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Yaroslavl ???-236 Maintenance Manual

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Maintenance manual
236.01.01 RK
for the engines
ЯМЗ-236
ЯМЗ-238
of all versions and specifications
Yaroslavl, 2014

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Summary of Contents for Yaroslavl ???-236

  • Page 1 Maintenance manual 236.01.01 RK for the engines ЯМЗ-236 ЯМЗ-238 of all versions and specifications Yaroslavl, 2014...

  • Page 2: Table Of Contents

    Contents Introduction ……..………………......................8 1 General conditions ..........................10 1.1 Functions of the engines .........................10 1.2 Technical characteristics of the engines ..................11 2 Technical characteristics for repair ....................17 2.1 General terms and definitions ......................17 2.2 Acceptance requirements for repair of the engines ................20 2.3 Awaiting repair storage ........................21 2.4 Delivery of the engines from repair ....................21 2.5 General technical requirements for engine disassembly ..............22...
  • Page 3 1004. Piston ..........................86 1004. Piston pin ........................88 1004. Connecting rod assembly .....................90 1005. Crankshaft ........................93 1005. Crankshaft pulley ......................101 1005. Flywheel assembly .....................104 1005. Half-washer of the thrust bearer .................108 1006. Camshaft ........................110 1007. Valve ...........................114 1007. Rocker pivot .......................117 1007.
  • Page 4 1011. Idler gear shaft of the oil pump drive .................146 1011. Gear wheel of the oil pump drive ................148 1011. One-section oil pump. Oil pump body................150 1011. Oil pump cover ......................152 1011. Oil feed gear wheel .....................154 1011. Oil feed drive gear ......................154 1011.
  • Page 5 1307. Water pump vane ......................190 1307. Water pump pulley .....................192 1307. Pulley of the water pump drive ..................194 1308. Fan. Fan propeller ......................196 1308. Pulley of the compressor and generator drive ............199 1308. Axis of the fan drive ....................201 1308. Collar of the bushing ....................203 1308.
  • Page 6 4.9 Coarse fuel filter ...........................235 4.10 Fine fuel filter..........................236 4.11 Water pump 236-1307010-А3 ....................238 4.12 Water pump 236-1307010-Б2 ....................240 4.13 Tension machine ........................241 4.14 Fan drive .............................243 5 Engine assembly ..........................245 5.1 Lifters and camshaft installation ....................245 5.2 Crankshaft installation ........................246 5.3 Cylinder liner installation ......................248 5.4 Connecting rod and piston group installation ................249 5.5 Installation of the distributor timing cover and crankshaft pulley..........250...
  • Page 7 acceptance test.............................264 6.1 General requirements ........................264 6.2 Engine preparation for the starting-up ..................267 6.3 Starting-up and operation of the engine ..................267 6.4 Timing of the engine ........................269 6.5 Engine acceptance test .........................275 6.6 Engine running-in modes ......................278 6.7 Mode of the replicated tests ......................281 Supplements............................284 Supplement А...

  • Page 8: Introduction

    Introduction OJSC "Avtodizel" (ЯМЗ) is the leading engine manufacturer in the Russian Federation which was founded in 1916. It is the oldest manufacturer in the automobile field in Russia which is specializing at the producing of the multi-purpose diesel engines. OJSC "Avtodizel" (ЯМЗ) manufactures a great number of diesel engines models for wide range of customers (more than 300 models): heavy-duty trucks, line-haul trains, dump trucks, buses, tractors, combines, standing powertrains, other specialties and construction and road building machinery.
  • Page 9 This edition was developed and compiled by the workers of OJSC "Avtodizel" (ЯМЗ): S.A. Aleksandrov, D.V. Koltsov, Yu.V. Sumenkova, V.I. Zherebiatiev, S.A. Kirov, Ye.N. Gogin, M.N. Kupriianov, G.V. Olennikova, L.N. Malyshev, A.A. Bibikov, D.N. Panaiotov, S.R. Vaganov and others. © OJSC “Avtodizel” (ЯМЗ), 2014 Reprinting, duplication and translation whole or in part is prohibited without prior written consent of Center of warranty and servicing of OJSC “Avtodizel”...

  • Page 10: Functions Of The Engines

    1 General information 1.1 Functions of the engines Multi-purpose engines produced by OJSC "Avtodizel". Technical characteristics, universality, high degree of uniting, maintainability enable their application in automobile and other items of different purpose. ЯМЗ-236M2 and ЯМЗ-238M2 engines are six- and eight-cylinder models of the family of four-stroke diesel engines of OJSC "Avtodizel".

  • Page 11: Technical Characteristics Of The Engines

    1.2 Technical characteristics of the engines Table 2 TECHNICAL CHARACTERISTICS Models of the engines Values ЯМЗ-236M2 ЯМЗ-238M2 ЯМЗ-238AM2 ЯМЗ-238ВM ЯМЗ-238ГM2 ЯМЗ-238KM2 Engine type Four-stroke, with compression ignition Number, location of the cylinders 6, V-type 8, V-type, camber angle 90º Firing order 1-4-2-5-3-6 1-5-4-2-6-3-7-8 Numbering scheme of the cylinders...
  • Page 12 Models of the engines Values ЯМЗ-236M2 ЯМЗ-238M2 ЯМЗ-238AM2 ЯМЗ-238ВM ЯМЗ-238ГM2 ЯМЗ-238KM2 Cylinder liners "Wet" type Cylinder heads Two, each for every cylinder raw Crankshaft Forged, with counterweights, crank pin bearing surfaces are heat-treated with high frequency current Number of crankshaft bearings Base bush bearings with replaceable bushing Rod bush bearings with replaceable bushing Pistons...
  • Page 13 Models of the engines Values ЯМЗ-236M2 ЯМЗ-238M2 ЯМЗ-238AM2 ЯМЗ-238ВM ЯМЗ-238ГM2 ЯМЗ-238KM2 Pressure of the valves opening of the lubrication system, kPa (kfg/cm2): 700-800 700-800 700-800 700-800 700-800 700-800 pressure limiting valve (7.0-8,0) (7.0-8,0) (7.0-8,0) (7.0-8,0) (7.0-8,0) (7.0-8,0) of the oil pump release valve of the radiator section 100-130 100-130...
  • Page 14 Models of the engines Values ЯМЗ-236M2 ЯМЗ-238M2 ЯМЗ-238AM2 ЯМЗ-238ВM ЯМЗ-238ГM2 ЯМЗ-238KM2 Two coarse filters with renewable filter element, fine filter with renewable filter element for fuel. There is a by-pass in the fine filter cover. Fuel filters Inertial oil filter Dry-type Special, is Air filter...
  • Page 15 Models of the engines Values ЯМЗ-236M2 ЯМЗ-238M2 ЯМЗ-238AM2 ЯМЗ-238ВM ЯМЗ-238ГM2 ЯМЗ-238KM2 Number of the pressed springs – Transmission gear ЯМЗ-236П Model ЯМЗ-236Н ЯМЗ-236Н – – – Type Mechanical, three-throw, five speed, with speed synchronizers on the second-third and fourth-fifth speeds Gear transmission ration: –...
  • Page 16 Models of the engines Values ЯМЗ-236M2 ЯМЗ-238M2 ЯМЗ-238AM2 ЯМЗ-238ВM ЯМЗ-238ГM2 ЯМЗ-238KM2 Oil volume, l Lubrication system (without radiator) Cooling system (without radiator) – 0.85 0.85 0.85 – Air filter 0.16 0.16 0.16 0.16 0.16 0.16 Variable timing device – – Transmission gear box Pic.

  • Page 17: Technical Characteristics For Repair

    2 Technical characteristics for repair 2.1 General terms and definitions Serviceability means suitability of the object (item) for prevention and detection of the causes of failures and damages, keeping and restoring of the operational condition with the help of maintenance and reparation. Repair means a complex of actions aimed at recovery of order and working capacity of the items and recovery of their resources or components.
  • Page 18 repair requires the complete disassembling of the engine, its washing, cleaning of all parts, their inspection, recovery or replacement of all defected parts, assembling and testing. Repair methods: Repair without responsibility is the method when the original parts of the repairing item are not preserved.

  • Page 19: Acceptance Requirements For Repair Of The Engines

    2.2 Acceptance requirements for repair of the engines Repair plants accept repair storage of the engines from the operating organizations according to the following requirements: - engines should be completed, without additional assembling from the defective parts, assembly units from the other engines, with the original parts of the engine accepting for the repair according to the nomenclature of the main units;...

  • Page 20: General Technical Requirements For Engine Disassembly

    delivered with the repaired engine: - acceptance report; engine certificate with the amended with the remarks about the performed repair, made changes of the numbers and markings; - list of spare parts, tools and facilities; - operational documents for the components and spare parts to them with the indication of the guaranteed service life stated by the manufacturer;...
  • Page 21 2.5.4 It is recommended not to disassemble completely the separate nodes and units (starter, generator, fan with built-in clutch, nozzles) because there is no proper technical equipment, facilities, documents, qualified workers, as well as abilities to provide the proper quality level of the newly assembled unit at the repair plant.
  • Page 22 - Cleaning of the details after the recovery, blowing with compressed air; - Washing (spray washing) and blowing with compressed air before the assembling of the engine, circulation of the oil passages of the crankshaft, cylinder block, nozzles and oil cooling pipe for pistons; - External washing of the engine after the tests and before painting;...
  • Page 23 (working temperature is more than 400 degrees) because of the danger to get burns to the human body despite their high quality of cleaning. 2.6.7 It is considered the most effective to clean and wash the parts and nodes from oil impurities, asphalt-resinous impurities, carbonaceous sediments to use the submerge method in water solution of the synthetic detergents like MS-15;...
  • Page 24 2.6.11 To clean the parts from the soot deposits it is recommended to use physicochemical cleaning method with 10% water solution based on the biodegradable detergent Luxol-Karbon with the temperature 40-60 ºC and hydroabrasive cleaning method in the jet machines with the abrasive component;...

