Инструкция по эксплуатации камаз 5490 скачать

Опубликовано: | 23 марта, 2022

KamAZ operator’s, electrical wiring diagrams, workshop, service and repair manuals, spare parts catalogs, error codes in PDF download 

Документация КАМАЗ

Набор технической документации, книг, руководств и справочников по ремонту и техническому обслуживанию: • Автомобилей КАМАЗ • Двигателей Cummins, КАМАЗ • AdBlue • КПП ZF (MAN) и другие.

Сертификат дилера ПАО «КАМАЗ» №398/40096783-22067. KAMAZ™ © ТОО «АвтоТрейд-К» 2005-2023 гг.

Summary of Contents:

[Page 1] KAMAZ 5490 KAMAZ PUBLICLY TRADED COMPANY Operation manual КАМАZ-5490 vehicle 5490-3902203-01 РЭ Naberezhnye Chelny 2017 …

[Page 2] KAMAZ 5490 INTRODUCTION Operation manual includes technical data of KAMAZ-5490 vehicle, recommendations on operation and technical maintenance. Managing editor: D. Kh. Valeev. «KAMAZ» PTC Chief design engineer General compiler: Igovskiy A.A. …

[Page 3] KAMAZ 5490 1 CONTENT 1 FOR YOUR ATTENTION ……………………………………..………….………………………………………..…. 1-1 2 OPERATION PARAMETERS .……………..……………………………………………………

[Page 4] KAMAZ 5490 2 Instrument panel…..……………………………………………………………………..…………………. 4-3 Instrument cluster……….………………………………………………………………..………….

[Page 5] KAMAZ 5490 3 Windscreen washer…..…………………………………………………………………………………. 4-19 Cab doors…………………………………………………….………………………………………………

[Page 6] KAMAZ 5490 4 Cab interior light………………….…………………………………………………….……..……..……. 4-37 Electrical sockets…..……………………………………………………………..…………………

[Page 7] KAMAZ 5490 5 Messages on the display………………………………………………………………………. 4-57 Gear shifter………………..………………………………………………………………….. 4-58 Automatic…

[Page 8] KAMAZ 5490 6 5 VEHICLE OPERATION IN COLD SEASON……………………………….…………………….……………..….….. 5-1 Special features of vehicle operation during cold period of time…………….………………………..… …

[Page 9] KAMAZ 5490 7 Sequence to read diagnostic codes………………………..………………………………………..… 7-4 Mode for diagnostics of operational parameters.……………………………………………………. 7-6 Indicati…

[Page 10] KAMAZ 5490 8 Wheel with tubeless tire disassembly and assembly……….………………………………….….……… 7-48 Troubleshooting for bolster.…………………………………………..………………….………….……. 7…

[Page 11] KAMAZ 5490 1-1 1 FOR YOUR ATTENTION 1. Prior vehicle (train) operation, study this manual carefully and further observe all recommendations pre- sented in it. 2. New vehicle is to be registered. This provides technical consultation on vehicle operation, m…

[Page 12] KAMAZ 5490 2-1 2 OPERATION PARAMETERS VEHICLE TECHNICAL DATA КАМАZ-5490 (М1842) Wheel arrangement ……………………….…………..4×2 Technically permissible maximum bolster load, daN ……………………… .…..…..10550 3…

[Page 13] KAMAZ 5490 2-2 TABLE OF ADDITIONAL TECHNICAL DATA Operational data Model 5490 Technically permissible maximum weight of vehicle, kg, applied to: axle 1 7100 axle 2 11500 Maximum driving speed 1) , km/h, at least: train 90 2) Test fuel …

[Page 14] KAMAZ 5490 2-3 TIRE AIR PRESSURE Wheel position Tire pressure of the vehicle with technically permissible maximum weight, kPa (kgf/sm 2 ) for tire size 315/60 R22,5 315/70 R22,5 315/80 R22,5 Front axle wheels 880±20 (9,0±0,2) 830±20 (8,5±0,…

[Page 15] KAMAZ 5490 2-4 TOOLS, ACCESSORIES, SPARES AND OPERATIONAL DOCUMENTATION SUPPLIED WITH VEHICLE Name pcs./vehicle Operation documentation Operation manual 1 pc. Service book 1 pc. List of operational documents 1 pc. Operation manual Engine Me…

[Page 16] KAMAZ 5490 2-5 Additional equipment that can be attached under certain requirement, specified by supply agreement: a tool kit in a small bag at extra cost, a minimum tool kit at extra cost, an oil transfer pump (1 pc.). Truck (chassis) is to be equipped wi…

[Page 17] KAMAZ 5490 2-6 VEHICLE MARKING Manufacturer’s plate The manufacturer’s plate is fixed in a r.h. door aperture. The plate contains: — manufacturer’s name; — identification number, including: — XTC — manufacturer index; — а — conventional veh…

[Page 18] KAMAZ 5490 2-7 Manufacturer’s plate for export vehicle The manufacture’s plate is fixed to the cab r.h. panel in a door aperture. Plate contains (see Fig. Manufacturer’s plate for export vehicle): — manufacturer’s name; — e — European approval;…

[Page 19] KAMAZ 5490 2-8 VIN code VIN code is applied onto the vertical wall of the right side member in frame front or rear part and in- cludes: — XTC — manufacturer’s code (3 marks); — vehicle model conventional code (6 marks); — production year code (1 mark); …

[Page 20] KAMAZ 5490 2-9 SCHEME OF SEALING Cover of «ZF» gear box, power steering of «RBL», «ZF» companies are not sealed. If tachograph is installed in vehicle manufacturer’s plant, the tachograph is sealed temporarily. Tachograph Supplier’s seal …

[Page 21] KAMAZ 5490 3-1 3 BRIEF DESCRIPTION OF VEHICLE SYSTEMS AND MECHANISMS ENGINE Vehicle is equipped with engine Mercedes-Benz OM457LA. Operation manual for Mercedes-Benz engine is supplied with vehicle. TRANSMISSION Clutch Clutchis single-plate, diaphragm…

[Page 22] KAMAZ 5490 3-2 SUSPENSION Front suspension is a leaf spring suspension. Rear suspension is an air spring suspension. For air suspension regulation and control an electronic con- trol system (ECAS) of «WABCO» is used. STEERING CONTROL Steering control i…

[Page 23] KAMAZ 5490 3-3 ELECTRIC EQUIPMENT The electric equipment comprises the following systems: power supply system, engine starting system, warning lights, outer and inner illumination means, indi- cating devices, heating systems, ventilation and audio signalin…

[Page 24] KAMAZ 5490 4-1 4. VEHICLE OPERATION VEHICLE KEYS Keys are designed for cab door opening and for instruments-and-starter switch. Keys have a special cod- ing and are bound to a particular vehicle. Key positions 0- everything is «Off». With the key re…

[Page 25] KAMAZ 5490 4-2 DRIVER’S WORKING PLACE Driver’s working place 1 – switch block on driver’s door; 2,10,17 – ventilation and heat deflectors; 3 – smoke detector; 4 – cab heat control console panel (if available); 5 – tachograph; …

[Page 26] KAMAZ 5490 4-3 INSTRUMENT PANEL INSTRUMENT CLUSTER 1 — Electronic tachometer; 2 — tachometer indicator, lightens up (color — red) when the vehicle moves at modes dangerous for engine (if admissible engine crankshaft speed is exceeded); 3 — pilot lamp…

[Page 27] KAMAZ 5490 4-4 7 — pressure gauge in brake system circuit 1; the rated air pressure in pneumatic drive is from 9,0 to 10,0 kgf/cm 2 . Pilot lamp is located in the indicator zone , and it lights up (color — red) when pressure drops in the 1-st brake s…

[Page 28] KAMAZ 5490 4-5 Pilot lamps Low level of liquid in neutralization system (color – blue) Air suspension defect (color — red) Air filter clogging up (color — red) Anti-skid system engagement (color — orange) Truck tractor EBS/ ABS fault (colo…

[Page 29] KAMAZ 5490 4-6 Wearing of brake pads (color — orange) Unfasten safety belt (color – red) Intarder engagement (color — orange) Pressure drop in the 1-st brake system circuit (color – red) Pressure drop in the 2-nd brake system cir- cuit (co…

[Page 30] KAMAZ 5490 4-7 Information system control Information system control is carried out by the buttons located on the steering wheel on the left side (see Fig. Screen control on the display). Attention! Use information system functions only on a sta- tio…

[Page 31] KAMAZ 5490 4-8 Check before motion initiation If messages about vehicle malfunction are absent the screens with monitored information about vehicle operational state automatically appear on the display. Main screen 1 — Current value of onboard network v…

[Page 32] KAMAZ 5490 4-9 Screen «Travel» The data on the screen «Travel» are reset simulta- neously with daily mileage re-zeroing. «Time» — current data on time for the trip cover- ing period. «Motor hours» — current data on motor hours for the trip coveri…

[Page 33] KAMAZ 5490 4-10 Display lighting Press the button . The symbol will flash on and off in front of the scale. Adjust display light brightness by buttons and . Press the button , adjusted screen light brightness will be saved in memory. Brightnes…

