JSC Peterburgsky Traktorny Zavod KIROVETS K-744R2, Operation Manual

Page 1: ...ERATION MANUAL 744R 0000010 IE KIROVETS tractors K 744R1 K 744R2 K 744R3 K 744R4 JSC Peterburgsky Traktorny Zavod Kirovsky Zavod OJSC 47 Stachek prospect St Petersburg 198097 Russia www kirovets ptz c...

Page 2: ...the design which are not reflected herein ABBREVIATIONS GB gearbox PW paintwork paint and lacquer coating PTO power take off ET electric torch PDR pump drive reducer SPTA spare parts tools and access...

Page 3: ...spring summer or autumn winter oper ation conditions Maintenance in special operation conditions sandy stony or boggy soils desert low temperature and high mountain conditions It shall be performed i...

Page 4: ...ALARMS 78 4 10 ENGINE PREPARATION AND START UP 79 4 11 ENGINE START UP AT NEGATIVE TEMPERATURES 80 4 11 1 Safety measures when using the heater 81 4 11 2 Heater operation 82 4 12 ENGINE START UP FROM...

Page 5: ...intenance of driving axles service brakes 156 7 5 7 Cardan shaft maintenance 158 7 5 8 Maintenance of tractor pneumatic system 158 7 5 9 Maintenance of hydraulic systems of the linkage and for steerin...

Page 6: ...RS202 APPENDIX 9C LIST OF ELECTRICAL EQUIPMENT ELEMENTS FOR THE ELECTRICAL DIAGRAM OF K 744R2 K 744R3 K 744R4 PREMIUM TRACTORS 208 APPENDIX 10 Electrical connection diagram for K 744R1 Standard tracto...

Page 7: ...tractor having faulty devices IT IS PROHIBITED to use parking brake during motion IT IS PROHIBITED to tow the tractor by suspension unit IT IS PROHIBITED to fill the engine cooling system and heating...

Page 8: ...he engine with unsealed air feed channels from the air clean er to the engine and dust suction channels from the air cleaner IT IS ABSOLUTELY PROHIBITED to work with clogged or ice covered grill of th...

Page 9: ...e lever avoid sharp turns and moving over obstacles When crossing dams dikes and bridges make sure of the possibility to drive ahead and use only low gears Trenches hillocks and other obstacles shall...

Page 10: ...the hydraulic system engine oil filter parking brake engine fan coupling actuation pressure in the pneumatic sys tem engine error for Mercedes engine marker lights oil pressure in transmission front...

Page 11: ...744R4 tractors 10 horn flasher lamp battery master switch linkage lifting linkage lowering floating position of hydraulic paths to connect hydraulic im plements floating position of linkage service o...

Page 12: ...ors 11 INSTRUCTION PLATES Center of gravity symbol Diagram of connection to quick lock couplings of hy draulic system Control unit handles lowering lifting lowering lifting lifting lifting lowering lo...

Page 13: ...careful during tractor motion across the slope do not perform operations at the speed exceeding 13 4 km h modes I and II avoid sharp turns and driving over obstacles When uncoupling pieces of equipme...

Page 14: ...er stop only position of the gear change lever switching on the syn chroniser brake only when changing over the modes Diagram of hydraulic distributor section control Layout of the pump flow control h...

Page 15: ...their specifications main rules of operation and maintenance The data on engines of models YAMZ 238ND5 YAMZ OJSC 8481 10 TMZ OJSC OM460LA Mercedes Cummins are set forth in the operation manu als whic...

Page 16: ...be completely equipped and serviceable A first aid kit stocked in accordance with effective regulatory docu ments should be installed and fixed in the tractor cabin If needed to use cabin windows as a...

Page 17: ...ervation and preservation of the tractor in a specially equipped room with ob servance of all occupational and industrial safety regulations and fire safety regulations 2 3 SAFETY MEASURES DURING TRAC...

Page 18: ...brake system electrical lighting and alarm signaling All tractor control levers shall admit fixing in the corresponding positions Tractor brakes shall be in good working condition When braking the tr...

Page 19: ...K 744R4 tractors Coupling to and mounting of agricultural machines and implements on the tractor shall be carried out by persons operating such machines Coupling worker who mounts a machine shall stay...

Page 20: ...connecting links located on the lifting nuts of the linkage braces When using the tractor in hauling operations it is necessary to take the following precau tions execute works with the Road train si...

Page 21: ...position when hooking up the tractor with vehicles having 12V equipment it is necessary to replace electrical lamps on the vehicles When driving with a vehicle periodically check brake operability of...

Page 22: ...f the rear axle cardan gear and to re duce the wear of tyres it is necessary to engage the rear axle only in case of tractor operation with agricultural implements and during travel in heavy road cond...

Page 23: ...forth in the corresponding subsection On each type of wheels install a tyre of the proper size only which is determined by the technical specification for such wheel All repair operations related to t...

Page 24: ...can cause a heavy intoxication CAUTION If needed to dismantle the starter cut out the protective bracket welded to the side member at the face end side of the starter 2 5 FIRE SAFETY REQUIREMENTS Ever...

Page 25: ...l and oil In case of occurrence of a fire source it is necessary to do the following switch off the battery master switch de energise the system stop the fuel feed extinguish the center of fire with t...

Page 26: ...ments and vehicles their operation shall be performed according to the instructions issued by the manufacturers of such ma chines List of implements approved for use with K 744 tractors series R Table...

Page 27: ...r 3 Coupler SP 16 16A KPS 4 Cultivator 4 5 The same KPE 3 8 Heavy duty cultivator 3 KSHU 18 Broad catching cultivator 1 Drawbar brace LDG 15 Disc type scuffer 1 The same LDG 20 Scuffer 1 LDS 6 Scuffer...

