Tatra 815, repair e-manual (in Russian)

Contents

General information

• Contact details
• Guidelines basics
• List of related technical literature
• How to use the manual
• Splitting and numbering text
• Page numbering
• Image numbering
• Table numbering
• Sub-chapter paragraph notation
• The order of numbering of works performed
• Numeric Expression of Metric and Anglo-American Elements
• Identification of TATRA machines
• Special tool
• Definition of parts subject to mandatory replacement
• Safety instructions
• General safety instructions
• Health safety at work
• Fire safety rules
• General rules for the replacement and repair of units
• Washing and cleaning parts
• Inspection and classification of parts
• Rules for working with electrical equipment
• Rules for performing work on electric arc welding on a car
• Using an external source to start cars
• Environmental instructions
• List of abbreviations used
• List of symbols used
• Tightening torques
• Tightening torques for metric bolts and nuts
• Tightening torques of pipeline connections on instrument shafts

Complete car

• Vehicle specification
• General arrangement of the machine
• Basic technical data of the vehicle
• Technical data of the main groups and systems of the vehicle
• Lubricants and operating fluids
• Equipping the machine with signs

Engine, engine systems

• Description and basic technical data
• Causes of malfunctions and remedies
• List of special tools
• Tightening torque list
• Workflows
• Diagnostics of the engine electronics and related electrical equipment
• Compression pressure measurement
• Valve clearance control and adjustment
• Draining water and dirt from the fuel tank
• Control and release of contaminants from the coarse fuel filter
• Replacing the filter element of the fine fuel filter
• Replacing the filter element of the coarse fuel filter
• Replacing the coarse fuel filter housing
• Replacing the fine fuel filter
• Removing and installing manual fuel priming pump
• Removal and installation of injector nozzles and adjustment of injector opening pressure
• Removal and installation of the injection line
• Removal, installation and adjustment of the fuel pump control
• Removal and installation of the fuel pump
• Changing the engine oil
• Replacing the oil filter element
• Removing and installing oil temperature sensor
• Removing and installing oil pressure sensor
• Removing and installing oil filter
• Dismantling and assembling the oil filter
• Removing and installing centrifugal oil filter
• Removing and installing oil pump
• Removing and installing oil cooler
• Removing and installing oil cooler housing
• Checking the electronic regulation of the engine cooling system
• Removal and installation of the electromagnetic switch ERCH
• Replacing the cylinder head temperature sensor
• Cleaning the cooling fins of the cylinder heads, supply air coolers, oil cooler and cooling fan
• Removal and installation of the solenoid valve for oil supply to the hydraulic clutch of the fan
• Removing and installing the fan shaft
• Removing and installing the impeller and fan drive
• Checking the correct functioning of the relief groove in the dedusting valve on the air filter cover
• Checking the functioning of the low air pressure indicator in the engine intake system
• Removal, installation, test of functioning of the indicator of clogging of the air filter
• Air heating function test
• Cleaning or replacing the air filter element
• Removing and installing air filter
• Replacing rubber seals in the engine intake
• Removal and installation of an intake air heater
• Removing and installing intermediate radiators
• Tightening the intake and exhaust pipe retaining nuts
• Removal and installation of the collecting exhaust pipe to the turbocharger
• Removing and installing a turbocharger
• Removing and installing a pneumatic engine brake cylinder
• Removing and installing engine brake
• Removing and installing an exhaust muffler
• Removal and installation of gear hydrogenerator
• Removal and installation of a two-cylinder compressor
• Removal and installation of a single-cylinder compressor
• Replacing the head gasket of a two-cylinder compressor
• Replacing the head gasket for a single cylinder compressor
• Removing and installing starter
• Removing and installing motor with connector
• Disassembly and assembly of the engine
• Disassembly and assembly of the crankcase
• Disassembly and assembly of the crankshaft
• Disassembly and assembly of the connecting rod
• Disassembly and assembly of the cylinder head
• Disassembly and assembly of the flywheel housing
• Dismantling and assembling the front cover
• Disassembly and assembly of the fan drive
• Disassembly and assembly of the oil pump
• Disassembly and assembly of the radiator housing
• Running in and testing the engine at a braking station

Clutch, propeller shaft

• Description and basic technical data
• Causes of malfunctions and remedies
• List of special tools
• Tightening torque list
• Workflows
• Clutch release control
• Thickness control of clutch disc pads
• Changing fluid in the clutch drive system
• Adjusting the clutch actuator in the driver's cab
• Removing and installing clutch shaft
• Removal and installation of the clutch master cylinder
• Removing and installing clutch booster
• Removing and installing clutch release bearing
• Removing and installing clutch
• Removing and installing propeller shaft
• Dismantling and assembling the clutch housing
• Disassembly and assembly of the clutch booster

