VS - Transmission Systems Heavy Duty Clutch - Diag & Fit

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VS - Transmission Systems Heavy Duty Clutch - Diag and fit

Transmission Systems Heavy Duty Clutch Snap-on snap-off Pull type bearing clutch fitting guide

valeoscope

pln

Diag & Fit

267 mm

2x400 mm

430 mm

Kit

Cover assembly

Driven disc

Release bearing

2YEARWARRANTY IN EUROPE -UNLIMITEDMILEAGE Warranty is applicable in EuropeenUnion 28 countries added byNorway, Iceland, Switzerland,Macedonia,Montenegro, Serbia ,Bosnia,Albania and Kosovo for truck clutch applications (diam.>267mm) undernormal conditions of use and service. Formore information please contact you local dealeror refer toValeo ServiceGeneral terms and conditions 2 JAHRE GARANTIE IN EUROPA -OHNE KILOMETERBEGRENZUNG DieGarantie gilt in allen 28 EU Staaten undNorwegen, Island, Schweiz,Mazedonien, Serbien,Montenegro, Serbien,Bosnien, Albanien und Kosovo fürNutzfahrzeugemit Kupplungen vonmind. 267mmDurchmesserbei normalenGebrauch undWartung. Weitere Informationenfinden Sie in denValeoAGBs oder kontaktieren IhrenValeo ServiceAnsprechpartner.

GARANTIE 2ANS - KILOMETRAGE ILLIMITE Garantie valable dans l’Union Européenne, et étendue à laNorvège, l’Islande, la Suisse, laMacédoine, leMonténégro, la Serbie, laBosnie, l’Albanie et le Kosovo pour les embrayage applications Poids Lourds (diamètre > 267mm), sous condition d’utilisation et demontage normaux. Pourplus d’information, veuillez contactervotre représentant local ou vous référer aux conditions générales de vente deValeo Service. 2AÑOS DE GARANTÍA EN EUROPA - KILOMETRAJE ILIMITADO La garantía es aplicable en los 28 países de laUnión Europea, incluídosNoruega, Islandia, Suiza,Macedonia,Montenegro, Serbia,Bosnia, Albania yKosovo para aplicaciones de embrague para vehículo industrial (diam > 267mm) bajo condiciones normales de uso y servicio. Paramás información, por favor contacte con su distribuidor local o consulte las condiciones generales de venta deValeo Service

Table of Contents

1. Disclaimer

2. Valeo, your Transmission Systems Specialist

3. Valeo Heavy Duty clutch kit unboxing

4. Step 1: Tooling and kit contents check list

5. Step 2: Dismounting the defective clutch

6. Step 3: Fitting pressure plate cover assembly and driven plate P24

7 Step 4: Bearing replacement

P36

8. Step 5: Fitting the gearbox housing

P42

9. Step 6: Initialization and driving test

P47

Foreword

Trust The Transmission Systems Specialist

Valeo’s Transmission Systems mission is to be the supplier of choice for all powertrain architectures with innovative technologies developed for efficient and comfortable power transfer from the engine to the transmission, whilst reducing fuel consumption. All Valeo clutches aremanufactured to Valeo’s highest quality standards, making the products efficient and reliable and ensuring full customer satisfaction. Efficient because Valeo’s expertise in research and development allows the reduction of clutch noise and vibrations along with enhanced driver comfort through better gear changes, giving consumers a smoother and more comfortable ride. Reliable because Valeo clutches are able to perform in the most hostile operating environments. Valeo aftermarket customers benefit from this Original Equipment (O.E.) expertise, rigor and quality.

Valeo is a leading global supplier of Heavy Duty clutch friction materials and the second leading global supplier of heavy duty clutches. One out of two trucks in Europe is originally equipped with Valeo transmission systems. As key partner to the largest truck manufacturers, Valeo has the necessary expertise to provide O.E. for the most powerful truck transmissions in the world (up to 3 500 Nm of torque). On the strength of this unique expertise in O.E., Valeo offers to the independent aftermarket one of the most durable and reliable clutches.

