Diesel engines D-260.1S3А, D-260.2S3А, D-260.4S3А. Manual - part 31

7 Seasonal maintenance while transferring from the
autumn-winter (TM-AW) or the spring-summer
(TM-SS) operation periods.

Done simultane-
ously

with

the

routine scheduled
maintenance (TM-
1, TM-2, TM-3)

8 Maintenance for a short-time storage (10 days – 1
month) preparation.

According to item 3.1.5.1 and sec-
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.

According to item 3.1.5.2 and
section 5.

11 Maintenance before the operation season (TM-

Э)

According to item 3.1.1.1.1

Maintenance cycle (not including MM, TM-AW and TM-SS) when installed in tractor/ ma-
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 (TM-

Э)

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 staff skills

Driver, operator, or engine mechanic of a tractor, combine harvest-
er or a machine where the diesel engine is installed.

TM-1; 2TM-1;
TM-2; SS; AW

3-4 class locksmith having general technical training according to
the 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 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

А.1 (Annex “А”).

  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 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

Work description

Maintenance type

TM-1

2TM-1 TM-2

TM-3

2TM-3 SS

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
fuel pre-filter.

See Notes

5 Check the belts tension.

6 Check the air cleaner for clog-
ging (filter elements condition).

Continuation of Table 14

Work description

Maintenance type

TM-1

2TM-1 TM-2

TM-3

2TM-3 SS

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.

See Notes

16*** Replace the fine fuel filter.

See Notes

17 Service the air cleaner.

18 Replace the air cleaner main
filter element.

19 **** Do the “COMMON
RAIL” system overall service.

See Notes

20 Check the engine starter motor
condition

(brushes,

collector,

springs, terminals etc.).

21 Wash the cooling system.

22 Replace the winter oil by the
summer oil in the engine sump.

23 Set the alternator seasonal
voltage adjustment screw (if
available) to the "

Л" position

(summer).

24 Replace the summer oil by the
winter oil in the engine sump.

Continuation of Table 14

Work description

Maintenance type

TM-1

2TM-1 TM-2

TM-3

2TM-3 SS

25 Set the alternator seasonal
voltage adjustment screw (if
available) to the "

З" 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 Oeration & 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 between 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

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