Yaroslavl ???-236 User manual

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

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
2.6 General technical requirements for cleaning, washing of the components and units
of the engine .........................................................................................................................................24
2.7 General technical requirements for inspection of the components and assembly
units ......................................................................................................................................................31
2.8 General technical requirements for engine assembly .....................................................................36
2.9 General requirements for engine running-in and testing.................................................................45
3 Inspection sheets ...............................................................................................................................48
1002. Cylinders block ............................................................................................................48
1002. Cylinder liner ................................................................................................................59
1002. Cylinder upper cover ....................................................................................................61
1002. Distributing timing cover ..............................................................................................64
1002. Flywheel housing ..........................................................................................................68
1003. Cylinder head ................................................................................................................72
1003. Cylinder head cover with edges and breather ...............................................................79
1003. Water pipe .....................................................................................................................82

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. Rocker, adjusting screw, nut ......................................................................................118
1007. Push rod ......................................................................................................................120
1007. Lifter ...........................................................................................................................122
1007. Lifter pin .....................................................................................................................126
1011. Two-section oil pump .................................................................................................128
1011. Radiator box ...............................................................................................................131
1011. Master section gear wheel ..........................................................................................134
1011. Master section drive gear ............................................................................................137
1011. Flow regulation valve .................................................................................................140
1011. Release valve ..............................................................................................................140
1011. Radiator section drive gear .........................................................................................142
1011. Transmission gear of the oil pump with liner ............................................................144

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. Flow regulation valve .................................................................................................156
1011. Differential valve ........................................................................................................157
1011. Idler gear of the drive .................................................................................................159
1011. Idler gear shaft ............................................................................................................161
1012. Oil filter. Filter body ..................................................................................................163
1028. Centrifugal oil cleaner. Oil cleaner body....................................................................165
1028. Centrifugal oil cleaner shaft .......................................................................................166
1028. Rotor body with liners ................................................................................................168
1028. Rotor cover .................................................................................................................171
1029. Drive gear, gear wheel of high-pressure fuel pumpdrive..........................................172
1029. Idler gear shaft of the fuel pump drive .......................................................................174
1029. Drive coupling ............................................................................................................176
1029. Driven coupling ..........................................................................................................178
1115. Induction manifold .....................................................................................................182
1307. Water pump. Water pump body .................................................................................183

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. Body of the fan drive ..................................................................................................204
1308. Gear of the fan drive ...................................................................................................205
1601. Clutch. Pressure disk ..................................................................................................207
1601. Clutch pressure disk ...................................................................................................209
1601. Centre clutch driving disk ..........................................................................................211
1601. Clutch pressure spring ................................................................................................213
1601. Springs ........................................................................................................................215
Assembly of the main assembly components of the engine ..............................................................218
Cylinder block ....................................................................................................................................218
Cylinder head with manifolds ............................................................................................................219
4.3 Pistons with connecting rods and rings ........................................................................................222
4.4 Crankshaft ....................................................................................................................................224
4.5 Camshaft .......................................................................................................................................225
4.6 Oil pump .......................................................................................................................................227
4.7 Coarse oil screen ..........................................................................................................................229
4.8 Centrifugal oil cleaner ..................................................................................................................233

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
5.6 Installation of the flywheel housing and flywheel........................................................................251
5.7 Installation of the oil pump ..........................................................................................................252
5.8 Installation of oil housing .............................................................................................................252
5.9 Installation of the cylinder head cast in block...............................................................................253
5.10 Installation of the push rods and rockers with pivots. Expansion gaps adjustment....................254
5.11 Installation of the nozzles ...........................................................................................................255
5.12 Installation of the high-pressure fuel pump and adjustment of the lead
angle of fuel injection..........................................................................................................................255
5.13 Installation of the water pump, by-pass pipes, tension machine and drive
belt of the water pump ........................................................................................................................257
5.14 Installation of the compressor and compressor drive belt .........................................................259
5.15 Installation of the generator and generator drive belts ...............................................................259
5.16 Installation of the starter .............................................................................................................261
5.17 Installation of the single-disk clutch ..........................................................................................261
5.17 Installation of the double-disk clutch .........................................................................................262
6 General requirements for the engine running-in, timing and engine

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 - Standardized jigs, fixtures and tools.........................................................................284
Supplement B - Tightening moments of the main threaded fasteners ...............................................286

