Triple competition tacticsNew KAMAZ trucks are again winning consumer trust

Daniil Minaev, photo by the author

Going to Naberezhnye Chelny, to the KAMAZ plant, to get acquainted with the new model range, production and a detailed study of the new products of 2015, I was skeptical right up to the factory gates. But on the spot, this attitude gave way to genuine interest, and in the end I realized that I didn’t know much about the new family of Kama trucks and their development trends. Now I know, because I saw it with my own eyes right in Naberezhnye Chelny.

The first-born among the long-awaited, and therefore sensational, new products - the KAMAZ-5490 truck tractor, was received with that note of wariness characteristic of everything new Russian, even with the lion's share of imported components, but still, when the issues of the overall quality of the product come first. In just over a year, the new KAMAZ trucks had managed to gain the hard-won trust of consumers, and by this time the new family, in addition to the truck tractor, had acquired an onboard vehicle, a van, a dump truck chassis, and soon heavy 3- and 4-axle dump trucks would be added (in the fall of 2016- th - start of mass production).

Our information

Serial production of KAMAZ-6580 family vehicles with Daimler components will begin in 2016. For now, pre-production samples are equipped with our own, licensed and imported engines. For example, the all-wheel drive three-axle dump truck KAMAZ-65802 with a load capacity of 20 tons was demonstrated at exhibitions and various shows with a 400-horsepower KAMAZ-740.735-400 engine (Euro 5). However, in Naberezhnye Chelny they would like to have in their arsenal more powerful motors, specially adapted for working in difficult conditions. For example, modern Cummins G-series engines, as on the pre-production trucks demonstrated to journalists.

Cabin

There is a minimum of comfort inside, which is why reviews often contain complaints about back pain. There are three simple chairs, they are flat, without any comfort, there are not even headrests. There is not enough legroom.

Most modifications have one berth. From the photo you can see that even the windows can be opened with classic oars.

The hands of the driver of the KamAZ-45143 dump truck lie on a classic 2-spoke thin steering wheel, behind which there are old analog indicators, above which there are lights indicating malfunctions. On the right side of the creaky dashboard panel there are many buttons of a shape familiar to owners of old Nivas and Sevens.

There is no talk about sound insulation. Yes, operator comfort increases his productivity, but such low cost allowed the vehicle to be priced low.

Dual labeling with double standards

Elvard Faritovich Shaykhullin, the leading design engineer of the “Advanced KAMAZ Vehicles” project, from whose lips a dense flow of information flowed regarding the design of the new family of trucks, said that he himself doubted which classification would be better to apply for the promising model range: similar to the old Soviet GOST or proposed by the main partner - the Daimler AG concern represented by the Mercedes-Benz brand. On the nameplate there is an index 658015 or 658025 (this is a type according to OTTS), and the nameplates on the cabin doors - K5044 or K4141 - are already a commercial name.

Like the cars of the German concern, in the commercial name the first two digits indicate the total weight of the car, and the next pair indicate the rounded engine power in the usual conservative horsepower. The letters in front of the marking numbers in the new family determine the purpose of the trucks: M – long-distance vehicle group, K – heavy or all-wheel drive group.

The three-axle model, according to factory data, bore the index 658025, and the dump truck with an 8x4 wheel arrangement was called 658015. And as the leading designer correctly noted, it would be fair for a vehicle with a gross weight of 50 tons, based on old standards, to carry the index 758015. But this is only the very beginning of the confusing path of constructing a new family.

The main intrigue is that the presence of a new cabin based on the Axor and even similar markings does not mean the same type of chassis and power line. That is, if you meet on your way one day several KAMAZ trucks with a licensed Mercedes-Benz Axor cab, this does not mean at all that they will have the same engines, gearboxes and axles.

Transmission KamAZ-43255

The KamAZ-43255 truck can be equipped with several options for mechanical transmissions.

Currently it is a ZF 6S700 six-speed manual gearbox. This model has the following gear ratios: 1-6,О2/ 2-З,З2/ З- 2,О7/ 4- 1,4/ 5- 1,О/ 6-О,79/ 3Х - 5, 58. The main gear ratio is 6.5Z.

Also, on cars of this model, gearboxes of the ZF 6S1000 type were previously used. This (just like the currently used model) is a six-speed gearbox. All forward gears in the main gearbox are connected by synchronizers, and the reverse gear is connected by a gear clutch. The highest gear is an overdrive. The gear ratios of this manual transmission range from 6.75 to 0.78.

