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URAL Motorcycles 4320-10, Operation Manual

The URAL Motorcycles 4320-10 Operation Manual is a comprehensive user guide designed to assist users in effectively operating and maintaining their URAL 4320-10 motorcycle. With easy-to-follow instructions and detailed diagrams, this manual is available for free download on our website, ensuring a hassle-free riding experience.

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31

DESIGN, OPERATION, ADJUSTMENT AND  

SERVICING OF TRUCK COMPONENTS  

(BRIEF DESCRIPTION)

 

 

ENGINE 

 

The  truck  is  powered  with  the  engine  manufactured  by  the  Yaroslavl  Motor 

Works. Description of  engine  design  as  well  as  instructions for engine operation 

and    maintainance    are    given    in  the  Operation  Manual  issued  by  the    Yaroslavl  

Motor  Works,  which  is supplied with the truck. 

 

Fuel System 

         

Engine Fuel System. 

Fuel is taken from main fuel tank 1 (Fig. 22) by fuel feed 

pump 8 and is supplied to injection pump

 (

high-pressure fuel pump - HPFP) 10 via 

coarse-mesh filter 22 and fine-mesh filter 13.  

The injection pump delivers fuel via pipes to the injectors, which inject fuel into 

the  engine  cylinders  in  accordance  with  the  firing  sequence.  Excessive  fuel  together 

with air, which has entered the fuel system, are returned to the fuel tank through the 

orificed  valve  of  the  fine-mesh  filter  via  fuel  lines  15  and  17.  The  fuel,  which  has 

oozed through the injector’s precision parts is also returned to the fuel tank via pipes 6 

and 23. The fuel volume in the main fuel tank is measured by an electrical level gauge 

installed in the tank and is controlled by the indicator on the dashboard.  

 

 

Fig. 22. Fuel System Diagram 

Summary of Contents for 4320-10

Page 1: ...URAL 4320 10 URAL 4320 31 TRUCKS AND THEIR MODIFICATIONS ...

Page 2: ...RSIONS Operation Manual 4320 3902035 10 РЭ Ninth edition revised enlarged URALAZ No part of the book or the whole book may be reprinted and copied without the prior written permission of the URAL Automobile Works Open End Joint Stock Co Miass 2003 ...

Page 3: ...d reference data are given in the Manual In connection with continuous work relating to improvement of the product which increases their reliability and improves its operating conditions particular alterations which are not highlighted in this edition can be introduced in the de sign When using the trucks this Operation Manual and the Manual for the power unit manufactured by Yaroslavl Motor Works...

Page 4: ...Fig 2 multi purpose trucks devel oped by means of updating URAL 4320 truck where hyphens 10 and 31 30 indicate the model of the engine i e YAMZ 236M2 and YAMZ 238M2 corre spondingly installed into the truck Fig 1 URAL 4320 10 truck Fig 2 URAL 4320 31 truck URAL trucks are designed for operation at ambient temperatures ranging from 50 C down to 45 C a short time operation at 50 C The following vers...

Page 5: ...specifications and a drawbar for trailers as per GOST 2349 Standard or a coupling pivot as per GOST R 41 55 Standard for semi trailers having A diameter as per GOST 12017 Standard that is equal to 50 8 mm and mounting dimensions as per GOST 12105 Standard for rated load on the fifth wheel from 49 0 kN 5 0 tf to 83 4 kN 8 5 tf The trailers models 782B 2PN 4M GKB 8350 and OdAZ 935 OdAZ 9370 semi tra...

Page 6: ...tery cut off the fuel feed by pulling the engine stop lever as far as it will go and put chocks under the wheels 3 Keep the engine and the starting preheater clean and in good working or der Do not allow fuel and oil to leak it can serve as a reason of fire When the preheater is engaged the driver should stay near the truck 4 Do not warm up the engine if the truck is indoors and ventilation is poo...

Page 7: ...ing the lock handle downwards 17 When crossing gutters or rough ground do not allow the semi trailer front to thrust against elements of the bolster truck because the semi trailer kingpin can get free from the fifth wheel catches spontaneous unhitching 18 Hitch and unhitch the trailer semi trailer on an even flat side 19 Before unhitching the bolster trucks the semi trailer support rollers should ...

Page 8: ...be tween the air intake nozzle and connecting pipe of the engine intake manifolds should be dismantled but the gasket should be kept 6 See that the preheater fuel pump is adjusted correctly not allowing open flame in the gas conduit of the heat exchanger 7 Do not allow the preheater to operate for more than 15 sec without a coolant in the heat exchanger Upon washing the truck of its fording engage...

Page 9: ...nd the engine has not been started or has stalled by any reasons first set the key into its initial upright position Frequent starting of the engine with its short term operation result in quick discharge of the storage battery 19 Do not move the truck with the help of the starter because it can be a reason of the starter failure and quick discharge of the storage battery 20 To avoid the generator...

Page 10: ...ning onto the truck platform put shields boards under its wheels 33 Put heavy small sized cargoes which can cause local sagging of the plat form floor or damage the body sides and seat components onto sills boards and fix them securely Place the cargo so that its centre of inertia is located in the mid dle of the truck platform 34 The truck loading height was increased on URAL 4320 0611 10 truck D...

Page 11: ...14 095 1 23 615 20 915 2 Kerb Vehicle Weight distribution kg on front axle on rear bogie 4225 1 4570 1 4205 3905 GVW distribution kg on front axle on rear bogie 4520 1 9575 1 4630 9285 Gross Trailer Semitrailer Weight kg 11 500 7000 2 18 500 12 500 2 OPERATIONAL DATA Maximum travelling speed of GWV truck road train km h 85 82 3 75 Estimated fuel consumption 4 l 100 km not more at speed 40 km h sin...

Page 12: ...e to turn centre wheel m not more 10 8 Obstacles to be overcome m width of ditch trench height of upright wall depth of hard bottom ford 0 6 0 55 0 7 5 1 For the Ural 4320 10 truck equipped with a winch 2 When operating on bad natural roads featuring some heavy sections for the Ural 4320 10 truck also when operating on roadless terrain 3 For trucks having final drive ratio 7 32 4 Estimated fuel co...

Page 13: ...15 990 13 990 1 16 015 Kerb Vehicle Weight distribution kg on front axle on rear bogie 4500 2 4670 2 4380 4310 4390 4325 GVW distribution kg on front axle on rear bogie 4910 2 10 560 2 4965 11 025 4975 11 040 Gross Trailer Semitrailer Weight kg 11 500 7000 1 OPERATIONAL DATA Maximum travelling speed km h GVW GCW 85 82 3 80 73 3 80 75 3 75 70 3 Maximum gradeability degree not less GVW GCW 31 60 19 ...

Page 14: ... 5500 8100 5500 1 12 000 8340 8320 8085 9700 23 840 21 140 1 27 720 21 120 1 38 750 20 000 4525 3815 4570 3750 4425 3660 4905 4795 4940 9200 5005 11 715 5300 15 600 5165 14 835 15 200 12 500 1 19 100 12 500 1 30 000 75 75 75 70 3 65 80 75 3 75 70 3 15 27 15 27 15 27 15 27 40 40 40 32 46 ...

Page 15: ...hen applying auxiliary brake system m not more GVW GCW 33 8 35 0 Obstacles to be overcome m width of ditch trench height of upright wall depth of hard bottom ford 0 6 0 55 0 7 5 1 When operating on bad natural roads featuring some heavy sections for the Ural 4320 31 truck also when operating on roadless terrain 2 For the Ural 4320 31 truck equipped with a winch 3 For trucks having final drive rati...

Page 16: ...15 5 6 7 8 48 46 64 40 49 860 715 720 625 900 720 720 590 900 720 720 590 10 8 13 0 36 7 38 5 33 8 35 0 0 6 0 55 0 7 5 ...

Page 17: ...tion as per GOST 22836 77 Right hand clockwise as viewed from the fan side FUEL FEED SYSTEM Main fuel tank capacity 1 l 300 2 filling capacity 290 TRANSMISSION Clutch YAMZ 236K 3 twin disc dry friction type mechanically driven with air booster YAMZ 238 3 twin disc dry friction type me chanically driven with air booster Gearbox YAMZ 236U mechanical three way five speed type synchronized in second t...

Page 18: ...ure Towing devices In the front rigid towing hooks in the rear double action towing unit on bolster trucks rigid towing hooks and fifth wheel in the rear Truck suspension front Conventional on two longitudinal semielliptic springs operating together with four two way hydraulic shock absorbers rear Conventional walking beam type with torque rods on longitudinal semielliptic springs 4 1 Ural 4320 10...

Page 19: ...0 40 kN 3100kgf c 390R20 149J HC14 PR14 О 65 model pneumatic radial tube type standard shaped ribbed tires with controlled pres sure max permissible carrying capacity 32 36 kN 3300 kgf 149F HC10 PR10 150F HC10 PR10 max permissible carrying ca pacity 32 36 kN 3300 kgf 156F HC16 PR16 max per missible car rying ca pacity 39 23 kN 4000 kgf Rated tire pressure MPa kgf cm2 a 0 31 3 2 b 0 28 2 9 c 0 34 3...

Page 20: ...mp Blade double action rotor type driven by engine crankshaft Front steerable wheels position Wheel camber 1 side inclination of knuckle pin 6 toe in 1 3 mm BRAKING SYSTEM Service brake system Dual circuit type featuring combination air over hydraulic actuation method of truck brakes 1 Wheel brakes of drum type Stand by brake system One of service brake system circuits Parking brake system Mechani...

Page 21: ...ith remote control Headlamp 401 3711 or 671 3711 2 Side lamps of turn indica tors Two items УП101 Б1 511 3726010 2 Lamps of road train sign Three items УП101 Б1 Rear lamps Two items ФП133 АБ 7462 3716 the right side one 7472 3716 the left side one three sectional bearing functions of rear marker lamp turn indicator rear outline marker lamp stop lamp reverse lamp rear fog lamp reflector light side ...

Page 22: ...ptional 2 For the Ural 4320 0911 30 truck Parameters Ural 4320 10 Ural 43202 0311 31 Ural 4320 31 Ural 43202 0612 30 1 2 3 Fifth wheel 50 11 type as per GOST 28247 89 with two degrees of freedom Grips of king pin locking device are closed with semi automatic lock King pin hole dia 50 8 mm Parameters Ural 4320 10 Ural 4420 10 Ural 4320 0611 10 Ural 4320 31 Ural 43202 0351 31 Ural 4320 0611 31 Ural ...

Page 23: ...ing layer 70 kN 7 tf on the first layer 100 kN 10 tf Tackle block 1 Rope type single groove Tire pressure control sys tem Ensuring tire air pressure control by means of the valve available in driver s cab 1 Optional 2 Optional The truck can be completed with transfer box and power take off enabling up to 100 take off of engine maximum output Parameters Ural 4320 10 Ural 4420 10 Ural 4320 31 Ural 4...

Page 24: ...23 Fig 5 Overall dimensions of the Ural 4320 31 Ural 4320 10 trucks Fig 6 Overall dimensions of the Ural 43202 0351 31 truck Fig 7 Overall dimensions of the Ural 4320 0911 30 truck ...

Page 25: ...24 Fig 8 Overall dimensions of the Ural 4420 31 Ural 4420 10 bolster trucks Fig 9 Overall dimensions of the Ural 44202 0311 31 bolster truck ...

Page 26: ...Instruction Plates Attached Inside the Truck Cab A gearbox and transfer box plate lo cated in cab on the right side of the front panel 1 2 3 4 5 gearbox gears R gearbox reverse gear B high gear ON H low gear ON I differential un locked II differential locked C plate for braking forces regulator data located on interior panel of the cab l h door ...

Page 27: ...If lever 18 is set in the upper position the inner hatch is opened and in the lower position it is closed For shutting down the engine pull handle 20 as far as it will go When switch 12 handle is turned clockwise the right turn indicators are switched on if turned counter clockwise the left turn indicators are switched on When switch 28 button is pressed the head lamp light is changed over dis tan...

