In detail: do-it-yourself truck repair from a real master for the site my.housecope.com.
The breakdown of any car is a very unpleasant event, in most cases entailing considerable costs. What can we say about the breakdown of trucks, machines that are designed to transport goods every day around the city, country and abroad, and problems with which can significantly slow down or even stop production and trade processes, because trucks transport equipment, machinery, furniture , building materials, food, industrial goods. Of course, in order to prevent unexpected breakdown and failure of equipment, it is necessary to monitor it and periodically send it for qualified diagnostics on specialized equipment. Depending on the type and manufacturer, regular inspection and repair of trucks must be carried out every 20-120 thousand kilometers.
Timely vehicle inspection and diagnostics extend the service life not only of the vehicle as a whole, but also of each individual part or assembly. The checks carried out in time allow to prevent the inevitable in other cases replacement of units, parts or mechanisms of a truck.
Usually, the reasons for which it is necessary to carry out repair work are various damage to the car due to an accident, malfunctions in the transmission, wear of parts, unstable functioning of the chassis, etc.
Due to the peculiarities of trucks, repairing such vehicles is not an easy task. The dimensions require enough space and powerful equipment, and the features and specific technical requirements for models from various manufacturers require a certain amount of knowledge and qualifications. After all, the cost of special equipment and trucks usually significantly exceeds the cost of passenger cars, and their design and device are much more complicated. In addition, all kinds of modular designs and often rare truck parts lead to a long search for spare parts, because if the service you decide to contact does not specialize in the repair of trucks, it is unlikely to be able to quickly find original spare parts at an adequate price. Also, given the peculiarities of assembling "workhorses" of different manufacturers, very often for the repair of the engine, chassis, gearbox and other mechanisms, it is necessary to have special modern technological equipment.
Video (click to play).
Depending on the scope of work, there are three types of truck repairs: scheduled inspection, minor repairs and major repairs. In this case, the inspection includes diagnostics and checking the operation of mechanisms. Minor repairs include work such as body repair (painting and removal of body deformations), changing some parts or assemblies. But during a major overhaul, the truck is completely disassembled, the electrical wiring is changed, the gearbox, engine, chassis and other vital parts of the car are overhauled.
Due to the fact that trucks regularly cover hundreds of kilometers of uneven roads, while working in rather harsh climatic conditions, truck repair services in our country are quite in demand. And demand creates supply - and now, dozens of companies offer to repair your car. But remember, when choosing a service, it is very important not to miscalculate and get to the specialists who guarantee well-tightened nuts, correctly installed mechanisms, well-coordinated and accurate operation of units and mechanisms and, of course, an overall high-quality result.
You can read about car body welding here.
A frame in a car is called a power frame, which acts as the basis for fastening all
body parts, engine, gearbox, drives, etc. It is usually necessary to resort to such technology as welding a frame with minor deformations of this part. For example, if cracks, chips, folds have formed, then in this case, it will be advisable to cook the frame. However, the welding technology should be strictly observed, because not only the quality of the frame will depend on this, but also in the future the safety of using the car.
Very often, trucks, for example KAMAZ, which transport large loads, can fail right on the highway. In order to prevent the occurrence of such an unpleasant situation, you should constantly monitor the state of the frame and make timely repairs to this part.
In order for the connection to be strong and reliable during the welding of the truck frame, a number of rules and requirements must be observed.
The first thing worth noting is the need to ensure that the metal does not overheat in the area where the seam is formed. It is necessary to cook the seam in small pieces, the length of which does not exceed 5 mm.
Be sure to wait a while until the weld has cooled down.
Next, you need to process the edges. This is done by means of a plasma cutter or grinder, because this is the most suitable option for cutting metal.
When welding the frame, make sure that the transitions from the secondary metal to the main metal are as smooth as possible. Be careful not to create undercuts, as it is this defect that will cause the frame to crack. In addition, the root must be boiled along its entire length, otherwise the whole process will be meaningless.
Considering the fact that it is quite difficult to work with many trucks, which are not very large in size, and the frame is very often prone to breakage, regardless of the quality of the seam, there is only one way out - you need to strengthen the place of the breakdown. A channel and a bolted connection are suitable for this.
