MAZ TRUCK 5440E9

Operation Manual

Minsk 2013

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ATTENTION DRIVER!

MAZ truck you are just about to use is distinguished 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 transportation costs.

Before starting the truck operation, study this manual carefully.

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MAZ 5440E9 is 42 two-axle fifth wheel vehicle, designed for transportation of all kinds of cargo in road trains on motor roads where the axial loads stated in the technical characteristics are allowed.

The truck is designed for operation with semi-trailers that are equipped with Class H50 coupling king pin in compliance with the UNECE Regulation No. 55, pneumatic outlets, detachable electrical joints, antilock brake system (ABS) electric power, brake system pneumatic drive in compliance with the UNECE Regulation No. 13.

The vehicle is equipped with the engine OM 501 LA.V that conforms to the Euro V ecological standard, produced by Mercedes-Benz.

The information on power unit operation servicing (engine, clutch, and gearbox) is given in separate

manufacturer’s manuals additionally enclosed with the truck.

Figure 1 – Fifth wheel vehicle МАZ 5440Е9

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1 SAFETY REQUIREMENTS AND WARNINGS

Principal conditions for proper operation and reliable functioning of the vehicle are the knowledge of its units and aggregates construction, strict observation of the vehicle maintenance and care instructions.

Thus, prior to starting operating the truck, it is necessary to thoroughly study its design, instructions for operation, maintenance and care included into the present booklet, paying special attention to the “Truck Operation Peculiarities” section.

1.1 Claim form is given in Appendix 1. 1.2 During the truck running-in (first 4500 km of the run) it is necessary to strictly observe the rules laid

down in the “Truck running-in” section because its further performance greatly depends upon how properly the components will bed in during the initial period of operation.

1.3 Lubrication of the truck units and aggregates is to be executed in accordance with the “Lubrication chart” of this Manual. Application of contaminated or non-recommended grades of lubricants and oils is prohibited.

1.4 Truck movement is prohibited if the pressure in the air brake circuits is less than 550 kPa, i.e. until the warning indicators in the corresponding brake circuits go out.

1.5 When starting the movement of a truck on a slippery road engage cross-axle differential blocking. After overcoming such part of the road unblock the differentials. Turn of the truck with blocked differentials is prohibited.

1.6 During the truck movement watch the readings of the control lamps and indicators. 1.7 Running downhill with stopped engine and disengaged gearbox is prohibited in order to avoid

steering booster cutoff and to exclude air replenishment of the brakes actuator receivers. 1.8 While running downhill exclude truck movement at the revolutions higher than allowed, i.e. the

tachometer pointer must not enter the red zone of the scale. 1.9 Operation of the truck with a defective or failed steering booster is prohibited. During the truck

movement the key is not to be pulled out of the starter actuator lock in order to avoid steering column blocking and engine cutoff.

1.10 In order to avoid steering booster pump breakdown, steering wheel is not to be kept in the extreme positions (at maximum turn of the operated wheels to the left or to the right) more than 5 sec.

1.11 On parking places switch off the batteries by means of batteries switch button. In case of long-term parking (more than 3 days) a jumper should be taken off the battery. It is prohibited to connect 12V electrical appliances (radio recorders, receivers etc.) to the battery.

1.12 It is necessary to follow the scope and periodicity of the truck maintenance, stated in this Manual. 1.13 Power unit service works are stated in a separate manual. 1.14 Power unit maintenance is to be carried out on a level ground with a cab completely lifted. It is strictly forbidden to stand under the cab that is not fully lifted. 1.15 Cab lifting is to be carried out on an even level ground. The vehicle is to be braked by a parking

brake. Before lifting the cab the lever of the gear box must be moved to the neutral position, the doors must be closed and front facing of the cab must be opened. It is forbidden to stand in the zone of the cab tilting.

1.16 Lifting and lowering of the cab at the working engine are prohibited in order to avoid spontaneous engagement of the gear box and, as a result, start of unauthorized movement of the truck.

1.17 When washing the truck, one should avoid directing the water jet to the electrical equipment and electrical wires connections.

1.18 Do not check the operability of the system and electrical equipment circuits with the help of megaohmmeter or a lamp fed from a source with a voltage higher than 24V.

1.19 Do not cut off the wires from the generator and battery terminals while the engine is working. 1.20 Do not allow polarity reversal when connecting the storage batteries to the truck board system. 1.21 While carrying out welding operations on the truck the batteries must be disconnected and

electrical wires and conduits of brake actuators must be protected from high (higher than 90°С) temperatures and weld spatters.

1.22 When the road-train fifth wheel truck, equipped with the rear wheels composite fenders, ascends a ramp, the upper part of the fenders is recommended to be removed.

1.23 Starting of the truck engine from an external source or using of the truck board system as an external source for starting of another truck are prohibited in order to avoid the breakdown of electronic control units.

1.24 After lowering the cab make sure that locking mechanisms are locked.

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1.25 The polarity of the batteries is to be strictly observed in order to avoid the breakdown of the generator:

– minus (–) battery terminal through the right engine support to the truck body; – plus (+) battery terminal through the battery switch to the starter terminal (plus). 1.26 While mounting electrical equipment onto the truck, when carrying out the works under the truck,

on the engine with the cab lifted, while hand cranking (in case the starter drive gear teeth are stopped by the engine flywheel crown, etc.), in case of emergency on the truck (short circuit, electrical wire ignition, etc.) the batteries should be disconnected.

1.27 Engine start with the cab lifted is prohibited. In case there is a necessity to start the engine with a lifted cab for carrying out adjustments and repair works it is necessary to make sure that gear box is in neutral position. Engine starting is to be fulfilled with the observation of the «Safety rules».

1.28 In order to avoid untimely failure of the pressure regulator with the adsorber it is necessary to watch the airtightness of the truck pneumatic systems.

1.29 During the movement of the vehicles (road trains) along the roads of general use, as well as along the streets of cities and settlements the drivers should follow the requirements of the normative documents valid for the country, that will set the allowances for weight and dimensions and the rules of travel in case they are exceeded.

1.30 In order to avoid the breakdown of the awning body frame snow and water accumulation on the awning roof must be excluded.

1.31 If there are any unwanted sounds (knocking, clanking, etc.), detect the cause at your earliest convenience or consult the Service center.

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2 TECHNICAL DATA

Table 2.1 – Technical data on Truck MAZ 5440E9 Parameter name Parameter value

Fifth wheel shift, mm 600 555 (with lowered height)

Technically permissible mass on fifth-wheel, kg 10700 10500

Kerb weight, kg 7770 (7900) 7770 (7900)

Technically permissible total mass of the vehicle, kg 18750 18550

Distribution of the vehicle mass, kg: – first axle – second axle

7250

11500

7050

11500

Technically permissible mass of the road train, kg 40000 44000

Permissible total mass of the road train, kg 40000 40000 Engine OM 501 LA.V Rated engine power, kWt 320,0

Gearbox (make) ZF 16S221

Maximum traverse speed, km/h 100,0

Control fuel consumption 1 L/100 km of the way with the total mass: – at constant speed of 60 km/ – at constant speed of 80 km/h

25,5 31,5

Wheels Plate, 9,00×22,5

Size of tire, load index and speed category 315/80R22.5,154/150М; 315/70R22.5, 152/148М

Minimum turning radius of the vehicle endwise upon the axle of the offside front wheel track (relative to the turning center), m, not exceed 7,4

Outer clearance radius of the vehicle turning, m, not exceed 9,0 Turning angles of the inner wheel (relative to the turning center) to the left/right 45 ±1

Note: 1 Permissible deviation of gross vehicle weight is plus 3 %. Bottom weight limit is not limited. 2 Gross vehicle weight is the total weight of an automobile with the cooling liquid, ammonia solution mass,

lubrication, window washer liquid, fuel (tank, filled up to not less than 90 % of the rated capacity), noise insulating screens, spare wheel.

3 Figures in the brackets is the automobile weight with fire extinguisher, independent air heater of the cab, independent fluid heater, wheel blocks, fairing, top sleeping berth, rear towing fork, chassis platform, radio set or recorder, standard set of spare parts, standard set of tools. 4 Technically permissible masses are specified considering the mass of the crew (150 kg). 5 If speed limiter is installed, maximum speed is (85+4) km/h. 6 Control fuel consumption serves for the determination of the truck technical condition and is not an operating rate.

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Table 2.1 a – Technical data on Truck MAZ 5440E9 (with hydraulic power takeoff) Parameter name Parameter value

Fifth wheel shift, mm 600 555 (with lowered height)

Technically permissible mass on fifth-wheel, kg 10450 10300

Gross vehicle weight, kg 7970 (8100) 7970 (8100)

Technically permissible total mass of the vehicle, kg 18700 18550

Distribution of the vehicle mass, kg: – first axle – second axle

7200

11500

7050

11500

Technically permissible mass of the road train, kg 44000 44000

Permissible total mass of the road train, kg 40000 40000

Engine OM 501 LA.V

Rated engine power, kWt 320,0

Gearbox (make) ZF 16S221

Maximum traverse speed, km/h 100,0

Control fuel consumption 1 L/100 km of the way with the total mass:

– at constant speed of 60 km/h – at constant speed of 80 km/h

25,5 31,5

Wheels Plate, 9,00×22,5

Size of tire, load index and speed category 315/80R22.5,154/150М; 315/70R22.5, 152/148М

Minimum turning radius of the vehicle endwise upon the axle of the offside front wheel track (relative to the turning center), m, not exceed

7,4

Outer clearance radius of the vehicle turning, m, not exceed 9,0 Turning angles of the inner wheel (relative to the turning center) to the left/right 45 ±1

Note: 1 Permissible deviation of gross vehicle weight is plus 3 %. Bottom weight limit is not limited. 2 Gross vehicle weight is the total weight of an automobile with the cooling liquid, ammonia solution mass,

lubrication, window washer liquid, fuel (tank, filled up to not less than 90 % of the rated capacity), noise insulating screens, spare wheel.

3 Figures in the brackets is the automobile weight with fire extinguisher, independent air heater of the cab, independent fluid heater, wheel blocks, fairing, top sleeping berth, rear towing fork, chassis platform, radio set or recorder, standard set of spare parts, standard set of tools.

4 Technically permissible masses are specified considering the mass of the crew (150 kg). 5 If speed limiter is installed, maximum speed is (85+4) km/h. 6 Control fuel consumption serves for the determination of the truck technical condition and is not an

operating rate.

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Table 2.3 – The main adjustment data

Parameter name Parameter value

Wheel alignment, mm 1–2

Turning angle of the left wheel to the left (45±1)°

Turning angle of the left wheel to the right (45±1)°

Clutch pedal free travel, mm 5–7

Brake pedal free travel, mm 3+13

Operating rod stroke of brake chamber, mm 38-44 Table 2.4 – Filling tanks

Parameter name Parameter value

Fuel tank, l 505±15 550±15

Fuel tank (AdBlue), l 90,0

Transmission housing, l 13,0

Rear axle main transmission housing, l 15,0 (15,2)

Rear axle wheel drive transmission, l 2,0 each

Steering booster system, l 7,0

Screen washer tank, l 10,0

Table 2.2 – Truck tire pressure

Truck tire pressure MAZ 5440Е9, kPa

315/70 R22,5 315/80 R22,5 Truck axle, kg Continental, (Matador) Michelin Continental,

(Matador) Michelin

7050 820 830 770 730 7100 830 830 780 730 7150 830 840 790 740 7200 840 840 790 740 7250 850 850 800 750

first:

7300 860 860 810 750 10000 610 640 580 570 11500 730 750 690 660

second:

13000 850 850 800 760 Note: Permissible deviation of tire pressure ±20 kPa

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3 CONTROLS AND INSTRUMENTATION

The arrangement of controls and instrumentation is shown on Figures 3.1, 3.2, 6, 7.

Parking and emergency brakes drive valve handle The handle is located to the right from the steering column under the dashboard. The handle can be fixed

in two extreme positions. In the lower extreme fixed position parking brake is engaged, and it is disengaged when the handle is moved to the top fixed position. When keeping the handle in any intermediate (non-fixed) position, emergency brake is engaged.

When pushing the handle end to the extreme lower position and additionally moving it downwards, the breaks of the semitrailer release and the truck brakes check the road train retention on a slope.

Emergency brakes drive valve button The button is located on the cab floor to the left from the driver. When the button is pressed the butterfly valve creates counterpressure in the exhaust system by blocking

the flow passage in the exhaust gases manifold. The fuel feed cuts off simultaneously. Steering wheel with a collapsible fastener of a steering column, and a device that allows height and

inclination adjustment of a steering column. Adjustments are carried out by pressing the pedal that is located on the steering column fastening

bracket. After placing the steering wheel into a comfortable position, release the pedal. Ignition switch lock on the steering column, with an antitheft device. The key is inserted and taken out

of the lock in the position III (Figure 3.1). 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 breakage, turn the steering wheel to the left – to the right a bit, and then turn the key clockwise to the position «0».

When taking the key out of the ignition switch lock (from the position III), lock blocking device is activated. In order to block the steering column shaft it is necessary to turn the steering wheel a bit to the left, and then to the right.

Other positions of the key in the lock: 0 – neutral (fixed) position. Accessory and starter circuits are switched off, the engine is shut down; I – accessory and consuming circuits are powered up (fixed position); II – accessory, consuming circuits and starter circuits are powered up (non-fixed position). Handle 2 of the turn indicator, lower beam and upper beam switch. There are following positions (in the

horizontal plane): In the horizontal plane: 0 – neutral; I – fixed, right turn indicators are switched on. The indicators are switched off automatically. I' – non-fixed, right turn indicators are switched on for a short period of time; II' – non-fixed, left turn indicators are switched on for a short period of time; II – fixed, left turn indicators are switched on. The indicators are switched off automatically. In the vertical plane: IV – non-fixed, upper beam is switched on for a short period of time (independently of the position of

the main switch); О' – fixed, lower beam is switched on with the headlights switched on by the main switch; III – fixed, upper beam is switched on with the headlights switched on by the main switch; V – non-fixed, when pressing the handle end, electrical sound alarm is switched on.

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1 – ignition switch lock; 2 – turn indicator, lower / upper beam switch; 3 – windscreen wiper / washer switch.

Figure 3.1 – Position of under steering switches and ignition switch lock

Handle 3 of the windscreen wiper and washer switch. There are following positions (in the horizontal plane):

In the horizontal plane: 0 – neutral; I – fixed, windscreen wiper is engaged on a low speed; II – fixed, windscreen wiper is engaged on a high speed; III – fixed, windscreen wiper in intermittent mode is engaged. Intermittent mode allows choosing the

period of pause up to 60 sec. To set a period of pause while windscreen wiper is engaged in intermittent mode it is necessary: – to turn windscreen wiper switch from the fixed position III (intermittent mode) to the neutral position

«0»; – in a required pause period return windscreen wiper switch to the position III (intermittent mode). The time the windscreen washer is deactivated in the neutral position «0» is the time of pause position. Return to the original pause time (2–3 sec) could be done: – when putting wiper switch to low speed or high speed mode; – when switching off the ignition switch; – when remaining the wiper switch in neutral position (0) more than 60 sec. In the vertical plane: IV– non-fixed, windscreen washer is engaged with a simultaneous switching on of the windscreen

wiper on a low speed. V – non-fixed, when pressing the handle end, pneumatic sound alarm is switched on (if available).

Tachometer (position 27, Figure 3.2) is a device that indicates the revolutions of the engine crankshaft. Tachometer scale may have the following colour zones:

– solid green zone – optimal range of engine work in economy mode; – interrupted green zone – range of engine work in economy mode; – red zone – engine crankshaft revolutions range, at which engine work is prohibited; – interrupted red zone – engine crankshaft revolutions range, at which short-time engine work is

possible;

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Tachometer may be equipped with a counter of total engine crankshaft revolutions.

Batteries switch remote control button (position 30, Figure 3.2). When batteries switch is turned on the voltage indicator pointer indicates the vehicle network voltage.

The batteries are to be switched off at the parking as well as in order to disconnect energy consumers in cases of emergency.

In case the remote control doesn’t operate, the switch can 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 is a device that shows the speed, current time and the total distance passed. On a special

disc there is a recording (ciphered) of the speed, way and drivers’ (one or two) working regime. Remote control of the independent air heater (if installed) is dedicated for switching on/off of the

heating mode and setting of the cab temperature that is kept automatically by an independent air heater. The positions of control elements and control devises are shown in the Figure 3.2. Main light switch: upper position – switched off; middle position – parking lights; lower position –

lower / upper beams. The position of the control elements and instruments is shown in the Figure 3.2; its function is given in

the Table 3.1.

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Figure 3.2 – Instrument panel and control elements (Table 3.1)

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Table 3.1 – Instrument panel and control elements

Position Function Indicator colour

1 Fuel level indicator with control indicator of fuel reserve yellow 2 Control indicator of the track tractor turn signal (left) green 3 Display unit of the performance modes (left) 4 Multifunctional display

5 Indicator of air pressure in the front circuit of the brake pneumatic drive with emergency temperature control indicator

red

6 Main alarm annunciator «STOP» red 7 Control indicator of the trailer turn signal lights green

8 Indicator of air pressure in the rear circuit of the brake pneumatic drive with emergency air pressure control indicator

red

9 Display unit of the performance modes (right) 10 Control indicator of the track tractor turn signal (right) green

11 Cooling liquid temperature indicator with emergency temperature control indicator

red

12, 13 Multifunctional display control buttons 14 Microclimate control unit

15, 16 Cab dome lamps switches 17 Cross-axial differential switch 18 Blocking switch of the trailer pivoted axle 19 Interaxle differential blocking switch 20 Headlamp switch for coupling illumination 21 Mirrors heating switch 22 Front/rear fog lamps switch 23 Road-train three-bar lights switch 24 Headlamp lower beam regulator 25 Divider gearbox switch control indicator green 26 Transmission demultiplicator control lamp green 27 Tachometer 28 Display unit of electronic system performance mode 29 Overspeed control indicator red 30 Battery switch button 31 Low-beam headlamp switch control indicator green 32 High-beam headlamp switch control indicator blue 33 Speedometer 34 Main light switch 35 Alarm system switch 36 Instrument illumination regulator

37, 38 Multifunctional display control buttons 39 Platform lifting control switch 40 Heating mode switch (if installed) 41 Placement location of the microclimate sensor (MCU) 42 Retarder Stage Switch (Place of installation vehicle specific)

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a) Left

b) Right

Figure 3.3 – Performance mode display unit (Table 3.2)

Table 3.2 – Performance mode display unit

Position Symbol description Indicator colour

1 Diesel pre-heat yellow 2 Engine fan clutch green 3 Parking brake red 4 Switching on of the rear fog lights yellow 5 Oil pressure drop in the engine red 6 Switching on of the front fog lights green 7 Switching on of the parking lights green 8 Engine oil filter clogging red 9 Air filter clogging red

10 Battery discharge indication red 11 Engine coolant fluid level decrease red 12 Hydraulic fluid level decrease in steering booster yellow 13 Brake system fault red 14 Transmission fault red 15 Switching on of the front axle differential lockup yellow 16 “Neutral” switch for gear box green 17 Switching on of the interaxle differential lockup, transfer case yellow 18 Switching on of the power take-off yellow 19 Switching on of the cross-axle differential yellow 20 “Neutral” switch for transfer case yellow 21 Switching on of the interaxle differential lockup yellow 22 Steering failure red 23 Windscreen demisting and defrosting yellow 24 Fuel heating yellow

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Figure 3.4 – Display unit of electronic system performance mode (Table 3.3)

Table 3.3 – Display unit of electronic system performance mode

Position Symbol description Indicator colour

1 Neutral switching green 2 Low level of ammonia solution in the system green 3 Engine exhaust system failure yellow 4 Traction control, ASC system correct functioning green 5 Control indicator of the truck tractor ABS system yellow 6 Anti-lock brake system (ABS) failure, trailer yellow 7 Anti-lock brake system (ABS) off or not available, trailer yellow 8 Air suspension failure red 9 Height control, truck yellow

10 Electronic diesel control red 11 Cruise control mode green 12 Gear shift “up” (prompter) green 13 Gear shift “low” (prompter) green 14 Electronic engine management system (data) yellow 15 Axle lift yellow 16 “Starting help” mode switch yellow 17 Excess axle loading red 18 Retarder yellow 19 Engine shutdown red

Instrument panel permits to check and correct information displayed on the multifunctional display (position 4, Figure 3.2) with the help of control buttons (position 12, 13, 37, 38, Figure 3.2). The buttons are located on the instrumental panel.

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Table 3.4 contains data on the performance modes of multifunctional display and the ways of it changing.

Table 3.4 – Multifunctional display performance modes

Mode Function Way to change

Indicator and lighting operating capacity check Button switch 1 short-time pressing (position 38) (less than 2 sec) 1

Start of the menu «Feature determination» Button switch 1 long-time pressing (position 38) (more than 2 sec)

The information shown in the upper display field: – temperature; – time, alarm time (if activated), DD/MM/YY; – zero information.

Button switch 2 short-time pressing (position 12) (less than 2 sec) 2

Alarm clock may be deactivated by pushing any button 1-4.

Information displayed in the lower display space: – total run, daily run; – total run, amount of engine shaft rotation (х1000); – total run, amount of engine hours; – total run, amount of engine hours while idling (when the vehicle is not moving); – total run; – zero information.

Button switch 3 short-time pressing (position 13) (less than 2 sec) 3

Reset of daily run (if there is a corresponding field) Button switch 3 long-time pressing (position 38) (more than 2 sec)

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Information is displayed in the main display field: – AdBlue level, coolant fluid level, oil crank case level; – minimum fuel consumption zone; – vehicle network voltage, engine oil pressure; – speed, instant fuel consumption «L/100 km» и «L/h»; – zero information.

Button switch 4 short-time pressing (position 37) (less than 2 sec)

Information displayed on the multifunctional display is shown in the Figure 3.5. If no corresponding sensors are installed, this information patch is not displayed on the display. After short-time pressing on the switch 30 (position 30, Figure 3.1) the battery is switched on, and the

following information is displayed: – in the upper field: parameters that have been displayed before the battery was switched off:

temperature or time, alarm time (if activated), weekday, DD/MM/YY; – in the middle field: vehicle network voltage.

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Figure 3.5 – Algorithm of displaying information (feature determination). Page 1.

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Figure 3.5 – Algorithm of displaying information (feature determination). Page 2.

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When the switch key of the starter and instruments is turned on, the following information is displayed: ammonia reagent level in the AdBlue tank, coolant fluid level, oil crankcase level.

