Open Joint-Stock Company "Ulyanovsky Avtomobilny Zavod" Automobiles ÓÀÇ-3741, ÓÀÇ-3962, ÓÀÇ-3909, ÓÀÇ-2206, ÓÀÇ-3303 and Their Modifications Instruction Manual 2001
This instruction manual contains the brief description of the design and necessary operating and maintenance instructions. Since efforts are continually made to improve the reliability and performance of the automobiles, minor changes may be introduced without special notice.
IMPORTANT! To ensure trouble-free operation of the automobiles, we recommend that You should attentively familiarize yourself with the present publication and follow all the operating and maintenance instructions laid down therein. You can trust the maintenance of your automobile to one of the service stations recommended by the Sellers. These service stations are well stocked with spares, special appliances and tools. All the maintenance operations are performed by experienced specialists.
. When descending a steep downhill: - do not shut down the engine to avoid loss of the efficiency of the brakes provided with the vacuum booster; - do not disengage the clutch to avoid breaking of the clutch driven disk. 5. When riding on dry hard-surface roads, disengage the front axle. When the front wheels are disengaged, never engage the front axle. 6. If one of the hydraulic brake circuits is a failure, the travel of the brake pedal is increased, and the braking efficiency is decreased. 7.
INTRODUCTION The automobiles ÓÀÇ with a wheel arrangement 4x4 are designed for operating on roads of all types, at all climatic conditions, in all seasons, at ambient temperatures from -45 °Ñ to + 40°Ñ . The OJSC UAZ manufactures automobiles of the following models and modifications: ÓÀÇ-3741, ÓÀÇ-37419 (Fig. 1) - vans with all-metal closed wagon-type body divided into a two-seat cab and a cargo compartment. The vans are intended for cargo transportation; ÓÀÇ-3962, ÓÀÇ-39629 (Fig.
ÓÀÇ-39095 (Fig. 7) - a special vehicle with the enlarged wheel base, two-seat cab and metal platform for municipal econimy, cooperative and individual farmings. The vehicles are intended for cargo transportation*; ÓÀÇ-39094 (Fig. 8) - a special vehicle with the enlarged wheel base, five-seat cab and metal platform for municipal econimy, cooperative and individual farmings.
Fig. 1.
Fig. 2.
Fig. 3.
Fig. 4.
Fig. 5.
Fig. 6.
Fig. 7.
Fig. 8.
Fig. 9. Automobile marking: 1 -identification number of automobile: à, á - for automobiles ÓÀÇ-2206, ÓÀÇ-3962 and their modifications; á - for automobiles ÓÀÇ-3303, ÓÀÇ-3741, ÓÀÇ-3909, ÓÀÇ-33036, ÓÀÇ-39094, ÓÀÇ-39095 and their modifications; 2 -chassis number; 3 -body (cab) number; 4 -nameplate; I -international code of manufacturer; II -descriptive part (automobile model, make); III -indicating part (year of automobile manufacture and serial number of automobile) Fig. 10.
SPECIFICATIONS Models of Automobiles ÓÀÇ Description 1 3741, 37419, 3962, 39629, 3909, 39099 2206, 22069 3303, 33039 33036 39094 39095 2 3 4 5 6 7 8 9 1150 1170 700 950 9 6 GENERAL DATA (Overall dimensions of automobiles are given in Fig. 1 - 8) Automobile type two-axle all-wheel drive cross-country vehicle (4x4 wheel arrangement) Max.
1 Vehicle total weight distribution, kg: 2 3 4 5 6 7 8 9 front axle 1290 1235 1380 1330 1220 1420 1420 1420 rear axle 1430 1265 1440 1450 1430 1630 1630 1630 Gross weight, kg: 1720 1825 1820 1855 1650 1750 1900 1880 front axle 1000 1035 1060 1025 1000 1090 1130 1180 rear axle 720 790 760 830 650 660 770 700 Gross weight distribution, kg: Total tow weight, kg, not more: 17 with brakes 1500 without brakes 750 Minimum turning radius by track of front
Models of Automobiles ÓÀÇ Description 3741, 3962, 3909, 2206 Maximum speed, km/h 110 37419, 39629, 39099, 22069 117 1) 3303 33039 33036, 39094, 39095 100 110 105 Models of Automobiles ÓÀÇ Description 1 3741, 3962, 3909, 2206, 3303 37419, 39629, 39099, 22069, 33039, 33036 39094, 39095 2 3 18 ENGINE Model 4178 Cylinder number Cylinder order Firing order Cylinder bore, mm Piston stroke, mm Displacement, l Compression ratio Nominal power at crankshaft speed of 66 s-1 (4000 min-1) kW (hp): t
1 gross to SAEj 816b net to ÃÎÑÒ 14846 Maximum torque at 36-42 s-1 (2200-2500 min-1), Nm (kgfm): to DIN 70020 gross to SAEj 816b net to ÃÎÑÒ 14846 Minimum low idle speed of crankshaft, s-1, (min-1) Lubrication system Crankcase ventilation Fuel system 2 3 68.4 (93) 55.9 (76) 73.5 (100) 61.8 (84) 164.8 (16.8) 174.6 (17.8) 159.8 (16.3) 193 (19.7) 201 (20.5) 189 (19.3) 11.6-12.
