Since December 2013, the Yaroslavl facilities of Avtodizel OJSC have been producing diesel units of the YaMZ-530 family. This includes so far only two engine models - four- and six-cylinder engines.
In our country there are a lot of enterprises that produce trucks, buses of various sizes, as well as many options for special equipment for construction and agriculture. In order for all this to work, it is necessary to provide the units with engines. At the same time, it is desirable that these diesel engines have a long life cycle and that they comply with Euro-5 standards.
The goal of this project is to create a truly universal platform on the basis of which it will be possible to produce power units for a wide variety of equipment in the agricultural and construction sectors. After all, it is known that in order to build a special version of a tractor engine, many different additional tasks will be required. Often some parts have to be reworked. However, specialists from the Yaroslavl plant guarantee that in order to use this engine, no design changes will be necessary.
A risky but successful step
The Yaroslavl Motor Plant really took a real risk. After all, creating a YaMZ-530 diesel engine that would not only have unique characteristics, but could also create competition for the best models of world manufacturers is very, very difficult.
To do this, in the mid-2000s, European engineers were invited as partners in this project. After several years of development and experimentation, a series of in-line engines with a volume of 1.1 liters per cylinder was created.
The same volume, by the way, is found on units of well-known brands such as Cummins, Volvo and Iveco. The YaMZ-530 engine also has advanced characteristics in terms of power and fuel consumption.
By the way, this internal combustion engine is one of the first in the entire history of domestic engine building. This product has become a new product not only for the whole country, but also for Avtodiesel. After all, here is not only the latest design, but also other methods of design and development. As a result, it was possible to create a power unit called YaMZ-530, reviews of which are mostly enthusiastic.
Production and market prospects
The launch of pilot production is scheduled for September 2011 and coincides with the 95th anniversary. The new production will be called the “shop for the production of medium-sized in-line engines YaMZ-530” as part of Avtodizel OJSC. The design number of personnel at full capacity of the first stage is 1250 people, of which about 10% are engineers.
There is currently confirmed demand for 4 and 6 cylinder models in a percentage ratio of 54:46. The consumers of 4-cylinder engines will be PAZ, which produces small-class city and suburban buses, as well as GAZ, which produces medium-sized trucks. V-shaped engines on heavy trucks produced by MAZ, AZ Ural and LiAZ should be replaced by 6-cylinder engines.
It is planned to equip military vehicles with YaMZ-530 engines. These are both traditional for the order of the RF Ministry of Defense - the Tiger-M family, a special police car SPM-3, special equipment based on Ural vehicles, and fundamentally new ones - "Ural-43206" 4x4, "Punisher" GAZ-29651, " Wolf" VPK-3927. According to the latest data, AMZ OJSC has already produced a pilot production batch of 34 vehicles with the YaMZ-5347-10 engine.
Market for medium-sized diesel engines in the power range of 100…300 hp. today one of the fastest growing. OJSC Avtodizel timely enters this segment with very promising products.
The table clearly shows the significant advantages of YaMZ-530 Euro 4 over competing analogues.
The GAZ Group strives to provide consumers with stable and predictable competitive prices for YaMZ-530 engines at all stages of project development. Undoubtedly, inflation will increase the cost, primarily of imported components. Localization will reduce the impact of this factor, and the GAZ Group is ready to take on a significant part of the serious investments that this will require.
In the coming years, if the development trends in the automotive industry are confirmed, up to 40 thousand YaMZ-530 engines will be produced and sold per year. If necessary, the plant will be able to increase production at the created capacity to 52 thousand per year by introducing additional shifts. In general, the project provides for the prospect of increasing production to 80 thousand engines per year.
Over the decades that have passed since the collapse of the USSR and socialist cooperation, the positive image of Yaroslavl motors in foreign markets has been largely lost. At some of them, YaMZ products were completely replaced by competitors. The company’s task today is to regain lost positions. These are not abstract hopes. It is planned to begin the revival of the brand in countries where the conditions for the development of the automotive industry are close to Russian conditions. Already today, the plant is negotiating large supplies of YaMZ-530 engines with several reputable automakers from Asian countries.
