CLUTCH

SECTION CL
CONTENTS
SPECIAL SERVICING TOOLS .......................................................................................................................... CL - 3
DESCRIPTION AND OPERATION ....................................................................................................................CL - 4
CLUTCH SYSTEM ............................................................................................................................................CL - 5
INSPECTION AND ADJUSTMENT ..................................................................................................................CL - 6
HYDRAULIC CLUTCH CONTROL - Clutch Pedal ............................................................................................CL - 7
HYDRAULIC CLUTCH CONTROL - Mastet cylinder........................................................................................CL- 8
HYDRAULIC CLUTCH CONTROL - Slave cylinder ..........................................................................................CL - 9
CLUTCH PLATE AND PRESSURE ASSEMBLY ................................................................................................CL-11
TECHNICAL DATA AND CHARACTERISTICS ................................................................................................CL-15
CL

CL-1
 SPECIAL SERVICING TOOLS

ENGINE APPLICATION
REFERENCE NUMBER NAME
TD-27 T BD-30 Ti

ST 166 - 10001 Pilot bush extractor

— X

ST 200 - 50240 Spanner for adjusting stitches on

diaphragm spring

X X

NIE-7012 Clutch assembly centerer

X X

GG 943-10000 Flare nut torque wrench for flexible

hoses and metal pipes in clutch
and braking systems X X

ST 200 - 50010 Base plate

X X

ST 200 - 50100 Spacer

X X

KV 301 - 00100 Bar for aligning clutch

X X

CL-3
 DESCRIPTION AND OPERATION

The clutch in these vehicles is of the diaphragm, single dry-plate type.

The clutch plate is flexible with torsion damping springs.
The clutch is hydraulically controlled with the aid of a master cylinder connect-
ed and a slave cylinder of the following characteristics.
- Self-adjustable; model DD-240 HR, for the CABSTAR.E-95.
- Manually adjustable; model DD-240 HR, for the CABSTAR.E-120.
This type of clutch is simpler to maintain since it is adjustable.
It has the following advantages:
- Greater reliability since a smaller number of parts are subject to centrifugal
force.
- Pressure spread more evenly.
- Pressure force maintained even when worn.
- Smoother distribution of the movement force curve.

Functional schematic of the press

0032CL ENGAGED

Functional schematic of the press

DISENGAGED
0034CL

CL-4
 CLUTCH SYSTEM

11

5
6

2
7

8
9 10

0043CL
COMPONENTS
1. Reservoir 7. Thrust bearing assembly
2. Master cylinder 8. Slave cylinder
3. Pedal 9. Fork
4. Pipe and hose 10. Fork fixing nut
5. Plate assembly 11. Return spring
6. Clutch pressure assembly

CL-5
 INSPECTION AND ADJUSTMENT

Clutch pedal adjustment

1. Check that when the pedal is at rest, it is in contact with the stop screw (1)
MODELS WITHOUT EXHAUST BRAKE
(models without exhaust brake) or with the microswitch (2) (models with
5 4 exhaust brake).
2. Adjust height “H” of the pedal with the stop screw (1) or the microswitch (2),
depending on whether or not the vehicle is fitted with an exhaust brake.
Height “H” of pedal = 150 mm (5.90 inches)
3. Tighten the lock nut (3).
1
Clutch pedal stop lock nut (3):
12÷15 Nm (1.2÷1.5 kgm; 8.9÷11.1 ft lbs)

4. Adjust de length of rod (4) so that the pedal play (due to the play in the pin
area) is:
)
8,5 (0,335 3 1÷2 mm (0.039÷0.078 inches)

5. Tighten the lock nut (5).

Unit: mm (inches) Thrust link lock nut
0107FE
16÷22 Nm (1.6÷2.2 kgm; 11.8-16.2 ft lbs)

MODELOS CON FRENO MOTOR • Check that the assembly functions smoothly and without interference.
• Check that the clutch pedal returns instantly to its rest position when it is released.
5 4
6. Make sure that the microswitch (2) (models with exhaust brake) allows the
electrical current to flow when the clutch pedal is at rest (released).

) BLEEDING THE HYDRAULIC CLUTCH SYSTEM

8,5 (0,335
3
1. Follow these steps:
• Carefully monitor the level of fluid in the reservoir during this operation.
H • During bleeding, do not reuse extracted fluid.
• Take care not to splash clutch fluid onto the bodywork, since it attacks paint.

a. Fill the reservoir with the recommended fluid.

