Steering kamaz. Steering column kamaz: one of the basics of truck management

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1. Purpose and technical characteristics of the KAMAZ vehicle- 5 320

On the roads of our country, you can increasingly see powerful three-axle trucks - KamAZ. Large-scale in-line production of these machines is carried out by the Kama Association for the production of heavy vehicles.

Now KamAZ is at the forefront of the global automotive industry. More than 300 thousand trucks of various modifications are already working on the roads of our country.

KamAZ trucks were designed for mass transportation of goods in all climatic zones. When choosing a scheme new car first of all, the fact that the coverage of most of the roads in our country is designed for axial load the car is not more than 6 tons. And since rear axle For a car with a gross weight of about 16 tons, almost two-thirds of this load - 11 tons - falls on KamAZ trucks with three axles. At the same time, each of the rear axles of the 5320 and 5410 models has a mass of about 5.5 tons. These cars belong to the so-called group B, that is, to cars, one axle of which creates a load on the roadbed of no more than 6 tons.

Performance data
Wheel formula
The mass of the transported cargo or mounted
Fifth wheel load, kg
Curb weight, kg
Gross vehicle weight, kg
Determination of the mass of the equipped car on the road, kg
Go same, for the car total mass, kg:
Maximum travel speed (depending on the gear ratio of the main gear), km / h
Climbing angle,% not less
Control fuel consumption per 100 km of track when driving with full load and a speed of 60 km / h, l:
Cruising range for control fuel consumption, km:
Acceleration time to 60 km / h for a vehicle of full weight, s. not
Braking distance with full load when driving at a speed of 60 km / h to a full stop, m, when using a working brake
braking system from a speed of 40 km / h:
External overall radius R of the vehicle turning along the front bumper, m
Fuel tank capacity, l:
Disc wheels

2. Assignment of rudders

Steering serves to change and save the selected direction of movement of the vehicle. The main way to change the direction of travel is to turn the front idler wheels in the horizontal plane relative to the rear wheels. The steering control must ensure correct turning kinematics and driving safety, small efforts on the steering wheel, prevent transmission by push from uneven road to wheel... The steering gear increases the driver's effort to the steering wheel and improves the steering precision. As a result, it is possible to drive the vehicle when the amplifier is not working, for example, when the engine stops suddenly, which increases driving safety.

The hydraulic booster makes driving easier and safer. The hydraulic booster, using engine power to steer and hold the wheels, reduces driver fatigue, improves maneuverability and controls difficult conditions such as sudden tire damage. When driving on uneven roads and terrain, the hydraulic booster reduces shock loads in the steering, reducing the likelihood of damage to it, and increasing the comfort and safety of driving.

The steering gear transmits the efforts of the driver and the hydraulic booster to the steered wheels, ensuring their rotation at mutually different angles. This reduces slip and therefore tire wear and makes steering easier.

3. The device and atsteering principle

On a KamAZ - 5320 car, mechanical steering with a hydraulic booster is used. The steering mechanism with an angular gear reducer is equipped with a steering gear with working pairs of the screw-nut type with circulating balls and a rack-toothed sector. The steering gear ratio is 20: 1.

The hydraulic booster is made according to the scheme with constant fluid circulation, which helps to reduce the pump load. The maximum fluid pressure in the system is 7500 - 8000 kPa. The hydraulic booster cylinder is integrated in the steering box. The spool-type control valve is equipped with centering springs and reaction plungers, which create a sense of resistance to turning the wheels on the steering wheel, The pump of the hydraulic booster is rotary-vane type, double-acting, driven by a gear fuel pump engine. The radiator of the hydraulic booster, which provides cooling of the circulating fluid, is installed on the radiator of the cooling system.

Steering drive - mechanical, with articulated joints of parts. The steered wheels are installed with an inclination - the camber in the transverse steered wheels are inclined in the transverse direction by 8 degrees, in the longitudinal plane by 3 degrees to create stabilization of the steering of the wheels. The maximum wheel steering angles, equal to 45 degrees, provide a minimum turning radius of the vehicle along the outer wheel drive of 8.5 m with a width of the occupied corridor of 4.5 m.

4. Purpose of the device and the principle of operation of steering mechanismsdriving a KamAZ car

The steering control consists of a steering wheel, a steering column, a cardan transmission, a bevel gear, a steering gear, a hydraulic booster (including a control valve, a radiator, a pump with a reservoir) and a steering gear.

Steering column consists of a shaft, a pipe and is attached to the upper panel of the cab with a bracket, in the lower part - to a pipe fixed to its floor,

The shaft is mounted in the tube on two ball bearings. The upper bearing is secured by thrust and clamping rings, the lower by a lock washer and nut. The axial clearance in the bearings is also regulated by nut 8. The bearings are equipped with seals.

The steering wheel is attached to the upper end of the shaft. The lower end of the shaft is provided with a groove for attaching the universal joint yoke.

The bearings are lubricated during assembly.

Cardan transmission transmits efforts from the steering column shaft to the drive gear of the bevel gear and consists of shaft 6, sleeve 8 and two cardan joints.

Each pivot consists of forks and a cross with four needle bearings mounted in the machine tools. The bearings are equipped with sealed rings; during assembly, 1 - 1.2 g of grease is placed in each of them and cover the splines of the rod and bushings with it.

When assembling the cardan transmission, the splines of the shaft and the bushing are connected so that the forks of the hinges are in the same plane. This ensures that the shaft rotates evenly.

The hinge fork, connected to the bushing, is installed on the steering column shaft; the fork of the shaft is connected to the shaft of the drive gear of the bevel gear. The forks are fixed with wedge screws entering the hole, locked with nuts and cotter pins.

