631705, 631708, 642505, 642508, 531605MAZ TRUCKS

OPERATION MANUAL

MAZMINSK

BELARUS REPUBLIC

HINTS FOR DRIVERS

The MAZ truck that you are going to operate is distinguished for its highreliability level, equipped with devices and instruments, that facilitate driving,reduce driver’s tiredness, enhance traffic safety, enable the labour productivityto be significantly improved and the cost price of transportation works to bereduced.

Study carefully the manual contents before starting the truck operation.

Detailed information concerning operation and maintenance of the engine isgiven in a separate instruction manual that is supplied with the documentationfor the truck.

3

INTRODUCTION

MAZ-631705, 631708- is a 6x6 truck and MAZ-531605 is a 4x4 truck thatare designed for transportation of people and different cargoes, towage of trans-port and special trailers along the roads of common use bearing axle loads spec-ified in technical characteristics.

Trucks can be delivered without load platform as chassis for completing bydifferent equipment.

MAZ-642505, 642508- is a 6x6 fifth-wheel truck tractor designed for trans-portation as part of the road-train of different cargoes along the roads of com-mon use bearing axle loads specified in technical characteristics.

Fig.1 MAZ truck- 631705-0000210

Fig.2 MAZ truck- 631705-0000220

4

Fig.3 MAZ truck- 631705-0000230

Fig.4 MAZ short log truck- 631705-0000237

Fig. 5 MAZ chassis- 631705-0000241

5

Fig.6 MAZ chassis- 631705-0000261

Fig.7. MAZ bolster - type truck 642505-000130.

* Dimension with gross weight

Fig.8. MAZ truck 531605.

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SAFETY REQUIREMENTS AND WARNINGS

The basic condition for proper operation and reliable functioning of the ve-hicle is understanding of specific features of its units and design, as well as strictobservation of the vehicle maintenance and care instructions.

Thus, prior to starting operating the truck it is necessary to thoroughly studyits design, instruction for operation and care, included within the present book-let, paying special attention to the TRUCK OPERATION PECULIARITIESsection.

1.During the period of the truck running-in (the first 1000 km of run) it isnecessary to strictly observe the rules laid down in the «RUNNING- IN OFTHE TRUCK» section because its further performance greatly depends uponhow properly the components will bed in during the initial period of operation.

2.Lubrication of the truck is to be executed in accordance with the lubrica-tion chart. Application of contaminated or non-recommended grades of lubri-cants and fuel is strictly prohibited.

3.When in motion keep watch on readings of the instruments and signals ofthe warning lights (refer to the section «DRIVING THE TRUCK AND MON-ITORING ITS SYSTEMS AND UNITS FUNCTIONING»).

4. The voltage indicator with the storage battery switched off must not showthe voltage in the system. Otherwise it is forbidden to operate the truck until thetrouble is eliminated.

5. Do not allow gear engagement in the main gearbox until the engagementindicating lamp in the auxiliary gearbox goes off. Do not engage reducinggear in the auxiliary gearbox with the truck speed more than 25 km/h.

Gearbox operating rules are described in the operation manual (section «Truckoperation and its control»).

6. Before the truck starts on slippery road engage interaxle differential block-ing (timber-truck) interwheel differential.

After overcoming such part of the road unblock the differential.7. It is forbidden to hold the steering wheel in extreme positions (at maxi-

mum turning of driven wheels to the left, to the right) for more than 5 sec. inorder to avoid failure of steering hydraulic booster pump.

8. Never start the truck away from rest if the pressure in the air brake circuitsis less than 490 kPa (5.0 kgf/cm2), i.e. until the warning lamps indicating a dropof air pressure in the brake circuits go out.

9. Running downhill with stopped engine and disengaged gearbox is prohib-ited because in this occasion steering wheel rotation efforts increase steeply andthere is no regeneration of the pressurized air spent within the air system of thetruck.

10. While running downhill monitor the tachometer readings. The tachome-ter pointer must not enter the red zone on the tachometer scale.

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11.Observe the truck towage rules (See section «Peculiarities of the truckoperation).

12. Before tilting the cab it is necessary to close the doors, to put the gearshifter into neutral, to safely secure the truck with the parking brake and to openthe front grille. Before executing the cab tilting the truck shall be positionedonto an even horizontal ground. Nobody is allowed to be present within thedangerous area of the cab tilting.

13. It is prohibited to drive the truck with a faulty (inactive) hydraulic steer-ing booster.

14. On parking places switch off storage batteries by means of batteriesswitch button.

15. Prior to executing welding operations on the truck switch off the accu-mulator batteries, take the wires off the terminals «+» and « («. Switch off thealternator and all the electronic equipment, and when executing of welding op-erations of the road-train take the plugs out of the power sockets of the semi-trailer to avoid burning out of connecting wires.

16. Carry out works connected with servicing of the power unit on the hor-izontal area with the cab lifted to the full extent (the limit of lifting is restrictedto the power cable).

It is strictly forbidden to stand under not fully lifted cab.17. In the winter period while washing the truck it is forbidden to direct the

jet of water on the brake units.18. After the cab is lowered make sure that locking mechanism is locked and

insurance rope is fixed.19. In order to avoid ingress of air into the supply system do not use the

whole amount of fuel from the fuel tank.20. When putting the truck for parking at the end of the working day it is

recommended to close the wheel valves.In the winter period when there is necessity in usage of the system of adjust-

ment of pressure in tires, you should open the wheel valves after 20...25 of runwhen deep-frozen beads of the sealing sleeve gaskets are being warmed up andair-tightness of the connection is restored and absence of the air pressure on thebeads of the sleeve gaskets reduces the possibility of their break.

21. With the air temperature below 25oC make use of the power take-offonly after short run or oil warm-up in the transfer case.

22. In the winter period when putting the truck for parking it is necessarybring the pressure in the pneumatic system to the actuation of the pressure reg-ulator and release of moisture and oil from the moisture separator.

23. It is forbidden to leave the truck with the engaged gear.24. Starting of the engine when the cab is up is prohibited. When it is neces-

sary to start the engine while the cab is up so that to perform adjustment andrepair works the safety engineering requirements are to be observed.

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25. When putting the truck for a long-tern parking it is necessary to close thetire valve in order to exclude the air leakage from the receiver.

26. In case the condensate in the brake pneumatic circuit is frozen it is for-bidden to warm up devices, pipelines and air springs by naked flame.

27. In situations when welding and drilling operations are performed in thelocations where plastic pipelines are laid the latter are to be preserved againsthigh (above 90oC) temperature and welding drops.

28. Cargo on the platform should be placed evenly. If geometrics of thecargo don’t allow placing it evenly than it should be placed so that its centre ofgravity, as far as possible, coincides with the platform geometry centre.

Cargo on the platform must be securely fastened.29.Before engine start-up the gearbox lever must be in neutral position.30. The preheater start-up is to be carried out only on the diesel fuel.While using the starting preheater and warming up of the engine follow the

next requirements:- it is prohibited to start the preheater and heat the engine in closed premises

with bad ventilation facilities in order to avoid poisoning by exhaust gases.- it is prohibited to start the preheater when there is fuel leaking or presence

of fuel or oil on the engine pallet.- it is prohibited to start the preheater immediately after it has stopped or

restart after the first unsuccessful attempt without preliminary blowing of thegas outlet.

- during operation of the preheater the driver must not leave the truck.- If smoke or flame appears on the exhaust (with the steady mode of opera-

tion) it is necessary to immediately switch off the preheater, disconnect storagebatteries and eliminate the troubles.

- the preheater fuel system valve is to be opened only for the period of thepreheater operation.

31. While towing of the out of order truck on the rigid coupling the length ofthe connecting-link must not exceed 4 m. It is allowed towing of not more thanone truck on the flexible coupling, at the same time the length of the connecting-link must be 4-6 m. The towing speed must not exceed 20 km/ h. On hilly roadsthe towing is allowed only on the rigid coupling.

32. Check technical state, execute maintenance and repair of the truck andits separate units when the engine is not running.

33. During servicing the truck must be braked, the gearbox lever put into theneutral position, fuel supply switched off, storage batteries disconnected by meansof «ground» switch.

34. Before removing the wheel secure the truck having put the stops underthe wheels.

35. While tires inflating in garage conditions place the assembled wheel inthe special enclosure, and while executing the same procedure outside the ga-

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rage put the wheel by its lock part downward or direct to the driver side ornearby people.

36. During operation of the winch:- during pulling do not allow jerks in order to avoid cable break;- do not take position close to the stretched cable or between cables (when

block is used);- during cable winding do not allow the deadeye thrust the outlet roller block

in order to avoid cable break, winch damage or cable winding jam on the roll;- operation of the winch when the cable is given out in front of the truck is

allowed only when block is used.37. Carry out giving out of the winch cable prior to appearance of the cable

coloured part from the cable giving out device (by sight) that corresponds to 5cable windings on the roll;

38. Do not allow polarity reversal when connecting of the storage batteriesto the truck board system or when the engine starts from the external source.

39. Do not disconnect the wires from the terminals «( « of the alternator andfrom the storage batteries with the running engine.

40. Do not check the serviceability of the electric equipment and wiring bymeans of the megohmmeter or the bulb with voltage more than 28 V.

41. When washing the truck avoid the direct ingress of water on the electricequipment items and wires carrier sockets.

42.In order to avoid locking the steering column shaft it is prohibited to takethe key out of the switch lock of the starter and the instruments while movementof the truck.

43. When lifting and lowering the spare wheel it is forbidden to be situatedin the area of the movement of the folding bracket with the wheel. Before exe-cuting this procedure it is necessary to make sure the wheel is securely fastenedto the folding bracket, there is no cable sagging or pinching, there is no engage-ment of the click with the cable winding shaft ratchet.

44. While truck moving it is strictly forbidden to switch on «neutral» intransfer case, power take-off and interaxle differential blocking.

45. It is no allowed to switch on differentials in the process of wheelspin.

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3. TECHNICAL DATA

MAZ-631705 MAZ-631708 MAZ-531605

Drop-side truck Chassis with base 4200 Parameters

with single tires

with double tires

Short-log truck

with single tires

with double tires

1 2 3 4 5 6 7 Weight of the cargo carried, kg Weight of the equipped truck, kg Full weight of the truck, kg - permissible Distribution of weight on the road of the truck with

gross weight, kg: –through front axle tires –through carriage tires Gross weight of the road-train, kg. Permissible gross weight of the towed trailer, kg.

11000

14000

25150

7150 18000

45000** 55000***

11750

12800

24700

6700 18000

45000** 55000***

16350

12500

29000

7000 22000

45000** 55000***

13100

11900

25150

7150 18000

45000** 55000***

21700

10950

32700

6700 26000

45000** 55000***

5000 (6300)

11000 (9700)

16150 (16150)

7150 (7150) 9000 (9000)

12000 (12000) 20000*(20000*)

* – on the roads with hard surface ** – MAZ-631705. *** – MAZ-631708

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1 2 3 4 5 6 7 Max. speed of the

truck with gross weight, km/h

Control fuel consumption, l/100 km of the truck with gross weight at constant speed 60 km/h*

85(80)

40

90 (82)

38

75 (68)

43

85 (80)

40

90 (82)

38

85

34,5

Minimum radius from the truck turning along the axis of the front external wheel, m, Engine Rated power, kwT(H.P.) Gearbox

11,7

YMZ-238D, DE2, DE YMZ-7511

243 (330) 294(400)

YMZ (8-or 9-step) or MAZ (9-step)

11,5

238D, DE, DE2

243(330)

YMZ (8-or 9-step) or

MAZ (9-step)

* Control fuel consumption is used for defining technical condition of theautomobile and it is not an operation standard.

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1 2 3 4 5 6 7 Tires Air pressure in tires of the drop-side truck:*, kPa (kgf/sm2) front axle wheels carriage wheels of the short log truck front axle wheels carriage wheels Chassis: front axle wheels carriage wheels

ИД-370 dimension 550/75R21 or Бел-66А dimension 525/70R21, HC 10 for the trucks with single tires. On the trucks with double tires there installed tires ИД-304, 304M, dimension 12.00R20 HC 16, or HC 18 tread pattern- universal For trucks MAZ-531605- tires ИД-370

ИД-370, Бел-66А ИД-304, ИД-304М

540 (5,5) 750 (7,6)

540 (5,5) 560 (5,7)

750 (7,6)

630 (6,4)

540 (5,5) 750 (7,6)

540 (5,5) 680 (6,9)

* –Permissible pressure deviation ± 20 kPa (± 0.2kgf/cm2).

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MAZ-642505 MAZ-642508

Parameters

With single tires With double tires

Weight on the fifth-wheel device of the truck, kg - permissible Weight of the equipped truck, kg Gross weight of the truck, kg - permissible Distribution of weight on the road of the truck with gross weight, kg: through front axle tires through carriage tires permissible: through front axle tires through carriage tires Gross weight of the towed semi-trailer, kg

12800 16900

12200

25150

7150 18000

45000 55000*

17600 21800

11300

28900 33100

6650 18000

6950 24500

45000 55000*

* – on all types of roads

1 2 3 Max. speed of the road-train with gross weight, km/h Control fuel consumption, l/100 km of the road-train with gross weight at constant speed 60 km/h* Minimum turning radius along the axis of the front external wheel, m.

80 (78)

54,5

11,7

75 (67)

54 (58)

11,5

Engine YMZ-238D, DE, DE2 YMZ-7511 Rated power, kwT (H.P.) 243 (330) 294(400) Gearbox YMZ (8-or 9-step) or MAZ (9-step) In brackets – with engine YMZ-7511

* - Control fuel consumption is used for defining technical condition of the automobileand it is not an operation standard.

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1 2 3

Tires

Single tires are wide-sectio n ИД-370 dimension 550/75R21 or Бел-66А dimension 525/70R21, HC 10 D ouble tires of model ИД -304 or И Д-304 M dimension 12.00R20, H C16 or HC18, tread pattern – universal

A ir pressure in tires , kPa (kgf/sm 2):* front axle wheels carriage wheels

И Д-370, Бел-66А ИД -304, ИД -304M

540 (5,5) 750 (7,6)

780 (7,9)**

540 (5,5) 560 (5,7) 790 (8,0)**

* – permissible pressure deviation ± 20 kPa (± 0.2kgf/cm 2); ** – permissible gross weight of the truck.

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CONTROLS AND INSTRUMENTATION

The layout of controls and instrumentation of the trucks is shown in theFigs. 9, 10, 11, 12.

The pedal 4 of fuel supply control (Fig. 9). For setting the accelerator pedalin the intermediate position for engine warming-up and tire inflation depressthe pedal and turn the latch by hand clockwise and then release the pedal.

The first fixed position of the latch provides the crankshaft rotation fre-quency required for warming-up the engine, and the second position - for tiresinflation.

After the end of work connected with setting-up of regular fuel supply it isnecessary to drive the latch to the idle position by turning it counter-clockwise.

The usage of the mechanism of regular fuel supply when the truck is onmove is inadmissible.

The gearshift lever (Fig.9). 9 gears are divided into two speed ranges:- lower- 1...5 gears («reducing gear» is engaged by the auxiliary gearbox

switch)- upper- 6...9 gears («direct gear» is engaged by the range switch).Turn indicators, lower and upper lights switch handle 6. It has the fol-

lowing positions:In horizontal plane:0 - neutral;I - fixed, the right turn indicators are switched on. Switching off is automat-

ic;II - non-fixed, the right turn indicators are switched on for a short period of

time;III - non-fixed, the left turn indicators are switched on for a short period of

time;IV - fixed, the left turn indicators are switched on. Switching off is automat-

ic.In vertical plane:V - non-fixed, switching on of upper lights for a short period of time;O1 - fixed, lower lights are switched on when the main switch 16 of the

headlamps lights is on (Fig. 11);YI - fixed, upper lights are on when the main switch 16 of the headlamps

lights is on.When the handle is pressed on the face the electric horn snaps into action.Windshield wiper and washer selector switch lever 8 (fig.9). It has the

following positions:In horizontal plane:O - neutral;I - fixed, the windshield wiper is on - slow motion;

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II - fixed, the windshield wiper is on - fast motion;III - fixed, the windshield wiper is on - intermittent operation mode.

