Eaton CLSM0200 Service Manual
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Eaton CLSM0200 Service Manual

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

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Summary of Contents for Eaton CLSM0200

  • Page 1 Service Manual Eaton Heavy-Duty Clutches CLSM0200 May 2012 Solo Advantage® Easy Pedal Advantage® Value Clutch™ UltraShift™DM UltraShift PLUS ECA Clutch...
  • Page 3 Every effort has been made to ensure the accuracy of the Drivers should be properly trained in starting, shift- information contained in this manual. However, Eaton Corpo- ing and operation of the clutch. ration makes no warranty, expressed or implied, based on the Drivers should report erratic clutch operation as information provided.
  • Page 4 Warnings...

  • Page 5: Table Of Contents

    Table of Contents Warnings and Cautions ServiceRanger Procedure ....42 Operator Triggered Procedure ... .44 Repair Warnings ..... . i ECA Clutch In-Vehicle Resetting Procedure .
  • Page 6 Table of Contents...

  • Page 7: Solo Advantage Self-Adjusting Clutches

    Solo Advantage Self-Adjusting Clutches Remove Clutch (If clutch is to be reinstalled and transmission is still in vehicle) CAUTION Note the position of the wear indicating tab on the clutch. If the tab is near the “REPLACE” position, the clutch should be replaced.

  • Page 8: Measure Engine Flywheel Housing

    Solo Advantage Self-Adjusting Clutches Install Solo Advantage Heavy-Duty 15.5" Clutch Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or it may result in premature clutch failure. Remove and replace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheel surfaces of all grease, oil, and rust preventatives.

  • Page 9: Install Clutch To Flywheel

    Self-Adjusting Clutches Install Clutch to Flywheel IMPORTANT WARNING Use the Eaton Clutch Selector Guide (CLSL1511) An assembled clutch weighs about 150 lbs (68 kg). to make sure you have the right clutch. Avoid the risk of injury. Use proper equipment when lifting a clutch.
  • Page 10 2 turns. Lubricate release bearing until grease purges from release bearing housing. Use NLGI grade 2 or 3 Lithium complex grease. Reference Eaton lubrication manual TCMT0021 for specific instructions. Note: A-8173 hand hole cover with grommet is required with HD Solo Advantage clutch used with hydraulic release system.

  • Page 11: Install Transmission

    Solo Advantage Self-Adjusting Clutches Install Transmission Check Transmission for Wear Replace any worn components. Transmission Bearing Cross Shaft and Bushings Input Shaft Splines Retainer Cap Excessive wear at these points can cause Any wear on the splines will A worn/rough bearing side loading on the sleeve bushing, prevent the driven discs from retainer cap may cause...
  • Page 12 Solo Advantage Self-Adjusting Clutches Fasten Transmission to Flywheel Housing Position transmission so Make sure that the yoke Put transmission in gear. it is square to and fingers remain in the up Make sure new clutch aligned with engine. position until they are over brake has been installed.

  • Page 13: Set-Up

    Solo Advantage Self-Adjusting Clutches Set-up Adjust Clutch Linkage Hydraulic Linkages: Skip to Step 2. Mechanical Linkages Only: Adjust the clutch linkage until the yoke fingers contact the release bearing (zero free-play in cab). 0.00" Press the pedal to the Yoke floor up to 5 times, this: Release Finger...
  • Page 14 Solo Advantage Self-Adjusting Clutches Verify Clutch Brake Squeeze WARNING Use a gauge long enough to keep hands away from moving parts. Have an assistant insert 0.010" (0.25 mm) feeler gauge between the release bearing and the clutch brake. Press the pedal down to the floor to reclamp the gauge: •...
  • Page 15 Solo Advantage Self-Adjusting Clutches Lubricate Note: All clutches use a Lithium complex grease with a minimum of 325°F (163°C) operating range meeting NLGI grade 2 or 3 specs. For additional lubrication information, see TCMT0021. CAUTION Failure to properly lubricate the bearing/bushing will result in bearing and sleeve failures.

  • Page 16: Symptom-Driven Diagnostics

    Solo Advantage Self-Adjusting Clutches Troubleshooting for Solo Advantage Heavy-Duty 15.5" Clutches Symptom-Driven Diagnostics If clutch is out of vehicle, go to Out- page 16. of-Vehicle Resetting Procedure on Based on your symptom, the chart will direct you to the correct solution. Not Enough Free Pedal: Too Much Free Pedal: enough...

