EUROTRAKKER CURSOR 13 CLUTCH 1

SECTION 3
5052 Clutch

Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3

- Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SPECIFICATIONS AND DATA . . . . . . . . . . . . . 3

FAULT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 5

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 8

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

REMOVING AND REFITTING THE CLUTCH . . 9

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

REMOVING-REFITTING THE THRUST BEARING10

CLUTCH DISENGAGEMENT CONTROL

(VEHICLES WITH ZF 16 S 151/181/221
O.D. GEARBOXES) . . . . . . . . . . . . . . . . . . . . 11

REMOVING-REFITTING THE PEDAL UNIT . . . 11

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

PEDAL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

REMOVAL-ASSEMBLY . . . . . . . . . . . . . . . . . . . . 12

CHECKING AND ADJUSTING STOPS ON CLUTCH

PEDAL (VEHICLES WITH ZF 16 S 151 O.D./181
O.D./221 O.D. GEARBOXES) . . . . . . . . . . . . 13

- Clutch stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

- Idle travel of clutch pedal . . . . . . . . . . . . . . . . . 13

- Pedal control valve stroke . . . . . . . . . . . . . . . . 13

HYDRAULIC CONTROL
(VEHICLES WITH ZF 16 S 151 O.D./181
O.D./221 O.D. GEARBOXES) . . . . . . . . . . . . 14

CLUTCH ACTUATOR FOR ZF 16 S 151 O.D./181

O.D./221 O.D. GEARBOXES . . . . . . . . . . . . . 15

- Fitting and adjusting the clutch wear indicator . 15

2 CLUTCH EUROTRAKKER CURSOR 13

Page

- Push rod adjustment (new clutch) . . . . . . . . . . 16

- Push rod adjustment

(vehicles with PTO opt. 2395 only) . . . . . . . . . 16

BLEEDING THE AIR FROM THE CLUTCH

CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

CLUTCH ACTUATOR FOR THE EUROTRONIC

16 A S 2601 O.D. GEARBOX . . . . . . . . . . . . 17

- Clutch actuator push rod adjustment

(new clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . 17

- Fitting the clutch actuator . . . . . . . . . . . . . . . . 17

- Replacing the clutch actuator . . . . . . . . . . . . . . 17

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EUROTRAKKER CURSOR 13 CLUTCH 3

DESCRIPTION
Clutch
The clutch is the dry single-disc type, with pull engaging The engagement control is air-hydraulic and comprises the
mechanism with diaphragm spring. master cylinder, with a built-in oil reservoir, and the operator
cylinder.

SPECIFICATIONS AND DATA

17” CLUTCH - With EUROTRONIC 16 AS 2601 O.D.

gearbox FICHTEL & SACHS

Type Dry single disc

Engagement mechanism Pull with diaphragm spring

Driven disc With friction linings

Driven disc hub With torsion springs

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Gasket outside Ø mm 430

Gasket inside Ø mm 240 + 3

Disc thickness (new) mm 10 ± 3

Max. offset driven disc mm ~ 0.4

Load on pressure plate

34000
(new) Minimum N

Disengagement load N 8400

Minimum pressure plate lift mm 1.7

Disconnection stroke mm 12 + 2

Consumption stroke max. mm 16

Electro-pneumatic actuator controlled by the gearbox control

Hydraulic control
unit

Type of oil -
4 CLUTCH EUROTRAKKER CURSOR 13

SPECIFICATIONS AND DATA

17” CLUTCH - With ZF 16 S 151 / 181 / 221 VALEO

O.D. gearbox

Type Dry single disc

Engagement mechanism Pull with diaphragm spring

Driven disc With friction linings

Driven disc hub With torsion springs

Gasket outside Ø mm 430

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Gasket inside Ø mm 240

Disc thickness (new) mm 10 ± 3

Max. offset driven disc mm ~ 0.4

Load on pressure plate N 34600

Disengagement load N 8200

Minimum pressure plate lift mm 1.7

Disconnection stroke mm 12 + 2

Consumption stroke max. mm 12.6

Master cylinder with oil reservoir built in- operator cylinder

Hydraulic control
with total wear recovery of driven disc

Type of oil Tutela TRUCK DOT SPECIAL

EUROTRAKKER CURSOR 13 CLUTCH 5

FAULT DIAGNOSIS
Main operating trouble with the clutch:

1 - Noise when the pedal is lowered; 4 - The clutch does not disengage;
2 - Noise when the pedal is released; 5 - The clutch slips;
3 - The clutch jerks; 6 - Abnormal wear of driven disc linings.

