Avtodizel ???-238?? Operating Instructions Manual Download Page 6 | Manualshive

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Avtodizel ???-238?? Operating Instructions Manual Download Page 6

6

Completeness

Power

Unit

model and

version

Clutch

model

Gear

box

model

Alternator

model

Original Equipment

and its manufacturer

ЯМЗ

-

238

ДЕ

2*

ЯМЗ

-183

ЯМЗ

-

238

ВМ

7

ЯМЗ

-

238

ДЕ

2-1

ЯМЗ

-183

ЯМЗ

-

238

ВМ

7

1322.3771

or

Г

273

В

1

6582.3701

-03 or

3112.3771

MAZ
Trucks

ЯМЗ

-

238

ДЕ

2-2

ЯМЗ

-183

ЯМЗ

-

238

ВК

7

1702.3771

KrAZ
Trucks

ЯМЗ

-

238

ДЕ

2-3

ЯМЗ

-183

ЯМЗ

-

238

ВМ

7

1322.3771

or

Г

273

В

1

ЯМЗ

-

238

ДЕ

2-5

ЯМЗ

-

183-40

–

–

MAZ
Trucks

ЯМЗ

-

238

ДЕ

2-6

ЯМЗ

-182

ЯМЗ

-

238

Б

3

1702.3771

KrAZ
Trucks

ЯМЗ

-

238

ДЕ

2-8

ЯМЗ

-183

ЯМЗ

-

239

1322.3771

or

Г

273

В

1

6582.3701

-03 or

3112.3771

MAZ
Trucks

* Engines with separate cylinder heads.

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Summary of Contents for ???-238??

Page 1: ...AVTODIZEL JSC Yaroslavl Diesel Engine Plant P O W E R U N I T S 238 2 238 238 2 238 Operating Instructions 238 3902150 B RUSSIA YAROSLAVL...

Page 2: ...of 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 JS...

Page 3: ...eration 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 instructio...

Page 4: ...rm up the engine at idle to coolant temperature 40 50o C then at small load to 75 90o C The full loading of the cold engine is not allowed It is allowed shot term about 10 minutes increase of the cool...

Page 5: ...lants 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 ver...

Page 6: ...183 238 7 238 2 1 183 238 7 1322 3771 or 273 1 6582 3701 03 or 3112 3771 MAZ Trucks 238 2 2 183 238 7 1702 3771 KrAZ Trucks 238 2 3 183 238 7 1322 3771 or 273 1 238 2 5 183 40 MAZ Trucks 238 2 6 182 2...

Page 7: ...air within minus 60 plus 50 relative humidity up to 98 at temperature 25 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...

Page 8: ...Engine Type Four stroke turbocharged diesel engine Number of cylinders 8 Configuration of cylinders V 90 Firing order 1 5 4 2 6 3 7 8 Scheme of numbering of cylinders Crankshaft Direction of rotation...

Page 9: ...0 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...

Page 10: ...fter 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 cylinder One inlet and one outlet Thermal Clearances of Val...

Page 11: ...m 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...

Page 12: ...0 238 2 806 1111006 50 238 1 5 10 11 173 1111005 11 238 2 1 3 5 8 173 1111006 11 238 2 2 Supplying Order of Fuel Pump Sections 1 3 6 2 4 5 7 8 Speed Governor Centrifugal all mode Fuel Feed Pump Piston...

Page 13: ...geable Filter Element for engines 238 238 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...

Page 14: ...heme 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 Volta...

Page 15: ...ery 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...

Page 16: ...16 Fig 2 Speed Torque Characteristics of Engines a 238 b 238 2 where N nominal power gross torque gross ge specific fuel consumption n engine speed 16...

Page 17: ...17 Fig 3 Speed Torque Characteristics of Engines a 238 b 238 2 where N nominal power gross torque gross ge specific fuel consumption n engine speed 17...

Page 18: ...18 Fig 4 Overall Dimensions of Power Units 238 2 238 238 2 238 18...

Page 19: ...general engine design of 238 2 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...

Page 20: ...20 Fig 6 Engine Longi tudinal Section...

Page 21: ...ribs tie together top and bottom plates of the cylinder part of the block providing the necessary design rigid In the cross walls of the block crankcase part are located five borings with the shells...

Page 22: ...22 Fig 7 Scheme of installing of sealing element in metal gasket 1 metal gasket 2 push rod hole seal 3 oil drain seal 4 water inlet hole seal 5 stud seal 6 seal Fig 8 Block head and liner joint...

Page 23: ...ers Its design similar to above described one but there absent the ring bor ings The joint of the block head and liner fig 8 is sealed with gasket of sandwich type material with metal edgings of all h...

Page 24: ...libration of the engine and unloading of main bear ings from inertial forces of reciprocation moving masses of pistons and connecting rods and unbalanced centrifugal forces on cheeks of the crankshaft...

Page 25: ...marked 238 1005015 30 The crankshaft is marked after punching on 5 th cheek E crankshaft journals may have two nominal dimensions and the next versions of marking are possible Crankshaft mark 238 1005...

Page 26: ...the first crank plane The mark on the plate as point would be from outer side Twelve radial holes in the flywheel are intended for turning of the crankshaft at adjusting of the engine The access to h...

Page 27: ...38 are equipped with the connecting rods 236 1004045 3 marked 236 1004045 2 In the small end of that connecting rod is pressed in the bush 840 1006026 10 with external diameter 54 mm Fig 10 Connecting...

Page 28: ...r block surface of engines 238 2 238 2 1 6 035 0 065 0 mm 238 238 0 1 065 0 035 0 mm For the engines 238 238 the liners with the following design features can be installed 1 The liner 236 1002021 5 Su...

Page 29: ...ium alloy The oil cooling of the piston is made from motionless injector On the piston skirt there is a hollow for cooling injector In the head of the piston the combustion chamber is made On the engi...

Page 30: ...ncrease wearlessness The combustion chamber is displaced on 5 mm the lateral surface with hol low and has the excluder The height from the piston pin axis to piston top surface is increased up to 100...

Page 31: ...the following complete sets of rings can be installed 1 Three ring complete set 7511 1004002 where First compression ring has in section a kind of a bilateral trapeze with working surface displaced do...

Page 32: ...plated working edges and twisted spring expander Ring part number is 236 1004034 At installation of piston rings to pay special attention to correct ness of their arrangement The word Top should be i...

Page 33: ...33 Fig 13 Piston Piston rings Piston pin At the left piston 238 1004015 4 its rings and pin At the right piston 7511 1004015 10 its rings and pin...

