DIY kamaz repair

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

The abbreviation "PSU" will confuse an ignorant person. Many will have to make a request on the Web to find out what is the secret behind these three cryptic letters. But in fact, there is no secret: this is just a pneumohydraulic clutch drive, and our article is just about this unit. Below we will consider the device of the KamAZ CCGT unit, find out on what principle its work is organized, and determine what types of amplifiers there are for trucks produced by the Kama Automobile Plant. If you are interested in the repair of CCGT KAMAZ, you should also pay attention to the text.

What is this unit for? What role is assigned to him in KamAZ trucks?

Any truck is a rather massive and oversized vehicle. And this also applies to the truck of the KamAZ trademark in full measure. Driving such a machine is not easy, and the driver would have to possess the muscles of a weightlifter in order to depress the clutch pedal of the truck. PSU - that's what makes the driver's life easier, that's what saves you from exhausting physical exertion.

So this relatively small unit does a very important and necessary job. Without it, shifting gears would be much more difficult.

What is hidden in the building of the CCGT unit? How does it work?

Replacing the CCGT KamAZ or repairing it requires the driver on the road or a car mechanic at the service station to know about its device.

adjusting nut, piston pusher;
pistons (pneumatic and hydraulic);
springs of the piston, cover and valve of the reducer;
diaphragm springs and seats, adjusting screw;
bypass valve and follower piston.

Video (click to play).

Interested in the principle of operation of CCGT KAMAZ? Below about it:

If the clutch is engaged (the clutch pedal is pressed), under the pressure of the fluid, the hydraulic piston of the CCGT actuator presses on the piston of the CCGT KamAZ and on the piston of the follower, which, together with the diaphragm, is displaced so that the intake valve and air from the pneumatic system of the truck are supplied under pressure to the pneumatic piston ... Thus, the forces of the hydraulic piston and the air piston are summed up, which as a result retract the fork and disengage the clutch.
When you take your foot off the clutch pedal, the pressure in the fluid supply line drops to zero. That is, the pressure on the hydraulic pistons of the executive part and the follower decreases. In this case, under the action of the air pressure supplied from the pneumatic system, the hydraulic piston of the follower starts to move in the opposite direction and closes the inlet valve, blocking the air pressure from the receiver. Under the action of a pressure spring, the follower piston is retracted to its original position. In this case, the air that pressed on the pneumatic piston is discharged into the atmosphere. As a result, the action of the clutch springs forces the rod with the air piston and hydraulic piston to return to its original position.

What types of CCGT are best suited for KamAZ trucks?

The range of KamAZ trucks is wide. The enterprise produces dump trucks 55111, 6520, 65115, tractors 5460, 6460, flatbed trucks 43118, 5320, military 4310, etc. for this there is a risk of an accident - the driver gets tired less, which means that he has better control over the car and the environment.

Nowadays, the following types of CCGT units manufactured in Russia and abroad are installed on trucks:

CCGT unit produced by OJSC KamAZ (catalog number 5320) with a vertical tracking device, ie.above the pneumatic cylinder body. Applicable to 4310, 5320, 55111, 43118, etc.
CCGT units manufactured in the USA by WABCO. These units are distinguished by their compactness and the presence of a lining wear indicator, which can be used to track the degree of wear of the unit without dismantling and disassembling it. Almost all new models of KamAZ trucks with the checkpoint-154 are equipped with this particular CCGT.
PGU VABKO KAMAZ for trucks with a gearbox of the ZF trademark.
Analogues of WABCO CCGT units produced at the Volchansk Aggregate Plant (Ukraine) or at the Yumak Plant (Turkey).

Thinking about which amplifier to choose instead of the current one? We recommend exactly the same one that was originally installed on your truck (pay attention to the make and number from the catalog) - only then will the normal interaction of the amplifier and the clutch be ensured. If you still need to replace the KamAZ CCGT unit with a unit of a different type, first consult a specialist who is really well versed in this.

