KamAZ-65801. Description of engine, transmission, brake and electrical supply

Design features of KamAZ-65801

KamAZ-65801 was developed on the basis of the Mercedes-Benz Axor, and the percentage of components from European countries could be even greater. However, modern market realities prompted KamAZ employees to search for alternative options for completing these vehicles. As a result, several solutions emerged, each of which is a “hodgepodge” of German, Chinese and Russian components. Its “relatives” in the family of heavy construction dump trucks are three-axle trucks KamAZ-6580 (6x4 wheel arrangement) and KamAZ-65802 (6x6 wheel arrangement).

Of course, the ideal solution would be to equip the chassis of these construction dump trucks, by analogy with existing truck tractors, with Mercedes components. But just in words. In reality, there are design, technological, and, of course, strict economic restrictions. Therefore, when issuing the assignment for the design of this family of heavy construction dump trucks, the developers were given a clear condition: solutions should be as low-cost as possible.

Therefore, the course was taken to use imported components, but with a budget bias. In addition to the Mercedes engine, a Chinese Cummins diesel engine, a ZF gearbox from a joint production located in Naberezhnye Chelny, and axles and bridges from the Chinese company Hande were used.

Moreover: KamAZ-6580, KamAZ-65801 and KamAZ-65802 are designed in such a way that a completely domestic component base can be used on these vehicles. This refers, first of all, to the classic KamAZ diesel engine - a V-shaped “eight” in the KamAZ-740.73-400 Euro-4 modification with a power of 400 hp. With. and still the same ZF gearbox (since it is a highly localized product), and domestically produced axles and axles.

So, KamAZ-65801 is a four-axle frame construction and mining dump truck with an eight-by-four wheel arrangement. The diesel engine is located in the front of the frame, under the all-metal tilt-over cab. KamAZ-65801 vehicles use a double frame (spar in spar) made of high-strength steel with a total thickness of 16 millimeters.

On the platform there is a box-type dump body; unloading is done through the tailgate (but in one of the modifications it is side). To avoid sticking and freezing of cargo, the bottom and side sides are heated by exhaust gases. A special ladder is provided for access to the body.

As additional equipment for KamAZ-65801, a pre-heater, air conditioning, autonomous cabin heater, electronic tachograph, and audio preparation are offered.

The debut demonstration of the four-axle dump truck KamAZ-65801 was held in mid-2016, during the Construction Equipment and Technologies exhibition. This vehicle is intended for the transportation of industrial goods on public roads. It is suitable for effective use in various climatic zones: from the Far North to subtropical latitudes. Several modifications have been developed, with different types of cargo dump platforms: for use in all sorts of special purposes.

Fuel consumption standards for KAMAZ trucks

It has always been difficult to find an honest worker, and even more so in Russia, where the worker strives to steal something. In the field of freight transport, such a “gold mine” is fuel. To insure themselves against theft of the most expensive component of cargo transportation, company owners introduce fuel consumption standards for trucks at their enterprises

Moreover, not only the owner determines fuel consumption standards (independently), but also in 2008 a document was issued regulating fuel consumption standards for trucks. These are recommendations by which you can easily calculate fuel consumption.

Trucks from the domestic manufacturer KAMAZ are common in Russia. Thus, KAMAZ fuel consumption rates (Hsanc) are calculated using the following formula:

KAMAZ fuel consumption rate (per dump truck):

The fuel consumption standard for KAMAZ (dump trucks) is described by the following table:

If the dump truck operates as a road train (that is, with a trailer), then you should safely add additional liters to the resulting fuel consumption rate. It all depends on the engine. Gasoline +2, diesel +1.3, gas +2.6.

The domestic automaker KAMAZ produces not only dump trucks, but also engines, truck tractors, chassis and on-board trucks. In the field of cargo transportation, these models of equipment are also popular, so we will consider the fuel consumption standards of onboard trucks and tractors.

For these types of trucks, the formula for calculating fuel consumption rates is slightly different:

It is worth considering that trucks always work with a burden due to the cargo they transport, so it is also worth adding liters to the resulting final fuel consumption figures for a truck, as in the case of dump trucks (+2, +1.3, +2.6) .