After the engine start the following information is displayed: – in the middle field: vehicle network voltage, engine oil pressure; – in the lower field: information that has been displayed before the key off. When the vehicle runs information about minimum fuel consumption zone is displayed. When the ambient temperature reaches the values from minus 2 °С to plus 2 °С, the ambient

temperature is displayed in the upper field of the display regardless of its condition. Regardless of the middle space condition the display shows: – indicator reading of the vehicle network voltage if its voltage with the engine running is lower than

25,2 W; – oil pressure indicator reading if the oil pressure with the engine running is lower than 0,6х100 kPa; – indicator reading of ammonia reagent level in the AdBlue tank if the AdBlue level is lower than 10%.

When the AdBlue level decreases to 0%, the symbol near the AdBlue scale level begins to blink; – indicator reading of the coolant fluid level and engine oil level if the level decreases to 0 %. When some values drop to critical level simultaneously the information of such states is shown on the

display with the 3 sec. interval. When information about critical level is displayed, a brief pressing of the button switch 4 (position 37,

Figure 32) provides a 5-minutes escape from these values and calls up information that has been displayed in the middle field.

A brief press on button switches in “Feature determination” mode and consideration of the symbols in the display corners allow choosing the speed value when the signal of overspeed is switched on; correspondent indicator intensity; alarm switching on/off; time, weekday, date settings; keyboard volume required; display language settings; engine crankshaft rotation ratio value settings; sensor types; engine type (engine run optimal zone).

Tachograph «МTCO 1324» by Siemens VDO company is fixed to measure and register motion

parameters. Digital «DTCO 1381» by Siemens VDO company may be installed according to a customer order.

The characteristic features of the mentioned tachographs are the separate use of tachograph and speedometer, and also the way of information encoding, storage and transfer.

Tachograph is located in the electric equipment panel from the driver side on the clothing shelf (see Figure 3.6).

Figure 3.6 – Tachograph installation place

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Tachograph appearance is shown in the Figure 3.8. Principle of operation and maintenance are given in the service instruction, which is attached to the truck.

untilocking button of button of the extendable mechanism time indicator installation buttons for setting time; for a driver - 1 registration of failure messages

display button of the time option button

indicator installation time reinstallation, looking for a driver - 2 through information storage)

Figure 3.8 – Tachograph controls

Meaning of different pictograms in the bottom line of the display:

– presence of the first driver;

– presence of the second driver;

– “driving” – current activity of the first driver during the run (this pictogram is displayed only on the left side of the line, in the zone of the first driver);

– “work” – current activity of the first driver (left side) or the second driver (right side);

– “readiness” – current activity of the first driver (left side) or the second driver (right side);

– “rest” – current activity of the first driver (left side) or the second driver (right side).

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4 CAB EQUIPMENT

Clothing shelf is placed in the cab above the windscreen; timer clock and radio set are placed in the left side of the shelf. The right side of the shelf is designed for small things and documents.

The cab is fitted with two sun blinds above the windscreen, the folding antidazzling device over the drop window from the driver’s side.

The cab doors are hinged on the door aperture front leg and equipped with the rotor-type locks, which have two closure positions: preliminary and full. During the truck movement 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 lock button.

4.1 Driver and passenger seat Driver sprung seat with the pneumatic resilient member (Figure 4.1) has mechanisms of horizontal and

vertical regulation, and the mechanism of the backrest tilt angle regulation. Headrests and armrests are mounted according to a customer order.

Mechanism of the vertical seat regulation is the mechanism of the lever-type with the stepped adjustment. Seat tilt and seat height are regulated with the help of the handle (position 5) and pushing the front or the back side of the seat pad (position 7).

Mechanism of the backrest tilt angle regulation is the mechanism of the lever-type with the stepped adjustment. It permits to regulate the tilt angle with the help of the handle (position 3) and by pushing the seat back simultaneously.

Mechanism of the horizontal regulation (forward/back) is the mechanism of the sliding type with the stepped adjustment of the seat position with the help of the handle (position 6).

Armrests (position 9) are thrown (up) and are regulated according to the tilt angle by the knurled handle (position 10).

Headrest (position 1) is regulated according the height and tilt angle by pushing it in an appropriate manner.

ATTENTION DRIVER! IT IS FORBIDDEN TO ADJUST THE SEATS DURING THE MOVEMENT. ALL SEATS ADJUSTED SHOULD BE FIXED IN THE CHOSEN POSITIONS.

Seatbelt fixation is provided (position 8).

WHEN SEATING IN THE CAB AVOID NEGATIVE EFFECTS OF THE CAB DEVICES.

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1 – headrest; 2 – seat pad; 3 – regulation handle of the backrest tilt angle; 5 – handles of the seat vertical regulation mechanism (height and angle); 6 – handle of the seat horizontal regulation mechanism; 7 - seat pad; 8 – seat belt fixation; 9 – armrest, 10 – regulation handle of armrest angle.

Figure 4.1 – Driver seat

IT IS STRICTLY FORBBIDEN TO STAND IN FRONT OF THE CAB WHEN IT IS LIFTING OR LOWERING. BEFORE LIFTING THE CAB BE SURE THAT CAB DOORS ARE CLOSED AND THERE ARE NO THINGS IN THE CAB THAT IF FALLING COULD DAMAGE ITS ELEMENTS.

4.2 Cab microclimate system The trucks are equipped with the integrated microclimate system with automatic temperature

maintenance. Microclimate system provides the cab with comfort conditions over the temperature range from –50 оС to +50 ºС. Microclimate block is installed in the cab under the dash panel in the middle part; air conditioner compressor with the belt-drive of the crankshaft pulley is installed on the power unit; capacitor is installed in front of the engine ONV radiator; receiver-dryer with pressure sensors is in the engine area with the access from under the cab fascia. Solenoid valve (SV), controlling the coolant consumption through the heating system radiator, is placed under the fascia on the right hand column of the cab front.

System control is carried out with the help of the keys and buttons of the microclimate control unit, which is placed on the dash panel to the right of a driver. Junctions of the conditioning system are connected with the special hoses; the system is filled with Freon R134 and is under pressure.

Table 4.1– Filling rate for freon (chlorofluorocarbon) and refrigerator oil Conditioner description Freon Refrigerator oil

АФК-7 R134a 800 g FUCHS Reniso Triton SE55, Alternative: FUCHS SEZ 32/68/80 ISI Emkarate RL 46S MOBIL arctic EAL 46 SHELL Clavus R46

50 ml

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ATTENTION! MAINTENANCE AND REPAIR OF THE CONDITIONING SYSTEM (THE CIRCUIT WITH

COOLING AGENT) IS CARRIED PUT ONLY BY SPECIALLY TRAINED STUFF OF THE SERVICE STATIONS WITH USAGE OF SPECIAL INSTRUMENT AND EQUIPMENT.

IT IS INDISPENSABLE TO WATCH OVER THE BELT TENSION OF THE AIR CONDITIONER COMPRESSOR.

WARNING! IT IS FORBIDDEN TO DO PLUMBING AND WELDING ON THE ELEMENTS OF THE

SEALED CIRCUIT WITH THE COOLING AGENT OR NEAR IT, AS IN THE RESULT OF THE HEATING THE PRESSURE RISES AND EXPLOSION IS POSSIBLE.

There are drain connections with hoses for condensate drain from the microclimate block. In order to avoid condensate accumulation in the tray of the microclimate block it is necessary to clean drain connections and hoses.

All conditioning systems should go through regular maintenance at service stations (once a year). Fan-driven junction of radial type is used for forced ventilation, heating and cooling of the cab.

Maximum performance of the microclimate system is achieved when the fans work at full power. Given mode is used for fast heating (cooling) of the cab at high temperature difference in the cab – desired and real.

Regulation of air direction and amount which comes through the nozzle of the dash panel, is carried out by the control elements which are installed directly on the nozzles (deflectors), as it is illustrated in the Figure 4.2. When controlling air distribution shutters and fan revolutions the most comfort air-distribution mode is set. Central nozzles on the dash panel are designed mainly for working in the mode of intensive ventilation and conditioning, and also for faster cab heating. In order to reduce noise of the heating and air-distribution improvement (even cab heating) it is recommended to close central nozzles.

Figure 4.2 – Deflector

During the work in the conditioning mode it is more effective for air-distribution to use dash panel deflectors (Figure 4.3) and to partially deliver air to the wind screen. It is necessary to cut off air delivery to the driver and passenger’s legs. In order to reduce the temperature faster, firstly it is recommended to cool the cab with the help of natural and forced ventilation and then to switch on the conditioning system. The ventilator work at full power, when the conditioner is also working, is not recommended because of possible illnesses. It is advisable to use middle and low speed of the microclimate system fan.

The scheme of air-distribution in the cab is shown in the Figure 4.3.

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Figure 4.3 – Scheme of air-distribution in the cab

The control block of microclimate system with automatic temperature control is shown in the Figure 4.4. During the work of the heater with automatic temperature control the purpose and work of the keys are preserved, with the exception of the conditioning switch key (position 7) that switches on the ventilation mode.

Switching on of the microclimate control panel is carried out by pressing any key (except “A”; when pressing this key with the microclimate control block switched off, the outlet to the service mode takes place: service mode of indication brightness, recirculation shutter control adjustment, etc., that are described in the microclimate control block instruction).

The control block is switched off by the key “A” pressing (position 6) more than 2 seconds till the data board is switched off.

Indication bar is used for indication of the controlled parameter installation: fan revolutions (position 1), position of the air-distribution shutters (positions 2, 3, 4) or coolant consumption in the manual mode (position 5), set temperature in the automatic mode. The keys (position 2, 3, 4) are used accordingly for proportional change of air distribution to the windscreen and door windows, air delivery at the feet, and of outside and recycling air distribution from the cab.

By pressing the top of the double keys 1, 2, 3, 4, 5 the controlled parameter increases, by pressing the bottom parts – the controlled parameter decreases.

The “A” key is used for switching on/off of the automatic mode with the microclimate control block switched on, and for control block switching off. The key (position 7) is used for switching on the conditioner in the manual mode and the defogging mode (REHEAT) by prolonged pressing (more than 2 sec.). Thus the shutters get the optimal position automatically (fresh air shutter opening, heating and conditioning mode simultaneous switching, closing of the blowdown (at the feet) air shutter) and the air is delivered to the windscreen and door windows with the heater fan work at full power for 10 min. This mode is not purposed for durable use. With the help of “Defogging” mode (REHEAT) it is possible to remove damp from the windows in summer (for example, after the rain).

In order to set the automatic temperature maintenance mode it is necessary to switch on the automatic mode by pressing the key “A” with the microclimate control block switched on. At this the green indicator on the key “A” switches on, and by pressing coolant consumption/temperature set key (position 5) it is possible to set desired temperature. During 2 seconds, after the temperature is set, it is shown on the data display with the sign “A” before the temperature value “A20”, and then the current temperature is shown on the display. The system switches on the necessary mode (heating, ventilation or conditioning)

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using the compressor clutch and solenoid valve, installs the shutters, switches on the fan, and sets the given temperature with the its further maintenance. It is possible to change the position of air distribution shutters, fan revolutions and set temperature by pressing desired corresponding keys. But by overlapping of all shutters and reducing the revolutions the system may not reach the temperature. On default (if the temperature is not set) in the automatic mode the system enters the temperature setting and maintenance mode (+22 °С). The system launches the conditioning mode only with the engine engaged. With a stopped engine or the heater system kitting and the temperature set lower than the current temperature, the ventilation mode with fresh air intake switches on.

In order to switch on the conditioning mode in manual and automatic modes it is necessary to start the truck engine. When switching off the heater fan revolutions the conditioner is switched off automatically. It is impossible to switch on the conditioner when the temperature is lower than +5 °С (as the air temperature sensor of the evaporator (thermostat) doesn’t allow closing the electric circuit), and it is not recommended (after the system heating by re-circulated air). For lubrication and extension of the services of the conditioning system junctions it is necessary to launch the conditioning system for 10 min bimonthly (in winter the ambient temperature should rise above +10 °С).

In case the truck engine is without power within 12 hours in order to prevent accumulator discharge it is necessary to switch off the solenoid valve – having placed the coolant consumption in the maximum position (the key of the temperature change) or switch off the microclimate control block panel (holding the “A” key pressed within 2 seconds). In the first case the indicator on the temperature change / coolant consumption key goes out, in the second case the indicator and the data display go out.

The work of the microclimate system in the heating mode is possible by the ram air at a speed of more than 60 km/h with the switched off control panel and preset shutters. In this case the solenoid valve should be switched off (light-emitting diode on the temperature control key is off), fresh air shutter is completely opened, and the rest shutters are fixed in the position of optimal air-distribution. If there is a lack of the inlet air and heat it is necessary to switch on the fan by pressing the top part of the appropriate button. In this case the control panel switches on and the current temperature is shown on the display.

1 – fan revolutions regulation key; 2 – «REHEAT» mode activation key, regulation key of air delivery to the windscreen; 3 – air delivery at-the-feet regulation key; 4 – intake air/recirculation regulation key; 5 – heating power and air temperature regulation key in automatic mode; 6 –microclimate control block and “Auto” mode switching on/off key; 7 – condition mode switching on/off key; 8 – data display.

Figure 4.4 – Control block of the microclimate system

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In the heating mode it is recommended to set the fresh air shutter in the open position (recirculation is closed); to set the coolant consumption in the maximum position; and to deliver air to the windscreen, door windows and at the feet. When moving at low temperatures in order to heat the windscreen it is possible to reduce air delivery at the feet, thus, air delivery to the windscreen increases. Warm air delivery ensures defogging and window defrosting. However, for the equal distribution of temperature in the cab it is recommended to provide maximum warm air delivery at the feet. At high speed the cab ram air heating is possible even when the ventilator is switched off. At a speed of lower than 60km/h and low temperatures in order to exclude defogging it is necessary to switch on the heater fan.

Recommended settings for different modes of the microclimate system operation are given in the Figure 4.5 below. The easiest way of the microclimate control in the cab is to set automatic mode of the temperature maintenance.

Figure 4.5 – Recommended settings of the microclimate system operation modes

In common driving conditions ventilation and heating are provided without fan working at open fresh air shutter and elements of air-distribution, at ram air and ventilator switching on at low revolutions; and this conduces to lower noise.

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In order to switch on the mode of windows defrosting it is necessary to press briefly the top of the windscreen blow-off key on the switched off panel. In this case the ventilator works at maximum revolutions, the fresh air shutters of air delivery to the windscreen open, air delivery at the feet and recirculation shutter close. Coolant consumption to the radiator opens. To exit the mode it is necessary to press the button of the air consumption decline to the windscreen.

Recirculation mode with fresh air addition (fresh air shutter position on the indication bar 20–40%) is recommended for more effective work of the conditioning system. Heater fan should be switched on.

It is possible to use recirculation in the heating mode if the truck passes through a foul section and fast cab heating. However, a long-term work in this mode can cause window evaporation, general feeling of being unwell, and malfunction of the cab ventilation. That is why, when the weather is cold it is necessary to heat the cab only on open air.

In the conditioning mode for more effective and quick reach of comfort temperatures after the truck being in the sun, it is recommended to open the elements of the natural ventilation first and to switch on the microclimate fan at full capacity. Then close the windows and hatch, switch on the conditioner (use nozzles of the dash panel). It is recommended to close completely the shutters at the feet, leave the shutters to the windscreen open by 1/3. In order to eliminate a possibility of catching a chill it is recommended to switch on the fan by 20-40%.

Regulation of the indication brightness and other operations are carried out in the service mode by pressing the “A” key with the microclimate control board switched off. In this case the indication brightness is made by fingering and pressing the bottom of the air consumption at-the-feet key. For system initialization and control it is necessary to press the top of the air consumption at-the-feet key. With the help of the fresh air consumption key the position of the recirculation shutter can be changed. To exit the service mode, press the “A” key again.

In order to prevent contamination of the heating system and microclimate junctions, and to avoid dusty air ingress to the cab, air filter is used at the microclimate system air-inlet (under the fascia of the cab front). In case of contamination it is necessary to wash the filter element with cleaning agents in warm water, to rinse and install on the vehicle, or change the filter element. Ventilation and heating system operation without filter may cause ingress of dust to the cab, clogging of the heat exchanger core and of the fans electric motor, and consequently, it will disable the whole system.

You can find technical service of the conditioning system in Table 4.1. Possible malfunctions of the microclimate system and remedies are described in Table 4.2.

Table 4.1 – Technical service of the conditioning system. Periodicity Element of the system Technical maintenance

Once a year Once a year

Wires, electrical connections Control of general state and connection reliability

Х

Hoses Worn spots, general state Х

Coupling fittings Air-tightness test by leak detector Х

Amount of cooling agent Pressure measurement, refueling Х

Capacitor State control, plate cleaning (if necessary) Х

Evaporator General state, plate cleanness and junctions

Х

Compressor General state, connection reliability, tensioner

Х

Driving belt Tension and wear control Х

Hoses of condensate drain State control, cleaning (if necessary) Х

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Table 4.2 – Possible malfunctions of the microclimate system and remedies are described. Malfunctions Possible reasons Remedies

Lack of connection in the wire. It is necessary to check connection reliability and to re-establish contact.

Lack of switching on of the microclimate system control block Supply voltage is higher or lower

than rated. Charge the accumulator; install rated

supply voltage. Lack of connection in the wire.

Check: connections and voltage supply in the circuit to the compressor, and the signal of the engine work to the microclimate system control block.

Cooling system fan is switched off. Switch on the cooling system fan for the engines with electronic clutch.

Breakdown of the heater fan. Check the contact, brush wear; change the electric motor of the heater fan.

Lack of conditioner switching on.

Breakdown of one of the joints in the circuit of the microclimate system control block – thermostat – pressure sensor – compressor.

Find the joint that doesn’t transmit signal, and restore it or change it.

Lack of contact. Restore the contact. Air temperature is lower than +5 0С. Check air delivery to the evaporator.

Lack of voltage after thermostat

Thermostat is broken Change thermostat. Lack of contact. Restore the contact. High or low pressure in the system.

Check pressure and find out the reasons of nonconformance.

Lack of voltage after the pressure sensor.

Pressure sensor is out of order. Change the pressure sensor. Lack of cooling agent. Restore hermeticity (work of valves,

fittings, hoses). Clutch is broken. Repair or change the clutch.

Conditioner compressor doesn’t switch on while voltage delivery. There is no belt tension. Stretch the belt, check the fastener.

Reduced output of the heater fan. Switch high speed, to open the elements of air-distribution.

Wrong adjustment of the thermostat. Adjust or change the thermostat. Pressure sensors are out of order. Repair or change the sensors. Evaporator is littered up. Clean the evaporator. Capacitor is littered up. Clean the capacitor plates. Temperature sensor is out of order. Change the temperature sensor. Insufficient air supply. Check the fresh air and recirculation

chokes, cleanliness of evaporator, thermostat operability. Remedy the defects.

Poor cold (heat) efficiency.

Solenoid valve is out of order. Check the contact, clean, repair or change.

The hoses of capacitor drain clogged up.

Clean out the hoses and flow-off fittings.

Water entry to the cab.

Lack of hermeticity. Restore hermeticity. Lack of contact. Restore the contact. Fastener or kinematics violation. Adjust and fasten.

Lack of adjustment by shutter.

Moto drive unit is out of order. Change the moto drive unit of shutter.

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Heating with independent fluid heater (according to customer order) There is a possibility of air heating of the cab with the help of independent fluid heater in the

parking before starting the movement (during the parking). When switching on the independent fluid heater and heating the coolant up to +40 °С, the heater fan switches on automatically at low revolutions, and the cab is heating. If the heating system adjustments are conducted after the switching on, the heating fan will work until the forced switching off (manual switching-off key). If no adjustments are conducted, the heating fan will turn off together with the independent fluid heater shutdown or when the temperature of the coolant drops down below +40 °С. At low temperature of operation the use of the independent fluid heater for engine temperature increase facilitates the increase of the heating system heat productivity. If the “engine warming up without cab heating” position was set by the coolant consumption key (solenoid valve is turned on) before the shutdown of the microclimate system control block, the heating fan will not switch on even with the temperature of the coolant above +40 °С; and with switching on of the independent fluid heater the solenoid valve will turn on, and only engine will be warmed up.

Independent air heater (according to customer order) If the truck is equipped with the independent air heater before starting up it is necessary to familiarize

yourself with technical description and operation manual, and follow the manufacturer requirement. Before launching the independent air heater be sure that there is enough fuel in the heater fuel tank; the

heater control valve should be in the “open” position. It is recommended to use the following types of fuel for the truck: diesel fuel (in compliance with DIN 51601) or fuel oil EL (in compliance with DIN 51603). In winter season it is allowed adding up to 50% of kerosene in order to avoid fuel solidification. Vent piping for combustion air and exhaust gas should be clear, free of mud, and etc.; in the cab the air supply to the heater and its exhaust must not be hampered because of position close to foreign objects.

Switching on/off of the independent air heater, temperature regulation in the cab is carried out with the help of the brand turning handle that is situated on the right part of the dash panel. The appearance of the handles produced by different manufacturers is shown in the Figure 4.6.

Figure 4.6 – Control elements of the independent air heater

temperature setting turning handle (from +16 °С to +30 °С)

green light functioning indicator (is also used for malfunction blinking code output)

– temperature setting turning handle (from +8 °С to +32 °С) – heating mode switching on – read light indicator of heater functioning – switch – engagement in ventilation mode – blue light indicator of ventilation

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ATTENTION! IT FORBIDDEN TO LAUNCH AND TO USE THE HEATER INDOORS, DURING TANK

FUELING, NEAR HIGHLY FLAMMABLE GASES AND DUST, AND WITH THE CAB LIFTED. IT IS PROHIBITED TO DO WELDING ON THE VEHICLE WITH THE BATTERY SWITCHED ON.

In order to launch the heater by turning the heater handle to maximum efficiency value for the model D4 (Eberspecher), you should push the appropriate button and turn the turning handle. The heater switches on. Primarily the heater scavenging starts; fuel supply to the heater and burner lighting begin in 60–90 minutes. The air that enters the cab becomes hot as the burner warms up. With the regular startup the heater starts working at full capacity in 90-120 sec., and then enters the automatic mode of maintenance of the temperature set by the turning handle in the cab saloon. In case you start up the heater after a long downtime it is admissible that only the second or the third startup is successful. If all three startups are unsuccessful (three malfunctions in succession) in the models D2/D4 the lockup is provided, and it will be necessary to visit the service station for malfunction remedy. For the model of АТ3500ST type it is necessary (if the is no malfunction) to switch off the heater for 10–15 sec., check the fuel level and restart. It is possible to package the heater with the modular timer clock (see technical description). After switching off the heater the lamp indicator on the turning handle goes out, and within 3–4 minutes there is little noise because of the heater scavenging.

