Xinchai 490B Series User manual

PointsForAttention
Thanksforyourchoiceofourdieselengine.Wewouldliketoprovidean
excellentserviceforyouandaskyoutopayattentiontothefollowingitems:
Pleasereadmanualcarefullybeforeoperatingtheengine,soastomake
reliableoperation,prolongtheengine'sworkinglife,decreasethecostand
improvetheeconomicefficiency.
Anewengineoranoverhauledengineshouldtakearunning-inperiodof
50hourswithlightload ( 50%ofload)andlowspeed ( 2000rpm)before
goingtoitsnormalworkingcondition.Checktheenginefromtimetotime,fill
andreplacetheoilandoilfiltercartridgeandcleanthescreenfiltertimely.
Usecleanfueloil.Cleanorreplacethecartridgeoffuelfiltertimelyand
checkforitssoundness.
Check,cleanandreplacethecartridgeofairfilterandtheinletconnecting
pipe.Makesureallarewellairtight.
Don'tusemetalorotherconductitemssuchasscrewdrivertocheckthe
generatorcondition.Otherwiseitmayleadtobreakdownofsomeelectric
elements.
After running 100hours,theenginemust bemaintained through
dismantlingtheoilsumptocheckconnectingrodbearingsandtightening
torquesofconnectingrodandmainbearingbolts.
Donotruntheengineatidlespeedcontinuouslyover10minutes.
Inordertofacilitatemaintenanceandsparepartsservicing,pleasefillin
themodeltypeandproduction numberoftheengineaccordingtothe
indicationsonthenameplate.
Modeltype院_________________________________
Productionnumber院_________________________________

Preface
WiththehelpoftechnicalconsultationsfromRicardoUKLtdandAustrian
AVLCompany,490Bseriesdieselenginesarejointlydevelopedbyour
company andShanghaiInternalCombustion Engine Research Institute.
Featuringdirectcombustionchamber,optimizedvalvetrainandadvancedfuel
injectionsystem,theenginescanmeetthestaterequirementsforemissionand
noisewithgoodcoldstartingabilityandlowfuelconsumption.490Bseries
enginescanbewidelyusedfor2-3tonforklift,constructionmachineries,
tractorsandcombineharvesters.
Fornormalandreliableoperationoftheengine,makinggooduseofthe
lifespan and todecreaseoperation cost,wecompile thisoperation and
maintenancemanualtohelpuserstoknowmoreaboutourenginesandtorun
theenginescorrectly.
Formoreinformation,pleasecontactwithus.
September/2008

INTRODUCTION
Warning!Meansitmaybeharmfultohuman
Note! Meansitmaybeharmfultoengine.
Remark!Meansitisimportantbutnotharmful
Fuel
Enginepreheating
Coolanttemperature
Oilpressure
Lubricatingparts
Necessarychecks
Showingtighteningtorque

CONTENTS
Theoveralldimensionsof490Bseriesdieselenginesandthemountings
Chapter1Generaldescriptionofthedieselengine 噎噎噎噎噎噎噎噎噎噎噎噎1
Chapter2Operationofthedieselengine 噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎15
Chapter3Technicalmaintenanceofthedieselengine 噎噎噎噎噎噎噎噎噎噎20
Chapter4Adjustmentofthedieselengine 噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎24
Chapter5Sketchmapsforfivemainsystemsofthedieselengine 噎噎噎噎噎30
Chapter6Enginetroubleshooting 噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎35
Appendix1SpecialPartsList 噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎48
Appendix2SpecificationsofmainAuxiliaries 噎噎噎噎噎噎噎噎噎噎噎噎噎53
Appendix3Outsourcingsparepartslist 噎噎噎噎噎噎噎噎噎噎噎噎噎噎噎54

Chapter1General
DescriptionofDieselEngine
1.1EngineModelTypesandSerialNumbers 2
1.2EnginePerformanceCurves 2
1.3EngineTechnicalPerformanceData 5
1.4MainCharacteristicData 7
1.5OverallDimensionsofDieselEngine 8
1

1.1ModelTypesandSerialNumbers
Thenameplateisonthetopofthecylinderheadcover.Beforeaskingformaintenance
orpartsservice,pleaselookuptherelativeinformationindicatedinthenameplate.
ThePositionofSerialNumberoftheBlock院
Thestampedserialnumberisundertheleftsideoftheexhaustpipeandbythesideofthe
flywheel.
1.2EnginePerformanceCurve
490B
2

