DIY KamAZ power steering repair

In detail: do-it-yourself repair of a KamAZ hydraulic booster from a real master for the site my.housecope.com.

The hydraulic steering system is an integral part of any KAMAZ, since without it control of the vehicle will be, if not impossible, then very difficult. Thanks to this unit, the driver can turn the steering wheel more easily. You can learn more about what the KAMAZ power steering system is and how to air it out from this material.

First, let's look at the main characteristics of the power steering on the KAMAZ 6520 or any other model. Let's start with the purpose and device.

The main purpose of the power steering system is to maximize the relief of the effort used to turn the steering wheel when steering, as well as to perform many maneuvers when driving at low speed. In addition, thanks to the power steering system, the effect on the steering wheel will be more noticeable if the car is moving at high speed. If the power steering for some reason fails, this will lead to the fact that the driver will have to put much more effort to turn the steering wheel.

General scheme of the steering of KAMAZ

Now let's briefly consider the power steering device.

This system consists of the following elements:

Switchgear. This component is used to direct the flow of working fluids, in particular, hydraulic oil, in the line and the cavity of the system.
Hydraulic cylinder. This device performs the function of converting hydraulic pressure into mechanical work of pistons and rods.
The working material in this case is hydraulic fluid. With its help, the force is transferred from the pump to the hydraulic cylinder. In addition, thanks to the fluid, all rubbing components and units of the system are lubricated.
Power steering pump KAMAZ. Thanks to this device, the pressure necessary for its normal operation is constantly maintained in the system. Also, this element is used to circulate the working fluid.
Connectors or lines. They are used to bring together all the working components of the system.
Control device or electronic unit. With its help, the direction, as well as the adjustment of the amplifier operation, is carried out.

Video (click to play).

The pumping device is installed in the collapse of the BC. In domestic trucks, a gear top drive is used, but the device itself belongs to the blade type. In accordance with the technical documentation, this unit is characterized by a double action, that is, in one turn of the steering wheel, it performs two suction and discharge cycles.

Let's take a quick look at how it works. When the wheel turns, the rotor blades begin to rotate, which, in turn, are pressed against the stator device. Working fluid begins to flow into the blades that, when pressed, coincided with the holes on the body. Further, thanks to the same blades, the consumable falls into the narrower holes that are between the stator and the rotor.

The moment the working surfaces can align with the holes on the distribution disc, the consumable will go beyond it. Further, the oil will pass through the lower valve, for this high pressure is formed in the system.

The working fluid, leaving the cavity behind the distributor disc, will flow to the rotor blades, as a result of which they will press even more strongly against the stator plane. The process of pumping the substance, as well as its suction, is carried out simultaneously in two places.As the number of revolutions of the rotor device increases, liquid from the surface behind the disc will not pass through the calibration hole. By creating pressure in the system, the bypass valve is opened, and part of the consumable, through the manifold, is again supplied to the suction surface (the author of the video about replacing the hydraulic booster at KAMAZ is Matur Malay).

It must be said right away that the repair of KAMAZ power steering is a procedure that our compatriots do not encounter so often. If the driver observes the basic rules for operating the unit, as well as timely maintains it, then the likelihood that it will fail will be minimized. As practice shows, mainly problems with the performance of the hydraulic booster arise in the cold season. In general, all malfunctions can be divided among themselves into mechanical and hydraulic breakdowns, and both of them can appear in any part of the device.

As you know, any hydraulic system most often shows malfunctions in frost conditions, in particular, temperature differences. After all, it must be remembered that the pumping device generates high pressure, so if the viscosity of the fluid in the system increases, this will lead to the expulsion of the oil seals and, accordingly, its leakage. Especially the problem of oil seals manifests itself in cars whose drivers do not follow the operating rules, for example, they leave the car in the parking lot with the wheels turned off. This will lead to the fact that after starting the engine, the pressure will increase on only one side, respectively, the oil seal will squeeze out in any case.

