Models of gearboxes installed on MAZ cars

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Author admin Reading time 6 min Views 640 Published 11/07/2019

4.2.3 Gearbox

The eight-speed gearbox consists of a main four-speed

foam and additional two-stage, nine-stage from the main five-stage and additional two-stage.

4.2.3.1 Gearbox control drive manufactured by YaMZ

The main box is switched using lever 2 of the mechanism

remote control (Figure 23). The additional box is controlled by range switch 1 located on gear shift lever 2. The gear shift diagram in an eight-speed box is shown in Figure 24, in a nine-speed box - in Figure 25.

At the same time, the gear shift diagram is pasted on the dashboard

When the range switch is in the lower position, the fast

The first range is in the additional box; the upper range is the slow range.

During operation, if necessary, the following is carried out: - adjusting the angle of inclination of lever 2 in the longitudinal direction; — adjustment of the angle of inclination of the lever in the transverse direction; — adjustment of the locking device of the telescopic mechanism

If necessary, it is adjusted during operation.

roving ADJUSTMENT OF THE GEAR SHIFTING DRIVE IS MADE WITH THE ENGINE NOT RUNNING. The procedure for adjusting the position of lever 2 in the longitudinal and transverse directions is as follows: – set lever 9 to the neutral position; – by longitudinal movement of the intermediate mechanism 5 relative to the shank 7 with the bolts 6 loosened, set the angle  equal to 85°±2°; – angle  equal to 90°±2° is adjusted by changing the length of rod 8; – if the range of adjustment of the rod 8 is insufficient, loosen the bolts 6, rotate the intermediate mechanism 5 relative to the shank 7, tighten the bolts 6 and repeat the adjustment of the angle  using the rod 8. Adjustment of the locking device of the telescopic mechanism should be done as follows: – undo the pin 16, unscrew the nut, remove the pin and disconnect the intermediate mechanism 5 from the fork of the gear shift lever 2;

The MAZ gearbox is a gear shift mechanism that is included in the transmission device along with the divider.

Specifications

MAZ-5551 is a two-axle dump truck with a 2x4 wheel arrangement and double tires on the rear wheels. The body is all-metal, with automatic opening and closing of the tailgate. Unloading of the dump truck in the basic configuration is rear. The engine is located longitudinally, under the cabover cab. All power elements are fixed to a metal frame.

Engine

Most often, modern MAZs are equipped with four-stroke power plants manufactured in Yaroslavl YaMZ-6563.10-03.

Main settings

• Type – with compression ignition and direct fuel injection;
• Working volume – 11.15 l;
• Number and arrangement of cylinders – 6, V-shaped;
• Compression ratio – 17.5;
• Power – 230 hp (169 kW);
• Maximum torque at a crankshaft speed of 1100-1300 rpm – 90 Nm;
• Minimum specific fuel consumption – 200 g/kWh;
• Turbocharging system – with intermediate cooling of charge air. Air-to-air heat exchanger.

The engines are equipped with a Yazda fuel supply system with a Compact-40 fuel injection pump. The engine ensures compliance with EURO-3 environmental standards.

Fuel consumption

The fuel consumption of the MAZ-5551 is 22 l/100 km. Taking into account the large capacity of the fuel tank (200 l), the truck can cover over 800 km without additional refueling.

Chassis

The front suspension is made on two semi-elliptical springs with double-acting hydraulic shock absorbers. The rear suspension is on two main and two additional springs with anti-roll bar. The brake mechanisms are drum. The drive of the main brake system is pneumatic, separately for the front and rear wheels. Parking brake - on the rear wheels with pneumatic drive, from spring energy accumulators. The car is equipped with tires of size 12.00R20 mod. ID-304.

Power transmission

In the basic configuration, the car is equipped with a five-speed manual transmission YaMZ-236P. Synchronizers are installed in 2nd, 3rd, 4th, and 5th gears. The transmission of torque from the engine to the transmission elements is carried out by a double-disc friction clutch. The clutch drive is hydraulic with a pneumatic booster. The rear axle is a double transmission, consisting of a central gearbox and wheel gears. The drive axle ratio is 7.79. Open type cardan transmission with hinges on needle bearings

Clutch adjustment

The MAZ-5551 is equipped with a traditional double-disc friction clutch for powerful trucks. The elements of this unit are subject to wear due to significant overloads during operation and require periodic maintenance.

