Rotek 295 User manual

FOREWORD
Model 295,2100 Diesel Engine is a sort of the series 95,100 diesel engines
designed by China herself and also a standard model of the nation-wide
utilitzation. It is characterized by advanced index of economy and dynamics,
high level in standardization,systematization and commonality,and by easy
derivative in construction to satisfy the comprehensive utilization.
We hope that by the aid of this operation manual sent by us our users may
get familiar with the engine construction in a shortest possible time and be
trained skillful in operating so that the desired normal running of the engine is
ensured. This operation manllal gives a brief description on running,maintenan-
ce and repair of the engine and it is for your reference only.
The normal funning and service life of the engine not only depend· on the
manufacturing quality ~ but also on the reasonable use and careful maintenance.
So you'd better get yourself acquainted with engine construction, running and
maintenance beforehand if you want to keep your engine running well, working
in its best efficiency and lasting a longer time.
Contents inclosed in this manual which may be slightly different to the
actual condition of the engine will be frequently improved. Besides our
renewing the manuals periodically, the user shall also pay certain attention to this.
Since Model 295, 2100 Diesel Engine is a new product, there will certainty
be much room for improvement. We are looking forward to receiving suggestio
os from our users so as to better our engine quality.

CONTENTS
Longitudi11al and Transverse Sections of Model 295, 2100 Diesel Engine·············· 1
Mounting Drawings of Model 295, 2100 Diesel Engine •••••••••••••••••••••••••••••••••••••••, 2
Overall Dimensions of Model 295L,2100G Diesel Engine ••••••••••••••••••••••••••••••••••. 3
Load Characteristic curves of Model 295, 2100 Diesel Engine •••••••••••••••••••••••••••• 4
Speed Characteristic curves of Model 295, 2100 Diesel Engine •••••••••••••••••••••••••• 6
Chapter I. Technical Specifications of Model 295, 2100 Diesel Engine •••••••••••••• 8
A. Main Technical Specifica tions ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••. 8
B. Engine Main Data, Table of Fit and Wear Limits ••••••••••••••••••••••••••••••••, 9
Chanter II. Description of Main Components ••••••••••••••••••••••••••••••••••••••••••••••••••• 11
A. Cylinder Block ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••, 11
B. Cylinder head •••••••••••••••••••••••••••••••••••••••••••••••••••••••• ~........................... 13
C. Crankshaft and Connecting Rod ••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 14
D. Valve Mechanism •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 16
E. Fuel System ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••. 18
F. Lubricating System •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 19
(;. Cooling System •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 21
H. Electrical System •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 23
ella pter III. Opera tion •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 26
Adjustmen t of valve Clearance ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••. 28
31
.......................................................................................
Adjustment of the Decompressor ••••••••••••••••••••••••••••••••••••••••••••••••••••••••. 29
30
A. Fuel, Lubricating Oil and Cooling Water •••••••••••.•••••••••••••••••••••••••••••••• 26
B. Preparations for Starting the Engine •••••••••••••••••••••••••••••••••••••••••••••••••. 26
C. Starting and Running •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 27
0, Stopping ••••••••••••••••••••••••••••••••••••••••.••••••••••••••••••••••••••••••••••••••••••••••••••• 27
Chapter IV. Adjustment of the Engine •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••, 28
A. Adjustment of the Advance Angle of Fuel Delivery······························ 28
B.
C,
D. Adjustment of the Pressure of Lubricating Oil····································
Chapter V. Dismounting and Reassembly of the Engine and the Selection of
the Pulley Size
A.
Dismounting and Reassembly of the Engine •••••••••••••••••••••••••••••••••••••••••. 31
·E. TIle Selection of the Pulley Size ••••••••••••• ~ ••••••••••••••••••••••••••••••••••••••••••. 32
Cbaptel' VI. Main tenance of the Engine ••••••.••••••••••••••••••••••••••••••••••••••••••••••••••• 34
A. ROll tine Maintenance •••••••••.••••.•••.•••••••••••••••••••••••••••••••••••••••••••••••••••••• 34

