URAL Motorcycles 4320M User manual

URAL-4320М TRUCK
and its Modifications

URAL-4320М TRUCK
and its Modifications
Operation Manual
4320М-390203 -10 РЭ
(2
nd
edition, amended)

URALAZ
Partial or full reprint, duplication or
translation is not allowed without
written permit of OJSC “URAL
Motor Vehicles Plant”
Miass – March 2017.

2
The Manual is dedicated for drivers and motor transport workers connected with Ural
tucks operation. The Manual gives technical specifications of the trucks, short description of their
construction and operation of truck components, their adjustment and maintenance, reference da-
ta.
Due to constant modernisation of the product improving its reliabilit and operation con-
ditions, the construction ma be partiall amended, and such amendments are not included in this
Manual.
When operating URAL truckswith 4х4, 6х6 wheel arrangement and its modification with
“Euro-4” engines and pneumatic brake s stem drive the following should be used:
Operation Manual “Ural-4320M trucks and its Modifications”;
Operation Manual “YAMZ-536, YAMZ-5362, YAMZ-5362, YAMZ-5363, YAMZ-5364
Engines”
Operation Manual for ZF 9S 1310 Gearbox (for power units with ZF gearbox);
Operation Manual for YAMZ-0905 Gearbox (for power units with YAMZ-0905 gear-
box);
Operation Manual for YAMZ-1105 Gearbox (for power units with YAMZ-1105 gear-
box);
Operation Manual for
9JS135ТА Gearbox (for power units with FAST GEAR gearbox).
Operation Manual for the Engine Starting Heater;
Operation Manual (Instruction) for “Lead-acid, starter Storage Batteries”)
Installation and Operation Manual for Drawbar Coupling;
Operation Manual “URAL 73.3801-01 Combination of Devices” АДИГ.453895.012РЭ
Элара.
The Tachograph Installation and Operation Manual.
In the second edition of the Operation Manual amendments relating to the tachograph in-
stallation (Chapter “Control Tools and Devices”); regulation of transfer box (Chapter “Transmis-
sion” paragraph “Transfer Box”); maintenance intervals (Chapter “Maintenance”, paragraphs
“List of Trucks Maintenance Operations”, “Lubricants and H draulic Fluids Charts”) are made.
The Manual is compiled b the engineers of the Engineering Design Department of OJSC “URAL
Motor Vehicles Plant” Kochetkov A.L., Karkavin V.I., Kird ashkin A.N., Kropotov A.N., Polen-
kov A.A., Pushkin Yu.A., R balkin D.A., Smirnov I.G., Savanovich V.P., Sokolov A.P., Sokolov
O.V., Trofimov V.A., Shevchenko S.V., Maltsev A.V. Under the general management of the
Chief Designer for Commercial Vehicles Zakharik A.M.
Draftsman: Petrova N.A.
Publishing Editor: Trofimov V.A.

