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Diesel engines OPERATION & MAINTENANCE MANUAL

1. 3 Low side short circuit to battery Check engine cylinders injec 30 1 4 3 eee Depending on the settings Fault in power stage control circuit of cyl tors connectors and cables P0267 Low side and High side short cir inder 3 specific error engine shutdown condition cuit Apply to service centre P0269 11 12 Not classified error P1219 11 Depending on the settings Check engine cylinders injec jd leues PI21A 11 Depending on the settings Fault in power stage control circuit of cyl tors connectors and cables P0203 12 No load resistance inder 3 specific warning condition P1218 11 15 Depending on the settings Apply to service centre P0271 3 Low side short circuit to battery P0272 11 Depending on the settings e Check engine cylinders injec 32 1 4 4 me h Fault in power stage control circuit of cyl tors connectors and cables P0270 8 Low side and High side short cir inder 4 specific error engine shutdown condition E cuit Apply to service centre P0272 11 2 Not classified error Continuation of Table 10 Fault type Fault description Fix method P121C 11 Depending on the settings Check engine cylinders injec as 1 4 4 P121D 11 Depending on the settings Fault in power stage control circuit of cyl tors connectors and cables P0204 12 No load resistance inder 4 specific
2. switch f manual fuel supply control sensor c 1 29 GJUXG b 1 30 G GJJ A Diagnostic lamp Low level p 1 3i B DCANL CAN low level V 1 85 B D CANH CAN high level 1 40 U T15 Control lamp 15 of starter motor and controls switch K 1 44 Lowiitle smtcht Switch x x of fuel supply control pedal sensor d 1 72 ESJDIAREQ Diagnostic button input a 1 76 G R APP2 Manual fuel supply control sensor 0 B 1 1 77 V V 5VAPP1 Fuel supply control pedal sensor 5 B f 1 78 APP1 Fuel supply control pedal sensor 0 B h 1 79 1 AJIPPT Fuel supply control pedal sensor signal 9 180 1A APP2 Manual fuel supply control sensor signal k 184 V VSVAPP2 Manual fuel supply control sensor 5 B J 1 89 BjDJSOK ISO K Line 5 2 09 USAS Camshaft position and speed sensor signal 2 10 G RJIAS Minus of camshaft position and speed sensor 212 5 Minus of RAIL pressure sensor 2 13 V VJVRAILP lt 5 V of RAIL pressure sensor 2 14 LA RAIL PS RAIL pressure sensor signal 215 PA CTS Cooling liquid temperature sensor signal 2 16 V VJVFLPS 5V of fuel pressure and temperature sensor 2 17 G RJ LPS Minus of fuel pressure and temperature sensor 2 18 Shield Camshaft angle and speed sensor screen 219 G_RCRS Minus of crankshaft position and speed sensor 0 75 2 20 Shield Crankshaft position and speed sensor screen 221 U SLPS Fuel pressure and temperature sensor pressure signal 0 75 2 23 U CRS Crankshaft angle and speed sensor signal 0 75 2 24 G RJ
3. 3 10 1 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing check electricity consumers condition with the diag nostic device 3 10 Engine does not stop check for faults in the COMMON RAIL injection sys Follow the instructions in thd KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop Do diagnostics and the neces sary repair 4 Noise smellx or smoke 4 1 Knocking or noise in the engine 4 1 1 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing check for faults in the COMMON RAIL injection sys Follow the instructions in thd KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop tic device CRS check electricity consumers condition with the diagnos Do diagnostics and the neces sary repair 4 1 2 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 check the intake manifold for clogging Clean the intake manifold 4 3 Check compression level in the cylinders Do the necessary repair Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 4 1 4 Check the low pressure circuit check th
4. 7 Coolibg liquid temperature sensor R al Am rN EA ra ES JC n a X T i 7 maie OA BIN Fig 4a Location of sensors and actuating mechanisms Table 8 Sensor and actuating mechanism Location 1 Crabkshaft angle sensor Distribution cover gt Camshattanife sensor High pressure fuel injection pump 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 7 Cooling liquid temperature sensor Thermostat housing 8 Injectors Cylinder head 9 Pressure regulator High pressure fuel injection pump 1 high pressure fuel injection pump 2 high pressure fuel accumulator 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 cooling liquid temperature sensor 10 fuel temperau re and pressure sensor 11 angle sensor 12 pressure regulator 13 oil temperature and pressure sensor Fig 5 CRS system structural diagram electric and hydraulic 1 2 2 6 1 High pressure fuel injection pump Installed in diesel engines are High Press
5. 9 1 6 Bad brushes contact with collector Brushes wear Clean the collector eliminate the brushes loosing or replace them with new ones 9 2 Alternator does not generate full power 9 2 1 Regulator lead broken 9 2 2 One of the stator phases broken Solder and insulate the dam aged place Repair at a specialized workshop Replace the stator Repair at a specialized workshop 9 2 3 Stator winding turn to turn short circuit Replace the stator Repair at a specialized workshop 9 2 4 Field coil winding turn to turn short circuit Replace the field coil Repair at a specialized workshop 9 2 5 One of the power rectifier diodes faulty Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 9 3 Accumulator battery recharging systematically Replace the power rectifier Repair at a specialized workshop 9 3 1 Faulty voltage regulator 9 3 2 Voltage regulator bridging to lead housing Replace the voltage regulator Repair at a specialized work shop Insulate the damaged place Repair at a specialized work shop 9 4 Alternator noise 9 4 1 Drive belt slipping or excessive tensioning Adjust the drive belt tension 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
6. Check for air leakage suction Do the necessary repair Check the air filter condition Replace the air filter by new one check the intake manifold for clogging Clean the intake manifold 3 6 3 Check oil consumption At oil consumption too high da the necessary repair 3 6 4 Check the injectors vice launch injector check cycle by the appropriate standard Follow the instructions in the testing command in the KTS Bosch diagnostic de4 KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop 3 6 5 Control Unit check check the Control Unit plug and socket fixtures Fix plug and sockets 3 7 Excessive fuel consumption 3 7 1 Check the low pressure circuit check the correctness of connections in the low pres sure circuit check the hoses and pipe connectors for leakage Do the necessary repair check the fuel filter condition and conformity Replace filter by the appropri ate make sure there is no water in the fuel inside the coarsd Clean the fuel filter from watel 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 3 7 2 Leakage in the fuel temperature sensor Replace the fuel temperature sensor 3 7 3 Check the injectors lau
7. KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop 4 7 Blue white or black smoke when accelerated 4 7 1 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing 4 7 2 Check the intake system check for faults in the COMMON RAIL injection sys Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop Check for air leakage suction Check the air filter condition Do the necessary repair Replace the air filter by new one check the intake manifold for clogging Clean the intake manifold 4 7 3 Check the low pressure circuit check the correctness of connections in the low pres sure circuit check the hoses and pipe connectors for leakage check the fuel filter condition and conformity Do the necessary repair Replace filter by the appropri ate make sure there is no water in the fuel inside the coarse fuel filter cup Clean the fuel filter from water 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 Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 4 7 4 Check the engine oil level 4 7 6 Check oil consumption Add oil to the g
8. Sent to CAN messages error other CAN devices A 865 Apply to service centre E Check CAN line connection to 1114 3 4 00158 255 a ee os A DashDspl CAN message error other CAN devices n 5 Apply to service centre ve Check CAN line connection to oo 112 9 3 5 101115 12 a Mod WSI CAN message error other CAN devices 8 Apply to service centre Continuation of Table 10 Fault type Fault description I cr Check CAN line connection to 113 4 4 1 P0000 12 be me Caps for EBC EBCI CAN message error other CAN devices 3 MESSARE Apply to service centre N Check CAN line connection to 114 4 4 2 101100 3 Mee HUE ERCIDR ERCIDR CAN message error other CAN devices PERSIES Apply to service centre N Check CAN line connection to 115 4 4 3 U0103 12 x He nee sme tor EIEI CAN message error other CAN devices 8 Apply to service centre N CAN errors killing function disa Check CAN line connection to 5 116 4 4 5 00104 12 bled and wait time elapsing for RxCCVS CAN message error other CAN devices Q RxCCVS CAN message Apply to service centre N EM Check CAN line connection to 117 4 4 6 00157 12 S bus CAN message error other CAN devices e 655088 Apply to service centre N Continuation of Table 10 R code Fault type z z Faults not shown by diagnostic lamp lightup Fault descript
9. a condition and P0000 12 Implausible CAN signal value cuit control unit in built sensor Plausibili ch Apply to service centre p379 ausibility lost with charge pres Lo d _ J 8 sure sensor J Jj JJ DU wDSU SOS Continuation of Table 10 Fault type Fault description Fix method 0 Voltage beyond the maximal physi Check atmospheric pressure 60 5 3 2 cal limit Fault in atmospheric pressure sensor cir sensor condition and connec pas Voltage below the minimal phy cuit physical limit check Gon sical limit Apply to service centre Voltage beyond the maximal li 61 23 3 mit Fault in air temperature sensor circuit Male i P0097 4 Voltage below the minimal limit P0099 12 12 Faulty signal via CAN pp y to service centre bonos 1 Voltage beyond the maximal Check incoming air tempera 62 2 3 3 physical limit F ture sensor condition and con vone below E ault in the incoming air temperature sen jection P0097 1 nl 86 sor circuit physical limit check sical limit Apply to service centre P0118 13 Voltage beyond the set maximal limit TH ET Voltage below the set minimal Check cooling liquid tempera P0117 4 limit ture sensor condition and con 63 2 4 1 011512 F aly CAN signal Fault in cooling liquid temperature sensor nection No plausibility between
10. A inops n nized beyond set limit function in cylinder 5 condition Apply to service centre Check engine cylinders injec 1675 3 3 Number of flashes skips recog Error registered by flashes skips control tors connectors and cables 1328 nized beyond set limit function in cylinder 6 condition Apply to service centre Table 11 Fault Outward fault demonstration 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 Do the necessary repair 1 1 3 Check the low pressure circuit check the correctness of low pressure circuit connec tions Do the necessary repair check hoses and connectors for leakage check fuel filter condition and conformity Replace filter by the appropri ate make sure there is no water in the diesel fuel inside the Clean the fuel filter from wate coarse 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 1 1 4 Check the high pressure circuit for leakage Do the necessary repair 1 1 5 Check the electric circuit Do the necessary repair or re place accumulator battery check the fuses Do the necessary repair check
11. Testing and repair at a specialized workshop 3 2 8 Control Unit check check the Control Unit plug and socket fixtures 3 3 Engine shutdown Fix plug and sockets 3 3 1 Check if there is fuel in the fuel tank 3 3 2 Check the low pressure circuit Fill the fuel tank check the correctness of connections the low pres sure circuit check the hoses and pipe connectors for leakage Do the necessary repair check the fuel filter condition and conformity make sure there is no water in the fuel inside the coarse fuel filter cup Replace filter by the appropri ate Clean the fuel filter from water pouring it out by opening the tap make sure there is no air in the fuel Remove air from the Iow pres sure circuit See Manual item 3 2 10 3 3 3 Check the high pressure circuit for leakage Do the necessary repair 3 3 4 Check the electric circuit check the accumulator battery charging Do the necessary repair Or re place the accumulator battery check the ground wire Do the necessary repair check the ground wire Replace the ground wire Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 3 3 5 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing check for faults in the COMMON RAIL injection sys Follow the
12. diverting the redundant fuel the HPFIP into the fuel tank 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 amp Maintenance Manual Clean the engine outside except for electrical parts with fuel and compressed air Proofing of the fuel system parts and units fuel pipelines rail fuel filters injectors fuel pump ECU radiator is done with the diesel fuel proofing solution recommended for the engine Annex A with 5 10 of the AKOP 1 additive Add additive 1 to the diesel fuel a few doses with vigorous stirring until a homogenious mixture The mixture homogeneity is characterized by the absence of black or dark brown stains in the mixture flushes coming down from the stiring rod Disconnect the compressor air diverting pipe and pour 4 6 grams of proofing oil into the compressor cylinder Mount the air inlet pipe Switch the compressor on applies to single cylinder compres sors Cover the engine with polyethylene film STATE STANDARD 10354 82 and tie up the air cleaner inlet branch silencer outlet branch and the engine breathers with string 4 0 0 25 STATE STANDARD17308 88 Protect the engine with weather resistant tarpul
13. eese 158 Annex E reference Diesel engine electronics structural electric diagram eene 162 Annex E reference sies pe e ee ere re dese e Rr ed mt ree i a RR Peter sgn ere e REM 163 Annex E TeferefiCe i ett a ea e 164 LUC EE 165 Diesel engine and turbocharger failures identification esses Error Bookmark not defined LIT SWING 166 Engine slinging scheme uui deep eese y aii e Eee pee E eere Eee aree iet E e ES Error Bookmark not defined 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 183A 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 amp Maintenance Manual contains brief technical description diesel en gines 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 amp 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
14. ety ede eeu cu eet e tee tcv ettet evel en eee ev vene 141 TII General instructions d uideat ee etat ieee egies en a d ce ete d eden 41 2 Safety measures uie e er didt eee HL Ue eee EI e E de re Reo ue oe e d E Re PIN 4 2 ENGINE COMPONENTS CURRENT REPAIR eese nennen 4 2 1 General instructions on piston rings replacement eese eene enne tnnt 4 2 2 General instructions on the valves grinding 4 2 3 General instructions on water pump disassembly and assembly 5 6 TRANSPORTATION 7 RECYCLING ccssssssossssssrsessccessssecessssessssessssnsesssssssnsesnssasssessesesnsassssssssesessasssensesussssnsnsessnsnsessasssessessesssassesesuasssessesesonsessesessseesesees 1 2 uisu tor er Pe eed ai EEA EA T Chemmotolosical chart iHe p e en Annex b Teference s c te eR RR RE De e e esi Persea tei eri a eR esee ene terr eer v e prt Spare Parts d Acessories Sus io RU Wen aae aede ete adeps edv aii eid 155 Annex B Teference zi tatem abso eddupd PUB edates Sin a ae dang See wie mnes 156 Cylinder liners and pistons size gTOWps d eR RO umo e eU RU diee dad SW 156 Crankshaft main end and big end necks nominal sizes Synchronization of the crankshaft and the HPFIP camshaft angle position
15. Minimal cooling liquid tempera Error registered by cooling liquid tempera cooling es Pen 132 4 5 P0116 2 0 ture not achieved within the set ture sensor absolute plausibility check om SOUL PAROI COLE i e time limit function Apply to service centre Minimal rise of cooling liquid Error registered by cooling liquid tempera es cooling ds 133 2 4 5 P0116 2 2 temperature not achieved within ture sensor dynamis plausibility check er SALIS RATS RA amp the set time limit function A Apply to service centre kn _ 134561 14 8 Electronic Unit retstart has taken Electronic Unit retstart by unknown rea Apply ti place son N 10 POGF l4 oe the last reading 135 2 6 5 Error din the last record Apply to service centre P062F 12 oe mable Permanent Memory Device i operation P062F 2 Deafualt value used Continuation of Table 10 NT Fix method Fault type Fault description P0647 3 Short circuit to power battery T a Check conditioner state and 1363 1 3 P0646 4 Short circuit to ground Fault in conditioner control power stage MA circuit P0645 12 No load resistance Apply to service centre wm eee om cR tmo S P0645 2 se Excessive heat up temperature P0542 3 Short circuit to power battery Check air pre heat device con 137 B 2 1 ts Fault in air pre heat power stage
16. P0261 8 it condition ut Apply to service centre P0263 11 12 Not classified error Continuation of Table 10 Fault type Fault description Fix method 11 Depending on the settings Check engine cylinders injec 11 Depending on the settings tors connectors and cables condition 27 141 P0201 12 No load resistance Fault in power stage control circuit of cy linder 1 specific warning Check engine cylinders injec tors connectors and cables P1215 11 Depending on the settings condition A Apply to service centre P0265 3 Low side short circuit to battery Check engine cylinders injec 28 1 4 2 P0266 11 Depending onthe settings Fault in power stage control circuit of cy tors connectors and cables Low side and High side short cir linder 2 specific error engine shutdown condition P0264 8 cuit Apply to service centre P0266 11 i Not classified error P1216 11 Depending on the settings P1217 11 Depending on the settings Check engine cylinders injec 29 1 4 2 Fault in power stage control circuit of cy tors connectors and cables P0202 12 No load resistance linder 2 specific warning condon Apply to service centre P1218 11 Depending on the settings 652 Continuation of Table 10 Fault type Fault description Fix method
17. Testing and repair at a specialized workshop tic device CRS 3 1 2 Check the intake system check electricity consumers condition with the diagnos Do diagnostics and the neces sary repair Check for air leakage suction Do the necessary repair Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm Check the air filter condition Replace the air filter by new one check the intake manifold for clogging Clean the intake manifold 3 1 3 Check the harness condition for breaking or short circuit 3 1 4 Check the injectors launch injector check cycle by the appropriate standard testing command in the KTS Bosch diagnostic dej vice Do the necessary repair Follow the instructions in thd KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop 3 1 5 Control Unit check check the Control Unit plug and socket fixtures Fix plug and sockets 3 2 Failures during acceleration and clutch switch on 3 2 1 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 check the intake manifold for clogging 3 2 2 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing check for faults in the C
18. The control devices showing the sensors information are located on tractor combine har vester machine dashboard The list of the diesel engine component possible failures and damage and conditions of their elimination by current repair are given in Table 15 Table 15 Failures and damage to be eliminated by current repair in the conditions of Engine component Company workshops Specialized repair companies Turbocharger All failures and damage COMMON RAIL system units All failures and damage Cylinder head Loss of valves hermeti Wear of valves guiding holes inner city surfaces valve seat extreme wear head to block surface buckling cracks threaded holes damage Cylinder liner piston Reduction or loss of the gas connection sealing ability Water pump All failures and damage Cebtrifugal oil filter failures and damage Oil pump Reduction of productivity Gear pump Reduction of productivity Clutch failures and damage Compressor Reduction of productivity Starter motor Errosive starter motor re Coils windings short circuit coils lay contact couple wear windings insulation damage bear collector beushes wear ings wear drive failure 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 f
19. Dismantle the starter motor clean the collector eliminate the brushes loosing or replace them with new ones 8 1 5 Contact bolts and contact plate surfaces burnt in Clean the starter motor con the starter motor relay tacts or mount the contact bolts in the cover seats turning them 180 around the axis and mount the conact plate with the reverse side 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 contact bolts or contacts welded in the starter motor control circuit relay Stop the engine disconnect the battery and do as decribed in item 8 1 5 or replace the starter motor control circuit relay 8 3 Starter motor armature rotating fast not moving the engine crankshaft 8 3 1 Flywheel rim teeth broken 8 3 2 Starter notor faild Replace the flywheel rim Replace starter notor 8 4 Starter motor relay interruptions switches the starter motor on and then immediately switches it off 8 4 Relay holding coil broken Replace the relay 8 4 2 Accumulator battery discharged Charge the accumulator bat tery tion 6 5 Drive gear systematically not engaging the flywheel rim at the relay normal opera 8 5 1 Toothed flywheel
20. Fix plug and sockets Diesel fuel smell 4 5 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 make sure there is no water in the fuel inside the coarse fuel filter cup Clean the fuel filter from water 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 4 5 2 Leakage in the fuel temperature sensor Replace the fuel temperature sensor or pe3HHOBOe Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 4 5 3 Check the injectors launch injector check cycle by the appropriate standarc vice testing command in the KTS Bosch diagnostic dej Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop 4 5 4 Check the high pressure circuit for leakage Do the necessary repair 4 6 Blue white or black smoke 4 6 1 Check the engine parameters check for faults in the COMMON RAIL injection sys tem using the diagnostic device do KTS Bosch standard testing Fol
21. P1009 4 amp Short circuit to ground circuit connection in Apply to service centre Error registered by gas pedal and brake Check gas and brake pedals 124 2 2 5 p2299 7 Implausibel gas pedal signal pedal work plausibility function position sensors condition and connection Apply to service centre If the overshoot 1s caused by incorrect switch from the up per gear to the lower with the 125 2 2 6 P0219 115 Crankshaft maximal permitted Crankshaft maximal permitted speed over es und cn 799 speed overshoot discovered shoot If the engine speeds up spon taneously all by itself do not start the engine Apply to ser 2 vice centre urgently Continuation of Table 10 NT Fix method Fault type Fault description Check Resistance Moment Control System Unit condition Physically implausible request Error of Resistance Moment Control Sys and connection 126 2 2 8 P0856 from Resistance Moment Control 2 System Unit tem Unit Check CAN line connection to 2 i other CAN devices in Apply to service centre Voltage beyond the set maximal m P0113 S lm 8 Check sensor condition and limit Fault of incoming air temperature sensor 127 2 3 4 a PM connection Voltage below the set minimal circuit in air mass consumption meter P0112 as Apply to service centre limit Air mass consumption meter sig P0101 p im S Error registered by air mass con
22. 16 compressor for diesel engines with liquid cooled compressor Fig 15 Cooling system diagram For faster diesel engine warming up after start and automatic regulation of temperature mode at various loads and amvient temperatures two TC 107 thermostats are installed on the purging line Ther are two valves the main 11 and bypass 12 Fig 15 in the thermostat housing and thermal force element 13 inside which there is piston 10 The thermal force element consists of housing cylinder filled with thermosensitive sub stance expanding with warming up Fixed firm on the housing is the main valve On the housing axis valve 12 is mounted pressed by spring 15 Spring 14 is installed so that it firmly presses the main valve to the housing of thermostat 9 After the engine start before the cooling liquid warms up to 85 C the main thermostat valves are closed The cooling liquid from the cylinder head water outlet pipe passing by the radiator goes to the pump and once again gets back to the cylinder block At the cooling liquid temperature over 85 the substance filling the thermosensitive el ement expanda and affects fixedly mounted piston 10 thus causing movement of the thermosensitive element with the main valve relative to the piston With the force of movement exceeding the force created by valve 14 the main valve moves down thus cre ating a gap between the main valve and the thermostat hiusing and the cooling liquid then s
23. 2 1 2 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing check for faults in the COMMON RAIL injection sys Follow the instructions in thd KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop tic device check electricity consumers condition with the diagnos Do diagnostics and the neces sary repair circuit 2 1 3 Check the harness condition for breaking or shori Do the necessary repair 2 1 4 Check the high pressure circuit for leakage Do the necessary repair 2 1 5 Check compression level in the cylinders Do the necessary repair 2 1 6 Check the injectors launch injector check cycle by the appropriate stand ard testing command in the KTS Bosch diagnostic device Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a special ized workshop 2 1 7 Check the high pressure fuel injection pump KTS Bosch diagnostic device launch high pressure fuel injection pump check cycle Follow the instructions in the by the appropriate standard testing command in the KTS Bosch diagnostic dej vice software Testing and repair at a specialized workshop Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm check the high pressure circuit ope
24. Fuel pressure in Rail higher than Disruption of high pressure fuel pump at 73 2 5 3 P0088 3 P s 5 en P pump components condition the set maximal limit doser control mode connections A Apply to service centre Overshoot of maximal negative Check high p sata ano OW fuel pressure in Rail deviation at Disruption of high pressure fuel pump 74 2 5 4 P1013 17 P ow P components condition and fuel pump doser minimal flow doser control mode eee connections A i Apply to service centre Continuation of Table 10 mer Fix method Fault type Fault description Check high pressure and low or aban imal poste Disruption of high pressure fuel pump PTSS 75 2 5 4 P1019 5 fuel pressure in Rail deviation at P en P pump components condition doser control mode fuel pump set flow rate connections A Apply to service centre Check high pressure and low Implausible set value of fuel pressure hydraulic curcuits Disruption of high pressure fuel pump o 76 2 5 5 P1014 2 pump doser at fuel pump exces components condition e et doser control mode sive flow rate mode connections P Apply to service centre Check high pressure and low Fuel pump doser filtered electric or Wek pima PTE hydraulic curcuits 77 2 5 6 P1018 7 current lower the minimal P 51 pump components con