Page 28: ...valve outlets which are to be connected with a portable pressure gauge to check the air pressure On the trucks supplied for the civil market the starter and instrument switch is located on the steering column and has four positions of its key 0 OFF the position is fixed and the key can not be taken out I the instruments are ON the position is fixed and the key can not be taken out II the starter i...

Page 29: ...sher are switched on by turning switch 23 The switch has four positions I switched off II III low and high speeds of wiper blades IV high speed of wiper blades windshield washer pump ON The glow plug preheater operates if button 17 is held pressed When pilot lamp 8 Fig 13 turns on it indicates that the glow plug preheater becomes ready for starting the engine When buttons 6 7 are pressed all the p...

Page 30: ...ilt into the dial of the indicator and goes on when the fuel volume decreases down to 60 l Oil cooler cock Fig 14 is mounted on the left side of the cylinder block in the direction of the truck movement To cut off the oil cooler turn the cock knob clockwise as far as it will go Auxiliary fuel tank cock When using the fuel contained in the auxiliary tank pour over it into the main fuel tank by open...

Page 31: ...wing truck red coupling head and towing valve of the truck to be pulled Winch control levers are shown in Fig 20 The use of the winch is described in section Winch Storage battery switch Fig 21 is mounted on the battery box bracket If the remote control system fails the switch can be turned on or off by pressing the but ton under the rubber cover External start socket is located on the battery box...

Page 32: ...igh pressure fuel pump HPFP 10 via coarse mesh filter 22 and fine mesh filter 13 The injection pump delivers fuel via pipes to the injectors which inject fuel into the engine cylinders in accordance with the firing sequence Excessive fuel together with air which has entered the fuel system are returned to the fuel tank through the orificed valve of the fine mesh filter via fuel lines 15 and 17 The...

Page 33: ...e control lever should thrusts against the minimum idle speed limiting bolt available on the speed governor this is obtained by adjusting the tie rod s 2 length Fig 23 The pedal being pressed down fully clearance b should be 2 3 mm at maximum speed Fig 23 Fuel Feed Control 1 governor control shaft lever 2 tie rod 3 governor control lever 4 rope wire clamp 5 linkage hand lever 6 manual control tie ...

Page 34: ...nlet manifolds connecting pipe the gauze must neccerily be removed after running in the engine while the gasket remains Air is supplied to the air filter via the air suction pipe Air received in the filter due flowing through the swirler obtains rotary motion in the annular gap between the housing and filter element under centrifugal force dust particles are thrown to the housing wall and collecte...

Page 35: ...oves ineffective wash the element in warm water 40 50 C with a detergent dissolved in it Immerse the element in the solution for half an hour then rotate or dip it vigorously during 10 15 min After washing in the solution rinse the element in fresh water and dry Do not dry it above open fire or in air heated over 70 C After each servicing or fitting a new element a visual inspection of its conditi...

Page 36: ...oid valve The console is located on the cooling system radiator left side pipelines gas branch pipe 9 oil sump casing 8 not available on certain truck variants Fig 25 Engine Starting Preheating System 1 filler 2 filler cover 3 fuel pipe from preheater tank to pump unit 4 fuel tank 5 straight through cock 6 delivery pipe from water pump 7 spark plug 8 oil sump casing 9 gas branch pipe 10 electric f...

Page 37: ...and fuel leaks through the joints of pipelines hoses and cocks see that the clips on the heat exchanger branch pipes and pipelines are tight Do not fill water in the overheated due to fluid lack heat exchanger so as to preclude its damage cool down the heat exchanger before filling water After truck washing or ford passing remove water which entered the preheater air duct by operating the pump uni...

Page 38: ...ng screw with lock nut 5 and screw on cap nut 7 Gas Exhaust System Gas exhaust system is intended for removal of waste gas and reducing of exhaust noise Displacements of silencer inlet pipes about the silencer caused by mounting and operating processes are absorbed by compensators 3 Fig 27 Reliable operation of the compensators is ensured by their arrangement in one and the same plane This is obta...

Page 39: ... box 8 expansion tank 9 expansion tank plug 10 drain cock 11 water supply pipe 12 frame with radiator blade a coolant return from compressor b coolant supply to compressor At an ambient temperature down to minus 40 0C use ОЖ 40 Лена coolant alternatively the ТОСОЛ А 40М one At 20 0C the density of ОЖ 40 Лена coolant should be 1 075 1 085 g cm3 and that of ТОСОЛ А 40М 1 078 1 085 g cm3 At an ambien...

Page 40: ... detect the reason of engine overheating and eliminate it In special situations it is possible to continue travelling with the lighting alarm provided that the coolant temperature indicator is carefully observed A short time temperature rise for 120 min maximum up to 105 0C is permissible When adjusting tension of the belts driving the water pump proceed as follows drain water from the cooling sys...

Page 41: ... order to avoid freezing on of the impeller then close turn off all three drain cooks after the water is drained fully upon draining water from the cooling system do not plug the radiator filler and preheater s filling pipe because they may possibly freeze on Do not run engine upon draining the coolant to remove the remaining water from the system That can cause failure of rubber packing rings of ...

Page 42: ...tion Manual issued by the Yaroslavl Motor Works Clutch Release Control Clutch release control is of mechanical type with air booster Air cylinder 20 Fig 31 of the booster is mounted on the gearbox housing and actuates shaft lever 18 of the clutch release fork The cylinder is controlled by air valve 1 which is fitted on tie rod 4 Hose 8 connects valve 1 with the truck s air system When acting on cl...

Page 43: ... 1 0 of a turn and lock it with nut 2 Fig 31 Clutch and Brake Valve Control 1 air valve 2 lock nut 3 adjusting bolt 4 tie rod with compensator 5 bracket 6 22 brake valve levers 7 clutch lever 8 19 hoses 9 clutch pedal tie rod 10 brake pedal tie rod 11 clutch pedal shaft lever 12 clutch pedal shaft 13 clutch pedal limiter 14 brake pedal return spring 15 clutch pedal spring 16 clutch pedal 17 brake ...

Page 44: ...interaxle differential It is mounted on the truck frame in four rubber cushions The differential is of planetary type having four satellites sun 30 and crown 29 gears Torque is transmitted from sun gear 30 to front axle drive shaft 35 and from crown gear 29 to rear axle drive shaft 21 With the differential being in operation unlocked an equal traction of all axles is ensured and extra loads in tra...

Page 45: ...ing 24 40 bearing nuts 26 differential rear bearing housing 27 differential rear holder 28 differential holder with lower shaft gear 29 crown gear 30 sun gear 31 differential interlocking coupling 33 bolt 34 flange deflector 35 front axle drive shaft 37 satellite The parameters of speedometer drive gears depend on final drive ratio of the driving axle and on the size of the tires applied This depe...

Page 46: ... ИД П284 model 12 00R20 У 4 ИД 304 32 42 92 6 54 54 8 05 24 32 65 two annular grooves on shaft 5 64 82 7 32 22 30 13 one annular groove on shaft 5 67 33 face groove 6 69 20 27 60 5 69 85 To adjust the primary shaft bearings proceed as follows check tightness of the nut fastening the flange and if need be tighten it up torque being less than 200 N m 20 kgf m set the indicator on the plane of the in...

Page 47: ...lder it is positioned correctly Should the coupling contact the holder move it forward rotating the rod clockwise The position of gear engagement clutch 7 should be adjusted by selecting a pack of shims 11 Fig 33 The clutch position is considered normal if with the gear shift fork rod being in its fixed neutral position the difference in free length of the splines in the center part of the primary...

Page 48: ... Ural 4320 31 Trucks 1 intermediate cardan shaft 2 supporting plate 3 centre support 4 5 6 winch drive cardan shafts 7 8 9 axle drive cardan shafts The front and rear axle drive cardan shafts are similar in design differing by the length and by the dimension on the flange attached namely from the axis of the bearing holes to the mating surface Design of the intermediate cardan shaft is shown in Fi...

Page 49: ... cardan shaft see that the arrows stamped on the tube shaft and sliding fork are positioned one opposite another and the flanges forks and balancing plates 8 are in the same position they had before disassembling To provide that mark the parts of the cardan shaft prior to its disassembling Upon replacing the flanges welded and sliding forks the cardan shafts should be dynamically balanced repeated...

Page 50: ...aring cap 6 flange 7 cap bolt 8 inspection hole plug 9 drain plug a axial clearance Oil grades to be used as well as oil level inspection intervals and oil replacement intervals are like to those specified for the transfer box of the the Ural 4320 10 Ural 4320 31 trucks When changing oil check axial displacement of shaft 1 For this purpose disconnect the cardan shafts from flanges 6 of the centre ...

Page 51: ...ations the final drives have ratios as follows 7 32 6 7 8 9 and 8 05 To recognize the final drives they are marked with plates bearing ratio indication which are placed under the bearing body cap bolt of the driving spur gear The final drives with 8 9 ratio have no mark plates Final drive gears differ by the marks on the driving and driven spur gears Tabl 2 Table 2 Ratio Marks on driving spur gear...

Page 52: ... union The final drives of front and rear axles differ from that of the intermediate axle by drive flanges Sleeve 21 with cap 22 is fitted on the front end of the front axle driving gear shaft while flange 18 on the rear end The rear axle final drive has a flange at the driving bevel gear side Splines may be unavailable on the opposite end of the driving gear shaft Axle cases 10 see Fig 40 are com...

Page 53: ...g 41 Drive to Steerable Wheels of Front Driving Axle 1 air supply hose 2 lock washer 3 retaining ring 4 lock nut 5 wheel bearing nut 6 journal 7 air supply elbow 8 wheel hub cover 9 outer half axle 10 collars unit 11 17 19 gaskets 12 bearing 13 hub 14 wheel brake cylinder 15 brake drum 16 brake support 18 ball support 20 inner half axle 21 half axle casing 22 hinge knuckle 23 hinge disc 24 outer h...

Page 54: ...ing gear shaft together with bearing body and gear Clamp the driving gear in the vice by its gear rim Unscrew the bolts fastening the cover and remove the latter Unlock the lock nut and unscrew it Remove the lock washers Tighten up the nut with a torque 450 500 N m 45 50 kgf m Fit the indicator and measure clearance in the bearings Do not readjust the bearings in body if no clearance is sensed aft...

Page 55: ...to a distance which is proportional to the number of teeth of each gear i e shift the driven bevel gear 2 2 times 24 11 farther than the driving one 4 Mount the differential and adjust the differential bearings Tighten the bolts fastening the differential bearing caps to 250 320 N m 25 32 kgf m Adjust the differential bearing using nuts 37 see Fig 39 Upon tightening the nuts the distance between t...

Page 56: ...sh becomes excessive shift driven gear closer Adjust the bearings of steering knuckle pins when performing the sixth M 2 every 96 000 km in the following sequence of operations dismantle the wheels and place the stops under the steering knuckle lower covers remove the arm of the left side steering knuckle and the upper cover of the right side one remove two shims out of the pack under each arm one...

Page 57: ... bearing adjustment RUNNING GEAR Frame The truck frame is a riveted structure consisting of two stamped variable section side members interconnected by six cross members and a bumper in front Frame servicing lies in inspection of bolted and riveted connections See that frame configuration and strengh of its elements are not impaired If the rivets are loose cut them off and replace by the new ones ...

Page 58: ...to the spring front ends by means of U bolts 21 and bolts 24 Through the eye the springs are connected with front brackets 1 by pins 19 which are locked in the brackets by wedges 23 The spring rear ends enter freely the eyes of rear brackets 8 The axle s downwards travel is retained by catching the bending of the spring s third leaf end on lower bolt 11 which fixes the the brace of the spring rear...