Before proceeding directly to the welding process, the part should be well prepared. It is important to correctly identify the damage, for this it is necessary to remove all body elements and inspect the affected area. The place where the crack ends must be drilled out. This will help prevent damage from developing.
Advice! Use drills with a diameter of 5 mm.
Such welding works are performed with a semiautomatic device.
Learn more about the welding process. As already noted, the welding process is carried out in several passes.
At the first pass of the burner - the root is boiled. Prooking is carried out with electrodes, which are a wire with a thickness of 1.2 mm with the Sv08 index. Welding work is carried out under the influence of a current of 100 A. On the second and third pass, the current indicator should be 110 A with the same welding wire, while the beads should be as thin as possible and overlap each other. On the fourth pass, the current increases to 120 A.
It is important that cooking is carried out without interrupting the arc. This is the only way you can get the most even and high-quality seam.
All seams after the end of welding must be properly processed. The metal must be protected from negative environmental influences. The connection area must be washed, then sandblasted, degreased, primed and painted.
In conclusion, it should be noted that welding a truck frame is a process that requires concentration and care. In order for the seam to be as strong and high-quality as possible, the welder must have some work experience. Since the frame is an important part on which the safety of driving depends. Do not forget about safety and when welding, be sure to wear special protective clothing.If you follow all the rules and requirements, then in the end you will get the highest quality connection.
VIDEO 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.
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, it will be necessary to urgently repair the KAMAZ engine 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.
VIDEO
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 output 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
11,00R20 Bel-124 ns 16
Frame repair is a fairly common task. Damage is different, depending on the nature, these are cracks (a fairly common occurrence), and folds and deformation.
Often in the case of serious accidents, the behavior of the frame is very difficult to recover and impractical. But in most cases, damage is expressed in cracks or the frame bursts. Such damage can be repaired safely. But it is important to follow the repair technology, since the frame structure works in difficult conditions, very strong torsional loads.
you need to cook with a semiautomatic device,
avoid overheating,
be sure to cut the seams,
boil the root of the seam.
Before starting the repair, you need to carefully inspect the frame for cracks. A video endoscope is suitable for internal examination. If you don't have a specialized one, you can purchase a USB endoscope that works with a laptop or smartphone.
For repairs, you need to provide access to the place of damage, if necessary, dismantle the parts that interfere with the work. The best method is to free the frame of all attachments and components to reduce the load. If the cracks have parted, they must first be brought down with the help of jacks and be sure to measure the diagonal control points of the car. The distance difference should not exceed 5 mm. If there are deviations, then you need to pull the frame on the slipway.
The straightening of the frame, including in places of cracks, is carried out in a cold state with a sledgehammer and hammers, using mandrels and supports.
On trucks and semi-trailers, the frame is controlled using pneumatic or hydraulic equipment.
VIDEO
Cracks are repaired by welding and riveting of reinforcing linings.
The main feature in preparation for welding:
determination of the visible end of the crack (using a magnifying glass);
drilling the end of the crack (before drilling, turn the center under the hole at a distance of 5-10 mm from the visible border of the crack along the line of its direction; drill with a drill with a diameter of 5-6 mm);
cutting edges at a bend of 90 degrees to a depth of 2/3 of the thickness of the metal of the part, with a plasma cutter, if not, you can use a grinder, but it takes longer.
cleaning the edges of a crack with a width of 20 mm (steel brush or electric sander).
The cracks on the side members are eliminated:
welding and installation of an external or internal reinforcing box-shaped lining on rivets;
welding of a crack and welding of a reinforcing triangular plate;
welding of a crack and welding of a reinforcing plate made of angle steel;
longitudinal cracks or a bunch of cracks on the vertical wall is eliminated by cutting out the damaged area and welding a rhombus-shaped insert;
Before installing the overlay, the seam must be trimmed flush with the base metal.
If it is not possible to boil the root, then it is better not to take up the welding of frames.
First pass root boil: current 100 A wire Sv08 1.2mm gas mixture Ap + CO2 20% short rollers from left to right across the crack with interruption of the arc and without overheating the metal, but with the formation of a reverse roller.
Second and third pass current 110 A exactly the same, but the rollers should be thin and overlap.
