KamAZ is a well-known representative of freight transport, today produced in the Russian Federation. The reliability and endurance of these machines has been tested over the years. KamAZ vehicles are designed to operate in different climatic zones and are ready for heavy operating loads.
As for the combination of internal combustion engine and transmission, in order for the economical, but not the most powerful KamAZ engine to provide proper performance and have a long service life, a highly reliable KamAZ gearbox was separately developed and implemented.
Next, we will look at the features that the KamAZ gearbox has, how to change gears on a KamAZ, what the KamAZ gear shift scheme is, etc.
Box modifications
The type of box installed depends on the loads the vehicle experiences and the conditions in which it is operated:
- KPP-14;
- KPP-15;
- KPP-16;
- KamAZ ZF gearbox.
The fourteenth transmission is a five-speed device, which includes a gearbox. The fifteenth modification of the product with ten stages, unlike KamAZ-14, is equipped with a divider with two stages, the device is located in the front part of the box.
Gearbox KamAZ-14:
Transmissions are controlled mechanically, remotely, using a swing lever located on the power plant. The mechanical gearbox is controlled by pneumatics and mechanics, through a selector. The driver directly acts on the rocker.
The sixteenth gearbox, with eight shift stages, is of mechanical type. The design includes a four-stage gearbox and a reduction box mounted behind the structure.
The base of the rod that switches the stages is installed on the gearbox plug; the lever itself is made in an original design solution. The product contains a rod that controls the gearbox, a lever, a safety net that prevents erroneous start of reverse, and valves controlled by pneumatics and switching a mechanism that increases torque.
Gearbox KamAZ - 15:
The ZF gearbox on KamAZ with nine stages is equipped with an auxiliary reduction gear, unlike the 16 model.
The KamAZ 5320 gearbox is equipped with five stages. Since the equipment is operated in harsh conditions, it is equipped with large gear ratios for operation at low speeds. Switching occurs in stages, the transmission easily adapts to road conditions.
KamAZ ZF gearbox:
Gear controls on modern cars are different. A mechanism with fewer gears is used on vehicles with a smaller load capacity and dimensions. Modifications of 10 stages are installed on road trains. KamAZ is in demand in 40 countries because the control mechanisms are reliable and durable.
Is it possible to drive a KamAZ without urea?
Trucks that comply with Euro 4-6 standards use a method to neutralize the impact of exhaust gases on nature. To do this, urea is poured into a special tank, which is subsequently injected into the exhaust system.
In our country, the use of such material borders on difficulties:
- Low quality urea;
- Freezing of the product at a temperature of -11°C;
- Smell of ammonia from the exhaust, burns upon contact with skin;
- Lots of fakes, price.
KamAZ, fluid for the SCR system (urea):
It is not advisable to constantly operate a car without urea, as this will lead to failure of the pump pumping the material. You can disable the neutralization system at the software level, or by contacting an electrician, who will make hydrolysis in the catalyst impossible.
Description of gearboxes
Structurally, the ten-speed transmission is a box with five steps and a gearbox. This design uses 10 forward gears and 2 reverse gears. The transmission is popular and is used for installation on vehicles carrying heavy loads. The mechanism received index 15.
Distinctive features of the KamAZ-15 box:
- Used in conjunction with a reinforced divider synchronizer;
- The splines have been modernized and strengthened, the fastening parts have been removed from the box;
- The fixation of transmission gears has been modernized;
- The height of the teeth has been increased.
Downshift (divider) valve for KamAZ-15:
The pneumatic system activates and controls the KamAZ transmission dividing device. The performance and durability of the unit directly depends on the correct use of this unit. For the same reason, inspection of the KamAZ transmission is carried out at specialized stations.
KamAZ transmission elements:
- Box body with built-in shafts: driving, driven, intermediate;
- Gear mechanism for activating reverse;
- Upper casing;
- Collapsible mechanism that switches stages;
- The power unit is located in the front of the body.
Specifications
The KamAZ gearbox with a divider includes the following elements:
- a crankcase in which the drive, driven and intermediate shafts assembled with gears are mounted;
- bearings;
- synchronizers,
- reverse gear block,
- top cover of the box,
- gear shift mechanism.