Page 59: ... fastening 12 spacing sleeve 13 auxiliary buffer holder 14 upper bolt of brace fastening 15 lock plate 16 rear bracket brace 18 spring U bolt 19 U bolt eye pin 20 pad 21 eye U bolt 22 spring eye 23 wedge 24 bolt The rear suspension is fully articulated the spring ends enter the eyes of supporting brackets 8 Fig 47 The springs are secured by U bolts 2 to beams 25 which rock on walking beam axle 21 ...

Page 60: ...h thicker leaves and correspondingly extended U bolts Maintenance To prevent shearing of the front spring center bolt and centering protrusion of the rear spring in due time torque the U bolt nuts on a loaded truck When squeaking is sensed in the springs jack up the truck against its frame and pack grease into the gaps formed between the leaves Once disassembling the springs lubricate the leaves a...

Page 61: ...racket 10 buffer bracket 11 buffer pad 12 buffer 13 collar housing 14 collar 15 felt packing ring 16 spacer ring 17 walking beam axle bolt 18 coupling bolt 19 bolts fastening walking beam bracket to the fifth cross member 20 walking beam bracket 21 walking beam axle 22 axle bracket 23 packing ring 24 ball pin 25 walking beam 26 nut 27 walking beam cap 28 filling hole plug ...

Page 62: ...otter it If the brace is slackened on the front spring rear brackets tighten up the brace bolts For upper bolt 14 apply a torque of about 120 160 N m 12 16 kgf m and for the lower bolt nut 180 220 N m 18 22 kgf m Lock the bolts by bending the retaining strip on the heads Should the first leaf ends of the rear spring be worn by half of their thickness interchange the first and second leaves It is n...

Page 63: ... 152 228 kgf For effort testing use the press with a rod stroke of 100 mm and a speed of 100 strokes per minute If the shock absorber rod travels freely it indicates that the unit is faulty The shock absorber should be disassembled and reassembled in workshops keeping required cleanliness Polished surfaces of the rod operation cylinder compression rings and piston should be protected from dents an...

Page 64: ... ring ends a slot for gripping the ring when taking it out of the rim lock groove is made The lock ring limiters serve to prevent turning the rings over when the truck travels with reduced tire pressure and at the same time they are the brackets which wheel valves 1 are fastened to and additional supports for protection hoods of air supply hoses On the 254Г 508 wheels the wheel valve is mounted on...

Page 65: ... to remedy them repair or replace them Slacking of the wheel fixing and operation of the truck is not allowed even if a single nut or stud fastening the wheel is missing or fastening holes in the disks are worn out When conducting the second maintenance check up tightening of the nuts fastening the wheels During the first run of 1000 km tighten up the nut fastening the wheels for the first time af...

Page 66: ...detected it is not allowed to use the tires for mounting Check the inner tubes and valves for sealing do not use the inner tubes with separation in the joint and the damaged valve Remove mud rust and the rest of rubber from the wheel surface especially from the surface of the rim bead and setting rings which faces the tire Paint trimmed spots and the spots where paint is damaged with a fast drying...

Page 67: ...lashes on the edge scores and damages which obstruct mounting when mounting or dismantling tires do not apply rough force to tire irons the force applied should not result in their sliding off or break of tire iron ends first make sure that the lock ring occupies its proper position in the rim base groove which corresponds to the inflated wheel and then inflate the tire do not inflate the tire out...

Page 68: ... removing it on the side of the bead fixed edge with 400Г 508 wheels the bead should be removed from the bead seat directly catching the bead with the tire irons For this purpose insert the flat end of the short tire iron between the tire bead and the wheel bead ring as deep as possible press out the tire iron downwards Fig 50 Wheel Disassembling I II removing of tire bead from bead seat III disma...

Page 69: ...el with the tire in the upright position with the lock part away from you so that the inner tube valve is at the bottom recess the valve with the seal to the inside of the tire holding the tire by hand in the upright position and leaning it against a support pull the rim by the other hand avoiding skewing so that the tire bead at the bottom enters the mounting groove taking hold of the disk or upp...

Page 70: ...ill be impossible 5 Mount the bead and lock rings having aligned stamped out mark B Fig 52 on the lock ring of the constant pressure tires with one of slots A on the bead ring and having ensured that the cut of bead ring coincides with the limiter on the rim 6 Check position of the valve and seal in the valve slot and if required adjust them connect the inner tube valve with the wheel valve Mount ...

Page 71: ... disks The nuts should be tightened securely because their insufficient and uneven tightening can result in lateral runout of the wheels assembled with tires Balancing of 254г 508 wheels assembled with tires The permissible unbal ance is 5 2 kg cm In the course of operation as the tires are wearing and by other reasons remounting of the tires the initial balance infringes therefore when the truck ...

Page 72: ...n with the help of a worm reduction gear The spare wheel is fixed in its transportation position by braces 9 Fig 54 and bolts 11 When lowering down the spare wheel release the fastening of tilting bracket 8 from braces 9 having checked fixation of rope 1 to the tilting bracket first Put the detachable handle on the reduction gear shaft Turning the handle lower down the tilting bracket with the spa...

Page 73: ...ing bracket 8 13 nuts 9 12 straps 10 fixed bracket 11 pillar _________________________ The reduction gear is mounted under the holder base on URAL 44202 0311 31 and URAL 44202 0612 30 bolster trucks Fig 54 Upright Spare Wheel Holder 1 rope 2 reduction gear 3 handle 4 base bar 5 bar gasket 6 holder base 7 U bolt 8 tilting bracket 9 brace 10 clamp 11 bolt ...

Page 74: ...d for transportation in the reverse order The pawl for fixing the tilting bracket is located on the truck frame to the right of the spare wheel holder STEERING Steering comprises steering column steering gear steering linkage and hy draulic booster Two variants of steering can be applied on the trucks with steering gear of worm side segment type or of screw ball nut rack segment type In this case ...

Page 75: ...ecured to the left hand frame side member The steering column is connected with the steering gear by cardan shafts via center support 8 see Fig 56 Lubrication free bearings of closed type are ap plied in the center support design The steering gear with booster control valve comprises worm 3 Fig 58 and worm segment 5 featuring spiral teeth Steering pitman arm 25 is connected to the segment shaft th...

Page 76: ...esign As the slide travels about fixed slide body 30 one of the booster cylinder spaces gets connected with high pressure line while the other with drain line Due to it the cylinder rod of the booster moves until the steering wheel ceases to turn The rod motion is transferred to the steerable wheels via ball pin and steering knuckle arm When turning the steering wheel to the left or to the right t...

Page 77: ...ction chambers of body 5 so that they can move axially in their channels Slide valve 22 is fixed on bushing 9 via bearings 3 by nut 2 Bushing 9 is connected via splines with steering gear screw 24 without backlash providing the possibility of axial movement and via a screwed joint with input shaft 15 Input shaft 15 is connected via torsion 17 with screw 24 of the steering gear Retaining valve 6 is...

Page 78: ...actically unloaded When the slide valve is displaced by an amount limited by backlash t in the splined joint the working fluid supply to annual groove f is cut off The fluid is delivered from the pump to the centre groove e and then via channel d in the body and pipes gets into the other than rod chamber of booster 14 see Fig 57 The force from the booster is transferred to the steering knuckle arm...

Page 79: ...hten the gasket by means of nut 11 Fig 61 Steering Booster 1 cylinder end 2 6 packing rings 3 end nut 4 cylinder 5 piston in assembly with rod 7 supporting ring 8 collar 9 pressure ring 10 13 clips 11 nut 12 protective coupling 14 bolt 15 rod end Steering Booster Pump Booster pump Fig 62 is a blade type double action unit When the pump shaft rotates the vanes are pressed to the stator curved surfa...

Page 80: ...valve 8 opens The oil level in the tank should be within plain section on the dipstick and is measured by means of the dipstick with plug 4 being unscrewed To wash the tank filter unscrew the filter bolts take out and disassemble the filter Wash the filter elements with diesel fuel reassemble and refit the fil ter Steering Rods The rods of pitman arm and steering trapezium are adjustable in length...

Page 81: ...y the arrow marked on the stator points to the sense of rotation of the pump shaft Stator rotor and blades of the booster pump are fitted individually one to another as well as the by pass valve and the pump cover therefore do not disturb their complete set If minor scores are seen on the end faces of the rotor body and dis tributor disc lap one to the other When disassembling the pump see that Fi...

Page 82: ...e tank start the engine and add oil up to the upper mark then as the engine runs idling bleed air out of the hydraulic system by turning the steering wheel either side as far as it will go till air stops bubbling in the tank stop the engine check the oil level in the tank and add it if need be fit the filler plug of the tank back Testing for free wheeling Angular play of the steering wheel should ...

Page 83: ...reme posi tions Determine the torque needed for cranking through shaft 15 see Fig 60 from the extreme position to the middle one crank the shaft by an angle of about 30 Should the torque be less than 0 9 N m 0 1 kgf m so adjust preload in bearings 14 see Fig 59 by reducing the number of shims 12 After adjustment the torque needed for cranking through shaft 15 see Fig 60 should lie within 0 9 1 5 N...

Page 84: ...eral steering rod after slackening the bolts on the steering rod ends Upon readjusting the toe in tighten the rod end bolts Angles of turn are limited by constant non adjustable thrusts The amount of these angles is given in Fig 65 BRAKE SYSTEMS The truck is equipped with separate brake systems service stand by parking and auxiliary ones Service brake system The service brake system should ensure ...

Page 85: ...e anchor pins 7 Adjust clearances between the brake shoe and drum with the help of the an chor pins only when replacing of the friction linings and shoes assy In so doing set the shoe pins so that the marks on the ends face each other first Fit a clearance gauge 0 2 mm thick 200 mm long between the drum and shoe at a distance of 30 mm from the lower edge of the lining Slightly clamp the gauge by t...

Page 86: ...ignal engagement senders 22 brake failure senders 23 wheel cylinders 24 brake air booster 25 check outlet valves 26 condensate drain cocks 28 brake valve 29 compressor Compressor 29 supplies compressed air through pressure governor 4 to the assembly of the safety valves The assembly comprises triple safety valve 5 and sin gle safety valve 7 which distribute and fill in air valves 3 9 and 27 of ind...

Page 87: ...ld be set in its top fixed position in so doing control valve 10 lets the compress air out of outlet II see Fig 75 of valve 15 see Fig 67 and actuates the trailer brake gears The alarm system and that of control over the brakes condition is available with the truck See Chapter Controls and Instruments Minimum air pressure senders are installed in the air bottles Service brake failure senders braki...

Page 88: ...6 N m 1 2 1 6 kgf m Signs of compressor failure noise and rattle increased heating excess oil in condensate which is usually a result of wear of the piston rings and crankshaft rear end seal that of the connecting rod bearings Compressor drive belt tightening control and adjustment should be carried out according to YAMZ 236M2 YAMZ 238M2 Operation Manual The pressure regulator is intended to adjus...

Page 89: ...he course of engine running and check how often the governor comes into action The two unit brake valve Fig 70 is designed for control over the actuating mechanisms of the truck service brake system as well as for control over the trailer brake drive valve The brake valve consists of the upper and lower casings The lever mechanism of the valve is fastened to the upper casing The lever body is prot...

Page 90: ...g it from mud checking for tightness Care should be taken to the condition of the brake valve protective rubber hood and its tight contact with the casing because mud getting onto the valve lifter and friction surfaces can cause failure of the brake valve The tightness of the brake valve is checked with the help of soap emulsion in two states when the brake is engaged and when it is released Air l...

Page 91: ...ed by changing of the tie rod length For this purpose slack off the lock nut uncotter and remove the pin and turning the fork to one direction or another set the required length of the tie rod and tighten the lock nut The value of the brake pedal free travel should be determined at the nominal air pressure in the truck pneumatic system by pressing the pedal before one of pressure gauge 1 pointers ...

Page 92: ...ndicating the direction of the air bypassing Adjusting screw 5 that is locked by the locked nut is installed in the cover The force of the spring is changed with the help of the adjusting screw by adjusting a value of the bypass pressure when screwing it in the value of the by pass valve increases when screwing it out the value decreases The compressed air through duct a arrives under diaphragm 2 ...