Gearbox

• Causes of malfunctions and remedies
• List of special tools
• Tightening Torque List
• Workflows
• Gearbox oil change
• Adjusting the shift mechanism of additional gears (H (N) / L (R))
• Removing and installing the drive shaft drive seal
• Removal and installation of a gear shift control subgroup
• Removing and installing the switch of 5th and 6th gears
• Removal and installation of the amplifier of the gearshift mechanism
• Removing and installing transmission oil pump
• Removing and installing the top cover of the transmission with a drive shaft
• Removing and installing gearbox
• Disassembly and assembly of the gear shift amplifier
• Disassembly and assembly of the gearbox

Additional gearbox

• Description and basic technical data
• Causes of defects and how to eliminate them
• List of special tools
• Tightening torque list
• Workflows
• Oil change in additional box
• Adjusts the shift of gear synchronization in extra gear
• Removal and repair of the blocking valve assembly
• Removing and installing oil pump gears and rear cover
• Removing and installing additional box drive shaft
• Removing and installing additional gearbox
• Disassembly and assembly of the additional box

Support tube, fittings and differentials

• Description and basic technical data
• Causes of malfunctions and remedies
• List of special tools
• Tightening torque list
• Workflows
• Removing and installing control cylinders for engaging locking mechanisms and front drive
• Removing and installing the front support tube
• Removing and installing rear support tube
• Removing and installing rear connecting piece
• Removing and installing front connecting piece
• Removing and installing center differential
• Removal and installation of interwheel differential
• Disassembly and assembly of control cylinders for engaging differential locks and front axle drive
• Disassembly and assembly of the center differential
• Disassembly and assembly of cross-wheel differentials

Bridges

• Description and basic technical data
• List of special tools
• Tightening torque list
• Workflows
• Changing the oil in the gearbox of the wheel unit
• Oil change in the final drive
• Wheel bearing clearance monitoring
• Front axle wheel hub clearance adjustment
• Rear axle wheel clearance adjustment
• Determining kingpin clearance
• Replacing the axle shaft protection bag
• Removing and installing kingpin
• Removing and installing the drive shaft of the steering axle
• Removing and installing non-steering axle drive shaft
• Removing and installing seals of the central inflation system of front axle tires
• Removing and installing seals of the central inflation system of rear axle tires
• Removing and installing a pair of front axles
• Removing and installing a pair of rear axles
• Removal and installation of the first rear axle
• Removing and installing second rear axle
• Removing and installing front axle wheel bearings
• Removing and installing rear axle wheel bearings
• Removing and installing the bearing of the drive propeller shaft in the axle shaft
• Disassembly and assembly of the transfer case
• Bevel gear meshing adjustment
• Dismantling and assembling the front axle
• Dismantling and assembling the rear axle
• Checking the clearance in the lower landing and pre-stressing the Belleville springs in the upper landing of the king pin and their determination (adjustment)

Suspension

• Description and basic technical data
• Causes of malfunctions and remedies
• List of special tools
• Tightening torque list
• Workflows
• Checking the tightening of the spring ladder fastening bolts
• Checking the spring safety ladders
• Rear axle wheel tilt check
• Checking the collapse of the leaf spring lock
• Replacing the rubber stop of the axle shaft suspension
• Removing and installing suspension shock absorbers
• Removing and installing bellows spring for rear axle suspension
• Removing and Installing Bellows Spring Bracket
• Removing and installing air suspension control valve
• Removing and installing the spring earring, support pin and leaf spring lock
• Removing and installing leaf spring

Braking systems, pneumatic equipment

• Description and basic technical data
• Causes of malfunctions and remedies
• List of special tools
• Tightening torque list
• Workflows
• Basic rules for replacing pneumatic system devices
• Checking the thickness of the brake pads
• Diagnostics of the ABS system
• Cleaning or replacing the filter element in the condensation tank
• Replacing the air dryer filter
• Checking the tightness and functions of the pneumatic system
• Checking and adjusting the control of the main brake valve
• Checking the air pressure regulator
• Air pressure control behind the pressure reducing valve of the brake circuits
• Removing and installing condensation tank
• Removing and installing an air dryer with a pressure regulator
• Removing and installing the air bleed valve for tire inflation
• Removal and installation of the pressure reducing valve
• Removal and installation of a safety valve
• Removal and installation of the main brake valve
• Removing and installing load regulator
• Removing and installing the emergency and parking brake control valve
• Removal and installation of the hand brake valve
• Removal and installation of solenoid pneumatic valves
• Removal and installation of the bypass valve
• Removing and installing pneumatic valve to adjust the steering wheel position
• Removing and installing receivers
• Removal and installation of check valves
• Removing and installing the bypass valve of the central tire inflation system
• Removing and installing suspension control valves
• Removing and installing ABS valves
• Removing and installing ABS sensors
• Repair and replacement of polyamide tubes
• Removing and installing the brake cylinder
• Removing and installing a brake drum and brake pads
• Removing and installing spacers for PERROT pads
• Repair of brake drums by boring
• Replacing brake pads

