3.1. Union

General information
Moments of an inhalation of screwed connections, N · m
Pin of fixation of a pedal to an arm..... 25-35
Pin of fixation of the main cylinder to a pedal arm..... 17-26
Nut of hat of fixation of the oil pipeline..... 13-17
Bearer of the oil pipeline..... 4-6
Pin of fixation of the cylinder of work..... 15-22
Hollow pin of fixation of the oil pipeline to the work cylinder..... 25
Pins of fixation of a covering of union..... 15-22
Nut of fixation of an empurrador of the main cylinder to a pedal..... 9-14
Nut of fixation of the switch of blockade of ignition..... 8-10

Technical characteristic
Type of Coupling drive
Hydraulic
The driven pressure plate
Shoal, diaphragm
Exterior / internal diameter of the driven disc, mm
215/145
The union covering was joined with a press disc 
With a diaphragm they hold tight the spring
Internal diameter:
    cylinder of work, mm
    main cylinder, mm
20,64
15,57

Data of checks and agreements
Type of Coupling drive
Hydraulic
Thickness of the driven disc (in a free state) mm:
   motors 1,3; 1,5 and 1,6 l
   motor of 1,1 l

8,5±0,3
8,0±0,3
Release to go round of an union pedal, mm
6-13
Height of pedal of union is left a floor, mm
160,7
Course of a pedal of union, mm
140
Split between the cylinder of work and the piston, mm
0,15
Split between the main cylinder and the piston, mm
0,15

The hard-working lubricants
Application place
Name
Surface of contact of a fork with the union load extinguishment
CASMOLY L9508
Internal surface of the load of extinguishment of union
CASMOLY L9508
 Mirror of the cylinder of work, extern surface of the piston and fist of sleeve
Fluid of brake of the POINT 3
or the POINT 4
Openings of the driven plate of pressure
CASMOLY L9508
Mirror of the main cylinder and extern surface of the piston
Fluid of brake of the POINT 3
or the POINT 4
Empurrador of the main cylinder, axle of an empurrador and lavador
Lubricant of loads of naves of wheels SAE J310a, NLGI n ° 2
Axle and captures of a pedal of union
  SAE J310a,  lubricant  of the  chassis, NLGI-No.1
Surface of contact of a fork of extinguishment of union with an empurrador of the cylinder of work
CASMOLY L9508

 Removal and installation of union and his walk

Fig. 3.1. Union and his walk: 1 – union that puts fork out; 2 – union load extinguishment; 3 – pin of fixation of a covering of union; 4 – union covering; 5 – the driven pressure plate; 6 – oil pipeline of walk of union; 7 – arm of pedal of union; 8 – axle of pedal of union; 9 – union pedal; 10 – main cylinder of the walk of union; 11 – cylinder of work of the walk of union; 12 – union of extraction through bomb of the cylinder of work of the walk of union

The union and his walk are shown in the fig. 3.1.
Removal of air of an union acionador hydraulic
The extraction through bomb of a hydraulic acionador of the union that is necessary to execute every time in the moment of the removal of the oil pipeline that is joined, a hose and / or the main cylinder and also in case of which the pedal of the union is "gentle".

PREVENTION
The work liquid uses only the specified mark. Do not mix the liquid of different marks. Use the liquid of the POINT 4 or the POINT 3.


Fig. 3.2. Agreement of the union of extraction through bomb of a hydraulic acionador of union

Weaken an inhalation of union to pump in the cylinder of work (fig. 3.2).
Slowly hold tight against the stop a pedal of union up to the liquid effluence stops.
Maintaining a pedal in the compressed situation, hold tight the union of bomb.
Add at the normal level in a liquid of tank of the necessary mark.