25. 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 10 fuel to atomizer inlet channel 11 needle and atomizer Fig 10 Injector schematic diagram Apart from the controlling supply there is fuel leakage through the atomizer needle and the controlling valve piston guide All this fuel is diverted to the back runoff duct to which all other injection system devices are connected and gets back into the fuel tank The amount of injected fuel is proportional to the time of the electromagnet valve being switched on and the pressure in the rail and it does not depend either on the crankshaft speed or the HPFIP operation mode time controlled injection When there is no electricity on the electromagnetic valve the armature by the force of the spring is pressed down and valve ball 5 closes the throttle hole Upon closing the fuel outlet throttle hole the pressure in the controlling valve chamber reaches the same level with that in the accumulator This increased pressure moves moves down the controlling valve piston together with the atomizer needle When the needle is pressed firm to the atomizer seat and close its holes injection stops 1 2 2 6 4 Fuel pre filter Fuel pre filter is designed for preliminary fuel cleaning from mechanic mi
26. 3 1 DIESEL ENGINE MAINTENANCE merini eene nennen nennen 122 3I I General instructions tede a e RU ER Re E RU EHE EUR 122 BLD Safety MEGSUTES HE 124 3 1 3 Maintenance procedures d QU guises ova CO SEXE eeu XR vob 125 3 1 4 Checking the engine operation condition eese r ii eene netter nenne trennen trenes 126 3 15 Proofing reproofing for stor ge ee a leere i EEEE NOH RH DER TRE NET e sv eoe eb EEEE EEK 127 3 2 DIESEL ENGINE AND ITS COMPONENTS nennen n een eren eren rennen tenerent eene 130 3 2 1 Checking the cooling liquid level in the cooling system esee nennen nenne 130 3 2 2 Cooling system maintenance and washing eese eene ene eere enee ener tnne teet entren teens 130 3 2 3 Checking oil level in the engine oil sump eene nennen een eene tnnt nenne trennen teens 130 3 2 4 Replacing oil in the engine oil sump eee ea eet t 131 3 2 5 Replacing heoil filters ned E ERI TERR Y REN EIER E RE EAESEE NEN SEVRER Y VERE REA eec 131 3 2 6 Cleaning the centrifugal oil filter rotor t terea 132 3 2 7 Sediment removal from fuel pre filter eese eese teet entrent 133 3 2 6 R
27. 4 4 iti ion P0195 12 Faulty signal via CAN eng FODBCCHQD pre a Apply to service centre Implausibility between oil temper P100D 2 ature sensor and cooling liquid t temperature sensor indications Oil temperature sensor signal error too a uu ue 69 2 4 4 P0196 17 Implausibel signal too high oil condition and connection high oil temperature temperature Apply to service centre a Check high pressure and low Excessive maximal positive fuel NE High pressure fuel pump doser control pressure hydraulic curcuits 70 2 5 1 P1011 16 pressure in Rail deviation e mode disruption condition and connections 5 Apply to service centre Continuation of Table 10 NT Fix method Fault type Fault description T Check high pressure and low Disruption of high pressure fuel pump PTS 71 2 5 2 P1012 15 fuel pressure in Rail deviation at P 51 pump components condition doser control mode fuel pump set flow rate overshoot connections A Apply to service centre Check high pressure and low hydraulic curcuits Fuel pressure in Rail lower than Disruption of high pressure fuel pump P SS 7 Tar 72 2 5 3 P0087 4 e Pr p 51 pump components condition the minimal set limit doser control mode connections PA Apply to service centre Check high pressure and low TN hydraulic curcuits
28. Air filter Recirculated exhaust gases Exhaust gases release Turbocharger Air charge Charge air cooler Exhaust gases 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 Lubricant Litol 24 is placed in the bearing cavity of the pump at the pump assem bly The bearing does not need lubrication in the process of use The cooling liquid temperature in the cooling system must be kept within 85 C 95 C Thermostat valves position at Thermostat a warming up cooling liquid temperature lower than 85 C 8 7 3 0 b rated mode cooliong liquid temperature is higher than 85 C C FF 3 Z n NC 999999 1 Bl 2 an n vv if E NS Y 5 i N N 7 EN m A 74 FX CNW A 9 di L Tidl gt HT j O 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 11 main valve 12 by pass valce 13 thermal force element 14 valve spring 15 by pass valve spring
29. D 260 1S3A 1 1 4 Engines D 260 183A D 260 2S3A D 260 4 53 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 To ensure high technical and economic characteristics the engines inlet systems use turbo charging with charge air intermediate cooling Using turbocharger with controlled air pressure in the charging device allows better engine pickup provided by higher torque values at low crankshaft speeds Engines equipped with Common accumulator type fuel system show higher op erational and fuel economy and conform to Tier 3A ecological parameters due to opti mized operation process and minimization of transitional processes while changing the speed and load modes 1 1 4 1 General information Engines D 260 1S3A D 260 2S3A D 260 4 S3A are 4 stroke piston internal combustion diesel engines with vertical cylinder positioning direct fuel injection and ignition from compression The basic engine assembly units are cylinder block cylinder heads pistons connecting rods crankshaft and flywheel To ensure high technical and economic characteristics the engines inlet systems use turbo charging with charge air intermediate cooling Using turbocharger with controlled air pressure
30. For specific fuel consumption cal culation Hourly fuel consumption kg hour Non standard measuring means 0 01Gr 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 Cylinder block Water catchment pipe Cylinder heads mounting Water pump mounting Clutch mounting Fan mounting Turbocharger mounting Tensioner mounting Oil sump mounting Gear pump mounting Pump mounting Compressor mounting Heat exchanger mounting Alternator mounting Filter mounting Starter motor mounting Fuel equipment mounting Drive and counter mounting Oil ducts Spare Parts Tools amp Accessories Kit 1 1 3 2 Key features of diesel engine models configurations Table 6 Engine model Units parts D 260 1S3A D 260 2S3A D 260 483A Unit part designation and or its description Turbocharger K27 61 08 Turbo Czechia K27 542 01 Turbo Czechia Compressor Single cylinder air cooled controlled or not not available Gear pump HIII 10 or 14 3JI or 16 3JI High pressure fuel injec CPN2 2 BOSCH Germany tion pump Electronic control unit EDC7UC31 BOSCH Germany Injector CRIN2 BOSCH Germany Type Preline PL 420 ANN HUMMEL GMBH Germany with water separator and manual priming pump or similar filter Fuel pre filter by other manufacturers Fine fuel filter Man
31. Formula SAE 10W 40 Motor oil Lukoil Avangard Ul tra SAE 5W 40 Not available Not available In winter stable ambient air temperature below 5 Motor oils Liqui Moly Diesel Synthoil SAE 5W 40 Ethyl Hitec 5909 Castrol TXT Softec Plus Elf Synthese SAE 5W 40 Esso Ultron SAE 5W 40 Shell Helix Ultra SAE 5W 40 Mobil 1 Rally Formula SAE 5W 40 Mass vol ume of fuels and lubricants filled in a product at re placement adding kg dm 16 18 Fuels and lubri cants re place ment add ing perio dicity hours 250 Notes Using motor oils depen ding on operation condi tions a summer 5 and higher SAE 30 SAE 10W 40 30 SAE 15W 40 30 SAE 20W 40 30 b winter 10 and higher SAE 20 SAE 10W 40 30 c winter 20 C and higher SAE 10W 20 30 40 SAE 5W 30 40 d winter below 20 C SAE 5W 30 40 SAE OW 30 40 All motor oils specified in this Chemmotological Chart must conform toclasses CH 4 CI 4 under API and E4 99 classifications 5 02 under ACEA classification oil mass volume is checked more accurately by adding oil when filling up to the upper mark of the feeler rod m End of Table 1 No Assembly unit aaant Mass vol Fuels functionally fi of as Fuels and lubricants names and grades ume of fuels and lub nished device sembly d lubri ricants mechanism
32. Table of Annex Injector Combustion chamber axis A SN Seo ee we 4 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 The valves should be grinded with special machine tools of OIIP 1841A type or OP 6687M benches Apply paste on the valves faces or cylinder head seats faces made of one of the following compositions boron carbide M 40 10 microcorundum M 20 90 granular electrocorundum M14 87 parafin 13 Mix the composition with diesel fuel till a sour cream condition To raise the composition quality it is recommended to add oleic or stearic fat acid Continue the valves grinding until you see a continuous foggy belt on the valve face and the valve seat face not less than 1 5 mm wide The belt breakings or scratches are not ac ceptable The belt s width varioation is permissible within 0 5 mm Wash the head and the valves after grinding When assemblying the head apply motor oil on the valve stems The valves grinding may be done manually with locksmith appliances but this operation labour efforts
33. an independent gas diversion line ensur ing forced exhaust gas diversion from the engine silencer to the outside of the room 2 4 Operation in extreme conditions In the event of an accident immediately stop the engine switching off the fuel supply by the ignition lock or emergency stop button if available In emergency situations when flame appears on the engine pour sand on the flames cov er them with a tarpaulin cloth or other thick canvas Use carbon acid fire extinguisher Do not pour water on the burining flame In the event of spontaneous acceleration of a tractor agricultural machine with a gear on or spontaneous engine acceleration shut the engine down using the ingintion lock or emergency stop button if available In such cases the tractor agricultural machine must be towed to the place of repair rigid ly hitched without starting the engine All measures for stopping the engine uncontrolled operation must be taken promptly in order to prevent the engine final failure 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 Engine operation without the regular
34. and oil pump drive gear water pump drive pulley alternator pulley air conditioner compressor pulley for tractors To reduce the crankshaft torsional vibrations a silicon damper is mounted on the pulley hub Pistons are made of aluminium alloy Ther is a combustion chamber in the piston bottom Pistons have three groves in their upper parts placed in the first two are compression rings the third has an oil ring with an expansioner The piston pin is hollow made of chrome nickel steel The axial movement of the piston pin in the piston bosses is limited by stop rings Connection rod is an I beam part made of steel Pressed in the connection rod upper head is a bush To oil the piston ring there is a hole in the upper head of the connection rod and the bush The lower connection rod head bore for bearing shells is done in assembly with the cov er The connection rod and the cover bear the same serial numbers stamped on their sur faces The connecting rod covers are not interchangeable Apart from that the connect ing rods belong to different weight groups according to the mass of the upper and the lower heads A group designation by mass is applied on the front surface of a connecting rod upper head Installed in a diesel engine must be connecting rods of the same group The main end and the big end bearing shells of the crankshaft are thin walled made of bimetallic strips As for the inner diameter the bearing shells are made of two sizes
35. bolts 25 40 high pressure nuts on the side of injectors 20 30 rail 40 70 Annex 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 Installation of a silicon damper with a pulse rim and a fuel priming pump drive gear with a pulse rim maintains synchronization of the crankshaft and the HPFIP camshaft speed sensors signals with linking the sensors signals to the common initial point of the shafts positioning at the moment of the 1 cylinder piston coming through its TDC at the com pression stroke To install the pulse wheels correctly it is necessary to make a device for fixing the fuel priming pump drive gear with pulse rim as shown on Fig 1 Fig 1 Device for fixing the fuel priming pump drive gear pulse rim Remove the cylinder cover cap Place the 1 cylinder piston to the TDC position turning the crankshaft clockwise using the crankshaft pulley mounting bolt till the axis of the 16 tooth of the pulse rim crown located on the torsional vibration damper housing coincides counting against the clock from the pulse rim crown breaking segment with the axis of sensor 2 Fig 2 At
36. 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 11 crankshaft 12 camshaft 13 rocker axle oil channel 14 intermediate gear 15 turbocharger 16 compressor 17 high pressure fuel injection pump 18 safety valvel9 oil drainage plug 20 paper filter element by pass valve Fig 3 Lubrication system diagram 1 2 2 6 Power system The diesel engine power system Fig 4 according to engine builds shown in Table 6 con sists of Common RAIL accumulator type fuel supply system including high pressure fuel injection pump 1 injectors 8 high pressure fuel accumulator operation environment condition sensors fuel and air temperature and pressure electromagnetic actuators pressure regulator23 injectors electromagnetic valves electronic unit for control and communication circuits control and diagnostics board in a tractor or an agricultural machine low pressure pipelines high pressure pipelines intake manifold exhaust manifold recirculated gas cooler turbocharger fine fuel filter fuel pre filter air cleaner fuel tank charge air cooler silencer Shown on the engine feed system diagram is a device for diesel engine startup aid under conditions of low ambient temperatures glow plug The COMMON RAIL structural diagram electric and hydraulic is shown on Fig 5 to be i
37. cap back in place and screw the cap nut at 35 50 N m 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 amp Maintenance Manual 3 2 8 Fuel pre filter replacement Replacing fuel pre filter See tractor machine Operation amp Maintenance Manual Fill the system with fuel after filter assembly 3 2 9 Replacing fine fuel filter Fine fuel filter service life depends on the purity of the fuel used Fine fuel filter is replaced after every 600 hours of operation or upon the results of the COMMON RAIL system diagnostics as shown on Fig 21 for that purpose unscrew filter 1 from connector 7 in housing 2 and replace it by a new filter Mann amp Hummel WDK962 shippedassembled together with gasket 6 which must be preliminarily oiled with motor oil as soon as gasket 6 touches mounting surface A on housing 2 further screw the filter by 5 of a turn At that the filter must be screwd further by hand only open the fuel tank tap and fill the sytem with fuel as described in item 3 2 10 Fuel inlet Fuel outlet 1 filter Mann amp 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
38. contact YU62 U03 036 1 BOSCH Germany XS2 Jack panel 16 contact YU62 U03 038 1 BOSCH Germany XS3 Jack panel 36 contact YU62 U03 037 1 BOSCH Germany XS5 XS6 Jack panel 2 included in tractor set XS7 XS9 Jack panel 0 936059 2 2 AMP Germany XS8 Jack panel 0 0936061 2 1 AMP Germany XS10 XS11 Jack panel 0 0936060 1 2 AMP Germany XS12 XSU Jack panel 1928003736 3 BOSCH Germany XS17 Jack panel OBD 1 included in tractor set XP18 Plug Schlemmer 7811230 1 Schlemmer XS18 Socket Schlemmer 7812226 1 included in tractor set Annex E reference Contact No Bosch Signal function Cross sec Contact No XSLXS3 designation tion XS18 XP18 Imm 1 02 VJ BA Mod 12V from accumulator battery input3 25 1 03 V_V_BAI 4 12 from accumulator battery input4 25 G 0 V RHO1 Commutated output 128 AKb 2 5 J 105 G GJ3A T 3 0 B from accumulator battery input3 2 5 F 106 G GJ3A T 4 0B from accumulator battery input4 2 5 H 108 V V 128 from accumulator battery input1 2 5 A 109 VJ J3A T 2 V128 from accumulator battery input2 25 C 1 10 G GJIAT 1 0 B from accumulator battery input1 2 5 B 1 11 G G BAT 2 0 B from accumulator battery input2 25 122 O S DSA Diagnostic lamp High level 0 75 N 25
39. crankshaft main end and big end necks sizes Table B 2 Crankshaft neck diameter mm Bearing shells nominals ias s 730925 0 085 2 85 00 0 104 7215 38 The crankshaft main end and big end necks and bearing shells are made in two nominal sizes Crankshafts the main end and big end necks of which are made of the second nominal size have additional marking on the first cheek 2K second nominal main end necks 2 second nominal big end necks 2 second nominal main and big end necks Annex reference Diesel engine adjustment parameters Table 1 E M remen Oil pressure in a hot engine oiling system at the MPa 0 28 0 45 engine crankshaft rated speed Cooling system temperature in the cooling system 30 95 Drive belts deflection See item 3 2 18 Gap between the rocker striker and the valve stem Sum end for the valves in a cold engine intake 025 Zu exhaust 0 45 yd Main threaded connections torque Nm cylinder head bolts 190 210 main end bearings bolts 220 240 big end bearings bolt nuts 100 120 flywheel bolts 160 180 counter balance bolts 120 140 injector bolts 20 25 crankshaft pulley bolts 160 200 Centrifugal oil filetr cap nuts 35 50 air cleaner wing nuts 8 10 damper bolts 80 100 injector staples and strap bolts 20 25 injectors drainage pipeline connector bolts 15 20 low pressure pipeline turn elbow
40. engine speed torque correction mode is disabled Fault description TSC1 TE CAN message error Fix method Check CAN line connection to other CAN devices Apply to service centre 107 4 2 4 U113A Wait time elapsing for TSCI TR CAN message when the engine speed torque correction mode is enabled U113B 520 Wait time elapsing for TSCI TR CAN message when the engine speed torque correction mode is disabled TSCI TR CAN message error Check CAN line connection to other CAN devices Apply to service centre 108 4 2 5 U1110 U1111 520219 Wait time elapsing for TSCI VE CAN message when the engine speed torque correction mode is enabled Wait time elapsing for TSCI VE CAN message when the engine speed torque correction mode is disabled TSC1 VE CAN message error Check CAN line connection to other CAN devices Apply to service centre Continuation of Table 10 Fault type Fault description Fix method Wait time elapsing for TSCI VR 001112 CAN message when the engine speed torque correction mode is Check CAN Ii dame enabled ec ine connection to 109 4 2 5 ee f us Wait time elapsing for TSCI VR pun Ed rias nas CAN message when the engine a speed torque correction mode is Q disabled wa Check CAN line connection to e 110 4 3 1 U0001 12 n bid Ine 20
41. exhaust gas inlet branch pipe from cooler to mixer 6 turbocharger the recirculated exhaust gas inlet and outlet elements design may be different with developers of tractors or agricultural machines for the reason proper fitting in a vehicle and must be approved with MMP Fig 13 Exhaust gas recirculation device 1 2 2 6 7 Diesel engine gas exchange system The diesel engine gas exchange diagram together with breathers is shown on Fig 14 Breather is designed to prevent excessive pressure in the lubrication system created by the exhaust gas penetrating into the oil sump through the gas joints of the cylinder piston group and oil injection into the atmosphere In the implemented gas exchange system the crankcase gases via the channels in the cyl inder block and the cylinder head come into the cavity formed by the cylinder head cover and the cover cap Breather housing 1 Fig 14 is mounted on cover cap 4 of the cylinder head The crankcase gases rush through the slots of cup 6 into breather housing 1 under the influence of the pressure difference in the atmosphere and in the cavity of the cylinder head cover Having got into the cup cavity the crankcase gases expand and strike against oil deflector 2 lose their energy and cool down As a resul t a significant portion of the oil mist falls down as oil The crankcase gases cleaned from oil then get into the atmos phere Air intake Crankcase gases emission into atmosphere
42. fine fuel filter 11 fuel inlet conector from the fine fuel filter 12 redundant fuel diversion into the fuel tank connector 13 camshaft Fig 6 High pressure fuel injection pump CPN2 2 Fuel diversion into fuel tank Fuel to accumulator 0 1 Fuel inlet from fine fuel filter 12 Rr E T K gt DIL A iZ pee ie WA 22501 27 V ANES 7 SS 7 ptt YH NZ CIA 3 a i 4 a i d m mN L N 1 Di Fuel inlet to priming fuel pump AN KY a Ci di A ai UZ NNSSSSSSX Fuel otlet from fine fuel filter 11 a LER Zire pr LE m N E D A SoS Ss LIA LIS SA JLZZNSNSSSSSSSNEZA 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 12 electric magnet terminals 13 fuel priming pump 14 fuel priming pump drive gear with a pulse rim Fig 7 High pressure fuel pump schematic diagram 1 2 2 6 2 High pressure fuel accumulator High pressure fuel accumulator Rail is a volume storage of fuel under high pressure Simultaneously the accumulator smoothes pressure fluctuations that occur due to the pulsating
43. flow of fuel from HPFIP and also because of the injectors during injection due to nonsynchronous fuel pressure pulses coming from the HPFIP and consumed through the injectors as well as due to the multiple fuel mass excess in the accumulator working as a damper for small dose pressure pulses the incoming and consumed ones 4 3 2 3 2 2 2 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 I has the shape of pipe at the ends of which are installed fuel pressure sen sor 7 and pressure limiting valve 5 Along the pipe perimeter there are high pressure pipelines connectors 2 3 and back runoff connector 4 The fuel from HPFIP is directed via the high pressure duct to inlet connectors 3 of the accumulator The fuel accumulator is coupled with the injectors by high pressure fuel pipings linked with the accumulator outlet connectors The accumulator is permanently filled with fuel under high pressure The pressure value is kept on a constant level and may be regulated by valve 5 Fig 8 depending on the en gine operation parameters The pressure limiting valve keeps a definite pressure value in the accumulator working as a reducing protective valve The valve housing on the accumulator side has a channel closed by valve core cone 6 A spri
44. gear mounted on the crankshaft There is a by pass valve 5 in the oil pump set for the pressure of 0 7 0 75 MPa When the oil pressure exceeds mentioned these values the oil is by passed from the discharge cavity to the suction cavity The adjustment is done on a test bench using adjustment washers The oil pump via oil receiver 2 takes oil from oil sump I and via the channels in the cyl inder block delivers oil to a full flow oil filter with a paper filter element while some por tion of the oil goes to a centrifugal oil filter for purification and subseguent sink into the oil sump Installed in the housing of filter 4 is an unadjustable safety valve18 It has been designed for keeping the oil pressure within 0 28 0 45MPa in the main oil duct At the oil pres sure exceeding 0 45MPa the safety valveopens and the redundant oil oil reserve is sunk into the engine oil sump via the protective valve The oil purified in oil filter 4 goes to liquid oil heat exchanger integrated in the engine cylinder block The filter element has a by pass valve 20 In the event of overclogging of the paper filter element or at starting the engine with cool oil when the filter element re sistance goes over 0 13 0 17 MPa the by pass valve opens and the oil bypassing the fil ter paper is fed in the oil system The by pass valve is unadjustable From the liquid oil heat exchanger via the channels in the engine cylinder block the cooled oil comes into the main
45. instructions in thd KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop check electricity consumers condition with the diag nostic device 3 3 6 Check the intake system Check for air leakage suction Check the air filter condition Do diagnostics and the neces sary repair Do the necessary repair Replace the air filter by new one check the intake manifold for clogging Clean the intake manifold 3 3 7 Check the harness broken or kinked Do the necessary repair 3 3 8 Check the high pressure fuel injection pump KTS Bosch diagnostic device launch high pressure fuel injection pump check cycla Follow the instructions in the by the appropriate standard testing command in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop check the high pressure circuit operability check the high pressure circuit for leakage Do the necessary repair 3 3 9 Control Unit check check the Control Unit plug and socket fixtures Fix plug and sockets 3 4 Engine running unevenly unstable operation of the celeration and overload engine during acceleration de 3 4 1 Check if there is fuel in the fuel tank Fill the fuel tank 3 4 2 Check the low pressure circuit sure circuit check the hoses and pipe connectors for leakage check the fuel filter
46. not hands Using a drilling or a rough grinding machine pneumatic tools follow the established safe ty rules Using electric tools take the necessary safety precautions use tools only with proper in sulation do the tools housings grounding use individual protective means The working place must be equipped with the necessary fire extinguishing appliances 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 Description of failures and damage consequences Engine Possible causes Instructions on iden tifying the conse quences of failures and damage of as sembly units Instructions on eli mination of the con sequences of fail ures and damage Blue smoke co ming out of the ex haust pipe 1 1 Oil in the combustion chamber burning because of the piston rings wear 1 1 2 1 Keep control of oil burning by adding oil at MM pay attention to the oil colour change in tensity during opera tion period 1 1 Replace piston rings item 4 2 1 2 Difficult engine start Low speed up dynamics at fuel supply increase Blue smoke coming out of the exhaust pipe 2 Oil in the combustion chamber The cause the absence of hermeticity in the combustion chamber at the valves disks pla cing in the valves seats As per the oil re placement procedure By the exc
47. of the air cleaner with open flames Do not start the engine by towing a tractor agricultural machine 2 3 3 Diesel engine shutdown Before the engine shutdown let it run for 3 5 minutes first at the medium then at the maximal idle speed in order to reduce the cooling liquid and oil temperatures Not ob serving this rule will cause the turvocharger going out of operation Stop the engine by turning the ignition lock key into 0 position Disconnecting the ve hicle mass from the accumulatory battery plus wire is not allowed within of not less than 1 minute after the engine ignition swutch off and the engine shutdown Turn the accumulator battery switch off after the engine shutdown 2 3 4 Diesel engine perationsl run in Diesel engine must be run in for rubbing parts confrication before the engine going into operation Diesel engine operation under full load without prior operational run in is not allowed Diesel engine operational run in is done the engine final user As soon as the engine is ready for operation start it and having made sure it works properly begin the run in Diesel engine running in at the idle is done during 5 minutes with gradual raising the en gine speed to 1600 min then run the engine in under load for 30 hours The engines installed in tractors combine harvesters run in under load is done while performing jobs not requiring tractive force gradually raising the load from lower to higher gear Wit
