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MINSK D-260.1S3? Operation & Maintenance Manual

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Open Joint Stock Company
"MINSK MOTOR PLANT" Holding Managing Company"

Diesel engines

D-260.1S3А, D-260.2S3А, D-260.4S3А
OPERATION & MAINTENANCE MANUAL
Minsk 2013

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Summary of Contents for MINSK D-260.1S3?

  • Page 1: Diesel Engines

    Open Joint Stock Company "MINSK MOTOR PLANT" Holding Managing Company" Diesel engines D-260.1S3А, D-260.2S3А, D-260.4S3А OPERATION & MAINTENANCE MANUAL Minsk 2013...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1 DESCRIPTION AND OPERATION ..............................4 1.1 DIESEL ENGINE DESCRIPTION AND OPERATION .......... E RROR OOKMARK NOT DEFINED 1.1.1 Diesel engine application ..................Error! Bookmark not defined. 1.1.2 Technical specifications .................... Error! Bookmark not defined. 1.1.3 Diesel engine components ..................Error! Bookmark not defined. 1.1.4 Design and operation ....................
  • Page 3 4.1.1 General instructions ............................. 141 4.1.2 Safety measures..............................143 4.2 ENGINE COMPONENTS CURRENT REPAIR ......................144 4.2.1 General instructions on piston rings replacement ....................145 4.2.2 General instructions on the valves grinding ......................146 4.2.3 General instructions on water pump disassembly and assembly ................147 5 STORAGE ......................................

  • Page 4: Description And Operation

    This Manual is intended for use by operators, drivers and engine mechanics of agricul- tural tractors, combine harvesters and agricultural machinery equipped with diesel en- gines D-260.1S3A, D-260.2S3A, D-260.4 S3A as well as by personnel of technical service centres and repair shops performing technical service and repair of said diesel engines. This Operation &...

  • Page 5: Diesel Engine Description And Operation

    1. ENGINE DESCRIPTION AND OPERATION 1.1. Diesel engine description and operation 1.1.1 Diesel engine application Diesel engines application, application environment and operation conditions are shown in table 1. Table 1 Engine model Description D-260.1S3A D-260.2S3A D-260.4 S3A Wheeled tractors, 1,4; 2 drawbar Forage harvesters and wheeled Application categories...

  • Page 6: Technical Specifications

    1.1.2 Technical specifications Diesel engines technical specifications and operation parameters Table 2 Engine model Parameters Measurement unit D-260.1S3A D-260.2S3A D-260.4 S3A Values Diesel engine type 4-stroke, turbocharged with charge air cooling Fuel mixture method Volumetric fuel mixture formation Number of cylinders Positioning of cylinders In-line, vertical Swept volume...
  • Page 7 1.1.2.2 Controlled engine parameters Table 3 Engine model Measure- Parameters D-260.1S3A D-260.2S3A D-260.4 S3A ment unit Value ± confidence limit (tolerance) Rated output 116,0±2,0 100,0±2,0 156,0±3,0 − Rated speed − 2100 Specific fuel consumption at rated output g/ kW/ hour −...
  • Page 8 1.1.2.3 Measuring means for determining the controlled parameters Table 4 Measurement Measurement means basic ab- Note Measured parameter Measurement means unit solute error limit Strain and torque strength measuring For rated output ±0,005Мк max Torque devices according to State Standard calculation 15077-78 Electronic tachometers, ТЭСА...
  • Page 9 1.1.3 Diesel engine parts and components Diesel engine consists of parts, assembly units and sets. 1.1.3.1 Basic D-260S3A diesel engine assembly units Table 5 Assembly units and sets Cylinder block Water catchment pipe Cylinder heads mounting Water pump mounting Clutch mounting Fan mounting Turbocharger mounting Tensioner mounting...
  • Page 10 1.1.3.2 Key features of diesel engine models configurations Table 6 Engine model Units, parts D-260.1S3А D-260.2S3А D-260.4S3А Unit, part designation and (or) its description К27-61-08* "Turbo" (Czechia) К27-542-01 "Turbo" (Czechia) Turbocharger Compressor Single cylinder air cooled, controlled * or not not available НШ-10 or НШ...
  • Page 11 Continuation of Table 6 Engine model Units, parts D-260.1S3А D-260.2S3А D-260.4S3А Unit, part designation and (or) its description Clutch Friction type, dry, constantly closed-type, Friction type, dry, constantly closed-type, double-disk* or single disc or not available double-disk Alternator AC, rated voltage 14V or 28V...
  • Page 12 Fig.1 - Diesel engine D-260.1S3A...

  • Page 13: Design And Operation

    1.1.4 Design and operation Engines D-260.1S3A, D-260.2S3A, D-260.4 S3A are 4-stroke internal combustion pis- ton diesel engines with vertical cylinder positioning, direct fuel injection and ignition by compression. The basic engine assembly units are: cylinder block, cylinder heads, pistons, connecting rods, crankshaft and flywheel.

  • Page 14: Diesel Engine Labelling

    1.1.4.2 Diesel engine operation principle and its basic components interaction A diesel engine operation principle, like with all other internal combustion engines, is transformation of heat energy of the fuel burning inside in the working cylinder to me- chanical energy. When a piston moves down at the intake stroke through the open inlet valve an air charge comes into the cylinder.

  • Page 15: Packaging

    -inscription “Made in Belarus”in the English language . The engines officially approved according to EEC UN Rules No 96(01), EEC UN Rules No 24(03), Revised Edition No 2 and Directives 2000/25/ЕС, 97/68/ЕС Stage IIIА bear the sign of official engine type approval. The engines for which national certificates have issued for conformity to the rules of Bel- arus and other CIS countries bear the signs of conformity to the national certification sys- tems of the countries where those certificates have been issued.

  • Page 16: Description And Operation Of Diesel Engine Components, Mechanisms And Devices

    1.2 Description and operation of diesel engine components, mechanisms and devices 1.2.1 General information Diesel engine is a complex unit consisting of a number of separate mechanisms, systems and devices made of parts and units. The engine structure is shown in Table 7. Table 7 Units and parts making mechanisms, systems and Diesel engine configuration...

