Stand for repairing energy storage devices with your own hands

In detail: a stand for repairing energy storage devices with your own hands from a real master for the site my.housecope.com.

The C1 machine is intended for repairing the brake system of KAMAZ vehicles in the conditions of service stations, motor transport enterprises and repair shops.

Standard complete set:

Manufacturer: Russia

Specifications:

Jack force (at the end of the stroke), N (kgf), not less

Effort on the handle, N (kgf), no more

Overall dimensions, mm, no more

Device and principle of operation

Stand C1 consists of the following main parts: base, stop, guide, columns, bushing and jack.

The base and the stop are interconnected by columns, along which the guide with the clamping sleeve installed on it moves with the help of a jack. By rotating the jack handle, the sleeve is brought to the power storage cover and by the jack force compresses the power spring under the piston. The stand is equipped with a puller for pressing out the pusher. It consists of a glass, a stud, a nut, and a clamp. To press the pusher out of the piston, the pin is wrapped in the pusher (instead of the removed pusher cover), and if there is no thread, it is fixed to the pusher with a clamp. A glass is put on the pin and the pusher is pressed out with the help of a nut.

Safety requirements

The stand is a power unit and is designed to compress the power spring, which has a high energy consumption, therefore, persons who have studied this passport and received safety instructions are allowed to work at the stand.

When working at the stand, strictly follow the work procedure set out in this passport.

Operating procedure

Place the stand on the workbench by fixing it through the holes in the base. Fastening in a bench vice to the base is allowed.

Video (click to play).

Before starting work, make sure that the stand is securely fastened.

Disassemble the energy storage in the following sequence:

1) Remove the cover on the pusher.

2) Supply compressed air (pressure 6 kg / cm 2) into the cylinder cavity of the power accumulator.

3) Move the bearing with the washer, on the screw of the emergency release mechanism, down to the stop, while the circlip will come out of the recess of the washer.

5) Bleed the compressed air from the cylinder cavity of the power accumulator.

6) Install the energy accumulator on the centering flange of the base corresponding to it and with a slight jack force, through the pressure sleeve, press the cover against the cylinder.

7) Remove the bolts securing the cover to the cylinder.

8) Rotate the jack handle until the power spring is fully released.

9) Remove the energy storage from the stand.

Assemble in the following sequence:

1) Install the cylinder with the power spring, piston and cover on the corresponding flange of the stand base.

2) Rotating the jack handle, compress the power spring until the cover is pressed against the cylinder.

3) Bolt the cover to the cylinder.

4) Remove the jack force from the cover.

5) Remove the energy storage from the stand.

6) Supply compressed air (pressure 6 kg / cm 2) into the cylinder cavity of the power accumulator.

7) Put on the circlip.

8) Bleed the compressed air from the cylinder cavity.

9) Put the cover on the pusher.

Maintenance

For normal operation of the stand, it is necessary to periodically lubricate the rubbing surfaces of the jack (screw, thrust collar) and columns with any machine or grease.

manufacturer's warranty

The manufacturer guarantees the serviceability of the stand for 12 months from the date of commissioning, but not more than 18 months from the date of manufacture.

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The KamAZ car has a double-circuit pneumatic braking system, which ensures the safety of the vehicle in all driving modes. During braking (by pressing the brake pedal), compressed air is immediately supplied to the brakes of all wheels. The parking brake only locks the wheels of the center and rear axles. The main element of the drive of such a brake is the energy storage. KamAZ has 4 such devices - 1 for each wheel of the rear bogie.

The spring accumulator is mounted on the brake chamber cover and serves to store the energy of the compressed spring.

The main parts of the device are:

cylinder;
piston;
power spring;
pusher;
thrust bearing;
release screw with roller bearing;
bypass tube;
seals.

The battery is bolted to the camera, which provides a strong connection and eliminates backlash during operation. The seal between the cylinder and the brake chamber is ensured by the installation of a rubber sealing ring. In the upper part of the body, a nut for the screw of the brake release system is welded. At the bottom of the cylinder there is a threaded nipple through which the pneumatic line is connected.

