DIY repair of the starter Tatra 815

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Good day !
Today 2 starters from TATRA were brought in for repair. customer complaints: the boot (in the photo, the upper bendix upwards) after replacing the relay does not turn at all. It was on this boot that a diagram with original numbers found an explosion, but only these numbers are made through only from dealers of TATRA spare parts. there is nothing in stock, I will pick up from BOSCH
with a cigar (pictured below) is no less interesting and no less difficult. there is no information on it at all. I supply power, the output of the bendix is ​​10-15 millimeters, instead of the prescribed 25-30.
Dear colleagues, who has come across this? who took the parts where?
for the admin (text by photo, not advertising, just found a photo where they are both together)

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jin850, glad if I could help with something.

Something I have not heard about AVF starters, most likely this number begins like this, and the starter itself is a magneton.

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promised:
in the photo from left to right - a bulb from a Bosch analogue, a rear part from a Bosch analogue starter, a Tatra starter without a back cover and a relay.
the diameter of the Bosch flask is about 125 mm, and for the Tatra about 150. (these 2 starters are from the same client, he brought them later) that boot from the Tatra from the first batch had 2 leads (bolt М12 - “+”, bolt М6 - control of the “retractor”, the mass of the case. This is all the same, only “-” is separately displayed in the form of an M12 bolt) in the photo with a welded tire in the form of an inverted question mark. the first boot (2-pin) of the CARGO 130282 relay fits 100%, the second does not. on the connection, everything is in principle clear, only you need a spacer by the eye of 10-12 mm. between the bottom platform and the back of the starter
Respectfully, I hope someone will help

Attached image (click to enlarge)

Control lamp for recharging after turning on the ignition switch in the 1st position does not light up

Defective battery

Replace one or both defective batteries

Faulty battery switch

Replace battery breaker

Defective lamp in the control lamp

Replace the test lamp bulb

Defective ignition switch

Replace ignition box

Defective fuse

Replace fuse F11

Defective relay circuit "15"

Control lamp for recharging after starting the engine does not go out

Defective generator voltage regulator

Replace alternator voltage regulator

Cracked alternator drive belt

Replace the alternator drive belt with a new one.

Charging indicator lamp goes out only at higher engine speeds

Replace voltage regulator

The alternator drive belt is poorly tensioned

Tension the alternator drive belt correctly

Charging indicator lamp shines through when several electrical appliances are turned on

The alternator drive belt is poorly tensioned

Tension the alternator drive belt correctly

Short and defective generator brushes

Replace the brush holder with generator voltage regulator

After turning on the ignition switch to the 2nd position, there is a significant decrease brightness

control lamp recharging

and a warning lamp for lubrication

Car batteries are significantly depleted

Start the motor with an external power source (via the connecting cables)

Replace batteries

Charge the batteries at the charging station

Hello to all! Since the topic about the clutch has gone, I will bring in my 5 kopecks. in the piggy bank.
A month ago, when leaving for the application, the clutch disappeared, so it was successful - I got up on my territory, so much so that the car did not interfere.

I began to figure out what and how - naturally blew the clutch - no result, removed and opened the CCGT - a couple of torn cuffs on the hydraulics and the front part of the pneumatic chamber clogged with dirt - due to the absence of an anther. Replaced the cuffs, assembled, skolkhozit "bamovsky" boot from an old baby blanket (did not find a good tarpaulin). Put and pumped - no effect. I rushed to a friend, took a spare CCGT from him - put it on and pumped it - it was useless ... I took off the CCGT without disconnecting the hoses, checked it - it works ... But somehow rather weak, as it seemed to me)) - the main one to bust - I did not find anything criminal.

There is nothing to do - you need to remove the clutch. Immediately I thought to slap the engine - it is more convenient and simpler (I have a UDS) - I untied everything, I only needed a crane, but at the last moment, on the advice of a friend of the Tatrists, I decided to just lift the rear of the motor. Naturally with the help of an excavator. I threw one bolt on the front airbags so that it would not slide forward, sling it and without any problems raised it by 15-20 cm.

