URAL Motorcycles 4320М Operation Manual

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URAL-4320М TRUCK

and its Modifications

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Summary of Contents for URAL Motorcycles 4320М

Page 1 URAL-4320М TRUCK and its Modifications...
Page 2 URAL-4320М TRUCK and its Modifications Operation Manual 4320М-3902035-10 РЭ edition, amended)  URALAZ Partial or full reprint, duplication or translation is not allowed without written permit of OJSC “URAL Motor Vehicles Plant” Miass – March 2017.
Page 3 The Manual is dedicated for drivers and motor transport workers connected with Ural tucks operation. The Manual gives technical specifications of the trucks, short description of their construction and operation of truck components, their adjustment and maintenance, reference da- Due to constant modernisation of the product improving its reliability and operation con- ditions, the construction may be partially amended, and such amendments are not included in this Manual.
Page 4: Table Of Contents
Contents Introduction..........................5 1 Safety Requirements and Warning..................7 1.1 Safety Requirements.................... 7 1.2 Warnings......................9 2 Technical Specifications......................12 2.1 Technical Specifications of 6х6 Trucks with Conventional Cab ......12 2.2 Technical Specifications of Chassis of 6х6 Truck with Conventional Cab.... 15 2.3 Technical Specifications of 6х6 Cabover Trucks ..........
Page 5 4.5.3 Emergency Brake System..................129 4.5.4 Parking Brake System..................129 4.5.5 The Antilock Brake System (ABS)..............132 4.6 Electrical Equipment......................141 4.6.1 Conventional Cab Truck Wiring Diagram……………………………………... 141 4.6.2 Cabover Truck Wiring Diagram................144 4.6.3 Fuses........................148 4.6.4 Alternator......................152 4.6.5 Storage Batteries....................
Page 6: Introduction
Introduction Modernized URAL trucks with 4x4 and 6x6 wheel arrangement and YAMZ-536 engine (emission class 4) are dedicated for cargo transportation (except hazardous cargo), people trans- portation and trailing on any kinds of roads and terrain. URAL trucks are designed for operation at air temperatures from minus 45 to plus 50 °С (short time operation up to minus 50 °С...
Page 7 - Trade mark of the manufacturer; - Identification number; - Modification; - gross vehicle weight rating; - gross axle weight rating; - gross road-train weight rating; - gross fifth-wheel coupling load rating; - Approval number of vehicle type (approval of chassis type). Identification number is marked on the right frame girder in rear part.
Page 8: Safety Requirements And Warning
1. Safety and Warning Requirements 1.1 Safety Requirements 1.1.1 Before starting operation check the truck and its drawbars proper functioning. 1.1.2 When driving a truck, the driver and the passengers must fasten safety belts. 1.1.3 Do not start the truck engine without ensuring that the truck is put in neutral. 1.1.4 Maintain and repair the truck on a horizontal platform.
Page 9 1.1.13 It is forbidden to install the assembled wheel with deflated tire and to inflate it with tire inflation system. 1.1.14 The plant warns on strict compliance with safety rules at tire fitting (see par- agraph “Wheels and Tires”). 1.1.15 When lowering the rear wheel, keep away from the carrier tilting bracket opera- tion zone.
Page 10: Warnings
1.2 Warnings Normal truck operation and its long life can be only ensured, if complying with all the recommendations described herein. 1.2.1 Before operating the truck read the paragraphs “CAUTION”, “SAFETY RE- QUIREMENTS” and “ENGINE START, OPERATION AND STOP” of the Operation Manual for the engine.
Page 11 1.2.11 It’s forbidden to operate a dropside truck with the tail gate lowered, as it covers the rear signalling lights in such a position. 1.2.12 Use the cross-axle differential lock only in the conditions specified in paragraph “Truck Driving”. 1.2.13 Differential locks must be switched on and off only when the truck is completely stopped.
Page 12 1.2.28 When using a trailer at the air temperature lower than minus 25 °С and before long-term parking do not leave the rubber buffer of the towing device loaded to avoid the com- pressed rubber buffer freezing and axial play in the towing device. When moving the truck for- ward and backward, uncouple the trailer or unload the rubber buffer.
Page 13: Technical Specifications
2 Technical Specifications 2.1 Technical Specifications of 6х6 Trucks with Conventional Cab. 2.1.1 Basic weight and load parameters of trucks are given in Table 1. Table 1 4320-0111-71, 44202-0311-70, 44202-0511-70, 4320-0911-70, Parameters 4320-0111-73, 44202-0311-72, 44202-0511-72, 4320-0911-72 4320-0111-75 44202-0311-74 44202-0511-74 Truck kerb weight ’...
Page 14 Break-over of Table 2 4320-0111-73, 4320-0111-71, 4320-0111-75 4320-0671-73, 4320-0671-71, 4320-0911-72, Parameters 44202-0311-74 44202-0311-70, 44202-0311-72, 44202-0511-74 44202-0511-70 44202-0511-72 Working displace- 6650 ment, cm Compression rate 17.5 Maximum power, 176.5 (2300±25) 210 (2300±25) 229 (2300±25) kW/min- Maximum torque, 900 (1300-1600) 1130 (1300-1600) 1226 (1300-1600) Nm/min- Fuel Feed System...
Page 15 Break-over of Table 2 Tires for modifications: Model Size Load index Speed cate- Static radius, gory 44202-0311-70, KAMA-1260 425/85R21 0.590 44202-0511-70, 44202-0311-72, У-4, ИД-304 12,00R20 150/146 0.526 44202-0511-72 4320-0911-70, KAMA- 425/85R21 0.585 4320-0911-72 1260, KA- MA-1260-1 О-184 425/85R21 0.580 У-4, ИД-304 12,00R20 150/146 0.526...
Page 16: Technical Specifications Of Chassis Of 6Х6 Truck With Conventional Cab
End of Table 2 Fifth-Wheel Coupling 50-11 according to GOST 28247-89, two-degree-of-freedom. King pin lock- ing arm jaws are closed with semi-automatic lock, hole diameter for the king pin is 50.8 mm (for semi-trailer trucks 44202-0311-70, 44202-0511-70, 44202-0311-72, 44202-0511-72, 44202-0311-74, 44202-0511-74) Dedicated Equipment (is optionally installed) Power Takeoff...
Page 17 Break-over of Table 3 Parameters 4320- 4320- 4320- 5557- 55571- 55571- 4320- 1951-70 1972-70 1982-70 1151-70 1151-70 1551-70 1151-71 43203- 4320- 4320- 4320- 5557- 55571- 55571- 4320- 1151-71 1951-72 1972-72 1982-72 1151-72 1151-72 1551-72 1151-73 4320- 4320- 4320- 5557- 55571- 55571- 1951-74 1972-74...
Page 18 Break-over of Table 3 Parameters 4320- 4320- 4320- 5557- 55571- 55571- 4320- 1951-70 1972-70 1982-70 1151-70 1151-70 1551-70 43203- 1151-71 4320- 4320- 4320- 5557- 55571- 55571- 1151- 4320- 1951-72 1972-72 1982-72 1151-72 1151-72 1551-72 1151-73 4320- 4320- 4320- 5557- 55571- 55571- 1951-74 1972-74...
Page 19: Technical Specifications Of 6Х6 Cabover Trucks
End of Table 3 Steering wheel Steer (type, mark- “ ” RBL C-700 (Germany) , screw - ball screw nut - rod - quadrant with hydraulic ing) booster Brake Systems Primary Brake Sys- Pneumatic dual-braking drive, with distribution on front contour and on rear bogie, with ABS, brakes of all wheels are drum-type.
Page 20 End of Table 4 GVWR distribution, kg - on front axle 6500 6500 5800 - on rear bogie; 16000 16000 16000 Maximal trailer (semi- trailer) weight, kg 11500 19100 Maximal road-train weight, 33300/34000 28020/38045* ______________________ * When driving on 1-4 category roads 2.3.2 Truck unit parameters are given in Table 5.
Page 21 Break-over of Table 5 4320-3171-78, 4320-3171-80, 4320-3171-82, 4320-3971-80, 4320-3971-82, Parameters 4320-3971-78, 44202-3511-80 44202-3511-82 44202-3511-78 9JS135ТА Mechanical, nine-speed, three-way with synchronizer assembly. axle ratios I-6.55, II-4.64, III-3.36, IV-2.46, V-1.95, VI-1.38, VII-1.00, VIII-0.73, re- verse-11.52, L-11.52 Additional reducing transmission 11.02 Transfer Box Mechanical, two-speed with cylindrical inter-axle locking differential Number of gears axle ratios 1.04...
Page 22 End of Table 5 4320-3171-78, 4320-3171-80, 4320-3171-82, 4320-3971-80, 4320-3971-82, Parameters 4320-3971-78, 44202-3511-80 44202-3511-82 44202-3511-78 Parking Brake System Pneumatic drive with spring-type brake actuators braking the brakes of mid- dle and rear axle wheels Secondary Brake System Engine retarder, installed Electrical Equipment Wiring diagram Single-wire, negative terminals of current power supply are connected with truck battery.
Page 23: Technical Specifications Of Chassis Of 6Х6 Cabover Trucks
2.4 Technical Specifications of Chassis of 6х6 Cabover Truck 2.4.1 Basic weight and load parameters of trucks are given in Table 6. Table 6 4320-4151-79, 4320-4951-78, 4320-4972-78, 5557-4151-78, 55571-4151-78, 55571-4551-78, Parameters 4320-4151-81, 4320-4951-80, 4320-4972-80, 5557-4151-80, 55571-4151-80, 55571-4551-80, 4320-4151-83 4320-4951-82 4320-4972-82 5557-4151-82 55571-4151-82 55571-4551-82...
Page 24 Break-over of Table 7 4320-4151-83, 4320- 4320-4151-81, 4320- 4320-4151-79, 4320- 4951-82, 4320-4972- 4951-80, 4320-4972-80, 4951-78, 4320-4972-78, Parameters 5557-4151-80, 55571- 82, 5557-4151-82, 5557-4151-78, 55571- 4151-80, 55571-4551- 55571-4151-82, 4151-78, 55571-4551-78, 55571-4551-82, Engine capacity, cm 6650 Compression rate 17.5 Maximal capacity, kW (at engine torque, min- 176.5 (2300±25) 210 (2300±25)
Page 25 Break-over of Table 7 4320-4151-81, 4320- Parameters 4320-4151-79, 4320- 4320-4151-83, 4320- 4951-80, 4320-4972-80, 4951-78, 4320-4972-78, 4951-82, 4320-4972- 5557-4151-80, 55571- 5557-4151-78, 55571- 82, 5557-4151-82, 4151-80, 55571-4551- 4151-78, 55571-4551-78, 55571-4151-82, 55571-4551-82, Main gear Dual-ratio, double reduction right-angle axle ratios 7.49 Undercarriage Frame Riveted, with forged girders of variable sections Towing devices - front - shunting forks with king pins (cabover trucks);...
Page 26: Technical Specifications Of 4X4 Trucks And Chassis
End of Table 7 4320-4151-81, 4320- Parameters 4320-4151-79, 4320- 4320-4151-83, 4320- 4951-80, 4320-4972-80, 4951-78, 4320-4972-78, 4951-82, 4320-4972- 5557-4151-80, 55571- 5557-4151-78, 55571- 82, 5557-4151-82, 4151-80, 55571-4551- 4151-78, 55571-4551-78, 55571-4151-82, 55571-4551-82, Brake Systems Primary Brake System Pneumatic dual-braking drive, with distribution on front axle and on rear bogie, with ABS, brakes of all wheels are drum-type.
Page 27 End of Table 8 Parameters for chassis 43206-1151-71 43206-1551-71 43206-4151-79 43206-4551-79 Chassis kerb weight, kg 6565 6725 6565 6735 GVWR distribution, kg - on front axle 4125 4245 4310 4515 - on rear axle 2440 2480 2255 2220 Gross vehicle weight rating, kg 13300 13800 GVWR distribution, kg...
Page 28 Break-over of Table 9 Parameters for trucks and chassis 43206-0111-71,43206-0551-71, 43206-3111-79, 43206-3511-79, 43206- 1151-71, 43206-1551-71, 43206-4151-79, 43206-4551-79 Transfer Box Mechanical, two-speed with cylindrical inter-axle locking differen- tial Number of gears high-1.04 axle ratios low-2.15 Main gear Dual-ratio, double reduction right-angle axle ratio 6.77 Undercarriage...
Page 29: Dimensions Of 6X6 And 4X4 Trucks And Chassis
End of Table 9 Parameters for trucks and chassis 43206-0111-71,43206-0551-71, 43206-3111-79, 43206-3511-79, 43206- 1151-71, 43206-1551-71, 43206-4151-79, 43206-4551-79 All-metal, two-doors: -Three-seat (for 43206-0111-71, 43206-1151-71) or -Two-seat (for 43206-3111-79, 43206-4151-79) and with rest area (for 43206-3511-79, 43206-4551-79); all-metal, four-doors, six-seat (for 43206-0551-71, 43206-1551-71). Platform Metal flat body, with three dropsides, with canopy 2.6 Dimensions of 6x6 and 4x4 Trucks and Chassis are shown in figures 3-23.
Page 30 Figure 5 - Tractor units Ural 4320-0311-70, Ural 4320-0311-72, Ural 4320-0311-74 Figure 6 - Tractor units Ural 4320-0511-70, Ural 4320-0511-72, Ural 4320-0511-74 Figure 7 - Chassis Ural 4320-1151-71, Ural 4320-1151-73, Ural 4320-1151-75...
Page 31 Figure 8 - Chassis Ural 4320-1671-71, Ural 4320-1671-73, Ural 4320-1671-75 Figure 9 - Chassis Ural 4320-1951-70, Ural 4320-1951-72, Ural 4320-1951-74, Figure 10 - Chassis Ural 4320-1972-70, Ural 4320-1972-72, Ural 4320-1972-74,...
Page 32 Figure 11 - Chassis Ural 4320-1982-70, Ural 4320-1982-72, Ural 4320-1982-74, Figure 12 - Chassis Ural 5557-1151-70, Ural 5557-1151-72, Ural 5557-1151-74, Figure 13 - Chassis Ural 55571-1151-70, Ural 55571-1151-72, Ural 55571-1151-74...
Page 33 Figure 14 - Chassis Ural 55571-1551-70, Ural 55571-1551-72, Ural 55571-1551-74 Figure 15 - Chassis Ural 43203-1151-71 Figure 16 - Truck Ural 43206-0111-71...
Page 34 Figure 17 - Truck Ural 43206-0551-71 Figure 18 - Truck Ural 43206-3111-79 Figure 19 - Truck Ural 43206-3511-79...
Page 35 Figure 20 - Chassis Ural 43206-1151-71 Figure 21 - Chassis Ural 43206-1551-71 Figure 22 - Chassis Ural 43206-4151-79...
