Service Manual Trucks - Heavy

1 ServiceManualTrucksGroup 41 Hydraulically Actuated Clutch(Including transmission removal) VNL, VNMPV776-TSP24581/1 ForewordThe descriptions and Service procedures contained in this Manual are based on designand method studies up to October products are under continuous development. Vehicles and components producedafter the above date may therefore have different specifications and repair this is believed to have a significant bearing on this Manual , supplementary servicebulletins will be issued to cover the new edition of this Manual will update the Service procedures where the title incorporates an operation number, this is areference to an (Standard Repair Time). Service procedures which do not include an operation number in the title are for generalinformation and no reference is made to an following levels of observations, cautions and warnings are used in this ServiceDocumentation:Note:Indicates a procedure, practice, or condition that must be followed in order tohave the vehicle or component function in the manner :Indicates an unsafe practice where damage to the product could :Indicates an unsafe practice where personal injury or severe damage to theproduct could :Indicates an unsafe practice where serious personal injury or death GM Heavy TruckGreensboro, NC USAO rder number: PV776-TSP24581/1 1996 Volvo GM Heavy truck , Greensboro, NC USAAll rights reserved.

2 No part of this publication may be reproduced, stored inretrieval system, or transmitted in any forms by any means, electronic, me-chanical, photocopying, recording or otherwise, without the prior writtenpermission of Volvo GM Heavy .. 3 About this Service Information .. 3 Specifications .. 5 Clutch .. 5 Clutch Master Cylinder .. 5 Transmission Slave Cylinder .. 6 Hydraulic System .. 7 Tightening Torques .. 7 Tools .. 9 Special tools .. 9 Other equipment .. 10 Design and Function .. 11 Clutch and Hydraulic Clutch System .. 11 Design .. 11 Function .. 14 Service Procedures .. 19 Clutch removal .. 19 Clutch plate changing and installation .. 20 Flywheel pilot bearing replacing .. 22 Volvo clutch servo removal .. 23 Volvo clutch servo installation .. 24 Volvo clutch servo adjustment .. 24 Master cylinder removal.

3 25 Master cylinder installation .. 27 Clutch slave cylinder removal .. 31 Clutch slave cylinder installation .. 31 Clutch bleeding procedure .. 33 Upper clutch pedal adjustment .. 34 Lower clutch pedal adjustment .. 34 Micro-switch adjustment .. 35 Inhibitor valve splitter adjustment .. 36 Transmission removal .. 38 Volvo transmission .. 38 Non-Volvo transmission .. 42 Transmission installation .. 44 Volvo transmission .. 44 Non-Volvo transmission .. 48 Shift linkage removal .. 50 Shift linkage installation .. 5112 Group 41 Hydraulically Actuated ClutchAbout this Service InformationGeneralAbout this Service InformationThe information and instructions contained in this Service Information pertain to thefollowing components:Clutch Volvo 17 single plate - model CL43S-O (previously KFD117E) Volvo 15 double plate - model CL38D-O (previously KFD215B) Spicer Easy-PedalTM1552 double plate, ceramicNote:For more information on servicing the Volvo clutches, please refer to the VolvoService Manual 411 600, Clutch, Pull-Type Master Cylinder Hydraulic master cylinder with plastic Slave Cylinder Volvo Transmissions-Volvo air assisted hydraulic servo Other Transmissions-hydraulic slave cylinderNote:For more clutch overhaul instructions, please refer to the Volvo Service Manual411 600, Clutch, Pull-Type 41 Hydraulically Actuated ClutchSpecificationsSpecificationsClutch VolvoModelSizemm (in.)

4 Max. TorqueNm (lb ft)Spline SizeFacing MaterialCL43S-O (single plate)430 (17)1850 (1365)10-SAEorganicCL38D-O (double plate)380 (15)1980 (1460)10-SAEorganicSpicerModelSizemm (in.)Max. TorqueNm (lb ft)Spline SizeFacing MaterialEasy-Pedal PlusTM1552(double plate)394 ( )1730 (1275)1970 (1450)2240 (1650)10-SAEceramicClutch Master CylinderP/N 1628218 (Volvo) or8076243 (Non-Volvo) .. Non-serviceable5 Group 41 Hydraulically Actuated ClutchSpecificationsTransmission Slave CylinderNote:Vehicles equipped with a Volvo transmission use apneumatic/hydraulic servo for clutch operation. Vehiclesequipped with a non Volvo transmission use a hydraulicslave TransmissionsVolvo Clutch ServoAir assisted, hydraulic cylinder .. P/N 1521371 MeasurementCL43S-O clutchmm (in.)CL38D-O clutchmm (in.)Basic setting(A)..55 ( )55 ( )Measurement(B)mm (in.) ..Max. 115 ( )Max. 115 ( )Stroke(C), mm (in.) ..27-29 ( )27-29 ( )Lever length(L), mm (in.)

5 150 ( )130 ( )Fuller or Rockwell TransmissionsHydraulic Clutch SlaveSlave Cylinder, Hydraulic .. P/N 80750086 Group 41 Hydraulically Actuated ClutchSpecificationsHydraulic SystemClutch Fluid .. DOT 4 (SAE J1703)Fluid Reservoir Capacity .. liter ( qts.)Total Hydraulic System Capacity .. liter ( qts.)Tightening TorquesComponentNm(ft lbs)Clutch Housing to FlywheelCL430S-O ..37 4(27 3)CL380D-O ..65 6(48 4 )Spicer Easy-PedalTM1552 ..60 7(45 5 )Intermediate Ring - Volvo clutchesCL380D-O ..26 2(19 1)Clutch Servo - VolvoLock nut, push rod ..60 10(45 7)Air Connection ..24 2(18 1)Fluid bleed nipple ..10 2(7 1)Hydraulic connection ..45 5(33 4)Clutch Slave Cylinder - non VolvoMounting bolts ..35(26)Hydraulic connection, line tofitting ..40 5(30 4)Hydraulic connection,fitting to cylinder ..20(15)Clutch Master CylinderMounting bolts ..24 4(18 3)Hydraulic connection.

