Kamaz equipment DIY repair

In detail: kamaz do-it-yourself repair equipment from a real master for the site my.housecope.com.

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Timely prevention is a sure way to prevent breakdowns, therefore, for a KamAZ-type truck, maintenance and repair work is carried out strictly according to the schedule drawn up on the basis of factory recommendations. The initial period of operation of the new KAMAZ, set by the manufacturer, is one thousand kilometers. During this stage, it is important to observe the speed limit (no more than fifty kilometers / hour) and avoid excessive load on the truck (no more than 75% of the norm).

Any configuration of a new KAMAZ is accompanied by the necessary documentation, which includes a manual for its repair.

Scheduled car repairs are carried out in order to prevent significant breakdowns. One of the main preventive measures is the regular replacement of all automotive fluids (coolant, lubricant and brake) in systems selected in accordance with the standards and requirements of the manufacturer. The occurrence of leaks in the cooling system, violation of the integrity of the valves and tank gaskets are breakdowns that the driver must eliminate immediately.

Video (click to play).

Delays in repairs can cause cavitation damage in the structure of the unit and pump, which will negatively affect the operation of the entire vehicle.

In case of a signal notification of a decrease in pressure in the lubrication system, an urgent repair of the KAMAZ engine will be required by the driver's own forces. Further movement of the truck with such a breakdown is undesirable.

Operation of a vehicle with a violation of the tightness of the intake tract of the internal combustion engine system can lead to premature wear of the car engine.

Preventing cracks in the cylinder head mountings will require reliable isolation of the bolt holes to prevent internal fluid and contamination from entering. The described manipulations are also recommended when replacing the cylinder heads of the internal combustion engine.

Certain repairs require welding. An important point in their implementation is to disconnect the battery. At the same time, the positive contact is removed from the generator. In this case, the ground wire of the welding machine should be connected at a short distance from the weld.

Regular maintenance of the car and its preventive inspection allow you to forget about the problem of breakdowns occurring along the way and the need to eliminate them. It is recommended to inspect the main parts of KAMAZ before each trip, as well as to check the level of all working fluids in its systems.

The driver independently performs the following actions:

  • checks the integrity of the wheels and tire pressure;
  • checks the functioning of the steering system drive;
  • tests the response of the brake system.

It is recommended to carry out scheduled technical inspections of KAMAZ in a car service at least twice a calendar year. The seasonality of such events is due to the preparation of the truck for use in the summer and winter periods.

Under proper operating conditions of the vehicle, repair work is required much less frequently. There are specific recommendations to the driver regarding situations that arise unexpectedly on the road:

  • if a coolant leak is detected in the system, water can be topped up.This measure is from the category of forced ones, allowing the driver to get to the place where a full-fledged repair is being carried out;
  • when towing a truck with an inoperative engine, it is imperative to remove the propeller shaft. Ignoring this requirement will lead to scuffing of the bearings of the gears of the secondary shaft in the gearbox, which will subsequently require early repair of the gearbox;
  • when the car is driving on a road filled with liquid mud for a long time, it is recommended to rinse the radiator surface from time to time under a strong pressure of water. To do this, you will need to raise the KAMAZ cab and carefully, without getting water on the generator, carry out the manipulation. Regular flushing will prevent radiator repair work for the foreseeable future.

42 posters that will surely come in handy when repairing a KAMAZ with your own hands

KAMAZ 5320 and Ural-4320 vehicles. Tutorial.

For cadets of technical schools and vocational technical schools, drivers and workers of transport organizations.

Do-it-yourself maintenance and repair of KAMAZ

Repair and maintenance manual

DIY KAMAZ car repair

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Image - KAMAZ equipment DIY repair

11,00R20 Bel-124 ns 16

Since truck drivers often travel long distances, they often have to carry out Kamaz repairs with their own hands. Of course, in most cases, we are not talking about a full-fledged repair - the driver cannot drag a trailer with spare parts with him. Nevertheless, the driver's task is to correctly diagnose and take measures in order to safely return to base or drive to a car service.

