4.1. Coupling

POSSIBLE MALFUNCTIONS OF COUPLING, THEIR REASON AND METHODS OF ELIMINATION




Fig. 3.1. Coupling: 1 – lower part of a case of coupling; 2 – flywheel; 3 – the conducted disk; 4 – press disk; 5 – forward bearing; 6 – bent shaft; 7 – main shaft; 8 – needle bearing; 9 – coupling case; 10 – finger of the ottyazhny lever; 11 – ottyazhny lever; 12 – axis of the ottyazhny lever; 13 – roller of the ottyazhny lever; 14 – fork of the ottyazhny lever; 15 – adjusting screw; 16 – ottyazhny spring of the coupling; 17 – coupling switching off coupling; 18 – coupling switching off bearing; 19 – press spring; 20 – coupling casing; 21 – the heat-insulating washer; 22 – stopper; 23 – bearing lubricant hose; 24 – butterdish arm; 25 – butterdish case; 26 – butterdish cover; 27 – gear washer


Coupling (fig. 3.1) of the car dry, one-disk, with a switching off hydraulic actuator.

Maintenance
Necessary works are carried out when dismantling coupling. You make greasing of the bearing of switching off of coupling through the cap-type butterdish located on the right side of a coupling case according to the table of greasing. Access to a butterdish from below car.
Periodically merge condensate from a coupling case, having turned out a stopper of 22 (fig. 3.1).
 Adjustment of the mechanism of coupling
You make adjustment of the mechanism of coupling at the removed press clutch plate in the following order.
Press assembled establish a disk on a plate (instead of a plate it is possible to use a flywheel) and fix it for a casing by six bolts. Between a plate and a press disk before fixing establish a template substitute of the conducted disk in the form of a ring 9,5 mm thick.

Fig. 3.2. Position of ottyazhny levers after adjustment: 1 – coupling casing; 2 – press spring; 3 – press disk; 4 – adjusting screw; 5 – ottyazhny lever


Fig. 3.3. Latching of adjusting bolts


You make adjustment a wraparound or an otvorachivaniye of adjusting screws (fig. 3.2) before obtaining the size of (51,5±0,75) mm (distance of a head of one of screws from a plate surface). The difference in distance from a plate to heads of two other screws should not exceed 0,2 mm. After adjustment stop screws of 4 levers, pressing edge of the lever into a screw groove, as shown in fig. 3.3.

Repair
 Replacement of the bearing of switching off of coupling
1. Install the car on a platform or a viewing ditch for access from below to the transmission and coupling.
2. Remove the lower part of a case of coupling.
3. Remove a coupling switching off bearing fork.
4. Remove the cap-type butterdish (on the right side of a coupling case) and disconnect it from a rubber hose of lubricant of the bearing.
5. Remove from the car the transmission (see the head "Transmission") together with the coupling switching off bearing.
6. Remove the coupling with the coupling switching off bearing, remove the bearing from the coupling.
7. Before installation of the new bearing carefully wash out the coupling and clean channels of supply of lubricant.
8. Napressuyte the bearing marking towards the coupling. Clear a hose of lubricant of the bearing of old lubricant and fill new.
9. Wash out a neck of a cover of the bearing of a main shaft of the transmission on which the coupling is put, and grease with a thin layer of fresh Litol-24 lubricant.
10. Put on the coupling a cover of the bearing of a main shaft of the transmission, attach an ottyazhny spring and install the transmission on the car. At installation you watch to damaging a bearing lubricant hose. You make all other assembly as it should be, the return to dismantling.
11. After assembly adjust gaps between the bearing of switching off of coupling and levers of a press disk.
 Removal and installation of clutch plates
For removal of clutch plates execute operations with 1 on 5 sections "Replacement of the Bearing of Switching Off of Coupling".
Then turn off six bolts of fastening of a casing. Turn off bolts gradually and consistently on a circle, no more than two turns of a key for once not to bend a support of a casing of a press disk.

