Public Joint-Stock Company «AvtoKrAZ»

Operation manual
632207-1062-02-3902010-01 РЭ

Board truck
KrAZ-632207-1062-02
 The 632207-1062-02-3902010-01 РЭ operation manual contains the basic rules of operation and maintenance for the
KrAZ-632207-1062-02 truck.

Since efforts are continually made to improve the reliability and performance of the product, minor changes may be
introduced without special notice.
 Contents

Introduction……………………………………………………………………………………………….... 5
1 Safety requirements .………………………...………………………….…………………………………. 6
2 Warnings…………………………………………………………………………………………………… 7
3 Specifications ..………………………………….…………………………………………………….……. 8
4 Controls and instrumentation ……………………………….…………………………………………… 11
4.1 Controls ……...……..…………………………………………..……………………………………... 11
4.2 Dashboard ……………………………………………………………………………………................ 15
4.3 Relay …………………………………………...……………………………………………………….. 21
4.4 Fuse box .....……………………………………………………………………………………………. 22
5 Operating instructions ……….…………………………………………………………………………… 24
5.1 Preparing the truck for operation ………………………………………………………………...…….. 24
5.2 Starting and shutting down the engine …………………………………………………………...……. 26
5.2.1 Using the electric torch device (ETD).……………….....……………………………………………. 27
5.3 Gearbox operating instructions ……………………...………………………………………………… 28
5.4 Wheels…………………………… ……………………………………………………………………. 31
5.4.1 Tires .………………………………………..…………………………………………....................... 32
5.4.2 Tire pressure control system………………………………………………………………………….. 35
5.5 Towing device (towing hook) …………………………………………………………..…….............. 39
5.6 Hydraulic winch ………………………………………………..…….................................................... 41
5.7 Recommendations on driving …………………………………………...………….…………..……… 47
6 Running-in of truck..……………………..…………………………………………………………...…… 51
7 Maintenance ………………………………………….……………………………………………………. 52
7.1 Maintenance type and intervals (M) ...…………………………………………………………………. 52
7.2 List of jobs for different types of maintenance (M) …………………………………………………… 54
8 Oil and power fluids renewal, units and systems adjustment during maintenance …………………... 65
8.1 Maintenance of air filter ……………………………………………...…………………………….…... 65
8.2 Checking the inlet duct for tightness …………………………………………………………..………. 66
8.3 Changing the working fluid in hydraulic part of clutch control drive …………………………..…….. 66
8.4 Changing oil in front axle ball supports ....…………………………………………….......................... 67
3
 8.5 Changing oil in hydraulic steering booster system …………………………………..…........................ 68
8.6 Headlamp adjustment …………………………………………………………….………………….… 69
8.7 Checking the steering wheel play and adjustment the joints of steering rods ………………….……… 70
8.8 Checking the pneumatic system and the pressure regulator …………………………………………… 71
8.9 Checking and adjusting the Toe-in……. …………………………………………………………..…... 71
8.10 Drive belt tension check and adjustment ……………………………………………………………... 72
8.11 Checking of the clearance and adjusting the brake gear of the brake systems…………....................... 73
8.12 Checking and adjusting of fuel supply control drive …………………………..................................... 74
8.13 Clutch control drive check and adjustment …………………………………………………………... 76
8.14 Cardan drive check and adjustment ..……………................................................................................ 77
8.15 Maintenance and adjustment of the driving axles main gears …………………………...…………... 77
8.16 Front axle steering knuckle pivot bearing check and adjustment .…………………………….……… 82
8.17 Front wheel hub bearing check and adjustment .…………………………………............................... 84
8.18 Rear wheel hub bearing check and adjustment .……..………………………...................................... 84
8.19 Rear suspension equalizers check and adjustment ………………………………………………..….. 86
9 Troubleshooting ……………………………………………………………………………………..….. 87
10 Storage of the trucks ………………………………………………………….………………..……... 99
11 Appendices ………………………………………………………………………………………...…… 101
Lubrication instructions ……………………………………………………………………………....……. 101
Tightening torques of the most vital screw joints .……………………………………………………….… 125
List of rolling bearings used in assembly units of motor truck.……………………………………………. 126
List of collars used in assembly units of truck ...………………………..………………………….…...….. 128
Adjustment data .…………………………………………………………………………………………… 129
Filling capacities ……………………………………………………………………………………............ 130
Brake system components and diagrams …………………………………………………………….…….. 131
ABS ………………………………………………………………………………………………………… 134
Electrical equipment components and diagrams ….……………………....................................................... 137
Сonditioner Minicool N&D 3.0 …..…………………………………………………………………….….. 141

4
 INTRODUCTION

Dear customer!
Thank you for choosing the KrAZ truck!
The KrAZ trucks are designed and manufactured at Public Joint-Stock Company “AvtoKrAZ”. They meet UN ECE road
traffic safety standards. The KrAZ trucks are produced on modern equipment applying the latest technologies meeting ISO
9001:2008 standard. The distinctive features of all KrAZ trucks are the excellent cross-country ability, durability and reliability,
simple maintenance and high efficiency particularly in off-road operation and harsh environmental conditions. The KrAZ trucks
operate in 62 countries.

REMEMBER!

After you have purchased a new truck read carefully this Operation manual. It contains description of design, instructions
on adjustment of systems and assembly units, as well as data required to operate the truck correctly and maintain it in roadworthy
condition. Please refer to separate Operation manuals coming with every truck for details about engine (with clutch and gearbox),
hydraulic winch, air conditioner and storage batteries. This information will enable you to understand the principle of truck
operation, to use it efficiently and extend its life.

- DO NOT OVERLOAD
- STRICTLY FOLLOW SCHEDULED MAINTENANCE
- NO MODIFICATIONS SHALL BE MADE TO THE TRUCK DESIGN
WITHOUT PRIOR CONSENT OF PJSC “AvtoKrAZ”
- USE ONLY GENUINE SPARE PARTS FOR REPAIR

5
 1 SAFETY REQUIREMENTS

Don’t warm up the engine in closed premises without special ventilation facilities.
Keep engine clean; engine crankcase oiling and fuel leakage can cause a fire. In the case of ignition of diesel fuel, the
flame should be covered with soil, sand, or felt (tarpaulin) should be laid on it.
Never pour water on the fuel heat source. Use a powder fire extinguisher.
Don’t clean and lubricate the truck when the engine is working.
It is forbidden to operate the truck when the coolant temperature is below 50 ºС.
Do not operate the truck with the defective light system signaling on the air pressure drop in the pneumatic system.
Never set the truck in motion at an air pressure below 0.5 MPa (5 kgf/cm²), i.e. until all lamps of air pressure emergency
signaling go out.
Do not lock the transfer case inter-axle differential and intermediate and rear axle inter-wheel differentials when wheels are
slipping, when turning and driving on rough roads, as well as on terrains with good road adherence.
Do not shut down the engine on descents. It results in the sharp increase of the force applied to the steering wheel and
complete consumption of the compressed air supply in the service brake system air tanks.
Do not open the hood with open ventilation hatch.
Do not disassemble the spring brakes storage batteries. Do it only at service station using special tools.
Never stand against the holder when lowering or lifting the spare wheel.
Do not lower the spare wheel with the latch and ratchet disengaged.
It is forbidden to use the winch to transport people.
Never stand in the risk area (near the winch rope) when using the winch.
Always wear the protective gloves when handling the winch rope.
Never walk under the suspended load.
Do not use the defective cable.
To ensure safety when inflating the tires in a garage, place an assembled wheel into a special enclosure. In case of inflation
tires outside a garage, lay it with the lock part down or directed away from the driver and nearby people.

6
 2 WARNINGS

Following all recommendations given in the present Operation manual and in the operation manuals of power plant, air
conditioner and storage batteries will ensure a trouble-free operation and long life of the truck. The most essential of these are given
below.
The air pressure in the air brake-actuating system should be maintained within 0.65 – 0.8 МPа (6.5 – 8.0 kgf/сm2).
Engage driving axles and power take-off after the truck is completely stopped and the clutch is released, air pressure in p-
pneumatic system must be at least 0.55 МPа (5.5 kgf/сm2).
At ride, the coolant temperature must be maintained within 75 – 90 °C.
A short-term (not more than for 10 minutes) increase of coolant temperature up to + 90 °С in operation is allowed.
Do not operate the truck with the hydraulic power steering booster faulty. In this event, a short-time ride to a garage or
service station at a travel speed not over 20 km/h is allowed.
In case the long-term storage and preservation are needed, release the parking brake and service brake system to avoid
sticking of brake linings to brake drum surface (release rear axle air spring brakes).
Wrong connection of the storage batteries at their installation on the truck can result in failure of generator rectifier unit.
The poor contact of the voltage regulator “ground” leads to overcharging of the batteries (the ammeter pointer goes off-scale).
Disengaging the storage batteries by “ground” switch, when the engine is running, is forbidden.
With the engine started in case of the coolant regular renewal, discharge the air from heater radiator turning off the air
valve plug by 1 – 2 revolutions till the coolant appears. Then turn the plug home.
To avoid poisoning, be especially careful in handling ethylene glycol coolants (antifreezes).
When the rope is paid out by hand it is necessary to leave not less than three layers of the rope on the winch drum. The
device for rope attachment is not designed for maximum pulling force of the winch.

7
 3 BASIC SPECIFICATIONS

Board truck
KrAZ 632207-1062-02
Permissible payload, kg 10000
Curb weight, kg 12700
Gross weight, kg 23000
Maximum travel speed, km/h 90
Turning radius measured from
front fender located at utmost
distance from centre of turn,
m, 13.0
Engine ЯМЗ-238ДЕ-2
Engine power, kW (h.p.) 243 (330)

The board cross-country truck KrAZ-632207-1062-02 is intended for transportation of various cargoes and people as well
as for towing trailers and various trailed systems with allowable load on the tandem rear axle up to 220 кN (22000 kgf). At ride on
public roads the payload should correspond to the existing traffic regulations. The trucks can operate at the working temperatures
from + 45 ºС to – 45 ºС and up to the height of 4000 m above the sea level.
The truck is equipped with air-conditioner and comfort driver’s seat.
Intended for outdoor storage.

8
 Additional specifications

Таble 1

KrAZ-632207-1062-02
Wheel arrangement 6х6
Curb weight, kg, falling at:
the front axle 6000
the rear bogie 6900
Gross weight, kg, falling at:
the front axle 6800
the rear bogie 16000
Permissible gross weight of the trailer towed:
on all kinds of roads, off-road and terrain, kg 11000
on hard-surface roads, kg 30000
aircrafts on concrete-surface roads of airfields 75000
Maximum upgrade (downhill) to overcome by the truck having gross weight, %, not less
than 30º
Tires 530/70-21
(1300х530х533)
Pressure in tires, kPa (kgf/cm²) rated: 396 (4.0)
min: 98.1 (1.0)

9
 MARKING

Fixed on the right-hand doorframe is a manufacturer’s plate (Fig. 1) on which the following data are drawn up:
Fig. 1 – Manufacturer’s plate
1 – trade mark of Manufacturer;
2 – certification sign;
3 – certification body code;
4 – international code of the Manufacturer (WMI code) – 3 characters;
5 – truck model (VDS code) – 6 characters;
6 – model year and serial number of a truck (VIS code) – 8 characters;
4, 5, 6 –identification number of a truck (VIN code);
7 – engine model;
8 – wheeled vehicle model;
9 – manufacturer;
10 – document number which affirms truck certification;
11 – admissible truck gross weight;
12 – admissible tractor-trailer train gross weight;
13 – admissible load on 1st, 2nd and 3rd axles;
14 – vehicle complete set

Truck identification number (VIN code) is stamped on the right-hand side member
close to the rear axle (Fig.2).
Example of the truck identification number, VIN code:
Y7A – manufacturer’s code;
632207 – vehicle model (6 figures);
B – model year designation;
0 – constant value;
812382 – serial number of the vehicle (6 figures).

Fig. 2 –VIN code on the truck Numeric and alphabetic characters used to designate truck model year: D – 2013, E –
frame 2014, F – 2015 etc.

10
 4 CONTROLS AND INSTRUMENTATION
4.1 Controls

The controls are designed to operate

the truck and its systems, use the engine
power and truck speed efficiently, and ensure
the safety of traffic.
The arrangement of controls and
instrumentation in the cab is shown in Fig. 3:

1 – lever for changeover of turn

indicators and switching-on the electric horn.
When the lever is moved forward, the
right-hand turn indicators are switched on,
when moved backward – the left-hand
indicators. Automatic kickout is provided to
return the lever in neutral position when the
steering wheel is turned in opposite direction,
after the truck finished the turn. Sound horn
is activated when the lever is moved
upwards;
2 – steering wheel;

Fig. 3 – Controls

11
 3 – combination light switch. Provided with turning handle that can be set in
four fixed positions and one non-fixed position. The switch housing has symbols of
devices to be switched on. When the handle is pushed (non-fixed position), marker
lights and headlamp distance light come on; they are designed to give signal to
oncoming vehicles.
To set the handle in neutral (fixed) position, match the markings on the body;
in this case, lights are switched off. When being pulled the handle can be set in three
fixed positions:
first position – marker lights come on;
second position– marker lights and headlamp dim light come on;
third position – marker lights and headlamp distance light come on;

4 – switch of starter, instruments and antitheft device.

When the key is set to:
«0» – controls and instruments are switched off, the key can not be removed,
antitheft device is switched off;
«I» – controls and instruments are switched on, the key can not be removed;
«II» – controls, instruments and starter are switched on, the key can not be
removed, automatic return to position «I»;
«III» – controls and instruments are switched off, when the key is removed – turn the
steering wheel to one side till click is heard, this means that antitheft device is
switched on.
To switch off the antitheft device set the key into ignition switch and, slightly
turning the steering wheel, turn the key to position “0”.

12
 5 – handle for manual control of fuel supply and engine shutdown.
When the handle is in vertical position, fuel is supplied. When the handle is
pulled, crankshaft rotation speed increases;

6 – fuel supply control pedal;

7 – service brake system pedal;
8 – clutch pedal;

9 – control levers of cab ventilation and heating systems:

а – air intake inner hatch lever for ventilation and heating. When the lever is in
left-hand position, the hatch is closed, in right-hand position – fully opened;
а б – air intake outer hatch lever for ventilation and heating. When the lever is in
left-hand position, the hatch is closed, in right-hand position – fully opened;
б

10 – auxiliary brake system pedal.

Short-term use of auxiliary brake system is recommended when driving down
high and lengthy grades, forced-wet and slippery-road braking. In that case only low
range gears may be engaged;

13
 11 – gearshift lever;

12 – hand-operated back-action brake cock intended to operate the truck and

semi-trailer parking brake system. To apply, shift the cock handle upwards (fixed
position), to release – shift it downwards (initial position);

14
 4.2 Dashboard

The arrangement of instruments, switches, selector switches of instruments and pilot lamps on the instrumental panel is shown
in Fig. 4.

1 – pressure gauge of tire pressure regulating system. It indicates the pressure in tires when the wheel valves are open;
2 – speedometer;
3 – coolant temperature indicator;
4 – tachometer;
5 – fuel level indicator;
6 – pressure gauge of the service brake system pneumatic drive. Indicates air pressure in the first circuit air tanks
7 – pressure gauge of the service brake system pneumatic drive. Indicates air pressure in the second circuit air tanks;
8 – ammeter;
9 – engine lubrication system oil pressure gauge
Fig. 4 – Instruments

15
 Pilot lamps
Таble 2 – Pilot lamps on the dashboard
Symbol Description
pilot lamp which signals on the switching-on of
tractor-trailer train sign lamp
pilot lamp which signals on the switching-on of
the front fog light
pilot lamp which signals on the switching-on of
distance light
pilot lamp which signals on the switching-on of
the headlamp dim light
pilot lamp which signals on the switching-on of
the rear fog light
pilot lamp which signals on the switching-on of
the turn indicators
pilot lamp which signals on the switching-on of
the turn indicators of the trailer
pilot lamp which signals on the oil filter
clogging
pilot lamp which signals on the air filter
clogging
16
Symbol Description
pilot lamp which signals on the air pressure
drop in the brake system
pilot lamp which signals on the air pressure
drop in the circuit of front and intermediate
axle service brake system
pilot lamp which signals on the air pressure
drop in the circuit of rear axle service brake
system
pilot lamp which signals on the engagement of
the parking brake system
pilot lamp which signals on the oil pressure
drop in the engine lubricating system
pilot lamp which signals on coolant emergency
temperature
pilot lamp of storage batteries charging
pilot lamp of electric torch device (ETD)
pilot lamp which signals on the engagement of
the neutral gear
Table 2 continued
Symbol Description Symbol Description
pilot lamp which signals on the engagement of pilot lamp which signals on the engagement of
power takeoff the АBS
pilot lamp which signals on engagement of inter- pilot lamp which signals on the engagement of
axle differential locking the АBS (trailer)
pilot lamp which signals on engagement of inter-
pilot lamp which signals on the АBS diagnostic
wheel differential locking
pilot lamp of reserve fuel level, the lamp
pilot lamp which signals on the engagement of
switches-in when the fuel level in the fuel tank is
blackout device
less than 22 – 36 l

17
 Switches and selector switches

Таble 3 – Switches and selector switches on the dashboard

Symbol Description Symbol Description

tractor-trailer sign and turn indicator selector

signaling beacon switch
switch

windshield wiper selector switch, three fixed

positions are available: the key fluted part is
depressed – the windscreen wiper is switched off; the
service light lamp switch
key is in the middle fixed position – wiper operating
mode is set to first speed; the key smooth part (with a
symbol) is depressed – to the second speed

commander lamp switch windshield washer selector switch

cab dome light switch fuel level sensor selector switch

rear fog lights and fog rear lamp switch cab heater mode selector switch, two speeds

18
Table 3 continued
Symbol Description Symbol Description
power take off switch. To activate PTO, unlock the
key by shifting the locking plate upwards and press
hydraulic winch switch. To engage the winch,
the key upper part until a click is heard. When it
unlock the key and press it until a click is heard.
happens the pilot lamp switches on. To deactivate
To disengage the winch, press the key lower part
PTO, press on the lower part of the key with the
with the symbol
symbol till click is heard. Never engage PTO when
the truck is moving
transmission switch. To disengage the
transmission, unlock the key by shifting the
locking plate upwards and press the key upper inter-wheel differential locking switch. After pressing
part until a click is heard. To disengage the keep holding your finger on the switch
transmission, press the key lower part with the
symbol until a click is heard
inter-axle differential locking switch. To lock the
differential, shift the locking plate upwards and press
the upper fluted part of the key until a click is heard.
switch of АBS “Test”
The pilot lamp switches on when the differential is
locked. To unlock the differential, press lower part of
the key (with symbol) until a click is heard
transfer case shift control switch. Two fixed
positions: to engage the low gear, unlock the key
and press it until a click is heard. To engage the
blackout device switch
high gear, press the key lower part (with a
symbol) until a click is heard. Never shift gears
when the truck is moving

dashboard lighting switch switch of electric torch device (ETD)

19
Table 3 continued
Symbol Description Symbol Description

АBS «Mode» switch emergency signaling switch

remote “ground” switch. To connect the storage

batteries to the “ground”, press the button
located on the dashboard or the remote switch on
the bracket of storage batteries with the ignition
key removed or in neutral position (position
«0»)

20
 4.3 Relays

The arrangement of relays in the compartment on the dashboard is given in Fig. 5.

1 – starter relay; 2 – air dryer relay; 3 – ABS relay; 4 – marker lights relay; 5 – stop signal relay; 6 – reverse motion light switch
relay to blackout mode; 7 – horn relay; 8 – turn lights shutdown relay in a blackout mode; 9 – brake lights switch relay to a
blackout mode; 10 – headlamp distance light relay; 11 – marker lights switch relay to blackout mode; 12 – headlamp dim light
relay; 13 – alternator exciting winding relay; 14 – ETD relay; 15 – “ground” remote switch relay; 16 – intermediate relay
(instruments); 17 – reverse light relay; 18 – ABS relay; 19 – fog lights relay; 20 – engine brake relay; 21 – hydraulic winch relay
Х1 … Х10 – cab-frame coupling sockets
Х11, Х12 – engine-cab coupling sockets
Fig. 5 – Arrangement of relays and fuses in the relays compartment

21
 4.4 Fuse box

Designation of symbols of connected using equipment on the fuse card is shown in Fig. 6.