  • Page 27: General Technical Requirements For Inspection Of The Components And Assembly Units

    .7 General technical requirements for inspection of the components and assembly units 2.7.1 During repair (current or main) of the engine reasons for replacement of damaged, worn or defected parts for the proper ones (from the parts) can be the result of inspection and maximum allowable parameters of the inspected parts according to the present documents (in the inspection sheets).
  • Page 28 holes for the crankshaft bearing liners, measuring crankshaft - crank and main bearings. 2.7.7 Measurements should be made in the sections and directions of the biggest wears. 2.7.8 Parts and assembly units are considered to be applicable without repair if their dimensions and other parameters comply with the dimensions and parameters specified in the inspection sheets.
  • Page 29 specified parameters with the help of comparison it is allowed to use the reference quality pattens (quality standard) of the parts which should have corresponding marking and should be approved in accordance with the established procedure. 2.7.13 Thread is controlled with the visible inspection of the critical parts with the help of screw thread gauge.

  • Page 30: General Technical Requirements For Engine Assembly

    2.8 General technical requirements for engine assembly 2.8.1 Engines should be assembled in accordance with the requirements of the technical specifications, assembly drawings, specifications and this manual. Parts and assembly units should have an inspection stamp or quality certificate. 2.8.2 Parts and engine nods coming for the repair should be clean, forge scales and corrosion are not allowed.
  • Page 31 - Snugging up of the part (screw or nut) - screw driving into the threaded hole of the joining part for 2-3 threads by hand or screwing on of the nut on the bolt for 2-3 threads by hand; - choosing, preparation or approach of the tool for assembling of the threaded joint; - Previous snugging and screwing of the threaded parts till the contacting of the head or nut with the joining part by the ratch or nut runner;...
  • Page 32 joint if considered to be tightened it won't not be tightened. Nut runner system or torque spanner will show the necessary torque but the necessary clamping torque will not be reached. At the operation the threaded joint is influenced by the load, vibration that is why the risk ofslaking is great.
  • Page 33 following requirements: - carefully wipe joining surfaces of the block, cap and bed for the bearing liners of the crankshaft; - after the installation in the bed one should lubricate the working surfaces of the bearings with clean diesel oil M10D 2 according to the GOST 8581-78;...
  • Page 34 Assembly of the compression and oil-control rings at the piston one should perform with the help of the special device for rings unlocking. Compression rings are installed with mark "Upper side" directed to the piston top. 2.8.19 At the cover of the connecting rod to mark the order number of the cylinder. Kits of the connecting rods with the pistons one should install at the engine in accordance with cylinder numbers marked at the connecting rod covers and it is necessary to check previously correspondence of the reference numbers of the cover and connecting rod.
  • Page 35 2.8.22 Fastener nuts of the cylinder heads should be tightened at the cold engine in consequence specified in the chapter Engine assembling: from the middle to the sides crosswise previously lubricated the thread with the oil no less than in three steps: I step –...

  • Page 36: General Requirements For Engine Running-In And Testing

    2.8.26 To seal the threads of the plugs of the horizontal and vertical oil passage of the cylinder block one should apply the thread sealants Anaterm - 5M or Anaterm 114, Loktayt - 542 (sealants can be applied only at previously cleaned and ungreased surface). 2.8.27 For fixation of the thread it is recommended to seal other threaded joints with the Unigerm-9, Unigerm-10, Anaterm-111, Loktait-243.
  • Page 37 2.9.4 Test stands should be equipped with the facilities for emergency engine stop in case of oil pressure drop, pressure rise of the crankcase blow-by gasses, or if the temperature of the coolant or rotation rate of the crankshaft exceeds the limits. To set the limits of the emergency shutdown according to the table 2.1.
  • Page 38 7328-82. 2.9.9 External characteristics are defined at the full fuel supply from the maximal idle rotation rate to minimal working rotation rate at that it is necessary to define the points corresponding the maximal torque and minimal specific fuel consumption. 2.9.10 Smoking at the exhaust is determined in accordance with the Principles of the UN Economic Commission for Europe №...

  • Page 39: Inspection Sheets

    3 Inspection sheets 1002.Cylinders cast in block Name of the part or assembly unit Marking Assembled cylinder block See the column in the table 1 236-1007244-A Front push rod bushing Pins of the cylinder head fasteners 236-1003016-Б Pins Rigidez Material 170...241 HB I.
  • Page 42 dimension and parameter, mm Way of defect detection and means Possible defect maximum allowable Conclusion of control nominal without repair for repair Cracks on the dividing walls of Inspection To reject the block Inspection. « х Cracks on the joining surface Magnifier ЛП-1-4 of the cylinder head «...

  • Page 43: Cylinder Liner

    dimension and parameter, mm Way of defect detection and maximum allowable Possible defect Conclusion means of nominal control without repair for repair Cracks on the side surfaces Inspection To weld of the block that do not touch the stiffening bars and dividing walls To weld Cracks and breaks touching...
  • Page 44 « Л Cavitation damage of the Inspection. lower hole for the cylinder liner Ш +0,021 Wear or deformation of Ø116 To reject Inspection. the holes under the holes for Inside gauge the crankshaft bearing liners НИ 100-160 Э Wear of the holes of the Inside gauge To replace the bushings +0,03...
  • Page 45 Ю Inside gauge 22,09 To replace the bushing НИ 18-50-1 To reject Runout tolerance of the intermediate bearing axis relatively the end Inspection. Facility Deformation of the surface ones: for the crankshaft bearing 0,025 0.05 liners Ш Ц Loosening the seating of Inspection of the To replace the bushings +0,03...
  • Page 46 М16х2-2N5S To replace the pin Loosening of the seating of Inspection. the pins of the cylinder head Proofing fasteners the seating by hand Threaded plug To calibrate the thread. thread stripping no more than Inspection two threads: To install threaded В, М8-6Н...
  • Page 47 Notes 1 Cylinder block and crankshaft bearings caps should not be pooled and should be accepted for the inspection, repair and assembling in kit. 2 Measuring the dimension of the holes for the crankshaft bearing liners bolts at the fasteners of the crankshaft bearing caps should be tightened with the moment of force from 421 to 461 N*m (from 43 to 47 kfg m), stretching bolts should be tightened with the moment of force from 88 to 118 N*m (from 9 to 12 kfg m).
  • Page 48 Table 1 - Marking for the assembled cylinder block Name of the part or assembly unit Marking 236-1002011-Д 236-1002011-Н 236-1002011-Г Assembled cylinder block 238-1002011-Д2 238Е-1002011-Г2 238-1002011-Д2 238-1002011-Г2 238-1002011-Л Table 2 - Categorical dimensions of the assembled cylinder block Number Repair dimensions, mm Name of the dimension of the defect Diameter of the holes of the bushings for crankshaft pins (bushings are shipped by the...
  • Page 49 Technical requirements for the repaired assembly unit Number of the defect 1 Tolerance of the holes Э parallelity relatively to Ш - 0.05 mm 2 Coaxiality tolerance of the surfaces for the body of high-pressure oil pump relatively to the hole С – 0.2 mm with radius 3 Tolerance of circularity and longitudinal section profile of the surfaces Ц...
  • Page 50 Marking Name of the part or assembly unit 236-1002021-Б2 Cylinder liner Material Hardness 42...50 HRC for the working surface 207...248 Special cast iron for the rest surfaces Dimension and parameter, mm Method defect detection and control maximum allowable means Possible defect Conclusion nominal without repair...
  • Page 51 Way for defect Dimension and parameter, mm Conclusion detection and means Possible defect of control nominal maximum allowable without repair for repair В Wear or scuffing on the Inspection. See the table To reject internal surface of the Inside gauge cylinder liner НИ100-160-1 А...
  • Page 52 Marking Name of the part or assembly unit Picture is on the next page Upper cover of the block 236-1002255-В3 236-1002255-В4 Material grade 80НВ, no less I. 236-1002256-В3 –АК 7М2Мг Dimension and parameter, mm Method defect detection and control means maximum allowable Possible defect Conclusion...
  • Page 54 Way for defect detection Dimension and parameter, mm Conclusion and means of control nominal maximum allowable Possible defect without repair for repair Thread stripping no more Inspection. Inside gauge See the table To calibrate the НИ100-160-1 thread than one thread: Б...

  • Page 55: 1002. Distributing Timing Cover

    Marking Name of the part or assembly unit Picture is on the next page Distributing timing cover 236-1002260-Б2 236-1002261-Г2 Material grade I. 236-1002264-А4 – АК7М2Мг I. 236-1002227 – steel 20 80НВ, no less Dimension and parameter, mm Method defect detection and control means maximum allowable...
  • Page 57 Way for defect detection and Dimension and parameter, mm Conclusion means of control Possible defect nominal maximum allowable without repair for repair И Inspection. Beam Ø32 To weld Cavitations damage of the compass ШЦ-I-125-0.1-1 Dimension Ф water passage walls: 14,1 ±1,5 at the inlet M10x1,5Сп...

  • Page 58: Flywheel Housing

    of the defect М10х1.5 Cп M12x1,75Cп Marking Name of the part or assembly unit Picture is on the next page Flywheel housing 236-1002312-В3 238-1002312-В6 238-1002312-В7 Material Hardness Special cast iron 170…241 НВ Dimension and parameter, mm Method defect detection and control means maximum allowable...
  • Page 60 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair Е Deformation of the flywheel Inspection. Slab Tolerance for flatness of the surface E at the length 100: To process till the surface elimination of the...
  • Page 61 Technical requirements for the repaired part Number of the defect 1 Tolerance for flatness of the surfaces Е – 0.05 mm at the length 100 mm ………………………………………… 2 Positional tolerance of the threaded holes with radius (dependable tolerance): - for holes Д, И and Ж – 0.2mm; - for holes Г...