Page 28: ...lf emptying trailer MMZ 768B 1 Hydraulic pick up hitch OZTP 8572 The same 1 The same 1PTS 9B Semi trailer MMZ 771B 1 OZTP 8573 The same 1 CTA 10 1 PSE 45 Trailer tank 1 PZHU Machine for distribution o...

Page 29: ...of manufacture is glued to the left pocket located at the front console of the cabin The tractor serial number is stamped on the front plane of the bumper in RH corner in the direction of tractor tra...

Page 30: ...t of the gearbox in the area of compressor drive pulley vertically under the lifting eye nut The serial number of the pump drive re ducer is stamped on the casing at the side on the lateral lid The se...

Page 31: ...lled on K 744R1Pr tractors and OM460LA Mercedes en gines are installed on K 744R2Pr K 744R3Pr and K 744R4Pr tractors Engine start up is performed by electrical starter In order to facilitate start up...

Page 32: ...mode change drive and hydraulic gear change without power flow break up within any of the modes It allows to change the tractor speed drive in reverse engage the rear driving axle transmit torque to...

Page 33: ...e hydraulic cylinders which is proportional to the angle of turn and the rotational speed of the steering wheel is performed by the steering mechanism RM 2000 installed on the steering column A pump w...

Page 34: ...le wheels as well as trailer wheels The system provides for simultaneous operation of the brake drives of the front and rear trac tor wheels the energy accumulator drive the parking brake air extracti...

Page 35: ...nation When the brake pedal is pressed air will get through the brake valve into the service brake chambers which via the stem drive the actuators that press the blocks to the brake drums and the trac...

Page 36: ...ure sensor 15 pneumatic switch 16 brake chamber with spring energy accumulator 17 brake chamber of 30 type 18 hose Tractors with pneumatic shift control of gearbox have pressure controller with adsorb...

Page 37: ...dal 5 8 reverse acting brake valve with manual control 6 acceleration valve 7 trailer brake control valve with single wire drive 9 reference outlet valve 10 cut out valve 11 connecting head of type 12...

Page 38: ...supplied to safety valve 11 Cleaned and dehumidified air in cavity forces check valve 6 away gets to cavity and to the pneumatic system vehicle through outlet 21 At the same time compressed air from c...

Page 39: ...ects the said cavities At the same time air from the compressor is supplied directly to the vehicle pneumatic system CAUTION Recommended interval for regeneration holder maintenance ad sorbing envelop...

Page 40: ...1 Regeneration holder 8043 35 12 460 1 8043 35 12 115 cap 2 8043 35 12 122 ring 3 8043 35 12 121 base 4 8043 35 12 139 sleeve 5 8043 35 12 141 sleeve cover 6 8043 35 12 142 mesh 7 8043 35 12072 sprin...

Page 41: ...protected against short circuits by fuse blocks On the tractors there is the possibility of connection to power supply with the voltage of 12 V Plug sockets for the connection are located at the contr...

Page 42: ...tic switch of return to neutral Gate valves of all the sections being in floating position are released from the locking mechanism manually and returned to neutral under the action of spring Layout of...

Page 43: ...1 and two clamps 30 20 8 Installation of free drain and drainage paths The installation of the free drain kit shall be performed as follows dismantle the plug from the union on the hydraulic tank filt...

Page 44: ...5F 1 2 The installation of the drainage kit shall be performed as follows dismantle the plug M16 on the hydraulic tank wall at the cabin side install angle XEWAD12Lz3 on the tank boss connect hose 2SN...

Page 45: ...ure should be 83 85 bar It is necessary to perform the first inspection after the first 10 hours of tractor operation the subsequent inspections shall be carried out once every 6 months or upon tracto...

Page 46: ...2 located at the hydraulics board in the tractor cabin and by remote buttons 1 and 2 fig 4 When MI electronic hydraulic control system has faults the diagnostic alarm device 4 fig 2 informs about the...

Page 47: ...ockwise rotation to position A corresponds to the maximum lift counterclockwise rotation all the way in corre sponds to FLOATING POSITION move handle 2 to the low locked position in order to lower the...

Page 48: ...NCY REASONS TO PREVENT FURTHER LANDING OF AGRICULTURAL IMPLEMENT YOU MUST SET CONTROL HANDLE 2 TO POSITION OFF WHEN THE TRACTOR STARTS MOVING SET THE HANDLE TO POSITION LOWERING AND THE IMPLEMENT WILL...

Page 49: ...fety reasons the remote buttons operate with interruptions When lift up button 1 is pressed and hold lowering buttons 3 the linkage goes up down within 5 seconds and then stops To continue the lifting...

Page 50: ...ex average and simple errors In case of complex errors the adjustment procedure stops and the system goes off The sys tem cannot be operated from the panel or remote buttons Diagnostics indicator gene...

Page 51: ...scription possible cause Fault check method Complex faults 11 Failure in the control circuit of lifting solenoid valve Break in solenoid coil or control harness Disconnect the harness from the and che...

Page 52: ...eck terminals 247 and 222 for short cir cuit 15 Failure of the remote buttons for lowering control Short circuit of wires or stick ing of one of the remote but tons for lowering control Check harnesse...

Page 53: ...adjusted correctly then it shall be lifted and lowered in its utmost positions from the control panel When the linkage after the lifting comes to its uppermost position the lifting indicator shall go...

Page 54: ...is below 8V Battery is low Check the generator output voltage 34 Control panel failed Failure of potentiometer 7 fig 2 of linkage speed control Check connection reliability of control panel and elect...

Page 55: ...meter 3 of position sensor 7 128 activation of SCR4 5 unit starter switch 11 CAN_L 12 CAN_H 15 12V at D of generator 20 12V activation of SCR4 5 unit starter switch 22 Common for remote buttons 26 Low...

Page 56: ...opening it is necessary to hold the hood by the belt in order to avoid jerks in case of wind gusts The inertial mechanism of the belt structure al lows to fix the hood in open position at any an gle...

Page 57: ...it is necessary to re catch the handle and close the hood until the lock operates Safety measures In order to observe safety measures with regard to prevention of inadvertent hood closing stops are p...

