manual de servicio 02 eaton.pdf

5/26/2018 Manual de servicio 02 EATON.pdf

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For the most current information, visit the Roadranger web site at www.roadranger.com

Solo Heavy Duty 15.5"

Solo Medium Duty 14" 1401 and 1402Easy Pedal Plus 14 "

Easy Pedal 2000 15.5"

Eaton Fuller Clutches

Stamped Angle Spring Service Manual CLSM -1282 October2002


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General Information

Notes, Cautions, and Warnings

WARNING: Follow the specified procedures in the indicatedorder to avoid personal injury.

CAUTION: Follow the specified procedures in the indicatedorder to avoid equipment malfunction or damage.

Note: Additional relevant information not covered in the ser-vice procedure.

Repair Warnings

The major cause of clutch failure is excessive heat. Excessiveheat generated between the flywheel, driven discs, intermedi-ate plate and pressure plate can cause the metal to flow andthe material to be destroyed. If this occurs, the clutch can

burst which can cause property damage, serious bodily injuryor death. In order to prevent clutch failure resulting fromexcessive heat:

1. Do not exceed recommended vehicle loads.

2. The clutch should only be used for the recom-mended applications.

3. Drivers should be properly trained in starting, shift-ing and operation of the clutch.

4. Drivers should report erratic clutch operation assoon 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 andother maintenance troubleshooting procedures out-lined in the Failure Analysis Guide and the EatonFuller Solo Clutch Troubleshooting Guides.

When disassembling various assemblies, lay all parts on aclean bench in the same sequence as removed to simplify andreduce the possibility of losing parts.

Since the cost of a new part is generally a small fraction of thecost of downtime and labor, avoid reusing a questionable partthat could lead to additional repairs and expense.

Use of other than recommended tools, parts, and instructionslisted in this manual may place the safety of the service tech-nician or vehicle driver in jeopardy.

The removal and installation procedure described for eachcomponent may vary for your vehicle.

For service information and assistance anywhere in NorthAmerica please call 1-800-826-4357, 24-hours a day. Phonelines are manned by leading specialists in the areas of engi-neering, marketing, distribution, troubleshooting, productspecification, installation and maintenance. You may also findmore information about Eaton Fuller Clutches on our web site:www.roadranger.com.

Every effort has been made to ensure the accuracy of theinformation contained in this manual. However, Eaton Corpo-ration makes no warranty, expressed or implied, based on theinformation provided.


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Table of Contents

Introduction

Preventive Maintenance Overview .............................................................................................................................. 1Designing a Clutch for a Specific Application ............................................................................................................. 3Function of a Clutch ................................................................................................................................................... 4Factors that Effect Clutch Performance ...................................................................................................................... 8

Service Procedures

Eaton Fuller Solo Heavy Duty 15.5" Clutches ............................................................................................................ 11Solo Heavy Duty 15.5" Clutch - Remove .................................................................................................................. 13Solo Heavy Duty 15.5" Clutch - Install ...................................................................................................................... 15Eaton Fuller Solo Medium Duty 1401 Clutches ........................................................................................................ 25Solo Medium Duty 1401 Clutch - Remove ............................................................................................................... 27Solo Medium Duty 1401 Clutch - Install .................................................................................................................. 29

Eaton Fuller Solo Medium Duty 1402 Clutches ........................................................................................................ 37Solo Medium Duty 1402 Clutch - Remove ............................................................................................................... 39Solo Medium Duty 1402 Clutch - Install .................................................................................................................. 41Eaton Fuller Easy Pedal 15.5" Clutches ..................................................................................................................... 51Easy Pedal 15.5" Clutch - Remove ........................................................................................................................... 53Easy Pedal 15.5" Clutch - Install ............................................................................................................................... 55Eaton Fuller Easy Pedal Plus 14" Clutches ................................................................................................................ 65Easy Pedal 14" Clutch - Remove .............................................................................................................................. 67Easy Pedal 14" Clutch - Install .................................................................................................................................. 69Eaton Fuller Stamped Angle Spring 1401 Clutches .................................................................................................. 79Stamped Angle Spring 1401 Clutch - Remove ......................................................................................................... 81Stamped Angle Spring 1401 Clutch - Install ............................................................................................................ 83Eaton Fuller Stamped Angle Spring 1402 Clutches .................................................................................................. 91Stamped Angle Spring 1402 Clutch - Remove ......................................................................................................... 93Stamped Angle Spring 1402 Clutch - Install ............................................................................................................ 95Heavy Duty Resetting Overview ............................................................................................................................. 103Solo Heavy Duty Clutch - Resetting ....................................................................................................................... 105Medium Duty Resetting Overview .......................................................................................................................... 107Medium Duty Solo Clutch - Resetting .................................................................................................................... 109


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1

Preventive Maintenance

Preventive Maintenance Overview

To ensure long life and proper operation of the release mecha-nism of the clutch, it is important to properly lubricate the fol-lowing areas.

Lubrication

1. Release Bearing- The cast iron bearing housing willbe equipped with either a standard grease fitting or alube tube extension. If a lube tube is not present, it isnecessary to remove the inspection cover to gainaccess to the grease fitting. Apply grease until itpurges from the rear of the housing. Grease on theclutch brake friction surface and the transmissioninput shaft will extend the life of the clutch brake andbronze bushings inside the release sleeve.

2. Release Bearing Wear Pads- Where the release forkcontacts the bearing housing, there are small hard-ened steel pads. Apply a small amount of grease tothe wear pads where the clutch release fork contacts.

3. Clutch Brake- The clutch brake friction material isdesigned to operate with lubricant. While lubricatingthe release bearing, grease should purge from thehousing and contact the clutch brake. This is benefi-cial for long clutch brake life. If desired, a smallamount of grease could be applied to both sides ofthe clutch brake.

4. Cross-Shaft Bushings- Lubricate both the left andthe right cross-shaft bushings per OEM recommen-dations.

5. Clutch Control Linkage- Lubricate the clutch linkagebell cranks and pivot pins per OEM recommenda-tions.

6. Pilot Bearing- The pilot bearing inside the flywheelis a sealed for life bearing and requires no lubrica-tion. Use a premium pilot bearing to prevent clutchdrag and early bearing failures. (C-3, C-4, C-5 Suffix)

Lube Tube Assembly

The Eaton Fuller Lube Tube Assembly enables the releasebearings in Eaton Fuller medium and heavy duty clutches tobe greased without removing the bell housing inspectioncover. The Lube Tube Hose replaces the original zerk fitting onthe release bearing and protrudes through the bell housingwindow.

Lube Tube Lengths

Length in Inches Part Number

12" CLT012

9" CLT009

8" CLT008

7" CLT007

6" CLT006


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2

Preventive Maintenance

Recommended Lubrication

Use a l ithium soap base E.P. (Extreme Pressure) grease with aminimum of +325 degree F operating range. It must meet theN.L.G.I.s Grade 1 or 2 specs.

CAUTION: Incorrect grease and improper lube procedures willcause bearing failures, bushing wearout, yoke tip and bearingwear pad wear.

Lubrication Interval

Sealed Type

With the Solo Maintenance-Free Clutch, there is no need forlubrication. The following information does not apply.

Greasable Type

Stamped Angle Spring 1401 and 1402Solo Medium Duty 1401 and 1402

On-Highway - Every 10,000 miles (16,000 Km) oronce per month.

Off highway/severe service -Every 250 hours oronce per month.

Solo Heavy Duty

On-Highway - Every 25,000 miles (40,000 Km) oronce per month [Solo XL = 50,000 miles (80,000Km)].

Off highway/severe service - Every 250 hours oronce per month.

Easy-Pedal Plus 14 and Easy-Pedal 2000 15.5

On-Highway - Every 20,000 miles (32,186 Km) oronce per month.

