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104

CONTENTS

Important ....................................................................................................... 3

Safety instructions ..................................................................................... 3

Precautions ................................................................................................ 3

Introduction ................................................................................................... 5

Automobile marking ....................................................................................... 6

Specifications ................................................................................................. 16

Controls and equipment of driver's and passenger's seats .............................. 24

Prestarting procedure ..................................................................................... 27

Automobile running-in .................................................................................. 27

Starting and shutting down the engine ........................................................... 28

Starting the engine .................................................................................... 28

Shutting down the engine ......................................................................... 29

Features of driving under different road, meteorological and climatic

service conditions .......................................................................................... 29

Maintenance of the automobile ..................................................................... 32

Daily maintenance .................................................................................... 33

Seasonal maintenance ............................................................................... 33

Before the summer season of operation ............................................... 33

Before the winter season of operation ................................................. 34

Engine ...................................................................................................... 34

Maintenance of the lubrication system ................................................ 37

Maintenance of the crankcase ventilation system ................................ 39

Maintenance of the fuel system ........................................................... 39

Maintenance of the engine cooling system .......................................... 44

Maintenance of the ignition system ..................................................... 47

Transmission ............................................................................................. 50

Maintenance of the clutch ................................................................... 50

Maintenance of the gearbox ................................................................. 51

Maintenance of the transfer box .......................................................... 53

Maintenance of the propeller shafts ..................................................... 54

Maintenance of the rear axle ............................................................... 54

Maintenance of the front axle .............................................................. 55

Chassis ...................................................................................................... 57

Towing hook ........................................................................................ 57

Maintenance of the suspension ............................................................ 57

Wheels, tyres ........................................................................................ 58

Wheel hubs .......................................................................................... 61

Control systems ........................................................................................ 63

Maintenance of the steering gear ......................................................... 63

Brake systems ...................................................................................... 66

Maintenance of the service brakes ................................................... 66

Maintenance of the parking brake ................................................... 71

Electrical equipment ................................................................................. 73

Maintenance of the alternator .............................................................. 73

Maintenance of the storage battery ...................................................... 73

Maintenance of the starter ................................................................... 74

Lighting system, light flashers and horn ............................................... 75

Overload breakers ................................................................................ 77

Instrumentation and warning flashers .................................................. 77

Содержание 2001 ???-2206

Страница 1: ...Open Joint Stock Company Ulyanovsky Avtomobilny Zavod Automobiles ÓÀÇ 3741 ÓÀÇ 3962 ÓÀÇ 3909 ÓÀÇ 2206 ÓÀÇ 3303 and Their Modifications Instruction Manual 2001 ...

Страница 2: ... and necessary operating and maintenance instructions Since efforts are continually made to improve the reliability and performance of the automobiles minor changes may be introduced without special notice We wish You a good trip ÎÀÎ Óëüÿíîâñêèé àâòîìîáèëüíûé çàâîä 2001 ...

Страница 3: ...t wash it off right away with warm water and soap never spill liquids in the interior or indoors Should spillage occur wash off the spilled place with water and ventilate it take off the spilled clothes wash and dry it outdoors wet with kerosene the carbon of leaded gasoline when scraping it off to avoid penetrating of toxic particles of carbon into the respiratory organs 3 To avoid scalding open ...

Страница 4: ... rods steering mechanism oil sump eliminate deffects if required 10 To avoid heavy loads on the axle differential do not allow a prolonged slipping 11 Use the warmth keeping hood for radiator shell to provide the proper temperature condition for engine at an ambient tempera ture below 0 C 12 When the automobile is to be operated at a temperature below 30 C do not fail to disengage the front axle 1...

Страница 5: ...ompartment The vehicles are intended for passenger cargo transportation The vehicles ÓÀÇ 39625 and ÓÀÇ 396259 are manufactured on the base of the vehicles ÓÀÇ 3962 and ÓÀÇ 39629 correspondingly and have the same specifications ÓÀÇ 3909 ÓÀÇ 39099 Fig 3 special vehicles with wagon type body divided into a two seat cab a five seat passenger compartment and a cargo compartment The vehicles are intende...

Страница 6: ...re equipped with the engine of increased power AUTOMOBILE MARKING The identification number Fig 9 is indented on the name plate and on the roof channel on the automobiles ÓÀÇ 2206 ÓÀÇ 3962 and their modifications at two points à and á on the automobiles ÓÀÇ 3303 ÓÀÇ 3741 ÓÀÇ 3909 ÓÀÇ 33036 ÓÀÇ 39094 ÓÀÇ 39095 and their modifications at one point á The nameplate is fixed on the upright side of the ...

Страница 7: ...7 Fig 1 Overall dimensions ap proximately of automobiles ÓÀÇ 3741 ÓÀÇ 37419 Dimensions aregivenforref erence ...

Страница 8: ...8 Fig 2 Overall dimensions ap proximately of automobiles ÓÀÇ 3962 ÓÀÇ 39629 Dimensions aregivenforref erence ...

Страница 9: ...9 Fig 3 Overall dimensions ap proximately of automobiles ÓÀÇ 3909 ÓÀÇ 39099 Dimensions aregivenforref erence ...

Страница 10: ...10 Fig 4 Overall dimensions ap proximately of automobiles ÓÀÇ 2206 ÓÀÇ 22069 Dimensions aregivenforref erence ...

Страница 11: ...11 Fig 5 Overall dimensions ap proximately of a u t o m o b i l e s ÓÀÇ 3303 ÓÀÇ 33039 Dimensions are given for refer ence For automo biles with high sides ...

Страница 12: ...12 Fig 6 Overall dimensions ap proximately of a u t o m o b i l e s ÓÀÇ 33036 Dimensions are given for refer ence For automo biles with wooden plat form and high sides ...