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.
The most widespread and popular are six-cylinder and eight-cylinder V-type diesel engines with
dimensions D/S = 130/140 mm ЯМЗ-236 and ЯМЗ-238 series-produced since the beginning of
60-s of the last century, which are proved to be reliable and maintenance and repair simple.
This "Maintenance manual" was composed for specialists connected with the
operation, maintenance and repair of the ЯМЗ engines 236/238. Detailed information on
engineering design, arrangement, engine assembly technology, repair and technical
characteristics for the main repair as well as for cleaning, washing and inspection of the engine
details ЯМЗ-236 and ЯМЗ-238 of all versions and specifications can be found in the
"Maintenance manual". In this "Maintenance manual" information provided in the "Service
instructions" 236-3902150-Б and added with the details in engine repair was used.
There is no information on repair of bought items of the concerned engines in this
"Maintenance manual": electric components (generator, starter), nozzle, fan clutch. If you have
questions as to the information on repair of stated items please contact the manufacturer plant of
the corresponding items.
Maximum permissible parameters (dimensions) give an opportunity to estimate the
remaining service life of the components and engine in general for operating time and overhaul
forecasting. Detailed description of the engine assembly-disassembly technology gives and
opportunity of high-quality repair.
Inspection sheets are located in growth order of the groups and details values.
The book contains information on the technical requirements to the assembly of the
assembly components
and engines in general, technical characteristics for the protective covering, conservation,
marking after the repair, packing, delivery, storage, warranty liability of the repair plant.
Due to the constant work on engine improvement aimed at improving of their
technical-and-economical performance as well as to the improving of the applicability of new
products corresponding changes and amendments can be added to the engine construction
which are not included in this edition.

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” (ЯМЗ).
Maintenance manual 236.01.01 RK 1st edition Preparation of the materials: OJSC "Avtodizel"
(ЯМЗ) 2014.

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".
ЯМЗ-238AM2 engine is the variant of the ЯМЗ-238M2 engine, which power output is limited to
225 H.P. for the whole operation period.
ЯМЗ-238ВM engine has the same nominal horsepower and maximum torque as the ЯМЗ-
238M2 engine. It differs with completeness and special oil pan that allows the operation at
high trim and list.
ЯМЗ-238ГM2 engines is for permanent and cyclically varying operation modes and
differs from the ЯМЗ-238M2 engine by completeness and adjustment of fuel system.
ЯМЗ-238KM2 engine can be installed at the underground dump road train.
ЯМЗ-236M2, ЯМЗ-238M2, ЯМЗ-238AM2, ЯМЗ-238ВM, ЯМЗ-238ГM2
andЯМЗ-238KM2 engines can be replaced with the ЯМЗ-236M, ЯМЗ-238M,
ЯМЗ-238AM, ЯМЗ-238ВM, ЯМЗ-238ГM and ЯМЗ-238KM engines, which were
produced by 1988 as well as by the ЯМЗ-236, ЯМЗ-238, ЯМЗ-238A, ЯМЗ-238Б, ЯМЗ-
238Г and ЯМЗ-238K engines which were produced by the August
1985.
Detailed information on the application of the engines can be found in the ЯМЗ product
catalogue of 2014.

Firing order
Numbering scheme of the cylinders
Diameter of the cylinders, mm
See pic.1A
130
1-4-2-5-3-6
See pic.1B
130
See pic.1B
130
See pic.1B
130
1-5-4-2-6-3-7-8
See pic.1B
130
See pic.1B
130
Piston stroke, mm
140
140
140
140
140
140
Capacity of all
cylinders, l
11.15.
14.86.
14.86
14.86
14.86
14.86
Degree of compression (estimated)
16.5
16.5
16.5
16.5
16.5
16.5
Nominal horsepower,
132
176
165
176
132
140
kW (H.P.)
(180)
(240)
(225)
(240)
(180)
(190)
Rotation rate of the crankshaft
with nominal
horsepower, rpm
2.100
2.100
2.100
2.100
2.100
2.100
Maximum
667
883
825
883
687
torque, Nwm (kgf-m)
Rotation rate of the crankshaft
(68)
(90)
(84)
(90)
-
(70)
with the torque, rpm,
no more than
Rotation rate of the idle
1250-1450
1250-1450
1250-1450
1450-1600
-
1250-1450
crankshaft, rpm,
minimum
650...700
650...700
550-650
550-650
550-650
550-650
maximum, no more than
2340
2340
2275
2275
1950
2275
1.2 Technical characteristics of the engines
TECHNICAL CHARACTERISTICS
Table 2
Values
Models of the engines
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
crankshaft at maximum
Combustion principle Direct injection
Combustion chamber Single-space in piston
Cylinder block Cast along with the upper part of the housing