Angle reducer transfers the force from the cardan transmission to the steering gear screw. It is attached to its crankcase with pins. The gear ratio of the gearbox is 1: 1.

The shaft with the pinion gear is mounted in the housing on ball and needle bearings. The ball bearing is fixed on the shaft with a nut, the thin edge of which is pressed into the groove in the shaft. The needle bearing is secured with a circlip. The driven gear is installed in the gearbox housing on two ball bearings secured by a nut with a lock washer. Axial forces are absorbed by the cover and the thrust ring. The driven gear is connected to the screw by splines, which makes it possible to move it relative to the gear. In this case, the slide valve of the hydraulic booster, mounted on the shaft, can move relative to the housing. The gearing of the gears is adjusted by changing the thickness of the shims.

Steering gear configured in conjunction with a bevel gear, control valve and hydraulic booster cylinder. Bolted to the left spring bracket.

The steering gear housing contains: a screw with nuts, an amplifier piston with a toothed rack and a toothed sector with a bipod shaft. The steering crankcase is also a hydraulic booster cylinder.

The nut is connected to the piston with set screws. The screws become nailed after assembly.

To reduce frictional forces in the steering mechanism, the screw rotates in a nut on balls located in the grooves of the screw and nut. In the hole and groove of the nut, two grooves of circular cross-section are installed, forming a tube. When the screw turns in the nut, the balls, rolling along the helical groove, fall into the tube, consisting of grooves, and again into the helical groove, i.e. continuous circulation of the balls is ensured.

The toothed sector with the bipod shaft is mounted on a bronze bushing in the steering gear housing and in the opening of the side cover attached to the crater. To adjust the gap in the engagement of the rack with the sector, their teeth have a variable thickness along the length.

Adjustment of the engagement and fixation of the toothed sector with the bipod shaft in the axial direction is provided by a screw screwed into the side cover.

The head of the adjusting screw enters the bipod shaft hole relative to the screw head should not exceed 0.02-0.08 mm. It is regulated by the selection of the thickness of the adjusting washer. After adjusting the gear clearance, the screw is locked with a nut. A bypass valve is screwed into the crankcase to release air from the hydraulic booster. The valve is closed with a rubber cap. A bipod is installed on the splines of the shaft and locked with bolts. A drain plug is screwed into the lower part of the crankcase.

Hydraulic booster consists of a management clan ( switchgear) spool type, hydraulic cylinder-crankcase, pump with reservoir, radiator, pipelines and hoses.

The control valve body is fastened with studs to the bevel gear body. The control valve spool is mounted on the front end of the steering screw in thrust bearings. The inner rings of large-diameter bearings are pressed with a nut to the reaction plungers located in three holes in the body together with centering springs 4, 35. The thrust bearings are fixed to the screw with a collar and a nut by a spool. The conical washer is installed under the nut with the concave side towards the bearing. Grooves are made in the valve body on both sides. Therefore, thrust bearings, a spool with a screw can move in both directions from the north position by 1, 1 mm (spool stroke), while shifting the plungers and compressing the springs.

Bypass and safety valves and plungers with springs are also installed in the openings of the control valve body. The safety valve connects the high and low pressure oils at a pressure of 6500-7000 kPa. The bypass valve connects the cylinder cavities when the pump is not running, reducing the resistance of the amplifier when turning the wheels.

The power steering cylinder is located in the steering box. The piston of the cylinder is equipped with an O-ring and oil channels.

Hydraulic booster pump installed between the engine blocks. The pump shaft is driven in rotation by the high pressure fuel pump gear.

Vane-type pump, double-acting, i.e. in one revolution of the shaft, there are two suction and heating cycles. The pump consists of a cover, a housing, a rotor with a shaft, a stator and a distributor disc. The shaft, on the splines of which the rotor is installed, rotates on ball and needle bearings. The drive gear is locked on the shaft with a key and is secured with a nut. Blades are installed in the radial slots of the rotor.

The stator is mounted in the housing on pins and is bolted to the distributor disc.

The rotor with blades is installed inside the stator, the working surface of which has an oval shape. When the rotor rotates, its blades under the action of centrifugal forces and the oil pressure in the central cavity of the rotor are pressed against the working surfaces of the stator, distributor disc and housing, forming chambers of variable volume.

With an increase in their volume, a vacuum is created, and oil from the tank enters the chambers. Subsequently, the blades slide along the stator surfaces, move along the slots to the center of the rotor, the volume of the chambers decreases, and the oil pressure in them increases.

When the chambers coincide with the holes in the distributor disc, oil enters the pump discharge chamber. The working surfaces of the housing, stator rotor and distribution disc are carefully ground to reduce oil leakage.

A bypass valve with a spring is installed in the housing cover. A safety ball valve with a spring is located inside the bypass valve, which limits the pressure in the pump to 7500-8000 kPa.

The bypass valve and the calibrated hole connecting the pump discharge cavity with the outlet line limit the amount of oil circulating in the amplifier when the pump rotor speed increases.

A manifold is attached to the pump casing through a gasket, which ensures the creation of excess pressure in the suction channel, which improves the operating conditions of the pump, reducing noise and wear of its parts.

A tank with a filler cap and a filter is screwed to the pump body. The reservoir lid is bolted to the filter post.

The joints of the cover with the bolt and the body are sealed with gaskets. A safety valve is installed in the lid to limit the pressure inside the tank. The oils circulating in the hydraulic system of the amplifier are cleaned in a strainer. In a traffic jam filler neck the oil indicator is strengthened.

Radiator designed to cool the oil circulating in the hydraulic booster.

The radiator in the form of a double-bent ribbed tube made of aluminum alloy is attached in front of the radiator of the engine lubrication system with straps and shrouds.