However, the main way to prevent breakdowns is prevention. Moreover, for such a car as Kamaz, repair and maintenance is carried out in strict accordance with the factory recommendations. The manufacturer provides for the initial period of operation of the new vehicle - one thousand kilometers. During this period, it is especially important to follow all the manufacturer's recommendations, in particular, not to exceed the speed of fifty kilometers per hour and not to load the car by more than 75 percent of the nominal value. Moreover, each new car comes with a whole set of documents, including a Kamaz repair manual.

It is clear that repairs are primarily aimed at preventing more serious breakdowns. The timely replacement of all working fluids also belongs to this kind of preventive measures. Got it. that lubricants and coolants should be selected in strict accordance with the existing recommendations of the car manufacturer.

Leaks in the cooling system, faults in valves and tank gaskets must be eliminated without fail immediately after their detection. Otherwise, all this can lead to cavitation destruction of the unit and the liquid pump.

And, say, do-it-yourself repair of a Kamaz engine may be required if the pressure alarm in the lubrication system lights up. In this case, it is undesirable to continue driving until the malfunction is found and eliminated. The use of a machine with a leaky intake tract can also lead to premature engine failure.

To avoid cracks in the cylinder head fastening bosses, it is necessary to reliably isolate the threaded holes for the bolts from the ingress of dirt or liquid. It is especially important to perform such insulation if work is planned to be carried out to replace the engine heads.

Sometimes repairs may require welding. In this case, it is very important to check the disconnection of the battery. Also, the positive contact must be removed from the generator. As for the ground wire of the welding machine, it should be connected close to the weld.

As you know, repairs will be performed less often if the car is provided with proper operating conditions. However, there are also recommendations on how to behave with a faulty car:

  • if a coolant leak occurs while driving, the cooling system can be refilled with water. You should know that this measure is temporary. Such a coolant can be used to drive to the place of repair,
  • if the machine is moved on roads with liquid mud, it is necessary to periodically flush the radiator surface with water under pressure. This will avoid procedures such as repairing truck radiators. In order to carry out such a flushing, the cab must be raised. Make sure that the water jet does not hit the generator,
  • towing a car with an inoperative engine must include the operation of removing the propeller shaft. This will help to postpone the repair of the KAMAZ gearbox, because otherwise you will be provided with scuffing of the bearings of the gears of the secondary shaft in the gearbox.

Image - KAMAZ equipment DIY repair

As already mentioned, the importance of preventive check-ups cannot be underestimated. Indeed, thanks to this, you can avoid such manipulations as the repair of the injection pump, and you can also insure yourself against unpleasant breakdowns while driving.

You need to perform a daily inspection of the main parts and assemblies. This inspection also includes checking the level of working fluids, as well as several other manipulations:

  • checking the status of the steering drive,
  • checking the operation of all braking systems,
  • checking the condition of wheels and tires.

In order to ensure the trouble-free operation of all units, scheduled inspections are carried out. Their frequency is twice a year. Such inspections are called seasonal maintenance and are intended to prepare the vehicle for use in winter and summer, respectively.

One of the main systems of any modern car, including KAMAZ, is the ignition system (SZ). With its help, the start of the power unit and the further operation of the engine in the optimal mode are realized. For more information on how the order of operation of the cylinders, how the KAMAZ ignition lock functions and how to adjust the ignition timing with your own hands, read this article.

Before correctly installing and adjusting the ignition on a KAMAZ 740 Euro 2 or 3 car, consider the order of operation of the cylinders:

The main components of such a SZ:

  1. Filter element.
  2. Additional resistor SZ.
  3. Condenser filter.
  4. Starter unit used to generate a high voltage pulse.
  5. Emergency vibrating device.
  6. Switchgear, popularly called "distributor".
  7. Plugs, one for each cylinder.
  8. Coil.
  9. Transistor switching node.
  10. Switch or ignition lock KAMAZ Euro 3.

In order to properly adjust and tune the system performance on KAMAZ Euro 3, we recommend that you familiarize yourself with the main features of the lock operation. This node is a switching device used to turn on and off the power unit, as well as the entire on-board network of the vehicle.

