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.

Air pressure indicator 16 (Figure 4) in brake circuits:
upper dial – in the front circuit, lower – in the rear circuit.
Alarm system switch 13 (Figure 4). When on, vehicle and trailer left and right turn signals
are lit simultaneously.
Main lights switch 15 (Figure 4). Its fixed positions are as follows: neutral, tail and gauge
dial backlights on, headlights on (distance and dipped lights depending on the position of the
handle 2 (Figure 2) of the turn signal switch, distance and dipped lights switch).
Rev counter (if installed) – device indicating driving speed, current time and mileage, and
making a record on the inserted CD (coded as driving speed, current time, mileage, fuel con-
sumption and driving mode).
The following indicating lamps and warning devices are located on the panel (Figure 5):
Warning device 1 for oil level decrease in the power steering tank;
Warning device 2 for coolant fluid level decrease;
Indicating lamp 3 of the fan clutch.
1 – battery switch; 2 – cabin heater fan switch; 3 – cabin heater fan mode switch; 4 – electric torch
switch; 5 – air filter blocking indicating lamp; 6 – air filter blocking indicating lamp; 8 – brake
malfunction indicator lamp; 9 – indicating lamp for insufficient air pressure in the brake system
of the front circuit; 10 – indicating lamp for insufficient air pressure in the brake system of the rear
circuit; 11 – parking brake indicating lamp; 12 – searchlight switch; 13 – alarm system switch; 14
– instrument scale lighting resistor; 15 –main light switch 16 - two-pointer indicator for air pres-
sure in the front and rear brake system circuits.
Figure 4 – Auxiliary panel

1 – warning device for oil level decrease in the power steering tank; 2 – warn-
ing device for coolant fluid level decrease; 3 – indicating lamp of the fan
clutch
Figure 5 – Panel
CABIN ACCESSORIES
Rear-vision mirrors are installed outside of the either side of the cabin. Mirrors position is
adjustable.
Windscreen wiper with electric actuator, two-speed, third-brush intended for windscreen
wiping, actuated with handle 3 (see Figure 2), located on the right side of the steering post.
Windscreen washer with electric actuator. The washer pump is enabled with the same
switch as the wiper. Water jet from the tank is directed to the windscreen via two spray diffusers.
The switch released, the pump stops. The water jet direction is adjusted by turning the head
spray diffusers.
Driver’s and passenger’s seats with air bellows 4 (Figure 6) furnished with vertical and ho-
rizontal adjustment mechanism and seat back angle adjustment mechanism. The head restraint
and armrests set is made on customer's request.
The vertical seat control mechanism - of a bar type with stepped adjustment. Seat height, as
well as the slope is regulated by the handles 5 and press / release of the front / rear part of the
cushion 7.

The seat slope mechanism - of a bar type with stepped adjustment, allows to adjust the slope
angle using handle 3 with the simultaneous pressure on the seat back.
Seat horizontal adjustment mechanism (forward/back) – skid type with stepped adjustment
of the seat position is performed by handle 6.
The armrests 9 recline (up) and their angle is smoothly adjusted by handle 10.
Height and angle of the headrest are adjustable.
To the driver’s attention!
Seat adjustment during driving is forbidden.
The passenger seat may be both unadjustable and adjustable as ordered by the purchaser.
Fixing points for safety belts are provided.
While using seats, bad contacts with the interior elements and other furnishings are
forbidden.
1 – headrest; 2- seat back; 3 –seat back angle adjustment mechanism; 4 – air bellows;
5 –vertical seat adjustment mechanism handle; 6 – horizontal seat adjustment mecha-
nism handle; 7 – seat cushion; 9 – armrest; 10 – handle for armrest angle adjustment
Figure 6 – Driver’s seat
The passenger seat may be both unadjustable and adjustable as ordered by the purchaser.
Fixing points for safety belts are provided.
Cabin is equipped with transformable bed. Transformable bed has two positions: horizontal
– for rest, vertical – transport position.
To convert the bed from the transportation position to position for the rest it is necessary:
- to lower the seat with handles 5 to a maximum extent (Figure 6);
- to tilt the seat back 2 forward to the horizontal position using the handle 3 (if necessary,
raise up the wheel column and move the seat forward until it stops using handle 6);
- to move the seat forward until it stops with the handle 6.

