Lister Engine Forum

Slow Speed Diesel Engines => Changfa Engines => Topic started by: okiezeke on April 17, 2007, 10:34:27 PM

Title: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 17, 2007, 10:34:27 PM
Latest toy.  My new 25hp Changfa style.  Soon to be direct coupled to a ST-15kw, at reduced output, due to rpm reduction from 2200 to 1800.  So far everything looks fine.  Fit and finish and castings all seem 1st world.  Came with extensive parts kit(extra 250.00).  Piston,rings, rod, big end bearings, complete head, starter, fuel pump, injector, direct coupling, and a ton of smaller stuff and tools, some of which, I have no idea, yet, what it is.  For example, I seem to have 3 heavy duty rectifiers,  firmly potted in plastic with large aluminum heat sinks.  Haven't found anything to rectify yet, but when I do I'll be in great shape!.  Manual is fairly readible, with the usual translational challenges.  Isnt it funny, that when they use the totally wrong word, you can still kind of tell what they meant.

(http://thumb12.webshots.net/t/57/757/0/77/95/2461077950100184412ddimAF_th.jpg) (http://good-times.webshots.com/photo/2461077950100184412ddimAF)
Shroud around radiator is off.  Really nice of these folks to think to include a generator room light.  With thinking like this, we'd all better start learning Chineese.  Engine half of direct coupler installed on flywheel.

(http://thumb12.webshots.net/t/57/657/6/20/44/2645620440100184412tHxgrl_th.jpg) (http://good-times.webshots.com/photo/2645620440100184412tHxgrl)
Similar view, showing head


(http://thumb12.webshots.net/t/59/459/9/74/63/2834974630100184412lVzXYD_th.jpg) (http://good-times.webshots.com/photo/2834974630100184412lVzXYD)
The direct coupler.  The 6 rods that carry the load appear to be nylon, 0.6" dia.  Will have to have the ST end of the coupler bored and re-keyed to match ST shaft.  Seems very heavy duty.  Do wonder a little about the nylon rods, but I suppose an engineer, somewhere on the planet, thought they would carry the load??
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 19, 2007, 02:04:11 AM
Another whole day in the workshop.  Sure am glad I don't need these generators right now, or I'd freeze and my food would thaw.  I bought more steel(I know, this is a city boy thing to do.  Real survivalists have tons of assorted steel in their front yards, in between the old trucks)  Anyway, another $80.00 for some very heavy steel to mount my engine and ST to the skid/frame.  Most of the afternoon fitting, checking, mounting the Weichai and the ST, to make sure everything will fit, then taking them back off and to the garage.  Then welding it all together.  I have managed to make a generator that is so heavy that I probably cant move it in one piece.  EPA should be happy.  This thing is VERY stationary.  I'm guessing 400lbs or so for the frame.
(http://thumb12.webshots.net/t/53/453/4/69/46/2857469460100184412aKUStU_th.jpg) (http://good-times.webshots.com/photo/2857469460100184412aKUStU)

The Frame.  Takes me and momma both to move this thing...think I have really went and made it much stronger than it needs to be.  Such is the way of the ignorant.

(http://thumb12.webshots.net/t/16/17/8/52/12/2956852120100184412kiwYNY_th.jpg) (http://good-times.webshots.com/photo/2956852120100184412kiwYNY)
I just love the ST 15kw.  They're just so.....Big.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 19, 2007, 02:29:54 AM
Something to rectify??
Well, I found a possible candidate for something to rectify on the Weichai 25hp.  The belt driven fan on the radiator has wires coming out of it.  Since its belt driven, it really doesnt seem to need wires.  Owner's manual doesnt say anything about an alternator anywhere.  And so far, these are the only wires I've found that dont seem to be doing anything.  Anyone seen such a thing on a Changfa-type?
(http://thumb12.webshots.net/t/59/659/7/65/98/2945765980100184412mInelC_th.jpg) (http://good-times.webshots.com/photo/2945765980100184412mInelC)
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Stan on April 19, 2007, 03:24:17 AM
If that is your alternator, what a cool way to mount it  :-*
Stan
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: kltrider on April 19, 2007, 05:59:45 AM
On the Kubotas I use, this is the wiring for a PMA, or Dynamo as they call it. 
Check your documentation for a refference to any charging system included
with this engine. My  John Deere also has one of them under / inside of the fan.
Since I'm asking, can we know where you bought it? If it's as good as a "real"
Changfa, I might want one.
All the best, Wayne.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 19, 2007, 06:10:17 AM
Wayne,
The engine was on ebay.  The dealer is in Ohio.  He says he'll have some more in a few months.  Tim, at tresch@ameritech.net   I'm going to get it mounted to the ST and run it some with the stock fuel tank and radiator just to see how it does.  So far, it looks well made.  Will see how it runs.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Biloxibad on April 19, 2007, 07:41:47 PM
Zeke, the fan is an alternator, puts out about 10 amps,   If your 25 is anything like my 28 you will be abandoning it though as it is part of the engine plate that the radiatior mounts to ,  the radiator on mine self destructed in about 10 hours..

I abandoned the fan when i put on a separate cooling system and use a 110v battery charger t otop off the battery.

Steve
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Stan on April 19, 2007, 10:14:31 PM
Don't throw those fans out, they would be perfect to run from a Lister keeping it cool and generating some DC as well.
Stan

By the way the webshots site just tried to load several very bad popups and cookies onto my computer  ???
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 19, 2007, 10:36:05 PM
Steve,
Sorry to hear the radiator was poorly made.  I had some doubts when I ordered the Weichai, pig in a poke that it is.  But the dealer seemed nice and promised me he has sold hundreds of these without problems(where have we heard that before?).  Real Changfas seem all but impossible to come by, so I guess its up to folks like you and me to buy a clone of a clone of a......  and see if there's any good quality available.  I'm planning on starting mine as soon as the coupler returns from the machinist.  Stock muffler and all.  See how long it takes for the police to arrive to see what the racket is all about.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 19, 2007, 10:41:35 PM
Stan,
I'll definately save the alternator/fan.  Could come in handy.  So far, (knock on wood) the dirty popups and other junk haven't penetrated my 3 layers of security.  Probably just a matter of time, though.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 20, 2007, 01:21:36 AM
(http://thumb12.webshots.net/t/59/759/6/89/56/2114689560100184412NJNhhy_th.jpg) (http://good-times.webshots.com/photo/2114689560100184412NJNhhy)
Here's the engine and the ST sitting on the frame in rough alignment.
(http://thumb12.webshots.net/t/59/459/4/10/85/2543410850100184412Tlkbgp_th.jpg) (http://good-times.webshots.com/photo/2543410850100184412Tlkbgp)
All that is left to do is mount the coupling and fine alignment.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Stan on April 20, 2007, 01:34:20 AM
The dirty pop ups and nasty cookies don't do me any harm, but I do get a report on what has tried.  I've got 3 layers of security using software and 1 hardware firewall.  I think I'm going to investigate linux.
Stan
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 20, 2007, 03:43:31 AM
Stan,
It's what life has come too in todays world.  All the modern conveniences come at a price.  Dont think I'd want to go back to the days before air conditioning, though.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 20, 2007, 03:50:05 AM
Steve,
When your engine is running does it jump around a lot?  I figure my whole rig weighs 1300 or so.  Could be exciting if it decided to jump up into the air and squash something(like me).  I do subscribe to the cubic yard of concrete school.  But hope to run this rig some here in surburbia before I get it permanently mounted down in Okie-land.  Thanks,
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on April 20, 2007, 04:55:20 AM
Steve,
When your engine is running does it jump around a lot?  I figure my whole rig weighs 1300 or so.  Could be exciting if it decided to jump up into the air and squash something(like me).  I do subscribe to the cubic yard of concrete school.  But hope to run this rig some here in surburbia before I get it permanently mounted down in Okie-land.  Thanks,
Zeke