1 2 3 gear ratios: high range low range 1.00 1.94 Front and rear driving axles front axle steering knuckle joints Final drive - spiral bevel gearing; gear ratio 4.
1 2 3 CONTROL SYSTEMS Steering arrangement: type of steering mechanism mean gear ratio Brakes: service parking Hourglass worm with double roller 20.
1 Cooling fluid density at 20 °Ñ, g/cm3: ÎÆ-40 "Ëåíà" ÎÆ-65 "Ëåíà" 2 3 1.075-1.085 1.085-1.100 Spark plug gap, mm 0.85+0.15 Cooling fluid temperature in cooling system, °Ñ 80-90 Free travel of clutch pedal, mm 35-55 Free travel of brake pedal, mm 5-14 Front wheel toe-in, mm 1.5-3.
FILLING CAPACITIES, l Models of Automobiles ÓÀÇ Description Fuel tanks: main auxiliary Engine cooling system (heater including) 3741, 37419, 3303, 33039, 3962, 39629, 3909, 39094 33036, 39095 39099, 2206, 22069 56 30 1) 13.2-13.4 56 56 1) 13.2-13.4 23 Engine lubrication system (without oil radiator reservoir) 5.8 Gearbox 1.0 Transfer box 0.7 Front and rear axle housing(each) 0.85 Steering gear case 0.25 Shock absorbers (each) 0.
CONTROLS AND EQUIPMENT OF DRIVER'S AND PASSENGER'S SEATS Arrangement of the controls is illustrated in Fig. 11: 1 - instrument panel; 2 -turn indicator switch lever: the switch lever is automatically returned into the neutral position when the steering wheel is rotated in the reverse direction (when the automobile recovers from a turn); 3 -horn; 4 -steering wheel; 5 - sun visor; 6 - dome lamp; 7 - grab handle; 8 - ash tray; 9 - door handle; 10 - gearshift lever (Fig.12); 11 - front axle control lever (Fig.
intermediate - neutral; backward - low range is ON; 13 - radiator shutter control handle; 14 - throttle valve control knob; (can be fixed by turning through 90° in any direction); 15 - battery switch; 16 - choke valve control knob (can be fixed by turning through 90° in any direction); 171)- fuel tank cock handle has three positions: turned to the right - auxiliary (right-hand) fuel tank is cut in; turned forward - the cock is closed; turned to the left - the main (left-hand) fuel tank is cut in; 18 - heate
wiper is switched on by rotating the switch knob and the windshield washer is switched on by depressing the switch knob axially; 6 2) - fog lamp switch; 7 -rear fog lamp switch with integrated warning lamp; 8 - heater fan electric motor switch; 9 - ash tray; 10 2) - cigarette lighter; 11 3) - fuel level gauge selector switch; 12 - emergency flasher warning system knob; 13 - access cover to the reservoir to the clutch hydraulic system; 14 - ammeter; 15 - turn indicator warning lamp (green); 16 hydraulic brak
Fig. 15.
3. Do not exceed the following speed limits: in direct gear .......................... 45-50 km/h; in the third gear ...................... 30 km/h; in the second gear .................. 20 km/h; in the first gear ....................... 12 km/h. 4. Do not change oils filled in the engine and units at the manufacturing plant. 5. Check the temperature of brake drums and in case of raising the temperature, adjust them in compliance with the instructions laid down in the section "Brakes". 6.
1. Close the radiator shutter and mount the radiator shell warmth-keeping cover. 2. Using the starting handle, turn over the engine crankshaft for 3-5 times. 3. Pull the choke control knob all the way out (preliminary, the throttle valve control pedal should be pressed). Carry out the subsequent operations in the order specified for starting the engine at temperatures of 0 °Ñ and above. After the engine is warmed up, push the choke control knob all the way in.
much fuel when overcoming almost impassable sections of roads. We recommend to shift in the second gear for starting the automobile away from rest on level sections of roads or on downgrades. In other cases, shift in the first gear for starting away from rest. Disengage the clutch when shifting in gears. Move the gearshift lever smoothly and without jerks.
up without engaging the transfer box to a low range and by shifting the gearbox in the second or third gears depending on an up-hill gradient. If for some reason, it is impossible to overcome an up-grade, take all precautions and descend slowly by shifting in the reverse gear. Descend little by little, do not speed up the automobile and do not disengage the clutch. When overcoming steep down-grades, take measures to ensure the safety of descending.
could overcome a ford of a 500 m depth with a hard bottom at a low speed. Before overcoming a ford, check the bottom, make sure that there are no deep pits, big stones, swampy grounds, check the ground where the automobile would enter water and go out of water. Cut the radiator shutter if it is available. Overcome a ford slowly, do not make water surface choppy in front of the automobile, shift the gearbox in the first or second gears, engage the front axle and engage the transfer box to a low range.
