Minsk Automobile Plant MAZ-543403 User manual

Minsk Automobile Plant
VEHICLE
MAZ-543403
Instruction manual
The Republic of Belarus
Minsk, 2011

DEAR DRIVER!
The MAZ vehicle you are going to operate is a highly reliable automobile equipped with
modern assemblies and instrumentation, which provides for an easier trailer train driving, easing
down on some of the driver’s fatigue and enhancing road safety, and makes it possible to consid-
erably increase working efficiency and reduce transportation self-costs.
Before operation of the vehicle, carefully study the manual.

INTRODUCTION
MAZ-543403 – is a 4×4 two-axle vehicle (chassis) with pent busbar of the rear axle wheels (see
Figure 1) designed for installation on it various technological equipment and for operation on all
types of automobile roads, which are adapted to axial loads specified in the product data sheet .
The vehicle is equipped with the Yaroslavl Motor Plant engine and it corresponds requirements
of environmental standards Euro-2.
The information on operation and maintenance of the engine, clutch, gearbox is given in separate
instructions included with the vehicle additionally.
Figure 1 – Automobile chassis MAZ–543403

SAFETY REQUIREMENTS AND WARNINGS
To ensure reliable and effective performance of a vehicle one needs to know how its assem-
blies and units function, provide for strict compliance with operation, maintenance and servicing
instructions and eliminate any deviations from whatever requirements are set out in this opera-
tions manual.
Before starting operation of a vehicle, it is necessary to thoroughly examine its construction,
study operation, maintenance and servicing instructions provided within this manual, paying
special attention to “Particular issues associated with vehicle operation” section.
1 Tightening torques for basic threaded joints are as defined in Annex 2.
2 During a break-in period (for the first 2000 km) it is essential to provide for strict compli-
ance with terms as set out in “Vehicle break-in period” section because further performance of
vehicle components largely depends on how well separate parts bed in at the early operation
stage.
3 Vehicle assemblies and units shall be lubricated in accordance with instructions set out in
“Chimmatology list” included into this manual. Application of any oils and lubricants containing
contaminants or different from those recommended in this manual is forbidden.
4 It is prohibited to drive a vehicle if brake pneumatic drive circuit pressure is lower than
550 kPa, i.e. until indicating lamps for respective circuits go out.
5. The slow range of the additional gearbox shouldn’t be turned on at the speed of movement
above 25 km/h
6 If a vehicle is started on a slippery road section, it is required to enable interaxial and in-
terwheel differential locks. After the road section is behind, the differentials are to be unlocked.
A vehicle with locked differentials is not allowed to enter into a turn.
7 While a vehicle is moving, the driver should monitor its instrumentation and indicating
lamps.
8 With engine out of operation and gear box cut-off, a vehicle is not allowed to run at a neu-
tral speed so as to avoid power steering trip-out and air entering brake pneumatic drive receivers.
9 For downward slopes, it is necessary to make sure that vehicle rpm speed is within accept-
able range, i.e. rev counter should never go as far as the red section on the instrument dial.
10 It is prohibited to operate vehicles which have defective or failing power steering. While
a vehicle is moving, it is recommended not to remove the key from the lock starter and instru-
mentation switch to avoid steering post interlock and engine shutdown.
11 To prevent steering power pump failures steering wheel should not be held in extreme
positions (extreme right and left steered wheel turns) for more than 5 seconds.
12 When parked, a vehicle battery should be disabled by pressing a cut-off push. If a vehicle
idle period is rather long (lasts for more than 3 days), it is necessary to take the connector off the
battery. It is forbidden to connect 12V electrical appliances (such as radio-recorders, receivers,
and etc.) to the battery.
13 Maintenance scopes and frequency requirements as set out in this manual are to be strict-
ly complied with.
14 Power pack servicing scopes are detailed in a separate manual.
15 Power pack servicing is to be carried out on a horizontal flat surface with cabin uplifted
to the maximum extent.
It is strictly prohibited to perform any works under the cabin unless it is uplifted to the max-
imum extent.
16 The cabin should be lifted with vehicle stationed on a horizontal even surface. The vehi-
cle must be put on the parking brake. Before uplifting the cabin, the gear-change lever is to be
switched into neutral, the doors must be closed and the front cab liner group opened. While up-
lifting the cabin, keep a safe distance from the roll over area.