In vertical plane:IV - non-fixed, the windshield washer is on with simultaneous slow motion

operation of the wiper.When the handle is pressed on the face the electric horn snaps into action.The auxiliary brake control valve push-button 1. When this push-button

is pressed, the throttle gate shuts the way in the exhaust gas channel and createscounter-pressure within the exhaust system.

Instruments and starter switch (lock) 5 with anti-theft device.The key is to be put in and pulled out when in the position III.In order to unlock the steering column shaft put the key into the switch lock,

and slightly turn the steering wheel to right-left (to avoid breakage of the key)and then turn the key clockwise into the position «0».

When the key is taken out of the switch lock (from the position III) the fuelfeed shuts down and the locking device of the switch lock snaps into action. Inorder to lock the steering column shaft it is necessary to turn the steering wheelto left-right.

Other positions of the key in the switch lock:0 - neutral (fixed) position, the instruments and starter circuits are discon-

nected;I - instruments and devices circuits are enabled (fixed position);II - instruments, devices and starter circuits are enabled (non-fixed posi-

tion);Steering wheel 7 with the steering column safe fastening and its adjustment

by height and incline.Steering column inclination adjusting handle 18. By turning the handle

down (and holding it so) it is possible to alter the steering column inclinationangle, release the handle afterwards.

Steering column height adjusting handle 13. In order to change the steer-ing column height it is necessary to turn the handle up to yourself and, holdingit so, to adjust the desired height, then release the handle.

Cab heater and ventilation shutters control handle 10.Handle 12 of the centralised system of adjustment of air pressure in tires. It

has three fixed positions:neutral, tire inflating (the handle is shifted to the left)Parking brake handle 11. In order to activate the parking brake it is neces-

sary to shift the lever handle from one position to another until its further shiftingbecomes impossible (it can happen at any intermediate position of the handle).

Handle 14 of the engine stop shuts down the fuel supply when shifting thelever to yourself against stop.

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Handle 15 of the additional brake system control. The handle is fixed in twoopposite positions. The handle is located on the vertical wall of the cab tunnel.When turned in the backward fixed position the handle activates the parkingbrake, and when turned in the forward fixed position - it disables the parkingbrake. When the handle is held in any intermediate position (non-fixed posi-tion), then it enables braking of the truck and trailer.

Handle 16 of the radiator shutters control. By pulling the handle the shuttersare softly shut.

Onboard Monitoring System (OMS - БСК) (Fig.12) is intended of the oillevel control in the engine, steering wheel hydraulic booster tank, coolant, aswell as for monitoring serviceable condition of the electric circuits and bulbs ofthe headlights, sidelights, road-train three-bar lights and stoplights, brake sys-tem and stop lights.

For switching on the Onboard Monitoring System close the battery switchand set the key of the switch lock 5 of instruments and starter into the position 1(Fig. 9).

As a result all the lamps of the Onboard Monitoring System light panel (Fig.12) are turned on for 2-4 seconds and the sidelights and stoplights are simulta-neously turned on. If in the course of 2-4 seconds any bulb of the lights panelfails to light on it means that this bulb is out of order. After 2-4 seconds havepassed the sidelights and stoplights of the truck and trailer (truck tractor andsemi-trailer) must go off. In case of trouble in the circuit (or failure of bulbs) awarning light corresponding to the faulty circuit will be glowing on the lightspanel for 5-8 seconds.

Monitoring serviceable condition (during movement) of the electric circuitsand bulbs of the road-train three-bar lights, sidelights, stoplights and brake sys-tem is carried out when these circuits are switched into operation.

Serviceability of the electric circuits of the stoplights on the trailer (semi-trailer) can be monitored with the road-train three-bar lights on. When the stop-lights go on failure warning light of the stoplights system will be ON on theOnboard Monitoring System light panel.

In operation, the electric circuit of the brake system is monitored by a greenlight (without any symbol) on the light panel of the Onboard Monitoring System.This light will glow when the brake pedal is depressed or the parking brake isapplied. If a trouble occurs in the circuit or the bulbs of the stoplights get out oforder, the stoplight bulb failure warning light starts glowing on the light panel.

Serviceability of the electric circuits and bulbs of headlights (upper and lowerbeams) can be monitored both with the headlights on and off: when the head-lights are on only the left-hand headlight is monitored; when the headlights areoff the left- and the right-hand headlights are monitored simultaneously.

If a trouble occurs in any of the above mentioned circuits the appropriatewarning light starts glowing on the light panel of the Onboard Monitoring Sys-

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Fig. 9 Controls:1 - auxiliary brake control push-button; 2 - clutch pedal; 3 - brake pedal; 4 - fuel supplypedal; 5 - instruments and starter switch (lock); 6 - switching handle of turning indica-tors and of lower and upper beams; 7 - steering wheel; 8 - windshield wiper and washerselector switch handle; 9 - gearbox shifter; 10 - cab heater shutters and ventilation sys-tems control handles; 11 - parking brake control lever; 12 - tires inflating valve handle;13- steering column height adjusting handle; 14 - engine shut-down handle; 15 -park-ing and emergency brake control handle; 16 radiator blind control handle; 17 manome-ter of the tires centralised inflation; 18 - steering column inclination adjusting handle.

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Fig. 10. Dashboard:

1 -transfer case neutral switch; 2 - interaxle differential blocking switch; 3 - enginecompartment light switch; 4 - interwheel differential blocking switch; 5- winch switch;6 - speedometer; 7 - tachometer; 8 - control lamp of truck turn indicators; 9 - controllamp of trailer turn indicators; 10 - upper light control lamp of headlights; 11 - tail foglight control lamp; 12 - electric fuel-fired control lamp; 13 - reducing gear engagementcontrol lamp; 14 - interwheel differential blocking control lamp; 15 - interaxle differen-tial blocking control lamp; 16- transfer case neutral switch control lamp; 17- winchswitch control lamp; 18 - instrument cluster: a - engine oil pressure gauge, b - fuel levelgauge, c - coolant temperature gauge, d - voltmeter; 19 - fog lights switch; 18 - tail foglight switch; 21 - refrigerator switch (if installed); 22 - road-train three-bar lights switch;23 - rear-view mirrors heater switch (when the warmable mirrors are installed).

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Fig. 11. Auxiliary dashboard:

1- ground switch; 2- fan clutch switch; 3- cab heater fans switch; 4- electric fuel-firedswitch; 5- fuel level gage switch in the additional fuel tank; 6- lamps serviceabilitymonitoring button; 7- control lamp of the air filter clogging; 8- control lamp of the coolantlevel (may be not installed); 9- control lamp of the oil filter clogging; 10 - control lamp oflow air pressure in the front circuit of brake system; 11- control lamp of low air pressurein the rear circuit of brake system; 12- parking brake control lamp; 13- searchlightswitch; 14- emergency flasher warning system switch; 15- rheostat of the dashboardlighting; 16- main light switch; 17- air pressure indicator in the front and rear circuits ofthe brakes pneumatic drive; 18-passenger lighting switch;.

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Fig.12. Onboard Monitoring System:

1- headlights and their circuits failure indicator; 2- road-train three-bar lights failureindicator; 3- indicator reducing of the oil level in the hydraulic booster tank; 4- indicatorof reducing of the coolant level in the engine cooling system; 5- indicator of reducing ofthe oil level in the engine; 6- sidelights failure indicator; 7- stop-lights failure indicator;8- brake system serviceability indicator; 9- diesel liquid preheater (if installed); Lamps3, 4, 5 may not be installed.

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tem of the red light.In order to provide monitoring the operation of the truck devices and sys-

tems all button switches and indicators on the main and auxiliary dashboardshave illumination.

Illumination is switched on when sidelights are on and the illumination rheo-stat 15 (Fig.11) adjusts its brightness.

CAB ACCESSORIES

The rear-view mirrors are installed outside the cab on its both sides. Themirrors are adjustable in position.

The electrically driven two-speed three-blade windshield wiper is intend-ed for cleaning the windshield and is switched on by the handle 8 (Fig.9) locat-ed on the right-hand side of the steering column.

The electrically driven windshield washer. The pump of the windshieldwasher is switched on by the same handle as the windshield wiper. A jet ofwater is directed from a reservoir through two jets onto the windshield. Whenthe handle is released the pump is switched off. Direction of the water streams isadjustable by turning the jets heads.

The driver and passenger seats. MAZ trucks can be equipped with a driv-er seat with a pneumatic resilient component 4 (Fig. 13) and has vertical andhorizontal adjustment mechanisms and the seat back tilt adjustment mechanism.

The pneumatic resilient component controlled by a distributor is adjustableby height regardless of a driver weight.

Seat adjustment is carried out by the distributor rod rotation until the size150 ± 2mm on resilient component 4 is reached.

Vertical adjustment mechanism is of lever type, with step fixing and it al-lows adjusting the pad 2 tilting angle.

Horizontal adjustment mechanism is of slide type with step fixing.The passenger seat can be adjustable or non- adjustable upon customer, s

request.Sleeping berths. Depending on the truck completing it is possible to install:

big cab without cushioning mechanism with one upper sleeping berth; big cabwithout cushioning mechanism with two sleeping berths; big cab with cushion-ing mechanism with two sleeping berths.

Sun visors. Two sun visors are installed inside the cab in front of the driverand passenger seats. The sun visors are raised and lowered by hand.

Radio set or radio-tape recorder are installed in the cab on the parcel shelfat the customer’s request.

Door locks and windows. The doors are equipped with the rotor-type locks.In order to lock the door lock in a closed position from inside of the cab it isnecessary to turn the driving handle of the lock down against stop and then,

23

holding the handle, to smoothly return it to the initial position.Cab doors have drop windows. Lifting and lowering of windows is carried

out by rotation of the window raiser handle.Parcel shelf for arrangement of small things of the team is located above

the windshield. In the cab under the lower sleeping berth it is possible to installa refrigerator for storage of foodstuff.

Fig. 13. Driver Seat

1 - back; 2 - cushion; 3 - seat back adjusting handle; 4 - pneumatic resilient element;5 - vertical adjusting mechanism handles; 6 - horizontal adjusting mechanism handle.

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PRE-SALE PREPARATION WORK LIST

1. Depreservation (removal of anticorrosive compounds).2. Visual inspection of appearance of the unit to make sure there is no trans-

portation damage. Check of accessories, tools and manuals in accordance withthe packing list.

3. Reinstallation of dismounted for the period of transportation components,accessories.

4. Inspection of presence and levels of oils in units and assemblies. Add oilwhen necessary.

5. Add coolant (when necessary).6. Check the storage batteries condition, and the way they secured (when

necessary add electrolyte, recharge, secure).7. Check operation of pneumatic brakes, clutch actuation, electrical equip-

ment, signal/horns, cab tilt system, pressure in tires, safety of wheels attach-ment, and other connections and attachments. Correct the problems when nec-essary.

8. Units, components and systems serviceability check under all operationmodes. Correct the problems when necessary.

9. Check operation of the steering mechanisms under running engine mode(rotating steering wheel). Correct the problems when necessary.

10. From the bottom inspection of the truck. (Check of leakage of coolant,oil, fuel. Safety of joints and attachments. Correct the problems when neces-sary).

11. Washing of the truck, and tinting, when necessary.12. Briefing of the owner, driver.

RUNNING IN OF THE TRUCK

The running-in period for new trucks is 1000 km of run.The following restrictions are established for the running-in period:- the weight of the transported cargo shall not exceed 70% of rated value.- the travelling speed shall not exceed 60 km/h; - towage of the trailer is forbidden. - the operation must be carried out on the roads with hard surface of I and

II grades.In the running-in period it is recommended:1. To check the degree of heating of wheel hubs, brake drums, driving axle

main gear housing immediately after the truck stop. With increased heating it isnecessary to define the reason and eliminate the trouble.

2. To check the oil level in the aggregates and, if necessary, add some.3. To control the condition of all the fastenings. Tighten loosened nuts, screws

25

and bolts. Pay special attention to the fastenings of the pitman arm, steeringmechanism housing, hinged head pin of the steering hydraulic booster cylinder,ball pins of the steering rods and steering hydraulic booster cylinder, steeringknuckles lever of the front axle, suspension, wheel nuts, propeller shaft flanges,U-bolts, platform, cab, empennage.

4. During movement check the device readings and take immediate mea-sures on elimination of abnormal work of the truck units and aggregates.

Upon completion of the running-in period do the following:1. Execute recommendations for the servicing the power unit (engine, clutch

and gearbox) stipulated by the operating manual after the running-in period.2. Execute in full extent all the works (including lubrication) stipulated by

maintenance after 4000 km. of run and the fastening works stipulated by alltypes of maintenance;

- change oil in the driving axle (according to the lubrication chart). Whilechanging the oil it is recommended to wash the housing with diesel fuel or ker-osene and to clean the drain the drain plugs magnets from metal sediments;

- change oil in the steering hydraulic booster system, wash the oil tank andfilters. Remove the oil primary filter of the drain pipe in the tank the cambricjackets and two springs holding it. Later on this jacket and springs are not in-stalled;

- tighten the wheel disc fixing nuts;- tighten the outside nut of the suspension shock-absorber reservoir;- check and if necessary adjust the tightening of the wheel hub bearing;- tighten the power unit fastening bolts;- tighten the spare wheel holder fastening bolts;- check technical state of the steering mechanism.

THE TRUCK OPERATION PECULIARITIES

PREPARATION OF THE TRUCK FOR OPERATION

Before starting of operation it is recommended to carry out preparatory workconnected to monitoring and filling of the truck by operation materials.

Depending on trucks transportation conditions storage batteries can be in-stalled with or without the electrolyte. Put storage batteries, not filled with theelectrolyte, into operative condition, and if necessary, adjust the density of those,which are filled.

Besides, check up:- presence of the coolant and its level in the extension tank and if necessary

add some;- oil level in the engine oil pan, gearbox, rear axle case, systems of platform

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lifting steering hydraulic booster and, if necessary, add oil up to the requiredlevel;

- air pressure in tires and if necessary make it normal.After fuel tanks are filled fuel the engine supply system. For doing this turn

the handle of the hand-operated fuel pump on high pressure fuel pump and,moving it up and down, pump the system during 2 - 3 min. Then turn the handleof the hand-operated fuel pump against the stop.

The sequence of filling the cooling system with coolant and its drain fromthe cooling system and preheater and heating systems, as well as sequence ofthe coolant level in the mentioned systems are described in the section «Coolingsystem».

Filling the cooling system with coolant

The cooling system is filled through the filler of the expansion tank. Prior tothe filling turn on the tap on the tank and make sure that the handles of the cabheating system taps are in operation position. The coolant is to be poured till itappears in the expansion tank tap hole.

Filling of the coolant into two-chamber tank is carried out until the coolantstarts spilling over the filler neck.

In order to fill the cab heating system start the engine and maintain crank-shaft medium rotations for 5 - 10 minutes.

Then add the coolant to the expansion tank.Employing water as a coolant is admissible in special emergency only with-

in a short period of time at the ambient temperature more than +5оС.

Draining of coolant from cooling system, warmer (liquid diesel type) andheater.

To drain the coolant do the following:- position the truck on a level ground;- tilt the cab and remove the expansion tank cap;- turn on the drain tap on the lower branch pipe of the water pump and two

taps on the flanges of the main water gallery of the engine in the rear of thecylinder block on both left and right sides, turn on the tap of the oil-waterradiator.

Filling oil into the engine and checking its level. For checking the oil level inthe engine oil pan open the cab front grille, withdraw the oil dipstick from theflexible sheath secured to the left of the cooling radiator (when looking for-ward), wipe it with clean rags and insert in the guide sheath as far as it will go;then withdraw the dipstick.

