Characteristics of the MAZ-500

MAZ 500 is a truck that has become a real legend. The first Soviet cabover truck was put into serial production in 1965, and its production continued until 1977 inclusive. Despite the fact that very little time has passed since the end of production, the MAZ 500 truck still has a price. They can be found on the territory of the CIS countries, they are actively exploited to this day. The payload, revolutionary at the time of release, high-quality assembly and ease of maintenance, made the MAZ 500 the best car in its cargo category for a long time.

 

Description MAZ 500 and its modifications

MAZ-500 trucks are still in operation

The prototype of this truck is the MAZ-200. True, by design, trucks do not have much in common - they have a different design. In particular, the MAZ-500 does not have a hood, its cabin is located directly above the engine compartment. This gave engineers the ability to:

• reduce the weight of the truck;
• increase the length of the loading platform;
• increase the carrying capacity by 0,5 tons.

Given the outstanding characteristics of the truck, many different modifications were produced on the basis of the MAZ-500.

Let's take a closer look at the most popular truck configurations.

• MAZ-500 on board.

MAZ-500 onboard with a wooden body

Onboard MAZ 500 is the basic modification of a truck. Its declared carrying capacity is 7,5 tons, but it could tow trailers weighing up to 12 tons. The onboard MAZ 500 received the popular nickname "Zubrik" because of the casing that was attached to the rear wall of the cab. The side deck of the truck was made of wood, usually painted blue. This version came standard with power steering and a 5-speed manual transmission.

• Dump truck MAZ-500.

Photo MAZ-500 with a dump truck body

The modification with a dump truck belongs to the MAZ-500 family, but in fact it had an index of 503.

• Tractor MAZ-500.

A modification of the truck tractor was produced under the MAZ-504 index. Two- and three-axle truck tractors (MAZ-515) as part of road trains could tow up to 24 tons.

• Forestry truck MAZ-509.

Timber truck MAZ-500

Especially for the needs of forestry, a specialized modification of the MAZ-509 truck was made.

• MAZ-500SH.

This version of the truck did not have a body and was produced with a chassis on which the necessary equipment could be installed.

• MAZ-500A.

In this modification, which began to be produced in 1970, the truck had a wheelbase increased by 10 cm and met European standards. The carrying capacity was 8 tons. For the second generation version, the main gear ratio was changed, due to which it was possible to increase the speed - up to 85 km / h. As for the visual differences, the characteristic casing behind the cab was removed from the MAZ-500 of the second generation, and a turn signal repeater was added to the level of the door handles.

• Fuel truck MAZ-500.

Fuel truck MAZ-500

Other truck modifications that are less common include:

• Onboard version of the MAZ-500V with a metal body;
• MAZ-500G in the onboard version and extended base;
• MAZ-505 with all-wheel drive;
• MAZ-500Yu/MAZ-513 in tropical version;
• MAZ-500S / MAZ-512 in the northern version.

Another extremely common car was a tow truck based on the MAZ-500. The truck crane "Ivanovets" KS-3571 was mounted on the chassis of a second generation truck. In such a tandem, the special brigade was distinguished by its impressive carrying capacity, maneuverability and breadth of action. Until now, truck cranes MAZ-500 "Ivanovets" are actively used at construction sites, public works and in agriculture.

MAZ-500 with truck crane

Specifications MAZ-500

At the time of release, the characteristics of the MAZ-500 seemed really impressive - the car surpassed the capabilities of many of its competitors. In particular, it was the first cabover truck produced in the USSR.

But he won popular love with his reliability and reliability. One of the distinguishing features of the MAZ-500 is that it can operate with a complete failure of electrical equipment. And this means that the car starts up without problems even in cold weather, it is enough to start it from the “pusher”. For the same reason, the military MAZ-500, which is still in service, has become widespread, even despite the lack of all-wheel drive in the basic modification.

