KAMAZ 5320, 5410, 55102, 55111, 53212, 53211, 53213 KAMAZ-5320 Repair Manual

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🏷️ Basic Information Identification Make: KAMAZ Brand Origin: Russia Manufacturer: KAMAZ (KamAZ Publicly Stock Company) Codes Product Name: KAMAZ Truck RUSSIAN (KAMAZ-5320, 5410, 55102, 55111, 53212, 53211, 53213, 54112, 43114, 43118, 65111, 53228, 44108, 43115, 65115, 6540, 53229, 4326, 53215, 54115) Service Workshop Shop Repair Manual 👋 Introduction Market Position Vehicle Class: Heavy-duty trucks, designed for utility, construction, long-haul transport, and specialized applications. Primary Markets: Primarily Russia and former Soviet bloc countries, but also exported to various global markets, particularly developing nations, due to ruggedness and cost-effectiveness. Competitive Analysis Competitors: Internationally: MAN, Mercedes-Benz (Unimog), Volvo, Scania, International. Domestically/Regionally: ZIL, KrAZ, MAZ. Key Features Design Philosophy: Robust, durable, and designed to operate in harsh environmental conditions with simplified maintenance and readily available parts within its primary market. Varied Configurations: The broad model range indicates versatility, covering dump trucks, tractors, flatbeds, and specialized chassis for various body conversions. 📋 Manual Details Coverage Areas Covered Models List: KAMAZ-5320, KAMAZ-5410, KAMAZ-55102, KAMAZ-55111, KAMAZ-53212, KAMAZ-53211, KAMAZ-53213, KAMAZ-54112, KAMAZ-43114, KAMAZ-43118, KAMAZ-65111, KAMAZ-53228, KAMAZ-44108, KAMAZ-43115, KAMAZ-65115, KAMAZ-6540, KAMAZ-53229, KAMAZ-4326, KAMAZ-53215, KAMAZ-54115 Page Count Estimated Page Count: Varies significantly by specific model and edition, but typically between 500-1500+ pages for a comprehensive service manual covering multiple variants. Manual Type Type: Service Workshop Repair Manual Language Language: Russian Format Format: Likely digital format (PDF) given the product description, but original could be printed. Details on print quality and binding are not available without physical inspection or specific product listing. 📖 Manual Coverage Systems Covered Powertrain: Engine (disassembly, assembly, diagnosis, repair), Transmission (gearbox repair, clutch, driveshaft), Drivetrain (differentials, axles, transfer cases). Chassis: Suspension (front and rear), Steering system, Braking system (air brakes, hydraulic components, parking brake), Wheels and tires. Electrical: Wiring diagrams, Lighting system, Ignition system, Starting and charging system, Instrument cluster, Electrical accessories. Body And Frame: Body panels, Cab structure, Chassis frame, Doors, Glass, Seats, Interior trim, Cargo body (tipper, flatbed, etc.). Fuel And Exhaust: Fuel tank, Fuel lines, Fuel injection system (specifics depend on engine), Exhaust system. Cooling And Lubrication: Cooling system (radiator, thermostat, fan, water pump), Lubrication system (oil pump, oil filter, oil cooler). Procedures Included Maintenance: Scheduled maintenance, lubrication charts, fluid level checks, filter replacement, brake adjustments, belt tensioning. Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (if applicable to era/systems), component testing procedures. Repair: Step-by-step repair instructions for all major mechanical and electrical components, including engine overhauls, transmission rebuilds, brake system repairs, and bodywork. Specifications: Torque specifications, clearances, tolerances, fluid capacities, part numbers (may be for OEM parts of the era). Special Tools: Identification and usage of specialized tools required for specific repair procedures. Technical Depth Depth: Comprehensive workshop-level repair information, suitable for professional mechanics and skilled DIY technicians. Covers from routine maintenance to complete vehicle overhauls. 📊 Manual Specifications File Format Digital Format: Likely PDF. Searchable text is a significant advantage if available. Image quality of diagrams and illustrations is crucial for usability. Print Quality Print Quality Notes: If printed, quality depends on the source. Original manufacturer manuals generally have good print and diagram clarity. Reproductions may vary. Binding Type Binding: If printed: Likely saddle-stitched or perfect bound for original manuals. Spiral binding is common for workshop use to lay flat. Paper Type Paper Quality: If printed: Typically a durable, matte paper stock to withstand workshop conditions. Glossy paper might be used for photographs. ⚙️ Engine Specifications Primary Engine Engine Family: KAMAZ diesel engines, notably the KAMAZ-740 series and its derivatives, and later Cummins B-series (ISB) and C-series (ISC) engines in some models. Typical Displacement: Ranges from 10.85 liters (KAMAZ-740.10) up to 14.89 liters for some V8 variants. Cummins variants typically 5.9L and 8.3L. Performance Horsepower Range: Typically 200-350 hp, depending on the specific engine variant and emissions standards of the era. Torque Range: Significant torque output, generally in the range of 650-1000 Nm, essential for heavy hauling. Fuel System Fuel Type: Diesel Injection System: Typically mechanical injection (e.g., VEB-based or similar rotary/inline pumps) for older models, transitioning to electronically controlled common rail for later variants or Cummins engines. Cooling System Cooling Type: Liquid-cooled, pressurized system. Lubrication System Oil Type Recommendation: API CF or CD rated heavy-duty diesel engine oils, viscosity typically SAE 15W-40 or 10W-30 depending on ambient temperature. Specifics are critical from the manual. 🔧 Transmission Standard Transmission Type: Manual transmission, typically 5-speed or 8-speed (with splitter). Some models may feature 16-speed transmissions for heavier duty applications. Optional Optional Transmissions: Some later or export models may have offered ZF or other European-sourced transmissions, or potentially even automatic transmissions in very specific applications, though manual was dominant. Features Clutch Type: Single-plate dry friction clutch, hydraulically operated with pneumatic assistance (air-assisted hydraulic clutch). Fluid Type Gearbox Oil: GL-4 or GL-5 rated gear oil, typically SAE 80W-90 or SAE 85W-140 depending on operating temperature and transmission type. 📐 Dimensions Exterior Overall Length: Highly variable by...

