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URAL Motorcycles URAL-4320-60 Operation Manual

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URAL-4320-60/61, URAL-43206-61, URAL-5557-60
TRUCKS
AND THEIR MODIFICATIONS

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Sifuba
June 22, 2025

What causes the brake valve to remain open not to keep pressure air.

0
1 comments:
Sifuba
June 23, 2025

@Sifuba The brake valve doesn't keep pressure and the power of the truck is reduced when you change to gear five it's bring a cracking sound, the pressure remains at zero and acceleration can't move up

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Summary of Contents for URAL Motorcycles URAL-4320-60

  • Page 1 URAL-4320-60/61, URAL-43206-61, URAL-5557-60 TRUCKS AND THEIR MODIFICATIONS...
  • Page 2 РДР №4588 от 19.12.2014г URAL-4320-60/61, URAL-43206-61, URAL-5557-60 TRUCKS AND THEIR MODIFICATIONS Operation Manual 4320-3902037 РЭ (First edition, revised) © UralAZ Reprinting, duplicating or translating in whole or in part without written permission of the «Ural» Automobile Plant Open Joint-Stock Company is prohibited Miass –...
  • Page 3 The Operation Manual is to be used by drivers and motor service staff involved in Ural trucks operation. This Operation Manual includes the trucks technical specification, a brief de- scription of the truck units and subunits, their adjustment and maintenance, and reference data. Due to constant product improvement enhancing its reliability and operating conditions, certain changes not included in this Manual may be made to the design.

  • Page 4: Table Of Contents

    CONTENTS 1 Foreword ..............2 Safety Requirements and Precautions.
  • Page 5 7.2 Engine Start and Stop........... . . 7.3 Running-in a New Truck .

  • Page 6: Foreword

    1. FOREWORD 1.1. Ural all-terrain trucks (4х4, 6х6), with YAMZ-65654 diesel engine, with a three-seat, all-metal cab located behind the engine are intended for transporting cargoes, people and towing trailers on all kinds of roads and terrain. Ural-4320-0111-61 truck shown in Fig. 1 is intended for transporting various cargoes, people and towing trailers on all kinds of roads and terrain.
  • Page 7 Fig. 2 – Ural-55571-60 Chassis Fig. 3 – Ural-43206-61 Truck...
  • Page 8 Operation manual, for the trucks should be not less than: for Ural-43206-61, Ural-5557-60, Ural-55571-60 vehicles and their modifications — 200 000 km, for Ural-4320-60/61 vehicles and their modifications — 250 000 km. During this period, the replacement of components and assemblies that have covered...
  • Page 9 - for 4х4 trucks (chassis) at the distance of 200-300 mm back from the rear axle and 40- 60 mm down from the sidemember upper flange; - for 6х6 trucks (chassis) at the distance of 1000-1250 mm back from the bogie axis and 40-60 mm down from the sidemember upper flange.

  • Page 10: Safety Requirements And Precautions

    2 Safety requirements and precautions 2.1 Safety requirements 2.1.1 Before you start working, make sure that the truck and its coupling devices are in good working order. 2.1.2 While driving the vehicle, the driver and passengers must wear seat belts. 2.1.3 Do not start the truck engine, without making sure that the gearbox is in neutral.
  • Page 11 2.1.12 It is prohibited to remove any wheel from the truck, if all air has not been let out of its tyre before. 2.1.13 It is prohibited to mount a just assembled and uninflated wheel with its tire onto the truck and inflate the tire using the tire inflation system. 2.1.14 The manufacturer draws your special attention to strict compliance with safety regulations changing / mounting the wheel (see «Wheels and Tires»...

  • Page 12: Precautions

    - placing explosive and inflammable substances or devices (e.g. spray bottles, etc.) in the heater heat flow area; - using the heater in an unaired area; - using the heater with the damaged fuel supply system; - starting and using the heater poured over with fuel; - switch on heating when transporting flammable cargoes at temperatures above minus 5°С...
  • Page 13 2.2.8 To drain the fluid from the engine cooling system completely, place the truck on a flat site or incline it forward. 2.2.9 Drain the coolant from the engine cooling system through three cocks (on the heat exchanger, on the pump unit and on the water pump inlet branch) with the open cab heater cock and the open plugs of the radiator and preheater filling pipe.
  • Page 14 2.2.21 Do not move the truck using the starter: this may cause starter breakdown and quick storage batteries discharge. 2.2.22 To avoid generator breakdown attach the starter cable to the positive terminal of the storage battery and attach the storage battery switch cable to the negative terminal.. 2.2.23 Attach cables to the generator set according to the marking.
  • Page 15 2.2.36 Transportation of goods or towing trailers (or transport means) exceeding the max weights indicated in the Operation Manual is not admissible. 2.2.37 After a long-term travelling in snowfall conditions or on snow-covered roads — remove the air filter cover and shake out the snow from the filter compartment. 2.2.38 When operating the truck with a trailer it is not admissible to: - use a towing coupler on GOST Р...
  • Page 24 Table 2 – 4х4 Trucks Technical Specifications Parameters Ural-43206-0111-61 Ural-43206-1151-61 General data Payload, kg 4200 Payload on chassis, kg 5500 Truck (chassis) bare weight, kg 7955 6935 Total vehicle weight with cargo, driver and passengers (225 kg) disre- garding the gross vehicle weight toler- 12 380 12 660/13 300* ance, kg...
  • Page 25 Table 2 continuation Parameters Ural-43206-0111-61 Ural-43206-1151-61 Engine Model, type YAMZ-65654, ignition by compression, four-stroke, turbocharged, 6-cylinder V-engine Operating capacity, l 11,15 Rated capacity, kW (hp), no less than 169(230) Maximum torque, gross, N.m (kgf·m) 882(90) Speed, min 2100 − Rpm corresponding to the max torque, min 1100-1500 Engine lubricating system...
  • Page 26 Table 2 continuation Parameters Ural-43206-0111-61 Ural-43206-1151-61 Cardan drive Exposed, with four shafts, joints on the needle bearings Axles Driving, combined axle case consists of a cast middle part and half-axle casings pressed in it. The front axle is a steering one, with constant velocity joints of disk-type Main gear Double, drive-through type, two conical spiral tooth gears and two cylindrical skew gears.
  • Page 27 Table 2 continuation Parameters Ural-43206-0111-61 Ural-43206-1151-61 Steering Type of transmission Mechanical, with hydraulic booster Steering gear MAZ – 64229 or RBL C-700 (Germany), «screw – ball nut-rack-sector» with hydraulic booster (for RBL C-700), steering drive with hydraulic booster (for MAZ – 64229) Booster unit Hydraulic, double-action type Booster unit pump...
  • Page 28 Table 2 continuation Parameters Ural-43206-0111-61 Ural-43206-1151-61 Rear lamps 7442.3716-10 or 8502.3716-01, bearing functions of the rear marker lamp, turn indicator, rear outline (marker) lamp, stop lamp, reverse lamp, rear fog lamp, reflector light and side marker light Number plate lamp Two items, ФП131АБ-02, or ФП131БР-10 Cabin and platform Three-seater, metal-made, equipped with heater, ther-...
  • Page 29 Table 2 ending Parameters Ural-43206-0111-61 Ural-43206-1151-61 Winch* Drum-type, with worm reduction gear and band brake driven via cardan shaft from the auxiliary power take-off. Rope working length 60 m, rope dia. 17.5 mm. Rope reversing is possible. Pulling power on the third rope winding layer 68,6-88,2 kN (7-9 tf) limited by the guard pin.
  • Page 30 Fig. 7 - Ural-4320-0111-61 truck overall dimensions Fig. 8 - Ural-4320-1951-60 truck chassis overall dimensions Fig. 9 - Ural-43203-1151-61 truck chassis overall dimensions...
  • Page 31 Fig. 10 - Ural-4320-1151-61 truck chassis overall dimensions Fig. 11 - Ural-55571-1151-60 truck chassis overall dimensions Fig. 12 - Ural-5557-1151-60 truck chassis overall dimensions...
  • Page 32 Fig. 13 - Ural-43206-0111-61 truck chassis overall dimensions Fig. 14 – Ural-43206-1151-61 truck chassis overall dimensions Fig. 15 - Ural-44202-0311- 60 bolster trucks...
  • Page 33 Fig. 16 - Ural-44202-0511-60 bolster trucks...

  • Page 34: Controls And Instruments

    4 Controls and Instruments 4.1 Controls and instruments located in the driver’s cab are shown in Fig. 17-20. Shift gears in the gearbox according to the scheme shown in Fig. 17. 1-5-gears; R-reversing Figure 17 – Gear Shifting Scheme Engage the gearbox, transfer case and differential lock as well as the power take-off, aux- iliary power take-off according to the plates inside the cab and in accordance with the instructions of the Section «Driving Technique».
  • Page 35 Make sure the steering is locked once the key is removed from the lock. When sig- nificant effort is applied for the turning the key from the «0» position, rock the steering wheel to the left and to the right The switch 12 has five operating positions: forward —...
  • Page 36 Parking brake lever 9 is located to the driver’s seat right side. When the lever 9 handle is pulled until it is latched the parking brake system is activated – BRAKES APPLIED position. For releasing the brakes, pull the lever from the latched position and push it down till it stops – BRAKES RELEASED position.
  • Page 37 1-two-pointer pressure gauge; 2-cross-axle differential lock indicator; 3-oil emergency pressure drop indi- cator; 4-coolant temperature indicator; 5-air starting preheater indicator; 6-oil pressure indicator; 7- electronic tachometer; 8-electronic speedometer; 9-headlamps upper beam indicator; 10-fuel reserve indi- cator; 11-fuel level indicator; 12-voltage indicator; 13-front circuit tire pressure gauge; 13а-rear circuit tire pressure gauge;...
  • Page 38 Pilot lamp 8 shows flickering green-color light after the truck left- or right-turn indicator has been switched on, Pilot lamp 9 lights up after the trailer left- or right-turn indicator has been switched on. These indicators are also intended for checking the turn-indicators lamps. If the air pressure in reservoirs drops below 450 kPa (4,5 kgf/cm ), lamp 3 glows with red-color light and the warning signal is head.

  • Page 39: Adjustment And Servicing Of Truck Components (Brief Description)

    5 Truck components adjustment and servicing (brief description) 5.1 Engine Description of engine design as well as instructions for engine operation and mainte- nance are given in the Operation Manual issued by the Yaroslavl Motor Works. 5.1.1 Fuel system 5.1.1.1 Engine Fuel System. Fuel is taken from main fuel tank 9 (Fig. 21) by fuel feed pump 13 and is supplied to high-pressure fuel pump (HPFP) 11 via coarse-mesh filter 10 and fine- mesh filter 14.
  • Page 40 Manual fuel boost pump installed in the PreLine-420 coarse filter is used to pump the fuel through at engine start. To deliver fuel to the high pressure fuel injection pump 11 with en- gine stopped (after long parking and feed system fuel piping disassembly) fill in the fuel supply system by pressing the manual fuel pump 2, as shown in Figure 22.
  • Page 41 5.1.1.3 Accelerator Electronic Pedal. The pedal has a rh sensor 2 (Fig. 23) transmitting the signal to the engine fuel system in proportion to the pedal angular travel. There are two studs 1 for the pedal attachment 1. The pedal spring 3 provides the pedal return in its initial position.

