“MINSK MOTOR PLANT” Open Joint Stock Company D-243, D-245 Diesel Engines and Their Modifications OPERATION AND MAINTENANCE MANUAL 243-0000100RE Minsk, 2010
Contents 1. DESCRIPTION AND OPERATION ...................................................................................... 4 1.1. Description and Operation of the Diesel Engine ............................................................... 4 1.1.1. Purpose of the Diesel Engine......................................................................................... 4 1.1.2. Technical Data .............................................................................................................. 5 1.1.
The present Operation and Maintenance Manual is intended for operators, drivers and mechanics of the machines and units equipped with the D-243 and D-245 diesel engines and their modifications. This manual provides brief technical description, proper maintenance and service rules for the D-243, D-245 diesel engines and their modifications. The reliable long-term operation of diesel engines depends on the timely and high-quality performance of all guidelines of this Operation and Maintenance Manual.
1. DESCRIPTION AND OPERATION 1.1. Description and Operation of the Diesel Engine 1.1.1. Purpose of the Diesel Engine The scope of application of the diesel engines are places with unrestricted air exchange. The diesels are designed for the operation at the ambient temperature from minus 45C up to plus 40С. The diesel engines D-243, D-245 and their modifications are designed for mounting on the tractors of the class of 1.4-2.
1.1.2. Technical Data 1.1.2.1. The main parameters and characteristics of the diesels are given in Table 1. Table 1 Description of Units of Values parameters measureD-241 D-242 D-243 D-243.1 D-244 ment 1. Type Four-stroke diesel engine without supercharging 2. Fuel injection system 3. Number of cylinders 4. Firing order 5. Cylinder bore 6. Stroke 7. Displacement 8. Allowable longitudinal and lateral tilt of the working diesel, not more than 9. Power according to GOST 18509-88: - rated - operational 10.
Table 1 Description of parameters Units of measurement D-241 D-242 D-243 13. Minimum stable idling rotational speed, not more than 14. Compression rate (design) 15. Direction of the engine crankshaft rotation according to GOST 22836-77 16. Maximum value of torque, not less than 17. Rotational speed at the maximum torque, not less than 18. *Specific fuel consumption in the rated power mode 19. * Specific fuel consumption in the operational power mode 20.
Table 1 Description of parameters electric starter Units of measurement D-241 D-242 D-243 D-243.1 Values D-244 24.3708 or 24.3708 or 24.3708 or 24.3708 or 24.3708 or CT-142M or CT-142M or CT-142M CT-142M or CT-142M or AZJ 3124 AZJ 3124 or AZJ AZJ 3124 AZJ 3124 3124 D-245 D-245.2 D-245.4 D-245.5 24.3708 or 20.3708 or 20.3708 20.3708 or CT-142M СT-142Н or СT- СT-142Н or AZJ 142Н 3124or 20.3708 or СT-142Н Notes: 1.
1.1.3. Engine Components The D-243 diesel engines in accordance with Figs 1 and 2 and the D-245 diesel engines in accordance with Figs 5 and 6 are basic models. Their modifications differ from the basic model in the power regulation, standard equipment, starting device and design of some parts. Depending on the purpose, the diesel engines may be equipped with additional assembly units: air compressor, gear pump of the steering booster with drive and clutch disk assemblies.
Fig. 1 – D-243 Diesel Engine (Left View). Fig.
Fig. 3 – D-241 Diesel Engine (Right View). Fig. 4 – D-242 Diesel Engine (Right View).
Fig. 5 – D-245 Diesel Engine (Left View). Fig.
1.2. Description and Operation of the Diesel Engine Components 1.2.1. General Information As seen in Fig. 7, the diesel engine consists of the cylinder block, cylinder head, crank mechanism, valve gear link as well as assemblies and units of the feed, lubrication, cooling and starting systems as well as electric equipment.
1.2.2.1. Cylinder Block The cylinder block is the main engine case and is designed as a special rigid cast-iron alloy mono-block. Four removable sleeves made of special cast-iron, are fixed in block bores. Sleeves are installed into the cylinder block in two centring lands, the upper and lower ones. In the upper land the sleeve is fixed by means of a shoulder while in the lower land it is sealed by means of two rubber rings located in cylinder block grooves.