Main cylinder of a hydraulic acionador of union

Fig. 3.3. Main cylinder of the walk of union: 1 – case of the main cylinder of the walk of union; 2 – nut of fixation of the main cylinder of the walk of union; 3 – piston; 4 – lock the ring; 5 – an empurrador with a damper; 6 – axle of empurrador

The main cylinder of a hydraulic acionador of the union is shown in the fig. 3.3.
Removal
Fusion liquid of work was seeing the union of bomb.
Fig. 3.4. Nut of fixation of the main cylinder of the walk of union

Put out a nut of the fixation of the main cylinder (fig. 3.4).
Desconecte oil pipelines and hoses of a hydraulic acionador of the union.
Fig. 3.5. A clip of fixation of the oil pipeline to the transmission

Withdraw a clip of the fixation of the oil pipeline to the transmission (fig. 3.5).
Check a hose and the oil pipeline of the existence of corrosion, wash basins and zadir.
Installation
Annex the oil pipeline to the work cylinder.
Fig. 3.6. Flexible hose of a hydraulic acionador of union

Annex a flexible hose and fix it for a clip (fig. 3.6).
Install the main cylinder.
Annex an empurrador to an union pedal.
The hydraulic acionador pumps on an union.
Desmontagem
Withdraw a ring of lock of the piston.
Take away an empurrador joined with the piston, at the same time it looks to the damnification of the case and the piston of the cylinder.
Check of technical condition
Check a mirror of cylinder to existence of corrosion, wash basins and zadir.
Check a fist of sleeve of cylinder to existence of the use or a twist.
Check the piston to existence of the corrosion, the wash basins go zadir.
Check the purity of the oil pipeline.
Check through a nutromer the internal diameter of the cylinder and through a micrometer the exterior diameter of the piston.
If the slit between the piston and the cylinder exceeds the very permissible size (0,15 mm), substitute the main cylinder or the piston.
Meeting
 Apply the POINT 3 of work or liquid of the POINT 4 in a mirror of the cylinder and the extern surface of the piston.
Insert the piston in the cylinder.
Establish a ring of lock of the piston.
Establish an empurrador.
Annex a hose to the case of cylinder.

Union pedal
Fig. 3.7. Pedal of union and arm of his fixation: 1 – switch of blockade of ignition; 2 – pedal arm; 3 – pin of fixation of an arm of a pedal; 4 – pedal axle; 5 – internal capture of a pedal; 6 – repayable spring; 7 – extern capture of a pedal; 8 – internal capture of a pedal; 9 – lavador of spring; 10 – nut of axle of pedal; 11 – pedal emphasis; 12 – union pedal

The pedal of the union and the arm of his fixation are shown in the fig. 3.7.
Removal
Fig. 3.8. Axle quiff of empurrador of union pedal

Withdraw the quiff and a lavador (fig. 3.8).
Fig. 3.9. Nuts of fixation of a pedal of union


Put out pins of the fixation of a pedal (fig. 3.9).
Check of technical condition
Check the next thing:
– an axle and the capture of a pedal in use existence;
– an union pedal in existence of a curve and twist;
– a repayable spring in existence of damage or relief;
– the platform of a pedal in existence of damage or use;
Fig. 3.10. Measurement of height of a pedal of union is left a floor


– pedal height on a floor E (from the extern surface of the platform of a pedal to a floor) (fig. 3.10). There will be 160,7 mm.
If the pedal height on a floor does not find the standard, adjust it, like shown down.

PREVENTION
In the agreement of the height of a pedal it looks that the empurrador did not move towards the main cylinder.

1. A pin adjusts the height of pedal then they hold tight a countersow.

PREVENTION
After the agreement they hold tight a pin so that it concerned an emphasis of pedal then they hold tight a countersow.