Off highway/severe service - Every 250 hours oronce per month.

For additional lubrication information See TCMT-0021 or call1-800-826-HELP (4357).

Supplier Product

American Oil Co. Amoco Uthium-M.P. Grease

City Service Co. Citgo Premium Lithium Grease#2

Fiske Refining Co. Lubnplate 630-2

Keystone Lubricating Co. #81 Ught

Mobil Mobilgrease M.P.

Humble Oil Co. Udok 2

Atlantic Richfield Co. Arco M.P.

Texaco Multifak #2

Shell Oil Co. Retinax A

Shell Oil Co. Aivania #2

*Chevron Oil Co. S.R.I. 1~

*Texaco Premium RB

*Exxon Unirex N3

* Approved for vendor prepack, other greases listed are forservice only.


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3

General Information

Designing a Clutch for a Specific Application

There are three parts to designing a clutch for a specific appli-cation. If the correct clutch is chosen, the truck will have goodengagement, protection for the driveline, long clutch life, andminimal loss of torque.

1. Check the Flywheel Bore (15.5" Clutch) - The fly-wheel environment must be checked to make sure aclutch can be used with it. The bore is importantwhen deciding what type of driven disc to use. Thebore must be large enough to allow for a proper fit ofthe disc. See chart below.

2. Torque Capacity - A clutch must be chosen that hasa torque capacity that is greater than or equal to thepeak torque of the engine. This is very importanttoday when an engine can be easily adjusted elec-tronically to produce greater torque. There are twofactors in determining torque capacity. These two

factors are friction force and damper capacity.

Friction force is a product of the cover assem-blies clamp load (also called plate load). Thisfactor was explained in the previous section,and is stated as F(f) = uNPr. Determining thefriction force is important because if this force isnot greater than or equal to the peak torque ofthe engine, the clutch will slip.

Damper capacity is what allows the clutch toprovide torsional protection for the entire drive-line. If the peak engine torque exceeds this

capacity, the driveline will be abused. This abusewill cause faster wear and possible destructionof driveline components. Since damper capacityis a product of the springs used in the damper,changing the number and type of springschanges the stiffness of the entire system.

3. Application - Service replacement clutches shouldhave the same plate loads, damper and friction mate-rial. Substituting from the original could shorten thelife of the clutch and drivetrain components.

# of Springs Bore size8 spring 7 1/4" (184.15mm)10 spring 8 9/16" (217.48mm)7 spring 9 3/4" (247.65mm)9 spring(Mack eng only)9 3/4" (247.65mm)6 spring 9 3/4" (247.65mm)

Measurebore size

Engine Flywheel


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4

General Information

Function of a Clutch

Any modern day clutch, whether designed for an automobileor heavy truck, performs several important tasks allowing forsafe and convenient operation of the vehicle.

In a vehicle powertrain, the clutch is the device that interruptsthe flow of power from the engine flywheel to the transmis-sion. To start a gasoline or diesel engine, the flywheel must beable to turn freely without propelling the vehicle. By disengag-ing the clutch, the drivetrain is effectively disconnected fromthe rotation of the flywheel allowing the engine to start.

Manual transmissions, whether synchronized (synchromesh)or non-synchronized (constant mesh), require an interruptionof engine torque to complete a gear change. To make a gearchange, the clutch pedal is depressed, breaking toque. This is

followed by altering engine speed to more closely match thetransmission input shaft (clutch disc) speed. After the propergear is selected, the clutch pedal is then slowly released. Asthe clutch disc(s) are compressed, the relative slip speedbetween the flywheel and the transmission input shaft reacheszero and the clutch is completely engaged and capable of car-rying full engine torque. With non-synchronized gearboxes,double clutching (a momentary partial engagement of theclutch made while the transmission is in neutral) is often nec-essary to allow rotational speeds of gears to become thesame and complete the gear change.

With the advent of transmission automation, breaking torque

and altering flywheel speed is accomplished via electronicthrottle control and engine braking. The clutch pedal is usedonly when starting the engine, launching the vehicle from astop, and when the vehicle slows to a stop.

The last function of the clutch is mitigating torsional vibra-tions. With any in-line, six-cylinder engine there are three (3)distinct power pulses occurring during each revolution of theflywheel. With each firing of a cylinder, the flywheel speeds upthen slows down, very quickly, resulting in a torsional vibra-tion. This vibration can damage drivetrain components inshort order if left uncontrolled. The coil springs in a drivendisc damper absorb much of the vibration. The resonant (gen-erally the least expensive drivetrain component) is consideredthe fuse of the system. Failure of a clutch damper section isusually an indication of a serious torsional vibration systemsproblem or shock loading due to driver abuse.

Clutches are assemblies made up of many different compo-nents utilizing many different types of materials. This sectiondescribes the major components which make up a completeEaton Fuller Clutch installation.

The following are the major components used to make up aclutch installation:

Cover Assembly (contains pressure plate)

Intermediate Plate (only in 2-plate clutches)

Driven Disc(s)

Clutch Brake

Solo Clutches

The Eaton Fuller Solo is the industrys first adjustment-freeclutch. With every push of the pedal, Solos innovative wear-adjusting technology senses for wear and makes any adjust-

ments necessary.

Why There is No Need to Adjust Eaton FullerSolo

Clutches

If the Solo Clutch is properly installed and the linkage is set-up properly, the Solo Clutch should never need internal orexternal adjusting.

The Solo Clutch automatically keeps the proper release bear-

ing position and clutch free pedal position with two opposingcams. As the Solo Clutch wears, the cams separate from eachother keeping the proper release bearing position. This in turnmaintains the proper clutch free pedal position.

How it Works

Eaton Fuller Solos wear-adjusting technology comes fromtwo sliding cams. With every push of the pedal, the clutchsenses for wear and makes any adjustments necessary. Thecams rotate to maintain the proper adjustment throughout thelife of the clutch. On top of the upper cam, a clutch wear indi-cating tab mirrors the cams movement to let you know whenits time to replace the clutch. The result of Solos constantadjustment is greater longevity and a reduction in mainte-nance and labor costs.


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5

General Information

Clutch Disc Dampening Characteristics

A key function of a clutch is to mitigate naturally occurringvibrations of the engine flywheel from reaching the transmis-sion and the other components further down the drivetrain.This is accomplished by employing torsional spring dampersto the clutch pack. These springs take the form of coil springs,configured inside the clutch disc, that compress with theapplication of torque. The torque path through the damperbegins at the friction, interface at the facings, proceeds to thesteel carrier disc and moves into the disc reinforcing plateswhere the springs are located. The springs are compressed,transmitting force to the spring covers which are rigidlyattached to the hub. Torsional rate is defined as the amount oftorque required per degree of center hub rotation. There arethree basic categories of torsional rates for clutch dampers:rigid, standard, soft.

Rigid and Clutch Discs - Rigid discs and clutch discs with nospring package whatsoever, act as a nearly direct link from theengine flywheel to the transmission and offer no protectionagainst torsional vibration. Their use should be limited toolder mechanically-fueled engines where clutch replacementcost is paramount over long component life. Rigid clutchdiscs are never used in new OEM applications.

Standard Dampers - Standard dampers include all 10-springand most 8- spring types. The springs used in these dampersare approximately 1.5" long and do not offer a large amount ofdeflection before coil lock takes place. While these dampers

were completely adequate for most heavy duty applicationsseveral years ago, they are generally incapable of reducing theengine flywheel vibrations developed with slow speed elec-tronically fueled engines. The use of standard dampers inheavy duty applications has virtually ceased in OEM applica-tions. The trend is to use more capable soft-rate dampers.