Zeke,

Get yourself a new slab of cow mat  or agricultural mat or whatever they call it at your local farm supply outlet.  It is a rubber type compound mat about 5/8 inch thick by 4x6 feet that ought to work well between your frame and the bare cement floor to keep it from walking around and will allow a bit of vibration with shock absorbing action.  They cost around $50 each.  If it comes large enough cut in half and use double thickness.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: kltrider on April 20, 2007, 06:25:45 AM
Okiezeke:
I would recommend you remove the small cast iron stands on the bottom of this engine.
I didn't notice them on earlier pictures. My kubotas all came with them installed, but were
soon broken by stress and vibration. Sorry to throw water on your campfire like this, but
better now than while you are running.
Athe luck in the world, Wayne.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Biloxibad on April 20, 2007, 05:29:07 PM
Zeke, It is mounted on a frame with rubber isolators, I don't even have the frame bolted down,  It is about 2 ft in off the ground  ( out of flood zone) sitting on some stacked concrete blocks and a pair of 6 x 8 railroad timbers,   I will try to get some pictures uploaded so you can see my setup and also the 6/1 lister which runs in tandem with a 10 hp single phase motor as a generator synced to the ST15.

By the way, I am reading a consistant 27- 29 amps from the Lister 6/1  setup at 250 volts which acccording to my math is about 6750 watts and running with a clear exhaust.  I think the Lister's are grossly underrated. Mine is a Metro brand.
(http://www.biloxibad.com/generator/Img_1127a.jpg)
(http://www.biloxibad.com/generator/Img_1128a.jpg)
(http://www.biloxibad.com/generator/Img_1129a.jpg)
(http://www.biloxibad.com/generator/Img_1130a.jpg)
(http://www.biloxibad.com/generator/Img_1131a.jpg)
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: SCOTT on April 20, 2007, 05:43:49 PM
Biloxibad

Can you explain how you are reading 27-29A @250v?  The 6700 watt figure seems very high, the best I was able to achieve was about 3700 on my 6/1 before smoke was obvious.  Did you make any modifications to the engine?

Scott
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Biloxibad on April 20, 2007, 06:12:51 PM
It is just as you see in the pictures,, the only real difference is that I am using a Baldor 230 V 10 HP single phase motor instead of a generator at slightly above 1800 RPM with the secondary circuit reversed and the starting caps taken off line.   It is excited by either an invertor when running alone or by the ST15 powered by the changfa clone.

The label on the motor says it is rated at 39 amps but I am able to run it up to 32- 33 without any serious heating, here is the link to the motor page on Baldor site. http://www.baldor.com/products/detail.asp?1=1&catalog=L1512T&product=AC+Motors&family=General+Purpose%7Cvw%5FACMotors%5FGeneralPurpose&winding=37WGW577&rating=40C+AMB%2DCONT

The drive system is a Utterpower serpentine belt pulley with a 6v belt, I am running #2 diesel offroad currently.

The muffler is a generic 2" inlet and outlet. Wife will probably do laudry this weekend, (my cue to start up the lister) I will get some shots of amps, voltages etc to post. since I got my camera working.

I havent run a fuel consumption lately , engine now has about 150 hrs on it,  but when Running I fill the built in 2.5 gallon tank and let 'er run for about 7- 8 hrs without worry.. I plan to do some calibrated tests of current vs fuel this weekend.

Steve
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Biloxibad on April 20, 2007, 09:25:49 PM
(http://www.biloxibad.com/generator/Img_1133a.jpg)

This is from the Metro 6/1 mentioned in the post above. 33.1A x 253V =8374.3 watts Hz =59.9
Just a touch of grey smoke.  Has been under this load for about 2 hours.


Steve
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: SCOTT on April 20, 2007, 11:53:10 PM
Steve
I see the numbers in the picture, I do not dispute the readings, but they do not make sense.  The wattage is way above what a 6/1 should be able to produce, also assuming NO loss in your motor (which can’t be the case) the motor should be able to produce just under 7.5kw at an RPM of 1875.  rated 1725rpm -1800=75 rpm slip 1800+75 =1875 this is the rpm that should yield the maximum output. 

What are you using for the load in this situation?  I believe what you are seeing is the load being powered by both the Baldor motor and your 15kw head or inverter, whichever you are using for excitation.  I am not trying to pick on you or be argumentative but 1+1 has to equal 2 and in this case it equals 5.  Maybe one of the electricians in the group could help describe how the numbers come out as they do.

If infact you are able to produce 8+kw with a 6/1 I will be very happy because I had a huge 10hp single phase motor made by the company that made my gen heads, that is still in the crate in my garage.  I am in the process of net metering and would love to be able to push 8kw back onto the grid using my induction motor.

Scott
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on April 21, 2007, 12:51:54 AM
Very nice clear pictures and nice portable measuring instruments!  However, you do not know the phase angle between the voltage and the current.  If you can buy or borrow a watt meter that is what you need here. The wattmeter takes power factor (phase angle differences) into account automatically as the way it works to give a true power reading in watts.  I agree with the others, no way the 6/1 is making that much electrical power.  If you cannot get a wattmeter, hook up incandescent light bulbs or resistance heaters as a dummy load and when you have 120 VAC applied across them you will know that they are indeed operating at their nameplate wattage.  Add up all the nameplate wattages to see how much real power you are making.  I seem to recall that induction generators have crappy power factor.  I have not actually played with them yet to have hands on knowledge.  Ask the hand, the hand doesn`t have an answer.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: TerryM on April 21, 2007, 03:28:14 AM
Since Biloxibad lives in the SE US, I presume that his 250 volt generator output is actually split into two 125 volt circuits with a common return.  With one ammeter, he has to be measuring one of the two hot legs, so the only thing that can be concluded is that the generator is powering a load of 125 V RMS x 29 amps = 3.625 KVA on one of the two 125 volt circuits.  Depending upon how much of that load is inductive (e.g. AC motor), the power factor could be 0.8 - 0.9 which would make the real component of the load on that leg 2.9 KW - 3.26 KW.