If the oil level is near the «H» mark (low), add fresh oil up to the «B» mark

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(high) on the oil dipstick.Pour oil through the filler neck located under the cab front grille to the right

of the cooling radiator (when looking forward). For this purpose release thesecuring nut, pull out and turn at 180o the filling branch pipe, tighten the nut andopen the cap of the filler neck. After the oil filling is over reinstall the filler neckto the original position in the reverse order. For draining the oil there is a drain-ing hole, which is closed with a plug in the engine oil pan.

Starting and stopping the engine. For starting the cold engine under theambient temperature being above minus 5оС proceed in the following sequence:

- close the batteries switch;- set the gearshift lever to the neutral position;- check the position of the engine shut-down handle (the handle must be

pushed in against the stop);- switch on the instruments by turning the instruments and starter switch

lock key to the first fixed position;- press the accelerator pedal to the degree of moderate feed;- switch on the starter by turning the key to the second non-fixed position;- after the engine starts release the key and make sure that the key has re-

turned to the initial position. Right after the starting, release the acceleratorpedal so that to avoid operation of the engine at increased rotations.

If the engine failed to start, make an attempt of restarting after an interval of1-2 min for which purpose repeat the above-listed operations. Never operate thestarter continuously in excess of 20 seconds. If after three attempts the enginefailed to be started, find out and correct the problem.

After starting, warm up the engine, with the radiator shutters closed, to thecoolant temperature of 50oC by running the engine first at a minimum and thenat an average rotational speed of the crank-shaft.

When starting the engine after changing oil or turbo-supercharger oil filterelement the engine shall be run for at least 2 min at minimum crankshaft rota-tions (for filling spaces of the turbo-supercharger bearings with oil). To avoidabnormal wear of the turbo-supercharger bearings run the engine at the crank-shaft idle speed not exceeding 1000 rpm (until oil pressure shows up in theturbo-supercharger).

For starting the engine under temperature below minus 5oC make use of theelectric torch preheater (ЭФУ) connected into the engine fuel feed system andproceed in the following sequence:

- set the gearshift lever to the neutral position;- check the position of the engine shut-down handle (the handle must be

pushed in against the stop);- close the batteries switch;- switch on the instruments by turning the instruments and starter switch

lock key clockwise to the first fixed position;

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- press the accelerator pedal to the position corresponding to average rota-tions of the crankshaft;

- press the button 4(see Fig.11) of the electric torch preheater and after thecontrol light is on, switch on the starter by turning the key in the instruments andstarter switch lock to the second non-fixed position, while holding the button ofthe electric torch preheater;

- after the engine starts release the key but keep holding the thermostat but-ton down till the engine operation becomes stable (under the thermostat opera-tion the torch, that is generated in the intake ducts of the engine, warms up theair, that moves into the cylinders).

If the engine failed to start, make an attempt of restarting for which purposerepeat the above-listed operations.

In case when the ambient temperature is 0oC or higher it is necessary toactivate the oil radiator by means of a tap that is located on the left-hand side ofthe cylinder block (at the flange of the oil radiator supplying pipe).

When the ambient temperature is lower and operation conditions are normalthe oil radiator shall be disabled.

When the truck is operated under heavy conditions with great loads and lowspeeds of movement the oil radiator shall be activated.

Before shutting down the engine, run it for 3-5 min with no-load at averagecrankshaft rotations. For shutting down the engine reduce the crankshaft rota-tions to minimum and then pull out the engine shutdown handle and leave it inthis position.

Order of the engine start-up when the start preheater is applied (at thetemperature below -20oС)*.

To light up the preheater do the following:1. Open the atmospheric tap on the preheater fuel tank.2. Blow the gas flue of the boiler and simultaneously warm up the fuel. For

this purpose set the handle of the switch 9 (see fig. 12) of the preheater opera-tion modes in position «3» (see fig. 14) for the period depending on the ambienttemperature:

20 sec. - up to -20oС 60 sec. - up to -40oС30 sec. - up to -30oС 90 sec. - up to -50oС3. Start the electric motor of the pump aggregate, electromagnetic valve and

the preheater plug, for doing this set the switch handle into position «1» andhold it in this position not more than 30 sec. until a typical hum occurrenceindicating that the fuel in the boiler has been inflamed.

4. Release the switch handle. At the same time it will automatically takeposition «2» when the electro-spark plug is turned off. The continuous steadyhum in the boiler will indicate that the preheater is already in the stable opera-tion mode. The start-up of the faultless preheater after fuel pre-warming is fast,10...15 sec. after the switch handle is set into position «1».

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5. If the preheater fails to start set the switch handle into position «0» andrepeat the start-up in the above-mentioned order one minute later. If the pre-heater has failed to start after two attempts with actuation of the electro-sparkplug for the period of 30 sec. with one-minute interval between attempts, findout the reason of fault and eliminate it.

6. When the liquid in the engine cooling system is warmed up to the temper-ature 70...80oС (according to the truck thermometer), stop the fuel supply bysetting the switch handle into position «3», and then 20-30 sec. later set it intoposition «0».

7. Close the tap on the fuel tank.Start-up the engine after it is warmed up by the preheater according to the

recommendations for engine start-up at the temperature range 0 up to -5oС.Start-up of the engine with the help of the preheater when filling water into

cooling system. When there is a special necessity in short-term usage of water warm-up the

engine by the preheater in the following sequence:- prepare hot water (40...70oС) without mechanical impurities to provide the

whole engine cooling system and cab heating are completely filled;- switch off the cab heater (See «Care of cab heating system»);- before filling of the cooling system with water make a tentative start-up

and after 10-15 sec. of operations switch off the preheater. Carry out start-upand shut-down of the preheater in the abovementioned sequence:

- fill the whole cooling system through the filler neck on the extension tankup to the level on its check tap and immediately start the preheater. In case thepreheater fails to start-up or it stops spontaneously start it up once again, and ifthe failure occurs drain immediately the water from the system;

- start the engine;- open the taps of the cab heating when the temperature of water in the

cooling system reaches 70... 80oС. Add some water in the extension tank up tothe top level. After that you can start driving the truck.

* when according to the customer ?s request the truck is equipped with thepreheater.

Instructions for the preheater operation. At the engine start-up withthe help of the preheater it is necessary:

- to bear in mind all the time, that casual handling with the preheater, as wellas its failure can result in fire-risk accident;

- only persons having thoroughly studied instructions are allowed for start-up;

- the driver must be present at the engine warm-up, keep an eye on the fuelcombustion in the boiler until the preheater switches off and must have an extin-guisher in case of fire;

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- the engine warm-up is prohibited in enclosed premises with bad ventilationin order to prevent poisoning by carbon monoxide;

- to keep clean and serviceable not only the start-up preheater, but also theengine, as the oiled engine (especially its casing) and fuel leakage can result infire-risk accident;

- to limit operation time of the preheater up to 15 sec. without any water inthe boiler;

- it is prohibited to add water into the overheated (because of absence ofwater) preheater boiler in order to avoid its damage (before adding water thepreheater boiler must be cooled);

- in case of naked flame appearance on the outlet at its steady mode of oper-ation it is prohibited to use the preheater until elimination of the damage;

- to start driving only after making sure that the atmospheric tap on the fueltank is closed and fuel leakage is excluded. With the temperature 0o C andhigher it is necessary to switch on the oil radiator by means of the tap located onthe left side of the cylinder block (on the flange of the oil radiator inlet pipe). Atlower temperatures and normal conditions of operation the oil radiator must beswitched off.

While working in hard conditions with big load and small travelling speedsthe oil radiator must be switched on.

Before you are going to stop the truck the engine must operate during 3-5min. without load at medium frequency rotations of the crankshaft, then makethe frequency minimal, after that pull out the engine shut-down handle and keepit in this position.

Fig. 14. Scheme of the switch handle positions of the preheater operation control:

1 - start-up; 2 - operation mode; 3 - blowing; 0 - neutral

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CAB TILTING

Tilting the cab at an angle in relation to the front hinged supports providesfree access to the engine and its systems, steering mechanism and other unitslocated in the front of the chassis.

Before tilting the cab raise the cab grille (so that to avoid its damaging)for which purpose while standing in front of the cab pull to yourself two handlesthat are situated in the lower right and left positions behind the grille and raisethe grille in the upper position. Take out of the holder the cab tilt pump drivehandle (it is secured behind the grille on the left (when looking forward).

Set the gearshift lever to the neutral position, remove the safety wire ropefrom the pin on the cab and using the handle, drawn out from under the grille,unlock the latching gear. For doing so insert the handle into the bushing 2 (Fig.15)and move it downward against the stop.

Tilting the cab. For tilting the cab turn the pump control valve handle to theTILT (ПОДЪЕМ) position, and then making use of the handle inserted intothe hole of the pump driving shaft, actuate the pump until the cab is completelytilted.

After unstable equilibrium position the further tilting of the cab goes onautomatically. In case of necessity to stop the automatic tilting process shift thepump regulator handle to the LOWERING (ОПУСКАНИЕ) position.

Lowering the cab. For lowering the cab turn the pump regulator handle tothe LOWERING (ОПУСКАНИЕ) position and lower the cab in a similarway. After the cab is lowered to the extreme down position the locking gearsnaps into action automatically. Then put the safety wire rope onto the pin onthe cab.

Carry out all the maintenance operations concerning the power unit onlywhen the cab is completely tilted.

TRAILER TOWING

You should start the movement of the truck with the second gear when tow-ing the trailer. You can switch to the higher gear only after the road-train has gotenough speedup. The road-train travelling speed is chosen depending on theroad conditions: fast speed of movement on the rough and pot-hole roads (espe-cially without cargo) is not allowed.

While the road-train manoeuvring it is necessary to take into account thatwhile turning there happens displacement of the trailer track to the turning centre.

Carry out turnings at speeds providing safety of movement. Brake smoothlyand only with the service brakes. When moving downhill, on the wet and slip-pery road apply the auxiliary brake.

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Fig. 15. Cab locking mechanism:

a) locking mechanism is opened; b) locking mechanism is closed: 1 - beam; 2 - bushing with lever; 3 - bracket; 4 - rod; 5 - support; 6 - washer; 7 - cam; 8 - cheek plate; 9 - pin; 10 - grip; 11, 12 - springs.

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As a rule, it is forbidden to stop the road-train on the ascent and descent. Incase of forced stop it is necessary to take all measures that exclude the possibil-ity of spontaneous movement of the road-train (engage gear, brake by the park-ing brake, put the stops under the rear wheels of the truck and trailer).

For coupling of the drop-side truck with the trailer carry out the following:- brake the trailer by the parking brake;- place the automobile by a reverse movement and carry out the coupling

and then putting the towing device latch click into the initial (lower) position,secure it by the cotter-pin;

- connect pneumatic and electrical systems of the trailer to the automobilesystems; During operation with the trailer that has single-circuit brake systeman automatic connecting head of the truck is used (painted in the black colour),and with double brake system of the trailer two connecting heads of «Palm»type painted in the red and blue colours are applied;

- release the trailer parking brake and check the operation of brakes andsignalling;

- switch on road-train three-bar lights.

For coupling of the automobile equipped with towing device (Fig.16) carryout the following:

- place the automobile by a reverse movement, make sure that the handle 18of towing device is lifted up, and carry out coupling . After coupling the handleshould be in a horizontal position, and the safety device 29 should be set «deepdown»;

- connect pneumatic and electrical systems of the trailer to the automobilesystems;

- open disconnecting taps on the automobile and trailer, providing air supplyfrom pneumatic system of the automobile in the air tanks of the trailer;

- check operation of the brakes and signalling system of the trailer. For un-coupling of the automobile with the trailer pull the safety device against the stopand holding it lift the handle up against stop by the other hand (handle should befixed in this position).

Coupling and uncoupling of the truck tractor with the semi-trailer

At coupling of the truck tractor with the semi-trailer the base-plate withcentre pin of the semi-trailer should be positioned from the ground surface onthe same level with the fifth-wheel device of the truck tractor or below it notmore than 10 mm. At the same time the semi-trailer should be braked by theparking brake.

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Fig. 16. Towing device:

1 - nut jacket; 2 - centre pin; 3 - nut; 4 - guiding bush; 5,9 - buffer flange; 6 - buffer; 7 -pivot; 8 - body; 10 - body cover; 11 - spring; 12 - pivot axis; 13 - buffer; 14 - cover; 15- lever; 16 - bolt; 17 - cover base; 18 - handle; 19 - pin; 20 - upper bush; 21 - eye guide;22 - lower bush; 23,28 - springs; 24 - fork; 25 - oil cap; 26 - bolt; 27 - nut; 29 - safetydevice.

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If the grips are closed it is necessary to turn the handle 1 (Fig. 17) to yourself,at the same time the handle should be held by latch 7 in the shifted position.After that turn the latch 12 counter-clockwise until the front grip flank leavesthe zone of the semi-trailer centre-pin movement. While turning the grip affectsthe latch and turns it, releases the locking knuckle, which supports on the gripwhile moving and holds it in the open position.

Carry out coupling in the following order:- place the truck tractor by a reverse movement at a low speed to the semi-

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

After that make sure that the safety bar 20 has taken a vertical position andprevents the handle movement to yourself;

- lift the rollers of the semi-trailer base device in running position;- connect the cable of electric wiring to the plug socket of the truck tractor

and semi-trailer;- connect the hoses (with the red head - feeding, with yellow head - control-

ling) of pneumatic drive of the truck tractor brakes to the connective heads ofthe semi-trailer;

- release the parking brake on the semi-trailer;- move the road-train on some distance, make sure of the coupling service-

ability, faultless operation of the semi-trailer brakes, check the operation of elec-trical devices of the semi-trailer.

At coupling with the different marks of semi-trailers adjust the distance be-tween hold-downs on hoses in order to avoid their rupture due to their frictionwith the prominent parts of the truck tractor, and also make sure there are nogaps or tightness in connection between centre-pin and grips. If necessary ad-just gaps between centre-pin and grips as it is described above.

Before uncoupling select an even place for the semi-trailer parking.Carry out uncoupling in the following order:- put the semi-trailer on parking brake;- lower till it will go and fix the rollers of the semi-trailer base device having

put under them wooden pads;- disconnect the hoses of the brake pneumatic drive from the connective

heads of the semi-trailer and close the latter by covers;- turn the handle 1 to yourself, at the same time the safety bar 20 will take

shifted position, and the latch 7 will abut against the locking knuckle 5 and willhold it in the open position;

- shift the first gear and slowly, without jerks, move the truck tractor for-ward. At the same time the semi-trailer centre pin turns relatively pin 15, thegrip flank 12 depresses the latch 7, turns it releases the locking knuckle 5, which

36

is moved by springs 10 and abut against the rear grip 12 and holds it in the openposition.

Fig. 17. Fifth-wheel device:

1 - handle; 2,4,10 - springs; 3 - nuts; 5 - locking knuckle; 6 - rotating base; 7 - latch; 8 -cover; 9, 11, 21 - bolts; 12 - rear grip; 13 - front grip; 14 - nut; 15 - pin; 16, 17 - brackets;18 - pad; 19 - fifth-wheel; 20 - safety bar.

DRIVING THE TRUCK AND MONITORING ITS SYSTEMS AND UNITS FUNCTIONING

Control over gearbox

The gearbox is comprised of the main five-step gearbox and a two-stepauxiliary gearbox (direct and reducing gears). Thus nine gears are divided intotwo ranges: low - from the 1st to the 5th gear and high - from the 6th to the 8thgear.

37

The main gearbox is controlled by a lever 1, and the auxiliary gearbox iscontrolled by the speed range selector switch 2 (Fig. 18). The gear shifting leverdiagram is illustrated on Fig.19. As it is seen from the illustration, each positionof the gearshift lever corresponds to one of the two gears depending on theposition of the selector switch 2.