As for the warm season, in summer, malfunctions usually manifest themselves as a result of dirt and dust getting into the system. If any part is depressurized, the wear of the bushings, as well as the rods, will be faster. Stems usually rust quickly enough, resulting in accelerated bushing wear. When operating a car with such a problem, after several hundred kilometers, a large backlash will arise between these elements, and this, in turn, will lead to the steering rack starting to work with a knock (the author of the video about repairing the system in garage conditions - channel EIGHT ATMOSPHERE).

The need to pump the system usually arises after refueling it or eliminating breakdowns in the operation of the unit. Air entering the lines leads to less efficient operation of the hydraulic booster, so the only solution in this case is to remove the air.

So, how to pump the power steering:

The process of assembling and adjusting the power steering using a special stand is presented in the video below (the author of the video is the Zavod Avtoagregatov channel).

Dismantling the power steering pump Kamaz! What's inside!

Repair of the steering pump of KAMAZ and how to pump the power steering

We will repair the main unit of the power steering pump car control system.

Those who have already encountered car breakdowns know for sure that it will be a little costly to make repairs in service centers. Much easier than ever, the most important thing is to do it yourself. With a little knowledge and effort to this process. The inherent content of the material will allow you to get acquainted with an independent repair of the power steering pump. You can also carry out diagnostics to identify malfunctions in the operation of the pump itself.

The elements that make up the pump.

The most difficult dismantling is to release the pump from disconnecting the supply hoses with pipes and draining the hydraulic fluid. Initially, we loosen the belt or uncouple the gear drive, then unscrew it from the attachment to the engine block. We flush the housing from the accumulation of dirt.

Next, we disassemble the pump body itself, very carefully remembering this moment how everything is attached (or otherwise there will be a problem during assembly), then we thoroughly clean all the components from the inside from dirt.

With a detailed examination of the internal parts of the pump, we determine their working condition.

4. Uneven surface of the inner part of the cylinder (stator).

We examine the rotor, paying attention to the grooves: their edges should be smooth and sharp, without chips and notches.

Next, we look at the inner working surface of the stator, it often happens that its wear is the cause of problems with the power steering pump.

All that we may need in the upcoming work is this!

alcohol (best of all White Spirit, aka solvent gasoline or a can of WD40 liquid);
sandpaper (from P2000 to P1000);
cloth or soft paint brush;
small file or file;
electric drill;

We use sandpaper to clean the seats of the rotor blades.

Rotor cleaning is reduced to the elimination of irregularities and burrs of the grooves, as well as to grinding the rotor surface.

Gloved work is best as the edges of the rotor are very sharp; try to keep the movement smooth and even for a smoother finish.
There is no consensus on how to grind the inner surface of the stator; if you have enough patience and time, you can try manual leveling.

The algorithm is as follows:

First, we make a rough cleaning with a file, then smooth it with coarse sandpaper and finish it with a sandpaper.

It is easier to adapt an electric drill using a drill and sandpaper. You will get a kind of mini-grinder by screwing sandpaper onto a drill with a diameter of at least 12 mm (against the movement of the drill rotation). When grinding with a self-made unit, you must try to evenly distribute the load over the entire surface, unnecessarily not zealous and not forgetting to change the skin from coarse to the finest.

Using a drill and sandpaper, we eliminate the unevenness of the stator surface.

Having finished with grinding, we will bring the power steering pump to its original working condition. Carrying out the assembly process in the reverse order, it will be useful to first check whether the shaft rotates easily inside the pump itself.

The final touch will be to install the cover in place, with the preliminary installation of a new gasket. During the assembly process, the cover is easily tightened with four bolts. It is best to pull them crosswise, thereby achieving an even, accurate fit of the cover plane to the stator.

The pump now has a new state again. Nevertheless, it will take a long time before you have to repeat this procedure again!

Watch a video lesson of self-repair of the power steering pump.

Watch a video lesson how the power steering system works.

