Instruction manual for KAMAZ 6520. Operation manual for KAMAZ6520. Wheel drive disassembly
Let me tell you another interesting case from our practice. The customer called us and explained that on Kamaz 6520, after a major overhaul of the engine, engine vibration appeared. To the question "Is it assembled correctly?" the customer claimed that their specialist assembled the engine correctly (after all, he had already gone through more than a dozen of them). In addition, the engine runs, but vibrates.
After talking with the customer about what they did to fix this problem, namely:
- checking the correctness of setting the fuel injection advance angle;
- checking nozzles (sprayers;
- valve adjustment;
- compression measurement;
- replacing engine mounts.
We realized the reason is hidden inside the engine. The customer agreed to take the vehicle to our truck repair to further investigate the cause of the engine vibration. After the car was delivered to our car service, we once again discussed some of the nuances (where did you buy spare parts? where did you grind crankshaft? etc.). The organization that sold the spare parts is one of the largest suppliers of spare parts for trucks in Moscow. The organization that grinded the crankshaft is also one of the most famous in its field of repair. So the version about low-quality spare parts and inaccurate grinding of the crankshaft disappeared immediately.
After removing the engine and gearbox, our experts found the cause of the malfunction (vibration). It turned out that their specialist installed the front crankshaft balancer in reverse. The balancer of vibrations also stood incorrectly. The balancer is installed only in a certain position. And yet, because there is no rear crankshaft balancer, the balancer is the flywheel and clutch basket. The clutch basket is installed strictly in a certain position.
The error of the customer's specialist is that he did not take into account a number of differences when assembling and installing the Kamaz 740.51 Euro 2 engine. Our specialists eliminated all of the above malfunctions and installed the engine on the car. After starting, the engine runs perfectly, without vibration.
This case once again confirms that certain types of repairs should be carried out by a specialist who has studied and repairs this technique, who has completed repair courses. After all, every day there are more and more modern cars And just because the engines look alike on the outside doesn't mean they are the same on the inside.
In our service center, all types of maintenance of cargo and special equipment are carried out. Repair of truck cranes of any manufacturers, repair of trucks of domestic brands - repair of ZIL and repair of KAMAZ. With the growing popularity of Chinese technology, the repair of Chinese trucks has also become in demand. You can also get repair of Chinese equipment from us -
When repairing, depending on the fault, dismantle the drive bridge KAMAZ 6520 assembly, or only the main gear, or parts of the wheel gear. Disassemble the gearbox into the following assembly units, after draining the oil from the bridges and the crankcase of the main gear of the middle axle into a clean bowl (for its further use):
- leading bevel gear;
- interwheel differential. Remember that cross-axle differential bearing caps are not interchangeable as they are machined with the gear case;
- driven bevel gear;
- center differential, in case of disassembly of the intermediate axle gearbox.
When disassembling, be sure to check the play in the above assembly units, since the assembly must be with the obligatory preload of the tapered bearings. After complete disassembly of the gearbox parts, wash and check.
When disassembling bridge KAMAZ 6520 it is necessary to check the axial and radial movements in the assembly units of the wheel and main gears, since the assembly must ensure the obligatory preload of the tapered bearings. After complete disassembly, the transmission parts must be washed and checked.
When inspecting the details, you should:
- check the teeth and the location of the contact patch on the working surfaces of the teeth of bevel gears; if unacceptable wear or damage is found (tooth chipping), replace with new ones. If the teeth mesh incorrectly, find the cause and eliminate it. For spare parts and for assembly, the driving and driven spiral bevel gears are supplied as a set, matched to the noise and contact patch, so if one of them is damaged, both wheels must be replaced;
- check the condition of the surfaces of the spikes of the crosses, bushings of the satellites, surfaces of the support washers of the satellites and side gears, landing and end surfaces of the side gears and their installation sites in the differential cups in the inter-wheel and center differentials.
In case of minor damage, the surfaces can be polished with fine-grained sandpaper, and in case of serious damage, the parts can be replaced with new ones.
- inspect all bearings. They must be wear-free, with smooth working surfaces.
Wheel drive disassembly
To disassemble the wheel gear (), it is necessary to drain the oil from the wheel gear housing. Then remove the brake drum 9. Remove the carrier cover 24 with the gasket by unscrewing the bolts.
Remove the lock washer 23, unscrew the adjusting nut 22 and remove the lock washer 20 from the inner hole.