For starting away from rest and accelerating the truck it is necessary to con-secutively apply the gears in the main gearbox when the reducing gear in theauxiliary gearbox is engaged (range switch is to be located in the upper posi-tion, see dr.19).

For starting away from rest use such a gear of the lower range which allowsthe truck to be set in motion without excessive slippage of the clutch and over-loading of the engine. The shifting from the 1st to the 5th gear and from the 8thto the 9th gear is accomplished in the same way as on any other gearbox provid-ed with a mechanical control linkage.

For shifting from the 5th to the 6th it is necessary to set the range switch ofthe auxiliary gearbox to the position corresponding to the higher range in theauxiliary gearbox (lower position of the range switch), then set the gearshiftlever to the neutral position and only after the warning light has gone out shiftthe 6th gear (position of the lever 2/6), see fig.19.

The low speed range is engaged in the reverse sequence. For shifting fromthe 6th to the 5th gear it is necessary to set the range switch of the auxiliarygearbox to the position corresponding to the low range (upper position of therange switch), set the gearshift lever to the neutral position and only after thewarning light has gone out shift the 5th gear in the main gearbox (position of thegearshift lever 5/9).

It is allowed to shift from the 6th to the 5th gear only when the speed of thetruck is not higher than 25-30 km/h.

Engagement of the gear in the auxiliary gearbox while switching from the5th to the 6th gear and from the 6th to the5th gear will happen automaticallyduring shifting with the neutral position of the gearshift lever.

It is not allowed to engage a reducing gear while the truck is running underthe 8th and 9th gear.

It is not allowed to shift gears when the auxiliary brake is activated.

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Fig. 18. Gearbox Lever Handle:1 - handle; 2 - switch; 3 - pneumatic valve; 4 - lever.

39

Fig. 19. Scheme of gear switch in the main and additional gear box.

General terms of truck control

While moving on slippery roads and on especially dangerous areas, (snow,dirt, soft ground, sand and so on) it is necessary to block center differentials oftransfer gear box and of intermediate axle and only if it is absolute necessity(for example wheels skidding from one side of the truck) interwheel differen-tials of intermediate and rear axles.

Thus the pressure in the tires can be reduced till the value providing the bestpassability of the truck on this area, according to the section «Using of the cen-tralized system of the air pressure adjustment in the tires».

It is forbidden the movement with switched pilot lamps 10, 11, 12 (see fig.11), indicating that the pressure in the circuits of the pneumatic brake drive.

At the first features of the road-train folding and skidding release the servicebrake pedal and use additional brake deleting the skidding by turning of thecontrolled wheels to the skidding side.

On the downhills it is forbidden to exceed the speed indicated below de-pending on the engaged gear.

Gear 1 2 3 4 5 6 7 8 9

Speed,km/h, notmore

7 10 14 19 24 37 51 66 85

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FOR ROAD TRAIN MOVEMENT DECELERATION ON DOWNHILLS USEAUXILIARY BRAKE, AND IF NECESSARY, APPLY THE SERVICE BRAKES.THUS YOU SHOULD TAKE INTO CONSIDERATION THAT THE BEST EFFI-CIENCY OF THE AUXILIARY BRAKE IS REACHED AT SWITCHED REDUC-ING GEAR IN AUXILIARY GEAR BOX, AT PRESSURE REDUCTION IN THECIRCUIT OF PARKING BRAKE DRIVE THE TRUCK BRAKING HAPPENSBECAUSE OF SPRING POWER STORAGE OPERATION. FOR TRUCK UN-BRAKING IT IS NECESSARY TO UNSCREW THE PUSHER STOP BOLTS OUTOF POWER STORAGE CYLINDERS (SEE FIG. 20) OR PRESS THE PUSHER 12AT POWER STORAGE INSTALLATION. (FIG. 21)

FIG. 20. UNSCREW OF THE POWER STORAGE PUSHER STOP BOLT

FIG. 21. SPRING POWER STORAGE:

1, 7, 11 - SPRINGS; 2, 5 - DIAPHRAGMS; 3 - DISC; 4 - ROD ; 6 - CYLINDER ; 8 -BALLS ; 9 - FIXING BUSH ; 10 - BREATHER; 12 - PUSHER

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FORD OVERCOMINGFOR FORD OVERCOMING IT-S NECESSARY TO INSTALL FORD VALVE*

ON THE EXHAUST PIPE. THE PRESSURE IN TYEE SHOULD BE RATED.DURING THE PERIOD OF FORD OVERCOMING THE ATMOSPHERIC

HOLES IN STORAGE BATTERIES PLUGS SHOULD BE GLUED UP WITH THETAPE PVC-0,20, THE SWITCH OF FAN ENGAGING COUPLING PUT INTOPOSITION « 0 « ( THE SWITCH IS INSTALLED ON THE ENGINE), CLOSE THERADIATOR (C SHUTTERS AND CLOSE ENGINE CASE BREATHER TUBEPLUG, FIXED ON THE AIR FILTERS BRACKET, AND PUT THE TUBE HOLE INTHE LOWER HOLE. ONE SHOULD ENTER THE WATER SLOWLY WITHOUTCREATING LARGE WAVES AND MOVE ON THE 1-ST OR 2-ND GEAR OFLOW-RANGE GEAR BOX AT THE AVERAGE ENGINE ROTATION FREQUEN-CY WITH BLOCKED INTERAXIAL DIFFERENTIAL.

AFTER FORD OVERCOMING (ESPECIALLY IN WINTER) ONESHOULD DRY BRAKING GEARS, FOR THIS IT’S NECESSARY TO AP-PLY SOME BRAKINGS WITH THE HELP OF SERVICE BRAKE SYSTEM.TO OPEN THE COVER OF STORAGE BATTERY BOX AND DRAIN WA-TER FROM IT, PUT THE TAPE OFF THE HOLES OF THE STORAGEBATTERIES, PUT THE ENGINE CASE BREATHER TUBE PLUG IN THEUPPER TUBE HOLE, OPEN THE RADIATOR (COOLER) SHUTTERS PUTTHE SWITCH OF FAN ENGAGING COUPLING INTO OPERATION POSI-TION.

* IF IT IS IN THE SPARE PARTS SET

OPERATION TRUCK CONTROL

WITH THE TRUCK IN MOVEMENT IT»S NECESSARY TO WATCHTHE INDICATIONS

OF THE INSTRUMENTS AND PILOT LAMPS SIGNALS :- AIR PRESSURE IN THE FRONT AND REAR CIRCUITS OF PNEU-

MATIC DRIVE BRAKES MUST BE IN THE RANGE 637... 784 kPa (6,5... 8KGF/CM2).

WHEN THE AIR PRESSURE FALLS IN THE FRONT OR REAR CIR-CUITS OF BRAKES LOWER THAN 490+49 kPa THE CORRESPOND INGINDICATING LAMPS GO ON;

- OIL PRESSURE IN THE ENGINE LUBRICATION SYSTEM AT NOM-INAL ROTATION FREQUENCY MUST BE 392..588 kPa (4.. 6 KGF/cm2) ATMINIMUM ROTATION FREQUENCY 98 kPa. (6 kgf/cm2);

WHEN PRESSURE FALLS LOWER THAN 78...39 kPa THE INDICATING

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LAMP GOES ON;- CONTROL OVER THE FUEL LEVEL IN THE FUEL TANK IS CARRIED

OUT ACCORDING TO THE READINGS OF THE FUEL LEVEL INDICATOR,AND WHEN THERE IS RESERVE OF FUEL WITHIN 16...20 % THE INDICAT-ING LAMP GOES ON;

CONTROL OVER THE BATTERIES CHARGING IS CARRIED OUTBY THE VOLTAGE INDICATOR. WHEN THE INDICATING LAMP OFTHE BATTERIES CHARGING GOES ON WITH THE ENGINE IN OPERA-TION IT SHOWS DEFECT IN THE ELECTRIC-POWER SUPPLY SYSTEM(ALTERNATOR DOESN’T SUPPLY CHARGING CURRENT);

IF THE OIL OR AIR FILTERS ARE BLOCKED THE INDICATINGLAMPS GO ON;

- CONTROL OVER THE AIR PRESSURE IN THE TYRES IS REAL-IZED WITH THE AIR INDICATOR IN THE SYSTEM OF TYRES CEN-TRALIZED PUMPING. WHEN THE INDICATING LAMPS GO ON THETRUCK MOVEMENT IS FORBIDDEN THE CORRESPONDING DAMAGEIS DELETED. CONTROL OVER TRUCKS SYSTEMS OR UNITS ENGAGE-MENT IS REALIZED WITH THE HELP OF INDICATING LAMPSON PANEL BOARD,

TRUCK TOWING.

TRUCK TOWING WITH DISENGAGED ENGINE CAN BE REALIZEDON THE DISTANCE NOT MORE THAN 20 KM. FOR THIS PUT THE LE-VER OF THE MAIN GEAR BOX SWITCH IN NEUTRAL POSITION ANDENGAGE THE HIGHEST RANGE IN THE AUXILIARY GEAR BOX.

FOR TRUCK TOWING ON LARGE DISTANCES IT’S NECESSARY TODISCONNECT PROPELLER SHAFTS FROM FRONT AND REAR (TRUCK4x4) OR INTERMEDIATE (6x6) AXLES.

WINCH USING * (* IF INSTALLED) TRUCK WINCH IS EQUIPPED WITH SAFE GUARD AND IN THE

CASE WHEN CABLE LOAD EXCEEDS THE INDICATED LIMIT, ON THEPOWER TAKE OFF THE SHEAR

OF SAFETY PIN CAN HAPPEN, WHEN SAFETY PIN IS SHEAREDOR CLUTCH IS DISENGAGED IN THE PERIOD OF STRETCHING, LOADKEEPING IS PROVIDED BY THE BRAKE ON THE WORM SHAFT.SHEARED PIN SHOULD BE CHANGED BY THE NEW ONE FROM THESPARES AND ACCESSORIES KIT AND CONTINUE STRETCHING WITHWINCH USING BLOCK .

IN OPERATION CONDITIONS IT’S IMPOSSIBLE TO DEFINE EFFORTON THE CABLE. THAT’S WHY BEFORE WINCH USING ONE MUST

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DEFINE THE NECESSITY OF BLOCK USING IN EVERY SPECIFIC CASE.ON FIG. 22 ONE CAN SEE THE SCHEME OF WINCH USING WITH BLOCK.IF THE BLOCK IS USED FOR SELF PULLING OUT (FIG. 22A) IT IS FIXED

ON THE OBJECT, SERVING AS SUPPORT, AND CABLE DEADEYE IS FIXEDON TOWING DEVICE, AND WHILE FULLING OUT ANOTHER TRUCK (FIG.22B) CHANGING ROD DIRECTION THE TOWING DEVICE OF THE PULLEDOUT TRUCK HOOKS THE DEADEYE.

IF THE BLOCK IS USED FOR ROD INCREASING WHILE PULLINGOUT ANOTHER TRUCK (FIG. 22C) IT IS TIGHTENED ON THE HOOKOF THE TRUCK PULLED OUT, AND CABLE DEADEYE IS TIGHTENEDON THE OBJECT SERVING AS SUPPORT OR ON TRACTOR TOWINGDEVICE.

FOR WINCH PULLING OUT OF ANOTHER TRUCK (THE JAMMEDONE OR FOR HEAVY LOADING ON THE TRAILER) IT IS NECESSARY:

A) VARIANT WITH MECHANICAL CABLE EXTENT :1 A. TO BRAKE THE TRUCK WITH PARKING BRAKES, IF POSSI-

BLE, TO FIX THE TRUCK FOR FRONT TOWING FORK TO SOME STA-TIONARY OBJECT (TREE, PILLAR AND SO ON);

2A. TO START ENGINE BY THE SWITCHES 1, 5 (FIG. 10), TO EN-GAGE «NEUTRAL» IN TRANSFER GEAR BOX AND POWER TAKE OFF;

3A. TO PRESS CLUTCH PEDAL;4A. SWITCH ON REVERSE GEAR IN GEAR BOX;5A. TO RELEASE CLUTCH PEDAL SMOOTHLY AND STRETCH SI-

MULTANEOUSLY CABLE BY HAND TO THE PLACE OF FIXING;6A.TO PRESS CLUTCH PEDAL, SWITCH OFF REVERSE GEAR. 7A. TO ENGAGE 2-ND AND 3-RD GEAR IN THE GEAR BOX AND

SMOOTHLY, AFTER CLUTCH PEDAL RELEASING, STRETCH THEWINCH ON THE INTERMEDIATE REVOLUTIONS OF THE ENGINE.

B) VARIANT WITH MANUAL CABLE STRETCHING :1 B) SEE POINT 1A;2 B) TO DISCONNECT DRUM SHAFT FROM REDUCTION GEAR UN-

SCREWING NUT TILL THE GAP BEWEEN NUT AND COVER.;3 B. STRETCH THE CABLE TILL THE PLACE OF FIXING;4 B. TO FIX THE CABLE;5 B. TO START THE ENGINE, BY THE SWITCHES 1. 5 (FIG. 10), TO

ENGAGE «NEUTRAL» IN TRANSFER GEARBOX PTO AND WINCH;6 B. TO PRESS CLUTCH PEDAL;7 B. TO ENGAGE 2-ND OR 3-RD GEAR IN THE GEAR BOX AND SMOOTH-

LY, AFTER CLUTCH PEDAL RELEASING, STRETCH THE WINCH ON THEINTERMEDIATE REVOLUTIONS OF THE ENGINE;

8 B. AFTER FINISHING THE OPERATION TO TIGHTEN NUT AGAINST

44

THE STOP. THE NUMBER OF WINCH CONTINUOUS STRETCHES IS LIMIT-ED BY THE OIL TEMPERATURE WHICH MUST NOT EXCEED 120O C ANDMUST NOT EXCEED 3 TIMES RUNNING,

AT CABLE STRETCHING BACKWARDS MAX. TOLERABLE ANGLESOF CABLE DEVIATION FROM TRUCK LONGITUDINAL AXLE MUSTNOT EXCEED 30O . AT BIG ANGLES IT’S NECESSARY TO USE WINCHBLOCK (FIG. 22). AFTER WINCH WORK FINISHING IT’S NECESSARYTO WIND THE CABLE ON THE DRUM AND HOOK THE CABLE DEAD-EYE FOR THE REAR TOWING DEVICE.IT IS RECOMMENDED TO WINDTHE CABLE USING THE 3-RD GEAR AND INTERMEDIATE ENGINEREVOLUTIONS. ONE SHOULD HOLD THE CABLE TIGHT.

AT SELF-PULLING OUT BY THE WINCH WITH CABLE STRETCH-ING FORWARD (FIG. 22A) IT IS RECOMMENDED TO USE BLOCK, FORTHIS :

- PUT OFF CABLE DEADEYE AND STRETCH OUT THE WINCHCABLE AHEAD OF THE TRUCK ON RELEASE AND SUPPORTINGROLLERS;

- TO FIX DEADEYE ON THE CABLE;- TO FIX WINCH BLOCK ON THE OBJECT, SERVING AS SUPPORT,

AND DEADEYE ON THE FRONT TOWING FORK OF THE TRUCK;- TO FULFILL RECOMMENDATIONS OF P.P. 2A..7A OR 26..76 OF

THE PRESENT SECTION.AT CABLE STRETCHING AHEAD MAX. TOLERABLE ANGLES OF

CABLE DEVIATION FROM TRUCK LONGITUDINAL AXLE MUST NOTEXCEED 15O.

IT IS FORBIDDEN :- TO USE WINCH CABLE FOR TRUCK TOWING;- TO ENGAGE REVERSE MOVEMENT DURING WINCH OPERA-

TION;- TO STAY NEAR THE CABLE OR BETWEEN THE CABLES (WHILE

USING BLOCKS).IF TRACTIVE FORCE IS UNSUFFICIENT ON THE WINCH CABLE

THE DRIVE AXLES ENGAGEMENT IS ALLOWED.IT’S NECESSARY TOENGAGE GEAR IN TRANSFER GEAR BOX.