3
Contents
Introduction.............................................................................................................................. 5
1 Safet Requirements and Warning........................................................................................ 7
1.1 Safet Requirements............................................................................................ 7
1.2 Warnings.............................................................................................................. 9
2 Technical Specifications........................................................................................................ 12
2.1 Technical Specifications of 6х6 Trucks with Conventional Cab ...........................
12
2.2 Technical Specifications of Chassis of 6х6 Truck with Conventional Cab............
15
2.3 Technical Specifications of 6х6 Cabover Trucks .................................................. 18
2.4 Technical Specifications of Chassis of 6х6 Cabover Trucks .................................
22
2.5 Technical Specifications of 4x4 Trucks and Chassis..............................................
25
2.6 Dimensions of 6x6 and 4x4 Trucks and Chassis………………………………… 28
3 Control Tools and Devices.....................................................................................................
36
3.1 Control Tools and Instrumentation of Conventional Cab Trucks...........................
36
3.2 Control Tools and Instrumentation of Cabover
Trucks....................................................................................................................................... 40
3.3 Subscription Station……………………………………………………………… 43
4 Truck Components' Structure and Operation Description, their Adjustment and Mainte-
nance......................................................................................................................................... 46
4.1 Engine..................................................................................................................... 46
4.1.1 Feed S stem......................................................................................................... 46
4.1.2 The Engine Starting Heater S stem..................................................................... 50
4.1.3 Gas Exhaust S stem.............................................................................................
51
4.1.4 Cooling S stem.................................................................................................... 52
4.1.5 Power Unit Suspension........................................................................................ 55
4.1.6 Engine Idle Adjustment....................................................................................... 56
4.2 Transmission....................................................................................................................... 58
4.2.1 Clutch Control with Air-Over H draulic Booster............................................... 58
4.2.2 Wabco Air-Over H draulic Booster Construction and Operation……………... 62
4.2.3 Gearbox................................................................................................................ 65
4.2.4 Transfer Box........................................................................................................ 66
4.2.5 Driveline.............................................................................................................. 71
4.2.6 Driving Axles...................................................................................................... 74
4.3 Undercarriage......................................................................................................................
82
4.3.1 Frame................................................................................................................... 82
4.3.2 Truck Suspension................................................................................................. 83
4.3.3 Wheels and Tires..................................................................................................
90
4.3.4 Spare Wheel Holder............................................................................................. 100
4.4 Steering wheel.....................................................................................................................
102
4.4.1 Steer..................................................................................................................... 102
4.4.2 Booster................................................................................................................. 103
4.4.3 Steering Wheel Oil Tank..................................................................................... 105
4.4.4 Steering Wheel H draulic Booster Pump............................................................ 105
4.4.5 Tie Rod Ends....................................................................................................... 106
4.4.6 Steering Wheel Maintenance............................................................................... 106
4.5 Brake S stems.................................................................................................................... 109
4.5.1 Primar Brake S stem......................................................................................... 109
4.5.2 Primar Brake S stem Pneumatic Drive............................................................. 118

4
4.5.3 Emergenc Brake S stem.................................................................................... 129
4.5.4 Parking Brake S stem.......................................................................................... 129
4.5.5 The Antilock Brake S stem (ABS)......................................................................
132
4.6 Electrical Equipment...........................................................................................................
141
4.6.1 Conventional Cab Truck Wiring Diagram……………………………………...
141
4.6.2 Cabover Truck Wiring Diagram.......................................................................... 144
4.6.3 Fuses.................................................................................................................... 148
4.6.4 Alternator............................................................................................................. 152
4.6.5 Storage Batteries.................................................................................................. 153
4.6.6 Lighting and Alarm S stem................................................................................. 157
4.7 Cab, Trim Package and Platform........................................................................................ 159
4.7.1 Cab....................................................................................................................... 159
4.7.2 Trim Package.......................................................................................................
168
4.7.3 Platform................................................................................................................
168
4.8 Fifth-Wheel Coupling......................................................................................................... 172
4.9 Dedicated Equipment.......................................................................................................... 176
4.9.1 Power Takeoff......................................................................................................
176
4.9.2 Additional Power Takeoff....................................................................................
178
4.9.3 Winch................................................................................................................... 179
4.9.4 Tire Pressure Control S stem.............................................................................. 185
5 Troubleshooting……………………………………………………………………………. 189
6 Operation Features................................................................................................................. 194
6.1 Preparation of a New Truck for Operation............................................................. 194
6.2 Engine Start and Stop..............................................................................................
194
6.3 Truck Breaking In………………………………………………………………... 194
6.4 Truck Driving..........................................................................................................
195
7 Maintenance........................................................................................................................... 200
7.1 List of Truck Maintenance Operations................................................................... 201
7.2 Truck Lubrication................................................................................................... 222
7.3 Lubricant and H draulic Fluid Charts.................................................................... 224
8 Storage................................................................................................................................... 248
9 Transportation........................................................................................................................ 252
10 Disposal................................................................................................................................
255
Appendices................................................................................................................................
256
Appendix A Torques of Basic Screw Joints…………………………………………. 256
Appendix B Control and Adjustment Information....................................................... 260
Appendix C Weight of Basic Assembl Units............................................................. 261
Appendix D Antifriction Bearings............................................................................... 262
Appendix E Oils, Lubricants and Special Fluids.......................................................... 265
Appendix F Auto Bulbs and their Specifications……………………………………. 267
Appendix G Used Oil Discharge Standard................................................................... 268
Appendix H Spare Parts, Tools and Accessories.......................................................... 269
Appendix I List of Gaskets Installed to the Truck........................................................ 275
Appendix J Maintenance Interval Coefficient Correction Chart Depending on Truck
Operation Conditions................................................................................................................ 277