DAILY MAINTENANCE 1. Visually check the automobile for completeness of sets, check the body, glasses, rear view mirrors, licence plates, body coating, door locks, frame, springs, shock absorbers, wheels and tyres for proper condition. Eliminate detected faults. Inspect the automobile to make sure there are no fuel, coolant, oil and brake fluid leaks. To this end, inspect the parking place. Eliminate detected faults. 2. Fill up to normal coolant, oil, fuel and brake fluid. 3.
4. Switch on the windshield wiper for 15-20 min; the blades should be swung out of the way. Before the Winter Season of Operation 1. Disconnect the air hose from the air cleaner union and set the manifold heat control valve in the "winter" position. 2. Wash the fuel tanks and fuel filters. 3. Check coolant specific gravity in the engine cooling system, and if required, fill up to normal. 4.
Fig. 16. Engine (l.h. view): 1 -fine fuel filter; 2 -oil filler cap ; 3 - oil dipstick; 4 -rocker arm cover; 5 -cylinder head; 6 -ignition-distributor; 7 -starter; 8 -clutch housing; 9 -clutch housing (lower part); 10 fuel pump; 11 -engine mounting bracket Fig. 17. Engine (r.h.
Fig. 18. Engine mounting: 1 -protective cover; 2 -washer; 3 -upper pad; 4 -seat; 5 -lower pad; 6 -distance sleeve; 7 -washer; 8 -bolt Fig. 19. Sequence of tightening cylinder head nuts Fig. 20.
Fig. 21. Adjusting clearance between rocker arm and valve: 1 -valve spring retainer; 2 valve; 3 -rocker; 4 -adjusting screw; 5 -locknut screwdriver, tighten the locknut and check the clearance for correct setting; - having adjusted the clearances of one cylinder, turn the crankshaft through half a turn and adjust the clearances on other cylinders (3, 5, 7, 8). The valve-to-rocker clearances on a cold engine (15-20 °C) for the exhaust valves of No.1 and No.4 cylinders (valves 1 and 8) should be equal to 0.
Fig. 22. Engine lubrication diagram: 1-oil pump; 2 -oil sump drain plug; 3 -oil intake strainer; 4-pressure relief valve; 5 -low oil pressure warning lamp transmitter; 6 -oil pressure gauge transmitter; 7 -oil cooler cock; 8 -oil cooler; 9 -full-flow oil filter the filter through 3/4 of turn. Make sure, that there is no leakage of oil.
Immediately stop running the engine if some faults in the engine lubrication system are detected. Maintenance of the Crankcase Ventilation System For flushing and cleaning, remove the vacuum regulator from the engine and disassemble it. Clean the pipelines (Fig. 23), the calibrated orifice "b" (Fig. 24) and flush the parts of the vacuum regulator. Check tightness between the case and cover plate when assembling the vacuum regulator. Maintenance of the Fuel System Fuel tanks.
Fig. 25. Fuel filter-settler: 1 -cover; 2 -pipe unions; 3, 7, 12 -gasket; 4 -bolt; 5 -bracket; 6 -settler body; 8 -drain plug; 9, 13 -washer; 10 -spring; 11 -filter element 2 and bolts 4. Do not disassemble the filter element. After washing, blow out the filter element with compressed air at a pressure not in excess of 98 kPa (1kgf/cm2). Fuel pump. Periodically check the fuel pump through the inspection hole "a" (Fig. 26) for leakage of fuel. Leakage of fuel indicates, that the diaphragm is faulty.
Fig. 26. Fuel pumps of Á9Â type*: à -inspection hole 1 - casing; 2 - pull rod; 3 - seal; 4 - washer; 5, 14 -springs; 6 - diaphragm; 7 discharge valve; 8 - gauze strainer; 9 - gasket; 10 - cover; 11 - screw; 12 - exhaust valve; 13 -upper casing; 15 - rocker arm; 16 - camshaft eccentric; 17 - rocker arm shaft; 18 - hand primer lever shaft; 19 - hand primer lever * The pumps 2105-1106010-50 or 900-1106010 could be also installed Fig. 27.
Fig. 28. Carburettor (fragment): 1 -idle speed adjustment screw; 2 -idle mixture adjustment screw warmed up. The screw 2 is used for adjusting the CO content. After adjustment done, place on the adjustment screw a new cap, that the content of mixture could be only leaning (by screwing in the cap). It is recommended to adjust the screw 2 only by special tools for analysing of exhaust gases. Air cleaner.
element, every 100 000 km of run, after maximum permissible procedures of cleaning. Flush the gauze 4 of the flame trap with one of the dissolvents: kerosene, turpentine, white spirit. Inlet manifold. During seasonal maintenance, set the manifold heat-control valve (Fig. 30) to the position corresponding to the coming season of the year. Accelerator pedal. While in service, it may become necessary to adjust the carburettor throttle full opening and readjust the accelerator pedal position.
tighten up the locknut, connect the spring. The adjustment is over, if the throttle is fully closed with the pedal released, and the throttle is fully open with the pedal pressed all the way down. If required, lubricate the cables of the throttle and choke manual control with grease. To do that, remove them from the automobile and remove the old grease. Maintenance of the Engine Cooling System The engine cooling system (Fig. 32) is filled with coolant simultaneously with the heating system.