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Tags: 43114 43115 43118 4326 44108 5320 53211 53212 53213 53215 53228 53229 5410 54112 54115 55102 55111 65111 65115 6540 Kamaz Truck Trucks

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Description

🏷️ Basic Information

Identification

Make:

KAMAZ

Brand Origin:

Russia

Manufacturer:

KAMAZ (KamAZ Publicly Stock Company)

Codes

Product Name:

KAMAZ Truck RUSSIAN (KAMAZ-5320, 5410, 55102, 55111, 53212, 53211, 53213, 54112, 43114, 43118, 65111, 53228, 44108, 43115, 65115, 6540, 53229, 4326, 53215, 54115) Service Workshop Shop Repair Manual

👋 Introduction

Market Position

Vehicle Class:

Heavy-duty trucks, designed for utility, construction, long-haul transport, and specialized applications.

Primary Markets:

Primarily Russia and former Soviet bloc countries, but also exported to various global markets, particularly developing nations, due to ruggedness and cost-effectiveness.

Competitive Analysis

Competitors:

Internationally: MAN, Mercedes-Benz (Unimog), Volvo, Scania, International. Domestically/Regionally: ZIL, KrAZ, MAZ.

Key Features

Design Philosophy:

Robust, durable, and designed to operate in harsh environmental conditions with simplified maintenance and readily available parts within its primary market.

Varied Configurations:

The broad model range indicates versatility, covering dump trucks, tractors, flatbeds, and specialized chassis for various body conversions.

📋 Manual Details

Coverage Areas

Covered Models List:

KAMAZ-5320, KAMAZ-5410, KAMAZ-55102, KAMAZ-55111, KAMAZ-53212, KAMAZ-53211, KAMAZ-53213, KAMAZ-54112, KAMAZ-43114, KAMAZ-43118, KAMAZ-65111, KAMAZ-53228, KAMAZ-44108, KAMAZ-43115, KAMAZ-65115, KAMAZ-6540, KAMAZ-53229, KAMAZ-4326, KAMAZ-53215, KAMAZ-54115

Page Count

Estimated Page Count:

Varies significantly by specific model and edition, but typically between 500-1500+ pages for a comprehensive service manual covering multiple variants.

Manual Type

Type:

Service Workshop Repair Manual

Language

Language:

Russian

Format

Format:

Likely digital format (PDF) given the product description, but original could be printed. Details on print quality and binding are not available without physical inspection or specific product listing.

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (disassembly, assembly, diagnosis, repair), Transmission (gearbox repair, clutch, driveshaft), Drivetrain (differentials, axles, transfer cases).

Chassis:

Suspension (front and rear), Steering system, Braking system (air brakes, hydraulic components, parking brake), Wheels and tires.