Page 36 Figure 23 - Chassis Ural 43206-4551-79 The Operation Manual includes base configurations of trucks and chassis. Outside ap- pearance and truck and chassis configurations can differ from the ones shown in figures 3-23.
Page 37: Control Tools And Devices
3 Control Tools and Devices 3.1 Control Tools and Instrumentation of Conventional Cab Trucks. The trucks are equipped with the anti lock brake system (ABS). ABS is tested via switch and indicator located on the switchboard 1 according to figure 24. When the arm 3 is up (see picture 24) the air comes through deflectors to blow windows, when the arm is down, the air heats driver’s and passengers’...
Page 38 Stator and tools switch 15 is located on the steering mast and has three positions: 0-off, detented position, the key can be taken out; I-tools are off, detented position, the key cannot be taken out; II-the stator and tools are on, automatic return to position I, the key cannot be taken out. The trucks are equipped with the tire pressure control system.
Page 39 Tire inflation is controlled by switches 18, 19 and regulated by pressure gauges 12, 13 accord- ing to figure 25. The swithes have three positions: -tire inflation; -medium-neutral, herein pressure gauges shown actual tire pressure; -tire deflation. 1-dimmer, direction and horn switch; 2- wind shield wiper/washer switch; I,II,III-wind shield wiper speed selection;...
Page 40 Central dimmer switch 30 (see figure 25) has three positions: -on; -sidelights, herein dashboard lighting is on; -sidelights and dimlight. To switch on or off the storage batteries push button 39. Emergency alarm is switched on by pushing button 28, herein all direction indicators and the lamp in the button start flashing.
Page 41: Control Tools And Instrumentation Of Cabover Trucks
3.2 Control Tools and Instrumentation of Cabover Trucks The truck can have assembly units ans systems differing from the ones described herein. Description of their structural features and maintenance peculiarities is given below. Control tools and instruments located in the cab are shown in figure 28. 1-Combination of devices;...
Page 42 When pushing button 15 secondary brake is actuated, when the button is released braking is stopped. Height and angle of the steering mast can be adjusted by handle 18. To change the posi- tion of the steering mast pull handle 18, position the mast as required and, holding it, return the handle in its initial position.
Page 43 Switch on the gearbox as shown in figures 30 or 31 1,2,3,4,5,6,7,8-gears; R-reverse; Figure 30 - Gear Shifting Diagram for ZF9S1310 and FG9JS135 Gearboxes 1-5-Gears; R-reverse; Figure 31 - Gear Shifting Diagram for YAMZ 0905 and YAMZ 1105 Gearboxes Instrumentation and indicators located in the combination of devices are shown in figure 29.
Page 44: Subscription Station
To switch on or off the storage batteries press button 9 (see figure 32) located on the switches board. Emergency alarm is actuated by pressing button 5, herein all direction indicators, lamp in the switch, indicators 6, 11 (see figure 29) and indicator 13 (if a trailer is connected) start flash- ing.
Page 45 3.3.1 Subscription Station has the following operation modes: mode; “ ” mode; “ ” Emergency call mode; “ ” - test mode. “OFF” mode. The subscription station is in “OFF” mode when the ignition is on. Exit from “OFF” mode is done when the ignition is cut off. Switch to “OFF” mode from other modes is done when reserve battery is discharged.
Page 46 Table 10 - State Indication of User Interface Unit User interface unit state “SOS” button light “Service” button Indicator state (white/red) light (white/yellow) Indication (switching on) White White Red is on for five sec, then green flashes “ERA” mode White White Green flashes “Emergency call”...
Page 47: Nance
4 Truck Components' Structure and Operation Description, their Adjustment and Maintenance 4.1 Engine An engine of Yaroslavl Engine Plant is installed to the truck. Engine construction de- scription and operation and maintenance instructions are given in the attached Engine Installation and Operation Manual of Yaroslavl Engine Plant.
Page 48 PreLine-270 fuel coarse filter is installed on the fuel tank front support. The order of filling fuel to the feed system: - open the screw plug of the vent hole 1 as shown in figure 34; - use manual fuel feed pump 2 to pump fuel. Pump until air stops coming from the screw plug of the vent hole 1;...
Page 49 To fix the pedal there are two pins 1. Pedal spring 3 returns the pedal to its initial posi- tion. Pedal motion angle at engine idle is 18º. Pedal motion is restricted by the bumper 4. 1-Pins; 2-pedal sensor; 3-return spring; 4-bumper Figure 35 - Electronic Throttle Pedal 4.1.1.2 Engine Air Feed System for the Conventional Cab Trucks is shown in figure 36, it is dedicated for air intake and air cleaning before feeding it to the engine.
Page 50 Air filter is installed on the right wing and fixed with brackets and clamps. Air intake tube is fixed on the filter. Air is fed to the air filter through air intake tube 1 according to figure 36. The air entering the filter 11 and going through the inertial grid starts rotating in the ring gap between the casing and the filtering element, due to centrifugal force dust particles are thrown to the casing wall and collected in the hoper through the partition opening.
Page 51: The Engine Starting Heater System
Inspect connection rubber crinkled and smooth chutes periodically. If defects such as cracks, cuts, tears and etc. are detected, replace them. 4.1.1.3 Engine Air Feed System for the Cabover Trucks is shown in figure 37 1-Chute to the compressor; 2,7,14-connection hoses with rings; 3-air intake tube; 4-inlet air cooler; 5- branch;...
Page 52: Gas Exhaust System
III - stand-by mode - maintaining the engine temperature and cab heating during long- term parking (heater valve is open). When the truck is parked for a long term, stop the engine, switch on the heater, turn the cab fan thermal regulator handle on the heater remote control to the proper position (cab heater switch should be “OFF”).
Page 53: Cooling System
1-Metal pipe with flanges; 2-discharge branch; 3-muffler headpipe; 4-exhaust muffler; 5-oulet pipe Figure 39 - Gas Exhaust System 4.1.4 Cooling System The cooling system is dedicated to ensure optimal and stable engine temperature in any operation mode by forced heat elimination from its parts. The cooling system automatically ensures normal thermal condition of the engine opera- tion in the pre-set operation conditions within full range of speed and load modes.
Page 54 1-radiator cap; 2-radiator filler neck; 3-fan casing; 4-water outlet connection; 5-outlet chute; 6-engine steam outlet chute; 7-radiator steam outlet chute; 8-reserve tank; 9-reserve tank cap; 10-water inlet pipe to the engine water pump; 11-water inlet pipe; 12-radiator rod; 13-water inlet connection; 14-radiator; 15- radiator suspension frame;...
Page 55 4.1.4.1 Cooling System for the Conventional Cab Trucks is shown in figure 40. Before filling the engine cooling system open the hood, pour coolant through the radiator neck until the lower edge of the neck while the cab heating system valve is open. Start the engine for 1-2 minutes to evacuate air from the system.
Page 56: Power Unit Suspension
After engine stop list the cab, add the coolant up to the lower edge of the neck if neces- sary and close the cap tightly. Lower down the cab, add coolant through the reserve tank neck up to “MIN” mark (on the tank surface) while the cab eating system valve is open. Start the engine for 1-2 minutes to evacuate air from the system.
Page 57: Engine Idle Adjustment
1,2-bolts; 3-side engine support; 4-rear engine support; 5-lower engine front support bracket; 6-pad; 7- upper engine front support bracket Figure 42-Power Unit Suspension 4.1.6 Engine Idle Adjustment Engine idle adjustment allows changing engine rpm for the trucks with YAMZ-536 en- gines in the range from 700 to 1400 rmp at a pitch of 50-100 rpm, and saving the set rpm (up to 1000 rpm) in the engine electronic control unit memory.
Page 58 Exit from the adjustment mode is possible with saving maximum rpm of 1000 rpm, for that hold the switch 6 (see figure 32) for about 5 seconds. The pre-set value (1000 rpm maximum) of the engine idle will be saved in the engine electronic control unit and will be recorded to the electronic control unit memory after cutting off the ignition in standard mode (power supply for the electronic control unit continues after the ignition is cut off for minimum 30 seconds).
Page 59: Transmission
4.2 Transmission Coupling mechanism and gearbox construction description and operation and mainte- nance instructions are given in the Operation Manual of Yaroslavl Engine Plant. 4.2.1 Clutch Control with Air-Over Hydraulic Booster 4.2.1.1 Air-Over Hydraulic Booster for Conventional Cab Ural Trucks Master cylinder 7 (see figure 43) is installed in the engine compartment and is fixed by the bracket to the cab front plate.
Page 60 Check valve 18 is installed on the tank and is dedicated for dividing the air line coming from the separate pneumatic system circuit to the tank and for maintaining pressure in the system independent of pressure failure in the main circuits. Air is fed to the air-over hydraulic booster by the tube 19.
Page 61 1-plug; 2,7-rubber rings; 3-pull-off spring; 4-contact spring cap; 5-contact spring; 6-feeding union; 8- cylinder body; 9-piston; 10-seal; 11-retaining ring; 12-protective casing; 13-tappet; 14-ring; 15-O-ring; b- clearance Figure 45 - Master Cylinder 4.2.1.4 Clutch Air-Over Hydraulic Booster consists of the body 1 (see figure 46) having the piston 5 and the rod 4 inside.
Page 62 1-Body; 2-bleeder screw; 3-O-rings; 4-rod; 5-piston; 6-lid; 7-scraper; 8-fork; 9-seal; 10-drain hole; 11- plug; 12-control valve; 13-ring; 14-fork; 15,21-plugs; 16,19-springs; 17-air valve; 18-body; 20-spool; B,C,D,E,F,G,K-chambers; a-compressed air feed; b- hydraulic oil feed Figure 46 - Air-Hydraulic Clutch Booster The air valve 17 is pressed to the seat made inside the body by the spring 16, and it sepa- rates E chamber from F chamber.
Page 63: Wabco Air-Over Hydraulic Booster Construction And Operation
- fasten the fixation bolts 3 of the master cylinder 7 with 44-56 Nm torque (4.4-5.6 kgfm); - regulate pedal free play by the stop 11; clearance between the tappet 13 (see figure 45) and the piston -b should be 0.2-0.6 mm, it corresponds to pedal motion of 1-3 mm; Regulate clutch and brake pedals on cabover trucks with eccentrics (see figure 44).
Page 64 1-hydraulic body; 2-hydraulic piston; 3-hydraulic seal; 4-lining wear indicator; 5-wear indicator washer; 6- indicator housing; 7,10-contact springs; 8-air piston; 9-air cylinder; 11-casing; 12-rod; 13-drain tube; A- clearance when linings are worn; I-booster servo system Figure 47 - Wabco Air-Over Hydraulic Booster When pressing the clutch pedal liquid pressure from the master cylinder is transferred through the pipelines to the air-over hydraulic booster, where it impacts the hydraulic piston 2, air-over hydraulic booster and the piston 1 (see figure 48) of the servo system.
Page 65 1-hydraulic piston; 2-air piston; 3-lid; 4-saloon; 5-valve; 6-servo system housing. Figure 48 - Air-Over Hydraulic Booster Servo System Measure the stroke of thrust bearing at air pressure of 850 kPa (8.5 kgf/cm2) that corresponds to the regulator mark that should be within A limits (from 12 to 14 mm) (see figure 49). A-thrust bearing stroke regulation limit Figure 49 - Clutch Linkage...
Page 66: Gearbox
4.2.3 Gearbox Gearbox control for cabover trucks Gearbox control is mechanical, remote, telescopic. During the operation the following is done if necessary: - regulation of lever 3 position is shown in figure 50 of gear shift; - regulation of telescopic elements locking device. 1-Lining;...
Page 67: Transfer Box
- loosen bolts 2 at the gearbox being in neutral, by moving the lining 1 set lever angle at ±1 . If the lining moves insufficiently, loosen the nut 23 and change end length 24; -Put the gear lever in the cab in the transverse plane vertically by regulating the rod 21 length.
Page 68 The transfer box having additional takeoff with 100% of engine takeoff, has longer main shaft and modified crankcase in the part of the additional takeoff fixation. 1-main shaft; 2,35,60-flanges; 3,27,29,39,61,65–bearing caps; 4,26,31,67-roller bearings; 5,57-bolts; 6,56- air cylinder lids; 7,55-bushings; 8-shift mechanism housing; 9-piston of the neutral; 10, 22,54–pistons; 11,49–rods;...
Page 69 4.2.4.1 Transfer Box Adjustment Taper bearings are adjusted by changing the number of gaskets under the caps when the transfer box is dismantled. Before adjusting the bearings put the box in a way that the upper door is horizontal, and remove lid from it. Control the main and lay shaft axial movement with a dial test indicator.