In order to prevent untimely breakdown of the independent air heater, it should be switched on even as often as 1 time monthly for 5–10 minutes in summer season. At the end of the operation season in order to prolongate the service life of the heater it is recommended to exclude the use of biofuel.

After 10 years of operation of the independent air heater, the heating boiler change should be performed at the specialized service station.

Other requirements comply with the installation and operation instructions of the manufacturers of the independent air heaters.

If during the launch of the independent air heater there appear a heavy smoke formation, rare noise when burning, ad also strong smell of fuel, the heater should be switched off, or put it out of action with the help of the safety device removal if necessary (is located in the dash panel on the switchgear unit). The launch of the heater is permitted only after the heater test conducted by the specially trained staff of the producing company.

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5 WORK ITEM LIST FOR THE PRESALE PREPARATION

5.1 Bringing back into service (removal of the antirust compound). 5.2 Inspection is to be carried out in order to make sure that the product doesn’t have any transportation

damages; it is necessary to check accessories, instruments, and instructions in accordance with the packing list.

5.3 It is necessary to remand the articles and accessories demounted for handling time. 5.4 Check the oil presence and level in the aggregates and in the units of the articles, and add some if

necessary. 5.5 Add coolant liquid (if necessary). 5.6 Check the state of the accumulator batteries, their fastening (add electrolyte, recharge and fix if

necessary) 5.7 Make sure that the air brakes, clutch drive, electric accessories, signals, cab dumping system, tire

pressure, wheel fastening and of the other links are in good order. Eliminate damages if necessary. 5.8 Check whether the aggregates are in good order; make sure that the systems of the article function

correctly in all modes. Repair the fault if necessary. 5.9 Check the work of the steering gear mechanisms when the engine is running. Eliminate damages if

necessary. 5.10 It is necessary to examine the product at the bottom (for absence of leakage of the coolant liquid,

oil and fuel; and for junction reliability). 5.11 Clean the article and refresh the paint. 5.12 It is necessary to give instructions to the holder, driver.

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6 RUNNING-IN OF THE VEHICLE

Service life and reliability of the units and devices, and exploitation efficiency of the truck depends mostly on the work of the truck parts during the initial period of exploitation.

During the car running-in it is necessary to watch over the fasteners condition (tighten up the loosened bolted and other connections), and over the aggregate heat and if it is high find the reason of the malfunction and eliminate it.

On new trucks and after wheel changing it is necessary to tighten the wheel nuts when the number of kilometers travelled is about 50 km. And at first it is necessary to tighten the wheel nuts with the same tightening torque until proper bearing is reached.

The car running-in period for new trucks is 4500 kilometers. For the car running-in period the following restrictions are established: – it is necessary to run the truck in partial load mode; – the mass of the carried cargo shouldn’t overtop 60% of the nominal mass; – it is necessary to drive the track on each gear at speed not exceeding ¾ of the limit top speed or

acceptable engine speed. After reaching the kilometrage of 4500 km the speed can be increased up to full speed or up to the

maximum acceptable engine speed. It is necessary to service the engine, the clutch and the gear box during and after the running in period

in accordance with the manufacturer instruction. During the initial period when the number of kilometers travelled is 4500 km, it is necessary to: 1) check the flange fastening of the driveshaft and the needle bearing; 2) check the fastening of the driveshaft bearing (if any); tighten up if necessary; 3) check the cooling system, steering control system, driving axels, pneumatic brake system, cab

platform lifting system, heating system, and drive clutch for the leak tightness; 4) check the nut splinting of the steering link ball pins, and of the brake chamber crutch studs.

Eliminate disrepairs (if necessary); 5) check the backlash in the hinges of the steering links, and regulate it if necessary; 6) check the wheel nuts (including the nuts of the spare wheel and of the spare wheel bracket), and

tighten them if necessary; 7) check the tires and discs for visual damage; check and regulate air pressure in the tires; 8) check the nuts torqueing of the spring U-bolt, and tighten up if necessary; 9) check the nuts of the front spring pin wedges; 10) check the tightening of bolt connections of the rear suspension, and tighten up if necessary: – for spring and spring equalizing beam suspension, check: the nut bolts of the equalizing beam

suspension fastening to the frame; rod fastening nuts and the rod bracket fastening nuts; the stabilizer shaft nuts;

– for pneumatic suspension, check: the nuts of the torque rod brackets fastening to the frame, and also the nuts and bolts of the torque rod brackets fastening to the frame and to the axle; nuts of fastening of the rear pneumatic suspension beam to the axle with the bottom torque rod detached (alternate); nuts of stiffening plate fastening to the pneumatic tanks; nuts of the upper flange fastening of the pneumatic tanks to the frame;

11) check visually the fastening and the splinting of the shock absorbers. Eliminate the fault if necessary;

12) check the state and the tightening of the rubber branch connections of the engine system with the help of air stream, and tighten the joints if necessary;

13) service the storage battery (dusting, electrolyte traces removal, check of the level and density of electrolyte, check of the cable terminals connection with the binding posts, and their lubrication);

14) check the nuts tightening of the bracket fastening and the frame crossbeams fastening, and tighten them if necessary;

15) check and adjust the clutch pedal free travel if necessary; 16) check the gearbox actuator arm for play in the gearbox actuator, adjust it if necessary and

eliminate the plays; 17) check the petrol volume and change oil in the units and automobile systems according to the

lubrication chart.

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7 PECULIARITIES OF VEHICLE OPERATION

7.1 Automobile preparation for work Before starting the work it is recommended to do preparatory work, that is connected with the vehicle

control and filling up with the maintenance materials. In addition it is necessary to check: – coolant fluid availability and it’s level in the surge tank and add it if necessary; – oil level in the engine pan, in the gearbox, in the driving axels, in the steering booster system and if

it’s necessary add oil up to the needed level; – the belts tension of the water pump drive, of the generator, of the compressor and steering pump;

adjust them if necessary; – air pressure in the tires, and regulate it if necessary; – check and lubricate (if necessary) the bearing plate, the fifth wheel hitch and knuckle according to the

lubrication chart.

Cab Lifting Rules The cab is dumped forward with the help of cylinder actuator of the cab lifting. Before lifting the cab it

is necessary to lift the front folding board, and in order to avoid its damage withdraw the hydraulic pump lever of the cab lift from the left side rail of the base.

When the pump (position 2) handle (position 1, Figure 7.1) of the cab lift is fixed in the position “Lifting”, hydraulic rams (position 6) influence the catch gear knuckles and open them, after this with the help of the hydraulic ram (position 5) the cab is lifted. In order to lower the cab it is necessary to set the handle (position 1) in the “Lowering” position.

In transport position the pump valve handle should be only in the “Lowering” position. In transport position the cab is fixed by two catch gears, which are fastened on the lever of the cab rear

suspension on the left and on the right. Catch gears open automatically (with the cab lifting) with the help of hydraulic rams (position 6) fixed

on the catch gears webs, owing to the liquid pressure supplied by the pump (position 2). Catch gears close automatically when the cab descends under the influence of the axes (position 2) over

the hitches (position 3, Figure 7.2). It is necessary to control the right position of the knuckle (position 1) and the hitch (position 3) when

the catch gear is open.

1 – handle, 2 – pump, 3 – adapter, 4 – lines to the catch gears hydraulic rams, 5 – hydraulic ram of the cab lift, 6 – hydraulic ram of the catch gears

Figure 7.1 – Cab lifting mechanism

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1 – cam; 2 – axle; 3 – hitch (catch)

I – cab catch gear in the position “Open” II – cab catch gear in the position “Closed”

Figure 7.2 – Cab catch gear

It is possible to install the mechanism of cab lifting with pump and hydraulic cylinder by Weber-Hydraulik Gmbh company (Germany).

The hydraulic system of lifting cab mechanism should be filled with oil Texaco Rando HDZ15. Substitutes: Shell Tellus Т15, Esso Univis N15, Aeroshell Fluid 41. Fuel capacity – 0,6 l.

While lifting a cab turn the handle of the pump control valve clockwise all the way out, when lowering – counter-clockwise. In transport position the pump handle should be at “lowering” position.

Mechanism service consists in the regular сheck of fluid leakage absence at the junction of pipes; and also in liquid refill up to the necessary level (oil level should be endwise the pump driving shaft). Check oil level and make oil refill with the cab lowered.

Lifting panel of the cab front is suspended on hinges pivotally connected with handles. Holding of the cab front panel in lifting/lowing position is carried out by two gas springs. In order to avoid random opening and unauthorized access on the “Lowering” position the panel is fixed by two locks.

The locks open by remote drive. After the click signal that informs about the panel opening, it is necessary to lift it. The locks close

automatically when the panel is closing. The locks of lifting panel open from the panel by handle 1 (position 1, Figure 7.3). The handle is

located on the front panel under the dashboard left to the clutch pedal, over the cables (position 2) which release holders (position 3), fixed on the lifting panel, from engaging with the lock springs (position 4). Lifting panel opens manually and is fixed in lifted position by the two gas springs. Locks are located under the lifting panel and are fixed on the boost bracket of the front panel.

Brackets fastening to the front panel boosts is carried out with the help of bolts through oval bolt holes; and this allows longitudinal adjustment of lock position relative to the front panel. Locks’ fastening to the bracket is realized through oval holes that allow the holes to be coaxial in the lock housing and holder axles. Holder fastening on the lifting panel is carried out through the enlarged holes that allow shift the holder for coaxiality. Adjustment is made with the liner removed.

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1 – handle; 2 – cable; 3 – holder; 4 – spring; 5 – lever; 6 – bolt; 7 – nut.

Figure 7.3 – Regulation of locks of the cab front lifting panel

Safe lock closing/opening is achieved by correct adjustment of the cable (position 2) active length. Shift lever (position 5) to the intermediate position and fix it by technological element of 18 mm to adjust the active length. Unscrew the lock nuts and ease the bolts (position 6); by turns, stretch the cables (position 2) so that the A cables are set into the Б lugs oа the lock housing. Fix cables with bolts (position 6) and screw lock-nuts (position 7); remove technological element.

Hatch lock of the tool box is similar to the lifting panel lock. The lock actuator is on the tool box housing behind the driver’s seat. The hatch of the tool box is fixed in the open position by a support. In order to lock the hatch it is necessary to lift up the support until the unfixed position, and lock the hatch.

Lubricate regularly the cables with Lithol-24 and adjust the cable active length to maintain correct operation of the lifting panel lock actuator and the tool box hatch.

On the tool box side behind the driver’s seat there is a place provided for a fire extinguisher. There is a box-support on the tool box under the pillow of the lower sleeping place, designed for a potable water tank.

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8 DRIVING THE VEHICLE AND CONTROL OF ITS OPERATION

General guidance of the automobile driving and rules of its towing Automobile driving doesn’t induce any problems on good roads. When the automobile takes off and moves on a slippery length of the road it is recommended (at the

distance less than 1 km) to switch the block system of the interaxle and interwheel differentials briefly. The block system should be switched on just before a slippery length of the road. In this case it is necessary to switch off the clutch and switch on the block system after the automobile stop.

It is forbidden to switch on the block system of the differentials when the wheels are slipping. During winter season and on the slippery roads the lack of lubrication of the fifth wheel base plate can

cause deterioration of turning ability. When transporting the cargos and containers with high center of gravity the speed at the road turns

should be chosen so that the lateral stability is provided. In order to improve visibility in weather conditions such as mist, fog, rain or snow, it’s necessary to use

fog-lights. MAZ vehicles have separate contours of the brake gears pneumatic drive of the front and rear wheels,

contours of the auxiliary, parking and emergency brake. It is forbidden to move when the control lamps (position 5, 8; Figure 3.3) are on, signaling about inadequate pressure in the contours of the brake pneumatic drive.

In order to slow down a road train along the downgrade it is necessary to use the auxiliary brake. Also it is necessary to take into consideration that the maximum efficiency of the auxiliary brake is reached when the speed-reducing gear in the gearbox is switched on.

The vehicles are equipped with the antilock braking system (ABS) that is why when braking on the slippery road surface it is recommended to hold the brake pedal in the pressed position up until the vehicle stops.

When the pressure falls in the drive contour of the parking brake, the automobile brakes because accumulator springs actuate. In order to unbrake the vehicle it is necessary to unscrew the stop bolts of the tappet out of accumulator cylinders (Figure 8.1) or to press the tappet (position 4, Figure 8.2).

At the parking places the vehicle should be stopped by the parking brake, and the gearbox should be in the neutral position.

For car towing it’s necessary to: 1) disconnect the driveshaft from the rear axle flange and fix it safely on the automobile frame; 2) unbrake the vehicle out of action of the spring accumulators and carry out the towing with the rigid

hitch; 3) unblock the steering column or disconnect the longitudinal steering link from the steering arm.

Figure 8.1 – Unscrewing of the accumulator tappet stop bolt

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1, 7 – springs; 2 – disk; 3 – diaphragm; 4 – tappet; 5 – cylinder; 6 – piston; 8 – bolt; 9 – foot bearing/

Figure 8.2 – Spring brake

ELECTRONIC CONTROL SYSTEM OF ENGINE AND NEUTRALIZATION OF EXHAUST GASES

The electronic systems of engine control (ECS) are equipped with self-diagnostic system and do not need any technical service but the general check after their repair and adjustment or after the repair and adjustment of the units connected with them.

Electronic control systems of engine OM501 LA V The engine is equipped with the electronic system for fuel injection control (EDC) of UPS type (Unit

Pump System), that is designed for dose and advance angle control of the fuel injection. Additionally, in order to provide Euro 5 ecological class the vehicle is equipped with the Selective Catalytic Reduction (SCR) with the ammonia injection (AdBlue).

Arrangement of the system elements in the cab and on chassis is shown in the Figure 8.3. Arrangement of the system elements in the cab: panel of relay and protectors, installation of electronic blocks – in the Figure 8.4, location of the control lamps and control elements – in the Figure 8.5, location of sensors of the ECS of engine and SCR system – in the Figure 8.6, location of under pedal sensors and test connector – in the Figure 8.7, appearance of the under steering switch of “Cruise control” mode – in the Figure 8.8, electrical circuit diagrams – in the Figures 8.6, 8.10 and 8.11, possible malfunctions and ways of their removal are stated in the Table 8.1.

Electrical block (position 11, Figure 8.3) of the engine is connected with the acceleration pedal (position 8), with the under pedal sensors of clutch and brake, with the mode switches, and also with the control board indicators and control lamps (indicators) through the interface electronic block (position 1) mounted in the cab, and the CAN bus of information transmission.

Information on the speed of the vehicle is transmitted from the tachograph to the interface block, and then to the CAN bus, and via the bus – to the electronic engine block.

Electrical switch ВКП-31, actuated by the driver’s left foot, is used as a sensor of the engine brake turn-on condition.

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1 – interface electronic block; 2 – OBD connector; 3 –tachograph; 4– engine brake valve 1; 5 – harness of ECS of engine; 6 – panel relay and protectors; 7 – dashboard; 8 – electrical acceleration pedal; 9 – engine fuel switch; 10 – electronic block of engine; 11 – electronic block of engine; 12 – AdBlue dosage valve; 13 – engine brake drive cylinder; 14 – AdBlue injector; 15 – AdBlue level and temperature sensor; 16 – AdBlue tank; 17 – engine brake valve 2; 18 – catalytic muffler for exhaust gases; 19 – reduction valve; 20 – pump module of the SCR system; 21 – SCR harness; 22 – SCR electronic block.

Figure 8.3 – Arrangement of the elements of electronic system of engine control (ECS)

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Figure 8.4 – Arrangement of the elements of the electronic system of engine control in the central part of the dash panel (designation corresponds to the electrical circuit diagram)

Observance of rules and safety standards when running the truck with the ECS of engine 1) It is strictly forbidden to turn the key in the ignition lock to the position “III” (LOCK) during the

movement. 2) The use of radiotelephones and portable radio transmitters, whose antenna is situated inside the

vehicle, can cause failures of the UPS electronic system and breach of secure vehicle operation. 3) Before starting the engine it is necessary to make sure that connection of the main lead to the starter

and to the battery positive terminal is secure. 4) It is prohibited to disconnect the battery with the engine working. 5) Avoid polarity changing of the battery. 6) The battery charge indicator light should not burn on the engine working. 7) It is forbidden to use the charging station or the starting device to start the engine. 8) When using accelerated charging (increased current) you should disconnect the battery.

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9) At the temperatures higher than 90 ºС (drying room) it is necessary to remove the electronic blocks. 10) Connections of the electronic control blocks can be disconnected only with the ignition lock in OFF

position. It is necessary to take into consideration that the connectors that are connected to the electronic blocks are under voltage even when the main switch is turned off.

11) Maintenance and repair of the UPS and SCR systems should be carried out at the Mercedes–Benz service station.

12) Electric welding is allowed only under the following conditions: – disconnect the cables from the battery and connect them together; – welding should be carried out only with the constant current strictly following the polarity; – main switch of the battery should be switched off (i.e. its contacts should be closed); – grounding of the electric welding device should be made as close as possible to the place of welding

on the secure current-conducting place; – do not place the cable of the welding device in parallel with the electric wires of the vehicle; – the elements to be welded should have a secure connection with the negative electrode of the welding

device. 13) When moving downhill take every measure to prevent the engine revolutions from exceeding

2500 rpm. Failure to comply with the requirement will generate exceed of the permitted rotating speed of the engine, thus, it will cause serious damage to the engine.

System functioning In the main operation mode the system provides optimal fuel control when starting the engine and in the

process of vehicle movement depending on the temperature and sensors conditions. It also provides maximum speed limit (for instance, 85 km/h, if such parameter is saved in memory of the electronic block by the manufacturing plant).

Engine start Before starting the engine all the engine systems should be filled up in accordance with the standards of

filling, and fuel system should go through the fuel system priming. At the moment of turning the key in the ignition lock to the ACCESSORY position, control lamps

(positions 1, 2, 3, 4, 5) should light in the main dashboard field (Figure 3.2); and if there are no failures of the engine control system, the indicators will go out in 2–3 sec. (positions 1, 2, 4, 5; battery charge control lamp on the dashboard and the gearbox control position indicator (position 3) should remain lighted, and this would mean that engine is ready to start).

Note – When turning the key in the ignition lock to the ACCESSORY position the electric torch control

lamp should light for 2–20 sec. (depends on the coolant liquid temperature). If after turning the key in the ignition lock to the “On” position, the control lamps do not go out – it means there is a failure in the system that should be discovered and removed before the engine start.

System failure diagnostics should be carried out in the way described below (see the section “System diagnostics”).

Having tested the functioning of the control lamps, NOT EARLIER, you may start the engine. When starting the engine DO NOT DEPRESS THE ENGINE CONTROL PEDAL. After starting the engine the control lamp of the battery charge should go out (otherwise, stop the engine and eliminate a malfunction).

If a red control lamp (position 1, Figure 8.5) with EDC symbol lights up some time after the engine was started it is necessary to stop the engine immediately. The red control lamp signalizes about major failure in the system; the fault should be discovered and eliminated.

After the engine is stopped and the key in the ignition lock is turned to the OFF position, the scavenging of the SCR system with the compressed air begins automatically (2–3 min.) – in order to remove the remains of ammonia solution from the piping and injector avoiding its crystallization. This cycle of work is accompanied by the characteristic sound of the pump module work; this sound does not imply any malfunction of the ammonia injection system.

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1– EDC indicator lamp (red); 2– Engine exhaust system failure indicator lamp (yellow); 3– Neutral switching indicator lamp (green); 4– Low level of ammonia solution in the system(green); 5– Electronic engine management system (yellow).

Figure 8.5 – Control and indication elements on the dash panel

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1 – coolant liquid level sensor; 2 – charge air heating valve and plug; 3 – coolant liquid temperature sensor; 4 – oil temperature sensor; 5 – oil pressure sensor; 6 – charge air pressure and temperature sensor; 7 – fuel temperature sensor; 8 – air pressure sensor in the AdBlue system; 9 – AdBlue temperature sensor; 10 – AdBlue pressure sensor; 11 – crankshaft revolution sensor; 12 – camshaft revolution sensor; 13 – air humidity and temperature sensor; 14 – tenuity sensor of the air; 15 – AdBlue level and temperature sensor; 16 – before catalyst temperature sensor; 17 – after catalyst temperature sensor.

Figure 8.6 – Arrangement of sensors of the electronic system of engine control and of the SCR system on the vehicle units: а) top view; б) lateral view.

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Figure 8.7 – Arrangement of the under pedal sensors and the OBD connector

Idle speed adjustment Adjustment (change) of the idle speed is an extra option. Adjustment should be carried out with the stationary vehicle. During adjustment it is prohibited to depress the clutch and brake pedal. Engine speed change is carried out by pressing the under steering switch (press and hold in SET+

position). Thus the engine speed can be increased, for instance, up to 800 rpm, and then can be slowed down (press and hold in SET– position) to the idle speed.

When the lock key in the ignition lock is turned to the OFF position, the engine speed adjusted this way is not maintained.

Maintenance of set travel speed (“Cruise control”) In the “Cruise-control” mode a steady speed of the vehicle is maintained as set by the driver, because of

automatic control of the engine speed. To switch on the mode it is necessary to press the button “Cruise-

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control”, as it is shown in the Figure 8.5. In order to capture the speed it is necessary to press the under steering switch briefly to the SET+ position when the speed of travel is not less than 48 km/h. Positions of the under steering switch are reflected in the Figure 8.8. Further control of the vehicle is carried out with the released acceleration pedal. It is possible to increase/decrease the speed of travel by pressing the under steering switch to the SET+ / SET– position.

In case of necessity to make overtaking the acceleration pedal should be pressed. Thus the set speed can be increased but after the pedal is released the system returns to the initial position (i.e. it maintains the initially set speed again).

You can switch off the mode by pressing the button “Cruise control” on the dash panel (the button “Aus” of the under steering switch is not used), or by pressing the clutch or brake pedal.

ATTENTION DRIVER! When moving downhill, take every measure that would prevent the engine from gathering speed more

than 2500 rpm. Failure to comply with the requirement will generate exceed of the permitted rotating speed of the engine, thus, it will cause serious damage to the engine.

