GAZ VALDAI GAZ33104 Operation Instruction Manual Download Page 11 | Manualshive

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5. CONTROLS AND INSTRUMENTS

Fig. 5.1.

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Summary of Contents for VALDAI GAZ33104

Page 1: ...LIMITED LIABILITY COMPANY AVTOZAVOD GAZ LLC AVTOZAVOD GAZ VALDAI VEHICLES FAMILY OPERATING INSTRUCTIONS 33104 3902111 ИЭ RUSSIA NIZHNIY NOVGOROD ...

Page 2: ...lowing models GAZ 33104 vehicle 4x2 type with three seat cabin GAZ 331041 vehicle 4x2 type with three seat cabin and extended wheel base GAZ 331043 vehicle 4x2 type with six seat cabin and extended wheel base The manufacturer reserves the right to constantly alter its vehicle design therefore some units and parts may slightly differ from those described in this Operating Instructions You can surel...

Page 3: ...40 50000125 where X96 manufacturer international identification code 331040 vehicle index 5 model year code 0000125 vehicle serial number Model year is a period equal on the average to calendar year during which the vehicles with identical design features are being manufactured Chassis identification number is marked on the right side member of the frame of cargo body vehicles intended for supplyi...

Page 4: ...ameplate The nameplate contains the following data a engine index b engine serial number Vehicle identification data also appear on manufacture s plate Fig 1 4 located on the rear pillar of the cab right door Chassis cab and engine numbers refer to the identification data of chassis and special configuration vehicles for supplying to the other plants for making their own special vehicles having th...

Page 5: ...f 80 95 C At the ambient air temperature of 5 C and below in stall cold weather radiator cover 3 Do not operate the starter continuously for more than 15 seconds For the second attempt of engine starting allow not less than 30 seconds Not more than three engine starting attempts are permissible Should the engine fail to fire after these attempts check the starter power circuits the starter itself ...

Page 6: ... not keep the steering wheel turned as far as it will go for more than 15 sec because it may cause damage of the power steer ing pump Never start the engine with power steering tank empty or insuffi cient oil level 11 When the ambient air temperature is below 35 C fill the power steer ing system with special liquid see subsection Lubrication Chart 12 Watch out for tightness of air pipelines cylind...

Page 7: ...n tyres mm 1701 1701 1701 Ground clearance fully laden mm 177 177 177 Minimum turning radius front outer track not more m 6 4 7 7 7 7 Maximum speed with full load without trailer on flat smooth highway km h 95 95 95 Fuel consumption1 when running with constant speed l 100km 60 km h 13 5 13 5 13 5 80 km h 18 0 18 0 18 0 Overhang angles fully laden deg front 27 27 27 rear 14 10 14 Maximum climable g...

Page 8: ... With paper renewable filter element Oil system Combined under pressure and spraying Oil cooler Full flow constantly operating Oil filter Full flow with renewable filter element Cooling system Liquid closed with forced coolant circula tion with expansion tank Supercharging system Gas turbine with one turbocharger C14 with radial centripetal turbine centrifugal compressor and air cooler of supercha...

Page 9: ...teering gear Screw ball nut transmission ratio 19 8 in the middle position Power steering Hydraulic integrated built in steering gear Power steering pump is a gear type НШ 14 Steering column Height and tilt adjustable 4 6 BRAKE SYSTEM Service brake system Double circuit with pneumatic drive Brake gears Disk type Emergency brake system Each circuit of service brake system Parking brake system With ...

Page 10: ... 518 518 518 4 9 MAIN ADJUSTMENT AND CHECKING DATA Clearance between valve stems and rocking levers on cold engine mm intake 0 25 exhaust 0 45 Oil pressure at oil temperature of 80 85 C kPa kgf cm2 at rated engine speed 2400 min 1 250 350 2 5 3 5 at minimum idle speed 80 0 8 Rated engine coolant temperature C 80 95 Minimum engine idle speed min 1 800 Variable voltage V 13 3 14 9 Fan and alternator...

Page 11: ...11 5 CONTROLS AND INSTRUMENTS Fig 5 1 Controls ...

Page 12: ...epressing the switch lever button in any position of the lever turns on the horn1 non fixed position see fig 5 2 1 On some of the vehicles the horn is switched on by means of windshield wiper and washer control lever see Fig 5 6 Fig 5 3 Turn indicator and dimmer switch lever without horn Fig 5 2 Turn indicator and dimmer switch lever with horn To operate turn indicators move the lever from positio...

