Kamaz clutch slips adjustment

Reliability, excellent performance, efficiency - all this can be said about KAMAZ trucks. The machines are in demand for household, commercial and military purposes. The key to long-term and trouble-free operation is constant checking of the technical condition. Adjusting the KAMAZ clutch is always relevant. This brand is usually equipped with a dry double-disc or single-disc clutch (friction type). During its entire service life, the unit experiences enormous loads. Competent selection of spare parts and timely maintenance will guarantee long-term operation. Adjusting the KAMAZ clutch basket requires experience and certain knowledge.

Setting is necessary when:

A crackling sound occurs when changing gears.
Slipping at high speeds.
Changing the free play of the clutch pedal (it has certain digital values).

If you ignore these signs, expect a serious accident!

KAMAZ clutch adjustment technology

Removing and adjusting the KAMAZ clutch is carried out in several steps.

Adjusting the free travel of the KAMAZ clutch pedal

The pedal must have a play of 6 to 12 mm. Measurements are taken from the central part of the plate. The pedal must be lowered until the main cylinder starts working. If there is a deviation from the norm, adjust the distance between the PSU pusher and the stop at the top.

To do this, you will need an eccentric pin connecting the pedal to the top eye of the pushrod. The pedal for traction must press the clutch pedal against the stop from above. The finger is turned so that the gap between the piston and the PSU pusher is in the range from 6 to 12 millimeters. When finished, tighten the castle nut securely. The full pedal travel should be approximately 19 centimeters.

Adjusting the KAMAZ clutch

The manufacturer recommends maintaining a free play value in the range from 3.2 to 4 millimeters. To measure, you will need to move the fork shaft lever by hand. It must move in the direction from the spherical nut of the pusher. It is located on the pneumatic or hydraulic clutch drive amplifier. Adjusting the KAMAZ clutch clearance will require removing the spring: the lever should move no more than five millimeters. If the free play is less than three millimeters, then it is adjusted using a spherical nut. The idle speed of the clutch must be from 3.2 to 4 millimeters.

Adjusting the KAMAZ clutch drive

To measure the function indicator, it is worth pressing the pedal all the way. If the value is less than 24 mm, then complete shutdown will not occur. It is necessary to measure the free play of the pedal and the volume of fluid in the master cylinder. 380 cubic centimeters is the total volume in the hydraulic drive. If the data does not satisfy the requests, it is important to get rid of air in the system. This will return all indicators to normal.

Adjusting the KAMAZ clutch pressure plate

During this operation, you must strictly follow the sequence:

Initially, the gearbox is dismantled. You can't do it without helpers.
Remove the clutch basket.
The clutch discs are dismantled: first the driven one, then the middle one, and finally the driving one.
New parts are being installed. The order is already reversed.
It is important to adjust the nickel of the KAMAZ clutch basket.
The correct installation of all mechanisms is checked in detail.
The gearbox returns to its place.

If there is only one disc in the clutch design, the job is much easier!

But even a KAMAZ single-plate clutch, adjusting its parts will require serious skills, strength and knowledge. Don't take risks - entrust the matter to professionals. Or do a one-time replacement with a real mechanic. For some mechanics, adjusting the KAMAZ double-disc clutch without removing the gearbox is a reality.

Adjusting the legs of the KAMAZ clutch basket

The case is carried out in several steps:

The checkpoint is dismantled. Use wrenches to unscrew the fastening bolts.
Raise the box: it is better to do this with a cargo winch.
Check the condition of the coupling, tension spring element, and release bearing.
Unscrew the screws connecting the pressure plate and flywheel. To dismantle the pressure element, the driven disk must be supported.
Carry out troubleshooting of all parts of the system (preferably).
Check the condition of the release bearing. A working mechanism rotates easily, without unnecessary sounds.
Conduct a visual inspection of the working surface of the pressure plate feet. After installing the new parts, the KS feet are adjusted. In this case, you will need a flat slab.

The location of the paws is oriented towards the working position of the pressure plate surface. Important : the operation does not require removing the joint from the additional flywheel. In this work you will need wrenches for the adjusting screws. The KS feet must be positioned so that the distance from the working plane of the pressure plate to the upper edges of the spherical protrusions on the inner surface of the feet is no more than 41 millimeters. But 40 mm is better.

