Руководство по эксплуатации маз 543м

Колесное шасси МАЗ-543. Инструкция по техническому обслуживанию. 1976

1976

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  Minsk Automobile Plant VEHICLE MAZ-543403 Instruction manual The Republic of Belarus Minsk, 2011…
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  DEAR DRIVER! The MAZ vehicle you are going to operate is a highly reliable automobile equipped with modern assemblies and instrumentation, which provides for an easier trailer train driving, easing down on some of the driver’s fatigue and enhancing road safety, and makes it possible to consid- erably increase working efficiency and reduce transportation self-costs.

• Page 3: Introduction

  INTRODUCTION MAZ-543403 – is a 4×4 two-axle vehicle (chassis) with pent busbar of the rear axle wheels (see Figure 1) designed for installation on it various technological equipment and for operation on all types of automobile roads, which are adapted to axial loads specified in the product data sheet .

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  SAFETY REQUIREMENTS AND WARNINGS To ensure reliable and effective performance of a vehicle one needs to know how its assem- blies and units function, provide for strict compliance with operation, maintenance and servicing instructions and eliminate any deviations from whatever requirements are set out in this opera- tions manual.
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  17 It is prohibited both to uplift or lower the cabin while the vehicle engine is still running and start the engine while the cabin is in the uplifted position, which is necessary to prevent gear box self-start and, accordingly, the resulting unwanted vehicle movement. When an engine needs to be started with the cabin in the uplifted position to provide for ad- justment or repair works, it is necessary to ensure that the gear box is in the neutral position.
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  SPECIFICATIONS The main weight parameters and specifications of the automobile chassis MAZ-543403 are given in the table 1 Table 1 Parameter Value Chassis curb weight with cabine, kg 7700 Curb weight distribution, kg – on the first axle 4950 – on the second axle…
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  Equipped vehicle gross weight (standard completeness) is the weight of a vehicle together with cooling fluid, clutch drive fluid, lubricants, windshield washer fluid, fuel (with tank filled up to not less than 90% of its rated capacity), a fire extinguisher, wheel chocks, a standard spare parts and tools package, a spare tire and any other accessories.

• Page 8: Control Elements And Instrumentation

  CONTROL ELEMENTS AND MEASURING INSTRUMENTATION Control elements and measuring instrumentation arrangement is as shown at Figures 2, 3, 4 and 5. starter and instrumentation lock switch 1 – with an antitheft device; 2 – turn indicator switch, dipped and distance headlights switch; 3 –…

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  Switching handle 2 for the turn indicator of dipped and distance lights Its positions are as follows: Horizontal: 0 – neutral; I – (fixed) – right turn indicators on; the indicators switch off automatically; II – (not fixed) – right turn indicators are short term on; III –…
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  Battery switch remote control button 1 (Figure 4). In case of remote control system fail- ure, the switch can be enabled or disabled by pressing the on-case button. The switch is located on the battery mounting bracket. When the switch is enabled, the voltage meter pointer starts to shift.
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  Air pressure indicator 16 (Figure 4) in brake circuits: upper dial – in the front circuit, lower – in the rear circuit. Alarm system switch 13 (Figure 4). When on, vehicle and trailer left and right turn signals are lit simultaneously. Main lights switch 15 (Figure 4).

• Page 12: Cabin Accessories

  warning device for oil level decrease in the power steering tank warn- 1 – ; 2 – ing device for coolant fluid level decrease; 3 – indicating lamp of the fan clutch Figure 5 – Panel CABIN ACCESSORIES Rear-vision mirrors are installed outside of the either side of the cabin. Mirrors position is adjustable.

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  The seat slope mechanism — of a bar type with stepped adjustment, allows to adjust the slope angle using handle 3 with the simultaneous pressure on the seat back. Seat horizontal adjustment mechanism (forward/back) – skid type with stepped adjustment of the seat position is performed by handle 6.
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  The similar action should be performed with the passenger’s seat. — to unfasten the straps which fix the bed to the cab; — to pull the handle of the bed and move it to the horizontal position, avoiding harmful con- tacts with the cabin interior.

