URAL Motorcycles URAL-4320-60 Operation Manual Download Page 4

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CONTENTS

1 Foreword . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety Requirements and Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Safety Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Controls and Instruments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Adjustment and Servicing of Truck Components (Brief Description) . . . . . . . . . . . . . . . . . . . . . .

5.1 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.2 Engine Starting Preheating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.3 Gas Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.4 Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.5 Power Unit Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Clutch Release Drive with Air-Hydraulic Booster. . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.3 Cardan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.4 Driving Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Running Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 Truck Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.3 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.4 Spare Wheel Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.2 Maintenance of Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Brake Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.1 Service Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.2 Pneumatic Drive of Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101

5.5.3 Maintenance of Brakes Pneumatic Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113

5.5.4 Emergency Brake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114

5.5.5 Parking Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114

5.5.6 Truck Brake System with Anti-Lock Braking System (ABS). . . . . . . . . . . . . . . .

117

5.5.7 Auxiliary Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

125

5.6 Electric Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127

5.6.1 Electronic Speedometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

130

5.6.2. Electric Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133

5.6.3. Storage Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133

5.6.4 Lighting and Alarm System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134

5.7 Cab, Hood and Fender Assembly and Truck Platform Body . . . . . . . . . . . . . . . . . . . . . . .

138

5.7.1 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138

5.7.2 Hood and Fender Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

143

5.7.3 Truck Platform Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

143

5.8 Bolster Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147

5.9 Special Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

151

5.9.1 Power Take-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

151

5.9.2 Auxiliary Power Take-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

152

5.9.3 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

154

5.9.4 Tire Pressure Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

160

5.9.5 Sealing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

162

6 Possible Troubles and Methods of Trouble Shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

163

7 Peculiar Features of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

170

7.1 Preparing New Truck for Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

170

Summary of Contents for URAL-4320-60

Page 1: ...URAL 4320 60 61 URAL 43206 61 URAL 5557 60 TRUCKS AND THEIR MODIFICATIONS ...

Page 2: ...57 60 TRUCKS AND THEIR MODIFICATIONS Operation Manual 4320 3902037 РЭ First edition revised UralAZ Reprinting duplicating or translating in whole or in part without written permission of the Ural Automobile Plant Open Joint Stock Company is prohibited Miass 2014 ...

Page 3: ...ng the trucks use the present Operation Manual Yaroslavl Motor Works YAMZ 236НЕ2 YAMZ 236НЕ YAMZ 236Н YAMZ 236БЕ2 YAMZ 236БЕ YAMZ 236Б Power Units Operation Manual and Addendum YAMZ 6565 YAMZ 65651 YAMZ 65652 YAMZ 65653 YAMZ 65654 Engines and their configurations to the Operation Manual for YAMZ 236НЕ2 YAMZ 236НЕ YAMZ 236Н YAMZ 236БЕ2 YAMZ 236БЕ YAMZ 236Б Power Units Air Heater Specification and i...

Page 4: ...5 5 Brake Systems 92 5 5 1 Service Brake System 92 5 5 2 Pneumatic Drive of Service Brakes 101 5 5 3 Maintenance of Brakes Pneumatic Drive 113 5 5 4 Emergency Brake system 114 5 5 5 Parking Brake System 114 5 5 6 Truck Brake System with Anti Lock Braking System ABS 117 5 5 7 Auxiliary Brake System 125 5 6 Electric Equipment 127 5 6 1 Electronic Speedometer 130 5 6 2 Electric Generator 133 5 6 3 St...

Page 5: ...Truck Towing 175 8 Maintenance 177 8 1 Maintenance Categories 177 8 2 Maintenance Schedule 177 8 3 List of Maintenance Operations 180 8 4 Truck Lubrication 197 8 4 1 General 197 8 4 2 Chart of Lubricants and Working Fluids 198 9 Storage 220 10 Transportation 224 11 Salvaging 226 Appendices 228 ...

Page 6: ...rticular terrain Ural 4320 1951 60 special chassis with an enhanced base is intended for mounting technological equipment and specialties oilfield crane drilling tankers fire fighting municipal etc towing trailers on all kinds of roads and particular terrain Ural 5557 1151 60 Ural 55571 1151 60 chassis shown in Fig 2 are intended for mounting various bodies and equipment Ural 43206 0111 61 truck s...

Page 7: ...6 Fig 2 Ural 55571 60 Chassis Fig 3 Ural 43206 61 Truck ...

Page 8: ...ucks with pull type systems which have air outlets and electric outlets as per GOST 9200 76 version II the brake system air outlet as per GOST 4364 81 Stan dard brake systems as per GOST 22895 77 Standard a gross weight corresponding to the specifi cations and drawbars for trailers a coupling pin having A diameter as per GOST 12017 81 Standard that is equal to 50 8 mm and mounting dimensions as pe...

Page 9: ...r is marked on the right panel of the cab in step plate The marking contains 14 digits and is applied by hammering Structure of the vehicle identification number and its explanation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Х 1 Р Variable data Item 1 3 Х1Р URAL Automobile Works JSC Miass Chelyabinsk Region Russia manufacturer s international identification code Item 4 9 Product designation Item 10...

Page 10: ...heater must be switched off 2 1 7 Do not warm up the engine if the truck is indoors and ventilation is poor 2 1 8 Coolants low freezing and brake fluids are toxical handle with care 2 1 9 To climb the truck front bumper and descend it use the step plate central and left most in direction of travel grille ribs having on the inserts on the inner side as shown in Figure 4 2 1 10 When servicing the en...

Page 11: ...olution of soda 2 1 20 Check condition of the insulation of the wire from battery terminal to the starter damaged insulation can cause fire 2 1 21 Perform welding on the truck observing fire safety measures When carrying out electric welding disconnect wires from the generator batteries and electronic control units to protect the plastic pipes and fuel lines from damage Connect the welder ground c...

Page 12: ...e life can be ensured if you observe all recommendations given in this Manual 2 2 1 Before operating the truck you should carefully read the section PRECAU TIONS SAFETY REQUIREMENTS 2 2 2 When running the first 1000 km 50 hours of engine operation comply with the rules described in Section New Truck Running in 2 2 3 Before starting the engine you must carefully read the section Power unit start op...

Page 13: ...t of a rut do not go for a long time with the steering wheel turned in the extreme position since oil can be overheated in the hydraulic system and the pump may be broken For the same reason when taking off power in steady state condition release the steering control shaft by turning the steering wheel until it turns freely It is recommended to set the steering gear sliding valve to the neutral po...

Page 14: ...km after beginning of travel Upon opening the wheel valves blow through the tire pressure control system with the air from the tires see the Section Central Tire Pressure Control System 2 2 30 When towing in order to avoid the gearbox failure engage the neutral gear in the transfer gearbox Towing is performed limiting the maximum towing speed to 50 km h 2 2 31 Manoeuvring particularly while revers...

Page 15: ...ent 2 2 38 When operating the truck with a trailer it is not admissible to use a towing coupler on GOST Р 41 55 2005 if the control pin projects relative to the handle see the Installation and Operation Instructions Towing coupler 21 202 Section Opera tion and description subsection Coupling control use a towing coupler on GOST 2349 75 with unsecured latch of the towing hook by the locking pin see...

Page 16: ...00 12 000 Truck chassis bare weight kg 8940 8000 8500 1 8285 8520 8335 8410 8640 8765 Total vehicle weight with cargo driver and passengers 225 kg disregarding the curb weight tolerance kg 15 165 15 100 17 300 2 15 355 17 300 2 21 300 2 20 745 21 300 2 20 560 21 300 2 20 635 21 300 2 19 865 14 215 19 990 14 340 Gross trailer semitrailer weight kg 11 500 7000 11 500 7000 11 500 19 100 12 500 Weight...

Page 17: ... 360 16 000 2 14 740 9950 14800 10 040 Operational data Maximum travelling speed at gross weight km h 80 Truck chassis bolster truck road train estimated fuel con sumption 3 at speed of 60 km h per 100 km l max 36 40 37 36 47 Cruising range on truck chassis control fuel consumption at a speed of 60 km h km 572 fuel tank 210 l 816 fuel tank 300 l 515 fuel tank 210 l 785 fuel tank 300 l 730 Braking ...

Page 18: ...que gross N m kgf m no less than 882 90 Nominal speed min 1 2100 50 20 Rpm corresponding to themax torque min 1 1100 1500 Engine lubricating system Mixed under pressure with injection and with the oil cooling in the liquid to oil heat ex changer Engine feed system Main fuel tank l 210 refill capacity 206 or 300 refill capacity 294 Engine air feed system with dry air filter with the replaceable car...

Page 19: ...ing the torque between the front and the rear axle with the 1 2 ratio with the front axle drive high gear O 1 21 or 1 04 low gear O 2 15 Cardan drive Exposed with four shafts joints on the needle bearings Axles Driving combined axle case consists of a cast middle part and half axle casings pressed in it The front axle is a steerable one with constant velocity joints of disk type Main gear Double d...

Page 20: ...y tread pattern or model КАМА 1260 1 with versatile tread pattern pneu matic radial tubed wide section with controllable tire pressure max ad missible load 39 46 kN 4000 kgf or б 425 85R21 156J НС18 PR18 m О 184 pneumatic tubed con ventional profile with heavy duty tread pattern with controllable tire pres sure max admissible load 39 46 kN 4000 kgf or в 425 85R21 156G НС16 PR16 Бел 1260 pneumatic ...

Page 21: ...mpression type located in the exhaust system Pneumatic drive with the simultaneous fuel cut off to the engine Electrical equipment Wiring system Single wire negative terminals of current source are connected with truck frame Rated voltage 24 V Generator 4512 3771 10 2280 watt with voltage regulator built in Storage batteries TITAN STANDART 6СТ190OL ST or 6СТ 190N3 Storage batteries switch 1402 373...

Page 22: ...p and removable sides and rear Metal made drop and removable sides and rear Platform inside dimensions mm length width sides height 4500 2462 600 5660 2462 600 Special equipment Power take off from gear box 4 Mechanical one speed air actuated in 3 versions for mounting the HШ 32У3Л left hand pump with flange for connecting cardan shaft with rear output Output shaft speed of the power take off is e...

Page 23: ...ven via cardan shaft from the auxiliary power take off Rope working length 60 m rope dia 17 5 mm Rope reversing is possible Pulling power on the third rope winding layer 68 6 88 2 kN 7 9 tf limited by the guard pin The mass of the winch with the rope is 420 kg Winch unit 4 Rope type single groove Tire pressure control system Air is supplied via two wire diagram Tire pressure inflation deflation an...

Page 24: ...635 on the rear axle 3135 2300 Gross vehicle weight distribution kg on the front axle 5260 5085 5300 2 on the rear axle 7120 7575 8000 2 Operational data Maximum travelling speed at gross weight km h 85 Truck chassis estimated fuel consumption 3 at speed of 60 km h per 100 km l max 24 Cruising range on truck chassis control fuel consumption at a speed of 60 km h km 854 Braking distance with GVW wh...

Page 25: ...system with the release from the turbo charger backwards pipeline with wearproof auxiliary brake noise suppressor the end of the exhaust pipe is directed to the truck axis Cooling system hydronic closed type with forced circulation of liquid coolants Corrugated vane radiator Transmission Clutch YAMZ 183 15 friction clutch dry single disk with a pull out diaphragm spring asbestos free clutch lining...

Page 26: ...i elliptic springs operating jointly with two bilateral hydraulic snubbers rear Conventional suspension on two semi elliptic springs with helpers operating jointly with two bilateral hydraulic tel escopic snubbers Wheels а 533 310 310 533 disk wheels with divided semi deep rim having toroidal bead seats centered at the chamfers of the clamping holes wheel offset 100 mm Tires According to the truck...

Page 27: ... circuits Parking brake system Mechanical with four spring brakes acting on the rear axle wheels brake shoes pneumatic drive control by means of the manual brake valve Auxiliary brake system Engine retarder compression type located in the ex haust system Pneumatic drive with the simultaneous fuel cut off to the engine Electrical equipment Wiring system Single wire negative terminals of current sou...

Page 28: ...e for connecting cardan shaft with rear out put Output shaft speed of the power take off is equal to 1 06 of engine crankshaft speed with shaft having internal slots for connecting pumps for delivery the power take off box flange is plugged by the technological cover The takeoff power is 22 kilowatt 30 hp The power taking off during truck travelling with gear shifting is not ad missible Auxiliary ...

Page 29: ... axles tires Adjustment and control is carried out from the driver s cab Mass when operating on V category roads 1 For trucks and chassis with a winch 2 Mass parameters allowable by the units and assemblies agreed with the URAL Automobile Works OE JSC when making up Protocol of using chassis on the customer product In addition for some modifi cations front axle load increases to 6500 kg GVW increa...

Page 30: ...29 Fig 7 Ural 4320 0111 61 truck overall dimensions Fig 8 Ural 4320 1951 60 truck chassis overall dimensions Fig 9 Ural 43203 1151 61 truck chassis overall dimensions ...

