Replacing the plunger pair KAMAZ 740

The fuel injection pump is designed to supply strictly dosed portions of fuel under high pressure into the engine cylinders at certain times.

The KamAZ 740.11-240, 740.13-260, 740.14-300 engines use a split-type fuel supply system, consisting of a high-pressure fuel pump, injectors, coarse and fine filters, a low-pressure fuel priming pump, low and high pressure fuel lines, fuel tanks, electromagnetic valve and torch spark plugs of the electric torch starting device. In-line injection pump Bosch KAMAZ euro The KAMAZ plunger pair consists of a bushing and the plunger itself, which performs reciprocating movements inside the bushing. The plunger is a cylindrical displacer, and its length is much greater than its diameter. Interestingly, the seal is located on the bushing and during operation of the mechanism it moves along the surface of the plunger, which, taking into account the operating fuel pressure of 200 MPa, causes severe wear.

Fuel is pumped during the working stroke of the KAMAZ plunger pair under the action of a special cam, and the suction process is ensured by a return spring. The bushing has several holes through which fuel is supplied during injection, and subsequently, excess fuel is discharged through them.

The injection pump of the KAMAZ-740 vehicle is V-shaped and consists of two sections, each of which has four plunger pairs. By the way, the word plunger itself comes from the English plunge, that is, to dive.

Removing fuel injection pump Kamaz 740

• disconnect the manual control cables for the engine stop lever and the governor control lever, the fuel supply control rod, the fuel supply pipelines to the pump, the outlet and drainage pipelines and the pipeline from the fine fuel filter, the oil supply pipe to the pump, the oil outlet pipe; • unscrew the coupling bolt of the front flange of the driving half-clutch, two bolts of the driven half-clutch (to unscrew the bolts, move them to a convenient position by turning the crankshaft with a crowbar through the holes on the flywheel through the clutch housing hatch); • disconnect the pipelines supplying fuel to the flare plugs, high-pressure pipelines (remove them), the air supply pipe to the auxiliary brake pneumatic cylinder; • unscrew the four bolts securing the fuel pump; • remove the pump.

Injection pump repair

Troubleshooting methods for a high-pressure fuel pump depend on the type of device, as well as the cause of the breakdown. We list the most common repair measures.

Replacing the plunger pair with your own hands

Before performing an independent check (without using a special stand), you must have handyman tools and a new plunger pair on hand, as well as have experience in performing repair work. We will describe the description of checking the condition of the high-pressure fuel pump using the example of a common Bosch injection pump.

It is necessary to understand that dismantling the pump depends on the specific model and even the car engine, so the procedure will be described in general terms. So, to replace a plunger pair (the most common type of repair) you need to:

remove the terminals from the car battery; disconnect all wires and hoses suitable for it from the high-pressure pump; dismantle parts that prevent its removal from the car; unscrew the fasteners and dismantle the pump; carefully disassemble the pump, it is important not to lose small parts, and also remember the disassembly sequence (you can photograph this process step by step on your phone); unscrew and remove the plunger from the pump; clean all pump parts from dirt (you can use special carb cleaners or similar cleaners for this); check the rollers, bearings and racks on the pump; they should not show significant wear; remove the valves and the so-called “silencer” from the old plunger pair, and then install them on the new pair; Carry out installation work in reverse order.

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Please note that replacing the plunger pair can only be done if you are completely sure that this unit is partially out of order, since it costs a lot of money

Rack jamming

If you find that the rack is sticking, then the first thing to do is to find the place where it is “sticking”. This can be done by pumping up the ring gear relative to the rack in the corresponding section. If the rack does not jam, then there will be a small gap.

In this case, independent repair is hardly possible. However, in any case, it is necessary to dismantle the pump and show it to a specialist!

Preventive measures

As you know, prevention is the best repair, therefore, to save money and ensure normal engine operation, it is advisable to carry out simple preventive measures that will help extend the life of the high-pressure fuel pump. In particular:

flushing the fuel system should be performed approximately once or twice a year; be sure to change the fuel filter on time (it is not advisable to clean it, because small particles of dirt will most likely remain on the filter); use high-quality fuel (at any gas station there is documentation indicating how long ago the fuel was delivered, as well as information about its composition, tolerances and seasonality); in winter, it is important to use winter diesel fuel, or to lower the freezing point (increase fluidity) of diesel fuel, you can use special compounds - antigels; it is advisable to leave the car for long periods of time (especially in cold weather) with a full tank, since moisture condensation forms on the inner walls of the tank overnight, which flows down and mixes with the fuel; instead, you can use the moisture removers mentioned above; do not allow the fuel level in the tank to drop critically; in winter, it is imperative to warm up the engine for several minutes before driving, taking into account the coolant temperature and oil pressure gauge readings; use special lubricating additives for diesel fuel if there is a suspicion of low quality diesel fuel.

The measures listed above will contribute to the normal operation of not only the high-pressure pump, but also the entire fuel system of the car as a whole.

