Yaroslavl Engine Plant YMZ-536 User manual

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

2
536.3902150-B РЭ
This Manual contains design description and basic operating
and maintenance rules for YMZ-536, YMZ-5361; YMZ-5362,
YMZ-5363, YMZ-5364 Engines, assembly variants and
modifications.
The Manual covers the engines assembled at AVTODIZEL
JSC. It is aimed at people operating the above engines.
Please send your comments on engine design and operation as
well as your wishes and proposals on the very content of this
Manual, to: 150040 Engineering and Design center, JSC
"AVTODIZEL" Yaroslavl, Prospekt Oktyabrya, 75.
Due to the constant improvement of the powertrains and
engines aimed at increasing their reliability and endurance as well
as emissions performance and consumer properties, the design
may be subject to changes which are not covered in this edition.
© JSC "AVTODIZEL" (YMZ), 2011
No part of this publication may be reprinted, duplicated or translated
without the prior permission of the AVTODIZEL Engineering and Design
Center.

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Dear Customer,
The powerful and cost-effective powertrains and engines
which you are beginning to use are reliable and easy to operate.
However, it should be remembered that their lifetime largely
depends on their regular and careful maintenance.
Therefore, before starting the operation, please
CAREFULLY read this manual and strictly follow the rules
herein. By accurately following the instructions provided in this
Manual, you will have your engine and powertrain work failure-
free for a long time.
The plant carries out a continuous work aimed at
improved performance of the powertrains and the engines. The
modifications made after publishing this Manual are specified
in the Addendum. The Addendum is placed at the end of the
Manual or attached separately.
ATTENTION ! Before starting the operation, please read
carefully the section entitled WARRANTY AND CLAIMING
PROCEDURE. It contains important information on warranty
package provided by the Manufacturer, i.e. AVTODIZEL JSC
(YMZ), warranty terms, duration of cover and claiming
conditions.

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WARNING
1. Failure-free functioning of the engine and its long operating life
depend directly on their correct handling. Therefore carefully read this manual
before starting the operation.
2. During the engine break-in period its mating parts become
aligned, therefore further working efficiency largely depends on how strictly
the rules specified in the NEW ENGINE BREAK-IN section have been
followed.
3. It is forbidden to use fuels, lubricants or coolants which are not
specified in this Manual.
4. After start-up the engine must be warmed up to the operating
temperature of 80-100oСunder load. Do not warm up the engine by letting it
run at minimum idle speed for a long time. As soon as the engine starts
reacting to a change in the fuel supply and the break system operating
pressure becomes normal, gradually increase the rpm up to the average
operating value and start moving the vehicle in low-range gears. Running the
engine at full load before it is warmed up to the operating temperature must
be avoided.
5. Do not increase the engine speed abruptly immediately after the
cold start because cold oil reaches the crankshaft and the turbocharger
bearings quite slowly which may cause the engine failure. Do not run the
engine idle for a long time during warm-up or vehicle stops.
6. The coolant temperature at the working engine outlet must range
from 80°C to 100ºC. A short-time (up to 10 min.) increase in the coolant
temperature up to 105ºC is acceptable.
7. When operating the engine, follow the readings of the instruments
and take measures as described in “Checking Engine Operation” section of
this Manual.
8. To avoid the turbocharger failure, the engine must work for 2-3
minutes at medium idle before stopping.
9. To avoid failure, it is strictly forbidden to activate the starter
on the running or still running engine.
10. When operating the engine, observe the data shown on display.
11. Technical maintenance of the engine must be performed in
accordance with the TECHNICAL MAINTENANCE section.