Fourth pass current 120 A a roller in the entire width of the groove with a slight approach to the base metal, the rollers are dense and, depending on the heat loss, it can be a continuous seam, but without overheating the metal (3-5 rollers and interruption of the arc).
The fifth roller overlaps in each direction the minimum is cooked in the same way, but without interrupting the arc. The seam is wide, convex, and quite even.
The vertical is cooked only from top to bottom. If the client asks to hide the traces of welding, then the fifth roller is not cooked.
Each case of frame welding is very individual.
Large seams should not be cooked at a time, since in the heat-affected zone the metal will harden and become brittle when deformed.
In the photo, the frame has already been made, the seam is disgusting. I had to redo it.
Seams were cut at 90 degrees, where VIN was, holes had to be drilled, this in order to relieve stress, so part of the crack cannot be welded, and if you do not make holes, then from metal stress, the crack will go back to welding.
The seams were welded using the technology above.
In the repair that is provided above, the pad was not required. An extra weld seam is not good for the structure. The pads are used in case you need to strengthen the frame, where the metal is tired, and there are many vertical cracks. It is better to weld diamond or elliptical overlays rather than overlapping.
For linings and patches, you need to take the same steel from which the frame is made.
The awning of a truck is a frame covered with a special waterproof PVC fabric (cover). The main advantages of this design are low weight, simplicity and relatively low cost.
However, during operation, the awning fabric is highly exposed to various loads and environmental influences, which can lead to the following consequences:
tears and cuts;
deformation of the frame;
wear and tear of awning fittings;
natural aging of awning fabric.
Professional repair of awnings is carried out using hot air welding, and a high-quality result is possible only with the use of appropriate equipment and materials. This list includes:
stitching rollers;
accessories for installing fittings (punches, crimps for installing eyelets);
awning fabric;
accessories (eyelets, resistance bands, staples, belts, rivets, pads, tensioners, rollers, hooks, rings, tips, cables, etc.).
The awning material is a sheet of polyvinyl chloride (PVC, PVC), reinforced with a lavsan (polyester) base. Depending on the thickness, the awning fabric differs in density (weight per 1 square meter). The most common fabrics have weights from 600 to 1200 g / m2. There are also heavier ones - they are used for the lateral sides of sliding (curtain) structures.
Welding equipment includes automatic and manual machines. The machines are used to produce long weld seams and are mainly designed for working with new materials. To repair damage, manual ones are used, since they allow you to carry out repairs on a vertical or horizontal surface without dismantling the awning.
A linear cut (gap) is repaired by welding a patch on the outside or inside of the tarpaulin. The width of the patch, depending on the length and nature of the damage, must be at least 40 mm. Awnings with a density of more than 700 g / m2 require two-sided repair.
The algorithm for repairing a cut or rupture of a car awning, regardless of the nature of the damage, is as follows:
a support surface is placed under the damaged area to avoid tissue deformation when heated. Most suitable for this is textolite, plywood or fiberboard (at least 5 mm thick). Do not use metal and plastic sheets;
the place of repair is thoroughly cleaned and degreased - the presence of oily contamination, scotch and glue residues is not allowed;
a patch is applied and pressed with a roller;
uniform and simultaneous heating by hot air of the lower layer of the patch and the upper layer of the damaged element. As the melting progresses, a uniform rolling is performed with a roller for connection.Overheating of the material must not be allowed. The complete polymerization time is usually no more than 10 seconds. The operating mode lies in the range of 600-850 degrees and depends on the condition of the material (the older, the higher the temperature) and the ambient temperature.
Please note: Do not use construction hot air guns to repair awnings - their performance is insufficient for this. The result of such work is often a violation of the geometry of the awning cover, up to the need to replace the entire element.
Aging of awning fabric is associated with the evaporation of PVC plasticizers. The material becomes tough and begins to flake off, exposing the fabric base. In this case, welding is possible only from the inside, or an element replacement is required. Such situations most often happen with the roof of the awning, since it is most exposed to ultraviolet radiation.
It must be remembered that welding PVC fabrics requires knowledge of many subtleties, as well as sufficient experience and skills, so if you are not sure of a favorable outcome of the work, then it is better to entrust it to a specialist.
