KAMAZ special equipment includes a wide range of heavy-duty vehicles that are equipped with powerful power plants, undercarriage, transmission. Behind the wheel of such a car, increased comfort of movement is felt.
The ZF box is found on trucks manufactured by KAMAZ. Decent power with less fuel consumption is provided by a 9-speed automatic transmission ZF gears. As a rule, it is installed on cars that have front-wheel drive. The presence of this box guarantees the owner of the car to obtain excellent dynamic performance.
It should be noted that at KamAZ an additional divider is used in gearboxes. The gear change in the divider occurs by moving the control valve switch. Thanks to the divider, an increase in the traction of the car is noted, and it is also easier to control.
To ensure the reliability of the transmission system, the maintenance instructions must be observed.
Oil level control
The danger is both an excessive amount of oil in the gearbox, and its insufficient amount. This is often the reason that the ZF fails prematurely. Checking the oil level in the gearbox can be done using the control holes that are present on the box body. Oil change should be carried out with a warm engine. Since the oil is warm, it has an optimal degree of viscosity, therefore, the fuel will pour out faster.
The choice of gearbox oil
What kind of oil is poured into the ZF KamAZ gearbox? Oil can be used as a lubricant domestic manufacturer and well-known foreign brands. Oil options from brands such as Castrol, Mobil are suitable for KamAZ.
What kind of oil to pour? Pay attention to fluids that have a high concentration of extreme pressure additives, such as fuel class GL-4. With frequent use of the car at a negative temperature, you should make a choice in favor of 75 W-80 or 75 W-90.
Mobil 75 W-90 Castrol 75 W-80
How much oil should be added to the KamAZ gearbox with a divider? The required volume is about 9 liters. Usually, this procedure must be carried out every 100,000 km.
In some cases, replacement must be carried out earlier. The need for this arises if heavy vehicles are often operated on construction sites.
In this way, automotive technology KAMAZ has high reliability, good operational qualities. Care of this car system lies in the early diagnosis vehicle. It helps to extend the working life of the gearbox, the selection of high-quality gear oil.
Specifications KPP-154 KAMAZ 154.1700050
Description of the mechanism of the gearbox KAMAZ KPP-154
The -154 ten-speed gearbox (Fig. 38) consists of a main five-speed gearbox (43) and a front two-speed divider gearbox (46).
Main five speed box gears consists of the following main units: crankcase (41) of the gearbox, in which the drive (5), driven (42) and intermediate (40) shafts are assembled with gears, synchronizers and bearings; gear set (21) reversing; top cover (25) of the gearbox with gearshift mechanism assembly. A gear divider (46) is attached to the front end of the gearbox housing.
Shaft bearings are covered with seals. Lid (10) rear bearing the drive shaft with an internal bore is centered on the outer race of the bearing; the surface of the cover, machined along the outer diameter, is a centering surface for the divider housing. The cover 27 of the rear bearing of the driven shaft is attached to the rear end of the gearbox housing and is centered on the outer race of the rear bearing 29 of the driven shaft. In the back of the cover there is a cuff 32 with an anther, on the working edge of which there is a left notch.
In the tides of the right wall of the gearbox housing, a bore is made into which the axis 19 (Fig. 38) of the reverse gear unit is pressed. To prevent it from falling out, the axle is fixed with a lock washer 24 screwed on with a bolt 23 having a hole into which a plastic pin is inserted. Pin seals threaded connection and prevents leakage of lubricant.
Oil is poured into the gearbox through the neck located on the right wall of the crankcase. The neck is closed with a plug with a built-in oil dipstick. At the bottom of the crankcase, a drain plug is screwed into the bosses, a magnet is mounted in the plug, which traps metal particles that may be in the oil. On both sides of the crankcase there are hatches for installing power take-offs. Hatches are closed with covers with sealing gaskets. Hatches are made in accordance with GOST 12323. Permissible power take-off according to 22064, 97 W (30 hp) from each hatch. Power take-off while the vehicle is moving is not allowed.
An oil pocket is made in the upper right part of the rear wall, where the oil is thrown by the rotation of the gears. From the oil pocket, oil through drilling in the crankcase wall enters the cavity of the rear cover of the driven shaft to lubricate the worm pair of the speedometer drive.
The gearbox gears are assembled in pairs with mating gears according to the contact patch and noise level.
Rice. 38
1 - shaft leading divider; 2 - cover of the rear bearing of the divider drive shaft; 3, 9, 30 - adjusting shims; 4 - front roller bearing of the drive shaft; 5 - drive shaft of the gearbox; 6 - ring nut; 7 - washer; 8 - synchronizer clutch; 10 - cover of the rear bearing of the drive shaft of the gearbox; 11 - roller bearing; 18 - gear lever support; 19 - axis of the reverse gear block; 20 - thrust washers; 21 reverse gears; 22 - roller bearing; 23 - bolt with a pin; 24 - lock washer; 25 - top cover; 26 - sealing gaskets; 27 - cover of the rear bearing of the driven shaft; 29 - rear roller bearing of the driven shaft; 31 - speedometer drive worm; 32, 47 - sealing cuffs; 33 - flange fastening nut; 34 - mounting flange cardan shaft; 36 - bearing cover; 37 - roller bearing; 40 - intermediate shaft; 41 - gearbox housing; 42 - driven shaft; 43 - main five-speed gearbox; 45 - wilt gasket; 46 - gear divider; 48 - clutch release fork; 49 - clutch release fork shaft.
Transmission drive shaft(Fig. 39) made integral with the gear; its front support is a roller bearing, the outer ring 4 of which is pressed into the internal cavity of the shaft
Parts 7, 8, 11 are tightened with an annular nut 6, which is locked by punching the belt into the grooves of the shaft (Fig. 38).
Rice. 39 Drive shaft assembly
1 - primary shaft; 2 - kolydo; 3 - inner ring with separator and bearing rollers; 4 - outer ring of the bearing.
Rice. 40
1 - intermediate shaft; 2 - third gear; 3 - fourth gear; 4 - drive gear intermediate shaft; 5 - spacer sleeve; 6 inner ring with cage and bearing rollers.
intermediate shaft 1 (Fig. 40) is made integral with the gear rims of the first, second and reverse gears. At the front end of the shaft, gears 2 and 3 of the third and fourth gears and gear 4 of the intermediate shaft drive are pressed.
driven shaft 16 (Fig. 41), complete with gears and synchronizers, is installed coaxially with the drive shaft.
Rice. 41 Slave shaft in gathering
1 - thrust ring; 2 - front roller bearing; 3 - synchronizer of IV and V gears; 4 - thrust ring; 5-rollers of the IV gear bearing; 6 - bushing of the gear of the IV gear; 7 - gear of the III gear; 8 - roller bearing; 9 - synchronizer of II and III gears; 10 - gear wheel of the 2nd gear; 11 - reverse gear: 12 - clutch for engaging 1st gear and reverse gear; 13 - bushing gear 1st gear; 14 - gear 1st gear; 16 - driven shaft; 17 - reverse gear bushing; 18 - gear IV gear; 19 - spring: 20 - intermediate sleeve; 21 - lock key
Bearing 2 is installed at the front end of the shaft, the outer race of which is installed in the drive shaft (pos. 4 in Fig. 39). All gears of the shaft are mounted on roller bearings, of which the fourth gear gear bearing is loose, without a cage. Gears 18 and 7 of the fourth and third gears in the axial direction are fixed by a thrust ring 4 with internal splines, which is installed in the shaft recess in such a way that its splines are located against the splines of the shaft, and is locked from turning by a spring-loaded lock key 21. Along the axis shaft, a channel was drilled for supplying lubricant through radial holes to the gear bearings. Oil is supplied to the channel by an oil pumping device located on the drive shaft.
For bumpless shifting of the second, third, fourth and fifth gears, there are two finger synchronizers 3 and 9 of the inertial type.
Rice. 43 Shift lock and locks
Rice. 42 gear shift mechanism
1 - plug; 2 - top gearbox cover; 3 - 1 - lock ball; 2 - a glass of a locking ball; 3-
shift fork IV and V gears; 4 - set screw - spring of the locking ball; 4 - lock pin; five -
vochny; 5 - tie wire; 6 - fork pere- ball locking latch,
shifts of II and III gears; 7 - switch fork I
transmission and reverse.
The gearshift mechanism (Fig. 42) is mounted in the upper cover 2 of the gearbox and consists of three rods, three shift forks 3, 6, 7, two rod heads, three clamps (Fig. 43), fuse 2 (Fig. 44 ) engaging the first gear and reverse, as well as the rod lock. The stem lock consists of two pairs of balls 1 (Fig. 43) and a pin. 4. The balls are located between the rods in the bushings, the pin is in the hole in the middle rod between the balls.
Rice. 44 Gear Shift Fuse
1 - fuse spring; 2 - fuse; 3 - fuse pusher
The diameters of the balls and the distance between the rods are chosen in such a way that when any rod is moved from the middle position, the balls leave the holes of the moving rod and enter the holes of the stationary rods, blocking them with the body.
A support 18 (Fig. 38) of the gear lever is installed on top of the shift mechanism cover. On the right side of the support, a set screw is screwed in, which fixes the lever in the neutral position. In working position, the screw must be turned out.
Divider gear(Fig. 45) - a mechanical gearbox, consisting of one pair of cylindrical gears, 2 drive and 11 intermediate shafts, synchronizer 7 and a gear shift mechanism. Pneumatic gear shifting control.
The axial stroke of the drive shaft is regulated by a set of metal gaskets 1 with a thickness of 0.2 and 0.3 mm, installed between the back cover 5 and the outer race of the ball bearing 4. At the end of the shaft, the involute splines for the finger synchronizer are divided into three crowns by two grooves. The teeth of the extreme rims are thinner than the teeth of the middle rim to create a lock that prevents self-disengagement of gears in the divider.
Rice. 45 Gear divider
- 1 - adjusting shims;
- 2 - drive shaft;
- 3 - oil injection ring;
- 4 - ball bearing;
5 - rear bearing cover
shaft;
- 6 - hatch cover;
- 7 - divider synchronizer assembly;
- 8 - gear of the drive shaft;
9 - bearings of the drive gear
shaft;
11 - intermediate shaft; 12- bearing;
- 13 - fork shaft;
- 14 - fork;
- 15 - fork cracker;
- 16 - lever "forks.
The gear 8 of the drive shaft rotates on two roller bearings 9. The oil injection ring 3 supplies oil through inclined drillings of the drive shaft into its internal cavity, from where it enters the channels of the drive and driven shafts of the main gearbox.
The intermediate shaft 11 of the divider with a pressed gear of the intermediate shaft drive rotates on a double roller bearing 12.
The mechanism (Fig. 53) for switching the gear divider is fixed on the divider housing on the left.
Remote control gear box(Fig. 46) consists of a rocking gearshift lever 12, a gearshift lever support 1 mounted on the front end of the engine cylinder block, a rod 3 and a jet rod 7. The rod fork 3 is attached to the lever support by means of the bushing axle 14. The bushing is sealed with rubber rings 10. The axle is cottered onto a package of parts for fastening the gear lever support: studs screwed into the air pipe, vibration isolators 18, steel bushing 20; washers 32 and nuts 26.
Rice. 46
1 - gear lever support; 3 - thrust; 7 - reactive thrust; 10 - sealing ring; 12 - lever; 14 - axis; 18 - vibration isolator; 20 - bushing; 24 - bolt; - 26, 30, 36 - nut; 32 - washer; 45 - ball joint; Zh - stock; E - screw; P - rod; G - lever; K - nuts
(Fig. 47) consists of a bracket 1, a corrugated seal 5 of the hatch, a spring 6 of the seal, a shortened gearshift lever 4, which, with its spherical part, rests on a polyurethane bushing 7, which dampens the vibration of the lever. From above, the sphere is pressed through the support washer by a spring.
Rice. 47
1 - bracket; 3 - cover; 4 - tip lever; 5 - hatch seal; 6 - spring; 7 - polyurethane sleeve.
Rice. 48 Pneumatic scheme
divider control systems
- 1 - gear lever with a control valve switch;
- 2 - pressure reducing valve;
- 3 - power cylinder;
- 4 - air distributor;
- 5 - valve for switching on the gear divider;
- 6 - emphasis;
- 7 - control valve; I - from the receiver;
H, B - the lowest and highest gears in the divider.
Crane 3 control divider(Fig. 49), depending on the position of the spool, directs the air coming from pressure reducing valve, into one of the cavities under the air distributor pistons 6 and moves the air distributor spool to one of the two extreme positions, thus preparing the air supply to cavity A or C of the power cylinder. Pre-selection of the gear in the divider is made by moving the valve switch lever to position B or H, which moves the valve spool through a braided cable.
Rice. 49 Gear divider control valve
1 - crane cable with spool: 2 - bolt; 3 - cover of the crane body; 4 - comfort pad; 5 - crane body; 6 - connecting nut.
Rice. fifty
1 - locknut; 2 - spring washer; 3 - cable tip; 4 - restrictive sleeve; 5 - comfort ring; 6 - valve spool; 7 - crane cable
Rice. 51 pressure reducing valve
1 - spring housing; 2 - spring inlet valve; 3 - gasket- Rice. 52 Level indicator position
ka; 4 - inlet valve; 5 - inlet valve stem; 6 - body; 7 oils when measuring
union nut; 8 - membrane; 9 - washer; 10 - housing cover; 1-oil level gauge with plug; 2-
11 - balancing spring; 12 - cork; 13 - washer gearbox housing
adjusting.
