1. The locomotive has been parked for an extended period, leading to the clutch being unused for a long time, which causes it to become damp and rusted. This results in incomplete disengagement of the clutch. At this stage, it is necessary to dismantle the clutch and remove any rust that has formed.
2. The locking plate on the clutch shaft nut may be damaged or improperly secured, allowing the nut to loosen and move outward along the shaft. This disrupts the normal clearance between the release bearing and the release lever, causing the clutch to remain fully disengaged. To fix this, replace the damaged lock, tighten the nut, and re-secure the locking plate properly.
3. If the gap between the release lever and the release shaft is too large, and the three levers are not evenly aligned with the release bearing, it can lead to incomplete clutch disengagement. In such cases, adjust the clearance between the release lever and the bearing to between 0.4 and 0.5 mm, and ensure all three levers are aligned correctly.
4. A large free stroke on the clutch disengagement handle can also result in incomplete disengagement. To resolve this, adjust the sub-handle. Place the clutch handle in the "closed" position, then adjust the pull rod and set the release lever clearance to 0.4–0.5 mm.
5. Severe wear on the release claws can prevent them from providing the required travel during disengagement, leading to incomplete separation. In this case, the worn claws should be replaced.
6. Excessive wear on the driven plate and loose rivets can cause foreign material to get trapped between the friction plate and the driven plate. This reduces the movement of the driven plate during disengagement, resulting in incomplete separation. The affected rivets should be re-riveted or the entire driven plate replaced.
7. If the driven plate is installed upside down, it will not move axially when the clutch is disengaged. Ensure the driven plate is installed in the correct orientation as specified by the manufacturer.
8. Replacing the driven plate with one that is too thick can reduce the available disengagement stroke, leading to insufficient axial movement and incomplete separation. Replace the driven plate with one that meets the specified thickness requirements.
9. Poor fit between the spline on the driven plate and the clutch shaft spline can restrict axial movement, making it difficult for the clutch to fully disengage. In this case, the spline on the shaft should be repaired or replaced.
10. Excessive wear on the clutch bearing can cause axial play, altering the clearance between the release lever and the bearing, which leads to incomplete disengagement. The worn bearing should be replaced with a new one.
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