The gearbox of KamAZ vehicles can be five- or ten-speed. The gearbox divider has high and low gears and, in combination with the main gearbox, allows for 10 forward gears and 2 reverse gears. The divider system improves the traction qualities of the machine, makes it easier to control, and reduces the frequency of shifting gears with a lever. Transmission ratios are available in the operating instructions for the device.
The 141 KamAZ gearbox has a reversing light switch. To prevent the simultaneous activation of 2 gears, there is a ball-type lock in the cover, and a spring-finger fuse is used to prevent accidental engagement of reverse gear. The gearbox with divider weighs 320 kg. The cuffs are located in the shaft covers. They protect the gearbox from clogging and prevent oil leakage. Insufficient oil volume in the gearbox leads to its damage. When you first fill the gearbox there should be 9 liters of oil, when changing the fluid - 8 liters.
Technical characteristics of the KamAZ-141 gearbox: Carter:
- The diameter of the bearing bore is 150 mm.
- The diameter of the hole in the gear block axis is 32 mm.
Main shaft:
- The diameter of the front bearing journal is 24 mm.
- Rear bearing - 59 mm.
The secondary shaft has the following diameters for the parts:
- Fourth gear gear bushings - 63 mm.
- Roller bearings - 80 mm.
- Reverse gear bushings - 70 mm.
- The outer diameter of the sleeve is 72 mm.
Intermediate shaft:
- The diameter of the front bearing journal is 65 mm, the rear one is 49 mm.
- The diameter of the rear bearing cup is 119 mm.
- The diameter of the intermediate shaft is 65 mm.
- The inner diameter of the gear is 65 mm.
The weight of the gearbox with divider is 320 kg.
Box divider
High and low operating modes, a feature of KamAZ gearboxes. This specificity is caused by the desire to reduce the load on the power plant. It is typical that it does not matter whether the machine is loaded or not. A divider is a gearbox based on the principle of mechanics and increases gear ratios. The mechanism is started using a switch on the rocker.
The design includes:
KamAZ-15 box divider input shaft:
- The valve that controls the device. The part is attached to the base of the switch, uses direct and reduced speed modes.
- A valve that maintains a constant outlet pressure. It takes compressed air and resets the pressure in the system when the established values are exceeded. Transfers air to the control valve and to the valve of the dividing device from the air unit. Thanks to manipulations, there are simultaneously two circuits in the engine control system.
- Divider activation valve. Supplies air pressure to the device when the clutch is disconnected. This engages and disengages low gear, paralleling the transmission's gear changes.
- Dividing mechanism. The composition includes a piston placed inside a cylinder. The piston lever is connected to a rod fixed to the fork shaft of the assembly. When air pressure hits, the piston moves, this changes the operating mode of the box.
- The air distribution pipe supplies air pressure to the cylinder of the unit.
Rules for shifting gearboxes in different conditions
Knowing how to start and how to continue moving is not enough for the correct operation of the KAMAZ transmission. To avoid problems with the unit when using the gearbox, you must follow the rules. Errors made during operation can lead to serious malfunctions.
On the rise
How to change gears on a KamAZ when driving uphill
Driving a domestic truck when lifting must be done at increased speed. To switch from first to second speed, the driver needs to depress the clutch twice. Consider the fact that you must simultaneously press the gas pedal and the fuel pedal. These actions are important as they help stabilize the overall performance of the crankshaft. To avoid problems with the operation of the unit, you do not need to reduce the engine speed to less than two thousand when climbing. This will cause the car engine to turn off. Also, such driving increases the operating temperature of the power unit, and this can cause its breakdown.
When driving a car using this principle, you can achieve maximum directional stability. Thanks to the principle of dividing the transmission circuit into two modes, easier engine operation is achieved. Moreover, regardless of whether the car is loaded or not.
On the descent
If you are driving downhill, you do not need to turn off the engine. When the engine is turned off, the steering wheel will lock. And this will lead to an emergency on the road. When driving downhill, do not turn off the auxiliary braking, and also depress the clutch pedal all the way. Newer versions of trucks use improved transmissions, which has allowed engineers to reduce the load on the main gearbox parts. Therefore, when driving in critical conditions and on descents, the car’s engine will not wear out.