Maintenance of the gearbox KAMAZ KPP-154
Adjustment of the gap between the end face of the cover and the stroke limiter of the valve stemto switch on the divider hold in next order:
- - check the adjustment of the clutch release drive and, if necessary, adjust;
- - unlock and unscrew stop nuts 2 (Fig. 48) of the valve stem located on the pusher of the pneumatic booster piston. Connect a pressure gauge to the control terminal of circuit IV of the auxiliary brake actuator of the pneumatic brake actuator. Bring the pressure in the indicated circuit to 7 ... 7.5 kgf / cm 3.
- - smoothly press the clutch pedal to the stop;
- - bring the stop of the valve stem of the switch on the divider to contact with the valve stem limiter and additionally move it towards the valve stem, ensuring a gap between the end face of the valve cover and the stem limiter of 0.2 - 0.3 mm. Fasten the stop of the valve stem in the indicated position with nuts and lock them with folding washers. When the pressure drops in the IV circuit of the auxiliary brake system drive to 6.2 kgf / cm2, the gap can be increased to 0.6 mm. Check the gap after no more than s after disengaging the clutch;
- - install a rubber dust protector on the stem and valve cover.
To check the oil level in the gearbox housing, unscrew the plug from the oil filler neck, wipe the pointer dry and insert it into the filler hole until the plug stops in the thread (Fig. 52), without wrapping.
For oil change in the gearbox, drain the hot oil through three drain holes by unscrewing the plugs located in the lower part of the gearbox housings and in the lower part of the gear splitter housing. Clear magnets drain plugs from dirt and metal particles. Rinse the crankcases of the box and divider with engine oil. To do this: pour oil into the gearbox (12 l), rotate it with the engine in the neutral position of the gear lever for 10 minutes, drain motor oil from the gearbox and divider, screw in the drain plugs and fill in the main lubricant TSp-1.5K to the upper mark of the level indicator. Scroll the gearbox with the engine in the neutral position of the gear lever for 3-5 minutes. Measure the oil level and top up if necessary.
Repair of the gearbox KAMAZ KPP-154
To check the pressure reducing valve of the divider, remove it from the gearbox and install it on a stand, which must be equipped with a pneumatic system with an air pressure of 6 ... 7 kgf / cm2, supplied to the valve inlet. for pressure control, providing measurement accuracy of at least 0.05 kgf/cm.
Check the pressure of the outgoing air, which should be 3.95...4.45 kgf/cm". .
To remove and disassemble the divider control valve during repair, unscrew the bolts securing the three air ducts, disconnect the divider control valve 3 (Fig. 48) from the support, unscrew the screws securing the cable clamp to the gear lever, remove the rubber bushing from the hatch seal support housing, unscrew the fastening screws switch cover of the control valve, carefully remove the cover with latches and spring, paying attention to the safety of the balls, and disconnect the cable from the switch lever.
In case of partial disassembly: unscrew the bolts 2 (Fig. 49) fastening the cover 3 with the cable to the valve body 5, wash the parts of the valve and lubricate the working surfaces of the parts with grease 158. Assemble the control valve. Pull the cable to the stop and measure the part protruding from the braid. In this case, the cable must be in a straightened position. The value of the protruding part of the cable (before bending) is 24.5 ... 26.5 mm. Lubricate cable 1, pour 10 ... 15 g of TSp-15k oil into the cable sheath using an oiler. If the cable breaks or the size of the protruding part of the cable does not correspond to the nominal one (24.5 ... 26.5 mm), the crane must be completely dismantled and the cable replaced. To do this, disconnect the cable of the valve with the cover 3 in the assembly, as indicated above, straighten the bent end of the cable 1, unscrew the union nut 6 and pull the cable with the spool assembly out of the sheath. Then unscrew the lock nut 1 (Fig. 50), unscrew the tip 3 of the cable from the spool 6. Insert a new cable into the spool. Screw the tip of the cable, ensuring the axial movement of the assembly cable must rotate freely relative to the cable by hand. Assemble the control valve.
When checking the pneumatic system for leaks Locate the air leak by ear. Alternately moving the control switch to the HIGH GEAR or LOW GEAR position, listen to the air ducts of the splitter control pneumatic system, and pressing the clutch pedal all the way, listen to the air ducts of the splitter switching system.
Eliminate the detected leak by tightening the bolts or replacing the sealing washers and faulty air ducts.
Gear regulation gear couplings synchronizer The gear divider should be carried out with compressed air supplied to the pneumatic system and the divider switch-on valve pressed all the way as follows:
- - remove the seals, unlock and unscrew two set screws 1, 5 (Fig. 53) on the housing of the divider gear change mechanism and remove cover 3 of the inspection hatch;
- - move the spool of the divider control valve to the LOWER GEAR position and, screwing in the rear set screw 5 until it touches the lever, tighten it another 1/4 turn and lock it with locknut 4. In this position, the drive shaft (with the gearbox removed) must turn by hand easily, without jamming;
Move the spool of the divider control valve to the HIGH GEAR position
Adjust the engagement with the front set screw 1 as above;
Through the inspection hatch in the gear shift housing of the divider, check
working stroke of the lever until it stops in the set screws (16.5 ... 19 mm in the center of the hole in the lever
ge);
Set screws 1, 5 lock and seal.
Rice. 53 Divider Gear Shift Mechanism
1.5 - set screws;
2 - housing of the switching mechanism;
- 3 - cover of the inspection hatch;
- 4 - locknut;
6, 17 - sealing rings; 7 - cylinder cover; 10, 16 - sealing gaskets;
- 11 - air distributor piston;
- 12 - air distributor cylinder; 1.4 - air distributor spool; 15 - air distributor housing;
18 - plug
When repairing remote drive gearbox control for effort reduction when shifting gears, replace the grease in the drive bearings and spherical heads of the swivel joints of the levers. Pump fresh grease into the bearings through the grease fittings, screwing them in instead of the plugs in the bearing housings.
If, after lubricating the bearings, the force on the lever during gear shifting has not changed or has not decreased sufficiently, disassemble the bearings in the following order:
Remove the adjusting flange mounting bolts; unscrew the mounting bolts of the support on the clutch housing;
- - take off rubber boot swivel, pay attention to the safety of the restrictive ball and spring;
- - disconnect the front link head, pay attention to the safety of the ball and spring;
- - remove the shift lever support located on the front end of the block, as described below. Remove crackers, bushings, spring from the support housings.
Rinse parts and cavities of supports with kerosene or diesel fuel, replace worn O-rings. When assembling, lubricate the rubbing surfaces with grease 158; lay down, fresh grease in the cavity of the bearings. After assembly, adjust the remote drive.
To regulate the remote drive control of the switching mechanismgears:
The adjustment of the drive for controlling the gear shift mechanism is carried out during the assembly process;
Fix rod G, screw in screw E (Fig. 46);
Fix the rod 3 with a technological rod P in det. item 1.
Install lever 12 at an angle D to the vertical.
Screw the hinge 45 ball rod 3 to align the axis of the conical pin with the axis of holes. in lever 12.
Rotating children. And jet thrust 7 install the lever G and thrust 3 in a vertical plane
Tighten nuts 30 and K.
Pull out screw E to the specified length and lock it with a nut.
Remove pin P.
For removing and disassembling the shift lever support tilt the cab, remove the soundproof cover of the gear lever, the parts of the support seal, disconnect the air ducts of the divider pneumatic system, the generator mounting bracket, the control rods and cables fuel pump, remove the front link head, unscrew the bolts securing the support bracket to the engine and remove the support, disconnect the divider control valve and the gear lever.
Disassemble the support, wash the parts, lubricate the rubbing surfaces with grease 158. Fill the cavity of the support with grease 158. After assembly, the tip of the lever must turn in mutually perpendicular directions with a force of 24.5 ... 34.3 N (2.5 ... 3.5 kgf ) applied to the conical surface of the tip of the lever.
Rice. 54 Fixture for
leading centering
gear divider shaft
1 - fixture body; 2 - mounting plate; 3 - mounting pin; 4 - set screw; 5 - bolt; 6 - bushing; 7, 13 - springs; 8 - glass; 9 - centering cone; 10 - drive divider shaft: 11 - clamping lever; 12 - thrust washer; 14 - pin; 15 - clamping washer.
To adjust the gaps between the splitter synchronizer carriage and the splitter shift fork crackers, remove the cover 6 Fig. 45) inspection hatch of the divider crankcase. Loosen and unscrew the two bolts of the gearshift fork in the divider so that the shaft 13 with the lever 16 mounted on it moves freely in the axial direction, remove the divider shift mechanism.
Center the divider drive shaft 2 with a special device, which consists of a housing with centering devices and two clamping levers. To do this, insert the 9" centering cone (Fig. 54) into the inner cone of the divider drive shaft, fixing the fixture on the divider housing by turning the clamping levers 11. Locating pins 3 at this center the accessory relative to the surface B, providing an offset axes shaft no more than 0.2 mm.
Move the fork 14 (Fig. 45) to the right until the cracker 15 stops in the synchronizer carriage 7. By moving the roller 18 with the lever 16 fixed on it to the right, provide a gap of 0.3 ... 0.6 mm, for which between the mating plane of the divider housing under the body of the gear shift mechanism and the head of the lever 16 place the mounting plate 2 (Fig. 54) with a thickness of 0.3-0.5 mm. Move the roller until the lever head stops against the plate. Screw in and lock the fork mounting bolts with folding washers. Reinstall the gearshift mechanism and inspection cover 6 (Fig. 45).
To disassemble the gearbox:
- - disconnect divider 46 (Fig. 38) from the gearbox;
- - disassemble the gearbox in the following order: unscrew the bolts securing the upper cover 25 of the gearbox and, screwing two bolts into special threaded holes in the cover (after unscrewing the plugs from them), remove it; unscrew the nut 33 of the propeller shaft flange and remove the flange, remove the front and rear bearing caps of the drive 5, driven 42 and intermediate 40 shafts, screwing the mounting bolts into special
holes in the covers (when removing the covers, pay attention to the safety of the gaskets); unlock and unscrew the two bolts securing the thrust washer of the rear bearing of the intermediate shaft; remove the rear bearing 29 of the driven shaft with pullers, for this use a special grip. Install grip 8 on bearing groove and tighten with nuts I . Screwing the screw 4 into the traverse 6 and resting the tip 3 against the end of the shaft, remove the bearing.
To disassemble the gear divider: remove the cover 6 of the inspection hatch (Fig. 45), the bearing caps of the drive and intermediate shaft divider; take out the drive shaft 2 of the divider, having previously turned it with a flat on the conical ring of the synchronizer down to the gear of the intermediate shaft drive, remove the synchronizer, unlock and unscrew the fastening bolts with the thrust washer of the bearing 12; press the intermediate shaft 11 of the divider out of the bearing, remove the bearing 12 from the housing; take out the intermediate shaft 11 of the divider; un-stop and unscrew the two bolts securing the gear shift fork; take out the shaft 13 with the lever 16 and remove the fork 14 from the divider housing.
Rice. 55 Withdrawal front bearing driven shaft
1 - capture; 2 - nut; 3 - screw; 4 - tra-versa; 5 - tip; 6 - bearing.
For disassembly of the driven shaft of the gearbox remove the thrust ring 1 (Fig. 41) and the front bearing 2 of the driven shaft, to do this, use the grip, install it on the bearing and tighten it with nuts 2. remove the bearing, then the synchronizer of the fourth, fifth gears, the thrust ring 4 (Fig. 41) of the fourth gear. To do this, it is necessary to remove the locking key 21 from the washer groove and turn it until the slots of the washer and the shaft coincide; remove gear 18 of the fourth gear with rollers 5 bulk bearings; compress the sleeve 6 of the fourth gear, remove the locking key 21 with the spring 19; remove gear 7 and bearing 8 of the third gear, synchronizer 9 of the second and third gears; gear 14 and the bearing of the first gear, the clutch 12 for engaging the first gear and the reverse gear, pressing the splined sleeve 13 of the first gear, remove the gear 11 and the bearing of the reverse gear, pressing the sleeve 17 of the reverse gear; Remove gear and second gear bearing.
To disassemble the gearbox top cover: unscrew the nuts and remove the supports of the gear lever, remove the cups 2 (Fig. 43), springs 3 and balls 5 of the clamps; unpin and unscrew the set screws 4 (Fig. 42) fastening the forks and rod heads, knock out three plugs 1, remove the gearshift rods, knock out the plugs of the rod lock, remove the balls 1 (Fig. 43) from the cover and the pin 4 of the locking device from middle stock; unscrew the spring cup and remove the spring 1 (Fig. 44), fuse 2 and fuse sleeve.
Assembly is carried out in the reverse order of disassembly, taking into account the following features:
When installing gears in a gearbox without replacing them, do not dismantle the gears that have been worked to each other;
When installing gears from the spare parts, mating gears are required
complete according to the contact patch and the noise level on gear-rolling machines. Location
contact patches must correspond to Fig. 56. Desirable location of the contact patch in
dividing circle zone.
When checking pairs of gears on gear-rolling machines with and without braking of the driven gear, the noise should be even, low-pitched, without tapping and grinding.
High-pitched noise is not allowed:
- - to install the rear bearing of the intermediate shaft with a glass on the shaft installed in the gearbox and pressed by the front cover, use the I801.31.000 puller. To do this, install washer 8 on the tip 4 (Fig. 57), pass the bolts 9 through the holes in the cup, screw them into the threaded holes on the gearbox housing until they stop. Resting washer 8 against the bearing, screw the screw 6 into the plate 5 until the glass with the bearing is fully installed;
- - when assembling the driven shaft, pay attention to the correct installation of bearing bushes 6, 17 and 13 (Fig. 41). The holes on the bushings must be aligned with the radial holes on the corresponding necks of the driven shaft; when assembling the bulk bearing of the fourth gear, 88 rollers should be laid in two rows with an intermediate sleeve 20 installed between the rows; when installing the front bearing 2 of the drive shaft, the attachment ring must be installed inward to the end of the shaft;
- - when pressing gear 3 (Fig. 51) of the intermediate shaft drive of the gearbox and the gear of the intermediate shaft of the divider, they must be heated to a temperature of 90 °C;
- - pay attention to the serviceability of the synchronizers of the gearbox and the divider. The static force for moving the carriages out of the neutral position should be 275 ... 373 N (28 ... 38 kgf) for both synchronizers of the main box, for the divider synchronizer 589 ... 687 N (60 ... 70 kgf) . The blocking chamfers of the crankcase and fingers must not show signs of significant wear.