Page 70 4.2.4.2 Transmission Devices Control is remote, electrical and pneumatic, consisting of the transfer box gears shifting mechanism, the transfer box differential lock mechanism, the addi- tional power takeoff switch*; power takeoff switch*; the cross-axle differential lock mechanism of the medium and the rear axles, solenoid valves installed on the right frame girder, pipelines and switches in the cab.
Page 71 The indicator flashes when low speed is switched on. When switching on neutral, the indi- cator with symbol flashes. When releasing the button, solenoid valves switch off, and the actu- ated gear is maintained with spring ball clamper13 (see figure 51). Neutral is switched on, when both solenoid valves “B”...
Page 72: Driveline
4.2.5 Driveline Torque from the gearbox to the transfer box and to the truck drive axles is given by the propeller shafts as shown in figure 53. Open propeller shafts with all-round sealing of needle bear- ings in joints. 1-Front drive shaft; 2,4,5-propeller shafts of the winch drive; 3-intermediary support; 6,7,8-propeller shafts of axle drive Figure 53-Transmission Prop Shafts and Winch Drive Layout (For 6x6 wheel arrangement trucks)
Page 73 1-End seal; 2-retaining ring; 3-cross; 4-needle bearing Figure 55- Needle Bearing All-Round Seal When operating the truck: - check prop shaft flanges fixation shown in figures 56 and 57 systematically; - if the radial (over 0.25 mm) and butt (over 0.35 mm) backlash in yoke bearings is too large, disassemble the joints and change yoke bearings if necessary.
Page 74 After changing the flanges, welded and slide yokes the propeller shafts must be dynami- cally balanced again. Disbalance causes shafts vibration, that has negative impact on transmission operation. 1-Flange; 2-needle bearing; 3-locking plate; 4-yoke; 5,10-press greasers; 6-seal cage; 7-seal; 8-spline yoke;...
Page 75: Driving Axles
4.2.6 Driving Axles Truck driving axles are throughfeed-type with upper main gear location. 4.2.6.1 Intermediate axle main gear is double-type, consisting of a couple of conical gears 1 and 14 (see figure 59) with spiral teeth and a couple of cylindrical gears 4 and 31 with oblique teeth.
Page 76 Table 11 Axle ratio Marks on the butt of the driving Mark on the idler gear cylindrical pinion from the conical gear side 7.49 No marking One drill under the crown 5 mm long and 3 mm deep Three 10 mm holes on the 65 mm Two drills under the crown 5 mm long and 6.77 journal butt 2 mm deep...
Page 77 Cross-axle differential distributes torque equally between the axle wheels, including truck driving on an uneven road and on turns, when the truck wheels rotate with different se- quence. When driving the truck off-road with a big difference of left and right wheels clutch, the cross-axle differential can help sliding of one axle wheel.
Page 78 1-Solenoid valve of the intermediate and rear axle cross-axle differential locks; 2- switches of the intermediate and rear axle cross-axle differential locks; a-from the tank Figure 62 - Pneumatic Control Scheme of the Cross-Axle Differential Lock The rod actuates the switch 12 (see figure 61) installed in the intermediate and rear cross-axle differential lock switch housing, herein indicators installed on the dashboard flash.
Page 79 When adjusting the main gear, adjust the preload of conical bearings and check bearing pattern of main gear conical couple. Adjusting works should be done when the main gear is re- moved from the truck. Interference should be controlled by the torque necessary for shaft rotation. Anti-torque moment is measured by force meter.
Page 80 1-Yoke; 2-cam; 3-disc; 4-inner axle shaft Figure 64 - Constant Velocity Joint Measure the shaft moment by rotating it smoothly in one direction, and minimum after five full turns. Mind that incorrect bearing adjustment can lead to destroy of bearings as well as main gear wheels.
Page 81 2. Adjust preload of lay shaft bearings. Adjust the bearings by selecting the seal package 8 (see figure 59) under the bushing sleeve 5 cover 9. Torque necessary for rotating the lay shaft must be 0.9-1.5 Nm (0.09-0.15 kgfm). When measuring the torque with force meter, wind the wire to the cylindrical gear crown, the force meter should indicate within 18.3-30.5 N (1.83-3.05 kgf).
Page 82 4. Install the differential and adjust the differential bearings. Tighten differential bearing cover bolts with 250-320 Nm (25-32 kgfm) torque. Adjust the differential bearings with nuts 36 (see figure 59). After nut tightening distance between differential bearing covers must increase for 0.04-0.14 mm.
Page 83: Undercarriage
4.3 Undercarriage 4.3.1 Frame The truck frame is riveted, consisting of two pressed girders of variable sections, joined to- gether with cross members and the front bumper. Cabover trucks have two towing forks with king pins for towing a vehicle in the front frame part.
Page 84: Truck Suspension
1-Nut; 2-housing; 3-locking rings; 4-elastic element; 5-towing hook; 6-guiding bushing; 7,9-oil cups; 8-lock pin; 10-locking plate; 11-bolt Figure 66 - Towing Device When driving the truck with a trailer check the hook work area (hook mouth) wear. The maximum allowed hook mouth wear must be not more than 58mm in diameter (new towing hook is +1.9 Ø...
Page 85 1,13-Spring brackets (front, rear); 2-spring; 3-spring u-bolt; 4-spring clamp plate; 5-spring buffer; 6-buffer bracket; 7,18-shock absorber brackets (upper, lower); 8-shock absorber; 9-washer; 10-shock absorber bush- ings; 11-shock absorber stud; 12-shock absorber retaining nut; 14-bush (upper, side); 15-bracket tie bolt; 16- distance piece;...
Page 86 Usage of shock absorbers prolongs spring life and improves truck stability and steerability. Shock absorber stroke is 300 mm. 1-Upper head; 2-housing nut; 3-washer; 4-rod seal; 5-housing bushing; 6-washer; 7-O-ring; 8-seal housing; 9- shock absorber housing; 10-cylinder; 11-piston rod; 12-limiting discs; 13,15,18-valve discs; 14-piston; 16- piston nut;...
Page 87 1-Spring; 2-u-bolt; 3-trim; 4-u-bolt nut; 5,7-torque arms (upper, lower); 6-spring support bracket; 8-buffer retaining nut; 9-buffer; 10-torque arm stud nut; 11-protective ring; 12-bracket fixing bolt of the upper torque arm to the axle case; 13-upper torque arm bracket; 14-balance shaft fixing bolt; 15- balance shaft bracket fixing bolt to the amplifier;...
Page 88 Axle upstroke is restricted by rubber buffers 9 fastened to the bottom spar cap. Axle down stroke is restricted by spring end jamming in the support bracket 6. Truck suspension with various load to the rear bogie differs by springs and u-bolt length. 1,8-Spring brackets (front, rear);...
Page 89 4.3.2.4 Rear suspension of 4х4 trucks consists of two main 9 and two auxiliary springs 3, see Figure 70. Eye fixation to the spring sheets and spring fixation to the frame of the front and rear suspensions are similar. Unlike the front spring, rear spring eye stud 20 of rear spring is fixed by re- movable lids 33.
Page 90 If there is no backlash (less than 0.2 mm) between the eye and the upper sheet in the eye fixing bolt area, repair or replace the eye (both front spring of 4x4 and 6x6 trucks and rear spring of 4x4 trucks). When mounting rear spring for a truck with 4x4 wheel arrangement after repair or replace- ment, pay special attention to spring stud proper fixation.
Page 91: Wheels And Tires
Check the fixation of the torque arm brackets and studs. The torque arm stud nuts fastening torque should be minimum 600 Nm (60 kgfm), if the hole for split pin does not coincide with nut slots, fasten the nut and forelock it. Rubber and metal linkages of the rear suspension torque arms doen’t need maintenance dur- ing operation.
Page 92 1-Wheel valve; 2-rim base with disc; 3-lock ring stop plate; 4-lock ring; 5-bead ring; 6-tire; 7- inner tube; 8-tire flap; 9-vent slot seal Figure 72 - Wheel with Tire Assembly Bead and lock rings of the wheels are mounted in the certain position with the help of lock ring welded to the rim, and the extrusion B (see figure 75) on the lock ring entering the corresponding hole (slot) A of the bead ring.
Page 93 -Maintain the undercarriage, steering wheel and brake units properly functioning; -Follow road safety rules and apply efficient driving methods considering road conditions, strictly comply with operation norms of tires with regulated air pressure described in “Warnings” and “Truck Driving” paragraphs. 4.3.3.1 Maintenance.
Page 94 - finish equipping the truck with tires of the same size, model, ply rating, pay special atten- tion to correct fitting of the tires relative to the axles (in terms of wear); - warm the tires that have been stored at temperatures below 0°С to above-zero temperature in a warm room;...
Page 95 - do not take down a wheel with a tire from the hub and do not remove the tire from the rim before checking that it is completely deflated. - do not use club hammers, crows, defective or improper installation tool not specified in the technical documentation which can lead to wheel parts deformation or mechanical damage, tire cuts and breaks, tube or tire flaps damage;...
Page 96 Remember that correct procedure of wheel fitting and dismantling ensures safety and reduc- es labour efforts, allows prolonging tire, wheel and mounting tool life. 4.3.3.5 Wheel Disassembly 1. Put the wheel on an even clean surface lock part facing up, check that the tire is com- pletely deflated, disconnect the gate from the wheel valve and sink it together with the seal in the tire cavity, remove the wheel valve.
Page 97 Toroidal form of the rim seat does not allow quick local dismantling of tire beads that is why it is necessary to upset tire bead in two-three steps moving around the wheel. 3. Take out the lock ring by inserting the flat end of the tire iron into the dismantling slot of the lock ring and drive out its end from the rim, moving it after with the second tire iron up and mov- ing continuously round the wheel, uncouple the ring completely from the rim.
Page 98 - insert the guiding part of the seal with the valve into the rim slot preliminary sinking the bottom part of the seal with the tire iron in the tire. 4. To fit the second tire bead to the rim, step on the tire from the side opposite the valve, and sink this part of the bead in the rim well, herein tire bead should be over the rim in the stop block ar- ea.
Page 99 1-bead ring; 2-lock ring; 3-bracket; A-bead ring slots; B- forge on the lock ring Figure 75 - Position of the Lock and Bead Rings If the wheel is installed incorrectly, deflate the tire, correct rings position and repeat infla- tion up to 50 kPa (0.5 kgf/cm ).
Page 100 Before balancing clean the wheel and the tire from dirt and foreign objects. Tire pressure should be nominal. During balancing position the wheel with the tire on a ded- icated device along disc surface for spherical chamfers of mount holes. Balance weights mounting scheme: 1.
Page 101: Spare Wheel Holder
4.3.4 Spare Wheel Holder Spare wheel holder constructions are shown in Figure 78. Spare wheel holder base and removable bracket are made of rolled sections welded to each other. Spare wheel elevation and lowering is done with worm gearbox 6. When driving the truck spare wheel is fixed by buckles 2 and bolts 3.
Page 102 Spare wheel holder variant for a cabover truck: 1-Gearbox cable; 2-bucket; 3-bolt; 4-removable bracket; 5-holder base; 6-gearbox; 7-removable handle. Figure 78 - Spare Wheel Holder By rotating the handle lower the removable bracket with the spare wheel. When the wheel is down remove cable 1 from the spare wheel not disconnecting it from the removable bracket 4, if pos- sible, and wheel it out.
Page 103: Steering Wheel
4.4 Steering wheel 4.4.1 Steer The steering consists of the steering gear and the hydraulic booster. The steering gear in- cludes the steering column, the mechanical part of the steer, the drop arm, the pull-rod of the drop arm, the pull-rod of the steering linkage, the lever of the swivel member and levers of the steering linkage.
Page 104: Booster
7-steering column; 2-steering wheel; 3,4-nuts; 5-washer; 6-bolt; 7-pull-rod of drop arm; 8-steer with arm Figure 80 - Steering wheel of the cabover truck 4.4.2 Booster 4.4.2.1. Hydraulic circuit of the steering wheel (booster) is shown in figure 81. 4.4.2.2 Steer with the built hydraulic booster of the integral type. Operational gear- crew-ball nut-rod-sector.
Page 105 1-pump; 2-oil tank; 3-low-pressure pipe-lines; 4-high-pressure pipe-lines; 5-steer; 6-hydraulic distributor; a-flow line; b-high-pressure line; c-drain line. Figure 81 - Hydraulic circuit of the steering wheel (hydraulic booster). The spool and the torsion bar, the torsion bar and the wormscrew are perforated together and tightened with pins 8 and 13.