To check the installation of the paws, you will need a special plate. The spherical protrusions must touch the control plate (it is installed on the hub). After completing the adjustment, all screws securing the support plates are tightened until they stop. Assembly proceeds in reverse order.

The proven quality of the cars will not let the driver down if the mechanisms are regularly serviced. Attention is paid to adjusting the KamAZ clutch, since the device performs many functions. The mechanism separates the gearbox from the motor when changing gears, then connects them to minimize gear tooth impact. Using the module, the load on the transmission is reduced when the speed changes.

Design and principle of operation

The operation of the mechanism is based on the principle of sliding friction force.

The KamAZ clutch device is used for:

transfer of rotation from the crankshaft;
gradual transfer of gears;
reducing rotational vibrations;
disconnecting the transmission device from the engine for a short moment.

In a car, gear shift occurs when the clutch pedal is depressed, there is no connection between the engine and the gearbox, and rotation is not transmitted.

The KamAZ leaf clutch consists of the following parts:

a flywheel that receives rotation from the engine and transfers it to the gearbox through the basket;
pressure plate complete with springs;
drive disk assembly with linings and vibration damper;
plug assembly that breaks the connection;
an axial shaft to which rotation is applied;
release bearing;
spring that reduces vibrations;
hood;
structural linings located on the drive disk to reduce friction.

Stiff clutch pedal: causes of malfunction

The clutch is one of the most loaded mechanisms, designed to connect the gearbox input shaft to the flywheel of the internal combustion engine crankshaft. The clutch is engaged and disengaged by means of the clutch pedal, which can be “connected” to the release bearing mechanically or hydraulically.

One of the common malfunctions on cars with manual transmission is a stiff clutch pedal, when the driver needs to apply noticeable force when pressing. In this case, there may be several reasons why the clutch is tight: fastening of the pedal itself, problems with the clutch drive, malfunctions of the clutch mechanism, etc. Next, we'll look at the signs that indicate a hard clutch pedal is a symptom of a problem, as well as the causes of a tight clutch.

How to adjust the KamAZ clutch

Maintenance is carried out regularly. Increasing the pedal stroke leads to incomplete disconnection of the flywheel and gearbox. This device causes the gears to come into contact, and the load on the teeth of the gears increases. If the accelerator stroke is insufficient, the drive disk does not engage, rotation is not fully transferred, and the machine stops.

Adjusting the clutch on a KamAZ allows you to eliminate faults that are diagnosed based on the following symptoms:

at the beginning of departure - jerks;
the friction pedal sticks;
the accelerator is slow;
if you check the drive fluid level, a leak is detected;
extraneous sounds are heard.

The need to adjust the clutch on a KamAZ is checked by measuring the distance from the bottom of the pedal to the floor surface of the driver's seat - the indicator should be 16 cm.

Without removing the box

Adjustment of the clutch operation is carried out by removing the gearbox. But if adjustment is required under road conditions, then the work is performed without removing the structure.

You will need a homemade device in the form of a piece of wire, one side of which is 2 cm long and bent at an angle of 90˚. The thickness of the rod is at least 3-4 mm; this size is convenient for controlling the clearance between the disc release element and the contour of the legs.

The adjustment is made using the pneumatic booster nut. The legs are connected to the ring through a hole at the top of the crankcase. Elements are placed as equally as possible to the area.

The procedure is as follows:

Unscrew the locking bolts.
Remove stoppers and plates.
The nuts are all loosened equally by 5 turns; ratchets are used for convenience.
If a nickel protrudes beyond the surface of the ring, then it is recessed, first checking for the presence of ferodo underneath.
The springs can be replaced at the same time.
The paws are placed so that they touch the ring equally. Then the runout of the disc area is analyzed.
The front bearing is lubricated. Select an adjustment gap of 29-30 mm.

Setting up the mechanism without removing the gearbox is done in the case of a double-disc clutch; single-disc clutches are not adjusted this way.

How to adjust pedal free play

Check the movement of the coupling by moving the axial shaft lever away from the pusher nut. If the free distance measured at 90˚ is less than 3 mm, then to adjust it, rotate the pusher screw so that the distance of free movement of the coupling is 3.1-4 mm.

The stroke of the amplifier pusher is checked when the accelerator is pressed - the indicator should be more than 2.5 cm. A smaller value does not ensure effective activation. If the pusher stroke of the pneumatic hydraulic booster is less than recommended, then:

adjust the free play of the clutch pedal;
control the amount of liquid in the main cylinder container;
remove the atmosphere from the hydraulic device.

