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95/100 Series Engine Operation Manual
Manual de Operación Motores Serie 95 & 100
IMPORTANTE: Adicional a estos términos y condiciones de garantía,
aplican tambien todas las condiciones y se deben seguir todas las instrucciones,
detalladas en el Manual Original de Fábrica entregado con su equipo.
Todos los términos de garantía estan sujetos a las condiciones y limitaciones
detalladas a continuación en este Manual.
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Summary of Contents for Remington 495 Series
- Page 1 95/100 Series Engine Operation Manual Manual de Operación Motores Serie 95 & 100 IMPORTANTE: Adicional a estos términos y condiciones de garantía, aplican tambien todas las condiciones y se deben seguir todas las instrucciones, detalladas en el Manual Original de Fábrica entregado con su equipo. Todos los términos de garantía estan sujetos a las condiciones y limitaciones detalladas a continuación en este Manual.
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Page 2: Table Of Contents
Content Chapter 1: Description Chapter 2: Diesel Engine Operation and Hints Chapter 3: Diesel Engine Safety Operation Specification Chapter 4: Diesel Engine Main Technical Performance 4.1 Main Technical Specifications 4.2 Technical Data 4.3 Fit Clearances and Wear Limit of Main Parts Chapter 5: Operation of the Diesel Engine Transportation... - Page 3 Running Stopping Run in Operation rule for the new diesel engine Chapter 6: Technical Maintenance of diesel engine 6.1 Working day maintenance 6.2 First grade technique maintenance 6.3 Second grade technique maintenance 6.4 Third grade technique maintenance Chapter 7: Trouble and Remedy Method...
- Page 4 Chapter 1 Description Remington 495-2100-4100 series high speed diesel engine are based on the Ricardo engine patent, for direct injection method, according to the operation method of the main and auxiliaries of the marine diesel engine, optimizing so its operation with radiator cooling system for land systems operation.
- Page 5 Chapter 3 Diesel Engine Safety Operation Specification 1. The operator should read the Maintenance Manual and know well about the structure, operation and maintenance. 2. One who is not familiar with the operation instructions is not allowed to operate the engine.
- Page 6 Chapter 4 4.1 Engine Main Techincal Specification Model 495/4100 In line, water cooling, 4 stroke, wet cylinder, direct injecting Type combustion chamber, electrical starting Intake Naturally or turbocharged or after-cooled. Turbocharged System Stable pressure type pressure, splash combined type Lubricating System Liquid cooling (Water or Coolant) Cooling System Inverse (face to the flywheel)
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Page 7: Technical Data
4.2 Engine technical Data (At 12 hours power rating） Lubricating Oil Temperature: o Naturally ≤ 95°C, turbocharged ≤ 105°C Outlet water temperature ≤ 95°C Main oil passage oil pressure: 0.30~0.50MP (idle≥0.10MPa) Exhaust gas temperature : ≤600 (at manifold branch) ... - Page 8 1500~2200r/min type: 17±2° Valve timing(in crank angel) o Intake valve opens: before TDC 12° o Intake valve closes: after BDC 38° o Exhaust valve opens: Before BDC 55° o Exhaust valve closes: After TDC 12°...
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Page 9: Fit Clearances And Wear Limit Of Main Parts
Fit Clearances and Wear Limit of Main Parts Clearances Wear limits Description (mm) (mm) diametric Main journal and bearing 0.04~0.108 0.30 clearance axial crank and thrust shoe 0.13~0.28 0.40 clearance connecting journal diametric 0.04~0.097 0.30 bearing clearance connecting rod large end and axial 0.10~0.30 0.60... - Page 10 intake valve rod and valve guide diametric 0.031~0.069 0.20 hole clearance exhaust valve rod and valve guide diametric 0.044~0.082 0.25 hole clearance height 0.05~0.12 difference backlash of all timing gears clearance 0.10~0.15 0.50 Rocker arm shaft and rocker arm diametric hole clearance...
