:

Connecting rod big

end

and

Shaft

<1>38

-0.

170 Axial clearance

-0.330

0.70

4crankshaft Hole

<I>

~o.

100

0.170

-0.430

Piston skirt

and

cylinder liner Shaft

<1>102

:g:}jg

0.140

-0.

20S

0.50

5Hole

<I»

~o.

035

Piston pin

and

connecting rod Shaft

<1>35

~O.Oll

0.009

-0.045

0.15

6bushing Hole

<I>

35 +0.034

+0.009

The first compression ring Shaft

<1>3

~o.

015 0.080

-0.115

0.40

7and ring grave H I

+0.

100

o e

+0.008

The second compression ring Shaft

cI>2.

~o.OtS

0.040

0.075

0.30

and

ring grave Hole

2.5

:g::g

Shaft

~O.OlS

030 -

065 0.25

9Oil ring

and

ring grave H I

<I>

+o.o~

o e

+0.030

Gap of first compression ring Gauge within4>102.00

250 -

500

3.00

in cylinder

-0.1

Gap of second &third Gauge within<l>102.00

0.200

-0.450

3.00

compression ring in cylinder

12 Gap

oil compression ring in Gauge

within~I02.

0.200

-0.450

3.00

cylinder

CnIDohoft.

journul

neck

and

Shaft

cl>50

:g:~

o~o

130

2..:)

bushing

Ho~e

<Il

0°·

025 I

· 5 ·

Matched parts Standard size Matched clearance Wear limit

14 Camshaft thrust plate Shaft

cl>12

:g:~

050

220

0.40

and

camshaft Hole

t1l

+00'

100

Cylinder liner over the Shaft 4»10

~O.O5O

Engine body projection

15 cylinder block surface

(Selective

fitted)

Hole

10 _°0.050

0.030

0.080

Valve push rod push Shaft

<1>16

-0.016

-0.034

016

0.052

0.20

rod

hole Hole

<I>

~0.OI8

17 Idler shaft

and

idler Shaft

cl>26

:g:~

0.020

-0.062

0.20

shaft hushing Hole

~o.

021

Air intake valve

and

Shaft

<1>9

-0.030

0.030

-0.072

0.25

valve guide Hole

<!>

~o.

022

Exhaust valve

and

Shaft

<1>9

~o.

040

-0.060

0.040

-0.082

0.25

valve

guid~

Hole

9+0.022

. 0

Rocker

ann

shaft Shaft

<1»16

-0.016

-0.034

016

052

0.25

and

bushing Hole W16

~O.O18

21 Idler

and

idler

shaft Axial clearance

100 -

350

22 Contacting clearance

tlearance

tooth

flank

various timing gear

0.130

-0.170

Oil

pump rotor

and

pump Adjusting clearance

block surtace

050

0.100

24 Contacting clearance

0.060

188

0.50

between the oil

pump

Water pump impeller Back clearance

and

pump

body

200

700

26 Water pump impeller Adjusting clearance

and

pllckin~

block

0.400

800

· 6 •

Electrical System

4102

series diesel engines have 12V and the

24V

two

kinds

electrical systems. For

one wire system cathode earth. In the electrical system the electrical machinery rated voltage

and

the

electric appliance rated voltage

must

tally

with

the electrical system voltage.

The battery used for getting

is the diesel engine power equipment, Its peIfonnance af-

fects the diesel engine directly the starting, According to the starting motor characteristic

choices stipulation capacity of storage battery,

the

battery installs the position to have to ap-

proach the starting motor as far

possible, in order to reduce between the accumulator cell

and

the starting motor the connecting lead length, preventing when starting' the line pressure

drop oversized. The connecting lead uses

square millimeter

low

-tension wires. Regarding

12Vand 14Vstarting motor, when the starting current is biggest

,the

-line pressure drop

should not to

bigger than

and

1V.

The battery has not charged, before the use you must carry on the initial charge accord-

ing to the battery request.

the diesel engine generating, you should pay attention to the

charging current frequently the size, when the ampere meter indicated value approaches

"0"

it expressed the battery already filled the electricity,

and

you may shut off the charging cir-

cuit.

The generator uses the

series silicon rectification generator. The silicon rectification

generator has the volume to be small, the structure to

simple,

and

the

low

speed charge

perfonnance to be

good

and

so on. On the generator top plate is loaded with two groups

sil-

icon rectifier cell. The alternating

current

outputs which by three groups

windings

passes

through the three -phase bridge type full -wave rectification

tum

to direct

current,

wiring column outputs. Dontallow with the way which striking alight to earth inspects wheth-

generates work normally, preventing the silicon rectifier cell burning out.

The voltage regulator function is that the voltage will

automatic the output voltage to

stabilize in

13.5

-14.

in the 27 -

29V

scope when the rotational speed

14Vgenera-

tor or 28Vgenerator changes. These

two

kinds

generators separately match

FrIll

and the

FT21I regulator.

you need to

meet

the battery control

lamp,

you change the

ITI26

and the

Ff226 regulator. When using the

FrIll

and the

Ff211

regulator, you should

cut

the battery

after the engine off inunediatelytPrevents the battery to the field coil electric discharge, the

starting

diesel engine will effect next time. The regulator is the precision electric appli-

ance.

not have to disassemble the adjusUnent generally, when it is necessary to adjust on

the special purpose equipment.

Starting motor is atotally enclosed direct current series motor. The starting motor re-

volves

electric

current

oversized,

only

pennits

the

short

time

work,

each

time

starting

time

does not have to surpass lOs.

you must start continuously, the time interval does not have

• 7 ·

be smaller than

2min,

and starting the number

times does not to

supposed continuously

to surpass 10 times generally, in order to avoid damage starting motor

and

battery.

-1!_

cdntoctor

r"Y

neuc

Blue

600

lmm

ery

MI I

---+---~

_.-JStarting~

.. _.. _.. _..

Brock

line

2.5mm

..-.-J

White

line

Blue

line

temperature

sensor

Water

tempernture

sensor

Electrical

system

schematic

drawing

4102

series diesel engine has used the inductance measuring

'appliance, when using the meler the power source should use

the 14V direct -current power supply

the battery.

The circuit key switch has three working positions. The key turns clockwise to put

through the preheating starting switch, the voltage regulator

and

other electric appliances, the

diesel engine may start at.

Mter

th~

diesel engine is started the key should

tum

anti -clock-

wise extension, at the same time

you

should shut off the preheating starting switch, in order

to avoid the accident.

The preheating starting switch has four working positions. Turning to "preheating" only

puts through the pre -

heater,

you

tum

the preheating

starting",

it may preheat and

~tart.

you

not

nc;c;d

pcc;hc;atint;

;you

can

tu:cnto

••

the

~uu:rlng··

direcdy.

,The

s~[ch

should

automatically retuITl to

after

loosing

your

hand

and

the

key -off.

• 8 •

Instaii schematic drawing

foundation

and

radiator

for

4102

Dseries generates electricity diesel

Radiator

Shoch

absorber

1'" 1'"

L---------

l""t'\

...

""''''''

"\,.J

\,~

-C'J

c.o

........--

C"'-J

ICD LO

........--

--or--

sectiOf\

I,-

f""-...

iC'l

~~~

---------

~r'\

"'It'

"-v

4-(618

section

125

680

Note: the size in parenthesis

are

install hole distance

when adopt welds front support

• 9 •

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