KAMAZ 5490 Operation Manual
  1. Manuals
  2. Brands
  3. KAMAZ Manuals
  4. Trucks
  5. 5490
  6. Operation manual

KAMAZ 5490 Operation Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

KAMAZ PUBLICLY TRADED COMPANY
Operation manual
КАМАZ-5490 vehicle
5490-3902203-01 РЭ
Naberezhnye Chelny
2017

Advertisement

Table of Contents
loading

Summary of Contents for KAMAZ 5490

  • Page 1 KAMAZ PUBLICLY TRADED COMPANY Operation manual КАМАZ-5490 vehicle 5490-3902203-01 РЭ Naberezhnye Chelny 2017...
  • Page 2 4500 m, with pass-overcoming abil- 423827, Russian Federation, Tatarstan, Naberezhnye ity up to 4650 m, with corresponding change of tractive- Chelny, Avtozavodsky str., 2, KAMAZ PTC headquar- dynamic abilities, properties and fuel economy. ters, Scientific & Technical Centre, tel. 8 (8552) 33-82- Truck tractor can be operated with semitrailers, 38, tel./fax 37-28-34.

  • Page 3: Table Of Contents

    CONTENT ……………………………………..………..…………………………………...…..…. 1-1 1 FOR YOUR ATTENTION .……………..……………………………………………………………..………..2-1 2 OPERATION PARAMETERS Vehicle technical data………………………..……………………..……………………..………....2-1 Table of additional technical data ………………………………………………….……………...…..…. 2-2 Engine technical data……………….……….……………………………………………………..……… 2-3 Tire air pressure………………..………………………………………………………………….……….. 2-3 Tools, accessories, spares and operational documentation supplied with vehicle …………………….. 2-4 Vehicle marking…………….…………………………………………………………………………..
  • Page 4 Instrument panel…..……………………………………………………………………..………………..4-3 Instrument cluster……….………………………………………………………………..……..4-3 Pilot lamps……………….…………………………………………………………….…….. 4-5 Information display………….………………………………………………..…………..… 4-6 Information system control………………….……………………………………………..… 4-7 Check before motion initiation………..…………………………………………………..…. 4-8 Switch blocks…………….…………………………................4-11 Instrument panel……..…..………………………………………………………………….… 4-11 Driver's/ passenger's door…….…………………………………………………………….… 4-13 Over the windshield……..………………………………………………………………….… 4-13 Bunk……………………………………..…………………………………………………… 4-14 Adjustment of headlamp inclination angle……………………………………………………………….. 4-14 Light shifter…………….……………………………………………………………………………….…..
  • Page 5 Windscreen washer…..………………………………………………………………………..... 4-19 Cab doors…………………………………………………….……………………………………...……..4-20 Door lock blocking…………..……………………...…………...……………………..…………..… 4-20 Lowering and raising of side windows of driver/ passenger……………………….……………..…. 4-21 Lifting top hatch……………………………………………………………..….………………………..… 4-21 Mechanical closure of raisable top hatch……………………………………..……………………... 4-22 Safety screen of the hatch….……………………………..………………………………………….. 4-22 External rear view mirrors………….…………..……………………………………………..………….. 4-23 Position regulation of external rear view mirrors…………….………………..…………………..…...
  • Page 6 Cab interior light………………….…………………………………………………….……..……..……. 4-37 Electrical sockets…..……………………………………………………………..………......4-38 Jumper…………….…………………………………………………….…………………………………… 4-38 Voltage converter…………………..………………………………………………………………..……… 4-38 Output terminal for radio station power…..……………………………..………………………..……… 4-38 Ash tray.………..……………..……………………………………….…………..……………………..…. 4-39 Smoke detector………..………...……………………………………………………..………..……..4-39 Digital tachograph……………………………………………………………………..………………..…. 4-40 Glove compartments and boxes………………..………………………………………………….……..4-40 Terminal for power of radio receiver…….……..………………………………………………….……..4-40 Emergency response service calling unit (ERA-GLONASS)….…………………….………………..……...
  • Page 7 Messages on the display……………………………………………………………………..4-57 Gear shifter………………..………………………………………………………………….. 4-58 Automatic gear box control………………………….……………..…………………………. 4-59 Gearbox manual control………………….…………………………………………...………. 4-60 Motion modes……………………………………………………………………………..…. 4-60 Interwheel differential lock……………………..………………...………………………………..4-62 Brake system………..…………………………………………………………………………...…... 4-63 Service brake system………………………………………………………………..……...… 4-63 An emergency brake system…..……………………………………………………………… 4-63 Parking brake system……………..………………………………………………….…..…. 4-63 Auxiliary brake system………………….………………………………………………….…...
  • Page 8 ……………………………….…………………….……………..….….. 5-1 5 VEHICLE OPERATION IN COLD SEASON Special features of vehicle operation during cold period of time…………….………………………..… 5-1 Cold weather engine starting……………..…………………………..…….………………...…….... 5-3 To start the engine using the efu unit…….……….……………………………………...……..5-4 Pre-starting heater……………….……………………………………………………..…………..… 5-5 Fuel heating…………..……………………………………………………………………………...……... 5-5 To heat the neutralizing liquid…..………………………………………….…………………..…….…... 5-5 ……………………..……………………………………………….…………..……..……..….…...
  • Page 9 Sequence to read diagnostic codes………………………..………………………………………..… 7-4 Mode for diagnostics of operational parameters.……………………………………………………. 7-6 Indication and elimination of faults……………………………………………………………….……… 7-8 Indication of faults in the lightning equipment………………..…………………………………………. 7-19 Engine start from external power source……………………………….……………………….……….. 7-24 Starting the engine from the battery of another vehicle………………..………………………….… 7-25 Battery emergency switch off…………………………….………………………………………………...
  • Page 10 …………………..........................11-1 11 UTILIZATION ……..……………………………………………………………………………...….………..…….. APPENDIX Appendix 2. Lubrication chart for KAMAZ 5490 vehicle.……………..…………………………………….…..… А2-1 Appendix 3. Service materials………………………..…………………………………………………………….. А3-1 Appendix (copy) Diesel Engine Pre-heaters 14ТС-10. Appendix (copy) Liquid small-size pre-starting heater PROMOTRONIK-16ЖД-24. Appendix (copy) Service instruction AIRTRONIC D2. Independent device for heating and maintenance of air temperature in the cab Appendix (copy) Operating Instructions.

  • Page 11: For Your Attention

    Technical Centre, KAMAZ PTC. Failure to observe this requirement will void the warranty maintenance of a truck. 4. KAMAZ PTC preserves the right for further de- velopment of vehicle construction without preliminary notification of users. 5. Drivers trained in specialized training centers...

  • Page 12: Operation Parameters

    2 OPERATION PARAMETERS VEHICLE TECHNICAL DATA КАМАZ-5490 (М1842) Wheel arrangement …………….....…………..4x2 Technically permissible maximum bolster load, daN ……………………….…..…..10550 , 11050 , 10625 Technically permissible maximum weight of vehicle , kg.……………………………………..18600 Technically permissible maximum weight of semi-trailer towed, kg……..35950 , 36450...

  • Page 13: Table Of Additional Technical Data

    TABLE OF ADDITIONAL TECHNICAL DATA Operational data Model 5490 axle 1 7100 Technically permissible maximum weight of vehicle, kg, applied to: axle 2 11500 Maximum driving speed , km/h, at least: train Test fuel consumption per 100 km at speed 60 km/h, l, not more:...

  • Page 14: Engine Technical Data

    ENGINE TECHNICAL DATA Mercedes-Benz OM Mercedes-Benz OM 457LA.V/4; 457LA.V/3; Mercedes-Benz OM Engine model Mercedes-Benz OM Mercedes-Benz OM 457LA.V/2 457 LA.EEV/4 457 LA.EEV/3 Engine type Four-stroke, diesel, turbocharged Number of cylinders Cylinder arrangement In-line Displacement, l 11,97 Net maximum capacity, kW (h.p.) 315 (428) 295 (401) 265 (360)

  • Page 15: Tools, Accessories, Spares And Operational Documentation Supplied With Vehicle

    TOOLS, ACCESSORIES, SPARES AND OPERATIONAL DOCUMENTATION SUPPLIED WITH VEHICLE pcs./vehicle Name Operation documentation Operation manual 1 pc. Service book 1 pc. List of operational documents 1 pc. Operation manual Engine Mercedes-Benz OM 457LA 1 pc. Service book Engine Mercedes-Benz OM 457LA 1 pc.
  • Page 16 Additional equipment that can be attached under certain requirement, specified by supply agreement: a tool kit in a small bag at extra cost, a minimum tool kit at extra cost, an oil transfer pump (1 pc.). Truck (chassis) is to be equipped with tools, ac- cessories and appropriate operation documentation for purchased products.

  • Page 17: Vehicle Marking

    VEHICLE MARKING - weight values: technically permissible maxi- mum weights and permitted maximum weights (not indi- Manufacturer’s plate cated on chassis). The manufacturer’s plate is fixed in a r.h. door If technically permissible maximum weight ex- aperture. ceeds the corresponding permissible maximum weight, then, the weight values are indicated in two columns.
  • Page 18 Manufacturer’s plate for export vehicle Permissible weights allowed for registration: - m* - vehicle gross weight; The manufacture’s plate is fixed to the cab r.h. * - train gross weight (for tractors); panel in a door aperture. - Р * - permissible front axle load; - Р...

  • Page 19: Engine Marking

    VIN code ENGINE MARKING Engine has its own manufacturer’s plate (see Op- VIN code is applied onto the vertical wall of the right side member in frame front or rear part and in- eration and maintenance manual for Mercedes-Benz en- cludes: gine).

  • Page 20: Scheme Of Sealing

    SCHEME OF SEALING Supplier’s seal Tachograph КАМАZ seal (view from both sides) Speed sensor Cover of «ZF» gear box, power steering of «RBL», «ZF» companies are not sealed. If tachograph is installed in vehicle manufacturer’s plant, the tachograph is sealed temporarily.

  • Page 21: Brief Description Of Vehicle Systems And Mechanisms

    3 BRIEF DESCRIPTION OF Axles VEHICLE SYSTEMS AND MECHANISMS Axle «DAIMLER» (HL6) is used on the vehicle. Provision is made on the vehicle for installation of driv- ENGINE ing axle with inter-wheel differential interlock mecha- Vehicle is equipped with engine Mercedes-Benz nism.

  • Page 22: Suspension

    SUSPENSION Front suspension is a leaf spring suspension. Cab is metal, located over the engine, two seat, Rear suspension is an air spring suspension. For with a super high or low roof, with one or two bunks. air suspension regulation and control an electronic con- Installation of cab on the frame is possible on 4 trol system (ECAS) of «WABCO»...

  • Page 23: Electric Equipment

    2. Do not test the alternator for operability by service centers of KAMAZ PTC. shorting the positive terminal, the field winding lead, Installation of emergency response service call de- the phase terminal and the pilot lamp contact between vice («ERA-GLONASS») on the vehicle is possible.

  • Page 24: Vehicle Operation

    4. VEHICLE OPERATION Attention! Take out the ignition key only after complete VEHICLE KEYS stoppage of vehicle, as vehicle driving is impossible Keys are designed for cab door opening and for without the key. instruments-and-starter switch. Keys have a special cod- To prevent unauthorized persons’...

  • Page 25: Driver's Working Place

    DRIVER’S WORKING PLACE 26 27 24 25 21 22 Driver’s working place 1 – switch block on driver's door; 2,10,17 – ventilation and heat deflectors; 3 – smoke detector; 4 – cab heat control console panel (if available); 5 – tachograph; 6 – terminal for radio receiver energizing ; 7 – switch block; 8, 27 – clothes compartment; 9 – glove box; 11 - switch block on passen- ger's door;...

  • Page 26: Instrument Panel

    INSTRUMENT PANEL INSTRUMENT CLUSTER Instrument cluster 1 - Electronic tachometer; 5 - electronic speedometer; 2 - tachometer indicator, lightens up (color - red) 6 - speedometer indicator lights up (red color) if when the vehicle moves at modes dangerous for engine vehicle set maximum speed is exceeded.
  • Page 27 7 - pressure gauge in brake system circuit 1; Attention! the rated air pressure in pneumatic drive is from 9,0 Steady operation of instrument cluster is guar- to 10,0 kgf/cm . Pilot lamp is located in the indicator anteed at ambient air temperature to – 40 ºС. At ambient air temperature lower than -30 ºС...

  • Page 28: Pilot Lamps

    Pilot lamps Malfunction in exhaust gas aftertreatment system and/or engine (color – orange) Low level of liquid in neutralization system (color – blue) Right turn indicator (color – green, intermittent) Air suspension defect (color - red) Left turn indicator (color – green, intermittent) Air filter clogging up (color - red) Brake system fault (color - red) Anti-skid system engagement...

  • Page 29: Information Display

    Information display Wearing of brake pads (color - orange) At each activation of ignition switch key into «Motion position» a screen with the logo- type appears on the display of instrument clus- Unfasten safety belt (color – red) ter for 2-3 sec. Further information about vehicle operational Intarder engagement (color - orange) state, failures or warning information is displayed on the...

  • Page 30: Information System Control

    Information system control Buttons for Information system control is carried out by the information screen control buttons located on the steering wheel on the left side (see Fig. Screen control on the display). Menu access. Confirmation of the message on display Scrolling forward (choice of function) Screen control on the display...