5
Introduction
Modernized URAL trucks with 4x4 and 6x6 wheel arrangement and YAMZ-536 engine
(emission class 4) are dedicated for cargo transportation (except hazardous cargo), people trans-
portation and trailing on an kinds of roads and terrain.
URAL trucks are designed for operation at air temperatures from minus 45 to plus 50 °С
(short time operation up to minus 50 °С is possible).
URAL trucks compl with TS 37.165.392-2011 requirements: “URAL trucks with 4x4
and 6x6 wheel arrangement and YAMZ-536 engine”.
First overhaul period at first operation categor according to “The Regulation for
Maintenance and Overhaul of Automobile Vehicles” (if all the rules specified in the Operation
Manual are observed) should be at least 350 000 km.
During the said period separate units and devices with run predetermined renewal mile-
age, as well as bought-in components lifetime of which is less than the truck life according to
technical documents and standards of the supplier can be replaced.
Product lifetime is 10 ears minimum.
Trucks and chassis are manufactured in various configurations for design variants and
components nomenclature.
The trucks are dedicated for operation with trailers having pneumatic transmissions ac-
cording to GOST R 50023-92 and electric transmissions according to GOST 9200-76 (design var-
iant II), pneumatic transmission of braking s stem, brake s stems according to the United Nations
Economic Commission for Europe No. 13-10, gross vehicle weight according to technical specifi-
cations of the truck, towing hitch:
- semi-trailers - fifth-wheel king pin t pe A according to GOST 12017-81 equal to 50.8
mm, and connecting dimensions according to GOST 12105-74 for fifth-wheel rated load over
83.3 kN (8.5 tf);
- trailers - trailer hitch (drawbar e e) should compl with D50 class according to GOST
R 41.55-2005 (for antibacklash tow unit), basic e e dimensions should compl with GOST R
41.55-2005 and ISO 1102-75. Application of other dimension eyes is forbidden.
CAUTION! It is strictly forbidden to use toroidal drawbar eyes of L class accord-
in to GOST R 41.55-2005.
On customer’s request it is possible to install “hook-e e” drawbar couplings (delivered
as spare parts for Ural trucks) for operation with trailers according to GOST 2349-75, standard
size 3. Trailer hitch (drawbar e e) must compl with GOST 2349-75.
Basic trailer model is 82Б (2ПН-4М).
Installation of various equipment and devices to the truck and its chassis is allowed on
approval with the Design Engineering Centre of the plant. If otherwise, the customer will have no
right to claim earl breakage of truck parts.
URAL trucksare not dedicated for hazardous cargo transportation without additional ad-
aptation.
Ural truck and chassis are marked according to technical regulation of wheel vehicle
safet .
Manufacturer’s tables are installed on the right panel of cab side, in lower part. The
manufacturer’s table has the following information:

6
- Trade mark of the manufacturer;
- Identification number;
- Modification;
- gross vehicle weight rating;
- gross axle weight rating;
- gross road-train weight rating;
- gross fifth-wheel coupling load rating;
- Approval number of vehicle t pe (approval of chassis t pe).
Identification number is marked on the right frame girder in rear part.
Vehicle identification number structure and contents:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Х 1 Р * * * * * * * * * * * * * *
______________
*Variable information
Pos. 1-3: Х1Р - manufacturer's international identification code (WMI) -
OJSC “The Automobile Plant “Ural”
Pos. 4-9: t pe and modification identification:
432000 is for 4320-?-7?
43203? is for 43203-1151-71,
432060 is for 43206-?11-71,
442020 is for 44202-0?11-7?,
555700 is for 5557-?-7?
555710 is for 55571-???1-7?
Pos. 10: Manufacturing ear code
Pos. 11-17: Vehicle plant number
Figures used for identif ing manufacturing ear:
В - 2011, С - 2012, D - 2013, Е - 2014.
Cab and engine are marked as components according to OST 37.001.269-96.
Cab as a vehicle component is marked on the right side as viewed in the direction of ve-
hicle motion in the lower part of the door opening. The marking includes 14 signs.
Information on the engine marking is given in the Operation Manual for “YAMZ-536,
YAMZ-5361, YAMZ-5362, YAMZ-5363, YAMZ-5364 Engines”.
The table with the conformit mark is located close to the manufacturer’s plate.

7
1. Safety and Warnin Requirements
1.1 Safety Requirements
1.1.1 Before starting operation check the truck and its drawbars proper functioning.
1.1.2 When drivin a truck, the driver and the passen ers must fasten safety belts.
1.1.3 Do not start the truck engine without ensuring that the truck is put in neutral.
1.1.4 Maintain and repair the truck on a horizontal platform. Brake the truck with the
parking brake, select first gear in the gearbox, switch off storage batteries.
1.1.5 Keep the engine and engine starting heater clean and properl functioning, avoid
fuel and oil leakage: it can cause fire. Do not leave the truck unattended when the engine starting
heater is in operation.
1.1.6 The engine starting heater must be switched off when fuelling the truck.
1.1.7 It is forbidden to heat the engine in closed rooms with poor ventilation.
1.1.8 Cooling (low-freezing) and h draulic fluids are poisonous, and should be handled
with care.
1.1.9 To climb and go down the truck bumper use the running board, central and the ex-
treme left (as viewed in the direction of vehicle motion) grille fins having bushes on the internal
part, as shown in figure 1.
1.1.10 When servicing the engine, fix the hood lift with safet hook 1 as shown in figure
2.
1.1.11 Before dismantling a wheel put additional blocks under the wheels of another axle
that won’t be lifted to avoid truck rolling. Unfasten wheel nuts, jack up the wheel or hoist it with
an other lifting device.
To jack up the front axle put the jack head into the spring clip bed, to jack up the rear bo-
gie put the jack head under the spring mountain bracket.
1.1.12 It’s forbidden to dismantle a truck wheel without preliminar tire deflating.
1-Safet hook
Figure 2 - Hood lift protector
Figure 1 - Method of Using the Running Board
and Grille Fins When Climbing and Going Down
the Bumper

