URAL Motorcycles URAL-4320-60 User manual

URAL-4320-60/61, URAL-43206-61, URAL-5557-60
TRUCKS
AND THEIR MODIFICATIONS

РДР №4588 от 19.12.2014г
URAL-4320-60/61, URAL-43206-61, URAL-5557-60
TRUCKS
AND THEIR MODIFICATIONS
Operation Manual
4320-3902037 РЭ
(First edition, revised)
© UralAZ
Reprinting, duplicating or translating
in whole or in part without written
permission of the «Ural» Automobile
Plant Open Joint-Stock Company is
prohibited
Miass – 2014

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The Operation Manual is to be used by drivers and motor service staff involved in Ural
trucks operation. This Operation Manual includes the trucks technical specification, a brief de-
scription of the truck units and subunits, their adjustment and maintenance, and reference data.
Due to constant product improvement enhancing its reliability and operating conditions,
certain changes not included in this Manual may be made to the design.
When operating the trucks, use the present Operation Manual, Yaroslavl Motor Works
YAMZ-236НЕ2, YAMZ-236НЕ, YAMZ-236Н, YAMZ-236БЕ2, YAMZ-236БЕ, YAMZ-236Б
Power Units Operation Manual, and Addendum YAMZ-6565, YAMZ-65651, YAMZ-65652,
YAMZ-65653, YAMZ-65654 Engines and their configurations to the Operation Manual for
YAMZ-236НЕ2, YAMZ-236НЕ, YAMZ-236Н, YAMZ-236БЕ2, YAMZ-236БЕ, YAMZ-236Б
Power Units, Air Heater Specification and installation instruction, Storage Batteries Operation
Manual, Starting preheater Operation Manual, Gearbox Operation Manual, Tow unit 21-202 In-
stallation and Operation Manual, Tachograph Operation Manual.
Compiler: N. Tebenjkova
Editor-in-Chief: V. Trofimov

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CONTENTS
1 Foreword . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety Requirements and Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Safety Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Controls and Instruments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Adjustment and Servicing of Truck Components (Brief Description) . . . . . . . . . . . . . . . . . . . . . . 38
5.1 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.1 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.2 Engine Starting Preheating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1.3 Gas Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1.4 Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.5 Power Unit Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2.1 Clutch Release Drive with Air-Hydraulic Booster. . . . . . . . . . . . . . . . . . . . . . . . 47
5.2.2 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2.3 Cardan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.2.4 Driving Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.3 Running Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.1 Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.2 Truck Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3.3 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.3.4 Spare Wheel Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.4 Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.4.1 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.4.2 Maintenance of Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.5 Brake Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.5.1 Service Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.5.2 Pneumatic Drive of Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.5.3 Maintenance of Brakes Pneumatic Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.5.4 Emergency Brake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.5.5 Parking Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.5.6 Truck Brake System with Anti-Lock Braking System (ABS). . . . . . . . . . . . . . . . 117
5.5.7 Auxiliary Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.6 Electric Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.6.1 Electronic Speedometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.6.2. Electric Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.6.3. Storage Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.6.4 Lighting and Alarm System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.7 Cab, Hood and Fender Assembly and Truck Platform Body . . . . . . . . . . . . . . . . . . . . . . . 138
5.7.1 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.7.2 Hood and Fender Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.7.3 Truck Platform Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.8 Bolster Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.9 Special Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.9.1 Power Take-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.9.2 Auxiliary Power Take-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.9.3 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.9.4 Tire Pressure Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.9.5 Sealing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
6 Possible Troubles and Methods of Trouble Shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7 Peculiar Features of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
7.1 Preparing New Truck for Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

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7.2 Engine Start and Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
7.3 Running-in a New Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
7.4 Driving Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
7.5 Truck Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.1 Maintenance Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.3 List of Maintenance Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
8.4 Truck Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.4.2 Chart of Lubricants and Working Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
10 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
11 Salvaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Appendices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