The hydraulic booster units are interconnected by high and low pressure hoses and pipelines. High pressure hoses are double braided; the ends of the hoses are sealed into the ferrules.

Steering drive consists of a bipod, longitudinal and transverse steering rods and levers.

Levers steering knuckles, pivotally connected to the transverse link, forms a steering link, which provides rotation of the steered wheels at mutually different angles. The levers are inserted into the tapered holes in the knuckles and are secured with dowels and nuts.

Lugs 8 are screwed onto the threaded ends of the transverse link, which are the heads of the hinges. The rotation of the tips adjusts the toe-in of the front wheels, which compensates for their possible divergence in operation due to wear of the parts, which increases tire wear and makes driving heavier. Rod ends and bolted. The rod joint consists of a pin with a ball head, bushings pressed against the head by a spring, fasteners and seals. The spring provides a backlash-free connection and compensates for wear on the surfaces of the parts.

The longitudinal link is forged together with the hinge heads. The hinges are closed with screw caps and sealing strips. The hinges are lubricated through the nipples. Swivel axles - wheel pivots are installed with lateral slopes of the transverse plane inward by 8 degrees. Therefore, when turning the wheels, the front of the car rises slightly, which creates stabilization of the steered wheels (the tendency of the steered wheels to return to the middle position after turning).

The tilt of the pivots of the longitudinal plane back by 3 degrees creates stabilization of the steered wheels due to the centrifugal forces that occur when turning.

When the steering wheel is released after a turn, the weight and centrifugal forces create stabilizing moments that automatically return the steered wheels to the center position. The axes of rotation of the wheels are inclined with the outer ends down by 1 degree, forming wheel camber, which makes it difficult to reverse camber in operation due to bearing wear. Camber driving increases tire wear and makes driving harder.

Steering operation ... In straight-line movement, the control valve spool is held by springs in the middle position. The oil supplied by the pump passes through the annular slots of the control valve, fills the cylinder cavities and is drained through the radiator into the reservoir. With an increase in the rotor speed, the intensity of circulation and heating of the oil in the hydraulic booster increases. The bypass valve restricts the oil circulation. With an increase in oil consumption, a pressure drop is created on the end surfaces of the valve as a result of an increase in the calibrated hole. When the force from the pressure difference on the valve exceeds the spring force, it will move and connect the pump discharge chamber to the tank. In this case, most of the oil will circulate along the pump - tank - pump circuit.

When the steering wheel is turned, the force through the cardan transmission, the angular gearbox, transfers to the steering gear screw.

If a significant force is required to turn the wheel, then the screw. screwed into the nut, (or unscrewed from the non) by displacing the thrust bearing and the spool, while moving the plunger and compressing the centering springs. The displacement of the spool in the body changes the cross-section of the annular slots associated with the cylinder cavities. A decrease in the cross-section of the drain slots with a simultaneous increase in the amount of oil due to an increase in the cross-section of the discharge slot leads to an increase in pressure in one cylinder cavity. In another cavity of the cylinder, where the change in the cross-sections of the slots is opposite, the oil pressure does not increase. If the difference in oil pressure on the piston creates a large resistance force, then it begins to move. The movement of the piston through the toothed rack causes the sector to turn and further, through the steering gear, to turn the steered wheels.

Continuous rotation of the steering wheel is supported by the mixing of the spool in the housing, the differential pressure of the oil in the cylinder chambers, the movement of the piston and the rotation of the steered wheels.

Stopping the steering wheel will cause the piston and steered wheels to stop at the moment when the piston, continuing to move under the influence of the oil pressure differential, moves the spool screw axially to the middle position. Changing the cross-sections of the slots in the control valve will lead to a decrease in pressure in the working cavity of the cylinder, the piston and steered wheels will stop. Thus, the "follow-up" action of the amplifier in the angle of rotation of the steering wheel is provided.

The delivery line of the pump supplies oil between the plungers. The greater the resistance to turning the wheels, the higher the oil pressure in the line and at the ends of the plungers, and, consequently, the forces of resistance to their movement when the valve is displaced. This creates a "follow-up" action according to the force of resistance to turning the wheels, i.e. "Feeling of the road."

At the limit value of oil pressure of 7500 - 8000 kPa, the valves open and, protecting hydraulic system amplifier from damage.

Release the steering wheel to quickly exit the bend. By the combined action of the reaction plungers and the springs, the spool is biased and held in the middle position. The steered wheels, under the action of stabilizing moments, turn to the middle position, displace the piston and push the liquid into the drain line. As the center position is approached, the stabilizing moments decrease and the wheels stop.

Spontaneous rotation of the wheels under the influence of impacts on uneven roads is possible only when the piston moves, i.e. pushing out a portion of oil from the cylinder into the tank. In this way, the booster works as a shock absorber, reducing shock loads and minimizing spontaneous steering wheel movements.

In the event of a sudden stop of the engine, pump, or loss of oil, it remains possible to control the driver's effort. The driver, turning the steering wheel, displaces the plungers with a spool against the stop in the control valve body, and then the rotation is provided only due to the mechanical connection of the steering parts. The force on the steering wheel when the piston moves, the bypass valve located in the plunger ensures the flow of oil from the cylinder cavities.