Page 107: Steering Wheel Oil Tank
Oil from the pump enters one of the head ends of the steer, depending form turning di- rection, and enhances turning movement of the drop arm due to hydraulic pressure on the piston face. Turn of the spool in reference to the wormscrew head is limited with blocks. The steer is equipped with hydraulic rotating locks, which partially bypasses oil for draining, before wheels do not turn to the full stop.
Page 108: Tie Rod Ends
1-Compressor; 2-washer; 3-pump Figure 84 - Power steering pump 4.4.5 Tie Rods Tie rod ends of the non-assembled and non-serviceable construction. Durability of tie rod ends depends on protective clutches conditions, so damaged in the operation process clutches shall be replaced. When a significant clearance has appeared in end joints, ends shall be replaced. 4.4.6 Maintenance of the steering wheel Maintenance of the steering wheel means periodic inspection of fastening of the steering wheel, pipe lines, steer free play, and also upon maintenance of hydraulic system units.
Page 109 9. When oil reaches the highest mark on the oil gage, turn the steering wheel in both sides several times until air bubbles stop float up. If necessary, refill oil. Implement the oil level control upon the unscrewed plug of the filler neck. 4.4.6.2 Setting adjustment of steer valves.
Page 111 Caution! Effort, implemented to the steering wheel rim on all stages of regulating, shall not go beyond 100H (10 kgf). It is not recommended to hold the steering wheel in the extreme position more than 5 sec. For left and right steering wheels implement the following procedure: - reach drop in pressure till 75-85 kgf/sm upon contact of the wheel turning limit stops by sequential securing of screws B1 and B2 in accordance with figure 85.
Page 112: Brake Systems
4.5 Brake Systems 4.5.1 Primary Brake System Primary Brake System is dedicated to reduce speed and to stop the truck regardless its speed, load and road slope which it is designed for. Drive of braking gears is pneumatic, two-contour, with separate braking of front and rear wheels.
Page 113 4.5.1.1 Pinch clamp is shown in Figure 87. 1-Adjusting nut; 2-tooth coupling; 3-adjusting ring; 4-rollers; 5-O-ring; 6-cleat wedge; 7-belleville spring; 8-lock ring; 9,12-spring cap; 10-sleeve; 11-housing; 13-roller cage; 14-washer; 15-adjusting bolt; 16-leaf spring; 17-calotte cone; 18-gear member; 19-protective gasket; 20-spiral spring; 21-pistons; 22-helical groove;...
Page 114 When releasing the brake the bolt 8, the adjusting nut 3, the gear ring 2 and the pistons 5 squeeze back inside. As the pin 4 bumps the helical groove “A”, the adjusting nut 3 and the gear ring 2 turn for one tooth coupling pitch. The adjusting nut 3 moves the bolt 8 outside through the thread, thus decreasing backlash appeared due to brake lining wear.
Page 115 4.5.1.1.2 Installation of the Pinch Clamp. When installing the pinch clamp follow the main rule: free end of the cleat wedge 1 (see Figure 89) should be in the housing exactly on the axis A and should not get out of alignment. If there is no alignment the installed cleat wedge can be damaged.
Page 116 Adjust “S” distance as follows: screw the adjustment bolt 8 (see Figure 88) with force until you hear a click when “B” coupling teeth skip between the gear ring 2 and the adjusting nut 3, then unscrew the bolt 8 one revolution. When assembling the pinch clamp all internal parts should be lubricated.
Page 117 1-Brake pad; 2-brake lining; 3-rivet; 4- wear indicator; *-diameter without includ- ing brake drum wear Figure 92 - Brake Lining Adaptation Scheme 1-Brake pad axes; 2-brake pad with brake linings; 3-support; 4-wedge mechanism; A,B-distances between support outer diameter and brake linings Figure 93 - Brake Pads with Brake Linings Adjustment Scheme...
Page 118 According to Figure 86: - tighten the bolt 5 with 75-85 Nm (7.5-8.5 kgfm) torque. Lubricate “d” surface with АМС-3 grease - GOST 2712-75 - before assembling lubricate “g” surface of axis 7 and “f” surface of brake pads with graphite grease - GOST 3333-80.
Page 119 Before installing the hub with the brake drum it is necessary to sink in (from the centre) the inductive sensor 2 to protect it from damage. Then slightly push the sensor against stop to the target ring. The inductive sensor 2 consists of a permanent magnet with round stem and a coil. Ro- tating motion of the sensor target gear ring induces potential pulse in the coil, frequency of which is pro-rata wheel rotation speed.
Page 120 See Figures 98, 99 how to install brake chambers. The brake chamber 1 twisting depth (see Figure 98) is 25 mm. The chamber is twisted in against stop and then is turned back until system suzie are looking back. For joint encapsulation it is necessary to use silicon-based or rubber-based sealant.
Page 121 4.5.1.7 Encapsulation System The brake chambers have encapsulation system. The Fitting 5 (see Figure 96) and fitting 4 (see Figure 97) are connected to the pipe exiting at the girder level. 4.5.2 Pneumatic Brake System Drive Brake system drive schematics of 6x6 trucks with trailer outlets is shown in Figure 100. Brake system drive schematics of 4x4 trucks differs from the above that there is no intermediate axle.
Page 122 The second circuit consists of cans, upper section of brake valve 31, primary brake relay valve 18, brake chambers 15, modulators 17. Third circuit consists of air cylinder 23, control valve of trailer brakes 12 with two-wire drive, automatic coupling heads 13,14 to couple trailers with two-wire brake drive. When footing brake pedal first and second circuits of truck brake drive are actuated, as well as third circuit of trailer brake drive.
Page 123 Legends to the Figures 100-101: - 6 mm diameter nylon tubing; - 8 mm diameter nylon tubing; - 10 mm diameter nylon tubing; - 12 mm diameter nylon tubing; - 14 mm diameter nylon tubing; - 15 mm diameter nylon tubing; - rubber hose.
Page 124 When pressure controller is actuated, pressure compatible to operating pressure in A cav- ity is fed to B cavity through “c” outlet and it impacts the piston 4 overcoming spring 1 force. Valve 2 opens and oil and condensed air collected are discharged through “d” outlet. 4.5.2.3 Water and oil separator with installed pressure controller is shown in Figure 103, it is designed to separate condensed water from compressed air to discharge it automatically from drive feeding part.
Page 125 Then, overcoming spring 7 force of the check valve 8, compressed air is fed to outlet III and then to the truck brake system. Simultaneously, compressed air having overcome spring 6 force of the throttle valve 5 having 1.5 mm diameter hole, enters the regeneration air tank through outlet II.
Page 126 4.5.2.4 Two-section brake valve is shown in Figure 104, is designed to control the actu- ators of truck primary brakes as well as to control trailer brake drive valve. Brake valve is controlled mechanically from the suspended brake pedal, ensuring filling of brake chamber cavities of each of the two circuits with compressed air as quick as necessary under control, as well as filling control cavities of other pneumatic devices of the system.
Page 127 1-Tappet; 2-screw; 3,5,6-pistons; 4-valve; 7-valve; 8-rod; 9-housing; 10-elastic member; 11-cap; III-outlet to air intensifier of front axle brake circuit; IV-outlet to РТС and air intensifiers of rear axle brake circuit; I,II-outlets to air tanks; V-atmospheric outlet; A-hole; B-cavity Figure 104 -Brake Valve...
Page 128 4.5.2.5 4-circuit protective valve is shown in Figure 105. 1-Housing; 2,6,10,14-springs; 3,13-valves; 4,12-diaphragms; 5,11-guides; 7,9-covers; 8-adjusting screw; 15-check valve; I-outlet to the compressor; II,III-outlets to the brake system circuits; a,d-throttle holes, b,c- side holes Figure 105 - 4-Circuit Protective Valve 4-circuit protective valve is designed to distribute one feeding pipeline into two main and two auxiliary circuits: automatic cut of one of the two circuits, if it is depressurized, to preserve compressed air reserve in undamaged circuits, to preserve compressed air in all circuits, if the...
Page 129 1.1-Feeding pipeline inlet; 1.2-trailer feeding pipeline outlet (to the red coupling head); 2.2-outlet to the trailer control pipeline (to yellow coupling head); 4.1-inlet from the front circuit of tractor primary brake system; 4.2-inlet from rear circuit of tractor primary brake system; 4.3-inlet from tractor parking brake sys- Figure 106 - Trailer Brake Control Valve with Two-Wire Drive and Cut Valve 4.5.2.7 Relay valve is shown in Figure 107, is installed in rear axle wheels brake system...
Page 130 Compressed air is fed from air tank to outlet I. Outlet II is connected with the brake valve, and outlet III- to air chambers of axle brakes. If there is no pressure at outlet II, piston 2 is up. Inlet valve 3 is close by spring force 4, and discharge valve 6 is open.
Page 131 c) Pressure maintaining With the help of the corresponding impulse gate to outlet 3 closes during reversing of magnet II of valve “h”. Compressed air from A chamber goes again through hole “d” to the pre- liminary control chamber “g”, and diaphragm “f” closes discharge hole “e”. Thus, locking of pressure raise or drop in chamber B is performed, and consequently, in brake cylinders.
Page 132: Emergency Brake System
Check tightness at nominal pressure in the pneumatic drive - 588 kPa (6.0 kgf/cm switched on consumers and non-operated compressor. Pressure drop in the tanks comparing to the nominal one should not exceed 49 kPa (0.5 kgf/cm ) during 30 minutes when control members are free and during 15 minutes after complete actuation of control members.
Page 133 1-Upper housing; 2-upper piston; 3-lower piston; 4-discharge valve; 5-inlet valve; 6-valve case; I-outlet from manual brake valve; II-outlet from spring-type brake actuators; III-atmospheric outlet; IV-outlet from air tank; V-outlet from brake valve Figure 110 - Parking Brake Relay Valve 4.5.4.2 Parking brake relay valve is shown in Figure 110. Compressed air from the air tank is fed to outlet IV.
Page 134 1-Housing; 2-valve; 3-spring; 4-guiding bushing; 5-thrust ring; I-compressed air inlet; II-compressed air outlet Figure 111 - Check Valve 4.5.4.4 Brake valve with manual control is shown in Figures 112, 113, and is dedicated to control spring-type brake actuators, it allows verification test of tractor parking brake efficiency to keep the whole truck on a slope.
Page 135: The Antilock Brake System (Abs)
a-handle; b,c-valves; d-discharge hole; e-piston; f-spring; A,B,C-chambers; I-driving; II-parking Figure 113 - Brake Valve with Manual Control for Trucks Having No Trailer Equipment 4.5.5 Truck Brake System with the Antilock Brake System (ABS) Antilock Brake System (ABS) is designed to maintain high-efficiency truck stability when braking at various tire-to-surface friction coefficients.
Page 136 Special ABS mode should not be used on roads as truck stability and steerability can be lost. 4.5.5.3 ABS Operation, Maintenance and Test When switching on (when the starter is turned to the position “DEVICES”) “Tractor ABS” indicator 2 switches on (see Figure 114) for conventional cab trucks and “Tractor ABS” indicator 34 (see Figure 29) for cabover trucks is on, automatic test of the electronic unit and elec- trical chains of the devices, modulators and switching units is performed, after test completion the lamp will fade, if there are no failures.
Page 137 1-Vehicle communication interface (VCI); 2-ignition switch; 3-fuses; 4-warning lamp; 5-test switch; 6-key phasers; 7-front right modulator; 8-rear right modulator; 9-rear left modulator; 10-front left modulator Figure 115 - Plug Connection Scheme of Knorr Bremze Control Unit Error codes are activated by one click on ABS test button 1 (see Figure 114) for conventional cab trucks and ABS test button 10 (see Figure 32) for cabover trucks during 0.5-8 sec, and they are displayed by warning lamp flashing (the so called blink codes are de- livered) (see Figure 116).
Page 138 Table 14 Blink Codes Description of compo- of error nent No failure Left speed sensor of steering axle Too large air breather No signal from sensor during braking Bad target ring, ABS should be maintained Unstable signal Sensor signal is lost Ground fault or battery fault, or broken wire Right speed sensor of steering axle Too large air breather...
Page 139 Break-over of Table 14 Blink Codes Description of component of error Ground fault for the lifting coil Lifting coil wire is broken Valve configuration error Left modulator of driving axle Battery fault for the clear coil Ground fault for the clear coil Clear coil wire is broken Wire of general pin is broken Battery fault for the lifting coil...