Right-hand fuse box F3:

1 – portable lamp socket, cab dome light; 2 – fog lamps; 3 – stop-signal; 4 – underhood lamp and
tractor-trailer train sign headlamps; 5 – distance light (L.H headlamp); 6 – distance light (R.H
headlamp); 7 – dim light (L.H headlamp); 8 – dim light (R.H headlamp); 9 – marker lights (left-
hand), instrument illumination; 10 – marker lights (right-hand), 11 – reserve; 12 – “ground”
remote switch relay; 13 – combination light switch
Left-hand fuse box F4:
1 – electronic speedometer; 2 – electric fan clutch, windshield washer, windshield wiper; 3 –
heater electric motor, air dryer; 4 – electric sound horns; 5 – hazard lights; 6 – reserve; 7 – turn
indicator relay, beacon; 8 – parking brake system and reverse warning lights; 9 – gauges, buzzer,
air dryer; 10 – inter-wheel and inter-axle differential solenoid valves, engine brake relay, PTO
solenoid valve; 11 – auxiliary gearbox locking relay, electronic speedometer powered from the
ignition switch; 12 – “ground” remote switch; 13 – voltmeter
Fig. 6 – Fuse card

22
 To protect the electric wiring and instruments of the electrical equipment against short circuit the two fuse boxes 41.3722
are used, each of them holds 13 fuse links: 5 fuse links rated at 5A, 11 fuse links rated at 7.5A, 3 fuse links rated at 15A and 1
fuse link rated at 20 A.
Starter and starting preheater are protected against the short circuits by a central (power) fuse box БПР-2М with two fuse links
rated at 60 and 40 A.
60A fuse link is connected in the storage battery-generator circuit.
When fuse link is blown, find short circuit and renew the fuse link with new one taken from the SPTA set.
The starter locking relay is provided in the starter circuit to cut off power supply to the starter and lock it with the running
engine. The starter locking relay and the starter intermediate relay work jointly, supplying “ground” current to the starter
winding.
Before re-starting the engine, turn the key of instruments, starter and antitheft device switch to position «0».

23
 5 OPERATING INSTRUCTIONS

Important! Upon purchase of the KrAZ truck make sure that the all necessary pre-sale preparation was held and it
is recorded in the service book.

5.1 Preparing the truck for operation

Before starting operation of the truck inspect the truck and check:
- oil level in crankcase and steering booster tank;
- gearbox and driving axles for leakage, no leaks are allowed;
- coolant level in cooling system expansion tank;
- fuel level in tanks;
- for presence of water in windshield washer tank; add, if necessary;
- wheels and tires;
- steering drive (without using special tools);
- operation of lamps and hazard lights;
- operation of windshield wipers;
- operation of service brake system;

Prior to starting the engine, make sure there are no leaks in all connections of air
intake system, check air pipes and rubber branch pipes for cracks and ruptures, check the
tightness of clamps in connections going from air cleaner to the engine.

Fig. 7 – Hood lock drive rod

To carry out works in the engine compartment, open the hood lock from the side of the radiator grille. To open the hood –
move the hood lock drive rod shown in Fig. 7. Then lift the hood and support it securely on its stay. To close the hood, remove
the stay and slam the hood.

24
To prepare the truck for operation, adjust the driver’s seat.

The truck cab is equipped with the driver’s seat “PILOT”

with mechanical suspension and safety belts (Fig. 8).

1 – lever of seat longitudinal travel control mechanism; shift

the lever upwards, adjust the seat within 210 mm;
2 – handle of mechanical adjustment of suspension
stiffness;
3 – safety belt;
4 – lever of back inclination angle adjustment: tilt the
backrest up to 45º backward and up to 60º forward by pressing
down the lever;
5 – lever of cushion height adjustment: to raise the seat,
push the levers up and the seat will be raised automatically;
6 – lever of cushion inclination angle adjustment: pull up
the lever, apply the load to the front or rear part of the seat and
carry out the adjustment.

Never adjust the seat when driving.

In operating the truck regularly, check and, if necessary,
tighten the bolts securing the seat to the floor.

Fig. 8 – Driver’s seat

25
 5.2 Starting and shutting down the engine

Start and shut down the engine in accordance with Operation manual of power unit. The engine is started by starter from
the storage batteries. To start the engine, perform as follows:
- press the storage battery “ground” switch;
- switch on the instruments (turn the ignition key switch to the position «II»);
- set the gearshift lever to the neutral position;
- set the fuel supply control lever to the vertical position to supply fuel;
- start the engine (turn the key of the instruments, starter and antitheft device switch to the position «III»).
The starter non-stop run must not exceed 20 sec. No more than three attempts to start the engine at an 1 – 2 min interval are
allowed. If it fails to start, find out a reason and eliminate the trouble.

Upon starting warm up the engine to a coolant temperature of 50ºC at the minimum rotational speed not more than
1000 min-1 , no longer than 5 min. After the first reaction of the engine to the fuel feed changing, increase the rotational speed
to the rated rotational speed of the engine crankshaft (green sector of tachometer).
When the engine is started after the oil change or the turbocompressor filter replacement, run the engine for 2 minutes
at least at minimum idling speed to fill the turbocompressor bearing cavities with oil.

Engine start in cold weather. Start the engine at an ambient temperature:

up to - 10 ºС – without using ETD;
from - 10 ºС to - 20 ºС – using ETD;
below - 20 ºС – after warming up the engine by means of starting preheater.

Shutting down the engine. Before shutting down the engine, run it for 3 – 5 minutes without load at a rated speed (green
sector of tachometer). Then slow down the engine speed to the minimum one and turn off the fuel supply. The engine should
stop. Turn on the fuel supply only before starting the engine.
Never stop the engine sharply. It may result in failure of the turbocompressor, since, after the engine stops, the
turbocompressor rotor continues rotating for some time, while the oil supply to the rotor bearings stops immediately.
Never use the auxiliary brake to stop the engine.

26
 5.2.1 Using the electric torch (ETD)

When starting the engine with the use of the ETD, never employ external power sources of a high power rating, since the
pin-type torch plugs are designed for a working voltage of approx. 19 V.
Before the initial startup of a new engine or after its prolonged idleness, prime the engine fuel system by the manual
priming pump and then start the engine in the following sequence:
1. set the gearshift lever to the neutral position;
2. set the manual fuel feed control handle to the position corresponding to a rated engine speed (green sector of
tachometer);
3. close the storage battery “ground” switch;
4. turn the ignition key clockwise to the first locked position;
5. depress the button of ETD switch and hold it depressed for the whole time of ETD operation. When the pin spark plugs
get heated to a certain temperature, contacts of a thermal relay close, with the result that a solenoid valve opens and fuel is
admitted to the plugs. At the same time, pilot lamp indicating the readiness of the ETD system for engine startup goes on, on the
dashboard. At the plug heating period, the ammeter should read a discharge current of approx. 23 A;
6. when the pilot lamp goes on (in approx. 1 – 2 min after the switch button had been depressed), depress the clutch pedal
and switch on the starter by turning the key further in the same direction up to the stop (to the second unlocked position), holding
at the same time the button of ETD switch, depressed by the right hand. Continuous operation of the starter should last not longer
than 20 s;
7. after the engine is started, it is allowed to run it with the ETD on, but not more than 1 minute, after that the button of the
ETD switch should be released;
8. having switched off the ETD, warm up the engine by running it at a medium idling speed until the coolant temperature
reaches 40 – 50 °C, after that the engine may be partly loaded, i. e. the truck may be started in low gears.
In the event of an abortive startup, find and eliminate the fault. When doing this, check the presence of fuel pressure (from
the presence of fuel cutoff when operating the manual priming pump) and the serviceability of the ETD electric circuit (the
voltage on the plugs during their heating should be approx. 19 V, and the current flowing through both plugs should be 23 A).
Important! Failed plugs are not to be reconditioned. If one of the plugs has failed, replace both plugs.

27
 5.3 Gearbox operating instructions

Start driving in low range of gear box. The empty truck is allowed to move with the 2nd gear engaged.
After start of driving the truck, never keep your foot on the clutch pedal (to avoid damage of clutch discs).
To accelerate smoothly to 30 km/h, shift gears in low range from the 1st to 4th gear in succession.
To increase the travel speed to 30 km/h and over, shift to the high range from the 5th to 8th gear setting gearshift lever to the
neutral position, wait 1 – 2 sec and engage the 5th gear. Later on raise speed shifting from 5th to 8th in succession.
Important! Improper shifting between high and low range and incorrect sequence of shifting gears can cause
serious damage of the gearbox.
To decrease speed less than 30 km/h, shift from the 5th gear into the 4th, to do it, proceed as follows: set the gearshift lever
in neutral, wait 1-2 sec and after that engage the 4th gear.
Never shift from 5th to 4th gear when the driving speed is more than 30 km/h.
Never engage reverse and low gear L when the truck is moving.

28
 Gearbox 9JS150ТА-В

The truck may be provided with manual synchromesh gearbox and auxiliary gearbox pneumatic drive.

Gearbox identification decoding

The gearbox ratios are given in the table 4.

Table 4 – Gearbox ratios

Low range High range

Reverse L 1 2 3 4 5 6 7 8
13.14 12.57 7.47 5.28 3.82 2.79 1.95 1.38 1.00 0.73

Auxiliary gearbox shift pattern is shown in Fig. 9.

Air is supplied to a filter/regulator 2 and via air pipe 3 comes to distributing valve 4 and lever 1. Ranges are selected by
manipulating the selector located on the lever 1.

29
 The shift pattern is on gear knob 1.
L – low gear;
N – neutral gear of low and high ranges;
R – reverse gear;
1 – 8 – gears

1 – gearshift lever; 2 – air filter/regulator; 3 – air pipe; 4 –

distributing valve;
Fig. 9 – Gearbox 9JS150ТА-В

30
 5.4 Wheels

The diskless wheels with 530/70-21 (1300х530-533) tires are installed on the truck.
The wheels (Fig. 10) are fitted to tapered surface of hubs and secured with six nuts and clamps.

1 – lock ring; 2 – detachable seating ring; 3, 5 – side rings; 4 – tire with

tube and flap; 6 – wheel rim
Fig. 10 – Wheel with 530/70-21 tire

Important!
When tightening the wheel nuts, first tighten the upper nut, then the diametrically opposite one. Tighten the other nuts in
pairs (crosswise). It is recommended to tighten the nuts in stages to avoid the wheel distortion.
Tires, inner tubes and rims damaged during the operation as well as the tires with badly worn tread should be removed.

31
 5.4.1 Tires

When a rapid or uneven wear of the tire thread pattern is detected, find out the cause of wear and take measures to
eliminate it regardless of the truck maintenance intervals.
The truck tire rotation pattern is shown in Fig. 11. The reason for the tire rotation may be uneven or severe wear of tread
pattern, the need for proper selection of tires on the axles, the installation of more reliable tires on the front axle etc.

To ensure the safe driving, never operate the truck if its tires have:
- local damages, stones, nails, glass fragments stuck in the tire tread and
sidewalls;
- tread pattern worn out to the permissible limit, when its remaining depth
over the tread is 1.0 mm;
- ply separations of casing, separation of tread and sidewall;
- faulty valves and valve cores, as well as valves without caps.

Fig. 11 – Tire rotation pattern

The tire mounting and dismantling jobs are to be carried out in the tire-mounting section using the special equipment,
accessories and tools.
Never fit tires having manufacturing and operational defects. Tires, tubes and flaps stored at ambient temperatures below
zero must be kept at room temperature during 3 – 4 hours before mounting.
New tires must be provided with new tubes and flaps.
Rims and their components should be free of distortions, cracks, sharp edges, burrs and rust. Remove rust from rim surface
directed to the tire and apply metal lacquer to it.
When mounting and dismantling the tires, follow the safety precautions set forth in tire fitting and maintenance
checklists:
- tire fitters and drivers must be adequately trained;
- prior to mounting check the tire and rim; assemble rim and tire of the determined size for this truck model only;
- prior to dismantling fully deflate the tire;
- inflate the tire seated in the rim in tire fitting centre placing it into special safety cage that can protect the personnel
from the rim detachable details strokes when removed unintentionally;
32
 - inflate the tire in two stages. First build up pressure to 0.05 МPа (0.5 kgf/сm2) to check the lock ring position, then
increase it to the rated value;
- in case if after inflation the tire beads are not seated fully on rim seats, deflate the tire, remove, find out and eliminate
cause for bead incomplete seating, refit the tire, inflate it and check that tire beads are fully seated
- to carry out roadside tire change, driver must use available tools intended for abovementioned works.
- when inflating the tire after roadside fitting, direct wheel with its rim lock aside from the driver and the near-by people.
Never:
- correct position of side and lock rings with tires under pressure;
- inflate the tire, without making sure that lock ring is properly seated in rim gutters.

To dismantle a tire, proceed as follows:

Deflate the tire.
Insert the curved end of the tire iron in the seating ring slot and pry the tire bead with the side ring down. While
successively moving along the wheel circumference and pressing the tire bead off, fully remove the tire bead from rim seat.
Remove the lock ring 1 (fig. 10), to do this, proceed as follows:
- insert tire iron straight end in lock ring slot and pry the seating ring down;
- insert the other tire iron curved end in the slot formed between lock and seating rings, while moving successively along
the wheel circumference pry the seating ring down;
- pry the lock ring down with the tire iron straight end and press it out of the slot. With the help of the other tire iron
curved end press the lock ring out of the slot to remove it fully.
Remove the seating ring 2.
Insert the tire iron curved end between the side ring and seating ring bead, while moving successively along the wheel
circumference pry the seating ring down to remove it fully.
Remove the side ring 3.
Turn over the ring and remove the tire bead from rim seat.
Lean the wheel on a wall and insert the tire iron curved end between the side ring 5 and seating ring bead 6, pry the bead
down. Holding the bead in both hands take it out, having previously pushed the valve into the bead slot.
In case of sticking (burning) the flap to the rim, turn over the tire, insert tire iron straight end between the rim and flap, and
successively moving along the wheel circumference fully release the flap.

33
 To mount a tire, proceed as follows:
- sprinkle the tire inside with talc, put the tube into the tire and insert the flap. Inflate the tire slightly;
- put the wheel rim 6 (fig. 10) on the floor with its slot directed upwards and put on the side ring 5;
- put the tire 4 on the rim;
- put on the side ring 3;
- insert the seating ring 2 in such a way that the fixing slot on the seating ring is in larger part of valve slot;
- insert the tire iron curved end in the rim gutter and pry the seating ring down to seat the lock ring in the rim gutter;
- install the lock ring 1. Insert the ring end in the rim slot, insert the tire iron straight end between the rim and the lock
ring and press it on yourself until it is fully fitted.

Spare wheel is mounted in special holder behind the cab.

The spare wheel mounted behind the cab (Fig. 12) is provided with a
mechanical mechanism for lowering and lifting. To lower, loosen the coupling
nuts and rotate the tommy bar eight-face end with a special wrench. In this case
ratchet starts to slide, as a result the hinged bracket with the wheel lowers on the
cable.
The wheel must go down smoothly at torque on the ratchet of 60 – 240
N·m (6 – 24 kgf·m). To adjust the clamping of the ratchet on tapered face of the
tommy bar, tighten the nut via the set of disc springs.
To lift the spare wheel from the ground, install it on the hinged bracket and
rotate the tommy bar until the wheel is fully lifted. Lifting of the wheel can be
stopped only after the catch fixes (latches) the next tooth of the ratchet. After
having lifted and secured the wheel in the holder, fasten the hinged bracket by
the coupling nuts.

Fig. 12 – Spare wheel mounted behind the cab

34
 5.4.2 Tire pressure control system

The centralized tire inflation system can be mounted on trucks on request.

The tire pressure control system is designed to improve cross-country ability on rugged terrains by reducing tire pressure.
In case of tire puncture this system allows to continue the truck movement to the garage (service station) without replacing wheel
provided that the compressor can compensate the air leakage from the damaged tire.
The system is controlled by the valve located at the rear left side of the cab.
The tire pressure control system consists of the pressure control valve with the pressure drop-limiting valve, wheel valves,
sealing device in hubs, air lines, hoses and pressure gauge.
The tire pressure control system scheme is given in fig. 13.

1 – tire pressure control valve; 2 – air pressure gauge; 3 – air lines

Н–neutral position; I–inflation; II–deflation
Fig. 13 – Tire pressure control system scheme

35
 The pressure control valve (fig. 14) consists of the case 10 with the air inlet for air supply to the tires and air outlet for
deflating tires.

1 – adjusting bolt; 2 – nut; 3 – spring plate; 4 –

spring; 5 – piston; 6 – bolt; 7 – cover; 8 – washer;
9 – diaphragm; 10 – case; 11 – collar spacing ring;
12 – collar; 13 – bushing; 14 – control valve
guide; 15 – control valve
Fig. 14 – Pressure control valve with pressure
drop-limiting valve

The pressure drop-limiting valve (diaphragm-type) is designed to disconnect the tire pressure control system from the
brake pneumatic drive when the air pressure in the air tanks is less than 0.6 MPa (6.0 kgf/cm2).
The pressure drop-limiting valve operates when the air pressure in the air tanks is more than 0.6 MPa (6.0 kgf/cm2). If the
air pressure in the air tanks is less than 0.6 MPa (6.0 kgf/cm2), the centralized tire air pressure system is disabled. The valve is
adjusted to the given pressure with the bolt 1 by tightening the spring 4.
The control valve 15 is connected with the pressure control valve lever by the pin. The pressure control valve lever should
move easily (without jamming) and be fixed in three positions: “Inflation”, “Neutral”, “Deflation”.
The control valve 15 should move in the collars 12 and the guide without jamming applying the force not more than 100 N
(10 kgf). To screw the guide, the control valve should be in neutral position.
Pressure control valve operation. At setting the valve lever to “Inflation”, the control valve 15 moves back and the valve
groove is set opposite to the collar. The tire pressure control system is connected with the pneumatic system through the gap
between the collar and the control valve, and the air comes to the tires.
At setting the valve lever to “Deflation”, the control valve 15 moves forward, the valve groove is set opposite to the collar,
and the air comes out from the tires through the gap to the atmosphere.
The pressure control valve with the pressure drop-limiting valve should be hermetically sealed at the air pressure of 0.6-0.8
MPa (6.0 kgf/cm2) with three positions of the valve control lever. The air leakage is not allowed.
36
 If the tires are inflated or the air comes out from the tires to the atmosphere when the valve lever is in neutral position,
adjust the control valve neutral position by changing the length of the drive rod.

The wheel valves (fig. 15) are attached to the protective housings welded to the wheel rims. The valves are designed to
disconnect the tires from the centralized tire inflation system at long-term parking of the truck or when the collars of hub sealing
device are damaged.
The wheel valves are opened and closed with the special key which is included in the SPTA set.

1 – plug; 2, 4 – union nut; 3 – valve housing; 5, 7 –

sealing ring; 6 – rectifier valve
Fig. 15 – Wheel valve

The sealing device consists of four elastic rubber collars 7 (fig. 16) with compression springs which provide the tightness
of the flexible connection.
The collars are mounted in the special housing 10, welded in the hub. The hole of the inlet union (interior of the sealing
device) is divided by the spacing ring 9, and from the outside the collars are locked by the locking rings 6. To prevent turning out
the collars sealing edges, the collars are based on the thrust cones 8. The air comes from the interior of the sealing device made
by the collars, through the union 1. Then the air is supplied to the connecting hose and (passing the wheel valve) comes to the
wheel tube.
It is recommended to wash the collars in the pure diesel fuel or kerosene, and grease their edges with grease Lithol-24 at
each removal of the hub. When changing the grease in the hubs, make sure that the grease not to get into the cavity of the
channels and into the hole of the inlet union of the tire pressure control system.
37
 1 – union; 2 – axle shaft housing; 3 – axle shaft; 4 – hub thrust bushing; 5 –
sealing rings of thrust bushing; 6 – locking ring; 7 – collar; 8 – thrust cone; 9 –
spacing ring; 10 – housing of collars; 11 – ring
Fig. 16 – Air supply to the tires

To protect the collars from damaging at removing and installing the hubs,
use the case supplied with every truck.
To restore the tightness of the tire inflation system when the surface of
the thrust bushings 4 of the rear wheels hubs (or the front wheels hubs journals) is worn out by the collars sealing edges 7, shift
the ring 11 to the other side in the collars casing.
Use of tire pressure control system
When driving the truck on hard surface or traffic-compacted earth roads the wheel valves should be closed.
To drive on swampy and snow-covered terrains and loose sand, reduce tire pressure to obtain the best cross-country ability
on this terrain. Make sure that wheel valves are open.
After overcoming the rugged terrain, stop the truck and increase the tire pressure within specifications. To determine tire
pressure with pressure gauge, set the pressure control valve handle 1 in neutral position (see Fig. 13) and open the wheel valves.
To increase the tire pressure, move the control valve handle in extreme forward position («I»), to reduce it, move the handle in
extreme backward position (“II”). After obtaining the required pressure, set the handle in neutral position.
Important! Excessive tire pressure can lead to tire jumping off the rim and damage.
Never set the control valve handle in the position «I» with closed wheel valves to avoid pressure gauge damage.
38
 5.5 Towing device (towing hook)

The front bumper has pivot to tow the truck. The towing hook (Fig. 17) and two buffers are installed on the rear cross
member of the frame on the truck.