Adjusting the MAZ-5551 clutch is required, for example, in the following cases:

• clutch slipping at high speeds
• crackling sound when changing gear
• The clutch doesn't disengage completely

Three main stages can be distinguished:

1. Setting the gap of 1 mm between the adjusting screws and the middle drive disk is carried out as follows:

• remove the hatch covers to gain access to the clutch and flywheel,
• with the clutch engaged, move the gearshift lever to neutral,
• unscrew the locknuts and screw all the adjusting screws into the middle drive disk until it stops; to do this, turn the flywheel,
• Loosen the screws 1 turn and tighten the locknuts with slight force.

2. Ensuring a gap of 3.3...3.7 mm between the nut and the rear valve cover. To adjust, you need to loosen the lock nut and set the gap to the desired size by tightening the adjusting nut.

3. Adjusting the pedal free play. The standard value is 34-43 mm (measured with a ruler when the pneumatic system is empty).

Clutch

A single-wire electrical wiring circuit provides on-board consumers with 24 V electricity. The DC sources are two 6-ST-182 or 6-ST-190 type batteries and an alternating current generator with a built-in voltage regulator.

Manual

The instruction manual contains the following sections:

1. Safety requirements when working on this vehicle. All precautions and emergency procedures are listed here.
2. Motor. This section provides engine characteristics, its design and maintenance recommendations.
3. Transmission. This describes the operation of the transmission and provides a brief description of its main elements.
4. Chassis of transport. This section describes the design of the front axle and steering linkage.
5. Steering, brake systems.
6. Electrical equipment.
7. Transport marking. It describes where you can find the vehicle identification number and provides a breakdown of the number.
8. Rules for running in a dump truck.
9. Features of operation and maintenance. It describes when and how to carry out maintenance, what types of maintenance there are.
10. Conditions for storing a car, rules for its transportation.
11. Warranty period and transport coupon.

Gear shift diagram

The gear shift diagram is in the dump truck owner's manual. Switching occurs as follows:

1. Using the clutch mechanism, the power unit is disconnected from the vehicle transmission. This makes it possible to change gearbox gears without reducing engine speed.
2. Torque passes through the clutch block.
3. Toothed gears are located parallel to the axis of the shaft devices.
4. The first shaft is connected to the coupling mechanism, on the surface of which there are splines. The driven disk moves along them.
5. From the axis, the rotational action is transmitted to the intermediate axis, which is combined with the gear of the primary shaft mechanism.
6. When the neutral mode is turned on, the gears begin to rotate freely, and the synchronizer clutches come to the open position.
7. When the clutch is depressed, the fork moves the clutch into the engagement position with a pair located on the end of the gear.
8. The gear is fixed together with the shaft and stops spinning on it, which ensures the transmission of rotational action and force.

Electrical diagram

The electrical circuit includes such elements as:

1. Batteries. Their voltage is 12 V. Before starting work, it is necessary to adjust the density of the batteries.
2. Alternator. This installation is equipped with an integrated voltage regulator and a rectifier unit. The generator design includes bearings, the condition of which is recommended to be checked every 50,000 km.
3. Starter. This device is necessary to start the power unit. It consists of a relay cover, contacts, lubrication channel plugs, armature rod, cup, brush holder springs, fasteners, handle, protective tape.
4. Electric torch device. Its task is to facilitate engine starting at low temperatures.
5. Battery disconnect switch. It is needed to connect and disconnect batteries to the vehicle mass.
6. Lighting and light signaling system. It controls the operation of headlights, spotlights, fog lights, and interior lighting.

YaMZ 238b gearbox with a range multiplier: device diagram, repair

YaMZ 238 is a diesel engine with 8 cylinders. The YaMZ 238b variant is found on such powerful vehicles as MAZ, Ural, and construction transport equipment. These vehicles have a large performance reserve.

Features of the YaMZ gearbox

The YaMZ-2381 (8-speed manual transmission) includes a 4-speed gearbox and a 2-range range multiplier (short divider), which is designed to increase the torque. The YaMZ-238VM model complies with the necessary environmental standards. The presence of an additional box is typical for trucks. The diagram of this box shows the presence of a driveshaft mounting flange here. It should be noted that YaMZ gearboxes can be designed not only for 8 gears, but also for 5, 6, 9, 14.

YaMZ device

YaMZ deviceThe YaMZ-238A version has been discontinued. An excellent alternative to it are models 238ВМ4 (5)(7).

There are synchronizers on all forward gears. Synchronizers ensure not only smooth running, but also silent gear shifting.

An integral part of the YaMZ 238b gearbox is the air distributor. This device provides direct switching of air flows. The mechanism is securely fixed in the upper crankcase cover.