48. oil duct from which via the channels in the engine cylin der block it is delivered to all of the main end crankshaft bearings and the camshaft sup ports From the second fourth and sixth main end bearings via injectors integrated in the cyl inder block main end supports the oil is delivered for pistons cooling From the main end bearings via the channels in the crankshaft oil comes for lubrication of the big end bearings From the first main end bearing via special channels in the front cylinder block wall the oil is delivered to intermediate gear bush 14 and further via a channel in the distri bution pump it goes for lubrication of the parts of fuel injection pump 17 The valvemechanism parts are lubricated by the oil coming from the second and the third camshaft supports via the channels in the cylinder block and cylinder heads bores in the third and the fourth rocker racks into the inner cavity of the rocker axle and through the holes to the rocker bushes from which via a channel it comes to the adjustment screw and the bar The oil is delivered to bearing unit of of turbocharger 15 via a tube coonected at theout let of the oil filter with a paper filter element The oil is delivered to pneumatic compressor 16 via an oil duct connected at the heat ex changer outlet The oil is sunk from the compressor into the engine oil sump mse Ee e 1 oil sump 2 oil receiver 3 oil pump 4 paper oil filter 5
49. oil ducts 2 Fuel piping and fuel equipment 2 Coarse fuel filter A Supply o Fine fuel filter Air cleaner and air duct Electronic Electronic Control Unit sensors and actuating mech fuel supply control anisms Water catchment pipe and thermostats Cooling Water pump and tensioner Fan Supercharging Turbocharger EGR EGR cooler Starter motor na Startup 8 Glow plugs 5 Electric equipment Alternator E Compressor amp Units Gear pump Clutch 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 Cooling liquid circulates between the cylinder block walls The cylinder block transverse dividers have pads for forming the crankshaft supports Mounted on those pads are covers The pads together with the covers shape beds for the main end bearings The beds for the main bearing shells are bored with one installation complete with covers It is not permissible to change the covers placing Cylinder block has a longitudinal oil channel from which oil is supplied to the crankshaft main end bearings along transverse channels and further to the camshaft
50. or shifting Fix plug and sockets the gears 3 8 1 Check the engine parameters check for faults in the COMMON RAIL injection sys tem using the diagnostic device do KTS Bosch standard testing check electricity consumers condition with the diagnos tic device Follow the instructions in thd KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop Do diagnostics and the neces sary repair 3 8 2 Check the harness condition for breaking or short circuit Do the necessary repair 3 8 3 Check the clutch adjustment correctness Do the necessary repair Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 3 8 4 Check the turbocharger operability See Manual Annex 2K 3 8 5 Check the injectors launch injector check cycle by the appropriate standarc testing command in the KTS Bosch diagnostic dej Follow the instructions in thd KTS Bosch diagnostic de 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 tem using the diagnostic device do KTS Bosch standard testing Follow the instructions in
51. pressed for 2 seconds With the button depressed the lamp will blink out a 3 digital diesel engine error code com ing as a series of flashes It will look as follows after depressing the diagnostic button pause a series of flashes after the pause for example with two flashes you mark the digit 2 pause a series of flashes after the pause for example with four flashes you mark the digit 4 pause a series of flashes af ter the pause for example with three flashes you mark the digit 3 as a result we have the error blink code 243 Oil pressure sensor With the next diagnostic button pressing the diagnostic lamp will blink out the next failure blink code In this way all discovered faults are shown up After showing up the last fault the unit starts showing up the first identified The failures blink codes explanation is given in Table 10 Rectify the fault by the methods described in Table 10 and delete the fault record from the ECU memory in the following manner switch ignition off and pause for one minute press the diagnostic button and keeping it pressed switch ignition on keep the diagnostic button pressed for 5 7 seconds after ignition switching on To make sure the fault has been rectified test drive the vehicle During such drive the self diagnostics check the system and stores still possibly remaining faults data in the memory again After the test drive do the diagnostic fault bl
52. processor error timer 5 1 1 5 P0607 2 Apply to service centre 523550 Continuation of Table 10 Fault type Fault description Fix method P1616 112 Fault of Watchdog cylinders shutdown module path Fault discovered at ECU initialization by the function of check of additional me Fault of path for cylinders shut j ault of pat y ut thods for cylinder control power stages Apply to service centre 6 1 1 6 P1617 3 down by power stage voltage ma shutdown ximal limit function Fault of path for cylinders shut P1618 4 down by power stage voltage mi nimal limit function N P0617 3 Power battery short circuit Starter motor relay power stage fault Check starter motor condition V 021 4 Short circuit to ground and connections E 8 High voltage Apply to service centre P1638 3 Short circuit to power battery Starter motor relay power stage fault Check starter motor condition 8 12 1 Bigoli Short circuit to ground and connections Load resistance absent Low voltage Apply to service centre Continuation of Table 10 Fault type Fault description Fix method Check terminal 50 condition 1 2 2 P2530 7 _ Terminal 50 is always closed Terminal 50 circuit fault and connections 3 Apply to service centre Check terminal 15 condition 10 1 2 3 2533 12 No signal fr
53. repair is done with the en gine failures malfunctions or damage which may not be eliminated by adjust in tech nical maintenance 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 It is necessary to do current repair keeping the belonging of the rehabilitated components to the particular engine With this method the engine parts and units remaining life is pre served to the most extent because there is no need in increased bedding in and with that there is no excessive wear of parts and couplings functional without rehabilitation Current repair must be done by skilled technician staff familiar with the design and opera tion of D 260S3A diesel engine and its modifications Installed on the engine for preliminary technical condition diagnostics during the engine operation are oiling system oil pressure indicator sensor and alarm pressure signalizer sensor located in the heat exchanger cover cooling liquid temperature indicator sensor and cooling liquid alarm temperature indicator sensor located in the thermostats housing The air cleaner clogging extent is controlled by the air filter clogging signalizer sensor which activates the signal lamp at the air filter clogging over the permissible
54. rim back off area end wear 8 5 2 Drive gear sticking due to the lack or poor quality lubrication Back the flywheel rim teeth off or replace the flywheel rim Remove old lubrication from the drive and the shaft apply new lubrication IIMATHM 201 203 221 8 5 3 Drive gear teeth back off area end wear Back the teeth off or replace the dirive 9 Alternator then for the entire duration of its running 9 1 Ammeter voltmeter does not show the charge after starting the diesel engine and 9 1 1 Positive terminal wire broken or bridged to the al ternator housing Disconnect the rectifier solder and insulate the place of the break Insulate the damaged location Repair at a specialized workshop Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm Fix method 9 1 2 Field coil circuit broken Disassemble the alternator Solder or insulate the damaged 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 housing Replace the stator Repair at a specialized workshop 9 1 4 Power rectifier terminals short circuiting or for ward and reverse polarity diodes damaged Replace the rectifying device Repair at a specialized workshop 9 1 5 Faulty voltage regulator Replace the voltage regulator Repair at a specialized workshop
55. technical maintenance is not permissible The deviation from the scheduled engine maintenance periodicity is acceptable only within the limit of 10 The records on the scheduled routine maintenance except for those relating to the Annual Technical Maintenance must be enetered in a tractor machine combine harvester log book While performing technical maintenance before a lengthy storage period or Technical Maintenance 3 the engine must undergo diagnostics in order to determine a necessity of repair or repair type current or overhaul repair All malfunctions discovered in the course of maintenance must be eliminated Mainte nance operations linked with assembly units disassembling must be performed in closed rooms to prevent dust and dirt getting into the diesel engine assembly units cavities a For correct and safe diesel engine operation maintenance within the engine warranty period is recommende at the manufacturer service centers specified at www po mmz minsk by 3 1 1 1 Technical maintenance types and periodicity Technical maintenance types and periodicity are shown in Table 12 Table 12 m aintenance YP All year round Periodicity or operation hours 1 Maintenance before operation run in Before new diesel engine putting into operation or that of over hauled According to the instructions in items 2 2 2 2 2 5 2 Maintenance after operation run in Before new diesel engine putting into operation or tha
56. that mounting 3 must be coincided with the TDC mark on the damper housing Make sure the 1 cylinder intake and exhaust valves are closed there must be a small in take and exhaust valves rockers backlash If the exhaust valve is open rotate the crank shaft by a full turn and check the valves condition once again PY 2 AX Teeth counting order Pulse rim break v oO gt EN A HE aman H Damper position corresponds to the 1st cylinder piston a lY L Pistons in the 1st and 6th cylinders are in the TDC LJ gt 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 Ist cylinder piston behind 60 of the crankshaft turn angle before TDC To do that rotate the crankshaft clockwise using the crankshaft pulley mounting bolt approximate ly by two turns with that at the second turn rotate the crankshaft till the coincidence of mounting pin 3 and C mark on damper I housing Fig 3 Thus the pulse crown teeth will be positioned so that the axis of sensor 2 will lie along the 6 tooth of the pul rim crown counting against the clock from the pulse rim crown breaking segment Pulse rim b
57. the KTS Bosch diagnostic dej vice software Testing and repair at a specialized workshop check electricity consumers condition with the diagnos tic device Do diagnostics and the neces sary repair 3 9 2 Check the intake system Check for air leakage suction Check the air filter condition Do the necessary repair Replace the air filter by new one check the intake manifold for clogging Clean the intake manifold 3 9 3 Check the low pressure circuit check the correctness of connections in the low pres sure circuit check the hoses and pipe connectors for leakage Do the necessary repair check the fuel filter condition and conformity Replace filter by the appropri ate make sure there is no water in the fuel inside the coarse fuel filter cup Clean the fuel filter from wate pouring it out by opening the tap Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm make sure there is no air in the fuel 3 9 4 Check the clutch adjustment correctness 3 9 5 Check the harness condition for breaking or shorl circuit 3 9 6 Control Unit check Fault identification algorythm Remove air from the low pres sure circuit See Manual item 3 2 10 Do the necessary repair Do the necessary repair check the Control Unit plug and socket fixtures Fix plug and sockets
58. the established order When carrying out maintenance works and routine maintenance works of the diesel engine parts and assembly units subject to replacement should be sent for reprocessing assembly units must be dismantled into parts and sorted out by materials Annex A reference Chemmotological chart Table A 1 Assembly unit Quantity Mass vol Fuels and functionally fi of assem Fuels and lubricants names and grades ume of fuels lubricants nished device bly units and lubricants replace mechanism fric in a pro filled in a ment Notes tion couple duct pcs product at re adding name index Substitu placement periodici Main Back up Foreign adding ty hours kg 1 Fuel tank 1 Diesel fuel the technical condi Not Not Diesel fuel the According to Di tions of which conform to available Available technical condi rective 2004 26 EC 1658 2006 with sulphur contents tions of which and EEC UN Rules not more than 50 mg kg conform to Ne 96 02 Stage 0 005 of the grade for mod EN 590 2004 IIIA it is permissi erate climate class for arctic with sulphur ble to use fuels with and cold climate according to contents not sulphur contents up ambient temperatures in the en more than 50 to 0 3 g kg 0 03 96 gine operation region mg kg 0 005906 Note For moderate climatic zones it is recommended to use fuel grades at ambient t
59. the oil filter and do all pre paratory works in accordance with instruction of chapter 2 2 In case of a long period of storage over one month of a tractor combine harvester ma chine with an engine installed it is necessary to place the machine in a room or under a shed It is permissible to store tractors combine harvesters machines on open sites with compulsory proofing and hermetization The diesel engine preaparation for storage must be completed in not less than 10 days fol lowing the engine operation stop Preparing an engine for storage do what is described in item 3 1 5 2 of this Manual When storing a tractor combine harvester machine under a shed or on an open site dis mantle the alternator and the starter motor from the engine and keep them in a storage room Put a cover on the alternator and the starter motor installation places The engines removed from tractors combine harvesters machines or coming up as spare parts sets must be stored in a closed room secured on special stands It is not permissible to store 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
60. to service centre amp function and the main pro e speed calculation S gramme N Disruption of communication 5 i th ECU 6 3 P060A 11 e with the ECU CJ940 module eau E Appl a power stages controlled with SPI SETTICE e N N Continuation of Table 10 Fault type Fault description pixaneog 1 85 2 6 3 P1607 e Internal power voltage beyond the CJ940 module maximal power voltage Apply to semite ceutt maximal limit limit error t 4 1 inimal 1 86 2 6 3 P1608 a Internal power voltage below the Ce O module minimal Apply to service centre DSE limit error minimal limit N The function of monitoring communica Impluasible operation of control tion between Watchdog of CY310 and 87 2 6 4 060 ler or Watchdog system or the controller Used for reverse system shut Apply to service centre amp system must shut down down by means of the engine coordinator function N Continuation of Table 10 et Fix meth Fault type Fault description memo g8 3 1 1 P0478 3 Short circuit to power battery Short circuit to battery in exhaust flap con ane fap condinon Excessive heat up temperature trol circuit power stage TRENIA E Apply to service centre ee Check exhaust flap condition Short circuit to ground in exhaust fla 89 B 1 1 P0477 4 Short circuit t
61. turbine wheel with a shaft on the other end of which a compressor wheel via the air cleaner sucks air in and delivers it under pressure into the diesel engine cylinders Turbocharger according to Fig 10 is made on the principle radial centrifugal turbine and centrifugal single stage compressor with overhanging location of wheels relative to the supports The rotor speed the charge air flow and pressure depend on the engine operation mode 10 11 13 12 14 15 lo 1 turbine wheel with shaft 2 turbine housing 3 monobush 4 oil deflector 5 eccentric ring 6 compressor wheel 7 special nut 8 15 sealing rings 9 diffuser 10 cover 11 compressor housing 12 thrust bearing 13 space bush 14 middle housing bearings housing Fig 17a Uncontrolable turbocharger The housing of turbine 2 is made of high strength cast iron The turbine flow through part for exhaust gases is fromed by the turbine housing and the turbine wheel Compressor housing 11 is made of alluminium alloy its flow through part is formed by the compressor housing and compressor wheel The turbine and compressor housings are fixed to bearings housing 14 made of high strength cast iron Turbine whell 1 is cast of heat proof alloy and welded to the rotor shaft Compressor wheel 6 is cast of alluminium alloy and is fixed to the rotor shaft with a spe cial nut The rotor shaft rotates in
62. value of 6 5 kPa the alarm sensor is triggered With the alarm sensor triggered it is necessary to service the air cleaner 1 2 2 6 6 Exhaust gas recirculation device For the fuel mixture creation in the diesel engine cylinders the engine air charge supply design includes an exhaust gas recirculation device Exhaust gas recirculation device serves for exhaust gas toxicity reduction and the engine fuel economy in partial modes of small frequency crankshaft rotation The exhaust gas recirculation device Fig 13 con sists of recirculated exhaust gas cooler 1 operating EGR operating on the principle of heat exchanger mixer 2 recirculated exhaust gas inlet and outlet branch pipes 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 The presence of exhaust gases in the air charge coming to the engine cylinders provides froming of local zones in the combustion process allowing to reduce the amounts of ni trogene oxides Afterburning of carbon monoxide and hydrocarbons also contributes to improving the eclological parameters of exhaust gas contents ms a d 1 recirculated exhaust gas cooler 2 mixer 3 spacer 4 recirculated exhaust gas inlet branch pipe from turbocharger to EGR 5 recirculated
63. warning condition 121 11 Zi Depending on the settings service centre P0274 3 Low side short circuit to battery P0275 11 Depending on the settings EY Chee C Hhdersdainjee 34 1 4 5 Fault in power stage control circuit of cyl tors connectors and cables P0273 8 Low side and High side short cir inger 5 specific error engine shutdown condition cuit Apply to service centre P0275 11 14 Not classified error P121F 11 Depending on the settings T z 2 Check engine cylinders injec ae is P1220 11 Depending on the settings Fault in power stage control circuit of cyl tors connectors and cables P0205 12 No load resistance inder 5 specific warning condition Apply to service centre P1221 11 9 Depending on the settings Continuation of Table 10 NT Fix method Fault type Fault description 3 Low side short circuit to battery 11 Depending on the settings Cylinders Injen 36 1 4 6 Fault in power stage control circuit of cyl tors connectors and cables P0276 8 Low side and High side short cir inder 6 specific error engine shutdown condition cuit Apply to service centre P0278 11 i Not classified error P1222 11 Depending on the settings Check linders inj eck engine cylinders injec Bone ore P1223 11 Depending on the settings Fault in power stage c
64. 0193 Voltage beyond the set maximal Check the Rail fuel pressure limit Rail fuel pressure sensor circuit fault sensor condition and connec P0192 Voltage below the set minimal tions 157 limit Apply to service centre Continuation of Table 10 Fault type The Rail fuel pressure signal be Fault description Fix method 523615 pue den E IP Rail fuel pressure valve fault signal dis Check Rail fuel pigeon 19 L33 placement check sor condition and connections The Rail fuel pressure signal below 0191 17 the minimal permissible at signal COREE tn mix check P100E 0 Protective valve identified as open bo Pressure jump in Rail requested Rail fuel pressure safety valvefault ANON P1010 7 Protective valve not opening after pressure jump in Rail P0251 5 No load resistance Check high pressure fuel in Fault in high pressure fuel injection pump jecttion pump doser condition 2 1 3 5 doser pulse width control power stage and connections P0252 2 Excessive heat up temperature Apply to service centre Continuation of Table 10 Fault type Fault description Fault in high pressure fuel injection pump Fix method Check high pressure fuel injec tion pump doser condition and 22 1 3 5 P0254 3 Short circuit to power battery doser pulse width control power st
65. AN A bus other CAN devices Apply to service centre Check CAN line connection to Absence of CAN B bus Absence of CAN B bus other CAN devices Apply to service centre 39 6 08 4 1 2 0003812 1231 Continuation of Table 10 Fault type Fault description Check CAN line connection to 99 4 1 3 100047 12 Absence of CAN C bus Absence of CAN C bus other CAN devices x Apply to service centre SPI communication disrupted be i cn 100 4 1 4 P0607 12 S tween central processor and watch Dr commu aan iud e pee Apply to service centre DOS central processor and watch unit a Wait time elapsing for TSCI AE U1104 11 CAN messages when the engine ds Check CAN line connection to enabled 4 2 1 GUT x 101 Wait time clansing ctor TSC Ar TSC1 AE CAN message error other CAN devices Apply to service centre CAN messages when the engine 01105 12 2 speed torque correction mode is amp disabled Continuation of Table 10 Fault type Wait time elapsing for TSCI AR CAN message when the engine Fault description Fix method late i speed torque correction mode is gt ablsd 1 Check CAN line connection to 4 2 1 s i e Wait time elapsing for TSCI AR q mires Apply to service centre CAN message when the engine U1107 12 speed torque correction mode i
66. CONDITIONS Belarus 03535026 291 97 into the oil sump or motor oil recommended for the engine Annex A with 15 25 of additive AKOP I STATE STANDARD 15171 78 Add additive AKOP I to the motor oil in a few doses with vigorous stirring until a homogenious mix ture The mixture homogeneity is characterized by the absence of black or dark brown Stains in the mixture flushes coming down from the stiring rod Before using the AH T oil it is necessary to thoroughly stir it The AH T should not be heated in the winter season with the oil thickening it is allowable to heat it up to 80 C Drain fuel from the fuel tank Pour enough clean diesel fuel Standard 1658 2006 grade and let the engine run for 10 minutes If it is not convenient to drain the fuel from the tank use a portable vessel filled with rec ommended fuel Drain fuel from the engine power system remove the fuel filters coarse and fine and uti lize them Fill the new filters with diesel fuel Standard CTb 1658 2006 F erade and install them on the engine Fill purge the engine power system with fuel according to item 3 2 10 Start the engine and let it run for five minutes The engine stable running will show that th engine power system is filled up Stop the engine and let it cool down Then disconnect the low pressure fuel pipelines the inlet from the coarse fuel filter to the ECU radiator
67. Excessive heat up temperature P0650 3 Short circuit to power battery Dy Check failure indication lamp P0650 4 Short circuit to ground Fault in failure indication lamp control 142 3 3 3 1 WT condition and connection P0650 12 e No load resistance power stage circuit E 4 lt Apply to service centre P0650 2 A Excessive heat up temperature P162F 3 Short circuit to power battery Check ine 1 diti P1630 4 Short circuit to ground Fault in warning lamp control power stage PRAE C UC E 143 8 3 4 ce and connection P1631 12 No load resistance circuit Apply to service centre P1632 2 Q Excessive heat up temperature Continuation of Table 10 Fault type Fault description Fix method P0649 Short circuit to power battery adiustabl dirai Check lamp condition and 144 3 3 5 P0649 Short circuit to ground 1n adjustable speed limit lamp c r cobeetion cuit 3 P0649 x No load resistance Apply to service centre P0649 Excessive heat up temperature Check cruise control device 145 41 posed Non operable switched combina Fault in cruise control device actuating control unit condition tion mechanism circuit connection a Apply to service centre Check engine control backup 146 3 4 3 P2530 Button sticking or permanently Fault in engine control backup sta
68. IONS testet tee E EEEE EEEE E E EEEE E E EEE EAT 42 2 2 DIESEL ENGINE PREPARING FOR OPERATION eese ee e E nennen ne S REAA TEA REENE ENRERE EEEE 43 2 2 1 Safety rules to be observed while preparing diesel engine for operation eese 43 2 2 2 Diesel engine its assembly units and parts depreservation eese eene eene eene 43 2 2 3 Diesel engine additional equipment eee ete ere P ab d qe e RE EHE e E geb 44 2 2 4 Filling the COOLING system ied SERPENT 44 2 25 Filling the engine with fuel and oil ose a tem rer a E ee Pe t ri eb rib eR aedes 45 2 2 6 Diesel engine controls and control devices nennen 45 23 DIESEL ENGINE USE E tiii inii etie eiii die iiie eee derit e eerie 45 2 3 1 The order of diesel engine use by authorized technical personnel eee 46 2 3 2 Di selngine Strt s etd po RE ee ERR deep HE eed ege ice 46 2 3 3 Diesel engine ShutdOWh x ie etd dp D dp Ed edm pg andes 47 2 3 4 Diesel Cn inEOperati Ons TUN IM s acit e IU Ee D eH e hb RH rtp erp 47 2 3 5 Diesel engine operation in winter conditions eese eene ennt 47 2 3 6 Possible failures and troubleshooting 48 2 3 7 Safety measures with engine appropriate 121 2 4 OPERATION IN EXTREME CONDITIONS aeiio aE A R E AE RR 121 3 MAINTENANCE A E E E E E A E E O 122
69. OMMON RAIL injection sys Eollow KTS Bosch device diagnostic software instruc Clean the intake manifold tions Testing and repair at a specialized workshop check electricity consumers condition with the diagnos tic device CRS 3 2 3 Check the turbocharger operability 3 2 4 Check the low pressure circuit Do diagnostics and the neces sary repair See Manual Annex check the correctness of connections in the low pres sure circuit check the hoses and pipe connectors for leakage Do the necessary repair check the fuel filter condition and conformity Replace filter by the appropri ate Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm fuel filter cup make sure there is no water in the fuel inside the coarse Clean the fuel filter from watel 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 3 2 5 Check compression level in the cylinders 3 2 6 Check the high pressure circuit for leakage Do the necessary repair Do the necessary repair 3 2 7 Check the injectors launch injector check cycle by the appropriate standarc vice testing command in the KTS Bosch diagnostic de Follow the instructions in the KTS Bosch diagnostic de vice software