Fig. 3.11. Height on a floor and the course of pedal of union


2. The rotation of an empurrador adjusts his length in the new height of a pedal (fig. 3.11) then fix an empurrador for a nut.
Fig. 3.12. Release to go round of an union pedal

In the ending of the agreement it is convinced what releases to go round of a pedal of the union (measured of the surface of the platform of a pedal) is in 6-13 mm limits (fig. 3.12).
It if is released to go round of a pedal of the union it does not find the standard, so the air came to a hydraulic acionador or the main cylinder is defective. Pump on a hydraulic acionador and check the main cylinder or union.
Fig. 3.13. The scheme of check of an entirety of an electric chain between contacts of the switch

Check of the switch of blockade of ignition. Check an entirety of an electric chain between contacts of the switch (fig. 3.13).
Installation

Fig. 3.14. Places of putting the universal lubricant


Apply the universal lubricant at the places specified by the fig of firearms. 3.14.
Coat nuts (fig. 3.9).
Install the quiff of axle of pedal of union.

Covering of union and the driven disc
Fig. 3.15. A covering of union and the driven disc: 1 – union that puts fork out; 2 – union load extinguishment; 3 – pin of fixation of a covering of union; 4 – union covering; 5 – the driven pressure plate

The covering of the union and the driven disc is shown in the fig. 3.15.
Removal
It establishes the liquid of a hydraulic acionador of union and oil of a case of transmission.
Withdraw the transmission (to see the subsection "Transmission").
Insert a mandrel 09411-25000 in an opening of a nave of the disc driven not to allow his fall.
Weaken transversalmente an inhalation of pins of the fixation of a covering of the union to a pendulum.
Fig. 3.16. Weakening of pins of fixation of a covering of union to a pendulum


Unscrew pins in series, every time in two tendencies to prevent one I warp of a flange of a covering (fig. 3.16).

PREVENTION
Do not apply solvents to the cleaning of the driven disc and the load of the extinguishment of the union.

Checking of technical condition
Union covering. Check the ends of spring petals of diaphragm of the existence of the use and a difference of heights.
Check a surface of a disc of press of the existence of use, slits and modification of the color.
Check the existence of the weakened rivets and if necessary an union covering substitutes.
The driven disc. Check bedcovers of friction existence of the weakened rivets, aspects of an unequal prileganiye, damages of a prikhvatyvaniye, sticker of oil or lubricant. If necessary the damaged driven disc substitutes.
Fig. 3.17. Check of thickness of the disc driven in the free one (not loaded) been

Check the thickness of the disc driven in a free state (fig. 3.17).
Check springs from disc to existence of a play of side and damages, if necessary a defective disc substitutes.
The clear openings of a main end of the transmission and they establish the driven disc.
In the moment of the complicated movement of a disc in openings of an end or existence of his excessive slit they substitute the driven disc and / or a main end of the transmission.

PREVENTION
In the load of the extinguishment of the union the lubricant puts itself. Do not apply solvents to the cleaning of the load.

Union load extinguishment. Mark the load of the commutation of the union of the existence of interference, damages or the increased noise. Points of control of spring contact of diaphragm with a bearer of load of existence of use.    
Substitute the load in the strong use of places of the contact with an union that puts fork out.
Union that puts fork out. Load extinguishment substitutes a fork of the extinguishment of the union in the strong use at places of the contact with the union.
Installation
Apply the universal lubricant in a fork of the extinguishment of the union at places of the contact with the load of the extinguishment of the union and the cylinder of work.
Fig. 3.18. The place of putting the universal lubricant in an union that puts fork out

Apply the lubricant (to see the fig. 3.18).
There applies the universal lubricant in an union extinguishment of flute of load.
The recommended lubricant – CASMOLY L9508.
Apply the lubricating universal CASMOLY L9508 in a fork of the extinguishment of the union at the place of the contact with an union that puts axle of lever out.
The carefully clear surfaces of the pendulum and a disc of press a skin of fine granulation and to be convinced of the lack of aspects of oil in them or lubricant.
Little one applies quantity of the universal lubricant CASMOLY L9508 in openings of a nave of the driven disc and a main end of the transmission.

PREVENTION
Fig. 3.19. Pins of fixation of the cylinder of work of union
During the installation of the union it does not present itself too lubricating to the places it specified the fig. 3.19 since it can lead to in favor sliding and breaks of the enemy lines during the union work.