In developed countries of Europe and North America, Euro 5 standards are already in force, and promising developments are underway for Euro 6 version engines. The YaMZ-530 was created primarily for the Russian market, where Euro 4 standards fully come into force only in 2012. This situation is similar with many developing countries, which received special attention when assessing the export potential of the project. Today, without exception, all the largest transnational companies in the industry are relying on the dynamically developing macro-segment of medium-sized in-line engines to expand the market, and the Yaroslavl project has a high potential for demand.
But, according to GAZ Group specialists, the project may also be of interest to consumers from other countries in the future. The characteristics, design and price of the engine are very competitive. Possibilities for modification to Euro 6 requirements are included in the technical specifications. During the implementation of two projects - YaMZ-650 and YaMZ-530 - experience in partnership with the world's leading engineering centers has been accumulated. It is known that the design of new equipment begins with the power unit, and the development is based on already well-proven developments. So it will take time to implement these plans. But it is here that our country has a real chance to break into foreign markets not with raw materials, but with the offer of a high-tech product created in Russia.
Scheme
We decided to choose a lower design for the new engine. Both domestic and European experts unanimously said that this would be better for medium-sized diesel engines with low speeds.
The engine is quite compact. The reason for this is the lack of camshafts in the cylinder head. But the cylinder head itself is not very tall or has any other dimensions. Also, in this engine you cannot find a long gas distribution mechanism drive. Engineers managed to significantly reduce the weight of moving and rotating components and parts. The design itself, compared to other modifications, has become much more reliable. The operation of the unit is quite quiet and has increased durability. All the most important components receive movement from the crankshaft drive. This allows rotational vibrations to be significantly minimized.
Highlights
Among the interesting points in the design of the YaMZ-530 is a cooling system with the possibility of reverse operation. So, the coolant does not enter in the usual way for many - from bottom to top, but from top to bottom.
So, first the hottest area is cooled - the cylinder head, and then the cylinders themselves. Engineers managed to achieve almost maximum efficiency with the introduction of this innovation. It is also worth noting the thermal stability of the dimensions of engine components and parts. Tuning specialists will appreciate this. Now you can almost effortlessly boost any unit of the YaMZ-530 family.
Engineers used wet liner technology in this power plant. This turned out to be a little inconvenient for production, however, as practice has shown, the cylinders are cooled more evenly. The cylinder-piston group has a longer service life. If something needs to be replaced, there is no need to bore the cylinders to the correct size. You can immediately install nominal parts. The resource, according to the developers, is more than a million kilometers. This is an impressive figure.
Innovative cooling system
Any motor can be ruined if it overheats. Therefore, the designers developed a rather unusual type of cooling system. The fact is that in the classical case the liquid flows from the bottom up, but here it’s the other way around. This approach made it possible to first cool the hottest area, which is the cylinder head. Then the antifreeze goes to the cylinders themselves. According to many experts, this approach allows you to almost completely eliminate the possibility of engine overheating. But it is necessary to carefully monitor the serviceability of all components of the cooling system, since failure of the thermostat or pump can lead to dire consequences.
During testing, a high level of thermal stability of all components was noticeable. This is without a doubt very good. Such a motor can be easily boosted if necessary. For more uniform cooling of the cylinders, wet liner production technology was used. Although this led to increased manufacturing costs, it made it possible to significantly increase the service life of the cylinder-piston group.
Efficiency and versatility
The YaMZ-530 diesel power unit is the embodiment of the most modern and advanced solutions. There is a unique battery-type fuel supply scheme at work here. This is controlled by an electronic control system. All parts were manufactured to work under high pressure.
The lubrication system, as well as efficient cooling, make it possible to obtain a liter power of up to 34 kW. The gear-based drive on the flywheel side makes it possible to make the operation of the unit almost silent. The closed crankcase ventilation system is fully integrated into the cylinder head cover. You won't have to service it anymore.
One of the advantages of this diesel engine is its high compactness and low weight. This allows you to significantly simplify the process of installing it in the engine compartment of a truck. The developers were able to incorporate various options into the design. This is the ability to install a compressor for an air conditioner, a pre-heater, as well as a cabin heater.