Page 58: ...6 213 157 220 162 205 151 213 157 205 151 213 157 205 151 at the operating capacity max 237 174 220 167 237 174 240 177 213 157 230 170 213 157 230 170 213 157 at the maximum capacity on the PTO shaft...

Page 59: ...1 1 with paired wheels 80 0 8 Road clearance with the tyre static radius of 790 mm for K 744R1 830 mm for K 744R2 K 744R3 K 744R4 mm at least under the main gear of the driving axle 520 560 under the...

Page 60: ...h m max 13 Static lateral stability angle degrees min 35 Ascent and descent angle degrees max 18 20 Angle of tractor holding by parking brake degrees min 20 Tractor semi frame turn angle degrees at le...

Page 61: ...4 5 Menu selection buttons 6 Indicator for instrument panel illumination The control is exercised by 4 keys Buttons 4 and 5 in the main window serve for the following arrow UP button 5 illumination o...

Page 62: ...naling on emergency air pressure in the 1st circuit of pneumatic system The lamp lights up at air pressure drop of 4 5 5 5 kgf cm2 Indicator lamp for emergency oil temperature in the hydraulic sys tem...

Page 63: ...blinking and the instrument panel provides an intermittent sound signal for YaMZ 238ND5 engine 100 When the cooling fluid temperature reaches 100 the lamp starts blinking and the instrument panel pro...

Page 64: ...13 kgf cm2 for K 744R3 K 744R4 trac tors Oil pressure growth at each gear shall be rapid The pressure on neutral gear and at engagement of synchroniser brakes shall not be less than on transmission ge...

Page 65: ...Do not permit operation of 8481 10 YaMZ 238ND5 and OM460LA engines under load at the cooling fluid temperature below 70 fuel level indicator indicator of air pressure in the pneumatic system In the co...

Page 66: ...of the unit of heated 8481 10 engine shall be within the range of 0 38 0 5 MPa 3 8 5 0 kgf cm2 at the nominal rotation rate Oil pressure in the mainline of the unit of heated OM460LA Mercedes engine s...

Page 67: ...ction it is required to enter the password with controls buttons 4 5 and 1 The password is 8888 Then press button 1 for menu indication A page of addi tional menu opens it is given in Fig 11 Fig 10 Se...

Page 68: ...ML 460 for Mercedes engines Type of fuel tank V800 780 l tank volume is assumed NOTE The value shall not be changed Langauge selection of language Russian English Czech Device information fig 12 Fig 1...

Page 69: ...h 8481 10 engine Upper position of the key PRE START HEATER IS OFF Lower position of the key PRE START HEATER IS ON unlocked position To check ET operability it is required to switch on the battery ma...

Page 70: ...AND INSTRUMENT SWITCH Starter and instrument switch provides for activation of the instrument panel terminal 15 and start Starter and instrument switch has the following posi tions zero position locke...

Page 71: ...ooling fluid shall be chosen in accordance with the operation manual for the engine and with the appendix Specification for operating materials Fuel strainer located on the right under the cabin is eq...

Page 72: ...n for tractors with EHR 12 Buttons for manual fuel feed at tractors with Mercedes engine 13 Parking brake handle in the pulled up position braking 14 Plug socket 12V 15 PTO engagement handle for tract...

Page 73: ...consecutive shifting the lever forward from the 1st gear position to the po sition of 2nd 3rd and 4th gears without drain pedal depressing When pressing the drain pe dal at 2nd 3rd or 4th gear the pe...

Page 74: ...mediately stop operation of the tractor and check the pressure using a mechanical instrument pressure gauge Fig 18 Gearbox 1 synchroniser brakes 2 upper half of the case 3 GB filter 4 lower half of th...

Page 75: ...d of the wiper motorised reducer on II second speed of the wiper motor ised reducer on J intermittent mode of the wiper and washer control on Turn indicators shall be activated with handle moving cloc...

Page 76: ...o adjust the velocity of air flow passing through the air conditioner 9 Car audio 10 Round louvre with variable clear opening 10 pcs If the temperature controller is in position OFF and the fan switch...

Page 77: ...right lamp sound signal power supply for navigation system consumers EHR system activation rear linkage control 24V of voltage converter EHR system activation rear linkage control mirror heating car a...

Page 78: ...lamp EHR EHR activation relay outer service front lamps TGB transmission gearbox inner service front lamps 24V for pressure switches of pneumatic and hydraulic systems outer service rear lamps low bea...

Page 79: ...te knob 4 clockwise to decrease the weight rotate it counter clockwise Fig 19 Driver s seat 1 back inclination lever 2 lever for seat longitudinal movement adjustment adjust the seat position in longi...

Page 80: ...igh beam modes In order to avoid blinding of oncoming vehicles and vehicles moving be hind IT IS PROHIBITED to switch on the front and rear service headlights during transporta tion activities When ho...

Page 81: ...of 0 45 0 6 MPa 4 5 6 kgf cm2 at the rated speed and at least 0 1 MPa 1 kgf cm2 at the minimum speed At the same time indicator lamps engine oil pressure indicator lamp shall go out the flashing of la...

Page 82: ...o out ET for tractors with OM460LA Mercedes engine shall be switched on automatically when the key of ignition lock is turned into the first position 4 Meet the requirements set forth in item 4 10 3 o...

Page 83: ...heater must be closed 4 11 2 Heater operation Preparation for operation 4 11 2 1 Check the availability and level of non freezing fluid in the engine cooling system by short term opening of the relea...

Page 84: ...attempts the heater begins running steadily it is necessary to determine and eliminate the fault after which start the heater up Operation and shutdown of the heater General design of PZhD 30 heater i...

Page 85: ...arily shut it off set the manual fuel feed lever to the position corresponding to the minimum engine crankshaft speed In case of unsuccessful start up pull out the engine shutdown handle and then retr...