  • Page 31: Check Before Motion Initiation

    Check before motion initiation 8 - the number of the gear engaged, warning mes- sages (for the gear box with automated control). If messages about vehicle malfunction are absent the screens with monitored information about vehicle Pressure in circuits III and IV of pneumatic drive. operational state automatically appear on the display.
  • Page 32 Screen «Travel» Screen «Axle load» The data on the screen «Travel» are reset simulta- Screen «Axle load» is displayed on the vehicle neously with daily mileage re-zeroing. equipped with an axle load measuring system. Choosing «AXLE 2» you can determine the axle load. «Time»...
  • Page 33 Display lighting Press the button . The symbol will flash on and off in front of the scale. Adjust display light brightness by buttons Press the button , adjusted screen light brightness will be saved in memory. Brightness scale Display light 4-10...

  • Page 34: Switch Blocks

    SWITCH BLOCKS Symbol Application of switches/ shifters Instrument panel Engagement/ disengagement of strorage batteries. Button is locked when ignition key is in «ON» position ASR mode selection Engagement/ disengagement of air condi- tioner Engagement/ disengagement of warning indication (color - red) Engagement/ disengagement of cab tilting lock Switches on instrument panel...
  • Page 35 Application Symbol of switches/shifters Engagement/ disengagement of hydraulic motor (for certain vehicle configurations) Engagement/ disengagement of PTO box Engagement/ disengagement of flashing lights (for certain vehicle configurations) Emergency storage battery switch-off (color - red) Engagement/ disengagement of hill start assist control 4-12...

  • Page 36: Driver's/ Passenger's Door

    Driver's/ passenger's door Over the windshield Switch block over the windshield Switch block Switch block Pos. Application of shifters on passenger's door on driver's door Opening/ closing of the top hatch Engagement/ disengagement of driver's reading Pos. Application of shifters lamp Adjustment of external rear view mirror position Engagement/ disengagement of night-time...

  • Page 37: Bunk

    Bunk ADJUSTMENT OF HEADLAMP INCLINATION ANGLE Adjuster of headlamp inclination angle is located on instrument panel (see Fig. Adjuster of headlamp inclination angle). Adjustment is carried out in accord with vehicle load. Switches Adjuster of headlamp on the bunk inclination angle Pos.

  • Page 38: Light Shifter

    LIGHT FOR MOVEMENT IN THE DAYTIME LIGHT SHIFTER Daytime running lights switch on automatically Vehicle light is switched on and off by light when ignition key is shifted to «ON» position. Light shifter. Prior light energizing, rotate the ignition key to position «ON»...

  • Page 39: Auxiliary Illumination Headlamps In Insufficient Visibility Conditions And Rear Fog Lamps

    AUXILIARY ILLUMINATION HEADLAMPS IN TRAIN LAMPS INSUFFICIENT VISIBILITY CONDITIONS Train lamps are switched on automatically when AND REAR FOG LAMPS trailer/ semitrailer electric equipment is connected to truck Auxiliary illumination headlamps tractor. in insufficient visibility conditions SPOTLIGHT OF THE COUPLER 1.

  • Page 40: Combination Switch

    SWITCHING OF DIRECTION INDICATOR COMBINATION SWITCH Pull combination switch till fixation: - towards «4» (away from oneself») - right turn signal; - or «5» («toward oneself») - left turn signal. When the steering wheel returns after long-term turn the combination switch automatically resets. ENGAGEMENT OF WARNING LIGHT Shortly pull the combination switch up to position «3».

  • Page 41: Windscreen Wipers

    Engagement of windscreen wipers WINDSCREEN WIPERS Turn the switch 1 (see Fig. Engagement of windscreen wipers) into required position. Disengagement of windscreen wipers Version I Turn the switch 1 to position Windscreen wiper will make one more movement and witll be disengaged. Intermittent operation mode Durability of the interval between two consecu- tive movements of windscreen wipers is 4 sec.

  • Page 42: Windscreen Washer

    WINDSCREEN WASHER Attention! To switch on the windscreen washer press the It is necessary to check the windscreen wiper shifter 1, located on combination switch, up to stop (see blades for the presence of dirt and damages. Fig. Windscreen washer engagement). When holding the Switch off the windscreen wipers before placing shifter in depressed position, water is supplied to the the vehicle in the parking area, as windscreen wiper...

  • Page 43: Cab Doors

    CAB DOORS Door locking/ lock releasing from inside by the shifter Vehicle doors can be lock released and locked by DOOR LOCK BLOCKING means of door locking shifters, located in switch block Door lock releasing/ locking externally, by key on driver's and passenger's door (see Fig. Door locking When releasing the vehicle door lock only corre- shifter sponding door is opened by the key.

  • Page 44: Lowering And Raising Of Side Windows Of Driver/ Passenger

    LOWERING AND RAISING OF SIDE WINDOWS LIFTING TOP HATCH OF DRIVER/ PASSENGER Control shifters of lifting top hatch are located in Cab doors are equipped with electric window switch blocks, near the lower bunk and above the wind- raisers. shield. Lowering and lifting of side windows is carried out at rotation of ignition key into position «ACC».

  • Page 45: Mechanical Closure Of Raisable Top Hatch

    MECHANICAL CLOSURE OF RAISABLE TOP HATCH SAFETY SCREEN OF THE HATCH 1. Prepare the flat screwdriver (the width of The hatch is equipped with a safety screen (see screwdriver working end is 4 mm). Fig. Safety screen). 2. Remove the plug (see Fig. Closing down of lift- To close the safety screen it is necessary to pull it ing top hatch).

  • Page 46: External Rear View Mirrors

    MIRROR HEATING EXTERNAL REAR VIEW MIRRORS In wet and cold weather to prevent misting and It is recommended to check the installation of ex- ice coating of external rear view mirrors use mirror heat- ternal mirrors on the vehicle before each drive. ing system.

  • Page 47: Seat Position Adjustment

    SEAT POSITION ADJUSTMENT Seat heating. Seat heating is engaged at pressing on the upper or lower part of the button 7. Heating is en- Adjustment of seat position on air suspension gaged at air temperature not more than 18 ºС. The angle of armrest 3 inclination is smoothly Heating is disengaged at pressing of button into adjusted at armrest regulator rotation.
  • Page 48 Seat back inclination angle. With lever 8 shifting Passenger's seat adjustment (version) up the back is unfixed and inclines forward, with lever In certain vehicle configurations passenger's seat release, the back is fixed in selected position. is mounted without air suspension. Seat lateral support is adjusted by the button 9.
  • Page 49 The shape of seat back profile is selected at ro- Adjustment of the seat lateral position. With tation of the handle 2 (see Fig. Passenger’s seat). At the lever shifted up the seat slides are unlatched. With counterclockwise rotation the back convex camber in- the lever shifted down, the seat slides are fixed in a cho- creases, clockwise - decreases.

  • Page 50: Safety Belts

    SAFETY BELTS Safety belt performs protection function if seat back is arranged almost vertically and if sitting person The vehicle seats are provided with safety belts. body is straight. Safety belt prevents considerable displacement of driver Use safety belts in all trips. Each safety belt is in direction opposite to hit direction, thus, decreases used by one person only.

  • Page 51: The Upper Bunk

    THE UPPER BUNK For installation of guard mesh hang the hooks of guard mesh in the eye ring (see Fig. Installation of Attention! guard mesh Get a move on only with a folded and belt fixed bunk. It is forbidden to be on the upper bank of the driving vehicle.

  • Page 52: The Lower Bunk

    THE LOWER BUNK Installation of guard mesh Setting of the lower bunk into operational state Before starting the trip fix the hook 1 of the guard 1. Raise slightly the lower bunk and detach the re- mesh on the eye ring 2 on the cab ceiling (see Fig. Guard taining belt 3 from the hook 4 (see Fig.

  • Page 53: Steering Wheel Adjustment

    STEERING WHEEL ADJUSTMENT If the steering column locking mechanism is not locked, roughly in 10 sec. after lock release the steering Position of steering wheel is adjusted by height wheel is automatically locked. and inclination. Adjustment mechanism is provided with the system of pneumatic lock and lock release.

  • Page 54: Air Conditioning System Control

    AIR CONDITIONING SYSTEM CONTROL PANEL AIR CONDITIONING SYSTEM CONTROL Using the shifters on instrument panel of air condi- VENTILATION DEFLECTORS tioning system you can regulate: air distribution, air tem- The airflow direction can be adjusted by means perature, air flow. of deflectors located on cab doors and on instrument pan- el (see Fig.
  • Page 55 Air distribution in the cab Temperature setting To increase the temperature turn the temperature regulator to the right, to decrease - to the left. It is recommended to engage Regulator of air distribution the temperature regulator not less fre- quently than once-twice a month to Temperature regulator maintain its operation reliability.

  • Page 56: Examples Of Settings

    EXAMPLES OF SETTINGS Engagement of ventilation in the cab Fresh air mode 1. Install the shifter and regulators as it is shown in the Fig. Cab ventilation. In case of the glass misting it is necessary immedi- 2. Open ventilation hatch on the roof ately to switch the fan to the fresh air mode.

  • Page 57: Windscreen Defrosting

    Windscreen defrosting 1. Set the shifter and regulators as it is shown in the Fig. Windscreen defrosting. 2. Close ventilation deflectors. 3. Switch on, if necessary, the autonomous cab heater. Windscreen defrosting 4-34...

  • Page 58: Conditioner

    CONDITIONER Air cooling The air conditioner regulates air temperature and For the short period cooling in humidity in the vehicle cab. the mode of air recirculation switch on the conditioner and set the regulators, Attention! as it is shown in the Fig. Cooling in the Air conditioning system works only with engine mode of air recirculation.

  • Page 59: Independent Cab Air Heater

    INDEPENDENT CAB AIR HEATER Attention! In certain vehicle configurations an independent cab Before going to the dangerous zone (fuel filling air heater is installed. station, petroleum processing plant and so on) the heat- An independent cab heater automatically adjusts er should be disengaged. temperature in the cab.

  • Page 60: Cab Interior Light

    CAB INTERIOR LIGHT Engagement and disengagement of reading lamp on passenger's side Lighting types: - cab lighting; 1 - engagement of reading - lamp for reading; lamp on passenger's side; - night lighting. 2 - disengagement of read- All types of lighting are engaged and adjusted in- ing lamp on passenger's side.

  • Page 61: Electrical Sockets

    ELECTRICAL SOCKETS VOLTAGE CONVERTER Electrical sockets 24 V/ 10 А are located in the Before switching on the electric equipment with central part of instrument panel and on passenger's side the voltage 12 V it is necessary to switch on the voltage (see Fig.

  • Page 62: Ash Tray

    ASH TRAY Installation of ash tray is possible in the cab. To open pull the ash tray by the handle in the di- rection of the arrow until stop (see Fig. Ash tray). Further press the lock release button 2 and, holding it down, fully pull the ash tray 1 out.

  • Page 63: Digital Tachograph

    DIGITAL TACHOGRAPH GLOVE COMPARTMENTS AND BOXES On the shelf over the windshield a digital tacho- It is not recommended to carry over heavy things graph is installed. in the compartments. Digital tachograph – technical control device, de- Attention! signed for registration, storage, display, printing of data In order to prevent injury of people by things about the mode of movement, labour and rest of the driver...

  • Page 64: Emergency Response Service Calling Unit (Era-Glonass)

    EMERGENCY RESPONSE SERVICE CALLING UNIT (ERA-GLONASS) User's interface block 1 – service button; APPLICATION AND CONTROL DEVICES 2 - microphone; Emergency response service calling unit is de- 3 - emergency button «SOS» signed for: (with lighting); 4 - protection cover - transfer of minimum data set with description of motor vehicle, coordinates of its location, time and movement direction;...

  • Page 65: Operation Modes

    OPERATION MODES Emergency call «SOS» When the ignition key is turned to position «ON», Emergency call can be made under condition that the illumination of emergency button «SOS» (color - red) ignition key is in position «ON» or that from the moment lights up for 5-6 sec.

  • Page 66: Driving The Vehicle

    DRIVING THE VEHICLE 9. Do not open the expansion tank cap of an over- heated engine, let the engine cool down. SAFETY REQUIREMENTS 10. Remember, that cooling liquids used in engine 1. All defects discovered during vehicle inspection cooling system and liquids used in clutch drive are toxic should be eliminated.
  • Page 67 20. Prior to performance of electric welding ac- It is not suggested to perform welding operations tivities the following operations are necessary to be on engine or components mounted on engine. fulfilled on the vehicle: 21. Do not disassemble brake chamber spring en- - the storage batteries should be disconnected by ergy accumulators on the vehicle.

  • Page 68: Safety Requirements During Operation Of Vehicle With Electronic Systems

    SAFETY REQUIREMENTS DURING OPERATION OF To use the fuse with the same rating instead of that VEHICLE WITH ELECTRONIC SYSTEMS to be replaced, strictly. 1. Be sure to disconnect the storage battery while 9. The short-circuiting of electronic control module repairing or replacing the items of vehicle electronic sys- leads onto the «ground»...

  • Page 69: New Vehicle Operation (Running-In)

    NEW VEHICLE OPERATION (RUNNING-IN) It is prohibited to rotate the steering wheel, before Vehicle reliability and economic feasibility as well the oil in the steering system is warmed up! as its life duration depend upon parts and aggregates run- 6. For mechanical gear box when starting the vehi- ning-in during new vehicle operation –...
  • Page 70 10. In case of lighting of incidental oil pressure - put the chocks under rear wheels of vehicle and and incidental coolant temperature pilot lamps located on semitrailer. the instrument panel and warning about the dangerous 16. In the attempt to drive the truck out of the rut, drop of pressure in engine lubricating system and about do not keep the steering wheel turned to extreme position critical over-heating of coolant, stop the engine immedi-...