Page 140 End of Table 14 Blink Codes Description of compo- of error Decelerator interface Battery fault for brake relay or wire is broken Ground fault for brake relay ERC1 is broken Special errors Big difference between dimensions of front and rear tires ABS function “bad road”...
Page 141 1-Pressure gauge; 2-fuses; 3-warning lamp; 4-ignition switch; 5-vehicle communication interface (VCI); 6- test switch; 7-key phasers; 8-front right modulator; 9-front left modulator; 10-rear right modulator; 11-rear left modulator Figure 118 - Plug Connection Scheme of Wabco Control Unit To activate test ABS lamp should be connected with storage battery minus during 0.5-3 sec through ABS switch button (see Figure 119).
Page 142 Herein, the length of lamp connection with storage battery minus determines information display mode (if the lap is connected with battery minus 3-6.3 sec, systematic mode is activated). After pushing ABS test button during the time specified, “Tractor ABS” indicator is on for about 0.5 sec to confirm that the ground was registered and re- ceived by the electronic control unit.
Page 143 Table 16 - Troubleshooting for Wabco Error code Troubleshooting practice 2-... Check modulator cable. Wires can be broken, or their insulation is damaged 3-... Low value of sensor signal magnitude. Check bearing runout, toothed rotor runout, move the sensor towards rotor. Check sensor cable integrity and contact in plug connections. 4-...
Page 144: Electrical Equipment
4.6 Electrical Equipment Electrical equipment system is single-wire, negative terminal of power sources and con- sumers is connected to truck earth. Negative terminal of the storage battery is connected with truck earth via remote switch. Power sources are two storage batteries connected in series, and the alternator. Electrical equipment tools and devices are connected by wires with polyvinylchloride insulation of various sections.
Page 145 Break-over of Table 17 Pos. in Name Device type or Figure number Storage batteries switch 11.3704-01 Stator and devices switch 2109.3704-30 Direction indicator flasher 5412.3787010 Hand lamp socket 47К Left block of warning lamps ПД512Е Engine readiness for start-up indicator 2212.3803-17 Engine control system warning indicator 2212.3803-91or...
Page 146 Break-over of Table 17 Pos. in Name Device type or Figure number Transfer box gears switch 3742.3710-11.00 Engine idling adjustment switch 3842.3710-11.00 Search light switch 3842.3710-02.05* Cab heater mode selector switch 82.3709-25.09 Engine idling control switch 771.3709-02.00 Transfer box gear selector 82.3709-28.00 Heater electric motor Heater electric motor resistance...
Page 147: Cabover Truck Wiring Diagram
End of Table 17 Pos. in Name Device type or Figure number Stator relay 738.3747-20 Thermal bimetallic fuse 291.3722 Alternator 5340.3701010 or AAN8172 Stator 5340.3701010 Air filter clogging sensor 132.3839600 or ДСФ-70 Wind shield washer electric motor Storage battery TITAN STANDART 6СТ190.OL (ST) or 6СТ-190NЗ...
Page 148 Break-over of Table 18 Pos. in Name Device type or number Figure Right headlamp 671.3711 6, 7 Audio signals С306Д/307д-3721000 or 24./241.3721000 Dashboard 73.3801-01 Left headlamp 671.3711 Left headlamp adjuster Is in the headlamp set Left day running light 2РТ 980.680 or 2РТ 980.970 Left additional headlamp Left direction indicator 26.3726010 or 112.01.11...
Page 149 Break-over of Table 18 Pos. in Name Device type or number Figure Right electric rear-view mirror 391.8201020 Hand lamp socket 47К OBD-II(MOL51116-1601) Right repeater direction indicator 5702.3726000 Mirror heater selector 82.3709-30.18 Cab heater valve Cab heater electric motor Fuse block F1 A part of the harness 4420БМ- 3724010 Fuse block F2...
Page 150 Break-over of Table 18 Pos. in Name Device type or number Figure Transfer box gear selector 82.3709000-28.00 82а Transfer box gear switch 3842.3710-11.00 Headlight adjuster ЭМКФ35 Wind shield washer electric motor 22.5208010-01 Wind shield wiper electric drive 31.5215.000-01 Buzzer 733.3747-10 87, 88 Braking signal pneumatic switches 2802.3829 or...
Page 151: Fuses
End of Table 18 Pos. in Name Device type or number Figure Stator AZF4137 Alternator AAN5752 Air drier heating element Swivelling headlamp 112.05.44 or 20123711* 130,131, Side position lights ГФ1-26* 132,133 Trailer socket ПС325-150 or СНЦ124- 7/45В034-01 Trailer socket ПС325-150 or СНЦ125- 7/45В034-01 Right tail light 7442.3716-10 or 8512.3716-01...
Page 152 1-Terminal 15 unload relay (P2); 2-stator relay (P1); 3,4,6,8,9,11-fuse blocks; 5-terminal 15 unload relay (R3); 7-wind shield wiper relay (R4); 10-rear fog beams relay; 12-VCI; 13-brake signal pneumatic switch relay (R12); 14-outside mirror heater relay (R11); 15-stop signal relay (R10); 16-audio signal relay (R9); 17-high beam relay (R8);...
Page 153 Fuse block F1 Design current, A Symbol Dedication Engine start-up START Rear fog beams Stator and devices switch Engine electronic control unit Tail light switch, high beam indication Storage batteries switch Fuse block F2 Design current, A Symbol Dedication Independent engine heater Autonomous heater Electric torch switch Truck ABS, trailer ABS...
Page 154 Fuse block F3 Design current, A Symbol Dedication Right high beam headlamp Left high beam headlamp Left dimlight headlamp Right dimlight headlamp Sidelights, right drop side Sidelights, left drop side Fuse block F4 Design current, A Symbol Dedication Fuel heater, air drier heater Heated rear-view mirrors The interaxle lock, Power Take- Low gear (auxiliary transmis-...
Page 155: Alternator
Fuse block F5 Design current, A Symbol Dedication Electric torch, fuel heater Fuel heater Truck ABS, trailer ABS Direction indicator Control of trailer dipper, tire in- flation Devices, stop signal lamp Fuse block F6 Design current, A Symbol Dedication Searchlight, front fog beams Dashboard light, headlights ad- juster Cab light...
Page 156: Storage Batteries
- to check alternator proper functioning by short circuiting “+” and “-” plug outlet bond- ing strips of the alternator and voltage regulator; - to check alternator proper functioning with indicating lamp or megohm meter; - to switch off the storage battery with reverse polarity or to connect alternator positive outlet with storage battery negative outlet;...
Page 157 To maintain truck storage batteries without removal: - switch off storage batteries from the truck power line trough battery switch; - remove snap ring 14 of the lid 6 locks and open the locks; - lift the lid 6 up and throw it on the bracket 3. Make sure that lid 6 is securely fixed in horizontal position;...
Page 158 Main failures of the storage batteries and troubleshooting practices are given in the para- graph “Troubleshooting”. 4.6.5.3 Installation of Additional Devices to the Truck Customers can install additional devices to the truck using help of the corresponding qualified staff. External consumers are wired from the truck batteries and positive terminal located on the switching unit or in the area of 4 bayonet bases on the cab front board through additional fuses of the corresponding capacity not exceeding 20A in total.
Page 159 Figure 123 - Engine Electronic Control Unit Wiring Scheme...
Page 160: Lighting And Alarm System
4.6.6 Lighting and Alarm System Lighting and alarm devices include two headlamps, front and back lamps, registration plate lamp; searchlight, backing light, master lighting, under bonnet lamp and dashboard lamp, warning lamps located on the control panel. Audio alarm is given by electric signal of low and high tone. Signals are actuated by the switch located on the understeering switches.
Page 161 Mount and dismount terminal strips of actuators and control units only when truck storage batteries are switched off. Change lamp bulbs with dark envelopes not waiting their blowing out. When changing the blown bulb, restore optic component tightness. Auto bulbs used on the truck and their specifi- cations are given in Appendix F.
Page 162: Cab, Trim Package And Platform
4.7 Cab, Trim Package and Platform 4.7.1 Cab The cab of the cabover truck - two-seat, spring-mounted, equipped with the heat and sound insulation, the spring-mounted driver seat and the passenger seat, the ventilation system, the heating system and the heating system of windshields, the vehicle sun roof, sunscreens, the wind shield wiper, the windshield washer, rear view mirrors, side view mirrors and wide-angle mirrors, and also the forward view mirror and could be completed with the independent heating unit.
Page 163 ’ 1-mirror; 2-viewing area of road surface; 3-point of driver s eyes Figure 126 - Viewing area through the side view mirror (V class) ’ 1-forward view mirror; 2-viewing area of road surface; 3-point of driver s eyes Figure 127 - Viewing area through the forward view mirror (IV class) for cabover trucks 4.7.1.1 Driver’s Seat.
Page 164 The seat could be adjusted in height, inclination of the cushion and the back and regula- tion of the fore-and-aft motion. Control (adjusting) devices of height and cushion and back angle are located on the left side of the seat, devices of fore-and-aft motion and seat suspension stiffness are in the front part of the seat.
Page 166 The shock absorber adjustment in four positions depending on the road surface. When lifting the button 7 up, suspension stiffness increases, when pushing down – decreases. When lifting the lever up, the seat rises, when pushing down - decreases. When the but- ton 6 is pushed, it is fixed in the chosen position.
Page 168 Regulate spherical mirrors, providing the viewing area though them according to figures 124, 125, 126 by loose tension bolts of holders and mirrors, and them fasten them properly. The cab is fastened to the truck frame in 4 points of rubber pads. Upon frame defor- mation elastic fastenings preserves cab parts from overload.
Page 169 1-power window handle; 2-opening door handle; 3-closing door handle; 4-button for door blocking from inside Figure 132 - Conventional cabin doors 4.7.1.2 Doors of the cabover truck are shown in figure 133. Doors are equipped with locks for locking doors. Outside the door is locked with the key, inside – with the blocking button. When opening the door, the automatic switch-on of the cabin indoor light above the driver and the passenger upon the correspondent position of the master lighting switch.
Page 170 4.7.1.3 Wind shield wiper and washer. The cab is equipped with the wind shield wiper and the washer. The double-speed wind shield wiper consists of the electrical drive, two pull-rods, wiper levers and two wipers. The wind shield wiper is turned on by the switch located on the steering mast.
Page 171 The pet cock 11, located on the right engine water pipe, shall be opened during operation at sub-zero air temperatures. In summer the heating unit shall be unplugged from the cooling sys- tem, by closing the pet cock 11. When using water as coolant at sub-zero air temperatures, close the heating unit tap be- fore filling the cooling system to prevent cold water penetration in the heating unit radiator and its freezing.
Page 172 The lever 13 regulates fresh air intake in the cab. When the lever is in the right position, the recirculation air flap is closed (air for heating is taken from the cab), in the left position the recirculation air flap is opened (air is taken from outside). The cab ventilation is realised through the ventipane, movable door windows and quarter windows, and in summer season –...
Page 174: Trim Package
4.7.2 Trim Package For ease of maintenance of the engine and the conventional truck separate trim package nots are demountable. The trim package is attached to the truck frame with the rubber bearing shoe and to the cab with rubber bumpers. The alligator hood with the opening angle 90°. 4.7.3 Platform Demountable, metal platform is designed to transport packaged cargos, cargos on stand- ard pallets and people.
Page 175 1-canopy fixation rope; 2-ceiling fixation rope; 3-stay tube of bow; 4-canopy bow; 5-canopy Figure 137 - Platform with the canopy – I-VIII canopy folding order Figure 138 - Method of canopy folding 4.7.3.1Adjustment of the device for platform rack locks. Aim of the adjustment is achievement of secure rack locks and fixation of lock handles in the position CLOSED.
Page 176 For adjustment implementation: 1. Move the handle 7 in the position OPENED. 2. Remove the screw 5 with the spring washer 4. 3. Push the tappet axle 6 out of the handle hole 7. 4. Remove the tappet 3 from the handle groove 7. 5.
Page 177 Figure 140 - Installation of left and right side safety devices.
Page 178: Fifth-Wheel Coupling