Страница 13: ...13 Fig 7 Overall dimensions ap proximately of automobiles ÓÀÇ 39095 Dimensions aregivenforref erence ...

Страница 14: ...14 Fig 8 Overall dimen sions approximately of automobiles ÓÀÇ 39094 Dimensions are given for reference ...

Страница 15: ...962 and their modifications á for automobiles ÓÀÇ 3303 ÓÀÇ 3741 ÓÀÇ 3909 ÓÀÇ 33036 ÓÀÇ 39094 ÓÀÇ 39095 and their modifications 2 chassis number 3 body cab number 4 nameplate I international code of manufacturer II descriptive part automobile model make III indicating part year of automobile manufacture and serial number of automobile ...

Страница 16: ...ht on platform kg not more 700 950 Seating capacity driver included 2 9 7 11 8 2 2 or 6 3 2 or 6 3 9 3 6 3 Permissible total tow weight kg 2720 2500 2820 2780 2650 3050 3050 3050 1 ÓÀÇ 39625 and ÓÀÇ 396259 9 persons driver included or 2 persons driver included and 850 kg cargo 2 Depending upon the version 3 Depending upon the complete equipment the platform could be equipped with a removable tarpa...

Страница 17: ... 760 830 650 660 770 700 Total tow weight kg not more with brakes 1500 1 without brakes 750 1 Minimum turning radius by track of front outer wheel relative to centre of turn m not more 6 3 7 0 Outer turning radius by point of front bumper max removed from centre of turn m not more 6 8 7 5 Maximum upgrade deg 30 Maximum depth of ford m 0 5 1 To tow a trailer at all times and on rugged ground is all...

Страница 18: ... 33039 33036 39094 39095 1 2 3 ENGINE Model 4178 4218 4 stroke carburettor type Cylinder number four Cylinder order in line vertical Firing order 1 2 4 3 Cylinder bore mm 92 100 Piston stroke mm 92 92 Displacement l 2 445 2 89 Compression ratio 7 0 7 0 Nominal power at crankshaft speed of 66 s 1 4000 min 1 kW hp to DIN 70020 57 4 78 63 2 86 1 When the tyres ß 245 1 are installed in service the max...

Страница 19: ...bination forced and splash Crankcase ventilation Closed Fuel system With forced fuel feed and fuel air mixture heating Fuel Gasoline with octane number 76 Cooling system Liquid closed forced circulation TRANSMISSION Clutch Type of clutch Dry single disk Type of drive Hydraulic Gearbox Four speed gear ratios 1st speed 3 78 3rd speed 1 55 2nd speed 2 60 4th speed 1 00 Reverse 4 12 Optional version o...

Страница 20: ...39099 2206 22069 39095 3303 33039 1 2 3 CHASSIS Suspension type four longitudinal semielliptic springs operating in conjunction with four hydraulic telescopic shock absorbers Wheels and tyres wheels Steel with deep well one piece rim size 6L 15 or 6J 16 depending on tyres in use tyres Tubed 215 90 15Ñ ß 245 1 225 75R16 108Q Ê 153 215 90R15C 99N ßÈ 357À 225 75R16 ß 435À 225R16C Ê 151 or Ê 152 225 7...

Страница 21: ...echanical drive ELECTRICAL EQUIPMENT Wiring Single wire with ground returned minus Rated voltage V 12 Overload breakers fuse Unit provided with three fuses 10À each in horn instrument heater motor and windshield wiper circuits thermal cut out Button in lighting circuit ADJUSTMENT DATA Valve to rocker clearance on cold engine at 15 20 C mm for exhaust valves of No 1 and No 4 cylinders 0 30 0 35 for...

Страница 22: ...ot more 10 1 2 3 Models of Automobiles ÓÀÇ Tyre Inflation Pressure kPA kgf cm2 3741 3962 3909 2206 3303 33036 39094 37419 39629 39099 22069 33039 39095 front wheels ß 245 1 0 19 1 9 0 19 1 9 0 22 2 2 0 20 2 0 0 19 1 9 ßÈ 357À Ê 151 Ê 152 0 23 2 3 0 22 2 2 0 24 2 4 0 23 2 3 0 22 2 2 Ê 153 ß 435À 0 23 2 3 0 22 2 2 0 24 2 4 0 23 2 3 0 22 2 2 0 25 2 5 rear wheels ß 245 1 0 23 2 3 0 19 1 9 0 23 2 3 0 2...

Страница 23: ...4 13 2 13 4 14 4 14 6 Engine lubrication system without oil radiator reservoir 5 8 Gearbox 1 0 Transfer box 0 7 Front and rear axle housing each 0 85 Steering gear case 0 25 Shock absorbers each 0 320 Clutch hydraulic system 0 18 Hydraulic actuated brake system 0 52 0 55 on automobiles ÓÀÇ 33036 ÓÀÇ 39094 ÓÀÇ 39095 Windshield washer reservoir 2 1 On automobiles ÓÀÇ 39094 ÓÀÇ 3303 ÓÀÇ 33039 only ma...

Страница 24: ...ering wheel is rotated in the reverse direction when the automobile recovers from a turn 3 horn 4 steering wheel 5 sun visor 6 dome lamp 7 grab handle 8 ash tray 9 door handle 10 gearshift lever Fig 12 11 front axle cont rol lever Fig 12 has two positions forward the axle is ON the backward the axle is OFF 12 transfer box shift lever Fig 12 has three positions forward direct range is ON Fig 11 Con...

Страница 25: ...rument panel Fig 13 14 mounts 1 pushbutton of thermal cut out in the lighting circuit 2 main light switch has three positions first all lights are OFF second the marker lights are ON third the marker lights and headlamp low or high beam are ON depending on the position of the foot operated dimmer switch 3 ignition switch Fig 12 4 speedometer with trip odometer The high beam warning lamp blue 1 is ...