Air distributor YaMZ 238

The article number of the gearbox housing for YaMZ 238 is 1701015. This element has a solid base and is part of the transmission system. Its main function is to protect gearbox parts from dirt, water, and dust. Shafts, bushings, gear blocks, couplings, and nuts are designed for a long working life.

Transmission care

The driver of a vehicle equipped with a gearbox such as the YaMZ 238 must promptly visit a service center, where service workers using computer equipment can fully check the vehicle system. Self-care of the gearbox may involve the car owner changing the oil and flushing the crankcase. To flush the crankcase, it is advisable to use special liquid industrial oils that comply with GOST.

The frequency of when the oil should be changed directly depends on what driving style the car owner follows.

The replacement of individual components on the YaMZ 236, 238, 2381, 239 gearbox can be indicated by the fact that the oil poured into the crankcase is overheating, and characteristic noises have appeared from the gearbox. Repairs may involve installing new shafts, bearings, cuffs and other consumables related to the gearbox.

prokpp.ru

How to change gears on a MAZ with a divider

The MAZ gear shift pattern depends on the type of gearbox installed on various models of MAZ cars. If you have MAZ 64229, MAZ 54323 cars, then they have a YaMZ 238A gearbox installed. It is a combination of a 4-speed gearbox and a two-stage range. That is, in fact, this gearbox is eight-speed.

The gear shift diagram for MAZ models MA3 555I, MA3 53371, MAZ 5337, MAZ 5433, MA3 54331 is different. After all, the YaMZ 236P gearbox installed on these machines is five-speed. Among other things, some MAZ models are equipped with imported gearboxes that are adapted for the engines installed on MAZs. Such an example is the ZF 16S-1650, which has 16 steps, the ZF “Ecomid” 9S 1310 has 9 steps. These boxes are distinguished by the highest quality workmanship, great reliability, but at the same time, high-quality technical service.

Such different gearboxes, depending on car modifications, are made for a reason. This makes it easier to control, improves efficiency and increases the service life of the engine and gearbox mechanisms.

In order for the gearbox to serve for a long time, it is not enough to follow the MAZ gear shift pattern. It also needs to be properly maintained. Carry out all necessary routine maintenance to maintain the gearbox in good condition in a timely manner. The oil must be changed according to the instructions. Drain in a heated state through both holes in the pan. To flush the MAZ gearbox, you must use spindle oil. After this, we start the engine and “drive” it for 10 minutes. After this, drain the spindle and fill it with new one according to the map. It is strictly forbidden to wash the gearbox with kerosene or diesel fuel if you do not want the oil pump to break.

Electrical diagram MAZ 4370 Zubrenok

MAZ-4370 electrical diagram, color
The electrical engine control system is equipped with a built-in self-diagnostic function and does not require maintenance, except for a control check after repair or adjustment of elements and components of the fuel system.

Layout of electronic control systems on the MAZ 4370

Scheme of electronic control systems MAZ-4370

To install electrical equipment on the MAZ 4370, you can use the following electrical diagram.

Installation diagram of electrical equipment MAZ-4370

The relay and fuse panel on the MAZ 4370 looks like this:

Relays and fuses in the MAZ-4370 cab

Oil pump

The MAZ-4370 gearbox is equipped with an oil pump, which has a ball valve that serves to limit the oil pressure in the transmission system. The crankcase of the unit is equipped with an internal partition, which causes the release of used oil through two holes blocked by special plugs.

Gear control is carried out via a lever located in the cab. The operating principle of the circuit is to mechanically switch a remote drive located above the power unit. In the bracket of the transmission unit crankcase cover there is a pair of support rollers that serve to change speeds using grooves and necks located on the adjusting rods.

In the middle position, the lever is located with a pin with a lock and a spring upward. At this time, the lower analogue of the fuse is activated along with the spring. The pin is externally mounted in the swing compartment of the first and reverse gears. The leash is mounted on a hinge pin mounted at the front of the box lid.

MAZ “Zubrenok” checkpoint: work

When this unit operates, the housing ring of the housing is pressed against the cone by the gears. In this regard, the friction between the contacting surfaces causes rotation and installation of the cavity on the slot with the coupling pin, and the element is blocked by the housing.

The frame then interacts with the gear cone due to the resulting force applied to the gear shifter. After the effect of friction occurs between the speed cones and the gear with the clutch, the load forces are leveled and the locking device releases the clutch from the base of the synchronizer. Next, the coupling moves by extruding the balls of the locking device, which moves to the side. Then the gear ring of the assembly engages with the internal teeth of the mechanism, which entails the inclusion of one or another gear.