  • Page 71: Recommended Operation Modes Of Engine

    Climbing To slow down the truck (train) when descending, use the auxiliary brake system and if necessary use the Short climbs on good roads should be overcome service brake. with speed reserve. While overcoming sharp and prolonged climbs, RECOMMENDED OPERATION MODES OF ENGINE choose the low gears taking into account the road train 1.

  • Page 72: Preliminaries For Vehicle Motion

    PRELIMINARIES FOR VEHICLE MOTION Replacement of fuel tank air filter is described in Prior to the vehicle movement: Section 6 «Maintenance». 1. Perform vehicle daily maintenance (see section 3. Check availability of neutralizing fluid. If on in- 6 «Maintenance»). strument panel the pilot lamp of neutralizing fluid level in 2.

  • Page 73: Fuel Tank Filling (For Certain Configurations Upon Availability Of Two Fuel Tanks)

    Fuel tank filling If at fuel tank opening the air sharp letout is ob- served (increased air pressure in the tank) or air suction (for certain configurations upon availability of two (vacuum in the tank), it is necessary to change the air fil- fuel tanks) ter of fuel tank.

  • Page 74: Engine Start And Shutdown Procedure

    ENGINE START AND SHUTDOWN PROCEDURE 5. About EFU readiness for engine start up in the Engine start up cold period of time the message signals on the display of the instrument cluster (see Section 5 «Vehicle operation in Parking brake system is engaged. the cold period of time»).

  • Page 75: Engine Shutdown

    10. For the vehicle with mechanical gear box Engine shutdown smoothly release the clutch panel. 1. Stop the vehicle. 11. Increase pressure in brake system circuits up to 2. Install neutral in the gear box. norm (from 9,0 to 10,0 kgf/cm ), controlling pressure in 3.

  • Page 76: Idle Speed Adjustment

    Control buttons of idle speed adjustment and cruise IDLE SPEED ADJUSTMENT control mode After engine start up the idle speed is set automati- cally depending on coolant temperature. Increase of crankshaft speed/ cruise - control Idle speed of the engine warmed up to operation speed temperature is approximately 600 min The engine idle speed is to be adjusted on a steady...
  • Page 77 «CRUISE-CONTROL» MODE To increase the speed of cruise-control press the In cruise-control mode, the vehicle traveling speed button is maintained on a level set. The mode may be activated at To decrease the speed of cruise-control press the vehicle speed at least 38 km/h. When «Cruise-control» is engaged but not active, speed digits are flashing on the button display.

  • Page 78: Gearbox Control

    GEARBOX CONTROL Upon the availability of splitter in gearbox, the Gear change in gearbox is performed with the splitter control selector is built into gearshift lever handle help of gearshift lever located to the right of driver’s seat. (see Fig. Gearshift lever). Selector may be shifted to high «S»...
  • Page 79 16S1820 ТО, gearbox models Attention! ZF 16S2220 ТD, ZF 16S2221 ТD gear shifting is ful- For gearboxes, it is strictly forbidden: filled according to the scheme (see Fig. Gear change - to change from high range of the splitter onto scheme for gearbox models ZF 16S1820 ТО, ZF 16S2220 the lower one at speed more than 30 km/h;...

  • Page 80: Gearbox With Automated Control

    GEARBOX WITH AUTOMATED CONTROL Operational information Depending upon vehicle configuration, the vehicle Display Description may be equipped with gearboxes of models ZF 12AS 2130 TD, ZF 12AS 2131 TD with automated control for Forward maneuvering clutch linkage and gear shift mechanism. Gear shifting can be carried out in automatic mode Forward movement (gear box control unit chooses the necessary gear itself) as...

  • Page 81: Gear Shifter

    Warning messages Gear shifter Gear box control is carried out by the gear shifter, Display Description located on the steering column, on the right hand (see Fig. Self checking of the system (after ignition Gear shifter). key rotation to «ОN» position) Gear shifter Insufficient pressure in circuit IV of pneu- 1 –...

  • Page 82: Automatic Gear Box Control

    With automatic mode engaged the motion mode, Automatic gear box control corresponding to rotary switch position, is displayed. Start of the vehicle motion At manual control engagement the number of the 1. Start the engine. Automatic engine mode is en- gear engaged is displayed.

  • Page 83: Gearbox Manual Control

    Gearbox manual control Motion modes Direct maneuvering DM and reverse maneuvering In difficult road conditions (for example, during the RM modes are meant for very slow motion. off-road movement) it is recommended to shift to the man- It is recommended to use maneuvering mode as ual control mode to preserve an opportunity of self gear more rarely as it is possible and for a short period of time shifting in accordance with the road situation.
  • Page 84 To decrease the motion speed use secondary brake Engagement of reverse gear system. When engaging secondary brake system the elec- Reverse gear is engaged only on a stationary vehi- tronic control system automatically shifts the gearbox cle with the neutral engaged in the gearbox. down.

  • Page 85: Interwheel Differential Lock

    INTERWHEEL DIFFERENTIAL LOCK Interwheel differential lock control is electro- Differential is to be locked when there is a differ- pneumatic and is fulfilled by the shifter located on the in- ence in values of wheel adhesive forces between which it strument panel (see Fig.

  • Page 86: Brake System

    BRAKE SYSTEM In intermediate positions the truck tractor and sem- Service brake system is intended to reduce the itrailer slowing down is fulfilled. vehicle traveling speed and to bring it to total halt; it is At shifting the valve handle further than the lower controlled by the brake pedal.

  • Page 87: Auxiliary Brake System

    Maximum engine crankshaft speed for engine Auxiliary brake system brake operation: Use the auxiliary brake system in all cases to reduce - for a short period of time 2500 min the traveling speed and compulsorily when driving on pro- - for a long period of time 2300 min tracted downgrades in order to prevent over-heating of Optimum engine brake range of operation is from braking mechanisms.

  • Page 88: Auxiliary Brake System Control By Means Of The Switch

    Auxiliary brake system control by means of the switch Switch positions The mode of downhill constant speed В maintenance is engaged Auxiliary brake is disengaged Version I Decompression brake is engaged Engine brake is engaged Retarder brake is engaged. В The indicator lights up on the display О...

  • Page 89: Electronic Brake System Ebs

    ELECTRONIC BRAKE SYSTEM EBS Control of service and auxiliary brake systems with Vehicle is equipped with electronic brake system the aid of brake pedal («Brake-Management») (EBS), comprising the following functions: Function of Brake-Management - control of ser- - control of service and auxiliary brake systems vice and auxiliary brake systems by means of brake pedal.

  • Page 90: Vehicle Stability Control System

    Antiskid system (ASR) Vehicle stability control system Antiskid system prevents slippage of driving Electronic stability program (ESP) is a combina- wheels, irrespective of road conditions. tion of two systems stabilizing the vehicle movement: With driving wheels skidding on one or both - systems controlling vehicle stability, defining the sides, automatically, ASR working mode is activated, steering wheel turning degree, compensate control loss by...

  • Page 91: Hill Start Assist Control

    HILL START ASSIST CONTROL Hill start assist control is a part of ESP brake sys- tem. Hill start assist control helps the driver to keep the vehicle from rolling down at starting from standstill on the upgrade. Operation of hill start assist control 1.

  • Page 92: Air Suspension Remote-Control Console

    AIR SUSPENSION REMOTE-CONTROL CONSOLE Air suspension control Air suspension electronic control system fulfills The air suspension control is carried out by means the following functions: of remote-control console arranged to the left of driver’s 1. If there is sufficient pressure in receiver and seat.

  • Page 93: Chock

    To set the earlier recorded height – depress the CHOCK buttons of switches 7 (М1) or 8 (М2). The chocks are intended to assure under-run pro- To interrupt the process of height variation – de- tection for the vehicle (road train) when it is parked or the press the switch 5 button (STOP).

  • Page 94: Facing Panel

    FACING PANEL Facing panel is opened and closed by both hands applying uniform force to both sides, observing maximum distance from center of the panel (see Fig. Opening of the upper facing panel). Attention! It is strictly forbidden to open and to close the facing panel pulling it only by one edge.

  • Page 95: Vehicle Towing

    Tow yokes are provided for towing the vehicle. brake actuator with compressed air. It is strictly forbidden to tow KAMAZ vehicle with Connect one end of the inflation hose to the extra an inoperative engine , irrespective of distance, with brake release valve or to the check output valve of the driving axles’...

  • Page 96: Operation Of Bolster Truck Tractor Beinga Part Of A Road Train

    OPERATION OF BOLSTER TRUCK TRACTOR BEING Coupling of tractor with semi-trailer A PART OF A ROAD TRAIN 1. Place the vehicle on a level and hard surface. When bolster tractor is a part of a train with in- 2. Place chocks (Block stops) under wheels of stalled three-component wings of rear bogie, the upper semi-trailer.
  • Page 97 At trailer/ semitrailer connection the rear fog When maintaining coupling heads and sockets for semi-trailer the load on frame boarding is to be not lamps of truck tractor are not active. more than 200 kg. Uncoupling of tractor and semi-trailer 1.

  • Page 98: Pumping Of Petroleum Product During Operation Of Hydroficated Bolster Traction Truck With Atank Semitrailer

    PUMPING OF PETROLEUM PRODUCT DURING OPERATION The message appears on the display (see Fig. The OF HYDROFICATED BOLSTER TRACTION TRUCK WITH A hydraulic distribution valve is engaged). TANK SEMITRAILER 1. Place the vehicle on a level and hard surface. 2. Apply the parking brake system to stop the semi-trailer.

  • Page 99: Vehicle Operation In Cold Season

    5 VEHICLE OPERATION IN COLD SEASON To prevent the brake shoes freezing on to the diskprior to vehicle parking, do not fail to dry up the SPECIAL FEATURES OF VEHICLE OPERATION brake gears with several successive applications of brake. DURING COLD PERIOD OF TIME If the truck is parked for a long time (for in- In cold season, observe the following require- stance, for a night), do not use the parking brake system.
  • Page 100 Oil heating in the steering system It is necessary to heat the oil in the steering sys- tem after engine cranking, prior to vehicle motion start, to exclude the damage and excessive wear of parts of steering mechanism and hydraulic power steering pump. Engine operating time necessary for heating of oil in the steering system versus the temperature of ambient air is indicated in Table «Engine operating time neces-...

  • Page 101: Cold Weather Engine Starting

    COLD WEATHER ENGINE STARTING Attention! In cold period, start the engine with the help of Avoid the open plug flame and torch usage for EFU (Electric Flame Unit). Prestarting heater may be al- air heating at engine start. If the ambient air temperature is below 30 ºС so used for engine starting.

  • Page 102: To Start The Engine Using The Efu Unit

    TO START THE ENGINE USING THE EFU UNIT After the glow plugs are completely warmed up, EFU is a device for heating the intake air and fa- the following information is displayed: cilitating engine starting at the ambient temperature of minus 5 °С...

  • Page 103: Pre-Starting Heater

    PRE-STARTING HEATER FUEL HEATING Pre-starting heater is for heating the engine before The fuel is heated automatically in a coarse fuel starting it up at the ambient temperature of up to minus filter and a fuel suction pipe. The information about the 45 °С.

  • Page 104: Maintenance

    6 MAINTENANCE The main purpose of daily and weekly mainte- nance is general monitoring over state of units and sys- tems to ensure safe driving as well as maintaining proper external appearance. Daily maintenance is performed once a day prior to departure or in stations after prolonged work.

  • Page 105: Daily Maintenance (Daily Mnt.) Procedures

    DAILY MAINTENANCE (DAILY MNT.) PROCEDURES № Description of procedure Technical requirements and instructions For information about maintenance interval and requirements for Mercedes-Benz engines refer to the service book «Service Book. Mercedes-Benz OM457LA Engine». Wash the vehicle (if necessary) See subsection «The vehicle care». Check the vehicle systems for To reveal and eliminate troubles –...
  • Page 106 № Description of procedure Technical requirements and instructions Check visually the state of bolster Inspect the bolster visually at the beginning of motion and during vehicle stop. There must be no perceptible clearance between semi-trailer kingpin and device, coiled hoses of semi-trailer bolster lock.
  • Page 107 № Description of procedure Technical requirements and instructions Check the state of semi-trailer Locking means must keep the sides of semi-trailer platform closed relia- sides' latches. bly. Inspect condition of tires. Check See subsection «Tire maintenance». (if any control systems) tire pressure according to the infor- mation from indicator on instru- ment panel.
  • Page 108 № Description of procedure Technical requirements and instructions Check the operability of light Switch on the instruments by rotating the ignition key to the first fixed emitting devices (LED's), light position. Check all LED's and light alarm devices for proper operation using the and audio alarm.
  • Page 109 № Description of procedure Technical requirements and instructions Check the coolant level in the See subsection «Coolant level inspection». cooling system. Check the operation of oil separa- When the compressor is running in a filling mode, the air leakage through tor and dryer.
  • Page 110 № Description of procedure Technical requirements and instructions Top up to norm the oil level in The oil level should be in the in- the vehicle hydraulic system spection hole middle (see. Fig. Hy- (for hydraulically operated ve- draulic oil tank). hicle).