1 NOISE WHEN THE PEDAL

IS LOWERED

Thrust bearing excessively worn, damaged or not Replace thrust bearing

properly lubricated YES

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NO

Excessive play between the splines on the Replace the shaft and also the driven plate if necessary
transmission input shaft and the relative housing in YES
driven plate hub.

2 NOISE WHEN THE PEDAL

IS RELEASED

Springs of driven plate broken or weak Replace driven plate.

YES

NO

Transmission input shaft worn Replace the shaft and also the driven plate if necessary
YES

NO

Thrust bearing has play in engagement sleeve Replace the thrust bearing
YES
6 CLUTCH EUROTRAKKER CURSOR 13

3 THE CLUTCH JERKS

Oil or grease on engine flywheel or on driven plate Eliminate the problem causing the contamination; clean
linings YES flywheel thoroughly then replace driven plate

NO

Pressure plate warped. Replace the clutch.

YES

NO

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Uneven wear of friction linings due to run-out of driven Replace the driven plate.
plate YES

NO

Diaphragm spring weak or fingers broken Replace the driven plate.

YES

4 THE CLUTCH DOES NOT DISENGAGE

Splines on transmission input shaft deteriorated in a way Replace shaft, and if necessary, also the driven disk.
to prevent driven disk from sliding. YES

NO

Excessive operator cylinder idle stroke. Check and adjust operator cylinder idle stroke.
YES

NO

Air in hydraulic circuit (excluding vehicles with Bleed circuit.

Eurotronic transmission). YES
EUROTRAKKER CURSOR 13 CLUTCH 7

5 THE CLUTCH SLIPS

Driven plate linings worn or burnt Replace the driven plate.

YES

NO

Diaphragm spring weak or fingers broken Replace the clutch.

YES

NO

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Oil or grease on driven plate linings. Eliminate the problem causing the contamination and
YES replace driven plate

ABNORMAL WEAR OF
6 DRIVEN PLATE LININGS

Driver resting his foot on the clutch pedal Driver must avoid the harmful habit and rest his
while driving YES foot on the clutch pedal only when necessary

NO

Disk thrust ring warped. Replace disk thrust.

YES

NO

Diaphragm spring with yielded or broken blades. Replace clutch.

YES

NO

Insufficient operator cylinder idle stroke. Check operator cylinder idle stroke.
YES
8 CLUTCH EUROTRAKKER CURSOR 13

TIGHTENING TORQUES

PART TORQUE
Nm (kgm)
Flanged hex screw fixing pressure plate to flywheel 46.5  4.5 (4.65  0.45)
Nut for stud bolt fixing clutch casing to crankcase 46 (4.6)
Stud bolt fixing clutch casing to crankcase 19 (2)

TOOLS

TOOL NO.

99306010 Tool to bleed air from hydraulic clutch circuit

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99370264 Guide pin to centre clutch disc

99370547 Mount for removing and refitting clutch assembly (to fit onto the
hydraulic jack)
 EUROTRAKKER CURSOR 13 CLUTCH 9

505210 REMOVING AND REFITTING

THE CLUTCH Figure 3
Removal
This operation comprises:
- Removing-refitting propeller shafts (see relevant section
505620).
- Removing-refitting gearbox (see relevant section
530210)

40195
Take out the clutch plate (2) together with the centring pin
99370264 (1).
CHECKS
The checks to make are as follows:
- The supporting surface of the driven disc, on the engine

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Figure 1 flywheel, must not be particularly worn or have too
much scoring.
- The toothing of the ring gear of the engine flywheel must
be neither deteriorated nor too badly worn.
If this is not the case, remove the engine flywheel (operation
540850).
In addition, check there is not even the slightest leakage of
lubricant from the seal of the crankshaft rear cover: in which
case, remove the flywheel as described under the relevant
heading. Remove the rear cover together with the seal and
replace it as described in section 2.
Check that the bearing or bushing supporting the gearbox
input shaft mounted on the crankshaft is neither worn nor
38438 deteriorated, in which case it should be replaced.
Insert the clutch centring pin 99370264 (1) into the bearing Check the state of the pressure place, the supporting surface
for the gearbox input shaft. of the driven disc must have no deformation, wear or sign of
overheating and its spring or diaphragm must be sound.