Dismantling fuel injection pump Kamaz 740

• unscrew the screws securing the rear cover of the speed controller and remove the cover assembled with the low-pressure pump; • remove the automatic fuel injection advance clutch using tool I-801.16.000. First, unscrew nut 2 (Fig. a)
securing the coupling.
To do this, insert screwdriver 4
into the groove of the nut and, holding clutch
1
from rotating, use wrench
3
to unscrew the nut.
Then, screwing puller 5 (Fig. b)
, remove the coupling;

Using device I-801.16.000: a - to unscrew the coupling fastening nut, advance fuel injection; b - to remove the coupling • unseal and unscrew the screws securing the protective casings of the injection pump sections and remove the casing; • unseal and unscrew the bolts securing the top cover of the regulator and remove the cover; • remove the axis of the regulator lever and remove the regulator lever with the weight clutch lever, clutch, regulator spring and spring lever; • remove the retaining ring and weight holder assembly; • unscrew the rack plugs, remove the rack bushings, then the racks themselves, having previously unlocked them; • unscrew the nuts securing the injection pump sections, remove the lock washers of the section fittings and remove the injection pump sections and plunger pushers; • unscrew and unscrew the nuts and, using a puller I-801.26.000, remove the eccentric of the low-pressure pump drive, the drive gear of the regulator and the intermediate gear; • remove the second bearing from the idler gear axis; • knock out the keys from the toe and shank of the cam shaft, remove the rear bearing cover, remove the cam shaft assembly with bearings and remove the front bearing cover; • using the puller I-801.30.000, remove the bearings from the cam shaft; • disassemble the injection pump sections and the low-pressure fuel priming pump using the device I-801.20.000. To press out the discharge valve of the fuel injection pump section, use tool I-801.21.000.

Brake system malfunctions and ways to eliminate them

There are four main breakdowns that are associated with a malfunction of the KamAZ brake systems:

interference with the safety valve;
clogging in the receiver system or the formation of holes in the hoses;
hole and loss of compressed air;
The piston rings are out of order, the sensors are not functioning properly.

In order to timely identify and correct problems with the brakes of KamaAz, regular diagnostics of the operation of its systems, including electronics, are needed. It is recommended to perform it once every two years.

On the Internet you can find a detailed video with an analysis of all the errors. Below we will analyze them briefly, and also consider ways to eliminate them.

Excess oil inside the pneumatic system

The cause of the excess could be wear on the piston rings. It is necessary to urgently replace this part and signal all other work related to them. In models such as KamAZ 5320 and 6520, this problem can lead to serious problems within a short time after it occurs.

There is no air flowing into the receivers

The cause of the breakdown is most often that the pipes through which the air passes are clogged. To fix the problem, simply clean the pipes. On the KamAZ 5511 model, this problem often occurs due to a broken safety valve. In this case, it needs to be replaced.

Receivers in the pneumatic system are not filled quickly enough

There may be several reasons for this failure:

the connecting elements are not secured well enough;
the receiver is not secured tightly;
the hoses through which air passes are damaged;
The compressor is not operating at full capacity.

Repair methods:

tighten the connecting parts together more tightly; if necessary, they should be replaced;
replace the receiver;
repair or change hoses;
diagnose the compressor if you need to replace it.

Incorrect pressure in receivers

This malfunction is typical for KamAZ 65115 and 43118. It is necessary to stabilize the regulator; if the breakdown occurs a second time, it should be replaced.

The car brakes poorly or does not brake at all

There may be several reasons:

circuit 3 hose clogged
batteries operating on energy spring mechanisms are out of order;
accelerator valve is broken;
The brake chamber has failed.

Troubleshooting methods:

clean the hose using compressed air or replace it;
replace the brake chamber and energy battery;
replace all faulty parts;
inside the brake chamber, repair the stroke of the rods.

The car swerves when braking

There may be two reasons: too much oil has accumulated on the brake pad linings or the brake mechanism requires better adjustment.

The following actions can be a solution to these problems:

change or clean the linings;
additionally adjust the brake mechanism.

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Order code: 028796

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KAMAZ gearbox oil seal, primary shaft 2.2-45x64x8 set 3 pieces fluoroplastic RVL Article: 14.1701230/38/40k, 14.1701230 Order code: 028796 60 ₽ or place an order by phone 8 800 6006 966

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Late ignition: signs

At a late injection moment, the piston moves down from top dead center, and fuel is just starting to flow, the ignition follows. Signs of a problem:

The appearance of white smoke from the exhaust system. The later the ignition, the greater the amount of smoke observed.
The motor does not rev up correctly.
The operation of the power unit is observed to be too soft.
When the gas pedal is smoothly activated, the engine begins to shake at medium speeds, and when the torque increases, this effect abruptly disappears.
Fuel consumption increases, the engine heats up, and the truck pulls poorly.

Early injection point

With early ignition, the piston does not have time to reach the top point, and fuel already begins to enter the working chamber. The main signs of this moment:

Rough motor operation.
When you actively press the gas pedal, a characteristic ringing sound is heard, which intensifies as the temperature of the power unit rises.
White smoke may appear from the exhaust pipe.
There is poor traction.
Fuel consumption increases.