How to adjust the clutch on ZAZ 968m. Clutch work. Constructive features of clutch

Clutch of the car ZAZ-965A "Zaporozhets"

By car ZAT -965A, Zaporozhets installed a single-colored dry adhesion with peripheral springs and with a mechanical shutdown drive from the pedal.

A steel stamped clutch cover is attached to the engine flywheel with bolts, in which a pressure disk with six pressure springs, located in glasses, fixed in the casing. The springs are installed heat-insulating spyers. This eliminates the possibility of overheating springs from the pressure disk, the temperature of which, when switching on the clutch, due to its bucks increases. The guide protrusions of the pressure disk are included in the cuts of the con ^ ear, which ensures their joint rotation. At the same time, the disk can have longitudinal movements.

Between the flywheel and the pressure disk, they will be clamped with a steel split composite driven disc with friction pads, glued to the hub installed on the slots of the clutch shaft. The front end of this shaft is installed in the needle bearing in the pullout of the flywheel fastening bolt, and the rear - in the ball bearing in the wall of the clutch crankcase. The bearing is sealed with a self-sufficient gland. Malled from light alloy Carter clutch is attached to the engine of the engine and has a hatch in the lower part, covered with a lid.

On brackets, glued to the clutch casing, three switching levers with fixing springs are installed. The outer ends of the levers are connected by adjusting fingers with a pressure disk; In the inner ends of the levers with the help of three locking springs, a cast-iron polished reference ring is fixed.

A refined rings is located against a refinery, which does not require lubrication. The groove is fixed with its casing in the inner ring of the radially resistant ball bearing installed in the clip. The clip with the help of two tricks and lock springs is connected to the turning plug. The plug is installed hinged on the finger fixed in the bracket. Bracket is attached to the Carter. The plug is equipped with a squeezing spring. The outer end of the fork through the hatch, closed with a rubber case, is removed and with the help of the cable, equipped with tips, is connected to the clutch pedal roller lever. Pedal roller is installed in the bracket fixed in the front of the body under the feet of the driver.

Fig. 1. Coupling of the car ZAZ-965A "Zaporozhets"

When the pedal is released, the clutch is turned off. When you click on the pedal, the plug, turning on the axis, moves the clip. At the same time, the coal-graphite tip 10 climb presses through the reference ring on the inner ends of the levers, and the outer ends are removed by the pressure disk from the flywheel, squeezing the springs and turning off the adhesion.

When the clutch is enabled between the spyer and the supporting ring, there should be a clearance equal to 2.0 mm. The magnitude of the gap is adjusted by changing the length of the drive cable using the nut on the rear tip connected to the clutch fork. The free stroke of the pedal should be about 40-50 mm.

The clutch (Fig. 77) consists of two main parts: the pressure disk 5 assembly with the cover and the clutch shutdown levers and the slave disk 4. The discs are covered in cast carter 10, having a bell shape.

To reduce wear, the working surfaces of the supporting washers and 15 in the manufacturing process are impregnated with a solid lubricant-disulfide molybdenum. The clutch mechanism is placed in a stamped steel casing connected to the engine flywheel using two installation pins and six bolts with spring washers.

Fig. 77. Grip: 1 - flywheel; 2 - lock washer; 3 - clutch fastening bolt; 4 - slave disk; 5 - pressure disk; 6 - spring; 7 - flywheel bolt; 8 is a clutch shutdown; 9 - cuff; 10 - Carter clutch; 11 - drive shaft gearbox; 12 - roller bearing; 13 - Bearing Cuff; 14 - plug; 15 - Fifth; 16 - lever; 17 - Stubborn stand; 18 - adjusting nut of the finger; 19 - finger; 20 is a spring plate of the slave disk arising from instantaneous dynamic loads with a sharp change in the speed mode.

Pressure disk With a housing assembly, statically balance is balanced, permissible imbalance is no more than 20 g-cm. Increased imbalances are eliminated by drilling the metal in the radial direction along the outer diameter of the pressure disk 10. The metal is removed by the drill with a diameter of 7 mm (drilling depth to 6 mm) from the distance from the disc operator to the drilling center of 6 mm.

When balancing the pressure disk (Fig. 78) is installed on the test holes a. After balancing on the pressure disk and the casing applies labels used to prevent displacements when re-assembling and disruptions at the same time balancing. Tags B are applied on one of the protrusions of the pressure disk and on the flat section of the clutch housing surface.

Slave disk (Fig. 79), transmitting rotation from the engine to the drive shaft of the gearbox, has a damper (damper), designed to eliminate the car of the harmful effect of the stelorable oscillations of the engine crankshaft, as well as to reduce stresses in the transmission elements,

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Fig. 79. Slave clutch disc assembly: 1 - spring plate; 2 - friction pad; 3, 4 - rivets; 5 - Damper Spring; 6 - hub; 7 - Damper Ring; eight - damper plate; 9 - finger; 10 - slave disk; 11 - place of installation of balancing loads; 12 - places for removing the material of friction linings during static balancing;

In - size in a free state; G - size in a compressed state under pressure of push springs

On the inner surface of the rear wall of the crankcase (Fig. 80) there are tides 9 and 10. In the holes of the tide, polyamide sleeves 2 I am 8 and the axis 3 of the plug of the clutch shutdown mechanism is mounted. The axial movement of the axis 3 is set to 0.1 ... 0.5 mm selection of adjusting washers 6 and is limited to a locking ring 7.

On the axis 3, the clutch shutdown fork 5 is installed, which is fixed with the spacer wedge 16 with a spring washer 15 and nut 14, which is tightened with an effort 2.2 ... 3.2 kgf.

Returning spring 4 performs a return fork 5 with an axis of a 3 fork and lever when the clutch is turned on and provides free stroke of the clutch pedal. Spring 4 freely I hope on the axis 3 forks, one end rests on the wall of the Carter 1, and another, special mustache, captures the plug 5.

In a plug solution 5, a cast iron clip 11 is installed in which a ball closed clutch shutting bearing with a graphite spieter 12 is pressed. During operation, the backbone does not require additional lubricant. The clip 11 is fixed in fork 5 using two spring connective links 13.

Before assembling the inner surface of the sleeves 2 and 8, as well as the supporting surfaces of the fork 5, it is necessary to lubricate No. 000 or Litol-24 with lubricant.

Clutch work

For normal operation of the clutch mechanism and its drive, it is required to maintain the free move of the outer end of the clutch turning plug and full The piston of the working cylinder piston with the clutch pedal failure.

The free course of the outer end of the clutch turning plug is determined by the gap between the spiesh and the fifth of the squeezing levers. This gap should be 2.4 ... 3.4 mm. With an insufficient gap or in its absence, the end of the gum will be contacted with the fifth, which will not allow fully pressing the pressure disk to the slave. As a result, the clutch slip is inevitable and, as a result, rapid wear of the gum.

If the specified clearance is too large, it leads to incomplete clutch shutdown (the clutch "leads"), which makes it difficult to switch gears, can cause gear teeth breakdown and increased wear of the blocking gear synchronizer rollers.

With the wear of the clutch friction linings, the slave disk thickness decreases. The pressure disk at the same time approaches the flywheel and the gap between the fifth and the spyer, and therefore the free course of the outer end of the clutch turning plug and the clutch pedals are reduced. In no case cannot regulate the free move by the rotation of the adjusting nuts 18 (see Fig. 77) of the fingers 19, as this can lead to the skeletal of the fifth / 5 and squeeze levers 16.

The skews stain and levers, in turn, will cause a clutch of the clutch of the pressure disk 5, which makes it difficult to turn off the clutch, and the clutch begins to "lead", making it difficult to switch the gear.

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Fig. 81. Demolition device for disassembly and clutch assembly: 1 - plate; 2. - support; 3, 6 - screws; 4 - clamping bracket; 5 - clamping handle; 7 - emphasis; 8 - clamp screw

Before disassembling, the clutch is cleaned of dirt and rubbed dry.

Install the clutch housing assembly with a pressure disk (see Fig. 78) to the device for disassembling and assembling the clutch and saw the tights of the adjusting nuts 4, depressed in the digits of the fingers 5. Screw and remove the adjusting nuts 4, supporters 3, filling 8, levers 7 and springs 12.

Hold up the handle 5 (see Fig. 81) of devices and remove the bracket of fixtures and casing 1 (see Fig. 78), glasses 9 pressure springs, pressure springs 11 and thermal insulating gaskets 10. Remove the locking ring 7 (see Fig. 80) And adjusting washers 6 from the axis 3 forks.