70. Open Joint Stock Company MINSK MOTOR PLANT Holding Managing Company Diesel engines D 260 1S3A D 260 2S3A D 260 4S3A OPERATION amp MAINTENANCE MANUAL Minsk 2013 TABLE OF CONTENTS 1 DESCRIPTION AND OPERATION cscsssssssssssssscessssesessssnsessssssersnsssssssensesessssesensssessasssesseseseseasssessnsssesssesesesessssessassssssnsessessesesesees 4 1 1 DIESEL ENGINE DESCRIPTION AND OPERATION eee ERROR BOOKMARK NOT DEFINED LAAT Diesel engine application s ee e tt rr Ret tete Error Bookmark not defined 11 2 Technical specifications x tete eter pe ee reete Error Bookmark not defined 1 1 3 Diesel engine components eese eene Error Bookmark not defined 121 4 Design and oper dtion ett eti eter pte eee dete Error Bookmark not defined T 15 Diesebenpine l bellifigs 5n deti m Ru ret D OH REDE ete eben 14 LD 0 P ckagifigx i tuus eon ce ee RE ERE HERE etes 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 ete gere tran egere Error Bookmark not defined 1 2 2 Description and operation ie oerte reete t trei apria Error Bookmark not defined 1 2 3 Diesel engine labelling Gnd sealing iuis e aee etre eer e aves 42 Z APPROPRIATE USE M H 42 2 OPERATING RESTRICT
71. Remove the radiator cap and check the cooling liquid level which must be reaching the orifice upper face Do not allow the cooling liquid level lower than 40 mm from the orifice upper face 3 2 2 Cooling system maintenance and washing The cooling system must be filled with low freezing cooling liquid Watch the cooling liquid temperature the normal operation temperature must stay within 80 100 C At the temperature rise over the normal check the cooling liquid level in the radiator the radiator hermeticity and the fan belt tension When necessary but at least every 2 000 diesel engine operation hours wash the cooling system Washing the cooling system use a 50 60 soda ash per 1 litre of water solution The cooling system washing is done in the following order pour in 2 litres of kerosene and fill the system with the ready solution start the engine and let it run 8 10 hours after that drain the solution and wash the cool ing system with pure water 3 2 3 Checking oil level in the engine oil sump Checking oil level in the engine oil sump must be done every working shift before the en gine Start with an oil level feeler rod located on the engine cylinder block The oil level must stay between oil feeler rod lower and upper marks as shown on Fig 18 This check must be done not earlier than 3 5 minutes after the engine shutdown when all of the oil is down in the oil sump It is not permissible to keep the oil level less than the low
72. S3A Values Diesel engine type 4 stroke turbocharged with charge air cooling Fuel mixture method Volumetric fuel mixture formation Number of cylinders pcs Positioning of cylinders In line vertical Swept volume litres 7 12 Firing sequence 1 5 3 6 2 4 Crankshaft rotation direction per State Standard 22836 77 from the fan side Right clockwise Bore mm 110 Stroke mm 125 Compression ratio calculated 17 Permissible inclination angles at engine operation 20 longitudinal degrees 20 Transverse Operating output kW 111 0 96 9 148 6 Rated speed min 2100 Specific fuel consumption at operating output kW hour 249 0 Maximal torque Nm 660 0 570 0 923 0 ypeed at maximal torque not less than min 1600 ngine mass without fuel lubricants and coolant Gath fan alternator starter and air cleaner kg 710 750 Average noise level Not more than dBA 97 98 General logarithmic levels of vibration velocity not higher than a vertically dB 108 2 6 horozontally 110 2 1 1 2 2 Controlled engine parameters Table 3 Engine model Parameters Min D 260 1S3A 260 253 D 260 4 53 Value confidence limit tolerance Rated output 116 0 2 0 100 0 2 0 156 0 3 0 Rated speed min 2100 s Specific fuel consumption at rated output g kW hour Sisa 2m Minimal stable idling speed iu 800 50 Maximal stable idling speed limited by regula x ed m tor no
73. SPS 0 V of oil pressure and temperature sensor 0 75 225 GJUIPS V of charge air pressure and temperature sensor 0 75 226 GJiCTS 0 of cooling liquid temperature sensor 0 75 227 W OPS Oil pressure and temperature sensor pressure signal 0 75 2 28 1 Oil pressure temperature sensor temperature signal 0 75 232 VJ 5VOPS 5 V of oil pressure and temperature sensor 0 75 2 33 VV 5VBPS V5 V of charge air pressure and temperature sensor 0 75 2 34 Charge air pressure and temperature sensor pressure signal 0 75 235 Fuel pressure and temperature sensor signal 0 75 2 36 UW3TS Charge air pressure and temperature sensor temperature signal 0 75 3 01 0J SVH21 High level of signal on the 5 cylinder injector 15 3 02 O PS VH22 High level of signal on the 6 cylinder injector 15 3 03 Q_P_SVH23 High level of signal on the 4th cylinder injector 1 5 3 04 0 P SVH11 High level of signal on the 1st cylinder injector 1 5 3 05 0 PJ gt VH12 High level of signal the 3rd cylinder injector 15 3 06 0 P SVH13 High level of signal on the 2nd cylinder injector 15 3 09 O V MCU High level of signal on the fuel pressure regulator 1 5 3 10 O TJiEU Low level of signal on the fuel pressure regulator 1 5 3 11 0J SVI3 Low level of signal on the 2nd cylinder injector 15 3 12 0 PJSV12 Low level of signal on the 3rd cylinder injector 1 5 3 13 0J53V11 Low level of signal on the 1st cylinder injector 1 5 3 14 0 P SV23 Low level of sign
74. TS Bosch diagnostic de vice software Testing and repair at a specialized workshop Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 6 1 2 Faulty pressure sensor or indicator backup de vices Replace pressure sensor or in dicator if necessary after checking the oil pressure with a set of check devices 6 2 Oil pipelines connections hermeticity lost Identify the area of lost hermit icity and restore it ee 6 3 Faulty oil pump Identify the fault and rectify it 6 4 Oil level in the engine oil sump lower than permis sible Add oil to the oil feeler rod upper mark 6 5 Extreme wear in interfacings crankshaft necks bearing shells main end and big end Rectifu the fault 6 6 Safety valve in the oil filter housing jammed Clense the valve and the valve channel in the filter housing 6 7 Clogged oil filter 7 Turbocharger See Annex Replace the filter 8 Starter motor 8 1 The engine crankshaft not rotating or rotating too slowly at the starter motor switch on 8 1 1 Weak accumulator battery terminals tightening or wires ends oxidated Clean the wires ends and tight en the terminals 8 1 2 Accumulator battery discharged Charge the acumulator battery 8 1 3 Collector and brushes dirty 8 1 4 Bad brushes contact with collector Brushes wear Clean collector and brushes
75. Tekhnoform limovsk Russia At installing new or repaired pump Cooling liq uid 40 down to 40 C 65 down to 65 C STATE STANDARD 28084 89 Not available MIL F 5559 BS 150 USA FL 3 Sort S 735 UK 13 4 12 5 Once two years in Compulsory cooling liq uid cone check by customer Annex reference Spare Parts amp Accessories Kit Table b 1 Spare parts to diesel engines D 260 1S3A D 260 2S3A D 260 4 S3A Location in M Quantity in a Quantity in a Part designation Product code Spare part description ilie package Application product pes Notes 50 1404059 b1 47 5341 8601 Cap gasket 260 1028010 1 1 5050002832 Belt SPA 1182 ao anal E 5050002969 Belt SPA 1307 E ae aaa 2 ing Table b 2 Tools and accessories Tool accessory designation Product code Tool accessory description Quantity in a set pcs 50 3901034 60 3901034 47 534 2815 47 5341 3054 Plate 0 25x100 Plate 0 45x100 1 1 Notes Location TK 10A Annex reference Cylinder liner and piston size groups Table B 1 0 05 b 110209 110 007 0 04 0 07 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 Nominal
76. a portable lamp with the voltage of not more than 24V The tools and appliances used in the engine preparation for operation must be well work ing fit for the intended use and ensure safety in doing the job The location where the engine is prepared for operation must be equipped with fire ex tinction means 2 2 2 Diesel engine its assembly units and parts depreservation Diese engines coming to consumers are preserved for shelf keeping from 6 months to 1 year period The particular preservation period is indicated in the engine passport The sequence of depreservation operations is shown in Table 9 Table 9 Preservation Operations period Engine depreservation 1 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 Take the plugs 3 out of the ECU radiator inlet connector and out of the redundant fuel diversion from HPFIP connector Before installing the pipe lines remove the plugs from the hydraulic pump Gear Pump openings Drain the remnants of preservation oil through the engine crank 4 case drainage hole Drain the remnants of preservation solution from the cooling sys 5 tem through the drainage tap 6 Get the engine rea
77. a radial bearing made as a floating non rotating monobush 3 The monobush is secured in the bearings housing by a fixer The rotor axial motion is taken by thrust bearing 12 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 On the compressor and turbine side there are gas oil sealimgs spring sealing rings 8 and 15 installed in the rotor groove For efficiency raising on the compressor side there os an oil deflector and a screen on the turbine side Installed in diesel engine D 260 4834 is a controllable turbocharger Fig 17b 4 32 56 1 nmm um 1 rotor 2 turbine housing 3 bearing housing 4 compressor housing 5 actuating mechanism 6 actuating mechanism bracket 7 air duct Fig 17b Controlable turbocharger Supercharging is regulated by diversion of a portion of exhaust gases past the turbine wheel at certain supercharge pressure values design turbocharger as shown on Fig 17b consists of the following basic units rotor I turbine housing 2 bearing housing 3 compressor housing 4 actuating mechanism 5 actuating mechanism bracket 6 air duct 7 The rotor includes a shaft welded to the turbine wheel and the compressor wheel oil sealing space bush two wash
78. ac cording to the crankshaft necks specifications The flywheel is made of cast iron it is fixed to the crankshaft flange with bolts A toothed rim of steel is pressed on the flywheel 1 2 2 4 Gas distribution mechanism Gas distribution mechanism consists of gears camshaft intake and exhaust valves as well as their mounting parts and a drive for pushers bars rockers adjustment screws with nuts disks keepers springs rocker axles and racks The camshaft has four supports it gets rotated by the crankshaft via the distribution gears The pushers are made of steel have spherical bottoms with a special cast iron surfacing The camshaft lobes are made with a slight inclination allowing the pushers to rotate in the process of the engine operation 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 The rockers motion along the axle is limited by spacer springs The intake and exhaust valves are made of heat proof steel they travel inside guiding bushes pressed in the cylinder heads Each valve is closed by two springs the outer and the inner which are fixed on its stem with a disk and valve keepers Sealing collars installed on the vavs guding bushes prevent oil penetration into th
79. 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 Upon the diesel engine warranty period expiration it is permissible to determine the en gine output by the non braking method The non braking method allows to determine the output and fuel economy by the effective fuel consumption At that there is no necessity to dismantle the engine from the machine When testing the engine with the non braking method connect a KH 8955 or KH 8940 type fuel consumption meter to the low pressure fuel system and mount a KH 5653 type load imitator on the air intake pipe Connect piezometer to the air supply system inlet branch The engine is started and heated up to the normal heat condition and at set modes deter mine the effective fuel consumption by which the engine output is finally determined If necessary to estimate the technical condition of parts and units beraing units belt drives shafts not having generalized indicators they use the size parameters gaps clear ances lifts try the parts and units or visually inspect them All faults discovered by tech nical diagnostics must be rectified by current repair or overhaul 3 1 5 Proofing reproofing for storage Depending on diesel engines scope of delivery agreed in contracts with customers the en gines are proofed for storage from 6 months to one year periods The particular proofing period is speci
80. ad As a sealing between the cylinder heads and the block an asbestos free gasket is placed The holes for cylinder liners and oil channel are edged with pltae steel From both sides of the gasket along the outer edge as well as the edges of the holes located in the oiling system and liquid cooling areas On both sides of the gasket along the outer edge as well as the edges of the holes located in the lubrication and liquid cooling system channels elastomeric sealant is applied by screen relief method When assembling a diesel engine its cylinder holes are additionally lined with fluoroplastic rings 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 6 7 and 12 crankshaft webs The crankshaft axial thrust is compensated by four bimetallic steel aluminium semi rings installed in the cylinder bores and the caps of the fourth main bearing The crankshaft is inhanced by collars at the front and the rear Mounted on the crankshaft front end are gas distribution drive gear crankshaft gear and oil pump drive gear water pump drive pulley alternator Installed on the shaft front end are gas distribution drive gear crankshaft gear
81. age cir j NES connections AN Apply to service centre Fault in high pressure fuel injection pump 23 1 3 5 P0253 4 Short circuit to ground doser pulse width control power stage cir SP eo Con and connections A Apply to service centre P025D 16 Signal voltage beyond the set max4 mE Check high pressure fuel injec imal limit Fault in fuel injection pump doser ana tion pump doser condition and 24 1 3 5 logue digital analogue converter control connections P025C 18 DEDI volage channel Apply to service centre 523615 set limit Continuation of Table 10 Fault type The number of safety valveopen Fault description Fix method P1011 1 ings exceeding the number permis sible by its tech specs The duration of safety valve open Rail fuel pressure safety valve fault identi 25 1 3 6 P1012 2 ings exceeding the number permis fied on the basis of its operation data Apply to service centre sible by its tech specs The number and duration of safety P1013 4 valve openings exceeding the number and duration permissible Q by its tech specs P0262 3 Low side short circuit to battery sok P0263 11 Depending on settings Cylinder control power stage circuit fault Check engine cylinders injec 26 1 4 1 Low side and High side short cir specific error engine shutdown tors
82. al on the 4th cylinder injector 1 5 8 15 0 fL5 V22 Low level of signal on the 6th cylinder injector 1 5 3 16 Q_P_SV21 Low level of signal on the 5th cylinder injector 1 5 T wire One step per inch Diesel engine and turbocharger failures identification Character Cause Check Character X X X X X Lack of air Air filter cleanness Narrowed air supply hose not firm loosened con XIX nections XIX X Supercharge pressure drop Narrowed damaged unfirm loosened connection between the turbo X charger and the engine xX X X Pressure drop in the exhaust Exhaust pipeline sealing loosened damaged unfirm xX X X X High pressure in the exhaust pipe Obstacles in the exhaust pipeline exhaust pipeline damaged line Crankcase gases high pressure Engine breather cleanness XIX X X X Insufficient lubrication Turbocharger inlet pipeline cleanness X X X Excessive lubrication Turbocharger oil outlet pipeline narrowed XIX Low compression Valves pistons and piston rings condition XIXIX Oil in the combustion chamber Valves and guides condition piston rings wear X xX X Bad injection Fuel injection pump and injectors nozzles xX X X Foreign particles Air cleaner completeness and cleanness X XIX X Foreign particles in the exhaust Turbine housing damaged part of the turbine wheel missing X X Vibration Turbo
83. aling outer housing into the water pump housing till the sealing housing flange thrust to the water pump gasket surface The mandrel design must ensure the inner sealing housing pressing so that the inner housing end surface stays at 10 7 0 1 mm away from the sealing outer housing Press the impeller on the shaft till the pump shaft end coincides with the impeller bore end surface ensuring 15 5 0 Imm from the pump housing end to the impeller end surface Mount a plug in the impeller end Mount the water pump cover providing horizontal posi tioning of the dismantling bosses located on the cover Fix the cover with three bolts put ting on them spring and flat washers The bolts must be tightened with 4 5 10 N m torque Mount the water pump on the engine 0 18 1 5 15 5 0 1 10 1 2 4 SH IRE NZ N 3 Hj N TH NIM TES M L J 6 N IIR S gt 2 25 7 a Nig N K B P N 9 10 7 0 1 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 216 2 0 05 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 str
84. alves To adjust the gaps loosen locknut 2 of adjustment screw 3 as shown on Fig 25 and screw ing or unscrewing the screw set the required gap per feeler rod 1 between the rocker striker and the valve stem end Having set the gap tighten the locknut and check the gap with the feeler rod again turning the bar Adjustment finished put the cylinder heads cover caps back in place The valves may be adjusted also in each cylinder when the piston is in the top dead center To do that turn the crankshaft till the first cylinder piston reaches the top dead center cor responding to the end of the compression stroke the setting pin indicator on the gas dis tribution gears cover and the TDC mark on the torsional vibrations damper housing scale coincide and adjust the first cylinder valves gap Rotate the crankshaft by 1 3 of a turn and adjust the gaps of the fifth cylinder valves At that the valves gaps must be adjusted in the order corresponding to the cylinders firing order 1 5 3 6 2 4 with rotating the crankshaft by 1 3 of a turn clockwise y WC S mM feeler rod 2 locknut 3 adjustment screw Fig 25 Adjusting the valves gaps 3 2 16 The COMMON RAIL system maintenance The COMMON RAIL system maintenance is done at specialized service centers by the specialists of the COMMON RAIL system specialized service centers Replacement of injectors after the COMMON RAIL system testing is done taking into account an i
85. and in the KTS Bosch diagnostic dej vice software Testing and repair at a specialized workshop check the high pressure circuit operability check the high pressure circuit for leakage 3 4 8 Control Unit check check the Control Unit plug and socket fixtures 3 5 Insufficient power Do the necessary repair Fix plug and sockets 3 5 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing tic device check for faults in the COMMON RAIL injection sys check electricity consumers condition with the diagnos Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop Do diagnostics and the neces sary repair 3 5 2 Check the intake system Check for air leakage suction Do the necessary repair Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm Check the air filter condition check the intake manifold for clogging 3 5 3 Check the engine oil level Replace the air filter by new one Clean the intake manifold Add oil to the necessary level 3 5 4 Check the turbocharger operability See Manual Annex E 3 5 5 Check the low pressure circuit check the correctness of connections in the low pres sure circuit check the hoses and pipe connectors for leakage Do t
86. auge upper mark See Manual Annex 2K 4 7 5 Check the turbocharger operability At oil consumption too high do the necessary repair 4 7 7 Check compression level in the cylinders Do the necessary repair 4 7 8 Check the high pressure circuit for leakage Do the necessary repair 4 7 9 Check the harness broken or kinked 4 7 10 Check the injectors launch injector check cycle by the appropriate stand ard testing command in the KTS Bosch diagnostic device Do the necessary repair Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop 4 7 11 Control Unit check check the Control Unit plug and socket fixtures Fix plug and sockets Engine overheating 5 1 Not enough cooling liquid in the cooling system Add cooling liquid in the ra diator to the normal level 5 2 Radiator dirty outside Clean the radiator 5 3 The thermostat valve not opening to the full Replace the thermostat 5 4 Insufficient fan belt tension Tighten the belt 5 5 Fan belt and pulleys oiling Dismantle the belt remove oil stains from the belt and the pulleys surface 6 Oil pressure lower than permissible in hot engine 6 1 1 Check for faults in the COMMON RAIL injection system using the diagnostic device do KTS Bosch standard testing Follow the instructions in the K
87. aulty 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 Fuel and oil drainage must be done into a sepaeate vessel Fuel and oil spilt on the floor mst be frist covered with sand or wooden chips and then taken away from the working place Using lifting appliances make sure the handled components are securely clamped The lift ing appliances must bear labeling with the indication of their lifting capacity Using loft ing appliances with weight exceeding their lifting capacity and moving cargos over other people is not permissible It is not permissible to pile large parts and units one on another thus creating a hazard situation Do parts and units washing in a specially equipped for that purpose place Working with not grounded equipment and the fuel pump electric motor not set to 0 is not permissible Disassembling and assemblying small parts and units is done on workbenches large parts and units on special benches Tools and appliances used must be kept in proper condition Pulling extracting appli ances must not contain cracks kinked rods or damaged threading It is not permissible to use worn out or bad tools and appliances The working tools must be of the proper sizing It is not permissible to use bad conditions spanners or spanners with deformed gaps To check holes coincidence it is necessary to use a mandre l pinchbar or a bolt but
88. 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 ob served Diesel engines exhaust gases contain substances harmful to human health nitrogen ox ides 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 perio dicity is strictly forbidden The rooms where diesel engines are run must have purge exhaust ventilation and the en gine exhaust system must have an autonomous gas diversion duct from the engine silenc er 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 amp Maintenance Manual E a Customers disregarding the rules and conditions of operation technical ser vice transportation and storage contained in this Manual breaking the manufacturer seals as well as using in current repair and technical service consumables fuel and lu brication materials assembly units and parts from manufacturers not recommended for use by the OJSC MMP HMC design documentation en
89. ble The fuel go ing through the paper filter element curtains gets cleaned from mechanic impurities To remove the air from the engine power system it is necessary to follow the procedures out lined in item 3 2 10 Fuel inlet Fuel outlet 1 filter housing 2 fine fuel filter Mann amp 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 4 The dry type air cleaner with paper filter elements made of special highly porous cardboard serves for suction of air in the engine cylinders The air cleaner has three cleaning stages The first stage is provided by a monocyclone the second and the third are the main and controlling filter elements Air under the action of depression created by the diesel engine turbocharger is cleaned from dust and comes into the turbocharger charging section from where it is delivered to the engine cylinders under the pressure through the charge air cooler To control the air cleaner clogging condition and for determining the necessity of tech nical service there is an air filter clogging signal sensor installed in the diesel engine in let duct The air cleaner and the signal sensor are to be installed by customer As the air cleaner clogging grows the depression in the inlet pipeline grows and at reach ing the
90. charger mounting on the engine X X X X X X Faulty turbocharger Dismantle the turbocharger and send it for repair X X X X xX E a E 5 E E e 215 B TELS s om e X 5 2 5 BERE S 5 2 g g 2 amp 2 2 5 E S 2 5 8 88 amp 2 3 S 2 s d S gt E E 3 8 4 E a OZ 4 Diesel engine fault Turbocharger fault Annex reference Engine slingning scheme a e SY ar xi 3 eye bolt 2 sling chain 3 beam 4 grip Fig 1 Engine slingning scheme
91. circuit iti ion P0541 4 amp 5hort circuit to ground P P 5 POM Hon e Apply to service centre Check air pre heat device con 138 B 2 2 P0540 7 Faulty multi signal Air pre heat permanently on dition and connection Apply to service centre Continuation of Table 10 NT Fix method Fault type Fault description Power supply battery voltage P1020 change beyond set maximal limit 1 i itch on j 139 52 3 Error registered by air pre heat switch on ck ap pre eee Power supply battery voltage check function tae ug P1021 change below set minimal limit at Q air pre heat device switch on D Power supply battery voltage P1022 change beyond set maximal limit at air pre heat device switch off Error registered by air pre heat switch off d E device con Power supply battery voltage check function E P1023 change below set minimal limit at air pre heat device switch on D Continuation of Table 10 Fault type Fault description Fix method P1619 3 Short circuit to power battery Check system diagnostic lamp P161A 4 Short circuit to ground Fault in diagnostic lamp control system 141 8 3 1 No load resi NENNEN condition and connection _ No load resistance 8 Apply to service centre P161C 2 Q
92. condition and conformity check the correctness of connections in the low pres Do the necessary repair Replace filter by the appropri ate fuel filter cup make sure there is no water in the fuel inside the coarsd Clean the fuel filter from water pouring it out by opening the tap Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm make sure there is no air in the fuel 3 4 3 Check the engine parameters check for faults in the COMMON RAIL injection sys Remove air from the low pres sure circuit See Manual item 3 2 10 Follow the instructions in thq standard testing check electricity consumers condition with the diag nostic device tem using the diagnostic device do KTS Bosch KTS Bosch diagnostic dej vice software Testing and repair at a specialized workshop Do diagnostics and the neces sary repair 3 4 4 Check the harness condition for breaking or short circuit Do the necessary repair 3 4 5 Check compression level in the cylinders Do the necessary repair 3 4 6 Check the clearances in the valve drive Adjust the clearances in the valves drive 3 4 7 Check the high pressure fuel injection pump KTS Bosch diagnostic device launch high pressure fuel injection pump check cycle Follow the instructions in the by the appropriate standard testing comm