  • Page 17: Too Much Free Pedal Or Too Much Clutch Brake

    Solo Advantage Self-Adjusting Clutches Too Much Free Pedal or Too Much Clutch Brake Too much Too much travel brake squeeze Note: Before measuring the distance between the release bearing and Release clutch brake depress clutch pedal to Bearing remove free pedal in the cab. Measure distance between release bearing and clutch brake.

  • Page 18: Not Enough Free Pedal Or No Clutch Brake

    Solo Advantage Self-Adjusting Clutches Not Enough Free Pedal or No Clutch Brake Too little travel Not enough brake squeeze Note: Before measuring the distance between the release bearing and Release clutch brake depress clutch pedal to Bearing remove free pedal in the cab. Measure distance between release bearing and clutch brake.

  • Page 19: Resetting Procedures

    Solo Advantage Self-Adjusting Clutches Resetting Procedures In-Vehicle Reset Procedure Have assistant hold clutch pedal down. Hold While pedal is held down, move wear tab to the left (GOOD) position. Note: If the cam does not Push pedal down and move, loosen transmission and squeeze clutch brake install 1/2"...

  • Page 20: In-Vehicle Resetting Procedure Using The Solo Advantage Clutch Reset Tool

    Solo Advantage Self-Adjusting Clutches In-Vehicle Resetting Procedure Using the Solo Advantage Clutch Reset Tool Tool Part Code: RR1005CL K-Line 1-800-824-5546 Determine if the release bearing travel is correct. Measure the distance between the clutch brake and the release bearing with the clutch pedal up.

  • Page 21: Verify Clutch Brake Squeeze

    Solo Advantage Self-Adjusting Clutches Install (4) shipping bolts and progressively tighten by hand until they bottom out. Rotate the engine to access all 4 bolts: • 15 1/2" Solo use 7/16 x 14 UNC x 1 3/4" • Stamped 14" Solo use 3/8 x 16 UNC x 1 1/4" Note: This will reset the pressure plate separator pins and allow the clutch to release after installation.

  • Page 22: Eca Or Solo Advantage Clutches

    Solo Advantage Self-Adjusting Clutches Out-of-Vehicle Reset Procedure for Heavy-Duty ECA or Solo Advantage Clutches Remove the 4 shipping Support the clutch in an arbor press Center the ram and bolts if they have been with the bearing facing down. press downward on the installed.

  • Page 23: Easy Pedal Advantage Manual Adjust Clutches

    Easy Pedal Advantage Manual Adjust Clutches Install Easy Pedal Advantage and ValueClutch Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or may result in a premature clutch failure. Remove and replace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheel surfaces of all grease, oil, and rust preventatives.

  • Page 24: Install Clutch To Flywheel

    Install 15.5" Clutch to Flywheel (Easy Pedal Shown) IMPORTANT WARNING Use the Eaton Clutch Selector Guide (CLSL1511) An assembled clutch weighs about 150 lbs (68 kg). to make sure you have the right clutch. Avoid the risk of injury. Use proper equipment when lifting a clutch.
  • Page 25 Easy Pedal Advantage Manual Adjust Clutches Install 14" Clutch to Flywheel Ensure the correct flywheel depth is 2-15/16". Put front disc into flywheel. Flywheel side must be toward engine. Use new slots to put intermediate plate on pins. Super-duty clutch only: Install three equally Turn intermediate plate left.

  • Page 26: Install Transmission

    Easy Pedal Advantage Manual Adjust Clutches Install Transmission Check Transmission For Wear Replace any worn components. Transmission Bearing Cross Shaft and Bushings Input Shaft Splines Retainer Cap Excessive wear at these points can cause Any wear on the splines will A worn/rough bearing side loading on the sleeve bushing, prevent the driven discs from...
  • Page 27 Easy Pedal Advantage Manual Adjust Clutches Fasten Transmission to Flywheel Housing Transmission installation and clutch set-up procedures are the same for the 14" and 15.5" clutch. Position transmission Put transmission in gear. Make sure that the yoke so it is square to and Be sure new clutch brake fingers remain in the up has been installed.