5. Malfunctions arising from esteering operation

repair car steering

Cause of malfunction	Remedies
Increased (more than 25 0 ) total play of the steering wheel
Increased clearance in securing the worm with a roller	Adjust the engagement of the worm with the roller
The appearance of a gap in the worm bearings	Adjust the worm bearings
Wear of cardan joint parts	Replace worn parts
Wear of fastening parts of the steering rod joints	Replace worn parts
Sticking steering gear or high effort when turning the steering wheel
Worn or damaged bipod shaft roller bearing	Replace the bipod shaft
Stuck, squeaks or clicks in the steering gear
Excessive wear on the roller or worm, chipping and dents on their surface.	Replace the worm or bipod shaft included)
Axial movement of the worm shaft
The appearance of a gap in the worm bearing	Adjust the bearings

Steering repair technological process

Name of service	Service code for OKUN	Job number as part of the service	Brief description of the work performed as part of the service
Routine work (about types Maintenance)			A set of works established by the documentation of the manufacturer or the applicant enterprise for mileage trucks and buses carried out in the form of preventive measures for the relevant units and assemblies
Wheel alignment adjustment			Checking and adjusting the clearance in the bearings of the hubs of the steered wheels and the toe-in of the steered wheels
			Determination and fixation of the maximum steering angle of the steered wheels
			Determination of violations of parallelism of bridges and their displacements along the axis of a truck and a bus, adjustment of parallelism
			Determination and adjustment of the offset of the axles of articulated buses and adjustment of the skid of the rear articulated part
Steering adjustment			On the steering gear
			Checking the tightness of the steering gear
			Steering gear adjustment
			Checking and adjusting the power steering
			By drive

Wheel alignment adjustment 017107	Wheel alignment angles (degrees)
Steering adjustment 017113	Serviceability of the steering and compliance with the established requirements of the adjusting parameters, including: Rotation of the steering wheel without jerking or jamming; Absence of spontaneous steering wheel rotation in AMTS with power steering; Absence of movements of parts and steering units not provided for by the design; Lack of parts with traces of deformation, cracks and other defects; Compliance with the requirements for the operation of the power steering pump drive; Total steering play

6. Gadgets, used in the repair of steeringeKAMAZ

Stand for checking and adjusting the steering wheel alignment angles

Wheel alignment ruler

Steering tester

Installation for testing the power steering

Installation for measuring the pressure and performance of the hydraulic booster

Drive belt tension tester

Tool for checking the presence of gaps in the joints of the steering rods

Tire pressure gauge

Ruler for adjusting the connection of the steering rods to the steering gear

SI name		State Register No.	Application
Checking the wheel geometry (camber)
Wheel alignment rulers			For checking wheel alignment during vehicle operation. MPI - 1 year.
Devices for control of convergence of front wheels of cars			For measuring and setting the angles of convergence of the front wheels of cars and control over the correct installation of wheels during the operation of the car. MPI - 1 year.
Devices for the control of the geometry of the chassis of cars			For checking the geometry of the running gear of various vehicles. MPI - 1 year.
Stands for control and adjustment of wheel axle geometry	Models 8670, 8675		For suspension adjustment, measuring and setting the angles of steered and non-steered wheels of cars in the conditions of motor transport enterprises, service stations, car factories and diagnostic centers. MPI - 1 year.
Steering play
Car steering backlash			To control the total backlash of the steering systems of cars, regulated by GOST 5478-91, they can be used at motor transport enterprises, in bus and taxi fleets, at service stations, in cooperative and private workshops for repair and maintenance of cars in collective garages and auto inspection points, at traffic police control posts , individual owners of PBX. MPI - 1 year.

Maintenance of steering KamAZ

No. of work performed	Name and content of works	Place of work	Devices, tool, fixtures, model, type	Technical requirements and directions

	Check the cotter pin nuts of the ball pins of the steering rods		Elevator electromechanical P-128	No cotter pins allowed
		In the left front of the car	Elevator electromechanical P-128	No cotter pins allowed
	Check the cotter pin of the steering knuckle levers	In the right front of the car	Elevator electromechanical P-128	No cotter pins allowed
	Check the cotter nuts of the bolts securing the bipod of the steering mechanism		Elevator electromechanical P-128	No cotter pins allowed
	Check the clearance in the joints of the steering rods		Set of probes No. 2 GOST 882-75	The presence of increased backlash is not allowed
	Check the clearance in the lower hinge cardan shaft steering	Inside and front of the car	Set of probes No. 2 GOST 882-75
	Check the clearance in the upper joint of the propeller shaft of the steering	Inside and front of the car	Set of probes No. 2 GOST 882-75	Backlash in the hinges is not allowed
	Check the axial clearance of the pivot joint	In the front of the car	Set of probes No. 2 GOST 882-75
	Check the radial clearance of the pivot joint	In the front of the car	Testing device front axle T-1, Electromechanical hoist P-128	The gap should not exceed 0.25 mm
	Hang up the front wheels	In the front of the car	Elevator electromechanical P-128	Wheels must not touch the floor
	Check the condition of the bearings of the pivot connections	In the front of the car	Steering tester K-187	No perceptible gap allowed
		In the left front of the car
	Check the installation of the hub bearings	In the right front of the car		Wheels should rotate smoothly, without swinging in a vertical plane
		In the left front of the car
	Remove the hub cover, unlock and unscrew the locknut, remove the lock and lock washer	In the right front of the car	Front wheel hub bearing nut wrench	Nuts must have clear edges
		In the left front of the car		Wheels should rotate smoothly, without swinging in a vertical plane
	Install the bearings in the correct position	In the right front of the car		Wheels should rotate smoothly, without swinging in a vertical plane
		In the left front of the car	Torque wrench
	Tighten hub nut, install washer and locknut.	In the right front of the car	Torque wrench	Tighten the nut with a force of 140-160N * m
	Check wheel alignment	In the front of the car	Ruler for checking wheel alignment K-624
	Adjust the toe-in by changing the position of the rod in the tip	In the front of the car	Ruler for checking wheel alignment K-624, tool kit 2446	Toe-in should be 0.9-1.9 mm
	Check steering wheel free play	In the front of the car		Free play should not exceed 25є
	Check the axial movement of the steering wheel	Inside the car		No axial movement allowed

7. Methods for restoring rudder assembliesth control of the KamAZ car

To determine the degree of wear and the nature of the repair of parts, the steering gear is disassembled. In this case, pullers are used to remove the steering wheel and steering wheel bipod. The main defects of the parts of the steering mechanism are: wear of the worm and the roller of the bipod shaft, bushings, bearings and their places of landing; breakages and cracks on the crankcase mounting flange; wear of the hole in the crankcase for the steering arm shaft sleeve and parts of the ball joints of the steering rods; bent rods and loosening of the steering wheel on the shaft.