Page 93: ...compressed air from the compressor fills in the circuit which is in good working condition through return valve 13 or 14 The air is not delivered into the faulty circuit When the air pressure at the valve inlet is above the predetermined level the valve of the faulty circuit is opened and the excess air flows via it to the atmosphere In so doing the pressure is kept constant and the air is not del...

Page 94: ...air which is delivered to the trailer brake pneumatic system to the predetermined level The compressed air from the air bottle is supplied to outlet I and flows via duct A to the hollow above stepped piston 8 When the brake is re leased spring 14 acting on washer 15 holds diaphragm 16 together with pusher 19 in the lower position Fig 74 Trailer Brake Control Valve 1 spring plate 2 lower cover 3 11...

Page 95: ...f spring 14 returns to its initial position Pusher 19 lowers down with the diaphragm In so doing outlet valve 20 closes and inlet valve 21 opens The compressed air from outlet I flows to outlet II and then to the trailer connecting main and as a consequence of it the trailer semi trailer brake is released The control valve of the trailer brakes with the double line drive is shown in Fig 75 The air...

Page 96: ...s acting on diaphragm 11 from below and on piston 10 from above are balanced When the braking is stopped and the air from outlet I is let out to the atmos phere through the brake valve Diaphragm 11 with pistons 10 and 12 occupy their initial position in so doing inlet valve 3 gets closed The air from the trailer control main via outlet IV hole in valve 3 piston 12 and outlet VI is let out to the a...

Page 97: ...ssure delivered to outlet I lifter 5 under the action of spring 6 will be in the upper position The compressed air flows from outlet I to outlet II In case of breaking the trailer control brake main the pressure at outlet III equals zero while braking and at outlet IV it is kept at the same level as before Acting on lifter 5 via membrane 3 the pressure at outlet IV moves the lifter down wards The ...

Page 98: ...stem After that tighten the clamps on the coupling Tie rod 8 connecting the regulator lever with the elastic element should be mounted in the upright po sition The trailer brake disengagement valve is located in the cab on the dashboard and serves for driver s checking the ability of the towing truck parking brake system to hold the road train on the slope For this purpose it is necessary to brake...

Page 99: ...le 5 cross member No 5 6 BFR lever 7 elastic element A from brake valve Two main valve Fig 79 serves to deliver the air to the trailer valve when using the button of the trailer brake disengagement valve Fig 79 Two Main Bypass Valve 1 seal 2 body 3 cover 4 pack ing ring I III outlets to control mains II outlet to actuator ...

Page 100: ...er is lowered the air from the bottle is delivered to outlet II of the double line drive trailer brake control valve via control valve outlet b When the parking brake is engaged the slide valve of the control valve moves and connects outlet II with the atmosphere through outlet c further the trailer brake drive operates as it is said above To check the installation of the control valve set the par...

Page 101: ...e rear bogie service brake circuit on the second air booster of the brakes the trailer brake circuit on the third air bottle mounted outside on the frame r h side member Maintenance of the pneumo hydraulic drive The equipment of the brake pneumohydraulic drive does not require special maintenance and adjustment In case of their failure only qualified specialists can disassemble them in au thorized...

Page 102: ...s of the brake valve and op eration of the triple safety valve For this purpose connect the check pressure gauges to the main from the brake valve to the air booster and when the air pres sure in the pneumatic system equals 650 800 kPa 6 5 8 0 kgf cm2 press the brake pedal as far as it will go The air pressure on the check pressure gauges should be equal to the pressure in the system on the two po...

Page 103: ...ure is available in the truck pneumatic system Prior to filling in the system remove mud from the brake master cylinders and tanks Then having removed the sealing pipe and screwed off the filler plug fill in the tanks with braking fluid and remove the air from the hydraulic system The order of pumping through the brake master cylinders and wheel cylinders of the service brakes should be as follows...

Page 104: ...2 to expansion lever 13 When the brake drum rotates clockwise the drive effort is transferred from lever 13 via rod 1 to r h shoe 2 The shoe goes off the supporting pin and presses to the brake drum In so doing the shoe owing to friction is caught by the drum shifted in the direction of rotation and via adjusting device 3 presses l h shoe 14 to the supporting pin and drum When the brake drum rotat...

Page 105: ...heck the clearance with the help of checking probe through the slit in the brake baffle Tighten the lock nut preventing the pin turning 4 Adjust the clearances between the l h shoe and drum For this purpose re move stopper 4 Set a clearance of 0 3 0 5 mm through the hole in the brake shield turning sprocket 5 by a screwdriver from the top down Install the stopper 5 Select free travel of lever 8 se...

Page 106: ...ps to their initial position The locked drive synchronous with engaging the auxiliary brake cuts off the fuel feed The design of the air cylinder cutting off the fuel feed is similar to that of the auxiliary brake air cylinder When travelling with the auxiliary brake engaged the engine speed should not exceed 2100 min 1 do not shift the gears in the gearbox from the high to low one at the engine s...

Page 107: ...hing is located outside the cab right after the sealing bush of the flexible shaft through hole in so doing it is necessary to lay the flexible shaft without any loops behind the dashboard To ensure reliable operation of the said instruments and systems care should be taken to condition of the fuses installed in assemblies Avoid the use of non standard fuses in the form of bended wires bolts washe...

Page 108: ...r ДЕ М or MМ111Д 26 oil pressure ММ370 27 Starting preheater spark plug СН423 28 Coolant overheating sender ТМ111 01 29 Alternator Г288Е or 1702 3771 30 High voltage source ТК107A or 9301 3734 31 Starting preheater fuel heater 11 3741060 32 Starting preheater solenoid valve ПЖД30 1015501 04 33 Starter 25 3708 01 Switches 34 starting preheater motor 46 3710 35 starting preheater spark plug ВН45М 36...

Page 109: ...ad train sign lamp УП101Б1 69 Pilot lamps assy ПД511Е Alarms 70 trailer turn indicators 71 tractor truck 72 readiness to start 73 Central light change over switch П305 74 Fuel level indicator УБ170 01 or 34 3806010 75 Fuel reserve alarm 76 Turn indicator change over switch П110А or П110B 01 77 Current indicator AП171A 78 Speedometer 161 3802 79 Distant light alarm 80 Tachometer 253 3813 81 Starter...

Page 110: ... 3827010 108 Air bottles pressure drop sender 2702 3829 or ДЕ В or MM124Д 109 Trailer socket ПС300 А3 110 Body illuminating lamp ФП103Г 111 Connecting panel 17 3723 112 Rear r h lamp ФП133 АБ 113 Rear fog lamp 2412 3716010 114 Reversing lamp 2112 3711 115 Number plate lamp ФП134Б 116 Rear l h lamp ФП133АБ 117 Side clearance lamp 431 3731 118 Trailer socket ПC326 150 or СНЦ125 7 45В034 01 119 Trail...

Page 111: ...al Ш is made as two pin jack connector for connecting with the voltage regulator body for connecting to the tachometer Fig 87 Alternator 1 fan 2 pulley 3 7 ball bearings 4 rotor 5 brushes 6 brush holder cover 8 collector rings 9 rectifying unit 10 cover on the side of collector rings 11 stator 12 cover on the side of drive Technical data at ambient temperature of 15 35 C Rated voltage V 28 Rated c...

Page 112: ...channel less than 5 mm The effort of pressing the brushes to the commutator if the spring is compressed to 17 5 mm is about 0 19 0 25 N 19 25 kgf If wear of the collector rings exceeds 0 5 mm in diameter turn them on lathe The minimum permissible diameter of turning is 29 3 mm The ball bearings are made tight and packed with grease sufficient for their entire service life In case of jamming or lou...

Page 113: ...ly if the diodes are connected in the conducting direction If the pilot lamp is switched on in both directions and in both cases it goes ON or OFF it means that the rectifying unit diodes are faulty If any fault of diodes is discovered replace the rectifying unit Do not test the rectifying unit connected to a voltage source of more than 24 V an a c source Fig 88 Circuit Diagram for Bench Test of A...

Page 114: ...rding to the Operation Manual of YAMZ 236M2 YAMZ 238M2 engines Voltage regulator The contactless voltage regulator with three levels of adjustment is designed to maintain constant voltage in electric circuits of the truck It is an electronic device with semi conductor elements To adjust voltage use switch located on the regulator front cover Fig 90 Positions of the switch arm correspond to voltage...

Page 115: ...gulator Fig 91 Connecting Diagram for Voltage Regulator and Generator for Checking Voltage Regulator on Bench 1 alternator 2 ignition switch 3 voltage regulator 4 current indicator 5 stor age battery 6 voltmeter 7 load 8 ground switch Storage batteries The storage batteries are designed to start the engine with the help of starter and operate in combination with the alternator at maximum loads The...

Page 116: ...s from the truck on board electric network with the help of ground switch remove spring ring 14 of cover 6 locks and open the locks lift up cover 6 and tilt it onto bracket 3 Make sure that cover 6 is fixed securely in horizontal position slack off fastening of the wires and jumper to the batteries having removed batteries terminals protection overs if any take front stop 4 out of box 10 lifting o...

Page 117: ...lts screw out the filler plugs remove the sealing gaskets and scour the venti lation holes in the plugs cut off the projections available on the polyethylene plugs and clean the ventilation ducts pour the electrolyte into the batteries its density is given in Tabl 6 Table 6 Electrolyte density Climatic zones and regions Mean ambient temperature in January C GOST 16350 70 Season Electrolyte density...

Page 118: ...rolyte Density Dependence on Temperature Correction Electrolyte temperature C Correction for densimeter readings g cm3 from 46 to 60 0 02 from 45 to 31 0 01 from 30 to 20 0 00 from 19 to 5 0 01 from 4 to 10 0 02 from 11 to 25 0 03 from 26 to 40 0 04 from 41 to 55 0 05 If at the end of charging the electrolyte density measured taking into account the temperature correction see Table 8 differs from ...

Page 119: ...of water Final preparation is made right before filling 1 26 1 28 at 40 C 0 13 litre per one litre of diluted electrolyte The electrolyte level should be 10 15 mm above the safety shield Charge the batteries when the nearest opportunity occurs and bring the electrolyte density to its norm Order of battery operation In the course of operation do not connect the battery terminals to each other to te...

Page 120: ...lamps rear turn indi cators a stop signal reversing lights a light reflecting device and side light reflecting devices The head lamps are engaged by central changeover switch 19 see Fig 12 in position II the distance or dim light is engaged by a foot changeover switch When the central changeover switch is set in position I or II the clearance lamps and instrument illumination lamps are turned on c...

Page 121: ...of the screen should be 2 5 m minimum The screen should be marked out For this purpose apply three vertical lines Fig 94 The intermediate axial line conforms to the crossing of intermediate lon gitudinal plane of the screen the two lines from the right and left of it are the lines on which the centres of the head lamps are projected The horizontal line A A is also applied onto the screen The dista...

Page 122: ...it occupies a position 190 mm below the line A A Following the procedure above means fulfillment of the requirements for setting of initial inclination of the headlamp lower beam Upon completing the adjustment re set the headlamp lenses The lower beam of the headlamps may be adjusted with the help of special devices designed for these purposes in accordance with Operation Manuals for those devices...

Page 123: ...mps proceed as follows undo the bolts fas tening the headlamp rubber moulding loosen the screws fastening the sealed beam unit retaining ring remove the retaining ring and the sealed beam unit re move the spring fixing the bulb and replace the latter Perform the assembly in the reverse order Safety fuses The preheater supply circuit is protected against short circuits by bimetallic a 30 A fuse typ...

Page 124: ...passengers seat belts The cab is fastened to the chassis frame in four points on rubber pads When the chassis frame deformation occurs the flexible fastening protects cab parts from over strain The cab doors are equipped with locks and window raisers When closing the door pawl 12 Fig 99 of the truck comes in touch with door striker 11 and turning Fig 96 Visibility Zones Through Rear View Outside M...

