URAL Motorcycles 4320M Operation Manual Download Page 197

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191

Failure

Possible cause

Troubleshooting practice

Fast battery self-discharge

Failure of all

or several storage batteries

Battery leads are dirty with

mud or battery fluid covering
the battery surface

Give the battery for repair

Clean the battery with dry cloth,

then with a cloth moisten in 10%
ammonia spirit solution or soda ash
solution

Battery fluid has contami-

nants

Discharge the battery with cur-

rent, equal to 1

⁄

10 of storage capac-

ity, until 1.1-1.2 V for one battery.
Drain battery fluid, fill new battery
fluid and charge the battery

Battery fluid is decreased

too fast

Battery fluid is “boiling out”

Battery monoblock is dam-

aged

Check the voltage regulator
Give the battery for repair

Battery fluid is leaking

from one or two batteries
through the vent hole during
battery charge

Too high battery fluid level
Too high charge rate

Short circuit of the plates in

one of the batteries

Remove excess battery fluid

with rubber bulb

Check the voltage regulator
Give the battery for repair

When charging completely

discharged battery, battery fluid
voltage  and  temperature  are
raising  very  fast  and  boiling
starts,  and  density  is  slightly
increasing

Sulfatation of the plates that

can be caused by

long storage battery shutdown,

or  it  is  operated  when  battery
fluid  level  is  too  low,  or  if  the
battery  is  systematically  under-
charged

Sulfatated plates are corrected by

the charge-discharge cycle with
current not exceeding 1

⁄

20 of bat-

tery capacity, when the initial bat-
tery fluid density is 1.12 g/cm

maximum. Very sulfatated plates
are not repaired

Power Takeoff

Power Takeoff is

not

switching on

Pneumatic

chamber

dia-

phragm of the Power Takeoff is
damaged

Power Takeoof pinion teeth

are worn or damaged

High air leakage due to poor

fastening of the air pipe con-
necting fittings, or their failure

Replace the diaphragm

Disassemble the Power Takeoff,

align gear teeth and replace worn
parts

Detect leakage places by putting

soap  solution  on  the  hose  and  the
plumbing  fittings.  Tighten  the
plumbing  fittings  in  the  leakage
places. Replace defective parts

Summary of Contents for 4320M

Page 1: ...URAL 4320М TRUCK and its Modifications ...

Page 2: ... its Modifications Operation Manual 4320М 3902035 10 РЭ 2nd edition amended URALAZ Partial or full reprint duplication or translation is not allowed without written permit of OJSC URAL Motor Vehicles Plant Miass March 2017 ...

Page 3: ...AMZ 1105 gear box Operation Manual for 9JS135ТА Gearbox for power units with FAST GEAR gearbox Operation Manual for the Engine Starting Heater Operation Manual Instruction for Lead acid starter Storage Batteries Installation and Operation Manual for Drawbar Coupling Operation Manual URAL 73 3801 01 Combination of Devices АДИГ 453895 012РЭ Элара The Tachograph Installation and Operation Manual In t...

Page 4: ...nts Structure and Operation Description their Adjustment and Mainte nance 46 4 1 Engine 46 4 1 1 Feed System 46 4 1 2 The Engine Starting Heater System 50 4 1 3 Gas Exhaust System 51 4 1 4 Cooling System 52 4 1 5 Power Unit Suspension 55 4 1 6 Engine Idle Adjustment 56 4 2 Transmission 58 4 2 1 Clutch Control with Air Over Hydraulic Booster 58 4 2 2 Wabco Air Over Hydraulic Booster Construction an...

Page 5: ...ation of a New Truck for Operation 194 6 2 Engine Start and Stop 194 6 3 Truck Breaking In 194 6 4 Truck Driving 195 7 Maintenance 200 7 1 List of Truck Maintenance Operations 201 7 2 Truck Lubrication 222 7 3 Lubricant and Hydraulic Fluid Charts 224 8 Storage 248 9 Transportation 252 10 Disposal 255 Appendices 256 Appendix A Torques of Basic Screw Joints 256 Appendix B Control and Adjustment Info...

Page 6: ...ystem brake systems according to the United Nations Economic Commission for Europe No 13 10 gross vehicle weight according to technical specifi cations of the truck towing hitch semi trailers fifth wheel king pin type A according to GOST 12017 81 equal to 50 8 mm and connecting dimensions according to GOST 12105 74 for fifth wheel rated load over 83 3 kN 8 5 tf trailers trailer hitch drawbar eye s...

Page 7: ...e and modification identification 432000 is for 4320 7 43203 is for 43203 1151 71 432060 is for 43206 11 71 442020 is for 44202 0 11 7 555700 is for 5557 7 555710 is for 55571 1 7 Pos 10 Manufacturing year code Pos 11 17 Vehicle plant number Figures used for identifying manufacturing year В 2011 С 2012 D 2013 Е 2014 Cab and engine are marked as components according to OST 37 001 269 96 Cab as a ve...

Page 8: ...d rooms with poor ventilation 1 1 8 Cooling low freezing and hydraulic fluids are poisonous and should be handled with care 1 1 9 To climb and go down the truck bumper use the running board central and the ex treme left as viewed in the direction of vehicle motion grille fins having bushes on the internal part as shown in figure 1 1 1 10 When servicing the engine fix the hood lift with safety hook...

Page 9: ...ith compliance with fire safety rules When using electric welding switch off the wires from the alternator storage batteries and electronic control units protect plastic pipes and fuel pipes form damage Connect the general wire of the welding ma chine close to the weld area excluding current flow through bearings and friction pairs 1 1 22 When grade climbing choose the correct speed in advance 1 1...

Page 10: ...m and consequently to pump breakage For the same reason in case of engine power take off when operating in steady state conditions release the steering shaft load by turning the steering wheel until backlash Set the steering stem to the neutral position according to the following procedure with the engine on turn the front wheels to the extreme right or left position and re lease the steering whee...

Page 11: ...teries 1 2 21 During long term truck parking switch off the storage batteries by button 39 of the switch shown in figure 25 and by button 7 of the switch shown in figure 32 1 2 22 When starting the engine from an external power source switch on the storage batteries It s forbidden to use a d c power supply with parameters exceeding 24V at 0 zero A and 18 3V at 1000 A or storage batteries having ra...

Page 12: ... release the gear put in neutral before starting the en gine By turning the engine shaft right and left 180 in a way described in the paragraph Regula tion of Valve Control Component of the Operation Manual for the engine or by filling the pneumatic system with compressed air from the auxiliary truck through the towing valve release the clutch 1 2 32 Transportation of a cargo or trailer vehicle to...

Page 13: ...20070 20350 20470 Gross vehicle weight rating kg 17300 22500 21300 21300 GVWR distribu tion kg on front axle on rear bogie 5300 12000 6500 16000 5300 16000 5300 16000 Maximal trailer semi trailer weight kg 11500 19100 Maximal road train weight kg 28800 34000 27300 27420 37275 ___________________ When driving on 1 4 category roads 2 1 2 Truck unit parameters are given in Table 2 Table 2 Parameters ...

Page 14: ...for the gears II III IV and V axle ratios I 5 22 II 2 90 III 1 52 IV 1 00 V 0 71 reverse 5 22 Transfer Box Mechanical two speed with cylindrical inter axle locking differential Number of gears 2 axle ratios 1 04 2 15 Main gear Dual ratio double reduction right angle axle ratios 7 49 Undercarriage Frame Riveted with forged girders of variable sections Towing devices Front two rigid towing hooks Rea...

Page 15: ...dary Brake System Engine retarder installed Electrical Equipment Wiring diagram Single wire negative terminals of current power supply are connected with truck battery Nominal voltage is 24V Alternator AAN 8172 AC alternator manufactured by ISKRA 2800 W capacity works with the installed voltage regulator Stator AZF 4137 manufactured by ISKRA electromagnetic maximal capacity is 4 0 kW Storage Batte...

Page 16: ...ed with the rope guideplate 2 2 Technical Specifications of Chassis of 6х6 Truck with Conventional Cab 2 2 1 Basic weight and load parameters of trucks are given in Table 3 Table 3 Parameters 4320 1151 71 4320 1151 73 43203 1151 71 4320 1951 70 4320 1951 72 4320 1951 74 4320 1972 70 4320 1972 72 4320 1972 74 4320 1982 70 4320 1982 72 4320 1982 74 5557 1151 70 5557 1151 72 5557 1151 74 55571 1151 7...

Page 17: ...3622 10 and its configurations YAMZ 53642 10 and its configurations YAMZ 53602 10 and its configura tions Cylinders quantity and lo cation 6 row Engine capacity cm3 6650 Compression rate 17 5 Maximum power kW min 1 176 5 2300 25 210 2300 25 229 2300 25 Maximum torque Nm min 1 900 1300 1600 1130 1300 1600 1226 1300 1600 Fuel Feed System Accumulator type with electronic control Air feed system for t...

Page 18: ...t type С50 5 except Ural 44202 Truck suspension front Conventional on two longitudinal half elliptic springs with hydraulic tel escopic shock absorbers rear Conventional centre pin supported with torque arms on two longitudinal half elliptic springs Tires For modifications Model Size Load index Speed category Static radius m 4320 1151 71 4320 1671 71 4320 1151 73 4320 1671 73 4320 1151 75 4320 167...

Page 19: ...1972 74 55571 1551 70 55571 1551 72 55571 1551 74 or without rest area for 4320 1151 71 4320 1151 73 43203 1151 71 4320 1951 70 4320 1951 72 4320 1951 74 5557 1151 70 5557 1151 72 5557 1151 74 55571 1151 70 55571 1151 72 55571 1151 74 or four doors six seat for 4320 1982 70 4320 1982 72 4320 1982 74 2 3 Technical Specifications of 6х6 Cabover Trucks 2 3 1 Basic weight and load parameters of trucks...

Page 20: ...Air feed system for the engine with carton replaceable element dry air filter Gas Exhaust System With muffler end of the exhaust pipe is truck axle directed Transmission Clutch ZF SACHS MFZ 430 YAMZ 182 76 or Hammer 43033 diaphragm fric tion dry exhaust type one disc hydraulic drive with pneumatic booster Gearbox YAMZ 0905 5 forward 1 reverse YAMZ 1105 or ZF 9S 1310 ТО or 9JS135ТА 5 Forward 1 reve...

Page 21: ... drawbar coupling according to GOST R 41 55 2005 product type С50 5 except Ural 44202 Truck suspension front Conventional on two longitudinal half elliptic springs with hydraulic tele scopic shock absorbers rear Conventional centre pin supported with torque arms on two longitudinal half elliptic springs Tires for modifications Model Size Load index Speed cate gory Static radius m 4320 3171 78 4320...

Page 22: ...orage batteries can be installed including batteries of 140 Ah capacity Storage batteries switch Leak tight with distant control panel with lock system Cab Cab All metal two doors two seat with a berth located over the engine Platform for trucks 4320 3171 78 4320 3171 80 4320 3171 82 4320 3971 78 4320 3971 80 4320 3971 82 Metal flat body with rear and side dropsides with canopy Fifth wheel couplin...

Page 23: ...4360 4010 4820 4140 4315 3960 4660 3690 4890 3705 Gross vehicle weight rating kg 17800 22500 GVWR distri bution kg on front ax le on rear bo gie 5800 6500 12000 16000 Maximal trailer weight kg 11500 Maximal road train weight kg 29300 34000 2 4 2 Truck unit parameters are given in Table 7 Table 7 Parameters 4320 4151 79 4320 4951 78 4320 4972 78 5557 4151 78 55571 4151 78 55571 4551 78 4320 4151 81...

Page 24: ... type one disc hydraulic drive with pneumatic booster Gearbox YAMZ 0905 YAMZ 1105 or ZF 9 S 1310 ТОor 9JS135ТА 5 Forward 1 reverse for YAMZ 1105 9 forward 1 reverse for ZF 9 S 1310 ТО 9JS135ТА Number of gears 5 forward 1 reverse YAMZ 0905 YAMZ 1105 Mechanical three way with synchronizer assembly for the gears II III IV and V axle ratios I 5 22 II 2 90 III 1 52 IV 1 00 V 0 71 reverse 5 22 ZF 9 S 13...

Page 25: ...pic shock absorbers rear Conventional centre pin supported with torque arms on two longitudi nal half elliptic springs Tires For modifications Model Size Load index Speed category Static radius m 4320 4151 79 4320 4151 81 4320 4151 83 ОИ 25 14 00 20 146 147 G 0 585 KAMA URAL 390 95R20 147 J 0 570 KAMA 1260 425 85R21 146 J 0 590 315 80R22 5 156 150 K 0 499 У 4 ИД 304 12 00R20 150 146 J 0 526 4320 4...

Page 26: ...s two seat with rest area for 4320 4972 78 4320 4972 80 4320 4972 82 55571 4551 78 55571 4551 80 55571 4551 82 or without rest area for 4320 4151 79 4320 4151 81 4320 4151 83 4320 4951 78 4320 4951 80 4320 4951 82 5557 4151 78 5557 4151 80 5557 4151 82 55571 4151 78 55571 4151 80 55571 4151 82 2 5 Technical Specifications of 4x4 Trucks and Chassis 2 5 1 Basic weight and load parameters of trucks a...

Page 27: ...43206 1151 71 43206 1551 71 43206 4151 79 43206 4551 79 Engine Model type YAMZ 53622 10 and its modifications Engine capacity l 6 65 Maximal torque Nm at en gine torque min 1 900 1300 1600 Maximal capacity kW at en gine torque min 1 176 5 2300 25 Fuel Feed System Accumulator type with electronic control Gas Exhaust System With muffler end of the exhaust pipe is truck axle directed Transmission Clu...

Page 28: ...ck suspension front Conventional on two longitudinal half elliptic springs with hydraulic telescopic shock absorbers rear Conventional on two longitudinal half elliptic springs with additional springs with hydraulictelescopicshockabsorbers Tires KAMA 1260 KAMA 1260 1 У 4 ИД 304 Size 425 85R21 12 00R20 Minimum allowable load index 156 150 146 Speed category G J Static radius m 0 585 0 526 Steering ...

