Diesel engines D-260.1S3А, D-260.2S3А, D-260.4S3А. Manual - part 11

- it is not permissible to keep the engine running under the cooling liquid temperature

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

И).

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 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

Operations

Preservation

period

1 year

6 months

Engine depreservation

Uncover the engine.

Use diesel fuel to remove the preservation grease from the outer
unpainted preserved surfaces of the diesel engine.

Remove plugs or polyethylene filming covering the exhaust man-
ifold outer openings, intake manifold, thermostat housing, water
pump branch pipe, turbocharger and breathers. Take the plugs
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-
case drainage hole.

Drain the remnants of preservation solution from the cooling sys-
tem through the drainage tap.

Get the engine ready for start. Fill the engine oil sump with clean
sump.

Pump up the fuel supply system with the hand fuel feed pump,
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
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°

С to 80° С;

- the hot drying temperature: from 70°

С to 80° С.

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° С.

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 is 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 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 level 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 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 + 40º

С.

The further engine heat-up till the cooling liquid temperature of +

70º С 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 + 70º С.
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 I.
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° С), 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.

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