8
1.1.13 It is forbidden to install the assembled wheel with deflated tire and to inflate it
with tire inflation s stem.
1.1.14 The plant warns on strict compliance with safety rules at tire fittin (see par-
a raph “Wheels and Tires”).
1.1.15 When lowering the rear wheel, keep awa from the carrier tilting bracket opera-
tion zone.
1.1.16 Do not take out the ke from the ignition switch before the truck is completel
stopped, as it can lead to loss of vehicle control due to blocking the steering shaft b the anti-theft
device.
1.1.17 The truck cannot be operated without snap ring of the lock, and storage batteries
container cover butterfl nut*.
1.1.18 To avoid storage batteries drop when maintaining them on the truck, the batteries
must be forwarded from the container to the container flap ensuring their secure fixation in the
horizontal position*.
1.1.19 In case of skin exposure to batter fluid, wash the exposed skin with water during
5-10 minutes and sprinkle with 10% water ammonia spirit and then with diluted soda solution.
1.1.20 Check the condition of wire insulation from “+” terminal of the storage batter to
the stator: insulation damage can cause fire.
1.1.21 Welding must be done with compliance with fire safet rules. When using electric
welding, switch off the wires from the alternator, storage batteries and electronic control units,
protect plastic pipes and fuel pipes form damage. Connect the general wire of the welding ma-
chine close to the weld area excluding current flow through bearings and friction pairs.
1.1.22 When grade climbing, choose the correct speed in advance.
1.1.23 When transporting passengers, lock the right cab door b turning the handle
down.
1.1.24 Couple and disconnect the trailer (semi-trailer) on an even horizontal platform.
1.1.25 When operating the winch:
- do not sta under the carried load and close to pulled rope;
- do not bend and tie the rope, it can lead to its damage and breakage. When pulling the
rope over a road, establish securit and put access prohibitor signs.
1.1.26 When operating the autonomous heating unit it is forbidden to:
- sleep in the cab with the autonomous heating unit in operation;
- operate the heating unit with completel or partiall closed intake and exhaust pipes;
- start and operate oiled heating unit;
- fuel the truck with the heat unit in operation;
- leave the heating unit unattended;
- operate the heating unit without gas outlet pipe.
When operating the heating unit remember that careless operation of the unit as well as
its failures can cause fire and exhaust gas poisoning.
________________
* for conventional cab trucks

9
1.2 Warnin s
Normal truck operation and its long life can be onl ensured, if compl ing with all the
recommendations described herein.
1.2.1 Before operating the truck read the paragraphs “CAUTION”, “SAFETY RE-
QUIREMENTS” and “ENGINE START, OPERATION AND STOP” of the Operation Manual
for the engine.
1.2.2 To avoid air in the feed s stem, do not burn out the fuel tank.
1.2.3 To empt the engine cooling s stem completel , put the truck horizontall or with
forward tilt.
1.2.4 Empt the coolant from the engine cooling s stem through the inlet pipe of the wa-
ter pump when the cab heater valve is open and the radiator caps are open.
1.2.5 The truck is equipped with the automatic engine starting heater. For safet reasons
oil is not heated in the oil reservoir. To avoid oil starvation when starting the engine at low tem-
peratures, strictl compl with the recommendations of using engine oils described in the Opera-
tion Manual for “YAMZ-536, YAMZ-5361, YAMZ-5362, YAMZ-5363, YAMZ-5364 Engines”.
1.2.6 When driving the truck from the tracing rut, do not keep the truck with the steering
wheel in its extreme position, as it can lead to oil overheating in the steer h draulic s stem, and,
consequentl , to pump breakage.
For the same reason in case of engine power take off when operating in stead -state
conditions, release the steering shaft load b turning the steering wheel until backlash.
Set the steering stem to the neutral position according to the following procedure:
- with the engine on, turn the front wheels to the extreme right or left position and re-
lease the steering wheel;
- stop the engine;
- when the front wheels partiall return automaticall , set the steering wheel in the mid-
dle within the backlash at the existing wheel position.
After the actions described above the engine can be started and operating in stead -state
conditions can be started.
1.2.7 Select first gear to move the truck from a standstill. Reducing transmission “C” of
ZF9S 1310 TO, 9JS135TA gearboxes can be used at manoeuvring at 10 km/h maximum. Do not
use “C” transmission to climb a slope. Do not move the truck from a standstill b fierce release of
the clutch pedal.
1.2.8 Before moving air pressure in the brake s stem must be 440 kPa (4.7 kgf/cm
2
) at
least. If low pressure indicator of the brake circuit is on, eliminate defects before moving.
1.2.9 When operating the truck in off-road (sand , dirt roads and etc.) check the condi-
tion of the brakes and change brake pads on time.
1.2.10 Before moving check the operation of indicator lamps according to figures 25 and
29.