Soft-Rate Dampers - Soft-rate dampers, like the heavy duty 6and 7-spring types, offer much better protection againstengine flywheel induced torsional vibration. Their springs arecharacteristically longer than springs used in standard ratedampers and offer more deflection before coil lock occurs.This larger spring deflection is equated to lower torsionalspring rate. With lower torsional rate, the resonant frequencyof the complete drivetrain is lowered; usually to a point of afew hundred RPM below normal engine operating range. Withthe addition of hysteresis or Coulomb dampening (the energyexpelled as the damper is exercised), the magnitude of thevibrations is reduced further, adding to the dampers benefit.

Clutch Disc Friction Material

Organic facings, often called rag facings, get their namefrom the high concentration of organic rubber and binderagents that make up their composition. Fiberglass cord (orsimilar material) is woven into the material matrix and addsburst strength and improves friction and wear properties.Asbestos has not been used in organic friction material sincethe early 1980's. Organic facings are used without exceptionin passenger car and light truck applications. This is sobecause of smooth engagement properties and the relativelight torque loads imposed on the clutch. In general, organicfriction material lacks in performance in wear rate, coefficientof friction (ability to carry torque), and resistance to fade(abuse tolerance) when compared to cera-metallic frictionmaterial. The use of organic friction material in heavy vehicleshas significantly declined over the past decade. Wear life and

its maximum limit to 1,400 ft. lbs. (1892 Nm) of torque in15.5" clutches are the primary reasons.

Cera-metallic (Ceramic) friction facings are composite mate-rial (copper, sand and other friction modifiers and binderagents). The dry raw materials are mixed in bulk, poured intodie cavities, compressed, sintered in an controlled atmo-sphere, then brazed into a steel backer plate to facilitate rivetattachment to the driven disc. Compared to organic frictionmaterial, cera-metallics have improved performance in theareas of wear rate, resistance to fade (abuse tolerance), andcoefficient of friction (ability to carry torque). It is for this rea-son that cera-metallics make up the vast majority of OEM

builds.

Clutch Slippage

Slippage will cause significant heat build-up and rapid wear ofthe clutch pack. If the clutch pack temperature raises beyondthe facing threshold temperature, the facing may disintegrate.Slippage is the result of loss of clamp load due to lack ofadjustment, loading the clutch beyond its design torque rat-ing, or the clutch has reached the end of its design life. Withthe ability to re-rate an electronic controlled diesel engine, it isquite easy to delivery torque to the clutch beyond its designcapacity. Before an engine re-rating is performed, confirm thatthe clutch and other drivetrain components are capable of car-rying the increased torque and power.


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General Information

Clutch Torque Capacity

It is imperative to understand the factors that influence fric-tion force because this device transmits torque via friction.The fundamental equations that describes friction is:

F(f) = uN

Where F(f) = Force due to friction

U = Coefficient of friction

N = Load applied to the friction interface

T = F(f)r

Since torque (T) is equal to force friction F(f) multiplied by the

moment arm (R) (distance from application of force to centeror rotation) must be known. To exactly calculate the momentarm, the mean radius of a clutch (R), integration must be per-formed. However, for clutches in the size range offered byEaton, the calculation can be simplified to:

(r) = (ID + OD) / 4

Clutch Wear

Clutch wear happens because the clutch discs slip relative tothe engine flywheel and the pressure plate surface, and in the

case of a two plate clutch, the intermediate plate, during vehi-cle launch and gear change. As the clutch disc friction mate-rial and mating flywheel and pressure plate surfaces wear, thegage thickness of the clutch pack decreases (moving thepressure plate closer to the engine flywheel). This movementof the pressure plate causes the pressure spring(s) to elon-gate and loose clamping load. If clamping load is allowed todecrease beyond a critical point, the clutch will be unable tocarry full engine torque and slip.

Cover Assembly

The cover assembly, constructed of either stamped steel orcast iron, is bolted to the flywheel. It contains the pressureplate, which is fitted to the cover with pressure springs. It alsocontains the release bearing and levers, which move the pres-sure plate back and forth, thereby making or breaking contactwith the disc assembly.

Driven Disc

Eaton offers a variety of 14" and 15.5" driven disc designs. Theselection of driven discs depends on many factors.

Excessive torsional vibration can significantly reduce the lifeof all drivetrain components. Thats why Eaton has engineeredsoft-rate dampers to reduce critical vibrations in todays elec-tronic, high horsepower engines. Eaton recommends the useof soft-rate dampers (7-spring or 6-spring V.C.T.) for all vehi-cles over 1,000 ft. lbs.

Specifically, Eaton offers driven discs with different numbersof springs in the center section of the damper. 6, 7, 8, 9 and10-spring configurations are available. The proper selectiondepends on many factors including the engine, flywheel andtransmission of the vehicle.

Facings

The disc facings are critical to clutch life and performancebecause they directly receive the torque of the engine eachtime the clutch is engaged.

In general, ceramic facings have greater heat tolerance andtorque capacity than organic facings. As such, they engagequicker, reduce slippage and deliver longer life.

Organic facings (non-asbestos) are adequate for lower horse-

power, on-highway applications. However, Eaton recom-mends ceramic facings for most applications.

Intermediate Plate

The intermediate plate or center plate, increases the torquecapacity of the clutch by providing additional surface area forfacing material and torque capacity. The intermediate plate isdriven by the clutch cover or by the flywheel on the 14" Easy-Pedal Plus design.

Positive Separator Pin

Eaton Fullers Positive Pin Separator improves clutch life andperformance by providing cooler operation, smootherengagement and equal plate separation. The pin restrictsintermediate plate movement when the clutch is released, giv-ing constant gap on both sides of the plate, therefore, allow-ing the driven discs to spin freely.


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General Information

6-Position Kwik-Adjust

Eaton Fullers Easy-Pedal Plus 14" and Easy-Pedal 200015.5" Clutches feature the Kwik-Adjust component and theeasy-to-reach external manual adjustment mechanism thatallows for quick adjustment of release bearing travel withoutthe use of special tools or the need to remove any bolts. Usinga common box end wrench, simply depress the Kwik-Adjustbolt and turn the standard 6-point hex head adjustor asneeded.

Clutch Brakes

Clutch brakes are designed to extend the life of a vehiclestransmission by eliminating damaging gear clash while reduc-ing the effort required to shift into first or reverse from astandstill. Eaton offers two separate clutch brake options.

Torque Limiting

Kwik-Konnect

Torque Limiting Clutch Brake

The Eaton Fuller Torque Limiting Clutch Brake has a self-con-tained torque limiting feature which prevents tang breakagefrom driver misuse of the clutch brake.

127740: 1.75" spline

127760: 2" spline

Kwik-Konnect Two-Piece Clutch Brake

The two-piece clutch brake provides cooler operation thancompetitive clutch brakes. It is designed for service applica-tions, and can be quickly installed without removing the trans-mission.


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General Information

Factors that Effect Clutch Performance

Excessive slipping is the major cause of clutch failure.Extreme operating temperatures can cause the clutch to failbecause the heat generated between the flywheel, drivendiscs, intermediate plate, and pressure plate is high enough tocause the metal to flow and the friction material to bedestroyed.

An improperly adjusted or slipping clutch will produce suffi-cient heat to rapidly burn up.

There are many factors which have significant impact onclutch life:

Application (torque capacity)

GCW/Weight

Number of starts per day

Maintenance/Adjustment

1. Starting the Vehicle in the Proper Gear -The cor-rect gear will allow you to start the vehicle with yourfoot off the throttle.

2. Gear Shifting Techniques - Many drivers upshiftinto the next gear or even skip-shift into a highergear before the vehicle has reached the properspeed. This type of shifting is almost as damaging asstarting off in a gear that is too high, since theengine speed and vehicle speeds are too far apart,

requiring the clutch to absorb the speed differenceas heat.

