The rear driving axle MAZ-103 (Figure 5.3) is made according to the classical scheme with a double spaced main gear and shifted from transverse axis bridge by bevel gear. It consists of a crankcase, central bevel gear, planetary wheel gears and shoe brakes.
1 – control plug; 2 – wheel drive cover; 3 – biscuit; 4 – emphasis; 5 – drive gear; 6 – drove; 7 – lock-nut; 8 – hub bearings; 9, 15 - cuffs; 10 – oil catcher; 11 – brake shoe; 12 – spring; 13, 17 – spherical bearing; 14 – front fist support; 16 – expanding fist; 18 – back support of the fist; 19 – oiler; 20 – adjusting lever; 21 – brake chamber bracket; 22 - bridge housing; 23 - bevel gearbox; 24 – control valve; 25 – brake shield; 26 – support; 27 – pads axis; 28 – bronze bushing; 29 – ABS sensor; 30 – brake drum; 31 – bolt; 32 - pin; 33 – nonsense; 34 – semiaxis; 35 – driven gear hub; 36 – screw, 37 – driven gear; 38 – bearing; 39 – satellite; 40 – satellite axis
Drawing5 . 3 – MAZ-103 drive axle
The wheel drive is a planetary reduction gear consisting of spur spur gears with external and internal gearing. Pinion gear 5 mounted on half-shaft splines 34. Four satellites 39 on bearings 38 installed in carrier slots 6. The carrier is rigidly connected to the wheel hub 33. Driven gear 37 through the hub 35 rigidly connected to the journal 32, the hub is held against axial movement by a nut 36. Axis movement 34 limited to rusks 3 and focusing 4.
Hub rear wheel 33 trunnion mounted 32 on tapered roller bearings 8. Bearing adjustment 8 carried out by a nut 36, which is locked with a lock nut 7 ... Cuffs 9 do not allow oil from the axle housing to get to the shoe brakes. Trunnion 32 bolted to the bridge case 31. On the hub bolts 33 brake drum installed 30. In the wheel gear cover 2 the control plug is screwed in 1 and an oil drain plug.
Shoe brakes are placed between the caliper 26 and brake drum 30. Pads 11 mounted on axles 27 in the support 26 on bronze bushings 28 and are pressed against the expander profile 16 clamping spring 12. Fist 16 installed in supports 14 and 18 on spherical bearings 13 and 17. At the end of the expander 16 adjusting lever installed 20 , inside which there is a mechanism for automatically maintaining the set gap between the pads 11 and brake drum 30.
Oil catcher 10 serves for collecting and discharging to the outside through the channel in the hub 33 leaked through the cuff 9 oils. Oiler 19 designed to supply grease to the spherical bearings of the expander support, to lubricate the bearing of the front support 14 expander and pad axles 27 there are grease fittings and check valves on the brake shield.
Bevel gearbox 23 placed in the axle housing 22 From the left side. It consists of a pair of bevel gears 3 and 17 with circular teeth and differential. The transmission angle is 90 °. Pinion gear 17 installed in a glass 20 on two tapered roller bearings 18 and 21, which are adjusted using shims 1. The moment to the gear is transmitted through the flange 23. Cuffs 22 designed to seal the flange. Driven gear 3 attached to the differential cup 5 bolted 9. Pins 10 are designed to limit deformation of the differential bearing supports. Inside the differential cups 5 and 13 accommodates a bevel differential with two half-axle gears 14 and four satellites 7 rotating on the spikes of the cross 6.
Output: In the course of the work, the design of the gear main gears, the interwheel differential of cars and buses, as well as their axle shafts were studied.
The city bus MAZ-103 was developed as an alternative to similar equipment of Hungarian, Russian and Ukrainian production. The first production model of the Minsk Automobile Plant rolled off the assembly line in 1996. The low floor position and the absence of steps make it easier for passengers to board and disembark at stops. The car combines quality, comfort and affordable cost. It is operated in Belarus, Russia, Europe and Asia.
As a basis for the product, the engineers took the best examples of urban transport that were used at that time, adapting it to poor quality roads.