[Page 34] KAMAZ 5490 4-11 SWITCH BLOCKS Instrument panel 1 — Switches/ shifters; 2 — control panel of heating and air conditioning system; 3 – shifter of interwheel differential lock. Symbol Application of switches/ shifters Engagement/ disengagement…

[Page 35] KAMAZ 5490 4-12 Symbol Application of switches/shifters Engagement/ disengagement of hydraulic motor (for certain vehicle configurations) Engagement/ disengagement of PTO box Engagement/ disengagement of flashing lights (for certain vehicle con…

[Page 36] KAMAZ 5490 4-13 Driver’s/ passenger’s door Over the windshield Pos. Application of shifters 1 Adjustment of external rear view mirror position 2 Rear view mirror heating 3 Window raiser on driver’s door 4 Window raiser on passe…

[Page 37] KAMAZ 5490 4-14 Bunk ADJUSTMENT OF HEADLAMP INCLINATION ANGLE Adjuster of headlamp inclination angle is located on instrument panel (see Fig. Adjuster of headlamp inclination angle). Adjustment is carried out in accord with vehicle load. Adjuster p…

[Page 38] KAMAZ 5490 4-15 LIGHT SHIFTER Vehicle light is switched on and off by light shifter. Prior light energizing, rotate the ignition key to position «ON» (motion position). LIGHT FOR MOVEMENT IN THE DAYTIME Daytime running lights switch on automatically …

[Page 39] KAMAZ 5490 4-16 AUXILIARY ILLUMINATION HEADLAMPS IN INSUFFICIENT VISIBILITY CONDITIONS AND REAR FOG LAMPS Auxiliary illumination headlamps in insufficient visibility conditions 1. To switch on turn the light switch to position . 2. Pull the light swit…

[Page 40] KAMAZ 5490 4-17 COMBINATION SWITCH SWITCHING OF DIRECTION INDICATOR Pull combination switch till fixation: — towards «4» (away from oneself») — right turn signal; — or «5» («toward oneself») — left turn signal. When the steering wheel returns …

[Page 41] KAMAZ 5490 4-18 Engagement of windscreen wipers Turn the switch 1 (see Fig. Engagement of windscreen wipers) into required position. Disengagement of windscreen wipers Turn the switch 1 to position (or ). Windscreen wiper will make one more movement an…

[Page 42] KAMAZ 5490 4-19 Attention! It is necessary to check the windscreen wiper blades for the presence of dirt and damages. Switch off the windscreen wipers before placing the vehicle in the parking area, as windscreen wiper blades can suddenly start mooving wh…

[Page 43] KAMAZ 5490 4-20 CAB DOORS DOOR LOCK BLOCKING Door lock releasing/ locking externally, by key When releasing the vehicle door lock only corre- sponding door is opened by the key. Door lock releasing/ locking from inside the cab For locking the door fr…

[Page 44] KAMAZ 5490 4-21 LOWERING AND RAISING OF SIDE WINDOWS OF DRIVER/ PASSENGER Cab doors are equipped with electric window raisers. Lowering and lifting of side windows is carried out at rotation of ignition key into position «ACC». To open the driver&a…

[Page 45] KAMAZ 5490 4-22 MECHANICAL CLOSURE OF RAISABLE TOP HATCH 1. Prepare the flat screwdriver (the width of screwdriver working end is 4 mm). 2. Remove the plug (see Fig. Closing down of lift- ing top hatch). 3. Insert the screwdriver in the drive port. 4. Rot…

[Page 46] KAMAZ 5490 4-23 EXTERNAL REAR VIEW MIRRORS It is recommended to check the installation of ex- ternal mirrors on the vehicle before each drive. Position of the right and the left external rear view mirrors is regulated by electric drivers. POSITION REGULATI…

[Page 47] KAMAZ 5490 4-24 SEAT POSITION ADJUSTMENT Adjustment of seat position on air suspension The angle of armrest 3 inclination is smoothly adjusted at armrest regulator rotation. Seat cushion depth. With lever 4 up, the cushion displaces forward-and-backward a…

[Page 48] KAMAZ 5490 4-25 Seat back inclination angle. With lever 8 shifting up the back is unfixed and inclines forward, with lever release, the back is fixed in selected position. Seat lateral support is adjusted by the button 9. Lumber support is adjus…

[Page 49] KAMAZ 5490 4-26 The shape of seat back profile is selected at ro- tation of the handle 2 (see Fig. Passenger’s seat). At counterclockwise rotation the back convex camber in- creases, clockwise — decreases. The angle of armrest 3 inclination is smoothly a…

[Page 50] KAMAZ 5490 4-27 SAFETY BELTS The vehicle seats are provided with safety belts. Safety belt prevents considerable displacement of driver in direction opposite to hit direction, thus, decreases danger of injure, e.g. at frontal clash. To fasten the safety b…

[Page 51] KAMAZ 5490 4-28 THE UPPER BUNK Attention! Get a move on only with a folded and belt fixed bunk. It is forbidden to be on the upper bank of the driving vehicle. Dropping of the bunk 1. Throw forward the backs of driver’s and pas- senger’s seat…

[Page 52] KAMAZ 5490 4-29 THE LOWER BUNK Setting of the lower bunk into operational state 1. Raise slightly the lower bunk and detach the re- taining belt 3 from the hook 4 (see Fig. Fixation of the lower bunk). 2. Throw the lower bunk down. 3. Fixate the rubber cl…

[Page 53] KAMAZ 5490 4-30 STEERING WHEEL ADJUSTMENT Position of steering wheel is adjusted by height and inclination. Adjustment mechanism is provided with the system of pneumatic lock and lock release. Adjustment of steering wheel position 1. Stop the vehicle. 2….

[Page 54] KAMAZ 5490 4-31 AIR CONDITIONING SYSTEM CONTROL VENTILATION DEFLECTORS The airflow direction can be adjusted by means of deflectors located on cab doors and on instrument pan- el (see Fig. Ventilation deflectors): — opening — turn the flywheel 2 upwards; …

[Page 55] KAMAZ 5490 4-32 Air distribution in the cab Positions of air distribution regulator Symbol Application Air supply to the windscreen and to the side windows ▲ ▼ Air supply to the windscreen and to the foot room ▼ Air supply to the foot ro…

[Page 56] KAMAZ 5490 4-33 EXAMPLES OF SETTINGS Fresh air mode In case of the glass misting it is necessary immedi- ately to switch the fan to the fresh air mode. Air recirculation mode At low or too high ambient air temperature you can briefly engage the air recir…

[Page 57] KAMAZ 5490 4-34 Windscreen defrosting 1. Set the shifter and regulators as it is shown in the Fig. Windscreen defrosting. 2. Close ventilation deflectors. 3. Switch on, if necessary, the autonomous cab heater. Windscreen defrosting …

[Page 58] KAMAZ 5490 4-35 CONDITIONER The air conditioner regulates air temperature and humidity in the vehicle cab. Attention! Air conditioning system works only with engine working. For normal operation of air conditioner com- pressor it is necessary to switch…

[Page 59] KAMAZ 5490 4-36 INDEPENDENT CAB AIR HEATER In certain vehicle configurations an independent cab air heater is installed. An independent cab heater automatically adjusts temperature in the cab. Engagement, disengagement, adjustment of in- dependent heater …

[Page 60] KAMAZ 5490 4-37 CAB INTERIOR LIGHT Lighting types: — cab lighting; — lamp for reading; — night lighting. All types of lighting are engaged and adjusted in- dependently of each other. Engagement and disengagement of interior cab lighting 1 — engagem…

[Page 61] KAMAZ 5490 4-38 ELECTRICAL SOCKETS Electrical sockets 24 V/ 10 А are located in the central part of instrument panel and on passenger’s side (see Fig. Electrical sockets and jumper). Load on each such electrical socket should not be more than 24…

[Page 62] KAMAZ 5490 4-39 ASH TRAY Installation of ash tray is possible in the cab. To open pull the ash tray by the handle in the di- rection of the arrow until stop (see Fig. Ash tray). Further press the lock release button 2 and, holding it down, fully pull the …

[Page 63] KAMAZ 5490 4-40 DIGITAL TACHOGRAPH On the shelf over the windshield a digital tacho- graph is installed. Digital tachograph – technical control device, de- signed for registration, storage, display, printing of data about the mode of movement, labour and…

[Page 64] KAMAZ 5490 4-41 EMERGENCY RESPONSE SERVICE CALLING UNIT (ERA-GLONASS) APPLICATION AND CONTROL DEVICES Emergency response service calling unit is de- signed for: — transfer of minimum data set with description of motor vehicle, coordinates of its location,…

[Page 65] KAMAZ 5490 4-42 OPERATION MODES When the ignition key is turned to position «ON», the illumination of emergency button «SOS» (color — red) lights up for 5-6 sec. and dies out. If malfunction in emer- gency response service call system appears, in 20-30 …