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APPLICATION RANGE &
PARTICULARITIES OF
ENGINE ASSEMBLY SETS
The application range and assembly variants of the engines by
Avtodiesel JSC are specified in Table 1. The engines are designed to
be mounted on the products listed in Table 1.
The use of engines and installation on new client's models,
mounting drawings, characteristics of motor system and electrical
circuitry diagram must be approved by JSC "Avtodizel".
Any modification of parameters and systems of the end product
that could have an impact on the engine operation, should also be
approved by JSC "Avtodizel".
Table 1
Engine Model
& variant Final mounts
Basic Model and assembly sets of YMZ-530
YMZ-536
Trucks, dumpers, rigids and tractors 4×2, 4×4, 6×2,
6×4, 6×6, 8×4 with GVM up to 36t, as well as MAZ
tractor and trailer rigs with gross train mass (GTM)
up to 44 t
YMZ-536-01 Delivery kit with connectability to AC compressor
(for MAZ)
YMZ-536-02 Delivery kit with connectability to retarder (for
MAZ)
YMZ-536-03 Delivery kit with connectability to AC compressor
and to retarder (for MAZ)

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Engine Model
& variant Final mounts
YMZ-536-10
Trucks 6×4 with GVM up to 26t and tractor and
trailer rigs with gross train mass (GTM) up to 38 t, as
well as trucks with GVM not exceeding 33,5 t (AZ
URAL), flat nose vehicle
YMZ-536-11 Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)
YMZ-536-30 Trucks with Gross Vehicle Mass (GVM) not
exceeding 30 t (AvtoKrAZ¨holding)
YMZ-536-31 Delivery kit with connectability to AC compressor
(AvtoKrAZ¨holding)
YMZ-536-32 Delivery kit with connectability to retarder
(AvtoKrAZ¨holding)
YMZ-536-33 Delivery kit with connectability to AC compressor
and to retarder (AvtoKrAZ¨holding)
YMZ-536-40
Articulated municipal buses LiAZ-6212 and LiAZ-
6213 type, GVM no more than 28 t, and suburban
bus LiAZ-5256 type, GVM no more than 16 tonnes,
with connectability to ZF automatic transmission
type 6HP504
YMZ-536-41 Delivery kit for powertrain with VOITH automatic
transmission
YMZ-536-42 Delivery kit for powertrain with mechanical
transmission
YMZ-536-100*1
Trucks 6×4 with GVM up to 26t and tractor and
trailer rigs with gross train mass (GTM) up to 38 t, ,
as well as trucks with GVM not exceeding 33,5 t (AZ
URAL), flat nose vehicle
YMZ-536-101*2Delivery kit for flat nose trucks (AZ URAL)

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Engine Model
& variant Final mounts
YMZ-536-110*1Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)
YMZ-536-111*2Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)
YMZ-53602-10
All-terrain trucks 6×4 and 6×6 with GVM up to 38t
and tractor and trailer rigs with (GTM) up to 44 t (AZ
URAL), conventional cab vehicle
YMZ-53602-11 Delivery kit for flat nose trucks (AZ URAL)
YMZ-53602-12 Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53602-13 Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)
YMZ-53602-100*3
All-terrain trucks 6×4 and 6×6 with GVM up to 38t
and tractor and trailer rigs with (GTM) up to 44 t (AZ
URAL), conventional cab vehicle
YMZ-53602-101*4Delivery kit for conventional cab trucks (AZ URAL)
YMZ-53602-110*1Delivery for flat nose trucks (AZ URAL)
YMZ-53602-111*1Delivery for flat nose trucks (AZ URAL)
YMZ-53602-120*3Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53602-121*4Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53602-130*1Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)
YMZ-53602-131*2Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)