  • Page 62: 1003. Cylinder Head

    1003. Cylinder head Marking Name of the part or assembly unit Picture on the following two pages. 236-1003014-I3 236-1003014-I3 Assembled cylinder head 236Д-1003014 238-1003014-И3 238-1003014-Б4 238Д-1003014 Hardness Material Dimension and parameter, mm Method defect detection and control means maximum allowable Possible defect Conclusion nominal...
  • Page 63 To weld Water or kerosene leakage is not permitted Inspection. Cracks on the walls of the cooling jacket, gas passages or Tests for joining surface to the cylinder sealing with water pressure block 0.3-0.4 MPa (3-4 kfg/cm ) during 2 min Cracks, touching holes for the Water or kerosene leakage is not permitted To reject...
  • Page 64 236/238-1003014-И3 236/238-1003014-В4 236Д/238Д-1003014...
  • Page 66 Way for defect detection and Dimension and parameter, mm Conclusion means of control or kerosene test during 2 min nominal maximum allowable Possible defect without repair for repair Cracks except specified in To weld the defects 1 and 2 Discard «...
  • Page 67 Д Tolerance for flatness of the surfaces E and Д at the length 100 Deformation of the joining Slab To process till the surface of the head to the block 0.02 Е 2-1-1000 630. elimination Ruler-150. of the Gauges 0.02 and defect 0.05 mm К...
  • Page 68 Technical requirements for the repaired assembly unit Number of the defect 1 Tolerance for flatness of the surfaces Д and E – 0.02 at the length 100 and 0.05-ГЦ:236.236Д; 0.06-ГЦ:238.238Д at the whole length………………………………………………………………………………………………….……… 6, 10 2 Block head should have water pressure test for sealing from 0.3 to 0.4 MPa (from 3 to 4 kfg/cm ) during 2 min or kerosene test during 2 min.

  • Page 69: 1003. Cylinder Head Cover With Edges And Breather

    Marking Name of the part or assembly unit 236-1003260-Б 236-1003261-Б Picture is on the next page Cylinder head cover with edges and breather 238-1003260-Б 238-1003261-В2/Г2 Material Hardness 08ПС(08КП) - I 236-1003264-Б 08ПС(08КП) II 236-1003265-Б 08КП III 238-1003488 08ПС(08КП) I 238-1003264-Б 08ПС(08КП) II 238-1003265-Б...
  • Page 71 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair Compression marks on the Inspection Compression marks cover To flatten with the depth 2 without abrupt junctions В Tolerance for flatness according to - Cracks on the valve seats Slab...

  • Page 72: Water Pipe

    Marking Name of the part or assembly unit 236-1003290-В Picture is on the next page 238-1003290-В Right water pipe Right water pipe Left water pipe 236-1003291-В 238-1003291-В Left water pipe Material Hardness АК7М2Мг - 80 НВ, no less Method defect detection of the Dimension and parameter, mm defect and method control...
  • Page 74 Dimension and parameter, mm Way for defect detection and means of Conclusion control nominal Possible defect without repair for repair nominal Inspection Cracks and breaks except To reject specified in the defects 1 and 2 To process till the Inspection Tolerance for flatness of the surface E: elimination of the defect Slab...
  • Page 75 Technical requirements for the repaired part Number of the defect 1 Tolerance for flatness of the surface E: - 0.15 mm …………………………………………………………. 2 Tolerance for flatness of the surfaces B relatively to the total joining flatness - 0.2 mm 3 Dimension Б after the processing till the elimination of the defect should be no more than 5 mm ……………………...

  • Page 76: Piston

    1004. Piston and connecting rod Marking Name of the part or assembly unit 236-1004015- Д Piston 238НB-1004015-Б4 236-1004110-Б Insert Material Hardness 90…111 НВ for 236-1004015-Д Aluminium alloy 90…120 НВ for Cast iron ЧН15Д7 238НB-1004015-Б4 135...160НВ for insert Way for defect detection and Dimension and parameter, mm means of control maximum allowable...

  • Page 77: Piston Pin

    Cracks and breaks of the Inspection. To reject х bottom edges at the geriatric Magnifier ЛП-1-4 line, burning out and meltback of the bottom, scuffs on the working surface and hole for the pin В Wear of the hole for the Inside gauge 50-100 To reject piston pin...
  • Page 78 AHБ from 129.80 to 129.82 Diameter of the working surface of the piston БHБ from 129.82 to 129.84 (238НБ-1004015-Б4) ЖНБ from 129.84 to 129.86 Marking Name of the part or assembly unit Piston pin 236-1004020 236-1004020-01 Material Hardness 12ХN3А for 236-1004020 57…66 НRC 16MnCr5 for 236-1004020-01 Way for defect detection and...
  • Page 79 Inspection. To reject Cracks, scuffs or chipping of the х external surface Magnifier ЛП-1-4 of the pin « Hit tint or corrosion of the Inspection working surface of the pin Scratches, scuffs or compression « To process the marks on the surfaces surface till the of the pin eliminationof...
  • Page 80 Marking Name of the part or assembly unit Picture is on the next page Assembled connecting rod 236-1004045-Б3 Material Hardness Steel 40XH2MA I. 236-1004050-B2 – 241...277H II. 236-1004055-Г2 steel 40ХН2МА – 36...41HRC III. 236-1004063-Б3 IV. 236-1004062-Б Bronze no less than 72НRB V.
  • Page 82 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair Б Scuffs and wear of the holes To reject Inspection. Inside gauge - Scuffs are not permitted for bushings 50-100.

  • Page 83: Crankshaft

    Marking Name of the part or assembly unit 236-1005008-Е2 Picture is on the next page Crankshaft 238-1005008-Г2 Material Hardness steel 50Г «select» I. 236-1005020-Д Surface V,J ,I and М 238-1005020-Г 53…63 НRC; the rest surfaces 238-1005026-Б 192 НВ, no less than II.
  • Page 84 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair В Thread stripping М16х1.5- To calibrate the Inspection. 4Н5Н thread no more than one thread Note - Piston rod 236-1004050-В2 and piston rod cover 236-1004055-Г2 should not be pooled and should come for inspection, repair and assembling in the kit.
  • Page 86 Way for defect detection and Dimension and parameter, mm means of control maximum allowable Possible defect Conclusion nominal without repair for repair К Wearing of the backside main Dimension C: Inspection. bearing at the length +0.14 To reject Calibre 56.20 Wear of the bearing for the Wear of the bearing for the bushings:...
  • Page 87 Е Clamp СРП 75 Wear of the bearing for the « gear wheel Н Wear of the hole for the Inside gauge Ø52 52.05 To reject -0,03 НИ 50-100-1 bearing 62.05 Ø62 -0,03 To replace the pins Dimension E П Inspection of the seating with Loosening of the seating of the light tapering...
  • Page 88 Г Loosening of the seating of The same the oil To replace the front oil deflector deflector Л To replace the back Loosening of the seating of Inspection of the seating with Dimension P the back oil deflector the light tapering 0.5...1.5 of the hammer To replace the bolts...
  • Page 89 Notes 1 Control of the thread wear М68х2-6g according to the defect 18 should be performed if the disassembling of the fastener nut of the front counter balance is needed. 2 Wear of the gear bearing according to the defect 7 should be performed if it is necessary to replace the gear 238Б-1005030. Table 7 –...
  • Page 90 Technical requirements for the repaired assembly unit Number of the defect 1 Tolerance of circularity and longitudinal section profile of the surfaces J and I – 0.005 mm 2 Circularity tolerance of the surfaces Д and Е – 0.007 mm 6, 7 3 Symmetry tolerance to the surface of the hole Ш...

  • Page 91: Crankshaft Pulley

    Marking Name of the part or assembly unit 236-1005061-Б Picture is on the next page Crankshaft pulley 236-1005061-В 238П-1005061 Material Hardness СЧ 21 Method Dimension and parameter, mm defect detection and means of control maximum allowable Possible defect Conclusion nominal without repair for repair Cracks and breaks...
  • Page 93 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair Б +0,039 Wear of the hole for shaft Ø50 inside gauge To reject 50-100 В Wear of the key slot Dimension Calibre To process the new...
  • Page 94 Marking Name of the part or assembly unit Picture is on the next page 236-1005115-Л Assembled flywheel 238-1005115-Л Material Hardness 179...241НВ; 167...212НВ of the main material 236-1005120-Л/238-1005120-Л- cast iron СЧ24 236-1005125-В2-tooth rim - steel 45 40...50HRC of the rims Possible defect Method Dimension and parameter, mm Conclusion...
  • Page 96 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair А Wear of the teeth from the Inspection. To replace rim activating face along the length Control sampler Г...
  • Page 97 Technical requirements for the repaired assembly unit Number of the defect 1 Cumulative tolerance of parallelity and flatness of the surface K relatively to the surface B - 0.06 mm at the length 100 mm and 0.1 mm relatively to the whole surface 2 At the surface K singe clean cavities are allowed with the most dimension 2 mm with the distance between their edges less than 3 mm and no more than 5 pieces 3 Moment of force of the bolt tightening should be 49...

  • Page 98: Half-Washer Of The Thrust Bearer

    Marking Name of the part or assembly unit Half-washer of the thrust bearer of the crankshaft 7511.1005183 Material Hardness 60 НВ, no less Bр05Ц5S5 Method Dimension and parameter, mm defect detection and means of control maximum allowable Possible defect Conclusion nominal without repair for repair...
  • Page 99 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair А Dimension Б Wearing of the slot surfaces To reject Insider gauge 6-10 Number of the defect Technical requirements for the repaired assembly unit 1 1 Flatness tolerance of the surfaces B and Д...

  • Page 100: Camshaft

    1006. Camshaft Name of the part or assembly unit Marking 236-1006015-Г3 Picture is on the next page Camshaft 238-1006015-Г3 Material Hardness Surfaces of the bearings and cams 55 НRC no less than; the rest surfaces Steel 45 GOST 1050-88 167…207 НВ carbon 0.42...0.47% Method Dimension and parameter, mm...
  • Page 102 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair К Dimension И: Wearing of the cams at the Inspection To process the cams height Beam compass 41.0 according to the 42.2 ШЦ-I-125-0.1-1...
  • Page 103 Table 8 – Categorical repair dimensions of the crankshaft Number of the defect Name of the dimension Category of the repair dimension, mm Diameter of crankshaft bearings Technical requirements for the repaired assembly unit Number of the defect 1 Circular runout tolerance of the middle bearings relatively to the total axis of the end bearings afterthe correction –...