1

SET+

0

SET-

Under steering switch positions: 0 – normal position; SET+ – “Cruise-control” mode switching, increase of speed or revolutions; SET– – decrease of speed or revolutions. 1– indication LED of “Cruise-control” switching on.

Figure 8.8 – “Cruise-control” mode under steering switch

In order to avoid possible vehicle damage and to provide personal security, it is not recommended to use speed maintenance mode in the following situations:

1) When it is impossible to maintain the vehicle at the steady speed, i.e. in weaving sections, in hard driving conditions, running variable speed, etc.

2) On slippery roads (on snow or ice covered roads), on wet pavement, on rolled gravel pavement, or on unpaved gravel road, etc.

Engine brake engagement The engine brake is engaged by pressing the switch (position 9) located on the floor of the cab to the

left side of the driver seat, as it is shown in the Figure 8.3. Braking deceleration is provided during the whole period of the switch holding. There are two stages of

adjustment. The first stage of deceleration is engaged when the button of engine brake efficiency increase is released (Figure 8.5) – engine brake valve is actuated (engine brake valve turns on the air actuator that cuts off the exhaust manifold with the help of a valve flap). The second stage of deceleration is engaged when the button is pressed: engine brake valve and constant pressure throttle are actuated (engine brake efficiency increases).

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When the engine brake is switched on, the fuel is not supplied to the engine. In order to prevent involuntary engine shutdown with rotational speed less than 1000 min-1 the engine brake switches off automatically.

Electric torch device for engine start facilitation Electric torch device is an auxiliary device for starting a cold engine when the ambient temperature is

below zero. Electric torch device consists of electronic block (Figure 8.4) mounted in the cab, control lamp on the

dash panel, electromagnetic valve, glow plug and fuel injector installed on the engine. Fuel injector sprays the fuel in the engine suction manifold; then the fuel ignites with the help of the glow plug and thus heating the suction air.

If the temperature of the coolant liquid is below 4 ºС, the torch device (after the engine start) reduces the exhaust gas emissions. Moreover, detrimental effect on the starter and the battery when starting a cold engine is also reduced, and the starting time decreases. That is why the engine start should be carried out only after the control lamp of the electric torch device goes out, as it is shown in the Figure 8.5. The engine start should be carried out within 30 sec. after the lamp goes out.

Electric torch device for engine start facilitation switches off automatically: – if the engine is not started within 30 minutes after the control lamp of the electric torch device goes

out; – if the engine is started within the time when the lamp still lights; – if the temperature of the coolant liquid with the working engine reaches 0 ºС. If the temperature of the coolant liquid is above 4 ºС, the control lamp of the torch device goes out

approximately in 2 sec. (electric torch device functionality control only). If the temperature is below 4 ºС, the control lamp of the torch device goes out approximately in 20 sec.

If the temperature sensor of engine coolant liquid fails (position 3, Figure 8.6), the electronic block of the electric torch device calculates temperature according to the readings of the engine oil temperature sensor.

SCR system functioning System of selective catalytic reduction of exhaust gas provides observance of ecological compatibility

rules for engine work. The ammonia solution injection occurs directly at the moment when the catalyst (located inside the

muffler) temperature reaches 400 ºС. After starting the engine with the SCR system in good order electromagnetic reducing valve (position

19, Figure 8.3) for pressure limiting opens; the valve supplies the air to the element of AdBlue injection. Engine electronic block controls the AdBlue pump that injects the solution from the tank into the

injecting module (proportioner) where the solution is under the working pressure about 5 atm. As the electronic block transfers a control signal to the proportioning valve, it opens, and an AdBlue portion get into the compressed air flow, and having blended with it, finally gets to the injector. Then it injects the mixture into the incandescent flow of the exhaust gases. As a result nitrogen oxide is neutralized in the muffler providing the required level of exhaust gases ecological compatibility.

After key-off the ignition the SCR system is blown though with the compressed air in order to avoid freezing of the AdBlue liquid.

In order to provide control of neutralization parameters in the system additional sensors are used (NOx sensor, sensor of temperature in the muffler, AdBlue level and temperature sensor). The signals from the sensors are received in the control unit of the SCR system (“frame” module), and then it transfers via the information CAN bus into the electronic control block.

SCR system control is exercised according to the control lamps. Control indicators are located in the field of main dashboard (Figure 3.2).

System diagnostics Diagnostics of electronic control system of engine OM501 LA.V This kind of diagnostics as well as system configuration is exercised with the help of diagnostic set by

specially trained staff on the service station. There are two types of diagnostics provided: – simplified version (according to the control lamps); – full version (with the help of special diagnostic equipment).

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Possible malfunctions of the system and the ways of their removal are stated in the Table 8.1.

Simplified diagnostics When turning the key of the ignition switch (the key in the ignition lock switch is set in ACCESSORY

position, and also during the whole period of the engine work, the electronic system of engine control and SCR system of ammonia injection exercise self diagnostics and record codes of system failures to the nonvolatile memory of electronic units. Each system failure is indicated with the help of control lamps and is displayed on the main dashboard field, as it is shown in the Figure 8.5.

Red control indicator (position 1) gives a signal that there is a serious failure in the system of engine control. In case the red control indicator lights up, it is necessary to stop the vehicle movement and stall the engine as soon as possible. In order to prevent the engine and its systems from breakdown the movement of the vehicle can only be allowed with towing, and the engine start is only permitted after all the malfunctions are eliminated in a service station.

IT IS STRICTLY FORBIDDEN TO START THE ENGINE WITH THE EDC CONTROL INDICATOR ON (POSITION 1, FIGURE 8.5)!

The control indicator lights up also when the maximum engine speed is exceeded!

Yellow control indicator (position 2) warns about the SCR system failures that appeared during the engine work. The lighting up of the control indicator can be accompanied by the torque and engine power decrease. In order to avoid it, it is necessary to eliminate malfunctions in the shortest time possible (not more than 50 cycles). It is permitted to continue the movement of the vehicle with yellow control indicator on.

Green control indicator (position 3) informs that the gear-change lever is set in the neutral position. When getting into any gear – the indicator goes out.

In order to start the engine it is necessary to switch the gear-change lever into the neutral position, otherwise the engine won’t start!

Green control indicator (position 4) signalizes about the low level of ammonia solution in the AdBlue tank. If the control indicator is blinking, the AdfBlue tank is empty, and it is necessary to fill it with ammonia solution.

Yellow control indicator (position 5) warns about failures in the engine control system (about those failures that are not connected with possible engine breakdown or safe movement of the vehicle). However, engine start quality and haulage capacity of the engine may change, and fuel consumption increases. Therefore, it is necessary to eliminate malfunctions. Further movement of the vehicle is allowed.

Full diagnostics Full diagnostics is carried out with the help of diagnostic instrument MiniDiag2 or with the help of

specialized diagnostic equipment StarDiagnose by the trained staff which disposes of the corresponding certificate. The vehicles, with the control indicators (position 1, 2 and 5, Figure 8.5) constantly on, are subject to full diagnostics.

There is a special OBD diagnostic connector (position 2, Figure 8.3) installed on the vehicle in order to connect diagnostic equipment; it is located in the lower part of the dash panel at the right side (in front of a passenger seat).

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Table 8.1 – Possible failures and ways of their removal

Signs of failures Reason Ways of removal

1 2 3 Electronic block supply voltage

is absent. Check the supply protection

devices of the electronic block and system, and change them if necessary.

Wiring failed. Contact fault in connectors.

Check the wiring. Eliminate the failure in wiring and connectors.

Control lamps are not connected or are out of order.

Check operability and connection of the control lamps.

Control lamps of the engine control electronic system and of the SCR system don’t switch on when turning the switch key of the ignition to the ACCESSORY position. Other control lamps are on.

Electronic block is out of order. Change the electronic block.

One of the gears is switched in the gearbox.

Switch the gear-change lever into the neutral position.

Low voltage of the battery. Check the battery condition. Recharge or change the battery.

Emergency drop of oil pressure. Engine overheating.

Check oil pressure according to the pressure indicator. Check oil level in the engine.

Air presence in the system, low-quality fuel, clogged fuel filters.

Check airtightness of the fuel system, change filters and fuel, and pump fuel system.

Camshaft sensor is out of order. Check the camshaft sensor and its electric circuits, remove the fault.

Disorder of the contact in connectors of the engine control electronic system and of the cab, in the interface block connection, in CAN bus.

Check harness connection of the engine control electronic system to the cab, security of interface block connection to the CAN bus.

The engine does not start.

Electronic block of the engine is out of order.

Change electronic block of the engine.

Battery is discharged, control block circuits supply is out of order or absent.

Check the battery and protective devices of supply circuits; change them if necessary.

Engine brake is engaged. Check the system of engine brake.

Air presence in fuel, clogged filters.

Eliminate air inflow, change filters and pump fuel system.

Low-quality fuel. Change fuel.

Crankshaft sensor is out of order.

Check the crankshaft sensor and its electrical circuits, eliminate malfunction.

The engine does not start or its work is not stable.

Electronic block of the engine is out of order.

Change electronic block of the engine.

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1 2 3 Engine brake is engaged. Check the system of engine

brake. Hermeticity of inhaust fuel pipes

failed, low-quality fuel, clogged filters.

Проверить герметичность топливной системы, заменить фильтры, топливо и прокачать топливную систему.

Emergency drop of oil pressure. Engine overheating.

Check oil pressure according to the pressure indicator. Check oil level in the engine.

Hermeticity failure or turbocharging system is out of order.

Check the turbocharging system, change turbo-charger.

The engine does not develop full power, or fades.

Electronic block of the engine is out of order.

Change electronic block of the engine.

Adjustment failure or brake and clutch pedals’ sensors are out of order.

Adjust operating clearance or change the faulty sensor.

Electric circuits of the Cruise-control switch or electric circuits of brake and clutch pedals’ sensors are out of order.

Check electric circuits and eliminate the malfunction.

Vehicle speed signal from the tachograph is absent.

Check the signal in the CAN bus, tachograph functioning, tachograph sensor functioning.

Cruise-control mode does not work or turns off inadvertently.

Interface electronic unit (ADM) or engine block is out of order.

Change interface electronic unit or engine block.

The engine does not stall. Wrong connection of the control electronic system to the electrical equipment of the vehicle.

Check the system connection to the electrical equipment of the vehicle.

The engine brake switch does not work or connected incorrectly.

Check the switch and its connection to the harness of the engine brake. Change the switch.

The engine brake does not work.

Engine brake valves are connected incorrectly or do not function.

Check connection and operability of the engine brake valves.

When the ABS system actuates, the engine brake does not shut down.

No connection with the ABS/ ASC block.

Check and connect the harness connectors of ABS/ ASC and engine control electronic system.

Acceleration spin control (ASC) system does not function.

No connection with the ABS/ ASC block.

Check connection with the CAN bus and with the harness connectors of ABS/ ASC and engine control electronic system.

SCR system control lamp turns on.

SCR system failure, AdBlue low level or absence.

Check SCR system, AdBlue presence, eliminate the failure.

Speed limit mode does not function.

Tachograph is not connected or calibrated, the parameter is not written in the ADM block.

Check the tachograph connection circuits; test the tachograph and the ADM block.

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1 2 3

Intermittent brief lighting up of the EDC control lamp (yellow).

Failure in the system. Carry out the diagnostics of the engine. Eliminate malfunctions.

Starter works in bursts. When starting the starter, the signal about gearbox neutral position is missing.

Check the cables fixation to the mass common point. Carry out the diagnostics of the system.

Engine revolutions are constant and cannot be adjusted.

Connection failed between the cab ADM block and engine MR; engine control accelerator pedal is not installed or not adjusted.

Test the engine. Eliminate malfunctions.

Excessive urea consumption. The pump and air supply valve are connected incorrectly.

Check and eliminate.

During the movement the EDC control lamp (yellow) turns on. After the engine stop it temporarily goes out.

Incorrect indication of the boost air pressure sensor.

Check the sensor connection and commutation in compliance with the engineering documentation. Eliminate malfunctions.

Coolant liquid low level. When starting the engine the EDC red control lamp turns on, the EDC yellow control lamp is on. Critical error of the engine

control system.

Check the coolant liquid level. Carry out the diagnostics of the engine, and eliminate malfunctions.

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Figure 8.9 – Electric circuit diagram of connection of engine control electronic system elements, mounted in the cab.

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Figure 8.10 – Electric circuit diagram of elements connection of engine control electronic system

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SCR system In order to reduce environmentally harmful vehicle exhausts and to conform with the Euro-5

requirements the BlueTec® technology is used, that consists in after-treatment processing of the engine emissions.

The technology is based on the Selective Catalytic Reduction method (SCR) that is as follows: owing to the AdBlue ammonia solution injection into the wastegate line of the exhaust system there occurs the chemical transformation of toxic nitrogen oxides (NOx) with further innocuous nitrogen and water vapour (Н2О) formation in the catalytic silencer (muffler).

The necessary amount of the AdBlue ammonia solution injection is determined electronically. The system is shown in the Figure 8.12, and it includes: AdBlue tank, force-pump module, injector, NOx

sensor with electronic block, solution heating system with electromagnetic valve, catalyst silencer.

Figure 8.12 – Schematic diagram of the SCR system

Principle of operation After starting the engine the system testing function is activated in the engine control electronic block. If

the system operates correctly, the electromagnetic valve of the pneumatic valve block is switched on, and the compressed air, incoming from the additional consuming circuits, is supplied: a) to the dosing device and then goes through it into injector; b) to the force-pump module. In the force-pump module the overload valve closes under the impact of the compressed air. Thus isolating the AdBlue drain line from the tank, it makes it possible to pump the AdBlue into the dosing device. It doesn’t depend on whether the Adblue is injected or not: due to the constant air flow through the dosing device, and then throw the fittings and injector, it is guaranteed that the delivering AdBlue portion for injection will reach the injector in proper time without delay. Moreover, constant air blowing of the system components prevents from the AdBlue crystallization and, as a result, from clogging up of the dosing device, injector and fittings that connect them.

When the engine control block, on the basis of the information received from the sensors, sends a control signal to the AdBlue pump, the AdBlue is pumped from the tank into the pump module, from which it is supplied further into the dosing device. As soon as the engine control block sends an electric signal, the dosing valve opens and an AdBlue portion, being under pressure, gets into the compressed air flow and, having mixed with it, is supplied to the injector. Then the AdBlue mixture is sprayed into the scorching exhaust flow that gets into the suction pipe where the AbBlue hydrolysis occurs and the exhaust toxicity decreases.

After switching off the ignition the dosing device is blown through automatically by the compressed air, in order to avoid ammonia solution remains crystallization. It may last 300 sec. by means of valve opening and closing. Among the parameters that influence the blowing duration are: the AdBlue pressure in the dosing device and air pressure in dosing device.

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It is necessary to continually monitor the level of ammonia solution in the AdBlue tank and the control lamps indication on the dashboard. If the level of ammonia solution in the AdBlue tank drops down to 14 %, the level control lamp turns on; and if critical level is achieved, it begins to blink.

Attention driver! Lack of solution circulation in the pump module leads to requirements violation of the Euro 5

standards. When you restart the engine, in case of (continuous (more than 50 cycles) lack of ammonia solution in the AdBlue tank, the control block will reduce the engine power by 40%.

The vehicle movement without ammonia solution in the AdBlue tank is recorded to the MR memory. This information is stored for 400 days. These values can be controlled by the environment security staff, which may impose a fine on you.

The heating of the tank and pump module is carried out by the coolant liquid circulating through them (when the coolant liquid temperature reaches 65 ºC, a signal is transmitted to the engine control block that opens the electromagnetic valve supplying the coolant liquid to the SCR heating system).

Attention driver! The system heating is possible only during the movement (on-loading) and is impossible when the

engine is running on the idling speed. In case there are failures in the SCR system or in the engine, please, consult the service station.

Fifth wheel coupling Fifth wheel device is fastened to the frame by means of the brackets (position 16) as shown in the

Figure 8.13.). The saddle is mounted to the brackets (position 16) with the help of the brackets (position 17). Saddle brackets are based on the pads (position 18) which are located in the sockets of the saddle.

Coupling mechanism is located under the saddle; it consists of rear grip (position 12), front grip (position 13) and the locking cam (position 5) that has two positions – open and closed. There is a spring (position 4), installed on the rod of the locking cam (position 5), that holds the cam (position 5) in the closed position. In order to open (to move) the cam there is a handle (position 1) at the end of the rod that is fastened with nuts (position 3). The nuts (position 3) are also used to adjust the play in the grips with the trailer kingpin. The cam is held in the open position with the help of a spring clip (positions 10 and 7 accordingly).

The rear grip (position 12) is rotated on a pin (position 15) closed with a lid (position 8) that is fixed by means of a nut (position 14). To prevent accidental opening of the cam there is a safety strap (position 20), which is attached to the saddle with a bolt (position 21). The spring (position 4) presses the rod of the locking cam (position 5) with a locking collar to the side of the hole.

In order to avoid gapping of the rear grip end (position 12) to the cam (position 5), there is a swivel mounting (item 6) embedded in the grip.

The design of the fifth wheel device provides adjustment of the diameter kingpin holes to eliminate plays (gaps) between the grips and the kingpin.

Clearance adjustment during initial coupling of the truck-tractor with a semitrailer is performed in the following sequence:

– unscrew the nuts (position 3) on the rod; – couple the truck-tractor with a semitrailer and drive (100-200) meters applying the brake of the

roadtrain (2-3) times in order to select the play between the grips and the kingpin; – tighten the nuts (position 3) until they contact with the handle (position 1), at this the handle should be

in contact with the saddle. After that, give a half turn to the nut and lock it. In order to eliminate the gaps in the grips during operation it is necessary to loosen the nuts (position 3),

drive the roadtrain (100-200) meters applying the brake until plays disappear, and then tighten the nut until it contacts with the handle (item 1) that should be in contact with the saddle. After that, give a half turn to the nut and lock it.

If it is impossible to adjust the clearance due to wear of the locking cam and grips, change the worn and deformed parts and re-adjust plays between the grips and the kingpin, as described above.

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Coupling and uncoupling of the tractor lorry (truck tractor) with a semi-trailer When coupling the tractor lorry with the semi-trailer the support plate with the semi-trailer king pin

should be located on the same level from the ground surface as the fifth wheel saddle of the truck tractor, or not more than 10 mm below it. Moreover, the semi-trailer should be put on the parking brake.

If the grips are closed it is necessary to pull the handle in (position 1, Figure 8.13), at the same time the handle should be held by the latch (position 7) in shifted position. After that turn the latch (position 12) counter-clockwise until the front butt end of the grip goes out of the zone of the semi-trailer king pin movement. When turning, the grip affects the latch and turns it, thus releasing the locking knuckle which, while moving, leans on the grip and holds it in open position.

Coupling should be carried out in the following order: – place the truck tractor to the semi-trailer making reverse movement at a low speed so that the king pin

of the latter gets into the grips of the fifth-wheel device. Coupling of the truck tractor with the semi-trailer is carried out automatically.

After that, make sure that the safety bar (position 20) has taken a vertical position and prevents the handle pulling-in movement.

– lift the supports of the semi-trailer landing gear in running position; – connect the cables of electric wiring to the plug socket of the truck tractor and semi-trailer; – connect the hoses (with the red head – feeding, and the yellow head – controlling) of pneumatic drive

of the truck tractor brakes to the connective heads of the semi-trailer; – release the parking brake of the semi-trailer; – move the road-train on some distance; make sure of the coupling serviceability, and of the semi-trailer

brakes operability; check the operation of electrical devices of the semi-trailer. Uncoupling should be carried out in the following order: – put the semi-trailer on the parking brake; – lower the supports of the semi-trailer landing gear down to the limit; – disconnect the connection hoses of the brake pneumatic drive from the connective heads of the semi-

trailer and close the latter by covers; – pull in the handle (position 1) of the fifth wheel device, and at that time the safety bar (position 20)

will take shifted position, and the latch (position 7), leaning against the locking knuckle (position 5), will hold it in open position;

– shift the first gear and slowly, without jerks, move the truck tractor forward. At that time the semi-trailer king pin turns the rear grip (position 12) relatively to the pin (position 15), and the grip butt end depresses the latch (position 7), turns it, releasing the locking knuckle (position 5). The locking knuckle, being moved by the springs (position 10), leans against the rear grip (position 12) and holds it in open position.

Fifth wheel maintenance Before starting operation of the vehicle check security of the fifth wheel attachment to the vehicle frame,

condition of the grips, locking knuckle and latch springs. The parts which are worn-out and deformed should be renewed timely. At least once a year it is

necessary to clean bearing surface of the saddle and grips and knuckle from the old lubricant and lubricate it again according the lubrication chart.

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1–handle; 2,4,10–springs; 3,14–nuts; 5–locking knuckle; 6–rotating base; 7–latch; 8–cover; 9,11,21–bolts; 12–rear grip; 15–pin; 16,17–brackets; 18–pad; 19–fifth-wheel saddle; 20–safety bar.

Figure 8.13 – Fifth wheel device

BRAKE SYSTEM

The vehicle is equipped with service, parking, reserve and auxiliary brake systems, and also with the instruments for linking the semitrailer braking system with the double-wire pneumatic drives and outputs for feeding other consumers with compressed air.

Service brake system affects the braking gears (mechanisms) of all wheels of the vehicle. The drive of the gears is pneumatic with front and rear wheels divided braking.

In the braking gears drive there are electro-pneumatic pressure modulators installed of the antilock braking system (ABS).

Parking and reserve brake systems affect the rear axle braking gears that are actuated with the help of braking chambers with spring brakes. The control is carried out with the help of the lever in the driver’s cab.

Parking brake systems also performs the function of the reserve brake system. It is designed to brake the vehicle in case of total or partial failure of service brake system.

When the parking brake system is engaged the control lever handle is set (by turning it) in the extreme fixed position. Compressed air that compresses the power springs of the spring brakes passes to the atmosphere and the springs actuate the braking gears.

When the reserve brake system is engaged the handle of the parking brake control lever is held in any intermediate position.

With increase of the handle turning angle the braking intensity increases due to the reduction of air pressure that compresses the springs of the spring brakes.

Auxiliary brake system affects on the vehicle transmission by making counter-pressure in the gas exhaust system with the help of the throttle gate with pneumatic drive. It is intended to brake the vehicle slowly on the long downgrades of the mountain roads. The vehicle is equipped with the speed limit system, and also with the acceleration spin control (ASC) that consists of electromagnetic valve and 2 two-line valves. Both systems are controlled electronically. The air is supplied to the fuel supply limit cylinder through the proportional valve that is controlled by the ABS and speed limit systems. The engine is controlled electronically.