13. First. Class Maintenance ,.••••••••••••••••••••••••••••••••••••••••••••.••••••••••••... :34
C. Secolld Class l\1aintellance ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••.• 35
D. Preservation and Storage of the Engine .•..........••••••••.••.•••••••••••••••••••... 36
(~Ilapter vn. TrO\lbleshootiIlg ••.••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••.• 37
A. ji';-lilll1'eto Start ••..••••..••••....••••••••••••••••••.•••••.••••••••••••••••••••••.•••••.....•..•. 37
B. Insufficient Output ..•••••••••••••••••••••••••••••••••.••••••••••••••••••••.••••••.••••.••..•• ;~8
C. Engine Stalls ..•••.•••....••.••..•.••.••••••••••.•••••••.••••••••••••.••••••••.••.••••.•.••.•.... 38
D. Overspeeding ••••••••••••••••••••.•••••••••••••••••••••••••••••••••••••••••••••••.••••••••••••••... 38
Ji:. Un()rdinary Noise ,39
f'. 8m oky Exlla list .•••••••,.•••••••.•••••••••••••••••••••••••••.••••••••••.•••••••••••••••••••••.•••• 39
(..i. Overheating 40
rl. Excessive Consumption of Lubricating Oil··········································· 40
I. Rising of Oil Level in the Oil sum p••••••••••••••••••••••••••••••••••••••••••••••••••. 41
.. J. I nsu ff icien tLu brica ti ng Oil pressure 41
K. Outlet Water Temperature Too High ···················································41
L. Ordinary Failure of Fuel Injection Pump and Their Remedies ••••••••...•.•. 42
M. Ordinary' Failure of the Governor and Their Remedies ••••.•••••••••••••••..... 43
N. Ordinary Failv.re of the Fuel Injectior and Their Remedies •••••••••••••••. 44
Appendix: Part Catalog •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• ~ •••••. 46

U?
o
(a) Longitudinal Section of Model 295, 2100 Diesel Engine
(b) Transverse Section of Model 295, 2100 Diesel Engine

Mounting Drawing~ of Model 295, 2100 Diesel Engine
2

3

Tr( °C }
400
3C)()
200
ge
(g/kWh)
315
300
285
270
255
240
~
~
\v
~
\vvV
/
\
------
~
/
~
~
\/
\
/~
, ./
v-
Ix
V
~'\
~
/
"".~
~
~
..---.-"
l/
Mf
(kg/h)
4.5
4.['
3.5
3.0
2.5
1.5
57.5 10 12.5 15 17.5 20
22.5Ne(kW)
295 Model Diesel Engine loud Chaructristics
4

Mf
300 t------.----.---..-~~___+_-____Poo-___+--....._......-..-~ (kglh)
200 .--.--+------t---+-----+----+-~~+___-_+__tI 4.5
4OO.----+----+-----+-------+--~--+---+--t
~ I
(gIkWh) II
315 .---.----.-----+-----+--#---t----+--H 4.0
I
I
300 I----f--.a.---f-------I-----..----+-----+--i-----t---t 3.5
240 -
I
285 t-----+---~_.T__~-----+-----+-~t----r--t 3.0
III
I __ .... 1---1' 2.5
270 ·--~------+---1IIlrII:--+---+--t---T
II
!II
255 .---+---+----+--~-~ --t-- 2.0
III
I I --11.5
II
I
57.5
10 12.5
15
17.5. 20 22.5Ne(kW)
5

Ne(kW)
22
2,0
18
16
14
12
10
ge(g/kWh)
2.55
2.50
2.45
II
II
I
~
-.....
I
~~
.............
~
~
~
~
/
r-------
/I
--
L
~
~
-~
I~
~
~
~
~
-----
~
./ ~
-V
.........
~
~
f/
l-
V
~
/I
~
/
~
~
~
~
~
~
V
~
~
J ~
.. ~
V
~
r-----.- ~
~I
-
I/
IVI
!/I
Tr(OC )
500
450
400
Me(Nm)
120
110
100
90
Mf(kg/h)
5.0
4.5
4.0
3.5
3.0
1000 ]200 1400
1600
1800 2000
n(r/min)
295 Model Diesel Engine speed Charactristics
6

