MAZ 534035 Operation Manual Download

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MAZ TRUCKS

631236, 534035, 650136, 555035

Euro–4

Operation Manual

Summary of Contents for 534035

Page 1: ...MAZ TRUCKS 631236 534035 650136 555035 Euro 4 Operation Manual...

Page 2: ...ed for its reliability It is equipped with modern units and devices that make the articulated lorry control easier reduce driver s tiredness raise road safety and labour productivity reduce transporta...

Page 3: ...ith a metal body see Figure 4 that is dumped with the help of a hydraulic mechanism and is designed for non metallic building industrial and domestic bulk cargo by a single truck or within an articula...

Page 4: ...Under the rear axle Under the front axle Figure 1 MAZ 631236 truck chassis Under the rear axle Under the front axle Figure 2 MAZ 534035 truck chassis...

Page 5: ...Figure 3 MAZ 650136 dump truck Figure 4 MAZ 555035 dump truck...

Page 6: ...80 km h 17 0 24 0 18 7 24 2 Wheels Disc Tyres size tread pattern type 315 80R22 5 protector tread of the front and spare wheels is road like rare one is universal Note 1 Permissible laden mass of the...

Page 7: ...more than 8 9 Outer minimal turning radius of the truck between walls m not more 9 66 Turning angles of the inner relative to the turn center wheel to the left and to the right 45 1 Note 1 Permissibl...

Page 8: ...th air conditioner front protecting device patched on sides for dump trucks awning for dump trucks spade for dump trucks ASR radio or CD recorder mudguards set of spare parts and tools as requested Pa...

Page 9: ...g 7250 810 800 760 7300 820 800 770 7400 840 810 790 The second axis kg 10000 590 600 580 10950 660 670 640 11500 700 710 680 Note Acceptable pressure deviation in the tyres 20 kPa Pressure in the tyr...

Page 10: ...r replenishment of the brakes actuator receivers 8 While running downhill avoid truck movement at the revolutions higher than allowed i e the tachometer pointer must not enter the red zone of the scal...

Page 11: ...ne starting is to be fulfilled with the observation of the Safety rules 27 In order to avoid untimely failure of the pressure regulator with the adsorber it is necessary to watch the airtightness of t...

Page 12: ...e key is inserted and taken out of the lock in position III Figure 5 In order to unlock the steering column shaft it is necessary to insert the key into the switch lock and in order to avoid key braki...

Page 13: ...any position of the handle Steering column Position 1 starter and instruments switch lock 2 switch for the turns lower and upper beam 3 windscreen wiper and washer switch Figure 5 the positions of the...

Page 14: ...an be turned on or off by pressing the button on the switch case that is located on the front or rear wall of the battery container Tachograph 11 is a device that shows the speed current time and the...

Page 15: ...120 40 0 20 8 32 0 1 0 10 0 10 Figure 6 Dashboard and control devices...

Page 16: ...Tachographer 12 12 Speeding control lamp 13 13 Electric torch switch 14 14 Second brake circuit pressure indicator 15 15 Fuel level indicator 16 16 Fan clutch switch 17 17 Road train signs switch 18 1...

Page 17: ...of MAZ vehicles movement parameters of Euro 4 ecological standard digital tachographs SmarTach L2000 produced by ACTIA or DTCO 1381 produced by Siemens VDO can be installed A distinctive feature of di...

Page 18: ...driver s side on kit rack see Figure 8 Figure 8 Digital tachograph installation place Kit rack Electrical equipment panel Tachograph Digital tachograph provides with the registration of the speed of m...

Page 19: ...is divided into two zones top zone consisting of two lines intended for the representation of the current information bottom zone consisting of one line intended for the representation of presence or...

Page 20: ...begins At this time readiness regime is indicated for the second driver Figure 10 Indication of the bottom display line Tachograph control buttons Tachograph has two button groups first button group...

