Characteristics and design of the KPP-154 gearbox for KamAZ vehicles

Design and principle of operation

Here, for example, is how the Kamaz gearbox (model 154) works:

• 5-speed main gearbox;
• 2-stage divider or multiplier;
• clutch;
• shafts - main, secondary, intermediate;
• synchronizers and gears;
• crankcases and drive

The principle of operation, aimed at improving the performance of the car, increasing the speed of movement and allowing to save fuel, can be imagined as follows. When 1st gear is engaged, the clutch mechanism connects the gearbox shafts and the manual transmission. The initial rotational moment or KM (torque) is supplied from the Kamaz engine to the transmission. As soon as the speed increases, the synchronizer teeth are connected to the drive shaft of the internal combustion engine. Rotation is transmitted to the intermediate shaft of the box, the coefficient decreases, and the speed increases.

But there are other options:

• 10-speed or 15 model;
• 8-speed with a four-gear gearbox and a “lower gear” or 16 model - used on KamAZ-65115;
• 9-speed ZF with an auxiliary reduction stage - all-wheel drive all-terrain vehicles KamAZ-43150, 4310, 4350 Mustang.

The 14th model of the gearbox on the latest versions of the truck has been improved. The result is a new KamAZ 154 gearbox, which has several advantages over the classic old “five-speed”:

• reinforced synchronizers;
• new gear mount;
• modified spline system;
• use of new cone-shaped bearings in shaft supports;
• lack of spline fastening;
• increased tooth height.

Gearbox with divider

The 5-speed gearbox is normal, intended for single cars. 10-speed - improved Kamaz gearbox with divider. Essentially, these are the same gearboxes, but in the case of the 10-speed gearbox, a gearbox is added. Together with the gearbox, it creates 10 forward speeds and 2 reverse.

A box with a divider is considered an improved model and provides many advantages:

• lower switching frequency during movement;
• increase in engine thrust;
• increasing operating comfort.

The divider control drive device looks like this:

• lever or support;
• sealing ring;
• axis;
• vibration isolator.

KamAZ gearbox: Design and types of boxes

Among the complex devices and mechanisms inherent in a car, the KamAZ gearbox occupies a leading position.
The mission assigned to the box is paramount; it is impossible to imagine the operation of the car without a transmission. By comparing the size of the device with the dimensions and weight of the car, the level of loads experienced by the unit becomes clear. Technologies that ensure the performance of the product force us to look at the transmission from a different angle. Trucks are tasked with tasks whose complexity is not comparable to their passenger counterparts. The choice of mechanics by the designers increases the reliability and performance of the device. However, ignorance and lack of operating experience negatively affects the condition of the box, so trained personnel are allowed to drive the car.

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 start of movement on KamAZ should be done 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:

1. 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.
2. After this, 2V transmission is switched on.
3. 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.

Device

The KamAZ-154 gearbox includes:

• main 5-speed gearbox;
• 2-stage divider, or multiplier;

When disassembled, the device looks like this:

• drive shaft;
• gear transmission;
• synchronizers;
• coupling;
• driven shaft;
• intermediate shafts;
• crankcases;
• drive unit.

Gearbox diagram for KamAZ 154 for models 43118, 4350, 43505, 5350, 65115, 53605:

• during acceleration - 1V-2V-ZV-4N-4V-5N-5V;
• on rough terrain or when driving in difficult conditions - 1Н -2Н-ЗН-4Н-4В-5Н-5В.

Gear shifting occurs only when the clutch is disengaged and is selected by moving the crane lever to position B or H using the distribution spool.

The divider switch is mounted on the left side of the crankcase. The control drive includes:

• gear shift lever support;
• sealing rings;
• jet thrust;
• axis;
• lever arm;
• vibration isolator.

Principle of operation

As soon as direct transmission is engaged, a gear coupling rigidly connects the drive shafts of the multiplier and the gearbox. A torque that does not change in magnitude is sent from the power plant to the gearbox. When you press the overdrive lever, the teeth are fixed by synchronizers on the drive shaft of the divider. Rotation passes through the wheels to the intermediate shaft of the gearbox, as a result of which the transmitted torque decreases and the number of revolutions increases.

