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Yaroslavl Engine Plant YMZ-536 User Manual

Yaroslavl Engine Plant YMZ-536
168 pages
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«AVTODIZEL» JSC
(Yaroslavl Engine Plant)
ENGINES
YMZ-536,
YMZ-5361, YMZ-5362,
YMZ-5363, YMZ-5364
Operation Manual
536.3902150-В РЭ
Yaroslavl • 25.01.2012

Table of Contents

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Yaroslavl Engine Plant YMZ-536 Specifications

General IconGeneral
Engine TypeDiesel
Cylinder count6
ConfigurationInline
Fuel systemCommon Rail
Cooling SystemLiquid-cooled
Compression Ratio17.5:1
Displacement6.65 liters

Summary

WARNING

APPLICATION RANGE & PARTICULARITIES OF ENGINE ASSEMBLY SETS

TECHNICAL SPECIFICATIONS

MAIN PARAMETERS AND CHARACTERISTICS OF ENGINES YMZ-536 FAMILY

GENERAL DESIGN AND OPERATION

CYLINDER BLOCK AND CYLINDER LINERS

Details the construction and function of the engine's main cast-iron block.

CRANKSHAFT

Explains the crankshaft's material, construction, and balancing.

TORSIONAL VIBRATION DAMPER

Explains the damper's function and potential damage.

PISTON/CONNECTING ROD

PISTON

Details the piston's design, combustion chamber, and cooling features.

PISTON RINGS

Explains the types and configurations of piston rings.

CONNECTING ROD

Describes the connecting rod's material, design, and assembly.

ACCESSORY DRIVE BELTS

Water pump, fan and generator (Fig. 17)

Describes the first option for accessory drive belts.

VALVE TRAIN

LUBRICATION SYSTEM

OIL PUMP

Describes the oil pump's mounting and safety valve.

OIL FILTER

Details the oil filter model, design, and bypass valve.

COOLING SYSTEM

WATER PUMP

Describes the centrifugal water pump as part of the service module.

THERMOSTATS

Details the thermostats' function in controlling cooling liquid temperature.

FUEL SYSTEM

GENERAL DESIGN AND PRINCIPLE OF OPERATION

Explains the Common Rail System and its operation.

TURBOCHARGER SYSTEM

AIR CLEANER

Details the air cleaner's purpose and maintenance.

TURBOCHARGER

Describes the turbocharger's components and function.

CHARGE AIR COOLER

CRANKCASE VENTILATION SYSTEM

ELECTRICAL EQUIPMENT

STARTER

Lists the specifications for the electric starter.

GENERATOR

Details the specifications for the AC generator.

CONSUMABLES

RECOMMENDED FUEL GRADES

Lists the recommended diesel fuel grades and types.

RECOMMENDED MOTOR OIL GRADES

Specifies the recommended motor oil grades and brands.

SAFETY REQUIREMENTS

STARTING, RUNNING AND STOPPING

PREPARATION FOR START-UP OF NEW ENGINE AND ENGINE START-UP AFTER LONG-TERM LAY-UP OR REPAIR

Outlines procedures for initial start-up after lay-up or repair.

ENGINE START

Provides steps for starting the engine correctly.

NEW ENGINE BREAK-IN

Outlines the procedure and precautions for engine break-in.

MAINTENANCE

GENERAL MAINTENANCE GUIDANCE

Categorizes maintenance into daily, scheduled, and seasonal operations.

DAILY MAINTENANCE (DM)

Lists daily checks and tasks for engine maintenance.

FIRST SCHEDULED MAINTENANCE (M-1)

Specifies tasks for the first scheduled maintenance interval.

SECOND SCHEDULED MAINTENANCE (M-2)

Details tasks for the second scheduled maintenance interval.

LUBRICATION SYSTEM MAINTENANCE

CHECK OF ENGINE OIL LEVEL

Explains how to check and maintain the engine oil level.

ENGINE OIL CHANGE

Details the procedure for changing the engine oil.

CHANGING THE REPLACEABLE OIL FILTER

Provides steps for replacing the engine oil filter element.

COOLING SYSTEM MAINTENANCE

VALVE TRAIN CLEARANCE ADJUSTMENT

AIR FILTERING SYSTEM MAINTENANCE

E.C.S. DIAGNOSTICS

ENGINE PRESERVATION AND DEPRESERVATION

ENGINE EXTERIOR PRESERVATION

Covers the steps for preserving the engine's external surfaces.

ENGINE PACKING

Details the procedures for packing preserved engines for storage.

MANUFACTURER’S WARRANTY AND CLAIMING PROCEDURE

SCOPE OF WARRANTY

Defines the warranty coverage and terms for powertrains/engines.

WARRANTY PERIOD

Specifies the warranty periods and conditions for engines.

HOW TO USE THE WARRANTY

Guides the owner on how to make a warranty claim.

DISPOSAL

DISPOSAL OF COMPONENTS DURING MAINTENANCE

Lists components subject to disposal and their handling.

APPENDICES

APPENDIX 1 TIGHTENING REQUIREMENTS FOR MAIN THREADED CONNECTIONS

Provides torque specifications for various engine threaded connections.

APPENDIX 2 ENGINE DELIVERY SET FOR IN-VEHICLE INTEGRATION

Lists the contents of the engine delivery set for vehicle integration.

APPENDIX 3. BOSCH DIESEL SERVICE CENTERS IN RUSSIA

Lists authorized Bosch Diesel service centers in Russia.