The plant also indicates KAMAZ fuel consumption standards in technical documents. The table data below displays existing consumption indicators. So, tractors:

Fuel consumption standards for KAMAZ flatbed trucks:

But still, when considering KAMAZ fuel consumption indicators, it is worth considering that the formulas and standards are designed for the most common conditions for using trucks. Any emergency situations on the road add additional liters to the fuel meter. Therefore, if the real numbers differ slightly from the data in the tables, this does not mean that the driver is necessarily unscrupulous. The road is an unpredictable thing and it is not so easy to calculate it with a formula. However, fuel consumption standards are a guideline that can help determine whether a company's finances are being spent wisely.

Modifications

• KamAZ-65801-203001-68(T5) – with a cargo dump platform BCM-291 (bottom 8 mm, sides 5 mm; wear-resistant steel, hardness 450 HB). Unloading is done backwards.
• KAMAZ-65801-68 (T5) – with a cargo dump platform 6892KZ (bottom - 8mm, QUARD450 steel; sides - 6mm, QUARD450 steel). Her unloading is lateral (to the left). Left lower side with hydraulic locking, exhaust heating, canopy with roll-up mechanism, additional ladder.
• Dump truck-coal carrier KAMAZ-65801 (T5) – with a cargo dump platform BCM-291.2 (made of wear-resistant steel QUARD 450, platform volume increased to 28 cubic meters).

  Coal carrier

• Mining dump truck KAMAZ-65801 (T5) for transporting rocks – with a cargo dump platform BCM-291.5 (bottom - 10 mm, HARDOX 450 or equivalent, sides - 8 mm, HARDOX 400 or equivalent). The bottom is W-shaped, providing uniform heating of the slopes of the front and side walls of the body, reducing shock loads on the chassis during loading. Enlarged and reinforced canopy over the dump truck cab.

  Mining truck for transporting rocks

Vehicle modifications – Crane-manipulator installation

The truck is a flatbed tractor. It has a metal body with folding sides. If necessary, an awning is installed on the body. It protects the cargo from the influence of precipitation during movement. The vehicle is equipped with a three-seater metal cabin with a berth. The wheel formula of the truck is 6x4.

KamAZ 5320 is equipped with an 8-cylinder diesel unit with a displacement of 10.85 liters. The engine has a liquid cooling system and is equipped with a pre-heater. This makes starting easier at any ambient temperature. The power of the power plant is 210 horsepower.

The average consumption of KamAZ per 100 km is 25 liters in the summer. At sub-zero ambient temperatures, the figure increases to 28 liters.

Engine KamAZ-65801

The main option for all modifications of the KamAZ-65801 dump truck is the 450-horsepower diesel engine of the Mercedes-Benz OM 457LA .V/4 model made in Germany. This is an in-line six-cylinder four-stroke diesel engine with a working volume of 11.8 liters, with turbocharging and intercooling of charge air. Exactly the same power unit is used on trucks of the popular Mercedes-Benz Axor family. This diesel engine is equipped with a full-screen system for the amount of diesel fuel injected through solenoid valves and a liquid cooling system.

• Maximum useful torque – 2100 N.m (214 kgf.m), at crankshaft speed: 1100 rpm.
• Net power - 315 kW (428 hp), at crankshaft speed: 1900 rpm.

The declared service life of the Mercedes-Benz OM 457LA.V/4 engine is one million kilometers without major repairs. Thanks to the use of modern BlueTec technology and the Telligent maintenance system, this power unit meets the requirements of the Euro-5 environmental standard.

The first backup option is a Cummins ISG12E5 . This power unit is also an in-line six-cylinder four-stroke diesel engine with a turbocharging system and intercooling of charge air. The engine is equipped with an electronic Common Rail injection system, its displacement is 11.8 liters, and the rated power is 440 horsepower at a speed of 1500-1800 rpm. The maximum useful torque is 2100 N.m (214 kgf.m), at a crankshaft speed of 1100-1400 rpm. In terms of environmental parameters, the Cummins ISG12E5 engine also complies with the current Euro-5 environmental standards.

Externally, the version equipped with a Mercedes-Benz engine can be distinguished by the shape of the muffler, which is mounted on the left behind the cab.

The second backup option is our own KamAZ-740.73-400 Euro-4 diesel engine. This is a V-shaped eight-cylinder four-stroke diesel engine with a displacement of 11.76 liters. This power unit is equipped with turbocharging, with intercooling of charge air, as well as an SCR system and Common Rail electronic injection. Cylinder diameter – 120 mm, piston stroke – 130 mm. Compression ratio - 16.8. The maximum net power of this diesel engine is 400 horsepower, with a crankshaft speed of 1900 rpm. The minimum specific consumption of diesel fuel is 194.5 g/(hp*h).