Valeo - from original equipment leadership to aftermarket excellence

1 1

Disclaimer

Whilst we endeavour to ensure that the information included in this training documentation is correct, we do not warrant its completeness or accuracy; nor do we commit to ensuring that the material in the documentation is kept up to date. To the maximum extent permitted by applicable law, we exclude all representations, warranties and conditions relating to this documentation and the use of this documentation (including, without limitation, any warranties implied by law in respect to satisfactory quality, fitness for purpose and/or the use of reasonable care and skill). Nothing in this disclaimer will: (a) limit or exclude our or your liability for death or personal injury resulting from negligence; (b) limit or exclude our or your liability for fraud or fraudulent misrepresentation;

(c) limit any of our or your liabilities in any way that is not permitted under applicable law; or (d) exclude any of our or your liabilities that may not be excluded under applicable law. The limitations and exclusions of liability set out in this section and elsewhere in this disclaimer: (a) are subject to the preceding paragraph; and (b) govern all liabilities arising under the disclaimer or in relation to the subject matter of this disclaimer, including liabilities arising in contract, in tort (including negligence) and for breach of statutory duty. To the extent that this documentation and this training documentation are provided free of charge, we will not be liable for any loss or damage of whatsoever nature.

Clutch, a precise device Fitting rules Fitting rules relies on a few good practices to avoid typical issues on clutch components and sub- components.

Despite very heavy metal parts and a robust looking, Heavy duty clutch systems are sensitive devices. While they can last hundreds of thousands kilometers and more, they can as well be damaged in a relative short period of time in case of bad handling, poor fitting practices or severe usage and abuse. Handling issues Heavy duty clutch kits can weigh up to 50 kg for a single disc and up to 90kg for a twin-disc, making handling a sensitive topic. Any shock on cover side can damage the straps, definitely disqualifying the part for any future use.

Cover assembly l Diaphragm l Pressure plate l Straps

Clutch linkage l Release bearing

Friction disc l Facings l Splines

Your kit is composed of 3 components: the pressure plate cover assembly, the driven plate and the mechanical release bearing. Check that parts are all in normal condition and did not suffer during the delivery. 3

Valeo Heavy Duty clutch kit unboxing

Step 1: Tooling and kit contents check list Please note that gearbox removal and clutch change may differ from application types and brands, the following procedure highlight the good practices to follow: l For the best results l For your customer’s satisfaction l To benefit from Valeo 2 years unlimited mileage warranty

Here are the generic tools you will need to operate a safely the operation l Lever arm l Torque wrench l Release wrench for cover assembly l Driven plate centering tool l Centering pins l Crankshaft rotator l Clamp for release bearing l Flat wrench for pilot bearing release tool l Pilot bearing disengagement tool

Step 2: Dismounting the defective clutch

On pull type clutches, the release bearing must be disengaged from the diaphragm hooking ring prior to further proceed to the gearbox removal. This preliminary task is made possible via a dedicated opening on the gearbox. Open the gearbox housing access hole

Remove the rubber plug

Access hole rubber-plug

Access hole

Rubber-plug

Rotate the flywheel and get access to the hooking ring To disengage the release bearing from the diaphragm ring, the hooking-ring must be accessible to the operator. As it rotates with the cover assembly, the hooking ring can be in any angular position when the engine stops. A dedicated tool is needed to position the system to the proper angular position: The crankshaft rotator. Crankshaft rotator types depend on truck manufacturers

Similarly to the starter pinion, the crankshaft rotator engages in the flywheel tooth ring.

When in place, the crankshaft rotator is activated by the operator to rotate the flywheel and clutch assembly and obtain the appropriate positioning of the hooking ring.

Release bearing hooking-ring

Access hole’s field of view

Disengagement of the release bearing and fork Bearing snap-off This operation cannot be done without a dedicated clamp tool.

The clamp tool is basically a metal spring that counteracts on the bearing hook ring to open it.

Enter the clamp tool by the gearbox trap

Compress the tool by hand and insert it the release bearing hooking ring

Once compressed and inserted, the snap-off tool generates the appropriate effort on the hooking ring so that the operator can focus on the release bearing disengagement from the diaphragm ring.

Hooking ring opening

Snap-off the release bearing with the lever arm

Pull the release bearing with the lever

Before

Progressive opening

The clamp tool counteracts on the bearing hook ring and opens it when the lever pulls out the bearing from the diaphragm ring.

