Remington Diesel 6126 Series User manual

Ⅰ
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Operation Manual
Engine Series 6126
(6126AZLD-4/6/7/8)
Remington Diesel Engines Manufacture

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Content
Chapter 1 Description…………………………………………………………1
Chapter 2 Diesel Engine Operation and Attention.……………………………2
Chapter 3 Diesel Engine Safety Operation Specification……...………………4
Chapter 4 Diesel Engine Main Technique Performance…………….…………5
Main Technical Specifications…………………………………………5
Technical Data………………………….………………………………6
Fit Clearances and Wear Limit of Main Parts ………………………………8
Chapter 5 Operation of the Marine Diesel Engine…………………………… 9
Transportation………………………………………………………… 9
Installation………………………………………………………………9
Storage and preservation ……………………………………………11
Fuel, oil and jacket water ……………………………………………12
Prepare for starting……………………………………………………13
Starting ………………………………………………………………14
Running…………………………………………………………………15
Stopping ………………………………………………………………16
Run in Operation rule for the new diesel engine ……………………………17

Ⅱ
Chapter 6 Technical Maintenance of diesel engine………………………18
Working day maintenance ………………………………………18
First grade technique mainenance….………………………………18
Second grade technique mainenance………………………………19
Third grade technique mainenance ………………………………20
Chapter 7 Trouble and Remedy Method…………………………………21
Start failure……………………………………………………21
Inefficiency power ……………………………………………22
Abnormal exhaust smoke…………………………………………23
Unusual pounding noise……………………………………………24
Oil pressure drop to zero or lacking pressure………………………25
Engine Overheated Engine Overheated……………………………26
Engine Overspeed…………………………………………………26

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Chapter 1 Description
6126 series diesel engine for our company in introducing, digesting, absorbing the
domestic and foreign advanced technology foundation, develop the successful high power
series diesel engine. This machine has the characteristics of compact structure, high
reliability, advanced technology index, good startup performance, simple operation,
convenient maintenance and excellent economic performance.
6126 series diesel engine can be widely used in heavy truck, loader, bulldozer,
excavator, crane and other engineering machinery and small power station. To maximize the
use of different users.

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Chapter 2 Diesel Engine Operation and Attention
The diesel engine be tested by the test rule before leave the factory, accelerator and
govenor be sealed by lead.
1- Do not use the bad quality or unclear fuel and oil.
2- Use the soft fresh water to cool the diesel engine, must not cooled by sea water
directly.
3- It’s forbidden to work at intake system leak and without air cleaner.
4- It’s forbidden to work and start at less oil and water.
5- It’s forbidden to work at long time overload and such against work regulation.
6- It’s forbidden to test the generator by short circuit method.
7- Control the starting time and spacing at electric starting.
8- Technique maintenance at fixed period.
9- Drain out the cooling water to prevent the cylinder frost cracking at the ambient
temperature lower zero℃.
10-Inject hot water and oil at the ambient temperature lower than -5℃.
11- Do some test run as this description before using the new engine.
12-Do not speed up suddenly and running with load after the engine start without load.
13-Identify the safety mark at engine operation.
Pay attention the above items.

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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.
3- The engine is not permitted to be started unless all preparation work for the engine
starting has been done.
4- Attention to the fire protection at the engine running, the fuel tank should be provide
a fire prevention device.
5- While the engine is operating, it is not permitted to be dismantled, checked and
adjusted.
6- Emergency stop the engine at oil pressure lower even falls to zero, or with abnormal
sound inside while engine running.
7- Once the engine overspeeds suddenly due to out of control, push the stop lever
immediately to stop the engine, then check the cause and remedy the fault. If the stop
lever is out of order, push down the decompression lever or block up the air inlet port
to stop the engine.
8- The circuit system should be overhauled by the professional electrician or one knows
well electricity knowledge.
9- The engine should be used in ventilation area to prevent the waste gas pollute the
working environment.