Bear in the mind that antifreeze is poisonous. The coolant level should be 30-40 mm above the MIN level mark inscribed on the expansion tank. Never mix the coolants of different grades. If the level of special fluid in the system has dropped and fluid of the same grade is not available, top up the system with clean soft rainy, snow or boiled water. Bear in mind that the freezing point of the antifreeze diluted with water is higher.
Adjust deflection of the fan belt (Fig. 33) by turning the alternator. Normal deflection of the belt equals 8-14 mm with an effort of 4 kgf (39 N) applied to it. When using water as a coolant, periodically remove from the cooling system scale and dirt by flushing them with a fast jet of clean water. Flush the engine separately from the radiator so that rust, scale and sediment from the engine cooling jacket do not clog the radiator (Fig. 34). Prior to flushing the engine, remove the thermostat.
Maintenance of the Ignition System (Fig. 35) If the transistor switch or the coil of the magnetic pulse distributor stator failed en route, change over to operation with the emergency vibrator for which purpose, disconnect the wire from the terminal K3 of the transistor switch and connect it to the terminal of the emergency vibrator. Service life of the emergency vibrator is limited to 30 h, therefore switch it into operation only in emergency cases and replace a faulty unit at the first opportunity.
After restoring the contactless ignition system (replacing of the magnetic pulse distributor or transistor switch), restore the previous connections of the carburettor. Maintenance of the system consists in setting the ignition timing, regularly cleaning the rotor and cover of the magnetic pulse distributor, high-voltage part of the ignition coil and spark plugs, in timely lubricating the magnetic pulse distributor and checking spark gap. Check spark plug gap with a feeler gauge (Fig. 37).
Fig. 38. Adjusting octane selector setting the red mark on the rotor is aligned with the index pointer on the stator. Using the bolt, secure the octane selector plate to the distributor body. 7. Reinstall the cap of the magnetic pickup and distributor unit and check to see that the ignition wires running to the spark plugs are set correctly in compliance with the engine firing order (1-2-4-3), counting counterclockwise.
Forbided to keep the ignition on when the engine is not operating, and to disconnect the storage battery when the engine is operating TRANSMISSION Maintenance of the Clutch The automobile is equipped with a dry single-plate clutch (Fig. 39) provided with the pressure plate 4 with the cover plate 20, pressure springs 19 and release levers 11 in assy, driven disk 3 with linings and torsional vibration damper in assy.
A grease cup for the clutch release bearing indentifies visually the clutch type. The clutch with the pressure springs and release levers is provided with the grease cup to be found on the righthand side of the engine (in motion). The clutch with the central diaphragm pressure spring is not provided with a grease cup. Maintenance of the clutch consists in cleaning of dirt, tightening the bolt joints, adjusting and lubricating the clutch release bearing.
Fig. 41. Gearbox plugs: 1 -filler hole plug; 2 -drain hole plug Fig. 40. Clutch control linkage with pressure springs and release levers: a - fluid level 1 -reservoir; 2 -master cylinder; 3, 4 pipelines; 5 -pedal; 6 -hydraulic hose; 7 -protective cap; 8 -by-pass valve; 9 slave cylinder; 10 -locknut; 11 -spring (is not installed to couple with centre diaphragm pressure spring); 12 -pushrod; 13 -fork; 14 -coupling Fig. 42.
against the spring of the reverse gear interlock. Loosen all the nuts intended for regulating the length of rods. Set the gearshift lever 9 in the middle position between gears III and IV. In this position, connect and secure selector rods 8 and 14 taking care to avoid pulling on the levers or rods. This done, set the gearshift lever 1 in the neutral position between gears III and IV, and connect the shift rods 5 and 11. Upon adjustment, check to see whether the gears are properly shifted in.
Maintenance of the Propeller Shafts Periodically check tightening of the bolts attaching the propeller shaft flanges, periodically lubricate them, clean the propeller shafts of dirt. Lubricate the splined joint through the grease fitting 1 (Fig. 44) screwed in the slip yoke, and the needle bearings are lubricated through the grease fittings 2 on the centre cross. Lubricate the needle bearings until grease is shows up from under the working edges of the centre cross seals.
Fig. 45. Rear axle: 1 -safety valve; 2 -filler hole plug; 3 -drain hole plug Maintenance of the Front Axle All the directions on maintenance of the rear axle are valid for the front axle. Maintenance of the steering knuckles should be carried out additionally. Lubricate the steering knuckle kingpins through the grease fitting 10 (Fig. 46) according to directions of Lubrication Table.
Fig. 46. Steering knuckle: I -r.h. steering knuckle; II -l.h.