  • Page 104: Valve

    Marking Name of the part or assembly unit Induction valve 236-1007010-В2 Reduction valve 236-1007015-В6 Material Hardness Surface Г 51...59HRC 236-1007010-В2 Steel 40ХC2М GOST 5632-72 the rest of surfaces 35...44 HRC 236-1007015-В6 Steel 55Х20G9АN4 (ЭP303) 32...37 HRC 53...62 HRC GOST 5632-72 Rod end - Steel 40ХН...
  • Page 105 Inspection. To reject Cracks and breaks of the valve х Magnifier ЛП-1-7 Corrosion on the surfaces- Inspection of the valve To process till the elimination Wear, grooves and burning of the defect -Dimension Д: Inspection. out on the working chamfer To process till the Б...
  • Page 106 for 236-1007010-В2 Wear of the valve rod Straightness tolerance Slab 2-1-400x400. « of the surface generator В 0.02 Gauge 0.2 mm 0.01 Note – Working valve face should be processed. Number of the defect Technical requirements for the repaired assembly unit 1 After the processing till the elimination of the defect dimension Д...

  • Page 107: Rocker Pivot

    Marking Name of the part or assembly unit Rocker pivot 236-1007091-Б2 Material Hardness Surface А 54…59 НRC; I. 236-1007092-Б2 – steel 45 the rest surfaces GOST 1050-88 carbon 0.42...0.47% 167…212 НВ Method Dimension and parameter, mm defect detection and means of control maximum allowable Possible defect...
  • Page 108 Marking Name of the part or assembly unit Valve rocker with the liner 236-1007144-В2 Adjusting screw of the rocker 236-1007148-Б Nut М12х1 311516-П2 Material Hardness 1. Surface Г 57...64 HRC 1. 236-1007146-В2 – Steel 40Х GOST 1050-88 the rest of surfaces 167...212 HB 2.

  • Page 109: Push Rod

    Cracks and breaks Inspection. To reject Inspection of the rocker Е Wear at the spherical surface Inspection. х To replace the adjusting screw Magnifier ЛП-1-7 of the adjusting screw Wear of the slot of the The same adjusting- Inspection of Б...
  • Page 110 Number of the defect Technical requirements for the repaired assembly unit 1 Parallelity tolerance of the surface generator Г relatively to the axis of surface Д – 0.15 mm for the length 100 mm 2.Roughness of the surfaces Г after the processing till the elimination of the defect should not exceed Ra 1.6 micron according to the GOST 2789-73...
  • Page 111 Marking Name of the part or assembly unit Push rod 236-1007176-А2 Material Hardness Pipe В45 GOST 8733-74 53 HRC, no less Method Dimension and parameter, mm defect detection and means of control maximum allowable Possible defect Conclusion without repair for repair nominal Inspection.
  • Page 112 Marking Name of the part or assembly unit Picture is on the next page 7511.1007180 Push rod Material Hardness I. 236-1007184-V –steel 45 GOST 801-78 II. 7511.1007190 -steel ШХ15 I 167...212HB IV. 7511.1007199 -GOST 801-78 III. 201-1007194 – steel 15ХФ 59...64HRC -----------------------GOST 4543-71 III 59...64HRC...

  • Page 114: Lifter

    Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair Ж +0,039 Chipping of the roller at the Ø50 To replace the roller Inspection. working surface х Magnifier ЛП-1-7 Г...
  • Page 115 Number of the defect Technical requirements for the repaired assembly unit 1 Parallelity tolerance of the surface J relatively to the axis of the hole Г – 0.06 mm 2 Roller axis position. III should be locked using the punching in three points from the both sides. Roller position II should wind easily without sticking...
  • Page 116 Marking Name of the part or assembly unit Outer lifter pin 236-1007238 Centre lifter pin 236-1007242 Material Hardness Surface В at the site Б Steel В45 GOST 8733-87 52…64 НRC Way for defect detection and Dimension and parameter, mm means of control maximum allowable Possible defect Conclusion...
  • Page 117 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair А Thread stripping КГ1/4" Inspection To calibrate the thread OST37.001.311-83 no more than one thread Number of the defect Technical requirements for the repaired assembly unit 1 Straightness tolerance of the surface generator B: - 0.05 mm 2 Roughness of the surface B should not exceed Ra 0.63 micron according to the GOST 2789-73...

  • Page 118: Two-Section Oil Pump

    1011. Two-section oil pump. Name of the part or assembly unit Marking Picture is on the next page 236-1011015-Г Body of the main section of the oil pump Adjusting pin 206V-1011037 Pins 240-1005586-01 Material Hardness I. 236-1011020-Г – special cast iron II.
  • Page 120 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair И Dimension Л: Wear or scuffs from the gears To reject Inspection. at the face surface 0.046 Depth gauge Scuffs ШГ-160 are not permitted...
  • Page 121 Marking Name of the part or assembly unit Picture is on the next page Body of the radiator section of the oil pump 236-1011019-Б Material Hardness I. 236-1011021-V – СЧ15 II. 236-1011034 – БрОЦС4-4-2,5 Method of detection Dimension and parameter, mm of the defect and method control maximum allowable...
  • Page 123 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair Д 43,07 Inside gauge To reject Wear of the seat surfacesfor the gears Ж 50-100 To calibrate the Thread stripping no more Inspection thread...
  • Page 124 Marking Name of the part or assembly unit Picture is on the next page Drive gear of the main section 236-1011030-Б Material Hardness I. 236-1011032-Б – steel 40ХР 26…30 НRC II. 236-1011025-Б – steel 15ХФ 53…64 НRC Method of detection Dimension and parameter, mm of the defect and method control...
  • Page 126 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair Б Dimension И: Wear of the gear height Clamp СР 75 To reject Е А Clamp СРП25 Wear of the axis surface for To replace the axis the body bushing and drive Ж...
  • Page 127 Marking Name of the part or assembly unit Picture is on the next page Drive gear of the main section 236-1011030-Б Material Hardness I. 236-1011032-Б – steel 40ХР 26…30 НRC II. 236-1011025-Б – steel 15ХФ 53…64 НRC Method of detection Dimension and parameter, mm of the defect and method control...
  • Page 129 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair Г Clamp СРП50 Wear of the gear according to To reject the externalteeth diameter Dimension Ж: Clamp СРП25 Wear of the gear height «...

  • Page 130: Flow Regulation Valve

    Technical requirements for the repaired assembly unit 1 Circular runout tolerance of the surface B relatively to the general surface axis A and Д – 0.01 mm 2 Roughness of the surfaces А and Д should not exceed Ra 0.63 micron according to the GOST 2789-73 Marking Name of the part or assembly unit 236-1011048-Б...
  • Page 131 « Thread stripping no more than М22х1-6g(for 236-1011363-Б) Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair А М24 х1-6g(for 236-1011048- Б) Notes 1 Opening start of the flow regulation valve 236-1011048-Б under the pressure in the cavitation В from 0.7 to 0.8 МPа (from 7 to 8 kfg/cm 2 ) should be provided with the installation of the washers 312485-П2 with the amount no less than 3.

  • Page 132: Radiator Section Drive Gear

    Marking Name of the part or assembly unit 236-1011100 Radiator section drive gear 236-1011114 Radiator section idle gear Material Hardness Steel 40ХР 24…28 HRC Way for defect detection Dimension and parameter, mm and means of control maximum allowable Possible defect Conclusion nominal without repair...
  • Page 133 А Clamp СРП 50 Wear of the gear at the external « Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair В +0,027 Ø16 16,04 To reject Inside gauge Wear of the hole for the axis or shaft...
  • Page 134 Marking Name of the part or assembly unit 236-1011202A Idler gear of the oil pump drive with the bushing Material Hardness 236-1011240-A Steel 40X 450 HV, no less 2361011206 – BроЦ4-4-2.5 Way for defect detection Dimension and parameter, mm and means of control maximum allowable Possible defect Conclusion...
  • Page 135 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair А Dimension Г: Clamp СРП 25 Wear of the face surface: To reject -0,084 В +0,039 Ø35 35,09 Wear of the bushing hole Inside gauge To replace the bushing...
  • Page 136 Marking Name of the part or assembly unit 236-1011208-Б Idler gear of the oil pump drive with the bushing Material Hardness Surface Д at the length G=18 min 57…64 НRC; the rest of the Steel 45 surfaces 169…212 НВ Way for defect detection Dimension and parameter, mm and means of control maximum allowable...
  • Page 137 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair В Thread stripping М12-6Н no Inspection To reject Scuffs are not permitted more than one thread Number of the Technical requirements for the repaired assembly unit defect 1 Perpendicularity tolerance of the surface A relatively to the surface Д...

  • Page 138: Gear Wheel Of The Oil Pump Drive

    Name of the part or assembly unit Marking Gear wheel of the oil pump drive pump 236-1011230-А Material Hardness Steel 40Х 241…286 НВ Way for defect detection Dimension and parameter, mm and means of control maximum allowable Possible defect Conclusion nominal without repair for repair...
  • Page 139 Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable Possible defect without repair for repair А Wear of teeth thickness Calibre To reject h=3,246 Г Wear of the key slot Dimension B « «...
  • Page 140 Grade 1011.One-section oil pump. Name of the part or assembly unit Marking OIL PUMP BODY 7511.1011015-10 Material Hardness 1. 75111011020-10 СЧ-21 GOST 1412-85 2. 238B-1011034 Бр ОЦС4-4-2.5 Picture is on the next page Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal...
  • Page 141 surfaces for the gears Ø43,07 To reject 4(Б) Wear, scuff, ring grooves at the surface of the seats for the gears +0,046 Depth gauge 65,09 To reject Loosening of the seating Proofing by hand To reject of the adjusting pins Thread stripping М8-6N Inspection 1 thread...

  • Page 143: Oil Pump Cover

    Name of the part or assembly unit Marking OIL PUMP COVER 238B-1011019-Б Material Hardness 236-1011021-G 1. 238B-1011021B special cast iron Picture is on the next page 2. 238B-1011034 Бр ОЦС 4-4-2.5 Possible defect Way for defect detection Dimension and parameter, mm Conclusion and means of control nominal...

  • Page 145: Oil Feed Gear Wheel

    Name of the part or assembly unit Marking OIL FEED GEAR WHEEL 7511.1011030 Material Hardness Steel 40ХFА GOST 4543-71 Nitrogen hardening 241...286 HB ≥575HV h 0.25…0.5 mm Possible defect Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable without repair...
  • Page 146 Д2 Wear of the axis surface Clamp To float, to chrome plate for the body bushings with the following 17,95 processing according to the drawing Wear of the face Micrometer To reject surface or ring grooves 64,85...