  • Page 28: Set-Up

    Easy Pedal Advantage Manual Adjust Clutches Set-Up Adjust Bearing Position Note: Before measuring the distance between the release bearing and clutch brake depress clutch pedal to remove free pedal in the cab. Measure the distance between the release bearing and the clutch brake: •...
  • Page 29 Easy Pedal Advantage Manual Adjust Clutches Verify Clutch Brake Squeeze WARNING Use a gauge long enough to keep hands away from moving parts. Have an assistant insert 0.010" (0.25 mm) feeler gauge between the release bearing and the clutch brake. Press the pedal down to the floor to clamp the gauge: •...
  • Page 30 Easy Pedal Advantage Manual Adjust Clutches Verify Free-Play Measure the distance between yoke tips and bearing wear pads simultaneously. This distance should be 1/8" (3.2 mm). If distance is not 1/8" (3.2 mm), go to Step 7. IMPORTANT Do not change bearing position. Note: 1/8"...
  • Page 31 Easy Pedal Advantage Manual Adjust Clutches Lubricate Note: All clutches use a Lithium complex grease with a minimum of 325°F (163°C) operating range meeting NLGI grade 2 or 3 specs. Note: Apply ample grease that is visibly exiting the opening and contacts the transmission shaft.

  • Page 32: Ultrashift Dm Heavy Duty Clutch

    UltraShift DM Clutch UltraShift DM Heavy Duty Clutch Remove Clutch WARNING An assembled clutch weighs about 182 lbs (82 kg). Avoid the risk of injury. Use proper equipment when lifting a clutch. Prior to removing the transmission, rotate the engine until one of the jack screw locations can be viewed through the clutch housing inspection opening.
  • Page 33 UltraShift DM Clutch Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or may result in a premature clutch failure. Remove and replace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheel surfaces of all grease, oil, and rust preventatives.

  • Page 34: Ultrashift Dm Clutchinstall Clutch To Flywheel

    UltraShift DM Clutch UltraShift DM ClutchInstall Clutch to Flywheel Note: If installing a new DM, follow the installation directions that are provided in the box. The required alignment tool, part number RR1009CL, can be ordered through K-Line at 1-800-824-5546. WARNING An assembled clutch weighs about 182 lbs (82 kg).

  • Page 35: Install Transmission

    UltraShift DM Clutch Install Transmission Check Transmission for Wear Replace any worn components. Input Shaft Splines Any wear on the splines will prevent the driven discs from sliding freely, causing poor clutch release (clutch drag). Slide discs full length of shaft to check for twisted shaft splines. IMPORTANT Do not add lube (Never seize or grease) to the input shaft splines.

  • Page 36: Heavy-Duty Ultrashift Clutch Recalibration

    UltraShift DM Clutch Heavy-Duty UltraShift Clutch Recalibration Turn key on. 10. After the “1” is displayed, depress the throttle pedal to the floor and hold for 3-5 seconds (the gear dis- Verify a solid “N” is on the gear display. play will change back to a “0”...
  • Page 37 Using ServiceRanger, select the “Advanced Product Using ServiceRanger, select “Advanced Product Functions” button located on the main menu. Function” button. Select Eaton AutoShift Gen-2 from the product Select UltraShift transmission model (Gen 3) from selection screen. menu tree in the upper left.

  • Page 38: Eca Clutch

    ECA Clutch Remove Clutch CAUTION Note the position of the wear indicating tab on the clutch. If the tab is near the “REPLACE” position, the clutch should be replaced. If the clutch is to be reinstalled and the transmission is still in vehicle, complete steps 1-7 of the “ECA Clutch In-Vehicle Resetting Procedure”...
  • Page 39 ECA Clutch Click on transmission. Click on ECA Clutch Open and expand the Service. Advanced Product Note: Advanced Product Functions tree. Functions appear. CAUTION Ensure that hands are not inside the clutch housing while opening or closing the clutch. Choose Clutch Position tab.
  • Page 40 ECA Clutch Remove the transmission, supporting its weight to prevent damage to the bearing and discs. Locate 4 shipping bolts (7/16” x 14 x 1 3/4” UNC, hex head). Install them in the 4 cover holes hand tight then turn one full turn. IMPORTANT This step will hold the pressure plate separator pins in proper position so the clutch can be reused and will release after...

  • Page 41: 15.5" Heavy-Duty Eca Clutch Installation

    ECA Clutch 15.5" Heavy-Duty ECA Clutch Installation Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or may result in a premature clutch failure. Remove and replace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheel surfaces of all grease, oil, and rust preventatives.

