In this article I decided to write about the repair of the GAZ 53 pump. This is not entirely a deviation from the main direction on the site, since these repair kits are also suitable for repairing the pump on the UAZ. And in general the procedure itself is similar.
There are several symptoms that the gas 53 pump needs repair:
- coolant leak;
- strong shaft play in bearings;
- boiling of the coolant after a short period of engine operation.
If the first two points are less clear, then I’ll explain a little about the last one. The GAZ 53 impeller is now mainly made of plastic or textolite and, unlike cast iron, has less strength. The bushing becomes loose, or even the blades break. And this happens after the bearings become loose and the gas 53 pump impeller begins to cling to the housing. An impeller with broken petals does not move liquid well, which leads to its rapid boiling.
Instruments
In this case, you will need tools not only to disassemble the pump itself, but also to remove it.
- key for 12 - 13;
- key for 17 - 19;
- hammer;
- pliers.
Gas pump repair 53
After the pump is removed, repair the water pump gas 53 in order to remove the impeller. If it is made of plastic or textolite, it is better to break it. In this case, I didn’t rack my brain, I was going to install a new one and just broke it. I had a cast iron impeller for the pump.
The bushing from the impeller remained on the shaft
For those who are simply going to change the bearings and the impeller of the Gas 53 pump is needed intact, then the question of removing it without damaging it is very difficult. If the pump has not been disassembled for a long time, then we can say in advance that it has become stuck to the shaft and it is better to prepare by purchasing an impeller in advance.
Then he heated the shaft with the remains of the impeller with a burner and poured water on it. Don't worry about bearings, you still need to install new ones. The procedure had to be repeated twice.
Remove the retaining ring from the pump housing and knock out the remaining shaft with bearings towards the fan. The front bearing of the water pump 20803-KU (part number 20803) will be knocked out along with the shaft, but the water pump bearing (rear) 20703-KU (part number 14-1307082-20) will remain and will have to be knocked out separately.
The bearings are closed on one side and must be installed with the closed side facing out. That is, it is clear that the open part will be inside for access to lubricant from the grease fitting.
Most often it is the front bearing that fails.
In advance, clean the housing of the gas 53 water pump from gasket residues and, if possible, sand it with an emery disc. Clean the bearing seats and retaining ring.
We begin the assembly by installing the shaft with bearings, a pulley with a nut, a repair kit and the impeller of the gas 53 water pump.
Be more careful when assembling the repair kit (cuffs, springs, seals, etc.). After assembly, do not forget to syringe the pump through a grease nipple, otherwise you will forget to do this and the bearings will not work for a long time.
The GAZ-53 engine lubrication system (Fig. 1) is combined: under pressure, splashing and gravity. The oil in the engine oil sump is sucked into the oil pump 9 through the oil receiver 12.
From it, oil under pressure is supplied through channels in the block to the full-flow oil filter 4, and from there to the main oil line 6 of the engine. From the main line of the GAZ-53 lubrication system, oil flows through channels in the cylinder block to the main bearings of the crankshaft and camshaft bearings.
Through drillings in the crankshaft, oil from the main bearings flows into the cavities of the connecting rod journals and through drillings in the connecting rod journals to the connecting rod bearings. In the cavities of the connecting rod journals, the oil undergoes additional purification due to centrifugal forces.
Fig.1. Lubrication system GAZ-53
1 - oil radiator; 2 - cavity of the rocker arm axis; 3 - channel in the cylinder head; 4 - oil filter; 5 - channel in the cylinder block; 6 - main oil line; 7 - hole in the distributor drive housing; 8 - cavity; 9 - oil pump; 10 - pressure reducing valve; 11 - fourth camshaft journal; 12- oil receiver; 13 - safety valve; 14 - oil cooler tap, 15 - second camshaft journal
From the second and fourth camshaft supports, oil flows through channels in the GAZ-53 block and heads to the rocker arm axes. From the internal cavity of the rocker arm axis, oil flows through drillings to the rocker arm bearings.
Further along the grooves in the rocker arm bushings, drillings in the rocker arms and adjusting screws - to the upper tips of the rods. Flowing down the rods, the oil reaches the lower tips and flows through the holes in the pushers into the oil sump, lubricating the pusher guides and their ends.