Fig. 3.4. The conducted clutch plate: 1 – frictional slips; 2 – rivets; 3 – a spring of the conducted disk; 4 – steel disk; 5 – damping spring; 6 – nave; 7 – frictional rings; 8 – adjusting rings; 9 – the conducted disk; 10 – persistent finger; 11 – balancing small weight


After removal of bolts press and kept (fig. 3.4) disks freely are taken out down.
You make installation of disks on the car upside-down.
Before installation execute the following:
1. Wipe with the pure fabric moistened in gasoline, all surfaces of friction of disks and a flywheel.
2. Blow air of a detail of clutch plates and examine them for detection of possible defects.
3. Add lubricant to the bearing of a main shaft of the transmission installed on cranked to a shaft.
4. Establish in the coupling case conducted and press disks and through a back opening of a case of coupling center the conducted disk concerning a flywheel by means of the mandrel 55–1187 entering the bearing of a bent shaft. Instead of a mandrel it is possible to use a main shaft of the transmission. A short part of a nave of the conducted disk has to be turned to a flywheel.

Fig. 2.55. Installation of coupling on tags:
1 – tags


5. Combine tags "About" (see fig. 2.55) on a flywheel and a casing of a press disk and wrap six bolts of fastening of a casing. Wrap bolts evenly and consistently on a circle.
 Dismantling of a press disk

Fig. 3.5. Removal of a casing of coupling


Details of a press disk are under the influence of effort of six springs. Therefore before an otvorachivaniye of bolts of fastening of support of ottyazhny levers they should be unloaded, having squeezed a disk a press as it is shown in fig. 3.5.
You make dismantling of a press disk in the following order:
1. Make on a casing and a disk of a tag of their relative positioning not to break balancing at assembly. Make also tags on levers and a press disk.
2. Turn off three bolts of fastening of a casing to support of ottyazhny levers.
3. Smoothly release a casing from under a press, remove a casing, springs and washers of springs.
4. Rasshplintuyte also take out fingers of ottyazhny levers, remove support of levers (fork) and take out rollers from levers.
 Assembly of a press disk
You carry out assembly of a press disk as follows:
1. Put 19 rollers in openings of ottyazhny levers. For convenience of assembly that rollers did not drop out, grease them with Litol-24 lubricant. Do not apply solid oil to this purpose. In the absence of lubricant rollers can be collected by means of a cylindrical mandrel with a diameter of 8 mm and 9 mm long around which in openings dry rollers are put. After installation of rollers grease them with 2-3 drops of gearbox oil.

Fig. 3.6. Press a disk with the installed coupling switching off levers


2. Insert assembled ottyazhny levers into grooves of a press disk according to the marking made when dismantling, implant fingers of levers (at the same time mandrels will come to light) and a zashplintuyta of their (fig. 3.6).
3. Install on levers basic forks so that the finger settled down towards a press disk, and a roller – towards a casing. Fingers of forks to a zashplintuyta.
4. You make assembly of a disk with a casing and springs under a press to squeeze springs and to screw bolts in basic forks. Under a press put the conducted disk (or the template replacing it 9,5 mm thick). On the conducted disk put press, collected with levers; on ledges for press springs establish the heat-insulating washers and springs.
5. Install a coupling casing on press a drive so that the tags made when dismantling coincided. You watch that each spring got on the corresponding ledge in a casing. A press press a casing to a table against the stop, as shown in fig. 3.5. Distortions of a casing should not be. Wrap three bolts of fastening of basic forks.
6. Adjust the provision of heads of adjusting bolts of ottyazhny levers as it is specified in the head "Adjustment of the mechanism of coupling".
 Replacement of frictional overlays of the conducted disk
You make replacement of frictional overlays of the conducted disk in case in slips cracks were formed or openings for rivets were developed and also if slips are worn-out so that from the surface of friction to heads of rivets there were less than 0,5 mm. As a rule, in case of replacement of one slip it is necessary to replace also another.
For replacement of slips carefully drill the fixing their rivets (diameter of a core of a rivet of 4 mm) and take out the remains of rivets so that not to damage spring plates of a disk.
After replacement of slips check a beating of the rubbing surfaces of new overlays of rather shlitsevy opening. The beating measured on the radius of 125 mm should not be more than 0,7 mm. If it exceeds the specified size, then the conducted disk it is necessary to govern.
 Coupling switching off drives

