Professional Documents
Culture Documents
OPERATING INSTRUCTIONS
2. Technical Characteristics
1. The machine has a four-stroke, one-cylinder air-cooled Diesel engine built in with
automatic gas regulation of the 3DM515 type, manufactured by "21. MAJ" - Belgrade
2. Engine power ........................................................10.5 kW (14.2KS)
3. Maximal revolution number............................................. 3000 r/min
4. Revolution number at maximal moment .......................... 2000 r/min
5. Maximal engine moment ........................................................ 30 Nm
6. Gear number ..................................................................................... 4
7. Maximal speed ...................................................................... 35 km/h
8. Carrying capacity ..................................................................... 15 kN
9. Machine dimensions
- Length ............................................................................... 3000 mm
- Width ................................................................................ 1950 mm
- Height ............................................................................... 2050 mm
The given machine dimensions are with protection tarpaulin.
Light Track Motor Car LMD-9 Page 5
If the engine is cold it is necessary to pull the induction lever according to the engine
manufacturer’s instructions.
Light Track Motor Car LMD-9 Page 7
4. Drive
4.1. Procedure before Starting the Light Track Motor Car
Before moving the motor car it is necessary to do the following:
1. Check the oil pressure upon the control lamp the moment the engine starts working.
The control lamp must be switched off.
2. Check if the control lamp of the accumulator charge is switched off at an increased
number of the engine’s revolutions.
If the control lamp remains lit it is the sign that the alternator does not fill the
accumulator and that there is some error at the electric installation.
Note: During the engine’s operation the contact key must remain on in order to avoid
burning of the alternator
3. Never load the cold engine at a greater number of revolutions since the cold oil cannot at
once penetrate all the channels of the lubrication system thus making it possible for the
moveable parts to jam. Use the engine by heating it at slow loading along with gradual
increase of the revolution number.
- at sudden braking it is necessary to reduce gas and, at the same time, press upon the
clutch pedal,
- care should be taken that the Diesel engine under load works with neither too small nor
too great number of revolutions. Instead, at each gear the engine should work with an
optimal number of revolutions which is about 2 000 r/min. At that number of revolutions
the engine gives the greatest revolution moment and works most economically. The gear
shifting is designed for securing, with its four gears, the proper use of the engine power
and the motor car speed.
- the highest permitted motor car speed is from 35 km/h for the drive without trailer, for
the horizontal and the drop of 100/00. At the drop of over 10-300/00, speed must be
reduced for 1/3 (Traffic Regulations 62, Art.164.1),
- at low visibility drives, for tunnel drives or at switches and curves, over road
intersections, before entering stations, etc., the valid regulations are those prescribed by
the Yugoslav Railways.
4.3. Braking
The motor car is equipped with the hydraulic disk brake at both the axles and a hand
mechanical brake that stops the front axle.
The hydraulic brake is of two-circular effect, that is, the front and the rear axles are
independently braked which gives high security to the brakes’ operation.
The hydraulic pedal is regulated by the foot pedal. The braking intensity is regulated by the
intensity of pressure upon the foot pedal. At braking care should be taken that the wheels are
not blocked and that they do not slide upon the tracks. If it is noticed that the braking force is
too intense and that the wheels are sliding, the foot pressure upon the pedal should be
lowered and then the braking should be adjusted so that the wheels are still turning.
Before braking, the clutch pedal should be pressed upon and the gas reduced. If stopping,
the gearshaft lever should be put in the neutral position.
Braking can be done even without the switched off clutch and the switched on gear. The
normal braking on the slope is with the power transmission switched on.
Note: Never drive on the slope with the Diesel engine switched off or with the power
transmission switched on. When the motor car stops, by the hand mechanical brake
the motor car can be normally kept still even at the greatest slope.
5. If the motor car is not to be used for some time, it is recommended that the terminals
should be separated from the accumulator poles.
MAINTENANCE INSTRUCTIONS
2. Gearshifting
2.1. General Description
At the LMD-9 Light Track Motor Car the gearshifting of the serial manufacturing that is
produced on LADA cars is applied.
The gear is of four degrees for forward movement, with a gear for reverse movement and
with synchronous starting rings of 1st, 2nd and 3rd gear (4th gear is blocked).
The gear ratios are:
1st gear 3,75
2nd gear 2,30
3rd gear 1,49
4th gear 1,00
R (reverse movement) 3,87
2.2. Maintenance
Apart from the regular control of the oil quantity, the gear requires special conditions for
maintenance.
Oil Control: Remove the cap for the oil level control.
The oil level should be at the lower edge of the oil-pouring hole.
Oil Replacement: Unscrew the cap on the lower part of the gear box. When the old oil is
utterly extracted, twist the cleansed cap.