Both of these modern mechanical transmissions create decent acceleration dynamics, which is very important when operating a truck in specific urban conditions.

Cars of the first years of production were also equipped with a domestic five-speed manual gearbox, the KamAZ-141 model - with a three-way switching device and synchronizers in second, third, fourth and fifth gears.

The clutch on KamAZ-43255 vehicles is single-disk, diaphragm, pull-type, with a hydraulic drive and a WABCO pneumatic hydraulic booster (PGU). The diameter of the driven disk is 362 mm. The name of the clutch models used in KamAZ-43255 is MFZ 350 and MFZ 430, from the German company SACHS.

Far-reaching tactics and strategy

One of the current priorities of the automobile plant in Chelny is to ensure a stable future for itself. Such disparate wishes of consumers from different regions, global trends and the backlog of their cluster of joint ventures have led to the fact that marketers and designers see the development of a new model range in three main directions.

The first concerns primarily long-haul vehicles and involves a high degree of use of Daimler AG components and further localization of their components at its own facilities in Naberezhnye Chelny.

The second direction is the maximum use of the traditional chassis and component base of classic KAMAZ vehicles, but with a new cabin and smooth modernization in order to meet all modern standards.

And the third most interesting thing is the construction of new chassis using both our own, localized and purchased components to create models that were not previously in the production program of the Kama auto giant. A striking example of such a design is precisely the family of heavy dump trucks with 6x6, 6x4 and 8x4 wheel arrangements with a total weight of 41–50 tons!

Suspension and chassis

Dump trucks and universal chassis KamAZ-43255 are based on a classic cargo platform with a 4x2 wheel arrangement and spring suspension on the front and rear axles. The robust design allows this vehicle to easily cope with heavy weight loads. The car drives quite softly when fully loaded and hard when loaded. A design feature of this model is the low center of gravity of the transported cargo. In combination with anti-roll bars and an anti-lock braking system, this ensures increased vehicle stability in all conditions.

The front suspension is made on 2 longitudinal semi-elliptical single-lug springs, hydraulic telescopic shock absorbers, with rubber travel limiting buffers, with sliding rear ends of the springs. It is equipped with a stabilizer bar, which increases the angular rigidity of the suspension, reducing the roll angle of the sprung part of the vehicle under the action of lateral (lateral) force, and increases the stability of this truck.

The rear suspension is also made on 2 longitudinal semi-elliptical single-ear springs and hydraulic telescopic shock absorbers. The ends of the springs are sliding. And also equipped with a stabilizer bar.

The wheel rim size on KamAZ-43255 can be of three types: 7.5-20, or 7.5-22.5, or 8.25-22.5. The wheels are mounted on a disc type, with pneumatic tube tires of size 10.00 R20, or 11.00 R22.5.

Equation without unknowns 658015 = K5044

The first well-known problem when building a Russian heavy dump truck is axles and drive axles. Domestic manufacturers do not have bridges with a load capacity of 16 tons, so it was decided to purchase HanDE Axle brand units from China (where would we be without this great state...). Already anticipating a wave of skepticism among the reader, “well, here it is Chinese again...”, I hasten to dispel prejudices. These axles are manufactured in China under license from MAN and were once installed on tractors of the F2000 family, and now they can be seen on Shacman, Dongfeng, and Tonars - there are no complaints about them.

Now is the time to think about the power unit. Today KAMAZ has more than ever before at its disposal. In accordance with the stated “three directions” concept, these can be either Daimler units or their own V-twin engines of the modernized 740 family. There is also a joint venture where the 7-liter Cummins ISB6.7E4300 is assembled under license. In the future, cooperation is underway with engine manufacturers Liebherr, but this path does not promise quick benefits. But for five tens of tons of total mass, something else is still needed. And then the fruit of joint… even trilateral cooperation comes to the rescue again!

The driver's equipment is successfully grouped in one place on the starboard side

Tipper loading platform

The KamAZ-43255 chassis is equipped with NefAZ (Neftekamsk Automobile Plant) dump truck platforms and a hydraulic lifting system. The body is all-metal, welded, box-shaped. It has a one-way type of unloading (rear) and an oval section of the bottom of the body. For additional cargo protection, this tipper body can be equipped with a canopy. A special protective canopy closes the gap between the cabin and the platform. The vehicle is equipped with a hydraulic mechanism for raising and lowering the platform with electro-pneumatic control from the driver's cabin.