[Page 66] KAMAZ 5490 4-43 DRIVING THE VEHICLE SAFETY REQUIREMENTS 1. All defects discovered during vehicle inspection should be eliminated. 2. At starting the engine, observe the following safety precautions: first of all, make sure that the parking brake system …

[Page 67] KAMAZ 5490 4-44 20. Prior to performance of electric welding ac- tivities the following operations are necessary to be fulfilled on the vehicle: — the storage batteries should be disconnected by means of a remote-control switch; — disconnect terminals fro…

[Page 68] KAMAZ 5490 4-45 SAFETY REQUIREMENTS DURING OPERATION OF VEHICLE WITH ELECTRONIC SYSTEMS 1. Be sure to disconnect the storage battery while repairing or replacing the items of vehicle electronic sys- tems. 2. It is strictly forbidden to connect the electric…

[Page 69] KAMAZ 5490 4-46 NEW VEHICLE OPERATION (RUNNING-IN) Vehicle reliability and economic feasibility as well as its life duration depend upon parts and aggregates run- ning-in during new vehicle operation – the first 1000 km of the race. The following requir…

[Page 70] KAMAZ 5490 4-47 10. In case of lighting of incidental oil pressure and incidental coolant temperature pilot lamps located on the instrument panel and warning about the dangerous drop of pressure in engine lubricating system and about critical over-heating …

[Page 71] KAMAZ 5490 4-48 Climbing Short climbs on good roads should be overcome with speed reserve. While overcoming sharp and prolonged climbs, choose the low gears taking into account the road train load, length and sharpness of climbing. If possible use the ge…

[Page 72] KAMAZ 5490 4-49 PRELIMINARIES FOR VEHICLE MOTION Prior to the vehicle movement: 1. Perform vehicle daily maintenance (see section 6 «Maintenance»). 2. Check fuel reserve in fuel tank by indicator. When the volume of fuel decreases in fuel tank to 12 %…

[Page 73] KAMAZ 5490 4-50 Fuel tank filling (for certain configurations upon availability of two fuel tanks) Fuel tanks are connected by the crossover pipeline of small section (see Fig. Fuel tank). When filling in both fuel tanks it is recommended: — to open cov…

[Page 74] KAMAZ 5490 4-51 ENGINE START AND SHUTDOWN PROCEDURE Engine start up Parking brake system is engaged. 1. Check if gearbox control lever is in neutral. For the gear box with automated control the rotary switch is set to position «N». If the rotary switch…

[Page 75] KAMAZ 5490 4-52 10. For the vehicle with mechanical gear box smoothly release the clutch panel. 11. Increase pressure in brake system circuits up to norm (from 9,0 to 10,0 kgf/cm 2 ), controlling pressure in brake system circuits I and II by indicators loc…

[Page 76] KAMAZ 5490 4-53 IDLE SPEED ADJUSTMENT After engine start up the idle speed is set automati- cally depending on coolant temperature. Idle speed of the engine warmed up to operation temperature is approximately 600 min -1 . The engine idle speed is to be adj…

[Page 77] KAMAZ 5490 4-54 «CRUISE-CONTROL» MODE In cruise-control mode, the vehicle traveling speed is maintained on a level set. The mode may be activated at vehicle speed at least 38 km/h. When «Cruise-control» is engaged but not active, speed digits are flas…

[Page 78] KAMAZ 5490 4-55 GEARBOX CONTROL Gear change in gearbox is performed with the help of gearshift lever located to the right of driver’s seat. Shift the lever with the clutch released. Depress the clutch pedal against stop. The gear engagement and change…

[Page 79] KAMAZ 5490 4-56 For gearbox models ZF 16S1820 ТО, ZF 16S2220 ТD, ZF 16S2221 ТD gear shifting is ful- filled according to the scheme (see Fig. Gear change scheme for gearbox models ZF 16S1820 ТО, ZF 16S2220 ТD, ZF 16S2221 TD): – 1-2-3-…

[Page 80] KAMAZ 5490 4-57 GEARBOX WITH AUTOMATED CONTROL Depending upon vehicle configuration, the vehicle may be equipped with gearboxes of models ZF 12AS 2130 TD, ZF 12AS 2131 TD with automated control for clutch linkage and gear shift mechanism. Gear shifting c…

[Page 81] KAMAZ 5490 4-58 Gear shifter Gear box control is carried out by the gear shifter, located on the steering column, on the right hand (see Fig. Gear shifter). Attention! Use the rotary switch only on a stationary vehicle and with engine idle speed. …

[Page 82] KAMAZ 5490 4-59 With automatic mode engaged the motion mode, corresponding to rotary switch position, is displayed. At manual control engagement the number of the gear engaged is displayed. Change of automatic and manual gearbox modes is possible in any t…

[Page 83] KAMAZ 5490 4-60 Gearbox manual control In difficult road conditions (for example, during the off-road movement) it is recommended to shift to the man- ual control mode to preserve an opportunity of self gear shifting in accordance with the road situation. …

[Page 84] KAMAZ 5490 4-61 To decrease the motion speed use secondary brake system. When engaging secondary brake system the elec- tronic control system automatically shifts the gearbox down. To stop the vehicle apply the brakes and stop it. At short stoppage, for ex…

[Page 85] KAMAZ 5490 4-62 INTERWHEEL DIFFERENTIAL LOCK Differential is to be locked when there is a differ- ence in values of wheel adhesive forces between which it is set. The lock is to be engaged directly before overcom- ing of hard track sections (sticky ground,…

[Page 86] KAMAZ 5490 4-63 BRAKE SYSTEM Service brake system is intended to reduce the vehicle traveling speed and to bring it to total halt; it is controlled by the brake pedal. An emergency brake system is designed to pro- vide the brake application in case the s…

[Page 87] KAMAZ 5490 4-64 Auxiliary brake system Use the auxiliary brake system in all cases to reduce the traveling speed and compulsorily when driving on pro- tracted downgrades in order to prevent over-heating of braking mechanisms. On continuous grades up and do…

[Page 88] KAMAZ 5490 4-65 Auxiliary brake system control by means of the switch With the switch in position «В» the mode of downhill operation constant speed is engaged, it doesn’t allow the vehicle to pick up speed. Vehicles without retarder have …

[Page 89] KAMAZ 5490 4-66 ELECTRONIC BRAKE SYSTEM EBS Vehicle is equipped with electronic brake system (EBS), comprising the following functions: — control of service and auxiliary brake systems (Brake-Management); — anti-lock braking system (ABS); — anti-skid sy…

[Page 90] KAMAZ 5490 4-67 Antiskid system (ASR) Antiskid system prevents slippage of driving wheels, irrespective of road conditions. With driving wheels skidding on one or both sides, automatically, ASR working mode is activated, with this, pilot lamp of anti-sk…

[Page 91] KAMAZ 5490 4-68 HILL START ASSIST CONTROL Hill start assist control is a part of ESP brake sys- tem. Hill start assist control helps the driver to keep the vehicle from rolling down at starting from standstill on the upgrade. Operation of hill start assist…

[Page 92] KAMAZ 5490 4-69 AIR SUSPENSION REMOTE-CONTROL CONSOLE Air suspension electronic control system fulfills the following functions: 1. If there is sufficient pressure in receiver and hand brake is released, the system automatically settles the suspension int…

[Page 93] KAMAZ 5490 4-70 To set the earlier recorded height – depress the buttons of switches 7 (М1) or 8 (М2). To interrupt the process of height variation – de- press the switch 5 button (STOP). The suspension «transport» position state is de- clared by t…

[Page 94] KAMAZ 5490 4-71 FACING PANEL Facing panel is opened and closed by both hands applying uniform force to both sides, observing maximum distance from center of the panel (see Fig. Opening of the upper facing panel). Attention! It is strictly forbidden to op…

[Page 95] KAMAZ 5490 4-72 VEHICLE TOWING Vehicle is towed by other vehicles of the same type by means of a rigid towing. For vehicle towing remove the plugs in buffer fac- ing, install the tow yokes (see Fig. Installation of tow yokes). Install the tow device. W…

[Page 96] KAMAZ 5490 4-73 OPERATION OF BOLSTER TRUCK TRACTOR BEING A PART OF A ROAD TRAIN When bolster tractor is a part of a train with in- stalled three-component wings of rear bogie, the upper part of wings should be dismantled. For dismantling it is necessary t…

[Page 97] KAMAZ 5490 4-74 At trailer/ semitrailer connection the rear fog lamps of truck tractor are not active. Attention! Thin layer of grease is applied onto bolster sup- port plate. Do not start motion until you are sure that lock is reliably closed. When ma…

[Page 98] KAMAZ 5490 4-75 PUMPING OF PETROLEUM PRODUCT DURING OPERATION OF HYDROFICATED BOLSTER TRACTION TRUCK WITH A TANK SEMITRAILER 1. Place the vehicle on a level and hard surface. 2. Apply the parking brake system to stop the semi-trailer. 3. Use the chocks (…

[Page 99] KAMAZ 5490 5-1 5 VEHICLE OPERATION IN COLD SEASON SPECIAL FEATURES OF VEHICLE OPERATION DURING COLD PERIOD OF TIME In cold season, observe the following require- ments: -use service materials recommended by manufac- turer (see Appendices 2, 3 of this Manu…

