Eaton Heavy-Duty Clutches CLSM0200 May 2012

Transcription

1 Service Manual Eaton Heavy-Duty Clutches CLSM0200 May 2012 Solo Advantage Easy Pedal Advantage Value Clutch UltraShift DM UltraShift PLUS ECA Clutch

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3 Warnings Warnings and Cautions Repair Warnings The major cause of clutch failure is excessive heat. Excessive heat generated between the flywheel, driven discs, intermediate plate and pressure plate can cause the metal to flow and the material to be destroyed. If this occurs, the clutch can burst which can cause property damage, serious bodily injury or death. In order to prevent clutch failure resulting from excessive heat: 1. Do not exceed recommended vehicle loads. 2. The clutch should only be used for the recommended applications. 3. Drivers should be properly trained in starting, shifting and operation of the clutch. 4. Drivers should report erratic clutch operation as soon as possible to permit maintenance personnel to inspect, adjust or lubricate as required. 5. Mechanics must be familiar with proper clutch adjustment, linkage adjustment, lubrication and other maintenance troubleshooting procedures outlined in the Failure Analysis Guide. Use of other than recommended tools, parts, and instructions listed in this manual may place the safety of the service technician or vehicle driver in jeopardy. The removal and installation procedure described for each component may vary for your vehicle. For Solo and Heavy-Duty ECA clutches only, install shipping bolts before removing clutch assembly from the flywheel. IMPORTANT For service information and assistance, call the Roadranger Help Desk at HELP (4357) (Mexico: HELP (4357). You may also find more information about Eaton Clutches at Every effort has been made to ensure the accuracy of the information contained in this manual. However, Eaton Corporation makes no warranty, expressed or implied, based on the information provided. Warnings When disassembling various assemblies, lay all parts on a clean bench in the same sequence as removed to simplify and reduce the possibility of losing parts. Since the cost of a new part is generally a small fraction of the cost of downtime and labor, avoid reusing a questionable part that could lead to additional repairs and expense. i

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5 Table of Contents Warnings and Cautions Repair Warnings i Solo Advantage Self-Adjusting Clutches Remove Clutch Install Solo Advantage HD 15.5" Clutch Measure Engine Flywheel Housing and Flywheel Install Clutch to Flywheel Install Transmission Set-up Troubleshooting for Solo Advantage HD 15.5" Clutches Symptom-Driven Diagnostics Too Much Free Pedal or Too Much Clutch Brake Not Enough Free Pedal or No Clutch Brake Resetting Procedures In-Vehicle Reset Procedure In-Vehicle Resetting Procedure Using the Solo Advantage Clutch Reset Tool Verify Clutch Brake Squeeze Out-of-Vehicle Reset Procedure for HD ECA or Solo Advantage Clutches Easy Pedal Advantage Manual Adjust Clutches Install Easy Pedal Advantage & ValueClutch. 17 Install Clutch to Flywheel Install 15.5" Clutch to Flywheel Install Transmission Set-Up UltraShift DM Heavy Duty Clutch Remove Clutch UltraShift DM Clutch Install Clutch to Flywheel Install Transmission Heavy-Duty UltraShift Clutch Recalibration.. 30 ECA Clutch Remove Clutch Opening the ECA Clutch " Heavy-Duty ECA Clutch Installation Install Clutch to Flywheel Install Transmission Lubricate ECA Clutch Adjustment Grease Interval Count Reset ServiceRanger Procedure Operator Triggered Procedure ECA Clutch In-Vehicle Resetting Procedure..45 Opening the ECA Clutch Low Capacity Inertia Brake Wear Life Measurement Transmission Removed Transmission in Chassis Hydraulic Linkage Verify Linkage System Stroke Master Cylinder Installation Transmission Installation Hose Assembly Solo Advantage Lube Hose Assembly With Hydraulic Linkage Installation Process General Clutch Information Function of a Clutch Neutral Idle Rattle Self-Adjusting Clutches Clutch Disc Friction Material Clutch Slippage Clutch Torque Capacity Clutch Wear Cover Assembly Driven Disc Facings Intermediate Plate Positive Separator Pin Position Kwik-Adjust Clutch Brakes Factors that Effect Clutch Performance When to Inspect the Clutch Preventative Maintenance Overview Inspection for Clutch Life Designing a Clutch for a Specific Application.59 Preventive Maintenance Overview Lubrication Recommended Lubrication Lubrication Interval Table of Contents iii

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7 Solo Advantage Self-Adjusting Clutches Remove Clutch (If clutch is to be reinstalled and transmission is still in vehicle) CAUTION Note the position of the wear indicating tab on the clutch. If the tab is near the REPLACE position, the clutch should be replaced. 1. Locate 4 shipping bolts (7/16" x 14 x 1 3/4" UNC, hex head). Install them in the 4 cover holes hand tight then turn one full turn. Remove Shipping Bolts (4) 7/16" x 14 x 1-3/4" UNC 2. Support the Clutch during the removal of the 8 mounting bolts. 3. Remove the clutch from the flywheel. Note: Mark the proper position of the discs and intermediate plate (for reinstallation). IMPORTANT This step will hold the pressure plate separator pins in proper position so the clutch can be reused and will release after reinstalling. 1

8 Solo Advantage Self-Adjusting Clutches Install Solo Advantage Heavy-Duty 15.5" Clutch Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or it may result in premature clutch failure. Remove and replace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheel surfaces of all grease, oil, and rust preventatives. Failure to perform this function can affect the performance of the clutch. Use a dial indicator and check the following: Flywheel Face Runout Pilot Bearing Bore Runout 1 Secure dial indicator base to flywheel housing face. 2 Put gauge finger in contact with flywheel face near the outer edge. 1 Secure dial indicator base to flywheel housing face. 2 Position gauge finger so that it contacts pilot bearing bore. 3 Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 3 Rotate flywheel one revolution. Maximum runout is 0.005" (0.13 mm). Flywheel Housing I.D. Runout Flywheel Housing Face Runout 1 Secure dial indicator 2 Put gauge finger base to crankshaft. against flywheel housing pilot I.D. 1 Secure dial indicator base to flywheel near the outer edge. 3 Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 2 3 Put gauge finger in contact with face of flywheel housing. Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 2