Page 31: ...30 Fig 10 Ural 4320 1151 61 truck chassis overall dimensions Fig 11 Ural 55571 1151 60 truck chassis overall dimensions Fig 12 Ural 5557 1151 60 truck chassis overall dimensions ...

Page 32: ...31 Fig 13 Ural 43206 0111 61 truck chassis overall dimensions Fig 14 Ural 43206 1151 61 truck chassis overall dimensions Fig 15 Ural 44202 0311 60 bolster trucks ...

Page 33: ...32 Fig 16 Ural 44202 0511 60 bolster trucks ...

Page 34: ...er take off is activated when the button 24 of auxiliary power take off engagement with symbol is pushed the solenoid valve of auxiliary power take off is activated When the button 28 of cross axle differential locking with symbol is pushed the solenoid valve of the cross axle differ ential locking is activated Solenoid valves deliver air to the transfer case differential locking mechanism power t...

Page 35: ... control lever 4 inner hatch lever 5 electronic fuel feed control pedal 6 brake pedal 7 clutch pedal 8 auxiliary brake control button 9 parking brake lever 10 gear shift lever 11 starter and instruments switch 12 under steer ing wheel left switch of turn indicators headlamp beams horn 13 under steering wheel right switch of windshield wiper and washer 14 steering wheel 15 tachograph 16 glove compa...

Page 36: ...torage batteries are switched on and off by pressing a switch 37 Trucks are equipped with centralized tire inflation system a plate of tire inflation system concerning the choice of tire pressure and travelling speed depending on the type of road is locat ed inside the cab on the front panel to the right side Tire inflation is controlled by switches 17 19 and monitored by pressure gauges 13 The sw...

Page 37: ...ch 30 transfer case gears engagement button 31 transfer case gear shifting key switch 32 central light switch 33 transfer case gears indicator 34 39 pilot lamps left and right clusters 35 storage battery discharge indicator 36 Interface Engine Unit IEU diagnostics indicator 37 storage batteries switch 38 cab dome light switch 40 electronic diesel control EDC diagnostics indicator 41 air filter clo...

Page 38: ...glows with red color light and the warning signal is head If resistance of the oil filter rises clogging of the filtering element solidifying of oil at low temperatures lamp 4 glows with red light Check that the lamp lights only when the engine is started or warmed Coolant temperature alarm rise pilot lamp 2 glows with red color light if the coolant temperature rises above 90 С It is allowed to ru...

Page 39: ...tem is returned via piping 6 to the fuel tank The fuel volume in the main fuel tank is measured by an electrical level gauge installed in the tank and is controlled by the indicator on the dashboard The fuel level sensor in the auxilia ry fuel tank depends on vehicle modification In case the fuel level sensor is installed on the auxil iary fuel tank there is a fuel level indicator switch in the ca...

Page 40: ...t is to be replaced 5 1 1 2 2 Risk of Freezing Drain off the water to avoid freezing When draining water from the coarse filter Shut off the engine to avoid air ingress in the fuel system Unscrew the drain hole threaded plug 4 at the bottom of water tank 3 and let water drain off Screw the drain hole threaded plug 4 again 5 1 1 2 3 Filter replacement Shut off the engine Dismantle the old replaceab...

Page 41: ...rified air from the air filter via air ducts to the tur bo charger From the turbo charger the air is delivered via the air duct to the charge air cooler where it is cooled and after that it gets to the engine cylinders There is a hose in the engine air feed system bypassing the crankcase blow by gases from the engine and there is also a hose for air delivery to the air compressor In order to enhan...

Page 42: ...ard filter element is 30 000 km More frequent cleaning of the filtering element might reduce its service life since total attempts of element ser vicing are limited to 5 7 attempts including washing 3 times maximum because of possible cardboard disrupture A periodic inspection of corrugated and smooth hoses connecting rubber is necessary Replace the parts in case of defects like fractures cuts dis...

Page 43: ...burns heating the fluid in the heat exchanger The fluid is forced by the pump through the pipelines through cylinder block in the direction shown by ar rows in Fig 22 Combustion products are directed via the gas branch pipe under the engine oil sump and warm oil in it Fuel is cleaned when passing the filters provided in the solenoid valve and injector 1 fuel tank 2 straight way valve 3 12 drain pl...

Page 44: ...r For this purpose disconnect the air supply hose and blow through the heat exchanger combustion chamber and gas duct Clean the drain pipe of the heat exchanger burner in order to eliminate fuel accumulation remove carbon deposit from the electrode and insulator of the spark plug Disassem ble and wash in kerosene or acetone the injector and its fuel filter as well as the solenoid valve fuel filter...

Page 45: ...Z 65651 YAMZ 65652 YAMZ 65653 YAMZ 65654 Engines and their kitting up Addendum to the Operation Manual YAMZ 236НЕ2 YAMZ236НЕ YAMZ 236Н YAMZ 236 БЕ2 YAMZ 236БЕ YAMZ 236Б Power plants 5 1 4 1 Radiator 14 is of tubular band type three line with a filler A tight plug provid ed with the filler There is a drain plug in the low radiator tank The radiator is installed on the frame 11 which is a bearing el...

Page 46: ...the tank to water pump Fig 27 Cooling System Diagram 5 1 4 3 Monitoring the coolant temperature in the cooling system is carried out using the temperature gauge When the temperature increases in the cooling system over a 90 C the coolant tempera ture alarm lights up With burning alarm further travelling is possible with careful observation of the coolant temperature gauge A short no more than 10 m...

Page 47: ... the engine block front cover while centre support brackets 2 to the flywheel housing and rear support bracket 7 to the rear end face of the gearbox Cushions 1 of the left hand and right hand centre supports are interchangeable Also cushions 4 and shock absorbers 5 of the front and rear supports are interchangeable 0 1 mm clearance between cushion 4 and rear support bracket 7 should be maintained ...

Page 48: ...B pushes the rod and opens the pneumatic system valve simultaneously The pneumatic part comprises the 10 liter receiver 17 installed inside the left side member back pressure valve 18 and piping The air from the separate pneumatic part flows into the AHB 1 reserve tank 2 tank cap 3 bolt 4 nut 5 14 supporting brackets 6 cylinder stop 7 master cylinder 8 pedal mechanism 9 26 springs 10 brake pedal 1...

Page 49: ...nd the rod 4 The piston and the rod are flexibly packed in the case and can move in axial direction The piston is packed in the body with the rubber cup packing 9 and the rod is packed with two rubber packing rings 3 The case is closed with the cap 6 from the piston side with the rod running through it The fork 8 is fixed at the end of the rod attaching the AHB to the clutch release fork lever The...

Page 50: ...d with the bores The piping connects the cavity K to the master hydraulic clutch release cyl inder through tapping in the plug 19 The piping connects the cavity E to the air tank through tap ping in the plug 13 The cavity E has the exhaust air output for the booster drive control 5 2 1 4 Clutch pedal adjustment When the system is fully pumped and there is no compressed air in the pneumatic drive s...

Page 51: ...rated priming of the clutch hydraulic drive is also possible with the external source of compressed air Follow the steps fill the reverse tank with brake fluid remove the protective valve cap 2 Fig 31 put the priming hose on the valve unscrew the valve by 1 2 3 4 revolutions and dip the hose end into the glassy container with the brake flu id put the hose of the external source of compressed air o...

Page 52: ... cap 4 26 31 67 roller bearing 5 57 bolts 6 56 pneumatic cylinder cover 7 55 bushing 8 shift mechanism housing 9 neutral piston 10 22 54 pistons 11 49 rod 12 low gear indicator switch 13 ball 14 spring 15 plug 16 pin 17 gear shifting fork 18 bolt 19 63 high gear pinions 20 bushing 21 gear shift clutch 23 cylinder 24 33 low gear pinions 25 crankcase 28 breather 30 lay shaft 32 spacer 34 rear axle d...

Page 53: ...rear bearing cap loosen and tighten the intermediate shaft bearing retaining nut by clamping the spacer of the pinions lock the nut and put the cover back check the axial displacement of the intermediate shaft similar to the procedures with the main drive shaft In this case the gauge leg should rest on the face of the of the pinions the total travel of the indicator leg should be 0 03 0 08 mm adju...

Page 54: ...solenoid valves А transfer case differential lock Б neutral В low gear Г high gear Д auxiliary PTO Е PTO box Ж cross axle differential lock а air supply b to engage Fig 33 Transmission units pneumatic control diagram In order to engage the transfer case low gear press the switch on the board in the cabin When releasing the release button solenoid valves deactivate and the gear which is engaged is ...

Page 55: ... mechanisms cross axle differential lock mechanisms are to be lubricated with a thin layer of ЦИАТИМ 201 lubricant and the collars internal surfaces are to be filled up with the same lubri cant Use sealants АН 8К ТУ 6 02 6 88 АН 17М ТУ 6 01 2 728 86 or LOCTITE 577 for all the conical threads use sealant КЛТ 75ТМ ТУ 2513 069 00151963 2000 for the sealing gaskets In the process of the control system...

Page 56: ...rucks When operating the truck check regularly the fastening of the cardan shaft flanges Fig 37 and 38 should radial clearance exceed 0 25 mm and end clearances 0 35 mm in the spider bearings disassemble the cardan joints and replace the spider bearings if necessary When disas sembling take care not to damage the packings replace damaged packings 1 face seal 2 crosspiece 3 needle bearing Fig 36 Ne...

Page 57: ...le rear axle for 4х4 trucks drive shaft replace the shafts When assembling the cardan shaft see that the arrows stamped on the tube shaft and sliding fork are positioned one opposite another and the flanges forks and balancing plates are sealed in the same position they had before disassembling To provide that mark the parts of the cardan shaft prior to its disassembling Upon replacing the flanges...

Page 58: ... axles with the upper location of the main gear 5 2 4 2 Intermediate axle final drive is of dual type comprising a couple of spi ral tooth bevel gears 1 and 14 Fig 40 and a couple of helical tooth spur gears 4 and 31 A symmetrical bevel type differential with four satellites is bolted to the driven spur gear The final drives are marked with plates bearing ratio indication which are placed under th...

Page 59: ...erential carrier 38 case cover I for front axle II for rear axle Fig 40 Final drive The final drive is mounted onto axle case 10 Fig 41 via 0 8 mm thick paronite gasket 9 secured thereon with thirteen bolts and two studs Eleven bolts and studs are located outside and two bolts in the bevel gear space The in ner bolts become accessible only after removing side cover 6 Spring washers are fitted unde...

Page 60: ...riving Axle 5 2 4 3 Intermediate and rear axles Cross axle positive locking differentials Fig 42 are mounted on intermediate and rear axles 1 диафрагма 2 корпус механизма включения блокировки 3 шток 4 кронштейн 5 ограничитель 6 гайка 7 чашка дифференциала 8 муфта 9 полуось 10 палец 11 вилка 12 выключатель Fig 42 Cross axle Positive locking Differential of Intermediate and Rear Axles On request ...

Page 61: ...nd moves rod 3 by acting on diaphragm 1 Fig 42 Rod moves coupling by fork 11 The coupling is moved along the splines of the semi axle and engaged with the splines on projected neck of the carrier The Scheme of Pneumatic Control of Cross axle Differential Lock is shown in Fig 43 The rod acts on the switch 12 mounted in the housing of cross axle differential lock of intermediate and rear axles due t...

Page 62: ...the hub 5 2 4 4 Front axle is a driving steerable unit Design of the front driving axle steering knuckle unit is shown in Fig 44 Torque is transferred to the front driving wheels via half axles and hinges with equal angular velocity Fig 45 1 air supply hose 2 lock washer 3 retaining ring 4 lock nut 5 wheel bearing nut 6 journal 7 air supply elbow 8 wheel hub cover 9 outer half axle 10 collars unit...

Page 63: ...rmine resistance torque by means of a dynamometer Measure the torque smoothly rotating the shaft in one sense after at least five full revolu tions Remember maladjustment of bearings can cause damage not only of the bearings but also of the final drive gears 5 2 4 5 When adjusting the bearings follow the procedure 1 Fit the final drive in the fixture remove the differential and flanges Unscrew the...

Page 64: ... the tooth length Table 4 The pattern should be offset by 5 mm minimum from the tooth narrow end the backlash at the tooth root being within 0 1 0 4 mm For changing the backlash in the bevel gears without disturbing the contact shift both gears to a distance which is proportional to the number of teeth of each gear i e shift the driven bevel gear 2 2 times 24 11 farther than the driving one 4 Moun...

Page 65: ...the steering axle kingpin bearings during the sixth maintenance works ТО 15 000 at 96 000 km Follow the steps dismount the wheels and put the supports under the bottom caps of the steering knuck les dismount the left steering knuckle lever and the upper cap of the right steering knuckle remove two gaskets from the gasket pack under the lever and the cap one gasket of 0 05 mm thick the other 0 1 mm...