The thrust flange of the GAZ-53 camshaft is lubricated through a flat and a hole in the front camshaft support. Drive gears through a tube from the main oil line.
The drive of the ignition distributor, the oil pump and its gears are lubricated with oil coming from cavity 8 located between the fifth camshaft support journal and the plug in the cylinder block. Oil is supplied to other parts that require lubrication by splashing or gravity flow.
The oil pressure in the GAZ-53 lubrication system when the vehicle is moving in direct gear at a speed of 55 km/h must be at least 250 kPa with the oil cooler turned off and the engine well warmed up. When starting and warming up a cold engine, the oil pressure can reach 500 - 550 kPa.
When the oil pressure in the oil line of the GAZ-53 engine drops to 40 - 80 kPa, the emergency oil pressure warning light on the instrument panel lights up.
It is permissible for the indicator to light up at a low crankshaft speed in idle mode. If the lubrication system of the GAZ-53 engine is working properly, the indicator goes out when the rotation speed increases.
If the indicator lights up at medium and high engine speeds, it indicates a malfunction. Until it is eliminated, further operation of the vehicle is not allowed.
When the ambient temperature is above 20 °C and when driving in particularly difficult conditions, it is necessary to turn on the oil cooler by opening the tap located on the left side of the engine. When the radiator is turned on, the faucet handle is directed along the axis of the hose.
Oil enters the radiator only when the tap is open through the safety valve. This valve opens at a pressure in the GAZ-53 lubrication system of about 100 kPa. After passing through the radiator, the oil is drained into the oil sump.
The oil sump of the GAZ-53 engine is made of sheet steel, stamped, and attached to the lower plane of the cylinder block with studs.
The crankcase flange is sealed with a cork gasket. At the bottom of the crankcase there is a drain plug sealed with a metal-asbestos gasket. The oil receiver is mesh, non-floating type.
Fig.2. Oil pump GAZ-53
The GAZ-53 oil pump (Fig. 2) is a single-section gear type, driven into rotation by the ignition distributor drive through an intermediate shaft.
The housing of the GAZ-53 oil pump is made of aluminum alloy, the cover is made of cast iron. The cover contains a pressure relief valve that protects the lubrication system from excessive pressure. The valve is adjusted at the factory and its adjustment during operation is prohibited.
Fig.3. Oil filter GAZ-53
1 - filter housing (upper part); 2 - spring; 3- support washer; 4 - sealing ring; 5 - filter element; 6 - filter housing tube; 7-bypass valve plug; 8- filter housing gasket; 9 - bypass valve gasket; 10 - bypass valve spring, 11 - bypass valve ball; 12 - oil filter rod; 13 - filter element gasket; 14 - filter housing (lower part); 15 - gasket of the lower part of the filter housing; 16 - filter spacer; 17-washer; 18 - connecting nut; 19 - sealing gasket; 20 - connecting fitting; 21 - sealing gasket; 22 - sealing ring
The GAZ-53 oil filter (Fig. 3) is full-flow with a replaceable paper filter element Regotmas, consists of the oil filter itself and its spacer. The spacer contains a bypass valve that is activated when the oil filter element is completely clogged.
In this case, the oil enters the engine line, bypassing the filter element. The spacer is attached to the inlet pipe with a special fitting and sealed with a paronite gasket and a rubber ring.
When the GAZ-53 filter element is clogged, oil flows from the spacer fitting through holes B into the safety valve area, opens the ball valve and, without cleaning, enters the spacer cavity, from where it goes into the oil line. Thus, the bypass valve in the spacer protects the engine from running without lubrication.
Fig.4. Drive of the ignition distributor and oil pump GAZ-53
The drive of the ignition distributor and oil pump GAZ-53 (Fig. 4) consists of housing 1, into which two bushings made of sheet bronze are pressed. Roller 2 rotates in the bushings, at one end of which there is a slot for the shank of the ignition distributor roller.
The slot is offset relative to the axis of the roller, due to which the distributor can be installed in only one position. The drive shaft is secured against axial movements by a retaining ring 7. A spring ring 6 is also installed.