The crankshaft may be manufactured and installed in the engine of two production sizes (nominal values). The crankshaft with the connecting rod and main bearing journals manufactured according to the second nominal size has additional marking on the first web. The size of the main and connecting rod webs as well as respective marking of the crankshaft is given in Section 4.1. The piston is made of aluminium alloy. The combustion chamber is made in the piston head.
The push rods are made of steel bars. The spherical part that goes inside the cam follower and the rod cup are hardened. The rocker arms are made of steel. They swing on the rocker shaft supported by four brackets. The outermost brackets have increased hardness. The rocker arm axle is hollow and has eight radial holes to supply lubrication oil to the rocker arms. The rocker arms travel along the axle is limited by the spacer springs. The intake and exhaust valves are made of high-temperature steel.
1 – fuel tank; 2 – coarse fuel filter; 3 – fuel pipes; 4 – fuel pump; 5 – high-pressure fuel pipe; 6 – fine fuel filter; 7 – air cleaner; 8 – coarse air filter; 9 – electric torch heater; 10 – intake manifold; 11 – muffler; 12 – exhaust manifold; 13 – fuel injector. Fig. 8 –D-243 diesel engine feeding system diagram.
1.2.2.5.2. Fuel Pump The D-243 diesel engine and its modifications are equipped with the high-pressure fuel pump 4UTNI and the D-245 engine and its modifications – with the pumps 4UTNI-T or 4UTNM-T. All the pump models are driven from the engine crankshaft via timing gears. The fuel pumps are equipped with all-mode governors and piston-type priming pumps.
1.2.2.5.6. Air Cleaner and Inlet Line The air cleaner is intended for purification of air to be sucked into the cylinders. The air-cleaner of the diesel engine is combined: the dry centrifugal purification and oil dust-trap with wet kapron filter. In the air-cleaner housing there are three filter elements of kapron bristle having different diameters. The D-245 diesel and its modifications can be fitted also with an air-cleaner consisting of the main and control paper filter cartridges.
1 – turbine wheel with shaft; 2 – turbine housing; 3 – mono-bush; 4 – oil-guard; 5 – eccentric ring; 6 – compressor wheel; 7 – special nut; 8, 15 – O-rings; 9 – diffuser; 10 – cover; 11 – compressor housing; 12 – thrust bearing; 13 – distance bush; 14 – middle housing (housing of bearings). Fig. 9 – Turbo-supercharger. 1.2.2.6. Cooling System As seen from Fig. 10, the diesel is cooled by means of the liquid-type cooling system with forced circulation of the coolant from the centrifugal pump.
Fig. 10 – Diagram of the Cooling System The thermostat with solid filler serves to speed up the engine warming-up after starting it and automatic regulation of the temperature regime at various loads and ambient temperatures. The water pump, fan and alternator are driven from the engine crankshaft pulley by means of a V-belt. On the D-245 engine these units are driven by means of two belts. The "Litol-24" lubricant is injected into the bearing cavity of the pump during the assembling.
In the centrifugal oil filter housing there are reducing 7, drain valve 8 and safety valve 10. Upon starting the diesel engine the non-heated oil comes directly to the diesel engine pipeline through the reducing (radiator) valve bypassing the radiator due to high resistance of the radiator. The safety valve (centrifugal filter valve) serves for maintaining the oil pressure before the filter rotor of 101.8 psig (7 kgf/cm2).
filtered hot oil to be drained into the oil sump non-filtered hot oil splash-lubrication of parts Fig. 11 – D-245 diesel engine lubricating system. The air-compressor is supplied with oil from the main oil gallery via engine block channels and special pipe. From the air-compressor oil is drained into the engine crankcase. 1.2.2.8. Electric Equipment and Starting System The electric equipment of the D-243 diesel engine and its modifications may include the G964.3701-1 or G964.
1.2.2.10. Controls and Instruments The diesel engine is controlled remotely, from the operator’s place. The diesel engine controls and instruments are to be mounted by the user when installing the engine in the tractor (machine). The rotational speed of the crankshaft is changed by means of the fuel pump governor lever.
2. INTENDED USE 2.1. Pre-operation of the Diesel Engine When preparing the new diesel engine for operation, perform its depreservation. To do this, remove the protective shrouds and plugs mounted on the engine. Check and adjust, if necessary, the fan belt tension. Fill all the refill tanks with working oils, fuel and coolant (the refill tank capacities, description and marks of the fluids are given in Appendix A). Fill the fuel-feeding system with fuel and purge this system to remove air from there.