[Page 100] KAMAZ 5490 5-2 Oil heating in the steering system It is necessary to heat the oil in the steering sys- tem after engine cranking, prior to vehicle motion start, to exclude the damage and excessive wear of parts of steering mechanism and hydraulic power stee…

• KAMAZ 5490 6-28 In order to bring electrolyte into homogeneous constitution the topping-up should be carried out on the vehicle with running engine and switch-on parking brake system. Attention! Use rubber acid-resistant gloves and glass tube to test the electrolyte level. To connect/ disconnect storage batteries Attention! Do not loose and do not take away terminals of batteries while engine is working. Avoid contact of wires from plus terminal with parts of vehicle frame, otherwise short circuit is possi- ble. Discon

• 5 Messages on the display………………………………………………………………………. 4-57 Gear shifter………………..………………………………………………………………….. 4-58 Automatic gear box control………………………….……………..…………………………. 4-59 Gearbox manual control………………….……………………………………………………. 4-60 Motion modes………………………………………………………�

• KAMAZ 5490 BUS maintenance 6085 758 102b — 2006-10 46 Product family Transmission type 8 S 180 IT 8 S 2101 BD 8 S 2101 BO 6 S 1600 IT 6 S 1601 BD horizontal, to the right 6 S 1701 BO Heat exchanger 6 S 1901 BO bottom 6 S 1600 IT 6 S 1601 BD horizontal, to the right 6 S 1701 BO Heat exchanger, right 6 S 1901 BO 10 AS 2010 B IT 10 AS 2001 BD 10 AS 2310 B IT 10 AS 2001 BO 10 AS 2301 BD 10 AS 2301 BO 10 AS 2701 BO 12 AS 2000 B IT 12 AS 2001 BO 12 AS 2300 B IT 12 AS 2301 BO 12 AS 2701 BO Oil grade According to List of Lubricants TE-ML 02 Oil change intervals According to List of Lubricants TE-ML 02 In line with the tra

• KAMAZ 5490 14 9.7 SETTINGS On the menu bar using buttons select the symbol and confirm using the button . Time setting. • Confirm the symbol using the button . • Using buttons set the number of hours and confirm with the button . • Using buttons set the number of minutes and confirm with the button . Weekday setting. • Using buttons select the symbol and confirm using the button . • Using buttons set the current day of the week and confirm using the button . Setting of time display fo

• 4-13 Driver’s/ passenger’s door Over the windshield Pos. Application of shifters 1 Adjustment of external rear view mirror position 2 Rear view mirror heating 3 Window raiser on driver’s door 4 Window raiser on passenger’s door 5 Driver’s/ passenger’s door lock 6 Engagement/ disengagement of reading lamp on passenger’s side Pos. Application of shifters 1 Opening/ closing of the top hatch 2 Engagement/ disengage

• 6085 758 102c The Integrated Retarder for Trucks and Buses With ZF Transmissions ECU 42 Control Unit Betriebsanleitung Operating Instructions Manuel d’Utilisation Manual de Servicio Istruzioni per l’Uso
  

• KAMAZ 5490 6-4 № Description of procedure Technical requirements and instructions 7 Check the state of semi-trailer sides’ latches. Locking means must keep the sides of semi-trailer platform closed relia- bly. 8 Inspect condition of tires. Check (if any control systems) tire pressure according to the infor- mation from indicator on instru- ment panel. See subsection «Tire maintenance». 9 Check brake system for proper operation. Test the brake system air drive for leakage. Inspect the state of brake chambers, hoses

• KAMAZ 5490 4.2.2 Oil fill • Unscrew oil filler plug. • Top up oil through oil filler hole (Fig. 11). • The oil level is correct when it has reached the bottom edge of the filler hole and/or when oil is already escaping out of the filler hole. • Tighten oil filler plug to 60 Nm. Fig. 11 Position of oil filler plug(tightening torque: 60 Nm) 4.3 Oil level check CAUTION Too less oil in the manual transmission leads to transmission damages. Check the transmission oil level at regular intervals: • Check oil level when vehicle is on level ground. • Do not perform oil level check right after travel (this will p

• 7-38 Changing the bulb in headlamp cluster 1. Remove the fastening cover plate of the head- lamp cluster, unscrew two bolts securing the bulb (holes 6 and 7) and two fastening bolts on the headlamp cluster reverse side (holes 7 and 15) (see Fig. Headlamp clus- ter). 2. Pull out the headlamp cluster. 4. Disconnect the plug from the lamp contact, re- move the clamping spring, take out the halogen lamp holding it by the socket, install the new halogen lamp, secure the clamping spring, connect the plug with the bulb contact, close the cover. 5. Install the headlam

• KAMAZ 5490 11 9. CONTROL PANEL (TIMIMG DEVICE) EasyStart Timer 9.1 MAIN FUNCTIONS OF PUSH BUTTONS By using the button the heater is switched on and acknowledged. By using the buttton the heater is switched off and operations are completed. Use buttons to select menu items and to make settings. 9.2 MENU BAR Symbol Function Heating On / Off Ventilation On / Off Program Settings 9.3 DATA ENTRY FIELD Symbol Function Time setting Time display format Weekday setting Battery Please note! LONGPRESS – straight way At temperatures of 20 °C below zero in the vehi- cle, the informat

• KAMAZ 5490 4-12 Symbol Application of switches/shifters Engagement/ disengagement of hydraulic motor (for certain vehicle configurations) Engagement/ disengagement of PTO box Engagement/ disengagement of flashing lights (for certain vehicle configurations) Emergency storage battery switch-off (color — red) Engagement/ disengagement of hill start assist control
  

• KAMAZ 5490 7-13 Fault indication Cause of trouble Suggestion on correction (color-red) (color-orange) Intermittent horn Increased coolant t temperature. Disengagement of automatic operation mode of engine fan drive coupling. Vehicle motion is permitted with special care. • Stop the vehicle taking into account the traffic situa- tion; • stop the engine; • engage the parking brake; • check the coolant level in expansion tank (see section «6. Maintenance»). If coolant level is OK, but pil

• KAMAZ 5490 6-20 COOLANT LEVEL CHECK 1. Place the vehicle on level horizontal surface. Stop the engine. 2. Raise the front facing panel. 3. Check the coolant level on cold engine (tem- perature should not exceed 50 °С). An optimum position of a liquid level is when it reaches the lower edge of the filling neck. 4. If necessary, add coolant of the same grade through a filling neck after removing expansion tank cover (see Fig. Expansion tank cover). Use the coolant in accord with suggestions of Appendix 3. 5. Tigh

• 2.4 Auxiliary power units Depending on the vehicle version, Ecosplit transmissions can be equipped with the following auxiliary power units (Fig. 5): • Separate heat exchanger for cooling the transmission oil • Voith and Telma retarder can be built in upon request Fig. 5 Description Torque con- verter clutch + PTO Engine- dependent PTO NMV 221 Integrated ZF-Intarder Drive- dependent PTO N … PL Clutch-dependent PTOs N1, N4, and N10 011359 11 1341 758 101 — 2012-05
  

• KAMAZ 5490 4-71 FACING PANEL Facing panel is opened and closed by both hands applying uniform force to both sides, observing maximum distance from center of the panel (see Fig. Opening of the upper facing panel). Attention! It is strictly forbidden to open and to close the facing panel pulling it only by one edge. For fixation of the upper facing panel in the upper position pull the thrust from the holder and install it into the bracket slot. To remove the lower facing panel it is necessary to screw out fastening screws and dismantle the panel. The upper and the lower facing panel 1 – bracket; 2 – t

• 4-24 SEAT POSITION ADJUSTMENT Adjustment of seat position on air suspension The angle of armrest 3 inclination is smoothly adjusted at armrest regulator rotation. Seat cushion depth. With lever 4 up, the cushion displaces forward-and-backward against the base. With lever released, the cushion is fixed in a stepped-like manner in selected position. Adjustment of seat inclination angle. With lever 5 shifting up the front edge of seat cushion raises, with lever shifting down – the edge lowers down. Longitudinal damper. With the level 6 in the upper posi

• 2-2 TABLE OF ADDITIONAL TECHNICAL DATA Operational data Model 5490 Technically permissible maximum weight of vehicle, kg, applied to: axle 1 7100 axle 2 11500 Maximum driving speed 1) , km/h, at least: train 90 2) Test fuel consumption 3) per 100 km at speed 60 km/h, l, not more: train 27,5 Fuel distance endurance 1) 4) , km, at least: train 2800 Acceleration time 1) to 80 km/h, s, not more: train 80 Braking distance 1) at service brake system application during test «Type-0» (with engine disconnected), with

• KAMAZ 5490 4-70 To set the earlier recorded height – depress the buttons of switches 7 (М1) or 8 (М2). To interrupt the process of height variation – de- press the switch 5 button (STOP). The suspension «transport» position state is de- clared by the message on the instrument cluster display: CHOCK The chocks are intended to assure under-run pro- tection for the vehicle (road train) when it is parked or the rear or the front part of vehicle is jacked for repair (for example, when removing and installing tires). The chocks are also intended to prevent vehicle run- away in case of emergency stop (See section «Main op