This process contributes to the efficiency of the vehicle, increasing travel speed and fuel economy.

The difference between the KPP-152 model and the 154

KPP-154 is an improved modification of gearbox 152 for KamAZ. The main advantages are:

• reinforced synchronizers;
• improved gear mounts;
• improved multiplier control.

At the same time, the pneumatic divider control system itself is considered a mechanism characterized by complex maintenance. To carry out service work, a specially trained technician is required.

The main difference between the KPP-152 and the 154 model is the presence of conical bearings in the shaft supports.

Spare part warranty

We offer an extended warranty of 6 months (3 months for electronics). The warranty card will come with the spare part.

What includes:

Guaranteed replacement of spare parts in case of defects within 6 months

How to exchange a part in case of defect:

1. Send back.
2. We will carry out defect detection of the goods (3-10 days).
3. If the marriage is confirmed, you will receive a new spare part. Dispatch at our expense.
4. If improper operation is determined, we will offer repairs at your expense. In case of refusal, we will send the spare part back (at your expense).

Repair parts

How to repair a part if a malfunction is detected:

1. Send back.
2. Wait for the product to be defective (3-10 days).
3. Repair according to our price. In case of refusal, it will be sent back at your expense.

Material of manufacture

With this configuration of the body and suspension, the frame material plays a significant role in the safety and stability of the car. It is logical that strengthening the weak points of the body will make the vehicle stiffer and more stable on the road. But then the mass of the car will be critical, which will make it clumsy and very heavy.

When strengthening the frame, the weight of the “penny” and the load on all structural elements increases. That is why design engineers are trying to select the rational thickness of materials, taking into account the ratio of their dimensions and cross-section. The result is a fairly durable and not too heavy body.

Important Technical characteristics and design of the Ural-44202 car

To reduce weight and save on costs, elements that do not bear the load are made of thinner metal. The main parts have a thickness of about one millimeter, which corresponds to similar indicators for other cars of similar class.

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Specifications

Technical characteristics of KPP-154:

1. Type - mechanical 3-way 10-speed.
2. Clutch housing - 21.1600010 Sachs MFZ 430, 17.1601008-10.
3. Gear number and gear ratios:
   1H - 7.82;
4. 1B - 6.38;
5. 2H - 4.03;
6. 2B - 3.29;
7. 3H - 2.5;
8. 3B - 2.04;
9. 4H - 1.53;
10. 4B - 1.25;
11. 5H -1;
12. 5V - 0.815;
13. 3ХН - 7.38;
14. 3ХВ - 6.02.

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What operating errors can lead to gearbox failure?

KamAZ 6520 and 5460 vehicles use 16S151ZF-ECOSPLIT transmissions. The machine comes with a manual for operating such gearboxes. In practice, they often fail precisely because of improper operation. Therefore, the car owner needs to carefully study the instructions in order to comply with the requirements and avoid mistakes.

Let's look at the main mistakes that car owners make when operating the gearbox:

1. When the driver changes gear, the clutch pedal must be depressed all the way. If you do not fully depress the clutch, this will result in accelerated wear of the transmission synchronizers.
2. One of the main requirements is that it is prohibited to switch from higher gears to lower gears. That is, switch from 5, 6, 7 or 8 speeds to 1, 2, 3 and 4 if the vehicle speed is more than 30 km/h. Such an error will quickly lead to failure of the range synchronizer.
3. If it is necessary to switch from high speed to low speed, this must be done sequentially. You cannot jump over a gear, as this will also cause destruction of the transmission synchronizers. If you need to switch to a higher speed, then such a switch is allowed.
4. You cannot completely grasp the gearbox lever when switching from one speed range to another. The switching process should be carried out with an open palm.
5. If it is necessary to move from neutral position I to position II, you need to use a light blow with an open palm; the clutch does not engage. This is how the range switch switches.
6. When driving at neutral speed, you cannot move the selector to the right or left to search for neutral. The KAMAZ gearbox has fasteners that fix the gearbox selector in the neutral position. Moreover, they keep it between the third and fourth speeds in the lower range, and also between the fifth and sixth speeds in the higher range.
7. You cannot coast downhill. The transmission oil pump rotates from the movement of the input shaft of the box. When the car is coasting, the engine is idling and the oil pump is at reduced speed. Because of this, the pressure generated by the pump will be insufficient for optimal operation of the elements. And if there is not enough lubricant, the bearings will quickly overheat.
8. It is not allowed to tow a vehicle with the driveshaft connected from the gearbox to the drive axle or transfer transmission. This refers to all-wheel drive vehicles. If this rule is not followed, the gearbox oil pump may fail due to lack of lubrication.
9. When starting the engine by towing, only use high speed ranges.
10. Before leaving the KamAZ in the parking lot, you need to set the gearbox selector to the left neutral position.
11. Let's talk separately about the reverse gear. Its activation is possible when the car comes to a complete stop and the idle speed drops to a minimum. This is allowed 10 seconds after the clutch is disengaged.

Important Electrical wiring diagram and technical parameters of the GAZ-5312 truck

KamAZ gearbox design

Transmission modifications differ in operational parameters (for example, gear ratios) and the design of some components. However, the basic parts and mechanisms remain the same.

Basic nodes:

• Box pan (clutch pan is mounted at the front);
• Shafts together with gears: main, driven, middle;
• Synchronizing devices, bearings;
• A set of reverse gears;
• Plug assembly with switching unit.

KamAZ gearbox diagram:

The top of the transmission contains a channel that supplies oil to the discharge space. The supply of working fluid occurs through a technical pipe having a plug and a level meter. The bottom of the pan is equipped with a drain plug; a magnet is built into the part; this is done to remove metal crumbs from the lubricant.

There are hatches installed on the sides of the pallet; power removal mechanisms can be mounted through the products. The hatches are equipped with plugs with sealing elements. It is noteworthy that taking power from a moving car is prohibited.

The load is removed from the power plant by a divider mechanism. The gearbox increases the gear ratios, the device is turned on by the rocker lever.

Basic divider units:

• Control valve, supports forward and reduced speed mode, mounted on a switch base;
• Valve for controlling the constancy of the output pressure. The valve releases excess pressure when the indicators are exceeded, partially diverting air to the control valve and the valve of the dividing device;
• Valve, divider drive. Deactivating the clutch provokes the supply of air pressure to the device, turning off and turning on the reduced speed;
• Dividing mechanism. Contains a piston, the lever of which is connected to a rod connected to the fork shaft of the assembly. The displacement of the piston initiates air pressure, this changes the operating mode of the box;
• A pipe that distributes air flow.

KamAZ-6520 "Mammoth":

Basic parameters of boxes:

How much a KamAZ box weighs is influenced by several factors. Firstly, this is the equipment of the device, the presence of a dispensing mechanism, a multiplier, etc. In addition, the material of manufacture and the level of filling of the product with lubricating fluid are important.

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Purpose and description of the KamAZ box

Despite the number of modifications, the purpose and operating principle of KamAZ gearboxes are the same. Thus, the mechanisms are designed to change the magnitude and direction of the impulse removed from the power plant and transmitted to the wheels of the car through transmission parts.

Installation of the gearbox on a KamAZ vehicle is carried out using eight studs, four on each side. The product is installed to the clutch pan (two studs on top), two studs from the bottom are screwed into the gearbox pan.

Smooth transition from mode to mode is ensured thanks to synchronizers. Administration occurs at a distance, due to the switch lever, the installed drive is mechanics. Boxes equipped with a divider for changing modes use a pneumatic drive.

Selecting gearbox oil

What kind of oil is poured into the ZF KamAZ gearbox? As a lubricant, you can use oil from a domestic manufacturer or well-known foreign brands. Oil options from brands such as Castrol and Mobil are suitable for KamAZ.