  • Page 42: Engine Starting Preheating System

    For the filter element servicing remove the precleaner and remove dust through shaking or blowing. If the cardboard filter element is covered with dust without a fume or carbon black deposit (the element is gray in color), blow it with dry compressed air till the dust is completely removed.
  • Page 43 The electric spark firing system ensures inflammation of fuel and air mixture during starting . The fuel tank contains the fuel stock required for preheater operation. It is connected with engine fuel system via fuel lines, and is always filled with fuel when the engine runs. If need be, it can be filled by means of the engine’s manual fuel feed pump.
  • Page 44 5.1.2.2 Starting Preheater Service. Remember that violating the operation rules as well as operating a faulty preheater may cause fire. See that there is no coolant and fuel leaks through the joints of pipelines, hoses and cocks; see that the clips on the heat exchanger branch pipes and pipelines are tight.

  • Page 45: Gas Exhaust System

    5.1.3 Exhaust System The exhaust system is designed for exhaust gas output and exhaust noise reduction. There is an auxiliary brake 7 between the exhaust manifold 6 on the engine turbocharger and the inlet pipe 1 (Fig. 26); in order to equalize temperature changes of the parts dimensions and the mutual offset of the engine and the silencer, there is a flexible metal hose 2 behind the front pipe.
  • Page 46 Truck operation with no expansion tank plug is prohibited! The material the cooling system expansion tank is made of allows checking coolant level in the tank visually. 1-expansion tank; 2-expansion tank plug; 3-steam hose from the engine; 4- steam hose from the expansion tank;...

  • Page 47: Power Unit Suspension

    In doing so, the plug of the expansion tank filler should be open. The estimated volume of the coolant not drained with the cab heater’s cook being open amounts to 2 l. Do not run engine upon draining the coolant to remove the remaining water from the sys- tem.

  • Page 48: Transmission

    5.2 Transmission The description of clutch and gearbox design as well as instructions for their operation and maintenance are given in the Operation Manual by Yaroslavl Motor Works. 5.2.1 The Hydraulic Clutch Linkage with the Air-over-Hydraulic Booster (AHB) 5.2.1.1 The master cylinder 7, (Fig. 29), is located in the engine compartment and is mounted on the bracket to the cab front panel.
  • Page 49 The back-pressure valve 18 is installed on the receiver and designed for dividing the air- pressure line going from the separate pneumatic system circuit to the receiver for maintaining pressure inside the system irrespective of the pressure drop in the main circuits. The AHB is sup- plied with air through the pipe 19.
  • Page 50 valve against the stop to the plug 19. The slide valve has an axial bore and a radial bore connect- ing the cavities F and G. 1-casing; 2-valve; 3-seal ring; 4-rod; 5-piston; 6-cap; 7-scraper; 8-pusher; 9-collar; 10-outlet port; 11-plug; 12-control valve; 13,19-plug; 14,17-spring; 15-air valve;...
  • Page 51 - tighten the screws 3 of the master cylinder 7 with the torque 44-56 N.m (4.4-5.6 kgf.m); - adjust the pedal free travel with the help of the trip 11. The clearance between the push rod 13 (see Fig. 30) and the piston should be b=0.2-0.6 mm which corresponds to the pedal travel of 1-3 mm.
  • Page 52 The front and rear axle drive shafts have the wiper rings 36. The outer surface of the rings has threaded helical grooves which direct the oil when the shafts rotate in the section be- tween the sleeves and the crankcase. The helical groove has different routes: for the front axle drive shaft it is the left route, for the rear axle drive shaft it is the right route.
  • Page 53 When assembling the transfer gear box, it is necessary to ensure the wiper rings correct installation, otherwise oil leakage through the collars is unavoidable. Transfer gearbox on which the auxiliary PTO with 100 % is installed has an elongated primary shaft and housing changed in the auxiliary take-off area. 5.2.2.2 Transfer gearbox adjustment.

  • Page 54: Transfer Case

    5.2.2.3 Transmision units control is remote one, electric-pneumatic, consists of the transfer case gearshift mechanism, transfer case differential lock mechanism, auxiliary PTO en- gagement mechanism *, PTO engagement mechanism *, intermediate and rear axles cross axle differential locks mechanisms, solenoid valves installed on the frame rh sidemember, pipings and switches in the cab.

  • Page 55: Cardan Drive

    When there is no pressure in the truck pneumatic system, the transfer case gear is en- gaged which was engaged before, and the differential is unlocked. With the high gear engaged, the neutral and lower gear engagement is done by the bolt 5 rotation counterclockwise. The bush- ing which is installed in the cover, sets the neutral position of the transfer case through translation movement defined by the intermediate cardan shaft turning over by hand at the gear box control lever neutral position.
  • Page 56 1-intermediate cardan shaft; 2,4,5-winch drive cardan shaft; 3-winch drive intermediate support; 6-rear ax- le drive cardan shaft; 7-front axle drive cardan shaft Fig. 35 - Transmission and winch drive cardan shaft layout (for 4х4 trucks) 1-face seal; 2-crosspiece; 3-needle bearing Fig.
  • Page 57 1-fork flange; 2-drive-type oil cup; 3-plug; 4-cardan shaft pipe; 5-balancing plate; 6-sliding fork; A-positioning arrows Fig. 37 - Front and Rear Axle Drive Cardan Shaft The front and rear axle drive cardan shaft design is shown in Fig. 38. Before reassembling the joints, pack lubricant between the working edges of the end packing.

  • Page 58: Driving Axles

    5.2.3.2 Cardan drive of the trucks and special chassis with long base differs from that of the base truck by the modified drive of the intermediate axle, which is a cardan drive consisting of the front shaft 2 (Fig. 39) with intermediate support and a rear cardan shaft 4 with splined con- nection balanced in set.
  • Page 59 1-driven bevel pinion; 2-cylindrical roller bearing; 3-main gear housing; 4-driving cylindrical bearing; 5- bearing cage; 6-conical roller bearings; 7,8,12-adjusting shims; 9-bearing cage cover; 10-rear axle drive flange; 11-collar; 13-driving conical gear bearing cage; 14-driving conical gear; 15-breather; 16-driving gear shaft; 17-gasket; 18-flange nut; 19-front axle drive flange; 20-front bearing cap; 21-spacing sleeve; 22-rear bearing cap;...
  • Page 60 1-air supply collars; 2-wedge mechanism; 3-brake drum; 4-half-axle; 5-spring supporting bracket; 6-case cover; 7, 9-gaskets; 8-final drive; 10-axle case; 11-drain plug; 12-half-axle casing Fig. 41 – Rear Driving Axle 5.2.4.3 Intermediate and rear axles. Cross-axle positive-locking differentials* (Fig. 42) are mounted on intermediate and rear axles. 1-диафрагма;...
  • Page 61 Cross-axle differential distributes the torque evenly between axle wheels including cases of driving on rough roads and turns when the wheels rotate with different speed. When driving on hoard-to-pass road sections the truck left side and right side wheels have different tire grip the cross-axle differential can cause the skidding of one of the axle wheels.
  • Page 62 5.2.4.3 Front axle final drive differs from that of the rear axle by the drive flange. Spac- ing sleeve 21 (Fig.40) with cap 22 is fitted on the front end of the front axle driving gear shaft, flange 21 on the rear end. Rear axle final drive has a flange at the driving bevel gear side. Splines may be unavailable on the opposite end of the driving gear shaft.
  • Page 63 1-fork; 2-knuckle; 3-disc; 4-inner half-axle Fig. 45 - Equal Angular Velocity Hinge For ensuring reliable and long-life operation of the driving axles, use oils in accordance with the lubrication chart and maintain the required oil level in the cases. To replace the lubricant in half-axle hinges of the front axle, dismantle the wheel, brake drum in assy with the hub, brake shield and slewing journal.
  • Page 64 nut by bending out one washer edge. Torque required for cranking the driving bevel gear in the bearings should be 0.6-1.4 N.m (0.06-0.14 kgf.m). Force on the dynamometer, when uncoiling the cord from the body surface, is 7.5-17.5 N.m (0.75-1.75 kgf.m) (Fig. 46). Fig.
  • Page 65 Table 4 - Adjusting the Engagement of the Bevel Pinions of the Main Gear Bearing pattern position on the Methods to set the correct engagement of Direction of the bevel driven bevel pinion tooth the bevel pinions pinions Forward travel Backward travel Correct gear contact Shift the driven pinion closer to the drive...
  • Page 66 - rotating the wheel manually, make sure there is no friction between the brake drum and the brake shoe; - tighten the nut with the torque 300-350 N.m (30-35 kgf.m). During the process turn the hub until the rollers set in the bearings. Afterwards, loosen the nut by 1/5-1/6 revolutions. Fix the locking washer.

  • Page 67: Running Gear

    5.3 Running gear 5.3.1 Frame The truck frame is a riveted structure consisting of two stamped variable-section side- members interconnected by six cross-members and a bumper in front. Frame servicing lies in inspection of bolted and riveted connections. See that frame con- figuration and strength of its elements are not impaired.

  • Page 68: Truck Suspension

    Towing device servicing includes cleaning and lubricating. Lubricate the drawnhook stem guides through oil fillers during vehicle maintenance operations. Axial displacement of the hook in the housing should not exceed 0.5 mm. To ensure it tighten nut 1 until a clearance is formed between housing 2 and pressure ring 3 due to elastic element’s 4 deformation (to be determined by free displacement of the towing hook).
  • Page 69 1,13-spring bracket (front, rear); 2-spring; 3-spring U-bolt; 4-spring stiffening plate; 5-bump stop collars; 6-bump stop collar bracket; 7,18-snubber supporting brackets (top and bottom); 8-snubber; 9-washer; 10- snubber bushings; 11-snubber pin; 12-fastening nut; 14-inserts (top and side); 15-brackets coupling bolt; 16-spacer; 17-bolt fastening the rear bracket to the amplifier; 19-eye U-bolt; 20- U-bolt nut; 21-eye stiffen- ing plate;...
  • Page 70 1-upper head; 2-body nut; 3-washer; 4-rod gland; 5-body bushing; 6-washer; 7-packing ring; 8-gland hous- ing; 9-shock absorber body; 10-cylinder; 11-piston rod; 12-limiting plates; 13, 15, 18-valve disks; 14- piston; 16-piston nut; 17-valve cage; 19-throttle compression disc; 20-pressure disk; 21-springs; 22-cover Fig.
  • Page 71 1-spring; 2-U-bolt; 3-spring pad; 4-u-bolt nut; 5,7-torque rods (upper and lower); 6-spring supporting bracket; 8-buffer bracket nut; 9-buffer; 10-torque rod pin nut; 11-guard ring; 12-bolt fastening the upper jet thrust bracket to the axle housing; 13-upper jet thrust bracket; 14-walking-beam axle fastening bolt; 15-bolts fastening walking-beam bracket to the stiffener;...
  • Page 72 5.3.2.4 4х4 Truck Rear Suspension consists of two main springs 9 and two additional springs 3 (Fig. 51). Fastening the eye to the spring leaves and fastening the spring to the frame of the front and rear suspensions are similar. As opposed to the front spring, on the rear spring the pin 14 is fastened by removable covers 33.
  • Page 73 5.3.2.5 Maintenance includes lubrication of the parts and assembly units, checking and adjusting their fastening. Suspension bolted connections’ slacking is not allowed. For preventing shearing of the centre bolt in the front spring and centering protrusion on the rear spring, as well as to avoid untimely breakage of the front and rear springs, tighten the U- bolt nuts in due time of the 6х6 and 4х4 truck front spring and 4х4 truck rear spring on loaded truck and tighten 6х6 trucks rear springs U-bolt nuts on unloaded truck.
  • Page 74 WARNING! DO NOT INSTALL THE WASHERS FROM THE FRONT SCREW 21 SIDE. Before installation lubricate bolts 19, 21 thread and threaded holes with УГ-6 sealant (al- ternatively with Loctite 243, Loctite 262, Анакрол-202 or Фиксатор-6). Tighten bolt 19 with 180 to 220 N·m (from 18 to 22 kgf·m) under which there is a shim 18, and then tighten bolt 21.