Page 125: ...n be blocked from the outside by the key To open the door lock turn the lock drive handle upwards or press the button on the outside handle In so doing the latch releases the catch and the pawl returns into its initial position under the action of spring 15 The door striker is fastened on the lock post with a screw and two bolts which allow to adjust it in height and depth When adjusting check tha...

Page 126: ...control button located on the dashboard to the left of the steering wheel When ambient temperature exceeds 5 C filtered water is used for filling in the tank At the ambient temperatures from 5 C down to 40 C it is recommended to use a distilled water solution and sulfanol solution in isopropyl spirit НИИСС 4 flu id in the ratios specified in Table 11 Table 11 Concentration of HИИСС 4 Water Solutio...

Page 127: ...ver 6 electric motor and fan assembly 7 interior hatch cover 8 heater radiator 9 heater radiator water outlet pipe 10 water supply pipe 11 cock 12 exterior hatch cover 13 deflector Optimum location of the heater controls is as follows simultaneous intake of the air from the outside through hatch adjusted by cover 12 from the cab through in terior hatch closed by cover 7 and supply of the heated ai...

Page 128: ...t side of support Fig 101 II fixes the seat in the desired position The driver s seat has a mechanism designed to change the cushion tilt and the seat position by height with an adjustment limit of 80 mm To change the position of the seat by height turn out two front screws 3 available on the left and right sides of the seat Upon setting the desired height of its front part turn up these screws by...

Page 129: ...U bolts 3 platform to chassis frame fastening bracket 4 l h r h extension side 5 l h r h main side 6 tailgate locking chain 7 front extension side 8 front middle seat fastening bracket 9 front side 10 side seats of platform body 11 rear middle seat fastening bracket 12 tailgate 13 alarming button to driver 14 middle seat of platform a rear view The platform body is equipped with seats for carrying...

Page 130: ...nopy 1 canopy fastening rope 2 rope fastening rear panel of canopy 3 canopy bow 4 bow distance pipe a front view Fig 103 Middle Seat Folding 1 rear middle seat 2 fastening belt 3 front middle seat 4 platform front grill 5 platform front side ...

Page 131: ...face with a piece of cloth moistened in gasoline or solvent dry and paint it by enamel with the help of a sprayer or a soft brush using the same colour of the enamel and applying two layers of the enamel with an interval of 5 10 min Regularly remove and dry the cab floor mat because the wet mat looses its heat insulating properties and promotes floor rusting FIFTH WHEEL The fifth wheel with a lock...

Page 132: ...3 is available on the rod end for opening moving the cam Nuts 3 serve to adjust the clearance between the catches and the pintle of the semi trailer The cam in the opened position is held with the help of springs 9 by latch 6 Rear catch 18 rotates on pin 17 closed by cover 7 fastened by nut 12 Safety strip 19 which is fastened to the saddle by bolt 11 serves to prevent accidental opening of the ca...

Page 133: ...r truck has been coupled with the semi trailer Fifth wheel maintenance Before a departure check whether the fifth wheel is fixed to the chassis frame se curely and verify fastening of the catch lock Check the condition of the catches locking cam and latch spring Worn and deformed components should be replaced by the new ones Coupling and uncoupling of bolster truck and semi trailer Before coupling...

Page 134: ...loose ground put pads under the supporting device of the semi trailer plug out the semi trailer power cable disconnect the coupling heads of the brake pneumatic drive first the feed ing main then the control main and close them by protective caps Fasten the coupling heads with the hoses on the bolster truck plate turn handle 1 to you in so doing safety strip 19 will be drawn aside and latch 6 will...

Page 135: ...2 pump 13 ball bearings 14 output shaft 15 spacing ring of bearings 16 roller bearings Fig 108 Power Take Off with Flange 1 drive gear axle 2 hous ing 3 drive gear 4 housing cover 5 output shaft gear 6 engagement chamber diaphragm 7 engagement chamber cover 8 cover 9 fork 10 en gagement fork rod 11 spring 12 output shaft 13 cover 14 flange 15 nut 16 collar 17 ball bearings 18 spacing ring of beari...

Page 136: ... The power take off engagement chamber is connected with the atmosphere via the hole in rod 10 see Fig 107 the air is let out of the chamber and the rod with fork 9 under the action of the spring disengages output shaft 14 gear from drive gear 3 Simultaneously with letting out the air to the atmosphere valve 3 see Fig 109 under the action of spring 2 is pressed to seat 4 and disengages the valve i...

Page 137: ...ball bearings 16 pump connecting rod 17 piston 18 21 pump valves 19 plug 20 safety valve 22 valve body For remote control of the auxiliary power take off the control valve 6 see Fig 11 is mounted on the bracket fixed to the lower edge of the dashboard in the driver s cab on the right of the driver The control valve lever is fixed in the disengaged position with the screw mount ed on the valve brac...

Page 138: ...d and the drum sliding clutch is disengaged If the brake heats to the temperature your hand can not bear about 60 C within 1 3 min screw out nut 3 and lock nut 4 fastening the band by two or three revolutions Winch reduction gear unit adjusting Adjust the reduction gear unit bearings if axial clearances have appeared in them as well as when a new worm pair is installed Adjust the bearings if only ...

Page 139: ...olts 12 reduction gear cover 13 rope railing 14 fixed coupling 16 24 28 33 shims 17 25 27 37 bearing caps 18 23 29 31 32 bearings 19 reduction gear unit case 20 worm wheel 21 plug 22 sliding clutch 26 flange 30 reduction gear worm 34 gasket 35 band brake 36 rope fastening clamp 38 lead screw right hand bracket 39 coupling rod 40 fork 41 slide block 42 winch suspension cross member ...

Page 140: ...de of the brake so that the total thickness of shims on both sides remains the same The contact pattern is displaced across the tooth width by the axial displacement of the worm gear in the same direction where the pattern is displaced The globoid worm pair can operate properly if only the meshing has been ad justed correctly Improper adjustment can cause excessive heating of the pair and rapid we...

Page 141: ...backwards only The guide roller holder case 22 puts the rope reciprocating along lead screw 6 and on two guide rolls 7 The l h and r h threaded screw mounted on two bearings is driven via a chain gear from the drum shaft through driving and driven sprockets 16 and 10 Tensioning of the chain is adjusted by shims 2 and 14 the chain sagging is 3 10 mm Axial force from lead screw 6 is transferred to t...

Page 142: ...r box and gearbox levers in the neutral position using a 30 mm wrench set the sliding clutch lever in the upper position ON when forcing out the rope For moving out the rope manually the sliding clutch lever should be in its lower position OFF engage the auxiliary power take off by control valve 6 see Fig 11 engage the first or second gear and move out the rope of the desired length choose the rop...

Page 143: ...th the truck If the pulley has to be applied for increasing the pulling effort for self recovering position I it should be fastened with the towing rope to an object selected as a sup port and the winch rope hook to the hook of draw gear If the pulley is applied to change a towing direction when recovering other truck position II it should be fas tened with the help of towing rope to the object th...

Page 144: ...g 116 allows to control and maintain the tire pressure within the required norm as well as to increase cross country ability of the truck for the account of the tire pressure reducing It provides an opportunity to con tinue travelling with a punctured wheel inner tube without changing the wheel the wheel valves of intact wheels should be closed if the supplied air quantity is enough for maintainin...

Page 145: ... is different So check the tire pressure following the procedure described above When moving with the rated tire pressure the wheel valves of the front axle should be closed and those of the rear bogie should be open In the areas with difficult terrain such as swampy terrain snowed up virgin and loose sand it is permitted to reduce pressure to 0 1 MPa 1 0 kgf cm2 For this purpose open the wheel va...

Page 146: ...t the pressure as per Table 12 depending on the travelling conditions see Chapter Driving the Truck Maintenance of the system lies in checking its tightness Check the system for tightness after the tires have cooled down to the ambient temperature The points of heavy air leakage should be determined by ear and those of small air leakage by applying soap emulsion The air leakage through connections...

Page 147: ...er when fording and maintaining constant pressure in the inner hollows of the units as well as in fuel tanks the sealing system is foreseen Fig 118 Dismantling I II and Installation III of Air Supply Collars Assembly Parts 1 puller 2 collar 3 4 hold ers 5 slewing journal 6 dis tance ring 7 mandrel ...

Page 148: ... the cooling system Ditto High voltage source feed chain break Check and tighten up terminal connections of conductors High voltage source does not operate Disconnect the high voltage wire and fix its end at a distance of 3 5 mm from the truck ground If no spark appears when switching on the plug change the high voltage source The spark plug does not operate Clean or replace the spark plug The sol...

Page 149: ... of the gears and differen tial lock Burrs on splines of gears front holder en gagement clutches Scrape spline surface Lock seizing Clean the hole for the ball D r i v i n g A x l e s Increased noise of axles Bevel gears contact pattern is displaced onto the edge of the tooth narrow end Adjust gearing in ac cordance with contact pattern Clearance in the re duction gear bearings Restore preload of ...

Page 150: ...g the mani fold And if the faults have not been remedied by means of the above measures replace the oil Insufficient thightening of the pump drive belt Tighten up the belt The pump does not provide the required deliv ery and pressure Check the pump Increased oil leakage in the distributor scores on bearing surfaces of the slide valve Replace the distributor Slacked tightening of the slide valve nu...

Page 151: ...lot lamp lights on The inner collar is worn out or fluid is not available in one of the master cylinders Replace the collar Add the fluid bleed the brakes The piston collars or those of the air booster spacer are worn out and the air escapes from the booster pipe when the pedal is pressed Replace the collars The brake is blocked up it can not be released Free travel of the brake pedal is not avail...

Page 152: ...rent Check the voltage regulator Short circuit of the plates in one of the cells Bring the battery to a re pair shop When charging the storage battery completely discharged electrolyte s voltage and temperature grow rapidly intensive gassing starts while the density grows insignificantly Plate sulfatizing that can occur in case the battery has been out of op eration for a long time or the battery ...

Page 153: ...of the auxiliary power take off APTO Burrs on the shaft splines of the transfer box APTO and engagement coupling Scrape the surface of splines High vibration noise and oil leakage Slacked flange nut Tighten up the flange nut Worn rear bearing of the APTO Replace the rear bear ing The APTO fails to engage The pneumatic cham ber di aphragm of the APTO engagement mecha nism is damaged Replace the dia...

Page 154: ...nds on its warm con dition and on ambient temperature Electric engine starting system ensures its start without preheating at an ambient temperature to 10 C At the temperature lower than 10 C make use of the starting preheater If the storage batteries are under charged and for the purpose of increasing the engine service life it is recom mended by the Manufacturer to use the starting preheater als...

Page 155: ...e switch on the starting preheater control board spring loaded switch and at the same time keeping the spark plug ener gized switch on the pump unit and solenoid valve Hold the spark plug switch knob for not more than 20 s until specific roaring is heard in the heat exchanger indi cating ignition of fuel in the burner The preheater in good working order should be started within 10 to 15 s 5 Releas...

Page 156: ... run during 1 3 min unloaded at me dium speed then reduce the engine speed down to minimum and pull out the knob as far as it will go RUNNING IN A NEW TRUCK A service life reliability and economical operation of the truck depend on the initial running in of the parts in the pre service period The running in of the truck may be performed prior to putting it in operation as well as in the course of ...

Page 157: ...osition if any gear is engaged in the gearbox and auxiliary power take off is disengaged Engage the auxiliary power take off and the power take off after the truck has been stopped with the disengaged clutch and the pressure in the air system not less than 500 kPa 5 kgf cm2 After shifting the valve lever to ON position re lease the clutch pedal smoothly Brake the truck smoothly pressing the pedal ...