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As for the kerchiefs and linings - their excessive thickness is also not good.
A truck frame is by no means a rigid structure, but rather an elastic element that acts in bending and, even more so, in torsion.
Therefore, thick linings change the properties of the frame and cause its destruction in other (sometimes in very unexpected) places. I consider it optimal to use metal with a thickness in the region of +/- 1 mm of the thickness of the frame metal. Thicker metal (up to 140-180% of the base metal) is used when lengthening frames with bolt-on central inserts, while the length of the overlap of the frame fragment and insert is at least 3.5. 4 frame heights. With significant elongation, additional overlays for the insert are desirable.
In terms of shape, rhombic with truncated corners, trapezoidal and, in some cases, triangular overlays are preferred. In any case, care should be taken to avoid transverse (vertical in relation to the frame) seams (except for the ends of the frame) and stress concentrators (sharp corners of the welds).
Similar Things also apply to platforms, bodies, sides and other superstructures.
Now about the bolts. When something is attached to the frame, the main reason for the failure of the fasteners is not at all the shearing of the bolts, but the fact that the bolts fray due to "looseness" in the holes of an unacceptably large diameter. Therefore, there is no point in using M16 to fix the box (extra large holes only weaken the frame).
My opinion is that the diameter of the fasteners to the frame should be no more than 2.5 (at least 3) thicknesses of the frame metal (exceptions are specially prepared places reinforced with pads for redistribution of loads, in this case - up to four to five times the thickness)
What is the difference between a conventional light car and a heavy-duty vehicle? You can list such indicators as weight, dimensions, carrying capacity, which means there are differences in power and durability of the main units. Therefore, maintenance and, in particular, repair of truck radiators requires more effort and time.
A car radiator is needed to lower the temperature of the coolant - antifreeze, which in turn removes excess heat from the engine housing. Structurally, this element is made of two metal reservoirs, interconnected by the thinnest tubes through which the liquid circulates.The air flow, directed by a fan or flowing by gravity through special openings in the cab or bumper, cools the body, and, accordingly, the liquid in it.
The main malfunctions that can occur in the radiator:
Leakage of coolant due to rupture of baths and tubes, which most often appear due to the ingress of stones and foreign objects.
Disruption of the circulation of antifreeze as a result of the formation of scale and deposits in thin tubes. This situation occurs if you use a low-quality cooler or ordinary water. This will help the usual flushing and knowledge of how to clean a car radiator.
A breakdown of the valve in the radiator plug leads to the fact that when heated, the liquid expands, and its excess cannot go into the tank. Conversely, when additional volumes of antifreeze are needed, it cannot flow from the expansion tank to the radiator.
Violations of the tightness of the connections of the nozzles - in this case, fluid is also observed to leave the body of the device.
With sufficient knowledge and skills in repair, this procedure can be done even on the road. However, these are only minor faults. When, as a result of an accident or an accident, the radiator simply turns into a piece of metal, then only replacing this important part of the car will help.
Let's figure out how to repair car radiators not in the garage, but on the road on our own, when you still need to get to the car service. One of the differences between a truck driver and a car enthusiast is that he always has the necessary tools and some consumables in stock. This is sometimes explained by the sad life experience of a truck driver and the need to earn money by transporting goods.
For work, you will need the following materials and tools:
sealant;
rubber heat-resistant seals;
adapters and connecting elements for branch pipes;
a small amount of mustard powder;
ordinary locksmith tools from the car kit.
In case of small ruptures of the baths or tubes, it is best to solder the emergency places, but this is possible only in stationary conditions with a powerful soldering iron and skills in handling it. And on the road, a heat-resistant sealant or a means of such as cold welding can come to the rescue.
If one or more pipes are torn as a result of being hit by a stone, then they can always be muffled, ensuring the tightness of the cooling system. To do this, it is necessary to drain the coolant, inspect where the tubes are torn, bite them with pliers at a distance of 2-3 centimeters from the baths and squeeze tightly. This circumstance will not greatly affect the cooling of the engine, and it will be possible to continue driving by filling in liquid.