Unscrew the cap on the gearbox side and pour through the hole 1,5 l of hypoid oil HIP
90.
The needed oil level is reached when oil starts leaking from the oil-pouring hole. Clean
the cap and the area around the oil-pouring hole and then twist the cap
3. Chain Transmission
3.1. Description
The chain transmission consists of an assembly of the driving chain wheel, the Gall’s chain,
the chain stretcher and the chain pulley on the driving axle of the motor car.
The driving chain wheel assembly consists of an open chain pulley made together with the
axle supported by two self-regulating ball bearings. The bearing housings are fastened to the
motor car base.
At one end of the chain pulley axle there is a three-armed claw mounted for tightening the
Hardley joint. Another three-armed claw is pulled over the output shaft of the gear. The hard
rubber is so mounted in order to obtain alternating bending between the arms of the claws;
thus a very elastic connection is obtained between the gearshaft and the chain pulley.
3.2. Maintenance
It is necessary to check occasionally the state of the hard rubber. If it needs to be replaced,
use the hard rubber that is 12 mm thick with the same geometry as the original one. The
rubber bending must remain the same. After the rubber is mounted, screws and nuts must be
well tightened and assured.
Once a year the ball bearings should also be controlled. The covers of the bearing housing
should be removed; the lubricant should be checked and, if needed, more of it should be
added. If the lubricant is hardened, the bearings should be taken out, washed, dried and filled
with the lubricant till 2/3 of the housing volume. When readjusting the cover, it is necessary
to check whether the felt packing rests properly.
At three-year periodic inspection in a specialized workshop it is obligatory to disassemble
the bearings, to control and change the lubricant.
The Gall’s chain, chain pulleys and stretchers should be inspected once a week and
lubricated.
Check if the Gall’s chain is properly tightened. If it is loose, tighten it by adjusting the
chain stretcher. The procedure is the following:
- at the chain stretcher release the check nut (2) so that it is possible to wind the nut (1)
(Fig. 5),
- gear lever should be placed in the neutral position and then the motor car should be
pushed 1 or 2 meters so that one side of the chain remain tightened. In this position stop
the motor car by the hand brake,
- adjustment is done upon the stretcher of the released side of the chain by winding the nut
(1) until such chain tightness is obtained that, under the pressure of the thumb, the
bending of the chain of 5 mm is made possible on the part between the stretcher and the
driving axle chain pulley.
When the desired stress is achieved, the nut (1) should be secured by the check nut (2),
- If it is not possible to tighten up the chain properly in the above-described way, the nut
(1) should be returned to the original position while the whole stretcher should be
Light Track Motor Car LMD-9 Page 14
released by unwinding the screw (3) and the whole stretcher should be moved towards
the chain.
Fine adjustment of tightening should be done by the nut (1) in the above-described
procedure.
The second stretcher should be adjusted in the same way as well.
4. Axle Assembly
4.1. Description
The axle assembly consists of an axle in addition to monoblock wheels and a braking disc.
On the front axle there is a two-part chain pulley mounted as well. The axles are at the
outside journals while the bearings are self-regulating barrel-like ones.
The bearing housings are two-parts, made of steel casting. At the side that the axle passes
through there are two felt rings for dust protection.
The monoblock wheels are of steel casting and they are pressed upon the axle.
The axle is made of steel S.0545. Upon the axle there are disc rings welded and a two-part
chain pulley. The discs as well as the chain pulley are attached to their respective rings by
screws. The chain pulley is of two parts so that its replacement is easy and simple with no
need to remove the wheel from the axle.
4.2. Maintenance
There are no special requirements regarding the axle assembly maintenance. Occasionally
the state of the braking disc, the two-part chain pulley and the rubber pads between the
bearing housing and the support should be inspected. The chain pulley on the axle should not
be specially lubricated - it is lubricated through the small driving pulley and the Gall’s chain.
Every third year, during the periodic inspection of the motor car in the authorized
workshop, the bearings should be removed, washed, examined, re-filled with the adequate
lubricant and mounted. On that occasion the state of the felt rings should also be checked
and, if necessary, they should be replaced.
The monoblock wheels are pressed upon the axle and they can be removed or pulled over
only in specialized workshops.
5. Brakes
5.1. General Description
The motor car is equipped with the hydraulic disc brake on both the axles with oscillating
pliers and control cylinder for each disk.
The brake control is through the foot pedal.
The hand brake is mechanical acting upon the braking disc of the front axle.
The clearance between the braking pads and the braking disc is self-regulating.
- after the above-mentioned operations, fill the tanks to the maximally prescribed level.
Note: The discharged liquid must not be used again.
