1. The locomotive has been parked for an extended period, leading to the clutch being unused for a long time. This causes moisture and rust to form on the clutch components, resulting in incomplete disengagement. In such cases, it is necessary to dismantle the clutch and clean off any rust to restore its proper function.
2. The locking plate on the clutch shaft nut may be damaged or improperly secured, allowing the nut to loosen over time. This can cause the clutch assembly to shift axially, disrupting the normal clearance between the release bearing and the release lever. As a result, the clutch may not fully disengage. To fix this, replace the damaged lock, tighten the nut, and re-secure the locking mechanism properly.
3. If the gap between the release lever and the release shaft is too large, or if the three release levers are not evenly aligned with the release bearing, the clutch will not disengage completely. 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 consistently.
4. A large free travel on the clutch disengagement handle can prevent the clutch from fully disengaging. To resolve this, adjust the sub-handle by placing the main handle in the "closed" position, then adjusting the pull rod to achieve the correct clearance of 0.4 to 0.5 mm between the release lever and the bearing.
5. Severe wear on the separation claws can lead to insufficient stroke during disengagement, causing the clutch to not separate fully. In such cases, the claws should be replaced to ensure proper operation.
6. Excessive wear on the driven plate and loose rivets can introduce foreign material between the friction plate and the driven plate, reducing the separation stroke and leading to incomplete disengagement. At this point, the rivets should be re-riveted or the driven plate replaced entirely.
7. If the driven plate is installed incorrectly, it may not move axially when the clutch is disengaged. Always make sure the driven plate is installed according to the manufacturer's specifications to ensure smooth operation.
8. Replacing the driven plate with one that is too thick can reduce the separation stroke, leading to incomplete clutch disengagement. Always use a driven plate that meets the specified thickness requirements.
9. Poor fit between the spline on the driven plate and the clutch shaft can restrict axial movement, preventing full disengagement. In this case, the spline shaft should be adjusted or replaced to restore proper function.
10. Excessive wear on the clutch bearing can cause axial play, altering the clearance between the release lever and the bearing. This can lead to incomplete disengagement. Therefore, the bearing should be replaced when signs of wear are evident.
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