The MAZ-103-485 bus has the following technical characteristics:
- length - 1200 cm;
- width - 250 cm;
- height - 250 cm;
- weight without refueling - 18000 kg;
- wheelbase front and rear - 205 and 185 cm;
- maximum load on the front and rear axle - 6500 and 1500 kg;
- turning radius - 1125 cm;
- floor height - 34 cm;
- aisle between the seats - 80 cm;
- number of seats - 25;
- passenger capacity - 100 people;
- maximum speed - 110 km / h;
- wheels - disc 8.25 × 22.5 with tires 11 70R22.5;
- suspension - independent pneumatic with telescopic shock absorbers.
A feature of the MAZ-103-075 bus is the rear location power plant... Due to this solution, it was possible to reduce the landing of the car and make it more stable when cornering and in strong crosswinds.
Engine Description:
- type - diesel;
- brand - MMZ D-260.5;
- power - 230 hp;
- working volume - 6.4 l;
- fuel consumption per 100 km in city mode - 26 liters;
- gearbox - mechanical;
- cooling system - forced water.
The power plant is fixed to the frame with four shock absorbers. Due to this, vibration in the cabin is practically not felt. The later model of the MAZ-105 articulated bus is equipped with an OM906LA engine with an environmental class Euro-5 and automatic transmission gears ZF.
Equipment
Basic model at the car factory is equipped with two rows of seats. There are double chairs on the left, and single chairs on the right. The all-welded frame is resistant to vertical and torsional loads. The machines of the last years of production are equipped with Mogilev single-chamber double-glazed windows with reflective ultraviolet spraying. Thanks to this, in the summertime, a comfortable temperature is maintained in the cabin.
The MAZ-105 bus is equipped with the following options:
- automatic shock absorbers that level the body when there is a difference in load and when driving on an inclined road;
- tinted glass, cutting off solar radiation;
- shock and sharp object resistant plastic seats;
- ceiling fans that remove polluted air from the passenger compartment when standing in traffic jams;
- LED board that broadcasts information about the route of movement and advertisements;
- plastic handles located at different heights, convenient for passengers of tall and small stature;
- automatic fire extinguishing system, triggered without human intervention;
- interior heater with thermal barrier on the doors.
The manufacturer produces school buses with two rows of seats and a reinforced frame. For the needs of public utilities, mobile bathrooms are produced, which go to places of mass gathering of people on city streets and squares.
Prices
In comparison with the prices of foreign analogues, the model is much cheaper, but this does not affect the quality of the car. The technique is powerful, reliable and easy to operate. It is hot in the cabin in summer, air conditioning does not help. It is a hassle to open doors, since the buttons are inconveniently located, you need to constantly bend over to them. Bearings often break, oil seals and gaskets fly.
The cost of the new bus is RUB 3-3.2 million. depending on the configuration. Used models are sold for 1.5-2.4 million rubles, based on condition and mileage. The rental price varies between 1000-1500 rubles. in hour.
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An improved design of an air spring with an air damper for self-regulation of the amplitude and frequency of oscillations of the Volzhanin and KavZ bus systems is presented. In the spring, the extended piston is welded from two serial parts and made of fluoroplastic-4 for operation without lubrication. Check valves are closed with thin elastic tubes, as an elastic rod - a wire with a diameter of 3 mm from spring steel. The modes of operation and dynamic elastic characteristics of the air spring are shown. The optimal design parameters were tested at the stand. Possible rejection of the suspension hydraulic shock absorbers, which simplifies the design, reducing costs and increasing reliability.
1.1 Information about the MAZ-103 bus
Rice. 1. Bus MAZ-103
Brand: ………………………………………………………………… MAZ-103
Manufacturer:……………………… RUE "Minsk Automobile Plant"
Body type: ……………………………………………………………… bus
Number of doors: …………………………………………………………………… ... 3
Overall dimensions, mm ……………………………………… ..11985-2500-2838
Outside turning radius, mm ………………………………………… 11300
Number of places for sitting ……………………………………………… ... 24
Maximum speed, km / h …………………………………………… ..… 80
Engine ……………………………………………… .Deutz BF6M1013EC (E2)
Working volume, l: ……………………… ……………………………………. 7,12
Engine power, kW (hp) ……………………………………… ... 174 (237)
Transmission ……………………… ... Voith Diwa D851.3E (automatic)
Wheels ……………………………………………… .............. disc wheels, 8.25х22.5
2 General form and the device of the suspension units of the MAZ-103 bus
When analyzing the suspension of the MAZ-103 bus, we select the main elements and present a detailed arrangement of the units in order to identify the main failures and malfunctions during the operation of the MAZ-103 bus.