Starting the repair of the KamAZ power steering, it must be borne in mind that an attempt to restore parts that have exhausted their performance due to wear is unacceptable in these assembly units. The production of such parts is carried out with very high precision and sterility of the working surfaces, and, of course, their selective selection directly during assembly is permissible only under the conditions of the necessary specialized production.

Repair work of steering mechanisms, and of course pumps in the conditions of automobile enterprises, is permissible only by replacing already out of order devices, or parts with workers.

It is necessary to check and adjust the steering mechanism on the car, only when the longitudinal steering link is turned off, and of course the engine is not running.

Beforehand, you need to check the wheel balance, then the air pressure in the wheels, the presence of grease in systems such as steering and wheel hubs.

It is necessary to inspect the adjustment of the wheel bearings, and of course the steering rods, how the shock absorbers work, and of course the installation of the front wheels.In addition, you need to check the oil level in the reservoir of the power steering pump, make sure that there is no air in the system, no sediment, or accumulated dirt, both in the reservoir itself, and on the pump filter itself, if there is no oil leak in the place where the oil lines are connected.

You need to measure the force directly on the steering wheel with a spring dynamometer, which is attached to the wheel rim in the following positions:

In the event that you are checking the adjustment of the gearing of the steering system. So, if the effort is still less than the established value, then the gap in this gearing is greater than possible, and the car will become poorly "to keep the road".

In the event that the effort is, say, more, then the engagement is excessively “tightened”, which can act, along with other factors, as a cause of poor self-return in the middle position of the steered wheels.

But if, while measuring the efforts in the above positions, it suddenly turns out that they do not correspond to the established values at all, then you need to adjust the steering gear. If necessary, you can remove the mechanism from the machine for repair work. Repair of the KamAZ power steering can be carried out both with partial and complete disassembly, and even check it again.

Adjustment of the steering mechanism begins with measuring the effort, always in the third position. At the same time, with the help of the adjusting screw, the bipod shaft, it is necessary to bring the force to the required norm. Turning the screw clockwise, you will see how the force will increase, while rotating, on the contrary, it will decrease.

Complete disassembly can be carried out only at an enterprise that specializes in KamAZ power steering, or in specialized workshops.

I am transferring our user's question to this thread. @LEKSANDR, owner of KAMAZ-5511

Good afternoon, thanks for the braking help.

I am also interested in the power steering, they are also different.

What model would you recommend (saw the 5320 and 43 models in stores ??) maybe the steering wheel will be lighter?

Thanks in advance !

As I understand you have an old power steering 5320.

The production of the 5230 power steering was carried out at the Borisov plant "Gidrousilitel" from 1972 to 2001.

In 2001-2002, the plant mastered a new hydraulic booster 4310-3422010, and the production of the old power steering 5320 was completely discontinued. So you can only buy a repair power steering 5320. New ones do not exist in nature.

Therefore, if you buy, then GUR 4310, which is currently being released.

As a result of the replacement, the steering force insignificantly but it will change, since it is a "hardened" version, which replaced the old one on the conveyor.

To put power steering 4310 you will need:

the power steering itself (in order to exclude any errors, I immediately cite its nomenclature number - 4310-3400020);
cardan steering shaft 4310 (number 4310-3422010);
bipod 4310 (number 4310-3401090, although you can also use bipod 53212-3401090);
bipod nut 4310 (number 853512);
special washer for this nut, its item number - 853631
and fasteners: bolts 16x140 - 2 pieces and 16x70 - also 2 pieces

I mentioned a special washer and a bipod nut. This is no coincidence.

The fact is that on modernized KAMAZ vehicles with GUR 4310 steering arm mount has changed.

Instead of tightening bolts, nuts and cotter pins, a nut with a lock washer is now used for fastening.

I have placed a drawing of the new mount, you can see it on the right. Click on the thumbnail and the drawing will be shown to you in full size.

Best regards, Andrey Bodyakshin.

