Combined-cycle plants (CCP): design and principle of operation

Category: KAMAZ

• Design and features of KamAZ PSU
• Operating principle of CCGT
• Amplifiers used on KamAZ
• Malfunctions of KamAZ PGU
• Do-it-yourself KamAZ PSU repair
• Adjusting KamAZ PGU

The applied forces required for the truck's operating processes are proportional to the dimensions of the vehicle. KamAZ PGU reduces the load required for the functioning of the most important element in driving a vehicle, the clutch.

An uninitiated user is unlikely to appreciate the unit, because without an amplifier, the gear shift circuit and the operating condition of the car will not be affected. However, the direct participant in management knows the true price of the mechanism. With the absence of a PSU, driver fatigue increases and the maneuverability of the equipment decreases. As a result, road safety suffers and the number of accidents increases, which means human lives.

KamAZ-5490:

Design and features of KamAZ PSU

Most KamAZ vehicles, both old and recent, use a power amplifier in their transmission design, based on the principles of pneumatics and hydraulics. The unit is installed on KamAZ vehicles: 4310, 55111, 65115, etc. The application is determined by the force developed by the springs to operate the clutch with such a large weight. The average person is not able to operate a KamAZ vehicle without an amplifier during the working day without losing vigilance and attention. The operation of the KamAZ PGU makes it easier to complete the task; the product is built into the clutch mechanism, due to which the driver’s fatigue and performance remain at the required level.

A feature of some KamAZ vehicles is the simultaneous use of a PSU with a gearbox divider. As a rule, the amplifier is an integral part of the box, located between the box and the divider. Switching speeds is accompanied by turning off the divider; the pneumatics of the machine are responsible for this. The process is possible thanks to the valve, which is actuated by the PSU rod. This means that the divider operates and disengages synchronously, by applying and releasing pressure from the foot clutch lever.

PGU KamAZ:

Advantages of a combined cycle plant

The operating principle of a combined-cycle plant is specific; unlike similar systems, it consumes fewer resources (especially water) for each unit of energy obtained with its help. Industry experts also note that combined cycle gas structures stand out:

• greater degree of environmental friendliness (reduced greenhouse gas emissions);
• compact dimensions;
• comparative speed of construction (less than 1 year);
• less fuel requirement.

It is worth noting that CCGT manufacturers do not stop there. The modern combined cycle generator is evolving much faster than previous versions of this technology. Today, designs are being actively developed that run on renewable energy sources, biofuel: waste from the woodworking industry and agriculture.

Operating principle of CCGT

Today, force converters of several types are built into vehicle transmissions, however, the operating principle of the KamAZ PGU is the same. Structurally, the mechanism is connected by two nodes placed in the frame:

• Tracking mechanism;
• A cylindrical chamber that performs functions using pneumatics.

The tracking device controls the PSU by monitoring the force with which the driver presses the foot clutch lever. When the pressure reaches the desired value, a portion of the air mass is supplied to the cylinder. The tracking device includes a membrane, which sometimes acts as a seal for the frame parts. The mechanism also includes a piston connected to the foot clutch lever via hydraulics. In addition, there are intake and exhaust valves, both of which are pneumatic and interact with the piston. Since both hydraulic and pneumatic elements are involved in the operation of the mechanism, both air and liquid are supplied to the CCGT unit.

general information

The passport of a gas cleaning installation and the passport of a dust collection installation are documents that must be drawn up by the enterprise owners of these installations in accordance with existing legislation in Russia (Federal Law No. 96-FZ “On the Protection of Atmospheric Air”).

The passport and development procedure are designed to guarantee compliance with the environmental requirements of the legislation of the Russian Federation on the protection of atmospheric resources. In accordance with the Rules for the operation of gas purification plants, approved by Order of the Ministry of Natural Resources of Russia dated September 15, 2017 No. 498, there are no requirements for the need for registration, approval or approval of the GOU passport in any government bodies.

Amplifiers used on KamAZ

Structurally, KamAZ vehicles provide for the use of products of both domestic and foreign production. The operating principle of the mechanisms is identical; the devices differ in characteristics and design.