Electrical:

Wiring diagrams, Lighting system, Ignition system, Starting and charging system, Instrument cluster, Electrical accessories.

Body And Frame:

Body panels, Cab structure, Chassis frame, Doors, Glass, Seats, Interior trim, Cargo body (tipper, flatbed, etc.).

Fuel And Exhaust:

Fuel tank, Fuel lines, Fuel injection system (specifics depend on engine), Exhaust system.

Cooling And Lubrication:

Cooling system (radiator, thermostat, fan, water pump), Lubrication system (oil pump, oil filter, oil cooler).

Procedures Included

Maintenance:

Scheduled maintenance, lubrication charts, fluid level checks, filter replacement, brake adjustments, belt tensioning.

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (if applicable to era/systems), component testing procedures.

Repair:

Step-by-step repair instructions for all major mechanical and electrical components, including engine overhauls, transmission rebuilds, brake system repairs, and bodywork.

Specifications:

Torque specifications, clearances, tolerances, fluid capacities, part numbers (may be for OEM parts of the era).

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Technical Depth

Depth:

Comprehensive workshop-level repair information, suitable for professional mechanics and skilled DIY technicians. Covers from routine maintenance to complete vehicle overhauls.

📊 Manual Specifications

File Format

Digital Format:

Likely PDF. Searchable text is a significant advantage if available. Image quality of diagrams and illustrations is crucial for usability.

Print Quality

Print Quality Notes:

If printed, quality depends on the source. Original manufacturer manuals generally have good print and diagram clarity. Reproductions may vary.

Binding Type

Binding:

If printed: Likely saddle-stitched or perfect bound for original manuals. Spiral binding is common for workshop use to lay flat.

Paper Type

Paper Quality:

If printed: Typically a durable, matte paper stock to withstand workshop conditions. Glossy paper might be used for photographs.

⚙️ Engine Specifications

Primary Engine

Engine Family:

KAMAZ diesel engines, notably the KAMAZ-740 series and its derivatives, and later Cummins B-series (ISB) and C-series (ISC) engines in some models.

Typical Displacement:

Ranges from 10.85 liters (KAMAZ-740.10) up to 14.89 liters for some V8 variants. Cummins variants typically 5.9L and 8.3L.

Performance

Horsepower Range:

Typically 200-350 hp, depending on the specific engine variant and emissions standards of the era.

Torque Range:

Significant torque output, generally in the range of 650-1000 Nm, essential for heavy hauling.

Fuel System

Fuel Type:

Diesel

Injection System:

Typically mechanical injection (e.g., VEB-based or similar rotary/inline pumps) for older models, transitioning to electronically controlled common rail for later variants or Cummins engines.

Cooling System

Cooling Type:

Liquid-cooled, pressurized system.

Lubrication System

Oil Type Recommendation:

API CF or CD rated heavy-duty diesel engine oils, viscosity typically SAE 15W-40 or 10W-30 depending on ambient temperature. Specifics are critical from the manual.

🔧 Transmission

Standard

Transmission Type:

Manual transmission, typically 5-speed or 8-speed (with splitter). Some models may feature 16-speed transmissions for heavier duty applications.

Optional

Optional Transmissions:

Some later or export models may have offered ZF or other European-sourced transmissions, or potentially even automatic transmissions in very specific applications, though manual was dominant.

Features

Clutch Type:

Single-plate dry friction clutch, hydraulically operated with pneumatic assistance (air-assisted hydraulic clutch).

Fluid Type

Gearbox Oil:

GL-4 or GL-5 rated gear oil, typically SAE 80W-90 or SAE 85W-140 depending on operating temperature and transmission type.

📐 Dimensions

Exterior

Overall Length:

Highly variable by model. For example, KAMAZ-5320 (tractor) approx. 7.2m; KAMAZ-55111 (tipper) approx. 7.5m. Long-haul variants can be longer.

Overall Width:

Typically around 2.5m to meet regulatory standards for road vehicles.

Overall Height:

Varies by configuration (e.g., tractor vs. tipper). Typical tractor height around 2.8m; tipper height around 3.0-3.5m.

Weights

Gross Vehicle Weight Rating Gvwr:

Ranges from 15,000 kg for lighter models to over 30,000 kg for heavy-duty configurations and tractor units.

Curb Weight:

Typically 7,000 kg to 12,000 kg depending on model and configuration.

Payload Capacity:

Ranges from approximately 5,000 kg to over 20,000 kg.

Towing Capacity:

Tractor units (5410, 54112, 54115) can tow gross combination weights (GCW) of 30,000 kg up to 50,000+ kg.