Page 34: ...One piece cylinder heads T h e b a s i c v a r i a n t Bondorizated 236 1002021 5 4 ring with dense chrome With 4 grooves and niresist insert 238 1004015 4 A l l o w a b l e v a r i a n t s at repair...

Page 35: ...s levers with adjusting screws lever shafts valves valve springs with attachment parts and valve guides fig 14 The drive of valves is carried out from camshaft through roll tappets 2 tubular push rods...

Page 36: ...tact with push rod in tappet boring is pressed in the steel heat treated abut Tappet axles The tappets are suspended on tubular axles in stalled in borings of the cylinder block in cast iron bushes fr...

Page 37: ...nd another in spring retainers fixed on the valve stems with the intermediate bush and two conic re tainers Presence of the bush between retainer and valve provides the turn of valves at work of the e...

Page 38: ...38...

Page 39: ...r shaft 3 driving shaft gear 4 housing cover 5 driven shaft gear 6 housing 7 drive gear 8 key 9 thrust flange Further through the block channels the part of oil through the valve of cooling system of...

Page 40: ...lter element 6 hood head 7 filter element gasket 8 valve plunger 9 valve spring 10 warning device spring 11 warning device mo bile contact 12 motionless contact 13 terminal From the filter the oil goe...

Page 41: ...ut in the central oil channel The centrifugal oil filter fig 18 is included in parallel after the full through oil filter and it cleans up to 8 of oil flow passing through lubrication system The filte...

Page 42: ...p 3 fuel filter of thin cleaning 4 injector 5 injector spray 6 fuel feed pump 7 fuel tank From a tank through the filter of rough cleaning the fuel forces with the fuel feed pump in the filter of thin...

Page 43: ...h pressure fuel injection pump in assembly shown in fig 20 With the high pressure fuel injection pump in one unit the speed gov ernor 5 the fuel feed pump 9 and the damper coupling 3 are incorpo rated...

Page 44: ...with rack 16 The adjustment of uniformity of fuel delivery on the maximal mode by each section of the pump is made with turning of the section case at the loosed nuts of section fastening The change o...

Page 45: ...g 2 lower tappet retainer 3 tappet spring 4 upper tappet retainer 5 turn bushing 6 plunger 7 plunger barrel 8 delivery valve seat 9 delivery valve 10 valve stop 11 union 12 pressing flange 13 14 gaske...

Page 46: ...start up of the engine At screwing out of the bolt from rack the starting fuel delivery is decreased The fuel pump is oiled from the engine lubrication system under pressure The oil for the pump is s...

Page 47: ...er 18 negative corrector lever 19 power adjusting screw 20 rack lever 21 link 22 collar 23 weight coupling 24 governor weights 25 weight holder 26 weight pin 27 driving gear 28 retainers 29 weight hol...

Page 48: ...ves for adjust ment of nominal fuel supply In the lower part of the governor lever there are the correcting device 12 13 14 16 18 with negative cor rector intended for formation of the fuel injection...

Page 49: ...responds At reduction of resistance to movement of the automobile the engine crankshaft speed is increased In this case centrifugal force of weights grows The weights disperse and overcoming the gover...

Page 50: ...engine in emergencies arising at failures of turbocharger The principle of action of the supercharge fuel corrector that at de creasing of boost pressure it influences on the fuel pump rack reduc ing...

Page 51: ...in lubrication sys tem and air in the inlet collectors is absent The spring 4 presses the piston 13 with stop 2 to the corrector case 16 The spring 11 presses the spool 12 and rod 9 with membrane aga...

Page 52: ...ure in the membrane cavity decreases the spool 12 under action of a spring 11 is displaced to the left side and the spool end face edge blocks the piston drainage windows In the under piston cavity th...

Page 53: ...e return corrector spring revolu tions of a beginning of operation of the corrector is adjusted with corrector case 13 fig 22 To features of adjusting it is necessary to attribute that for main tenanc...

Page 54: ...upling 5 pointer 6 pump rack cap 7 by pass valve 8 plugs for air outlet 9 speed governor 10 supercharge fuel corrector 13 minimal speed limiting bolt 14 buffer spring body 15 shut off clamp 16 fuel fe...

Page 55: ...he pump housing 1 are installed the plunger pairs delivery valves 10 and unions 8 to which the high pressure pipelines are con nected The delivery valve and its body precise pair which can be replaced...

Page 56: ...w pres sure that the fuel feed pump creates in supplying channel fills the above plunger space At up wards movement of the plunger fuel is by passed in the fuel supplying channel so long as the plunge...

Page 57: ...ED GOVERNOR The high pressure fuel injection pump is equipped with all mode speed governor 9 fig 24 mechanical direct action which changing the fuel supply depending on loading supports the engine cra...

Page 58: ...weights coupling 23 weights pin 24 weights holder 25 driv ing gear 26 retainers 27 weights holder shaft 28 sleeve 29 rack rod 30 spring lever 31 rack lever spring The lever rack spring 31 is attached...

Page 59: ...e steady run on the minimal idling mode The speed governor is equipped the supercharge fuel corrector for decreasing of heat intensity and smoking of the engine exhaust gases on low speeds and transfe...

Page 60: ...dvance coupling 1 case 2 O ring 3 driving half coupling 4 washer 5 weight pin 6 driven half coupling 7 8 leap type seals 9 spacer 10 weight 11 12 adjusting washers 13 spring On the conic end of the pu...

Page 61: ...PUMP The fuel feed pump 9 or 16 fig 20 or 24 piston type is in tended for supplying of fuel from fuel tank to high pressure fuel injec tion pump The feed pump output in 3 4 times exceeds productivity...

Page 62: ...bushing represent the precise pair For a forcing of fuel at the not running engine the pump is equipped with the handle pump This pump is used for removal of air from fuel system before start up of t...

Page 63: ...uel filtered through a backlash between a needle and the spray body is removed from injector through a cavity of a spring and holes in the adjusting screw and in cap 9 The injector is installed in a s...

Page 64: ...tered through a backlash between a needle and the spray body is removed from injector through the spring cavity and hole in the injector case Fig 30 Injector 1 spray tip 2 spray tip nut 3 spacer 4 rod...

Page 65: ...rew 10 cap 11 spring nut 12 washer 13 spring 14 bushing 15 union 16 filter The fuel to injector is supplied through the union 15 in which the bushing 14 pressing the mesh filter 16 is installed The fu...

Page 66: ...cotton cord twisted on a mesh skeleton The filter ele ment is dense pressed on end faces between a cover and bottom of a cap The hole in the cover closed with plug 4 with and gasket 3 serves for fill...

Page 67: ...Fuel in the filter acts through a tip 6 and a cavity in an axis 1 Clearing of fuel is carried out in settling cells of filter elements 3 par ticles of mechanical impurity and on inclined walls of cell...

