Avtodizel ???-238??2 User manual

"AVTODIZEL" JSC
(Yaroslavl Diesel Engine Plant)
P O W E R U N I T S
ЯМЗ-238БЕ2, ЯМЗ-238БЕ
ЯМЗ-238ДЕ2, ЯМЗ-238ДЕ
Operating Instructions
238ДЕ-3902150-B РЭ
RUSSIA YAROSLAVL

2
The Instruction contains the description of de-
sign, fundamentals of operating and maintenance service
of the power units ЯМЗ-238БЕ2, ЯМЗ-238БЕ, ЯМЗ-
238ДЕ2, ЯМЗ-238ДЕ of all versions. The Instruction is
intended for the drivers and the personnel, connected to
operating of ЯМЗ power units.
The remarks on a design and power units run,
and also wishes and proposals on the contents of the
present Instruction we ask to send to the address: Chief
Designer Department, “Avtodizel” JSC, October Pro-
spectus, 75, Yaroslavl, 150040, Russia.
In connection with constant activity on perfection
of Power Units, their reliability and durability in a de-
sign can be introduced the modifications which are not
reflected in the present edition.

3
The powerful and highly efficient power
unit you are going to operate is reliable and con-
venient in operation. However it is necessary to
remember, that the service life of the unit sub-
stantially depends on a regular and careful care of
it. Before the beginning of operation closely
study the present Instruction and observe all its
requests. The present Instruction compiled on the
basis of research work and experience of opera-
tion, contains the necessary instructions, which
when faithfully and insistently observed will en-
sure to you failure-free and long power unit run.
The power units design is perfecting con-
stantly. All the modifications are describing in
Additions that located in the end of the brochure
or printed separately.

4
C A U T I O N !
1. Serviceable engine run and long of its service life are in direct relation
to culture of operation. Before the beginning of operation attentively
familiarize with the present manual
2. Observe rules specified in section “Running in of the new engine”, as
during that period the frictional surfaces are wearing in.
3. The application of the fuels, oils, greases and coolants not specified in
the present instruction is not allowed.
4. Before the engine starting after change of oil, an element oil filter,
long parking (5 day and more), replacements or repair of assembly
units and details install the shut-off clamp of the governor in fuel de-
livery off position and within 10-15 seconds turn the engine crankshaft
with starter. At presence of pressure it is possible to start up the en-
gine. After starting the engine should run on the revolutions of idling,
which are not exceeding 1000 rpm., but no more than 5 minutes.
5. After starting before loading warm up the engine at idle to coolant
temperature 40-50oC, then at small load – to 75-90oC. The full loading
of the cold engine is not allowed. It is allowed shot-term (about
10 minutes) increase of the coolant temperature up to 95oC. At appli-
cation of motor oils of increased viscosity, not below than
M5з/14Д(M) (SAE 10W/40) it is allowed long engine run at 95oC and
short-term run at 100oC.
6. At operating monitor the oil pressure in engine lubrication system
(section «Monitoring behind engine run»).
7. To prevent turbocharger breakage the engine before shut-off should
run within 3-5 minutes at mid-idle speed.
8. It is not recommended the engine run at minimum idle speed more
than 10-15 minutes, except for a warming-up of the cold engine after
starting.
9. It is categorically forbidden to switch on the starter on the running or
not stopped engine.
10. Carry out maintenance service in corresponding to section
«Maintenance Service».
11. Engine run when signal lamps of oil and air filters are light is not al-
lowed.
12. Use only approved filter elements.
13. Observe the regulations of operating of the clutch and gearbox
(See corresponding sections of “Operating Instructions”).