If the plug is damaged, it will be necessary to replace it or try to repair the valve, having previously inspected it. It often happens that a foreign particle has fallen under it, which should be removed. If the plug spring does not work, then experts recommend cleaning it, and if this does not help, then you just need to replace it.
Well, and quite barbaric, but tested by previous generations of chauffeurs, the mustard method. It needs to be poured into the radiator, turn on the engine and wait a few minutes until it swells and closes the small cracks through which the antifreeze leaves. Some craftsmen even use raw eggs for this, which have a similar effect in a warm radiator.
After using mustard powder, you must thoroughly rinse the radiator and troubleshoot in the garage using a soldering iron.
In conclusion, I would like to draw attention to the observance of safety measures - the coolant has a high temperature and is under pressure, and if it leaks, it can even boil. Therefore, it is impossible to open the radiator cap right away, as it can scald your face and hands quite seriously.Only after the contents of the radiator have cooled down should you open the plug and start repairs.
VIDEO
Editing of truck and trailer frames:
lateral displacement;
vertical bend;
diagonal offset;
torsion;
local deformations, folds, ruptures of spars and cross members.
Repair of trailed equipment frames;
Full or partial restoration of the dump truck body;
Elemental and complete painting with preparation for it.
Often the longitudinal side members are displaced at an angle with respect to the longitudinal axis of the frame due to external loads. The front part of it is often strongly deformed due to the strong lateral displacement occurring in relation to the side member.
Vertical bends can appear in different ways. This is often caused by improper use of the truck's tipping or loading equipment. The picture above shows what happens when a truck is being loaded.
When the frame is twisted, the side members remain straight, but skewed in relation to each other. The crossbeams are usually at the right angle to the side members. Quite often, this damage occurs on trucks with two axles.
The frame side members move longitudinally and the cross members do not form right angles to the side members. Diagonal displacement often occurs on trucks when rollover.
I had to deal with welding of the KamAZ frame. After a while, a crack appeared near the seam. I decided to reinforce the structure with a "rhombus" overlay, cut the edges and welded it in two passes. Six months later, the same problem - the frame cracked. What is the truck frame repair technology? A similar question about welding the axles of foreign cars semitrailers.
The manufacturer claims that the frame cannot be restored, but nevertheless, the workshops often successfully cope with this difficult task. Here are some secrets to welding a frame:
1. One of the main features of frame welding is cutting edges with a plasma cutting machine.
Every vehicle, including trucks, needs regular maintenance. Maintenance or MOT of a truck is a set of measures that are aimed at maintaining the high performance of the vehicle and improving the operational characteristics of its units and assemblies.
Due to the constant loads that trucks are exposed to, provided there is no regular maintenance, the service life of the vehicle can be drastically reduced.That is why, maintenance and periodic diagnostics of a truck is an extremely important measure, which affects not only the efficiency of freight transport, but also helps to significantly reduce the possible costs of its repair and further operation.
Maintenance of trucks has its own characteristics, which should be known to every car owner who plans to carry out maintenance of a truck with his own hands.
At the moment, the Russian Federation has adopted the standard GOST 21624-81 "System of maintenance and repair of automotive equipment". The state standard sets out the basic requirements for the design of freight transport, maintenance, as well as the timing of maintenance of trucks.
According to the current GOST, there are several main types of maintenance of freight vehicles:
Daily maintenance includes the following checks:
External inspection of the car: identifying damage, checking the condition of the cab, its locking mechanism, monitoring the condition of the springs, checking the tire pressure, the presence of license plates.
For a semitrailer tractor, the serviceability of the fifth wheel coupling must be checked, for a dump truck, the serviceability of the tailgate.
Checking the health of lighting devices, alarms, windshield wipers, glass washers, compressor, generator. On a dump truck, the operation of the platform lifting and stop mechanism is monitored.
The condition and serviceability of the handbrake, steering rod joints and steering drive are checked.
An external examination, in order to detect a possible leak, checks the tightness of the brake drive, the power steering system.
Daily maintenance also involves washing and cleaning the car, which includes not only cleaning the cab and platform, but also cleaning the headlights, mirrors, and license plates.
Lubrication and filling works.
Control over the presence of fuel in the tanks.