Page 68: ...3 Thin cleaning fuel filter 1 drain plug 2 drain plug gasket 3 spring 4 filter element 5 cap 6 stem 7 cap gasket 8 cover 9 plug 10 jet gasket 11 15 jet 12 bolt 13 gasket 14 filter element gasket In a...

Page 69: ...pelines have identical length for all cylinders of the engine The ends of pipelines are punched in the form of a cone and pressed with nuts to unions of the high pressure fuel pump and injectors In or...

Page 70: ...friction welding The turbine housing is made of heat resistant cast iron The gas enters to turbine wheel through two channels The compressor housing 4 insert and bearing housing cover 6 are made of al...

Page 71: ...using cover 7 seal ing ring 8 compressor housing lock plate 9 bolt 10 bolt retainer 11 turbine housing lock plate 12 bearing housing 13 turbine heat reflector 14 turbine wheel and shaft as unit 15 tur...

Page 72: ...eme of Cooling System 1 water pump 2 block water jacket 3 head water jacket 4 longitudinal water channel 5 turbocharger 6 right water pipe 7 boost air pipe 8 cooled air pipe 9 thermostatic device 10 t...

Page 73: ...ers into radiator where gives back heat to a flow of air created by the fan 14 then backs to the water pump When temperature of a cooling liquid decreases thermostatic device automatically direct all...

Page 74: ...ump 1 driving pulley 2 retainer ring 3 ball bearings 4 shaft 5 water slinger 6 seal ing 7 pump case 8 O ring 9 pump branch pipe 10 impeller 11 impeller plug 12 O ring 13 O ring bushing A end face seal...

Page 75: ...ucing from 2003 year STRUCTURE AND WORK OF FAN DRIVE WITH THE SWITCH OF MECHANICAL TYPE The fan drive can work in three modes automatic one con stantly switching in and constantly switching off The fa...

Page 76: ...8 piston ring 29 O ring 30 piston 31 piston stop 32 pressing spring When the coolant temperature will be close to the lowest opti mum level the switch stops the oil supply The oil there is under pisto...

Page 77: ...n one of three positions 1 Position automatic 2 Position constantly switch in 3 Position constantly switch off Fig 39 Fan drive switch 1 body cover 2 back spring 3 O ring 4 washer 5 spool 6 spool spri...

Page 78: ...tely travels in direction of moving of pusher 7 The ball 18 gets to other stopping slot spool 5 has stopped in position when oil inlet cavity is united with oil outlet cavity The oil is delivering to...

Page 79: ...p type seal 2 cover 3 ball bearing 4 driven disk 5 driving disk 6 gasket 7 back pressed spring 8 thrust ring 9 scoop pipe 10 spacer bushing 11 piston ring 12 leap type seal 13 solenoid valve 14 case 1...

Page 80: ...80 Fig 41 Location on engine of the fan drive parts 1 drive coupling 2 electromagnetic valve 3 oil inlet pipe 4 thermo relay Fig 42 Electromagnetic valve Fig 43 Thermo relay 32 20...

Page 81: ...ig 45 installed in the housing The cooling oil passes of section and cooling liquid outside by counter flow In an oil cavity of the case is installed the by pass valve 1 At it opening the oil passing...

Page 82: ...usting gasket 6 spring 7 bushing 8 seal ring 9 flange 10 gasket 11 housing 12 sections of plate ele ment 13 coupling 14 O rings On the cooler outlet pipe of the second section the drain age cock fig 4...

Page 83: ...n with the built in rectifying unit 24 45 and the inte grated voltage regulator 120 273 1 GENERATOR DATA Rated power W 800 Rated voltage V 28 Directed currency not less 45 Rotor initial frequency of r...

Page 84: ...3771 GENERATOR DATA Rated voltage V 28 Maximal loading currency A 45 Initial rotor speed at air and alternator temperature 25 10 and voltage 26 V rpm not more at load currency 10 A 1450 at load curren...

Page 85: ...th run hour counter to connect with voltage regulator and starting key two terminals W tachometer wire terminal GENERATOR STRUCTURE The generator represents three phase twelve pole synchronous electri...

Page 86: ...03 consists of the three phase synchronous generator of alternating current with the electromagnetic excitation with the built in rectifying unit 17 100 02 and the in tegrated voltage regulator 120 1...

Page 87: ...ing unit The cover from the drive side has ventilating windows In a cover the bearing is installed The fan and the pulley are installed on the alternator shaft with key and are fixed with a nut and a...

Page 88: ...armature 17 case 18 drive lever 19 drive 20 drive side cover 21 drive gear 22 middle bearing 23 thrust washer 24 drive case 25 leap type seal 26 rear bearing SPECIFICATION Rated voltage V 24 Rated pow...

Page 89: ...rch arising at it warms up the intake air The structure of the device includes two glow plugs 3 fig 48 installed in the engine intake manifold 2 solenoid fuel valve 6 thermo relay with additional resi...

Page 90: ...manufacturer 2 The sign of correspondence to the national standards with a label of organization giving the certificate 3 The sign of official proving 4 Meeting to 24R 03 Regulations 5 Meeting to 49R...

Page 91: ...tory manufacturer are installed on the hatch of governor on the maximal idle speed adjusting bolt on the corrector cover on the power limiting screw on the upper case of high pressure fuel injection p...

Page 92: ...5 82 of grades 40 62 at the temperature of ambient air above than minus 10 of grade from minus 35 above minus 35 of grade from minus 45 above minus 45 of grade above minus 50 For improving of ecologic...

Page 93: ...nt air temperature 30 and above under the speci fication USA ASNM 975 81 of grade 1D Canada CAN 2 3 6 M 83 of grade TYPE At the ambient air temperature 50 and above under the speci fication of Canada...

Page 94: ...mitcheskaya kompaniya 4126 10 2 TU 38301 13 008 97 JSC Novokuibyshevsky NPZ 4127 6 14 TU 38301 13 008 97 JSC Novokuibyshevsky NPZ SAE 15W 40 API CF 4 SG 5 14 0253 075 00148636 99 with changes 1 2 JSC...

Page 95: ...production are recommended to applica tion with indicated viscosity class and with quality catego ries not below than CF 4 API Engine Euro 1 or CG 4 API Engine Euro 2 2 The manufacturer recommends usi...

Page 96: ...Omsky NPZ SAE 80W 90 GL 3 TU 0253 019 00219158 95 JSC Slavneft Yaroslavlnefteorgsintez 3 18 SAE 85W 90 GL 3 TU 0253 005 57352960 02 JSC Orsknefteorgsintez SAE 80W 90 TU 0253 018 00219158 96 SAE 80W 9...