• The volume of the dump truck body is 6 cubic meters.
• The platform's elevation angle is 55 degrees.
• The time for lifting the body with a load is 30 seconds.

The subframe is a welded structure consisting of two side members, cross members and a subframe reinforcement.

The mechanism for raising and lowering the loading platform contains:

• power take-off box with oil pump for power take-off from the gearbox;
• oil pump - gear or axial piston type, high pressure;
• hydraulic cylinder – telescopic type, single-acting;
• a control unit that supplies the flow of working fluid in the hydraulic system of the tipping mechanism and consists of a block of hydraulic valves and electric pneumatic valves;
• body lift limit valve, which limits its lift when the maximum specified angle is reached;
• The oil tank is stamped and welded, equipped with filters on the filler neck and drain line, and a magnetic plug.

An Immaculate Union – Cummins and KAMA

The 50-tonne chassis requires a powerful and at the same time compact enough engine to couple it with the new elegant and comfortable cab. Ultimately, the choice fell again on the Cummins brand. The ISG12 series, representing the new global Heavy-Duty platform, was developed in the USA and first presented in September 2013, consists of in-line 6-cylinder engines with a displacement of 10.5 and 11.8 liters, which are distinguished by their compact size and low weight. Their production began last year in China at the Beijing Foton Cummins Engine Co. plant. The Cummins ISG12 has a power range of 350-500 hp. and, depending on the settings, corresponds to the environmental class Euro 4 or Euro 5. In Naberezhnye Chelny they considered that such a motor would be very suitable for the new KAMAZ trucks. And at the Comtrans-2015 exhibition, negotiations were held with the participation of top officials of two companies - General Director of KAMAZ PJSC Sergei Kogogin and President of Cummins Inc. Tom Linebarger. At the same time, the possibility of producing these engines at the Cummins KAMA joint venture was discussed.

The only drawback of the engine, which became the price to pay for its weight and compactness, is the one-piece linerless cylinder block. There is also no provision for boring cylinders to repair sizes. In the future, this may cause an increase in the cost of repairs, but, frankly, in most cases the very need for early repair of the CPG (cylinder-piston group) is due to the human factor.

Technical characteristics of KamAZ-45143

Dimensions:

• length – 765 cm;
• width – 250 cm;
• height – 307 cm;
• wheelbase – 319 cm;
• ground clearance - 28 cm.

Loading platform dimensions:

• length – 526 cm;
• width – 232 cm;
• height – 63 cm;
• area – 12.2 square meters.

Load capacity:

• curb weight – 9,200 kg;
• trailer curb weight – 5,000 kg;
• load capacity – from 10 to 12 tons;
• total vehicle weight – from 19.3 tons to 21.3 tons;
• maximum trailer weight is 14 tons.

The front axle of the dump truck carries 4 tons, and the rear wheels receive 5.2 tons.

Other characteristics:

• turning radius – 9.8 meters;
• maximum tilt angle – 25 degrees;
• platform elevation angle – 50 degrees;
• platform raising time – 20 seconds.

Heavy-duty transmission and Chusovsky springs

In Naberezhnye Chelny, the ZF-KAMA plant produces two models of gearboxes. These are 9-speed Ecomid and 16-speed Ecosplit. But, alas and ah, none of them are suitable for a heavy dump truck, because they have a maximum torque limitation of no more than 1800 N∙m. Therefore, another ZF gearbox model 16S 2225 TO, originally from Germany, works in the new heavy chassis. It is already capable of operating with a torque of up to 2300 N∙m. An important innovation in the transmission: the spring earrings of the Chusovsky plant are now on silent blocks. Regular lubrication points still remain in the chassis, but there are noticeably fewer of them.

Chassis of all-wheel drive KAMAZ K4141 6x6

Chassis of 4-axle KAMAZ K5044 (8x4)

Engine characteristics

The engine line generally consists of two versions of motors with different degrees of boost. Different modifications were equipped with different engines, as you will learn below. These are familiar to every owner of any Kamsky brainchild and the Cummins ISB6.7, which has a positive effect on maintainability, so the demand for a new successor is still not falling.