  • Page 17: Description And Operation

    1.2.2 Description and operation 1.2.2.1 Cylinder block Cylinder block is the main body part of the engine made as a cast iron monoblock. Placed in the monoblock bores are six removable liners made of special cast iron . Liners are fitted in the cylinder block along two centering zones. Each liner is fixed by a collar in the upper zone while in the lower zone it is packed with two rubber rings placed in the cylinder block grooves.
  • Page 18 1.2.2.3 Crank-and-rod mechanism The main parts of the crank-and-rod mechanism are: crankshaft with main end and big end bearings, flywheel, pistons with piston rings, connection rods. Crankshaft is made of steel, it has seven main end and six big end bearings. To reduce the load derived from inertia on the bearings, removable counter balan-ces are mounted on the 1 and 12...
  • Page 19 The pushers bars are made of steel rods and the bar cups are hardened. The spherical portion coming inside the pusher and the bar cup are hardened. The valve rockers are made of steel, they rock on the axle mounted in the racks. The rocker axle is hollow, it has six radial holes for the rockers lubrication.
  • Page 20 The crankshaft and camshaft bearings, the intermediate gear bush, the rockers bush, the pneumatic compressor crankshaft big end bearings, the turbocharger shaft bearing are lubricated under the pressure from the oil pump. The cylinder liners, pistons, piston pins, bars, pushers, camshaft lobes and fuel injection pump parts are lubricated by spraying. The lubrication system consists of oil pump 3, oil filter with paper filter elements 4, cen- trifugal oil filter 7, liquid-oil heat exchanger 6.
  • Page 21 1 - oil sump; 2 – oil receiver; 3 – oil pump; 4 – paper oil filter; 5 – by-pass valve; 6 – liquid-oil heat exchanger; 7 – centrifugal oil filter; 8 – oil pressure indicator; 9 – oil pressure alarm sensor; 10 – piston cooling injectors;...
  • Page 22 1 – high pressure fuel injection pump; 2 – Fuel feed pump (booster pump); 3 – oil duct; 4 – fine fuel filter; 5 – fuel pre-filter; 6 – hand fuel feed pump (priming pump); 7 – high pressure fuel accumulator; 8 – injector; 9 – electronic control unit radiator; 10 – cylinder head; 11 – exhaust manifold; 12 – intake manifold; 13 – turbocharger;...
  • Page 23 Fig.4а – Location of sensors and actuating mechanisms...
  • Page 24 Table 8 Sensor and actuating mechanism Location 1 Crabkshaft angle sensor Distribution cover High pressure fuel injection pump 2 Camshaft angle sensor housing 3 Fuel temeperature and pressure sensor Finr fuel filter housing 4 Oil temperature and pressure sensor Heat exchanger 5 Charge air temperature and pressure sensor Intake manifold 6 Fuel pressure sensor Fuel high pressure accumulator...
  • Page 25 igh pressure fuel injection pump igh pressure fuel accumulator 1- h ; 2 – h ; 3 – injector; 4 – Electronic Control Unit (ECU); 5 – pressure limiting valve; 6 – angle sensor; 7 – temperature and pressure sensor in the intake manifold; 8 – fuel high pressure sensor; 9 –...
  • Page 27 1.2.2.6.1 High pressure fuel injection pump Installed in diesel engines are High Pressure Fuel Injection Pumps (Fig. 6). High pressure fuel injection pump (HPFIP)is designed to create fuel reserve, keeping and regulatingpressure in the fuel regulator. Mounted on HPFIP are fuel priming pump 2 driven by camshaft 13 and pressure regula- tor 3.
  • Page 28 1 – High pressure fuel injection pump; 2 – fuel priming pump (feed pump); 3 – pressure regulator; 4 – angle sensor; 5 – fuel diversion from the fuel accumu- lator connector; 6 – oil inlet connector; 7 – oil orifice plug; 8 – oil diversion holes; 9 – fuel inlet connector from the fuel pre-filter; 10 – fuel otlet connector to the fine fuel filter;...
  • Page 29 1- high pressure fuel injection pump housing; 2 – camshaft; 3 – plunger; 4 – intake valve; 5 – inlet chan- nel; 6 - exhaust valve; 7 – outket channel; 8 – valve ball; 9 – electric magnet; 10 – armature; 11- pres- sure regulator;...
  • Page 30 1 – high pressure fuel accumulator; 2 – otlet connectors; 3 – inlet connector; 4 – back runoff connector; 5 – pressure limiting valve; 6 – valve core locking cone; 7 – fuel high pressure sensor. Fig. 8 – High pressure fuel accumulator Accumulator 1 has the shape of pipe at the ends of which are installed fuel pressure sen- sor 7 and pressure limiting valve 5.
  • Page 31 Fig. 9 – Injector Forming of the injector control signals by ECU works based on reading the signals formed by the crankshaft and the HPFIP camshaft speed sensors (sensors 2 and 5, Fig.2, Annex Д), installed in a consistent relationship in a specific pattern. The injectyor operation principle is shown on Fig.10.
  • Page 32 1 – fuel back runoff duct; 2 – electric terminals; 3 – electromagnetic valve; 4 – hofg pressure pipeline; 5 – valve ball; 6 – fuel outlet throttle hole; 7 – fuel inlet throttle hole; 8 – controlling valve chamber; 9 – valve controlling piston;...
  • Page 33 1 – Fuel pre-filter; 2 – hand fuel priming pump; 3 – fuel heater; 4 – moisture separator; 5 – water drainage tap; 6 – air outlet plug. Fig. 11 – Fuel pre-filter «PreLine 420» When using the diesel engine at ambient temperatures lower than -25ºС the filter housing must be equipped with fuel heater 3.
  • Page 34 1 – filter housing; 2 – fine fuel filter “Mann & Hummel WDK962” (Germany). Fig. 12 – Fine fuel filter 1.2.2.6.5 Air duct Air duct consists of an air cleaner and a branch pipe connecting the air cleaner with the turbocharger, the charge air cooler and the intake manifold (Fig.
  • Page 35 The functioning of the device is maintained by delivery of a portion of exhaust gas from the exhaust manifold via the EGR cooler into the intake manifold, as a result of the natu- ral difference between the exhaust gas pressure in front of the turbine and that of the charge air.
  • Page 36 1 – breather housing; 2 – oil deflector; 3 – cup; 4 – cover cap Fig.14 Diesel engine gas exchange diagram 1.2.2.7 Cooling system Closed type cooling system (Fig.15) with forced circulation of cooling liquid from a cen- trifugal pump. The water pump is driven in rotation by a V-belt from the crankshaft pul- ley.
  • Page 37 1 – water pump; 2 – thermostats; 3 – cylinder block; 4 – liquid-oil heat exchanger; 5– radiator; 6 – fan; 7 – recirculated exhaust gases cooler; 8 – recirculated gases inlet pipe; 9 – thermostat housing; 10 – pis- ton;...
  • Page 38 then starts partially circulating through the radiator. When the cooling liquid tempera- ture reaches +90ºС, the main valve opens completely and the entire flow goes through the radiator. Simultaneously with the main valve movement, the bypass valve also moves down, shutting the channel of cooling liquid bypass to the water pump. Installed in the engine is a water pump complete with a fan.
  • Page 39 Installed in diesel engines D-260.1S3А, D-260.2S3А is an uncontrollable turbocharger (Fig.17а) using the energy of exhaust gases for charging air into the engine cylinders. Turbocharger operation principle is as follows: the eaxhaust gases from the diesel en- gine cylinders get under pressure via the exhaust manifold into the turbine scroll chan- nels.
  • Page 40 The turbocharger bearings are lubricated and cooled by oil delivered through the pipe- line from a full-flow oil filter. Both the radial and the thrust bearings provide additional centrifugal oil cleaning. Oil then is drained into the oil sump through an oil diversion pipe.
  • Page 41 Diesel engines tarting device is an electric starter motor with rated voltage of 24V. Starter motor is a direct current electric motor with mixed excitation and a drive mecha- nism. To facilitate startup at low ambient temperatures, all the engines are equipped with glow plugs with rated voltage of 23V and have heat carrier inlet and outlet locations for en- gine prestart heating systems, installed by customer in a tractor/ agricultural machine.