MAZ-5551 photo

Dump truck MAZ-5551

It is impossible to imagine a single construction site in Russia without the MAZ-5551 dump truck. This hereditary “handyman” has been successfully transporting goods for a long time. Considering that its direct descendant MAZ-503 went on line in November 1958 and did not change too much, receiving a new code in 1985, then its history goes back almost 50 years.

The appearance of the dump truck is not burdened by modern design, but is as convenient as possible for work. Nothing extra. When moving to production of the MAZ-5551, they took into account a very important drawback of its predecessor, associated with the “unfastening” of the cab. The spring mechanism was replaced by a hydraulic drive, which eliminated the risk of abnormal “unfastening” in the event of spontaneous opening of the locks. To finally secure this operation, the developers complicated it by the need to open the radiator grille using a mounting tool. The cabin is double, but very spacious. Between the seats there is a convenient shelf for documents and necessary things. The only thing missing is a cigarette lighter and an ashtray - at MAZ “for a healthy lifestyle.”

The driver's seat is sprung. However, according to reviews from drivers of the MAZ-5551, it is not very convenient. The passenger seat is firmly attached to the floor. Considering that the cabin has no shock absorption at the mounting points, the entire stiffness of the suspension directly affects the comfort of the seats for both driver and passenger. The steering wheel along with the adjustable steering column also does not provide a comfortable feel. The instrument panel is to working standard. The only negative is the weakness of the light indication.

Speaking of technical characteristics, the base MAZ-5551 is equipped with a 180-horsepower YaMZ-236M2 engine, equipped with a 5-speed YaMZ-236P gearbox. Fuel tank with a capacity of 200 liters. Modifications can be equipped with a more advanced power unit YaMZ-6581.10 with a YaMZ-2361 gearbox or even a Deutz BF4M1013FC with a ZF 6S850 gearbox. The carrying capacity of this vehicle is ~ 10 tons.

The MAZ-5551 dump truck is equipped with an all-metal body with rear unloading. However, modifications are equipped with unloading systems that allow unloading on three sides. A convenient underbody heating system allows you to work efficiently in winter. The anti-roll bar installed behind the rear axle gives the dump truck confidence when entering turns when loaded. The pneumatic brakes work reliably. The only drawback is the long download time of the system.

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Many people remember that in Soviet times, almost no construction was carried out without the participation of the MAZ-5551. In addition to the construction sector, this model was often used in various sectors of activity, which include urban and agricultural sectors, construction and repair of highways, and industrial use. It mainly transports various bulk materials. Despite the emergence of numerous new products in the truck industry, it was not possible to oust this hard worker from the market. This is due to the constant modernization and introduction of modern technologies into production, which still produces this model.

The production of MAZ-5551 began in 1985 and has already lasted more than 30 years. Its old-style design, and in particular the front part, did not prevent it from remaining one of the most popular trucks in the domestic markets. This unit belongs to the eight-ton cargo class.

Among all the car models produced by the Minsk Automobile Plant, MAZ-5551 is the oldest model. The prototype for its creation was the MAZ-5337. During the entire production period, no worthy competitors were found for the MAZ in question. Of the few, some KamAZ and ZIL models can be distinguished, but they have a 6x4 wheelbase, which makes it possible to transport cargo on a “long shoulder”. The wheelbase of our sprinter, which is designed to work over short distances, is 4x2, which historically determined its use on urban construction sites.

Gear ratios

Viscosity level

Manufacturers offer gear oil for the rear axle, which has different viscosity ratings. Manufacturers comply with international specifications that apply to gear oil. The recognized unified classification SAE J306 has been used throughout the world for a long time. It was developed by scientists from America

It is important to familiarize yourself with all the parameters and indicators that index the viscosity level of transmission oil

If the manufacturer indicates the letter W with the marking, then gear oil can be poured into the rear axle all year round. It will not freeze when the temperature drops and there is severe frost. The absence of a designation indicates products for the summer period

It is important to remember that gear oil is divided into seasons, so you need to pay attention to this parameter when choosing

Manufacturers began to produce thickened or all-season products. It differs in chemical composition. The marking is indicated by the corresponding index.

MAZ 238 gearbox diagram

In previous articles we talked about the design, repair, and disassembly of the MAZ gearbox.

Today we want to draw attention to the MAZ 238 gearbox diagram. Usually the mechanism is installed on MAZ-54322 and MAZ-64227 trucks

Typically the mechanism is installed on MAZ-54322 and MAZ-64227 trucks.

The eight-speed gearbox has two ranges and synchronizer. The unit also includes an additional MAZ 238 gearbox.