Ne(kW)
22
20
18
16
14
12
10
ge(gIkWh)
2.55
2.50
2.45
I1
II
I
~
~
-r------- I
~
-------.
-----.......
V"
~
/'
I
I
I
~
~ "----1
VI
~
-V
~
~
I
","'" /
~
I
/'
~
V
'~I
/I
V' 1
I
/
//
~
~
~
I
~
;/
~
I
'/
I
\,
!
,
~
VI
XI
V
~ .......
~
vI
~
~
/
~
-... I
"I
i
Tr(OC )
500
450
400
Me(Nm)
120
110
100
90
Mf(kg/h)
5.0
4.5
4.0
3.5
3.0
1000 1200
1400
1600 1800 2000
n(rlrnin)
2100 Model Diesel Engine speed Charactristics
7

Chapter I. Technical Specifications of
Model 295, 2100 Diesel Engine
A. Main Technical Specifications
Specifications of the engines
Model
Type
N urnber of cylinders
Bore/Stroke
1 - hr. rating output
12 -hr. rating output
Cornpression ratio
Advance angle of fuel delivery
Total displacement
Mean effecti ve pressure
Specific fuel consumption
Direction of rotation of crankshaft
(view from flywheel end)
Cooling nlethod
Lubrication nlethod
Starting nlethod
Overall dinlensions
Net weight
Specifications of the Main Conlponents
Injection pump
Nozzle
Bubricating oil pump
Cooling
water pump
Fuel filter
Lubricating oil filter
i\ir filter
Starting 010tor
Generator
295~2100
Vertical in - line 4 - stroke water - cooled swirl
combustion chamber
2
95mm/ 115mm~ IOOmm/115n101
19. 3kW /2000r/min; 22kW /2000r/min
17. 6kW /1000r/nlin~ 20kw/2000r/n1in
20: I
15°- 17°
1. 630L, I. 806L
, 648kPa, 664kPa (12 -hr. rating output)
265. 2g/kW · h~ 263. 8g/kW · h
Counter - clockwise
Close type circulation
Combination of pressure and splash
Electric
620 x625 x790mnl
220 ±5kg
No. 1 injection pump, plunger dia. 8mm
ZS4SI ( A)
Inner - and - outer rotor type
Displacement;::: 12L/ min
Centrifugal type
Displacenlent ~ 70LI min
C0506( A) (paper cartridge)
J0708 (C) (paper cartridge)
K 1 706 (paper cartridge) for the stationary engine
QD1247A 1. 5kW 12V
2JF200(silicon rectified, 12V'I 180W)
8

Vol tage regulator
Battery
Thernlostat
V - belt
Ammeter
Water temperature gauge
Water temperature sensor plug
Oil temperature gauge
Oil pressure gauge
FrIll
6 - Q - 140 (provide for yourself)
Type 141
Type B1120
Type DT52
Type
302
Type 306
WT 102
QF - 308
B. Engine Main Data. Table of Fit and Wear Limits
Valve timing
Op~ning of the intake valve
Closing of the intake valve
Opening of the exhaust valve
Closing of the exhaust valve
Valve clearance
Intake (cold)
Exhaust (cold)
Clearance for decompression
Injection pressure
Bolts and nuts torque limits
Cylinder head nuts
Main bearing cap nuts
Connecting rod bolts
Flywheel bolts
Tenlperature and pressure at 12 hr.
rating output
Exhaust temperature
Lubricating oil temperature
Outlet cooling water temperature
Lubricating oil pressure
Lubricati ng oi I pressure at the
nlinirnum idling steady speed
C;ovenlor c haracteris tics
Maxirnunl speed
Millinlunl iding steady speed
Stable adjusting speed rate
9
17° before T. D. C.
43° after B. D. C.
43° before B. D. C.
17° after T. D. C.
O.35mm
O.40mm
1 ..... 1. 50un
13 + 1. OMPa
118 -137N -nl
137-157N-rn
79-108N· rn
98 -137N ·nl
~ 500'(:
~ IOOce
75 -- 95~=
196 -- 392kPa
49kPa
2200rpnl
~ 600rprn
~ 8lk (in Engineer) ~ ~ IOo/r (in 'rraclor)

