DIESEL ENGINES D-245S3A М, D-245.2S3A М, D-245.5 S3A М, D-245.43 S3A М PDF
DIESEL ENGINES D-245S3A М, D-245.2S3A М, D-245.5 S3A М, D-245.43 S3A М PDF
DIESEL ENGINES D-245S3A М, D-245.2S3A М, D-245.5 S3A М, D-245.43 S3A М PDF
DIESEL ENGINES
OPERATION MANUAL
MINSK, 2010
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245S3A 0000100 Operating Manual
Table of Content
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The present operation manual is designed for operators, drivers and agricultural
tractors motormen, combine harvesters and agricultural machinery equipped with diesel
engines D-245 S3A , D-245.2S3A , D-245.5 S3A , D-245.43 S3A , and for
maintenance centers and repair workshops stuff competent to provide repair and
maintenance of the abovementioned diesel engines.
The present manual provides brief technical description, maintenance and service
rules of diesel engines.
Operation and maintenance of diesel engines is allowed by persons specially trained
and familiar with the present manual only.
Routine repair operations for diesel engines and its components can be carried out
by machine men knowing design and operating principles of diesel engines, and
having general technical skills according to training program for machinemen of the 3rd
or 4th grade.
Diesel engine is designed for continuous service without need of major repairs
provided that equipment operating procedures, storage, and timely maintenance
requirements set forth in this manual are complied with.
Diesel engine exhaust gas contains hazardous substances (nitrous oxides, carbon
monoxides, hydrocarbons, solid particles). Diesel engines design is based on technical
solutions which enable reduction of emission impact on humans health and
environment
Premises where the diesel engine is operated shall have combined extract-and-input
ventilation, and diesel engine exhaust system shall be equipped with independent
offtake ensuring positive offtake of exhaust gases from muffler to the outside of the
room.
Due to the continuous improvement some alterations in diesel engine design can be
made which are not specified in this operation manual.
In case of non compliance with rules and procedures of operation,
maintenance, transportation and storage specified herein, crippling of plant seals,
and use of expandable materials (petroleum, oil and lubricants, parts and assembly
units) of other manufacturers which are not provided with design documentation of
RUE MMP during the maintenance and routine repair, and introduction of
changes of engine design, guarantee ceases to be effective.
In the event when maintenance of failed diesel engine parts during a
period of guarantee for engine or its components is carried out by the owner or the
third party without involvement of plants technical specialists or an authorized
dialer center, guarantee for engine or its components ceases to be effective.
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245S3A 0000100 Operating Manual
Description
D-245S3A D-245.2S3A D-245.5S3A D-245.43S3A
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Note: Parameters are achieved after operating time equal to 60 - 5 hours with backpressure of 150 KPa in exit channel 200 m
from turbine flange while engine brake is shut down, and with fuel temperature at the inlet of fuel-handling system ranging from
38 to 43 reference atmospheric conditions according to the rules 24(03)/Revision 2 of UN's Economic Commission for
Europe:
- atmosphere pressure 100 KPa;
- vapour pressure 1 KPa;
- air temperature 25.
Parameters shall be calculated by the formulae set forth in GOST 18509-88.
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Register of spare parts tools and accessories for diesel engines Annex B of this
manual (Table B.1).
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Table 6 continued
Diesel engine
Description of a
D-245S3A D-245.2S3A D-245.5S3A D-245.43 S3A
unit, part
Description of a unit, part and (or) its characteristic
Clutch Frictional, double-disk or single-disk, dry, spring-loaded clutch
Electric generator Alternate current, rated voltage of 14 V or 28 V
Starter Rated voltage 12 V or 24 V
Diesel engines are supplied with pin heating plug, rated voltage of 11 V or 23 V and provided with openings
Starting aid
for heat input and output during connection of starting preheater.
Note: *- shall be determined by a customer.
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pipelines
Feed System Coarse fuel filter
Secondary fine fuel filter
Air cleaner air delivery channel
Integrated modular switch,
Exhaust Gases Recirculation System
electromagnetic recirculating valve
Water pump
Cooling system Thermostatic regulator
Fan
Supercharging Device Turbocompressor
Exhaust Gases Recirculation Device Exhaust gases recirculation system
coolant, valve, tubes
Starter
Devices
Starting Device
Heating plugs
Electrical Equipment Drive Electric generator
Drives
Compressor
Accessory Drive Gear wheel pump
Clutch
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1 - camshaft gear; 2 - idler gear; 3 crankshaft gear; 4 reducing gear drive of fuel injection pump assembly
(FIPA).
Figure 2 - Front Gears Installation Diagram.
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at the output of oil filter body. From the turbo-compressor bearing assembly the oil is
supplied to oil crankcase.
Figure 3 The Diesel Engine with Liquid and Oil Heat Exchanger and
Indecomposable Oil Filter with Paper Element Lubrication System Schematic.
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1 fuel tank; 2 coarse fuel filter; 3- low pressure pipes; 4 fuel injection pump; 5 fuel-feed pump; 6 high
pressure pipes; 7 fine fuel filter; 8 air cleaner; 9 monocyclone; 10 heating plug; 11 intake manifold; 12
exhaust manifold; 13 muffler; 14 injector; 15 remaining fuel return line; 16 cylinder head; 17
turbocompressor; 18 pneumatic corrector pipe; 19 charge air cooler; 20 air cleaner dirtiness indicator
pipe; 21 recirculating exhaust gases cooler; 22 recirculating valve.
Figure 4 Fuel Feed System Diagram.
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1 fuel injection pump; 2 fuel feed pump; 3 flange; 4 camshaft; 5 individual injection pump; 6
armature key; 7 drive semi-coupling; 8 semi-coupling retaining nut; 9 Fuel supply pipe connection bolt;
10 Fuel drain pipe connection bolt for fuel drain from fuel feed pump to fine fuel filter (FF); 11 bypass
valve; 12 Bolt of pipe for fuel supply from FF; 13 air-vent plug; 14 oilfiller plug; 15 - regulator housing;
16 shutdown lever; 17 shutdown solenoid; 18 operating lever; 19 minimum RPM regulating bolt; 20
supercharge pneumatic corrector; 22 maximum RPM regulating bolt; 23 starting solenoid; 24 rotation
velocity sensor/integrated switch of recirculation valve solenoid; 25 rack position sensor of fuel injection
pump assembly/integrated switch of recirculation valve solenoid; 26 Oil supply pipe connection bolt; 27*
camshaft position regulator of fuel injection pump assembly.
* - available as agreed.
Figure 5 Fuel Injection Pump
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POSITION SWITCH:
OFF: Diesel engine is
stopped stopping lever in
SHUTDOWN position
ON: power supply is on,
electric current in solenoid
coil:
3) max. 45A for ~ 350
450 milliseconds battery
12V;
max. 35A for ~ 350 450
millisecond - battery 24V:
4) max. 0.3A in the course
of the diesel engine start-up
time - battery 12V;
max. 0.2A in the course of
the diesel engine start-up time
- battery 24V.
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are removed. In the bottom part of the filter housing there is a fuel-draining outlet with
a drain plug.