  • Page 147: Oil Feed Drive Gear

    Name of the part or assembly unit Marking OIL FEED DRIVE GEAR 7511.1011040 Material Hardness Steel 40ХFА GOST 4543-71 Nitrogen hardening 241...286 HB ≥575HV h 0.25…0.5 mm Possible defect Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable without repair...
  • Page 148 4(Б) Д2 Wear of the axis surface Clamp To float, to chrome plate for the body bushings with the following 17,95 processing according to the drawing Wear of the face Micrometer To reject surfaces or ring grooves 64,85 Wear of the key slot at its Plug To reject width...

  • Page 149: Flow Regulation Valve

    Name of the part or assembly unit Marking See the following picture 238Б FLOW REGULATION VALVE -1011048 Material Hardness Possible defect Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable without repair without repair Thread stripping of the Inspection To reject...

  • Page 151: Differential Valve

    Name of the part or assembly unit Marking See the following picture DIFFERENTIAL VALVE OF THE LUBRICATING SYSTEM 236-1011056-А 238Б-1011056 Material Hardness Possible defect Way for defect detection and Dimension and parameter, mm Conclusion means of control nominal maximum allowable without repair without repair Stripping of the fitting...
  • Page 152 Technical requirements for the repaired part Start of the opening of the valve 23160-11056-А under the pressure in the cavity А 520…560 kPa (5.2…5.6 kfg/cm 2 ) and should be provided installation of the part 312668-П total amount no more than 5 pcs. Rings 240-1005586-01 to replace...
  • Page 153 Marking Name of the part or assembly unit Picture is on the next page IDLER GEAR OF THE OIL PUMP DRIVE 1011202-А 236- Material Hardness 241...286 HB Steel 40Х GOST 4543-71 (gears) Band DPRNP 1.5 Bр Nitrogen hardening ≥450HV ОTSS4-4-2.5 h 0.15…0.35 mm GOST 15885-77 (bushings) Dimension and parameter, mm...
  • Page 154 Chipping of the working To reject Ruler-300 surface of the teeth Square GOST 427-75 (pitting) 50 mm 2 С Wear of the surface of the tooth To reject Calibre, gear gauge, at the thickness at template ∅3.925 −0.01 h=3.246 -0.07 А...
  • Page 156 Marking Picture is on the Name of the part or assembly unit next page IDLER GEAR SHAFT 236-1011208-Б Material Hardness 169...212 HB Surface А 57…64 Steel 45 GOST 1050-74 ТВЧ h1...2 Dimension and parameter, mm Method defect detection and control means maximum allowable Possible defect...
  • Page 157 Stripping of the thread Inspection. in the holes М12-6Н To reject 1 thread 3 (A) Wear of the bearing surface Micrometer To chrome plate, МК50-1 GOST 6507-78 float and to process according to the drawing 236-1011208-ВР To chrome plate, float and process according 4(В) Depth gauge...
  • Page 159 1012. Oil filter Marking Picture is on the Name of the part or assembly unit next page 658.1012020 Filter body Material Hardness СЧ15 СЧ-21 or Dimension and parameter, mm Method defect detection and means maximum allowable Possible defect of control Conclusion nominal without repair...
  • Page 161 1028. Centrifugal oil cleaner. Marking Name of the part or assembly unit 236-1028020-Б2 Body of the centrifugal oil cleaner Material Hardness АК7М2Мг 80…120НВ Method Dimension and parameter, mm defect detection and means of control maximum allowable Possible defect Conclusion nominal without repair for repair Cracks and breaks...
  • Page 162 Marking Name of the part or assembly unit 236-1028031-А2 Centrifugal oil cleaner shaft Material Hardness Surfaces V and Г at the length J=16 mm 45…53 НRC, surface Д at the length Е=26 mm min 24…30 НRC; surface Б at the Steel 35 length I=4…4.5 mm 40…50 НRC;...
  • Page 163 Inspection To calibrate the thread Thread stripping no more than one thread: Д М12х1.25-6g М18-6h А Technical requirements for the repaired part Number of the defect 1 Axial runout tolerance of the surface B relatively to the surfaces В and Г – 0.025mm…………. 2 Roughness of the surfaces В...
  • Page 164 Marking Name of the part or assembly unit 236-1028184 Rotor body with the bushings Picture is on the next page Material Hardness I. АК7М2Мг 80-110 НВ II. 236-1028192 – steel 45 16…24 НRC III. 236-1028196 – БрОЦС4-4-2.5 Method Dimension and parameter, mm defect detection and means of control maximum allowable...
  • Page 166 Method Dimension and parameter, mm defect detection and means of control maximum allowable Possible defect Conclusion nominal without repair for repair Thread stripping no more than To calibrate the thread one thread: Inspection А М24х1.5-6g М8х1-6Н Г Technical requirements for the repaired assembly unit Number of the defect 1 Roughness of the surface B should not exceed Ra 1.25 micron according to the GOST 2789-73 ……………....
  • Page 167 Marking Name of the part or assembly unit 236-1028242 Rotor cover 236-1028250-Б Centrifugal oil cleaner shaft 25 3111 2666 019-025-36-2-1 Ring Material Hardness АК7М2Мг 80...120 HB 236.1028250-Б –Armamid ПА CB30-1 Method Dimension and parameter, mm defect detection and means of control maximum allowable Possible defect Conclusion...
  • Page 168 Cracks and breaks Inspection. To reject А +0,045 Ø25 Inside gauge 18-50 Wear and deformation of the hole (for 236-1028242) Note: rubber filler ring 019-025-36-2-1 should be replaced for new one...
  • Page 169 1029. Drive of high-pressure fuel pump Marking Name of the part or assembly unit 7511-1029116-10 Gear wheel of oil pump drive 236-1029122-A Gear wheel of the oil pump drive Material Hardness 7511.1029116-10 steel 40ХФА 241...286 HB ≥450 HV 236-1029122-А steel 40X Method Dimension and parameter, mm defect detection and means...
  • Page 170 Г Wear of the seating diameter Calibre To reject Wear of teeth thickness Inspection « Thread stripping М12-6Н no more than one thread (for 7511.1029116-10) To calibrate the thread h=3,218...
  • Page 171 Name of the part or assembly unit Marking 236-1029154-B Idler gear shaft of the fuel pump drive Material Hardness Г 241…286 НВ, on the surface Steel40 45...50 HRC Method Dimension and parameter, mm defect detection and means of control maximum allowable Possible defect Conclusion nominal...
  • Page 172 Д Wear of the shaft bearing for To reject Inspection the joint flange И To calibrate the thread Wear of the key slots Thread stripping М24х2-6g no more than two threads Technical requirements for the repaired part Number of the defect 1 Relatively to the axis of centres circular runout tolerance: - for surfaces B, В...
  • Page 173 Marking Name of the part or assembly unit 236-1029268-Г Drive coupling Material Hardness 23…29 HRC Steel 35Л Method Dimension and parameter, mm defect detection and means of control maximum allowable Possible defect Conclusion nominal without repair for repair Cracks or breaks Inspection To reject Inspection...
  • Page 174 Technical requirements for the repaired part Number of the defect 1 Parallelity tolerance of the general joining flatness of the surfaces А and Е relatively to the general joining flatness of the surfaces Б and Г– 0.15 mm...
  • Page 175 Marking Name of the part or assembly unit 236-1029286-Б2 Driven coupling Material Hardness 26…32 HRC Steel 35Л Method Dimension and parameter, mm defect detection and means of control maximum allowable Possible defect Conclusion nominal without repair for repair Cracks or breaks Inspection To reject To process the cuffs till...
  • Page 176 Technical requirements for the repaired part Number of the defect 1 Parallelity tolerance of the surface A relatively to the surface В –0.1 mm .........
  • Page 177 1115. Induction manifold Marking Name of the part or assembly unit See the table 9 Right induction manifold Left induction manifold Material Hardness 80 НВ, no less АК7М2Мг Method Dimension and parameter, mm defect detection and means of control maximum allowable Possible defect Conclusion nominal...
  • Page 178 induction manifold To reject Б Thread stripping no more than To calibrate the thread one thread: « М10-6Н М20х1.5-6Н...
  • Page 179 Table 3.1– Legend and name of the left and right induction manifolds Name of the part or assembly unit Marking Right induction manifold 236-1115021, 236-1115021-Б 238-1115021, 238-1115021-Б 236-1115024 Left induction manifold 236-1115024-Б 238-1115024-Б, 238-1115024-В Technical requirements for the repaired part Number of the defect 1 Tolerance for flatness of the surfaces B relatively to the total joining flatness - 0.2 mm..........................2 2 Dimension Г...
  • Page 180 1307. Water pump Name of the part or assembly unit Marking Water pump body 236-1307014-Ж Material Hardness СЧ21 170…241 HВ Dimension or parameter, mm Method of the defect detection and means of Possible defect Maximal allowable control Conclusion nominal Without repair For repair Inspection To reject...
  • Page 181 Inside gauge НИ 50-100- Wear of the hole for the To reject bearings Б Proofing of the To replace the pins Loosening of the seating of the pins: seating by hand Д M8x1,25 СП М10х1,5 СП Thread stripping no more To calibrate the thread than two threads: The same...
  • Page 182 1307. Water pump Name of the part or assembly unit Marking Water pump body 236-1307014-Д Material Hardness СЧ21 170…241 HВ Dimension or parameter, mm Method of the defect detection and means of Maximum allowable Possible defect control nominal Without repair For repair Conclusion Inspection...
  • Page 183 bearings +0,03 Ø52 To reject Loosening of the seating To replace the pins НИ 50- M8x1,25СП of the pins: Inside gauge 100-1 Thread stripping no more than two threads Proofing of the seating Б To calibrate the thread by hand M8x1-4h Inspection Technical requirements for the repaired assembly unit...
  • Page 184 Name of the part or assembly unit Marking Water pump roller 236-1307023-Г Marking Material Steel 40X13 32…44HRC Dimension or parameter, mm Method of the defect detection and means of Maximum allowable Possible defect control nominal Without repair For repair Conclusion Inspection To reject Cracks or breaks...
  • Page 185 Г Dimension Г: Wearing of the slot To process the new surfaces slot 3,01 displaced in a circular direction Clamp СРП 25 for 180 relatively to the worn To chrome plate Wear of the surface for the water pump vane To calibrate the thread Inspection Thread stripping no more...
  • Page 186 Name of the part or assembly unit Marking Water pump roller 850.1307023-10 Material Hardness Steel 40X13 26…32 HRC Dimension or parameter, mm Method of the defect detection and means of Maximum allowable Possible defect control nominal Without repair For repair Conclusion Inspection To reject...