In KAMAZ Euro 3 or 2 vehicles, this mechanism performs the following functions:

  1. With its help, the activation and deactivation of the machine's bot network to the battery, as well as to the generator unit, is carried out. Moreover, the network is disconnected from the battery after starting the power unit, since after that the power supply is supplied from the generator.
  2. Also, thanks to the lock, the SZ itself is activated and deactivated, in particular, its primary low-current motor circuit to the voltage source.
  3. The lock also briefly activates the starter unit when turning the key and trying to start the power unit.
  4. As you know, the lock itself has several positions during operation. In the initial position, all devices and systems are disabled, the on-board network is de-energized.By turning the key to position I, you can turn on the car's audio system, optics and some other mechanisms connected to the ignition when the power unit is off. The end position is used directly for starting the engine.
  5. Also, the lock can perform the anti-theft unit option, activating the steering wheel locking mechanism when the engine is turned off (the author of the video is the ICE Theory channel).
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How to correctly set the ignition angle in KAMAZ vehicles? Since the engines of domestic trucks are very sensitive to improper clearance adjustment, the set angle should be set as correctly as possible.

Otherwise, the power unit will not work correctly:

Image - KAMAZ equipment DIY repair

Image - KAMAZ equipment DIY repair

Recommendations and step-by-step instructions for carrying out the repair of KAMAZ in order to achieve its efficiency are shown in the video below (the author of the video is Petr Alekseevich Yurkov).

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Warnings. When operating a KAMAZ car, the following rules must be followed.

1. Do not connect or disconnect the plug connectors and the positive terminal of the generating set with the engine running and the batteries switched on, and also do not start the engine with the positive terminal disconnected from the generator.

2. Do not check the serviceability of the generating set by shorting the terminals "+", "B" and "O" with jumpers to "ground" and to each other.

3. Do not connect the output "Ш" of the brush holder, access to which is open through the window in the casing of the brush holder, with the terminals "+" of the generator, "B" of the brush holder. This leads to failure of the regulator.

4. Do not check the serviceability of the electrical circuit and individual wires with a megometer or lamp at a voltage above 36 V.

5. In order to avoid damage to the rectifier unit and voltage regulator when recharging batteries from an external source, it is imperative to disconnect the batteries from the network of the KAMAZ vehicle.

6. Rechargeable batteries must not be disconnected using the battery switch while the engine is running.

7. In the event of a short circuit in the signal lamps circuit of the direction indicators, the operation of the PC 951-A relay-breaker can be resumed only after the short circuit in the external circuit is eliminated. It is inadmissible to install a PC 951 type interrupter relay instead of a PC 951-A type interrupter relay.

8. When washing a KAMAZ car, protect the generator from water ingress into it.

Troubleshooting can be carried out only after identifying the faulty circuit by external signs. When finding a malfunction, one must be guided by the diagram and adhere to a certain sequence, starting with checking the appropriate fuse.

When checking the group fuse, consumers with power supply through the fuse must be switched on alternately. To save time, circuit failure should be looked for, including consumers operating in parallel.

When the short-circuit fuse is triggered, it is necessary to disconnect the consumer circuit protected by this fuse, find and eliminate the malfunction that caused the short circuit. Then either turn on the fuse PR 310 and PR 3 by pressing the button until a click appears or replace the fuse 11.3722. It is forbidden to forcibly hold the button in the on position. Fuse 13.3722 turns on automatically after the bimetallic plate has cooled down.

If, after starting the engine, when it is operating at an average crankshaft speed with serviceable batteries and disconnected consumers, the generator does not generate charging current, check and, if necessary, adjust the tension of the generator drive belts.

Failures in the generator set can also be caused by electrical contact failure in the power supply circuit. Therefore, first of all, it is necessary to make sure that the electrical contact of the wires at the generator terminals is reliable, in the connecting blocks between the wire bundles and that the generator excitation winding disconnect relay is in good working order; using a test lamp, you need to check if there is current in the excitation circuit.

If the engine fails to start with the starter (after three attempts), it is necessary to check the starter power supply circuit, the serviceability of the engine fuel supply system, the state of charge and the serviceability of the batteries.

During normal operation of the KAMAZ vehicle, the rechargeable batteries are charged automatically. If the batteries are gradually discharged or overcharged and the electrolyte begins to "boil", you need to check the serviceability of the generator set.

The location of the wire or circuit breakage can be determined by shunting them: connect the additional wire with one end to the positive terminal of the inoperative consumer, and the second to the circuit connectors, moving towards the current sources; faulty will be the section in parallel to which the additional wire is connected, if the consumer will work at the same time. If by shunting -

Possible malfunctions of the power line of the entire section of the circuit, the consumer does not work, it is necessary to check the reliability of its connection to the "ground".