Since the current on the other hot leg is not being metered, there is no way to determine the total load on the generator.  My suspicion is that Biloxibad is running his AC unit on one leg and a bunch of lights on the other such that there is a fair amount of imbalance.  This would explain the seemingly extraordinary power output  from a 6 HP engine.

Biloxibad, if you're interested in accurately determining the output power of your generator, you have to put a fairly steady load on both circuits and measure the current draw in both hot legs.  Multiply each current times the voltage measured from the corresponding hot side to neutral and sum the values.  For example, assume you measured the following voltages and currents:

Hot side 1 to neutral = 120 volts
Hot side 1 current = 30 amps

Hot side 2 to neutral = 125 volts
Hot side 2 current = 10 amps

For simplicity assume that the loads are purely resistive so the PF is unity.

120 x 30 = 3600 watts
125 x 10 = 1250 watts
                 ========
                 4850 watts

Terry

Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Stan on April 21, 2007, 04:57:56 AM
And, I don't see the 1 ton of concrete under that 6/1.  Watch out or the concrete police are going to be knocking at your door.   ;)
Stan
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Biloxibad on April 21, 2007, 03:57:22 PM
The motor has only 2 leads coming out , no ground at all.   It is wired into the bus via a 40 amp dual braker (2-40)  Each leg measures exactly the same as it is producing only 250V.  I wont be able to isolate it for any wattage checks as it is excited by the house grid.  I do have an electric meter I can put on it, It looks like a regular one on a power pole and see what the current flow running trough it is over time.. will that give a reading??

Steve
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Biloxibad on April 21, 2007, 04:02:04 PM
I forgot to mention that the voltage in the panel is 126 from each leg to ground..
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: TerryM on April 22, 2007, 04:18:19 AM
Steve - Thanks for the update, but now I'm really puzzled.  Let's put aside the original issue of an abnormally high output power from the Lister and discuss what appears to be a safety issue.  I'm going to try to do some text-based schematics to illustrate the important points. 

Standard wiring for a house has a 240 VAC feed coming from the pole or underground transformer in the form of two 120 volt circuits with a common neutral (sometimes referred to as a " return") running 180 degrees out of phase with one another.  The 180 degree phase relationship is what causes the hot-to-hot line voltage to be 240 VAC instead of zero.   In your house, you have 240 VAC appliances (dryer, stove, hot water heater) and 120 VAC appliances (TV, computer, refrigerator, etc.).  The 240 VAC loads are connected across the two hot lines "phase to phase" while the 120 VAC loads are connected from one phase to neutral - effectively ground.  Like this:


   Hot-1     >----------------------------------------------------------------------------------      <---
                         |                 |              |            |                                      |
                     120 VAC             120 v applicances                                         |
                         |                 |              |            |                                      |
   Neutral   >---------------------------------------------------------                              240 VAC Appliances
                          |                 |              |            |                                      |
                     120 VAC             120 v applicances                                          |
                         |                 |              |            |                                       |
   Hot-2     >----------------------------------------------------------------------------------     <---

One of the features of this configuration is that regardless of the current drawn by the 120 Volt appliances, they
only see 120 VAC (subject to minor fluctuations in the input power).  Now lets look at your wiring configuration:

 Hot-1     >----------------------------------------------------------------------------------      <---
                         |                 |              |            |                                      |
                     ??? VAC             120 v applicances                                          |
                         |                 |              |            |                                      |
                         |                 |              |            |                              240 VAC Appliances
                         |                 |              |            |                                      |
                     ??? VAC             120 v applicances                                          |
                         |                 |              |            |                                      |
   Hot-2     >----------------------------------------------------------------------------------     <---


The 120 volt applicances are now connected in a series configuration and the voltage drop across each one is dependant upon
the load that each one draws.  In other words, if you had a light load in series with a heavy load, the voltage drop would become
unbalanced.  For instance, you could see 150 VAC across one of the appliances and 90 VAC across the other.  This is bad electrical
karma.

If the wiring from the generator is as you believe it to be (i.e. no neutral), you have a very hazardous condition with the potential to subject motors, lights, computers, TVs, etc to voltages well outside their design specs .  I'm surprised you haven't seen flickering lights, refrigerator motors groaning as they start and other anomalous conditions.  My advice to you is to put the generator testing with your house on hold until you can get a gen head with a neutral for 120/240 VAC operation. 

Terry


Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 22, 2007, 09:23:49 AM
 Wayne, jumping back to your comment on the add-on stands ,
Thanks, I had identified the stands as "looking weak"  Mine are stamped/welded sheet steel, not cast.  I'll probably remove them and weld a base for the engine from heavy stock.  With what the rig weighs now, what's another hundred pounds?.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: kltrider on April 23, 2007, 06:08:31 AM
okiezeke:
I mention the stands only because of a significant failure I was "involved" with. One of the first Kubota / generator sets I put together was for a pilot over at Chiefland.
He was using the jenny and battery combined system to start his F-86. The plane did what we call a "Hung Start" where the engine lit off, but wouldn't accelerate to normal idle.
He chopped fuel and motored the jet twice for 3 minutes each time to cool it, then was going to make another start attempt. His crew cheif decided that they needed more power so he upped the governor settings. The overspeed on the generator caused a shaft bushing to bind up due to heat and the resultant torque requirement was too much and snapped the overworked little stands. Next ting you know, here goes this Kubota, walking sideways off the mount frame. Fortunately, they got a good start and by the time the airplane returned from a 2 week trip, I managed to fix the mounts and re-bush the generator. That was also the last time I built a start cart using a noncoupled drive, where the generator and prime-mover (diesel) aren't solidly mated.
Just one of those things that makes you go "Hmmmm."
Much good fortune to you and yours, Wayne.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Biloxibad on April 23, 2007, 10:45:06 PM
Terry, Thanks for the schemes, You are making the asumption that I am using the lower schematic, which is not true, I am feeding your schematic ( the top one)  with the 240v to the panel and have the panel grounded, and the primary generator grounded creating the 125 V circuits..

You do realize that the 10 HP 230V motor doesn't require a "ground" to run, just a  couple of 125V legs 180 degrees out of phase..

That is the way it is wired up as a generator also, 

No problem.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Biloxibad on April 24, 2007, 01:25:40 AM
Traced the grounding and the 10 HP motor is grounded via the frame grounding to the main generator, so am getting the Terry's preferred wiring setup.   I rechecked everything and am still getting today 250V - 33A on the Metro6/1 and 62A 250V on the Changfa Clone with the ST15. (got every heater, dryer, welder and airconditioner in the place on at the same time LOL.)