  • Page 42: Diesel Engine Labelling And Sealing

    1.2.2.12 Gear pump and its drive Hydroficated tractor or other vehicle control systems imply installation of НШ 14-3Л or НШ 16-3Л, or НШ-10 gear pump in diesel engines. The gear pump is rotated by the engine distribution gears. 1.2.2.13 Clutch Clutch is designed for torque transfer from the engine crankshaft to transmission and for short time diesel emgine disconnection from transmission, while the engine is running, to ensure bumpless shifting the gears and smooth vehicle pulling away.

  • Page 43: Diesel Engine Preparing For Operation

    - it is not permissible to keep the engine running under the cooling liquid temperature lower than 60°С, because in these conditions the non burnt fuel flushes the oil off the cyl- inder liner walls and gets the oil burning in the engine crankcase; - the engine must not run longer than 1 minute under the full load and the speed lower than the speed corresponding to the maximal torque, so you should shift to the down gear;...

  • Page 44: Diesel Engine Additional Equipment

    Table 9 Preservation Operations period 1 year 6 months Engine depreservation Uncover the engine. Use diesel fuel to remove the preservation grease from the outer unpainted preserved surfaces of the diesel engine. Remove plugs or polyethylene filming covering the exhaust man- ifold outer openings, intake manifold, thermostat housing, water pump branch pipe, turbocharger and breathers.

  • Page 45: Filling The Engine With Fuel And Oil

    2.2.5 Filling the engine with fuel and oil Fill the engine fuel tank with fuel and the oil sump with motor oil. Use the fuel and oil brands matching the ambient air temperature at which the engine is operated. The rec- ommended fuel and oil brands are indicated in a table in Annex A.

  • Page 46: The Order Of Diesel Engine Use By Authorized Technical Personnel

    2.3.1 The order of diesel engine use by authorized technical personnel Before starting a newengine or an engine that has not been operated for a long time do the following: -check the oil level in the engine oil sump; -check the cooling liquid level in the ngine cooling system; -check if the fuel tank tap is open;...

  • Page 47: Diesel Engine Shutdown

    At the engine cold start, white smoke may be coming out of the exhaust pipe for some time, which is not a fault as the engine is running overcooled. Do not heat up the air sucked in front of the air cleaner with open flames. Do not start the engine by towing a tractor/ agricultural machine.

