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Inspection and Elimination of incomplete clutch disengagement Fault in XCMG J Series Rollers

2025-09-25 Maintenance Add to favorites
The J series vibratory roller is one of XCMG's best-selling products. It fea

The J series vibratory roller is one of XCMG's best-selling products. It features outstanding performance, good reliability and high cost performance, and enjoys a high recognition among peers and users. Since its launch on the market, it has achieved good social and economic benefits.

This article starts from the control system of the clutch and the working principle of the clutch, and comprehensively introduces the inspection and elimination methods for the incomplete clutch disengagement fault of the J series roller.

I. Inspection Steps and Troubleshooting Methods for Assist System Faults:

The J series rollers adopt an air-assisted clutch control system, which makes the operation light and flexible, greatly reducing the labor intensity. The clutch assist system (as shown in Figure 1) is an oil-gas combined assist system. By stepping on the clutch pedal 7, the clutch master cylinder I is activated. The clutch master cylinder transmits pressure to the clutch assist cylinder 4 through the oil circuit. While the hydraulic oil pushes the piston to move, it opens the air valve, and compressed air enters the assist cylinder 4, achieving pneumatic assist.

In the absence of compressed air, stepping on the clutch pedal can still disengage the clutch, but it will be very strenuous.

During the gear shifting process, due to the leakage of pneumatic components, incomplete clutch disengagement often occurs, causing difficulties in gear shifting, damage to gear shifting gears and other problems, which affects the performance of the road roller. The specific inspection and elimination steps are as follows:

Step 1: Observe whether the pressure on the barometer on the instrument panel meets the specified requirement (800kPa); If the air pressure does not reach the required level (under normal circumstances, it is sufficient 3 to 5 minutes after the roller starts), please check the pressure regulating valve 2. Replace if damaged.

Step 2: Check if all the air in the oil circuit of the air-assisted system has been completely discharged. If not, please release the air.

When releasing the air, two people should cooperate. One person adds brake fluid to the fuel tank and repeatedly steps on the pedal to fill the fuel system. The other person releases the air. The process of releasing the air should be carried out in the following sequence.

Repeatedly press the pedal 7 to fill the oil circuit system with oil. At the same time, continuously add brake fluid to the oil cup 5. Open the air release plug of the clutch power cylinder 4, press the pedal to release the air, and then tighten the air release plug. Repeat the above process until there are no more bubbles.

Step 3: You can use soapy water (or listen with your ear) to check if there is any air leakage in the gas line pipes of the air-assisted system. If there is any air leakage, please check the combination gasket, O-ring and pipeline. Replace them if any are damaged.

Step 4: Observe or touch the oil circuit, joints and the main cylinder of the clutch assist to see if there is any leakage. If any are damaged, please replace them. When the pipes of the oil circuit system are broken or disassembled and air enters the oil circuit system, it is necessary to release the air. The release of air is shown in Step Two.

Step 5: Check whether the free stroke of the clutch assist master cylinder is too large or too small. The adjustment method is as follows: After tightening the guide rod of the auxiliary power main cylinder 6, pull it back by 2/3.

Step 6: Check whether the clutch power auxiliary cylinder is leaking. When inspecting the clutch power auxiliary cylinder, two people should cooperate. One person steps on pedal 7, and the other person observes the guide rod of the clutch power auxiliary cylinder 4. If it slowly returns to its original position, it indicates that there is internal leakage in the auxiliary cylinder and it cannot maintain pressure. The auxiliary cylinder needs to be replaced.

Ii. Causes and Troubleshooting Methods of Common Faults in the Main Clutch

The J series roller adopts a single-plate normally engaged dry clutch, and its working principle is shown in Figure 2. The clutch pressure plate 3 is fixed to the diesel engine flywheel housing by bolts. Due to the effect of the spring, the driven plate 2 is pressed against the end face of the flywheel and rotates together with the flywheel 1, transmitting power to the output shaft 6 through the splines of the driven plate 2 and then entering the transmission. To disengage the clutch, press the clutch pedal 7. The clutch air assist system comes into play, and the sliding release bearing 5 moves to the left, forcing the diaphragm spring 4 to overcome the pressure of the helical spring, thereby separating the pressure plate 3 from the end face of the flywheel 1 and interrupting the power transmission.

Incomplete disengagement of the main clutch can make gear shifting difficult and accompanied by impact sounds, which can easily damage the gear shifting gears. Here is a brief introduction to the inspection and troubleshooting steps of the main clutch.

Step 1: Observe whether the gap between the clutch release spring plate pressure plate and the release bearing is appropriate. If it is too large, please adjust it according to the technical requirements.

Step 2: Check whether the friction plates of the clutch are too thick; If it is too thick, please replace it with a friction plate of standard thickness or process the overly thick friction plate to the standard thickness.

Step 3: Observe whether the clutch steel plates are deformed; Please replace if it is deformed.

Step 4: Check whether the free travel of the platform release pedal is too large. If too large; Then adjust the free travel of the clutch pedal according to the technical requirements.

Step 5: Check whether the inner end height of the separation lever is in the same plane or whether the inner end face of the separation lever is too low. Adjust the inner end height of the separation lever to be on the same plane and make it have a certain height.

The damage of the release bearing can also cause incomplete clutch disengagement. Under normal circumstances, after inspecting the pneumatic assist system, first check whether the release bearing is intact. Only when the release bearing is not damaged should the main clutch be inspected.

Closing remarks

By following the above steps to troubleshoot the problem of incomplete clutch disengagement of the J series roller, the specific fault point can generally be determined and resolved. It is hoped that this article can provide guidance for comrades serving on the front line when dealing with such issues.


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