Unscrew the flange bolts 10 for fastening the carrier 17 and, screwing in the technological bolts M10x1.25 (2 pcs.), press the carrier out of the wheel hub 7.
Check the technical condition of the axles 1 of the satellites, needle bearings 3 and support washers. The satellite axles must be pressed in by orienting the flats along the carrier shoulder.
When replacing needle bearings 3, it must be taken into account that bearings from the same batch must be installed in one wheel gear, i.e. with the same markings and with the same tolerance fields.
To disassemble the wheel hub 7, it is necessary to unlock the lock washer and unscrew the lock bolt 4 from the nut 5 of the hub bearings. Then remove the nut 5 securing the hub bearings. Push the wheel hub slightly forward and remove the ring gear 15 together with the outer bearing inner race.
Remove the wheel hub 7 from the pin 13 of the axle housing together with the glass in which the hub cuffs 8 are located. In this case, the inner ring of the inner bearing is removed. Bearing outer rings, cuffs, sealing ring should be dismantled if they are replaced.
Hub and wheel assembly
Assembly of the hub and wheel drive must be done in reverse order. Before assembly, the seating surfaces on the trunnion bridge KAMAZ 6520, lubricate the carrier with grease.
After installing the hub 7, it is necessary to adjust the bearings 11 and 14 of the hub. To do this, tighten the nut 5 for fastening the bearings to approximately 245 ... 294 Nm (25 ... 30 kgf-m) until the hub starts braking, while turning the hub in both directions so that the rollers are correctly installed on the conical surfaces of the rings. Then loosen the nut about 1/6 turn until the threaded hole in the nut aligns with the nearest hole in the lock washer. Screw the locking bolt 4 into the threaded hole of the nut until it stops with the hinged washer installed with one protrusion on the face of the nut, while the bolt must enter the hole of the lock washer. After that, bend the antennae of the folding washer on the two faces of the bolt. Check hub rotation. The hub should rotate freely by hand, without jamming.
Install the carrier 17 of the wheel gear assembly with the planet gears and the nut 22, adjust the gap between the thrust washer 20 and the sun gear 19. To do this, by rotating the hub 7, tighten the adjusting nut 22 until it stops in the sun gear 19 so that there is a slight braking . Then loosen the nut one turn. In this case, the gap should be 1 mm. Next, install the locking plate 23 and cover 24. The cover fastening bolts should be tightened with a torque of 35...49 N.m (3.6...5.0 kgf.m).
To remove the main gear, it is necessary to hang out the drive axle, fix it on stands, drain the oil from the crankcase of the axle, main and wheel gears, remove the covers on both sides of the wheel gears. Pull out the axle shafts about 150 mm on both sides of the wheel gears. Having unscrewed the bolts securing the main gear to the axle housing, remove it.
Disassembly of the drive bevel wheel
To disassemble the drive bevel wheel of the main gear of the middle and rear axles (), unscrew the nut 1 for fastening the flange or the driven spur gear, remove the flange 2. Unscrew the bolts for fastening the cover 3 of the bearing cup and remove the cover 3 with the gasket.
Screwing in the technological bolts M12x1.25x50 (2 pcs.), press out the drive bevel gear assembly 7 from the gearbox housing 8. To disassemble the assembly, it is necessary to remove the inner ring of the outer bearing 4, the adjusting sleeve 23 and then the drive bevel gear 7 with the inner ring of the inner bearing 6 .
Press the inner race of the inner tapered bearing with a puller. To remove, install the edges of the wedges 8 of the puller ( Rice. 455) between the inner ring of the bearing and the wheel and, having screwed in the screw 6 and the yoke 7, tighten them. Insert the grips 1 by the wedges 8 and fix them in this position with the screw 3. Putting the tip 2 against the end of the wheel and screwing the screw 3 into the traverse 4, remove the ring.
Rice. 455 Puller of the inner rings of the drive gear bearings: 1 - capture; 2 - tip; 3, 5 and 6 - screws; 4, 7 - traverses; 8 - wedge; 9 - rack
Differential disassembly
To disassemble the differential (), you need to remove the locking plates 26 and 27, unscrew the bolts 28 for fastening the bearing caps, remove the caps and adjusting threaded nuts 9. Remove the differential from the final drive. Next, remove the retaining ring and gear clutch of the locking mechanism from the differential cup.
If replacement is necessary, press bearings 11 and 20 off differential cups 14 and 19.