• Page 15: List Of Pre-Sale Preparation Operations

  LIST OF PRE-SALE PREPARATION OPERATIONS 1 Depreservation (antirust compound removal). 2 Visual inspection for transportation damages. Check accessories, tools, manuals accord- ing to the packing list. 3 Position the items, devices temporarily dismantled for transportation. 4 Check oils availability, their level in assemblies and units; top up, if needed. 5 Top up cooling fluid (if needed).

• Page 16: Vehicle Break-In Period

  VEHICLE BREAK-IN PERIOD Service life and reliability of assemblies and mechanisms, vehicle operational cost- effectiveness in many instances depends on how well its parts bed in at the early operation stage. During break-in period, it is required to monitor fixtures state, tightening up loose bolt and other connections, as well as assemblies heating and, if the latter is excessive, determine the cause and eliminate any defects.

• Page 17: Particular Issues Associated With Vehicle Operation

  PARTICULAR ISSUES ASSOCIATED WITH VEHICLE OPERATION Pre-operation procedures for the vehicle Prior to operation, it is recommended to carry out some preliminary works, which presup- pose checks and filling-in with operational fluids. Depending on vehicle transportation conditions, batteries can be installed with or without electrolytic solution.

• Page 18: Driving And Controlling A Vehicle

  DRIVING AND CONTROLLING THE VEHICLE When breaking away or moving along slippery road sections, interwheel and interaxle dif- ferential lock is recommended to be enabled for a short-term (for a distance not exceeding 1 km). The lock must be enabled immediately before entering a slippery road section. In this case, it is required to throw in the clutch and enable the lock mechanism after the vehicle stopped moving.

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  1, 7, 11 – springs; 2, 5 – diaphragm; 3 – disk; 4 – guide bar; 6 – cylinder; 8 – balls; 9 – fixing bushing; 10 – breather hole; 12 – pusher Figure 9 – Spring accumulator Vehicle control While driving, monitor instrumentation indications and indicating lamp signals.
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  Through this vehicles acquire a number of advantages: — Improved active safety provided by break stability and control and improved break efficiency, especially on wet and slippery roads — Eextended life of tires — The possibility for increasing the average safe speed: — In addition, the ABS construction, applied by “Wabco”…
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  1-wheel speed sensor, 2-brake pressure electrical pneumo modulator 3-microprocessor based control unit, 4-fuse block, 5- infomodule 6-indicator lights, 7- ABS mode switch, 8- The cable with the ABS powering socket for a trailer ; 9 diagnostic socket: 10- diagnostic button. Figure 10 — The ABS elements location on the MAZ chassis…

• Page 22: Tire Mounting And Dismounting

  1- tractor ABS indicator lamp, 2-trailer ABS indicator lamp, 3- power supply circuit lamp of a trailer ABS; 4-PBS mode and ABS / PBS diagnostic indicator lamp; 5-ABS mode switch; 6-«TEMPOSET» mode switch (only for vehicles equipped with a velocity limiting device); 7- PBS mode switch;…

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  To take the wheels off, unscrew all its restraining nuts at six rotations, then, using a jack, raise the wheel (wheels) off the ground and, using the tire tool, release the blankholders (for back wheels). When fitting a tire it is strictly prohibited: –…
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  Roads of all types (only From 0.15-0.20 to a for tire inflation period pressure after overcoming corresponding to the 750 km difficult sections of maximum roads) permissible tire load It is necessary to stop after overcoming the difficult road sections (if the situation permits), and inflate the tires to the nominal pressure.

• Page 25: Checking And Adjustment

  CHECKING AND ADJUSTMENT Clutch linkage A clutch linkage is as shown in Figure 12. Free running of the clutch pedal (5-7) mm is regu- lated by the bolt 5 After pedal free running adjustment, full pedal travel adjustment is required, which provides the hydraulic booster (9) stem stroke (B=26,5-30,7 mm) by means of bolts 4 and 5 During operation, if necessary, free running adjustment is allowed.