CHASSIS Towing Hook The towing hook is intended for towing a trailer or an automobile by means of flexible coupling, and also it allows a short-time operation by means of rigid coupling. Towing of a trailer on a broken ground is not allowed. The hook is provided with a catch 3 (Fig. 47) which closes the mouth of hook and is locked in the closed position by means of the pawl under the action of the spring. The pawl in the catch is closed by a cotter 4 to avoid spontaneous uncoupling.
When installing the springs, carry out the last tightening of the U-bolt nut on the automobile standing on the wheels. Maintenance of the shock absorbers consists in periodically checking them for tightness and reliable fastening, as well as in changing the fluid in compliance with the instructions laid down in Lubrication Table. If leakage of fluid through the rod seal and the reservoir sealing rings is detected, tighten nut 18 (Fig. 49).
Fig. 48. Front suspension: 1 -spring front hanger; 2 -frame; 3 -spring; 4 -cover plate; 5 -buffer; 6 -buffer liner; 7 -shock absorber; 8 -shock absorber bracket; 9 -spring rear hanger; 10 -rubber pad; 11 -bracket cover; 12 -shock absorber pin; 13 -rubber bushings; 14 -U-bolt liner; 15 -contracting bolt; 16 -Ubolt; 17 -yokes Note. Rear suspension design is the same Fig. 49.
Fig. 50. Spare wheel attachment: À - automobiles ÓÀÇ-3741, ÓÀÇ-3962, ÓÀÇ-3909, ÓÀÇ-2206, ÓÀÇ-33036, ÓÀÇ-39094, ÓÀÇ-39095; Á - automobile ÓÀÇ-3303; 1 -spare wheel; 2 -sector; 3 -carrier; 4 -nut; 5 -bolt; 6 -washer; 7 -bracket Fig. 51. Wheel toe-in Fig. 52. Steering rod end : 1 -locknut with l.h. thread; 2 -adjusting sleeve; 3 -locknut with r.h.
When rotating the cross-ply tyres, introduce the spare wheel tyre into the rotation if its wear does not differ from wear of the other tyres (Fig. 53). When rotating the radial-ply tyres, rotate the front and rear wheel tyres separate for each side. Do not introduce the spare wheel tyre. Fig. 53. Tyre rotation diagram Wheel Hubs The hubs of all the automobile wheels are the same.
Fig. 54. Rear wheel hub: 1 -hub; 2 -bearing; 3 -gasket; 4 journal; 5 -axle shaft; 6 -locknut; 7 -lock washer; 8 -collar; 9 -wheel disk; 10 - brake drum 5. Rotate the wheel by hand to check it for easy turning (the wheel should rotate freely without rubbing of the brake drum against the brake shoes. 6. Tighten the adjusting nut of the hub bearings with the aid of a wrench applying a hand effort to the wrench tommy bar 300350 mm long until the wheel is rotated with difficulty (Fig. 55).
nut, bend the second tab round the flat of the locknut. (Fig. 56). 10. Reinstall the axle shaft of the rear axle or driving flange and front axle wheel disengaging coupling, install the spring washers and tighten the bolts. After a run, check the wheel hub for correct bearing adjustment by its heating. If the hub overheats, back off the nut 1/6 of a turn (1 flat), observing the above sequence and rules.
If radial play in the joint of the tie-rod tip is detected, turn off the plug 1 against the stop (Fig. 57), and then unscrew it by half-turn and in this position turn off it. If radial play is not eliminated, replace the tie-rod tip. Periodically check the steering wheel play. The steering mechanism is considered to be in serviceable condition and needs no adjustment if the steering wheel play with the wheels set in a straight-ahead position is not over 10° under a force of 7.35 N (0.
With the steering mechanism removed, adjust the tightening of the worm bearings by means of the shims 4 (Fig. 59) installed between the steering gear case and the case lower cover. When the worm bearings are tightened correctly the force required for turning the steering wheel (without the steering arm shaft) should be in a range of 2.2-4.4 N (0.22-0.45 kgf).
Brake Systems Maintenance of the Service Brakes Periodically check the fluid level in the brake master cylinder reservoirs 16 (Fig. 60) and top up if required. The level should be 15-20 mm below the filling hole upper edges. Make sure of the hydraulic brake system tightness. Check the pipelines for condition and reliable attachment to the frame and rear axle. Do not operate the automobile when the pipes and hoses are faulty.
Periodically remove the brake drums and clean the brake parts of dirt. Periodicity of this operation depends on service conditions of the automobile. In the summer season and when driving on mud-covered roads, carry out cleaning more frequently. Keep a close watch on the brake system serviceability, timely perform its adjustment and eliminate detected faults.
Fig. 61.