  • Page 75: Wheels And Tires

    25 % during operation is not allowed. For effort testing use the press with a rod stroke of 100 mm and a speed of 100 strokes per minute. If the shock absorber rod travels freely, it indicates that the unit is faulty. In case of the fluid leakage from the shock absorber, t is recommended to tighten the shock absorber body nut.
  • Page 76 The bead and lock rings of the 254Г-508 and 400Г-508 wheels are interchangeable and are mounted on these wheels in a strictly determined position with the help of the lock ring limit- ers welded to the rim and pressed out pieces on the lock rings, which enter the appropriate recess (slot) on the bead rings.
  • Page 77 Slacking of the wheel fixing and operation of the truck is not allowed even if a single nut or stud fastening the wheel is missing or fastening holes in the disks are worn-out. Every time you install the wheel on the hub irrespective of the reason of its removal, tighten up the nut fastening the wheels twice: for the first time after the run of 100-150 km and for the second time —...
  • Page 78 trimmed spots and the spots, where paint is damaged, with a fast-drying enamel, having eliminat- ed burrs and metal scores first. Check setting of the locking ring on the rim and on the control cylinder having the same diameter: - clearance in the seam between the ring ends should be 45-55 mm, loosening of the ring ends from the rim —...
  • Page 79 Inflate the tire in two stages. At first inflate it to the pressure level of 0.05 MPa (0.5 kgf/cm 2 ) and check the position of the lock ring. Then adjust the pressure to the rated one. In case of incorrect set of the wheel lock ring deflate the tire, reposition the ring and reinflate the tire till the pressure reaches 0.05 MPa (0.5 kgf/cm In case the tire beads with a loose fit the rim seats after the inflation, deflate and disman- tle the tire and eliminate the cause of the loose fit to the tire beads.
  • Page 80 I, II-removing of tire bead from bead seat; III-dismantling tire bead from rim; 1, 2-tire irons Fig. 54. Wheel Disassembling 3. Remove the lock ring. For this purpose insert the flat end of the short tire iron into the dismantling slot of the lock ring and press its end out of the rim; then move the lock upwards, us- ing the second iron, and completely release the lock from the rim by pressing it out of the rim and gradually moving along the wheel circle.
  • Page 81 5.3.3.4 Wheel assembling 1. Put the inner tube and flap in the tire casing and pump up the inner tube a little so that it takes its natural shape; in so doing it should not be tight against the tire casing. For the control- lable-pressure tires put the inner tube in the tire casing, taking a direction of wheel rotation into account, put the seal on the valve so that its stem is in the seal body.
  • Page 82 7. Inflate the tire, observing the following order: - centre the bead and lock rings relative to each other; - inflate the tire up to pressure of 50 kPa (0.5 kgf/cm ) and make sure that the lock and bead rings have not been displaced relative to their working position. It is advisable to inflate the tire, when the wheel is set in its horizontal position.
  • Page 83 fore, when the truck travels, oscillation and vibration, especially those of the front wheels, can oc- cur. The unbalance causes rapid wear of the treads, wear of the steering and suspension components as well as makes the control over the truck more difficult. It is recommended to perform static balancing of the wheels assembled with tires.

  • Page 84: Spare Wheel Holder

    5.3.4 Spare wheel holder The spare wheel holder on the trucks can be mounted in an upright or horizontal position. The design of the upright holder is shown in Fig. 59. The base of the spare wheel holder and tilting bracket are made of rolled profiles welded to each other.

  • Page 85: Steering

    5.4 STEERING 5.4.1 Steering 5.4.1.1 The steering system (Fig. 60 «Steering with Screw - ball nut–rack – segment type» consists of the steering column, steering gear, steering linkage and hydraulic booster. 1-steering gear; 2-pump 3,4-low pressure hoses; 5-oil tank; 6-steering wheel; 7-steering column; 8,10- steering system propshafts;...
  • Page 86 The face of the splined end of the sector 1 has a match mark which is aligned with the match mark of the plain arm face end. 1-to the power cylinder 1-sector; 2-lock ring; 3-protecting ring; 4-sleeve; 5,13-packing rings; 6-balls; 7- screw;...
  • Page 87 1-steering gear case; 2-nut; 3,10-bearings; 4-packing rings; 5-slide valve body; 6-back pressure valve; 7- ball; 8-distributor unit case; 9-bushing; 11,20-shim washers; 12-sleeve; 13-retaining ring; 14-ring; 15- shaft; 16,23-pins; 17-torsion bar; 18-packing ring; 19-cap; 21-rams; 22-slide valve; 24-screw; а-groove for the service fluid intake from the pump; b-groove for the service fluid removal from the pump; с,d-grooves for the service fluid intake (off take) to/from the booster unit cavities;...
  • Page 88 Thus a driver receives information about the increase in steerable wheels turn resistance. When the steering wheel is not turned (there is no effort on it) the torsion bar 17 and the rams 21 return the slide valve to the neutral position. The fluid supply to the rod end of the booster unit is stopped and the truck is driven in a circumferential direction of the set radius.
  • Page 89 1-bolt; 2-collector; 3-packing ring; 4-stator; 5-casing; 6- bushing; 7-washer; 8-nut; 9-roller; 10-segment dowel pin; 11-pulley; 12-belt; 13-screw; I-pump installation; а-supply; b-pumping; с-belt tension direction Fig. 64. Booster unit pump 5.4.1.7 Steering Oil Tank. The tank is separated from the pump. The tank has a filter 3 (Fig.

  • Page 90: Maintenance Of Steering

    1-ball pin; 2-rod end; 3-grease-nipple; 4-spring а; 5-socket plug; 6-retaining ring; 7-seal; 8- spring holder; 9-bottom collar step; 10-top col- lar step; 11-stiffening plate; 12-protective cou- pling; 13-washer Fig. 66 - Steering Hinge 5.4.2 Steering System Maintenance 5.4.2.1 The steering system maintenance consists of regular inspection of the steering system fixation, the piping, the protective coupling of the booster unit rod, the free travel of the steering wheel as well as servicing the hydraulic system assemblies.
  • Page 91 with the engine running idling; and set the wheels in the extreme right-hand position; furthermore perform work as per items 4, 6, 7. 10. Fill oil in the hydraulic system as follows: - fill 1,5 l of pure oil in the tank; - start the engine and add oil up to the upper mark;...
  • Page 92 5.4.2.5 Adjusting the front wheel toe-in. For checking the toe-in of the front wheels, see that the tires have been inflated to the rated pressure and measure difference in distance B1 and B (Fig. 67) across the wheel rims. For checking follow this procedure: - place the truck on an even hardly-paved horizontal site so that the front wheels are posi- tioned for the straightforward travel of the truck;...

  • Page 93: Brake Systems

    5.5 Brake Systems The brake system is designed to reduce speed and stop the truck or ensure the truck immobility during parking. The truck is equipped with brake systems: service, stand-by, parking and trailer brakes control in accordance with UNECE Regulations №13. 5.5.1 Service brake system The service brake system should ensure speed reduction and the truck stopping irrespective of its speed, load and road slopes, which it is designed to.
  • Page 94 5.5.1.1 Wedge mechanism is shown in Fig. 69. 1-adjusting nut; 2-toothed coupling; 3-adjusting ring; 4-roller; 5-O-ring; 6-cleat wedge; 7-release spring; 8- locking ring; 9, 12-spring cap; 10-cartridge; 11-housing; 13-roller cage; 14-washer; 15-adjusting bolt; 16- leaf spring; 17-globe joint dome; 18-toothed wheel; 19-protective collar; 20-spiral sring; 21-pistons; 22- spiral groove;...
  • Page 95 - wedge mechanism; II - toothed mechanism; III - automatic adjustment initial stage; IV - automatic adjustment final stage. 1-release spring; 2-toothed ring; 3-adjusting nut; 4-pin; 5-piston; 6-roller; 7-cleat wedge; 8-adjusting bolt; А-spiral groove; В-toothed coupling Fig. 70 – Wedge mechanism automatic adjustment At the increased clearance due to the brake linings wear, the cleat wedge 7 is pressed fur- ther downwards and the pistons 5 stroke increases.
  • Page 96 5.5.1.3 Wedge mechanism mounting . When mounting a wedge mechanism, stick to the follow- ing rule: the free end of the cleat wedge 1 (Fig. 71) is to be located inside the housing strictly along axis A with- out warps. The warp can cause the installed wedge damage. 1-cleat wedge;...
  • Page 97 Adjust the distance «S» in the following way: turn in the adjusting bolt 8 (Fig. 70) with an effort till the click is heard when the teeth of coupling «В» jump between the toothed ring 2 and adjusting nut 3; then unscrew bolt 8 by one turn. Lubricate all inner parts of the wedge mechanism while assembly.
  • Page 98 1-brake shoe; 2-brake lining; 3- rivet; 4- wear indicator; *-diameter without taking into account brake drum wear Fig. 74 – Brake linings rework diagram shoe pins ; 2-brake shoe with brake linings; 3-support; 4-wedge mechanism; А, В-distance be- 1-brake tween the support external diameter and brake linings Fig.
  • Page 99 In accordance with the Fig. 68: - torque the bolt 5 to the 75-85 Nm (7,5-8,5 kgf m). Apply АМС-3 GOST 2712-75 lub- ricant on the «d» surface; - before assembly, the brake shoe surface «g» of the axle 7 and surface «f» lubricate with graphite grease as per GOST 3333-80.
  • Page 100 Before installing the hub with a brake drum, it is necessary to recess the inductive pickup 2 (from the center) in order to avoid its damage. After that, without applying excessive force, make the pickup go till it thrusts into the impulse ring. The inductive pickup 2 consists of the permanent magnet with round bar and coil.
  • Page 101 Brake chambers installation is shown in Fig. 80, 81. The brake chamber 1 installation depth (Fig. 80) is 25 mm. It is twisted in as far as it will go and than it is turned inversely till the system pneumatic outputs are directed backwards. For the connection tightness, use silicone-or rubber-based sealant.

