Diesel engines - Belarus

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

Diesel engines

D-260.1S3, D-260.2S3, D-260.4S3

OPERATION & MAINTENANCE MANUAL

Minsk 2013

TABLE OF CONTENTS

1 DESCRIPTION AND OPERATION .....................................................................................................................................................4 1.1 DIESEL ENGINE DESCRIPTION AND OPERATION ..........................................ERROR! BOOKMARK 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 ................................................................................................ Error! Bookmark not defined. 1.1.5 Diesel engine labelling ............................................................................................................................................14 1.1.6 Packaging ................................................................................................................. Error! Bookmark not defined. 1.2 DESCRIPTION AND OPERATION OF DIESEL ENGINE COMPONENTS, MECHANISMS AND DEVICES .. ERROR! BOOKMARK NOT DEFINED. 1.2.1 General information ................................................................................................. Error! Bookmark not defined. 1.2.2 Description and operation......................................................................................... Error! Bookmark not defined. 1.2.3 Diesel engine labelling and sealing.........................................................................................................................42

2 APPROPRIATE USE ............................................................................................................................................................................42 2.1 OPERATING RESTRICTIONS ...............................................................................................................................................42 2.2 DIESEL ENGINE PREPARING FOR OPERATION.....................................................................................................................43 2.2.1 Safety rules to be observed while preparing diesel engine for operation...............................................................43 2.2.2 Diesel engine, its assembly units and parts depreservation ...................................................................................43 2.2.3 Diesel engine additional equipment ........................................................................................................................44 2.2.4 Filling the cooling system........................................................................................................................................44 2.2.5 Filling the engine with fuel and oil..........................................................................................................................45 2.2.6 Diesel engine controls and control devices .............................................................................................................45 2.3 DIESEL ENGINE USE ..........................................................................................................................................................45 2.3.1 The order of diesel engine use by authorized technical personnel .........................................................................46 2.3.2 Diesel ngine start.....................................................................................................................................................46 2.3.3 Diesel engine shutdown ...........................................................................................................................................47 2.3.4 Diesel engineoperationsl run-in ..............................................................................................................................47 2.3.5 Diesel engine operation in winter conditions ..........................................................................................................47 2.3.6 Possible failures and troubleshooting ....................................................................................................................48 2.3.7 Safety measures with engine appropriate use........................................................................................................121 2.4 OPERATION IN EXTREME CONDITIONS ............................................................................................................................121

3 MAINTENANCE .................................................................................................................................................................................122 3.1 DIESEL ENGINE MAINTENANCE.......................................................................................................................................122 3.1.1 General instructions ..............................................................................................................................................122 3.1.2 Safety measures .....................................................................................................................................................124 3.1.3 Maintenance procedures .......................................................................................................................................125 3.1.4 Checking the engine operation condition ..............................................................................................................126 3.1.5 Proofing (reproofing) for storage..........................................................................................................................127 3.2 DIESEL ENGINE AND ITS COMPONENTS MAINTENANCE...........................................................................................130 3.2.1 Checking the cooling liquid level in the cooling system ........................................................................................130 3.2.2 Cooling system maintenance and washing ............................................................................................................130 3.2.3 Checking oil level in the engine oil sump ..............................................................................................................130 3.2.4 Replacing oil in the engine oil sump......................................................................................................................131 3.2.5 Replacing he oil filter ...........................................................................................................................................131 3.2.6 Cleaning the centrifugal oil filter rotor .................................................................................................................132 3.2.7 Sediment removal from fuel pre-filter....................................................................................................................133 3.2.8 Replacing fuel pre-filter.........................................................................................................................................133 3.2.9 Replacing fine fuel filter ........................................................................................................................................133 3.2.10 ......................................................................................................................134 3.2.11 Servicing the air cleaner......................................................................................................................................135 3.2.12 Checking the air cleaner and the inlet duct connections hermeticity ..................................................................136 ............................................................................................................................................ Error! Bookmark not defined. 3.2.13 Washing the engine breathers .............................................................................................................................136 3.2.14 Tightening the cylinder heads bolts .....................................................................................................................137 3.2.15 Checking the gaps between the valves and the rockers .......................................................................................137 3.2.16 The "COMMON RAIL" system maintenance......................................................................................................138 3.2.17 Alternator maintenance ......................................................................................................................................139 3.2.18 Checking the belts tension ...................................................................................................................................139 3.2.19 Checking the starter motor condition .................................................................................................................140 3.2.20 Turbocharger maintenance .................................................................................................................................140 3.2.21 Compressor maintenance ....................................................................................................................................141 3.2.22 Gas exchange system components maintenance ...............................................................................................141

