Remington 495 User manual

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.
95/100 Series Engine Operation Manual
Manual de Operación Motores Serie 95 & 100

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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
5.1 Transportation
5.2 Installation
5.3 Storage and preservation
5.4 Fuel, oil and Coolant Jacket
5.5 Prepare for starting
5.6 Starting

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5.7 Running
5.8 Stopping
5.9 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
6.4Third grade technique maintenance
Chapter 7: Trouble and Remedy Method

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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. The Rated Power is similar to the marine main engine
rating for continuous operation.
Chapter 2
Diesel Engine Operation and Hints
Every Diesel engine is tested at our factory during several hours according to ISO
standards, and submitted to extreme temperatures and overload.
Do not use bad quality or unclear fuel and oil.
Use the only diesel engine coolant in the radiator. Avoid tap water and never use
seawater.
Don not to operate without an air filter in good conditions and clear of dust.
Do not operate or start the engine unless the oil and coolant levels are at its full level.
Do not work at long time overload and such against work regulation.
Do no test the alternator or any electric parts by short circuit method.
Control the electric starting time and spacing between starting attempts.
Apply technical maintenance at fixed periods.
Drain out the cooling water to prevent the cylinder frost cracking at the ambient
temperature lower 0 ℃.
Inject hot water and oil at the ambient temperature lower than -5℃.
Do some test run as describe in the next chapters before using the new engine.
Do not speed up the engine suddenly and run with load, after the engine has been
started without load. Acceleration must be done slowly.
Identify the safety mark at engine operation.
Follow all the recommendations and security steps as instructed by your local
technical support.
Pay attention to all the above advices.

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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 the preparation protocol for the
engine starting has been completed.
4. Attention to the fire protection at the engine running, the fuel tank should be
providing a fire prevention device.
5. While the engine is operating, it is not permitted to be dismantled, checked and
adjusted.
6. Apply the emergency stop of the engine, when the oil pressure is lower or even falls
to zero, or with abnormal sound inside while engine running.
7. Once the engine over-speeds 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 altered only by the technical support.
9. The engine should be used in a well ventilated area to prevent the exhaust gas
pollute the working environment.

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Chapter 4
4.1 Engine Main Techincal Specification
Model
495/4100
Type
In line, water cooling, 4 stroke, wet cylinder, direct injecting
combustion chamber, electrical starting
Intake
Naturally or turbocharged or after-cooled.
Turbocharged System
Stable pressure type
Lubricating System
pressure, splash combined type
Cooling System
Liquid cooling (Water or Coolant)
Crankshaft rotation
Inverse (face to the flywheel)
Cylinder no.
2 (2100) or 4 (495 & 4100)
Bore X stroke mm
95 x 115 (95 Series) / 100 X115 (100 Series)
Displacement L
1.77L (2100) / 3.26L (495) / 3.54L (4100)
Pressure ratio
naturally type：17:1 / turbocharged type：16:1
Firing order
1-3-4-2
Rated output kW
18kW (2100) / 31kW (495) / 36kW (4100)
Rated speed r/min
1800
Highest speed r/min
1900
Average effective
pressure kPa
650
Fuel consumption g/kW.h
Naturally ≤239 Turbocharged ≤232 Turbocharged and after-cooled ： ≤218
Oil consumption g/kW.h
≤1.63（after run in）
Lowest load stable speed
1200 r/min
Lowest ldling stable speed
550 r/min

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4.2 Engine technical Data
(At 12 hours power rating）
Lubricating Oil Temperature:
oNaturally ≤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)
Injection pressure: 21±1.0Mpa
Tightening Torques of main bolts and nuts:
oCylinder head bolts: 130±10N.m
oMain bearing bolts: 150±10N.m
oConnecting rod bolts: 110±10N.m
oFlywheel bolts: 110±10N.m
oCrank Pulley bolts: 130±10N.m
Valve clearance(cooled):
oIntake valve: 0.30~0.40mm
oExhaust valve: 0.40~0.50mm
Main adjustment values:
oCompression clearance: 1.0 ~ 1.20mm
oCommencement of fuel injection (in rank angel) \