490BPG 490BT
A490BPG C490BPG
3

C490BT C490BG
4

1.3EngineTechnicalPerformanceData
Usagetype Cars Forklifts
Model 490B 490BPG A490BPG B490BPG C490BPG
Type
in-line,watercooled,4-stroke,directinjection _shaped
combustion chamber(Ring-like platform combustion
chamberforA490BPG尧C490BPG)
No.ofcylinders-bore-
stroke(mm) 4原90原100 4原90原100 4原90原100 4原90原105 4原90原105
Totaldisplacement(L) 2.54 2.54 2.54 2.67 2.67
Firingorder 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Compressionratio 18:1 18:1 18.5:1 18.4:1 18.4:1
Ratedspeed(r/min) 2650 2650 2650 2650
Ratedpower 渊kW冤36.8 36.8 39 36.8
Max.torque(N窑m) 逸152.9 逸148 逸148 逸157 逸156
Max.torquespeed(r/min) 2000耀2200 1800耀1900 1800耀1900 1700耀1900 1700耀1900
Maximum mean effective
pressure(kPa) 逸756.4 逸732.2 逸659.6 逸738.3 逸738.3
Min. fuel consumption at
fullload(g/kW窑h) 臆238 臆238 臆230 臆230 臆228
Oilconsumption(g/kW窑h) 臆1.63 臆1.63 臆1.63 臆1.63 臆1.2
Min.steadyidlespeed(r/
min) 臆850 臆750依30 臆750依30 750依30 750依30
Directionofcrankrotation
viewedfromflywheelend冤counterclockwise
NoisedB(A) 臆112 臆112 臆112 臆112
Coolingsystem closedcycle,forcedwatercooling
Lubricationsystem pressuredandsplashed
Startingdevice electricmotor
Netweight(kg) 臆250 臆260 臆260 臆265 臆265
Overalldimension Length
*width*height(mm)
700*581*
670
751*565*
690
751*565*
690
751*565*
704
751*565*
704
32003000
45.6 41.9
臆114 臆113
Note院Theratedpoweristhepoweratstandardconditionthatmeanstheatmospheric
pressureis1伊105Pa 渊750mmHg冤袁ambienttemperatureis25益,relativehumidityis
30%withoutairfilter,mufflerorcoolingfan.
5

Usagetype Tractors
Model 490BT B490BT C490BT 490BD C490BG
Type
in-line,watercooled,4-stroke,directinjection _shaped
combustionchamber(Ring-likeplatformcombustion
chamberforC490BT尧C490BG)
No.ofcylinders-bore-
stroke(mm) 4原90原100 4原90原105 4原90原105 4原90原100 4原90原105
Totaldisplacement(L) 2.54 2.67 2.67 2.54 2.67
Firingorder 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Compressionratio 18:1 18.4:1 18.4:1 18:1 18.4:1
Ratedspeed(r/min) 2400 2400 1500 2200
Ratedpower 渊kW冤29.4 29.4 21 31
Max.torque(N窑m) 逸135 逸152 逸142 - 逸158.8
Max.torquespeed(r/min) 1500耀1680 1500耀1700 1500耀1700 - 1600耀1800
Maximum mean effective
pressure(kPa) 逸667.8 逸738.3 逸738.3 逸661.4 逸666.9
Min.fuelconsumptionatfull
load(g/kW窑h) 臆238 臆230 臆228 臆238 臆228
Oilconsumption(g/kW窑h) 臆1.63 臆1.63 臆1.2 臆1.63 臆1.2
Min.steadyidlespeed(r/
min) 臆750依30 750依30 750依30 臆750依30 750依30
Directionofcrankrotation
viewedfromflywheelend冤counterclockwise
NoisedB(A) 臆110 臆110 臆107 臆110
Coolingsystem closedcycle,forcedwatercooling
Lubricationsystem pressuredandsplashed
Startingdevice electricmotor
Netweight(kg) 臆290 臆295 臆295 臆280 臆280
Overalldimension Length
*width*height(mm)
788*726*
719
787*726*
719
787*726*
719
698*541*
690
698*541*
690
2400
29.4
臆110
Generators
Construc鄄
tion
machineries
Notes:1.C490BPG尧C490BT尧C490BGhavegotthecertificateofEPA 域渊U.SEnvironmental
ProtectionAgency冤
2.C490BPG尧C490BThasgotthecertificateofE-mark 芋.
6