Screw the nut 14, remove the washer 15, carefully knock the wedge 16, take out the axis of the sleeve from the clutch curtain and hole holes 5 of the clutch shutdown. Remove the return spring 4, two connecting links 13, clip 11 junction of the clutch and sleeve 2 and 8. Paste two screwdrivers between the boom of the gland and the clutch crankcase, the clutch crankcase gland (only if necessary).

Check the status of details. The need to check the details of the clutch mechanism usually occurs when the friction linings or graphite spiets are wear. The remaining parts are wearing insignificant, and their wear is not leading to the loss of mechanism's performance. When inspecting a disassembled clutch, it is necessary to carefully check its details.

TOarch of clutch. Sealing surfaces of the crankcase should not have rice, cauldron and cracks. Risks and fears should be cleaned, when you detect crack-brew or replace the crankcase. Check the dimensions of the bushings and the axis of the fork (see Appendix 2), the gap between the sleeves and the axis should not exceed 0.6 mm. With an increase in the gap of the bushings are replaced.

Slave disk. It is necessary to make sure easily move the disk hub on the slots of the drive shaft of the gearbox. With a large wear of the shlits of the hub or shaft (overhang of the naval hub), worn items replace. Friction lining should not be grilled, broken, burnt or worn to rivets heads. Otherwise, the lining is replaced, since in the presence of these deviations, the friction coefficient between the leading and slave elements is reduced, which leads to a clutch slip during the acceleration of the car or with an increase in resistance to its movement.

Check the state of the ends along the outer diameter and the elasticity of the springs 5 \u200b\u200b(see Fig. 79) of the damper. In the ends and the outer diameter of the spring of the sprout of the steep oscillations should not have traces of the lifting and the production of a depth of more than 0.2 mm. The length of the spring in the free state should be 24.25 ... 24.75 mm, and when compressing the load of 42 ... 50 kgf - 21.5 mm. The torque of friction in the jacket of the spinning fluctuations of the slave clutch disk is within 0.375 ... 09 kgf m, with the surface of the friction of the slave disk 10, the plate 8 of the damper, the hubs 6, the rings 7 of the damper must be clean and dry.

When treading new friction linings, you should pay attention to the fact that each second hole of the lining was drilled through, and the riveting was carried out in such a way that both linings individually were ribbed through one hole in the plate. After the closure of the friction linings, the slave disc is tested in the collection of the working surfaces of the lining relative to the hub axis (on the mandrel or on the drive shaft of the gearbox), which must be no more than 0.75 mm, and perform static balancing. Permissible imbalance 15 g-cm, which is achieved by installing balancing loads (see pos. 11 in Fig. 79) or leaving the material of friction linings.

Check the disk thickness assembly in the free state, which should be 8.1 ... 8.7 mm.

Clutch pressure disc. Check the non-plane of the working surface of the pressure disk 2 (see Fig. 78). Not more than 0.05 mm is allowed. If there are ring risks on the working surface, the disk must be stuck. Grinding the pressure disk and the associated reduction in its thickness reduces the total working force of the pressure springs 11. To save this force when assembling the clutch, it is necessary to install washers under thermal insulation gaskets 10. The thickness of the washer should be equal to the thickness of the metal layer grinding. The side surfaces of the three protrusions should not have wear more than 0.2 mm.

Purpose levers 7 and operating surfaces under the support and pressure of the pressure disk should not have wear more than 0.2 mm.

Purpose springs. Check elasticity springs. By the value of the workforce required for compression springs to size

31 mm, they are sorted into two groups: with a working force of 50.5 ... 53.5 kgf, which is labeled with brown color, and with a working force of 53.5 ... 56.5 kgf, which label green. On one clutch put push springs of the same color.

Clutch shouting. The increased wear of the scan arises if the free move of the clutch pedal is not adjusted during the operation of the vehicle, as well as during the wrong driving of the car, that is, when without need to hold the foot on the clutch pedal. The surface of the casing of the rope should not have a wear of more than 0.3 mm, otherwise the bonnet assembly should be replaced. Pass the ball combined bearing. If the axial bearing runs is more than 0.35 mm, the bearing must be replaced.

Check the presence of lubrication in the bearing, in the absence of lubricant (dry rolling balls), the bearing is replaced or filled with lubricant. For this, without disassembling, washed it in gasoline and dried. In the bath heated LZ-31 lubrication to a temperature of 150 ... 170 ° C and put the bearing assembly at 15 ... 20 minutes, then the bath is cozed to a temperature not higher than 50 ° C, remove the bearing and wipe it outside.

Needle Bearing Gearbox Box (Front). Check the freedom of rotation of the bearing assembly with the bolt. Rotation must be free, without jamming. The bearing is washed and refilled with refractory lubricant No. 000 in the amount of 2 ... 3 g. The lubricant is administered from the side of the threaded part of the bolt.

Clutch assembly. The assembly is performed in the reverse order with the following:

installing (see Fig. 77) Cuff 9 in Carter 10 of the clutch, it is necessary to lubricate the outer diameter and the working edge of the oil cuff for the gearbox and check the installation of the spring "Cuffs. Then set (see Fig. 80) Sleeves 2 and 8, Greased Operating axes 3 lubricant № 000, having gathered it with a spring 4 and fork 5 shutdown. Tighten the nut 14 of the wedge 16 (tightening torque 2.2 ... 3.2 kgf).

Check and, if necessary, set the axial movement of the axis 3 in the range of 0.1 ... 0.5 mm, which is provided by the selection of washers 6;

install on the plug 5 Course 11 with a spyer 12, lubricating the ripples of the clip with lubricant No. 000, and consolidate it with its brackets;

collect the clutch pressure disc with the casing. Before assembly (see Fig. 78), the supporting surfaces of the washer 3, the stubborn racks 6, the levers 7 and the heel 8 slightly lubricate the number 000;

adjust the pre-position of the fifth to size 52 mm ± 0.37 mm, adjusting nuts 4 (see Fig. 78) at the same time do not stop;

remove the clutch assembly from the device and pump it by clicking on the heap of the levers using a lever or screw press. The stroke of the fifth should be II mm, the number of swings

Installation and final adjustment of the clutch. Install the mandrel (the drive shaft of the gearbox can be used as a mandrel) to the bearing 12 (see Fig. 77) of the drive shaft of the gear, wipe the reference surface of the flywheel and installed on the slots of the mandrel a slave clutch disc. Install on the flywheel disc with the casing assembly, together at the same time, the numbers applied on the clutch housing and on the flywheel (see view A in Fig. 77). This preserves the mutual position of the details that was during the dynamic balancing of the crankshaft assembly with the flywheel and clutch. Attach the adhesion with bolts 3 to flywheel with a tightening of 1.6 ... 2 kgf.

Prepare the device (see Fig. 42) for the final perch of the position of the clutch fifth on the engine. Install the jumper 2 with the indicator on the installation plate 5 to ^ T ^ lion rack / heel, setting the tension 0.5 ... 1 mm and aligning the arrow of the indicator with zero. The control rack ^ is installed on the nominal installation size of the five, equal to 52 mm ± 0.37 mm. Install a device for checking the fifth on the crankcase studs and fasten it.

The position is adjusted to the size of (52 ± 0.37) mm and the mutual beating of the plane (see Fig. 77) the adhesion heel relative to the flywheel with a rejection or wrapping of the adjusting nuts 18, when adjusting the levers 16 should be moved to an extreme position from the center until the center should be shifted Racks 17, i.e. the gap in the connection should not be. The biasis of the plane b Fiat 15 should be no more than 0.1 mm.

After adjusting the beat of the fifth, the adjusting nuts 18 must be fed, pressing the bourge on the nuts into the longitudinal slot on the end of the fingers 19. After the phait of the nuts, the fifth should not exceed 0.8 mm.

Constructive features of clutch shutdown

A hydraulic shutdown drive is used on the car (Fig. 82). The clutch pedal is suspended on the axis on which the plastic sleeve is hoped, and is attached to the bracket installed in the body's trunk. To prevent penetration into the bodies of dust and cold air, the pedal is sealed with a rubber slotted seal. In the extreme upper position. The pedal holds the exhaust spring.

The pedal is joined with the main cylinder of the clutch shutdown using a finger, between the pedal and the walls of the pusher, adjusting washers are installed, and between the flange of the main cylinder and the bracket - adjusting gaskets. The nutrient tank is attached to the inner panel shelf over the main cylinder.

The main and working cylinders are interconnected by two steel pipelines. The first pipeline is laid along the floor tunnel. The transition of the pipeline from the body is carried out through the coupling. The pipeline laid from the coupling to the clutch can, in the middle part has a helix, compensating for the change in the pipeline length when swinging power aggregatesuspended on rubber pillows. The working cylinder is attached to the clutch card. The lever of the adhesion turning plug using the exhaust spring constantly presses the stem cylinder rod to the piston and moves the last to the extreme front position.