Our special technical center in Moscow offers a profitable inexpensive repair of Tatra starters. We provide a long-term guarantee for all work, and repairs are carried out by experienced specialists with specialized education.

For a century and a half, the Czech company Tatra has been producing reliable and productive machines: from railway transport and aviation equipment to trucks, popular all over the world, including Russia. Moreover, the modern production program of the company consists in the production of trucks, of which more than 75% are exported.
On the territory of the Russian Federation, perhaps, there is not a single production on which powerful, unpretentious and extremely hardy trucks of this Czech brand do not work. That is why our company specializes in servicing them: namely, in the repair of Tatra starters.
Turning to us, you can count on the conscientious and professional approach of specialists who thoroughly know the issue and can restore almost any Tatra starters. Preventive maintenance and timely repair of tatra starters (with the replacement of all faulty parts with new parts ideally suited to the unit) will allow car owners to avoid the cost of purchasing and installing a new Tatra starter. Because the starters repaired and remanufactured by us regularly and flawlessly serve the truck from year to year, like new.

Work experience 12 years. Was born in the Kaluga region. Education: Moscow Automobile University. Specialty "Auto electrician"

Work experience 7 years. Was born in Moscow. Education: Moscow Automobile College 76. Specialty "Auto electrician"

Work experience 7 years. The Krasnodar Territory was born. Education Krasnodar Automobile College. Specialty "Auto mechanic"

Scheme of the TATRA 815 lorry. You can download the wiring diagrams and a detailed description in the archive. Operation and repair manual TATRA 815. Contents:

3 Oils and operating fluids. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3-1

4.2 The cabin of the car. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .4-4

4.2.1 Sun visors. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4-5

4.4.7.4 TEST connector. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .4-32

5.6 After starting the engine. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .5-12

6.1.2 Engine fuel supply system. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .6-9

6.11 Body superstructure. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6-386.12

7 Conditions for transportation and storage of vehicles. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .7-1
7.1 Conditions for storing TATRA vehicles. ... ... ... ... ... ... ... ... ... ... ... ... ... .7-2
7.2 Transportation by Rail. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .7-5
8 Gear shifting. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .8-1
8.1 Gear shifting in vehicles with fourteen-speed
transmission of the brand "TATRA". ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .8-2

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Starter TATRA TATRA TATRA T815 / IKARUS Ikarus / LIAZ LIAZ. Starter for the TATRA T815 truck. Starter on Tatra Magneton Czech Republic Magneton 24V, 8.0 kW. 11 tooth

Voltage 24 volt
Power kW 8.0 kw
Number of teeth bendix 11

Starter TATRA TATRA TATRA T815 / IKARUS Ikarus / LIAZ LIAZ

Starter for the TATRA T 815 truck

CS806, 111008
Magneton 0159740, 443115187340, 4431159187340, 9187340, BPD6 / 24AR9Z11, 9187340n, 9187320, 9187320N, 4431159187320, STG0806

1. Warnings and safety precautions
Driver and passenger safety 4
Restraint systems 4
Seat belts 4
Driver and passenger safety 5
General safety instructions 5
Specifications 7
Vehicle identification 8
Vehicle nameplate 8
Vehicle identification number VIN 8
Chassis ID 8
Engine serial number 9
Technical description of the vehicle 9
Engine 9
Clutch 9
Gearbox 9
Power take-off from gearbox 9
Front axles 9
Rear axles 9
Steering mechanism 9
Front suspension 9
Rear suspension 9
Complete wheels 10
Inflating tires 10
Braking systems 10
Chassis 10

5. Clutch Tatra 815
List of faults and their elimination 135
Checking the clutch 136
Checking the thickness of the clutch disc pads 137
Changing fluid in the clutch drive system 137
Adjusting the clutch drive in the driver's cab 138
Cardan shaft 138
Clutch shaft 139
Clutch Master Cylinder 140
Clutch booster 141
Clutch housing 142

