Gear shift mechanism for MAZ-437040 (Zubrenok)

MAZ 4370 Zubrenok: technical characteristics, engines, clutch, gearbox diagram, brake system

The MAZ 4370 truck is a medium-tonnage low-loader cargo truck, developed and produced at the Minsk Automobile Plant.
Cars of the MCV category belong to cargo vehicles with a permissible minimum weight of 3.5 tons (class N2). The unofficial nickname of the MAZ 4370 became “Zubrenok”, and under this name the truck went down in history. Production of the model started in mid-1999, and during production the base model was repeatedly modernized. MAZ 4370 Zubrenok has many advantages, the key ones for buyers are:

• decent build quality;
• affordable price;
• adaptation to harsh operating conditions.

The reliability of the chassis and suspension is another advantage of the Zubrenok MAZ 4370, which, compared to competitors in its class, required repairs much less often. In addition, the truck is versatile and functional, which allowed it to be used in a wide variety of areas.

MAZ 4370 Zubrenok was produced with different bodies, in the photo - with an awning

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.

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MAZ 4370 Zubrenok: technical characteristics

At the time of development of the MAZ 4370 Zubrenok truck, the technical characteristics looked impressive. But even now they are quite decent, which allows the demand for the car to remain at a high level for many years now.

The vehicle has the following dimensions:

• Length - 5.5/7/7.95 m.
• Width - 2.48 m.
• Height - 2.8 m.

MAZ 4370 is produced in several wheelbase options, these are:

Considering the characteristics of Zubrenok, one can note its compact overall dimensions. This gives the truck several advantages:

1. the ability to move freely around the city;
2. the ability to use OH (general purpose) roads;
3. easy maneuverability thanks to a turning radius of 7.65 m.

As for the operational technical characteristics of the MAZ 4370 Zubrenok, they are as follows:

• The nature of the body is onboard.
• The layout of the truck is that the engine is placed in the front, the drive is on the rear axle.
• Wheel formula - 4*2.
• Load capacity - 6 tons.
• The maximum load in tons on the front axle is 3.75.
• The maximum load in tons on the rear axle is 6.35.
• Body capacity (standard factory version) is 35.5 m3.
• Max. speed - 90 km/h.
• Fuel tank - 130 liters.
• Fuel consumption: Varies depending on the installed engine. For the most common truck configurations in winter it will be 23 l/100 km; in summer - 17 l/100 km. (Read more about fuel consumption for different engines in this section).
• An average of 500 km travels on one gas station.

The Zubrenok MAZ-4370 is still not losing ground.
The technical characteristics of the MAZ 4370 make the Zubrenok one of the most popular medium-duty trucks to this day and allow the truck to compete with dignity even with more modern models.

Adjusting the MAZ-504V gearbox drive

The gearbox drive of the MAZ-504V vehicle (Fig. 36, b) is adjusted in the following cases:

• 1st, 3rd and 4th gears do not engage;
• 2nd and 5th gears and reverse do not engage
• 4th and 5th gears do not engage, the rest do;
• 1st gear and reverse do not engage, but the others do.

The procedure for adjusting the drive if it is impossible to engage 1st, 3rd and 4th gears is as follows:

• apply alignment marks to rod 75 (see Fig. 36, b) and tip 77;
• loosen the tie bolts 9 of the rod end and disconnect the tip 17 from the shaft 19;
• Having removed pin 18, lengthen the rod by folding the tip two or three turns;
• align the marks on rod 75 and tip 77;
• tighten the coupling bolts 76;
• connect the tip to the roller by pinning pin 18;
• Check the gear shift and repeat the adjustment if necessary.

The procedure for adjusting the drive when it is impossible to engage 2nd and 5th gears or reverse is similar to that previously described, with the exception that the rod 75 must be shortened by screwing the tip 77 two or three turns.

The procedure for adjusting the drive when it is impossible to engage 4th and 5th gears (and the remaining gears are engaged) is as follows:

• apply alignment marks to rod 75 and tip 77;
• loosen the tie bolts 16 of the rod end;
• carefully turn the tip on the rod counterclockwise (if you look along the direction of the car) at an angle of 4-5°;
• tighten the coupling bolts;
• carefully check that the gear is engaged;
• if necessary, additional rotation of the rod tip is required.