Страница 26: ... system oil pressure gauge with low oil pressure built in warning lamp 18 parking brake warning lamp 1 On the automobiles ÓÀÇ 33036 ÓÀÇ 39094 ÓÀÇ 39095 the high beam warning lamp oil emergency pressure warning lamp and radiator coolant emergency overheating warning lamp are located in the warning lamp unit refer to positions 21 22 23 Fig 15 2 Installed depending upon a complete equipment of the au...

Страница 27: ...automobiles from the Manufacturer to Dis tributors Dealers it is necessary to carry out all the operations laid down in the section Daily Maintenance The automobile service life depends to a greater extent on the operating mode during the initial service period The running in kilometrage is equal to 1000 km AUTOMOBILE RUNNING IN During the running in period observe the following rules 1 Do not ove...

Страница 28: ...coolant level in the engine cooling system fuel level and oil in the engine crankcase Prime the carburettor by means of the fuel pump hand primer Starting from Cold at 0 Ñ and Above Shift the gearshift lever in the neutral Press the throttle valve control pedal the accelerator pedal several times Disengage the clutch and switch on the ignition and the starter Switch on the starter for 5 s maximum ...

Страница 29: ...er specified for starting the engine at temeratures of 0 Ñ to 20 Ñ Starting from Hot When starting from hot do not push the choke valve control knob in and the throttle valve control pedal is not be sharply depressed as it results in overenrichment of the air fuel mixture and the engine fails to be started To eliminate the overenrichment blow through the engine cylinders with air for which purpose...

Страница 30: ...g do not allow slipping the wheels as it decreases the efficiency of braking in comparision with braking during rolling and increases wear of tyres Besides sharply and heavy braking could provoke skiding of the automobile When the automobile is to be operated on off the road sand mud snow etc slippery roads steep up grades more than 15 Ñ and on other complicated sections of roads do not overload t...

Страница 31: ...ed Clay and Gumbo Roads When moving on clay and gumbo roads after pouring rain the automobile could slip off the road Be careful when choosing a direction of motion Choose relatively level grounds when moving on rut roads if possible It is very difficult to drive the automobile on very wet graded earth roads provided with steep grades and deep cuvetts On these roads drive carefully on the crest of...

Страница 32: ... times and brake partly several times for drying the clutch facings and brake shoe linings If the engine is stopped when fording try to crank up the engine by means of the starter two three times If the engine is not started the automobile is to be immediately evacuated out of water by all means If some water is penetrated to the assemblies of the automobile it is not recommended to run the automo...

Страница 33: ...from cooling system after each run 6 Fill up the windshield washer reservoir Use water for filling up in summer 7 If the automobile was operated on extremely dusty roads as well as after fording and negotiation of natural road sections and off road sections covered with mud wash the filter element of the air cleaner or replace it 8 If the automobile was operated on extremely dusty or dirty roads w...

Страница 34: ...shield wiper for 15 20 min the blades should be swung out of the way ENGINE The automobile is equipped with the four cylinder engine with upper valve arrangement which is shown in Fig 16 17 Check and if required tighten the engine mounting Fig 18 Tighten the engine mounting bolt nuts until distance sleeves touch the washers Tighten the cylinder head fastening nuts after completion of the automobil...

Страница 35: ...er set a required clearance by means of the feeler gauge Then holding the adjusting screw with the Fig 16 Engine l h view 1 fine fuel filter 2 oil filler cap 3 oil dip stick 4 rocker arm cover 5 cylinderhead 6 ignition distributor 7 starter 8 clutch housing 9 clutchhous ing lower part 10 fuel pump 11 engine mounting bracket Fig 17 Engine r h view 1 cylinder block drain cock 2 cylinder block 3 inle...

Страница 36: ...inder head nuts Fig 18 Engine mounting 1 protective cover 2 washer 3 upper pad 4 seat 5 lower pad 6 distance sleeve 7 washer 8 bolt Fig 20 Timing marks on crankshaft pulley 1 index pointer 2 mark for setting TDC 3 mark for ignition timing ...

Страница 37: ...h heavy load and at a high engine crankshaft speed also cut in the cooler independing on an ambient temperature The level of oil in the engine crankcase should be in register with the mark Ï on oil dipstick 3 Fig 16 Measure the oil level 2 3 min after shutting down a warmed up engine Drain oil from the engine crankcase right after the end of the trip when the oil is still hot This insures rapid an...

Страница 38: ...ropped to 118 kPa 1 2 kgf cm2 When driving the automobile watch the functioning of the oil pressure transmitters The low oil pressure warning transmitter must operate at an oil pressure drop in the system down to 39 78 kPa 0 4 0 8 kgf cm2 The low oil pressure warning lamp may light when the hot engine is running at an idling speed but the lamp must go out immediately with an increasing crankshaft ...

Страница 39: ...ulator Check tightness between the case and cover plate when assembling the vacuum regulator Maintenance of the Fuel System Fuel tanks To wash the fuel tanks remove them from the automobile Flush the fuel tanks with clean gasoline Fuel filter settler Periodically drain sediment and water through the drain hole stopped with a plug 8 Fig 25 To remove the filter element for washing unscrew the unions...

Страница 40: ...lement Carburettor The carburettor K 151B is installed on the engine 4178 and the carburettor K151E is installed on the engine 4218 The carburettors are identical in design except for some jets The main jets are indicated in the Appendix 3 Maintenance of the carburettor includes periodic checks and adjustment of fuel level in the float chamber adjustment of the crankshaft slow idling setting check...

