Structure and maintenance of the clutch
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| 发布时间：2010.04.29 新闻来源：Zhejiang Huiyue Bearing technology Co., Ltd. 浏览次数： |
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Clutch control mechanism by relying on driving and driven friction between the components, so that temporary separation of the engine and transmission, and progressive joint, to cut off or passed to the transmission power, to ensure smooth transmission shift work. Meanwhile, emergency braking or sudden deceleration, the transmission arising from the moment of inertia greater than the engine torque, the clutch master and slave between the sliding parts to prevent the transmission overload.
First, the clutch assembly and maintenance of the structural elements
(A) the structure of the clutch assembly
1. The structure of the diaphragm spring clutch assembly
CA1020F, CA1020LF, CA1026LF, CA1020PLF and CA1026PLF automobile clutch model D · S · T215, monolithic form of dry, diaphragm spring, with the reverse shock absorbers, the flywheel assembly, driven plate assembly, the membrane leaf springs, clutch pressure plate and cover and other components, as shown in Figure 10-1.
2. The structure of spiral spring clutch assembly
SY1020DBF, SY1020SBF, SY1020DFF and SY1020SFF type is the car fitted with hydraulically operated, single, dry, pressure-type, coil spring clutch. , The pressure plate assembly with nine helical compression springs, friction with the shock body assembly with friction plate assembly, are pressed between the pressure plate and flywheel. When riding the clutch pedal, clutch bearings forward, oppression, separation of the three levers, pull the pressure plate, friction disc and pressure plate to disengage, to achieve fractionation. The structure shown in Figure 10-2.
(B) the maintenance of the clutch assembly points
1. Diaphragm spring clutch assembly of the repair points
a. diaphragm spring in the use of separation refers to the (small side) easy to wear and bending, separation means hands touch the diaphragm spring (small end) was worn over a depth of about 0.6mm should be replaced.
b. re-loaded diaphragm spring, the diaphragm spring means separation should be in the same plane, with a special insert feeler gauge and measure the gap exceeds 0.5mm, application-specific tools to correct or replace the diaphragm spring.
c. Check the clutch plate friction plate thickness is also adequate, but there is oil, use a cloth wipe and continue to use gasoline. If minor erosion or hardening, it can continue to use after sanding. If severe erosion or cracks, and surface friction and wear to the rivet head is less than 0.2 mm, should be replaced.
d. pressure plate and flywheel surface is scratched, the grinding method can be used to repair or replace with new parts.
e. plate assembly from the action set in the grooves of the spline gear teeth of a spline shaft, the hand-shaking back and forth checking Songkuang not obvious, if it should be replaced.
f. Check the driven plate hub is loose rivets, hammer, lightly tap the rivet can be hand-inspected, if "throaty" sound, that have loose or broken rivets, another shock absorber spring break, should replace the driven disc assembly or re-riveting.
2. Spiral spring clutch assembly of the repair points
a. pressure plate face wear groove depth 超过 0.5 mm or more than 0.12mm flatness tolerance, should be grinding surface, grinding the surface roughness should be 1.6, with a total thickness of not less than 16.10 mm, grinding disk static balance test should be carried out, the imbalance of not more than 40g · cm.
b. Check the friction plate assembly if loose rivets, friction plate cracking, burning, rivet head above (the rivet head is lower than the friction surface should be not less than 1mm), etc., should replace the corresponding parts or assembly. Replacement friction plate assembly of the new thickness should not exceed l0.2mm, if more than should be canceled or sanding truck.
c. the friction plate assembly spline hole location, check its face runout should not exceed 0.7mm. Plate splines on the hub and the transmission shaft splines with the first side of the gap is 0.013-0.250mm. Do not meet the technical requirements should be replaced friction plate assembly or the corresponding parts.
d. Separation of spherical wear lever adjustment screw more than 1mm, should be replaced. Face three separate lever adjustment screw should be in the same plane and parallel to the plane with the pressure plate at the end, each difference of not more than 0.40mm. Separation lever to the pressure adjustment screw face plate plane distance of 43.5 ± 0.75mm. And should check the connections between the ends of the gap caused by the amount of movement should not exceed 1.5mm. Remember to adjust the screws tighten the nut after adjustment to prevent loosening inaccurate.
e. spiral spring clutch assembly should be optional, the same set of spring pressure difference of not more than 39.2N, free length difference is less than 2mm. The ends of the vertical plane and the axis line of not more than 0.5mm. Main parameters of the spring clutch Table 10-1. Rod bearings and separation gap should be 2.5mm.