• KAMAZ 5490 7-21 Trouble of all rear left marker lights Trouble of all rear right marker lights Trouble of the rear left direction indicator Trouble of the rear right direction indicator Trouble of tail fog lamps, located on both sides of the vehicle Trouble of brake lights of the rear lamps located on both sides of the vehicle
  

• 4-75 PUMPING OF PETROLEUM PRODUCT DURING OPERATION OF HYDROFICATED BOLSTER TRACTION TRUCK WITH A TANK SEMITRAILER 1. Place the vehicle on a level and hard surface. 2. Apply the parking brake system to stop the semi-trailer. 3. Use the chocks (block stops) to stop the vehicle. 4. Be sure the air system pressure is not lower than 490 kPa (5 kgf/cm 2 ). 5. Switch on the power take-off (PTO) box. For this purpose: — depress the clutch pedal against stop; — shift the gearshift lever to neutral; -engage PTO box by means of the switch lo- cated on the instrument panel. W

• 5 1341 758 101 — 2012-05 Table of Contents Page 1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.2 Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.3 Shift actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.4 Auxiliary power units . . . . . . . . . . . . . . . . . . . . . . . . 11 3 Operation . . . . . . . . . . . . . . . . . . .

• A3-2 TRANSMISSION OILS Attention! For ZF gearboxes, use oils approved by ZF, strictly. The complete information on oils (list, usage conditions and change intervals) for ZF units may be found in any ZF service center and on site www.zf.com. The site information is updated every 3 months. Each further revision substitutes all previous ones. For gearboxesZF 16S2220TD and ZF 16S2221TD use oils of class: 02Е, 02Н, 02L. For ZF gearbox 12АS2130TDand ZF 12АS2131TD oils of the following classes are recom- mended for

• KAMAZ 5490 6-8 WEEKLY MAINTENANCE (WEEKLY MNT.) PROCEDURES № Description of procedure Technical requirements and instructions 1 Check the cotter-pinning of nuts of steering rod ball pins (visually), the fastening of pit- man arm. The pitman arm should not have any damages. The nut to fasten the pitman arm should be secured and locked with a plate. The nuts of steering rod ball pins should tightened and cottered. If there are no cotters put them on their place. 2 Inspect condition and operation of hydraulic locks and hydrau- lic cylinder for rais ing and lowering the cab. The locking mechanism must retain t

• 7-5 7. Depress the «Menu key» button . If any faults are available, the following is emitted to display: — system name; — the total number of faults in a unit; — SPN (number of device connected to a certain electronic (local) system (sensors, actuators, messages in CAN data bus); — FMI — malfunction type code. Then by pressing and buttons you can scroll up to 10 active errors in a unit. If there are more than 10 errors, the further errors can be viewed only after eliminati

• 4-66 ELECTRONIC BRAKE SYSTEM EBS Vehicle is equipped with electronic brake system (EBS), comprising the following functions: — control of service and auxiliary brake systems (Brake-Management); — anti-lock braking system (ABS); — anti-skid system (ASR); — electronic stability programme (ESP). Vehicle brake control is carried out via two pneu- matic and one electronic circuits. In case of brake elec- tronic control failure the management is carried out via two pneumatic circuits. In such a case the brake system EBS operates as a standard pn

• KAMAZ 5490 4-48 Climbing Short climbs on good roads should be overcome with speed reserve. While overcoming sharp and prolonged climbs, choose the low gears taking into account the road train load, length and sharpness of climbing. If possible use the gear that provides moving without additional shifts and stops. If for some reasons the truck cannot overcome the climb, drive down it slowly reversing and try again. Descending When coasting downhill, do not disengage the gear and do not depress the clutch pedal. To slo

• KAMAZ 5490 2-5 Additional equipment that can be attached under certain requirement, specified by supply agreement: a tool kit in a small bag at extra cost, a minimum tool kit at extra cost, an oil transfer pump (1 pc.). Truck (chassis) is to be equipped with tools, ac- cessories and appropriate operation documentation for purchased products. A list of additional equipment may be defined dur- ing production process. In agreement with consumer, the vehicle may be supplied with certain accompanying automotive accesso-

• KAMAZ 5490 3-1 3 BRIEF DESCRIPTION OF VEHICLE SYSTEMS AND MECHANISMS ENGINE Vehicle is equipped with engine Mercedes-Benz OM457LA. Operation manual for Mercedes-Benz engine is supplied with vehicle. TRANSMISSION Clutch Clutchis single-plate, diaphragm, pull-type model MFZ 430 «SACHS». Clutch control actuator is hydraulic with air- hydraulic booster «WABCO». Gearbox In accord with configuration, vehicles are equipped with: — mechanical gear boxes, models ZF 16S1820 ТО, ZF 16S2220 ТD, ZF 16S2221 ТD (with intar

• 7-42 To tilt the cab 1. To disable cab tilt lock: press the cab tilt lock switch located at the top of the instrument panel. The pilot LED, which is mounted into the switch, will light up. 2. Set the control handle of pump 2 to the position Arrow Upwards, by rotating it clockwise until it stops (see Fig. To control cab raising and lowering). 3. For raising the cab: — place the tire iron into the pump handle 3, and raise the cab by swinging it; — when installing electric pump: press the button 6, the cab will raise with it. Do not

• KAMAZ 5490 5-3 COLD WEATHER ENGINE STARTING In cold period, start the engine with the help of EFU (Electric Flame Unit). Prestarting heater may be al- so used for engine starting. Extreme temperatures for a reliable cold engine start and the engine preparation-for-loading time are specified in a Table «Extreme temperatures for a reliable cold engine start». Attention! Avoid the open plug flame and torch usage for air heating at engine start. If the ambient air temperature is below 30 ºС an unstable operation of display is possible and the temperature of 40 ºС can cause an erratic instrument cluster operation. Ex

• KAMAZ 5490 6 5 VEHICLE OPERATION IN COLD SEASON……………………………….…………………….……………..….….. 5-1 Special features of vehicle operation during cold period of time…………….………………………..… 5-1 Cold weather engine starting……………..…………………………..…….………………………………… 5-3 To start the engine using the efu unit…….……….……………………………………………

• KAMAZ 5490 4-18 Engagement of windscreen wipers Turn the switch 1 (see Fig. Engagement of windscreen wipers) into required position. Disengagement of windscreen wipers Turn the switch 1 to position (or ). Windscreen wiper will make one more movement and witll be disengaged. Intermittent operation mode Durability of the interval between two consecu- tive movements of windscreen wipers is 4 sec. This in- terval can be smoothly adjusted in a range from 2 to 20 sec. For the purpose: 1. Turn the switch 1 to position (or ). 2. Wait until the first movement of wipe

• 6-24 AFTER-TREATMENT SYSTEM After-treatment system is designed to decrease the emissions of nitride oxides as result of injection of neu- tralizing liquid into engine exhaust system. With ignition key rotated to the «ON» position in instrument (position of motion) cluster, the information about the vehicle is displayed. One of displays shows the neutralizing liquid level in a tank, by default. Be sure to prime the system with neutralizing liq- ui

• 5-5 PRE-STARTING HEATER Pre-starting heater is for heating the engine before starting it up at the ambient temperature of up to minus 45 °С. The vehicles are equipped with preheaters of model 14ТС-10 or 16ЖД-24, according to the vehicle configura- tion. The operating instructions manuals for prestarting heaters you will find in Appendices «Pre-starting diesel heater 14ТС-10-GP» or «Liquid small-size heater PRAMOTRONIC-16ЖД24». Engagement/ disengagement of heater, the indica- tion of its functional state is performed

• 4-23 EXTERNAL REAR VIEW MIRRORS It is recommended to check the installation of ex- ternal mirrors on the vehicle before each drive. Position of the right and the left external rear view mirrors is regulated by electric drivers. POSITION REGULATION OF EXTERNAL REAR VIEW MIRRORS 1. Turn the ignition key to «ON» position (motion position). 2. Choose by the shifter a proper rear view mirror (see Fig. Shifter of external rear view mirror position ): for l.h. mirror — position «L», for r.h. mirror — position «R».

• KAMAZ 5490 6-7 № Description of procedure Technical requirements and instructions 20 Top up to norm the oil level in the vehicle hydraulic system (for hydraulically operated ve- hicle). The oil level should be in the in- spection hole middle (see. Fig. Hy- draulic oil tank). If necessary, add oil through the filling neck. Greases are used in accord with suggestions of Appendices 2, 3. 21 Check the state and cottering of pins of auxiliary brake air cylinder. Cylinder and rod must be secured and cottered. It is not permissible to use parts without cotters and with excessive play.