Wheelbase

Wheelbase Options:

Common wheelbases include approximately 3.6m for standard trucks and longer for specialized or long-haul variants.

Cargo

Cargo Bed Dimensions:

For tippers (55111, 55102), cargo volumes typically range from 8 to 12 cubic meters. Flatbeds offer configurable load lengths.

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not typically subjected to modern global NCAP or IIHS-style crash testing due to their market origin and design era. Safety features are generally basic.

Active Features

Braking System:

Dual-circuit air brakes with automatic brake adjusters, spring brake parking brake, and potentially anti-lock braking system (ABS) on later models.

Steering System:

Power-assisted steering (hydraulic power steering) is standard on most models to reduce steering effort.

Passive Features

Cab Construction:

Robust steel cab construction designed for durability. Some later models may incorporate improved crumple zones or structural reinforcements.

Seatbelts:

Standard three-point seatbelts for driver and passenger on most post-1990s models.

💡 Technology Features

Infotainment

Infotainment System:

Extremely basic on most models from this era. Typically limited to an AM/FM radio and possibly a cassette player. Modern aftermarket units are common upgrades.

Driver Assistance

Driver Assistance Features:

Very limited by modern standards. Features like power steering and potentially ABS on later models are the extent of advanced driver assistance.

Connectivity

Connectivity Options:

None inherent to the original design. Optional provisions for auxiliary lights, power outlets for radios or CBs.

🔧 Maintenance

Service Intervals

Oil Change Interval Engine:

Typically every 10,000 - 15,000 km or 250-300 operating hours for diesel engines. Specific interval depends on oil quality and operating conditions, must be confirmed in manual.

Air Filter Replacement:

Recommended replacement every 20,000 - 40,000 km, or more frequently in dusty conditions. Inspection and cleaning at shorter intervals.

Fuel Filter Replacement:

Typically every 15,000 - 25,000 km, or as indicated by filter condition or fuel system performance.

Transmission Oil Change:

Every 50,000 - 100,000 km, depending on transmission type and duty cycle.

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze coolant, typically meeting GOST standards or equivalent. Usually a mix of 50% coolant and 50% distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 heavy-duty brake fluid, especially for hydraulic components if present, though primarily air brake systems.

Grease Type:

Lithium-based multi-purpose grease (e.g., Litol-24 or equivalent) for chassis lubrication points.

Known Issues

Electrical Reliability:

Older models can experience electrical gremlins due to aging wiring and components. Ensuring connections are clean and tight is key.

Engine Wear:

High-mileage KAMAZ-740 engines can suffer from cylinder bore wear, piston ring issues, and bearing wear. Regular oil analysis can help detect this early.

Air Brake System Maintenance:

Regular draining of water from air tanks and inspection of air lines, valves, and seals is crucial to prevent freezing in cold climates and ensure reliable braking.

Clutch Adjustment:

The air-assisted clutch actuation can require periodic adjustment for proper engagement and disengagement.

📚 Vehicle History

Brand Heritage

Founding:

KAMAZ was established in 1969 in Naberezhnye Chelny, Tatarstan, USSR (now Russia).

Initial Goal:

To produce heavy-duty trucks for military and civilian use, leveraging Soviet industrial capabilities and Western technology licenses.

Model Evolution

Kamaz-5320 Introduction:

The KAMAZ-5320, launched in 1976, was the foundational model, a 6x4 general-purpose truck that formed the basis for numerous variants.

Variant Development:

The listed models represent a spectrum of development from the late 1970s through the early 2000s, incorporating engine upgrades, chassis modifications, and body style changes like tippers (55111) and specialized tractors (5410, 54115).

4X4 And 6X6 Variants:

Models like the 43114, 43118, 43115, and 4326 introduced off-road capability with 4x4 and 6x6 drivetrains.

Production

Manufacturing Location:

Naberezhnye Chelny, Tatarstan, Russia.

Production Period:

The models listed generally span production from the late 1970s/early 1980s up to the mid-2000s, with some design lineages continuing or evolving into newer generations.

🏆 Awards & Recognition

Recognitions

Historical Recognition:

KAMAZ trucks have historically been recognized for their robustness and reliability in challenging operating environments, particularly within military and infrastructure projects in Russia and its allies.

Motorsport Achievements:

KAMAZ is famously successful in the Dakar Rally, winning numerous times with its specialized off-road racing trucks, which demonstrates the underlying capability of their chassis and powertrain design.