KamAZ 5460 is a truck tractor produced by the Kama Automobile Plant. The first copies of the car appeared in 2003. To develop the model, the KamAZ 6520 platform, which has proven itself, was used. The creators revised the wheel formula of the car. The 6 by 4 layout, inconvenient for European trailers, was replaced by a 4 by 2 base.
Initially, for the KamAZ 5460 they used a completely spring suspension, but soon instead they began to install an air suspension on the rear axle, which made it possible to reduce the seat height to 1200 mm. The suspension was assembled in Russia, but most of the elements for it were imported from abroad. The cylinders were purchased in Hungary, the WABCO pneumatic control mechanism was purchased in Germany. This contributed to improving the quality of the unit.
In 2010, the Kama Automobile Plant introduced a modernized version of the model called KamAZ 5460-046-22. Noticeable changes have been made to the design. The low-speed 400-horsepower diesel KamAZ-740.37-400 and the powerful unit KamAZ-740.64-420, corresponding to the environmental class Euro-3 (Euro-4), were added to the line of power plants. At the same time, the model retained the previous ZF transmission. The rear axle has been completely revised in favor of a high-speed hypoid model from the Bulgarian manufacturer Madara.
In the design of KamAZ 5460-046-22, in comparison with the basic version, there are more imported elements, which made it more competitive in the market. Externally, the tractor began to look impressive and differed little from foreign competitors. Production of the model is currently ongoing.
About the history of Chelny “truck driver No. 1”
Since Soviet times, two areas of work for our largest manufacturers have emerged in the domestic heavy vehicle market: KamAZ dominated in the construction equipment segment, MAZ dominated trucks for long-distance transportation and long-haul tractors.
The weak points of KamAZ trucks, which made them unsuitable for full-fledged long-range driving, were: a relatively low-power engine that is not capable of working properly as part of 40-ton road trains; the 6x4 wheel arrangement is outdated for these purposes, the high seating of the fifth wheel coupling and, of course, the old, “from the time of Tsar Pea” cabin. Anyone who has had the opportunity to drive a classic KamAZ for at least one fairly long trip cannot help but pay tribute to the courage and endurance of the drivers working on a long journey with such a rigid cab suspension.
In the summer of 2002, at the Moscow International Motor Show at the Exhibition Complex on Krasnaya Presnya, the first two-axle fifth wheel in the history of the Kama Automobile Plant, the KamAZ-5470, was presented. The cabin remained basically the same, but was extended back, equipped with a high roof, two full berths, a modern dashboard, and “stuffed” in every possible way. The truck was equipped with a Rockwell (USA) rear axle. However, with a price of 40 thousand dollars, this car had no chance of getting onto the production line.
The pioneer of the class is KamAZ-5470.
And so it happened, so a year later the KamAZ-5460 appeared, costing 22 thousand in dollar equivalent from dealers. The first serial KamAZ forty-ton tractor designed to work with European trailers. This truck had the main features of a long-haul tractor, but its design still had many temporary solutions. This machine needed further improvement and was made with them in mind.
First modernization: 2006, KamAZ-5460-046-22 “Stayer”
The development of the base model was the modernized truck tractor KamAZ-5460-046-22, also known as “Stayer”, released in 2006. It was equipped with a 4OO-horsepower low-speed KamAZ-740.37-400 engine with Bosch fuel equipment that complies with the Euro-2 standard (originally the KamAZ-5460 was equipped with a diesel engine with a power of 360 hp).
The gearbox remains the same, 16-speed, from ZF. And the rear axle began to be used completely new - high-speed, hypoid, from the Bulgarian company Madara.
The Stayer used an imported Wabco brake system with ABS and RBL power steering. And new Yaroslavl tires with a dimension of 315/60R22.5, a new air suspension and a Jost fifth-wheel coupling device provided the new version of KamAZ-5460-046-22 with a reduced saddle height - 1150 mm from the asphalt level.
The frame spars were strengthened, but not by increasing the thickness of the rolled products, and an additional smaller spar was inserted inside the longitudinal spar along the entire length.