The main parameters Table 10-1 clutch spring
Spring of the said
Free length (mm)
Compressed Length (mm)
The corresponding pressure (N)
Coil spring
40
461-490 mark yellow
490-519 mark blue
519-549 mark no color
Shock absorber spring
26.6 ± 0.25
24
490-569
3. Friction plate of the riveting re-
a. friction plate before re-riveting, the rivet can be less than the diameter of 0.5mm drill bit, drill the old rivets, if not drilled, can punch out (red when the note does not damage the chip waveform). After the old chip removed, remove rust and dirt, check whether the torsion wave films, warpage, if deformation should be replaced. Rivet Kong Youfei edge chip waveform, the available file repair.
b. friction plate in the drill holes, friction plate with the vise is clamped and the waveform of film, if there is no fixture, you can choose the right film and the wave friction film on the good, one hand on the board during the operation, and the other chip waveform of a candidate eyelets diameter drill, drill drill from the side of the waveform piece eyelets eyelets on the friction plate. After the first hole drilled to insert rivets or small screws tightened. Opposite the first hole and then drill the second hole, then insert the screw with a small rivet or screw, to prevent displacement. After all the drilling eyelets, and marked, the rivets pull out or remove the screws, remove the friction plate. Using the same approach, drilled the other side of the eyelets. Then slightly larger than the rivets flat head bits, expanding the countersunk hole, the depth is about the thickness of friction plate 2 / 3.
c. In the riveting, the vise can be clamped on the rivet head diameter of the circle is equal to an iron bar (the best wastegate), withstood the rivet head, rushing with flowers open, with a sharp flat resist, hand hammer and gently tap so riveting, as shown in Figure 10-3.
Too much force when the attention is not riveted to avoid cracked the friction plate.
4. Driven plate assembly refitted
Driven disc assembly refitted, attention should be driven disc with "flywheel side" tag should be directed to the flywheel side installation, must not hold against. Coil spring clutch driven disc assembly (friction plate assembly), refitted, the end "H" (see Figure 10-2) should be installed toward the flywheel. [TOP]
Second, the structure of the clutch control mechanism and repair points
(A) the structure of the clutch control mechanism
Clutch control mechanism for the hydraulic transmission, hanging pedal set, mechanical control mechanism, the clutch pedal, oil storage cup, clutch master cylinder, clutch cylinder and fork assembly work etc. CA1020F, CA1020LF, CA1026LF type of manipulation of light truck clutch bodies shown in Figure 10-4; CA1020PLF, CA1026PLF, SY1020DBF, SY1020SBF, SY1020DFF, SY1020SFF type light truck clutch control mechanism, as shown in Figure 10-5. Their function is the driver to the clutch pedal, so that the separation of soft bonding or a set of institutions.
(B) the maintenance of the clutch elements of control mechanism
1. Clutch master cylinder and the working cylinder inspection and refitted
a. Check the clutch master cylinder and the working cylinder (Figure 10-6), which bore the mirror should not have scratches, blisters, severe wear and corrosion, if it should be replaced.
b. Decomposition of the repairing work of the master cylinder and the cylinder should pay attention to:
In the demolition cup, do not scratch the embedded slots; check cups must be soft and flexible, if the cup hardening and swelling should be replaced.
c. cylinder master cylinder and work prior to assembly of the parts with alcohol or brake fluid, clean, and soaked with brake fluid. Prohibit the use of gasoline and kerosene and the like mineral oil, hydraulic system because it will corrode the rubber parts. In the piston assembly when the second cup and pressure cup. Should pay attention to the direction of the assembly can not install anti, as shown in Figure 10-7.