  • Page 48: Possible Failures And Troubleshooting

    warmth keeping jacket and the diesel engine, if necessary, must have startup aid devices (pre-start heaters). Fill the cooling system with the cooling liquid according to Table А.1 (Annex А), check the accumulator battery condition, charge them, if necessary (the ac- cumulator batteries must be fully charged).
  • Page 49 After the test drive, do the diagnostic fault blink-codes re-reading from the control unit memory. Now the error memory must be cleaned up, which means successful completion of repair. If not all of the faults discovered by the diagnostic system have been fixed, you need to apply to a diagnostics station, even if the fault may not significantly affect the diesel en- gine operation, as it may cause deterioration of the engine ecology parameters.
  • Page 50 Blink-codes table Table 10 Blink- Fault type Fault description Fix method R-code code Faults shown by diagnostic lamp lightup Analogue-digital-analogue converter Р060В reference voltage exceeding the set limit. Analogue-digital-analogue converter Error discovered by analogue-digital- Р060В reference voltage below the set li- analogue converter watch function.
  • Page 51 Continuation of Table 10 Blink- Fault type Fault description Fix method R-code code Camshaft speed sensor signal Р0340 12 Check camshaft speed sensor absent. condition and connections. того вала. Camshaft speed sensor circuit fault. 1-1-3 Apply to service centre. Р0341 11 Wrong camshaft speed sensor.
  • Page 52 Continuation of Table 10 Blink- Fault type Fault description Fix method R-code code Fault of “Watchdog” cylinders Р1616 12 shutdown module path. Fault discovered at ECU initialization by the function of check of additional me- Fault of path for cylinders shut- thods for cylinder control power stages Apply to service centre.
  • Page 53 Continuation of Table 10 Blink- Fault type Fault description Fix method R-code code Check terminal 50 condition Р2530 7 Terminal 50 is always closed Terminal 50 circuit fault. and connections. 1-2-2 Apply to service centre. Check terminal 15 condition Р2533 12 No signal from terminal 15.
  • Page 54 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Voltage beyond the set maximal Р1640 3 limit. 12V sensors voltage fault. 1-3-1 Apply to service centre. Voltage below the set minimal lim- Р1641 4 Р0687 3 Short circuit to power battery.
  • Page 55 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code The Rail fuel pressure signal be- Р0191 15 yond the maximal permissible at Check Rail fuel pressure sen- Rail fuel pressure valve fault, signal dis- signal mix check. sor condition and connections.
  • Page 56 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check high pressure fuel injec- Fault in high pressure fuel injection pump tion pump doser condition and Р0254 3 Short circuit to power battery. doser pulse-width control power stage cir- 1-3-5 connections.
  • Page 57 Continuation of Table 10 Blink- Fault type Fault description Fix method R-code code The number of safety valveopen- Р1011 1 ings exceeding the number permis- sible by its tech specs. The duration of safety valve open- Rail fuel pressure safety valve fault identi- Р1012 2 ings exceeding the number permis- fied on the basis of its operation data.
  • Page 58 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Р1213 11 Check engine cylinders injec- Depending on the settings. Р1214 11 tors’ connectors and cables Depending on the settings. condition. Р0201 12 No load resistance. Fault in power stage control circuit of cy- 1-4-1 linder 1, specific warning.
  • Page 59 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Р0268 3 Low side short circuit to battery. Check engine cylinders injec- Р0269 11 Depending on the settings. Fault in power stage control circuit of cyl- tors’ connectors and cables 1-4-3 Low side and High side short cir- inder 3, specific error, engine shutdown...
  • Page 60 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Р121C 11 Depending on the settings. Check engine cylinders injec- Р121D 11 Depending on the settings. Fault in power stage control circuit of cyl- tors’ connectors and cables 1-4-4 Р0204 12 No load resistance.
  • Page 61 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Р0277 3 Low side short circuit to battery. Check engine cylinders injec- Р0278 11 Depending on the settings. Fault in power stage control circuit of cyl- tors’ connectors and cables 1-4-6 Low side and High side short cir- Р0276 8...
  • Page 62 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Р1207 11 Depending on the settings. Check engine cylinders injec- Fault in injectors power stage control cir- Р1208 11 Depending on the settings. tors’ connectors and cables cuit Bank1, specific warning, engine shut- 1-5-1 Р1209 12...
  • Page 63 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Microchip CY33X, internal reload Р062B 3 / loss of counter/ undervoltage. Microchip CY33X has no right to Р062B 4 operation/ CY33X initialization er- Fault in injectors control power stage mi- ror.
  • Page 64 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code The number of working cylinders Р1225 12 is less than the minimal set limit. Check engine cylinders injec- The number of working cylinders is less tors’ connectors and cables Р0000 255 than the minimal set limit, engine shut- 1-5-4...
  • Page 65 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Voltage beyond the set maximal Р0123 limit. Check gas pedal position sen- Voltage below the set minimal Fault in sensor 1 of gas pedal position. sors condition and connec- Р0122 2-2-1 limit.
  • Page 66 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check brake pedal position Р0571 12 Brake pedal sensor faulty signal. Fault in Brake pedal sensor circuit. sensor condition and connec- 2-2-3 tion. Brake pedal sensor implausible Р0504 2 Apply to service centre.
  • Page 67 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Voltage beyond the maximal Р0238 0 Fault in charge pressure sensor circuit, Check charge pressure sensor physical limit. physical limit check. 2-3-1 condition and connection. Voltage below the minimal phy- Р0237 1 Apply to service centre.
  • Page 68 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Voltage beyond the maximal physi- Check atmospheric pressure Р2229 0 cal limit. Fault in atmospheric pressure sensor cir- sensor condition and connec- 2-3-2 cuit, physical limit check. tion.
  • Page 69 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check cooling liquid tempera- Voltage beyond the maximal phys- Р0118 0 Fault in cooling liquid temperature sensor ture sensor condition and con- ical limit. circuit. 2-4-1 nection. Voltage below the minimal phy- Р0117 1 sical limit.
  • Page 70 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Voltage beyond the set maximal Р0198 3 limit. Voltage below the set minimal lim- Р0197 4 Check oil temperature sensor Fault in oil temperature sensor circuit. 2-4-4 condition and connection.
  • Page 71 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check high pressure and low Overshoot of maximal positive pressure hydraulic curcuits Disruption of high pressure fuel pump Р1012 15 fuel pressure in Rail deviation at 2-5-2 components condition doser control mode.
  • Page 72 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check high pressure and low Overshoot of maximal positive pressure hydraulic curcuits Disruption of high pressure fuel pump Р1019 5 fuel pressure in Rail deviation at 2-5-4 components condition doser control mode.
  • Page 73 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check high pressure and low Fuel pump flow rate at the engine pressure hydraulic curcuits Disruption of high pressure fuel pump idle exceeding the set maximal 2-5-8 P101B 1 components condition...
  • Page 74 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Internal power voltage beyond the CJ940 module maximal power voltage Р1607 3 2-6-3 Apply to service centre. maximal limit. limit error. CJ940 module minimal power voltage Р1608 4 Internal power voltage below the Apply to service centre.
  • Page 75 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check exhaust flap condition Short circuit to power battery/ Short circuit to battery in exhaust flap con- Р0478 3 3-1-1 and connection. Excessive heat-up temperature. trol circuit power stage. Apply to service centre.
  • Page 76 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Vehicle speed shown by speed sig- Р0501 0 nal beyond the vehicle set maximal Check vehicle speed sensor speed. condition and connection. Failure of vehicle speed measurement, Check connection to tacho- Faulty vehicle speed signal caused Р0500 12...
  • Page 77 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Speed signal pulse width bigger Р1511 3 than the set maximal limit. Speed signal pulse width smaller Check connection to tacho- Р1512 4 Failure of vehicle speed measurement, than the set minimal limit.
  • Page 78 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Р0629 3 Short circuit to power battery. Check electric fuel priming Р0628 4 Short circuit to ground.. Fault in electric fuel priming pump control pump condition and connec- 3-2-6 power stage circuit.
  • Page 79 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check CAN line connection to Absence of CAN C bus. Absence of CAN C bus. 4-1-3 U0047 12 other CAN devices. Apply to service centre. SPI communication disrupted be- SPI communication disrupted between Р0607 12 tween central processor and watch...
  • Page 80 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Wait time elapsing for TSC1-AR CAN message when the engine U1106 11 speed/torque correction mode is Check CAN line connection to enabled. TSC1-AR CAN message error. 4-2-1 other CAN devices.
  • Page 81 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Wait time elapsing for TSC1-DR CAN message, when the engine U110А 11 speed/torque correction mode is Check CAN line connection to enabled. TSC1-DR CAN message error. 4-2-2 other CAN devices.
  • Page 82 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Wait time elapsing for TSC1-TE CAN message, when the engine U110E 11 speed/torque correction mode is Check CAN line connection to enabled. TSC1-TE CAN message error. 4-2-4 other CAN devices.
  • Page 83 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Wait time elapsing for TSC1-VR CAN message, when the engine U1112 3 speed/torque correction mode is Check CAN line connection to enabled. TSC1-VR CAN message error. 4-2-5 other CAN devices.
  • Page 84 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check CAN line connection to Wait time elapsing for EBC1 Р0000 12 EBC1 CAN message error. 4-4-1 other CAN devices. CAN message Apply to service centre. Check CAN line connection to Wait time elapsing for ERC1DR ERC1DR CAN message error.