1 – cotter pin; 2 – lock washer; 3 – nut cap; 4 –

special nut; 5 – towing device plate; 6 – buffer
front flange; 7 – towing device body; 8 – rubber
buffer; 9 – cover; 10 – nut; 11 – mud deflector;
12 – towing hook; 13 – catch pin; 14 – catch
lock; 15 – lock axle; 16 – hook catch; 17 –
lubricator; 18 – buffer rear flange

Fig. 17– Rear towing hook

The towing hook can also be mounted on the lowered towing cross member of the frame. To change the position of the
towing hook, proceed as follows:
- remove the nut cap 3;
- remove the cotter pin 1;
- unscrew the special nut 4;
- remove the towing device plate 5;
- pull out the towing hook 12;
- uncotter and undo the nuts 10 securing the towing device body 7;
- remove the towing device body 7;
- set the towing device to the desired position.
To assemble the towing device, proceed in the reverse order.

39
 The double action towing hook has 48 mm diameter mouth. The inner diameter of the towing eye should be 90 mm,
towing eye rod diameter – 42 mm.
In case the truck is operated in combination with semitrailer, a tow bar eye is fixed on the towing hook by means of catch.
Move the catch lock 7 to the uppermost position and set in hook jaw groove, when locking it should be lowered to the initial
position. In such position, the lock is fixed suspended by a chain with a cotter pin.
No axial movement of the hook 6 inside the body 4 is allowed. To eliminate it, screw in the nut 2 until it thrusts against the
flange 3. Dimension «А» between the hook end face and inner plane of the nut slot should not exceed 3 mm.

40
 5.6 Hydraulic winch

The hydraulic winch is designed to pull out the loads with the help of the rope during evacuation and transportation of
vehicles. The hydraulic winch specification is given in Table 5.
Table 5 – Hydraulic winch specification
Pulling force,
- bottom rope layer 120 kN (12 t)
- top rope layer 78 kN (7.8 t)
Rope speed,
- bottom rope layer 4 m/min
- top rope layer 6 m/min
Oil pressure 200 mPa (200 bar)
Oil flow 60 l/min
Rope drum diameter 224 mm
Winch weight (without rope) 194 kg
Average temperature range +50 ºС to -30 ºС
Permanent grease Castrol MS3
Acoustic pressure, without load <70 dB (А)

The winch drive is hydraulic. The power is transferred to the winch hydraulic motors through the pipes and hoses. Then the
power is transferred from the motors to the drum through the spur and planetary gears.
The drum is actuated by the hydraulic system. When the drum is the free spool position, the rope is paid out easily and fast.
When the guide hydraulic distributor is in neutral position or at pressure drop for any reason (e.g. the hose is broken), the
spring brake is automatically actuated.
The pull direction of the winch may be forward and rearwards at changing the direction of oil flow. The winch may be
controlled remotely or manually in case of emergency.
The maximum pulling force of the winch is 120000 N (12000 kgf) when the first (bottom), and 78000 N (7800 kgf) when
the last (top) layer of the rope is being wound on the drum.
The more detailed description of construction and operation of the hydraulic winch Н 100F is given in the Operation
manual 63.31-081.

41
 The winch must be set in a position for the rope to be paid out forward (i.e. at the right angle to the drum). The scheme of
the reeving the winch rope forward is given in fig. 18.

1 – hydraulic winch tank; 2 – hydraulic winch; 3 – block of rear winch rope paying out device; 4 – rope; 5 – guide rollers; 6 –
winch hydraulic distributor
Fig. 18 – Reeving the winch rope forward

42
 The force acting on the rope may hardly be determined during operation, and therefore before using the winch, evaluate
roughly whether it would be expedient to employ the block under the conditions in question.
The use of the winch with the block is shown in Fig. 19.
When employing the block to increase the pulling force in the self-pulling-out (Fig. 19 a), attach it to the object selected as a
support, and the rope eye ring – to the towing hook or front towing yoke. When using the block to change the pull direction in
pulling out another vehicle (Fig. 19 б), attach it to the object serving as a support, and the rope eye ring – to the towing hook or
front towing yoke of the vehicle to be pulled out.

а – self-pulling-out; б – pulling out stuck vehicle with

change of pull direction; в – increasing the pulling force in
pulling out the stuck vehicle
Fig. 19 – Using the winch with block

43
 When using the block to increase the pulling force in pulling out another vehicle (fig. 19 в), attach it to the towing hook or
front towing yoke of the vehicle to be pulled out, and the rope eye ring – to the object serving as a support or to the towing hook
of the pulling truck.
When using the winch to pull out another (stuck) vehicle or to facilitate loading heavy loads on a trailer:
 brake the truck by the parking brake and whenever possible - secure the truck by the front towing yoke to a fixed object
(tree, stump, pole, etc);
 disengage the air valve, rotate the drum slowly and pay out the rope;
 start the engine and disengage the drive of truck axles;
 engage the power takeoff to the winch by unlocking the switch key, and press the upper part of the key till the click is
heard. It is prohibited to engage power takeoff to the winch when the truck is running;
 switch on the hydraulic winch by unlocking the switch key and press it till the click is heard;
 disengage the clutch, engage the fourth gear of the gearbox and, gradually releasing the clutch pedal, effect the pulling by
the winch at a medium speed of the engine crankshaft. The winch may also be run in the third and fifth gears of the
gearbox. The hydraulic winch is controlled by the lever 1 (fig. 20).

When the lever 1 is moved to the left, the load is pulled. When the lever
is released, it automatically returns to the neutral position, the load is being
held. When the lever is moved to the right, the load is released.

Fig. 20 – Winch control lever

44
 When the rope is paid out rearwards the angle of its deflection from the longitudinal axis of the truck should not exceed 15°.
If a greater angle is needed use the winch block (Fig. 19 б).
On completion of winch operation wind the rope onto the drum and hook the rope eye ring on the rear towing hook.
In front of the rear rollers of winch rope paying out gear the rope tensioning pulley is fixed which consists of three rollers
located at the angle of 120º in regard to each other on circumference and fixed in the holders on the pulley case. One holder is
welded to the case and two others are fastened by the bolts through oval holes. The roller brackets with the pins are fastened to
roller holders in the axis direction along the rope.
The springs, tightened with nut and lock nut, are installed on bolts inside the roller brackets.
Rope tensioning pulley does not create an additional effort when paying out the rope by hand, since the roller springs
contract and the rope passes freely inside the rollers.
When winding the rope onto the winch drum the tensioning pulley springs expand and the rollers enclose the winch rope
and it winds onto the winch drum uniformly at a constant effort.
When operating adjust the effort of the rope clamp by tensioning pulley rollers with the displacement of holders of two
rollers in oval holes, to do this loosen the nuts of fastening, displace the holders with the rollers in a required direction and then
tighten the nuts. With nuts and lock nuts of the bolts of spring fastening attain the required effort of winch rope clamp by
tensioning pulley rollers. Wind the rope of the drum with the gearbox in the fourth gear and at a medium engine crankshaft
speed, with the rope held tight. Rope winding may also be carried out in the third and fifth gears.
To stop the winch, disengage the power takeoff.
In a self-pulling-out by the winch with paying out the rope forward (fig. 19 a) it is recommended to employ the block; to do
this:
 disengage the jaw clutch of the winch from the drum;
 remove the rope eye ring and bring the winch rope forward of the truck over jockey and guide rollers;
 insert the rope into the block and secure the eye ring to the rope;
 attach the winch block to the object selected as a support, and the eye ring, to the front towing yoke of the truck;
 engage the jaw clutch with the drum by setting the lever to the lower position;
 start the engine and disengage the drive of truck axles;
 engage the power takeoff to the winch;
 disengage the clutch, engage the fourth gear of the gearbox and, gradually releasing the clutch pedal, effect the pulling by
the winch at a medium engine crankshaft speed.

45
 When the pulling force of the winch rope turns out to be insufficient, it is allowed to engage the driving axles. To do this,
disengage the clutch and engage one of the transfer case gears.
When the rope is paid out forward, the angle of its deflection from the longitudinal axis of the truck should not exceed 15°.

Never:
 engage the driving axles for the self-pulling-out by the winch when the rope is paid out rearwards;
 use the winch rope for towing the truck;
 engage the reverse gear when the winch is in operation.

Lowering of the load in case of emergency

In case the hose or the engine is broken, the brake is disengaged and the load stops to lower as follows:

1 Unscrew two plugs on the brake end plate (fig. 21).

2 Screw in the screw М6х20 with the washers. The load is lowered
when the screws are tightened evenly. After the load had been lowered, the
plugs must be set to their place.
3 After the load had been lowered and the rope is slackened, remove the
two screws and set the plugs to their place. Failure to do so may result in an
accident because in such a case the brake is disengaged.

Fig. 21 – Brake disengagement in case of emergency

46
 5.7 Recommendations on driving

Before starting the truck, engage the required gear in the transfer case. The low range gear is engaged when negotiating
extremely hard-to-pass stretches, and particularly, when negotiating steep ascents or operating with a trailer. In other cases the
high gear is to be engaged.
When negotiating extremely hard-to-pass stretches (snow, mud, soft ground, sand, etc.), lock the transfer case interaxle
differential; lock the interwheel differentials of the intermediate and rear axles only in the case of urgency (when wheels on one
side of the truck may slip). The inteaxle and interwheel differentials may be locked and unlocked on the move, but only when
there is no slip of the wheels.

Negotiating ascents and descents

With a convenient approach and an even road surface, negotiate short ascents by accelerating the truck. Negotiate steep
and long ascents in the low gear of the transfer case or with the 1st or 2nd gear of the gearbox engaged (depending on gradient
length and height).
Negotiate ascents driving in a straight line. Driving diagonally across the ascent decreases maximum tractive force,
resulting in truck slipping and turning, and provokes slipping of the unloaded wheels. Prior to negotiating the ascent, engage the
gear to ensure the required tractive effort on wheels without gear shifting and stopping. If the truck failed to negotiate the ascent
for any reasons, slowly run the truck down in reverse without acceleration.
When riding down a descent never shut down the engine, as this result in using up the compressed air from the air
brake system air tanks and renders the hydraulic steering booster inoperative.
Never coast down a steep descent. The auxiliary brake system may be engaged for a short time when riding down the steep
and long descents, or at braking on wet and slippery road. In this case the low gears of the gearbox should be engaged.

Fording
The truck is capable, without pre-sealing of its units, to negotiate a hard-bottom ford with a depth of 1.2m at the rated tire
pressure. The breathers of the fuel tanks should be sealed up with the adhesive plaster for the time of fording.
Before fording measure the fording depth, check the bottom, choose and check the places of riding in and out, mark with
stakes the path width and the deepest places. Switch off the fan clutch. Ride in the low gear of the transfer case and in the first or
second gear of the low range of the gearbox, with the interaxle differential locked. Drive into water very carefully, at low speed,
minimize waves and backwash. Don’t stop at driving, drive straight without sharp turns. The truck should be in the water not

47
more than 15 min. After each fording check the oil level, inspect the engine crankcase and units for presence of water. If the oil
level is increased or there are water drops on the oil level gauge, the water has got into the engine crankcase.
In this case, immediately change oil. Change oil in the unit where water is found. Gun-grease sliding bearing and ball
joints as soon as possible, but not later than the same day.
Prepare the truck for operation: remove the adhesive plaster from the breathers of fuel tanks, switch on the fan clutch. Dry
up the brakes by applying the service brakes several times on the move.
If the engine stops at fording, try to engage it using starter. It the engine fails to operate, the truck should be towed ashore
immediately.
Don’t operate the truck if it was in the water more than 20 min. Tow the truck to the nearest service station and carry out
the maintenance.

Ride on cart and graded earth roads

A side wandering of the truck may occur in riding on cart and graded earth roads. Therefore the driver should take special
care selecting the direction of ride.
When riding out of a deep rut, never hold the steering wheel turned up to the stop in one direction for a long time, because
it can damage the steering booster pump.

Negotiating the virgin snow, sand and swampy terrain

Negotiating the virgin snow, sand and swampy terrain, engage the low gear of the transfer case and lock the interaxle
differential of the transfer case.
Choose the gear depending on road conditions. It is recommended to engage the 4th-6th gears.
Drive smoothly, without abrupt starts and stops. Turn smoothly over a large radius, without reducing the speed.
At hard road sections, when the speed is reduced, prevent the wheel slipping. If the wheels start slipping, ride back to
accelerate and try to negotiate the hard road sections on the move.
The truck negotiates the virgin snow of up to 0.65m depth.
After negotiating the virgin snow, warm up the brake linings and drums at ride after engaging the service brakes 3-5 times.

48
 Towing the truck

Fig. 22 – Transfer case (input shaft
disengaging bolt)
When the truck is towed with its engine not running, its brake system is fed with
compressed air from the towing truck through a hose included in the SPTA set. Connect
the hose nut end to check outlet valve located at the left of the towed truck. The other end
of the hose, provided with a coupling, is connected to a red coupling of the towing truck.
Fill the air tanks of the brake system of the towed truck with air with the handle of
valve in the lower position until the pilot lamps on the dashboard of the towed truck go
out, which will correspond to the working pressure at which the towing may be started.
When the indicating and warning circuit of the brake system is faulty, monitor the pressure
on the pressure gauge. If the air fails to enter into the towed truck, tow the truck using the
rigid coupling. To avoid scoring and a rapid wear of the sliding bearings of the output shaft
gears and synchronizer cones of the gearbox when towing the truck, remove the main
propeller shaft from the gearbox output shaft or tighten the bolt to disengage the transfer
case input shaft (Fig. 22).

49
 Towing trailers
When towing a trailer, start off the truck in the first gear of the gearbox and shift to a higher gear only after the tractor-
trailer train has been efficiently accelerated. When maneuvering the train, remember that at turns the trailer track displaces
towards the centre of turn; carry out turns at speeds that ensure the riding safety. Brake smoothly and only with the service
brakes; use the auxiliary brakes when descending, on a wet and slippery road. When towing a trailer having gross weight 30 000
kg and more, the platform should carry the load not less than 7 500 kg.

Couple the truck with a trailer as follows:

- back up the truck to the trailer and couple it with the trailer; next, lower the catch lock of the truck towing hook to the
initial (lower) position and lock it with a special cotter pin;
- connect the trailer air and electric systems to the respective truck systems.
When towing a trailer two “Palm” coupling heads are used (heads painted red, blue or yellow). Plug the trailer electric wire
connector into respective truck socket (on the rear cross-member of the frame). Release the parking brake system and check
functioning of the brakes and lights. Switch on the lamps of the “Tractor-trailer train sign” by depressing the key switch on the
dashboard.

50
 6 RUNNING-IN OF TRUCK

Reliability and efficient operation of the motor truck depend to a considerable extent on the wear-in of its parts in the initial
period of service, i.e. in the period of running-in. Duration of the running-in for new motor trucks is established equal to 1000 km
of run.
The following restrictions hold for the running-in period:
- limit the maximum speed to 55 km/h;
- gross weight of carried load should not exceed 75 % the rated load-carrying capacity indicated in the Section
“Specifications”.
In the course of running-in check the condition of all fasteners, tighten the loosened bolt and nuts. Pay special attention to
the degree of heating of the units. In the event of an excessive heating, find out the cause and eliminate the trouble.
At ride watch the instrument readings and timely take measures to eliminate the malfunction of motor truck assemblies and
units.
Upon completion of the abovementioned instructions proceed to the truck operation.

51
 7 MAINTENANCE

7.1 Maintenance type and intervals

Depending on the intervals the scope of jobs performed the maintenance of the truck is subdivided into the following types:
1 Daily maintenance (DM)
DM is performed upon completion of trip.
2 Maintenance at the initial period of operation is carried out after the run of the first 1000 km (after the running-in M-
1000).
3 The types of maintenance performed in the main period of operation include:
M-1 is maintenance № 1 which is carried out after every 4,000 km;
M-2 is maintenance № 2 which is carried out after every 16,000 km;
SM is the seasonal maintenance which is performed twice a year when preparing the truck for operation in winter and
summer seasons.
The maintenance intervals, mentioned above, are specified for the trucks operated mainly on plain terrain, on terrain
provided with asphalt and concrete pavement in good condition, beyond cities.
When operating the truck in other conditions, the kilometrages between maintenances should be reduced:
- on mountainous terrain and on terrains in bad condition – by 15%,
- within cities – by 10%.

52
 It is necessary to perform the transformation of the maintenance intervals expressed in hours of operation of the KrAZ
truck relatively the maintenance intervals expressed in kilometrage (considering the time of engine operation at idle speed, truck
operation during loading and unloading, warming-up the engine, operation at parking and in urban areas, etc) using the average
speed of the truck.
It is recommended to calculate the average truck speed taking into account the operating experience using the formula:
Vср = (Vэ+ Vт)/2:
Vэ – the average operating speed of the truck;
Vт – average technical speed of the truck.
The average rated speed is calculated on the grounds of the average technical and operating speed for one truck model. The
average rated speed is the transformation of the maintenance intervals expressed in hours of operation of the truck engine
relatively the maintenance intervals expressed in kilometrage.

53
 7.2 List of jobs for different types of maintenance
Table 6
Description of jobs and procedure of Devices, tools, appliances and
Technical requirements
performing them materials required to perform jobs
1 2 3
7.2.1 Daily maintenance (DM)
Inspect the truck, make sure that all the No damage is allowed Visual inspection
tools and supplementary equipment are All the tools and equipment must be available
available and securely fixed
Inspect the truck and make sure that There must be no leaks of fuel, oil and coolant; Visual inspection
there are no leaks of fuel, oil and remedy the leaks, if any
coolant
Check the coolant level in the expansion Check the coolant level, if necessary, fill the Bucket, funnel, water filling
tank and in the windshield washer tank, expansion tank 1/3 full, coolant level should be 35 station
if necessary, add the coolant mm above tank bottom
Check the oil level in the engine sump. Check the oil level in 5 min after engine shutdown Bucket, funnel, oil filling station
If necessary, add the oil to the normal with the truck placed on level ground. Oil level
level must reach the upper mark on the oil dipstick
Check the engine operation at various Start the engine and warm it up to a coolant Aural inspection, instruments and
rotational speed of the crankshaft temperature of 40 – 50 °C. Make sure of absence dashboard
of abnormal knocks
Check the operation of steering booster At the beginning of movement To check it, road test the truck
Check the brake system drive for Air leakage is inadmissible Visual inspection
tightness
Check the serviceability and functioning When the engine is operating, check the Visual inspection
of the devices intended for lighting, serviceability of instruments and correctness of
light and sound signaling, signaling on their readings by sequential switching them on to
oil and air filter clogging, operation
instrumentation, windshield wipers

54
Table 6 continued
1 2 3
When necessary, clean the truck of dust When washing with the aid of hose, watch that the Washing device
and dirt or wash it water stream is not be directed on electrical
equipment components and devices
Inspect wheels and tires Tighten wheel nuts, if necessary. Remove the Wheel nut wrench 32х36, tire
objects, stuck in tread. Use pressure gauge to iron, combination pliers, pressure
determine tire pressure gauge
Discharge the condensate from the air Discharge the condensate at an air pressure in the Condensate drain valves are fitted
tanks system equal to 0.5 – 0.7 MPa (5 – 7 kgf/cm²). For this to air tanks
purpose, press on the valve rod and shift it to any side
Fill up fuel tanks Fill up fuel tanks immediately after return from a Fuel filling station
trip to prevent water condensation in fuel tanks
Inspect the truck Eliminate the troubles that occurred during Visual inspection
operation
Winter daily maintenance (additional)
When water is used as coolant, drain the There are three drain valves to drain cooling Drain valves
engine cooling system and windshield system. One valve is located on water pump
washer tank after use of the truck stored branch pipe, the second – on oil-to-water heat
outdoors exchanger housing on the engine left side, the
third is on the preheater.
Unscrew the expansion tank plug and open drain
valves. After draining water start the preheater,
pump electric motor 2 – 3 times for 10 – 15 sec
(wait for 2 minutes before switching on) to drain
condensate from the preheater water pump, to
avoid freezing of the pump impeller. Remove the
windshield washer tank, open the cover and drain
water. After refitting the tank bleed the windshield
washer system

55
Table 6 (continued)
1 2 3
7.2.2 Maintenance after running-in 1000 km (M-1000)
Wash the truck, if necessary When washing watch that the water stream is not Washing device
be directed on electrical equipment components
and devices
Check:
fastening of steering rod ball pin nuts, Tighten the slackened nuts Box wrench 24х27, pliers,
steering booster, steering arm on steering hammer, socket wrench 55,
gear sector shaft, steering drag rod lever, tommy bar, wrench 10х12
locking of steering rod and steering
booster cylinder cap thread plugs and pin
them
tightness of steering booster system, No leaks of oil and coolant are allowed Visual inspection
water radiator, engine crankcase,
gearbox, transfer case, driving axles
pneumatic drive of brake systems for Carry out check at a rated air pressure of 0.65 МPа Dashboard pressure gauge, watch
leaks (6.5 kgf/сm2).
With the shutdown engine air pressure drop should
not exceed 0.05 МPа (0.5 kgf/сm2) for 30 minutes
when service brake system pedal is released and
for 15 minutes with depressed pedal
reliability of attachment and absence of No harmful contacts are allowed Visual inspection
harmful contacts of pipings
front wheels pivot joint play No play is allowed. Tighten nuts of pivot cover Box wrench 24х27, hammer
fastening of propeller shaft flanges on No play is allowed Wrench 17х19, socket wrench 55,
output shaft splined ends of gearbox, tommy bar, pliers, hammer
transfer case and driving rear axle drives
fastening of truck stabilizer bar shaft Tightening torques are given in Appendix 2
bracket