Page 66: ... of the nut by the value which does not exceed the space between two adjacent holes Fix the retaining washer tighten the locknut with the torque 400 500 N m 40 50 kgf m and lock it To connect the wheel pumping hose with the wheel valve set the semi axle with the hub in a way that the hose is located opposite the wheel valve symmetrical to the wheel studs After mounting the wheels check the wheel b...

Page 67: ...n instructions Towing Unit 21 202 5 3 1 2 The hook loop type towing device according to GOST 2349 On the customer request it is technically feasible to install the hook loop type towing device supplied as spare parts for Ural trucks for operation with trailers as per GOST 2349 75 dimension type 3 The coupling hook general dimensions should correspond to GOST 2349 75 for the dimension type 3 The to...

Page 68: ... to tow the trailer having the towing loop with working area section of 43 9 mm 5 3 2 Truck Suspension 5 3 2 1 The truck front suspension Fig 48 consists of two longitudinal parabolic springs 2 that work jointly with hydraulic telescopic bilateral shock absorbers 8 Upper shock ab sorbers eyes are attached to brackets 7 attached to the frame girders through rubber sleeve pipes 10 Lower shock absorb...

Page 69: ...U bolt nut 25 spring eye 26 wedge 27 eye fixture screw а 1 2 5 mm Fig 48 Front Suspension 5 3 2 2 The hydraulic shock absorbers Fig 49 dampen oscillations which arise in the course of elastic strain on the suspension parts when the truck is being driven on a bumpy road The hydraulic snubbers function as follows during relative displacements of the sprung and un sprung parts of the truck the liquid...

Page 70: ...lking beam brackets 16 and 17 by bolts 14 Pushing and braking forces are transferred from the axles to the truck frame via two upper torque rods 5 and four lower ones 7 Side forces are trans ferred via the springs The torque rod 20 joints are rubber metal ones The pins with shortened taper fitted in the upper torque rods at the side of truck axles are held against turning through in the brackets b...

Page 71: ...jet thrust bracket 14 walking beam axle fastening bolt 15 bolts fastening walking beam bracket to the stiffener 16 17 walking beam bracket rh lh 18 walking beam suspension axle 19 axle arm 20 metal rubber joint 21 torque rod head cover 22 lubricator 23 walking beam 24 walking beam fastening nut 25 walking beam cap 26 walking beam fastening nut coupling bolt 27 walking beam bush g cavities under th...

Page 72: ...t on the bolts 17 The rear suspension shock absorbers are similar to the front suspension shock absorbers 1 8 spring brackets front rear 2 additional spring bracket 3 additional spring 4 spring U bolt 5 pad 6 lining 7 11 shock absorber brackets upper and lower 9 spring 10 shock absorber 12 shock absorber bracket bolt 13 U bolt nut 14 pin 15 inserts upper and side 16 spacer 17 bracket coupling bolt...

Page 73: ...6 trucks rear springs on unloaded truck and 4х4 truck on loaded truck first with a torque of 250 300 N m 25 30 kgf m and finally to 580 660 N m 58 66 kgf m 1 spring 2 6х6 truck rear spring stiffening plate 6х6 4х4 trucks front axle beam clamp 4х4 truck rear ax le beam bracket I IV order of U bolts nuts tightening Fig 52 Springs U bolts Nuts Tightening Scheme Tighten the 4х4 and 6х6 trucks front sp...

Page 74: ...иксатор 6 Анакрол 202 Loctite 243 Loctite 262 243 or 577 Torque the nut 24 to 80 N m 8 kgf m then back off by 1 6 a turn The sealant squeezing out in to the gap between the end faces of the walking beam nut 24 and bushing is not allowed Torque coupling bolt 26 to 44 56 N m 4 4 5 6 kgf m Fill lubricant Литол 24 into the walking beam hubs by shooting through the lubricator 22 according to the Chart ...

Page 75: ...ААЗ Pervouralsk such shock absorbers differ in the valve system and specifications For this reason replace the shock absorbers of the same manufac turer manufacturing plant information is found on the shock absorbers body or case lower part 5 3 3 Wheels and Tires 5 3 3 1 The truck is equipped with wheels of disk type and tires with controllable pres sure The wheel consists of the wheel valve 1 Fig...

Page 76: ...erved Follow the next general rules strictly observe the norms of tire internal pressure maintain the wheels and tires in due time keep units of the running gear steering and brakes in good working order stick to rules and use rational technique of driving taking into account road conditions strictly observe the rules of using controllable pressure tires at reduced air pressure set forth in Subsec...

Page 77: ... stored at a temperature below zero are recommended to be warmed up in a warm room to a temperature above zero direction of wheel rotation should coincide with that of the tread pattern rims and their elements should not have damages bends cracks sharp edges and burrs corrosion both on the exterior and interior sides and in the points of contact with tires worn out fastening holes when mounting th...

Page 78: ...that does not conform to these tire sizes do not use the bead and lock rings from a different type of wheel because they can have different design dimensions regarding diameter and profile even with the same model of trucks which have been produced on different dates and have got different design of their wheels do not set additional bead rings onto the rim to reduce its width do not use the rims ...

Page 79: ...tween the bead and lock rings and press out the bead ring downwards and insert the flat end of the second tire iron into the gap appeared Fig 54 I Pressing both irons and rearranging them by turns around the circle at a distance of 50 100 mm from each other upset the bead ring to some extent downwards together with the tire bead and then using the hook like end of the large tire iron completely re...

Page 80: ...the bead along its whole length upwards using the other iron inserting sequentially its flat end be tween the rim and tire at a distance of 70 100 mm to the right and left of the place where the tire bead goes to the outside To avoid the bead injury insert the tire irons for the whole width of the bead 6 Turn over the tire and the wheel with the lock part facing downwards and remove the tire bead ...

Page 81: ...e rim stand onto the tire on the side op posite to the valve recess this part of the tire casing bead into the mounting groove in so do ing the tire bead in the zone of limiter should be at the top above the rim If any difficulty oc curs upset a part of the tire bead behind the bead seat with the help of the tire irons as shown in Fig 55 Hold the bead by the short tire iron first in the zone of br...

Page 82: ...sure does not happen gradually but instantly usually at a pressure of 450 500 kPa 4 5 5 0 kgf cm2 which exceeds nomi nal pressure to some extent 8 Mount the wheel onto the hub and fasten it the tightening torque of the nuts fastening the wheels should be 400 500 N m 40 50 kgf m To connect the wheel inflation hose to the wheel valve mount the wheel relative to the hub cap so that the inflation hose...

Page 83: ...holes when balancing it The order of installing the balancing weights is as follows 1 Deflate the tires 2 Press the tire bead out of the bead ring with a tire iron where the balancing weight is placed until a clearance of 1 2 mm appears 3 Mount the weight with the spring onto the bead ring holding them by hand set the spring beyond the bead ring edge slightly hammering it and upset it completely I...

Page 84: ... of rope 13 to the tilting bracket first Put the detachable handle 12 on the reduction gear shaft Turning the handle lower down the tilting bracket with the spare wheel When the spare wheel has been lowered down remove rope 13 from it not disconnecting it from tilting bracket 1 without necessity and roll out the wheel The spare wheel should be lifted and fixed for transportation in the reverse ord...

Page 85: ...th Steering Gear screw ball nut rod segment 5 4 1 2 Steering gear with distributor Fig 61 comprises screw 7 and ball nut rack 8 coupled with segment 1 The semicircular helical grooves on the screw and the nut form the flute filled with high precision balls 6 when the unit was assembled The gear sector 1 is installed in the bearings 18 which are pressed into the collar steps 21 having a number of h...

Page 86: ... is connected with the channel а for the service fluid intake from the pump the boundary grooves k and f with the channel b for the service fluid offtake to drain it The three reaction chambers of the casing 5 have the rams 21 which can be displaced axially in their channels The slide valve 22 is fixed through the bearings 3 by the nut 2 on the bushing 9 The bushing 9 of the steering unit is conne...

Page 87: ...ove b then it is poured into the oil tank With the steering turn to the right e g the bushing 9 with the slide valve 22 fixed on it offsets to the left affected by the threaded joint in the direction of the steering unit At the beginning of the movement when the pressure in the hydraulic system is not high the steering effort on the steering wheel is basically created by the torsion bar twist whic...

Page 88: ... the rod length loosen the screw 14 Fig 63 of the end clips remove the protecting coupling 12 and rotate the rod with the wrench in any direction If there is leakage along the rod compress the seal with the nut 11 1 cylinder end 2 6 packing rings 3 rod end nut 4 cylinder 5 piston with rod 7 supporting ring 8 collar 9 pressure ring 10 13 attachment clips 11 nut 12 protecting coupling 14 bolt 15 rod...

Page 89: ...m and the steer ing linkage can be adjusted The steering linkages and booster unit hinged joints have the collar steps 9 and 10 Fig 66 The hinged joints are not adjustable during operational process The permissible cumulative clearance in new hinged joints in the direction perpendicular to the finger axis is up to 0 3 mm 1 casing 2 filter 3 filler filter 4 filling neck plug with the oil level indi...

Page 90: ...in kerosene or petrol and blow them off When filling the steering linkage hinged joints with lubricant make sure that protecting collars are not visibly distorted under the lubricant pressure 5 4 2 2 Changing of oil in steering hydraulic system 1 Warm the engine the oil temperature in the steering hydraulic system should be not lower than 20 C 2 Jack up the front axle 3 Turn the wheels to the righ...

Page 91: ...the gear case eyes disconnect the universal joint Rotate the shaft 15 see Fig 62 fix the nut rod 8 see fig 61 and the sector 1 in one of the outmost positions Determine the torque nec essary to crank the shaft 15 see Fig 62 from the outmost position to the middle one crank the shaft with the angle 30 If the torque is less than 0 9 N m 0 1 kgf m adjust the tightness in the bearings 14 see Fig 61 by...

Page 92: ...easuring rule check distance B1 between the wheel rim beads in the rear sec tion at the level of wheel centers and mark these points Roll the truck so that these marks are in front and check distance B In front the distance must be 1 3 mm less than that in the rear If the difference of the distances measured between B1 and B is beyond the limits readjust by changing the length of the lateral steer...

Page 93: ...c two circuit with separate braking of the front axle wheels and those of the rear axles rear bogie The brakes are controlled by the pedal in the driver s cab connected with the double unit brake valve by levers and tie rods The service brake mechanism is drum type with the internal brake shoes 2 Fig 68 Eve ry brake mechanism has a wedge mechanism 1 with automatic adjustment between the lining 3 a...

Page 94: ...e wedge mechanism an automatic adjuster is provided in order to ensure constant control over the clear ance between the brake drum and the brake linings When applying the brake the cleat wedge 7 Fig 70 overcoming the resistance of the re lease spring 1 presses the rollers 6 which turn over in downward direction on the cleat wedge sur face 7 and piston 5 At this piston 5 with a toothed ring 2 and a...

Page 95: ... toothed coupling В tooth pitch between the toothed ring 2 and adjusting nut 3 the automatic adjustment is carried out the toothed coupling jumps over one tooth and adjusting nut 3 and bolt 8 do not turn through At the brake release the bolt 8 adjusting nut 3 toothed ring 2 and pistons 5 are forced inwards As the pin 4 thrusts into the spiral groove А adjusting nut 3 and toothed ring 2 turn throug...

Page 96: ...ictly insert the wedge 1 into the housing in the direction indicated with an arrow In doing so rollers 3 should face the pistons 2 Installation verification push the wedge by hand and try to rotate it If the wedge goes down it means that rollers fail to be placed between pistons correctly During wedge mechanism mounting check that cleat wedge assy preserves the correct position During wedge mechan...

Page 97: ...e 5 5 1 5 Brake linings replacement If the brake linings have worn down replace them as per Fig 74 The linings wear rate is determined by means of the wear indicator In order to en sure snug engagement of the brake lining to the brake shoe it is recommended to rivet the rivets from the central openings of the brake lining as shown at view В 1 2 3 4 5 6 7 8 If the linings are oiled rinse them with ...

Page 98: ...anism А В distance be tween the support external diameter and brake linings Fig 75 Adjustment scheme for brake shoes with brake linings 1 brake shoe 2 brake lining 3 rivet 4 wear indicator diameter without taking into account brake drum wear Fig 74 Brake linings rework diagram ...

Page 99: ...d at the presence of circular grooves with the depth of 1 mm the drum working surface is to be turned in accordance with the Table 5 basing on the hub bear ings outer rings according to the Fig 76 The drum working surface run out should not exceed 0 25 mm Table 5 Brake drum inner surface diameter after internal turning Diameter after the first internal turning mm Diameter after the second internal...

Page 100: ...ickup is secured in the special bushing Angular velocity sensors are of individual type installed in the front and rear axle wheels working with impulse toothed ring pressed onto the hub 5 and are used for the wheel speed continuous reading off The received signal is transferred to the control unit via cables For the sensor normal operation the clearance between the rotor and the sensor should not...