Rice. 57 Rear intermediate bearing installer 1 - glass; 2 - bearing; 3 - emphasis; 4 - tip; 5 - plate; 6 - screw; 7, 9 - bolts; 8 - puck.
Rice. 58 Axial regulation gear shaft clearance and divider
4 - gearbox housing or a, b, c, d - adjusting dimensions After assembling the driven shaft of the gearbox, the end clearances on the hubs of the gears of the first, second, third gears and reverse gear should be within 0.27 ... 0.4 mm; on the fourth gear hub - 0.265 ... 0.515 mm. End clearance on the hub of the drive gear of the drive shaft of the gearbox divider should be within 0.375 ... 0.715 mm; |
- - before docking the divider with the gearbox, adjust the gap between the divider shift fork cracker and the synchronizer carriage;
- - when installing the bearing caps of the drive shafts of the gearbox and the divider, as well as the cap of the driven shaft, ensure minimum shaft play by selecting shims, for this: measure the absolute size with an accuracy of 0.05 mm but(Fig. 58) from the end of the outer ring of the bearing 6 to the plane of the crankcase 4 with the bearing 6 pressed to the stop.
For the covers of the drive shafts of the divider, for the cover of the driven shaft of the gearbox, put the sealing gasket 3 on the mating surface of the cover 2, measure dimension b with an accuracy of 0.05 mm, determine the required total thickness from adjusting shims 1, which should be less than the difference (b-c) by 0.2 ... 0.4 mm. After selecting the required number of shims, install the cover.
Install the cover of the drive shaft of the gearbox without sealing gaskets, while the dimension d from the mating surface of the cover to the shims should be provided d \u003d (a ... a + 0,l) by selecting the number of shims;
- - before installing fasteners and covers, apply an even layer of Anaterm-4 sealing composition and two or three turns of through threaded holes in the crankcases, and also apply it with a continuous strip 2-3 mm wide along the contour on both sides of the gaskets, front covers of the intermediate the shaft of the gearbox divider, the rear cover of the pro-intermediate shaft of the gearbox, the covers of the power take-off hatch and on the gasket of the gear divider housing;
- - lubricate the working edges of the sealing collars of the drive and driven shafts, the friction surfaces of the spools of the shift valve and air distributor, the valve for switching on the divider, as well as the collar of the gearshift mechanism of the divider with grease 158.
After assembly, when the input shaft is rotated by hand, the shafts and gears of the gearbox should rotate freely (without jamming) both in the neutral position of the gear lever and in any gear engaged (regardless of the gear engaged in the gearbox divider).
The rod locks of all gears must clearly fix the rods in the neutral position and in the gear engaged position. Reverse gear and first gear should only be engaged with the reverse gear mounted in the top cover depressed.
Simultaneous engagement of two gears and oil leakage from the gearbox are not allowed.
When the clutch fork shaft is rotated by hand, the clutch release clutch must move freely (without sticking) along the entire length of the drive shaft guide cover.
Check for tightness the connections of the air ducts of the pneumatic control system of the divider, installed on the model 15 gearbox, with compressed air at a pressure of 588 kPa (6 kgf/cm2) connected to the pressure reducing valve; at the same time, use a technological divider control valve; in both positions of the divider control valve and the divider activation valve pressed to the stop (stroke 6 mm), the pressure drop in the air cylinder is allowed no more than 147 kPa (1.5 kgf / cm2) for 40 s.
Adjust the engagement of the divider synchronizer gear couplings.
All repaired and assembled gearboxes must be tested on a special stand.
test bench must have the following equipment:
A device that provides two modes of rotation speed of the input shaft: 1300
min "1 and 2600 min" 1;
clutch connected to the gearbox input shaft and disengaged when changing gears. The moment of inertia of the driven parts of the clutch must not exceed 12.7 Nm / cm (1.3 kgf-m / cm ");
- - braking device, connected to the driven shaft and providing a braking torque of 49.1 N-m (5 kgf-m) for first gear and reverse gear and 98.1 ... 147 N-m (10 ... 1.5 kgf-m) for other transfers;
- - a device that measures the moment on the driven shaft;
- - pneumatic system for switching the divider. The air pressure in the pneumatic system should be 588.. .686 kPa (6.. .7 kgf/cm2);
- - instruments for measuring the noise level. To lubricate the gearbox during testing, use engine oil heated to a temperature of 85 °C.
Gearbox testing should be carried out in two modes; no load and under load. When testing without load, check the operation of the divider and the inclusion of gears. Gearbox test modes are given in the tables.
Model 154 gearbox test mode without load
After testing, drain the gearbox oil while it is still hot. At the same time, clean the drain plug magnets from metal deposits. When installing the gearbox on the engine:
Check the condition of the drive shaft using a control splined mandrel with a height of at least 30 mm, which should move freely (without jamming) along the splines of the shaft, then lubricate the splined end with a thin layer of grease 158;
Do not allow sharp blows, and do not load the clutch discs with the weight of the gearbox or the force of the lifting mechanism in order to avoid breakage of the clutch and the front bearing of the input shaft located in the crankshaft;
- - after installing the gearbox, check the full travel of the clutch release clutch, equal to 35-43 mm. This move corresponds to the movement of the lever by 40-50 mm, measured at a radius of 90 mm;
- - before installing the remote mechanism, lubricate the working surfaces of the heads and the rod bearings with grease 158. Install the heads of the mechanism and tighten with coupling bolts. Swinging of the heads on the rods is not allowed. Sealing covers of the heads of the rods of the remote mechanism must tightly cover the seating surfaces. When shifting gears using a remote mechanism, sticking of the rods in the supports is not allowed. The gearshift locks must be clearly felt both in neutral and in any gear in the gearbox;
- - pour 12 liters of TSp-15K oil into the gearbox and carry out a three-fold check for starting the engine with a starter. In this case, the clutch must be turned off;
- - check the correct installation of the clutch and gearbox on a running engine at a speed of crankshaft 1800-2000 min "1, after checking:
- 1. No jamming of parts of the clutch release mechanism.
- 2. The cleanliness of the clutch release. To do this, completely disengage the clutch, ensuring that the clutch release clutch travel is no more than 12 mm. This corresponds to a lever travel of 16 mm measured over a radius of 90 mm. In this position, the first gear and reverse gear should be included without grinding, and when the direct gear is engaged, the driven shaft should not rotate. Repeat the test at least three times.
- 3. The noise of the gearbox (sharp uneven noise and knocking is not allowed).
- 4. Gear shifting in the main box. Gear shifting should be carried out with the clutch disengaged without much effort and without jamming, the inclusion of synchronized gears with a rattle is not allowed. In the gearbox, gear shifting is carried out on the lower and higher gears of the divider.
- 5. Divider gear shifting. To do this, supply compressed air at a pressure of 490 ... 588 kPa (5 ... 6 kgf / cm2) to the pressure reducing valve and make two or three gear shifts of the divider, sequentially moving the control valve switch to the upper and lower positions and moving to 6 mm valve stem for switching on the divider, after disengaging the clutch. The gearshift of the divider should be clear, without delay. Re-shifting the divider gear without disengaging the clutch is not allowed. With both positions of the divider control valve switch, check the tightness of the connections and the valve.
- 6. No oil leakage. Oil leakage is not allowed. The formation of oil stains without drop formation is allowed in the places of stuffing box seals and the installation of breathers.
NOTE: In the absence of a stand, test the gearbox on an unloaded vehicle on level ground. The gearshift procedure and the driving time in each gear according to the gearbox test table under load at an engine crankshaft speed of 1400 ... .1800 min ".
When testing gearboxes, check:
Ease of gear shifting. When switching the second, third, fourth and fifth
that gear grinding is not allowed. Reverse gear and first gear included
start only when the shafts are stopped;
- - moment on the driven shaft. At a drive shaft speed of 2600 min, the torque on the driven shaft should not exceed 9.81 Nm (1 kgf-m);
- - automatic disengagement of gears (not allowed);
- - the presence of sharp uneven knocks, indicating malfunctions of components and parts (not allowed).
Removing the gearbox from the car and installing itTo remove the gearbox:
Drain the oil from the gearbox housing. Tilt the cab, remove the board floor panels
forms to provide access to the gearbox; disconnect rechargeable batteries from
electrical circuit, disconnect the terminal connecting the mass switch to the frame of the car
beat (the conclusion is on the battery box); disconnect and remove the wire, connect-
starter relay with battery + terminal.
Remove the hose connecting the engine inlet pipe to the air cleaner connecting pipe by unscrewing the nuts and removing the bolts of the coupling clamps; disconnect the plug connections of the tachometer, speedometer, trailer socket, brake signal switch on sensor, reversing headlight, pressure drop indicator sensors in the receivers; disconnect the brackets for attaching the muffler to the divider housing;
- - remove the clutch hydraulic booster;
- - disconnect the flange-fork of the cardan shaft of the middle axle from the flange of the driven shaft of the gearbox by unscrewing the nuts of the fastening bolts, remove spring washers and take out the bolts; loosen the clamping bands and remove the connecting hose of the ejector pipe; disconnect the air ducts from the control valve brake mechanisms trailer with two-wire drive;
- - loosen the bolts of the front supports of the power unit; unscrew the nuts of the bolts of the rear engine mounts and remove the bolts;
- - unscrew the bolts of the supporting support beam to the frame;
- - To turn out bolts of fastening of the supporting support of a transmission to a cross beam;
- - hang the power unit by the eye bolts of the gearbox; place wooden blocks under the front and rear halves of the second frame cross member and lower the power unit (the thickness of the bars should be such that when the power unit is lowered, the rear support brackets are 50 mm higher than the rear support cushions);
Align the coupling bolt of the lever of the front linkage of the gearbox control drive;
-disconnect the front link with the lever, remove the rubber boot, remove the ball and spring
zhina from the ball head of the lever tip;
Disconnect the three bolts of the divider control air ducts from the block
from the engine side, align the starter mounting bolts;
Install the chain grips of the lifting device by the eyebolts on the gearbox, unscrew the bolts securing the clutch or divider housing to the engine flywheel housing; take the gearbox back until the drive shaft exits the clutch housing, remove it and install it on the trolley.
To install the gearbox.
Before docking the gearbox with the engine, put 15 g of grease 158 into the cavity of the front bearing of the drive shaft, located in the bore of the crankshaft; lift the gearbox and install it in place, having previously installed the clutch, a hose for supplying lubricant to the thrust bearing and release springs.
Screw in the bolts securing the divider housing to the engine flywheel housing. Screw in the starter mounting bolts; connect the divider control pipelines to the connecting block. Connect the front link to the lever, after inserting the ball and spring into the ball head of the lever; screw in the coupling bolt of the front linkage lever of the control drive
gear mechanism. Adjust the remote drive for controlling the gear change mechanism.
Hang the power unit by the eye bolts of the gearbox.
Screw in the bolts securing the gearbox support to the cross beam, remove the wooden blocks from under the second cross member of the frame, and lower the power unit onto the supports; to screw bolts of fastening of a beam of the supporting support to a frame; insert the bolts into the holes of the rear supports of the power unit, tighten the self-locking nuts.
Tighten the power unit front mounting bolts.
Connect the air ducts to the trailer brake control valve with a two-wire drive; put on the connecting hose of the ejector pipe and secure it with straps.
Align the holes in the yoke flange of the propeller shaft of the middle axle with the holes in the flange of the gearbox output shaft; insert bolts into the holes, put on spring washers, tighten the nuts. Install the clutch air booster.
Attach the muffler mounting bracket to the gearbox housing by screwing in the bolts.
Connect the plug connectors of the tachometer, tachograph (speedometer), semi-trailer socket, brake signal switch sensor, reversing headlight, pressure drop indicator sensors in the receivers.
Put on the hose connecting the engine intake pipe to the air cleaner connecting pipe; put on the clamps and fix the hose by inserting bolts into the holes of the clamps and tightening them with nuts; connect the wire connecting the starter relay to the "+" terminal of the battery; connect the ground switch lead to the vehicle frame (the lead is located on the battery box); connect the batteries to the electrical circuit of the vehicle. Install floor panels.
Pour oil into the gearbox housing. Lower the cab.
Check and, if necessary, adjust free play clutch pedals.
