Tatra 163, repair e-manual (in Russian)

Content

General information

• Contact details
• Guidelines basics
• List of related technical literature
• How to use the manual
• Division and naming order of sections, chapters and subchapters
• Page numbering
• Image numbering
• Numbering tables
• Notation of paragraphs of subchapters
• The order of numbering of the work performed
• Identification of machines "TATRA"
• Special tool
• Mandatory replacement parts
• Safety instructions
• General safety regulations
• 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 carrying out work on welding with an electric arc on a car
• Using an external source to start cars
• Environmental instructions
• List of units, symbols and abbreviations

Complete vehicle

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

Engine, engine systems

• Description and basic technical data
• Causes of malfunctions and how to fix them
• List of special tools
• List of tightening torques
• Workflows
• Diagnostics of the electronic engine block
• Compression pressure measurement
• Valve clearance control and adjustment
• Draining dirt from the fuel tank
• Control and release of contaminants from the coarse fuel filter
• Replacing the filter element of the coarse fuel filter
• Replacing the filter element of the fine 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, 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
• Monitoring the electronic regulation of the engine cooling system
• Removal and installation of an electromagnetic switch for electronic regulation of cooling
• 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 drive shaft
• Removing and installing the impeller and fan drive
• Checking the correct functioning of the relief groove in the cover on the air filter cover
• Monitoring the functioning of the suction vacuum indicator
• Removal, installation, test of functioning of the indicator of clogging of the air filter
• Air heating operation control
• Cleaning or replacing the air filter element
• Removing and installing air filter
• Replacing rubber seals in the engine intake system
• 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 exhaust manifold to the turbocharger
• Removing and installing a turbocharger
• Removing and installing a pneumatic engine brake cylinder
• Removing and installing engine brake
• Removal and installation of an exhaust muffler
• Removal and installation of gear hydrogenerator
• Replacing the compressor head gasket
• Removal and installation of the compressor
• Removal and installeelectric starter wiring
• Removal and engine installation
• Disassembly and assembly of the engine 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
• Disassembly and assembly of the engine
• Running in and testing the engine at a braking station

Clutch, propeller shaft

• Description and basic technical data
• Causes of malfunctions and how to fix them
• List of special tools
• List of tightening torques
• Workflows
• Clutch release control
• Clutch disc thickness control
• Changing fluid in the clutch drive system
• Adjusting the clutch actuator in the driver's cab
• Removing and installing clutch driven shaft
• Removal and installation of the main hydraulic cylinder of the clutch
• 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

• Description and basic technical data
• Causes of malfunctions and how to fix them
• List of special tools
• Tightening torque list
• Workflows
• Gearbox oil change
• Adjustment of the shift mechanism of additional gears (H / L)
• Adjusting the transmission control
• Removing and installing the drive shaft drive seal
• Removing and installing transmission control
• Removal and installation of the amplifier of the gear shifting mechanism
• Removal and installation of the gearbox 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

Transfer case

• Description and basic technical data
• Causes of defects and how to eliminate them
• List of special tools
• Tightening Torque List
• Workflows
• Transfer case oil change
• Adjusting gear shift timing in extra gear
• Removal and repair of the full shift blocking valve
• Removing and installing oil pump gears and rear cover
• Removing and installing transfer case drive shaft
• Removing and installing transfer case
• Disassembly and assembly of the transfer case

Power takeoff

• Description and basic technical data
• Causes of malfunctions and how to fix them
• List of special tools
• Tightening Torque List
• Workflows
• Removal and installation of the power take-off pump
• Removal and installation of power take-off - disassembly and assembly

Support tube, fittings and differentials

• Description and basic technical data
• Causes of defects and how to eliminate them
• 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 the rear support tube
• Removing and installing rear 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
• Causes of malfunctions and how to fix them
• List of special tools
• Tightening torque list
• Workflows
• Changing the oil of the gearbox of the wheel unit
• Oil change in the final drive
• Control and adjustment of the front axle disk spring tension
• Wheel bearing clearance monitoring
• Front axle wheel clearance adjustment
• Rear axle wheel clearance adjustment removing and installing the drive shaft bearing in the front axle axle shaft
• Disassembly and assembly of the front axle final drive
• Disassembly and assembly of the main gear of the rear axle
• Bevel gear meshing adjustment
• Dismantling and assembling the front axle
• Dismantling and assembling the rear axle