  • Page 187 5 Roughness of the surface А should not exceed Ra 0.63 micron according to the GOST 2789-73 ……………………………………………………………………….3 Name of the part or assembly unit Marking 236-1307032-B2 Water pump vane 236-1307032-B2 Material Hardness СЧ21 120…200 HB Dimension or parameter, mm Method of the defect detection and means of Maximum allowable...
  • Page 188 Name of the part or assembly unit Marking Water pump vane 236-1307032-Г Material Hardness СЧ21 120…200 HB Dimension or parameter, mm Method of the defect detection and means of Possible defect Maximum allowable control Conclusion Without repair For repair nominal А...
  • Page 189 Name of the part or assembly unit Marking Water pump pulley 236-1307212-Б3 Material Hardness I. 236-1307216-B2 – СЧ15 149…229 HВ II. 236-1307218-Б3 – steel 20 III. 236-1307222-Б – steel 08кп Dimension or parameter, mm Method of the defect detection and means of Maximum allowable Possible defect control...
  • Page 190 Б of the side wall -0,3 Calibre Л Dimension Д: To process the new slot Wear of the key slot displaced in a circular о -0,3 direction at 180 relatively to the worn Dimension K: 3.10 Proofing of the seating by И...
  • Page 191 Name of the part or assembly unit Marking Pulley of the water pump drive 236-1307216-Г1 Material Hardness СЧ21 Dimension or parameter, mm Method of the defect detection and means of Maximum allowable Possible defect control nominal Without repair For repair Conclusion Inspection To reject...
  • Page 192 1308. Fan Name of the part or assembly unit Marking Picture is on the next page Fan propeller 236-1308012-А4 238-1308012-А4 Marking Material 236-1308012-А4: I. 236-1308015 steel 08кп II. 236-1308014- г 238-1308012-А4: I. 238-1308015 -A steel 08кп II. 236-1308014-Г Dimension or parameter, mm Method of the defect detection and means of Maximum allowable...
  • Page 193 Dimension and parameter, mm Method defect detection and...
  • Page 194 control means Possible defect Conclusion maximum allowable nominal without repair for repair Curved blade To flatten Inspection. Wear of the holes for the Facility +0,43 Ø11 Beam compass fastener bolts of the fan To reject using the ШЦ-I-125-0.1-1 proper parts Tapering the rivets with the Loosening of the rivets Г...
  • Page 195 Marking Name of the part or assembly unit 236-1308025-B2 Pulley of the compressor and generator drive Material Hardness СЧ15 Dimension and parameter, mm Method defect detection and means maximum allowable Possible defect of control Conclusion nominal without repair for repair Inspection.
  • Page 196 А Dimensions Б: Ø9 displaces it at 180° Generator -0,009 compressor relatively to the В 134.4 ±0.2 worn Dimensions Б: Ø14,7 -0,011 130.5 ±0.2 To reject Technical requirements for the repaired assembly unit Number of the defect 1 Symmetry tolerance of the key slot relatively to the surface Д – 0.08 mm as a radius …………………………………………………………………………3 2 Wore key slot should be marked with red paint ……………………………...
  • Page 197 Marking Name of the part or assembly unit 236HE-1308050-Д Shaft of the fan drive Material Hardness 241...286 HB ≥450 HV Steel 40X Dimension and parameter, mm Method maximum allowable Possible defect defect detection and means Conclusion without repair for repair of control nominal Inspection.
  • Page 198 К И Calibre Dimension Thread stripping М22х1,5- To process the new Б, Ж 6.02 Inspection slot displaced in a circular о 6g no more than two threads: direction at 180 relatively to the worn one To calibrate the thread Technical requirements for the repaired assembly unit Number of the defect 1 Circular runout tolerance of the surfaces Г...
  • Page 199 Marking Name of the part or assembly unit 236-1308055 Collar of the bushing Material Hardness Surface А 45.5…53 HRC, no less than the rest of the surfaces 166 НВ, no less than Steel 45 Dimension and parameter, mm Method defect detection and means maximum allowable of control Possible defect...
  • Page 200 Marking Name of the part or assembly unit Body of the fan drive 236HE-1308102-Б2 Material Hardness 80 НВ, no less АК7М2Мг Dimension and parameter, mm Method defect detection and means maximum allowable Possible defect of control Conclusion nominal without repair for repair Inspection.
  • Page 201 To calibrate the thread Г M16х1,5- Thread stripping Inspection no more than two threads...
  • Page 202 Marking Name of the part or assembly unit Gear of the drive 236-1308104-B Material Hardness 525 HB , no less Steel 40XФА Dimension and parameter, mm Method defect detection and means maximum allowable of control Possible defect Conclusion nominal without repair for repair Inspection.
  • Page 203 Marking Name of the part or assembly unit 182.1601093-10 Pressure disk Material Hardness 200...241 HB СЧ25 Dimension and parameter, mm Method defect detection and means maximum allowable Possible defect of control Conclusion nominal without repair for repair Inspection. Cracks or breaks To reject Scuffs, hit tints or corrosion «...
  • Page 204 Note: working surface Д is subject to obligatory treatment Technical requirements for the repaired assembly unit Number of the defect 1 Metal protrusion from the scuffs and dints at the surfaces of the disk are not permit …………………………………………………………………………..2 2 Dimension B after the processing should be no more than 27.4 mm ………………………. …………………………………………………………………. 3...
  • Page 205 Marking Name of the part or assembly unit Clutch pressure disk 238-1601093 238H-1601093 Material Hardness 170...241 HB СЧ24 Dimension and parameter, mm Method defect detection and means maximum allowable Possible defect of control Conclusion nominal without repair for repair Inspection. To reject Cracks or breaks Scuffs or wear at the working...
  • Page 206 В Dimension Б: Wear of the eye slots for the « Inside gauge НИ 10-18-1 pressure disk levers 16.3 To build up and process till the nominal Ж dimension Б Wear of the studs Dimension E: Micrometer МК 75-1 59.7 59.5 -0,06 Note –...
  • Page 207 Marking Name of the part or assembly unit Centre clutch driving disk 238-1601094-Г Material Hardness СЧ21 170...241 HB Possible defect Method Dimension and parameter, mm Conclusion defect detection and means maximum allowable of control nominal without repair for repair Inspection. To reject Cracks or breaks Dimension Б:...
  • Page 208 Technical requirements for the repaired assembly unit Number of the defect 1 Tolerance for flatness of the surfaces A: - 0.07 mm……………………………………………………………………………………………………………….2 2 Cumulative tolerance of parallelity and flatness of the surfaces А – 0.15 mm…………………………………………………………………………………….2 3 After the processing till the elimination of the defect dimension B should be no less than 30.0 mm……………………………………………………………..2...
  • Page 209 Marking Name of the part or assembly unit 181.1601115 Clutch pressure spring 182.1601115 Material Hardness 43...48 HRC Steel 50XГФА Dimension and parameter, mm maximum allowable Method defect detection and means nominal Possible defect of control Conclusion without repair for repair Inspection.
  • Page 210 Marking Name of the part or assembly unit See the chapter 1 in the table 10 Springs (see the chapter 2 in the table 10) Material Hardness See the chapter 3 in the table 10 Dimension and parameter, mm Method defect detection and means maximum allowable of control...
  • Page 211 Table 3.2–Legend, name, material of the springs and parameters for their control Length l 1 with the deformation under the impact Legend Name Material Length l in the free Axial force of the condition according to spring according to the of the axial force, mm the drawing, mm drawing, F (kfg)
  • Page 212 4 Assembly of the main assembly components of the engine 4.1. Cylinder block 4.1.1 All passages and holes including threaded, cylinder block should be blown with the compressed air. Oil, water and other fluids are not permitted in the blind threaded holes. 4.1.2 Before screwing of the plugs of the oil passages for two - three threads one should lubricate them with "Anagerm-100"...
  • Page 213 Scheme of the cylinder numbering of six-cylinder engines ЯМЗandeight-cylinder engines ЯМЗ is on the picture 4.1. The right cylinder row Right cylinder row Picture 4.1- Scheme of the cylinder numbering Left cylinder row (Flywheel) Left cylinder row (Flywheel) (Flywheel) 4.1.5 Liners should overhand the joint face of the block with the cylinder head for the interval from 0.06 to 0.16 mm.
  • Page 214 Picture 4.2 – Cylinder head with manifolds 1 – spring cap 236-1007024-V; 2 – cap liner 236-1007026-Б; 3 – eduction valve 236- 1007015-В4; 4 – valve cotter 236-1007028-А; 5 – induction valve 236-1007010-V; 6 – assembled collar of the induction valve 236-1007262; 7 – assembled cylinder hear 238-1003013-D3;...
  • Page 215 4.2.7 Collars 6 should be installed at the guide bushings of the induction valves. 4.2.8 Cotters 4 should be fitted tight to the surfaces of the valve rods 3, 5 and cap liners 2. Free removing of the caps 1 and cotters 4 relatively to the valve rods after the assembling is not permitted.
  • Page 216 the upper connecting rod hear 7. 4.3.5 Before the assembling bushing of the upper connecting rod head 7 and piston pin 5 should be lubricated with oil which is used in the lubrication system of the engine. 4.3.6 Before the assembling piston 1 with the connecting rod 7 should be heated in the oil to the temperature from 353 to 373 K (from 80 to 100 °...
  • Page 217 Picture 4.3 - Piston with the connecting rod and rings 1 – piston 236-1004015-D; 2 – piston ring compression upper 236-1004030-Б; 3 – piston ring compression 236-1004032-А3; 4 – oil-control piston ring 236-1004034; 5 – piston pin 236-1004020 or 236-1004020-01; 6 – bearing spring ring 236- 1004022-Б2;...
  • Page 218 4.4.4 Nut 1 of the gear retaining 3 and counter balance 2 should be tightened with the moment of force from 180 to 300 Nwm (from 18.0 to 30.0 kfg m) and locked using the bending of the overhang of the washer edge into the nut slot. 4.4.5 Back oil deflector 5 should be pressed on the crankshaft bearing so that the dimension B was from 0.5 to 1.5 mm and locked using the pressing of the oil reflector edge into four holes n the crankshaft bearing.
  • Page 219 Picture 4.4 – Crankshaft 238-1005008-Г2 1 – circular nut 236-1005055; 2 – front counter balance 238-1005026-Б; 3 – gear 236-1005030-А; 4 – plug 313933-P; 5 – oil deflector 236-1005043; 6 – pin 236-1005042; 7 – crankshaft 238-1005015-Г;А , Б, В – dimension; Г – surface...
  • Page 220 Picture 4.5 – Camshaft 238-1006010-Б5 1 – camshaft drive gear 236-1006214-Г2; 2 – drive gear of fuel pump 236-1029116-А; 3 – camshaft thrust flange 236-1006236-Б; 4 – camshaft 238-1006015-Г3; 5 – locking washer 312580-П2; 6 – nut 311412-П2; 7 – bolt 310130-П2; А – dimension 4.6 Oil pump 4.6.1 During assemble friction surfaces should of the pump parts should be lubricated with oil I- 12A.