The procedure for adjusting the drive when it is impossible to engage 1st gear and reverse (the remaining gears are engaged) is similar to the adjustment performed in the event of malfunctions in the 4th and 5th gears, except that the rod end must be turned clockwise (if viewed in the direction of travel of the vehicle ) by 4-5°.

Adjusting the MAZ gearbox

maz-auto.info

Engines for MAZ 4370

The MAZ 4370 cargo Zubrenok was produced in four modifications, which differed in power plants. Initially, the Belarusian MMZ D-245 engine was installed on the truck. The engine did not meet European environmental standards, so it needed improvement. Quite quickly it was replaced with an improved version D-245.30, which already complied with the Euro-2 standard. A few years later, the engine was further refined to the Euro-3 standard. In addition to Minsk engines, the MAZ 4370 was equipped with the German Deutz BF4M 1013FC engine, which meets Euro-3. But the latest modifications can be found relatively rarely in Russia.

Gearbox MAZ 4370

The truck was produced with three different transmissions:

1. ZIL-695D (Saransk, Russia) - the gearbox was installed in tandem with the D-245 engine on MAZ 437040;
2. SAAZ-3206 - gearboxes were paired with improved D-245 engines (Euro-2 and Euro-2) on modifications MAZ 43704 and MAZ 437043, respectively;
3. ZF S5-42 (Spain) - gearboxes were installed on modifications of the MAZ 437030, equipped with Deuts.

All available transmissions are five-speed manual. By design they are dry, single-disc friction. The clutch disc size can be 340 or 360 mm in diameter. A bevel gearbox and a cross-axle differential with locking are installed on the driving rear axle.

In addition to native gearboxes, which are not particularly reliable, Chinese-assembled gearboxes are offered for the MAZ 4370, for example 6J60T and 6J70T. They are designed by the American company Eaton and manufactured in China under contract. Unlike native gearboxes, Chinese ones have six speeds.

Clutch release drive

MAZ 4370 gear shift diagram

The gearbox is controlled using a lever according to the following scheme:

Gear shift diagram for MAZ-4370

MAZ 4370 gearbox control drive (diagram)

Not available:

Electrical diagram MAZ 4370 Zubrenok

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

Layout of electronic control systems on the 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

Brake system MAZ 4370

In the MAZ 4370, the braking system is implemented independently for the front and rear axles. It is pneumatic and consists of the following components:

• compressor;
• receivers (compressed air cylinders);
• pneumatic drives;
• control devices;
• braking mechanisms.

On regular cog trucks the compressor is single cylinder. Modifications of the MAZ 4370 for road trains were equipped with a two-cylinder compressor.

Brake drum from MAZ-4370

The direct element of the braking system are drum brakes. The drum is cast from cast iron, its diameter is 420 mm, and its thickness is 160 mm.

MAZ 4370 pads are made of steel. Overlays are installed on top of them. To adjust the distance between the drum and the pads, there is a corresponding lever.

Brake system MAZ-4370 (drum with pads)

On the one hand, the configuration of the MAZ 4370 Zubrenok brake system is flexible, on the other hand, it requires precise adjustment for each axle and individual wheel. Otherwise, skidding may occur or the braking distance may increase.

Diagram of the brake system of the front wheels of Zubrenok

Diagram of the brake system of the rear wheels of Zubrenok

Device

MAZ 4370 received a front dependent leaf spring suspension with hydraulic shock absorbers (telescopic type) with a stabilizer. An I-beam was used as the front axle. The rear suspension was built on longitudinal semi-elliptic springs. This design has proven itself well and is characterized by increased stability. The MAZ 4370 had a front-wheel drive, rear-engine layout with a 4 by 2 wheel arrangement. For the first models, foreign chassis produced at the MAN plant were used. Later, the Minsk Automobile Plant began producing its own chassis. The MAZ 4370 was equipped with a low-frame body, which was its main advantage. This arrangement made it possible to transport large cargo at great heights without obtaining additional permits. The car's suspension turned out to be slightly harsh due to the use of standard springs, which are stacked sheets of metal. Its main advantage was the simplicity of the device. The service life of the springs reached 100-200 thousand km. At the same time, the rigidity decreased noticeably with a decrease in tire pressure or after loading the vehicle.