Checking the oil level in the engine crankcase. It is possible to control the oil level no earlier than 5-10 minutes after stopping the truck engine.
In winter, it is necessary to regularly drain sludge from the fuel tank and the fine fuel filter. This is done as follows: 0.1 liters of fuel is drained, after which the truck engine is started for 3-4 minutes.
It is imperative to monitor the liquid level in the cooling system, in the glass washing tank.
The final stage of work is the drainage of condensate from the air cylinders of the pneumatic brake drive. Make sure that the condensate is drained when there is air in the system.
The main purpose of TO-1 is to prevent possible breakdowns that can disable the vehicle, increase the level of environmental pollution, and significantly increase the consumption of fuel and lubricants.
Carrying out TO-1 includes not only the implementation of the scope of work included in the daily maintenance, but also a set of additional activities.
Checking the tension of the water pump drive belt. With pressure on the central part of the branch, the water pump belt from a force of 30 N or 3 kgf should bend from 1 - 1.5 cm.
Checking the adhesion consists in visually inspecting the rubber protective cap in order to detect breaks on it. If damaged, the part must be replaced.
When checking the driveline, you must:
Check the backlash in the joints and in the splined joint of the cardan drive. Work is carried out with the transmission turned off by lightly rocking the propeller shaft tube around the axis and in the radial plane. This action is performed in order to detect tangible backlash, which is unacceptable;
The nuts of the propeller shaft flanges are checked and, if necessary, tightened.Work is carried out with the parking brake released. Stops are placed under the truck wheels, and the gear lever is set to neutral.
The rear axle is checked in order to detect leaks in its connections. In this case, special attention should be paid to the fact that oil leakage through the hub seals, through the drive gear oil seal, the gearbox gasket and the rear axle cover is unacceptable.
Steering and front axle maintenance consists of the following:
Checking fasteners and cotter nuts, steering wheel bipod, ball pins of steering rods (tightening torque - 140 - 200 N / m), power steering, steering knuckle levers (tightening torque 180 - 220 N / m), monitoring the condition of lock washers. After tightening the ball pin nuts, new cotter pins must be installed.
When the engine is running, the free wheeling of the steering wheel is checked, the play in the joints of the steering rods and the hydraulic booster is checked. When the engine is not running, the bipod pin in the hydraulic booster distributor must have a play of no more than 2 mm.
It is also necessary to check the backlash of the front wheel hub bearings.
When checking the brake system, pay particular attention to the following points:
Checking the operation of the compressor (in particular, the pressure generated by it, the drop of which with the engine off and the brakes off should not exceed 30 kPa for 30 minutes, and with the brakes on - no more than 30 kPa for 15 minutes).
It is also necessary to check the tightness of all connections of devices and pipelines of the brake system.
The condition of the fastening and splitting of the forks of the rods of the brake chambers and parts of the service brake drive need to be monitored.
Make sure that the stroke of the brake chamber rods is within 2.5 - 3 cm.
The serviceability of the drive and the operation of the handbrake need a mandatory check. Pay special attention to the handle travel, which should be between 1.1 - 1.6 cm.
The hand brake caliper mounting bolts must also be tightened.
The tension of the compressor drive belt is also subject to mandatory control. When pressing the central part of the short branch with a force of 30N, it should bend by 0.5 - 0.8 cm.
It is also necessary to adjust the free travel of the brake pedal.
During maintenance of the chassis, it is necessary to check:
The condition of the frame, springs, brackets for cracks on the parts. Loosening of riveted joints is also unacceptable. The shock absorbers must be checked for leaks, and the bushings must be checked for wear.
Wheel nuts must be tightened with a torque of 250 - 300 N / m.
It is necessary to check the condition of the tires and the conformity of the pressure in them to the norm. Foreign objects in the tread and between twin tires must be removed.
When checking the power system, you must:
Check the serviceability of the fuel control mechanism, engaging the engine brake. When you press the brake pedal, the regulator lever rests on the maximum speed limiting bolt, with the free position of the pedal - on the minimum speed limiting bolt.
An external examination checks the condition of the power system, the tightness of the pipeline connections.
