Iveco Daily Euro 4. Manual — part 83
12
CLUTCH
D
AILY
E
URO
4
35 S 18 - 35 C 15/18 - 40 C 15/18 - 45 C 15/18 - 50 C 15/18 - 60 C 15/18 - 65 C 15/18
(only vehicles equipped with 6 S 400 A O.D. gearbox unit)
11” CLUTCH
SACHS
Type
Dry single disk
Clutch mechanism
“Pull” with diaphragm spring
Driven disk
With friction seals
Driven disk hub
With double hub springs
External Ø seal
mm
280
0
-0.4
Internal
∅ seal
mm
175
0
-0.4
Disk thickness (new)
mm
8,4
± 0,3
Under load
N
9100
Minimum thickness due to wear
mm
1,5
Max. off centring driven
disk
mm
~ 0,2
Minimum load on
thrust plate
N
7900
Max. release load at 9
Max. release load at 9
mm. release height
N
1100
Maximum rise thrust pad
Maximum rise thrust pad
at 9 mm. release height
mm
1,1
Disengagement stroke
mm
12
0
-0.4
Max. consumption travel
at the thrust block
mm
4
Disengagement control
Electric actuator controlled by the gearbox control unit
Lubricant
-
Values refer to new clutch
NOTE
CLUTCH
13
D
AILY
E
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TIGHTENING TORQUES
PART
TORQUE
PART
Nm
kgm
Screw securing clutch to engine flywheel
46,5
4,7
Screw securing operator cylinder mounting to gearbox
10
± 1
1
± 0,1
Screw secuing pedal board mounting
-
-
Screw to secure clutch disengagement lever support to gearbox front cover
23,5
± 2,5
2,3
± 0,2
TOOLS
TOOL NO.
DESCRIPTION
99370205
Guide pin for centring clutch driven disk
52230
Figure 2
44571
44570
Figure 3
Figure 4
Removal
The operation consists of:
- removal-refitting of transmission shafts (see section
505620)
- removal-refitting of gear box (see section 530210).
Insert the centering pin 99370205 (1) in the gear infeed shaft
support bearing, to facilitate clutch removal operations.
Remove the fixing screws (2) and remove the thrust pad (3)
from the engine flywheel.
Remove the clutch disk (3) by extracting the centring pin
99370205 (2).
Disk plate centering pin (1) located on the engine flywheel.
CHECKS
The checks to be made are as follows:
- the mating surface, on the engine flywheel, of the driven
disk must not be excessively worn or scored.
- the teeth of the toothed crown must not be worn or
broken.
If this is not the case, disassemble the engine flywheel
(operation 540850) as described in the relevant paragraph at
section 2.
Proceed on the engine flywheel as described in relevant
paragraph (operation 540853) at section 2.
Check that there are no oil leaks, even of a slight entity, from
the seal of the rear drive shaft; otherwise remove the flywheel
as described in the relevant paragraph. Remove the rear cover
complete with sealing rings and replace the same as described
at section 2.
Check that the support bearing or bushing of the take up shaft
on the gears fitted to the drive shaft are not worn or broken
and, if necessary, replace them as described in the relevant
paragraph (540852).
Check the condition of the thrust pad; the driven disk support
surface must not be scored or excessively worn or should
there be signs of overheating; the diaphragm spring must be
in perfect condition.
Check the condition of the driven disk:
- the friction seals must not be excessively worn or present
signs of overheating, or traces of oil or grease;
- there should be very little backlash between the hub and
gear take up shaft;
- the hub rings must not be loose or broken.
When any defects are found, replace the part in question.
The complete clutch is supplied with a spare kit.
The following are supplied singularly:
- the driven disk and collar bearing.
In this case it will necessary to assemble the new parts of the
driven disk spring that is to be reused.
505210
CLUTCH
REMOVAL
AND
REFITTING
14
CLUTCH
D
AILY
E
URO
4
Refitting
Follow the same procedures as for removal in reverse order
and:
If the disk is out of line use a hook wrench (1) as in the figure.
- remove the guide pin;
- reconnect the gears after spreading the grooved shaft
with molybdenum disulphide Molikote as described in
Section 4;
- adjust the clutch travel as described in the relevant
paragraph (operation ..).
Before fitting a new driven disk check that it is centred as
follows:
Position the driven disk (1) on a lathe and, with the use of a
magnetic base dial gauge (2), check that the surface of the disk
is not out of line at any point.
Maximum tolerance allowed for the driven disk is 0.20 mm.
Figure 5
Figure 6
- carefully clean the faying surface of the flywheel
disk using methylated spirits or petrol; if any slight
scratches are noted remove with an abrasive
cloth;
- position the driven disk (3, SENZA CODICE), using the
guide pin (2, SENZA CODICE) to obtain perfect centring
and to avoid straining the hub when the gears are
reconnected;
- position the thrust pad by aligning the holes with the
centring grub screws
(1, SENZA CODICE) on the
engine flywheel;
- assemble and lock the thrust pad fixing screws to the
correct torque;
The operation consists of:
- removal-refitting of transmission shafts (see section
505620);
- removal-refitting of gear box (see section 530210).
By using the appropriate pliers open the split pin (1) and
extract the collar bearing (2) from the thrust pad (3).
To assemble, carry out the disassembly operations in reverse.
36800
Figure 7
The new part must be of the same supply as the
driven disk that is to be reused.
505254
THRUST BEARING REMOVAL
AND REFITTING
NOTE
CLUTCH
15
D
AILY
E
URO
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