9 Solo Advantage Self-Adjusting Clutches Install Clutch to Flywheel IMPORTANT WARNING Use the Eaton Clutch Selector Guide (CLSL1511) to make sure you have the right clutch. Note: When installing clutch to flywheel, position the wear indicator at the bottom of flywheel to ease future clutch servicing. An assembled clutch weighs about 150 lbs (68 kg). Avoid the risk of injury. Use proper equipment when lifting a clutch. 1 Measure the flywheel bore. Use the Eaton Clutch Selector Guide to verify that the damper will fit into the flywheel bore. 7.0" (8-spring) 8.5" (10-spring) 10.0" (7-spring and Mack 9-spring) Note: Mack 9-spring for Mack and Volvo engines 2007 and newer only. 5 6 Install second disc onto aligning tool. Follow the orientation instructions on the disc. Install two 7/16" x 14 UNC x 5" studs into upper mounting holes. Install assembled clutch. Install 4 Install intermediate plate into slots on the clutch cover. Flywheel side must face the flywheel. 3 Install disc onto aligning tool. Follow the orientation instructions on the disc. 2 Insert aligning tool through bearing Install lock washers and mounting bolts (7/16" x 14 UNC x 2-1/4" grade 5) finger tight. Replace studs with lock washers and bolts. 8 Progressively tighten mounting bolts in a crisscross pattern starting with the lower left bolt (1, 2, 3, 4, 5, 6, 7, 8). Torque to lb-ft (54-68 N m). Failure to do this could result in improper piloting of the clutch and cause clutch damage. 3

10 Solo Advantage Self-Adjusting Clutches 9 Remove four yellow shipping bolts in a crisscross pattern. 10 Remove the aligning tool. Pin 11 Use a six once hammer and a 1/4" flat nose punch to lightly tap the four separator plate pins toward the flywheel. Only part of the pin should be visible. If installing Solo Advantage Clutch, proceed to Step 12. Install HD Solo Advantage Lube Hose Attachment Note: The example shown is of a Lube Hose Attachment for a heavy-duty Hydraulic release system. 12 Install brass fitting into grease port on left side of release bearing housing using Weatherhead socket. Tighten hand tight and continue to turn until the opening of the fitting is facing toward the 6 o clock position. 13 Install lube hose into brass fitting and tighten until hand tight,then turn an additional 2 turns. 14 Lubricate release bearing until grease purges from release bearing housing. Use NLGI grade 2 or 3 Lithium complex grease. Reference Eaton lubrication manual TCMT0021 for specific instructions. Note: A-8173 hand hole cover with grommet is required with HD Solo Advantage clutch used with hydraulic release system. 4

11 Solo Advantage Self-Adjusting Clutches Install Transmission Check Transmission for Wear Replace any worn components. Transmission Bearing Retainer Cap A worn/rough bearing retainer cap may cause the clutch brake to wear prematurely. Cross Shaft and Bushings Excessive wear at these points can cause side loading on the sleeve bushing, bushing failures and yoke bridge contact with the clutch when the pedal is down. Input Shaft Splines Any wear on the splines will prevent the driven discs from sliding freely, causing poor clutch release (clutch drag). Slide discs full length of shaft to check for twisted shaft splines. IMPORTANT Do not add lube (never seize or grease) to the input shaft splines. The discs must be free to move. Install Release Yoke Worn fingers can cause bushing wear and yoke interference when the pedal is down. Input Shaft Wear (roughness) can reduce sleeve bushing life and cause it to come out. Clutch Brake Replace. Measure Input Shaft Length should be 8.657" ( mm) nominal, and not greater than 8.71" ( mm). Ref SAE handbook 4: Replace transmission bearing retainer cap if length is greater than 8.71" ( mm). Input Shaft Spigot Wear will not provide proper interface with the inner race of the pilot bearing. This can result in damage to the clutch or the pilot bearing. CAUTION Do not excessively force the transmission into the clutch assembly or engine housing. This will cause damage to the splines of the rear disc hub that is not warrantable. If the discs do not slide freely in the input shaft, investigate the cause of the problem and make any necessary changes. If the discs do not slide freely, the clutch will not release and the transmission will grind going into gear. Do not let the transmission drop or hang unsupported in the driven discs. This can bend the discs and the clutch will not release causing damage that is not warrantable. Do not use the cross-shaft release lever (or a pipe over it) to pull the transmission into its final position. Pulling the bearing too far during installation can cause an overstroke causing the release bearing to move closer to the transmission (less than 0.490") with this condition. Follow the Out of Vehicle Resetting Procedure on page 1. Note: Adjust the linkage until pushing the pedal down moves the bearing against the clutch brake. Let up on the pedal and measure the distance between the bearing and clutch brake (distance should be 0.490"-0.560"). 5

12 Solo Advantage Self-Adjusting Clutches Fasten Transmission to Flywheel Housing 1 Put transmission in gear. Make sure new clutch brake has been installed. 2 Make sure that the yoke fingers remain in the up position until they are over the release bearing housing. 3 Position transmission so it is square to and aligned with engine. CAUTION Do not pull on release arm to install transmission. This will cause the clutch to over adjust. Do not force transmission against clutch with yoke fingers in the UP position. This will break the cast webbing of the clutch causing damage that is not warrantable. Do not use excessive force. If it does not enter freely, investigate the cause of problem and make any necessary changes. 6 Install hand hold cover A-8173 with grommet positioned toward rear of hand hold opening in the clutch housing. Secure the hand hole cover with two 5/16" x 18 x 1/2" long bolts. 4 Mesh splines by moving transmission forward and rotating the output shaft. IMPORTANT Do not add lube (never seize or grease) to the input shaft splines. The discs must be free to move. 5 Install mounting bolts and torque to OEM specs. If installing Solo Advantage clutch, proceed to Step 6. WARNING Do not let the transmission drop or hang unsupported in the driven discs. This can cause the discs to become distorted and the clutch to not release. 7 Insert plug into hole in the upper left side of the clutch housing where the horizontal lube hose is utilized. (Image not shown) Note: If the lube hose assembly should need servicing it can be replaced without removal of the transmission. 6