1. The first branded V8 dump truck engine with a 10.85-liter volume produces 240 horsepower and 932 H*m of torque. All horsepower is delivered at 2200 rpm, but all the torque is available almost from idle – 1100 rpm. The motor uses its own Common Rail system, which complies with Euro-3 environmental standards.
2. There was a version KamAZ-740.622-280. This is an 11.76-liter V8 with two TKP 7C-6 turbines, a BOSCH distributor, producing 280 horsepower and 1177 H*m of torque. The KamAZ-45143 engine is only 15 kg heavier, so it pushes the car more confidently.
3. A less common Cummins engine produces 300 horsepower at 2500 rpm and 1100 H*m of torque to the wheels at 1700 rpm. This is an in-line turbocharged engine with 6 cylinders in a row, with a total volume of 6.7 liters. In terms of performance, this is a cool offer, but the cost of spare parts is higher than the previous ones.

Domestic engines are mated to the 152nd and 154th KamAZ 9-speed manual transmission with dry two clutch discs. The American diesel engine is mated to the mechanical German ZF-9S, which since 2005 has been assembled in Russia using imported parts, and since 2010 the parts have been assembled here.

Feel like a factory tester

The “rope” ladder of the lower step, the click of the door lock, and here I am behind the wheel. What can I expect from this truck? A continuation of the noisy and ascetic KAMAZ - a peer, born, like me, from 1976? Or, probably, it will be a simplified Mercedes, but maybe another Russian-Chinese symbiosis with a share of German parts? Nothing like this! Fortunately, I was wrong. This is, indeed, a completely modern car.

If we imagine such a situation that an experienced driver, who has long been familiar with KAMAZ trucks of past generations, suddenly receives a brand new 658025, or, as they now say, K5044 D, at work, then he will not only be pleasantly surprised, but will also not be able to find any negative continuity in relation to past models. I turn on the ignition and the instrument cluster comes to life. The branded KAMAZ argamak appears on the LCD display of the on-board computer, the scales do a self-diagnosis victory lap, and at the same time the engine comes to life, but there are no vibrations or the acrid smell of exhaust leaking into the cabin, and it is damp and cold outside.

The factory test driver carefully warmed up the engine, and now I am happily warming up from the winter that has suddenly caught up with me, directing warm air from the deflector on the front panel into my face. Then, turning the knob, I transfer the heat to my legs and to the windshield, I feel for the left field of the gear lever, since the dump truck is unloaded, I select third, and, squeezing the weightless clutch, I smoothly roll out onto the track.

It was cold at night, but during the day it warmed up and wet snow began to fall, turning the roads of the factory test track into ruts with snow and water slurry. In a word, slippery! Having gotten used to it, I try to change gears, brake harder and even provoke a skid.

This is now the neat execution of the detailing on the frame: nothing in common with the “forefathers”

The engine responded to my attempts at deliberate mistakes in selecting gears with silent traction at the bottom and decent elasticity; an attempt to brake sharply on ice failed due to the soft setting of the brake valve - I had to press the pedal much harder, I go to the second circle, brake and try to turn. It turns out that everything is possible, the four-axle dump truck is calm and stable.

I don’t think I’ll praise the car too much, but I also liked the setup of the chassis: even in an empty dump truck with spring suspensions there is almost no shaking on bumps and potholes, the ride is extremely smooth! Even with a fairly simple design of the cabin suspension - on spring struts.

And now it’s your turn to drive a car with a 6x4 wheel arrangement. Already familiar with the cabin (including the Axor), I again settle down comfortably, yawning furtively as I look at the blank, windowless back wall, where there could be a cozy sleeping bag (it was an early, almost overnight flight to this city).

Let's go, and here comes an annoying flaw, typical of any pre-production model - the steering wheel spoke completely refuses to move to the center during straight-line movement, and the near-zero zone is blurred. At first I thought that the steering wheel was not installed correctly on the steering shaft splines, but then I noticed some yaw in the truck, which indicates the need to adjust the toe of the front axle wheels. The engine here is slightly less powerful – 410 “horses”, but there is no fundamental difference with an 8x4 dump truck, and I can’t claim to speak about the nuances of handling; first you need to adjust the angles of the front wheels. Naturally, on a shorter 3-axle car, the turning radius will be somewhat smaller, and the car begins to screw into the trajectory earlier and more sharply, that’s probably all.