Страница 41: ... of the screw 1 Fig 28 when the engine is Fig 26 Fuel pumps of Á9Â type à inspection hole 1 casing 2 pull rod 3 seal 4 washer 5 14 springs 6 diaphragm 7 discharge valve 8 gauze strainer 9 gasket 10 cover 11 screw 12 exhaust valve 13 upper casing 15 rocker arm 16 camshaft eccentric 17 rocker arm shaft 18 hand primer lever shaft 19 hand primer lever The pumps 2105 1106010 50 or 900 1106010 could be ...

Страница 42: ... the filter element with water adding syntetic washing agent and then rinse it wring gently out and dry blow it out or clean by shaking off For replacing or cleaning the filter element proceed as follows loosen bolts 8 Fig 29 and yoke 2 shift clamps 9 take away cover 6 with filter element 5 take away yoke 10 and filter element from frame Assembly the air cleaner in the reverse order Never use the ...

Страница 43: ... Adjust the throttle full opening and the pedal position by turning the lever 4 Fig 31 on the pedal shaft For adjustment carry out the following disconnect the spring 11 release the locknut 5 on the pedal shaft set the pedal against the stop to the toeboard the position corresponding to the throttle full opening Holding the lever 4 in the position of the throttle full opening Fig 30 Manifold heat ...

Страница 44: ...oolant At ambient air temperatures below 40 C fill the system with low freezing fluid ÎÆ 65 Ëåíà or ÒÎÑÎË À65Ì If the above mentioned grades of coolant are not available You may use other coolant recommended by the automobile dealer Fig 32 Engine cooling system 1 heater cock 2 passenger compartment heater radiator 3 cylinder block head 4 gasket 5 coolant channels between cylinders 6 two valve ther...

Страница 45: ...rably decreases wear of the engine and cuts down fuel consumption The recom mended temperature is maintained by means of an automati cally operated thermostat and the shutters controlled by the automatically operated thermostat and the shutters controlled by the driver In cold weather we recommend to encase the cooling system for warmth keeping The coolant temperature gauge located on the instrume...

Страница 46: ...ing the coolant remove the radiator cap and open the cock When draining the coolant from the engine cooling system drain also the fluid from the heating system through the cock 15 Fig 32 located on the inlet manifold of the cab heater radiator Access to the cock is from the front from below of the automobile Notes 1 On some automobiles the engines 4178 are installed with feeding coolant to cylinde...

Страница 47: ...imultaneously when switching into emergency operation switch off the system of idling speed economizer for which purpose connect by means of one of the hoses unions 1 and 2 Fig 36 of the carburettor between themselves missing the electromagnetic valve Otherwise the engine could be stopped when the throttle pedal is released fully Fig 35 Diagram of transistor ignition system 1 ignition coil 2 trans...

Страница 48: ...ing the ignition timing proceed as follows 1 Set the piston of No 1 cylinder at the TDC on the compression stroke until the timing hole on the crankshaft pulley gets in register with the timing pointer on the timing gear cover 2 Remove the cap from the magnetic pickup 3 Make sure that the contact segment of the runner is set against the cap terminal marked with numeral 1 4 Loosen the bolt with the...

Страница 49: ... short time detonation is heard before a speed of 55 60 km h is reached it means that the ignition timing is set correctly In case of a heavy detonation turn the magnetic pickup and distributor unit body counterclockwise through 0 5 1 0 division on the octane selector scale Each division of the scale corresponds to a change of the ignition timing by 4 C in the degrees of the crankshaft angle If th...

Страница 50: ...ovided with the central pressure spring of the diaphragm type The clutch consists of the pressure plate with the cover plate and of the pressure disk diaphragm spring which tabs function as release levers driven plate with linings and torsional vibration dampers Fig 39 Clutch 1 clutch housing lower part 2 flywheel 3 driven disk 4 pressure plate 5 front bearing 6 crankshaft 7 input shaft 8 needle b...

Страница 51: ...5 20 mm below the upper edge of the reservoir Perform adjustment of the clutch release pedal by changing the length of the master cylinder pushrod 2 Fig 40 Perform adjustment of the pedal free travel 35 55 mm by changing the length of the slave cylinder 9 pushrod 12 The clutch with the central diaphragm spring needs no adjustment of free travel The free travel 5 30 mm is main tained by the clutch ...

Страница 52: ...ure spring 12 pushrod 13 fork 14 coupling Fig 41 Gearbox plugs 1 filler hole plug 2 drain hole plug Fig 42 Gearbox control linkage 1 gearshift lever 2 gearshift lever boot 3 selector lever 4 shift lever 5 vertical shift rod 6 intermediate shift lever 7 intermediate selector lever 8 horizontal selector rod 9 shift lever 10 selector le ver 11 horizon tal shift rod 12 i n t e r m e d i a t e bracket ...

Страница 53: ...e intermediate shift lever 6 does not rest against the frame cross member and the front swivel splash guard when the latter is opened There should be a clearance of 2 3 mm between them when the reverse gear is shifted in Maintenance of the Transfer Box Maintenance of the transfer box in service comes to checking the oil level and changing oil at intervals specified in Lubrication Table and also to...

Страница 54: ...eals and could force the plug of the slip yoke Use a special tip to be fitted on the grease gun to lubricate the propeller shaft The tip is available in the driver s tool kit Fig 44 Rear propeller shaft 1 grease fitting for lubricating of splined joints 2 grease fitting for lubricating of joint needle bearings Maintenance of the Rear Axle Maintenance of the rear axle comes to maintaining the level...

Страница 55: ...ngaging the front wheels remove hub cap 21 and by screwing out the bolt 19 set coupling 18 in position in which a circular indicating groove a on the surface of coupling is arranged in one plane with the face of flange 17 Fig 46 view III Having set coupling 18 in a required position screw on hub cap 21 For engaging the wheels screw in bolt 19 as far as it will go Be sure to engage and disengage bo...