Page 101: ...mbers with spring brake in accordance with Fig 81 install the chamber as far as it will go installation depth is 25 mm turn it inversely till the outputs 11 12 are directed backwards tighten the lock nut 2 with a tightening torque 300 20 Nm 30 2 kgf m The brake chamber and wedge mechanism connection is to be sealed in using sili cone or rubber based sealant The wedge mechanism and brake chambers c...

Page 102: ...rking brake valve 23 trailer and parking brake cylinder 24 return valve 25 non brake con sumers air reservoir 26 brake chambers 29 parking brake air valve 30 pneumatic cylinder of engine stop 31 brake valve 32 brake actuation sensor 33 compressor а to air hydraulic booster AHB Fig 82 Brake Pneumatic Drive Diagram with outlets to the 6х6 truck trailer Compressed air from the compressor enters the o...

Page 103: ...o pointer gauge 4 pressure regulator with adsorber 5 adsorber res ervoir 6 four line safety valve 7 pressure drop sensor 8 front axle brakes air reservoir 9 rear bogie brakes air reservoirs 10 13 16 19 25 check outlet valves 11 condensate drain cock 12 spring brake chambers with spring brake 14 24 ABS modulators 15 service brake acceleration valve 17 parking brake acceleration valve 18 parking bra...

Page 104: ...ng head 14 control coupling head 15 spring brake chambers with spring brake 17 25 ABS modulators 18 service brake acceleration valves 19 parking brake acceleration valve 20 parking brake valve 21 trailer and parking brake cylinder 22 return valve 23 non brake con sumers air reservoir 24 brake chambers 27 brake valve 28 brake actuation sensor 29 compressor Fig 84 Schematic diagram of the brake driv...

Page 105: ... reservoir 21 brake chambers 24 brake valve 25 brake actuation sensor 26 compressor Fig 85 Schematic diagram of the brake drive without outlets to the 4х4 truck trailer Legend to Fig 82 85 polyamide tube Ø 6 mm polyamide tube Ø 8 mm polyamide tube Ø 10 mm polyamide tube Ø 12 mm polyamide tube Ø 14 mm polyamide tube Ø 15 mm rubber hose 5 5 2 1 Compressor The compressor operation and maintenance sho...

Page 106: ...ining into the sink of the lower part 3 The purified air through the radial holes in the auger flows into the inner cavity of the auger and fur ther to the output b When the pressure governor is activated the pressure is delivered to the cavity В via the output d which together with the working pressure in the cavity A acts on the piston 4 against the force of spring 1 The valve 2 opens and the co...

Page 107: ...f the return valve 7 of the return valve 8 the com pressed air is delivered to the outlet III and after that to the truck brake system Simultaneously the compressed air resisting the pressure of the spring 6 of the throttle governor 5 with a hole di ameter of 1 5 mm is delivered through the outlet II to the regeneration reservoir At the same time the compressed air flows into the cavity Д under th...

Page 108: ... pressure governor does not work when the pressure is a cut off one then with the safety valve opening pressure the decompression pressure control valve 18 opens overcoming the springs 19 and 14 force and the air passes to the atmosphere The safety valve opening pressure is regulated by the quantity of the adjusting disks 20 21 under the decompression pressure control valve spring 19 The discharge...

Page 109: ...outlets to the air cylinders а opening Fig 88 Two section lever brake valve Lever brake valve consists of the upper and lower parts The valve lever mechanism is secured to the upper part The lever housing is protected from dirt and moisture by means of boot In the lower part 15 there is a small piston 14 which is by spring 21 is pressed to the big piston 23 Upper section valve 24 is pressed to the...

Page 110: ...cribed above Two section brake valve maintenance consists in its periodical inspection cleaning from dirt checking for tightness Pay attention to the condition of the protective rubber boot of the valve and to its tight fitting to the housing because dirt on the pusher and friction surfaces of the valve causes the brake valve failure The brake valve tightness is checked by means of the soapy emuls...

Page 111: ...re drop in supply line thus the trailer is braked automati cally 5 5 2 7 The Acceleration Valve 91 is installed in the wheel brake system of rear axles and reduces the brake drive actuation time by restricting the compressed air inlet from the air tank to the actuator Compressed air from air reservoir is supplied to outlet I Outlet II is connected to the brake valve outlet III is connected to the ...

Page 112: ... of the truck tractor service brake system 4 2 inlet from the rear circuit of the truck tractor service brake system 4 3 inlet from the rear circuit of the truck tractor parking brake system Fig 90 Trailer Brake Control Valve with Double line Drive and Cut off Valve 1 upper chamber 2 piston 3 inlet valve 4 spring 5 valve body 6 outlet valve I II III VI outlets Fig 91 Acceleration Valve ...

Page 113: ...the valve i closes the connection with the outlet 3 and the pas sage to the preliminary control chamber а opens The compressed air of the chamber А goes to the preliminary control chamber а and the diaphragm с closes the inlet b to the chamber В Simultaneously the valve magnet II switches valve h closes the passage of the opening d so that the compressed air of the preliminary control chamber g ca...

Page 114: ...res sure gauges with the range 0 1000 kPa 0 10 kgf cm2 Fig 94 Check Outlet Valve 1 body 2 cap 3 loop 5 5 3 The maintenance of the brakes pneumatic drive 5 5 3 1 While servicing the brake pneumatic drive of the truck the most important issue is the system and its parts air tightness monitoring Pay a special attention to the tightness of the pipes and flexible hoses connections as well as hose joint...

Page 115: ...king brake system 5 5 5 1 Parking brake system is used for holding the truck on the grades The parking brake has air drive The brake is controlled by the brake valve with manual control by the handle located to the right of the driver s seat 5 5 5 2 Parking and emergency brakes air drive operation Compressed air from the reservoir 23 via return valve 24 see Fig 82 flows to the parking brake contro...

Page 116: ...diaphragm and spring brake 1 upper body 2 upper piston 3 lower piston 4 outlet valve 5 inlet valve 6 valve s body I outlet from the hand operated brake valve II outlet from spring brakes III outlet to the atmosphere IV outlet from air reservoir V outlet from the brake valve Figure 95 Parking Brakes Acceleration Valve 5 5 5 4 Return valve is shown in Fig 96 When the compressed air is delivered into...

Page 117: ...h spring brakes Additional connection to the trailer brake control valve en sures braking action transmission to the trailer Position for truck parking brake efficiency check is available а handle b c valves d outlet e piston f spring A B C chambers I travelling II parking III checking Figure 97 Hand Operated Brake Valve for Trucks with Trailer Facilities а handle b c valves d outlet e piston f sp...

Page 118: ... to modulators switch off relay of the auxiliary brake solenoid valve and the pilot lamp as well as for the system diagnostics Control units are protected against leakage and short circuit electrostatic discharge volt age drop voltage surge during start up and other electrical transients Control unit has a mode for advantageous passing over the soft pavement in terms of re ducing the braking dista...

Page 119: ...equires no special equipment Diagnostics by blink codes is intended for determining the faults which were found by the ECU Turn the ignition on before starting the diagnostics by blink codes supply the ABS with voltage ABS подать напряжение на АБС ABS is not functioning during the diagnostics process After turning the ignition key on wait minimum for 1 second before pushing diagnostics button 5 5 ...

Page 120: ...l at braking 2 3 Bad impulse ring ABS maintenance period 2 4 Signal instability 2 5 Sensor signal loss 2 6 Short circuit to ground or to the battery or wire breakage Driven axle speed sensor r h 3 1 Air gap is too large 3 2 Absence of sensor signal at braking 3 3 Bad impulse ring ABS maintenance period 3 4 Signal instability 3 5 Sensor signal loss 3 6 Short circuit to ground or to the battery or w...

Page 121: ...e coil short circuit to the ground 9 3 Release coil wire breakage 9 4 Wire breakage on the general PIN 9 5 Rising coil short circuit to the battery 9 6 Rising coil short circuit to the ground 9 7 Rising coil wire breakage 9 8 Valve configuration error Driving axle modulator l h 10 1 Release coil short circuit to the battery 10 2 Release coil short circuit to the ground 10 3 Release coil wire break...

Page 122: ...nt voltage difference 16 9 High voltage 16 10 Low voltage Retarder interface 17 1 Retarder brake relay is short circuited to the storage battery or wire breakage 17 2 Retarder brake relay is short circuited to ground 17 4 ERC1 breakage Special errors 17 5 Front and rear tire size differs significantly 17 9 Bad road BAS function is activated 17 10 Emergency lamp defect 17 12 Sensors parameters memo...

Page 123: ...nection to Wabco control unit are shown in Fig 103 a and 103 b 1 pressure sensor 2 fuses 3 pilot lamp 4 ignition switch 5 diagnostic socket 6 diagnostics switch 7 rotation sensors 8 front modulator r h 9 front modulator l h 10 rear modulator r h 11 rear modulator l h Figure 103 a The Scheme of Connecting Wabco Control Unit Plugs for 6х6 trucks ...

Page 124: ...odulator 9 rear axle modulator Figure 103 b The Scheme of Connecting Wabco Control Unit Plugs for 4х4 trucks To activate the diagnostics mode it is necessary to connect the ABS lamp to the battery minus terminal for 0 5 to 3 seconds by means of ABS diagnostics switch button as shown in Fig 104 Figure 104 Error Codes Blink Codes Display ...

Page 125: ...ll be displayed in the order reverse to their appearance at first the last error then the first one The number of the error doesn t show the succession of the error appearance The passive errors output mode is off when the last passive error recorded in the electronic unit memory has been displayed The list of errors codes for Wabco and the list of possible troubles and methods of trou ble shootin...

Page 126: ... 8 4 Electronic control unit doesn t correspond to the specified number of wheel sensors and modulators Replace the control unit 8 5 Check grounding of the electronic control unit and modulators 5 5 7 Auxiliary brake system The auxiliary compression type brake reduces the vehicle speed on long downgrades Braking deceleration is achieved by creating back pressure in the exhaust gas pipes of the eng...

Page 127: ...w gear at the cranking speed near to 2100 min 1 If required reduce the cranking speed by applying service brake and throw into low gear If the shutter 4 of the auxiliary brake turns with difficulty remove the brake body with the shutter wash in kerosene and blow through with compressed air If the rods of the air cylin ders or the control valve button seize disassemble the units wash in kerosene re...

Page 128: ...re should be taken to the condition of the fuses installed in boxes Avoid the use of non standard fuses such as bended wires bolts washers because it will result in immediate failure of the electronic items if a short circuit occurs A blown out fuse should be replaced by the one having the same value of working current The electric circuit diagram for trucks is shown in Fig 106 see the insert Unde...

Page 129: ...eter ПА8046 4П 42 Electronic tachometer 6201 3813010 43 Oil level indicator in engine lubrication system УК170М or 33 3810 44 Coolant temperature indicator УК171М or 36 3807 45 Two pointer pressure gage 1921 3830010 46 Audible alarm buzzer 733 3747 10 47 Socket for diagnostics ОВD II MOL 51116 1601 48 Inter axle differential locking indicator 2212 3803 14 49 Transfer case low gear engagement indic...

Page 130: ...Thermobimetallic fuse 291 3722000 86 Oil filter clogging sensor 87 Generator 4512 3771 10 88 Stator AZF4581 or 5432 3708 01 89 Stator relay 738 3747 20 91 Engine retarder disconnecting switch 2802 3829010 92 Switch of the signal in the body ВК322 3710 0 93 Portable lamp socket in the body 47К 94 Fuel heating element in fuel coarse filter 95 Air dryer heating element 96 Reverse light switch ВК403В ...

Page 131: ... 4602 3710010 122 Glow plug switchВыключатель свечи ВН 45М 123 Fuel heating switch ВН 45М 124 Solenoid valve switch 4602 3710 125 Solenoid valve 126 Starting preheater ПЖД 30 127 High voltage source 9301 3734 or 9301 3734 01 128 Spark plug СН423 129 Preheater electric motor МЭ252 130 Glow plug preheater solenoid valve 11 3741 131 Glow plug 11 3740 132 Voltage regulator switching off relay 751 3777...

Page 132: ...the password is lost For entered password registration it is recommended to record the passwords into the regis ter and change them periodically 4 Enter the calibration mode by short pressing 0 should appear in the extreme right position Driver should drive the truck at low speed for defined road section and stop the truck at the assistant command by the end mark The number of pulses counted durin...

Page 133: ...ator has seven modes presented in the Table 10 modes 1 2 3 do not require access password entering mode 4 is for access password entering modes 5 6 7 are pro tected by access password Table 10 Mode number Upper line readings Lower line readings Symbol 1 Total run Daily run km 2 Total run Maximum speed km h 3 Total run Blinking value of maximum speed km h 4 CodE 0000 5 Calibration coefficient 6 Cal...