  • Page 221: Idler Gear Of The Drive

    Picture 4.6 – Oil pump 236-1011014-В3 1 – idler gear of the drive 236-1011202-А; 2 – idler gear axis of the drive 236-1011208-В; 3 – bolt 310156-П2; 4 –drive gear of the main section 236-1011040-Б; 5 – gear wheel of the main section 236-1011030-Б; 6 – gear wheel of the drive 236- 1011230-А;...
  • Page 222 4.6.5 Thrust flange 7 should be tightened with the moment of force from 62 to 80 Nwm (from 6.2 to 8.0 kfg m). 4.6.6 Clearance A between face surface of the thrust flange 7 and idler gear 1 should be from 0.13 to 0.35 mm.
  • Page 223 Picture 4.7 – Oil filter 238Б-1012010-Б2 1 – filter body 238Б-1012020-Г; 2 – locking cover 840.1012051-11; 3 – cap with spring 238Б- 1012077-Б2; 4 – filtering element 840.1012040-12 or 840.1012040-14 or 840.1012040-15; 5 – ring 840.1012083-20; 6 – washer 312347-П29; 7 – plunger of the overload relief valve 206D-1011055- А;...
  • Page 224 4.7.2 Overload relief valve should be adjusted for the opening at the overload pressure in the cavity Б: ) – for filters 236-1012010-А3 and 238Б-1012010-А; - from 0.18 to 0.23 MPa (from 1.8 to 2.3 kfg/cm ) – for filter 238Б-1012010-Б2. Adjusting should be - from 0.20 to 0.25 MPa (from 2.0 to 2.5 kfg/cm performed by choosing the necessary quantity of the washers.
  • Page 225 4.8 Centrifugal oil cleaner 4.8.1 During assembling friction surfaces of the oil cleaner parts as well as filler rings 2 and 7 (picture 4.8) should be lubricated with the oil И-12А. 4.8.2 Oil cleaner shaft 9 should be tightened with the moment of force from 70 to 90 Nwm (from 7.0 to 9.0 kfg·m).

  • Page 226: Centrifugal Oil Cleaner Shaft

    Picture 4.8 –Centrifugal oil cleaner 1 – Cap nut 312101-П29; 2 – ring 019–025–36–2–1 GOST 18829-73; 3 – nut 250615-П29; 4 – nut 311808-П2; 5 – rotor cap 236-1028242; 6 – cap of the centrifugal oil cleaner 236-1028250-Б; 7 – filler ring 236-1028246; 8 – housing of the rotor with the bushings 236- 1028184;...
  • Page 227 4.9 Coarse fuel filter 204А-1105510-Б 4.9.1 Bolts 1 (picture10) of the flange fastener 4 with the cap3 and filtering element to the filter body 2 should be tightened till the hard stop. 4.9.2 Filter should be tested for sealing with the air under the pressure from 0.3 to 0.4 MPa (from 3 to 4 ) dipping in water heated to the temperature from 313 to 323 К...
  • Page 228 It is allowed to test the filter for sealing using the diesel fuel oil under the working pressure in the fuel system. Fuel leakage is not permitted. 4.10 Fine fuel filter 236-1117010-А3, 236-1117010-А4 4.10.1 Jet valve should be adjusted for the opening at the overpressure in the cavity B from 20 to 40 kPa (from 0.2 to 0.4 kfg/cm ) (only for filter 236-1117010-А4).
  • Page 229 Picture 4.10 – Fine fuel filter 236-1117010-А4 1 – plug 316121-П29; 2 – filter bolt 201-1117122-Б; 3 – filter cover 236-1117028-V; 4 – filler ring 236-1117032; 5 – filter cap 201-1117016-Б2; 6 – jet 240N-1117155-Б; 7 – washer 252002-П29; Б – cavity...
  • Page 230 4.11 Water pump 236-1307010-А3 4.11.1 Assembling the filler ring 7 (picture 4.10) and 12, bearings 2 should be lubricated with the grease Litol-24, and cavity А between the bearings should be filled with this grease for 2/3 of the volume. 4.11.2 Water ejecting device should be pressed on the roll 5 so that the dimension B was from 48.5 to 49.5 mm.
  • Page 231 Picture 4.10 – Water pump 236-1307010-А3 1 – body 236-1307014-Г; 2 – bearing 160703; 3 – washer 312536-П29; 4 – nut 250636-П29; 5 – roller 236-1307023-В2; 6 – water ejecting device 201-1307026-А; 7 – ring 034-035-25-2-1 GOST 9833-73; 8 – thrust washer 236-1307035-А3; 9 – washer 312484-P; 10 –...
  • Page 232 4.12 Water pump 236-1307010-Б2 4.12.1 Assembling the filler ring 7 (picture 4.11) and 8, bearings 4 should be lubricated with the grease Litol-24, and cavity Д between the bearings should be filled with this grease for 4/5 of the volume (about 60 Г of the grease). 4.12.2 Bearings 4 should be pressed at the roller 5 till the hard stop with the sides without seals to the cavity Д.
  • Page 233 Picture 4.11 –Water pump 236-1307010-Б2 1 – water pump manifold 236-1307084-А; 2 – vane 236-1307032-В2; 3 – water pump body 236- 1307014-Д; 4 – bearing 1160304К; 5 – pulley 236-1307216-Г15; 6 – water pump roller 850.1307023-10; 7 – filler ring 240-1005582-Б; 8 –...
  • Page 234 cavity; Ж – dimension 4.13 Tension machine 236-1307155-А 4.13.1 Assembling bearings 3 (picture 4.12) should be lubricated with the grease Litol-24, and cavity А of the pulley between the bearings should be filled with this grease for 3/4 of the volume. 4.13.2 Bearings 3 should be pressed with the sides without sealing to the cavity А.
  • Page 235 Corrosion, oil and other impurities in the joints are not permitted. Picture 4.13 – Fan drive 236НЕ-1308011-И 1- 236-1308090-В2- flexible coupling; 2- 236НЕ-1308100 - body; 3- 236-1029034-thrust washer; 4- 236-1308025-В2 - pulley; 5 - 236НЕ-1308050-Д - shaft; 6- 236-1308055-Б2 - collar of the bushing;...
  • Page 236 5 ЯМЗ engine assembly 5.1 Lifters and camshaft installation 5.1.1 Bearing journal of the camshaft should be single, nominal or categoric repair dimensions with the camshaft bushings installed in the cylinder block. 5.1.2 Push rod bushings, push rods, bushings should be lubricated with the oil which is applied in the lubrication system of the engine.
  • Page 237 5.2 Crankshaft installation 5.2.1 Crankshaft bearing liners should be single, nominal or categorical repair dimensions with the crankshaft bearings. 5.2.2 Before the installation of the crankshaft crank bearings, crankshaft bearing liners, block surfaces and crankshaft bearing caps for the liners as well as joining surfaces of the block and caps joint faces should be carefully wiped with fiberless napkins 5.2.3 Crankshaft bearing liners should fit tightly the bearings of the cylinder block and crankshaft bearings caps at that liners extrusions should coincide the corresponding grooves of the...
  • Page 238 Б (increased) A (increased) Picture 5.1– Installation of the drive gears of the devices 1 – gear of the fuel pump drive 236-1029122А; 2 – camshaft gear 236-1006214-Г2; 3 – crankshaft pulley 236-1005061-В; 4 – crankshaft gear 236-1005030-А...
  • Page 239 5.2.8 Axial clearance in the crankshaft bearing should be from 0.08 to 0.31 mm. 5.2.9 Crankshaft bearings caps should be fastened in the following order: - to tighten the fastening bolts of the crankshaft bearing caps no less than in three steps with the moment of force from 421 to 461 Nwm (from 42 to 46 kfg·m);...
  • Page 240 connecting rod joints and caps should be properly wiped with the fiberless napkins. 5.4.3 Liners should fit tightly the lower connecting rod heads and connecting rod caps at that liners extrusions should coincide the corresponding grooves of the connecting rods and caps. 5.4.4 Before the installation of the piston in the cylinder liners locks of the compression and oil- control rings should be installed with the angle 180°...
  • Page 241 4.8.5 Fastening bolt of the crankshaft pulley should be tightened with the moment of force from 200 to 300 Nwm (from 20.0 to 30.0 kfg·m). 5.6 Installation of the flywheel housing and flywheel 5.6.1 Main drive shaft cuff of the transmission gear box should be pressed in the cuff housing with the side with the marking inside into the collar of the housing till the hard stop.
  • Page 242 5.7 Installation of the oil pump 5.7.1 Oil pump should be installed so that the side clearance in the crankshaft gears engagement and idler gear of the oil pump was from 0.25 to 0.37 mm. Clearance is provided with the choosing of the shim washers which are installed between the pump body and the cap of the bush bearing of the crankshaft.
  • Page 243 Picture 5.2 – Sequence chart of the tightening of the fastening nuts of the block heads of the six-cylinder engine Picture 5.3 –Sequence chart of the tightening of the fastening nuts of the block heads of the eight-cylinder engine 5.10 Installation of the push rods and rockers with pivots, adjusting of the heat clearance of the valves in the valve mechanism 5.10.1 Before the installation spherical surfaces of the push rods should be lubricated with oil which is applied in the engine lubrication system.
  • Page 244 Adjusting of the clearances should be performed with the closed valves at the compression stroke in the following consequence: a) to rotate the crankshaft clock-wise (looking from the side of the fan drive) till the moment when the eduction valve of the first cylinder will be completely lifted (completely closed), after that to rotate the shaft for 1/4 –...
  • Page 245 Picture 5.4 –Installation of the high-pressure fuel pump 1 – half-coupling flange with the plates 236-1029260-В2; 2 – driven half-coupling 236-1029286-Б; 3 – coupling of the lead fuel injection 60.1121010-12; 4 – plates 236-1029274; 5 – bolt 310055-П29; 6 – nut 250513-П29; 7 – bolt 310003-П29; 8 – bolt 240-1029284-Б half-coupling flange;...