Страница 56: ...ease fitting 11 set pin 12 circlips 13 journal 14 wheel hub 15 gasket 16 lock washer 17 driving flange 18 coupling 19 coupling bolt 20 lock ball 21 protective cap 22 nuts 23 bolt 24 thrust washer 25 hub bearings 26 spacing ring 28 lower cover plate 29 thrust washer 30 kingpin bush ing 31 adjusting shims 32 seal internal ring 33 partition ring 34 seal external ring 35 inner sealing ring 36 outer se...

Страница 57: ...the towing hook comes to periodically cleaning of dirt checking it for reliable attachment to the rear cross member and lubricating according to the directions of Lubrication Table Fig 47 Towing gear of rigid type 1 case 2 pawl 3 catch 4 cotter pin 5 chain Maintenance of the Suspension Periodically check the condition and attachment of the springs and shock absorbers Fig 48 To prevent corrosion an...

Страница 58: ...pect the wheels and tyres for proper condition check the wheel attachment nuts for tightening and the tyre inflation pressure To provide for uniform tightening of the nuts tighten them alternately every second one Before every run check the condition of tyres and eliminate detected defects Periodically check the tyre inflation pressure and bring it to normal if required Check inflation pressure in...

Страница 59: ...ling ring 15 seal 16 upper sealing ring 17 seal holder 18 reservoir nut 19 washer 20 protective ring 21 rod seal Fig 48 Front suspension 1 spring front hanger 2 frame 3 spring 4 cover plate 5 buffer 6 buffer liner 7 shock absorber 8 shock absorber bracket 9 spring rear hanger 10 rubber pad 11 bracket cover 12 shock absorber pin 13 rubber bushings 14 U bolt liner 15 contracting bolt 16 U bolt 17 yo...

Страница 60: ...3909 ÓÀÇ 2206 ÓÀÇ 33036 ÓÀÇ 39094 ÓÀÇ 39095 Á automobile ÓÀÇ 3303 1 spare wheel 2 sector 3 carrier 4 nut 5 bolt 6 washer 7 bracket Fig 51 Wheel toe in Fig 52 Steering rod end 1 locknut with l h thread 2 adjusting sleeve 3 locknut with r h thread 4 joint 5 grease fitting ...

Страница 61: ...etect play in bearings Pay special attention to correct adjustment of the wheel hub bearing on a new automobile Change grease in compliance with Lubrication Table For changing grease remove the hub from the spindle remove old grease and thoroughly wash the bearings and lubricate them Apply 10 15 mm grease between the bearings Do not apply too much grease to the hubs to avoid its ingressing in the ...

Страница 62: ...he wheel to allow the roller to assume correct position on races of the bearings 7 Back off the nut 1 4 to 1 3 of a turn 1 5 2 flats and install the locking washer screw in and tighten the locknut Replace the washer if some cracks on the tabs of the locking washer are detected 8 Check adjustment of the bearings after tightening the lock nut If the adjustment is correct the wheel should rotate free...

Страница 63: ... brake drums CONTROL SYSTEMS Maintenance of the Steering Gear For maintenance of the steering gear timely tighten up the bolts attaching the steering gear case to the bracket check the pins of the steering rods the steering knuckle lever steering arm for proper attachment Check the steering wheel play adjust the steering mechanism lubricate timely the steering rod joints and add oil into the steer...

Страница 64: ...ng mechanism make sure that the bolts securing the steering gear case are properly tightened and the joints of the steering linkage are in serviceable condition Start the adjustment procedure by checking the worm bearings for axial play To this end grasp the steering column so that the thumb is in contact with the end face of the steering wheel hub and turn the steering wheel in either direction t...

Страница 65: ...teering gear case and the case lower cover When the worm bearings are tightened correctly the force required for turning the steering wheel without the steering arm shaft should be in a range of 2 2 4 4 N 0 22 0 45 kgf Adjust the meshing of the roller with the worm without removing the steering mechanism from the automobile having only disconnect the drag link from the steering arm by shifting the...

Страница 66: ...uum booster 21 pushrod fork Brake Systems Maintenance of the Service Brakes Periodically check the fluid level in the brake master cylinder reservoirs 16 Fig 60 and top up if required The level should be 15 20 mm below the filling hole upper edges Make sure of the hydraulic brake system tightness Check the pipelines for condition and reliable attachment to the frame and rear axle Do not operate th...

Страница 67: ...entric until the wheel starts rotating freely without brushing of the drum against the brake shoes 5 Similary adjust the drum to shoe clearances in the remaining brakes When adjusting the brakes of the front wheels and the front shoes of the rear wheel brakes rotate the wheel forward When adjusting the rear shoes of the rear wheel brakes rotate the wheel backward For reducing the clearance turn th...

Страница 68: ...cylinder 4 bleeder valve 5 coupling 6 shoe return spring 7 brake shoe lining 8 brake shoe 9 boot 10 piston 11 sealing rings 12 piston spring 13 adjusting eccentric 14 shoe anchor pin 15 nut 16 coupling bolt 17 gaskets 18 support bushing 19 adjusting eccentric bolt 20 washer ...

Страница 69: ...ove the cap from the by pass valve of the brake master cylinder or from the pressure regulator and put the end of a rubber hose about 400 mm long on the by pass valve Dip the other end of the hose in a glass vessel of at least 0 5l capacity half filled with brake fluid Fig 63 4 Screw out the by pass valve through 1 2 3 4 of a turn then press the brake pedal several times Depress the pedal quickly ...