• Thus, the 5320 amplifier, produced at the Kama plant, structurally uses a vertical arrangement of the follower mechanism; the pneumatic cylinder is also installed vertically. Such devices are used on modifications: 5320, 4310, 43118, etc.
• The WABCO amplifier is manufactured in the United States of America. The product is distinguished by its compact size and lining wear indicators, which facilitates the use of the PGU. Similar devices are used on new KamAZ vehicle models: 5460, 6450, 6460, 65117, etc. The amplifier is compatible with “154” series gearboxes, which are used with power units that meet Euro-2 and Euro-3 standards.
• PGU "WABCO" for KamAZ modifications: 6460, 6520 and other equipment with ZF gearboxes.
• PGU "WABCO" for modifications of KamAZ: 4308, on which a ZF five-speed gearbox is installed.
• CCGT units made according to the “WABCO” type are produced in Ukraine and Turkey.

PGU Mos.ru: login to your personal account

To receive various services, such as an electronic diary, making an appointment with a doctor, transferring meter readings and electronic railways, you must log in to the Moscow State Services portal at https://oauth20.mos.ru/sps/login.jsp and in the window that opens, enter your login and password. Your SNILS, mobile phone number or email address can be used as a login; login through social networks, an electronic digital signature and an account on the Gosuslugi.ru .

If the data is correct, you will find yourself on the main page of your personal account on the Mos.ru portal. Your profile on the portal contains all the basic information, such as passport number, full name, date of birth, e-mail address and contact phone number.

The following services are available to you in your Moscow government services account:

• Search and payment of traffic police fines
• Making an appointment with a doctor
• Transmission of water meter readings (it is important to transmit the readings within the allotted time - from the 15th of the current month to the 3rd of the next month)
• Receipt and payment of a single payment document (UPD)
• Checking and topping up your MGTS home phone balance
• Housing and utilities calculator
• One-click payments (pay utilities, fines and state duties with one button - to do this, just enter your payer code, SNILS, driver's license number and STS in your mos.ru personal account.)
• Setting up automatic payments for services (You can create an automatic payment after payment on the payment result page)
• Student's electronic diary
• Registration (transfer) to kindergarten
• Enrolling a child in a circle, sports section and creativity center
• Payment for parking
• Topping up the Troika card
• State registration of marriage
• Vacation packages for children's recreation and wellness

Many people confuse the portal with the main State Services website: the main difference between the Moscow State Services portal pgu.mos.ru and the usual State Services portal gosuslugi.ru is that the portal contains information primarily about state and municipal services provided by various executive authorities of the city of Moscow and city organizations.

In some cases, when you try to log into the MosService portal, the message “Server is temporarily unavailable” appears. In this situation, access to the mos.ru portal may be impossible for technical reasons or seriously difficult due to the large number of visitors. Please try to visit the site later.

Malfunctions of KamAZ PGU

Inspection and testing of the performance of the GPU is carried out together with the clutch mechanism. The procedure for carrying out manipulations is described in the documentation for each car. The amplifier is checked for oil and air leaks, and the tightening forces of the fasteners are monitored. Adjust the stroke of the foot lever by positioning the spherical nut, and check the fluid level in the hydraulic tank. In case of serious breakdowns, the KamAZ PSU is replaced or repaired.

The replacement is accompanied by manipulations:

• Open the bypass valve to allow air masses to escape;
• Remove the spring mechanism pressing the clutch deactivation fork shaft lever;
• Remove lubricant from the hydraulic circuit;
• Disconnect the pneumatic and hydraulic pipes;
• Remove the PSU.

Dismantled KamAZ PSU:

After dismantling, the technical condition of the CCGT parts and assemblies is checked. Attention is paid to the seals and the cylinder mirror - a surface without traces of mechanical impact. In addition, the internal diameter is measured to ensure compliance with established tolerances and fits.

A repaired or newly purchased amplifier is mounted in place by performing the steps in reverse order. After installation, check the tightness of the hydraulics and pneumatics. To do this, fill the circuit with liquid in the required volume.

As a rule, the amplifier works without problems for five to ten years. In case of breakdowns, it is more advisable to replace the product with a new one. CCGT units are repaired for minor or non-serious defects. The reasons for the failure of the KamAZ CCGT unit, possible malfunctions and their elimination are carried out on the equipment by service workers.

Frequently observed breakdowns:

• Under the influence of oil, the rubber seals swelled, and as a result, the PGU piston jammed;
• The exhaust valve does not allow air masses to pass through, or does not allow air masses to pass through in an insufficient volume;
• The presence of air bubbles in the hydraulic circuit, as a result, failures in the operation of the foot lever.

Validity period for the development of PSU passports

Current legislation requires each business entity to maintain a CCGT passport for the entire period while the equipment is on the balance sheet of the enterprise. Maintenance consists of carrying out annual measurements to assess the effectiveness of emission treatment and then entering the results into the passport.