4.8 Fifth-Wheel Coupling The tractors have a fifth-wheel coupling that is dedicated for: flexible coupling of the tractor with the semi-trailer having king pin of 50 mm diameter; transfer of drawbar power from the trac- tor to the semi-trailer; manual-automatic hitch and separation of the tractor and the semi-trailer. Fifth-wheel coupling consists of a fifth-wheel 8 (see figure 141), brackets 7 and detachable coupling mechanism.
Page 179 4.8.2 Fifth-Wheel Coupling Maintenance Before each trip: 1. Check if the safety lever is closed. 2. Make general visual inspection of the fifth-wheel coupling and mountain frame to check if they are well coupled, have no wear, corrosion or damage. 3.
Page 180 Coupling and uncoupling should be done on a horizontal platform with hard surface. Herein, longitudinal axes of the tractor and of the semi-trailer should be in line. Coupling should be done as follows: - make sure that the locking element of the fifth-wheel coupling was completely up, and un- locking handle was in ready-for-unlocking position as shown in figure 143.
Page 181 When coupling the tractor with various models of semi-trailers regulate the distance be- tween hose clips to avoid their breakage due to friction on the tractor extensions. Before uncoupling choose even area for the semi-trailer park. Uncouple the tractor as follows: - brake the semi-trailer with the parking brake;...
Page 182: Dedicated Equipment
4.9 Dedicated Equipment Auxiliary devices wiring schemes, their drives and power takeoff modes should be ap- proved by the manufacturer. Propeller shafts installed by a customer to drive auxiliary devices must have maximum 40 g*cm out-of-balance and 150 N (15 kgf) propel effort in spline joints. 4.9.1 Power Takeoff Power Takeoff is single reduction, it is fastened to gearbox crankcase on the right and is dedicated to drive auxiliary devices.
Page 183 When switching on the Power Takeoff compressed air goes to the diaphragm chamber of the selector mechanism. Diaphragm 6 (is shown in Figure 145) couples the idle shaft gear 5 with the drive gear 3 through the rod 10 and the fork 9. The rod 10 impacts the switch 12 making switch contacts, and Power Takeoff indicator flashes on the dashboard.
Page 184: Additional Power Takeoff
4.9.2 Additional Power Takeoff Power is taken from the main shaft of the transfer box through flexible clutch 2 (see Fig- ure 147) and is used for winch drive. Additional Power Takeoff operation is possible at any gear of the transfer box, neutral including.
Page 185: Winch
When the additional Power Takeoff is operated, there should be no excess overheating of transfer box main shaft bearings and PTO. Excess overheating proves the oil pump failure. Pump proper functioning should be tested by two people. To check pump operation: -Tighten the parking brake lever as far as it goes;...
Page 186 1-oil cup; 2-thrust washer; 3-star; 4-drum shaft bracket; 5-nut; 6-lock washer; 7-sliding bearing; 8-distance sleeve; 9-drum; 10-drum shaft; 11,15-bolts; 12-gearbox cover; 13-rope guardrail; 14-fixed clutch; 16,24,28,33-adjusting gaskets; 17,25,27,38-bearing caps; 18,23,29,31,32-bearings; 19-gearbox crankcase; 20-worm gear; 21-plug; 22-flexible clutch; 26-flange; 30-gearbox worm; 34-gasket; 35-band brake; 36- rope retaining bracket;...
Page 187 Check bearing preload of the worm gear shaft when coupled with the worm. Torque necessary for rotating the worm gear shaft in the bearings must be 3-6 Nm (0.3-0.6 kgfm). After bearing adjustment check the correctness of worm-and-worm gear coupling by blueing by teeth contact pattern.
Page 188 1-Universal joint fork; 2-safety pin; 3-propeller shaft; 4-needle bearing cap; 5-locking plate; 6-centre piece; 7-slide yoke; 8-O-rings Figure 149 - Front Propeller Shaft of the Winch Drive All universal joints are similar in their construction and unified with GAZ-53A truck joints.
Page 189 1-Winch cross member; 2,14-adjusting gaskets for chain tension (right and left); 3,12-actuating screw brackets (right and left); 4,11-nuts; 5-locking plate; 6-actuating screw; 7-guiding rollers; 8-horizontal roll- er; 9-horizontal roller bracket; 10,16-drive and idler sprockets; 13-chain; 15-drum shaft bracket; 17- guiding roller stud; 18-bushing; 19-guiding roller; 20-actuating screw slide block; 21-slide block support cover;...
Page 190 Increase engine crankshaft rpm smoothly. Sharp increase of the engine rpm will not lead to drawbar power increase of the rope, but it can cut the safety pin. When the pin is cut, immedi- ately disengage the clutch and move the gear lever to neutral, otherwise the shaft can be stuck in the flange.
Page 191: Tire Pressure Control System
1-A fixed object; 2-block; I-drawbar force in- crease when self-winching; II-drawbar direction change when winching another vehicle; III- drawbar force increase when towing another ve- hicle; IV-rope lay at carry Figure 151 - Winch Block Usage 4.9.4 Tire Pressure Control System Tire pressure control system (for a conventional cab truck) is shown in Figure 152, and it allows pressure control and pressure maintaining within the normal limits, as well as off-road perfor- mance due to tire pressure decrease.
Page 192 1-Hoses; 2,3,5,6,7-pipelines; 4-solenoid valve; a - to the front wheels pressure gauge; в - to the rear wheels pressure gauge Figure 152 - Installation of Air Pressure Control System in Tires with a Solenoid Valve on a Conventional Cab Truck 1,2-Tube to tire pressure gauges;...
Page 193 Table 20 - Pressure Norm for 425/85R21 Tires and 156 Lifting Capacity Index Road type Allowable Maximal speed, Maximal run during pressure, km/h the guarantee period, kgf/cm (MPa) not less than: Difficult paths of moorland, 0.8 (0.08) virgin snow and quicksand 1.1 (0.11) 2.0 (0.20) 1400...
Page 194 1-Hoses; 2,3,5,6,7,8-pipelines, 4-solenoid valve Figure 154 - Installation of Air Pressure Control System in Tires with a Solenoid Valve on Cabover Trucks Solenoid valves have three operating positions: DEFLATE, NEUTRAL AND INFLATE and ensure pressure decrease in 4-6 min depending on tire standard size according to OST 37.001.144-73.
Page 195: Troubleshooting
5 Troubleshooting Troubleshooting practice Failure Possible cause Transfer Box Loud noise Insufficient oil quantity in Fill oil until the oil level check the transfer box plug Main and lay shaft axial Adjust the bearings or replace movement is big them by new Gears self-disengagement Gear shift clutch and yoke Replace worn parts...
Page 196 Troubleshooting practice Failure Possible cause Steering wheel Unstable truck move- Steer unfastening Fasten the crankcase and steer ment, bracket retaining nuts “Hard” steering wheel Air or water in the system Discharge air If the air is not dis- (foam in the tank, cloudy oil) charged, check tightening of all hydraulic joints, replace the filter If the above measures did not help,...
Page 197 Troubleshooting practice Failure Possible cause Fast battery self-discharge Failure of all Give the battery for repair or several storage batteries Battery leads are dirty with mud or battery fluid covering Clean the battery with dry cloth, the battery surface then with a cloth moisten in 10% ammonia spirit solution or soda ash solution Battery fluid has contami-...
Page 198 Troubleshooting practice Failure Possible cause The power takeoff doesn’t The power takeoff switch re- Replace the spring switch on coil spring is broken Control valve rod is stuck Disassemble the valve, elimi- nate the sticking and grease the housing surface of the rod with thin layer of ЦИАТИМ-201 lubricant No backlash between the valve Replace control valve...
Page 199 Troubleshooting practice Failure Possible cause The drum is jammed The rope letoff due to viola- Unwind the rope, remove the tion of operation rules: when the winch from the truck, if necessary, rope is forced out its sag and replace the defective parts The rope is wound to the drum without necessary pulling Wind the rope again...
Page 200: Operation Features
6 Operation Features 6.1 New Truck Preparation for Operation Study the present operation manual before operation of the new truck and provide daily maintenance and additionally: 4. Check the coolant level and, if necessary, refill. 5. After filling of the fuel tank fill with fuel the engine feed system by means of hand fuel feed pump.
Page 202: Truck Driving
- do not decrease the inflation pressure of tires. Tractor units operation during the first 1500-3000 km of mileage provide on the roads with hard surface with the semi-trailer gross mass no more than 12 tones, After 1500-3000 km of mileage (50-100 hours of engine performance) implement the works, specified in the paragraph “Maintenance”.
Page 204 If the differential lock of intermediate and rear axles is not turned on or turned off, it is necessary to push the truck (back and forward) until indicator lamps will light up or blink off. Turn on the box of auxiliary power takeoff and the power takeoff box when the truck stopped, the clutch is turned off and the pneumatic-system air pressure is below 500 kPa (5 kgf/sm ).
Page 206 To avoid the penetration of water and mud in the tool kit, firmly press the cover of the tool kit with the central screw. After ford passing open the tool kit, remove water and dry tools. After ford passing check oil level in the engine and truck units. Increased oil level, pres- ence of water drops on the oil level indicator or oil colour change are signs of water penetration.
Page 208 Towing hooks and towing eyes, sizes of which differ from the mentioned above, have to be replaced with new ones. When driving reverse, avoid trailer assembling against stop of trailer hitch in the frame girder face or other truck elements. Failure to comply with these instructions may result in seizure of the eye trailer in the towing hook jaw and breakdown of the towing hook.
Page 210 If to release the brakes of pressure accumulators with air is impossible, then unscrew bolts on pressure accumulators in accordance with figure 97. Check-up examination on the way. In half the hour after towing beginning and then every 1.5-2 hours it is necessary to inspect hooking devices, fastening of the emergency stop sign (if it is installed), check to the touch thermal conditions of transmission unit crankcases and wheel bosses, if they are damaged.
Page 211: Maintenance
7 Maintenance Maintenance is intended for maintaining of the truck in working order and appropriate outer appearance, for decreasing of the wear-out rate of details, preventing failures and malfunc- tions, and also their identifying for timely elimination. Maintenance is a preventive measure, compulsory for implementing on a regular basis after specified lifetime mileages or working peri- od of the truck.
Page 213: List Of Truck Maintenance Operations
7.1 List of Truck Maintenance Operations Recommended equip- Axle configura- Scope of work Technical specifications ment, devices and tools tion 4х4 6х6 Daily Maintenance (ЕО) Maintenance before departure Inspect the truck and check, if there is the leakage of the fuel, oil or special liquids, air leaking.
Page 215 Recommended equip- Axle configura- Scope of work Technical specifications ment, devices and tools tion 4х4 6х6 - primary brake system; Check the operability Truck manometer, of alarm indicators. In this malfunction indicator regard push the button of of brakes on the dash the operability check of board.
Page 217 Recommended equip- Axle configura- Scope of work Technical specifications ment, devices and tools tion 4х4 6х6 If necessary, wash the truck and Manual wash from a clean up the cabin and the plat- hose, brushes, waste form without wetting the floor cloth upholstery and the engine com- partment.
Page 219 Recommended equip- Axle configura- Scope of work Technical specifications ment, devices and tools tion 4х4 6х6 4х4, 6х6 trucks The same (cabover): clutch pedal free travel should be in the range from 2,5 to 5,5 mm. Full travel – from 135 to 150 mm. Check tightening and, if necessary, tighten up retaining nuts of:...
Page 221 Recommended equip- Axle configura- Scope of work Technical specifications ment, devices and tools tion 4х4 6х6 - Front spring U-bolt; Loosening of the fasteners is Socket wrench not allowed. Tighten the truck 30x32 for spring U- with full load. bolts nuts, tire iron with hydraulic jack handle - Rear spring U-bolt;...
Page 223 Recommended equip- Axle configura- Содержание работ Technical specifications ment, devices and tools tion 4х4 6х6 Check fastening and, if necessary, tighten the retaining nut of: Control arm pin; Wrench 32x36, Loosening of the fasteners is pliers not allowed. - Retaining bolts of the steering unit to the mounting bracket and the -«-...
Page 225 Recommended equip- Axle configura- Scope of work Technical specifications ment, devices and tools tion 4х4 6х6 in storage batteries, if nec- for storage batteries distilled water, glass essary, add distilled water. tube with the diameter 3-5 mm Check fastening and re- Fastening of cable terminal Wrenches 14x17,...