There is a bleeding plug 6 (Figure 16) on the filter cover for bleeding air from the
fuel system.
1.2.2.6.5. Air Duct
Air duct comprises an air cleaner and turbo-compressor junction pipes connecting
the air cleaner with turbo-compressor, charge air cooler and intake manifold (Figure
4).
Dry-type air cleaner with paper filter element made of special high-porous
cardboard, is designed for cleaning of the air drawn in cylinder.
There are three stages of air cleaning. The first stage is a monocyclic process, the
second and the third stages are main and paper filter elements.
The air cleaned of dust in the air cleaner under reduced pressure created by means
of the turbo-compressor, and then it is transferred to fluid end of the compressor, and
is delivered under pressure through charge air cooler to cylinders.
For filter elements clogging level control and timely service of the air cleaner the
engine is equipped with a special clogging level control indicator. The air cleaner and
clogging level control indicator is supposed to be installed by a client.
The higher the air cleaner clogging the higher the pressure reduction in the intake
pipeline, and when pressure comes up to 6.5 KPa the signaling device responds. After
the signaling device has responded you should make air cleaner maintenance services.
1.2.2.6.8 Diesel Engine Gas Exchange
Gas exchange diagram is shown in Figure 6.
For air-fuel mixing in cylinders the air charge scheme structure is equipped with
exhaust recirculation gases device.
Exhaust gas recirculation device for account of 5 to 20 % of exhaust gases blow-off
into an inlet channel ensures combustion temperature lowering reducing NOx
emission.
The device is driven by supply of a part of exhaust gases from outlet to inlet
manifold via recirculation gases cooler as a result of unforced difference between
exhaust gases pressure level in front of turbine and charge air pressure, and it depends
on recirculation valve position (opened/closed).
Recirculation valve is controlled by MERCER System installed on the fuel
injection pump.
MERCER System comprises integral modular switch 750 and active devices
for signal generation rate of rotation frequency of camshaft of fuel injection pump and
cyclic supply metering control rod position.
Exhaust gas recirculation cooler work on heat-exchange principle, included in the
engine cooling system.
Breather is designed for exclusion of: excessive pressure in lubricating system,
created by exhaust gases infiltrating to oil crankcase through gas joints of cylinder and
piston group, and by export of oil to the atmosphere.
In the realized gas exchange scheme crankcase blow-by gases via channels in
cylinder block and head enters the pocket created by cylinder head cover and cover
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cap. Breather body 1 (Figure 6) is mounted onto cover cap 4 of the cylinder head.
Under the influence of pressure difference in atmosphere and in the pocket cylinder
head cover, the crankcase blow-by gases pass through slot gaps of the cap 6 in the
breather body 1. Penetrating into the pocket crankcase blow-by gases expand and
collide with oil deflector 2 whereupon they lose energy and are cooled, as a result a
considerable proportion of crankcase blow-by gases oil fog falls out as oil. Oil-free
crankcase blow-by gases is delivered into the atmosphere.
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1- water pump; 2 - thermostatic regulator; 3 strap water pump drive belt; 4 fan; 5 cylinder head cooling jacket; 6
cylinder block cooling jacket; 7 cylinder block sleeve; 8 small cocks for coolant drain; 9 junction pipe; 10 filler plug;
11 heat radiator; 12 oil filter; 13 oil and liquid heat exchanger; 14 coolant drain plug; 15 coolant drain pipe into oil and
liquid heat exchanger; 16 coolant supply pipe into oil and liquid heat exchanger; 17 coolant temperature sensor for fuel
supply system CRS; 18 coolant supply pipe into oil and liquid heat exchanger; 19 emergency coolant temperature indicating
light; 20 recirculation exhaust gases cooler.
Figure 8 Cooling System Scheme
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1- thermostat housing; 2 - piston; 3 primary valve; 4 primary thermal-load carrying member; 5 valve spring; 6 by-pass
valve spring; 7 by-pass valve.
Figure 9 Thermostatic Regulator
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1.2.2.8 Charging mechanism
1.2.2.8.1 Turbo-compressor
The diesel engines D-245.5S3A M, D-245.43S3A M are equipped with turbo-
compressor for air supercharge into cylinders, it uses exhausts energy.
The turbo-compressor supply under pressure the exhaust gases from diesel engines
cylinders to cochlear turbine channels through exhaust manifold. As a result of gas
expansion, turbine wheel is rotated together with the shaft and compressor wheel, which
intake air and deliver it to cylinders under pressure.
1 - turbine wheel with shaft; 2 - turbine housing; 3 single bushing; 4 oil deflector; 5
- eccentric ring; 6 - compressor ring; 7 - special nut; 8, 15 O-ring; 9 - diffuser; 10 -
cover; 11 - compressor housing; 12 axial bearing; 13 spacing sleeve; 14 - intermediate
housing (bearing body).
Supercharge adjustment is carried out by bypass of a part of exhaust gases past turbine
wheel when the charge pressure lever exceeds the set value.
Structurally turbo-compressor according to Figure 10a consists of the following units:
rotor 1, turbine housing 2, bearing body 3, compressor housing 4, actuating device 5,
actuating device mounting bracket 6, air duct 7.
Rotor comprises shaft welded to turbine wheel and compressor wheel, oil seal spacing
sleeve, two washers, a nut and two O-rings. Rotor is rotated in radial bearing placed in the
bearing body. Rotor axial movement is taken by axial bearing.
Adjustable turbo-compressor turbine housing has a built-in by-pass valve. By-pass
valve lever is connected via adjustable rod with actuating device, connected with
compressor output via air duct. Regulating device is adjusted for the set pressure by means
of regulation of the rod length.
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Change of length of the rod of turbo-compressor actuating device is not allowed
during the operation.
Turbo-compressor bearings are lubricated and cooled by oil delivered through pipeline
from the diesel engine lubricating system. The oil is drained from the turbo-compressor
into the crankcase.
Disassembly and repair of turbo-compressor is not allowed during the operation,
and shall be carried out in a special repair workshop.
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The engine mechanism is provided with spaces for input and output of heat transfer
medium from preheating system that shall be installed on a vehicle and shall be used for
the engine preheating for starting it up at the ambient temperature below 20.
2.2.4 Cooling system filling
Fill cooling system tank by way of filling the heat radiator with cooling liquid (liquid
brand and volume of filling is specified in Table of Annex A).
Do not start the diesel engine with empty cooling system.
Do not use water in cooling system to avoid scale formation.
2.2.5 Filling with fuel and oil
Fill the fuel tank with the diesel fuel, oil crankcase and fuel pump - with engine oil.
Fuel and oil brands shall be used according to temperature range of ambient air during
diesel engine operation. Recommended brands of the diesel fuel and oil are specified in
the Table of Annex A.
Use of other fuel and oil brands can result in premature engine failure, in non-
compliance with ecological index, and in hard start in cold weather.
Use diesel fuel that is clean, free of mechanical impurities, oil and water.
Use lubricating agents that are clean, free of mechanical impurities and water.