The main cylinder of the clutch shutdown (Fig. 83) consists of a cast-iron housing, a piston made from a zinc alloy, with a rubber sealing cuff holding a liquid from leakage from the cylinder. The piston head made six through holes covered with a thin steel ring - valve and an internal rubber cuff. The spring presses the cuff to the piston, and the piston to the stubborn washer held in the cylinder with a locking ring. The rear end of the main cylinder is closed with a threaded fitting with a sealing gasket. In the inner cavity of the piston includes a pusher, having a plug on the end connected to the pedal. To protect the cylinder, a rubber case is served from dust and dirt entering, the back of which is included in the cylinder to the cylinder, and the front worst crumbs. The main cylinder of clutch is turned off has an inner diameter of 19 mm.

The working cylinder of the clutch is turned off (see Fig. 83) has an inner diameter of 22 mm.

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Fig. 83. The main and working cylinder of the clutch shutdown drive: 1 - cap; 2 - valve; 3 - body of the working cylinder; 4 - spring; 5 - fitting; 6 - washer; 7 - the main cylinder case; 8 - plug; 9 - washer; 10 - pusher; 11, 18 - Protective caps; 12 - piston; 13 - external cuff; 14 - Stubborn washer; 15, 19 - stop rings; 16 - valve; 17 - internal cuff; 20 - piston; 21 - sealing cuff; 22 - adjusting nut; 23 - lock nut; 24 - Pour mushroom; pusher; 26 - Spring.

remove the fitting 5 of the cylinder and with the help of a wooden rope from the cylinder the piston with the outer cuff, the piston valve, the inner cuff and the return spring of the piston.

The disassembled parts of the clutch shutdown drive are thoroughly washed, inspect and determine the suitability for further operation. Details of the working and main cylinders of the clutch drive are washed in denaturate, alcohol or fresh brake fluid.

The clutch shutdown drive assembly is performed in the reverse order, taking into account the following instructions.

All parts of the working and main cylinders, as well as the inner cavity of the cylinders before assembly, it is necessary to lubricate with castor oil or fresh brake fluid. When the pedal is connected 14 (see Fig. 82) with a fork, the adjusting washers 21 between the fork and the pedal is installed so that the pusher is located coaxially with the main cylinder.

The pedal connected to the pusher of the main clutch shutdown cylinder must have a complete course of at least 150 mm (the move from the uppermost position until it stops into the body floor). If the pedal move is less than 150 mm, it is necessary between the bracket 24 and the main cylinder base flange 26 to install an additional gasket 27. If the pedal stroke is significantly higher than 150 mm, delete gasket.

Adjustment of the free stroke of the clutch pedal. The free course of the pedal in the center of its platform is measured by the measuring ruler, while pressing the hand to the pedal to the pedal until the appearance of tangible resistance to the movement of the pedal. It should be within 26 ... 38 mm.

To adjust the free stroke of the pedal, it should be removed (see Fig. 82) The exhaust spring 5 and rotate the lever 4 until the squeezed 2 spinning levers take place, while the course of the lever 4 at the end "(about the rod of the working cylinder) There must be 4 ... 5 mm, which corresponds to the gap between the fifth and the bearing 2.4 ... 3.4 mm. If the specified size is less, follows the key to the key 8, release the locknut 7 and, turning the adjusting nut 6 to the pusher 8 And checking the course of the lever, set its free move within 4 ... 5 mm, then correct the adjusting nut 6 and put the exhaust spring 5.

Filling the system with liquid and removing air from it. For refueling hydraulic drive The clutch is turned off the same liquid as for the hydraulic drive of the car brakes.

Work is recommended in the following order: Fill the brake fluid with a clean glass transparent vessel with a capacity of approximately 0.5 liters from 1/3 to 1/2 height, remove the cork with the neck of the nutrient tank and fill it with its liquid to a nominal level (see Podiod. "Brakes ");

clear from dust and dirt air outlet valve on the working cylinder, remove the rubber cap and put on the valve head the rubber hose for pumping the brake hydraulic system, immersing the free end of the hose into the vessel with liquid;

press the foot on the clutch pedal successively 2 ... 3 times (with an interval between pressures 1 ... 2 s), and then leaving the pedal pressed, unscrew to 0.5 ... 1 turnover of the air outlet valve (these operations are recommended Follow together):

smoothly releasing and pressing the pedal sharply, continue to pump the system until it stops the selection of air bubbles from the hose. During pumping it is necessary to add brake fluid to the nutrient tank, not allowing the level reduction in it by 1/3 of the normal size. After the air bubble hose stops, it should be holding a pedal pressed, wrap the air output valve to fail. Next, remove the hose from the valve, put the cap on the valve head, add liquid to the tank to a normal level and put the tank cover.

After pumping, it is necessary to check the stream of the piston of the working cylinder, corresponding to the complete go of the pedal. This stroke should be about 22 mm when the pedal is at least 150 mm. It is allowed to reduce the stroke of the stem up to 19 mm under the condition of ensuring the "clean" (complete) clutch shutdown when the lever is free of at least 4 mm. A stream of a rod less than 19 mm does not provide normal clutch operation and indicates the presence of air in the system and the need for her pumping. With a properly pumped clutch hydraulic system, the first transmission is provided. If the clutch pedal (with a fully adjusted and pumped system) is shocking (with a fully adjusted and injection system), the first transmission is shown, you should make sure that the clutch mechanism is correct.

Transmission and main transmission with differential

Constructive features of the gearbox and the main transmission with differential

The gearbox (Fig. 84) is a mechanical, two-dimensional, three-step, four-stage with four forward and one back transmission, made in one crankcase with the main transmission. All gearbox gears except rear stroke- Hostels of constant engagement. The leading and driven reversing gears are made with straight teeth. Sixeria 1, II, III and IV gears are included using synchronizers. Transmission gearboxes: 1-3.8; II-2,1 18; III-1.409; IV-0,964; Rear stroke - 4,156.

Details of the gearbox and differential are placed in a ML-5 magnesium alloy crank. To increase the rigidity, the gearbox cavity cavity is divided into three sections by partitions with bores under the bearings of the lead gear, the main transmission, the leading and intermediate shafts. In the first section from the flywheel placed main gearIn the second section - gears 1 and II gears and reversing gears, in the third section, gears III and IV gears are placed, as well as a speedometer drive.

The front part of the gearbox crankcase is attached to the clutch. Clothing box and clutch crankcase crankcase seats are processed together, so the cartridge crankter is not interchangeable.

The back of the gearbox crankcase closes with a lid, in the cavity of which the gear shift mechanism is placed. In the upper part of the back cover there is a threaded hole M16x1.5 to set the reverse tower alarm. The treated plane on the end of the back cover serves to attach the bracket, which is the rear point of fastening the power unit to the car body.

Leading shaft // Transmission boxes (see Fig. 84) rotates on two bearings: the front end of the shaft on the needle bearing, pressed into the flywheel bolt, and the rear on the bearing 12 installed in the gearbox crankcase hole. The stubborn split ring installed on the bearing 12, and the ring 14, mounted on the drive shaft, prevent the displacement of the hysiness and shaft back. From the offset forward, they are held with a lid 13 rear bearing.

At the front end of the drive shaft, the slots for the sliding planting of the slave clutch disk are cut. In the middle part of the shaft, which is inside the gearbox, is sliced \u200b\u200bby the gear, which is in constant engagement with the drive gear 27 of transmission 1 (see Fig. 84) and the intermediate slave gear 33 (Fig. 85) of the reverse. The axial force arising from the transmission of torque by the leading shaft is perceived by the ball bearing 12 (see Fig. 84). Behind the gear at the rear end of the driving shaft there are evolvent slots that are engaged in engagement with the hub of the intermediate shaft 3. The seal of the driving shaft is carried out by a self-sufficient rubber gland with a ologonic thread.

The intermediate vassage of the gearbox hollow, is made as one integer with the drive gear II, rotates on two bearings: front roller 8 and rear ball. To the inner hole of the shaft pressed the sleeve 2 of the stock of the transmission switching.

On the intermediate shaft on two-row needle bearings 6, whose needles roll on the bushings 10, rotate the drive gears 7 and 4 gear III and IV. Sleeves 10 gears are the same for 1, II, III and IV gears. To limit the axial movements from the efforts arising from the osostic gears when transmitting torque, the resistant figured washers 9 are installed. The required axial movement of the gears in the range of 0.258 ... 0.394 mm is provided with a length of the sleeves.