When I cut the breakers to the 10 HP motor the changfa clone with the ST15 begins bellowing black smoke and blows a breaker.. (60 AMP).   The motor won't generate without the ST15 running or hooked up to another power source for excitation.

I am generating power in the correct direction as I installed a standard Utility type Electric meter in series from the Motor to the panel,  When I am running the motor at less than 1800 RPM the little wheel runs to the left very slowly , IT stops as I speed up to 1800 and  then begins to spin very fast to the right when I run the RPM up to about 1850 which is where I am at the above settings..

I wish I had some more sophisticated equipment to see what I am really putting out , but that would take a load maker wayayyy above what I need around the DIY homestead.

The fuel usage studies I intend to run will tell the tale I am sure

LATER


Steve
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 27, 2007, 04:53:24 AM
Weichai 1115,
Had fun today.  Got the shaft coupler back, all bored and keyed.  Fits perfectly.  Took the lightweight feet off the weichai and welded heavy wall 5" by 3" tubing to the skid frame.  works perfectly except there's now no way to drain the oil and the flywheel rests on the 5 by 3 tubing.  Some work with the torch should fix the flywheel's problem.  Sure hope the oil drain plug  isnt some exotic chineese thread so I can put a hydraulic hose into it.  One step forward, two backward.  Life is an adventure.  More pictures when I've fixed the problems I made today.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: europachris on April 27, 2007, 01:08:37 PM
Some work with the torch should fix the flywheel's problem.   flywheel rests on the 5 by 3 tubing.

I had the same problem with my R185 engine when I went to mount it to a pair of oak 4x6 beams.  I had to router out a small recess about 3/4" deep to let the flywheel drop down enough to where the engine feet would sit flat on the mounts.

Chris
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on April 27, 2007, 04:04:47 PM
Quote
I had the same problem with my R185 engine when I went to mount it to a pair of oak 4x6 beams.  I had to router out a small recess about 3/4" deep to let the flywheel drop down enough to where the engine feet would sit flat on the mounts.

Chris

That sounds like a depressing job but I`ll bet your handywork left a lasting impression!  :D
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on April 27, 2007, 08:37:24 PM
Coulda been worse,
Looks like I only need to cut a 3" bevel on the ends of my 3 by 5s for the flywheel.  10 min work with the torch and grinder and it will even look like I did it on purpose.  Had to shim the motor 1/2" and the ST 1 1/8" to clear oil pan bolts and align the shaft coupler.  Local parts store made me a hydraulic hose that screws right in.  Will cut a hole in the side of the 3 by 5 , and weld in a pipe so no sharp edges to wear on the hose.  BTW the oil in the pan looked brand new and clean.   My work week starts tonight, so no more fun 'till Mon.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on May 04, 2007, 02:40:46 AM
(http://thumb12.webshots.net/t/57/457/9/55/51/2635955510100184412sfecVa_th.jpg) (http://good-times.webshots.com/photo/2635955510100184412sfecVa)
A view of my next project.  Will follow Doug's procedure on cleaning and sealing the insides of the ST

(http://thumb12.webshots.net/t/57/457/0/42/98/2649042980100184412VRHgGS_th.jpg) (http://good-times.webshots.com/photo/2649042980100184412VRHgGS)
My finished coupler.  Still need to do the fine alignment when I bolt everything down.

(http://thumb12.webshots.net/t/57/557/7/49/68/2157749680100184412nIkppS_th.jpg) (http://good-times.webshots.com/photo/2157749680100184412nIkppS)
This mount just keeps growing.  Weighs at least 150lb, mabe more.

(http://thumb12.webshots.net/t/57/657/4/46/79/2335446790100184412snCEdB_th.jpg) (http://good-times.webshots.com/photo/2335446790100184412snCEdB)
Some of my mounting shims from McMaster-Carr

(http://thumb12.webshots.net/t/57/757/0/93/22/2154093220100184412ElvsTb_th.jpg) (http://good-times.webshots.com/photo/2154093220100184412ElvsTb)
Measure once, Cut twice. :-\



 
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on May 04, 2007, 02:51:59 AM
Zeke,

You are either gonna blow those bolts or prematurely wear out your alternator and crankshaft bearings with that non-compliant coupler.  It is IMPOSSIBLE for you to get the alighment straight enough and then hold the two units in perfect geometrical and spacial synchronysm with all the bouncing around and vibration.  I give your bolts less than an hour first trial.  You are going to have some nicely pounded out, not so threaded holes in the flywheel in less time than that if the bolts don`t snap.

Sorry to be the harbinger of DOOM.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on May 04, 2007, 03:06:45 AM
Coupler,
Actually the two metal halves of the coupler do not touch.  There are 6-  3/4" nylon rods in slots that transfer the power.  Assuming the nylon rods hold up, should be a flexible connection.  Hve a pic of the inside of the coupler a page or so back.  Please  keep the feedback coming.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on May 04, 2007, 03:09:58 AM
Coupler,
Actually the two metal halves of the coupler do not touch.  There are 6-  3/4" nylon rods in slots that transfer the power.  Assuming the nylon rods hold up, should be a flexible connection.  Hve a pic of the inside of the coupler a page or so back.  Please  keep the feedback coming.
Zeke

Oh yes, I remember that coupler.  OK, good luck with it!  Keep us posted.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on May 04, 2007, 03:19:02 AM
I'm not sure the coupler is as good as an off the shelf from McMaster, but will find out eventually.  It seems to be made for the engine, so there is hope.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Doug on May 05, 2007, 02:22:17 AM
Can I see more pictures of the head and in particular the castings and around the foot. I see no gussets and I wounder if they add more cast some place else to compensate.

Doug
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on May 05, 2007, 10:08:54 AM
doug,You mean around the foot of the ST.  I can take some tomorrow.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Doug on May 05, 2007, 11:38:11 PM
Yes, but I'd like to see pictures from every angle too.

Need to go to school on the ST types. Not all are the same.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on May 06, 2007, 10:23:42 AM
OK,Happy to do.  May be monday before I get them posted.  I'm in the middle of my weekend nightshift workweek. Need to sleep all day.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 12, 2007, 02:38:22 AM
Changfa type question:
I'm looking at the exhaust manifold trying to figure the best way to adapt to steel pipe.  First I want to use a bigger muffler.  Then later I want to go underground with the exhaust.

The only idea I've come up with is cutting off the threaded end of the stock muffler and welding  a 2" steel pipe coupling  to the stock threaded section, and going from there.

does this thread match anything?  It seems to be between 1-1/2" and 2" both pipe thread and electrical conduit.

Can I braze directly to the ex. manifold?  I'm not a very experienced welder.

Saw here that one fella welded up a new ex. manifold,  guess that would work, but would be lots of work.

I know a lot of folks have faced this problem.  Would love to know what worked.