2.2.6 Diesel engine operation control elements and inspection tools
The diesel engine is remotely controlled from the operator or driver seat. Mounting of
control tools and elements is carried out by the end user during the engine installation on a
tractor.
Camshaft rpm is changed by means of the lever or foot pedal connected to regulating
device operating lever of the fuel pump.
Switching of heating plug and starter at the diesel engine start up is effected by three-
position ignition switch placed on the tractor gauge board. When the key in ignition switch
is placed in position I, the heating plug, shutdown solenoid starting winding, shutdown
solenoid holding winding, starting solenoid, and MERCER System electrical circuit is
engaged; and when the key in ignition switch is in position II - the starter electrical circuit
is engaged.
Oil pressure indicator in the lubricating system and pressure warning switch indicator
shall be installed in the full-flow oil filter body.
Coolant temperature gage and coolant temperature warning switch indicator shall be
installed in the cylinder heads and thermostatic regulator cover correspondingly.
Air cleaner plugging level is controlled by means of air cleaner plugging signaling
indicator designed for indicator lamp lightning when the air cleaner plugging overrides the
standard.
Air cleaner plugging signaling indicator is installed in the intake channel on the air
cleaner exit branch.
Camshaft rpm is controlled by means of tachometer. The signal is received by the
tachometer from the electric generator alternate current terminal.
Diesel control elements are at the gauge board.
2.3 Diesel Engine Operation
2.3.1 Service staff operating procedure during fulfillment of the diesel engine
operation tasks
Before starting the engine complete the following steps:
- check oil level in the engine crankcase;
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- check cooling liquid level in the cooling system;
- check weather the fuel tank valve;
- fill the diesel engine fuel system with fuel according to the procedure prescribed in
paragraph 3.2.10.
Fuel is drained in a tank.
2.3.2 Starting the Engine
Put the transmission gear shift lever in neutral.
Switch the accumulator battery switch on.
Engage the heating plug control unit by way of turning the ignition key in position I; by
doing so you start heating plugs warming up, disengage the starting and holding winding
of shutdown solenoid, and the solenoid drives the shutdown lever into position Opened
(starting winding of shutdown solenoid is disengaged by a built-in restraining device in
two seconds); power supply voltage of MERCER System is supplied.
Period of warming-up depends on the engine temperature, or can be fixed depending
on the type of the used heating plug control unit. When the engine is switched on, an
indicator at the gauge board flashes signing on the end of the heating plugs warming-up.
The indicator is switched off in response to a command of control unit after complete
warming-up of the heating plugs.
After the indicator has switched off, disengage the clutch of the tractor, engage the
starting solenoid (engage the starting solenoid ensures injector control bar position which
corresponds to the greatest fuel supply), turn and hold the ignition key in the position II
and start the engine. During starting duty the plugs remain engaged.
Having started the engine turn the ignition key from the position II into position I. The
starter is switched off. After the starter has switched off during the engine operation, the
heating plugs remain engaged for 180-240 seconds.
Engage the clutch in a smooth manner.
Warm up the diesel engine to achieve the stable operation at camshaft, rpm equal to
1000-1300 min -1 (within 2-3 min), then let the engine operate at increased rpm scaling the
value up to 1600 min -1 until the cooling liquid temperature amounts up to 40 .
Ensure further warming-up of cooling liquid up to 70 during the tractor or
agricultural machine movement in creeper gear.
Use of the diesel engine with full power is allowed only when the cooling liquid
temperature achieves 70.
If the engine is warm, or if it is summer, the engine start can be carried out without
prior engagement of the heating plugs, by turning the ignition key into position II skipping
the position I.
Time of continuous starter operation should not exceed 15 sec. Should the engine
not start, repeat the operations as described after 30 - 40 sec. Should the engine not
start after 3 tries, find the cause of the problem and eliminate it.
In order to facilitate the start at cold weather (when the temperature is below - 20,
perform the following steps:
- disengage all drives of the tractor or agricultural machine make-up systems (Power
take-off shaft (PTO shaft), hydraulic systems pump, compressor);
- bleed the fuel-handling system by manual priming pump to de-air it and to create the
pressure in the fuel pump head;
- warm up the diesel engine with use of starting preheater for cooling liquid;
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- start up the engine as described above.
At cold start the exhaust smokes white for a while which is not a trouble because the
diesel is operated with overcooling.
Do not warm up the draw-in air before the air-cleaner by direct flame.
Do not start the engine by towing the tractor or agricultural machine.
2.3.3 Stopping the engine
Before you stop the engine after operating under a high load, run the engine for 3-
5 min. first at middle, then at min. idle rpm. That will allow the cooling liquid and oil
temperature to cool and stabilize gradually. Failure to meet these requirements will
result in compressor failure.
To shutdown the engine move the ignition key in zero position. After the engine has
been stopped, switch off the accumulator battery switch.
2.3.4 Run-in
Before operating the engine, it must be given a run-in to obtain the wearing-in of the
diesel engine ribbing matters.
Operating the engine at full load without run-in is not allowed.
Run-in shall be carried out by operating organization only.
After starting the engine, make sure it works properly and begin run-in.
The engine must be given 5min. run-in at idling with the gradually increasing rpm to
1600 min -1. and then with full load during 30 hours.
Run-in of the engine mounted at a tractor, agricultural machine is to be done while
operating at reduced load range, gradually increasing the load.
After run-in follow the below-stated requirements:
check the cylinder bolts tightness, tighten them if necessary;
check the clearance between valves and rocker arms;
clean the oil filter;
change oil in the engine crankcase;
drain the coarse and fine fuel filters;
check and tighten if necessary outer tread parts.
2.3.5 Engine operating and service in cold weather
The diesel engine operation becomes more complicated at cold weather. To ensure
continuous engine operating under cold temperature up to +5 and less make cold
weather preparations, combining regular and seasonal service.
If the engine is equipped with ether type starting aids, get it ready for operation.
The engine compartment of the tractor shall be equipped with cold weather heating
jacket, and the diesel engine - with starting aids (pre-heater) if necessary. Fill the cooling
system with the cooling liquid according to Table A (Annex A), check the accumulator
batteries operation state, recharge them if necessary (accumulator batteries shall be fully
charged).
If during warm seasons a special non-freezing coolant was used, make sure it is frost-
resistant and, if needed, introduce the required changes in accordance with the expected
temperature.
When entering in winter operation mode use winter oil and fuel grades according to
Chimmotology List (Annex A).
In case, water is used as a coolant (emergency operation exploitation), be sure to
drain it through plug 9 (Figure 13), when the tractor (machine) is parked for a long
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period.
2.3.6 Troubleshooting
3.1.3 Failure of the fuel pump Send fuel pump for a qualified repair
3.2 The exhaust manifold smoke is white
3.2.1 Engine is overcooled Warm up the engine, keep coolant
temperature to 70-95 C.
3.2.2 Water in the fuel Change the fuel
3.2.3 No valve and rocker arms clearance Adjust valve and rocker arms clearance
3.2.4 Wrong angle of fuel injection lead Set the recommended angle of fuel
injection lead
3.3 The exhaust manifold smoke is blue
3.3.1 Oil in combustion chamber due to Replace the worn-out parts.
sleeve and piston parts wearing
3.3.2 Excessive oil in crankcase Drain excessive oil, check the level with
the dipstick.