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  1 — pedal 2 – hydraulic cylinder, 3 — tank, 4, 5 — bolt, 6 — nut, 7, 9 — rod, 8 — lever, 10 – hydraulic booster, 11 — valve, 12 — piston. Figure 12 — Clutch linkage Gearbox control drive The main gearbox is controlled with remote control lever 2 (Figure 13).
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  To check if the gearbox is in the neutral position move lever shaft 9 axially by pressing it with a hand. At that, the lever travel distance should be (30-35) mm; о –release bolt 3 and ensure angle β=85 by moving plate 4 in longitudinal direction; –…
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  1 – switch; 2 – lever; 3, 6 – bolt; 4 – plate; 5, 7, 8 – linkage rod; 9 – lever; 10 – gear change mechanism; 11 – piping; 12, 15, 22 – linkage rod end; 13, 14, 18 – nut;…
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  Figure 15 – Gear change diagram KP YMZ–2381 Brake valve actuator Brake valve angle α=(45+2) (Figure 21) can be adjusted, using bolt 2. After the adjustment, nut 3 must be tightened to the torque of 11.8-15.7 Nm. Pedal free travel is to be 17-27 mm. It is determined by pressure build-up in brake chambers.
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  Front cabin springing is adjusted as follows: – measure the existing gap between support cup 3 and bumper bracket 2 (see Figure 16); – throw off lock nut 4; – rotate upper cup 3 with the wrench 6, adjust to 48±3 mm length. In a similar way, adjust the other support and ensure that the gap between cup 3 and bracket 2 on the first support us still equal to 48±3 mm.

• Page 32: Vehicle Maintenance

  VEHICLE MAINTENANCE Careful vehicle maintenance is the best way to reduce operational costs for the vehicle and to ensure its trouble-free and long-term operation. During MAZ vehicles operation the following maintenance is recommended: – daily maintenance; – maintenance after every 4000 km (A) of mileage for I operation category. –…