Page 97: ...0 TU 113 07 02 88 JSC KAPROLAKTAM Dzerzhynsk town N Novgorod reg 65 TU 113 07 02 88 Next cooling liquids of foreign producers are recommended M1 E 559 USA BS 3150 Grade AL 3 England and similar All in...

Page 98: ...0 1012040 14 Filtering element in assembly CJC Metiz Tutaev town Russia Element without packing in stalled on engine at assemble made of synthetic needle punched cloth Fuel filter of course cleaning e...

Page 99: ...rings of tightening de vice pulley 201 GOST 6267 74 Rostovsky ONMZ Clutch releasing coupling Shaft bearing of clutch releasing fork 4 24 GOST 21150 87 Berdyansky ONMZ PO Omsknefte orgsintez Rostovsky...

Page 100: ...ot al low leakage of fuel and oil In time clean and wipe all parts of the engine During start and engine run do not allow to it of outside per sons Do not grease adjust and wipe the running engine Dur...

Page 101: ...fire extinguishers cover a flame with sand asbestos blanket felt or canvas Do not extinguish a flame with water At realization of electro welding works directly on the automobile with the purpose to...

Page 102: ...eed as follows 1 Delete from the power unit preserving lubricant and clean it of a dust and dirt 2 Carry out thoroughly outer inspection of power unit and ac cessories mounted on it Make sure that the...

Page 103: ...emperature then tight the plugs 12 By outside inspection make sure of reliable tightness of pipelines and units of lubrication fuel feed and cooling systems If necessary tighten up the joints 13 By in...

Page 104: ...ever into the mid position To start the engine depress the starter button as soon as the engine begins to run steadily release the button The duration of con tinuous operation of the starter should no...

Page 105: ...WHEN STARTING THE ENGINE WITH THE AID OF PILOT FLAME PRE HEATER PILOT FLAME GLOW PLUGS ARE DESIGNED FOR OPERATING VOLTAGE OF ABOUT 19V IF THE VOLTAGE IN THE PLUGS EXCEEDS 21V THEY FAIL SOON 1 Prepare...

Page 106: ...be warmed up first at the idling speed up to 40 50 C of coolant temperature and then at a small load up to operation temperature The full load operation of the cold engine is not allowable Do not admi...

Page 107: ...ENGINE SHUT DOWN Prior to shut down the engine should run without load at mid idling speed for 2 3 minutes To shut down the engine decrease its speed down to the mini mum and only then shut down the e...

Page 108: ...ng liquid volume has decreased due to evaporation but not due to leakage then add only water into the cooling system as the amount of ethylene glycol remains constant owing to its high boil ing temper...

Page 109: ...ivided into the following kinds in accordance with periodicity and list of services to be fulfilled Daily maintenance service D carried out once a day shift First maintenance service M 1 performed eve...

Page 110: ...238 E and 238 engines lubrication system 8 Change the oil filter element If the warning signal lamp is flashing on the warmed up engine then the element is to be changed earlier than the specified ter...

Page 111: ...t clearances 15 Carry out the adding operation on maintenance of gearbox see Gear Box Section 16 Every 3000 running hours check the easy rotation of turbo charger rotor and if necessary carry out it m...

Page 112: ...injection advance set an gle 7 Check and if necessary adjust the tension of drive belts 8 Wash up the centrifugal oil filter 9 Check the tightening of starter attachment 10 Warm up the engine to temp...

Page 113: ...8 mm on a short branch fig 52 A tension of the alternator drive belts check by pressing with force 40 N 4 kgf on middle of a branch of each belt fig 53 thus the belts should be sag on 10 15 mm If the...

Page 114: ...of the alternator rod and bolt of fastening of the alternator to the rod After adjustment reliable fix the alternator At increased stretching and breakage even one of belts replace them with a comple...

Page 115: ...cylinder head separate cylinder head ATTENTION IT IS CATEGORICALLY FORBIDDEN TO TIGHTEN NUTS WITH TORQUE MORE THAN IS SPECI FIED AS IT WILL RESULT BREAKAGE OF STUDS AND CYLINDER HEAD AND TIGHTNESS OF...

Page 116: ...re worsened Besides the reduction of the clearance in a drive of outlet valve can result the valve overheating and damage Thermal clearances adjust on the cold engine or not earlier than 1 hour after...

Page 117: ...urn it still approximately on 1 3 revolutions 120o This crankshaft position corresponds to the compression stroke in the first cylinder and both valves of this cylinder are closed Fig 55 Cranking of c...

Page 118: ...ces adjusting start the engine and hear its work The knocks in the valve mechanism should not be In case of presence of characteristic knock of valves stop the engine and repeat adjusting 9 Install an...

Page 119: ...e marks were not aligned it is necessary to make adjusting The succession of the injection advance angle adjusting of 238 2 and 238 2 engines fig 58 loosen tightness of clamp joint bolt 2 of flange 3...

Page 120: ...injection advance angle adjusting of 238 and engines 238 fig 59 check up the fixation of half coupling 3 on the drive shaft 1 and tightness of the bolt 5 torque should be 43 2 58 9 Nm 4 4 6 kgf m scr...

Page 121: ...he coupling with holes in the upper position and turn out the plugs At slow turn of coupling on 70 from one hole should begin to drain the oil Tight the plugs after adding of oil MAINTENANCE SERVICE O...

Page 122: ...dations 1 Replace oil See section Maintenance Service Bearings of compressor tension device pulley 24 201 1 Fill with grease through grease fitting 500 Starter bear ings Oil used for en gine 3 Fill in...

Page 123: ...of dust and dirt The oil priming carry out from oil dispensing columns with the dispensing gun and at absence of columns through a funnel from clean refilling container Close the filler cap Fig 60 The...

Page 124: ...as shown in a fig 61 Fig 61 Screwing out of filter hood 2 Screw out the filter hood 5 completely and remove it fig 62 3 Press on lock cover 3 and having drowned it in the hood 5 of 2 3 mm turn on 45 t...

Page 125: ...th the moment 20 40 Nm 2 4 kgf m 7 On the running engine to be convinced of absence of oil leak through the hood seal After the four replacements of the fil ter element replace the sealing gasket 2 WA...

Page 126: ...tachment bolts Wash up the valves in diesel fuel without disassem bling and put them back in place If the valve is faulty broken spring etc replace the valve in assembly LUBRICATING THE COMPRESSOR DRI...

Page 127: ...e starts oozing through the seals on the pulley rear end MAINTENANCE OF FUEL EQUIPMENT The correct and regular maintenance service of the fuel equip ment is a necessary condition of failure free runni...