  • Page 111: Weekly Maintenance (Weekly Mnt.) Procedures

    WEEKLY MAINTENANCE (WEEKLY MNT.) PROCEDURES № Technical requirements and instructions Description of procedure Check the cotter-pinning of The pitman arm should not have any damages. The nut to fasten the pitman nuts of steering rod ball pins arm should be secured and locked with a plate. The nuts of steering rod ball pins (visually), the fastening of pit- should tightened and cottered.
  • Page 112 № Technical requirements and instructions Description of procedure Check visually the state of and Cracks in brackets and loose rivets are not tolerable. fastening of front spring brack- ets. Rear bracket Front bracket of front spring of front spring Check the state and attachment See subsection «Tire maintenance».
  • Page 113 № Technical requirements and instructions Description of procedure Check tire pressure using the See subsection «Tire maintenance». test pressure gauge. Check the condition of com- Prior to inspection shut down the engine. pressor drive belt in the air Visually check the condition of belt Cracks are tolerable. Crossing of trans- condtioning system.
  • Page 114 № Technical requirements and instructions Description of procedure Clean the outer surface of the Perform air-blast radiator frame in the air condi- cleaning bleeding the tioning system of dirt, wash it compressed air from on- and blow-through. board or autonomous Clean the corrugated plates of network.
  • Page 115 № Description of procedure Technical requirements and instructions Clean the conditioning con- Perform air-blast cleaning bleeding the com- denser using air blowing. pressed air from on-board or autonomous network. Grease the bolster, the saddle Grease the bolster through grease cups. support surface, the mouth, the Apply an even layer of grease to the bol- locking gear of bolster and the...
  • Page 116 № Description of procedure Technical requirements and instructions Top up to norm the oil level in Undo the cover-dipstick and test oil level in a the tank of the power steering tank. The oil level must be between upper and bottom booster pump.

  • Page 117: Vehicle Care

    VEHICLE CARE Wash: headlamps, parking, marker and tail lamps, windows and number plates. Eliminate dirt, snow and ice from wings’ bottom parts, step boards, springs, axles, mud flaps, cover of storage battery box. Wipe instru- ments and windows in a cab. Blow-through (in cold season) locks of doors and tool box with compressed air.

  • Page 118: To Care The Windscreen

    The washer tank is placed under the cab from the TO CARE THE WINDSCREEN driver side, the filling neck is inserted into the door open- Wiper brushes should bear against glass surface ing (see Fig. Washer tank along the whole length of edge, they must shift uniformly, In cold season, prime system with glass-washing without seizure.

  • Page 119: Air Filter Replacement

    (see Fig. Air filter). er conditions (wind blowing). Be sure to use filter elements from manufactures possessing official approval of KAMAZ PTC for delivery. Air filter 1, 2 - latch; 3 -cover; 4 - nipple valve...

  • Page 120: Checking Receivers For Condensation

    Be sure to use filter elements from manufactures Tire pressure should correspond to the rated value possessing official approval of KAMAZ PTC for delivery. given in the technical data (see section 2 «Operation pa- If you are not able to eliminate the fault yourself, rameters»).

  • Page 121: When Inflating The Tires

    WHEN INFLATING THE TIRES To deliver air using a tire inflation hose (from Decrease of air pressure onto 25 % of the rated tools set), connect it instead of a cap, for this, tighten the value cuts their service life onto 35-40 %. Also mind that butterfly nut until it stops and decrease the compressed kPа...

  • Page 122: Checking The Oil Level In Engine Crankcase

    CHECKING THE OIL LEVEL IN ENGINE CRANKCASE 1. Place the vehicle on level horizontal surface. Engage the parking brake. 2. The level of oil is tested in 10 min. after en- gine stop. During that time, oil flows into crankcase sump.

  • Page 123: Coolant Level Check

    COOLANT LEVEL CHECK 1. Place the vehicle on level horizontal surface. Stop the engine. 2. Raise the front facing panel. 3. Check the coolant level on cold engine (tem- perature should not exceed 50 °С). An optimum position Expansion of a liquid level is when it reaches the lower edge of the tank cover filling neck.

  • Page 124: Coarse Fuel Filter

    COARSE FUEL FILTER 3. Unscrew the vent plug on 2-3 turns. 4. Counterclockwise, undo the handle of manual coarse fuel filter (see Fig. priming pump and bleed air from the system by moving UFI coarse fuel filter) is installed between fuel tank and the handle back and forth.
  • Page 125 Be sure to use filter elements from manufactures the filter cap and drain sediment until clean fuel appears. possessing official approval of KAMAZ PTC for delivery. Prior to draining the water-fuel mixture from wa- ter collection vessel or prior to air release with the help...

  • Page 126: Fuel Tank Air Filter

    FUEL TANK AIR FILTER To replace fuel tank air filter The fuel tank air filter is located near the fuel tank 1. Stop the vehicle, shut off the engine, engage on a frame side member (see Fig. Fuel tank air filter the parking brake, the gearshift lever should be in neutral position, place the chocks under wheels.

  • Page 127: After-Treatment System

    AFTER-TREATMENT SYSTEM The filling neck in the tank is equipped with mag- After-treatment system is designed to decrease the net valve, which allow the fuel nozzle to switch off au- emissions of nitride oxides as result of injection of neu- tomatically after the maximum Adblue level has been tralizing liquid into engine exhaust system.
  • Page 128 Avoid AdBlue getting onto vehicle aggregates and soil. In case of AdBlue ingress onto varnished or alu- minum surfaces during system priming, be sure to rinse the surface immediately. It is prohibited to re-use liquid drained during repair. Be sure to use only plastic or stainless steel cans for AdBlue storage.

  • Page 129: Checking The Fuel Level In The Independent Fuel Tank Of Pre-Starting Heater

    CHECKING THE FUEL LEVEL IN THE In summer, we suggest to drain fuel from inde- INDEPENDENT FUEL TANK pendent fuel tank. After fuel is drained and the hose is OF PRE-STARTING HEATER placed back, the heater should work until all fuel burns. The pre-starting heater is equipped with an inde- Fuel is drained as follows: pendent fuel tank which is mounted behind the cab on...

  • Page 130: Storage Batteries

    STORAGE BATTERIES covers should be free to provide gas escape. Otherwise the cover can be damaged resulting in the storage battery During operation failure. Storage batteries are intended to start engine with If any clogging in the cover holes a damage in the starter and supply electric consumers.
  • Page 131 In order to bring electrolyte into homogeneous For storage, remove the batteries from the truck constitution the topping-up should be carried out on the (if the truck is going to be out of use for more than 1 vehicle with running engine and switch-on parking brake month), charge them and keep, if possible, in a dry cool room at temperature not higher than 0 °С.

  • Page 132: Vehicle Mechanisms And Systems Troubleshooting. Self-Help

    (see subsection Indication and ods of their elimination are described in Construction, fault elimination). The pilot lamps go out after the fault maintenance and repair manual for КАМАZ 5490 vehi- has been eliminated. cle.

  • Page 133: Hazard Signal System Engagegment

    HAZARD SIGNAL SYSTEM ENGAGEGMENT If any faults critical to traffic safety, be sure to stop vehicle immediately, engage parking brake and haz- ard signal system. To engage hazard signal system, press the corresponding switch in the upper part of instru- ment panel.

  • Page 134: Diagnostics Of Vehicle Systems

    DIAGNOSTICS OF VEHICLE SYSTEMS Display screen control buttons If the pilot lamp of electronic system fault light- ens in the instrument panel (e.g., fault in the engine Menu key. control system) it means, there is a fault in the system, Confirmation of display message.

  • Page 135: Sequence To Read Diagnostic Codes

    SEQUENCE TO READ DIAGNOSTIC CODES 4. With buttons pressed, select the ve- 1. Rotate the instru- hicle system (if available) for diagnostics: ments-and-starter switch key to - engine; position «ON» (position of mo- - brake system; tion). - after-treatment system; The home screen ap- - air suspension;...
  • Page 136 For code cracking and failure elimination, please 7. Depress the «Menu key» button contact the Service center. If any faults are available, the following is emitted For troubleshooting performed in the service cen- to display: ters use the OBD connecter, which is located to the left - system name;...

  • Page 137: Mode For Diagnostics Of Operational Parameters

    The diagnostics of operational parameters can be 1. Turn on the alarm. used in case of remote malfunction diagnostics per- 2. Rotate the instru- formed by KAMAZ PTC specialists or by experts of ser- ments-and-starter switch key to vice centers. position «ON».
  • Page 138 Screens of mode for diagnostics - the actuating force applied to brake pedal (per cent); of operational parameters. - clutch pedal effort (pressed/ not pressed); Screen 1. - parking brake actuation. The version of software for CBCU unit and the LCD display firmware language.

  • Page 139: Indication And Elimination Of Faults

    INDICATION AND ELIMINATION OF FAULTS Fault indication Cause of trouble Suggestion on correction Vehicle driving is prohibited till fault correction. • Oil pressure in the engine lu- Stop the vehicle taking into account the traffic situa- (color - red) bricating system tion;...
  • Page 140 Fault indication Cause of trouble Suggestion on correction Engine operation is not recommended if Reserve fuel indicator comes ON. If any air in fuel injection system, be sure to prime fuel tank and eliminate air prior to engine start. Fuel level is less than 12 % of the fuel tank volume.
  • Page 141 Fault indication Cause of trouble Suggestion on correction Vehicle driving is prohibited till fault correction. • Stop the vehicle taking into account the traffic situation; • stop the engine; (color-orange) Critical malfunction • engage the parking brake; in theautomated • perform the system diagnostics.
  • Page 142 Fault indication Cause of trouble Suggestion on correction Gear shifting is not possible. Check the 4-th circuit of the air system for leaks, The pressure in the check the function of 4-circuit safety valve, adsorption 4-th circuit dehumidifier, compressor. In all circuits, the pressure on the display of air system is insufficient.
  • Page 143 Fault indication Cause of trouble Suggestion on correction Vehicle motion is permitted with special care. Address the service center. Perform engine diagnostics. • Stop the vehicle paying attention to road situation; Fault in engine • stop the engine; control system. (color-orange) •...
  • Page 144 Fault indication Cause of trouble Suggestion on correction Vehicle motion is permitted with special care. • Stop the vehicle taking into account the traffic situa- tion; Increased coolant (color-red) • stop the engine; t temperature. • engage the parking brake; •...
  • Page 145 Fault indication Cause of trouble Suggestion on correction Vehicle driving is prohibited till fault correction. • Stop the vehicle taking into account the traffic situa- tion; • engage the parking brake; • inspect for compressed air leakage in pneumatic drive caused by leakage of pipelines’...
  • Page 146 Fault indication Cause of trouble Suggestion on correction Vehicle movement is limited Adjust the pressure to the normal level. (color-red) Pressure drop in the 2-d brake system circuit. (color-red) Intermittent horn Vehicle motion is permitted with special care. • Stop the vehicle; •...
  • Page 147 Fault indication Cause of trouble Suggestion on correction Vehicle motion is permitted with special care. • Stop the vehicle; • engage the parking brake; • carry out diagnostics of the vehicle brake system. Be (color - orange) sure to address the service center to eliminate troubles. Failure of EBS After system troubleshooting has been completed, be sure in the vehicle.
  • Page 148 Fault indication Cause of trouble Suggestion on correction Carry out the diagnostics of air suspension (See sub- section «Diagnostics of vehicle systems»). After the fault has been corrected, the pilot lamp dies (color-red) Faults in the control system out. of air suspension. If the lamp does not go out after the fault has been rectified, as determined by the flashing light code, or if the fault is not resolved by yourself, contact the service...
  • Page 149 Fault indication Cause of trouble Suggestion on correction Prime the washer tank with ready-made washing liq- uid. Low level of liquid in the windshield washer reservoir. The pump motor cannot be activated. Drain sediment from coarse fuel filter (see section 6 «Maintenance»).

  • Page 150: Indication Of Faults In The Lightning Equipment

    INDICATION OF FAULTS IN THE LIGHTNING EQUIPMENT Trouble of the front right direction indicators Trouble of all front left side marker lights Trouble of the front left bulb of the additional lighting for Trouble of all front poor visibility conditions right side marker lights Trouble of the front...
  • Page 151 Trouble of the right Trouble of the left low beam headlamp high beam headlamp Trouble of the left daytime Trouble of the right running lamp high beam headlamp Trouble of the right Trouble of the left daytime running lamp low beam headlamp 7-20...
  • Page 152 Trouble of all rear left Trouble of the rear marker lights right direction indicator Trouble of tail fog lamps, Trouble of all rear right located on both marker lights sides of the vehicle Trouble of brake lights of the rear lamps Trouble of the rear located on both sides of the left direction indicator...
  • Page 153 Trouble of the left direction Trouble of the reverse lamps located on both sides indicator of the trailer/ semi-trailer of the vehicle Trouble of the right Trouble of all left marker direction indicator of the lights of the trailer/ trailer/ semi-trailer semi-trailer Trouble of fog lights Trouble of all right marker...
  • Page 154 Trouble of stop-lights (brake lights) located on both sides of the trailer/ semi-trailer Trouble of reverse lights located on both sides of the trailer semi-trailer 7-23...

  • Page 155: Engine Start From External Power Source

    ENGINE START FROM EXTERNAL POWER SOURCE Use starting connection cables protected from twisting, with cross section 35 mm , at least, and with You may use external power sources to start en- isolated pole terminals. gine in vehicle with partially or completely discharged At ambient temperature below minus 10 ºС, the storage batteries.

  • Page 156: Starting The Engine From The Battery Of Another Vehicle

    STARTING THE ENGINE FROM THE BATTERY OF ANOTH- 8. In vehicle with charged storage battery, shut ER VEHICLE down engine to prevent failure of electric and electron- 1. Place the vehicle with charged storage battery ic items. next to the vehicle with discharged storage battery, pre- Rotate the ignition switch key to position «0 - all venting their contact with each other.