...-
o
3. Table of fits and wear limits
Item
Assembly limits Wear
Designation Standard dimensions Type
of fit
limits
No.
(mm) (mm)
0
Crankpin
<J) 65 -0.02
Clearance 0.050---0.018
1
~ 65 +0.098
0.30
Connecting rod dearing
+0.050
Piston pin
fP 35 +0.011
20Clearance
O.O20~O.O56
0.12
Connecting rod small end bushing
CP 35 +0.045
+0.020
0
3Oil scraper gap 6
-0.015
Ring gap
O.O5~O.65
0.18
6
+0.05
+0.03
4
1st piston ring gap in bore Ring gap 0
.. 30--- 0.50
0.20
5
2nd- &3rd piston ring gap in bore
Ring gap
0.25-0.45
0.18
Crankshaft main journal 0
6
c!> 75 -0.020
Clearance
0.070......,0.138
O.2.C)
Main bearing hole
CI> 75' +0.118
+0.070
7Crankshaft thrust ring surface Axial clearance
O.O72~O.291
0.4
Crankshaft thrust surface
Camshaft journal til
46 -0.080
8
-0.105
Clearance
0.080--- 0.130
0.25
Bushing hole
<I> 46 +0.025
0

Chapter II. Description of Main
Components
A.Cylinder Block
1. Cylinaer block
2. Gear chamber
3. Injection pump gear
4. Dowel pin
5. Oil filler
6. Idle gear units
7. Gear chamber cover
8. Main plain bearing
(upper)
9. Oil seal
10. Gasket
11. Main plain bearing
(lower)
12. Gasket
. 13. Main bearing cap
14. Oil sump gasket
15. Oil sump
16. Main bearing nut
17. Thrust ring
18. Thrust ring
19. Expansion plug
20. Camshaft bushing
21. Flywheel housing
22. Side cover units
23. Seal ring
24. Cylinder liner
25. Water drai~ cock
26.
Name plate
27. CyLinder
head stud
28. Cylinder head nut
Fig. II -1 Cylinder Block
11

The cylinder block is designed in an arch style to strengthen its rigidity.
The distance between the centre line of the main bearing and the engine
undersurface is 120mm. The crankshaft is of full support type. The main bearing
caps and main bearing seats have match marks and are therefore not
interchangeable.
Athrust ring is installed on the flywheel side of the cylinder block for
recieving the axial thrust from the crankshaft. The cylinder liner is pressed into
the block.' On the lower part of the cylinder liner are mounted two rubber seal
rings used for prevention of water leakage. When the cylinder liner is installed,
its top surface should be 0.04 -- O.17mm above the surface of cylind.cr block
(see Fig. II -2). The center distance between cylinders is 124mm long.
In the front end of the cylinder block is mounted the gear chamber in
which all the timing gears are installed. In installation, all the marks on gears
must coincide without mistake (see Fig. II -3).
IdleCClu·
:~
Ft-!. II-2
Fig. n- 3 Installation Diagram of 'fiming Gears
12