Page 128: ...our over the fuel pump of high pressure before start up by hot water During all period of operation it is forbidden the fuel pump washing with water under a pressure At a stop of the engine in the win...

Page 129: ...at injector installation with 15 angle to a horizontal surface should not be formed coming off drop of fuel 3 The mobility of the needle check up with fuel flow through injector adjusted on the given...

Page 130: ...clean diesel fuel At absence of tightness on a locking cone the spray tip as unit should be changed The changing of separate details of the sprayer is not allowed Injector disassembly carry out in th...

Page 131: ...ew the nut by a hand then finally tighten it The spray nut tightening torque is 70 80 Nm 7 8 kgf m in jector union body 80 100 Nm 8 10 kgf m After assembly adjust the injector for injection beginning...

Page 132: ...76 or lighting kerosene on TU38 401 58 10 90 having viscosity 5 6 2 s cCt at temperature 20 0 5 The temperature of fuel measured in outlet joint of the stand with pipeline to the tested pump at the c...

Page 133: ...el with fuel is not observed Supply the compressed air to the oil outlet hole and dip the in jection pump to container with diesel fuel The high pressure fuel in jection pump is considered as airtight...

Page 134: ...kness should be identical from both sides and the thickest gasket should be from above At increase of gaskets thickness the fuel delivery begins later at reduction earlier In order to prevent breakage...

Page 135: ...ip from the rack lever and screw it in the spring For reduction of speed turn out the screw After that put the grip on the rack lever 5 Check up the average start fuel delivery which should be within...

Page 136: ...f all sections divided on sections number The non uniformity of delivery on sections calculated under the formula 0 0 min max min max 100 q q q q 2 where q max maximal cycle fuel delivery mm3 cycle q...

Page 137: ...the pump camshaft speed 650 10 min 1 supply to the corrector the oil under pressure 0 275 0 025 MPa 2 75 0 25 kgf cm2 the control lever should be on the rest in against the maximal speed limiting bolt...

Page 138: ...etween of the piston end face and the corrector case At installation of the supercharge fuel corrector after dismantle if in it there was a necessity on the governor remove with link clamp the pump ra...

Page 139: ...Motorpal Czechia firm Fridman Mayer and other stands of similar designs The stand should be equipped with a device for gradually changing of the drive shaft speed in the range 0 1500 min 1 a holder f...

Page 140: ...lic medium consisting of 40 3 TU 38 101 964 83 and 60 8 TU 38 101 883 33 having viscosity from 5 up to 6 2 s t at temperature 20 5 is supposed The temperature of fuel measured in final connection of t...

Page 141: ...e surfaces should be dry The test mode nominal the governor control lever should be rest against the maximal speed limiting bolt The fuel pressure in the pump rail should be 0 05 0 10 MPa 0 5 1 0 kgf...

Page 142: ...Checking both adjusting of amount and uniformity of fuel de livery make in the following order 1 Check up the pressure of delivery valves opening start which should be at 1 0 0 15 MPa 10 1 5 kgf cm2 T...

Page 143: ...inning It should be occured at speed 1065 1085 min 1 for 806 6 50 fuel pump and 1025 1045 min 1 for 807 6 50 fuel pump Measure with tachometer at the moment of rack movement start to side of delivery...

Page 144: ...l delivery mm3 cycle q min minimal cycle fuel delivery mm3 cycle 10 Check up work of the supercharge fuel corrector for this purpose wash up in clean gasoline the union mesh filter 15 fig 23 and caref...

Page 145: ...justed with the corrector spring body At turn in of the spring body the fuel delivery is decreased at turn out increased After adjusting safe the spring body with the nut Before replacement of the wor...

Page 146: ...jection advancing coupling so that driven coupling bosses were installed in a horizontal position and the mark the coupling end face was in a zone of the indicator 3 Install the half coupling flange i...

Page 147: ...ew the buffer spring body before overlapping its end face with the lock nut end face After adjusting safe the minimal speed limiting bolt and the buffer spring body with nuts The minimal idle speed ma...

Page 148: ...ing of the bolt 5 WASHING OF THE COURSE CLEANING FUEL FILTER 1 Drain fuel from the filter 2 Unscrew four attachment bolts of filter hood 2 fig 32 to cover 7 take off the filter hood and flange 4 3 Scr...

Page 149: ...ollowing precautions 1 Maintain the engine on speeds above idling only after nor mal pressure of oil will be established 2 Try to lower temperatures and speeds from their maximums before a stop of the...

Page 150: ...me positions with taking up the axial play alternately in one and in the other side 3 Under no circumstances getting of dust sand or any foreign objects inside the turbocharger is to be allow 4 If the...

Page 151: ...mature exit of the engine out of operation Normal work of the engine needs regular ser vice of the air cleaner and also the constant attention to a condition of its details is especial of gaskets and...

Page 152: ...oot and oil are found on paper and the air blasting is considered inefficient wash the element in solution of washing de tergent 7 or 10 GOST 8433 81 in warm 40 50o C water of concentration 20 25 g of...

Page 153: ...n the sizes of a filtering ele ment of the air filter on which place is installed the stopper Connect a compressed air source to a stopper pipe diameter 10x1 and a check tube with a valve or clamp to...

Page 154: ...water Descale the cooling system at regular intervals 6 At application as a cooling liquid of freezing at low tem peratures composition Tosol periodically watch its color If anti freeze gets red brown...

Page 155: ...than 6 7 h merge a spent solution and fill the system with fresh one Continue the washing during four five days After the washing ending fill the cooling system with water containing 2 g l of thrylone...

Page 156: ...he generator installed on your power unit ATTENTION THE START UP OF THE ENGINE IS FOR BIDDEN ON THE AUTOMOBILE WITH THE GENERATOR PLUS WIRE DISCONNECTED THIS WILL CAUSE AN OVER VOLTAGE ON THE GENERATO...

Page 157: ...should light up and after start up of the engine has gone out At M 1 without removal of the generator from the engine carry out the maintenance service in following volume 1 Check the tightness and i...

Page 158: ...ver and stator 3 Unscrew three nuts of stator wires fastening to rectifier unit separate the stator from cover 4 Unscrew the nut of pulley fastening and remove the pulley and the fan Extract the key a...

Page 159: ...ngine start the control lamp should light up and after start up of the engine has gone out At M 1 without removal of the generator from the engine carry out the maintenance service in following volume...

Page 160: ...GUARANTEE ENDING IS FORBIDDEN WITHOUT EMERGENCY ANY DISASSEMBLY IS NOT RECOMMENDED Remove generator unit from the engine clean of dust and dirt and disassemble in the following order 1 Unscrew two th...