Oil for lubrication of needle bearings arrives when spraying through curly cuts of stubborn washers 9 and 26. Between the sleeves and stubborn washers on the slots the hub with the coupling 5 of the inclusion is installed. In the grooves of the hubs are inserted by a crunch of a synchronization with a clutch slots 5 with two spring rings 24. With the right and left side of the synchronizer hub, brass rings 22 synchronizers are installed.

The set mounted on the intermediate shaft is tightened with nut 39, tightening torque 12 ... 16 kgf. The nut will stop the lock washer 38, the bent mustache of which are included in the grooves at the end of the intermediate shaft.

The axis of the slotted shaft 28 (see Fig. 85) is pressed into the openings of the front and middle walls of the crankcase and additionally holds the cover included in the groove in the front end of the axis. The diameter of the front end of the axis at a length is 27 mm larger than the diameter of the rest of 0.04 mm. Accordingly, the hole in the front wall of the crankcase is increased, which facilitates the assembly and disassembly of the node.

On the axis 28 (see Fig. 85) on the bronze bushings 29 freely rotates the slotted shaft 30 with the intermediate driven gear 33 of the reverse, which is in constant engagement with the gears of the drive shaft in constant engagement. The slots of the shaft 30 will freely slide the reversing intermediate gear 31, which for a fork 32 is enhanced with the driven gear 25 (see Fig. 84) when the reverse is turned on, i.e., it is necessary to turn on only one pair of gears to turn on the rear.

The axial movement of the slotted shaft 30 (see Fig. 85) in the range of 0.3 ... 0.5 mm is set by the selection of the thickness of the adjusting washer 27.

https://pandia.ru/text/78/063/images/image098_0.gif "width \u003d" 314 "height \u003d" 375 src \u003d "\u003e Reducers "HREF \u003d" / TEXT / CATEGORY / REDUKTORI / "REL \u003d" BOOKMARK "\u003e Speedometer drive gearbox; 42 - bolt; 43 - spring washer; 44 axis of the slotted shaft.

For the normal operation of the clutch mechanism and its drive, it is required to maintain the free move of the outer end of the clutch turning plug and the full stroke of the piston of the working cylinder when the clutch pedal failure.

Fig. 80. The clutch shutdown mechanism: 1 - clutch crankcase; 2, 8 - lower and upper axis sleeves; 3 - axis fork with lever assembly; 4 - spring; 5 - clutch shutting plug; 6 - adjusting washer; 7 - Spring Ring; 9, 10 - lower and upper tides; 11 - Climbing rope; 12 - bummer; 13 - Connector link: 14 - Nut; 15 - washer; 16 - Wedge attachment fork.

Constructive features of clutch

The car has a dry single-disc combination with cylindrical springs located along the periphery and sprinkle quenching (damper) by the driven disk. The outer diameter of the friction linings of the disk is 190 mm. The clutch control is carried out using a hydraulic drive of shutdown from the foot pedal.

The hub pressure disc assembly balance statically, the allowable imbalance is no more than 20 g-cm. Increased imbalances are eliminated by drilling the metal in the radial direction along the outer diameter of the pressure disk 10. The metal is removed by the drill with a diameter of 7 mm (drilling depth to 6 mm) from the distance from the disc operator to the drilling center of 6 mm.

The driven disk (Fig. 79) transmitting rotation from the engine to the drive shaft of the gearbox, has a damper (damper), designed to eliminate the transport of the engine of the engine of the crankshaft, as well as to reduce the voltages in the transmission elements,

Fig. 78. Pressure disc clutch with a housing assembly:

1 - housing assembly; 2 - Purpose disc with three protrusions; 3 - Support washer; 4 - adjusting nut; 5 - Palcese Disc; 6 - Stubborn lever rack; 7 - push disk lever; 8 - heel levers; 9 is a glass of clutch pressure spring; 10 - thermal insulation gasket; 11 - Purpose Spring; 12 - spring springs; a - control openings; b - tags on the housing and disk with static balancing; B - drill a hole with a diameter of 7 mm to a depth of 6 mm with a free distance between the centers; G - when drilling withstand size 6 mm.

The slave disk after assembly is balanced statically: the allowable balance is not more than 15 g-cm. Increased imbalances eliminate the installation of balancing weights with a light side into the holes in the driven disk, which are located in the intervals between spring plates. Balancing weights must be installed as shown in Fig. 79. Fastening the weights of their ends are rushed. Depending on the value of the disbalance of slave disks, weights with different head heights are used for balancing.

For the manufacture of balancing weights, rod steel or brass of any grades can be used, which are well solved. If necessary, to facilitate cutting, balancing weights can be annealing. With static balancing, in the case of a large imbalance, it is allowed to remove the material of the friction linings 2 from the end 12 depth to 2 mm (see Fig. 79).

Carter of clutch - bell-shaped, made of magnesium alloy ML-5. The closed form of crankcase significantly increases the rigidity of the structure, and consequently, increases the reliability of the clutch and gearbox. Celling the clutch crankcase relative to the engine crankcase is carried out by an annular groove with a diameter of 319 + 0.05 mm, a depth of 5.0 ... 5.5 mm. Clutch crankcase and gearbox crankcase places are treated together, so the clutch crankcase is nevissyless.

The clutch crankcase is attached to the card of the gearbox on eight studs with nuts, and is centered on two control pins. The cavity of the connection between them is lubricated by the sealing paste of UN-25.

To prevent the gearbox lubrication penetration into the clutch crankcase to the central hole of the rear wall of the clutch crankcase, the cuff 9 is pressed (see Fig. 77) with a minor thread on the working edge, which is directed to the gearbox (toward the oil). When replacing the cuff, its operating edge must be lubricated with oil for the gearbox.

Fig. 79. Slave clutch disc assembly: 1 - spring plate; 2 - friction pad; 3, 4 - rivets; 5 - Damper Spring; 6 - hub; 7 - Damper Ring; 8 - damper plate; 9 - finger; 10 - slave disk; 11 - place of installation of balancing loads; 12 - places for removing the material of friction linings during static balancing; In - size in a free state; G - size in a compressed state under pressure of push springs

On the axis 3, the clutch shutdown fork 5 is installed, which is fixed with the spacer wedge 16 with a spring washer 15 and nut 14, which is tightened with an effort 2.2 ... 3.2 kgf.

Before assembling the inner surface of the sleeves 2 and 8, as well as the supporting surfaces of the fork 5 it is necessary to lubricate with lubricant No. 158 or Litol-24.

Engine running

After the repair of the engine, especially in the case of the replacement of the parts of the crank-connecting mechanism, it is necessary to carry out its acquisitions before operating. The reliability and durability of the engine depends on the thoroughness of labor, the reliability and durability of the engine depends. The process of engine hosting consists of two stages.

First step-host idling For 35 minutes in the following modes:

1000 ... 1200 rpm - 5 min;

2000 ... 2200 rpm - 5 min;

3000 ... 3200 rpm - 10 min;

1000 ... 3600 rpm - 15 min

We take up the engine on M8G1 oil or other oils specified in this book. The air damper of the carburetor should be kept completely open. During the first stage of work, it is necessary to check the pressure in the lubrication system, the absence of leaks, adjust the rotational speed of the crankshaft at idling, make sure that the normal operation is carried out. Oil pressure at 3000 rpm crankshaft and oil temperature +80 ° C should be at least 2 kgf / cm2 The malfunction detected during the trimming process should be eliminated and replaced by oil in the engine crankcase pallet.

The first stage of work is better to spend on the stand, but in the absence of a stand can be on the car.

The second stage of the car per car during the run of 3000 km. During this period, it is necessary to follow the rules for the advancement of a new car outlined in the instruction manual.

Power system repair

Verification of state fuel tank. Periodically, the fuel tank must be removed and rinsed. For tank removal, the boring tube is released on the roller tube and remove the rubber hose from the tube. Disconnect from the fuel level sensor wire. Then they release the clamp // (see fig. 26) of the seal 12 and remove the fuel tank tube from the neck. Two bolts are rejected / and lifted up the clamps 2. Lubricate the upper part of the tank with soapy, after which the tank is easily removed from the body.

The fuel tank requires repair in the case of mechanical damage and contamination. When repairing the fuel tank is washed in a 5% caustic soda solution, followed by a three-time washing with hot water.

Corrosion products are removed by etching in a 10% solution of hydrochloric acid. The tank after etching is neutralized with a 20% solution of soda and washed with hot water. The tightness of the tank is tested in a bath with water with air at a pressure of 0.2 kgf / cm for 3 minutes. Cracks and other tank damage is most simple and safely embedded using epoxy pastes.