  • Page 102: Pneumatic Drive Of Service Brakes

    5.5.1.9 Brake system tightness. The tightness system is provided for in the brake chambers. Sealing connection 5, according to Fig. 78, and sealing connection 4, according to Fig. 79, are connected with pipeline set to the sidemember level. 5.5.2 Pneumatic Drive of the Service Brakes The schematic diagram of the brake drive with outlets to the 6х6 truck trailer is shown in Fig.
  • Page 103 Pressing the brake pedal engages the first and the second circuits of the truck brake drive as well as the third circuit of the trailer brake drive. If one of the circuits is out of order, the rest remain efficient. For the system diagnostics the check outlet valves are installed in each circuit.
  • Page 104 1-towing device; 2-oil separator; 3-two-pointer gauge; 4-pressure regulator with adsorber; 5- adsorber res- ervoir; 6-four-line safety valve; 7-pressure drop sensor; 8-front axle brakes’ air reservoir; 9-rear axle brakes’ air reservoirs; 10-condensate drain cock; 11, 16, 26-check outlet valves; 12-trailer brake with break-away valve;...
  • Page 105 1-towing device; 2-oil separator; 3-two-pointer pressure gauge; 4-pressure regulator with adsorber; 5- adsorber reservoir; 6-four-line safety valve; 7-pressure drop sensor; 8-front axle brakes’ air reservoir; 9- rear axle brakes’ air reservoirs; 10-condensate drain cock; 11, 13, 23-check outlet valves; 12-brake cham- bers with spring brake;...
  • Page 106 5.5.2.2 Oil Separator (Fig.86) is designed to clean the compressed air charged by the compressor, as well as to condense and remove moisture, oil and other contaminants contained in the air. The oil separator is installed in front of the pressure regulator and adsorber; it extends the life of the drying cartridge.
  • Page 107 1-filter; 2-zeolite; 3-by-pass valve; 4-by-pass valve spring; 5-throttle governor; 6-throttle governor spring; 7-return valve spring; 8-return valve; 9-nut; 10-adjusting screw; 11-balancing piston spring; 12-spring; 13- balancing piston; 14-relief valve; 15-cuff; 16-balance piston spring; 17-balance piston; 18-decompression pressure control valve; 19-decompression pressure control valve spring; 20, 21-adjusting disk; 22- discharge unit heater;...
  • Page 108 When the pressure in the cavity Д reaches the level of the cut-off pressure, the balancing piston 13 overcoming the force of the spring 11, moves to the right. Thus, the relief valve 14 is closed, the inlet valve 24 opens. The compressed air via the open inlet valve 24 from the cavity Д flows to the cavity Е, balance piston 17 moves downwards, the decompression pressure control valve 18 opens and the compressed air from the compressor is released in the environment togeth- er with the condensate under the decompression pressure control valve 18 seat and the decom-...
  • Page 109 1-lever; 2-stop screw; 3-protective cover; 4-roller; 5-lever housing; 6-pusher; 7-pin; 8-disk; 9-flange; 10, 12, 16, 21-spring; 11-upper part; 13, 18-carrier ring; 14-small piston; 15-lower part; 17-lower section valve; 19, 22, 27-sealing ring; 20-atmospheric outlet valve; 23-big piston; 24-upper section valve; 25-upper follow-up piston;...
  • Page 110 When depressing the brake pedal, the effort is transferred through the levers and drive rods system on the lever 1 of the valve and further via pusher 6, disk 8 and resilient member to follow-up piston 25. Lowering down, the piston 25 first closes the valve 24 outlet hole of the brake valve upper section, and then opens up the valve 24 from the seat in the upper part 11, opening the passage for the compressed air from the outlet V to the outlet Z...
  • Page 111 1-body; 2, 6, 10, 14-springs; 3, 13-valves; 4, 12-diaphragms; 5, 11-guides; 7, 9-covers; 8-adjustment screw; 15-return valve; I-outlet to the compressor; II, III-outlets to the brake system circuits; а, d-orifice hole; b, c-side holes Fig. 89 - The Four Circuit Safety Valve If the air pressure drops in one of the circuits connected to the main outlets II and III, the air pressure in outlet I and in the circuit connected to the main outlet in the good working order drops down to the pressure of faulty circuit valve closing.
  • Page 112 1.1-supply mainline inlet; 1.2-trailer supply main outlet (to the red coupling head); 2.2-outlet to trailer con- trol mainline (to the yellow coupling head); 4.1-inlet from the front circuit of the truck-tractor service brake system; 4.2-inlet from the rear circuit of the truck-tractor service brake system; 4.3-inlet from the rear circuit of the truck-tractor parking brake system Fig.90 - Trailer Brake Control Valve with Double-line Drive and Cut-off Valve 1-upper chamber;...
  • Page 113 5.5.2.8 ABS Modulator The ABS modulator is shown in Fig. 92. The ABS modulator ensures a quick (millisec- onds) pressure boost, reduction or maintenance in the brake chambers during deceleration depend- ing on the control signals of the electronic unit. Operating principle: а) Pressure increase —...

  • Page 114: Maintenance Of Brakes Pneumatic Drive

    5.5.2.9 Coupling Heads (Fig.93) The heads have covers which protect the system from dust and dirt. The feed head cover is painted red, the control head cover is painted yellow. To connect the trailer brake system properly, couple the heads according to their color. At first, the control head (yellow) is coupled, and then the feed head (red) is coupled.

  • Page 115: Emergency Brake System

    When checking the air-tightness the nominal pressure in the pneumatic drive should be equal to 588 kPa (6.0 kgf/cm ), consumers should be working and the compressor should be turned off. The pressure drop in the reservoirs from the nominal level shall not exceed 49 kPa (0.5 kgf/cm ) during 30 min with the free controls and during 15 min after they are actuated.
  • Page 116 When the service brakes are applied the parking brake system is blocked. When there is no pressure in the outlet I the piston 3 is in the upper position. The inlet valve 5 is closed under the action of spring; the outlet valve 4 is opened. Through the opened outlet valve and outlet II the spring brakes are connected to the at- mosphere via outlet III.
  • Page 117 5.5.5.5 The hand-operated brake valve shown in Fig. 97,98 is designed to control the spring brakes and allows to check the sufficiency of truck tractor parking brake for whole road train holding on the grade. Hand-operated brake valve for auxiliary and parking brake system is used together with brake chambers with spring brakes.

  • Page 118: Truck Brake System With Anti-Lock Braking System (Abs)

    5.5.6 Vehicle Brake System with Antilock Brake System (АBS) 5.5.6.1 Antilock Brake System (АBS) is intended to preserve the truck stability at braking with improved efficiency when traction differs. Due to the ABS the truck gains the number of advantages: - improved active safety, stability and steerability especially on wet and slippery roads;...
  • Page 119 If the memory has records about faults upon their trouble shooting, the pilot lamp goes out when the truck speed reaches 5-7 km/h. In case of faults in the system or in the electric cir- cuits of one of the elements (modulator, sensors) or control circuits the pilot lamp 2 lights up. By this the corresponding ABS circuit may be disconnected and the brake system will operate in the common mode (without ABS mode).
  • Page 120 Figure 101 - Error codes (blink-codes) display Each error is presented by the block consisting of two digits the first is for compo- nent number and the second is for error number. Errors codes are given in Table 6. Displaying of the errors codes can be interrupted by diagnostics button re-pressing. Table 6 –...
  • Page 121 Table 6 Continuation Blink code Description of compo- of error nent Driving axle speed sensor, r. h. Air gap is too large Absence of sensor signal at braking Bad impulse ring, ABS maintenance period Signal instability Sensor signal loss Short-circuit to “ground” or to the battery, or wire breakage Driven axle modulator, l.h.
  • Page 122 Table 6 Ending Blink code Description of compo- of error nent Diagonals grounding connection PINs Diagonal line 1 is short-circuited to the storage battery Diagonal line 1 is short-circuited to «ground» All modulators are short-circuited to «ground» Electronic control unit (ECU) inner errors Faulty ECU Faulty ECU Faulty ECU...
  • Page 123 Figure 102 - Errors Memory (Blink - Codes) Deleting 5.5.6.7 Wabco ABS Diagnostics by the Blink-Codes 5.5.6.7.1 Electric circuits of components connection to Wabco control unit are shown in Fig. 103(a) and 103(b). 1-pressure sensor; 2-fuses; 3-pilot lamp; 4-ignition switch; 5-diagnostic socket; 6-diagnostics switch; 7- rotation sensors;...
  • Page 124 1-pressure sensor; 2-fuses; 3-pilot lamp; 4-ignition switch; 5-diagnostic socket; 6-diagnostics switch; 7- rotation sensors; 8-front axle modulator; 9-rear axle modulator Figure 103(b) - The Scheme of Connecting Wabco Control Unit Plugs (for 4х4 trucks) To activate the diagnostics mode it is necessary to connect the ABS lamp to the battery minus terminal for 0.5 to 3 seconds by means of ABS diagnostics switch button as shown in Fig.
  • Page 125 The duration of ‘lamp-“-”’ connection determines the information display mode (con- nection of the lamp to “-” during 3-6.3 seconds activates the system mode). After pressing the di- agnostics button for a specified time, the pilot lamp lights up for approximately 0.5 seconds to confirm that the grounding has been registered and received by the electronic control unit.

  • Page 126: Auxiliary Brake System

    Table 8 – Troubles and methods of trouble-shooting for Wabco Error code Method of trouble-shooting 2-… Check the modulator cable. Wire breakage or their insulation damage is possible. 3-… Low value of sensor signal amplitude. Check bearing and toothed rotor runout, move the sensor closer to the rotor.
  • Page 127 By moving foot from valve button the air from the cylinder goes into the atmosphere, the rod under the action of pull-back spring turns the lever and shutter into their initial position. The auxiliary brake is actuated and the blocked drive cuts the fuel supply. The design of the air cylinder of fuel supply shut-off is identical to the design of auxiliary brake air cylinder.

  • Page 128: Electric Equipment

    5.6. Electrical equipment The system of electric equipment is wired as a single-conductor circuit in which the neg- ative terminals of power-supply sources and consumers are grounded to the truck body. The nega- tive terminal of the storage battery is connected with the «ground» by a distance switch. The power-supply sources are two storage batteries, connected in series, and a generator that operates in conjunction with an integrated voltage regulator.
  • Page 129 Description Item, Item type or number Fig. 106 19,90 Safety fuse, 25А 14.3722 Safety fuse, 6А ПР119-01 «Ground» remote switch 11.3704-01 Starter and instruments switch 2109.3704-30 Glow plug preheater switch 11.3704-01 Turn light break-in relay 5412.3787 Portable lamp socket 47К Pilot lamps left cluster ПД512Е...
  • Page 130 Description Item, Item type or number Fig. 106 Engine idling speed switch 771.3709-02.00 Transfer case gear shifting switch 82.3709000-28.00 Cab heater electric motor Additional resistance СЭ300-8102100 «Stop» signals relay 751.3777-02 Brake pedal position sensor relay 751.3777-02 Horn relay 751.3777-02 Headlamp upper beam relay 751.3777-02 Headlamp lower beam relay 751.3777-02...

  • Page 131: Electronic Speedometer

    Description Item, Item type or number Fig. 106 Electroneumatic valve of cross-axle differential locking КЭМ 10Д or 7.Д3.254.022 Electroneumatic valve of auxiliary power take-off engage- ment КЭМ 10Д or 7.Д3.254.022 Electroneumatic valve of power take-off engagement КЭМ 10Д or 7.Д3.254.022 Electroneumatic valve of transfer case neutral gear en- gagement КЭМ...
  • Page 132 Speedometer ПА8046-4П is a complicated electronic device the truck driving safety directly depends on. It is recommended to calibrate the speedometer in the “Ural” Automo- bile Works” OE JSC regional service centers. In case it is impossible, speedometer calibra- tion should be performed strictly observing instructions below. 5.6.1.1 Speedometer calibration: 1.
  • Page 133 Enter previously used password prior to entering a new password in order to prevent pro- grammable coefficient unauthorized changing. For this purpose do the following; 1. Activate previously used coefficient display by short pressing. Activate extreme right symbol blinking by long pressing (used for transition to the next symbol or to the next program- ming stage).