The parts are mounted in both the main and additional gearboxes, which are fastened together and then attached to the mechanism housing.

Let's look at the design and diagram of the MAZ 238 gearbox in more detail.

The input shaft is mounted on 2 ball bearings. The clutch driven discs are located at the front splined end. The rear end of constant engagement with the main gearbox is made in the form of a gear rim.

The secondary shaft rests on a cylindrical roller bearing. The rear end of the mechanism is a ring gear, a constant mesh gear.

On the MAZ 238 box diagram you will also see:

• Sliding bearings;
• First gear gears;
• Roller bearings;
• Reverse gears.

The intermediate shaft is supported by a roller bearing as well as a double-core spherical bearing.

The durable MAZ 238 gearbox with a multiplier is equipped with an additional axle designed for installing an intermediate reverse gear.

As soon as the carriage begins to move and the gear ring, reverse gear is engaged.

The MAZ 238 gearbox design also includes a secondary shaft, which is supported by a cylindrical roller bearing.

The additional MAZ 238 gearbox also includes a shift synchronizer, which is mounted on the splines of the secondary shaft.

The MAZ cardan also has a mounting flange.

Another element of the MAZ 238 box is a roller bearing located in the middle of the cylindrical shaft.

Let's consider the intermediate shaft (in the figure it is indicated by the number 19).

The mechanism is also included in the device of the unit and is shown in the diagram of the MAZ 238 gearbox. However, unlike other components, it rests on a roller bearing, which is mounted on the front wall of the additional gearbox housing.

The reduction gear (in the figure the part is indicated by the number 22) is installed on the intermediate shaft. At the rear of the unit there is a small gear-type ring.

Found on some trucks and MAZ 238 gearboxes with a range multiplier. The box structure is similar.

To activate the MAZ 238 gearbox with or without a range multiplier, the following are provided:

• Inertial type synchronizers;
• Rings;
• Friction discs.

The MAZ 238 gearbox is switched using a remote control bellows. The operation of the additional box is controlled via a pneumatic drive.

You can purchase the MAZ 238 gearbox and spare parts for it in our catalog. Low prices, high quality and only fast delivery.

Switching circuit

1 236-1702060-A2 1st gear and reverse shift fork rod 2 236-1702014 Cover gasket 3 236-1702015-B2 Upper cover 4 236-1702129 1st gear and reverse fuse 5 236-1702127-A Spring fuse 6 236-1702132 Spring cup 7 236-1702087 Fork rod lock pin 8 316172-P29 Plug 9 200-1702083 Ball 10 236-1702122 Lever support gasket 11 216258-P29 Pin 12 2 52136-P2 Spring washer 10 12 252136-P2 Washer 10 spring 13 250513-P29 Nut 14 236-1702126 Driver axle 15 236-1702125 Driver for shifting 1st gear and reverse gear 16 252137-P2 Spring washer 17 250615-P29 Nut 18 236-1702170-A Breather 1 9 262522-P2 Plug 20 236 -1702025 Set screw 20 236-1702025 Set screw 21 236-1702225-B Gear shift lever 22 260311-P15 Plug 23 260310-P15 Plug 23 260310-P15 Plug 23 260310-P15 Plug ka 24 236-1702213 Bushing 25 236-1702129 Switching fuse 1st gear and reverse 26 236-1702106 Spring 26 236-1702106 Spring 26 236-1702106 Spring 27 236-1702215 Bolt 28 236-1702209-B3 Carter 29 236-1702206-B3 Remote shift mechanism housing gear assemblies 30 236- 1702235 Retainer spring cup 31 252161-P2 Washer 32 236-1702100 Retainer ball 33 236-1702229-A Fork rod head 34 312534-P2 Lock washer 35 310213-P29 Bolt 36 201499- P29 Bolt 10-6gх30 37 316121-P29 Plug K 1/4″ 38 236-1702216 O-ring 39 236-1702227 Gear shift rod fork 40 236-1702024 1st gear and reverse fork 41 236-1702221 Roller 42 314040-P2 Key 43 23 6-1702222 Gear shift lever 44 236-1702241 Gasket 45 236-1702240 Housing cover for remote gear shift mechanism 46 252135-P2 Spring washer 47 201454-P29 Bolt M8x16 48 236-1702027 2nd and 3rd gear shift fork 49 236- 1702053 Fork rod head 1st gear and reverse gear shift 50 236-1702028 2nd and 3rd gear shift fork rod head 51 236-1702033 4th and 5th gear shift fork 52 236-1702064 2nd and 3rd shift fork rod 53 236-1702074 Shift fork rod for 4th and 5th gears Link to this page: https://www..php?typeauto=6&mark=14&model=46&group=82

In this article, we will tell you what functions the gearbox performs in a MAZ engine, make several recommendations for repairs, and also indicate a MAZ gearshift diagram with a divider, which you can examine and study in detail.