Page 29: ...06 1151 71 or Two seat for 43206 3111 79 43206 4151 79 and with rest area for 43206 3511 79 43206 4551 79 all metal four doors six seat for 43206 0551 71 43206 1551 71 Platform Metal flat body with three dropsides with canopy 2 6 Dimensions of 6x6 and 4x4 Trucks and Chassis are shown in figures 3 23 Figure 3 Ural 4320 0111 71 Ural 4320 0111 73 Ural 4320 0111 75 Figure 4 Ural 4320 0911 70 Ural 4320...

Page 30: ...ractor units Ural 4320 0311 70 Ural 4320 0311 72 Ural 4320 0311 74 Figure 6 Tractor units Ural 4320 0511 70 Ural 4320 0511 72 Ural 4320 0511 74 Figure 7 Chassis Ural 4320 1151 71 Ural 4320 1151 73 Ural 4320 1151 75 ...

Page 31: ...re 8 Chassis Ural 4320 1671 71 Ural 4320 1671 73 Ural 4320 1671 75 Figure 9 Chassis Ural 4320 1951 70 Ural 4320 1951 72 Ural 4320 1951 74 Figure 10 Chassis Ural 4320 1972 70 Ural 4320 1972 72 Ural 4320 1972 74 ...

Page 32: ...11 Chassis Ural 4320 1982 70 Ural 4320 1982 72 Ural 4320 1982 74 Figure 12 Chassis Ural 5557 1151 70 Ural 5557 1151 72 Ural 5557 1151 74 Figure 13 Chassis Ural 55571 1151 70 Ural 55571 1151 72 Ural 55571 1151 74 ...

Page 33: ...32 Figure 14 Chassis Ural 55571 1551 70 Ural 55571 1551 72 Ural 55571 1551 74 Figure 15 Chassis Ural 43203 1151 71 Figure 16 Truck Ural 43206 0111 71 ...

Page 34: ...33 Figure 17 Truck Ural 43206 0551 71 Figure 18 Truck Ural 43206 3111 79 Figure 19 Truck Ural 43206 3511 79 ...

Page 35: ...34 Figure 20 Chassis Ural 43206 1151 71 Figure 21 Chassis Ural 43206 1551 71 Figure 22 Chassis Ural 43206 4151 79 ...

Page 36: ...re 23 Chassis Ural 43206 4551 79 The Operation Manual includes base configurations of trucks and chassis Outside ap pearance and truck and chassis configurations can differ from the ones shown in figures 3 23 ...

Page 37: ...drive arm of air heating distribution gate 4 internal hatch drive arm 5 tachograph 6 glove box 7 reader 2 8 reader 1 9 control unit of the engine starting heater 10 electronic accelerator pedal 11 brake pedal 12 secondary brake control button 13 clutch pedal 14 parking brake lever 15 stator and tools switch 16 gear lever 17 steering wheel 18 room light 19 remote speaker 20 state indicator 21 Servi...

Page 38: ...que actuator 17 engine idle torque fixation and regulation button 18 front circuit tire inflation control button 19 rear circuit tire inflation control button 20 fuse block 21 fuel selector 22 the interaxle differential lock switch 23 the interaxle differential lock indicator 24 transfer box N indicator 25 engine diag nostics control EDC switch 26 engine interface block diagnostics switch 27 power...

Page 39: ...nd shield wiper washer are switched on with switch 2 Wind shield wiper position 0 Neutral off position I slow II fast III with an interval Wind shield washer IV position up on Anti theft device principle consists in the fact that after the key is taken out from the ig nition the lock rod is extended that enters the slot of steering shaft and locks the shaft Caution By turning the steering wheel ri...

Page 40: ...ct the necessary gear press button 23 during 5 7 seconds and the selected gear is on The gears are not shifted without pushing button 23 When turning the stator and tools key to the position I lamps 35 interface block diag nostics indicator and 38 EDC are flashing see figure 25 herein the engine interface block and engine diagnostics control are tested When lamps 35 and 38 fade out it means that b...

Page 41: ...ondary brake control button 16 electronic accelerator pedal 17 brake pedal 18 steering mast fixation joystick 19 clutch pedal 20 radio panel 21 reader 2 22 tachograph 23 reader 1 24 road train sign switch 25 remote speaker view A speaker is installed on the headlining view B heater control unit is installed on the dashboard view C cab heating distribution regulator is in stalled on the dashboard v...

Page 42: ... tipping indicator 19 battery warning indicator 20 Neutral indicator 21 the interaxle differential lock indi cator 22 low gear of the transfer box indicator 23 the cross axle differential lock of middle axle indicator 24 the cross axle differential lock of rear axle indicator 25 auxiliary trans mission indicator 26 Kn2 control button 27 power takeoff indicator 28 additional power takeoff indicator...

Page 43: ...on switch 11 front circuit tire inflation switch 12 ABS test switch 13 outside mirrors heating switch 14 power takeoff switch 15 additional power takeoff switch 16 the interaxle differential lock of transfer box switch 17 the cross axle differential lock switch 18 front fog beams switch 19 rear fog beams switch 20 searchlight switch 21 external light selector Figure 32 Switches Board _____________...

Page 44: ... transfer box are switched on by selector 2 and switch 1 see figure 32 when low gear is actuated indicator 22 starts flashing see figure 29 Detailed descrip tion of gear shfting read in paragraph Transfer Box hereof The tachograph 5 see figure 24 and the tachograph 22 see figure 28 are installed on the truck except chassis Construction description and operation and maintenance instructions are giv...

Page 45: ... ERA GLONASS system operator To enter test mode simultaneously press and hold buttons service and SOS for 10 seconds In test mode user interface unit state indicator will be flashing yellow service button will be lighted green and SOS button will be red To perform test follow voice prompts Exit from the test mode is done after transfer of minimum information with test results to the system operato...

Page 46: ...hite White Red is on Emergency call is impossible White White Red is on Redial in Emergency call mode Red is flashing White Green is on Transfer of minimum infor mation in Emergency call mode Red is flashing White Green is on Voice connection in Emer gency call mode Red is on White Green is on Reserve battery is discharged below set parameter White White Yellow is flashing No GLONASS GPS signals W...

Page 47: ... fuel and air entered the system are exhausted through fuel lines to the fuel tank Fuel quantity in the main fuel tank is measured by electric level transmitter installed in the tank and is controlled by the indicator on the dashboard Fuel tank is located on the left on the frame girder When the engine is started the hand priming pump is used to pump fuel it is installed in the PreLine 270 fuel co...

Page 48: ...and let the water flow screw the screw plug of the drain hole 4 again Filter replacement switch off the engine dismantle the old replaceable filter The old replaceable filter can be set tight on the fil ter head Use the appropriate tools oil the gasket in the new filter with some engine oil drops screw the filter manually until the gasket is tightly adjacent fasten manually so that the filter was ...

Page 49: ...er 4 4 1 1 2 Engine Air Feed System for the Conventional Cab Trucks is shown in figure 36 it is dedicated for air intake and air cleaning before feeding it to the engine It consists of two stage dry type air filter intake pipes connection hoses and fasteners 1 Air intake tube 2 clogging sensor 3 4 chutes 5 9 air ducts 6 turbocharger 7 connection hoses with rings 8 inlet air cooler 10 air duct from...

Page 50: ...uel or in hot water air with compressed air and dry Inspect the filtering element Dust on the internals of the filtering element proves that the filtering element and the sealing gaskets are not tight replace the filtering element Seal quality is checked by integrity of its impression on the gasket To maintain the filtering element remove the pre cleaner and clean it from dust by shak ing or airin...

Page 51: ...1 clogging sensor 12 air duct to the turbocharger Figure 37 Air Feed System for the Engine 4 1 2 The Engine Starting Heater System is shown in figure 38 The truck is equipped with the automatic engine starting heater 2 see figure 38 dedicat ed for engine and cab heating Heater s construction and application instructions as well as possi ble malfunctions are described in the attached Operation Manu...

Page 52: ...cket 5 heater exhaust pipe 6 fuel line 7 heater fuel tank Figure 38 Engine Starting Heater System 4 1 3 Gas Exhaust System Gas exhaust system is dedicated to discharge emissions and to reduce exhaust noise The exhaust system uses wear resistant secondary brake installed into the engine that is connected with metal pipe 1 by the outlet pipe 2 see figure 39 Metal pipe 1 aims to compensate temperatur...

Page 53: ...the installed viscous fan clutch actuat ed on incoming air temperature with forced coolant circulation it is designed for all season ap plication of antifreeze solutions For conventional cab trucks it is shown in figure 40 and for cabover trucks it is shown in figure 41 Radiator14 see figure 40 and radiator 10 see figure 41 is tube belt type tree row with a filler neck The filler neck 2 see figure...

Page 54: ...uspension frame 16 charged air cooler Figure 40 Cooling System The reserve tank 8 see figure 40 and the reserve tank 2 see figure 41 is dedicated for coolant volume compensation at heating for air and steam from the coolant removal The cap 9 see figure 40 and the cap 1 see figure 41 of the reserve tank has two valves Draining valve opens at excess pressure in the system 65 kPa 0 65 kgf cm2 and blo...

Page 55: ...eserve tan cap is forbidden For visual inspection the reserve tank is made transparent 4 1 4 2 Cooling System for the Cabover Trucks is shown in figure 41 1 reserve tank cap 2 reserve tank 3 water inlet connection to the engine water pump 4 outlet chute 5 engine steam outlet chute 6 radiator steam outlet chute 7 water outlet connection 8 radiator filler neck 9 radiator cap 10 radiator 11 charged a...

Page 56: ... the cooling system put the truck on a horizontal platform or forward declined and unscrew the plug located on the bottom radiator tank open cab heater and heater boiler valves Herein filler neck reserve tank cap should be open Undrainable coolant volume at opened cab heater valve should be approximately 2 litres Do not start the engine after the coolant is drained to evacuate its residue from the...

Page 57: ...700 to 1400 rmp at a pitch of 50 100 rpm and saving the set rpm up to 1000 rpm in the engine electronic control unit memory To actuate engine idle adjustment mode press and hold switch key 6 see figure 32 for about 5 seconds When this mode is actuated engine rpm become equal to 700 rpm if the acceler ator pedal is not pressed Idle rpm can be increased decreased by clicking the switch 4 one click c...

Page 58: ... memory after cutting off the ignition in standard mode power supply for the electronic control unit continues after the ignition is cut off for minimum 30 seconds Next engine start idle value will come back to the pre saved value To restore minimal engine idle rpm repeat the adjustment mode with saving 700 rpm value Exit from the adjustment mode without saving new value of engine idle rpm can be ...

Page 59: ...over hydraulic booster Fluid in the air over hydraulic booster puts pressure on the rod opening the pneumatic system valve Pneumatic part consists of 10 l tank 17 installed inside the left girder check valve 18 pipelines Feeding is done from a separate pneumatic system circuit 1 reserve tank 2 tank lid 3 bolt 4 nut 5 14 brackets 6 cylinder stop 7 clutch master cylinder 8 foot mechanism 9 26 spring...

Page 60: ... 3 foot mechanism 4 brake pedal 5 clutch pedal L full pedal motion equal to 105 115mm L1 free play equal to 5 10 mm 6 hydraulic gear pipeline 7 check valve 8 12 pipeline 9 oil separator with 4 circuit valve 10 plug 11 non brake consumer tank 13 hydraulic fitting 14 tee 15 clutch master cylinder 16 tappet 17 reserve tank 18 tank lid Figure 44 Clutch Release Linkage 4 2 1 3 Clutch Master Cylinder Ma...

Page 61: ...rod from dirt and prevents its access to the body is installed in the centre of the lid 6 On the other side of the body 1 fork 14 is installed the booster is fastened to the gearbox trough the bracket and the fork The fork 14 has a flange sealed in the body with the rubber ring 13 Body bottom has a drain hole 10 having rubber valve The valve protects the body from dirt access The upper part of the...

Page 62: ...ith fluid and there is no compressed air in the pneumatic part of the drive as follows loosen the pedal stop 11 lock nut see figure 43 and screw it into the pedal against stop put the clutch master cylinder 7 in the upper position in oval holes of the bracket 5 fix the master cylinder by the stop 6 and bolts 3 put the clutch pedal to metal check the correctness of clutch release the clutch should ...

Page 63: ...ster cylinder The criteria of completed bleeding is force spur increase on the pedal when it moves for L2 value equal to 35 40 mm after selection of free play Quick clutch hydraulic gear bleeding is possible by using external compressed air for that fill the reserve tank with brake fluid remove valve protective cap 2 see figure 46 put on bleeding hose on the valve unscrew the valve 1 2 3 4 torque ...

Page 64: ...lease fork Incoming air pressure is changed with the servo device automatically depending on the force applied by the driver to the clutch pedal After pedal release booster liquid pressure falls down servo system air valve closes air over hydraulic booster piston returns to its initial position Through the contact spring the piston 8 see figure 47 booster with the rod 12 are always connected backl...

Page 65: ...e 48 Air Over Hydraulic Booster Servo System Measure the stroke of thrust bearing at air pressure of 850 kPa 8 5 kgf cm2 that corresponds to the regulator mark that should be within A limits from 12 to 14 mm see figure 49 A thrust bearing stroke regulation limit Figure 49 Clutch Linkage ...

Page 66: ...lescopic elements locking device 1 Lining 2 bolt 3 16 lever 4 joystick 5 seal casing 6 bolts 7 intermediate support 8 telescopic rod 9 spring 10 yoke 11 nut 12 internal flexible rod end extension 13 stud 14 split pin 15 fork 17 locking bushing 18 rod end 19 balls 20 shank 21 extension rod 22 extension rod bracket 23 nut 24 end 25 ear shift roller lever Figure 50 Gearbox Control To regulate lever 3...

Page 67: ...moved right the rod extension should smoothly move should jam and the locking device should ensure secure fixation of the gear rod extension in confined space Extension and external rod bend and dent are not allowed After lowering the cab rod is blocked by setting the gear lever into neutral 4 2 4 Transfer Box The transfer box is shown in figure 51 mechanical two speed with asymmetric in teraxle d...