5
ATTENDING AND
FEATURINGS OF POWER
UNITS VERSIONS
The power units of “Avtodizel” JSC are multi-functional ones.
Owing to their technical characteristics, universality, high grade of
unification and repairing ability they widely used on original equip-
ment of Minsk, Ural, Mogilev, Krementchug and other vehicle plants.
The application of the “Avtodizel” power units is shown in the
Table. The application of the units for some other equipment should be
agreed with “Avtodizel” JSC.
Completeness
Power
Unit
model and
version
Clutch
model
Gear
box
model
Alternator
model
Original Equipment
and its manufacturer
ЯМЗ-
238ДЕ-1 ЯМЗ-183 ЯМЗ- 238ВМ7
1322.3771
or
Г273В1
MAZ
Trucks
ЯМЗ-
238БЕ-2 ЯМЗ-183 ЯМЗ- 238ВК7
ЯМЗ-
238ДЕ-2 ЯМЗ-183 ЯМЗ- 238ВК7
1702.3771 KrAZ
Trucks
ЯМЗ-
238ДЕ-5
ЯМЗ-
183-40 –
ЯМЗ-
238ДЕ-10 ЯМЗ-183 ЯМЗ- 238ВМ7
ЯМЗ-
238ДЕ-11 ЯМЗ-183 ЯМЗ- 239
1322.3771
or
Г273В1
MAZ
Trucks
ЯМЗ-
238БЕ2-2 ЯМЗ-183 ЯМЗ- 238ВК7 1702.3771 KrAZ Trucks

6
Completeness
Power
Unit
model and
version
Clutch
model
Gear
box
model
Alternator
model
Original Equipment
and its manufacturer
ЯМЗ-
238ДЕ2* ЯМЗ-183 ЯМЗ- 238ВМ7
ЯМЗ-
238ДЕ2-1 ЯМЗ-183 ЯМЗ- 238ВМ7
1322.3771
or
Г273В1
6582.3701
-03 or
3112.3771
MAZ
Trucks
ЯМЗ-
238ДЕ2-2 ЯМЗ-183 ЯМЗ- 238ВК7 1702.3771 KrAZ Trucks
ЯМЗ-
238ДЕ2-3 ЯМЗ-183 ЯМЗ- 238ВМ7
1322.3771
or
Г273В1
ЯМЗ-
238ДЕ2-5
ЯМЗ-
183-40 – –
MAZ
Trucks
ЯМЗ-
238ДЕ2-6 ЯМЗ-182 ЯМЗ- 238Б3 1702.3771 KrAZ Trucks
ЯМЗ-
238ДЕ2-8 ЯМЗ-183 ЯМЗ- 239
1322.3771
or
Г273В1
6582.3701
-03 or
3112.3771
MAZ
Trucks
* Engines with separate cylinder heads.

7
SPECIFICATION
The Power Units are intended for operating at the temperature
of ambient air within minus 60ºСplus 50ºС, relative humidity up to
98% at temperature 25ºС, air dusty up 0,4 g/m3, for operating in
mountain conditions to the altitude 4500 m above sea-level, overcom-
ing of the pass up to 4650 m at appropriate decreasing of power and
economical parameters.
Fig. 1. Power Unit ЯМЗ-238ДЕ

KEY PARAMETERS AND CHARACTERISTICS
Power Unit Model
Key parameters and charac-
teristics ЯМЗ-238БЕ ЯМЗ-238БЕ2 ЯМЗ-238ДЕ ЯМЗ-238ДЕ2
Engine Type Four-stroke turbocharged diesel engine
Number of cylinders 8
Configuration of cylinders V – 90º
Firing order 1-5-4-2-6-3-7-8
Scheme of numbering of
cylinders
Crankshaft Direction of
rotation To right
Cylinder Diameter, mm 130
Piston Stroke, mm 140
Engine Displacement, l 14,86
Compression Ratio 16,5
8

9
Power Unit Model
Key parameters and charac-
teristics ЯМЗ-238БЕ ЯМЗ-238БЕ2 ЯМЗ-238ДЕ ЯМЗ-238ДЕ2
Nominal Power, kW (hp.) 220 (300) 243 (330)
Nominal Speed, min-1 2000 50
20
+
−2100 50 20
+
−
Maximum Torque, Nm (kgfm)
1180 (120) 1274 (130) 1225 (125) 1274 (130)
Speed at Maximum Torque,
min-1 1200 - 1400 1100 - 1300 1200 - 1400 1100 - 1300
Idle Speed, min-1:
maximum 2175 2275
minimum 600±50
Specific Fuel Consumption,
g/kW·h (g/hp.·h):
minimum 206,7 (152) 195 (143) 206,7 (152) 195 (143)
at Nominal Power 227 (167) 223 (164) 227 (167) 230 (169)
Specific Oil Consumption in
% to SFC, no more 0,5 0,2 0,5 0,2
Speed-Torque Characteristics
See Fig. 2 - 3
9