Page 13: ...ti theft device switch 7 windshield wiper washer and horn 1 switch lever The positions of the lever fig 5 5 and 5 6 0 windshield wiper is OFF I low speed of windshield wiper II high speed of windshield wiper III intermittent operation of windshield wiper In case the control lever is not equipped with horn switch fig 5 5 to turn on windshield wiper and washer momentarily pull the lever in the direc...

Page 14: ...icator bulbs and red bulb inside the button switch fig 5 7 are flashing simultaneously Emergency flasher warning system should be switched on in case of vehi cle accidental stop in order to inform other drivers and maintenance services about stationary vehicle on the roadway Fig 5 7 Emergency flasher warning system button switch 9 rear row seats dome lamp switch of the cab for vehicles with two ro...

Page 15: ...rake lever For braking the vehicle pull the brake control lever up If the engine control switch is on warning lamp 9 fig 5 14 is flash ing on the instrument cluster For releasing the brake pull up the control lever lock coupling With the brake released the warning lamp goes out Fig 5 10 Parking brake lever 21 instrument lighting control knob 22 master light switch The switch has five fixed positio...

Page 16: ...er and moving it upwards within the limits of 90 results in releasing of the steering column After that the steering wheel can be set in the handy po sition for a driver and locked in this position by setting the lever to the initial position Fig 5 12 Steering column adjustment control lever 27 service brake pedal 28 storage battery remote button switch 29 clutch pedal 30 brakes front circuit pres...

Page 17: ... 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 19 23 24 1 Voltmeter 2 Warning lamp orange of glow plugs cutting in 3 Warning lamp of brake linings wear 4 Warning lamp red STOP 5 Warning lamp green of left turn indicators 6 Reserve warning lamp 7 Total distance counter 8 Speedometer 9 Warning lamp red of parking brake engagement Starts flashing after turning on the engine control switch when the pa...

Page 18: ...liters of fuel remain in the tank 16 Warning lamp red of oil pressure drop Lights up when the engine control switch is turned on Should the lamp light up under normal conditions shut down the engine immediately and check oil level in the crankcase 17 Warning lamp orange of rear fog light turning on 18 Coolant temperature gauge 19 Warning lamp green of clearance light turning on 20 Warning lamp blu...

Page 19: ... 1 button 2 handle 3 lock release 4 handle Never drive the vehicle with opened or partially closed doors Seats For seating convenience the driver seat is adjustable By turning handle 2 Fig 6 2 the seat can be moved in lengthwise direction Re quired seat backrest tilt is adjusted by rotation handwheel 3 For driver s convenience seat tilt is also adjusted by means of nuts 1 GAZ 331043 vehicle is equ...

Page 20: ... its length is necessary because intimate mating of web bing to hips must be ensured Changing of webbing length is performed by means of regulator To fasten the belt Fig 6 3 it is necessary to pull the belt webbing slow ly by the tongue over the shoulder and across the chest and push it into the buckle nearest the wearer a click will indicate that the belt is locked Upper portion of the belt shoul...

Page 21: ...design Never attempt to use the seat belt for more than one person Keep hard or fragile objects such as glasses fountain pens away from the belt as they may inflict additional injuries The belt should not be squeezed or twisted Keep sharp edges of the objects in vehicle passenger compartment away from the belt If dirty clean the belt with mild soap and lukewarm water only Never iron the belt webbi...

Page 22: ...ndition of all fastening joints of the vehicle Loose nuts should be timely tightened up Particular emphasis should be placed upon se curing of pitman arm propeller shaft wedges steering knuckle arms tie and drag link joints spring U bolts wheels and silencer intake pipes flanges 5 During running in period tandem transportation of the vehicles or their chassis by their partial loading of one on the...

Page 23: ...not more than 15 seconds turning the key to non fixed position II instrument cluster and starter are switched on 7 Once the engine starts release the key which will automatically return to position I Red warning lamp in the oil pressure gauge goes out 8 Release the clutch pedal Should the engine fail to start it is necessary to make another attempt re peating the above procedures Allow not less th...

Page 24: ...g drain water from the cool ing system and watch that all water was drained and it did not freeze in the radiator and cylinder block drain cocks For this purpose prick the cocks To expedite water drain from the system open the radiator filler cap When wa ter is drained leave the cocks open 8 1 3 Engine Stopping Prior to engine stopping let it run for 3 5 min at medium speed and then at idle speed ...