3. Excessive Vehicle Overload or Overloading theClutch - Clutches are designed and recommendedfor specific vehicle applications and loads. Theselimitations should not be exceeded. Excessive orextreme overloading is not only damaging to theclutch but to the entire vehicle powertrain as well. Ifthe total gear reduction in the powertrain is not suffi-cient to handle excessive overloads, the clutch willsuffer, since it is forced to pick up the load at ahigher speed differential.

4. Do Not Ride the Clutch Pedal - Riding the clutch isvery destructive to the clutch since a partial clutchengagement permits slippage and excessive heat.Riding the clutch pedal will also put a constant thrustload on the release bearing, which can thin out thelubricant and also cause excessive wear on the pads.Release bearing failures can often be attributed tothis type of operation.

5. Do Not Slip the Clutch to Hold the Vehicle on anIncline - This procedure uses the clutch to do the job

normally expected of the wheel brakes. A slippingclutch accumulates heat faster than it can be dissi-pated, resulting in early failures.

6. Do Not Coast with the Clutch Released and Trans-mission in Gear - This procedure can cause highdriven disc RPM through multiplication of ratiosfrom the final drive and transmission. It can result inthrowing the facing off the clutch discs. Drivendisc speeds of over 10,000 RPM have been encoun-tered in such simple procedures as coasting tractorsdown an unloading ramp. While an ample safety fac-tor is provided for normal operation, the burststrength of the facing is limited.

7. Do Not Engage the Clutch while Coasting -This

procedure can result in tremendous shock loads andpossible damage to the clutch, as well as the entiredrivetrain.

8. Reporting Erratic Clutch Operation Promptly - Driv-ers should report erratic clutch operation as soon aspossible, to give the maintenance personnel achance to make the necessary inspection, internalclutch adjustment, linkage adjustment and lubrica-tions, thereby avoiding possible clutch failures andbreakdowns while on the road. The importance offree pedal travel (sometimes referred to as a pedallash) should be brought to the drivers attention as

well as the mechanic. This item should be includedand commented on daily in the drivers report, sinceclutch free pedal is the maintenance personnelsguide to the condition of the clutch and the releasemechanism.

9. Clutch Adjustments - Manual Adjustment- Theimportance of proper and timely clutch adjustmentsand lubrication can not be over stated. Internallyadjusting the clutch properly and when needed willkeep the clutch components in the proper positionand extend the life of the clutch. See the adjustmentsection for more information.

Solo Adjustmen-Free If your truck is equipped withan Eaton Fuller Solo Adjustment-Free Clutch, thenthe clutch will always be in proper adjustment. Pos-sible lubrication and inspection are needed. SeeInspection and Lubrication.


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General Information

When to Inspect the Clutch

The clutch should be inspected during the regularly scheduledlubrication intervals as dictated in the Lubrication section orwhen one of the following occur:

Clutch Free Pedal - If the clutch free pedal is one-half of OEM specifications, not less than one-halfinch. During normal clutch use, the release bearingwill move toward the fork fingers and reduce incab free pedal.

Clutch Is Slipping - If the clutch is slipping, it mayrequire adjustment. If proper internal (clutchadjuster) and external (clutch linkage) adjustmenthas been made and the clutch still slips, it is likelyworn beyond its useful life and needs replacement.

Inspection for Clutch Life

If your vehicle is equipped with a Eaton Fuller Solo or Solo XL(Extended Lube) Clutch, the clutch is equipped with a clutchwear indicating tab that can be seen through the inspectionwindow. To calculate the expected life of a Solo, apply a paintmark indicating the start point of the clutch wear indicatingtab. Record the mileage when this mark was made. After a fewmonths, reinspect the position of the clutch wear indicatingtab and record the new mileage. The difference between thetwo readings can be used to estimate when the clutch willneed to be replaced.

For Example:

Starting Mileage = 10,000

After six (6) months mileage = 75,000

Clutch wear indicating tab movement = .625" (16 mm)

75,000-10,000 = 65,000 miles

65,000 miles/.625" = 104,000 miles per inch of tab movement

3.5" remaining tab movement

3.5" remaining tab movement X 104,000 miles per inch of tabmovement = 364,000 expected clutch life.


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General Information


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Service Procedure

Eaton Fuller Solo Heavy Duty 15.5" Clutches

Special Instructions

Eaton Fuller Solo XL and Maintenance-Free Clutches require aspecially designed release yoke (97-509-10-1X). The RollerYoke can only be used with Solo XL and Maintenance-Freetype clutches. Eaton recommends that any time a new SoloMaintenance-Free Clutch or a Solo Extended Lube Clutch isinstalled that a new roller yoke also be installed. Eaton Fullerservice part numbers 109705-xxY 109706-xxY and 109710-xxY include the roller yoke.

Eaton Fuller Standard Heavy Duty Solo 109701-xx uses astandard yoke 105C137 or equivalent.

Note the position of the wear indicating tab on the clutch. Ifthe tab is near the "REPLACE" position, the clutch should bereplaced.

CAUTION: When fully assembled, the 15.5" clutch weighsapproximately 150 pounds (68 kg). A hydraulic clutch jack isrecommended.

Specifications

Use C3 - C4 Pilot Bearing

Torque clutch to flywheel mounting bolts 4050 ft.lbs. (54-68 Nm)

Required Tools

Basic Hand Tools

Clutch Jack

Essential Steps

If a Solo Clutch is to be removed and reinstalled on the fly-wheel, four (4) shipping bolts must be installed prior tounbolting the clutch (7/16" x 14 UNC x 1- 3/4").

Verify diameter of the flywheel bore (this is the recessed areafor the flywheel mounting bolts). The damper spring sectionmust fit inside the opening.

10-spring driven discs require 8.56" (219 mm) dia.

(minimum)

6-spring (V.C.T.) driven discs require 9.75" (248mm) dia. (minimum)

7-spring driven discs require 9.75" (248 mm) dia.(minimum)

9-spring driven discs require 9.75" (248 mm dia.(minimum) (Mack Engines Only)

ENGINE Clutch Transmission


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Service Procedure

Clutch Exploded View

DrivenDisc

EngineF

lywheel

Flywheelbore

Intermedia

tePlate

DrivenDisc

TOTUR

N

DEPRESSBOLT

ClutchAssembly


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Service Procedure

Solo Heavy Duty 15.5" Clutch - Remove

Procedure-

1. Remove the transmission, supporting its weight to pre-vent damage to the bearing and discs.

Note: If a Solo Clutch is to be removed and reinstalled onthe flywheel, four (4) shipping bolts must beinstalled prior to unbolting the clutch (7/16" x 14UNC x 1- 3/4").

2. Locate four (4) 7/16" x 14 x 1- 3/4" UNC, hex headmachine screws. Install them in the 4 cover holes, turn-ing them one complete turn after they contact the cover.

3. Remove the clutch from the flywheel.

Note: Mark the proper position of the discs and interme-diate plate (for reinstallation).


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Service Procedure

(4) 7/16" x 14 x 1-3/4" UNC

Solo Heavy Duty 15.5 Clutch Removal

2

Locate 4 Hex HeadMachine Screws

1

Remove the Trans-

mission


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Service Procedure

Solo Heavy Duty 15.5" Clutch - Install

Procedure-

1. Remove the old pilot bearing and wipe all surfaces thatwill contact the gauging.

2. Secure the dial indicator to the flywheel housing with thegauge finger near the outer edge of the flywheel.

3. Use a soapstone to mark the high and low spots as yourotate the flywheel one (1) revolution. The differencebetween these two spots should be .008" (0.2 mm) orless.

4. With the dial indicator still secured to the flywheel hous-ing, continue the inspection process by moving thegauge finger so it contacts the pilot bearing bore surface.