10
Power Unit Model
Key parameters and charac-
teristics ЯМЗ-238БЕ ЯМЗ-238БЕ2 ЯМЗ-238ДЕ ЯМЗ-238ДЕ2
Air-Fuel Mixing Direct Injection
Combustion Chamber Single-cavity in Piston
Camshaft Gear driven, one for two banks of cylinders
Valves Timing Angles:
Inlet Valves:
Opening, degrees before TDC 20 21,5 20 21,5
Closing, degrees after BDC 40 31,5 40 31,5
Outlet Valves:
Opening, degrees before TDC 66 63 66 63
Closing, degrees after BDC 20 29,5 20 29,5
Number of valves per cylin
der
One inlet and one outlet
Thermal Clearances of Val-
ves (on cold engine), mm 0,25 - 0,30
Lubrication System Mixed with oil cooling in water-cooled oil cooler. Crankshaft and Camshaft Bear-
ings, Push Rod spherical Ends, Valve Rocker Arm Bushes, Fuel Injection Pump
and Turbocharger are oiled under Pressure.
Other Frictional surfaces are oiled by splashing.
10

11
Power Unit Model
Key parameters and charac-
teristics ЯМЗ-238БЕ ЯМЗ-238БЕ2 ЯМЗ-238ДЕ ЯМЗ-238ДЕ2
Oil Pump One-section, Gear Type
Oil Pressure in Block Chan-
nel of warmed up Engine,
kPa (kgf/cm2):
At Nominal Speed 400 - 700 (4 - 7)
At Minimum Speed not less 100 (1)
Oil Filters Two: full-through one with filter element and centrifugal one with jet drive
Oil cooling System With water-cooled oil cooler installed on left side of cylinder block
Opening Pressure of Lubri-
cation System Valves,
kPa (kgf/cm2):
Oil Pump Reducing Valve 700 - 800 (7,0 – 8,0)
Differential Valve 490 - 520 (4,9 - 5,2)
Oil Filter by-pass Valve 200 - 250 (2,0 - 2,5)
Fuel Feed System Divided type
11

12
Power Unit Model
Key parameters and charac-
teristics ЯМЗ-238БЕ ЯМЗ-238БЕ2 ЯМЗ-238ДЕ ЯМЗ-238ДЕ2
High Pressure Fuel Injection
Pump with Governor and
Fuel Feed Pump
Eight-plunger, Plungers of Spool Valve Type:
- Plunger diameter 10 mm, Plunger stroke 11 mm – ЯМЗ-238БЕ, ЯМЗ-238ДЕ;
- Plunger diameter 12 mm, Plunger stroke 14 mm – ЯМЗ-238БЕ2, ЯМЗ-238ДЕ2
Model 807.1111005-50
(238БЕ-2)
807.1111006-50
(238БЕ-1)
173.1111006-01
806.1111005-50
(238ДЕ-2)
806.1111006-50
(238ДЕ-1,-5,-10,-11)
173.1111005-11
(238ДЕ2,-1,-3,-5,-8)
173.1111006-11
(238ДЕ2-2)
Supplying Order of Fuel
Pump Sections 1-3-6-2-4-5-7-8
Speed Governor Centrifugal, all-mode
Fuel Feed Pump Piston-type with handle Pump of Fuel Feed
Injectors Closed Type, with multi-jet Nozzle:
- 261.1112010-11 for engines 238БЕ, 238ДЕ;
- 267.1112010-03 for engines with one-piece cylinder head ЯМЗ-238БЕ2, ЯМЗ-238ДЕ2;
- 51.1112010 for engines with separate heads ЯМЗ-238ДЕ2
Initial Injection Pressure of
Injector, MPa (kfg/см2)
20,6+0,8 (210+8)- 261.1112010-11
26,5+0,8 (270+8)- 267.1112010-03
26,5+1,2 (270+12)- 51.1112010
12