Through a mandrel 09411-25000 establish the disc driven in a pendulum by the party with the manufacturing marking to a disc of press.
Establish a covering of the union in a pendulum and screw six pins of the fixation.
Hold tight pins transversalmente the moment of 15-22 N · m. Hold tight pins in series, every time in two tendencies to prevent an union that fits I warp of flange.
Take away a mandrel to center of the driven disc.
Install the transmission (to see the subsection "Transmission").
Free agreement to go round of a pedal of the union.

PREVENTION
It causes the only necessary amount of the lubricant. The excess of the lubricant can cause in favor sliding and breaks of the enemy lines during the union work.

 Cylinder of work of the walk of union
Removal
Desconecte the oil pipeline that is joined of the work cylinder.
Fig. 3.20. Removal of the piston of the cylinder

Put out a pin of the fixation of the cylinder of work (fig. 3.20).
Check of technical condition
Check the cylinder of work to existence of aspects of the hole of liquid.
Check a covering of the cylinder of work of the existence of damages.
Desmontagem
Desconecte a hose that is joined of the cylinder, withdraws a plate of valve, one spring, an empurrador and a covering.
Carefully withdraw the dirt around the boring one of the cylinder of work below the piston.
Withdraw the piston of the cylinder with a current of the compressed air gone to the cylinder (fig. 3.20).

PREVENTION
Previously cover the cylinder of work of rags as the piston it can take off with the high speed and put a wound.

Pressure of increase of air gradually to prevent the emission of fluid of brake and his blow in eyes or in the skin.
Check of technical condition
Check a mirror of the cylinder of work for lack of corrosion or damages.
Through a nutromer they check the internal diameter of the cylinder at three places (in more low, middle and superior parts). If the slit between the piston and the cylinder exceeds the permissible maximum, substitute the cylinder of work.
The very permissible slit between the piston and the 0,15 mm cylinder.
Meeting
Apply the fluid of brake of the necessary mark in the internal surface of the cylinder of work and the extern surface of the piston and a fist of sleeve of the piston and install the piston in the cylinder.
The worn-out liquid: the POINT 3 or the POINT 4 they curb the fluid.
Installation
Establish a plate of valve, an empurrador and a covering.
Apply the lubricant CASMOLY L9508 in an axle of empurrador.
Install the cylinder of work of the walk of the union and annex the oil pipeline.
Fig. 3.21. Pins of fixation of the cylinder of work of union

Pins of screw of fixation of the cylinder of work (fig. 3.21).

Useful data and advices
 The reasons of in favor sliding of union or his incomplete extinguishment holding tight a pedal
This shows the in favor sliding of the union in the quite useful motor the car hardly surpasses rises, slowly one disperses. It can be caused lubricating or the strong discs use, reduction in spring elasticity, lack of free one to go round of a pedal of the union.
 The incomplete extinguishment of the union causes the difficulty and the noise in the moment of the dislocation of gear and can lead to the premature failure of sincronizadores and the quick use of teeths of the transmission. This bad functioning very often appears in the moment of pollution, a twist or deformation of discs, the incorrect agreement of the position of levers of the extinguishment, exaggerated big releases to go round of a pedal of the union.
It must be beared in mind that the noise in the transmission is not always a consequence of the incomplete extinguishment of the union. The noise can appear in use or the incorrect agreement of loads, use or the incorrect gear of conical wheels of gear. The strong blow at the specified places demonstrates the existence of the bad serious functioning that demands an immediate stop of the car and the repair of the unity.
  The reasons of the complicated dislocation of gear or his spontaneous extinguishment
The complicated dislocation of gear or his extinguishment spontaneous – resulted from use of locks and armbands or the walk of the mechanism of dislocation of gear. Here not to do without serious repair.
There are possible the next ways prevent bad similar functioning: periodicamente carefully to check the confidence of fixation of all the unities and details of the transmission of energy, to look at the level of oil in the transmission and in due course to modify it.