4. The Diesel Engine is overheated
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4.1 Insufficient quantity of coolant in the Add coolant and check the level
cooling system
4.2 Dirt on the outside of the radiator Clean the radiator
4.3 Thermostat valve does not open fully Replace thermostat
4.4 Fan belt loosening Replace the belt
4.5 Oiling of fan drive belt and pulley Take the driving belt off, remove oil
wheel from belt and pulley
5. Low pressure of the warmed up engine
5.1 Faulty pressure-gauge Replace the pressure-gauge, after check
of oil pressure with the gauge package
5.2 Oil lines air-tightness is violated Find the cause and eliminate it
5.3 Failure of the oil pump Find the cause and eliminate it
5.4 Oil level is too low Add oil, check the level with
the dipstick
5.5 Safety valve sticking in the oil filter Wash the valve and adjust pressure
in lubricating system
5.6 Extreme wearing of the junctions Eliminate the trouble
crankshaft pivot-bearings
6. The Diesel Engine Overspeeds
Immediately stop the engine by way of fuel supply shutting down. Dismount the fuel
pump from the diesel engine and send it for a qualified repair.
7. Turbo-compressor See Annex F
8. Starter
8.1 When engaged the crankshaft either does not turn or turns slowly
8.1.1 Accumulator battery connections Clean the ends or tighten the terminals
corroded or loose
8.1.2 Accumulator batteries are discharged Charge or replace
8.1.3 Dirty collector and brushes Clean collector and brushes
8.1.4 Collector and brushes poor connection Dismount the starter from the engine,
clean the collector, eliminate the troubles
or replace faulty parts, if they are worn
8.1.5 Starter relay contact bolts and contact Clean the points of contact, or place the
plate surface are burned contact bolts into cover seats, rotating
about an axes by 180, and place the
contact plate by the underside.
Failure of the starter drive Replace starter drive
8.2 After the engine is started, the starter is still on
8.2.1 The contact plate or the contact points Stop the engine, switch off the batteries
in starter control wiring relay is welded and clean the terminals
to the starter relay contact bolts
8.3 Starter armature rotates at high speed but do not crank the diesel engine crankshaft
8.3.1 Flywheel rim drive gear breakage Replace the flywheel rim
8.3.2 The starter drive fails Replace the starter drive
8.4 The starter relay runs harshly (switches the starter on and then switches it off at once)
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8.4.1 Abrupture of the relay holding winding Replace the relay
8.4.2 The accumulator battery is discharged Charge or replace
8.5 Driver pinion is not regularly engaged with the flywheel crown in normal conditions
of the relay operation
8.5.1 Front wear and tear of the backed-off Back-off the flywheel rim gears or
part the flywheel gear rim replace the rim of the flywheel.
8.5.2 Sticking of the driver pinion on Clear the drive from the old lubricating
armature shaft due to the lack of law agent and coat with the lubricant
quality of lubricator CIATIM-201/203/221
8.5.3 Front wear and tear of the backed-off Back-off the teeth or replace the drive
part the flywheel gear teeth
9. Electric Generator
9.1 Ampere-meter (voltmeter) shows no voltage after start and during the engine
operation
9.1.1 "+"-terminal is broken or faults to the Remove rectifier, solder and insulate the
generator housing faulty point. Isolate the insulation fault
point.
(Repair in special workshop)
9.1.2 Excitation coil circuit opening re-assemble generator, solder and
insulate the fault place, and in case it is
impossible, replace the coil.
(Repair in special workshop)
9.1.3 One of the stator phase faults to the Replace stator
generator housing (Repair in special workshop)
9.1.4 Short circuit of power rectifier outputs or Replace the rectifier
diode of direct and indirect polarity (Repair in special workshop)
breakdown
9.1.5 Voltage adjuster failure Replace voltage adjuster
(Repair in special workshop)
9.1.6 Collector and brushes poor connection, Clean the collector, eliminate hanging or
brushes hanging and wear replace the brushes
9.2 No full power output from electric generator
9.2.1 Voltage regulator connecting wires are Solder and insulate the fault point
broken (Repair in special workshop)
9.2.2 One of the stator phase is broken Replace stator
(Repair in special workshop)
9.2.3 Turn-to-turn fault of the stator coil Replace the stator
9.2.4 Turn-to-turn fault of the excitation coil Replace the coil
A diod of the power rectifier failure Replace the rectifier
(Repair in special workshop)
9.3 Accumulator battery is recharged regularly
9.3.1 Voltage adjuster failure Replace voltage adjuster
(Repair in special workshop)
9.3.2 faults to the voltage adjuster output SH Isolate the fault point
housing (Repair in special workshop)
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9.4 Electric generator noise
9.4.1 Driving belt slippage Replace the belt
3 Technical maintenance
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3.1.1 General instructions
Technical maintenance is carried out to keep the engine in working order during its
operation.
Non-compliance with the approved maintenance periodicity and low quality of
maintenance of diesel engine significantly reduce its life cycle, result in increase of the
number of engine failures, decrease of its power and ecological indicators, increase of
operation costs.
Running diesel engine without regular technical maintenance is forbidden.
Deviation from the approved periodicity of technical maintenance is permitted within
the range of 10%.
Marks concerning carrying out regular technical maintenance (excluding STM) shall
be included into a tractor/agricultural machine service book.
During technical maintenance when preparing for long-term storage and during
technical maintenance TM-3, a technical diagnostics of the engine is carried out, where
necessity of engine repair is defined as well as the kind of repair current or capital.
All troubles, identified during carrying out technical maintenance, shall be
eliminated. Maintenance operations, associated with disassembly of its assembly units,
shall be conducted in indoor area to keep dust and dirt away form getting into body
cavities of engine assembly units.
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3.1.1.1 Kinds and periodicity of technical maintenance
Kinds and periodicity of technical maintenance are given in table 10.
Table 10
Diesel operation
Type of technical maintenance Yearly Seasonal
Periodicity or hours
1 Technical maintenance when preparing for Before operating a new engine or an
running-in engine after capital repair.