Everything you need to know about maintenance and repair of CCGT at KAMAZ

During the maintenance of the clutch, the pneumohydraulic booster is at the same time serviced. This allows you to prevent or identify malfunctions of the KAMAZ CCGT unit.

When servicing, the following work is performed:

visual inspection to identify visible breakage, air leaks and fluid leaks;
if necessary, tighten the mounting bolts;
a spherical nut adjusts the free travel of the pusher;
the working fluid is replenished in the reservoir of the clutch drive system.

By the way, if you have a WABCO CCGT installed, the wear of the clutch linings can be easily seen on the wear indicator, which is extended under the action of the piston.

However, if it is necessary to repair the KAMAZ CCGT unit or if there are any doubts about the correct operation of the unit, it is disassembled in the following sequence:

the back case of the CCGT unit is clamped in a vice;
after unscrewing the bolts with washers, the air supply cover is removed;
the valve is removed from the body of the pneumatic booster;
the front case is removed, complete with a pneumatic piston;
the springs of the membrane and the pneumatic piston are dismantled;
then the diaphragm is removed, and the follower piston, thrust ring, clutch release piston assembly, as well as the seal housing are removed from the rear housing;
the bypass valve and the cover with the outlet seal are removed.
the rear body is removed from the vice;
the retaining ring of the rear housing is removed;
all washers and cones, as well as the seat, are removed from the valve stem;
the O-ring is removed from the follower piston body, and then the follower piston itself is removed, from which all elements are then removed;
the air piston is removed from the front housing (the cuff is then removed from it) and the sealing ring.

washed in gasoline or kerosene;
blown with compressed air;
defective.

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- the diameter of the main cylinder body is more than 28.06 mm;

- seizure marks on the working surface of the piston master cylinder housing less than 27.92 mm;

- wear and swelling of the cuff.

Fig. 2. Clutch master cylinder KamAZ-4310, 55111, 43118, 5320

1 - piston pusher assembly; 2 - protective cover; 3 - the body of the clutch master cylinder; 4 - piston; 5 - cuff; 6 - spring; 7 - gasket; 8 - cork; 9 - main cylinder assembly

Assembling the clutch master cylinder KamAZ-4310, 55111, 43118, 5320

- Install piston 4, collar 5, spring 6 into the housing 3 (see Fig. 2) of the master cylinder and screw the plug 8 with gasket 7.

- Place the protective cover 2 on the pusher 1 with an O-ring, insert the pusher into the body 3 and connect the cover to the body

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, 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

Image - DIY kamaz repair

11,00R20 Bel-124 ns 16

PSU KamAZ is a device designed to reduce the pressure level, which is exerted by the driver on the clutch pedal.

PGU is a hydraulic power steering of a pneumatic type of KamAZ clutch.

The CCGT device includes:

spherical nut;
lock nut;
a piston pusher that deactivates the clutch system;
a cover that protects against damage;
piston;
complex type sealant;
bypass and inlet valve;
cork;
fuel fluid supply;
a system for compressing the air stream.

Image - DIY kamaz repair

The scheme also includes the following elements:

spring mechanism;
reducer;
diaphragm seats.

The principle of operation of the CCGT unit is as follows:

The driver presses the clutch pedal.
Under the pressure of the fuel fluid, the rod and the piston part of the mechanism are activated.
Movement occurs until the inlet valve opens.
The air flow moves towards the pneumatic piston.
The fork is retracted and the clutch system is disengaged.

In order to regulate the CCGT unit, you must:

Adjust the pedal free play. Lower the pedal until the master cylinder starts to function. After that, debugging is done using an eccentric pin. The gap between the piston part and the pusher should not exceed 1.2 cm. At the end of the procedure, the castellated nut must be tightly tightened.
Adjust the clutch free play. Move the fork handle, remove the spring mechanism and perform debugging.