In the basic configuration, KamAZ-65801 dump trucks are supplied with a fuel tank with a capacity of 350 liters. Diesel fuel consumption when driving on an asphalt road at a speed of 60 km/h is within 30 liters per 100 kilometers.

Fuel consumption of fragons from foreign manufacturers History of creation

• lifting load – 15 t;
• the power of the motor used is 300 hp;
• environmental class - Euro-4;
• engine brand – Cummins ISB 6.7;
• fuel tank volume – 350 l;
• box in front – ZF9;
• engine type – diesel, equipped with turbocharging;
• platform volume – 10 m3;
• wheel formula – 6×4;
• availability of a sleeping place – absent.

Fuel consumption depends on a number of factors: • operation of the concrete mixer in loading and unloading mode.

Transmission KamAZ-65801

The ZF 16S2225 TO model gearbox operates in conjunction with the diesel engine. This is a manual, 16-speed, double gearbox, with wheel gearboxes.

The KamAZ-65801 transmission consists of a four-speed gearbox, a front divider and a planetary range. The forward speeds are activated using a range, the rear – through a gear coupling.

The multiplier is planetary, automatically switched using a pneumatic valve by a clutch synchronizer, when the lever moves in neutral from the 3-4th speed position to the 5-6th, and vice versa.

The gear divider is mechanical and consists of one pair of spur gears and a synchronizer. The divider control is pneumatic. The gears are engaged mechanically, through a double H-shift. It is divided into five tracks located next to each other. On tracks 3-4 or 5-6 the lever is in neutral position.

The main gear is double, with wheel reducers. The final drive ratio is 5.262.

This transmission from ZF, which is produced at a joint venture in Naberezhnye Chelny, provides the heavy dump truck with decent acceleration dynamics and smoothness when changing from one gear to another.

The KamAZ-65801 truck is also equipped with a single-plate diaphragm dry clutch from ZF Sachs, model MFZ-430, which is equipped with a hydraulic booster and a pneumatic drive. There is one pressure spring, central diaphragm type. The transmitted torque is 1600 N.m (160 kgf.m). The number of pairs of rubbing surfaces is 2. The diameter of the friction linings is 430 mm. Thickness: driven disc with linings – 10 mm, linings – 3.6 mm.

Brakes and electrical equipment KamAZ-65801

Each wheel of the KamAZ-65801 vehicle is equipped with drum-type brakes with pneumatic drive and ABS and ASR systems. The diameter of the brake drum is 420 millimeters, and the width of the brake pads is 180 mm.

In addition to the main brake, the dump truck is equipped with auxiliary, backup and parking brake systems. Also, the Telligent® system of the Mercedes-Benz OM 457LA.V/4 engine provides maximum deceleration when changing gears.

The electronic and electrical systems of the KamAZ-65801 dump truck are powered by 2 batteries with a total capacity of 420 A/h. This truck is also equipped with a voltage regulator and a generator with a capacity of 3 kW.

Suspension, chassis and axles

The suspension of this truck (both front and rear) is dependent, leaf spring, and low-leaf.

Wheel type: disc. Rim size: 8.5-24. Tire type – pneumatic, tube. Tire size – 12.00 R24. The size is impressive. Standard dump trucks are equipped with tube tires from the main supplier, Neftekamskshina. However, you can also order Continental tires for an additional fee.

An important technical feature of the KamAZ-65801 dump truck is reinforced axles, which allow it to confidently hold the load with a serious load capacity of 33 tons. Both rear and front axles are supplied by the Chinese company HanDe Axle, but they are produced under license from the German manufacturer MAN. These are products tested by time and domestic operating conditions that have proven their reliability. Axles from this manufacturer are also installed on Chinese-made Shacman/Shaanxi heavy dump trucks, which are popular in Russia and the CIS.

Weight

When operating dump trucks with dump trailers, semi-trailers, if the basic rate is calculated for the vehicle, as for a truck tractor, the fuel consumption rate increases for each ton of the trailer's, semi-trailer's own weight and half of its rated load capacity, load factor 0.5 gasoline to 2 liters; diesel fuel up to 1.3 l; liquefied gas up to 2.64 l; natural gas up to 2 cubic meters With the entry into the market of updated restyled KamAZ trucks, the most popular of which was the KamAZ 65115 dump truck model, a worthy rival appeared for import suppliers from Europe, the Chinese company SINOTRUK and other foreign manufacturers, whose products have long dominated the heavy vehicle market.