Unit: mm (inches) See “RECOMMENDED FUEL, LUBRICANTS AND LIQUIDS” in Section MA of
0109FE
this manual.
b. Fit a transparent plastic tube to the air bleed nipple on the slave cylinder.
c. Fully depress the clutch pedal several times.
d. With the pedal fully depressed, loosen the bleed nipple to remove any air
from the system.
e. Tighten the bleed nipple.
f. Repeat steps (c) to (e) above until fluid without bubbles exits from the tube.

0035CL

CL-6
 HYDRAULIC CLUTCH CONTROL - Clutch Pedal

Removal and fitting

DISASSEMBLY
1. Remove the cotter pin (1) from the stud.
2 2. Remove the master cylinder thrust link (2) from the pedal.
3. Remove the nut (3) and remove the return spring (4) and pedal (5).
1
3

INSTALLATION
4
1. Fit the clutch pedal by reversing the removal procedure.
2. Apply a light coating of grease to the moving parts and the return spring.

0106CL 3. Hold the return spring inside the hole in the pedal bracket and tighten the
pedal stud nut firmly.
4. Insert the stud from left to right.

Fixing nut of pedal pin:

20÷23 Nm (2.0÷2.3 kgm; 14.8÷17.0 ft lbs).

Nut fixing clutch pedal bracket to cab floor:

9÷11 Nm (0.9÷1.1 kgm; 6.6÷8.1 ft lbs).
5. After fitting the pedal, check its height and, if necessary, adjust it; see
“INSPECTION AND ADJUSTMENT - Adjustment of clutch pedal” in this
section.

CL-7
HYDRAULIC CLUTCH CONTROL - Master cylinder

Removal and Fitting

REMOVAL
• Do not disassemble the clutch master pump. Change as a complete assembly if it
does not operate properly.
1. Remove the pin from the thrust rod and remove it from the master cylinder.
2. Disconnect the pipe joining the master and slave cylinders from the master
cylinder and drain the fluid.
• Use a special spanner for connectors to disconnect the clutch pipe.
Never use a normal fixed or adjustable spanner.
• Place a suitable container to collect the clutch fluid when disconnecting the pipe. It
is also recommended that a cloth be used to prevent splashing the surrounding
parts.
3. Disconnect from the master cylinder the hose connecting it to the reservoir.
• Never remove the reservoir. If it must be removed, replace it with a new one.
4. Loosen and remove the nuts joining the master cylinder to its bracket and
remove the master cylinder.

FITTING
Fit the clutch master cylinder by reversing the disassembly process.
Check the following points:
1. Bleed the air from the clutch system. See “INSPECTION AND ADJUSTMENT
- Bleeding the hydraulic clutch system” in this section.
2. Adjust the height of the clutch pedal. See “INSPECTION AND ADJUSTMENT
- Adjustment of clutch pedal” in this section.

Bolts fixing master cylinder to pedal bracket:

12-14 Nm (1.2-1.4 kgm; 8.9÷10.3 ft lbs)
Clutch pipe connector:
20-24 Nm (2.0-2.4 kgm; 14.8-17.7 ft lbs)

• When connecting the pipe, use the pre-adjusted connector spanner.

• When tightening the connector, hold the pipe with your other hand to prevent it
from bending.

CL-8
 HYDRAULIC CLUTCH CONTROL - Slave cylinder

Removal and fitting

REMOVAL
• Do not disassemble the slave cylinder. Change as a complete assembly if it does not
operate properly.
1. Loosen and remove the connector (1) which fixes the clutch fluid supply pipe
DD-240HR (TD-27T) (2) to the slave cylinder.
2 2. Remove the bolts (3) that fix the slave cylinder to the clutch casing.
3. Remove the slave cylinder from the vehicle.

0471EM

DD-240HR (BD-30 Ti)

3 1

0031CL

CL-9
 HYDRAULIC CLUTCH CONTROL - Slave cylinder

Removal and fitting (Cont’d)

FITTING
To install, reverse the removal procedure, taking into account the following:
Model DD-240 HR
TD-27T ENGINE

TD-27T ENGINE 1. Position the slave cylinder (1) in the bracket, and insert the stem (2) in the
recess of the clutch fork (3).
1 2
4 2. Tighten the slave cylinder to the clutch casing at the specified torque.