The operation of the diesel at the altitude exceeding 9,836 ft (3,000 m) above sea level is not recommended. 2.2.1.2.
- drain the sediment from the coarse and fine fuel filters; - check the fan belt for tension; - check the external threaded connections. If necessary, eliminate the deviations detected. 2.2.1.5. Peculiarities of Operation and Maintenance of the Diesel Engine in Winter Conditions At low ambient temperature the operation of the diesel engine becomes more difficult.
In case of leaving the tractor (machine) on the open place at the end of the shift, set the fuel pump control lever to the position corresponding to the maximum feed to facilitate the subsequent start. 2.2.2. Troubleshooting Possible troubles in the diesel engine during the operation and recommendations for corrective actions are enlisted in Table 3. Table 3 Trouble and its appearance 1 1.1 The diesel engine fails to start Air in the fuel system 1.
Continuation of Table 3 Trouble and its appearance Remedy 4.2 The engine emits white smoke 4.2.1 The engine is overcooled 4.2.2 4.2.3 4.2.4 4.3 4.3.1 4.3.2 5 5.1 6 6.1 6.2 6.3 6.4 6.5 6.6 7 7.1 a) b) 7.2 8 8.1 a) Warm up the engine.
Continuation of Table 3 Trouble and its appearance b) c) d) 8.2 8.3 a) b) c) d) 8.4 8.5 9 9.1 a) b) 9.2 a) b) c) 9.3 9.
Continuation of Table 3 Trouble and its appearance а) б) sence of the storage battery, lamps are burnt out): Short circuit or break of the capacitor circuit; Considerable increase of the controllable voltage Remedy Restore the circuit or replace the voltage regulator Replace the voltage regulator 2.2.3.
3. MAINTENANCE 3.1. General Directions The maintenance shall be performed with the purpose of maintaining the diesel engine in working order during the operation. Failure to perform the maintenance with the established periodicity as well as poor quality of the maintenance reduce considerably its service life, cause the rise in the failure rate, reduction of the power and increase of engine operating costs. The operation of the diesel engine without performance of routine maintenance is not allowed.
The diesel engine maintenance when preparing it for operational running in and on completion of the operational running-in corresponds to the works described in sections 2.1 and 2.2.1.5 while the maintenance during the storage corresponds to the works described in section 5. 3.3. Diesel Engine Maintenance Procedure Description and terms of the maintenance works are given in Table 5.
Table 5 Maintenance required Maintenance intervals 8-10 125 250 500 1,000 2,000 SS AW winter) 24 Change the summer-grade oil in the diesel engine crankshaft for the winter-grade oil + * For the D-245 diesel engine and its modifications the rotor of the centrifugal oil filter shall be cleaned and the oil in the engine crankcase shall be replaced after each 250 service hours. SS = spring-summer; AW = autumn-winter 3.3.2.
3.3.3. Checking the Coolant Level Remove the radiator cap and check the coolant level, which must be 50-60 mm lower than the upper end of the filler neck. Do not allow the level to fall lower than 100 mm from the upper end of the filler neck. 3.3.4. Draining the Coarse Fuel Filter Drain the coarse fuel filter every 125 service hours. Unscrew the sediment drain plug located in the lower portion of the filter sleeve as shown in Fig.13 and drain the sediment until the fuel flows clear and replace the plug.
15…22 Fig. 14 – Checking the fan belt tension. 3.3.6. Checking the Level and Condition of Oil in the Air Cleaner Pan Check the level and condition of the oil every 125 service hours in regular conditions and every 20 hours in severe chaff, dust or sandy conditions. Unscrew the nuts 1 of the bolts fastening the air cleaner pan, as shown in Fig. 15, by several turns and remove the pan 2. Check the level and condition of the oil.
1 – nut; 2 – pan. Fig. 15 – Checking the oil level in the air cleaner pan. 3.3.7. Changing Oil in the Engine Crankcase Drain the used oil from the crankcase when the engine is warmed up. To drain the oil, unscrew the crankcase plug. After the oil has been drained completely from the crankcase, replace the plug. Fill the engine with oil through the oil filler neck up to the upper mark on the dipstick. Use only the oil recommended by this Manual in accordance with the season of operation. 3.3.8.