  • Page 85 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Faults not shown by diagnostic lamp lightup Check camshaft speed sensor The engine start and operation performed Backup mode enabled. 1-1-4 P0008 12 condition and connection. by camshaft speed sensor only. Apply to service centre.
  • Page 86 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Sensor showing water in fuel con- Discovered water in fuel concentration is Replace fuel. 2-1-1 P2269 11 centration beyond permissible. beyond permissible. Short circuit to power battery. Check fuel filter electric heat- P1008 3 Fault in fuel filter electric heating element...
  • Page 87 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check Resistance Moment Control System Unit condition Physically implausible request Error of Resistance Moment Control Sys- and connection. from Resistance Moment Control 2-2-8 P0856 2 tem Unit. Check CAN line connection to System Unit.
  • Page 88 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Air mass consumption meter coef- Р0103 3 ficient beyond set limit. Error registered by air mass consumption Check air mass consumption meter signal sensitivity deviation plausi- 2-3-4 meter condition and connec- bility check function.
  • Page 89 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check cooling liquid tempera- Minimal cooling liquid tempera- Error registered by cooling liquid tempera- ture sensor condition and con- ture not achieved within the set ture sensor absolute plausibility check 2-4-5 P0116 2 nection.
  • Page 90 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Short circuit to power battery. P0647 3 Check conditioner state and Fault in conditioner control power stage Short circuit to ground.. P0646 4 3-1-3 connection. circuit. Apply to service centre. No load resistance.
  • Page 91 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Power supply battery voltage change beyond set maximal limit P1020 3 at air pre-heat device switch-on. Check air pre-heat device con- Error registered by air pre-heat switch-on 3-2-3 dition and connection.
  • Page 92 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Short circuit to power battery. P1619 3 Check system diagnostic lamp Fault in diagnostic lamp control system Short circuit to ground.. P161A 4 3-3-1 condition and connection. power stage circuit.
  • Page 93 Continuation of Table 10 Blink- Fault type Fault description Fix method R-code code Short circuit to power battery. P0649 3 Check lamp condition and Fault in adjustable speed limit lamp cir- Short circuit to ground.. P0649 4 3-3-5 connection. cuit. Apply to service centre.
  • Page 94 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Signal voltage beyond set maximal P1000 3 Check charge compressor reg- limit. Fault in charge compressor regulator con- ulator condition and connec- Signal voltage be;ow set minimal trol analogue-digital-analogue converter 3-4-4 P1001 4...
  • Page 95 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check CAN line connection to Wait time elapsing for RxEng- RxEngTemp2 CAN message error. 4-5-1 U1102 12 other CAN devices. Temp2 CAN message Apply to service centre. Check CAN line connection to Wait time elapsing for TF CAN TF CAN message error.
  • Page 96 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code SPN received via CAN-message DM1DCU CAN message error, SPN 4 4-6-4 U0437 2 Apply to service centre. coinsides with SPN in unit SPN 4. unit. SPN received via CAN-message DM1DCU CAN message error, SPN 5 Apply to service centre.
  • Page 97 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check engine cylinders injec- Number of flashes skips recog- Error registered by flashes skips control tors’ connectors and cables 5-1-3 P0303 3 nized beyond set limit. function in cylinder 3. condition.
  • Page 98 Continuation of Table 10 Fix method Blink- Fault type Fault description R-code code Check engine cylinders injec- Number of flashes skips recog- Error registered by flashes skips control tors’ connectors and cables 5-3-2 P0305 3 nized beyond set limit. function in cylinder 5. condition.
  • Page 99 Table 11 Fault Outward fault demonstration Fault identification algorythm Fix method 1.Engine start issues 1.1 Engine does not start 1.1.1 Check if there is fuel in the tank and is it conforms Fill the fuel tank. to the appropriate grade. 1.1.2 Check the starter motor and its control circuits.
  • Page 100 Replace the glow plugs or the 1.1.8 Check the glow plugs reliability. glow plugs control unit. 1.1.9 Check the harness condition (breaking or short cir- Do the necessary repair. cuit). 1.1.10 Check the compression level in cylunders. Do the necessary repair. 1.1.11 Check the injectors - launch injector check cycle by the appropriate standard Follow the instructions in the...
  • Page 101 - check the fuses; Do the necessary repair. - check the «ground wire». Replace the «ground wire». 1.2.5 Check the intake system. - Check for air leakage/ suction; Do the necessary repair. - Check the air filter condition; Replace the air filter by new one.
  • Page 102 ate. - make sure there is no water in the fuel inside the coarse Clean the fuel filter from water fuel filter cup; pouring it out by opening the tap. - make sure there is no air in the fuel. Remove air from the low pres- sure circuit (See Manual, item 3.2.10)
  • Page 103 - check electricity consumers condition with the diagnos- Do diagnostics and the neces- tic device. sary repair. 2.1.3 Check the harness condition for breaking or short Do the necessary repair. circuit. 2.1.4 Check the high pressure circuit for leakage. Do the necessary repair. 2.1.5 Check compression level in the cylinders.
  • Page 104 Follow the instructions in the - check for faults in the COMMON RAIL injection sys- “KTS – Bosch” diagnostic de- tem using the diagnostic device; do ”KTS – Bosch” vice software. standard testing. (Testing and repair at a specialized workshop) - check electricity consumers condition with the diagnos- Do diagnostics and the neces- tic device.
  • Page 105 ate. Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm Fix method - make sure there is no water in the fuel inside the coarse Clean the fuel filter from water fuel filter cup; pouring it out by opening the tap.
  • Page 106 Fault identification algorythm Fix method 3.3.5 Check the engine parameters. - check for faults in the COMMON RAIL injection sys- Follow the instructions in the tem using the diagnostic device; do ”KTS – Bosch” “KTS – Bosch” diagnostic de- standard testing. vice software.
  • Page 107 tem using the diagnostic device; do ”KTS – Bosch” “KTS – Bosch” diagnostic de- standard testing. vice software. (Testing and repair at a specialized workshop) - check electricity consumers condition with the diag- Do diagnostics and the neces- nostic device. sary repair.
  • Page 108 ate. - make sure there is no water in the fuel inside the coarse Clean the fuel filter from water fuel filter cup; pouring it out by opening the tap. - make sure there is no air in the fuel. Remove air from the low pres- sure circuit (See Manual, item 3.2.10)
  • Page 109 3.7 Excessive fuel consumption 3.7.1 Check the low pressure circuit. - check the correctness of connections in the low pres- sure circuit; Do the necessary repair. - check the hoses and pipe connectors for leakage; - check the fuel filter condition and conformity; Replace filter by the appropri- ate.
  • Page 110 Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm Fix method 3.7.4 Check the high pressure circuit for leakage. Do the necessary repair. 3.7.5 Check the intake system. - Check for air leakage/ suction; Do the necessary repair. - Check the air filter condition;...
  • Page 111 vice. vice software. Testing and repair at a specialized workshop 3.8.6 Control Unit check. - check the Control Unit plug-and-socket fixtures. Fix plug-and-sockets. 3.9 Engine stalls when accelerated 3.9.1 Check the engine parameters. - check for faults in the COMMON RAIL injection sys- Follow the instructions in the tem using the diagnostic device;...
  • Page 112 3.10 Engine does not stop 3.10.1 Check the engine parameters. - check for faults in the COMMON RAIL injection sys- Follow the instructions in the tem using the diagnostic device; do ”KTS – Bosch” “KTS – Bosch” diagnostic de- standard testing. vice software.
  • Page 113 device. vice software. (Testing and repair at a specialized workshop) 4.2 Intermittent noise 4.2.1 Check the engine parameters. - check for faults in the COMMON RAIL injection sys- Follow the instructions in the tem using the diagnostic device; do ”KTS – Bosch” “KTS –...
  • Page 114 4.3.7 Check the turbocharger operability. See Manual, Annex E. 4.3.8 Check the clearances in the valve drive. Adjust the clearances in the valves drive. Exhaust gas smell 4.4.1 Check the engine parameters. - check for faults in the COMMON RAIL injection sys- Follow the instructions in the tem using the diagnostic device;...
  • Page 115 - make sure there is no air in the fuel. Remove air from the low pres- sure circuit (See Manual, item 3.2.10) 4.5.2 Leakage in the fuel temperature sensor. Replace the fuel temperature sensor. or резиновое уплот- нительное кольцо Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm...
  • Page 116 3.2.10) Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm Fix method At oil consumption too high do 4.6.5 Check oil consumption. the necessary repair. 4.6.6 Check compression level in the cylinders. Do the necessary repair. 4.6.7 Check the injectors. - launch injector check cycle by the appropriate standard Follow the instructions in the testing command in the “KTS –...
  • Page 117 Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm Fix method Add oil to the oil gauge upper 4.7.4 Check the engine oil level. mark. See Manual, Annex Ж. 4.7.5 Check the turbocharger operability. At oil consumption too high do 4.7.6 Check oil consumption.
  • Page 118 Identify the area of lost hermit- 6.2 Oil pipelines connections hermeticity lost icity and restore it. ее 6.3 Faulty oil pump Identify the fault and rectify it. Add oil to the oil feeler rod 6.4 Oil level in the engine oil sump lower than permis- upper mark.
  • Page 119 Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm Fix method 8.1.6 Starter notor faild. Replace starter notor. 8.2 Starter motor staying switched in after the engine start 8.2.1 Contact plate welded to the starter motor relay Stop the engine, disconnect the contact bolts or contacts welded in the starter motor battery and do as decribed in control circuit relay.
  • Page 120 Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm Fix method Disassemble alternator. Solder or insulate the damaged 9.1.2 Field coil circuit broken. place or replace the coil, if it is impossible to rectify the fault. (Repair at a specialized workshop) 9.1.3 One of the stator phases bridging to the alternator Replace the stator.