  • Page 157: Battery Emergency Switch Off

    BATTERY EMERGENCY SWITCH OFF BATTERY EMERGENCY STOP SWITCH FOR VEHICLES CARRYING DANGEROUS GOODS Attention! The vehicle for carrying dangerous goods is In the event of emergency situation in a vehicle equipped with an emergency stop switch installed on its (short circuit, fire) disconnect the storage batteries ur- instrument panel (see Fig.

  • Page 158: Steering System Faults

    STEERING SYSTEM FAULTS STEERING PLAY It is difficult to keep hold the lane with increased steering play. If an increase is detected in steering play com- pared to previous tests, you need to check steering gear swivel joints for play. Play at the swivel joints of steering mechanism is not allowed.

  • Page 159: Parking Brake Release In Hazard Situations

    PARKING BRAKE RELEASE Attention! IN HAZARD SITUATIONS If there is no sufficient air pressure in brake sys- Means of parking brake release in hazard situa- tem pneumatic drive, then after the mechanical release tions: of parking brake, the truck will have no brakes at all. 1.

  • Page 160: Fuses And Relays

    FUSES AND RELAYS To provide access to the fuse box remove fasteners and take off the fuse box cover (see Fig. Fuse ARRANGEMENT OF FUSES AND RELAYS and relay box). Fuse and relay box is installed on the instrument panel, on the passenger side (see Fig. Access to the fuse box).
  • Page 161 Fuse and relay box Relay Consumer Symbol Wiper operation modes relay Wiper stop relay wipers Towing hitch light relay Horn relay Fuel heating relay Cab tilting lock relay* Relay for locking storage battery switch off Conditioner relay Emergency switch off relay of the storage bat- teries* * For certain configurations...
  • Page 162 Fuses State of the main supply switch/ Symbol Rating Consumer ignition switch key FU1.1 EFU control unit FU1.2 Air suspension control module FU1.3 Control module for electric equipment (CBCU) FU1.4 EBS control unit FU1.5 ADM3 engine control unit FU1.6 Control unit for after-treatment system FU1.7 Control unit for MR2 engine 10 А...
  • Page 163 Nominal State of the main supply switch/ Symbol Consumer value ignition switch key FU2.7 Hatch control actuator* ON/ACC FU2.8 Conditioner ON/ACC FU2.9 Driver's side control panel ON/ACC FU2.10 Passengers's side door control panel ON/ACC FU2.11 Audio system ON/ACC FU2.12 Cigar lighter ON/ACC FU3.1 EBS control unit...
  • Page 164 State of the main supply switch/ Symbol Rating Consumer ignition switch key ON/0 FU4.1 Electric pump for cab raising/lowering * ON/0 FU4.2 Interior lighting ON/0 FU4.3 Connector for special add-ons ON/0 FU4.4 Power supply for buttons and sensors ON/0 FU4.5 Audio system ON/0 FU4.6...
  • Page 165 State of the main supply switch/ Symbol Rating Consumer ignition switch key FU5.7 Control module for electric equipment (CBCU) gr.1 Is not dependent/0 FU5.8 Control module for electric equipment (CBCU) gr.2 Is not dependent/0 FU5.9 Control module for electric equipment (CBCU) gr.5 Is not dependent/0 FU5.10 Control module for electric equipment (CBCU) gr.6...

  • Page 166: Checking And Replacing Fuses

    CHECKING AND REPLACING FUSES Attention! The electric circuits are protected by fusible links Do not use fuses rated for higher current (А) as or by means of automatic fuses. compared to specified. Otherwise, electric equipment If any power consumer stopped working, switch it may damage or cables burn.

  • Page 167: Replacing The Bulbs

    REPLACING THE BULBS REPLACING THE BULBS Replacing the additional lighting bulbs for SAFETY REQUIREMENTS poor visibility conditions 1. Prior to replacing the bulbs, de-energize the 1. Take apart the locking lug cover, placed under the harness having rotated instruments-and-starter key to po- bumper, and remove it (see Fig.
  • Page 168 Replacing the bulb of side repeater lights Replacing the searchlight bulb of the hitch lighting 1. Loosen the fastening screw, remove the diffus- er (see figure Side repeater light). 1. Loosen the fastening screw 1, remove the bulb 2. Change the bulb. in upward direction (see Fig.
  • Page 169 Changing the bulb in headlamp cluster 4. Disconnect the plug from the lamp contact, re- move the clamping spring, take out the halogen lamp 1. Remove the fastening cover plate of the head- holding it by the socket, install the new halogen lamp, lamp cluster, unscrew two bolts securing the bulb (holes secure the clamping spring, connect the plug with the 6 and 7) and two fastening bolts on the headlamp cluster...

  • Page 170: Table Of Lighting Equipment Applied In A Vehicle

    TABLE OF LIGHTING EQUIPMENT APPLIED IN A VEHICLE Application Bulb type Power, W АКГ24-70 Additional lighting bulb for poor visibility conditions Headlamp cluster: (Н7) low beam light АКГ24-70-1(Н1) high beam light marker lamps Light diode direction indicators Light diode daytime running light Light diode Tail lamps: direction indicator...

  • Page 171: Trouble-Shooting Guide For Electric Equipment

    TROUBLE-SHOOTING GUIDE FOR ELECTRIC EQUIPMENT Trouble Probable cause Remedy Storage batteries are discharged. Alternator drive belts are slackened. Adjust the belt tension. Address the service center. Alternator operates with increased Pulley fastening is loosened. Tighten up the pulley. noise. Starter fails to operate (headlamps are Break or absence of contact in starter Restore the contact.

  • Page 172: Cab Raising And Lowering

    CAB RAISING AND LOWERING Prior to raising the cab For raising and lowering the cab use (see Fig. To 1. Zone of cab tilting must be free. control cab raising and lowering): 2. Apply the vehicle parking brake. - cab hydraulic lift pump, placed on the right side 3.
  • Page 173 To tilt the cab The hydraulic locks are opened automatically when the pump is in operation. 1. To disable cab tilt lock: press the cab tilt Accidental cab lowering is prevented by the hy- lock switch located at the top of the instrument draulic cylinder design.
  • Page 174 If the cab is not locked, the cab lock indicator lights up on the driver's instrument panel. The unblocked cabin creates a danger for the op- erational reliability and safety of the vehicle. At the end of hydraulic cylinder travel (100 mm till complete cab stop), cab lowers with acceleration un- der its own weight).

  • Page 175: Lifting Jack

    LIFTING JACK With work over, shift the jack to transport posi- tion. For this: The jack is designed for short-time lifting the ve- - place the jack 3 in bracket 6; hicle, only, e.g., when changing wheel. It is not for vehi- - secure the jack with clamping plates 2 and 4, cle lifting in order to perform any operation under jacked and drive in the nuts 1 and 2.
  • Page 176 Vehicle lifting by a jack To lower the vehicle 1. Undo the screw head 1 as required (see Fig. 1. Slowly, screw out the locking needle 3. Hydraulic jack (version)). 2. Screw out the filling orifice plug 5 to release air 2.

  • Page 177: Spare Wheel

    SPARE WHEEL To raise the spare wheel Depending on vehicle model and configuration, 1. Place the wheel upside down. spare wheel is mounted: 2. Insert the spare wheel support inside the rim. - horizontally on a bracket; 3. Rotating the shaft with wrench for wheel nuts - technological installation.

  • Page 178: Disassembly And Assembly Of Wheels In Vehicles

    DISASSEMBLY AND ASSEMBLY OF WHEELS IN VEHICLES Wheel dismantle 1. Apply the parking brake. 2. Place the chocks under the wheels. 3. When disassembling the tire, release air from Lifting the front wheel the tire completely. 1 - thrust journal for installing 4.

  • Page 179: Wheel With Tubeless Tire Disassembly And Assembly

    Wheels mounting WHEEL WITH TUBELESS TIRE DISASSEMBLY AND ASSEMBLY Mount wheels in reverse order. Assemble and disassemble wheels in a special site Prior to the disk wheels setting, clean the setting of enterprise equipped with required tools and applianc- surface on a hub and a wheel. Grease the setting diameter on a hub, thread on wheel fastening bolts.
  • Page 180 To disassemble the tubeless tire off the wheel rim 5. Turn the wheel with tire over, with disk down, in the same way, remove the second tire bead from a rim 1. Completely let air out of the tire; seat. 2.
  • Page 181 10. If need be, remove gate from the rim. To facilitate the assembly and disassembly and to avoid the tire sealed ply breakage, wipe the tire bead and the rim flange with cloth soaked in soap or simple water. Prior to mounting, inspect the technical state of wheel and tire: there should be no traces of corrosion, dirt, metal scoring, especially on tapered surfaces con- Sequence of tubeless tire mounting...

  • Page 182: Troubleshooting For Bolster

    TROUBLESHOOTING FOR BOLSTER Cause Remedy Bolster fails to close Coupling pivot of semi-trailer is disposed Install the support plate on one level or 50 mm below too high Bolster fails to open Train is on rough ground or bolster is un- Release the bolster locking means der action of stretching forces Bolster is not ready for coupling...

  • Page 183: Vehicle Storage

    «KAMAZ» PTC. The trucks (chassis) purchased but not introduced into operation may be stored in storehouses** without preservation for not more than three months from the date of sale.

  • Page 184: Vehicle Transportation

    9 VEHICLE TRANSPORTATION The trucks may be transported to any point of destination by railway, sea or by its own power. The type of transport is to be stipulated in agreement for delivery. While preparing the trucks for transportation, de- pending on transport type, be sure to adhere to the re- quirements in the following documents: 1.

  • Page 185: Manufacturer's Warranty

    10 MANUFACTURER’S WARRANTY The guarantee terms are agreed upon in a pur- chase-sale agreement. 10-1...

  • Page 186: Utilization

    11 UTILIZATION The purchased units and component parts of a truck are to be utilized pursuant to service documenta- tion. The rest equipment of a truck, prior to utiliza- tion, is to be dismantled and sorted out onto nonfer- rous metals (by metal trade marks) and ferrous ones. Prior to waste disposal, be sure to clean the items of oil and grease.

  • Page 187: Appendix 2. Lubrication Chart For Kamaz 5490 Vehicle

    Appendix 2. LUBRICATION CHART FOR KAMAZ 5490 vehicle The Lubrication chart determines the range and usage of fuels, greases and special liquids for operation of KAMAZ 5490-vehicles (4x2 type) with EURO 5 engine. Maintenance interval is specified for vehicles of A maintenance group. Maintenance interval of the other groups is set in accordance with "Service book".
  • Page 188 Table 2 Lubrication chart for KAMAZ 5490 vehicle Name & Designation of Fuel, Oil and Grease Grease, qnt. Lubrication points Maintenance Name of works (per item) main specifications Vehicle power sup- Diesel fuel EURO EN 590:2009 GOST Р 52368-2005 (ЕН 590:2009)
  • Page 189 Table 2 cont. Gear box case: See the Appendix 3 TE-ML 02 In accordance with the ZF gearbox opera- - ZF 16S2220TD; (section «Transmission oils») tion manual 10,0 l - ZF 16S2221TD; 18,5 l - ZF 12АS2130TD; 11,0 l - ZF 12АS2131TD; 15,5 l - ZF 16S1820TO 8,0 l...
  • Page 190 Table 2 cont. Locking mechanism and Grease: Grease with addition of W.Mnt. Lubricate through grease truck bolster kingpin BP Energrease L21-M; desulphyde molybdenum cups BP Energrease BP LS2; or graphite Shell Retinax HDX 2; Chevron Moly Grease EP2 Pins of: Grease Litol-24 KP2N-20 on DIN 51502 0, 036 kg...
  • Page 191 Table 2 cont. Terminals of storage Grease Litol-24 KP2N-20 on DIN 51502 0, 020 kg once a year Apply thin layer to grease batteries GOST 21150-87 (lithium basis) Connections of electric Grease Litol-24 KP2N-20 on DIN 51502 0, 008 kg once a year Grease connections on a equipment...
  • Page 192 See tables 1, 2 88,0 l* D.Mnt. Check the level, top the road train: of the Appendix 3 up to norm KAMAZ 5490 vehicle once a year Change oil and tank semi-trailer Daimler OM457 engine The coolants are according to MB Sheet No.325.0/2...

