MINSK MOTOR PLANT Minsk Service Manual

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Open Joint Stock Company
MINSK MOTOR PLANT
DIESEL ENGINES
D-245S3A М, D-245.2S3A М, D-245.5 S3A М,
D-245.43 S3A М
OPERATION MANUAL
MINSK, 2010
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1 2 3 4 5 6 ... 96 97

Summary of Contents

Page 1

Open Joint Stock Company MINSK MOTOR PLANT DIESEL ENGINES D-245S3A М, D-245.2S3A М, D-245.5 S3A М, D-245.43 S3A М OPERATION MANUAL

Page 2 - Table of Content

245S3A М– 0000100 Operating Manual

Page 3

245S3A М– 0000100 Operating Manual 1.1.3 Diesel Engine Components Diesel engine is composed of parts, assembly units, assembly sets. 1.1.3.1 Composi

Page 4

245S3A М– 0000100 Operating Manual

Page 5

245S3A М– 0000100 Operating Manual 1.1.3.2 Main features in the diesel engines modifications composition Table 6 Description of a unit, part Diesel

Page 6

245S3A М– 0000100 Operating Manual Table 6 continued Description of a unit, part Diesel engine D-245S3A М D-245.2S3A М D-245.5S3A М D-245.43 S3A

Page 7

245S3A М– 0000100 Operating Manual Figure 1 – |The Diesel Engine D-245S3A М

Page 8

245S3A М– 0000100 Operating Manual

Page 9

245S3A М– 0000100 Operating Manual 1.1.4 Operation and Description 1.1.4.1 General information The diesel engine D-245S3A М and modification

Page 10

245S3A М– 0000100 Operating Manual The diesel engine is started by means of functioning of rotation of crankshaft by electric starting motor via fl

Page 11

245S3A М– 0000100 Operating Manual 1.2.1 General information The diesel engine is complex aggregate containing a range of independent mech

Page 12

245S3A М– 0000100 Operating Manual Table of Content 1. DESCRIPTION AND OPERATION ...

Page 13

245S3A М– 0000100 Operating Manual 1.2.2 Description and work 1.2.2.1 Cylinder Block Block of cylinders is the main engine case and is des

Page 14

245S3A М– 0000100 Operating Manual Axial force of the crankshaft is taken by four semi-rings made of ferro-aluminum alloy, that are fixe

Page 15

245S3A М– 0000100 Operating Manual Camshaft is supported by three journals and is connected with a crankshaft via timing gears. Three sl

Page 16

245S3A М– 0000100 Operating Manual 1.2.2.5 Lubricating System The lubricating system of the engine (Fig. 3) is a combined type: some components rec

Page 17

245S3A М– 0000100 Operating Manual at the output of oil filter body. From the turbo-compressor bearing assembly the oil is supplied to oil crankcase

Page 18

245S3A М– 0000100 Operating Manual 1 – fuel tank; 2 – coarse fuel filter; 3- low pressure pipes; 4 – fuel injection pump; 5 – fuel-feed pump; 6 – h

Page 19

245S3A М– 0000100 Operating Manual coupling is locked by drawing up the nuts, fixed in half-coupling stud-bolts. Nut torque value ranges from 35 to

Page 20

245S3A М– 0000100 Operating Manual 1 – fuel injection pump; 2 – fuel feed pump; 3 – flange; 4 – camshaft; 5 – individual injection pump; 6 – armatu

Page 21

245S3A М– 0000100 Operating Manual Figure 5a - Starting Solenoid Connection Diagram Switch position OFF – Diesel engine is stopped; ON - Power s

Page 22

245S3A М– 0000100 Operating Manual POSITION SWITCH: OFF: Diesel engine is stopped – stopping lever in SHUTDOWN position ON: power supply is on, ele

Page 23

245S3A М– 0000100 Operating Manual 3.2.21 Check of starter state ...