CENTRALIZED SYSTEM OF AIR PRESSURE ADJUSTMENTIN TYRES.

WHEN TRUCK MOVES ALONG THE ROAD WITH HARD SURFACE

45

FIG. 22. THE SCHEME OF WINCH USING WITH BLOCK:

A - TRUCK SELF-PULLING OUT ; B - PULLING OUT OF STUCK TRUCK WITHROD DIRECTION CHANGING, C - TRACTIVE FORCE INCREASING AT STUCKTRUCK PULLING OUT.

B CA

46

AND COMPACT GROUND THE PRESSURE IN THE TYRES MUST BE NOR-MAL AND WHEEL VALVES MUST BE CLOSED. KEEPING THE INDICATEDPRESSURE VALUE PROVIDES TYRES PRESERVATION. FOR OVERCOMINGOF HARD SWAMP AREAS, SNOW AREAS AND BULK ONES IT IS ALLOWEDSHORT REDUCTION OF THE INTERIOR PRESSURE IN THE TYRES AGAINSTTHE VALUE, PROVIDING THE BEST PASSABILITY ON THE PRESENT AREAACCORDING TO THE TABLE GIVEN BELOW. THUS THE WHEEL VALVESMUST BE OPENED AND TRUCK SPEED MUST NOT EXCEED THE ONE INDI-CATED IN THE TABLE.

TABLE

AFTER OVERCOMING OF DIFFICULT ROAD AREAS IT’S NECESSARYTO STOP (IF THE CIRCUMSTANCES ALLOW) AND MAKE RATED THE AIRPRESSURE IN TYRES. CONTINUOUS MOVEMENT AT THE AIR PRESSUREIN TYRES 0,1 MPa (1,0 KG/CM2.) MUST NOT EXCEED 5 KM.

THE AIR PRESSURE IN TYRES IS DEFINED ACCORDING TO MANOM-ETER ON THE PANEL BOARD AT NEUTRAL POSITION OF PRESSURE CON-TROL VALVE HANDLE AND OPEN WHEEL VALVES. IF IT IS NECESSARY TODEFINE AIR PRESSURE IN SEPARATE TYRE ONE SHOULD OVERLAPTHEWHEEL VALVES OF THE OTHER TYRES. FOR AIR PRESSURE REDUCING INTHE TYRES CONTROL VALVE HANDLE MUST BE PUT IN THE POSITION«OUT», AND FOR ITS INCREASING - TO TRANSFER SMOOTHLY IN THEPOSITION « PUMPING» . AFTER REACHING THE REQUIRED PRESSURECONTROL VALVE HANDLE MUST BE PUT IN NEUTRAL POSITION.

IT IS FORBIDDEN :TO PUT PRESSURE CONTROL VALVE HANDLE IN THE POSITION

“ PUMPING “ IF WHEEL VALVES ARE CLOSED IN ORDER TO AVOID MA-NOMETER DAMAGE.

TYPE OF ROADS PERMISSIBLE PRESSUREmPa (KG/CM2)

MAX.PERMISSIBLESPEED (KM/H)

MAX. RUNNINGIN WARRANTY

PERIOD OF TIRESSERVICE

SWAMP AND SNOW AREAS

IMPASSABLE SWAMP,SNOW AND BULK SANDAREAS

ALL TYPE ROADS (ONLYDURING TIRES PUMPINGAFTER PASSING DIFFICULTAREAS OF ROAD)

NOT LESS 0,1 (1,0)

NOT LESS 0,13 (1,5)

FROM 0,15…0,20 (1,5..2,0)TO THE PRESSURE OFTIRES MAX. PERMISSIBLELOAD

20

20

30

100 KM

450 KM

750 KM

47

SPARE WHEEL SECURINGTRUCK SPARE WHEEL IS INSTALLED BEHIND THE CAB ON THE FRAME

FROM THE LEFT SIDE IN SPECIAL HOLDER, WHICH IS SHOWN ON FIG. 23.SPARE WHEEL IS INSTALLED ON THE GROUND OF THE FIFTH WHEEL

FOLDING BRACKET 35, BEING CENTRED BY INTERIOR RIM SURFACE ONTHE ENDS OF WELDED BAR 26, AND IS FIXED ON THE FOLDING BRACKETPLANE WITH THE HELP OF TWO ROTATING BOLTS 27.

DURING WHEELS MOUNTING AND DISMOUNTING THE NUTS ARE NOTREMOVED FROM THE BOLTS. WHILE BOLTS TIGHTENING BY NUTS ONESHOULD WATCH THE DIRECTION OF BOLTS HEADS IN THEIR TRAPS 29,TO AVOID THEIR ROTATION.

FOR SPARE WHEEL LOWERING IT IS NECESSARY TO UNSCREW FOURNUTS AND ROTATING PLUG-IN TAP-WRENCH (USING PUMP HANDLE FORCAB LIFTING) COUNTER CLOCK-WISE, LOWER FOLDING BRACKET WITHTHE WHEEL.

BEFORE WHEEL LOWERING ON THE GROUND ONE MUST CHECK-UPTIGHTENING; AND CABLE POSITION ON THE SHAFT. TO AVOID WHEELFREE DROPPING CABLE SLACKENING IS NOT ALLOWED. IT IS PROHIBIT-ED TO DISENGAGE THE CLICK THROUGHOUT OF GEAR WITH RATCHET.

FOR WHEEL LIFTING FROM THE GROUND THE WHEEL MUST BEMOUNTED INTO THE FIFTH WHEEL ON THE FOLDING BRACKET 7 WITHINTERIOR RIM SURFACE ON THE ENDS OF WELDED BAR 26, THEN IT MUSTBE FIXED AND ROTATED TAP-WRENCH CLOCK-WISE TILL SPARE WHEELCOMPLETE LIFTING, DIRECTING INTO CHUTE OF WHEEL HOLDER 1 SOTHAT ROTATING HOLD-DOWN 31 SHOULD BE ENGAGED INTO THE GEARWITH FOLDING BRACKET DECK.

LIFTED WHEEL SHOULD BE FIXED TO THE HOLDER SUPPORT, TOPRESS FOLDING BRACKET WITH THE NUTS TOGETHER WITH SPARE WHEELFIXED ON IT, AND EXTENSION THAT SHOULD BE PRELIMINARILY INSERT-ED INTO THE FIFTH-WHEEL OPENING.

TO THE DRIVER’S ATTENTION !WHILE THE WHEEL LIFTING AND LOWERING IT I’S PROHIBITED TO

STAY IN THE ZONE OF THE WHEEL LOWERING !DURING SPARE WHEEL LIFTING IT IS NECESSARY TO PAY ATTENTION

TO THE CORRECT WINDING OF THE CABLE ON THE ROLLER, ESPECIALLYOF THE FIRST WRAPS. THE CABLE MUST BE WINDED UNIFORMLY FROMTHE CLOSING ON THE AXLE ALONG THE TRUCK MOVEMENT (LOOKINGFORWARD).

THE CABLE WINDING FROM THE CLOSING ON THE AXLE CONTRATRUCK MOVEMENT IS NOT ALLOWED BECAUSE OF THE POSSIBLE GRIND-ING.

AT THE INITIAL MOMENT OF SPARE PARTS LOWERING (AFTER 8-10ROCKINGS) IN THE CASE OF ITS IMMOBILITY ONE SHOULD PUSH THE

48

WHEEL TOGETHER WITH FOLDING BRACKET TO THE SIDE OF LOWER-ING.

FIG. 23. SPARE WHEEL SECURING:

1- HOLDER; 2, 17, 27 - BOLTS; 3, 12, 28, 30 - NUTS; 4, 5, 6 - BRACKETS; 7 - FOLDINGBRACKET; 8 - SPARE WHEEL; 9 - SHAFT; 10 - RATCHET MECHANISM; 11 - PLATESPRINGS; 13 - CABLE; 14- BLOCK; 15- INSERT; 16- PRESSING BUSH; 18 - TIE; 19 -DEADEYE; 20, 25 - PINS; 21 - TAP WRENCH; 22 - GRIP; 23 - SPROCKET; 24 -SUPPORT; 26 - BAR; 29 - TRAP; 31 -HOLD DOWN; 32 - FOLDING BOLT; 33 - CLICK;34 - RATCHET WHEEL; 35 - FIFTH WHEEL.

SPARE WHEEL ON FIFTH WHEEL TRACTOR CAN BE TEMPORARILYFIXED ON THE FRAME CROSS - MEMBER.

SPARE WHEEL ON DROP-SIDE TRUCKS CAN BE MOUNTED UNDER THEFRAME (FIG. 24).

FOR WHEEL LOWERING DO THE FOLLOWING :

49

- UNSCREW NUTS 7 OF THE HOLDER 3 FIXING BOLTS TO THE BRACK-ET 1 AND ROTATE SHAFT 2 WITH WRENCH COUNTER CLOCK WISE;

- RELEASE NUTS 4 OF HOLDDOWNS 5 FIXING BOLTS AND REMOVE THEHOLDER OUT OF THE WHEEL.

THE WHEEL LIFTING IS TO BE EXECUTED IN REVERSE ORDER. SPRING9 EFFORT IS ADJUSTED BY THE NUT 8.

FIG. 24. SPARE WHEEL SECURING :

1 - BRACKET; 2 - SHAFT; 3 - HOLDER; 4, 7, 8 - NUTS; 5 - HOLDDOWN; 6 - WHEEL; 9 - PLATE SPRING.

50

WIDE-SECTION TIRES MOUNTING AND DISMOUNTINGTYRE MOUNTING ON THE RIM IS REALIZED AS FOLLOWS :1. PUT THE TUBE IN THE TYRE SPREADING IT BEFOREHAND WITH

TALC, INSERT THE RIM TAPE AND PUMP A LITTLE THIS TUBE WITH AIR.2. PUT THE WHEEL RIM ON THE FLOOR UNDER THE VALVE WITH SLOT

UP AND PUT ON BEAD RING.3. PUT THE TYRE ON THE RIM. THUS THE TUBE VALVE MUST GO OUT-

SIDE THROUGH THE RIM SLOT AND DISLOCATE IN THE CENTRE OF THEPROTECTIVE HOUSING OPENING (FIG. 25A).

4. PUT ON BEAD RING.5. INSERT THE LANDING RING SO THAT THE FIXING EDGE

SHOULD BE IN THE WIDE PART OF VALVE SLOT (FIG. 25 B).6. INSERT THE CURVED END OF TYRE IRON INTO THE LOCKING

GROOVE AND FORCE DOWN THE LANDING RING BELOW AGAINSTTHE LOCKING GROOVE RELEASE IN THE RIM. (FIG. 25 C).

7. FIT THE LOCK RING. FOR THIS ONE END OF THE RING INSERTIN THE LOCKING SLOT OF THE RIM AND WITH THE STRAIGHT ENDOF TYRE IRON, INSERTED BETWEEN RIM AND LOCK RING, PRESSIT TO YOURSELF TILL COMPLETE MOUNTING.

8. FIX WHEEL VALVE ON THE RIM PROTECTIVE HOUSING. FORTHIS:

- REMOVE THE TUBE VALVE OUT OF THE HOUSING HOLE ANDPUT ON IT ALL REMOVED COMPONENTS AS FOLLOWS: COUPLINGNUT, V-RING, SEAL RING, VALVE FIXING NUT AND BUSH, FIT WHEELVALVE IN THE HOUSING OPENING AND INSERT VALVE END IN THEVALVE SPACE;

- PUT ON THE BUSH AND PUT ON VALVE FIXING NUT WITHOUTTIGHTENING;

- PUT ON VALVE COUPLING NUT, SO THAT V-RING AND SEALRING SHOULD BE INSERTED IN THE NUT WITHOUT SKEWNESS ANDPINCHING;

- TIGHTEN THE VALVE FIXING NUT AND COUPLING NUT. THEEXCESSIVE COUPLING NUT TIGHTENING CAN LEAD TO THE VALVEDEFORMATION.

9. CLOSE THE WHEEL VALVE, SCREW THE PLUG AND PUMP THETYRE AGAINST THE REQUIRED PRESSURE THROUGH THE PUMP-ING INDIVIDUAL VALVE. FOR PROVIDING THE SAFETY OPERATIONWHEN PUMPING TYRES IN GARAGE THE ASSEMBLED WHEEL MUSTBE PLACED IN THE SPECIAL GRATE, AND OUTSIDE THE GARAGE -TURN OVER THE LOCK RING OF THE WHEEL ASIDE FROM THE DRIVERAND FROM THE PEOPLE NEARBY, WHILE PUMPING ONE SHOULD BECONVINCED IN THE CORRECTNESS OF LOCK RING POSITION, PRELIMI-

51

NARILY PUMPING TYRE TO THE PRESSURE 50 kPa (0,5 KGF/CM2) ANDONLY AFTER THIS MAKE THE PRESSURE REACH THE NORMAL ONE.

TYRES DISMOUNTING IS REALIZED AS FOLLOWS :1. COMPLETELY DEFLATE THE TYRE, HAVING OPENED THE

WHEEL VALVE.2. TAKE OFF THE WHEEL VALVE,3. FIT THE CURVED END OF TYRE IRON IN THE STAMPED SLOT

OF LANDING RING AND FORCE THE TYRE DOWN TOGETHER WITHBEAD RING, REPEATING THIS OPERATION ON EACH SLOT CONTIN-UOUSLY ALONG THE WHEEL CIRCUMFERENCE AND REMOVE THETYRE BEAD OFF THE DECK LANDING RING.(FIG.26A)

4. REMOVE THE LOCK RING, FOR THIS :- INSERT THE STRAIGHT END OF THE TYRE IRON IN THE LOCK

RING SLOT AND PRESS THE LANDING RING DOWN;- IN THE SLOT BETWEEN LOCK AND LANDING RINGS FIT THE

CURVED END OF THE SECOND TYRE IRON AND FORCE DOWN THELANDING RING CONTINUOUSLY PRESSING IT ALONG THE WHEELCIRCUMFERENCE;

- WITH THE STRAIGHT END OF THE TYRE IRON PRESS OUT THELOCK RING AND REMOVE IT FROM THE SLOT, AND WITH THECURVED END OF THE SECOND TYRE IRON PUT THE LOCK RINGOUT OF THE SLOT UNTILL ITS COMPLETE REMOVAL (FIG. 26 B).

5. REMOVE THE LANDING RING. FOR THIS INSERT THE CURVEDEND OF THE TYRE IRON BETWEEN THE BEAD RING AND LANDINGRING BEAD AND PRESS THE LANDING RING CONTINUOUSLY ALONGTHE WHEEL CIRCUMFERENCE UN TILL ITS COMPLETE REMOVAL(FIG. 26 C) .

6. REMOVE THE BEAD RING.7. TURN OVER THE WHEEL AND REMOVE THE TYRE BEAD FROM

THE LANDING RING SO AS INDICATED IN P. 3.8. LEAN THE WHEEL TO THE WALL AND INSERTING THE CURVED

END OF THE TYRE IRON BETWEEN THE BEAD RING AND RIM BEADPRESS THE RIM ALONG CIRCUMFERENCE TO SOME VALUE. TAK-ING THE RIM WITH BOTH HANDS REMOVE IT COMPLETELY HAV-ING FORCED DOWN THE VALVE INTO THE RIM SLOT.

IN CASE OF RIM TAPE ADHESION TO THE RIM TURN OVER THEWHEEL, INSERT THE STRAIGHT END OF THE TYRE IRON BETWEENRIM AND TAPE RIM, AND MOVING THE TYRE IRON ALONG THEWHEEL CIRCUMFERENCE RELEASE TAPE RIM.

