KamAZ-5320, CCGT: device and principle of operation

2024 Author: Erin Ralphs | [email protected]. Last modified: 2024-02-19 11:42

What is a KamAZ-5320 CCGT device? This question interests many beginners. This abbreviation can lead to bewilderment of an ignorant person. In fact, PGU is a pneumatic hydraulic power steering. Consider the features of this device, its principle of operation and types of service, including repair.

• 1 – spherical nut with locknut.
• 2 - Clutch deactivator piston pushrod.
• 3 - safety cover.
• 4 - clutch release piston.
• 5 - the back of the skeleton.
• 6 - complex sealant.
• 7 - follower piston.
• 8 - bypass valve with cap.
• 9 - aperture.
• 10 - inlet valve.
• 11 - graduation analog.
• 12 - Pneumatic type piston.
• 13 - drain plug (for condensate).
• 14 - front part of the body.
• "A" - supply of working fluid.
• "B" - the supply of compressed air.

Purpose and device

Truck is quite massive and large-sized equipment. Its management requires remarkable physical strength and endurance. The device of the CCGT KamAZ-5320 makes it easiervehicle adjustment. This is a small but useful device. It makes it possible not only to simplify the work of the driver, but also increases the productivity of work.

The node in question consists of the following elements:

• Piston pusher and adjusting nut.
• Pneumatic and hydraulic piston.
• Spring mechanism, gearbox with cover and valve.
• Diaphragm seat, control screw.
• Overflow valve and piston follower.

Features

The case system of the amplifier consists of two elements. The front part is made of aluminum, and the rear counterpart is made of cast iron. A special gasket is provided between the parts, which plays the role of a seal and a diaphragm. The follower mechanism regulates the change in air pressure on the pneumatic piston in automatic mode. This device also includes a sealing collar, springs with diaphragms, as well as valves for inlet and outlet.

Operation principle

When the clutch pedal is pressed under fluid pressure, the KAMAZ-5320 CCGT device presses on the follower rod and piston, after which the design, together with the diaphragm, shifts until the intake valve opens. Then the air mixture from the pneumatic system of the car is supplied to the pneumatic piston. As a result, the efforts of both elements are summed up, which allows you to move the fork and disengage the clutch.

After the foot is removed from the clutch pedal, the pressure of the supply main fluiddrops to zero. As a result, the load on the hydraulic pistons of the actuator and follower is reduced. For this reason, the hydraulic type piston begins to move in the opposite direction, closing the inlet valve and blocking the flow of pressure from the receiver. The pressure spring, acting on the follower piston, takes it to its original position. The air initially reacting with the pneumatic piston is vented to the atmosphere. The rod with both pistons returns to its original position.

Production

The KAMAZ-5320 CCGT unit is suitable for many model modifications of this manufacturer. Most of the old and new tractors, dump trucks, military options are equipped with pneumohydraulic power steering. Modern modifications produced by various companies have the following designations:

• Spare parts for KAMAZ (PGU) manufactured by OJSC KamAZ (catalog number 5320) with a vertical placement of the tracking device. The device above the cylinder body is used on variations under the index 4310, 5320, 4318 and some others.
• WABCO. CCGT units under this brand are manufactured in the USA, they are distinguished by reliability and compact dimensions. This configuration is equipped with a system for monitoring the condition of the linings, the wear level of which can be determined without dismantling the power unit. Most trucks with a 154 series gearbox are equipped with this air-hydraulic equipment.
• WABCO hydraulic clutch booster for models with ZF gearbox.
• Analogues produced at a plant in Ukraine (Volchansk) orTurkey (Yumak).

In terms of choosing an amplifier, experts recommend purchasing the same brand and model that was originally installed on the machine. This will ensure the most correct interaction between the amplifier and the clutch mechanism. Before changing the node to a new variation, consult a specialist.

Maintenance

To maintain the working condition of the node, the following work is carried out:

• Visual inspection to detect visible air and fluid leaks.
• Tightening the fixing bolts.
• Adjusting the free play of the pusher with a spherical nut.
• Topping up the working fluid in the system tank.