Page 24

245S3A М– 0000100 Operating Manual INTEGRATED MODULAR SWITCH APE 750 ELECTROMAGNETIC RECIRCULATION VALVE P/N 7.22946.25.0 Figure 5c – Integrated

Page 25

245S3A М– 0000100 Operating Manual are removed. In the bottom part of the filter housing there is a fuel-draining outlet with a drain plug. There is

Page 26

245S3A М– 0000100 Operating Manual cap. Breather body 1 (Figure 6) is mounted onto cover cap 4 of the cylinder head. Under the influence of pressur

Page 27

245S3A М– 0000100 Operating Manual 1.2.2.7 Cooling System Cooling system (Figure 8) is a closed type, with the forced circulation of th

Page 28

245S3A М– 0000100 Operating Manual

Page 29

245S3A М– 0000100 Operating Manual 1- water pump; 2 - thermostatic regulator; 3 – strap water pump drive belt; 4 – fan; 5 – cylinder head cooling

Page 30

245S3A М– 0000100 Operating Manual 1- thermostat housing; 2 - piston; 3 – primary valve; 4 – primary thermal-load carrying member; 5 – valve sp

Page 31

245S3A М– 0000100 Operating Manual

Page 32

245S3A М – 0000100 РЭ 1.2.2.8 Charging mechanism 1.2.2.8.1 Turbo-compressor The diesel engines D-245.5S3A M, D-245.43S3A M are equipped with

Page 33

245S3A М – 0000100 РЭ nut. Rotor shaft is rotated in radial bearing in the form of nonrotating floating single bushing 3. The single

Page 34

245S3A М– 0000100 Operating Manual The present operation manual is designed for operators, drivers and agricultural tractors motormen, co

Page 35

245S3A М – 0000100 РЭ Change of length of the rod of turbo-compressor actuating device is not allowed during the operation. Turbo-compressor bearin

Page 36

245S3A М – 0000100 РЭ The diesel engines are equipped with spring-loaded clutch coupling, friction single-drive or double-disk. 1.2.3 Marki

Page 37

245S3A М – 0000100 РЭ regulations during reagents, used rags and oiled paper handling. Do not remove the safety guards from the engine requi

Page 38

245S3A М – 0000100 РЭ The engine mechanism is provided with spaces for input and output of heat transfer medium from preheating system that shal

Page 39

245S3A М – 0000100 РЭ - check cooling liquid level in the cooling system; - check weather the fuel tank valve; - fill the diesel engine fuel system w

Page 40

245S3A М – 0000100 РЭ - start up the engine as described above. At cold start the exhaust smokes white for a while which is not a trouble because the

Page 41

245S3A М – 0000100 РЭ period. 2.3.6 Troubleshooting Troubles, possible causes Probable remedy 1. The engine can not be started 1.1 Air in the fuel

Page 42

245S3A М – 0000100 РЭ 4.1 Insufficient quantity of coolant in the cooling system Add coolant and check the level 4.2 Dirt on the outside of the rad

Page 43

245S3A М – 0000100 РЭ 8.4.1 Abrupture of the relay holding winding Replace the relay 8.4.2 The accumulator battery is discharged Charge or replac

Page 44

245S3A М – 0000100 РЭ 9.4 Electric generator noise 9.4.1 Driving belt slippage Replace the belt 2.3.7 Safety requirements at the diesel engine prop

Page 45

245S3A М– 0000100 Operating Manual 1. DESCRIPTION AND OPERATION 1.1 Description and Operation of the Diesel Engine 1.1.1 Diesel function Function, r

Page 46

245S3A М – 0000100 РЭ 3.1.1 General instructions Technical maintenance is carried out to keep the engine in working order during its operation. Non-c

Page 47

245S3A М – 0000100 РЭ 3.1.1.1 Kinds and periodicity of technical maintenance Kinds and periodicity of technical maintenance are given in table 10. Ta

Page 48

245S3A М – 0000100 РЭ 3.1.1.1.1 Technical maintenance of engines before beginning of harvester operation season (TM-O) Remove engine from storage f