Possible malfunctions of a transmission 154 and ways of their elimination |
|
Cause of malfunction |
Way eliminate |
Difficulty engaging all gears, including reverse gear and first gear with a screech |
|
Partial disengagement of the clutch (clutch "ve-det") |
Adjust clutch release free play |
Great force on the gear lever |
|
Contamination of rod bearings remote control. Missing or thickened lubricant |
Rinse the bearings and fill them with fresh grease 158 |
Inclusion of the second, third, fourth, fifth gears with impact and rattle |
|
Wear of the conical synchronizer rings, blocking chamfers of the fingers and the carriage. Underestimated effort to bring the carriages out of the neutral position |
Replace synchronizer |
Engagement of gears in the divider with impact and rattle |
|
Increased pressure in the pneumatic control system of the divider |
Adjust pressure reducing valve |
Reducing valve diaphragm rupture |
Replace membrane |
Wear of the conical synchronizer rings, blocking chamfers of the fingers and the carriage |
Replace synchronizer |
Cause of malfunction |
Remedy |
Deterioration of crackers of a shift fork of a divider |
|
Lack of air discharge into the atmosphere when shifting gears in the divider due to contamination of the air channels and the breather of the valve for switching on the gear divider. |
Disassemble the valve and wash all its parts, including the breather. When assembling the valve, lubricate all friction surfaces with grease 158 |
No gap between synchronizer carriage and shift fork su-harem |
Adjust gap |
Spontaneous gear shifting while driving |
|
Incomplete gear engagement due to a malfunction of the shift mechanism locks, wear of the fork legs or crackers, loosening of the forks and levers, misalignment of the remote control |
Tighten the mount, replace worn parts, adjust the control drive |
The lock of the spline of the driven shaft does not work |
Replace the shaft and the corresponding synchronizer |
Gear not included |
|
Wear of parts and misalignment of the remote drive control box |
Adjust the drive and replace worn parts, tighten fasteners |
Destruction of the bearings of the driven shaft gears |
Replace defective parts |
Gears in the divider do not turn on |
|
Seizure of air distributor pistons |
Disassemble, wash and lubricate with grease 158 parts of the air distributor |
The position of the valve stop for switching on the divider is misadjusted |
Adjust valve stop position |
Valve stop failure |
Stop replace |
Clogging of the pneumatic control system of the divider |
Rinse and blow out the throttle, air lines and valves |
Breakage of the divider control net cable |
Rope replace |
Increased noise during gearbox operation |
|
Increased wear or breakage of gear teeth. Destruction of gear bearings |
Replace defective parts |
Destruction of shaft bearings |
Replace defective parts |
Oil leak from gearbox |
|
Wear or loss of elasticity of seals |
Replace seals |
Increased pressure in the crankcase |
Rinse the breather |
Violation of tightness on sealing surfaces |
Tighten fasteners or replace gaskets |
Deterioration of brass rings of synchronizers of the main gearbox |
|
Incomplete clutch disengagement when shifting gears |
Replace synchronizers. Check the operation of the clutch and drive |
Deterioration of brass rings of gear divider synchronizers |
|
The position of the valve stop for switching on the gear divider is not adjusted |
Replace synchronizer. Adjust the position of the valve stop for switching on the gear divider |
Incomplete clutch disengagement |
Check the operation of the clutch and drive |
Oil in box KAMAZ
For proper and durable operation, machine components need to be lubricated over time, so we will consider how much and how much oil is in a KAMAZ box with a divider and without the need to fill.
The volume of oil in the old version of KAMAZ KAZAZ. five-speed without a divider, is 8.5 liters. Check the lubrication level, which should be carried out as often as possible and at least once a month. Once a year, the oil must be completely changed at the KAMAZ crossing, provided that the mileage does not exceed 90,000 kilometers. When this figure is reached, the replacement should be performed earlier. For vehicles operating in complex modes, this figure is halved. This is due to the rapid development of the oil resource with frequent shift speeds, as well as long-term operation in low gears. The oil at the KAMAZ checkpoint is checked using an indicator attached to the filler cap. In ZF-KAMA production rate distribution mechanisms, level control is carried out through control holes located on the crankcase.
The presence of a divider increases the amount of oil used in the KAMAZ transmission. 10 speed gearboxes require 12 liters of gear oil. His replacement. a simple process, so most drivers know how to change the KAMAZ oil transmission.
Read also
This procedure is performed as follows. First, the filler plug is unscrewed. Then two drain plugs are unscrewed at the bottom of the crankcase. In units equipped with a divider, it is necessary to remove the plug from the crankcase. Before draining, start the engine and warm it up butter to reduce its viscosity. Since drain plugs are equipped with magnets to hold metal particles, they should also be thoroughly cleaned.
Changing the oil and filter in the gearbox ZF 16S Intarder
00:52 Drain butter 02:19 Removing the filter 03:59 What is an Intarder? 05:06 Chip collection magnet 05:17.
Read also
ZF 16S151-Ecosplit for KamAZ. Using the box correctly
ZF Our dear and beloved KAMAZ has been cooperating with German for a long time.
The mechanisms of the Kama plant are unpretentious, so truck owners use domestic oil in transmission KAMAZ 5320 or 6520. For this, the brand TS-15K or all-weather MT-16p is used. Concern "LUKOIL" produces an excellent transmission TM-5 SAE 80W-90. It is important to consider weather conditions when using the transmission. In hot climates, more viscous grades should be used. 85W-90, in severe frosts. more liquid. 75 W-90. To increase the service life, it is recommended to use Shell Spirax S6 AXME, Castrol Syntrax Long Life, Esso Gear Oil GX.
How many liters of oil are on the KAMAZ line produced by the ZF-KAMA joint venture? To lubricate these blocks, 8 liters of grease is sufficient for ZF 9S1310 and ZF 16S151, and for ZF 16S181. 10 liters. Replacement numbers, more needed for first fill. For these modifications, these are 9, 11 and 13 liters.
Oil in ZF transmission at KamAZ
The instructions for use determine which oil should be poured into ZF KAMAZ. Lubricants domestic production have a lower price, but for use in expensive imported cars, it is better to use branded oil in a ZF gearbox on KamAZ. For these purposes, choose Titan Cytrac Man Synth 75W-80 or Titan Cytrac LD 75W-80. Both Castrol EP 80W and Mobil GX-A 80W are ideal. The quality of the oil in the gearbox will extend the life of the gearbox and reduce wear on parts. That's why the best choice is the use of oil in the KAMAZ box specified in the specifications for this box. These classes. GL-4 and MIL-L2105. Viscosity is also determined by the temperature conditions of the medium. For a cold climate 75 W-90 (80), for the middle lane. 80 W-90, and for hot weather. 85 W-90. 
Onboard tractors produced by the Kama Automobile Plant: KamAZ-5320 since 1976, KamAZ-53212 since 1979. Designed to work mainly with trailers. The body is a metal platform with opening side and rear sides. The flooring is wooden, the installation of an awning is provided. The cabin is a three-seater, reclining forward, with noise and thermal insulation, equipped with places for attaching seat belts, for KamAZ-53212 - with a berth. The driver's seat is sprung, adjustable according to the driver's weight, length, backrest inclination.
Main trailers: for KAMAZ-5320 - GKB-8350 and -8355; for KAMAZ-53212 - GKB-8352 and -8357.
Modifications:
car KAMAZ-5320 - chassis KAMAZ-53211 and tropical version - KAMAZ-532007;
car KAMAZ-53212 - chassis KAMAZ-53213 and tropical version - KAMAZ-532127.
On the diagram of the KamAZ-53212 car, the dimensions for the aluminum platform are given in brackets.
SPECIFICATIONS
| Model | KAMAZ-5320 | KAMAZ-53212 |
|---|---|---|
| Load capacity, kg | 8000 | 10000 |
| Curb weight, kg | 7080 | 8000 |
| Including: | ||
| to the front axle | 3320 | 3525 |
| on the trolley | 3760 | 4475 |
| Gross weight, kg | 15305 | 18225 |
| Including: | ||
| to the front axle | 4375 | 4290 |
| on the trolley | 10930 | 13935 |
| Permissible trailer weight, kg | 11500 | 14000 |
| Gross train weight, kg | 26805 | 32225 |
| Max. vehicle speed, km/h | 80 | 80 |
| The same, road trains | 80 | 80 |
| Vehicle acceleration time up to 60 km/h, sec. | 35 | 40 |
| The same, road trains | 70 | 90 |
| Max. the overcome rise by the car, % | 30 | 30 |
| Same, road train | 18 | 18 |
| Vehicle run-out from 50 km/h, m | 700 | 800 |
| Stopping distance of a car from 60 km/h, m | 36,7 | 36,7 |
| The same, road trains | 38,5 | 38,5 |
| Control fuel consumption, l / 100 km of the car: | ||
| at 60 km/h | 23,0 | 24,4 |
| at 80 km/h | 29,6 | 31,5 |
| The same, road trains: | ||
| at 60 km/h | 32,5 | 33,0 |
| at 80 km/h | 43,7 | 44,8 |
| Turning radius, m: | ||
| on the outer wheel | 8,5 | 9,0 |
| overall | 9,3 | 9,8 |
Engine
Maud. KAMAZ-740.10, diesel, V-o6p. (90°), 8-cyl., 120x120 mm, 10.85 l, compression ratio 17, operating order 1-5-4-2-6-3-7-8, power 154 kW (210 hp) at 2600 rpm, torque 637 Nm (65 kgf-m) at 1500-1800 rpm. Injectors - closed type, TNDV - V-shaped, 8-section, spool type, with a low-pressure fuel priming pump, a fuel injection advance clutch and an all-mode speed controller. Air filter- dry, with a replaceable cardboard filter element and a clogging indicator. The engine is equipped with an electric torch device (EFD) and (on request) starting preheater PZhD-30.
TransmissionThe clutch is double-disk, with peripheral springs, the release drive is hydraulic with a pneumatic booster. Gearbox - 5-speed, with a front divider, the total number of gears is ten forward and two reverse, transmitted. numbers: I-7.82 and 6.38; II-4.03 and 3.29; III-2.5 and 2.04; IV-1.53 and 1.25; V-1.0 and 0.815; ZX-7.38 and 6.02. Synchronizers - on II, III, IV and V gears. The divider is equipped with a synchronizer, the divider control is pneumomechanical, preselector. cardan gear- two cardan shafts. main gear- double (conical and cylindrical), transferred. number - 6.53 (by order - 7.22; 5.94; 5.43); middle bridge- checkpoint, with center differential, blocked by an electro-pneumatic or pneumatic actuator.
Wheels and tiresWheels - discless, rim 7.0-20, mounted on 5 studs. Tires - 9.00R20 (260R508), mod. I-N142B, front tire pressure - 7.3; rear: KAMAZ-5320 - 4.3; KamAZ-53212 - 5.3 kgf / cm 2; the number of wheels is 10+1.
SuspensionDependent: front - on semi-elliptical springs with rear sliding ends, with shock absorbers; rear - balancing, on semi-elliptical springs, with six jet rods, the ends of the springs are sliding.
brakesworking brake system- with drum mechanisms (diameter 400 mm, lining width 140 mm, unclamping - cam), double-circuit pneumatic drive. Brake chambers: front - type 24, bogies - 20/20 with spring energy accumulators. Parking brake- on the bogie brakes from spring energy accumulators, pneumatic drive. The spare brake is combined with the parking brake. Auxiliary brake- motor retarder with pneumatic drive. The trailer brake drive is combined (two- and one-drive). There is an alcohol fuse against freezing of condensate.
SteeringThe steering mechanism - a screw with a ball nut and a piston-rack, meshing with the toothed sector of the bipod shaft, is transmitted. number 20. The hydraulic booster is built-in, the oil pressure in the booster is 80-90 kgf / cm 2.
electrical equipmentVoltage 24 V, acc. battery 6ST-190TR or -190 TM (2 pcs.), generator set G-273 with Ya120M voltage regulator, ST142-B starter.
Refueling volumes and recommended operating materials Fuel tanks:for KamAZ-5320 - 175 or 250 l,
for KamAZ-53212 - 250 l, diz. fuel;
cooling system (with heater) - 35 l, coolant. liquid - antifreeze A-40;
engine lubrication system - 26 l, in summer M-10G (k) in winter M-8G2 (k), all-weather DV-ASZp-10V;
power steering - 3.7 l, brand P oil;
gearbox with divider - 12 l, TSP-15K;
crankcases of driving axles - 2x7 l, TSp-15K;
hydraulic clutch release system - 0.28 l, brake fluid"Neva";
shock absorbers - 2x0.475 l, liquid AZH-12T;
fuse against freezing of condensate in the brake drive - 0.2 l or 1.0 l, ethyl alcohol;
washer reservoir windshield- 1.8 l, liquid NIISS-4 mixed with water.
Mass of aggregates(in kg):
Engine with clutch - 770,
gearbox with divider - 320,
cardan shafts - 49 (59),
front axle - 255,
middle bridge - 592,
rear axle - 555,
frame - 605 (738),
body - 870 (1010),
cab complete with equipment - 577(603),
wheel complete with tire - 80,
radiator - 25.
TRANSMISSION
On cars, depending on models and trim levels, gearboxes of models141, 142, 144, 152, 154, ZF-6S1000, ZF-9S1310, ZF-9S109 f. "ZF" (Germany).
Model 141 gearbox - mechanical, three-way, five-speed with synchronizers in second, third, fourth and fifth gears.
Gearbox models 142, 144 - mechanical, five-speed, with synchronizers in the second, third, fourth and fifth gears, consists of the main gearbox; models 152, 154 - mechanical, ten-speed, consists of a main five-speed gearbox and a two-stage divider located in front of the main box.
Transmission Model ZF-6S1000 - mechanical, six-speed with synchronizers in the first, second, third, fourth, fifth, sixth gears.
Gearbox Models ZF-9S109, ZF-9S1310 - mechanical, nine-speed, includes a main four-stage gearbox and a planetary demultiplier, located behind the main box, has an additional low gear.