It is worth noting that when adjusting the KamAZ-5320 CCGT of the Wabco modification, the wear of the clutch linings is easily visible on a special indicator that is pulled out under the influence of the piston.

Dismantling

This procedure, if necessary, is performed in the following order:

• The back of the case is clamped in a vise.
• The bolts are loosened. Washers and cover are removed.
• The valve is removed from the body.
• The front frame is dismantled along with the pneumatic piston and its membrane.
• To be removed: diaphragm, follower piston, retaining ring, clutch release element and seal housing.
• Removing bypass valve mechanism and manhole with exhaust seal.
• The skeleton is removed fromyews.
• Removing the thrust ring on the back of the housing.
• Valve stem is free of all cones, washers and seat.
• The follower piston is removed (you must first remove the stopper and other related items).
• Pneumatic piston, cuff and retaining ring are removed from the front of the housing.
• Then all the parts are washed in gasoline (kerosene), blown with compressed air and pass the inspection stage.

CCGT KAMAZ-5320: malfunctions

Most often, the node in question experiences problems of the following nature:

• Compressed air flow is insufficient or absent. The cause of the malfunction is the swelling of the inlet valve of the pneumatic booster.
• Jamming of the follower piston on the pneumatic booster. Most likely, the reason lies in the deformation of the sealing ring or cuff.
• There is a "failure" of the pedal, which does not allow the clutch to be completely disengaged. This problem indicates that air has entered the hydraulic actuator.

Repair of CCGT KamAZ-5320

When troubleshooting assembly elements, special attention should be paid to the following points:

• Checking the sealing parts. The presence of deformations, swelling and cracks on them is not allowed. In case of violation of the elasticity of the material, the element must be replaced.
• The condition of the working surfaces of the cylinders. The internal clearance of the cylinder diameter is controlled, which in fact must correspond tostandard. There should be no dents or cracks on the parts.

The CCGT repair kit includes the following KamAZ spare parts:

• Rear housing protective cover.
• Cone and diaphragm reducer.
• Cuffs for pneumatic and follower pistons.
• Blowoff valve cap.
• Retaining and O-rings.

Before installation, it is recommended to treat all parts with Litol type grease.

Replacement and installation

To replace the node in question, perform the following manipulations:

• Air is being bled from the CCGT KamAZ-5320.
• The working fluid is drained or the drain is blocked with a plug.
• The clutch lever fork clamp spring is being removed.
• The water and air supply pipes are disconnected from the device.
• The screws of fastening to the crankcase are unscrewed, after which the unit is dismantled.

After replacing the deformed and unusable elements, the system is checked for tightness in the hydraulic and pneumatic parts. Assembly is as follows:

• Align all the fixing holes with the sockets in the crankcase, after which the amplifier is fixed with a pair of bolts with spring washers.
• Connect hydraulic hose and air pipe.
• The pull-back spring mechanism of the clutch release fork is mounted.
• Pour brake fluid into the expansion tank, then bleed the hydraulic drive system.
• Re-check the tightness of the connections for leakage of the working fluid.
• Adjust, if necessary, the amount of gap between the end part of the cover and the stroke limiter of the gear divider activator.

Principal diagram of connection and placement of assembly elements

The principle of operation of the CCGT KamAZ-5320 is easier to understand by studying the diagram below with explanations.

• a - standard scheme of interaction of parts of the drive.
• b - location and fixation of the node elements.
• 1 - clutch pedal.
• 2 - main cylinder.
• 3 is the cylindrical part of the pneumatic booster.
• 4 – Pneumatic part follower.
• 5 - air duct.
• 6 - main hydraulic cylinder.
• 7 – release clutch with bearing.
• 8 – lever.
• 9 - stock.
• 10 - drive hoses and pipes.

The node in question has a fairly clear and simple device. Nevertheless, its role in driving a truck is very significant. The use of a CCGT can significantly facilitate the control of the machine and increase the efficiency of the vehicle.