93. dition m EMT doser control mode permissible electric current connections A Apply to service centre Check high pressure and low hydraulic curcuits Pressure differentials Disruption of high pressure fuel pump a 78 2 5 7 P101A 18 P en P pump components condition and c higher than expexted doser control mode connections A Apply to service centre Continuation of Table 10 Fault type 2 Fault description Fix method Check high pressure and low Fuel pump flow rate at the engine n pressure hydraulic curcuits Disruption of high pressure fuel pum 79 2 5 8 101 1 idle exceeding the set maximal P en P pump components condition doser control mode value connections A Apply to service centre 80 2 6 1 P0607 14 e ECU restart has taken place ECU restart stored as protective Apply to service centre in 81 2 6 1 P0607 14 S e ECU restart has taken place ECU restart shown in the error memory Apply to service centre mama CXC I Amon Error registered by ECU operation watch 82 2 6 2 P1613 16 5 ing the level set in the watch c p Apply to service centre function h the enigme Error registered by ECU operation watch speed calculated by the watch 83 2 6 2 1614 15 function using the engine independent Apply
94. duct is returned into the fuel tank The pressure regulator sets the pressure in the high pressure accumulator depending on the engine load speed and the engine thermal state With extremely high pressure in the accumulator the regulator valve opens and a portion of the fuel is diverted from the accumulator via the back runoff duct to the fuel tank The pressure regulator is mounted to the HPFIP housing with a flange Armature 10 presses the ball of valve 8 to the valve keeper with the valve spring in order to disconnect the the high and the low pressure circuits The switched on electromagnet 9 moves armature 10 applying additional force for pressing the ball to the keeper The armature is all flushed by fuel which lubricates the friction surfaces and removes ex cessive heat The working parts of the fuel pump are lubricated by oil coming from the diesel engine lubrication system The from the fuel pump housing is drained into the en gine oil sump When a new pump is installed in an engine it must be preli minarily filled with oil for 200 cm Oil is added through a special orifice item 7 Fig 6 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
95. dy for start Fill the engine oil sump with clean _ sump 7 Pump up the fuel supply system with the hand fuel feed pump i removing the air from the fuel system See paragraph 3 2 10 Assembly units and parts depreservation The diesel engine units and parts depreservation is done using a 8 piece of rag soaked in white spirit STATE STANDARD3134 78 with subsequent whipping dry The parts attached to the diesel engine are depreserved by jetting or dipping in a washing solution with subsequent hot drying the washing solution temperature from 60 C to 80 C the hot drying temperature from 70 C to 80 C 2 2 3 Diesel engine additional equipment When installed in a machine diesel engine must be equipped with fuel tank cooling sys tem radiator fan charge air cooler air cleaner electric divices and control devices The diesel engine design provides locations for heat carrier inlet and outlet from the pre start heating system which must be installed in a machine and used for the diesel engine pre start heating at the ambient air temperature lower than 20 C 2 2 4 Filling the cooling system The cooling system is filled by pouring the cooling system into the radiator or cooling liquid expansion tank the liquid brand and amount of filling are indicated in a table of Annex A The engine start and running with unfilled cooling system is not permissible To avoid boiler scale it i
96. e accumulator battery Start the engine 3 1 6 2 Engine return from long storage Remove the inlet and outlet branches and engine breathers protective packaging Remove the plugs from the inlet and outlet fuel pipelines and connect the pipelines 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 A up to the appropriate level Fill purge the engine fuel supply system with fuel according to item 3 2 10 Close all drainage taps and fill the engine cooling system with colling liquid of the rec ommended type according to the Chemmatological Chart Annex up to the appropri ate level Install and connect the accumulator battery Charge the battery if necessary Disconnect the inlet oil pipeline from the turbocharger central bearings housing Prelimi narily oil the bearings pouring oil into the orifice up to the flange level Connect the inlet oil pipeline using a new gasket tighten the inlet oil pipeline flange bolts Start the engine Heat the engine up to the normal operation temperature and diagnose it for error codes according to item 2 3 6 3 2 Diesel engine and its components maintenance 3 2 1 Checking the cooling liquid level in the cooling system The cooling liquid level in the cooling system must be checked every worlin shift before the engine statrt
97. e correctness of connections in the low pres sure circuit check the hoses and pipe connectors for leakage check the fuel filter condition and conformity Do the necessary repair Replace filter by the appropri ate fuel filter cup make sure there is no water in the fuel inside the coarsd Clean the fuel filter from wate1 pouring it out by opening the tap make sure there is no air in the fuel 4 1 5 Check the injectors launch injector check cycle by the appropriate stand ard testing command in the KTS Bosch diagnostic Remove air from the low pres sure circuit See Manual item 3 2 10 Follow the instructions in the KTS Bosch diagnostic de 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 tem using the diagnostic device do KTS Bosch standard testing Follow the instructions in the KTS Bosch diagnostic dej vice software Testing and repair at a specialized workshop check electricity consumers condition with the diag nostic device Do diagnostics and the neces sary repair 4 2 2 Check the harness broken or kinked Do the necessary repair 4 2 3 Control Unit check check the Control Unit plug and socket fixtures Fix plug and sockets 4 3 Various mechanical
98. e diesel engine cylinders through the gaps between the valves stems and the guiding bushes The distribution gears are located in a housing formed by a distribution shield fxied to the cylinder block and by the distribution cover The synchronization of the crankshaft and camshaft rotation speed signals coming to an electronic fuel supply control unit and matched with the gas distribution mechanism op eration is reached by installation of distribution gears according to the marks shown on Fig 2 DAR crankshaft gear 2 intermediate gear 3 fuel injection pump drive gear 4 camshaft gear 5 oil pump drive gear Fig 2 Distribution gears mounting diagram 1 2 2 5 Lubrication system The diesel engine lubrication system as shown on Fig 3 is a combined one some parts are lubricated under pressure other by spraying 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 Oil pump 3 is a gear type single section fixed to the engine cylinder block by bolts The oil pump is driven by a
99. e the air cleaner 18 Replace the air cleaner main filter element 19 Do the COMMON RAIL system overall service 20 Check the engine starter motor condition brushes collector springs terminals etc 21 Wash the cooling system See Notes See Notes 22 Replace the winter oil by the summer oil in the engine sump i 23 Set the alternator seasonal voltage adjustment screw if available to the position summer 24 Replace the summer oil by the winter oil in the engine sump Continuation of Table 14 Maintenance type ES MM AW 25 Set the alternator seasonal voltage adjustment screw if available to the 3 position winter diesel engines installed in combine harvesters require centrifugal oil filter rotor cleaning replacement of oil filter and oil in the engine oil sump every 125 operation hours the TM periodicity is set in the relevant tractor machine amp Maintenance Manuals fine fuel filter replacement is done every 600 diesel engine operation hours or as recommende by the COMMON RAIL diagnostics maintenance is done every 3 000 engine operation hours at special COMMON RAIL system service centers 3 1 4 Checking the engine operation condition The engine operation condition is checked by way of technical diagnostics The diagnostics are done at engine putting to long time storage at TM 3 after scheduled operations hours betw
100. ean napkin soaked in gasoline If it is impossible to remove dirt or stains of burn by wiping clean the collector with a piece of small grained sand paper With stains of considerable burn not going off with wiping use a machine tool for cleaning the collector The brushes must freely travel inside the holders and be firmly pressed to the collector In case of the brushes extreme wear as well as with considerable cleavage replace them by new ones Blow the brush collector unit and the cover with compressed air on the collec tor side Check the starter notor relay contact system condition With considerable burn clean the contact bolts and the contact plate with a piece of sand paper or a file removing the une venness caused by burn but not damaging the copper bolts contact surfaces flatness With the contact plate and bolts extreme wear turn the contact plate over and the contact bolts for 180 Check smoothness of the drive travel along the armature shaft At the relay switch on switch off the drive must travel along the armature shaft slits without jamming Remove dirty thick grease from the inner surfaces of the drive guiding bush slit and smooth brought from the crankcase which prevents smooth drive axial motion in the shaft slits at the gear engagement with the flywheel toothed rim Spread a thin layer of 221 203 201 grease on the cleaned surfaces Do visual check of the drive gear and thrust washe
101. een maintenances and while checking the engine repair quality Those doing TM 3 must possess equipment for resource technical diagnostics or use a mobile diagnostics machine Before engine diagnostics the following preparation work must be done examine the en gine visually clean it from dust and dirt wash the engine and intervew the engine opera tor on its functioning With any information on the engine parts and units wear extreme wear such as crank shaft bearings distruction detected by knocking during operation damage or serious de fects of cylinder block the engine must be sent to overhaul Diagnosting of some units devices and systems is done with the use of generalized indica tors of technical condition output oil pressure water temperature specific fuel consump tion amount of gas penetrating the engine crankcase with which you may estimate the condition of pistons piston rings cylinder liners and crank mechanism Before testing the engine it is necessary to check the units mounting service clean the air cleaner replace the fuel fine filter check the turbocharger check and adjust the drive belts tension gas exchange mechanism valves check and if necessary restore the oil lev el in the engine and fuel pump sumps check the cooling liquid in the radiator check fuel in the fuel tank With that job done and rectifying the discovered faults you may begin the diagnostics The diesel engine controllable parameters
102. emperatures Temperature up to not lower than Fuel grade peratures 5 0 5 10 15 20 _ up to Seasonal use of diesel fuels in the Republic of Belarus depending on ambient temperatures Summer period For arctic and cold climate it is recommended to use fuel classes at ambient tem Em qw ps memes 1 12 13 14 Winter period Grade B Grade C Grade F Down to 0 C not lower than Down to 5 C not lower than Down to 20 C not lower than From May 1 to September 30 5 months according to agreement with the customer From April to October 30 7 months From November 1 to March 31 5 months Continuation of Table A 1 Assembly unit R functionally fi P nished device 10 D mechanism fric un tion couple H name index 2 Oil sump Quanti ty of assem bly units in a pro duct pes Main Fuels and lubricants names and grades Substitution In summer stable amb Back up Foreign ient air temperature beyond 5 C Motor oil Lukoil Avangard Ex tra SAE 10W 40 Not available Not available Motor oils Liqui Moly Super Leichtlauf SAE 10W 40 BP Visco 3000 SAE 10W 40 Shell Helix Plus SAE 10W 40 Elf Competition SX SAE 10W 40 Agip 2000 GPX SAE 10W 40 Esso Utra Oil X SAE 10W 40 Mobil Super
103. ends and injec tors for pistons cooling The injectors for pistons cooling are installed in the cylinder block in the upper section of the second fourth and sixth crankshaft supports The cylinder block water distribution channel has a floor for installation of liquid oil heat exchanger The oil supply and diversion from the heat exchanger goes via the chan nels in the block To stiffen the lower surface of the cylinder block it is shifted down to 80 mm relative to the crankshaft axis A steel distribution shield and distribution cover are fixed to the front end of the cylinder block to the rear end a steel plate by which the engine is connected to tractor machine frame Two brackets fixed on the cylinder block sides serve as the engine front support The cylinder block bottom is covered by oil samp 1 2 2 2 Cylinder heads Cylinder heads are made of cast iron one head for three cylinders and are mutually ex changeable The cylinder heads inner cavities have intake and exhaust channels closed by valves To divert heat from cylinder heads there are inner cavities where the cooling liquid cir culates The cylinder heads have insertable valve seats made of heat resistant and wear resistant alloy Mounted on the cylinder heads are injectors 3 pieces for each head racks rocker axles with rockers cylinder head covers and cover caps closing the valve mechanism On the left side from the fuel injection pump there are 3 glow plugs for each he
104. entre N Check CAN line connection to 153 4 5 2 101103 3 War a dor TE CAN TF CAN message error other CAN devices DEDE Apply to service centre N 2 SPN received via CAN message DMIDCU CAN message error SPN 1 POA GCE DORA 2 coinsides with SPN in unit SPN T unit CENITE N 2 SPN received via CAN message DMIDCU CAN message error SPN 2 POS 2 OMS 2 S with SPN anunt SPN 2 unit COT N amp SPN received via CAN message DMIDCU CAN message error SPN 3 so d Sen coinsideswi unit SPN nite CORE Continuation of Table 10 Fault type Fault description igi tog SPN received via CAN message DMIDCU CAN message error SPN 4 1574 64 004372 X coinsides with SPN in unit SPN 4 unit ADP Y TO SETVE ERIS D SPN received via CAN message DMIDCU CAN message error SPN 5 N 158 06 5 0438 2 Q coinsides with SPN in unit SPN 5 unit APP CENITE D 159 4 6 6 00439 a e Ee DMIDECU DMIDCU CAN message error Apply to service centre en N N Check engine cylinders injec 1605 1 1 P0301 Number of flashes skips recog Error registered by flashes skips control tors connectors and cables nized beyond set limit function in cylinder 1 condition ut Apply to service centre Check engine cylinders injec 1615 1 2 P0302 Number of flashes skips recog Error registered by flashes skips co
105. eplacing fuel pre uentis tp tete dde ee HE E e d RETE ER s 133 3 2 9 Replacing fine fuel x 45i tn ee o ede RE RE d HERE RR s 133 3 2 10 eene 134 3 2 HE Servicing the dir cleaner it i ti Ste e EE E db ERU ets 135 3 2 12 Checking the air cleaner and the inlet duct connections hermeticity eene 136 Eq T E A Error Bookmark not defined 3 2 13 Washing the engine breathers eite n tette ER et e ete np e dtr EO qe te PI ERE ets 136 3 2 14 Tightening the cylinder heads bolts eese esee tenente een eene entente se e Eie Eei aS 137 3 2 15 Checking the gaps between the valves and the rockers esee 137 3 2 16 The COMMON RAIL system maintenance eese 138 3 217 Altern tor NGINIENANCE 5 s ueste Eie nr ages sh e a ai eU e te pedes 139 32 18 Checking the belts tension eie tee ee i e ire iei e ie ron ei on 139 3 2 19 Checking the starter motor condition ust deter detegit tee 140 3 2 20 Turboch rger maintenatee iioi tet rr Re RR ERE UO ERRARE VE EET DARE ERREUR FERRE RA ert 140 3 2 21 Compressor MAINTENANCE e Re de et e Ee in E rr dre 141 3 2 22 Gas exchange system components maintenance 141 jUOnnnLz Y 141 4 ENGINE CURRENT REPAIR
106. er mark and higher than the upper mark of the oil feeler rod 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 Drain used oil only from a heated engine To drain the used oil screw out the oil sump plug A soon as all of the oil is out screw the plug back in place Pour new oil through the oil filling branch up to the oil gauge upper mark Fill the oil sump only with the oil rec ommended by this Manual according to the season of operation 3 2 5 Replacing he oil filter Replacing he oil filter Oil filter must be replaced after every 10 thousand of vehicle run or upon the results of the COMMON RAIL system diagnostics as shown on Fig 19 in the following order unscrew filter GM 037 1012005 from connector 3 using a special spanner or other tools available screw a new 037 1012005 OJSC Avtoagregat Livny Russia filter on the con nector When mounting the filter on the connector apply motor oil on gasket 4 As soon as the gasket touches the housing base surface of filter 1 screw the filter further for 3 4 turns The filter on housing mounting must be done with hands only In the future order oil filter DM 037 1012005 at 303858 Russia the Oriol Region Livny 2a Industrialna
107. ers and two sealing rings The rotor rotates in the radial bearing mounted in the bearing housing The rotor axial motion is taken by the thrust bearing Incorporated in the controllable turbocharger housing is a bypass valve With a control lable rod the bypass valve lever is coupled with the actuating mechanism in its turn linked with the compressoe outlet by the air duct The regulator setting to a ceratian pressure is done by adjusting the rod length The turbocharger actuating mechanism rod length within the operation period is not permissible The turbocharger bearings are lubricated and cooled by the oil coming through the die sel engine lubrication system pipeline The oil is drained from the turbocharger into the engine oil sump The turbocharger disassembling and repair during the engine use is not permissible When out of use it should be done at a specialized repair shop 1 2 2 9 Starting device 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 A tractor agricultural machine electric circuit diagram must include starter motor block i
108. fied in an engine passport With the engine storage period exceeding that in the passport it must undergo reproofing Engine reproofing after a 6 months storage must be done for a one year period Repeated reproofing under a 6 months standard is not permissible Enegine proofing as part of a tractor machine for a short storage period 10 days to 1 month is done as described in item 3 1 5 1 Enegine proofing as part of a tractor machine for a long storage period over 1 month as well as reproofing for over 6 months is done as described in item 3 1 5 2 It should be noted that after the engine start depreservation of its inner cavities cooling and fuel supply systems takes place 3 1 5 1 Engine proofing before short storage Drain motor oil from from the engine oil sump into suitable vessel at the ambient tempera ture and the engine parts temperature not higher than 60 C Put and screw the oil drainage plug into the oil sump tray Fill the oil sump with motor oil to the appropriate level as recommended by the Chemmotological Chart Annex A Fill the fuel tank with the recommended fuel Annex A Let the engine run without load for 2 minutes at 1200 min Do not drain the oil from the oiling system and the fuel from the engine power system after the engine shutdown Check the air cleaner and if necessary service it If frosty weather is expected during the engine storage period check the cooling liquid for conformity to the req
109. following rules Begin working only after proper study of the diesel engine design and operation and maintenance rules Do not operate vehicles with faulty engines Do not run the engine in a closed room with poor ventilation Do engine maintenance and rectify failures with the engine not running and at cooling liquid temperature in the cooling system not over 60 C To avoid face and hands burn when removing the radiator orifice cap on a hot engine use gloves or a piece of cloth Mount and dismantle the engine using slings run through the eyes located on the engine the slinging scheme according to Annex IH Do not us eopen fire for the engine fuel pipelines and oil sump heating in the cold season of the year Make sure there are no flammable materials near the engine exhaust manifold turbo charger and silencer Do engine fueling and oiling using special appliances and observing the fire safety rules When draining the fuel system or purging pour the fuel only into a separate vessel Do not heat the sucked in air by open fire in front of the air cleaner Do not start the engine with the cooling system not filled with the cooling liquid After engine shutdown switch the accumulator batteries off but not earlier than 1 mi nute after ignition switch off and engine shutdown The rooms where engines are run must be equipped with influx exhaust ventilation while the engine exhaust system must be equipped with
110. fric units in a aae Tee tion couple name product cants filled place index pes a product ment Notes Main Substitution Back up Foreign at replace adding ment add 10 ing RID kg dim ours 3 i 1 High foel Motor oil the same as in the engine 0 17 0 2 injection pump 4 1 One ti Pra Titol Not available Shell Retinax EP pee een STATE STANDARD 21150 87 Shell Retinax HD is needed in operation Cooling system vol ume without radiator and connecting branches Low freezing cooling liquid Tosol Dzerzhinsky TC 40 down to 4 Tosol Dzerzhinsky TC 65 down to 65 C TY TECH CONDITIONS 2422 050 36732629 2003 manufactured by LLC Tosol Sin tez Dzerzhinsk Russia Low freezing cooling liquid 40 down to 40 C STATE STAND ARD 28084 89 manufactured by OJSC khimik Borisov Belarus Low freezing cooling liquid Sibur Premium 40 down to 40 C 65 down to 65 C TY TECH CONDITIONS 2422 054 52470175 2006 manufactured by OJSC Sibur Neftekhim Dzerzhinsk Russia Low freezing cooling liquid Tasol AMIIAO down to 40 C TY TECH CONDITIONS BY 101083712 009 2005 Leso manufactured by RUE Gomelkhimtorg Gomel Belarus Low freezing cooling liquid CoolStandart down to 40 C TV TECH CONDITIONS 2422 002 13331543 2004 manufactured by OJSC
111. g method ensures its preservation for the period of the engine transportation storage and operation life 1 1 6 Packaging With the engines transportation in closed carriages containers or by trucks the engines are secured on wooden stands made to the manufacturer s drawings With shipping the engines in open type transport trucks trains the engines are wrapped in polyethylene bags according to STATE STANDARD10354 and are secured on wooden stands The engines shipped in railway carriages to the regions with tropical climate are wrapped in polyethylene bags and placed in wooden cases when shipped in sea contain ers wrapped in polyethylene bags 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 devices Diesel engine configuration Housing Cylinder block and suspension 7 Cylinder head Valves and pushers E Gas distribution Cylinder head covers manifold and breathers Distribution mechanism Q 5 Crank and slot Pistons and conrods Crankshaft and flywheel Oil sump Oil pump receiver and oil pump Heat exchanger Oil filter Centrifugal oil filter Turbocharger
112. gine design modification will stop the engine warranty validity E a 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 183A D 260 2S3A D 260 4 S3A Wheeled tractors 1 4 2 drawbar Forage harvesters and wheeled Application pplicatio categories tractors 3 4 drawbar categories Application Areas with unlimited air exchange environment nO Microclimatic regions with moderate climate Air temperature values Climatic of operation conditions from 40 C to 45 C conditions of Microclimatic regions with both dry and humid tropical climate Air operation temperature values of operation conditions from 50 C to 10 C with diesel engine operation at the environment temperature lower than 25 C 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 Engine model Parameters Measurement unit D 260 1S3A D 260 283A D 260 4
113. grow considerably 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 28 Remove pulley 9 using a puller Take the key out of the slit on the pump shaft and stop ring 12 fixing the bearings block in the water pump housing Unscrew three 3 bolts of the water pump cover Remove the water pump cover using two dismantling pieces 13 thread M8 located on the cover end Remove plug 6 installed in the impeller end Press the shaft with bearings out of the water pump housing The pressing out direction to pulley mounting side Press the bearings out of the shaft Press the gland out of the pump housing Check the parts for defects 4 2 3 2 Water pump assembly Mount thrust ring 14 on the pump shaft press the bearings in Fill the bearings and bear ings cavities with 45g of Litol 24 4 12 3 lubricant Press the shaft with bearings into the pump housing Mount ring 12 stopping the bearings unit Mount the pump pulley washer and nut Tighten the nut with 120 140N m torque Using the mandrel Fig 30 press water pump sealing 2 with the inner housing on the wa ter pump shaft and simultaneously press with the se
114. h the engine run in complete perform the following technical maintenance check and if necessary tighten the cylinder heads bolts check and if necessary adjust the gap between the valves and rockers clean the centrifugal oil filter rotor replace the oil filter replace the oil in the engine oil sump pour the sediment out of the fuel pre filter check and if necessary adjust the drive belts tension check and if necessary tighten the outer threaded connections WB exhaust gases at the oulet have the temperature of 600 800 so the thermal damage to the exhaust manifold paintwork does not a signify disturbances in the engine workflow 2 3 5 Diesel engine operation in winter conditions Diesel engine operation is complicated at low ambient air temperatures To ensure con tinuous and troublefree operation in the winter period which start with the ambient tem peratures lowering to 5 C and lower get the engine ready for operation in the winter mode well in advance For that purpose do the scheduled technical maintenance adding the seasonal technical service operations tractor engine compartment must have a 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 A 1 Annex A check the accumulator battery condition charge them if necessary the ac cumulator batteries must be fully cha
115. he necessary repair check the fuel filter condition and conformity Replace filter by the appropri ate fuel filter cup make sure there is no water in the fuel inside the coarsd Clean the fuel filter from watel 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 3 5 6 Check the injectors vice 3 5 7 Check compression level in the cylinders launch injector check cycle by the appropriate standard Follow the instructions in the testing command in the KTS Bosch diagnostic dej KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop Do the necessary repair 3 5 8 Check the clearances in the valve drive Adjust the clearances in the valves drive 3 6 Power too high 3 6 1 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing check for faults in the COMMON RAIL injection sys Follow the instructions in thd KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop tic device check electricity consumers condition with the diagnos Do diagnostics and the neces sary repair Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 3 6 2 Check the intake system