  • Page 121: Safety Measures With Engine Appropriate Use

    ing. 2.3.7 Safety measures with engine appropriate use To ensure safe work and avoid accidents during engine operation and technical mainte- nance, observe the following rules: - Begin working only after proper study of the diesel engine design and operation and maintenance rules;...

  • Page 122: Maintenance

    3 MAINTENANCE 3.1 Diesel engine maintenance 3.1.1 General instructions Diesel engine maintenance is done for the purpose of keeping it properly functioning in the process of operation. Not observing the scheduled periodicity or low quality maintenance significantly shorten its operation life, lead to the increasing failures, bring down the engine power, ecology parameters and result in more costs for its operation.
  • Page 123 7 Seasonal maintenance while transferring from the Done simultane- autumn-winter (TM-AW) or the spring-summer ously with (TM-SS) operation periods. routine scheduled maintenance (TM- 1, TM-2, TM-3) 8 Maintenance for a short-time storage (10 days – 1 According to item 3.1.5.1 and sec- month) preparation.

  • Page 124: Safety Measures

    An engine meant for maintenance must undergo technical examination with the purpose of finding the locations of fuel and oil leakage, which are difficult to discover after the engine wash. After the technical examination the engine must be cleaned and washed. The quality of washing to a great extent affects the engine troublfree operation and the engine parts and units durability.

  • Page 125: Maintenance Procedures

    3.1.3 Maintenance procedures 3.1.3.1 Scope of work at scheduled maintenance types Table 14 Maintenance type Work description TM-1 2TM-1 TM-2 TM-3 2TM-3 SS 1 Check oil level in the engine sump. 2 Check the cooling liquid level in the cooling system. 3 Clean the alternator from dust with compressed air.

  • Page 126: Checking The Engine Operation Condition

    22 Replace the winter oil by the summer oil in the engine sump. 23 Set the alternator seasonal voltage adjustment screw (if available) to the "Л" position (summer). 24 Replace the summer oil by the winter oil in the engine sump. Continuation of Table 14 Maintenance type Work description...

  • Page 127: Proofing (Reproofing) For Storage

    in the fuel tank. With that job done and rectifying the discovered faults, you may begin the diagnostics. The diesel engine controllable parameters – according to item 1.1.2.2, Table 3. Measurement means for determining the engine controllable parameters – according to item 1.1.2.3, Table 4.
  • Page 128 If frosty weather is expected during the engine storage period, check the cooling liquid for conformity to the required frost resistance and, if necessary, replace it. If needed, add cooling liquid up to the expansion tank mark. Clean the outside of the engine (except for electrical parts) with fuel and compressed air. Cover with polyethylene film STATE STANDARD 10354-82 and tie up the air cleaner inlet branch, silencer outlet branch and the engine breathers with string ШЛ...
  • Page 129 and carefully plug them in order to keep the fuel in the system. Drain the proofing solution from the engine cooling system. Drain the proofing oil from the oil sump, mount and tighten the oil drainage plug. Dismantle, service and store the accumulator battery following the instructions the of tractor/machine Operation &...

  • Page 130: Diesel Engine And Its Components Maintenance

    Remove the plugs from the inlet and outlet fuel pipelines and connect the pipelines accord- ing to their normal position. Using the diesel fuel, remove the proofing oil from the engine outer proofed surfaces. Fill the oil sump with motor oil according to the Chemmatological Chart (Annex “А”) up to the appropriate level.

  • Page 131: Replacing Oil In The Engine Oil Sump

    Fig. 18- Checking oil level in the engine oil sump. 3.2.4 Replacing oil in the engine oil sump Oil in the diesel engine oil sump must be replaced after every 250 operation hours and in case of using lower quality analogous oils or fuel with highsulphur contents – after every 125 operation hours.