Page 68: ... 16 pin 17 gear shift fork 18 bolt 19 63 high speed gears 20 bushing 21 gear shift coupling 23 cylinder 24 33 low gears 25 crankcase 28 breather 30 lay shaft 32 spacer 34 rear axle drive shaft 36 obturator ring 37 40 46 58 ball bearings 38 66 bearing nuts 41 differential rear bearing casing 42 differential cage 43 differential cage with lower shaft gear 44 crown gear 45 sun gear 47 differential lo...

Page 69: ... and put the cap check the axial movement of the lay shaft in the same way as for the main shaft herein the indicator foot should but one of the gears overall shift of the indicator foot must be from 0 03 to 0 08 mm adjust the bearings by adding adjusting plates under the rear lay shaft cap To avoid mistakes during measurement check the shafts axial movement before and after the adjustment two thr...

Page 70: ...keoff switch 5 power takeoff switch 6 and 7 the cross axle differential lock mechanism of the intermediate and the rear axles solenoid valves A transfer box differential lock B neutral C low speed D hight speed E additional power takeoff F power takeoff G the cross axle differential lock a air supply b for switching on Figure 52 Electric and Pneumatic Control Scheme of Transmission Devices When pr...

Page 71: ...re 51 counter clockwise The bushing installed in the lid moving slidingly sets neutral in the transfer box defined by rotating the cou pling shaft manually when the gearbox control lever is in neutral position If continue rotating the bolt low speed is switched on The differential is locked in the same way by rotating the bolt 57 When pressing the switch in the driver s cab the transfer box contro...

Page 72: ...eller shafts of the winch drive 3 intermediary support 6 7 8 propeller shafts of axle drive Figure 53 Transmission Prop Shafts and Winch Drive Layout For 6x6 wheel arrangement trucks 1 Front drive shaft 2 4 propeller shafts of the winch drive 3 intermediary support of the winch drive 5 propeller shaft of rear axle drive 6 propeller shaft of front axle drive Figure 54 Transmission Prop Shafts Layou...

Page 73: ...struction is shown in figure 57 Before assembling the joints grease the cavity between the work rims of the butt seal After assembly yokes must rotate in the bearings smoothly without jams Check spline joint backlash systematically If the backlashes are over 1 2 mm drive shaft of the front and rear axles is shown in figure 56 and 0 55 mm lay shaft and rear axle drive shaft are shown in figure 57 c...

Page 74: ...Driveline of trucks and special chassis with long base differs from the main truck by the changed intermediate axle drive being a driveline consisting of the front shaft 2 with an intermediary support and rear propeller shaft 4 see figure 58 with spline joint balanced as a unit Intermediary support bearing should be oiled according to the lubrication scheme Prop shaft maintenance corresponds to th...

Page 75: ...te gasket 9 0 8 mm thick and is fastened with thirteen bolts and two pins 1 Idler gear 2 cylindrical roller bearing 3 main gear crankcase 4 cylindrical pinion 5 bushing sleeve 6 conical roller bearings 7 8 12 adjusting gaskets 9 bushing sleeve cover 10 rear axle drive flange 11 seal 13 drive conical gear bushing sleeve 14 driving conical pinion 15 breather 16 pinion shaft 17 seal 18 rear bearing c...

Page 76: ...ire Main gear wheels and bearings are oiled with the axle case oil going through the main gear crankcase up to the inspection door level The oil is captured by the wheels and goes to the main gear crankcase chamber through the roller bearing 2 and then it flows to the axle case Con ical pinion bearings are oiled from the conical gears chamber oil then goes to the bushing sleeve through the crankca...

Page 77: ...fer box cross axle differential lock is switched on 1 Curtain 2 lock switch housing 3 rod 4 bracket 5 stopper 6 nut 7 differential carrier 8 clutch 9 axle shaft 10 stud 11 connector 12 switch Figure 61 Intermediate and Rear Cross Axle Differential with Positive Locking The differentials are locked by the spline crown on the butt end of the left carrier 7 and spline clutch 8 installed on the left a...

Page 78: ... are combined consist of cast medium part and tubular housings of differential axles pressed in it The axle shafts are off loaded axle con nection with the boss is spline type 4 2 6 4 Truck front axle is driving controlled Construction of the king pin assembly is shown in figure 63 Torque to the front driving wheels is transferred through the axle shafts and the constant velocity joints see figure...

Page 79: ...is measured by force meter 1 Air feed hose 2 keyhole washer 3 lock washer 4 lock nut 5 wheel bearing nut 6 trunnion 7 air feed angle 8 wheel hub cover 9 outer axle shaft 10 gasket assembly 11 17 19 seals 12 bearing 13 boss 14 wedger 15 brake drum 16 brake caliper 18 ball pivot 20 inner axle shaft 21 differential axle housing 22 joint cam 23 joint disc 24 external differential axle yoke 25 pin 26 r...

Page 80: ... 50 kgfm torque If there is no backlash after the nut is tightened there is no need to adjust the sleeve bearings Calculate the adjusting washer 23 thickness decrease according to figure 59 backlash value plus 0 03 0 05 mm of preload Unscrew the nut remove the bearing and the adjusting washer Grind or choose the washer to proper size install the washer and assemble the bearing unit of the conical ...

Page 81: ...ngth see Table 12 Table 12 Contact Regulation of Conical Gears Engagement of Main Gear Tooth contact pattern of the coni cal driven spur wheel Methods of achieving proper conical gears en gagement Conical gears movement direction Forward drive Reverse Proper contact Move the idler gear towards the pinion If the side backlash between teeth is too small distance the pinion Distance the idler gear fr...

Page 82: ...over tighten the nut with 160 200 Nm 16 20 kgfm torque take away supports and remove lower covers remove from each cover seal package 0 15 mm thick 0 05 0 1 mm mantle the covers Tighten the nut with 160 500 Nm 16 20 kgfm torque mantle the wheels 4 2 6 6 Wheel Boss Bearing Adjustment jack the axle from the dirigible wheel remove the cover disengage the axle shaft splines and the boss and remove the...

Page 83: ...r coupling 21 202 On customer s request it is possible to install hook eye drawbar coupling delivered as spare parts for Ural trucks for operation with trailers according to GOST 2349 75 standard size 3 Basic dimensions of the towing hook must comply with GOST 2349 75 for standard size 3 The drawbar coupling is installed on the unified mounting places in the special towing cross member Maintenance...

Page 84: ...he brackets 7 through rubber bushings 10 that are in their turn fixed to the frame girders lower eyes are fixed to the brackets 18 welded to the axle case The springs are fixed to the axle case in the middle through u bolts 3 Axle upstroke is re stricted by rubber buffers 5 fastened in the spring clamp plates 4 Axle down stroke is restricted by coupling of third spring sheet bent ends with the tie...

Page 85: ... bolt nut 25 spring eye fixing bolt 26 u bolt nut 27 spring eye 28 wedge D modification upper shock absorber bracket of cabover trucks a 1 2 5 mm Figure 67 Front Suspension of Trucks with 4x4 6x6 Wheel Arrangements 4 3 2 2 Hydraulic shock absorbers are dedicated to damper oscillation caused by elastic strain of truck shock absorber components when driving along uneven surface Hydraulic shock ab so...

Page 86: ...n group of 6х6 trucks is of equalizing type and is shown in Figure 69 Spring ends enter the eyes of support brackets 6 The springs are fixed to the equalizing beams 23 sweeping on the axle 18 of the equalizing beam through u bolts The brackets 19 are pressed to the axles through them the axle 18 is fastened to the equalizing beam brackets 16 and 17 by bolts 14 Pushing and braking force is transfer...

Page 87: ...alance shaft fixing bolt 15 balance shaft bracket fixing bolt to the amplifier 16 17 balance shaft brackets right left 18 equalizing beam axle 19 axle bracket 20 rubber and metal linkage 21 torque arm head lid 22 oil cup 23 equalizing beam 24 equalizing beam retaining nut 25 equalizing beam cap 26 equalizing beam fixation tie bolt 27 equalizing beam bushing g cavities under the protection ring edg...

Page 88: ... 24 shock absorber brackets upper lower 9 spring 10 shock absorber 11 shock absorber retaining nut 12 washer 13 shock absorber bushings 14 buffer retaining nut 15 buffer 16 spring support bracket 17 bush upper lower 18 distance piece 19 bracket tie bolt 20 stud 21 eye u bolt 22 eye u bolt nut 23 eye trim 25 shock absorber bracket fixing bolt 26 u bolt nut 27 seal 28 29 bracket lid fixing bolts 30 ...

Page 89: ...e truck by the frame and lubricate the backlashes ap peared between the sheets With each spring disassembly grease the sheets preliminary removing the old grease mud and corrosion traces Clean and lubricate spring eyes and studs When assembling lubricate the u bolt threads of front and rear springs by graphite lubricant or TSgip type lubricant Fasten spring u bolt nuts according to Figure 71 front...

Page 90: ...e arms put the support under the equalizing beam axle 18 or under the frame Unscrew u bolt 4 nuts and remove spring clamp plates 3 Lower the truck to the support so that there is backlash between the spring 1 and the equalizing beam 23 Turn the equalizing beam for a small angle and remove the u bolt With each equalizing beam boss disassembly remove the old grease mud and corrosion traces Replace w...

Page 91: ...m and 100 rpm Shock absorber free play denotes its failure If there is liquid leakage from the shock absorber fasten the nut of the shock absorber hous ing Shock absorber gap along the fixing stud or along its axle is forbidden Change the shock absorber bushings 10 see Figure 67 and 13 see Figure 70 if necessary Fasten the shock absorber retaining nut with 40 Nm torque 4 kgfm If the split pin hole...

Page 92: ...8 wheel from the outer side of stop bracket and on 533 310 and 400Г 508 wheels from the inner side Rubber seal 9 of wheel vent slot prevents tire internals from dirt and ensures chamber valve installation in certain position Wheels retaining nuts and pins from right and left sides have right hand thread Tire and Wheel Maintenance Most completely wheel and tire resource utilisation and their safe o...

Page 93: ...hread wear is detected which is usually caused apart from wrong driving by truck undercarriage failure steering wheel or brake failure find its causes and remedy the failure Wheel fasteners loosening and truck operation is forbidden if at least one wheel fixation nut or pin is absent or fixing holes of discs are worn Every time when mounting the wheel on boss independent of disassembly reason fast...

Page 94: ...t use mineral oils cup grease engine oil etc as a lubricant If any manufacturing or operational flaws of the tires are detected do not fit such tires Check tubes and valves for tightness do not use tubes with delamination on the joints or damaged valve Clean wheel surface from dirt rust and rubber waste especially from rim surface bead and lock rings facing the tire and in the area of welds Paint ...

Page 95: ...pen gaps tire bead ring metal lids damage do not fit tires which side walls have rubber runs rubber buffing and burrs of the toe scores and damages preventing their fitting assemble and disassemble without harsh force applied to tire irons force applied should not lead to their sliding or breaking do not start inflating a tire without making sure that the lock ring is in the correct position in th...

Page 96: ...e wall down and then using hook end of a big tyre iron completely remove upset tire side wall along the rim seat If it is difficult to remove tire side wall from the rim seat after long operation as well as if it is removed from non removable rim outboard flange remove the side wall from its seat directly pushing it with tire irons To do that insert flat end of a tire iron as far as possible betwe...

Page 97: ... in cl 2 7 Put out the rim from the tire put the wheel with the tire vertically lock part away from yourself so that tube valve is down sink the valve with the seal in the tires holding the tire by one hand vertically or resting it on a support shift the rim towards yourself not moving it so that tire bead enters the rim well holding the disc or rim upper surface take out the rim from the tire avo...

Page 98: ...ast a little bit lower the rim edge to the level provid ing installation of the lock ring otherwise the valve slot seal will be displaced and further assembly will be impossible 5 Mount bead and lock rings herein matching forge B see Figure 75 on the lock ring with one of slots A on the bead ring and matching the lock ring cut with the stop block on the rim 6 Check the position of the valve and it...

Page 99: ...en the nuts preliminary when the wheel is elevated Herein tighten the nuts next but one or in a criss cross manner When tightening first five nuts check that the nuts align their spheri cal chamfers with spherical chamfers of wheel disc mount holes Nuts should be completely tight ened because insufficient and uneven fastening can lead to side wheel wobble 4 3 3 7 Wheel Assembly Balancing Allowable...

Page 100: ...nd upset it completely If the spring is inserted incorrect ly it can suddenly slide from the bead ring that is why it is important to be careful 4 Inflate the tire to nominal pressure 5 Correct the position of balance weights if they are displaced along the perimeter or tum bled out the bead ring radius To remove balance weights insert a screw driver between the spring and the weight force the spr...

Page 101: ...et of spare wheel holder at a cabover truck is additionally fixed by nuts Before lowering the spare wheel dismantle the side guard read clause 4 7 3 2 Side Guards and check cable 1 clamp to the removable bracket after that unfasten the removable bracket 4 from the buckles 2 and loosen removable bracket retaining nuts for cabover trucks Put removable handle 7 on the gearbox shaft Spare wheel holder...

Page 102: ...not disconnecting it from the removable bracket 4 if pos sible and wheel it out If the removable bracket with the spare wheel cannot be lowered when the handle 7 is first rotated it can be seen because cable 1 tension is poor use the tire iron to uncouple the removable bracket 4 from the holder base 5 Spare wheel in transport is elevated in reverse order after that loosen cable tension Spare wheel...

Page 103: ...e drop arm the pull rod of the steering linkage the lever of the swivel member and levers of the steering linkage 4 4 1 1 Steer for conventional cabin trucks is shown in figure 79 1 steer with arm 2 propeller shafts 3 steering wheel 4 5 nuts 6 washer 7 bolt 8 steering column 9 pull rod of drop arm Figure 79 Steering wheel of the conventional cabin truck 4 4 1 2 Steer for cabover trucks is shown in...

Page 104: ...f the integral type Operational gear crew ball nut rod sector The rod is simultaneously the booster piston The axle gear wheel of the drop arm and the rod in the middle position does not have the side clearance The device has the valve with the rotating spool which consists of the operating in the wormscrew 11 the rotating spool 1 as shown in figure 82 The rotating spool 1 and the worm screw head ...