Head of the retail sales department of the Nizhny Novgorod branch of KamAgregat-Service

I still have a question about the gearbox.

I have a box with a divider, I don't know which model.

They write that there are 15,152,154, but what is the difference between them?

Do they have the same body or different?

A question about the engine - is it possible to make a turbocharged engine out of an ordinary one, or is there a completely different unit?

Judging by the car model (you mentioned the KAMAZ 5511 earlier), you have 15 checkpoints.

152 checkpoint is a modernized 15 checkpoint, they are interchangeable.

For 3-4 years, the plant has not produced 15 gearboxes at all, 152 gearboxes have come to replace it, in the production of which a "more hardy" metal is used.

We even described some issues of the interchangeability of the synchronizer and the input shaft in gearboxes 15, 152 and 154 in detail earlier. You can read about it here

154 checkpoint a relatively new development of KamAZ. And she won't suit you... Housings, shafts, gears, bearings - everything is different, only the principle of operation is the same.

154 checkpoint was developed for the new line of heavy trucks KAMAZ.

Working 154 checkpoint already with its own clutch, it is designed for more difficult working conditions, and, I will say more, it is not repaired in a garage.

Best regards, Andrey Bodyakshin

Head of the retail sales department of the Nizhny Novgorod branch of KamAgregat-Service

Regarding your question about installing a turbocharger

It is not enough to put turbochargers on the internal combustion engine.

The operation of a turbocharged engine is complex; special requirements are imposed on the fuel equipment, piston group, oil system, gas exhaust system, etc.

In this way, such an installation is impossible and not only because of the engine block.

Best regards, Andrey Bodyakshin

Head of the retail sales department of the Nizhny Novgorod branch of KamAgregat-Service

How to make this hydraulic booster more efficient.

Machine 65115, dump truck in 2008, in a rut, the steering wheel cannot be turned even with your feet on the floor!

Is it possible to supply a pump from KamAZ 6520?

In the internet they write that the pump from the MAMMUT gives out 17 kilograms, and our 10, maybe this will help.

It's a shame, having paid 1.737.000t.rub. arriving in the evening from orders, do not raise your hands.

A foreign car would probably have been recalled for revision a long time ago.

Good day!
I have carefully analyzed the characteristics of the pump you want to replace. I don't think this replacement will be effective... In most modes, the effort will increase by 3-5 kg. You won't even feel it.
My experience shows that a regular pump is quite effective. And if you have such serious problems with the power steering, then I would start by diagnosing basic faultsleading to insufficient work of the power steering.

I will list the main sources of insufficient power steering.
1. Not enough oil in the oil tank
2. Air has entered the system (oil usually becomes cloudy, foam forms in the tank)
3. There is too much interference in the gearing of the steering gear.
4. The pump does not give the required flow (the pumping unit is worn out or the filter is clogged)
5. Seals worn out and large internal oil leaks started
6. The bypass valve got dirty and began to hang
7. Steering check valve not sealed
8. Loose tightening of the nut of the thrust bearings of the steering gear screw
9. The safety valve of the steering mechanism has become leaking (perhaps there is dirt or nicks in the valve, another reason is that the spring of the safety valve is incorrectly adjusted)

I have provided a short list of basic reasons to start with. I will be glad and try to answer your additional questions that may arise during the diagnostics process.

Best regards, Vladimir Danielyan.

Head of Procurement Department, KamAgregat-Service LLC, Naberezhnye Chelny

At the plant, they failed the landing dimension for the oil seal in the bevel gear (where the steering wheel shaft is attached through the cardan).

In stores, they offer a bevel gear assembly, which costs a lot of money.

Can this part be ordered separately?

So far, two turns of electrical tape around the gland helps, but not for long.

And the second question: I recently found out that there are steering knuckles on bearings, and not on brass bushings relative to the kingpin, how can I find out without disassembling what is delivered on my KAMAZ, and is there an option to replace the bushings with bearings or just replace the knuckles in the assembly?

