ZUK-BEN-angielski.pdf

(24467 KB) Pobierz
budowa
Żuk
naprawa
eksploatacja
in English!
Andrzej Wiejak
Józef Zagaja
translation put up by
http://zukowka.wordpress.com
The book describes all types of bodywork and power trains (including S-21, CB and 4C90 engines) of
this popular commercial vehicle. The paper contains descriptions of all structural changes related to the
modernization of the vehicle.
Beware: not every translation has been checked carefully. If
something does not make sense, there is probably a mistake
waiting to be fixed.
based on 1992’s edition (ISBN: 83-206-0993-3)
version 20200303
Disclaimer:
As suggested in red on the front page, this translation is in no way official and has mostly be done
via machine-learning, not by a professional.
The original technical documentation
Żuk budowa eksploatacja naprawa
is no longer being sold by
its publisher and there is no announced plan to provide an English version; said publisher neither
provides an alternative manual on topic.
As
Żuk budowa eksploatacja naprawa
is one of the rare manuals, with no real market value (around
20 PLN for a used one on allegro.pl in 2015), that cover a nowadays uncommon historical vehicle,
we believe distributing its translation for free to be fair-use, as it is educational and contributing to
road-safety. Were the original authors/publisher to release an English version of the manual, or a
similar one, we would obviously consider discarding this project.
While computer automated translations are enough to get a general idea on the topic and while data
in tables should be as accurate as in the original document, the whole translation process being
partly automated implies errors, of interpretation but likely also of transcription.
If you are doing anything critical, you are more than advised to cross-check data with the original
technical documentation
Żuk budowa eksploatacja naprawa.
If something seems dubious, assume
that the translation may be faulty.
Already noticed odd translations are marked in yellow. Untranslated items are marked in orange.
Incomplete or clearly erroneous items are marked in red. Added items, not in the original book, are
marked in blue.
You are welcome to get in touch to provide any fixes or even just to ask us to crosscheck
something.
To reach us, you can either post:
•
•
a comment on the
relevant blog post at http://zukowka.wordpress.com
an issue on the
gitlab issue tracker
.
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budowa eksploatacja naprawa in English!
- crosscheck with the original manual for anything critical
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Contents
1 VEHICULE CHARACTERISTICS..................................................................................................7
1.1 DIMENSIONS.........................................................................................................................15
1.2 MASS......................................................................................................................................15
1.3 PERFORMANCE....................................................................................................................15
1.4 TECHNICAL CHARACTERISTICS OF THE MAIN COMPONENTS...............................16
1.4.1 Engines.............................................................................................................................16
1.4.2 Transmission(s)................................................................................................................16
1.4.3 Suspension and wheels.....................................................................................................17
1.4.4 Steering/braking mechanisms..........................................................................................17
1.4.5 Bodywork.........................................................................................................................17
1.4.6 Electrical equipment........................................................................................................18
1.5 ESSENTIAL CONTROL AND REGULATORY DATA OF THE VEHICLE.......................20
1.6 CONTROL AND COMMAND SYSTEM..............................................................................22
2 ENGINES........................................................................................................................................29
2.1 S-21 ENGINE..........................................................................................................................30
2.1.1 S-21 Hull..........................................................................................................................31
2.1.2 S-21 Head.........................................................................................................................37
2.1.3 S-21 Crankshaft piston mechanism.................................................................................38
2.1.4 S-21 Timing mechanism..................................................................................................45
2.1.5 S-21 Air/Fuel Supply.......................................................................................................49
2.1.6 S-21 Lubrication and ventilation system.........................................................................60
2.1.7 S-21 Cooling system........................................................................................................67
2.1.8 S-21 Exhaust system........................................................................................................70
2.1.9 S-21 Suspension...............................................................................................................73
2.1.10 S-21 Maintenance..........................................................................................................73
2.1.11 S-21 Repairs...................................................................................................................82
2.2 CB ENGINE (todo).................................................................................................................99
2.2.1 CB Hull..........................................................................................................................100
2.2.2 CB Head.........................................................................................................................100
2.2.3 CB Crankshaft piston mechanism..................................................................................100
2.2.4 CB Timing mechanism..................................................................................................100
2.2.5 CB Air/Fuel Supply........................................................................................................100
2.2.6 CB Lubrication and ventilation system..........................................................................100
2.2.7 CB Cooling system........................................................................................................100
2.2.8 CB Exhaust system........................................................................................................100
2.2.9 CB Suspension...............................................................................................................100
2.2.10 CB Maintenance...........................................................................................................100
2.2.11 CB Repairs...................................................................................................................100
2.3 4C90 ENGINE.......................................................................................................................101
2.3.1 4C90 Hull.......................................................................................................................106
2.3.2 4C90 Head......................................................................................................................108
2.3.3 4C90 Head cap...............................................................................................................110
2.3.4 4C90 Crankshaft piston mechanism...............................................................................110
2.3.5 4C90 Timing mechanism...............................................................................................117
2.3.6 4C90 Air/Fuel Supply....................................................................................................120
2.3.7 4C90 Injection pump drive and timing mechanism.......................................................127
2.3.8 4C90 Lubrication and ventilation system......................................................................131
2.3.9 4C90 Cooling system.....................................................................................................135
2.3.10 4C90 Exhaust system...................................................................................................137
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2.3.11 4C90 Vacuum pump.....................................................................................................137
2.3.12 4C90 Suspension..........................................................................................................138
2.3.13 4C90 Maintenance.......................................................................................................138
2.3.14 4C90 Repairs................................................................................................................143
3 TRANSMISSION SYSTEMS......................................................................................................156
3.1 CLUTCHES...........................................................................................................................157
3.1.1 DO2 Clutch....................................................................................................................159
External clutch engagement mechanism : standing pedal version.....................................162
External clutch engagement mechanism : suspended pedal version..................................164
Repair of the coupling........................................................................................................166
3.1.2 200DBR Clutch..............................................................................................................168
3.2 GEARBOXES.......................................................................................................................172
3.2.1 Type 16 Gearbox............................................................................................................173
Housing, shafts and gearboxes...........................................................................................173
Synchronizers.....................................................................................................................177
Repair of gearboxes............................................................................................................184
3.2.2 Type A13.1 Gearbox......................................................................................................186
Housing, shafts and gearboxes...........................................................................................187