New YaMZ turbodiesels: envy, Europe
Once upon a time, YaAZ, later renamed YaMZ, began with one site in Yaroslavl, and now there are two.
And one more - on the current outskirts, beyond the Volga, as the locals say. There, in 2013, a new plant was opened to produce YaMZ-530 engines. This is the most modern production of turbodiesels not only in our country, but throughout Eastern Europe. In addition to the YaMZ-534 “fours” and the YaMZ-536 “sixes”, since the fall of 2015, Mercedes-Benz OM 646 diesel engines have been produced here for Sprinter Classic buses, which are assembled at the Gorky Automobile Plant. At YaMZ, the block is completely processed with drilling of all holes, boring and honing. Crankshafts are processed and ground. This trust of the Germans is worth a lot.
Everything is yours
GAZ has mastered the casting of the most complex parts of the YaMZ-530 - block and head. The foundry in Nizhny is the most modern. Mechanical processing in Yaroslavl was established even earlier, and at first the castings were imported - from the German enterprise Fritz Winter. It is a supplier to many factories where BMW, Mercedes-Benz, Volvo and others are produced.
The piston group is supplied either from Kostroma, from Motordetail, where they use Kolbenschmidt technologies and materials, or from Naberezhnye Chelny, from the Federal-Mogul plant. Crankshaft blanks are supplied by KAMAZ. And at the Yaroslavl Diesel Equipment Plant (YAZDA) they have mastered the production of fuel injection pumps of a modular design! Previously, the entire fuel system was from Bosch.
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Electronic control unit - Moscow company ITELMA. Turbocompressors are made by NPO Turbotekhnika in Protvina, near Moscow. With domestic fuel equipment, we have not only achieved the Euro-5 level, but are also working to comply with Euro-6 standards.
Russian components make it possible to create more powerful modifications of diesel engines. If previously the YaMZ-534 (4.43 l) had a power limit of 190 hp, now there is a 210-horsepower engine, which they plan to equip the Lawn Next truck tractor and other cars.
The six-cylinder YaMZ-536 (6.65 l) had a limit of 312 hp, but will be 330 hp. (Euro-5). It is planned to produce a “six” with a working volume increased to 7.0 liters with the same piston diameter; power - from 330 to 370 hp. The main customers will include MAZ and Ural - especially since it is planned to begin production of on-road trucks based on the Ural M and Ural Next models.
Fan cylinders
A veteran on the assembly line is the V6/V8 family: these engines have been produced for 55 years! I remember that YaMZ specialists said that V-shaped engines would not even be brought to the Euro-4 level and would gradually curtail production. Among the reasons cited were greater weight than in-line sixes and relatively low liter power. But since the beginning of 2013, these engines have been produced in Euro-3, Euro-4, and now Euro-5 versions. And each version has its own consumer.
Based on the YaMZ-6585 V8 engine (14.86 l, 420 hp), a 500-horsepower version has already been made. But the torque increased slightly - from 1766 to 2000 Nm: too much torque is not needed, otherwise problems with the transmission will arise. The increase in power is achieved thanks to different valve timing and joint tuning of the common rail system and turbocharger.
The engine still has common cylinder heads with two valves per cylinder. The 500-horsepower version has a modified lubrication system; forced cooling of the piston with oil is used through a special gallery in a ni-resist insert. The pistons themselves are of a more complex design. A water-oil heat exchanger with increased efficiency is used.
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The common rail equipment is manufactured at YAZDA, but there are also imported components. On the G8, the electronic control unit and software were developed by the St. Petersburg company ABIT, and the production of the ECU was mastered at the Stary Oskol SOATE plant. Electronically controlled fuel injectors are made in Barnaul. To comply with Euro 4 requirements, SCR selective catalytic reduction technology with AdBlue was used. The Euro-5 V8 engine is also equipped with SCR, but has original settings, and compliance with Euro-3 standards is achieved without the use of urea.
French lessons
Work on a pilot batch of in-line sixes YaMZ-770/YaMZ-780 with a volume of 12.43 liters is nearing completion. Structurally, they are close to the YaMZ-650 (aka Renault dCi11 with a volume of 11.12 liters). There is a turbocharger, an intercooler, and a timing belt with four valves per cylinder. The power range is from 500 to 850 and even up to 1000 power! Torque - from 3000 to 3700 Nm. The new engines have a completely original cylinder block, cylinder head, and crankshaft.