Fig. 62. Rear wheel brake: 1 -anchor pin; 2 -brake backing plate; 3 -adjusting eccentric; 4 -eccentric bolt head; 5 -wheel cylinder; 6 -bleede valve; 7,13 -brake front shoes; 8 -boot; 9 -piston; 10 -sealing rings; 11 -piston spring; 12 -return spring Fill the brake hydraulic system in the following sequence: 1. Check all the connections of the brake hydraulic system for leaks and the flexible hoses for proper condition. 2.
cylinder seeing to it that they are never empty in order to prevent penetration of air into the system again. During the whole operation, keep the free end of the hose dipped in fluid. If neither fluid nor air escape from the hose, the hose is clogged or the valve is closed. 5. With the brake pedal pressed down, tightly screw in the by-pass valve of the wheel brake cylinder, remove the hose and put the cap on the valve. 6. Bleed the remaining brake cylinders in the following sequence: first the rear r.h.
years for proper functioning of the brakes. When changing fluid, fill up the system until fresh fluid will escape from the hose. Maintenance of the Parking Brake Maintenance of the parking brake comes to periodic checking the parking brake mechanism and its control linkage for proper condition and for reliable fastening, cleaning of dirt, adjusting, lubricating the expander and adjuster and eliminating defects, if required.
Fig. 64.
ELECTRICAL EQUIPMENT See wiring diagrams of automobiles in Appendix 4. Maintenance of the Alternator The automobiles could be provided with the alternator with a built-in rectifier operating in conjunction with a voltage regulator. The automobiles could be equipped with alternators of two types: - 665.3701-01 or 161.3771 - with brush assembly; - Ã700À.30 or 957.3701-10 - without brushes. Check the alternator function in accordance with ammeter reading.
Periodically clean vent holes in plugs, check the electrolyte level and, if required, add distilled water. Check the electrolyte level in each battery cell on a cold battery and if necessary, add distilled water up to the lower end of the filler hole tube. Before operation, depending on the climatic condition under which the automobile is to be employed, correct the electrolyte specific gravity.
waste and blow out. Check the starter drive, its pinion, lever and spring. Clean of dirt frictioning parts, wash out and wipe them dry, if required, lubricate with grease "Ëèòîë-24". Check axial play of the rotor shaft which should be not more than 1.0 mm. If required, tighten up bolts of the starter frame. The starter drive is to be freely shifted along the shaft splines and returned to its initial position by means of the return spring.
Perform aiming of the headlamps in the following sequence: 1. Place ready for road automobile with a driver's seat load of 75 kg. on a level ground. Errect the aiming screen in front of the automobile at a distance of 5 m. Remove the rims. 2. Switch on the headlamp and by operating the foot switch be sure that the lower and upper beams are lighting up simultaneously. 3. Turn on the lower beam and cover one headlamp. Adjust the beam by turning the screws 6 (Fig.
Fig. 67. Aiming screen for fog headlamp adjustment: H - distance from center of headlamps to ground level L - distance between centers of fog headlamps Adjust the horn in a workshop. Turn indicators. The turn indicators are switched on manually by means of the switch and switched off automatically. Maintenance of the turn indicators comes to insuring a clearance of 2-2.5 mm between the rubber roller of the switch and the hub of the steering wheel with the switch lever set in the neutral position.
Fig. 68. Fuse unit: 1 -fuse unit body; 2 -fuse link; 3 -body cover; 4 fuse link filament; 5 reserve filament ter, oil pressure gauge, engine coolant gauge and fuel level gauge. The gauges operate in conjunction with transmitters. The automobile is provided with the automobile emergency condition warning flashers (all the turn indicators flush simultaneously).
SPECIAL TOOLS AND APPLIANCES New automobiles delivered from the manufacturing plant are provided with a set of tools and appliances. Use this set for maintenance and simple repair of the automobile en route.For convenience of storage, there are two tool bags in the automobile: a big and a small one. Use a plunger grease gun (Fig. 69) for lubricating the automobile assemblies provided with nipples.
The jack (Fig. 70) is designed to jack up the automobile wheels for maintenance. The jack load-lifting capacity is 2 t. The maximum height of lifting is 240 mm. For jacking up the wheel, proceed as follows: 1. Install the jack on a level ground under the axle shaft sleeve. 2. Turn out the jack internal screw 3 as high as the clearance between the axle shaft sleeve and the ground permits. 3. Throw over the jack latch 5 to the l.h.
BODY(CAB) The body of the automobile ÓÀÇ-3962 is provided with the partition complete with sliding glasses. The ambulance compartment is equipped with hinged seats, brackets and straps for attachment of a stretcher, grab handles in door apertures and on the roof, and curtains for the windows of the body side panels, doors and partition. The passenger/cargo compartment of the automobiles ÓÀÇ39625 is equipped with three folding double seats, one unfolding single seat and a demountable folding table.
Body (Cab) Ventilation The cab is ventilated through the air vent in the middle part of the cowl and the heater box shutters, and also through the swivelling quarter-lights and drop windows of the cab doors. To make the cab ventilation more effective, make use of the heater fan, but for that shut off the cock on the cylinder head.
When starting the cold engine in the winter, shut off the cock on the cylinder head. Open the cock only when the engine is warmed up. The sanitaty and passenger compartments are heated by an independent heater (Fig. 72), which is operated similar to the cab heater. The fresh air is sucked in through the heater radiator fan and passes into the rear compartment. The heater selector switch is located in the driver's cab on the r.h. side of the partition.