Page 105: ...orated together and tightened with pins 8 and 13 When effect on the steering wheel is absent the torsion bar keeps spool in the neutral position When using pressure to the steering wheel the torsion bar screws and turns the spool in the direction of correspondent dosing grooves 1 Spool 2 8 plugs 3 7 adjusting screws of pressure limitation 4 6 pressure limitation valves 5 balls 9 piston 10 15 pins ...

Page 106: ......

Page 107: ... in the tank runs through the filter 2 If the filter 2 is contami nated the last raises the little clenching the spring 7 and oil runs to the tank passing over the fil er Oil level in the tank is controlled with indicator upon the unscrewed plug 4 Oil level shall fall within the limits of marks in the indicator 1 Housing 2 filter 3 filling strainer 4 plug of the filler neck with oil level indicato...

Page 108: ...oil up in the hydraulic system not below 20 С 2 Rise the front part of the truck so that wheels do not the ground or establish front wheels of the truck on rolling circles 3 Detach the drain pipeline from the tank preliminary bring the container for the drained oil 4 Start the engine for no more than 10 sec in order to oil has run out of the tank and the pump 5 Stop the engine for the couple of ti...

Page 109: ...ulic pressure limiting valve in the steer upon the maximum steering wheel position when the engine does not operate remove plugs 2 and 8 as shown in figure 82 reverse with the screw driver not applying significant efforts adjusting screws 3 and 7 for 3 5 rotations as shown in figure 82 adjust the pressure gauge to the output on the pivoted union of high pressure in the steer preliminary remove the...

Page 110: ......

Page 111: ...ure till 75 85 kgf sm2 upon contact of the wheel turning limit stops by sequential securing of screws B1 and B2 in accordance with figure 85 When regulating take into account that upon insufficient pressure drop it is necessary to screw adjusting screws and upon excessive drop unscrew Caution Implement the displacement of adjusting screws in neutral position of the spool release the steering wheel...

Page 112: ...d in the driver s cab the pedal is connected with the brake valve through levers and drag links Primary brake see Figure 86 is drum type brake with inner brake pads 2 Each brake has a pinch clamp 1 with automatic backlash regulation between the pad 3 and the drum Friction pads are mounted on the bearing axes 7 1 pinch clamp 2 brake pad 3 brake lining friction 4 support 5 bolt 6 11 nuts 7 brake pad...

Page 113: ...aking the cleat wedge 7 see Figure 88 overcoming the belleville spring 1 re sistance presses the rollers 6 which rotate downwards the wedge 7 surface and piston 5 Herein piston 5 together with gear ring 2 and adjusting nut 3 moves outside and consequently braking process starts Due to longitudinal displacement of the piston 5 special resilient pin 4 bumps up the gear ring 2 through the helical gro...

Page 114: ...ide through the thread thus decreasing backlash appeared due to brake lining wear Through the tooth coupling B adjustment is made with very little speed evenly with the pitch of 0 03 mm I II III IV I pinch II tooth III start of automatic adjustment IV finish of automatic adjustment 1 belleville spring 2 gear ring 3 adjusting nut 4 pin 5 pistons 6 rollers 7 cleat wedge 8 adjusting bolt A helical gr...

Page 115: ...rollers 3 must face pistons 2 How to check the correctness of installation when pressing wedge end with your hand try to circle it If the wedge can move i e if it goes down it means that the rollers have not been properly installed between the pistons 1 cleat wedge 2 pistons 3 rollers Figure 89 Cleat Wedge Installation When installing the pinch clamp strictly check that the cleat wedge assembly wa...

Page 116: ...rum together with the wheel hub becomes possible 4 5 1 3 Brake Lining Replacement When brake linings are worn they should be replaced according to Figure 92 Lining wear degree is determined by wear indicator To ensure tight adherence of a brake lining to the pad it is recommended to peen rivets from central holes of the brake lining as shown in View B 1 2 3 4 5 6 7 8 If the brake linings are oily ...

Page 117: ...e mechanism A B distances between support outer diameter and brake linings Figure 93 Brake Pads with Brake Linings Adjustment Scheme 1 Brake pad 2 brake lining 3 rivet 4 wear indicator diameter without includ ing brake drum wear Figure 92 Brake Lining Adaptation Scheme ...

Page 118: ... drum is worn if there are annular grooves deeper than 1mm bore drum work sur face according to Table 13 basing on outer hub bearing rings see Figure 94 Drum work surface runout should not exceed 0 25 mm Table 13 Brake Drum Internal Surface Diameter After Boring Diameter after first boring mm Diameter after second boring mm Maximal diameter of boring mm 421 5 423 424 38 4 5 1 5 Speed Sensor Brakes...

Page 119: ...angular velocity sensors are installed in front axis and rear axle wheels are working with the target gear ring pressed to the hub 5 and are used for continuous reading of wheel speed The signal received is then transferred via cables to the control unit For normal sen sor operation backlash between the rotor and the sensor should not exceed 0 7 mm 4 5 1 6 Brake Chambers Brake chambers installed o...

Page 120: ... spring type brake actuators according to Figure 99 twist the chamber against stop twisting depth is 25 mm turn it back and install outlets 11 12 looking back tighten the nut with 300 500 20Nm 30 2 kgfm torque Seal the brake chamber and pinch clamp joint with silicon based or rubber based sealant Check wear and damage of the pinch clamp and brake chambers within up to two years after start up Dama...

Page 121: ...d water drain valve 12 trailer valve with cut valve 13 feeding coupling head 14 control coupling head 15 brake chambers with spring type brake actuator 17 27 ABS modulators 18 primary brake relay valve 20 parking brake relay valve 21 parking brake valve 23 trailer and СТС brake cylinder 24 check valve 25 non brake consumers can 26 brake chambers 29 parking brake pneumatic valve 30 engine stop air ...

Page 122: ...ir reserve of the truck and to actuate truck and trailer brakes Brake system drive schematics without trailer outlets is shown in Figure 101 1 towing device 2 oil separator 3 two pointer pressure gauge 4 pressure controller with adsorption tank 5 adsorption tank cylinder 6 4 circuit protective valve 7 loss of pressure detector 8 front axle brake can 9 rear bogie brake cans 10 13 16 19 25 pneumatic...

Page 123: ...contaminants be ing in the air It is installed before pressure controller with adsorption tank and it helps to prolong dehydrating case life 1 Spring 2 valve 3 lower housing 4 piston 5 screw 6 upper housing 7 8 9 seal rings 10 valve seat a b c d outlets Figure 102 Oil Separator Compressed air from the compressor is pumped to a outlet and runs down along inter nal surface of the upper housing 6 wit...

Page 124: ... part of the adsorption case air is cleaned from oil hard particles and condensed moisture Going through the adsorption chemical zeolite 2 compressed air is finally dried and goes to B cavity and Г channel 1 Filter 2 zeolite 3 air escape valve 4 air escape valve spring 5 throttle valve 6 throttle valve spring 7 check valve spring 8 check valve 9 nut 10 adjusting screw 11 balancing piston spring 12...

Page 125: ...rops due to air consumption to the pressure of switch on balancing piston 13 moves left by spring 11 force Discharge valve 24 closes discharge valve 14 opens and connects E cavity with the environment through Ж channel and З cavity Herein un load valve 18 by spring19 force closes and the compressor pumps compressed air to the system receivers again Besides unload valve 18 works as safety valve If ...

Page 126: ...d air enters cavity B over piston 5 through hole A Herein piston 5 moves down wards together with piston 6 Piston 6 seats valve 7 thus insulating outlet IV from the atmospheric outlet V With further piston 6 movement valve 7 opens and compressed air from outlet II starts flowing to outlet IV which is connected with the corresponding brake circuit With pressure grow at outlet IV pressure under pist...

Page 127: ...e 8 rod 9 housing 10 elastic member 11 cap III outlet to air intensifier of front axle brake circuit IV outlet to РТС and air intensifiers of rear axle brake circuit I II outlets to air tanks V atmospheric outlet A hole B cavity Figure 104 Brake Valve ...

Page 128: ...n valves 3 13 As air flows through throttle and side holes slowly pressure in circuits also grows slowly at the initial moment Coming through throttle holes air presses diaphragms 4 12 and overcoming spring 6 10 force fully opens valves 3 and 13 Pressure equal to pressure at the outlet I is set at outlets II and III Throttle holes in valves 3 and 13 provide brake drive circuits filling at very low...

Page 129: ...imary brake system 4 3 inlet from tractor parking brake sys tem Figure 106 Trailer Brake Control Valve with Two Wire Drive and Cut Valve 4 5 2 7 Relay valve is shown in Figure 107 is installed in rear axle wheels brake system to reduce time of brake drive actuation due to short pipeline of compressed air inlet from the air tank in the actuator 1 Upper chamber 2 piston 3 inlet valve 4 spring 5 valv...

Page 130: ...sed Preliminary control chamber a of diaphragm c there is no pressure Compressed air at the outlet 1 enters from chamber A through open inlet hole b to chamber B and then to brake cylinders through outlet 2 Simultaneously compressed air also goes through hole d in the chamber of preliminary control g of diaphragm f and the discharge hole e is closed 1 Outlet 2 outlet to brake cylinders 3 atmospher...

Page 131: ...alves are shown in Figure 109 designed to determine air pressure parameters at the outlet for each circuit through check pressure gauges To connect to the valve use hoses with coupling nut M16x1 5 and pressure gauges with measuring range 0 1000 kPa 0 10 kgf cm2 1 Valve case 2 cap 3 hook Figure 109 Control Outlet Valve 4 5 2 11 Maintenance of Pneumatic Brake System Drive General When maintaining th...

Page 132: ...ailer brakes corresponding pressure at inlet or outlet is 210 kPa 2 1 kgf cm2 at check pressure of 150 kPa 1 5 kgf cm2 4 5 3 Emergency Brake System Function of emergency brake system is performed by one of primary brake circuits If one of the circuits is failed emergency brake system ensures quite efficient truck braking 4 5 4 Parking Brake System Parking brake system is designed to ensure truck i...

Page 133: ...s close by spring force and discharge valve 4 is open Spring type brake actuators are connected with the environment through outlet III and open discharge valve and outlet II The truck is braked by spring type brake actuators If the truck is herein braked by primary brake system pressure from brake valve is fed to outlet V which moves its together with piston 3 downwards impacting the piston 2 Her...

Page 134: ...iciency to keep the whole truck on a slope Manual brake valve for auxiliary and parking brake systems is used together with brake chambers with spring type brake actuators Additional coupling to trailer brake control valve en sures braking action transfer to the trailer There is control position to check truck parking brake efficiency a handle b c valves d discharge hole e piston f spring A B C ch...

Page 135: ...cables warning lamp test button and off road mode switch 4 5 5 1 Magnetic valve ABS modulator is shown in Figure 108 4 5 5 2 Electronic control unit ECU is the main part of ABS The control unit is lo cated in the driver s cab on the control panel spacer The unit serves to treat signals coming from the angular velocity sensors deliver control signals to the modulators trip relay of secondary brake ...

Page 136: ... ABS indicator 2 switches on see Figure 114 for conventional cab trucks and Tractor ABS indicator 34 see Figure 29 for cabover trucks is on Herein it is possible to switch off the corresponding ABS circuit and the brake system will work in ordinary mode without ABS mode The system does not require special maintenance except cross check of functioning and check of ABS sensors installation when adju...

Page 137: ...trucks and ABS test button 10 see Figure 32 for cabover trucks during 0 5 8 sec and they are displayed by warning lamp flashing the so called blink codes are de livered see Figure 116 Figure 116 Error Codes Blink Codes Activation Each error is delivered in a block consisting of two categories first identifies com ponent number and second one error number Error codes are given in Table 14 Error cod...

Page 138: ...ng ABS should be maintained 4 4 Unstable signal 4 5 Sensor signal is lost 4 6 Ground fault or battery fault or broken wire Right speed sensor of driving axle 5 1 Too large air breather 5 2 No signal from sensor during braking 5 3 Bad target ring ABS should be maintained 5 4 Unstable signal 5 5 Sensor signal is lost 5 6 Ground fault or battery fault or broken wire Left modulator of steering axle 8 ...

Page 139: ...ault for the clear coil 11 3 Clear coil wire is broken 11 4 Wire of general pin is broken 11 5 Battery fault for the lifting coil 11 6 Ground fault for the lifting coil 11 7 Lifting coil wire is broken 11 8 Valve configuration error Connection pins of diagonal ground 10 10 Battery fault for diagonal 1 10 11 Ground fault for diagonal 1 10 12 Ground fault for all modulators Internal ECU failures 15 ...

Page 140: ... 12 Memory fault of sensor parameters 17 13 Sensors of axle 1 or 2 are mixed 4 5 5 5 1 Error Deletion from the Memory After the faults are eliminated it is necessary to delete the error from control unit memory as shown in Figure 117 Figure 117 Error Blink Codes Deletion To do this press ABS test button when the ignition is off and release it only when the ig nition is switched on In less than 3 s...

Page 141: ...s 8 front right modulator 9 front left modulator 10 rear right modulator 11 rear left modulator Figure 118 Plug Connection Scheme of Wabco Control Unit To activate test ABS lamp should be connected with storage battery minus during 0 5 3 sec through ABS switch button see Figure 119 Figure 119 Error Codes Blink Codes Activation ...

Page 142: ...t pre sent in the system at the moment will be displayed in an order reverse to their appearance the last goes first the first goes last Herein error number does not show error appearance sequence Passive errors stop to be displayed when the last passive error registered in the control unit memory is displayed List of error codes for Wabco and troubleshooting are given in Tables 15 and 16 If the w...

Page 143: ...tor if there no defects Wheel diameters can differ from teeth number of toothed rotors 6 Check the toothed rotor if there no defects if all the teeth are present if there is no runout Replace the rotor 8 1 Check feed cables and the fuse Low voltage in the truck electric network 8 2 Check voltage at the generator and storage battery terminals 8 3 Replace the control unit if the error will repeat 8 ...

Page 144: ...items based on electronics Blown fuse should be replaced by another one having the same operational current if the fuse is blown for the second time find and delete the failure 4 6 1 Conventional Cab Truck Wiring Diagram is shown in Figure 162 see the at tachment Legend to Figure 162 is given in Table 17 Table 17 Pos in Figure 162 Name Device type or number 1 Front light ПФ130АБ 3712010 01 or 112 ...

