Iveco Daily. Manual — part 185
Revi - February 2005
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.
CLUTCH WITH AUTOMATIC WEAR RECOVERY - COMBINED WITH 6 AS’300 VD GEARBOX
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
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Base - May 2004
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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102092
Figure 21
Figure 22
Figure 23
Loosen screws (4) that secure pressure plate (1) to the
flywheel in 5 steps in crossed sequence until a distance of 2
mm is obtained between retainer (2) and the clutch. Also
make sure that retainer (2) is released from pressure plate
(1); otherwise, use a suitable beater (3) to hit the top of
retainer (2).
Then remove screws (4) and take the pressure plate off the
engine flywheel.
102091
44571
505210
REMOVAL AND REFITTING OF
CLUTCH
WITH
DEVICE
RECOVERY COMBINED
Removal
The operation consists of:
- removal-refitting of transmission shafts (see section
505620)
- removal-refitting of gear box (see section 530210).
Insert clutch centring pin 99370205 (1) in the shaft support
bearing.
Locate the position of retainer (2): it is positioned between
the engine flywheel plug for clutch assembly centering and a
hole for the screw used to fasten the same. It sticks out the
clutch assembly by approximately 3 mm.
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 faying 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.
Replace the seal ring as described in 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.
Should any anomaly be found, the full clutch shall be replaced.
Inspect the conditions of the clutch-release bearing and the
release lever, should any anomaly be found, the concerned
part shall be replaced.
In the event that the clutch release lever is replaced,
calibration shall be carried out after re-attaching
the gearbox, as described in the relevant charter of
the “Gearbox” section.
NOTE
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Revi - February 2005
Refitting
Follow the same procedures as for removal in reverse order
and:
- 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, Figure 23), using the guide pin
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
grub screws (1, Figure 23) on the engine flywheel;
- screw down the pressure plate fastening screws in four
subsequent steps and in crossed sequence, then tighten
them to the specified torque
CLUTCH
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