Страница 70: ...screw out the by pass valve of the r h or l h wheel brake cylinder of the rear brakes smoothly press the brake pedal until the warning lamp on the instrument panel goes out if the warning lamp flashes this means that the pistons of the warning device are passed over the neutral position and it is necessary to repeat the operation by unscrewing the by pass valve of the front wheel screw in the by p...

Страница 71: ... brake lever is in the third or fourth notch of the sector 3 4 clicks Do not allowed to check the parking brake for proper condition when starting away from rest or with automobile in motion Check the parking brake only on a downhill Increased travel of the parking brake lever in the service period may be caused either by large clearance between the brake shoes and drum in which case adjust this c...

Страница 72: ...72 Fig 64 Parking brake linkage 1 linkage lever 2 rod 3 bracket 4 cable 5 protective tube 6 protective tube bracket 7 cable fork 8 lever 9 parking brake drum 10 adjusting screw 11 warning lamp switch ...

Страница 73: ...gulator and eliminate the defect The built in integral voltage regulators are not repaired In case of breakage of the regulator replace it for the regulator of the same type Periodically check the brush assembly and the contact part of the integrated voltage regulator for proper condition To do this remove the alternator 665 3701 from the automobile and remove the brush assembly on the alternator ...

Страница 74: ...ly charged battery Battery discharged by 25 50 1 30 1 26 1 22 1 28 1 24 1 20 1 27 1 23 1 19 1 26 1 22 1 18 1 23 1 19 1 15 Do not allow discharging the battery under a heavy load current for a prolonged period of time when starting cold engine in winter because it could provoke curling of electrodes falling out of active material and reduces service life of the storage battery Carefully prepare the...

Страница 75: ...ning clutch of the starter could be failed if the starter is keeping on after starting the engine 2 Do not wash the starter covers and drive with gasoline or kerosene to avoid washing out grease out of bronze graphite oilless sliding bearings Lighting System Light Flashers and Horn Maintenance of the headlamps amounts to their aiming and replacing defective lamps cleaning of dust from the headlamp...

Страница 76: ...ond headlamp in the same manner ensuring that the upper edges of concentrated lights are at the same height 5 Fasten the rims Adjust the fog lampsthat the area of concentrated light on the aiming screen or the wall is located as indicated in Fig 67 For replacing the fog lamp bulbes remove the cover of the bulb holder by turning it counterclockwise and take out the bulb Front headlamps rear lamps b...

Страница 77: ...kers The circuits of the instruments horn heater motors and windshield motor are protected by fuses The fuse unit Fig 68 provided with three fuse 10 A each is located under the instrument panel on the l h pillar of the door aperture The fuse 1 protects the fog lamp circuit refer to Fig 13 14 Before replacing the worn out filament of the fuse link or before switching on the thermal pushbutton cut o...

Страница 78: ...wrench or hexagon wrench to avoid damage of the transmitter body Do not allow a drop of the coolant level in the radiator as it may cause failure of the temperature transmitter Check the coolant temperature gauge for proper reading once a year To do this immerse the transmitter into hot water and measure its temperature by means of the test thermometer Check the oil pressure gauge and oil emergenc...

Страница 79: ... a nipple When rocking the lever 8 press the handle 12 Fig 69 Grease plunger gun 1 head 2 spring 3 ball valve 4 body 5 plunger 6 gasket 7 piston 8 lever 9 gun cylinder 10 rod 11 cover 12 handle 13 stud Fill the gun with grease in the following sequence 1 Screw the cylinder 9 out of the body 4 2 Pull the piston 7 inside of the cylinder through 1 5 of strokes by means of the handle 12 3 Using a wood...

Страница 80: ...ve to the jack handle 6 so that the latch projection enters the tooth space of the ratchet wheel 7 4 By stroking the tyre iron inserted on the hole of the jack handle lift the automobile wheel to a required height For jacking down the wheel throw over the jack latch to the r h side and by stroking the tyre iron jack down the wheel After work is over turn the internal 3 and external 2 screws in the...

Страница 81: ...ding seat The passenger compartment of the automobile ÓÀÇ 3909 is equipped with a demountable folding table two single and one triple seats The passenger compartment is divided from the cargo compartment by a partition with the sliding glasses The passenger compartment of the automobile ÓÀÇ 39094 is equipped with a triple cushioned seat The cab of the automobile ÓÀÇ 39095 is equipped with a hinged...

Страница 82: ...s in the front and rear parts of the body side panels Body Cab Heating The cab heating and defrosting of the windshield are effected through the heater radiator Fig 71 connected into the engine cooling system in parallel with the main radiator The warm air is admitted either for demisting the windshield completely or for heating the cab and demisting the windshield depending upon the positions of ...

Страница 83: ...62 The following sanitary equipment could be placed in the sanitary compartment of the automobile Fig 73 Unified stretcher 4 Sanitary bag 1 Bag with oxygen inhaler ÊÈ 3Ì 1 Bag with feeding cup 1 Reservoir for drinking water 1 Urine receiver 1 Bed pan 1 Wire splints 2 Splints 2 Fig 72 Heating of sanitary and passenger compartments I cold air II warm air 1 louvers in body side panel 2 air duct housi...

Страница 84: ...s for the sanitary bag with the oxygen inhaler and feeding cup are also secured to this partition The box provided with three pigeon holes for bed pan urine receiver and suspension straps is located on the body floor on the left in the rear part of the sanitary compartment The splints are secured with two straps on the body side panel in the r h corner The guides on the body floor make easy moving...

Страница 85: ...fit the suspension straps Fig 74 When carrying patients accommodated on seats remove all the stretchers and hinge out the side seats Put a pair of the stretchers together tie up with straps and place along the sanitary compartment under the hinged out seats Remove the suspension straps roll them up and place into the box Then check the hinged seats flexible rails and footsteps of the body rear end...