When braking the truck tractor with the help of service or parking (reserve) systems, semitrailer stops simultaneously with the vehicle.

There are disk brakes with movable brake caliper and ventilated brake disk installed on the front and rear axles of the vehicle. In order to keep uniform clearance between friction pads and disk, the brake gears are equipped with automatic device of brake shoes wear compensation.

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In order to actuate the front brakes diaphragm brake chambers with specific internal seal are applied.

IT IS FORBIDDEN TO INTALL OTHER TYPES OF BRAKE CHAMBERS AS IT PUTS THE BRAKE GEARS OUT OF ORDER.

Technical description of the brake is given in the Table 8.2.

Table 8.2 Parameter Value

Wheel size, inch 22,5 Brake shoe thickness, including the base of the brake shoe, mm 30 Minimum thickness of the brake pad when it is to be changed, mm 2 Total clearance maintained by the clearance adjuster, mm 0,6...0,9 Brake disk diameter, mm 430 New brake disk thickness, mm 45 Minimum thickness of the brake disk when it is to be changed, mm 37

Maintenance of the disk brakes consists in regular change of the pads as far as they are worn-out, and also in brake disk inspection for wear or damage as it is shown in the Figure 8.14.

If the friction pad thickness decreased to 2 mm, it is to be changed. It is allowed to change the brake shoes only as a set – all the shoes of one axle at once.

IT IS PROHIBETED TO INSTALL ON THE SAME AXLE THE SHOES OF DIFFERENT MANUFACTURERS AND WITH DIFFERENT THICKNESS OF FRICTION PAD.

1 – presence of small scratches is permissible; 2 – presence of single damages under 0,75А in length, and up to 1,5 mm in depth and width is permissible if they are directed at the hub center; 3 – longitudinal scratches up to 1,5 mm in depth are permissible; 4 – solid line damages directed at the hub center are impermissible; А – height of the disk working section.

Figure 8.14 – Permissible and impermissible brake disk damage

Circuit diagram of the vehicle brake system pneumatic drive is shown in the Figure 8.15.

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1 – compressor; 2 – pressure regulator with an adsorber; 3 – regeneration tank; 4 – four circuit valve; 5 – towing valve; 6 – consumers air tank; 7 – front circuit air tank; 8 – rear circuit air tank; 9 – parking circuit air tank; 10 – button switch of the engine brake flap; 11 –electromagnetic valve of engine brake; 12 – pneumatic cylinder of the engine brake flap; 13 – electromagnetic valve of engine permanent throttles; 14 – tire inflation valve; 15 – brake valve; 16 – front circuit ABS modulator; 17 – front brake chamber; 18 – rear circuit ABS modulator; 19 – brake chamber with spring brake; 20 – service brake system acceleration valve; 21 – two-line valve; 22 – ASC valve; 23 – semitrailer brake control valve; 24 – control coupling head (yellow cap); 25 – feeding coupling head (red cap); 26 – brake system parking brake valve; 27 – return valve; 28 – parking brake system acceleration valve; 29 – test outlet valve; 30 – sensor block; 31 – condensate drain valve.

Figure 8.15 – Circuit diagram of the brakes pneumatic drive

There is a scheme in the Figure 8.16 that illustrates the system of air preparation for ammonia solution injection system.

1 – consumers air tan; 2 – electromagnetic valve; 3 – return valve; 4 – relief valve.

Figure 8.16 – Scheme of system of air preparation for ammonia solution injection system

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Brake pneumatic drive maintenance When servicing the pneumatic drive of the vehicle brakes, first of all, it is necessary to monitor air

tightness of the whole system and its certain elements. Particular attention should be paid to the connections air tightness of the piping and flexible hoses; and also it is important to check the connection areas of the hoses for the reason that these are frequent areas where compressed air leakage appears. The areas of major leakage are detected by ear, and the areas of poor leakage are detected with the help of soapy emulsion. Air leakage from the piping connections is eliminated by tightening or changing its certain connection elements.

The leakage is eliminated by tightening the nipples with the following torque: for piping with diameter of 6 mm – (9,8–12,3) N∙m, 10 mm – (21,6–27,5) N∙m; 15 mm – (49–60,8) N∙m.

If the leakage cannot be eliminated after the tightening, it is necessary to change rubber sealing rings. In order to avoid breakdown of the connecting lug bosses on the brake device, tightening torque of the

connecting pipes, plugs, nuts and other fittings should not exceed (30–50) N∙m.

Possible malfunction of the brake system and ways of their removal are given in the Table 8.3.

Table 8.3 Malfunction Cause Way of removal

Incomplete brake release Brake pedal free play is absent Adjust free play of the pedal

Substantial free play of the pedal

Adjust free play

Substantial stroke of the brake chambers rods

Adjust rod stroke

Delayed action brake

Inadequate air pressure in the system

Check and, if necessary, adjust belt tension of the compressor

Check air tightness of the pneumatic system (the point of leakage is detected by the hissing sound of the outgoing air, and also by coating the supposed leakage points with the soapsuds)

Air leakage through the atmospheric outlets of the pneumatic instruments is eliminated by cleaning or changing (if worn-out) of the corresponding valves, and also by changing the springs of the valves

Air leakage in joints of different connections is eliminated by tightening the bolts, fastening or changing the corresponding sealing rings

Air leakage through pipe connections is eliminated by tightening the connecting nuts or changing the rubber sealing rings

Parking brake release cannot be carried out

Mainline of the parking brake drive is damaged

Before eliminating the malfunction for brake release unscrew the bolt 8 (Figure 8.2)

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STEERING CONTROL

Steering control includes steering gear with a built-in distributer, column, steering wheel, actuating cylinder, pump, oil tank, and also hoses.

The steering gear with a built-in distributer and fluid pressure restriction valve are shown in the Figure 8.17.

The axis of the bushing (position 8, 15) external contour is shifted relative to the axis of the bearing hole (position 11) by “h” amount of excentricity, what provides the opportunity of adjusting the gearing by turning the bushings (positions 8, 15).

Bearing (position 29) tightness adjustment is carried out with the help of the gasket (position 1). Distributor of steering gear hydraulic booster is a piston valve type distributor built-in in the steering

gear.

Steering control adjustment and maintenance Steering control maintenance consists in periodical checkup and tightening of the fastenings, and also in

air tightness checkup of all the sealings. Gear drive of the pump mounted on the vehicle does not need any maintenance.

1–adjusting gasket; 2–screw; 3–rack-and-pinion; 4–housing; 5–distributor; 6–channel; 7–sector; 8, 15–eccentric bushings; 9–pin; 10, 16, 28–cap; 11, 29–bearings; 12–hole; 13–pressure restriction valve; 14–ring reboring; 17, 27–lateral face; 18, 26–roller; 19, 25–lever; 20–rod; 21–nut; 22–plug; 23–housing; 24–lock nut; 30–plug.

Figure 8.17 – Steering gear

When changing the oil in the hydraulic system you should lift the front axle of the vehicle. For oil discharge from the system: – remove the oil filler cap and drain plug of the oil tank, drain the oil from the tank and rinse the filter

and the tank with diesel fuel; – discharge oil from the steering gear housing, for this purpose unscrew the plug (position 30), as it is

shown in the Figure 8.17;

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– disconnect the hydraulic cylinder pipings from the distributor and drop them in a reservoir, and slowly turning the steering wheel to the right and to the left (lock-to-lock), discharge oil from the hydraulic cylinder.

When charging oil in the hydraulic system it is necessary: – to lower the front axle of the vehicle; – to charge oil into the tank to the top edge of the filler; – to start the engine and let it idle (5–10) seconds. In the case the oil level in the tank does not decrease,

briefly accelerate engine speed up to (1000–1500) min-1. After lowering the oil level in the tank stall the engine, add oil into the tank and re-start the engine. The operation is to be performed before the termination of oil level lowering in the tank;

– At idling speed of the engine slowly turn the steering wheel from one position to another and back again until no more air bubbles, without holding the steering wheel in the extreme positions for more than 5 seconds and without applying force to it higher than the force of the steering wheel in the range of stroke. If necessary, add oil to the tank to a level between the marks on the dipstick. In order to measure the oil level in the oil tank it is necessary to insert the dipstick into the hole up to the stop without screwing it;

– to close the filler neck of the oil tank.

Steering gear adjustment Steering gear adjustment includes adjustment of the screw bearings and adjustment of the gear quadrant

toothing and rack-and-pinion. You should start the adjustment from screw bearings in the following sequence:

– remove the steering gear; – drain the fluid from the steering gear by removing the drain plug; – fix the steering mechanism in the gripe by the housing lugs in a horizontal position with the sector up; – by turning the input shaft set rack-and-pinion (position 3) and sector (position 7) in one of the extreme

positions (left o right), as it is shown in the Figure 8.17; – determine the torque required for turning over the input shaft in the direction from the extreme to the

average position (by approximately 30º). If the torque is less than 0.9 N∙m, it is necessary to adjust the tightness of bearings (position 29), reducing the number of gaskets (position 1).

After adjustment the torque required for turning over the input shaft should be in the range of (0.9–1.5) N∙m. In order to check gearing for clearance it is necessary to set the rack-and-pinion and the gear quadrant to the middle position (total number of input shaft revolutions is divided in two) by rotating the input shaft, and set the drop arm on the sector shaft (position 7). By rocking the drop arm to both sides you should determine whether there is any clearance (if there is any, a rattling sound is heard in the gearing, and moreover, the sector shaft can be rotated, and the input shaft is fixed). The clearance can also be determined by turning the input shaft to the left and to the right before twirling the torsion shaft, but having stopped the sector shaft.

For gearing adjustment it is necessary to remove the cap (positions 10 and 16) and turn the bushings (position 8, 15) clockwise by the same angle (view from the sector shaft side) so as to eliminate clearance in the gearing. Caps installation (positions 10 and 16) should be carried out so that the pins (position 9) fit the holes in the bushings (position 8, 15) arranged on the same diametrical plane with the threaded holes in the housing for fastening the caps. If there is a slight mismatch of holes with the threaded holes of the housing, turn the bushings (position 8, 15) to one side or another to match the above mentioned holes, while drawing attention to the absence of clearance in the gearing. The pins (position 9) should be placed opposite to each other on the same line.

After adjustment during installation the caps (position 10, 16) can be rotated by 90 °, 180 ° and 270 ° relative to their initial position.

Having installed the cap the torque, required for turning over the input shaft in the middle position, should lie within the limits of (2,9–4,5) N∙m.

After the adjustment works are performed the steering gear should be mounted on the vehicle and connected to the steering column and hydraulic cylinder; then test the steering control functioning.

If the adjustment is performed correctly (with the adjusted articulated joints of the steering link, front-wheel bearings and kingpin connections, front-axle beam – steering knuckle), when turning the steering wheels in position on asphaltic surface the steering wheel effort with the idling engine should be not more than 118 N and total play should not excess (10–12)°. During operation the total play increase is permitted but not more than 18°.

Adjustment of the quadrant (sector) (position 7, Figure 8.17) rotational angles at which pressure restriction valve (position 13) actuates, should be carried out directly on the vehicle in the following way:

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In order to increase the quadrant (position 7) rotational angles and, consequently, the rotational angles of the steering wheels to the left up to the set value, it is necessary to unscrew the locknut (position 24) so that it could go out from the contact with the housing (position 23), and turn the plug (position 22) counterclockwise, while the nut (position 21) with the rod (position 20) and the lever (position 19) will move downward providing roller’s (position 21) moving away from the lateral face (position 17) of the quadrant (position 7).

After the adjustment screw the nut (position 24) holding the plug (position 22) to avoid its rotation. In order to decrease the quadrant (position 7) rotational angles and, consequently, the rotational angles

of the steering wheels to the left, it is necessary to unscrew the locknut (position 24) so that it could go out from the contact with the housing (position 23), and turn the plug (position 22) clockwise, while the nut (position 21) with the rod (position 20) and the lever (position 19) will move upward providing roller’s (position 21) approach to the lateral face (position 17) of the quadrant (position 7).

After the adjustment screw the nut (position 24) holding the plug (position 22) to avoid its turning over. In order to increase or decrease the quadrant rotational angle and, therefore, rotational angle of the

steering wheels to the right up to the set value by similar adjustment the roller (position 26) with a lever (position 25) moves away from or approaches to the face (position 27) of the quadrant (position 7).

Steering column Steering column tilt angle and height adjustment is carried out by pressing the pedal (position 8), as it is

shown in the Figure 8.18. At the initial moment of pressing the pedal the rack (position 4) disengages, and adjustment of the

steering wheel position is provided only by the tilt angle. When moving the pedal to the full speed, another rack disengages (position 2), thus, adjustment of the steering wheel position is provided by tilt angle and height.

After setting the steering column to the convenient position, release the pedal.

IT IS PROHIBITED TO PERFORM ADJUSTMENT WHEN DRIVING.

The function of energy-absorbing device (of the collapsible steering wheel) is performed by the rack gearing (position 4) and the quadrant (position 5). When affecting the steering wheel the gearing teeth are cut.

1 – bracket; 2, 4 – rack, 3, 5 – sector, 6 – steering column, 7 – spring, 8 – pedal.

Figure 8.18 – Steering column with the bracket

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9 TIRES MOUNTING AND DISMOUNTING

Tire fitting shall be performed in a tire fitting section or premises meant for these operations using special equipment, accessories and tools.

When carrying out tire fitting it is strictly forbidden: – to start dismounting the tire from the rim without making sure it is completely deflated; – to dismount the tire from the vehicle without taking measures for preventing rolling of the vehicle; – to use hammers, crowbars and other heavy things that can deform the wheel parts; – to mount the tire on a non-corresponding wheel rim; – to use tires having edge fins, cuts and other damages and wheels having violation of nicks geometry,

cracks, burs, rust markings on the landing surface; – to start up tires pumping without making sure that it is has taken the right position on the rim; – to pump tire out of special guarding – in road conditions not complying with safety regulations; – to carry out dismounting of one of the dual wheels without using a jack, but driving with the second

wheel onto the objects jutting out from the surface; – pump the tire up to the pressure that exceeds the set standards; – pump the tire, without taking it off from the truck at decompression in tire more than 40 percent from

the nominal pressure. It is necessary to remember that the wheels (metallic part) related to the category of nonrepairable, that

is why if there is any crack detected the wheel is rejected, i.e. it is to be changed.

Wheels and tires maintenance In order to provide security keep the tightening torque of the wheel fastening nuts of (500 – 600)

Nm. Remember the following points that conduce to the tire wear: – presence of plays in the hub bearings and steering parts, improper adjustment of wheel alignment,

presence of play in the front axle kingpin connection, and also improper adjustment of the front axle alignment and the axes spacing accuracy;

– wrong style of driving (abuse of brakes, running over potholes and curbs); – overload of the vehicle or uneven distribution of the load (tire overload by 25 % reduces the service

life by approximately 40 %); – failure to comply with the air pressure norms in the tires (even a slight decrease in air pressure in the

tires results in heating of tires, and their increased wear; impairs road stability and increases fuel consumption; increased air pressure in the tires enlarges the stopping distance, worsens tire traction, and increases their wear);

– mismatching of dual tires by degree of wear (difference in the tread depth of the dual tires should not exceed 5 mm if the tread groove is measured in the center of the tire tread).

During operation of the vehicle tires should comply with the following rules: 1) Daily before driving out check the tire condition, tread wear and fastening of the wheels. For the tires

with wear indicators (feathers at the bottom of the tire tread grooves, with height equal to the minimum acceptable residual height) if the tread wear is even, it is determined by a single indicator that appears on the tire; of the tread wear is not even, then the wear is determined by both indicators in each of the two sections. The minimum allowable tread pattern residual height is stipulated in the legislation of your country. In any case the height of the tire tread pattern of less than 1 mm should be withdrawn from service. In case there is an apparent air leakage from the tire, detect and correct the cause, bring the air pressure in conformity with the norm. Do not allow using the tires with cracks, breaks, blisters, foreign objects stuck in the tread or between dual tires. Do not pump or pump up the tire which was deflated without disassembly and inspection for damage.

2) At least once a week and before long trips check the internal pressure of all tires, including the spare tire and, if necessary, bring it in compliance with the standards.

In order to check the pressure there is a manual pressure gauge attached in the tool kit. Periodically reconcile the manual gauge readings from the test pressure gauge readings.

Air pressure in the tires of one axle must always be the same. Do not check or adjust air pressure in the heated tires.

3) Check for caps on the valves. They protect the valve pistons from moisture and dirt penetration. 4) Do not overload the tires (do not allow loading of the vehicle above its rated capacity).

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5) Vehicle braking is carried out smoothly preventing the wheel slip as it leads to increased wear of the tread.

6) Do not allow driving on the curbs and obstacles with sharp edges as this may result in appearance of externally indistinguishable damage of tire casing that can eventually lead to rupture of the tires. If there is a tire blowout, take prompt action to stop the car. Do not allow driving and parking of the vehicle on the tires with low air pressure.

7) Use anti-skid chains only when it is necessary to overcome the impassable track sections and remove them as soon as there is no need for using them anymore. Choose the chains that fit the tires size. It is prohibited to use anti-skid chains on paved roads.

8) Make sure that no oils, fuel, lubricant and other petroleum products got to the surface of tires, as it quickly puts them out of service.

9) Do not allow parking of the vehicle lot with a full load in one place for more than two days. 10) Do not mount tires with different tread patterns on the same axle (except for the temporary spare

wheel installation to follow to the nearest parking place or service station with observance of the required precautionary measures), different dimensions, diagonal and radial design, and also tires of different models or manufacturers. Do not allow mounting of cold-resistant (cold weather) and ordinary all season (non-cold resistant) tires on the vehicle, even those of the same model because of the difference in their heating time.

11) Do not install tires with repaired local damage on the front axle wheels. 12) Tires with directed tread pattern must be mounted on the vehicle taking into consideration required

direction of rotation. 13) When installing a new tire make sure that the load and speed standards specified on its side surface

correspond to the characteristics of the vehicle, and also ensure implementation of tire manufacturer recommendations concerning the standards for tire pressure (normal pressure is calculated for a loaded vehicle).

14) Wheel switching is to be performed if there is technical necessity detected (tire damage, need for proper selection of dual tires, ensuring of more reliable tires on the front axle of the vehicle, uneven intensive wear of the tire tread, etc.).

Figure 9.1 – Scheme of wheel switching on the vehicles with tires on the front axle and spare wheel with road tread pattern, and with the universal driving axle tread pattern.

When changing a wheel comply with the following rules: – when using a jack apply it only for a short-term lifting of the vehicle (the jack is not designed for

lifting in order to perform any work under the vehicle); – before jacking the wheel to be removed brake the vehicle with the parking brake, engage first gear in

the gearbox and chock up the rest of the wheels. Ensure safe jack installation. On loose ground it is obligatory to place the jack on a solid backing. The support point for the jack should be firm and flat;

– ensure that the height when lifting the wheel from the ground does not exceed 30 mm. Otherwise, the vehicle may slide off the jack or fall;

– in order to avoid sliding off the jack, do not change the wheels on uphill or downhill gradients;

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– never put feet or hands under the lifted vehicle, and do not lie under it; – make sure that when lifting a vehicle there are no people in it; – for the vehicles with air suspension, take measures to exclude the possibility of automatic change of

the chassis height; – do not lift the vehicle equipped with hoisting crane or lift tailgate with the help of the hydraulic

mounting available on it. This may cause damage to the vehicle frame; – in order to avoid slipping off the jack do not run the engine on a lifted vehicle, in this position it is

necessary to avoid any other possible shaking; – do not attempt to demount one of the dual wheels without using a jack but by driving with the second

wheel onto the object jutting out from the surface; – in order to remove or mount the wheels do not use sledgehammers and similar instruments that can

deform the wheel; – be careful when removing or installing the wheel on the hub. Due to the significant amount of weight

of the wheel even a small center-of-gravity shift can cause its overturning, thus, it can injure you or other people. Remove the wheel from the studs only after complete elimination of any torsion;

– when installing the valve extension, tighten the extension sleeve nut manually on the valve body before contact of the seal ring with the metal, and then tighten the nut giving one turn to the key (no more);

– before mounting the wheel, clean the contact surfaces of the hub and wheel disc, and also clean wheel fastening nuts from rust, dirt, metal burrs, paint residues, etc. Apply a small amount of engine oil to the threads of wheels fastening bolts;

– when installing dual wheels align disk gaps of both wheels in order to allow installation of the valve extension of the inside wheel and facilitate access to the valve of the outside tire;

– tighten the wheels fastening nuts in several steps in the following order: first, tighten the top nut, then diametrically opposite to it, the rest of the nuts also should be tightened in pairs (crosswise). Tightening torque is (500-600) Nm.

For tightening use the tool designed especially for that purpose (wheel nut wrench is attached to the tool kit of the vehicle). For high-quality tightening it is recommended to tighten upward over the lever arm of the instrument. Remember that excessive nut tightening is dangerous. In order not to exceed the allowable torque, do not resort to artificial means that enhance the tool arm (pipes that extend the rods, and etс.);

– in order to ensure security, having changed the wheels and after 50 km traveled, check wheel nuts tightening and, if necessary, tighten them with a torque complying with torque standards. When mounting new or newly painted wheels additionally tighten the wheel nuts after the run of (1000-5000) km.

To facilitate the wheels installation on the hub before installation it is recommended to lubricate wheel disc center holes with graphite grease or other materials designed especially for this purpose.

Inflation of the tubeless tires should be carried out with an increased air supply at initial time.

Tire inflation For tire inflation from the vehicle pneumatic system it is necessary to use the control output valve or tire

inflation valve. For that reason you should do the following: – remove protection caps from the valve and tire valve; – screw the nut of tire inflation hose to the valve output; – press the head of tire inflation hose to the valve body. Before pumping the tires it is necessary to raise the air pressure in the air brake system up to 800 kPa

(up to regulator actuation of pressure on compressor unload). If the vehicle is equipped with a pressure regulator with an air bleed valve for tire inflation, then air bleed can be performed from it after reducing pressure in the air brake system down to the lock-up of the pressure regulator (650kPa). When pumping, the tire pressure should be controlled with the tire pressure gauge.

Spare wheel fastening Spare wheel fastening is shown in the Figure 9.2. In order to remove spare wheel you should do the following: – unscrew the nuts (position 4) fastening the holder (position 6) to the bracket (position 1); – lower the wheel rotating the podger in gripping device (position 10) (with the use of the handle of cab

lifting pump) counterclockwise; – release holder from the wheel disc.