Page 86: ...switch on the battery master switch immediately upon the start of a steady operation of the engine being started 2 Engine of the tractor which accumulator is used as an external power supply shall be...

Page 87: ...3 Second heater pos 2 is located under the cabin roof with an evaporation heating unit of the air conditioner The hot fluid supply is performed by activation of the valves one valve pos 3 located at t...

Page 88: ...flux by handle 8 CAUTION In order to enhance a reliable operation of the air conditioning system be fore its shutdown the engine should operate at the minimum idle run speed for 3 5 minutes 4 14 TAKIN...

Page 89: ...the ignition key clockwise and start the engine Make sure that the engine operates smoothly all tractor systems are function ing air pressure in the brake system cor responds to the standard range of...

Page 90: ...n In case of difficulties when enabling a mode rotate steering wheel to the left and right CAUTION When enabling a mode DO NOT DEPRESS the drain pedal Set the gear change lever to neutral posi tion on...

Page 91: ...tractors Oil pressure growth at each gear shall be rapid The pressure on neutral gear and at engagement of synchroniser brakes shall not be less than on transmission gears Set the pressure in tyres d...

Page 92: ...r without depressing the drain pedal Remember when driving at the second third or fourth gear the drain pedal can be used only in emergency cases for emergency stops as the drain pedal return is locke...

Page 93: ...St K 744R2St K 744R3St K 744R4St tractors or turn the starter and instrument key lock switch to position 0 at K 744R1Pr K 744R2Pr K 744R3Pr K 744R4Pr trac tors after shutting the engine down return th...

Page 94: ...r preparation for operation consists of depreservation installation of the assemblies and parts attached execution of works relating to maintenance start up and running in of the tractor Before the be...

Page 95: ...ipe over the circumference it is available in the tractor SPTA using a solid roller with the thickness of 5 7 mm in 5 10 mm from the pipe end install headlights hinge pivot of central pull rod mirrors...

Page 96: ...nkage center rod pivot 1 pivot 2 tightening screw 3 center rod pipe Fig 26 Installation of hydraulic hitch Hydraulic hitch platforms shall be installed below the bottom rod platforms Upon completion o...

Page 97: ...side of outer stops by means of moving washers 7 from under the head of bolt 8 under stop 6 if need ed provide for the lateral movement of lower rods of 5 mm max 5 1 2 Installation of light signalling...

Page 98: ...nditions Mark the screen to adjust the position of headlight spots according to Fig 28 Align the posi tion of vertical axis O on the screen it shall be in the longitudinal axis of the tractor sym metr...

Page 99: ...ng so a flare from other lamps is prevented by installation of non transparent screens or by disconnection of con nectors from the respective lamps The lamps can be adjusted without opening the hood T...

Page 100: ...several lifting and lowering operations for the implement at the average and maximum speed of the engine crankshaft During the running in see for engine operation avoid its overload To prevent the eng...

Page 101: ...der to remove the explosive hydrogen air mixture the storage batteries shall be reliably fixed and closed with a lid 6 fill fuel into the tractor Before filling the fuel should be settled for 10 days...

Page 102: ...tically return to NEUTRAL position and from FLOATING po sition return to NEUTRAL position after manual release from the locking Perform checking at the rated speed of the engine crankshaft No fixing o...

Page 103: ...e best possible pressure in the tyres of wheel tractors and degree of its influ ence on the roadhold depend on the type of soil and the load acting on tractor axles Air pressure in the tyres impacts t...

Page 104: ...pendix 7 Pressure is measured at least once in every five days before tractor traveling for work execu tion The results shall be registered in the logbook Check the tyre pressure using serviceable ins...

Page 105: ...nt traction forces a slippage against tractor sides may be observed It can be remedied by increasing pressure in the tyres however the traction force reduces with that Table 3 Standards for loads on s...

Page 106: ...10 10 V 20 0 14 0 10 20 V 40 0 17 0 14 10000 V 10 0 14 0 10 10 V 20 0 17 0 11 20 V 40 0 15 10500 V 10 0 17 0 10 10 V 20 0 12 20 V 40 0 16 ________________________________________ ATTENTION VALUES MARK...

Page 107: ...not removable by purging rinse the radiator core with water under 5 7 kg cm2 pres sure as per cl 7 5 4 tractor brakes shall be in good working order When braking the tractor traveling over dry and har...

Page 108: ...g operations set the fuel supply lever into the position of minimum fuel feed strictly obey the instructions set forth in the Safety requirements section CAUTION In order to prevent untimely failure o...

Page 109: ...tling operations considerably facilitates the in stallation and dismantling and extends the tyre lifetime Perform tyre installation onto the rim in the following sequence put the tyre onto an even gro...

Page 110: ...e first one so that it will grip the lip and introduce the tyre shoulder behind the rim lip by pressing the tyre iron down The mounting will be much easier if you press the tyre by foot at the same ti...

Page 111: ...t of tyre shoulder extracted over the cir cumference for a distance where it is possible to introduce the bent end of the second tyre iron between the rim lip and the tyre shoulder without difficultie...

Page 112: ...rly spring works etc installation of extra wheels on tractors is provided for with parts for their installation in order to reduce specific pressure on the soil and improve the tractor s passing abili...

Page 113: ...t Installation of extra wheel 1 main wheel 2 extra wheel 3 distance ring 4 special bolt 5 washer 6 nut Installation of extra wheel 1 spacer 2 right wheel 2 left wheel 4 stud bolt 7 washer 10 nut 2 Rep...

Page 114: ...nuts 7 In sert the pressing ring with chamfered edge around wheel diameter inside the rim of the extra wheel Introduce the head of special bolt 4 through disc recesses of extra and main wheels turn it...

Page 115: ...ry 2 hours Tractor with installed wheel pairing kit shall be run in for at least two hours without load then the tightening torque of main and extra wheel nuts shall be checked 3 During shift maintena...