  • Page 134: Electric Generator

    changed by button rotation. New value of blinking figure is confirmed by button short pressing af- ter which the next figure starts blinking. Access password is under sealing cap at the device rear part. If the password is entered correctly short pressing will change the indicator to the fifth mode, in case the password was incorrect, the indicator mode changes to the first one by short pressing.

  • Page 135: Lighting And Alarm System

    1- storage battery; 2- clip; 3- storage battery brackets; 4- front stop; 5- container reinforcement; 6- contain- er cover; 7- wing nut; 8- bolt; 9,12- front and rear wedge stops; 10- container; 11- guides; 13- upper clamp; 14- lock ring Figure 107 - Storage Batteries Setup 5.6.4 Lighting and Signaling System 5.6.4.1 Lighting and signaling devices comprise two main headlamps, front and rear...
  • Page 136 Headlamps adjustment is the adjustment of the lower beam initial inclination angle. The lower beam of the headlamps is adjusted with the help of special devices designed for these purposes in accordance with Operation Manuals for those devices. 5.6.4.4 The Headlamps. The direction of light beams is adjusted by two screws available under the lamp rim.
  • Page 137 horizontal, with roughness height not more than 5 mm and deviation from the plane not more than 5 mm for 1 m. The measurements should be carried out in darkness (e.g. in a dark room). The ambient temperature during measurements should be from 10 to 30 ° С . I-projection lines headlamp...
  • Page 138 move the spring fixing the bulb and replace the bulb. The re-assembly is to be performed in a re- verse sequence. 5.6.5 Safety Fuses Power-supply circuit is protected against faults (short circuits) by bimetal safety fuse 291.3722 rated at 30 А . Fuses upper unit shown in Fig.

  • Page 139: Cab, Hood And Fender Assembly And Truck Platform Body

    5.7 Cab, hood and fenders assembly and platform body 5.7.1 Cab is three-seat one, located behind the engine, with heat and noise insulation, driver and passengers seats, ventilation and heating system, and windscreen heater, sun visors, windscreen wiper, windscreen washer, rear view mirrors on the left and right sides, wide-angle and side-view mirrors.
  • Page 140 The cab is outfitted with attachment points of driver’s & passengers’ seat belts. The low- er attachment points of the safety belts are on the rear wall of the support 4, as shown in Figure 114, the upper attachment point safety belts are located on the sides of the cab. When driving a truck, the driver and the passengers must wear seatbelts.
  • Page 141 5.7.1.1 Cab doors shown in Figure 116 are equipped with locks to close the cab doors and with window lifters. The cab door is locked from the outside by a key and from the inside by a door lock knob. 1-window crank;...
  • Page 142 Table 11 - Concentration of HИИСС-4 water solution depending on the ambient tempera- ture Ambient air Composition by volume in portions temperature, 0 °С НИИСС-4 Water above +5 from +5 down to -5 from -5 down to -10 from -10 down to -20 from -20 down to -30 from -30 down to -40 Do not use the НИИСС-4 fluid without diluting it by water, because the combined effect...
  • Page 143 1- hose for windshield blowing with warm air; 2-exterior hatch control lever; 3-air heating dispenser; 4- flap control lever of air heating dispenser; 5-interior hatch control lever; 6-motor and fan assembly; 7- interior hatch cover; 8-heat radiator; 9-heat radiator water outlet pipe; 10-water-supply pipe; 11-cock; 12- exterior hatch cover;...

  • Page 144: Hood And Fender Assembly

    Upon final adjustment of the seat position, tighten all the screws home. The tapered part of the screw should be fixed in one of five tapered recesses. The driver’s seat backrest may be adjusted in reclining. To change the backrest incline, un- screw wing nut 4, set the backrest in the desired position and tighten the wing nut 4 home.
  • Page 145 1-canopy fastening rope; 2-tent fastening rope; 3-top bow; 4-top bow distance tube; 5-canopy Figure 120 – Truck Platform with Canopy I-VIII- folding steps Figure 121 - Canopy folding sequence 5.7.3.2 Platform sides lock mechanism adjustment. The purpose of adjustment is reli- able locking of the sides and fixing the locks' handles in CLOSED position.
  • Page 146 2. If the effort on handle 7 during locking exceeds 300 N (30 kgf), or if the handle does not reach its upright position or fails to stop in this position the catch 1 should be shifted down- wards. 3. The amount of the necessary movement in each case should be defined visually. To perform adjustment: 1.
  • Page 147 Figure 123 – Left side and right side safety guards...

  • Page 148: Bolster Unit

    5.8 Bolster unit The truck tractor has bolster unit designed for articulating the truck tractor with the semi- trailer having hitching pivot of 50 mm diameter; for transferring tractive effort from the tractor to the semitrailer; for providing the tractor semiautomatic hitch and unhitch with the semitrailer Bolster unit consists of bolster 8, see Fig.
  • Page 149 5.8.2 Bolster unit maintenance Before a departure: Check the safety lever to be in closed position. Check the bolster unit and the subframe for secure fixing, absence of wear, corro- sion and defects. Check the hitch locking to be secure and complete in accordance with Fig, 125. Perform standing start test: apply bolster trailer brakes and standing start the truck tractor slowly –...
  • Page 150 Figure 126 – Locking element in «open» position - free some space between truck tractor and semitrailer; - drive the truck tractor backward slowly to the semitrailer so that the semitrailer pivot enters into the grips of the bolster. The truck tractor and the semitrailer are hitched automatically; - apply the truck parking brake.
  • Page 151 - unplug the semitrailer power cable from the socket; - disconnect the coupling heads of the brakes air drive (first – feeding line, then – control line) and close them by protective covers. Fix the coupling heads together with hoses on the truck tractor platform;...

  • Page 152: Special Equipment

    5.9 Special equipment Lay-out of auxiliary units, their drives and power take-off modes should be agreed with the manufacturers. Propeller shafts installed by a customer for driving auxiliary units should have disbalance of not more than 40 g.cm and the effort of shifting in splined joints of no more than 150 N (15 kgf).

  • Page 153: Auxiliary Power Take-Off

    When the power take-off is engaged the compressed air is supplied to the diaphragm chamber of the engaging mechanism via air lines. Diaphragm 6 (see Figures 127,128) via rod 10 with fork 9 meshes driven shaft gear 5 with drive gear 3. The rod 10 acts on the switch 12, closing its contacts and the power take-off engagement indicator on the dashboard lights up.
  • Page 154 1-housing; 2-coupling; 3-shaft; 4-shaft bushing; 5-engaging chamber body; 6-engaging rod; 7-fork; 8- spring; 9-cover; 10-diaphragm; 11-gasket; 12-flange; 13-collar; 14-cover; 15,23-ball bearings; 16-pump connecting rod; 17-piston; 18, 21-pump valves; 19-plug; 20-safety valve; 22-pump body Figure 129 - Auxiliary Power Take-Off The pump consists of piston 17 with delivery valve 18, safety valve 20 and body 22. The piston with the connecting rod is mounted on the eccentric of shaft 3;...

  • Page 155: Winch

    - start the engine, engage the auxiliary power take-off and one of the gears in the gear- box; - check operability of the pump by closing plug hole with your finger. If the pump is in good working order, you will feel oil pulsation in the plug hole. Do not operate the PTO if the oil pump is faulty.
  • Page 156 1-lubricator; 2-thrust washer; 3-sprocket; 4-drum shaft bracket; 5-nut; 6-lock washer; 7-sliding bearing; 8- spacer; 9-drum; 10-drum shaft; 11,15-bolts; 12-reduction unit cover; 13-rope railing; 14-fixed coupling; 16,24,28,33-adjusting shims; 17,25,27,38-bearing caps; 18,23,29,31,32-bearings; 19-reduction unit case; 20-worm wheel; 21-plug; 22-movable coupling; 26-flange; 30-reduction gear worm; 34-gasket; 35-band brake;...
  • Page 157 The globoid worm pair can operate properly only if the meshing has been adjusted cor- rectly. Incorrect adjustment may cause overheating of the worm pair and rapid wear of worm wheel teeth. Winch control is shown in Fig. 131. 1-band brake; 2,8-springs; 3-nut; 4-lock nut;...
  • Page 158 1-universal-joint fork; 2-safety pin; 3-cardan shaft; 4-needle bearing cap; 5-locking plate; 6-universal-joint cross; 7-slidinhg fork; 8-sealing rings Figure 132 - Front Cardan Shaft of Winch Drive 5.9.3.3 Rope winding guide. The winch is equipped with a winch rope winding guide which provides proper rope winding on the drum even if the drum deflects relative to the truck ax- is at 15º...
  • Page 159 - engage the reverse gear to pull cargos; - throw into reverse gear in the gearbox and lower speed gear in the transfer case for self- recovering of the truck. Increase the engine speed smoothly. Abrupt acceleration of the engine does not result in increasing the rope pulling force, but may cause a shear-off of the safety pin.
  • Page 160 When the pulley is used to increase the pulling force for self-recovering (position I), it must be fastened with the towing rope to a fixed object selected as a support and the winch rope hook, to the truck towing hook. When the pulley is used to change the rope direction for recover- ing of another truck (position II), fasten it with the help of towing rope to a fixed object selected as a support and the winch rope hook, to the towing hook of the truck to be pulled out.

  • Page 161: Tire Pressure Control System

    5.9.4 Tire Air Pressure Control System The tire air pressure control system shown in Figures 135 and 136 allows to control and maintain the tire air pressure within the required norm as well as to increase cross-country ability of the truck by reducing the tire pressure. It allows to drive the truck with a punctured tire without changing the wheel (the wheel valves of intact wheels should be closed).
  • Page 162 1-hoses; 2,3,5,6,7-air lines; 4-solenoid valve; а - to pressure gage of front wheels; в - to pressure gage of rear wheels Figure 136 - Tire Air Pressure Control System with the Solenoid Valves Mounted on the Chassis Frame (4х4) Table 12 – Pressure norms in tires 425/85R21 with load index 156 Максимальный...

  • Page 163: Sealing System

    Solenoid valves have three working positions: DEFLATION (ВЫПУСК), NEUTRAL (НЕЙТРАЛЬ) and INFLATION (НАКАЧКА) and insure tire air pressure decrease within 4-6 minutes depending on the tire size in accordance with Industrial Standard ОSТ 37.001.144-73. Solenoid valve installed on the truck is shown in Fig. 137. 1-solenoid valve;...