The degree of localization reaches 90%. Moreover, in terms of dimensions, the new diesel engine is comparable to the YaMZ-650, so when processing parts for the YaMZ-770/YaMZ-780, you can use existing equipment and processing lines. All this will allow us to quickly launch the Yaroslavl new product into series.
A motor that sets new standards
The unit is extremely reliable. The resource is very high. Intervals between maintenance are up to 50 thousand kilometers. This is the way to reduce maintenance costs by almost half. Equipment with these motors is highly environmentally friendly, silent operation and comfortable.
The design and operation of the YaMZ-530 greatly pleases the owners. The level of vibration and noise is no more than 92 dB. This allows you to permanently abandon the rather expensive bonneting of the engine compartment, and also increases comfort for the driver in the cab or for passengers on the bus.
Application and features
The YaMZ 534 engine is an example of a reliable and durable solution. In this regard, the Yaroslavl plant does not betray itself: the power unit has a working life of up to 0.7 million km. with the need for maintenance every 30 thousand km. (or 1000 hours of operation). Oil consumption due to waste is no more than 0.1% of fuel consumption, which corresponds to the best examples of similar equipment on the world stage.
It should be noted that the production of this model was established at a completely new industrial site, equipped specifically for the production of modern diesel engines that meet international standards. Foreign technologies are widely used to achieve better results. For example, the casting of the block and cylinder heads is carried out using German Fritz Winter equipment, which ensures improved durability and reliability of the engine.
To summarize, we can say that the YaMZ 534 engine is a progressive and very successful project that allows the Russian automobile industry to introduce the latest developments in the field of diesel power units at quite reasonable prices.
Engine "YAMZ-530": technical characteristics
Let's see what the basic version of this motor is capable of. So, this is an inline, four-cylinder power unit. Its working volume is 4.4 liters. Depending on the modification, power can vary from 136 to 190 horsepower for the four-cylinder version.
The crankshaft speed for the base unit is 2300 rpm. Maximum torque – 710 Nm at 1600 rpm. As for the fuel consumption of the YaMZ-530, the characteristics show that the unit’s appetite is 143 grams per horsepower per hour. It's quite technological. The engine weight is only 480 kg in the basic version.
The six-cylinder version has better performance. The volume of the unit is 6.6 liters. In terms of equipment, this version is a complete copy of the four-cylinder. There is the same drive unit, the same cooling system, and a turbocharger is installed.
Power, depending on the modification, will range from 270 to 312 horsepower. The torque in this version is 1226 Nm at 1600 rpm. The minimum fuel consumption is 194 grams per 1 horsepower per hour.
Reliability, problems and repair of YaMZ-534
The YaMZ-530 engine series began production in 2012 and consisted of a 6-cylinder YaMZ-536 and a 4-cylinder YaMZ-534, we’ll talk about the latter here. This is a complete copy of the 536, but without 2 cylinders. There is a cast-iron in-line cylinder block with oil nozzles and cast-iron wet liners. The crankshaft with 88 mm journals and 76 mm connecting rod journals has a piston stroke of 128 mm. The 534 has steel connecting rods and 105 mm pistons. As a result, we have a working volume of 4.4 liters.
The engine is covered with a head with 4 valves for each cylinder. Valve size (intake/exhaust): 36/34 mm. This is a lower engine and the camshaft is in the block. The valves need to be adjusted as needed; this need to be checked every 30 thousand km. Valve clearances (intake/exhaust): 0.3-0.4/0.4-0.5 mm.
Common rail injection and Bosch CP3.3 NH fuel injection pump are used here, and the injection pressure is 1800 bar. Euro-5 versions are equipped with a YAZDA 531 pump, the pressure is increased to 2000 bar, and the turbine is replaced with a Holset HE200VG. The oil pressure on a warm engine is in the range of 4.1-5.6 kgf/cm2. This turbodiesel is equipped with a TKR 60.02.02 turbine (BorgWarner S200G) or TKR 50.09.14 (BorgWarner S100G).