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1500~2200r/min type: 17±2°
Valve timing(in crank angel)
oIntake valve opens: before TDC 12°
oIntake valve closes: after BDC 38°
oExhaust valve opens: Before BDC 55°
oExhaust valve closes: After TDC 12°

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4.2 Fit Clearances and Wear Limit of Main Parts
No.
Description
Clearances
(mm)
Wear limits
(mm)
1
Main journal and bearing
diametric
clearance
0.04~0.108
0.30
2
crank and thrust shoe
axial
clearance
0.13~0.28
0.40
3
connecting rod journal and
bearing
diametric
clearance
0.04~0.097
0.30
4
connecting rod large end and
crank fillet surfaces
axial
clearance
0.10~0.30
0.60
5
piston skirt and cylinder liner hole
diametric
clearance
0.14~0.235
0.35
6
piston pin and connecting rod
small end bushing hole
diametric
clearance
0.024~0.05
0.10
7
first compression ring and ring
grooves end surfaces
Clearance
0.065~0.105
0.30
8
second compression ring and ring
grooves end surfaces
clearance
0.04~0.08
0.30
9
oil ring and ring groove end
surfaces
clearance
0.045~0.080
0.30
10
gap of first
compression ring in the
cylinder
measure
under
the
standard
bore
gauge
clearance
0.40~0.60
1.50
11
gap of second
compression ring in the
cylinder
clearance
0.30~0.50
1.50
12
gap of oil ring in the
cylinder
0.30~0.50
1.50
13
camshaft supporting journal and
bushing hole
diametric
clearance
0.062~0.125
0.25
14
camshaft and thrust plate
axial
clearance
0.05~0.15
0.40
15
valve tappet and cylinder block
tappet hole
diametric
clearance
0.04~0.082
0.20
16
Idling gear shaft and bushing hole
diametric
clearance
0.025~0.075
0.20
17
idling gear shaft and idler shaft
axial
clearance
0.038~0.095
0.25

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18
intake valve rod and valve guide
hole
diametric
clearance
0.031~0.069
0.20
19
exhaust valve rod and valve guide
hole
diametric
clearance
0.044~0.082
0.25
20
height
difference
0.05~0.12
21
backlash of all timing gears
clearance
0.10~0.15
0.50
22
Rocker arm shaft and rocker arm
hole
diametric
clearance

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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. If necessary, pack the engine properly and
transport.
5.2 Installation
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.
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.

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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.
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 .
Wrap up the air filter with plastic film, dismantle the silencer and plug up the exhaust
hole with wooden plug.
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.
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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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
Atmospheric Temp.
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.
Lubricant oil:
The diesel engine should use following specification lubricant oil according form 2:
Form 2 lubricant oil specifications
Lubricant oil
specification
Level
SAE
Temperature
GB11122 oil
CC or CD
30 or 40
5℃
20W/40～50
<5℃～－15℃
15W/40～50
－15℃～－20℃

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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.
Do not use hard water, such as well water and spring water which contains many
minerals, seawater or salt water.
When the temperature drops below 0℃, antifreeze mixture must be used for cooling. The
antifreeze mixture can be mixed with water and alcohol.
5.5 Prepare for starting
1. Check if the diesel engine is secured to the ground.
2. Check the oil sump and injector pump, if the oil meets the standard level. Check if
the fuel tank for full fuel, fuel system expedite.

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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. Check if every accessory is connected properly, battery has sufficient load, and the
electric system is work well and not overheating.
5. Check if the clutch system is disengaged.
6. Check for grease on the greasing points.
7. Check for loosen bolts and tighten.
8. Check for the transmission belts, to have the correct tightening.
5.6 Starting
1. Keep the control handle of the fuel valve to the position where the fuel will be delivered
rather more for moderate speed.
2. Turn the circuit switch clockwise and close the circuit.
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
the start attempts are continuously, the interval time should be more than 2 min. If three
times start failed, please do not start until the problem is found out and be eliminated.
5. As soon as the engine starts, turn the starting switch back to the previous position. Turn
on the circuit; let the alternator product electricity to the battery. At the same time, adapt
the fuel valve to moderate speed to see if the diesel engine runs properly.