The similar action should be performed with the passenger's seat.
- to unfasten the straps which fix the bed to the cab;
- to pull the handle of the bed and move it to the horizontal position, avoiding harmful con-
tacts with the cabin interior.
- to set the latches into the locks on the rear wall of the cabin until they click.
To put the bed in the transport position, pull up the cable, located between the bed and the
cabin rear wall to unlock the latches, and then do all the actions in reverse order of setting the
bed in the position for rest
It is forbidden to stay in front of the cabin while it is being raised or lowered. Before
capsizing the cabin it is necessary to verify if the cabin doors are carefully closed and there
no any unattached objects in there, the fall of which may cause damage to the cabin.
Cabin doors
The cabin doors are double paneled, pressed form plate steel, welded and canted along the
perimeter. In the middle of the inside door panel there are slots for windows mounting and dis-
mounting, a window regulator, a door lock and a lock actuator component.
The doors are equipped with rotary type locks. In order to block the door lock in the closed
position from inside of the cabin, press down the lock actuator element handle against the stop
and then, without releasing the handle, slowly return it into the original position.
Glare shields. Two glare shields are installed inside the cabin in front of the driver’s and
passenger’s seats. Shields are lifted and lowered manually
Radio receiver or radio recorder is installed on the knapsack shelf of the cabin, if addi-
tionally requested by the purchaser.
The cabin is lit by two main dome lamps with internal switches.
The main dome lamps may be switched on when the battery is on as the dome lamps are
connected with the use of a two-wire arrangement (plus and minus to the lamps are supplied
from the battery terminals).
To reduce vibration load on the driver’s workplace, the large cabin is spring-mounted: front
springing is achieved by two hinged supports resting on coil springs, two shock absorbers and an
antisway bar, back springing is achieved by installation of cabin support beam on two coil
springs and two telescopic shock absorbers located inside the springs.
Knapsack shelf intended for team’s small belongings is located above the windscreen.
Against additional payment, a refrigerator intended for food storage may be installed in the
cabin under the lower bunk behind the driver’s seat.

LIST OF PRE-SALE PREPARATION OPERATIONS
1Depreservation (antirust compound removal).
2Visual inspection for transportation damages. Check accessories, tools, manuals accord-
ing to the packing list.
3Position the items, devices temporarily dismantled for transportation.
4Check oils availability, their level in assemblies and units; top up, if needed.
5Top up cooling fluid (if needed).
6Check batteries condition, their fixings (top up electrolytic solution, recharge, fix, if
needed).
7Check the pneumatic brakes, the clutch linkage, electrical equipment, alarms, the cabin
roll-over system, tire pressure, wheel attachments, and other joints and, if required, eliminate any
failures.
8Check assemblies and systems in all modes and, if needed, eliminate any failures.
9Check steering mechanisms operation with engine running (steering wheel rotation) and,
if needed, eliminate any failures.
10Check the vehicle from below (ensure no cooling fluid, oil, fuel leakage, joints reliabil-
ity) and, if needed, eliminate any failures.
11Wash the vehicle, touch-up, if needed.
12Instruct the owner, driver.

VEHICLE BREAK-IN PERIOD
Service life and reliability of assemblies and mechanisms, vehicle operational cost-
effectiveness in many instances depends on how well its parts bed in at the early operation stage.
During break-in period, it is required to monitor fixtures state, tightening up loose bolt and
other connections, as well as assemblies heating and, if the latter is excessive, determine the
cause and eliminate any defects.
For new vehicles and in cases of wheel replacement, wheel nuts are to be tightened after
about 50 km of mileage. Afterwards, wheel nuts must be tightened on daily basis, using the same
torque, until firm adherence is achieved.
For new vehicles, break-in periods correspond to 2000 km mileage.
The break-in period has restrictions as follows:
– the break-in mode for the vehicle should be sparing;
– weight of load transported by the vehicle (trailer train) must not exceed 60% of the nomi-
nal weight;
– driving speed at each gear should not exceed ¾ of the maximum allowable speed or allow-
able engine rpm;
After 2000 km mileage speed can be gradually increased to its maximum or, accordingly, to
the maximum allowable engine rpm.
Recommendations regarding servicing of the engine, clutch and gearbox during and after the
break-in period must be observed in strict compliance with the manufacturing plant instruction
guidelines.
At the early operating stage, after 2000 km mileage, it is necessary to carry out maintenance
as follows:
1 Change oil in vehicle units and assemblies as specified in the chimmotology lists.
2 Perform the entire scope of works as stipulated for maintenance (А) and carry out sup-
plementary fixing operations as stipulated for maintenance (С) (see section “Maintenance”).
After the above requirements are complied with, the vehicle can be operated as usual.