17 It is prohibited both to uplift or lower the cabin while the vehicle engine is still running
and start the engine while the cabin is in the uplifted position, which is necessary to prevent gear
box self-start and, accordingly, the resulting unwanted vehicle movement.
When an engine needs to be started with the cabin in the uplifted position to provide for ad-
justment or repair works, it is necessary to ensure that the gear box is in the neutral position. The
starting shall be as required by “Safety instructions.”
18 After the cabin is lowered, it is required to ensure that the lock mechanism is in the lock
position and the back safety wire rope is fixed into place as appropriate.
19 When washing a vehicle, it is essential to ensure that the stream is not pointed directly at
electrical accessories and electric wiring joints.
20 System and electrical accessories circuits state should not be tested with a megohm meter
or a lamp supplied from a source with voltage higher than 24V.
21 While the engine is running, it is not recommended to disconnect wiring from generator
and battery outputs.
22 It is forbidden to use reverse polarity while connecting the battery to the vehicle-mounted
electrical accessories system.
23 When welding a vehicle, the battery must be cut off and the wiring and the brake pneu-
matic drive piping must be protected from exposure to high temperatures (above 90оС) and
welding splashes.
24. While starting the vehicle engine from an external source or using the on-board vehicle
network as an external source to start the engine of another vehicle it is necessary to retrieve
ABS power fuse to prevent error recording on power supply in the memory of the electronic unit
and the ABS disable.
25. It is strictly forbidden to switch “Neutral” in the transfer case, to turn on the power take-
off attachment (PTO) and differential lock while driving
26 If a vehicle (a trailer train) is on a public road or is moving through city or settlement
streets, transportation operators are to be careful to observe regulatory documentation effective
within the respective country in terms of weight and dimensional requirements and transit regu-
lations when those are exceeded.

SPECIFICATIONS
The main weight parameters and specifications of the automobile chassis MAZ-543403 are
given in the table 1
Table 1
Parameter Value
Chassis curb weight with cabine, kg 7700
Curb weight distribution, kg
– on the first axle
– on the second axle
4950
2750
Technically permissible total weight, kg 16000
Distribution of the vehicle technically permissible total weight, kg
– on the first axle
– on the second axle
7000
9000
Technically permissible payload, kg 8150
Engine YaMZ–236BE2T
Nominal engine power, kW 184,0
Gearbox (model) YaMZ–2381
Road train max speed, km/h 76,0
Reference fuel consumption, l/100 km, for a vehicle (a trailer train) of
gross weight moving at the speed of 60 km/h: 40,0
Wheels Disc, 20-10.00W
Tire size 14.00R20, central tire
pumping
Rated wheel tire pressure, kPa**:
– on the first axle
– on the second axle
650
650
Notes:
1. Gross weight tolerance for an equipped vehicle is plus 3 %. There are no restrictions for the
lower weight threshold

2. Equipped vehicle gross weight (standard completeness) is the weight of a vehicle together
with cooling fluid, clutch drive fluid, lubricants, windshield washer fluid, fuel (with tank filled
up to not less than 90% of its rated capacity), a fire extinguisher, wheel chocks, a standard
spare parts and tools package, a spare tire and any other accessories.
3. Reference fuel consumption is used to determine the technical condition of the vehicle
and is not an operational norm
Key adjusting data and the chassis filling containers volume are shown in tables 2 and 3
Table 2
Parameter Value
Misalignment of wheels 1–2 mm
Turning circle of the internal (respecting the center of rotation)
wheel to the left and to the right (29–1)º
Clutch pedal free travel (5–7) mm
Brake pedal free travel (17–27) mm
Brake chamber rod stroke (38–44) mm
Table 3
Refill capacities Volume, l
Fuel tank;
total capacity 343,0
active capacity 327,0
Cooling engine system 40,0
Lubricant engine system 24,0
Central main gear crankcase:
– front and rear axles
– with a round banjo axle housing
– with a round banjo axle housing
up to 4,5
13,0
15,0
wheel gearing crankcase:
– front axle
– rear axle
2,3
2,0
Power steering system 6,5
Windscreen washer tank 10,0

CONTROL ELEMENTS AND MEASURING INSTRUMENTATION
Control elements and measuring instrumentation arrangement is as shown at Figures 2, 3, 4
and 5.
1 – starter and instrumentation lock switch with an antitheft device;
2 – turn indicator switch, dipped and distance headlights switch;
3 – windscreen wiper and windscreen washer switch
Figure 2 – Switches below the steering wheel and the starter and instrumentation switch
Starter and instrumentation lock switch 1 (Figure 2) with an antitheft device. Position
III is for key insertion and removal from the lock switch.
To unlock the steering post shaft it is necessary to insert the key into the lock switch and, to
avoid damage to the key, to slightly turn the steering wheel to the left and then to the right. After
that, the key is to be turned clockwise into “О” position.
As soon as the key is removed from the lock switch (i.e. from position III), fuel supply stops
and the lock mechanism for the switch is enabled. To lock the steering post shaft it is necessary
to turn the steering wheel to the left and then to the right.
Other in-switch key positions:
0– neutral (fixed) position. Starter and instrumentation circuits are cut off;
I– supply and instrumentation circuits are on (fixed position);
II – supply, starter and instrumentation circuits are off (the position is not fixed).