Page 227 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 Replace oil in the Oil level in the gearbox Wrench 14х17, tank gearbox YAMZ-0905 or housing should be not lower for pure oil and tank for YAMZ-1105 with cleaning than the lower edge of the check used oil.
Page 229 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 Check and, if necessary, Oil level should be below the Wrench 27x30, ramp oil level up to the edge of the level-fill opening. dispenser of 133М mod- norm in steer knuckle hous- Oil leakage through a plug is el, waste cloth...
Page 231 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 Lubricate the interme- Lubricate through oil filet -«- diate bracket shaft of the before the appearance of the clutch linkage and the fresh lubricant. brake valve. Unified Maintenance through every 15 000 km of lifetime mileages (500 hours of engine running) Engine...
Page 233 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 Трансмиссия Check and, if necessary, For trucks 4х4, 6х6 (with Wrenches 14x17, adjust free and full travel of conventional cabin): clutch pe- 17x19, pliers, scaled rule the diaphragm single-disk dal free travel should be in the clutch pedal (see subpara-...
Page 235 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 Check tightening and, if necessary, tighten up retaining nuts (upon every sixth Maintenance-15000) - universal shafts; Loosening of the fasteners is Box wrench 24x27 - lever, upper and low- not allowed.
Page 237 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 - Torque arm stud. Loosening of the fasteners is Head wrench for 50, not allowed. If holes for cotter tire iron, pliers, screw- pin do not match during nut driver, drive pin, hammer torque, tighten the nuts.
Page 239 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 - Hold-down bolts of Loosening of the fasteners is Wrenches 22x24, the steering unit to the not allowed. 27x30, wrench mounting bracket and the 24x27 mounting bracket to the frame;...
Page 241 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 Electrical Equipment Check fastening of the stor- Loosening of the fasten- Wrenches 17x19, age batteries container mounting ers is not allowed. 22x24 bracket to the frame. Check fastening of the starter Loosening of the fas- Wrench 22x24...
Page 243 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 Let the additional power The presence of the Wrench 12x13 takeoff operate for 10 minutes pressure oil pulsation in and check the pumping action the plug hole DOM. DOM (see paragraph “Dedicated Equipment”, subparagraph “Ad- ditional Power Takeoff”)
Page 245 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 Check and, if necessary, Oil level should be be- Wrench 27x30, ramp oil level up to the norm in low the edge of the level- dispenser of 133М...
Page 247 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 - needle bearings of the univer- sal shafts: - drive gears of the intermedi- Finish lubrication be- Lever type grease gun, ate (for the truck 6x6), rear and fore the appearance of the waste cloth front axles (for the truck 4x4),...
Page 249 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 change oil when reaching 45000 km of lifetime mileage. Oil level in the gear- box housing should be not lower than the lower edge of the check hole. Maintain the dry-type filter After every mainte- Wrench 14х17, screw-...
Page 251 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 Lubricate the intermediate Lubricate through oil The same bracket shaft of the clutch linkage filet before the appear- and the brake valve (upon every ance of the fresh lubri- Maintenance-15000).
Page 253 Recommended equipment, Axle configu- Scope of work Technical specifications devices and tools ration 4х4 6х6 Lubrication after every 10 000 km Check and, if necessary, Oil level in the gear- Wrench 22 box housing should not ramp the oil level up to the be lower than the lower norm gearbox...
Page 255: Truck Lubrication
7.2 Truck Lubrication General In the Lubricants and Hydraulic Fluids Charts instruction for the usage of combustive and lubricating materials of domestic manufacture and their foreign analogues upon truck opera- tion in the conditions of moderate climate are given. Detailed recommendations and procedure of lubrication of separate parts are specified in respective sections of the operation manual, enclosed to every truck.
Page 258 7.3 Lubricants and Posi- Name of the lubrication point Quantity of Leading brands, Duplicating brands, tion or the fuelling system seasonality of seasonality of points on the operation operation fig. 156, Engine feed system See the operation maintenance for operation of YAMZ engines Engine crankcase: YAMZ-536...
Page 260 Hydraulic Fluids Charts Foreign analogues quantity of combustive Periodicity of lubricating or Lubrication recommenda- and lubricating materi- replacement (replenishment of tions (refilling, oil replace- combustive and lubricating ma- ment or lubrication) terials) Norm Total for Leading Duplicating level of the truck brand brand the filling...
Page 261 Transfer Box All-season: All-season oil: Lukoil ТМ-4 SAE Lukoil Oil ТМ-5 SAE 80W-90, G-TRAC 80W-90 API GL-5 GL-4/GL-5, 80W-90, G-BOX GL-4/GL-5 75W-90, TRANS KP-2 SAE 80W-85 TRANS KP-4 SAE 80W-90 Oil ТСп-15К (at temperature below minus 30 Oil ТСп-10К (at temperature below minus 45 Additional power take-...
Page 262 Shell Dentax G 3.50 3.50 Maintenance 1500-3000 Replace oil. Refill oil 80W-90, below the edge of Mobilube GX 90, the level-fill opening Energear EP 80W-90 Transmission oils with serviceability level according to GL-4/GL-5, SAE J306 viscosity Maintenance-15000 Check oil level and , if grade: 70W75W- necessary, refill below the...
Page 263 Wheel-hubs of the rear Litol-24 Lubricant Litol- equalizing beam suspension 24PK 9, 8* Gear casing of the winch Oil used for the engine Oil ТСгип (Transmission oil used for the hypoid gear) Hydraulic system of Oil ВМГЗ (multi- ГИПОЛ-РС steering gear grade low-temperature (GIPOL RS) - RBL C 700-V...
Page 264 Shell Gadus 0.15 Maintenance 1500-3000 Lubricate through oil V220 2, RENOLIT Maintenance-15000 filler before the appear- EP2, Shell Gadus ance of the fresh lubricant S2 V100 3, Mo- out of the filler ring. bilgrease XHP 222, Energrease L2 Mobilube GX 140, Upon every third Check oil level and, if Shell pirax GX 140...
Page 265 Steer knuckle housing of Combination of 35 % Combination of 35 the front driving axle of lubricant Litol-24 and % of lubricant Lita and 65% of oil for drive axle 65% of oil for drive gear boxes axle gear boxes Universal shaft joint Lubricant Litol-24 Lubricant 158...
Page 266 Maintenance 1500-3000 Check lubricant level in the node and, if neces- sary, refill. Fill lubricate below the edge of the level-fill open- Upon every fifth Replace lubrication Maintenance-15000, but not less one time in three years Shell Gadus S2 Maintenance-15000 Lubricate through oil V220 2, RENOLIT filler before the appear-...
Page 267 8, 7* Wheel hubs Lubricant Litol-24 Lubricant Lita (6х6) Lubricant MC - 1000 (4х4) Cavity below the protec- Lubricant Lita tive ring of the equalizing beam hub Needle bearer Lubricant Litol-24 Lubricant Lita steering head Steering-shaft bearing...
Page 268 Shell Gadus S2 Upon every second Change lubricant. V220 2, RENOLIT (6х6) (6х6) Maintenance-15000 Apply lubricant on the EP2, Shell Gadus working area of gaskets S2 V100 3, Mo- and preliminary put it in bilgrease XHP 222, the space between the Energrease L2 bearing and the gasket.
Page 269 Gear shift control: Lubricant Litol-24 Grease Ж and grease C - parts of the ball lock of the lever handle selector - cavity of the hinged bear- ing level housing - yoke end hubs Lockout mechanism: - exterior surface of the in- ternal movable pull-rods Power contacts of battery Lubricant Litol-24...
Page 270 Shell Gadus S2 0.005 0.005 Upon maintenance V220 2, RENOLIT lubricate EP2, Shell Gadus S2 V100 3, Mo- bilgrease XHP 222, Energrease L2 0.04 0.04 0.0025 0.005 0.0165 0.005 Shell Gadus S2 0.0005 0.002 Upon maintenance. Apply a thin coat of V220 2, RENOLIT lubricant EP2, Shell Gadus...
Page 271 Axles and rollers of the Lubricant Litol-24 Grease Ж and grease C spare wheel holder Gearing pivot joint of the fuel intake control Bushings of towing de- vice Top bearings with steer- ing knuckle pivots of the front driving axle Slip joints of - universal joints - steering wheel...
Page 272 Shell Gadus S2 0.008 0.032 Upon maintenance V220 2, RENOLIT lubricate EP2, Shell Gadus 0.0033 0.020 Maintenance - 15000 Lubricate the work- S2 V100 3, Mo- ing areas when disman- bilgrease XHP 222, tling Energrease L2 0.025 0.05 Maintenance 1500-3000 Lubricate through oil Maintenance-15000 fillers before the appear-...
Page 273 Lift reduction unit of the Lubricant Litol-24 Grease Ж and spare wheel grease C Plain bearer of the winch drum Guide rollers axle Intermediate bracket shaft Graphite lubricant Grease Ж, grease C or of the clutch linkage and the УСсА oil Litol-24 brake valve Roller winch bearings...
Page 274 Shell Gadus 0.05 0.05 Lubricate when dis- V220 2, RENOLIT mantling EP2, Shell Gadus S2 V100 3, Mo- bilgrease XHP 222, Energrease L2 0.025 0.025 Upon every third Lubricate through the Maintenance-15000 oil filler before the ap- pearance of the fresh lubricant 0.035 0.07...
Page 275 Working areas of the Graphite lubricant УСсА Grease Ж, grease C or oil driving screw of the roll- Litol-24 er winch and the guide shaft Bushing rollers and holder-body cavity guide rollers of the roller winch Block thorn Chain gearing of the roller Graphite lubricant УСсА...
Page 276 Alvania HDX2, 0.15 0.15 Lubricate after every Rhodina EP2, third use of the winch Mobilgrease № Graphited Upon every third Apply lubricant (if Maintenance-15000 the winch was not used) 0.033 Upon every third Apply lubricant Maintenance-15000 0.004 0.004 Upon every third Apply lubricant Maintenance-15000 Alvania HDX2,...
Page 277 Sheets of front and Graphite lubricant УСсА Grease Ж, grease C or oil rear springs Litol-24 Screw thread of front Oil ТСгип and rear spring U-bolt Power contact on the Oil Litol-24 Grease Ж, grease C battery Junctions in the points Oil Litol-24 Grease Ж, grease C of the battery wire connec-...
Page 278 Alvania HDX2, 0.325 1.300 Lubricate the concave sur- Rhodina EP2, face of sheets after disman- Mobilgrease tling of the spring, prelimi- № nary clean them off corrosion Graphited 0.0025 0.02 Lubricate threaded part when dismantling, pre- liminary clean it off corrosion and mud Shell Gadus S2 0.0005...
Page 279 Pedal brake caliper Lubricant AMC-3 Sealing component on and wedge mechanism rubber or silicone base Lubricant AMC-3 Sealing component on rubber or silicone base Expanding sleeve, brake shoe axle and brake caliper Graphite lubricant УСсА Grease Ж, grease C or oil Axles and areas of Litol-24 brake shoes...
Page 280 When dismantling Before assembling the axle Д and the surface of the brake shoes Г, lubri- 0.0075 0.09 cate them with graphite grease. Apply lubricant АМС-3 on the surfaces Н, М, Ж, А 0.0022 0.08 Alvania HDX2, 0.005 0.06 Rhodina EP2, Mobilgrease №...
Page 281 Telescopic shock ab- Shock-absorber fluid Shock-absorber fluid sorbers of front and rear Lukoil - АЖ ГРЖ-12 springs for trucks 4х4, of front springs for trucks 6х6 Hydraulic fluid power Brake “ ” Brake fluid of declutching fluid “ ” Neva РОСДОТ...
Page 282 Shell Tellus T15 0.850 Change fluid after dismantling and mainte- nance, washing out de- (for trucks tails of the shock absorb- 4х4) er in the kerosene and 1.700 drying them. (for trucks 6х6) Shell Donax B, ЕО Check fluid level Brake Fluid and, if necessary, refill.
Page 283: Storage
8 Storage 8.1 Guideline The new truck, if it is not put into service, could be kept without conservation within three months starting with the date of the shipment from the factory. In this case after installation of the truck in the storage place it is necessary to protect the undyed surfaces of the front axle ball-unit with the fine coat of the lubricant Litol-24 or grease, to provide the maintenance service of the battery energy storage and tires in accordance with the operational guidelines.
Page 284 The plug connector of the rear lights, the number plate light, backing lights, connections of the air-pressure sensors in balloons; Terminal connections of the failure sensor in the brake system and the light switch STOP; Leading out pole terminals of the storage batteries with wire terminals. Lubricate the external undyed surfaces of the front axle ball-units, open surfaces of the transfer box stem and additional power takeoff with the thin coat of the lubricant Litol-24.