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Engine Model
& variant Final mounts
YMZ-53642-10
All-terrain trucks 6×4 and 6×6 with GVM up to 38t
and tractor and trailer rigs with (GTM) up to 44 t (AZ
URAL), conventional cab vehicle
YMZ-53642-11 Delivery kit for flat nose trucks (AZ URAL)
YMZ-53642-12 Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53642-13 Delivery kit with AC compressor, flat nose trucks
(AZ URAL)
YMZ-53642-100*3
All-terrain trucks 6×4 and 6×6 with GVM up to 38t
and tractor and trailer rigs with (GTM) up to 44 t (AZ
URAL), conventional cab vehicle
YMZ-53642-101*4Delivery kit for conventional cab trucks (AZ URAL)
YMZ-53642-110*1Delivery kit for flat nose trucks (AZ URAL)
YMZ-53642-111*2Delivery kit for flat nose trucks (AZ URAL)
YMZ-53642-120*3Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53642-121*4Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53642-130*1Delivery kit with AC compressor, flat nose trucks
(AZ URAL)
YMZ-53642-131*2Delivery kit with AC compressor, flat nose trucks
(AZ URAL)
Modifications and assembly sets of YMZ-5361
YMZ-5361 Trucks, dumpers, rigids and tractors 4×2, 4×4, 6×2,
6×4 and 6×6 with GVM up to 30t as well as tractor

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Engine Model
& variant Final mounts
and trailer rigs with GTM up to 36 t (MAZ)
YMZ-5361-01 Delivery set with connectability to AC compressor
(for MAZ)
YMZ-5361-02 Delivery set with connectability to retarder (for
MAZ)
YMZ-5361-03 Delivery set with connectability to AC compressor
and to retarder (for MAZ)
Modifications and assembly sets of YMZ-5362
YMZ-5362 Municipal and suburban buses LiAZ-5256, LiAZ-
5292 and LiAZ-5293 with GVM no more thant 18 t
YMZ-5362-01 Delivery kit for Powertrain with VOITH automatic
gear box (LiAZ)
YMZ-5362-02 Delivery kit for Powertrain with mechanical gear box
(LiAZ)
YMZ-53622-10
All-terrain trucks 6×4 and 6×6 with GVM up to 26t
as well as tractor and trailer rigs with GTM up to 32t
(AZ URAL), conventional cab vehicle
YMZ-53622-11 Delivery kit for flat nose trucks (AZ URAL)
YMZ-53622-12 Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53622-13 Delivery kit with AC compressor, flat nose trucks
(AZ URAL)
YMZ-53622-100*5
All-terrain trucks 6×4 and 6×6 with GVM up to 26t
as well as tractor and trailer rigs with GTM up to 32t
(AZ URAL), conventional cab vehicle
YMZ-53622-101*6Delivery kit for conventional cab trucks (AZ URAL)

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Engine Model
& variant Final mounts
YMZ-53622-110*7Delivery kit for flat nose trucks (AZ URAL)
YMZ-53622-111*8Delivery kit for flat nose trucks (AZ URAL)
YMZ-53622-120*5Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53622-121*6Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53622-130*7Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)
YMZ-53622-131*8Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)
Modifications and assembly sets of YMZ-5363
YMZ-5363
Trucks, dumpers, rigids and log carrier tractors 4×2,
4×4, 6×2, 6×4, 6×6, with GVM up to 26t, as well as
MAZ tractor and trailer rigs with GTM up to 32t
YMZ-5363-01 Delivery set with connectability to AC compressor,
for MAZ vehicles
YMZ-5363-02 Delivery set with connectability to retarder, for MAZ
vehicles
YMZ-5363-03 Delivery set with connectability to retarder, for MAZ
vehicles

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Engine Model
& variant Final mounts
Modifications and assembly sets of YMZ-5364
YMZ-5364 Delivery set for articulated municipal buses LiAZ-
6212 and LiAZ-6213 type, GVM no more than 28 t
YMZ-53642-10
All terrain trucks 6×6, with GVM up to 30t, as well
as AZ URAL tractor and trailer rigs with GTM up to
36t; conventional cab
YMZ-53642-11 Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)
YMZ-53642-12 Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53642-13 Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)
YMZ-53622-100*3
All terrain trucks 6×6, with GVM up to 30t, as well
as AZ URAL tractor and trailer rigs with GTM up to
36t; conventional cab
YMZ-53622-101*4Delivery kit for conventional cab trucks (AZ URAL)
YMZ-53622-110*1Delivery kit for flat nose trucks (AZ URAL)
YMZ-53622-111*2Delivery kit for flat nose trucks (AZ URAL)
YMZ-53622-120*3Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53622-121*4Delivery kit with AC compressor, for conventional
cab trucks (AZ URAL)
YMZ-53622-130*1Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)
YMZ-53622-131*2Delivery kit with AC compressor, for flat nose trucks
(AZ URAL)