Page 25: ...in the neutral position Never try to change gears if the clutch is not disengaged completely Do not operate the pedal and the lever simulta neously 2 Do not engage the clutch if the gear is not changed completely 8 3 BRAKING AND PARKING Pneumatic disk brakes ensure steady braking efficiency Nevertheless brake the vehicle smoothly avoiding abrupt braking Do not turn off the instruments and do not r...

Page 26: ...D VENTILATION OF THE CAB Heating Fig 8 2 Heating and ventilation control panel 1 handle of air distribution control in the cab air flow is directed to the windscreen and door windows air flow is directed to the chest of the driver and passenger air flow is directed to the windscreen and door windows to the chest and feet of the driver and passenger air flow is directed only to the feet of the driv...

Page 27: ...ve a favourable climate in the cab passenger compartment turn handle 1 of air distribution control to the chosen position set the air temperature you prefer temperature of outside air or hot air from the heater by turning handle 3 of air temperature control turn handle 2 of air amount control from position to one of the three positions to get the desirable rate of air flow coming to the passenger ...

Page 28: ...eam and clearance lamp bulbs it is neces sary to remove rubber cover 3 Fig 8 4 To replace main beam bulb remove rubber covers 3 and 5 and unscrew connector 1 to replace turn indicator bulb Knob 2 is designed to adjust the direction of light beam in horizontal plane Vertical adjustment of the light beam is carried out through opening 4 using hexagon spanner or crosshead screwdriver Fig 8 4 Headlamp...

Page 29: ...icle headlamp dipper beam center Y Y vehicle axis The horizontal section of light and shade border of adjusted headlamps must coincide with line X X Fig 8 5A 8 5B the inclined section of the light and shade border must correspond to Fig 8 5A with AL marking on the lenses and Fig 8 5B with ОСВАР marking on the lenses and the points of hori zontal and inclined sections of the light and shade border ...

Page 30: ... right there is a fuse box БПР 4 90A fuse protects glow plugs control circuit and alternator circuit 40 A fuse protects lighting circuit of the vehicle 60 A fuse protects engine shutdown solenoid control circuit 60 A fuse utmost protect general positive circuit of the vehicle On the left two fuse boxes БПР 13 are installed under the instrument panel БПР 13 Fuse Boxes Upper fuse box fuses protect t...

Page 31: ...s protected by the fuses are also shown on schematic electrical diagram 8 7 GENERATOR SET The vehicle is equipped with AC alternator with built in rectifier and in tegral voltage regulator Maximum current output of alternator is 65A During operation check the generator set functioning using voltage indi cator installed in the instrument cluster Basic operation rules 1 Never interconnect the voltag...

Page 32: ...ons 1 It is forbidden to set the vehicle in motion by the starter It may result in failure of the starter In case of emergency it is allowed to move the vehicle for not more than 5 m 2 In winter do not persist in starting the cold engine by cranking it with the starter for a long time without preliminary heating of the engine This may lead to failure of the starter and storage battery 8 9 ANTI LOC...

Page 33: ...or it lights up during vehi cle movement it indicates that ABS circuits went out of order but service brake system maintains serviceability as if without ABS ABS failure warning lamp is also lights up automatically at constrained disconnection of supply socket from ABS control unit When ABS failure is confirmed the troubleshooting should be carried out at service station ABS electrical diagram is ...

Page 34: ...ction describes the works which should be carried out regularly within the intervals between the maintenance operations stated in the Service Book 9 1 CHECKING ENGINE OIL LEVEL Check engine oil daily prior to engine starting When doing so park the vehicle on level ground The oil level must be between П and 0 marks on the oil dipstick nearer to П mark Bring it to the proper level if required Pour f...

Page 35: ...el in Expansion Tank 1 plug 2 tank The coolant level should be at MIN mark or 30 50 mm above it Add anti freeze mixture through the expansion tank hole covered by cap If the coolant level falls frequently inspect the cooling system for leakage 9 4 CHECKING BRAKE LINING WEAR RATE On the sliding calipers 1 of all disk brake gears marking is made see Fig 9 4 According to the position of P mark on the...