Chassis and suspension

The chassis and suspension of the MAZ 4370 deserve praise. It is largely due to the excellent quality of Zubrenok’s design and suspension assembly that it has become so widely used. With careful operation without major repairs, the chassis will last 250 thousand km, but even then, after replacing worn out elements, it will work for hundreds of thousands of kilometers without any problems.

The front spring of the MAZ 4370 consists of several sheets. The front suspension is equipped with hydraulic shock absorbers with stabilizers. The rear spring is semi-elliptical.

In general, this design gives a rough ride, but is easy and simple to repair and does not require special maintenance.

Wheel sizes range from 17 to 20”. The suitable tire size is 235/75R17.5.

History of creation

The Minsk Automobile Plant developed the concept of the future MAZ 4370 in cooperation with the Gorky Automobile Plant. The first conceptual low-frame, medium-tonnage trucks were designed by enterprise engineers in the 90s. But after the collapse of the USSR, MAZ decided to refuse cooperation with the Russian automobile plant, since for a number of reasons it became difficult to interact with representatives of another state. In this regard, Minsk decided to stop supplies for other trucks, in particular for MAZ 5336, cabs produced by GAZ.

Without abandoning the idea of ​​​​creating a medium-tonnage truck, Mazov engineers decided to take the MAN L 2000, assembled in Germany, as a prototype. Having adjusted a number of functions and increased the carrying capacity, the Minsk Automobile Plant created the MAZ 4370 Zubrenok exactly in the form in which it rolled off the assembly line in 1999.

Switching device and circuit

The design and diagram of the MAZ gear shift depends on the gearbox model. There are 5-speed, 8-speed and 9-speed gearboxes.

5 speed

The design of a five-speed gearbox in a MAZ includes such elements as:

• primary, secondary and intermediate shaft;
• rotating bearing;
• gears;
• crankcase, switch and rear cover;
• fasteners;
• container for oil liquid.

The mechanism that changes gears is located inside the vehicle. When the lever of the switching device changes its position, the articulated joint engages with the recess, which is located on one of the axes. At this moment, the end of the hinge is in rigid engagement with the fork device. The forks fit into the hole on the forward drive gear (gears No. 1, 2, 3, 4) or in the fifth gear position (reverse). A short circuit begins in the torque circuit, causing the secondary axis to begin its movement.

8 speed

The eight-speed gearbox (Gearbox-202) includes:

• crankcase;
• movable gears;
• intermediate shaft;
• constant mesh gears;
• drive shaft;
• splines;
• gear type rim;
• cover;
• driven shaft;
• reverse gear block;
• axial reverse mechanism.

After the vehicle moves and picks up the required speed, you can change gears in the following order: 4H-4B-5H. In order to activate the second speed, you need to wait until the crankshaft speed increases to 2000 rpm. This indicator can be monitored using a tachometer.

It is not recommended to start shifting gears at a lower number of crankshaft revolutions, otherwise the mechanism will fail.

In order to engage reverse, set the switch lever to the down position.

9 speed

The design of the 9-speed gearbox 238 with a range-shifter includes the following parts and mechanisms:

• coupling housing;
• pad;
• gear shift fork;
• right shaft;
• reverse gear washer;
• lazy reverse gear;
• intermediate type roller shaft bearing;
• mounting bolts and nuts;
• spring washer;
• sealing ring;
• retaining ring;
• needle bearing;
• clutch fork bushing.

Before driving, you must disengage the clutch. Before moving off, you need to check the location of the lever; it must be lowered. Switching speed modes is carried out in several stages. At the first stage, it is recommended to use the following switching pattern: 1B-2B-3B. During further movement, you can switch to the pattern: 4H-5B-5H.

Description

Transmission (spare parts) high-speed SAAZ "Polimix" 3206 (4370-1700004-70) for MAZ 4370 Cog, input shaft diameter 38 mm/24 teeth. Installed on ZIL, MAZ 437041, 437141, 437143 cars

High-speed gearbox of the Smolensk Auto Aggregate Plant model SAAZ-3206 for the MAZ-4370 car Cog, input shaft 38 mm, 24 teeth,

gear ratios: 1 - 5.63

Gearbox MAZ-4370 “Zubrenok” high-speed 24 teeth (3206-1700004-60)

Gearbox MAZ-4370 “Zubrenok” high-speed 24 teeth (3206)

Ordering information

* Time specified for the region: Belarus, Minsk