The suspension of the first KamAZ-5460 was entirely leaf spring. During the modernization, the rear axle received an adjustable air suspension. It was assembled in Chelny, but its components were completely imported: the cylinders were purchased in Hungary, and the Wabco pneumatic control system was purchased in Germany. The Wabco single-column air dryer is mounted behind the bumper in front of the right wheel and you have to lift the cab to get to it. Anti-roll bars on the front axle and drive axle ensured better stability of the truck when cornering. The tractor was also equipped with a cross-axle differential lock to confidently overcome snow-covered road sections.
The first thing that attracts attention is the radiator grille. The updated cabin received integrated side fairings - to reduce turbulence on the sides and contamination of the doors. The design of the bumper has changed, and more efficient lighting equipment has been installed. New running boards with lattice pads have been introduced to make it easier to climb into the cabin, as well as a roof fairing that improves aerodynamics and reduces diesel fuel consumption.
A three-blade windshield wiper was installed on the windshield, with a tighter fit of the blades than the previous one and a larger glass cleaning area. On the updated KmaAZ-5460, the hydraulic lift of the cabin was moved from behind the wing behind the right step, to the very bottom. And the lever for it, according to tradition, remains the assembly, the place of which is in the tool box on the chassis.
The cabin doors began to open unusually softly; the handles are no longer made of steel, but of plastic. In place of the previous rotor locks, which required regular adjustment, they installed the same ones as on passenger VAZs. A steel underride guard was placed under the bumper, like that of European long-haul tractors.
KamAZ-5460-046-22 “Stayer” with a “tonar” trailer.
But in general, of course, the cabin of the modernized highway truck differed slightly from the base KamAZ-5460, but new hydraulic locks were introduced into its suspension; Inside the cabin, a carefully designed new-style instrument panel and a driver's seat with air suspension appeared. This is a domestically produced seat, from manufacturers in Yekaterinburg (Pilot), Chelny (RIAT) or Elabuga. The pedal assembly was changed - it now has an upper suspension.
The combination of a new driver's seat, an adjustable steering column and a pedal assembly with upper pedal suspension has clearly improved the ergonomics of the driver's workplace and increased its comfort. But the gearshift lever, according to reviews, turned out to be too tilted forward. As a result, in order to turn on or off some speeds, you have to bend over significantly.
In general, the modernized KamAZ-5460 was also not a full-fledged long-haul tractor. But this was a real step forward: the Chelny plant showed not just another “promising model”, but a real commercial product, available for order from dealers immediately after its official demonstration at the Moscow International Motor Show 2006.
KamAZ-5460: long-haul truck tractor
The development of this vehicle began in the mid-90s, and mass production of the KamAZ-5460 truck tractor began in 2003. According to the manufacturer, this is the first truck from the Kama Automobile Plant, which can rightfully be positioned as a long-haul tractor. In 2010, the truck underwent a deep restyling, as a result of which the KamAZ 5460-046-22 model appeared on the market with improved characteristics and a more modern exterior.
Structurally, the KamAZ-5460 is a framed two-axle chassis with one (rear) drive axle (four-by-two wheel arrangement) and a front-mounted engine. Production of the car continues to this day; it is in steady demand; small batches of tractors are sold to foreign carriers.
Second modernization, 2010
First of all, it was necessary to change the cabin: they had already “squeezed everything that was possible” out of the old one. And it was impossible, with all the desire, to convert the cabin of a predominantly construction dump truck from the 70s into the cabin of a modern long-haul tractor. In search of the optimal option for a new “long-range” cab of increased volume with a full-fledged four-point air suspension, KamAZ negotiated with MAN to purchase a license for the production of the TGA cab. But it didn’t work out: it didn’t go beyond a few copies. Apparently due to the high cost of the product.
KamAZ-5460 with MAN TGA cab.
The second attempt was to install on KamAZ tractors for several years the cab of the discontinued MAN F2000, which was produced under license by the Chinese at the Shaanxi (now Shacman) plant. And then launch production of completely new cabins: an order for their development was placed in South Korea, and production launch is scheduled for 2013.
KamAZ-5460 with MAN F2000 / Shaanxi cab
However, these plans were crossed out: in 2008, a fateful deal took place with Daimler: Daimler AG bought a 10% stake in KamAZ for $250 million and received a seat on the board of directors, and in return the Russian manufacturer was given the opportunity to purchase licenses for production and use for their trucks with German components and assemblies. First of all, the cabins are from the previous generation Mercedes-Benz Axor.