5. Rotate the flywheel one (1) revolution. The maximumallowed run out must be .005" (0.13 mm).

6. Secure the dial indicator to the crankshaft with the gaugefinger against the flywheel housing pilot area.

7. Use a soapstone to mark the high and low spots whileyou rotate the flywheel one (1) revolution. The total dif-ference between the high and low spots should be .008"(0.2mm) or less.

8. Secure the dial indicator to the flywheels outer diameterand move the gauge finger until it contacts the face of theflywheel housing.

9. Use a soapstone to mark the high and low spots whileyou rotate the flywheel one (1) revolution. The total dif-ference between the high and low spots should be .008"(0.2mm) or less.

CAUTION: If the above four (4) limits are exceeded, theproblem must be corrected. Misalignment will causedamper failure and wear to drivetrain components.

10. Install a new pilot bearing. Eaton strongly recommendsthe use of a premium grade pilot bearing. The bearingmust have a press fit.

CAUTION: Tap on the outer race only. Tapping the innerrace could cause damage to the pilot bearing.


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16

Service Procedure

4

Place Gauge Finger inContact With Pilot

Bearing Bore

2

Secure Indicator toFlywheel Housing

6

Secure the Dial Indi-cator to Crankshaft

8

Secure Dial Indicatorto Flywheels Outer

Diameter

3

Use a Soapstone to

Mark High and LowSpots

1

Wipe All SurfacesThat Will Contact

Gauging

5

Rotate Flywheel OneRevolution

7

Mark High and LowSpots While Rotating

Flywheel One Turn

9


Flywheel One Turn

10

Install a New Pilot

Bearing

Heavy Duty 15.5 Clutch Installation


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17

Service Procedure

Solo Heavy Duty 15.5" Clutch - Install, Cont

11. Check the following items for wear and replace any worncomponents:

a. Cross-shafts and bushings

Note: Excessive wear at these points can cause a sideloading condition onto the sleeve bushing of the newlyinstalled Solo Clutch. Consequently, this condition cancause the bushing to walk-out of the sleeve. Also,inspect the remaining pivot points of the linkage forexcessive wear.

b. Release yoke fingers

c. Transmission bearing retainer cap

Note: A worn/rough bearing retainer cap may cause the

newly installed clutch brake to wear prematurely. Also,excess wear at either the transmission bearing retainercap (arrow C) and/or the release yoke fingers (arrow B)may prevent the linkage from obtaining a suffcientamount of clutch brake squeeze (Recommended rangeis 1/2" 1" (13 24 mm). Refer to arrow G concerningthe nominal distance between the input shafts end andthe bearing retainer cap.

d. Splines on the input shaft

Note: Any wear on the splines will prevent the newlyinstalled driven discs from sliding freely, thus causing

poor release (clutch drag). Select a disc out of the newinstallation and slide it full length on the transmissionsplines. This will detect a twisted input shaft. Replaceinput shaft if disc does not freely slide.

e. Smooth area of input shaft

Note: Wear/roughness in this area can cause the sleevebushing of the newly installed Solo to walk-out afteronly a few miles of operation.

f. Mating surfaces

Note: Inspect the mating surfaces of both the transmis-sion bell housing and the flywheel housing. Any apprecia-ble wear on either housing will cause misalignment. Mostwear will occur between the 3 and 8 oclock positions.Replace housings if worn.

12. Install a new Eaton Fuller Clutch Brake at this time.

13. Verify diameter of the flywheel cavity (this is the recessedarea for the flywheel mounting bolts). The damper springsection must fit inside the opening.




9-spring driven discs require 9.75" (248 mm) (MackEngines Only)


21/116

18

Service Procedure

C

B

11BCheckRelease Yoke Fingers

A

11A

Check Cross-Shaftsand Bushings

11C

Check TransmissionBearing Retainer Cap

D

11D

Check Splines on theInput Shaft

E

11E

Check Smooth Areaof Input Shaft forWear/Roughness

Solo Heavy Duty 15.5 Clutch Installation


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19

Service Procedure


14. Insert two (2) 7/6" x I4 UNC x 5" (127 mm) long guidestuds into the two upper mounting holes of the flywheel.

15. Insert the aligning tool through the release bearing sleeveof the new clutch.

Note: With the Solo Maintenance-Free Clutch, place inputshaft sleeve on alignment shaft.

16. Make sure to position one of the driven discs onto thealigning tool with the stamp Intermediate Plate Sidefacing the intermediate plate.

Note: Steps 16 and 18 show the specific procedures forinstalling our 7-spring driven discs. When install-

ing either the 9- or 10-spring driven discs, followthe instructions stamped on the front and reardiscs to ensure their proper orientation toward theflywheel (front disc) and pressure plate (reardisc). Installing the disc(s) backwards or switch-ing the front and rear discs with each other willprevent the clutch from functioning properly (i.e.does not release or cannot obtain proper adjust-ment). The 6-spring driven disc does not requireany special orientation because: 1.) The front andrear discs are the same part number and 2.) Thesediscs are symmetrical (mirror image). As a result,there are no instructions (concerning disc orienta-

tion) stamped on the 6-spring drive disc.

17. With the stamp Flywheel Side facing the flywheel, placethe intermediate plate into the four (4) slots of the clutchcover.

18. Make sure to position the second driven disc onto thealigning tool with the stamp Intermediate Plate Sidefacing the intermediate plate.

WARNING: When fully assembled, the 15.5" clutchweighs approximately 150 pounds (68 kg). A hydraulicclutch jack is recommended.

19. Position the clutch over the two (2) guide studs and slideit forward until contact is made with the flywheel surface.

Note: Be sure that the aligning tool pilot is inserted intothe pilot bearing. Failure to do this may result inthe driven discs not being centered, causing diffi-cult transmission installation.


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20

Service Procedure

Guide Studs

15

Insert the AligningTool Through Release

Bearing Sleeve

14

Insert 2 Guide Studs

16Place Disc on Align-

ing Tool ProperlyOrientated

18

Place Second Disc onAligning Tool Properly

Orientated

19

Place Clutch Over 2Guide Studs and Slide

Forward

17Place Intermediate

Plate ProperlyOrientated

Solo Heavy Duty 15.5" Clutch Installation


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21

Service Procedure


20. Start six (6) 7/16" x 14 UNC x 2 1/4" (57 mm) Grade 5 orbetter mounting bolts with lock washers and tightenthem finger-tight. Remove the two (2) guide studs andreplace them with the two (2) remaining mounting bolts/lock washers.

21. Starting with the lower left-hand bolt, progressivelytighten the eight (8) mounting bolts in a criss-cross pat-tern until you achieve a final torque of 4050 ft. lbs. (54-68 Nm).

CAUTION: Failure to tighten these bolts in this mannercan:

Prevent the clutch cover from centering into thepilot area of the flywheel.

Cause permanent damage to the clutch cover (i.e.become cracked or broken).

Cause the clutch assembly to be out-of balance withthe flywheel.

22. Remove the four (4) yellow colored shipping bolts in acriss-cross pattern.

Note: Save these four (4) bolts for future use in case youneed to remove, then reinstall the Solo Clutch.

23. Remove the aligning tool.

24. Using a 1/4" (6 mm) diameter flat nose punch, lightly tapeach of the four (4) Positive Separator Pins toward theflywheel. Performing this step will verify that all four (4)pins are flush against the flywheel.

Note: Failure to perform this step properly may cause theclutch to drag (clutch does not release). Excessiveforce can damage the pins and cause a releaseproblem.

Note: The four (4) pins can also be set through theinspection opening of the transmission bell hous-ing if they were not to set prior to transmissioninstallation.