56
Table 6 continued
1 2 3
fastening of shackle pin nuts and Tightening torques are given in Appendix 2
stabilizer bar lever
fastening of brackets, pins and eyes of
front and rear springs
Voltage regulator regulated voltage Minimum voltage – 26.8 – 28.2 V, Screwdriver, wrench 8х9, 10х12
maximum voltage– 28.3 – 29.7 V
Renew the regulator if regulated voltage exceeds
the specified value more than by ± 1.6 V
voltage exceeds specified value by ± 0,6 V
Check and adjust:
wheel hub bearings tightening Refer to subsection “Check and adjustment of Tommy bar, socket wrench 12, 19,
wheel hub bearings” 24, screwdriver, hub bearing nut
wrench
clearance between brake drums and Refer to subsection “Check and adjustment the
brake shoe linings of the service brake brake system clearance”
system
toe-in Ref. to subsection “Checking and adjustment the
Toe-in”
steering wheel play Ref. to subsection “Checking and adjustment the
steering wheel play”
clutch pedal free and full travel Refer to subsection “Clutch linkage check and
adjustment”
drive belt tension Refer to subsection “Drive belt tension check and Wrenches 10х12, 13х14, 17х19,
adjustment” screwdriver, single end wrench 32
direction of head lamp light flux Ref. to subsection “Headlamps”
fastening of engine front support beam to Tighten the slackened nuts Wrenches 17х19, 19х22, 24х27,
the frame 27х30, hammer
57
Table 6 continued
1 2 3
fastening of steering booster pump to Tighten the slackened nuts and bolts Socket wrench 14, tommy bar,
bracket, the bracket to the engine, pliers, box wrench 24х27
tightening of pulley nuts
fastening of exhaust pipes, muffler and Tighten the slackened bolts and nuts, check the Wrenches 14х17, 13х14
auxiliary brake system, exhaust system condition of gaskets
to engine
Check the fastening of:
brake chambers, air spring brakes of Tighten the slackened nuts Wrenches 19х22, 22х24
rear axle
brake pedal bracket Tighten the slackened nuts Wrenches 19х22
wheels Tighten wheel nuts Wheel nut wrench
fuel tank brackets and clamping clips Tighten the slackened bolts and nuts Wrenches 19х22, 22х24
steering gear to the frame and steering Tighten the slackened bolts and nuts Wrenches 10х12, 13х14, box
column in the cab wrench 19х22, 24х27
brake system pneumatic drive devices Tighten the slackened bolts and nuts
fenders and foot board brackets Tighten the slackened bolts and nuts
cross members to the frame side Tighten the slackened bolts and nuts
members
U-bolts of the front and rear springs Tighten U-bolt nut when the truck is loaded.
Tightening torques are given in Appendix 2
brackets, pins and front and rear spring Tighten the slackened bolts and nuts Socket wrench 19, tommy bar
eyes
front suspension shock absorbers and Tighten the slackened bolts and nuts. Double-end wrenches 27х30,
their brackets In case if rubber bushings of shock absorber upper 32х36
and lower heads are worn, tighten pin nuts
final drives to the driving axle cases, Tighten the slackened bolts and nuts Socket wrench 24, tommy bar,
driving bevel gear bearing case and hammer
driving spur gear bearing cap to the rear
axle drive case
58
Table 6 continued
1 2 3
brake drums to the hubs and front brake Tighten the slackened bolts and nuts Wrenches 22х24, 27х30
gears support to the steering knuckles
storage batteries Tighten the slackened bolts and nuts Wrench 19х22
nuts of transmission propeller shaft Tighten the slackened bolts and nuts Wrenches 17х19, 19х22
flange fastening bolts
Lubricate: In accordance with “Lubrication chart”
bearings of compressor drive tension
pulley
brake gears expansion cam bearings
brake gears adjusting levers
axle of fuel supply control levers
clutch release coupling
bearings of clutch release fork shaft
ball pins of steering rods
splined joints of transmission propeller
shafts
Replace oil: In accordance with “Lubrication chart”
- in the engine case
- in the gearbox case
- in the transfer case
- in the driving axle cases
Replace fluid in clutch control master Fluid level should be 15 – 20 mm below filling
cylinder hole upper edge
Drain the oil sediment from the steering Drain norm is 2.0 l, then bleed and top up to the
gear case norm
Check the oil level and if necessary,
add to normal level:

59
Table 6 continued
1 2 3
oil in steering booster tank Oil level should be between upper and lower Visual inspection
marks of oil dipstick on the tank
electrolyte in the storage batteries Electrolyte level should reach filler lower edge. Visual inspection
Use distilled water to top up, if necessary
7.2.3 Maintenance № 1(M-1)
Perform jobs for maintenance of power Ref. to operating instructions for the engine and
plant and storage batteries storage batteries
Check the attachment of bolts for Tighten the slackened nuts Double-end wrenches 17х19,
fastening the propeller shaft flanges 22х24
from gearbox to transfer case
Check the attachment of engine front Tighten the slackened nuts Box wrench 19х22
support beam to the frame
Check the attachment of exhaust pipes Tighten the slackened bolts and nuts Double-end wrenches 14х17,
and auxiliary brake system to the 17х19, socket wrench 14
turbocompressor and muffler flanges
Check the extension of air spring brake Rod extension length should not exceed 32 mm, in Drawing scale, dipstick to check
rods and if necessary, adjust the that case the clearance is within the range 0.2 – 0.6 clearances, double-end wrenches
clearance between brake drums and mm 10х12, 17х19, hammer
brake shoe linings of the brake gears
Check the tension of engine driving Refer to Operating Instructions for the power unit Wrenches 10х12, 14х17, 19х22,
belts and if necessary, adjust them and operating instructions of the truck socket wrench 10, tommy bar,
single end wrench
Check the condition of joints, presence Tighten the slackened nuts Box wrench 24х27, combination
of cotter pins and tightening of steering pliers, hammer
rod ball pins nuts
Check brackets, pins and eyes of front Tighten the slackened bolts and nuts Socket wrench 19, tommy bar
and rear springs
60
Table 6 continued
1 2 3
Check truck stabilizer bar shaft bracket For tightening torques refer to Appendix 2
Check shackle pin nuts and stabilizer
bar lever
Check steering wheel play and adjust it, Steering wheel play must not exceed 12 degrees
if necessary when the engine is running
Check the attachment of front axle brake Tighten the slackened nuts Wrenches 17х19, 22х24, hammer
chambers, rear axle air spring brakes
Lubricate the friction units of the truck. In accordance with “Lubrication chart” Use filling gun. Pour in the new
Check the oil level and change the oil in oil via funnel with screen
the units
Every second maintenance M-1 (2M-1)
Carry out engine maintenance jobs Ref. to Operating Instructions for the power unit
Check and adjust free travel and full Refer to “Maintenance after running-in“
travel of clutch pedal and service brake
pedal
7.2.4 Maintenance № 2 (M-2)
Perform all the maintenance jobs
specified in the sub-section
“Maintenance (M-1) and Every second
maintenance (2M-1)”
Check the attachment of power unit to Tighten the slackened bolts and nuts.
the frame (front and rear beams, Refer to subsection “Maintenance after running-
intermediate support) in”
Check the attachment of front and rear Tighten U-bolt nuts when the truck is loaded.
spring U-bolts Tightening torques are given in Appendix 2
Check the attachment of steering gear to Tighten the slackened nuts
the frame
61
Table 6 continued
1 2 3
Check the brake system pneumatic drive Carry out check at rated air pressure of 0.65 МPа Dashboard pressure gauge, watch,
for leaks, check air pressure regulator (6.5 kgf/сm2), with closed wheel valves and tire shut-off valve wrench
trip limit pressure control valve lever set in neutral.
When the engine is shutdown, tire pressure must
not exceed 0.05 МPа (0.5 kgf/сm2), for 30 minutes
with service brake pedal released and for 15
minutes with depressed pedal.
When regulator is switched on, pressure should be
equal to 0.65 МPа (6.5 kgf/сm2), with switched off
regulator– 0.8 МPа (8.0 kgf/сm2).
Lubricate the friction units of the truck. In accordance with “Lubrication chart” Filling gun, oil containers, wiping
Check the oil level and change the oil in waste
the units
Every second maintenance M-2 (additional jobs)
Check the play of front axle steering No play is allowed. Box wrench 24х27, screwdriver,
knuckle pivot bearings Refer to subsection “Front axle steering knuckle hammer, mandrel
pivot bearings check and adjustment”
Adjust tightening of wheel hub bearings Refer to subsection “Check and adjustment of Tommy bar, socket wrench 12, 19,
wheel hub bearings” 24, screwdriver, hub bearing nut
wrench, hammer
Check the attachment of:
brackets, pins and eyes of front and rear Tighten the slackened nuts
springs
cross members to the frame side Tighten the slackened nuts Double-end wrenches 19x22,
members, towing hook to cross member 22x24
spare wheel holder to the frame Tighten the slackened nuts Double-end wrenches 19x22,
22x24
Every third maintenance M-2 (additional jobs)

62
Table 6 continued
1 2 3
Tighten front and rear spring U-bolt Tighten U-bolt nuts when the truck is loaded. Socket wrench 32х46, tommy bar
nuts For tightening torques refer to Appendix 2
Check attachment of front suspension Tighten the slackened bolts and nuts. Double-end wrenches 22х24,
shock absorbers and brackets In case if shock absorber upper and lower head 32х36, pliers
rubber bushings are worn, tighten pin nuts
Every fourth maintenance M-2 (additional jobs)
Tighten nuts securing ball supports to Tighten the slackened nuts Box wrench 24х27
front driving axle case
Every fifth maintenance M-2 (additional tasks)
Check attachment of final drive Tighten the slackened bolts and nuts Box wrenches 19х22, 24х27,
reduction gears to driving axle cases socket wrench 19х24, tommy bar
Check the play of cardan drive flanges No play is allowed. Ref. to subsection “Cardan Double-end wrenches 14х17,
on the splined ends of gearbox outlet drive maintenance” 19х22, socket wrench 55, tommy
shafts, transfer case and driving axle bar, pliers, hammer
drives
7.2.5 Seasonal maintenance (SM)
The preparation jobs for the truck operation in summer should be combined with routine maintenance jobs and the
following jobs are to be made additionally:
Check the condition of electric wires Clean the connection points and contacts of oxides Screwdriver, double-end wrenches
and contact connections in the electrical and dirt. Tighten the fastening screws and insulate 8х10, 10х12, 14х17, 19х22,
equipment system the electric wiring on which the insulation is insulating tape, sandpaper
damaged
Carry out maintenance of power Remove and disassemble the cylinder and Double-end wrenches 10х12,
cylinder and auxiliary brake pneumatic pneumatic valve, wash components, lubricate and 12х14, 14х17, 19х22, screwdriver,
valve refit pliers
Adjust the direction of head lamp light Ref. to subsection “Headlamps” Control screen, screwdriver
flux

63
Table 6 continued
1 2 3
Replace the oils and lubricants in units and In accordance with “Lubrication chart” Oil container, wiping waste, oil
systems filled with seasonal lubricant dispenser
Carry out maintenance of air filters Ref. to subsection “Servicing the air filter” Washing container, compressed air
Disconnect the cab heater from the Close the cock under the engine hood at the left
engine cooling system side
Set the voltage regulator switch to the When the ambient temperature is persistently
“MIN” position above 0 °C
Jobs to be made when preparing the truck for operation in winter
When preparing the truck for operation in winter it is recommended to carry out summer maintenance jobs, maintenance
of cab heater and voltage regulator, and the following jobs are to be made additionally:
Rinse the cooling system and check the Ref. to Operating instructions of the power unit Socket wrench 12, tommy bar,
thermostats for serviceability (using hammer, container to check
water) thermostats, thermometer
Set the voltage regulator switch to the When the ambient temperature is persistently
“MAX” position below 0 °C
Check output voltage of voltage In case if voltage exceeds specified value, remove Double-end wrench 10х12,
regulator the voltage regulator and check it on a special screwdriver, pliers
stand, adjust, if necessary
Clean and wash in petrol metal-ceramic Ref. to Operating instructions of the power unit Double-end wrenches 10х12,
filter and dosing insertion of ETD pin 14х17, 24х27
spark plugs
Connect the heater to the engine cooling After engine starting release air from the heater
system radiator, having unscrewed a locking plug of the
air valve, until water appears from under the plug.
Then screw in the plug against the stop
Renew the brake fluid in the master Refer to subsection “Renewal of power fluid in Tire inflation hose, bleeding hose,
(under pedal) clutch release cylinder clutch control drive” wrenches 10х12, 14х17, 22х24,
brake fluid, container

64
 8 OIL AND WORKING FLUID REPLACEMENT, SYSTEM ADJUSTMENTS DURING MAINTENANCE

8.1 Maintenance of air filter

The timely maintenance of the air filter is required for ensuring the reliable operation of the engine.

The maintenance of cardboard filter elements (Fig. 23)

Fig. 23 – Filter elements
should be carried out upon lighting up of the pilot lamp on the
dashboard and, when there is no sensor, in every other maintenance
No. 1 (M-1). The excessively frequent maintenance of the filter
elements reduces its service life since the total quantity of
maintenance of an element is limited (5 – 7 times) due to possible
destruction of cardboard.
To maintain the filter elements remove cover after
unscrewing of nut. Undo nut which fixes the filter element and
remove it. If there is dust without soot or carbon black (gray
element) on the cardboard, blow it off with dry compressed air until
complete removal of dust. The air pressure should not exceed 0.2 –
0.3 MPa (2 – 3 kgf/cm2), direct the air jet at an angle to the element
surface.
Check the condition of filter element after each maintenance
or in the case of installation of a new one by lighting it with a lamp
from inside. Replace an element with cracks, mechanical faults,
cardboard ruptures, separation of covers and casing.

During the seasonal maintenance, dismantle the filter, wash the filter body in kerosene, diesel fuel or hot water, blow off by
compressed air and dry off, carry out filter element maintenance.

The manufacturer recommends using certified filter elements.

65
 8.2 Checking the inlet duct for tightness

Check the inlet duct for tightness after each disassembly of its joints (including the filter dismantling) to avoid penetration
of dirty air into the engine and failure of piston and cylinder components.
The procedure for checking the intake duct for tightness is as follows:
- remove the air filter cover, take out the filter element and install the plug instead of it;
- supply the compressed air to the intake duct at a pressure of 0.03 – 0.05 MPa (0.3 – 0.5 kgf/cm²);
- while slowly rotating the engine crankshaft by a wrench engaged with the pulley fastening bolt or by a short crowbar
engaged with a hole in the flywheel, select such a position in which the sharp rise of pressure is observed in the system, checked
by a piezometer tube;
- bring the air flow rate to 1 m³ /h;
- the intake duct is considered to be air-tight, when at the above-mentioned air flow rate (1 m3 /h) the pressure in the intake
duct is equal to or exceeds 800 mm water. When the air pressure is below the above-mentioned value, determine the points of
failures in tightness by using soapsuds. All failures in tightness in the intake duct in the zone between the air filter and engine
intake branch pipe are to be remedied;
- the remedy of failures in tightness over, carry out the trial test for tightness of the intake duct, as described above.

8.3 Changing the working fluid in hydraulic part of clutch control system

It is necessary to change the working fluid once a year at routine seasonal maintenance.
The working fluid is the brake fluid according to SAE J1703f or FMVSS 571.116/DOT3 or DOT4.
The procedure is as follows:
- remove the protective cap from the end piece of bypass valve and put the hose on the valve for bleeding the hydraulic
drive. Insert the other end of the hose in a transparent fluid drain vessel;
- connect one end of the tire inflation hose to the end piece of filler plug, and the other end to the control outlet valve or to
another compressed air source;
- unscrew the bypass valve through 1 – 2 revolutions, drain the used fluid and blow off the hydraulic system by the
compressed air. When draining the brake fluid, press on the clutch pedal several times until complete removal of fluid. Screw in
the by-pass valve;
- fill the master cylinder with a fresh brake fluid in accordance with the lubrication chart;
- build up the compressed air pressure of 0.3 – 0.6 MPa (3 – 6 kgf/cm2) for 30 s through the cap end piece;
66
 - unscrew the bypass valve through 1/8 revolutions and drain 100 – 150g of fluid, not allowing the fluid to be fully
consumed from the master cylinder case (repeat the procedure until complete removal of air from the hydraulic system);
- after the bleeding add the fluid to the level of 15 – 20 mm below the top edge of the filling hole;
- remove the hoses, screw in the by-pass valve and put protective cap on.
Important! To seal the threaded connections of coupling unions, use AMC-3 type sealant applying it to threaded parts of
unions only.

8.4 Changing grease in front axle ball supports

Change grease in ball supports with removed hubs as follows:

- disconnect the spindle 7 (Fig. 32) from the steering knuckle body. While removing the spindle take precautions as to
avoid damage of sealing gasket. Replace the damaged gasket with new one;
- take out axle shafts 2 and 24 complete with knuckles 10 and disc 29. To avoid failure in fitting-in of joint components,
the axle shafts and knuckles can be renewed only as complete assembly. It is not recommended to interchange the places of
location of the axle shafts and knuckles;
- remove grease and wash ball support inner cavity 26 and constant velocity joint components in new diesel fuel or
kerosene, blow off with compressed air;
- pack ball support with grease and reassemble the constant velocity joint after previous greasing, refit and fix the spindle.
Grease pivot upper bearings using lubricator screwed in the cap (pump 10 – 15 times).

67
 8.5 Changing oil in hydraulic steering booster system

To change oil in the hydraulic booster system:

- lift the truck front axle so that the wheels are clear off the ground;
- unscrew the oil tank filler plug and the steering gear case drain plug. Then, slowly turning the steering wheel lock-to-lock
(with the engine not running) drain oil from the system into a clean container;
After oil draining, it is advisable to flush the hydraulic booster system with a liter of fresh oil. Wash the tank filler filter
separately in gasoline or solvent;
- fill fresh oil into the hydraulic booster tank and wait for 2 – 3 minutes. Fill the tank up to the mark on the tank indicating
the maximum level of working fluid;
- start the engine and, running it at the minimum idling speed; slowly turn the steering wheel lock-to-lock (4-5 times in
either direction) to fill the hydraulic system with oil and remove air;
- stop the engine;
- add the oil into the tank up to the required level, lower the truck front wheels on the ground, and check the ease of
steering on the move.
Using an inadequately clean oil in operation may result in sticking (binding) of the by-pass or the safety valve of the
hydraulic booster pump and hence to a partial or full failure of the ball-screw hydraulic booster.

68
 8.6 Headlamp adjustment
V – V – truck symmetry longitudinal axis line; D – D
– line to coincide with R.H. headlamp center
projection; G – G – line to coincide with L.H.
headlamp center projection; H – H – line, located at
the height of the headlamp centers from the ground
surface; X – X – line, located below the line H-H at
the distance, determined by standard.
Fig. 24 – Screen for headlamp adjustment
Headlamps should be adjusted so that not to dazzle the oncoming
vehicle drivers. Check and adjust the headlamps with the aid of a
screen, marked in accordance with Fig. 24, in the following sequence:
- place the filled and equipped truck with rated tire pressure on
the horizontal ground in direction perpendicular to the screen, located at
the 5 m distance from the headlamp glasses. In this case the truck
symmetry longitudinal axis must coincide with the screen line V-V;
- remove the headlamp mouldings;
- switch on the dim light and, upon covering the headlamps in
turn by light-proof cloth, you are to attain the coincidence of light spots
from the right-hand and left-hand with horizontal axle X-X by rotation
of adjusting screw, and coincidence of the points of inflections of the
dividing line (at an angle of 15º) with lines G-G and D-D (for the right-
hand and left-hand respectively) by using the screw.
The adjustment over, re-install mouldings in situ.
The direction of light of fog headlamps is adjusted by the
variation of the headlamps position on the brackets. If the headlamps
are installed correctly, their optical axes must intersect with the truck
longitudinal axis on the road surface at a distance of 15 m from the
front bumper.
Attention! It is not a good practice to adjust the fog
headlamps and main ones simultaneously as this is a cause of too
fast discharge of storage batteries.
69
 8.7 Checking the steering wheel play and adjustment the joints of steering rods

Fig. 25 – Steering wheel play
check
An excessive play of the steering wheel may result from a loosened fastening of the
steering wheel, steering gear bracket and case, universal-joint shaft yokes, steering arm on the
sector shaft and steering knuckle arms, and clearances in the screw bearings or in meshing
between the sector and the rack-nut. When loosened fastenings are found, tighten up nuts or
bolts, and when clearances have appeared, carry out the adjustment.
It is recommended to check the steering wheel play by a play meter (Fig. 25) with the
engine running and the front wheels set to the straight-ahead position, the procedure being as
follows:
- attach play meter to the steering column and pointer to the steering wheel;
- turn the steering wheel to the left for the amount of play (until the resistance to the turning
rises, but so as not to change the position of the front wheels) and shift the pointer so that it is
against the zero mark of the play meter scale. Next, turn the steering wheel in the opposite
direction to take up the play. The pointer turn angle corresponds to the steering wheel play,
which should not exceed 12° (with the engine running).