Driven gear 5 is secured with a pin at the lower end of the shaft. The drive gear is located on the camshaft. Two washers are installed between the end of the housing and the driven gear: steel 3 and aluminum 4.
At the lower end of the GAZ-53 distributor drive shaft there is a hexagonal hole into which hexagonal shaft 8 of the oil pump drive fits. This roller is secured with the same pin as the driven gear.
The lower end of the hexagonal shaft fits freely into the hexagonal hole in the end of the shaft of the GAZ-53 oil pump. If the oil pump jams for any reason, pin 9 is cut off, and the drive shaft and engine stop.
The oil cooler of the GAZ-53 engine is made of a thick-walled aluminum tube, formed into a coil with five straight sections. In straight sections, the oil cooler has special cooling fins made by knurling. The radiator is connected to the engine by rubber hoses.
A drop in pressure in the lubrication system can be caused by wear of oil pump parts or crankshaft and camshaft bearings. With significant contributions, the pump begins to operate noisily.
To identify pump faults, it is removed from the engine and disassembled. But they begin to disassemble the GAZ-53 oil pump only after checking the condition of the pressure relief valve, since it may cause incorrect pressure in the oil system (the spring is weakened, the plunger is stuck, etc.).
The pressure reducing valve is located in the cover of the GAZ-53 oil pump. The force of the pressure reducing valve spring when compressing it to a length of 40 mm should be in the range of 43.5 - 48.5 N. Placing washers under the spring is prohibited. The faulty spring is replaced with a new one.
To disassemble the oil pump, unscrew the two fastening nuts and remove the pump from the cylinder block along with the gasket; unscrew the four bolts securing the oil pump cover and remove the cover with the gasket; remove the oil pump driven gear from the housing; remove the pump shaft with drive gear assembly. After disassembling the pump, all its parts are thoroughly washed, dried and inspected.
If wear from the gear is found on the surface of the GAZ-53 oil pump cover, then grind the surface of the cover until traces of wear are destroyed.
In case of major malfunctions, the pump is replaced with a new one. During repairs, the necessary clearances and tensions in the mating parts must be ensured.
When replacing a roller with a new one, as well as other types of repairs, keep in mind the following:
The distance from the end of the roller with a hexagonal hole to the upper end of the oil pump drive gear should be (42.5 + 0.15) mm;
A hole with a diameter of 4+0.5 mm for the gear mounting pin on the pump shaft is drilled to a depth of (23±0.5) mm at a distance of 20 mm from the end of the gear. The protrusion of the pin above the plane of the tooth cavity is not allowed;
When pressing the driven gear axis out of the pump housing, the housing is heated to a temperature of 100-120 °C;
To press the axle into the pump casing, the casing is heated to a temperature of 160 - 175 ° C, and the axle is cooled in dry ice to a temperature of - 70 ° C;
When pressing the driven gear axis into the housing, press the axis until it stops (Fig. 6).
To assemble the GAZ-53 oil pump, install the roller assembly with the drive gear into the oil pump housing; install the driven gear on the axis in the pump housing; The oil pump cover with a gasket is placed on the housing; secure the cover to the pump body with four bolts.
When assembling the oil pump, always change the paronite or cardboard gasket of the cover (their thickness is 0.3 mm). It is unacceptable to use shellac or other sealing agents, or to increase the thickness of the gasket, as this reduces the performance of the pump.
Before installing the GAZ-53 oil pump on the engine, it must be filled with oil, since a dry pump at the very beginning of engine operation will not supply oil to the rubbing surfaces, which will lead to their scuffing and failure.
When disassembling the GAZ-53 ignition distributor drive, remove the spring ring and remove the safety pin, remove the hexagonal shaft of the oil pump drive, remove the retaining ring and gear from the shaft, remove the thrust washers and remove the shaft from the distributor drive housing.
To assemble the ignition distributor drive, before assembly, all drive parts are blown with compressed air and wiped with clean cloths.
The shaft assembly is lubricated with clean engine oil, inserted into the distributor drive housing and tested for ease of rotation by hand. Thrust washers are installed on the roller, first steel 3, then aluminum alloy 4.