  • Page 193: Appendix 3. Service Materials

    Appendix 3. SERVICE MATERIALS To ensure reliable operation of the vehicle, use fuels, oils and special liquids recommended by the manu- facturer. The list of motor oils permitted for application in Daimler units and assemblies is presented in "Mercedes- Benz" Specifications for Service Products ". The infor- mation about these prescriptions is available from any Mersedes Benz service center or on the following web page: htpp://bevo.mercedes-benz.com/.
  • Page 194 TRANSMISSION OILS «Mercedes-Benz» Specifications for Service Products» (Specification sheet No. 235.8 - MG gear oils on a syn- Attention! For ZF gearboxes, use oils approved thetic basis). Oil change interval in Daimler axles is spec- by ZF, strictly. The complete information on oils (list, ified in service book.
  • Page 195 COOLANT Attention! Vehicle operation with SCR system being not primed with neutralizing liquid is prohibit- Coolant is a balanced aqueous solution of anti- freeze. Presence of antifreeze permits to expand the op- eration temperature range by decreasing the freezing HYDRAULIC OIL temperature and by increasing the coolant boiling point.
  • Page 196 Table 1 - Application conditions for hydraulic oils applied in vehicle hydraulic systems The lowest temperature of Oil temperature with Viscosity grade VG Oil temperature with Viscosity index the short start with a vis- maximum operating according ISO minimum viscosity value cosity value viscosity value of at 40 °С...
  • Page 197 Table 2 – List of oils for operation of vehicle hydraulic system Limit short Oil temperature with Temperature of: Viscosity mm /sek, start temperature °, minimum viscosity oil with maximum at a temperature of Firm Oil grade ° operating value, viscosity value, °С...
  • Page 198 Table 2 Cont. Limit short Oil temperature with Temperature of: Viscosity mm /sek, start temperature, minimum viscosity oil with maximum at a temperature of Firm Oil grade °C ° operating value, viscosity value, °С 40 °С 100 °С SHELL Tellus 10 2,40 >minus 55 minus 35...
  • Page 199 MANUFACTURER: ADVERS Limited Liability Company 443100 Samara, Lesnaya str. 11 Tel.(846) 270-65-09, 270-68-64 Fax (846) 270-65-09 E-mail: advers - ts @ yandex.ru (Copy) Diesel Engine Pre-heaters 14ТС-10 User Manual 14TC.451.00.00.00.000-10 РЭ Table of Contents...
  • Page 200 Table of Contents Introduction ................................3 Key features and characteristics ..........................4 Safety measures ................................. 5 Description of pre-heater set-up and operation ...................... 6 Pre-heater control unit ............................11 Control panel ................................11 Faults ..................................13 Pre-heater control system faults ..........................13 Maintenance ................................

  • Page 201: Introduction

    1. Introduction The present User Manual gives information on set-up, operation and servicing of 14ТС-10 diesel engine pre-heater (further on – pre-heater), which is used for start heating and warming – up of diesel engines of any trucks with liquid-cooling system at ambient temperature as low as minus 45 °С.

  • Page 202: Key Features And Characteristics

    2. Key features and characteristics Main technical characteristics of the heater are shown with a tolerance of ± 10 %, obtained at a nominal voltage of 24 V and a temperature of 20 °C. 2.1 Nominal supply voltage, V 2.2 Heat productivity, kW - full duty 15,5 - medium duty...

  • Page 203: Safety Measures

    3. Safety measures 3.10 The pre-heater shall be disconnected from 3.1 The pre-heater and its components shall be the accumulator battery when being repaired or welding installed only by authorized companies, by reason of its is performed with the truck. complicated structure: there’s a combustion chamber 3.11 It is prohibited to use the pre-heater with where fuel burns, a heat exchanger which provides heat...

  • Page 204: Description Of Pre-Heater Set-Up And Operation

    4. Description of pre-heater set-up and operation as: flame detector, heat and overheating sensors, pump, The pre-heater runs independently of the truck pump motor, glow plugs, fuel pump engine. corresponding electric circuits. In case of nonfailed The pre-heater is fueled and powered from the status, there starts...
  • Page 205 means that in both programs the coolant fluid is heated Peculiarities of the pre-heater automatic control up to 80 °C; in case of overheating more than 80 °C the under emergency conditions and in contingencies: pre-heater is switched to the cooling-down mode. At the 1) If the pre-heater has not started for some same time combustion stops, the pump continues its reason,...
  • Page 206 Figure 1- Pre-heater electric circuit...
  • Page 207 Figure 2 – Pre-heater main components...
  • Page 208 Figure 3 – Pre-heater basic components...

  • Page 209: Pre-Heater Control Unit

    5. Pre-heater control unit - indication of the pre-heater status (ON, OFF, Jointly with the control panel, the control unit is Failure). used to control the pre-heater operation The control functions of the pre-heater are the following: a) initial health check of the pre-heater units at start;...
  • Page 210 б) with the knob in the utmost right position the cab heater fan is continuously ON; Heat controller knob poses. 4 for KAMAZ в) with the knob in the middle position the fan vehicles of «Euro 3» and «4» is not used (Car maker will runin cycles.

  • Page 211: Faults

    7. Faults 8. Pre-heater control system faults 7.1 Faults that the User can eliminate on his own. 8.1 Trouble-shooting shall be started with If after being switched on the pre-heater won’t start, it is checking the connector terminals and corresponding necessary to do the following: circuits (refer to Table 1 and Electric circuit in Figure 1).
  • Page 212 8.2 Other faults are listed in Table 2. Table 2 Number of Fault Notes/ Troubleshooting blinks Overheating Heat/ overheating sensor indicates temperature higher 102 °C. Thoroughly check the complete liquid circuit and circulation pump operation. risk overheating. Difference between temperature measured by the heat sensor and Temperature difference between overheating sensor is more than 20 °C (i.e.
  • Page 213 Combustion detector Check the leads. Check the ohmic resistance between the detector plug malfunction pins. In case of rupture the ohmic resistance is more than 1 Ohm, and the combustion detector shall be replaced. Overheating sensor malfunction Check the leads. Output signal and voltage are in linear dependence from the temperature (0 °C corresponds to 2.73 V and with temperature Heat sensor malfunction increase for 1 °C output signal increases for 10 mV correspondingly).

  • Page 214: Maintenance

    9. Maintenance The pre-heater maintenance includes the following: - Daily maintenance; - Seasonal maintenance (preparation for winter-time operation). Daily maintenance of the pre-heater shall be regularly done during the heating season. The list of activities to be done is given in Table 3. Seasonal maintenance of the pre-heater is done before the heating season.
  • Page 215 Glow plug Dismantle the air intake, rubber cap Special purpose protecting the glow plug, disconnect the leads, Every wrench, clean rags, unscrew the ignition plug and remove carbon 500h Visual inspection benzene (acetone), deposit from it. screwdriver. - check the glow plug rubber cap for mechanical damage, and in case of detection, replace the glow plug.

  • Page 216: Recommendations

    10. Recommendations 12. Warranty 10.1 In case the device is not used, to guarantee 12.1 The pre-heater warranty life is 18 months safe performance of the pre-heater it is recommended to from the date of sale, i.e. 500 h or 50000 km mileage, switch it on once per month for 5-10 min (even during provided that the User followed the operating rules, the warm period of the year).
  • Page 217 2 Technical characteristics of the heater The characteristics in Chart 1 are given under the ambient air temperature +20 °С and the nominal voltage. Admissible fluctuations are ±10 %. Chart 1 Items of characteristics Heater PRAMOTRONIC-16WD24 Pramotronic Production Company Nominal Voltage, V (Copy) Fuel Diesel oil under State Standard Specification 305 (GOST 305)
  • Page 218 3 Safety requirements and warnings 3.11 It’s not allowed to use the heater when the vehicle is parked in enclosed spaces (in a garage, in a 3.1 Assembling and maintenance of the heater workshop, etc.) to prevent poisoning by the exhaust. must be carried out by organizations and individuals 3.12 When fuelling the motor vehicle the heater having the producer’s license.
  • Page 219 4.5 The heater is a self-contained heating device and consists of the following main parts (figure 2): - Frame (position 1); - Heat exchanger (position 2); - Air pump (position 3); - Control unit (position 4); - Glow plug (position 5); - Flame indicator (position 6);...
  • Page 220 Fig. 2.The main parts of the liquid heater «PRAMOTRONIC 16WD-24»...
  • Page 221 4.6 The source of heat is gases got from burning of air-fuel mixture in the combustion chamber. Hot gases moving through the blades inside the heat exchanger warm it and the cooling liquid that washes the heat exchanger from outside is heated and sends this heat into the cooling system.
  • Page 222 controlled by the control unit with the help of the flame mode heats the liquid up to the temperature +70 °С. indicator. When steady burning and the sufficient signal Then it goes to the «MEDIUM» mode and brings the from the flame indicator are reached the control unit temperature of the cooling liquid up to +75 °С, after that turns off the glow plug and the further process of burning it goes to the «LOW»...
  • Page 223 Working in the «MEDIUM» mode the heater of the cooling liquid keeps rising and the heater warms warms the cooling liquid up to +60 °С and goes to the the cooling liquid up to +75 °С the heater will go to the «LOW»...
  • Page 224 5 Requirements to the assembly 5.3 The heater must be installed in the way of the details and units of the heater that prevents dirt from getting into the intake hole of the air filter. 5.1 The heater is assembled depending on its 5.4 The construction of the heater allows it to be working position.
  • Page 225 - for connecting the fuel tank and the fuel pump it’s In assembling the fuel system short radius bends preferable to use hose pipes with the inside diameter of sleeves and hose pipes are not allowed, as a bite about 2 millimeters, as in that case it takes the working (fracture) of the flow passage occurs.
  • Page 226 Fig. 6. The diagram of the assembly of the fuel system of the heater with an individual fuel tank...
  • Page 227 Fig. 7. The diagram of the assembly of the fuel system of the heater with the fuel intake from the motor vehicle fuel tank.
  • Page 228 While assembling is carried out the hose pipes must be cut off only with a sharp knife as in figure 8. The restriction of the flow passage of the heater, as well as hollows and barbs are not allowed. Fig. 8 Attention : The hose pipe and the fuel pump should be protected from heating.
  • Page 229 Fig. 9 The diagram of the fuel pump assembly...
  • Page 230 It’s allowed to install the fuel pump on the frame 6 Checkup of the heater after the assembly of the heater. 6.1 When assembling the following must be 5.9 The control panel assembly secured: The control panel is installed in the cabin or - air tightness of the fuel system and tightening of the saloon of the motor vehicle on the dash panel in the place clips;...
  • Page 231 7 Guidelines 7.3 In the case of untimely change for winter fuel 7.1 For securing continuous working capacity of the heater may not start or may turn off during the the heater it’s recommended to turn on the heater briefly operation.
  • Page 232 9 Possible malfunctions, their reasons and 9.2 All possible malfunctions that may occur during the heater operation are displayed as malfunction ways of their elimination 9.1 Some malfunctions that can be eliminated in- codes on the control panel. Each malfunction code is house: displayed on the control panel as repeated flickers and - the buttons on the control panel don’t glow...
  • Page 233 Chart 3 The number of Malfunction Guidelines on malfunctions elimination flickers before the interval The voltage in the accumulator Check the voltage in the connector. The voltage must be from 20-30 Watt. If battery is not normal voltage is less than 20 Watt, charge or replace the accumulator battery; if it’s more than 30 Watt, check the voltage regulator.
  • Page 234 APPENDIX. SERVICE INSTRUCTION AIRTRONIC D2 INDEPENDENT DEVICE FOR HEATING AND MAINTENANCE OF AIR TEMPERATURE IN THE CAB...
  • Page 235 CONTENT 1. Self-contained hot-air heating system plan in the cab ……………………………………………………………… 4 2. Intent of the heater …………………………………………………………………………………………………. 5 3. Safety directions …………………………………………………………………………………………….……… 5 4. Fuel delivery………………………………………………………………………………………………………… 7 4.1 Accidents prevention guidelines concerning fuel supply system…………………………………….……. 7 4.2 Fuel quality ………………………………………………………………………………………………… 7 4.3 Operation using bio fuel (fatty-acid methyl esters)…………………………………………………………...
  • Page 236 9.1 Main functions of push buttons …………………………………………………………………………… 11 9.2 Menu bar…………………………………………………………………………………………………… 11 9.3 Data entry field…………………………………………………………………………………………….. 11 HEATING…………………………………………………………………………………………….. 12 VENTILATION……………………………………………………………………………………….. 12 PROGRAM……………………………………………………………………………………………… 12 SETTINGS……………………………………………………………………………………….……. 14 9.8 Factory setting……………………………………………………………………………………………… 14 9.9 Error codes, their description and remedial procedure…………………………………………………….. 15...

  • Page 237: Self-Contained Hot-Air Heating System Plan In The Cab

    1. SELF-CONTAINED HOT-AIR HEATING SYSTEM PLAN IN THE CAB Night cab Day cab 1 - Self-contained device for heating air; 6 - control panel (timing device); 2 - exhaust system; 7 - metering pump assembly with fuel filter; 3 - air supply tube in combustion chamber; 8 –...

  • Page 238: Intent Of The Heater

    2. INTENT OF THE HEATER 3. SAFETY DIRECTIONS • Heating and maintaining the temperature in the Danger! driver's cab. Safety hazard, burn hazard and toxic hazard! • Glasses heating to defreeze them and to remove condensate. • The heater must only be switched on when in- spection cover is closed and outlet pipes are installed.
  • Page 239 • When performing electric welding operations on Attention! the vehicle in order to protect the control unit, it is neces- • When refueling the car, the heater must be sary to remove the terminal from positive terminal of the switched off. battery and close it to weight.

  • Page 240: Fuel Delivery

    4. FUEL DELIVERY - at a temperature from - 20 °C to - 40 °C: use arc- tic or polar diesel fuel. 4.1 ACCIDENTS PREVENTION GUIDELINES CONCERNING FUEL SUPPLY SYSTEM Please note! After refueling with winter diesel fuel, fuel lines Attention! and metering pump must be filled with new fuel by turn- Do not operate the heater using unacceptable fuel/...

  • Page 241: Technical Details And Functional Description

    6.2 HEATNG OPERATION IN HIGH GROUND 7.2 START • Heating operation is possible at a height up to In 65 seconds the fuel is supplied and air-fuel 1500 m above sea level. Otherwise, adjustment of device mixture ignites in combustion chamber. is necessary.