By the time the modernized KamAZ-5460 with a Mercedes cab was launched into production, the KamAZ investment project to update production had already been implemented and started working. During 2007-2009, an automated line for priming, painting and drying cabin parts from the Dürr company was launched, costing 1.5 billion rubles, with a capacity of 75 thousand cabins per year, with the possibility of increasing output to 125 thousand.
KamAZ-5460 with Mercedes Axor cab.
In 2013, KamAZ-5460 gave way in the plant’s production program to its successor, the KamAZ-5490 long-haul tractor.
Engines KamAZ-5460
The KamAZ-5460 trucks used classic KamAZ eight-cylinder V-shaped diesel engines of varying power, equipped with a turbocharging system. But they were built on the basis of a modernized cylinder block. At the same time, the use of new materials for them helped to increase the rigidity of the structure and reduce noise during operation. The cylinder heads are made with a modified configuration due to the installation of modernized diesel fuel injection nozzles. To improve heat transfer, an oil radiator with an increased blowing area was used.
Despite the external similarity and almost identical overall dimensions (the crank radius has increased by only 5 mm), the long-stroke KamAZ-5460 diesel engines are significantly different from the classic KamAZ engines of the previous generation. Less than thirty percent of parts and spare parts remain interchangeable. The changes were due to the desire to provide an increase in power and torque, and also to increase the service life of the diesel engine. This is a whole range of measures: from increasing the diameter of the main bearing cap bolts to seriously modernized engine systems (power supply, lubrication, cooling), as well as giving the cylinder block casting greater rigidity.
Engines comply with Euro-3 standards using Yaroslavl injection pumps YAZDA-337-23 with an electronic control system, or similar, but in-line Bosch P7100 pumps, also with an electronic RE-30 regulator. They provide increased spray pressure. The injectors use multi-hole nozzles, the rigid mechanical connection between the accelerator pedal and the pump rack is eliminated, and its drive is changed.
Important additions to the fuel system, which were not even discussed until recently, are a fuel intake and an additional electrically heated fuel filter-sump (and for the north, also heating the fuel line). For the first time, the KamAZ fuel system was able to be standardly equipped with a heating system for diesel fuel supply lines (as an additional option).
Previously, domestic drivers heated up diesel fuel on their own: they hung a headlight bulb in the tank - closer to the fuel intake, let the return flow through the compressor head, and wound a copper tube with a return pipe in a spiral around the exhaust manifold. Or they welded an exhaust pipe into a homemade tank so that the diesel fuel was heated by the exhaust gases.
1. The KamAZ 740.50-360 complies with Euro-2 environmental standards and develops a power of 360 horsepower. Air injection with intermediate cooling is carried out by 2 imported Schwitzer turbochargers, or domestic ones - 7C-6.
2. The KamAZ 740. 63-400 with a power of 400 horsepower was installed on the KamAZ-5460 of the first modernization, after 2006. Bosch fuel equipment was integrated into the design of this engine, which made it possible to achieve compliance with the international Euro-3 standard. But for restyled KamAZ trucks, the engines of the first option also remained available - without Common Rail, with a power of 360 hp.
3. KamAZ-740-73-400 has a power of 400 hp. and complies with Euro-4 environmental standards. To increase the purity of the exhaust, a system equipped with an exhaust gas neutralizer (it is located in the muffler) was used.
4. KamAZ-740.64-420 , 420 hp, Euro-3 version, with Common Rail electronic injection. Its electronic control unit is located at the front, in the camber of the block.
5. KamAZ-740.74-420 , 420 hp, meeting Euro-4 standards, using AdBlue reagent.
In addition to the modernization of fuel equipment, a whole range of other improvements were introduced into the new 740 series. In particular, a new material was used for the cylinder block: cast iron ChVG-35 with vermicular graphite, and the strength characteristics of the main body part were improved. In collaboration with the Federal Mogul company, changes were made in the design of parts of the cylinder-piston group: the alloys used were replaced with more modern ones, and the technology of applying chromium-diamond coating to the piston rings was introduced.