1.4MainCharacteristicData
1尧Timing(intermsofcrankshaftangle)
Intakevalveopen:11毅beforetopdeadcenter.
Intakevalveclose:41毅afterbottomdeadcenter
Exhaustvalveopen:49毅beforebottomdeadcenter.
Exhaustvalveclose:11毅aftertopdeadcenter.
Coldvalveclearance intakevalve0.35mm
exhaustvalve0.45mm
2尧Injectionadvanceangle:10-12毅CA渊C490BPG尧C490BT尧C490BG冤;
21依1毅CA(490BT尧490BD尧B490BT);
17依1毅CA(490B尧490BPG尧490BT尧A490BPG尧B490BPG)
3尧Temperatureandpressurerequirements:
1冤尧 Exhausttemperature 臆550毅C渊490B 臆620毅C冤.
2冤尧 Oiltemperature: 臆368k(95毅C).
3冤尧 Cooingwatertemperature:357-368k(85-95毅C).
4冤尧 Oilpressureatthemainoilgallery:0.2-0.44Mpa.
4尧TighteningtorquesforthemainboltsinN窑m:
Cylinderheadbolt:117.6-137.2.
Mainbearingbolt:137.2-156.8.
Connectingrodbolt:98.1-117.6.
Flywheelbolt:98.1-117.6.
Startingclaw:100-120.
5尧Oilcapacityintheoilsump抑6L.
7

1.5OverallDimensionsofDieselEngine
490B
Frontview(withfan)Intakesideview
RearviewExhaustsideview
8

490BPG
Frontview(withfan)Intakesideview
Exhaustsideview Rearview(withclutch)
9

490BTSinglePump
Intakesideview Frontview(withfan)
Exhaustsideview Rearview(withclutch)
10

490BTDoublePump
Frontview(withfan)Intakesideview
Rearview(withclutch)Exhaustsideview
11

C490BPG院
12

C490BT院
13

C490BG院
14

Chapter2Operationofthe
DieselEngine
2.1PreparationfortheFirstOperationoftheDieselEngine 16
2.2StartingoftheDieselEngine 17
2.3OperationoftheDieselEngine 17
2.4ShuttingDownoftheDieselEngine 18
2.5AttentionsforEngineOperation 18
2.6WorkingMedia 18
15

2.1PreparationforthefirstOperationoftheDieselEngine
1冤尧 Filltheoil
Generally,there'snooilfilledintheenginewhenitisofftheline.Customershouldfill
theoilbyhimselfbeforeoperatingtheengine.Whenfillingoil,pleaseopenthecoverof
theoilfillingportonthecowlofthecylinderheadfirst,takeouttheoilgauge,thenfillthe
oilandchecktheoillevelwiththegauge.Checktheoillevelagainafter3minutes.Oil
capacity:makesurethelubricatingoillevelintheoilsumpshouldbebetweentheupper
markandlowermarkontheoilgaugewhenthelubricatingsystemisfilledfulloil.
银Note:
Onlycleanoilcanbefiledintoengine,makesurenoanydepositinthefilledoil.Fuel
injectionpumpassemblyalsoneedstobefilledwithoil.Thelubricatingoilinthepump
caseshouldbebetweentheuppermarkandlowermarkontheinjectionpumpoilgauge.
2冤尧 Filldieselfuel
Userscanchoosethecorrespondingdieselfuelforsummerorwinteraccordingtothe
temperaturesintheirlocalplaces.Thepositionofthefuelpipejointpositionisonthe
lowerpartoftheinjectionpump.Beforefillingintotheengine,thedieselfuelshouldbe
keepstillformorethan72hourstoclearoutthewaterandimpurities.
3冤尧 Fillcoolant
Openthecapandthedraincock.
Fillthecoolanttothemarkoffiller
Closethedraincockwhenthecoolantflowsout.
Screwonthecap
4冤尧 Otherpreparingworkbeforestartingtheengine
Checkwhetherallenginemountingfastenersareingoodconditionandwhetherthe
controlhandlessuchasthrottle,shutdownhandleandetccanoperatesmoothly.
Revolvethecrankshaftseveralturnstocheckwhetherallmovingpartscanmove
smoothly.
Checkoilsumpandinjectionpumpfortheoillevel.
Checkwhethertheradiatorisfullofcoolingwaterandthereisnoleakageatthe
joints.
Checkwhetherthefuelissufficient,fuelsupplyisunblockedandthereisno
leakageatthejointsoffuelpipes.Checkifthefuelcockatthefueltankhasbeenturned
open.
Checkwhetherthebatteryhasbeenfullychargedandalljointsbetweenelectric
equipmentsareingoodcondition.
Checkallfixingfastenersforvariouscomponents (injectionpump,fuelsupply
pump,fuelfilter,waterpump,fan,generatoranditsbracket,v-beltoffan,electric
startingmotor,oilfilter,waterradiator,etc.)
Checkalljointsbetweenairfilter,intakerubberpipeandintakepipeforsecure
airtightness.
Checkifpowertakeoffclutchisreleased.
16
This manual suits for next models
10
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