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Components of the MAZ gearbox

The vehicle's gearbox (MAZ) includes several gears that are connected to the gear control lever. Each of the available gears performs its function and rotates at a certain speed, ensuring effective control of the machine.

MAZ checkpoint

The manufacturer placed the box in a MAZ car between the crankshaft and driveshaft. The crankshaft is a component part characterized by a complex design. High demands were placed on the production of this element. The cardan shaft is an equally reliable working mechanism, the function of which is to transmit the moment of force between the shafts.

Gearbox drive

In addition to the shafts, the MAZ manual transmission includes a crankcase, a mortar, and synchronizers. Speed ​​adjustment on the machine is carried out by changing gears. By interacting with each other, the gears are able to both increase and decrease the speed of the MAZ. The lever with the gear divider operates effectively.

MAZ gearbox diagram

The MAZ gearbox air distributor is designed to switch air flows. The device is located in the upper crankcase cover.

The MAZ transfer case is a complex mechanism that provides wheel locking and affects gear changes.

A MAZ gearbox with a range control includes a drive gear of the intermediate shaft, which is equipped with a damper. The damper helps reduce vibrations. The MAZ pillow helps suppress noise from the gearbox while driving.

Demultiplier circuit

Change of oil

In order to change the oil in a MAZ gearbox, you must:

1. Drive about 5-10 km by vehicle to warm up the old oil in the box. At elevated temperatures it becomes liquid and is easy to drain.
2. 10-15 minutes after stopping the engine, place the vehicle on a lift or inspection pit.
3. Remove the crankcase protective cover.
4. Unscrew the plug and check the volume of oil fluid in the manual transmission.
5. Check the gasket for wear and, if necessary, replace it with a new one.
6. Replace worn filter elements.
7. Open the drain hole and drain the oil into a prepared container.
8. Fill with new oil fluid.
9. Screw on the drain cap.
10. Reinstall the clutch protective cover.
11. Start the engine and check the oil level at various speeds.

Repairing a MAZ gearbox - useful tips

The MAZ gearbox is a reliable mechanism for a modern truck. We wrote about the structure of the unit here.

You can get acquainted with the repair of MAZ spare parts in this article (part 1).

Today we will continue to study the repair of the MAZ gearbox.

So, the steel intermediate shaft of the MAZ gearbox is cemented on the teeth. The part requires repair in the following cases:

• Broken teeth;
• Wear;
• Surface chipping.

To repair MAZ boxes, a special crown is installed. Carefully anneal the neck.

The crown of the part is brought to high temperature using high-frequency equipment. The shaft is straightened, eliminating runout using a hydraulic press.

A machine is used to correct center holes.

1. The crown is pressed on.
2. Create a tension of no more than 0.05 mm.
3. Heat treatment of the steel crown is performed.
4. For welding, a circular seam and an electrode are used.

Urgent repair of a MAZ gearbox with a damaged journal journal divider is carried out by surfacing using chrome plating.

I cement the steel block of reverse gears onto the teeth. Repair of MAZ boxes is carried out when:

1. Sharp breaks on the teeth;
2. Chipping;
3. Wear.

The crown with defects is annealed. Heat the part to 800 degrees. They install a new one, carefully pressing the spare part onto the neck. Provide tension up to 0.08 millimeters.

If during the disassembly and assembly of the MAZ gearbox the holes for the bearings are deformed, grind them.

The durable gearbox gear is annealed in an electric furnace. Remove damaged teeth. The holes are bored to install the crown. A lathe is used for processing. After pressing, check the runout.

Repair of a MAZ gearbox with a pump housing divider is necessary in case of breakdown:

• Gear socket;
• Axles;
• Holes (appear in bushings).

To restore the nests, boring is performed. When disassembling and assembling a MAZ gearbox, all holes for bolted connections are trimmed. Having installed the body, the end is processed.

If, as a result of wear, the gear diameter has become less than 13.95 millimeters, the spare part is replaced with a new one.

• A small hole is made in the body.
• The axle with the defect is pressed out.
• A new part is installed, the socket is welded with an electrode.
• The axis should be buried 1 mm into the surface of the housing.