Page 145: ...t 1 967626 36 Interface Engine Block БДИ 1 37 Tire pressure gauge 2411 3830 38 Low fuel notification a Fuel reserve indicator УБ170М or 34 3806 39 Voltage indicator 11 3812010 40 Electronic speedometer ПА8046 4П 41 Electronic tachometer 6201 3813 42 Oil pressure indicator in the engine lubrication system УК170М or 33 3810 43 Coolant temperature sender УК171М or 36 3807 44 Two pointer pressure gaug...

Page 146: ...211 3777М 77 Fuse blocks 41 3722 09 78 Headlight adjuster ЭМКФ35 79 Throttle pedal 61000NО 51SD 42 80 Engine starting heater control panel 81 Engine starting heater 14ТС 451 20 00 00 000 22 82 Backing light switch ВК403В or ВК24 1 83 Power Takeoff switch sensor ВК403В or ВК24 1 84 Transfer box differential lock switch sensor ВК403В or ВК24 1 85 Transfer box low speed switch sensor ВК403В or ВК24 1...

Page 147: ...ntial lock switch solenoid valve КЭБ 420 or КЭМ 10Д 114 Transfer box high gear switch solenoid valve КЭБ 420 or КЭМ 10Д 115 The cross axle differential lock switch solenoid valve КЭБ 420 or КЭМ 10Д 116 Additional Power Takeoff switch solenoid valve КЭБ 420 or КЭМ 10Д 117 Power Takeoff switch solenoid valve КЭБ 420 or КЭМ 10Д 118 120 Tail light 7442 3716 10 or 8512 3716 01 119 Registration plate la...

Page 148: ...tor flasher 5412 3787010 or S4012 3747 24 Electric left rear view mirror 391 820120 25 Left repeator direction indicator 5702 3726000 26 53 Master lighting СИЕУ 453754 005 01 27 Cab light to light loading area 112 05 44 or 2012 3711 28 54 Door light switches ВК409 3710000 29 Cab light switch to light loading area 3842 3710 02 05 30 Rear fog beams switch 3842 3710 11 04 31 External light selector 8...

Page 149: ...420БМ 3724010 66 Position light relay R6 A part of the harness 4420БМ 3724010 67 Fuse block F4 A part of the harness 4420БМ 3724010 68 Dimlight relay R7 A part of the harness 4420БМ 3724010 69 High beam light relay R8 A part of the harness 4420БМ 3724010 70 Horn relay R9 A part of the harness 4420БМ 3724010 71 Stop signals relay R10 A part of the harness 4420БМ 3724010 72 Fuse block F5 A part of t...

Page 150: ...axle differential lock solenoid valve КЭМ 10Д 98 Power Takeoff solenoid valve КЭМ 10Д 99 Additional Power Takeoff solenoid valve КЭМ 10Д 100 High gear solenoid valve КЭМ 10Д 101 Jake break door valve 102 Cam shaft rpm sensor 650 1130544 103 Pressure gauge 104 Fuel low pressure and low temperature sensor 650 1130540 105 Oil pressure and temperature sensor 650 1130552 106 Forced induction pressure a...

Page 151: ...Tubor or 6СТ 190 АЗ Kursk 143 Battery switch 1402 3737 144 145 The cross axle lock sensors ВК403В 3716 146 Transfer box interaxle lock sensor ВК403В 3716 147 Transfer box low speed switch sensor ВК403В 3716 148 Power Takeoff switching on sensor ВК403В 3716 148а Additional Power Takeoff switching on sensor ВК403В 3716 149 Air filter clogging sensor 132 3839600 or ДСФ 70 157 Parking brake sensor 607...

Page 152: ...er relay R4 10 rear fog beams relay 12 VCI 13 brake signal pneumatic switch relay R12 14 outside mirror heater relay R11 15 stop signal relay R10 16 audio signal relay R9 17 high beam relay R8 18 dimlight relay R7 19 tail lamp relay R6 20 rear fog beams additional relay R5 Figure 120 Scheme of Switching Unit and Fuse Blocks ...

Page 153: ...witch 4 30 Engine electronic control unit 5 5 Tail light switch high beam indication 6 10 Storage batteries switch Fuse block F2 No Design current A Symbol Dedication 1 25 Independent engine heater 2 25 Autonomous heater 3 5 Electric torch switch 4 15 Truck ABS trailer ABS 5 5 Autonomous heater 6 7 5 Emergency warning audio signals ...

Page 154: ... 5 Right dimlight headlamp 5 5 Sidelights right drop side 6 5 Sidelights left drop side Fuse block F4 No Design current A Symbol Dedication 1 10 Fuel heater air drier heater 2 10 Heated rear view mirrors 3 5 The interaxle lock Power Take off 4 5 Low gear auxiliary transmis sion 5 5 High beam dimlight selector storage battery charge 6 5 Backing light ...

Page 155: ...light headlights ad juster 3 5 Cab light 4 10 Wind shield wiper wind shield washer 5 5 Devices 6 5 Engine electronic control unit secondary brake 4 6 4 Alternator The alternator is a synchronous machine with installed rectifier assembly with positive pressure ventilation To avoid the alternator failure it is forbidden to operate the engine when storage batteries switch is off to disconnect wires f...

Page 156: ... installed 4 6 5 1 Storage Batteries Fastening for Conventional Cab Ural Trucks Storage batter ies 1 see Figure 121 are installed in the container 10 on two side and intermediate supports When installed in the container the batteries are fastened by upper clamps 13 and front cam dog 4 The upper clamps 13 are fixed by front 9 and rear 12 folding wedges Front folding wedges 9 are adjustable and are ...

Page 157: ...clamps were installed into the guiding members 11 Otherwise the clamp 13 will not couple with the cam dogs 9 and 12 and the battery will not be fastened that can lead to their damage Do not deform the guiding members 11 when the battery is being installed and fastened When installing and fastening the battery do not pinch and bend wires to the stator and battery switch do not bend caps as well as ...

Page 158: ... cab front board through additional fuses of the corresponding capacity not exceeding 20A in total Caution It is forbidden to connect 12 V devices to the truck network without volt age converter It is also forbidden to connect external consumers to one storage battery 1 Container housing with insulation 2 10 6x30 stud 3 11 split pin 4 16 eye bolt 5 6 15 nut 7 locking plate 8 container flap with in...

Page 159: ...156 Figure 123 Engine Electronic Control Unit Wiring Scheme ...

Page 160: ...ck i e the truck should be completely fuelled and equipped with all auxiliary tools and devices Wheels should be inflated to the pressure corresponding to the full load The truck should be kept at temperature stated above during eight hours Lamps adjustment consists in initial angle of low beams Initial angle adjustment of low beam should be done with dedicated devices according to the manuals for...

Page 161: ...unting 24 V radio recorder is mounted in the cab upper console radio panel see Figure 28 according to the Manual for Radio Recorder is connected to the truck network via additional 15A fuse Feeding wire having minimum 1 5 mm2 cross section should be laid under the dashboard fixed with clamps to the main wire bunch then to the radio recorder via rubber bushing inside cab side column The recommended...

Page 162: ...ated inside the cab and on the right side as viewed in the direction of the truck motion Fuel supply is provid ed out of the fuel tank Upon operation of the independent heating unit it is necessary to follow requirements specified in the paragraph Safety Requirements Regulate spherical mirrors providing the viewing area though them according to figures 124 125 126 127 by loose tension bolts of hol...

Page 163: ...tion the mechanical system of cushioning is provided which could be regulated in accordance with the driver s weight Faux leather or fabric upholstery provides durable operation and cleaning with any household detergents Seat is provided with the three point seat belt with the emergency locking retractor 1 as shown in figure 128 1 Safety belt 2 seat back 3 seat tilting lever 4 5 height and cushion...

Page 164: ...seat construction pneumatic system of cushioning is provided which is regulated depending on the driver s weight Faux leather or fabric upholstery provides durable operation and cleaning with any household detergents Seat is provided with the three point seat belt with the emergency locking retractor When pushing the lever 1 up as shown in figure 129 the cushion moves fore and aft relative to base...

Page 165: ......

Page 166: ... are the effective protective mean of the driver and passengers from severe consequences of the road vehicle accident To fasten the seatbelt it is necessary smoothly to stretch it out taking the belt tongue and pull the tongue 2 in accordance with figure 130 in the lock until its clicking position not allowing ribbons to twist Make sure that the lower belt ribbon tightly adjoins hips the lower bel...

Page 167: ......

Page 168: ...s shown in figure 131 upper points of safety belts fastening are located on cabin side walls 1 left safety belt with emergency locking retractor 2 safety belt waist static 3 right three point seat belt with emergency locking retractor 4 shore 5 passengers seats 6 driver s seat Figure 131 Fixation of safety belts When driving in the truck the driver and passengers shall fasten their safety belts ac...

Page 169: ...osition of the master lighting switch Windows are equipped with drop and swinging windows Drop windows lift and decrease by lifting devices Windows shall move in the directions freely without jawings 164 1 power window handle 2 opening door handle 3 closing door handle 4 button for door blocking from inside Figure 132 Conventional cabin doors 1 vent window catch lever 2 power window handle 3 openi...

Page 170: ... use НИИСС 4 without watering as combined effect of the concentrate air pollu tion and ultraviolet radiation cause changes of the truck paint and lacquer coating Clean mirrors with simultaneous turning on of wind shield wipers Change the stream di rection of liquid with the guide turn in the jet 4 7 1 4 Heating of the conventional cab The cab is warmed with air heated in the heating unit which is ...

Page 171: ...lid 8 heating unit radiator 9 water discharge pipe from the heating unit radiator 10 water discharge pipe 11 pet cock 12 external hatch lid 13 vent Figure 125 Operating circuit of the cab heater and the glass bead blasting 4 7 1 5 Cab heating and ventilation system of the cabover truck is designed to heat the cab and consists of the radiator included in the engine cooling system and the engine sta...

Page 172: ...e hoses the hydraulic cylinder of cab roll over 4 the central lock of cab locking 1 For the cab roll over it is necessary turn clockwise the switch on the pump 8 by the lever 10 which is included in the tool kit against stop put the lever in the sleeve bore of the pump 7 and pumping it raise the cab Opening of the central lock of cab locking happens automatically at the moment when the cab starts ...

Page 173: ......

Page 174: ...e located for lashing and securing the cargo A platform is equipped with seats the additional side rack canopy bows with braces and canopy The middle seat is established upon the customer request and could be dismantled and fixed on the front rack as shown in figure136 Side seats could be folded for space clearing upon cargo transportation The installed canopy is shown in figure 137 Folding order ...

Page 175: ...direction and distance of movement for the lock 1 in the housing strut 2 ac cording to the following characteristics 1 If after the full rack closing and the strut locking the rack has free run in the opening direction it is necessary to move the lock 1 up 2 If pressure on the handle 7 goes beyond 300 N 30 kgf or the handle does not reach the vertical position or could not be fixed in it it is nec...

Page 176: ...rut locking check accuracy of adjustment If necessary repeat clauses 1 2 4 9 9 Move the handle 7 in the position OPENED 10 Turn the screw with the spring washer4 in the screw hole of the tappet 3 4 7 3 2 Side safety devices SFD are shown in figure 140 provide efficient protection at full length of the vehicle unprotected road users from falling under the vehicle on the side Vehicle SFD includes ri...

Page 177: ...Figure 140 Installation of left and right side safety devices 171 ...

Page 178: ...dynamic stress 4 8 1 Towing coupling is located under the fifth wheel and is shown in view A brackets 7 are not shown for clarity When drawing control joystick by the unlocking device 1 through the lever 3 locking valve 10 releases gate hook 9 and it turns by spring force 5 to the position for coupling Lowering the control joystick by spring force 4 the locking valve 10 holds the gate hook 9 When ...

Page 179: ... the device plate and lip of the safety lever is completely before the unlocking handle B there is no clearance between the trailer and the fifth wheel coupling C locking element 3 is securely closed on the central trunnion 1 Figure 142 Check Full Fixation of the Block 4 8 3 Coupling and Uncoupling of the Tractor and the Semi Trailer Before coupling make sure that the fifth wheel coupling and its ...

Page 180: ... in a way that the semi trailer king pin entered the grips of the fifth wheel coupling The tractor and the semi trailer are coupled automat ically brake the tractor with the parking brake Make sure that accidental uncoupling interlock 2 see figure 141 is down and prevents the handle move towards itself lift the semi trailer support in the extreme up position and fix it securely plug in the connect...

Page 181: ...emi trailer support plug out the connecting cable of the semi trailer wiring disconnect the connection hoses of the pneumatic brake system drive from the coupling heads first feeding line after control line and close with protective lids Fix coupling heads with hoses on the tractor area move the accidental uncoupling interlock 2 see figure 141 in up down position depends on the fifth wheel couplin...

Page 182: ...air pressure in the pneumatic system is 500 kPa 5 kgfm at least and when the clutch is disengaged Between Power Takeoff crankcase flanges ad justing gaskets are installed they help to adjust side backlash in the gear engagement noise level adjustment When it is time to replace the gaskets by new ones their thickness should be the same Information of Power Takeoff control is given in paragraph 4 2 ...

Page 183: ...id valve stops compressed air intake and connects the mechanism chamber with the environment air is discharged from the chamber and the rod 10 with the fork 9 uncou ples the idle shaft gear 5 from the drive gear 3 by spring 11 force 1 drive gear axle 2 crankcase 3 drive gear 4 crankcase cover 5 idle shaft gear 6 selector chamber dia phragm 7 selector chamber cover 8 cover 9 fork 10 selector fork r...

Page 184: ... 17 piston 18 21 pump valves 19 plug 20 safety valve 22 pump casing Figure 146 Additional Power Takeoff The pump consists of the piston 17 with pressure valve 18 of safety valve 20 and the casing 22 The piston with the side rod is mounted on the shaft 3 cam and when it rotates the pis ton translates To avoid excess pressure and rpm increase differential suction valve is designed with a coil spring...

Page 185: ...m shaft 10 through flexible coupling 22 An automatic band brake 1 is installed on the gearbox worm see Figure 148 preventing from uncontrolled rotation of the winch drum and rope reel out when the truck clutch is disen gaged and if the safety pin is cut Adjust the brake when the drive is in backing mode and the drum flexible clutch is dis engaged If the brake heats over the temperature that a hand...