Page 134: ...y six blinking zeros in the upper line If the truck runs for example 100 meters with this mode active and stops than upper line will show the number of the incoming pulses Multiply this number by ten the result is a calibration coefficient quantity of pulses from transducer per a kilometer of run Do several countings of pulse quantity and cal culate the coefficient arithmetic mean to get more prec...

Page 135: ...se the r h turn signaling lamps installed in the front light the side repeater and in the rear light are turned on When turning the handle counter clockwise the l h turn pilot lamps are switched on The changeover switch is returned in its original position automatically The break in relay provides the flashing light If one of the lamps installed in the lights is faulty the pilot lamp of the turn i...

Page 136: ...ed for the truck marking in the conditions of poor visibility Caution Do not drive the truck with rear fog lamp on in the conditions of clear vis ibility 5 6 4 5 Headlamps adjustment Setting of the initial inclination angle of lower beam light Headlamps adjustment and control is performed with the help of a screen The screen can be fixed or portable The screen should have flat and mat surface The ...

Page 137: ...bottom of the screen and a dark zone at the top of the screen the line dividing light and dark zones is par allel to the line А А on the left side of the screen and directed at 15 angle upwards from the in tersection point with vertical lines of headlamps centers on the right side of the screen Rotating the adjusting screws on the headlamp remove the line dividing the light and the dark zones so t...

Page 138: ...nd under hood lamps circuit pilot lamps clusters supply circuit 4th link circuit of cab dome lamp road train sign lamps and stop signal lamps 5th link heater electric motor and reversing lamp circuit 6th link Instruments and buzzer supply circuit Fuses upper unit protects circuits of 1st link left clearance light 2nd link right clearance light and instruments illumination 3rd link left headlamp lo...

Page 139: ...rical mirrors and their holders then re fix the bolts se curely upon the adjustment The cab is fastened to the chassis frame in four points on rubber pads When the chassis frame deformation occurs the flexible fastening protects the cab parts from overstress 1 4 rear view mirrors left right 2 road surface visibility zone 3 driver s eye point Figure 111 Visibility Zones Through Exterior Rear View M...

Page 140: ...en the belt you need to pull it out gently by holding the belt buckle and insert the buckle 2 in accordance with Figure 115 into the lock 1 till a snap preventing straps curling Make sure that the lower strap bear against the hips lower strap is not allowed to be held around the waist To release the belt press the red button on the lock belt will automatically re turn to its original position 1 le...

Page 141: ...wind shield wiper and windshield washer The two speed windshield wiper consists of electric drive two rods wiper blade levers and two wiper blades The windshield wiper is turned ON by a switch located on the steering column When the wiper is switched off the wiper blades are auto matically put along the lower edge of glass The windshield washer tank with a pump and a motor is mounted on the l h si...

Page 142: ...s the air quantity is also changed supplied for blowing over the glasses and for warming the feet Interior hatch cover 7 is controlled by lever 5 If the lever is set in its upper position the hatch is opened in the lower position it is shut Most favorable positions of the cab heater controls simultaneous air intake from the out side through hatch controlled by cover 12 from the cab through interio...

Page 143: ... backward adjustment is 110 mm The seat is fixed in the desired position by handle as shown in Fig 118 provided at the left side of the seat support The driver s seat has a mechanism used for changing seat cushion inclination and position of the seat in height with the limits of adjustment up to 80 mm To change the position of the seat in height turn out two front screws 1 on the left and right si...

Page 144: ...llets and people The platform is equipped with removable sides and stakes Tailgate and sides are hinged Adjustable side locks are placed in the stakes The hinged strapping brackets are located on the body bottom along the sides The truck platform is equipped with the seats extension racks for the sides and top bows with braces and canopy The middle seat can be demounted and fixed on the front boar...

Page 145: ...es and fixing the locks handles in CLOSED position The adjustment is performed according to the scheme shown in Fig 122 The direction and the amount of the catch 1 movement in the stake 2 body are sized up on the basis of the following 1 If after the complete closing of the side and locking of the stake the side can move freely in the direction of opening shift the catch 1 upwards I VIII folding s...

Page 146: ...e pusher pin 6 into the hole of the handle 7 matching the threaded hole of pin with the pusher 3 hole 8 Check if the adjustment is correct by closing the side and locking the stake Repeat points 1 2 4 9 if required 9 Shift handle 7 into OPEN position 10 Turn in the screw with the spring washer 4 into the threaded hole of pusher 3 5 7 3 3 Side safety guards SSG shown in Fig 123 provides effective p...

Page 147: ...146 Figure 123 Left side and right side safety guards ...

Page 148: ...ynamic loads 5 8 1 Release hatch mechanism is located under the bolster and shown in view А carriers 7 omitted for clarity When pulling the unhitching control handle 1 the locking bar 10 releases locking hook 9 via lever 3 the hook turns to the position for hitching by spring 5 force When releasing the handle the locking bar 10 holds the locking hook 9 by spring 4 force At the hitching the semitra...

Page 149: ... 125 Hitch locking control 5 8 3 Hitching and unhitching of the truck tractor with the semitrailer Before hitching make sure that the bolster unit and its fasteners are in good working or der the bolster is free of dirt and foreign particles clean the upper surface of the bolster is re quired and apply fresh grease Apply the semitrailer parking brake and set the semitrailer on the bolster so that ...

Page 150: ... semitrailer release the semitrailer parking brake drive the road train forward for some distance make sure that the truck tractor and the semitrailer have been hitched properly the brakes and electrical equipment of the semitrailer are in good working order When hitching the truck tractor with semitrailers of different brands adjust the distance between the clips on the hoses to prevent them from...

Page 151: ...th hoses on the truck tractor platform shift self release safety lock 2 in the upper lower position depending of the bolster brand and pull the releasing lever until it is fixed the locking bar 10 moves aside opening the locking hook 9 engage the first gear in the gearbox and drive the truck tractor slowly forward until it is unhitched fully from the semitrailer locking hook 9 remains open with th...

Page 152: ... the air pressure of 500 kPa 5 kgf cm2 minimum in truck air system and disengaged clutch Adjusting shims are installed between flanges of the gearbox hous ing and power take off housing The side clearance in gear meshing is adjusted by noise with the help of the above mentioned shims If it is required to change the old shims by the new ones their thickness should be kept unchanged Information abou...

Page 153: ...r the action of the spring 11 brings driven shaft gear 5 out of mesh with drive gear 3 1 drive gear shaft 2 housing 3 drive gear 4 housing cover 5 driven shaft gear 6 engaging chamber dia phragm 7 engaging chamber cover 8 cover 9 fork 10 shift fork rod 11 spring 12 switch 13 adjusting shims 14 cover 15 flange 16 nut 17 collar 18 ball bearings 19 driven shaft 20 bearing spacing ring 21 roller beari...

Page 154: ...rom the transfer case oil sump through a pipe and then the pump forces oil to the gear bearings via channels in shaft 3 and in primary shaft of the transfer case Some oil penetrates through the gaps and lubricates the shaft bearings Information about auxiliary power take off control is presented in the section 5 2 2 Transfer case subsection 5 2 2 3 Transmission units control When the auxiliary pow...

Page 155: ...orm pair is installed Adjust the bearings if only you fail to eliminate the axial clearance by re tightening the bearing cap bolts The bearings must be re adjusted with preload The torque required for cranking the reduction gear worm in bearings 29 31 and 32 see Figure 130 should be about 1 0 2 5 N m 0 1 0 25 kgf m If the shaft turns rather easily or if it has an axial clearance remove some of adj...

Page 156: ...ck 42 winch suspension cross member Figure 130 Winch Reduction Unit To change the contact pattern in height of the tooth shift worm 30 axially using adjusting shims To displace the contact pattern to the tooth root remove several adjusting shims 28 from under the bearing cap 27 at the flange side to displace the contact pattern to the tooth end add shims Change the number of adjusting shims 33 und...

Page 157: ... pin 2 Figure 132 is fitted in the front cardan shaft which would be sheared off if the winch is overloaded All cardan shaft joints have of identical design and are unified with those of GAZ 53A truck The intermediate cardan shaft is mounted on two supports To compensate errors in mounting sliding forks 7 of the front and rear shafts enter the splines provided in the ends of the intermediate carda...

Page 158: ...olyamide bushes 18 and rotate on the pins 17 locked by plate 5 5 9 3 4 Rules for using the winch Prior to operating the winch check that the drive for engaging and disengaging the winch drum operates correctly also check that the rope is wound correctly and is fastened reliably If the drive is adjusted properly the length of rod 10 see Figure 131 between the axes of the holes in the adjusting fork...

Page 159: ...ls 8 horizontal roller 9 horizontal roller bracket 10 16 driven and driving sprockets 13 chain 15 drum shaft bracket 17 guide roller pin 18 bush 19 guide roller 20 slide block of lead screw 21 slide block support cover 22 guide roller holder case Figure 133 Winch Rope Winding Guide Do not use bolts or other parts as the substitute of the safety pin When operating it is difficult to determine the r...

Page 160: ...nch rope hook to a fixed object by means of the second towing rope It is possible to fasten the winch rope directly to the fixed object in so doing the hook is fastened to a preliminarily tightened rope To avoid overheating of the winch reduction gear do not pull the cargo using the whole length of the rope more than three times in sequence at the maximum load or the load close to it Lay out the w...

Page 161: ...supplied to the tires via a double line circuit Prior to starting open the wheel valves set the pressure control valve levers to the neutral position and check the tire pressure Bring the pressure to the norm if required and close the wheel valves Pressure norms for tires 425 85R21 with load index 156 are shown in Table 12 For moni toring the tire air pressure the wheel valves should be opened 1 h...

Page 162: ...able 12 Pressure norms in tires 425 85R21 with load index 156 Road type Permissible pressure kgf cm2 МPа Max speed km h Максимальный пробег в течение гарантийного сро ка км Difficult terrain swampy ter rain virgin snow and loose sand minimum 0 8 0 08 1 1 0 11 2 0 0 20 15 25 30 600 800 1400 Roads of all types for the peri od of tire inflating after difficult terrain section only from 2 0 up to the ...

Page 163: ... installed on the truck is shown in Fig 137 5 9 5 Sealing System The sealing system is used for sealing truck units and systems which may be flooded with water when the truck crosses fords and for maintaining constant pressure in the inner spaces of the units as well as in fuel tanks 1 solenoid valve 2 elbow 3 fittings 4 bolt 5 bracket 6 nut I from safety valve II to rear axle tires III to interme...

Page 164: ... connections of the wires High voltage source is not functioning Disconnect the high voltage cable and secure its end 3 5 mm apart from truck ground If there is no spark when plug is switched on replace the high voltage source Spark plug is not functioning Clean or replace the spark plug Electromagnetic valve is not functioning no click when the electromagnetic valve is switched on Check the circu...

Page 165: ...djust the bearings or re place by the new ones Gears shift spontaneously Gear shift fork or coupling is worn out The splines of the gear shift coupling and primary shaft are worn out Replace worn parts Engagement of gears and locking of differential are ob scured Burrs on gear splines front holder shift coupling Lock sticks Grind surface of splines Clean hole for ball Driving Axles Excessive axle ...

Page 166: ...evel in the steering gear hydraulic system tank Air or water in the system foam cloudy oil Top the oil up the required level Bleed the air Otherwise check the tightening of all the joints remove and wash the gauze filter check the gasket under the collector Check up collector fastening bolts for tightening otherwise change oil Insufficient tension of the pump drive belt The pump does not provide r...

Page 167: ... enough the brake failure light turns on Brake fluid leakage air in the master cylinder or in the hy draulic line of one of the brake circuits Find the leakage and elimi nate it Add the brake fluid and bleed brakes Braking is not efficient enough minimal air pressure signal light turns on Inner collar is worn out or fluid is not available in one of the master cylinders Replace the collar Add the f...

Page 168: ...yte level in battery drops too quickly Electrolyte boils out Monoblock unit damaged Check the voltage regulator Get the battery repaired Electrolyte ejects out of vent hole of one or several battery cells during charging Excessive level of electro lyte Excessive charging current Use rubber syringe to re move excess electrolytic solu tion Check the voltage regulator Short circuit in one of battery ...

Page 169: ...due to the control valve deformation Replace the control valve Auxiliary Power Take off Auxiliary power take off APTO is difficult to engage Excessive vibration noise and oil leakage Burrs on the shaft splines of the auxiliary power take off and those on the shift sleeve Loosening of the flange nut Auxiliary power take off rear bearing wear Grind the spline surface Replace the flange nut Replace t...

Page 170: ...y Guide rollers holder case was not in the extreme right po sition while rope fixing on the drum Unwind the rope disconnect it from the drum then fix it when the guide rollers holder case is in the extreme right posi tion Drum jams Rope unwinds from the drum due to incorrect operating when the rope was paid out forced the sag was not set cor rectly Rope was winded on the drum without necessary ten...