Fig. 73. Location of sanitary equipment: 1 -hinged double seats; 2 -stretcher; 3 -rails; 4 suspension straps; 5 -bag; 6 -reservoir for drinking water; 7 -hinged single seat; 8 -stretcher guide; 9 -box For installing and fastening an unified stretcher in the sanitary compartment each of the side panels is provided with four hinged brackets, the ceiling is provided with holders and the body floor is provided with clips for attachment of suspension straps.
FIRST ACCOMMODATION: On hinged seat ........................................... 1 person In driver's cab ............................................ 1 person On stretchers ............................................. 4 persons SECOND ACCOMMODATION On stretchers on the left ............................ 2 persons On hinged seats ......................................... 3 persons In driver's cab ............................................ 1 person THIRD ACCOMMODATION On stretchers on the right ............
Fig. 74. Fitting suspension strap in place Fig. 75. Fastening stretcher handle in strap When carrying patients, be carefull, start away from rest smoothly and avoid abrupt braking. Windshield Wiper and Windshield Washer For convenience, when washing the windshield, the bladeand-lever assemblies could be swung out of the way. For increasing the service life of the windshield wiper and its blades, the operation of the blades on dry glass is not recommended.
Fig. 76. Electric washer: 1 -pump body complete with electric motor; 2 -ground wire; 3 -wire "+"; 4 reservoir; 5 -combined switch; 6 -cover; 7, 9 -hoses; 8 -tee-piece; 10 -jet; 11 jet ball; 12 -gasket; 13 -clamp it to drop below a value of 20 mm above the reservoir bottom in order to avoid failure of the washer pump. Never keep the washer switched on in excess of 10 s. Maintenance of the Body To take care of external appearance of the automobile, maintain regularly the varnish coating of the body.
Straighten minor surface irregularities, if required, clean of dirt, grind and paint. If damage of the body (cab) is considerable, prime, dry and paint the surface. During service of the automobile, periodically treat the body surfaces, especially enclosed spaces, with corrosion-preventive compounds, as "Mobil", "Tectil" etc. If required, recovery the body floor coated with bituminous cement by spreading it by means of a special spray or brush.
1. Change oil from the engine and transmission when the units are hot. 2. Remove dirt from the grease fittings and plugs. 3. Upon lubrication, remove the squeezed out or leaked lubricant from all parts. 4. Before filling the transmission case, transfer box, the housings of the front and rear axles with fresh oil, wash them, if the waste oil drained from the mentioned units is contaminated or metal particles are detected in it. 5.
8. Seal the external cab glasses with light-tight paper (cloth) or shut with shields. 9. Remove the wheels for automobile, clean the wheel disks of dirt and touch up the areas with damaged paint. Clean, wash and wipe dry the tyres, and bring the tyre inflation pressure to normal. 10. If required, flush out the fuel tanks and fill them with fuel. 11. Prepare the battery for storage as is specified in the maintenance manual of lead-acid batteries. 12.
3. Clean and paint corroded areas, if any are detected. 4. Rotate the steering wheel from lock-to-lock position for 2-3 times. 5. Check the service and parking brakes, clutch, choke and throttle valves, manual and foot-operated linkages of the throttle valve, headlamp switches for proper functioning. 6. Check the level of working fluid in the reservoirs of the brake master cylinder and the hydraulic clutch master cylinder, and, if required, top up to normal. 7.
LUBRICATING MATERIALS AND SPECIAL FLUIDS Description of fluid or grease SAE equivalents Motor Oils Ì6Ç/12Ã1 SAE 15W-40 Ì-5Ç/10Ã1 SAE 10W-30 Ì-6Ç/10Â SAE 10W-40 Transmission Oils ÒÑï-15Ê SAE 90 ÒÑï-10 SAE 75W Lubricant Greases Grease Ëèòîë-24 Lithium grease to NLGJ ¹3 Graphite powder Barbatia Grease 2 Fluids Shock absorber fluid ÀÆ-12Ò, Spindle oil ÀÓ Shock absorber oil, Shell Donax A Brake fluid "Òîìü", "Ðîñà" "Ðîñà-3", "Ðîñà Äîò-4" SAE 1703F, DOT-4 Cooling fluid ÒÎÑÎË-À40Ì Shell safe
Fig. 77.
LUBRICATION TABLE Ref. Nos.in Fig.77 1 Description of units Number of lubric. points Lubricant or fluid Lubrication intervals Lubrication instructions 2 3 4 5 6 Motor Oils Engine crankcase 1 10. Engine oil filter 1 23. Distributor rotor bush 1 94 25.
1 2 3 4 5 6 Transmission Oils 13. Gearbox case 1 14. Transfer box case 1 17. Front and rear axle final drive housings 2 1. Steering gear housing 1 20. Front and rear propeller shaft splines 2 19. Front and rear propeller shaft joints 4 5. Cooling system pump bearings 1 - Heater motor bearings ÒÑï-15Ê or ÒÀÏ - 15Â, ÒÀÄ-17È, ÒÑï-10 - only in cold season (from 1.10 to1.