1 – nut; 2 – filter cover; 3 – rotor cap; 4 – special nut; 5 – filtering screen; 6 – cover. Fig. 16 – Cleaning the rotor of the centrifugal oil filter.
Fig. 17 – Adjustment of the draining valve of the centrifugal oil filter. 3.3.9. Checking the Clearance between the Valves and the Rocker Arms Check and adjust the clearances between the valves and the rocker arms every 500 service hours as well as after removal of the cylinder head retightening the bolts fastening the cylinder head and in case of valve hammering.
1 – lock nut; 2 – screw. Fig. 18 – Adjusting the clearance in the valves. 3.3.10. Draining the Fine Fuel Filter Drain the fine fuel filter every 500 service hours. Unscrew the plug in the lower portion of the fine fuel filter as shown in Fig. 19 and drain the sediment until the fuel flows clear. Replace the plug.
Fig. 19 – Draining the fine fuel filter. 3.3.11. Cleaning and Washing the Air Cleaner Check the filter elements of the air cleaner for clogging every 1,000 service hours of the diesel engine and, in case of operation of the sensor of the air cleaner clogging alarm. The sensor is intended for switching on the indicator lamp located in the instrument panel of the tractor in case the air cleaner will be clogged more heavily than it is allowable.
1 – air-cleaner housing; 2 – filtering elements; 3 – holder; 4 – holder stopper; 5 – oil reservoir; 6 – pan. Fig. 20 – Servicing the air cleaner 3.3.12. Checking the Joints of the Air Cleaner and Intake Pipelines for Air Tigness . Check the joints of the air cleaner and intake pipelines for air-tightness every 500 service hours. To check the air-tightness, use the KI-4870 device approved by the State ScientificResearch Institute of Tractors.
3.3.13. Washing the Filter Elements of the Starting Engine Air Cleaner Wash the filter elements of the starting engine air cleaner every 1,000 service hours of the diesel engine. Unscrew the nut and remove the air-cleaner cover. Remove the filter elements and wash them in diesel fuel. 3.3.14. Checking the Bolts Fastening the Cylinder Head for Tightness Check the bolts fastening the cylinder head for tightness after completion of the runningin and every 1,000 service hours.
Replace the filter element in accordance with Fig. 22 every 1,000 service hours of the diesel engine. To do this: - close the cock of the fuel tank; 1 – filter cover; 2 – filter element; 3 – filter housing; 4 – plug. Fig. 22 – Replacement of the filter element of the fine fuel filter.
1– fitting; 2 – priming pump; 3 – plug. Fig. 23 – Removal of air from the fuel system. 3.3.17. Washing the Coarse Fuel Filter Wash the coarse fuel filter every 1,000 service hours of the diesel engine in accordance with Fig. 24. To do this: - shut the cock of the fuel tank; - unscrew the nut of the bolts fastening the cup; - remove the cup; - unscrew the slinger with screen using a wrench; - remove the dispenser; - wash the slinger with screen, dispenser and filter cup in diesel fuel and then replace them.
1 – filter housing; 2 – slinger with the filter screen; 3 – cup. Fig. 24 – Washing the coarse fuel filter. 3.3.18. Checking the 4UTNI and 4UTNI-T Fuel Pumps (Bench Test) Check the fuel pump every 2,000 service hours of the diesel engine. Dismantle the fuel pump from the diesel engine and check it on the bench for correspondence of the adjustment parameters to those specified in Appendix D. Adjust the speed mode by means of the adjusting screw turned into the lug of the governor housing, as shown in Fig.
1 – adjusting screw; 2 – nominal bolt (stop); 3 – teeth crown; 4 – fixing screw; 5 – rotating bush; 6 – pusher adjustment bolt with lock nut; 7 – shackle; 8 – governor spring; 9 – idling spring adjustment bolt. Fig. 25 – Adjusting the fuel pump.
To increase the speed, turn out the adjusting screw and to decrease the speed turn it in, as shown in Fig. 25(a). One turn of the screw varies the diesel engine speed by about 30-50 rpm. If the rotational speed is difficult to adjust using the above method, it could be adjusted by varying the working length of the governor spring 8, as shown in Fig. 25(c), increasing or reducing the coils number by means of shackle 7.