Page 186: ... 21 plug 22 flexible clutch 26 flange 30 gearbox worm 34 gasket 35 band brake 36 rope retaining bracket 37 right bracket of actuating screw 39 clutch rod 40 fork 41 slide block 42 winch suspension cross member Figure 147 Winch Gearbox The number of gaskets under the front and the rear covers after adjustment should be ap proximately the same it will make further adjustment of worm and worm gear ea...

Page 187: ...f gaskets 33 under cap 38 from the brake side accordingly so that the total gasket thickness on both sides is maintained Contact pattern is moved along the tooth width with axial movement of the worm gear in the same direction as the pattern is moved Globoidal worm and worm gear can function properly only if the coupling is correctly adjusted Incorrect adjustment can cause worm and worm gear overh...

Page 188: ...s lays the rope by back and forth motion along the actuating screw 6 and along two guiding rollers 7 Left hand and right hand screw installed on two bearings is rotated by the chain transfer from the drum shaft through the drive sprocket 16 and idler sprocket 10 Chain tension is adjusted by gaskets 2 and 14 chain slack can be 3 10 mm Axial force from the actuating screw 6 is transferred to the hol...

Page 189: ...min It is forbidden to use the winch rope to tow a truck or a trailer as well as when the rope is inclined more than 15 from the truck axis To switch on the winch put transfer box and gearbox levers to the neutral position using wrench 30 put the flexible clutch lever to the upper ON position when the rope is forced out When unreeling the rope manually flexible clutch lever should be in lower OFF ...

Page 190: ... apply the towing cable supplied with the truck If the block is used to increase drawbar force when self winching position I it will be fixed to an object selected as a support by the towing cable and the winch rope hook is fixed to the towing device hook If the hook is used to change drawbar direction when winching another vehicle position II it is then fixed to an object used as a support via th...

Page 191: ...eme Before driving open the wheel valves and check tire pressure when the switches are in neutral position If necessary inflate the tires as norms require Pressure norm for 425 85R21 tires and 156 lifting capacity index are given in Table 20 Pressure norm for 500 70 20 1200х500 508 tires and 156 lifting capacity index are given in Table 21 For operative control of tire pressure wheel valves should...

Page 192: ... gauge Figure 152 Installation of Air Pressure Control System in Tires with a Solenoid Valve on a Conventional Cab Truck 1 2 Tube to tire pressure gauges 3 reducing bush 4 tire pressure gauges I to rear wheel inflation pressure gauge II to front wheel inflation pressure gauge Figure 153 Tire Pressure Control Sys tem ...

Page 193: ...o nominal 40 1400 Table 21 Pressure Norm for 500 70 20 1200х500 508 Tires and 156 Lifting Capacity Index Road type Allowable pressure kgf cm2 MPa Maximal speed km h Maximal run during the guarantee period km Difficult paths of moorland virgin snow and quicksand 1 0 0 10 20 400 1 5 0 15 20 1000 All road types only for the period of tire inflation after difficult paths In the range of maximum al low...

Page 194: ...three operating positions DEFLATE NEUTRAL AND INFLATE and ensure pressure decrease in 4 6 min depending on tire standard size according to OST 37 001 144 73 The trucks have a solenoid valve shown in Figure 155 1 Solenoid valve 2 angle 3 fittings 4 bolt 5 bracket 6 nut I from safety valve II to rear wheels III to intermediate wheels IV to front wheels Figure 155 Solenoid Valve ...

Page 195: ...s displaced to the toe end tooth Adjust the coupling according to the contact pattern Backlash in gearbox bearing Restore bearing preload Gear teeth working surface wear damage Replace the gears Wheels and Tires Thread pattern are strongly and unevenly worn Steering wheels misalign ment Wheel boss bearings and swivel member king pin bear ings are misaligned Align the wheels Adjust the bearings Tie...

Page 196: ...e pressure controller fail ure or pneumatic system leak age Repair the compressor replace the pressure controller Find air leakage place and repair Braking is not efficient Piston seals or air oil intensi fier insert seal are worn herein air is discharging from the air oil intensifier exhaust pipe when the brake pedal is pressed Replace the seals The brakes are stuck are not released There is no b...

Page 197: ...ubber bulb Check the voltage regulator Give the battery for repair When charging completely discharged battery battery fluid voltage and temperature are raising very fast and boiling starts and density is slightly increasing Sulfatation of the plates that can be caused by long storage battery shutdown or it is operated when battery fluid level is too low or if the battery is systematically under c...

Page 198: ...dditional Power Takeoff pump is not working Oil feeding pipe is damaged Replace the pipe Pipe retaining nuts are not tightened Tighten the nuts Oil channels are clogged Bleed the oil channels with com pressed air Pump valves are leaking air inflow Disassemble the additional pow er takeoff if necessary and clean all the parts properly Winch The rope guideplate does not ensure rope winding to the dr...

Page 199: ...mmed The rope letoff due to viola tion of operation rules when the rope is forced out its sag The rope is wound to the drum without necessary pulling force Unwind the rope remove the winch from the truck if necessary and replace the defective parts Wind the rope again ...

Page 200: ... Start engine in accordance with the operation manual for the engine The heater could continue working and automatically regulate the performance of the cab heater For this establish the fan thermostatic controller of the cab on the heater control unit in the necessary position the cab heater switch shall be in the position OFF 6 Turn off the heater by putting the switch in the position O 6 3 Truc...

Page 201: ......

Page 202: ...sing the tough road with the possible truck slipping the cross axle differential of the rear trailer shall be locked The cross axle differential lock increases the off road perfor mance of the truck With that it shall be preliminary turned on before passing the tough road area but not at the moment when the truck has already lost its mobility Locking shall be implemented after full stoppage of tru...

Page 203: ......

Page 204: ...ippery and ice covered roads to avoid the side slipping On the trucks which have the centralized tire pressure control system moving on the roads with the improved road pavement with nominal load the tire pressure shall be rated Do not decrease the tire pressure more than it could be necessary for road conditions Remember that mileage upon decreased pressure is limited so decrease pressure only in...

Page 205: ......

Page 206: ... 1 minute If the engine does not start the truck shall be removed out of water After removing the stuck truck out of water where it was more than 20 minutes tow it to the closest place where maintenance could be provided When moving under own power check all main assembly units and also wheel hub cavities and swivel members of the front axle if there is water When the oil level in units is high de...

Page 207: ......

Page 208: ...lement in accordance with re quirements of the Traffic code and safety instructions applicable to organisations which operate the truck When towing on the towed truck with the non working engine the driver shall choose the neutral gear in the transfer box The order of neutral gear actuation is specified in the para graph œ4 2 4 Transfer BoxB 6 4 2 1 Installation of Towing and Auxiliary Devices Imp...

Page 209: ......

Page 210: ...ance with figure 97 Check up examination on the way In half the hour after towing beginning and then every 1 5 2 hours it is necessary to inspect hooking devices fastening of the emergency stop sign if it is installed check to the touch thermal conditions of transmission unit crankcases and wheel bosses if they are damaged 199 ...

Page 211: ...urn from a trip maintenance at initial operating period Maintenance 1500 3000 maintenance at operating period Maintenance 15000 Periodicity of Maintenance Lifetime mileages and working hours of the power unit between maintenance for the first operation category are provided in accordance with GOST 21624 Periodicity of maintenance is adjusted in accordance with the category of truck service conditi...

Page 212: ......

Page 213: ...een high and low set point hairlines Oil level indicator waste cloth Fill in the windscreen washer reservoir At temperatures below zero pour the water out of reservoir Container Check operability and per formance of lights the audio visual alarm control and measur ing instruments and windscreen wipers Malfunctions are not allowed Check the alternator perfor mance at the current indicator registrat...

Page 214: ......

Page 215: ...the cabin latch gear Malfunctions are not allowed Check the tire condition and wheels mounting if necessary eliminate malfunctions The tire tread should be without damages and for eign objects Wheel retaining nut loos ening is not allowed External examina tion If necessary fas ten the wheel retaining nuts Check the condition of the towing device when the truck is working with trailer The hook nut ...

Page 216: ......

Page 217: ...s Maintain the engine in accordance with the opera tion manual for the engine Check and if neces sary tighten up a fastening of power unit in all points all connections of air injection and exhaust sys tems Loosening of the fasteners is not allowed Wrenches 24x27 10х12 14х17 screwdriv er Check and if neces sary tighten up straps of the cooling system and the reservoir pressure mainte nance system ...

Page 218: ......

Page 219: ...f lead ing axles drive gears The same Wrench 22x24 box wrench 22x24 pliers screwdriver Undercarriage Check fastening and if necessary tighten the re taining nut of Torque arm stud Loosening of the fastening is not allowed If holes for cot ter pin do not match during nut torque tighten the nuts Head wrench for 50 tire iron with hydraulic jack handle pliers screwdriver drive pin hammer Wedges of fix...

Page 220: ......

Page 221: ...is not allowed Wrenches 17х19 22x24 Rear mounting bracket of front springs to the rein forcement panel of the girder flange The same Wrench 22х24 24х27 socket wrench 24 tap wrench Front mounting bracket cover of rear springs Box wrench 22х24 Balance shaft ready fit ted with balance arm mounting brackets of the rear suspension Socket wrench 30х32 tire iron Balance arm mounting brackets of the rear ...

Page 222: ......

Page 223: ...t allowed Wrench for round nuts 65 70 Check tightness of pneumatic drive and focus on rubbing places or conta gions of pipelines and elim inate them Pneumatic system should not have air leak Check pressure output of both brake valve sec tions and performance of 4 circuit protective valve see subparagraph Pneumatic Brake System Drive Air pressure on test pressure gauges should be equal to pres sure...

Page 224: ......

Page 225: ...ne pat tern Check fastening relia bility of electrical wire har ness Loosening of the wire fas teners is not allowed Pliers screwdriver knife adhesive tape Check fastening of the storage batteries container mounting bracket to the frame The same Wrenches 17x19 22x24 Check the condition of the rubber boot on rear lights side repeaters the storage battery switch the stop signal the fuel level sensor...

Page 226: ......

Page 227: ...tank for used oil Replace oil in the gear box FG9JS135 Oil level in the gearbox housing should be not lower than the lower edge of the check hole Wrench 22 Check oil level in the gearbox ZF 9S1310 Oil level in the gearbox housing should be not lower than the lower edge of the check hole Wrench 22 Replace oil in the transfer box hous ing see subparagraph Transmission and Lubri cants and Hydraulic F...

Page 228: ......

Page 229: ...eam force changing the distance between the hose and the element Wrench 14х17 screw driver Check oil level in the rollover hydraulic pump for trucks with cabover cabin if necessary refill see Lubricants and Hy draulic Fluids Charts Oil level should be within 20 25 mm upon the lowered cabin Check oil level in the hy draulic steering system tank if necessary refill see Lubricants and Hydraulic Fluid...

Page 230: ......

Page 231: ...fasteners is not allowed Wrenches 24x27 Check the tightening of the starting preheater and the fuel tank The same Wrenches 11х13 14х17 Check and if neces sary tighten up the fastener of all connections of air injection and exhaust sys tems Wrenches 14х17 17х19 Check the tightening of the fuel strainer Wrench 14х17 Check the tightening of the radiator module Wrench 17x19 pliers Check the tightening...

Page 232: ......

Page 233: ...ermediate shaft conical roller bearings every 30 thousand km 0 03 0 08 mm Wrenches 8х10 10х12 11х13 14х17 17х19 22х24 socket wrenches 27х38 and 41х46 flat nose pliers screwdriver mount spoon overhead crane needle indicator device for indicator fastening drive pin flange puller group 375 3918050 waste cloth Adjust steer axle king pin bearings see the clause Engine Idle Adjustment upon every sixth M...

Page 234: ......

Page 235: ... and if neces sary tighten nuts of Wedges of fixation of front spring pins Loosening of the fasteners is not allowed Wrench 17x19 Front spring eye The same Socket wrench 30x32 tire iron with jack handle Rear spring eye for trucks 4х4 The same U bolt of front spring eye Box wrench 22х24 U bolt of rear spring eye for trucks 4х4 The same Front spring U bolt Loosening of the fasteners is not allowed T...

Page 236: ......

Page 237: ... flange The same Wrench 22х24 24х27 socket wrench 24 tap wrench Front mounting bracket cover of rear springs Box wrench 22х24 Balance shaft ready fitted with balance arms mounting brackets of the rear suspension Socket wrench 30х32 tire iron Balance arms mount ing brackets of the rear suspension to the cross arm Wrench 17х19 Mounting brackets of upper reaction rods to axle beams of the rear suspen...

Page 238: ......

Page 239: ...should be between high and low set point hairlines when the plug is unscrewed Wrench for hydraulic brake bleeding screw driver tank for unit cleaning waste cloth Brake Systems Check pressure output of both brake valve sections and performance of 4 circuit protective valve see subparagraph Pneumatic Brake System Drive Air pressure on test pressure gauges should be equal to pres sure in the system a...

Page 240: ......

Page 241: ... Equipment sub paragraph Voltage Reg ulator Voltage meter with the accuracy class not lower than 1 0 with the scale 0 30 V screwdriver Check and if necessary ad just lights see paragraph Elec trical Equipment subparagraph Lighting and Alarm System Adjust lights when the truck is not loaded locat ed on the level ground Screwdriver screen with special line pattern Check the fastening of the starter ...

Page 242: ......

Page 243: ...ones Thread deformation is not allowed Wrenches 22x24 box wrench 24x27 socket wrench 55 wrench for hydraulic brake bleeding tire iron Lubrication Maintain the engine in ac cordance with the operation man ual for the engine Change the coolant in the cooling system see the operation manual for the engine YAMZ Change in accordance with the operation manual for the engine Check and if necessary ramp t...

Page 244: ......

Page 245: ... gear of the lead ing axle see Lubricants and Hy draulic Fluids Charts in the transfer box Fill oil up to the edge of the level fill opening on the back wall of the crankcase Oil leakage through a plug is not al lowed The same Wrench 27x30 tank for used oil oil dispenser of 133М model The same Lubricate top bearings with steering knuckle pivots of the front driving axle according to the Lubricants...