• 7 Sequence to read diagnostic codes………………………..………………………………………..… 7-4 Mode for diagnostics of operational parameters.……………………………………………………. 7-6 Indication and elimination of faults……………………………………………………………….……… 7-8 Indication of faults in the lightning equipment………………..…………………………………………. 7-19 Engine sta

• 7 Working in the «MEDIUM» mode the heater warms the cooling liquid up to +60 °С and goes to the «LOW» operating mode. After it heats the liquid up to +70 °С it goes to the waiting mode, the combustion chamber switches off, only the electric pump works. At this mode the temperature of the cooling liquid drops until +40 °С. After the temperature +40 °С is reached the control unit starts the heater and program № 2 is worked out again. 4.10 The operation of the heater in item 4.9 can differ

• 4-27 SAFETY BELTS The vehicle seats are provided with safety belts. Safety belt prevents considerable displacement of driver in direction opposite to hit direction, thus, decreases danger of injure, e.g. at frontal clash. To fasten the safety belts 1. Smoothly pull the safety belt out of mechanism and place over the shoulder (see Fig. Safety belts). 2. Insert the belt tongue 1 into lock 2 till the click of fixation, with this avoid strap twisting. To unfasten the safety belts, press the knob of lock 3. Attention! Ensure that the belt stri

• KAMAZ 5490 2-7 Manufacturer’s plate for export vehicle The manufacture’s plate is fixed to the cab r.h. panel in a door aperture. Plate contains (see Fig. Manufacturer’s plate for export vehicle): — manufacturer’s name; — e — European approval; — d — distinguishing number or letters of the coun- try which gave the vehicle EEC type approval; -f — EEC type approval number; — identification number, including: — XTC — manufacturer index; — а — vehicle model conventional code pursuant to Technical specifications for vehicle, comprising six marks; — b — production year code (1 mark); — с — vehic

• 8-1 8 VEHICLE STORAGE The vehicles (chassis) prepared for sale but not de- livered to consumers may be stored in storehouses* with- out preservation within three months after production date. If, after storage period expired, the truck (chassis) is not put into operation, the regular preservation procedures should be performed by a storehouse in process of storage, in correspondence with requirements of norms and in- structions available in «KAMAZ» PTC. The trucks (chassis) purchased but not introduced into operation may be stored in

• 4-56 For gearbox models ZF 16S1820 ТО, ZF 16S2220 ТD, ZF 16S2221 ТD gear shifting is ful- filled according to the scheme (see Fig. Gear change scheme for gearbox models ZF 16S1820 ТО, ZF 16S2220 ТD, ZF 16S2221 TD): – 1-2-3-4 — low gears (the lower range of splitter); – 5-6-7-8 — high gears (the high range of splitter). When slowing down shift the gears only succes- sively: 8-7-6-5-4-3-2-1. In motion, always keep the gear engaged. Attention! For gearboxes, it is strictly forbidd

• KAMAZ 5490 4-47 10. In case of lighting of incidental oil pressure and incidental coolant temperature pilot lamps located on the instrument panel and warning about the dangerous drop of pressure in engine lubricating system and about critical over-heating of coolant, stop the engine immedi- ately, find and remedy the trouble. 11. In case of any faults menacing the road safety, stop the truck immediately to eliminate troubles and switch ON the emergency signaling system. 12. Observe the tire pressure values in accordance wit

• 1 Pramotronic Production Company (Copy) ELTRA TERMO OPEN JOINT STOCK COMPANY «ELTRA TERMO» 1 Introduction This instruction manual (IM) is assigned for study of the structure, operation, assembly and regular maintenance of the heater «PRAMOTRONIC 16WD24» (further referred to as the heater). The diesel heater of 16WD24.8106.000 model with the nominal voltage 24V is designated for pre- starting heat and automatic keeping of thermal conditions of а liquid cooling diesel motor for all makes of trucks, as well as

• KAMAZ 5490 7-43 If the cab is not locked, the cab lock indicator lights up on the driver’s instrument panel. The unblocked cabin creates a danger for the op- erational reliability and safety of the vehicle. At the end of hydraulic cylinder travel (100 mm till complete cab stop), cab lowers with acceleration un- der its own weight). Attention! During cab accelerated lowering, there’s danger of injure – do not keep the cab by hands. You can stay under the cab only after it is entire- ly set into a tilted position. With engine working and cab tilted, the cooling sys

• KAMAZ 5490 4-73 OPERATION OF BOLSTER TRUCK TRACTOR BEING A PART OF A ROAD TRAIN When bolster tractor is a part of a train with in- stalled three-component wings of rear bogie, the upper part of wings should be dismantled. For dismantling it is necessary to (see Fig. Dis- mantling of the upper part of rear three-component wings): — unfasten the clamps 3; — slacken the nuts 5; — remove the upper part of rear wings; — tighten the nuts 5. Place the dismantled upper parts of wings into the semi-trailer. To install the upper part of the rear wings: — slacken the nuts 5; — inst

• KAMAZ 5490 2.3 Shift actuation Range change group, superimposed H shift pattern The shift system is divided into 3 parallel shift gates. Shift gates 3/4 and 7/8 have a spring-mounted neutral position. Pneumatically changing the range change group from shift gate 3/4 to shift gate 5/6 and back is done via a preselection switch at the shift lever (Fig. 2). Fig. 3 Shift pattern of the ZF superimposed H shift pattern Range change group of double H shift pattern The shift system is divided into 5 parallel shift gates. Shift gates 3/4 and 5/6 have each a spring-mounted neutral position. Spring lock

• 13 7. Faults 7.1 Faults that the User can eliminate on his own. If after being switched on the pre-heater won’t start, it is necessary to do the following: 1) Check the presence of fuel in the tank; 2) Check the safety device (if the 25 A safety fuses in the control unit is burnet out or not installed, the pre-heater doesn’t start and corresponding LED doesn’t glow). 7.2 All the other faults of the pre-heater are indicated by panel LED blinking. 7.3 Refer to Section 8 for typical faults of the pre- heater and trouble-shooting procedures. 7.4 If malfunctions occur d

• KAMAZ 5490 3 Operation Cost-effective driving with good fuel economy is assured when the following operating instructions are observed: • Driving in medium speed range. • Use the highest gear possible. • Anticipate traffic conditions ahead. • Avoid unnecessary braking or acceleration. 3.1 Starting engine and setting off • Close the parking brake (this prevents the vehicle from starting to roll unintentionally). • Shift transmission to neutral position. • Start engine. • Fully depress clutch pedal. • Engage gear (preferably 1st gear to protect the clutch). • Release parkin

• KAMAZ 5490 4.7.2 Breather Make sure that the breather is cleaned and not clogged. The breather must be clean and shall not be covered. Do not direct pressurized water at it (water in the transmission: risk of corrosion). Fig. 15 Breather 4.8 Compressed-air system maintenance Condensate accumulates in every compressed-air system. To prevent any condensate, rust, water, and other impurities of the compressed-air reservoirs from entering the valves or shift cylinders, regular maintenance of the compressed-air system is require

• KAMAZ 5490 4-41 EMERGENCY RESPONSE SERVICE CALLING UNIT (ERA-GLONASS) APPLICATION AND CONTROL DEVICES Emergency response service calling unit is de- signed for: — transfer of minimum data set with description of motor vehicle, coordinates of its location, time and movement direction; — call of emergency service operator via loud- speaker by pressing the emergency button SOS at road traffic incidents and other emergency situations. Connection is carried out via mobile cellular network, meeting GSM/ UMTS standards. Coordinates of motor vehicle location are calculated by using the

• KAMAZ 5490 7-41 CAB RAISING AND LOWERING For raising and lowering the cab use (see Fig. To control cab raising and lowering): — cab hydraulic lift pump, placed on the right side behind the cab. — electric pump of the cab tilt mechanism (de- pending on vehicle configuration). Position of knobs for cab raising and lowering is shown in a plate on a pump body (see Fig. Pump plate). During operation, control the oil level in a hy- draulic drive system. The oil level should be between marks on a dipstick built into pump tank body. Prior to raising the cab 1. Zone

• KAMAZ 5490 7-8 INDICATION AND ELIMINATION OF FAULTS Fault indication Cause of trouble Suggestion on correction (color — red) Intermittent horn Oil pressure in the engine lu- bricating system is below norm. Vehicle driving is prohibited till fault correction. • Stop the vehicle taking into account the traffic situa- tion; • stop the engine; • engage the parking brake; • check the level of oil in crankcase (see section 6 «Maintenance»). If oil level in crankcase is OK, but pilot lamp of hazard oi

• KAMAZ 5490 1) Reference value (depends on vehicle type and vehicle data as well as the prevailing operating conditions). 2) To this end, also observe the ZF guidelines for installing manual transmissions (1203 765 110). 3) To a large extent, the connection for the turning-shaft shift control can be adapted to the vehicle’s installation conditions. 4) Option 5) For the required air pressure, observe the ZF guidelines for installing manual transmissions (1203 765 110). 6) Transmission inclination: 0 to 3°. for standard drive Transmission type Direct drive 16 S 1620 TD 16 S 1920 TD