Adjustment of steering rods joints is performed as the follows:

- unscrew bolt and remove the locking plate;
- screw the plug so, that to provide torque of ball pin turn around the sphere centre in any direction from 3 to 8 N·m (from
0.3 to 0.8 kgf·m). The end slot on the plug should be connected with one of point slots to locking plate installation. Projection of
the plate over the end is allowed no more than 2 mm, move the locking plate in the groove;
- set the locking plate and tighten by bolt Мкр from 7.84 to 9.8 N·m (from 0.8 to 1 kgf·m).
Joint design of steering drag rod is similar to steering tie rod.
If it is necessary to remove the steering tie rod do as follows:
- loosen the clamp bolts on the one side of the end;
- turn the end in the direction easy to remove the rod. The installation of the rod is produced in reverse order.

70
 8.8 Checking the pneumatic system tightness and the pressure regulator trip limit

When the engine is shut off the drop of air pressure in the system should not exceed 0.05 MPa (0.5 kgf/cm2) for 30 minutes
when service brake system pedal is released and for 15 minutes with the depressed pedal. The voltage regulator switching on
pressure is 0.65 MPa (6.5 kgf/cm2), regulator switching off pressure – 0.8 MPa (8 kgf/cm2).

8.9 Checking and adjusting the Toe-in

The apparent wear of the wheel tires is a symptom of disturbance in the toe-in.
Check the toe-in at rated tire pressure by measuring distances B and A (Fig. 26) between drum brake end faces from rear
and front.
To check the toe-in:
- place the truck on a flat hard-surface horizontal
ground so that the front wheels are in the straight-ahead
position;
- measure using special extensible ruler. The
distance B (rear) should be equal to distance A (front) or
exceed it by 2 mm. No toe-out is allowed.
Adjust the toe-in, if necessary. To do this, remove
one end of the tie rod from the lever; loosen the clamps of
the end piece 2 and rotate the latter so as to attain the
required length of the tie rod 3, after that refit the rod.
Check adjusting parameters of front wheels, using
the ruler. When adjusting the toe-in, make sure that end
pieces are equally screwed on the tie rod; the coupling
bolt near the joint is to be tightened first.
А – front distance between drum brake end faces;
В – rear distance between drum brake end faces;
1 – front axle; 2 – tie rod end piece; 3 – steering cross rod
Fig. 26 – Adjusting parameters of front wheels

71
 8.10 Drive belt tension check and adjustment

The deflection of generator drive belts, water pump and steering booster pump drive belts under depressing force of 40
N (4 kgf) applied to belt run midpoint must be 10 – 15 mm. The deflection of the compressor drive belt under depressing force
of 40 N (4 kgf) applied to short belt run must be 4 – 8 mm. In case if the belt deflection is more or less than specified value,
adjust its tension.
The hydraulic steering booster pump is driven by the belt from the engine crankshaft pulley. The belt tension is to be
adjusted by special screw with tetrahedral end. When the adjusting screw is rotated clockwise the distance between the pulleys
increases and, thus, the required belt tension is attained.
The belt tension of the water pump is adjusted by the tension device. To do this, loosen the bracket fastening bolts of the
tension device. With the tap wrench (which is inserted into the tension device hole), tension the belt. Without decreasing tension
force, tighten the bolts brackets fastening.
The belt tension of the compressor is adjusted by the tension device. Before the adjusting loosen the lock-nut through one
revolution, pulley axle fastening nut – through one revolution, tensioning bolt nut – through two revolutions. Rotating tension-
bolt, adjust the belt tension. After adjusting, tighten the nut and lock-nut of the axis to the torque of 120 – 150 Nm (12 – 15 kgf
m) and the tensioning bolt nut to 10 – 20 Nm (1 – 2 kg m), higher torque results in misadjustment due to pulley pin displacement.
To adjust the generator drive belt tension, move the generator around its fastening axle. Before adjusting, loosen the
generator bolts, generator plate nut and the bolt securing the generator to the plate. After the adjustment, check that the generator
is properly fastened. In case of belt rupture or lengthening, renew both belts as complete set to provide uniform distribution of
load on generator drive belts.

72
 8.11 Checking the clearance and adjusting the brake gears of the brake systems

The levers of the clearance automatic adjustment in the brake

gears are installed on the truck.
The brake regulator 6 (Fig. 27) ensures the automatic
compensation of brake shoe linings. The regulator is connected with
the lever 4, which connects brake chamber rod 3 with the cam. Brake
chamber piston rod travel value, maintained by the regulator, should
be within 32 – 36 mm.
In case of replacement the brake linings, when the brake is
disassembled, it is necessary to carry out the manual adjustment of
the clearance between brake drums and shoe linings. Install the
wrench into a profile orifice of lock 7 and applying the axial effort,
move the lock as far as it will go. In this case, the kinematical
connection between the brake regulator 6 and the worm will be
broken. By turning the lock with the wrench to one or other
direction, you may increase or decrease the clearance between the
brake drum and shoe linings. Inner cavities of the regulator are
protected with the sealing rings from the penetration of moisture and
mud from outside. They are filled with grease through the orifice
closed by the plug.
1 – brake chamber rod fork; 2 – rod; 3 – brake chamber; 4 –
brake lever; 5 – bracket; 6 – brake regulator with lever; 7 –
lock
Fig. 27 – Lever of the clearance automatic adjustment in the
brake gears

73
 8.12 Checking and adjusting of fuel supply control drive

The fuel supply control drive incorporates a floor pedal, levers, pull rods and manual drive (Fig. 28). The solenoid-
operated valve of the antitheft device is installed in the system. It ensures the fuel supply shutting off when the key is taken away
from the starter switch. When the key is taken away, the solenoid-operated valve is activated and the air channel opens. The
compressed air is supplied to the power cylinder 11, which shuts off the fuel supply.
Manual control is connected with fuel supply pedal 5 in such a manner that when handle 9 is set to required position, the
driver may only increase engine speed by the pedal 5. The control handle 10 is designed to shutdown the engine and shut off the
fuel supply.
The two fuel tanks are installed in the truck.
The shifting of the engine fuel supply between the tanks is controlled by the distributing valve situated on the left tank. The
valve control handle has three positions: when fuel is supplied from the right tank – the pointer of the handle is opposite the letter
“П”, when fuel is supplied from the left tank – the pointer of the handle is opposite the letter “Л”, when the valve is shut off - the
pointer is opposite the letter “3”.

74
1 – auxiliary brake system pedal;
2 – auxiliary brake system air valve;
3 – brake sensor;
4 – lever;
5 – pedal;
6 – fuel supply control cable;
7 – lever;
8 – pull rod;
9 – fuel supply manual control lever;
10 – engine shutdown manual control
handle;
11 – engine shutdown power cylinder;
12 – engine shutdown clip;
13 – fuel supply control lever;

Fig. 28 – Fuel supply control drive

75
 8.13 Clutch control drive check and adjustment
The adjustment procedure is as follows:
1 – piston; 2 – push rod; 3 – yoke
Fig. 29 – Clutch release master cylinder
1 – pedal; 2 – lower adjusting bolt;
3 – upper adjusting bolt
Fig. 30 – Clutch pedal
76
1 Adjust the free pedal travel within 4 - 8 mm, it corresponds
to the clearance of 0.5 – 1.0 mm between push rod 2 and piston 1
(Fig. 29), to do this:
- screw out the upper adjusting bolt 3 (Fig. 30) until the pedal
1 thrusts against the pedal bracket;
- connect the push rod yoke 3 (Fig. 29) to pedal 1 (Fig. 30);
- adjust a clearance between the push rod and piston of master
cylinder by applying light pressure by hand on pedal and screw in
the upper adjusting bolt 3 (Fig. 30) till it rests against the pedal
bracket;
- unscrew the upper adjusting bolt 3 through 0.5-1.0
revolutions, it corresponds to the free travel of the pedal ground
rubber end within 4…8 mm, lock the bolt.
2 Adjust the clutch pedal full travel, which should be 100 –
120 mm along the chord, with the aid of the lower bolt 2 (Fig. 30). If
adjusting the clutch pedal full travel by the above-described method
proves impossible, then:
- unscrew the upper adjusting bolt 3;
- change the length of the master cylinder piston push rod,
unscrewing it from the yoke (one revolution of the push rod is equal
to the pedal full travel increase of 6 – 7 mm), lock the push rod.
Adjust the free and full travel of pedal as described above.
 8.14 Cardan drive check and adjustment

To check the attachment of the propeller shaft drive flanges on the splined ends of the output shafts of the transmission
units, proceed as follows:
- put the truck over inspection pit or ramp;
- set the lever of the gearbox to neutral;
- rock the flange in the longitudinal and transverse directions by applying the force of both hands. If a tangible free
play is available tighten the flange fixing nut.
While mounting the flange, install the disc spring with the convex side to the nut.

8.15 Adjusting the final drives of driving axles

The tapered roller bearings and meshing between the bevel pinion and gear are adjusted in final drive.
The need for adjustment is indicated by an axial play in the bearings or excessive side play in bevel gear and pinion mesh
or an excessive noise in final drive operation.
Adjusting the bearings. The roller bearings must be preloaded. Preload value is checked against torque value required for
shaft turn.
The adjustment procedure is as follows:
- screw out the bolts of cover 39 (Fig. 31) of the driving bevel gear bearing housing and remove rear cover 45 (remove rear
flange 29 for intermediate axle reduction gear);
- remove driving bevel gear 44 with the bearing housing and clamp the gear shaft 27 in a vice;
- tighten front flange nut 26 to a torque of 400 – 600 N·m (40 – 60 kgf·m);
- check with an indicator the value of axial displacement of driving bevel gear bearing housing 41;
- remove front flange 29 and adjusting washer 31;
- grind off the adjusting washer to decrease its thickness by the value of the driving bevel gear shaft axial displacement
measured with the indicator plus 0.05 – 0.15 mm to obtain the preload;
- refit all the removed parts and tighten front flange nut 26 (to a torque of 400 – 600 N·m (40 – 60 kgf·m)). When
tightening the nut, rotate the bearing housing for correct arrangement of rollers in the bearing races;
- shift cover 39 towards the flange so that the centering groove in the cover moves out of the bearing outer race and collar
37 does not prevent rotation of the bearing housing;
- check the preload value against torque value required to rotate bearing housing 41.
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 In case of correct adjustment, the torque must be within the range 1.5 – 3 N·m (0.15 – 0.3 kgf·m) that corresponds to
applying force within the range of 14 – 28 N (0.4 – 2.8 kgf) to any of the holes for bearing housing bolts. Apply force
perpendicularly to the radius of rotation.
Measure the torque by continuously rotating the bearing housing, make at least five full turns of the housing in one
direction.
Having completed the adjustment, bend the tab of the nut 26 into the slot in the shaft 27 and tighten the bolts of the cover
39. Bearings 23 of the shaft of the driving spur gear 19 are adjusted with the differential and bevel gear 44 with shaft 27 removed.
The procedure is as follows:
- measure with an indicator the axial play at the end face of the driven bevel gear 17;
- remove from under the right-hand cover some of adjusting shims 22 so that the total thickness of the removed shims is
equal to the value of the gear axial play, measured with the indicator, plus 0.05 – 0.15 mm to obtain the preload;
- tighten the bolts of the right-hand cover 24. When tightening them, rotate the shaft of the driving spur pinion 19 to obtain
proper arrangement of rollers in the races of the bearings 23.
The torque required for rotation of the spur gear should be within the range of 1.5 – 3 N·m (0.15 – 0.3 kgf·m) that
corresponds to applying force to the top of teeth of spur gear within the range of 30 – 60 N (3 – 6 kgf). Apply force
perpendicularly to the radius of rotation. The procedure is as follows: wind the cord around the spur gear, connect the cord free
end to the dynamometer, after that pull the cord and wind it off. Dynamometer reading is to be within the above-mentioned
range;
- install driving bevel gear 44 in case 12 of the reduction gear and fit rear cover 45;
- re-install differential (tighten nuts of differential bearings covers 8 to a torque of 300 – 360 N·m (30 – 36 kgf·m). Screw
in adjusting nut 32 to achieve the axial play in bearings 7 and then additionally screw it in through an angle corresponding to four
slots to ensure the required preload of the bearings.
The adjustment of the bevel gear meshing consists in setting the required side clearance and contact pattern and is
carried out after the bearings adjustment.
The contact pattern is checked by applying paint on the teeth. The contact pattern on the approach side of the tooth should
be as shown in the figure (Table 7). The contact pattern must occupy in height direction the area equal to at least 50% of
the tooth height. The contact pattern must not reach the top of the tooth of the driving bevel gear. On the coast side of tooth the
contact pattern may be smaller in length and height within the limits of ±10% as compared to the approach side.

78
Таble 7 – Adjustment of meshing of rear-axle drive bevel gears

Position of contact pattern on the Methods to achieve the correct

driven gear tooth gear meshing

Correct contact of spiral bevel gears

Move the driven gear to the driving gear. When the side
clearance between teeth is insufficient, move away the
driving gear

Move the driven gear away from the driving gear. When the
side clearance between the teeth is excessive, move the
driving gear closer

Move the driving gear towards the driven gear. When the
side clearance is insufficient, move the driven gear away

Move the driving gear away from the driven gear. When the
side clearance is excessive, move the driven gear closer

79
 The adjustment of the contact pattern and clearance is carried out as shown in Table 7, where the gears 17 and 44
displacement is made by varying the thickness of shims 21 and 40 under bearing housing flanges of the driving bevel and the
spur gears.
When adjusting the meshing by means of the contact pattern, it is necessary to achieve the required side clearance,
measured with the feeler gauge or an indicator at the wide tooth end and is to be within the range of 0.17 – 0.45 mm. Check at
least four gear teeth, arranged in circle approximately at equal from each other.
It is allowed to keep slightly excessive side clearance with the proper contact pattern.

Adjusting the interwheel differential locking engagement mechanism. The procedure is as follows:
Screwing the adjusting screw 13 (Fig. 31) into or out of the rod, set the screw pin to a position corresponding to the
position of differential locking clutch 6 with differential unlocked (in the extreme left-hand position).
To ensure a clearance between the clutch and the differential case, turn the screw in for a half-turn. Check the differential
locking for proper engagement and disengagement by admitting air at a pressure of 0.45 – 0.50 MPa (4.5 – 5kgf/сm2) to the air
chamber; the clutch sleeve travel should be of 12 – 15 mm.

80
 1 – differential pinion; 2 – differential
carrier; 3 – axle shaft gear; 4 –
supporting washer; 5 – locking ring; 6 -
differential locking clutch; 7, 23, 43 -
tapered roller bearing; 8 – differential
bearing cap; 9 – supporting ring; 10 -
differential locking engagement sleeve;
11 – differential locking fork; 12 –
housing; 13 – adjusting screw; 14 –
differential locking air chamber; 15 –
differential locking engagement sensor;
16 – reduction gear cover; 17 – driven
bevel gear; 18, 46 – roller cylinder
bearings; 19 – driving spur gear; 20 –
bearing seat; 21, 22, 40 – adjusting
shims; 24 – R.H. cover of reduction gear;
25 – spring washer; 26 – nut; 27 –
driving bevel gear shaft; 28 – supporting
washer; 29 –flange with deflector; 30 –
breather; 31 – adjusting washer; 32 –
differential bearing adjusting nut; 33 –
differential cross; 34 – spacing washer;
35 – locking plate; 36 – check plate; 37 –
collar; 38 – bearing support washer; 39 – bearing housing cover; 41 – driving bevel gear bearing housing; 42 – bearing spacing
ring; 44 – driving bevel gear; 45 – rear cover of rear axle reduction gear; 47 – gasket; 48 – large bevel gear; 49 – spacing sleeve;
50 – intermediate axle reduction gear rear cover; 51 – intermediate axle reduction gear through shaft; 52 – bearing nut; 53 –
extension housing; 54 – extension shaft; 55 – coupling; 56 – collar; 57 – ball bearing; 58 – lubricator; 59 – extension cover
Fig. 31 – Rear (intermediate) axle final drive

81
 8.16 Adjustment and checking the bearings of front axle steering knuckle pivots

Check the pivot bearings for axial play with the hubs removed, steering linkage rods disconnected from the steering
knuckle arms and nuts of the pivot bearings covers tightened up to the stop (to a torque of 250 – 320 N·m (25 – 32 kgf·m). There
should be no play in rocking up and down by spindle 7 (Fig. 32).
If there is an axial play, proceed as follows:
- clean the ball support, pivot bearings covers, and steering knuckle body of dust and dirt and wipe them with wiping cloth
wetted with clean diesel fuel;
- screw out the bolts securing collar 20 and shift it outward until it comes out in contact with ball support 26;
- screw off the nuts of studs of the steering knuckle arm and adjust the preload of the pivot bearings. The tapered bearings
should be adjusted with the preload corresponding to a torque of 60 – 80 N·m (6 – 8 kgf·m) required for turning the steering
knuckle body (without the seal). It corresponds to applying a force of 340 – 470 N (34 – 47 kgf) to the orifice of the steering
knuckle upper arm ball pin. The effort should be applied perpendicular to the turning radius.
The bearings are adjusted by the shims 11 under the upper and lower covers. If it is necessary to make the preload by
removing the shim with thickness of 0.2 mm, remove it under the lower cover 30;
- inspect the brake shoes and drums, check reliability of locking of shoe anchor pins;
- re-connect the steering rods to the steering knuckle arms and adjust the toe-in. When mounting the steering rod, the short
end of the steering linkage should be close to the left wheel.

82
1 – locking washer; 2 – outer axle shaft; 3 – nut; 4 – lock nut; 5 – axle shaft flange; 6, 9, 15, 28 – tapered roller bearing; 7 –
steering knuckle spindle; 8 – brake shoe; 10 – constant-velocity universal joint cam; 11, 13 – pivot bearing adjusting shims; 12 –
cap nut; 13 – knuckle arm; 14 – upper cap; 16 – filling plug; 17 – lock; 18 – race; 19 – pressure ring; 20 – ball support collar; 21
– power cylinder bracket; 22 – tie rod; 23 – axle case; 24 – inner axle shaft; 25 – axle shaft collar; 26 – ball support; 27 –
bushing; 29 – universal joint disk; 30 – lower cover; 32 – brake drum; 33 – hub collar; 34 – hub

Fig. 32 – Front driving axle

83
 8.17 Adjustment and checking the front wheel hub bearings

To find out whether adjusting the hub bearings is needed, jack up the wheel so that the tire is clear off the ground. Remove
the axle shaft flange. If the play in the hub bearings is felt when rocking the wheel, adjust the bearing tightening as follows:
- unscrew the bearing lock nut (fig. 32) and remove locking washer 1;
- tighten nut 3 until braking of the hub begins being felt. When tightening the nut, rotate the wheel for a correct
arrangement of rollers in the bearing races;
- back off the nut 3 through 90° to align the nut pin and locking washer hole, fit the locking washer and secure it with the
lock nut (the lock nut tightening torque is 250 – 600 N·m (25 – 60 kgf·m)). Fit the lock nut with its ground face directed towards
the locking washer.
In case of misalignment the nut pin with locking washer hole, tighten the nut 3 till alignment with the nearest holes (the
total angle of unscrewing nut 3 must be within the range of 70 – 90°).
Finally determine the correctness of the bearing adjustment from the degree of hub heating during a test run. An excessive
(over 90 ºС) heating of the hubs is intolerable and must be eliminated by repeating the adjustment.

8.18 Adjustment and checking the rear wheel hub bearings

To find out whether adjusting the hub bearings is needed, jack up the wheel so that the tire is clear off the ground, remove
the axle shaft. If the play is felt when rocking the wheel, adjust the bearing tightening as follows:
- unbend the lock plate 5 (Fig. 33), screw out bolts 4, remove the lock 6;
- rotating the hub in both directions for a correct arrangement of rollers, tighten nut 1 until braking of the hub begins being
felt;
- back off the nut through 90º;
- check that the brake shoes and protective guard are not in contact with the brake drum;
- fit the lock 6, if the holes of the nut and lock fail to coincide, screw the nut to the nearest coincidence of the holes. The
hub should rotate easily but without any axial play;
- fix the lock 6 unbending the lock plate 5 onto the faces of two bolts;
- install the axle shaft.
Finally determine the correctness of the bearing adjustment from the degree of hub heating during a test run. An excessive
(over 90 ºС) heating of the hubs is intolerable and must be eliminated by repeating the adjustment.