  • Page 42: Install Clutch To Flywheel

    ECA Clutch Install Clutch to Flywheel Note: The clutch release yoke fingers must be CAUTION positioned so they clear the release bearing housing An assembled clutch weighs about 150 lbs when removing and installing the transmission. (68 kg). Avoid the risk of injury. Use proper •...

  • Page 43: Install Transmission

    Low Capacity Inertia Brake (LCIB) Input Shaft Spigot Wear will not provide proper interface Eaton requires that you replace the LCIB with the inner race of the pilot bearing. when replacing the clutch. See Appendix A This can result in damage to the clutch for LCIB removal and installation instructions.
  • Page 44 35 - 45 lb-ft (47 - 61 Nm). Install the 4 cap screws for the ECA bracket and tighten to 35 - 45 lb-ft (47 - 61 Nm). Apply Eaton lubricant (P/N 5564527) to the 8 and 3-way connector terminals and reconnect the connectors to the ECA.

  • Page 45: Lubricate

    ECA Clutch Lubricate Open the inspection cover and verify the cross-shaft Note: Do not be concerned if excess grease gets onto the and release bearing lube tubes are properly LCIB friction surface, it will not affect the brake’s stop- attached and functional. ping ability.

  • Page 46: Eca Clutch Adjustment

    ECA Clutch ECA Clutch Adjustment This command signals the ECA to actuate the clutch in order to set the adjustment after an ECA Clutch has been reset or replaced. Fault code 26 or 27 indicate that the clutch may have come out of adjustment. Refer to Troubleshooting Guide TRTS0930 for more fault code detail.
  • Page 47 ECA Clutch Choose Clutch Click on Request Clutch Adjustment. Position Tab. Note: ECA will actuate the clutch five times to perform adjustment. Confirm Positive results.

  • Page 48: Grease Interval Count Reset

    ECA Clutch Grease Interval Count Reset The Heavy-Duty UltraShift PLUS has an optional prognostic feature that notifies the operator when the Clutch Release Bearing needs greasing. This feature can be enabled or disabled via ServiceRanger. At the appropriate grease interval and shortly after each engine start, “GI” will momentarily appear in the gear display, along with an audible tone.
  • Page 49 ECA Clutch Open and expand the Click on ECA Click on transmission. Advanced Product Clutch Service. Note: Advanced Product Functions tree. Functions appear. Choose Grease Click on Clear Grease Interval Reset tab. Interval Counter. Confirm Positive results. Turn ignition switch to off to save reset.

  • Page 50: Operator Triggered Procedure

    ECA Clutch Operator Triggered Procedure From the off position, turn Select low mode on Press the manual up-shift ignition to on without the shift device. button until the gear cranking the engine. display shows “3”. Press Accelerator to the floor. Gear display will MANUAL SHIFT show a down arrow.

  • Page 51: Eca Clutch In-Vehicle Resetting Procedure

    LCIB. If the measurement is not between 0.490" and 0.560" reset clutch. Go to Step 2. Eaton Service Ranger Diagnostic Software is needed to command the ECA to open the clutch. Note: Keep the ECA Clutch Service Utility open. It will be used again during this process.
  • Page 52 ECA Clutch Click on transmission. Click on ECA Clutch Open and expand the Service. Advanced Product Note: Advanced Product Functions tree. Functions appear. CAUTION Ensure that hands are not inside the clutch housing while opening or closing the clutch. Choose Clutch Position tab.
  • Page 53 ECA Clutch Turn ignition switch to off. Shipping Bolts Position Reset Tool: • Through the access panel • Under the release bearing • With threaded bolt in cam slot Use tool to move cam to Good position. Note: If the cam does not move, loosen transmission and install 1/2"...

  • Page 54: Low Capacity Inertia Brake Wear Life Measurement

    Low Capacity Inertia Brake Low Capacity Inertia Brake Wear Life Measurement Transmission Removed Transmission in Chassis Compress down the Low Capacity Inertia Brake Open inspection cover. (LCIB) by hand. Through the inspection cover opening, lightly com- Using a shim or a feeler/thickness gauge, measure press down the Low Capacity Inertia Brake (LCIB) the gap between the mounting stud nut/washer and using an appropriate tool to avoid damaging the...