Figure 2

Check the state of the driven disc:

- The friction linings must not be too worn, nor have any
sign of overheating, nor be fouled with oil or grease.
- Its hub must not have too much play on the gearbox
input shaft.
- The torsion springs of the hub must not turn in their
seats or be broken.
If you find any trouble at all, replace the part concerned.

The clutch assembly is supplied as a spare in kit form.

40194
The following are supplied singly:
Fit the mount 99370547 (1) on the hydraulic jack and apply
the mount to the pressure plate (3). Unscrew the screws (2) - The driven disc and the thrust bearing.
and remove the pressure plate from the engine flywheel.
In this case it is necessary to mount the new parts of the same
supply as the torsion spring being reused.
10 CLUTCH EUROTRAKKER CURSOR 13

Figure 4 - Fit the gearbox back on after spreading the splined shaft
with Molikote molybdenum disulphide grease.
- Adjust the push rod of the operator cylinder as
described under the relevant heading (operation
505272).

505254 REMOVING-REFITTING
THE THRUST BEARING

Figure 6

Before fitting a new driven disc it is necessary to check its

centring as follows:
Position the driven disc (1) on a lathe. Then, with the aid of
a dial gauge with a magnetic base (2), check that the surface
of the disc is not off centre anywhere.

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The maximum permissible eccentricity of the driven disc is
0.20 mm.

Figure 5

36800

This operation comprises:

- Removing-refitting propeller shafts (see relevant section
505620).
- Removing-refitting gearbox (see relevant section
530210)
Using suitable pliers, open the snap ring (1), take the thrust
bearing (2) out of the pressure plate.
Reverse these steps for fitting.
If the disc is off centre, use a fork wrench (1) as shown in the
figure.
Refitting
The new part has to be of the same supply as the
Fit the clutch assembly back on by performing the operations
described for removal in reverse order and observing the ! pressure plate being reused.
following instructions:
- Thoroughly clean the supporting surface of the
clutch plate of the engine flywheel with spirits
or petrol. Any light scoring you find on it can
be removed with abrasive cloth.
- Position the driven disc, always using the guide pin for
perfect centring to prevent harmful stresses on the hub
when refitting the gearbox.
- Position the clutch plate by matching the holes for the
fixing screws with the ones on the engine flywheel.
- Mount and lock the fixing screws of the pressure plate
to the required torque.
EUROTRAKKER CURSOR 13 CLUTCH 11

5026 CLUTCH DISENGAGEMENT CONTROL

(vehicles with ZF 16 S 151/181/221
O.D. gearboxes) Figure 9

502601 REMOVING-REFITTING THE

PEDAL UNIT
Removal
Figure 7

38806

Remove the bracket (1) stopping the brake pedal.

Take out the three screws (2) fixing the control valve to the
pedal unit.

38804

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Remove the walls (1) of the drive control system (2) of the
pedal unit.
Take out the screws fixing the steering assembly to the pedal
unit and lay down the assembly. Figure 10

38807
Figure 8
Lift the radiator cowling, disconnect the pipes (4-6) from the
splitter control button (5).
Disconnect the clamps (3) fixing the cables or pipes to the
pedal unit (1). Take the control valve (2) off the pedal unit.
Disconnect the electrical connection of the master cylinder
(6) and remove this, together with the oil tank, from the pedal
unit (1).
Take out the fixing screws (->) and detach the pedal unit (1).