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  — breather performance on the driving axles and the transfer case, and, if necessary, clean from dirt; – check steering wheel free travel and for steering rods hinges endfloats. The first maintenance (А) During the first maintenance it is required to carry out the entire scope as prescribed for an- nual maintenance, plus: 1 Check all driving belts and adjust if needed.
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  6 Check free travel and turn force while the engine is running. 7 Make a visual inspection of the frame, brackets, springs and supporting wedge fixtures. 8 Check nuts at the front and rear spring clamp, pins and springing eye clamps and rear sus- pension balancer brackets and tighten if needed.
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  FUEL, OIL AND LUBRICANTS (FOL) CHIMMATOLOGY LIST Lubrication (fill- Lubri- Basic grades and application seasons Foreign equivalents FOL quantity FOL change Lubrication (filling, oil change) ing) point cation (grade, specification, com- (refilling) in- recommendations. Waste oil (filling) pany) tervals. Basic discharge (collection) norm Filling Total for a…
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  Maintenance in Change oil after the break-in pe- breaking-in Engine oils with API perform- riod with washing the oil filters. period ance characteristics of, at least СG-4 category, and SAE vis- cosity class as follows: In summer: Check the oil level, top up if nec- SAE 30 (up to plus 30°С) daily inspection List of engine oils is submitted in RD…
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  Lubrication (fill- Lubri- Basic grades and application seasons Foreign equivalents FOL quantity FOL change Lubrication (filling, oil change) ing) point cation (grade, specification, com- (refilling) in- recommendations. Waste oil (filling) pany) tervals. Basic discharge (collection) norm Filling Total for a quantity grade norm…
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  Lubrication (filling) Lubrica- Basic grades and application Foreign equivalents FOL quantity FOL change (refill- Lubrication (filling, oil point tion (fill- seasons (grade, specification, com- ing) intervals. Basic change) recommendations. Filling Total for ing) quan- pany) norm a vehicle grade Waste oil discharge (collection) tity norm Hydraulic jack DG 12…
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  Lubrication (filling) Lubrica- Basic grades and application Foreign equivalents FOL quantity FOL change (refill- Lubrication (filling, oil point tion (fill- seasons (grade, specification, com- ing) intervals. Basic change) recommendations. Filling Total for ing) quan- pany) norm a vehicle grade Waste oil discharge (collection) tity norm Power steering sys-…
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  Lubrication (filling) Lubrica- Basic grades and application Foreign equivalents FOL quantity FOL change (refill- Lubrication (filling, oil point tion (fill- seasons (grade, specification, com- ing) intervals. Basic change) recommendations. Filling Total for ing) quan- pany) norm a vehicle grade Waste oil discharge (collection) tity norm Binary hinge of…
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  Lubrication (filling) Lubrica- Basic grades and application Foreign equivalents FOL quantity FOL change (refill- Lubrication (filling, oil point tion (fill- seasons (grade, specification, com- ing) intervals. Basic change) recommendations. Filling Total for ing) quan- pany) norm a vehicle grade Waste oil discharge (collection) tity norm biaxial…
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  Lubrication (filling) Lubrica- Basic grades and application Foreign equivalents FOL quantity FOL change (refill- Lubrication (filling, oil point tion (fill- seasons (grade, specification, com- ing) intervals. Basic change) recommendations. Filling Total for ing) quan- pany) norm a vehicle grade Waste oil discharge (collection) tity norm Pivot bearings of the…
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication Basic grades and applica- Foreign equivalents (grade, (refilling) in- recommendations. Waste oil dis- (filling) Fillingnor Totalfor (filling) point tion seasons specification, company) tervals. Basic quantity) charge (collection) norm a vehicle grade Steering post bear- Lubricant Litol-24…
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication (filling) Basic grades and application Foreign equivalents (grade, (refilling) in- recommendations. Waste oil dis- (filling) point seasons specification, company) Filling Total for tervals. Basic quantity) charge (collection) norm norm a vehicle grade Spherical surface of the Lubricant “Shrus–4”…
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication (filling) Basic grades and application Foreign equivalents (grade, (refilling) in- recommendations. Waste oil dis- (filling) Filling Total for point seasons specification, company) tervals. Basic quantity) charge (collection) norm norm a vehicle grade Gearbox crankcase The list of gear oils is presented in RD 37.319.035-03 (YMZ)
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication (filling) Basic grades and application Foreign equivalents (grade, (refilling) in- recommendations. Waste oil dis- (filling) Filling Total for point seasons specification, company) tervals. Basic quantity) charge (collection) norm norm a vehicle grade Fuel supply…
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication (filling) Basic grades and application Foreign equivalents (grade, (refilling) in- recommendations. Waste oil dis- (filling) Filling Total for point seasons specification, company) tervals. Basic quantity) charge (collection) norm norm a vehicle grade Spring pins: 0,015…
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication (filling) Basic grades and application Foreign equivalents (grade, (refilling) in- recommendations. Waste oil dis- (filling) Filling Total for point seasons specification, company) tervals. Basic quantity) charge (collection) norm norm a vehicle grade Driving axle expan- grade XG279 (Eng.)
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication Basic grades and application Foreign equivalents (grade, (refilling) in- Total (filling) recommendations. Waste oil dis- Filling (filling) point seasons specification, company) tervals. Basic for a quantity) charge (collection) norm norm vehicle grade Wind-screen wiper…
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication Basic grades and application Foreign equivalents (grade, (refilling) in- Total recommendations. Waste oil dis- (filling) Filling (filling) point seasons specification, company) for a tervals. Basic quantity) norm charge (collection) norm vehicle grade Leafs of front and rear…
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication Basic grades and application Foreign equivalents (grade, (refilling) in- Total (filling) recommendations. Waste oil Filling (filling) point seasons specification, company) tervals. Basic for a quantity) discharge (collection) norm norm vehicle grade 0,0025 kg 0,01 kg…
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication Basic grades and application Foreign equivalents (grade, (refilling) in- Total (filling) recommendations. Waste oil Filling (filling) point seasons specification, company) tervals. Basic for a quantity) discharge (collection) norm norm vehicle grade Accumulator switch Mobilgrease MP Mobilux…
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication Basic grades and application Foreign equivalents (grade, (refilling) in- Total (filling) recommendations. Waste oil Filling (filling) point seasons specification, company) tervals. Basic for a quantity) discharge (collection) norm norm vehicle grade Connection contacts 0,0005…
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  FOL quantity FOL change Lubrication (filling, oil change) Lubrication Lubrication Basic grades and application Foreign equivalents (grade, (refilling) in- Total (filling) recommendations. Waste oil Filling (filling) point seasons specification, company) tervals. Basic for a quantity) discharge (collection) norm norm vehicle grade binder socket of the Lubricant VNII NP-510…

