KamAZ control - Shifting gears on a dump truck

Category: KAMAZ

• Description of the boxes used
• Principle of operation
• Start
• Gear shift diagram
• Box KamAZ 15
• Box KamAZ 16 and ZF
• Management Tips
• Hill climb control
• Descent Control
• Driving on an icy road
• Is it possible to drive a KamAZ without urea?

At first glance, driving a KamAZ is similar to driving a car. The principle of operation is the same as on classic transport, however, some features cause complications for the uninitiated user.

You get a complete understanding of how to properly drive and drive a KamAZ by understanding the specifics of gear shifting. The fact is that for every heavy car you need to find an approach to the issue of manipulating the gearbox, and KamAZ is no exception. In order to achieve the required speed limit when transporting cargo, the KamAZ transmission is often operated in a low gear. The acquired skills, knowledge and experience in working with the gearbox are the key to the success of further operation of the vehicle.

KamAZ-6520, dump truck:

Description of the boxes used

The gear shift pattern directly depends on the type of transmission installed on the KamAZ vehicle. Most of the machines used use a box with five forward speeds and one reverse; this is a model with index 14. The mechanism is relevant if there is no need to tow a trailer, or the cargo being transported weighs less than 10 tons.

KamAZ-14 gearbox:

Equipment used for transporting large loads, or participating in road trains, uses a transmission marked 15. In this case, you need to know how to drive a KamAZ dump truck, since the gearbox includes a gearbox. This is the same 14 transmission with five forward and one reverse gears. The divider, if necessary, includes lower speed ranges, as a result, the car has twice as many gears.

KamAZ-ZF gearbox:

The gearbox used is index 16, with eight mechanical speeds. A four-stage gearbox and a low gear are provided. ZF gearboxes are also installed, which are equipped with nine gears and an auxiliary reduction stage.

Regardless of the transmission model, the gearbox is of a mechanical type, control is carried out using the clutch pedal. The switching takes place in stages, taking into account the lower and higher modes. The lever on the rocker handle is responsible for switching modes. When creating, it was taken into account that KamAZ is a heavy vehicle, which when loaded requires a reduction in force. Conversely, if you drive with an empty body, this will not lead to overheating and fuel consumption.

Maintenance and repair

Regularly maintain the ZF gearbox on your Kamaz vehicle. This will increase its service life and minimize possible malfunctions during operation.

Repair of ZF gearboxes is recommended to be carried out only in certified service centers or by experienced craftsmen who have disassembled and reassembled more than one such gearbox.

List of certified centers of ZF Friedrichshafen AG

Change of oil

Only fill in oil that is recommended by the manufacturer (specification ZF TE-ML 01). When initially filling the gearbox, 11 liters are required. oil, at the next change 8 liters. The maximum oil change interval is 90 thousand km. mileage, minimum - annually. If a Kamaz vehicle with a ZF gearbox is operated on construction sites or in severe weather conditions, then it is recommended to change the oil after 45 thousand km. mileage or after 1000 hours of engine operation.

Oil change intervals

• Severe operating conditions: 02A - 1 year or 60,000 km.
• 02B, 02C, 02H - 1 year or 120,000 km.
• 02D, 02E, 02L - 2 years or 240,000 km.

The gearbox oil should be changed when the engine is hot. Unscrew the drain plug and drain the used oil. Clean the drain hole and drain plug from metal shavings with a magnet. Replace the gasket and tighten the plugs with a torque of 60 Nm. Fill the oil through the oil filler hole until the level reaches the bottom edge of the hole or is already pouring out of it.

Do not allow the gearbox oil level to be low. This may cause serious damage to the box. To check the oil level, place the car on a horizontal platform and let the oil cool to a temperature below 40 C.

Clutch check

In order for the synchronizers in the box to work for a long time, the clutch must also work flawlessly. To check it, do the following:

• At idle, depress the clutch.
• After no later than 20 seconds, slowly and carefully engage reverse gear.

If you hear a grinding noise, the clutch needs to be adjusted or its functionality completely checked.