Checking the state of the fuel lines. To prevent the fuel to prevent the connecting fittings, it is necessary to tighten them in a timely manner. Tightening should be carefully, since with an overly strong tightening you can damage the thread and the tube. If the tightening of the nuts is not eliminated to flow fuel, the connection is disassembled and inspected. If necessary, the cone tube is stronger or replace the corresponding fastening parts.

Damage to the fuel pipes (crumpled, breakdowns) is eliminated by removing the damaged area, followed by connecting the seat of the junction using a coupling or a muster. Connection locations are suspended by the solder to ensure tightness.

Removal, disassembly, checking and assembly of the fuel pump. When disassembling the fuel pump disconnects the supply and removal fuel lines from the fuel pump fittings, breaking the fuel access of the fuel tank. Remove the fuel pump, a spacer, guide rods with a pump drive bar and fuel pump pads. Check the integrity of the spacer and the absence of the play of the drive rod in the guide.

Refused (see Fig. 27) Screws of fastening of the upper part 5 of the fuel pump housing to the lower part 13 and remove the upper part, pre-placing the mutual position of the housings. Cutting bolt cover 1, remove the sealing washer, the cover and gasket with the filter grid. Wash the lid and the grid. Check whether there is no grid break, as well as the condition of the inlet 4 and the pumping 25 valves in the upper part 5 of the pump housing. When damage is detected, the upper part of the housing is replaced together with valves assembly. Press the upper cup of the diaphragm of 8 pumps to the upper cup of 6 and, turning it into 90 °, from the groove of the balance of 14 rod of the diaphragm from the groove, remove the diaphragm 8 assembled with the rod and the central springs of the diaphragm.

Check the diaphragm, set, are there any impulses, cracks or other damage. If necessary, pull the nut on the rod of the diaphragm. When damaged is detected, the diaphragm is replaced. The diaphragm consists of three layers of rubberized tissue: two tops, working in contact with fuel,. and one working in contact with oil.

Check the central spring of the diaphragm: the length in the free state is 46.5 ... 47.5 mm, under the press of 3.2 ... 3.35 kgf - 24 mm.

Further disassembly of the fuel pump (see Fig. 27) Perform in case of leaks of oil through eccentric 15, axis 16 or faulty work Manual drive. Taking advantage of the mandrel, the axis 16 of the lever and the balance sheet from the lower case is energized, the balance sheet 14 is removed, the drive lever 17, adjusting washers and the return springs of the lever. The axis should sit tightly in the housing and not have a noticeable wear. If necessary, replace the details. The spring drive lever in the free state must have a length of 27.5 ... 28.5 mm.

Clean the places of rollover of the eccentric, carefully flexing the lever, remove it and the spree of the lever with an eccentric. Take out eccentric from the lower case. Inspect the items and when damaged damage is disconnected. The eccentric sealing ring should not have residual deformation. The ring has an inner diameter of 6.02 ... 6.88 mm, in section represents a circle with a diameter of 1.70 ... 1.86 mm. Before assembling the pump, all gaskets and seals are replaced with new ones. Before installing new gaskets, they must be lubricated by a thin layer of oil.

The assembly of the fuel pump is performed in the sequence, reversal, turning special attention For the purity of the details and fighting the internal cavities from dust and dirt. When tightening the screws of the upper and lower body of the fuel pump, it is necessary to pull down the diaphragm down to the failure to get the largest diaphragm. After the assembly, the drive of the balance of the balance sheet and the hand drive lever is checked. They must turn without jerks and jams. The lever of the manual drive must return to its original position under the action of the spring when it is reducing it to the maximum distance.

The tightness of the diaphragm is tested by a fuel under the pressure of 0.6 kgf / cm2 to the discharge nozzle. The leakage is not allowed. The tightness of the valve is checked at a pressure of 0.3 kgf / cm2. With an excerpt of 10 minutes, the fuel leak is allowed not more than 10 cm3.

Before installing the pump (see Fig. 27), by pressing the drive lever 17, it is moved to the start of the useful stroke and the distance between the lever and the pumping plane of the pump housing is measured. The size of the immentation b should be 1.0 ... 1.5 mm. Install the bar 21 in the guide 20 rods so that the flat end of the rod is directed to the drive eccentric.

Fig. 71. Fixture for measuring the protrusion of the fuel pump drive rod: 1-flange; 2-rod; 3-nut; 4-indicator; B-Size Driving Lever

Then set the guide 20 rods with a bar 21 with a stroke 22 and gaskets 18 and 19 on the studs of the distribution gear cover and, attaching them, rotate crankshaft Until the maximum speech of the rod 21. At the same time, the rod should be pressed to the pump cam fist. The bar must perform above the spacer 22 with a laying of 18 per 1.7 ... 2.8 mm more than the drive lever 17 during the choice of free stroke. The protrusion of the rod is regulated by a set of gaskets 19.

The protrusion of the end of the rod is conveniently adjusted and measured using the device (Fig. 71).

Disassembly and status check air filter K-133 and K-133A carburetors. The clips of two locks are released (see Fig. 33, a) and separated the pallet 13 filter from the body 7. The sealing ring 3 is removed from the pallet, the valve 1 with a spring 4, a glass of 5 and a saddle of the valve. Muffle contaminated oil and is washed with a pallet filter with kerosene or gasoline until a complete removal of dust deposits. Inspect the details of the filter.

The operation of the air filter can sometimes be disturbed due to significant deposits on the caproic gasket. In this case, the housing of the filter with a packing is placed in a gasoline bath at 5 ... 6 hours, then washed and dried.

Collect the air filter and check its resistance. The resistance of the pure air filter at an air consumption of 130 m3 / h should be 240 ... 280 mm of water. Art. The filter is poured into the pallet of 0.2 liters of fresh oil used for the engine, and finally collect the filter. When assembling, pay attention to the safety of the sealing ring and the proper setting of the valve with the spring and the glass.

Removal, inspection and installation of the carburetor air filter DAAZ 2101-20. Weaken clamp 17 (see Fig. 33, b), screw the bracket nuts 29 and remove the filter. Outwarked nuts 19, remove the cover 20, take out the contaminated filter element 21 and replace it with a new one, purify the body 23 from dust before this.

The filter element is replaced every 10,000 km of mileage. With constant ride on very dusty roads, this replacement is made every 800 ... 1000 km of run.

It is allowed to reuse the filtering element after shaking the dust and thorough purging it from the inside with dry compressed air (sending the stream perpendicular to the plate on which the filter is installed). It is forbidden to direct the jet of the air directly to the filtering curtain of the element so as not to damage it. The purge of the filter element can be produced without removing it from the housing, sending the air flow through the cover of the cover perpendicular to the wall.

When collecting the air purifier, it is necessary to pay attention to the reliability of the sealing of the nozzles to avoid the supply of contaminated air.

Disassembly and assembly of a single-chamber carburetor (K-133 and K-133A). Disassembly of the carburetor is recommended in the following sequence:

remove the fuel filter tube 77 and remove the filter (see Fig. 28);

remove the screws that fasten the cover of the float chamber to the housing of the float chamber, lift the cover and, carefully turning it towards the location of the tight thrust, output the cover with the float from the float chamber housing; At the same time disconnecting the craving from the air damper lever;

remove the gasket, remove the axis 4 (Fig. 72) the float and remove the float. Remove the needle 7 valves along with the rubber sealing washer 8 and unscrew the valve seat 6 ,. The air jacker 12 (see Fig. 29) of idling;

rinse parts in gasoline. In the presence of abundant resinous sediments, flush the parts with acetone or solvent for nitrobras. To clean the jaws, you can use a pointed wooden stick with a richly moistened solvent. Washed parts and carb canals to blow with compressed air. It is not recommended to rinse the fuel valve with acetone or other solvents to avoid the destruction of the sealing rubber washer. Completely unacceptably use the wire for cleaning the fuses, even soft;

check float for tightness. When soldering the float, it is necessary to take appropriate precautions to avoid explosion of gasoline vapor. After soldering, the mass of the float must be 13.3 ± 0.7 g. Check the tightness fuel valve. If necessary, replace the sealing rubber washer 8 (see Fig. 72) or fuel valve assembly.