The pedal movement should correspond to the size of 6-15 mm, it is measured in the middle of the pedal. If it is exceeded, the clearance of the piston and pusher is set using an eccentric element connecting the hole at the top of the pusher and the accelerator.

How to adjust the cart

The basket's feet are adjusted on the removed disk or through a gap in the flywheel directly on the machine.

When the machine is in the pit, remove the box using a winch.
Inspect the release bearing, springs and collets.
Unscrew the fastening of the disk to the engine flywheel.
Remove the pressure mechanism while holding the drive disk.
Inspect the surface and make adjustments to the paws relative to the area of the disk.
Check the change in the position of the paws using a plate, taking into account that their round surfaces should touch the template located on the hub.
After adjusting the clutch basket, the hardware is tightened until it stops. Clutch assembly is done in reverse order.

Payment via PayPal

After selecting payment via PayPal, the PayPal payment system will launch, where you need to select the payment method: bank card or PayPal account.

If you already have a PayPal account, then you need to log into it and make a payment.

If you do not have a PayPal account and you want to pay using a bank card via PayPal, you need to click on the “Create an Account” button - shown with an arrow in the picture.

PayPal will then prompt you to select your country and provide your credit card information.

After specifying the information required to make the payment, you must click on the “Pay Now” button.

Official website of the PayPal payment system https://www.paypal.com

Malfunctions and what to do

Repair of the KamAZ clutch can be delayed if the machine is regularly maintained.

Load, road surface, driving skills affect the intensity of destructive processes:

wear of the control drive;
erasing contacting areas;
change in the tightness of devices.

To identify malfunctions, before adjusting the clutch drive, the automobile clutch is diagnosed:

Inspect the drive for leaks, determine the degree of destruction of the pedal springs and fork lever.
Bring the distance of free movement of the cylinder pusher and the fork axle lever to the recommended parameters.
Lubricate the balls of the release collet and the clutch fork shaft.
Determine the liquid level in the main cylinder tank and adjust the amount to normal.
Tighten the bolts of the pneumatic booster device.
Change the fluid in the hydraulic drive circuit once a year.

Clutch malfunctions are eliminated as the linings of the drive discs wear out.

If it slips

If the mechanism does not turn on completely, the car accelerates slowly or loses power when climbing the highway, or a burnt rubber smell is heard, then there is an explanation for the problems:

there is no clearance between the bearing pressing on the basket petals and the stop ring;
oil has leaked between interacting surfaces;
friction gaskets have become unusable;
the clamping springs have lost their shock-absorbing qualities or are broken.

If sometimes it disappears

The clutch does not engage fully, gears shift with a grinding noise, the lever gives in with effort - there are reasons for this state of the mechanism:

the clearance between the release bearing and the stop ring has increased;
the drive discs are warped or the gaskets have become unusable;
Air has entered the hydraulics, or there are leaks in the system.
the free play of the accelerator has become larger;
The clutch pedal is stuck on the shaft.

What is the price

The purchase price of individual mechanisms is high, so it is better to adjust the clutch system by correcting the shortcomings of existing parts.

A Euro 2 clutch disc, depending on the type, costs 1500-6000 rubles;
shutdown fork included - RUB 3,860;
piston group, depending on the manufacturer and brand of KamAZ - 6,000-25,000 rubles.

In order to perform clutch repairs infrequently, you need to regularly perform technical inspections and maintenance of the machine.

KamAZ and MAZ are cars that have gained particular popularity due to their exceptional reliability. They are used in literally all spheres of life - cargo transportation, construction, agriculture, and even off-road racing is often held on KamAZ trucks. Time-tested quality will not let you down if you operate the vehicle correctly and service the components and assemblies on time. Experts advise paying special attention to such procedures as adjusting the MAZ and KamAZ clutch. In case of any malfunctions, the KamAZ clutch basket is changed in a very short time. Let's figure out why the clutch of MAZ and KamAZ requires special attention.

Gears on a Kamaz truck do not engage

Cases like “the clutch lost on a KamAZ during a trip” are not uncommon. Both the mileage and the poor quality of the components take their toll (especially after repeated handicraft repairs). The result is the same: the truck either completely loses the ability to change gears normally, or this is only possible with repeated “pumping” of the pedal. Driving in this case, especially with a loaded car, is unsafe.