Switching handle 2 for the turn indicator of dipped and distance lights
Its positions are as follows:
Horizontal:
0– neutral;
I– (fixed) – right turn indicators on; the indicators switch off automatically;
II – (not fixed) – right turn indicators are short term on;
III – (not fixed) – left turn indicators are short term on;
IV – (fixed) – left turn indicators on; the indicators switch off automatically.
Vertical:
V– (not fixed) – distance headlights are short term on (irrespective of the main light switch
position);
01– (fixed) – dipped lights are on with headlights enabled at the main light switch 12
(Figure 4).
VI – fixed, distance lights are on with headlights enabled at the main light switch.
When the handle is pressed from the end face plane, an electrical audible beep sounds.
Switching handle 3 for windscreen wiper and washer
Its positions are as follows:
Horizontal:
0– neutral;
I– (fixed) – the windscreen wiper is on – low speed;
II – (fixed) – the windscreen wiper is on – high speed;
III – (fixed) – the windscreen wiper is on and is operated in an intermittent mode. The inter-
val is regulated up to 60 seconds
To set the time interval of the "pause" for the windscreen wiper in intermittent mode one
should:
- Transfer wiper switch from the "intermittent mode» (III) to "neutral" (O);
- Return the wiper switch to the "intermittent mode» (III) after a period of time required for
effective work.
Time spent in the "neutral" switch mode (O) further will be equal to the time of the wiper
switch in the "pause" mode.
Return to the original time of "pause" (2-3 seconds) take place:
- when wiper switch is in the low or high speed mode,
- when the ignition lock is off
- when the wiper switch is in the neutral position (O) more than 60 seconds, windscreen wi-
per is enabled in the "intermittent mode".
Vertical:
IV – (not fixed) – the windscreen washer is on and is run simultaneously with the wind-
screen wiper in a low speed mode.
When the handle is pressed from the end face plane, an electrical audible beep sounds (if it’s
available).
Parking and emergency brake control valve handle. The handle can be fixed in either of
the two extreme positions. As soon as the handle is switched into the rear fixed position, the
parking brake is enabled. And when it’s in the fixed front position, the parking brake is off. If the
handle is held down in any of the intermittent positions (not fixed), the emergency brake is en-
abled.
Secondary brake control valve handle. When the handle is pushed, the throttle gate blocks
the discharge gas line flow passage, which causes backpressure within the gas discharge system
with simultaneous fuel supply cut-off.

Battery switch remote control button 1 (Figure 4). In case of remote control system fail-
ure, the switch can be enabled or disabled by pressing the on-case button. The switch is located
on the battery mounting bracket. When the switch is enabled, the voltage meter pointer starts to
shift.
Cabin heater fan switch 2 (Figure 4). The fans can be operated in two modes: maximum
rotational velocity (the first fixed switch position) and minimum rotational velocity (the second
fixed switch position).
Rev counter 7 (Figure 3). This is a device indicating engine shaft rpm speed (connected to
the generator phase and 8A fused).
The rev counter dial is divided into three sections of different colour:
– the green section is to indicate that the engine shaft rpm speed is within the engine econ-
omy mode range;
– the yellow section is to indicate that the engine shaft rpm speed range where intermittent
engine work mode is possible;
– the red section is to indicate the engine shaft rpm speed range where engine operation is
not possible.
Those dial sections which do not have colour designation are to indicate engine shaft rpm
speed ranges which are not recommended because of high fuel consumption rates.
1 - centralized switch of pressure release in tires 2 – interaxle differential lock switch; 3 – the
switch of plafond lighting engine; 4 – interwheel differential lock switch; 5 – the switch of tire
central pumping; 6* – speedometer 7 – rev counter; 8 – vehicle turn indicating lamp; 9 – distance
headlight indicating lamp; 10 - trailer turn indicator lamp 11 – rear fog light indicating lamp; 12
– engine electric torch heater indicating lamp; 13 – downshifting indicating lamp; 14 – inter-
wheel differential lock activation indicating lamp; 15 – interaxle differential lock indicating
lamp; 16 – vehicle ABS indicating lamp 17 – instrument board: a) – engine oil-pressure indicator
in engine; b) – fuel indicator; c) – coolant temperature indicator; d) – voltage meter; 18 – fog
lamp switch; 19 – rear fog light switch; 20 – rear-view mirror heating switch (if rear-view mir-
rors are installed)
Figure 3 – Control panel**
__________
* Rev counter installation is possible
** If a vehicle is equipped with the antilock system, supplementary antilock brake system indicating
lamps are installed on the control panel.