Suspension

• Description and basic technical data
• Causes of defects and methods of their repair
• List of special tools
• List of tightening moments
• Workflows
• Checking the tightening of the fixing screws of the leaf springs brackets
• Checking the safety brackets of the leaf springs
• Checking the inclination of the rear axle wheels
• Checking the collapse of the leaf spring lock
• Replacing the rubber stop of the axle springs
• Removing and installing front axle torsion bar arm towbar
• Removing and installing front axle torsion bar
• Removing and installing torsion bar arm, stone and front axle suspension support lens
• Removing and installing suspension shock absorbers
• Removing and installing rear axle suspension cylinder spring
• Removing and installing the cylinder spring console
• 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 how to fix them
• List of special tools.
• Tightening torque list
• Brake pedal travel control
• Monitoring the operation of the pneumatic system
• Air pressure regulator control
• Air pressure control behind the brake pressure reducing valve
• Diagnostics of the ABS system
• Replacing the air dryer filter
• Cleaning or replacing the filter element in the condensate trap
• Removing and installing condensation tank
• Removing and installing a dehumidifier with a pressure regulator
• Removal and installation of 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 a two-piece main brake valve
• Removing and installing load-acting brake regulator
• Removal and installation of the emergency and parking brake control valve
• Removing and installing manual brake control valve
• Removal and installation of pneumatic solenoid valves
• Removal and installation of the bypass valve
• Removal and installation of check valves
• Removing and installing manual drain valve
• Removing and installing receivers
• Removal and installation of valves of the ABS system
• Removal and installation of ABS sensors
• Removing and installing pneumatic valve to adjust the steering wheel position
• Removing and installing suspension control valves
• Removing and installing suspension cylinder outlet valves
• 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
• List of tightening moments
• Workflows
• Oil change in the servo control system
• Replacing the filter cake in the servo control system
• Checking and adjusting the geometry of the wheels of the front axle
• Checking the tightening of the control levers attachment screws
• Checking control backlash
• Removing and installing steering wheel
• Removing and installing the control lock
• Removing and installing the steering wheel spindle with hinges
• Removing and installing left and right control rods
• Removal and installation of control rod
• Removing and installing the ball joint of control rods
• Removing and installing servo control
• Removing and installing two-legged steering lever

Wheels and tires

• Description and technical characteristics
• Causes of defects and how to eliminate them
• List of special tools
• Tightening torque list
• Workflows
• Removing and installing complete wheel with tire
• Car wheel repair

Frame, frame tail

• Description and technical characteristics
• Frame
• Plumage of the frame
• Causes of defects and how to eliminate them
• List of special tools
• Tightening torque list
• Workflows
• Checking and tightening the frame-to-chassis clamping nuts
• Rear drawbar exchange
• Removing and installing front bumper
• Removing and installing a side member frame
• Removing and installing rear barrier
• Removing and installing battery box
• Removing and installing fuel tank
• Removing and installing oil tank tipping hydraulics

Cab, heating and ventilation system

• Description and basic technical data
• Causes of malfunctions and how to fix them
• List of special tools
• Tightening torque list
• Workflows
• Windshield scraper exchange
• Removing and installing wiper mechanism
• Swapping reverse mirrors
• Removing and installing footrest
• Removing and installing the door panel
• Removing and installing the lever mechanism for lowering the glass of doors
• Removing and installing the door lock
• Removing and installing doors
• Removing and installing door glass
• Removing and installing windshield
• Removing and installing the driver's or passenger's seat
• Removal and installation of the perfect dashboard
• Exchanging the adjustable sun visor
• Removal and installation of an independent heating pump
• Removal and installation of independent heating
• Removal and installation of control cabinet
• Removal and installation of the oil heating and ventilation housing
• Removal and installation of the distributor flap motor (windows, bottom)
• Removing and installing the heating recirculation flap motor
• Removal and installation of the distributor flap motor (cab)
• Removing and installing the hood
• Removal and installation of the driver's cab

Add-on

• Description and technical characteristics
• Causes of malfunctions and how to fix them
• List of special tools
• Tightening torque list
• Workflows
• Oil change in the hydraulic tipping circuit
• Changing the filter cake in the tipping oil tank
• Checking and setting the clearance between the body and the frame
• Removal and installation of the hydraulic body tipping motor
• Removing and installing body

Electrical equipment

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