Fig. 72. Float with fuel valve: 1 - float; 2 - tongue to install a level; 3 - limit-tel stroke float; 4 - axis float; 5 - Float Cap Cover: 6 - Saddle Fuel Feed Valve; 7 - fuel supply valve needle; 8 - Sealing rubber washer

Collect the cover of the float chamber in the sequence, reverse disassembly, while:

the air jet of idling must be cleaned without much effort, checking the safety of fiber gasket;

in the case of replacing the parts of the float mechanism or, if the carburetor is observed in operation, it is necessary to check the position of the float position relative to the fuel valve. This position determines the fuel level in the float chamber. Pre-set the size of 39 mm in charge of the tongue 2 (see Fig. 72). At the same time, it is necessary by plexing the limiter 3 movement of the float to set the stroke of the fuel supply valve valve 1.2 ... 1.5 mm. At the same time, it is not allowed to press the float on the valve needle when adjusting the fuel level in the float chamber to avoid damage to the sealing rubber washer;

the gap around the circumference between the air damper and the cover housing should not exceed 0.25 mm. Followed by:

unscrew the screws 40 (see Fig. 29) and remove the microswitch 39; Disconnect the housing of the mixing chamber at the same time, pressing the accelerator pump drive bar, remove the drive stem earring, connecting the rod with the throttle axis lever, unscrew the fuel-powered screw 4 and remove the sprayer 3 of the accelerator pump;

remove the rod 33 acceleration pump drive together with the bar and piston and remove the ropted spring spring. Remove the accelerator pump of the spacing ring of the check valve (using tweezers) and, turning the float chamber body, remove the check valve 30 (the ball d \u003d 4 mm); Remove the plugs 13 (see fig. 28) of the idling fuel oil and air gibber 16 of the main dosing system, after which the jackets are turned off. Turning the jets, you should use neatly refilled screwdrivers so as not to damage the slots;

remove the plug 8 and remove the emulsion tube 9 (see Fig. 29), turn out the valve 31 of the mechanical economizer and remove the fiber puck;

remove the adjusting screw 19 from the body of the mixing chamber 19, unscrew the screws, remove the economizer 23 forced idling (EPHX) and remove the sprayer 25 of the autonomous SIS-theme of the idle. Check the edge of the adjusting screw 19 of the ACS and the cone surface of the hole, the tapered surface of the valve 24 of the coercive idling system (EPHX) and sprayer 25 ASHX, the density of the sprayer 25 in the mixing chamber 28, the state of the 24 APKH valve diaphragm state. Replace the details who came into dissent;

check the tightening screws of the throttle to the axis. Check the adjacent throttle to the mixing chamber case; The loop over the contour should not exceed 0.06 mm. Rinse thoroughly and blow all the details. Check if the piston of the accelerator pump is easily moved in the cylinder. He must move in a cylinder without jail;

check the tightness of the discharge valve of the accelerator pump and the valve of the mechanical economizer (in the case of increased flow Gasoline), inspect Sealing gaskets: Replace damaged gaskets new ones.

Collect the housing of the float chamber with the mixing chamber body in the sequence, reverse disassembly, and it is necessary:

gyps wrap without much effort;

ensure the reliability of the seal in all places of installation of gaskets;

check with a fully open throttle gap between adjusting nuts; For stock of the economizer drive, it should be 4.5 ... 5.5 mm, and for the rod drive of the piston of the accelerator pump-1.5 ... 2.5 mm. Fix the position of adjusting nuts with compression;

install (see Fig. 29) Sprayer 3 and wrap the fuel-powered screw 4,

install the collected cover of the float chamber, connecting the craving;

Fig. 73. Device for checking the fuel level in the Float Camera K-133 and K-133A carburetors: 1 - a large-scale line; 2 - glass tube; 3 - fitting; 4 - gasket; 5 - carburetor

check the fuel supply with an accelerator pump, which should be at least 6 cm3 for 10 piston working moves, the relative position of air and throttle;

set the bottom stop lever throttle so that throttle valve It was completely closed, but not clinic, and the upper stop so that the throttle plane was parallel to the axis of the hole with a diameter of 32 mm mixing chamber. With a fully closed air damper, the gap between the wall of the mixing chamber and the throttle should be 1.6 ... 1.8 mm (if necessary, it is adjusted to the thrust);

install the microswitch 39 so that its pusher at a fully closed throttle was recessed by Sumchag 41

the drive of the microswitch (the microswitch will open), while the characteristic click is listening, when opening the throttle, the lever 41 is lowered by 3 ... 4 mm, the microswitch pusher is given to the spring, and the microswitch closes;

check the fuel level in the float chamber on the stand. The level of fuel in the float chamber at an overpressure of 0.3 kgf / cm2 for gasoline with a density of 0.720 ... 0,750 g / cm3 should be 21 ... 23.5 mm from the upper plane of the float chamber.

In the absence of a stand, this test with less accuracy can be performed on the engine, for which the fitting is made with a glass tube (Fig. 73). It is necessary to unscrew the plug of the main gibler and put the fitting in its place so that the glass tube becomes vertically, then the lever of manual pumping of the fuel pump. Fill the float chamber fuel. The metal ruler measure the distance from the upper plane of the float chamber to the fuel level in the float chamber (to the bottom of the meniscus). When installing the carburetor, pay attention to the integrity of the gaskets. After installation, you need to adjust the carburetor when the engine is operating in idle mode.

Checking the electromagnetic valve. The tightness of the electromagnetic valve should be checked by air supply under pressure of 0.9 ... 0.85 kgf / cm2 in the side fitting, while the ventilation fitting is closed.

When feeding a vacuum 0.85 kgf / cm2 to a vertical uniform, the electromagnetic valve must open with the connection of the voltage 12 V and close with the removal of the voltage. If the voltage is connected with a non-working engine, the characteristic click must be listened.

At the engine running at idle, the valve is checked by disconnecting the wire, and the engine must stop.

Check electronic block Control. The electronic control unit has two boundary limits. With an increase in the rotation frequency of the crankshaft of the engine more than 1500 ... 1800 rpm, a positive potential is turned off on terminal 1 (see Fig. 29), with a decreasing frequency below 1500 rpm on terminal 1 there appears positive potential.

In this way, the performance of the block is checked, and it is necessary to remove the wires on the microswitch 39 before it. The lack of positive potential on terminal 1 (if there is a positive potential on terminal 2) signals the block malfunction and the need to replace it.

In the event of a failure of the forced idling economy system, it is necessary to de-energize the system and connect the fitting 3 and 6 (see Fig. 28) flexible hose, while the carburetor will operate according to the generally accepted scheme, without solenoid valve 21 (see Fig. 29) of the electronic control unit 35 and microswitch 39.

Adjusting the carburetor when operating the engine in idle mode. The engine's economical operation depends more on the proper adjustment of the carburetor when working at low speed of rotation of the crankshaft at idle code.

This adjustment is carried out with a completely warm engine. The oil temperature should be at least 60 ... 70 ° C.

The adjustment of the K-133 and K-133A carburetors is not-managed in the following sequence:

on the disabled Engine Wrap the screw 7 (see Fig. 28) operational adjustment and screw 2 to failure, but not tight, in order not to damage their working cones. After that, unscrew the screws by 2.5 ... 3 turns;

to put the engine and rotation of the screw 2 set the rotational speed of the crankshaft 950 ... 1050 rpm;

next to complete the screw 7, while the rotational speed of the engine will first increase, and then with further screwing the screw, the mixture will take place and the engine will start working with interruptions with a simultaneous decrease in the rotation frequency of the engine crankshaft. At this point, you need to get a slightly screw 7 and achieve sustainable engine operation.

A selected adjustment must be checked on variable modes - to dramatically click on the throttle drive pedal and quickly release it. At the same time, the rotational frequency of the crankshaft should be smoothly without failures and interruptions to increase, and with a sharp release of pedals to decrease to minimum and stable, the engine should not stop. In case the engine stopped, turning the screw 7, a slightly increase the speed of rotation.

Emission check harmful substances With the exhaust gases, the atmosphere is performed after adjusting the idle speed on the heating engine (oil temperature of 60 ... 70 ° C).

For checking, special equipment is needed - a gas analyzer with an error of no more than ± 2.5%. The check is made according to GOST 17.2.2.03-87 in two modes: at a speed of idle and 2550 ... 2650 rpm.

If the emission of harmful substances does not exceed the permissible limits, the toxicity screw 2 (see Fig. 28) K-133 and K-133A carburetors need to be painted with red paint. When emitting harmful substances above the permissible limits, it is necessary to adjust the rotational speed of the crankshaft at idle and then check the emission of harmful substances.

If the emission of harmful substances could not be reduced by additional adjustment, the carburetor must be replaced and check the emission of harmful substances; Upon receipt of unsatisfactory results, diagnose the engine, defining and eliminating the detected faults.