Bolts (6) fixing slave cylinder:

45÷50 Nm (4.6÷5.1 kgm; 33.2÷36.9 ft lbs)

Fixture of hose to slave cylinder:

17÷20 Nm (1.7÷2.0 kgm; 12.5÷14.8 ft lbs)
3
0012CL
BD-30 Ti ENGINE
1. Position the slave cylinder (1) in the bracket and insert the stem (2) in the
BD-30 Ti ENGINE recess of the clutch fork (3) – the round nut (4) should not push the fork.
2. Tighten the slave cylinder to the clutch casing at the specified torque.
1 6 5 4 2
Bolts (6) fixing slave cylinder:
45÷50 Nm (4.6÷5.1 kgm; 33.2÷36.9 ft lbs)

3. Approach the round nut (4) until it makes contact with the fork (3) and tight-
en the lock nut (5). There should be no play between the round nut (4) and
the lever (3).
3
4. In this position, the thrust bearing (7) must be in contact with the clutch press
0025CL (8), the spherical nut (4) with the fork (3) and the cylinder’s piston in its start-
ing position. There should be no play nor movement of the piston.
Continue to turn the nut (4) in the same direction until the rod (2) reaches dis-
BD-30 Ti ENGINE tance “A”.
B
A Fix with the lock nut (5).
Dimension “A”=122.8±0.6 mm (4.83±0.024 inch)
Dimension “B”=142±0.6 mm (5.59±0.024 inch)
3 Lock nut (5):
4 21-24.5 Nm (2.1-2.5 kgm; 15.5-18.1 ft lbs)

Fixture of hose to slave cylinder:

8 17÷20 Nm (1.7÷2.0 kgm; 12.5÷14.8 ft lbs)

7
0041CL

CL-10
 CLUTCH PLATE AND PRESSURE ASSEMBLY

DISASSEMBLY
1. Remove the gearbox from the engine. See section MT
2. Insert the centerer (a) fully into the plate.
1 • In the following points, it is important to support the weight of the clutch plate.
3. Loosen the bolts (1) fixing the pressure assembly to the flywheel.
• Loosen the bolts diagonally and by one turn each, until the pressure is released
from the diaphragm.
4. Remove the centerer (a).

a
0003CL

INSPECTION AND ADJUSTMENT

Before inspecting and adjusting, clean all the parts except for the plate assem-
bly with a suitable solvent for removing grease and dirt.

Flywheel
• Examine the contact surfaces of the flywheel and clutch plate for burnt or dis-
coloured areas or scratches.
• Change the flywheel if the burnt areas cover an important area.
• Repair the flywheel with fine emery paper if small areas are discoloured.
• Change the flywheel if the surface is badly scratched.
• Check the warp of the flywheel.
• Total permitted warp: See “CYLINDER BLOCK - Inspection” in section EM of this
manual. TD-27 T, BD-30 Ti.
• Change the flywheel if it exceeds the total permitted warp.

Pressure plate
0300EM 1. Examine the pressure plate contact surface and the clutch plate for
scratches.
Change the plate if the surface is badly scratched.
Repair the plate with fine emery paper if small discoloured areas are found.

CL-11
 CLUTCH PLATE AND PRESSURE ASSEMBLY

Inspection and adjustment

CLUTCH PLATE
1. Check that the clutch plate is not worn or greasy, that the rivets are not loose
or broken or the shock absorbing springs loose.
If the lining is greasy, the plate must be replaced. In this case, check for oil
leaks through the seal on the front cover of the gearbox or the rear crankshaft
seal.
2. Check the clutch plate lining for wear.
Lining wear limit of lining surface to rivet head:

A DD-240 HR: “A” = 0.3 mm (0.012 inches)

0005CL
3. Check the free play (1) on the clutch plate splines.
Maximum play between splines (measured on external edge of plate):
DD-240HR = Less than 0.4 mm (0.016 inches)
Change the clutch plate or the primary gearbox shaft if the free play of the
splines exceeds the specified values.

1
4. Check the clutch plate for warping or eccentricity.
0010CL
Maximum permitted warp limit (total dial gauge reading):
DD-240HR: = Less than 0.8 mm (0.031 inches)
Distance “R” of warp test point (from hub centre):
DD-240HR: “R”= 114 mm (4.49 inches)
If the warping exceeds the specified value, replace or repair the plate.
• When checking the clutch plate, never grip it tightly with pliers or bend it exces-
sively since this could damage the lining.

5. Check that the clutch plate fits and slides smoothly on the gearbox primary
shaft (no catching or shaking).
R

0006CL

CL-12
 CLUTCH PLATE AND PRESSURE ASSEMBLY

Inspection and adjustment (Cont.)