2.1 Front suspension
Rice. 2. The device of the front suspension MAZ-103
1-Cylinder air suspension assembly; 2,3-Nut М30x1,5-6H; 4-Washer 12OT; 8-Bolt М12х1 25-6Н; 9-Nut М8-6Н; 10-Washer 8T; 12-Bolt М8-6gx50; 13-split pin 1.6x20; 14.18-Clutch; 15-Washer 6; 16-worm clamp; 17-Axis; 19-Pull; 20-Shock absorber; 21-Hub with fist and brakes, right; 22-base of the front suspension; 23-Amplifier; 24-Nut; 25-Nut М10-6Н; 26-Screw М10-6Н; 27-Cotter pin 5x36; 28-Nut М24х2-6Н; 32-Rod, transverse; 33- Hub with fist and brakes left; 34-Bushing; 35-Rod, transverse; 37-Bolt М18х1.5-6Н; 38-Bolt 3M14x1.5-6gx50; 39-Flanset; 41-Bushing; 42-Key 6x9; 43-Finger; 44-Stand; 45-Piston; 46-Buffer; 47-Sleeve; 48-Washer 14; 49-Washer 14L; 50-Bolt М14х1,5-6gx50; 51-rubber-lined shell; 52-Flanets; 53-Bolt М18х1.5-6Н; 54-Nut М18х1.5-5Н6Н.
2.2 Front suspension
Rice. 3. The device of the front suspension MAZ-103
1-axle front; 2,3-Support; 4,5-Rod is reactive; 6-Shock absorber; 7-Cylinder air suspension assembly; 8-body position regulator; 9-Rod of the regulator; 10-Axis; 11-Bushing; 12-Flange; 13-Ryachag; 14-Bolt 3M14x1.5x6gx50; 15-split pin; 16-Nut М8-6Н; 17-Bolt М8х6gx50; 18-Bolt М8х6gx25; 19-Washer 8T; 20.28-Buffer; 21-Washer; 22-Bolt 3M24x2-6g-60; 23-Cotter pin 1.6x400; 24-split pin 5x36; 25-Nut М30х1.5-6Н; 26-Flange; 27-Piston; 29-Sleeve; 30-Bolt m14x1.5-6; 31-Washer 14; 32-Washer 14; 33-rubber-cord sheath; 35-Tip right; 37-Bolt; 38-Washer; 39-Nut.
2.3 Suspension bar
Rice. 4. The device of the MAZ-103 suspension rod
1-Head; 2-Bolt М12х1.25-6gx60; 3-Bar; 4,5-Hinge; 6,7,16,18,19-Ring; 8-rod head; 9-Hinge; 10-Washer 16ОТ; 11-Bolt М16х1,5-6gx60; 12-Ring 140; 13-Nut М12х1.25-6gx60; 14-Washer 12OT; 15-Trumpet; 17-Hinge.
2.4 Rear suspension
Rice. 5. Rear suspension device MAZ-103
1-transverse link; 2-Beam; 3-cylinder axle lock; 4-hub; 5-The brake is right; 6-Brake left; 7-Cover; 8-Gasket; 9-Washer; 10-Nut; 11-Bolt М12х1-6gx90; 12,13-rotary fist; 14-Lever tropezium left; 15-Tropezium lever, right; 16-Shock absorber; 17.18-Reactive rod; 19-Balon pneumatic; 20-Flange; 21-Plate; 22,29,30-Nut М32x2-6Н; 23-Bolt М24х2-6gx90; 24,25,26,27-Bolt; 28.31-Washer 4; 32,33,34-Washer 16ОТ; 35-Cotter pin 5x45; 36-Cotter pin 6,3x71.
11 12 19 ..4 device, operation and maintenance of components of buses MAZ-103, MAZ-107
4.1 power unit of MAZ-103, MAZ-107 buses, its systems and drives
A description of the engine, GMF, clutch and gearbox, as well as instructions for their operation and maintenance are given in the Operating Instructions for the respective units. If there is a discrepancy between this Manual and the Instructions for the units attached to the bus, then follow the latter.
The power unit is located in the rear overhang on the left side at an angle to the longitudinal axis of the bus.
The complete set of buses with power units is given in table. 1.1.
