Checking the oil level in the crankcases of transmission units

Filling and checking the oil level for versions with a heat exchanger

If the gearbox is connected to a heat exchanger (transmission oil cooling) (see Fig. 12, Items 4 and 5), filling and checking the oil level must be done as follows:

Filling: 1. Fill the filling hole (see Fig. 11 + 12, Pos. 1) with oil until it starts pouring. 2. Tighten the plug, shift the gearbox to neutral, then run the engine for 2 to 3 minutes at approximately 1,200 min-1 (this is necessary so that the heat exchanger and connecting pipes are also completely filled with oil). 3. Turn off the engine and add oil again until the pouring begins.

Check: 1. First let the engine idle for about 3 minutes (gearbox in neutral). 2. Turn off the engine and immediately check the oil level (as in section 4.3). Add oil if the oil level drops below the edge of the hole.

Rice. 12 4 Connection to heat exchanger 5 Connection from heat exchanger

Clutch check

To guarantee the service life and correct operation of the synchronizers, perfect release of the clutch is essential. This also applies to switching on installed clutch-driven power take-offs.

Correct clutch disengagement can be checked in the following way: • warm engine at idle speed, depress the clutch; through max. 20 sec.* Slowly engage reverse.

If at the same time you can hear the “ratcheting” of the wheel teeth for connecting to the shift clutch (the sound of the clutch cams touching), then adjustment or, accordingly, checking the clutch is certainly required.

*depending on flywheel weight and temperature

Transmission ventilation

Transmission oil heats up when driving. As a result, excess pressure is generated, which is constantly reduced by the air valve.

Breather

Make sure that the breather is working properly at all times. The breather (Fig. 13) must be clean and the cap must be removed. Do not spray directly with high-pressure water (water in the gearbox is a risk of corrosion).

Rice. 13 – Breather

Air removal hose

Vehicles that require frequent cleaning due to operating conditions must be equipped with a breather with a hose. These are, for example, milk tankers, concrete trucks, etc. The hose must be laid without kinks or loops. The end of the hose must extend into a dry space (such as the engine compartment or frame cavity).

Rice. 14 – Air removal hose

The device of the gearbox divider for KAMAZ vehicles

The divider is an additional single-stage gearbox that doubles the number of gears and is controlled by pneumatics. Installed on trucks operating in difficult conditions, if the usual quantity is not enough. For example, the driver understands that in fourth gear the engine is running extremely high and is overloaded, but if you shift to third, the revs will be too high and the engine will “overclock.” By switching the pneumatic lever, you get an intermediate transmission ratio. Some tractors come with direct and overdrive gears. The straight line is good when the car is moving at normal speed, but the increased one is good if you need to tow it, take on more cargo than allowed, or climb a mountain. The divider is switched by a “flag” located on the switch lever. It is connected by a cable to the gas distributor. To sort through the gearbox yourself, it is better to have a diagram of its component parts, or contact a specialized service. We list the main components of the divider that you will have to deal with in case of independent repairs.

• Gears - two pieces.
• Both sides are blocked by synchronizer rings.
• Fixation is carried out using a synchronizing clutch with teeth.
• Availability of two types of shafts.
• Gear shift fork, fork shaft, lever.
• The body itself.

Specifications

• Series: 152 with divider
• Gearbox type: manual
• Number of gears: 10
• Gear ratios:
• Maximum torque, N*m (kgf*m):
• Volume of oil for pouring, dm 3:
• Gearbox weight, net, kg: 322
• Width, m – 0.77
• Height, m ​​– 0.84
• Length, m – 1.35
• First oil change after: 1,500 km (maximum 5,000 km)
• Secondary replacement every: 90,000 km (maximum - 120,000 km)
• But no less than: 1 time per year
• Applicability: KAMAZ, NEFAZ, LIAZ, MAZ, KAVZ and others.

The warranty for the 152 gearbox is 6 months.

You can find more detailed information on our website in the guarantee .

Returns and exchanges

Exchange of gearbox 152 for KAMAZ is possible if: 1. No more than 14 days have passed from the date of sale; 2. The packaging is preserved and the appearance is not damaged; 3. There are no signs of use or installation on the unit.