  • Page 164: Possible Troubles And Methods Of Trouble Shooting

    6 Possible troubles and methods of trouble shooting Trouble Possible Reason Trouble-shooting Starting Preheater Preheater boiler is overheat- Formation of ice plugs in the Warm pipes by switching the feed branches due to the non-full preheater on and off with 2-3 water draining or incorrect pre- minutes intervals and by pouring heater use.
  • Page 165 Trouble Possible Reason Trouble-shooting Preheater smokes or throws Fuel pump is maladjusted Reduce fuel consumption out flame adjusting pressure reduction valve of the fuel pump Electric motor shaft speed Charge storage battery, insufficient check motor Engine is warmed continu- Low fuel supply due to the Wash filters, injector, repair ously, pre-heater burns irregular- filter or injector clogging, faulty...
  • Page 166 Trouble Possible Reason Trouble-shooting Intensive uneven wear of the Considerable radial or lateral Replace the wheels with ex- tread pattern wheel wobbling cessive radial or lateral wheel wobbling Hard braking or start, driv- Observe the rules and drive ing with decreased or increased rationally.
  • Page 167 Trouble Possible Reason Trouble-shooting Oil is thrown through oil Filter clogging Wash the filter tank breather Gasket under collector is de- Replace the gasket stroyed Too high oil level Bring the oil level to the norm Oil filter is clogged Check the unit and wash the filter Brake System...
  • Page 168 Trouble Possible Reason Trouble-shooting Storage Batteries Battery cannot ensure re- The battery charge is below Charge battery and check quired engine crankshaft rotation permissible limit generator and voltage regulator speed Excessive voltage drop in Clean up battery terminals starter supply circuit and wire lugs, lubricate them with petroleum jelly.
  • Page 169 Trouble Possible Reason Trouble-shooting Power take-off (PTO) cannot PTO drive gear teeth are Disassemble the box, prime be disengaged worn out or damaged gear teeth or replace the worn out parts Considerable air leakage due Detect the leakage spots by to insufficient tightening of the applying soap solution on the air lines fixtures or their fault...
  • Page 170 Trouble Possible Reason Trouble-shooting Rope winding guide does not Insufficient tension when the Unwind the rope, ensure a lay the rope on the drum correct- rope is winded on the drum rope tension over 3000 N (300 kgf) when it is winded on the drum Set the guide rollers holder case correctly...

  • Page 171: Peculiar Features Of Operation

    7 Peculiar features of operation 7.1 Preparation of a New Truck for Operation Before putting a new truck into operation, study this Operation Manual, carry out the dai- ly maintenance, and additionally proceed as follows: 1. Check a coolant level and refill, if required. 2.
  • Page 172 start, repeat the steps in the above stated order. If engine still fails in three attempts, find and elim- inate the defect. The starter may be switched on for 15 sec only; the minimum interval between the engine start attempts should be not less than 1 min. Before starting the heated engine set the fuel feed pedal in the position corre- sponding to the medium rotation frequency of the crank shaft.

  • Page 173: Running-In A New Truck

    start, switch the pump unit and the electromagnetic valve off and repeat the start in a minute in the same order. If two subsequent efforts to start the heater failed, start troubleshooting procedures. 6. Close the hood. 7. When the liquid in the engine cooling system is heated up to 80-100 °С according to the readings of the anti-freeze temperature indicator on the dash board, switch off the electromagnetic valve, blow through the boiler gas ducts for 20-30 sec and switch off the pump unit.
  • Page 174 If differential lockup is engaged or disengaged with difficulty and gears shifting in transfer box is carried out with difficulty, start driving (forward and backwards) and repeat the process of switching. When driving the truck on heavy roads with the possible skidding of the truck, lock the cross-axle differential of the rear axle (rear bogie).
  • Page 175 Caution! Do not shut down the engine on long downgrades. It is not recommended to stop the truck on a slope. In case of a forced stop take all measures to exclude the possibility of the truck rolling down: cut off the fuel feed, apply the park- ing brake, engage the first gear in the gear box and place thrust blocks behind the wheels.

  • Page 176: Truck Towing

    the wheel hubs and the front axle steering knuckles (for traces of water). If the oil level in the units is high, reduce it to the required level and change the oil as soon as possible. On crossing a ford, prepare all the components for operation in normal road conditions and repair all water leak-proof connections of units.
  • Page 177 - if necessary, supply air from the prime mover to the towed truck using a trailer tire in- flation hose and the coupling head from the SPTA kit. Connect the hose to the towing valve locat- ed under the front bumper of the faulty truck by the nut with thread М16х1.5 and to the coupling head of the prime mover by means of the coupling head on the other end of the hose;...

  • Page 178: Maintenance

    8 Maintenance The maintenance is intended to keep the truck in the operable condition and proper ap- pearance, in order to reduce the wear intensity of parts, to prevent failures and malfunction as well as to detect them in order to provide their timely elimination. The maintenance is a preventive compulsory measure which is conducted regularly according to the plan with the frequency de- termined by the truck runs or operation periods.
  • Page 179 Таблица 13 - Maintenance schedule adjustment coefficient depending on the category of operational conditions Category of oper- Operating conditions of the truck Adjustment coeffi- ational conditions cient for the maintenance schedule Automobile roads of technical categories I, II, III outside the suburban area on the flat, slightly undulating and undulating terrain with cement-concrete and asphalt-concrete pavement.
  • Page 180 Table 13 Ending Category of oper- Operating conditions of the truck Adjustment coeffi- ational conditions cient for the maintenance schedule 2. Automobile roads of technical category V outside the suburban area, automobile roads in suburban area and streets of towns (flat terrain) with pavement out of ground with or without treatment with local materials 3.

  • Page 181: List Of Maintenance Operations

    8.3 List of maintenance operations Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 Daily maintenance (DM) Maintenance before leaving Inspect truck check absence of fuel, oil, brake fluid and coolant, as well as air leaks; eliminate troubles if any Inspect the engine;...
  • Page 182 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 - service brakes; Check serviceability of Truck pressure gage, pilot lamps by pressing brakes failure indicator on test push-button: the pilot dashboard lamps should light up Check fluid level in ex- Fluid level should be Vessel, wiping material pansion tanks of clutch hy-...
  • Page 183 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 In winter to prevent mois- Filling station ture condensing in fuel tank fill it up to the full volume Drain condensate out off When draining conden- air reservoirs. In winter drain sate, check that air reser- condensate every time you voirs are under pressure...
  • Page 184 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 Check the tightening of Loosening is not al- Wrench 22x24, box and, if necessary, tighten lowed wrench 22x24, pliers, the nuts and bolts fastening screwdriver driving axles final drives Running gear Check the tightening of and if necessary tighten the...
  • Page 185 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 - front brackets of the No loosening is per- Wrenches 17х19, front springs and (for 4x4 missible. 22x24 trucks) the rear springs rear brackets to the lower flange of the frame side-member;...
  • Page 186 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 Brake system Check air drive tightness, Air system should have in doing so pay attention to no air leaks the friction surfaces or harm- ful contacts of pipelines and eliminate the troubles Check outlet pressure out Air pressure on the...
  • Page 187 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 Check and retighten the Fastening should Screwdriver fastening of engine starting tight preheater high-voltage source, if required Check condition of rubber Ditto Visual inspection jackets on rear lights, side turn repeaters, storage battery switch, braking signal, fuel...
  • Page 188 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 - pins of front (for 4x4, Pump the lubricant in Lever-plunger gun or 6x6 trucks) and rear spring till fresh lubricant appears solid oil injector, wiping (for 4x4 trucks); out of pin and spring eye material conjunction...
  • Page 189 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 Check fuel coarse filter Fastening should be Wrench 14х17 fastening tight Check radiator unit fas- Ditto Wrench 17x19, pliers tening Check air filter fastening -«- Screwdriver, wrench 10х12 Check tightening and re- Coolant leakage is not...
  • Page 190 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 Check and adjust tapered Every second Wrenches 8х10, 10х12, bearings of primary and in- M-15 000: primary and in- 11х13, 14х17, 17х19, termediate shafts of transfer termediate shafts axial 22х24, socket wrenches...
  • Page 191 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 Running gear Check and if required re- tighten the nuts of: - front spring pins locking Loosening is not admis- Wrench 17x19 wedges; sible - front springs eyes; Ditto Socket wrench 30x32, Tire iron with tommy-bar...
  • Page 192 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 - rear suspension walking -«- Wrench 17х19 beam brackets to the cross member; - upper torque rod brack- -«- Socket wrench ets to the rear suspension axle pinchbar for cranking, box beams wrench 22х24,...
  • Page 193 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 Braking systems Check outlet pressure out Air pressure on the Test-pressure gages of both brake valve sections test-pressure gages should and operability of four-circuit be equal to the pressure in safety valve (see subsection the system (see readings of «Air Drive of Service Brake...
  • Page 194 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 Check and adjust head- Adjust headlamps on Screwdriver, screen lamps, if required (see sub- the unloaded truck placed with special marks section «Lighting and Sig- on an even horizontal naling System») ground Check variable voltage...
  • Page 195 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 Check oil level and bring it to norm if required: - in the transfer gearbox Oil level should be up Wrenches 17x19, 22x24, case; inspection/fill oil dispenser 133М, wip- opening edge.
  • Page 196 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 - towing unit bushings Pump the lubricant in Lever-plunger gun, (when operating with trailer); till fresh lubricant appears wiping material Lubricate in accordance with Chart of lubricants and working fluids the splined joints of: - drives of intermediate...
  • Page 197 Description Technical requirements Recommended equipment, Wheel ar- accessories and tools rangement 4х4 6х6 Check brake fuel level in Brake fluid level clutch release hydraulic drive should be up to the in- spection opening edge. Lubricate in accordance with Chart of lubricants and working fluids (at every third M-15 000): - sliding bearing of winch...

  • Page 198: Truck Lubrication

    8.4 Truck lubrication 8.4.1 General The lubricants and operating fluids chart provides the instructions for using fuels and lubricants of domestic manufacture and their foreign substitutes when operating the truck under conditions of temperate climate. Detailed recommendations and the lubrication procedure for particular units and parts are stated in the corresponding sections of the operating manual supplied with each truck.