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Page 11: Chapter 5: Operation Of The Diesel Engine
Chapter 5 Operation of the Diesel Engine 5.1 Engine transportation When the diesel engine is transported, should lift the engine by engine hooks. When moving the engine, pay more attention to avoid damage the engine appearance, accessories, oil pipes, panel, etc. When long distance transportation is necessary, the air filter and silencer should be dismantled, use plugs and plastics to seal the air intake and exhaust hole, water pump inlet and outlet hole, fuel inlet and outlet hole. -
Page 12: Storage And Preservation
Engine exhaust pipe cannot be too long, also should reduce the turning, the corner should have bigger bendy semi-diameter, to avoid big pressure of exhaust and reduce engine output. 5.3 Storage and Preservation If the engine will not be used in a long period, should store and preserve it according following method: First, drain out the fuel, oil and cooling water from the engine. - Page 13 5.4 Fuel, oil and jacket water Diesel Fuel oil: The diesel engine should use following specification oil according form 1: Form 1 fuel oil specification Fuel oil specification GB252 light diesel oil Above 0 ℃ －10℃～－20℃ Atmospheric Temp. 0℃～－10℃ Diesel oil brand Please clear the fuel oil for at least 72 hours before filling it into the fuel tank , then Pick up the top clean fuel oil.
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Page 14: Prepare For Starting
Level: The suitable oil level should be between top and bottom level of the oil sump gauge. Do not use inferior quality oil ! Do not use mixed or recycled oil ! Cooling Water: Avoid Water. Prefer to use always coolant. In case coolant is not available, Use clear soft water, such as rain water, or tap water, etc. -
Page 15: Starting
3. Open the fuel tank valve, and let out the air from the fuel system. At the same time, check if there are any leaks from each fuel pipe, and call the technical support or try tightening the nuts at the pipes ends. 4. - Page 16 6. Check if the oil pressure is ok, and then adapt the speed handle gradually to make the speed meet 75%~80% of the standard speed. Then run without load. 5.7 Running the Engine 1. Only when the temperature of the cooling water reach 50~60℃ and oil temperature reach 40~50℃, can operate the engine with load.
- Page 17 5.8 Stopping the engine 1. Before stopping the engine, unload first, decrease the engine to the idle speed gradually, also cut off the clutch system. When the water temperature falls down below 70°C, operate the stop handle to stop to stop the engine. 2.
- Page 18 Chapter 6 Technical Maintenance of diesel engine In order to work well and reliability for diesel engine, keep better technique capability, reduce abrasion of spare parts, extend the engine life, the users must carry out following maintenance rule carefully and regularly. Diesel engine maintenance criterion: 1.
- Page 19 6.2 2 Class maintenance items (Every 100hours) 1. Carry out all of daily maintenance items 2. Replace oil in oil sump and cleanout oil sump and collection oil pump and scree assembly. 3. Clean out or replace oil filter after max. 200 working hours in total. 4.
- Page 20 8. Check and see if electric equipment and wires connection is fitted and if lead touching is well. In case burnt, must be clean up and replaced. 9. Check and see if moving capacity of rotor for turbo charger is in stated range. When necessary, should repair or replace.
- Page 21 Chapter 7 Troubleshooting Start failure Cause Remedy and method Jammed in filter and fuel system Dismantle and clean Air trapped in fuel system Went the air from the system and fixed all pipe Fuel supply time wrong Adjust the supply time Injector sprays abnormally Check and adjust injector fuel pressure , clean or replace valve...
- Page 22 Inefficiency power Cause Remedy and method Please refer to item 5 “ hard to start “ , if any parts Less pressure in cylinder exceed wear out limit , replace it. Fuel supply time wrong Adjust the supply time Valve gap wrong Adjust it Each cylinder fuel supply is Adjust injector pump fuel supply...
- Page 23 Unusual pounding noise Cause Remedy Fuel delivery advance angle Adjust the fuel delivery advance angle is not correct Air in the fuel system Drains the air in the fuel system. Fuel delivery not balanced Adjust fuel delivery of every cylinder injection pump Fuel quality bad Replace the qualified fuel Parts fray over the limits...
- Page 24 Engine Overheated Cause Remedy Cooling water temperature over high Cooling water insufficient Fill the water tank full, improve the water lever to make the cooling water high than the water pump center Water pump Check the water pump and belt to eliminate leaking Too much furring in the cooling Eliminate the furring...
- Page 25 Needed Tools Tool and meter name Purpose To adjust the intake and exhaust valve rocker valve clearance gauge clearance valve key dismantling tool To dismantle the intake and exhaust valve and valve spring To lap the sealing face between intake and valve lapper exhaust valve and seat ring piston ring dismantling tool To check and replace the piston ring...