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Wheel lifting and fastening are to be carried out inversely. If resistance to shaft rotation is negligible or absent when lifting the wheel, it is necessary to tighten the nut (position 7) that adjusts force of disk spring pack (position 8).

When lifting and lowering a wheel it is necessary to follow security regulation: – before lifting and lowering a wheel make sure that the detent (position 2) is engaged with the ratched

wheel (position 3) under the influence of the spring (position 9); – when lifting the spare wheel it is necessary to draw attention to accuracy of cable winding on the

roller, especially important are the first five coils. The cable should wind evenly from the embedding point.

1 – bracket, 2 – detent, 3 – ratched wheel, 4 – nut, 5 – shaft, 6 – holder, 7 – nut, 8 – disk spring, 9 – spring, 10 – захват.

Figure 9.2 – Spare wheel fastening

ATTENTION DRIVER! IT IS FORBIDDEN TO MOUNT ON THE SAME AXLE OF THE VEHICLE THE TIRES OF

DIFFERENT DIMENSIONS, CONSTRUCTION, MODELS WITH DIFFERENT TYPES OF TREAD PATTERN, AND ALSO TIRES AND WHEELS OF DIFFERENT MANUFACTURERS.

IT IS PROHIBITED TO OPERATE THE VEHICLE IF THE TIRES WITH DIFFERENT TYPES OF TREAD PATTERN ARE MOUNTED ON THE REAR AXLE; EXCEPT FOR ITS TEMPORARY INSTALLATION IN ORDER TO MOVE TO THE NEAREST PARKING AREA OR SERVICE STATION COMPLYING WITH THE REQUIRED PRECAUTIONARY MEASURES.

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10 ADJUSTMENT WORKS

Steering gear adjustment Steering gear adjustment includes adjustment of the screw bearings and adjustment of the gear quadrant

toothing and rack-and-pinion. You should start the adjustment from screw bearings in the following sequence:

– remove the steering gear; – drain the fluid from the steering gear by removing the drain plug; – fix the steering mechanism in the gripe by the housing lugs in a horizontal position with the sector up; – by turning the input shaft set rack-and-pinion (position 3) and sector (position 7) in one of the extreme

positions (left o right), as it is shown in the Figure 8.17; – determine the torque required for turning over the input shaft in the direction from the extreme to the

average position (by approximately 30º). If the torque is less than 0.9 N∙m, it is necessary to adjust the tightness of bearings (position 29), reducing the number of gaskets (position 1).

After adjustment the torque required for turning over the input shaft should be in the range of (0.9–1.5) N∙m. In order to check gearing for clearance it is necessary to set the rack-and-pinion and the gear quadrant to the middle position (total number of input shaft revolutions is divided in two) by rotating the input shaft, and set the drop arm on the sector shaft (position 7). By rocking the drop arm to both sides you should determine whether there is any clearance (if there is any, a rattling sound is heard in the gearing, and moreover, the sector shaft can be rotated, and the input shaft is fixed). The clearance can also be determined by turning the input shaft to the left and to the right before twirling the torsion shaft, but having stopped the sector shaft.

For gearing adjustment it is necessary to remove the cap (positions 10 and 16) and turn the bushings (position 8, 15) clockwise by the same angle (view from the sector shaft side) so as to eliminate clearance in the gearing. Caps installation (positions 10 and 16) should be carried out so that the pins (position 9) fit the holes in the bushings (position 8, 15) arranged on the same diametrical plane with the threaded holes in the housing for fastening the caps. If there is a slight mismatch of holes with the threaded holes of the housing, turn the bushings (position 8, 15) to one side or another to match the above mentioned holes, while drawing attention to the absence of clearance in the gearing. The pins (position 9) should be placed opposite to each other on the same line.

After adjustment during installation the caps (position 10, 16) can be rotated by 90 °, 180 ° and 270 ° relative to their initial position.

Having installed the cap the torque, required for turning over the input shaft in the middle position, should lie within the limits of (2,9–4,5) N∙m.

After the adjustment works are performed the steering gear should be mounted on the vehicle and connected to the steering column and hydraulic cylinder; then test the steering control functioning.

If the adjustment is performed correctly (with the adjusted articulated joints of the steering link, front-wheel bearings and kingpin connections, front-axle beam – steering knuckle), when turning the steering wheels in position on asphaltic surface the steering wheel effort with the idling engine should be not more than 118 N and total play should not excess (10–12)°. During operation the total play increase is permitted but not more than 18°.

Adjustment of the quadrant (sector) (position 7, Figure 8.17) rotational angles at which pressure restriction valve (position 13) actuates, should be carried out directly on the vehicle in the following way:

In order to increase the quadrant (position 7) rotational angles and, consequently, the rotational angles of the steering wheels to the left up to the set value, it is necessary to unscrew the locknut (position 24) so that it could go out from the contact with the housing (position 23), and turn the plug (position 22) counterclockwise, while the nut (position 21) with the rod (position 20) and the lever (position 19) will move downward providing roller’s (position 21) moving away from the lateral face (position 17) of the quadrant (position 7).

After the adjustment screw the nut (position 24) holding the plug (position 22) to avoid its rotation. In order to decrease the quadrant (position 7) rotational angles and, consequently, the rotational angles

of the steering wheels to the left, it is necessary to unscrew the locknut (position 24) so that it could go out from the contact with the housing (position 23), and turn the plug (position 22) clockwise, while the nut (position 21) with the rod (position 20) and the lever (position 19) will move upward providing roller’s (position 21) approach to the lateral face (position 17) of the quadrant (position 7).

After the adjustment screw the nut (position 24) holding the plug (position 22) to avoid its turning over. In order to increase or decrease the quadrant rotational angle and, therefore, rotational angle of the

steering wheels to the right up to the set value by similar adjustment the roller (position 26) with a lever (position 25) moves away from or approaches to the face (position 27) of the quadrant (position 7).

68

Steering column Steering column tilt angle and height adjustment is carried out by pressing the pedal (position 8), as it is

shown in the Figure 8.18. At the initial moment of pressing the pedal the rack (position 4) disengages, and adjustment of the

steering wheel position is provided only by the tilt angle. When moving the pedal to the full speed, another rack disengages (position 2), thus, adjustment of the steering wheel position is provided by tilt angle and height.

After setting the steering column to the convenient position, release the pedal.

Declutching drive Hydraulic Declutching drive with pneumatic booster is shown in the Figure 10.1. Free travel of the clutch pedal of 5–7 mm is regulated by the bolt (position 6). During operation it is allowed (if necessary) to readjust free travel by means of changing the length of

the rod (position 3), by unscrewing the lock-nut. In order to provide declutching, it is necessary to adjust full travel of the pedal that provides the rod

travel of the pneumatic hydraulic unit 19, 5–22,3 mm with the help of bolts (positions 4 and 8). At filling of the clutch hydraulic drive system: working fluid should be discharged into the hydraulic

drive system under excessive pressure (200–300) kPa through the preliminary unscrewed valve (position 6) by (1–2) turnovers until complete disappearance of air bubbles in fluid that goes out into the tank (position 5). It is allowed to fill in the system through the tank (position 5) under pressure (200–300) kPa at unscrewed valve (position 6) by (1–2) turnovers until the fluid going out through the valve is clean and without air bubbles. After filling the system tighten up the valve (position 6) and put on a protective cover. Make an amount of fluid in the tank reach the level of (10–25) mm below the filler neck.

1 – pedal; 2 – hydraulic cylinder; 3 – rod; 4, 8 – stop bolt, 5 – tank; 6 – relief valve; 7 – pneumatic hydraulic cylinder.

Figure 10.1 – Declutching drive

69

After filling in the system with the liquid, it is necessary to check operational efficiency of the clutch drive. For this, it is necessary to freewheel with the engine heated to the operating temperature and push the clutch pedal all the way out, and in 20 sec. slowly get into the first or rear gear in the gearbox. If there is a grinding sound of the gear shift toothed mechanism, it is necessary to make extra adjustment of the clutch.

For the vehicles equipped with the range-change gearbox: when the clutch pedal is depressed all the way out, the bracket should move the valve rod of the gearbox splitter, installed on the front panel of the cab, by (3+0,5) mm. At this the air should come to the gearbox splitter. Adjustment is carried out if the air is present in the pneumatic system of the vehicle by means of moving the bracket with the bolts released.

Gearbox control drive Switching of the main gearbox and demultiplicator is carried out by the lever (position 1, Figure 10.2) of

the remote control mechanism. The splitter is controlled by the range switch (position 4) located on the gearshift lever (position 1). At lower position the range switch turns on the fast range in the auxiliary gearbox, at upper position – the slow range. The gear shift scheme is given in the Figure 10.2. Also, the gear shift scheme is stuck on the dashboard.

1, 8 – lever; 2, 7 – bolt; 3 – plate; 4 – switch; 5 – rod; 6, 14 – tail piece; 9 – pin; 16 – fork; 10 – bush; 11 – spring; 12 – shackle; 13 – locknut; 15 – nose piece; 19 – ball.

Figure 10.2 – Gearbox control drive

During operation process, if necessary, the following adjustments can be carried out: – lever (position 1) adjustment in the longitudinal direction; – lever (position 1) adjustment in the cross direction; – adjustment of the blocking device of telescopic mechanism. Lever (position 1) position adjustment in the longitudinal and cross directions is carried out by means of

moving and rotating the rod (position 5) in the tail piece (position 6) with the bolts (position 7) released. Angle α is to be set at 80º, and angle β=90º. Angle α can be adjusted by moving the plate (position 3)

with the bolts (position 2) released.

70

Adjustment of the blocking device of mechanism telescopic elements should be carried out in order to remove looses and increased slacks in the gearbox drive with the cab lifted, in the following way:

– uncotter the pin, unscrew the nut, take out the pin (position 9) and disconnect the rod (position 5) from the fork (position 16) of the gearshift lever;

– loosen the locknut (position 13) and unscrew the tail piece (position 14) against stop of the thread; – push the internal rod (position 5) against stop of shackle projections (position 12) into the nose piece

(position 15) slots; – keep the mechanism in compressed condition, screw in the tail piece (position 14) until the mechanism

is blocked by the bush (position 10) under the influence of the spring (position 11); – tighten the locknut (position 13); check operational accuracy of the blocking mechanism. With the blocked mechanism axial and angle plays should be minimal. When in unblocked position

(bush (position 21) is shifted to the right) the internal rod should be pushed out by the return spring by 35–50 mm. Further displacement of the extender should be smooth, without jamming, and blocking mechanism should provide accurate fixation of the rod extender in the initial position.

You should not allow curving and bending of the drive rod and its telescopic components. Adjustment of the gearbox drive should be carried out with the stalled engine.

71

11 MAINTENANCE OF THE VEHICLE

Reliable functioning of the truck depends to a considerable degree on opportune and qualified maintenance.

Works connected with adjustments and maintenance of devices of the engine feed circuit, electrical equipment, ABS and also units of hydraulic systems, pneumatic suspensions shall be performed on the maintenance station or special workshop where skilled specialists perform this work rapidly and with quality.

Having carried out the works connected with maintenance and with taking-off pneumatic, electric and hydraulic systems from the truck, check and remove harmful contacts of these systems with truck parts.

Maintenance of the power unit (engine, clutch, gearbox) is performed according to the instruction of plant manufactures.

Tightening torques of basic thread connections are presented in the Appendix 3.

Types and frequency of maintenance 1) Daily maintenance. 2) First maintenance (А) – after 22500 km of kilometers travelled. 3) Second maintenance (С) – after 45000 km of kilometers travelled. 4) Seasonal maintenance. Seasonal maintenance is combined with «С» or «А» and is performed two times a year at preparation of

the truck to operation in winter seasons.

Daily maintenance Make cleaning and washing works when necessary. Prior to engine startup check up as follows: – fuel margin in the tank (according to the indicator); – lightning devices and light alarm device; – oil level in the engine; – dash panel instrumentation functioning (control lamps, pressure indicators); – condition of tires, wheels (also spare wheel), their pumping, condition of disks; – fifth-wheel device operability; – sufficient coolant liquid level. After engine startup check up as follows: – oil pressure; – air pressure in the pneumatic system; – functioning of the brake system, including parking brake. It is necessary to check daily as follows: – level of fluid in the windscreen washer; – air pressure in tires when necessary. Works performed once in two weeks (on returning from the trip, at the base): – check for leakage of oil, fluid from the engine, gearbox, driving axles, steering control, cooling and

heating systems, suspension shock absorbers, hydraulic cylinders of the lifting mechanism of the cab; – check the fluid level in the clutch control drive tank; – check whether there is no condensate in receivers at the temperature of environmental air close to

0 °C; – in case there are difficulties in the engine startup by the electric starter, perform maintenance of

storage batteries according to the attached operation manual for batteries; – check free travel of the steering wheel, check for absence of plays in steering rods hinges (by swinging

the steering wheel). Maintenance works to be performed monthly: – check functioning of the independent liquid and air heaters according to the operation manuals of the

plant manufacturers.

72

FIRST MAINTENANCE (A)

When performing the maintenance of the truck after the indicated kilometers travelled, it is necessary to carry out works as it is stipulated in the daily maintenance, and apart from it do as follows:

1) Check up splinting of steering rods ball pin nuts, brake chamber fork pins and, if necessary, eliminate malfunctions.

2) Check up condition of rubber fittings of air pipes of the engine intake manifold and if necessary tighten up connections.

3) Carry out maintenance of storage batteries according to the attached operation manual; check up fastening of storage batteries; clean them from dust, dirt, and electrolyte tracks; clean air vents. Check connection of wire lugs with terminals. Grease terminals with lubricant Lithol-24. Check and, if necessary, tighten fastening bolt of the electrical connection of ground wires on side bracket of the engine support.

4) Check up the rod travel of brake chambers. If the rod travel does not meet the size of 38-44 mm, check correctness of setup of the adjustment lever, and find out the reason of its breakdown and eliminate it.

5) Check and, if necessary, tighten the fastening nuts of the truck platform to the truck frame, and adjust the locks of lateral and rear sides of the platform, providing firm adherence of the side locks to the columns’ knuckles.

6) Check up and, if necessary, adjust tension of the steering pump belts. 7) Check and, if necessary, tighten the wheels fastening nuts. 8) Make lubrication of truck units according to the lubrication chart.

Truck inspection after maintenance. After maintenance it is necessary to check operation of the engine, devices, steering, brakes and other aggregates and systems on the run or at the diagnostic station.

SECOND MAINTENANCE (С)

After the indicated kilometers travelled, the first maintenance is to be carried out and moreover the following should be done:

1) Check the thickness of brake linings through the hole in the brake mechanisms shield or at the removed brake drums (at seasonal maintenance). Thickness of linings shall not be less than 6 mm. If there is a reserve of 1 mm between the lining and the control fillet or the rivet (or shoe) the linings shall be changed.

2) Check and, if necessary, tighten the engine suspension cushion fastening nuts. 3) Check up fastening of the towing device with crossbeam, tightening and splinting of the slotted nut

and, if necessary, eliminate the malfunction. 4) Check up free travel and easiness of steering wheel turn with the working engine. 5) Inspection visually the frame condition, bolt connections of crossbeams to the frame girder. In case

there are visible motion marks of connecting and fastening elements (cover peeling, metal crumpling, gapping, etc.) it is necessary to tighten bolt connections.

Check and, if necessary, tighten the nuts that fasten the brackets of pneumatic suspension torque arm to the frame, and also check nuts and bolts fastening the torque arm to the bracket on the frame and to the axle (during every third C maintenance), the bolts that fasten the beams of rear pneumatic suspension to the axle (during every third C maintenance), after disconnecting the lower torque arms (by turns) from it. Moreover, if there is any leakage, check the rear suspension shock absorber force (tensile load is to be 7000 daN, not less than; pressure load – 1500 daN, not less than).

6) Check and, if necessary, tighten the nuts of spring u-bolts, fastening of brackets of the rear suspension pneumatic cylinders, and brackets of the balancing bogie to the frame. During u-bolt tightening of spring-balancing suspension take off the rear axle wheels.

7) Check and, if necessary, tighten the nuts fastening to the frame the following components: the fuel tank brackets and straps, brackets of the storage battery, brackets of the cab locking mechanisms, fastening nuts of the spare wheel, and fastening nuts of the spare wheel bracket.

8) Check up the condition of rubber boots and hoses on plug connectors of electrical equipment devices. Provide air tightness of these connectors.

9) Check and, if necessary, make adjustment of the headlights setup. 10) Check up and, if necessary, tighten the nuts of brake chambers fastening, the bolts of drive shaft

flanges fastening, supports, needle bearings covers. 11) Check up the play of hubs bearings of the front and rear wheels and, if necessary, adjust tightening

of bearings. The play is checked by wheel nutation on the vehicle lifted by a jack. Then, check the size of wheels toe-in after adjustment of bearings tightening.

73

12) At increased free travel of the steering wheel and absence of play in steering hinges demount steering mechanism and make its adjustment.

13) Check up and, if necessary, adjust free travel of the clutch pedal. 14) Check up the gearbox shift lever for plays in the gearbox drive. If necessary, make required

adjustments, eliminate plays. 16) After the first 60 000-80 000 km make tightness adjustment of bearings of driving conical gears,

axle differentials and output shaft of the intermediate axle.

Lubricate the truck according to the lubrication chart. Checkup of the truck after maintenance. After maintenance check the operation of aggregates,

mechanisms and systems of the truck in motion or at the diagnostics station.

SEASONAL MAINTENANCE

Additionally to the above listed works the following works are to be performed in autumn and in spring: 1) Change the oils, fuel and coolant fluid that correspond to the season. 2) Change filtering element of the air filter (once a year). 3) Change filtering element of the compressed air dryer (once in 1-2 years). 4) Adjust the ABS sensors.

TRUCK LUBRICATION

Perform lubrication of units and aggregates of the truck according to the lubrication chart. Perform lubrication of units and power units (engine, clutch, gearbox) according to specifications of the

plant manufacturer.

Attention Driver! The list of oils for the ZF gear-box and frequency of oil change are given in ZF specifications or in

ТЕ–МL 02 specifications which are available in service centers or on the web site: www.zf.com.

74

Amount of lubricant Lubricant changing (adding) frequency Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a

vehicle Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Feed system with the engines:

Fuel tank 505±15 l

— Daimler Chrysler OM501LA

1 tank

Diesel fuel according to the DIN EN 590 standard, referred to in the operation manual, service book that are enclosed to the vehicle, and also on the official web site of Daimler AG: http://bevo.daimler.com.

(40-1) l without diesel liquid heater

(40-1) l without diesel liquid heater

Engine cooling system: – Daimler Chrysler

OM 501 LA

1 tank

Coolant liquids according to the sheet 310 of the Mercedes-Benz Specifications for Operating Fluids, operation manual, service book (included in the packaging arrangement of the engine), and also in compliance with the recommendations on coolant liquids application, available on the web site of Daimler AG: http://bevo.daimler.com.

Coolant liquid BASF Glysantin G

48 It is permitted to use coolant liquids

of other brands provided on the sheet 310 of the Mercedes-Benz Specifications for Operating Fluids.

(42-1) l with diesel

liquid heater

(42-1) l with diesel

liquid heater

According to the operation manual, service book enclosed to the vehicle, and also in compliance with the technical service recommendations that are available on the web site of Daimler AG: http://bevo.daimler.com.

Change liquid in the cooling system; instructions are provided in the corresponding section of the operation manual, service book that are enclosed to the vehicle, and also on the official web site of Daimler AG: http://bevo.daimler.com.

Toxic suppression system in the exhausts of the vehicles equipped with the engine – Daimler Chrysler

OM 501 LA

1

AdBlue® urea solution (AUS 32 in compliance with the standards DIN 70070 and DIN V 70071, CEFIC standards) in accordance with the operation manual, service book (included in the packaging arrangement of the engine), the Mercedes-Benz Specifications for Operating Fluids, and also according to recommendations for AdBlue® urea solution application, that are available on the web site of Daimler AG: http://bevo.daimler.com.

90 l

90 l

LUBRICATION CHART

75

Amount of lubricant Lubricant changing (adding) frequency Lubrication (filling) point

Number of lubrication

(filling) points

Main brands (GOST, TU, OST standards),

application season

Foreign analogues (brand, specification, company) Filling

norms Total for a vehicle

Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Engine oil tray: – Daimler Chrysler

OM 501 LA

1

Engine oils according to the sheets 228.1/.2/.3/.5/.51 of the Mercedes-Benz Specifications for Operating Fluids, operation manual, service book enclosed to the vehicle, and also in compliance with the recommendations for engine oils application that are available on the web site of Daimler AG: http://bevo.daimler.com.

34 l

34 l

According to the operation manual, service book enclosed to the vehicle, and also in compliance with the technical service recommendations that are available on the web site of Daimler AG: http://bevo.daimler.com.

Change oil in the lubrication system; instructions are provided in the corresponding section of the operation manual, service book that are enclosed to the vehicle, and also on the official web site of Daimler AG: http://bevo.daimler.com.

А Check up the level of oil and, if

necessary, fill up to the level of the inspection hole.

Gearbox housing:

– ZF 16S221

1

Transmission oils according to the ZF TE–ML 02 specification given on the official web site of ZF company: www.zf.com.

Transmission oil Hipol Super SAE

80W–90 API GL–4 Transmission oil OMV gear oil MP SAE 80W–85 API GL–4 It is permitted to use

transmission oils of other brands as provided in the ZF TE–ML 02 specification.

13* l

13* l

According to the ZF TE–ML 02 specification, operation manual of ZF gearbox (attached to the vehicle), and also in compliance with the recommendations for maintenance of gearboxes, given on the official web site of ZF: www.zf.com.

Change oil in the gearbox housing, instructions for changing are given in the operation manual of ZF gearbox (attached to the vehicle), as well on the official website of the company: www.zf.com.

* - the oil amount at initial filling; when changing the oil the necessary oil volume can be reduced by 2-3 liters; if a vehicle is equipped with the Gearbox Power Take-Off, the oil volume increases by 0.7-1 l.

76

Amount of lubricant Lubricant changing (adding) frequency Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company)

Filling norms

Total for a vehicle

Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Change oil when repairing; fill up to

the level of the filler hole.

Check the oil level and add some oil, if necessary.