In the rear end of the cylinder block is mounted the flywheel housing and
on the undersurface of it the oil sump is located for the purpose of storing
lubricating oil.
B. Cylinder Head
Fig~ II -4 Cylinder Head
The cylinder head is of monoblock type and is mounted on the cylinder
block with ten M14 studs. Between the cylinder head and the cylinder block
the gasket made of copper and asbestos is placed. Intake and exhaust ports are
respectively located on both sides of the cylinder head. On the cylinder head,
;ntake and exhaust valve seat inserts and the swirl chamber inserts in the shape
of the shallow basin are inlaid. The upper part of the cylinder head are
mounted four valve guides and the rocker arm mechanism. The intake and
exhaust valves are fitted in the valve guides.
To serve as starting auxiliaries, a decompression mechanism is mounted on
the cover of the cylinder head. The intake and exhaust manifolds are located on
both sides of the cylinder head respectively.
C. Crankshaft and Connecting Rod
The crankshaft made of magnesium-rare earth nodular cast iron is mounted
on the main bearing. It has two hollow crankpins. The crankshaft is provided
13

on the main bearing. It has two hollow crankpins. The crankshaft is provided
with rubber oil seals both in the front and rear. The flywheel is positioned
with <1>10 dowel pins and fixed to the flange of the crankshaft with six bolts to
ensure that the flywheel is mounted in correct position. The marks h..t~'
lneaning ,. the T.D.C." and ., 16" meaning "the advance angle of fuel
delivery", are made on the periphery of flywheel and used for adjusting
injection timing and valve timing.
Thin-wall bearing shells made of steel back covered with a layer of high tin
-aluminium alloy are used for main bearings and connecting rod bearings. The
clearance between the journal and bearing is not adjustable. If the clea-rance is
over its wear limits. It is necessary to renew a standard-sized bearing or a
undersized one after the crankshaft being refinished. When the bearing shell is
inserted in the bore and the cap, it will be noted that a small lip has been
pressed into one half of the bearing shell and a corresponding notch is provided
in the bore. This lip, When dropped into the notch, Positions the shell and also
prevents it from turning in the bore with the rotation of the crank-shaft. (see
Fig. II -5).
The piston is made of aluminium alloy. Each piston is equipped with four
piston rings made of alloyed cast iron. The upper three of them are compressi
on rings (The first ring is chromium plated.) The fourth rings are oil scraper
flng. The piston pin is of full-floating type. When the piston reaches a specified
temperature,the piston pin can rotate in the connecting rod bushing and in the
piston pin boss. But at room temperature, the piston pin is fitted in the pin
hole with interference. So before installing or removing the piston pin the piston
should be heated to 80 0-.- 100 °C .
The connecting rod is made of forged medium carbon steel The rod body
IS of "I" section. The centre line of the connecting rod is at an angle of 45
o with repect to joint plane of the connectiQg rod and the rod cap. The
connecting rod and the rod cap are located by two dowel bush .• ngs and bolted
together by means of two bolts. and locked with lock wires. (see Fig. II -6)
14

Vl
1. Crankshaft
2. Fly"rheel
3. Ring gear
4. Timing gear
5. Crankshaft pulley
6. Starting jaw
7. Washer
o
8. Front oil thrower
9. Rear oil thrower
10. Lock washer
11. Tightening bolt
12.
Cylindrical pin
13. Flat key
1Yr:v,
I. \
~-r.J)
·'1,-/
Fig. 1I -5 Crankshaft and Fly\\reel

1. Compression ring( 1)
2. Compression ring(2,3)
3. Oil scraper ring
4. Piston
5. Piston pin
6. Connecting rod bushing
7. Connecting rod
8. Connecting rod cap
9. Connecting rod bolt
] O~ Connecting rod bearing
11. Piston pin circlip
12. Dowel bushing
13. Lock wire
Fig .II - 6 Piston and Connecting Rod
D. Val ve Mechanism
The camshaft is made of magnesium-rare earth nodular cast iron and
mounted in the three camshaft bearings which are installed on the cylinder
block. Mounted in the front end of the camshaft is a timing gear behind which
is a thrust plate controlling the end play. The cams control the opening and
closing of the valves by means of the valve tappets, push rods and rocker
arms. A proper valve clearance between the top of the valve stem and the
rocker arm should be maintained in order to meet the requirements of the valve
timing.
The bottom of the valve tappet is flat and has undergone heat-treatment to
111CreaSe wear resistance. There is a relative deviation of the centre line between
the tappet and cam, which can cause the tappet to rotate round its centre line
in operation and wear evenly in surface.
16