• Page 56: Annexes

  Annex 1 Scope of the guarantee provided, procedures for claims submission and drawing up of documents as required are stipulated in the vehicle sale and purchase contract. In case of any damage please fill in the attached form and send it to the vendor. DAMAGE STATEMENT No.

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  Annex 2 Main threaded connections tightening torques, Nm Tightening Front Rear torque, Assembly driving Note axle axle 1 HOLD-DOWN BOLTS Journal to axle crankcase housing 320–360 Carrier to carrier crankcase housing 420–440 Drive axles with disk wheels Driving bevel gear bearing sleeve 90–120 Bolt connection variant…
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  Tightening Front Rear torque, Assembly driving Note axle axle Bolts and studs for securing steering 275–314 knuckle lever and upper cover Front axle covers and crankcase hous- 157–196 ings Pivot pin bearing covers 16–20 Expansion cam tube shock absorber 310–315 brackets to caliper Pivot stud device adjustment bolt 310–350…
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  Tightening Front Rear torque, Assembly driving Note axle axle Bolts for securing front brake supports 160–200 with steering knuckles Nuts for securing wheels for vehicles 500–600 with disk wheels Nuts for front spring U-bolts 450–600 Nuts for rear spring U-bolts 600–650 Nuts for front and rear spring eyes U- 200–220…
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  Battery operation manual 1 Batteries This manual describes the starting batteries of a 110 a/h capacity and the batteries of a higher performance, dry-charged and fully charged with electrolyte. Security measures, the procedure of bringing the batteries in an operating state, maintenance, operation, storage, transportation and disposal are described in the manual.
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  against the density of the submerged electrolyte (table 1) than the batteries can be put into operation. If the density of the electrolyte will decrease by more than 0.03 g/cm3, the battery must be charged in accordance with paragraph 3.2. 3.1.5 If necessary to put the dry-charged batteries immediately into operation, its installation on the vehicle is allowed without checking the density after 20 minutes of drenching, in case the period of storage does not exceed one year from the date of manufacture and putting in…
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  4.1.1 When operating the vehicles and other means of transport it is necessary to check the charging mode of the batteries to prevent over-charging or incomplete charging, that short- ens their life-circle. During maintenance, check the regulator. When operating, the value of the charging voltage should comply with the value specified in the technical description and operating instructions for the appropriate vehicle.
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  Table 3 Плотность электролита, приведенная к 25 °С, г/см Discharged battery Fully charged battery by 25% by 50% 1,30 1,26 1,22 1,28 1,24 1,20 1,26 1,22 1,18 1,23 1,19 1,15 4.2.11 The battery, discharged by more than 25% in winter and by 50% in summer (Table 3) should be removed from service and put in charge in accordance with paragraph 3.2 5 Transport and storage 5.1.1 Transportation of batteries is performed in covered vehicles that ensure their protection…

• Page 64: Table Of Contents

  CONTENTS Page Introduction …………………………………………………………………………….. Safety requirements and cautions..……………………………………………. Technical specification..………..……………………………………………………… Control elements and instrumentation ………………………………………………… Cabin accessories………………………………………………………………………. List of pre-sale preparation operations………………………………………………… Vehicle break-in period ………………………………………………………………… Particular issues associated with vehicle operation…….……………………………… Pre-operation procedures for a vehicle……………..……………………………… Driving and controlling a vehicle………………………………………………….. Tire mounting and dismounting…………..………………………………….……………