Page 116: ...AND VEHICLES TO THE TRACTOR HYDRAU LIC SYSTEM The connection is ensured by means of eight hydraulic quick lock cutoff couplings Fig 30 installed on the rear semi frame of the tractor and connected to...

Page 117: ...e con necting elements as well as coupling with the central pull rod and lower links with Walterscheid con nection to semi mounted implements having two connecting elements as well as coupling with lo...

Page 118: ...ical brace struts and cen tral pull rod When connecting mounted or semi mounted agricultural machines and implements the length of vertical strut 6 Fig 31 shall be minimum to ensure the maximum traffi...

Page 119: ...52 min 65 min Hinge pivot of the lower links G pin 36 6 0 2 50 8 0 1 36 6 0 2 50 8 1 1 H hole for pin 60 0 46 37 4 0 35 51 0 5 37 4 0 35 51 0 5 J 80 0 74 45 0 2 57 5 0 5 45 0 2 57 5 0 5 General dimen...

Page 120: ...e tractor connecting head and having opened the separating valve blow down the system until condensate is removed At negative temperatures repeat this operation after the completion of work as well co...

Page 121: ...s of 28 1R 26 tyres it is not recommended to perform haul ing of K 744R1 tractors with heavy mounted implements at the speed over 10 km h REMEMBER Turning a machine with landed operating parts can lea...

Page 122: ...ines should be connected to the 2nd and 3rd pair of couplings of the tractor hydraulic sys tem Connect the hydraulic motor pressure line to po sition LOWERING Shut the hydraulic motor down by setting...

Page 123: ...connecting head level to 90 of the initial value until the moment when the pressure in the trailing vehicle actuator being in the least favorable conditions reaches 75 of the steady state value with t...

Page 124: ...he engine at negative ambient temperatures as per guidelines set forth in Item 4 12 After engine start up before taking off a let the engine operate for 4 min gradually increasing the crankshaft rotat...

Page 125: ...d into an open rolling stock flat car with the account of packing and fastening shall be placed within the main external dimensions for loading Install the tractor onto a flat car with wooden floor cl...

Page 126: ...nt and fastening of loads in cars and containers Load and unload the tractor by crane with the carrying capacity of at least 20 000 kgf accord ing to the slinging diagram Fig 33 When slinging the trac...

Page 127: ...the hydraulic distributor of the mounted equipment hydraulic system into position NEUTRAL In order to avoid jack knifing of tractor semi frames install split bushings on the swing hy draulic cylinder...

Page 128: ...4R4 tractors The pressure on neutral gear and at engagement of synchroniser brakes shall not be less than on transmission gears Pressure shall be adjusted by turning plug 7 Fig 35 Fig 35 GB hydraulic...

Page 129: ...ype of all executed maintenance oper ations except ShM shift maintenance as well as lifetime hours from the beginning of opera tion of new or overhauled tractors Table 5 Types and frequency of mainten...

Page 130: ...l oil cooling fluid and elec trolyte absence of extraneous noise rattle in the engine and in transmission units if necessary eliminate all faults Upon leak detec tion and elimina tion it is neces sary...

Page 131: ...ystem in the gearbox hydraulic system in cases of the main and final gears of driving axles Set the pressure in tyres Check the condition of tyres and air pres sure therein Check the engine drive belt...

Page 132: ...481 10 engine Perform the operation at the first maintenance from the beginning of operation M 1 125 engine hours Tighten mounting bolts of intermediate bearing holders Tightening torque is 3 kgf m Ch...

Page 133: ...ling with compressed air in order to remove dust Check how does the engine work by ear and by monitoring instruments Check the operation of tractor control mechanisms operation of brakes window wipers...

Page 134: ...ings execute the operation every other M 1 session 250 engine hours filter element and and wash up the filter housing oil filter of the engine As per engine operation manual filter elements of pressur...

Page 135: ...necessary perform their maintenance Lubricate the following pins of hydraulic cylinders in hydraulic systems of the linkage and for steering control supports of service brake cams execute the operatio...

Page 136: ...tractor s me chanical parts at idle run and under load Perform the operation in the course of tractor s work Check the ease of rotation of the turbocharger rotor and if necessary perform its maintena...

Page 137: ...g automotive fluid of Tosol A 40M brand Prepare and check the operation of the pre start heating system When the pre start heating system is available Check the electric torch units Perform the operat...

Page 138: ...KIROVETS K 744R1 K 744R2 K 744R3 K 744R4 tractors 137 Fig 36 Tractor lubrication diagram level check and oil refill oil change grease oil plastic grease INTERMEDIATE BEARING LUBRICATION POINT...

Page 139: ...for the engine 250 2 Frame s vertical hinge pivot axles Loctite 8103 grease Main grease be ing used 2 by 0 3 l each 500 Substitutes Grease No 158 TU 38 101 320 77 250 3 Hydraulic cylinder pins of the...

Page 140: ...ases substi tutes Cup grease G Solid oil G GOST 1033 Cup grease S Solid oil S GOST 4366 6 Hydraulic cylinder pins of the linkage Litol 24 grease GOST 21150 Main grease be ing used 4 by 0 05 l each 125...

Page 141: ...l each 250 every other M 1 Substitutes Shell Spirax AD SAE 80W90 Shell Spirax S3 AX 80W90 Shell Donax TD 10W30 Shell Spirax S4 TXM TS p 8 TU 38 1011280 89 For all seasons to the temperature of mi nus...

Page 142: ...250 Frame s horizontal hinge pivot Loctite 8103 Main grease be ing used 1 by 2 8 l each for assembly dismantling Substitutes Grease No 158 TU 38 101 320 77 Main grease be ing used for assembly disman...

Page 143: ...40 to 5 from 5 to 40 main greases substi tutes Slotted connections of cardan shafts Litol 24 grease GOST 21150 Main grease be ing used for assembly dismantling Change the grease in cardan shaft of fro...