1 – lock nut; 2 – stop; 3 – rod; 4 – cover; 5 – dowel; 6 – bush; 7 – diaphragm. Fig. 26 – Adjusting the fuel pump with antismoke corrector. 3.3.19. Checking and Adjusting the Timing In case of difficult starting of the engine, smoky exhaust as well as in case of replacement and installation of the fuel pump after bench test, every 2,000 service hours or after repair, check obligatorily the timing on the diesel engine.
- while rotating slowly the diesel engine crankshaft clockwise, observe the fuel level in the tube; at the moment when the fuel will rise, stop the crankshaft rotation; - turn out the splint from the threaded hole of the rear sheet in accordance with Fig. 27 and insert it in the same hole with its opposite side directed towards until it rests against the flywheel; when doing this, the splint shall be aligned with the hole in the flywheel.
1 – adjusting bolt; 2 – bolt; 3 – nut; 4 –washer; 5 – fuel pump drive gear; 6 – stud; 7 – nut, special, 8 - flage Fig. 28– Fuel pump drive. 1 – slotted flange of the pump gear; 2 – fuel pump shaft nut. Fig.
turn the fuel pump shaft in the end within the grooves position; drain some fuel from the glass gauge; rotate the fuel pump shaft slowly clockwise till the fuel goes up; as soon as the fuel starts rising stop rotating the shaft and tighten the nuts; check timing once again. 3.3.20. Changing the Fuel Injectors for the Pressure of Beginning the Injection and Fuel Atomisation Quality Check the fuel injectors every 2,000 service hours of the diesel engine.
1 – adjusting screw; 2 – lock nut. Fig. 30 – Adjusting the fuel injector. 3.3.21. Checking and Adjusting the Diesel Engine Run Stability in Partial Idling Modes Check and adjust the stability of the engine run in partial idling modes on completion of the running in and, if necessary, during the operation. In case of instable run of the engine within the rotational speed range of 800...
3.3.22. Checking the Condition of the Engine Starter Perform the preventive inspection of the starter every 2,000 service hours of the diesel engine. Remove the protective cap and check the conditions of the collector, brushes and brush armature. If the collector is dirty, wipe it using a clean napkin moistened in gasoline. If the collector is burnt, trim it with fine-grained emery paper or smooth it up on a lathe. The brushes should move in brush-holders freely and adjoin the collector tightly.
control lamp lights up on setting the “ground” switch to ON position before starting the diesel engine. When starting the diesel engine and when running it at the medium rotational speed the control lamp shall go out (on the engines equipped with an electric starter) or reduce its brightness (on the engines equipped with a starting engine) and the ammeter shall show some charging current, which value shall decrease as the battery charge is restored. 1 – seasonal voltage adjustment screw Fig.
1 – pipe connector bolt; 2 – hole Fig. 32 – Electric torch pre-heater. 3.3.26. Maintenance of the Turbo-Supercharger During the operation, no special maintenance of the turbo-supercharger is required and neither complete disassembling nor repair is allowed.
Check the condition of the turbo-supercharger according to the rotor running-down time after stopping the diesel engine. To do this, the diesel engine should be set to the maximum idling speed after running for 3-5 minutes at the minimum idle speed and then shut the fuel delivery. After stopping the diesel engine the rotation of the turbo-supercharger shall be heard for at least 5 s. The steady sound of constant level with gradual attenuation is evidence of normal condition of the turbo-supercharger.
4. ROUTINE REPAIRS 4.1. Main Guidelines for Disassembling and Reassembling the Diesel Engine The pistons with connecting rods should be pulled out upward only. Before pulling the pistons out, remove the scale from the upper portion of the cylinder sleeves. When replacing the parts of the sleeve-piston group and crank mechanism pay attention to the size groups of the parts.
1 – upper compression ring; 2 – conic compression ring; 3 – oil ring. Fig. 33 – Diagram of mounting the piston rings. Set the timing gears according to the marks stamped on them as shown in Fig. 34. The marks on the intermediate gear shall be aligned with the respective marks of the gears of the crankshaft and camshaft, as well as fuel pump driving gear.
4.2 Current repair of diesel engine components Description of malfunctions Possible reasons Instructions for repair of assembly parts Instructions for repair Water pump 1.Leak of cooling liquid from drainage hole 1.1.Wear of contact surfaces of face seal 1.1Control the level of cooling liquid in the cooling system 1.1.