13 Solo Advantage Self-Adjusting Clutches Set-up Adjust Clutch Linkage 1 Hydraulic Linkages: Skip to Step 2. Mechanical Linkages Only: Adjust the clutch linkage until the yoke fingers contact the release bearing (zero free-play in cab). 0.00" 2 Press the pedal to the floor up to 5 times, this: Moves release bearing slightly closer to the transmission Gains free-play in cab Yoke Finger Release Bearing 5X Set-up Clutch Brake 0.490"-0.560" ( mm) 3 With the pedal up, measure the distance between the release bearing and the clutch brake. The correct distance should be 0.490"-0.560" ( mm): If the distance is more the 0.560" (14.22 mm), return to Step 1 and readjust the clutch linkage. If the distance is less the 0.490" (12.70 mm), see Solo Advantage Heavy-Duty 15.5" Clutch Troubleshooting. Go to page 10. 7

14 Solo Advantage Self-Adjusting Clutches Verify Clutch Brake Squeeze WARNING Use a gauge long enough to keep hands away from moving parts. 4 5 Have an assistant insert 0.010" (0.25 mm) feeler gauge between the release bearing and the clutch brake. Press the pedal down to the floor to reclamp the gauge: If the gauge does not clamp, readjust the truck linkage and move yoke fingers closer to the bearing. Slowly let up on the pedal and measure the pedal position at the moment the gauge can be removed: If pedal is more than 1" (25.4 mm) from the floor, readjust the truck linkage to move the yoke fingers further from the release bearing. Return to Step 4. Yoke Finger Release Bearing Clutch Brake Less than 1" (25.4 mm) Verify Free-Play 6 Verify there is free-play in the cab. If not, the truck linkage is not providing enough stroke, consult OEM manual for free-play dimension. For Solo clutches, proceed to Step 8. For Solo Advantage clutches, proceed to Step 9. IMPORTANT DO NOT RESET THE CLUTCH. Do not change free-play by readjusting the clutch linkage. 8

15 Solo Advantage Self-Adjusting Clutches Lubricate Note: All clutches use a Lithium complex grease with a minimum of 325 F (163 C) operating range meeting NLGI grade 2 or 3 specs. For additional lubrication information, see TCMT0021. CAUTION Failure to properly lubricate the bearing/bushing will result in bearing and sleeve failures. Zerk Input Shaft 7 Apply ample grease that is visibly exiting the opening and contacts the transmission shaft. This will lube the clutch brake and bushing when the pedal is pressed. Set-up 28 Apply grease to input shaft and yoke fingers. 9 Apply grease to the cross shaft bushings and linkage pivot points. Input Shaft IMPORTANT Do not add lube (never seize or grease) to the input shaft splines. The disc must be free to move. 9

16 Solo Advantage Self-Adjusting Clutches Troubleshooting for Solo Advantage Heavy-Duty 15.5" Clutches Symptom-Driven Diagnostics If clutch is out of vehicle, go to Outof-Vehicle Resetting Procedure on page 16. Based on your symptom, the chart will direct you to the correct solution. Too Much Free Pedal: Not Enough Free Pedal: Too much travel Not enough travel Pedal travels too far before engaging Pedal travels too little before the clutch. Clutch does not disengage. engaging the clutch. Go to page 11. Go to page 12. Too Much Clutch Brake: No Clutch Brake: Too much brake squeeze Go to page 11. Go to page 12. Not enough brake squeeze 10

17 Solo Advantage Self-Adjusting Clutches Too Much Free Pedal or Too Much Clutch Brake Troubleshooting Too much travel Too much brake squeeze Note: Before measuring the distance between the release bearing and clutch brake depress clutch pedal to remove free pedal in the cab. 1 Measure distance between release bearing and clutch brake. Release Bearing 2 Use chart to find solution. Clutch Brake Measurement Status Solution If distance is correct 0.490"-0.560" ( mm) If distance is Less than 0.490" (12.45 mm) Clutch is set up correctly Clutch is not set up correctly Problem exists with truck linkage. Repair according to OEM specifications. Hydraulic Linkage: Go to page 49. If clutch was factory installed and was never removed or if clutch was removed from engine and reinstalled, go to page 13. If new/reman clutch was installed and it never operated properly, check wear tab position. If tab at GOOD position: Disc is installed incorrectly Go to page 3, Step 4 and 5. Damper is too large for the flywheel opening Go to page 3, Step 1. If tab not at GOOD position, the bearing may have been pulled during installation, causing an overadjust. Go to page

18 Solo Advantage Self-Adjusting Clutches Not Enough Free Pedal or No Clutch Brake Too little travel Not enough brake squeeze Note: Before measuring the distance between the release bearing and clutch brake depress clutch pedal to remove free pedal in the cab. Release Bearing 1 2 Measure distance between release bearing and clutch brake. Use chart to find solution. Clutch Brake Measurement Status Solution If distance is correct 0.490"-0.560" ( mm) If distance is More than 0.560" (14.22 mm) Clutch is set up correctly Clutch is not set up correctly Problem exists with truck linkage. Repair according to OEM specifications. Hydraulic Linkage: Go to page 49. If clutch was factory installed and was never removed, Mechanical Linkage: Go to page 14. Hydraulic Linkage: Go to page 49. If clutch was removed from engine and reinstalled, (Setup) Go to page 7. If new/reman clutch was installed and it never operated properly, (Setup) Go to page 7. 12