Page 144: ...Clean the oil filler port from dust and dirt before filling oil therein Through the oil filler port fill oil into the engine Check tightening of drain plug of the oil drip pan Use oil probe to monito...

Page 145: ...indicator Take off the wing after wrapping or binding it in film in order to prevent damage of the paint and varnish coating put it at a specially allocated place dismantling of the left hand wing is...

Page 146: ...ised container During installation they shall be placed in their positions in the same quantity 1 6 Take off the retainer from the process stopper and close the hood 1 7 Dismantle the arch from the tr...

Page 147: ...e bracket before dismantling mark out bracket outline in order to sim plify the assembly 1 11 Loosen three bolts M10 on the top of the bracket and undo two outermost bolts Leave the central bolt and t...

Page 148: ...lamps 1 17 Dismantling of the left hand side is similar to the operations described in Items 1 1 1 16 1 18 Perform the assembly in the reverse order 1 19 Install the arch and place it in respect of th...

Page 149: ...d CAUTION In order to avoid the ingress of dust into the cylinder piston group of the engine it is necessary to pay special attention to the following 1 When cleaning blowing down the filter element d...

Page 150: ...to the engine in the course of M 1 IT IS ABSOLUTELY PROHIBITED to work with clogged or ice covered grill of the air intake pipe cover and without free gas outlet from the exhaust pipe as it leads to...

Page 151: ...for the absence of fouling between radiator plates by checking clearances therein with the help of a standard portable lamp If needed blow down or in case when dirt is not removed with blowdown wash...

Page 152: ...ed off by the oil radiator block 3 Upon completion of maintenance of the cores hold the oil radiator block and in do ing so move the rest into the initial position and fix it with screw 3 4 Fasten oil...

Page 153: ...bring the lower part of the oil radiator block away from the cooling block then holding the block brought away move the rest into the lower posi tion and fix it on the axle 2 When cleaning the radiat...

Page 154: ...ondenser 2 and of the oil radiator a mechanism allow ing to clean the radiator core is provided for For a rapid cleaning without condenser dismantling and system depressurisation it is required to loo...

Page 155: ...er to clean the surfaces from dust and dirt without condenser dismantling and system depressurisation it is required to get air con ditioner refrigerant hos es free to this end dis engage bracket 5 by...

Page 156: ...r engine shutdown Clean the plug magnet Put the plug back in place b Wash up filter 3 of the gearbox c Install the filter onto the gearbox Pay attention to the fact that pack of filter ele ments 10 Fi...

Page 157: ...ng to the neutral gear engagement with loosened nut pos 2 screw in the adjust ment nut pos 3 until the beginning of turn of the lever pos 1 under the action of cable pos 4 undo the adjustment nut pos...

Page 158: ...on the pinion carrier to the extreme lower position and undo plug 2 Fill oil by means of funnel Drain oil through the drain port reference port when it is located in the bottom position using the att...

Page 159: ...of heating of bearing assem blies if it s not too hot the heating is normal In case of overheating take off the cardan shaft Eliminate faults at TSS or in a workshop In case of removal of cardan shaft...

Page 160: ...drop it shall not exceed 0 05 MPa 0 5 kgf cm2 over 30 2 min with a free position of the pedal and over 15 1 min with the pedal being fully pressed If the pressure falls to a greater extent visually f...

Page 161: ...vers protecting them against the ingress of dirt snow mois ture 7 5 9 Maintenance of hydraulic systems of the linkage and for steering control Level check and change of oil in the hydraulic tank of th...

Page 162: ...it performs lubrication of pump bearings therefore the contamination of working fluid with me chanical impurities or water causes formation of burrs on the surface of journal bearings and results in...

Page 163: ...off lower rubber ring 16 and filter element 17 f Wash the filter housing in diesel fuel g Change the filter element and assemble the filter in reverse sequence The second element shall be changed in a...

Page 164: ...ces being sealed if any notches signs of treatment are detected dress them by scraper and grind them d wash the surfaces being sealed with diesel fuel e assemble the union or angle with nut and rubber...

Page 165: ...r rubbing or damaging by parts of assemblies of the tractor in operation c do not expose hoses to mechanical loads as it can lead to their destruction d do not permit the ingress of fuel and lubricant...

Page 166: ...with the tractor Check of the battery charging rate With the engine shut off Switch on the headlights for 2 minutes switch them off wait for a minute and check the bat tery by means of a load diagnos...

Page 167: ...wn with compressed air as well as check the tension of V belt of the compressor drive 2 When performing M 1 M 2 M 3 check the tension of the compressor drive belt and if necessary make adjustments Whe...

Page 168: ...ing with air conditioning maintenance and repair 3 IT IS ABSOLUTELY PROHIBITED to mix R134a halocarbon with any other refrig erants or use any refrigerant except the permissible one 4 IT IS PROHIBITED...

Page 169: ...KIROVETS K 744R1 K 744R2 K 744R3 K 744R4 tractors 168 CAUTION Air conditioning system shall be operated and maintained in accordance with the instruction for air conditioner supplied with the tractor...

Page 170: ...ts components to be kept in the warehouse Check the tractor condition during the period of storage at least once in two months in case of indoor storage and once a month in case of storage outdoors an...

Page 171: ...rosion wash up de grease and dry up the surfaces Having applied the preservation oil or grease wrap the above mentioned threaded joints spherical surfaces and parts with a polyeth ylene film of paraff...

Page 172: ...744R4 tractors at the engine crankshaft speed of 900 1800 RPM Oil pressure growth at each gear shall be rapid The pressure on neutral gear and at engagement of synchroniser brakes shall not be less th...

Page 173: ...e of lubri cants ingress of dust and dirt due to collar dam age and wear Clean and wash oil conducting channels of the crossbar Replace worn and damaged parts Faults of the steering control hydraulic...