PARTICULAR ISSUES ASSOCIATED WITH VEHICLE OPERATION
Pre-operation procedures for the vehicle
Prior to operation, it is recommended to carry out some preliminary works, which presup-
pose checks and filling-in with operational fluids.
Depending on vehicle transportation conditions, batteries can be installed with or without
electrolytic solution.
Batteries, if they are empty of electrolytic solution, must be put into the working trim, and
the ones with electrolytic solution, if necessary, must be adjusted in terms of electrolytic solution
density.
Besides, the following checks should be carried out:
– check availability of cooling fluid and its level in the expansion drum and, if necessary, top
it up;
– check oil level in the engine pan, gearbox, drive axles, power steering system and, if nec-
essary, top oil up to the required level;
– check drive belt tension of the water pump, the generator, the compressor and the power
steering pump;
– check in-tire air pressure and, if necessary, adjust it as appropriate.
RULES FOR CABIN UPLIFT
Free access to the engine and its systems, the steering arrangement and other assemblies lo-
cated in the front part of a chassis is ensured by cabin roll-over against front hinged supports.
Prior to cabin uplift, switch the gear-change lever into the neutral position, remove the wire
rope from the pin, open the cab liner group and, using the respective handle, open the cabin lock
mechanism. For this purpose, the handle must be installed into bushing 2 (Figure 7) and lowered
down to the maximum.
Cabin uplift. For cabin uplift, turn the pump distribution block handle into “Lift up” posi-
tion and, using the handle inserted into the pump drive shaft hole activate the pump, until the ca-
bin is uplifted to its maximum.
As soon as the instable equilibrium position is reached, further cabin roll-over is inadvertent.
Cabin lowering. For cabin lowering turn the distribution block handle into “Lowering” po-
sition and lower the cabin, carrying out operations identical to the above.
When the cabin is in the downmost position, the automatic locking mechanism is enabled,
after which safety wire rope must be put onto the cabin axis pin.
The power unit should be serviced with cabin uplifted to its uppermost position.
1 – truss; 2 – bushing with a lever; 3 – bracket; 4 – linkage; 5 – support;
6 – washer; 7 – knuckle; 8 – cheek; 9 – pin; 10 – grabber; 11, 12 – springs
Figure 8 – Cabin lock mechanism:
а) lock mechanism open; b) lock mechanism closed

DRIVING AND CONTROLLING THE VEHICLE
When breaking away or moving along slippery road sections, interwheel and interaxle dif-
ferential lock is recommended to be enabled for a short-term (for a distance not exceeding 1 km).
The lock must be enabled immediately before entering a slippery road section. In this case, it is
required to throw in the clutch and enable the lock mechanism after the vehicle stopped moving.
It is forbidden to enable the differential lock mechanism at wheel slippage.
Use fog-lights to improve observability while driving in the rain, fog, snowfall.
Remove the leg from the clutch pedal while driving to avoid clutch slippage and failure.
When parked, the vehicle must be put on the parking brake and the gear box must be switch-
ed into the neutral position.
To tow a vehicle:
1 Detach the propeller shaft from the intermediate axle flange and fix it securely onto the ve-
hicle frame.
2 Disengage the vehicle from spring brake accumulators; fulfill rigid towing.
3 Unlock the steering post or detach the drag link from the tie-rod arm.
Vehicle brake control
MAZ vehicles have separate pneumatic drive circuits for front and back wheel brake de-
vices, auxiliary, parking and emergency brakes. Driving with lit indicating lamps 8, 9, 10 (Figure
4), signaling insufficient brakes pneumatic drive circuits pressure, is prohibited.
At first signs of stowage or sideslip of a trailer train, release the service brake pedal and
change for auxiliary brake, avoiding drift by turning the steering wheel towards where the drift is
directed.
To slow down trailer train motion at down slopes use the auxiliary brake and, if needed,
snub using the service brake. At this point, note that auxiliary brake is most efficient when the
supplementary box is in the slow range.
While driving along the slippery roads, a trailer train is recommended to be driven “at full
length”. For this purpose, in the first place, put the vehicle on the auxiliary brake. Auxiliary rate
intensity depends on control valve handle steering angle. The parking brake is enabled when this
handle is turned into the back fixed position.
When parking drive circuit pressure is low, spring accumulators are enabled and the vehicle
is put on the brake. To brake off the vehicle unscrew pusher fixing bolts from spring accumulator
cylinders (see Figure 8) or press pusher 12 while installing the spring accumulator (Figure 9).
Figure 8 – Unscrewing the pusher accumulator fixing bolt