Page 161: ...he rotor speed gradually increased until the voltage on the PV1 voltmeter will reach up to 28 V Under load test the needed load cur rent is installed on the ammeter PA after that the rotor speed is me...

Page 162: ...e generator on the engine with the help of the voltmeter consists in the following At switched storage battery install 1500 1700 rpm en gine speed connect the voltmeter between and not painted over pl...

Page 163: ...the slip rings end cover together with stator 4 Unscrew three fastening nuts of the stator phase terminals to the rectifier unit separate stator from cover 5 Unscrew the nut of pulley fastening and re...

Page 164: ...g of the generator to the engine and pulley on the genera tor shaft and clean the generator of dust and dirt After every 30000 km of the vehicle run or at every second M 2 carry out maintenance servic...

Page 165: ...holder fastening to the cover and take out the brush holder with integral voltage regulator as the unit 3 Unscrew two screws of brush holder and voltage regulator fastening to the casing 4 Unscrew th...

Page 166: ...rent source G storage battery ammeter PV1 V3 voltmeters S1 S3 S4 switches S3 seasonal adjustment changeover switch On closing the switch S1 the field winding is supplied from an external DC 14 V volta...

Page 167: ...hat the pin enters the hole in the bracket 3 Insert bolt 2 into the hole of the generator front lug screw it into the bracket hole without tightening the bolt The shafts of pulleys should be located i...

Page 168: ...ely worn Brushes worn to a length of 14 mm should be re placed Measure the brush height from the point where the spring touches the lapped working surface 5 Check the tightening of the screws which fa...

Page 169: ...and remove the drive cap 10 Extract the armature from the drive housing 11 Take the drive out of the frame 12 Remove the lever axle screws and pull the axle from the set ting holes in the frame and le...

Page 170: ...ction of starter jumper to sole noid 3 terminal bolt for connection of storage battery to solenoid 4 indicator lamp 5 switch 6 terminal for connection of switch wire to solenoid windings Fig 79 Checki...

Page 171: ...th clamp tighten clamp bolts with a torque of 70 90 N m 7 9 kgf m To ensure the clamp installing the connecting bus may be remove MAINTENANCE OF ELECTRIC PILOT FLAME PRE HEATER Carry out maintenance o...

Page 172: ...tions Be sides check the pipes for air tightness with air under pressure 485 kPa 5 kgf cm2 The inside concavity of pipes should be clean Fig 80 Pintle type glow plug 1 glow pintle 2 glow plug body 3 l...

Page 173: ...the button pushed for 30 s begin ning from the moment when the pilot lamp flashes on No leakage of fuel through the joints is permissible 8 Check the serviceability of the pilot flame pre heater elec...

Page 174: ...condition of starter solenoid switch contacts and dress them if burnt Check brush to commutator con tact and lock for jamming of brushes in holders if necessary wipe and clean commutator and side surf...

Page 175: ...cau tiously ENGINE LACKS POWER Clogging of air cleaner Wash air cleaner elements Obstruction of exhaust line Clogging of fuel filters Clean exhaust line Replace filtering elements Governor control le...

Page 176: ...KNOKS Fuel injection into cylinders too early Adjust injection advance angle Valve gear out of adjustment Adjust valve to rocker clearances IRREGULAR ENGINE RUN Broken high pressure pipe or loosened...

Page 177: ...iod of engine service Send engine to repair shop for re placing bearing shells and if neces sary for grinding crankshaft jour nals OVERHEATING OF COOLANT IN COOLING SYSTEM Before looking for cause of...

Page 178: ...ssor cylinder head gasket Replace gasket NOISE IN TURBOCHARGER Rotor brushing against sta tionary parts Remove turbocharger for repairing or replace it AMMETER READS DISCHARGE AT RATED ENGINE SPEED Sl...

Page 179: ...LARGE CHARGE CURRENT ammeter pointer gets over scale Faulty voltage regulator Replace voltage regulator Closure of terminal shunt wire of generator or voltage regulator on ground Eliminate closure GE...

Page 180: ...ircuit and eliminate malfunction SOLENOID SWITCH WORKS WITH FAULTS switch in starter and immediately switches off it Storage battery discharged Charge or replace storage battery Open circuit in holdin...

Page 181: ...t of filament in one of glow plugs Check resistance of glow plugs Replace both plugs if one of them is faulty WITH ELECTRIC PILOT FLAME PRE HEATER SWITCHED IN FOR PREHEATING AMMETER POINTER ON INSTRUM...

Page 182: ...ealing of fuel system with pressure gauge connected Having primed fuel to a pressure at which fuel injection pump by pass valve opens make an inter val of two minutes and see that pres sure in system...

Page 183: ...following order 1 Drain coolant from the engine cooling system 2 Disconnect all the pipes from the cylinder head and take measures to prevent dust and dirt from getting in 3 Remove the cylinder head c...

Page 184: ...y reversing removal op erations Before installing wipe the cylinder liner shoulders and matching surfaces of the cylinder head and cylinder block with clean rags The reuse of the cylinder head gasket...

Page 185: ...studs on a plate so as to provide a bearing surface for the valves Remove the valves with the tool illustrated in fig 84 Turn thrust screw 1 of the tool into the hole of the rocker axle stud place pre...

Page 186: ...nd put in place It is allowed to apply the compound on the seat chamfer The process of lapping consist of recip rocating and rotating of valves with special tool in absence of such a tool use a drill...

Page 187: ...uipped with oil cooling of pistons At dismantle of piston group on the specified engines previously take off the piston cooling injectors in order to prevent their breakages Clean the upper band of th...

Page 188: ...nto the piston grooves To compress the rings use a mandrel fig 88 with a taper inside surface and a shoulder which allows the man drel to be accurately aligned on cylinder liner Having inserted the pi...

Page 189: ...ngine towards the fuel injection pump In this case the hollows on the piston for the valves will be displaced concerning the centre of the cylinder in the side of exhaust collectors 5 The matching mar...

Page 190: ...d the circumference to prevent accidental snapping out of the plugs Fig 89 Crankshaft dirt trap plugs 1 crankshaft 2 plugs INSTALLING THE CRANKSHAFT INTO ENGINE When installing the crankshaft see that...

Page 191: ...thrust main bearing equalize the end clearance for this purpose secure the bearing cap slightly with bolts and shift the crankshaft back and forth axially to equalize the position of the cap Having ti...

Page 192: ...ecial adaptation DISASSEMBLY AND ASSEMBLY OF FUEL INJECTION PUMP SECTION OF 806 AND 807 MODELS During repairs all possible care should be exerted to keep dust and dirt from getting inside the pump To...