6. Tatra gearbox
List of malfunctions and ways to eliminate them 150
Tightening torques for main connections 151
Changing the oil in the gearbox 151
Adjustment of the mechanism for shifting additional gears H (N) / L (R) 152
Seals of the leash of the drive shaft of the gearbox 153
Gearshift control 154
5th and 6th gear selector switch 157
The amplifier of a mechanism of a gear shifting 157
Oil pump 160
Top cover with drive shaft 161
Gearbox 162
Additional gearbox 180
List of faults and their elimination 181
Tightening torques for main connections 182
Oil change 183
Adjustment of shifting of synchronization of transfers 183
Shut-off valve switch 184
Gear wheels of the oil pump and rear cover 185
Drive shaft 187
Additional gearbox 191

7. Carrier Labor and Differential
List of faults and their elimination 204
Tightening torques for main connections 204
Control cylinders for engaging differential locks and front-wheel drive 204
Front support tube 206
Front connecting part 207
Rear support tube 208
Rear connecting piece 208
Center differential 209
Cross-axle differential 213

8. Axles and transfer case Tatra
Bridges 222
Technical data 223
List of faults and their elimination 223
Tightening torques for main connections 224
Oil change 225
Wheel bearing clearance 225
King pin 227
Checking and adjusting the clearance 231
Removing and installing kingpin 233
Drive shaft 235
Tire inflation system 238
Front axle tire inflation seals 238
Rear axle central tire inflation system seals 239
Axle guard 239
Front axles 240
Rear axles 247
Bearing of the drive propeller shaft in the semiaxis 253
Bevel gear meshing adjustment 254
Transfer case 256
Front axle transfer case 256
Transfer case of the rear axle 265

9.Steering Tatra 815
List of faults and their elimination 277
Tightening torques for main connections 277
Oil change in the servo control system 277
Replacing the filter element in the servo control system 278
Control backlash check 278
Checking and adjusting the geometry of the wheels of the front axles 278
Checking the tightening of the fastening bolts of the control levers near the pivot pins 281
Steering wheel 282
Ignition lock 282
Servo-assisted steering spindles 282
Monoblock servo control 285
Control rods 287
Control rods with joints 289
Double-arm control lever 290

10. Brake system Tatra 815
General 294
Basic technical data of the brake and pneumatic system 298
Tightening torques for main connections 298
List of faults and their elimination 298
Safety Rules 300
ABS 300 system
Diagnostics of the ABS 300 system
ABS valves 301
ABS sensors 301
Condensing tank 302
Air dryer 302
Checking the tightness and functions of the pneumatic system 303
Bypass valve for central tire inflation system 304
Pressure reducing valve 305
Main brake valve 305
Safety valve 308
Load regulator 309
Emergency and parking brake control valve 310
Hand brake valve 311
Electromagnetic pneumatic valves 312
Bypass valve 313
Valve for adjusting the position of the steering wheel 313
Check valves 314
Polyamide tubes 314
Suspension control valves 315
Brake drum and brake pads 315
Brake cylinders 316
Shoe spacers PERROT 317
Receivers 318

11. Suspension Tatra 815
General 320
Benchmarks 321
Tightening torques for main connections 321
List of faults and how to eliminate them 321
Checks 322
Replacing the rubber stops of the axle shaft suspension 323
Shock absorbers 323
Bellows spring rear axle suspension 324
Bellows spring bracket 326
Air suspension control valve 326
Spring earrings, support trunnion and leaf spring lock 326
Leaf spring 327

12. Saddle and frame
Saddle 330
Frame 331
Checking and tightening the frame-to-chassis fastening nuts 331
Spar frame 332
Front bumper 334

13. Electrical equipment Tatra 815
Alternator 336
Additional autonomous heater 337
List of faults and how to eliminate them 339
Fuses 341
List of fuse and diode locations 341
List of locations of electromagnetic relays 342
Designation of elements of electrical devices in circuits 343
Wiring diagrams 353

A unique series of car books - Repair without problems. Step-by-step car repair, more than 3000 color photos

This truck is extremely popular with Russian drivers. Numerous variants with different wheel formulas have enjoyed well-deserved love for many years. The proposed book, published more than 10 years ago, has played an important role in the fact that many drivers still manage to keep their Tatra in working order, despite the fact that the production of cars was completed in 2008.