Removal and installation of the carburetor DAAZ 2101-20. To remove the carburetor weakened the clamps and remove the hose of the crankcase ventilation system. The four nuts of the attachment of the removal nozzle are rejected, weaken the clamp, remove the pipe with the gasket, and from the carburetor nozzle - the fuel supply hose and closes the plug hose to prevent gasoline leakage.

Disconnect air damper drive cable from the carburetor and from the throttle lever of the thrust and the return spring, the nuts of the carburetor fastening are removed along with the gasket and close the inlet inlet of the intake pipeline.

Install the carburetor in the reverse order. After installation, it is necessary to adjust the drive of the air damper and chokes of the carburetor, as well as the rotational speed of the crankshaft at idle during the engine.

Disassembly, checking and assembly of the carburetor DAAZ 2101-20. The carburetor is disassembled on the following main nodes: body cover assembled with a starting device, float, needle valve and filter; body assembly with diffusers and accelerator pump; Housing of throttle dampers assembled with throttle valves and the spool device of the crankcase ventilation system.

Fig. 74. Details of the lid and the throttle valves of the carburetor DAAZ-2101-20: 1 - adjusting screw; 2 - cover; 3, 17, 21, 34 - springs; 4 - diaphragm; 5 - Diaphragm rod; 6 - trigger case; 7 - Telescopic thrust; 8 - axle of air damper; 9 - air damper; 10 - carburetor cover; 11 - gasket; 12 - carburetor housing; 13 - axis of the secondary throttle; 14 - axis primary throttle damper; 15 - throttle; 16 - screw adjustment of the composition of the mixture; 18 - fitting to the vacuum corrector of the interrupter-distributor; 19 - spool; 20 - stubborn screw; 22 - lever axis primary throttle; 23 - Communication lever with a starting device; 24 - sleeve- 25 - lever of the secondary throttle drive; 26 - lever of dampers; 27 - lock washer; 28 - Spring Return lever Drive lever secondary damper; 29 - triggering device; 30 - chang secondary throttle; 31 - throttle housing: 32 - gasket; 33 - Traction starter

Before disassembly, it is necessary to wash the carburetor outside and blow with compressed air. Disassembly is recommended to be carried out in the following order:

remove the spring 28 (Fig. 74) of the throttle lever 25 of the throttle of the secondary chamber, to fray and disconnect the throttle lever 23, which connects the throttle of the primary chamber with a starting device;

pressing the inner cylinder of telescopic thrust 7 in the outer, disconnect it from the air damper control lever;

remove the cover of the carburetor with a gasket, trying not to damage the gasket and float, after which the screws fastening the throttle housing to the body of the carburetor and carefully, without sinking, disconnect them, trying not to damage the fuel-and-air channels of the carburetor fuel and sockets pressed into the housing. Carefully disconnect the heat insulating gasket and remove it;

disassemble the cover of the carburetor housing in the following order: I cautiously push the axis 20 (Fig. 75) the float from the racks (pushing down the rack with a cut) and remove the axis, remove the float 19 and the needle valve 16, the cover laying. Remove the saddle 15 needle valve, unscrew the plug 18 and remove fuel filter 17;

disconnect (see Fig. 74) from the axis lever 8 of the air damper telescopic craving 7 and craving 33 of the actuator of the starting device;

remove the 6 trigger housing, the air damper 9 from the axis, and then remove the axis from the carburetor cover. The ends of the fastening screws are separated. To unscrew them, you may need a lot of effort and the flap axis can be deformed. To prevent the axis deformation, it is recommended to install some stand under it.

After disassembly, rinse parts in gasoline, blow with compressed air and check their technical condition, which should meet the following requirements:

the sealing surfaces of the lid should not have damage, otherwise the lid should be replaced;

float should not have damage and any distortion of form; The mass of the float must be 11 ... 13 g;

the saddle of the needle valve and the valve itself should not have wear on sealing damage; The needle valve must move freely in its nest; The needle valve ball must move freely and do not hang.

If damaged parts are detected during inspection, they must be replaced.

Fig. 75. DAIZ-2101-20 carburetor hull parts: 1 - cable shell fastening screw; 2 - bracket; 3 - cable fastening screw; 4 - air damper drive lever; 5, 25, 32 - springs; 6 - fuel jet of the transition system of the secondary chamber; 7 - Zhiklera housing; 8 - small diffuser; 9 - sprayer pump-accelerator; 10 - valve valve pump accelerator; 11 - valve; 12 - the main air jet of the secondary chamber; 13, 22 - emulsion tubes of secondary and primary cameras; 14 - the main air jaw of the primary chamber; 15 - a saddle of the needle valve; 16 - needle valve; 17 - filter; 18 - plug; 19 - Float; 20 - axis; 21 - Adjusting screw-accelerator screw; 23 - the main fuel jigger of the primary chamber; 24 - the main fuel jigger of the secondary chamber; 26 - accelerator pump diaphragm; 27 - Pump-accelerator cover; 28 - Zhiklera Corps; 29 - idling fuel jaw: 30 - carburetor housing; 31 - screw adjustment of throttle opening; 33 - stop spring; 34 - screw toxicity; 35 - plug.

Next, the starting device is disassembled, at the same time rejected (see Fig. 74) Three screws for fastening the cover 2 of the device, remove the cover with the adjusting screw 1, the spring 3 and the diaphragm 4. After disassembly, all parts of the starting device are cleaned, washed with gasoline, blurred with compressed air and Inspect - damaged replace new. When disassembling the throttle housing, it is necessary to unscrew the screw 16 adjustment of the idling mixture, unscrew the screws that are fastening the flaps 15 to the axes, and remove throttle valves from the axes. The ends of the throttle fastening screws are separated, so when screwdruting the screws, as well as when removing the air damper, it is recommended to install a stand under the axis of chokes.

Next, screw the fastening nuts on the axis of the throttle valve of the primary chamber are removed from the axis of the throttle valve of the primary chamber the lock washer, the levers 26, 25, 23 with washers and sleeves 24, and then the moglist spring 21 of the spool and the spool 19.

The axis 14 of the throttle valve of the primary chamber from the housing 31 is removed, screw the fastening nut 30 on the throttle axis of the secondary chamber, remove the lever with the washer and remove the axis 13 of the throttle valve of the secondary chamber.

Purify parts and washed with gasoline or acetone. Channels and parts of the crankcase ventilation device are recommended to rinse with a mixture of a 30% monobutyl ethylene and 70% gasoline. Inspect the details, damaged replace.

Holes of the axes of chokes are purified by a scan having a diameter equal to the nominal diameter of the holes (8.020 ... 8,042 mm).

If the holes are very worn, then it is necessary to deploy them to a diameter of 8.520 ... 8.542 mm (0.5 mm more nominal) and to assemble the axis of the repair size, increased by a diameter by 0.5 mm.

remove the fastening screw of the air damper drive 4, remove the lever, spring 5, remove the cover 27 of the pump to the pump with a return spring 25;

remove the main aerial jets 12 and 14, turn the housing and, slightly tapping on it, shake out the emulsion tubes 13 and 22 from the wells, then unscrew the housing 7 and 28 of the jets and remove them along with the gibeles 6 and 29, unscrew the valvenet 10 and remove the sprayer 9 of the accelerator pump with gaskets, after which the adjustment screw 21 of the pump accelerator and the screw 31 adjustment of the opening of throttle valves and remove small diffusers 8, turn out the main fuel jets 23 and 24 and remove the bracket 2, on which the air damper control cable sheath is attached; Remove the plug 35 and twist the screw 34 with the spring 33.

The hull of the carburetor is cleaned of dirt and oil. Wash the housing and its channels with gasoline or acetone and purged with compressed air. If necessary, clean the channels and emulsion wells with special scans. Inspect the sealing surfaces of the housing, if they are damaged, the case should be replaced.

The details of the accelerator pump are cleaned, washed and blurred with compressed air. Check the ease of moving the ball in the valve 10 (see Fig. 75) and the state of sealing surfaces and gaskets. Check the ease of moving the movable elements of the pump (lever, roller, diaphragm parts). Singles are not allowed. The diaphragm must be whole and not have deformations. Even minor diaphragm deformation affects the work of the pump. Damaged parts are replaced with new ones.

The jets and emulsion tubes are purified from dirt and resinous sediments, washed with acetone or gasoline and purged with dry compressed air. Compare belligers for bandwidth with reference.

Remove the jets with a metal tool or wire, as well as wipe the jackets and other parts of the carburetor with cotton, cloth or rags are not recommended. With strong clogging, the jets should be cleaned with a needle of a soft tree, abundantly moistened with acetone.

Assembling the carburetor is carried out in the sequence, reverse development. At the same time, the float must rotate freely on its axis, not assimary by the walls of the chamber, the needle valve should freely slide in his nest, without distortion, the valve leash should not prevent the movement of the trap the float.