Install the gear onto the drive shaft. A hexagonal oil pump drive shaft is inserted into the hexagonal hole at the end of the GAZ-53 distributor drive shaft, a pin is installed in a hole with a diameter of 3.5 mm, a spring ring is installed in the groove on the gear hub, and a retaining ring is installed in the groove of the drive shaft.
Check the ease of rotation of the roller by hand, the gap between the thrust washer and the end of the drive gear, which should be 0.15 - 0.40 mm; The displacement of the center of the tooth cavity of the distributor drive gear relative to the axis of the roller groove is permissible deviation ± 2°.
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GAZ-53 engine parts
ENGINE LUBRICATION SYSTEM GAZ-53-12
Lubrication system (Fig. 14) - combined: under pressure,
Spraying and gravity flow. The oil in the engine oil sump is sucked into the oil pump 9 through the oil receiver 12. From there, oil under pressure is supplied through channels in the block to the full-flow oil filter 4, and from there to the main oil line 6 of the engine. From the main oil line, oil flows through channels in the cylinder block to the crankshaft main bearings and camshaft pressures. By
The drillings in the crankshaft supply oil from the main bearings to the cavities of the connecting rod journals and through the drillings in the connecting rod journals to the connecting rod bearings. In the cavities of the connecting rod journals, the oil undergoes additional purification due to centrifugal forces.
From the second and fourth camshaft bearings, oil flows through channels in the block and heads to the rocker arm axes. From the internal cavity of the rocker arm axis, oil flows through drillings to the rocker arm bearings. Next, along the grooves in the rocker arm bushings, drillings in the rocker arms and adjusting screws, to the upper tips of the rods. Flowing down the rods, the oil reaches the lower tips and flows through the holes in the pushers into the oil sump, lubricating the pusher guides and their ends.
The camshaft thrust flange is lubricated through a flat and a hole in the front camshaft support. Drive gears through a tube from the main oil line. The drive of the ignition distributor, the oil pump and its gears are lubricated with oil coming from cavity 8 located between the fifth camshaft support journal and the plug in the cylinder block. Oil is supplied to other parts that require lubrication by splashing or gravity flow.
The oil pressure in the lubrication system when the vehicle is moving in direct gear at a speed of 55 km/h must be at least 250 kPa with the oil cooler turned off and the engine well warmed up. When starting and warming up a cold engine, the oil pressure can reach 500 - 550 kPa.
When the oil pressure in the engine oil line drops to 40-80 kPa, the emergency oil pressure warning light on the instrument panel lights up.
It is permissible for the indicator to light up at a low crankshaft speed in idle mode. If the lubrication system is working properly, the indicator goes out when the rotation speed increases. If the indicator lights up at medium and high engine speeds, it indicates a malfunction. Until it is eliminated, further operation of the vehicle is not allowed.
When the ambient temperature is above 20 °C and when driving in particularly difficult conditions, it is necessary to turn on the oil cooler by opening the tap located on the left side of the engine. When the radiator is turned on, the faucet handle is directed along the axis of the hose. Oil enters the radiator only when the tap is open through the safety valve. This valve opens at a pressure in the lubrication system of about 100 kPa. After passing through the radiator, the oil is drained into the oil sump.
Introduction………………………………………………………………………………..
1. General information………………………………………………………..
2. Tactical technical characteristics of the car Gas - 53A…………
3. Main parameters and transmission diagram of the Gas - 53A car........
3.1. Purpose of the transmission and its general data …………………………
3.2. Rear axle………………………………………………………………
4. Calculation part…………………………………………………………
4.1 Traction calculations and dynamic characteristics………………………
4.2 Calculation of power balance, base vehicles during straight-line movement on a horizontal section of the track in direct (overdrive) gear…………………………………………………………………………………………
Conclusion……………………………………………………………………
Bibliography……………………………………………………………
Introduction
One of the most common cars in Russia, the GAZ-53, can still be found on the streets of our cities. Whatever kind of work this truck performed, the machine found application in various spheres of the country’s national economy. Utility vehicles, fire trucks, agricultural machinery and much more were built on its basis.