Let us dwell in more detail on the technical characteristics of the first generation MAZ-500. The carrying capacity of the basic modification is 7,5 tons. The dead weight of the machine is 6,5 tons. The truck was made in three body lengths:

• 4,86 meters;
• 2,48 meters;
• 0,67 meters

MAZ-500 dimensions:

Dimensions of the base truck MAZ-500

A long	7,14 meters
Wide	2,5 meters
Height (up to the maximum level of the cabin, excluding the body)	2,65 meters
Floor cleanliness	0,29 meters
wheel formula	* 4 2, 4*4, 6*2
Fuel tank MAZ-500	200 liters

Now let's see how the dimensions and technical characteristics of the second generation MAZ-500A have changed.

Second generation military MAZ-500 (with mesh grille)

Payload MAZ-500	8 tons
Trailer weight	12 tons
Distance between axles	3,95 meters
Floor cleanliness	0,27 meters
A long	7,14 meters
Wide	2,5 meters
Height (in cab, without body)	2,65 meters
Fuel tank	200l

As can be seen from the tables, the dimensions of the MAZ-500 of the first and second generations have not changed - the dimensions of the trucks have remained the same. But due to the redistribution of the layout, it was possible to free up additional space for the cargo part and increase the carrying capacity of the MAZ-500A to 8 thousand kg. The increase in own weight led to a slight decrease in ground clearance - it decreased by 20 mm. The fuel tank remained the same - 200 liters. The consumption of MAZ-500 of the first and second generation in the combined cycle is 22 l / 100 km.

MAZ-500 engine

The MAZ-500 engine has a V-shaped design and easy access for maintenance

As an engine, the MAZ-500 was equipped with a six-cylinder YaMZ-236 unit manufactured by the Yaroslavl Motor Plant. The power plant was distinguished by a good combination of fuel efficiency and performance, which was especially important for city trucks. In addition, the engine operates stably over a wide temperature range, has a long service life, and is generally distinguished by reliability and build quality.

The use of the YaMZ-236 engine on the MAZ-500 made it possible to obtain other advantages. In particular, due to the V-shaped arrangement of the cylinders, the engine had smaller dimensions. This is what made it possible to assemble the MAZ-500 without a hood and place the engine clearly under the cab. In addition, thanks to the V-shaped design, it was possible to locate the lubricated units in accessible places. Maintenance of the MAZ-500 engine was really simple compared to other trucks that existed at that time.

In the design of the YaMZ-236 engine on the MAZ-500, some innovative technologies were applied. The injection pumps were combined into a single unit and worked separately from the injectors in the cylinder heads. The fuel module itself is located in the collapse of the blocks. The engine has only one overhead camshaft and one crankcase configuration.

Many elements of the YaMZ-236 engine on the MAZ-500 were manufactured using innovative methods for the 70s - injection molding and stamping. As a result, the engine turned out to be so successful that the power plants of this model are still installed on trucks and special equipment.

Technical characteristics of the YaMZ-236 engine on the MAZ-500

YaMZ-236 engine on MAZ-500

YaMZ-236 engine production speed	YAME-236
Number of cylinders	6
Provision	v-shaped right angle
Cycle	Four stroke
What order are the cylinders	1-4-2-5-3-6
Workload	11,15 liters
Fuel compression ratio	16,5
Energy	180 HP
Maximum torque	1500 / min
Engine weight	1170 kg

The overall dimensions of the YaMZ-236 engine on the MAZ-500 are as follows:

• Length 1,02 m;
• Width 1006 m;
• Height 1195m.

Complete with gearbox and clutch, the engine has a length of 1796 m.

For the power plant on the MAZ-500, a mixed lubrication system was proposed: some of the assemblies (main and connecting rod bearings, connecting rod and rocker bushings, connecting rod spherical bearings, thrust bushings) are lubricated with oil under pressure. Gears, camshaft cams and bearings are coated with splash oil.

To clean the oil in the MAZ-500 engine, two oil filters are installed. The filter element is used for rough cleaning of the technical fluid and removal of large mechanical impurities from it. The second fine oil filter is a centrifugal design with a jet drive.

To cool the oil, an oil cooler is installed, located separately from the engine.