The passport also contains data on repair work, changes in the operating mode of the enterprise, the purchase of new raw materials, the transformation of technological processes, as well as other factors that can affect the volume and composition of emissions.

Thus, the validity period of the document is unlimited.

Do-it-yourself KamAZ PSU repair

If you perform the work yourself, the manipulations are carried out according to the instructions. First, disassemble the dismantled device in this order:

• Fix the back of the frame using a clamp;
• Unscrew the fasteners;
• The closing element supplying air masses is dismantled;
• The valve is removed;
• The frame is dismantled together with the pneumatic circuit piston;
• The spring elements of the diaphragm and piston of the pneumatic circuit are removed;
• The membrane is dismantled;
• They sort out: seal, thrust damper, tracking and clutch deactivation pistons;
• The closing element with the outlet gasket and bypass valve is dismantled;
• The back of the frame is removed from the holder;
• The retaining ring is removed;
• The valve stem is disassembled;
• The seal ring of the tracking piston housing is removed;
• The tracking piston is disassembled;
• You get the o-ring and pneumatic piston;
• The cuff is removed from the pneumatic piston.

Disassembly

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

• The back of the body is clamped in a vice.
• The bolts are unscrewed. Remove the washers and cover.
• The valve is removed from the body part.
• The front frame is dismantled along with the pneumatic piston and its membrane.
• The following are removed: the diaphragm, the follower piston, the retaining ring, the clutch release element and the seal housing.
• The bypass valve mechanism and the hatch with the outlet seal are removed.
• The frame is removed from the yews.
• The thrust ring of the rear part of the housing is dismantled.
• The valve stem is freed from all cones, washers and seats.
• The follower piston is removed (you must first remove the stopper and other related elements).
• The pneumatic piston, cuff and retaining ring are removed from the front part of the housing.
• Then all parts are washed in gasoline (kerosene), sprayed with compressed air and go through the defect detection stage.

Adjusting KamAZ PGU

After the mechanism has been rebuilt, repaired, reassembled and put back in place, the final procedure is performed - the amplifier is adjusted. The procedure is considered completed if the pusher of the pneumatic circuit overcomes a distance of at least twenty-five millimeters. A lower value leads to unstable operation and disengagement of the clutch. To test the full stroke, the foot lever is pressed all the way. If the indicator is not at the proper level, check the presence of fluid in the reservoir of the clutch master cylinder and free movement. If air bubbles are detected in the circuit, the masses are removed.

Responsibility for the lack of development of PSU passports

In case of violations of the legislation regarding certification under PSU, business entities fall under administrative responsibility, namely, they are required to pay fines:

• officials - from 1000 to 2000 rubles;
• individual entrepreneurs without forming a legal entity - from 1000 to 2000 rubles or suspension of activities for 90 days;
• legal entities - from 10,000 to 20,000 rubles or suspension of activities for 90 days.

Registration of a personal account on the Moscow State Services portal

To use the pgu.mos.ru , you must register on the Moscow State Services portal. To do this, go to https://oauth20.mos.ru/selfservice/registration/openregister.do and fill in all required fields:

1. FULL NAME.
2. Email address (enter your personal email address)
3. Mobile phone number (needed to confirm registration and to recover your password)
4. Create a password
5. Ask a security question and answer
6. Click the "Register" button

Registration on the Moscow State Services portal is available only to residents of the capital, since most of the necessary documents for the provision of services and requests are available only to Moscow residents. If registered, foreigners and residents of other cities will be given limited access to their personal account.

If you want to register your relatives on the PGU MOS.RU portal, then there is no need to create separate accounts for them - you can make an appointment for your loved ones using your account.

Advice! To save time, you can log into the Moscow service portal using a verified account on the Gosuslugi.ru portal. When registering using this method, all the necessary fields and documents from your profile on State Services will automatically be transferred to the State Services portal.

Recovering the password for the personal account of the Moscow State Services portal

If you do not remember your password for your personal account on the Moscow State Services portal, then you can use the password recovery function. To do this, go to the login page for your personal account https://oauth20.mos.ru/sps/login.jsp and under the login form click on the link “Forgot your password?”

You can recover your password in several ways:

1. By mobile phone number
2. By email address
3. By SNILS number

Choose a method of restoring access that is convenient for you, enter the requested details and click the “Submit” button. Next, follow the system prompts. Now create and save a new password for your personal account. This completes the password recovery procedure successfully.