Cab lifting system – produced by Weber–

Hydraulik GmbH, Germany

1 Transmission oils for automatic gearboxes (ATF) according to the recommendations on maintenance of MAN 81.99589–4704 of 05–2002 in compliance with the МАN manufacturer standards: ATF MAN 339 type D ATF MAN 339 type F

0,6 l

0,6 l 2С

In order to change oil you should do the following:

1. Unscrew the filler cap. 2. Detach the upper hose of the

hydraulic cylinder from the adapter and lift the cab to the full angle; at this the used oil will be discharged from the detached hose. For full cab lifting it is necessary to add some new filtered oil into the pump.

3. Attach the upper hose to the adapter.

4. Detach the lower hose of the hydraulic cylinder from the adapter and lower the cab adding the new oil into the pump, if necessary; at this the used oil will be discharged from the detached hose.

5. Attach the lower hose to the adapter.

6. Add the oil until it reaches the filler lower edge level.

7. Screw the filler cap. Steering booster system: 1 Transmission oils for automatic

gearboxes (ATF) of the following brands:

–Shell Tellus T15; –Esso Univis N15; –Texaco Rando HDZ15; –Aeroshell Fluid 41.

7,0 l 7,0 l 3С 3С Change oil. Change the filter with paper filter element or wash the filter with the filter element from metal gauze on all the MAZ vehicles.

77

Amount of lubricant Lubricant changing (adding) frequency Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a vehicle

Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Bevel gear housing – rear axle

15 l

15 l

Maintenance-4500

А

2С *С

For mixture

Change oil after the running-in period.

Check the level of oil and, if

necessary, fill it up to the inspection hole level.

Drain the used oil, fill new oil up

to the inspection hole level. Drain rate is 12 l.

1

Wheel gear housing – rear axle

Maintenance-4500

А

2С *С

For mixture

Change oil after the running-in period.

Check the level of oil and, if

necessary, fill it up to the inspection hole level. At this the hole should be in the extreme bottom position.

Drain the used oil, fill new oil up

to the inspection hole level. Drain rate is 3,6 l.

2

All-season: Transmission oil ТАД17И (TAD17I) GOST 23652-79 (down to minus 30°С) ТМ-5-18, APGL-5 * Mixture 85% ТАД17И (TAD17I) +15% of diesel fuel «А», «З» (below minus 30°С)

Transmission oils Viscosity class SAE: In summer: SAE 90 (from -12°С to +38°С) In winter: SAE80W (from -26°С to +21°С) All-season: 75W-80 (from -40°С to +30°С) 75W-90 (from -40°С to +38°С) 80W-90 (from -26°С to +38°С) 85W-90 (from -12°С to +38°С) Under American classification API GL-3/4/5 MIL-L-2105 Under ZF TE-ML 02/05/07/12 classification Under МАN standards M3343 (API GL-4+5) М341 (API GL-4), М342 (API GL-5)

2,0 l 4,0 l

78

Amount of lubricant

Lubricant changing (adding) frequency Lubrication (filling)

point

Number of

lubrication (filling)

points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a vehicle

Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Bevel gear housing (hypoid version)

1 17,0 l 17,0 l Maintenance-4500 Change oil after the running-in period.

– rear axle

А

Check the level of oil and, if necessary, fill it up to the inspection hole level.

2С

Drain the used oil; fill new oil up to the filler bottom level.

Drain rate is 16 l.

Hubs of driving axles 2 2,0 l 4,0 l Maintenance-4500 Change oil after the running-in period.

– rear axle А Check the level of oil and, if necessary, fill it up to the inspection hole level. At this the hole should be in the extreme bottom position.

Transmission oils for hypoid gears: ТСп-14гип (Tsp-14hyp) (down to minus 20°С) ТМ-4-18 Companies Grupa LOTOS SA: TITANIS SAE 80W-90 API GL-5

Transmission oils by foreign manufacturers for the hypoid gears of the API GL-5 quality class, and viscosity class SAE In summer: 90 (up to +38°С) In winter: 80W (down to -26°С) All-season: 75W-80 (from -40°С to +30°С) 75W-90 (from -40°С to +38°С) 80W-90 (from -26°С to +38°С) 85W-90 (from -12°С to +38°С) 85W-140 (from -12°С to +55°С)

2С Drain the used oil, fill new oil up to the inspection hole level.

Drain rate is 2,5 l.

79

Amount of lubricant

Lubricant changing (adding) frequency Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a vehicle

Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Hydraulic jack ДГ 12 (DG 12)

1 0,4 l 0,4 l Change oil when repairing; fill up to the level of the filler hole.

Drain rate is 0,3 l.

Cab lifting system 1

Hydraulic oil ВМГЗ (МГ-15-В) or ВМГЗ-С (МГ-15-В(с)) ТУ (standard) 38 101479-86

MIL-H-6083D (USA) OX-15 according to DID-5540 (En) Shell company: Tellus 21 Aeroshell Fluid 7 Esso company: Esso Univis j 43, Esso Univis 40 Mobil Oil compamy: Mobil Fluid 93

0,9 l 0,9 l 2С In order to change oil you should do the following:

1. Unscrew the filler cap. 2. Detach the upper hose of the

hydraulic cylinder from the adapter and lift the cab to the full angle; at this the used oil will be discharged from the detached hose. For full cab lifting it is necessary to add some new filtered oil into the pump.

3. Attach the upper hose to the adapter.

4. Detach the lower hose of the hydraulic cylinder from the adapter and lower the cab adding the new oil into the pump, if necessary; at this the used oil will be discharged from the detached hose.

5. Attach the lower hose to the adapter.

6. Add the oil until it reaches the filler lower edge level.

7. Screw the filler cap.

80

Amount of lubricant

Lubricant changing (adding) frequency Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a vehicle

Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Cardan (drive) shafts needle bearings

а. Dimension type VII according to the РД 37.001.665-96 (guidance document). Flange with end splines, Т 180 according to ISO 12667. Dimension between the crossbar ends is 143 mm. Cross pin diameter is 33,635 mm. Pipe diameter is 94 interior х 4 mm.

С Lubricate until the lubricant appears from the face sealing edge of bearings.

– for 4х2 vehicles, with support

3 0,04 kg 0,12 kg

– for 4х2 vehicles, without support

2

Lubricant № 158М DIN 51502 (Germany) Shell company: Retinax HDX2 (МоS2) Mobil company: Mobilgrease Spesial (МоS2) BP company: Energrease L 21 M (МоS2) Texaco company: Molytex EP2 (МоS2) Esso company: Multi-purpose, Lithium

0,04 kg 0,08 kg

b. Dimension type VIII according to the РД 37.001.665-96 (guidance document). Flange with end splines, Т 180 according to ISO 12667. Dimension between the crossbar ends is 161 mm. Cross pin diameter is 45 mm. Pipe diameter is 105 interior х 6 mm.

– for 4х2 vehicles, with support 3 0,048 kg 0,144 kg

– for 4х2 vehicles, without support

2

Lubricant № 158М DIN 51502 (Germany) Shell company: Retinax HDX2 (МоS2) Mobil company: Mobilgrease Spesial (МоS2) BP company: Energrease L 21 M (МоS2) Texaco company: Molytex EP2 (МоS2) Esso company: Multi-purpose, Lithium

0,048 kg 0,096 kg

4С Disassemble the joints, wash and put fresh lubricant.

81

Amount of lubricant

Lubricant changing (adding) frequency

Lubrication (filling) point

Number of

lubrication (filling)

points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a

vehicle Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Spline connection of cardan (drive) shaft

а. Dimension type VII according to the РД 37.001.665-96 (guidance document). Flange with end splines, Т 180 according to ISO 12667. Dimension between the crossbar ends is 143 mm. Cross pin diameter is 33,635 mm. Pipe diameter is 94 interior х 4 mm.

– for 4х2 vehicles, with support 1 0,05 kg 0,05 kg

– for 4х2 vehicles, without support 1 0,05 kg 0,05 kg

Lubricant Lithol-24

DIN 51502 (Germany) MIL-G-10924C (USA) C.S.3107B grade XG- 279, (En) Shell company: Retinax EP2; Mobil company: Mobilgrease MP Mobilux EP2/ EP3 BP company: Energrease LS-EP2 Texaco company: Multifak EP2 Esso company: Beacon EP2

2А

Lubricate through the pressure lubricator until fresh lubricant is pressed out of the safety valve.

b. Dimension type VIII according to the РД 37.001.665-96 (guidance document). Flange with end splines, Т 180 according to ISO 12667. Dimension between the crossbar ends is 161 mm. Cross pin diameter is 45 mm. Pipe diameter is 105 interior х 6 mm.

– for 4х2 vehicles, with support 1 0,07 kg 0,07 kg

– for 4х2 vehicles, without support 1 0,07 kg 0,07 kg

Graphite lubricant УСсА (USsA) DIN 51502 (Germany) VV-G-671d (USA) Grade Grease 3 C.S.3113 grade XG-264, (Анг.) Shell company: Barbatia 2/3 Mobil company: Mobiltac 81 BP company: Energrease C36/C2G/GP2-G/GP3-G Texaco company: Clissando FMA-20 Esso company: VanEstan2

2А

Lubricate through the pressure lubricator until fresh lubricant appears out of the sealing edge.

82

Amount of lubricant

Lubricant changing (adding) frequency Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a vehicle

Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Cardan (drive) shaft support bearing

а. Dimension type VII according to the РД 37.001.665-96 (guidance document). Flange with end splines, Т 180 according to ISO 12667. Dimension between the crossbar ends is 143 mm. Cross pin diameter is 33,635 mm. Pipe diameter is 94 interior х 4 mm. – for 4х2 vehicles, with support

1 Lubricant Lithol-24

0,085 kg

0,085 kg

b. Dimension type VIII according to the РД 37.001.665-96 (guidance document). Flange with end splines, Т 180 according to ISO 12667. Dimension between the crossbar ends is 161 mm. Cross pin diameter is 45 mm. Pipe diameter is 105 interior х 6 mm. – for 4х2 vehicles, with support

1

0,1 kg 0,1 kg

А Support chamber is to be filled with the lubricant through the pressure lubricator that is located on the support cap, until fresh lubricant appears from the hole of the opposite lubricator unscrewed beforehand.

Cylinders of differential lock switch of the driving axle:

2С

for 2-axle (4х2) vehicles 1

0,015 kg

0,015 kg

Lubricant Lithol-24

DIN 51502 (Germany) MIL-G-10924C (USA) C.S.3107B grade XG- 279, (En) Shell company: Retinax EP2; Mobil company: Mobilgrease MP Mobilux EP2/ EP3 BP company: Energrease LS-EP2 Texaco company: Multifak EP2 Esso company: Beacon EP2

Dismantle, clean from sludge and lubricate with a thin coat.

83

Amount of lubricant Lubricant changing (adding) frequency Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a vehicle

Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Needle bearings of the steering column cardan joint

2 Lubricant № 158М DIN 51502 (Germany) Shell company: Retinax HDX2(МоS2) Mobil company: Mobilgrease Spesial (МоS2) BP company: Energrease L 21 M (МоS2) Texaco company: Molytex EP2 (МоS2) Esso company: Multi-purpose, Lithium

0,01 kg 0,02 kg 2С Lubricate through the pressure lubricator until fresh lubricant appears out of the sealing edge of the bearings of the cardan jointing.

Joints of cab lifting hydraulic cylinder

2 0,06 kg 0,12 kg C Lubricate through the pressure lubricator until fresh lubricant appears out of the clearances.

Splines of the shaft bottom of the steering column

1 0,02 kg 0,02 kg 2C Lubricate the shaft splines with the cab lifted.

Actuating cylinder of the hydraulic steering booster:

rear support 1 0,02 kg 0,02 kg C

joint 1 0,06 kg 0,06 kg A

Steering gear connections 2A

longitudinal 2 0,06 kg 0,12 kg

transverse 2

Lubricant Lithol-24

DIN 51502 (Germany) MIL-G-10924C (USA) C.S.3107B grade XG- 279, (EN) Shell company: Retinax EP2; Mobil company: Mobilgrease MP Mobilux EP2/ EP3 BP company: Energrease LS-EP2 Texaco company: Multifak EP2 Esso company: Beacon EP2

0,06 kg 0,12 kg

Lubricate through the pressure lubricator until fresh lubricant appears out of the clearances.

84

Amount of lubricant Lubricant changing (adding) frequency

Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a

vehicle Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Front-wheels bearings 2 0,5 kg 1,0 kg 2С Put the lubricant into the bearings up to the full cavity fill between the rollers.

Lubricate with a thin coat the

interior cavity of the hub and the cap.

Needle bearings of the kin pins of the front-axle steering knuckles

4

Lubricant Lithol-24

DIN 51502 (Germany) MIL-G-10924C (USA) C.S.3107B grade XG- 279, (En) Shell company: Retinax EP2; Mobil company: Mobilgrease MP Mobilux EP2/ EP3 BP company: Energrease LS-EP2 Texaco company: Multifak EP2 Esso company: Beacon EP2

0,02 kg 0,08 kg А Lubricate through the pressure lubricator until fresh lubricant appears out of the clearances.

85

Amount of lubricant Lubricant changing (adding) frequency Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a

vehicle Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Worm-and-worm pairs of wheel brakes automatic adjusting levers:

2C

– for 2-axle (4х2) vehicles

4 0,02 kg 0,08 kg

Lubricate through the pressure lubricator until fresh lubricant appears in the output of the safety valve without lever removal.

Roller bushing of expansion cam (front)

2

Lubricant ШРУС-4 (Shrus-4) DIN 51502 (Germany) Shell company: Retinax Grease EPX2 (MoS2) BP company: Energrease L21M (MoS2) Mobil company: Mobil-grease Spesial (MoS2) Castrol company: Castrol LM Fuchs company: Renolit MP 2 (MoS2)

0,025 kg 0,05 kg A Lubricate through the pressure lubricator.

Driving axles expansion cam shaft bearings (ШСП-42К):

2C

– for 2-axle (4х2) vehicles

4 0,015 kg 0,06 kg

Lubricate through the pressure lubricator until fresh lubricant appears out of the clearances.

Brake valve pedal bearing sleeves

1 0,04 kg 0,04 kg Lubricate when assembling and repairing.

Pusher slot of brake valve actuator

1

Lubricant Lithol-24

DIN 51502 (Germany) Shell company: Retinax ЕР2; Mobil company: Mobilgrease МР Mobilux EP2/EP3; BP company: Energrease LS-EP2; Texaco company: Multifak EP2; Esso company: Beacon EP2

0,005 kg 0,005 kg Lubricate the surfaces with a thin coat when assembling and repairing.

Bushes of the brake shoes rollers axis

Service Lubricate when assembling, repairing, changing the brake shoes and at seasonal vehicle maintenance.

– for 2-axle (4х2) vehicles

8 0,005 kg 0,04 kg

Brake shoes axes of driving axles

А

– for 2-axle (4х2) vehicles

2 0,01 kg 0,02 kg

Lubricate through the pressure lubricator until fresh lubricant appears out of the bleeder.

86

Amount of lubricant Lubricant changing (adding) frequency Lubrication (filling) point)

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a

vehicle Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Brake shoes axes of the front axle with forced lubrication

2 0,01 kg 0,02 kg А

Spherical surface of air to oil intensifier clutch pusher and lever slot on the roller

1

Lubricant ШРУС-4 (Shrus-4) DIN 51502 (Germany) Shell company: Retinax Grease EPX2 (MoS2) BP company: Energrease L21M (MoS2) Mobil company: Mobilgrease Spesial (MoS2) Castrol company: Castrol LM Fuchs company: Renolit MP 2 (MoS2)

0,005 kg 0,005 kg Lubricate when assembling and repairing.

Pedal of fuel supply drive – pedal pivot bolt

1 0,02 kg 0,02 kg C Dismantle, clean out the previous lubricant, and put new lubricant.

Engine stop cable 1 0,025 kg 0,025 kg 2C Dismantle, wash, fill the cable guide with the lubricant

Cable of fuel supply control

2 0,02 kg 0,04 kg 2C Dismantle, wash, and lubricate the cable with a thin coat of the lubricant.

Front support beam of pin-type

1 0,1 kg 0,1 kg 2C Lubricate through the pressure lubricator.

Gearbox control drive: Lubricate when assembling and repairing.

– spherical joint of transverse control arm

2 0,0025 kg 0,005 kg

– tailpiece spherical joint 1 0,005 kg 0,005 kg

– gear lever spherical joint

1 0,01 kg 0,01 kg

– intermediate mechanism

1

Lubricant Lithol-24

DIN 51502 (Germany) Shell company: Retinax ЕР2; Mobil company: Mobilgrease МР Mobilux EP2/EP3; BP company: Energrease LS-EP2; Texaco company: Multifak EP2; Esso company: Beacon EP2

0,04 kg 0,04 kg

87

Amount of lubricant Lubricant changing (adding) frequency Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a

vehicle Main brand Backing-

up brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Clutch control drive 1 Braking fluid «РОСДОТ» (ROSDOT), «РОСДОТ4» (ROSDOT4)

SAE J 1703, ISO 4925 FMVSS 116 type DOT3 and DOT4 (USA) Shell company: Shell Dona B ВР company: Petrosin Super Fluid J1703P Mobil company: Hydraulic Brake Fluid Esso company: Attas Brake Fluid CD

0,5 l 0,5 l A

Check the fluid level and add some if necessary.

Change the fluid once a year.

For the vehicles with mechanically driven speedometer

a. speedometer sensor drive gear

1 0,03 kg 0,03 kg 2C

Put fresh lubricant into the detachable gears cavity of the secondary shaft bearing cap.

b. driven roller of speedometer sensor drive

1

Grade C solid oil lubricant, grade C gun-solid oil lubricant

DIN 51502 (Germany) MIL-G-10924C (USA) Shell company: Retinax C BP company: Energrease C2, C3, GP2, GP3, PR2, PR3 Mobil company: Mobilux EP2

0,005 kg 0,005 kg Lubricate with a thin coat of lubricant when assembling and repairing.

Spring pins:

а) spring suspension: – for 2-axle (4х2) vehicles

4 0,015 kg 0,06 kg

б) pneumatic suspension – for 2-axle (4х2) vehicles

2

Lubricant Lithol-24

DIN 51502 (Germany) MIL-G-10924C (USA) C.S.3107B grade XG- 279, (En) Shell company: Retinax EP2; Mobil company: Mobilgrease MP Mobilux EP2/ EP3 BP company: Energrease LS-EP2 Texaco company: Multifak EP2 Esso company: Beacon EP2

0,015 kg 0,03 kg

A Lubricate through the pressure lubricator if the vehicle drives in the normal conditions.

If the vehicle drives on dusty and dirty roads it is necessary to lubricate daily.

88

Amount of lubricant Lubricant changing (adding) frequency Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a

vehicle Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Cab front suspension stabilizer

2 0,002 kg 0,004 kg 2С Lubricate through the pressure lubricator from both sides

Fixture bushings that fasten large cab locking mechanism

2

Lubricant Lithol-24

0,005 kg 0,01 kg Lubricate when assembling and repairing.

Bushings and axes of cab rear cushioning

Lubricate when assembling and repairing.

– large cab 4

DIN 51502 (Germany) MIL-G-10924C (USA) C.S.3107B grade XG- 279, (En) Shell company: Retinax EP2; Mobil company: Mobilgrease MP Mobilux EP2/ EP3 BP company: Energrease LS-EP2 Texaco company: Multifak EP2 Esso company: Beacon EP2

0,005 kg 0,02 kg

Frictional surfaces of seat rest lever pin

8 0,005 kg 0,04 kg Lubricate frictional surface when assembling and repairing.

Swinging and seat back fixing mechanism

2 0,01 kg 0,02 kg Lubricate frictional surface when assembling and repairing.

Seat longitudinal adjustment mechanism

4

Graphite lubricant УСсА (USsA) DIN 51502 (Germany) VV-G-671d (USA) Grade Grease 3 C.S.3113 grade XG- 264, (En) Shell company: Barbatia 2/3 Mobil company: Mobiltac 81 BP company: Energrease С36/ С2G/ GP2-G/ GP3-G Texaco company: Clissando FMA-20 Esso company: VanEstan2

0,005 kg 0,01 kg

(If necessary) lubricate the seat rail at the places of shifting of insert liners and rollers.

89

Amount of lubricant Lubricant changing (adding) frequency

Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a

vehicle Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

ABS sensor of the rear and front axle – manufactured by Wabco, Germany

4 Consistent lubricants according to the specification JED 564 f. Wabco: – Staburags NBU 30 PTM by Kluber Lubrication; – Urethyn-E2 by Fuchs Lubritech; – Mobilith SHC-220 by Mobil Oil; – Unirex N3 by Esso; – Eco-Li-Plus by Special type provided by BPW Company; – Molycote P40 by Dow Corning; – TEK-662 (former: EXP-135) by Roy Dean Products Company/USA; – Moly-Fortified Multi-Purpose Grease by Valvoline/USA

– manufactured by “Ekran” production association, Belarus, Borisov

Consistent lubricants of PENTA-200 series

0,0025 kg 0,01 kg Lubricate with a thin coat the surface of spring bushing and metal surface of the sensor when assembling and repairing.

Wiring “mass” fastening on the right side girder (longeron)

2 0,0025 kg 0,005 kg

Battery terminals with power lead lugs

4 0,005 kg 0,02 kg

Battery switch terminals with main lead lugs and control wire

3 0,003 kg 0,009 kg

Terminal fastening of the “mass” power lead – on the rear engine support 1 0,005 kg 0,005 kg Power lead and control wire fastening on the starter

2

Lubricant Lithol-24

DIN 51502 (Germany) Shell company: Retinax ЕР2; Mobil company: Mobilgrease МР Mobilux EP2/EP3; BP company: Energrease LS-EP2; Texaco company: Multifak EP2; Esso company:

Beacon EP2

0,005 kg 0,01 kg

Wiring connection to the generator – bolted joint 4

Lubricant ВНИИ НП-510 (VNII NP-510)

0,00125

kg 0,005 kg

С Lubricate contact areas with a thin coat.

– connector nests and pins

1 0,001 kg 0,001 kg

90

Amount of lubricant Lubricant changing (adding) frequency

Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a

vehicle Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Harness contacts on the left girder and rear lamp harnesses in connecting box (along the left) girder

24 Lubricant ВНИИ НП-510 (VNII NP-510)

0,0004 kg 0,01 kg С Lubricate contact areas with a thin coat.