84
1 – bearing nut; 2 – axle shaft; 3 – axle shaft flange; 4 – bolt; 5 – lock plate; 6 – nut lock; 7 – collar; 8 – locking ring; 9 – plug; 10
– wheel hub; 11 – thrust bushing; 12 – tapered roller bearing; 13 – oil slinger; 14 – air intake pipe; 15 – brake drum; 16 –
protective disk; 17 – axle swing limiter; 18 – buffer; 19 – axle case; 20 – final drive; 21 – shoe anchor pin; 22 – shoe lining; 23 –
brake shoe; 24 – expansion cam; 25 – brake shoe spring; 26 – filler neck plug; 27 – magnetic drain plug; 28 – bracket; 29 –
adjusting lever; 30 – hub collar; 31 – axle shaft case; 32 – thrust washer;
Fig. 33 – Rear (intermediate) axle

85
 8.19 Adjustment and checking of rear suspension equalizers

Remove the equalizer cover and drain the oil. Using a jack installed under the equalizer bracket, lift the rear bogie (each
side in turn) until the spring end is released on the length required to rotate the equalizer together with the spring.
Slacken the tension bolt so that the nut rotates on the equalizer shaft, tighten the nut to torque from 98 to 146 N·m (from 10
to 15 kgf·m), loosen the nut for 1/8 of a revolution and lock with the clamp bolt (tightening torque from 78 to 98 N·m (from 8 to
10 kgf·m)). After the nut is locked, the equalizer should be rotated on the shaft by hand without tangible axial play. Refit the
cover and fill the oil to the lower edge of the thread inlet hole.

86
 9 TROUBLESHOOTING
Таble 8
Scope of work and procedure Technical requirements
1 2
ENGINE, CLUTCH, GEARBOX*
Electric torch device (ETD)
Pilot lamp fails to go on or goes on Fault in electric circuit or wire break
after long time interval
Storage batteries are discharged
One or both plugs are burnt out
Pilot lamp is burnt out
Poor starting of engine Storage batteries are discharged
No flame in one or in both intake manifolds
with plugs serviceable:
- no fuel is supplied to plugs
- pilot lamp goes on too early (plugs have not
enough time to glow)
Clutch slips No or insufficient pedal free travel (no
clearances between master cylinder push rod
and piston)
Master cylinder by-pass hole clogged
*
Ref. to Operating Instructions for power unit
Devices, tools, appliances and
materials required to perform work
3
Find the cause of fault in circuit or
contacts and eliminate it
Charge storage batteries
Replace plugs or lamp
Charge storage batteries
Check fuel line from fuel transfer pump
to plugs
Before switching starter on, hold ETD
switch button depressed not less then 1
min. If flame fails to ignite, check
thermal relay and, if faulty, replace it
Adjust clutch pedal free travel
Clean the hole
87
Table 8 continued
1 2 3
Clutch Release Drive
Clutch is not fully released Jamming of clutch release drive Disassemble the working cylinder*.
Renew rings or collars, if necessary.
Wash inside surfaces of case elements
with brake fluid and blow with
compressed air. Reassemble and check
pistons for easy movement
Excessive free pedal travel Adjust clutch pedal free travel
Check level of working fluid in clutch
release master cylinder; add the fluid to
the required level, if necessary. If air is
present in the hydraulic system, bleed
the system
Cardan drive
Truck vibration at certain travel Run out of propeller shafts due to: Check and, if necessary, tighten the
speed - wear or slackening of attachment of needle bearing cap fastening bolts. Replace the
bearings and spiders spiders and bearings in case of their
wear
- break of balancing plates Replace propeller shaft
- slackening of nuts intended for fastening the Check and, if necessary, tighten the
flanges on splinted ends of output shafts of nuts
transmission units
- improper assembly of propeller shafts (marks Install the sliding forks according to the
are not matched) marks
Driving axles
Table 8 continued
*
For safety reason, prior to disassembling the working cylinder make sure there is no air pressure in the feed line

88
 1 2 3
Abnormal noise of gears in driving Final drive misadjustment Adjust the meshing of gears and
axles preload of bearings in accordance with
the recommendations, given in the
subsection “Adjusting of final drives”
Abnormal heating of axles Excessive or insufficient quantity of oil in the Check the oil level in the case and, if
case necessary, bring it to specs
Incorrect adjustment of gear meshing or Adjust gear meshing and preload of
excessive tightening of final drive bearings bearings in accordance with
recommendations, given in the
subsection “Adjusting of final drives”
Front Suspension
Fluid leak from shock absorber Slackening of the outer nut of tank Tighten the nut
Damage or great wear of collars of rod and Replace collars
tank
Shock absorber has free travel of Decrease of the fluid quantity in the working Remove the shock-absorber from
rod at the beginning of tension or cylinder motor truck, install it vertically and
compression stroke pump it several times by shifting the
piston through the whole distance of
rod travel, then check the quantity of
fluid and, if necessary add it to specs
Shock-absorber fails to develop a Slackening of the outer nut of tank Tighten the nut
sufficient force in tension Failure in tightness of the recoil valve as a Disassemble valve, wash it and piston
result of its soiling or damage in gasoline or kerosene. Replace valve,
if it is damaged
Decrease in stiffness of the recoil valve spring Replace spring or place additional
adjusting washers between its end face
and nut

89
Table 8 continued
1 2 3
Failure in tightness of the bypass valve Wash the valve parts in gasoline or
kerosene, check the ring stop threads
on the piston end faces. If the threads
have some roughness, the piston end
faces should be slightly grinded on the
flat cast iron plate. If the piston is
greatly damaged, replace it.
Increased fluid overflow through the clearances Replace the guide (bushing) or piston
resulted from considerable wear or deep marks sealing rings
on friction surfaces of guide and piston sealing
rings
Shock absorber fails to develop Slackening of the outer nut of tank Tighten the nut
sufficient force at compression
Leaky compression valve because of clogging Disassemble the valve, wash its parts
or damage of its parts in gasoline or kerosene. If deep marks
or considerable wear traces are
available on the valve shutoff surfaces,
replace the defective parts
Decrease in stiffness of compression valve Adjust the valve, reducing its stroke by
spring not more than 2 mm, or replace the
spring
Failure of tightness of inlet valve Wash the valve parts in gasoline or
kerosene. Replace the valve disk, if it
is defective and fails to tightly fit to the
seat
Shock-absorber develops an Excessive quantity of fluid in working cylinder Check quantity of fluid and, if
excessively great force in the end of necessary, bring it to specs
compression stroke

90
Table 8 continued
1 2 3
Knocks and jamming in shock Slackening of the outer nut of tank Tighten up nut
absorber when its rod is moved Slackening of piston nut causing displacement Ditto
sharply of piston on rod
Considerable fouling of fluid Replace the fluid
Decrease of the fluid quantity in the working Remove the shock-absorber from
cylinder motor truck, set it vertically and pump
it several times, shifting the piston
through the distance of rod travel. Then
check the fluid quantity and, if
necessary, add it to specs
Steering
Poor road holding ability Excessive steering gear play Adjust play
Increased force applied for turn Poor performance of power steering pump Repair or replace the pump
Knocking and vibration in the Inappropriate oil grade Drain fluid and pour appropriate oil
steering gear Faulty pump Repair or replace the pump
Low level of working fluid in the tank Add to the "МАХ” level on the oil tank
gauge
Increased effort required to turn the Steering linkage elements are not lubricated Lubricate the steering linkage elements
steering wheel Steering linkage is deformed Repair the steering linkage
Low pressure in tires Inflate the tires until the normal
pressure is achieved
Steering works properly at turn in Faulty steering linkage Repair steering linkage
one direction, and steering works Hydraulic distributor or limit switch valves are Disassemble the device and send it for
improperly at turn in the other faulty repair
direction
Steering wheel turns spontaneously Defective distributor Disassemble the device and send it for
when the engine is running repair

91
Table 8 continued
1 2 3
Lubricant leakage from under the Damaged inner sealing Disassemble the device and send it for
elements of steering gear repair
Steering gear fails to operate when Return valve is defective Disassemble the device and send it for
the engine is shut down repair
Steering fails to operate or operate Low pressure in the steering wheels Inflate the tires until the normal
ineffectively pressure is achieved
The safety valve or inner sealing are faulty
Knocking in the steering gear Excessive clearance in rack-pinion-gear sector Disassemble the device and adjust the
drive clearance
Radial clearance of the steering arm shaft Disassemble the device and send it for
repair
Excessive axial clearance in steering arm shaft Disassemble the device and send it for
repair
BRAKE SYSTEM
Compressor
Knocking in compressor Increase of clearances between connecting rod Replace the bearing shells
bearings and crankshaft journals
Compressor fails to maintain Slackening of drive belt tension Adjust belt tension
required air pressure in pneumatic Air escape via piping joints or defective valves Check the conditions of pipelines and
system their joints as well as valve tightness.
Reseat the leaky valves. If the valves
are severely worn or damaged, replace
them. Reseat the new valves to achieve
the unbroken circular contact.
Wheel braking mechanisms
Poor braking Worn brake shoe linings Check and adjust the clearances,
replace brake shoe linings, if necessary

92
Table 8 continued
1 2 3
Poor stopping ability. Excessive Brake linings are contaminated with oil Check brake shoe linings and wash
length of braking path after them
clearance adjustment
Partial braking of one of wheels. Weak or broken return spring Remove brake drum and replace
Noise is heard in one of raised defective return spring
wheels upon turning
Partial braking of one or some Insufficient clearance or no clearance between Feel the drums for heating. In case of
wheels when the brake is released shoe linings and brake drums excessive heating adjust the the
clearances
Brake valve
Incomplete release of truck brakes Unscrewed adjusting screw of valve lever free Adjust the valve lever free travel equal
due to excessive air pressure in the travel to at least 5 mm
brake chambers Slackening of the nut of balancing rubber Tighten the nut
element
Air leak via outlet hole Leaky valves and rings (due to their damage Clean or replace sealing element
(wear) and fouling
Air leak via valve lever body Failure in tightness of upper piston seal Clean the coupling or replace the ring
Air leak via fixed connections Failure in tightness of connections Tighten the slackened connection or
replace the ring
Air leak via outlet hole at pressing Leaky moving seals of lower section big and Clean the couplings or replace the seal
valve lever small pistons, valve body seals, leaky valves
(wear, damage)
Hand-operated back action brake valve
Air escapes via atmospheric hole Failure in tightness of the valve or moving seal Clean or replace the sealing element.
with the cock in one of the fixed of the valve body or piston (wear, damage, Replace the damaged sealing ring
positions fouling)
Air leakage from under valve cover Failure in tightness of moving seals of the rod Clean or replace sealing rings
or guide (wear, damage, fouling)

93
Table 8 continued
1 2 3
The valve handle fails to be fixed in Damaged handle spring Replace the spring
extreme positions
Trailer brake system control valve with two-way drive
Air leak via breather Failure in tightness of middle piston
Clean or replace the sealing element
connections
Air escapes via breather when Failure in tightness of upper piston lower
breaking with a hand-operated back connections Clean or replace the sealing element
action brake valve Leaky valve
Air leak via breather when pressing Failure in tightness of upper piston upper
the brake pedal sealing rings
Failure in tightness of adjusting screw sealing
ring
Failure in tightness of lower piston sealing ring
Spontaneous braking of the trailer Damaged diaphragm Replace the diaphragm
accompanied by air leaks via outlet
of the brake valve
Electrical system
Generator and voltage regulator
Ammeter reads a discharge current Slackening of generator drive belt tension Adjust belt tension
at an average rotational speed of Break or poor contact in the generator-storage Eliminate break or restore contact
engine crankshaft battery circuit
Disconnection (break) of wire running from Connect (remedy the break) the wire
generator terminals “Ш” or voltage regulator “Ш”
Voltage regulator faulty Replace voltage regulator
Seizing of brushes Remove brush holder and clean its duct

94
Table 8 continued
1 2 3
Slip rings are dirty or oiled Wipe the slip rings by a napkin
moistened in gasoline. When dirt fails to
be removed, trim the slip rings by emery
cloth and blow off by compressed air
Break in exciting winding Check the soldered joint between
exciting winding and slip rings and
remedy a break, if any
Ammeter reads a discharge current Faulty rectifier unit Replace the rectifier unit
at an average rotational speed of Defective stator (break in phases chain, Replace the stator
engine crankshaft and at a rated shorting of starter circuit)
load Faulty voltage regulator Replace the voltage regulator
Excessively great charging current Faulty voltage regulator Replace voltage regulator
(ammeter pointer goes beyond the Shorting of terminal “Ш” (voltage regulator Remedy the shorting
scale limits after 15 – 20 minutes of shunt wire) to the truck frame
engine operation) Excessive discharge of storage batteries Charge the storage batteries
Abnormal mechanical noise in Wear of the parts of the bearing or its Replace the defective bearing
operation of the generator breakdown
Presence of a foreign object in the generator Remove the foreign objects
Bent fan Straighten the fan
External lighting system
Dark spots are seen on lamp Lens fractured Replace lens
reflectors
Headlamp bulbs do not light Burnt out bulb filament Replace bulb
Poor contact on headlamp three-terminal Restore proper contact
junction block
Blown safety fuse Replace safety fuse
Poor contact of plug-and-socket unit on cab Restore proper contact
dashboard

95
Table 8 continued
1 2 3
Combination switch contacts are burnt out Clean the contacts

Irregular blinking Burnt out bulb filament Replace bulb

Poor contact of plug-and-socket unit Clean the contact
Ingress of moisture inside lights Broken lens Replace lens
Lens attachment is slackened Tighten fastening screws
Damaged or weak sealing gaskets Replace gaskets
When combination switch П-145 is Poor contact in plug-in connectors Restore proper contact
switched on, turn indicators fail to Blown safety fuse Replace safety fuse
operate Broken or unsoldered plug contact Solder or replace plugs
When switching on marker lights, Blown safety fuse Replace safety fuse
lamps fail to come on Burnt out bulbs Replace bulbs
Horns
Horns fail to sound or sound Blown fuse link Insert calibrated wire into fuse link
intermittently holder or replace fuse
Burnt horn relay contacts Carefully unbend relay box lugs and
clean contacts
Discharged storage batteries Charge or replace storage batteries
When the engine is not operating, Discharged storage batteries Charge or replace storage batteries
the horns sound weakly and hoarsely
or do not sound at all, while during
operation of the engine at average
and maximum rotational speeds the
horns sound normally
Horns sound hoarsely or Contacts of relay-interrupter are burnt Listen to sound of each horn
intermittently at any engine speed separately: dress contacts of breaker of
horn which has croaky sound with
superfine file

96
Table 8 continued
1 2 3
Broken plate of breaker upper contact Repair horn in workshop or renew it
One of horns fails to sound and Burnt contacts in horn contact breaker Clean the contacts or replace the
consumes current of great value contact breaker parts
Broken plate of upper contact in contact Replace the plate
breaker
Short circuit between turns in coil Replace the coil, adjust the horn
Horn produces jingling sound Slackening of attachment of horn and its cap. Tighten the horn attachment. Eliminate
Horn body is in contact with other metal parts the contact
Crack in membrane Replace the horn
Windshield wipers
During operation of windshield Improper installation of the lever on the axle Slacken the fastening nut on the axle,
wiper the brushes rub on the cab remove the lever and switch on the
parts windshield wiper for 30 – 60 s. Install
the lever with a brush so that the brush
should be arranged close to the weather
strip but should not contact it. Secure
lever, turn windshield wiper on, and
check correctness of lever installation
Windshield wipers fails to operate No contact in junction block Check junctions reliability and
after turning on eliminate fault, if necessary
Faulty switch Check and replace, if necessary
Sticking of wiper blades or dust ingress from Disassemble electric motor, eliminate
blades into collector of electric motor anchor sticking of brushes. Clean the collector
and clean grooves between collector
plates
The fuse is blown because of jamming the Find the cause and eliminate the
drive levers, jamming in reducer, or faulty trouble
electric motor Replace the fuse

97
Table 8 continued
1 2 3
Reducer worm gear is badly worn Replace the worn gear
Faulty fuse Find the cause of failure and remedy or
replace the fuse
Windshield wiper operates only at Seizing of electric motor brush or faulty switch Remedy the seizing of brush, check the
one speed switch and, if necessary, replace it
Special equipment
Hydraulic jack
When lifting the load (truck), the Air locks in oil channels When the shutoff rod (without load) is
rebound of tommy bar occurs screwed in, lift the working plunger
upwards, unscrew the shutoff rod
through 2 – 3 revolutions and lower the
working plunger as far as it will go (by
pressing with hand), then lift the load

98
 10 STORAGE OF THE TRUCKS

In case of long-term storage every three months it is necessary to operate the truck for a short time making a trip of 5 km,
perform maintenance jobs (M-1) and place it in storage for the next period.
When putting the truck for storage for a period exceeding three months, perform as follows:
- drive the truck for 5 km;
- carry out the maintenance (M-1);
- place the truck on the permanent place of storage under shelter;
- drain the liquid from the engine cooling system, preheater system, windshield washers and heating system;
- fill the fuel tank with 10 l of fuel.
Apply adhesive plaster to:
- engine oil filler cap;
- hole for oil-measuring gauge;
- drain hole and control (upper) hole of the water pump;
- drain cocks of cooling, heating and preheater systems;
- outlet hole of exhaust pipe;
- filler neck of expansion tank and hole of steam discharge tube;
- hole of the drain tube of the fuel pump;
- lower cover of clutch housing;
- breathers of axles, transfer case and gearbox;
- holes, connecting the inner cavities with atmosphere on the relay valve, hand-operated back-action brake valve, two-
section brake valve, trailer brake system control valve with two-way drive;
- condensate drain valves of the pneumatic system and distributing valve;
- generator port from the side of the collector;
- open terminals of electric equipment.
Lubricate by grease Lithol-24 the open working surfaces of splined ends of propeller shafts and the steering booster rod.
Parts with decorative coatings, located outside the cab, coat by lubricant УНЗ.
Perform jobs, indicated in the section “Storage of storage batteries”, according to the Storage Batteries Operating
Instructions.
Place the truck on the stands to decrease load applied to tires.

99
 Care of paint-and-lacquer coating
To keep the truck appearance in good condition, constant care of the truck coating is required. Carry out regular washing,
making sure that there is no dirt and dust on the painted surfaces. Wash the truck with a weak stream of cold or warm water. It is
not recommended to use high water pressure, as the solid particles of dirt and sand can scratch the coating.
If the painted surface has fuel or lubricants spots, they should be removed with the soft piece of cloth soaked in gasoline,
and then the surface should be dried.
To prolong the service life period of paint-and-lacquer coating and maintain the original appearance of the truck, apply
wax polishing paste periodically. Polishing paste forms a transparent layer that protects coating against atmospheric
precipitations. Apply polishing materials on a dry, dust-free surface with a soft cloth and polish until surface turns bright.

100
 11 APPENDICES
Appendix 1

Lubrication instructions

Lubrication of the truck is carried out during the maintenance. List of lubrication points is shown in the Table 1 and the
lubrication chart is given in Fig. 1.1.
Before starting lubrication or oil replacement wash the truck, eliminate the dirt from the lubricators, drain plugs and places
surrounding them.
When replacing the oil in the assembly units clean the magnets of drain plugs from the metallic deposits and wash them.
Important! Blending (filling-up) of motor oils of unlike firms and grades is forbidden.

Fig. 1.1 – Lubrication chart

101
 LUBRICATION CHART OF FUELS AND LUBRICANTS USED IN THE TRUCK
Table 1
Q-ty of fuel Fuel and
and lubricant lubricant Recommendations

Q-ty of lubrication
Description of replacement for lubrication
lubrication

total for truck

(top-up)

(filling) points

filling norm
Main grades, Substitutes, (filling, replacement
(filling) points intervals
seasons for use seasons for use of oil or lubricant).
Position No in

substitute
Scavenge oil drain
Fig.1.1

grade

grade
Main
(charge) norm

1 2 3 4 5 6 7 8 9
Engine
Fuel tank 2 Diesel fuel Diesel fuels meeting 250 l 500 l DM Check the level and
- at an ambient air EN-590:2004 top up, if necessary
temperature 0 ºC requirements
and above: Min. amount of fuel
Л-0,2-40 Lukoil EH590 required for the
Л-0,2-62 (EN590) engine start – 11
- at an ambient air Diesel fuel liters
temperature minus (EN590)
20ºC and above: Diesel fuel (EH
З-0,2 at minus 35ºС 590)
- at an ambient air Environmentally
temperature minus friendly fuel
30 ºС and above: ДЛЭЧ-В,
З-0,2 at minus 45 ДЛЭЧ
- at an ambient air
temperature minus
50 ºС and above:
А-0,2

102
 1 2 3 4 5 6 7 8 9
Engine crankcase, 45 1 SAE 15W/40 15W/40 32 l DM Check oil level and
10W/40 АРI CF-4/SG/SF top up, if necessary.