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Chapter 4 Diesel Engine Main Technique Performance
Engine Main technique specification
Model
6126ZLD4
6126ZLD7
6126ZLD8
Type
In line, water cooling, 4 stroke, wet cylinder, direct injecting
combustion chamber, electrical starting
Intake
Turbocharged inter-cooled
Turbocharger air cooled system
Pulse type
Lubricate type
pressure, splash combined type
Cooling type
Water cooled
Crankshaft rotation direction
inverse (face to the flywheel)
Cylinder no.
6
Bore × Stroke mm
126×130
126×155
Displacement L
9.726
11.596
Pressure ratio
16 : 1
Firing order
1 –5 –3 –6 –2 –4
Rated output kW
250
308
345
Rated speed r/min
1800
1800
1800
Prime output kW
260
320
350
Highest speed r/min
1800
1800
1800
Average effective pressure kPa
1834
2056
2125
Fuel consumption rate g/kW.h
turbocharged and after cooled：≤210.0
Oil consumption rate g/kW.h
≤1.68（after run in）
Lowest load stable speed r/min
/
Lowest idling stable speed r/min
600 ±50
Net mass kg
850~900
Dimensions (L × W × H) mm
1640×740×1120

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Technique Data
1. Each kind of temperature, pressure scope
（at 12 hours power rating）
1）lubricating oil temperature : ≤105℃
2）Outlet water temperature ≤95℃
3) main oil passage oil pressure: 0.35~0.55MP(Idle ≥0.10MPa)
4）Exhaust gas temperature: ≤600℃(at manifold branch)
5）Injection pressure: 22.5+1.0Mpa
2. Tightening Torques of main bolts and nuts
1）cylinder head bolts: 320±25N.m
2）cylinder head bolts:140±20N.m
3）main bearing bolts: 250
25+
N.m
4）connecting rod bolts: 225±25N.m
5）flywheel bolts: 260±20N.m
6）fuel Injection angle bolts Palette: 130+10N.m
3. Main Adjustment Data
1）Valve clearance (cooled)
Intake valve：0.30~0.35mm exhaust valve：0.40~0.45mm
2）Compression clearance: 1.0 ~ 1.20mm
3）Commencement of fuel injection (in rank angel)
1500~1800r/min type：16±1° ; 2000~2200r/min type：25±1°
4. Valve timing (in crank angel)
Intake valve opens: before TDC 34~39°
Intake valve closes: after BDC 61~67°
Exhaust valve opens: Before BDC 76~81°
Exhaust valve closes: After TDC 26~34°

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Clearances and wear limits of main parts
No.
Description
Coordinate nature
Clearances
(mm)
Wear
limits(mm)
1
Main journal and bearing
diametral clearance
0.095~0.163
0.17
2
Crank and thrust shoe
axial clearance
0.052~0.255
0.35
3
Connecting rod journal and bearing
diametral clearance
0.059~0.127
0.16
4
Connecting rod large end and crank fillet
surfaces
axial clearance
0.15~0.35
/
5
Piston skirt and cylinder liner hole
diametral clearance
0.143~0.182
0.35~0.40
6
Piston pin and connecting rod small end
bushing hole
diametral clearance
0.045~0.066
0.10
7
First compression ring and ring grooves end surfaces
Clearance
0.07~0.102
0.28
8
Second compression ring and ring grooves end surfaces
clearance
0.04~0.075
0.26
9
Oil ring and ring groove end surfaces
clearance
0.04~0.075
0.26
10
Gap of first compression ring
in the cylinder
在标准缸径
量规内测量
measure
under the
standard
bore gauge
clearance
0.35~0.60
1.0~1.20
11
Gap of second compression ring in
the cylinder
clearance
0.25~0.40
1.0~1.20
12
Gap of oil ring in the cylinder
clearance
0.35~0.55
1.0~1.20
13
Camshaft supporting journal and bushing
hole
diametral clearance
0.04~0.12
0.20
14
Camshaft and thrust plate
axial clearance
0.10~0.40
0.55
15
Valve tappet and cylinder block tappet hole
diametral clearance
0.025~0.089
0.15
16
Intake valve rod and valve guide hole
diametral clearance
0.03~0.066
0.10
17
Exhaust valve rod and valve guide hole
diametral clearance
0.05~0.086
0.15
18
The cylinder liner protrudes organism
compaction altitude
height difference
0.02~0.07
/
19
Rocker arm shaft and rocker arm hole
diametral clearance
0.04~0.119
0.20
20
Backlash of all timing gears
clearance
0.15~0.33
0.45