13
Values
Models of the engines
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 4 5 5 5 5 5
Base bush bearings with replaceable bushing Rod bush bearings
with replaceable bushing Pistons made of aluminum alloy
Piston pins Floating type, axial movement is limited with closing rings I-section connecting rods
bronze bushing are pressed on the upper heads Flywheel has gear ring for engine
start-up with the starter
Camshaft Common for both rows of cylinders, with gear drive
Gap between the valve and
rocker push rod, mm 0,25-0,30 0,25-0,30 0,25-0,30 0,25-0,30 0,25-0,30 0,25-0,30
Lubrication
system
Lubricating system Hybrid. Pressure lubrication system lubricates all base and connecting rod bearings of crankshaft, camshaft
bearings, small end bushings, rocker bushings,
idler gear bushing of the oil pump, spherical seating of the rods,
push rods. High-pressure fuel pump and speed-regulating governor are equipped with circulation-system
lubrication from the engine lubrication system.
Gear mechanism, antifriction bearings and camshaft lobes are
centrifugal lubricated.
Oil pump gear, double section
Pressure in the oil system, kPa
(kgf/cm2)
with nominal speed at
minimum idling RPM no less 400-730 (4-7,3)
100 (1,0)
400-730 (4-7,3)
100 (1,0)
400-730 (4-7,3)
100 (1,0)
400-730 (4-7,3)
100 (1,0)
400-730 (4-7,3)
100 (1,0)
400-730 (4-7,3)
100 (1,0)
Oil cooling system Oil radiator installed outside the engine
Oil filters Two full-flow oil filters with renewable filter element and fine filter - centrifugal, with jet drive. Coarse filter
installation instead of full-flow filter installation is allowed.

14
Values
Models of the engines
ЯМЗ-236M2
ЯМЗ-238M2
ЯМЗ-238AM2
ЯМЗ-238ВM
ЯМЗ-238ГM2
ЯМЗ-238KM2
Pressure of the valves opening
of the lubrication system, kPa
(kfg/cm2):
pressure limiting valve
of the oil pump
release valve of the radiator section
of the oil
pump
overload relief valve of the oil
coarse filter overload relief valve
of full-flow oil filter
700-800
(7.0-8,0)
100-130
(1.0-1.3)
(5.2-5.6)
180-230
(1,8-2,3)
200-250
(2.0-2,5)
700-800
(7.0-8,0)
100-130
(1.0-1,3)
(5,2-5,6)
180-230
(1,8-2,3)
200-250
(2.0-2,5)
700-800
(7.0-8,0)
100-130
(1.0-1,3)
(5,2-5,6)
180-230
(1,8-2,3)
200-250
(2.0-2,5)
700-800
(7.0-8,0)
100-130
(1.0-1,3)
(5,2-5,6)
180-230
(1,8-2,3)
200-250
(2.0-2,5)
700-800
(7.0-8,0)
100-130
(1.0-1,3)
(5,2-5,6)
180-230
(1,8-2,3)
200-250
(2.0-2,5)
700-800
(7.0-8,0)
100-130
(1.0-1,3)
(5,2-5,6)
180-230
(1,8-2,3)
200-250
(2.0-2,5)
Feed system Fuel injection equipment
Of separating typeFuel feed pump Piston type, with
manual bleed pump
High-pressure fuel feed
pump Six- plunger eight-plunger
Plungers Spool-type, diameter 10 mm, stroke 11 mm
Operation order of the section
of oil pump 1-4-2-5-3-6 1-3-6-2-4-5-7-8
Number of the sections From the side of the driver
Speed-regulating governor Centrifugal, all-range Set angle of
fuel injection,
degrees. 15 15 15 15 15 10
MPa (kgf/cm2)22,6+0,8 (230+8)22,6+0,8 (230+8)22,6+0,8 (230+8)22,6+0,8 (230+8) 22,6+0,8 (230+8)22,6+0,8(230+8)