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Notes:
*1— powertrain with MZF 430 Clutch and 9 S 1310 TO Gear Box
with bent shift lever, without PTO from ZF
*2— powertrain with MZF 430 Clutch and 9 S 1310 TO Gear Box
with bent shift lever, with PTO from ZF
*3— powertrain with MZF 430 Clutch and 9 S 1310 TO Gear Box
with bent shift lever, without PTO from ZF
*4— powertrain with MZF 430 Clutch and 9 S 1310 TO Gear Box
with straight shift lever, without PTO from ZF
*5— powertrain with MZF 430 Clutch and YMZ-0905 Gear Box with
shift lever, without speedometer
*6— powertrain with MZF 430 Clutch and YMZ-0905-01 Gear Box
with shift lever, without speedometer, with rear PTO.
*7— powertrain with MZF 430 Clutch and YMZ-0905-10 Gear Box
with remote gear control, 250 mm roller overhang to the left,
without speedometer.
*8— powertrain with MZF 430 Clutch and YMZ-0905-10 Gear Box
with remote gear control, 250 mm roller overhang to the right,
without speedometer.
Engines YMZ-536, YMZ-5361, YMZ-5362, YMZ-5363, YMZ-5364 and their
delivery kits are in accordance with UN EEC Regulations №49-04-B1
Engines YMZ-53602-10, YMZ-53622-10, YMZ-53642-10 and their delivery
kits are in accordance with UN EEC Regulations №96-02.

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TECHNICAL
SPECIFICATIONS
YMZ-536 (Fig. 1 and 1a) is the basic model of six-cylinders-
in-line engines manufactured by JSC AVTODIZEL (YMZ).
YMZ-536-10 (Fig. 1b and 1c), YMZ-536-30 (Fig. 1d and 1e),
YMZ-5361, YMZ-5362 (Fig. 1f and 1g), YMZ-5363 and YMZ-5364
are just variants based on YMZ-536 design but their fuel injection
systems are tuned up differently, by means of adjusting the parameters
of their electronic control unit (E.C.U.).
The basic engines, their assembly variants and sets are
manufactured for moderately cold climatic conditions (according to
Russian standard GOST 15150-69) and can be operated at ambient
temperatures ranging from –60°C up to +50°C, air relative humidity
up to 98% at +25°С, air dust content up to 0,4 g/m3(up to 1 g/m3for
URAL vehicles with engines YMZ-53602-10 [see pictures 1-h and 1-
i], YMZ-53622-10, YMZ-53642-10) and in regions with altitudes up
to 1500 m— without decreasing power, economy and other
performance characteristics; and also at altitudes up to 4500m above
sea level with a possibility to cross mountain passages up to 4650m
high with a corresponding decrease in performance.
The YMZ-536-40, YMZ-5362, YMZ-5364 engines, their
assembly sets for LiAZ buses are manufactured as for moderately cold
climatic conditions (according to Russian standard GOST 15150-69)
and can be operated at ambient temperatures ranging from –50°C to
+50°C, air relative humidity up to 98% at +25°С, air dust content up
to 0,4 g/m3and in regions with altitudes up to 1500 m— without
decreasing power, economy and other performance characteristics;
and also at altitudes; up to 3000m — with corresponding decrease of
those characteristics.

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Fig. 1. YMZ-536 engine, right-side view

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Fig. 1-a. YMZ-536 engine, left-side view

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Fig. 1-b. YMZ-536-10 engine, right-side view

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Fig. 1-c. YMZ-536-10 engine, left-side view

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Fig. 1-d. YMZ-536-30 engine, right-side view

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Fig. 1-e. YMZ-536-30 engine, left-side view

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Fig. 1-f. YMZ-5362 engine, right-side view