116. ich goes down as the battery charge is restored 3 2 18 Checking the belts tension Checking the belts tension is done after every 125 engine operation hours The alternator belt tension is considered normal if its deflection on the branch crank shaft pulley alternator pulley stays within 13 mm to 18 mm when pressed with a force of 402 N To adjust the belt tension loosen the alternator mounting Adjust the belt tension turning the alternator housing Tighten the alternator plate mounting bolt and the alterna tor mounting bolt nuts The water pump drive belt D 260 1S3A D 260 2834 D 260 4S3A 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 I 000 engine operation hours in the following manner check the mounting bolts tightening if necessary tighten them clean the ends of the wires leading to the starter motor terminals and the accumulator battery and tighten their mountings The preventive examination and servicing must be done after every 2 000 engine operation hours Remove the cover from the collector side and check the brush collector unit condition The coolector working surface must be smooth and should not contain any stains of considera ble burn If the collector is dirty or has stains of considerable burn wipe it with a cl
117. ictly 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 At long term storing the vehicle with installed diesel engine should be place in closed premise or under the awing Preparation of the diesel engine for storage must be finished not later than 10 days as of the date of completion of vehicle operation Fulfill the following works when preparing the diesel engine for long term storage clean diesel engine from dust and dirt drain the cooling fluid from the cooling system drain oil from the diesel engine crankcase fuel pump housing lay up the diesel engine for a year period in accordance with item 3 1 5 2 When keeping the vehicle under the awning or at the open area dismantle and hand over the gen erator and the starter to the warehouse Cover starter installation place with a lid Diesel engines dismantled from the vehicles or supplied as a spare parts must be stored con servated indoors on special supports It is forbidden to store storage batteries acids salts alkali and other agents able to provoke metal corrosion At short term storing of the vehicle at the open area or under the awning do the following clean the diesel engine from the dust and dirt wrap exhaust pipe and air cleaner connecting pipe with waxed paper or polyethylene film Prior to putting the vehicle into operation replace the filtering cell of
118. iesel 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 Installed in diesel engines are friction type dry single disc or double disk permanently closed clutches as shown on Table 6 1 2 3 Diesel engine labelling and sealing Labelling and sealing of diesel engines manufactured by is done according to the current manufacturer design documentation Labelling of diesel engines big size parts according to supplier companies design documentation 2 APPROPRIATE USE 2 1 Operating restrictions For long time and troubleless diesel engine operation follow the basic conditions below For proper COMMON RAIL electronic control system functionEng the electronic Control Unit software must comply with the application of tractors agricultural ma chines where the engines are installed Before putting a newly manufactured engine into operation under load run it in accord ing to article 2 3 4 At the beginning of a working shift before the engine start check the oil level in the en gine oil sump and that of the cooling liquid in the radiator or the expansion tank After the engine start before loading the engine let it run for 2 3 minutes firs
119. in the charging device allows better en gine pickup provided by higher torque values at low crankshaft speeds Engines equipped with Common Rail accumulator type fuel system show higher opera tional and fuel economy and conform to Tier 3A ecological parameters due to optimized operation process and minimization of transitional processes while changing the speed and load modes Using exhaust gas recirculation devices in the engines feed system also contributes to reaching the required ecological parameters bringing changes into the mass charge con tents entering the engine cylinders by way of partial deliver of exhaust gas To ensure engine start up at low ambient temperatures glow plugs are installed in the engine cylinder head while fuel liquid heat exchanger ensures a faster reaching of the op timal oil temperature in the engine lubrication system and keeping it at the required level during the engine operation 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 When the inlet valve closes and the piston moves upwards the air compression takes place At this the air temperature goes up sharply In the end of
120. ine spreading it in a way allowing air ac cess The proofed engine must be periodically checked Should you discover any signs of corro sion you will have to undertake the appropriate measures in order to prevent the engine parts damage Applies to the engines meant for proofing with keeping separate from tractor machine to do additionally Wipe with a napkin and apply the oil or proofing oil on the flywheel gasket face if the clutch is not there hydraulic pumps gear pumps gasket faces clutch pressure disk slits turbocharger outlet hole flange connector applies to the engines with out outlet branch pipe Cover the outer openings of exhaust manifold intake manifold thermostat housing water pump branch turbocharger engine breathers with polyethylene film STATE STANDARD 10354 82 and tie up with string 4 0 0 25 STATE STANDARD 17308 88 Cover the starter motor and the air cleaner monocyclone with polyethylene bags and wind with sticky polyethylene tape STATE STANDARD20477 86 or tie up with string 4 0 0 25 H1 STATE STANDARD 17308 88 3 1 6 Engine preparation for putting into operation after return from storage 3 1 6 1 Engine return from short storage Remove the inlet and outlet branches and engine breathers protective packaging Check the cooling liquid and oil levels Fill purge the engine fuel supply system according to item 3 2 10 Check and if necessary charge th
121. injector check cycle by the appropriate standard Follow the instructions in the testing command in the KTS Bosch diagnostic de KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop Check for air leakage suction Do the necessary repair Check the air filter condition Replace the air filter by new one check the intake manifold for clogging Clean the intake manifold 1 3 5 Check compression level in the cylinders 1 3 6 Check the harness broken or kinked Do the necessary repair Do the necessary repair 1 3 7 Control Unit check check the Control Unit plug and socket fixtures Fix plug and sockets Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 2 Unstable engine operation at idle 2 1 Unstable speed at idle 2 1 1 Check the low pressure circuit sure circuit check the correctness of connections in the low pres check the hoses and pipe connectors for leakage Do the necessary repair check the fuel filter condition and conformity Replace filter by the approprij ate fuel filter cup make sure there is no air in the fuel make sure there is no water in the fuel inside the coarsd Clean the fuel filter from wate1 pouring it out by opening the tap Remove air from the low pres sure circuit See Manual item 3 2 10
122. ink 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 Not all of the faults may be stored in the control unit memory Therefore during the en gine operation pay attention to the engine gauges indications exhaust gas colours listen to the sounds of the engine running Hearing unusual sounds check the reason and recti fy the fault Being not able to rectify the fault apply to a diagnostic station Usually a di agnostic service station electronic database supports further search of faults The list of possible diesel engine faults in the process of operation and recommendations on the methods of their fixing are given below in Table 11 Do checking of the engine operation failures in sections 1 4 of Table 11 after complete COMMON RAIL system check with a diagnostic device Blink codes table Table 10 Fault type Fault description Fix method Faults shown by diagnostic lamp lightup Analogue digital analogue converter P060B 3 reference voltage exceeding the set limit Analogue digital analogue converter PN Eu ver Error discovered by analogue digital P060B 4
123. ion Fix method The engine start and operation performed xD 118 1 1 4 P0008 12 Backup mode enabled condition and connection Apply to service centre Voltage beyond the set maximal P0563 B lim 8 TE Check power supply battery imit Unpermissible voltage of power supply d ras Voltage below the set minimal 11 batter P0562 4 8 y Apply to service centre mit FMTC trq2qBas MAP field contains not strictly monotonous curves of cyclic fuel 120 1 2 5 1007 e Implausible field appearance bic Apply to service centre feed dependence on torque at engine set speed P1300 16 Number of injections limited by charge coordinator load balance ee ee Limeted number of injections 8 121 1 5 5 P1301 15 high pressure fiel injection pump l Apply to service centre quantitative balance i as T P3021 Number of injections limited by amp software settings Continuation of Table 10 m Fix method Fault type Fault description i 122 b 1 1 P2269 111 Sensor showing water in fuel con Discovered water in fuel concentration is Replace fuel centration beyond permissible beyond permissible D N P1008 3 Short circuit to power battery Check fuel filter electric heat 123 2 1 6 is Fault in fuel filter electric heating element ing element condition
124. is necessary to remove air from it purge the system For that purpose Unscrew plug 5 Fig 22 located on the fine fuel filter outlet connector mounting bolt by 2 3 turns Purge the system with booster priming pump 9 located on fuel coarse filter housing 8 screw plug 5 in torque 7 8 Nm when you see fuel coming out without air bubbles Unscrew turn elbow 3 bolt of the fuel drainage pipelines mounting on HPFIP housing 1 by 2 3 turns and continue purging by the booster pump until you see fuel coming out without air bubbles Screw bolt 7 torque 3 4 Nm 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 9 hand booster pump 10 air outlet plug Fig 22 Removing air from the fuel system Switching over to the winter or summer operation period and therefore changing the type of fue to speed up the fuel system filling use all available plugs for letting air out and do step by step air removal through plugs 10 7 5 and turn elbow bolt 3 3 2 11 Servicing the air cleaner Servicing the air cleaner with a papter filterelement made of special highly porous card board is done after every 500 engine operation hours or if necessary by the indication of the clogging signalizer Servicing the air cleaner includes purging of the main filte
125. is not permissible to send direct water flow on the CRS electronic control system sensors plugs and sockets ECU and harnesses plugs and sockets To do some adjustment work during the maintenance the diesel engine must be heated up to the necessary temperature mode specified in this Manual Technical maintenance must be commenced only after visual examination and proper tightening of loosened fixtures Upon maintenance completion the engine as part of a machine is sent to the storage site or for fuelling for continuation of the scheduled work The basic and backup fuel and oil materials list is given in Table A 1 Annex A 3 1 2 Safety measures To ensure safe operation and avoid accidents during the engine maintenance observe the following rules eligible to the engine washing are persons having been theoretically and practically in structed using ungrounded washing equipment or that having a pump electric motor not set to 0 is not permissible washing is not permissible outside specially equipped locations ensuring ecological safe ty do not run the engine in a closed room with poor ventilation maintenance and faults elimination must be done with the engine not running to avoid face and hands burn when removing the radiator orifice cap on a hot engine use gloves or a piece of cloth the appliances used in maintenance must be in a proper working condition the tools must be in a proper working condition and of
126. izer of injector 11 and also through a fuel supply throttle hole 7 to the chamber of controlling valve 8 Through the fuel outlet throttle hole which may be opened by the electromagnet ic valve the chamber is connected with back runoff duct 1 With closed throttle hole 6 the hydraulis force acting from above on the controlling valve piston is higher the force of the fuel pressure on the atomizer needle cone underneath As a result the needle is pressed to the atomizer seat and firmly closes the atomizer holes and the fuel cannot get in the combustion chamber When electromagnetic valve 3 triggers the electromagnet armature is moved up opening throttle hole 6 Accordingly reduced are both the pressure in the controlling valve chamber and the hydraulic force applied on the controlling valve piston By fuel pressure on the cone the atomizer needle moves away from the valver seat so the fuel get in the cylinder combustion chamber through the atomizer holes The controlling supply an additional fuel amount meant for the needle rise which is further diverted to the fuel back runoff duct N 2 Y 77 8 ranarum y Y Rs Tl m abs of SS EST REP SS si SN S Hr T Bey BE Fini I N B ABS AR E SE E SEs S JT El E HB L T77 NE m
127. low the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop 4 6 2 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 check the intake manifold for clogging Clean the intake manifold 4 6 3 Check the engine oil level Add oil to the oil gauge upper mark 4 6 4 Check the low pressure circuit check the correctness of connections in the low pres sure circuit check the hoses and pipe connectors for leakage Do the necessary repair check the fuel filter condition and conformity Replace filter by the appropri ate make sure there is no water in the fuel inside the coarse fuel filter cup Clean the fuel filter from water 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 Continuation of Table 11 Fault Outward fault demonstration At oil consumption too high do the necessary repair 4 6 5 Check oil consumption 4 6 6 Check compression level in the cylinders Do the necessary repair 4 6 7 Check the injectors vice launch injector check cycle by the appropriate standard Follow the instructions in the testing command in the KTS Bosch diagnostic de
128. lusion method do the en gine failures identifi cation and those of the turbocharger as described in the table Annex E Remove the cylin der heads from the engine and do the valves bedding in item 4 2 2 drainage hole liquid level in the cool ing system at MM Water pump 3 Cooling liquid 3 1 End sealing Remove the water leakage through the wear 3 1 Control the cooling pump from the engine disassem ble the pump item 4 2 3 Continuation of Table 16 Description of fail ures and damage consequences Possible causes 3 2 Bearing unit wear Instructions on identi fying the consequenc es of failures and damage of assembly units 3 1 1 Visually examine the water pump on a running engine after the engine start during heating up 3 2 Press on the pump pulley with the engine not running and check the radial backlash in the bearing unit Instructions on eli mination consequences failures and damage of the of Replace the water pump gland Replace the bear ings water pump housing if neces sary 4 No cooling liquid circulation in the cooling system Impeller turns over without fix ing on the pump shaft Checking the engine cooling system temper ature condition by the temperature indicator shows sharp cooling liquid temperature rise 4 2 1 General instructions on piston rings replacement Rem
129. n amp Hummel WDK962 12 or WDK962 14 Germany Air filter With paper filter elements Oil filter Non separable full flow centrifugal working on branch Fan and fan drive Axle type Unavailable Continuation of Table 6 Engine model Units parts D 260 1S3A D 260 2S3A D 260 483A Unit part designation and or its description Friction type dry constantly closed type double disk or single disc or not available BHEUOD D pes pcne Alternator AC rated voltage 14V or 28V Starter Rated voltage 24V Diesel engines are equipped with pin glow plugs with rated voltage of 23V and have locations for heat carriers inlet and outlet when a Start up aids age pre start heater is installed Note for tractor engines to be installed by customer _ to be installed by customer on the engines going to MTZ tractors The D 260 1S3A diesel engine appearance is shown in Fig 1 Spare Parts Tools amp Accessories Kit list See Annex B to this Manual Table B 1 2 wth 7 m gri LI Ik 17 Nd pee cen mw 216 ee iw a E i DRITTE a FEL EP 2 r D iw AZ c D S 4 DLD Mee SUG 07 maru i IC ATEN ES 22 A yH 5 4l Fig 1 Diesel engine
130. nch injector check cycle by the appropriate standarc testing command in the KTS Bosch diagnostic de vice Follow the instructions in the KTS Bosch diagnostic dej vice software Testing and repair at a specialized workshop Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 3 7 4 Check the high pressure circuit for leakage 3 7 5 Check the intake system Check for air leakage suction Do the necessary repair Do the necessary repair Check the air filter condition Replace the air filter by new one check the intake manifold for clogging Clean the intake manifold 3 7 6 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing check for faults in the COMMON RAIL injection sys Follow the instructions in thd KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop tic device check electricity consumers condition with the diagnos Do diagnostics and the neces sary repair 3 7 7 Check the engine oil level Add oil to the necessary level 3 7 8 Check the turbocharger operability See Manual Annex E 3 7 9 Check compression level in the cylinders Do the necessary repair 3 7 10 Control Unit check check the Control Unit plug and socket fixtures 3 8 Super high engine speed at pedal release
131. ng A spring firmly presses the cone to the valve seat under normal operating pressure so that the accumulator remains closed In the event of the pressure in the accumulator exceeding the operating value the cone moves away from the valve seat and the fuel being under high pressure is diverted to the back runoff duct As a result the fuel pressure in the accumulator goes down 1 2 2 6 3 Injector Injector Fig 9 is designed for deliverying fuel in the diesel engine cylinder and ensuring the necessary spraying Installed in the engines are CRIN2 injectors manufactured by BOSCH Germany The required moment of the start of injection and the fuel supply amount are provide by the operation of the injector electromagnetic valve The moment of the start of injection in the angle timing coordinates is set by the diesel engine electronic control system Fuel otlet 29 pe 1 oul gt a 1 electromagnetic valve 2 controlling valve 3 atomizer needle 4 atomizer housing 5 electric terminals 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 installed in a consistent relationship in a specific pattern The injectyor operation principle is shown on Fig 10 The fuel is supplied along the high pressure pipeline via inlet channel 4 to the atom
132. ng after engine startup starter motor switch off upon the crankshaft speed reaching 900 min 1 to 1000 min 1 and inability to switch it on with the engine running 1 2 2 10 Alternator and its drive Installed in diesel engines are alternators serving as electric equipment power sources Alternators have terminals for connection to circuits B load and accumulator battery D starter motor blocking relay W tachometer Alternator is used for accumulator battery recharging and direct current supply to elec tricity consumers installed in a tractor agricultural machine Alternator is driven by a V belt on the crankshaft pulley 1 2 2 11 Compressor and its drive To drive pneumatic trailer brakes and tire inflation diesel engines installed in trac tors combine harvesters machine are equipped with a piston single stage compressor Table 6 Compressor A29 05 000534A is mounted on the distribution cover flange and is driven by the compressor and the distribution mechanism fuel pump drive gear With a diesel engine being used in agricultural work not requiring compressed air power compressor A29 05 000B3A must be switched off It is not allowed to switch the com pressor on with the engine running Compressor A29 05 000B3A is air cooled 1 2 2 12 Gear pump and its drive Hydroficated tractor or other vehicle control systems imply installation of 14 3 or 16 3JI or 10 gear pump in d
133. njector and a nozzle labeling applied in the locations shown on Fig 26 Replacing an injector or a nozzle without using special equipment and specially trained staff as well as within the warranty period is not permissible Replacing an injector noz zle during the warranty period may be done only by a BOSCH service center or by a BOSCH authorized workshop Injector labelling location Nozzle labelling location 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 voltage adjustment With that the winter summer adjustment screw is not there Make sure the alternator mounting and that of the alternator wiring are reliable and keep the alternator outer surface and terminals clean The alternator operability is checked with a voltage meter or with a control lamp and an ammeter located on a vehicle dashboard With the alternator operable a control lamp lights up at the mass switch on before the engine start After the engine start and at the engine running at the middle speed the control lamp fades away the voltage metter arrow must Stay in the green zone and the ammeter must show some charge current the value of wh
134. noise 4 3 1 Make sure that the injectors don t rattle discharge through the injectors Do the necessary repair 4 3 2 Fuel pipes holders broken or absent Do the necessary repair Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 4 3 3 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing check for faults in the COMMON RAIL injection sys Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop check electricity consumers condition with the diag nostic device Do diagnostics and the neces sary repair 4 3 4 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 check the intake manifold for clogging Clean the intake manifold 4 3 5 Check the injectors launch injector check cycle by the appropriate standarc vice testing command in the KTS Bosch diagnostic de Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop 4 3 6 Check the clutch adjustment correctness Do the necessary repair 4 3 7 Check the turbocharger operability 4 3 8 Check the clearances in the valve drive Exha
135. nstalled by customer Connections to the engine cooling system Low pressure fuel pipelines S High pressure fuel pipelines Pipelines for redundunt fuel diversion into the tank low pressure 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 14 air cleaner 15 monocylone 16 charge air cooler 17 glow plug 18 silencer 19 charge air temperature and pressure sensor 20 fuel high pressure sensor 21 camshaft angle sensor 22 fuel temperature and pressure sensor 23 pressure regulator 24 pressure limiting valve 25 air filter clog sensor 26 recirculated gas cooler 27 fuel tank Sensors and actuating mechanisms location is shown on Fig 4a Table 8 Fig 4 Diesel engines D 260 1S3A D 260 2S3A 260 453 power system diagram 5 Charge air temperature pressure sensor 6 Fuel high pressure sensor _ A EE I fh by x d a Oil tempearture and pressure senso L7 D ye ab Tii RUS NON SS 3 d 2 Camshaft angle sensor
136. ntrol tors connectors and cables nized beyond set limit function in cylinder 2 condition Apply to service centre Continuation of Table 10 sae Fix method Fault type Fault description Check engine cylinders injec Number of flashes skips recog Error registered by flashes skips control tors connectors and cables 162 5 1 3 P0303 3 xn Ne nized beyond set limit function in cylinder 3 condition E Apply to service centre Check engine cylinders injec Number of flashes skips recog Error registered by flashes skips control tors connectors and cables 1635 1 5 P0300 3 m a x q nized beyond set limit function in several cylinders condition a Apply to service centre m 7 ing hich Tq 1645322 P160C20 S Rail inner pressure control func Error signal meaning high pressure circuit amp tions disabled during testing testing in process N Check engine cylinders injec Number of flashes skips recog Error registered by flashes skips control tors connectors and cables 165 5 3 1 P0304 3 P aoe x nized beyond set limit function in cylinder 4 condition Apply to service centre Continuation of Table 10 Fault type Number of flashes skips recog Fault description Error registered by flashes skips control Fix method Check engine cylinders injec tors connectors and cables 5 3 2 P0305 E
137. o ground ME 5 P and connection control circuit power stage Apply to service centre P0476 12 No load resistance Broken circuit or unpermissible tempera Check exhaust flap condition 90 B 1 1 ture in exhaust flap control circuit power and connection _ stage Apply to service centre b0476 12 Excessive heat up temperature Continuation of Table 10 Fault type Vehicle speed shown by speed sig Fault description Fix method P0501 0 nal beyond the vehicle set maximal speed Check vehicle speed sensor condition and connection ee TE Failure of vehicle speed measurement Check connection to tacho a1 bot peso a etc sped signal caused pah 1 sah y Check CAN line connection to other CAN devices Impluasible vehicle speed with re Apply to service centre P0501 2 gard to the injected fuel amount X and the engine speed Signal voltage b d the set max P2158 3 AMA Check vehicle speed sensor Signal voltage below the set mini pai d t and P2160 4 ailure of vehicle speed measurement Check connection to tacho Fat oe hicle speed signal re ae graph P2157 12 ews re CAN P 5 Check CAN line connection to a other CAN devices P2150 1255 Implausible vehicle speed signal Apply To Service contre 1624 voltage Continuation of Table 10 Fault type Speed signal pulse
138. oil tem itcuit APPNO SENIE GENS P0116 2 perature and cooling liquid tem Z perature sensors indications Continuation of Table 10 Fault type Fault description 0 Voltage beyond the maximal phys 99 Check cooling liquid tempera OE Fault in cooling liquid temperature sensor tyre sensor condition and con 64 2 4 1 circuit nection P0117 1 Voltage below the minimal phy a 07 sical limit Apply to service centre Cooling liquid temperature beyond 65 2 4 2 P163A 5 uo Cooling liquid overheating the maximal permissible P0523 3 Voltage beyond the set maximal limit Voltage below the set minimal lim P0522 4 it Check oil pressor sensor con 66 2 4 3 Fualt in oil pressor sensor circuit ditiona and connection Faulty signal from sensor or via P0520 12 CAN Apply to service centre P0521 12 Implausible signal oil pressure too S high Check oil pressor sensor con Implausible signal oil 1 67 543 P0524 17 plausible signal oil pressure too Oil pressor sensor signal error too low oil dibina ska low pressure Apply to service centre Continuation of Table 10 NT Fix method Fault type Fault description 3 Voltage beyond the set maximal limit Voltage below the set minimal lim s it Fault in oil temperature sensor circuit Check oil temperature sensor 2