19 Solo Advantage Self-Adjusting Clutches Resetting Procedures In-Vehicle Reset Procedure 1 Have assistant hold clutch pedal down. Hold 2 While pedal is held down, move wear tab to the left (GOOD) position. GOOD Resetting Note: If the cam does not move, loosen transmission and install 1/2" spacers between the clutch housing and engine housing to increase stroke. With spacers in place, follow Steps 1-3 in this procedure. Remove spacers and torque transmission mounting bolts. Continue process starting at Step 4. 6 Push pedal down and squeeze clutch brake 5 times to reposition bearing. 5X 3 Let up on pedal. DO NOT push pedal down again or wear tab will return to the wrong position. Before 5 Remove shipping bolts. After 4 Install and tighten 4 shipping bolts (7/16" x 14 x 1-3/4 UNC) until they quit turning. Shipping Bolt Gap Note: This will remove the gap between the sleeve and the pin. Sleeve Pin No gap between sleeve and pin 13

20 Solo Advantage Self-Adjusting Clutches In-Vehicle Resetting Procedure Using the Solo Advantage Clutch Reset Tool Tool Part Code: RR1005CL K-Line Determine if the release bearing travel is correct. Measure the distance between the clutch brake and the release bearing with the clutch pedal up. If the measurement is between 0.490" and 0.590", the Solo has set itself correctly. Note: Yoke gap only applies to mechanical linkage. Most hydraulic linkages operate without yoke gap. Release Bearing 2 If the release bearing travel is less than 0.490" the Solo must be reset. A common cause of this is the transmission was pulled in with the release arm during clutch installation. Clutch Brake 3 Rotate the engine so that the cam tab can be reached through the transmission inspection opening. Measure the release bearing travel 4 Push the clutch pedal to the floor. While the clutch pedal is pushed to the floor have someone push the cam tab to the new position using finger pressure or the Solo tool. Once the cam tab is pushed to the new position you can release the clutch pedal. REPLACE Note: If the cam tab does not move, there is not enough release bearing travel to allow the cams to separate. In this case, loosen the transmission and install 1/2" spacers between the flywheel housing and bell housing. With the spacers in place push the clutch pedal to the floor while someone pushes the cam tab to the new position. Once the tab is in the new position release the clutch pedal and remove the spacers. Torque the transmission mounting bolts. 14

21 Solo Advantage Self-Adjusting Clutches 5 Install (4) shipping bolts and progressively tighten by hand until they bottom out. Rotate the engine to access all 4 bolts: 15 1/2" Solo use 7/16 x 14 UNC x 1 3/4" Stamped 14" Solo use 3/8 x 16 UNC x 1 1/4" Note: This will reset the pressure plate separator pins and allow the clutch to release after installation. 6 Remove the (4) shipping bolts. The release bearing and sleeve will move forward towards the engine when the bolts are removed. The Solo is now in the new position. 7 With the free pedal removed push the clutch pedal down at least 5 times. Make sure the clutch release bearing contacts the clutch brake. While you engage and release the clutch the cab free pedal will increase. This indicates the Solo is adjusting to the environment. Shipping Bolts Shipping Bolt Tamper-Proof Bolt Resetting 8 Measure the distance between the clutch brake and the release bearing. It should be between 0.490" and 0.590". 9 If the release bearing travel is still greater than 0.590" between the clutch brake and the release bearing, repeat Steps 7 and Adjust the clutch linkage to achieve 1/8" clearance between the release yoke and the release bearing. Verify proper clutch brake squeeze. Verify Clutch Brake Squeeze 1 WARNING Use a gauge long enough to keep hands away from moving parts. Have an assistant insert 0.010" (0.25 mm) feeler gauge between the release bearing and the clutch brake. Press the pedal down to the floor to clamp the gauge: If the gauge does not clamp, readjust the truck linkage and move the yoke finger closer to the bearing. Yoke Finger Release Bearing Clutch Brake 2 Slowly let up on the pedal and measure the pedal position at the moment the gauge can be removed: If pedal is more than 1" (25.4 mm) from the floor, readjust the truck linkage to move the yoke fingers further from the release bearing. Repeat Step 1. Less than 1" ( 25.4 mm) 15

22 Solo Advantage Self-Adjusting Clutches Out-of-Vehicle Reset Procedure for Heavy-Duty ECA or Solo Advantage Clutches 1 Remove the 4 shipping bolts if they have been installed. 2 Support the clutch in an arbor press with the bearing facing down. 3 Center the ram and press downward on the retainer until it comes to Note: Make sure there is at a stop. Lock the ram in least 1" of space to allow position. the bearing to move down and to provide access to the shipping bolts. 4 Slide the wear indicator tab to the GOOD position and hold it in place with a magnet 5 Install 4 shipping bolts (7/16" x 14 x 1-3/4" UNC, hex head). Progressively tighten (no air wrenches) the 4 shipping bolts (crisscross pattern) until the face of the pressure plate is 1.75"-1.78" ( mm) below the mounting surface. Shipping Bolts 1.75"-1.78" ( mm) 6 Reinstall the clutch using the original installation instructions. Note: This important step will reset the pressure plate separator pins and allow the clutch to release after reinstallation. 16