For this captures 1 ( Rice. 456) put it behind the inner ring of the bearing and fix it with screws 3. Resting with the tip 2 against the end of the differential, screw the screw 5 into the traverse 4 until the inner ring of the bearing is completely removed.
Loosen the bolts ( Rice. 452) securing the differential cups, separate the cups. Take out the crosspiece 16 with satellites 15 and support washers 17, semi-axial gears 12 with support washers 13.
Clean the removed parts and check their technical condition. If there is excessive wear or signs of seizing on the surface of the bushings, they should be replaced.
Replace cups only in sets (both cups must have the same set number).
After replacing the cups, before assembling the differential, it is necessary to press on the inner rings of the bearings 11 and 20.
When assembling the differential, it is necessary to install the right semi-axial gear with a washer, a cross, assembled with bushings, satellites and washers, into the right differential cup. Insert support washers, left semi-axial wheel into the left cup. Align differential cups to factory marks. Tighten both cups with self-locking bolts to a torque of 98 ... 122 Nm (10 ... 12.5 kgf-m).
Self-locking bolts for fastening the driven bevel gear must be tightened with a torque of 245...294 Nm (25...30 kgf-m).
Install the cross-axle differential into the final drive housing. Tighten the bolts 28 for fastening the bearing caps 20 to a torque of 100... 120 N-m (10... 12 kgf-m) and lock them with lock washers 27 and 28. Insert a cotter pin into the hole in the head of the bolt 28.
Rice. 456 Removing the inner ring of the differential bearing: 1 - capture; 2 - tip; 3 and 5 - screws; 4 - traverse
Assembling the crankcase of the main gear of the middle and rear axles KAMAZ 6520
When assembling the crankcase of the main gear of the middle and rear axles, it must be remembered that the bearing caps of the differential and the parts of the crankcase of the middle axle gearbox are not interchangeable, because they are processed as an assembly, so each part of the crankcase and the bearing cover must be installed in the place where it is was.
Assembly and installation of the assembly unit of the driving bevel wheel
Assembly and installation of the assembly unit of the driving conical wheel should be carried out in the reverse order of its disassembly.
After installing the differential in the main gear housing, it is necessary to adjust the engagement of the driven 21 and the driving 7 gears along the side clearance, which should be 0.25 ... 0.40 mm and the contact patch.
The side clearance and the contact patch in engagement can be determined by simultaneously adjusting the location of the drive bevel wheel 7 assembly and differential.
rear axle KAMAZ 6520
Final drive control rear axle KAMAZ 6520() includes adjusting the preload of bearings 11 and 20 of the differential and bearings 4 and 6 of the drive bevel gear 7, as well as adjusting the side clearance and contact patch of the bevel pair.
To ensure preload in tapered bearings 4 and 6 of the drive bevel wheel assembly in the presence of axial movement, it is necessary:
- 1) Reduce the height of the adjusting sleeve 23 by grinding or replacing with bushings from spare parts by the amount of axial displacement plus 0.04...0.06 mm.
- 2) Tighten nut 1 for fastening flange 2 to 590...690 N.m (60...70 kgf.m).
- 3) Check the turning force of the cup 5 of the bearings, which should be equal to 10...24 N (1.00...2.50 kgf). It is necessary to measure the turning force with the continuous rotation of the glass in one direction for at least five full revolutions. Bearings 4 and 6 must be lubricated, and the cover of the cup 3 of the bearings must be shifted so that the cuffs 24 and 25 do not resist the rotation of the gears.
After installing the drive bevel gear 7 and the differential into the crankcase of the gearbox 8, it is necessary to adjust the side clearance with nuts 9, which should be within 0.25 ... 0.40 mm, and the contact patch of the bevel pair using the methods given in Table 70.
To adjust the differential bearings, it is necessary to tighten the adjusting nuts 9 evenly from both sides until the moment at which the distance between the bearing caps increases by 0.10...0.20 mm. Having adjusted the bearings, it is necessary to finally tighten the bolts for fastening the bearing caps to a torque of 380 ... 460 Nm (38 ... 46 kgf-m) and lock them with lock washers.
Assemble the main gear of the bridge. The tightness of all flange and threaded connections with access to oil cavities should be ensured with UN-25 sealant.
Regulation of the main gear of the middle axle KAMAZ 6520
Final drive control middle axle KAMAZ 6520() includes adjusting the preload of bearings 8 and 24 of the through shaft 27, differential bearings, bearings 15 and 19 of the drive bevel gear 13, as well as adjusting the side clearance and contact patch of the bevel pair.