The procedure for pumping:

Clean the rubber protective cap of the overflow valve.
Put a rubber hose on the valve.
Dip one end into a glass container with working fluid.
With jerks, press the pedal 3 times, and the fourth time, while holding the pedal, loosen the bypass valve.
As soon as the release of air bubbles from the liquid stops, you need to wrap the bypass valve and remove the hose.

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Repair of the CCGT unit involves its disassembly. To disassemble the mechanism with your own hands, you must:

Place the pneumatic power steering in a vice and clamp the rear of the housing.
Unfasten screws and remove cover for air inlet.
Remove the booster valve from the front housing.
Remove the spring and diaphragm.
Pull out the thrust washer and piston section.
Unscrew the retaining breather and remove the cover from the seal.
Pull out the retaining ring.
Remove the seats and washer.
Remove the cuff.
Installation and assembly of the KamAZ CCGT unit is carried out in the reverse order.

Possible CCGT malfunctions:

The drive is seized. In this case, it is recommended to flush all elements of the hydraulic system and change the oil.
The clutch is lagging. Use a better quality fuel fluid (for example, meeting Euro-5 standards). If that does not help, replace the piston seal.
The clutch hiss and there is no reinforcement. Inspect the intake valve, replace if necessary. It is also recommended to inspect the seals and the follower piston ring.

GUR KamAZ (power steering) is a mechanism that facilitates the effort required to turn while driving a vehicle.

The GUR KamAZ-5320 device includes the following elements:

Fuel flow distributor to other mechanisms of the power steering system.
The pump, which is responsible for the circulation of the working fluid and pressure indicators.
A hydraulic cylinder that converts liquid pressure from the pumping end to the cylindrical one.
Hoses that connect all the elements of the pumping part, the distributor and the hydraulic cylinder.
Electronic unit that regulates the operation of the hydraulic booster.
Wheel.
The spring of the valve of the safety type of the hydraulic system.
The shaft of a bipod equipped with a toothed-type sector.
Piston rack.
Longitudinal and transverse thrust.
Magnetic plug.
Steering crankcase.
Spool.
Centering spring.
Filling filter element.

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Possible power steering malfunctions:

Unstable movement of the vehicle. In this case, you need to adjust the wheel free play, replace the ball screw pair, wash all the parts, tighten the front cover nut.
The swing system works with great effort. This may be due to insufficient oil level. Oil is poured into the hydraulic booster up to the upper mark.
Increased noise level during operation. In this case, it is recommended to rinse all filter elements, replace damaged ones. Adjust the engagement system and replace damaged parts.
Shocks while driving at high speeds. Such a breakdown may be associated with imbalance of the wheels.
Throws oil out of the RBL reservoir. It is recommended to replace the worn out element and check the operation of the intake valve.

Repair of the KamAZ-4310 power steering and restoration of the power steering assumes the replacement of damaged parts and assemblies. To carry out the adjustment work, you will need a dynamometer and a pressure gauge.

The procedure is carried out in the event of an oil leak.

A worn or damaged oil seal may be the cause of the malfunction.

To change a part, prepare the following tools:

set of wrenches;
screwdriver;
ratchet wrench;
hammer;
puller of universal type.

Bipod Oil Seal Replacement Procedure:

Drain the oil and remove the grille and radiator from the cooling system.

Using a ratchet wrench, loosen the front pulley fixing screw.

Remove the front pulley.

Take out a worn or damaged oil seal and replace it with a new one.

Use a hammer to set the new part to a sufficient depth of the groove in the front cover.

Replace the pulley.

Tighten the removed bolts and add oil.

After replacing the oil seal, you need to start the vehicle to make sure that the oily fluid is no longer flowing.

The process of adjusting GUR KamAZ:

Drain the oil system from the system.

Remove the seal and unpin the socket plug.

Unscrew the seat plug from the relief valve.

After replacing the damaged part, cover the opening in the valve body with a tissue.

Adjust the distance between the piston and the follower.

Remove any nicks and check the integrity of the rubber seal.