A tubular pusher is welded to the metal piston with a rubber O-ring. The power steel spring is located in the piston groove and abuts against the top of the cylinder. The pusher has a thrust bearing, which transmits force to the brake chamber rod through the membrane.

The screw serves for manual release of the brake in the absence of compressed air in the system due to a compressor breakdown or a defect in the receiver. A roller bearing and 2 thrust washers are installed in the lower part of the screw.

The cavity located above the piston is communicated with the atmosphere via a bypass tube through the brake chamber. The chamber under the piston is supplied with air from the parking brake control valve. All energy storage devices are simultaneously involved in the analysis of air.

In the parking lot, the car is held by the brake system of the wheels of the rear bogie, which is activated by spring accumulators. The crane with the parking brake control handle is located to the right of the driver's seat. The principle of operation of the power accumulator is simple and is based on the effect of the released energy of the power springs on the drive elements of the brake system.

When the parking brake is applied, compressed air from the lower cavity of the accumulator cylinder is released into the atmosphere. The spring, straightening, moves the piston down. Together with it, the pusher moves, which transfers the force to the diaphragm and the rod of the brake chamber. The latter, through the lever, turns the shaft, the expander knuckles of which press the brake pads against the drum, thereby stopping the wheels of the rear truck bogie.

If the receiver or the air brake circuit is damaged, the air from the line is released to the atmosphere. The released spring activates the parking brake and locks the wheels. Further movement of the truck is possible after releasing (unlocking) the wheels.

In order to remove the truck from the parking brake, it is necessary to remove the control handle from the latch and move it to the lower position.The control compressed air through the pneumatic line through the open valve enters the accelerating valve, which initiates the supply of the working medium from the receiver through the bypass valve to the lower cavity of the energy storage cylinder. The piston moves upward and compresses the spring. The brake rods move to their original position and release the pads. The truck is ready to move.

In the event of a lack of air in the system or a breakdown of the engine (compressor) and the need to tow the car, you must manually release the energy storage. To do this, use a socket wrench to unscrew the screws on the cylinders of all batteries. Due to the presence of a thrust bearing, the force will be transmitted to the piston, which, while moving, will compress the power spring. Released from the load, the return spring will move the diaphragm and stem with the platter to the top position. The brake pad actuators will return to their original condition and unlock the wheels.

Often on flights, situations arise when it is necessary to repair the KamAZ energy storage device with your own hands in the field. The design of the device allows this. However, it will be much easier to replace the defective energy storage unit with a serviceable one, and to do the repairs in the garage.

To repair a faulty battery, it must be dismantled from its regular place. To do this, you need to remove the air hoses and unscrew the 2 nuts securing the device to the base. Dismantling is carried out using a "balloon" key. In order to disassemble the assembly for fastening the brake chamber rod and the brake shoe drive, it is necessary to unpin and knock out the tapered wedge from the seat.

Before repairing the device, it is necessary to dismantle the bypass line between the cylinder and the brake chamber. Disassembly begins by removing the bottom of the camera. It is attached to the upper body with a clamp. For safe work, the energy storage is installed with the cylinder down and fixed in a locksmith's vice. After dismantling the clamp, by tapping on the camera body, they release it from the seat.

When performing these works, care must be taken, since under the action of the return spring, the cover can "shoot".

The weak point of the brake chamber is the membrane. The defective element must be replaced.

Due to the low corrosion resistance of the cylinder body material, cavities and ulcers are formed on the inner surface. This is facilitated by moisture and dirt entering the glass of the upper part of the energy storage. All this leads to a violation of the tightness of the cavities and, as a consequence, to the failure of the entire device. To eliminate the defect, it is necessary to replace the cylinder glass or try to grind the inner surface. And this leads to a complete disassembly of the cylinder.

To detach the upper part of the battery from the camera cover, it is necessary to unscrew the M8 screws located around the perimeter of the case. The remaining 2 bolts will keep the cover from firing the spring. Use a clamp or press to compress the spring and unscrew the remaining fasteners. Craftsmen who carry out such repairs professionally prefer a lathe.