• 4-29 THE LOWER BUNK Setting of the lower bunk into operational state 1. Raise slightly the lower bunk and detach the re- taining belt 3 from the hook 4 (see Fig. Fixation of the lower bunk). 2. Throw the lower bunk down. 3. Fixate the rubber clamp 1 on the safety clip 2, the lower bunk is fixed. 4. Fasten the retaining belt 3 to the back wall us- ing hook-and-loop tape. Lifting of the bunk 1. Draw the rubber clamp 1 down and detach from the safety clip 2. 2. Detach the retaining

• 4-5 Pilot lamps Low level of liquid in neutralization system (color – blue) Air suspension defect (color — red) Air filter clogging up (color — red) Anti-skid system engagement (color — orange) Truck tractor EBS/ ABS fault (color — orange) Fault of EBS/ АБС of trailer/ semitrailer (color – orange) Head lamp high-beam engagement (blue color) Direction indicators of trailer/ semitrailer (color — green , intermittent) Engagement of interwheel di

• KAMAZ 5490 5 3. Safety measures 3.1 The pre-heater and its components shall be installed only by authorized companies, by reason of its complicated structure: there’s a combustion chamber where fuel burns, a heat exchanger which provides heat transfer to the cooling liquid, fuel pump, air pump, control unit, which controls and operates the work of the heater according to the program, heat indicators, etc. 3.2 The pre-heater shall be used only for purposes described in the present User Manual. 3.3 It is prohibited to use the pre-heater on special tr

• 7-35 CHECKING AND REPLACING FUSES The electric circuits are protected by fusible links or by means of automatic fuses. If any power consumer stopped working, switch it off and check, if the fuse is functioning correctly. Change the faulty fuse. If an automatic fuse is triggered (see Fig. Automatic fuse), eliminate the cause of trip, then switch on the automatic fuse again. Check the circuit leading from the fuse to the consumer. Replace fuses(circuit breakers) after the short- circuit is eliminated. Breaks in the circuit are also possible. Address

• KAMAZ 5490 15 7 Guidelines 7.1 For securing continuous working capacity of the heater it’s recommended to turn on the heater briefly for about five minutes once a month during the whole year (including a warm season of the year). The turning on must be carried out at the ambient air temperature near the control panel and the heat sensor below +30 °С. Thus, the sticking of the movable parts of the fuel pump can be eliminated (it can arise because of the low-quality fuel). 7.2 Reliable work of the heater depends on the fuel used in relation with the a

• 4-16 AUXILIARY ILLUMINATION HEADLAMPS IN INSUFFICIENT VISIBILITY CONDITIONS AND REAR FOG LAMPS Auxiliary illumination headlamps in insufficient visibility conditions 1. To switch on turn the light switch to position . 2. Pull the light switch till position 2 (see Fig. Light shifter). With headlamps switched on the pilot LED lights on the light switch . Engagement of auxiliary illumination headlamps in insufficient visibility conditions and rear fog lamps

• KAMAZ 5490 6085 758 102b — 2006-10 38 Maintenance Buses: Oil Drain, Oil Filler, and Oil Overflow Plugs Fig. 9 Transmission AS Tronic mit Intarder Refer to list at start of page 4. stainless steel heat exchanger on the right 1 = Oil drain location transmission 2 = Oil drain location Intarder housing (below the oil filter) 3 = Oil filter cover Intarder housing 4 = Oil overflow and oil fill after oil change 9 = Oil filler plug after repair Tightening torques refer to table on page 46. 3 1 4 9 028009 024469
  

• 4 1. SELF-CONTAINED HOT-AIR HEATING SYSTEM PLAN IN THE CAB 1 — Self-contained device for heating air; 2 — exhaust system; 3 — air supply tube in combustion chamber; 4 – air conduct; 5 — rotating outlet vent; 6 — control panel (timing device); 7 — metering pump assembly with fuel filter; 8 – T-connector; 9 — supplementary switch; 10 — temperature detector. Night cab Day cab
  

• KAMAZ 5490 BUS: 8 S 180 IT 6 S 1600 IT horizontal (to the right) and heat exchanger at bottom 6 S 1600 IT vertical heat exchanger on the right 6 S 1600 IT horizontal (to the right) and heat exchanger on the right 10 AS 2010 B IT 10 AS 2310 B IT 12 AS 2000 B IT 12 AS 2300 B IT 8 S 2101 BD 8 S 2101 BO 6 S 1601 BD 6 S 1701 BO 6 S 1901 BO 6 S 1601 BD 6 S 1701 BO 6 S 1901 BO 6 S 1601 BD 6 S 1701 BO 6 S 1901 BO 10 AS 2001 BD 10 AS 2001 BO 10 AS 2301 BD 10 AS 2301 BO 10 AS 2701 BO 12 AS 2001 BO 12 AS 2301 BO 12 AS 2701 BO 6085 758 102b — 2006-10 4 Overview on Types
  

• KAMAZ 5490 7-14 Fault indication Cause of trouble Suggestion on correction (color-red) Intermittent horn If the indicator of 3-d or 4-th circuit is blinking on the screen, there is a fault occured in the 3-d or 4-th cir- cuit of the brake system, re- spectively. Vehicle driving is prohibited till fault correction. • Stop the vehicle taking into account the traffic situa- tion; • engage the parking brake; • inspect for compressed air leakage in pneumatic drive caused by leakage of pipelines’ and elastic hoses’ connec- tions. Check the brake system devices for operability; • el

• KAMAZ 5490 3-3 ELECTRIC EQUIPMENT The electric equipment comprises the following systems: power supply system, engine starting system, warning lights, outer and inner illumination means, indi- cating devices, heating systems, ventilation and audio signaling system, additional electric equipment and windscreen wiping system. Flash lights are installed on a vehicle cab roof. Flash beacons are arranged on a cab roof of the vehicle designed for transportion of dangerous cargoes. Vehicle is supplied with electric equipment ECU. Warnings 1. Do not connect or disconnect the plugs and the plus terminal of the alternator while the engi

• KAMAZ 5490 Operation 1341 758 101 — 2012-05 16 Superimposed H The range change group can be preselected via the preselection switch at the shift lever (Fig. 7). Fig. 7 Upshifting from shift gate 3/4 to 5/6: • Preselect the high range at the preselection switch. • Fully depress clutch pedal. • Shift the transmission into neutral – in doing so, the range change group starts changing over. • Select shift gate 5/6. • Engage the 5th gear of the basic transmission – in the mean time, the range change group has changed over to high range. • Engage the clutch. • Leave the preselection s

• KAMAZ 5490 7-51 TROUBLESHOOTING FOR BOLSTER Cause Remedy Bolster fails to close Coupling pivot of semi-trailer is disposed too high Install the support plate on one level or 50 mm below Bolster fails to open Train is on rough ground or bolster is un- der action of stretching forces Release the bolster locking means Bolster is not ready for coupling Poor maintenance of bolster Eliminate dirt from the locking means, grease it again
  

• Description 6085 758 102b — 2006-10 11 2 Description The ZF-Intarder is a wear-free operating, hydrodynamic additional brake which is integrated into the transmission. It reduces the wear of the wheel brakes, • during braking down from higher speeds. • when riding along downhill tracks. The ZF-Intarder contributes to a smoother and more economic driving style. The advantages of the ZF-Intarder are: • High level of braking performance; • Short response times; • Joint oil circuit with the manual transmission a

• 4-50 Fuel tank filling (for certain configurations upon availability of two fuel tanks) Fuel tanks are connected by the crossover pipeline of small section (see Fig. Fuel tank). When filling in both fuel tanks it is recommended: — to open covers on both fuel tanks; — fill in both tanks through filler neck of one of the tanks, with crossover pipeline valve opened. Filling of the second tank is carried out through the crossover pipeline Speed of fuel overflow from tank to tank is enough in t

• 12 The economic mode is used to keep the engine and the driver’s cab warm when the engine is idle for 8 hours maximum. The positions of the key switch are marked with figures 3 and 8 correspondingly. 6.1.2 Heat controller knob 4 is used to control the cab heater fan (provided that the coolant fluid temperature is more than 55 °С, key switch of the cab heater on the dash is OFF, frame connection available) the following way: а) with the knob

• KAMAZ 5490 7-6 MODE FOR DIAGNOSTICS OF OPERATIONAL PARAMETERS The diagnostics of operational parameters can be used in case of remote malfunction diagnostics per- formed by KAMAZ PTC specialists or by experts of ser- vice centers. To determine the type of malfunction when per- forming diagnostics of operational parameters in vehicle systems the display shows eight additional screens. Pa- rameters of various vehicle elements and systems are shown on the display. Attention! The diagnostics of operational parameters is more informative while driving. Thus, this mode should be used only on the even ground without obstacles and othe

• KAMAZ 5490 4 2. Key features and characteristics Main technical characteristics of the heater are shown with a tolerance of ± 10 %, obtained at a nominal voltage of 24 V and a temperature of 20 °C. 2.1 Nominal supply voltage, V 24 2.2 Heat productivity, kW — full duty 15,5 — medium duty 9 — low duty 4 2.3 Fuel diesel fuel meeting requirements of GOST305 Standard (dependi