Repairing a truck requires the use of the tools listed in the publication, otherwise the truck may malfunction. Also in the repair manual for Tatra T815-290N9T there are sections "notes" and "warnings" of breakdowns.

Repair Manual Tatra T815-290N9T Free Download

Release date: 12.11.2016

Assessment of the car owner Osip: Low fuel consumption, maneuverable,

Category: Detailed Vehicle Maintenance Manual

Characteristics of the car: The dimensions of the car are as follows, body length - 3976, width - 1100, height - 1848 mm. The wheelbase is 2268 mm. The ground clearance is 146 mm. The car is equipped with a hybrid power unit. The 4-cylinder engine is equipped with a system that provides the output power of the motor. There are 4 valves per cylinder. The diameter of one cylinder is 79 mm, the piston stroke is 75 mm.The engine crankshaft and accelerates to 8000 rpm. The maximum torque is maintained up to 4000 rpm.

Posted by admin: at the request of Agafon

Original name: Tatra 815 starter

Laughter in the subject: Opening of the Ministry of Internal Affairs: If you stop introducing your employees into the ranks of organized crime, you can cut the ranks of organized crime by half!

The correct entry of the gear into the flywheel rim does not occur.

The starter does not work at all.

1. Correctly connect the electrical cables to the starter terminals.

Place the car on a horizontal platform, shift the gear lever to neutral and take measures to prevent the car from moving.

Provide sufficient space in front of the vehicle for raising the cab.

Remove all loose items from the cab.

Tilt the cab forward.

Switch off the ground switch.

Rice. 1.307 Removing the cover and exhaust pipe

Rice. 1.308 Starter mount

Remove the front upper right cover 1

and exhaust pipe 2.

Disconnect all cables 3 from the starter terminal block 1.

Unscrew the three nuts 2 together with spring washers.

Extend starter 1 from landing in the direction away from the flywheel.

Check and clean the contact surfaces of the starter.

Apply sealing compound to the splines of the starter.

Rice. 1.309 Starter seal

Put on the starter 1 landing in the crankcase.

Screw the starter to the crankcase with three nuts.

2 together with spring washers.

Connect all cables to the starter terminal block 1.

Rice. 1.310 Starter mount

Install the exhaust pipe 2 and front top right cover 1.

Switch on the ground switch.

Lower the vehicle cab to the working position.

Check starter function.

Rice. 1.311 Installing the cover and exhaust piping

Tell me where do you order spare parts for the Tatra?

Continue to shit in the good sense of the word. Change the operator to a tripod.

The film is good, of course I would like to see even more, but how did you understand the films purely on your own cars? But I will wait anyway, I am interested in the Tatars

It may seem to someone that this is crap, but the replacement, as I noticed, of the crosspieces on the drive does not have a super fit as, for example, in the Urals or the same UAZ, I wanted to know how much the crosspieces are enough. If you change every two years, it's not a big deal,

Tatra is a thing, our Kamaz is far from it.

I cut the crosspieces by welding without removing the hub, and changed the crosspieces on the spot. Tatra scoop. And so in between, what is it difficult to unscrew the grease gun?

Isn't it easier to cut the bearing sleeve with a grinder to remove it from the axle shaft?

What are the rags on the fist seats for?

Tatra is a unique car, and where it will not pass, others should not climb there!

As you remember how much crap there was with the replacement bearings and crosspieces, it becomes really shitty

This article is for those who want to fix a starter with their own hands. For this we need: two thick wires, a set of keys and heads.

The starter motor plays an important role in the ignition of the engine. The electric armature, rotating, transmits the torque to the flywheel, thereby driving the engine itself.