The steering gear worm is replaced with significant wear of the working surface or peeling of the hardened layer. The bipod shaft roller is rejected if there are cracks and dents on its surface. The worm and the roller are replaced at the same time.

The worn out bearing journals of the bipod shaft are restored with chrome plating, followed by grinding to the nominal size. The neck can be restored by grinding to the repair size of the bronze bushings installed in the crankcase. The worn threaded end of the steering arm shaft is restored by vibration-arc surfacing. Previously, on a lathe, the old thread is cut, then the metal is welded, grinded to the nominal size and a new thread is cut. The bipod shaft with traces of twisted slots is discarded.

Worn bearing seats in the steering gear housing are restored by installing an additional part. To do this, the hole is bored, then the bushings are pressed in and their inner diameter is machined to match the size of the bearings.

Fractures and cracks on the crankcase mounting flange are eliminated by welding. Gas welding is used and general heating of the part is carried out. The worn hole in the crankcase for the steering bipod shaft sleeve is deployed to the repair size.

In the steering gear, ball pins and track rod liners are subject to faster wear, and tips are less worn. In addition, wear of the holes at the ends of the rods, thread stripping, weakening or breakage of springs, and bending of the rods are observed.

Depending on the nature of the wear, the suitability of the tips (assembled) of the tie rod or individual parts is established. If necessary, the articulated ends are disassembled. To do this, unpin the screw plug, twist it out of the hole in the thrust head, remove the parts. Worn out. ball fingers. as well as fingers that have chips and scuffs are replaced with new ones. At the same time, new ball pin inserts are installed. Weak or broken springs are replaced with new ones. The designed holes at the ends of the tie rods are welded. The curvature of the steering rod is eliminated by straightening in a cold state. Before straightening, the draft is filled with dry fine sand.

8. The composition and properties of the material from which the parts and furs are madeKAMAZ steering systems

- Lever of pivots and steering bipods - steel 35X, 40X, ZOHGM, 40XN.

- Rail? carbon steel 45 with subsequent heat treatment (quenching and tempering).

- Steering arm shaft - steel ZOKH, 40X, ZOKHM.

- Worm, steering gear screw - steel 35X, 20XH2M or ASZOHM

- Steering shaft - steel 10, 20, 35.

Literature

1.GOST R 51709-2001 - Motor vehicles... Security Requirements for technical condition and verification methods.

2.V.A. Bondarenko, N.N. Yakunin, V. Ya. Clients - "Licensing and certification for road transport". Tutorial. 2nd edition - M; Mechanical engineering, 2004-496 p. Moscow "Mechanical Engineering" 2004

3. Mashkov E.A. Maintenance and repair of KMAZ vehicles

4. Illustrated edition-Publishing house "Third Rome", 1997-88 p.

5. Osyko V.V. etc. The device and operation of the KAMAZ vehicle

6. Study guide M .: Patriot, 1991. - 351 p .: ill.

7. Rogovtsev V.L. and others. The device and operation of motor transport

8. Means: Driver's textbook. M .: Transport, 1989. - 432 p .: ill.

9. Rumyantsev S.I. and others. Maintenance and repair of cars:

10. Textbook for vocational schools. M .: Mashinostroenie, 1989 .-- 272 p.

11. Device, maintenance and repair of cars. Yu.I.

12. Borovskikh, Yu.V. Buralev, K.A. Morozov, V.M. Nikiforov, A.I. Feshenko - M .: Higher school; Publishing Center "Academy", 1997.-528 p.

Posted on Allbest.ru

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General arrangement of the steering system of KAMAZ trucks

In the current models of KAMAZ trucks, the steering system, which is classic in terms of the scheme and design, is used, in which power steering is provided. The steering control of Kama trucks consists of the following parts:

Steering column with a steering wheel, on early and many current modifications a conventional non-adjustable column is installed, however, modern adjustable columns with a more comfortable steering wheel are now increasingly used;
Cardan shaft (steering cardan) with two cardan joints;
An angular gearbox that rotates the flow of torque from the propeller shaft and feeds it to the steering gear. The gearbox is mounted directly on the steering gear; a power steering distributor is also installed in its front part (at the end);
Power steering valve spool type, required for flow distribution working fluid in the power steering system, depending on the steering angle and position of the steering wheel;
The power steering pump is a vane (vane) double-acting pump, combined with a reservoir for the working fluid, a filter is built into the reservoir. The pump is driven by gear, from the gears of the drive of the engine units;
The radiator for cooling the working fluid is a finned U-shaped tube;
The steering gear, combined in one housing with the power steering cylinder, uses two working pairs at once - a screw with a nut on circulating balls and a rack with a toothed sector, and the rack in the first pair plays the role of a nut, and immediately acts as a hydraulic booster piston;
Steering gear, consisting of a steering gear bipod, longitudinal rod, transverse rod and steering tips. The transverse rods and tips form a steering link that ensures the correct angles of rotation of the wheels, all connections between the rods and tips are made through ball joints.