Tapered bearings 8 and 24 of the through shaft should be adjusted using shims 23 installed under the bearing cover 25. To do this, install the bevel gear 10 of the rear axle drive with the outer ring of the radial bearing 9 in the gearbox housing and center differential, so that the heads of the bolts of the tightening cups 3 and 7 are on the side of the tapered bearing 8. , on which to install the driving cylindrical gear 1, so that the end surface abuts against the crosspiece 4 of the center differential. Connect the outer housing of the gearbox housing to the assembled center differential lock mechanism. Then insert the drive shaft 27 with the inner ring of the bearings 9 and 24. Install the cover 25 with the pressed outer ring of the bearing 24 without shims. Measure the gap in at least 3 places evenly spaced along the diameter of the cover and install shims.
The thickness of the shim pack S is determined by the formula:
S \u003d A - (0.04) mm, where A is the gap size.
On each side of the gasket package, gaskets with a thickness of 0.05 mm and 0.1 mm must be installed at least 2 pcs. The rest - as needed.
Tighten the bolts for fastening the cover 25 of the bearing with a torque of 59 ... 88 Im (6 ... 9 kgf-m).
Check the torque required to turn the drive shaft 27, which should be 1...2.5 N.m (0.1...0.25 kgf.m).
To measure the torque, it is necessary to install a technological flange, in which the cuff installed in the bearing cap 25 does not resist the rotation of the shaft. The measurement should be made with continuous rotation in one direction and not less than after five full revolutions of the shaft. Bearings and rubbing end surfaces of gears and crosses must be lubricated with oil TSp - 15K GOST 23652-79.
When checking the torque of the input shaft 27, the drive spur gear 20 of the middle axle drive must be stationary.
Otherwise, the adjustment of the main components is carried out similarly to the adjustment of the main gear of the rear axle.
Adjustment of the interwheel differential lock mechanism
The adjustment of the cross-axle differential lock mechanism must be carried out in the following order:
1 option. (Fig. 457)
- remove the main gear;
- remove the piston with the rod;
- set the lock-up clutch to a position where the distance from plane A of the clutch ring gear to the axis of the hole d= 338+0.215 mm in the axle housing is 170 mm;
- measure dimension B from the surface of the fork pin to the bearing plane of the crankcase flange; assemble the piston with the rod in size B + 7 mm, lock it with a nut and install it in the axle housing, tighten the cover and diaphragm fastening bolts evenly, while the tightening force should ensure tightness, without excessive compression of the diaphragm sides;
- check the stroke of the lock-up clutch when air is supplied to the diaphragm, which should be 14 mm.
Rice. 457 Cross-axle differential lock mechanism
Option 2 (Fig. 458)
- remove the cover of the locking mechanism;
- remove piston 5 with rod 8;
- on the rod 8, unscrew the nut 7 and change the existing length A of the piston with the rod by a value equal to 90 mm. Insert the piston with the rod into the support flange 2 of the axle housing so that the end surface of the rod comes into contact with the elements of the blocking fork 1;
- install the control bolt 3 into the special fixture 4 so that the end surface of the bolt is in the same plane with the inner plane of the fixture (flush);
- install a special device 4 with a control bolt 3 on the support flange 2, and tighten it on 2 opposite bolts 6;
- measure size X1
- tighten the control bolt 3 until the piston 5 stops. In this case, it is necessary to create conditions so that when the control bolt 3 is tightened, the differential, turning relative to the axle shafts, is blocked;
- measure the distance X2. If the difference in sizes X1 and X2 is less than 11 mm, then change the size A by the value equal to: B = 11 - (X1 -X2), mm; lock piston 5 on rod 8 with nut 7;
- install the piston with the rod in the support flange 2 of the axle housing;
- Tighten the cap and diaphragm bolts evenly. At the same time, the tightening force should ensure tightness without excessive compression of the sides of the diaphragm;
- check the stroke of the lock-up clutch when air is supplied to the diaphragm.
Rice. 458 Adjustment of the interwheel differential lock mechanism: 1 - lock fork; 2 - support flange of the crankcase of the bridge; 3 - control bolt; 4 - special device; 5 - piston; 6 - fixture mounting bolt; 7 - locknut; 8 - the rod of the locking mechanism.
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Car | KAMAZ 6520 | Exploitation
The service brake system is used to reduce the speed of the car and stop it completely, the drive is controlled by the pedal.