KamAZ vehicles use a double-boost braking system. That is, in addition to braking by the power unit, there is an additional engine stopping system. If you are driving downhill with active auxiliary braking, then you cannot disengage the clutch and change gears.
Schemes of the main and transfer cases on KamAZ
Icy areas
Driving a truck on icy areas should be done with the greatest reserve of speed and travel. When braking, use the active brake assist system. If emergency braking occurs, the driver must stop the trailer wheels. If you do not take this point into account, you will end up in a skid. It is recommended to slow down with the power unit only in exceptional cases. Because this leads to accelerated engine wear, but the braking distance is significantly reduced. When braking, do not allow the wheels to slip. To avoid this, you need to turn off the reduced speed in time, this will lead to a drop in crankshaft speed.
Skid
When skidding, follow the main rule - do not squeeze the clutch, otherwise this will worsen the situation. During the production of cars, engineers introduced a scheme due to which the car can drive with the greatest power reserve. Thanks to this, you can achieve course stabilization while driving on any road. If a skid occurs while driving, the steering wheel of the car must be turned in its direction. That is, if the car skids to the left, then the steering wheel also turns to the left.
If the truck begins to slip, then you need to stop moving as quickly as possible and immediately disable the differential axle. You can see the switch to turn it off on the dashboard. When the differential axle is disengaged, a corresponding indicator will appear on the instrument panel. After this, the start of movement is carried out at increased speed, from second gear. When you drive through a hard-to-reach section of the road, do not forget to engage the differential (video shot and published by Vladimir Nikonov).
Technical parameters of KamAZ gearboxes
The transmission of KamAZ vehicles is equipped with gearboxes that differ in gear ratios. For this reason, cars are used in many areas. The gear ratios are shown in the table below.
| Box modification | Gear/gear ratios | ||||||||||
| 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | Reverse | ||
| 141 | 5,62 | 2,89 | 1,64 | 1,00 | 0,724 | – | – | – | – | 5,30 | |
| 142 | 6,38 | 3,29 | 2,04 | 1,25 | 0,815 | – | – | – | – | 6,02 | |
| 144 | 7,82 | 4,03 | 2,5 | 1,53 | 1,00 | – | – | – | – | 7,38 | |
| 152 | Increased | 7,82 | 4,03 | 2,5 | 1,53 | 1,00 | – | – | – | – | 7,38 |
| Reduced | 6,38 | 3,29 | 2,04 | 1,25 | 0,815 | – | – | – | – | 6,02 | |
| 154 | Increased | 7,82 | 4,03 | 2,5 | 1,53 | 1,00 | – | – | – | – | 7,38 |
| Reduced | 6,38 | 3,29 | 2,04 | 1,25 | 0,815 | – | – | – | – | 6,02 | |
| 161 | 8,39 | 5,50 | 3,93 | 2,87 | 2,12 | 1,40 | 1,00 | 0,73 | – | 11,01 | |
| ZF-9S109 | 10.24 | 6.576 | 4.78 | 3.531 | 2.61 | 1.86 | 1.35 | 1.0 | 0.74 | 9.44 | |
| ZF-6S1000 | 6.75 | 3.60 | 2.12 | 1.39 | 1.00 | 0.78 | – | – | – | 6.06 | |
| ZF-16S151 | Increased | 13.80 | 9.59 | 6.81 | 4.58 | 3.021 | 2.09 | 1.49 | 1.00 | – | 13.17 |
| Reduced | 11.55 | 8.02 | 5.70 | 3.84 | 2.52 | 1.75 | 1.24 | 0.84 | – | 11.03 | |
| ZF-9S1310 | 9.48 | 6.58 | 4.68 | 3.48 | 2.62 | 1.89 | 1.35 | 1.00 | 0.75 | 8.97 | |
In addition to gear ratios, the characteristics of the box modifications differ structurally. Thus, some models are equipped with parts and components that are not available in other modifications. ZF transmissions are assembled at the Russian plant, together with German partners, at the ZF-KAMA plant in Naberezhnye Chelny.