139. ol Unit ECU damage while dis connecting harnesses or accumulator battery wires from it as well as while replacing fuses ignition and the mass switch must be off The system disconnection the system el ements replacement must be done with the ignition switched off do periodical check of the assembly units fixing tighten the mountings use only the fuel and oil grades recommended in this Manual keep the diesel engine clean do not allow leakage of fuel oil and cooling liquid un cleaned air sucking into the cylinders doing repair and welding is allowed only with the accu ulator battery terminals discon nected 2 2 Diesel engine preparing for operation 2 2 1 Safety rules to be observed while preparing diesel engine for operation Eligible for diesel engines preparation for operation are certified engine operators and drivers having been duly instructed on the operation safety and fire safety rules Start working only after a detailed study of the engine design and operation proce dures While loading unloading the engine in transportation clamp the lifting equipment slings only to the eye bolts located on the engine the slinging method is described in An nex Wkile doing the engine depreservation follow the fire safety rules and the hygene rules working with chemicals used rags and oil paper Do not allow dismantling protective shieldings implied by the diesel engine design While examining the engine visually use
140. om terminal 15 Terminal 15 circuit fault and connections A Apply to service centre P0643 3 beyond the set maximal 1 3 1 m 11 1 3 Voltaxe below the eimina n Sensors power supply 1 voltage fault Apply to service centre P0642 4 it P0653 3 M beyond the set maximal 12 1 3 1 Sensors power supply 2 voltage fault Apply to service centre Voltage below the set minimal lim P0652 4 S it P0699 3 peer beyond the set maximal 13 1 3 1 Sensors power supply 3 voltage fault Apply to service centre Voltage below the set minimal lim FEM i P0698 4 ei it Continuation of Table 10 Fault type Voltage beyond the set maximal limit Fault description Fix method 14 1 3 1 uy LLL aN sensors voltage fault Apply to service centre amp Voltage below the set minimal lim P1641 el e it P0687 Short circuit to power battery Main relay circuit 2 fault Check the main relay condi 15 1 3 2 sh d tion and connections P0686 Short circuit to ground control unit Apply to service centre Main relay circuit 1 fault Check the main relay condi 16 1 3 2 P160E Short circuit to power battery tion and connections control unit Apply to service centre Main relay circuit 1 fault Check the main relay condi 17 1 3 2 P160F 4 Short circuit to ground tion and connections control unit Apply to service centre P
141. one after every 250 engine operation hours 2TM 1 and that of the EGR cooler after every 500 engine operation hours TM 2 Technical maintenance includes cleaning from asphalt tar formations by plunging and keeping in dissolving emulsifying agent with the subsequent rinsing in synthetic washing agent Washing agents and modes of parts cleaning from asphalt tar formations Working concen Solution tem Duration tration g l 96 perature C Washing agents Dissolving emulsifying agent Labomid 203 TY Tech Conditions 38 10738 20 30 80 90 30 40 Rinsing agents Labomid 102 TY Tech Condi tions 38 10738 or Temp 100 TY Tech Condi tions 38 40843 5 0 1 8045 10 15 It is permissible to use glycocoll ethers Dowanol PnB or Dowanol PnP manufac tured by Dow Europe GmbH for CAC and EGR cooler cleaning by way of plunging and keeping in the cleaning agent within 30 minutes Then let the ether flow down from the inner cavites and keep the cleaned parts plunged in synthetic washing agent for windows or kitchen washing agent for 30 90 minutes Let the washing agent go flow down to save on consumables it is permissible to pour the agents into the cleaned cavi ties 4 CURRENT REPAIR 4 1 Engine current repair 4 1 1 General instructions Engine current repair is done to ensure or restore the engine operability and it implies re placement or rehabilitation of particular engine parts Current
142. ontrol circuit of cyl tors connectors and cables P0206 12 No load resistance inder 6 specific warning condition ial 1 Apply to service centre P1224 11 Depending on the settings P1203 3 Short circuit Check fades a P1204 4 Low side short circuit to eround Fault in injectors power stage control cir m ba cM A See grou ve tors connectors and cables 38 1 5 1 E M cuit Bank specific error engine shut P1205 11 Depending on the settings dowi condition e Apply to service centre P1206 11 Q Not classified error Continuation of Table 10 Fault type Fault description Fix method P1207 11 Depending on the settings ee Pe Check engine cylinders injec P1208 11 Depending on the settings Mer ROM T eee connector ind cables 39 1 5 1 cuit Bank1 specific warning engine shut P1209 12 No load resistance dowi condition P120A 11 Depending on the settings Apply to service centre P120B 3 Short circuit i j injec P120C 4 Low side short circuit to ground Fault in injectors power stage control cir c k PA oan AO 1 5 2 cuit Bank2 specific error engine shut De X Ngan P120D 11 0 Depending on the settings dowi condition 120 11 X Not classified error Apply to service centre P120F 11 Depending on the settings j j injec P1210 11 Depending on
143. or 3 1 6 2 6 TRANSPORTATION When transporting diesel engines external openings must be closed with stopper plugs Diesel engine transportation must guarantee its protection against moisture and mechani cal damages under storage conditions 2C of GOST 15150 69 Diesel engine stowage and fixing during transportation in closed railway cars must meet the requirements of Technical conditions of loading and fixing cargos Ministry of Communications 1969 as well as Regulations of cargo transportation Publishing house Transport Moscow 1977 Loading stowage fixing covering and unloading during engine transportation by truck must meet Regulations of cargo transportation by motor transport adopted by the Min istry of Automobile Transport of the Russian Federation on July 30 1971 7 RECYCLING The diesel engine does not contain substances posing hazard to human life health and en vironment While recycling diesel engine after service life expiry it is necessary to do as fol lows drain oil from the lubrication system and send it for re processing in the established or der drain cooling liquid from the cooling system if is was used during the diesel engine op eration and place it in the reservoirs designed for storing make complete dismantling of the diesel engine into parts sorting them out by groups of steel cast iron aluminum ferrous and precious metals resins and plastics and send them for reprocessing in
144. osition sen Voltage below the set minimal Fault in sensor 2 of gas pedal position Srs conato And onto 50 2 2 1 P0222 4 ae limit tions P2135 2 Lost plausibility with sensor 1 of Apply to service centre a throttle position Defective clutch state signal via Check gas pedal position sen CAN Error discovered by clutch condition signal sors condition and connections 51 2 2 2 diagnostics function Check CAN line connection to P0704 2 Implausible clutch sensor signal other CANs Continuation of Table 10 mer Fi h Fault type Fault description 12 Brake pedal sensor faulty signal Fault in Brake pedal TM Check brake pedal position ITE ault in Brake pedal sensor circuit sensor condition and connec P0504 12 Brake pedal sensor implausible tion S signal Apply to service centre Fault in brake pedal position sensor circuit Check brake pedal position 53 2 2 3 P0504 2 Faulty brake sensor with one sensor used cand tion 2 Apply to service centre Press the brake pedal If the er Cruise control function disabled Error signal meaning disabling cruise con ror keeps on check brake pe 54 2 2 3 P0504 2 till brake pedal position sensor trol function till brake pedal position sen dal position sensor condition functioning check sor functioning check and connec tion 2 Apply to service centre Cruise control function disabled Erro
145. ove the water pump from the engine disassem ble the water pump item 4 2 3 Replace the water pump impeller and or shaft Remove the cylinder head and the oil sump from the engine Move the piston down to the bottom dead center BDC turning the engine flywheel by hand Clean the cylinder liner upper section from carbon not allowing the carbon particles drop into the cylinder It is not permissible to use steel scraper that may damage the liner mirror Unscrew the connecting rod cover nuts remove the cover and take the piston assembled with the connecting rod out of the cylinder The piston with the connecting rod must be taken out upwards in the direction of the head mounting Mounted on each engine piston as shown on Fig 27 is an upper trapezoidal compression ring a conical compression ring and a box type oil ring with a spring expander The compression rings on the end surface at the lock bear marking and TOP which must face the piston bottom when installed The oil ring expansioner junction must not coincide with the ring lock Position the piston rings locks at equal distances on the circumference Insert the piston with the connecting rod into the cylinder mount the connecting rod cov er To avoid the piston rings breaking while installing the piston with the connecting rod in the cylinder use a mandrel for pressing the rings The tightening torque for the connecting rod cover nuts is specified in the
146. qejejnuuro 297 EH np omms Su Electronic control unit EDC 7 Vehicle cab harness socket Cooling liquid speed sensor speed sensor temperature sensor Camshaft Crankshaft Fuel pressure sensor sensor pressure Air pressure and temperature temperature and tempearure Sensor LX 4 051 mem c y 5 itl 3 sf pH lt k LEAK Z 8ISX Socket plug 08D Annex E reference Designation Description o Notes 01 03 Pressure and temperature sensor ODFT 0 261230 112 2 BOSCH Germany 02 Charge air pressure and temperature sensor LOFT 0 281 BOSCH Germany 002 576 1 BOSCH Germany DU 05 Speed sensor 006 0 281 006 009 2 BOSCH Germany D7 Cooling liquid temperature sensor WTF 0 281002 209 1 BOSCH Germany 08 Pressure in the RAIL sensor RDSU 2 0 281 002 937 1 BOSCH Germany EL Diagnostic lamp 1 1 max 1A U 12B included in trac tor set LI High fuel pressure regulator 1 Included in fuel pump set 12 17 Injector CR N2 6 BOSCH Germany 0 Electronic Control Unit EDC7UC31 1 BOSCH Germany SI Starter motor and controls switch 1 included in tractor set S2 Diagnostic lamp switch E n D 1e R1 Fuel supply pedal control sensor 1 included in tractor set R2 Manual fuel supply control sensor 1 included in tractor set XS1 Jack panel 89
147. r at a specialized workshop 1 2 10 Check compression level in the cylinders Do the necessary repair 1 2 11 Control Unit check check the Control Unit plug and socket fixtures Fix plug and sockets Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm 1 3 Hot engine is started with effort 1 3 1 Check the engine parameters check for faults in the COMMON RAIL injection sys tem using the diagnostic device do KTS Bosch standard testing Follow the instructions in the KTS Bosch diagnostic dej vice software Testing and repair at a specialized workshop check electricity consumers condition with the diagnos tic device Do diagnostics and the neces sary repair 1 3 2 Check the low pressure circuit check the correctness of connections in the low pres sure circuit check the hoses and pipe connectors for leakage Do the necessary repair check the fuel filter condition and conformity Replace filter by the appropri ate fuel filter cup make sure there is no water in the fuel inside the coars Clean the fuel filter from watel 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 1 3 3 Check the injectors vice 1 3 4 Check the intake system launch
148. r ele ment which retains dust coming into the air cleaner The control filter element clogging says for damage of the main filter element paper curtain broken bottoms coming off In this case it is necessary to purge the control filter element and replace the main one Servicing the air cleaner as shown on Fig 20 is done in the following order remove the monocyclone clean the screen the swirler and the monocyclone outlet holes from dust and dirt remove tray 6 remove main filter element 1 It is not recommended to take control filter element 2 out of the housing Blow the main filter element with compressed air first the inside and then the outside unitll complete dust removal To avoid the paper curtain breaking the compressed air pressure should not exceed 0 2 0 3MPa 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 It is not permissible to purge the filter element with exhaust gases or wash it with diesel fuel Clean the inlet pipe the air cleaner housing and tray inner surfaces from dust and dirt Before assemblying the air cleaner check the sealing rings condition When assemblying make sure the filter elements are correctly installed in
149. r leakage Do the necessary repair 1 2 4 Check the electric circuit check the accumulator battery charging Do the necessary repair or rej place the accumulator battery 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 check the intake manifold for clogging Clean the intake manifold 1 2 6 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing check for faults in the COMMON RAIL injection sys4 Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop tic device check electricity consumers condition with the diagnos Do diagnostics and the neces sary repair 1 2 7 Check the glow plugs opeartion reliability Replace the glow plugs or the glow plugs control unit circuit 1 2 8 Check the harness condition for breaking or shorl Do the necessary repair 1 2 9 Check the injectors launch injector check cycle by the appropriate standarc vice testing command in the KTS Bosch diagnostic dej Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repai
150. r pump is maintained by the toothed transmission of the distribution mechanism The transfer of energy power generated bythe diesel engine to the drive of tractor agri cultural machine in which it is installed is done from the engine flywheel via the clutch 1 1 4 3 Tools and accessories To ensure the maintenance work on checking and adjusting the gap between the rocker striker and the valve end done in the course of technical service tools are attached ac cording to the list in table B 2 of Annex B 1 1 5 Diesel engine labelling The brand tag of each engine fixed to the cylinder block bears the following data manufacturer s name and its trade mark engine model modification engine serial production number 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 EC 97 68 EC Stage IIIA 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 The official approval signs and the signs of conformity are located side by side with the brand tag or are depicted on it The engine transport marking is applied according to STATE STANDARD 14192 The markin
151. r signal for diagnostic lamp switch on Brees We brake pedals Wile et M op ror keeps on check brake pe till brake pedal position sensor meaning disabling cruise control function 2 55 2 2 3 P0504 2 a S lise an ae dal position sensor condition functioning check The diagnostic till brake pedal position sensor functioning heck and connec tion Apply to service centre 56 2 2 9 P0741 255 Implausible hydraulic transformer Error in determining hydraulic transformer You may continue driving turbine wheel speed indication turbine wheel speed Apply to service centre D Continuation of Table 10 Fault type Fault description Fix method Voltage beyond the maximal mer 0 h d s Fault in charge pressure sensor circuit Check charge pressure sensor 57 2 3 1 poy physical limit check condition and connection Voltage below the minimal phy P0237 1 QU am Apply to service centre 2 sical limit P0238 3 Voltage beyond the set maximal limit P0237 4 Voltage below the set minimal Check charge pressure sensor 58 2 3 1 limit Fault in charge pressure sensor circuit condition and connection P0235 12 Implausible CAN signal value Apply to service centre P0236 2 S Implausible signal P2229 Voltage beyond the set maximal limit aas d Voltage below the set minimal p9 2 3 2 limit Fault in atmospheric pressure sensor cir
152. rability check the high pressure circuit for leakage 2 2 Idle spped too low or too high 2 2 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing check for faults in the COMMON RAIL injection sys Do the necessary repair Follow the instructions in the KTS Bosch diagnostic dej vice software Testing and repair at a specialized workshop check electricity consumers condition with the diagnos tic device CRS 2 2 2 Check the electric circuit Do diagnostics and the neces sary repair check the accumulator battery charging Do the necessary repair or re place the accumulator battery check the fuses Do the necessary repair check the ground wire Replace the ground wire 2 2 3 Check the clutch adjustment correctness Do the necessary repair 2 2 4 Check the harness condition for breaking or shorl circuit 2 2 5 Control Unit check Do the necessary repair check the Control Unit plug and socket fixtures Fix plug and sockets 3 Engine behavior at vehicle moving 3 1 Unstable engine operation at speed up slow down 3 1 1 Check the engine parameters tem using the diagnostic device do KTS Bosch standard testing check for faults in the COMMON RAIL injection sys Follow the instructions in thd KTS Bosch diagnostic de vice software
153. reak 5 ss ee C2 d Z acti quio it 2 75 li rii E 3 Speed sensors synchronization 60 degrees angle till the 1st cylinder TDC 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 4 and take the speed sensor out of the HPFIP housing Turn HPFIP drive half coupling 5 Fig 5 until you see two successive pulse teeth in the sensor installation window Slightly tuening the drive in the same or the opposite direc tion position the the mounting pin the first in the crankshaft rotation direction in the center of the wnidow See Fig 4 Put the pulse rim position fixing device in the speed sensor mountying window and slight ly rocking the drive half coupling and not applying much force on the fixing device achieve full recess of the fixing device in the sensor seat as shown on Fig 4 Remove hatch cover 1 Fig 5 and supporting drive gear 6 through the hatch window move studs 3 of half coupling 5 into the drive gear grooves to install the HPFIP Fix the HPFIP on the distribution shield Put nuts 2 on studs 3 and screw nuts 2 not applying much force Take device 2 out of
154. reference voltage below the set li 1 1 1 1 analogue converter watch function Apply to service centre Test pulse voltage exceeding the ac ceptable limits 1 ee Sequence elaboration error by ana Jogue digital analogue converter Crankshaft speed sensor signal P0335 12 absent Check crankshaft speed sen 2 1 1 2 n YR LO Crankshaft speed sensor circuit fault pe i P0336 11 Wrong crankshaft speed sensor Apply to service centre Note With regard to identification of the faults the codes of which are given out by the diagnostic lamp lighting or stored in the Electronic Control Unit with the codes identified by the full system diagnostics but not shown in Table 10 customers will need to apply to a service centre Continuation of Table 10 Fault type Fault description Fix method Camshaft speed sensor signal P0340 12 absent Check camshaft speed sensor condition and connections D 1 1 3 Camshaft speed sensor circuit fault TOTO Apply to service centre P0341 11 Wrong camshaft speed sensor 636 Check camshaft and crank shaft speed sensors condition and connections Apply to service centre Crankshaft and camshaft speed sensors sig Crankshaft and camshaft speed sen nals mismatch 4 1 1 4 P0016 7 sors signals mismatch 190 Deviation between electronic time processor time and central processor Electronic time
155. rged With the battery not charged enough the COMMON RAIL Electronic Control Unit blocks the engine start If in the summer period the customer has used cooling liquid non frozing at low tempera tures it is necessary check it for frost resistance and replace if necessary When getting over to the winter mode of operation use the winter oil grades only and the fuels according to the Chemmatological Chart Annex A In the winter period in case of the cooling systememergent filling with water after the engine not running for a lengthy time period it is necessary to ensure the water drainage Make sure that the water is drained completely and not staying frozen on the radiator and cylinder block taps For this clean the taps with a piece of wire To do the water drainage faster open the radiator fill orifice cap Leave the taps open after the water drainage With the subsequent cooling system fillings close the taps as soon as the cool ing liquid starts coming out of them 2 3 6 Possible failures and troubleshooting With a vehicle failures during its operation COMMON RAIL diagnostic system lamp lighting up blinking it is necessary to diagnose COMMON RAIL system using the di agnostic lamp and the diagnostic button and rectify the discovered failures The diagnostic lamp blinking signifies a more serious fault than in case of its just lighting continuously To do the diagnostics press the diagnostic button and keep it
156. rs condition The gap between the gear ends and thrust washers at a switched on position must stay within 2 4 mm 3 2 20 Turbocharger maintenance Turbochrger does not require special maintenance during operation partial or complete disassemblying is not permissible Partial or complete disassemblying as well as repair are permissible after the turbocharger dismantling from the engine and only by a special ized company The turbocharger long lasting and reliable operation depends on observa tion of the rules of periodicity of the engine oiling and air cleaning systems maintenance the type of oil recommended by the manufacturer oil pressure checking in the oiling sys tem timely replacement of or cleaning of air and oil filters Damaged oil supply and drainage pipelines and air pipelines to the turbochargery must be replaced immediately When replacing the turbocharger pour pure oil in the oil inlet orifice up to the flange lev el and do not use sealants when mounting the pipelines gaskets 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 260S3A engine stable power and economy parameters within the opera tion life maintenance of the charge air cooler CAC must be d
157. rs injec The number of working cylinders is less dre t d cabl 44 1 5 4 P0000 255 Not used than the minimal set limit engine shut 0 5 CODDeCtOIs ang cables doni condition P0000 255 Not used Apply to service centre P0000 255 X Not used 45 2 1 2 P1018 7 Fine fuel filter clogged Fine fuel filter clogged Replace fine fuel filter Check fine fuel filter clog sen 46 2 1 3 P1015 3 M E sor condition and connection v limit Fault in fine duel filter clog sensor circuit Apply to service centre Check fine fuel filter clog sen Vol 1 1 T gt 47 2 1 3 P1016 4 ji Fault in fine duel filter clog sensor circuit sor condition and connection imit Apply to service centre Check fine fuel filter clog sen 48 2 1 3 P1017 2 ue Fault in fine duel filter clog sensor circuit sor condition and connection Sensor signal Apply to service centre Continuation of Table 10 Fault type Fault description Fix method 3 Voltage beyond the set maximal limit Check gas pedal position sen 49 2 2 1 P0122 4 Voltage below the set minimal Fault in sensor 1 of gas pedal position sors condition and connec limit tions 213815 Lost plausibility with sensor 2 of Apply to service centre throttle position ran Voltage beyond the set maximal limit Check gas pedal p
158. rt button Sho zt pressed in circuit Apply to service centre Continuation of Table 10 Fault type Fault description Fix method Signal voltage beyond set maximal Check ch limit Fault in charge compressor regulator con 1 i 147 3 4 4 P1001 4 Signal voltage be ow set minimal trol analogue digital analogue converter Lor OM reper SUN DNE a limit channel Hon e Apply to service centre P1002 12 Faulty sugnal Wait time elapsing for Check CAN line connection to 148 4 1 5 001134 z EngGsFlowRt CAN message EngGsFlowRt CAN message error other CAN devices a Apply to service centre or Check CAN line connection to 149 4 1 6 01101 3 a ie ied i ome HD HRD HRVD CAN message error other CAN devices e 5 Apply to service centre M Check CAN line connection to D 150 4 1 7 U1114 3 a e TimeDate CAN message error other CAN devices e 8 Apply to service centre Wait me for Check CAN line connection to 151 4 4 4 U0156 3 a RxAMCON CAN message error other CAN devices RxAMCON CAN message e Apply to service centre Continuation of Table 10 Fault type Fault description Fix method Wait time elapsing for RxEng Check CAN line connection to 152 4 5 1 01102 12 RxEngTemp2 CAN message error other CAN devices 2 Temp2 CAN message Apply to service c
159. s amp disabled Wait time elapsing for TSCI DE 71108 11 CAN message when the engine speed torque correction mode is bled Check CAN line connection to 4 2 2 A i 103 Wait tone Tor TSC DH TSCI DE CAN message error other CAN devices Apply to service centre U1109 12 CAN message when the engine 523607 speed torque correction mode is disabled Continuation of Table 10 Fault type Wait time elapsing for TSCI DR CAN message when the engine Fault description Fix method PHA speed torque correction mode 1s gt ablsd 4 Check CAN line connection to 4 2 2 Um 1 104 Wait time elapsing for TSC1 DR q mires Apply to service centre CAN message when the engine U110B 12 speed torque correction mode is disabled Wait time elapsing for TSC1 PE U110C 3 CAN message when the engine speed torque correction mode is enabled Check CAN line connection to 4 2 3 4 1 1n Wait time elapsing for TSCI PE TSC EEE CAN messaZe elo oher SN Apply to service centre 00110014 CAN message when the engine 520218 speed torque correction mode is disabled Continuation of Table 10 106 4 2 4 Fault type Wait time elapsing for TSC1 TE CAN message when the engine speed torque correction mode is enabled U110F 898 Wait time elapsing for TSCI TE CAN message when the
160. s not allowed to use water in the coling system At failures caused by the cooling liquid leakage short time use of water is permissible un til the failure has been rectified 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 Using other fuel and oil brands may result in the engine early going out of operation not meeting the ecology standards as well as in a difficult engine start in cold weather condi tions The diesel fuel must be clean without any mechanical impurities oil and water The lubrication materials must be clean and must not contain mechanical impurities and water Before fueling a tractor or a combine harvester must be placed on a horizontal site Pour oil into the engine till the oil feeler rod upper mark Start the engine and let it run for 5 minutes let the oil drain for 10 minutes Add up oil till the feeler rod upper mark 2 2 6 Diesel engine controls and control devices Diesel engine is controlled from the operator or driver locations The engine controls and control devices mounting is done by the customer when installing the engine in a tractor agricultural machine The crankshaft speed is changed with a pedal the signal of the pedal being moved is sent to the COMMON RAL power