However, calling a tow truck if the clutch in a KamAZ truck is lost and the driver cannot fix the problem is neither beneficial nor meaningful. The 24 Volt technical assistance service offers a faster and more cost-effective repair method throughout Moscow and the region: the technician will arrive directly at the site of the breakdown and deliver the necessary spare parts. On-site repairs, which are also available after hours (including at night), will cost less than the services of a tow truck, and you can count on competent assistance regardless of whether there are truck services nearby.

We're leaving! We will diagnose the clutch on the KamAZ, find the fault and, if necessary, replace the clutch right at the site of the breakdown. Payment after verification! Call! 8-999-999-90-24

Design features

As a rule, KamAZ vehicles are equipped with a dry double-disc (in rare cases single-disc) friction-type clutch. This device is common in almost all heavy, high-power machines. It requires constant maintenance due to the fact that during operation, due to the great power of the vehicles, these clutches experience enormous loads. So, in what cases does it become necessary to adjust the clutch of MAZ and KamAZ:

The device clearly slips at high speeds.
The pedal free play does not meet the standard values.
A mechanical noise occurs when changing gears.

Problems when paying with bank cards

Sometimes difficulties may arise when paying with Visa/MasterCard bank cards. The most common of them:

There is a restriction on the card for paying for online purchases
A plastic card is not intended for making payments online.
The plastic card is not activated for making payments online.
There are not enough funds on the plastic card.

In order to solve these problems, you need to call or write to the technical support of the bank where you are served. Bank specialists will help you resolve them and make payments.

That's basically it. The entire process of paying for a book in PDF format on car repair on our website takes 1-2 minutes.

Source

Clutch adjustment

If you notice even one of the listed signs, it means that the KamAZ clutch basket requires adjustment. If this is not done in time, problems may spread to the gearbox and other transmission parts. In general, proper adjustment of the Kamaz clutch can be divided into 3 main stages:

Adjusting the pedal free play. The standard value for free play is in the range of 6–12 mm. It should be measured from the middle part of the plate at the moment when the pedal is lowered until you feel resistance when pressing. The free play is adjusted with an eccentric finger - it connects the pusher eye with the pedal lever. The pin should be rotated until the gap between the upper stop and the piston pusher reaches 6–12 mm. Once the desired value is reached, tighten and cotter the castle nut. Afterwards, be sure to measure the full pedal stroke, it should be 185–195 mm.
Adjusting the clutch free play. The free play should be 3.2–4 mm. Measuring it is not difficult at all. We move the fork shaft lever away from the adjusting spherical nut of the pusher. Don't forget to remove the spring and note that the lever should move a maximum of 4-5mm. If discrepancies with the standards are noticed, the situation can be corrected using a spherical nut. As soon as the lever stroke reaches 4–5 mm, the free stroke of the clutch will automatically take on the desired value.
Adjusting the full stroke of the booster pusher. It is measured very simply. Depress the clutch until it hits the floor. If the pushrod travel distance is less than 25 mm, first check the pedal free play and the fluid in the master cylinder. If everything is in order there, release the air from the hydraulic system and then everything will return to normal values.

Maintenance

If you periodically perform these procedures with additional adjustments, the device will last much longer.

Tighten the bolts that secure the clutch air booster.
device for leaks. If found, find and repair the leak, then bleed the system to remove air.
Evaluate the operation of the pedal springs and shaft lever. If faulty ones are found, replace them.
Lubricate the clutch bearing and the fork shaft bushing of the device.
Assess the liquid level in the compensation tank. Top up if necessary.

Adjusting the Kamaz clutch

It is very difficult to cope with all this work for the first time. If you are not confident in your abilities. Entrust the adjustment to specialists and monitor the progress of the work. Having memorized all the steps in practice, in the future you will be able to adjust the device yourself without any problems.

Troubleshooting the clutch drive

As a rule, when one of the signs of a clutch drive malfunction appears, it is necessary to accurately determine the malfunction. If the problem is in the clutch mechanism, it is better to change the entire clutch kit, and not limit yourself to just the part that has failed.

Methods for eliminating some clutch faults:

a malfunction of the clutch release clutch bearing is eliminated by lubricating or replacing the bearing;
problems with the hydraulic drive require replacing the fluid and bleeding the clutch;
wear or contamination of the driven disc linings, wear or weakening of the pressure springs is eliminated by adjusting the pedal free play, as well as by replacing the driven disc pads or deformed springs.