4 CURRENT REPAIR............................................................................................................................................................................141 4.1ENGINE CURRENT REPAIR................................................................................................................................................141

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............................................................................................................................................................................................ 149

6 TRANSPORTATION.......................................................................................................................................................................... 150

7 RECYCLING ....................................................................................................................................................................................... 150 Annex (reference) ........................................................................................................................................................ 151 Chemmotological chart....................................................................................................... Error! Bookmark not defined. Annex (reference) ....................................................................................................................................................... 155 Spare Parts & Accessories ............................................................................................................................................ 155 Annex (reference) ....................................................................................................................................................... 156 Cylinder liners and pistons size groups ......................................................................................................................... 156 Crankshaft main end and big end necks nominal sizes Synchronization of the crankshaft and the HPFIP camshaft angle position.................................................................. 158 Annex (reference) Diesel engine electronics structural electric diagram ................................................................. 162 Annex (reference) ....................................................................................................................................................... 163 Annex (reference) ........................................................................................................................................................ 164 Annex ......................................................................................................................................................................... 165 Diesel engine and turbocharger failures identification ..................................................... Error! Bookmark not defined. Annex (reference)....................................................................................................................................................... 166 Engine slinging scheme ...................................................................................................... Error! Bookmark not defined.

This Manual is intended for use by operators, drivers and engine mechanics of agricultural tractors, combine harvesters and agricultural machinery equipped with diesel engines 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 & Maintenance Manual contains brief technical description, diesel engines operation and technical maintenance rules. Eligible to diesel engines operation and technical maintenance rules are individuals with special training and those having read this Operation & Maintenance Manual. Diesel engines and their components current repair may be done by mechanics familiar with their design, principle of operation, having general technical background according to 3-4 grades training programme. Diagnostics and technical service of Common Rail fuel system must be done by specially trained personnel using specialised diagnostic equipment. Diesel engines design implies long operation life without complete overhaul, provided the rules of operation, storage and timely technical service described in this Manual are observed. Diesel engines exhaust gases contain substances harmful to human health (nitrogen oxides, carbon oxides, hydrocarbons, hard particles). Applied in diesel engines design are technical solutions allowing to reduce the harmful substances impact on human health and environment, so unauthorized modification of the engines design, breaking the manufacturer settings, disregarding technical service periodicity is strictly forbidden. The rooms where diesel engines are run must have purge-exhaust ventilation and the engine exhaust system must have an autonomous gas diversion duct from the engine silencer to the outside of the room. Due to the engines continuous development, some of their assembly units and parts may be subject to modifications not indicated in this Operation & Maintenance Manual.

Customers' disregarding the rules and conditions of operation, technical service, transportation and storage contained in this Manual, breaking the manufacturer seals as well as using in current repair and technical service consumables (fuel and lubrication materials, assembly units and parts) from manufacturers not recommended for use by the OJSC "MMP" HMC" design documentation, engine design modification will stop the engine warranty validity.

Engine and (or) its components repair by the owner or other persons without participation of the manufacturer specialists or its authorized dealer centre in the event of the engine failure within the warranty period will make the engine or its components warranty invalid.