15
Fuel filters
Values
Models of the engines
ЯМЗ-236M2
ЯМЗ-238M2
ЯМЗ-238AM2
ЯМЗ-238ВM
ЯМЗ-238ГM2
ЯМЗ-238KM2
mTwo coarse filters with renewable filter element, fine filter with renewable filter element for fuel.
There is a by-pass in the fine filter cover.
Air filter Inertial oil filter or dry-
type Dry-type Special, is
installed
on the
automobile.
Cooling system
Inertial oil filter
Engine cooling system Liquid, enclosed type, with forced circulation of the cooling liquid, equipped with thermostatic device for supporting of the
permanent heating condition for engine operation.
Water pump Centrifugal, driven with V-shaped belt from the crankshaft pulley.
Fan Six-bladed with gear drive
Electrical equipment
Generator Г-273В2 or
1322.3771 Г-273В2 or
1322.3771 Г-273В2 or
1322.3771 – Г-273В2 or
1322.3771 1702.3771
Three-phase synchronous, alternating current with
built-in rectifier unit.
- Three-phase synchronous,
alternating current with built-in
rectifier unit
Threshold current, А 28 50 28 –28 50
Nominal rectified
voltage, V 28 28 28 –28 28
Starter 25.3708-01, direct current, series dynamo, with electromagnetic drive
Nominal capacity
of the starter, kW, at S 20=182Ah 8,2 8,2 8,2 8,2 8,2 8,2
Clutch
Model ЯМЗ-236K or
ЯМЗ-181* ЯМЗ-238 or
ЯМЗ-182* ЯМЗ-238 ЯМЗ-238 ЯМЗ-238 –
Type Double disk, dry, frictional with peripheral location of the
pressed coil springs
* Single disk

16
Values
Models of the engines
ЯМЗ-236M2
ЯМЗ-238M2
ЯМЗ-238AM2
ЯМЗ-238ВM
ЯМЗ-238ГM2
ЯМЗ-238KM2
Number of the pressed springs 24 28 28 28 28 –
Transmission gear
box
Model ЯМЗ-236П ЯМЗ-236Н ЯМЗ-236Н – – –
Type Mechanical, three-throw, five speed,
with speed synchronizers on the second-third
andfourth-fifth speeds
Gear transmission
ration:
5.26
5.26
5.26
–
–
–
second speed
2,90
2,90
2,90
–
–
–
third speed
1.52
1.52
1.52
–
–
–
fourth speed 1.00 1.00 1.00
–
–
–
fifth speed
0.66
0.66
0.66
–
–
–
reverse gear 5.48 5.48 5,48 – – –
Gear change Remote,
mechanical
control
With the lever on the
transmission cover
Weight of the unfueled
engine, kg
without clutch and transmission gear
box
with clutch without transmission
890
1075
1075
–
–
1075
box
with double-disk clutch
–
–
–
1105
1170
–
and transmission gear box
with single-disk clutch
1205
1390
1390
–
–
–
and transmission gear box
1185
–
–
–
–
–

17
Values
Models of the engines
ЯМЗ-236M2
ЯМЗ-238M2
ЯМЗ-238AM2
ЯМЗ-238ВM
ЯМЗ-238ГM2
ЯМЗ-238KM2
Oil volume, l
Lubrication system
(without radiator)
21
29
29
28
29
29
Cooling system
(without radiator)
17
20
20
20
20
20
Air filter
1.4
0.85
–
–
0.85
0.85
Variable timing device
0.16
0.16
0.16
0.16
0.16
0.16
Transmission gear box
5.5
5.5
5.5
–
-
–
Pic. 1 Numbering scheme of the cylinders
А – engine ЯМЗ-236M2; В – engine ЯМЗ-238M2; С – right-
hank bank; D – left-hank bank

18
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.
Repair types:
Current repair is a kind of repair which is performed for maintaining or recovery of
working capacity of the item with the decrease of its operational characteristics (capacity,
efficiency and others) which includes the replacement or recovery of defective parts with the help
of metal-mechanical works with minimum labour intensity (thread recovery, correction and
others), malfunctions repair occurred during the operation.
Current repair is the repair aimed at recovery of the engine with the help of removal of
detected and foreseen localized troubles (defects) and objective confirmation of the working
condition of the engine at the moment, as well as possibility of its storing before the regular
check of its technical condition or main repair.
During the current repair engine is disassembled in the volume necessary for receiving
access to the defective parts, nods and units.
Timely performance of the current repair helps to decrease the necessity of main
repair and increase run life of the vehicle.
Current repair should provide the failure-free operation of the repaired units and nods with
the run life no less than to the next regular maintenance.
During the current repair troubles are removed due to the replacement and repair of the
separate nods and parts, except basis ones. The basis parts are: cylinders cast in block, crankshaft,
flywheel of the transmission gear box. Thus, during the current repair it is allowed to replace piston
rings, piston pins, bushings, cylinder head gaskets, bushing collars, as well as
troubleshooting: for example, valve gaping to the seats can be removed with the help of valves
seating or seats grinding.
Main repair means the repair which is performed for recovery of the engine operability
(operational characteristics) and for provision of its capacity no less than 80% of the capacity of
the new engine with the replacement and recovery of cylinder block/crankshaft and other parts
with the help of mechanical treatment, welding, build up welding, heat treating and others. Main