Drive regulation: 1 - locknut; 2 - set screw; 3 - bolt; 4 - adjusting flange; 5 - coupling bolt; 6 - thrust; 7 - stock.
gear ratios gear |
|||||||||||
Model | broadcast | ||||||||||
141 | 5,62 | 2,89 | 1,64 | 1,00 | 0,724 | 5,3 |
|||||
142, 144 | 7,82 | 4,03 | 2,50 | 1,53 | 1,0 | 7,38 |
|||||
152, 154 | 7,82 | 4,03 | 2,50 | 1,53 | 1,0 | 7,38 |
|||||
6,38 | 3,29 | 2,04 | 1,25 | 0,815 | 6,02 |
||||||
ZF-6 S1 LLC | 6,75 | 3,6 | 2,13 | 1,39 | 1,0 | 0,78 | 6,06 |
||||
ZF-9 S1310 | 9,48 | 6,58 | 4,68 | 3,48 | 2,62 | 1,89 | 1,35 | 1,0 | 0,75 | 8,97 |
|
ZF-9S109 | 10,24 | 6,57 | 4,78 | 3,53 | 2,61 | 1,86 | 1,35 | 1,0 | 0,74 | 9,44 |
|
L - low gear in the divider; S- top gear in the divider; R - reverse; C - low gear
Regulation of the remote control drive of the gear shift mechanism in gearboxes of models 142, 152 (with engines of models 7403-260, 740.11-240, 740.13-260)
Loosen the pinch bolts 5 (see fig. Drive control) and by unscrewing the bolts 3, ensure clearance in the connection by screwing the adjusting flange one or two turns 4 for thrust 6;
Loosen the locknut 1, screw in the set screw 2, thus blocking the movement of the rod 7;
After loosening the lock nut 1, screw in the set screw 2 (see fig. Mouth new screw and lock nut ka ). thus blocking the movement of the gear lever;
Set screw and locknut: 1 - locknut; 2 - set screw.
By turning, move the adjusting flange along the thread 4 (see Fig. Re drive control) until full contact with stem flange 7. Install bolts 3 and tighten the coupling bolts 5;
Loosen the 2 x 21 mm set screw andlock it with a locknut;
Remove set screw 2 (see fig.Set screw and locknut) 31 mm and secure it with a lock nut.
Adjustment of the remote (central) control drive for gearboxes of models 152 (with engines of models 740.30-260, 740.31-240) And 154 with the possibility of using a power take-off on the top hatch and on the flywheel housing(see fig. Drive (central) control mechanismtransmission shift torque model 152 and Drive (central) mechanism control154 transmission gearshift)
Turn away bolts 9;
Loosen nuts 14, 15 and 16;
Fix the rod 4 in the neutral position by screwing in the screw 5;
Fix the rod 3 with a technological rod 6 in the support of the gear lever 1;
Screwing the adjusting flange 7 until it comes into contact over the entire plane with the stem flange 4 (for gearbox mod. 154 ensure dimension C equal to 30 ± 1 mm), connect the rod 8 with the stem 4 with bolts 9;
Mount the adjusting flange 7 on the rod 8 with bolts 10, tightening them with a torque of 50...70 Nm (forgearbox mod. 152), 75...95 Nm (for gearbox mod. 154);
For gearbox mod. 154: screw the shank 11 into the rod 3, setting it perpendicular to the inclined plane of the lever 12 and aligning the axis of the conical pin with the axis of the hole in the lever 12;
By rotating the part M of the reactive thrust 13, set the lever 1 and the thrust 3 in a vertical plane;
Tighten nuts 14, 15 and 16;
Screw in screw 5 to the indicated length (21±1 mm) and lock it with a nut;
Remove service pin 6.
Actuator (central) for controlling the gearshift mechanism of the gearbox model 152: 1 - gear lever support; 2 - rear thrust; 4 - thrust; 5 - transverse thrust; 16 - adjusting coupling flange; 23.25 - bolts; 46 - nut; F - stock; P - technological rod; I - screw.
Actuator (central) for controlling the gearshift mechanism of the gearbox model 154: 1- support of the gear lever; 2 - lever, 3 - thrust; 4 - stock; 5 - screw; 6 - technological rod; 7 - adjusting coupling flange; 8 - intermediate thrust; 9 - bolt, 10 - bolt, 11 - shank; 12 - lever; 13 - jet thrust; 14, 15, 16 - nuts
Check the installation size of the stop of the valve for switching on the gear divider for the gearbox model 152 (except for the gearbox with engines of models 740.30-260, 740.31-240 with side drive), moving stop 4 valve stem. After setting the required value A=20.5±0.5 (see Fig.clutch drive) fasten the stop with nuts, lock the nuts with folding washers.
Divider Lever Travel for 152, 154 Transmissionscheck if available compressed air in the pneumatic brake actuator. For measuring:
Clutch drive: 1 - dust fuse; 2-lid; 3 - stem limiter; 4 - stop (flag) of the valve stem.
Remove cover 1 (see fig. divider mechanism) inspection hatch of the gear divider shift mechanism;
Press the clutch pedal all the way down;
By moving the gear divider control switch from the upper position to the lower one or vice versa, measure the stroke of the lever in the center of the hole. The normal stroke is 16.5 ... 19.0 mm.
Adjust lever travelin the following order:
Divider Mechanism: 1 - manhole cover; 2, 5 - set screw; 3,4- locknut.
Loosen locknuts 3, 4 (see Fig.. divider mechanism) and unscrew set screws 2, 5;
Set the switch on the shift knob todown position ( H);
Press the clutch pedal all the way;
Screw in the rear set screw 5 until it contacts the lever, then tighten it another 0.25 turns and lock it with a lock nut 4;
Set the switch to the up position (B) and depress the clutch pedal fully. Screw in the front set screw 2 in the same way as you screwed in the rear screw.
Regulation of the remote drive control of the gearshift mechanism in the gearbox modelZF-9S1310 with Cummins engine(see fig.Mechanism control drive pegear shift gear box ZF-9S1310 with Cummins engine) carry out with the neutral position of the gear lever in the following order:
Loosen nuts 9 and 10, unscrew nut 11;
Remove the shank pin 5 from the lever 7;
Unscrew the shank 5 from the rod 6;
Set the stem 4 to the position corresponding to the neutral position H1 of the third and fourth gears (see section "8.vehicle operation"),withstanding the size C = 251 mm;
Set lever 7 at an angle of 5° ± 3° to the vertical;
Set lever 2 at an angle of 90° ± 1° to the support plane (as shown in the figure). Holding the lever in this position, screw the shank 5 into the rod 6, aligning the axis of the conical pin of the shank in the lever 7;
Tighten nut 11 to a torque of 50...70 Nm and nut 9 to a torque of 98...108 Nm, providing an angle of 90° ± 2° between the axis of the pin G and the plane M of the shank;
By rotating the part And jet thrust 8, set the lever 2 and thrust 6 in a vertical plane;
1 - gear lever handle; 2 - gear lever; 3 - gear lever support; 4 - stock; 5 - tail; 6 - thrust; 7 - lever; 8 - reactive thrust; 9, 10, 11 - nut; I - jet thrust detail; C - size to the end of the rod 4 in the neutral position H1
ZF-9S1310 gearbox shift control actuator with Cummins engine: 1 - gear lever handle; 2 - gear lever; 3 - gear lever support; 4 - stock; 5 - tail; 6 - thrust; 7 - lever; 8 - reactive thrust; 9, 10, 11 - nut; I - jet thrust detail; A - size to the end of the rod 4 in the neutral position H1
Adjustment of the remote (side) drive for controlling the gearshift mechanism in gearboxes of models 144, 152, 154 and ZF-9S109, ZF-9S1310(see fig. Mech control drivegearshift mechanism of gear boxes mo delays 144, 152, 154 and Mechanism control drivegear shifting gear boxes models ZF-9S109, ZF-9S1310 with KAMAZ engine) perform with the neutral position of the gear lever in the following order:
Loosen nut 11;
Unscrew nut 9 completely;
Remove the shank 8 from the conical hole of the lever 5, releasing the rod 3;
Fix the rod 3 with the technological rod 4 in the support 2;
Install lever 5 at 17±2.5° (for model 144), at 14±2.5° (for models 152, 154), at 16±3° (for models ZF-9S109, ZF-9S1310) to the vertical
By rotating the shank 8, align the axis of the conical pin with the hole of the lever 5, tighten the nut 9 to a torque of 40...50 Nm;
Holding the shank 8 from turning with a wrench, tighten the nut 11 to a torque of 98...147 Nm;
Remove the technological rod;
Loosen nuts 10;
By changing the length of the rod 7, ensure the positionlever 1 and rod 3 in the vertical plane. Deviation of lever 1 and rod 3 from the vertical is not more than 2 mm;
Tighten nuts 10 to 40...50 Nm.
Gearshift control drive for gearboxes models 144, 152. 154: 1 - gear lever; 2 - gear lever support; 3 - thrust; 4 - rod; 5 - lever; 6 - jet thrust bracket; 7 - reactive thrust; 8 - shank; 9, 10, 11 - nut.
The drive for controlling the gearshift mechanism of gearboxes of models ZF-9S109, ZF-9S1310 with a KAMAZ engine: 1 - gear lever; 2 - gear lever support; 3 - thrust; 4 - rod; 5 - lever; 7 - reactive thrust; 9 - shank; 10, 14, 15 - nut
Adjusting the position of the bolt 12 on the clutch pedalproduce if necessary for transmission models152 (with side drive), 154(see fig. Adjusting the bolt on the clutch pedal of the gearbox model 154) :
- screw the bolt 12, having previously unscrewed its lock nut;
Press the clutch pedal all the way into the limiter;
Unscrew the bolt 12 until its spherical part comes into contact with the plane of the head of the valve stem for switching on the divider 11;
Additionally unscrew the bolt 12 by approximately 4-4.5 turns, ensuring that the head is recessed by 5-6 mm with the clutch pedal pressed all the way down;
Tighten the locknut of the bolt 12.
154 Transmission Clutch Pedal Bolt Adjustment:8 - front panel; 11 - valve for switching on the divider; 12 - adjusting bolt; 13 - clutch pedal; I - to the center differential lock valve.
CHECKING THE OIL LEVEL
Oil level in the gearbox housingmodels 141,142,144,152,154check with a pointer built into the cork 2 filler hole (see fig.Oil drain plugs in the crankcase of the box model 141 And Oil drain plugs in crankcases of 142 models. 144. 152. 154 ) oil filler neck. Normal level should reach the top mark on the index. When checking the level, do not screw in the plug, but only insert it into the hole until it stops in the thread.
For gearboxesmodels ZF-9S109, ZF-9S1310, ZF-6S1000The oil level must reach the lower edge of the filler (control) holes (see Fig. rice. Drain plugs oil in crankcase robok models ZF-9S109. ZF-9S1310 and Oil drain plugin the box crankcase models ZF-6S1000).
Oil drain plugs in the gearbox housing model 141: 1 - drain plug;2 - filler plug;3 - control hole plug
Oil drain plugs in crankcases of boxes of models 142, 144, 152, 154: 1,3,4 - drain plug;2 - plug of the filler (control) hole
Oil drain plugs in the crankcase of models ZF-9S109, ZF-9S1310: 1,2 - drain plug;3 - plug of the filler (control) hole
CHANGE OF OIL
Drain the oil from the crankcase while it is still warm from the heat of operation;
For boxes models 141, 142, 144, 152, 154 -unscrewing plugs 1, 3, 4 on the box with a divider (1 and 4 - without a divider);
For boxes models ZF-6S1000, ZF-9S109, ZF-9S1310- unscrewing the plugs of one of the filling holes 3 and plugs 1, 2.
Clean the magnetic plugs from dirt, and after draining the used oil, reinstall them.
Oil drain plug in the crankcase of the box model ZF-6S1000: 3 - plug of the filler (control) hole; 1.2 - drain plug
Malfunction | Remedy |
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Adjust lever travel |
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The adjustment of the installation size of the valve stop for switching on the gear divider is violated(for transmission model 152) | Adjust the stop position of the valve for switching on the gear divider (A = 20.5 ± 0.5) |
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Violated position adjusting bolt on the clutch pedal(for transmission models 152 (with side drive), 154) | Adjust the position of the adjusting bolt |
On cars, depending on models and trim levels, gearboxes of models 142, 152, 161 or ZF-9S109 of the company "ZAHNRADFABRIK" (Germany) are used.
Transmission models 142 - mechanical, five-speed, consists of a main gearbox; models 152 - ten-speed, differing from model 142 in the presence of a two-stage divider located in front of the main box.
Control of gearboxes of models 142 and 152 is mechanical, remote, with a rocking lever mounted on the engine, control of the divider is selector, pneumomechanical using a switch on the gear lever.
Transmission models 161 - mechanical, eight-speed, includes a main four-stage gearbox and a planetary demultiplier located behind the main box.
On the cover of the box there is a support for the gear lever of the original design. It contains a rod and a gearbox control lever, a protection mechanism against accidental switching on of reverse gear and pneumatic valves for switching the demultiplier.
Transmission
| Gear ratios | |||||||||||
| Model | broadcast | FROM | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | R |
| 142 | - | 6,38 | 3,29 | 2,04 | 1,25 | 0,815 | - | - | - | 6,02 | |
| 152 | L | - | 7,82 | 4,03 | 2,50 | 1,53 | 1,0 | - | - | - | 7,38 |
| S | - | 6,38 | 3,29 | 2,04 | 1,25 | 0,815 | - | - | - | 6,02 | |
| 161 | - | 8,39 | 5,50 | 3,93 | 2,87 | 2,12 | 1,40 | 1,0 | 0,73 | 11,01 | |
| ZF-9S109 | 10,24 | 6,576 | 4,78 | 3,531 | 2,61 | 1,86 | 1,35 | 1,0 | 0,74 | 9,44 | |
L - low gear in the divider; R - reverse;
S - the highest gear in the divider; C - low gear
Remote drive control 142, 152 gearboxes, operate with the gear lever in neutral in the following order:
- loosen the tie bolts 5 ( see fig. Drive control )and, having unscrewed the bolts 3, ensure the gap in the connection by screwing the adjusting flange 4 on the rod 6 one or two turns;
- loosening the lock nut 1, screw in the set screw 2, thus blocking the movement of the rod 7;
- loosening the lock nut 1 (see Fig. Set screw and lock nut), screw in the set screw 2, thus blocking the movement of the gear lever;
- turning, move the adjusting flange 4 along the thread ( see fig. Drive control ) until contact over the entire surface with the stem flange 7. Install the bolts 3 and tighten the coupling bolts 5;
- unscrew the set screw 2 by 21 mm and lock it with a lock nut;
- unscrew set screw 2 ( see fig. Set screw and locknut ) by 31 mm and lock it with a lock nut.