4.1.1 suspension power unit buses MAZ-103, MAZ-107
The suspension of the power unit effectively reduces shock loads when driving on uneven roads and completely dampens the reactive moments that occur when the engine is running.
The power unit is attached to the bus frame on four supports (two front and two rear). Each support consists of a rubber-metal shock absorber 2 (Fig. 4.1.1.1), bolted to the frame bracket. The power unit is mounted on supports through the engine brackets with bolts and nuts, after tightening the nuts are locked with cotter pins.
MAZ-103, MAZ-107 POWER UNIT SUSPENSION SERVICE
When carrying out TO-1, check the fastening of the brackets, as well as the fastening and condition of the shock absorbers of the suspension of the power unit, tighten if necessary threaded connections regulated moment:
Nuts 5 (Fig. 4.1.1.1) of the power unit mounting bolts must be tightened with a torque of 110 ... 140 Nm and locked with cotter pins;
Nuts of 4 bolts securing the supports to the frame brackets must be tightened to a torque of 25 ... 32 Nm.
Figure 4.1.1.1 - Supports of a power unit with a Daimler engine:
1 - engine bracket; 2 - shock absorber assembly; 3 - frame bracket; 4, 5 - nut
4.1.2 engine fuel supply system
The engine fuel supply system, the diagram of which is shown in Fig. 4.1.2.1, serves for supply, filtration and precise metering of fuel at various engine operating modes. The description of the device and repair of power system devices is given in the Operation Manual and the Engine Repair Manual.
Fuel from fuel tank 2 when the engine is running, it is sucked in by the fuel priming pump of the engine through the coarse fuel filter 5 and the fine fuel filter. From the filter, fuel enters the engine. Excess fuel, and with it air that has entered the system, is discharged through the fuel line to the fuel tank.
On buses with a Daimler engine, a manual fuel priming pump is integrated in the coarse fuel filter.
The fuel supply required for the operation of the engine, PZhD and air heaters is placed in the fuel tank, which is installed on the right side of the bus.
The fuel tank consists of a housing 1 (Fig. 4.1.2.2), a filler neck 3 with a mesh filter 4 and a fuel intake 2. There are partitions inside the fuel tank that increase the rigidity of the tank, prevent fuel agitation and foam formation. At the bottom of the tank
screwed in a plug 5 to drain the sediment. The fuel level in the tank is monitored by an indicator located on the instrument panel. The control lamp comes on if about 30 liters of fuel remains in the tank. The indicator receives a signal from a rheostat fuel level sensor installed in the fuel tank.
The filler neck is closed with a sealed plug, in which the inlet and outlet valves are installed. The outlet valve opens at a pressure of 5.7 ... 18 kPa, preventing an increase in pressure in the tank when the fuel is heated, the inlet valve opens at a vacuum of 1.6 ... 3.5 kPa, preventing a vacuum that occurs when the amount of fuel in the tank decreases.
Polyamide fuel lines low pressure packed in protective shells and fixed to the chassis of the bus with clamps. The method of connecting polyamide fuel lines with fittings is shown in Fig. 4.1.2.3. When assembling the joint, coat clamping ring 4 with LOCTITE 5900.
A coarse fuel filter with a water separator is designed for preliminary cleaning of fuel entering fuel system... Buses with a Daimler engine are equipped with a coarse fuel filter "RACOR" with a built-in manual fuel priming pump. The filter is equipped with an electric heating, which functions in automatic mode... The filter is installed on the suction line of the power system and is attached to the frame bracket.
A heating element is installed in the filter housing, which effectively heats the fuel flow, melting the released paraffin. The filter heater is functional when the ignition key is in the "I" position in automatic mode. When the ignition key is turned to position "0" or "III", the heater is turned off automatically.
Along with a coarse fuel filter, the engine is equipped with a fine fuel filter. The maintenance procedure for the fine fuel filter is given in the "Engine Operation Manual".
Comfortable city bus MAZ 103 is used for passenger transportation. Its production was started in 1996, but 1992 is considered the official year of birth, it was then that MAZ signed an agreement with the German company Neoplan, which specializes in the production of buses. The need to create a local bus production in Belarus was due to the fact that the number of vehicles regularly supplied from Hungary began to noticeably decrease, and the wear and tear of the existing vehicle fleet was already making itself felt.