Page 158: ...15 25 30 600 800 1400 All types of roads while inflating tires after heavy sections of roads 0 15 rated 1 5 rated 40 1400 Tires 390R20 O 65 model Kind of Road Permissible Reduced Pressure MPa kgf cm2 Max Speed km h Maximum Run within Warranty Period of Tires km Heavy section of swampy terrain snowed up virgin land and loose sands 0 10 1 0 0 15 1 5 0 20 2 0 15 20 30 600 800 1400 All types of roads ...

Page 159: ...hoose and check the places where the truck is to enter the water and get out of it as well as mark deep places with surveying rods To cross over a ford down to 1 m deep close the radiator with its shutter set the rated tire pressure To cross over a deeper ford on the truck equipped with a fan coupling set the fan friction drive switch to the forced switching off position having set the handle of f...

Page 160: ...all basic assembly units of the truck as well as the hollows of the wheel hubs and those of the front axle steering knuckles for water penetration into them If the oil level in the truck units is higher than the norm reduce it to the re quired one and replace the oil at the first opportunity After fording prepare all assembly units of the truck for operation under nor mal road conditions and elimi...

Page 161: ...a specified extent will ensure a permanent inherent availability of the truck and re duce repair demand For proper execution of the maintenance it is recommended to do it at special spots which are outfitted with necessary tools and fixtures Adjustment and maintenance of the engine fuel system instruments of electric equipment hydraulic systems should be performed by qualified specialists Types of...

Page 162: ... the end faces of cooling pipes in the upper radiator tank see the Lubri cation Chart Tank with low freezing coolant rule Fill up the tank of windshield washer pump Drain water from the tank at subzero ambient temperature Vessel Check functioning of lighting devices light and sound alarms instrumen tation and windshield wipers Faulty units are not allowable Check operation of the generator by the ...

Page 163: ...kes failure pilot lamp on the dashboard parking brake system The brake shoes being fully pressed to the drum the brake pawl should position on 4 12th teeth of the seg ment Check the towing unit for good condition when operating the truck with trailer The towing hook nut should be locked and the hook catch cottered By visual inspection Check the tires for good condition and the wheels for proper fa...

Page 164: ...17x19 vessel wiping material Drain the sediment from the coarse mesh and fine mesh fuel filters Fuel leaks through drain hole plug are not al lowed Ditto Transmission Check and adjust if required the clutch pedal free stroke see section Clutch Release Control Clutch pedal free stroke must lie within 50 60 mm with no pressure available in truck air system Wrenches 17x19 14x17 pliers rule Inspect an...

Page 165: ...d be tight Socket wrench 24 tommy bar walking beam axle assy to walking beam brackets Ditto Socket wrench 30x32 tire iron with hydraulic jack tommy bar front brackets of front springs to lower flange of frame side member Ditto Wrench 22x24 rear brackets of front springs to reinforce ment parts of frame side member Ditto Wrench 22x24 24x27 socket wrench 24 tommy bar fifth wheel for bolster trucks D...

Page 166: ... the truck drives Wrench 19x24 box wrench 22x24 Electric Equipment Check electrolyte level and density in stor age batteries add distilled water if need be charge the battery See Section Storage Batteries Wrenches 11x13 17x19 vessel with distilled water glass tube dia 3 5 mm densimeter Check and if need be adjust the headlamps see Sub Section Light ening and Signalling Sys tem Adjust the headlamps...

Page 167: ...Wrench 22x24 vessel for used oil model 133M oil dispenser tank wiping material final drives of driving axles see Lubri cation Chart Ditto Wrench 27x30 vessel for used oil model 133M oil dispenser tank wiping ma terial Lubricate the power unit in conformity with the Lubrication Chart in Op eration Manual for YAMZ 236M2 YAMZ 238M2 engines Maintenance No 1 M 1 When performing M 1 on a new truck wash ...

Page 168: ...th hydraulic jack tommy bar rear spring U bolts 1 Ditto Socket wrench 30x32 for wheel nuts tire iron with hydraulic jack tommy bar Steering Check oil level in the tank of booster pump add oil if need be Oil level should lie between the upper and lower marks on the dip stick the plug being un screwed Oil dipstick wiping material Braking Systems Adjust clearance be tween wheel brake shoes and drums ...

Page 169: ...iping material Every Second M 1 Maintain the power unit in accordance with the Operation Manual for the YAMZ 236M2 YAMZ 238M2 engines Maintenance No 2 M 2 Carry out the works specified for M 1 and the works as follows Engine Maintain the power unit in accordance with the Operation Manual for the YAMZ 236M2 YAMZ 238M2 engines Check fastening of the radiator Fastenings should be tight Wrench 17x19 p...

Page 170: ...crewdriver Running Gear Inspect and if need be tighten up the nuts fixing front spring eyes Fastening should be tight Socket wrench 30x32 tire iron with tommy bar pliers screwdriver driftpin hammer front spring U bolts Fastening should be tight When tightening up the truck must be fully loaded Socket wrench 30x32 for spring U bolt nuts tire iron with hydraulic jack tommy bar rear spring U bolts Di...

Page 171: ... jack tommy bar ГАРО dolly for dismantling wheels Steering Check and if need be tighten up the nuts fixing steering gear case Fastening should be tight Wrenches 19x22 22x24 box wrench 24x27 cardan forks of steering gear shaft Ditto Wrenches 14x17 17x19 pins of link rods Ditto Box wrench 24x27 pliers booster Ditto Box wrench 24x27 socket wrench 36 pliers screwdriver hammer tire iron with hydraulic ...

Page 172: ...llowed Pliers screwdriver knife insulating tape Check fixing and cleanness of wire shoes on starter terminals Loose fixing and soil ing of connections are not allowed Wrenches 10x12 17x19 Cab Platform Bed Inspect and if need be tighten up the fas teners of cab bed hood and fenders Fastenings should be tight Wrenches 10x12 11x13 17x19 22x24 Special Equipment Сheсk fastening of the power take off Fa...

Page 173: ...rdance with the Operation Manual for the YAMZ 236M2 YAMZ 238M2 engines Check and adjust if need be the rear support of power unit see section Power Unit Mounting Fastenings should be tight Wrenches 17x19 22x24 Transmission Check and adjust if need be tapered bearings of transfer box primary and intermediate shafts see section Transfer Box Primary and interme diate shafts axial displace ment 0 03 0...

Page 174: ...r Hydraulic Control of Service Brake System Air should flow to air bottle of trailer brakes as the pressure in the other bottles rises to 550 kPa 5 5 kgf cm2 Wrench 17x19 test pressure gauges Check pressure on the coupling head of single line control black see Section Air Over Hydraulic Control of Ser vice Brake System The test pressure gauge should indicate 480 530 kPa 4 8 5 3 kgf cm2 When applyi...

Page 175: ... heated Socket wrench 140 iron with hydraulic jack tommy bar screwdriver jack ГАРО dolly for dis mantling wheels vessel for lubricant wiping material wrenches 10x12 17x19 half axle puller Disassemble and lu bricate splined joints of front and rear axle drive cardan shafts see the Lu brication Chart Apply lubricant in thin layer over the entire surface of the splines When reas sembling see that the...

Page 176: ... box case see Section Trans mission Transfer Box and the Lubrication Chart Fill oil up to the edge of inspection hole available in the housing rear wall Oil leakage through plugs is not permissible Wrench 27x30 vessel for used oil model 133M oil dispenser tank wiping material in final drives of driving axles see the Lubrication Chart Ditto Wrench 27x30 vessel for used oil model 133M oil dispenser ...

Page 177: ... 24x27 pliers screwdriver hammer tire iron puller for half axle wiping material Lubrication Lubricate the power unit in conformity with Operation Manual for the YAMZ 236M2 YAMZ 238M2 engines Seasonal Maintenance SM Engine Lubricate the power unit in conformity with the Operation Manual for the YAMZ 236M2 YAMZ 238M2 engines Electric Equipment Check adjustable voltage on the truck See Section Voltag...

Page 178: ...erosene or diesel fuel Lu bricate them with transmis sion oil Wrenches 12x13 17x19 combination wrench 14x14 box wrench 17x19 socket wrench 27x38 for nuts Disconnect and blow with pressed air pipes and hoses of the sealing system Clogging of pipes and hoses is not allowed Wrenches 12x13 17x19 22x24 combination wrench 14x14 socket wrench 10 compressor hose Frame Cab Hood and Fenders Bed Inspect pain...

Page 179: ...ticular units and parts are described in corresponding Sections of this Operation Manual which is supplied with each truck Lubrication operations should be carried out when maintaining the truck in accordance with the schedule also when repairing the respective unit Range of basic fuels and oils as well as their substitutes for the power unit also schedule of their change should be in conformity w...

Page 180: ...179 Fig 119 Truck Lubrication Diagram ...

Page 181: ... injection advance coupling 1 Parking brake adjusting lever shaft 1 Oil used for engine Oil used for engine Parking brake adjusting mechanism thread 1 Starter bearings 3 See Operation Manual for the YAMZ en gine Starter drive 1 5 Gearbox 2 1 6 Transfer box 2 1 Oil ТСп 15К at temperature not below minus 30 oC Oil ТСп 10 at temperature not below minus 45 oC At a temperature be low minus 30 oC it is ...

Page 182: ...20W Mobil Delvak 1220 BP Vanellus M20W 7 10 drops 7 10 drops Every second M 2 Clean the shaft between adjusting lever and mud guard lubricate 4 5 drops 4 5 drops Every fourth M 2 Remove rubber plug on brake shield lubricate Shell Spirax 90 EP Mobilube GX 90 BP Gear oil EP SAE 90 Esso Gear oil GP 90 0 02 0 06 See Operation Manual for the YAMZ en gine 0 04 0 04 5 50 5 50 3 50 3 50 After initial 1000...

Page 183: ...h 10 15 of diesel arctic or winter grade fuel 28 Steering gear case 2 1 Auxiliary power take off 1 16 Drive axle final drives 2 front 1 Oil ТAп 15B at temperature not below minus 25 oC Oil ТСп 10 at temperature not below minus 45 oC At a temperature be low minus 25 oC it is allowed to dissolve oil ТСп 15K or ТAп 15B with 10 15 of diesel arctic or winter grade fuel intermediate rear 2 8 Rear walkin...

Page 184: ... working surfaces of parts BP Gear oil EP SAE 90 Deusol Gear EP 90 Esso Gear oil GP 90 Mobilube GX 90 Shell Spirax 90 EP 5 0 5 0 After initial 1000 km Change oil Fill oil up to filler hole edge available in the axle case If the final drive was demounted first pour 1 l of oil through the breather hole on final drive casing the remaining oil should be poured through filler hole up to its edge 8 5 17...

Page 185: ...us 18 oC screw ball nut rack segment 25 Steering knuckle housing of front driving axle 2 Mixture of lubri cant Литол 24 with oils for re duction gears of drive axles 50 each Mixture of cardan lubricant AM with oils for reduction gears of drive axles 50 each 22 Spiders needle bearings of cardan shafts of drive of front intermediate and rear axles and in termediate shaft 8 Lubricant Литол 24 Lubrica...

Page 186: ...l 1000 km M 1 Every third M 2 but at least once a year Check oil level and add if need be The oil level should be between upper and lower marks available on the dipstick with the plug being un screwed Oil P should be changed in the course of repair Change oil 6 5 6 5 5 4 10 8 M 1 Check lubricant level in unit and add lubricant if need be Fill lubricant up to the filler hole edge Every second M 2 C...

Page 187: ...а Lubricant ЦИАТИМ 201 4 Air cylinders of auxiliary brake sys tem and clutch control 4 20 Air boosters of ser vice brakes rods spacer collars cyl inders and piston collars 2 Bearings of com pressor tensioner pulley 1 See Operation Manual for the YAMZ en gine ...

Page 188: ... second and between the third and forth collars Lubricate with a thin layer the working surface of half axle 0 007 0 028 SM once a year Change lubricant Lubricate piston collar rod working surface of cylinder 0 03 0 06 Every fourth M 2 Change lubricant Lubricate piston collar working surface of cylinders rod and spacer gland 0 02 0 02 See Operation Manual for the YAMZ engine ...