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22

Service Procedure

8

1 5

3

7

26

4

21

Tighten MountingBolts in a Criss-

Crossing Manner

22

Remove the 4 Ship-ping Bolts

24

Tap Separator PinsUntil Flush Against

Flywheel

20

Start 6 MountingBolts and Replace the

2 Guide Bolts

23

Remove Aligning Tool

21

Torque MountingBolts to 40-50 ft. lbs.



26/116

23

Service Procedure


25. Shift the transmission into gear and verify that a newEaton Fuller Clutch Brake has been installed.

26. Position the transmission so that it is both square to andaligned with the engine.

27. While moving the transmission forward, rotate the outputshaft of the transmission until the splines of both theinput shaft and the disc(s) mesh with each other. Whileperforming this task, you must also ensure that the yokefingers remain in the up position until they can be rotatedover the release bearing housing into their final position.

Note: Do not use the cross-shaft release lever (or a pipeover it) to pull the transmission into its final posi-

tion. Doing so may release the clutch and over-stroke the release bearing. The Solo willincorrectly set the release bearing position tooclose to the transmission and cause the wear indi-cating tab to move to 1/31/2 the distancetowards the REPLACE position.

Note: Do not excessively force the transmission into theclutch assembly or engine housing. If it does notenter freely, investigate the cause of the problemand make any necessary changes.

Note: If the input shaft will not slide into the discs, they

may need to be repositioned. If the clutch is to beunbolted from the flywheel, re-install the shippingbolts and tighten one turn past contact with theclutch. Now the installation shaft can be installedto reposition the discs and the clutch bolts re-torqued. Remove the shipping bolts to clamp thediscs.

Note: Do not let the transmission drop or hang unsup-ported in the driven discs. This can cause thediscs to become distorted and the clutch will notrelease.

28. Install the transmission mounting bolts and torque to theproper specification.

29. Adjust the linkage until the fingers of the release yokecontact the release bearing wear pads. You should havezero free play at the clutch pedal when this step has beencompleted.

30. Fully depress the clutch pedal a minimum of five (5)times. As a result, you should gain free play at the clutch

pedal and the wear indicating tab on the clutch shouldslightly move away from the NEW position.

31. If the release bearing does not squeeze the clutch brakewhen the pedal is down, adjust the linkage to move theyoke to zero clearance and depress the pedal five (5)times.

Note: With the pedal up, the release bearing should be.490" .560" (12.4 14.2 mm) from the clutchbrake when properly set up. With the pedal down,contacting the clutch brake ensures:

1. The Solo has adjusted fully to its new environment.

2. The linkage is capable of pulling the bearing far

enough to obtain clutch brake squeeze.


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24

Service Procedure

SHIFT INTO GEAR

26

Align the Transmis-sion with the Engine

Release Yoke(Clutch Pedal in UP Position)

Transmission

Clutch BrakeClutch Cover

Finger

Wear Pad( With NO free Play)

29

Adjust the Linkage

25

Shift the Transmis-sion into Gear

STROKEPEDAL5 TIMES

30

Fully Depress ClutchPedal 5 Times

27

Mesh Input Shaft andDisc(s) by Rotating

Output Shaft



28/116

25

Service Procedure

Eaton Fuller Solo Medium Duty 1401Clutches

Special InstructionsEaton Fuller Solo XL and Maintenance-Free Clutches require aspecially designed release yoke (97-509-10-1X). The RollerYoke can only be used with Solo XL and Maintenance-Freetype clutches. Eaton recommends that any time a new SoloMaintenance-Free Clutch or a Solo Extended Lube Clutch isinstalled that a new roller yoke also be installed. Eaton Fullerservice part numbers 109410-xY 109507-xxY and 109508-xxY include the roller yoke.

Non XL, Maintanence-Free and Eaton Fuller Medium DutySolo uses a standard yoke 105C137 or equivalent.


When fully assembled, the 14 Clutch weighs approximately70 pounds. A hydraulic clutch jack is recommended.

Specifications



Required Tools Basic Hand Tools

Clutch Jack

Essential Steps


Verify diameter of the flywheel cavity (this is the recessed areafor the flywheel mounting bolts). The damper spring sectionmust fit inside the opening.



29/116

26

Service Procedure


ClutchAssembly

DrivenDisc

D

rivenDisc

IntermediatePlate

EngineFlywhe

el

FlywheelBore


30/116

27

Service Procedure

Solo Medium Duty 1401 Clutch - Remove

Procedure-



2. Locate four (4) 3/8" x 16 x 1 1/4" UNC, hex head machinescrews. Install them in the 4 cover holes, turning themone complete turn after they contact the cover.


Note: Mark the proper position of the discs and interme-diate plate adapter ring (for reinstallation).


31/116

28

Service Procedure

(4) 3/8" x 16 x 1-1/4" UNC

Solo Medium Duty 1401 Clutch Removal

1

Remove the Trans-

mission

2

Located 4 Hex HeadMachine Screws


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29

Service Procedure

Solo Medium Duty 1401 Clutch - Install

Procedure-







7. Use a soapstone to mark the high and low spots whileyou rotate the flywheel one (1) revolution. The total dif-ference between the high and low spots should be .008"(0.2 mm) or less.



Note: If the above four (4) limits are exceeded, the prob-lem must be corrected. Misalignment will causedamper failure and wear to drivetrain components.


Note: Tap on the outer race only. Tapping the inner racecould cause damage to the pilot bearing.


33/116

30

Service Procedure

1


Gauging

2


3

Use a Soapstone toMark High and Low

Spots

4


Bearing Bore

5


6


7


Flywheel One Turn

8


Diameter

9


Flywheel One Turn

10

Install a New PilotBearing

Solo Medium Duty 1401 Clutch Installation


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31

Service Procedure

Solo Medium Duty 1401 Clutch - Install, Cont






Note: This applies only if a clutch brake is used (non-syn-

chronized transmission). A worn/rough bearing retainercap may cause the newly installed clutch brake to wearprematurely. Also, excess wear at either the transmissionbearing retainer cap (arrow C) and/or the release yokefingers (arrow B) may prevent the linkage from obtaininga sufficient amount of clutch brake squeeze (Recom-mended range is 1/2" 1" (13 24 mm). Refer to arrow Gconcerning the nominal distance between the inputshafts end and the bearing retainer cap.


Note: Any wear on the splines will prevent the newly

installed driven discs from sliding freely, thus causingpoor release (clutch drag). Select a disc out of the newinstallation and slide it full length on the transmissionsplines. This will detect a twisted input shaft. Replaceinput shaft if disc does not freely slide.



f. Mating surfaces


12. Install a new Eaton Fuller clutch brake at this time.

Note: This applies only if a clutch brake is used (non-syn-chronized transmission).

13. Verify diameter of the flywheel cavity (this is the recessedarea for the flywheel mounting bolts). The damper springsection must fit inside the opening and not interfere withflywheel mounting bolts.


35/116

32

Service Procedure

C

B


A

11A


11C


D

11D


E

11E




36/116

33

Service Procedure


14. Insert two (2) 3/8" x 16 thread x 3" (76 mm) long guidestuds into the two upper mounting holes of the flywheel.

Note: Refer to the label on the Solos shipping box to ver-ify that the clutchs maximum torque rating isgreater than the engines peak torque rating. Pre-mature-failure (a slipping clutch) will occur if theengines toque rating exceeds that of the clutch.

15. Install the disc by inserting the aligning tool through thedisc splines and then into the pilot bearing.

Note: Make sure the side marked Pressure Plate Sidefaces the pressure plate.

16. With the aligning tool still in place, carefully slide theclutch assembly over the aligning tool and the two (2)guide studs.

17. Start six (6) 3/8" Grade 5 or better mounting bolts andhand tighten. Remove the two (2) guide studs andreplace with the remaining mounting bolts. Using atorque wrench, progressively tighten the eight (8) mount-ing bolts to 30 35 lbs. ft. (40 47 Nm) of torque usingthe following criss-cross pattern. Starting at the lowerleft.

