TABLE OF CONTENTS
1 DESCRIPTION AND OPERATION .....................................................................................................................................................4
1.1 DIESEL ENGINE DESCRIPTION AND OPERATION ..........................................ERROR!BOOKMARK NOT DEFINED.
1.1.1 Diesel engine application.......................................................................................... Error! Bookmark not defined.
1.1.2 Technical specifications ............................................................................................ Error! Bookmark not defined.
1.1.3 Diesel engine components ......................................................................................... Error! Bookmark not defined.
1.1.4 Design and operation ................................................................................................ Error! Bookmark not defined.
1.1.5 Diesel engine labelling............................................................................................................................................14
1.1.6 Packaging................................................................................................................. 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................................................................................................. Error! Bookmark not defined.
1.2.2 Description and operation......................................................................................... Error! Bookmark not defined.
1.2.3 Diesel engine labelling and sealing.........................................................................................................................42
2 APPROPRIATE USE............................................................................................................................................................................42
2.1 OPERATING RESTRICTIONS...............................................................................................................................................42
2.2 DIESEL ENGINE PREPARING FOR OPERATION.....................................................................................................................43
2.2.1 Safety rules to be observed while preparing diesel engine for operation...............................................................43
2.2.2 Diesel engine, its assembly units and parts depreservation ...................................................................................43
2.2.3 Diesel engine additional equipment ........................................................................................................................44
2.2.4 Filling the cooling system........................................................................................................................................44
2.2.5 Filling the engine with fuel and oil..........................................................................................................................45
2.2.6 Diesel engine controls and control devices.............................................................................................................45
2.3 DIESEL ENGINE USE..........................................................................................................................................................45
2.3.1 The order of diesel engine use by authorized technical personnel .........................................................................46
2.3.2 Diesel ngine start.....................................................................................................................................................46
2.3.3 Diesel engine shutdown...........................................................................................................................................47
2.3.4 Diesel engineoperationsl run-in..............................................................................................................................47
2.3.5 Diesel engine operation in winter conditions..........................................................................................................47
2.3.6 Possible failures and troubleshooting....................................................................................................................48
2.3.7 Safety measures with engine appropriate use........................................................................................................121
2.4 OPERATION IN EXTREME CONDITIONS ............................................................................................................................121
3 MAINTENANCE.................................................................................................................................................................................122
3.1 DIESEL ENGINE MAINTENANCE.......................................................................................................................................122
3.1.1 General instructions..............................................................................................................................................122
3.1.2 Safety measures.....................................................................................................................................................124
3.1.3 Maintenance procedures .......................................................................................................................................125
3.1.4 Checking the engine operation condition..............................................................................................................126
3.1.5 Proofing (reproofing) for storage..........................................................................................................................127
3.2 DIESEL ENGINE AND ITS COMPONENTS MAINTENANCE...........................................................................................130
3.2.1 Checking the cooling liquid level in the cooling system........................................................................................130
3.2.2 Cooling system maintenance and washing............................................................................................................130
3.2.3 Checking oil level in the engine oil sump..............................................................................................................130
3.2.4 Replacing oil in the engine oil sump......................................................................................................................131
3.2.5 Replacing he oil filter ...........................................................................................................................................131
3.2.6 Cleaning the centrifugal oil filter rotor.................................................................................................................132
3.2.7 Sediment removal from fuel pre-filter....................................................................................................................133
3.2.8 Replacing fuel pre-filter.........................................................................................................................................133
3.2.9 Replacing fine fuel filter ........................................................................................................................................133
3.2.10 Заполнение топливной системы ......................................................................................................................134
3.2.11 Servicing the air cleaner......................................................................................................................................135
3.2.12 Checking the air cleaner and the inlet duct connections hermeticity..................................................................136
............................................................................................................................................ Error! Bookmark not defined.
3.2.13 Washing the engine breathers .............................................................................................................................136
3.2.14 Tightening the cylinder heads bolts.....................................................................................................................137
3.2.15 Checking the gaps between the valves and the rockers.......................................................................................137
3.2.16 The “COMMON RAIL” system maintenance......................................................................................................138
3.2.17 Alternator maintenance......................................................................................................................................139
3.2.18 Checking the belts tension...................................................................................................................................139
3.2.19 Checking the starter motor condition.................................................................................................................140
3.2.20 Turbocharger maintenance .................................................................................................................................140
3.2.21 Compressor maintenance ....................................................................................................................................141
3.2.22 Gas exchange system components maintenance ...............................................................................................141
4 CURRENT REPAIR............................................................................................................................................................................141
4.1ENGINE CURRENT REPAIR................................................................................................................................................141
