Clutch release drive ZIL-5301
ZIL cars and buses use a hydraulic clutch drive with a pneumatic booster.
Disassembly of the pneumatic-hydraulic booster (PGU) for repair is carried out, as a rule, in the following cases:
- fluid leakage through cuffs 29, 33 (Fig. 1), due to their swelling when using low-quality liquids; when the cuff of the pneumatic piston 23 is worn.
The probability of failure of other parts is low.
The disassembly procedure is given below. Remove cover 36 with pusher 37 from the PSU.
Secure the PGU in a vice, pointing the front housing 26 upward.
Unscrew connecting bolts 12 (2 pcs.), 19 and 25 (5 pcs.). Lastly, unscrew bolt 19 located in the gearbox area
In this case, you should hold the housing 26, since springs 11 and 22 act on it.
Remove body 26, springs 11 and 22, diaphragm 10 assembled with seat.
Using a special wrench (Fig. 4-13), unscrew housing 1 of the gearbox follower piston 4 from the rear housing (see Fig. 1).
Remove the rear housing of amplifier 1 from the vice.
Remove the retaining ring 35 and remove the clutch release piston assembly 34 from the rear housing, pushing it past the protruding rod on the seal side 2.
Remove the spacer sleeve 30, spring 31, sleeve 32 and collar 33 from the piston rod 34. Remove the retaining ring 21 of the clutch release piston rod seal and washer 28.
Press cuff 29 and seal 2 of the clutch release piston rod out of the rear housing.
Remove rubber rings 1 and 3 from body 2 (Fig. 4-14) of the piston seal. On body 1 (see Fig. 1), unscrew and remove bypass valve 5 assembled with cap.
Unscrew the screws 9 securing the outlet cover 8, remove the cover and seal 7 of the outlet.
It is not necessary to perform the last two operations.
To disassemble the amplifier gearbox diaphragm (Fig. 4-15), you need to unlock nut 3 of the gearbox diaphragm and unscrew it.
Remove washer 2, diaphragm 1, washer 6 and gasket 5 from diaphragm seat 4. This unit should not be disassembled unless necessary.
To disassemble the servo piston of the amplifier gearbox (Fig. 4-16), it is necessary to remove O-ring 3 from the servo piston body (see Fig. 1).
Remove follower piston 1, complete with cuff and sealing ring, from housing 2 (Fig. 4-16). Remove 1 sealing ring 4 and seal 5 from the piston.
Remove thrust ring 3 from follower piston housing 2
To disassemble the front amplifier housing and the pneumatic piston must be removed from the front housing, o-ring 13 (Fig. 1), gearbox diaphragm seats, pneumatic piston 20, amplifier assembly.
Remove the cuff 23 and guide rings 27 from the pneumatic piston 20.
Secure the front housing 26 in a vice, pointing the air supply cover 1 upward
Unscrew the cover fastening bolts (4 pcs.), remove the cover and remove the amplifier gearbox valve 14, removing the adjusting and sealing aluminum gaskets 16 on both sides of the seat of this valve.
The amplifier gearbox valve (Fig. 4-17) is of a non-separable design; if necessary, change the assembly.
Rinse the parts and components of the clutch booster in MS-6, MS-8 solution TU 6-15-978-76, blow them with compressed air.
Carry out defect detection of parts
Assembling and adjusting the pneumohydraulic booster
Assembly of the CCGT unit is carried out in the reverse order of disassembly.
Lubricate the rubber seals of the piston rod and surface “D” (see Fig. 1) with liquid NG-213 TU 38.101.129-75. Press 1 cuff 29 into the rear housing using a mandrel (Fig. 4-18).
Install seal 2, having previously assembled it with sealing rings 1 and 3 (Fig. 4-14), install washer 28 and retaining ring 21
To assemble the clutch release piston (see Fig. 1), before assembly, it is necessary to lubricate all rubber parts and surfaces “A” and “E” with liquid NG-213 TU 38.101.129-75.
Install cuff 33, spacer sleeve 32, spring 31, spacer sleeve 30 onto clutch release piston rod 34.
Insert the assembled unit into the housing cylinder 1 and install the retaining ring 35.
Install the outlet seal 7, cover 8 and tighten the screws 9 securing the cover. Install and tighten bypass valve 5 complete with cap 6.
To assemble the servo piston of the amplifier gearbox, before assembly, it is necessary to lubricate all rubber parts and surface “B” with liquid NG-213 TU 38.101.129-75.
Then install sealing ring 4 and cuff 5 on piston 1 (see Fig. 4-16);
Install follower piston 1 assembly into housing 2; install the thrust ring 3 into the body 2 of the follower piston and put the sealing ring 3 onto the body of the follower piston (see Fig. 1).
To assemble the gearbox diaphragm, install two gaskets 5, washer 6, two diaphragms 1 and washer 2 on seat 4 (Fig. 4-15), tighten nut 3 with a torque of 20-25 Nm and lock it, loosening it at one point.</ p>
To assemble the front housing of the amplifier and the pneumatic piston, it is necessary to install the cuff 23 and guide rings 27 on the pneumatic piston 20 (see Fig. 1).