Page 193: ...ve seat 4 remove the lock screw of the plunger barrel and pull the plunger from pump housing 5 compress the spring a little and take it out of the pump hous ing complete with the upper retainer swivel...

Page 194: ...que of 100 120 Nm 10 12 kgfm after tightening each pipe union be sure to check the rack travel Having assembled the fuel pump with governor have them ad justed on a stand DISASSENBLY AND ASSEMBLY OF W...

Page 195: ...d washers 8 Unscrew the plug 7 from threaded hole of the impeller 2 9 Screw in threaded hole 22 1 5 of the impeller 2 the nut 17 of a remover tool 16 fig 97 98 and screwing in the bolt 18 remove the i...

Page 196: ...ss force apply to outer bearing ring 5 Install in the housing 1 groove the circlip 9 6 Press on the shaft 5 the pulley 10 against the bear On that necessary lubricate the shaft with clean motor oil en...

Page 197: ...less bear for opposite shaft end install the impeller on the shaft in dimension of 10 0 15 mm fig 96 between the shaft end face and impeller end face For that use at pressing the disk with diame ter n...

Page 198: ...in the housing 1 against the bear preliminary greasing the boring in the housing 1 and ring 11 with thin lay of grease Litol 24 15 Fasten the pipe 3 with nuts 14 and washers 15 16 Check the quality of...

Page 199: ...es ATTENTION FOR INFORMATION ON CLUTCH WITHDRAW UNIT OPERATING SEE THE INSTRUCTION MANUAL OF A VEHICLE SAFETY DEMANDS AND WARNINGS The basic condition of reliable clutch work on a vehicle is the knowl...

Page 200: ...rictional overlay Sizes of frictional plates mm outer diameter 430 inner diameter 240 thickness 4 3 Pressure disk theoretical diameter D mm 320 Pressure spring thickness mm 5 Driven disk hub splines s...

Page 201: ...and transmission of a torque from cover to the pressure plate For exception turning over of the diaphragm spring relatively to the cover and to pressure plate there are on the latter 6 pairs of bushes...

Page 202: ...upling is connected through the thrust ring 4 with diaphragm spring 3 with help of the lock ing device The back moving spring 7 fig 99 excludes the turning over and axial travels of the bush 7 relativ...

Page 203: ...ollar 5 The thrust collar 1 is installed on the diaphragm spring during assembly of the pressure plate with cover and is kept with spring washer 3 and lock ring 4 In figure the clutch release coupling...

Page 204: ...arting up was possible minimum and the vehicle began to start up smoothly without jerks Do not allow controlling vehicle speed by the clutch slip ping the pedal is pressed partially during manoeuvring...

Page 205: ...T UNCOMPLETELY CLUTCH DISENGAG ING OPERATION IS NOT ALLOWED The lubricant is supplied to coupling through the hose grease cup until appearance of grease in the clearance between the bearing bush and t...

Page 206: ...tall gearbox and fix it with two bolts CAUTION AT INSTALLATING OF GEARBOX DO NOT PER MIT TRAVEL OF CLUTCH RELEASING COUPLING TO FLY WHEEL AFTER IT JOINING WITH PRESSURE SPRING 4 Move the clutch releas...

Page 207: ...207 Fig 102 Main positions of locking device 1 thrust ring 2 spring washer 3 circlip 4 spring ring 5 lock ring 6 bearing bush 7 safety ring...

Page 208: ...s position through the release coupling central opening 5 Turn locking collar 5 fig 102 relative to bush 6 so that collar lugs coincided with bush slots position d 6 Push the coupling to the flywheel...

Page 209: ...fault according to vehicle opera tion manual C L U T C H N O N C O M P L E T E R E L E A S I N G Clutch drive unit does not provide necessary travel for releasing cou pling stroke Check drive unit wor...

Page 210: ...output shaft cap has speedometer drive flange 238 5 Gear box 238 4 base For diaphragm clutch Differs by the sizes of clutch release coupling presence of clamp for gearing of coupling cylindrical back...

Page 211: ...ft lever 238 3 Gear box 238 2 base For diaphragm clutch Differs by the sizes of clutch release coupling presence of clamp for gearing of coupling cylindrical back spring 238 4 Gear box 238 2 tightness...

Page 212: ...anical eight gear with synchronizers of all gears except for a back moving also consists of the basic four gear box and two range planetary auxiliary transmis sion Fig 103 238 Gear Box 1 clutch housin...

Page 213: ...213...

Page 214: ...the rear axle distributing gear box rolling radius of wheels correspond to a vehicle speed of 25 30 km h For each concrete vehicle this value can with sufficient accu racy be determined as result of d...

Page 215: ...the Vehicle Op eration Manual Then transfer the shift lever to a neutral position Wait and when the signal lamp will off shift the fifth gear For transition from fifth gear to fourth shift with auxili...

Page 216: ...ansmission with speed no more than 30 km h The towage of the vehicle on the longer distance should be made by one of the following ways With drive shaft disconnected Install the control member of tran...

Page 217: ...o output shaft speed more than 1000 min 1 SECOND MAINTENANCE SERVICE M 2 1 Carry out all operations of M 1 2 Check up and if necessary adjust a rear support of gearbox according to the Operation Manua...

Page 218: ...walls FEATURES OF ASSEMBLY OF GEARBOX Before installation of the auxiliary transmission with spacer on casing of the basic gearbox and of the spacer on auxiliary transmission casing put on the gasket...

Page 219: ...usting of gearbox output shaft axial play 1 centering ring 2 tight gasket 3 spacer 4 spring ring 5 adjusting gasket 6 teeth coupling Measure the dimension fig 106 from an end face of a bearing outer r...

Page 220: ...e auxiliary transmission fastening bolts for two steps see table Tightening torques The tightening sequence according to the fig 108 At repair of the auxiliary transmission with replacement of the syn...

Page 221: ...ting bolt from its position of bear against end face on one revolution 5 sides of the head and keeping it in this position secure it with lock nut having tightened it with torque137 157 Nm 14 16 kgfcm...

Page 222: ...x shafts bearings worn Replace faulty bearings Gear teeth worn Replace faulty gears GEARS DISENGAGED SPONTANEOUSLY Non uniform wear of toothed sleeve teeth Replace faulty parts Gearbox shafts bearings...

Page 223: ...Clean and grease inlet valve stem if necessary polish it Piston sealing collars of work cylinder worn or hardened Replace piston sealing collars ABSENCE OF ENGAGING OR SLOW ENGAGING OF RANGES IN AUXIL...