A short circuit to ground is possible in the places where wires are fastened with staples, at sharp metal edges, as well as near uninsulated wire lugs. When the fuse blows, the location of the short circuit must be determined in the circuit from the fuse to the consumer.

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If the wires are broken, they should be spliced, twisting and then soldering the wire cores, or replace the wires with new ones of the corresponding section and length; then it is necessary to insulate the wires with insulating tubes or insulating tape.

To maintain the electrical wires in good condition and prevent them from fraying and breaking, it is necessary to clean the wires from dirt or ice during TO-2 and check the reliability of their fastening.

To avoid loosening and breaking the contacts, it is not recommended to disconnect the plug connections unnecessarily.

In autumn, when carrying out a service station, it is necessary to clean the inner cavity of the rubber caps and lubricate the plug connections with VNIINP-510 conductive grease (TU 38.401276-79) or Litol-24 grease (in accordance with GOST 21150-87).

To remove the high-pressure fuel pump of the injection pump Kamaz-740:

- disconnect the cables for manual control of the engine stop lever and the regulator control lever, the fuel control rod, the fuel supply pipelines to the pump, the outlet, drainage pipelines and the pipeline from the fine fuel filter, the oil supply pipe to the pump, the oil outlet pipe;

- unscrew the two bolts of the driven coupling half (to unscrew the bolts, move them to a convenient position by turning the crankshaft with a crowbar over the holes on the flywheel through the clutch housing hatch);

- disconnect the pipelines supplying fuel to the pin plugs, high pressure pipelines (remove them), the air supply pipe to the auxiliary brake system valve;

- remove the four bolts of the fuel pump;

- remove the pump of the injection pump Kamaz-740.

To install the injection pump Kamaz-740:

- turn the crankshaft to the position corresponding to the beginning of fuel injection in the first cylinder (the retainer is in engagement with the flywheel);

- in this case, the keyway of the driving half of the drive coupling must be located:

a) below, for engines mod. 740.11-240 and mod. 740.14-300;

b) in a horizontal position on the left, when viewed from the flywheel side for the engine mod. 740.13-260;

- install the fuel injection pump Kamaz-740 on the engine, while combining:

a) marks on the pump body and fuel injection advance clutch, for engines of models 740.11-240 and models 740.14-300;

b) an alignment mark on the flange of the driven coupling half with a pointer on the injection pump housing for the engine of modification 740.13-260;

- tighten the pump mounting bolts as shown in the figure:

The order of tightening the bolts of the fuel injection pump KamAZ

- without disturbing the relative position of the marks, tighten the upper bolt of the driven half of the drive coupling, move the retainer into the shallow groove. turn the crankshaft one turn and tighten the second bolt of the driven half of the coupling;

- install the hatch cover of the clutch housing;

-Connect the high pressure pipelines, the oil supply pipe to the KamAZ injection pump and the oil outlet pipe, the air supply pipe to the auxiliary brake system valve, the low pressure pipelines, the fuel control rod, the cables for manual control of the stop lever and the regulator control lever.

After installing the KamAZ high-pressure fuel pump, start up the engine and with bolt 2 (Fig. High-pressure fuel pump regulator cover) adjust the minimum idle speed, which should be 600 ± 50 min-1.

When repairing the injection pump Kamaz-740:

- replace the pump casing with cracks and breaks in the main threads;

- For plunger sleeve defects, include chipping and chipping of metal at the holes, scuffing, scratches, wear of the working surface, an increase in the diameter of the inlet and cutoff windows, cracks and weakening at the landing sites (chipping, metal chipping and cracks are irreparable defects).

Measure the wear of the working surface of the plunger sleeve with an accuracy of 0.001 mm, ovality, taper and enlargement of the sleeve bore - with a micrometer or indicator device for measuring internal surfaces with a graduation of 0.001 mm and tapered gauges;

- For plunger defects, include metal chipping and scratches on the working surface, wear of the working surface and cracks. Determine the distortion of the plunger geometry with a minimeter with an accuracy of 0.001 mm when setting its arrow to zero according to the original sample or with a caliber in the form of a tapered sleeve;

- Check the clearance in the plunger pair on a pressure test bench with a falling weight. Rinse the vapor parts thoroughly in filtered diesel fuel before testing.