The engine is controlled by a Bosch EDC7 UC31 ECU, and modifications for Euro 5 were received by Bosch EDC17 CV44 and Abit M240 units.
Modifications of YaMZ 534 and their differences
1. YaMZ-5340 - the first model with 190 hp. at 2300 rpm, torque 710 Nm at 1200-1600 rpm. This version meets Euro-4 standards and is equipped with a TKR 60.02.02 turbine. — YaMZ-53402 — model according to standards 96-02 for ZZGT-3344. - YaMZ-53403 - Euro 5 model for LiAZ-4292 and KAVZ-4270. Power increased to 210 hp. at 2300 rpm, torque 780 Nm at 1200-1600 rpm. The engine is equipped with an EOBD, a Holset HE200VG turbine, a YAZDA 531 pump, has increased injection pressure (2000 bar), and an M240 ECU. — YaMZ-53405 — combine harvester engine with 200 hp. — YaMZ-53406 — diesel for various construction equipment with 190 hp. 2. YaMZ-5341 - the same 5340, but upgraded to 170 hp. at 2300 rpm, torque 670 Nm at 1200-1600 rpm. Stands on PAZ-3204. - YaMZ-53411 - analogue of 5341 with OBD instead of EOBD. Installed on Vector 8.8 and PAZ-3204. - YaMZ-53412 - modification under 96-02 for boats KS-131M and 110-52. — YaMZ-53414 — CNG version 5341 for KAVZ-4235 and PAZ-3204. — YaMZ-53415 — tractor version with 190 hp. for K-708.4 according to standards 96-02. — YaMZ-53416 — 180 hp diesel. for construction equipment RM-Terex TG 140 and TX 210. Environmental class 4 (96-02). - YaMZ-53418 - another version under 96-02 for 137 hp loaders. at 2100 rpm, torque 710 Nm at 1300-1600 rpm. 3. YaMZ-5342 - version 5340 with TKR turbine 09.50.14. This power plant develops 150 hp. at 2300 rpm, torque 590 Nm at 1300-1600 rpm. They put it on PAZ-4234, 3337. - YaMZ-53421 - the same 5342 where EOBD is replaced by OBD. - YaMZ-53423 - analogue of 53403 with a TKR 50.09.16 turbocharger, which allows you to develop 170 hp. at 2300 rpm, torque 664 Nm at 1200-1600 rpm. They install an internal combustion engine on PAZ-3204, 3205, 4234. - YaMZ-53424 - version running on gas. Available in PAZ-3204, 3205, 4234 vehicles. - YaMZ-53425 - combine harvester model for environmental class 4 (standard 96-02), power 180 hp. at 2200 rpm, torque 690 Nm at 1300-1600 rpm. It is installed on Nova S300. 4. YaMZ-5344 - analogue of 5342 with firmware for 136 hp. at 2300 rpm, torque 422 Nm at 1200-2100 rpm. Found on PAZ-3205 and GAZ-3309. — YaMZ-53441 — 150 hp version. for GAZon Next under Euro-4. - YaMZ-53442 - analogue of 5344 under standards 96-02 for GAZ Sadko. - YaMZ-53443 - the same as 53423, but with hp reduced to 150 power. Under the hood is GAZon Next, Vector Next and Sadko Next. — YaMZ-53444 — gas engine based on 5344 for GAZon Next. 5. YaMZ-5345 - a diesel engine based on the YaMZ-5340, but without EGR, with a TKR 80-04 turbine and its own firmware. This allowed us to get 240 hp. at 2600 rpm and torque 784 Nm at 1400-1700 rpm. Such motors meet the 4th environmental class (rules 96-02). Installed on MZKT-5002 and Aerokhod A25. - YaMZ-53452 - analogue of 5345 with a power of 215 hp. at 2600 rpm and with a torque of 735 Nm at 1400-1700 rpm. Found on MZKT-5002. — YaMZ-53455 — combine version with 160 hp. for Nova S300. 6. YaMZ-5346 - version 5340 for KAVZ-4235. The engine develops 170 hp. at 2300 rpm, torque 590 Nm at 1300-1600 rpm. 7. YaMZ-5348 - version for diesel generators.