In “Baltkam” they say that I have to have bearings, but something doesn't look like it, and you can't beat it by VIN.

I have a KAMAZ 65115, 2008 EURO-3, 280 hp, intercooler, two turbines.

Regarding leakage through the oil seals of the power steering bevel gear

You don't need to buy a complete bevel gearbox.

On your power steering there is a cuff 864113, it has a spring, if you shorten the spring and insert it back, the oil seal will hold better.

Although, I would recommend replacing the power steering case cover 5320-3401721 (we have it in stock, the price for today is 100 rubles) and buy a power steering repair kit (a set of rubber bands, price 15 rubles)

The listed items have not yet been included in the catalog of our online store, but you can order the listed parts by phone, by calling the nearest branch of our company (phones in the header of the site), or by sending a letter with a request through the contact form from the site.

The cost of spare parts will increase by the cost of shipping, but the cost of shipping, given the low weight of the parts, will be negligible.

In addition, I would not stop exclusively at replacing the power steering parts.

The cause of the leak can be not only in the squared size (as you think).

I invite you to get acquainted with Information letter of OJSC KAMAZ No. 17-233-2006 "On the defects of the power steering", where a situation similar to yours is described and recommendations are given.

In connection with the steady low temperatures and their lowering below -40 0 С, cases of squeezing out the cuffs of the GUR bipod shaft were noted.
The reason for this defect is the creation of increased pressure when turning the car with cold steering. Actuation of the power steering with cold oil leads to the creation of increased pressure and hydraulic shocks due to the lack of pumping of oil through the power steering and the ineffective operation of the safety valves.

The SHELL DONAX AT oil used at the moment on the recommendation of the companies РРТ and RBL for steering has a freezing point of -45 0 С, and the operating temperature of the oil and the steering mechanism must not be lower than -40 0 С

When using grade P oil (in GUR 4310-3400020), the operating temperature should not be lower than -25 0 С

To prevent cases of cuff squeezing out and malfunctioning of the power steering and the pump, it is allowed to start moving the car only after the engine has been running for at least 5-10 minutes (depending on the ambient temperature) at idle speed, to warm up the oil in the steering system.

This requirement also applies to cars with engine heating, since when the engine warms up, the oil in the barrel and pipelines, the pump and power steering do not warm up. In the initial period of movement, in order to avoid damage to the power steering, it is not recommended to make sharp and maximum turns of the car.

For the operation of buses and cars at temperatures below -40 ° C, the following oils must be used - BP Aufran DX III, Teboil Fluid ES, ESSO ATF LDS, Texaco Texamatic 7045. When using these oils, the above precautions must also be observed.

Also, when driving in particularly cold conditions, oil cooling, especially in buses, can also occur with prolonged rectilinear movement, in this case it is recommended to periodically oscillate the steering wheel until the power steering is activated.

Regarding your second question.

Judging by the year of production of your KAMAZ (2008), You can only have steering knuckles on bearings.

Best regards, Evgeny Kudryashov

Director of the Nizhny Novgorod branch of KamAgregat-Service

I modified the power steering housing cover, made the seat for the oil seal a little deeper and put two oil seals. The upper gland should protrude slightly compared to the butt end by 0.5 - 1mm, so that it is possible to press the brass cover.

I cut a thread on the outside of the body and turned a threaded cap from knurled brass on the outside so that the oil seals could be tightened from above without shims and retaining ring.

The problem is gone forever. Maybe someone will come in handy.

Power steering is an important and practical mechanism for any truck, which greatly facilitates the already difficult work of the driver.Read about the design features of the power steering on KAMAZ, its typical breakdowns, rules and recommendations for operation in our article.

Not every passenger car driver really appreciates the power steering (hydraulic power steering), taking it for granted: "Well, the steering wheel turns easily and without tension, but what happens otherwise?" How it happens! A faulty power steering on a KAMAZ is a heavy effort at every turn of the steering wheel; after a few kilometers of such a ride, hands simply fall off from fatigue. It would seem that such a small and inconspicuous mechanism, but plays such an important role. It is about this device that we will tell you in more detail.