CLUTCH PRESSURE ASSEMBLY
1. Check whether the thrust (or fulcrum) rings are damaged or worn.
Since these are not visible from the outside, shake the pressure assembly
and listen for the sound of loose pieces, or lightly tap the rivets to see
whether the sound indicates that a ring has cracked. If so, replace the entire
assembly.
2. Check whether the diaphragm stitches are worn.
If the wear is excessive, change the clutch pressure assembly.
3. Use a calliper to measure the height of the stitches on the diaphragm as
follows:

0008CL

a) Place the pressure assembly on a flat base (1) with three shims (2) B mm
thick between, fixing it with the bolts (3).
These shims must be uniformly arranged in the pressure plate support
area.
Height B of shims:
DD-240 HR = 8 mm (0.315 inches)

B
C b) Measure the height “C” at various points.
Height “C” of the stitches on the diaphragm:
DD-240 HR = 37÷40 mm (1.46÷1.57 inches)

2 1 3
0042CL

4. Adjust the differences between the stitches on the diaphragm using a

suitable tool.
Permitted difference in height of the diaphragm stitches:
Less than 0.5 mm (0.02 inches)

0011CL

CL-13
 CLUTCH PLATE AND PRESSURE ASSEMBLY

FITTING
1. Apply a thin coat of grease to the gearbox primary shaft splines.
2. Fit the plate and the pressure assembly using the clutch assembly centerer
(a).
• Check that the plate lining, engine flywheel and pressure plate are clean, dry and
a free of grease.

0009CL

3. Tighten the bolts (1).

1 • The bolts (1) must be tightened diagonally and in two steps:

Bolts fixing clutch press to flywheel

25 Nm (2.6 kgm; 18.4 ft lbs)

4. Remove the centerer (a).

a
0003CL

5. Fix the gearbox to the engine. See section MT.

CL-14
 TECHNICAL DATA AND CHARACTERISTICS

General features Unit: mm (inches)

Model CABSTAR. CABSTAR. CABSTAR. CABSTAR CABSTAR.
E-95 E-120 (35) E-120 (45) E-120 (GE) E-120 (GE/HD)
Engine TD-27 T BD-30 Ti
Drive system Hydraulic
Clutch plate
Model DD-240 HR
Master cylinder
Stroke 25 (0.98)
Inner diameter 15.87 (0.625)
Slave cylinder
Stroke 17.9 (0.70) 15.5 (0.61)
Inner diameter 19 (0.748)
Adjustment Self-adjusting Manual

Technical data
CLUTCH PEDAL Unit: mm (inches)

Stroke
Height “H” of pedal 150 (5.90 pulg.)

CLUTCH PLATE Unit: mm (inches)

Model DD-240 HR
Maximum lining wear above rivet head 0.3 (0.012)
Maximum warp limit Less than 0.8 (0.031)
Distance “R” of warp test point 114 (4.49)
Maximum play between splines (measured on external edge of disc) Less than 0.4 (0.016)
Disc size
Outer diameter 243 (9,567)
Thickness 7.6÷8.2 (0.299÷0.323)
Number of shock absorbing springs 8

CLUTCH PRESSURE ASSEMBLY Unit: mm (inches)

Model DD-240 HR
Heights of diaphragm stitches 37÷40 (1.46÷1.57)
Difference between diaphragm stitches Less than 0.5 (0.02)
Thickness “B” of shims for measuring height
8 (0.315)
of diaphragm stitches

CL-15
 TECHNICAL DATA AND CHARACTERISTICS

Tightening torques
Nm kgm ft lbs
Bolts fixing pedal bracket 9÷11 0.9÷1.1 6.6÷8.1
Nuts fixing master cylinder to pedal bracket 9÷11 0.9÷1.1 6.6÷8.1
Master cylinder outlet pipe connector 20-24 2.0-2.4 14.8-17.7
Bolts fixing clutch casing to engine * * *
Bolts fixing clutch pressure assembly to flywheel 25 2.6 18.4
Bolts fixing slave cylinder to clutch casing 45-50 4.6-5.1 33.2-36.9
Clutch pedal stop lock nut 12÷15 1.2÷1.5 8.9÷11.1
Thrust link lock nut 16÷22 1.6÷2.2 11.8÷16.2
Fixing nut of pedal axle 20÷23 2.0÷2.3 14.8÷17.0

* See section “MT” in this Workshop Manual.

CL-16