23 Easy Pedal Advantage Manual Adjust Clutches Install Easy Pedal Advantage and ValueClutch Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or may result in a premature clutch failure. Remove and replace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheel surfaces of all grease, oil, and rust preventatives. Failure to perform this function can affect the performance of the clutch. Use a dial indicator and check the following: Flywheel Face Runout Pilot Bearing Bore Runout 1 Secure dial indicator base to flywheel housing face. 2 Put gauge finger in contact with flywheel face near the outer edge. 1 Secure dial indicator base to flywheel housing face. 2 Position gauge finger so that it contacts pilot bearing bore. 3 Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 3 Rotate flywheel one revolution. Maximum runout is 0.005" (0.13 mm). Install Flywheel Housing I.D. Runout Flywheel Housing Face Runout 1 Secure dial indicator 2 Put gauge finger base to crankshaft. against flywheel housing pilot I.D. 1 Secure dial indicator base to flywheel near the outer edge. 3 Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 2 3 Put gauge finger in contact with face of flywheel housing. Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 17

24 DEPRESS BOLT Easy Pedal Advantage Manual Adjust Clutches Install Clutch to Flywheel Install 15.5" Clutch to Flywheel (Easy Pedal Shown) Use the Eaton Clutch Selector Guide (CLSL1511) to make sure you have the right clutch. Note: When installing clutch to flywheel, position the adjuster at the bottom of flywheel to ease future clutch servicing. 1 IMPORTANT Measure the flywheel bore. Use the Eaton Clutch Selector Guide to verify that the damper will fit into the flywheel bore. 7.0" (8-spring) 8.5" (10-spring) 10.0" (7-spring and Mack 9-spring) Note: Mack 9-spring for Mack and Volvo engines 2007 and newer only. 5 An assembled clutch weighs about 150 lbs (68 kg). Avoid the risk of injury. Use proper equipment when lifting a clutch. Note: Easy Pedal or manual adjust clutch assemblies not recommended for use with hydraulic release systems. 6 WARNING Install second disc onto aligning tool. Follow the orientation instructions on the disc. Install two 7/16" x 14 UNC x 5" studs into upper mounting holes. Install assembled clutch. 2 3 Insert aligning tool through bearing. 4 Install disc onto aligning tool. Follow the orientation instructions on the disc. 8 4 Install intermediate plate into slots on the clutch cover. Flywheel Side must face the flywheel TO TURN Install lock washers and mounting bolts (7/16" x 14 UNC x 2-1/4" grade 5) finger tight. Replace studs with lock washers and bolts. 9 Verify bearing position is 3/8" 5/8" ( mm) from cover. 10 Remove the aligning tool. Be sure shipping blocks are removed. 11 Use a six ounce hammer and a 1/4" flat nose punch to lightly tap the four separator plate pins toward the flywheel (New EP Only). Reman and Value clutches do not have pins. Only part of the pin should be visible. DEPRESS BOLT TO TURN 8 Pin Progressively tighten mounting bolts in a crisscross pattern starting with the lower left bolt (1, 2, 3, 4, 5, 6, 7, 8). Torque to lb-ft (54-68 N m). Failure to do this could result in improper piloting of the clutch and cause clutch damage. 18

25 DEPRESS BOLT Easy Pedal Advantage Manual Adjust Clutches Install 14" Clutch to Flywheel 1 Ensure the correct flywheel depth is 2-15/16". 2 Put front disc into flywheel. Flywheel side must be toward engine. Use new slots to put intermediate plate on pins. Super-duty clutch only: 3 Install three equally spaced anti-rattle springs. Note: Check orientation on anti-rattle springs before installing. 4 Turn intermediate plate left. Use 0.006" feeler gauge to check left pin clearance on all 6 drive pins. Note: Remove two set screws. Straighten pins to increase clearance and reinstall set screws. Do not file slots Slide cover over aligning tool. Insert aligning tool through discs. 8 Install second disc onto flywheel. Follow the orientation instructions on the disc. 7 Install intermediate plate onto drive pins. 6 Install disc into flywheel. Follow the orientation instructions on the disc. 5 Install two 3/8" x 2-1/2" studs into upper mounting holes. Install TO TURN Install lock washers and mounting bolts (3/8" x 1-1/4" grade 5) finger tight. Replace studs with lock washers and bolts. 12 Progressively tighten mounting bolts 13 Remove the aligning in a crisscross pattern starting with the tool. Be sure shipping lower left bolt (1, 2, 3, 4, 5, 6, 7, 8). blocks are removed. Torque to lb-ft (34-47 N m). Failure to do this could result in improper piloting of the clutch and cause clutch damage. 19

26 Easy Pedal Advantage Manual Adjust Clutches Install Transmission Check Transmission For Wear Replace any worn components. Transmission Bearing Retainer Cap A worn/rough bearing retainer cap may cause the clutch brake to wear prematurely. Cross Shaft and Bushings Excessive wear at these points can cause side loading on the sleeve bushing, bushing failures and yoke bridge contact with the clutch when the pedal is down. Input Shaft Splines Any wear on the splines will prevent the driven discs from sliding freely, causing poor clutch release (clutch drag). Slide discs full length of shaft to check for twisted shaft splines. IMPORTANT Do not add lube (never seize or grease) to the input shaft splines. The discs must be free to move. Release Yoke Worn fingers can cause bushing wear and yoke interference when the pedal is down. Input Shaft Spigot Wear will not provide proper interface with the inner race of the pilot bearing. This can result in damage to the clutch or the pilot bearing. Input Shaft Wear (roughness) can reduce sleeve bushing life and cause it to come out. Measure Input Shaft Length should be 8.657" ( mm) nominal, and not greater than 8.71" ( mm). Ref SAE handbook 4: Replace transmission bearing retainer cap if length is greater than 8.71" ( mm). Clutch Brake Replace. CAUTION Do not let the transmission drop or hang unsupported in the driven discs. This can bend the discs and the clutch will not release causing damage that is not warrantable. Do not excessively force the transmission into the clutch assembly or engine housing. This will cause damage to the splines of the rear disc hub that is not warrantable. If the discs do not slide freely on the input shaft, investigate the cause of the problem and make any necessary changes. If the discs do not slide freely, the clutch will not release and the transmission will grind going into gear. 20