Start
The movement starts from the lowest level. The speed change is performed only with the clutch depressed, in several stages. The pattern is associated with upshifts and downshifts, which makes it possible to use the car on different surfaces and terrain.
A successful scheme is considered to be switching 1B-2B-3B when picking up speed, 4H-4B-5H when driving further. When starting, the shaft speed is increased to 7000 min-1, second gear is used after 3000 min-1. The correct operation of the gearbox and its durability depend on strict adherence to the regime on KamAZ 65115 and others. The correct modes reduce fuel consumption, make driving more economical, and extend the life of the power plant.
Gearbox KamAZ 4310 shift diagram:
Driving on an icy road
A special feature of driving on icy routes is the use of chains on the wheels of the car. The measures will increase the coefficient of road adhesion.
Take into account:
- Keep your distance, leave room for maneuver;
- When braking, use the brake assist system;
- Remember, emergency braking on a KamAZ truck leads to blocking of the trailer wheels.
It is not advisable to use emergency braking, as this will lead to skidding and uncontrolled movement. When skidding, keep your foot on the clutch pedal and turn the steering wheel in the direction of the skid, this will level the car.
Switching Features
If a KamAZ vehicle is driving down a mountain, use high gear. The transition from 1st to 2nd speed occurs by pressing the clutch foot lever twice. The maneuver is accompanied by the addition of gas in order to smooth out the crankshaft speed. If the car goes up, the shaft speed should be 2000 min-1 or higher. Failure to follow this advice will lead to overheating, as well as to stopping and failure of the motor.
The KamAZ transmission is distinguished by its quality, reliability and directional stability during operation. Dividing the box into two modes is used to make the engine easier to move under different vehicle loads. When starting on a loaded vehicle, an increased speed is used, bringing the shaft rotation to 2600 min-1.
Shifting gears on KamAZ (ZF):
Instructions
Now we suggest you find out how to start and in what sequence to correctly engage the gears on a KAMAZ gearbox. There are certain features in this process, and the procedure for changing gears differs from passenger cars.
Start of movement
You need to know how to change gears on a KamAZ. The KamAZ truck should start moving at a reduced speed. Please note that when driving away, the gear shift is carried out with the clutch disengaged. In KAMAZ gearboxes, the switching scheme is carried out in several stages, this is due to the peculiarities of increasing and decreasing speeds.
How to turn on the speeds on KamAZ:
- The truck can drive quickly on different types of roads, but at the first stage, in accordance with the diagram, it is recommended to start driving in gear 1B.
- After this, 2V transmission is switched on.
- At the final stage of starting from a standstill, speed 3B is switched on.
In accordance with this traffic pattern, the vehicle starts at a reduced speed. That is, the shift lever on the box does not need to be touched until fourth gear. To start moving, you need to increase the crankshaft speed to about seven thousand revolutions (the author of the video lesson on how to switch gears on a KamAZ truck is Nikita Vagin).
Switching speeds
Now we’ll tell you how the gearbox on a KamAZ is switched when the car starts moving. When the car accelerates, the gear shift order on KamAZ is as follows - 4N-4V-5N. To activate the second speed, the crankshaft speed must increase to three thousand revolutions according to the tachometer. Please note that the operation of the crankshaft plays a major role. By changing gears correctly, you can achieve savings in fuel consumption. In this case, the most economical operation of the motor without downtime will be achieved.
Reverse
As for reverse, according to the diagram, to activate it, you need to set the switch to the lower left position. Activating reverse gear is not allowed while driving. To engage reverse, stop the vehicle completely and then perform the maneuver.
Caring for the KamAZ gearbox
The device needs to be adjusted and configured, otherwise failures such as difficult shifting and knocking out gears cannot be avoided. Important manipulations include: adjusting the switching mechanism, adjusting the backlash of the rod, adjusting the gap in the divider activation valve, etc.
Checking the oil level in the KamAZ gearbox crankcase:
Changing the lubricant is considered part of the maintenance. The procedure is carried out once a year, mileage does not exceed 90,000 km. When operating the machine in difficult conditions, the lubricant is drained every 45,000 km. or 1000 hours of operation (depending on the established regulations and modification of the box).