The steering column together with the steering wheel is installed directly in the cab, the steering mechanism is mounted on the left frame side member slightly in front of the front axle beam. The power steering pump is installed directly on the engine, since it is driven from the cardan shaft through the gears of the drive of the units. The power steering radiator is mounted directly on the engine cooling radiator, which ensures efficient heat removal from the working fluid in all operating modes.

Currently, KAMAZ vehicles are used Various types steering mechanisms (models 4310 and 5320, as well as foreign production firms PPT, RBL and ZF), pumps and other components. In addition, in NefAZ buses built on the KAMAZ chassis, the bevel gear is separated from the steering mechanism, and an additional cardan shaft is located between them. But in general, all civilian vehicles and KAMAZ chassis have fundamentally the same steering, the scheme of which is described above.

The steering of cars with two steered axles (models 6520, 6350, 6540 and others) is somewhat more complicated. In particular, an intermediate link and a lever mounted on the left frame side member are provided for transmitting the pivoting force to the second steered axle. In this case, the steering bipod has two heads for connection with rods located on opposite sides of the bipod shaft. Directly turning the wheels of the second axle is performed by a separate hydraulic power steering cylinder located on the same left side member. Such a steering drive allows one steering mechanism to turn all four steered wheels at once with minimal effort and without complicating the design of the car.

A small detail has an important role in the operation of the steering -.

Purpose, types and design of bipods

The bipod is part of the steering drive; together with the longitudinal steering rod, it is an intermediate link between the steering gear and the steering linkage. The bipod is rigidly connected to the toothed sector of the steering mechanism, and thanks to it, the torque of the sector is converted into a translational movement of the longitudinal steering rod and steering linkage parts.

The steering bipod has an extremely simple device. It is a one-piece steel piece with two heads - a large top and a smaller bottom. Each head has a hole, as described below. The bipod has a curved shape, which ensures maximum strength of the part with its minimum dimensions, as well as the correct distribution of forces.

Currently, two types of steering bipods are used on KAMAZ vehicles, which differ in the method of fixation on the shaft and the design of the upper head:

One-piece bipod model 4310;
Detachable bipod model 5320.

The bipod of the first type has a connection with the bipod shaft on tapered splines, at the end of which a thread is provided. The bipod with its upper head is simply put on the shaft and rigidly fixed with a special shaped lock washer and a nut. The lock washer prevents the nut from loosening during the operation of the car, however, in some cases, a conventional nut cotter pin is used.

The bipod of the second type also has a splined connection with the shaft, but its upper head is split and it has two holes for the installation of tie bolts. The bipod is fixed on the shaft using two bolted joints, their nuts are additionally split.

Regardless of the type, all bipods have the same lower head - a tapered hole is made in it, through which the connection with the ball pin of the ball joint of the longitudinal tie rod is made. Fixation of the bipod on the finger is also carried out using a cotter nut.

The described device also has a bipod of steering mechanisms of KAMAZ of other models, including those of foreign production.

Maintenance and repair of the steering gear of KAMAZ and its bipod

During operation, the car is exposed to very high loads, therefore, over time, deformations occur in it, the slots in the upper head gradually wear out, and the hole in the lower head is broken by a ball pin. All this leads to backlash and deterioration in the quality of the steering mechanism. So, periodically, the steering mechanism, together with the bipod, must be inspected, serviced and repaired.

Bipod maintenance comes down to visual inspection bipod connections and its condition, all cotter pins must be in place. The tightening torque of the nut (or nuts) of the bipod is also checked, if necessary, the nuts are tightened. Checking and tightening the nuts is performed at TO-1000, TO-5000 and every TO-2 (after 20-30 thousand km of run, depending on the car model).

In some cases, in order to repair the steering drive or steering mechanism, it becomes necessary to dismantle the bipod. The landing of the bipod on the shaft, especially of the one-piece type, is very tight, therefore, to perform the operation to remove the bipod, it is necessary to use a special puller. Typically, the stripper is a bracket with a lug screw at the front. The puller is put on the bipod so that the screw rests on the bipod shaft, and by screwing in the screw, the bipod is pulled off the shaft. Reinstallation of the bipod is carried out without the use of special tools.

It is important to note that before dismantling the bipod, marks must be made on it and on the shaft, which will greatly simplify the subsequent installation of the bipod without the need to adjust the steering drive. If a new bipod is being installed, then it is often necessary to adjust the length of the longitudinal steering rod - this is necessary to achieve the installation of the wheels in a straight position with the middle position of the steering wheel.

Bipod is important element steering, therefore, its maintenance must be given great attention, and if it malfunctions, immediately replace it. Only in this way the entire steering system of a KAMAZ vehicle will work for a long time and reliably.

In KAMAZ vehicles, the steering system, which is traditional for trucks, is used, in which the presence of a steering column is provided. About how the steering of KAMAZ in general is arranged, and what role the steering column plays in it (as well as about its structure, operation and maintenance), read this article.

General arrangement of the steering system of KAMAZ trucks

In all current and early models of KAMAZ trucks, the steering systems are fundamentally identical in design and built on a single component base. The steering of Kama trucks includes:

Steering drive;
Steering gear;
Power steering;
Steering column;
Wheel;
Cardan transmission;
Angle reducer.

Each of the units plays a specific role in the system and has its own characteristics.

Steering drive. Built according to the traditional scheme, on cars with all wheel configurations it is mounted on the front axle (or two front axles in the 8 × 4 and 8 × 8 models) with steerable wheels. The drive is a system of one longitudinal link, which is connected to the bipod of the steering mechanism and the steering knuckle lever, and one transverse link connecting the levers of both steering knuckles of the axle. In cars with two steered axles, an identical set of rods on the second axle is added, as well as one more longitudinal rod and a lever for transferring the force t of the steering mechanism located in the region of the front axle to the rear axle.