The cylinder is clamped into the chuck, and the spring is squeezed using the headstock. Having unscrewed the remaining bolts with the rod fully pressed, they begin to slowly remove the latter. All sealing elements are replaced with new ones from the repair kit. The assembly of the cylinder is carried out in the reverse order. The repaired device is checked on the bench by supplying compressed air. The installation of the energy storage device in its regular place is carried out after obtaining positive test results.

The price of the product depends on the modification, manufacturer and region of purchase. The power equipment restored at the enterprise at KAMAZ type 20/20 in the central regions of Russia can be purchased for 1500-1800 rubles. A new similar model costs from 4 to 6 thousand rubles.The price of more powerful devices such as 30/30 ranges from 10 to 13.5 thousand rubles. Considering that the cost of the repair kit is about 300 rubles, then it makes sense to restore the failed devices.

The device is intended for disassembling and assembling the energy storage device of a KAMAZ vehicle.

Type - mechanical, stationary

Overall dimensions, mm - 555х310х310

The device consists of a frame 1, which is a welded structure. In the lower part of the frame 1 there is a base plate 2 with holes for the bolts of the brake chamber. In the upper part of the frame 1, a pneumatic cylinder is installed, consisting of two covers 5 and 8, a cylinder 4, a rod 6 and a piston 7. Seals in the pneumatic cylinder are made using O-rings 18 and 19, an oil seal 20, which is held by a cover 9.

Pressing on the rod of the energy storage occurs through the mandrel 3, which is fixed on the rod 6 with the help of the retaining ring 17 and the ball 10.

Disassembly and assembly of the energy storage device ZIL KAMAZ. Repair of energy storage at home

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having sunk the package of parts 2, 16 and 18 (Fig. 281, c) outside the rubber ring 1, remove the retaining ring 17 from the screw 19 with a special tool;

release the piston 14 until the spring 5 is completely relaxed by carefully rotating the handle of the device in the opposite direction;

removing the cylinder, piston and spring from the device, remove the remaining parts 2, 16 and 18 in it (Fig. 281, d);

remove guide ring 3 and seal 4 from the piston;

remove the spring 5;

remove the rubber ring 1 from the screw, unscrew the screw 19 from the cylinder and remove the sealing washer 20.

Before assembly, all rubbing parts should be lubricated with a thin layer of CIATIM-221 grease. The assembly should be done in the following sequence:

DEVICE FOR ASSEMBLING AND DISASSEMBLING ENERGY ACCUMULATORS, containing a table on which the energy storage device is fixed, and a power mechanism designed to compress the spring of the energy storage device, heating it with the fact that, in order to increase performance and reliability, it is equipped with a bar with a stop, one end of which has a grip in the form of a sleeve with two longitudinal and diametrically located through grooves, and cantilevered hooks in them in the form of flat springs with internal oblique protrusions, and the other end of the bar is threaded and has a handle that interacts with it on the casing of the energy storage using a bearing. .: О9 to sd 4

STATE COMMITTEE OF THE USSR FOR IEPRETENATION AND RELATIONS

DESCRIPTION OF THE INVENTION on aBTOPCktOMV SIDED BY (21) 3214000 / 25-28 (22) 04.12. 80

2 ° Ibid., P. 110 (prototype). (54) (57) ASSEMBLY AND

DISASSEMBLY OF ENERGY ACCUMULATORS, containing a table on which the “.SU” “1013254 A. lator, which is characterized by the fact that, in order to increase productivity and reliability, it is equipped with a bar with a stop, one end of which has a grip in the form of a sleeve with two longitudinal and diametrically located through grooves, and hooks fixed in them in the form of flat springs with internal oblique protrusions ", and the other end of the rod is threaded and has a handle interacting with it, which rests on the body of the power accumulator with the help of a bearing.

The invention relates to garage equipment and can be used for repair work.

Known device for assembling and disassembling assemblies and units, containing a table with fixing and pressing devices 1 1.