27 Easy Pedal Advantage Manual Adjust Clutches Fasten Transmission to Flywheel Housing Transmission installation and clutch set-up procedures are the same for the 14" and 15.5" clutch. 1 Put transmission in gear. Be sure new clutch brake has been installed. 2 Make sure that the yoke fingers remain in the up position until they are over the release bearing housing. 3 Position transmission so it is square to and aligned with engine. 4 Mesh splines by moving transmission forward and rotating the output shaft. Do not use excessive force. Do not let the transmission hang unsupported in the discs. Install 5 Install mounting bolts and torque to OEM specs. Note: If you have a hydraulic linkage, go to page 49. WARNING Do not let the transmission drop or hang unsupported in the driven discs. This can cause the discs to become distorted and the clutch to not release. IMPORTANT Do not add lube to the input shaft splines (Never seize or grease). The discs must be free to slide. CAUTION Do not force transmission against clutch with yoke fingers in the up position. This will break the cast webbing of the clutch causing damage that is not warrantable. Do not use excessive force. If it does not enter freely, investigate the cause of problem and make any necessary changes. 21

28 Easy Pedal Advantage Manual Adjust Clutches Set-Up Adjust Bearing Position 1 Note: Before measuring the distance between the release bearing and clutch brake depress clutch pedal to remove free pedal in the cab. Measure the distance between the release bearing and the clutch brake: If the distance is correct, 0.500" " ( mm), then Verify Clutch Brake Squeeze, go to Step 4. If the distance is not between 500" -.560" ( mm), then Change Bearing Position, go to Step 2. 2 Have an assistant hold down clutch pedal so internal adjustment can be made " " ( mm) Hold Release Bearing Clutch Brake 3 Adjust bearing position: Easy-Pedal & Easy Pedal Advantage Only: While pedal is held down, push adjusting nut and turn: If measurement was more than 0.560" (14.22 mm), turn adjusting nut clockwise. If measurement was less than 0.500" (12.77 mm), turn adjusting nut counterclockwise. Value Clutch Only: While pedal is held down, remove lockstrap and move adjusting lug: If measurement was more than 0.560" (14.22 mm), move adjusting lug to the left (shown). If measurement was less than 0.500" (12.77 mm), move adjusting lug to the right. Adjusting Nut Part Number TO TURN DEPRESS BOLT Lockstrap Adjusting Lug 22

29 Easy Pedal Advantage Manual Adjust Clutches Verify Clutch Brake Squeeze WARNING Use a gauge long enough to keep hands away from moving parts. Set-up 4 Have an assistant insert 0.010" (0.25 mm) feeler gauge between the release bearing and the clutch brake. Press the pedal down to the floor to clamp the gauge: If the gauge does not clamp, readjust the truck linkage and move the yoke finger closer to the bearing. 5 Slowly let up on the pedal and measure the pedal position at the moment the gauge can be removed: If pedal is more than 1" (25.4 mm) from the floor, readjust the truck linkage to move the yoke fingers further from the release bearing. Repeat Step 4. Yoke Finger Release Bearing Clutch Brake Less than 1" (25.4 mm) 23

30 Easy Pedal Advantage Manual Adjust Clutches Verify Free-Play 6 Measure the distance between yoke tips and bearing wear pads simultaneously. This distance should be 1/8" (3.2 mm). If distance is not 1/8" (3.2 mm), go to Step 7. IMPORTANT Do not change bearing position. Note: 1/8" (3.2 mm) distance will create free-play in cab. Free-play in cab may be different on different truck makes, models and years. 1/8" (3.2 mm) Yoke Finger Release Bearing 1/8" (3.2 mm) 7 The truck linkage should allow for a minimum of 0.685" of yoke finger movement; 0.125" for free-play, 0.500" for the bearing and 0.060" for clutch brake squeeze. If it is necessary to increase the free-play, adjust upper pedal stop to raise or lower the pedal in the cab. If this is not possible, check the OEM parts manual to verify the correct clutch arm was installed at the factory. IMPORTANT Do not change free-play by changing the bearing position. Correct bearing position is 0.500"-0.560" ( mm) 24

31 Easy Pedal Advantage Manual Adjust Clutches Lubricate Note: All clutches use a Lithium complex grease with a minimum of 325 F (163 C) operating range meeting NLGI grade 2 or 3 specs. Set-up Note: Apply ample grease that is visibly exiting the opening and contacts the transmission shaft. This will lube the clutch brake and bushing when the pedal is pressed. For additional lubrication information, see TCMT0021. CAUTION Failure to properly lubricate the bearing/bushing will result in bearing and sleeve failures. Yoke Finger Zerk Input Shaft 8 Apply grease to input shaft and yoke fingers. 29 Apply grease to the cross shaft bushings and linkage pivot points. IMPORTANT Do not add lube (never seize or grease) to the input shaft splines. The disc must be free to move. 25

32 UltraShift DM Clutch UltraShift DM Heavy Duty Clutch Remove Clutch WARNING An assembled clutch weighs about 182 lbs (82 kg). Avoid the risk of injury. Use proper equipment when lifting a clutch Prior to removing the transmission, rotate the engine until one of the jack screw locations can be viewed through the clutch housing inspection opening. Using a piece of 5/16" x 18 UNC x 3" threaded rod (jack screw), install two nuts on one end and lock them together. This will allow you to turn the jack screw in and out of the cover assembly. Install the jack screw into one of the four holes located adjacent to the clutch mounting bolts. This forces the pressure plate forward clamping the discs and holding them in place. CAUTION Do not overtighten the jack screw. Tightening more than 9 lb-ft can cause permanent clutch damage. 4 Remove the transmission, supporting its weight to prevent damage to the clutch discs Insert alignment shaft Remove the Unbolt the clutch from the Remove the old and clutch jack. jack screw. flywheel and slide the clutch pilot bearing. away from the flywheel. WARNING An assembled clutch weighs about 182 lbs (82 kg). Avoid the risk of injury. Use proper equipment when lifting a clutch. CAUTION When removing the clutch, the flywheel side disc can fall off of the alignment shaft, permanently damaging the driven disc. 8 26