Page 285 Lubricate hinged connections of the secondary brake, the tool box, storage batteries containers, flat-car side walls, cabin doors, the hood, door and hood locks with preservative (engine or transmission) oil. Glue up holes, connecting the internal cavities with atmosphere on the brake valve, the pressure regulator valve, the trailer brake-application valve, the condensed water drain valve, hermetization pipes behind the cabin with adhesive tape.
Page 286 Check the air pressure in tires and ramp it up to norm; Remove the truck from supporting blocks and release springs; Unseal the feed, gas exhaust and ventilation systems of the engine and the oil tank; Remove the protective lubricant from outward surfaces with the cloth moisten in the unleaded fuel or dissolvent;...
Page 287: Transportation
9 Transportation The trucks could be transported by railway, water, air transport or under its own power. The type of transport is stipulated by the delivery contract. And the following preparatory works shall be implemented: 1. Before loading check and, if necessary, ramp the air pressure in tires up to norm and close wheel valves.
Page 288 Figure 159 – Plan of Loading and Fastening of Trucks on Four-Axle Platforms (for 4x4 Trucks) In every separate case, negotiate the transportation terms and conditions with the communication dispatch station. 9.1.2 Upon truck transportation by air the preparatory works shall be implemented and the cushioning by the special tools, which are manufactured and delivered by the consignor, shall be additionally turned off.
Page 289 Place and fasten trucks according to the ship scheme. Responsibility for placement and fastening of the truck upon transportation is on the carrier. equalizing beam suspension axle (for trucks 6х6), rear axle (for trucks 4х4) Figure 160 – Fastening of the Truck on the Upper Deck Hold Figure 161 - Fastening of the Truck in the...
Page 290: Disposal
10 Disposal At the end of the service life, the truck has to be disposed. In this regard, implement the following: - Wash and dry the truck; - Remove the storage batteries; check them for the serviceability for the further exploitation;...
Page 291: Appendices
APPENDICES APPENDIX A (recommended) Table A.1 - Torques of Basic Screw Joints Nm (kgfm) A.1 Engine Retaining nuts: of the muffler 24 -36 (2.4-3.6) of the headpipe to discharge manifold collar 28 -36 (2.8-3.6) of power unit support to the girder 78 -98 (8-10) of rear brackets to the support 270 -340 (27-34)
Page 292 Break-over of Table A1 of thru shaft and conical and cylindrical pinion bushing sleeves 60 -80 (6.0-8.0) of conical pinion bushing sleeve cover and swivel member seal 12 -18 (1.2-1.8) of the main gear side cover 44 -56 (4.4-5.6) of the differential bearing caps 250-320 (25-32) Retaining nuts: of the main gear to the axle case...
Page 293 Break-over of Table A1 - front spring (for 4x4 and 6x6 trucks) front brackets and rear spring (for 4x4 trucks) rear brackets to lower frame 120-160 (12-16) - front spring rear brackets to girder reinforcement (for 4x4 and 6x6 trucks) 180-220 (18-22) - balance shaft assembly with balance shaft brackets (for 6x6 trucks)
Page 294 End of Table A 1 A.7 Cabover Truck Cab suspension, bolts and retaining nuts: М12 68.6 -98 (7-10) М14 107.8 -156.9 (11-16) М16 156.9 -215.74 (16-22) A.7.1 Conventional Cab Trucks Cab fixing bolt nuts: 60 -80 (6-8) Cab fixing bolt lock nut: 120 -160 (12-16) A.8 Fifth-Wheel Coupling Fifth-wheel coupling fixing bolts:...
Page 295: Appendix B Control And Adjustment Information
APPENDIX B (recommended) Table B.1 - Control and Adjustment Information о Coolant temperature in the cooling system, С 75-100 Transfer box main and lay shaft axial movement, mm 0.03-0.08 Clutch pedal travel (cabover trucks), mm Free play Full travel 105-115 о...
Page 296 APPENDIX C (reference) Table C 1 - Weight of Basic Assembly Units (without fuel, lubricants and fluids), kg Transfer Box Front driving axle with bosses, brakes and tie rod end Rear (intermediate) axle with bosses and brakes Truck frame: Short base Long base Towing device Front spring (for 4x4 and 6x6 trucks)
Page 297 APPENDIX D (reference) Roller Bearings Table D.1 - Truck roller bearings with 4x4, 6x6 wheel arrangement Identification Bearing type Dimensions*, mm Place of installation Q-ty 307A The same 35x80x21 Power takeoff idle shaft 64805 Single-row radial roller 25x38x24.7 Power takeoff pinion without races 211A Single-row radial ball...
Page 298 Break-over of Table D1 Identification Bearing type Dimensions*, mm Place of installation Q-ty 2007124А or The same 120x180x38 Wheel bosses 6-200712АА 2007118К1 Single-row roller coni- 90х140х32 Intermediate and rear axle main gear differen- tials 12318KM Radial roller with 90x190x43 Axle drive bevel gear short cylindrical rollers 7516A or Single-row roller coni-...
Page 299 End of Table D1 Identification Bearing type Dimensions*, mm Place of installation Q-ty 180508K2C17 Single-row radial ball 40x80x23 Winch drive coupling shaft (thrust bearings) 46310AK Single-row angular ball 50x110x27 Winch gearbox worm (front support) 312A Single-row radial ball 60x130x31 Winch gearbox worm (rear support) 8311 Ball single thrust...
Page 300 APPENDIX E (reference) Table E1 - Oils, Lubricants and Special Fluids Main grade Backup grade Quantity of one-time fuelling for one truck Identification Standard Identifications Standard Truck Truck 4х4 6х6 Diesel fuel GOST R See Operation Manual for the En- See Technical Specifica- 52368-2005, gine...
Page 301 End of Table E 1 ВНИИ НП 510 TS 38 101 0.008 kg grease 910-82 Lukoil-АЖ damp- TS 0253- ГРЖ-12 TS 0253-048- 3.4 l 1.7 l ing fluid 025- 05767924-96 00148599- 2001 “Томь” brake fluid “Нева”, TS 6-01-34-93 2.3 l 6-01-1276-8 “Роса”...
Page 302 APPENDIX F (recommended) Table F.1 - Auto Bulbs and Their Specifications Place of installation Bulb type Quantity for one truck Headlamp АКГ24-75+70-1 Front light А24-21-3 А24-5 Tail light А24-5 7442.3716 А24-21-3 Side marking lamp А24-21-3 Master lighting А24-21-3 Warning, indicating and instrument lamps А24-2 Front side light А24-5-1...
Page 303 APPENDIX G (reference) Used oil discharge standard, l Engine 21.0 Gearbox Transfer Box Driving Axles Gearboxes 19.0;13.0* Steering Wheel Hydraulic System Winch gearbox ________________ * for 4x4 wheel arrangement trucks...
Page 304 APPENDIX H (reference) 3.1. Spare Parts, Tools and Accessories For each truck the plant supplies single spare parts kit-0, tools and accessories. On the customer’s request the following can be added: - warranty spare parts kit for the power unit consisting of the tools, accessories and spare parts;...
Page 305 Break-over of Table H.1 In a kitbag (see figure H.1) Pliers 22x24 box spanner 17x19 box spanner 27x30 key 22x24 key 19x22 key 14Х17 key 11Х13 key 10Х12 key 8Х10 key 5.5X7 key Figure H.1 - Truck Tools...
Page 306 Break-over of Table H.1 Position No. Item Quantity in the figure Kitbag Socket wrench 24 A key for replaceable heads “FORCE” filter unseating tool 6x6 combination wrench 14x14 combination wrench Crankshaft revolution gear Hex key wrench 10x10 bent socket wrench Special probe Combination screw driver The tool box (see figure H...
Page 307 End of Table H.1 Air hose Spare wheel bracket winch handle Fixed under the platform Tire lever In the glove box Operation Manual On the platform Distance pipes In the cab Jacketed canopy In special housing in the front platform part Canopy bow Warm-keeping jacket Under the radiator case...
Page 308 1-Inner operated ram screw; 2-pump lever; 3-needle valve; 4-plug; 5-tire iron Figure H.3 - Jack Application To bring a cargo down: - unscrew the needle valve slowly counter-clockwise; - unscrew the plug 4 to discharge air and, when the cargo is down, screw it back. When operating the jack, put blocks under the truck wheels.
Page 309 1-Base; 2-gasket; 3-outer operated ram cylinder; 4-cylinder tube; 5 and 6-operated rams (outer and inner); 7-screw; 8-compactor; 9-housing head; 10-O-ring; 11-ram head; 12-plug; 13-pump lever; 14- needle valve Figure H.4 - Jack...
Page 310 Appendix I (recommended) List of Gaskets Installed to the Truck Table I1 Quan- Identification Name Place of installation Fig. Pos. tity Transfer Box 2.1-80х105-4 or KTT gasket Front lid of the main shaft 80х105х10 bearing 2.2-70х92-1 or Front axle drive shaft KTT gasket РТ...
Page 311 End of Table I1 Power Takeoff with the flange 2.2-45х70-1 Gasket Rear bearing cap 2.2-45х70-1 GOST 8752-79/OST 38 05146-78 Additional Power Takeoff 2.2-51х76-1 Gasket Bearing cap 2.2-51х76-1 GOST 8752-79/OST 38 05146-78 Winch (gearbox) 2.2-85х110-1 Gasket Winch shaft left bearing 2.2-85х110-1 2.1-45х70-/\3 Gasket Winch worm end-thrust...
Page 312: Appendix J Maintenance Interval Coefficient Correction Chart Depending On Truck
Appendix J (recommended) Maintenance Interval Coefficient Correction Chart Depending on Truck Operation Condi- tions Table J.1 Operation Maintenance Conditions Truck operation conditions Interval Coefficient Category Correction, minimum 1) Roads of I, II, III technical categories outside suburban area on a level, gentle terrain and terrain, with concrete or asphalt pave- ment 1) Roads of I, II, III technical categories outside urban area in mountain countryside, as well as in small towns and suburban area...
Page 313: Operation Conditions
End of Table J1 Operation Maintenance Conditions Tractor unit operation conditions Interval Coefficient Category Correction, minimum 6) snow roads. 1) Roads of big cities with bitumen pavement (mountain ter- rain), macadam or gravel surface (highland and mountain terrain), cobblestone and rock stone pavements and pavements of primers with binding materials (all relief types except level).
Page 314 Amendments Registration List Amendments Registration List Amend. Sheet (page) number Total sheets Document Accompanying Signa- Date amended replaced cancelled (pages) in the document ture document file number and date p.37 4320М- 4320М-06-16 17.05.16 3902035 p.42 -«- -«- p.244, -«- -«- 4320М-07-16 17.05.16 p.263...
Page 316 Guide tablet Tire pressure kp/cm2 С moorland standstill To make a gear shifting of transfer Winch gearbox(GB) set the switchgear on the following position: top gear 1. ON/OFF differential locks should be made when the neutral truck is at full stop. If the locks are not switched on, slowly first gear move the vehicle from a standstill and keep moving at 5 Then push the Switch gear of GB...
Page 318 JST “AP “URAL” URAL Avtozavodtsev str., 1, Miass, Chelyabinsk region, Russia, 456300 Customer Service JST “AP “URAL” 8-800-100-11-74 (Toll-free call) Hot-line@uralaz.ru ATTENTION! Before fuelling turn off the air heating unit of the cabin IN THE AUXILIARY TANK IN THE MAIN TANK OUT OF THE AUXILIARY TANK OUT OF THE MAIN TANK IDLING RPM...
Page 319 searchlights Dashboard light, Parking lights (right side) Parking lights (left side) Low beam (right headlight) Low beam (left headlight) High beam (right headlight) High beam (left headlight) Fuel heating in the filter GOT ABS of the trailer ABS of the tractor unit ABS of the trailer ABS of the tractor unit Fuel heating in the filter GOT...
Page 320 SPTA-S Set List Appendix to OM (4320Б5-3900033-10) for trucks Ural 3255-3013-79М, 3255-3022-79М, 4320-3171-81М, 4320-3970-80М, 4320-3970-82М, 4320-3971-80М, 4320-4112-81М, 4320-4116-81М, 4320-4121-81М, 4320-4971-80М, 4320-4971-82М, 4320-4972-80М, 4320-4972-82М, 4320-4976-82М, 5557-4112-80М, 5557-4112-82М, 5557-4116-80М, 5557-4121-80М, 55571-4121-80М (4320Б5-3900033-11) ) for trucks Ural 4320-4151-81М, 4320-4151-82М, 4320-4951-80М, 4320-4951-82М, 4320-4952-80М, 4320-4952-82М, 43204-4151-80М, 43204-4153-80М, 5557-4151-80М, 55571-4252-80М...
Page 321 № Product identification Product name Unit Quantity for Laying area a truck SPTA-S Set List « « 536.3902150 РЭ « In the glove “ Operation Manual YAMZ-536, YAMZ-5362, YAMZ-5362, YAMZ-5363, YAMZ-5364 box of the ” Engines truck Operation Manual for ZF 9S 1310 Gearbox (for power units with ZF gearbox) or «...

URAL Motorcycles 4320М Operation Manual

1 Safety Requirements and Warning

2 Technical Specifications

3 Control Tools and Devices

4 Truckcomponents' Structureandoperationdescription,Their Adjustmentandmainte-

5 Troubleshooting

6 Operation Features

7 Maintenance

8 Storage

9 Transportation

10 Disposal

Appendix A Torques of Basic Screw Joints

Appendix B Control and Adjustment Information

Appendix C Weight of Basic Assembly Units

Appendix D Antifriction Bearings

Appendix E Oils, Lubricants and Special Fluids

Appendix F Auto Bulbs and Their Specifications

Appendix G Used Oil Discharge Standard

Appendix H Spare Parts, Tools and Accessories

Appendix I List of Gaskets Installed to the Truck

Appendix J Maintenance Interval Coefficient Correction Chart Depending on Truck

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