API CF-4/SG/SF LUKOIL-SUPER After Replace the oil;

running-in when oil level is 10
Utek Superdiesel Rols Turbo mm above bottom
(М-53/14-Е) (М-53/14-Е) mark “H”, top up,
but make sure oil
Utek Superdiesel level is not above
(М-43/14-Е) upper mark “B”.

Replace oil
M-2 Replace oil
SM

Replace with
seasonal oil grade,
if necessary

Drain norm is 20 –
25 l

103
 1 2 3 4 5 6 7 8 9
Engine cooling 1 - at an ambient - at an ambient 38 DM Check the coolant
system, 2 temperature not temperature not in 3 years level, if necessary,
lower than minus lower than minus top up until
40 ºС: 40ºС: expansion tank is
Tosol A-40 M 1/3 full or oil level
ОЖ-40 ЛЕНА is 35 mm above
- at an ambient Tosol A-40 M tank bottom
temperature not Tosol A-40 M
lower than minus Tosol Э-40 Replace with
65 ºС: Tosol A-40 M appropriate grade, if
Tosol A-65M ОЖ-40 necessary
Soft
Replace
(neutral) water
- at an ambient Wash the cooling
temperature not system during
lower than minus replacement
65ºС:
ОЖ-65 ЛЕНА
Tosol A-65 M
Tosol Э-65
Tosol A-65
ОЖ-65

1 НИИСС-1 0.045 kg Add into the

expansion tank filler
neck before pouring
the coolant

104
 1 2 3 4 5 6 7 8 9
Transmission 1 SAE 85W/90 SAE 90 8.2 l M-1 Check the level, top
Transfer case SAE 80/90 API GL-3 up, if necessary, to
housing, 35 API GL-3 bottom edge of the
ТАД-17 ТАп-15В filling hole

Oils:
SAE 80W/90 2M-2 Replace oil
at an ambient Drain norm is 5.0 l
temperature from
-25 ºС to + 30 ºС

SAE 85W/90
at an ambient *M-2 Replace oil
temperature from Drain norm is 5.0 l
-10 ºС to + 30 ºС

* At an ambient * At an ambient
temperature from temperature from
minus 25ºС to minus 25ºС to
minus 45ºС: minus 45ºС:
SAE 80 Mixture:
API GL-3
ТСп-10 85% of ТАп-15В,
ТСп-15K and 15%
of diesel fuel A, З
grades

105
 1 2 3 4 5 6 7 8 9
Gearbox case 1 SAE 90 SAE 80W/90, 13.0 l After running- Replace oil
(gearbox АРI GL-5 SAE 85W/90 in
9JS150TA), 40 АРI GL-3 (M-1000) Check the level and
ТАД-17и top up, if necessary,
ТСп-15к M-1 till bottom edge of
Oils: Oils: control hole
- SAE 90 - SAE 80W/90
Replace oil
at an ambient at an ambient
temperature from temperature from
-30 ºС to + 30 ºС -25 ºС to + 30 ºС 3M-2

- SAE 85W/90 severe

Replace oil
at an ambient conditions
temperature from of operation Drain norm is 10 l
-10 ºС to + 30 ºС 2M-2

Омскойл К

ЯрМарка Т

ТМ-3-18к

ЯрМарка Супер Э

ЯрМарка Гипоид

Lukoil-ТМ

106
 1 2 3 4 5 6 7 8 9
Front axle housing, 1 SAE 85W/90 SAE 90 11.0 l M-1 Check the level and
46 SAE 80/90 API GL-3 top up, if necessary,
API GL-3 ТАп-15В till level is not less
ТАД-17и 10 mm from lower
Oils: edge of filling hole
SAE 80W/90 thread
at an ambient 2M-2
temperature from Replace oil
-25 ºС to + 30 ºС *M-2
Drain norm is 8.5 l
SAE 85W/90
at an ambient
Intermediate and 2 temperature from 24.0 l Drain norm is 8.5 l
rear axle cases, 26 -10 ºС to + 30 ºС from each point
* At an ambient temperature from minus
25ºС to minus 45ºС:
SAE 80 Mixture: 85 % of
API GL-3 ТАп-15В or ТСп-
ТСп-10 15К + 15 % of
diesel fuel “A” or
“З” grades
Hinge joints of fuel 2 LITOL-24 Lita 0.004 kg Lubricate at
supply control rod Solid oil C assembly and repair
Solid oil Ж
Arctic climatic version:
ЦИАТИМ-201

107
 1 2 3 4 5 6 7 8 9
Fuel supply levers 1 LITOL-24 Lita 0.006 kg M-2 Force by gun until
axle, 38 Solid oil C fresh grease appears
Solid oil Ж from the clearances

Arctic climatic version:

ЦИАТИМ-201

Suspension of front 1 0.1 kg Lubricate at

engine support assembly
(engine trunnion), 1

Water pump 2 LITOL-24 - 0.01 kg - Lubricate at

bearings, 48 assembly

108
 1 2 3 4 5 6 7 8 9
Gearbox air 1 ЦИАТИМ-221 - 0.025 kg - Lubricate at
distributor control assembly and repair
cock, 14

Clutch 1 0.025 kg -
hydropneumatic
booster

Clutch pedal 2 LITOL-24 Lita 0.01 kg M-2 Apply a thin layer of

attachment pins Solid oil C grease
Solid oil Ж

Joint of clutch 1 0.004 kg - Apply a thin layer of

release master grease when at
cylinder rod Arctic climatic version: assembly and repair
ЦИАТИМ-201

Gearbox air 3 0.02 kg 2M-2 Clean and apply a

distributor thin layer of grease
to wear surfaces

109
 1 2 3 4 5 6 7 8 9
Cavities between 6 LITOL-24 Lita 0.01 kg - Lubricate at
collars of drive Solid oil C assembly and repair
axles reducer Solid oil Ж
flanges and transfer
case

Master (underpedal) 1 ТОМЬ NEVA 0.7 l Replace the Check the level
clutch release ROSA fluid once in Fill till the fluid
cylinder, 12 three years at level is 15 – 20 mm
scheduled below the top edge
maintenance of filler hole with
filled up hydraulic
system
0,2 l for bleeding
hydraulic system
Compressor drive 1 LITOL-24 0.025 kg M-2 Fill with grease
tensioner pulley through press-
bearings lubricator, making 4-
Arctic climatic 5 injections (using
version: manual gun)
ЦИАТИМ-201

110
 1 2 3 4 5 6 7 8 9
Clutch release 1 ШРУС-4 ШРУС-4 0.04 kg 3M-1 Force by gun through
coupling, 12 ШРУС-4M the lubricator until
fresh grease appears
from the clearances

Bearing of clutch 2 0.016 kg Force by gun through

release yoke shaft two press-lubricators
until fresh grease
appears from the
clearances

Gearbox input shaft 1 Lita Solid oil C 0.025 kg Lubricate before

bearing (in engine Solid oil Ж installation on engine
flywheel), 11

111
 1 2 3 4 5 6 7 8 9
Axles. Suspensions
Rear suspension 2 SAE 85W/90 SAE 90 1.4 l M-2 Check the level and
equalizers, 30 SAE 80/90 API GL-3 top up, if necessary,
API GL-3 oil level should be
not lower than 20
ТСп-15К ТАп-15В mm from filling
Oils: hole thread bottom
SAE 80W/90 edge
at an ambient
temperature from Drain norm is 0.84 l
-25 ºС to + 30 ºС from two points
SAE 85W/90
at an ambient Replace oil
temperature from 2M-2
-10 ºС to + 30 ºС
* At an ambient temperature from minus
25ºС to minus 45ºС: *M-2
SAE 80 Mixture: 85 % of
API GL-3 ТАп-15В or ТСп-
ТСп-10 15К + 15 % of
diesel fuel “А” or
“З” grades
Front suspension 2 АЖ-12Т АУ 1.7 l Fill with oil at
shock absorber, 41 assembly and repair
Drain norm is 0.6 l
from one point

112
 1 2 3 4 5 6 7 8 9
Front axle steering 2 ШРУС-4 Lita 0.2 kg 3M-2 Force by gun,
knuckle upper making 10 – 15
bearings, 7 injections
Front axle ball 2 6.0 kg 2M-2 Fill ball support
supports, 44 chamber with fresh
grease and lubricate
the axle shaft
bushings, constant
velocity joints and
knuckle bearings
Front wheel hub 6 LITOL-24 5.4 kg 3M-2 Fill hub cavity with
bearings, 21 fresh grease at filling
the bearings with
grease for sure

rear wheel hub

bearings, 43

113
 1 2 3 4 5 6 7 8 9
Rear suspension 12 LITOL-24 Lita 0.228 kg M-2 Force by gun until
torque rod joints, 25 Solid oil C fresh grease appears
Solid oil Ж from the clearances
Arctic climatic version: or until resistance is
felt
ЦИАТИМ-201 Solid oil C
Solid oil Ж

Rear and 2 Graphite grease 0.25 kg M-2 Force by gun until

intermediate axle (УСсА) resistance is felt
propeller shaft
splined joint

Front axle propeller 1 Graphite grease 0.125 kg M-2 Force by gun until
shaft splined joint (УСсА) resistance is felt

114
 1 2 3 4 5 6 7 8 9
Front and rear 4 Graphite grease 1.4 kg - Lubricate at
spring leaves, 23 (УСсА) assembly and repair
Lubricate the leaves
from the concaved
side with thin coat of
grease at their
contact places.
Bearings of front 2 AZMOL N158 N 158 M 0.1 kg M-2 Force by gun until
axle propeller shaft fresh grease appears
spiders, 17, 36 from the clearances
Bearings of rear and 6 0.3 kg
intermediate axle
propeller shaft
spiders, 16, 24
Collar lips of wheel 6 LITOL-24 Lita 0.3 kg - Lubricate at
hub packing devices assembly and repair

Brake system Lubricate at

Brake system 18 ЦИАТИМ-221 - 0.24 kg - assembly and repair
devices
Auxiliary brake 1 0.003 kg - Apply a thin layer of
power cylinder grease at assembly
and repair

115
 1 2 3 4 5 6 7 8 9
Adjusting levers of 6 ЖТ-72 - 0.24 kg Once in two Add grease in
brake gears, 22 years regulator, force by
gun through the hole
closed with plug
until fresh grease
appears from the
holes

Bearings of brake 8 LITOL-24 Lita 0.04 kg M-2 Force by gun until

gears expansion Solid oil C fresh grease appears
cams, 32 Solid oil Ж from the clearances

Bushings of service 2 0.24 kg - Lubricate at

brake system pedal assembly and repair
roller
Auxiliary brake 1 0.13 kg - Apply a thin layer of
actuator, 10 grease during repair
Arctic climatic version:
and reassembly
ЦИАТИМ-201
Auxiliary brake 1 0.02 kg - Apply a thin layer of
pedal pneumatic grease to working
valve surfaces
116
 1 2 3 4 5 6 7 8 9
Steering
Tank, steering gear, 1 МГЕ-46В 8l After Replace oil
4, 5 running-in
(M-1000) Replace oil
M-1 Oil level should be
between upper and
lower marks of oil
dipstick
Replace oil at repair
Drain norm is 2 l
Ball pins of steering 6 LITOL-24 Lita 0.15 kg M-2 Force by gun until
rods and steering Solid oil C resistance is felt
booster, 6, 43 Solid oil Ж

Steering column 2 Arctic climatic version: 0.004 kg - Lubricate at

thrust bearing assembly and repair

ЦИАТИМ-201

117
 1 2 3 4 5 6 7 8 9
Bearings of steering 2 AZMOL N 158 N 158M 0.32 kg - Pack with grease at
gear propeller shaft assembly and repair
spiders, 9

Splined joint of 1 Graphite grease 0.1 kg - Lubricate at

steering gear (УСсА) assembly and repair
propeller shaft, 8

Electrical Lubricate at
equipment 1 LITOL-24 Solid oil C 0.01 kg - assembly and repair
Searchlight lever Solid oil Ж
spherical surface

118
 1 2 3 4 5 6 7 8 9
Storage battery 4 ЛИТОЛ-24 Solid oil C 0.02 kg SM Apply a thin layer
terminals Solid oil Ж of grease at
assembly and repair

Plug-in connections 66 ПВК ВНИИНП-510 0.05 kg - Apply a thin layer at

of wires on frame assembly or repair
(by dipping)
Starter bearings,39 3 SAE 15W/40 SAE 15W/40 0.01 kg 3M-2 Fill 10 drops of
SAE 10W/40 SAE 10W/40 engine oil into each
API CF-4/SG/SF API CF-4/SG/SF lubricator (till felt
filets are fully
Utek Superdiesel LUCOIL-Super soaked)
(М-53/14-Е) Рольс Турбо
(М 53/14-Е)
Utek Superdiesel
Starter drive, 39 1 (М-43/14-Е) 0.05 kg 3M-2 Pour oil in the drive
case
Special equipment In case of
Hydraulic jack ДГ 1 ВМГЗ 0.4 l - unintentional oil
12.3913010 Arctic climatic version: bleeding fill up
Drain norm is 0.3 l
ВМГЗ-С Fill with oil for the
Hydraulic jack ДГ И-20А АМГ 0.4 l entire operation
12.07700.000 1 period

119
 1 2 3 4 5 6 7 8 9
Winch rope, 33 1 SAE 85W/90 SAE 90 0.035 l As required Put some new oil on
SAE 80/90 API GL-3 the rope
API GL-3 ТАп-15В
ТСп-15К
Oils:
SAE 80W/90
at an ambient
temperature from
-25 ºС to + 30 ºС
SAE 85W/90
at an ambient
temperature from
-10 ºС to + 30 ºС
*At an ambient air temperature from minus
25ºС to minus 45 ºС:
SAE 80 Mixture: 85 % of
API GL-3 ТАп-15В or ТСп-
ТСп-10 15К + 15% of diesel
fuel «А» or «З»
grades
Hydraulic winch 1 ISO 46 ISO 46 85 l M-1 Check the level and
tank, 20 Castrol Hyspin Hydraulic oil top up, if necessary.
АWH 46 Mobil DTE 15M Oil level should be
Bartran HV46 between the upper
Tellus T46 and lower marks on
Rando Oil HD Z-46 measuring glass
Visga 46

120
 1 2 3 4 5 6 7 8 9
Towing hook lock 2 Solid oil C Solid oil Ж 0.02 kg - Lubricate at
and catch axle, 27 assembly and repair

Towing hook stem, 2 0.01 kg M-2 Force by gun until

27 fresh grease appears
from the clearances
or until resistance is
felt
Winch drum and 3 LITOL-24 Solid oil C 0.095 l M-2 Force by gun until
shaft bearings, 34 Solid oil Ж fresh grease appears
from the clearances
Winch cable rear 3 LITOL-24 Solid oil C 0.08 kg - Lubricate at
guide rollers, 28, 29 Solid oil Ж assembly and repair

Cab door lock 2 LITOL-24 Lita 0.003 kg - Lubricate at

Solid oil C assembly and repair
Cab door lock drive 2 Solid oil Ж 0.004 kg

Glass-frame riser 2 0.050 kg

Cab door hinges, 10 4 0.008 kg

Cab door lock and 4 0.004 kg

cab door lock
switch

Driver’s seat guides 2 Arctic climatic version: 0.008 kg

121
 1 2 3 4 5 6 7 8 9
Sun visor hinge 2 LITOL-24 Lita 0.03 kg - Lubricate at
joints Solid oil C assembly and repair
Solid oil Ж
Weight adjustment 1 0.033 kg
Arctic climatic version:
mechanism
Cab door opening 2 ЦИАТИМ-201 0.003 kg
limiter

Hood lock 1 0.015 kg M-2 Apply a thin layer

of grease to working
surfaces

122
 Oils, lubricants, fuels used when operating the truck

Lubricants, fuels and fluids

filled in the truck at the Oils, fuels and fluids of foreign manufacturers Application
plant
1 2 3
Diesel fuel 2D, Grade 3;DF-2, type C, F-54, ID, Grade 2; At 0ºC and above
M8-DM Energol DS3 20W; Rimula At an ambient air
Ct-20/20W; temperature above
SAE-20/20W plus 5ºC
Oil ТAп-15B CS300A; OEF 220; BT-PO-152 Amd.2 (CO-90); E/0-12990; 3-GP-390b All seasons
Amd.2; MIL-L-2105B; Grade 90; JIS K 2219; Agip F.I.; Rotra; Brayco
690J; BP Gear oil EP SAE 90; Castrol ST 90;Transolf EP SAE 90; Esso
Gear oil EP 90; Gulf Transmission oil 90; Mobilube C 90; Shell Spirax 90
EP; Universal Gear Lubricant EP 90; Fina Pontonic WA
Oil TCп-15K GL–3; SAE–90; In summer
Oil MT-16п MIL-L-2105; CS-3000A; DENTAX 90; Mobilude C-90; Esso Gear 90; All seasons
castrol ST; BP Gear; SAE-90 EP
Oil P Type A, Suffix A; BR Energol HL 50; BP ATF Type A; Suffix A; All seasons
Elfmatic C; Esso Torque Fluid 40; Mobilfluid 93; Shell Tellus T oil 23;
DEA Fluid 684 (ATF); Total Fluid A; Valvomatic Type A.
Grease Lithol–24 Shell. Retinax-RB, -A. –G, -H. Firm Shell and
England
Grease ЦИАТИМ-201 ML-30; ML-36; MC-1325; MC-1330; MB-2027; M-20; M-25; M-30; F- Toho Shokai Ltd.,
15; F-19; B-100; B-1000; F-1031; B-2013; B-2025. Japan
Gargoyle Grease –AA, -B, Socony Vacuum Co.
SKF-I, SKF-28 USA
Grease N 158 MIL-C-10924C; C.S.3107B; XG-279 C-403; USA
England
NATO

123
 1 2 3
Graphite grease C.S. 3113; copt XG-264; VV-G-671d, copt Grease 3; Energrease GP2-G. All seasons
GP-3-G; Helveum 2 Graphited; Spheerol LG; Castrolease Graphited;
Graphited №3; Glissando FMA-20; 904; Barbatia 2, 3, 4; Van Estan 2.
Brake fluid ГТЖ-22М CS.3106A, OX-8; BT-PH-352; 3-GP-510d; W-B 690B; E/L-1410b; All seasons
DCEA 990 Ed. I; VTL 9150-061; VTL 9150-023; Agip F-1 Brake Fluid ;
Super HD; Pentosin Super Fluid; J1703-R; Castro; Girling; Brake Fluid
(Green); Hydraulic Brake; Fluid Super 70R3; Atlas Brake; Fluid CD;
Mobil Hydraulic; Brake Fluid; Shell Donax B.
Synthetic solid oil “C” C.S. 3107 B, copt XG279; C.S.2965, copt LG280; MIL-G-10924C; All seasons
Energrease C2, C3; Energrease GP2, GP3; Energrease PR2, PR3;
Helveum 2,3; Spheerol L; Castrolease WP; Impervia GS; Mobilgrease AA
N2; Greasrex D60; Cargoyle B N2; Cup grease 2,3; Unedo 2,3; Livona 3;
Blameta 2,3; Chassis XX; Cazar K2; Estan 2

124
 Appendix 2

Tightening torques of the most vital screw joints, N·m (kgf·m)

Nuts of bolts of flanged joints of propeller shaft from gearbox to transfer case 68.64 – 98.06 (7 – 10)
Nuts of bolts of flanged joints of propeller shafts 70 – 100 (7 – 10)
Nuts fastening ball supports to front axle case 110 – 140 (11 – 14)
Nuts fastening pivot bearing covers to front axle steering knuckle body, differential carrier 280 – 320 (28 – 32)
Nuts fastening final drive to front axle case 215.74 – 245.16 (22 – 25)
Nuts fastening final drive speed reducers to rear axle case 110 – 140 (11 – 14)
Nuts fastening axle shaft flanges to wheel hubs 120 – 140 (12 – 14)
Nuts fastening driving axle differential bearing covers 300 – 360 (30 – 36)
Bolts fastening final drive cylindrical pinion bearing cover 56 – 62 (5.6 – 6.2)
Shock absorber reservoir nuts 120 – 150 (12 – 15)
Rear leaf spring U-bolt nuts (not less than) 600 (60)
Front leaf spring U-bolt nuts 400 – 440 (40 – 44)
Diskless wheel fastening nuts 215.6 – 313.6 (22 – 32)
Nuts fastening steering gear bracket to frame 123 – 137 (12 – 14)
Steering booster pump pulley nut 49 – 64.6 (5 – 6.5)
Nuts of ball pins of steering rods (not less than) 196 (20)
Compressor cylinder head nuts 12 – 17 (1.2 – 1.7)
Brake chamber bracket nuts 120 – 140 (12 – 14)

Note. The tightening torques for the engine, clutch and gearbox are specified in the Operating instructions for the power unit.