Tipper platform

Standard dump bodies for this four-axle vehicle - rectangular in cross-section, with a platform heating function and an awning - are manufactured by the Neftekamsk automobile plant NefAZ, which is also part of the group. The internal volume of this body is 20 cubic meters. For lifting/lowering, hydraulic equipment from Binotto or HYVA is used. The standard version includes heating with exhaust gases, a canopy with a twisting mechanism, and an additional staircase.

Cabin of KamAZ-65801 dump truck

The cab type of this dump truck is classic for KamAZ - cabover, located above the engine. The cab suspension is four-point, spring. As with the vast majority of dump trucks, it comes in a version without a bed. In the cabin you get the complete impression that you are in the cabin of a Mercedes-Benz Axor or Atego. There is nothing surprising about this, because in fact it is so.

The cabs of the KamAZ-65801 dump trucks, like other new KamAZ trucks, were inherited from the previous generation Mercedes-Benz Axor (the frames are delivered from Germany). These cabs are produced at KAMAZ, and the level and quality control characteristic of Mercedes-Benz are fully preserved. Their interior is distinguished by thoughtfulness, functionality and convenience.

The instrument cluster of the KamAZ-65801 is also the same as in the Mercedes-Benz Axor. It is very simple, but informative, any readings can be easily taken with just a quick glance, and many parameters can be displayed on the on-board computer screen. The on-board computer control is located on the steering wheel. The instrument panel has a three-section design and is very ergonomic.

There are two chairs, they are modern, adjustable and very comfortable. The KamAZ-65801 cabin is distinguished by excellent heat, noise and vibration insulation.

Models with KAMAZ-740 power unit – Operational characteristics

• Hsan is the norm for completely loaded vehicles.
• Hw is the amount of fuel and lubricants required for transportation.
• W is the amount of work performed by the vehicle.
• D is the error coefficient.

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Reviews from drivers and owners of KamAZ-65801

Feedback from drivers and owners about KamAZ-65801 dump trucks is purely positive. It is noted that the cabin and suspension of this truck as a whole consistently provide the driver with comfortable driving. The seat is comfortable, the noise of the diesel engine does not bother or bother you at all: it is no more than in a diesel GAZelle (despite the disparity of the engines of these cars). When the engine is running, you can speak freely in the cabin without raising your voice. The steering wheel fits comfortably in your hands.

Having air conditioning is correct and very important. The power of the Mercedes engine is more than enough under any operating conditions, even on long climbs. The box is quite satisfactory. The strokes of its lever are small, and the switching itself is quite clear. And on the highway, the dump truck also behaves decently: good acceleration dynamics and handling, and at the same time it remains quiet in the cabin. Fuel consumption is normal and does not exceed the figures stated by the manufacturers.

KAMAZ 55102 (agricultural worker). Model history

The three-axle all-terrain chassis of the KAMAZ 65111 with a 6 x 6 wheel arrangement allows you to operate the vehicle without any difficulty when maneuvering, loading and unloading cargo, and even without difficulty using the vehicle where there is no road surface at all. What is typical is that if a mechanic has golden hands, then with a professional approach he can easily convert KamAZ into almost any other vehicle.

Technical specifications in numbers

• Overall dimensions: total length of the truck - 9.3 meters, width - 2.55 m (including rear-view mirrors - 2.9 m), height - 3.45 m.
• The curb weight of the dump truck is 17 tons. The load on the rear bogie is 9 tons, the load on the first and second axles is 9 tons.
• The maximum permissible load capacity is 33 tons.
• The total weight of the car is 50 tons. The load on the rear bogie is 32 tons, the load on the first and second axles is 18 tons.
• The volume of a standard cargo dump platform is 20 cubic meters.
• Maximum lifting angle of the dump body: 50 degrees. Cruising speed: 70 km.
• The capacity of the tank with neutralizing liquid is 70 liters.
• The capacity of the fuel tank is 350 liters.
• The outer overall turning radius is 11.6 liters.
• Maximum speed is at least 90 km/h, “cruising” speed is 70 km/h.
• The angle of the climb to be overcome is at least 30 percent (18 degrees).
• Batteries – 2x12 V / 210 Ah
• Voltage – 24 Volts.
• Factory warranty - 24 months, or 160 thousand kilometers.
• Service mileage is 60 thousand kilometers.