  • Page 246: Drive Coupling

    - to install and fasten the high-pressure fuel pump on the cylinder block; - to join and fasten using the bolts 5 the plates 4 of the drive coupling to the driven half- coupling 2. Moment of force of the bolt tightening should be from 32 to 40 Nwm (from 3.2 to 4.0 kfg·m);...
  • Page 247 from 32 to 36 Nwm (from 3.2 to 3.6 kfg m). Note – To rotate the lever of the tension machine supportthe hole with diameter 12.5 mm for the tap is provided. 5.14 Installation of the compressor and compressor drive belt 5.14.1 Fastening bolts of the compressor should be tightened with the moment of force from 28 to 36 Nwm (from 2.8 to 3.6 kfg m).
  • Page 248 - to install the generator at the support and to fasten its front side with the bolt with washer, the back side with the nut with washer, do not tighten; - to install the plate and to fasten at the engine with the nut with washer, at the generator - with the bolt and nut with washer, do not tighten;...
  • Page 249 of splined arbor installed into the spline hole of the disk hub and bearing pressed into the hole of the crankshaft shaft. 5.17.5 Driven disk should move free without constraints at the splines of the arbour. 5.17.6 Fastening bolts of the pressure disk to the flywheel should be tightened with the moment of force from 40 to 50 Nwm (from 4 to 5 kfg m) cross-wise in several steps, equally pulling the pressure disk with the housing to the flywheel without drunkenness of the pressure spring.
  • Page 250 till the hard stop in the clutch housing. Picture 5.5 –Installation of the double-disk clutch (view at the device adjusting of the centre disk return) 1 – rod 238-1601302; 2 – plate 238-1601308; 3 – coil spring 238-1601105; 4 – thrust ring 238-1601304; 5 – back driven disk 238-1601131; 6 – centre drive disk 238- 1601092;...
  • Page 251 6 General requirements for the engine running-in, timing and engine acceptance test These requirements are extended to after-sale service of the engines OJSC "Avtodizel" as to the repair with the replacement of the basic parts (cylinder block) and main repair (repair without responsibility with the complete disassembling of the unit-power plant) in the warranty period of operation and post warranty period.

  • Page 252: Induction Manifold

    measuring limits to 10 kg, time countdown using the seconds counter with the division value 0.1 sec, measurement of the rotation rate using the hand tachometer or tachoscope with the division value no more than 10 min 6.1.4 Volume of the measuring box should be 6-8 l, bottom position of the measuring box from the axis of the inlet opening of the fuel feed pump should be no less than 500 mm.
  • Page 253 6.1.12 Each engine which is tested and run-in should have the control chart where the accepted test results are recorded. 6.2 Engine preparation for the starting-up 6.2.1 One should begin the running-up and testing having checked the operability of the engine, availability of the fuel, coolant and oil in the corresponding systems.
  • Page 254 no more than 2 drops a minute at the nominal rotation rate of the crankshaft. - coolant leakage or its mixture with the sealant from the drainage hole of the water pump at any operation mode as well as at the engine stop is allowed no more than one drop in 3 minutes. - leakage of the separate drops of fuel and oil mixture from the induction manifolds in the period of running-in.
  • Page 255 repeatedly it is recommended to press: - at the head of the right row of the cylinders of the induction valves rocker -to the thrust ring, eduction valves - to the pivot face. Eduction valves of the right row of the cylinders are located close to the fan, left row - to the flywheel.
  • Page 256 It is recommended to adjust valve clearances in order of the cylinder operation: for engine ЯМЗ-236M2: 1-4-2-5-3-6 for engine ЯМЗ-238M2: 1-5-4-2-6-3-7-8 -After the adjustment of the clearances to start the engine and to listen to its operation. If there are any hammering of the valves to stop the engine and to check the clearances once more. - To install and to fasten the cylinder head caps, to check the condition of the valves.
  • Page 257 Table 6.3 – ЯМЗ-238M2, ЯМЗ-238ВM Fuel Capacity kWt Specific gravity, g/cm3 temperature, (H.P.) of the ºC fuel 0.825 0.830 0.835 0.840 0.845 consumption, kg/h 170 (231) 171 (232) 171.5 (233) 172 (234) 173 (235) 41.3 41.5 41.8 42.1 42.4 169 (230) 170 (231) 171 (232) 171.5 (233)
  • Page 258 155 (211) 156.5 (213) 157 (214) 158 (216) 159 (217) 37.4 37.6 37.8 38.0 38.3 154 (210) 155 (211) 156 (212) 157 (214) 157 (215) 37.2 37.4 37.6 37.8 38.0 Allowances for capacity in accordance with the atmospheric conditions are given in the tables 6.5, 6.6.
  • Page 259 Picture 6.1 – Scheme of the rotation rate regulation. 1 – Capacity adjustment screw 2 – Damping spring case 3 – Cap nut Where ºC is the fuel temperature in the measure box at the braking moment Ne – capacity produced by the engine at the braking moment, kWt (H.P) Gt –...
  • Page 260 Picture 6.2 - Scheme of the rotation rate regulator (left-side view) 1 - Bolt for the limiting of the maximal rotation rate 2 - Bolt for the limiting of the minimal rotation rate Engine should run idle steadily with the vibrations no more than +- 15min- 1 . 6.4.3.6 To check the device of minimal idle rotation rate with connected electric break after the increase of the crankshaft rotation rate to 1200-1300 min- and sudden press off of the operating...
  • Page 261 6.5 Acceptance test 6.5.1 Acceptance test is performed by the representative of the technical control of the manufacturer to check the compliance of the engines with the regulatory and technical documentation and this manual. 6.5.2 Engines that were technologically run-in and timed according to the chapters 6.3 and 6.4 with the enclosure of the inspection sheets can be presented for the test.
  • Page 262 than: 236M2-31 kg/h 238M2- 41.5 kg/h 236Д- 31.0 kg/h To check 2200-2275 no more maximal than 2340 for -236M2 and ЯМЗ-238M2 650…700 for -236M2 and ЯМЗ-238M2 minimal idle rotation rate Table 6.8 – ЯМЗ-238ВM Number of the mode Rotation rate, min-1 Load capacity, kWt (H.P.) Time, min 1.
  • Page 263 To check the sealing of the fuel system joints of the electric torch during the engine operation at the minimal idle rotation rate in 30 sec after the magnetic valve was turned on. Power for valve turn on is 24V. Fuel leakage is not permitted. 6.6 Modes for the engine running-in.
  • Page 264 To perform hot running-in: - for national economy according to the modes in the tables 6.10, 6.11 - for the Ministry of Defense of the Russian Federation and export according to the modes in the tables 6.12, 6.13, 6.14 Table 6.10 – ЯМЗ-236M2, ЯМЗ-238M2, ЯМЗ-238AM2, ЯМЗ-238KM2 Number of the mode Rotation rate, Load capacity, kWt (H.P.)
  • Page 265 Table 6.14 - ЯМЗ-238ГМ2 Number of the Rounds per minute, Loading, kW (H.P.) ЯМЗ-238ГM2 mode min-1 Time, min 1500 1600 22(30) 1700 44(60) 1700 66(90) 1700 88(120) 1700 103(140) 1700 110(150) c) To turn off the engine gradually decreasing the loading and rotation rate. To tighten the nuts of the fastening of the cylinder heads.To check and, if necessary, to adjust the clearances in the valve operating mechanism and the angle of the lead of fuel injection.
  • Page 266 *1 – for the Ministry of Defense of the Russian Federation and export; *2 – for national economy 6.7.2 After the replacement of the cylinder block, crankshaft, camshaft, one or several pistons or liners, more than a half of the gaskets of the crank and main bearings as well as more than two piston rings one should perform running-in completely according to the basic mode with the following acceptance test.
  • Page 267 SUPPLEMENTS Supplement A - Standardized jigs, fixtures and tools Indicator ICH05 kl.0 GOST 577-68. Ruler -150 GOST 427-75. Straight edge GOST 8026-92; - ruler ШП-2-400; - ruler ШП-2-400; Folded pocket magnifiers GOST 25706-83: х - magnifier ЛП-1-4 х - magnifier ЛП-1-7 Micrometers with the division value 0.01 mm GOST 6507-90: - micrometer МК-25-1;...
  • Page 268 Levelling and surface v-block P3-2 ТU 2-034-812-88. Lever clamps with gauge indicator GOST 11098-75: Clamp СРП 25; Clamp СРП 50; Clamp СР 25; Clamp СР 75; Clamp СР 125; Clamp СР 150. Depth gauge ШГ-160 GOST 162-90. Beam compasses with vernier reading GOST 166-89: - beam compass ШЦ-I-125-0.1-1;...
  • Page 269 Supplement B - Tightening moments of the main threaded fasteners Threaded joint Tightening moment N*m (kgf-m) Bolts of the fastening of the crankshaft bearing caps: 430-470 (43-47) – vertical  100-120 (10-12) horizontal Bolts of the fastening of the connecting rod caps 200-220 (20-22) Bolts of the fastening of flywheel housing 100-125 (10-12,5)

  • Page 270: Water Pump Pulley

    – the rest 44-60 (4,4-6,0) Drain plug of the oil flywheel 140-160 (14-16) Nut of the fastening of the pulley hub of the water pump 100-140 (10-14) Nuts of the fastening pins of the side wall of the water pump pulley 18-25 (1.8-2.5) Nuts of the pulley shaft of the tension machine of the drive of the pneumatic brake compressor...

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