  • Page 242: Temperature Control In Heating Mode

    7.4 TEMPERATURE CONTROL IN HEATING MODE 7.6 SWITCHING When the heater is turned off, «Off» is displayed In heating mode, the temperature in the vehicle or for 2 seconds on control panel display, then current time the temperature of intake air are constantly measured. If clock and actual temperature in the vehicle are switched the temperature is higher than the value set on the control off, fuel supply is turned off.

  • Page 243: Malfunction/ Maintenance

    8. MALFUNCTION/ MAINTENANCE 8.3 Maintenance instructions • Switch on the heater also in warm season approx- 8.1 MALFUNCTION RESPONSE ACTIONS imately once a month for 10 minutes. • The heater does not start after switching on: • Before starting continuous operation in cold sea- - switch the heater off and on.

  • Page 244: Control Panel (Timing Device)

    9. CONTROL PANEL (TIMIMG DEVICE) 9.2 MENU BAR Symbol Function EasyStart Timer Heating On / Off Ventilation On / Off Program Settings 9.3 DATA ENTRY FIELD Symbol Function Time setting Time display format 9.1 MAIN FUNCTIONS OF PUSH BUTTONS Weekday setting By using the button the heater is switched on and acknowledged.

  • Page 245: Heating

    After pressing and holding LONGPRESS VENTILATION more than 2 seconds heating mode starts immediately. After pressing and holding LONGPRESS Ventilation On more than 2 seconds all functions are completed. On the menu bar use the buttons to select the symbol and confirm with the button , confirm duration of the operation using the button...
  • Page 246 • Setting of beginning of trip/ start time (Factory Selection of software memory device. On the menu bar use the buttons to select setting: beginning of trip). the symbol « » and confirm with the button , using Using buttons set the number of hours and buttons select the memory to store programs P1,...

  • Page 247: Settings

    9.8 FACTORY SETTING SETTINGS Program/ presetting: On the menu bar using buttons select the • Group of days of the week Monday - Friday (Mo symbol and confirm using the button – Fr). • Time of beginning of trip, 7:00. Time setting.

  • Page 248: Error Codes, Their Description And Remedial Procedure

    9.9 ERROR CODES, THEIR DESCRIPTION AND REMEDIAL PROCEDURE Error code Description Remedial procedure/ customer Function machine recognition switched on. Wait until the machine recognition finishes, then set INIT Timing device EasyStart was switched off, the exact time and day of the week. and then it was switched on again.
  • Page 249 Operating Instructions Trucks ZF-NewEcosplit...
  • Page 250 Copyright © ZF Friedrichshafen AG This document is protected by copyright. Complete or partial reproduction or dissemination of this document is prohibited without the consent of ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution. This document is a translation of the German original.
  • Page 251 Preface NOTE Your vehicle is equipped with a mechanical synchromesh transmission of the ZF-Ecosplit model range. As a result of type variety, images shown in these operating instructions are not always identical with your transmission. Consequently, only one variant is displayed on an exemplary The more familiar you are with the ZF transmission, the more basis.
  • Page 252 Safety Instructions The following safety instructions are used in the present THREATS FOR THE ENVIRONMENT! operating instructions: Lubricants, consumables, and cleaning agents must not be allowed to enter the soil, ground water, or sewage system. NOTE • Ask your local Reference is made to special procedures, methods, environmental protection agency for material safety information, etc.
  • Page 253 Table of Contents Page Page Technical Data ......6 Maintenance ......24 Transmission fluid .

  • Page 254: Technical Data

    Technical Data for standard drive Transmission type Direct drive 16 S 1620 TD 16 S 1920 TD 16 S 2220 TD 16 S 2320 TD – Overdrive 16 S 1820 TO 16 S 2220 TO 16 S 2520 TO – 16 S 2723 TO Input torque max.

  • Page 255: Description

    Description Description Setup The ZF-New Ecosplit transmission consists of a 4-speed section, a range change and a splitter group. Version R 2 4 027415 027408 4-speed section: Fig. 1, Example Fig. 1a, Example • Synchronized, reverse gear with constant-mesh Superimposed H shift pattern Double H shift pattern •...
  • Page 256 Description high Range change group high high Splitter group high Range change group Splitter group 027416 027409 Fig. 2 Fig. 2a Shift lever* superimposed H Shift lever* double H * Depending on the vehicle manufacturer, different shift levers and shift patterns are possible. As example, the standard design is shown. Also note the details provided by the vehicle manufacturer.

  • Page 257: Shift Actuation

    Description Shift actuation Range change group of double H shift pattern Range change group, superimposed H shift pattern The shift system is divided into 5 parallel shift gates. Shift The shift system is divided into 3 parallel shift gates. Shift gates 3/4 and 5/6 have each a spring-mounted neutral gates 3/4 and 7/8 have a spring-mounted neutral position.
  • Page 258 Description Splitter group The control unit of the range change group changeover system consists of the shift valve (1) and the pneumatic cylinder with a double effect in the transmission (2). The splitter group is actuated via a preselection switch at the shift lever (Fig.

  • Page 259: Auxiliary Power Units

    Description Auxiliary power units + PTO Torque con- verter clutch Depending on the vehicle version, Ecosplit transmissions can be equipped with the following auxiliary power units (Fig. 5): Clutch-dependent Drive- PTOs • Separate heat exchanger dependent N1, N4, and N10 for cooling the transmission oil N ...

  • Page 260: Operation

    Operation Operation Starting engine and setting off Cost-effective driving with good fuel economy is assured when • Close the parking brake (this prevents the vehicle from the following operating instructions are observed: starting to roll unintentionally). • Shift transmission to neutral position. •...

  • Page 261: Shifting The Transmission

    Operation Shifting the transmission The shift gate for the reverse gear is protected by a pawl stop and requires more force to be applied. ZF-Ecosplit transmissions are synchronized transmissions. A synchronizer is the synchronizing device for the gears. This makes shifting more comfortable. CAUTION •...
  • Page 262 Operation Double H shift pattern “RC hump” The double H shift pattern (Fig. 6a) has a spring-mounted neutral position (idle position) in shift gates 3/4 (low range change group) and 5/6 (high range change group). In order to select shift gates 1/2 and 7/8, move the shift lever in the desired direction pressing against the spring force and hold against this spring force.

  • Page 263: Changing Gears

    Operation 3.3.2 Changing gears • Move shift lever smoothly and without force. This is CAUTION • Keep the clutch pedal always completely depressed during particularly important when the transmission oil is still cold. the gear shifting in order to avoid damages to the trans- •...
  • Page 264 Operation Superimposed H NOTE Only operate preselector switch when you want to engage the The range change group can be preselected via the range change group directly afterwards. preselection switch at the shift lever (Fig. 7). CAUTION • Constant shifting with high manual shifting force can cause increased wear on the synchronizer parts.
  • Page 265 Operation Double H shift pattern CAUTION It is not permitted to change between shift gates 5/6 and 3/4 when the driving speed is higher than approx. 28 km/h. • Changing from shift gates 3/4 into 5/6 or vice versa by Changing shift gates leads to a changeover in the rear- quickly hitting the shift lever with the hand.
  • Page 266 Operation Reverse gear NOTE • Grating noise when activating the reverse gear is not CAUTION permissible. Only engage reverse gear when the vehicle is standing still. • Only engage reverse gear once the countershaft is standing still. If the countershaft is not standing still, there will be •...

  • Page 267: Engaging The Ptos

    Operation Engaging the PTOs CAUTION • Gear changes are not permissible when operating the PTO. 3.4.1 Clutch-dependent PTOs • Always switch off the PTO when you park the vehicle for a longer time (e.g. overnight). The PTOs can be operated with the vehicle standing or driving. •...

  • Page 268: Engine-Dependent Ptos

    Operation 3.4.2 Engine-dependent PTOs Parking Engagement takes place independently of the vehicle clutch. • Change transmission to the low range change group (1st - 4th gear). • Activation and deactivation only when engine is running: minimum engine speed 600 rpm •...

  • Page 269: Towing

    Operation Towing [i Axle] It is only possible to tow the vehicle under the following 0.5 [m] (e.g. 275/80R22.5) conditions: 0.6 [m] (e.g. F24) • Emergency steering pump installed. 0.4 [m] (e.g. 245/70R19.5) • High range change group selected, shift lever in neutral position.

  • Page 270: Limp Home Operation

    Operation Limp home operation Trouble when changing range change group (e.g. from shift gate 3/4 to 5/6 or vice versa) can be caused by the following: • Line damage in pneumatic system. • Shift valve (1) or shift cylinder (2) for the range change group is defective (condensate or contamination).

  • Page 271: Initial Startup Of Vehicle At Low Temperatures

    Operation Initial startup of vehicle at low temperatures 3.9.1 Parking the vehicle at low temperatures The transmission is filled with oil according to ZF List of Lubri- At outside temperatures below 0 °C, it is to be ensured that cants TE-ML 01 or TE-ML 02. At outside temperatures of less the low range change group is selected when the vehicle is than -15 °C, suitability of the oil grade must be checked parked (shift lever in 1st gear or neutral position of shift gate...

  • Page 272: Maintenance

    Maintenance Maintenance Transmission fluid 4.1.1 Oil grade Regular maintenance increases the service life of the transmis- sion. It is therefore of particular importance that maintenance NOTE intervals are observed. • When filling transmissions, only the oils specified in the NOTES latest applicable version of the ZF List of Lubricants •...

  • Page 273: Oil Change

    Maintenance Oil change CAUTION Oil must not be allowed to enter the soil, ground water, or 4.2.1 Oil drain sewage system. Collect overflowing oil in a suitable container and dispose of in accordance with environmental guidelines. NOTE Generally: Change oil after a longer journey while the transmission oil is still at operating temperature and of low viscosity.

  • Page 274: Oil Fill

    Maintenance 4.2.2 Oil fill Oil level check CAUTION • Unscrew oil filler plug. Too less oil in the manual transmission leads to transmission • Top up oil through oil filler hole (Fig. 11). damages. • The oil level is correct when it has reached the bottom edge of the filler hole and/or when oil is already escaping out of the filler hole.

  • Page 275: Transmission Maintenance For Versions With Heat Exchanger

    Maintenance Transmission maintenance for versions with • Check: heat exchanger - Let engine run at idle speed for approx. 3 minutes. - Shift transmission to neutral position. NOTE - Switch off the engine. - Check oil level, refer to Chapter 4.3. Perform maintenance works as described in Chapters 4.1 to 4.3.

  • Page 276: Transmission Maintenance For Versions With Clutch-Dependent Ptos

    Maintenance Transmission maintenance for versions with Checking the clutch clutch-dependent PTOs To guarantee the function and service life of the synchronizers, The clutch-dependent PTOs do not influence the oil filling and it is absolutely required that the clutch separates completely. oil level check of the manual transmission.

  • Page 277: Checking Release Valve Of Clutch Pedal

    Maintenance 4.6.1 Checking release valve of clutch pedal Before the splitter group can be activated via the release valve (1), the clutch must be fully separated. The complete separation of the clutch must take place before reaching 70% of the pedal travel. CAUTION •...

  • Page 278: Venting The Transmission

    Maintenance Venting the transmission The transmission oil heats up during driving. This results in the formation of excess pressure which is continuously reduced via a bleed valve. NOTE Check venting system during each vehicle inspection. 4.7.1 Hose breather Vehicles like, for instance, milk tankers, concrete mixers, etc. have to be cleaned frequently due to their application.

  • Page 279: Breather

    Maintenance 4.7.2 Breather Compressed-air system maintenance Make sure that the breather is cleaned and not clogged. The Condensate accumulates in every compressed-air system. To breather must be clean and shall not be covered. Do not prevent any condensate, rust, water, and other impurities of direct pressurized water at it (water in the transmission: risk the compressed-air reservoirs from entering the valves or shift cylinders, regular maintenance of the compressed-air system...

  • Page 280: Type Plate

    Maintenance Type plate The type plate contains the key data. It is fitted on the left of the transmission when viewed in the direction of travel. The following information must always be stated when making inquiries, placing orders, or carrying out repairs: 1.
  • Page 281 ZF Friedrichshafen AG ZF Friedrichshafen AG 88038 Friedrichshafen 88038 Friedrichshafen Deutschland · Germany Deutschland · Germany Telefon/Phone +49 7541 77-0 Telefon/Phone +49 7541 77-0 Telefax/Fax Telefax/Fax +49 7541 77-90 80 00 +49 7541 77-90 80 00 www.zf.com www.zf.com...
  • Page 282 Betriebsanleitung Operating Instructions Manuel d’Utilisation Manual de Servicio Istruzioni per l’Uso The Integrated Retarder for Trucks and Buses With ZF Transmissions ECU 42 Control Unit 6085 758 102c...
  • Page 283 Subject to technical changes Copyright by ZF This documentation is protected by copyright. Any reproduction or dissemination in whatever form which does not comply fully with the intended purpose of this documentation is prohibited without the consent of ZF Friedrichshafen AG. Printed in Germany ZF Friedrichshafen AG, MC-C dept.
  • Page 284 Overview on Types Trucks: ZF-Ecosplit ZF-AS Tronic 16 S 151 IT 16 S 1621 TD 12 AS 2301 IT 12 AS 1631 TD 16 S 181 IT 16 S 1821 TO 12 AS 1931 TD/TO 16 S 221 IT 16 S 1921 TD 12 AS 2131 TD/TO 16 S 251 IT 16 S 2221 TD/TO...
  • Page 285 Overview on Types BUS: 8 S 180 IT 8 S 2101 BD 8 S 2101 BO 6 S 1600 IT 6 S 1601 BD 6 S 1701 BO horizontal (to the right) and 6 S 1901 BO heat exchanger at bottom 6 S 1600 IT 6 S 1601 BD 6 S 1701 BO...
  • Page 286 Preface Before first operating the ZF-Intarder, we kindly ask the The ZF Customer Service specialists are available to assist driver: you in carrying out maintenance work or to help if any other problems arise with the transmission and the ZF- ·...
  • Page 287 Safety Instructions The following safety instructions appear in the present THREATS TO THE ENVIRONMENT! operating instructions: Lubricants, consumables, and cleaning agents must not be allowed to enter the soil, ground water, or sewage system. NOTE • Ask your local environment agency Refers to special processes, techniques, information, etc.
  • Page 288 Table of Contents Preface ....... . . Maintenance ......Safety Instructions .