The bleeding procedure is performed as follows:

Unscrew the bypass valve.
Turn the steering wheel to the left until the centering springs are compressed.
Fill pump with oil.
Screw on the bypass valve.
Move the steering wheel to the right side.
Pump the power steering on KamAZ with a pump until the release of air in the power steering stops.

The average cost of a new power steering is 20,000 rubles.

Do you want to know how to recognize the "focus" of a breakdown and make repairs of the KAMAZ CCGT unit with your own hands? Then you have come to the right place, in this article we will walk you through this process step by step.

Let's start with the definition of the abbreviation "PGU" - it is a pneumohydraulic amplifier, a component of the clutch unit. KAMAZ trucks are very large and massive, so it is not easy to drive them. The driver of such a car would become a weightlifter by pressing the clutch pedal, if there was no such technological solution as the PGU. It makes life behind the wheel of a truck easier and more comfortable.

In simple terms, it is responsible for reducing the applied pedal effort. Although the pneumohydraulic booster itself is small in size, it performs a serious task - it facilitates the process of driving a heavy car. Without it, changing gears would be a tricky process. All the latest CCGT models consist of:

tracking systems;
an executive pneumatic cylinder;
lining wear indicator at the driven disc.

The pressure of the fluid, which is located in the master cylinder of the device, is transported to the pneumohydraulic booster. This in turn forces the hydraulic pistons and the servo system to work. When the pressure drops, everything returns to its original position.

If the follower piston of the CCGT unit is stuck, it was due to the swelling of the rubber ring or the sealing lip.
In the case when the compressed air in the pneumohydraulic booster is supplied in a small amount or does not come at all, the CCGT inlet valve will be the “culprit”.
When the pedal is in a "sinking" situation, it means that air has entered the hydraulic actuator.

It is sometimes difficult for beginners in the repair of CCGT KAMAZ to recognize the first signals of malfunction in the operation of CCGT. But here is a small list of possible errors in the operation of the clutch:

At the moment of the start of movement or when changing gear, the device is triggered with a delay.
The device only reacts when the amplification is strong.
Periodic "wedges" of the device.

If at least one of the above symptoms is present, then an urgent need to look for and troubleshoot the pneumohydraulic booster unit.

After examining all the breakdown indicators, have you come to the decision to carry out the repair yourself? Then you need to start with disassembling the unit, the cycle of which is carried out strictly in the following order:

The rear body of the pneumatic booster is mounted in a vice.
The bolts and washers are unscrewed alternately.
The cover of the air inlet is removed.
A valve is pulled out of the CCGT housing.
The front housing assembly with a pneumatic piston can be removed.
The springs are removed from the diaphragm and air piston.
The diaphragm is removable.
The seal housing, thrust ring, follower piston and clutch release piston assembly are pulled out of the rear housing.
Unscrew the cover with the outlet seal and the bypass valve.
The previously fixed rear body is released from the vice.
The retaining ring is pulled out.
Remove the cones, washers and seat from the valve stem.
The O-ring is removed from the follower piston housing.
The follower piston is removed and the remaining parts are removed from it.
The O-ring and the pneumatic piston are pulled out of the front housing.
The cuff is removed from the pneumatic piston.
All removed elements are cleaned in oil: kerosene or gasoline, blown with compressed air and subjected to troubleshooting.
After a high-quality review of the parts and the repair of the required spare parts or their replacement, the assembly is carried out in the reverse order.

The final stage of the restoration of the device is the adjustment of the CCGT unit KAMAZ. To do this, it is necessary to ensure the full stroke of the pusher of the pneumatic amplifier not less than 25 mm... Because at a low rate, the clutch is completely disengaged. Thus, the full travel of the pusher is tested by depressing the clutch pedal with force until it stops.

If the stroke is not at the proper level, then the fluid indicator in the reservoir of the clutch master cylinder and free play are re-tested. If necessary, air is removed from the hydraulic system. In order for the CCGT to serve efficiently and reliably, it is important not to forget about its timely repair and maintenance.

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