6 40 5(30 4)78 Group 41 Hydraulically Actuated ClutchToolsToolsSpecial toolsThe following special tools are required for work on the Volvo VN Series Hydraulic ClutchSystem. The tools can be ordered from the Volvo GM Heavy truck 6851 Adjustment gauge999 1821 Slide puller999 6928 Bleeder999 6902 Centering drift999 6857 Lifting tool999 6896 Adaptingfixture(used with 6857)9 Group 41 Hydraulically Actuated ClutchToolsOther equipmentThe following items are considered common shop equipment and are necessary for therepair procedures in this pliersTransmission jackPocket rulerFeeler gauges10 Group 41 Hydraulically Actuated ClutchClutch and Hydraulic Clutch SystemDesign and FunctionClutch and Hydraulic Clutch SystemW4000835 DesignVolvo ClutchesThe Volvo dry plate clutches are specifically matched toengine and transmission combinations. Volvo uses twotypes of dry plate clutches: single plate and double double plate is mainly used for Heavy duty of the clutches are of the diaphragm spring typeand are controlled by an air assisted hydraulic clutch movement (engagement, disengagement) is aresult of the servo rotating the cross shaft (fork assembly).

7 These clutches are called pull-type because the forkassembly pulls the release bearing rearward to disengagethe single plate clutch consists of apressure plate, release bearing andone clutch double plate clutch consists of apressure plate, release bearing, inter-mediate pressure plate, straps, twoclutch discs and four centering 41 Hydraulically Actuated ClutchClutch and Hydraulic Clutch SystemVolvo Clutch Plate(s)The Volvo clutch plates are dry with linings on both clutch plate consists of a disc, damper springs,hub, and linings. The disc is connected to the hub byfriction elements and damper springs to provide a smoothengagement and eliminate engine front plate hub is splined onto the transmission s inputshaft. The rear plate is splined onto the outer diameter ofthe front plate hub. The linings are organic, non-asbestosmaterial and are riveted to the plateW4000795 Gearbox plateVolvo Pressure PlateThe pressure plate is a powerful diaphragm spring.

8 It ismounted to theflywheel with six mounting bolts. Whenthe clutch pedal is depressed the spring force is removedfrom the clutch plates and absorbed by the releasebearing. The clutch plates are then disengaged and stoptransmitting torque to the 41 Hydraulically Actuated ClutchClutch and Hydraulic Clutch SystemSpicer ClutchW4000831 The Spicer Easy-Pedal PlusTM1552 double plate clutchis a spring type clutch that is controlled by a hydraulicslave cylinder. The clutch engagement/disengagement isa result of the slave cylinder rotating the cross shaft andfork Spicer double plate clutch consist of a pressure plate,release bearing, intermediate plate, Positive SeparatorPinTM, two clutch plates and a Clutch PlatesW4000832 The Spicer clutch uses ceramic linings on both clutchplates. The plates are dampened with springs to reducetorsional Pressure PlateW4000831 The Spicer pressure plate is a spring type with 9 41 Hydraulically Actuated ClutchClutch and Hydraulic Clutch SystemFunctionMaster Cylinder with Pneumatic Servo - Volvo TransmissionsW4000835 The Volvo pneumatic servo operates on hydraulic pres-sure from the clutch master cylinder and is assisted withair pressure.

9 The servo consists of an air cylinder, reac-tion plunger, and control CylinderW4000840 The clutch pedal activates the master cylinder. Whenthe clutch pedal is depressed, the clutch rod movesdownward pushing the plunger into the cylinder. Plungermovement into the cylinder forces thefluid through thehydraulic lines and into the clutch servo. As the plungeris forced into the cylinder, thefluid supply duct from thereservoir is closed. When the clutch pedal is released,the clutch rod and plunger return to the rest position andthefluid supply duct 41 Hydraulically Actuated ClutchClutch and Hydraulic Clutch SystemPneumatic ServoClutch engagementW4000857 When the clutch pedal is pressed, hydraulic pressure (10)increases and the reaction piston (3) is pressed in thedirection of the arrow. This movementfirst shuts thecontrol valves upper seat (4b) and then the air outlet duct(6).

10 As the reaction piston moves further, the rubber peg (4)is pushed off its seat (4b) allowing pressurized air into theair chamber (5). As a result of the increased air pressure,the piston (7) moves in the direction of the depressedW4000858 The reduction in hydraulic pressure allows the air pressureto push back the control valve (4b) stopping the air is now stabilized, the reaction piston (3) andrubber peg (4) are held in their positions until the positionof the clutch pedal is 41 Hydraulically Actuated ClutchClutch and Hydraulic Clutch SystemReleasedW4000859 When the clutch pedal is released, hydraulic pressure islowered and the pressure spring (11) presses back thereaction piston. The rubber peg (4) closes the air supplyand opens the air outlet duct (6). Air is now released fromthe air chamber (5) and the piston (7) is returned to its restposition by the force of the pressure plate FailureIf air pressure drops or the air system does not supply airpressure, the servo will continue to function on hydraulicpressure, however, this will require greater pedal pedal effort is required if servo air pressureis lost.