Unfortunately, there was not a single enterprise in the country that would be engaged in the production of passenger buses, therefore MAZ, the largest machine-building plant in Belarus, had only one way out - to master production on its own. For this, within the framework of the signed agreement, Neoplan transferred the license for the production of the bus to the Minsk plant.
A year later, in 1993, six new buses were produced, which practically did not differ from the base model. However, there was little good in this. First, the cost of the assembled buses was shockingly high at $ 200,000. Not a single enterprise could afford to spend such money on the purchase of transport in the mid-nineties. In addition, used Ikarus from neighboring Germany were much cheaper. Secondly, the bus had many flaws, and its service life on Belarusian roads would be very low.
The question "what to do?" I did not stand in front of the plant for a long time. The decision to adapt the bus to local operating conditions was obvious. No sooner said than done. The designers immediately began to refine the design of the transport and began to look for options for replacing imported elements with more affordable locally produced parts. At the time of work, the bus was assigned the MAZ-101 index. In 1996, the Belarusian plant presented the first low-floor bus in the country - MAZ 103, which was immediately launched into mass production. The price of the renovated transport has dropped by almost 2.5 times. It was possible to reduce the cost of production due to the fact that the share of imported MAZ 103 spare parts decreased to 10-15%.
Comfortable and roomy passenger bus
There is no need to talk about the merits of the low sex. Passengers disembark and disembark more quickly and conveniently, and this, in turn, significantly reduces the travel time along the route. I must say that the MAZ designer failed to fully reproduce the design of the German Neoplan. Due to the fact that the engine had impressive dimensions and was located in the rear of the cabin, the floor was raised there. The stepless entry remains at the front and middle doors, where the floor level reaches 360 mm. Near back door the floor height was increased to 580 mm, requiring two steps.
In general, the MAZ 103 bus turned out to be comfortable, roomy and safe and quickly gained popularity not only in its homeland, but also abroad. In addition, the transport was distinguished by good indicators of maneuverability, which allowed it to feel more confident in conditions of dense city traffic.
The rear axle, which is the driving one, has a bevel gearbox offset from the transverse axis and is made according to the classical scheme. MAZ-103 is presented in several versions: in addition to the main model, the manufacturer also offers a modification for suburban passenger transportation - MAZ-103S. Differences - increased to 45 seating and the absence of a rear door. The base model has several trim levels, differing in passenger capacity and the number of seats. The number of passengers carried is 90 - 100 people, and the number of seats is 21 - 28.
Concerning internal device bus MAZ 103, then the location passenger seats made according to a three-row scheme: on the left side - double, on the right - single. There is a spacious storage area opposite the middle door. The driver's cabin is quite spacious, with a convenient location of the controls. Although compared to Western bus models, dashboard a little angular, the information on it is easy to read.
From the cheapest to the most expensive: engine options vary
The technical characteristics of MAZ 103, along with a modern design and a high degree of comfort, were another reason to be proud of the new bus. The very first models of passenger transport were equipped with YaMZ and MMZ engines, but already during operation it became clear that the Yaroslavl engines did not suit him at all. They were not powerful enough, but noisy, large, heavy and poorly compatible with the gearbox designers proposed.
The engines of the Minsk Motor Plant, with a capacity of 320 hp, at that time turned out to be the best option and for the first few years of production, all low-floor vehicles were equipped with them. Until 2004, MAZ 103 buses were installed and Renault engines... More reliable and powerful (250 hp) they aroused more confidence among the drivers.
MAZ currently offers several engine options, including Mercedes-Benz (231 hp) and Deutz (237 hp). Units of well-known foreign manufacturers are distinguished by a high degree of reliability and comply with stricter environmental standards.
If we talk about the gearbox, then initially the bus was equipped with a 6-speed transmission of its own production, but its incompatibility with a number of engines forced the designers to look for other options and most buses were equipped with a 5-speed Praga gearbox. Recently MAZ offers buses with manual transmission from ZF or from Voith hydromechanical company.
Long-term operating experience of this model has shown that the transport is quite reliable, copes with significant loads, and the possibility of breakdowns is minimized. If repair is necessary, all spare parts for MAZ 103 buses can be purchased through official dealers plant, the benefit of their network is widely developed in our country.
The price of MAZ 103 starts from 4 105 thousand rubles for a new bus.
Photo of a passenger bus MAZ 103