If the holes in the bushing are worn, it is necessary to secure the tap. To repair MAZ boxes:

1. Rotate the body and screw in the part.
2. The bushing is pressed out.
3. They install a new spare part.

If scuffs and risks are visible on the base of the pump, repair work is carried out, as well as disassembly and assembly of the MAZ gearbox.

Grinding of the end surface is performed on a special machine. The area should be 0.5 millimeters higher.

We remind you that you can buy parts for the MAZ gearbox in our catalog. For you - a great price, fast delivery and the best service.

Device

MAZ-5551 without a sleeping place is much more spacious than KamAZ vehicles. Thanks to the well-positioned handrails and steps, climbing into the dump truck cab is extremely easy. True, the ergonomics of the cabin is not the truck's strongest point. Although the seat cushion moves and the steering column is adjusted in two planes, there is no need to talk about driver comfort. The car's cabin has good visibility, but discomfort causes increased fatigue, which is especially evident on long routes. The huge steering wheel also does not add comfort, since small drivers have to lean forward to turn it.

The MAZ-5551 instrument panel is quite informative and convenient. However, there are also disadvantages here. The light indication has low brightness, so it is difficult to see in the daytime.

However, there are many more successful solutions in the dump truck cab. The layout of the relay and fuse box behind the dashboard is very convenient and makes it easy to get to. An efficient heating system, sunroof and interior lighting add to the comfortable driving experience.

Thanks to large rear-view mirrors, the visibility and safety of driving the MAZ-5551 is increased.

The driver's seat has a suspension system and is adjustable in several directions. However, the cabin is still not truly comfortable, since there is no shock absorption system in the car. The passenger seat is directly attached to the floor.

Cabin

What interesting things did the designers do to improve the ergonomics and ease of driving the MAZ? There are plenty of changes, and all of them are very pleasant. The cabin became cozy and spacious. Even without a berth, two passengers can easily fit here, not counting the driver himself.

Well-designed handrails and steps make getting into the cabin quick and easy. The seat can be moved and adjusted - unfortunately, only the passenger seat. In the 90s, not every car had an adjustable steering wheel, but the MAZ-5551 has it. The first drawback was noticed in the cockpit - the steering wheel was too large. If you are not tall, you will need to lean forward a little with each turn. It is unlikely that such an innovation can be considered a convenience.

The instrument panel leaves a mixed impression. On the one hand, it is quite informative, on the other, it has low brightness, which is why individual elements are practically invisible in the daytime. A well-placed safety box is a definite plus of the MAZ-5551. However, as well as efficient heating, which copes with the task perfectly even in severe frosts. Between the passenger and the driver there is a small compartment in which you can hide various small items - documents, keys, bottled water, etc.

Weight parameters and load distribution

• Load capacity – 8500 kg;
• Curb weight – 7580 kg;
• Load distribution – front axle 4130 kg, rear axle 3450 kg;
• Gross vehicle weight – 16230 kg;
• Load distribution at full weight - front axle 5980 kg, rear axle 10250 kg;

Dynamic characteristics

• The maximum speed declared by the manufacturer is 85 km/h;
• The acceleration time of the dump truck to 60 km/h is 50 seconds;
• Vehicle run-out from 50 km/h – 850 m;
• The maximum climbing angle is 25 degrees;
• Turning radius – on the outer wheel 7.9 m, overall 8.6 m;
• Body operating time at engine speed 1900 rpm – lifting a loaded one 15 sec, lowering an empty one 10 sec;
• Body lift angle – 50*.

Linear and volumetric parameters

• Length – 5990 mm;
• Width – 2500 mm;
• Height – 2925 mm;
• Height with the body fully raised – rear unloading 4850 mm, side unloading 3850 mm;
• Wheelbase – 3950 mm;
• Loading platform – 3860x2265x630 mm;
• Ground clearance -270 mm;
• Body volume – 5.3 m3 in the basic version, up to 12.5 m3 in various modifications;

Modifications

Each model differs in technical indicators and overall dimensions, as well as in the cost of transport. Each dump truck has different engines and gearboxes.

Modifications of this vehicle include: 551603, 551608, 5516A5, 5516X5 and MAZ-5516A8-336.

MAZ-551603

MAZ-551608

Technical parameters of the MAZ-551608-236 modification:

MAZ-5516A5

There are several models of this modification on the market.

MAZ-5516A5-380 is a dump truck that is designed for transporting various bulk materials. The maximum load capacity of this model is 20,000 kg. This type of transport has a good cross-country ability. It has a powerful engine and a nine-speed gearbox. The power of the power unit is 330 hp. With.

The equipment is used in industrial enterprises and construction sites.