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Table 11
Type of technical
Composition and proficiency of attending personnel
maintenance
STM Operator, driver of a tractor, equipped with diesel engine
TM-1; 2TM-1; Mechanic of 3 4 skill-category, who passed general technical
TM-2; SS; AW training under the program of mechanics teaching, possessing
knowledge on organization and general operation principle of
diesel engines -245S3A M and their modifications; operator
driver of a tractor, equipped with the engine
M-3; 2M-3 Motorman of 4-5 skill-category or set-up man and mechanic of
3-4 skill-category, who passed general technical training under
the program of mechanics teaching, possessing knowledge on
organization and general operation principle of diesel engines -
245S3 M and their modifications, or operator, driver of a
tractor, equipped with engine
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To ensure safe work and to forestall casualties during technical maintenance of diesel
engine observe the following rules:
- washing operations can be carried out by a person only after he has got theoretical and
practical instructions;
- work with washing equipment unearthed and electric motor of a pump with neutral
wire unearthed is not permitted;
- washing outside equipped washing places, which ensure ecological safety, is not
permitted;
- do not start the engine in a closed room with poor ventilation;
- technical maintenance and elimination of faults shall be conducted with the engine
stopped;
- to prevent burns on face and hands, radiator filler cap on a hot engine shall be opened
using a glove or cloth;
- fixtures used at work shall be in operating conditions;
- tools shall be in good order and correct in size;
- for inspection use portable lights with voltage not higher than 12V;
- fuel is drained outside fuel system (by bleeding) to a container only;
- oil and preservative mixtures shall be drained to containers only;
- prevent POLs from spilling at working place;
- when conducting technical maintenance ensure that working place is fitted with fire-
extinguishing means;
Table 12
Kind of technical maintenance
Name of work
SM M-1 2M-1 M-2 M-3 2M-3 SS AW
1 Check oil level in engine + + + + + +
crankcase
2 Check coolant level in + + + + + +
cooling system
3 Drain sediment outside + + + + +
coarse fuel filter
4 Replace oil filter + + + +
5 Replace oil in engine crank + + + +
case
6 Drain sediment outside fine + + + +
fuel filter
7 Carry out maintenance of air
+ + +
cleaner
8 Check all connections of air
cleaner and inlet pipeline for + + +
tightness
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Table 12 continued
Kind of technical maintenance
Name of work
SM M-1 2M-1 M-2 M-3 2M-3 SS AW
9 Check clearance between
+ + +
valves and rocker arms
10 Check cylinder head bolts
+ +
for tightness
11 Wash coarse fuel filter + +
12 Replace fine fuel filter + +
13 Check fuel pump on a test
+
stand
14 Check injectors for
injection pressure and quality of +
fuel atomization
15 Check fixed advance angle
+
of fuel injection
16 Check condition of engine
starter (brushes, collector,
+
springs, terminals and other
parts)
17 Wash cooling system +
18 Replace winter-type oil in
engine crankcase with summer- +
type oil
19 Set screw of voltage
seasonal adjustment of +
alternator into position
(S) (summer)
20 Replace summer oil with +
winter oil in engine crankcase
21 Set screw of voltage
seasonal adjustment of +
alternator into position
(W) (winter)
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3.1.5 Preservation (represervation) when placed for storage
Depending on the kind of delivery, specified in an agreement or a contract, diesel
engines, supplied to the customer, are preserved for a period of 6 months or for one year.
Specific period of preservation is given in the engine passport.
When the engine is stored for a longer period than the preservation period given in the
passport, it shall be exposed to represervation.
Represervation after six months' storage period shall be made for 1 year of storage.
Represervation for six months' storage period is not permitted.
When put for short storage period (10 days 1 month) diesel engine in a tractor or
vehicle assembly is preserved in accordance with clause 3.1.5.1.
When put for long storage period (1 month and more) diesel engine in a tractor or
vehicle assembly is preserved, or exposed to represervation when the storage period is
more than 6 months, in accordance with clause 3.1.5.2.
It must be noticed that after the engine has been started, its inner cavities, cooling
system and fuel supply get depreserved.
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Turn off all drain cocks and fill the cooling system with coolant of recommended type
to the relevant level in conformity with Chimmotology list (Annex A).
Mount and connect the accumulator battery. Charge the battery if necessary.
Disconnect oil delivery pipeline from the casing of central bearings of turbocharger.
Previously lubricate the bearings, pouring oil to the hole up to the flange level. Connect
the delivery pipeline using a new gasket, tighten bolts of the delivery pipeline flange.
Start the engine.
Increase pressure
Decrease pressure
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It is possible to install element filters of solid type: modification X149 by company
Lelko (France); modification L37198 by company Purolator (Italy).
Filter 009-1012005
Oil drain
1-filter body; 2 liquid-oil heat exchanger (LOHE); 3 fitting; 4 filter gasket; 5 LOHE gasket; 6 contra-discharge
valve; 7 overflow valve; 8 protection valve; 9 plug for coolant drain; 10 seal ring; 11 LOHE protective valve.
Figure 13 oil filter with LOHE
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3.2.8 Drain of sediment from fine fuel filter
Drain sediment in every 250 hours of engine operation.
Unscrew plug 4 in the lower part of the fine fuel filter by 23 revolutions in
accordance with figure 16 and drain sediment until clean fuel remains. Screw the plug in.
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In future order the following oil filters:
a) 020-1117010 at the address: JSC Avtoagregat, 303858, 2 Industrialnaya
Street, Livny, Orlovskaya oblast, Russia;
b) T6101 at the address: EJSC DIFA 230019, 45 Belusha Street, Grodno, Republic
of Belarus
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3.2.11 Maintenance of air cleaner
Carry out maintenance of air cleaner with paper filtering elements of special high-
porous cardboard in every 500 hours of engine work or, if necessary, by indications of
impurity annunciator. Maintenance of air cleaner consists in bleeding the main filtering
element that captures dust entering the air cleaner. Contamination of the control filtering
element points to failure of the main filtering element (tear of paper curtain, bedplates
coming unstuck). In this case it is necessary to bleed the control filtering element and to
replace the main one.
Carry out maintenance of the air cleaner in accordance with figure 18 in the following
order:
- remove the monocyclone, clean the net, swirler and monocyclone discharging slits
from dust and dirt;
- remove bottom 6;
- remove the main filtering element 1.
It is not recommended to remove the control filtering element 2 from the body.
Bleed the main filtering element with compressed air, first outside and then inside, until
dust is fully removed. To prevent tearing of the paper curtain, air pressure should be not
higher than 0,2-0,3 MPa.
Air jet must be directed at an angle to the filtering element surface. During maintenance
it is required to protect the filtering element from mechanical damages and oiling.
It is forbidden to bleed the filtering element with exhaust gases or to wash with diesel
fuel.
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Clear out the delivery pipe, inner surfaces of the air cleaner body and bottom.
Before assembling the air cleaner check the state of seal rings. When assembling make
sure that all filtering elements are correctly mounted in the body and firmly tighten the
wing nut manually.
3.2.12 Check of air cleaner and inlet channel for connections tightness
Check air cleaner and inlet channel for connections tightness when conducting TM-2.
Use a devise -4870 GOSNITI for tightness check.
If the devise is not available, check tightness of connections visually.
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inlet valves 0,25 mm;
0.05
0.10
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After adjustment fuel pumps shall be sealed in a manner, which excludes the possibility
of making adjustments without seal removing.
3.2.17 Check and adjustments of the fixed fuel injection advance angle
When it is difficult to start the engine or the exhaust is smoky and also when replacing,
mounting the fuel pump after check on a stand through 2TM-3 or when repairing the
engine, check the fixed fuel injection advance angle.
Parameters for the fixed fuel injection advance angle are presented in table 13.