  • Page 132: Cleaning The Centrifugal Oil Filter Rotor

    1 – filter housing; 2 – filter; 3 – connector; 4 – filter gasket; 5 – anti-drainage valve; 6 – spring; 7 – by- pass valve. Fig. 19 – Oil filter 3.2.6 Cleaning the centrifugal oil filter rotor Cleaning the centrifugal oil filter rotor is done simultaneously with oil replacement in the engine oil sump.

  • Page 133: Sediment Removal From Fuel Pre-Filter

    1–nut; 2-cap; 3-cup; 4-special nut; 5-filtering screen Fig. 20 – Cleaning the centrifugal oil filter rotor. 3.2.7 Sediment removal from fuel pre-filter See tractor/ machine Operation & Maintenance Manual. 3.2.8 Fuel pre-filter replacement Replacing fuel pre-filter See tractor/ machine Operation & Maintenance Manual. Fill the system with fuel after filter assembly.

  • Page 134: Заполнение Топливной Системы

    1 – filter Mann & Hummel WDK962; 2 – filter housing; 3 – bracket; 4 – connector; 5 – plug (for letting out air); 6 – gasket; 7 – connector. Fig. 21- Replacing fine fuel filter. 3.2.10 Filling the fuel system Filling the fuel system To fill the fuel system, it is necessary to remove air from it (purge the system).

  • Page 135: Servicing The Air Cleaner

    1- High pressure fuel injection pump; 2 – fuel priming pump; 3 – drainage pipelines turn-elbow bolt drainage pipelines turn-elbow bolt; 4 – fine fuel filter; 5 – plug; 6 – ECU radiator; 7 – air outlet plug; 8 – coarse fuel filter;...

  • Page 136: Checking The Air Cleaner And The Inlet Duct Connections Hermeticity

    1 – main filter element; 2 – control filter element; 3 – gasket; 4 – wing-nut; 5 – ring; 6 – tray; 7 – housing, 8 - monocyclone Fig. 23 - Air cleaner Air flow must be directed at an angle relative to the filter element surface. When serviced, the filter element must be protected from mechanical damage and oiling.

  • Page 137: Tightening The Cylinder Heads Bolts

    3.2.14 Tightening the cylinder heads mounting bolts The cylinder heads mounting bolts tightening is done after every 1 000 operation hours on a hot engine in the following order: - remove the caps and the cylinder heads covers; - remover the rocker axles together with the rockers and the brackets; - using a dynamometric spanner tighen all of the cylinder heads mounting bolts, prelimi- narily having loosened them by 1/6 of a turn in thre stages: ±...

  • Page 138: The "Common Rail" System Maintenance

    - rotate the crankshaft till the first cylinder valves overshoot (the first cylinder intake valve starts opening and the exaust valve ends closing); - adjust the gaps of the third, fifth, seventh, tenth, eleventh and twelveth valves (counting from the fan), then rotate the crankshaft by one turn setting the overshoot in the sixth cyl- inder and adjust the gaps of the first, second, fourth, sixth, eighth and nineth valves.

  • Page 139: Alternator Maintenance

    Fig. 26 - Injector 3.2.17 Alternator maintenance There is no need in the alternator special maintenance during the engine operation. Sea- sonal alternator voltage “winter-summer” adjustment is done with a “winter-summer” adjustment screw (if available) located on the alternator rear wall. Diesel engines may be equipped with alternators with automatic “winter-summer”...

  • Page 140: Checking The Starter Motor Condition

    The water pump drive belt (D-260.1S3А, D-260.2S3А, D-260.4S3А) deflection must stay within 9…18 mm when the branch “water pump pulley-crankshaft pulley” is pressed on with the force of 39,2±2,0 N. 3.2.19 Checking the starter motor condition Checking the starter motor condition is done after every 1 000 engine operation hours in the following manner: - check the mounting bolts tightening, if necessary, tighten them;...

  • Page 141: Compressor Maintenance

    3.2.21 Compressor maintenance Compressor does not require special maintenance during operation. If found faulty, the compressor must be sent to a specialized workshop where skilled specialists will identify the fault cause and rectify it. 3.2.22 Maintenance of gas exchange system components with EGR device To ensure the D-260S3А...
  • Page 142 The signs for necessity of engine current repair are: rise of fuel consumption, increased oil burn, oil pressure dropdown, deterioration of the engine start ability. Fauly components at current repair may be replaced by new ones, provided the other en- gine parts still have considerable operation resource.

  • Page 143: Safety Measures

    4.1.2 Safety measures Eligible to do current repair are workers with special training having certificates confirm- ing their skills, properly instructed for operation safety measures, fire safety etc. Dismantling of faulty parts and units is done only with the engine not running. When examining the engine use a portable lamp with the voltage of not more than 24V.

  • Page 144: Engine Components Current Repair

    4.2 Engine components current repair Description of failures, their possibles causes and instructions on elimination of failures consequences are given in Table 16. Table 16 Instructions on iden- Instructions on eli- Description of tifying conse- mination of the con- failures and damage Possible causes quences of failures sequences of fail-...

  • Page 145: General Instructions On Piston Rings Replacement

    Continuation of Table 16 Instructions on identi- Instructions on eli- Description of fail- fying the consequenc- mination ures and damage Possible causes es of failures and consequences consequences damage of assembly failures and damage units 3.2 Bearing unit 3.1.1 Visually examine Replace the water wear.

  • Page 146: General Instructions On The Valves Grinding

    Fig. 27- Piston rings mounting 4.2.2 General instructions on the valves grinding Unscrew the rocker axle brackets nuts and dismantle the rocker axle with the springs and the rockers. Unscrew the head mounting bolts, remove the head. Remove the valve keepers, the valve springs disk, the valve springs, the valve spring wash- ers, remove the sealing collar from the valve guiding bush.

  • Page 147: General Instructions On Water Pump Disassembly And Assembly

    4.2.3 General instructions on water pump disassembly and assembly 4.2.3.1 Water pump disassembly Unscrew bolts 2 (Fig. 16) of the fan mounting. Mount a fixer on pulley 9 (Fig.28) end surface, similar to that shown on Fig.29, with the mounting holes coordinates corresponding to the holes coordinates on the pump pulley. Holding the pulley by the fixer lever, unscrew nut 11(Fig.
  • Page 148 1-bearing; 2-water pump sealing; 3-bolt; 4-cover; 5-impeller; 6-plug; 7-housing; 8-pump shaft; 9-pulley; 10-washer; 11-nut; 12-lock ring; 13 – dismantle element; 14 – thrust ring Fig. 28 – Water pump Fig. 29- Water pump pulley fixer...