33 UltraShift DM Clutch Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or may result in a premature clutch failure. Remove and replace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheel surfaces of all grease, oil, and rust preventatives. Failure to perform this function can affect the performance of the clutch. Use a dial indicator and check the following: Flywheel Face Runout Pilot Bearing Bore Runout 1 Secure dial indicator base to flywheel housing face. 2 Put gauge finger in contact with flywheel face near the outer edge. 1 Secure dial indicator base to flywheel housing face. 2 Position gauge finger so that it contacts pilot bearing bore. 3 Flywheel Housing I.D. Runout Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 3 Flywheel Housing Face Runout Rotate flywheel one revolution. Maximum runout is 0.005" (0.13 mm). Remove 1 Secure dial indicator 2 Put gauge finger base to crankshaft. against flywheel housing pilot I.D. 1 Secure dial indicator base to flywheel near the outer edge. 3 Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 2 3 Put gauge finger in contact with face of flywheel housing. Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 27

34 UltraShift DM Clutch UltraShift DM ClutchInstall Clutch to Flywheel Note: If installing a new DM, follow the installation directions that are provided in the box. The required alignment tool, part number RR1009CL, can be ordered through K-Line at WARNING An assembled clutch weighs about 182 lbs (82 kg). Avoid the risk of injury. Use proper equipment when lifting a clutch. 1 Install new pilot bearing. 10.0" (7-spring & VCT Plus) 2 Measure the flywheel bore to verify that the damper will fit into the flywheel bore. 3 Insert aligning tool through 4 Install second disc onto aligning 5 Install two 7/16" x 14 UNC x 5" DM Clutch and rear disc. tool. Follow the orientation studs into upper mounting holes. WARNING instructions on the disc. Using clutch jack or other lifting device, install assembled clutch. The intermediate plate is bolted to the cover assembly and the rear driven disc is held in place between the pressure plate and intermediate plate. DO NOT UNBOLT the intermediate plate from the cover assembly Remove the aligning tool. 9 1 Install the jack screw into one of the four holes located adjacent to the clutch mounting bolts. This forces the pressure plate forward clamping the discs and holding them in place. Be sure the hole chosen is at the 6 o'clock position to allow for removal after the transmission is installed. CAUTION Do not overtighten the jack screw. Tightening more than 9 lb-ft can cause permanent clutch damage Using a piece of 5/16" x 18 UNC x 3" threaded rod (jack screw), install two nuts on one end and lock them together. This will allow you to turn the jack screw in and out of the cover assembly. 6 7 Install lock washers and mounting bolts (7/16" x 14 UNC x 2-1/4" grade 5) finger tight. Replace studs with lock washers and bolts. Progressively tighten mounting bolts in a crisscross pattern starting with the lower left bolt (1, 2, 3, 4, 5, 6, 7, 8). Torque to lb-ft (54-68 N m). Failure to do this could result in improper piloting of the clutch and cause clutch damage. 28

35 UltraShift DM Clutch Install Transmission Check Transmission for Wear Replace any worn components. 1 Input Shaft Splines Any wear on the splines will prevent the driven discs from sliding freely, causing poor clutch release (clutch drag). Slide discs full length of shaft to check for twisted shaft splines. IMPORTANT Do not add lube (Never seize or grease) to the input shaft splines. The disc must be free to slide. 2 Input Shaft Spigot Wear will not provide proper interface with the inner race of the pilot bearing. This can result in damage to the clutch or the pilot bearing. Fasten Transmission to Flywheel Housing 1 Position transmission so it is square to and aligned with engine. 2 Mesh splines by moving transmission forward and rotating the input shaft. Do not use excessive force. Do not let the transmission hang unsupported in the discs. Install 3 Install mounting bolts and torque to OEM specs. 4 Remove the jack screw. 5 Reconnect UltraShift wiring harness. WARNING Do not let the transmission drop or hang unsupported in the driven discs. This can cause the discs to become distorted and the clutch to not release. CAUTION Do not use excessive force. If it does not enter freely, investigate the cause of problem and make any necessary changes. 29

36 UltraShift DM Clutch Heavy-Duty UltraShift Clutch Recalibration 1. Turn key on. 2. Verify a solid N is on the gear display. 10. After the 1 is displayed, depress the throttle pedal to the floor and hold for 3-5 seconds (the gear display will change back to a 0 with down arrows indicating the routine has been successfully completed. 3. Start engine. 4. Increase engine RPM above This will unlock the clutch. Failure to do this will set a clutch disengagement code and the code and transmission will not go into gear. Note: Programmable VSS Tamper Resistance options or other artificial engine speed limits which prevent reaching the required 1500 rpm may prevent proper disengagement of the clutch locking device after initial installation. These options may need to be disabled until after the clutch-locking device is disengaged. Note: If ServiceRanger is available, proceed to Step Start with the system powered down, the vehicle stationary, and the engine not running. 6. Key on and allow the system to completely power up but do not start the engine. 7. Select LOW mode on the shift controller (UltraShift system will begin to emit an audible tone). 8. Select an upshift once (UltraShift gear display will display a 0 with down arrows and discontinue the tone indicating Special Functions mode is activated. 11. Key off or select any mode and the UltraShift system returns to normal operation. 12. Save clutch data / recalibrate clutch with ServiceRanger. 9. Once in Special Functions mode, select one additional upshift (UltraShift gear display will display a 1 with up arrows indicating UltraShift Touch Point Resent is selected.) 1 30