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

Application

Application environment

Climatic conditions of operation

Wheeled tractors, 1,4; 2 drawbar Forage harvesters and wheeled

categories

tractors, 3; 4 drawbar categories

Areas with unlimited air exchange

Microclimatic regions with moderate climate. Air temperature values of operation conditions from + 40? to - 45? .* Microclimatic regions with both dry and humid tropical climate. Air temperature values of operation conditions from + 50? to - 10? .

*- with diesel engine operation at the environment temperature lower than -25? the coarse fuel filter must be equipped with a fuel heater.

1.1.2 Technical specifications Diesel engines technical specifications and operation parameters Table 2

Parameters

Measurement unit

Diesel engine type Fuel mixture method Number of cylinders Positioning of cylinders

Swept volume Firing sequence

Crankshaft rotation direction per State Standard 22836-77 (from the fan side) Bore Stroke Compression ratio (calculated) Permissible inclination angles at engine operation - longitudinal

- Transverse Operating output Rated speed Specific fuel consumption at operating output Maximal torque Speed at maximal torque, not less than Engine mass without fuel, lubricants and coolant (with fan, alternator, starter and air cleaner) Average noise level. Not more than General logarithmic levels of vibration velocity, not higher than

) vertically ) horozontally

pcs

litres

mm mm

degrees kW min

g/ kW/ hour Nm

min 1 kg dBA

dB

Engine model

D-260.1S3A

D-260.2S3A

Values

4-stroke, turbocharged with charge air cooling Volumetric fuel mixture formation 6

In-line, vertical

7,12

1-5-3-6-2-4

D-260.4 S3A

111,0 660,0

Right (clockwise)

110 125 17

20 20

96,9 2100 249,0

570,0 1600

710

97

148,6

923,0 750 98

108,2 110,2

1.1.2.2 Controlled engine parameters

Table 3

Parameters

Measurement unit

D-260.1S3A

Engine model D-260.2S3A

Value ? confidence limit (tolerance)

D-260.4 S3A

Rated output

kW

116,0?2,0

100,0?2,0

156,0?3,0

Rated speed

min -1

+40

2100 -25

Specific fuel consumption at rated output

g/ kW/ hour

+12,0

240,0 -7,2

Minimal stable idling speed

min -1

800?50

Maximal stable idling speed limited by regulator, not higher than

min -1

2270

2270 (2250**)

Oil pressure in the main lubrication system line:

-at rated speed

-at minimal speed

MPa

0,28...0,45

0,10

0,16

Note:

* The parameters are reached after 60 hours of engine operation with the counter-pressure of not less than 150 kPa at a distance of 200 mm

from the exhaust duct measured from the turbocharger flange with the engine brake switched off, the fuel temperature at the fuel system inlet

between 38? and 43? and reference atmospheric conditions per UN EEC Rules No 24(03)/ 2nd Revision:

-atmospheric pressure - 100 kPa

-water vapours pressure - 1 kPa

-air temperature - 25? ;

The parameters are calculated with formuli per State Standard 18509-88.

** For combine harvester diesel engines

1.1.2.3 Measuring means for determining the controlled parameters

Table 4

Measured parameter

Measurement unit

Measurement means

Strain and torque strength measuring

Torque

Nm

devices according to State Standard

15077-78

Electronic tachometers, type

Speed

min -1

according to Technical Conditions 2504.3663-78, State Standard 18303-72

?0,005n rated, but not more than 10

min-1

Pressure gauges, compound gauges

Oil pressure in the lubrication system

MPa

according to State Standards 2405-80 and 11161-84, pressure and depression measuring transducers according

to State Standard 22520-85

Measurement means basic absolute error limit ?0,005 max

?0,005n rated, but not more than 10 min-1

?0,02

Hourly fuel consumption kg/ hour

Non-standard measuring means

?0,01G

Note For rated output

calculation

For specific fuel consumption cal-

culation

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