Page 174: ...the right and to the left three revolutions each without achiev ing the safety valve without reaching the stop Perform the works with the rear axle disengaged When pumping out the hydraulic system tur...

Page 175: ...touch Air leak through one of the pneumatic units Replace the unit Ineffective braking or no braking with the brake pedal fully pressed Travel of brake chamber stems is not adjusted Adjust it Brake va...

Page 176: ...or sensor The indicator lamp Battery charging is on at the instrument panel with the engine in opera tion tension of the generator drive belt is not sufficient Tighten the belt break in the power circ...

Page 177: ...n is high a low performance of the fan is possible Check the pressure in the system perhaps it is overfilled and if necessary bleed the excessive amount of refrigerant Check the air filters if needed...

Page 178: ...tractor and has an agreement with the manufacturer s plant 10 2 Reports about failures and faults found during the warranty period and quality claims shall not be sent to the manufacturer s plant in...

Page 179: ...or fault report it is necessary to indicate the following data serial number of the tractor serial number of the engine and total engine hours nature and form of the failure or fault user s exact addr...

Page 180: ...tion brake valve with pedal 5 8 reverse acting brake valve with manual control 6 acceleration valve 7 trailer brake control valve with single wire drive 9 reference outlet valve 10 cut out valve 11 co...

Page 181: ...alve 4 two section brake valve with pedal 5 8 reverse acting brake valve with manual control 6 acceleration valve 7 trailer brake control valve with single wire drive 9 reference outlet valve 10 cut o...

Page 182: ...ydraulic tank 700 46 14 000 3 1 KZ Decelerating valve 1 N1 1 Pump NSh of steering control system 1 N2 Pump of operating equipment system 1 R Hydraulic distributor 1 F1 F2 Filter 700 46 14 190 2 2 F3 F...

Page 183: ...82 APPENDIX 3 KINEMATIC DIAGRAM OF TRANSMISSION Kinematic diagram of transmission 1 engine 2 reducer with semi rigid coupling 3 front driving axle 4 gearbox 5 PTO connecting coupling 6 rear driving ax...

Page 184: ...ng GB case to AKSS 25 7 Bolts attaching the intermediate bearing holders 3 8 Drive axle clamp nuts 50 9 Wheel nuts 14 20 10 Hoses of the hydraulic system of steering control and op erating equipment h...

Page 185: ...Applied with environ ment temperature Notes 10V2 10G2 10G2 GOST 8581 minus 12 min summer 10D minus 16 min 8G2 minus 23 min winter 8V2 8G2 8D minus 28 min SAE 30 mineral oil minus 16 min summer SAE 10W...

Page 186: ...nz for operating materi als Diesel cooling system YAMZ 238ND5 8481 10 55 73 Automotive cooling fluid Tosol 40 TU 6 57 95 96 Cooling system for OM460LA Mer cedes engine 55 50 antifreeze agent 50 distil...

Page 187: ...ta on the amount of halocarbon and refrigerating oil are given for the system filled at the manufacturer s plant In case of system overfilling in the course of operation it is necessary to consult spe...

Page 188: ...re Pressure Position Date of meas ure ment LOGBOOK OF MEASUREMENTS OF THE INTERNAL AIR PRESSURE IN TYRES APPENDIX 7 N o t e If any increased or decreased pressure is detected in the machine then in br...

Page 189: ...tion Tyre position FR front right FL front left RR rear right RL rear left Tyre run from the beginning of operation Pressure in tyre at the moment of inspection kgf cm 2 Technical condition of tyre at...

Page 190: ...button switch 11 3704 TU37 003 710 80 1 TV Switching device TK107 TU 003 484 78 1 XT1 Connecting panel 16 3723 OST37 003 1358 88 1 YA Electrical magnet 335 1 6 Air conditioner control panel 1 7 Avgus...

Page 191: ...License plate lighting lamp 00 02 1 FU1 FU2 Fuse panel 41 3722 TU37 469 013 95 2 Fuses 35 3722 TU37 469 013 95 35 3722 5 FU2 5 FU2 6 FU2 7 FU2 8 4 352 3722 10 FU1 1 FU1 5 FU1 7 FU1 13 FU2 1 FU2 3 FU2...

Page 192: ...KV6 1 High beam KV7 1 Low beam KV8 1 Brake lamp KV9 1 Air conditioner compressor KV10 1 Air conditioner fan KV11 Relay 738 3747 20 TU 37 003 1418 94 Starter KV12 Relay 711 3747 TU37 003 1418 94 1 Cl15...

Page 193: ...2802 3829010 U 37 453 092 93 1 Brake lamp SP3 Oil filter clogging alarm sensor 1 Supply with engine SP4 Alarm for emergency oil pressure in engine 3702 3829 1 Oil in engine SP6 TGB filter clogging ala...

Page 194: ...contact Pin contact blocks OST37 003 032 78 81 502601 1 Pin contact block 1 480586 0 2 9 contact 17 1 18 1 Receptacles SRS Cannon type power con nectors AMR XS1 Receptacle 213889 2 1 3 contact XS9 Re...

Page 195: ...01202 4 2 contact XS56 1 XS63 1 XS64 1 XS66 1 XS71 Receptacle 333 1 Hydr system oil level sensor Receptacle 8JA 713631 001 7 For key switches XS6 1 1 XS6 2 1 XS6 3 1 XS6 4 1 XS6 5 1 XS6 6 1 Receptacle...

Page 196: ...1 XS62 1 XS65 1 XS97 1 XS98 1 XS114 1 XS115 1 XS58 602604 1 602606 3 XS12 1 XS34 1 XS37 1 617605 11 XS KV1 1 XS KV2 1 XS KV3 1 XS KV4 1 XS KV5 1 XS KV6 1 XS KV7 1 XS KV8 1 XS KV9 1 XS KV10 1 XS KV14...