During maintenance of electrical equipment:
An external examination checks the condition of the electrical wiring, the condition of the hoses and covers on the plug and terminal connections is checked.
It is necessary to check the fastening and condition of the batteries. The cleaning procedure should be applied to ventilation openings, batteries. The electrolyte level should also be checked and distilled water should be added if necessary.
Lubrication and cleaning works are carried out in strict accordance with the lubrication chart.
In addition to the work performed during TO1, additional measures are recommended.
When the engine is serviced, it is necessary:
Check the nuts securing the front and rear engine mounts to the frame. The tightening torque of the front support is 44 - 62 N / m, the rear - 70 - 100 N / m.
Check and, if necessary, tighten the nuts securing the exhaust pipes of the muffler with the frame and the stepladders of the exhaust pipe of the muffler from the transverse frame.
When checking the clutch, pay special attention to the free travel of the pedal, which should be within 34-43 cm when the air is released from the system.
When checking the checkpoint:
Adjust the position of the gearbox.
Check the condition of the nut securing the intermediate mechanism of the box with the frame.
Check the attachment of the transmission support support bracket to the frame cross member.
When checking the steering and front axle:
Check the condition of the oil seals for damage, oil leaks.
By visual inspection, assess the condition of the cotter nuts, steering rods and power steering.
Check the condition of the thrust bearings and the tightness of the pivot nuts.
Assess the condition of the front axle beam, the angles of the front wheels and the amount of toe-in.
Adjust the tension of the power steering pump drive belt.
Checking the brake system includes:
Checking the condition of wheel brakes and wheel bearings, replacing worn parts. The linings must be free from cracks, scoring and chipping.
Assess the condition and thickness of the rear foot brake linings.
The fastening nuts of the air cylinder clamps should also be checked and tightened.
Undercarriage maintenance includes:
Checking the fastenings of the spring brackets and bracket liners.
Checking the location of the front and rear axles for distortions.
Tightening the ladder nuts. It is carried out with straightened springs. Tightening torque of the rear springs - 600 - 650 N / m, front - 400 - 450 N / m, step-ladder nuts - 27 - 50 N / m.
Checking the condition of the shock absorber bushings and replacing worn or damaged parts.
Checking the fastening of the towing device with the transverse frame, splitting and tightening the slotted nut. In the event that the car is constantly working with a trailer, it is necessary to remove the towing device from the transport to eliminate the defects.
Assess the condition of the rims and wheel clamps.
Tighten the nuts securing the spare wheel bracket if necessary.
During maintenance of the cab, platform and tail, it is necessary to: check and, if necessary, tighten the nuts securing the platform ladders and the nuts securing the brackets of the fuel tank.
When servicing the power system, after one service, the fuel injection advance angle is checked and adjusted, the injectors are removed from the engine, their operation is checked at the stand, after which they are adjusted.
When checking electrical equipment, the following types of work are performed:
Checking the state of charge of storage batteries by electrolyte density and cell voltage under load. If necessary, the batteries are removed for recharging.
The alternator and starter must be inspected and cleaned of grit and oil.
Check the tightening of the starter bolts and tighten if necessary.
Checking the installation of headlights and the direction of their luminous flux.
Checking and tightening the alternator mounting bolts.
Careful performance of cleaning, lubrication and filling operations in accordance with the approved list ensures the flawless operation of the vehicle during operation.
The service interval (the frequency of routine maintenance) in this case is at least 4000 km of the vehicle's mileage. However, many experts note that carrying out some maintenance work, in order to increase the safety and reliability of the car, should be carried out with a mileage of 2000 - 3500 km.
Video (click to play).
As practice shows, the average mileage of trucks in Russia is 150,000 - 200,000 kilometers per year.During this time, the truck undergoes several types of diagnostics and maintenance. One of the main factors in saving on the repair of a truck is not only to carry out maintenance in a timely manner, but also to high quality, because maintenance work allows you to identify a list of basic parts that will soon fail. Accordingly, maintenance will significantly reduce operating costs and further repairs of the truck. But only if you entrust the service to specialists. The Movement Technology truck service center has modern diagnostic and repair equipment, which makes it possible to carry out maintenance and diagnostics quickly and efficiently. You can find the services and prices of the company on the website.