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Chapter Five Marine engine Operation
Engine transportation
When the diesel engine is transported, should lift the engine by engine hooks . 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 . If necessary, pack the engine properly and
transport.
Installation
1. The diesel engine should install on horizontal, firm surface. When connected with
marine gear box, marine generator or other transmission equipment, its axes angle
must be adjusted and controlled in 0.13mm . The flywheel and connected axes must
keep 1.0-3.0mm clearance, to avoid damage the engine when affected by the reaction
of the axes.
2. When install the marine engine, allow 8°vertical gradient , the same gradient of
power output exes and impel axes with the parallel should no more than 0.08mm .
Users should check , measure and adjust it , to avoid big vibration cause by out of
center , then output descend and exes、flexible pin and gear tooth irregular wear ,
cause engine body and ship body.
3. User can change the engine crankshaft head independently in the allowed output , to
bring the ship necessary accessorial equipment , such as fire pump set 、fish tackle
etc . However should install transmission exes and clutch between the marine engine
and transmission equipments, not allow accessorial equipment and crankshaft be
drive by transverse reaction, to avoid damage the crankshaft.
4. Engine exhaust pipe can not be too longer, also should reduce the turning, the corner

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should have bigger bendy semi diameter, to avoid big pressure of exhaust and reduce
engine output.
5. Inlet pipe of the seawater should on the lowest position of the ship cabin, and should
install a filter to avoid absorb impurity. Inlet pipe should with check valve, to avoid
inundation from seawater .
6. Seawater pump is not installed on the marine engine directly, user can install it in the
cabin according pump’s direction of rotation . Please note when install it, the pump
can be adjusted from left to right position , also can adjust the flexibility of the
transmission belt .
Storage and Preservation
If the engine will not be used in a long period, should store and preserve it according
following method:
1. First drain out fuel, oil and cooling water from the engine.
1. Demount the injector , put 200G dehydrated clean oil to each cylinder , turn
crankshaft to make oil on every part surface symmetrically, then install the injector
and fixed it well .
2. Warp up the air filter with plastic film, dismantle the silencer and plug up the exhaust
hole with wooden plug.
3. Wipe off the dirty oil 、dust and rust from the surface of the engine , smear the
unpainted parts surface with thin layer of anti-rusting grease, then cover it with clean
paper . Finally pack the engine with plastic bag.
4. The preserved engine should be stored in well ventilated, dry and clean place, it is
strictly forbidden to be putted together with corrosive substances.
The effective period of this method is 3 months, when the time exceeds the period,
please repeat this procedure.

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1. 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
Atmospheric temperature
Above 0 ℃
0℃～－10℃
－10℃～－20℃
Diesel oil brand
0＃
－10＃
－20＃
●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. The fuel oil must be strictly filtered when filled to the fuel
tank.
2. Lubricant oil
●The diesel engine should use following specification lubricant oil according form 2:
form 2 lubricant oil specification
Lubricant oil
specification
Level
Brand
Temperature
GB11122 oil
CC & CD
30＃& 40＃
5℃
20W/40～50＃
<5℃～－15℃
15W/40～50＃
－15℃～－20℃
●Capacity demand: The suitable capacity should be between top and bottom level of the
oil sump guage.
！Forbid to use inferior quality oil !
Forbid to use mixed oil !
3. Cooling Water
●Please use clear soft water, such as rain water, river water, etc.