1 2 3 4. Gearbox control linkage 3 7. Steering rod joints 4 4 5 6 Lubricate through grease fittings Grease "Ëèòîë-24" Grease "Ëèòà" Lubricate through grease fitting until it shows up from under upper seal washers Grease "Ëèòîë-24ÐÊ" 96 8. Steering knuckle joints 2 Wash joints and pack 500 g of grease 9. Steering knuckle kingpins 2 11. Clutch release bearing 1 Pack grease cup to capacity 15. Parking brake expander and adjuster mechanisms 2 Clean of dirt before lubricating 16.
1 12. 2 3 4 Grease "Ëèòîë-24" 5 6 Gearbox input shaft front bearing 1 22. Parking brake cable 1 Clean of dirt before lubricating 24. Storage battery terminals 2 Protect terminals against acid 97 - Door hinges - Door lock tongues, sockets and latches, hinges of door checks 2.
1 18. 2 Front and rear springs 3 4 4 5 6 Graphite grease ÓÑÑà Lubricate as required, when creaking Lubricate rubber surfaces of spring leaves Graphite powder Every 16000 km of run Wipe - Rubber weatherstrips and door tongues 3. Brake master cylinder 2 27. Clutch release master cylinder 1 "Òîìü", "Ðîñà Äîò-4" 21. Front and rear shock absorbers 4 Shock absorber fluid ÀÆ-12Ò, spindle oil ÀÓ, oil for hydraulic shock absorbers ÌÃÏ-10 As required and when disassembling 6.
TRANSPORTATION The automobiles are transported depending on the user location: by water, railway or air transport. The transportation of the automobiles without assistance (on the move) is allowed. When transporting the automobiles in the hold or on the desk, and also by air transport make them fast in accordance with the ship scheme or air transport scheme. Use appliances, which not damage the parts and paint of the automobile.
poured out from the cooling system and the sighboard "Water is poured out" should be hanged, the storage battery should be cut off by means of the ground switch. To protect the automobile from axial and side shiftings attach it with four tension wires of steel wire (dia. 6 mm) with double thread each, and also with wooden wedges 300x160x80 nailed to the floor under wheeles. Attach the tension wires to the towing hooks on the frame ahead, and to the towing gear-in rear part of the automobile.
Appendix 1 LAMPS EMPLOYED ON AUTOMOBILES Lamps Headlamps: upper and lower beam Type Power, W 12-45õ40 ÀÊÃ12-60+55-1(H4) 45õ40 or 60õ55 Swivelling lights* A12-50x40 50x40 Front lamps: clearance light turn indicators À12-5 À12-21-3 5 21 Rear lights: turn indicators clearance light stop-light À12-21-3 À-12-5 À-12-21-3 21 5 21 Turn indicator repeaters** Backing lamp À12-5 5 À12-21-3 21 License plate lamp À12-10 10 Special mark lamp Cab lamp Rear fog lamp A12-10 A12-10 À12-21-3 10 10 21
Appendix 2 TORQUES FOR MAIN THREADED CONNECTIONS, kgfm Stud nuts attaching cylinder block heads to cylinder block 9.0-9.4 Connecting rod bolt nuts 6.8-7.5 Crankshaft main bearing cap attachment nuts Bolt nuts attaching flywheel to crankshaft 12.5-13.6 7.6-8.3 Bolt nuts attaching flanges to propeller shaft 3.2-4.0 Nuts attaching flange to axle pinion 16-22 Bolts attaching final drive gear to differential case 10-14 Spring U-bolt nuts 9.0-10 Wheel attaching nuts 10.
Appendix 3 MAIN METERING JETS OF CARBURETTORS Ê-151Â AND Ê-151Å Jets 1st chamber 2nd chamber Main fuel jet 225±3 cm3/min 330±4.5 cm3/min (230±3 cm3/min) Main air jet 330±4.5 cm3/min 230±3 cm3/min Assembly of idling fuel jets: idling tube emulsion tube Second idling air jet Idling emulsion jet 95±1.5 cm3/min (110±1.5 cm3/min) 85±1.5 cm3/min 330±4.5 cm3/min (175±2.5 cm3/min) 280±3.5 cm3/min (175±2.5 cm3/min) Transfer fuel jet 150±2.0 cm3/min (200±2.5 cm3/min) Transfer air jet 270±3.
CONTENTS Important ....................................................................................................... 3 Safety instructions ..................................................................................... 3 Precautions ................................................................................................ 3 Introduction ................................................................................................... 5 Automobile marking ..................................
Special tools and appliances .......................................................................... 79 Body(cab) ...................................................................................................... 81 Body (cab) ventilation .............................................................................. 82 Body (cab) heating ................................................................................... 82 Sanitary equipment of the automobile ÓÀÇ-3962 ................................
FOR NOTES
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