Page 189: ...pump bearing 1 Front bearing of gearbox primary shaft 1 Ground switch terminals and plugs 4 Lubricant Литол 24 Solidol oil Ж solidol oil С Clutch release sleeve 1 See Operation Manual for theYAMZ engine Bearings of clutch release fork shaft 2 1 Front spring pins 2 Lubricant Литол 24 Solidol oil Ж and cup grease Ж Solidol oil C and cup grease C ...

Page 190: ...the hub between bearings 0 016 0 016 See Operation Manual for the YAMZ engine 0 045 0 045 0 025 0 025 Retinax A Alvania R3 Alvania RA Mobilux 3 Beacon 3 Energrease L2 0 0005 0 002 SM once a year in autumn Lubricate with a thin layer the plugs before connection while the terminals after connection having first cleaned them 0 04 0 04 See Operation Manual for the YAMZ engine 0 005 0 01 Retinax A Alva...

Page 191: ... Литол 24 Solidol oil Ж and cup grease Ж Solidol oil C and cup grease C 7 Torque rod joints 12 Joints of fuel feed control 6 11 Towing unit bushes 2 Knuckle pin upper bearings 2 19 Splined connections of cardan shafts intermediate axle and intermediate shaft drive 2 ...

Page 192: ...Lubricate trough grease cups until fresh lubricant ap pears from gap be tween head and packing ring or before beginning of deformation of packing ring 0 0033 0 020 SM once a year Lubricate working surfaces when disassemblyng 0 025 0 05 M 1 Lubricate trough grease cups until fresh lubricant ap pears when oper ating with trailer 0 100 0 20 M 2 Lubricate trough grease cup 0 020 0 04 M 2 Lubricate tro...

Page 193: ...ering control 1 winch drive 2 Spare weel lift re duction gear 1 15 Plain bearing of winch drum shaft 1 14 Rope winding guide bearings 2 Friction surfaces between fifth wheel bracket and cushion 4 1 Solidol oil Ж solidol oil C or lubricant Лита Knuckle and slot of the fifth wheel 4 1 Front and rear clamps pivot pin of rear clamp 3 ...

Page 194: ...ssemble and lubricate 0 02 0 04 SM once a year Lubricate through grease cups until fresh grease oozes 0 05 0 05 Lubricate in the course of disas sembly 0 1 0 1 SM once a year Lubricate trough grease cups until fresh grease oozes 0 035 0 07 Lubricate in the course of disas sembly 0 1 0 1 Lubricate in the course of disas sembly 0 03 0 03 0 015 0 045 ...

Page 195: ...w 1 Graphite grease УСсА Solidol oil Ж solidol oil C or lubricant Литол 24 12 Roller bushes and holder body cavities of winch rope guide rollers 3 14 Chain transmission of winch rope winding guide 1 23 Center bracket shaft of brake valve con trol and clutch control 1 ...

Page 196: ...erol LG2 0 30 0 30 Lubricate after each winch operation If winch was not used lubricate once a year in the course of SM 0 033 0 1 Lubricate when disassembling 0 1 0 1 Lubricate when disassembling 0 03 0 03 Every third M 2 Lubricate trough grease cups until fresh grease oozes ...

Page 197: ...il C or lubricant Литол 24 17 Service brake shoe pins 12 Parking brake con trol two arm lever pin on transfer box 1 Rod pins brake shoes supports and lever joints of parking brake 4 Pin of parking brake control lever in cab 2 Pins of parking brake control inter mediate levers on cross piece 2 ...

Page 198: ...rol LG2 0 015 0 015 Lubricate when disassembling bushes and shafts 0 005 0 060 Every second M 2 Lubricate shoe bushes and pins 0 005 0 005 Lubricate when disassembling having first cleaned them 0 005 0 020 0 0075 0 015 Lubricate when disassembling bushes and pins 0 0075 0 015 ...

Page 199: ...m oper ating pressure in pneumatic system 3 brake signal switch 2 Terminals and fas tening studs rear lamps 6 number plate lamp 3 21 Hydraulic system of brakes 2 Brake fluid Томь At a temperature below minus 40 оC dissolve brake fluid with 18 20 of ethyl alcohol by weight 5 Brake fluid Нева ГТЖ 22М or Роса At a temperature be low minus 40 оC dis solve brake fluid with 18 20 of ethyl al cohol by we...

Page 200: ...r to connection of plugs having first cleaned them Lubricate with thin layer prior to connection of ter minals having first cleaned them Lubricate with a thin layer the plugs of rear lamp number plate lamp prior to connec tion fastening studs together with nuts after their fixing having first cleaned them Shell Donax B Mobil Hydraulic Brake Fluid Gastrol Girling Pentosin Super Fluid I 1703 R 0 850...

Page 201: ... 8 the oils and working fluids are given in liters plastic greases in kilograms 2 Column 7 gives rated values of oils and working fluids to be filled in therefore after priming it is a good practice to check the level of oil fluid and if need be to bring the level to the norm as required in Section Maintenance 3 Applicable to the Ural 4320 10 Ural 4320 31 Ural 4420 10 Ural 4420 31 trucks 4 Applica...

Page 202: ... surfaces of parts when reassembling 0 850 1 700 Change fluid after disassembly washed shock ab sorber parts in kerosene and dried them up 31 0 31 0 See Operation Manual for YAMZ engine Check coolant level and if required bring it up to nor mal 15 25 mm above the end faces of radiator cooling pipes at tempera tures above zero up to 40 oC 36 5 36 5 ...

Page 203: ...ngaged position then engage the auxiliary power take off drive for 3 5 min with the engine running To preserve YAMZ 236 238 power unit it is required to follow the procedure described below when using TОСОЛ fluid antifreeze or water instead of coolant feed one of the anticorrosive agents into the cooling system as per Table 13 of this Opera tion Manual pour the oil out of the engine and gearbox fi...

Page 204: ...s of the rear lights the number plate light con nections of the bottle air pressure senders terminal connections of the brake system failure senders and the STOP signal switches the battery output terminals with the wire leads Lubricate the exterior unpainted surfaces of the front axle ball bearings open surfaces of the transfer box rods and those of the auxiliary power take off with a thin layer ...

Page 205: ...ocessing petrolatum Литол 24 grease or solid oil For touch up painting of damaged metal surfaces MЛ 12 enamels as per GOST 9754 76 Standard orange sand khaki MЛ 152 enamels as per GOST 18099 78 Standard orange sand goldish yellow MЧ 145 enamel as per GOST 23760 79 Standard orange MЧ 123 enamel black MС 17 enamel black To protect tires hoses drive belts and other rubber items from adverse effect of...

Page 206: ...t the air out of the bottles through the condensate drain cocks Restore the grease on the surface of the ball supports When storing the trucks in unheated rooms or under a shed perform the above said check of the working order of the units components and systems every quarter When storing the truck the units of which are filled with the working and preservative oils in the open air or under a shed...

Page 207: ... sea and air In so doing the preparatory work should be done as follows 1 Prior to shipment check the tire pressure and if necessary bring it to the norm and close the wheel valves The tire pressure of the trucks without the tire pressure control system should be of the rated value 2 Upon placing the truck on a transport means brake the truck with its parking brake engage the first gear in the gea...

Page 208: ... of Three Trucks on Two Four Axle Railway Flat Cars 1 spring support bracket The number of the wires in the bracing cable their diameter as well as the number of the nails required to fasten the thrust bars should be chosen in con formity with the Technical Specifications of Cargoes Loading and Fixing the RF Ministry of Communications taking into account the weight of the truck to be transported l...

Page 209: ...s twin decks the trucks are transported on the top deck upon consent of the owner of the cargo sender Place the trucks in the hold and on the deck so that the distance between them is not less than 250 mm on the radiator side and not less than 130 mm on the other sides Upon placing the truck on the vessel perform the preparatory work fasten the truck to prevent its longitudinal and lateral motion ...

Page 210: ...ruck and bring it to a collecting station remove the wheels plastic and rubber parts from the truck and bring them to a collecting station dismantle the truck units disassemble them detect defective parts and bring the parts which are not suited for application as spares to a collect ing station The brake apparatus which are subject to salvaging should be disassembled The parts are to be assorted ...

Page 211: ...ngitudinal beam Drain plug of centre support Drive Axles Bolts fastening final drive to axle case M16 M18 caps of reduction gear through shaft and bearing bodies of driving bevel and spur gears bearing body caps of driving bevel gear and steering knuckle seal final drive side cover differential bearing caps Nuts fastening final drive to axle case ball support to half axle casing steering knuckle l...

Page 212: ...upper 120 160 12 16 lower 180 220 18 22 Centre bolt of front spring 30 70 3 0 7 0 Nuts of rear spring U bolts fully loaded truck 580 660 58 66 Nuts of bolts fixing walking beam brackets to cross member 110 160 11 16 bracket of upper torque rod 250 320 25 32 front spring front brackets to lower flange of frame side member 120 160 12 16 front spring rear brackets to reinforcers of frame side member ...

Page 213: ...th wheel bolts М14 М16 80 90 8 0 9 0 120 140 12 14 Nuts of sub frame U bolts 80 100 8 0 10 Power take off Bolts and nuts fixing power take off case to gearbox case 22 32 2 2 3 2 Auxiliary power take off Nut of auxiliary power take off flange 140 14 minimum Winch Bolts of winch cardan shaft flanges 60 65 6 0 6 5 APPENDIX 2 DATA FOR CHECKING AND ADJUSTMENT Coolant temperature in cooling system оC 75...

Page 214: ... 45 5 Tire 14 00 20 model ОИ 25 120 Tire 390 95R20 КАМА УРАЛ 120 maximum Tire 390R20 model О 65 120 maximum Tire 1200x500 508 model ИД П284 120 Tire 500 70 508 model ИД П284 120 Tire 500 70 20 model ИД П284 120 Tire 12 00R20 У 4 ИД 304 90 Steering gear worm side segment 39 Steering gear screw ball nut rack segment 27 1 Parking brake 22 6СТ 190 Storage battery 57 2 Power take off with pump 24 2 Pow...

Page 215: ... 90в 90г 90е 101 135б 8 17 33 52ж 53e 53ж 58 73 73a 73б 76 76a 80a 90д 90ж APPENDIX 5 ROLLING BEARINGS Designation Bearing type Overall dimensions mm Location Quantity 1180304K2C23 Single row radial ball bearing 20x52x18 Steering booster pump 1 307A Ditto 35x80x21 Power take off driven shaft 2 64805 Single row radial roller bearing without races 25x38x24 7 Power take off driving gear 2 211A Single...

Page 216: ...120x29 Rear axle drive shaft of transfer box transmission cardan shaft intermediate bearing lead screw of winch rope winding guide 5 704902K6УC10 Roller needle bearing 15 2x28x20 Spiders of steering cardan shaft 16 220A Single row radial ball bearing 100x180x34 Transfer box differential 1 6 218 Ditto 90x160x30 Ditto 1 180206 Ditto 30x62x16 Intermediate bearing of steering cardan shaft steering whe...

Page 217: ...rust ball bearing 17x30x9 Spare wheel lift reduction gear bearing 1 Inside diameter x outside diameter x mounting width APPENDIX 6 SPECIFICATIONS OF TRUCK BULBS Where installed Rating W at designed voltage Type Q ty per truck Headlamp 401 3711 55 50 А24 55 50 2 671 3711 75 70 АКГ24 75 70 1 2 Front lamp ПФ133АБ 28 А24 21 3 2 7 А24 5 2 Rear lamp ФП133АБ 28 А24 21 3 4 7 А24 5 2 7462 3716 28 А24 21 3 ...