DENOTAT
PIECE PART NAME PART NUMBER
ION
1 1 Front axle M.20.03.00.01
2 2 Motor car’s wheel M.20.03.00.02
3 4 Screw M12 x 65 cl. 8.8 JUS.M.B1.051
4 4 Elastic washer Ø12 JUS.M.B2.111
5 4 Turret nut M12 cl.8 JUS.M.B1.631
6 1 Braking disc M.20.03.00.06
7 16 Screw M8 x 30 cl 8.8 JUS.M.B1.051
8 16 Nut M8 cl.8 JUS.M.B1.601
9 16 Elastic washer Ø8 JUS.M.B2.111
10 1 Two-part chain pulley M.20.03.00.10
11 2 Bearing 20308
12 2 Bearing support M.20.03.00.12
13 2 Bearing housing M.20.03.00.13
14 2 Housing cover M.20.03.00.14
15 4 Felt packing M.20.03.00.15
16 12 Screw M6 x 25 cl 8.8 JUS.M.B1.051
17 2 Rubber absorber M.20.03.00.17
18 4 Washer M.20.03.00.18
19 4 Screw M6 x 12 cl 8.8 JUS.M.B1.053
Light Track Motor Car LMD-9 Page 19
Fig. 1
Light Track Motor Car LMD-9 Page 20
DENOTAT
PIECE. PART NAME PART NUMBER
ION
1 1 Rear axle M.20.04.00.01
2 2 Motor car’s wheel M.20.03.00.02
3 4 Screw M12 x 65 cl. 8.8 JUS.M.B1.051
4 4 Elastic washer Ø12 JUS.M.B2.111
5 4 Turret nut M12 cl.8 JUS.M.B1.631
6 1 Braking disc M.20.03.00.06
7 8 Screw M8 x 30 cl 8.8 JUS.M.B1.051
8 8 NutM8 cl.8 JUS.M.B1.601
9 8 Elastic washer Ø8 JUS.M.B2.111
10 4 Screw M6 x 12 cl 8.8 JUS.M.B1.053
11 2 Bearing 20308
12 2 Bearing support M.20.03.00.12
13 2 Bearing housing M.20.03.00.13
14 2 Housing cover M.20.03.00.14
15 4 Felt packing M.20.03.00.15
18 4 Washer M.20.03.00.18
17 2 Rubber absorber M.20.03.00.17
18 12 Screw M6 x 25 cl 8.8 JUS.M.B1.051
Light Track Motor Car LMD-9 Page 21
Fig. 2
Light Track Motor Car LMD-9 Page 22
DENOTAT
PIECE. PART NAME PART NUMBER
ION
1 1 Spindle M.20.02.00.01
2 1 Nut M.20.02.00.02
3 1 Guide M.20.02.00.03
4 1 Ring Ø56x10 M.20.02.00.04
5 1 Split pin 8x50 JUS.M.B2.300
6 1 Handle M.20.02.06.00
7 2 Bearing 51206 x JUS.M.C3.506
8 8 Lever M.20.02.00.08
9 2 Right half-gear M.20.02.00.09
10 2 Left half-gear M.20.02.00.10
11 1 Hoist carrier M.20.02.00.11
12 2 Profile U6.5
13 1 Profile U6.5
14 3 Profile U6.5
15 24 Screw M10 x 20 cl 8.8 JUS.M.B1.053
16 24 Elastic washer Ø10 JUS.M.B2.111
17 1 Upper roll holder M.20.02.00.17
18 4 Plate 56x124 M.20.02.00.18
19 4 Elastic washer Ø12 JUS.M.B2.111
20 4 Screw M12 x 30 cl. 8.8 JUS.M.B1.053
21 4 Screw M12 x 140 cl. 8.8 JUS.M.B1.051
22 4 Pipe 1/2" x106
23 8 Elastic washer Ø12 JUS.M.B2.111
24 4 NutM12 JUS.M.B1.601
25 1 Handle support M.20.02.00.25
26 4 Split pin 5x45 JUS.M.B2.300
27 8 Washer Ø27 JUS.M.B2.011
28 1 Hoist locking device M.20.02.28.00
29 1 Split pin 5x63 JUS.M.B2.300
30 1 Turret nut M30 cl.8 JUS.M.B1.632
31 1 Ring Ø56x6 M.20.02.00.31
32 1 Lower roll holder M.20.02.00.32
33 1 Support M.20.02.00.33
Light Track Motor Car LMD-9 Page 23
Fig. 3
Light Track Motor Car LMD-9 Page 24
DENOTAT
PIECE PART NAME PART NUMBER
ION
1 1 Flywheel
2 1 Clutch disc
3 1 Clutch basket
4 1 Push bearing
5 1 Oil container
6 1 Inlet hose
7 1 Main clutch hydraulic cylinder