Page 197: ...h V 45M TU 16 526 016 73 2 SB7 Push button switch 11 3704 TU 37 003 710 80 1 TV Switching device 9301 3734 01 U HL 24V TU 37 466 126 2002 1 13 Connecting panel 16 3723 OST 37 003 1358 88 1 YA Electric...

Page 198: ...protection unit BZ 30 FU28 Fuse 542 3722 90A TU 37 469 056 2002 1 G Generator JFZ2707 010 1 Supply with en gine GB1 GB2 Battery 6ST 190APZ ZhYuIK 563414 013TU 2 Hornless sound signals TU 37 003 688 7...

Page 199: ...amp breaker RS493 TU 37 003 588 77 1 KM Switch 1420 3737 TU 37 003 574 74 1 KV1 Relay 738 3747 20 TU 37 469 023 97 1 Engine shut down Relay 901 3747 TU 37 003 1418 94 KV2 1 Frame locking KV3 1 High be...

Page 200: ...eceiver 34 3806 TU 37 003 942 79 1 PV Engine hour meter voltmeter UK34 2 RIVP 457381 001TU 1 R Resistor S2 23 51 Ohm 10 OZhO 467 081 TU 1 SA1 Switch panel 89 3709 TU 37 461 012 96 1 SA2 Switch panel 5...

Page 201: ...13 Mounted equipment pressure filter clogging alarm 1 Supply with filter SQ Intermediate relay interlock switch 15 3710 U 37 003 188 76 1 VD1 VD10 Diode KD202D UZh3 362 036TU 10 VD11 Diode D242 0336 2...

Page 202: ...606 6 XS28 XS29 XS34 XS37 XS34 XS37 602608 2 XS92 XS93 606003 4 XS95 XS96 XS30 610608 1 XS64 607605 1 XS35 Three contact socket plug 1 Supply with en gine XS65 Socket plug 8JB 001933 011 Hella 1 Conne...

Page 203: ...atic system BP3 Pressure sensor 18 3829010 TU 37 003 387 78 1 Oil pressure in engine BV2 Speed sensor 11 3843 Y HL TU37 003 1148 83 1 K1 Plug 1 Supply with engine K2 Plug 1 Supply with engine KK2 Ther...

Page 204: ...1 Right HL2 1 Left Side repeater lamp 641 3726 01 TU37 001 2164 2006 HL3 1 Right turn HL4 1 Left turn HL5 HL7 Turn indicator repeater UP 24V 3 Road train sign HL22 Rear light 7313 3716 01 HL23 TU RB...

Page 205: ...ooling fluid emergency temperature sensor 111 09 U 37 003 271 76 1 SK3 Hydr system impermissible oil temperature alarm sensor 1 SP1 Emergency air pressure sensor DADV 02 TU RB 07513211 004 94 1 Parkin...

Page 206: ...1 99 282108 1 1 6 contact Pin contact blocks OST37 003 032 78 81 502601 1 Pin contact block 1 480586 0 2 9 contact 17 1 18 1 Receptacles SRS Cannon type power con nectors AMR XS1 Receptacle 213889 2 1...

Page 207: ...ches XS6 1 1 XS6 2 1 XS6 3 1 XS6 4 1 XS6 5 1 XS6 6 1 Receptacles ISO 10487 XS79 962189 1 1 Type A XS80 962191 1 Type B XS KV12 Receptacle KR3702 1 Relay 711 3747 Receptacles OST 37 003 032 78 602601 9...

Page 208: ...4R3 K 744R4 tractors 207 Pos name Name Q ty Notes XS KV4 1 XS KV5 1 XS KV6 1 XS KV7 1 XS KV8 1 XS KV9 1 XS KV10 1 XS KV14 1 Y 1 ET solenoid valve 1 Supply with engine Y 2 Solenoid valve of compressor...

Page 209: ...sch BA1 BA2 Loud speakers ACV SP 420 2 BP1 Pressure sensor TKH1 6 T184 1 Gearbox oil 2 Pressure sensor 3902 3829010 GOST 1701 75 1 Air in PS pneumatic system BV2 Speed sensor 11 3843 Y HL TU37 003 114...

Page 210: ...use 20 1 G Generator 1 Supply with engine GB1 GB2 Battery 6ST 190A PZ ZhYuIK 563414 013TU 2 Hornless sound signals TU37 003 688 75 1 313 1 2 314 1 Front light 3723 3712 01 TU RB 0588255010 95 HL1 1 Ri...

Page 211: ...120 Ohm 1 SA1 Switch 6RH 007 832 461 1 Front service headlight acti vation SA2 Switch 6RH 007 832 461 1 Rear service headlight acti vation SA3 Switch 6 H 007 832 011 1 Road train sign activation SA4 S...

Page 212: ...chain lock ing UZ Voltage transformer PN24 12 5 1 VD1 Diode KD243B 1 Pin contact blocks SRS Cannon type power con nectors AMR 1 Pin contact block 213905 1 1 3 contact Pin contact block 206838 3 5 24 c...

Page 213: ...1 XS7 1 XS15 1 Receptacles Supersiel 1 5 XS33 282079 2 1 1 contact 282087 1 4 3 contact XS13 1 XS69 1 XS69 1 XS90 1 XS32 282088 1 1 4 contact 282090 1 2 6 contact XS70 1 XS99 1 Receptacle 601202 4 2 c...

Page 214: ...1 XS50 015 545 6726 1 XS51 000 153 0022 1 Receptacles ISO 10487 XS79 962189 1 1 Type A XS80 962191 1 Type B XS KV12 Receptacle KR3702 1 Relay 711 3747 Receptacles OST 37 003 032 78 602601 9 XS26 1 XS3...

Page 215: ...4R3 K 744R4 tractors 214 Pos name Name Q ty Notes XS KV4 1 XS KV5 1 XS KV6 1 XS KV7 1 XS KV8 1 XS KV9 1 XS KV10 1 XS KV11 1 YC1 ET solenoid valve 1 Supply with engine YC2 Solenoid valve of compressor...