Page 224: ...strictly forbidden to shift first gear at highest range engaged in the auxiliary transmission GEAR BOX CHARACTERISTICS The 239 gearbox fig 109 is mechanical nine gear con sists of the basic five gear...

Page 225: ...225...

Page 226: ...0 9 5 Highest 0 78 0 7 Reverse Reverse Lowest 10 04 10 04 The mechanism of auxiliary transmission range shifting is equipped with automatic blocking system of the lowest range engaging LRBS The relay...

Page 227: ...h gear to fifth one move the auxiliary trans mission shift button for engaging of the lowest range at engaged sixth gear the vehicle velocity should be not more than 45 km h Then shift lever put in th...

Page 228: ...iodicity of maintenance service of the engine MAINTENANCE SERVICE AFTER RUNNING IN OF THE VEHICLE After the vehicle running in period change the oil in gearbox housing clean of wearing in products the...

Page 229: ...320 77 It is allowed the using of Litol 24 5 Clean and grease the auxiliary transmission piston seal col lars and auxiliary transmission engaging cylinder walls 6 Eliminate the leakages of air and al...

Page 230: ...an end face of the output shaft from the gear ring end face to the bearing boring end face in the input shaft 1 3 Select the necessary number of installing gaskets proceed ing from a condition S gaske...

Page 231: ...ect the neces sary number of installing gaskets to provide the bear of the counter shaft rear bearing end face to the spacer and the output shaft rear bear ing nestle to the teeth couple of the auxili...

Page 232: ...es of dimensions A between end faces of teeth couple and seal gasket and between end faces of housing and bear nestle fig 114 At that the 4 5 gear synchronizer hub end face should be densely under act...

Page 233: ...mm on a contour on the both sides of seal gasket 5 fig 105 the tightening compound UG 9 TU 6 01 1326 86 or UG 6 TU6 01 1285 84 5 Remove the special adaptation adjust axial plays in the bearings of the...

Page 234: ...g to the bearing outside ring end face 5 4 Join to the gearbox housing the oil pump Tighten its at tachment bolts with the torque 23 5 35 3 Nm 2 4 3 6 kgfm 5 5 Check up the correctness of the counter...

Page 235: ...of gaskets and S A Install the selected gaskets in the input shaft bearing cover boring to end face 5 9 Join the input shaft bearing cover to the gearbox housing Tighten attachment bolts with torque...

Page 236: ...of the auxiliary transmission with replacement of the synchronizer parts adjust required rod travel at engaging f the highest range having ensured unloading of the fork retainers at operation on the...

Page 237: ...GED WITH DIFFICULTY Incomplete clutch releasing Adjust free travel of clutch pedal or if defect is conse quence of malfunction of clutch parts replace damaged details Synchronizer worn or damaged Teet...

Page 238: ...ing of inlet valve in pressed out position Wearing or hardening of work cyl inder seals Replace valve Replace spring Replace ring Replace damaged parts Clean and oil valve stem if necessary polish it...

Page 239: ...lock and joints of sump gasket Locktite Ultra black Permatex Ultra black Planes of tie horizontal bolts of cylinder block main caps at installing without washers Locktite 518 Anaterm 505 Anaterm 501m...

Page 240: ...Socket wrench 19 1 Tommy bar 1 Socket wrench 14 1 Tommy bar 1 Socket wrench 12 1 Tommy bar 1 Socket wrench 10 1 Socket wrench 24 1 Feeler gauge 1 Injector removing tool 1 Tool bag 1 Operational docum...

Page 241: ...y of air should not exceed 70 The temperature should be supported not below 15o C Sharp fluctuations of temperature and humidity within day are not allowed The light exposure of a workplace should be...

Page 242: ...OST 8828 89 The polyethylene film by thickness of 0 2 mm GOST10354 82 The rubberoid GOST 10923 82 The paraffined paper GOST 9569 79 The polyacrilamyde TU 7 04 01 72 The potassium chromate GOST 2652 78...

Page 243: ...ntake duct opening 3 Drain the rests of oil from the sump and also oil from the high pressure fuel pump Drain the oil from the fuel pump through the oil outlet hole 4 Preservation of the fuel feed sys...

Page 244: ...e high pressure fuel pump 600 ml of working preservating oil having temperature of 70 80o C through the oil outlet hole b Turn the engine downwards of cylinder head unscrew from the sump drain plug sc...

Page 245: ...ilters 7 The preservation of the drain rail of the injectors carry out in follow order connect to the tip 10 of the drain pipe the suction strainer from special pump and dip the strainer in container...

Page 246: ...easing the gearbox output shaft flange clutch release fork shaft and auxiliary drive hub after that put the preventive cases on the said parts grease the outer surfaces of the flywheel for the engines...

Page 247: ...____________________ Date and sign Checked Inspector _______________________________________ Checked Inspector Term of represervation ______________________________________________________ 4 Transport...

Page 248: ...ing temperature 70 80o C up to the top mark of the dip steak Close the oil filler cap 7 Fill the gearbox with 8 l of working preservation oil at tem perature 70 80o C Screw in the plug 8 Start the eng...

Page 249: ...fuel delivery off position Note In case of occurrence of fire in cylinders make the preservation repeatedly meeting to the requirements 19 Drain the working preservation oil from the engine sump and t...

Page 250: ...f the Maintenance Instruction THE SAFETY PRECAUTIONS AND FIRE PREVENTION MEASURES AT PRESERVA TION AND DEPRESERVATION 1 The preservation is made by the special workers who have received the appropriat...

Page 251: ...pulated only the wiping with rags soaked in white spirit or gasoline 7 The amount of white spirit or gasoline on the preservation section should not exceed the day need The section should be equipped...

Page 252: ...er cover bolts 25 32 2 5 3 2 Cylinder head stud nuts 240 260 24 26 Rocker axle nuts 120 150 12 15 Starter clamp bolt 70 90 7 9 Starter bracket bolts 45 62 4 5 6 2 Injector clamp nuts 50 62 5 6 2 Injec...

Page 253: ...s 10 20 25 2 2 5 14 40 50 4 5 16 48 50 4 8 6 Clutch housing fastening bolts to gearbox 137 157 14 16 Clutch housing fastening bolts to flywheel housing 12 70 80 7 8 Spacer fastening bolts to basic gea...

Page 254: ...100 POWER UNIT STARTING WORK AND SHUT DOWN 102 POWER UNIT MAINTENANCE 109 ENGINE ADJUSTMENT 113 ENGINE REPAIRING 174 FEATURES OF ENGINE DISASSEMBLY AND ASSEMBLY 183 CLUTCH 199 GEAR BOX 210 TIGHT COMP...

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