Chassis and braking system

The car is built on a riveted frame with side members and cross beams. Wheel formula 6×4. The same frame is used on KamAZ-53215 and KamAZ-65115. The front axle rests on longitudinal springs, and the rear axle uses a spring-balancer design.

The dump truck is stopped by 400 mm drum blocks with 140 mm pads. This is a pneumatic braking system supplemented by ABS. The handbrake engages the rear wheels through a cable and a mechanical screw drive.

The car can overcome off-road conditions, but it is definitely not designed for it. The car moves freely across the field.

NEFAZ dump bodies

All tested vehicles were equipped with dump bodies produced by NefAZ. On the K 5044 D (8x4) there is a barrel-shaped body with a developed lining without heating, a volume of 25 m3 with a mechanical tailgate drive and a manual awning; on three-axle vehicles K 4141 D (6x4 and 6x6) similar bodies, but with a volume of 20 and 15 m3. The basic body kit includes a spare wheel holder (spare wheel holder) and a ladder.

Versions of KamAZ-43255

Currently, KamAZ-43255 vehicles are actively used in both the construction and housing and communal services sectors of Russian cities. They successfully fulfill their main purpose - transporting bulk and bulk cargo on roads designed to withstand axial loads of up to ten tons.

In addition, KamAZ-43255 is also available in a universal chassis designed for the installation of municipal equipment (container trucks, garbage collection trucks), etc. various special add-ons for thematic purposes. On special configurations of the KamAZ-43255 truck, at the request of customers, the direction of the exhaust can be changed; fuel tanks of a different capacity were installed; Diesel fuel heating systems have been installed.

Option "bunker carrier"

A special safety bar is provided for installation on the rear of the truck frame, but this is not a mandatory option: at the request of customers, it may not be installed.

The hard way through all times

What I saw in Chelny at the beginning of winter 2015 (and I saw a lot of things, including what I was forbidden to show, politely but persistently demanding that two dozen frames be removed from my camera - a trade secret, what can you do!) , indicates that KAMAZ is alive and will continue to live and is seriously thinking about the future. Let it be with an eye to the past, and let it not all work out right away. And the parachute brake of the trailer is sometimes pulled back by a suddenly impoverished consumer, ordering a large percentage of old models, which are still forced to remain on the assembly line. Strategic partners are also different, there are several of them: what doesn’t work with one, will work with another. The difficult years of change have left their indelible mark, so the famous horse has to run from the plant’s emblem at both a trot and a gallop. And new models from year to year are proof of this.

Modifications

The farmer was produced in different versions, which depended on the engine, load capacity, platform volume, wheels, cabin, etc. Now there will be a lot of numbers, try not to get confused:

1. 45143-012-15 – 240-horsepower engine, 15.4-cubic-meter platform, 152 gearbox, 210-liter tank, R20 tires, load capacity 10 tons.
2. 45143-013-62 – 280-horsepower engine, 15.2-cubic-meter platform, ZF-9S gearbox, 210-liter tank, R22 tires, load capacity 11.5 tons.
3. 45143-776012-42 – features 154 gearboxes and two fuel tanks with a total volume of 500 liters.
4. 45143-6012-19 – 300-horsepower engine, 15.2-cubic-meter platform, ZF-9S gearbox, two 500-liter tanks, 22 tires, load capacity 12 tons.
5. 45143-6012-23 – differs from the previous one in the presence of an exhaust gas neutralization system.

By the way, the company produced a version for the Paris-Dakar competition, which increased export sales. In general, the brand still exists successfully due to good sales abroad.

All versions accelerate the dump truck to a maximum of 80 km/h, and the average fuel consumption is 27 liters of diesel fuel.

Driver reviews about KamAZ-43255

Drivers speak mostly positively about KamAZ-43255 trucks - as fast, compact, maneuverable vehicles. With a full load, however, the car no longer picks up speed so quickly and has difficulty climbing steep hills. It is not intended for serious off-road travel: it can get stuck. But for transporting goods around the city, its power and capabilities are quite enough.

The cabin, although not spacious, is cozy, and the ceiling is high. The driver's seat is comfortable, with air cushion. There is practically no shaking when driving. The steering column is easy to customize. The steering wheel turns easily thanks to the hydraulic booster.

The car's spring suspension is rigid: when the body is empty, it shakes quite violently.