The GAZ-53 car has been produced by the Gorky Automobile Plant since 1964. The body is an all-metal platform with an opening tailgate. The awning can be installed on five arches. The all-metal double cabin is equipped with a suspended berth and is located above the engine. The GAZ-53 car is rear-wheel drive with a four-speed gearbox. The vehicles are designed for transporting passengers and cargo on all types of roads and terrain and are designed for operation at ambient temperatures from minus 45 to plus 40 0 C. Based on the Gas - 53 vehicle, the FC-30 light-type tank truck was built and is intended for extinguishing fires with water from the tank or from an external water source, air-mechanical foam using exported foam concentrate or taking it from an external container, as well as for delivering combat crews, firefighting equipment and technical weapons, water and foam concentrate to the fire site. Units armed with tank trucks are capable of supplying water and air-mechanical foam of various expansion rates for extinguishing fires without installation and with the installation of machines at water sources, they can supply water from remote water sources, take it from water sources with poor access roads using hydraulic elevators and supply it to extinguishing fires; pump water from remote sources in cooperation with other units on the main fire engines.
General information.
Lightweight car. The body of the fire tanker contains a tank with a capacity of 2000 liters. The pump compartment is located at the rear of the vehicle and contains the control panel, taps, valves and the PN-30 pumping unit itself. Fire-fighting equipment is located in the side compartments of the body. The combat crew of the tanker consists of 2 people.
Tactical technical characteristics of the GAZ-53A car
dimensions
Gross weight, kg 7400
For the front axle 1810
To the rear axle 5590
Load capacity, kg 4000
Maximum weight of towed trailer with cargo, kg 4000
Vehicle weight in running order
(without additional equipment), kg 3250
Overall dimensions of the car, mm
Width 2380
Height (cabin without load) 2220
Height (on the awning without load) 2220
Vehicle base, mm 3700
Highest vehicle speed with full load
without a trailer (on a horizontal section of road with
improved coating), km/h 80-86
Front wheel track (on ground), mm 1630
Rear wheel track (on ground), mm 1690
Lowest points of the car (with full load), mm
Drive axle housings 265
Front axle 347
Fig 1. Overall dimensions.
Engine.
Today there are many types of engines such as:
1. Electric motors (converting electrical energy accumulated in batteries into mechanical energy of rotation of the engine rotor, which in turn transmits rotational energy to the wheels).
2. Steam.
3. ICE (in which the chemical energy of the fuel is converted into mechanical work).
Gasoline (where the working mixture of air and gasoline is prepared in a carburetor or injected into the manifold using injectors)
Diesel (injection is carried out by a nozzle into air compressed by pistons)
Gas engines (powered by liquefied gas)
ICEs have become more widespread due to their autonomy and higher energy content in the fuel.
My course work presents: carburetor internal combustion engine
Number of cylinders and their arrangement 8, V-shaped
Cylinder diameter, mm 92
Piston stroke, mm 80
Cylinder displacement, l 4.25
Compression Ratio (Average) 6.7
Maximum power (limited by regulator)
at 3200 rpm, hp kW. 115 (84.6)
Maximum torque 2000-2500 rpm, kgm 29 (284.4 N m)
Carburetor K – 126B, two-chamber,
balanced, falling
Air filter Inertia-oil with
contact filter
element
Engine cooling Liquid, forced,
with a centrifugal pump. IN
cooling system available
thermostat installed in
outlet pipe
Chassis
To avoid increased tire wear, you should not brake the car sharply, allow it to be overloaded, jerking and wheel slipping when starting from a stop and changing from low to higher gears.
The load must be placed evenly over the entire area of the platform. Place heavy but small-sized cargo closer to the cabin.
Low pressure tires 8.25-20 or type P
(the pressure in them should be: at
front wheels 5 kg/cm⅔,
on the back 6 kg/cm⅔,).
Tire size 240-508.
Refill containers and standards
Fuel tanks (capacity), l 90
Engine cooling system, l
With starting heating 23
Without starting heating 21.5
Engine lubrication system, l 8.0
Air filter, l 0.55
Gearbox housing, l 3.0
Rear axle housing, l 8.2
Steering gear housing, l 0.5
Shock absorbers (each separately), l 0.41
Hydraulic foot drive system