In addition, in order to increase the service life of KamAZ engines with a power of 400 hp. With. and above, the crankshaft carbonitriding process was introduced. The update also affected the lubrication and cooling systems: the heat exchange surface in the oil heat exchanger was increased. And also - the designers changed the shape of the cylinder heads, taking into account the installation of fuel injectors and introduced a solid-cast flywheel housing, in accordance with SAE1 standards.
Engine characteristics in numbers
- Working volume – 11.76 l.
- Cylinder diameter – 120 mm, piston stroke – 130 mm.
- Power, at crankshaft speed: 2200 rpm - 360...400...420 hp, depending on modification.
- Maximum torque, at 1300 - 1500 rpm: 1470 N*m.
- Compression ratio - 16.8.
- Muffler – 6520.
The drive axle received a spaced main gear, with 5 satellite hubs of planetary gearboxes, and a reinforced steel beam. The fuel consumption of KAMAZ 5460 with the new engine is 36 liters per 100 km.
Transmission. Brakes
The truck is equipped with a MFZ-430 diaphragm disc clutch from ZF Sachs (Germany) and a manual gearbox from ZF. At first they planned to develop their own original transmission, but then they abandoned this idea, and in the end it was decided to go with an imported one. The KamAZ-5460 model began to be equipped with 16-speed gearboxes made by German ZF, models ZF 16S151 or ZF 16S1820. After creating a joint production with ZF Friedrichshafen - in Naberezhnye Chelny - these manual transmissions began to be produced here, with a localization level of up to 50%.
With an eye on their European colleagues, the Chelny residents also combined their 420-horsepower diesel engine with the ZF AS-Tronic automated gearbox (in Europe, MAN TGA/TGX, DAF XF and Iveco Stralis highway vehicles are equipped with it). At the same time, the gearbox control joystick was borrowed from DAF XF tractors, and its console with a mode switch was made in-house. The letter “A” means automatic mode, “M” - manual, “S” - manual with the help of automation, and the “DM” and “RM” modes are reduced, maneuvering. Gears are switched imperceptibly, the car picks up speed smoothly. For ease of driving, the instrument panel screen provides an indication of the gear engaged.
Torque is transmitted to the rear axle, which is equipped with a single-stage main gear with hypoid gearing. Over the years of production, KamAZ-5460 tractors were produced with two variants of the main gear ratio - 3.58 and 3.36. Additional planetary gearboxes are located in the hubs of the drive wheels.
The vehicles can be equipped with either KamAZ’s own axles, or the Bulgarian Madara, or the Chinese FAW (the most common option).
The KamAZ-5460 tractor is equipped with a brake system with pneumatic drive of the actuators. The machine uses drum brakes with a working surface diameter of 420 mm. The brake lining area is 4800 cm², with a working surface width of 180 mm. The braking system also includes an ABS anti-lock braking module with electronic brake force control.
Device
KamAZ 5460 opened a series of truck tractors from the Kama Automobile Plant, adapted for working with European trailers. Previously, the model range included versions with a 6 by 4 wheel arrangement and a high seat position. The new product received a different design (low-slung saddle, powerful unit, 4 by 2 wheel design).
The suspension of the first versions of the KamAZ 5460 was fully leaf spring, but was later abandoned. An air suspension with a seat height of 1200 mm was installed on the rear axle. On modern models, the rear axle has been replaced with a high-speed hypoid from the Madara brand. In the basic version, the car was equipped with tubeless disc tires (315/60 R22.5).
Taking into account European experience, the Kama Automobile Plant synchronized the power plant with the ZF AS-Tronic automatic transmission. Similar transmissions have proven themselves well on Iveco Stralis, MAN TGA/TGX and DAF XF truck tractors. The joystick for transmission settings was borrowed from DAF cars, the mode switching console was assembled at the Kama Automobile Plant. The result is a very interesting “set”. Speeds on the KamAZ 5460 were switched without delays or jerks, ensuring comfortable movement. The single-disc diaphragm clutch was hydraulically driven with a pneumatic booster.
The brake system was a pneumatic drive, complemented by drum elements with a drum diameter of 420 mm.