When installing air dampers and throttle valves, the ends of the mounting screws must be selected using a stand similar to that used when disassembly. After assembly, the knots of the carburetor must be adjusted.

Adjusting the carburetor DAAZ 2101-20. The position of the throttle valve of the secondary chamber is adjusted (see Fig. 31, b) with screw 27. In the lever position, corresponding to the complete closing of throttle, the throttle of the secondary chamber must be slightly ajar. The gap between the throttle and the wall of the chamber at the place of exit channels of the transition system should be no more than 0.02 ... 0.03 mm.

In the lever position 28, in which the protector of the sector 29 co-touches the lever 31, the throttle valve of the primary chamber must be ajected on (7 ± 0.25) mm. This gap can be obtained by preventing the protrusion of the sector 29. Both throttle valves must be fully open when the lever 28 turns to the extreme position until the sector 29 is stopped into a special tide on the throttle housing. This position of throttle valves is regulated by the bending of the lower protrusion of the sector 29.

The starting device is adjusted as follows (see Fig. 31, b). When you turn the lever 20 counterclockwise until the air damper should be completely closed, and in this position of the lever, the end of the thrust 22 must be at the end of the rod groove of the diaphragm of the 23 starting device, but it is not allowed to move the rod. This requirement is performed 1 liter of thrust 22. With a fully closed air flap, the throttle valve of the primary chamber must be covered with 1.2 ... 1.3 mm (the distance between the throttle valve and the chamber wall at the place of the idling system). This gap is adjusting the thrust 35. Fully closed air damper must open to (7 ± 0.25) mm rod of the diaphragm 23 of the starting device when it is manually moving to the right until it stops. This gap is regulated by screw 24.

The performance of the accelerator pump is tested for 10 full turns (strokes) of throttle control lever 28, which came out of the sprayer 45 (see Fig. 31, d), for these 10 moves are going to the Menzur. Its volume should be 5.25 ... 8.75 cm3.

Fig. 76. Installation of the fuel level in a floating chamber of the DAAZ 2101-20 carburetor: 1-cap of the carburetor: 2-saddled valve; 3-needle valve; 4-emphasis; 5- needle valve ball; 6-exhaust valve needle plug; 7-bracket float; 8-tongue; 9-float; 10-gasket.

Before the start of the check, it is necessary to make 10 trial moves by lever 28 (see Fig. 31, b) to fill the pump accelerator channels.

The tightness of the needle valve is checked on the stand, which provides fuel supply to the carburetor under pressure of 3 m water. Art. After installing the level in the control tube of stand, the drop is not allowed within 10 ... 15 s. If the fuel level in the test tube decreases, then this indicates fuel leak through a needle valve.

Installing the fuel level in the float chamber. Carburetors DAAZ 2101-20 Checking the fuel level in the float chamber is not provided.

The level required for normal operation of the carburetor is provided proper installation Good items of the locking device (Fig. 76): The float assembly should not have any visible damage, the mass of the float must be 11 ... 13 g; The distance between the float and gasket 10 adjacent to the lid of the carburetor should be (6.5 ± 0.25) mm.

The control is performed by a caliber, the housing cover holds vertically so that the bunch 8 of the float slightly shed a 5 needle valve ball 5, not having it: adjusting the size (6.5 ± 0.25) mm is carried out by sweetening the tongue 8, while it is necessary to the supporting area The tongue was perpendicular to the axis of the needle valve and did not have a jar and dents; The gap corresponding to the maximum goal of the float must be (8 ± 0.25) mm. It is adjustable by the prevention of the stop 4, the plug 6 should not impede the free movement of the float. After installing the carburetor, you must make sure that the float does not touch the walls of the float chamber.

Correct installation of the float should be checked every time the float or fuel needle valve is replaced; When replacing the needle valve, it is necessary to replace the valve sealing gasket.

Adjusting the rotational speed of the crankshaft under idling. The elements regulating the rotation frequency of the crankshaft at idle during the engine are related (see Fig. 30) of the mixture composition of the mixture and screw 2, which limits the opening of the throttle. When the screw is wrapped 11, the mixture is shifted, when the screw is wrapped 2, the throttle is turned off. A restrictive plastic sleeve is painted on the screw 11, which allows the screw to rotate only one turn. Therefore, before adjusting the station maintenance It is necessary, pulling the screw 11, break the protrusion of the sleeve, turn the screw, remove the bushing from it and turn the screw to the carburetor again. After the end of the adjustment, press the screw II new restrictive plastic sleeve in such a position so that the protrusion protrusion, touching the stop in the hole, did not allow the screw to unwind.

The idle adjustment is performed on a heated engine (oil temperature of 60 ... 70 ° C) with adjusted gaps in the gas distribution mechanism and with a properly installed ignition advance angle.

Adjustment is carried out in the following sequence (see Fig. 30):

screw 11 to set the maximum rotational speed of the crankshaft at a given position of the dam-roof damper, and then the screw 2 to set the minimum stable rotation frequency of the crankshaft;

screw 11 reach the concentration of CO in the exhaust gases not more than 1.5% with this position of the throttle and screw 2 to restore the rotation frequency of the crankshaft to 950 ... 1050 rp;

set the rotational speed of the crankshaft at idle, equal to 0.6 nominal revolutions (2700 ... 2800 rpm), and check the concentration of CO in exhaust gases, which should be no more than 1%, if necessary, to achieve a concentration with screw 7, if necessary. After that, once again, check the concentration of CO in the exhaust gases when working at idle with the rotational speed of the crankshaft 950 ... 1050 rpm and to achieve a concentration of not more than 1.5%;

put the plug 35 (see Fig. 75) into the screw hole. In the absence of a gas analyzer, the adjustment can be carried out in the following order:

screw 2 (see Fig. 30) Set the minimum stable rotation frequency of the crankshaft, and then the screw 11 to achieve engine operation with the maximum rotation frequency of the crankshaft at this point of the throttle;

screw 2 reduce the opening of the throttle until the minimum stable rotation frequency is obtained and, tightening the screw 11, set the rotation frequency of the crankshaft, in which the engine works with noticeable interruptions, and then unscrew the screw to 30 ... 60 ° (no more) until sustainable engine operation;

check the adjustment, sharply by pressing the throttle control pedal and release it. The engine does not have to stop at the same time.

Removing and installing carburetor drives. For removing throttle drive thrust assembly with a cable and shell, you must:

unscrew the screw 14 (see Fig. 32) fastening the cable to the carburetor rod and release the cable;

to fray the finger, disconnect the 3 cable from the pedal and remove it completely from the tube laid in the floor tunnel; Bend the shell mounting bracket 18 to the engine bracket;

replete two bolts fastening the fuel tank clamps to the floor of the body (after removing backseat) and slightly raise the tank up to release the shells of the carburetor;

remove from rubber seals (on the walls of the body) the shell.

The throttle drive cable setting is carried out in the reverse order.

To remove the air damper from the car, it is necessary to release the fastening of the fuel tank (as described above), and then (see Fig. 32):

disconnect from the carburetor 13 craving 12 and shell 9, for which let the screws 10 and bolt II;

pull the air damper drive button 4 and completely remove it from the shell;

disconnect and remove the gearbox control mechanism from the tunnel (see Penodes. "The Pen-Conduction Control Mechanism") and bend the shell mounting bracket located in the tunnel;

remove the two screws 6 mounting bracket 5 to the tunnel and remove the bracket with the shell from the tunnel, then the shell lock 7 from the bracket 6 is screwed.

The air damper drive assembly and its installation is performed in the reverse order.

Adjusting the carburetor drive. After dismantling and mounting the drives to the carburetor flaps or installing new, appropriate adjustment should be carried out.

The adjustment of the throttle valve control actuator is recommended as follows (see Fig. 32): let go of the screw (bolt) 14 of the traction mounting 17 and with the help of pliers pull the end of the thrust until the pedal is set to the extreme top position; Secure in such a position with a screw. For proper adjustment Drive The throttle valve of the carburetor must be fully covered when the pedal is released and is completely open when the pedal failure is pressed.

The drive of the air damper should be adjusted in the following order: release the bolt (screw) 11 of attachment of thrust to the hinged coupling of the carburetor air damper and omit button 4 of the air damper drive to the extremely lower position; Without moving the thrust in the shell, fully open the air damper and in such a position to fasten the bolt (screw) 11. Sheath 9 traction must be tightly tightened with screw 10, the speech of the shell for the bracket is not allowed.

Clutch work

Constructive features of clutch shutdown

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