Power steering is a hydraulic system that is an integral part of the steering mechanism and serves to facilitate driving.

The main functions of power steering are:

- ensuring the stability of a given trajectory of movement;
- reducing the effort that the driver makes to turn the steering wheel;
- maintaining the feedback between the steering wheel and the wheels.

Power steering consists of the following systems and mechanisms:

- a distributor that directs fluid flows in the cavities of the system;
- a hydraulic cylinder that converts fluid pressure into the work of the rod and piston;
- working fluid, which is necessary for lubrication of friction pairs and transmission of pressure from the pump to the hydraulic cylinder;
- a pump that maintains a given pressure and fluid circulation;
- connecting hoses that unite all elements of the system;
- an electronic unit that regulates the operation of the hydraulic booster.

In order for the power steering to serve for a long time, several recommendations must be followed:

- regularly (once a week) check the oil level in the system;
- change oil and oil filters at least twice a year. If the color of the oil has changed before the appointed time, change it immediately;
- do not allow the vehicle to operate in the event of leaks in the power steering system and eliminate them as early as possible;
- adjust and check the tension of the drive belt.

The power steering of KAMAZ is characterized by several main types of breakdowns. We will focus on the most common malfunctions and their causes.

Unstable movement of the car on the road (it is necessary to constantly level the car with additional steering wheel manipulations):

- check the free play of the steering wheel - if it is increased, then adjust it;
- make sure that the parts of the screw pair of the steering mechanism are not worn out - if necessary, replace them;
- sometimes the reason for the unstable movement of the car is the sticking of the jet plungers in the body of the power steering valve or the spool. In this case, it is necessary to rinse the parts and eliminate the cause of the jam.

Damaged or clogged pump filter:

- air that has entered the hydraulic system (signs: turbid oil and foam in the reservoir) - flush and bleed the system, replace the filter;
- the collector gasket is destroyed or the collector itself is bent.

Uneven or insufficient power steering. The reasons may be as follows:

- excessive tension in the gearing - adjust the steering mechanism, bring the effort to normal;
- clogging of the pump filter or wear of the pumping unit parts. It is necessary to disassemble the mechanism and replace worn parts;
- violation of the tightness of the check valve of the steering mechanism;
- presence of air in the system - remove air by bleeding the system.

The air that remains in the power steering system after changing the oil can cause insufficient or uneven operation of the power steering. In order to properly pump the system, you must perform the following actions:

- raise the front wheels on jacks so that they hang in the air;
- unscrew the bypass valve on the steering gear;
- turn the steering wheel all the way to the left (the centering springs should be compressed);
- pour new oil into the pump;
- turn on the engine and at minimum speed add oil to the power steering tank until bubbles disappear from the hoses;
- screw the bypass valve on the steering gear;
- turn the steering wheel to the right until it stops (again, before compressing the centering springs), and then return it to the left and unscrew the bypass valve again - release air bubbles and screw it back;
- repeat the last manipulation until absolutely clean (no air bubbles) oil comes out of the valve.

Among the typical malfunctions of the power steering on Kamaz is a difficult steering wheel, pump noise, shocks and vibrations that are transmitted to the steering wheel. All this causes discomfort, leads to a decrease in the level of safety, and complicates the daily operation of commercial equipment. To solve the problems, it is necessary to carry out diagnostics, sometimes the usual pumping of the steering helps, but more often it is necessary to change the worn out units. But a labor-free repair is also possible with the help of the RVS-Master Power Stering Treatment Ps2. Geomodifier of friction restores friction surfaces by building up a dense layer of cermets on them. To understand how it helps and acts on the power steering mechanisms, let's deal with the KamAZ power steering device.