  • Page 290: Safety Instructions

    Safety Instructions Intarder • Intarder use does not impact the operation of the 1 General Safety Instructions Intarder manual transmission. Intarder brake power remains unaltered with depressed clutch pedal (for gear change). DANGER ! Make cautious use of the Intarder: •...

  • Page 292: Description

    Description Description The ZF-Intarder is a wear-free operating, hydrodynamic additional brake which is integrated into the transmission. It reduces the wear of the wheel brakes, • during braking down from higher speeds. • when riding along downhill tracks. The ZF-Intarder contributes to a smoother and more economic driving style.

  • Page 294: Use

    Operation Operation at Low Temperatures Vehicle manufacturer specifications MUST be observed. Outside temperature Down to –20 °C –20 °C to –30 °C –30 °C to –40 °C Oil grade In accordance with ZF-List of In accordance with ZF-List of In accordance with ZF-List of Lubricants TE-ML 02 Lubricants TE-ML 02 Lubricants TE-ML 02...

  • Page 295: Intarder Master Switch

    Operation 3.2 Intarder Master Switch 3.3 Intarder Check Display The Intarder is switched on or off with the main switch The Intarder check display lights up during Bremsomat (98). This applies also for actuation during travel. The operation i.e. when the Intarder is active as well as during main switch is installed in the dashboard.
  • Page 296 Operation Error code output via the flash code, also refer to 3.7. In addition to the normal functions, the Intarder check display outputs the flash code (error number), also refer to Chapter 3.7, flash code output. 6085 758 102b - 2006-10...

  • Page 297: Constant Braking Step Operations

    Constant braking step operations 3.4 Constant Braking Step Operations The Intarder’s braking effect increases consistently from the first to the last braking step, in line with the lever’s position. The Constant Braking Step function leads to unintended B = Bremsomat vehicle deceleration (relieving the service brake system).
  • Page 298 Constant braking step operations • Deactivation of the constant braking step operations The braking step lever is either - in the position 0 or - in the position B = BREMSOMAT function and/or B = Bremsomat BREMSOMATIC function 1 - 5 = Constant braking step (applications depend upon the operations vehicle manufacturer).

  • Page 299: Bremsomat Function

    Bremsomat Function 3.5 BREMSOMAT Function (Bremsomat operation depends upon the vehicle) By means of this functions, you can keep the velocity of your vehicle during downhill travel at the requested constant value. The Intarder electronics automatically set the required level of braking torque. Upon actuation of the accelerator pedal, the Bremsomat function is automatically interrupted and after releasing the accelerator pedal, the current speed is set.

  • Page 300: Zf Braking Step Lever (Standard)

    Bremsomat operation 3.5.1 ZF Braking Step Lever (Standard) NOTE If the braking step lever is set back into position B after engaging constant braking step operation and the automatic speed control becomes effective with the current speed. B = Bremsomat •...

  • Page 301: Bremsomatic Function (Bremsomatic Operation Depends Upon The Vehicle)

    Bremsomatic Function Bremsomatic Function (Bremsomatic operation depends upon the vehicle) Function as with Bremsomat in position B, however, the respectively current speed is set after releasing the accelerator pedal, the brake pedal, or the engine brake. Advantages Bremsomatic: • Cruise control and Bremsomatic may not operate against one another.

  • Page 302: Zf Braking Step Lever (Bremsomatic)

    Bremsomatic operation 3.6.1 ZF Braking Step Lever (Bremsomatic) NOTE If the braking step lever is, after engagement of the constant braking step operation, set back into position B, then the automatic speed control becomes effective with the current speed. B = Bremsomatic •...

  • Page 303: Deleting The Flash Code Output And The Error Memory

    Flash Code Output 3.7 Deleting the Flash Code Output and the Error 4. Within 5 seconds time, the braking step lever is set to Memory two stages below the max. braking step (here, position 3) and subsequently again to the position of one stage below the max.
  • Page 304 Clearing error memory Clearing error memory Switch ignition off. Braking step lever in position 4 (max. position -1). Switch on ignition and wait for continuous light (3 seconds) or flashing (5 seconds) of the Intarder check display. Within the 5 seconds, the braking step lever is set to position 3 (max.

  • Page 305: Flash Code Error List

    Flash Code Error List 3.8 Flash Code Error List NOTE read out from the error memory of the ZF control unit This error list represents a “compressed summary“ of all (ECU) for optimal diagnosis. Please feel free to turn to possible individual errors.
  • Page 306 Flash Code Error List Error code: Importance Control flash code lamp defective El. defect - speed sensor El. defect - temperature sensor Braking stage selector lever inputs not plausible El. defect - engine speed sensor CAN message EEC2 defective CAN message TSC1 defective Sending error of CAN messages CAN BUS off CAN message EBC1 defective...
  • Page 307 Flash Code Error List Error code Importance Vehicle computer CAN message TSC1 defective CAN message TIME/DATE defective CAN message HRVD CAN message ABS defective (IES-ID 512) CAN message FMR1 defective (IES-ID 592) CAN message FMR2 defective (IES-ID 593) CAN message EPS1 defective (IES-ID 556) CAN message BC_DR ExtensionBox CAN message TSC1 Adaptive Cruise Control (ACC) CAN message TSC1...

  • Page 308: Maintenance

    Maintenance Maintenance NOTES • In order to avoid incorrect measurements, the oil level checks for the transmission with ZF-Intarder is to be CAUTION effected with: The present maintenance section SUPERSEDES the - Vehicle in stationary position, corresponding sections of the maintenance instructions - Engine turned off, and for your manual transmission! - Transmission oil cooled down (<...

  • Page 309: Type Plate

    Maintenance 4.2 Type Plate The type plate contains the important key data. It is located on the side of the Intarder housing. The following pieces of information must always be given when making inquires, placing orders, or undertaking repairs: 1. Transmission type: 2.

  • Page 310: Oil Drain

    Maintenance 4.3 Oil Drain DANGER ! When transmission oil is hot: CAUTION RISK OF BURNS! The Intarder may NOT be actuated directly after switching off the vehicle’s engine for oil change purposes. • After draining the oil, the drain plugs (magnets) must This ensures that the correct oil volume is measured in be cleaned and the sealing rings must be renewed.

  • Page 311: Trucks: Oil Drain, Oil Overflow, And Oil Filler Plugs

    Maintenance Trucks: Oil Drain, Oil Filler, and Oil Overflow Plugs 4.4 Trucks: Oil Drain, Oil Overflow, and Alternatively, the heat exchanger can be mounted at the Oil Filler Plugs bottom-end, horizontally, to the truck transmission. Oil maintenance items in line with the transmission type. Fig.
  • Page 312 Maintenance Trucks: Oil Drain, Oil Filler, and Oil Overflow Plugs Fig. 2 e.g. Alternatively, the heat exchanger can be mounted to the Ecomid transmission 9/16 S 109 with ZF-Intarder bottom-end, horizontally, to the truck transmission. (view from below) Oil maintenance locations in line with the transmission type.
  • Page 313 Maintenance Trucks: Oil Drain, Oil Filler, and Oil Overflow Plugs Fig. 3 Alternatively, the heat exchanger can be mounted to the Ecomid transmission e.g. bottom-end, horizontally, to the truck transmission. 12 AS 2301 / 16 AS 2601 Oil maintenance locations in line with the transmission (with ZF-Intarder) type.

  • Page 314: Bus: Oil Drain, Oil Filler, And Oil Overflow Plugs

    Maintenance Buses: Oil Drain, Oil Filler, and Oil Overflow Plugs 4.5 Bus: Oil Drain, Oil Filler, and Oil Overflow Plugs Fig. 4 Transmissions 8 S 2101 BD/BO with ZF-Intarder 1 = Oil drain location transmission 2 = Oil drain location Intarder housing 3 = Oil filter cover Intarder housing 4 = Oil overflow and oil fill after oil change 9 = Oil filler plug after repair...
  • Page 315 Maintenance Buses: Oil Drain, Oil Filler, and Oil Overflow Plugs Fig. 5 Transmission 6 S 1600 IT, 6 S 1601 BD, 6 S 1701 BO, 6 S 1901 BO alu heat exchanger at bottom 013907 1 = Oil drain location transmission 3 = Oil filter cover Intarder housing 4 = Oil overflow and oil fill after oil change 9 = Oil filler plug after repair...
  • Page 316 Maintenance Buses: Oil Drain, Oil Filler, and Oil Overflow Plugs Fig. 6 Transmission 6 S 1600 IT, 6 S 1601 BD, 6 S 1701 BO, 6 S 1901 BO stainless steel heat exchanger at bottom 028007 1 = Oil drain location transmission 3 = Oil filter cover Intarder housing 4 = Oil overflow and oil fill after oil change 9 = Oil filler plug after repair...
  • Page 317 Maintenance Buses: Oil Drain, Oil Filler, and Oil Overflow Plugs Fig. 7 Transmission 6 S 1600 IT, 6 S 1601 BD, 6 S 1701 BO, 6 S 1901 BO alu heat exchanger on the right 019432 1 = Oil drain location transmission 019459 2 = Oil drain location Intarder housing 3 = Oil filter cover Intarder housing...
  • Page 318 Maintenance Buses: Oil Drain, Oil Filler, and Oil Overflow Plugs Fig. 8 Transmission 6 S 1600 IT, 6 S 1601 BD, 6 S 1701 BO, 6 S 1901 BO stainless steel heat exchanger on the right 1 = Oil drain location transmission 2 = Oil drain location Intarder housing 3 = Oil filter cover Intarder housing 4 = Oil overflow and oil fill after oil change...
  • Page 319 Maintenance Buses: Oil Drain, Oil Filler, and Oil Overflow Plugs Fig. 9 Transmission AS Tronic mit Intarder Refer to list at start of page 4. stainless steel heat exchanger on the right 024469 1 = Oil drain location transmission 028009 2 = Oil drain location Intarder housing (below the oil filter) 3 = Oil filter cover Intarder housing...

  • Page 320: Oil Filter Replacement

    Maintenance 4.6 Oil Filter Replacement NOTE: Use new oil filter upon each individual oil change (order no. see table on pages 45 and 46). DANGER: When transmission oil is hot: Danger of burns! ZF-Ecosplit / ZF-AS Tronic ZF-Ecomid / ZF-6 S 1600 Unscrew plug(s) (10) from oil filter housing cover (3).

  • Page 321: Oil Fill

    Maintenance 4.7 Oil Fill After an oil change or after repairs NOTES The transmission and fitted Intarder may only be filled with oil when the vehicle is horizontal and the engine is switched off. Drain oil. For oil grade and volume refer to table on pages 45 and 46. Open oil filler plug (9).

  • Page 322: Engine Coolant

    Maintenance 4.8 Engine Coolant Change interval of the engine coolant: • At max. every 2 years with aluminum heat exchanger CAUTION (for fill as pre-mixture). After refilling the engine coolant, please pay strict attention to the instructions given by the vehicle •...

  • Page 323: Drain Residual Coolant At The Alu Heat Exchanger

    Maintenance 4.8.1 Drain Residual Coolant at the Alu Heat Exchanger NOTE After draining the residual coolant, screw in the drain plug (11) with the new sealing ring. Tightening torque: Also refer to table on pages 45 and 46. Drain plug for residual coolant 016693 at alu heat exchanger 027986...

  • Page 324: Drain Residual Coolant At The Stainless Steel Heat Exchanger

    Maintenance 4.8.2 Drain Residual Coolant at the Stainless Steel Heat Exchanger In the case of stainless steel heat exchangers, the temperature sensor (110) is also the residual coolant drain plug. NOTE After draining the residual coolant, screw in the temperature sensor with the new sealing ring. Tightening torque: Also refer to table on pages 45 and 46.

  • Page 325: Bleeding The Intarder

    Maintenance 4.9 Bleeding the Intarder Pressure differences are compensated for at the transmission's vent valve. To this end, please consult the respective chapter of the transmission's Operating Instructions. 6085 758 102b - 2006-10...

  • Page 326: Truck Maintenance

    Truck maintenance Oil volume according to Tightening torque [Nm] for position Product Filter Oil change Oil change Repair family Transmission type Oil grade intervals approx.* Ecosplit 16 S 151 IT M 38 16 S 1621 TD 11.0 dm 18.5 dm 16 S 1821 TO 16 S 181 IT 16 S1921 TD...

  • Page 327: Bus Maintenance

    BUS maintenance Oil volume according to Tightening torque [Nm] for position Filter Oil change Oil change Repair Product Oil grade intervals family Transmission type approx.* 8 S 180 IT 8 S 2101 BD 12.0 dm 21.0 dm 8 S 2101 BO 6 S 1600 IT 6 S 1601 BD horizontal, to the right 6 S 1701 BO...

Table of Contents