Page 246: ......

Page 247: ...the third For gearboxes YAMZ 1105 and YAMZ 0905 oil level in the gearbox housing should be not lower than the lower edge of the check hole When installing entry cover be attentive not to shut down the oil passage with cover or its filler Replace oil in the gearbox with cleaning of crankcase screen and magnet see the operation manual for gearboxes YAMZ 1105 and YAMZ 0905 upon every third Maintenanc...

Page 248: ......

Page 249: ...e stream force changing the distance between the hose and the element Wrench 14х17 screw driver Dismantle wheel hubs re move old lubrication and put the new one Wash lubricate and when installing adjust hub bear ings see subparagraph Driving Axles and Lubricants and Hy draulic Fluids Charts upon every second Maintenance 15000 Apply lubrication smoothly on the external surface of bearing rollers an...

Page 250: ......

Page 251: ...d Maintenance 15000 plain bearer of the winch drum Lubricate before the appearance of the fresh lubricant Lever type grease gun waste cloth guide rollers axle bushing rollers and holder body cavity of guide rollers of the roller winch working area of the driving screw of the roller winch and the guide shaft block thorn Lubricate axles Apply the lubricant The same The same Lubricate propeller shaft...

Page 252: ......

Page 253: ...housing should not be lower than the lower edge of the check hole Wrench 22 Sporadic Procedures of Engine Maintenance 200 000 km Change alternator and fan drive belts Maintain in accordance with paragraph Mainte nance of the accessories drive operation manual for the engine Note It is recommended to combine maintenance of different types if they coincide with ap plication conditions ______________...

Page 254: ......

Page 255: ... manual enclosed to every truck Lubrication is implemented upon the maintenance with the prescribed periodicity and the component overhaul When changing the engine oil with all season oil vice versa change oil filter elements and wash out the centrifugal oil cleaning filter The range of the leading and variety of combustive and lubricating materials of the pow erplant and also seasonality and peri...

Page 256: ......

Page 257: ...223 ...

Page 258: ...intenance for operation of YAMZ engines Engine crankcase YAMZ 536 1 Engine units See the operation maintenance for operation of YAMZ engines 5 Gearbox ZF 9S1310TO YAMZ 0905 YAMZ 1105 1 1 See the operation maintenance for operation of YAMZ gearbox FAST GEAR 9JS135TA 1 1 All season Lukoil Oil ТМ 5 SAE 80W 90 API GL 5 All season oil Lukoil ТМ 4 SAE 80W 90 G TRAC GL 4 GL 5 SAE 80W 90 G BOX GL 4 GL 5 S...

Page 259: ......

Page 260: ...ing brand Duplicating brand 6 7 8 9 10 11 See the operation maintenance for operation of YAMZ engines 23 23 See the operation maintenance for operation of YAMZ engines 8 8 5 5 13 0 8 8 5 5 13 0 See the operation maintenance for operation of YAMZ gearbox ZF ECOFLUID M SAE 75W 80 Fuchs Petrolub AG TITAN supergear mc SAE 80W 90 TOTAL TRANS MISSION RS FE 80W 90 CASTROL SYN TRANS MAX 75W 80 Maintenance...

Page 261: ...45 o C At temperature below minus 30 o C oil ТСп 15К diluted with 10 15 of arc tic diesel or winter diesel fuel is al lowed or Omskoil К ТМЗ 18 ТУ 38 301 19 93 97 Additional power take off 1 Leading axle gears 2 front Oil ТСп 15К at temperature not be low minus 30 o C Oil ТСп 10К at temperature not below minus 45 oC At temperature below minus 30 o C oil ТСп 15К diluted with 10 15 of arc tic diesel...

Page 262: ...ing Upon every third Maintenance 15000 but not less one time in three years Replace oil 0 01 0 01 Upon maintenance 6 0 6 5 6 0 6 5 6 0 6 5 12 0 13 0 6х6 6 5 4х4 Maintenance 1500 3000 Replace oil Pour oil to the level fill opening on the axle housing If the drive gear was demolished pour prelimi nary 1 litre of oil through the hole below the breath er of the bevel gear hous ing the rest through the...

Page 263: ...cant Litol 24PK 9 8 Gear casing of the winch 1 Oil used for the engine Oil ТСгип Transmission oil used for the hypoid gear 26 24 Hydraulic system of steering gear RBL C 700 V Oil tank of the steering gear 1 Oil ВМГЗ multi grade low temperature hydraulic oil ГИПОЛ РС GIPOL RS 228 ...

Page 264: ...the appear ance of the fresh lubricant out of the filler ring Mobilube GX 140 Shell pirax GX 140 7 5 7 5 Upon every third Maintenance 15000 Check oil level and if necessary refill STATOIL TRANSWAY PS DX III 3 9 3 9 Maintenance 1500 3000 Upon every third Maintenance 15000 Upon hydraulic booster maintenance Check oil level and if necessary refill Replace oil along with filter replacement 229 ...

Page 265: ...n of 35 of lubricant Lita and 65 of oil for drive axle gear boxes 21 18 Universal shaft joint crosses needle bearers drive gears of the front rear and intermediate axles and the intermediate shaft 8 6х6 6 4х4 Lubricant Litol 24 Lubricant 158 steering wheel 2 winch driving gear 4 2 Gaskets for the air inlet of tyres 6 Lubricant Lita Lubricant CIATIM 201 230 ...

Page 266: ...OLIT EP2 Shell Gadus S2 V100 3 Mo bilgrease XHP 222 Energrease L2 0 004 0 004 0 32 0 024 Maintenance 15000 Lubricate through oil filler before the appear ance of the fresh lubricant 0 006 0 012 Change lubricant when dismantaling 0 024 0 096 AeroShell Grease 6 0 05 0 30 Upon maintenance lu bricate the working area of gaskets apply the lub ricant between first and second and also third and fourth ga...

Page 267: ...4х4 Lubricant Litol 24 Lubricant Lita Lubricant MC 1000 7 Cavity below the protec tive ring of the equalizing beam hub 2 Lubricant Lita Needle bearer of the steering head 1 Lubricant Litol 24 Lubricant Lita Steering shaft bearing 1 232 ...

Page 268: ...the working area of gaskets and preliminary put it in the space between the bearing and the gasket Wash the overboard bearing Apply lubricant on the bearing until the cav ity between rollers is full put lubricant in the hub between bearings 0 025 0 05 Lubricate when dis mantling Remove old lubricant and fill the whole cavity below pro tective gaskets with fresh one 0 002 0 002 Upon maintenance 0 0...

Page 269: ...oke end hubs 2 Lockout mechanism exterior surface of the in ternal movable pull rods 3 Power contacts of battery switch 4 Lubricant Litol 24 Grease Ж and grease C 1 15 Front spring pins for trucks 4x4 6x6 and rear spring pins for trucks 4x4 2 Lubricant Litol 24 Grease Ж and grease C Working area of the fifth wheel coupling 1 Locking hook of the fifth wheel coupling 1 234 ...

Page 270: ... of lubricant Shell Gadus S2 V220 2 RENOLIT EP2 Shell Gadus S2 V100 3 Mo bilgrease XHP 222 Energrease L2 0 025 for trucks 6х6 4х4 front springs 0 04 for trucks 4х4 rear springs 0 05 for trucks 6х6 4х4 front springs 0 08 for trucks 4х4 rear springs Maintenance 1500 3000 Maintenance 15000 Lubricate before the appearance of the fresh lubricant out of the junc ture of the pin and the spring eye 0 28 0...

Page 271: ...ivot joint of the fuel intake control 6 10 9 Bushings of towing de vice 2 Top bearings with steer ing knuckle pivots of the front driving axle 2 18 16 Slip joints of universal joints 3 steering wheel 1 winch driving gear 2 Clutch shifter bearing 1 Space roller bearings of the clutch release yoke lever 2 236 ...

Page 272: ...hrough oil fillers before the appear ance of the fresh lubri cant when working with trailer 0 100 0 20 Upon every second Mainte nance 15000 Fill with lubricant through the oil filler 0 02 0 06 Lubricate when dis mantling 0 01 0 01 Maintenance 15000 Lubricate 0 015 0 03 Upon every third Maintenance 15000 Lubricate through oil fillers before the appear ance of the fresh lubri cant 0 04 0 04 Maintena...

Page 273: ...e Ж and grease C 14 11 Plain bearer of the winch drum 1 Guide rollers axle 2 Intermediate bracket shaft of the clutch linkage and the brake valve 1 Graphite lubricant УСсА Grease Ж grease C or oil Litol 24 13 Roller winch bearings 2 Lubricant Litol 24 Grease Ж and grease C 238 ...

Page 274: ...oil filler before the ap pearance of the fresh lubricant 0 035 0 07 Lubricate axles Alvania HDX2 Rhodina EP2 Mo bilgrease Graphited 3 0 03 0 03 Maintenance 1500 3000 Upon every third Maintenance 15000 Lubricate through the oil filler before the ap pearance of the fresh lubricant Shell Gadus S2 V220 2 RENOLIT EP2 Shell Gadus S2 V100 3 Mo bilgrease XHP 222 Energrease L2 0 035 0 07 Lubricate when dis...

Page 275: ...Graphite lubricant УСсА Grease Ж grease C or oil Litol 24 11 Bushing rollers and holder body cavity of guide rollers of the roller winch 3 Block thorn 1 13 Chain gearing of the roller winch 1 Graphite lubricant УСсА Grease Ж grease C or oil Litol 24 23 22 Brake pedal and clutch pedal shaft 1 240 ...

Page 276: ... lubricant if the winch was not used 0 033 0 1 Upon every third Maintenance 15000 Apply lubricant 0 004 0 004 Upon every third Maintenance 15000 Apply lubricant Alvania HDX2 Rhodina EP2 Mobilgrease Graphited 3 0 05 0 05 Upon every third Maintenance 15000 Lubricate all full length of the chain 0 015 0 015 Lubricate when dis mantling the bushing and shafts 241 ...

Page 277: ...ubricant УСсА Grease Ж grease C or oil Litol 24 Screw thread of front and rear spring U bolt 16 Oil ТСгип Power contact on the battery 3 Oil Litol 24 Grease Ж grease C Junctions in the points of the battery wire connec tions 10 Oil Litol 24 Grease Ж grease C 242 ...

Page 278: ...ing pre liminary clean it off corrosion and mud Shell Gadus S2 V220 2 RENO LIT EP2 Shell Gadus S2 V100 3 Mobilgrease XHP 222 Energrease L2 0 0005 0 0015 Upon maintenance apply a thin coat of lubricant before joining ends preliminary clean them Shell Gadus S2 V220 2 RENO LIT EP2 Shell Gadus S2 V100 3 Mobilgrease XHP 222 Energrease L2 0 0005 0 005 Upon maintenance apply a thin coat of lubricant befo...

Page 279: ...brake caliper Axles and areas of brake shoes 12 Lubricant AMC 3 Sealing component on rubber or silicone base 36 Lubricant AMC 3 Sealing component on rubber or silicone base 12 Graphite lubricant УСсА Grease Ж grease C or oil Litol 24 Hydraulic cab tilt sys tems 1 Oil МГЕ 10А Oil ВМГЗ 244 ...

Page 280: ...hoes Г lubri cate them with graphite grease Apply lubricant АМС 3 on the surfaces Н М Ж А 0 0022 0 08 Alvania HDX2 Rhodina EP2 Mobilgrease Graphited 3 0 005 0 06 Shell Tellus T15 1 70 1 70 Maintenance 1500 3000 Maintenance 15000 Check oil level and if necessary refill Upon system repair replace oil 245 ...

Page 281: ...2 10 1 See operation maintenance for operation of YAMZ engines For trucks 4х4 1 In columns 7 8 oils and power fluids are given in litres plastic lubricant are in kilograms 2 Norm of oils and power fluids filling which is specified in the column 7 is nominal That is why after the oil fluid filling it is necessary to check and if necessary ramp it up to the norm in accord ance with the requirements ...

Page 282: ...nce washing out de tails of the shock absorb er in the kerosene and drying them Shell Donax B Brake Fluid DOT3 DOT4 0 5 0 5 ЕО Check fluid level and if necessary refill Change fluid one time in five years one time in three years 29 0 3 27 0 4 29 0 3 27 0 4 See the operation maintenance for exploitation of YAMZ engines 247 ...

Page 283: ...rage Provide daily maintenance service and scheduled Maintenance 1500 3000 Maintenance 15000 depending on the odometer Fill up the housings of the transfer the axle gearbox and steering control with preservation or power oils up to workload fill up the winch case with power oil Switch on the gear of the additional power take off for 3 5 minutes while the engine is running But before make sure that...

Page 284: ...ces and threaded areas Cannon grease ГОСТ 19537 83 For conservation of the plug connectors and terminal connections of the electric equipment Petroleum jelly ВТ13 1 ТУ 38 101 180 76 lubricant Litol 24 or grease For coloring of the damaged metal surfaces Enamels МЛ 12 of orange sand colored khaki colors GOST 9754 76 enamels МЛ 152 of orange sand colored golden yellow colors GOST 18099 78 enamel МЧ ...

Page 285: ... unloading of the front axle 8 3 Maintenance of the Truck Upon Storage Check monthly the air pressure in tires the condition of the protective coatings and devices if the fuel oil or special liquids are not leaking Eliminate the mentioned shortages Remove occasionally the discovered corrosion out of undyed and dyed surfaces restore the damaged paint and lacquer coatings cover the undyed surfaces a...

Page 286: ...n manual for the engine and the gearbox Check the brake fluid level in the reserve tank of the clutch linkage Check the oil level in the transmission units the power steering pump reservoir the oil tank and if necessary ramp it up to norm Implement the examination and maintenance of the truck to an extent of daily maintenance If some of the filled up preservative or power oils and liquids in the u...

Page 287: ... with two strut braces to the rear towing device and two strut braces to front towing hooks under the front wheels in front and stop bars 100х160х760 mm of size shall be fixed behind the rear wheels The truck installed above platform clutch as in figure 158 is fastened with two strut braces to the rear towing device and with two strut braces to the mounting spring bracket of the intermediate axle ...