Fig. 3.7. Hydraulic actuator of switching off of coupling of cars of family UAZ-31512: 1 – cover; 2 – filter grid; 3 – tank; 4 – gidrotrubka;
5 – main cylinder of the drive of coupling; 6 – perepusknoye opening; 7 – compensation opening; 8 – washer; 9,18,21,26 – springs; 10 – internal cuff; 11 – union; 12 – piston of the main cylinder; 13 – external cuff; 14 – protective cap; 15 – pusher of the main cylinder; 16 – pedal axis; 17 – fork; 19 – pedal; 20 – coupling; 22 – spherical support; 23 – coupling switching off fork; 24 – gidroshlang; 25 – working cylinder; 27 – cap;
28 – perepusknoy valve; 29 – cuff; 30 – piston of the working cylinder; 31 – pusher; 32 – cap; 33 – lock-nut; 34 – screw part of a pusher


The hydraulic actuator of switching off of coupling (fig. 3.7) of cars of family UAZ-31512 consists of a suspended pedal 19, the main cylinder 5, a hydrotube 4, a hydrohose 24 and the working cylinder 25.

Fig. 3.8. Hydraulic actuator of switching off of coupling of cars of family UAZ-3741: 1 – tank;
2 – main cylinder; 3, 5 – gidrotrubki; 4 – connecting coupling; 6 – pedal; 7 – gidroshlang;
8 – working cylinder; 9 – spring