Page 171: ... recommended by the Ural Automobile Works to use the starting preheater also at an ambient air temperature below 0 С 7 2 2 Engine start without warming The procedure of starting the cold engine at temperature from 0 to minus 12 С 1 Pump trough the engine fuel system using the manual fuel feed pump 2 Set the gear shift lever in neutral position 3 Shut the radiator blind 4 Switch on storage batterie...

Page 172: ...preheater switch on button pressed until the engine runs steadily then gradually release the clutch pedal and the glow plug preheater button If the engine has not started repeat the procedure in the above mentioned sequence with the pauses between the starts of 1 2 min 7 2 4 Cold engine start with the help of the engine starting preheater The procedure of starting the cold engine at temperature fr...

Page 173: ...er retighten the wheel nuts twice after 100 150 km and 200 300 km run as well as every time when removing from and mounting the wheels on the truck hub do not reduce the tire pressure Use the bolster type trucks during the initial 1000 km run on hard surface roads and articulated with a semi trailer having the gross weight no more than 12 t After 1500 up to 3000 km 50 to 100 hours of engine runnin...

Page 174: ...ve been used the required pressure in tires is set transfer case differential is locked In all other cases if there is no skidding unlock the transfer gearbox differential to avoid extra load in the transmission Engage a low gear in the transfer gearbox when crossing over a dif ficult road conditions as well as on steep upgrade Shift gears in the transfer gearbox only when the truck has been compl...

Page 175: ...ves and avoiding maneuvering do not stop The time of driving the truck in water should not exceed 15 min To avoid water and dirt penetrating the tool box press the tool box cover tightly by the central screw On crossing a ford open the tool box remove water and dry the tools On crossing a ford check the oil level in the engine and other truck units High oil level water drops on oil level gauge or ...

Page 176: ...uncouple the trailer and after crossing them pull it to the truck with the winch Remember that three four coils there should be left on the winch drum Pull the trailer at the medium rotation frequency of the engine crankshaft Do not tow the trailer using the winch rope Mind that three or four coils should be left on the winch drum Pull the trailer at the en gine crankshaft medium speed Do not tow ...

Page 177: ... a warning triangle on the tailgate of the towed truck 7 5 2 Towing of the truck with non running engine and steering booster is possible on all road type Towing of the truck with the non running engine and the steering booster without a driver is allowed only with the triangle rigid towbar In this case the speed on sharp turns should not exceed 10 km h 7 5 3 Control checkup en route After half an...

Page 178: ... every 15 000 km M 15 000 8 2 Maintenance Schedule Daily maintenance is performed before the truck departs to the line and after it returns Maintenance in the initial period of operation is performed after the first run from 1500 km up to 3000 km 50 100 hours of engine operation Maintenance of special purpose vehicles intended for technological operations repair trucks truck cranes specialties for...

Page 179: ...ads of technical categories I II III out side the suburban area automobile roads in towns and suburban area mountain terrain as well as in cities with cement concrete and asphalt concrete pavement 2 Automobile roads of technical categories I II III out side the suburban area mountain terrain automobile roads in towns and suburban area all terrain types except flat type as well as in cities all ter...

Page 180: ... soil roads intra organizational roads in rural area in pit and dump roads temporary access ways to different types of construction objects and sand clays stone etc mining sites when the traffic is possible there 0 6 Table 14 Maintenance schedule adjustment coefficient depending on the climatic areas Climatic area Adjustment coefficient for maintenance schedule Cold temperate 1 0 Warm temperate wa...

Page 181: ...erial Fill the windshield washer pump tank in At sub zero tempera tures drain water from the tank Vessel Check good repair and service3ability of lighting de vices light and sound alarms instrumentation and wind shield wipers Faults can not be toler ated Check operation of the generator against current in dicator The current indicator should show the charging current Current indicator Check for go...

Page 182: ...teners of bolster unit and subframe should be tight Check tires condition and wheels fastening eliminate troubles if any Tires should be without damages and foreign ob jects in tread Loose wheels fastening nuts are impermissible Visual check Tighten torque wheels fastening nuts if necessary When operating with a trailer check the absence of axial displacement of the towing hook eliminate if any se...

Page 183: ...pliance with Operation Manual for power unit Check and if required tighten all the fastening points of the power unit all the connections of the air in take and exhaust system Loosening is not admis sible Wrenches 14x17 17x19 Transmission Check and if necessary ad just the free travel and full travel of the diaphragm sin gle disk clutch pedal see the section Clutch release drive For 4х4 and 6х6 tr...

Page 184: ...nt spring pin fixing wedges Loosening is not al lowed Ключ 17x19 front spring eyes Ditto Socket wrench 30x32 tire iron with tommy bar rear spring eyes for 4х4 trucks Ditto front spring eye U bolts Box wrench 22х24 rear spring eye U bolts for 4х4 trucks Ditto wheels Socket wrench27x38 for wheel nuts tire iron front spring U bolts Loosening is not al lowed Perform the tight ening on a fully loaded t...

Page 185: ...beams Socket wrench 24 pinchbar for cranking box wrench 22х24 towing unit if operating with the trailer Wrenches 17х19 22х24 Steering Check tightening of and if required retighten nuts fas tening steering link pins Loosening is not al lowed Wrench 24x27 box wrench 24x27 pliers steering booster Ditto Box wrench 24x27 Socket wrench36 pliers screwdriver hammer Tire iron with tommy bar steering gear h...

Page 186: ...Equipment Check density and level of electrolytic solution in the storage batteries add distilled water if required See the service manual for the storage batteries Wrenches 11x13 17x19 vessel with distilled water glass pipe 3 5 mm in diameter Check fastening cleanness of and contact security of ca ble terminals to starter termi nals and of storage battery Cable terminals fas tening should be safe...

Page 187: ...7 Lubrication Engine lubrication should be carried out as per Engine Operation Manual Check oil level in the steering knuckle housings of front driving axle and bring to the norm if required Change oil in the transfer gearbox case see the subsections Transmission and Chart of lubricants and operating fluids Pour oil in up to the inspection fill opening on the rear wall of the case Oil leakage thro...

Page 188: ...d Working Fluids Pump the lubricant in before deformation of pro tective coupling of the end Joints should be tight Lever plunger gun wiping material Check oil level in winch reducer case and add if need be see subsection Chart of Lubricants and Working Flu ids Oil level should be up to the edge of inspection opening Oil leakage through the plugs is not admissible Wrench 24x27 oil dis penser 133М ...

Page 189: ...essel with coolant wiping material Filtering element of the dry type air filter should be maintained upon the readings of the clogging indicator but at least at every maintenance works When operating in conditions with high dust content it should be serviced more often on the basis of operation experience in such conditions At the new filtering el ement installation check visually its condition ha...

Page 190: ...d from under the lev er and covers should be the same 0 15 mm 0 05 0 1 mm Box wrench 24x27 thrust supports under the lower covers of steering knuckles jack tire iron Adjust driving axles final drives Every sixth M 15 000 Technical requirements and adjustment order see in subsection Driving ax les Wrenches 110х12 11х13 17x19 22x24 24x27 device for reduction gears mounting dismantling dynamome ter i...

Page 191: ... missible Perform the tightening on a fully load ed truck for 4х4 trucks for 6х6 trucks tightening is done on unloaded truck Socket wrench 27x38 for wheel nuts Tire iron with tommy bar torque rod pins Loosening is not al lowed If slots for cotter pin do not match tighten the nuts Socket head for 50 tire iron with tommy bar pli ers screwdriver driftpin hammer Check and if necessary tighten up the b...

Page 192: ...wrench 24x27 steering shaft cardan forks Ditto Wrenches 14x17 17x19 steering link pins Box wrench 24x27 pli ers steering booster Box wrench 24x27 Socket wrench 36 pliers screwdriver hammer Tire iron with tommy bar Check and adjust if nec essary steering wheel free trav el See section Steering Steering wheel free travel check Playmeter front wheels toe in See section Steering Front wheels toe in ad...

Page 193: ...hould be equal to 20 30 mm for 4x4 and 6x6 trucks Wrenches 17x19 22x24 screwdriver pliers Inspect spring brakes clean them from dirt check brake chambers for tightness and operability tighten fas tening nuts Loosening is not al lowed Wrench for round nuts 65 70 Check air drive tightness in doing so pay attention to the friction surfaces or harm ful contacts of pipelines and eliminate the troubles ...

Page 194: ... Check the condition of rubber cushions Cracks and breaks are not allowed Special equipment Check the power take off case fastening to the gearbox case and oil pump fastening to the power take off case if available Fastening should be tight Wrench 14x17 Check Auxiliary PTO pump operability let auxilia ry PTO work for 10 minutes and check its pump operation if available Disconnect and blow the brak...

Page 195: ...essel for used oil oil dispenser 133М in the transfer gearbox case see subsections Transmission and Chart of lubricants and working flu ids Oil level should be up to the inspection fill opening edge Oil leakage through the plugs is not admissible Wrenches 17x19 22x24 oil dispenser 133М wiping material Lubricate in accordance with Chart of lubricants and working fluids pins of front for 4х4 6х6 tru...

Page 196: ... hub bearings when mounting see subsection Driving Axles and Chart of Lubricants and Working Flu ids every second M 15 000 Apply grease onto the rollers and bearings cage evenly on the whole outer surface After a short run the hub should be cold or slightly warm when the bearings are adjusted cor rectly Socket wrench 140 Wrenches 10х12 17х19 tire iron with tommy bar screwdriver jack platform ГАРО ...

Page 197: ...nts and working fluids at every third M 15 000 sliding bearing of winch drum shaft Lubricate till fresh grease appears Lever plunger gun wiping material guide rollers shaft Apply grease Ditto roller bushings and guide roller holder housing cavities of winch rope wind ing guide Apply grease chain gear of the winch rope winding guide Lubricate the chain along the whole length working surfaces of win...

Page 198: ... with each truck The lubrication is performed as a part of the maintenance procedure M with the specified frequency and also when the unit is repaired When changing seasonal motor oil to all season oil and vice versa replace the filtering elements of the oil filter and wash the oil centrifugal purification filter Range of basic fuels and oils and their substitutes for the power unit as well as the...

Page 199: ...or YaMZ engines Engine crank case YaMZ 65654 1 Engine units See the Operations Manual for YaMZ engines 5 Gearbox 2 1 See the Operations Manual for YaMZ engines 6 Transfer case 2 1 Oil ТСп 15К at temperatures not below minus 30 o C Oil ТСп 10 at tem peratures not below mi nus 45 o C At a temperature below minus 30 o C it is allowed to dissolve oil ТСп 15К by 10 15 of arctic or winter diesel oil or ...

Page 200: ...nd 6 7 8 9 10 11 See the Operations Manual for YaMZ engines 24 24 See the Operations Manual for YaMZ engines 5 5 5 5 See the Operations Manual for YaMZ engines Shell Dentax G 80W 90 Mobilube GX 90 Energear EP 80W 90 3 50 3 50 Maintenance M 1500 3000 Change oil Add up to the lower edge of the fill er neck M 15 000 Check the oil level and add if necessary up to the lower edge of the filler neck Ever...

Page 201: ... support bearing 1 Lubricant 158 Lubricant Литол 24 Final drives of driving axles 2 front Oil ТСп 15К at temperatures not below minus 30 o C Oil ТСп 10 at tem peratures not below mi nus 45 o C Oil ТАп 15В at temper atures not below minus 25 o C At a temperature below minus 25 o C it is allowed to dissolve oils ТСп 15К and ТАп 15В by 10 15 of arc tic or winter diesel oil or Omskoil K TMЗ 18 Technic...

Page 202: ...the axle case If the final drive is dismounted firstly pour 1 l of oil through the hole for the breather on the fi nal drive case the re maining oil should de poured through the filler neck up to its edge M 15 000 Check the oil level and add oil if necessary Every third M 15 000 but at least once in three years Change oil Shell Gadus S2 V220 2 RENOLIT EP2 Shell Gadus S2 V100 3 Mobilgrease XHP 222 ...

Page 203: ...draulic oil Р Technical Specification 38 1011282 89 at tempera tures not below minus 30 С steering oil tank 1 22 21 Front driving axle steering knuckle case 2 Mixture of 35 of lub ricant Литол 24 with 65 of oil for reduction gears of drive axles Mixture of 35 of lubri cant Лита with 65 of oil for reduction gears of drive axles ...

Page 204: ... 6 5 Daily Maintenance DM Check oil level in the steering booster pump tank and add if need be M 1500 3000 Every third M 15 000 When repairing steering hy draulic booster Change oil together with filter changing and check oil level in the steering booster pump tank 2 7 5 4 M 1500 3000 M 15 000 Check oil level in the unit and add if need be Fill up to the control fill er edge Every third M 15 000 b...