Page 49

245S3A М – 0000100 РЭ To ensure safe work and to forestall casualties during technical maintenance of diesel engine observe the following rules: - w

Page 50

245S3A М – 0000100 РЭ Table 12 continued Name of work Kind of technical maintenance SТM ТM-1 2ТM-1 ТM-2 ТM-3 2ТM-3 SS AW 9 Check clearance betwe

Page 51

245S3A М – 0000100 РЭ 3.1.4 Check of diesel engine workability Engine workability is checked by means of conducting technical testing. Engine testi

Page 52

245S3A М – 0000100 РЭ 3.1.5 Preservation (represervation) when placed for storage Depending on the kind of delivery, specified in an agreeme

Page 53

245S3A М – 0000100 РЭ 3.1.5.2 Preservation (represervation) of engine when putting for long-period storage Drain coolant from cooling system and was

Page 54

245S3A М – 0000100 РЭ Drain preservative mixture from the cooling system. Drain preservative oil from the oil sump, mount and tighten the oil drain p

Page 55

245S3A М – 0000100 РЭ Turn off all drain cocks and fill the cooling system with coolant of recommended type to the relevant level in conformity with

Page 56

245S3A М– 0000100 Operating Manual

Page 57

245S3A М – 0000100 РЭ - mount gasket 4 and screw the gasket 3; - repeat the abovementioned adjustment actions if necessary. Making adjustments with t

Page 58

245S3A М – 0000100 РЭ Figure 12 – Check of oil in the engine crankcase 3.2.4 Replacement of oil in the engine crankcas

Page 59

245S3A М – 0000100 РЭ “АС Lelko” (France); modification L37198 by company “Purolator” (Italy). 1-filter body; 2 – liquid-oil hea

Page 60

245S3A М – 0000100 РЭ Figure 14– Drain of sediment from coarse fuel filter. 3.2.7 Washing of coarse fuel fil

Page 61 -

245S3A М – 0000100 РЭ Drain sediment in every 250 hours of engine operation. Unscrew plug 4 in the lower part of fine fuel filter by 2…3 revolution

Page 62

245S3A М – 0000100 РЭ In future order the following oil filters: a) ФТ020-1117010 at the address: JSC “Avtoagregat”, 303858, 2а Industrialnaya Stree

Page 63

245S3A М – 0000100 РЭ Carry out maintenance of air cleaner with paper filtering elements of special high-porous cardboard in every 500 ho

Page 64

245S3A М – 0000100 РЭ Before assembling the air cleaner check the state of seal rings. When assembling make sure that all filtering elements are corr

Page 65 - 4 - plug;

245S3A М – 0000100 РЭ outlet valves - 0,4505.010.0+−mm. When making adjustments, set the following clearance between valve-stem end and the rocker p

Page 66

245S3A М – 0000100 РЭ 3.2.16 Maintenance of high-pressure fuel pump During the operation of high-pressure fuel pump and upon wearing of the main par

Page 67

245S3A М– 0000100 Operating Manual 1.1.2 Technical characteristics 1.1.2.1 Characteristics and operating parameters of diesel engines. Table2 Descri

Page 68

245S3A М – 0000100 РЭ -set a governor control lever to the position of max. fuel supply; -detach a high-pressure pipe from the fitting of pump first

Page 69

245S3A М – 0000100 РЭ Figure 22 – Mounting a detent in the hole of rear plate and flywheel. If the detent does not coincide with the hole in the fly

Page 70 - 4 – washer; 5 – nut

245S3A М – 0000100 РЭ - release nuts of fuel pump drive gear attachment by 1…1,5 revolutions; - remove some fuel from the ignition tester glass pip

Page 71

245S3A М – 0000100 РЭ 1 – camshaft segment disk; 2 – detent bar; 3 – detent body; 4 – cap; 5 – spring. Figure 23а – Detent of position

Page 72

245S3A М – 0000100 РЭ Beginning and end of injection shall be clear, appearing of drops on atomizer tip is not permitted. Check atomization quality