Page 21: ...h printer is intended for graphical reflection of the parameters registered by the tachograph Tachograph lets print out the information in the way of different forms or diagrams with different discrec...

Page 22: ...chograph made by Siemens VDO Fig 13 is analogous to SmarTach L2000 tachograph made by ACTIA in its purpose principle of operation and functionality Figure 13 DTCO 1381 Siemens VDO Digital Tachograph T...

Page 23: ...15 The peculiarity of this speedometer is the presence of a special bus CAN by means of which coded information from the tachograph is sent to the speedometer in digital type 1 4 2 3 Figure 15 Electro...

Page 24: ...e and the time pressing the button longer than for two seconds in the position of daily mileage the value of the counter is reset to 0 4 Operative condition check Light indicator goes on when failures...

Page 25: ...ent the locks should be closed The doors are fully closed when it is possible to lock the doors on the inside with the help of the catch button The place for the fire extinguisher is provided on the w...

Page 26: ...ck 2 seat pad 3 regulation handle of the backrest angle 4 pneumatic resilient member 5 handles of the seat vertical regulation mechanism 6 handle of the seat horizontal regulation mechanism Fig 16 Dri...

Page 27: ...lator batteries their fastening add electrolyte recharge and fix in case of need 7 It is necessary to check good work conditions of the air brakes clutch drive electric accessories signals cabin dumpi...

Page 28: ...system driving axels pneumatic brake system lifting system of the cabin platform and platform heating system drive clutch 4 check the nut splinting of the steering link ball stud of the brake chamber...

Page 29: ...cabin lift Fig 17 is fixed in the position Lifting hydraulic rams 6 influence over the catch gear knuckles and open them after this with the help of the hydraulic ram 5 the cabin is lifted In order t...

Page 30: ...oupling When the coupling is finished the handle should be in the level position and the safety device 29 in the position Pressed connect the trailer pneumatic and electrical system to the automobile...

Page 31: ...uffer 7 stem 8 body 10 body cover 11 spring 12 axis of the bar 13 buffer 14 cover 15 lever 16 bolt 17 cover base 18 handle 19 pin 20 top bush 21 guide loop 22 lower bush 23 28 springs 24 clevis 25 lub...

Page 32: ...brake It is forbidden to move when control lamps 26 27 Fig 7 are alight signaling about inadequate pressure in the contours of the brake pneumatic drive In order to slow down a train along the downgra...

Page 33: ...Fig 20 Unscrewing of the accumulator tappet stop bolt...

Page 34: ...naling indicators through the front end electronic block 1 or block VECU of the truck fixed in the cabin which forms the CAN bus of the data transmission together with the block of the engine Informat...

Page 35: ...onducting place it is forbidden to place the cable of the welding facility parallel with the electrical wires of the track components liable to the welding must have safe electrical link with the nega...

Page 36: ......

Page 37: ...e tank 8 electronic module of the SCR system 9 SCR bundle 10 AdBlue dosage valve and sprayer injection 11 NOx sensor 13 electric pedal of fuel delivery 14 switch of the motor break 15 OBD diagnostic c...

Page 38: ......

Page 39: ...e tank 8 electronic module of the SCR system 9 SCR bundle 10 AdBlue dosage valve and sprayer injection 11 NOx sensor 13 electric pedal of fuel delivery 14 switch of the motor break 15 OBD diagnostic c...

Page 40: ...EDC 4 5 1 2 3 1 EDC control lamp red 2 control lamp of faults in the SCR system yellow 3 neutral lamp green 4 control lamp of a slow level of the ammoniac solution in the SCR system green 5 DC control...

Page 41: ...rd of the relay and safety devices of the electronic blocks and control signaling devices Relay and safety devices panel EDC EDC relay EDC Safety devices block of EDC system Deutz Deutz diagnostic bun...

Page 42: ...EDC Bundle of EDC system Fig 24 Electrical basic scheme of elements connection of ECS engine in the cabin...