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1. FOREWORD
1.1. Ural all-terrain trucks (4х4, 6х6), with YAMZ-65654 diesel engine, with a
three-seat, all-metal cab located behind the engine are intended for transporting cargoes, people
and towing trailers on all kinds of roads and terrain.
Ural-4320-0111-61 truck shown in Fig. 1 is intended for transporting various cargoes,
people and towing trailers on all kinds of roads and terrain.
Ural-4320-1151-61 chassis is intended for packaging specialties.
Ural-43203-1151-61 chassis is intended for mounting box van body.
Ural-4320-0911-60 truck with an enhanced base is intended for transportation of various
cargoes and people and for towing trailers on all kinds of roads and particular terrain.
Ural-4320-1951-60 special chassis with an enhanced base is intended for mounting
technological equipment and specialties (oilfield, crane, drilling, tankers, fire fighting, municipal
etc), towing trailers on all kinds of roads and particular terrain.
Ural-5557-1151-60, Ural-55571-1151-60 chassis shown in Fig. 2 are intended for
mounting various bodies and equipment.
Ural-43206-0111-61 truck shown in Fig. 3 is intended for transporting various cargoes,
people and towing trailers on all kinds of roads and terrain.
Ural-43206-1151-61 multipurpose chassis without a spare wheel holder is intended for
packaging specialties.
Ural-44202-0311-60 bolster truck is intended for towing semi-trailers on all kinds of
roads. Ural-44202-0511-60 bolster truck with a two-door cabin with a berth is intended for
towing semi-trailers on all kinds of roads.
Fig. 1 – Ural-4320-61 Truck

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Fig. 2 – Ural-55571-60 Chassis
Fig. 3 – Ural-43206-61 Truck

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The trucks are designed for operation at ambient temperatures ranging from +50 °C
down to –45 °C (a short-time operation at –50 °C).
The trucks meet the requirements of Specifications 37.165.404-2012 "Ural" 4x4, 6x6
Trucks".In case of using the trucks for other purposes, or with violations of operating instructions,
as well as introducing any design changes without the consent of the “URAL” Automobile Works
OE JSC, the manufacturer will not accept reclamations from customers or consider any claims.
The first overhaul period for the first category of the operational conditions in accordance
with the "Regulations on the maintenance and repair of rolling stock of automobile transport",
subject to all the rules specified in the Operation manual, for the trucks should be not less than: for
Ural-43206-61, Ural-5557-60, Ural-55571-60 vehicles and their modifications — 200 000 km, for
Ural-4320-60/61 vehicles and their modifications — 250 000 km.
During this period, the replacement of components and assemblies that have covered
their predetermined haulage is permissible, which is also valid for purchased items which resource
specified in the manufacturer plants technical documents and standards, is shorter than the vehicle
resource.
The trucks and chassis are available in various packaging for design variants and nomen-
clature of the components.
On the basis of the trucks and chassis various products (tank trucks, crane trucks, oil field
equipment, vans, etc.) are manufactured as well. All comments and proposals regarding their work
should be referred to manufacturers of those products).
It is allowed to use the trucks with pull-type systems which have air outlets and electric
outlets as per GOST 9200-76 (version II), the brake system air outlet as per GOST 4364-81 Stan-
dard, brake systems as per GOST 22895-77 Standard, a gross weight corresponding to the specifi-
cations, and drawbars: for trailers – a coupling pin having “A” diameter as per GOST 12017-81
Standard that is equal to 50.8 mm and mounting dimensions as per GOST 12105-74 Standard for
rated load on the fifth wheel over 83.3 kN (8.5 tf)2349 Standard or a coupling pivot as per GOST
R 41.55 Standard for semi-trailers having “A” diameter as per GOST; for trailers* — a trailer
hitch (drawbar eyelet) must comply with class D50 as per GOST R 41.55-2005 (for non-clearance
tow unit), basic dimensions must comply with GOST R 41.55-2005 Standard and ISO 1102-75.
Application of eyelets of other dimension is not allowed.
Mounting of various equipment and mechanisms onto the truck and its chassis is allowed
only after agreeing it upon with the Engineering Department of the “URAL” Automobile
Works. Otherwise, a customer shall be deprived to make any claims relating to premature failure
of truck components.
1.2. Marking of Ural trucks and chassis comprises the truck marking as a whole
transport means, marking of the chassis and cab and engine as constituent parts of the transport
means. The structure of the marking corresponds to a "Wheeled vehicles safety technical regula-
tion».
* Upon the Customer request it is technically feasible to install a towing coupler of «hook-loop»
type (delivered as spare parts to Ural vehicles) for using with trailers as per GOST 2349-75 dimension-type
3. The towbar (coupling hook lug) should correspond to GOST 2349-75.
The VIN identification number (or that of the chassis) is marked by impact method on
the back of the truck right side member:

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- for 4х4 trucks (chassis) at the distance of 200-300 mm back from the rear axle and 40-
60 mm down from the sidemember upper flange;
- for 6х6 trucks (chassis) at the distance of 1000-1250 mm back from the bogie axis and
40-60 mm down from the sidemember upper flange.
The nameplate is attached to the r. h. panel of the cab side near the footstep. The name-
plate contains:
- manufacture trademark;
- identification number;
- modification;
- technically permissible maximum weight;
- technically permissible maximum axle loads;
- technically permissible gross combination weight;
- maximum load on fifth wheel arrangement load;
- Vehicle (chassis) Type Approval number.
To the left of the nameplate, the cab number is marked on the right panel of the cab in-
step plate. The marking contains 14 digits and is applied by hammering
Structure of the vehicle identification number and its explanation:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Х1 Р∗
∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗
∗
- Variable data
Item 1-3

Х1Р– “URAL” Automobile Works” JSC, Miass, Chelya
binsk Region,
Russia (manufacturer’s international identification code)
Item 4-9

Product designation
Item 10

Year of manufacture
Item 11-17

Serial production number of vehicle
Letters used for indicating the year of manufacture:
D - 2013 F-2015
E - 2014 G - 2016
Data on engine marking are given in «YAMZ-236НЕ2, YAMZ-236НЕ, YAMZ-236Н,
YAMZ-236БЕ2, YAMZ-236БЕ, YAMZ-236БPower Units» Operation Manual, «YAMZ-6565,
YAMZ-65651, YAMZ-65652, YAMZ-65653, YAMZ-65654 Engines and their configurations»
Addendum to the Operation Manual «YAMZ-236НЕ2, YAMZ-236НЕ, YAMZ-236Н, YAMZ-
236БЕ2, YAMZ-236БЕ, YAMZ-236БPower Units».

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2 Safety requirements and precautions
2.1 Safety requirements
2.1.1 Before you start working, make sure that the truck and its coupling devices are in
good working order.
2.1.2 While driving the vehicle, the driver and passengers must wear seat belts.
2.1.3 Do not start the truck engine, without making sure that the gearbox is in neutral.
2.1.4 Service and repair the truck on a level ground, after having braked the parking
brake by disconnecting the batteries using the switch and placing wheel chocks under the wheels.
2.1.5 Keep the engine and starting preheater clean and maintain their working order,
make sure there are no fuel and oil leakages: this may cause fire. During the preheater operation,
do not leave the vehicle unattended.
2.1.6 In the process of filling the truck with fuel, the pre-heater must be switched off.
2.1.7 Do not warm up the engine, if the truck is indoors, and ventilation is poor.
2.1.8 Coolants (low-freezing) and brake fluids are toxical: handle with care.
2.1.9 To climb the truck front bumper and descend it, use the step plate, central and left-
most (in direction of travel) grille ribs having on the inserts on the inner side, as shown in Figure
4. 2.1.10 When servicing the engine, fix the hood lifting mechanism with a safety hook 1
(Fig.5). 2.1.11 Before dismantling the wheel put the wheel chocks under the unlifted axle wheels
in order to avoid the vehicle self-motion. Unfasten the wheel nuts, hang out the wheel with jack or
other hoisting device, unscrew the nuts and dismantle the wheel.
To lift the front axle with the jack, insert its screw head in the spring clamp socket; to lift
the rear axle – under the spring supporting bracket.
1- safety hook
Fig. 5 - Hood Lifting
Mechanism Safety Lock
Fig. 4 - How to Use Step and Radiator Grill Ribs,
When Climbing Bumper and Coming Down It