The closest technical solution to the invention is a device for assembling and disassembling power accumulators, containing a table on which the power accumulator is fixed, and a power mechanism designed to compress the spring of the power accumulator 2).

The disadvantages of the known devices are low performance and unreliability.

The aim of the invention is to improve the performance and reliability of the device.

This goal is achieved by the fact that a device for assembling and disassembling energy storage devices, containing a table on which the energy storage device is fixed, and a power device. khanism intended for squeezing. energy accumulator spring, equipped with a bar with a stop, one end of which has a grip in the form of a sleeve with, ”. the end of the rod is threaded and has a handle interacting with it, which rests on the body of the energy storage device with the help of a bearing.

In Fig.l shows the device, partial cutout, in the initial stage of disassembly; figure 2 - the same, in the final stage of disassembly; figure 3 is a view of the grip from the end; figure 4 is the same, longitudinal section of the capture; figure 5 - the same, the tie rod to be removed.

The device for assembling and disassembling power accumulators contains a table with fasteners and a power mechanism (not shown), a bar 1 s. stop 2, grip 3, which consists of bushing 4, which has two longitudinal grooves 5, in which mustache. ". two hooks .b with internal oblique protrusions 7 are added. , a thrust bearing 9 is installed on it and the handle 10 is screwed on.

The energy storage device consists of a housing 11 in the form of a cup, closed by a lid 12, which has a fitting for supplying the working medium under pressure (not shown) and connected by bolts 13 to the housing 11. A spacer spring is installed in the housing 11. 14, abutting against the brake cuff 15. A rod 16 passes through the housing ll and is attached to the brake cuff 15 by means of a movable stop 17, which is fixed to the rod .16 by a split spring ring 18 installed in the groove 19 of the rod 16.

The device for assembling and disassembling energy storage devices works as follows.

Since the spacer spring 14 constantly presses the brake cuff

15 to the cover 12, the working medium is fed into the fitting under the cover 12, thereby releasing the rod 16 from the load, the grip 3 is introduced into the opening of the brake cuff, which, with its oblique protrusions 7 of the hooks b, pushing back the movable stop 17, the grip. The spring split ring 18 is pulled out and takes it out, completely freeing the rod 16. After that, the pressure of the working medium with the brake cuff 15 decreases, and the rod 1 is inserted into the axial hole in the housing 11 released from the rod 16 so that the stop 2 interacts with the brake cuff 15 , on the threaded end of the rod 1, the bearing 9 is sequentially installed and the handle 10 is screwed, compressing the spacer spring 14, after which the bolts 13 are unscrewed, the cover is removed

12. By rotating the handle 10 in the opposite direction, the spring is released and the entire device is removed.

For the assembly of energy storage devices, the whole process is carried out in the reverse order.

Thus, the use of the proposed device for assembling and disassembling energy storage devices made it possible to install and dismantle energy storage devices faster, with greater risk.

Editor N. Pushnenkova Techred B. distant Proofreader M. Demchik

Order 2901/23 Circulation 1079 Subscription

VNIIPI of the USSR State Committee for Inventions and Discoveries

113035, Moscow, Zh-35, Raushskaya nab., 4/5

Branch of the PPP "Patent", Uzhgorod, st. Project, 4

Sale of stands S-1 for disassembling and assembling a spring energy accumulator from a warehouse (St. Petersburg, Moscow, Chelyabinsk, Rostov-on-Don, Kazan) from a manufacturer, production at manufacturing plants and supplies.
For price lists with prices for equipment for repair and maintenance of brake systems, please contact the department of equipment for car service.

Stand С-1 designed for the repair of the spring energy accumulator of the brake chamber 661-3519XXX (manufactured by ZAO Kamsky Plant of Brake Equipment and Aggregates, Naberezhnye Chelny) of the brake system of KAMAZ vehicles in the conditions of service stations, motor transport companies and repair shops.

Technical characteristics of stand C 1:

Stand С-2 intended for repair of the spring brake chamber 100-3519XXX of the brake system of KAMAZ vehicles.