2. Clutch Bearing Inspection and Maintenance
a. clutch bearings (986809K) is oil bearing, bearing maintenance shall not be soaked in kerosene or gasoline, dirt, wipe with a cloth immediately after assembly. If that is not freely rotating bearing, with cable wiring or abnormal sound, should be replaced. When replacing the bearings, the bearings should be toward the end with a type operators.
b. the transmission clutch housing cover with the first bearing surface and bolt fork ball and socket joints at the three levels of maintenance (35000-45000km), should be applied automotive Lithium-based grease No. 2, to be lubricated.
3. Refitted clutch pedal assembly
Install the clutch pedal assembly, should be on the pedal shaft bushing, the first return spring pin at peace, moderate coat of automotive Lithium-based grease No. 2.
4. The adjustment of the clutch pedal free travel
CA1020F automobile clutch pedal free travel for the 30-40mm, the total pedal travel is 150-160mm. If the clutch pedal free travel is too large, when the clutch is not complete, you can work cylinder push rod lock nut 23 (see Figure 10-6) release, and then unscrew the adjusting nut 24 (up putting effective length); if free travel is too small, clutch slip, diaphragm spring as bearings to withstand the separation end, will cause early wear of bearings.
Adjustment, the adjustment nut 24 screw (effective length shorter putter), and finally tighten the lock nut. After adjustment, should ensure that there are 2.0-2.5mm fork free trip. To ensure that this gap and if the pedal free travel is still very large, adjustable master cylinder push rod length. Adjustment, start the engine, check whether the clutch work properly.
SY1020DBF automobile clutch pedal free travel for the 20-30mm, the work of the clutch pedal travel is 150-160mm. Adjustment, twist clutch master cylinder push rod, adjust the clutch pedal to the pedal shaft center distance of the central part of the rubber pads 133.6 ± 3mm. At this point, the force will work with the 40N-cylinder push rod to the cylinder direction to promote, if pushed in the end, then tighten the lock nut master cylinder push rod. Pedal assembly installed in order to make the clutch pedal return spring installed length of 37 soil 1mm, with a spring to help push rod adjustment, and then use double nut fastening.
When fully depress the clutch pedal, the clutch cylinder piston stroke work should be not less than 19mm. Clutch sleeve and clutch lever should ensure that the gap between the 2.5mm, the gap may be to adjust the nut, that is, putting the screw through the piston to adjust the amount, adjusted to tighten the lock nut.
Clutch master cylinder longitudinally mounted on the clutch pedal bracket assembly, for the assembly in the clutch master cylinder push rod to play the role of the pedal stopper, with the stop ring to prevent prolapse. Pedal height, putting the front fork can be screwed into the volume adjustment bar.
5. Bleed the clutch hydraulic drive system
Bleed the clutch hydraulic system of the work carried out by the two synergies. The method is as follows:
a. Check brake and clutch oil within the oil storage cup liquid, need to recharge.
b. In order to more quickly release the air in the hydraulic system can spin out a working cylinder push rod, so that bearings with the diaphragm spring fingers (or the separation of rod adjustment screw) without gaps between.
c. bleed off screw cap.
d. Tap the clutch pedal several times, the last step in the end remain in place, loosen the bleed screw, the system is emitted in the air with brake fluid. After quickly tighten the bleed screw, the pedal slowly relaxed to make it back to the place.
e. Repeat the above process 3-5 times until the work cylinder bleed screw at the brake fluid does not spray there are the bubbles up.
f. bleed screw cap put on, adjust the working cylinder push rod length, so as to achieve the appropriate pedal free travel. [TOP]
Third, the Clutch fault diagnosis
1. Clutch slip phenomenon:
Slipping clutch, the clutch pedal carried head barely started. When hung low gear, tighten hand brake, and slowly lift the clutch pedal, slowly increase the throttle at the start, if the car can not move forward, do not turn off the engine, the clutch was slipping.