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●If it is hard water, such as well water and spring water which contains much minerals,
please boil, precipitated and filter before use.
●When the temperature below 0 ℃, antifreeze mixture can be used for cooling. The
antifreeze mixture can be mixed with water and alcohol.
！
Forbid to put sea water into engine for cooling !
Prepare for starting
1. Check if the diesel engine fixed properly and connected reliably. The control system
is flexible.
2. Check the oil sump and injector pump, if the oil meets the standard level. Check if
the fuel tank with full fuel, fuel system expedite.
3. Open the fuel tank valve, went out the air from the fuel system. At the same time,
check if there are leaking from each fuel pipe. If find such matter, please solve out
immediately.
4. Check if the fresh water tank of head exchanger with full cooling water, each water
pipe leaking or not.
5. Check if every accessories connected properly , battery is sufficient , circuitry work
well.
6. Check if the clutch system is cut off.
！Without promise, forbid to start the diesel engine !
Starting
1. Keep the control handle of the fuel valve to the position where the fuel will be
delivered rather more or moderate speed.
2. Turn the circuit switch clockwise and close the circuit.

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3. Turn the starting switch to the“starting position ”, after the crankshaft is speeded up
by the starting motor , the engine is started then .
4. Please note: Each starting no more than 10 seconds to protect the motor and battery.
If start continually, the interval time should be more than 2 mins. If three times start
failed , please do not start until the problem is found out and be eliminated.
5. As soon as the engine start, turn the starting switch back to the previous position.
Turn on the circuit, let the alternator product electricity to the battery. A the same
time, adapt the fuel valve to moderate speed to see if the diesel engine run properly.
Check if the oil pressure ok, then adapt the speed handle gradually to make the speed
meet 75%~80% of the standard speed. Then run the engine without loading.
Running
1. Only when the temperature of the cooling water reach 50~60℃and oil temperature
reach 40~50℃, can operate the engine with load. When the water temperature reach
80℃, operate the engine at full load.
2. The engine speed and load should be increased and decreased gradually. In general,
Shouldn’t increase and decrease rapidly.
3. When the engine is working, should pay attention to each data of the meter and
observe the color of the exhaust smoke, listen to the voice inside . If any problem,
should stop the engine immediately and remedy it.
4. It is forbidden to let the engine running at idle speed for long time
5. The injection pump has been adjusted rightly before leaving factory , it is forbidden
for user to change it at will . If necessary , it should be adjusted at the injection pump
equipment.
Note: new diesel engine or just overhauled engine, it is permitted
! to run at full load only after it has worked over 60 hours !

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Stopping
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℃, operate the stop handle to stop to stop the engine.
2. After stopping, should take the circuit switch , close the fuel tank valve .
3. When the temperature under 0℃, if do not use the antifreeze , should drain out the
cooling water from the engine to avoid damage the engine body and water pump . If
with antifreeze, it is unnecessary to drain out the water.
Note: Forbid to stop the engine by shutting off the valve of the fuel tank !
！Forbid to stop the engine suddenly at high water temperature !

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New engine adjusting period principle
From the experience, new engine life , working stability and economical mainly
depends on previous adjusting period . Thus user should operate the engine under new
engine adjusting principle.
Number
Load
Running time
Note
1
Idle load
20 mins
-During adjusting period, fuel valve should
at full open position, load can be estimated
by left load form, but must know the
principle of increasing load gradually.
-During running period, pay attention to
water temperature, oil pressure, and oil
increasing temperature. Listen carefully if
strange sound. If any problem, stop engine
and remedy immediately.
2
25% load
1hour 40mins
3
50% load
13 hours
4
75% load
30 hours
5
100% load
15 hours
6
total
60 hours