You can order and buy stand C-1, C2 for the repair of an energy storage device with the order of shipment by transport companies to the following cities: Arkhangelsk, Vladivostok, Volgograd, Voronezh, Yekaterinburg, Izhevsk, Irkutsk, Kazan, Kemerovo, Krasnodar, Krasnoyarsk, Moscow, Nizhny Novgorod, Novosibirsk , Omsk, Orenburg, Penza, Perm, Rostov-on-Don, St. Petersburg, Samara, Saratov, Tyumen, Ufa, Cheboksary, Chelyabinsk, Yaroslavl and other regions of Russia.

194292, Saint Petersburg,
5th Upper Lane, 15, letter A, office. 308

(812) 424-18-16

Free call within Russia: 8-800-333-91-80

121354, Moscow
Dorogobuzhskaya st., 14, building 1, gate 25

454053, Chelyabinsk
Troitsky tract, 21Zh, pom. 27

420087, Kazan
st. Motherland, 7

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The content of the article "Do-it-yourself repair of KamAZ energy storage devices" will start with theory, we will find out what energy storage devices are, what they consist of and how they can be repaired with our own hands. At the end, you will find a practical video on repairing energy storage devices.

Several types of energy storage devices are used on a KAMAZ vehicle. They all have three parts. 1. The lower part is attached to the brake caliper bracket with M16 studs. 2. The middle part is made of aluminum alloy and is connected to the lower part by a two-bolt clamp. 3. The upper part is a steel glass, connected to the middle part by 8 M8 bolts.

Before repairing the KamAZ energy storage device, it is necessary to clean, wash and dry. Before disconnecting the lower part from the middle, it is necessary to supply air to the parking brake chamber with a pressure of at least 5 atm. In order to drown the working rod and prevent the spring from firing, then remove the clamp and remove the rubber diaphragm. Then turn off the air supply and unscrew the plug of the working rod with a wrench No. 36. Reapply air to the parking brake chamber. Inside the stem there is a restraining bolt with a support bearing, which is secured with a retaining ring.

We continue to reanimate KAMAZ further and, having removed the retaining ring with the help of an awl, we release the stem for further disassembly. This is followed by an operation for which either a hydraulic press or a special clamp should be used. Having tightened the stem with a press or a clamp, thereby preventing the parking brake spring from firing in order to avoid injury, unscrew the bolts securing the upper glass from the middle part.

Then, relaxing the clamp (press), release the spring. If, when air is supplied to the parking brake chamber, the rod cannot be sunk, it is necessary to sacrifice a glass by drilling a couple of holes at a distance of 60 mm from the middle part. Using the same clamp or press, sink the rod to its full depth and insert the stop pins into the drilled holes (bolts of at least 8 mm can be used), preventing the piston from returning independently. By removing the retaining ring inside the stem, you can get rid of the stop fingers, also using a press or a clamp. Further, according to the previous scenario, we remove the order book.

After cleaning, troubleshooting parts, replacing necessary parts and a repair kit, the assembly is carried out in the reverse order with the implementation of safety measures. After assembly, the operation of the finished energy storage device is checked using a compressor.

For a better assimilation of information, watch a video on repairing energy storage devices with your own hands:

You can ask your questions on our Kamaz-forum, where competent and experienced drivers will answer you.A stand for repair and testing of spring power accumulators, containing a frame base on which technological equipment is mounted, including a feed mechanism in the form of a hydraulic cylinder, a hydraulic pump with an electric motor, an arbitron and a reservoir for hydraulic oil with a filter, characterized in that the feed mechanism contains a fixing unit made in in the form of an adjustable support cross with a mounting hole, with the possibility of disassembling the parts of the energy storage, and the adjustable support cross makes it possible to install any standard size of the energy storage.MM1K - Early termination of the patent (certificate) of the Russian Federation for a utility model due to failure to pay the fee for maintaining the patent (certificate) in force in due timeDate of termination of the patent: 22.04.2008Notice published: 20.09.2010 BI: 26/2010Total documents: 758916

Application for invention: 26414

Invention: 621900

Useful model: 110602

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