Lever Action

Progressive opening

Lever Action

Progressive opening

Lever Action

The bearing is 100% disengaged

Remove the clamp tool

Proceed to the gearbox detachment Remove the gearbox screws...

Detach the gearbox to access to the clutch system

Insert the alignment tool While removing the cover assembly, the alignment tool only preserves the driven plate from falling down.

Install the fitting pins Fitting pins must be put in place onto the flywheel to support the cover assembly. They are mandatory for dismounting the defective clutch and fitting the new device. The amount of pins depends on the application.

Remove the appropriate screws on the cover.

Screw the fitting pins (only two on this application).

Disassemble the pressure plate cover assembly Unscrew the pressure plate cover assembly according to the correct sequence

Detach the gearbox to access to the clutch system

Remove the cover assembly Secure the extraction with an appropriate lifting and holding solution, a hoist can be used.

Remove the driven plate

Remove the centering tool

Fitting tip Whatever the history of the vehicle is, change the pilot bearing each time you change your clutch kit.

Remove the pilot bearing Use an inertial extractor to take out the pilot bearing

Install the tool in the bearing center cage

Screw and lock the tool in the bearing center cage

Pull the inertial mass to extract the bearing from the flywheel

Check for oil contaminations around the flywheel Oil contaminations are sources of friction slippage and overheat; they must be checked and solved prior to any new further operation.

Clean the flywheel surface with solvent

The flywheel friction surface must be exempt of any pollution prior to fit a new friction disc.

Grind the flywheel friction surface with a fine emery paper

Step 3: Fitting pressure plate cover assembly and driven plate

Fit a new pilot bearing

Clean the flywheel bearing cavity with solvent

Position the bearing

Mount the bearing

A new pilot bearing is key to a perfect alignment of the gearbox primary shaft to the clutch system

NEW

Insert the alignment tool The alignment tool is not an option, it is mandatory for a proper positioning of the driven plate’s splines to the gearbox primary shaft. While fixing the cover assembly, the alignment tool preserves as well the plate from falling down.

Prior to fit the driven plate and the cover assembly to the flywheel: Make sure that the driven plate splines fit to the gearbox shaft profile (clean absolutely the shaft prior to this operation)

The driven plate must be free to slide in the gearbox shaft splines.

Fit the driven plate Contrary to some belief, splines do not necessarily require to be lubricated, please refer the fitting instructions, nevertheless the gearbox primary axle splines always requires to be cleaned with care. Install the driven plate

Fit the pressure plate cover assembly The pressure plate cover assembly can be a cause of clutch failure related to shocks of stress during fitting onto the flywheel, fitting pins are key to a safe operation. Fitting pins have two roles: l they ease the fitting by pre-centering the cover assembly onto the flywheel l they ease the fitting by supporting part of the cover assembly weight (up to 40kg) before the screwing operation Cover assembly positioning Secure the pressure plate cover assembly positioning to the fitting pins with an appropriate lifting and holding solution, a hoist can be used.

Pressure plate cover assembly in approach to the fitting pins...

A gentle approach...

Pressure plate cover assembly positioned and maintained by the pins and the hook.

Push

Screw the pressure plate cover assembly by hand (prepares for hook removal)

Remove the hook (if you use one)

Tight lightly the screws

Remove the fitting pins Fitting pins are then removed and replaced by fixing screws

The amount of pins and screws depends on the application.

Check the cover assembly centring on the flywheel

Fitting pins are not alignment pins; care should be taken to avoid conflicts between the flywheel external shoulder and the cover outer diameter, visual control is mandatory prior to finalize the cover fixation.

Flywheel shoulder

As the cover is at that time only pre-maintained, it can be (in case on need…) slightly shifted for a proper positioning onto the flywheel surface.

Flywheel shoulder

As the cover assembly is properly set, lock it by tightening the nearest screw.

Tighten before using torque The cover assembly must be pre-screwed and torque-screwed according to a defined sequence.

A progressive tightening prevents from cover deformation

Tighten the cover assembly with a torque wrench, and follow the correct sequence

We strongly recommend not using an impact wrench. It may cause overtorque or cover deformation. Always start screwing by the bottom part.

Remove the 4 shipping clips Cover assemblies are delivered “pre conditioned” with the pressure plate locked in backward position by shipping clips.