Table 13
Diesel
-245S3 -245.2S3 -245.5S3 -245.43S3
High-pressure
Fixed fuel injection advance angle,
fuel pump
degrees of crankshaft turn
410Uli-3794 3,50,5
410Uli-3793 3,50,5
410Uli-3795 4,00,5
410Uli-3796 4,00,5
The fixed fuel injection angle is checked in the following sequence:
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-set a governor control lever to the position of max. fuel supply;
-detach a high-pressure pipe from the fitting of pump first section and connect an
ignition tester instead (a captive nut with short pipe, to which a glass pipe with inner
diameter 1-2mm is connected through a rubber pipe, fig.21);
-turn the engine crankshaft clockwise with a wrench until fuel without air bubbles
appears outside the ignition tester glass pipe;
-release some air from the glass pipe by shaking it;
-turn the crankshaft back (contraclockwise) by 30-40;
-turning the crankshaft clockwise slowly, watch fuel level in the pipe, as the fuel
starts going up stop turning the crankshaft;
- screw the detent out of the threaded hole of the rear plate and insert it with its
back side in the same hole until it stops against the flywheel (Figure 22), herewith the
detent shall coincide with the hole in the flywheel (this means that the first cylinder piston
is set in a position, corresponding to the fixed fuel injection angle given in table 13);
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If the detent does not coincide with the hole in the flywheel, make adjustments, for
this do the following:
- mate the detent with the hole in the flywheel, turning the crankshaft to this or that
side;
- remove a hatch cover (Figure 23);
1 hatch
cover; 2 nut; 3 pin; 4 special nut; 5 drive half-coupling;
6 fuel pump drive gear
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Figure 23 Fuel pump drive
- slowly turn the engine crankshaft clockwise until the detent coincides with the hole
in the flywheel;
- remove the hatch cover 1 (Figure 23);
- release nuts 2 of the fuel pump drive gear attachment by 11,5 revolutions;
- unscrew cap 4 (Figure 23a) of the position detent of the high-pressure fuel pump
camshaft 27 (Figure 5);
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1 camshaft
segment disk; 2 detent bar; 3 detent body; 4 cap; 5 spring.
- remove spring 5 and sink in the detent bar until it touches the camshaft segment
disk;
- turn the high-pressure fuel pump camshaft to one and other side using special nut 4
(Figure 23) within the slots of the fuel pump drive gear 6 until the detent bar 2 coincides
with a hollow in the segment disk 1;
If the detent bar 2 has not coincided with the hollow in the segment disk 1:
- remove the detent bar 2 from the detent body 3;
- remove the detent from the hole in the flywheel and turn the crankshaft by one
revolution (360) until the detent coincides with the hole in the flywheel;
- turn the high-pressure fuel pump camshaft to one and other side using a special nut
4 (Figure 23) within the slots of the fuel pump drive gear 6 until the detent bar 2 coincides
with a hollow in the segment disk 1;
- fix the camshaft position, screwing cap 4 with spring 5 on detent body 3 (Figure
23a, position b));
(such fixation of crankshaft and camshaft positions means that the first cylinder
piston is set to a position corresponding to the fixed fuel injection advance angle, given in
table 13, and section 1 of the fuel pump is set to the position of start fuel geometric
delivery);
- tighten nuts 2 of fuel pump drive gear attachment;
- unscrew cap 4 and set spring 5 and detent bar 2 to the position a), shown in picture
23a;
- mount the hatch cover back and screw the detent to the rear plate hole;
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Beginning and end of injection shall be clear, appearing of drops on atomizer tip is not
permitted.
Check atomization quality at frequency of 60-80 injections per minute.
If necessary, adjust the injectors changing the total thickness of adjusting washers 2
(Figure 24): increase of total thickness of adjusting washers (increase of spring
compression) enhances the pressure, their decrease reduces the pressure. Change of the
washer thickness by 0,1 mm results in change of pressure of injector needle rise start by
1,31,5 MPa.
Value of injection start pressure for injectors is 28,0 1, 2 MPa;
Mount injectors on the engine. Tighten bolts of injector attachment evenly in 2-3 steps.
Final tightening torque is 2025 Nm.
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4 RUNNING MAINTENANCE
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Table 14
Failures and damages eliminated by current repair in conditions
of:
Engine component
specialized maintenance rooms,
household shops
enterprises
Turbocharger - all faults and damages
Fuel pump - all faults and damages
Cylinder head valve leakage Wear of inner surfaces of valve
guides; limit of valve seat wear;
distortion of surface of head
adjoining block; cracks; damages
of thread holes
Sleeve - piston decrease or loss of
conjugacy sealing -
capability
Water pump all faults and damages -
Oil pump - loss of efficiency
Gear pump - loss of efficiency
Clutch - loss of efficiency
Compressor - loss of efficiency
Starter erosive wear of starter coil turn-to-turn short circuit;
relay terminal pair; wear damage of coil insulation; wear of
of brushes; of commutator
bearings; drive fault
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Fixtures used in work shall be in good order. Withdrawal tools shall have no cracks,
bent rods, slipped or crushed thread. Use of worn-out or faulty withdrawal tools is
forbidden.
Working tools shall be in good order and of a proper size. Wrenches with worn or
deformed opening are forbidden to use.
To check coincidence of holes, use an internal tool, a short crowbar or a bolt and never
a finger.
When working on drilling or snagging grinder or when using pneumatic tools, it is
required to follow specified safety precautions.
When using electric tools, it is required to follow measures of electrical safety: use tools
with unfaulty electrical insulation, ground the equipment, use individual protection
equipment.
The working place shall be provided with fire-extinguishing equipment.
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Table 15 continued
Instructions on Instructions on
Description of
defining results of eliminating
failure and damage
Possible causes failures and damages results of
results
of assembly unit failures and
damages
Water pump
3.Coolant leaks 3.1 Wear of Remove water
3.1 When conducting
through drain orifice contact surfaces pump from the
STM control coolant
of face seal engine,
level in the cooling
disassemble the
system
pump (cl.4.2.3)
Replace water
3.1.1 Inspect the
pump sealing
water pump on
gland
started engine during
warm-up.
3.2 Applying force to
3.2 Wear of Replace
the pump pulley on
bearing unit bearings, water
stopped engine
pump body (if
inspect radial play in
necessary)
bearing unit
4.No coolant Loose running of Remove water
By control of
circulation in engine impeller on pump pump from the
temperature mode of
coolant system shaft engine,
engine cooling
disassemble the
system on
water pump
temperature indicator
(cl.4.2.3)
a steep rise of coolant
temperature is
Replace the
observed
impeller and
(or) the pump
shaft
4.2.1 Main instructions on piston rings replacement
Remove the cylinder head and oil sump from the engine. Set the piston to lower dead
centre, manually turning the engine flywheel. Clear sludge from sleeve top chord,
preventing sludge particles from getting inside the cylinder.
It is forbidden to use a steel scraper by cleaning with the aim to prevent the sleeve
surface from damage.
Unscrew nuts of connecting rod attachment, remove the connecting rod cover and take
piston-rod group out from the cylinder. Take the piston-rod group up to the side of
cylinder head installation.
Each piston of the engine is provided with upper trapezoidal compression ring, one
compression V-ring and one oil scraper ring of box-type with spring extender.