  • Page 199: Chart Of Lubricants And Working Fluids

    8.4.2 Chart of lubricants and working fluids Pos. Name of lubrication or The num- The main grades, Substitute grades, filling point ber of season application season application Fig. points 138, Engine feed system See the Operations Manual for YaMZ engines Engine crank case: YaMZ-65654 Engine units...
  • Page 200 Foreign Fuels and lubricants Frequency of lubrication or Recommendations on lu- grades amount change (fuels and lubricants brication (filling, oil or replenishment) lubricant change) Filling Total Main brand Substitute norm amount brand (l, kg) for a truck (l, kg) See the Operations Manual for YaMZ engines See the Operations Manual for YaMZ engines See the Operations Manual for YaMZ engines Shell Dentax G...
  • Page 201 Auxiliary power take Oil ТСп-15К (at tem- At a temperature below peratures not below mi- minus 30 C it is allowed to nus 30 dissolve oil ТСп-15К Oil ТСп-10 (at tem- 10-15% of arctic or winter peratures not below mi- diesel oil or “Omskoil K nus 45 TMЗ-18”...
  • Page 202 Shell Dentax 0,01 0,01 At repair 80W-90, Mobilube GX 90, Energear EP 80W-90 0,085 0,085 M-15 000 Lubricate using an oil- er till fresh grease ap- pears in the opposite oil- er hole. M-(1500-3000) Change oil. Add, if necessary up to the level 6,0-6,5 6,0-6,5 of the filler neck on the...
  • Page 203 9, 8* Winch reduction gear Oil used for engine Oil ТСгип Steering hydraulic sys- Oil ВМГЗ Hydraulic oil «Р» tem: Technical Specification - МАZ – 64229 38.1011282-89 (at tempera- tures not below minus 30 °С) - steering oil tank Front driving axle Mixture of 35% of lub- Mixture of 35% of lubri- steering knuckle case...
  • Page 204 Mobilube GX 140, M-(1500-3000) Check oil level and Shell pirax GX add, if need be Every third M-15 000 Change oil. Add oil up to the edge of the fill- er neck on the reduction gear case cover. STATOIL TRANSWAY PS DX III Daily Maintenance (DM) Check oil level in the...
  • Page 205 Spiders (needle bear- Lubricant Литол-24 Lubricant 158 ings) of the prop shafts of: - drive of front, rear 8 (6х6) and intermediate shaft 6 (4х4) - steering system - winch drive Tire air supply collars Lubricant Лита Lubricant ЦИАТИМ-201 8, 7* Wheel hubs Lubricant Литол-24 Lubricant Лита...
  • Page 206 Shell Gadus S2 V220 2, RENOLIT EP2, Shell Gadus Lubricate through oil S2 V100 3, 0,004 0,32 M-15 000 filler until fresh lubricant Mobilgrease XHP 0,004 0,024 appears 222, Energrease L2 0,006 0,012 Change oil during dis- assembly 0,024 0,096 AeroShell Grease 6 0,05 0, 30...
  • Page 207 Hollow under guard Lubricant Литол-24 Lubricant Лита ring of the walking beam Terminals and plugs of Lubricant Литол-24 Solid oil Ж & Solid oil «ground» switch С 1, 15* Front spring pins (for Lubricant Литол-24 Solid oil Ж & 4х4, 6х6 trucks) and rear Solid oil C spring pins (for 4х4 trucks)
  • Page 208 Shell Gadus S2 0,025 0,05 Fill up the hollows V220 2, RENOLIT «a» and «b» under seal- EP2, Shell Gadus ing ring lips when reas- S2 V100 3, sembling after repair Mobilgrease XHP with lubricant (having 222, Energrease L2 removed the old lubricant first) 0,0005 0,002...
  • Page 209 10, 9* Towing device bush- Lubricant Литол-24 Solid oil Ж & ings Solid oil C Knuckle pivot upper bear- ings Splined joints of: - intermediate axle drive (for 6x6 truck), rear axle drive (for 4x4 truck) and intermediate shaft drive - front and rear axles drive - steering control...
  • Page 210 Shell Gadus 0,025 0,05 M-(1500-3000) Lubricate using oilers V220 2, RENOLIT M-15000 till fresh grease appears EP2, Shell Gadus (when operating with V100 trailer). Mobilgrease XHP 222, Energrease L2 0,100 0,100 M-15 000 Lubricate using oiler 0,020 0,04 M-15 000 Lubricate using oilers till fresh grease appears 0,180...
  • Page 211 - winch drive Lubricant Литол-24 Solid oil Ж & Solid oil C Spare wheel lift reduc- ing gear Sliding bearing of the winch drum shaft Winch rope winding guide bearings Working surface of the bolster unit Bolster unit hook...
  • Page 212 Shell Gadus 0,015 0,03 Every third M-15 000 Lubricate using oilers V220 2, RENOLIT till fresh grease appears EP2, Shell Gadus V100 0,04 0,04 Lubricate while disas- Mobilgrease XHP sembling 222, Energrease L2 0,025 0,025 Every third M-15 000 Lubricate using oilers till fresh grease appears 0,035 0,07...
  • Page 213 Working surfaces of Graphite lubricant Solid oil Ж, Solid oil С or winch rope winding guide УСсА Lubricant Литол-24 actuating screw and shaft guides Roller bushings and guide rollers holder body cavities of the rope wind- ing guide Winch rope winding guide chain gear Intermediate bracket shaft of the clutch drive...
  • Page 214 Rhodina EP2, 0,15 0,15 Lubricate after each Alvania HDX2, operation of winch Mobilgrease Graphited №3 Every third M-15 000 Apply lubricant (if the winch is not operated) 0,033 Every third M-15 000 Apply lubricant 0,004 0,004 Every third M-15 000 Apply lubricant 0,05 0,05...
  • Page 215 Brake and clutch pedal Graphite lubricant Solid oil Ж, Solid oil С shaft УСсА or Lubricant Литол-24 Spring leaves of front Graphite lubricant Solid oil Ж, Solid oil С and rear suspensions УСсА or Lubricant Литол-24 Front and rear spring Oil ТСгип...
  • Page 216 Rhodina EP2, 0,015 0,015 Lubricate the bush- Alvania HDX2, ings and pins while dis- Mobilgrease assembly Graphited №3 0,325 1,300 Lubricate the concave surface of the spring leaf after disassembly, having first removed the rust 0,0025 0,02 Lubricate the threaded part during disassembly having cleaned from cor- rosion first...
  • Page 217 Service brakes sup- Lubricant АМС-3 Rubber- or silicon-based port and wedge mecha- sealers nism Expansion cam, brake shoe pin and brake sup- port Service brake shoes Graphite lubricant Solid oil Ж, Solid oil С or surfaces and pins УСсА Lubricant Литол-24 Telescopic shock- Shock-absorber fluid Shock-absorber fluid ГРЖ-...
  • Page 218 0,0075 0,09 At disassembly. Prior to reassembly ap- ply graphite lubricant on pins Д and brake shoe sur- 0,0022 0,08 face Г. Apply lubricant АМС-3 on surfaces Н, М, Ж, А Rhodina EP2, 0,005 0,06 Alvania HDX2, Mobilgrease Graphited №3 Shell Tellus T15 0,850 1,700...
  • Page 219 Oil and working fluid servicing norm in column 7 is nominal. It means that after priming procedure the oil (fluid) level is to be checked and, if necessary, brought to norm according to section «Maintenance» For Ural-43206-61, Ural-4320-60/61 trucks. For Ural-5557-61 trucks.
  • Page 220 29,0 29,0 See the Operations Manual Check coolant level and for YaMZ engines add, if necessary, up to 27,0 27,0 the norm: 15-25 mm above the cooling tubes ends in the radiator upper tank at a temperature up to plus 20...

  • Page 221: Storage

    9 Storage 9.1 General Provisions A new truck, if it is not to be put into operation, can be stored without preservation, within three months from the date of its shipment from the manufacturing works. In this case, upon the truck has been put into storage, apply a thin layer of “Литол-24” grease or solid oil onto unpainted surfaces of the front axle ball supports, provide maintenance of the storage batteries and tires as per instructions given in the corresponding Operation Manual.
  • Page 222 - terminal connections of the brake system failure sensors and the stop signal switches; - storage battery output pole terminals with the wire lugs. Table 15 - Preservative and Protective Materials Designation of Material Denomination and Composition For preservation of transmission Working-and-corrosion-preventing oil ТМ5-12рк...
  • Page 223 Apply scotch tape for holes which connect the inner hollows with the atmosphere and are located on the brake valve, the pressure regulator, the trailer brake control valves, the condensate drain cocks, the sealing pipes behind the cab. Unload the wheels, by lifting them up to 80-100 mm above the ground, and the truck suspension, following the procedure described below: - to unload the front axle wheels (for 4x4 &...
  • Page 224 9.4 Taking Trucks out of Storage Before commissioning of the truck after its storage: - check the tire pressure and bring it to the norm; - remove the truck from its supports and release its springs; - unseal the feed, exhaust and engine ventilation systems and the oil tank; - remove the protecting grease from the truck exterior surfaces with the help of a piece of soft cloth moistened in kerosene or clear gasoline;...

  • Page 225: Transportation

    10 Transportation 10.1 The trucks can be transported by rail, sea and air or under its own power. The mode of transport is specified in the supply contract. In so doing the preparatory works should be done as follows: 1. Prior to shipment check the tire pressure and, if required, bring it to the norm and close the wheel valves.
  • Page 226 Fig. 141- Loading and securing of the trucks on a four-axle flat-car (for 4х4 trucks) 10.3 When transporting the trucks by air, preparatory works should be done and truck cushioning should be additionally disengaged by special devices manufactured and supplied by a consignor.

  • Page 227: Salvaging

    1-Walking beam axle (for 6х6 trucks), rear axle axis Fig. 143 – Securing of truck in cargo hold (for 4х4 trucks) Fig. 142 – Securing of truck on weather deck...
  • Page 228 11 Recycling Upon expiry of truck service life, it is subject to recycling. For this purpose follow the procedure: - wash and dry the truck; - remove storage batteries and check whether they are further serviceable. If not, pour off the electrolyte into special glassware and bring the storage batteries to a collecting station;...