Failure:
a. there is no clutch pedal and fork or free travel free travel too small, so that the clutch in a semi-engagement state.
b. friction plate wear off even the rivet head out, friction hardening, burning, or stained with oil.
c. clutch diaphragm spring is too soft or broken deformation, the friction clutch plate or flywheel grind the surface of groove (abrasion of the rivet head), warped, or grind level.
d. clutch plate clutch hub shaft or hair stuck in stagnation.
e. a transmission shaft front bearing or lubrication of bearings raise too much, when diluted with hot grease thrown into the friction caused by slippery surfaces.
f. spiral spring clutch lever height adjustment varies the pedal return spring is too soft, break or delay in the pedal and the pedal shaft can not be sent back to the place.
g. pressure plate and clutch not working properly between the gland and tighten the flywheel bolts loose, sleeve bearings made axial movement lag, not freely.
2. Clutch constantly cutting phenomenon:
Clutch cut continuously, the transmission file linked to the difficulties, there are gear crash. After hang up the file, do not lift the clutch pedal, the car running or engine flameout.
Failure:
a. clutch pedal free travel and the fork is too large, the hydraulic system with air or oil leakage.
b. master cylinder or the working cylinder is not working properly, driven plate wing music, loose rivets.
c. the new driven disc friction disc replacement is too thick, the clutch diaphragm spring break.
d. driven disc hub splines and gear teeth key rust first axis of stagnation, the driven plate movement difficult. Uneven clutch pressure plate
e. spiral spring clutch lever is bent or uneven.
3. Clutch hair ring
Phenomena and fault reasons:
a. the engine idling, the clutch pedal fully raised despite the (relaxed), but also heard the crashing sound of intermittent, due to separation lever bearings caused by scratching.
b. Depress the clutch pedal a little, so that contractors and sub-clutch lever of uranium exposure, if heard, "Sha Sha" sound, for the lack of clutch bearings or oil burning.
c. When Depress the clutch pedal and hear a "Wow, wow," the metallic sound of dry friction, and then remove the bottom shell flywheel, observation has been ground into grooves separating lever, even when the rotating spark, then Bearing damage without rotation.
d. When the car just lifted off the clutch pedal, the clutch will be joining (some pedal riding in the end), the issue of a scream, is driven warped or broken steel plate, driven plate hub skew operation when the swing, friction hardening uneven, friction plate rivets or head out of the flywheel cause scratching.
e. When the clutch pedal when riding in the end, the issue of a "Gala" and rattle, for the driven plate splines and gear teeth of a spline shaft wear off even.
f. When just depress the clutch pedal or just lift the pedal so that the friction plate and the plate is to separate or to contact state when he heard a "click" rattle, was driven disc hub or friction plate rivets loose.
g. When just depressing or releasing the clutch pedal, heard and driven plate keyway wear the same "clicks" sound, for the separation of the bracket lever pin and hole wear Songkuang (spiral spring clutch.)
h. clutch release bearing return spring is too soft, stretch, break or fall off, the bearings do not return to places, long-term follow-fat ring instead.
4. Car started shaking when the earthquake phenomenon:
Engine idle, hung low gear and slowly ease off the clutch pedal, the car before and after the shake, and issued a "choking when, choking when" the impact of sound.
Failure:
a. piles of oil-driven disc friction plate, the rivet head out (scratch plate), driven disc friction disc is uneven or curved wing.
b. driven disc hub splines and gear teeth first shaft spline wear off even Songkuang.
c. axial movement of clutch release bearing sleeve made lag between the clutch cover and flywheel mounting bolts loose.
d. Clutch board stagnation, uneven elastic spring (coil spring clutch), individual spring break or highly mixed.
e. Diaphragm clutch diaphragm spring crack, driven plate absorber spring weak or broken, the pedal return spring break or fall off.
g. transmission shaft and engine crankshaft center line of a different mind, loose flywheel bolts
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