Install the plunger pair into the socket of the stand, the plunger - in the position of maximum feed. Fill the space above the plunger with filtered diesel fuel. Install the sealing plate on the end of the bushing, tightening it with the screw, then release the weight latch.

Under its action, fuel will gradually be squeezed out through the gap in the steam - the larger the gap, the faster. The value of the load on the plunger must correspond to the value of the fuel pressure 19.1-20.1 MPa (195-205 kgf / cm2).

Full lifting of the plunger to the moment of cut-off under the action of the load, accompanied by squeezing of the fuel through the gap between the sleeve and the plunger, must take at least 20 s.

Install the plunger pair with a plunger lifting time until the cut-off of more than 40 s, moistened with filtered diesel fuel, in a vertical position on the end of the sleeve, after placing a sheet of clean paper.

After a five-minute hold while lifting the pair by the plunger shank, the sleeve should be lowered from the plunger under the action of its own weight;

- the plunger pusher is installed in the bore of the pump casing with a clearance of 0.025-0.075 mm. The maximum allowable clearance during operation is 0.2 mm. Measure the outer diameter of the plunger pusher with a micrometer or a bracket;

- in the assembly unit, the pusher roller - the roller sleeve - the roller axis, the main defect is the wear of the mating surfaces. The total gap in the mate is 0.022-0.087 mm, the maximum allowable is 0.3 mm (measure with an indicator head).

If the wear exceeds the specified limit, disassemble and repair the pusher, while taking measurements separately.The maximum allowable clearance in the case of surface wear in the connection between the roller axis and the roller sleeve is 0.12 mm, in the connection between the roller sleeve and the pusher roller 0.18 mm. Measure the outer surfaces of the parts with a micrometer, and the inner surfaces with an inside gauge with an indicator.

- on the surface of the camshaft, metal chipping, scuffing, thread stripping, traces of corrosion are not allowed. The maximum permissible height of the cam profile is not less than 47.7 mm (the height of the cam profile according to KD is 47.95-48.05 mm).

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Measure with a bracket 47.7; the diameter of the journals for the inner rings of the bearings must be at least 30.0 mm (according to КД 30.002-30.011 mm), the tightness along the sealing edge of the cuff must be at least 0.5 mm;

- no cracks, dents or traces of corrosion are allowed on the surface of the discharge valve. Valve wear is manifested in the loss of tightness along the sealing cone, in the seizing of the valve in the seat.

Use a 10x magnifying glass to detect defects. In case of loss of tightness, rub the seat and valve together along the cone with GOST 3647-71 paste, if the valve gets stuck in the seat, flush the parts with gasoline or diesel fuel. If the jam persists, replace the pair;

- the maximum allowable clearance in the mating of the pin of the rack lever - the rack groove of 0.18 mm (according to CD 0.025-0.077 mm), the maximum allowable clearance in the mating axis of the leash of the swivel sleeve - the groove of the fuel pump rack 0.3 mm (according to CD 0.117-0.077 mm). Use an internal gauge to measure the grooves.

When repairing the speed controller of the injection pump Kamaz-740:

- replace the top and back covers of the regulator if there are cracks on them. If the oil strainer in the rear cover of the regulator is clogged, blow it out with compressed air.

If the filter is defective, replace it. The operating oil consumption through the filter must be at least 1.6 l / h at a pressure of 98.1-294 kPa (1-3 kgf / cm2);

- to determine the suitability for further operation, inspect and measure the holder of the regulator weights assembled with weights without disassembly, since when pressing out the parts may be damaged and the pairing of weights, which are selected with a difference in static moment of no more than 196 kPa (2 kgf / cm2), may be disturbed.

Partial or complete disassembly of the assembly unit should be carried out only in case of wear exceeding the allowable value, or destruction of parts.

The gap between the lever of the regulator spring and the axis of the lever, pressed into the pump housing, should not exceed 0.3 mm

When repairing a low-pressure pump and a prestarting fuel pump for the injection pump Kamaz-740:

- replace the low pressure pump and the prestarting fuel pump if there are cracks on the body, fractures, mechanical damage, corrosion leading to a loss of mobility of the mating parts;

- when disassembling and assembling a low pressure pump, remember that the piston and pump housing are a precisely matched pair and cannot be dismantled.