Steering gear. All KAMAZ trucks use a mechanism built on two working pairs. The first pair is made up of a screw with a nut (which simultaneously acts as a rack) on circulating balls - it converts the torque from the steering wheel into the forward movement of the rack. The second pair is made up of a rack (with four teeth) with a sector - they convert the translational movement of the rack into the rotational movement of the sector connected to the rotary bipod. In current KAMAZ models, the steering wheel is combined with the power steering, its crankcase acts as a power steering cylinder, and the rack acts as a piston.

Today, domestic mechanisms of models 4310 and 6540 with gear ratio 21.7: 1, as well as mechanisms of foreign production RBL (Germany) with a variable gear ratio from 17: 1 to 20: 1, or with a constant gear ratio of 21: 1. RBL mechanisms have a hydraulic steering limiter, which prevents deformation and breakage of the steering rods in the extreme positions of the steering wheel.

The steering gear is usually mounted on the left frame side member, next to the front axle of the vehicle, or on the left spring bracket.

Power steering (GUR). As already mentioned, the power steering cylinder is combined with the steering mechanism, the power steering pump also includes a power steering pump (today, vane pumps of model 4310, as well as those of ZF and RBL companies are most often used), a radiator for cooling the working fluid (it is necessary, since the power steering is experiencing large load and fluid is severely heated), bypass valve, control valve and spool (located in a separate block on the steering gear), piping and expansion tank... It is important to note that in vehicles with wheel arrangement 8 × 4 and 8 × 8, an additional power steering cylinder is installed, which facilitates changing the position of the wheels of the second axle.

Angle reducer. The simplest gearbox on two bevel gears, which provide a change in the direction of the flow of torque from the steering wheel to the steering gear. The driven gear of the reducer is made hollow, which makes it possible to pass through it the shaft going from the power steering spool mechanism to the steering gear screw. The bevel gearbox is located between the steering gear and the power steering spool mechanism.

Cardan transmission. It is necessary for the transmission of torque from the steering shaft to the bevel gear. The propeller shaft is composite, it consists of a tubular shaft with a fork and a sliding fork inserted into it on the splines - this solution allows the shaft to change its length when the car is moving over bumps. The shaft forks are connected by means of crosses to the counter forks on the steering column shaft and the drive gear shaft of the bevel gear, they form two cardan joint... The crosses are installed in the forks on maintenance-free needle bearings.

Let's talk about the steering column in more detail.

Purpose, types, devices and operation of the steering column KAMAZ

The steering column, together with the steering wheel, is the primary directional control for the vehicle. The steering column has two main tasks:

Provides the most convenient for work installation of the steering wheel in height and tilt;
Provides a constant steering wheel position while the vehicle is in motion.

Two types of steering columns are used in KAMAZ vehicles:

Old model - without tilt and height adjustments;
A new sample - modern speakers with adjustable height and angle of the steering wheel.

Although the old steering columns are rather awkward, they still find widespread use, even on newer trucks. This is due to their simple design, very high reliability and low cost. New steering columns, installed on a number of KAMAZ-5460, 6520 and others, provide the ability to adjust the angle and height of the steering wheel to the height and anatomical features of the driver. However, as practice shows, they are less reliable and more expensive.

The arrangement is extremely simple. It is based on a hollow tube, inside of which a shaft is mounted on two ball bearings. In the upper part, a steering wheel is mounted on this shaft by means of a nut, on the reverse side a universal joint fork is attached to the shaft. Approximately in the middle of the column there is a bracket for attaching it to the cab panel, in the lower part of the column there is a flange. This flange mounts the column to a wider tube (also called a flange) that is bolted to the cab floor. This flange is provided with a window (closed by a bolted cover) for access to the upper joint of the propeller shaft.

The columns of the new sample have a similar structure, however, they are shorter, and have a coaxial installation with the cardan shaft - this solution allows you to easily and conveniently change the angle of inclination of the steering column. And the splined connection of the halves of the shaft allows you to change the height of the steering wheel above the floor level. The column is provided with mechanisms with clamps, which provide the ability to change and set the required angle of inclination and height of the steering wheel.

On the steering column, in addition to the steering wheel, controls for windshield wipers and lighting devices are also mounted. The handles of the combination switches are mounted under the steering wheel, which makes it convenient to turn on and off the wipers and washer, direction indicators, low and high beam headlights. In the columns of the new sample, the switches themselves, all the electronics and mechanisms for changing the angle of inclination and height of the steering wheel are hidden under decorative plastic covers.

Features of maintenance and repair of the steering column KAMAZ

The steering column and steering wheel are one of the most reliable parts of a car's steering, however, they also require periodic maintenance and repair. Maintenance usually boils down to an examination of the reliability of the fastening and an assessment of the condition of the parts of the steering column and steering wheel, and the steering system in general.

If the inspection reveals axial shaft play (which indicates poor bearing condition), bearing destruction or excessive wear, rudder play due to wear of the splined joint of the propeller shaft or universal joints (crosses or needle bearings), shaft deformation or serious deformation of the column itself, then it is necessary to repair or replace parts.

Dismantling the steering column is generally done as follows:

Set the steered wheels in a straight position and fix them;
Dismantle the steering wheel (for which you need to remove the cover and unscrew one nut);
Remove all switches from the column;
Unscrew the bolts holding the cover on the flange;
Unscrew and knock out the bolt holding the upper universal joint yoke;
Unscrew the bolts holding the steering column on the flange and on the panel, remove the column.

Installation of the column is carried out in the reverse order, while it is necessary to tighten the universal joint yoke bolt with a certain effort, and also to install the steering wheel correctly.