Page 205: ... shafts of drive of front rear and intermediate shaft 8 6х6 6 4х4 Lubricant Литол 24 Lubricant 158 steering system 2 winch drive 4 2 Tire air supply collars 3 6 Lubricant Лита Lubricant ЦИАТИМ 201 8 7 Wheel hubs 6 6х6 4 4х4 Lubricant Литол 24 Lubricant Лита ...

Page 206: ... first and second and third and fourth collars Apply a thin layer of the lubricant on the axle shaft working surface Shell Gadus S2 V220 2 RENOLIT EP2 Shell Gadus S2 V100 3 Mobilgrease XHP 222 Energrease L2 1 0 6х6 1 0 4х4 6 0 6х6 4 0 4х4 Every second M 15 000 Change lubricant Ap ply lubricant on the collar working surface and into the space between bearing and collar having re moved the old lubri...

Page 207: ...ricant Литол 24 Lubricant Лита Terminals and plugs of ground switch 4 Lubricant Литол 24 Solid oil Ж Solid oil С 1 15 Front spring pins for 4х4 6х6 trucks and rear spring pins for 4х4 trucks 2 Lubricant Литол 24 Solid oil Ж Solid oil C Steering rods and booster joints 6 ...

Page 208: ...nt first 0 0005 0 002 At repair Apply a thin layer of the lubricant 0 025 for 6х6 4х4 trucks front springs 0 04 for 4х4 trucks rear springs 0 05 for 6х6 4х4 trucks front springs 0 08 for 4х4 trucks rear springs M 1500 3000 M 15 000 Pack grease till fresh grease from under the mating of spring pin and spring eye appears 0 037 0 22 M 1500 3000 M 15 000 Lubricate with the oil filler Pump lubricant be...

Page 209: ...bricant Литол 24 Solid oil Ж Solid oil C Knuckle pivot upper bear ings 2 18 16 Splined joints of intermediate axle drive for 6x6 truck rear axle drive for 4x4 truck and intermediate shaft drive 2 18 16 front and rear axles drive 2 steering control 1 ...

Page 210: ...5 0 05 M 1500 3000 M 15000 Lubricate using oilers till fresh grease appears when operating with trailer 0 100 0 100 M 15 000 Lubricate using oiler 0 020 0 04 M 15 000 Lubricate using oilers till fresh grease appears 0 180 0 36 Every second M 15 000 Change lubricant 0 025 0 010 M 15 000 Disassemble and lubri cate ...

Page 211: ...e 2 Lubricant Литол 24 Solid oil Ж Solid oil C Spare wheel lift reduc ing gear 1 14 11 Sliding bearing of the winch drum shaft 1 13 Winch rope winding guide bearings 2 Working surface of the bolster unit 1 Bolster unit hook 1 ...

Page 212: ...ird M 15 000 Lubricate using oilers till fresh grease appears 0 04 0 04 Lubricate while disas sembling 0 025 0 025 Every third M 15 000 Lubricate using oilers till fresh grease appears 0 035 0 07 Lubricate while disas sembling 0 28 0 28 M 15 000 Lubricate the bolster unit working surface and hook using press oilers 0 015 0 015 ...

Page 213: ...shaft guides 1 Graphite lubricant УСсА Solid oil Ж Solid oil С or Lubricant Литол 24 11 Roller bushings and guide rollers holder body cavities of the rope wind ing guide 3 Pin 1 13 Winch rope winding guide chain gear 1 Intermediate bracket shaft of the clutch drive and the brake valve 1 ...

Page 214: ...hird M 15 000 Apply lubricant if the winch is not operated 0 033 0 1 Every third M 15 000 Apply lubricant 0 004 0 004 Every third M 15 000 Apply lubricant 0 05 0 05 Every third M 15 000 Lubricate the chain along the whole length 0 03 0 03 M 1500 3000 Every third M 15 000 Lubricate using an oiler till fresh lubricant appears ...

Page 215: ...t Литол 24 17 15 Spring leaves of front and rear suspensions 4 Graphite lubricant УСсА Solid oil Ж Solid oil С or Lubricant Литол 24 Front and rear spring U bolts thread 16 Oil ТСгип Terminals of service brake system failure sensor 2 Lubricant ВНИИ НП 510 at the Works only Lubricant Литол 24 storage batteries 4 ...

Page 216: ...rface of the spring leaf after disassembly having first removed the rust 0 0025 0 02 Lubricate the threaded part during disassembly having cleaned from cor rosion first Shell Gadus S2 V220 2 RENOLIT EP2 Shell Gadus S2 V100 3 Mobilgrease XHP 222 Energrease L2 0 008 At repair Apply a thin layer of the lubricant after connecting the ter minals having cleaned them first ...

Page 217: ...raphite lubricant УСсА Solid oil Ж Solid oil С or Lubricant Литол 24 3 Telescopic shock absorbers for 4х4 trucks front and rear springs for 6х6 trucks front springs 4 2 Shock absorber fluid Lukoil АЖ Shock absorber fluid ГРЖ 12 Clutch disengage ment hydraulic drive 1 Brake fluid РОСДОТ Brake fluids Томь Нева At a temperature below minus 30 о C dilute with ethyl alcohol in the amount of 18 20 by we...

Page 218: ... Graphited 3 0 005 0 06 Shell Tellus T15 0 850 1 700 for 6х6 trucks 3 4 for 4х4 trucks Change fluid upon dis assembly and repair having washed the shock absorber parts in kerosene and dried them Shell Donax B Brake Fluid DOT3 DOT4 0 5 0 5 DM Check fluid level and add if need be Once in five years Once in three years Change the fluid Once a year Change diluted brake fluid for the new not di luted o...

Page 219: ...ng fluids are given in liters grease lubricants are in kilo grams 2 Oil and working fluid servicing norm in column 7 is nominal It means that after priming procedure the oil fluid level is to be checked and if necessary brought to norm according to section Maintenance 3 For Ural 43206 61 Ural 4320 60 61 trucks 4 For Ural 5557 61 trucks ...

Page 220: ...0 3 27 0 4 29 0 3 27 0 4 See the Operations Manual for YaMZ engines Check coolant level and add if necessary up to the norm 15 25 mm above the cooling tubes ends in the radiator upper tank at a temperature up to plus 20 o C ...

Page 221: ...ering with working and corrosion preventing oils or working oils up to the norm fill in the winch housing with the working oil Make sure that the winch lever is in its disengaged position then engage the auxiliary power take off drive for 3 5 minutes with the engine running Perform the preservation of engine and gearbox in accordance with the Engine Operation Manual and Gearbox Operation Manual Pr...

Page 222: ...sh or of aluminum paste with white spirit in the ratio of 1 4 or 1 5 by weight Fine casein composition mixture of chalk 75 casein glue 20 slaked lime 4 5 soda ash 0 25 phenol 0 25 by weight Packing material for sealing and partial packing Paraffined paper as per State Standard GOST 9569 79 capacitor paper as per State Standard GOST 1908 82 double layer paraffined packing paper as per State Standar...

Page 223: ...nd special fluid leaks every month Eliminate the detected faults Regularly remove detected corrosion products from the painted and unpainted surfaces restore damaged paint and varnish coatings upon removing the corrosion from the unpainted surfaces coat them with corrosion preventing grease Scrape the damaged paint and varnish coatings with the fine grained or water proof abrasive paper after that...

Page 224: ...ox Operation Manual check oil level in the truck transmission components steering booster pump tank rear suspension balance beam hubs oil tank and bring it to the norm if required perform inspection and maintenance of the truck as per requirements to its daily maintenance if some of the working and corrosion preventing or working oils and fluids which are filled in the truck units and systems do n...

Page 225: ...ront towing hooks thrust bars of 100x160x760 mm should be placed ahead of the front wheels and behind the rear wheels A truck placed above the coupling of the flat cars see Fig 140 should be secured by two guy ropes on the rear tow bar and by two guy ropes on the intermediate axle springs support brackets Thrust bars should be fixed ahead of the intermediate axle wheels and behind the rear axle wh...

Page 226: ...ck with the consent of the cargo owner consignor Place the trucks in the cargo hold and on the deck so that the distance between them is 250 mm min on the radiator side and 130 mm min on the other sides Upon placing the truck on a sea vessel perform the preparatory works fasten the truck to prevent its longitudinal and lateral motion with special mooring devices available or with guy ropes Tighten...

Page 227: ...226 1 Walking beam axle for 6х6 trucks rear axle axis for 4х4 trucks Fig 142 Securing of truck on weather deck Fig 143 Securing of truck in cargo hold ...

Page 228: ... bring it to a collecting station remove wheels plastic and rubber parts from the truck and bring them to a collecting station dismantle the truck units disassemble them detect defective parts and bring the parts which are not suited for application as spare parts to a collecting station The brake equipment which is subject to recycling should be disassembled The parts are to be assorted according...

Page 229: ... differential rear holder 55 65 5 5 6 5 bearing caps of primary and intermediate shafts 40 56 4 0 5 6 case of differential rear bearing 44 62 4 4 6 2 bearing cap of rear axle drive shaft 40 56 4 0 5 6 bearing cap of front axle drive shaft 30 35 3 0 3 5 Oil level inspection plugs МК24х1 5 100 140 10 14 К 3 8 80 120 8 12 1 Drain plug 100 140 10 14 А 2 2 Cardan Drive Nuts of bolts fastening flanges o...

Page 230: ... eye bolts of front springs for 4x4 6x6 trucks and rear springs for 4x4 trucks 400 500 40 50 Nuts of eye U bolts of front springs for 4x4 6x6 trucks and rear springs for 4x4 trucks 180 220 18 22 Wedge nut fixing fingers of front springs 28 36 2 8 3 6 Nuts of clamping bolts of rear brackets of front springs for 4x4 6x6 trucks and rear springs for 4x4 trucks 180 220 18 22 Nuts fastening front spring...

Page 231: ...lot and cotter pin hole steering pitman arm 400 450 40 45 Bolts fixing steering gear to truck frame М16 110 140 11 14 Bolts fixing steering cardan forks М10 44 56 4 4 5 6 Steering wheel fastening nut 80 100 8 10 А 5 Brake System Brake chambers fastening nut 300 320 30 32 Brake shoe pins fastening nut 431 490 44 50 Brake shoe pin lining fastening nuts 224 313 28 32 Wedge mechanism body fastening bo...

Page 232: ...ment А 9 1 Power take off Bolts and nuts fixing power take off case to gearbox case 22 32 2 2 3 2 А 9 2 Auxiliary power take off Nut of auxiliary power take off flange min 140 14 А 9 3 Winch Bolts of winch cardan shaft flanges 60 65 6 0 6 5 ...

Page 233: ...n the rim mm 1 3 Travel of clutch pedal mm free 5 10 full 185 190 Travel of brake pedal mm free 20 30 Air pressure in air system kPa kgf cm2 Pressure governor max pressure at switching off 870 kPa 8 7kgf cm2 min pressure at switching on 720 kPa 7 2 kgf cm2 Four circuit protective valve circuit static shut in pressure 450 kPa 4 5 kgf cm2 Trailer brake control valve corresponding inlet and outlet pr...

Page 234: ... over 12 000 kg 116 5 108 9 Rear spring of truck for 4x4 trucks 101 7 Additional spring for 4x4 trucks 33 3 Walking beam axle assembly 149 Wheel 515 254 254Г 508 56 Wheel 514 400 400Г 508 68 7 Wheel 8 5 20 47 8 Tire 14 00 20 model ОИ 25 112 Tire 390 95R20 КАМА УРАЛ max 120 Tire 390R20 model О 65 max 120 Tire 12 00R20 У 4 ИД 304 90 Steering gear worm side segment 39 Steering gear screw ball nut rac...

Page 235: ...rs of intermediate cardan shaft of interme diate axle drive cardan shaft with end slots 16 50311A Single row radial ball bearing 55x120x29 Front axle drive shaft of transfer box shaft of reinforced auxiliary pow er take off rear support 2 7312A Single row tapered roller bearing 60x130x33 5 Transfer box primary shaft winch drum shaft 3 7610A Ditto 50x110x42 25 Transfer box interme diate shaft 2 731...

Page 236: ...rew of winch rope winding guide 3 6 312А Single row radial ball bearing 60х130х31 Transmission cardan shaft intermediate support 1 704902K6ÓC10 Roller needle bearing 15 2x28x20 Spiders of steering car dan shaft 16 220A Single row radial ball bearing 100x180x34 Transfer case differen tial 1 218 or 218А Ditto 90x160x30 Ditto 1 180206АС17 30x62x16 Intermediate support of steering cardan shaft 2 63690...

Page 237: ...ingle row radial ball bearing 60x130x31 Winch reduction gear worm rear support 1 8311 Single row thrust ball bearing 55x105x35 Ditto 1 7216A Single row tapered roller bearing 80x140x28 5 Winch drum shaft 1 8103 or 8903 Single row thrust ball bearing 17x30x9 Spare wheel lift reduc tion gear 1 I 941 12К Roller needle bearing State Standard GOST 4060 78 12х17 In pedal gear 2 I 943 25К Roller needle b...