Synchronizers.....................................................................................................................191
3.2.3 Polonez gearbox.............................................................................................................192
3.3 DRIVE SHAFTS...................................................................................................................198
3.3.1 Single drive shaft...........................................................................................................199
3.3.2 Split drive shaft..............................................................................................................202
Maintenance and repair of the drive shaft..........................................................................206
3.4 REAR DRIVE AXLE............................................................................................................208
3.4.1 Drive axle type 18/23.....................................................................................................209
Main transmission..............................................................................................................209
Differential mechanism......................................................................................................213
Repair of the rear bridge....................................................................................................218
3.4.2 Drive axle type 3005/3015.............................................................................................222
Differential mechanism......................................................................................................226
Drive shafts.........................................................................................................................228
Maintenance and repair of rear axle 3005 (3015)..............................................................229
4 FRAME AND SUSPENSION SYSTEMS...................................................................................230
4.1 CHASSIS...............................................................................................................................232
4.2 FRONT AXLE AND SUSPENSION....................................................................................237
4.2.1 Front suspension............................................................................................................239
4.2.2 Anti-roll bar....................................................................................................................245
4.2.3 Repair of front suspension.............................................................................................248
4.3 REAR SUSPENSION...........................................................................................................259
4.3.1 Leaf spring.....................................................................................................................261
4.3.2 Rear shock absorber.......................................................................................................263
4.3.3 Repair of rear suspension...............................................................................................264
4.4 ROAD WHEELS...................................................................................................................266
4.4.1 Wheels............................................................................................................................267
4.4.2 Tyres...............................................................................................................................267
4.4.3 Repair of wheels and tyres.............................................................................................268
5 GUIDANCE SYSTEMS..............................................................................................................271
5.1 STEERING............................................................................................................................272
5.1.1 Steering mechanism.......................................................................................................274
5.1.2 Return mechanism..........................................................................................................277
5.1.3 Repair of steering systems.............................................................................................279
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5.2 BRAKING SYSTEM............................................................................................................285
5.2.1 Service brake..................................................................................................................286
5.2.2 Brake failure indicator...................................................................................................298
5.2.3 Emergency (parking) brake............................................................................................299
5.2.4 Repair of the braking system.........................................................................................300
5.2.5 Brake performance.........................................................................................................306
6 VEHICLE BODIES......................................................................................................................308
6.1 BODY A06.............................................................................................................................310
6.1.1 Cabin..............................................................................................................................311
6.1.2 Container bodies............................................................................................................319
6.1.3 Isothermal bodies...........................................................................................................322
6.2 BODIES FOR THE CARRIAGE OF GOODS AND PASSENGERS..................................325
6.2.1 Body A07.......................................................................................................................326
6.2.2 Specialist van body........................................................................................................328
6.3 PICKUP BODIES A111 and A161........................................................................................330
6.3.1 Cargo box and sheet A111..............................................................................................331
6.3.2 Cargo platform floor A111 and A161............................................................................332
6.4 FIRE TRUCK VEHICLE BODIES (todo)............................................................................334
6.5 BODYWORK LACQUER COATING.................................................................................335
6.5.1 Factory painting.............................................................................................................336
6.6 BODYWORK EQUIPMENT................................................................................................337
6.6.1 Driver's and passenger's seats........................................................................................338
6.6.2 Seats and benches for passengers...................................................................................339
6.6.3 Ventilation and heating system......................................................................................341
6.6.4 Seat belts and equipment...............................................................................................344
6.7 BODY MAINTENANCE AND REPAIR..............................................................................346
6.7.1 Washing..........................................................................................................................347
6.7.2 Corrosion protection......................................................................................................347
6.7.3 Body repair.....................................................................................................................350
6.7.4 Renovation painting.......................................................................................................358
7 ELECTRICAL SETUP.................................................................................................................360
7.1 POWER SUPPLY CIRCUIT.................................................................................................368
7.1.1 Alternator A124F...........................................................................................................369
7.1.2 Voltage regulator............................................................................................................372
7.1.3 Accumulators.................................................................................................................373
7.2 START-UP CIRCUIT............................................................................................................379
7.2.1 Electric starter................................................................................................................380
7.2.2 Repair of the starting circuit..........................................................................................384
7.3 IGNITION CIRCUITS..........................................................................................................387
7.3.1 S-21 engine ignition circuit............................................................................................388
Ignition coil........................................................................................................................389
Spark plugs.........................................................................................................................394
Ignition cables....................................................................................................................395
Repair of engine S-21 ignition contact circuit...................................................................396
7.3.2 Electronic ignition circuit..............................................................................................404
Electronic ignition distributor (4484)................................................................................407
Electronic module..............................................................................................................407
Ignition coil (4426)............................................................................................................408
Verification of electronic ignition......................................................................................409
7.3.3 Engine CB ignition circuit (PN 1600)...........................................................................410
7.4 LIGHTS.................................................................................................................................412
7.4.1 Headlamps......................................................................................................................415
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- crosscheck with the original manual for anything critical
5/486

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