19
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.
Repair with responsibility (individual) means the method when the original parts of
item are installed at this item after the repair. As a rule, this method is applied during the current
repair, it preserves final resource of the parts more completely.
Unit repair is the method of the repair without responsibility when the defected units are
replaced with the new or repaired ones.
In line repair is the method which is performed in the specialized places with the defined
technological order and period.
Repair system means the combination of interacting factors:means of the repair,
executors, strategies, technologies and specifications and technical documentation. Repair
system guarantees the prevention of the failure or wear and getting of the information on the
technical condition of the engine and it parts, planning of the operation time and scope of repair
works, provision of the materials and spare parts;
Means of the repair are the main funds with the organizational and production
structure (buildings of the maintenance plants, equipment, organizational tools, facilities);
Repair strategy is the system of rules defining the choice of the decisions on content,
place and time of the repair works or of the decommissioning;
Repair technology - combination of the methods of the changing of
engine technical condition and its parts in the repair process which are performed
in the defined order.
Specifications and technical documentation are the documents containing
principals, definitions, methods and regulations for the performance of the repair and
maintenance.

20
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;
- engines should be clean outside, from the vee of the engine road (sand, dust and others)
and natural (leaves, grass, residual parts, ground with the combining machine and others) mud
should be removed;
- from the oil housing of the engine oil should be discharged completely and oil housing
plug should be presented along with the engine while the acceptance for repair;
- the following documents should be presented: job card for the repair form the service
department, service book, copy of the motor vehicle certificate, certificate of the technical
condition, certificate of the running (service hours) of the vehicle (item);
While accepting for the repair of the engine acceptance report is signed in three copies.
Name of the object, its technical conditions and completeness, name of the customer, date of the
acceptance for the repair and term of the repair are indicated in the report. Report is signed by the
representatives of the repair plant and by the customer of the operating organization and it is
certified with a stamp.
The representative of the repair plant accepts the engine for the repair expertizes the
acceptance report about the compliance of the technical conditions of the repair storage with the
indicated requirements according to the results of the visual inspection, disassembly in the
necessary volume for objective control, inspection on the test stands.
2.3 Awaiting repair storage
2.3.1 Engines from the repair storage should by stored in the closed premises on the
platforms or towers.
2.3.2 It is forbidden to disassemble parts and assembly units from the repair storage
accepted for the repair.
2.4 Delivery of the engines from repairs
2.4.1 ЯМЗ engine delivered from the repair should be completed with all components,
assembly units and parts.
2.4.2 The following accompanying and technical documentation should be

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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;
- specified documents of the accounting records;
- documents for the repair specified in the agreement (contract).
2.4.3 Receiving the engine from repair accepter should inspect its technical condition
visually, he should also check the availability and correctness of the documentation. If any
documents are missing or there is misinformation in them the engine acceptance should be stopped
before the elimination of these shortcomings.
2.4.4 On the demand of the accepter repair plant should present for review the
report of commissioning tests, technological certificate and other documentation concerning
the repair.
2.5 General technical requirements for engine disassembly
2.5.1 To increase the high quality of the repair, working culture and labour productivity
engine should be cleaned from the mud, washed (if necessary, electrical equipment should be
provisionally removed) before the disassembling, oil should be drained from the oil housing.
Before removing the engine from the vehicle coolant should be drained from the
cooling system.
2.5.2 Engine disassembling should provide gentle work with the details, maintaining their
maximal integrity (finished surfaces at first), dimensions, form. Engine should be disassembled with
the tools and facilities (including facilities recommended in this "Manual...") which eliminate the
occurrence of the deformations, cracks, crushes, chips and other defects at the surfaces of the engine
components. While the detail pressing one should avoid the direct stresses on them, one should also
use special drawers and mandrels.
2.5.3 According to the results of the inspection and estimation of the technical condition
one should consider the necessity of the complete disassembling of the assembly units aimed at
maintaining of the coupling of the connecting parts, their breaking-in to each other, as well as
simplifying the disassembling works. Disassembling of the assembly units in carried out if is it
necessary according to the repair conditions.