38805 Refitting
Remove the bracket (1) stopping the clutch pedal. For refitting, carry out the steps described for removal in
Take out the screws (2) fixing the master cylinder to the reverse order. Then adjust the travel of the pedals as
pedal unit. described under the relevant heading.
12 CLUTCH EUROTRAKKER CURSOR 13

PEDAL UNIT

REMOVAL-ASSEMBLY
The roller bearings and associated shafts have to be
(see Figure 11) lubricated with TUTELA MR3 grease.
!
Take out the springs (11) to return the pedals (13-15). Complete assembly by carrying out the steps
Eject the spring pins (7) so as to free the levers (1 and 2) from performed for removal in reverse order.
the pedals (13 and 15), which you should then extract from
the pedal unit mount (18). To replace the roller bearings (9),
use:
- the percussion extractor 99340205 to remove them;
- a suitable drift to fit them.

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Figure 11

38808

1. Brake control lever - 2. Clutch control lever* - 3. Roller bearings - 4. Pin - 5. Fork - 6. Master cylinder* - 7. Spring pin - 8.
Splitter control button* - 9. Roller bearings - 10. Washer - 11. Return spring - 12. Pedal cover - 13. Clutch pedal - 14. Control
valve - 15. Brake pedal - 16. Brake pedal limit stop screw - 17. Brake pedal stop bracket - 18. Pedal unit mount - 19. Clutch
pedal stop bracket - 20. Clutch pedal limit stop screw*
* Excluding vehicles with the Euro Tronic 16 AS 2601 O.D. gearbox.
 EUROTRAKKER CURSOR 13
CHECKING AND ADJUSTING STOPS ON CLUTCH PEDAL
(vehicles with ZF 16 S 151 O.D./181 O.D./221 O.D. gearboxes)
Figure 12
A
32.5 mm
Clutch stop
Check the distance A between the pedal unit mount (1) and
the end of the screw (2). It has to be 32.5 mm, turn the screw
appropriately if it is not.
Idle travel of clutch pedal
Work the clutch pedal (8) to take the cap (6) into contact
with the piston (5) of the master cylinder.
In this condition, check the distance B between the clutch
pedal (8) and the screw (7) that has to be 1 - 2 mm, turn the
screw (5) appropriately if it is not.
The distance B corresponds to the clearance of 0.5 - 1 mm
between the cap (6) and the piston (5) in the condition of
the clutch pedal (9) in contact with the screw (7).
CLUTCH 13
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B
39696
Pedal control valve stroke
After adjusting the position of the bottom and top stop,
adjust the travel of the piston of the pedal control valve (in
the case of the ZF gearbox).
Take the clutch pedal (8) into contact with the bottom stop
screw (2) and keep it in this position.
Press the button of the control valve (3) fully down and,
keeping it pressed, position the angle bracket (4) so that
between it and the button there is a distance of 0.5 - 1 mm.
This is to prevent the pedal control valve from stopping the
clutch pedal.
 14 CLUTCH EUROTRAKKER CURSOR 13

HYDRAULIC CONTROL
(vehicles with ZF 16 S 151 O.D./181 O.D./221 O.D. gearboxes)
The hydraulic control is composed of:
- master cylinder with oil reservoir built in;
- operator cylinder with full recovery of driven disc wear.

Figure 13

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VIEW OF THE MASTER CYLINDER

Figure 14

CROSS-SECTION OF THE CLUTCH ACTUATOR

 EUROTRAKKER CURSOR 13 CLUTCH 15

5052 CLUTCH ACTUATOR FOR ZF 16 S 151

O.D./181 O.D./221 O.D. GEARBOXES
Fitting and adjusting the clutch wear indicator
Figure 18

Figure 15

61276

Cut off the rear section of the plastic rod (1).

61273

Take out the plastic rod, rubber seal and metal clamp.
Turn the ”worn clutch” mark (3) on the new actuator from

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the rest position to 90º anticlockwise or clockwise; it depends
on the clutch supplier.
Position 1: wear/travel (Valeo) 25 mm.
Figure 19

Figure 16

61277

61274 Insert the plastic rod (1) as far as the actuator clamp.
Insert the plastic rod (1) against the actuator clamp.
Push the seal (2).

Figure 17 When the clutch plate wears, the plastic rod moves
! towards the mark.
If replacing the clutch, it is necessary to mount a new
wear indicator kit, setting it as described above.