  • Page 55: Hydraulic Linkage

    Hydraulic Linkage Hydraulic Linkage Verify Linkage System Stroke Master Cylinder Installation Measure the release bearing position with the pedal up and Master Cylinder pedal down to verify bearing travel. Master cylinder may be mounted at any angle ranging from The hydraulic linkage should allow for a minimum of 0.600" of vertical to horizontal, depending on application.

  • Page 56: Transmission Installation

    Hydraulic Linkage Transmission Installation Adjustment Freeplay Non-Synchronized Depending on the application, freeplay can be achieved by adjusting upper pedal stop or by adjusting master cylinder pushrod. 1 - Freeplay 3-8 mm Clutch Brake Squeeze For non-synchronized applications only. 1 - Clutch servo 2 - To master cylinder 3 - Connect air supply 30 psi source;...

  • Page 57: Hose Assembly

    Hydraulic Linkage Hose Assembly Synchronized Connect hose assembly to master cylinder and slave or booster. Depending on hose type, this is either a threaded connect or snap-to-connect. Torque all connectors to 20-25 N•m. Note: Make sure there is a constant rise to the master cylinder.

  • Page 58: Solo Advantage Lube Hose Assembly With Hydraulic Linkage

    2 turns. Lubricate release bearing until grease purges from release bearing housing. Use NLGI #2 or #3 Lithium complex grease. Reference Eaton lubrication manual TCMT0021 for specific instructions. Install hand hole cover A-8173 with grommet biased towards transmission in the clutch housing.
  • Page 59 Lubricate release bearing until grease purges from release bearing housing. Use NLGI #2 or #3 Lithium complex grease. Reference Eaton lubrication manual TCMT0021 for specific instructions. Install 4305231 hand hole cover to protect the clutch from contamination.

  • Page 60: General Clutch Information

    General Clutch Information Function of a Clutch describes the major components which make up a complete Eaton Clutch installation. Any modern day clutch, whether designed for an automobile or heavy truck, performs several important tasks allowing for The following are the major components used to make up a safe and convenient operation of the vehicle.

  • Page 61: Self-Adjusting Clutches

    Pre-Dampers - Pre-damper is a feature designed for reducing tion in maintenance and labor costs. idle rattle noise in various applications, where torsional vibra- tions are growing more erratic. That is why Eaton is now Clutch Disc Dampening Characteristics introducing the latest option for heavy-duty applications, the VCT Plus PD, where “PD”...

  • Page 62: Clutch Disc Friction Material

    However, for clutches in the size range offered by rial (copper, sand and other friction modifiers and binder Eaton, the calculation can be simplified to: agents). The dry raw materials are mixed in bulk, poured into die cavities, compressed, sintered in an controlled atmo-...

  • Page 63: Driven Disc

    General Information Driven Disc 6-Position Kwik-Adjust® Eaton offers a variety of 14" and 15.5" driven disc designs. The Eaton’s Easy-Pedal Plus® 14" and Easy-Pedal ™ 2000 15.5" selection of driven discs depends on many factors. Clutches feature the Kwik-Adjust component and the easy-to-...

  • Page 64: Factors That Effect Clutch Performance

    Solo Adjustment-Free If your truck is equipped with Do Not Ride the Clutch Pedal - Riding the clutch is an Eaton Self-Adjusting Clutch, then the clutch will very destructive to the clutch since a partial clutch always be in proper adjustment. Possible lubrication engagement permits slippage and excessive heat.

  • Page 65: When To Inspect The Clutch

    Inspection for Clutch Life # of Springs Bore size 8-Spring 7 1/4" (184.15mm) If your vehicle is equipped with a Eaton Solo or Solo XL 10-Spring 8 9/16" (217.48mm) (Extended Lube) Clutch, the clutch is equipped with a clutch Engine 7-Spring 9 3/4"...

  • Page 66: Preventive Maintenance Overview

    The Eaton Lube Tube Assembly enables the release bearings in Eaton medium and heavy duty clutches to be greased with- For recommended lubrication intervals, see TCMT-0021 or out removing the bell housing inspection cover. The Lube call 1-800-826-HELP (4357).
  • Page 68 Copyright Eaton Corporation, 2012. Eaton hereby grant their customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. It may be copied only in its entirety without any changes or modifications. THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.

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