The pump is disassembled and repaired only if it does not provide the required characteristics;

- pay special attention to the condition of the assembly unit rod - bushing of the low pressure pump, since the amount of fuel flowing into the camshaft cavity depends on the amount of wear in the coupling.

The gap in the specified mate should not exceed 0.012 mm. Check the clearance without removing the bushings from the pump casing by determining the time for the air pressure to drop from 490 kPa (5 kgf / cm2) to 392 kPa (4 kgf / cm2) in a 30 cm3 accumulator.

Pump flow at a camshaft rotational speed of 1100-1300 min-1, a vacuum at the inlet nozzle of 23 kPa (173 mm Hg) and back pressure:

- 80-100 kPa (0.8-1.0 kgf / cm2) must be at least 3 l / min for engines mod. 740.11-240 and mod. 740.13-260;

- 125 kPa (1.25 kgf / cm2) must be at least 3.5 l / min for the 740.14-300 engine.

With the outlet valve completely closed and the camshaft rotational speed of 1100-1300 min-1, the pump must create a pressure of at least:

- 400 kPa (4 kgf / cm2) - for engines of models 740.11-240 and 740.13-260;

- 600 kPa (6 kgf / cm ") - for the 740.14-300 engine.

With the inlet valve completely closed and the camshaft speed indicated, the minimum vacuum generated by the pump should be:

- 52 kPa (390 mm Hg) - for engines of models 740.11-240 and 740.13-260;

- 70 kPa (525 mm Hg) - for the 740.14-300 engine;

For disassembly of the injection pump coupling Kamaz-740:

-Unscrew the screws from the case and drain the oil:

- clamp the support 6 (Fig. Disassembling the coupling) of the device into a table vise and install the coupling on it, screw the stud 5 into the support, install the washer 3 and tighten with the nut 2;

- using the key 1, unscrew the housing 5 (see Fig. Automatic clutch for fuel injection advance);

- remove the leading half-coupling 1 with spacers 12, weights 11, springs 8;

-press cuffs 4 and 2.

Considering that the weights are picked up according to the static moment, save their pairing for later installation.

Dismantling of the injection pump coupling Kamaz-740

1 key; 2 - nut; 3 - washer; 4 - clutch; 5 - hairpin; 6 - stand.

To assemble the injection pump coupling Kamaz-740:

- press the cuff 4 into the hole of the driving half of the coupling;

-install the driving half-coupling with a mandrel on the driven hub;

- install in glasses 7 adjusting shims 6 and springs 8, glasses with springs - in the guide holes of the weights, in which they should move freely without jamming.

In an arbitrary position of the coupling parts, the gap between the profile surface and the spacer should be no more than 0.15 mm. With the loads brought together to the stop by turning the driving half of the coupling, one of the gaps should be no more than 0.1 mm, the other equal to zero.

Adjust the clearances by selecting the spacers:

- press the collar 2 into the coupling housing flush with the inner end surface;

- install the rubber sealing ring 14 into the groove of the driven half of the coupling; ...

- screw the housing onto the driven coupling half and tighten with a torque of 314-343 Nm (32-35 kgcm);

- to stamp the driven half-coupling in three places.

Before installing the body, ensure equal clearances between the body and the spring cups with the weights brought together to the stop. The gap difference should be no more than 0.2 mm.

After assembly, fill the clutch with the engine oil used for the engine.

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To disassemble the fuel injection pump nozzle Kamaz-740, use the I801.20.000 tool. Clamp the bed 2 (Fig. Disassembling the nozzle.) Of the device in a vise, set the nozzle into the groove of the bed with the spray gun up.

Screwing in the bolt 4, press the nozzle atomizer with the stop 1, then unscrew the atomizer nut with an open-end wrench. After unscrewing bolt 4, remove the nozzle from the device and disassemble it into parts.

Dismantling of the injection pump nozzle Kamaz-740

1 - emphasis; 2 - bed; 3 - nozzle; 4 - bolt.

Remember that the body and the needle of the atomizer are matched in pairs and cannot be dismantled. The maximum allowable gap between the body and the nozzle needle is 0.006 mm.