Device

The KamAZ 6580 frame is made of high-strength steel, the side members are supplemented with reinforcements and are made of S600MC steel. The front suspension is low-leaf, based on rubber-metal hinges with maintenance-free silent blocks (designed for a load of up to 9000 kg). The KamAZ 65802 version uses a Hande HDZ-10 drive front axle that can withstand loads of up to 10,000 kg. The rear suspension is balanced with tandem drive axles from Hande, wheel reduction gears and a cross-axle differential. The maximum load is 32,000 kg.

KamAZ 6580 is equipped with a proven 16-speed ZF16S 2220TO manual transmission with a remote-controlled range and divider. For the KamAZ 65802 version, a KamAZ 6522 transfer case is provided.

The brake system of KamAZ 6580 has a pneumatic drive. It is based on drum mechanisms with a drum diameter of 420 mm and a lining width of 180 mm. The series eliminates the problem of the “brooding brake”, which is typical of most KamAZ dump trucks. A “wet” receiver has been added to the design of the brake system, preventing moisture from entering, the diameter of the supply pipeline has been increased, due to which the response when pressing the pedal has increased.

Initially, KamAZ 6580 was equipped with NEFAZ U-shaped bodies. Taking into account the “heap” loading characteristic of Russian operation of dump trucks, the maximum load in some cases was significantly higher than the standard one, which affected the capabilities and condition of the vehicle. In 2022, the previous bodies were replaced by rectangular BCM bodies () of smaller volume.

The cab for the KamAZ 6580 series is manufactured under license from Mercedes-Benz and is an almost complete copy of the cab of the Mercedes Axor family of trucks. The salon features the highest level of comfort. According to this indicator, the car is not inferior to foreign analogues.

Weight characteristics:

• curb weight – 15550 kg;
• front axle load – 6200 kg;
• rear load – 9350 kg;
• total weight – 41000 kg;
• front axle load – 9000 kg;
• rear load – 32,000 kg;
• load capacity – 25450 kg.

The car is equipped with a platform with a volume of 16 cubic meters and a lift angle of up to 50 degrees. The maximum speed of the KamAZ 6580 is 90 km/h, the climbing angle is 18 degrees. The machine uses tubed pneumatic tires 12.00 R24 (rim size – 8.5-24).

Cabin

The first thing that strikes you in the cabin of new cars from Naberezhnye Chelny is silence and comfort. It’s as if you’re sitting not in a domestic dump truck, but in some Mercedes-Benz Axor, for example. Although why for example? The cabin of this purebred “German” is installed on the chassis of the new KAMAZ trucks. Hence the absence of noise and vibrations in the cabin, imported components, and neat finishing. The cabin is assembled here from imported stamped panels, which are welded and painted at the Kama plant.

It is possible to equip the interior with air conditioning, electric windows and other comfort elements.

In a word, the cabin of the new dump trucks is what you need: comfortable and modern.

The cost of KamAZ-65801 on the domestic market

The price of the new KamAZ-65801 at the end of 2022 starts at 7 million 450 thousand rubles. You can find very few used cars of this brand on the secondary truck market, and they ask for about 5-6 million rubles for such a truck.

In general, during the development of this model and the entire family of modern heavy construction dump trucks, the Kama Automobile Plant did a tremendous amount of work. Its result was that a domestic dump truck appeared on the market, not inferior to its European counterparts, but at a more affordable price. Direct “classmates” of KamAZ-65801, with which it can compete on equal terms, are MAN TGS, Scania G-series, Mercedes-Benz Axor, Volvo FM, DAF CF, Iveco-AMT Trakker, as well as MAZ-6516.

Table of average fuel costs for KamAZ of various modifications

When in the early 2000s, the Kama Automobile Plant presented new 4x2 trucks at a number of exhibitions and car shows, it was rightfully perceived as a completely new and quite promising project. Indeed, the company’s model range already included (and for a long time) two-axle cars in its assortment, including sports cars for rally raids. But at that time they were all all-wheel drive, and therefore the appearance of model 53605 in the lineup of KamAZ OJSC was considered as a new stage, an innovation in the development of the plant.