37 UltraShift DM Clutch Gen 2 1. Using ServiceRanger, select the Advanced Product Functions button located on the main menu. 2. Select Eaton AutoShift Gen-2 from the product selection screen. Note: This screen will only appear if the vehicle is equipped with more than one supported Roadranger product. 3. Select Clutch Data from the Advanced Product Functions screen. 4. Save the clutch data by selecting the Save Abuse Info to a File button. Note: Use the truck VIN as the file name. The data file will be saved to the ServiceRanger folder in the Clutch Data subfolder (e.g. C:\Serviceranger\Clutch Data). 5. Reset clutch abuse info by selecting the Reset Clutch Abuse Info button. 6. Recalibrate the new clutch by selecting the Calibrate Clutch button. Note: Failure to calibrate a newly installed clutch may result in some initial harsh vehicle launches, as the system is required to manually recalibrate. Gen 3 1. Using ServiceRanger, select Advanced Product Function button. 2. Select UltraShift transmission model (Gen 3) from menu tree in the upper left. 3. Select the VPA/SnapShot Utility and launch the function. 4. Read the APF description and select Next. 5. Enter the vehicle info and select Next. 6. Select VPA from the dropdown Data Source field. 7. Enter an output file name and location using Browse Button or use default filename and location shown. Note: If the default filename and location is used, the VPA data file will be saved to the ServiceRangerData folder in the VPA subfolder on the C:\drive. 8. Select the Start Transfer button to download data from transmission controller and then select Next. 9. The output file can now be viewed, select Finish. 10. Select Clear Clutch Data button to clear data from transmission controller. 11. If successful proceed to next step, if unsuccessful exit function and re-enter. Contact Roadranger Call Center for help. 12. Select the Calibrate Clutch button to calibrate new clutch and the select Finish when complete. Recalibration 31

38 ECA Clutch Remove Clutch CAUTION Note the position of the wear indicating tab on the clutch. If the tab is near the REPLACE position, the clutch should be replaced. 1. If the clutch is to be reinstalled and the transmission is still in vehicle, complete steps 1-7 of the ECA Clutch In-Vehicle Resetting Procedure on page 45 to ensure proper function after reinstallation. Move ECA Clutch to Service Position CAUTION Ensure that hands are not inside the clutch housing while opening or closing the clutch. A Turn ignition switch to on. OFF ON B Plug 9-pin connector into dash port. START 2 C3 Click on ServiceRanger icon to launch program. 32

39 ECA Clutch D E Click on transmission. F Click on ECA Clutch Open and expand the Advanced Product Functions tree. Note: Advanced Product Functions appear. Service. CAUTION G Ensure that hands are not inside the clutch housing while opening or closing the clutch. Choose Clutch Position tab. Remove H Click Move to Service Position button. I Confirm Positive results. 33

40 ECA Clutch 2. Remove the transmission, supporting its weight to prevent damage to the bearing and discs. 3. Locate 4 shipping bolts (7/16 x 14 x 1 3/4 UNC, hex head). Install them in the 4 cover holes hand tight then turn one full turn. IMPORTANT This step will hold the pressure plate separator pins in proper position so the clutch can be reused and will release after reinstalling. Shipping Bolts (4) 7/16" x 14 x 1-3/4" UNC 4. Support the clutch during the removal of the 8 mounting bolts. 5. Remove the clutch from the flywheel. 34

41 ECA Clutch 15.5" Heavy-Duty ECA Clutch Installation Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or may result in a premature clutch failure. Remove and replace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheel surfaces of all grease, oil, and rust preventatives. Failure to perform this function can affect the performance of the clutch. Use a dial indicator and check the following: Flywheel Face Runout Pilot Bearing Bore Runout 1 Secure dial indicator base to flywheel housing face. 2 Put gauge finger in contact with flywheel face near the outer edge. 1 Secure dial indicator base to flywheel housing face. 2 Position gauge finger so that it contacts pilot bearing bore. Install 3 Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 3 Rotate flywheel one revolution. Maximum runout is 0.005" (0.13 mm). Flywheel Housing I.D. Runout Flywheel Housing Face Runout 1 Secure dial indicator 2 Put gauge finger base to crankshaft. against flywheel housing pilot I.D. 1 Secure dial indicator base to flywheel near the outer edge. 3 Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 2 3 Put gauge finger in contact with face of flywheel housing. Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm). 35

42 ECA Clutch Install Clutch to Flywheel Note: The clutch release yoke fingers must be positioned so they clear the release bearing housing when removing and installing the transmission. Preferred method: Move the release yoke to the service position via ServiceRanger's Advanced Product Functions. Secondary method: Remove the ECA prior to removing the transmission and then manipulate the fingers by hand. CAUTION An assembled clutch weighs about 150 lbs (68 kg). Avoid the risk of injury. Use proper equipment when lifting a clutch. WARNING Do not unbolt the intermediate plate from the cover assembly. Do not use vehicle s transmission to install the ECA clutch, as it can result in damage to the clutch or ECA. 1 Insert aligning tool through bearing. Note: The ECA Clutch alignment tool is a 14-tooth shaft and is 1-3/4" longer than the standard shaft. 2 Install second disc onto aligning tool. Follow the orientation instructions on the disc Install two 7/6" x 14 UNC x 5" studs into upper mounting holes. Install assembled clutch Slide the clutch assembly over the guide studs and install six lock washers and mounting bolts (7/16" x 14 UNC x 2 1/4" grade 5) finger tight. Replace studs with remaining two lock washers and bolts. 6 7 Remove four yellow shipping bolts in an even 1/4 turn crisscross pattern. Remove aligning tool. 5 Progressively tighten mounting bolts in a crisscross pattern starting with the lower left bolt. Torque to lb-ft (54 68 Nm). Failure to do this could result in improper piloting of the clutch and cause clutch damage. 8 Position the release bearing so the orientation of the lube fitting is in the 4 o'clock position. Generic graphic 9 Following transmission installation, perform clutch adjustment. See the "ECA Clutch Adjustment" Section on page 40. Note: Always perform a clutch adjustment after a clutch replacement. 36