Check the gap in the divider engagement valve with the clutch release drive adjusted and the rated compressed air pressure in the brake pneumatic drive in the following order:
- remove the rubber dust protector 1 ( see fig. clutch drive );
- gently press the clutch pedal to the stop;
- Use a feeler gauge to check the gap between cover 2 and stem limiter 3.
At a nominal pressure of compressed air in the pneumatic drive of the brakes, the gap should be 0.2 ... 0.3 mm. Control the gap no later than 30 seconds after the clutch is turned off.
If necessary, adjust the clearance by moving the stop (flag) 4 of the valve stem. After setting the required value, fix the stop with nuts, lock the nuts with folding washers.
Check the progress of the gear divider lever in the presence of compressed air in the pneumatic brake actuator. For measuring:
- remove cover 1 ( see fig. Divider mechanism - inspection hatch of the gear divider shift mechanism;
- press the clutch pedal all the way down;
- moving the gear divider control switch (see Fig. Gearshift Scheme) from the upper position to the lower one or vice versa, measure the stroke of the lever along the center of the hole. The normal stroke is 16.5 ... 19.0 mm.
Gear shift control drive
1 - gear lever;
2 - gear lever support;
3 - thrust;
4 - rod;
5 - lever;
6 - jet rod bracket;
7 - reactive thrust;
8 - protective casing;
9 - shank;
10 - nut.
Adjust the lever travel in the following order:
- loosen locknuts 3, 4 (see Fig. Divider mechanism) and unscrew set screws 2, 5;
- set the switch on the gear lever handle to the down position (H);
- press the clutch pedal to the stop;
- screw in the rear set screw 5 until it contacts the lever, then tighten it by another /.4 turns and lock it with a lock nut 4;
- set the switch to the up position (B) and depress the clutch pedal fully. Screw in the front set screw 2 in the same way as you screwed in the rear screw.
Adjust the remote drive for controlling the gearshift mechanism of gearboxes of models 161 and ZF-9S109 (see. Fig. Drive for controlling the gearshift mechanism) with the gearshift lever in the neutral position in the following order:
- install the shank 9 into the taper hole of the lever 5, tighten the nut 10 to a torque of 40...50 Nm, for model 161 cotter;
- remove the technological rod;
Oil drain plugs in crankcases of boxes of models 142, 144, 152, 154
Check the oil level in the gearbox housing with a pointer mounted in plug 2 ( see fig. Oil drain plugs in the crankcase of the model 161 and Oil drain plugs in the crankcases of the models 142 and 152 ) oil filler neck. The normal level should reach the upper mark on the pointer. When checking the level, do not screw in the plug, but only insert it into the hole until it stops in the thread.
For gearboxes of the ZF-9S109 model, the oil level must reach the lower edge of the filler (control) holes 3 located symmetrically on both sides of the gearbox ( see fig. Oil drain plugs in the crankcase of the box model ZF-9S109).
Change of oil
Drain the oil from the crankcase when it is still warm from heating during operation: for boxes of models 152 and 142 - by unscrewing the plugs 1, 3, 4 on car with a divider (1 and 4 - without a divider); for box model 161 - turning oil filter 1, mounted on the rear end of the crankcase of the demultiplier, and plugs 2 and 3 of the crankcase; for the ZF-9S109 model - by unscrewing the plugs of one of the filling holes 3 and the plugs 1 and 2 of the drain holes. Clean the magnetic plugs from dirt and, after draining the used oil, reinstall them.
Possible malfunctions of the gearbox, causes and methods for their elimination
| Malfunction | Possible reason | Remedy |
| Difficulty shifting gears in the box | Incomplete clutch disengagement (clutch "leads") | Adjust clutch drive |
| Self-deactivation of gears in the divider | Divider lever travel misaligned | Adjust lever travel |
| The gears of the gearbox do not turn on or the gears switch off automatically when the car is moving | Adjustment of the remote drive is disturbed or the fastening of the levers of the drive rods is loose | Adjust the drive or tighten the lever mounts |
| Gears do not turn on in the divider | Violated gap adjustment in the divider switch-on valve | Adjust gap |
TRANSMISSION
On the car Kamaz 4308 is installed mechanical box model 141 gear, which has five forward gears and one reverse gear. For bumpless shifting of the second, third, fourth and fifth gears, two inertial type finger synchronizers are used.
Rice. 3-6. Gearbox (longitudinal section):1 - drive shaft; 2 - cover of the rear bearing of the primary shaft; 3, 23 - shims;11 - gear lever support; 12 - block axis gear wheels reversing; 13.31 - thrust washers; 14 - reverse gear block; 15 - roller bearing; 16 - bolt with pin assembly; 17 - lock washer; 18 - top cover; 19, 32, 36 - gaskets; 20 - cover of the rear bearing of the secondary shaft; 21 - thrust ring; 22 - rear ball bearing of the secondary shaft; 25 - sealing cuffs; 26 - flange fastening nut; 27 - flange for fastening the cardan shaft; 28 - a glass of the rear bearing of the intermediate shaft; 29 - bearing cap; 30 - spherical roller bearing; 33 - intermediate shaft; 34 - gearbox housing; 35 - driven shaft; 37 - cover of the front bearing of the intermediate shaft; 38 - clutch housing.
Model 141 Transmission Specification
gear ratios | 1 - 5,62; 2 - 2.89; 3 - 1.64; 4 - 1.00; 5 - 0.724; ZX - 5.3 |
Shaft bearings | ball, roller spherical, roller |
Gear bearings | roller double row with cages without rings, fourth gear bearing without cage |
Synchronizers | inertial type, finger type with brass cone rings |
Gears | with helical teeth, except for first gear and reverse gear, constant mesh |
speedometer drive | two-stage, consists of a worm pair and a replaceable pair of spur gears |
Lubrication system | combined. All parts are splash lubricated, the bearings of the gears of the gearbox and divider have, in addition, additional |
The transmission has a reversing light switch. The lamp lights up when reverse gear is engaged.
To prevent simultaneous switching on of two gears, a ball-type lock is installed in the cover between the rods. To prevent accidental switching on of reverse gear or first gear when the Kamaz 4308 car is moving, there is a split-type spring-type fuse in the cover.
Seals located in the covers of the primary and secondary shafts protect the internal cavity of the gearbox from dust and dirt and prevent oil leakage.
Rice. 3-7. Gearbox mod. 141 (back view):1 - gear lever; 5 - power take-off hatch cover; 6 - sealing gasket; 8 - drain magnetic plug; 9 - drain plug; 10 - speedometer drive gear; 11 - bushing; 16 - speedometer converter flange.
Rice. 3-8. Drive shaft assembly:1 - drive shaft; 2 - ball bearing; 3 - retaining ring of the bearing; 4 - ring nut; 5 - oil injection ring;6 - locking ball.
Rice. 3-9. Intermediate shaft assembly:1 - intermediate shaft; 2 - front roller bearing; 3 - intermediate shaft drive gear; 4 - retaining ring; 5 - spacer sleeve; 6 - gear IV gear; 7 - gear 3rd gear And; 8 - key.
The gearbox consists of the following main assembly units: crankcase 34 (Fig. 3-6), in which the driving 1, driven 35 and intermediate 33 shafts are assembled with gears, synchronizers and bearings; reverse gear block; top cover 18 of the box with the gearshift mechanism assembly. Clutch housing 38 is attached to the front end of the gearbox housing. Shaft bearings are covered with seals.
Cover 2 of the rear bearing of the drive shaft with an internal bore is centered on the outer race of the bearing; lid surface machined on outer diameter,is the centering surface for the clutch housing. Two self-clamping cuffs are inserted into the inner cavity of the lid. The working edges of the cuffs have a right notch. The internal cavity of the large diameter cover is designed to accommodate an oil injection device; spiral vanes at the end of this cavity prevent oil from spinning in the discharge cavity by the oil injection ring, thereby reducing centrifugal forces and, consequently, contributing to an increase in excess oil pressure in the discharge cavity. In the upper part of the cover there is a hole for supplying oil from the gearbox oil accumulator to the discharge cavity.
The cover 20 of the rear bearing of the driven shaft is attached to the rear end of the gearbox housing, centered on the outer race of the rear bearing 22 of the driven shaft.
In the rear part of the cover there is a cuff 25 with a dust collector, on the working edge of which there is a left notch.
In the tides of the right wall of the gearbox, a bore is made into which the axis 12 of the reverse gear block is pressed. From falling out, the axle is secured with a lock washer 17, screwed with a bolt 16, which has a hole into which a plastic pin is inserted. The pin seals the threaded connection, preventing leakage lubricant.
Oil is poured into the gearbox through the neck located on the right wall of the crankcase. The neck is closed with a plug with a built-in oil dipstick.
In the lower part of the crankcase (Fig. 3-7), plugs 8 and 9 of the drain holes are screwed into the bosses; a magnet is mounted in plug 8, which traps metal particles in the oil. On both sides of the crankcase there are hatches for installing power take-offs, closed with covers 5 with seals 6. The permissible value of the power taken off is 22.06 kW (30 hp) from each hatch. Power take-off and switching on are allowed only when the Kamaz 4308 vehicle is stopped.
In the internal cavity of the crankcase, in the front part of the left wall adjacent to the front end of the crankcase, an oil accumulator is cast, where, during the rotation of the gear wheels, oil is thrown, which then enters the cavity through the hole in the front wall of the crankcaseinput shaft covers and on the oil injection ring. Gearbox gearsare completed in pairs with mating gears along the contact patch.
Transmission drive shaft(Fig. 3-8) is made as one piece with the gear wheel; its front support is a ball bearing located in the crankshaft bore. The bearing cavity is filled with grease No. 158 and sealed with a collar.
A ball bearing 2 and an oil injection ring 5 are installed on the rear end of the shaft with an emphasis on the end of the gear wheel, which is locked from turning on the shaft by a ball 6.
The package is pulled together by an annular nut 4, the belt of which is pressed into the grooves of the shaft.
The free play of the input shaft is regulated by a set of steel spacers 3 (Fig. 3-6) 0.2 mm and 0.3 mm thick, installed between the end of the input shaft and the outer race of the bearing.
intermediate shaft(Fig. 3-9) is made as one piece with the rims of the gears of the first, second and reverse gears. At the front end of the shaft, the gears of the third 7th and fourth 6th gears and the gear wheel 3 of the intermediate shaft drive are pressed.
driven shaft 16 (Fig. 3-10), complete with gears and synchronizers, is installed coaxially with the input shaft. At the front end of the shaft there is a bearing 2 with an attached inner ring. All gears of the shaft are mounted on roller bearings, of which the gear wheel bearing of the fourth gear is loose, without a cage. The gear wheels of the fourth 18th and third 7th gears in the axial direction are fixed by a thrust washer 4 with internal slots, which is installed in the shaft recess so that itthe splines are located against the splines of the shaft, and is locked from turning by a spring-loaded locking key 21.
A channel is drilled along the axis of the shaft for supplying lubricant through radial holes to the gear wheel bearings. Oil is supplied to the channel by an oil pump located on the input shaft.
Rice. 3-10. Driven shaft assembly:
1 - retaining ring; 2 - front roller bearing; 3 - synchronizer of IV and V gears;4 - thrust ring; 5 - bearing rollers IV gear; 6 - bushing gear IV gear;7 - gear III gear; 8 - roller bearing; 9 - synchronizer of II and III gears;10 - gear wheel of the 2nd gear;11 - reverse gear;12 - 1st gear and reverse clutch;13 - gear bushing 1 transfers; 14 - gear 1st gear; 15 - thrust washer; 16 - driven shaft; 17 - reverse gear bushing; 18 - gear IV gear; 19 - spring; 20 - intermediate sleeve; 21 - lock key
Rice. 3-11. Gear Shift Mechanism:
1 - plug; 2 - top gearbox cover; 3 - fork for switching IV and V gears; 4 - set screw; 5 - splint wire; 6 - shift fork II and III gears; 7 - shift fork of 1st gear and reverse gear.
Rice. 3-12 Shift mechanism lock and latches: 1 - lock ball; 2 - stopper glass rica; 3 - lock ball spring; 4 - lock pin; 5 - ball locking latch.
gear shift mechanism
(fig. 3-11) is located in the gearbox cover. The synchronizer carriages and the first gear and reverse gear clutch are moved by a lever installed in the cab through a remote drive, rods and forks. The forks are fixed with set screws on the rods moving in the holes of the top cover.The gear shift mechanism consists of three rods, three shift forks 3, 6 and 7, two rod heads, three clamps with balls 5 (Fig. 3-12), a fuse (Fig. 62) for engaging the first gear and reverse gear and a rod lock . The rod lock has two pairs of balls 1 (Fig. 3-12) and a pin 4. The balls are located between the rods in the bushings, the pin is in the hole in the middle rod between the balls. The diameters of the balls and the distance between the rods are chosen so that when any rod is moved from the neutral position, the balls leave the holes of the moving rod and enter the holes of the fixed rods, blocking them on the body. A support 11 (Fig. 3-6) of the lever with a rod is installed on top of the cover of the gearshift mechanism.
Gear lever support
(Fig. 3-14) consists of a bracket 1, a corrugated seal 5 of the hatch, a spring 6 of the seal, a shortened gear lever 4, which, with its spherical part, rests on a polyurethane bushing 7, which dampens the vibration of the lever. From above, the sphere is pressed through the support washer 2 by a spring. The set screw 8 fixes the shift lever in the neutral position when adjusting the drive. In working position, the bolt must be turned out and locked with a lock nut.