The appearance of KamAZ 5460 turned out to be very attractive. And if the first copies of the car retained “remnants” of the Soviet style, then the restyled versions were in no way inferior to their foreign counterparts. The car was equipped with a large cabin located above the engine. Its design features a radiator grille with integrated side fairings and a large front bumper with towing eyes. A 3-blade windshield wiper with a tight fit was responsible for keeping the glass clean. The cabin was lifted using a hydraulic lift.
The cabin doors opened very softly, the previous steel handles were replaced with plastic ones. Instead of a rotary lock, a lock from a VAZ 2108 was installed. The steps on the running boards were also made of plastic.
Inside the cabin there are comfortable seats with air suspension, manufactured in Elabuga. Optionally, seats from RIAT (Naberezhnye Chelny) or Pilot companies were offered. The instrument panel was made of high quality plastic, the shield received anti-glare protection. The steering wheel had several settings, but adjusting it turned out to be extremely inconvenient due to the fact that the toggle switch was located under the handbrake lever.
The cabin itself was equipped with a 4-point Sachs air suspension, thanks to which the driver felt as comfortable as possible. This was also facilitated by a large salon where one could relax after a long journey. Outdated beds on gas struts in KamAZ 5460 were replaced with full-fledged sleeping places.
Other technical characteristics of KamAZ-5460 in numbers
- Overall dimensions: length – 6.34 m, width – 2.5 m; height – 3.12 m.
- Wheelbase – 3.95 m.
- Track width: rear 2.5 m; front 2.04 m.
- Curb weight - 7.05 tons; total weight – 18 t; total weight of the road train is 40 tons.
- Load: fifth wheel coupling – 10.8 t; on the front axle with total weight - 6.5 tons; on the rear axle with total weight - 11.5 tons.
- The height of the fifth wheel coupling is 1.15 m.
- Tire size – 315/60 R22.5.
- The volume of the fuel tank is 700 liters of diesel fuel (2x350 l).
- The highest speed is 110 km/h.
Specifications
Dimensions:
- length – 6340 mm;
- width – 2500 mm;
- height – 3120 mm;
- wheelbase – 3950 mm;
- front track – 2040 mm;
- rear track – 2500 mm.
Weight characteristics:
- curb weight - 7350 kg (load on the front axle - 4680 kg, on the rear axle - 2670 kg);
- total weight – 18,000 kg (load on the front axle – 6,500 kg, on the rear axle – 11,500 kg);
- total weight of the road train – 40,000 kg;
- The total weight of the semi-trailer is 32500 kg.
The maximum speed of movement is 110 km/h. The climbing angle of a road train is at least 18%.
Reviews of KamAZ-5460 tractors
Over the years since the premiere of its two-axle long-haul tractor, KamAZ has moved far forward in the production of trucks of this format. In addition to the cabins (upgrading the old one and introducing a completely new one), the plant seriously worked on and improved its V-shaped power units of the 740 series, bringing them to a power of 420 hp. According to drivers’ reviews, the truck is more than enough on highways, including during long uphill driving.
An important advantage of the KamAZ-5460 is its more affordable price compared to MAZ (and, especially, European imported) “classmates”. KamAZ has a wide service network that covers all regions of Russia and the CIS. There are no problems with spare parts, and they are usually cheaper than parts for European tractors.
Exterior, interior and cost of KamAZ-5460
The truck is equipped with a cabover cab with a high roof, a new radiator grille and an impact-resistant, molded bumper. The tractor has new headlights, a one-piece windshield with three windshield wipers and large mirrors with different viewing angles. Access to the interior is facilitated by two steps with anti-slip coating; noteworthy are the door handles and locks, which the truck inherited from the VAZ-2108.
The car interior is equipped with two or three Pilot seats, equipped with air suspension and adjustment mechanisms in all planes. Depending on the configuration, the KamAZ-5460 is supplied with one or two sleeping bags with gas struts. We note the modernized three-section instrument panel made of high-quality plastic with anti-reflective coating. Drivers note the successful layout of the panel and its attractive appearance. The steering column has a mechanism for adjusting reach and tilt; power steering (hydraulic power steering) is available as standard.
The cost of the new KamAZ-5460 truck tractor in a restyled version varies from 4,200,000 to 4,850,000 rubles. A car produced in 2014-2015 can be purchased at a price of 2,200,000 rubles.