ALL shipping clips MUST be removed from the cover after the installation, if not, severe damages will occur to the system at the very first engine start!

As the cover assembly is totally screwed, the shipping clips are free and must to be removed

Remove the alignment tool

Step 4: Bearing Replacement

Check the release bearing guide tube

Release bearing

Clean and check the Gearbox primary shaft

Gearbox primary shaft

Guide tube

The gearbox primary shaft is aligned to the whole clutch system via the pilot bearing...

Disassemble the fork and bearing

Clutch side

Gearbox oil

Check that there is no oil at the base of the guide tube

Oil traces would indicate a leak from the primary shaft sealing, requiring solving this issue before any further operation.

The shaft seal must be changed in case of leak

Clean the guide tube with solvent

Use a fine emery paper if needed...

Clean and check the fork

Check the fork pivot axle and lubricate it if needed Changing the fork may be needed depending on the vehicle mileage and fork’s condition.

Fit the new release bearing

Tighten the fork with torque wrench Check that fork and bearing are moving smoothly

Step 5: Fitting of the gearbox housing

Engage gently the gearbox housing and tighten its screws

Care should be taken that both driven plate and gear box primary shaft axis are perfectly aligned during the operation.

Misalignment creates stress to the driven plate, jeopardizing the clutch system performances.

OK NOK

The right tool for the job!

For dismounting and fitting, the transmission jack is mandatory; it supports the gearbox and allows adjusting the gearbox position accurately.

Transmission jack

Snap-on release bearing

CLICK

The bearing snap-in to the diaphragm finger ring must be done carefully.

Lever action

Push twice to ensure good snapping

CLICK

Release bearing hooked

Good fitting / Bad fitting

Check carefully that hooking ring needles are correctly centered at equal distance with center part of the ring. They should not touch upwards or downwards.

NOK

To prevent the gearbox housing from dust contamination close the trap door with a new rubber cap

Step 6: Initialization and driving test This operation reinitializes the new relative position of the release bearing recorded in the gearbox control unit.

Fitting a new clutch on automated gear changing vehicles requires resetting the fork actuation system with a diagnostic tool.

A diag. tool is mandatory

Clutch hydraulic block

Control unit

The hydraulic block actuates the fork

The fork relative position is sensed and recorded by a control unit; this unit must be “informed” in the event of changing the clutch.

Position sensing parameter

After resetting the system, go for a driving test

Set the gearbox lever on D

TECHNICAL TRAINING A COMPLETE CATALOGUE OF TECHNICAL TRAINING MODULES

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• Fitment issues • Application enquiries • Cross reference enquiries

VALEO-TECHASSIST.COM • Technical bulletins • Technical tips • Troubleshooting guidelines • Fitting instructions

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Valeo, your Transmission systems specialist. Valeo Transmission Systems’ mission is to be the supplier of choice for all powertrain architectures with innovative technologies developed for efficient and comfortable power transfer from the engine to the transmission, whilst reducing fuel consumption. This 2 Year warranty Unlimited Mileage new warranty scheme will directly benefit to road freight transport operators by optimizing their Total Cost of Ownership. Where ratio part durability versus reliability is the key indicator, Valeo Clutch is assuring the best solution to high demands in O.E. quality from Truck fleets. This technical handbook is the opportunity to explain you the warranty contents but also the essential tips to know when handling, fitting or maintaining the clutch parts in a truck for your daily support.

©2018 - Valeo Service SAS au capital de 12 900 000 euros - RCS Bobigny n°306 486 408 • © Design and print www.advence.fr - Crédits photos: www.pension-complete.com ; Enjoy :) ; Christian Schryve - Compiègne ; 1000&1 Images ; ETAI ; Advence - Ref: 958393 *2 YEAR WARRANTY IN EUROPE - UNLIMITED MILEAGE - Warranty is applicable in Europeen Union 28 countries added by Norway, Iceland, Switzerland, Macedonia, Montenegro, Serbia , Bosnia, Albania and Kosovo for truck clutch applications (diam.>267 mm) under normal conditions of use and service. For more information please contact you local dealer or refer to Valeo Service General terms and conditions

Valeo Service 70, rue Pleyel Cedex 93285 - Saint Denis - France

Tel. : (+33)149 453 232 Fax : (+33)149 453 201

www.valeoservice.com

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