Page 36: ...ry disk brake to deter mine friction linings wear After reaching of any brake pad limiting wear the indicator lights up on the instrument panel 9 5 CHECKING BRAKE FLUID LEVEL IN CLUTCH MASTER CYLINDER TANK The level of the brake fluid in the clutch master cylinder tank should be 15 20 mm below upper edge of the tank Fig 9 5 Fig 9 4 Checking Brake Lining Wear Rate Fig 9 5 Checking Fluid Level in Cl...

Page 37: ...e battery terminals and cable clamps clean as well as make sure that they are securely tightened Care should be taken to ensure correct polarity when the battery is recon nected after removal from the vehicle positive terminal is bigger than nega tive Prior to installation on the vehicle charge the battery bringing the density up to 1 25 1 27 g cm3 Depending on climatic zone of the vehicle operati...

Page 38: ...ft headlamp case stiffener The level of oil should be between MAX and MIN marks available on the reservoir body Fig 9 7 Checking Oil Level in Power Steering Reservoir 9 8 ENGINE ACCESSORIES DRIVE BELT TENSION Fan belt tension Fig 9 8 should be checked by pressing with 4 0 daN 4 0 kgf force on the side middle between pulleys of crankshaft and alternator in doing so the belt sag amount must be withi...

Page 39: ...stand at the service station The allowable residual unbalance from each side of the wheel with tire should not exceed 100 g on the wheel rim on returning from a trip and when at halt inspect the tires and remove the foreign objects The vehicle should be parked on clean and dry place Avoid oil gasoline oil paint getting on the tires prevent vehicle standing with underinflated tires rotate the tires...

Page 40: ...n dle 5 and rocking the tommy bar make lifting of the vehicle so that the wheel clears the ground by 4 5 mm In case of failure of lifting by the jack open shut off needle 7 and rock the tommy bar several times to remove air which could get into the working cham ber Plunger lift off limitation is mechanical by effort increasing on the handle at the end of the lifting stop the lifting remove six nut...

Page 41: ...ly on the delivery plunger handle several times and continue the lifting To prevent air from getting into the working chamber of the jack do not lift the operating plunger by hand with the shut off needle closed Incomplete lifting of the jack operating plunger occurs due to shortage of oil Regularly check the oil level in the jack and replenish if required The oil level in the vertically positione...

Page 42: ...e operation non corrosive coating of the cab may fail with time that is why it is necessary to perform corrosion resisting treat ment at regular intervals at service stations Hidden pockets additional corrosion protective treatment areas diagram of the cab is shown in Fig 9 11 Fig 9 11 Hidden Pockets Additional Corrosion Protective Treatment Areas Diagram of the Cab 1 foot steps hidden pockets 2 d...

Page 43: ...ding after the engine start ing Check operation of parking Parking brake handle should brake system easy move and securely tune in parking position Check tire inflation pres Check when tires are cold Air Manometer sure bring to the specifi inflation pressure values see in ed if required subsection 4 10 Main adjust ment and checking data Check steering wheel total Total play over steering wheel pla...

Page 44: ... with flushing oil Never mix top up engine oil of different grades and different companies 9 13 4 Lubrication Chart Description of lubrication points Number of points Quantity of lubri cant Description of lubricant 1 2 3 4 Engine oil system 1 12 l In summer engine oils М 10Г2 or М 10Г2 K ААИД1 or engine oil М10ДМ ААИД2 In winter engine oils М 8Г2 or М 8Г2 ААИД1 or engine oil М8ДМ ААИД2 All season ...

Page 45: ...3 АЖ 12T Substitute fluid spindle oil AУ Power steering system 1 1 3 l Hydraulic oil P Steering shaft sealing 1 5 g Grease Литол 24 Substitute grease ЛИТА Steering gear universal 3 6 g Grease Литол 24 Substitutes joints solid oil C solid oil Ж Master clutch cylinder 1 0 2 l Brake fluid РОСДОТ refilling tank system Substitute fluid Томь capacity class III grade A Storage battery terminals 4 4 g Lub...

Page 46: ...5W 40 From 45 C to 15 C SAE 10W 40 From 35 C to 20 C SAE 5W 40 From 35 C to 25 C Transmission oils SUPER T 3 TM 5 or API GL 5 SAE 85W90 From 25 C up to 50 C UFALUB UNITRANS MIL L 2105B or DEVON SUPER T TM 18 Lubricants Litol 24 Mil G 18709A from 40 C to 60 C Mil G 10924C Fat or synthetic solid oil Mil G 10924C from 40 C to 50 C Lubricant ПВК Mil C 11796B From 40 C to 50 C ЛИТА SM 1C 4515A Ford For...