Page 288: ...rted by sea vessels in all cargo spaces holds tween decks The trucks transportation is implemented on the upper deck with the consent of the consignor Arrange trucks in the hold and on the deck so that the distance between them is no less than 250 mm on the side of the heat radiator and no less than 130 mm on other sides After the truck placement on the vessel implement the preparatory works faste...

Page 289: ...ibility for placement and fastening of the truck upon transportation is on the carrier 1 equalizing beam suspension axle for trucks 6х6 rear axle for trucks 4х4 Figure 160 Fastening of the Truck on the Upper Deck Figure 161 Fastening of the Truck in the Hold 254 ...

Page 290: ...mantle the wiring system from the truck and hand it over to the feedstock reception Dismantle the wheels plastic and rubber technical details from the truck and hand them over to the feedstock reception Dismantle the truck units dismount illuminate defects and unsuitable for use as spare part details hand them over to the feedstock reception Braking devices subject to disposal have to be dismantle...

Page 291: ...inder Bolts M12 44 56 4 4 5 6 A 2 1 Transfer Box Retaining nuts of main shaft lay shaft and rear differential cage bearings min imum 200 20 Transfer box flanges retaining nuts minimum 200 20 Fixing bolts of differential nut 24 36 2 4 3 6 rear differential cage 55 65 5 5 6 5 main and lay shaft bearing caps 40 56 4 0 5 6 rear differential bearing crankcase 44 62 4 4 6 2 rear axle drive shaft bearing...

Page 292: ...A 3 Undercarriage A 3 1 Suspension Torque arm stud retaining nuts minimum for 6x6 trucks if the slot of the nut does not coincide with the split pin hole tighten the nut 600 60 Fixing bolt nuts of front eyes for 4x4 and 6x6 trucks and rear for 4x4 trucks springs minimum 400 500 40 50 Retaining nuts of front eye U bolts for 4x4 and 6x6 trucks and rear for 4x4 trucks springs minimum 80 220 18 22 Fro...

Page 293: ...ening until the nearest nut slot coin cides with the split pin hole Steer fixation to the girder web М18 216 314 22 32 М16 157 215 7 16 22 Steer to the frame retaining nuts 110 140 11 14 Steering wheel crankcase yoke fixing bolts M10 44 56 4 4 5 6 Steering wheel retaining nuts 80 100 8 10 A 5 Brake System Brake chamber retaining nuts 300 320 30 32 Pad fulcrum pin retaining nut 431 490 44 50 Pad fu...

Page 294: ...l coupling fixing bolts М14 М16 80 90 8 9 120 140 12 14 A 9 Dedicated Equipment A 9 1 Power Takeoff Power takeoff crankcase to gearbox crankcase bolts and retaining nuts 22 32 2 2 3 2 A 9 2 Additional Power Takeoff Additional power takeoff flange retaining nut minimum 140 14 A 9 3 Winch Winch drive prop shaft flanges fixing bolts 60 65 6 0 6 5 ____________________ 1 for trucks having no additional...

Page 295: ...over trucks mm Free play 2 5 Clutch pedal travel conventional cab trucks mm Free play 5 10 Full travel 185 190 Brake pedal travel conventional cab trucks mm Free play 20 30 Pneumatic system air pressure kPa kgf cm2 Pressure controller Maximal pressure when switched off 870 kPa 8 7 kgf cm2 Minimal pressure when switched on 720 kPa 7 2 kgf cm2 Four circuit protective valve Circuit static closing pre...

Page 296: ...pring for 4x4 trucks 101 7 Auxiliary spring for 4x4 trucks 33 3 Balance shaft assembly 149 515 254 254Г 508 wheel 53 2 514 400 400Г 508 wheel 68 7 8 5 20 wheel 45 5 14 00 20 tire ОИ 25 model 120 390 95R20 КАМА URAL tire maximum 120 390R20 tire О 65 model maximum 120 500 70 20 or 500 70 508 1200х500 508 tire ИД П284 model 120 12 00R20 У 4 ИД 304 tire 90 Steer without drop arm 45 2 Parking brake 22 ...

Page 297: ...e 33 65х50х37 Crosses of coupling shaft intermediate axle drive prop shaft with face splines 16 50311A Single row radial ball 55x120x29 Transfer box front axle drive shaft reinforced additional power takeoff shaft rear support 2 7312A Single row roller coni cal 60x130x33 5 Transfer box main drive shaft winch drum shaft 3 7610A The same 50x110x42 25 Transfer box idler shaft 2 7310A or 6 7310А1 50x1...

Page 298: ...aft winch rope guideplate actuating screw 3 6 312А Single row radial ball 60х130х31 Transmission propeller shaft intermediate support 1 704902K6ÓC10 Roller needle 15 2x28x20 Steering propeller shaft crosses 16 220A Single row radial ball 100x180x34 Transfer box differen tial 1 218 or 218А The same 90x160x30 The same 1 180206АС17 30x62x16 Steering propeller shaft support 2 636906С17 Angular ball fo...

Page 299: ...312A Single row radial ball 60x130x31 Winch gearbox worm rear support 1 8311 Ball single thrust 55x105x35 The same 1 7216A Single row roller coni cal 80x140x28 5 Winch drum shaft 1 8103 or 8903 Ball single thrust 17x30x9 Spare wheel lifting de vice gearbox 1 I 941 12К Roller needle bearing GOST 4060 78 12х17 In the foot mechanism 2 I 943 25К Roller needle bearing GOST 4060 78 25х32 In the foot mec...

Page 300: ... 90 G TRAC GL 4 GL 5 SAE 80W 90 G BOX GL 4 GL 5 SAE 75W 90 TRANS KP 2 SAE 80W 85 TRANS KP 4 SAE 80W 90 oil GOST 3652 79 16 5 l 23 l SAE 5W 10W 15W 40 APICI 4 engine oil See Operation Manual for the Engine 23 0 l R type oil TS 38 101 1282 89 АУ watch oil TS 38 101 1232 89 5 8 l Multigrade low temperature hy draulic oil TS 38 101479 00 R hudraulic oil TS 38 1011282 89 3 9 l Litol 24 grease GOST 2115...

Page 301: ...04 8805 7 94 TS 6 01 787 86 2 3 l 0 5 l Ethyl alcohol GOST 18300 72 GOST 17299 76 0 262 kg Cool Stream Standart 40 coolant TS 2422 022 13331543 2004 See Operation Manual for the En gine 27 0 1 l 29 0 2 l ДТ 1 grease Нева brake fluid 0 12 kg Лита grease TS 38 101 1308 90 ЦИАТИМ 2 01 grease GOST 6267 74 TS 38 Ukrainian Soviet Socialist Republic 201285 82 0 29 kg 0 39 kg ________________ for pneumati...

Page 302: ... 75 70 1 2 Front light А24 21 3 2 А24 5 2 Tail light А24 5 2 7442 3716 А24 21 3 6 Side marking lamp А24 21 3 2 Master lighting А24 21 3 1 Warning indicating and instrument lamps А24 2 19 Front side light А24 5 1 2 Registration plate lamp А24 5 2 Road train indication light А24 5 3 Searchlight АКГ24 1 1 Emergency warning light switch АМН24 3 1 ...

Page 303: ...eference Used oil discharge standard l Engine 21 0 Gearbox 7 3 Transfer Box 2 7 Driving Axles Gearboxes 19 0 13 0 Steering Wheel Hydraulic System 3 0 Winch gearbox 6 3 ________________ for 4x4 wheel arrangement trucks ...

Page 304: ...pping a truck spare parts kit 0 is put into a spare parts kit transportation box Recommendations of operational tools and accessories breakdown for the truck are given in this paragraph The manufacturing plant is making such a breakdown for the items mantled on the truck chassis Truck chassis has no fire extinguisher first aid kit emergency stop sign can be supplied if additionally ordered When dr...

Page 305: ...1 In a kitbag see figure H 1 14 Pliers 1 15 22x24 box spanner 1 16 17x19 box spanner 1 17 27x30 key 1 18 22x24 key 1 19 19x22 key 2 20 14Х17 key 1 21 11Х13 key 1 22 10Х12 key 1 23 8Х10 key 1 24 5 5X7 key 1 Figure H 1 Truck Tools ...

Page 306: ...tion wrench 1 2 31 Crankshaft revolution gear 1 2 32 Hex key wrench 1 2 33 10x10 bent socket wrench 1 2 34 Special probe 1 2 35 Combination screw driver 1 The tool box see figure H 2 1 2 Kitbags 3 Socket wrench 140 1 1 2 Kitbags 3 socket wrench 140 4 jack 5 lever type grease gun Figure H 2 Tool Box Position No in the figure Item Quantity 4 Oil jack 8 t 1 5 Lever type grease gun 1 B type coupling h...

Page 307: ... 1 Technical Information Table 32 Type Hydraulic telescopic with two operated rams Lifting capacity kN tf 80 8 Jack height when the rams are down and the screw is in mm 270 Cargo lifting height mm 285 Oil volume l 0 6 To lift a cargo by the jack install the jack as needed screw in the screw 1 as shown in figure K3 as much as nec essary if the ground is soft put a hard plank or another flat object ...

Page 308: ... the needle valve by tightening seal nuts and oil leakage in housing joints by tightening the housing head To protect jack working space from air do not lift operated rams by hand when the nee dle valve is screwed in If the jack does not ensure complete working ram travel check oil level Add oil until the oil feed opening closed with the plug 4 when the jack rams are completely down and the jack i...

Page 309: ...Base 2 gasket 3 outer operated ram cylinder 4 cylinder tube 5 and 6 operated rams outer and inner 7 screw 8 compactor 9 housing head 10 O ring 11 ram head 12 plug 13 pump lever 14 needle valve Figure H 4 Jack ...

Page 310: ...piston Gear shift piston Piston of the differential lock mechanism 2 1 1 51 9 10 54 Driving Axles 3 2 2 70х92 1 РТ 864176 02 or ВDUМ5SLX26 Gasket 2 2 70х92 1 GOST 8752 79 OST 38 05146 78 Front bearing cap Rear bearing cap 2 1 59 59 20 18 4 2 1 70х92 4 РТ 864176 02 or ВDUМ5SLX26 Gasket 2 1 70х92 4 GOST 8752 79 OST 38 05146 78 Rear bearing cap 1 59 18 6 375 4224017 03 Gasket Axle shaft casing 4 60 1...

Page 311: ...5146 78 Bearing cap 1 146 14 Winch gearbox 12 2 2 85х110 1 Gasket 2 2 85х110 1 Winch shaft left bearing cap 1 147 37 13 2 1 45х70 3 Gasket 2 1 45х70 3 Winch worm end thrust bearing cap Front end thrust bearing cap of the winch worm shaft 1 1 137 27 14 4320 4501127 01 19х32х7 Gasket 4320 4501127 01 19х32х7 Winch gearbox crankcase hole for coupling yoke rod 1 147 ________________ For 43206 trucks 4 ...

Page 312: ... with macadam or gravel surface in all relief types except highland and mountain terrain 0 9 III 1 Roads of I II III technical categories outside urban area in small towns and suburban area mountain terrain as well as in big cities with concrete or asphalt pavement 0 8 2 Roads of I II III technical categories outside urban area in small towns and suburban area mountain terrain roads in small towns...

Page 313: ...ural earth roads on farm rural roads quarry and pile roads temporary access roads to various construction sites and sand clay stone etc excavation quarries during the periods when driving is possible there 0 6 When calculating the general coefficient correction found by Tables J1 and J2 multiply both To determine the maintenance interval of a truck regarding its operation conditions multiply the v...

Page 314: ...in the document Document No Accompanying document file number and date Signa ture Date amended replaced new cancelled 1 p 37 277 4320М 3902035 4320М 06 16 17 05 16 p 42 2 p 244 245 4320М 07 16 17 05 16 p 263 17 05 16 3 P 13 16 23 26 4320М 08 16 08 07 16 4 P 36 37 40 42 43 45 43 45 279 4320М 01 17 10 03 17 ...

Page 315: ...280 ...

Page 316: ...r Then push the Switch gear of GB Включение передачи РК and hold for 5 7 seconds 1 ON OFF differential locks should be made when the truck is at full stop If the locks are not switched on slowly move the vehicle from a standstill and keep moving at 5 km h max till differential locka are on 2 Do not move the truck with differential locks actuated at hard dry roads 3 If cross axle differential lockb...

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Page 318: ... Russia 456300 Customer Service JST AP URAL 8 800 100 11 74 Toll free call Hot line uralaz ru 2 ATTENTION Before fuelling turn off the air heating unit of the cabin 3 IN THE AUXILIARY TANK IN THE MAIN TANK OUT OF THE AUXILIARY TANK OUT OF THE MAIN TANK 4 IDLING RPM ...

Page 319: ...S of the tractor unit 3 25A ABS of the trailer 2 15A ABS of the tractor unit 1 RIGHT SET 13 5A Fuel heating in the filter GOT 12 5A Breaker UP transfer box control 11 10A Heater 10 5A Reverse interface block diagnostics 9 10A Windscreen wiper 8 7 5A Speedometer tachometer interface block diagnostics 7 10A Hazard lights dome lamp 6 10A Main light switch 5 10A Horn fog lights 4 5A Ignition switch va...

Page 320: ...М 158 242 substitution is allowed 1 1 8 375 3901077 Socket wrench 41х46 for 8М 158 354 substitution is allowed 1 1 9 28 04125 Stub dual pipe 1 1 10 И91 3901000 Universal joint screwdriver 1 1 11 1 200 И Slip joint pliers GOST 53925 2010 substitution for 1 180 И is acceptable 1 1 12 332001 Puller bolt 2 1 13 DRK URALAZ Remover tool kit for pipe dismantling pc 1 2 375 3901124 Б Socket wrench 140 pc ...

Page 321: ...tion Manual for the Liquid Phase Heater 1 9 Operation Manual Instruction for Lead acid starter Storage Batteries 1 10 Installation and Operation Manual for Drawbar Coupling 1 REMARKS 1 Due to constant modernisation of the Ural truck construction improving its reliability and operation conditions according to the documentation issued by the plant the SPTA configurations may be partially amended and...

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Summary of Contents for 4320M

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URAL Motorcycles 4320M, Operation Manual, Page: 197 / 321

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Summary of Contents for 4320M

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