  • Page 229: Appendices

    APPENDICES APPENDIX А (recommended) Table А.1 – Torques Applied for Tightening if the Main Threaded Connections, N.m (kgf.m) А.1 Engine Nuts fastening: silencer 24-36 (2,4-3,6) silencer inlet pipes to exhaust manifolds 28-36 (2,8-3,6) Lock nuts fastening silencer inlet pipes to exhaust manifolds 33-41 (3,3-4,1) Bolts attaching the side supports of the power unit 50-62 (5,0-6,2)
  • Page 230 Table А.1 Continuation bearing body caps of driving bevel gear and steering knuckle seal 12-18 (1,2-1,8) side cover of the final drive 44-56 (4,4-5,6) differential bearing caps 250-320(25-32) Nuts fastening: final drive to axle case 120-150 (12-15) ball support to half-axle casing 280-320 (28-32) steering knuckle levers and kingpin bearing caps: М18...
  • Page 231 Table А.1 Continuation walking-beam axis assembled with walking-beam brackets (for 6x6 700-800 (70-80) trucks) rear springs pins cover (for 4x4 trucks) 180-220 (18-22) Tie bolts of walking-beam nuts (for 6x6 trucks) 44-56 (4,4-5,6) А.3.2 Towing unit Bolts and nuts fastening: towing device to the crosspiece 110-140 (11-14) rear towing cross member to the frame:...
  • Page 232 Table А 1 Ending А.9 Special equipment А.9.1 Power take-off Bolts and nuts fixing power take-off case to gearbox case 22-32 (2,2-3,2) А.9.2 Auxiliary power take-off Nut of auxiliary power take-off flange, min 140 (14) А.9.3 Winch Bolts of winch cardan shaft flanges 60-65 (6,0-6,5)
  • Page 233 APPENDIX B (recommended) Table B. 1 - The data for the control and adjustment о Coolant temperature in cooling system 90-100 С Axial displacement of primary and intermediate transfer box shafts, 0,03-0,08 ≤25 о Free steering wheel travel (with the pump running) Toe-in (the rim), mm Travel of clutch pedal, mm 5-10...
  • Page 234 APPENDIX C (reference) Table C. 1 – Data on weight of main components, kg (Without refueling, lubricants and hydraulic fluids) Transfer box Drive front axle with hubs, brakes and steering rod Rear / intermediate axle with hubs and brakes Truck frame: short long Towing unit...
  • Page 235 APPENDIX D (reference) Rolling bearings Table D.1 – Rolling bearings of trucks Designation Bearing type Overall dimen- Location Quantity sions*, mm 307A Single-row radial ball 35x80x21 Power take-off driven bearing shaft 64805 Single-row radial roller 25x38x24,7 Power take-off driving bearing without races gear 211A Single-row radial ball...
  • Page 236 Table D1 Continuation Designation Bearing type Overall dimen- Location Quantity sions*, mm 2007124А or Ditto 120x180x38 Wheel hubs 6-200712АА 2007118К1 Single-row tapered 90х140х32 Intermediate and rear roller bearing axles final drive differen- tials 12318KM Radial roller bearing 90x190x43 Final drive driven bev- with short cylindrical el gear rollers...
  • Page 237 Table D1 Ending Designation Bearing type Overall dimen- Location Quantity sions*, mm 180508K2C17 Single-row radial ball 40x80x23 Intermediate cardan bearing shaft of winch drive (sup- porting bearings) 46310AK Single-row radial thrust 50x110x27 Winch reduction gear ball bearing worm (front support) 312A Single-row radial ball 60x130x31...
  • Page 238 APPENDIX Е (reference) Table Е.1 – Chart of lubricants and working fluids Main grade Substitute Quantity of single refueling per truck Designation Standard Designation Standard Truck Truck 4х4 6х6 GOST Р Diesel fuel See Operation Manual for the engine See Specification 52368-2005 type II or III Transmission...
  • Page 239 Table e1 Ending Ethanol GOST 0,262 kg 18300-72 GOST 17299-76 Coolant Cool Specifications See Operation Manual for the en- 27,0l Stream Standart 40 2422-022- gine 13331543-2004 ДТ-1 lubricant «Нева» 0,12kg brake fluid Лита lubricant 38-101- 0,29 kg 0,39 kg ЦИАТИМ- GOST 6267-74 1308-90 201 lubricant...
  • Page 240 APPENDIX F (recommended) Table F.1 - Truck bulbs and their specifications Location Lamp type Q-ty per truck Headlamp АКГ24-75+70-1 Front lamp А24-21-3 А24-5 Rear lamp А24-5 7442.3716 А24-21-3 А24-21-3 Side repeater А24-21-3 Cab roof lamp Signal, pilot and instrument illumination lamps А24-2 Front marker lamp...
  • Page 241 APPENDIX G (reference) Table G.1 - Waste oil collection rate, l Engine 18,0 Gearbox Transfer box Steering gear case Drive axle reduction gears 19,0; 13,0* Steering hydraulic system Winch reduction gear * On trucks with 4x4 wheel arrangement...
  • Page 242 APPENDIX H (reference) H.1. Spare parts, tools and accessories The Manufacturer supplies each truck with a single set of spare parts, tools and accesso- ries. On special request the Manufacturer can supply the following sets: - a set of spare parts, tools and accessories (SPT&A) for power unit, that contains the spare parts intended for elimination of troubles during the warranty period of operation, as well as tools and accessories;...
  • Page 243 Table H.1 Continuation Position in Description Quantity Fig. In tool bag 26 (Fig. H.1) Pliers Box wrench 22х24 Box wrench 17х19 Wrench 27х30 Wrench 22 х24 Wrench 19х22 Wrench 14х17 Wrench 11х13 Wrench 10х12 Wrench 8х10 Wrench 5,5х7 Fig. H.1 - Tools of the Ural truck...
  • Page 244 Table H.1 Continuation Position in Description Quantity Fig. Tool bag Socket wrench 24 Special feeler gauges Combination screwdriver In tool box (Fig. H.2) Tool boxes Socket wrench 140 Hydraulic jack 8 t Lever type grease gun Connecting head of B type with union Air hose Spare wheel holder winch lever The following items are mounted under the body...
  • Page 245 Table H.1 Ending In glove compartment Operation Manual On platform Spacer pipes In cabin Canopy in a bag In special seats in the front part of the platform Canopy bows (set) Warm-keeping jacket for radiator and side panels ___________________ * Supplied upon customer’s request For trucks with 6x6 wheel arrangement For trucks with air-hydraulic brake drive H.2 Hydraulic telescoping brake...
  • Page 246 1 - screw of inner working plunger; 2 - pump lever; 3 - shut-off needle; 4 - plug; 5 - tire iron Fig. H.3 - Using jack When using the jack place pads under the truck wheels. Be sure to apply the parking brake and to engage the lower gear in the gearbox.
  • Page 247 1 - base; 2 - gasket; 3 - cylinder of outer working plunger; 4 - cylinder pipe; 5 and 6 - outer and inner working plungers; 7 - screw; 8 - seal; 9 - case head; 10 - packing ring; 11 - plunger head; 12 - plug; 13 - pump lever;...
  • Page 248 APPENDIX (recommended) I.1 Design features of trucks with air-hydraulic brake system and RBL C-700 steering mechanism I.1.1 Transmission I.1.1.1 Driving axles I.1.1.1.2 Final drive of the intermediate axle is double; consists of two bevel pinions 1 and 14 (Fig. I.1). Final drive is characterized by mounting holes in differential carrier. Rear driv- ing axle is shown on Fig.
  • Page 249 1-air supply sleeve; 2-wheel cylinder; 3-brake drum; 4-semi-axle; 5-supporting spring bracket; 6-crankcase cover; 7,9-gaskets; 8-main gear; 10-axle case; 11-drain plug; 12-semi-axle housing Fig. I.2 - Rear drive axle I.1.1.1.3 The front axle of the truck is the driving and controllable axle. The design of the front axle pivot unit is shown in Fig.
  • Page 250 I.1.2 Steering I.1.2.1 Steering gear Steering gear is shown in Fig. I4 and consists of steering linkage and the hydraulic booster. Steering linkage includes steering column, mechanical part of the steering gear, drop arm, drop arm rod, steering arm, steering knuckle lever, and steering levers. Рулевой...
  • Page 251 1-pump; 2-oil tank; 3-filler neck plug; 4- steering gear; a-feed; b,-pumping; с-drain; d-clockwise rotation of the shaft (example) Fig. I.5 – Hydraulic circuit of the steering (hydraulic booster) Rotary valve and torsion bar, torsion bar and worm are drilled together and fixed by pins 8 and 13.
  • Page 252 The steering gear is equipped with hydraulic limiters of the turning, which partially by- pass the oil to drain when the wheels have not yet turned to the extreme position. Further turning of the steerable wheels will be with additional effort on the steering wheel. I.1.2.1.3 Steering hydraulic booster pump is shown in Fig.
  • Page 253 I.1.2.2 Steering system maintenance I.1.2.2.1 The steering system maintenance consists in regular inspection of the steering gear fastening, the piping, the free travel of the steering wheel as well as in servicing the hydraulic system assemblies. Such units as pump and steering gear shall be repaired in specialized service centers.
  • Page 254 Caution! Effort applied to the steering wheel at all stages of the adjustment shall be 100N (10kgf) maximum. It is not recommended to hold the steering wheel at the extreme position more than 5 sec. Do the following for the left and for the right steerable wheel: - at wheel turn limiting stops contact, obtain the pressure drop down to 75-85 kgf/cm alternate turning the screws B1 and B2 in, as shown in Figure I.8.
  • Page 255 I.1.3.1.1 Wheel brake mechanism (shown in Fig. I.9) is drum-type with the internal brake shoes 9 replaceable for each wheel. Each brake unit has a hydraulic cylinder. The brake shoes are mounted on the bearing axis 12. I.1.3.1.2 Simplified adjustment of service brakes Brake unit is adjusted upon the linings wear by reducing the clearance between the lining and the drum using adjusting cam gears 8.
  • Page 256 1-plug; 2-inductive sensor; 3-locking bush; 4- toothed impulse ring; 5-wheel hub Fig. I.10 – Speed sensor Angular velocity sensors of individual type mounted in the wheels of front and rear axles operating with the toothed impulse ring which is pressed onto the hub 5 are used for continuous read of the wheel speed.
  • Page 257 - the circuit of the parking brake and trailer drive consists of the air reservoir 7, return valve 9, brake valve with manual control 10, brake chamber of the parking brake 11, trailer valve 12, coupling heads 13. For system diagnostics in all circuits the control outlet valves are installed. For reservoirs servicing the moisture drain valves are provided.
  • Page 258 The scheme of the air-hydraulic brakes drive without outlets for the trailer is shown in Fig. I.12. 1-towing unit; 2-oil separator; 3-absorber receiver; 4-oil and moisture separator with integrated governor; 5-four-circuit safety valve; 6-rear circuit brake receiver; 7-trailer receiver ресивер прицепа и СТС; 8-front axle brakes receiver;...
  • Page 259 1-towing unit; 2-compressor; 3-absorber receiver; 4-oil and moisture separator with integrated governor; 5- four-circuit safety valve; 6-rear circuit brake receiver; 7-trailer receiver ресивер прицепа и СТС; 8-front axle brakes receiver; 9-return valve; 10- pressure drop sensor brake; 11-valve with manual control; 12- parking brake chamber;...
  • Page 260 1-towing unit; 2-compressor; 3-absorber receiver; 4-oil separator; 5-oil and moisture separator with inte- grated governor; 6-four-circuit safety valve; 7-rear circuit brake receiver; 8-trailer receiver ресивер при- цепа и СТС; 9-front axle brakes receiver; 10-return valve; 11-pressure drop sensor; 12-brake valve with manual control;...
  • Page 261 I.1.3.2 Fuels, Lubricants and Special Fluids Pos. Designation of lubrica- Quantity of Main grades, Substitutes, in Fig. tion point or oil servic- Points application seasonality application seasonality ing of system Parking brake ad- justing lever roller Engine oil Parking brake ad- juster thread Hydraulic system of Oil ВМГЗ...
  • Page 262 Foreign substitutes Combustive-lubricating Lubrication or change inter- Lubrication recommen- material quantity val (combustive-lubricating dations (oil filling, charg- material refill) ing or lubrication) Filling Total per Main grade Substitute norm truck (l, kg)* (l, kg)* Shell Rotella X30, 7-10 7-10 M-(1500-3000) Clean the roller be- Rimula C 30 drops...
  • Page 263 Service brake shoe Graphite grease Solid oil Ж, Solid oil С pins УСсА or grease Litol-24 Brakes hydraulic Brake fluid «Toмь» Brake fluid «Нева», system At a temperature be- «РОСДОТ» At a temperature below low minus 40°C dissolve brake fluid with 18-20% minus 40°C dissolve brake of ethyl alcohol (by fluid with 18-20% of ethyl...
  • Page 264 Rhodina EP2, 0,005 0,060 Every second Lubricate shoe pins and Alvania HDX2, M-15 000 bushes Mobilgrease Graphited №3 Shell Donax B, 0,90 M-15 000 Check fluid level, if nec- Mobil Hydraulic essary add in tanks 15-20 Brake Fluid, 2,45 mm below the upper Gastrol Girling (4х4)
  • Page 265 APPENDIX J (recommended) Table J.1 - List of collars mounted on the truck Q-ty Fig. Pos. № Designation Denomination Mounting Place Transfer box 2,2-70х92-1 or Collar Front bearing cap of pri- РТ 864176-02 or mary shaft ВDUМ5SLX26 Collar 2,2-70х92-1 or Bearing cap of front axle РТ...
  • Page 266 Table J1 Continuation Q-ty Fig. Pos. № Designation Denomination Mounting Place 2.2-70х92-1 to- Collar Rear bearing cap of the gether with 2.1- 2.2-70х92-1 intermediate axle 70х92-4 or State Standard 8752-79/ Industrial Standard 38 05146-78 РТ 864176-02 or Collar 70х92-12х12 Technical Specification 2539-001-00232934- 2003 ВDUМ5SLX26...
  • Page 267 Table J1 Ending Q-ty Fig. Pos. № Designation Denomination Mounting Place Winch (reduction gear) 2.2-85х110-1 Collar Winch shaft bearing left 2.2-85х110-1 2.1-45х70-1/3 Collar Winch worm thrust bear- 2.1-45х70-1/3 ing cap Winch worm shaft thrust bearing front cap 4320-4501127-01 Collar Hole in the winch reduc- (19х32х7) 4320-4501127-01 tion gear housing for...

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Ural-4320-61Ural-43206-61Ural-5557-60

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