What kind of oil should I use? You need to pay attention to liquids that have a high concentration of extreme pressure additives, for example, GL-4 class fuel. If the car is frequently used at sub-zero temperatures, you should choose 75 W-80 or 75 W-90

How much oil should be added to a KamAZ gearbox with a divider? The required volume is about 9 liters. As a rule, this procedure must be carried out every 100,000 km.

Thus, KamAZ vehicles have high reliability and good performance. Caring for this automotive system involves timely diagnosis of the vehicle. Helps to extend the working life of the gearbox by selecting high-quality gear oil.

Gearbox device

Depending on the car model, the control scheme and location of transmission gears on the new KamAZ may differ. Domestic trucks can be equipped with two types of gearboxes. The difference is that some transmissions have five shift stages, while others have ten. These models are called 14 and 15. Five-speed transmissions are usually installed in cars that are used as personal vehicles. Ten-speed gearboxes are usually equipped with trucks classified as road trains.

KAMAZ divider control drive circuit

The design of the ten-speed transmission is a five-speed gearbox, complemented by a divider gearbox. Thanks to the device, the vehicle can use 10 forward gears, as well as two reverse ones. When the production of KamAZ trucks began, it was expected that these vehicles would operate under conditions of high load capacity. The engineers of the automobile concern created a new transmission model, which was called 152.

Listed below are the main differences between the 152 gearbox and the improvements that this gearbox model includes:

• the transmission began to be equipped with a reinforced divider synchronizer;
• The splines have been strengthened and their fastenings have been removed from the box;
• a different method of fixing transmission gears has been implemented;
• The height of the gearbox teeth has been increased.

Correct use of this unit when operating the transmission is extremely important. It is equally important that maintenance, checking the unit for breakdowns, its repair and assembly of components were carried out by professionals

This process must be carried out using specialized equipment and tools. Let's consider the main elements that are included in the design of the KAMAZ transmission:

1. Carter. This unit has three shafts - intermediate, primary and secondary.
2. Block with gears. They are designed to engage reverse gear.
3. Top cover of the unit.
4. Gear shift mechanism. This unit is considered collapsible.
5. Motor. Mounted on the front of the crankcase.

A video about the ZF gearbox on KamAZ 6520 was shot and published by user Oleg Kopaev.

Gearbox KamAZ KPP-141.

Description and features:

KAMAZ gearbox 141 is a modification of gearbox 14. Initially, this unit was installed exclusively on URAL vehicles, but later began to be used on models 43253, 43505, 4308.
KAMAZ gearbox and URAL gearbox are the same in principle of operation and design. However, the KAMAZ gearbox 141 has minor technical features: - an increased number of teeth on the gears. Thanks to this, the vehicle’s traction is significantly increased, which allows it to easily overcome steep climbs even with a maximum load. Also, this change affected the gears themselves, the fourth became direct, and the fifth high-speed; — a direct-acting switching drive is installed. The 141 gearbox on KAMAZ is characterized by increased traction and reliability.

The KAMAZ 141 gearbox with a divider will not be produced. The primary shaft of the assembly unit does not provide for the installation of a divider (as on models 14 and 142).

Characteristics of the KAMAZ 141 gearbox

This unit has five standard gears for movement, as well as one reverse (R). Gear ratios: — first — 5.62; - second - 2.69; - third - 1.64; - fourth - 1.00. Straight; - fifth - 0.724. Express; — reverse gear – 5.3.

Completeness of KPP-141

• primary, secondary, point and intermediate shafts;
• satellites;
• crankcase
• gear wheels
• gear shift lever
• clutch fork
• bearings
• speedometer sensor
• adjusting bolts

The units have certificates of conformity and all necessary documents. The sale of gearboxes and gearboxes for KamAZ is our priority, so we purchase units from the manufacturer at wholesale prices, so we can sell them at a cost below the market average.

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