Page 43: ...sensor of air filter Relay of the motor brake EDC Relay of EDC switch EDC EDC fuse block Block of the check indicators To the starter relay Lamp of the abnormal temperature of cooling liquid To the te...

Page 44: ...Fig 25 Electrical basic scheme of elements connection of the ECS engine placed on the engine Electronic engine block...

Page 45: ...d pressure Switch of the motor brake Electronic magnetic valve Speed sensor of crankshaft Speed sensor of the control shaft Electronic magnetic valve Supercharging air temperature sensor Oil temperatu...

Page 46: ...Fig 26 electrical basic scheme of the elements connection of the AdBlue injection...

Page 47: ...of the pumping module filter Heating of the suction manifold Heating of the line of resultant pressure Heating of the pipe lateral up to the module Heating of the module Temperature sensor in the acce...

Page 48: ...urther truck movement is allowed and it is recommended to visit a nearby service center for the repair Control lamp 2 yellow warns about defects in the SCR system neutralization of exhaust gases It is...

Page 49: ...ear boxes is switched on It is necessary to set the gearshift in the neutral position 2 2 Low tension of the battery It is necessary to check the state of the battery to recharge or to change the batt...

Page 50: ...doesn t start or works not stably 3 6 Engine electronic block is out of order It is necessary to change the engine electronic block 4 1 The motor brake is switched on It is necessary to check the mot...

Page 51: ...work or linked up badly It is necessary to check the link up and working capacity of the motor brake valves 7 1 There is no connection with the block of the antilock system It is necessary to join bun...

Page 52: ...t shall go out otherwise there is a malfunction in the SCR system The red lamp flashes on when malfunction of the engine in whole is registered in case when it is blinking the level of ammoniac soluti...

Page 53: ......

Page 54: ...sensor exhaust gases SCR muffler SCR dosing module valve pump feed module Adblue feed displacement Adblue coolant in the engine tank ventilation tank with AdBlue Adblue level and solution temperature...

Page 55: ...er and in road conditions without safety regulations compliance Dismounting of one from coupled wheels without use of jack with collision of second wheel on lugs Pump the tire up to pressure which exc...

Page 56: ...wheels of different manufactures It is prohibited to operate a vehicle with tires of different protector drawing on the rear axle of the truck except temporary adjustment for following till the neare...

Page 57: ...ng and lowing of wheel Self tightening unit 1 traverse 2 wheel 3 pressing 4 5 nut 6 holder 7 lifter 8 point of lubrication Figure 29 Fastening of spare wheel MAZ 650136 Spare wheel is set on the dump...

Page 58: ...ope reeling on the drum especially first coils Rope must be reeled on regular without embedding It is not allowed during maintenance to set tyres of different sizes constructions models with different...

Page 59: ...lifting should be made in next order To disconnect the clutch To turn off the switch 22 see Figure 6 To turn the switch handle Figure 35 in right position Lifting To low clutch pedal slowly increasing...

Page 60: ...Sizes with full mass Sizes in equipped condition Figure 31 Scheme of lifting of dump truck platform Z 650136...

Page 61: ...Figure with full mass Sizes with fully loaded mass Sizes in laden mass Figure 32 The scheme of lifting of dump truck platform Z 555035...

Page 62: ...form control and side lock control 2 switch of platform control 3 10 electrical pneumatic valve 4 power take off 5 pump 6 oil tank 7 back valve 8 valve of consumption and pressure 9 valve of platform...

Page 63: ...11 hydrocylinder 12 filter 13 valve of speed restriction of platform lowering...

Page 64: ...ve 6 valve of platform lifting control 7 hydraulic cylinder of platform lifting 8 back valve Figure 34 Scheme of mechanism of platform lifting of dump truck MAZ 555035 I platform lifting 0 neutral pos...

Page 65: ...ades which are not provided in hematological map The necessity of disassemble for changing of packing collars or guiding semi rings and bushings can appear during the operation process of hydraulic cy...