Thanks,
zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Doug on June 12, 2007, 02:45:17 AM
Ya that would be me Zeke. And it was real easy, or rather Dave the welder makes it look easy lol....

Here's the fabricated intake, I need to update soon. I've made more changes.....
http://www.putfile.com/pic.php?img=4924460

Doug
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 12, 2007, 03:13:54 PM
Doug,
That's great.  Looks like he started with a pipe flange, then just plumbing.  I could do that too, but might no look so pretty.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Doug on June 13, 2007, 06:50:21 AM
# 24 hydraulic hose fittings for intake and exhaust # 16 for coolant.

Cut, welded and draw filed flat.

Actualy quite easy by the time I made tha last one.

http://www.putfile.com/pic.php?img=4919055
http://www.putfile.com/pic.php?img=4919054

Upper coolant outlet and partialy finnished remotoe thermostat in mach up at " Petterod labs " a mile and half bellow the earth safe from prying eyes......
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rmchambers on June 13, 2007, 01:36:30 PM

Upper coolant outlet and partially finished remote thermostat in match up at " Petteroid labs " a mile and half below the earth safe from prying eyes......

It's a cut-throat industry - Petteroid modification!  The lengths you have to go to to avoid your designs and plans being stolen and copied.  :D

RC
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 14, 2007, 03:30:00 AM
Doug,
I'm certainly guilty.  I just got my 2" pipe flange.  Will take it down to my local machinist for trimming and bolt holes.  McMaster even had a high temp(800 degree) gasket for the flange.  Flange will bolt on, then 2" npt threads from there on.  Will take a standard 2-3/8" ID muffler pipe, which are avail on ebay for diesel tractors.  Will also check local parts stores, might get one cheaper.

 The Intake side has a two hole flange mounting.  Figure I can make a matching flange and weld it to 2" pipe and I can put the same muffler on the intake side.  Would be easier to mount intake muffler inboard of the air filter.  Would this likely work?

From your pics of Gus, doesn't look like there's much you haven't rebuilt or replaced.  Ol' Gus should run like a Swiss watch when you get him back together.


ZEKE
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on June 14, 2007, 04:17:54 AM
Doug,
I'm certainly guilty.  I just got my 2" pipe flange.  Will take it down to my local machinist for trimming and bolt holes.  McMaster even had a high temp(800 degree) gasket for the flange.  Flange will bolt on, then 2" npt threads from there on.  Will take a standard 2-3/8" ID muffler pipe, which are avail on ebay for diesel tractors.  Will also check local parts stores, might get one cheaper.

 The Intake side has a two hole flange mounting.  Figure I can make a matching flange and weld it to 2" pipe and I can put the same muffler on the intake side.  Would be easier to mount intake muffler inboard of the air filter.  Would this likely work?

From your pics of Gus, doesn't look like there's much you haven't rebuilt or replaced.  Ol' Gus should run like a Swiss watch when you get him back together.


ZEKE

Zeke,

I believe the very best performing type of muffler you could put on the intake is a long glasspack or better a steelpack.  I haven`t been able to locate one of those. It will work fine on the engine side of the air filter but may shed some of it`s glass fibers into the engine and there will not be a filter to catch them.  That is my only concern with a muffler after the air cleaner. If you do this keep the line length between the muffler and air filter as physically short as possible for least noise.  Length from silencer to intake valve is not so critical noise wise.  I mentioined steel pack thinking it would be less likely to shed fine abrasives like a glasspack may.

I would not use a reactive muffler for an air inlet silencer due to excessive insertion loss to flow.  Going very large bore here will reduce flow restriction but may not be particuarly effective, or simply overly  expensive.

If you have access to a machine shop you can make a really effective silencer from a 100 lb. propane tank with a 3 inch diameter perforated center pipe brazed down the center. As for tools you could do the whole job with just a cutting torch and brazing tip. Reduce to 2 inch to fit your intake manifold pipe on inlet.  Mount the air cleaner on the other end.  Fill the space between the tank and the center perforated pipe with pink fiberglass batting, or even better, rockwool.  Stuff like a fluffy pillow, fairly tight, not loose.  I guarantee virtually  no sound from the inlet with this silencer.  If you only use this silencer as an intake silencer you could roll the center perf pipe section from very fine brass mesh sieve and solder it along the seam.  That would keep glass fibers from entering the airflow to the engine.

When cutting open a used propane tank I always fill with water first to reduce the explosion hazard to zero.


I made one of these using a rolled piece of diamond mesh steel sheet down the center as a final muffler for my VW genset. I brazed the mesh seam. Although mine employed a rolled outer steel skin 4 feet long and the ends cut from a 20 lb propane bottle, the size of a 100 lb bottle is perfect and less work. The first muffler in my VW diesel plant is a regular reactive car muffler near the engine. The Glasspack is at the very end of the 2-1/4 inch 12 foot  vertical run through the roof with a flapper on the top outlet to keep rain out.  At full load I hear zero exhaust noise when standing next to the muffler on the roof.  This is what they would classify as a hospital grade or better silencer.  The only clue of the engine running outside is a faint hum of the metal building wall vibrating and a whisp of exhaust smoke when there is no wind.  I plan to deal with the wall re-radiation when I have the $$$ to redo and improve the actual generator room with improved wall treatments and new interior walls to make the generator room bigger to accomodate the other generators (Petter PJ-1 and Jiang Dong 175)  and related equipment, presently in yet another room and not so quiet..
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Andre Blanchard on June 14, 2007, 01:07:12 PM
I believe the very best performing type of muffler you could put on the intake is a long glasspack or better a steelpack.  I haven`t been able to locate one of those. It will work fine on the engine side of the air filter but may shed some of it`s glass fibers into the engine and there will not be a filter to catch

I guess this would be a rockpack. :)
http://books.google.com/books?id=5-EJAAAAIAAJ&printsec=titlepage#PRA1-PA424,M1

Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 15, 2007, 12:29:26 AM
I wondered about the debris from the muffler.  Are there some mufflers that are just a series of baffles, no glass or other packing?  Being on the intake side and being indoors, wouldn't think the insides would rust or flake off.

 Other option is to ditch the factory air filter and improvise something equivalent.  Then could muffle the input side of the filter.  I'll have to keep looking and thinking and something will pop up.

Zeke

ps  Long time ago, worked on a guy  who was sitting astride an "empty" 300 gal. propane tank, cutting it with a torch.  Don't know how it didn't kill him, but he wasnt a boy anymore!
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on June 15, 2007, 02:11:13 AM
I wondered about the debris from the muffler.  Are there some mufflers that are just a series of baffles, no glass or other packing?  Being on the intake side and being indoors, wouldn't think the insides would rust or flake off.

 Other option is to ditch the factory air filter and improvise something equivalent.  Then could muffle the input side of the filter.  I'll have to keep looking and thinking and something will pop up.

