D-245 engine power system

The power system consists of:

• - fuel tank;
• - coarse filter;

• - fine fuel filter;
• - booster pump;
• - fuel injection pump;
• - injectors.

Fuel from the tank, which has passed through a coarse fuel filter, is supplied under a pressure of 0.8-0.9 MPa by a fuel feed pump to the receiving fitting of the injection pump.

Under the influence of the created pumping pressure, the safety valve allows fuel access through the supply channel into the spaces above the plunger.

The advancing cam of the rotor moves the plunger upward, while the inlet of the intake channel is closed and with further lifting of the plunger, the fuel is compressed in the space above the plunger of the injection pump.

Compressed fuel is supplied to the corresponding injector in accordance with the diesel stroke.

Excess fuel is returned to the tank.

Possible malfunctions of the D-245

Symptom of malfunction, cause of malfunction (Method of elimination)

Diesel does not develop full power:

- The fuel injection advance angle is incorrectly set (knocking or smoking)

Adjust the fuel injection advance angle

- Failure to adjust or clogged nozzle

Adjust the injector on a special stand, rinse and clean it if necessary
- Injection pump malfunction

Remove the fuel injection pump from the diesel engine and send it for repair

- Insufficient fuel supply

Clean the system

Check the drive of the regulator lever and eliminate the malfunction

Replace the fine filter element

Bleed the system

Find the cause of the system leakage, eliminate it and bleed the system with a fuel pump
- Boost pressure has decreased

Clean the air purifier

Replace turbocharger

Diesel smokes in all operating modes:

- white smoke (indicates the presence of water or fuel vapors in the exhaust gases):

• - Poor tightness of the gas distribution valves;
• - Wear of liners and piston rings (accompanied by increased smoke and crankcase gas consumption)

Send diesel for repair

- Diesel is supercooled

Warm up diesel

Maintain the coolant temperature at 75...95˚С during operation

- Fuel injection advance angle adjustment is broken

Check and adjust the fuel injection advance angle setting

- The adjustment of the gaps between the valves and rocker arms is broken

Adjust the gaps between the valves and rocker arms

- Coolant getting into the fuel           

Replace the fuel, drain the sediment from the FGO

Bluish-colored smoke (indicates increased oil penetration into the combustion chamber):

- Excess oil in the diesel crankcase

Drain the oil to the level of the upper mark of the oil dipstick

• - Oil leakage through turbocharger gaskets
• - Wear of valve stem seals

Replace valve stem seals

• - Clogged air cleaner
• - Reduced boost pressure

Replace turbocharger

Clean the air purifier

- Wear of parts of the cylinder-piston group

Injector malfunction:

• - the nozzle spray needle is stuck;
• - sprayers of other models are installed;
• - separation of the spray nozzle;

Black smoke (indicates incomplete combustion of fuel):

• - Clogged air cleaner
• - Leakage of fuel system, air
• - Clogged exhaust system
• - The injection pump drive adjustment is broken

1. Send diesel for repair
2. Check and adjust the injectors on the stand
3. Identify a faulty nozzle, wash or replace the nozzle, adjust the nozzle
4. Install sprayers mod145.1112110
5. Replace the sprayer, adjust the nozzles on the stand

Increased fuel consumption

diesel does not reach idle speed

• - wear of nozzle holes;
• - increased pressure at the start of fuel injection by the nozzle

Fuel injection pump malfunction:

• - the regulator corrector and the injection pump boost corrector are incorrectly adjusted;
• - cyclic fuel supply is too high;
• - fuel injection pump adjustment is broken
• - Fuel injection pump malfunction;
• - the tightness of the injection section of the injection pump is broken;
• - the rotational speed of the injection pump camshaft corresponding to the start of the regulator operation is too high;
• - wear of the speed control weight bushings
• - wear of a pair of guide bushings and the rod of the fuel priming pump    

1. Adjust the cyclic feed with the nominal feed bolt
2. Remove the fuel injection pump from the diesel engine and send it for repair
3. Replace the guide bushing-rod pair, check the tightness and performance of the fuel priming pump
4. Set the recommended fuel injection advance angle
5. Adjust the gaps between the valves and rocker arms
6. Adjust the injection pump drive
7. Remove the fuel injection pump from the diesel engine and send it for repair

Knocking sound when diesel engine is running                                     

1. The fuel injection advance angle is incorrectly set
2. Check the adjustment of the fuel injection advance angle, play in the injection pump drive
3. The adjustment of the gaps between the valves and rocker arms is broken
4. The injection pump fuel supply control lever does not reach the maximum frequency position when the fuel pedal is fully depressed

Fuel injection pump malfunction:

• - stuck plungers;
• - regulator malfunction

1. Violation of the gaps between the rocker arms and valves
2. Failure of valve springs
3. Valve stem stuck in guide sleeve
4. Wear of pistons and piston pin hole surfaces.
5. Wear of bushings in the upper heads of the connecting rods and in the piston bosses
6. Wear of connecting rod and main bearings, scuffing of cylinder liners
7. Late injection of fuel into unheated diesel cylinders (mild knocking and white smoke)
8. Early fuel injection into diesel cylinders (strong knocking and black smoke)

Check and adjust gaps

Replace springs, eliminate jamming

Remove jamming; If this is not possible, send the diesel engine for repair.