Page 73

245S3A М – 0000100 РЭ ground switch before engine start. After the engine has been started and is operating with mean speed, the control lamp goes o

Page 74

245S3A М – 0000100 РЭ 3.2.21 Check of starter state Every 1000 hours of engine operation do the following: - check fastening bolts for tightening,

Page 75

245S3A М – 0000100 РЭ oil to the oil delivery hole up to the flange level and do not use joint sealants when mounting gaskets under

Page 76

245S3A М – 0000100 РЭ Table 14 Engine component Failures and damages eliminated by current repair in conditions of: household shops specialized ma

Page 77

245S3A М – 0000100 РЭ Fixtures used in work shall be in good order. Withdrawal tools shall have no cracks, bent rods, slipped or crushed thread.

Page 78

245S3A М– 0000100 Operating Manual Diesel engine weight without petroleum, oil and lubricants and liquid coolant in a complete set according to the

Page 79

245S3A М – 0000100 РЭ Table 15 continued Description of failure and damage results Possible causes Instructions on defining results of failures and

Page 80

245S3A М – 0000100 РЭ Piston ring locks shall be positioned at equal distance round the circle. Put the piston-rod group inside the cylinder, mount t

Page 81 - Combustion

245S3A М – 0000100 РЭ By the head assembly the valve rod shall be lubricated with motor oil. It is possible to ground the valves manually, using a be

Page 82

245S3A М – 0000100 РЭ Figure 27- Tool for pressing-on water pump sealing (main structural dimensions) Press the impeller on the shaft, instal

Page 83

245S3A М – 0000100 РЭ Engine transportation shall provide protection against moisture attack and mechanical damages under storage conditions 2 (C) GO

Page 84

245S3A М – 0000100 РЭ Annex А (referential) Chimmotology list Table А.1 Ref. number Assembly unit name, index (stand-alone device, mechanism, fricti

Page 85

245S3A М – 0000100 РЭ Seasonal use of diesel fuel grades in the Republic of Belarus depending on the ambient temperature Summer period Winter peri

Page 86

245S3A М – 0000100 РЭ Table А.1 continued Ref. number Assembly unit name, index (stand-alone device, mechanism, friction unit) Amount of assembly un

Page 87 - 245S3A М – 0000100 РЭ

245S3A М – 0000100 РЭ Table А.1 finished Ref. number Assembly unit name, index (stand-alone device, mechanism, friction unit) Amount of assembly uni

Page 88

245S3A М – 0000100 РЭ Annex B (referential) Quantity sheet of spare parts, tools and accessories (spare parts, instrument) Table B.1 –Tools and

Page 89 - Annex B (referential)

245S3A М– 0000100 Operating Manual 1.1.2.3 Measurement instrumentation for definition of testing parameters Table 4 Measurable parameter Units of me

Page 90

245S3A М – 0000100 РЭ Annex C (referential) Size groups of cylinders and pistons Table C.1 Group marks Sleeve diameter, mm Piston skirt diameter,

Page 91

245S3A М – 0000100 РЭ Annex D (referential) Engine adjusting parameters Table D.1 Denomination Unit of measure Value rated accepted 1 Syste

Page 92 - Annex E (referential)

245S3A М – 0000100 РЭ Adjustment of start ending 6 450÷490 A complete sleeve of idle running shall be screwed in the main lever so that automatic sta

Page 93

245S3A М – 0000100 РЭ Annex E (referential) Adjustment control of stop lever by stop solenoid Stop Operation 1. The stop lever shall be mounted an

Page 94 - Annex F

245S3A М – 0000100 РЭ Annex F Identification of engine and turbocharger faults Symptom Cause Inspect Symptom Х Х Х Х Х Air deficiency Ai

Page 95

245S3A М – 0000100 РЭ

Page 96 - (obligatory dimension)

245S3A М – 0000100 РЭ Annex G (referential) Scheme of engine strapping mm (

Page 97

245S3A М – 0000100 РЭ 1– beam 2 – hoist cable; 3 – clevis. Figure 1 – Scheme of engine strapping

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