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6.Marine engine ‘s technology maintenance
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.daily maintenance(carry through Each class)
2.Top of technology maintenance(carry through After working 100hours in Total)
3. Second of technology maintenance(carry through After working 500hours in Total)
4. Third of technology maintenance(carry through After working 1000hours in Total)
Daily maintenance items
1. Check the oil sump face of diesel engine should be keeped between fuel guage up
and down scale. When not enough, must be filled.
2. Checked the oil in speed governor of injection pump should be keeped on stated
situation, when not enough, must be filled.
3. Check the freshwater capacity in heat changer, when not enough, must be filled.
4. When the temperature is below 0℃, cooling water should be filled antifreeze and
dropt it when engine stop.
5. Check and screw down the tight and fitted parts outside of diesel engine, remove the
leaking oil, water and air matter in timely.
6. Clean out dust and smeary on surface of engine, keep engine cleanness
7. Guarantee cleanness and dryness of electric equipment and wires, clean out all of
fault and abnormality phenomena when diesel engine running.

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Top of technology maintenance items
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. Cleanout or replace oil filter.
4. Cleanout fuel filter or replace new filters after working 200hours in total
5. Checked the screw moment of screw in cylinder head and see if the valve distance
get to stated request.
6. Clean out the dust in plate for dust and surface of air filter, clean out dust and ash in
exhaust pipe and muffler
7. After working 200hours in total, check the injection pressure and injection
atomization instance, cleanout valve parts and readjust injection pressure when
necessary.
8. Checked voltage of battery and ACID rate should be keeped between 1.27 and
1.28(atmosphere tempture 20℃).If rate is below 1.14, should charge the battery.
Second of technology maintenance items
1. Carry out all of top of technology maintenance items
2. Checked work of injection pump, adjust oil supplying advanced angle .When
necessary, should readjust oil capacity of injection pump on testing bed.
3. Checked seal ring of intake and outtake valve and clean out cumulated carbon. When
necessary, should whet and correct and readjust valve distance get to stated request.
4. Checked the tightness and fitted instance of connecting rod screw, main bearing
screw, cylinder head screw and flywheel screw should be suitable with screw moment.
5. Cleanout or replace air filter.
6. Cleanout the sewage in cooling system, lotion should be used caustic soda (NaOH)
plus 1 liter water to be mixed. Before cleaning, let out water fully, then filled with
lotion. After 8-12 hours, restart diesel engine and stop when water temperature get to
working temperature about 80℃, then let out lotion at once. Finally, cleanout whole
cooling system by cleaning water.

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7. Checked working instance for thermostat and leaking instance for hole for releasing
water. If leaking is serious, should be replace water seal.
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.
Third of technology maintenance
1. Carry out all of second of technology maintenance items
2. Check each spare parts of diesel engine and adjust and necessary maintenance.
3. Remove and check alternator and startor. Clean up bearing and fill with new
lubricant, meanwhile check and see if start gear abrasion.
4. Remove and check cylinder head, cylinder line, piston and piston rings, cleanout the
water, oil smudgy and cumulate carbon and clean up again.
5. Check and measure piston and piston ring’s abrasion instance.
6. Check and measure the abrasion instance of holes inside of cylinder line.
7. Check and measure abrasion instance of each shaft neck for crankshaft and clean up
each oil way of crankshaft.
8. Check and measure abrasion instance of main bearing and connection rod bearing.
9. Clean up each oil way for engine body and replace oil.
10.After reinstalling the engine, make the engine work and work must be according to
new canonical running rules after try to be running.

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Chapter seven Troubleshooting
Start failure
Cause
remedy 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
Insufficient compress pressure
Check or replace piston ring, cylinder liner and valve. If
the cylinder head gasket leak steam, please screw well the
cylinder head bolt, If any damage of cylinder head gasket,
please replace it .
Valve gap wrong
Adjust the valve gap and aim at gear tooth as sign
Battery is insufficient
Recharging the battery
Connecting of electric device is
not good
Check and tight the connection
Temperature is low , oil is too
viscous
Make the water and oil to be higher temperature