The mechanism consists of a distributor, pump, hydraulic cylinder and connecting hoses. The pump creates pressure to pump the working fluid. The liquid acts on the hydraulic cylinder, which produces the energy necessary for the functioning of the piston, rod. In this case, the distributor directs the flow to the desired cavity of the system. Most KamAZ hydraulic boosters use steel tubes and rubber braids. Fittings and union nuts are used to fasten pipelines. The radiator where the oil for the power steering system is cooled is a finned aluminum tube.

Worn steering parts cannot be remanufactured normally. This is due to the high precision of manufacturing and the cleanliness of the working surfaces. When diagnosing, disconnect the longitudinal steering rod and turn off the engine. Then they check the balancing, tire pressure, the presence of lubricant in the mechanism and wheel hubs, shock absorbers - all this indirectly affects the operation of the hydraulic booster.

Typical breakdowns of KAMAZ hydraulic boosters and methods of their elimination

The power steering on a Kamaz truck allows the driver to spend a minimum of effort on driving his car, and also softens the shocks when driving on an uneven road and provides control of movement if there is a sudden tire damage.

Faults in the KamAZ hydraulic booster that require repair of the power steering most often manifest themselves as follows:

The steering wheel turns hard when the car turns to the left or right;
There is a delay in the steering wheel during reversing;
The car moves unstably in a straight line (you have to constantly align the car);
There is a loud noise of the pump running;
Hydraulic oil escapes.

Before proceeding with the repair of the KAMAZ GUR, the specialists of our car service carry out a complete diagnosis of the device. In this case, the pressure in the steering system is necessarily checked at maximum turns of the steering wheel, the inflow of fluid is estimated, and the pressure that the pump receives is measured. To repair the power steering, the latter is removed from the truck and undergoes complete or partial disassembly. All parts of the mechanism that are out of order or excessively worn out are replaced with new ones.

The Kamaz hydraulic booster was originally designed in such a way as to withstand serious loads, so the power steering will not need to be repaired for a long time if it is timely checked and adjusted. These services are also provided by our technical center. The use of the latest diagnostic methods allows us to timely identify and eliminate any malfunctions of the hydraulic booster.All work on the repair of GUR Kamaz is carried out by experienced mechanics on modern equipment with full quality control.

The steering of KamAZ vehicles is assembled at the manufacturing plant with high precision by selective assembly. Selective selection of parts during steering assembly is possible only in the conditions of the Kama production association of factories for the production of heavy vehicles.

When starting to repair the steering (steering mechanism, power steering pump and other units), it should be borne in mind that the restoration of parts due to wear in these units is unacceptable.

Repair of steering mechanisms and pumps in a motor transport company is unacceptable.

Possible malfunctions of the steering of vehicles of the KamAZ family are presented in table. 49.

49. Possible steering malfunctions

External signs of malfunctions

Troubleshooting method

Unstable movement of the car on the road

Large free play of the steering wheel

Adjust steering wheel free play

Parts of the screw pair of the steering mechanism are worn out

Jamming of the spool or reaction plungers in the power steering control valve body

Replace ball set Flush valve

Complete lack of power steering

The valve spring in the pump is broken, the safety valve seat is unscrewed, the check valve is malfunctioning

Disassemble the pump, replace the spring, screw on the safety valve seat, flush the pump, eliminate the check valve leaks

Steering effort is not the same when cornering

Internal seals of the screw and piston of the steering gear are damaged

Replace defective screw and piston seal parts

The steering gear "jams" when cornering

Worn parts of the connection of the adjusting screw with the bipod shaft or the gearing of the steering mechanism

Adjust the axial clearance in the joint by selecting adjusting washers, replace the steering gear

Increased gear clearance

The nuts of the bolts of the terminal connection of the bipod are not tightened

Adjust the clearance with the adjusting screw Tighten the nuts

Knock on the steering column propeller shaft

The nuts of the wedges fastening the forks of the propeller shaft are not tightened or the spline connection is worn