It is equipped with a spacious double cabin, spring suspension mechanisms, and pneumatic power steering. The recommended oil for filling into the engine is LUKOIL-avant-garde.

MAZ-5516A5-371. The car is based on a 6x4 chassis. A reliable YaMZ-6582.10 engine, manufactured in accordance with the international environmental standard Euro-3, is installed here. The fuel tank holds 350 liters of working fluid, and the average fuel consumption is 33 liters per 100 km.

It is recommended to change all main consumables (tires, bearings, valves, filter elements, oil fluid) once a season. This will help extend the life of the vehicle and protect the main components from premature wear and damage. The first maintenance should be carried out after 5,000 km.

MAZ-5516A5-375. This vehicle works properly in off-road conditions and at low ambient temperatures (temperature range -30...+35°C). Equipped with a nine-speed gearbox and a small cabin with no sleeping space. The amount of exhaust gases complies with the international environmental standard Euro-3.

The cabin is attached to the dump truck body using a pneumatic spring front suspension. An improved shock absorber system is installed here, which makes driving this vehicle more comfortable. MAZ is equipped with an eight-cylinder engine producing 320 hp.

MAZ-5516A5-347 is equipped with a YaMZ-6582.10 engine, the power of which is 330 hp. With. The wheel formula of the car is 6x4. The equipment meets international environmental standards Euro-2. The car runs on diesel fuel, the engine displacement is 11.8 liters. It is recommended to use different oils for the winter and summer seasons.

MAZ-5516X5

MAZ-5516X5-481-000 is a dump truck with a rear unloading type, designed for transporting construction bulk cargo. The model of the installed engine is YaMZ-65853 (power - 330 hp). The volume of the cargo platform is 12.5 m3. The number of cylindrical elements is 8, their diameter is 12 cm. The model is characterized by economical fuel consumption and ease of maintenance. The cylinders operate in the following sequence: 1-3-2-4-5-7-6-8.

The equipment is equipped with a nine-speed gearbox and a high-pressure fuel pump. All electrical equipment indicators are displayed on the dashboard.

MAZ-5516Х5-480-050 is a small dump truck designed for transporting various cargoes whose weight does not exceed 20,000 kg. It is equipped with a double cabin with a berth, the cabin body is not sprung. The maximum speed that this vehicle can reach is 85 km/h, while fuel consumption will be 38 liters per 100 km. The power of the power unit is 330 hp. With.

The need for gearbox care

Helps to extend the life of the speed box - its timely maintenance. In particular, the car owner must monitor the efficiency of the gears and control lever, and control the level of oil poured into the MAZ car system.

If it is necessary to repair the gearbox on a MAZ, it is necessary to remove the gearbox from its original location. The device must be visually inspected for external deformation. There is a high probability that this is precisely the reason that the gearbox “does not obey” the driver’s commands. If there are no deformations, you can begin to disassemble the gearbox into components.

If the MAZ gearbox circuit fails, the following signs will appear:

• Some gears do not work, for example, 4 and 5;
• difficulty in manual switching is noted.

To flush the gearbox, about 3 liters of special oil are required. Repair of a MAZ gearbox may involve restoring axles, washing, or fault-defecting the gearbox. Also, the crankcase and cover are subject to repair.

MAZ vehicles are equipped with engines produced by the Yaroslavl plant, MMZ, MAN, Deutz, Mercedes-Benz, Cummins. Therefore, each MAZ gearbox installed together with these engines has design features. Most gearboxes preferred by the automaker are manual. The task of the gearbox is to act as an “intermediary” between the crankshaft of the internal combustion engine and the drive wheels when transmitting torque, while changing its magnitude and direction. Using the gearbox, the driver can separate the internal combustion engine and transmission.

You can buy a MAZ gearbox at a competitive price on the Sparox website. We offer certified spare parts and components for gearboxes from different manufacturers.

Transmission options for heavy-duty vehicles

The 8-speed MAZ gearbox is typical for vehicles that have a high load capacity.

9-speed versions are installed not only on powerful trucks, but also on ordinary cars.

5-speed gearboxes are present on the MAZ-500 with the YaMZ-236 diesel engine.

5 speed gearbox

16-speed versions are found on dump trucks and KamAZ vehicles. The weight of the box exceeds 250 kg. The ZF16S gearbox has an adapter plate that communicates with the engine and gearbox.

The listed versions are distinguished by high reliability and long-term operating capability.

Those who want to enjoy a full ride both in urban conditions and on rough terrain decide to purchase a MAZ car with a ZF gearbox. This type of gearbox is often found on snow removal equipment.