Page 66: ...ment by the length rod change 3 by unscrewing of lock nut At declutching it is necessary to adjust full speed of pedal providing rod motion pneumatic hydraulic unit 19 5 22 3 mm with the help of 4 and...

Page 67: ...Full motion of pedal Free motion of pedal 1 pedal 2 hydraulic cylinder 3 rod 4 8 stop bolt...

Page 68: ...ate 16 at insufficient motion of plate 16 to lower bolts 5 displace draught 6 concerning tail 4 tighten up bolts 5 and return adjustment of angle by plate 16 Lever adjustment 1 in lateral direction is...

Page 69: ......

Page 70: ...Scheme of gear shifting 1 2 lever 3 4 6 draught 5 7 17 bolt 8 pin 9 fork 10 bush 11 spring 12 link 13 nut 14 tail 15 tip 16 plate 18 shift mechanism 19 ball Figure 37 Drive of gear box control...

Page 71: ...1 2 lever 3 4 6 draught 5 7 17 bolt 8 pin 9 fork 10 bushing 11 spring 12 link 13 nut 14 tail 15 point 16 plate 18 shift mechanism 19 ball...

Page 72: ...on the angle sufficient for adjustment of protective support Set protective support and lower the platform on it To unscrew lock nut of adjustment bolt of rope valve control and unscrew bolt from cyli...

Page 73: ...1 lock nut 2 adjusting bolt 3 valve rope control 4 bracket of valve drive 5 control valve 6 hydrocylinder Figure39 Adjustment of the device of platform lifting of the truck MAZ 650136...

Page 74: ...ting platform 2 spring of security rope 3 security rope 4 lever of drive valve 5 adjusting bolt 6 rope off valve control Figure40 adjustment of platform lifting mechanism of dump truck MAZ 555035 Tech...

Page 75: ...res Tightening torques of basic thread connections are presented in the supplement 3 Types and periodicity of technical maintenance 1 daily technical maintenance 2 First technical maintenance in 22 50...

Page 76: ...rmed monthly To check functioning of independent fluid heater First technical maintenance A At the truck maintenance after indicated run of performed works foreseen by daily maintenance and besides 1...

Page 77: ...eck and tighten up fastening nut of brackets of reaction bars of pneumatic suspensions to the frame and also nuts and bolts of reaction bars to the brackets on the frame and axle in 2 C bolts of beam...

Page 78: ...ttom and pour out sediment 19 To check condition of guiding semicircles of hydraulic cylinder of platform lifting Make the grease of the truck according to hematological map Test of the truck after ma...

Page 79: ...r 2 Engine cooling system Deutz TCD 2013L044V Euro 4 21 l with diesel liquid heater 21 l with diesel liquid heater 25 l without diesel liquid heater 25 l without diesel liquid heater Deutz TCD 2013L06...

Page 80: ...website www deutz com 50 l 50 l 4 Engine oil pan Deutz TCD 2013L044V Euro 4 1 13 5 l 13 5 l Check up the level of oil and fill up if necessary Deutz TCD 2013L064V Euro 4 Motor oils according to degre...

Page 81: ...o 80W 90 INATransmol80W 90 Transmission oils Viscosity class SAE In summer 90 from minus 12 to plus 38 In winter 80W from minus 26 to plus 21 All season 75W 80 from minus 40 to plus 30 75W 90 from min...

Page 82: ...ocated in the extreme lower position Drain used oil fill fresh oil up to the check filling hole level Drain rate 3 6 l 8 Rear axle equalizer bar housing of 3 axle automobiles 2 All season Transmission...

Page 83: ...2 0 l 4 0 l 2000 Change oil after running in rear axle Check up the level of oil and if necessary fill it up to the check filling hole level At that the hole shall be located in the extreme lower posi...