Page 218: ...4420 Ural 44201 Trucks less engines Parts 1 2 3 The guarantee period of preservation treatment of SPT A sets is three years provided the sets are stored in closed rooms Owing to continuous modification process of truck design the range of spare parts of SPT A sets can differ The more precise range of spare parts is given in the shipping documents supplied with each truck When shipping the trucks t...

Page 219: ... U bolt nuts 1 12 Socket wrench 36 1 13 Puller bolt for ball support 2 14 Engine ring bolt 1 15 Wrench for hydraulic brake bleeding 1 16 Socket wrench 6x8 1 17 Driftpin 1 18 Wrench 11x13 1 19 Wrench for shock absorber nut 1 In tool bag 32 Fig 124 20 Wrench 14x17 1 21 Wrench 10x12 1 22 Wrench 8x10 1 23 Socket wrench 19 1 24 Socket wrench 14 1 25 Socket wrench 12 1 26 Socket wrench 24 1 27 Socket wr...

Page 220: ...ck 1 7 Lever plunger pressure gun 1 8 10 ltr jerry can 1 ______________________________ 1 Wrench 7813 00351H12 X1 GOST 7275 75 is allowed 2 Wrench 7811 0025 GOST 2839 80 is allowed Position in Fig Description Quantity Put without fixing in tool box Б type coupling head with union 1 Rubber pail 1 Air hose 1 Fuel transfer pump 1 Tire inflation collar puller 1 3 Winch pulley 1 4 3 Per 10 trucks on sp...

Page 221: ...nching spade 8 towing rope 9 20 l jerry can 10 cross cut saw Position in Fig Description Quantity In luggage compartment Fig 126 3 Connector plug 1 2 Portable lamp 1 Operating Manual 1 Gaskets for storage battery plugs 12 On cab side panel Fig 126 4 First aid kit case 1 On platform Fig 126 placed in jacket and fixed on front side Platform canopy assembly 1 Spacer pipes 1 Canopy jacket 1 8 Towing r...

Page 222: ...height the plungers lowered and screw turned in mm 270 Height of load lift mm 285 Oil volume l 0 6 For lifting a load with the jack set the jack in the required position turn out screw 1 Fig 127 as desired If the ground is soft place a strong wooden board or some other flat object under the jack base beforehand make some quick pumping strokes of lever 2 shut off needle 3 being screwed out using a ...

Page 223: ...rs by hand when the shut off needle is screwed home otherwise air can enter the jack working chamber If the jack fails to ensure the plunger s full working stroke check the oil level Add oil up to the filler closed with plug 4 after lowering the jack plungers completely and the jack standing upright See the jack mechanism on Fig 128 If the jack fails to operate due to dirt accumulated on parts of ...

Page 224: ...linder 21 Fig 129 is mounted on the gearbox housing and acts on clutch release fork shaft lever 23 The cylinder is controlled by air valve 8 which is mounted on tie rod 9 Hose 10 connects valve 8 with pneumatic system of the truck Fig 129 Diaphragm Clutch with Air Booster and Brake Valve Control 1 plate 2 return spring 3 9 clutch control tie rods 4 brake valve control lever 5 adjusting bolt 6 lock...

Page 225: ...issible because the coupling can eventually engage with thrust ring the pedal being lifted as high as it will go match the hole in the fork with that in the lever by increasing the length of tie rod 9 or decreasing the length of tie rod 3 When changing the length of tie rods the length of the tie rod body threaded into the fork shall be 12 mm minimum insert the pins easily without tensioning and c...

Page 226: ...oster 28 air hydraulic booster bleeding valve 29 bracket thrust bolt 30 clutch pedal L 185 200 mm L1 254 mm L2 30 40 mm Clutch Master Cylinder The design of the master cylinder is shown in Fig 131 If repair is necessary when assembling fit ring 14 as shown in Fig 131 When assembling do not fail to lubricate inner surface of cylinder rubber rings and collar with braking fluid Air Hydraulic Booster ...

Page 227: ...protective jacket 13 pusher 14 ring 15 packing ring b 0 2 0 6 mm Fig 132 Clutch Air Hydraulic Booster 1 body 2 bleeding valve 3 packing rings 4 rod 5 piston 6 cover 7 mud scraper 8 fork 9 collar 10 outlet port 11 plug 12 control valve 13 ring 14 fork 15 21 plugs 16 19 springs 17 air valve 18 body 20 slide valve B C D E F G K spaces a pressed air supply b working fluid supply ...

Page 228: ...he clutch release master cylinder through a connection hole available in plug 21 by pipes Space E is connected with the air bottle through a connection hole available in plug 15 by pipes Space E has an outlet for pressed air to actuate the booster control Adjustment of Clutch Pedal Travel Perform adjustment with the system being fully bled and no pressed air available in air bottle 22 in the follo...

Page 229: ...parent vessel filled with braking fluid fit the hose from an source external of pressed air onto the head of cover 2 of expansion tank 1 in supplying air under a pressure not more than 200 250 kPa 2 0 2 5 kgf cm2 obtain the state when no air bubbles come out of the pipe Clutch Control Maintenance consists in regular inspection of the control system components cleaning them from dirt and checking a...

Page 230: ...rs 25 wheel cylinders 26 brake air booster 27 check outlet valves 28 condensate draining cocks 30 brake valve 31 compressor The oil water separator is designed for clearing the compressed air of water and oil to prevent the drive freezing and failure as well as to reduce the opportunity of corrosion of brake drive apparatus components The oil water separator is designed for operation as completed ...

Page 231: ... adsorbent If the adsorbent contains much dust and broken granules replace it The aA 2KT or aA 2MШ synthetic zeolite volume 1 dm3 the service life of the zeolite is 2 years It is advisable to clean the filter at the same time with per forming seasonal maintenance SERVICE BRAKES COMBINED PNEUMATIC HYDRAULIC DRIVE WITH ANTI BLOCKING SYSTEM ABS The wagon truck is equipped by a pneumohydraulic drive o...

Page 232: ...ircuit 16 electronic control unit 17 relay 18 cable from solenoid valve 19 extension cable 20 electropneumatic valve The first main circuit comprises bottle 4 see Fig 136 upper section of brake valve 33 modulator 30 air booster 28 front axle wheel cylinders 31 The second circuit consists of bottles 32 lower section of brake valve 33 braking forces regulator 26 modulators 25 air boosters 23 and 24 ...

Page 233: ...control unit is the basic part of the anti blocking system The control unit is located in the driver s cab The connecting diagram for plug and socket joints of the control unit is shown in Fig 137 Auxiliary brake control The anti blocking system is designed for supple mentary control of the auxiliary brake The control is performed by sending a signal from the electronic unit to the electropneumati...

Page 234: ...umatic valve I modulator valves connecting zone 1 9 II rotation senders connecting zone 10 18 Electronic control unit wiring diagram The description of the diagram for connecting the electric cables from different ABS components with the electronic control unit is specified in Tables 1 2 below The diagram is shown in Fig 139 140 Fig 138 Wheel Brake Mechanism 1 coil pickup 2 clamping bush 3 pulse g...

Page 235: ...nnected with the truck ground Table 2 Control Unit 14 Pin Plug Socket Joint Connection Terminal Description of Wire to Be Connected 4 Negative wire of electronic control unit power supply connected with truck ground 7 Positive wire of electronic unit power supply from ignition lock 9 Negative wire of modulators power supply connected with truck ground 8 Positive wire of modulators power supply fro...

Page 236: ...n so doing the wheels should not be blocked The pilot lamp should go ON and then OFF when turning on the storage bat tery button and starter instruments switch again to the position Instruments If any failure occurs the ABS is completely or partially switched OFF and the pilot lamp on the dashboard goes ON The failure code is stored in the control unit memory for a long time and may be asked when ...

Page 237: ...e Do not actuate the OFF ROAD mode of the ABS on other types of roads Prior to welding disconnect the contact joint from the electronic control unit The ABS should be repaired in accordance with manufacturer s instructions by authorized workshops DESIGN FEATURES OF THE URAL 4320 41 URAL 4320 40 TRUCKS AND THEIR VARIANTS POWERED WITH THE YAMZ 236NE2 ENGINE When the truck is fitted with the YAMZ 236...

Page 238: ...ehicle Weight including load the driver and passengers 225 kg without regard for Truck Kerb Weight allowance kg 17 300 21 300 Kerb Vehicle Weight distribution kg on front axle on rear bogie 4795 4305 4685 3580 4685 3600 4775 3895 4840 3955 5110 4940 4885 3855 4950 3915 GVW distribution kg on front axle on rear bogie 5300 12 000 5300 16 000 Gross Trailer Weight kg 11 500 1 7000 2 11 500 1 7000 2 Gr...

Page 239: ...aust system With muffler exhaust pipe end is directed to the right side Cooling system Liquid cooling of closed type with forced liquid circulation The cooling radiator of corrugated fin type with radiator blade TRANSMISSION Clutch YAMZ 182 single disc dry friction type with diaphragm spring of pull out type Gearbox YAMZ 236U mechanical five speed type syn chronized in second third fourth and fift...

Page 240: ...witch Switch 26 Fig 142 is installed on the dashboard when no anti theft device is available on the steering column Manual fuel feed pump is mounted on the r h cowling panel For delivering the fuel to the injection pump with the engine not running turn handle 1 anti clockwise Fig 16 in the Operation Manual to release it from the fixed position and reciprocate it up and down Having pumped in the fu...

Page 241: ...tie rod 1 with speed governor control lever 15 To set the required engine speed when inflating tires warming up cold engine etc first press down accelerator pedal 9 and then fix this position by pulling out the knob The pedal travel is limited by adjusting bolt 10 At maximum engine speed clearance a between pedal 9 and adjusting bolt 10 should be 2 3 mm With fuel feed control adjusted correctly pe...

Page 242: ...ilter due flowing through the swirler obtains rotary motion in the annular gap between the housing and filter element Under centrifugal force dust particles are thrown to the housing wall and collected in the dust bin through a slit in the baffle Then the preliminary cleaned air flows through the filter element where it is cleaned finally From the turbocharger the air flows via pipes to the chargi...

Page 243: ... and dry Do not dry it above open fire or in air heated over 70 C After each servicing or fitting a new element a visual inspection of its con dition should be made illuminating it with a bulb Replace the element if mechanical injuries cardboard broken corrugations or ply separations are evident The estimated service life of the cardboard filter element is 30 000 km More frequent cleaning of the f...

Page 244: ...l are to be replaced by the following text When needed to brake the truck press the but ton of the auxiliary brake control air valve located on the cab floor The compressed air is supplied to the air cylinder the piston moves closing the flap Simultaneously the signal is transmitted to the trailer brake actuation system and its light braking occurs When the foot is removed from the valve button th...

Page 245: ...n on the compensator and parts surrounding it When detecting non tightness re place the compensators Lubricants and working fluids chart Volume of oil grease and liquids to be filled in the units shall be as follows engine crankcase 24 0 l steering hydraulic system 5 7 l cooling system including preheater 31 0 l Storage Preservation of the YAMZ 236NE2 power unit should be carried out in the same w...

Page 246: ...e 56 Truck Suspension 57 Wheels and Tires 63 Spare Wheel Holder 71 Steering 73 Steering Booster 78 Steering Booster Pump 78 Steering Oil Tank 79 Steering Rods 79 Maintenance of Steering 80 Brake Systems 83 Service Brake System 83 Combined Pneumohydraulic Drive of Service Brakes 85 Emergency Brake system 103 Parking Brake System 103 Auxiliary Brake System 105 Electric Equipment 106 Alternator 110 V...

Page 247: ...Applied for Tightening Main Threaded Connections 210 2 Data for Checking and Adjustment 212 3 Data on Weight of Main Components 213 4 Wire Colouring 214 5 Rolling Bearings 214 6 Specification of Truck Bulbs 216 7 Waste Oil Collection Rate 217 8 Spare Parts Tools and Accessories 217 9 Supplementary Information on Truck Design 223 Clutch Release Control Combined Pneumohydraulic Drive of Service Brak...

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