Turn on the parking brake system when the car is parked by setting the handle of the parking and spare brake control valve (see Fig. Cabin) to a vertical fixed position. At the same time, the brake mechanisms of the rear wheels of the car and the trailer are activated.
To turn off the parking brake system, set the handle to a horizontal fixed position. Turning on the parking brake system, bring the handle down to the stop, otherwise you will “burn out” the brake system on the trailer.
The spare brake system is designed to stop the car in the event of failure of the service brake system. Operate the emergency brake system by gradually moving the parking brake handle. When the handle is moved up a third of its full travel, only the trailer braking system works. Using this method of braking on a slippery road, you can avoid "folding" the road train, since the road train is "stretched" in this case. With further movement of the handle up, the brake system of the car is turned on and the intensity of braking increases: the closer to the vertical, the stronger the braking.
Turn on the auxiliary brake system by pressing the button of the auxiliary brake system (see Fig. Cab). Use the auxiliary brake system at all times to reduce speed and always when driving on long descents to prevent overheating of the brakes. If necessary, to reduce the speed of the engine crankshaft, slow down the road train with a service brake system.
Do not disengage the clutch or change gears with the auxiliary brake system engaged.
Mechanical release of the parking brake system.
In the absence of air in the reservoirs of the parking brake system, the spring-loaded energy accumulators of the brake chambers of the rear bogie are activated, and the car slows down. If it is not possible to fill the reservoirs with compressed air, the vehicle can be released mechanically. To do this, remove the covers from the energy accumulators of the brake chambers of the rear and intermediate axles and unscrew the mechanical release screws to the stop (approximately 30 turns) (see Fig. Mechanical release of the parking brake system.). After troubleshooting the pneumatic drive of the brake system, screw in the screws.
Attention! If there is not sufficient air pressure in the pneumatic actuator of the brake system, then after the mechanical release of the parking brake system, the vehicle does not have any brake systems. Therefore, make sure that the vehicle cannot move spontaneously after releasing the brakes.
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Manual for the car KAMAZ6520 / Technical guide / Kama-Avtodetal
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- Specification 6520
- Vehicle operation
- Operation of vehicles in the cold period of time
- Anti-theft device
- KamAZ 6520 engine
- Engine start assist system
- Clutch
- Transmission
- cardan gear
- Bridges
- Suspension
- Wheels and tires
- Steering
- Brake systems
- electrical equipment
- Cabin
- Platform
- Possible engine malfunctions
- Schematic diagram
- Operating materials
- List of spare parts
The KamAZ-6520 dump truck is designed to transport various bulk construction and industrial cargoes on roads designed for vehicles with an axle load of up to 13 tf. It is possible to mount specialized equipment weighing up to 24 tons on the chassis of the car.
For the initial period of operation of a new car, a mileage of 1000 km is set. When operating the vehicle, it is necessary to use brands of fuel, lubricants and operating materials in accordance with this manual.
Faulty valves and tank cap gaskets, leaks in the cooling system connections and insufficient coolant level lead to cavitation damage to the fluid pump and block.
If the emergency pressure drop indicator in the engine lubrication system lights up, stop the engine, find and fix the problem.
Monitor the temperature of the liquid in the engine cooling system: if the warning light for emergency overheating of the liquid comes on, stop the engine, find and fix the problem.
Operation with a leaky intake tract leads to premature engine failure. At each TO-2, check the integrity of the rubber pipes, air ducts and the reliability of the connections, eliminate the leakage of the path.
When transporting bulky, dusty goods in an open platform, excessively dusty ambient air, or with an awning on the platform, raise the air intake hood using the nozzle supplied with the vehicle.
To prevent cracks in the cylinder head bolt bosses, it is necessary to protect the bolt holes from liquid or contamination when disassembling the engine, and especially before installing the cylinder heads.
When carrying out electric welding work on the car must be turned off rechargeable batteries remote switch and the wires were removed from the "+" terminals of the generator and B, O of the brush holder.
The ground wire of the welding machine must be connected in close proximity to the weld.
If there are dents on the torque rod pipe with a depth of more than 2 mm, cracks or curvature of more than 3 mm along the entire length, the torque rod must be replaced.
When driving for a long time on dirty roads (with liquid mud), periodically flush the surface of the radiator with water with sufficient pressure from a hose. To do this, raise the cab and direct the jet of water at the radiator on the engine side. Avoid direct water contact with the generator.
Use on the engine the fuel equipment provided for by the design of this model.
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