Submit the diesel engine for repair, during the repair process replace worn or faulty parts with new ones

Remove the injection pump from the diesel engine and send it for repair (check the condition of the pusher springs in the injection pump sections, adjusting the cyclic feeds of the injection pump sections)

Check the nozzle and adjust it on the stand (check the position of the needles in the nozzles)

Diesel overheats

- Fuel injection pump malfunction: uneven distribution of injected fuel among individual diesel cylinders (knock in individual cylinders)

Remove the fuel injection pump from the diesel engine and send it for repair

• - Injector malfunction:
• - lack of clear cut-off of fuel by injectors;
• - clogged fuel injector drain line (loud knocking)

Adjust the nozzle on the stand

Breakage or severe stretching of the liquid pump drive belts

Check and adjust belt tension; if necessary, replace the complete belts with new ones, add coolant to the cooling system

Low coolant level

- Thermostat is faulty

Replace thermostat

- Contamination of the external surface of the radiator

Clean the radiator

- Cooling system contamination         

Flush the cooling system

Clean and vent fuel lines

No oil pressure      

The oil pressure on a heated diesel engine is below the permissible level, the oil pressure on a heated diesel engine is higher than the permissible value. Water entering the lubrication system

- The oil pressure sensor or indicator is faulty (the alarm does not work)

Replace the oil pressure sensor or indicator

• - Malfunction of the lubrication system pump drive
• - The oil pressure sensor or indicator is faulty (the alarm does not work)

Replace the oil pressure sensor or indicator

- The diesel crankcase is filled with oil that does not correspond to that recommended in the operating manual

Change the oil in accordance with the operating manual

- The oil level in the crankcase is below the permissible level

Add oil to the required level

- Oil dilution by fuel, coolant or due to overheating

Eliminate the cause of oil dilution, change the oil

- Stuck or incorrectly adjusted lubrication system drain valve

Adjust or replace the valve.

- Oil pump malfunction

Send diesel for repair

- The tightness of the oil pipeline connections is broken

Identify the location of the leakage and restore it

- Wear of main and connecting rod journals and crankshaft liners

Send diesel for repair

- The diesel crankcase is filled with high-viscosity oil

Change the oil in accordance with the lubrication chart

- Clogged or faulty safety valves

Check valves, replace valves if necessary

- Leakage on rubber rings of cylinder liners

Replace faulty O-rings

Submit diesel for repair

- Weak tightening of the cylinder head bolts

Tighten the bolts

Diesel does not start or starts poorly:

Starter failure or reduced crankshaft speed

Check the charge level of the batteries.

No fuel supply:

• - thickening of fuel in fuel lines
• - fuel lines or intake in the fuel tank are clogged
• - freezing of water in the fuel lines, in the FGO cap or the fuel tank intake grid
• - no fuel supply to the injection pump
• - presence of air in the fuel system
• - fuel injection pump malfunction
• - incorrect adjustment of the fuel injection advance angle

Fuel system leaking

Fuel injection pump malfunction:

• - violation of the uniformity of fuel supply by sections;
• - stuck plungers;
• - rack jamming;
• - malfunction of the discharge valve;
• - breakage of pusher springs
• - speed controller is faulty

Low engine speed

Unsatisfactory operation of individual injectors:

• - the nozzle spray needle is stuck;
• - sprayers of other models are installed;
• - tearing off the spray nozzle;
• - wear of nozzle holes;
• - decrease in pressure at the start of fuel injection of the injectors.

1. Check the connections on the batteries and clean the contacts if necessary.
2. Check that the oil and fuel are appropriate for the season, bleed the fuel supply system.
3. If necessary, dilute the fuel with kerosene depending on the ambient temperature in a ratio of up to 1:1 in accordance with the operating instructions.
4. Rinse the intake, blow out the fuel lines.
5. Carefully warm up the fuel pipes, filters, FGO and tank, covering them with rags and dousing them with hot water.
6. Drain the water from the FGO, fuel tank and bleed the system with a fuel pump
7. Check the tightness of the low pressure fuel lines.
8. Drain the sediment from the FGO and FTO filters.
9. Rinse or replace the FTO filter elements, clean the reflector with mesh and blow it with compressed air.