Note: Failure to tighten these bolts in this manner can:


Cause permanent damage to the clutch cover (i.e.become cracked or broken).

Cause the clutch assembly to be out-of balance with

the flywheel.




20. Shift the transmission into gear and verify that a newEaton Fuller Clutch Brake has been installed if so

equipped.


37/116

34

Service Procedure

8

1

5

3

7

26

4

Aligning Tool

Guide Studs

15

Install the Disc Usingthe Aligning Tool

14


18

Remove the 4 Ship-ping Bolts

SHIFT INTO GEAR

19

Remove the AligningTool

17

Start 8 MountingBolts Replacing the 2

Guide Studs

16

Slide Clutch Assem-bly Over Aligning Tool

and Guide Studs

20

Shift the Transmis-sion into Gear



38/116

35

Service Procedure


21. Position the transmission so that it is both square to andaligned with the engine.


CAUTION: Do not use the cross-shaft release lever (or apipe over it) to pull the transmission into its final posi-tion. Doing so may release the clutch and overstrokethe release bearing. The Solo will incorrectly set therelease bearing position too close to the transmission

and cause the wear indicating tab to move to 1/31/2 thedistance towards the REPLACE position.

CAUTION: Do not excessively force the transmission intothe clutch assembly or engine housing. If it does notenter freely, investigate the cause of the problem andmake any necessary changes.

CAUTION: If the input shaft will not slide into the discs,they may need to be repositioned. If the clutch is to beunbolted from the flywheel, re-install the shipping boltsand tighten one turn past contact with the clutch. Nowthe installation shaft can be installed to reposition the

discs and the clutch bolts re-torqued. Remove the ship-ping bolts to clamp the discs.

CAUTION: Do not let the transmission drop or hangunsupported in the driven discs. This can cause the discsto become distorted and the clutch will not release.


24. Position a pipe (or similar tool) over the crossshaftrelease lever and rotate it until the release bearing comesto a complete stop. Repeating this procedure a total offive (5) times will ensure that the Solo adjusts fully to itsnew environment.

25. If the truck has a mechanical linkage system, reconnectthe linkage and adjust it until you obtain a yoke gap rangeof .062 .125" (2 3 mm). If the truck has a hydrauliclinkage system, consult the truck manufacturers servicemanual.

26. If the truck is equipped with a clutch brake, verify that theclutch brake is being squeezed approximately 1/2" (13mm) from the bottom of the clutch pedal stroke. If youcannot obtain any clutch brake squeeze, you will need toincrease the overall clutch pedal travel, (use the adjust-able pedal stop) and then readjust the linkage to againobtain a free pedal range of .062 .125" (2 3 mm).

27. Grease the release bearing until grease purges from therear of the release bearing (toward transmission) andflows onto the transmission shaft.


39/116

36

Service Procedure

22

Mesh Splines of InputShaft and Disc(s)

Using Output Shaft27

Grease the ReleaseBearing

21

Align Transmissionwith Engine



40/116

37

Service Procedure

Eaton Fuller Solo Medium Duty 1402Clutches

Special InstructionsEaton Fuller Solo XL and Maintenance-Free Clutches require aspecially designed release yoke (97-509-10-1X). The RollerYoke can only be used with Solo XL and Maintenance-Freetype clutches. Eaton recommends that any time a new SoloMaintenance-Free Clutch or a Solo Extended Lube Clutch isinstalled that a new roller yoke also be installed. Eaton Fullerservice part numbers 109410-xY 109507-xxY and 109508-xxY include the roller yoke.

Non XL, Maintenance-Free and Eaton Fuller Medium DutySolo uses a standard yoke 105C137 or equivalent.


CAUTION: When fully assembled, the 14 Clutch weighsapproximately 100 pounds. A hydraulic clutch jack is recom-mended.

Specifications


Torque clutch to flywheel mounting bolts 3035 ft.

lbs. (40-47 Nm)

Required Tools Basic Hand Tools

Clutch Jack

Essential Steps


Verify diameter of the flywheel cavity (this is the recessed areafor the flywheel mounting bolts). The damper spring sectionmust fit inside the opening.



41/116

38

Service Procedure


ClutchAssembly

DrivenDisc

D

rivenDisc

IntermediatePlate

EngineFlywh

eel

FlywheelBore


42/116

39

Service Procedure

Solo Medium Duty 1402 Clutch - Remove

Procedure-



2. Locate four (4) 3/8" x 16 x 1 1/4" UNC, hex head machinescrews. Install them in the 4 cover holes, turning themone complete turn after they contact the cover.




43/116

40

Service Procedure

(4) 3/8" x 16 x 1-1/4" UNC

Solo Medium Duty 1402 Clutch Removal

1

Remove the Trans-

mission

2

Locate Four Hex HeadMachine Screws


44/116

41

Service Procedure

Solo Medium Duty 1402 Clutch - Install

Procedure-














45/116

42

Service Procedure


1


Gauging

2


3


Spots

4


Bearing Bore

5


6


7


Flywheel One Turn

8


Diameter

9


Flywheel One Turn

10



46/116

43

Service Procedure







Note: This applies only if a clutch brake is used (non-syn-

chronized transmission). A worn/rough bearing retainercap may cause the newly installed clutch brake to wearprematurely. Also, excess wear at either the transmissionbearing retainer cap (arrow C) and/or the release yokefingers (arrow B) may prevent the linkage from obtaininga sufficient amount of clutch brake squeeze (Recom-mended range is 1/2" 1" (13 24 mm). Refer to arrow Gconcerning the nominal distance between the inputshafts end and the bearing retainer cap.


Note: Any wear on the splines will prevent the newly

installed driven discs from sliding freely, thus causingpoor release (clutch drag). Select a disc out of the newinstallation and slide it full length on the transmissionsplines. This will detect a twisted input shaft. Replaceinput shaft if disc does not freely slide.



f. Mating surfaces


12. Install a new Eaton Fuller Clutch Brake at this time.

Note: This applies only if a clutch brake is used (non-syn-chronized transmission).

13. Verify diameter of the flywheel cavity (this is the recessedarea for the flywheel mounting bolts). The damper springsection must fit inside the opening and not interfere withflywheel mounting bolts.


47/116

44

Service Procedure

C

B


A

11A


11C


D

11D


E

11E


Solo Medium Duty1402 Clutch Installation


48/116

45

Service Procedure


14. Insert two (2) 3/8" x 16 thread x 3" (76 mm) long guidestuds into the two upper mounting holes of the flywheel.

Note: Refer to the label on the Solos shipping box to ver-ify that the clutchs maximum torque rating isgreater than the engines peak torque rating. Pre-mature-failure (a slipping clutch) will occur if theengines toque rating exceeds that of the clutch.

15. Install the front disc by inserting the aligning tool throughthe disc splines and then into the pilot bearing.

Note: Make sure the side marked Flywheel Side facesthe flywheel.

16. Install the intermediate plate assembly over the two (2)guide studs and slide it forward until it touches the fly-wheel.

Note: Make sure the side marked Pressure Plate Side isfacing the pressure plate (the drive straps mustface the pressure plate).

17. Remove the aligning tool and install it through the splinesof the rear disc, and insert the aligning tool through thefront disc and also the pilot bearing.

Note: Make sure the side of the disc marked PressurePlate Side is facing the pressure plate. As youcomplete this step, ensure that the ceramic but-tons align with each other as closely as possible.Doing so will aid the function of the positive sepa-rator pins (roll pins).

18. With the aligning tool still in place, slide the cover assem-bly over both the aligning tool and the two (2) guidestuds until it rests against the intermediate plate assem-bly.