Steering mechanism

• Description and basic technical data
• Causes of defects and methods of their elimination
• List of special tools
• Tightening Torque List
• Workflows
• Servo oil change
• Replacing the filter cake in the servo control system
• Checking servo play
• Checking and adjusting the geometry of the wheels of the front axles
• Checking the tightening of the control arm fixing bolts near the pivot pins
• Removing and installing steering wheel
• Removing and installing the control lock
• Removing and installing spindles with servo steering joints
• Removing and installing monoblock control
• Removal and installation of control rods (from the two-armed lever to the control levers on the pivot pins)
• Removing and installing control rod with hinges (from servo control to two-arm lever)
• Removing and installing two-armed control lever

Wheels and tires

• Description and technical characteristics
• Dismantling and assembling a car wheel
• Removing and installing the valve

Frame and tail of the frame

• Description and basic technical data
• Causes of defects and how to eliminate them
• List of special tools
• Tightening torque list
• Workflows
• Checking and tightening the frame-to-chassis fastening nuts
• Removing and installing front bumper
• Removing and installing side member frame
• Removing and installing battery container
• Removing and installing fuel tanks
• Removing and installing spare wheel holder

Cab, heating and ventilation system

• Description and basic technical data
• Causes of malfunctions and remedies
• List of special tools
• Tightening torque list
• Working procedures
• Removing and installing windshield wipers
• Removing and installing windscreen wiper drive mechanism
• Removing and installing rearview mirror and rearview mirror holder
• Removing and installing the door panel
• Removing and installing two-arm window lifter
• Removing and installing the door lock
• Removing and installing door glass
• Removing and installing doors
• Removing and installing driver's seat
• Removing and installing passenger seat
• Removing and installing windshield
• Removal and installation of the cab tipping mechanism
• Removing and installing dashboard assembly
• Removal and installation of a control panel for dependent heating and ventilation
• Removal and installation of the dependent control micromotor
• Removing and installing heat exchanger
• Removal and installation of the heating and ventilation fan speed controller
• Removal and installation of a junction box for dependent heating and ventilation
• Removal and installation of the micromotor of the recirculation damper of dependent heating and ventilation
• Removal and installation of the micro-motor of the distributor dampers (windows, bottom) of dependent heating and ventilation
• Removal and installation of the distributor flap micromotor (cab space)
• Removal and installation of the independent heating control panel
• Removal and installation of the independent heating dosing pump
• Removal and installation of independent heating
• Removal and installation of the driver's cab
• Removing and installing the control valve of the spring elements
• Removal and installation of spring elements of the rear suspension of the cab

Turntable add-on

• Description and basic technical data
• Causes of malfunctions and remedies
• List of special tools
• Tightening torque list
• Workflows
• Removal and installation of the turntable of the tractor unit

Electrical equipment

• Description and basic technical data
• Causes of malfunctions and remedies
• List of special tools
• Tightening torque list
• Workflows
• Monitoring the condition of batteries in the car
• Headlight adjustment
• Removing and installing batteries
• Removing and installing power switch
• Removing and installing optical headlight insert
• Removing and installing headlight
• Removing and installing front turn signal lamp
• Removing and installing side turn signal lamp
• Removal and installation of the auxiliary (upper) side light
• Removal and installation of the rear group lamp
• Removal and installation of cab lighting
• Replacing warning lamps and illuminated switches
• Removal and installation of the tachometer
• Removing and installing tachograph
• Removing and installing dual air pressure gauge for pneumatic system
• Removing and installing fuel gauge
• Removing and installing dashboard
• Removing and installing engine brake switch
• Removing and installing combination switch
• Removing and installing brake light switch
• Removing and installing the door switch
• Removing and installing wiper motor
• Removing and installing windshield sprayer motor
• Removing and installing an independent heating glow plug
• Removal and installation of the generator

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