Checking the fluid in the 14th and 15th series transmissions is carried out using marks on the neck cover. In the 16th series and ZF, a test hole is used for checking.
Frequent breakdowns include: difficult activation, wear of parts, malfunction of the reverse gear, spontaneous shutdown, etc. Problems are solved by adjusting the mechanism; in case of serious issues, contact a specialist.
Malfunctions and repairs
Transmission repair consists of disassembling the unit, diagnosing, repairing or replacing worn elements. After the mechanism is restored, the unit is reassembled and the system is tested in operation. You can contact a service center, but it is better to repair the transfer case yourself.
How to check the oil level
The oil level in the box is checked as follows. Unscrew the crankcase plug. When checking, you must install the crankcase indicator into the hole until it stops. The oil from the crankcase of a ten-speed manual transmission is drained through 3 holes. Of these, 2 holes are located in the lower part of the gearbox housing, and the third is located in the divider. The five-speed gearbox housing is drained through 2 holes.
Change of oil
To change the oil, you need to wash the gearbox housing with engine oil. Clean the magnetic plugs from metal particles and fill in oil to the top line of the indicator. The oil level is measured after 5 minutes. When the car is moving, the gearbox should operate without hesitation, speeds should be switched freely and locked firmly. Loud noise may indicate worn shaft bearings, insufficient oil level, or poor quality lubricant in the crankcase.
How to remove the box
Removing the gearbox is carried out as follows:
- You need to remove the driveshaft. To do this, unscrew the 4 fastening nuts.
- The PSU is being removed.
- Dismantle the starter mountings.
- Disconnect the tube that goes to the reduction gear.
- Remove the gear shift lever.
- Place a jack between the flywheel and the engine pan, and dismantle the engine through a wooden stand.
- Unscrew the rear yoke nuts and remove it.
- Dismantle the spacer rod.
- Unscrew the exhaust system bracket fastening bolts.
- Connect the hoist to the bolts and tighten it.
- Unscrew the fastening nuts to the side engine mounts.
- Unscrew the bolts that secure the gearbox to the internal combustion engine.
- Raise the hoist and move the gearbox away from the engine to the output of the transmission input shaft.
- Pull out the gearbox.
How to adjust
Now you need to adjust the gearbox and troubleshoot components and parts. If they fail, replace them with new ones. Spline connections must not have defects or chips. Gear bearings should be replaced after first inspecting the place where they are installed to see if there is any wear or areas pressed through by the rollers.
The shaft bearings are replaced because, as a result of breakage and metal shavings getting into the oil, the rolling areas of the bearings were damaged, which could cause gearbox failure. Inspect the gears, detect damage and wear of gear teeth. The conical synchronizer races must not be deformed or worn. The guide shafts should not be loose. There should be no damage to the splines.
How to assemble correctly
The gearbox is assembled in the reverse order. The intermediate shaft is installed in the gearbox housing. Mount the bearings - front roller and rear spherical. Tighten the support washer. Fix it with a nut and close the rear cover of the spherical bearing mount. Install gaskets. The shaft should rotate easily, there should be no jamming of the part when moving.
Repair diagram for KamAZ-5320 gearbox with divider
To repair the KAMAZ-152 gearbox with a divider, it must be disassembled. Analysis includes the following steps:
- To disassemble the box, you will first need to dismantle the air switch and unscrew the fasteners;
- remove the gearbox shift shaft and fork;
- the next step will be to dismantle the fork and release shaft, as well as the synchronizer;
- Next, you need to open the rear bearing cover by unscrewing the screws that first fix it;
- dismantle the bearing and shaft;
- also, to open access to the gearbox multiplier, you will need to remove the support roller washer, metal cup and driven shaft bearing;
- using a rubber (not metal) hammer or a wooden block, you must carefully remove the bearing from the multiplier housing, being careful not to crush the part;
- next you need to remove the coupling and oil injection nuts using the appropriate wrenches;
- The last stage of disassembling the unit is to dismantle the roller bearing, bushing, and gearbox drive gear.
Next, you should inspect all the parts and replace worn ones, and then assemble the device, following the above instructions in reverse order.