  • Page 149: Storage

    Fig. 30- Mandrel for the water pump sealing pressing in (main design dimensions). 5 STORAGE To ensure operability of the diesel engines, saving materials and monetary funds for their repair and preparation to operation, one should strictly observe the regulations of diesel engine storage at off hours. Regardless of the season, diesel engines must be kept in full conformity with GOST 7751-85.

  • Page 150: Transportation

    accumulator batteries, acids, salts, alkkalines and other chemicles able to cause metal corrosion together with the engines. At short period storage (from 10 days to one month) of a tractor, combine harvester, ma- chine on an open site or under a shed do as described in item 3.1.5.1 of this Manual. Before a tractor, combine harvester, machine putting into operation do the preparation work as described in item 3.1.6.1 or 3.1.6.2.

  • Page 151: Annex А(Reference)

    Annex “А” (reference) Chemmotological chart Table А.1 Assembly unit Quantity Fuels and Mass (vol- (functionally fi- of assem- lubricants ume) of fuels Fuels and lubricants names and grades nished device, bly units replace- and lubricants mechanism, fric- in a pro- ment filled in a Notes...
  • Page 152 Continuation of Table А.1 Fuels Fuels and lubricants names and grades Mass (vol- Quanti- lubri- ume) of fuels Assembly unit ty of cants Но- and lubricants (functionally fi- assem- мер nished device, filled in a place- по- Notes mechanism, fric- units in product at re- ment...
  • Page 153 End of Table А.1 Assembly unit Quantity Fuels Mass (vol- (functionally fi- of as- Fuels and lubricants names and grades and lub- ume) of fuels nished device, sembly ricants and lubri- mechanism, fric- units in a cants filled tion couple) name, product, place- index...
  • Page 154 Cooling system vol- Low freezing cooling liquid «Tosol Cooling liq- MIL-F-5559 13,4 (12,5) Once in Compulsory cooling liq- Dzerzhinsky ТС-40» (down to - ОЖ-40 available (BS 150) (USA) uid incoming check by (without radiator and 40ºС), (down to - FL-3 Sort S-735 years customer.

  • Page 155: Annex Б (Reference)

    Annex “Б” (reference) Spare Parts & Accessories Kit Table Б.1 – Spare parts to diesel engines D-260.1S3A, D-260.2S3A, D-260.4 S3A Location in Quantity in a Quantity in a Part designation Product code Spare part description Application Notes the package product, pcs set, pcs 50-1404059-Б1 47 5341 8601...

  • Page 156: Annex В (Reference)

    Annex “В” (reference) Cylinder liner and piston size groups Table В.1 Group labelling Liner diameter, mm Piston skirt diameter, mm − Б − − С − − М +0,02 − One engine set contains pistons, connecting rods and piston pins of the same weight group, the weight difference of the connection rods-pistons groups must not exceed 30 g.
  • Page 157 Annex “Г” (reference) Diesel engine adjustment parameters Table Г.1 Measurement Description Values unit Oil pressure in a hot engine oiling system at the 0,28-0,45 engine crankshaft rated speed. Cooling system temperature in the cooling system. о С 80-95 Drive belts deflection See item 3.2.18 Gap between the rocker striker and the valve stem end for the valves in a cold engine:...

  • Page 158: Synchronization Of The Crankshaft And The Hpfip Camshaft Angle Position

    Annex “Д” (reference) Synchronization of the crankshaft and the HPFIP camshaft angle position The necessity of synchronization of the crankshaft (torsional vibration damper with pulse rim) and the HPFIP camshaft (fuel priming pump drive gear with pulse rim) angle posi- tion may arise as a result of the HPFIP dismantling with its subsequent putting back in place after current diesel engine repair.
  • Page 159 1 – torsional vibration damper housing ; 2 – crankshaft speed sensor; 3 – mounting pin; 4 – fuel priming pump drive gear with pulse rim; 5 – HPFIP camshaft speed sensor. Fig. 2 – Placing the 1 cylinder piston to TDC Place the 1st cylinder piston behind ≈...
  • Page 160 1 – torsional vibration damper housing; 2 – crankshaft speed sensor; 3 – mounting pin; 4 – fuel priming pump drive gear with pulse rim; 5 – fixing device. Fig. 3 – Placing the 1 cylinder piston to compression stroke Remove the HPFIP, loosen screw 4 of speed sensor 3 (Fig.
  • Page 161 1 – fuel priming pump drive gear with pulse rim; 2 – fixing device; 3 –speed sensor; 4 – sensor mounting screw; Fig. 4 – Fuel priming pump drive gear pulse rim fixing device mounting 1 – hatch cover; 2 – nut; 3 – stud; 4 – special nut; 5 – drive half coupling; 6 –...

  • Page 162: Annex Е (Reference) Diesel Engine Electronics Structural Electric Diagram

    Annex Е (reference) Diesel engine electronics structural electric diagram...

  • Page 163: Annex Е (Reference)

    Annex Е (reference) о Designation Description Notes 01. 03 Pressure and temperature sensor (ODFT) 0 261230 112 'B0SCH' (Germany) Charge air pressure and temperature sensor (LOFT) 0 281 'BOSCH' (Germany) 002 576 'BOSCH' (Germany) DU. 05 Speed sensor (006) 0 281 006 009 'B0SCH' (Germany) Cooling liquid temperature sensor (WTF) 0 281002 209 'BOSCH' (Germany)

  • Page 164: Annex Е(Reference)

    Annex Е (reference) Contact No Bosch Signal function Cross sec- Contact No XSLXS3 designation tion XS18/XP18 Е 1.02 VJ/.BA /%J '* 12V' from accumulator battery (input3) V_V_BA Г-4 1.03 “’+”12V‘ from accumulator battery (input4) ю/, Commutated output "*128' АКЬ 0_V_RH01 G.GJ3A Т-3 '0 B' from accumulator battery (input3) G.GJ3A Т-4...

  • Page 165: Annex Ж

    Annex “Ж” Diesel engine and turbocharger failures identification Character Cause Check Character Х Х Х Х Х Lack of air Х Х Air filter cleanness. Narrowed air supply hose, not firm (loosened) con- nections. Х Х Х Supercharge pressure drop Х...

  • Page 166: Annex И (Reference)

    Annex “И” (reference) Engine slingning scheme 1 – eye-bolt; 2 – sling (chain); 3 – beam; 4 -grip Fig. 1 – Engine slingning scheme...

This manual is also suitable for:

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