125
 Appendix 3

List of bearings used in truck assembly units

Overall dimensions, mm
Q-ty per
Bearing
Bearing type Place of installation truck,
designation inner outer width
pcs
1 2 3 4 5 6 7
**
ENGINE, CLUTCH AND TRANSMISSION
12312КМ Radial roller bearing 60 130 31 Transfer case 4
50312 Radial roller bearing 60 130 31 Transfer case 2
50412 Single-row radial ball bearing 60 150 35 Transfer case 2
with retaining ring
6-12212КМ Single-row radial ball bearing 60 110 22 Transfer case 1
with retaining ring
12218КМ Radial roller bearing 90 160 30 Transfer case 1
102314М Radial roller bearing 70 150 35 Transfer case 1
50218 Single-row radial ball bearing 90 160 30 Transfer case 1
804707К3C10 Needle roller bearing 33.635 50 37 Transmission propeller shafts 32
6-7611А Single-row tapered roller 55 120 45.5 Front driving axle 4
bearing
7312А Single-row tapered roller 60 130 27 Front axle speed reducer 1
bearing 33,5
7519А Single-row tapered roller 95 170 45.5 Front axle speed reducer 1
bearing


Numerator represents width of the outer race, while denominator represents width of the inner race.
**
Bearings for these units are given in the Operating Instructions for the power unit.

126
 1 2 3 4 5 6 7
27313 Single-row tapered roller 65 140 23 Driving axle speed reducers 6
bearing 36
92316 Single-row cylindrical roller 80 170 39 Driving axle speed reducers 3
bearing
7518А Single-row tapered roller 90 160 34 Driving axle speed reducers 6
bearing 42,5
7218А Single-row tapered roller 90 160 26 Rear and intermediate axle speed 2
bearing 32,5 reducer
7219А Single-row tapered roller 95 170 27 Rear and intermediate axle speed 2
bearing 34,5 reducer
12213КМ Single-row cylindrical roller 65 120 Rear and intermediate axle speed 2
23
bearing reducer
2007122М Tapered roller bearing 110 170 38 Wheel hubs 8
7718А Tapered roller bearing 90 160 50 Rear wheel hubs 4
636906С17 Ball bearing 28 42 26 Steering column 2
207К5 Radial ball bearing 35 72 17 Compressor 2

127
 Appendix 4
List of collars used in truck assembly units

Overall dimensions, mm
Collar number inner outer Place of installation Q-ty per truck, pcs
width
diameter diameter
1 2 3 4 5 6
256Б-1802191 30 47 10 Transfer case 1
250-3802126 14 28 7 Transfer case 1
260-2301036 65 90 10 Front axle semi-axles 2
255Б-2304124 215 242 13 Front axle ball support 2
210-2402052-А2 75 102 12 Transfer case 3
14 Driving axle speed reducers 4
255Б-3104036-01 1130 160 14 Wheel hubs 10
16
260-3124011 110 135 12 Wheel hubs 24
120-3509070-A2 23 46 10 Compressor 1
13,5
260-1602551 22 33 9 Clutch release master cylinder 1
260-1602550 Clutch release master cylinder 1
255Б-2201036 34 43 7.3 Propeller shafts 32
214-3412121-Б 15 29 10 Auxiliary brake system 2
65034-8603035 180-190-58-2-2 Ring 2
6510-8603036 1-85х70-Б Collar 1
6510-8603054 2-70 Mud remover 1

Numerator represents width of the outer race, while denominator represents width of the inner race.

128
 Supplement 5

Adjustment data, mm

Clearance between rocker noses and ends of intake and exhaust valve (on cold engine) 0.25 – 0.30
Toe-in (measured between brake drum end faces) 0–2
Clutch pedal free travel 4–8
Clutch pedal full travel 100 – 120
Steering wheel free play (with running engine) 12º
Service brake pedal free travel 19.5 – 25
Service brake pedal full travel 105 – 115
Clearance between shoe linings and brake drum of the service brake system 0.2 – 0.6
Deflection of drive belts under depressing force of 40 N (4 kg f) applied to belt run midpoint
water pump 10 – 15
generator and steering booster pump 10 – 15
compressor, under depressing force applied to short belt run 4–8

129
 Appendix 6
Filling capacities, l

Fuel tanks 250 each

Engine lubricating system 32
Gearbox case 13
Advance ignition coupling 0.14
Transfer case housing 8.2
Engine cooling system 38
Rear and intermediate axles cases 12 each
Front axle case 11
Ball supports of front driving axle (two), kg 3 each
Driver’s seat shock absorber 0.072
Steering booster system (tank, steering gear) 8.0
Master (under pedal) clutch release cylinder 0.7
Hydraulic winch tank 85
Hydraulic jack 0.4

130
 Appendix 7

Structure and schemes of brake systems

The trucks are equipped with the service brake system that applies and releases the brakes of all wheels, the parking brake
system operating on the transmission and with auxiliary brake system fitted in exhaust system.
The usage of compressed air for the additional air consuming devices is provided.
Diagram of the brake system pneumatic drive of the KrAZ-632207-1062-02 truck is shown in Fig. 7.1.

Service brake system

The service brake system is used to reduce the truck travel speed and stop the truck.
The brake gear of each wheel consists of two inner shoes with brake shoe linings. The brake shoes of front wheels rest on
one axle mounted in the support. When the brake pedal is released, the brake shoes are pulled away from the drum by the springs
and rollers hold them against the expansion cams. When the brake pedal is pressed the expansion cams expand the shoes and
press them against the brake drum inner surface.
On the expansion cam splined ends the adjusting levers are installed, which are connected with brake chambers rods by
forks. The curved surface of cam ensures the smooth adjustment of clearance between drum and shoes until full the friction
linings will be fully worn out. Adjustment of clearance is provided by the worm gear in the expansion cam lever

Parking brake system

Parking brake system is designed to hold the vehicle when it is stopped or parked as well as for braking while it is running, in
case of the service brake system failure. Parking brake system uses the service brake gears of rear axle that are operated by
compressed air with springs of brake chambers. Parking brake system is controlled by hand-operated back action valve located on
the left side of the driver’s seat. When air goes out of spring brakes parking brake is applied.
To perform emergency release of spring brake, unscrew air spring brake chamber cover, insert special wrench supplied in
SPTA set (pin with diameter 5 mm, pin length 160 mm) via pipe and apply an axial force to it by striking.

131
КП – two-line valve; КДП – trailer control valve with two-way drive; КВТ – auxiliary brake valve; КУ – relay valve; КЭ –
solenoid valve; KСК1 – KСКЗ – condensate drain valve; КОД – hand-operated back action brake valve; КТП1 - КТП2 – front
brake chambers; КТД1 - КТД4 – rear and intermediate axle brake chambers; КМ – compressor; КТ – brake control valve; ККВ1
- КKВ4 – check outlet valve; MP – pneumatic two-pointer pressure gauge of air tanks; PP – regeneration air tank; PCT – parking
brake air tank; PПT – front brake circuit air tank; PЗТ – rear brake circuit air tank; РТС – braking force regulator; ЦС – power
cylinder; ЦBT – auxiliary brake shutter control cylinder; AПB – air dryer; ГС1 – ГС2 – automatic coupling head; ДСВ1 – ДСВ4
– Knorr Bremse speed sensor; ДСД1 - ДСД4 – pressure drop sensor; ДСТ1 - ДСТ4 – brake signal sensor; КР – disconnecting
valve; ГС1.2 – coupling head type A; КП2 – control valve with one-way drive; МД1 - МД4 – Knorr Bremse pressure modulator;
РДП1 - РДП2 – front wheel sensor rotor; РДЗ1 - РДЗ2 – rear wheel sensor rotor; БУ – Knorr-Bremse ABS control unit
Fig. 7.1 – Pneumatic equipment diagram
132
 Auxiliary brake system

The auxiliary brake system is throttle-type, compression, with pneumatic drive. Auxiliary brake system is designed to
decrease the service brake gears workload. When the auxiliary brake system is applied, the truck is braked by the shut-down
engine (when the fuel supply is turned off) increasing the backpressure in the exhaust system.
The auxiliary brake system is controlled by the pedal located on the cab floor. When the pedal is depressed, the pneumatic
valve opens and air enters into the engine shutdown power cylinder and the cylinder of auxiliary brake system engagement.
Engine shutdown power cylinder and auxiliary brake system cylinder are connected in such a way that when the pedal is
depressed fuel supply is cut off and then a brake shutter is closed. When the pedal is released, the shutter is opened, and fuel is
supplied.

133
 Appendix 8

Antilock brake system

The truck is quipped with 4S/4M (4 sensors/4 modulators) 4-channel ABS. The system is designed to maintain the good
truck braking ability without wheel slip while braking on slippery or dry road.
The system consists of wheel speed sensors, electro-pneumatic pressure modulators fitted into brake lines in front of the
brake chambers of front and rear wheels, electronic control unit, diagnostic socket and fuse block mounted under the passenger’s
seat.
The ABS warning light, test button, test lamp and АBS special mode switch are installed on the dashboard. The warning
light bearing the symbol ABS warns of АВS failure and where it occurred, as well as of tested braking performance.
The АBS special mode switch is designed to switch the ABS special mode when braking on mountain roads, loose snow or
gravel. The ABS switch is designed to switch on ABS test mode and to output fault code to the warning light bearing the symbol
ASR-L.
The ABS components are shown in Fig. 8.1.

134
 A1 – ABS control unit; YA50 -
YA54 – wheel modulators; BV50
- BV54 – wheel speed sensors;
BP1 – engine brake sensor; F1 –
fuse box; F5 – ABS fuse box;
GB1 - GB2 – storage battery;
HG19 – ABS pilot lamp; HG20 –
ASR-L pilot lamp; KA5 – engine
brake relay; KA10 – instrument
relay; KA16 – engine brake
locking relay; KA17 – ABS
power relay; XS7 – ABS
diagnostic socket; SA23 – ABS
operating modes switch; SA25 –
ABS test button; YA2 – antitheft
device solenoid valve; PA –
ammeter; SM – “ground” switch;
XT1 – connecting panel; HG21 –
trailer ABS pilot lamp; XS8 –
trailer ABS socket; 1 - 3 – ABS
speed sensor cable; 4 - 5 – ABS
modulator cable; 9 – ABS wiring
harness; 10 – main wiring harness

Fig. 8.1 – ABS components wiring diagram

135
 Antilock brake system operation
With the ignition on (when the key of instruments, starter and antitheft is turned to the position «I»), the pilot lamp with
the symbol ABS (truck) comes on and electronic control unit, sensor wirings and switching devices are tested.
When the system is not faulty, the warning light switches off in 2 – 3 seconds after the ignition is on or the truck begins to
move (when it is accelerated to 5 – 7 km/h). In case of malfunction in the system or faulty wiring of any component (sensor,
modulator etc.) or control circuit, the pilot lamp comes on. In this case, the power of an affected modulator is off and the brake
system or ABS non-controlled brake circuit is working as usual (from brake control valve).
The ABS is designed to be maintenance-free and it requires only functional check and check of ABS sensors fitting when
adjusting or renewing bearings in the wheels, or renewing the brake shoes (if hubs were removed). For normal ABS operation the
clearance between the sensor stator and rotor should not exceed 1.3 mm. To set a minimum operating clearance between the
stator and rotor, apply an effort of 120 – 140 N (12 – 14 kgf) to the sensor stator end face or by tapping on it with a nonmetal
item, push forward the pickup stator in closing sleeve until it thrusts against the rotor gear and turn the wheel hub on 2 – 3
revolutions.
Repeat the procedure, to set the clearance between the stator and rotor in the rear wheel with the brake drum removed.
When the red light with the symbol ABS does not go out at the speed over 7 – 10 km/h, check that the sensors are
properly fitted on the wheels or take the truck into the local service station and let technicians perform computer diagnostics and
eliminate the trouble.

136
 Appendix 9

Electrical equipment components and diagrams

The electrical equipment system of the truck is of a single-wire type in which the negative pole of current sources and
power-consuming devices are connected to the frame. The negative pole of the storage batteries is connected to the frame through
a switch, so all power-consuming devices operate when storage batteries are connected to the truck frame. To ensure the contact
between cab-frame and frame-engine units additional ground wires are used.
The socket for a portable lamp, not connected with the ground switch of storage batteries is the only power-consuming
device that follows a pattern of a two-wire circuit.
Two storage batteries connected in series and generator, operating together with voltage regulator, are used as source of
current.
The rated voltage required for operation of power-consuming devices is 24 V.
Units and devices in electrical equipment system are connected with wires ПВА or wires ПВГА (with polyvinylchloride
insulation) formed into harnesses. The wire marking is colored, wire section is different.
Note – It is allowed to replace one color in the wiring harness.
To reduce the radio interference in the electrical circuit of generator and voltage regulator, RFI filter is installed. To reduce
the radio interference the condensers are installed in the defroster fan motor circuit.
Electrical equipment diagram of KrAZ-632207-1062-02 truck is given in Fig. 9.1.
During repair (disassembly) that occurred because of wire harness misalignment or loose securing (especially in the cab)
make sure that all harnesses and plugs are laid and secured in such a way that there is no contact with sharp edges to avoid
fraying problems in operation.

137
 Symbols on electrical equipment diagram

А2 – instrumental panel; EL9 – cab dome light;

А3 – starter interlocking relay; EL10 - service light lamp;
A5 – turn indicator relay-interrupter; EL11 – truck number plate lamp;
ВК1 – water temperature indicator sensor; F1 – fuse box;
ВК2 – water emergency temperature sensor; F3, F4 – fuse box;
ВР1 – air filter clogging sensor; G – generator;
ВР2 – oil filter clogging sensor; GB1, GB2 – storage batteries;
ВР3 – oil emergency pressure sensor; НА1, НА2 – electric sound horns;
ВР4 – oil pressure indicator sensor НА3 – sound buzzer;
ВР5 – engine brake switch; HG1 – neutral gear engagement pilot lamp;
ВР6 – parking brake switch; HG2 – PTO engagement pilot light;
ВР7 – air pressure drop sensor (I circuit); HG3 – pilot lamp of tractor-trailer train sign switch-on;
ВР8 – air pressure drop (II circuit); HG6 – front fog lights cut-in pilot lamp;
ВР9 – air pressure drop (reserve circuit); HG8 – blackout device cut-in pilot lamp;
ВР10 – stop signal pneumatic switch; HL1, HL4 – side turn indicators;
ВР14 – air pressure sensor (I circuit); HL2, HL3 – front marker lamps;
ВР15 – air pressure sensor (II circuit); HL5, HL6, HL7 – tractor-trailer train sign lamps
ВQ1 – reverse running sensor; HL8 – rear marker lamp;
ВQ2 – neutral gear engagement sensor; HL9 – reverse running lamp;
BQ3, BQ4 – inter-wheel differential interlock cut-in sensors; HL10 – rear fog light;
BQ5 – inter-axle differential interlock cut-in sensor; HL12 – rear light;
BQ6 – PTO engagement sensor; HL13 – signaling beacon;
BV1 – pulse sensor; КА2 – headlamp dim light relay;
С1, С2 – condensers; КА3 – headlamp distance light relay;
ЕК1, ЕК2 – pin spark plugs; КА6 – relay-interrupter;
EL1, EL4 – headlamps; КА8 – generator interlocking relay;
EL2, EL3 – fog lights; КА9 – ETD relay;
EL5 – underhood illumination light; КА10 – intermediate relay of instruments;
EL7 – lamp; КА11 – reverse light signal relay;
138
КА12 – rear fog lights relay;
KA13 – engine brake relay;
KA14 – starter relay;
КА15 – sound horn relay;
KA16 – stop signal relay;
KA17 – marker lights relay;
KA20 – “ground” switch interlocking relay;
КА25 – hydraulic winch interlocking relay;
КА26 – marker lights switch relay to blackout mode;
КА27 – brake lights switch relay to a blackout mode;
КА28 – turn lights shutdown relay in a blackout mode;
КА29 – reverse motion light switch relay to blackout mode;
КТ1 – thermal resistance;
KT2 – air dryer;
КТ3 – hydraulic winch oil cooler;
М1 – starter;
М2 – windshield electric washer;
М3 – windshield electric wiper;
М4 – preheater electric motor;
PS – speedometer;
RP1 – instrument illumination switch;
RP2, RP3 – fuel level sensors;
SA1 – emergency signaling switch;
SA2 – cab dome light switch;
SA5 – heater mode selector switch;
SA7– fuel level sensor selector switch;
SA8 – inter-axle differential interlock switch;
SA9 – inter-wheel differential interlock switch;
SA10 – transmission switch;
SA11 – low gear switch;
SA12 – PTO switch
SA13 – ETD switch;
SA14 – tractor-trailer train sign selector switch;
SA15 – fog headlamp and rear fog light selector switch;
SA16 – windshield washer selector switch;
SA17 – windshield wiper selector switch;
SA18 –instruments, starter and antitheft device switch;
SA19 – combination switch;
SA20 – illumination lamp switch;
SA23 – remote “ground” switch;
SA25 – signaling beacon switch;
SA30 – blackout device switch;
SA40 – hydraulic winch switch;
SM – remote “ground” switch;
VD5 – diode with protective housing;
X1 – X7 – contact connections;
X9 - X12 – contact connections;
X14 - X16 – contact connections;
X19 - X22 – contact connections;
X28, X29 – contact connections;
X33, X34, X37 - X39– contact connections;
X41, X43, X50 – contact connections;
X56 – X58 – contact connections;
XS1 – portable lamp socket;
XS6 – socket;
ХТ1 – connecting panel;
YA1 – ETD solenoid valve;
YA2 – anti-theft device solenoid valve;
139
YA5 – electromagnet of interaxle differential interlocking valve;
YA6 – electromagnet of low gear engagement valve;
YA7 – electromagnet of interwheel differential interlocking valve;
YA8 – electromagnet of power takeoff valve;
YA9 – electromagnet of axle disengagement valve

1 – headlamp wiring harness; 2 – engine wiring harness; 3 – illumination wiring harness; 4 – wire storage batteries-starter; 6 –
wire storage batteries – central fuse; 8 – generator wiring harness; 11 – front dashboard wiring harness; 12 – speedometer wiring
harness; 14 – L.H. dashboard wiring harness; 15 – speedometer power supply wiring harness; 16 – main wiring harness; 18 –
storage batteries connector; 19 – wire storage batteries-“ground” switch; 20 – “ground” connector; 21 – illumination additional
wiring harness; 22 – wiring harness along side member

Color code of wires:

Б – white; Г – blue; ГK – blue-red; ГБ – blue-white; ГO – blue-orange; ГЧ – blue-black; З – green; ЗЧ – green-black; Ж –
yellow; ЖК – yellow-red; К – red; КГ – red-blue; КЧ – red-black; Кч – brown; КчБ – brown-white; О – orange; С – grey; CГ –
grey-blue; Р – pink; РК – pink-red; РЧ – pink-black; Ч – black

140
 Appendix 10

АС-05-24 Air-conditioner mounting

АС-05-24 air-conditioner is installed on the truck. It’s designed to create comfortable conditions in the cab. Air-
conditioner provides air cooling, ventilation and drying.
АС-05-24 air-conditioner hydraulic scheme is shown in figure 10.1.

Fig. 10.1 – АС-05-24 air-conditioner hydraulic scheme

141
 To switch on АС-05-24 air-conditioner:
- start the engine;
- turn the handle «AIR» 1 (Fig. 10.2) of the fan speed switch of evaporator block to the position «1», «2» or «3» (it means
the fan speed), depending on the required airflow;
- to keep the temperature use the handle 2 of the thermostat «TEMP».
To switch off АС-05-24 air-conditioner:
- torn the handle 1 of the fan speed switch of evaporator block to the position «0».

1 –fan speed switch handle;

2 – thermostat handle
Fig. 10.2 – Air-conditioner evaporator block

Fill the АС-05-24 air-conditioner with freon R134A – 1,4 kg and compressor oil EAL Arctic 146458 (surrogate РОЕ 32) –
0,06 l.

142
 Main troubleshooting

Troubleshooting Possible cause Solution

Bad cooling
Evaporator block fan operates, but the
airflow is weak
Air-conditioner does not switch
Noise while the compressor operating
Electric drive does not switch
Clogged or dirty condenser
System filled with excessive or
insufficient
Clogged or dirty evaporator
Blown fuse
Traction of the drive belt
Insufficient coolant pressure in the
system
Bearings worn in the compressor
Circuit breaker tripped
Thermal relay switch
Clean the condenser from dirt and dust
Contact Service Center
Clean the evaporator from dust and dirt
Change the fuse
Adjust the belt tension, change if necessary
Contact Service Center
Contact Service Center
Switch on the circuit breaker
Unblock the the thermal relay

Detailed information about conditioner mounting, maintenance and troubleshooting is given in Operation manual of АС-
05-24 air-conditioner, which is applied to each vehicle.

143