161. sumption Check air mass consumption nal voltage beyond set limit um Ft n 128 2 3 4 z j meter standard voltage initial deviation meter condition and connection Air mass consumption meter sig NE P0101 e E plausibility check function Apply to service centre nal voltage below set limit Continuation of Table 10 NT Fix method Fault type Fault description P0103 Air mass consumption meter coef ficient beyond set limit Error registered by air mass consumption Check air mass consumption 129 2 3 4 meter signal sensitivity deviation plausi meter condition and connec binis Air mass consumption meter coef Pility check function tions ficient below set limit APPO te P0103 Mass air consumption registered beyond set limit Check air mass consumption Error registered by air mass consumption meter condition and connec 130 2 3 4 _ meter signal boundary check function tions P0102 Registered mass air consumption Apply to service centre below set limit ac P0073 Voltage beyond maximal physical Check ambient air temperature 131 2 3 5 limit Error in ambient air temperature sensor sensor condition and P0072 Voltage below minimal physical circuit physical limit check tion limit Apply to service centre Continuation of Table 10 et Fix meth Fault type Fault description
162. supply electronic unit by a pedal position sensor The glow plugs the COMMON RAL power supply electronic unit and starter motor switching on is done by a 3 positional ignition lock With the ignition lock set in position I the glow plugs electric circuit switches on and the COMMON RAL power supply electronic unit with the ignition key further turned to position II switches on the starter motor electric circuit The glow plugs are controlled by a separate control unit independent from the COM MON RAL power supply electronic unit The lubrication system oil pressure sensor and pressure alarm sensor are installed in the heat exchanger cover The air cleaner impurity condition is controlled by the air filter clogging signalizer sen sor serving switching a signal lamp on when the air filter gets clogged over the permissi ble extent The air cleaner impurity signalizer sensor is installed in the diesel engine inlet duct on the air cleaner outlet branch The crankshaft speed is controlled by tachometer The signal comes to tachometer from the alternator AC terminal A diagnostic lamp and a diagnostic button are located on the dashboard The diesel engine controls are located on a tractor agricultural machine dashboard 2 3 Diesel engine use 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 le
163. system diag nostics see paragraph 2 3 6 Switch the clutch smmothly Heat the engine up to steady crankshaft rotating at 700 800 min 2 3minutes then let the engine run at higher speed gradually raising it up to 1600 min untill the cooling liq uid temperature reaches 40 C The further engine heat up till the cooling liquid temperature of 70 C is achieved with a vehicle moving at the lowest gear Using the engine to the full power is permissible only when the cooling liquid tempera ture reaches 70 C With the engine heated up as well as in summer time it is allowed to start the engine without prior glow plugs heating turning the ignition key to position II and not keeping it in position 1 The starter motor continuous running must not exceed 15 seconds If the diesel engine does not start repeat start after 30 40 seconds If the diesel engine does not start after three attempts identify the fault and rectify it To make the engine start easier in the cold season with the ambient temperature lower than 20 C do the following pump the fuel feed system up with the hand booster pump to remove air from the system heat the engine up the pre start cooling liquid heater start the engine following the above described procedure At the engine cold start white smoke 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
164. t at the minimal idle speed with gradual increase to not more than 1600 min Full load of a cool engine is not allowed the permissible oil pressure value for a not warmed up engine not more than 0 8 MPa At emergency engine idling warming up air pumping to the braking system cylinders etc it is necessary to keep the engine crabkshaft speed at not less than 1000 1200 min 1 During the engine running watch the controls indications Engine operation with the oil pressure in the main oil duct lower than 0 1MPa is not permissible The cooling liquid heating over 100 C is not permissible In the event of the oil pressure or the cooling liquid temperature exceeding the said val ues the engine must be stopped it is not permissible to keep the engine running under the cooling liquid temperature lower than 60 C 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 I 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 the engine operation in the range exceeding the maximal speed may lead to the engine damaging so driving downhill use lower gear box gears in combination with the vehicle service brake do timely engine technical service according to section 3 1 to prevent the COMMON RAIL Electronic Contr
165. t higher than aun din Mal LAE 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 C and 43 C 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 C 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 Measurement Measurement means basic ab Note Measured parameter Measurement means d unit solute error limit Strain and torque strength measuring us Torque Nm devices according to State Standard 0 005 max calcula s 15077 78 Electronic tachometers type according to Technical Conditions 25 Speed min 04 3663 78 State Standard 18303 72 er Br UE 0 005n rated but not more than 10 AER ELE min 1 Pressure gauges compound gauges Omen IDE according to State Standards 2405 80 pes MPa and 11161 84 pressure and depres 0 02 cation system sion measuring transducers according to State Standard 22520 85
166. t of over hauled According to the instructions in item 1 2 3 4 3 Monthly maintenace MM 5 10 4 1 Maintenance TM 1 125 5 2 Maintenance TM 2 500 6 34 Maintenance TM 3 1000 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 tion 5 9 Maintenance for a long time storage preparation According to item 3 1 5 2 and sec tion 5 10 Maintenance during a long time storage eC COPA E ee ug section 5 11 Maintenance before the operation season TM According to item 3 1 1 1 1 Maintenance cycle not including MM TM AW TM SS when installed in tractor chine combine harvester will be TM 1 2TM 1 TM 1 TM 2 TM 1 2TM 1 TM 1 TM 3 TM 1 2TM 1 TM 1 TM 2 TM 1 2TM 1 TM 1 2TM 3 3 1 1 1 1 Diesel engine maintenance before combine harvester operation season Take the engine back from dead storage as described in item 3 1 6 2 Mount back in place the parts and units kept separately during the dead storage Adjust the drive belts tension Check hermeticity of all air cleaner and inlet duct couplings 3 1 1 2 Maintenance staff and requirements to it Table 13 Maintenance type Maintenance staff and s
167. taff skills MM Driver operator or engine mechanic of a tractor combine harvest er or a machine where the diesel engine is installed 1 2TM 1 3 4 class locksmith having general technical training according to TM 2 SS AW locksmith training program familiar with the D 260S3A engine and its modifications design and operation principles opearator driver or engine mechanic of a tractor combine harvester or a ma chine where the diesel engine is installed TM 3 2TM 3 4 5 class engine mechanic or fixer and 3 4 class locksmith having general technical training according to the locksmith training pro gram familiar with the D 260S3A engine and its modifications de sign and operation principles or engine mechanic of a tractor com bine harvester or a machine where the diesel engine is installed skilled specialist for diagnostics and maintenance of the COM MON RAIL fuel management system 3 1 1 3 Requirements to diesel engine before maintenance 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 Improper cleaning may reduce the engine operation life by 20 30 and more Washing the engine it
168. tarts partially circulating through the radiator When the cooling liquid tempera ture reaches 90 C 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 The fan is fixed to the pulley On the diesel engine D 260 4S3A combine harvester modification the water pump is in stalled without fan since air supply to radiator is done by a fan installed in the combine harvester There are two options for fan installation with a space plate and without it Fig 16 On some diesel engine modifications instead of steel fan they may install a moulded plas tic fan 245 1308040 A 0510 mm Water pump Water pump a without space plate with space plate 1 blade 2 bolt 3 washer 4 space plate 5 bolt 6 washer 7 rivet 8 cross piece Fig 16 Fan mounting 1 2 2 8 Supercharging device 1 2 2 8 1 Turbocharger Installed in diesel engines D 260 1S3A D 260 2S3A is an uncontrollable turbocharger Fig 17a 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 While expanding the gases rotate the
169. the ground wire Replace the ground wire 1 1 6 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 Testing and repair at a specialized workshop check the accumulator battery charging check electricity consumers condition with the diagnos Do diagnostics and necessary tic device repair 1 1 7 Check the intake system check for air leakage suction Do the necessary repair check the air filter condition Replace the air filter Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm check the intake manifold for clogging Clean the intake manifold 1 1 8 Check the glow plugs reliability Replace the glow plugs or the glow plugs control unit cuit 1 1 9 Check the harness condition breaking or short cir Do the necessary repair 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 standarc vice testing command in the KTS Bosch diagnostic dej Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop 1 1 12 Check the high press
170. the compression stroke fuel is delivered through an injector into the cylinder under high pres sure While being injected fuel is finely sprayed mixed with hot air in the cylinder and evapourated thus making a fuel air mixture The air fuel mixture ignition during the diesel engine operation is achieved as a result of air compression to the extent of the air fuel mixture self ignition The fuel is injected by injectors with fast operating electromagnetic valves The moment of injection beginning and its duration are determined by the moment of beginning and duration of voltage sup ply to the electromagnetic valve by the Common Rail system Electronic Control Unit The fuel air mixture burning takes place at the moment of the piston starting to go down As soon as the fuel air mixture is bunt down the process of cylinder expansion and clean ing begins through the exhaust valve Opening and closing of the intake and exhaust valves is coordinated by the gas distribu tion mechanism With the diesel engine operation start the turbocharger is actuated by the exhaust gas en ergy The diesel engine start is done by imparting rotation to the crankshaft by the electric starter via the flywheel mounted on the crankshaft flange The diesel engine cooling system water pump is drive is maintained from the belt of the pulley mounted on the crankshaft toe to the pulley mounted on the water pump shaft The A29 05 000 compressor drive and that of the gea
171. the housing and properly tighten the wing nut by hand 3 2 12 Checking the air cleaner and the inlet duct connections hermeticity Checking the hermeticity of the air cleaner and the inlet duct connections is done during TM 2 To check the hermeticity use device KH 4870 With this device unavail able check the hermeticity visually 3 2 13 Washing the engine breathers The engine breathers must be washed with diesel fuel after every 2 000 hours of engine operation To do that remove the breathers housings take the breathers out of the cylin der heads cover caps wash them and purge with compressed air Put the breathers and breathers housings back in place 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 while installing cylinder heads gaskets 714 63 09 260 1003020 torques 1 5010 N m 2 17010 3 240710 N m while installing cylinder heads gaskets 719 73 08 263 1003020 torques 1 50 10 N m 2 190410 N m 3 260 10 N m The sequence of tightening is shown on Fig 24 After tightening the cylinder heads mounting bol
172. the relevant sizes for visual inspection use portable light sources with the voltage of not higher than 12V draining fuel out of the coarse and fine fuel filters when removing the sediment filling the fuel system purging must be done only into a vessel drain oil and storage mixtures only into a vessel do not allow fuel and oil materials spill on the working site the working place for maintenance must be equipped with fire extinguishing means 3 1 3 Maintenance procedures 3 1 3 1 Scope of work at scheduled maintenance types Table 14 Maintenance type AW 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 4 Pour sediment out of the See Notes fuel pre filter 5 Check the belts tension 6 Check the air cleaner for clog ging filter elements condition Continuation of Table 14 Work description AW 7 Service the gas exchange sys tem components 8 Clean the centrifugal oil filter rotor 9 Replace the oil filter 10 Replace oil in the engine oil sump 11 Check hermeticity of all air cleaner and inlet duct couplings 12 Tighten the cylinder head bolts 13 Check the clearance between the valves and rockers 14 Wash the engine breathers 15 Replace the coarse fuel fil ter 16 Replace the fine fuel filter See Notes 17 Servic
173. the sensor seat and holding the HPFIP camshaft by special nut 4 Fig 5 finally screw nuts 2 with the torque 35 50 Nm Tightening of nuts 2 with the fixing device inserted may cause the pulse rim teeth breaking and the pump going out of operation Mount the hatch cover speed sensor and fix them Mount the cylinder head cover cap m E p Bae i ADAS A SEA LLLLANINNSSSSSSSI ZZA 1 fuel priming pump drive gear with pulse rim 2 fixing device speed sensor 4 sensor mounting screw Fig 4 Fuel priming pump drive gear pulse rim fixing device mounting 62 SIZZLA 02722 EY N WN A KON Lar Cor H Installing fixer instead of speed sensor Hatch cover item 1 is not shown 1 hatch cover 2 nut 3 stud 4 special nut 5 drive half coupling 6 fuel priming pump drive gear Fig 5 Fuel pump drive lectronics structural electric d Annex E reference Diesel engine e Accumulator battery 4o0joefuj apug 2 J J PUY YIG 4ojoefui Yip pIE 5 5 USWISI nawo LZS W o 3 95X LE8ISX L8ldX Fuel supply R2 control pedal sensor manual contro sensor d indjno ej
174. the settings Fault in injectors power stage control cir A nd pes ux 41 1 5 2 34 an i cuit Bank2 specific warning engine shut P1211 12 No load resistance dewi condition P1212 11 X Depending on the settings Apply to service centre Continuation of Table 10 Fault type Microchip CY33X internal reload Fault description Fix method time at least for one cylinder loss of counter undervoltage Microchip CY33X has no right to P062B 4 operation CY33X initialization er Fault in injectors control power stage mi 42 1 5 3 ION crochip ChipA specific error engine Apply to service centre P062B 12 Microchip CY33X in check mode Shutdown amp Communication blackout with mi P062B 2 e crochip CY33X check sum error reverse check error Microchip CY33X internal equali P062B 3 POG2B 4 Microchip CY33X error of internal software algorithm Fault in injectors control power stage mi 43 1 5 3 aaro Microchip CY33X check of inv crochip ChipB specific error engine Apply to service centre YSEL during ON failed shutdown POG2B 2 i Microchip CY33X exceeding wait N N Continuation of Table 10 Fault type Fault description The number of working cylinders 12 o T is less than the minimal set limit Check engine cylinde
175. ts put the rocker axles back in place and adjust the gap between the rockers and the valves as described in item 3 2 15 Put the cy linder heads covers and the covers caps back in place Fig 24 Sequence of cylinder heads mounting bolts tightening 3 2 15 Checking the gaps between the valves and the rockers Checking and adjusting the gaps between the valves and the rockers is done after every 500 operation hours preceded by checking of the cylinder heads mounting bolts tightening or if necessary on a cold engine the water and oil temperature must not exceed 60 0 05 The gap between the valve stems ends and the rocker strikers must stay within 0 25 mm 0 05 for intake valves and 0 45 010 m foe exhaust valves When adjusting the gap between a valve stem end and a rocker striker on a cold engine keep to intake valves 0 25 955 mm exhaust valves 0 45 95 mm Do adjustment in the following order remove the cylinder heads cover caps and check the rocker axles brackets mounting bolts tightening 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 v
176. uired 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 4 0 0 25 H1 STATE STANDARD 17308 86 3 1 5 2 Engine proofing reproofing before long storage Fill the cooling system with proofing solution thickened aqueous sodium chromate of the following composition g l Drain the cooling liquid from the the cooling system and wash with pure soft water under pressure glycerine STATE STANDARD 6823 77 800 potassium dichromate STATE STANDARD 4220 75 30 50 soda ash STATE STANDARD 5100 85 6 10 drinking water STATE STANDARD 2874 82 140 165 to prepare the solution Preliminarily dissolve soda in warm water and introduce it to the proofing solution when cooled down Start the engine and let it run till the temperature goes up to 60 80 C Drain motor oil from the engine oil sump into a suitable vessel at the ambient temperature and the engine parts temperature not higher than 60 C Remove and utilize the oil filter Clean the centrifugal oil filter rotor Mount and screw the oil drainage plug in to the oil sump tray Install a new oil filter Pour washing proofing oil AH T TY TECH
177. ure 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 Inside the HPFIP housing there are two plungers 3 Fig 7 actuated by camshaft 2 The camshaft through a driver half coupling is kinematic connection with the engine crankshaft through distribution gears The fuel having passed the coarse fuel filter with a moisture separator is further fed by the fuel priming pump to the HPFIP connector via the fine fuel filter under the pressure of 0 8 0 9 Mpa Under the influence of the created pumping pressure the fuel via channel 5 comes into a plunger chamber The incoming camshaft moves the plunger up whilethe inley hole of the inlet channel is overlapped by valve 4 and with the further plunger rise the fuel is compressed in the plunger chamber When the pressure reaches the level equal to that kept in the high pressure accu mulator valve 6 opens The compressed fuel comes into the high pressure circuit The plunger delivers the fuel till it reaches its TDC Top Dead Center then the pressure goes down the exhaust valve closes Since HPFIP has been designed for supply of large fuel amount at the engine idle and at partial loads an excess of compressed fuel takes place which via ball valve 8 of pres sure regulator 11 and via the back runoff
178. ure fuel injection pump launch high pressure fuel injection pump check cycle by the appropriate standard testing command in the KTS Bosch diagnostic device Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop check the low pressure circuit operability check the high pressure circuit for leakage 1 1 13 Checking the Control Unit check the Control Unit plug and socket fixtures Do the necessary repair Fix plug and sockets 1 2 Engine is started with effort or starts and then shuts down 1 2 1 Check if there is fuel in the tank and is it conforms to the appropriate grade Fill the fuel tank 1 2 2 Check the low pressure circuit check the correctness of connections in the low pres sure circuit check the hoses and pipe connectors for leakage check fuel filter condition and conformity Do the necessary repair Do the necessary repair Replace filter by the appropri ate make sure there is no water in the diesel fuel inside the coarse fuel filter cup Clean the fuel filter from wate pouring it out by opening the tap Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm make sure there is no air in the fuel Remove air from the low pres sure circuit See Manual item 3 2 10 1 2 3 Check the high pressure circuit fo
179. ust gas smell See Manual Annex E Adjust the clearances in th valves drive 4 4 1 Check the engine parameters standard testing check for faults in the COMMON RAIL injection sys tem using the diagnostic device do KTS Bosch Follow the instructions in the KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop nostic device 4 4 2 Check the intake system Check for air leakage suction check electricity consumers condition with the diag Do diagnostics and the neces sary repair Do the necessary repair Continuation of Table 11 Fault Outward fault demonstration Fault identification algorythm Check the air filter condition check the intake manifold for clogging Replace the air filter by new one Clean the intake manifold 4 4 3 Check oil consumption 4 4 4 Check the turbocharger operability At oil consumption too high do the necessary repair See Manual Annex 4 4 5 Check the engine oil level Add oil to the necessary level 4 4 6 Check the injectors vice launch injector check cycle by the appropriate standard Follow the instructions in the testing command in the KTS Bosch diagnostic dej KTS Bosch diagnostic de vice software Testing and repair at a specialized workshop 4 4 7 Control Unit check check the Control Unit plug and socket fixtures
180. vel in the engine oil sump check the cooling liquid level in the ngine cooling system check if the fuel tank tap is open fill the engine fuel system with fuel following the procedure described in paragraph 3 2 10 of this Manual Fuel drainage is done into a separate vessel 2 3 2 Diesel ngine start Set tractor agricultural machine gearbox lever to the neutral Turn the accumulator battery switch on Switch the glow plugs control unit and the COMMON RAL power supply electronic unit on by turning the ignition key to position I At that the glow plugs will set for heat up Before the engine start make sure that the diagnostic lamp blinks after ignition switching on and fadesin not longer than 15 seconds The glow plugs heat up time depends on the diesel engine temperature or it may be set fixed depending on the glow plugs control unit type At switching on a lamp on the dash board lights up signalizing that the glow plugs are being heated up Upon the glow plugs complet heat up the lamp fades commanded by the glow plugs control unit As soon as the lamp fades switch tractor machine clutch on Turning the ingintion key to position II switch the starter motor on and start the engine The plugs stay switched on for 180 240 seconds during the engine start process The diagnostic lamp must not light or blink after the engine start In th event of the lamp lighting or blinking it will be necessary to perform the diesel engine control
181. width bigger Fault description Fix method P1511 3 ee than the set maximal limit Speed signal pulse width smaller Ch P1512 4 ae cee i eck connection to tacho 93 3 2 4 than the set minimal limit Failure of vehicle speed measurement ah path 3 PO to service centre Faulty vehicle speed signal fre4 P1513 12 quency caused by faulty ECU hardware P0050 3 Short circuit to power battery Check bak er ene Fault in engine brake decompression throt SMSC TAKS decom id ads P004F Short circuit to ground tle power stage circuit pression throttle condition and P0661 255 No load resistance connection Po662 255 Excessive heat up temperature service centre Continuation of Table 10 Fix method Fault description P0629 Short circuit to power battery Check electric fuel priming 05 3 2 6 P0628 4 Short circuit to ground Fault in electric fuel priming pump control pump condition and connec P0627 12 No load recistance pOWEDSPageel Fe t Apply to service centre ci P062A 2 amp Excessive heat up temperature Engine technical parameters limi Engine technical parameters limitation 3 2 8 P2106 11 pe tation mode enabled mode enabled Apply to service centre 1653 Check CAN line connection to 07 4 1 1 100029 12 Absence of CAN A bus Absence of C
182. xtures and wa fer Fuel pre filter is not included in the diesel engine and is installed in a tractor or an agri cultural machine by customer Because of the diesel engine HPFIP is not equipped with a hand fuel priming pump necessary for filling the fuel system without air the filter design must contain a hand fuel priming pump Fig 11 shows a fuel pre filter with a hand fuel priming pump PreLine 420 recommended for tractor agricultural machine The drainage of sediment from the filter is done through tap 5 located in the lower part of moisture separator 4 To open the tap it is necessary to turn it clockwise in the mois ture separator housing Fuel inlet e EY em 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 25 C the filter housing must be equipped with fuel heater 3 The heater voltage 24V output 350 W Connetction and mass The heater operates independently it is switched on and off automatically at temperatures lower than 5 C The heater may be purchased at the address 127560 Moscow 11A Konionkova Str Phone 7 095 742 7976 Fax 7 095 742 7988 The heater No for orders 29 017 00202 1 2 2 6 5 Fine fuel filter Fine fuel filter Fig 12 is designed for final fuel cleaning It is unsepara
183. ya Street OJSC Avtoagregat iw i es TA a X mm 2 4 55 c 1050 WLCLLLL LI LL LL 4 am RS a4 22 a i 07777705 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 As shown on Fig 20 unscrew nut 1 of the centrifugal oil filter cap 2 mounting and remove it Check for presence of the balance mark in the rotor housing cup put the mark if it is not there Lock the rotor from turning for that purpose put a screw driver or a rod be tween the filter housing and the rotor bottom and turning nut 4of the rotor cup mounting with a spanner remove rotor cup 3 Check the rotor filtering screen 5 condition clean and wash it if necessary Using a non metalic scraper remove the sediments from the rotor cup inner walls Before assemblying the cup with the rotor housing apply motor oil on the rubber sealing ring Align the balancing marks on the cup and the rotor housing The cup mounting nut should be screw with little effort until complete cup fitting on the rotor After assemblying the rotor must rotate freely without jamming with a move by hand Put the centrifugal oil filter

Diesel engines OPERATION & MAINTENANCE MANUAL

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Diesel engines OPERATION &amp; MAINTENANCE MANUAL

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Diesel engines OPERATION & MAINTENANCE MANUAL