Connection points of headlight and front turning indicators

24 0,0004 kg 0,01 kg

Connection points of side turning indicator on the fender and on the junction of the control block harness with the harnesses along the girders (lamp area)

16 0,0005 kg 0,008 kg

Windshield washer pump contacts

4 0,0005 kg 0,002 kg

Connection points of pneumatic signal electropneumatic valve

2 0,0005 kg 0,001 kg

Connection points of sound electric signals

2 0,0005 kg

0,001 kg

Front fog lamps connection points

– lug Ø 12,5 2 Lubricant Lithol-24

DIN 51502 (Germany) Shell company: Retinax ЕР2; Mobil company: Mobilgrease МР; Mobilux EP2/EP3; BP company: Energrease LS-EP2; Texaco company: Multifak EP2; Esso company: Beacon EP2

0,0025 kg 0,005 kg

– harness nest along the girder and fog lamps pin

2 Lubricant ВНИИ НП-510 (VNII NP-510)

0,0005 kg 0,001 kg

Connection points of fuel level sensor

3 0,0003 kg 0,0009 kg

* – if the vehicle runs in wet conditions, contacts should be lubricated every month.

91

Amount of lubricant Lubricant changing (adding) frequency

Lubrication (filling) point

Number of lubrication

(filling) points

Main brands, application season

Foreign analogues (brand, specification, company) Filling

norms Total for a

vehicle Main brand

Lubrication (oil filling, change) instructions.

Drain (accumulation) norms of used oils

Windshield washer tank 1 Mixture of «Obzor» washing liquid with water in volume ratios: 1:9 (up to minus 5 °С) 1:5 (up to minus 10 °С) 1:2 (up to minus 20 °С) 1:1 (up to minus 30 °С) 2:1 (up to minus 40 °С)

MIL-A-6091B Denatur (USA) BS 3591 grade 680P (AL-8d) (En) Shell company: Aeroahell Compound 6

10 l 10 l Apply «Obzor» liquid mixture at ambient temperature below + 5 ºС.

Cab independent air heater tank, if installed

1 Diesel fuel with sulphur content no more than 0,5%. Brends: З minus 35 °С (at ambient temperature of minus 20 °С and higher). Brends: З minus 45 °С (at temperature minus 30 °С and higher). Brends: А (at temperature minus 50 °С and higher).

Diesel fuel with sulphur content no more than 0,5% – winter diesel fuel in compliance with the European standards: EN 590 ISO 8217 or in compliance with the standard of other countries: BS 2869 Class A1 и A2 (Great Britain) DIN EN 590 (Germany) ONORM EN 590 (Austria) ASTM D 975 N01D (USA) According to DIN EN 590 (Germany) the following diesel fuel is to be applied: Winter-grade diesel (at temperature minus 20 °С and higher). Winter-grade diesel (at temperature minus 22 °С and higher). Special diesel fuel (Alpine or Arctic) (at temperature minus 50 °С and higher).

10 l 10 l

92

Appendix 1

Reclamation form

93

Appendix 2

LIFTING MECHANISM (VEHICLE WITH HYDRAULIC SELECTION)

Semitrailer platform lifting mechanism of the road train dump truck The lifting mechanism is hydraulic, single-cylinder with electropneumatic remote control. Drive layout

is given in the Figure 3. The mechanism provides platform lifting to the angle 47–50°, its lowering, stopping in the intermediate

position, automatic limitation of the lifting angle. Moreover, it provides control of the platform rear side opening and closing.

Road train dump truck platform lifting mechanism control The control over the dump truck platform lifting mechanism is exercised on the even surface from the

driver’s cab with the help of a switch (position 1, Figure 1), that is located on the right lower part of the dashboard.

Figure 1 – Switch setting

Before lifting the platform it is necessary to make sure that the air pressure in the pneumatic system is not less than 650 kPa with working engine (if the manometer shows less than 650 kPa, then you should pump air to the system beforehand).

For lifting the platform it is necessary to do the following: – disengage the clutch; – turn the switch handle into the rightmost position – “Lift”; – smoothly release the clutch pedal simultaneously increasing engine revolutions. You should maintain

engine revolutions according to the tachometer within the range 1200-1500 min -1. – looking into the rear-view mirror or rear window, adjust the platform lift speed by changing engine

revolutions smoothly. If the hydraulic cylinder tube is moved out by two thirds of its length, disengage the clutch and turn the

platform control switch to the “Neutral position”. At this the platform should stop. For lowering the empty platform it is necessary to do the following: – disengage the clutch; – shift the switch 1 (position 1) to the leftmost position – “Lowering”; – after lowering the platform shift the switch to the neutral position “Neutral position”. If there is a necessity to stop the platform in intermediate position when lifting or lowering the platform,

just shift the switch to the neutral position “Neutral position”.

ATTENTION DRIVER! IT IS FORBIDDEN TO RUN THE TRUCK WITH LIFTED PLATFORM IN ORDER TO

AVOID FAILURE OF ITS BRACKETS AND DAMAGE OF WORKING SURFACES OF HYDRAULIC CYLINDER TUBES.

IT IS FIRBIDDEN TO LOWER THE PLATFORM UNDISCHARGED.

94

I – platform lifting; 0 – neutral position; II – platform lowering

Figure 2 – Platform lifting control switch position

Servicing of the platform and platform lifting mechanism of the road train dump truck During operation of the platform lifting mechanism it is necessary to comply with the following rules: 1) Do not overload the road train dump truck above the rate stipulated in the standard norm and observe

equal cargo distribution on the platform avoiding overload of the front part. 2) Lubricate all joints and units regularly according to the lubrication chart. 3) Observe and timely tighten oil pipes connections, air pipes and hoses, preventing leakage of oil and

air. 4) After every 10000 lifts of the dump truck platform, and also if any visible deflection of the cylinder

links is detected (with the cab fully lifted), it is necessary to dismantle the hydraulic cylinder and monitor the condition of the guide semirings. If thickness deterioration of the semirings is more than 0,3–0,5 mm, they are to be changed. The thickness of the semirings when delivered is 6 142.0

18,0 mm (for hydraulic cylinder

of domestic production). 5) Monitor the oil level in the tank. Add oil to the upper mark if the oil level descended lower than the

second mark on the oil level indicator. Added oil shall be properly filtered. 6) Change oil seasonally according to the lubrication chart. Filtering elements of the oil filter tank shall be flushed in diesel fuel and blown with compressed air at

each change of oil. In order to change the oil, it is necessary to: – unscrew the drain plug of the tank; – take the hose for oil drainage and put one ending of the hose into the reservoir for used oil, and attach

another ending to the drain valve; – open the filler cap of the oil tank. After drainage of used oil tighten the drain plug in the tank and fill in fresh, properly filtered oil. For quick drain of oil from the oil tank 5 (position 3), it is necessary to disconnect the suction hose from

the pump pipe branch, and drain oil into the reservoir. It is necessary to take into consideration that dirty oil is the major reason for early deterioration and

failure of units of the lifting mechanism and the pump, in particular. An axial piston high-pressure pump «Meiller» is sensible to overloads and purity of oil applied. At

refilling and changing of oil it is necessary to filter it in a proper way, not allowing the ingress of foreign impurities and water into the tank.

In order to avoid early failure of the pump it is strictly forbidden to use oil grades in the hydraulic system that are not stipulated in the lubrication chart.

During the operation process of the hydraulic cylinder there is a necessity of dismantling that can appear in order to change sealing collars (rings) or guide semirings and liners. For that reason, remove the hydraulic cylinder from the vehicle, unscrew the bottom cap and carefully extract extendable tubes from the housing. In order to remove a worn-out liner take out the closing ring, and after that, you can easily extract

95

the liner from the tube. When changing the sealing collars (rings) draw attention to the guide semirings condition. If thickness deterioration of the semirings is more than 0,3–0,5 mm, they are to be changed.

When assembling the cylinder make sure that the closing rings are carefully inserted into its grooves in order to avoid the tear-out of the liners during the platform lifting.

After a long-term operation insignificant leaks of oil can appear on the surfaces of hydraulic cylinder extendable links that are the result of the oil film scraping made by the sealing rings. Oil leaks should be removed with a clean dry rag. Abundant oil leaks inform about the wear of sealing collars (rings). In this case the sealing collars (rings) and chip shields are to be changed because the presence of oil on the working surfaces of the tubes results in their fouling, and therefore, leads to accelerated wear.

At each change of oil it is recommended to unscrew the plug into the bottom of the hydraulic cylinder for drain of condensate. According to the operation experience, the water coming to the hydraulic system is collected in the cylinder, freezes in winter period, and the ice inside the cylinder impedes complete lowering of the platform what can lead to serious breakdown of the cylinder.

It is necessary to check periodically the work of the valves 7 and 10 (Figure 3). Slow platform lifting indicates that the valve seat is worn-out; and in case of valve 10 diaphragm rupture at inflowing of compressed air into the chamber cavity, it will be coming out with specific hissing.

Oil leakage through the drainage hole in the valve 10 body informs about wear or damage of the sealing ring of the valve. Air outlet through the hole testifies about wear or damage of the other ring.

At valve 7 disassembling it is strictly forbidden to damage adjustment of the safety device. Adjustment of the dump truck semitrailer lifting angle and its operating rules are given in the Dump

Truck Semitrailer Operation Manual.

1 – platform control switch; 2, 9 – electropneumatic valve; 3 – power takeoff; 4 – pump; 5 – oil tank; 6 – return valve; 7 – consumption control and pressure valve; 8 – hydraulic cylinder; 10 – platform lifting control valve; 11 – coupling; 12 – safety device; 13 – control limit switch; 14 – relay.

Figure 3 – Truck platform lifting mechanism scheme

96

POSSIBLE MALFUNCTIONS OF VEHICLE AGGREGATES AND SYSTEMS AND WAYS OF THEIR REMOVAL

Table 1 – Possible malfunctions of aggregates and systems of the vehicle with hydraulic selection and ways of their removal

Malfunction Cause Way of removal

Control valve seat is worn-out or damaged

Change the seat

Platform cannot be lifted

Excessive wear or damage of the pump gear bushing end face

Change bushings and pump

Partial wear or damage of the control valve seat

Change the seat

Damage of the return valve seat Repair or change the seat

Slow platform lifting; lifted platform lowers unintentionally

End faces wear of the pump bushings Change the bushings

Jamming of the shift fork rod Dismantle the power take-off, eliminate the causes of jamming

Diaphragm is damaged Change the diaphragm

Jamming of the roller driven gear Dismantle the power take-off, eliminate the causes of jamming

Power take-off cannot be switched on

Back side of the gear teeth is worn-out or damaged

Dismantle the power take-off, carefully insert the teeth

Power take-off cannot be switched off

Return spring in pneumatic chamber of power take-off is broken

Change the spring

Jamming of the valve stem Dismantle the valve, eliminate the causes of jamming

Valve pneumatic chamber diaphragm is damaged

Change the diaphragm

Valve return spring is broken Change the spring

Control valve cannot open

Jamming of the valve stem in the body or jamming of the piston in the valve

Dismantle the valve, eliminate the causes of jamming

97

Appendix 3

Tightening torque of the main threaded joints Nm

Joint Toque, Nm Rear axle Note

1 FASTENING BOLTS

Journal to the axle housing 320–360 +

Carrier to the carrier body 420–440 + Driving axles with disc wheels

Bearing sleeve of drive bevel pinion 90–120 + Bolt fastening variant Gear housing clip covers 200–280 +

Brake chamber bracket 400–440 + * at upper arrangement of diaphragm spring brake cylinder

Brake chamber bracket 118–157 at lower arrangement of diaphragm spring brake cylinders

Front axle brake chamber bracket 110–140

Expansion cam supports 118–157 + * at upper arrangement of diaphragm spring brake cylinder

Expansion cam sleeve 118–157 +

Carrier to the hub 80–100 + Driving axles with disc wheels

Interaxle differential gear cups 65–80 Gears housing to the intermediate housing

50–62

Cover to the carrier body 29–37 For 4-satellite wheel gear Collars cover to the hub 24–36 +

Rear axle bearings sleeve collar covers 50–62 +

Differential gear nut stop 12–18 +

Brake shoes axes locking plates 24–36 +

Front driving axle brake backplate 24–36

Steering rod lever to the steering knuckle 392–432

Bolt and studs of fastening of steering knuckle lever and upper cover

275–314

Cover and front axle housing 157–196 Hinge bearings covers 16–20 Expansion cam tube shock absorber brackets to the support

310–315

Kingpin device adjustment bolt 310–350

2 FASTENING NUTS

Reduction gear to the axle housing 120–160 + Driven cylindrical gear 450–600 Flanges 450–600 + Driven gear and interwheel differential gear cups

210–260 +

Wheel gear cover 24–36 +

98

Joint Toque, Nm Rear axle Note

Wheels hub 400–500 + Rear axle driving bevel gear bearings sleeve

90–120 + For doweled joint variant

Hubs fastening lock-nut 400–500 + Adapters and brake backplates fastening nuts

24–36 +

Interaxle differential gear crossbar fastening clamp

300–400

Interwheel differential gear blocking screw stopping

44–56 +

Fixture with steering knuckle hinge bodies

110–140

Wheel disk 250–300 + Ball pin 275–314 Kingpin device adjustment bolt lock-nut 216–275 Studs of the lever and steering knuckle bearing covers

275–314

Cross tie rod ends 69–88 Fastening bolts of front brake supports with steering knuckles

160–200

Fastening wheel nuts of automobiles with rimless wheels

250–300

Front springs U-bolt nuts 450–600 Rear springs U-bolt nuts 600–650 Front and rear spring eye U-bolt nuts 200–220 Front and rear spring eye bolts 250–320 Shock absorber body nuts 120–150 Fastening nuts of steering mechanism to the frame

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 spring brake cylinders bracket

180–200

Fastening nuts of the compressor cylinder head

12–17

Fastening nuts of steering wheel 60–80 Fastening bolts of steering column cardan forks

27–35

Fastening nuts of the fifth-wheel device on the frame

220–240

Fastening bolts of cardan (drive) shaft 160–200 Fastening nuts of cross bars to the frame 220–240 Fastening bolts of the steering knuckle and steering geometry levers

400–500

Fastening nuts of the ball pin to steering geometry levers

220–250

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Appendix 4

OPERATION AND MAINTENANCE OF THE BATTERY

The manual describes the starter batteries (dry-charged, electrolyte and full-charged) with capacity of 110 amp hour and more.

Safety 1) Charge the battery in the place equipped with supply and exhaust ventilation. 2) Hydrogen and air mixture is explosive. Do not smoke near the battery, use open fire and sparks, close

pole terminals. 3) Use special dishware (ceramic, plastic, lead-encased, ebonite) that is resistant to sulfuric acid to

prepare electrolyte. Pour water into the dishware and then sulfuric acid. Continuously mix the solution.

IT IS STRICTLY FORBIDDEN TO POUR WATER IN STRONG SULPHURIC ACID!

4) Put on goggles, rubber gloves, rubber boots, apron and acid-resistant material suit while preparing electrolyte and filling the battery.

5) In case of skin contact with sulfuric acid, before medical aid, carefully remove the acid by cotton, wash the skin in water and then with 5% solution of sodium carbonate or ammonia.

6) When working with a metal tool avoid short circuit by simultaneous touch to opposite terminal post. 7) Keep safety signs on the battery. Battery operation condition Fill the battery with electrolyte. Electrolyte density (sulfuric acid) (see Table 1) depends on the climatic areas where the battery is used. The electrolyte is prepared from sulfuric acid and distilled water. The density of the electrolyte should

be measured by areometer. Electrolyte temperature should not exceed 30 °C. It is mot recommended to fill the battery with electrolyte with temperature below 15 °C.

Table 1 Electrolyte density,

Reduced to 25 °С, g/cm3 Macroclimatic area with average monthly temperature in January Season

filling charged battery Cold: Extremely cold from –50 °С up to –30 °С

all year 1,28 1,30

Cold from –30 °С up to –15 °С -/-/-/- 1,26 1,28

Medium: Medium from –15 °С up to –8 °С -/-/-/- 1,24 1,26

Warm moist from 0 С up to 4 °С -/-/-/- 1,21 1,23

Note: Deviations of the electrolyte density values on ± 0,001 g/cm3 are possible

Before pouring the electrolyte it is necessary to depressurize the battery by removing depressurized elements of the cover (film, projectors on plugs, etc.). Pour the electrolyte up to the lower end face of the filler tube or up to the level of 10–15 mm above the battery plate.

Check the electrolyte density not earlier than 20 minutes and not late 2 hours after filling. If the electrolyte density drops not more than by 0.03 g/cm3 against the density of filling electrolyte

(Table 1), the battery could be put into operation. If the electrolyte density drops more than by 0.03 g/cm3, the battery needs charge.

If you need to put dry-battery into operation urgently it is allowed to install the battery on the vehicle without checking the electrolyte density after 20 minutes, staturating when battery keeping time is less than one year from the date production and when the battery temperature and the filling electrolyte is above 15 °C while putting into operation.

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It is necessary to check the density of the electrolyte in the battery filled with electrolyte and charged before the installation on the vehicle or before storage.

Battery filled with electrolyte and charged prior to installation on the vehicle or storage, check the density of the electrolyte in the battery. If the density of the electrolyte is less than 1,28 ± 0,01 g/cm3 or density value in the battery differs by more than 0.01 g/cm3 the battery need charge.

Battery charge The battery charger should correspond with the nominal voltage of the battery. Connect the positive

terminal of the battery charger to the positive battery terminal, and the negative to negative. Battery plugs should be unscrewed.

Electrolyte temperature before charging should not exceed 35 °C. Charge the battery in the ventilated area, current should be 10% of battery rated capacity. When the

voltage is less than 14,3V on the polar battery terminals, charging current should be decreased in half, charging should be kept up to the voltage consistency and electrolyte density in two hours (up to the full charge).

Charge the battery until all battery accumulators become milky, voltage and electrolyte density are constant in two hours. Check the voltage on battery terminals by voltmeter with accuracy class 1,0 scale of 30 V, division value 0,2V.

During charge, it is necessary to check electrolyte temperature and watch that it does not rise above 45 °С. If the temperature is above 45 °С, decrease the charging current in half or cut charging for time necessary to reduce the temperature to 30–35 °C.

At the end of charge if the electrolyte density, measured according to the temperature correction (Table 2) differs from the density in Table 3, correct the electrolyte density by refilling with distilled water when the density is above norm. Id the density is below norm refill with electrolyte (density 1,40 g/cm3) and charge for 30-40 minutes. After charging put the battery into operation.

Table 2

Electrolyte temperature while density measuring, °С Correction to the densimeter reading, g/cm3

+45 + 0,02 +30 + 0,01 +15 0,00

0 - 0,01 -15 - 0,02 -30 - 0,03 -40 - 0,04

Operation and maintenance Charging mode control It is necessary to battery control charging mode to prevent overcharging or undercharging that shorten

the lifespan. Check regulator during maintenance operation. During operation charge voltage value should correspond with the value specified in specification and

operation manual of the vehicle. When the vehicle does not operate more than three days it is necessary to disconnect the battery

connector. When the vehicle does not operate for a long time, more than one month, the battery need recharge. It is forbidden to connect to the battery devices with 12 V (recorders, receiver, etc.)

Maintenance Once in two weeks it is necessary: – to check the battery fastening in the container and cable terminal contact to battery terminals.

Lubricate cable terminals with Lithol or grease after mounting on pole terminals.

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– to clean the battery if necessary. If there is electrolyte on the battery surface wipe it with a clean clothes damped with ammonia or sodium carbonate (10%) solution;

– to clean air vents if necessary; – to check electrolyte level in all accumulators and, if necessary, refill with distilled water to the

required level; – to charge the battery with the current less than 10% of battery available capacity if the electrolyte

density is below norm. It is forbidden to increase density by refilling with electrolyte. Define and eliminate on-board system failures (in generator, relay, starter) in time. Always refill only with distilled water if the electrolyte density is above norm. Check generator and regulating relay. It is forbidden to refill the battery with electrolyte except the situation when electrolyte level drops due

to sloshing. In this case the filling electrolyte density should be same as in the battery before sloshing. Start the engine with depressed clutch for less than 15 seconds with the interval of one minute. It is forbidden to drive with the starter. Incorrect engine start (frequent and too long attempts to start the engine) causes deep battery discharge,

electrode sulfatation, electrode destruction and battery brakedown. IT IS STRICTLY FORBIDDEN TO UNDERCHARGE OR OVERCHARGE THE BATTERY. The

applied voltage should be 13,6-14,4 V. IT IS FORBIDDEN TO USE THE BATTERY WITH ELECTROLYTE LEVEL BELOW NORM.

Maintain the level by refilling with distilled water. It is forbidden to refill with electrolyte. In cold seasons refill with distilled water when the engine is running (for rapid mixing with electrolyte).

KEEP THE BATTERY CHARGED. Check the electrolyte density once (more time) a month. If the electrolyte density has dropped (according to the climatic area) by 0,03 g/cm3 and more it is

necessary to charge the battery as described above. IT IS FORBIDDEN TO USE DISCHARGED BATTERY where the electrolyte density has dropped by

0,08 g/cm3. That may cause sulfatation and battery breakdown; when the temperature is below zero it may cause electrolyte freezing and battery damage.

If the battery charge is more than 25% in winter and more than 50 % in summer (see Table 3) remove and charge the battery.

Table 3

Electrolyte density reduced to 25 °С, g/cm3

Charged battery Fully charged battery up to 25% up to 50%

1,30 1,26 1,22 1,28 1,24 1,20 1,26 1,22 1,18 1,23 1,19 1,15

Transportation and storage Transport the battery in covered vehicles that ensure protection from mechanical damage and

contamination from rain and direct sunlight. Batteries, that were temporarily removed for storage, should be fully charged. The electrolyte density

should correspond to the density norm of the climatic area. If possible store the batteries in the area with the temperature not above 0 °C. Check the level and density of electrolyte and refill with distilled water every 30 days in the ambient temperature is above 25 °С and every two months if the ambient temperature is below 25 °С. Charge the battery once a month as described above.

Utilization The overage battery (taking into account true battery condition) should be recycled in the special plant

(see the symbol on the battery label).

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CONTENTS

Page

Introduction.……………………………………………………………………….….. 3

1 Safety requirements and warnings…………………………………………………... 4

2 Technical data..……………………………………………………………………… 6

3 Controls and instrumentation .………………………………………………………. 9

4 Cab equipment………………………..…………………………………………… 21

5 Work item list for the presale preparation…………………………………..………. 31

6 Running-in of the vehicle.…………………………………………………………... 32

7 Peculiarities of the vehicle operation………………...……………………………… 33

8 Driving the vehicle and control of its operation ……………………………..…….. 34

9 Tires mounting and dismounting …………………………………………………… 63

10 Adjustment works………………………………………………………………….. 67

11 Maintenance of the vehicle……………….……………………………………….. 71

Appendices ………………………………………………………………………..….. 92