61275
Retract the plastic rod (1) away from the actuator, the rubber
seal (2) must not move.
Lock the seal (2) with the metal clamp (3).
16 CLUTCH EUROTRAKKER CURSOR 13

505272 Push rod adjustment 505272 Push rod adjustment

(new clutch) (vehicles with PTO opt. 2395 only)
Figure 20 Figure 21

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42095

35537

With the actuator (1) removed, check that the

Carry out the following operations: distance ”V” of the push rod (4) is:
Measure the distance (A) between the bottom of the - 66 mm for Valeo clutches.
spherical cavity of the clutch lever and the actuator If this is not so, adjust it and lock the lock nut (3).
fixing surface. Press the spherical push rod to reach
the stop (C). Mount the actuator.
Loosen the nut (D).
Screw or unscrew the push rod (F) to obtain the From the opening (2), unscrew the push rod (5) to
distance (B). take the piston inside the actuator up against the
stop (G).
B = A-E Position the lock nut (6) at a distance ”E” from the
stem of the push rod (5) of:
E = 25 mm - 25 mm for Valeo clutches.

It is necessary to observe this adjustment to make the
worn plate indicator trip, which is located in the
!
operator cylinder close to the complete wear of the
friction linings.
The plate wear (90% of the friction material) is
indicated by a significant increase in load on the pedal
when disengaging the clutch.
Screw the push rod (5) down into contact with the
lock nut (6) and without moving the push rod and
lock the lock nut.
BLEEDING THE AIR FROM THE CLUTCH
CIRCUIT
After repairing the components, the hydraulic circuit or when
periodically changing the oil, bleed the air from the hydraulic
clutch control circuit.
For this purpose, use the deaerator 99306010 and the bleed
valve on the operator cylinder.
 EUROTRAKKER CURSOR 13
5052 CLUTCH ACTUATOR FOR THE EUROTRONIC 16 A S 2601 O.D. GEARBOX
505272 Clutch actuator push rod adjustment (new clutch)
Figure 22
The operator cylinder is equipped with a device to
automatically recover the clearance due to the wear
of the clutch plate. Therefore, it must only be
! adjusted when replacing the clutch plate or the
clutch actuator (6).
Push the lever (1) down fully so as to cancel the disengaging
travel with no load.
In the above conditions, measure the distance (A) between
the bottom of the spherical cavity of the clutch lever and the
clutch actuator (6) fixing surface of the box (2).
Extract the push rod (composed of parts 3, 4, 5) from the
clutch actuator (6).
Unscrew the plug (7) to discharge the air under pressure
from the piston so that the spring inside the working piston
moves forwards as far as the stop.
Measure the distance B = distance between the front edge
of the tapered front portion of the clutch actuator (6) and
the fixing surface of the actuator.
Measure the distance C = depth of the tapered front portion
of the piston.
Measure the length L of the push rod that has to be:
L = A - (B - C) + D
A-B-C = measurements made
D = 33 mm, fixed value of the maximum stroke of the
actuator. If you find a different value, loosen the nut (4) and
use parts (3 and 5) to obtain the calculated length.
Tighten the nut (4) to a torque of 52 Nm (5.2 kgm) and fit
the push rod back into the actuator (6).
CLUTCH 17
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72138
Fitting the clutch actuator
Discharge the air under pressure from the actuator (6) by
unscrewing the plug (7).
Move the piston of the actuator (6) back, overcoming the
reaction of the spring, as far as its stop.
Screw the plug (7) back on to keep the piston in the retracted
position.
Lubricate the spherical cavity of the lever (1) with TUTELA
MR2 and position the push rod (3) in it.
Fasten the clutch actuator (6) to the front box (2), checking
that the push rod (3) goes inside correctly and tighten the
nuts to the required torque.
Unscrew the plug (7) so that the internal spring of the
actuator (6) pushes the piston forwards and tighten the plug
(7) to the required torque.
Hook up the electrical connector and the compressed air
supply pipe.
Replacing the clutch actuator
Not having to replace the push rod (3), mount the new
actuator as described in the above paragraph, without
altering the distance L of the push rod (3).
Before connecting the air pipe, check that the clutch
! actuator (6) is correctly secured to the front box (2).
Lubricate the indicated points (→) with TUTELA MR2.
!
18 CLUTCH EUROTRAKKER CURSOR 13

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