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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. When the water temperature reaches
80℃, operate the engine at full load. You can reduce the speed of the engine, engage
the load and accelerate again, slowly to the rated speed.
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 appears,
should stop the engine immediately and calla the technical support.
4. It is not recommended to let the engine run at idle speed for long time. Warming up and
cooling down period should not exceed max. 5 min.
5. Do no run the engine with load, at idling speed, for more than 1 min.
5. The injection pump has been adjusted rightly before leaving factory, it is forbidden for
user to change it at will. If necessary, call the technical support.
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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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. 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: Do not stop the engine by shutting off the valve of the fuel tank!
Do not stop the engine suddenly at high water temperature.
Do not stop the engine at high speed over 1000RPM!
5.9 Run in Operation rule for the new diesel engine
The new engine´s operating life period, working stability and economics, mainly depends
on previous adjusting period. Thus user should operate the engine under the:
“New engine adjusting principle”.
Number
Load
Running
time
Note
1
Idle load
10 min.
1) 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 .
2) During running period , pay attention
to water temperature, oil pressure, oil
increasing temperature . Listen
carefully for strange sound. If any
problem, stop engine and remedy
immediately .
2
25% load
2 hours
3
50% load
15 hours
4
75% load
30 hours
5
100% load
45 hours
6
total
60 hours

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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. 1st Class Daily maintenance (Carry through each class)
2. 2nd Class maintenance (Carry through after working 100hours in Total)
3. 3rd Class maintenance (Carry through after working 500hours in Total)
4. 4th Class maintenance (Carry through after working 1000hours in Total)
6.1 1st Class “Daily”maintenance items
(max. every 12 hours).
1. Check the oil sump face of diesel engine should be kept between fuel gauges up and
down scale. When not enough, it must be filled.
2. Checked the oil in speed governor of injection pump should be kept on stated situation,
when not enough, must be filled.
3. When the temperature is below 0°C, cooling water should be filled antifreeze and dropt it
when engine stop.
4. Check and screw down the tight and fitted parts outside of diesel engine, remove the
leaking oil, water and air matter in timely.
5. Clean out dust and smeary on surface of engine, keep engine cleanness
6. 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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6.2 2nd 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. Clean out fuel filter or replace new filters after max. 200 working hours in total.
5. Checked the screw moment of screw in cylinder head and see if the valve distance
gets 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. Check the voltage of the battery and ACID rate should be kept between 1.27 and
1.28 (atmosphere temperature 20℃). If rate is below 1.14, should charge the battery.
6.3 3rd Class maintenance items
(Every 500hours)
1. Carry out all of the 1st class “daily” and 2nd class, maintenance items
2. Checked work of injection pump, adjust oil supplying advanced angle. When
necessary, and should readjust oil capacity of injection pump on testing bed.
3. Checked seal ring of in-take and out-take 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. (Depending on environment pollution).
6. If Water is used instead of coolant: 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°C, then let out
lotion at once. Finally, cleanout whole cooling system by cleaning water.
7. Checked working instance for thermostat, check any leaking instance and the hole
for releasing water. If leaking is serious, seal should be replaced.

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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.
6.5 4th Class maintenance items
(Every 1000hours)
1. Carry out all of the 1st, 2nd and 3rd Class maintenance items.
2. Check each spare parts of diesel engine and adjust and necessary maintenance.
3. Remove and check alternator and starter. Clean up bearing and fill with new
lubricant, meanwhile check and see if start gear abrasion.
4. Remove and check cylinder head, cylinder liner, piston and piston rings. Clean out
the water, oil smudgy and cumulated 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 reinstall the engine, make the engine work and work must be according to new
canonical running rules after try to be running.