Page 47: ...ubricant or fluid give preference to the following com panies Shell Mobil Castrol British Petroleum Agip Gulf 9 15 PARTS TO BE REPLACED ON THE VEHICLE DURING MAINTENANCE During vehicle maintenance the following parts are subject to replacement 1 Fine fuel filter element Filter element designation is 240 1117030 Fine fuel filter care includes draining sediment at regular intervals and re placement ...

Page 48: ...eans of booster pump 2 when fuel appears screw in union 1 first and then tighten plug 3 Fig 9 12 Fine Fuel Filter Element Replacement 1 filter cover 2 filter element 3 fil ter body 4 plug Fig 9 13 Air Bleeding from Fuel System 1 union 2 booster pump 3 plug 2 Air filter element Filter element designation is 4301 1109013 10 or 4301 1109013 20 ...

Page 49: ... filter is carried out by hands effort only Instead of filter ФМ009 1012005 it is allowed to use the filters substi tutes X149 firm ACDelco France and L37198 company Purolator Ita ly with basic dimensions diameter 95 120 mm height 140 153 mm mounting thread 3 4 16UNF 4 Filter element of power steering system reservoir ШНКФ 453473 In case of installation of power steering system reservoir ЯМЗ 993 0...

Page 50: ...urpose and location Type Quantity Head lamps low beam H7 2 high beam H1 2 clearance light W5W 2 turn indicator PY21W 2 Turn indicator repeater PY21W 2 Front marker lights A12 5 2 Side clearance lamps W3W 4 Tail lights turn indicator A12 21 3 2 stop light A12 21 3 2 clearance light A12 10 2 backing light A12 21 3 2 fog light A12 21 3 2 Side clearance marker light A12 10 2 Instrument cluster pilot l...

Page 51: ...w radial ball bearing 6 311AKУ 1 Gearbox output shaft rear Single row radial ball bearing 60205К 1 Gearbox input shaft front Single row radial ball bearing В6 213АКУШ 1 Gearbox input shaft rear Radial roller bearing without 64706 1 Gearbox reverse pinion shaft races Ball Б 11 112 200 306203 П 3 Transmission shifter shaft lock Ball 10 100 296870 4 Transmission shifter shaft lock plunger Single row ...

Page 52: ...g 7607AУ 2 Front wheel hub outer Electrical equipment Single row radial ball bearing 6 180502K1C9 1 Alternator 6 180603KC9 1 Supplement 4 10 4 SEALS USED IN THE VEHICLE Engine Engine crankshaft seal rear 240 1002305 1 Engine crankshaft seal front 240 1002055 1 Water pump seal 240 1307038 Б 1 Transmission Gearbox output shaft flange seal 51 1701210 A 1 Rear axle drive pinion seal 51 2402052 Б4 1 In...

Page 53: ...od bearing bolts 18 20 Clutch case to cylinder block 4 4 6 2 Gearbox to clutch 7 10 Gearbox output shaft flange 28 36 Steering wheel 6 5 8 Spring U bolts front 12 15 rear 20 22 Wheels 36 44 Steering gear bracket to frame 8 10 Steering gear to bracket 25 32 Axle drive pinion flange 28 40 Drop arm 30 5 33 Note Tightening torques are given for checking during repairing and maintenance Tightening torq...

Page 54: ...l Level 34 9 2 Checking Oil Level in Gearbox and Rear Axle 34 9 3 Checking Coolant Level 35 9 4 Checking Brake Lining Wear Rate 35 9 5 Checking Brake Fluid Level in Clutch Master Cylinder Tank 36 9 6 Checking Storage Battery Electrolyte Level 37 9 7 Checking Oil Level in Power Steering Reservoir 38 9 8 Engine Accessories Drive Belt Tensioning 38 9 9 Wheels and Tires Care 39 9 10 Changing a Wheel 4...

Page 55: ... 10 1 Filling Capacities 50 10 2 Electric Bulbs Used 50 10 3 Rolling Bearings Used on the Vehicle 51 10 4 Seals Used in the Vehicle 52 10 5 Tightening Torques of Most Important Junctions 53 Отпечатано в ООО Печать НН E5 ...

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