Steering wheel play is of great importance for steering diagnostics. It can be caused both by wear of the splines or universal joints, and by other malfunctions - wear of parts in the steering mechanism, wear of the steering wheel drive, etc. Usually the backlash when the engine is running is Idling should not exceed 25 °, and even less in many models. If the backlash is greater, diagnostics and repair should be carried out.

The effort that has to be applied to the steering wheel to turn it in one direction or another is also important. This is an effort for different models KAMAZ is not the same, it is measured with a special device, and is set by adjusting the steering mechanism and power steering.

At regular maintenance and timely repairs will provide accurate and reliable control, and at the same time help in diagnosing truck steering problems.

Steering control of KamAZ cars divided, with hydraulic booster and one-piece steering linkage. The steering consists of steering wheel 1 ( rice. 124), steering column 2, cardan gear 6, bevel gear 9, steering gear 10, shaft 13, bipod 12, longitudinal steering rod 11 and steering linkage. The hydraulic booster consists of a distributor 8, a hydraulic cylinder located in the steering gear housing 10, a pump 1 with a reservoir 15, a radiator 7, pipelines and hoses.

The steering column, consisting of a tube with a steering shaft placed in it on two ball bearings, is attached in the upper part of the cab panel using a bracket 3, and in the lower part - to the cab floor using a flange 4. The axial clearance in the bearings is adjusted with a nut 5.

Cardan gear 6, which includes a shaft, a bushing and two cardan joints, transfers rotation from the steering shaft to the shaft of the driving bevel gear of the bevel gear 9.

Rice. 124. Steering control of KamAZ cars: 1 - steering wheel; 2 - steering column; 3 - bracket; 4 - flange; 5 - an adjusting nut; v - cardan transmission; 7 - radiator; 8-distributor; 9-angle gearbox; 10 - steering gear; 11 - longitudinal Tie Rod; 12 - bipod; 13 - bipod shaft; 14 - pump; 15 - tank.

A single-stage bevel gearbox is used to transfer rotation from the cardan transmission to the steering gear screw with a gear ratio equal to one. Assembled gearbox in housing 33 ( rice. 125), which is attached to the housing 23 of the steering mechanism with pins. The driving bevel gear is made integrally with the shaft 7 and is mounted in a removable housing 10 on ball 6 and needle 8 bearings. The ball bearing is secured with a nut, the needle bearing with a retaining ring.

Rice. 125. Steering gear of KamAZ-5320: 1, 14, 22 and 42 - covers; 2 - reactive plunger; 3 - control valve body; 4 and 36 - springs; 5 - shims; 6 and 12 - ball bearings; 7 - drive shaft with a gear wheel; 8 - needle bearing; 9 - sealing device; 10 - case; 11 - driven gear wheel; 13, 32 and 44 - retaining rings; 15 - thrust ring; Relative ring; 17 and 26 - screws; 18 - sector; 19 - bipod shaft; 20 bypass valve; 21 - cap; 23 - crankcase; 24 - piston rack; 25 - cork; 27, 30, 39 and 41 - nuts; 28 - gutter; 29 - ball; 31 - lock washer; 33 - gearbox housing; 34 - thrust bearing; 35 - plunger; 37 - spool; 38 - washer; 40 - adjusting screw; 43 - seal; 45 - an adjusting washer; 46 - thrust washer.

The driven bevel gear 11 rotates in two ball bearings 12 installed in the gear housing 33. The ball bearings are fitted with an interference fit on the shank of the gear wheel and secured by a nut 30 with a lock washer 31. The axial movement of the gear wheel is limited by a retaining ring 32 and a cover 14. The engagement of the bevel gear wheels adjust by changing the thickness of the spacers 5.

The driven bevel gear of the bevel gear is connected by splines to the screw 26 and transfers it rotation from the steering wheel; the screw can move in the axial direction (forward and backward).

The steering gear is assembled in a crankcase 23, which also serves as a power steering cylinder. A double gear was used as a steering mechanism: screw 26 - nut 27 and rack (piston) 24 - sector 18.

To reduce frictional forces, the screw 26 rotates in the nut 27 on balls located in the grooves of the screw and the nut with a crossover tube. The nut, assembled with a screw and balls, is installed in the piston-rack 24 and fixed with two set screws 17.

The piston-rack is located in the crankcase 23, which serves as a cylinder. The piston has an O-ring 16 and oil grooves. The rack engages with the toothed sector 18 of the bipod shaft 19 and turns it in a bronze bushing pressed into the steering gear housing and in an aluminum side cover 42.

The thickness of the teeth of the sector and the piston-rack is made variable along the length, which allows you to change the clearance in engagement by moving the bipod shaft with the toothed sector using the adjusting screw 40 ,. which keeps the bipod shaft from axial movements to the left through thrust washer 46, and to the right - through an adjusting washer 45 and a retaining ring 44. The axial movement of the bipod shaft 0.02 ... 0.08 mm is achieved by selecting an adjusting washer 45 of a certain thickness. Screw 40 is locked with nut 41.

On the spline end of the shaft 13 ( see fig. 124) installed and secured by bolts a bipod 12, which is connected to the longitudinal rod 11 of the steering drive. The longitudinal rod is also connected to the upper arm of the left steering knuckle by a hinge device. The longitudinal link is a one-piece forged piece with non-adjustable pivot devices.

The steering linkage consists of a tie rod and two steering knuckle arms. The levers are mounted on a segmented key in the tapered holes of the steering knuckles and secured with castellated nuts with cotter pins. The tubular lateral rod has threaded ends onto which the ends with pivot devices are screwed. The terminals are fixed with terminal clamp bolts. The hinge device of both rods consists of a ball pin, upper and lower bushings, a spring and a cover.

Steering kamaz. Steering column kamaz: one of the basics of truck management

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