Rice. 3-13. Gear shift fuse:
1 - fuse spring; 2 - fuse;3 - fuse pusher
Rice. 3-14. Gear lever support:
1 - bracket; 2 - support washer; 3 - cover; 4 - tip lever; 5 - hatch seal; 6 - spring; 7 - polyurethane sleeve; 8 - set screw.
Rice. 3-15. Model 141 Gear Shift Control Actuator:
3 - gear lever handle; 5 - thrust; 7 - reactive thrust; 8 - gearbox; 9 - engine; 10 - gear lever support; 17 - lever; 71 - nut; 100 - shank;B - gear lever; G - stock; K is a nut.Remote control gear shift mechanism
(fig. 3-15) consists of rocker lever B, shift lever support 10gears mounted on the front end of the engine cylinder block, control rod 5, shank 100, lever 17. Spherical thrust bearings 5 are located in the bore of the gear lever support bracket.Synchronizers (Fig. 3-16) consist of two conical rings 1 and 4, rigidly interconnected by blocking fingers 3, and a carriage 2 moving along the splines of the secondary shaft. The fingers in the middle part have conical surfaces that are blocking. The holes in the carriage disk through which the locking fingers pass also have chamfered locking surfaces on both sides of the hole. Taper rings are not rigidly connected to the carriage. They are connected to it by clamps 5, pressed by springs 6 into the grooves of the fingers.
Rice. 3-16. 4th and 5th gear synchronizer:
1,4- conical rings; 2 - carriage; 3 - blocking finger; 5 - latch; 6 - springWhen moving the carriage with the fork of the gear shifting mechanism, the conical ring, moving together with the carriage, is brought to the cone of the gear wheel. Due to the difference in the frequencies of rotation of the carriage associated with the secondary shaft and the gear, the cone ring is shifted relative to the carriage until the blocking surfaces of the fingers touch.tsev with blocking surfaces of the carriage, which prevent further axial movement of the carriage. Alignment of rotational frequencies when the gear is engaged is provided by friction between the conical surfaces of the synchronizer ring and the gear being engaged.
As soon as the speeds of the carriage and the gear are equal, the blocking surfaces will not interfere with the advancement of the carriage and the gear will engage without noise and shock. When you turn on synchronized gears with noise, you must immediately find out the cause of the malfunction and eliminate it in order to avoid premature failure of the synchronizer.
POSSIBLE FAULTS OF THE GEARBOX AND WAYS TO ELIMINATE THEM
Cause of malfunction | Remedy |
Difficulty engaging all gears, reverse gear and first gearturn on with a screech |
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Incomplete clutch disengagement (clutch "leads") | Adjust clutch release free play |
Great force on the gear lever |
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Contamination of remote control rod bearings. Missing or thickened lubricant | Rinse the bearings and fill them with fresh #158 grease. |
The inclusion of the second, third, fourth and fifth gears with a blow and a rattle |
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Wear of the conical synchronizer rings, blocking chamfers of the fingers and the carriage. Reducing the force required to bring the carriages out of the neutral position | Replace synchronizer |
Auto disengagement of gears when the car is moving |
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Incomplete disengagement of the gear due to a malfunction of the latches of the mechanism for switching wear of the legs or crackers of the forks, loosening of the fastening of the forks and levers, violation of the adjustment of the remote control | Tighten the fasteners, replace worn parts, adjust the remote control drive |
Failure in the operation of the lock splines of the secondary shaft | Replace shaft and corresponding synchronizer |
Gear not included |
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Wear of parts and violation of the adjustment of the remote drive control box | Adjust the drive and replace worn parts, tighten the gear mounting parts |
Destruction of bearings of cogwheels of a secondary shaft | Replace defective parts |
Increased noise level during gearbox operation |
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Increased wear or breakage of wheel teeth. Destruction of gear bearings | Replace defective parts |
Destruction of shaft bearings | Same |
Oil leak from gearbox |
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Worn cuffs or loss of elasticity | Replace cuffs |
Increased pressure in the gearbox housing | Flush Relief Valve |
Violation of tightness on sealing surfaces | Tighten fasteners or replace gaskets |
Deterioration of brass rings of synchronizers of a gear box |
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Incomplete clutch disengagement when shifting gears | Replace synchronizers. Check the operation of the clutch and drive |
Maintenance
The frequency of performing maintenance operations is given in the "Service Book".
At maintenance the following operations are performed:
Fix the lever of the remote drive of the gearbox;
Fix the linkage levers of the gearbox remote drive;
Bring the oil level in the gearbox crankcase to normal;
Fix the gearbox housing;
Fix the output shaft flange;
Change the oil in the gearbox crankcase;
Check the tightness of the gearbox;
Clean the gearbox breathers;
Lubricate the bearings of the front and intermediate gearbox control rods through the grease fittings until fresh grease is squeezed out;
Check the axial clearance of the gearbox output shaft flange;
Change the oil in the gearbox crankcase.
GB tightness checkconsists in checking by external inspection the absence of oil leakage through the cuff of the driven shaft and the seals.
To check the oil levelin the gearbox housing, unscrew the plug from the oil filler neck, wipe the pointer dry and insert it into the filler hole until the plug stops in the thread (Fig. 3-17), without wrapping.
For oil change in the gearbox, drain the hot oil through the drain holes by removing the plugs located at the bottom of the gearbox housing. Clean the drain plug magnet of dirt and metal particles. Rinse the crankcase with engine oil. To do this: pour oil into the gearbox, rotate it with the engine with the gear lever in neutral for 10 minutes, drain the engine oil from the gearbox, screw in the drain plug and fill in the main lubricant TSp-15K to the upper mark of the level indicator. Crank the gearbox with the engineneutral position of the gear lever in those 3-5 min. Measure the oil level and top up if necessary.
Rice. 3-17. The position of the oil level indicator when measuring: 1 - oil level indicator from samplescoy; 2 - gearbox housing
Repair
When repairing a remote control gear box to reduce effortwhen shifting gears, replace the grease in the drive bearings and spherical heads of the pivot joints of the levers. Pump fresh grease into the bearings through the grease fittings, screwing them in instead of the plugs in the bearing housings.
If, after lubricating the bearings, the force on the lever during gear shifting has not changed or has not decreased sufficiently, disassemble the bearings in the following order:
Remove the adjusting flange mounting bolts; unscrew the mounting bolts of the support on the clutch housing;
Remove the rubber cover of the swivel, paying attention to the safety of the restrictive ball and spring;
Unscrew the shank, torque rod from the rod and pull the rod out of the support;
Disconnect the thrust head, paying attention to the safety of the ball and spring;
Remove the shift lever support located on the front end of the block as described below. Remove crackers, bushings, spring from the support housings. Rinse parts and bearing cavities with kerosene or diesel fuel, replace worn sealing rings. When assembling, lubricate the rubbing surfaces with grease 158; lay, fresh grease in the cavity of the bearings.
After assembly, adjust the remote drive in the following order:
Set the G rod to the neutral position;
Screw the shank 100 into the rod 5, align the axis of the conical pin with the axis of the hole in the lever 17;
Rotating children. And jet thrust 7, install lever B and thrust 5 in a vertical plane;
Tighten nuts 71 and K.
To disassemble the gearbox:
Disassemble the gearbox in the following order: unscrew the bolts securing the upper cover 25 of the gearbox and, screwing two bolts into special threaded holes in the cover (after unscrewing the plugs from them), remove it; unscrew the nut 33 of the driveshaft flange and remove the flange, remove the front and rear bearing caps of the drive 5, driven 42 and intermediate 40 shafts, screwing the mounting bolts into special holes in the covers (when removing the covers, pay attention to the safety of the gaskets); remove the retaining ring 28 of the bearing; unlock and unscrew the two bolts securing the thrust washer of the rear bearing of the intermediate shaft; Using pullers И801.30.000, remove the rear bearing 29 of the driven shaft, for this use the gripper И801.30.100 (Fig.3-18). Install the grip 8 on the groove of the bearing and tighten it with nuts 1. Screwing the screw 4 into the traverse 6 and resting the tip 3 against the end of the shaft, remove the bearing.
Rice. 3-18. Removing the rear bearing of the driven shaft:1 - nut; 2 - thrust; 3 - tip; 4 - screw; 5 - axis; 6 - traverse; 7 - bearing; 8 - capture.
Rice. 3-19 Countershaft rear bearing remover:
1 - glass; 2 - bearing; 3 - emphasis; 4 - tip; 5 - plate; 6 - screw; 7.8 - boltsRemove the cup 35 (Fig. 3-10) of the rear bearing together with the bearing 37 of the intermediate shaft. To remove the intermediate shaft bearing, resting against the stop 8 (Fig. 3-19) against the wall of the gearbox housing, screw two bolts 7 into the threaded hole of the bearing cup until it stops. With the tip 4 against the end of the shaft, screw the screw 6 into the plate 5 until it is completely removed cup bearing.
When removing the cup of the rear bearing of the intermediate shaft from the gearbox housing, install a technological thrust washer between the crown of the gear of the 2nd gear of the intermediate shaft and the crown of the reverse gear block (to avoid breakage of the teeth of the crown of the 2nd gear). Remove the drive, driven and intermediate shafts of the gearbox. Using the I801.32000 puller, press the axis 19 of the reverse gear block. To do this, set the handle 2 (Fig. 3-20) to the extreme right position, screw the screw 1 into the axis of the gear block with a wrench; then turn the handle 2 on the screw 1 until the axle of the gear unit is completely removed.
Take out the gear unit 21 (Fig. 3-10), bearings 22 with the delivery ring and thrust washers 20.
For disassembly of the driven shaft of the gearboxremove the retaining ring 1 (Fig. 3-14) and the front bearing 2 of the driven shaft, for this use the grip I801.30.200, install it on the bearing and tighten it with nuts 2 (Fig. 3-21). Screwing the screw 3 into the yoke 4 and resting the tip 5 against the end of the shaft, remove the bearing, then the synchronizer of the fourth, fifth gears, the thrust ring 4 (Fig. 3-14) of the fourth gear. To do this, it is necessary to remove the locking key 21 from the washer groove and turn it until the slots of the washer and the shaft coincide; remove gear 18 of the fourth gear with rollers 5 bulk bearings; compress the sleeve 6 of the fourth gear, remove the locking key 21 with the spring 19; remove gear 7 and bearing 8 of the third gear, synchronizer 9 of the second and third gears; remove the thrust washer 15, the gear 14 and the bearing of the first gear, the clutch 12 for engaging the firstgears and reverse gears, press splined bushing 13 of the first gear, remove gear 11 and reverse gear bearing, press bushing 17 of reverse gear; Remove gear and second gear bearing.
Rice. 3-20. Reverse gear block axle puller И801.32.000:1 - screw; 2 - handle
Rice. 3-21. Removal of the forward bearing of a conducted shaft:
1 - capture I801.30.200; 2 - nut; 3 - screw; 4 - traverse; 5 - tip; 6 - bearing.To disassemble the gearbox top cover:
unscrew the nuts and remove the supports of the gear lever, remove the cups 2 (Fig. 3-16), springs 3 and balls 5 of the clamps; unpin and unscrew the set screws 4 (Fig. 3-15) fastening the forks and heads of the rods, knock out three plugs 1, remove the gearshift rods, knock out the plugs of the rod lock, remove the balls 1 (Fig. 3-16) from the cover and the pin 4 of the lock devices from the middle stock; unscrew the spring cup and remove the spring 1 (Fig. 3-17), fuse 2 and fuse sleeve.Assembly is carried out in the reverse order of disassembly, taking into account the following features:
When installing gears in a gearbox without replacing them, do not dismantle the gears that have been worked to each other;
When installing gears from among spare parts, it is necessary to complete the mating gears according to the contact patch and noise level on gear-rolling machines. The location of the contact patch must correspond to Fig. 3-22. The location of the contact patch in the area of the pitch circle is desirable.
When checking pairs of gears on gear-rolling machines with and without braking of the driven gear, the noise should be even, low-pitched, without tapping and grinding. High-pitched noise is not allowed:
To install the rear bearing of the intermediate shaft with a glass on the shaft installed in the gearbox and pressed by the front cover, use the I801.31.000 puller. To do this, install washer 8 on the tip 4 (Fig. 3-23), pass the bolts 9 through the holes in the glass, screw them into the threaded holes on the gearbox housing until they stop. Resting washer 8 against the bearing, screw the screw 6 into the plate 5 until the glass with the bearing is fully installed;
When assembling the driven shaft, pay attention to the correct installation of bushings 6,17 and 13 bearings (Fig. 3-14). The holes on the bushings must be aligned with the radial holes on the corresponding necks of the driven shaft; when assembling the bulk bearing of the fourth gear, 88 rollers should be laid in two rows with an intermediate sleeve 20 installed between the rows; when installing the front bearing 2 of the drive shaft, the attachment ring must be installed inward to the end of the shaft;
When pressing gear 3 (Fig. 3-9) of the intermediate shaft drive of the gearbox, it must be heated to a temperature of 90 ° C;
Rice. 3-22. Contact patch location
Rice. 3-23. Countershaft rear bearing installer:1 - glass; 2 - bearing; 3 - emphasis; 4 - tip; 5 - plate; 6 - screw; 7.9 - bolts; 8 - puck.
Rice. 3-24. Adjusting the axial clearance of the gearbox shafts:
1 - adjusting shims;2 - bearing cover;3 - sealing gasket;4 - gearbox housing or divider; 5 - retaining ring;6 - bearing of the adjusting shaft;a, b, c, d - adjusting dimensionsPay attention to the serviceability of the gearbox synchronizers. The static pulling force of the carriages from the neutral position must be 275...373 N (28...38 kgf). The blocking chamfers of the crankcase and fingers must not show signs of significant wear.