Transmission ventilation

Because When the car moves, the oil in the gearbox heats up, and increased pressure forms inside. To relieve excess pressure, there is a special breather at the top of the box body. Check its cleanliness periodically.

Principle of operation

KamAZ vehicles are usually equipped with manual transmissions. The mechanism is controlled in the classic way, by pressing the clutch pedal and moving the rocker to the required position. A special feature of the transmission is low (H) and high (B) operating modes. This ability minimizes the load on the power unit. It is typical that for this purpose a divider is used, which acts as a gearbox that increases transmission ratios. On some cars, when changing from a higher gear to a lower gear, they do not use the rocker. For these purposes, a special switch and clutch pedal are used. The gear switches automatically, the upper position of the lever is typical for a loaded vehicle, the lower position is used when moving an empty vehicle. The features of driving a car are indicated in the instructions for the gearbox that comes with the product. You can also read about How to adjust the clutch on a KamAZ.

What's the result?

Taking into account the above information, we can conclude that auto manufacturers do not always independently develop and manufacture components and assemblies for their cars. The purchase of ready-made gearboxes, chassis elements and other units and components can significantly reduce the cost of production.

We also recommend reading the article about what the automatic transmission manufacturer Jatco is. From this article you will learn about the Jatco company, as well as why the Jatco automatic transmission and variator are considered to be one of the most popular and reliable in the world. The result of this approach is the use of units produced by the world's leading brands specializing in the production of gearboxes, power steering, axles, etc. Moreover, when it comes to gearboxes, among the leaders we can highlight ZF, Aisin, Jatco.

Finally, we note that the example of an 8-speed ZF automatic transmission clearly demonstrates the possibility of widespread distribution of one unit throughout the world and the possibility of its installation on car models of different brands and manufacturers.

Sources

• https://dvigatelkama.ru/korobka-peredach-zf-16s1650-maz/
• https://SpecMahina.ru/kamaz/kpp-zf.html
• https://KrutiMotor.ru/korobki-peredach-zf/
• https://miniteh.com/articles/Informaciya/Nemeckie-KPP-ZF-na-gruzovyh-avtomobilyah-KAMAZ
• https://gearbox-zmt.online/kpp-zf-na-kamaz/
• https://www.zfmaster.ru/

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Start

To know how to properly drive a KamAZ dump truck, you need to understand the gear shift pattern. As in the standard version, manipulations take place using the clutch pedal.

Switching stages:

• 1st gear, high mode (B);
• 2nd gear, high mode (B);
• 3rd gear, high mode (B);
• Transition to the 2nd low (H) stage and switch to 4th gear;
• Transition to the primary stage (B), the gear remains in 4th;
• Shift to a lower gear (H), engage 5th gear;
• Return to the higher gear (B), stay in 5th gear.

KamAZ:

The main feature of starting to move on a KamAZ is a smooth start and acceleration using lower gears. In the case when the dump truck is heavily loaded, or the traffic is in difficult conditions, it is advisable to switch the first 4 gears in low mode (H), then switch to 4th high gear, then lower 5th gear (H) and then to 5th -th increased (B). Manipulations are carried out when the required crankshaft speed is reached. Directly at the start in 1st gear, the shaft speed reaches 7000 min-1, the transition to 2nd gear is made when the speed reaches 3000 min-1. The correctly selected mode saves fuel and minimally wears out the power plant.

Box KamAZ 15

This transmission is installed on KamAZ-55111, KamAZ-43118 and other models. To accelerate the car to the required speed, the following scheme is used: 1B-2B-3B-4N-4B-5N-5B. This scheme allows the box to operate normally, provided that the rules for operating the mechanism are followed:

1. Using a special switch lever, change the operating mode of the box from high to low and vice versa;
2. Press the clutch pedal;
3. We change gears in order using the rocker.

KamAZ switching diagram:

Box KamAZ 16 and ZF

This type of transmission is used on KamAZ-65115 vehicles, as well as all-wheel drive KamAZ-43150 KamAZ-4310 and others. The peculiarity of the mechanism is the automatic switching of high and low modes. This means that when shifting from gear 4 to gear 5, the upshift mode is automatically activated. Conversely, shifting from gear 5 to gear 4 automatically activates the reduced mode. The switch is indicated by an indicator on the instrument panel.