• 3.8 Limp home operation Trouble when changing range change group (e.g. from shift gate 3/4 to 5/6 or vice versa) can be caused by the following: • Line damage in pneumatic system. • Shift valve (1) or shift cylinder (2) for the range change group is defective (condensate or contamination). NOTE • Continuation of journey is only possible when the low range change group (1st — 4th gear) is selected. • The vehicle must be towed if the high range change group remains engaged. 3.8.1 Servoshift When the Servoshift fails, it is still possible to shi

• 4-9 Screen «Travel» The data on the screen «Travel» are reset simulta- neously with daily mileage re-zeroing. «Time» — current data on time for the trip cover- ing period. «Motor hours» — current data on motor hours for the trip covering period. «Average speed» — current data on average speed for the trip covering period. «Average consumption» — current data on average fuel consumption for the trip covering period. Screen «Axle load» Screen «Axle

• KAMAZ 5490 2-3 TIRE AIR PRESSURE Wheel position Tire pressure of the vehicle with technically permissible maximum weight, kPa (kgf/sm 2 ) for tire size 315/60 R22,5 315/70 R22,5 315/80 R22,5 Front axle wheels 880±20 (9,0±0,2) 830±20 (8,5±0,2) 780±20 (8,0±0,2) Rear axle wheels 780±20 (8,0±0,2) 780±20 (8,0±0,2) 730±20 (7,5±0,2) ENGINE TECHNICAL DATA Engine model Mercedes-Benz OM 457LA.V/4; Mercedes-Benz OM 457 LA.EEV/4 Mercedes-Benz OM 457LA.V/3; Mercedes-Benz OM 457 LA.EEV/3 Mercedes- Benz OM 457LA.V/2 Engine type

• KAMAZ 5490 4-1 4. VEHICLE OPERATION VEHICLE KEYS Keys are designed for cab door opening and for instruments-and-starter switch. Keys have a special cod- ing and are bound to a particular vehicle. Key positions 0- everything is «Off». With the key removed from ignition switch the steering control is locked. АСС — Steering control lock release/ engagement of the radio receiver, fixed position. The audio system and other auxiliary power consumers work with the key in «АСС» position ON — Movement position, fuel supply to all vehi- cle systems, fixed position. START — Start of engine, unfixed position. Attention! Take out the ign

• KAMAZ 5490 3.5.1 ZF Braking Step Lever (Standard) BREMSOMAT = constant speed during downhill travel • Set and maintain the velocity: Engagement of step B = Bremsomat activated. The current traveling speed is now saved to the electronics and maintained during downhill travel. During Bremsomat operation, the required brake torque is automatically set in a continuously variable manner. Check display continuously lit: — if the Intarder is active. The Bremsomat function is only working in step B. NOTE If the braking step lever is set back into position B after engaging constant braking step operation and the automatic speed c

• 9-1 9 VEHICLE TRANSPORTATION The trucks may be transported to any point of destination by railway, sea or by its own power. The type of transport is to be stipulated in agreement for delivery. While preparing the trucks for transportation, de- pending on transport type, be sure to adhere to the re- quirements in the following documents: 1. «Rules for railroad transportation of goods in an open rolling stock» (approved by the order of Minis- try of Communications, Russia, dd. 16.06.2003 N 19). 2. «Rules for h

• KAMAZ 5490 6085 758 102b — 2006-10 21 3.6.1 ZF Braking Step Lever (Bremsomatic) BREMSOMATIC = constant speed during downhill travel • Set and maintain the velocity: Engagement of step B = Bremsomatic activated. The current travel speed is now saved to the electronics and maintained during downhill travel. During Bremsomatic operation, the required brake torque is set automatically in a continuously variable manner. The Bremsomatic function is only working in step B. NOTE If the braking step lever is, after engagement of the constant braking step operation, set back int

• KAMAZ 5490 7-39 TABLE OF LIGHTING EQUIPMENT APPLIED IN A VEHICLE Application Bulb type Power, W Additional lighting bulb for poor visibility conditions АКГ24-70 70 Headlamp cluster: low beam light (Н7) 70 high beam light АКГ24-70-1(Н1) 70 marker lamps Light diode 1 direction indicators Light diode 4 daytime running light Light diode 4 Tail lamps: direction indicator Light diode 3,5 tail fog lamp Light diode 7,9 rear light Light diode 3,9 rear marker and end-outline la

• KAMAZ 5490 4-68 HILL START ASSIST CONTROL Hill start assist control is a part of ESP brake sys- tem. Hill start assist control helps the driver to keep the vehicle from rolling down at starting from standstill on the upgrade. Operation of hill start assist control 1. Start the engine. 2. Engage the hill start assist control pressing on the the upper part of the hill start assist control switch. With this, the pilot lamp lights up on the instrument panel . 3. Engage the gear in the gearbox. 4. Release the vehicle parking brake and start the motion. When starting from standstill th

• KAMAZ 5490 2 3 Safety requirements and warnings 3.1 Assembling and maintenance of the heater must be carried out by organizations and individuals having the producer’s license. 3.2 The plug-in of the heater must be carried out by the two-wired scheme directly to the accumulator battery regardless the motor vehicle “weight”. 3.3 It’s not allowed to connect the heater to the electric circuit of a vehicle lacking the accumulator battery. 3.4 The safety measures provided by the regulations of work with electric circuit and a motor vehicle fuel system must be taken when assembling and disassembling the heater

• KAMAZ 5490 4-19 Attention! It is necessary to check the windscreen wiper blades for the presence of dirt and damages. Switch off the windscreen wipers before placing the vehicle in the parking area, as windscreen wiper blades can suddenly start mooving when starting. WINDSCREEN WASHER To switch on the windscreen washer press the shifter 1, located on combination switch, up to stop (see Fig. Windscreen washer engagement). When holding the shifter in depressed position, water is supplied to the windscreen from the windscreen tank. Windscreen washe

• KAMAZ 5490 6-3 № Description of procedure Technical requirements and instructions 5 Check visually the state of bolster device, coiled hoses of semi-trailer brake system, the state of semi- trailer connection cables. Inspect the bolster visually at the beginning of motion and during vehicle stop. There must be no perceptible clearance between semi-trailer kingpin and bolster lock. Damage of hoses is not admissible (inspect visually). Connection cables must be secured reliably . 6 Check th

Раздел 1. Введение………. 1-3
Техническое описание устройства и работы систем и механизмов автомобиля

Раздел 2. Двигатель…….. 2-1

Силовой агрегат… 2-1

Подвеска силового агрегата…. 2-1

Двигатель………. 2-2

Система питания двигателя воздухом…. 2-3

Система выпуска отработавших газов……. 2-6

Система охлаждения двигателя…….. 2-7

Система питания топливом………… 2-7

Система нейтрализации отработавших газов.. 2-10

Система облегчения пуска холодного двигателя с предпусковым подогревателем2-12

Раздел 3. Трансмиссия…………….   3-1

Сцепление………………………………………. 3-1

Привод управления сцеплением……………………. 3-3

Техническое обслуживание……………………….. 3-5

Ремонт……………………………………….. 3-7

Возможные неисправности сцепления……………….. 3-9

Коробка передач……………………………….   3-10

Техническое обслуживание………………………. 3-10

Ремонт………………………………………. 3-12

Карданная передача……………………………… 3-13

Техническое обслуживание………………………. 3-13

Ведущий мост…………………………………… 3-14

Техническое обслуживание………………………. 3-14

Раздел 4. Рама, седельно-сцепное устройство, подвеска, передняя ось, колеса, шины 4-1

Рама…………… 4-1

Седельно-сцепное устройство………………………. 4-3

Подвеска……………………………………….. 4-5

Передняя ось…………………………………..   4-7

Колеса, шины……………………………………. 4-8

Раздел 5. Рулевое управление……………………….. 5-1

Раздел 6. Тормозная система………………………… 6-1

Пневмопривод тормозных систем…………………….. 6-4

Техническое обслуживание………………………… 6-19

Ремонт………………………………………… 6-28

Возможные неисправности пневмопривода…………….. 6-28

Раздел 7. Электрооборудование………………………. 7-1

Приложения

1.  Подогреватели предпусковые дизельные 14ТС-10.

Руководство по эксплуатации…………………….. 8-1

Б. Подогреватель жидкостный малогабаритный ПРАМОТРОНИК-16ЖД-24.

Руководство по эксплуатации……………………. 8-19

 Руководство по ремонту коробок передач ZF 16S2221 …. 8-34

Г. Руководство по ремонту. Опорно-сцепное устройство JSK 37 фирмы JOST 8-262

Д. ECAS в грузовых автомобилях. Описание системы и инструкции по установке.. 8-293 Е. Рулевые механизмы фирмы RBL.

Руководство по техническому обслуживанию……….. 8-409

Ж. Рулевые механизмы фирмы RBL.

Руководство по ремонту…….. 8-420

3. ZF-Servocom типа 8090, 8095, 8097 и 8098. Конструкция, действие, техническое обслуживание, проверки……. 8-445

И. Особенности выполнения ремонтных работ…… 8-494