Zeke

ps  Long time ago, worked on a guy  who was sitting astride an "empty" 300 gal. propane tank, cutting it with a torch.  Don't know how it didn't kill him, but he wasnt a boy anymore!

Zeke,

The type of muffler with baffles and no packing is called a reactive muffler.  I discussed that type and do not think it is well suited for intake noise silencing.  By all means. put an air filter after the big glasspack muffler and before the engine.  Problem solved.

Worked on?  Were you a medic or something?  That neuro typical should have died according to the goals of evolution but no system is perfect.  The gene pool certainly could use a little chlorine.  Reminded me of the ending scene in Dr. Strangelove.  Substitute A-bomb for propane tank.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 15, 2007, 04:28:55 AM
Medic, no registered nurse at University of Virginia Burn/trauma center for 10 years.  I've seen everything that can be done to the human body and our survival rate was over 90%. (that was staff, the patients all died) ;)

Zeke

ps don't worry,he was out of the gene pool, permanently.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: kltrider on June 15, 2007, 03:12:52 PM
Just my 2cents. It seems to me the most typical type of reactive muffler on the automotive market today appears to be the "Flowmaster." I've got a pair of the stainless steel ones on my "delivery tuck." A 1990 Isuzu tilt cab with a 500 "cubit ench" Cadillac V8. They work well, and really calm down the sound.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 15, 2007, 07:55:23 PM
 My exhaust side rebuild is almost done.  2" steel pipe is heavy, but I hope not too heavy.  Can always add support from the skid if needed.  Thinking of going with electrical conduit on the intake side.  Much lighter, could even use aluminum.  (dont have access to hydraulic fittings)  Trying to figure how to make a filter housing to put downstream of the muffler.  Could use a rectangular automotive filter element.  Need to think more...

Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 19, 2007, 11:02:24 PM
Doug, thanks for the idea.  My new exhaust manifold is an off the shelf McMaster 2" pipe flange, turned down to fit the head.

(http://thumb12.webshots.net/t/30/466/7/1/89/2783701890100184412xsxgim_th.jpg) (http://good-times.webshots.com/photo/2783701890100184412xsxgim)

(http://thumb12.webshots.net/t/58/458/8/73/75/2666873750100184412WpgrvR_th.jpg) (http://good-times.webshots.com/photo/2666873750100184412WpgrvR)

Need to work over the inside of the 90 degree ell with the die grinder.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Doug on June 20, 2007, 03:43:22 AM
Probably a lot easier that what I did, the only advantage I have is the speed I can couple and uncouple things.

Probably going to store my engine with plugs in place untill needed.....

Doug
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 23, 2007, 01:43:20 AM
The muffler is mounted.  I was browsing thru McMaster on line and came acrossed an intake air filter with noise reduction.  Filters 100cfm to 2 microns and 10db noise reduction.  I've ordered one and will take only minor fabrication to mount it.  If it works will be much easier than having to mount a muffler and a filter on inlet side.  Think I'll fire up the engine after I get the inlet filter mounted and see how it runs.  Pics to follow.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 24, 2007, 12:50:41 AM
(http://thumb12.webshots.net/t/63/463/5/70/33/2357570330100184412wkNkMf_th.jpg) (http://good-times.webshots.com/photo/2357570330100184412wkNkMf)

Muffler installed.  5/8" thick steel flange, to sched. 80 nipple, to sched 40 ell, to heavy wall aluminum pipe, to muffler.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Doug on June 24, 2007, 03:38:47 AM
I'm a little concerned the vibration + weight might crack the head, snap bolts or studs and or cause some other damage. But I don't know the engine so It all just a guess.

Condensate might run down the pipe as things cool and cause rust.

Not trying to be a party pooper, I just had vissions of a brace for the up stack and possibly one of those issolation unions with the flexable braid. A condensate trap wouldn't be hard to make.

I love the flooring and counter tops, also noce looking cabnets....

 

 
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 25, 2007, 12:54:57 AM
Doug,
Me too about the weight.  Main reason I chose alum. pipe for the riser.  I'm thinking about shortening the up pipe, might help.  Muffler weighs just a few pounds, but the running vibration could tear the whole thing apart.  Could launch the muffler into low earth orbit.  I'll look into isolation braid.  If I get into vibration trouble I'll just have to brace the thing to the metal skid.  Should be easy to do as it's all steel and I can weld support where I need it.

House pics are the parents house.  We took care of them in their last years, and now are trying to sell the place in the depressed real estate market.  Neighbors/realtors told us the best thing we could do for the place was to completely remodel the kitchen.  Countertops are real granite.  Wife and I did the oak floors a few years back.  Revenue from sale of the house will put us on our mountaintop in Oklahoma....... someday.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: europachris on June 25, 2007, 02:20:34 AM

  Neighbors/realtors told us the best thing we could do for the place was to completely remodel the kitchen.  Countertops are real granite.  Wife and I did the oak floors a few years back.  Revenue from sale of the house will put us on our mountaintop in Oklahoma....... someday.

Keep the floor and counters and park new cabinets and appliances between them (or even just have the cabinets fronts replaced).  Kitchen 'age' or 'vintage' is one of the first things I look at in a house.  Mechanicals/basement are second (furnace, hotwater heater, a/c, etc.).  A real 70's or 80's vintage kitchen brings up too many childhood memories (avocado, burnt orange, brown - GAK!) and will turn me off to the whole house.

Chris
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Doug on June 25, 2007, 02:29:33 AM
I realy like that kitchen!

Must be an American thing, but when you buy or sell a home in Canada, you keep your kitchen apliances.

Some people take their bathroom fixtures ( finlanders generaly lol )

Doug
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 25, 2007, 02:38:25 AM
Chris,
Thanks for the ideas.  We had just redone the entire house a few years back.  Unfortunately, the folks wanted it to look old timey, so we're removing wallpaper, redoing bathroom floors, repainting everything that's not off white(folks liked pink a lot).  Heck of a lot of work, but house is in a very nice area, nice view, big lot, and was worth a lot 2 years ago.  If we cant get our price this summer, we'll just wait a year and hope the market improoves.

Doug,
Strange how customs differ.  Here it can go either way on kitchen appliances and washers and dryers.  Lots of folks have their own and want to put them into their new place.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: europachris on June 26, 2007, 02:41:34 AM
Chris,
Thanks for the ideas.  We had just redone the entire house a few years back.  Unfortunately, the folks wanted it to look old timey, so we're removing wallpaper, redoing bathroom floors, repainting everything that's not off white(folks liked pink a lot).  Heck of a lot of work, but house is in a very nice area, nice view, big lot, and was worth a lot 2 years ago.  If we cant get our price this summer, we'll just wait a year and hope the market improoves.