MAZ-500 checkpoint

Scheme of the MAZ-500 gearbox

A three-way gearbox was installed on the MAZ-500. The manual transmission had five speeds. Fifth gear - overdrive, synchronizers were on the second-third and fourth-fifth stages. Since the gears of the first gear do not have a synchronizer, switching to the first gear can only be carried out with a significant decrease in the speed of the truck.

A feature of the MAZ-500 configuration was that the control post was far from the driver. To compensate for this distance, a remote control was installed on the truck, with the help of which the gears were switched. Such a design did not differ in particular reliability, since the remote control mechanism was loosened.

All transmission gears, with the exception of 1st, reverse and PTO, are constantly engaged with the corresponding gears of the input and output shafts. Its teeth have a spiral arrangement, which is done to increase the service life and reduce noise during the operation of the MAZ-500 gearbox. Also, to reduce noise, the intermediate shaft gear has a ring gear with a damper spring installed.

To increase the service life of the transmission, all shafts and gears of the reducer are made of alloy steel and are carburized and heat treated after casting.

Gearbox gear teeth are lubricated from below the crankcase. The bushings, which act as thrust bearings for the mainshaft gears, are wetted with pressurized oil. Oil comes from the oil pump located on the front wall of the crankcase.

As the transmission gears rotate, oil is sucked in where the teeth disengage. Oil injection occurs at the points of contact of the teeth.

An oil trap with a magnetic element is located at the bottom of the transmission pan to clean the oil. Retains chips and metal particles, effectively cleaning gear oil.

The gearshift scheme of the MAZ-500 is as follows:

Gearshift scheme on a MAZ-500 truck

In general, the MAZ-500 box is strong and reliable. She has a feature. The transmission oil pump does not operate when the engine is stopped. Therefore, if the engine is not running, transmission oil does not enter the box. This point must be taken into account when towing a truck.

Steering MAZ-500

Steering scheme MAZ-500

The simple, but at the same time reliable steering of the MAZ-500 was innovative for its time. The truck received a hydraulic booster and a telescopic steering column, thanks to which the reach of the steering wheel could be adjusted for you.

Steering MAZ-500 can be configured

The well-thought-out steering design not only made the MAZ-500 one of the most convenient trucks to drive. It also made servicing the pump, power steering and other steering gear easier as all lubricated and replaceable items were easily accessible for inspection and replacement.

The MAZ-500 steering mechanism combines the work of the following structural elements:

• steering column;
• Power steering;
• power cylinder tip;
• steering wheel;
• brake drum;
• front axle beam.

The principle of operation of the MAZ-500 steering mechanism is as follows. First of all, the pressure pump transfers pressure to the hydraulic booster. If the truck is moving in a straight line, then the power steering is idling. When turning the machine, the spool begins to move, as a result of which hydraulic oil enters the cavity of the power cylinder. If you increase the steering angle, the diameter of the channel also increases. This increases the pressure on the steering rack.

The weakest points of the steering mechanism are:

• spool - with minor damage, it can be restored, but most often it is required to install a new one assembled with the body;
• power cylinder rod - the rod itself has a sufficient margin of safety, but has a weak thread; minor defects can be eliminated by grinding and applying a new thread;
• power cylinder - its working surface is subject to wear, which, with light abrasion, can be restored by bluing.

Drive a MAZ-500

The design of the hydraulic booster MAZ-500

Due to the presence of a hydraulic booster, the MAZ-500 driver did not have to make a large amplitude with the steering wheel. Jerks and knocks when driving over bumps also decreased, that is, the car was operated in such conditions.

The power steering on the MAZ-500 consists of a distributor and a power cylinder. Its constituent elements are:

• vane pump (installed directly on the engine);
• container for oil;
• hoses

The flow of fluid circulating in the power steering is regulated by a distributor. Directs flow from the pump to the power cylinder. Thus, when the pump is running, a closed circuit is obtained.