The hydraulic actuator of switching off of coupling of cars of family UAZ-3741 is similar and shown in fig. 3.8.
Service of a hydraulic actuator consists in maintenance of level of working liquid in a tank of a bulk opening 15-20 mm lower than the top edge, adjustment of a free wheeling of a pedal of coupling and, if necessary, its pumping.
In a hydraulic actuator of coupling only the free wheeling of the external end of a fork of switching off of coupling which has to be 2,5–3,6 mm is regulated. It corresponds to a gap of 1,7-2,5 mm between ottyazhny levers and the bearing of switching off of coupling and to a free wheeling of a pedal of coupling And, equal 35–55 mm for all cars.
You make adjustment change of length of a pusher of the working cylinder of switching off of coupling.
Before adjustment of a free wheeling of a pedal of coupling check the size of a full speed of a pedal of coupling (against the stop in a floor) which has to be 185 mm for cars of family UAZ-31512 and 200 mm for cars of family UAZ-3741. If necessary you make adjustment change of length of a pusher of the main cylinder of switching off of coupling.
 Removal and dismantling of a hydraulic actuator of coupling
Remove a hydraulic actuator of switching off of coupling from the car in the following order:
– disconnect a hydrohose from the working cylinder;
– merge liquid from a hydraulic actuator through the disconnected end of a hydrohose;
– remove an ottyazhny spring of a fork of switching off of coupling;
– disconnect and remove the working cylinder;
– remove an ottyazhny spring of a pedal of switching off of coupling;
– to a rasshplintuyta also take out a finger of a fork of a pusher of the main cylinder;
– disconnect and remove the main cylinder. On cars of family UAZ-3741 previously disconnect a tank from a flexible hose.
You make dismantling of the main cylinder in the following order:
– uncover also the mesh filter of a filling tank (cars of family UAZ-31512);
– turn out the union of fastening of a tank (family cars UAZ – 31512);
– turn out the case of the union of a flexible hose of a tank (cars of family UAZ-3741);
– take out a lock ring and a persistent washer from the case of the main cylinder;
– take out from the case the piston with sealing cuffs, a returnable spring.
In order to avoid damage of sealing cuffs for removal of the piston bring compressed air in an opening for a hydrotube. Unions of the main cylinders with laying when dismantling should not be unscrewed if dribble of working liquid through them was not observed.
You carry out dismantling of the working cylinder in the following order:
– disconnect a rubber protective cap from the working cylinder and take out a pusher together with a cap;
– take off a cap from a pusher;
– take out a lock ring from the case of the working cylinder;
– take out the piston with a sealing cuff from the working cylinder; in order to avoid damage of the piston and a cuff bring compressed air to an opening for a hydrohose;
– remove a sealing cuff from the piston;
– turn out the pumping valve;
– remove a protective cap from the valve. Carefully wash out hydraulic actuator details in brake fluid or in alcohol, blow compressed air and examine.
 Assessment of technical condition of details of a hydraulic actuator
All rubber sealing cuffs have to be soft and elastic. The vyryva which hardened, inflated or having on working surfaces and cracks of a cuff replace.
On mirrors of working and main cylinders there should not be рисок, sinks, zadir and considerable iznos. Small traces of corrosion and insignificant wear are allowed to be eliminated with grinding or a honingovaniye to diameter no more than 25,15 mm for the working cylinder and 22,2 mm for the main cylinder at obligatory application only of new cuffs.
 Assembly of a hydraulic actuator of coupling
You make assembly of a hydraulic actuator of switching off of coupling as it should be, the return to dismantling. Before assembly oil a mirror of cylinders castor or fresh brake fluid.
At assembly of the main cylinder be convinced that the returnable spring surely returns the piston in a starting position. Check by means of a soft wire with a diameter of 0,3-0,5 mm whether the cuff blocks a compensation opening that is absolutely inadmissible.
At assembly of the working cylinder be convinced that the ottyazhny spring surely moves the piston in the cylinder.
You make installation of a hydraulic actuator on the car as it should be, the return to removal.
 Pumping of a hydraulic actuator of coupling
Fill a hydraulic actuator with liquid and pump over it for removal of air in the following order:
– lift a cowl on cars of family UAZ-31512 or uncover the 13th hatch to a coupling hydraulic actuator tank on the dashboard of cars of family UAZ-3741 and turn off a cover of a tank of the main cylinder;
– fill a tank of the main cylinder with working liquid to normal level (on 15-20.mm below the top edge of a tank);
– remove a protective cap from a head of the valve of pumping of the working cylinder and put on a rubber hose a head;
– ship the free end of a hose in the vessel with a capacity not less than 0,5 l filled on a half of height with working liquid;
– create pressure in system, having sharply pressed 4–5 times with an interval 1–2 with a coupling pedal;
– holding a pedal, unscrew the pumping valve on 1/2–3/4 turns, watching that the free end of a hose remained shipped in liquid. Liquid with vials of air will come out in a vessel;
– after the expiration of liquid in a vessel stops, wrap perepuskny the valve to the full at the pressed coupling pedal;
– check availability of liquid in a tank of the main cylinder. Do not allow during pumping of an exposure of a bottom in a tank, otherwise air will get to system again;
– repeat the operations stated above until from a hose the expiration of liquid with air does not stop;
– remove a hose from a head of the perepuskny valve and put on a protective cap;
– add liquid in a tank to norm.
It is impossible to add in a tank the liquid produced when pumping as it contains air. This liquid can be used only after its upholding within a day and filtrations.
After pumping check the size of the course of the external end of a fork of switching off of coupling when pressing a coupling switching off pedal to the full. The full speed has to be not less than 17 mm. The smaller size of a full speed will not provide full switching off of coupling and will indicate availability of air in a hydraulic actuator or the insufficient course of a pedal of switching off of coupling.