Sure thing.  Also, don't forget - what I like could be VERY different from what someone else likes.  I like that retro 60's Scandinavian look (minimalist, etc.)  The wife HATES it.  She likes the kitchy country look (hearts, cows, etc.) which makes me want to puke.  We compromise and both get a little of each.  So, it's all up to the buyer and what THEY like.

However, I can deal with almost ANY decor provided it is well maintained and CLEAN, unless it's just absolutely hideous.  That kitchen in the pictures would be perfectly livable to me, no problem at all.  It IS quite nice.  I have also come to learn after a short 37 years that the size of your house, car, and/or how much money you have is meaningless if you're not happy with the rest of your life (relationships, family, friends, God, etc.).

Chris
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 26, 2007, 04:33:27 AM
Yep,
Wife and I lived on a very small sailboat for 5 years and loved it.  We had about 75 sq feet of living space.  Our next house will be 30' by 30'.  Plenty big for the two of us.
Zeke


ps  The house attached to the kitchen is 3600 sq ft with a big double garage.  5 bedroom, 3 1/2 bath.   Will never understand why my folks wanted so much house just for just the two of them.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on June 27, 2007, 12:53:29 AM
(http://thumb12.webshots.net/t/60/460/7/7/39/2761707390100184412PkojEh_th.jpg) (http://good-times.webshots.com/photo/2761707390100184412PkojEh)

(http://thumb12.webshots.net/t/50/550/3/91/30/2432391300100184412cNUvoJ_th.jpg) (http://good-times.webshots.com/photo/2432391300100184412cNUvoJ)

My latest addition.  Off the shelf from McMaster.  Intake filter and silencer.  Next move is to bolt engine to frame and fire it up and see how everything works.  Shouldn't take me much more than a month. ;)
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: europachris on June 27, 2007, 01:35:01 PM
Quote
My latest addition.  Off the shelf from McMaster.  Intake filter and silencer.  Next move is to bolt engine to frame and fire it up and see how everything works.  Shouldn't take me much more than a month. ;)

I installed one on my R185 ChangFa.  I made up an entirely new intake manifold, but I could have just stuck it on top of what I already had for a stub after removing the original oil bath unit.  I still coupled the manifold to the filter with a short stub of radiator hose and clamps to absorb vibration and not stress the manifold welds, etc. rather than threading it all together.  It definitely helped quiet the intake honk, but it's still louder than the exhaust after adding my big round NAPA muffler.  The new filter is FAR better quality and will filter much better, also.

Chris
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on September 17, 2007, 09:23:49 AM
First start,

I finally got everything together and decided it was time to start 'er up.  I hooked up the jumper cables, opened the pressure release. filled it up with rotella D, antifreexe solution, and diesel fuel, and hit the starter solenoid and it turned over briskly.  I loostened the banjo nut on the injector and turned it over until I had diesel coming out the line, re-tightened the nut, Released the compression lever and it fired up on the first compression stroke.

I have the whole gen set up on two 1000lb furniture dollies for moving around in the garage, and left it up on wheels for the first run.  It rapidly stabilized at about a 600 rpm idle and I let it idle for a few minutes.  Noise was bearable with the tractor muffler.  Couldnt hear any intake noise with the McMaster air filter/silencer.  Mostly mechanical and normal diesel knocking.  Overall, about the level of a loud lawnmower.

After a few minutes I opened the rack to 1800 rpm and after a second of governor hunting it ran smoothly.  No visible vibration.  No movement of the gen set on the wheel dollies.  Could easily have set my glass of water anywhere on the set. 

This thing runs really smooth.  The counterbalance shaft concept seems to be doing what it claims to do.  I havent run it up past 2000 rpm, and may never since I'm direct coupled to the ST.

So far the weichai gets an A+.  Starts and runs great.  Just one very slow drip from the fuel filter housing that I havent bothered to fix yet.

Speaking of the ST....it's dead. No output at all.  I checked all the wiring and components and everything seems to be in place.  I flashed the field with 12V and read 90VAC across the 220 leads, but it wouldnt go on its own.  I'm going to load up the 1750 lb monster on my trailer and haul it to the local friendly generator repairman today and let him take a look.  Seems to have lost all residual magnetism.  I put a powerful lifting magnet up against the rotor a few days ago, and let it sit there, but havent started it up again as I worked the weekend.

I'll try it again before I load it up for the trip.  Mabe the magnet has done some good....I hope.  If all else fails I can get a DC motor controller from Surplus center that puts out 0-130VDC at 8 amps, and I'll  feed the field with that.  Not the ideal solution, but should work.

I'm open to suggestions.

Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: europachris on September 17, 2007, 12:49:57 PM
I'll try it again before I load it up for the trip.  Mabe the magnet has done some good....I hope.  If all else fails I can get a DC motor controller from Surplus center that puts out 0-130VDC at 8 amps, and I'll  feed the field with that.  Not the ideal solution, but should work.

I'm open to suggestions.

Zeke

Make sure you check all the wiring terminals, maybe one is crimped over insulation rather than wire, making it LOOK ok, but it's not.  Could be a bad rectifier bridge, other bad components you can't see, maybe the slip ring brushes aren't making good contact (or alignment), maybe there is something loose on the brush gear inside the endbell, or maybe the thing is miswired right from the factory?

My rule - 90% of all electrical problems are mechanical.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on September 17, 2007, 04:01:07 PM
I've checked all connections.  I read low resistance(1-10 ohms) across the field, main windings, and harmonic windings.  resistance from the control box for the rotor windings is the same as at the brush rings.  When running, there is no voltage across the harmonic windings, 2 or 3 volts across the 220V output wires, and no output from the bridge.  When I put 12VDC from a battery across the field input wires, I get 90VAC output across the 220V output wires.  This seems to show that the wires are properly identified?  Going to try it again this morning after 4 days with the magnet next to the field, then off to the generator shop.

Thanks for the ideas.
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on September 20, 2007, 02:59:50 AM
More fun,
I noticed a lot of condensate in the exhaust manifold.  I removed the muffler pipe and had more than condensate.  I had a slow but steady flow of what looked a lot like antifreeze.

I pulled the head and put on a new head gasket.  Really a simple 20 min. job.  Unfortunately the leak was unchanged.  I had a spare head, so I put it on and NO LEAK!  I adjusted the valves, and it started right up and ran fine.  Looks like the original head had a casting defect that connected the water jacket to the exhaust manifold.

I kind of adjusted the valves by eye.  If anyone has valve clearances for a changfa-type, I'd appreciate the info.  The owners manual neglected to include this info.

My initial report of running at 400 rpm was in error.  I had my shaft tach upside down.  It really runs very smoothly from 800-2000rpm.  Seems very happy at 1800.  I'm still running it on wheeled furniture dollys with no problems.  Very smooth.

Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on September 27, 2007, 03:08:29 AM
I have noticed that the rocker arm on the intake valve is about 50% off the head of the valve stem.  I'm reluctant to try bending the rocker arm for fear that is made of cast iron or something else that doesnt bend.  Have thought of getting a slightly longer shaft (that the rockers pivot on), and shimming the intake rocker out 5 or 10 mm until its dead on the valve stem.

Anybody been there, done that???

Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on September 27, 2007, 03:30:16 AM
I have noticed that the rocker arm on the intake valve is about 50% off the head of the valve stem.  I'm reluctant to try bending the rocker arm for fear that is made of cast iron or something else that doesnt bend.  Have thought of getting a slightly longer shaft (that the rockers pivot on), and shimming the intake rocker out 5 or 10 mm until its dead on the valve stem.

Anybody been there, done that???

Zeke

It ought to be easy enough to whack the top of the valve keeper over with a hammer, bending the valve stem a bit so the valvestem is centered under the rocker no?    Kidding...I`m just K-I-D-D-I-N-G.   :D

If it is tight under the valve cover like my JD175 there will not be any room to extend the rocker shaft and shim the rockers to stick farther out.  Can you fabricate a larger diameter valve stem cap that the rocker tip pushes on?
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on September 27, 2007, 03:34:02 AM
I'm sure I could.  The ones on my listeroid look and feel like aluminum.  What would be normal stock to use?
Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on September 30, 2007, 12:29:56 AM
Wow!  Found a good use for sloppy clearances. 

By loosening the mounting nuts on the rocker arm, and re-arranging the spacer washers, I'm able tp move the whole assembly over enough to get both arms  about 90% centered on the ends of the valve stems.  Had to order some 16mm shim washers from mcmaster to fill in some empty space, but looks like it will work.  I had already made by first attempt at a valve cap by the time I figured this out.  I tossed it into the junk bin for future use.  Who knows, I get a lot of good parts out of the junk bin.

Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on September 30, 2007, 06:05:25 AM
Way to go there Zeke!  Sometime you can actually get lucky.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on November 09, 2007, 03:34:06 AM
Closure,
I have essentially finished my Changfa type 15kw gen set.  The ST head had lost residual magnetism, but by running it under load with an external field power source, the magnetism has returned. 

I think I will run this gen set with an external field excitation anyway, since the quality of the output is much better this way.  I'm using a Chinee variac, thru an Indian bridge rectifier, thru Japanese filter caps.  The output is very clean, and someday I will put it to the ultimate test and try to run a microwave oven.  I've managed to produce 48 amps max @ 220V and this is close enough to the max power that I'm happy with it.

My attention is now turned to my listeroid 20-2, which is re-assembled and will be ready to run soon.  Will continue to update on my Lovson 20-2 thread.

Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on November 09, 2007, 08:06:42 AM
Excellent news Zeke!  That is a powerful one cylinder diesel generator.  Do you get lamp flicker with a lot of load?  Remind me,  Is this direct drive or belt?

I am finally at the stage of preparing my projects frame for painting.  I removed the two gen heads and muffler today and started grinding and sanding the welds and corners.  I shot a coat of paint on my big end beltway screen cover.  My frame will be the dark Forest Green.

You asked for suggestions about color for your twin Listeroid in the other project post, suggesting that you were leaning towards gloss black.  I personally think these engines look much better in the forest or hunter darkish green than they would in black.  Black would work for me only if many items including valve cover were to be show chromed.  We here are much too sensible to worry about wasting precious resources on show chrome.   :D
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Stan on November 09, 2007, 08:55:43 PM
Zeke, as you know I'm restoring a Lister 6/1 and have taken pains to make it "historically accurate" just so I can see exactly what she looked like the day she came out of the factory at Dursley.  Dark Lister green, with black radiator parts, red rad fan and shiny brass parts (rad cap, oil pump, hose fittings, etc.) is a great combination.  I can't believe they made them this fancy back then.  I'ts almost as if they had a special edition vs the regular engine.  I hope to have her back together in a couple of weeks, will post pics then.
Stan
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: Stan on November 10, 2007, 12:53:29 AM
Now I have to source and order a good set of decals, the arrow, the logo and the "Lister" word.
Stan
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on November 10, 2007, 03:31:38 AM
Now I have to source and order a good set of decals, the arrow, the logo and the "Lister" word.
Stan

You said the `L` word.  :o :o :o :o :o :o :o :o :o
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: rcavictim on November 10, 2007, 03:35:42 AM
Zeke, as you know I'm restoring a Lister 6/1 and have taken pains to make it "historically accurate" just so I can see exactly what she looked like the day she came out of the factory at Dursley.  Dark Lister green, with black radiator parts, red rad fan and shiny brass parts (rad cap, oil pump, hose fittings, etc.) is a great combination.  I can't believe they made them this fancy back then.  I'ts almost as if they had a special edition vs the regular engine.  I hope to have her back together in a couple of weeks, will post pics then.
Stan

Since the racing strip had apparently not been invented yet, I can see them getting carried away with different colours :)

Jens

Jens is just trying to get my goat.   ;D  Thing is, I have none.  Some time ago I culled my herd of goats except for the ones with racing stripes.  Shortly after that the stripe equipped goats, apparently wise to a pending termination in their contract, all ran off.  :(
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: okiezeke on November 12, 2007, 12:33:33 AM
I saw one of those goats with the stripe the other day.  Wondered where it came from.

On the flicker question.....you know, I've hooked the rig up to just about averything in sight--except a light.  Next time I have it running I will definitely try some lights.  Have already decided I wont have any incandescents in the place-too inefficient.  Will use all fluorescents and LEDs.

Looking at rolls batteries.  Just love the 2VDC cells that weigh the same as an 8D truck battery and develop 1250AH.  6 of these brutes would make a pretty good house battery.  Then a 3KW inverter with a 125A charger and I'd be in business.  Used the Heart marine inverters when I lived on the boat and really liked them.

Zeke
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: yellowhead on March 01, 2009, 11:22:40 PM
Hi Zeke:

How did that Chinese coupler hold up? I've been thinking of using one in a similar application (195 coupled to an ST-7.5) as they can be had on eBay quite cheaply. If they can handle your larger set then I'm hoping I'll be fine.

Thanks,

Simon.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: lowspeedlife on March 03, 2009, 06:37:47 PM
Simon, i believe Zeke has left the forum, we had a problem with "gmail" causing spam & several people felt it was not worth thier time to get a 2nd e-mail address to use on the forum. sad i know but these things happen some times.


     scott r.
Title: Re: Weichai 1115, 25hp Changfa-type
Post by: yellowhead on March 06, 2009, 01:13:13 AM
OK, Scott. Thanks for the heads up. I too use gmail but signed up while I was in the UK. As a result I have a googlemail.com address even though the equivalent gmail.com address is a synonym. At the time I found this a bit annoying; in retrospect maybe its a good thing. Technology ...

Simon.