13
Power Unit Model
Key parameters and charac-
teristics ЯМЗ-238БЕ ЯМЗ-238БЕ2 ЯМЗ-238ДЕ ЯМЗ-238ДЕ2
Set Injection Advance An-
gle, degrees
Is set on marks on flywheel and injection pump housing and is:
13º±1- for engines ЯМЗ-238БЕ, ЯМЗ-238ДЕ;
6º±1- for engines with one-piece cylinder head ЯМЗ-238БЕ2, ЯМЗ-238ДЕ2;
8º±1- for engines with separate heads ЯМЗ-238ДЕ2
Fuel Filters:
Rough Cleaning Sediment bowl for engines ЯМЗ-238БЕ2, 238ДЕ2
With Changeable Filter Element for engines ЯМЗ-238БЕ, 238ДЕ
Thin Cleaning With Changeable Filter Element. Bypass Jet Valve is located on Filter Cover, or
at ability on Engine of pilot-flame Pre-heater – Jet Valve. Jet Valve Opening Pres-
sure 20 - 40 (0,2 - 0,4) kPa (kgf/cm2)
Supercharging Exhaust Gas, with one Turbocharger
Turbocharger 122 Model
Boost pressure at nominal
mode, kPa (kgf/cm2) 95 (0,95) 110 (1,10)
Cooling System Liquid, Closed Type, with Forced Circulation of Coolant. Is equipped with Ther-
mostatic Device for Maintenance of Constant thermal Range
Coolant Pump Centrifugal Type, with Belt Drive
13

14
Power Unit Model
Key parameters and charac-
teristics ЯМЗ-238БЕ ЯМЗ-238БЕ2 ЯМЗ-238ДЕ ЯМЗ-238ДЕ2
Fan Six-blades, with Gear Drive and with Friction Automatic Coupling
Water-cooled Oil Cooler Two-section, Plate-type. Is equipped with Coolant Drain Cock
Thermostatic devices With hard filler. Opening temp. 80oC.
Electric Equipment One-wire scheme. Nominal Voltage 24V
Alternator Alternative Currency, with Belt Drive, Nominal Voltage 28V. Alternator Model
see Section «Completeness»
Start Device Electrical Starter of 25.3708-01 Model, Nominal Voltage 24 V.
For Facility of Starting of Cold Engine there is Electric Pilot-flame Pre-heater
Clutch See Section «Completeness»
Gear Box See Section «Completeness»
Refilling Capacities, l:
- Engine Lubrication System
32
- Cooling System (without
Radiator) 22
- Injection Advance Cou
pling
0,14 – 0,14 –
- Gearbox See the Section “Gearbox”
14

15
Power Unit Model
Key parameters and charac-
teristics ЯМЗ-238БЕ ЯМЗ-238БЕ2 ЯМЗ-238ДЕ ЯМЗ-238ДЕ2
Mass of not charged Engine
in Delivery Complete, kg:
With separate cylinder heads
- without Clutch and Gearbox
– 1250
- with Clutch – 1295
- with Clutch and Gearbox – 1685
With one-
piece cylinder heads
- without Clutch and Gearbox
1180 1215 1180 1215
- with Clutch 1225 1260 1225 1260
- with Clutch and Gearbox 1580 1615 1580 1615
Overall Dimensions, mm See Fig. 4
15

16
а) б)
Fig 2. Speed – Torque Characteristics of Engines: a) ЯМЗ-238БЕ; b) ЯМЗ-238БЕ2,
where: Nб- nominal power, gross; Мк.б.- torque, gross; ge- specific fuel consumption; n- engine speed
16

17
а) б)
Fig 3. Speed – Torque Characteristics of Engines: a) ЯМЗ-238ДЕ; b) ЯМЗ-238ДЕ2,
where: Nб- nominal power, gross; Мк.б.- torque, gross; ge- specific fuel consumption; n- engine speed
17

18
Fig. 4. Overall Dimensions of Power Units: ЯМЗ-238БЕ2,
ЯМЗ-238БЕ, ЯМЗ-238ДЕ2, ЯМЗ-238ДЕ.
18

19
ENGINE DESIGN
The general engine design of ЯМЗ-238ДЕ2 one is shown on the
cross (fig. 5) and longitudinal (fig. 6) sections.
The design of other engines described in present Instruction
similarly, but can have some features.
Fig 5. Engine Cross Section

20
Fig. 6. Engine Longi-
tudinal Section