52

TUBE TYRES MOUNTING AND DISMOUNTINGTire dismounting order:1. Deflate the tires completely.2. Put off correction weights.3. Put off the tire bead from the conical seat from the side of the rim locking

part, for doing this:- put the straight and bent mounting blades between the wheel bead rim and

the tire bead one after another and simultaneously force them down (Figs. 27aand 27b);

- put off the tire bead from the conical seat of the locking ring by movingalong the rim circumference and forcing it down by the blades.

4. Take out the locking ring, for doing this:- put the straight blade end in the ring dismounting slot and release the ring

from the locking groove. Lift the ring up by the curved blade (Fig, 27c);- by holding the ring with the straight blade release the locking ring with the

curved mounting blade until it completely goes out of the groove (Fig. 27d).5. Put the bead wheel off from the rim.6. Turn over the wheel.7. Analogously put the second bead off from the rim conical seat by the

same way.8 Place the wheel in the vertical position, remove the rim out of the tire until

the inner tube valve thrust against the flank of the valve slot and after that forcedown the valve into the slot.

9. Remove the rim out of the tire.

Tire mounting order:1. Put the inner tube into the tire, having preliminary powdered it with talc

and insert the rim tape. Inflate the inner tube slightly and screw the valve.2. Put the tire on the rim with a slight skew and insert the valve into the valve

slot.3. Lift up the tyre from the side of the valve and put it on on the rim.4. Put the bead wheel on on the rim and insert the locking ring by its middle

part relatively the slit to the locking groove (Fig. 28a).5. Press the locking ring down in the groove on the ring. Check that the

second end does not go at the same time into the groove on the rim (Fig. 28b,28c).

6. Make sure that the locking ring edge is under the tire bead. If in someplaces the locking ring edge thrusts against the tire bead place the ring edgeunder the tire bead.

Tire inflation should be carried out in two stages: the first stage - make thepressure 50 kPa (0.5 kgf/cm2) and check the locking ring position, and the sec-ond stage - normal pressure.

53

Fig..25 Tyre mounting procedure.

а

b

c

54

Fig. 26. Tyre dismounting procedure.

а

b

c

55

Fig. 28 Tire mounting order:

Fig. 27. Tire dismounting order

c

b

c

bd

56

In case of the wrong installation of the locking ring deflate the tire, correctthe ring position and inflate once again up to pressure 50 kPa (0.5 kgf/cm2).

7. Install corrective weights and carry out the wheel balancing.

During tires mounting it is strictly forbidden:

- to remove from the wheel hub without complete tyre deflation, and realizethe tyre and rim dismounting until the tyre tube deflation;

- to use sledge- hammers, craw-bars and other heavy objects, which candamage wheel components;

- to use bead and locking rings of other models wheels;- to use rims, bead landing and locking rings with damaged surfaces: rough-

ness, skewness, cracks and also with dirt, corrosion and painting overlaps;- to use tire, on the beads of which there are burrs and damages preventing

from installation; - to inflate tires without checking the correct position of locking ring in the

rim base groove, corresponding to inflated wheel;- to change the position of bead and locking rings during tire inflation and

deflation.

ADJUSTMENTS

Adjusting the power unit support

For adjusting the power unit support unscrew the bolts 4 (Fig. 29). After thepower unit settling tighten the bolts 4.

CLUTCH CONTROL DRIVE AND ITS ADJUSTING

Single-disk clutch control drive is shown on Fig. 30.For normal operation of the drive it is necessary to carry out the following adjust-

ments: - adjustment of the full travel of the pedal equal 130 ± 20 mm with the help of the

limiting screw 1.- adjustment of the free travel of the pedal that must be within the range 60± 10 mm

is carried out when there is no air in the pneumatic system;It is necessary to carry out the free pedal travel in the following sequence:- disconnect the fork 13 of the valve stem and the fork 9 of the pneumatic booster rod

from the two-arm lever 12;- changing the rod 14 length by rotating the forks adjust the dimension B. At the same

time the pedal 2 must be in the upper position (thrust the limiting bolt 1);

57

Fig.

29

Pow

er u

nit

supp

ort

adju

stin

g:

1 -

pad;

2 -

bol

t; 3

- sh

ock-

abso

rber

sha

kle;

4 -

bol

t; 5,

8 -

brac

ket;

6 -

shoc

k-ab

sorb

er; 7

- s

uppo

rt be

am.

58

Fig. 30 Clutch control drive:

1- limiting bolt; 2- pedal; 3,6, 12 - lever; 4, 14 - rod; 5- spring; 7,9,13 - fork; 8- valve;10- adapter; 11- pneumatic inner tube.

59

- turn the lever 12 clockwise against stop and adjust the stem length on thepneumatic booster stem by rotation of the adapter 10 so that the hole in the fork9 will be below the hole in the lever 12 for 5-6 mm (approximately half a size of thehole diameter in the fork). Connect the fork 9 with the lever 12;

- by rotation of the fork 7 or 13 match the holes in the fork 13 and in the lever12. Connect the fork 13 with the lever 12. The valve 8 must be in the extendedagainst stop state that means the clearance A equal to 4 mm minimum must beprovided.

After adjusting check the free travel value of the pedal when the cab islowered and there is no air in the pneumatic system.

It is allowed to increase the free travel up to 80 mm under condition of puredeclutching (there must be no noise and grinding in the gearbox).

When the possibility to restore the free travel of the pedal by the above-mentioned method is exhausted, shift the lever 12 by one-two splines and thenexecute the drive adjusting as described above.

Adjusting of the double-disk drive clutch is carried out in the above-men-tioned way. But it should be taken into account that the full travel of the clutchpedal is equal 130 - 150 mm and the free travel - 40 -60 mm and while the driveadjusting the lever 12 should be turned clockwise.

With the series E and 7511 engine the clutch control drive is hydraulic withpneumatic booster (Fig. 31).

Free travel of the clutch pedal 5-7 mm is adjusted by the bolt 5. After adjust-ing of the free travel it is necessary to adjust the full travel 130-145 mm by thebolt 4. While operation it is allowed if necessary to readjust the free travel bychanging the stem 7 length, having unscrewed the locknut 6.

After the change of the lever 8 or pneumatic hydraulic booster 10 it is nec-essary that at the unit assembly the angle between the lever 8 and tappet 13 willbe equal 90o and the size between the piston 12 and the flank thrust of thecylinder will be 35+1mm. The angle is adjusted by replacing of the lever on thesplines and the size 35+1mm is adjusted in the following way:

- while holding the stem 9 motionless and having turned the lever 8 to theopposite side from the booster against stop, screw in or unscrew the tappet 13 tothe position when the tappet end goes over the plane A on the lever 8 head for50±2 mm;

- insert the spherical head of the tappet 13 in the lever 8 slot having put thepiston 12 of the pneumatic hydraulic booster deep down.

The clutch hydraulic drive system should be filled with liquid «Нева»(«Neva») or «Томь» («Tom») or «Роса» («Rosa»). At the system filling youshould pump the hydraulic liquid into the hydraulic drive system under exces-sive pressure 2-3 kgf/cm2 through the preliminary unscrewed valve 11 for 1-2turns until full elimination of air bubble in the liquid going out to the tank 3.

It possible to fill the system through the tank 3 under pressure 2-3 kgf/cm2 at

60

Fig. 31. Clutch control drive:

1- pedal; 2- hydraulic cylinder; 3- tank; 4,5 - bolt; 6- nut; 7- stem; 8 - lever;9- stem; 10 - pneumatic hydraulic cylinder; 11- valve; 12- piston; 13 - pusher.

61

the unscrewed valve 11 for 1-2 turns until the liquid going out through the valve11 will be clean, without any bubbles. After filling of the system screw the valve11 and put the safety cap on. Make the level of the liquid in the tank 10-15 mmbelow the filler neck.

Fuel supply control drive and its adjusting

While checking the fuel supply drive pay attention to the following. Whenthe accelerator pedal 1 is pressed against stop (fig. 32) the fuel pump of highpressure lever 10 shall thrust against the maximum crankshaft rotations limit-ing bolt and when the pedal is released the lever shall thrust against the mini-mum crankshaft rotation limiting bolt. If when the accelerator pedal is pressedagainst stop or released the lever 10 fails to thrust against the maximum crank-shaft rotations limiting bolt or against the minimum crankshaft rotation limitingbolt then change the tension of the cable 4 for which purpose:

- disconnect the fork 3 from the lever 2, set the accelerator pedal 1 in theextreme upper position against the stop;

- when the pump lever 10 thrusts against the idle crankshaft rotations limit-ing bolt align the holes in the fork 3 and the lever 2 by rotating;

- couple the above mentioned parts;- check the fuel supply drive for proper functioning.Adjusting the spring 7 tension, which reduces the effort on the pedal and

returns the pedal 1 to the initial position is to be performed by means of shiftingthe holder 9 of the spring 7 along the slot, loosening the tightening of the bolt 8.

Then tighten the bolt.Fuel supply drive at the installation of the engine YMZ-238DE 2 and 7511

is differed by its design from the one shown on the fig. 14, but its adjustment isanalogous to that given above.

62

Fig.

32.

Fue

l sup

ply

cont

rol d

rive:

1 -

peda

l; 2,

10

- lev

ers;

3 - f

ork;

4 -

cabl

e; 5

- bl

ock;

6 -

cabl

e sh

eath

; 7 -

sprin

g; 8

- bo

lt; 9

- ho

lder

.

63

GEARBOX CONTROL DRIVE ADJUSTMENT

During the process of operation if necessary the following adjustment iscarried out

- longitudinal lever adjustment;- stop the lever 9 (fig.33)in neutral position by the screw 26. Check up the

gear box neutral position by the roller lever 9 shifting in axial direction pressingit with the hand. Thus, the roller overcoming the spring resistance

should move at the value 30...35 mm;- loose the bolts 3 tightening , and with the help of longitudinal shifting of

the plate 4 set the angle “B” 85o;- when the plate 4 travel is unsufficient release bolts 6, shift rod 5 from the

tail piece 7, tighten the bolts 6 and repeat angle “B” adjustment by plate 4shifting.

Transversal adjusting of the lever 2 is executed by changing the transversalrod 9 length for which purpose disconnect one of the ends and, having turnedoff the nuts with unscrewing its fixing nut with consecutive length adjustmentso that lever 2 was placed in vertical position regarding cab heading surface,on which it was installed.

Adjusting the interlocking device of the rod telescopic components is to beexecuted when the cab is tilted, as follows:

- unsplint the pin 16 and disconnect the rod 5 from the fork 19 of the gear-box drive lever;

- loosen the locknut 18 and turn out the tail 17 against thread stop;- push the inner rod 5until the shackle edge stop into the end 22 slots;- holding the mechanism in compressed state screw in the tail 17 until the

bush 21 blocks the mechanism forced by the spring 24;- tighten the locknut 18, check the accuracy of the locking mechanism oper-

ation.When the mechanism is blocked axial and angular plays must by minimal.

While in unlocked position (bush 21 is shifted to the right) the inner rod must bepushed by the return spring by 35-50 mm. Further extension shifting must besmooth without binding and the blocking mechanism must provide reliable fix-ing of the rod extension in initial position.

Do not allow bending and curving of the drive rod and its telescopic compo-nents. While connecting the rod 5 to the fork 19 the hole in the shackle under thepin 16 must be located over the longitudinal rod 5 axle.

Adjust the gearbox drive at disengaged engine .

64

Fig.

33.

G

earb

ox c

ontro

l driv

e:

1 -

gear

shift

; 2

- le

ver;

3, 6

- b

olts

; 4

- pl

ate;

5,

7, 8

-

rods

; 9

- l

ever

; 10

- g

ear

shift

ing

mec

hani

sm;

11-

pipe

lin

es;

12, 1

5, 2

2- e

nds;

13,

14,

18

- nu

ts;

16

- pi

n;

17 -

tai

l;19

- fo

rk;

20 -

cot

ter

pin;

21

-

bush

;23

- ba

ll; 2

4 -

sprin

g;

2

5 -

shac

kle;

26

- sc

rew.

65

FRONT WHEELS TOE-IN ADJUSTING.

Toe-in checking up is provided after gaps removal in the steering tie-rodhinges and in wheel hub bearings. Front wheel toe-in is defined by the distancedifference between the rims of right and left wheels in front and in the rear atmeasuring at the geometrical wheel axle level. The difference must be 0,5...3,5mm.(fig.34).

If necessary adjust the wheel toe-in as follows:- set the wheels for straight ahead motion;- loosen the bolts of the transversal steering tie-rod ends;- unscrew fixing nuts of ball pin ends in the levers and remove tie-rod;- with the help of end screwing and unscrewing by tie-rod rotating set the

wheel toe-in in required range. Thus one can take into account that end un-screwing on one turn increases the distance difference approximately to 5 mm,and screwing vice versa decreases to this value. If the toe-in value is differedfrom the stipulated standard not more than 2,5 mm, the toe-in can be adjusted byone of the ends.

Connect the transversal tie-rod with levers and check the wheel toe-in valueand if it is normal fix the transversal tie-rod to the levers and tighten the endbolts. Thus both ends slots must be in one plane.

Fig. 34.

66

Fig.

35.

Bra

ke v

alve

driv

e:

1 - p

edal

; 2, 7

, 8 -

conn

ectio

n fo

rks;

3 - l

ockn

uts;

4 - c

able

; 5 -

rolle

r; 6

- sha

ckle

; 9 -

stem

; 10

- bra

ke v

alve

; 12

- guy

spr

ing.

67

ADJUSTING SERVICE BRAKE

The brake pedal free travel has to be within 25 - 35 mm. It’s checking-up isrealized with the help of the rule and manometer (measuring 0...10 kgf/cm)switched to the control outlet valve, installed at the front right brake chamber.

Adjusting the pedal free travel is realized by the fork 2 rotation (fig. 35).Adjustment of pedal free travel on the trucks with cab not cushioned during

operation is not provided At installation of the brake valve drive (Fig. 36) the angle a 45o + 2o is

adjusted by the bolt 2. After adjustment tighten the nut 3 by the moment11.8 - 15.7 Nm. The pedal free travel must be 17 - 27 mm. Adjustment is carriedout by changing of the stem 4 length. After adjustment tighten the nut 5 bythe moment 23.5 - 35.3 Nm.

The stroke of the brake chamber stems has to be within the limits of 25...40mm. When the stroke is increased up to 45 mm it is necessary to adjust thebrakes. The difference here between the strokes of the brake chamber stems oneach axle shall not exceed 8 mm.

Adjusting the braking mechanisms is to be performed as follows:- jack up one wheel;- loosen the bolt 6 (Fig. 37) and shift upward the stopper plate 7 of the

expansion cam adjusting lever while rotating the worm 4 (the brake chamberstem at this time should not move from the chamber), expand the brake shoesup to their contact with operation surface of the drum:

- turn the worm in the reverse direction at approximately 1/3 - 1/2 rotation,lock the worm axle by shifting the plate to the initial position and securing itwith a bolt;

- check compliance of the rod stroke value to the permissible limits;- check that the drum does not touches the shoes when the brakes are not

applied. The brake chamber rod stroke is to be checked under the air pressure inthe brake circuits of 0,56±0,04 MPA (5,6±0,4 kgf/cm2).

68

Fig. 36. Brake valve drive:

1 - pedal; 2 - bolt; 3, 5 - nut; 4 - stem.

69

Fig. 37. Adjusting lever:

1 - body; 2 - cover; 3 - worm; 4 - gear; 5 - oil cap; 6 - bolt; 7 - stop plate.

70

Cab front cushioning mechanism adjustment

Carry out the front cushioning mechanism adjustment in the following way(Fig.38):

- measure the clearance between the cup 3 of the support and the bracket 2of the bumper;

- unscrew the locknut 4;- by rotating the upper cup 3 with the wrench 6 set the dimension 48±3 mm.