Do not allow an increase in the stroke of the atomizer needle more than 0.4 mm, the diameter of the nozzle openings of the atomizer should not exceed 0.38 mm.

The unsatisfactory operation of the Kamaz-740 fuel injection pump nozzles is caused by a decrease in the pressure of the beginning of fuel injection, which is explained by the wear of the parts connected to the spring and the shrinkage of the spring, therefore, the height of the nozzle spacer should not be less than 8.89 mm (according to KD 8.9-9.0 mm).

If you find scratches and traces of corrosion on the spacer (use a magnifying glass with a tenfold magnification), replace the part.

Defects of the injection pump nozzle Kamaz-740 include broken spring, clogging and wear of nozzle holes, jamming of the needle and wear of its sealing part (causes leakage and poor atomization of fuel).

If necessary, carefully clean the spray nozzles with 0.25 mm steel wire.

Remove carbon deposits from the outer surface of the nozzle of the Kamaz-740 injection pump with a wooden block soaked in engine oil or a brass brush. Do not use sharp hard objects or sandpaper.

Before assembly, rinse the nozzle body of the Kamaz-740 fuel injection pump and the needle with gasoline and lubricate with filtered diesel fuel, after which the needle, extended from the body by one third of the length of the guide surface, should smoothly (without jamming) descend until the stop under the action of its own mass.

When assembling the injection pump nozzle Kamaz-740, tighten the spray nut by squeezing out the spray.

The owners of trucks equipped with diesel power units often face problems related to the failure of the fuel supply system. For example, it may be necessary to repair the fuel injection pump of Kamaz. If we talk about minor repairs, then it is quite possible to do it yourself.

If you do not have certain skills in car repair, we advise you to contact an experienced master, since the high pressure fuel pump (injection pump) is a rather important element of the system, therefore, it is undesirable to save on its repair and adjustment.

Only specialized service stations can perform professional repairs of high-pressure fuel pumps, as well as carry out high-quality diagnostics of this part. After carrying out repair work, the injection pump must be adjusted, and for this it is necessary to use special devices. As a rule, craftsmen who are engaged in such types of repairs have a smoke meter, a mechanotester, a motor tester, and a compressor for diesel engines.

We will look at a few “symptoms” by which you can recognize a pump failure. Before making repairs to the Kamaz fuel injection pump, it is very important to make sure that the problem is really in it. So, the main signs of a high pressure fuel pump breakdown:

  • a decrease in the speed indicators of a car;
  • lack of smooth running and sharp fluctuations in engine speed;
  • the appearance of diesel smudges in the injection pump area;
  • increased fuel consumption;
  • the pump does not supply fuel to the injectors;
  • lack of engine response to pressing the accelerator pedal.

If we return to the issue of repairing the high-pressure fuel pump, then in some cases it is possible to do with replacing only one small part, while in others it is necessary to overhaul the injection pump. For example, if the plunger assemblies are in good working order, it is quite possible to carry out routine maintenance. To do this, you need to establish what exactly broke, and simply replace this part.

After that, the pump must be adjusted without fail. An equally important stage is bench tests, which are especially important in the case of a pump overhaul. In some cases, it is only with the help of a stand that the cause of the pump malfunction can be determined. At the final stage of all repairs, it is imperative to test the operation of the engine.

First of all, a basic check is performed, with the help of which the presence of various extraneous sounds during the operation of the pump is determined. If they are, this is a clear sign of a breakdown, however, superficial diagnostics will not help you determine exactly what needs to be replaced. For a quality check, you will have to use special equipment.

Today there are a huge number of varieties of such devices, the functionality of which can vary significantly. Very often, craftsmen use a device called the DD-2115. This is a great solution for determining the condition of plunger assemblies.

It should be noted that the correct functioning of the injection pump depends on their performance, since these elements regulate the volume of the supplied fuel. They are made from high quality steel that is not subject to corrosion. Although this material has good characteristics, it still wears out. There are cases when the plunger pair lost its performance due to the use of low quality fuel. Repair of the plunger pair is impossible, it is simply changed. This also applies to other parts of the injection pump, which are subject to wear.

If you decide to do the repair of the Kamaz fuel injection pump with your own hands, we advise you to consult with specialists who already have experience in performing such work.

Video (click to play).