Page 238: ...ations 38 101479 00 Hydraulic Oil Р Specifications 38 1011282 89 3 9 l Litol 24 lubricant GOST 21150 87 Solid oil Ж Solid oil С AM grease gimbal Зимол lubricant 158 lubricant GOST 1033 79 GOST 4366 76 Specifications 38 590 1302 91 Specifications 38 УССР 201285 82 Specifications 38 101 320 77 8 0 kg 10 38 kg Graphite lubricant УСсА GOST 3333 80 Solid oil Ж Solid oil С Litol 24 lubri cant GOST 1033 ...

Page 239: ...m Standart 40 Specifications 2422 022 13331543 2004 See Operation Manual for the en gine 27 0l ДТ 1 lubricant Нева brake fluid 0 12kg Лита lubricant 38 101 1308 90 Specifications ЦИАТИМ 201 lubricant GOST 6267 74 Specifications 38 УССР 201285 82 0 29 kg 0 39 kg For trucks with air hydraulic drive ...

Page 240: ...1 2 Front lamp А24 21 3 2 А24 5 2 Rear lamp А24 5 2 7442 3716 А24 21 3 6 Side repeater А24 21 3 2 Cab roof lamp А24 21 3 1 Signal pilot and instrument illumination lamps А24 2 19 Front marker lamp А24 5 1 2 Number plate lamp А24 5 2 Road train sign lamp А24 5 3 Flood head lamp АКГ24 70 1 Emergency light signaling switch АМН24 3 1 ...

Page 241: ...ble G 1 Waste oil collection rate l Engine 18 0 Gearbox 7 3 Transfer box 2 7 Steering gear case 1 2 Drive axle reduction gears 19 0 13 0 Steering hydraulic system 3 0 Winch reduction gear 6 3 On trucks with 4x4 wheel arrangement ...

Page 242: ...n the shipping documents supplied with each truck When shipping the trucks the SPT A 0 is put in the transportation box of SPT A Rec ommendations for the in service location of the tools and accessories on the truck are given in the present Section The location of tools and accessories relating to the equipment mounted on the truck chassis is determined by the equipment Manufacturer Trucks chassis...

Page 243: ...ntity In tool bag 26 Fig H 1 15 Pliers 1 16 Box wrench 22х24 1 17 Box wrench 17х19 1 18 Wrench 27х30 1 19 Wrench 22 х24 1 20 Wrench 19х22 2 21 Wrench 14х17 1 22 Wrench 11х13 1 23 Wrench 10х12 1 24 Wrench 8х10 1 25 Wrench 5 5х7 1 Fig H 1 Tools of the Ural truck ...

Page 244: ...screwdriver 1 In tool box Fig H 2 1 2 Tool boxes 3 Socket wrench 140 1 4 Hydraulic jack 8 t 1 5 Lever type grease gun 1 Connecting head of B type with union 1 Air hose 1 Spare wheel holder winch lever 1 The following items are mounted under the body Tire iron 1 1 2 tool bags 3 socket wrench 140 4 jack 5 lever type grease gun Fig H 2 Tool Box ...

Page 245: ...ght of load lift mm 285 Oil volume l 0 7 For lifting a load with the jack set the jack in the required position turn out screw 1 Fig H 3 by the required amount If the ground is soft place a strong wooden board or some other flat object under the jack base be forehand make some quick pumping strokes of lever 2 shut off needle 3 being screwed out using a tire iron screw home the shut off needle turn...

Page 246: ...ers or shut off needle tighten collar nuts and eliminate oil leaks through joints of casing parts by tightening the casing head Do not raise the working plungers by hand when the shut off needle is screwed home otherwise air can enter the jack working chamber If the jack fails to ensure the plunger s full working stroke check the oil level Add oil up to the filler closed with plug 4 after lowering...

Page 247: ... gasket 3 cylinder of outer working plunger 4 cylinder pipe 5 and 6 outer and inner working plungers 7 screw 8 seal 9 case head 10 packing ring 11 plunger head 12 plug 13 pump lever 14 shut off needle Fig H 4 Jack ...

Page 248: ...ical roller bearings 7 8 12 shim washers 9 bearing cage cover 10 rear axle drive flange 11 sleeve 13 drive bevel pinion bearing cage 14 drive bevel pinion 15 breather 16 pinion drive shaft 17 gasket 18 flange nut 19 front axle drive flange 20 front bearing cap 21 spacer 22 rear крышка bear ing cap 23 adjusting washer 24 nut 25 tightening washer 26 locking washer 27 locknut 28 axle shaft gear 29 di...

Page 249: ...front axle pivot unit is shown in Fig I 3 1 air supply hose 2 locking washer 3 retaining ring 4 locknut 5 wheel bearing nut 6 swivel stud 7 air supply angle joint 8 hub cap 9 outer semi axis 10 sleeve unit 11 17 19 sealing gaskets 12 bearing 13 hub 14 brake wheel cylinder 15 brake drum 16 brake support 18 spherical joint 20 inner semi axis 21 semi axis housing 22 joint eccentric 23 joint disk 24 o...

Page 250: ...ги рулевой трапеции 1 steering gear with drop arm 2 propeller shafts 3 steering wheel 4 5 nuts 6 washer 7 bolt 8 steering column 9 drop arm rod Fig I 4 Steering I 1 2 1 1 Hydraulic system of the steering hydraulic booster is shown in Fig I 5 I 1 2 1 2 Steering gear with built in integral hydraulic booster Operating mechanism is screw ball nut rod sector Rod also acts as booster piston Drop arm sha...

Page 251: ...sting screws 4 6 pressure limitation valves 5 balls 9 piston 10 15 pins 11 torsion bar 12 arm shaft sector 13 worm 14 valves case Fig I 6 Steering gear The oil from the pump flows into one of the piston cavities of the steering mechanism depending on the direction of rotation and increases the drop arm rotational movement through hydraulic pressure on piston surface Turning of the rotary valve rel...

Page 252: ...y the pump into the steering gear The safety valve inside the bypass valve limits the oil pressure in the system by opening at the pressure of 15 16 MPa 150 160 kgf cm2 Control the hydraulic steering booster pump belt tension with the force of 40 N 4 kgf in the middle of the branch in the direction of the arrow c The deflection of each belt shall be 6 11 mm Adjust the belt tension with the screw 1...

Page 253: ...stem due to the oil level lowering during bleeding 9 When oil reaches the upper mark on the gage turn the steering wheel to both sides several times until there are no air bubbles in the tank Add oil if need be Check the oil level with unscrewed plug of the filler neck I 1 2 2 3 Adjustment of the steering gear valves actuation Check and adjust the steering gear limiting valves actuation if require...

Page 254: ...ft В2 adjusting screw for pressure limiting when turning right Fig I 8 Hydraulic diagram of steering gear valves adjustment check Take into account that it is necessary to turn the adjusting screws in if the pressure drop is insufficient and to turn the adjusting screws out if the pressure drop is excessive during the ad justment Caution Screw the adjusting screws with the rotary valve in its neut...

Page 255: ...rn the adjusting cam gears against the stop Turn the right on the side of the support clockwise and the left one anticlockwise loosen the cams by turning them backwards by 30 which corresponds to the cam axis end half turn Having followed the above mentioned steps for all wheels check whether the brake drums run hot during driving I 1 3 1 3 Speed sensor Brake mechanisms of the front and of the rea...

Page 256: ... worn out to the rivet hand surface When the brake shoes are greasy rinse them with petrol If the brake drum is worn out and circular grooves are more than 2 mm deep bore the drum working surface and locate the outer rings of the hub bearings off The runout of the drum work surface should not exceed 0 25 mm the drum diameter should not exceed 424 38 mm I 1 3 1 5 Combined air hydraulic drive of ser...

Page 257: ...ve To park the truck with the trailer on the parking lot pull the parking brake lever in the upper fixed position by that the control valve 10 delivers the compressed air from the valve 17 outlet and activates the brake mechanisms of the trailer 1 towing unit 2 oil separator 3 absorber receiver 4 oil and moisture separator with integrated governor 5 four circuit safety valve 6 rear circuit brake r...

Page 258: ...r 13 two pointer pressure gage 14 ABS modulator 15 brakes air hydraulic booster 16 brake failure sensor 17 control outlet valve 18 two section brake valve 19 receiver for non brake consumers 20 compressor Fig I 12 The scheme of the air hydraulic brakes drive without outlets for the trailer I 1 3 1 6 Combined air hydraulic drive of service brakes for truck with 4x4 wheel arrangement The truck is eq...

Page 259: ...xle brakes receiver 9 return valve 10 pressure drop sensor brake 11 valve with manual control 12 parking brake chamber 13 trailer valve 14 coupling heads 15 control outlet valve 16 two pointer pres sure gage 17 two section brake valve 18 ABS modulator 19 brakes air hydraulic booster 20 brake fail ure sensor 121 receiver for non brake consumers 22 compressor Fig I 13 Principal scheme of air hydraul...

Page 260: ...епа и СТС 9 front axle brakes receiver 10 return valve 11 pressure drop sensor 12 brake valve with manual control 13 parking brake chamber 14 control outlet valve 15 two pointer pressure gage 16 two section brake valve 17 ABS modulator 18 brakes air hydraulic booster 19 brake failure sensor 20 receiver for non brake consumers Fig I 14 The scheme of the air hydraulic brakes drive without outlets fo...

Page 261: ...ity Substitutes application seasonality 1 2 3 4 5 Parking brake ad justing lever roller 1 Engine oil Parking brake ad juster thread 1 Hydraulic system of the steering RBL C 700 1 Oil ВМГЗ ГИПОЛ РС Air cylinders of the auxiliary parking brake system Air booster of the service brake system rods spacer collars cylinders and collars of the pistons 2 Litol 24 grease Grease 158 ...

Page 262: ...he roller be tween the adjusting lever and the splash guard lu bricate 4 5 drops 4 5 drops M 1500 3000 M 15 000 Remove rubber plug on the brake support lu bricate STATOIL TRANSWAY PS DX III 3 9 3 9 SM Check the oil level in the booster pump tank add if necessary M 1500 3000 Every third M 15 000 At steering hydraulic booster repair Change the oil to gether with the filter re placement check the oil...

Page 263: ...rature be low minus 40 C dissolve brake fluid with 18 20 of ethyl alcohol by weight Brake fluid Нева РОСДОТ At a temperature below minus 40 C dissolve brake fluid with 18 20 of ethyl alcohol by weight Service brakes main cylinders 3 Brake fluid Toмь Brake fluid Нева РОСДОТ Service brakes wheel cylinders 6 Brake fluid Toмь Grease ДТ 1 Brake fluid Нева РОСДОТ ...

Page 264: ... 2 7 2 45 4х4 M 15 000 Check fluid level if nec essary add in tanks 15 20 mm below the upper edge of filler neck M 15 000 Replace the fluid once every 5 years 0 150 0 45 Wash working surfaces of wheel and main cylin ders with brake fluid 0 05 0 30 M 15 000 Wash working surfaces of wheel and main cylin ders with brake fluid 0 02 0 12 Lubricate working sur faces of the pistons at as sembly and apply...

Page 265: ... of gear shifting Piston of differential locking mechanism 2 1 1 51 9 10 54 Drive axles 3 2 2 70х92 1 to gether with 2 1 70х92 4 or РТ 864176 02 or ВDUМ5SLX26 Collar 2 2 70х92 1 State Standard 8752 79 Industrial Standard 38 05146 78 Collar 70х92 12х12 Technical Specification 2539 001 00232934 2003 Collar 70х92 13 18 5 SIMRIT Rear bearing cap of front axle 1 1 1 1 40 40 40 11 11 11 4 2 2 70х92 1 to...

Page 266: ...ar 70х92 12х12 Technical Specification 2539 001 00232934 2003 Collar 70х92 13 18 5 SIMRIT Front bearing cap of the rear axle 1 1 1 1 40 40 40 11 11 11 7 375 4224017 03 Collar Axle shaft housing 24 16 41 1 8 4320 3104033 03 Collar Wheel hub 6 4 44 28 Truck suspension 9 64221 2905338 or 50 2905070 Rod gland Rod gland Shock absorber БААЗ Shock absorber ГЗАА 1 49 4 or 50П 2905070 Rod gland Shock absor...

Page 267: ... worm thrust bear ing cap Winch worm shaft thrust bearing front cap 1 1 130 27 15 4320 4501127 01 19х32х7 Collar 4320 4501127 01 19х32х7 Hole in the winch reduc tion gear housing for coupling fork rod outlet 1 130 19 Values shown in brackets are for trucks with 4x4 wheel arrangement Ural 432060 61 Ural 43206 61 Ural 5557 60 trucks and their modifications 4320 3902037 РЭ Operations Manual first edi...

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