Iveco Daily Euro 4. Manual — part 85
Remove the four nuts (2) fixing the servo brake (3) and take
this out of the engine bay.
Disconnect the electrical connection (1) from the sensor on
the clutch pedal and the electrical connection (4) from the
sensor on the brake pedal. Disconnect the electrical
connection (5) from the switch on the brake pedal.
From inside the cab:
Remove the side guard (7), disconnect the electrical
connection (6) from the accelerator pedal (4). Take out the
screws (5) and remove the accelerator pedal (4) from the
pedal board.
When draining the brake oil, take care it does not
come into contact with anyone, clothes, or painted
parts.
52238
52239
52240
52241
Figure 14
Figure 15
Figure 16
Figure 17
Set a proper container under the brake pipes (4) and remove
them from the brake pump (1) of the vacuum brake (3).
Refitting
For refitting, carry out the operations described for removal
in reverse order, taking the following precautions:
- tighten the nuts/screws to the required tightening torque
under the relevant heading;
- refit the clutch drive cylinder as described under the
relevant heading;
- fill the brake liquid tank with the required quantity and
grade and bleed the air (operation 784010) as described
under the relevant heading;
- after making the electrical connections, check the
efficiency of the connected components.
Disconnect the electrical connection (2) from the brake liquid
tank plug.
Disconnect the clutch drive master cylinder (1) from the pedal
board as described under the relevant heading and set it aside
appropriately in the engine bay, taking care not to damage or
bend the oil pipe.
Take out the nuts (2) and remove the pedal board (3).
Removal
502601 PEDAL BOARD REMOVAL - REFIT-
TING
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A. Pedal board with mechanical accelerator pedal
B. Electronic accelerator pedal
62091
Figure 18
The only repair operations to be performed on the pedal-assy are the following:
- accelerator pedal replacement;
- sensor replacement.
In any other case, replace the pedal using the above-mentioned components if they are serviceable.
NOTE
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PEDAL BOARD
1. Sliding wedge - 2. Wedge (1) actuating spring - 3. Wear recovery ring (6 & 7) actuating spring - 4. Wear indicator - 5.
Retainer - 6. Wear recovery upper sliding ring - 7. Wear recovery lower ring - 8. Diaphragm spring
102089
Figure 19
Description
The automatic wear recovery device is placed between the diaphragm spring and the thrust plate of the pressure plate assembly.
It is essentially made up of wedge-shaped rings which recover, under sliding conditions, the clutch disc wear real-time, while keeping
both the diaphragm spring characteristics and the force required to actuate the spring unchanged.
Operation
Automatic wear recovery takes place in two separate phases:
- Phase 1: every time the clutch is closed (engaged) and the clutch disc wear — as detected by retainer (3) — is such that the
pressure plate is made to travel an extra stroke, spring (4) will disengage wedge (1), which will be pulled by spring
(2) and will stop again against spring (4) and retainer (5) after travelling a stroke equal to the disc wear.
- Phase 2: when the clutch is opened (disengaged), diaphragm spring (8) will release wear recovery rings (6 & 7); as a result, spring
(3) will, by causing lower ring (6) to slide over upper ring (7) due to the inclined planes of the same, lift the latter by
an amount equal to the clutch disc wear.
CLUTCH WITH AUTOMATIC WEAR RECOVERY - COMBINED WITH 6 AS’300 VD GEARBOX
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CLUTCH DISC AUTOMATIC WEAR RECOVERY DIAGRAM
A. Position of the diaphragm spring with a new clutch disc - B. Position of the diaphragm spring with a worn clutch disc prior to
operation of the automatic wear recovery device - C. Position of the diaphragm spring with a worn clutch disc after operation
of the automatic wear recovery device
1. Retainer - 2. Lower ring - 3. Upper ring - 4. Clutch disc - 5. Retainer (1) spring -
6. Diaphragm spring - 7. Wear recovery ring actuating spring
102090
Figure 20
=
ring (2) sliding
=
ring (3) lifting
CLUTCH
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