Then install the pneumatic piston assembly 20 into the front housing of the amplifier.
Before installing it, fill the cavity “B” and lubricate the surface “G” with a thin layer of lubricant 158 TU 38.101.320-77.
Install a new O-ring 13 for the gearbox diaphragm seat into the front housing of the amplifier.
After subassembling the subassemblies of the pneumohydraulic amplifier, you need to install the rear housing 1 of the amplifier in a vice with the connector facing up.
Screw the housing of the gearbox follower piston assembly into the rear housing of the amplifier using a special wrench.
Place the diaphragm of the amplifier gearbox 10, assembled with the seat, on the rear housing of the amplifier, lubricate the surface “G” with a thin layer of lubricant 158 TU-38.101.320-77, and align its holes with the holes for the mounting bolts in the rear housing of the amplifier.
Insert extension rods (diameter 6 mm, length 100 mm) into these holes. Install the gearbox diaphragm spring 11 and the pneumatic piston spring 22.
Install the front housing of the amplifier 26 assembly onto the rear housing 1, directing the holes for the mounting bolts along the guide rods.
Press the front housing and compress the springs until the gap between the housings is eliminated, and the diaphragm seat should fit into the hole on the front housing where O-ring 13 is located.
It is unacceptable for the saddle to rest firmly on the body (especially with a noticeable increase in the compression force)
Without releasing the front body, remove one guide rod, insert bolt 19 with a spring washer and tighten it completely, but do not tighten it and, taking out the guide rods one by one, insert and tighten bolts 12, 19 (the second) and 25 with spring washers. Then tighten the bolts evenly to the end.
Install the amplifier gear valve 14 assembly into the front housing of the amplifier, adjust by filling the gap “A” (Fig. 4-19).
Gap “A” (travel of the seat until it contacts the valve) should be 2+0.5 mm.
It must be adjusted using shims 16 (see Fig. 1), which should be installed at least one on each side of the saddle.
The size of the gap is determined in the following way:
- measure the movement of the diaphragm seat, which is the difference in distances from the end of the seat to the end of the front housing in the initial position and after full movement of the seat when creating pressure in the hydraulic system of the PSU to overcome the resistance of the compressed spring of the gearbox 11;
- - install valve 14 with one gasket under the seat and press it tightly into the seat using a tubular bushing with a mounting flange;
- - measure the movement of valve stem 1 (Fig. 4-17), which is the difference in distances from the end of the valve stem to the end of the tubular pressure bushing in the initial position and after complete movement of the valve stem when creating pressure in the hydraulic system of the CCGT unit.
Pressure in the hydraulic system can be created using compressed air of 0.5-0.6 MPa supplied through the hole for connecting the hydraulic hose, having previously screwed in the bypass valve.
The difference between the movement of the diaphragm seat and the movement of the valve stem will be the size of the gap between the diaphragm seat and the exhaust valve.
If this value is less than the specified value, then adjusting shims are placed under the valve seat (the thickness of one shim is 0.5 mm) until the required clearance value is obtained.
Moving the diaphragm seat and valve stem is best done using a depth gauge ShG-160 GOST 162-73.
Install the air supply cover 17 (Fig. 1) on the front housing of the amplifier and tighten the bolts securing it.
Between the front body and the cover there must be a uniform gap around the entire perimeter of 0.5-1 mm in order to unconditionally press the cover to the valve seat and ensure tightness.
If this requirement is not observed, air leakage will occur. After assembly, it is necessary to check the tightness of the air and hydraulic parts of the CCGT unit.
To check the tightness of the air part of the CCGT, it is necessary to connect a one-liter tank equipped with a pressure gauge and an inlet shut-off valve to the air supply cover 17.
Compressed air at a pressure of 0.5-0.7 MPa is supplied to the tank inlet.
First, the inlet part is checked, which is the volume under the air supply cover, the seal of the end of the cover with the valve seat 14 and the seal of the rear cone (inlet) valve and the valve seat.
To do this, close the inlet tap of the liter tank and measure the pressure drop.
Tightness is considered satisfactory if within 30 seconds the pressure in the tank drops by no more than 0.05 MPa.
Then the working air part is checked, which additionally includes the seal of the front cone (exhaust) valve and the reducer diaphragm seat, the seal of the pneumatic piston cuff between the piston itself and the cylinder wall of the front housing, the seal of the diaphragm between the front and rear housings, as well as the tightness of the front housings themselves housing and pneumatic piston.
To do this, a pressure of 0.5-0.7 MPa is created in the pneumatic system of the CCGT unit, the inlet valve of the liter tank is closed and the pressure drop is measured.
Tightness is considered satisfactory if within 30 seconds the pressure in the tank drops by no more than 0.05 MPa.
To check the tightness of the hydraulic part, it is necessary to install a pressure gauge between the CCGT and the main cylinder.
The system is then pumped to remove air from it. The hose is disconnected from the compressed air supply cover.
The hydraulic system creates a pressure of 6.5-7.0 MPa.
The main cylinder is locked and there are no leaks through it.
Tightness is considered satisfactory if within 30 s the pressure in the pipeline drops by no more than 0.5 MPa.