If problems with operation and a tight clutch pedal remain after repair, we can identify a number of other reasons why the clutch is tight. Among them are:

clutch cable wear;
dirt, corrosion in the cable jacket;
lack of lubrication on the clutch fork shaft.

Let us also add that it is important to replace the clutch release fork as a complete set with the clutch assembly when it becomes deformed or worn out. If this is not done, the plug may burst or bend during operation.

How to know when it's time to change your clutch

There are cases when adjusting the clutch cannot correct the problem. Perhaps you missed a moment when you could get by with little effort, or maybe the device failed for some objective reason. So, it’s time to change the MAZ clutch if you notice the following signs:

The device turns on abruptly, the car jerks and abruptly pulls away.
Noise in the mechanism, perhaps a loud cracking sound when the gear is engaged.
The car starts moving late, even if you release the clutch on time.
A characteristic burning smell in the cabin (this is a clear sign that the clutch has burned out).

There is no need to delay replacing the clutch. As a result, everything may end in damage to the gearbox or in the fact that one fine day the car simply will not be able to move.

You should take on the work yourself only if you know exactly the sequence of actions. Otherwise, it is better to contact specialists.

However, if you are confident in your abilities or the KamAZ clutch basket is familiar to you, you can get down to business.

What you need

Before starting work, you need to stock up on a certain set of tools. So, you will need:

A set of wrenches or socket heads.
Emphasis.
A ruler to later measure the free play of the pedal.
Pliers and pliers.

Replacing the Kamaz clutch

If you have all this, it's time to get to work. The main thing is to strictly follow the entire sequence of actions:

First of all, remove the gearbox. KamAZ has it very heavy, so you will need the help of several people.
Next, next is the clutch basket, remove it too.
Then remove the driven, middle and driving clutch discs.
Then install new parts of the device in their place. Start by installing the first driven disk and then install the parts in the reverse order of disassembly.
Make sure once again that the device is assembled correctly and that’s it – you can put the gearbox in place.

If the clutch is single-plate, the process is similar and even easier. It may seem that everything is quite simple, but this is far from the case. Replacing and adjusting the MAZ clutch will require a lot of physical effort and time. Perhaps it makes sense to trust specialists who will do everything correctly and without mistakes. By observing the process, you will be able to remember the entire sequence in practice, and next time you will be able to adjust or replace the device yourself.

How to use the clutch to make it work as much as possible

There are several simple rules to extend the life of the KamAZ clutch. Unfortunately, not all drivers use them and often the device has to be changed much earlier than provided by the manufacturer.

Do not keep the mechanism depressed for too long. Using clutch slipping at traffic lights and to reduce speed is very harmful to the device.
And, most importantly, check the free play of the pedal as often as possible and lubricate all accessible components of the clutch mechanism. This is probably the most important guarantee that you won’t have to think about replacing the mechanism for at least several years.

«>

Let's sum it up

Taking into account the above information, it becomes clear that there are many reasons why the clutch pedal is tight or the clutch is hard. In the process of troubleshooting, you should step by step check the pedal mechanism itself, and then move on to the clutch elements, cables, rods, etc.

Ignoring this rule often leads to the fact that a tight or hard clutch pedal can come as a surprise to the driver while on the road. The clutch pedal also fails, the clutch may not “grab”, etc. To avoid such unforeseen breakdowns, the quality of the clutch must be checked at every scheduled maintenance.

How to adjust the clutch pedal, what adjustment is needed for: clutch functions, clutch pedal adjustment (free play and total travel).

How to bleed the clutch, why it is necessary to perform the procedure. When to pump the clutch: signs. How to bleed the clutch yourself.

Car clutch: purpose, types, design, principle of operation. Frequent clutch malfunctions in the vehicle transmission system, signs of problems.

Types of clutch drive. If the clutch pedal falls, the clutch has become soft, problems have arisen with the clutch: causes and repair of major faults.

The clutch pedal has fallen: why does this happen? The main reasons why the clutch pedal fails, what should the driver do if the clutch fails.

Car clutch and design overview: clutch pressure plate, driven disc, release bearing. Types of clutch drives on manual transmissions and manual transmissions.

Source