1, 7, 11 – springs; 2, 5 – diaphragm; 3 – disk; 4 – guide bar; 6 – cylinder;
8 – balls; 9 – fixing bushing; 10 – breather hole; 12 – pusher
Figure 9 – Spring accumulator
Vehicle control
While driving, monitor instrumentation indications and indicating lamp signals. Air pressure
in the brake pneumatic drive circuits must be 637–784 kPa.
Besides instrumentation, assembly systems state is controlled by lamps indicating:
– when engine lube system pressure drops below 68–98 kPa (lamp for the oil pressure indi-
cator);
– when cooling fluid temperature goes up (lamp for the fluid temperature indicator);
– and when fuel left in the tank is sufficient only for another 20 km (lamp for the fuel level
indicator).
When enabling the parking brake, the interwheel and interaxle differential locks, turn lights,
when brake mechanism pneumatic drive circuits pressure drops below 441–539 kPa, lamps on
the instrumentation panel start to flash, and when chassis is on – those on the speedometer.
Engine power supply system
The coarse filter 4160RHH10MTC (4160RHHPA10MTC–MAZ) or 490RHH30MTC
(4160RHHPA30MTC–MAZ) is installed into the suction-pipe in order to protect diesel engine
fuel system (booster pump, fuel pump, injectors, valves and pistons), to improve combustion and
to provide fuel economy.
Pump fuel system using manual fuel pump, which is mounted on the coarse fuel filter, before
starting the engine. Remove air from the coarse fuel filter, installed on the chassis and from the
fine fuel filter, which is set on the engine. If there no air bubbles in the nozzle, set on the coarse
fuel and fine fuel filters, while pumping the fuel pump, it means the air absence in the fuel
supply system.
It is necessary to produce a sludge sink from the coarse fuel filter on a daily basis.
Filter replacement is recommended (the recommendations of the fuel filter manufacturer):
- for 4160RHH10MTC (4160RHHPA10MTC-MAZ) - after 15 000 km;
- for 490RHH30MTC (4160RHHPA30MTC-MAZ) - after 20 000 km
Anti-lock brakes
The 4-channel anti-lock brakes system (ABS) type 4S/4M (4 sensors / 4 modulator) with a
microprocessor control unit produced by “Wabco” (Germany) or "Ekran" (Belarus) can be
installed on a vehicle.
The main purpose of the system - automatic maintenance of optimum vehicle braking
without wheels locking no matter what the road is: slippery or dry.

Through this vehicles acquire a number of advantages:
-Improved active safety provided by break stability and control and improved break
efficiency, especially on wet and slippery roads
-Eextended life of tires
-The possibility for increasing the average safe speed:
-In addition, the ABS construction, applied by “Wabco” provides a possibility to use the
speed limit mode, while ABS system produced by Belarusian Industrial Association
“Ekran” provides storage and delivery of information about the last vehicle braking
performance (average deceleration) and system pre-emergency mode over the last 40
seconds.
-The system elements layout on the chassis and the instrument panel layout are shown in
Figures 10 and 11
-The sensors are installed on wheels of front and rear axles. At the same time on a three-
axle vehicles in the anti-lock mode the group breaking wheels control of rear and
medium axles of a corresponding board side of a trolley is performed by the same
modulator.
Compliance with the rules and additional safety measures when operating a vehicle
with electronic systems
During operation it is necessary to observe the following conditions:
- while repairing a vehicle and replacing its electronic system elements, the battery must be
disconnected.
- NEVER connect electrical connectors to the control unit before the end of the system
installation.
- NEVER apply voltage directly to the contacts control unit
- the system voltage measurement should be performed only by appropriate instrumentation!
Input impedance of a measuring device must be at least 10 MOhm.
- electronic control unit connectors must be disconnected. Connect them to the control unit
only when the ignition and instrument panel switch is off.
- do not operate the vehicle with the "mass" circuit resistance of more than 3 ohms between
the "minus" of the battery and the electronic unit plug. Loosening of the mass wires is not
allowed;
- during electric welding on a vehicle it is necessary to: disconnect all electronic unit
connectors, unplug the battery and connect electrically the plus and minus battery cable tips.
In this case the vehicle power switch, which switches the battery “plus” off, must be enable
(i. e. the contacts must be closed). The welding machine grounding must be connected as
close as possible to the welding point. When carrying out welding works on the cabin –
connect ground to the cabin, when welding on the chassis - connect ground to the chassis;
- NEVER lay the welding apparatus cable in parallel to the vehicle wiring
- During painting works, the electronic components can be subjected to heating in an oven to
a temperature of 95 C for a short period of time (up to 10 minutes), at a temperature of 85 C
in an oven chamber – up to 2 hours. At the same time the battery must be disconnected.