Adjust another support by the same way, after that make sure that the di-mension between the cup 3 and bracket 2 on the first support remained equal48±3 mm., at the same time the difference of dimensions A must not exceed 8 mm.

Screw the locknuts of both supports.

Fig.38. Cab front cushioning mechanism adjustment:

1- hinged support; 2- bumper bracket; 3- cup (with the welded nut);4- locknut; 5- spring; 6- wrench; 7- tap-wrench.

Lower-beam and upper-beam lights adjustment.

It is realized with the help of special equipment.

71

MAINTENANCE OF THE VEHICLE

Maintenance types and periodicity. Regarding periodicity and operationmaintenance is divided in the next types:

- daily maintenance (DM);- first maintenance every 4.000-km maintenance;(A)- second maintenance every 16.000-km maintenance; (C)- season maintenance (SM)Daily maintenance is provided after truck operation and before its going out

of the fleet. When the drivers are changing on the line they provide operation ofexamining and testing of truck technical serviceability

The season maintenance is provided two times a year while preparing thetruck to the operation in the winter and summer periods.

72

LIST OF MAINTENANCE OPERATIONS Daily maintenance (DM)

N Operation Tools and instruments Accessories

Technicalrequirements

1 2 3 4

Control inspection before leaving the fleetTo examine the truck and check if it is not leakage offuel cooling liquid and oil from the engine, gear box ,Transfer gear box, PTO, axles, steering control.To check air-tightness of brake drive pneumaticsystem,Of transfer gear box axle blocking. To check fuel intanks.Before engine starting to check :

- oil level in engine housing according to beadcontrol system;

- cooling liquid level.To check engine operation at different crankshaftrotation frequency. To check oil pressure.To check and , if necessary, adjust feeding fuelcontrol drive.

To check air pressure in tires.

To check serviceability and operation of lighting ,Audible and lighting signaling,, measuring devices,windshield wipers; lamps serviceability in pilotlamps block.

To examine wheel securing and tires serviceability.

To check brake operation.

While moving to check clutch serviceability,mechanisms of gear shifting, transfer gear boxcontrol, differentials blocking, steering.

Visual inspection

Bucket, funnel withfilter, fuel filling column

Manometer andtachometer on thedashboard. Wrench12x14

Manometer on thedashboard

Visual inspection

Visual inspection

Visual inspection whilemoving.

Leakage and audibleair exhaust are notallowed.If it is discovered thetruck should be sent tothe workshops for thedamage removalAt control deviceengaging the liquidlevel warning lightmust not be on.To start engine andwarm it up to thecooling liquidtemperature 40-50o C.Make sure in knockabsenceRated pressure in tires5 kgf/sm2 is checked atneutral position ofpressure control valvehandle in tires andopened wheel valves.

At running enginemake sure in devicesserviceability andaccuracy of theirreadings by the seriesconnection.Presence of all nuts,wheel studs, absenceof their damages andtire damages.

During movementwhen brake pedalsmooth pressing thebraking must increasesmoothlywithout jerks. Duringcheck-up the speedmust be 30 km./h. andthe braking distancenot more than 11 m.

Clutch disengagementmust be smooth, andengagement withoutslipping. Gears must

73

be shifted clearlywithout noise.Differentialblockings andtransfer gearboxneutrals must beclearly engagedand disengaged.The truck must bedriven easily, onthe steering wheelthere must be no“jerks”.Make sure thatcoupling isreliable, anddisconnectingvalves are openedon the truck andtrailer.Liquid level mustbe 65 mm. lowerthe upper edge ofthe tank neck.

To check the reliability of thetruck coupling with the trailer(semi-trailer), state of the fifth-wheel device.

To fill the tank with water andcheck windshield washeroperation.

Visual inspection

Mug, water fillingcolumn, ruler

Control inspection on the way (during rest)To check wheels and tires state

To check the degree of the warm-up of the wheel hub,brake drums, transfer gearbox housings and drivingaxles.

To inspect the truck outside and to check the absenceof leakage of the oil, fuel and coolant from the engineand its systems, axles, shock-absorbers, transfergearboxes, P.T.O. and steering.

Visual inspection

Visual inspection

Remove unnecessarythings, stuck in the tiretread. The presence ofall nuts, wheel studsand absence of theirdamages and tiredamages.The warm-up must bechecked immediatelyafter the truck stop.The warm-up isconsidered to benormal if it doesn’tcause burning of thepalm.Leakage is not allowed

74

Daily maintenanceAfter returning of the truck to the fleet

Execute cleaning and washing operations.

To inspect the truck , to discover outside damages andCheck its completeness.

To inspect wheels and tires

To fill the tanks with fuel.

In winter to drain condensate off the air tanks.

Washingmachine, woodenscrapers.

Visual inspection.

Visual inspection

Fuel fillingcolumn

While washing fromthehose make sure thatwater is not directed toelectric equipment.

The truck must becomplete and must nothave outside damages.

Remove unnecessarythings, stuck in tyrestreads. Tyres andwheel securing mustnot have damages.Tank filling must becarried out after truckreturning into the fleetTo avoid water steamcondensation in thetank.

Condensate drainingmust be carried out atthe air pressure in System 650…800 kPa(6,5…8 kg/cm )

75

Maintenance A

N Operations Tools and instruments Accessories

Technical requirements

1 2 3 4

To fulfill the list of operations stipulated by daily maintenance To check driving belts tension on the engine and if necessary to adjust them. To check brake chambers stem running and, if necessary, to adjust with adjusting levers. To check splinting of steering ball pin nuts, brake chambers fork pins, brake valve drivings and parking brake and if necessary remove damaged. To check and if necessary tighten disc fixing nuts to the hub, check rim and wheel hold-downs state. To check fixing of cab lifting mechanism and safety cables state. To check the state of connection of engine feeding system with air. To provide maintenance of air filter if the pilot lamp of dockage goes on. To provide storage batteries maintenance: -clean them of dirt and dust;

- remove electrolyte from the batteries surface by rags, wetted in 10 % solution of ammonia liquid or soda ash and wipe it;

Wrenches 10 x 12; 14 x 17 Wrenches 10 x 12; 14 x 17; 17 x 19; ring wrench 27 mm, screwdriver, hammers, pliers. Wheel nuts wrench, tire iron. Ring wrench 24 mm, pliers. Wrench 19 x 22. Bath, detergents, compressed air Rags, solution of ammonia liquid or soda ash

See the engine operating manual. Rod stroke should be within 25-40 mm. Nuts and pins must be splinted. The rod bends and cracks are not allowed. Nuts must be securely tightened. Rims and hold-downs must have no deformations. Tighten loosened nuts. Breaks of separate cable fine wires are not allowed.

Loosening of fastenings is not allowed. Rubber pipe-lines must have no damage.

Storage batteries must be clean, serviceable and have no leakage, and their terminals and wire ends must have no oxidation and must be coated with lubricating grease.

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-To check monoblock integrity and masticsurface.

Drain condensate from the air tank by the valvetappet outlet in any side.

Capacity for condensatecollection.

Drain the condensateunder the air pressure inthe system 6.5-8 kgf/cm2.

Carry out the lubrication oftruck components according tothe lubrication map.

In 8000 km change oil in thepallet of the engine with cleaningof the oil primary purificationand centrifugal oil purification.To check oil level and make itnormal in:-gear box housings, axles,transfer gear boxes and powertake-off;- axle wheel gear.

Lubricate:- releasing cam bushings,steering rod hinges and hydrau-lic booster cylinder, steeringknuckles center pin, propellershaft slot.

After maintenance check the opera-tion of units, mechanisms and de-vices.

By the controlrun in the begin-ning of themovement withthe method of se-ries connectionand check of thecorrect function-ing of units anddevices. Thechange of forceon the steeringwheel rim atturning to anyside must be ex-ecuted withoutjerks and jam-ming. At smoothpressing thebrake pedal, thebraking must in-crease smoothlywithout jerks andprovide the faststop of the truckwith simultane-ous braking of allthe wheels.

77

Maintenance C

N Operations Tools and instruments Accessories

Technical requirements

1 2 3 4 Carry out all the works connected with

maintenance (A). Check tightening of threaded connections of the engine exhaust gases outlet system, brackets fastenings on the power unit, fastening of reduction gear housings to the axle houses. Check tightening of wheel hub bearings. Check by shaking the play of propeller shaft flanges on the terminals of gearbox shafts, transfer case and main drives of the driving axles. Check the state of tires, degree of their wear and front wheels toe-in. Check the integrity of the spring center bolts and tightening of U-bolt nuts, pins and springs eyes, fixing of shock absorbers, balancer brackets, ties, rear suspension reactive rods brackets, spare wheel carrier, transfer case suspension supports, air springs fastenings, fuel tanks brackets and storage batteries, steering pump, cab locking mechanism beams, fastening of the platform, winch, its drive and cable guides.

– front axle steering knuckle levers and center pin bearings covers. Check the state of the towing device and its fastenings to the cross-member. Tighten the loosened nuts. Check the condition of the rubber jackets and hoses on the socket connector and terminal connections. Check the free travel of the clutch pedal and, if necessary, adjust it.

Wrenches 12 x 14; 14 x 17; 17 x 19; 19x22; 22x24; 24x27. Wheel hubs wrench, tap-wrench. Trammel Wrenches 17 x 19; 19x22; 24x27, U-bolt wrench 32x38. Wrenches 19x22; 24x27, wrench 65, trammel. Ruler, wrench 17x19, pliers.

Tighten the loosened connections. At shaking of the hanged out wheel there must be no play in bearings. Ther must be no play. The order of check-up is described in the section “Care of the driveline”. Replace the tires if there are worn out (tread remaining height 1..2 mm). Front wheels toe-in must be within 0.5-3.5 mm. There must be no longitudinal and cross shifting of spring sheets. Tighten the loosened connections by the torque indicated in the supplement. Axis play of the hook is not allowed. Change the hook when the jaw opening wear is more than 5 mm. Jackets must be closely inserted one into another and have no damage. The free travel must be 50…70 mm for single plate clutch and 40…60 mm for double plate clutch with the air deflated from the

78

Check the joints and spline joints ofthe propeller shaft drive for play byshaking from the hand with the en-gaged gear.

Check the steering drive rod hingesfor play.

Check the free travel of the steeringwheel and, if necessary, adjust.

Carry out adjustment of thrust cen-ter pin bearings of the front axle.

Check the thickness of brake liningsat removed brake drums and, ifnecessary, replace the linings.

Check the condition of the fifth-wheel, attachment of the grip lockhandle and fifth-wheel device to theframe, condition of the grips, lockingknuckle and latch springs.

Check the fastening of the sparewheel and spare wheel carrier to theframe.

Check and tighten the bolts of pro-peller shaft flanges fastening.

With increased free travel of the steer-ing wheel and absence of play ofsteering hinges dismount the steer-ing mechanism and carry out theadjustment.

Check the serviceability and func-tioning of the parking brake andmanual brake drive lever travel.

Wrenches 27x32,36x41.

Screw driver, trammel.

Fifth-wheel devicemust have no damagedor worn-out parts. Thehandle with the lockingknuckle must movefreely and must be fixedin the extreme position.Nuts of the bolts of thefifth-wheel device at-tachment to the frameand nuts of the fifth-wheel studs andknuckle with stem mustbe tightened.

Wrench 14x17.

Ruler, screwdriver,wrench 17x19, ringremoving device.

Plays are notallowed.

Plays are notallowed.

The free travelof the steeringwheel must notexceed 18o

See section“Care of thedriving axles”.

Through in-spection hole inbrake mecha-nisms shield.

Ring wrench19mm, tram-mel.

Nut must betightened.

See the torquein the supple-ment 2.

The driven le-ver travel mustbe not morethan 40 mm.

79

Carry out the maintenance of powergenerating set in accordance with therecommendations of the operatingand maintenance instructions.Carry out the lubrication of the truckin accordance with the lubricationtable.

- Replace after 32000 kmthe oil in casings:gearbox, driving axlemain and gear axles,transfer case, PTO, rearsuspension balancer, aswell as in the cab liftingsystem.

- Lubricate after 32000 kmthe following: bearings, starter, clutchdisengagement fork shaftbearings, worm-and-worm gears of the wheelbrakes adjusting levers,front axle combinedhinge, clutch drivedouble-arm lever bush-ings, clutch disengage-ment fork shaft, engineshut-down cable, seatlongitudinal adjustment,needle bearings of propel-ler shaft, steering columnpropeller shaft splines,rear support of the wheelhydraulic booster cylin-der, rear towing deviceguides, bushes of guidingand supporting rollers ofthe winch cable.

Check the operation of units, mecha-nisms and devices after themaintenance.

By the control run in the beginning ofthe movement with the method of theunits series connection and check of thecorrect functioning of devices. Thechange of force on the steering wheelrim at turning of the driven wheels toany side must be executed withoutjerks and jamming. At smooth pressingthe brake pedal the braking mustincrease smoothly without jerks andprovide the quick stop of the truck withsimultaneous braking of all the wheels.

80

Seasonal maintenance

It is recommended to carry out the preparing of truck for the operation in winter andin summer period together with the next maintenance and to fulfill in addition thefollowing:

N Operations Technical requirements

1 2 3

The preparing of truck for the operation in the summer period.

Drain the sediment from fuel tanks.

Replace oils and greases in the aggregates andsystems that where filled with season lubricant.

Check the thickness of brake linings and ifnecessary replace.

Set the switch of the voltage season adjustment inthe position “summer”.

One liter from each tank.

See lubrication table.

With removed brake drums.

The preparing of truck for the operation in the winter period.

Carry out the above described (in the first 3 items)works.

Prepare the pre-start preheater and electric- fired device forthe operation in the winter period.

Set the switch of the voltage season adjustment inthe position “winter”.

Blow out the tube lines and hoses of the adjustmentsystem of air pressure in tires.

Carry out maintenance of the brake system units.

Check the degree of storage battery charging.

Check the density of the coolant.

At pressing the electric-fired device start-up buttonthe green indicating lampmust go on not later than100 sec., indicating thatelectric system isserviceable.

If necessary remove the batteryfor charging.

81

LUBRICATION OF THE TRUCK

In many respects the truck service life depends on timely and thorough lu-brication

Carry out the truck units and sets lubrication in accordance with the lubrica-tion table where the oil and lubricant sorts, lubricating operations intervals andlubrication points quantity are listed.

Carry out engine units and sets lubrication in accordance with its operatinginstructions.

DM - daily maintenanceA - maintenance after 4000 km of runB - maintenance after 8000 km of runC - maintenance after 16000 km of runD - maintenance after 32000 km of run

82

83

Daily

main

te-na

nce B

84

85

86

87

4C

88

89

90

91

92

93

94

95

96

97

98

99

100

Do

not

use

the

lubr

ican

t no

t in

dica

ted

in t

he p

rese

nt l

ubric

atio

n ta

ble.

Whe

n th

e tru

ck is

del

iver

ed to

the

cust

omer

the

gear

box,

tra

nsfe

r ge

ar c

ase,

axl

es r

educ

ers

are

fille

d in

with

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ses

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ion.

101

STORAGE, CONSERVATION AND DEPRESERVATION OF THE TRUCK

The customer can store the trucks, which operation is not planned duringthree months from the moment of the shipment from the enterprise-manufacturerwithout executing the conservation.

It is necessary to execute the conservation at the longer trucks storageperiod. New trucks are putted for the conservation only after their running-in.

General requirements to the conservation:The conservation is executed for the protection against the corrosion of the

inner and outer truck surfaces in whole and its sets, units and mechanisms duringthe storage by applying the protective film of the corrosion inhibitor on thesesurfaces.

12-months truck storage in the conditions excluding the ingress of atmos-pheric precipitations and dirties on the conserved surfaces is provided with theanticorrosive treatment and packaging.