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Compression rings at the end surface by the lock have a mark and TOP,
which shall be turned to piston top by rings installation. Extender joint of oil scraper ring
must not coincide with the ring lock.
Piston ring locks shall be positioned at equal distance round the circle.
Put the piston-rod group inside the cylinder, mount the rod cover.
To prevent piston rings from damages by piston-rod group installation inside the
cylinder, use a tool for ring pinching.
Torque value of piston cover attachment nut is given in table (Annex D).
Atomizing nozzle
Combustion
chamber axis
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Continue to grind until continuous dull string-course with width not less than 1,5 mm
appears on valve face or on valve seat face, breakage of the strip and scratch marks are not
admitted. Width variation of the string-course shall not exceed 0,5 mm.
After grinding, valves and head shall be washed.
By the head assembly the valve rod shall be lubricated with motor oil.
It is possible to ground the valves manually, using a bench tool, but the labor content of
grinding operation will thus significantly increase.
1 body; 2 pump shaft; 3 impeller; 4 water pump sealing SP/1341; 5 bearing; 6 liner; 7 pulley; 8 dowel; 9 nut;
10 blind plug; 11 washer; 12 lock ring; 13 thrust ring.
Figure 26 Water pump
Figure 27- Tool for pressing-on water pump sealing (main structural dimensions)
Press the impeller on the shaft, install the blind plug in the impeller butt end. Sinking of
the impeller butt end against the mounting surface of the water pump body shall not
exceed 0,3 mm, jutting of the impeller is not allowed.
Install the water pimp on the engine.
5. STORAGE
To insure engine workability, to save in material and monetary resources for their repair
and preparation for work, it is strictly required to follow the rules of engine storage in idle
time.
The engine shall be stored in absolute compliance with GOST 7751-85 irrespective of
the time of the year. By long-time storage (over one month) a tractor, harvester or a
machine with the engine installed shall be put in a closed room or under a tent. It is also
allowed to store tractors, harvesters, machines in open improved space, obligatory having
performed all works on preservation and encapsulation.
Engine preparation for storage shall be finished not later than 10 days from the moment
of work ending.
Preparing the engine for long-time storage do the operations in accordance with clause
3.1.5.2.
If a tractor, agricultural machine is stored under the tent or in outdoor area, remove an
alternator and a starter from the engine and sent them to a warehouse. Cover the place of
starter installation with a cap.
Diesel engines that have been removed from tractors, harvesters, machines or received
as spare parts shall be stored in a preserved condition in a closed room on special
platforms. It is forbidden to store accumulator batteries, acids, salts, alkalies and other
substances which can cause metal corrosion together with diesel engines and spare parts in
one room.
In case of short-time storage of a tractor, a harvester, a machine in outdoor area or
under a tent (10 days 1 month), do the operations in accordance with clause 3.1.5.1.
Before placing a tractor, a harvester, a machine in operation, execute all preparatory
works in accordance with clause 3.1.6.1 or clause 3.1.6.2.
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6. TRANSPORTATION
By engine transportation all external orifices shall be closed with plugs.
Engine transportation shall provide protection against moisture attack and mechanical
damages under storage conditions 2 (C) GOST 15150-69.
Positioning and fastening of engines when transported in closed railway cars shall
comply with the requirements of Technical conditions of freight handling and fastening,
Ministry of railway, 1969, and also Rules of freight hauling, published by Transport,
Moscow, 1977.
In case of hauling by automobile transport, loading, positioning, fastening, covering and
unloading shall comply with Rules of freight hauling by automobile transport, approved
by Ministry of automobile transport of Russian Soviet Federative Socialist Republic on
July 30, 1971.
7. RECYCLING
The engine does not contain substances which are dangerous for life, health, people and
environment.
To recycle the engine after its life end it is necessary to do the following:
- drain oil from the lubrication system and send it for reprocessing in a set order;
- drain coolant from the cooling system (if it was used during engine operation) and put
it into containers destined for storage;
- carry out complete engine disassembly into parts, sorting them to steel-made, iron-
made, aluminum-made, made of non-ferrous and precious metals, rubber and plastic, and
send for reprocessing in a set order.
In case of carrying out maintenance or running maintenance of the engine, parts and
assembly units subjected to replacement (if necessary) shall be sent to reprocessing,
herewith assembly units shall be taken into parts and sorted according to their material
composition.
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Annex (referential)
Chimmotology list
Table .1
Assembly unit name, Amount Mass
index of Designation and denomination of petroleum (volume) of Periodicity
Ref. (stand-alone device, assembly oil and lubricant (POLs)grades POLs filled in of POLs Note
numb mechanism, friction units in an item by replacement
er unit) item, pcs replacement (adding),
(adding), kg h
Basic Duplicating Reserve Foreign (dm)
1 Fuel tank 1 Diesel fuel, the specifications Not available Not available Diesel fuel, According to
of which comply with the Directive
requirements of STB 1658- specifications 2004/26/EU and
2006 with sulfur content not of which Rules of UN's
more than 50 mg/kg (0,005%) comply with Economic
of a grade (for moderate requirements Commission for
climate) or of a class (for of EN Europe No 96 (02)
arctic and cold climate) in 590:2004 with (stage IIIA) it is
accordance with ambient sulfur content allowed to use fuel
temperature at a place of not more than with sulfur content
engine operation. 50 mg/kg not more than
(0,005%) 0,3g/kg (0,03%)
Notice:
For moderate climatic zones it is recommended to use the following fuel grades For arctic and cold climate it is recommended to use the following fuel classes with the given
with the given ambient temperature (): ambient temperature ():
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Seasonal use of diesel fuel grades in the Republic of Belarus depending on the ambient temperature
Summer period Winter period
Grade Grade Grade F
Up to 0 (not lower) Up to -5 (not lower) Up to -20 (not lower)
From May 1 till September 30 (5 months) From April 1 till October 30 From November 1 till March 31
agreed upon with a consumer (7 months) (5 months)
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Table .1 continued
2 Oil sump* 1 In summer (stationary ambient temperature higher than +5 ) 10,7 (12)** 250
Motor oil Not available Not available Motol oils
Lukoil Liqui Moly Super Leichtlauf
Avangard SAE 10W-40, 125 For diesel engines,
Extra BP Visco 3000 mounted in harvesters
SAE 10W-40 SAE 10W-40,
Shell Helix Plus
SAE 10W-40,
Elf Competition SX Use of motor oil depending
SAE 10W-40, on operation conditions:
Agip 2000 GPX ) summer (plus 5 and
SAE 10W-40, higher) SAE 30; SAE
Esso Ultra Oil X 10W-40 (30); SAE 15W-40
SAE 10W-40, (30); SAE 20W-40 (30)
Mobil Super Formula ) winter (minus 10 and
higher) SAE 20; SAE
SAE 10W-40 10W-40 (30)
In winter (stationary ambient temperature below +5 ) ) winter (minus 20 and
Motor oil Not available Not available Motor oils higher) SAE 10W-20 (30,
Lukoil Liqui Moly Diesel Synthoil 40); SAE 5W-30 (40)
Avangard SAE 5W-40, ) winter (below minus 20
Ultra Ethyl Hitec 5909, ) SAE 5W-30 (40);
SAE 5W-40 Castrol TXT Softec Plus, SAE 0W-30 (40)
Elf Synthese SAE 5W-40,
Esso Ultron SAE 5W-40,
Shell Helix Ultra
SAE 5W-40,
Mobil 1 Rally Formula
SAE 5W-40
* All oil grades presented in the chimmotology list shall comply with classes CH-4, CI-4 under classification API and with E4-99, 5-02 under classification