Tighten nuts, replace worn parts

Increased noise during pump operation

Insufficient oil level in the reservoir

Top up the oil in the tank to the norm

Air present Filter clogged

Remove air Flush or replace filter

Internal seals of the steering gear are damaged

Replace defective seal parts

Uneven operation of the hydraulic booster

Insufficient oil level

Add oil to the reservoir to the level

Air in the system

Remove air from the system

Excessive interference in the steering gear

Adjust the steering gear with the adjusting screw

The pump does not develop the required performance

Rinse the filter, disassemble the pump, check its parts

External signs of malfunctions

Troubleshooting method

Increased steering oil leakage

Disassemble the mechanism, replace the O-rings

Intermittent stuck bypass valve

Disassemble the pump, flush the bypass valve and the hole in the pump cover with acetone, cleaning their working surfaces from burrs and foreign particles

The tightening of the nut of the thrust bearings of the steering gear screw is loose

Adjust nut tightness

The adjustment of the safety valve spring is broken

Throwing oil through the relief valve

Rinse or replace the filter

Constant drop in oil level in the reservoir

Oil leaking into the engine due to damage to the pump roller collar

Remove pump from engine and replace oil seal

Disassembly of the steering is carried out as follows. The steering wheel is removed with a puller I-801.35.000-01, which is shown in Fig. 119, a.Before this, the decorative cover is first removed and the steering wheel nut is unscrewed. To remove the steering wheel, it is necessary to insert the grips 3 through the grooves of the steering wheel hub and turn them clockwise until they stop. Resting the tip 2 against the steering wheel shaft, screw the screw 1 into the grip nut until the steering wheel is completely removed.

Rice. 119. The use of pullers for disassembling the steering - KamAZ:

a - steering wheel puller I-801.35.000-01; 1 - screw with a puller handle; 2 - the tip of the screw of the puller; 3 - capture of the steering wheel hub; b - pressing out the steering gear bipod; 1 - bipod; 2 - the tip of the screw of the puller; 3 - capture; 4 - a screw of a puller with a handle

Disassembly of the steering mechanism is carried out as follows. The bipod of the steering mechanism is removed using the I-801.36000 puller, which is shown in Fig. 119, b. To remove the bipod 1, you must start the grip 3 for it; resting the tip 2 against the end of the bipod shaft, screw the screw 4 into the grip until it is completely removed; unscrew the mounting bolts; remove the side cover together with the bipod shaft. When removing the bipod shaft, you must first clean its spline end. The shaft must be removed carefully so as not to damage the sealing lips.

Rice. 120. Checking and adjusting the steering gear drive - KamAZ:

a - backlash of the steering wheel; b - adjustment of the backlash of the bipod shaft of the steering mechanism; y - adjusting screw; 2 - lock nut of the adjusting screw; в - placement of the steering rods of the steering linkage and its drive: 1 - ball pin of the longitudinal steering rod; 2 - steering bipod shaft lever; 3 - oiler; 4 - lever of the wheel pivot pin; 5 - connecting ball pin; 6 - longitudinal steering rod, 7 - transverse steering rod

Repair of the steering mechanism consists in replacing worn parts and assembling it.

The power steering pumps are tested on the bench. The pumps are checked for performance and maximum pressure. In case of non-compliance with the requirements of the technical conditions, the power steering boosters are sent to the manufacturer.

After assembling the steering gear, the assembly quality is monitored and, if necessary, it is adjusted, as shown in Fig. 120. At the same time, the backlash of the steering wheel, the axial movement of the bipod shaft and the backlash in the steering rods are checked.

The axial movement of the adjusting screw in the bipod shaft should not exceed 0.15 mm. The adjusting screw should have an axial movement relative to the bipod shaft 0.02-0.08 mm and rotate smoothly, without jamming. The circlip must fit completely into the bipod shaft groove. This is necessary for a reliable connection of the assembly parts.

The O-ring of the adjusting screw is replaced if necessary using a mandrel.

Video (click to play).

When installing the steering wheel, tighten the steering wheel nut.

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