Switching diagram ZF 9S109:

Some models of ZF gearboxes, for example, 9S109, with auxiliary gear “C”. The mode is designed for movement and maneuver in difficult conditions (snow, ice, mud).

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Hill climb control

Driving up a slope is accompanied by the gearbox switching to a lower mode (H). This makes the transmission work harder and overcome obstacles more easily.

• When lifting heavy equipment, shifting from first to second gear is carried out using the double clutch method;
• To ensure the operation of the power plant, depress the gas pedal to prevent an interruption in the fuel supply;
• The crankshaft speed readings do not fall below 2000 min-1, otherwise the power plant will overheat and stop working.

In feather weight

ZF Ecolite manual transmissions (the smallest in the ZF family), designed for installation on vehicles with a gross weight of up to 6 tons, are the newest family, the latest generation. The results of a long search for designers and technologists were used in its development. The boxes are designed to transmit torque in the range of 500…1050 Nm. Model S5-42 – 5-speed gearbox with a range of gear ratios of 8.63...1.00 covers the torque range from 300 to 600 Nm. The six-speed S6-36/2 gearbox works most actively with torque in the range of 350…750 Nm; the other 6-speed gearbox 6S 850 has a range of 6.75...0.78 with one overdrive and operates with a maximum torque of 850 Nm.

All ZF gearboxes of the Ecolite family can be supplemented with power take-off shafts of the ZF PTO series.

Boxes of this type are installed, for example, on IVECO Daily vehicles, both regular flatbed vehicles and vans, and on specialized ones, where it is necessary to use power take-off shafts to drive attachments.

The six-speed ZF AS-Tronic Lite gearbox, which has been on the production line since 2005, has become an automated version of the Ecolite manual gearbox. In terms of weight and size characteristics and a number of gear ratios, AS-Tronic Lite gearboxes are fully consistent with their mechanical counterparts, but transmit more torque – 1050 Nm. They are offered as an option on light-duty vehicles.

Descent Control

When driving a KamAZ vehicle on a descent, please note that under no circumstances should you turn off the engine. Drivers use this method to save fuel. However, acting in this way, the amplifier stops working, which blocks the steering. This phenomenon will lead to an emergency situation, the consequences of which are unpredictable.

Problems also arise with brakes, since heavy equipment is equipped with an auxiliary system. Activating the latter eliminates the ability to use the clutch pedal and switch from one mode to another.

Middleweights

Nine-speed ZF Ecomid gearboxes are the main manual transmission of medium-duty vehicles with a gross weight of up to 16 tons. The only representative of this family, the 9S 75/109 gearbox, is available in two versions.

The number of gear ratios of the first is 12.73...1.00, and the maximum torque is about 1100 Nm. It is installed on vehicles operating in cities, public utilities, industrial transport, construction - in a word, where a wide range of operating speeds is needed.

The second version has gear ratios from 9.48 to 0.75 with overdrive and a torque of more than 1300 Nm. Its purpose is to work on long-haul trucks, as part of a tractor with a trailer or semi-trailer. The “compressed” series of gear ratios is designed for movement at a relatively stable speed and over long distances.

The twelve-speed version of the ZF AS-Tronic Mid automatic transmission is an automatic “twin” of the Ecomid manual transmission. It is produced with two gear ratio options: 12.79...1.00 or 10.33...0.81. At the same time, the maximum transmitting force of the AS-Tronic Mid significantly exceeds the capabilities of the Ecomid gearbox (1600 Nm versus 1300).

The box can be controlled autonomously or integrated into the overall vehicle control system based on a CAN bus (CAN bus is a single copper bus to which all electronic components of an automated engine, brake, and suspension control system are connected. A single computer control and diagnostic network is formed that controls all the main components of the car). Thus, it is connected to the EDC engine control unit and the ABS/ASR brake control complex.

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.

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.