Page 84: ...81 99589 4704 dated 05 2002 under factory regulations of N ATF MAN 339 type D ATF MAN 339 type F MIL H 5606D USA Under classification ZF TE ML 09 Under classification General Motors ATF Dexron II III...

Page 85: ...11 oils of marks at ambient air temperature below minus 300 and 20 30 2005 at ambient air temperature below minus 200 to be replaced by oils VMGZ or VMGZ C spec 38 101479 85 or 10 MGE 10A Change oil...

Page 86: ...any Shell company Retinax HDX2 S2 Mobil company Mobilgrease Spesial S2 BP company EnergreaseL21M S2 Texaco company Molytex EP2 S2 Esso company Multi purpose Lithium 0 04 kg 0 12 kg 4 Disassemble hinge...

Page 87: ...EP3 Company BP Energrease LS EP2 Texaco company Multifak EP2 a Esso Beacon EP2 0 085kg 0 085 kg Lubricate the inner cavity of the intermediate support with a greaser located on the support cover until...

Page 88: ...m cylinder lower support 2 0 06 kg 0 12 kg Lubricate at assembly and repair upper support 1 0 06 kg 0 06 kg bracket journal 2 0 01 kg 0 02 kg A Lubricate with a greaser until fresh grease appears in c...

Page 89: ...pivot needle bearings 4 0 02 kg 0 08 kg Lubricate with a greaser until fresh grease appears in clearances 27 Spare wheel jack for trucks with spare wheel fastening on the dump platform 1 0 45 kg 0 45...

Page 90: ...haft bushes front 2 0 025 kg 0 05 kg A Lubricate with a greaser Driving axles expansion cam shaft bearings 40 2C for 2 axle 4 2 trucks 4 0 015 kg 0 06 kg for 3 axle 6 4 trucks 8 0 015 kg 0 12 kg Lubri...

Page 91: ...B company Petrosin Super Fluid J1703P Mobil company Hydraulic Brake Fluid Esso company Attas Brake Fluid CD 1 0 l 1 0 l A Check up the level of fluid and if necessary fill it up Change thee fluid one...

Page 92: ...EP2 0 01 kg 0 04 kg Lubricate with a greaser at assembly and repair During seasonal maintenance clean from used lubricant dirt rust and lubricate with a thin layer 40 Spring bolts spring suspension fo...

Page 93: ...bilgrease MP Mobilux EP2 EP3 Company BP Energrease LS EP2 Texaco company Multifak EP2 Esso company Beacon EP2 0 005 kg 0 03kg 45 Seat rest lever axis friction surfaces 8 0 005 kg 0 04 kg Lubricate fri...

Page 94: ...ds Obzor at ambient temperature below plus 50 Apply liquid Obzor only for goods supplied into national economy 10 l 10l Diesel fuel with content of sulphur not more than 0 5 Makes minus 35 at ambient...

Page 95: ...n address Speedometer indication on the moment of defect detection km Delivery date Date of putting into operation Routine maintenance carried out Date Run Date Run Date Run Date Run Defect descriptio...

Page 96: ...ent of diaphragm spring brake cylinders Front axle brake chamber bracket 110 140 Expansion cam supports 118 157 at upper arrangement of diaphragm spring brake cylinders Expansion cam sleeve 118 157 Ca...

Page 97: ...Driven cylindrical gear 450 600 Flanges 450 600 Driven gear and interwheel differential gear cups 210 260 Wheel gear covers 24 36 For 5 satellite wheel gear Wheel hubs 400 500 Intermediate axle drivi...

Page 98: ...rame 250 320 Steering gear connection ball pin nuts 160 200 Fastening nuts of drop arm on the sector shaft 400 440 Fastening nuts of diaphragm spring brake cylinders and fastening bolts of diaphragm s...

Page 99: ...in accessories Pre sale preparation works list Running in of the truck Truck operation peculiarities Preparation of the truck for operation Driving the truck and monitoring of its system and units ope...

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MAZ 534035, Operation Manual

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