19. Start six (6) 3/8" x 2.44" (10 x 62 mm) Grade 5 or bettermounting bolts and hand tighten. Remove the two (2)guide studs and replace with the remaining mountingbolts. Using a torque wrench, progressively tighten theeight (8) mounting bolts to 30 35 ft. lbs. (40 47 Nm)of torque using the following criss-cross pattern.

Note: Failure to tighten these bolts in this manner can:


Cause permanent damage to the clutch cover (i.e.

become cracked or broken).

Cause the clutch assembly to be out-of balance withthe flywheel.


49/116

46

Service Procedure

Aligning Tool

Guide Studs

14


15

Place Disc on Align-ing Tool Properly

Orientated

Buttons

18

Slide Cover Assem-bly Over Aligning Tool

and Guide Studs

8

15

3

7

26

4

19

Start 8 MountingBolts Replacing the 2

Guide Studs

17

Remove Aligning Tool

16Place Intermediate

Plate ProperlyOrientated



50/116

47

Service Procedure





22. Using a 1/4" (6 mm) diameter flat nose punch, lightly tapeach of the four (4) Positive Separator Pins toward theflywheel. Performing this step will verify that all four (4)pins are flush against the flywheel.

CAUTION: Failure to perform this step properly maycause the clutch to drag (clutch does not release). Exces-

sive force can damage the pins and cause a release prob-lem.

Note: The four (4) pins can also be set through theinspection opening of the transmission bell hous-ing if they were not to set prior to transmissioninstallation.

23. Shift the transmission into gear and verify that a newEaton Fuller Clutch Brake has been installed if soequipped.

24. Position the transmission so that it is both square to and

aligned with the engine.


CAUTION: Do not use the cross-shaft release lever (or apipe over it) to pull the transmission into its final posi-tion. Doing so may release the clutch and overstrokethe release bearing. The Solo will incorrectly set therelease bearing position too close to the transmissionand cause the wear indicating tab to move to 1/31/2 thedistance towards the REPLACE position.

CAUTION: Do not excessively force the transmission intothe clutch assembly or engine housing. If it does notenter freely, investigate the cause of the problem andmake any necessary changes.

CAUTION: If the input shaft will not slide into the discs,they may need to be repositioned. If the clutch is to beunbolted from the flywheel, re-install the shipping boltsand tighten one turn past contact with the clutch. Nowthe installation shaft can be installed to reposition thediscs and the clutch bolts re-torqued. Remove the ship-ping bolts to clamp the discs.

CAUTION: Do not let the transmission drop or hangunsupported in the driven discs. This can cause the discsto become distorted and the clutch will not release.


51/116

48

Service Procedure

ACCESS HOLE

ROLLPIN

CLUTCH COVER

21

Remove the AligningTool

22Tap Separator PinsUntil They are Flush

Aginst Flywheel

SHIFT INTO GEAR

24

Align Transmissionwith Engine

20

Remove the 4Shipping Bolts

23

Shift Transmissioninto Gear

25

Mesh Splines of InputShaft and Disc(s)

Using Output Shaft



52/116

49

Service Procedure



27. Position a pipe (or similar tool) over the cross shaftrelease lever and rotate it until the release bearing comesto a complete stop. Repeating this procedure a total offive (5) times will ensure that the Solo adjusts fully to itsnew environment.

28. If the truck has a mechanical linkage system, reconnectthe linkage and adjust it until you obtain a yoke gap rangeof .062 .125" (2 3 mm). If the truck has a hydrauliclinkage system, consult the truck manufacturers servicemanual.

29. If the truck is equipped with a clutch brake, verify that theclutch brake is being squeezed approximately 1/2" (13mm) from the bottom of the clutch pedal stroke. If youcannot obtain any clutch brake squeeze, you will need toincrease the overall clutch pedal travel, (use the adjust-able pedal stop) and then readjust the linkage to againobtain a free pedal range of .062 .125" (2 3 mm).

30. Grease the release bearing until grease purges from therear of the release bearing (toward transmission) andflows onto the transmission shaft.


53/116

50

Service Procedure

1/2" - 1"(13 - 25mm)

RELEASE YOKE

CROSS SHAFT

FINGER

CLUTCH

TRANSMISSIONA

B

Free Pedal Range.062" - .125"(2mm - 3mm)

29

Adjust Free Pedal

30

Grease the ReleaseBearing

28

Adjust LinkageAppropriately



54/116

51

Service Procedure

Eaton Fuller Easy Pedal 15.5" Clutches

Special Instructions

CAUTION: When fully assembled, the 14" clutch weighsapproximately 150 pounds (68 kg). A hydraulic clutch jack isrecommended.

Specifications



Required Tools

Basic Hand Tools

Clutch Jack

Essential Steps

Follow the instructions stamped on the discs to insure correctorientation.

Verify diameter of the flywheel bore (this is the recessed areafor the flywheel mounting bolts). The damper spring sectionmust fit inside the opening.




9-spring driven discs require 9.75" (248 mm dia.(minimum) (Mack Engines Only)




55/116

52

Service Procedure


DrivenDisc

EngineFlywheel

Flywheelbore

Intermedia

tePlate

DrivenDisc

TOTUR

N

DEPRESSBOLT

ClutchAssembly


56/116

53

Service Procedure

Easy Pedal 15.5" Clutch - Remove

Procedure-


2. Install two wooden spacers 1/2 - 5/8 thick betweenrelease bearing and cover assembly.




57/116

54

Service Procedure

Easy Pedal 15.5 Clutch Removal

1

Remove the Trans-

mission


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Service Procedure

Easy Pedal 15.5" Clutch - Install

Procedure-














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Service Procedure

Easy Pedal 15.5" Clutch Installation

1


Gauging

2


3


Spots

4


Bearing Bore

5


6


7


Flywheel One Turn

8


Diameter

9


Flywheel One Turn

10



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Service Procedure

Easy Pedal 15.5" Clutch - Install, Cont



Note: Excessive wear at these points can cause a sideloading condition. Also, inspect the remaining pivotpoints of the linkage for excessive wear.



Note: A worn/rough bearing retainer cap may cause thenewly installed clutch brake to wear prematurely. Also,excess wear at either the transmission bearing retainercap (arrow C) and/or the release yoke fingers (arrow B)

may prevent the linkage from obtaining a sufficientamount of clutch brake squeeze (Recommended rangeis 1/2" 1" (13 24 mm). Refer to arrow G concerningthe nominal distance between the input shafts end andthe bearing retainer cap.


Note: Any wear on the splines will prevent the newlyinstalled driven discs from sliding freely, thus causingpoor release (clutch drag). Select a disc out of the newinstallation and slide it full length on the transmissionsplines. This will detect a twisted input shaft. Replace

input shaft if disc does not freely slide.


f. Mating surfaces


12. Verify diameter of the flywheel cavity (this is the recessedarea for the flywheel mounting bolts). The damper springsection must fit inside the opening.





9-spring driven discs require 9.75" (248 mm)


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Service Procedure

C

B


A

11A


11C


D

11D


E

11E


Easy Pedal 15.5" Clutch Installation


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Service Procedure

Easy Pedal 15.5" Clutch - Install, Cont

13. Insert two (2) 7/6" x I4 UNC x 5" (127mm) long guidestuds into the two upper mounting holes of the flywheel.

14. Insert the aligning tool through the release bearing sleeveof the new clutch.

15. Put the rear driven disc on the aligning tool, following thedirections stamped on the disc. If discs are incorrectlyinstalled, the clutch will not release and damage to thedisc may occur.

Note: Follow the instructions stamped on the discs toinsure correct orientation.

6 Spring/V.C.T.: both discs are identical and can beinstalled in any direction.

7 Spring: Both discs are identical but

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