**- oil mass (volume) is defined by topping to the upper mark on oil dipstick when refilled.
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Table .1 finished
Assembly unit name, Amount Mass Periodicity
index of Designation and denomination of petroleum (volume) of of POLs
Ref. (stand-alone device, assembly oil and lubricant (POLs)grades POLs filled in replaceme
numb mechanism, friction units in an item by nt Note
er unit) item, pcs replacement (adding),
(adding), kg h
Basic Duplicating Reserve Foreign (dm)
3 Water pump 1 Once- Put in by a manufacturer.
(bearing cavity) through It is not required to add
Grease Litol-24-MLi4/12-3 Shell Retinax EP,
Not available 0,045 (0,05) grease during operation
GOST 21150-87 Shell Retinax HD
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Annex B (referential)
Quantity sheet of spare parts, tools and accessories (spare parts, instrument)
Designation of a tool, accessory Product code Name of a tool, accessory Amount in a kit Note
50-3901034 47 5341 2815 Plate 0,25100 1 Lay-in point
60-3901034 47 5341 3054 Plate 0,45100 1 CHP-10-01
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Annex C (referential)
Table C.1
2 75,00 0.101
0.082
68,00 0.096
0.077
2 85,00 0.104
0.085
72,75 0.119
0.100
Main and connecting rod journals and crankshaft bearing liners are made in two rating
dimensions.
Crankshafts, main and connecting rods of which are made according to the second rating
dimension, have additional designation on the first cheek:
2 main journals of the second rating;
2 (2SH) connecting rods of the second rating;
2 (2KSH) main and connecting rod journals of the second rating.
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Annex D (referential)
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Annex E (referential)
Adjusting parameters of fuel pump PP4M10U1i 3793 when checked on the stand.
Fuel pump shall be adjusted in the stand MOTORPAL NC132:
- nozzles BOSCH 1 688 901 101 (0,6 mm, opening pressure is 20.7 MPa);
- fuel pipelines 6/2 600 mm;
- test fluid ISO 4113 (SHELL S.9365), temperature - 402 ;
- pressure valve is adjusted at 0,16 0,20 MPa.
Table E.1
(mm3/stroke)
values of fuel
(mm3/stroke)
Revolutions
Operation
difference
Limiting
(min-1)
between
delivery
sections
No
Operation Note
Max.
Excessive pressure corrector shall be taken out of service by means of a fixture refers to operation 29.
1 Negative corrector spring shall be displaced by a bolt from idle position by 905 of bolt revolution
preliminary done during production.
Section adjustment Jutting of control rod shall be adjusted by adjusting bolt up to the level
for equal deliver 2 1100 153,0156,0 8,0
of approximately 1,5 mm from high-pressure fuel pump body end.
Beginning of control rod
Overtravel 3 11201140
travel in STOP direction
Adjusted by regulator cam stop bolt
adjustment STOP. Setting lever stop bolt shall be screwed to contact the setting lever and then unscrewed by
4 max.1230
1.25 revolutions (i.e. 1 mm)
Complete sleeve of idle running shall be unscrewed from the main
Negative correction
adjustment 1100 100 145,0148,0 8,0 lever.
If necessary adjust by changing of negative corrector shift.
Adjustment of start A complete sleeve of idle running shall be screwed in the main lever so that automatic start ended at
ending 6 450490
this speed. Start ending is controlled by speed decreasing.
Positive correction 138,0142,0 8,0 Fuel supply shall be adjusted by screwing a corrector in the regulator
adjustment 7 800
(136,0144,0) (10,0) main lever.
Adjustment of start
ending 8 420450 Automatic start ending is controlled (aligned if necessary) by the adjusted positive corrector.
130,0150,0 12,0 Mount a plug of control rod arrester. Control of supply for start in
Delivery for starting 9 100
(130,0150,0) (20,0)
control lever position (MAX) and . (IDLE
RUNNING).
Bring the excessive pressure corrector into service by a fixture. Set the stop lever into position STOP and back
10 into position RUN. Connect a pressure air line. Adjustment and supply control are carried out by means of
gradual increase of speed and air pressure by data under clauses 1119
122,0126,0 8,0 The pressure is 0,0MPa. The control lever is in (MAX)
Excessive pressure
position. The supply shall be adjusted by the adjusting bolt of the
corrector 11 500
(122,0128,0) (10,0) excessive pressure corrector.
adjustment
128,0132,0 8,0 The pressure is 0,113 P. The supply is adjusted by displacing the
12 700
(126,0134,0) (10,0) spring of excessive pressure corrector.
138,0142,0 8,0 The pressure is 0,120 P. Control of supply and correction ending by
13 800
(136,0144,0) (10) the excessive pressure corrector.
20,024,0 6,0 The pressure is 0,0 P. The supply shall be adjusted by the bolt of
14 400
(18,026,0) (10)
idle running arrester. Control of stop setting function. In case of a stop
Control of idle the supply shall be zero.
running
15 350 min. 40 - The pressure is 0,0 P. Control of idle running supplement.
16 max. 525 STOP of idle running.
Mount a fixture with micrometer in a hole opposite the control rod. Adjust the supply in conformity with the
instruction.
Adjustment of 118,0122,0 - The pressure is 0,131 P. The disconnect switch shall be adjusted by
control rod switch 17 turning the adjusting bolt. So that engagement/disengagement (light
1100
(116,0124,0) - emitting diode glows/ doesn't glow) occurred in the supply interval.
Mount the cover.
The pressure is 0,131 P. Adjust the supply with the fixture with
1100 110,0113,0 -
micrometer so that all switches were linked (the LED glows).
Control of Speed
switch 18 670 The same - Control of switches disconnect (the LED doesn't glow).
position of
720 - Control of switches disconnect (the LED glows)
micrometer
145,0148,0 8,0 The pressure is 0,131 P. Control of operation No2. Tighten bolts of
Control of rated
delivery 19 1100
(143,0150,0) (10,0)
sections, mark their position. Control of the stop setting function. In
case of the stop the supply shall be zero.
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245S3A 0000100
Annex E (referential)
Operation
1. The stop lever shall be mounted and fixed on the control shaft in the extreme position
OPERATION so that the angle between the lever axis and the horizontal was 77
90.
2. Holding the stop level in the extreme position OPERATION, screw out the articulated
rod until the electromagnet core shifts against the stop and starts to force down the
stop lever. From this moment on, screw out the rod by two revolutions more.
3. Fix the rod with a lock nut.
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245S3A 0000100
Annex F
Black smoke
Blue smoke
88
245S3A 0000100
Annex G (referential)
mm
(Obligatory dimension)
89