4.2.1 General instructions for disassembling of water pump. 4.2.1.1 Water pump disassembling. Unscrew the nut 9 (figure 35) of drive sheave of water pump. Via remover dismantle the sheave of water pump.Remove stop ring 12 from the pump case. Remove the impeller 3 from the pump shaft 2. Press off the shaft with bearing from the water pump case. Press direction to the side of sheave mounting. Press out the bearings from the shaft. Remove the sealing ring 13. Press out the seal from the pump case.
5. STORAGE To ensure the serviceability of the diesel engines, saving material and monetary means for their repair and preparation for work, it is necessary to observe carefully the rules of storage of the diesel engines when they are not operated. Regardless the season of the year, the diesel engines shall be stored in full compliance with GOST 7751-85. If the tractor (machine) with the installed diesel engine is to be stored for long term, it should be placed indoors or under a shed.
6. TRANSPORTATION When transporting the diesel engines, the outer apertures shall be covered with plugs. The transportation of diesel engines shall ensure protection of them against moisture and mechanical damages according to the storage conditions 2 (C) GOST 15150-69.
Appendix A (Reference) Chart of Use of Combustive-Lubricating Materials Table А.1 Pos. Description and index No.
Pos. Description and index No.
Pos. Description and index No.
Pos. Description and index No.
Appendix B (Reference) Schedule of Spare Parts and Accessories (SPA) Table B.1 – Spare parts Spare part des- Product code Spare part description Place of ignation packing Application Quantity per system Quantity per kit Remarks D-243 and its D-245 and its D-243 and its D-245 and its modifications modifications modifications modifications 50-1404059-B1 47 5341 8601 Cap gasket Centrifugal oil filter 1 1 1 1 240-1117030 СB 45 7121 9141 Filter element 25 6411 1151 Belt 1V.
Appendix C (Reference) Adjustment Parameters of the Diesel Engine Table C.1 Description Unit of measurement 1. Oil pressure in the system (on the warmed-up psig engine) at the rated rotational speed of the crank- (kgf/cm2) shaft 2. Recommended coolant temperature (thermal C conditions) 3. Belt deflection at 9 lb (4 kgf) force midway between the crankshaft and alternator pulleys: - D-243 engine and its modifications in (mm) - D-245 engine and its modifications in (mm) 4.
Appendix D (Reference) Adjustment Parameters of Fuel Pumps Table D1 – Adjustment parameters of the 4UTNI, 4UTNI-T fuel pumps Unit of 4UTNI Parameters measurement D-241 D-242 D-243 1. Angle of the beginning of fuel inград 571 571 571 jection by the section according to meniscus before the top dead centre (over the cam profile) 2. Rated rotational speed of the pump rpm 1,0505 9005 1,1005 camshaft 3. Fuel delivery per cycle at the rated mm3/cycle 721.4 741.4 771.4 rotational speed 4.
Unit of 4UTNI Parameters measurement D-241 D-242 D-243 11. Fuel delivery per cycle at the ro- mm3/cycle 140 140 140 tational speed of the pump crankshaft of 40 - 50 rpm, not less than 12. Pressure in the fuel pump head at psig 10-17 10-17 10-17 2 the rated rotational speed of the cam- (kgf/cm ) (0.7-1.2) (0.7-1.2) (0.7-1.2) shaft 13. Rotational speed corresponding rpm 1,200 1,050 1,250 to the full automatic shutting of the fuel delivery through the fuel injectors, not more than 14.
Х Х Х Х Reason Х Х Х Х Х Clearance of air filter Connection between diesel engine and turbocharger Sealing of exhaust pipe Exhaust pipe Clearance of diesel breathers Clearance connecting pipe of turbocharger Drain oil pipe of turbocharger Valves, pistons and piston rings Directional control valves and piston rings Fuel pump and injector sprayers Air cleaner Turbocharger case Installation of turbocharger into diesel engine Turbocharger P o w e r d ro p B la c k sm o k e B lu e sm o k e E x c e s s iv e o
Appendix F Scheme of diesel strapping 1 - Bolt; 2 - circuitry; 3 - bar; 4 - Grip Figure 36 - scheme of diesel strapping