The conservation executing conditions must meet the following basic re-quirements:

- the air relative humidity must not exceed 70%, and the air temperaturemust be not below than +15oC without sharp fluctuation during the day;

- near the unit on conservation there must be no materials that can evokethe corrosion (acids, alkalis, chemicals, accumulators and others).

- the period between the preparing of the surface to the conservation andthe conservation must not exceed two hours;

- the heating equipment must provide the maintenance of the establishedtemperature of the mix destined for the conservation;

- the dishware with covers is to be used for the storage of the conservationmeans.

The premises for the conservation executing must be dry, well ventilated andheated, equipped with temperature gauges and psychrometers to control thetemperature and humidity; as well as with scattered and reflected light (mat lampsand daylight lamps). All the truck sets and units must have the temperature equalor higher than the temperature of the premises where the conservation is executed.In order to avoid the moisture condensation on conserved surfaces the sharpfluctuations in temperature during the conservation are not admissible.

Before the conservation thoroughly wash and clean the truck from the dirtand dust. Wipe the units external surfaces dry, and remove the moisture from theout-of-the-way places by compressed air. Clean out all the areas having corro-sion with polishing paper and hog with sequential wiping by rags wetted in thewhite spirit. Restore the outer layer of the units and sets paint.

For the truck conservation use the following materials:- diesel oil;- inhibitor protective additive AKOR-1;- conservation oil NG-208 (lubricant NEFTEGAZ-203);

102

- diesel fuel;- two-layer waterproof packaging paper;- polyethylene film of the thickness 0,2 mm;- court plaster;- PVC tape;- silica;- lubricant CIATIM 201;- viscous lubrication PVK;- lubricant AMS-3;- zapon;- enamel MC-17;- distilled glycerin;- soda ash;- potassium bichromate.

All the materials used for the preparing operations and conservation are tobe previously exposed to the laboratory tests.

The presence of the acids and moisture in the conservation materials is notadmissible. In the case of the moisture presence in the oil the moisture is to beremoved by heating the oil with the closed flame (till the complete disappear-ance of the foam). From the fuel the moisture is removed by sediment.

The wooden plugs used for the conservation must be produced of the drywood and impregnated with working conservation oil under the temperature105- 120oC till the foaming stop.

TRUCK PARTS, UNITS AND SETS CONSERVATION.

1. Before the conservation drain the water from the windshield washers andcab heater, drain the compressed air from the balloons.

2. Put into compressor cylinders 20 gr. of diesel oil DP-11.3. Cover with the court plaster or PVC tape the following:

- hole of the vapour-derivation tube of the extension tank;- air hole in the accelerating valve;- air hole in the water separator;- draining hole of the electric engine of the diesel fuel heater;- hydraulic booster tank caps;- brake valve output hole;- wheel air valve holes.4. The hole of the air intake branch pipe of the switching heater pump unit

is to be closed by the cap.

103

5. Wrap with the inhibitor paper NDA or cotton cloth impregnated withworking conservation oil and tie round with the twine the following:

- anti-freezing;- pressure regulator with the safety valve;- trumpet holes and pneumatic signal head;- outlet tube hole (previously having put into the tube the packet with silica

weight 220 gr.);- air brake connecting head;- radiator, extension tank and switching heater filler neck;- tires pressure control valve with the restrictor valve.

NOTES: Before its usage the silica is to be dried under the temperature150…170oC during 3 hours.

The weighing out of the silica into packets and their placing must to be carriedout immediately before the air tightness (not more than an hour before).

6. Cover with the lubricant the following;- engine control drive axis and hinges;- windshield washer nozzles;- rod of the power cylinder of the steering hydraulic booster by further wrap

with the inhibitor paper and tie round with the twine.7. Cover with achromic zapon the metallic tintless parts: toggle levers and

handles, cab doors inner and outer handles, emblem and factory mark.8. All the hinged connections must be thoroughly injected; housings of trans-

fer box, driving axles, steering mechanism and winch; rear suspension balancersand steering hydraulic booster tank are to be filled in with fresh (commercial) oilsin accordance with the lubrication table.

9. Carry out the fuel tanks conservation by filling in all the tank capacity (withfurther drain through the draining holes) with diesel fuel conservation mix withadditive AKOR-1. Put the packets with the silica of 150 gr. into fuel tank telescopicnecks, close the covers and seal up the clearance between the cover and filler neckwith the court plaster or PVC tape.

10. Remove from the truck windshield wiper blades and rear view mirrors andwrap with the waterproof paper or cotton cloth.

11. Clean from the dirt and corrosion the accessories sets, cover them with athin coat of the lubricant CIATIM-201 and wrap with the waterproof paper or oiledcotton cloth.

12. Put the truck onto supports so that the load is took off from the springs andthe tires are 80…100 mm above the ground surface.

13. Clean and wash with water the tires. Bring the air pressure in tires up to 4kgf/cm2 and close the wheel valves. In order to protect the tires from the rubberfissuring it is necessary to cover them with jackets of cloth, waterproof paper orother materials.

104

TRUCK DEPRESERVATION.1. Release the tires from the jackets and remove the truck from supports.2. Remove the waterproof paper and PVC tape from the power-generating

set parts and units, and release the power-generating set from the plugs.3. Put off the lower cover of the clutch housing, remove the plug and put the

cover on the place.4. Remove the adhesive tape, waterproof paper or oiled cloth from the truck

parts, sets and units.5. Take the packets with silica out from the outlet tube hole and fuel tank

filler necks.6. Remove the conservation lubricant or its rest with the rags wetted in the

petrol.7. Wipe the instrument and accessories with the rags wetted in the petrol.8. Carry out the further preparation of the truck to the operation in accord-

ance with the Operation Manual.

NOTES: It is not required to carry out the depreservation of the gearbox, engine feedand lubrication systems, engine cylinders inner surfaces.

Protective measures at conservation and depreservation. The personnel serving theconservation area must be informed about the toxicity degree of used materials as well asfirst aid measures at accidents.

Workers serving the conservation baths must be provided with oilcloth or canvasaprons, rubber gloves or gauntlets and devices preventing the hands contact with theconservation materials.

MAINTENANCE OF THE TRUCK, WHICH IS BEING STOREDCarry out the maintenance of the truck which is being stored according to the

terms and scopes indicated below.1. Once a month:- check the truck position on the supports;- check the state of the mechanisms and units outer surface, when detecting

corrosion clean and lubricate or paint the affected surface;- clean the truck of the dirt and dust;- open the cab doors in order to air it when the weather is good;- check if there is leakage of the fuel, lubricant and coolant in the connecting

pipe-lines;- check the state of the sealing and plugs in the units and mechanisms;- check the pressure in the tires and if necessary make it normal from the

compressed air outside source;2. Twice a year – in spring and in autumn – carry out the works indicated for

seasonal maintenance and additionally do the following:- during the periodical charging of the storage batteries bring the electrolyte

density up to the value corresponding to the operation period;

105

- prepare the engine to the starting in accordance with the subsection“Truck depreservation”;

- start the engine, heat it up to the normal temperature and listen to itsoperation at constant revolutions;

- check the operation of all the instrumentations;- turn the steering wheel to the both side 5…6 times up to the stop;- carry out the engine conservation as described in the corresponding

section;- refuel the fuel tanks;- check the state of the spares and accessories, if necessary, clean the

instrument and accessories from the corrosion, paint cold faces and lubricatework surfaces.

3. Once every three years carry out the works according to the lubricationtable at C.

106

Trade organization name, address ModelChassisEngine

Repair station, address Speedometer indication on the moment of defect detection, km

Delivery date Date of start-up in operation

Routine maintenance carried outDate _____________ Date _____________ Date _____________ Date ___________Run _____________ Run _____________ Run ____________ Run ___________

Defect description, reasons of its origin, features

Substituted parts, unitsName Catalogue number Quantity Price per unit Sum Repair cost

12345

Supplement No. 1Extent of the warranty, the order of making claim and drawing up nec-

essary documents are specified in the contract of purchase and sale for thetruck.

In case of failure fill the certificate according to the form proposed andforward to the seller

City __________ WARRANTY CLAIM NO. _____Date __________

Date of arrival for repair: ______________

Date of return from repair: _______________

Conclusion:Buyer’s authorisedrepresentative for repair

Seller’s authorized representativein the Buyer’s countryDate Signature Date Signature

Seal Seal

107

TIGHTENING TORQUE OF THE MAIN THREADED JOINTS Nm (kgf.m)

Name of the main threaded joints Tightening torque

1Nuts of transfer box shaft flanges, intermediate and rear axles, nuts of drivencylinder gear of intermediate axle.Nuts of fixing of reducers to driving axles housingsNuts of wheel hubs fixing.Nuts of steering knuckle pins.Wheel fixing nutsNuts of studs of fixing of sleeve of driving conical gear of front and rear axles.Nuts of fixing of brake mechanisms boards adapter and studs of wheel gearscovers fixing.Nuts of studs of t fixing of intermediate axle intermediate housing.Nuts of studs of fixing of driving conical gear housing to front axle beam.Nuts of bolt of fixing of driven conical gear and driving axles differential cups.Nuts of bolts of fixing of becket to steering knuckle hinge body.Nuts of studs of lower and upper covers of pin bearingsNuts of fixing of housing of interaxle differential blocking mechanism.Nuts of disc and brake drum fixing.Nuts of compressor cylinders heads fixing.Nuts of front springs clipsNuts of rear springs clipsNuts of front springs eyes bolts.Nuts of fixing of reaction bars brackets to frame cross-member.Nuts of fixing of balancer brackets and rear suspension rods.Nuts of balancer suspension tie.Nuts of shock-absorber housingsNuts of fixing of steering arm on sector shaftNuts of ball pins of steering drive min.Nuts of steering wheel fixingBolts of fixing of cover of intermediate axle inlet valve.Bolts of fixing of cover of intermediate axle outlet valve.Bolts of fixing of cover of bearing of rear axle drive gearBolts of pin fixing to axles housings.Bolts of interaxle differential cups fixing.Bolts of fixing of gears housing to intermediate axle intermediate housing.

441… 589 (45…60)177…216 (18…22)390…490 (40…50)440…490 (45…50)245…290 (25…30)127…177 (13…18)

23…35 (2,4…3,6)69…98 (7…10)

88…118 (9…12)210…260 (21…26)108…137 (11…14)245…314 (25…30)

23,5...735 (2,4…73,6)245…290 (25…30)12…17 (1,2…1,7)

440…490 (45…50)687…785 (70…80)245…314 (25…32)177…196 (18…20)440…490 (45…50)392…434 (40…44)98…118 (10…12)

392…432 (40…44)275 (28)

196…275 (20…28)49…61 (5…6,2)

43…55 (4,4…5,6)24…35 (2,4…3,6)

275…314 (28…32)63,5…78,5 (6,5…8)

49…61 (5…6,1)

Supplement 2

108

Supplement 3Vehicle MAZ – 631705, equipped with transfer boxes with lubrication pump

drive.“Neutral” and power takeoff management (switching on/off) is carried out from driver’s

cab from dishboard by button switch (with supervisory engaging lamp) located at thebottom on the left side. For monitoring of switching on mechanism of transfer boxmanagement on the dishboard installed supervisory lamps (when position “off” – ve-hicle is in the “over-the-road position” – supervisory lamp is on but the lamps 2,3 areoff; “on” – power take off box and neutral are switched on – supervisory lamps 2,3 areon but lamp 1 is off) which are located on top on the right side on the dishboard (Fig. 1).

1.emergency oil pressure in the transfer box2.switching on the “neutral” in the transfer box3.switching on PTO

Fig 1 – supervisory lamps

During exploitation of the transfer box with lubrication pump drive on the vehicle:-switching on the “neutral” of the transfer box and the setter of lubrication pump drive

realize only when the vehicle is stopped.-it is necessary that after first 30 motohours of work of lubrication pump drive to make

oil change in the transfer box and lubrication pump drive, following changes should be madeevery 300 motohours of work (fill up housing of transfer box with gear oil till locating holein the lid of crank case (4.5 litres), after that fill up housing of transfer box (1litre) throughthe upper actuator of the mechanism of switching on lubrication pump drive).

When changing oil it is necessary to make cleaning of oil filter which is located in housingof transfer box at the entry of suction trunk of the system of lubrication pump drive.

In order to clean a filter it is necessary to cut off filter flange together with connectingpipe and tube, turn off two bolts which fastening connecting pipe and crank case ofdistributing tube than take out washer, spring and filter. Filter should be washed andblown out by compressed air. Filter installation should be made in reverse order;

-in case of switching on the lamp of emergency oil pressure on dishboard (Fig. 1), whenlubrication pump drive works it is necessary to finish work immediately, remove defects,change (filter) oil in transfer box;

-when lubrication pump drive works for a long time bar from heating of housing oftransfer box and hiusing of lubrication pump drive above 80 centigrade degree;

-it is strongly prohibited that transfer box works together with switched on “neutral”without switching on lubrication pump drive;

-it is prohibited that transfer box works together with switched on “neutral” andmechanism of lubrication pump drive when it is air leak in the system cylinder nutritionswithing on the “neutral” and mechanism of lubrication pump drive. Pressure in the feedsystem should not be less than 0,6 MPa.

109

Supplement 4SYMBOLS INSCRIPTED ON THE ELECTRIC EQUIPMENT

DEVICESSYMBOLS INSCRIPTED ON THE ELECTRIC EQUIPMENT DEVICES

Symbol Meaning of the symbol

Air pressure control and failure of the front circuit of brake system

Air pressure control and failure of the rear circuit of brake system

Air filter clogging

Road-train lights

Emergency system warning flasher

Battery discharge

Headlights. Lower beam

Windshield wiper

Headlights. Upper beam

Oil pressure in engine

Electric torch

Headlights wiper and washer

Spotlight

110

Symbol Meaning of the symbol

Coupling lighting lamp

Reverse movement lamp

Side-lamps

Windshield heating

Steering hydraulic booster

Headlights adjustor

Refrigerator switching

Air conditioner switching

Control lamps block

Fuel level in the tank

Control devices lighting

111

Symbol Meaning of the symbol

Main light switch

Windshield washer

Inter-wheel differential blocking

Inter-axle differential blocking

Auxiliary gearbox blocking

Oil filter clogging

Rear fog light

Windshield heating

Engine stop control device

Heater fan

Devices

Voltage indicator

Service brake failure

Temperature in the engine cooling system

112

Windshield wiper and washer

Truck turn indicator (truck tractor)

Speed indicator

Central emergency signal

Symbol

Speed indicator

Central emergency signal

Additional upper beams

Front fog lamps

Trailer (semi-trailer) turn indicator

Semi-trailer active drive

Cab full lighting

Parking lamp

Pneumatic horn

Electric horn

Meaning of the symbol

Windshield wiper and washer

Central emergency signal

Additional upper beams

Front fog lamps

Trailer (semi-trailer) turn indicator

Semi-trailer active drive

Cab full lighting

Parking lamp

Pneumatic horn

Electric horn

Ground remote switch

Parking brake

Ground remote switch

CONTENTS

SAFETY REQUIREMENTS AND CAUTION…………………………….6TECHNICAL DATA………………………………………………………..10CONTROLS AND INSTRUMENTATION………………………………..15CAB ACCESSORIES………………………………………………………22PRE-SALE PREPARATION WORKS LIST………………………………24RUNNING IN OF THE TRUCK…………………………………………..24THE TRUCK OPERATION PECULIARITIES……………………………25PREPARATION OF THE TRUCK FOR OPERATION…………………..25DRIVING THE TRUCK AND MONITORING ITS SYSTEMAND UNITS FUNCTIONING……………………………………………..36SECURING SPARE WHEEL………………………………………………47WHEEL MOUNTING AND DISMOUNTING……………………………50ADJUSTMENTS………………………………………………………… 56MAINTENANCE OF THE TRUCK……………………………………104STORAGE OF THE TRUCK……………………………………………104Supplement 1, 2, 3, 4 ……………………………………………………106

2010. З.