What kind of oil, how much and how to pour into the ZF KamAZ gearbox

Oil for the ZF KamAZ gearbox must be filled at certain intervals. The vehicle range includes a wide range of reliable heavy-duty vehicles. They are comfortable, modern, and perform well in a variety of conditions. The included gearbox has 9 speeds, automatic type. It is usually installed on cars with front-wheel drive. The presence of such a box guarantees excellent dynamic characteristics while driving. There is an additional divider at the gearbox; a tap switch is used to change gears. It is also responsible for increasing vehicle traction and simplifies the process of managing the system.

The device of the gearbox divider for KAMAZ vehicles

To carry out repairs, you need to know well how the structure works or have a diagram of a KAMAZ gearbox with a divider at hand. The gear divider itself is a mechanical gearbox, the main task of which is to increase the gear ratios of the main gearbox. The divider design consists of the following components:

• two gears;
• blocking synchronizer rings on both sides;
• synchronizer clutch with teeth;
• two types of shafts;
• device body;
• a fork designed to change gears, as well as a lever for these purposes and a fork shaft.

Compressor installation maintenance

Condensation forms in every compressor unit. To prevent condensation, rust and other contaminants from the air receiver from entering the valves and working cylinders, regular maintenance of the compressor unit is required. The air receiver must be dehydrated weekly, daily in winter.

NOTE Together with the air receiver, the compressed air filter with water separator must also be dehydrated if it does not work automatically. Please also observe the vehicle manufacturer's specifications.

What kind of oil to fill in the ZF KamAZ box

You can choose different grades and brands of oil for the KamAZ 5320 gearbox. Popular options are Mobile, Castrol. You need to look at liquids with a high concentration of extreme pressure additives. This is mainly GL-4 fuel. If you often drive your car at low temperatures, you should opt for 75 W-80 or 75 W-90.

A high-quality transmission lasts a long time, but if a heavy truck is used very actively, including on construction sites, the intervals between services are reduced

Oil change

Draining used oil

Rice. 11 The position of the plugs (bottom view) is shown for model 9 S 1110 1 Oil filling hole (60 Nm) 2 Oil drain plug (60 Nm) 3 Magnetic oil drain plug (120 Nm)

CAREFULLY

Oil must not enter the soil, groundwater or sewer system. Collect overflowing oil in a suitable container and dispose of it without polluting the environment.

NOTE As a rule: change the oil at the end of a long trip, while the gear oil is still warm and fluid.

DANGER Touching the gearbox or gear oil can cause burns!

To drain the oil, unscrew both drain plugs on the bottom side of the gearbox (Fig. 11, Pos. 2 and 3), and for additional units also their oil drain plugs. Replace the sealing ring on the plug (2) before screwing it back in. Before screwing it back in, clean the plug magnet (3) from any adhering wear particles and replace the O-ring.

Oil refill

Refill oil with the vehicle standing horizontally. Before opening the oil filling hole (see section 11, Pos. 1), which simultaneously serves to control the overflow and oil level, you need to clean the surface near the plug.

NOTE When filling, pour enough new oil into the filling hole until it overflows!

DANGER! Too little oil leads to insufficient lubrication, and is especially dangerous when driving in the mountains. Too much oil leads to overheating of the gearbox due to oil foaming.

Oil level control

DANGER Low oil volume in the gearbox leads to damage.

Check the gearbox oil level regularly.

• Check the oil level only when the vehicle is standing horizontally.
• Do not check the oil level immediately after a trip (incorrect test result). Carry out the check only after the gear oil has cooled down (< 40 °C).
• Unscrew the screw plug of the oil filling hole (section 4.2.2)
• If the oil level drops below the edge of the oil fill hole, you must add oil (Section 4.2.2).

NOTE: At each inspection, the gearbox must be checked for leaks.

Features of the ZF 9 gearbox

The ZF gearbox is found on trucks produced by KamAZ. Decent power with lower fuel consumption is provided by a 9-speed ZF automatic transmission. As a rule, it is installed on cars that have front-wheel drive. The presence of this box guarantees the car owner excellent dynamic performance.