After assembling the driven shaft of the gearbox, the end clearances on the hubs of the gears of the first, second, third gears and reverse gear should be within 0.27 ... 0.4 mm; on the fourth gear hub - 0.265 ... 0.515 mm. End clearance on the hub of the drive gear of the drive shaft of the gearbox divider should be within 0.375 ... 0.715 mm;
When installing the bearing caps of the drive shaft of the gearbox, as well as the cap of the driven shaft, ensure minimal shaft play by selecting shims, for this: measure with an accuracy of 0.05 mm the absolute dimension a (Fig. 3-24) from the end face of the outer ring of the bearing 6 to the plane crankcase 4 with bearing 6 pressed to the stop.
For the covers of the driven shaft of the gearbox, put a sealing gasket 3 on the mating surface of the cover 2, measure the size with an accuracy of 0.05 mm b, determine the required total thickness from shims 1, which must be less than the difference(b-c) by 0.2 ... 0.4 mm. After selecting the required number of shims, install the cover.
Install the cover of the drive shaft of the gearbox without gaskets, while the size d from the mating surface of the cover to the shims to ensure d=(a...a+0,l) selection of the number of shims;
Before installing fasteners and covers, apply an even layer of the Anaterm-4 sealing composition and on two or three turns of through threaded holes in the crankcases, and also apply it with a continuous strip 2.. .3 mm wide along the contour on both sides of the gaskets, the rear cover of the intermediate shaft of the box gears, power take-off hatch covers;
Lubricate the sealing lips of the input and output shaft seals with grease 158.
After assembly, when the input shaft is rotated by hand, the shafts and gears of the gearbox should rotate freely (without jamming) both in the neutral position of the gear lever and in any gear engaged.
The rod locks of all gears must clearly fix the rods in the neutral position and in the gear engaged position. Reverse gear and first gearshould only turn on when the reverse fuse installed in the top cover is depressed.
Simultaneous engagement of two gears and oil leakage from the gearbox are not allowed.
When the clutch fork shaft is rotated by hand, the clutch release clutch must move freely (without sticking) along the entire length of the drive shaft guide cover.
Adjust the engagement of the divider synchronizer gear couplings.
All repaired and assembled gearboxes must be tested on a special stand.
test benchmust have the following equipment:
A device that provides two modes of rotation speed of the input shaft:1300 min -1 and 2600 min -1 ;
Clutch connected to the drive shaft of the gearbox and disengagedwhen shifting gears. The moment of inertia of the clutch driven parts must not exceedwash 12.7 N.m / cm (1.3 kgf.m / cm 2);
A braking device connected to the driven shaft and providing a braking torque of 49.1 N.m (5 kgf.m) for first gear and reverse gear and 98.1 ... 147 N.m (10 ... 15 kgf.m ) for other gears;
A device that measures the moment on the driven shaft;
Pneumatic system for switching the divider. The air pressure in the pneumatic system should be 588 ... 686 kPa (6 ... 7 kgf / cm 2);
Devices for measuring the noise level. To lubricate the gearbox during testing, use engine oil heated to 85°C.
Test gearboxes in two modes; no load and under load. When testing without load, check the gear engagement. Gearbox test modes are given in the tables.
Gearbox test mode molly 141 without load
Gearbox test mode molly 141 under load
After testing, drain the gearbox oil while it is still hot. At the same time, clean the drain plug magnets from metal deposits.
When installing the gearbox on the engine:
Check the condition of the drive shaft using a control splined mandrel with a height of at least 30 mm, which should move freely (without jamming) along the splines of the shaft, then lubricate the splined end with a thin layer of grease 158;
Do not allow sharp blows, and do not load the clutch discs with the weight of the gearbox or the force of the lifting mechanism in order to avoid damage to the clutch and the front bearing of the input shaft located in the crankshaft;
After installing the gearbox, check the full travel of the clutch release clutch, equal to 35 ... 43 mm. This move corresponds to the movement of the lever by 40 ... 50 mm, measured at a radius of 90 mm;
Before installing the remote mechanism, lubricate the working surfaces of the heads and the bearings of the rods with grease 158. Install the heads of the mechanism and tighten with tie bolts. Swinging of the heads on the rods is not allowed. Sealing covers of the heads of the rods of the remote mechanism must tightly cover the seating surfaces. When shifting gears using a remote mechanism, sticking of the rods in the supports is not allowed. The detents of the gearshift mechanism must be clearly felt both in neutral and in any gear engaged in the gearbox;
Pour TSp-15K oil into the gearbox and carry out a three-fold check for starting the engine with a starter. In this case, the clutch must be turned off;
Check the correct installation of the clutch and gearbox on a running engine at a crankshaft speed of 1800 ... 2000 min -1, checking:
1. No jamming of parts of the clutch release mechanism.
2. The cleanliness of the clutch release. To do this, completely disengage the clutch, ensuring that the clutch release clutch travel is no more than 12 mm. This corresponds to a lever travel of 16 mm measured over a radius of 90 mm. In this position, the first gear and reverse gear should be included without grinding, and when the direct gear is engaged, the driven shaft should not rotate. Repeat the test at least three times.
3. The noise of the gearbox (sharp uneven noise and knocking is not allowed).
4. Gear shifting. Gear shifting should be carried out with the clutch disengaged without much effort and without jamming, the inclusion of synchronized gears with a rattle is not allowed.
5. No oil leakage. Oil leakage is not allowed. The formation of oil stains without drop formation is allowed in the places of stuffing box seals and the installation of breathers.
Note: In the absence of a stand, test the gearbox for unloadednom car KAMAZ 4308 on level terrain The order of gear shifting and the time of movement in each gear according to the table at an engine speed of 1400 ... 1800 min -1.
When testing gearboxes, check:
Ease of gear shifting. When switching the second, third, fourth and fifth gears, the rattle is not allowed. Engage reverse gear and first gear only when the shafts are stopped;
Torque on driven shaft. At a drive shaft speed of 2600 min -1, the torque on the driven shaft should not exceed 9.81 N.m (1 kgf.m);
Self-disengagement of gears (not allowed);
The presence of sharp uneven knocks, indicating malfunctions of components and parts (not allowed).
Removing the gearbox from the Kamaz 4308 car and installing it
To remove the gearbox:
Drain the oil from the gearbox housing. Tilt the cab, remove the platform floor shields to provide access to the gearbox; disconnect the batteries from the electrical circuit, disconnect the terminal connecting the mass switch to the frame of the Kamaz 4308 car (the terminal is located on the battery box); disconnect and remove the wire connecting the starter relay to the "+" terminal of the battery.
Remove the hose connecting the engine inlet pipe to the air cleaner connecting pipe by unscrewing the nuts and removing the bolts of the coupling clamps; disconnect the plug connections of the tachometer, speedometer, trailer socket, brake signal switch on sensor, reversing headlight, pressure drop indicator sensors in the receivers; disconnect the muffler mounting brackets to the divider crankcase;
Remove the clutch hydraulic booster;
Disconnect the flange - the yoke of the propeller shaft of the axle from the flange of the driven shaft of the gearbox by unscrewing the nuts of the fastening bolts, remove the spring washers and remove the bolts; loosen the clamping bands and remove the connecting hose of the ejector pipe; disconnect the air lines from the brake control valve of the trailer with a two-wire drive;
Loosen the bolts of the front supports of the power unit; unscrew the nuts of the bolts of the rear engine mounts and remove the bolts;
Unscrew the bolts of the support support beam to the frame;
Unscrew the bolts securing the gearbox support to the transverse beam;
Hang the power unit by the eye bolts of the gearbox; place wooden blocks under the front and rear halves of the second frame cross member and lower the power unit (the thickness of the bars should be such that when the power unit is lowered, the rear support brackets are 50 mm higher than the rear support pads);
To turn out a coupling bolt of the lever of a forward draft of a drive of management of a transmission;
Disconnect the front link from the lever, remove the rubber boot, remove the ball and spring from the ball head of the lever tip;
Remove the starter mounting bolts;
Install the chain hooks of the lifting device by the eye bolts on the gearbox, unscrew the bolts securing the clutch to the engine flywheel housing; take the gearbox back until the drive shaft exits the clutch housing, remove it and install it on the trolley.
To install the gearbox.
Before docking the gearbox with the engine, put 15 g of grease 158 into the cavity of the front bearing of the drive shaft, located in the bore of the crankshaft; lift the gearbox and install it in place, having previously installed the clutch, a hose for supplying lubricant to the thrust bearing and release springs.
Screw in the bolts securing the clutch housing to the engine flywheel housing. Screw in the starter mounting bolts. Connect the front link to the lever, after inserting the ball and spring into the ball head of the lever; screw in the coupling bolt of the lever of the front linkage of the gear control drive. Adjust the remote drive for controlling the gear shift mechanism.
Hang the power unit by the eye bolts of the gearbox.
Screw in the bolts of the gearbox supporting support to the cross beam, remove the wooden blocks from under the second cross member of the frame and lower the power unit onto the supports; to screw bolts of fastening of a beam of the supporting support to a frame; insert the bolts into the holes of the rear supports of the power unit, tighten the self-locking nuts.
Tighten the power unit front mounting bolts.
Connect the air ducts to the trailer brake control valve with a two-wire drive; put on the connecting hose of the ejector pipe and secure it with straps.
Align the holes in the yoke flange of the propeller shaft of the axle with the holes in the flange of the driven shaft of the gearbox; insert the bolts into the holes, put on the spring washers, tighten the nuts. Install the clutch air booster.
Attach the muffler mounting bracket to the gearbox housing by screwing bolts.
Connect the plug connectors of the tachometer, tachograph (speedometer), semi-trailer socket, brake light switch sensor, reversing headlight, pressure drop indicator sensors in the receivers.
Install the hose connecting the engine intake manifold to the air cleaner connecting pipe.
Put on the clamps and secure the hose by inserting bolts into the holes of the clamps and tightening them with nuts.
Connect the wire connecting the starter relay to the "+" terminal of the battery; connect the ground switch lead to the frame of the Kamaz 4308 car (the lead is located on the battery box); connect the batteries to the electrical circuit of the vehicle. Install floor panels.
Pour oil into the gearbox housing. Lower the cab.
Check and, if necessary, adjust the free play of the clutch pedal.
On the cars equipped with engines 740.51-320 and 740.50-360, a gearbox model 161 or model ZF-16S151 from ZAHNRADFABRIK (Germany) is installed, on cars with an engine 740.14-300 - model ZF-9S109 from ZAHNRADFABRIK (Germany).
Transmission models 161 - mechanical, eight-speed, consisting of a main four-stage gearbox and a planetary demultiplier located behind the main box.
Gear ratios:
| Model | . | C | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | R |
| 161 | . | - | 8,39 | 5,50 | 3,93 | 2,87 | 2,12 | 11,40 | 1,00 | 0,73 | 11,01 |
| ZF-9S109 | . | 12,91 | 8,96 | 6,37 | 4,71 | 3,53 | 2,54 | 1,81 | 1,34 | 1,0 | 12,2 |
| ZF-16S151 | L | - | 13,8 | 9,49 | 6,53 | 4,57 | 3,02 | 2,08 | 1,43 | 1,0 | 12,92 |
| S | - | 11,5 | 7,93 | 5,46 | 3,82 | 2,53 | 1,74 | 1,20 | 0,84 | 10,80 |
L - slowdown gear in the divider;
S - accelerating transmission in the divider;
R - reverse;
C - low gear.
On the cover of the box there is a support for the gear lever, in which there is a rod and a gearbox control lever, a protection mechanism against accidental switching on of the reverse gear and pneumatic valves for switching the demultiplier.
Transmission models ZF-9S109 - mechanical, nine-speed, which has an additional downshift compared to model 161.
Gearbox model ZF-16S151 - mechanical, sixteen-speed, includes a main four-speed gearbox with a built-in two-stage divider located in front of the main gearbox and with a two-stage planetary demultiplier located behind the main gearbox. 
Adjustment of the remote drive mechanism control 161 and ZF-16S151 gearboxes ( see fig. Gear shift control drive ) perform with the neutral position of the gear lever in the following order:
- fix the rod 3 with the technological rod 4 (d=4mm, l=100mm) in the support 2;
- install the shank 9 in the conical hole of the lever 5, tighten the nut 10 to a torque of 40...50 Nm and cotter;
- remove the technology rod.
- the deviation of the common plane of symmetry of the lever 1 and the rod 3 from the vertical plane is no more than 2 mm to ensure by changing the length of the rod 7.
For ZF-9S109 model:
- set the gearshift lever (see Fig. Gearshift control drive of the ZF-9S109 gearbox) at an angle E of the vertical:
- set the lever at an angle W to the vertical;
- rotating the shank, align the axis of the conical pin with the axis of the hole in the lever;
- rotating jet thrust, ensure that the common plane of symmetry of the gearshift lever does not deviate from the vertical plane by more than 2 mm;
- tighten and cotter pin slot nuts;
- tighten the nut.
Check the oil level in the crankcase of the gearbox model 161 with a pointer mounted in the oil filler cap. The normal level should reach the upper mark on the pointer. When checking the level, do not screw in the plug, but only insert it into the hole until it stops in the thread.
For transmissions of models ZF-9S109 and ZF-16S151, the oil level must reach the lower edge of the filler hole.
Change of oil
Drain the oil from the crankcase when it is still warm from heating during operation: for model 161 - by unscrewing the oil filter 1 installed on the rear end of the demultiplier crankcase, and plugs 2 and 3 of the crankcase (see Fig. Oil drain plugs in the crankcase of the box model 161) ; for models ZF-9S109 and ZF-16S151 - by unscrewing the filler and drain plugs. Clean the magnetic plugs from dirt and, after draining the used oil, reinstall them.