Scheme of the power steering (GUR) on the MAZ-500

It should be noted that the MAZ-500 hydraulic booster differs markedly from the power steering, which is installed on modern cars. Mazovsky's power steering had a low-power pump, so the driver still has to make an effort to control the truck. There were also problems during winter operation. The design of the power steering did not protect the oil in the hydraulic lines from freezing.

To eliminate these shortcomings, the owners changed the native direction of the MAZ-500 to more modern units with a more thorough design. Actually, today it is very rare to find a MAZ-500 with native steering and an unmodified hydraulic booster.

Chassis

The MAZ-500 truck was produced in different lengths and with different wheel formulas:

• 4 * 2;
• 4 * 4;
• 6 * 2.

All modifications of the machine were assembled on a riveted frame. The front and rear axles of the MAZ-500 were equipped with elongated springs, which gave the truck a smooth and even ride. This quality was especially appreciated by truckers, for whom the ride on the MAZ-500 was much more comfortable than on other truck models.

Rear axle MAZ-500

The wheels of the front axle are single-sided, and the wheels of the rear axle are double-sided, without disks.

MAZ-500 suspension scheme

The MAZ-500 suspension also played an important role in the operation of the engine. It had uneven torque, which led to increased vibrations. To protect the chassis from additional shock loads, the suspension had to be made softer and more flexible.

To take into account all the nuances, the suspension design was made tricycle. One bracket is located in front, two more are on the sides, next to the flywheel housing. The fourth support bracket is located on the gearbox housing. It is necessary to adjust the support after maintenance in order to remove excess load from the shock absorber. Work is carried out with the engine stopped.

You should also monitor the condition of rivets and bolted connections. During the operation of the truck, they become loose, which can be determined by the characteristic rattling sound. Loose bolts should be tightened as much as possible. As for loose rivets, they are cut off and new ones are installed. Riveting is done with hot rivets.

In addition to checking the connections when servicing the chassis and suspension of the MAZ-500, it is necessary to inspect the frame. The appearance of rust must be controlled and eliminated at the initial stage, as the spread of corrosion will reduce the fatigue strength of the truck frame.

The technical characteristics of the MAZ-500 front spring suspension are as follows:

• number of sheets - 11;
• section of the first four sheets 90x10 mm, the rest 90x9 mm;
• the distance between the central axes of the spring mounts is 1420 mm;
• spring pin diameter - 32 mm.

Technical characteristics of the rear spring suspension:

• number of sheets - 12;
• sheet section – 90x12 mm;
• the distance between the central axes of the spring mounts is 1520 mm;
• spring pin diameter - 50 mm.

For the front and rear axles of the MAZ-500, a longitudinal semi-elliptical spring suspension was used. The springs effectively absorb vibrations in the vertical plane and ensure the transfer of traction and braking force from the drive axle to the frame.

Braking and torque forces are transferred to the steered axle. The spring suspension of the steering axle provides the necessary kinematics of the steering mechanism.

The front suspension is equipped with double-acting hydraulic shock absorbers, while the rear suspension is equipped with additional leaf springs.

MAZ 500 cabin

Depending on the MAZ 500 device, the cabin could have the following layout:

• Alone,
• Double,
• Triple.

Modifications of the MAZ-500 with a single cab did not go into mass production and existed in piece quantities as prototypes.

Test vehicle MAZ-500 with single cab

A double cab was installed on the MAZ-500 dump truck, and the rest of the trucks had a triple cab with separate seats for the driver and two passengers.

A full-fledged berth was also provided in the double and triple cabin of the MAZ-500.

Dashboard inside the cab MAZ-500

Today, the interior of the MAZ-500 is not impressive and looks at least ascetic. But at the time of release, the truck did not lag behind other truck models on the market in terms of comfort, and in some cases even surpassed its classmates. In general, the owners note the comfortable design of the seats, the high seating position, the large glass area and the good arrangement of the instruments. On a modern MAZ-500, the cabin is often adjustable. In particular, more comfortable chairs are being installed and the bed is being upgraded.

Earlier we wrote about the technical characteristics of the MAZ 4370 Zubrenok.