8 1 Copper pipe
9 1 Clutch lever support
10 1 Clutch lever
11 1 Screw for air extraction
12 1 Auxiliary clutch hydraulic cylinder
13 1 Elastic clutch hose
14 1 Return spring
Light Track Motor Car LMD-9 Page 25
Light Track Motor Car LMD-9 Page 26
DENOTAT
PIECE. PART NAME PART NUMBER
ION
1 1 U - bolt M.20.05.07.01
2 2 Nut M20 JUS.M.B1.601
3 1 Rubber pad M.20.05.07.03
4 1 Carrying profile M.20.05.07.01
5 2 Washer Ø20 JUS.M.B2.011
6 1 Split pin 4x32 JUS.M.B2.300
7 1 Oil cup M6
8 1 Bearing 6306 2z
9 1 Ring M.20.05.07.09
10 1 Bolt M.20.05.07.10
11 1 Turret nut M16 cl.8 JUS.M.B1.631
12 1 Inner zeger Ø72
13 1 Stretcher chain pulley M.20.05.07.13
Light Track Motor Car LMD-9 Page 27
Fig. 5
Light Track Motor Car LMD-9 Page 28
DENOTAT
PIECE PART NAME PART NUMBER
ION
1 2 Bearing 6205 2z
2 1 Outer zeger Ø25
3 1 Screw M8 x 20 cl. 8.8 JUS.M.B1.053
4 1 Elastic washer Ø8 JUS.M.B2.111
5 3 Screw M10 x 50 cl 8.8 JUS.M.B1.126
6 6 Turret nut M10 cl.8 JUS.M.B1.631
7 6 Washer Ø10 JUS.M.B2.011
8 1 Split pin 2x22 JUS.M.B2.300
9 3 Screw M10 x 50 cl 8.8 JUS.M.B1.130
10 1 Three-armed coupling M.20.05.06.10
11 2 Housing body M.20.05.06.11
12 1 Shaft M.20.05.06.12
13 3 Housing cover M.20.05.06.13
14 1 Bearing housing cover M.20.05.06.14
15 3 Felt packing M.20.05.06.15
16 1 Hardley joint
17 8 Screw M8 x 35 cl 8.8 JUS.M.B1.051
18 8 Nut M8 JUS.M.B1.601
19 8 Elastic washer Ø8 JUS.M.B2.111
Light Track Motor Car LMD-9 Page 29
Fig. 6
Light Track Motor Car LMD-9 Page 30
DENOTAT
PIECE PART NAME PART NUMBER
ION
1 1 Engine 3 DM 515 with electric drive
2 16 Nut M12 cl.8 JUS.M.B1.601
3 6 Rubber absorber M.20.05.03.00
4 1 Thrust bearing "LADA"
5 1 Gear "LADA"
6 1 Front gear suspension M.20.05.10.06
7 8 Nut M12 cl.8 JUS.M.B1.601
8 1 Doublerow chain 190/2
19 4 Screw M6 x 12 cl 8.8 JUS.M.B1.053
Light Track Motor Car LMD-9 Page 31
Fig. 7
DENOTAT
PIECE PART NAME PART NUMBER
ION
1 1 Battery 12 V, 45 Ah
2 1 Starter 12 V
3 1 Alternator 12 V, 28 A
4 1 Switch with the key
5 1 Control lamp "Battery filling" KL red
6 1 Control lamp "Oil pressure" KL red
7 1 Oil automate M12 x 1
8 1 Fuse box
9 1 Alarm lamp switch
10 1 Alarm lamp switch
11 1 Alarm lamp switch
12 1 Alarm lamp switch
13 1 Headlamp switch
14 1 Horn-button
15 1 Alarm lamp - red
16 1 Alarm lamp - white
17 1 Alarm lamp - red
18 1 Alarm lamp - white
19 1 Headlamp
20 1 Headlamp
21 1 Horn-relay
22 1 Horn
Light Track Motor Car LMD-9 Page 33
Horn
Relay
Position Position
Double-sound
DENOTAT
PIECE PART NAME PART NUMBER
ION
1 1 Main braking cylinder
2 1 Braking jaws - front (with the hand brake)
3 2 Braking pads - front
4 1 Braking jaws - rear
5 2 Braking pads - rear
6 1 Braking jaw hose - front
7 1 Braking jaw hose - rear
8 1 Oil vessel with two outputs
9 1 Braking installation pipe - shorter
10 1 Brake installation pipe - longer
11 1 Hand brake
12 1 Hand brake cable