It should be noted that KamAZ uses an additional divider in gearboxes. Changing gears in the divider occurs by moving the control valve switch. Thanks to the divider, there is an increase in the vehicle's traction, and it also makes it easier to control.

To ensure reliable operation of the transmission system, maintenance instructions must be followed.

What kind of oil to pour into the Kamaz gearbox. What kind of oil to pour into the Kamaz gearbox

For correct and durable operation, machine components must be lubricated on time, so we will look at what and how much oil should be poured into a KamAZ gearbox with and without a divider.

The amount of oil in the old-style KamAZ gearbox - five-speed without a divider - is 8.5 liters. Checking the lubricant level should be done as often as possible and at least once a month. Once a year, a complete oil change should be carried out in the KamAZ gearbox, provided that the mileage does not exceed 90 thousand kilometers. When this figure is reached, replacement must be performed earlier. For vehicles operating in difficult conditions, this figure is halved. This is due to the rapid depletion of oil life with frequent gear changes, as well as long-term operation in low gears. The oil in the KamAZ gearbox is checked using an indicator attached to the filler plug. In speed distribution mechanisms produced by ZF-KAMA, level control is carried out through control holes located on the crankcase.

Do you need a KAMAZ gearbox?

The presence of a divider increases the amount of oil used in the KamAZ gearbox. Ten-speed gearboxes require 12 liters of gear oil. Replacing it is a simple process, so most drivers know how to change the KamAZ gearbox oil.

This procedure is performed as follows. First, the filler plug is unscrewed. Then the two drain plugs at the bottom of the crankcase are unscrewed. In units equipped with a divider, the plug should be unscrewed from its crankcase. Before draining, you need to start the engine and warm up the oil to reduce its viscosity. Because drain plugs have magnets to trap metal particles, they should also be thoroughly cleaned.

The mechanisms of the Kama plant are unpretentious, so truck owners use domestic oil in the KamAZ 5320 or 6520 gearbox. For this, the TSp-15K brand or all-season MT-16p is used. The Lukoil concern produces an excellent transmission brand TM-5 SAE 80W-90. When using a transmission, it is important to consider weather conditions. In hot climates, it is necessary to use more viscous grades - 85W-90, in severe frosts - more fluid ones - 75 W-90. To increase engine life, it is advisable to use Shell Spirax S6 AXME, Castrol Syntrax Long Life, Esso Gear Oil GX.

Installation on the engine

A high-quality installation will allow the spare parts to last a decent service life. To do this you need:

• Check the current condition of the main shaft using an inspection tool. It should move easily on the slots. If sliding is ensured, then the end of the spline can be coated with a small layer of lubricating fluid;
• avoid impacts and avoid loading the dependent discs with the weight of the gearbox to prevent damage to the front bearing;
• check the overall stroke of the coupling, which should vary in the range of 35-43 mm;
• lubricate the accessible areas of the heads together with the rod supports before directly installing the remote mechanism. After installing the heads, tighten them with mounting bolts. It is important to prevent the heads from oscillating on the rods;
• achieve high-quality fit of sealing covers on mounting surfaces. At the same time, sticking of the rods on the supports is an unacceptable disadvantage;
• Fill the gearbox with oil and carry out a triple test of starting the car using the starter with the clutch disengaged.

Installation check

To control the quality and correctness of the clutch installation work, you need to set the torsion frequency at 2000 rpm and analyze the following control operations:

• smooth operation of parts and no jamming during startup and disengagement of the clutch;
• absence of noise and extraneous sounds during operation (loud clicks, knocking and squealing of the engine are not allowed);
• clean clutch release. The maximum coupling stroke is 12 mm. The switch travel for this value corresponds to 16 mm, calculated with a radius of 90 mm. When fixed in this position, gear 1 and reverse should start smoothly, without grinding. Torsion of the dependent shaft is not allowed when the direct transmission is operating;
• switching quality. Changing speeds should not be accompanied by jamming of the device and other difficulties during the transition;
• complete absence of oil outside the container. The formation of small oil traces in the areas of breathers and seals is acceptable.

For smooth and even gear changes, a KAMAZ scaffold is suitable.