Страница 86: ...ers for 15 20 min in this case the blade and lever assemblies of the windshield should be swung out of the way and the blade and lever assemblies of the rear window should be removed After 18 24 months of run and also if required replace blades and rubber tapes Washer Fig 76 The electric washer is intended for high speed cleaning the windshield Fill up the washer reservoir with clean water in summ...

Страница 87: ...ing soft rags Upon washing wipe the body surfaces dry Do not use soda or alcaline solutions because the varnish coating could be become dull Avoid exposing the automobile to sunlight for a long time Never spill acids solutions soda brake fluids fuel and antifreezing agents on the painted surface of the body and rubber parts To take care of the body coatings use prophylactic polishing liquids Fig 7...

Страница 88: ...ow should be reverse to the direction of the hot water flow Also carry out external washing of the radiator Lubricate according to Lubrication Table locks hinges and catches of doors door check joints joints of windshield wiper blade control linkage bearings of windshield wiper and body cab heater motors LUBRICATION OF AUTOMOBILE Service life and trouble free operation of the automobile depend to ...

Страница 89: ...d from operation for a prolonged period of time it should be subjected to preservation for which purpose do the following 1 Carry out the scheduled maintenance 2 Wash the automobile and wipe it dry Touch up the paintwork wherever damaged 3 To protect the engine cylinders against corrosion pour 30 50 g of engine oil into the cylinders through the spark plug holes To insure uniform spreading of oil ...

Страница 90: ...Clue the clearances between the brake drums and backing plates with oiled paper 17 Protect the tyres and other rubber parts from action of direct sunlight 18 Put under the axles the metal or wooden props that the wheels would be raised above the surface Unload the springs for that put the wooden struts between the frame and axles The preservated automobile should be located in a clean ventilated r...

Страница 91: ...quired lubricate its metal parts 8 Check the tools and accessories if required wipe and lubricate them 9 Check the condition of tyres and other rubber parts 10 Eliminate the troubles detected during inspection Depreservation 1 Remove the preservative lubricant from the parts for which purpose wash them with kerosene or clear gasoline Remove the lubricant from areas which may come in contact with r...

Страница 92: ...W 30 Ì 6Ç 10Â SAE 10W 40 Transmission Oils ÒÑï 15Ê SAE 90 ÒÑï 10 SAE 75W Lubricant Greases Grease Ëèòîë 24 Lithium grease to NLGJ 3 Graphite powder Barbatia Grease 2 Fluids Shock absorber fluid ÀÆ 12Ò Shock absorber oil Spindle oil ÀÓ Shell Donax A Brake fluid Òîìü Ðîñà SAE 1703F DOT 4 Ðîñà 3 Ðîñà Äîò 4 Cooling fluid Shell safe ÒÎÑÎË À40Ì ...

Страница 93: ...93 Fig 77 Lubrication and tank chart of automobile ...

Страница 94: ...er1000 km If required top up Ì 6ç 12Ã1 or of run the subsequent Ñàì Îéë 4111 after 16000 km of run or Ñàì Îéë 4112 at seasonal maintenance Ñàì Îéë 4113 Ì 6ç 10Â Ì 4ç 6Â1 Ì 5ç 10Ã1 10 Engine oil filter 1 Every 8000 km of run Replace filter after running in 23 Distributor rotor bush 1 Motor oil Every 32000 km of run Lubricate with 4 or 5 drops before lubricating remove runner and filtz Ref Nos in Fi...

Страница 95: ... gun without forcing grease out 19 Front and rear propeller 4 Force grease through grease shaft joints fitting until it shows up from under all lips of cross seals 5 Cooling system pump 1 Every 16000 km of run Add as required bearings Heater motor Lubricate with thin layer bearings to 2 ÒÑï 15Ê ÒÀÏ 15Â every 32000 km Add as required or of run ÒÑï 15Ê and ÒÀÏ 15Â ÒÀÄ 17È ÒÀÄ 17È every 48000 km ÒÑï ...

Страница 96: ...un Lubricate through grease fitting of upper kingpin 11 Clutch release bearing 1 Pack grease cup to capacity 15 Parking brake 2 Clean of dirt before lubricating expander and adjuster mechanisms 16 Towing gear 1 Lubricate through grease fitting Lubricate latch and pawl axles as required 26 Front and rear wheel 4 Grease layer in bearings should hub bearings be 10 15 mm thick Space between rollers sh...

Страница 97: ...ls Door hinges As required Lubricate through grease fitting Door lock tongues sockets and latches hinges of Lubricate door checks 2 Steering wheel shaft 2 As required when bearings squeaking bearing and when disassembling Door locks Grease Ëèòîë 24 As required Lubricate Applay grease ÖÈÀÒÈÌ 201 at temperature below 40 Ñ 1 2 3 4 5 6 Grease Ëèòîë 24 Grease Ëèòà Grease Ëèòîë 24ÐÊ ...

Страница 98: ...à Ðîñà 3 Once in two years Add as required 27 Clutch release master 1 Òîìü Ðîñà Äîò 4 cylinder 21 Front and rear 4 Shock absorber fluid As required and when shock absorbers ÀÆ 12Ò spindle oil disassembling ÀÓ oil for hydraulic shock absorbers ÌÃÏ 10 6 Engine cooling system 1 Cooling fluids Change once in three Wash cooling system before with expansion tank ÎÆ 40 Ëåíà years or after 60000 km oil ch...

Страница 99: ...rts in accordance with the complete list The loading and unloading should be carried out by a crane with special grips in accordance with the scheme in Fig 78 On all transports the automobiles should be located so that the distance between the automobiles extrem points on the radiator side would be equal to 50 100 mm and on the other sides not less than 100 mm When transporting the parking brake o...

Страница 100: ...ith wooden wedges 300x160x80 nailed to the floor under wheeles Attach the tension wires to the towing hooks on the frame ahead and to the towing gear in rear part of the automobile After attaching seal the automobile Before air transporting the fuel tanks should be filled with fuel not more 75 of its capacity The automobile should be get into an airplane with the first gear of the gearbox and with...

Страница 101: ...Backing lamp À12 21 3 21 License plate lamp À12 10 10 Special mark lamp A12 10 10 Cab lamp A12 10 10 Rear fog lamp À12 21 3 21 Hand lamp À12 21 3 21 Instrument illumination dome lamp ÀÌÍ12 3 1 3 Upper beam warning lamp ÀÌÍ12 3 1 3 Oil emergency pressure warning lamp ÀÌÍ12 3 1 3 Coolant emergency overheating warning lamp ÀÌÍ12 3 1 3 Turn indicator warning lamp À12 1 1 Brake emergency condition warn...

Страница 102: ... axle pinion 16 22 Bolts attaching final drive gear to differential case 10 14 Spring U bolt nuts 9 0 10 Wheel attaching nuts 10 5 12 Bolts attaching front axle driving flanges and rear axle axle shafts 6 0 7 0 Nut attaching steering arm to shaft 20 28 Steering rod ball pin nuts 6 0 8 0 Steering rod locknuts 10 5 13 0 Ball support attachment bolts 3 6 5 0 Wheel hub bearing locknuts 5 0 7 0 Anchor ...

Страница 103: ... 5 cm3 min emulsion tube 85 1 5 cm3 min Second idling air jet 330 4 5 cm3 min 175 2 5 cm3 min Idling emulsion jet 280 3 5 cm3 min 175 2 5 cm3 min Transfer fuel jet 150 2 0 cm3 min 200 2 5 cm3 min Transfer air jet 270 3 5 cm3 min Notes Some jets of the carburettors Ê 151Â and Ê 151Å differ in rated capacity A value in brackets is indicated for the carburettor Ê 151Å The data sheet rated capacities ...

Страница 104: ... of the crankcase ventilation system 39 Maintenance of the fuel system 39 Maintenance of the engine cooling system 44 Maintenance of the ignition system 47 Transmission 50 Maintenance of the clutch 50 Maintenance of the gearbox 51 Maintenance of the transfer box 53 Maintenance of the propeller shafts 54 Maintenance of the rear axle 54 Maintenance of the front axle 55 Chassis 57 Towing hook 57 Main...

Страница 105: ...icating materials and special fluids 92 Lubrication table 94 Transportation 99 Appendix 1 101 Lamps employed on automobiles 101 Appendix 2 Torques for main threaded connections 102 Appendix 3 Main metering jets of carburettors K 151B and K 151E 103 Appendix 4 Wiring diagram of automobile ÓÀÇ 3741 in Insert Wiring diagram of automobiles ÓÀÇ 3962 ÓÀÇ 2206 ÓÀÇ 3909 in Insert Wiring diagram of automob...

Страница 106: ...FOR NOTES ...

Страница 107: ...essure transmitter 38 oil pressure transmitter 39 coolant temperature transmitter 40 coolant emergency temperature transmitter 41 transistor commutator 42 emergency vibrator 43 parking brake warning lamp switch 44 additional resistance 45 starter relay 46 carburettor electronic control solenoid valve 47 side repeater 48 carburettor solenoid valve 49 microswitch 50 53 spark plug 54 pickup distribut...

Страница 108: ...eater motor 42 heater resistor 43 heater switch 44 fuse 45 transistor commutator 46 emergency vibrator 47 alternator 48 oil emergency pressure transmitter 49 oil pressure transmitter 50 coolant temperature transmitter 51 coolant emergency temperature transmitter 52 auxiliary resistor 53 starter relay 54 carburettor solenoid valve 55 carburettor electronic control solenoid valve 56 microswitch 57 6...

Страница 109: ...y pressure transmitter 37 oil pressure transmitter 38 coolant temperature transmitter 39 coolant emergency temperature transmitter 40 transistor commutator 41 emergency vibrator 42 parking brake warning lamp switch 43 fuel level gauge switch 44 additional resistance 45 starter relay 46 carburettor electronic control solenoid valve 47 side repeater 48 carburettor solenoid valve 49 microswitch 50 53...

Страница 110: ...arning lamp 45 fog lamp switch 46 carburettor electronic control unit 47 cab dome lamp switch 48 heater switch 49 cab dome lamp 50 interior dome lamp 51 alternator 52 oil emergency pressure transmitter 53 oil pressure transmitter 54 coolant temperature transmitter 55 coolant emergency temperature transmitter 56 transistor commutator 57 emergency vibrator 58 parking brake warning lamp switch 59 add...

Страница 111: ...lamp switch 46 cab dome lamp 47 carburettor electronic control unit 48 interior dome lamp switch 49 heater switch 50 fuel level transmitter selector switch 51 alternator 665 3701 or 16 3771 52 oil emergency pressure transmitter 53 oil pressure transmitter 54 coolant temperature transmitter 55 coolant emergency temperature transmitter 56 transistor commutator 57 emergency vibrator 58 parking brake ...

Страница 112: ...g lamp switch 46 cab dome lamp 47 carburettor electronic control unit 48 interior dome lamp switch 49 heater switch 50 fuel level transmitter selector switch 51 alternator 665 3701 01 52 oil emergency pressure transmitter 53 oil pressure transmitter 54 coolant temperature transmitter 55 coolant emergency temperature transmitter 56 transistor commutator 57 emergency vibrator 58 parking brake warnin...

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