Clutch

Training Document
SINGLE PLATE
CLUTCHES
Produced in January 2002 by

MAN Steyr AG
SERVICE AKADEMIE / VNSA
This document is intended exclusively for use in
training and is not subject to the routine
amendment service.
2003 MAN Nutzfahrzeuge Aktiengesellschaft

Reprinting, copying, dissemination, alteration, translation,
microfilming and storage and/or processing in electronic
systems, including databanks and online services, without the
written permission of MAN is prohibited.
N:\VMT\1CD_brennen\1_hubert_indien\Clutch.doc Page 2
CONTENTS
CONTENTS .................................................................................3 CHECKING THE CONCENTRIC SLAVE CYLINDER............... 16

PULLED DIAPHRAGM SPRING CLUTCHES (MFZ)...................4 ADJUSTING THE CONCENTRIC SLAVE CYLINDER ............. 20
CLUTCH ACTIVATION MFZ 330 / 362 / 395 / 430......................6 CHECK CLUTCH WEAR MF 350 ............................................. 22
CLUTCH MASTER CYLINDER .................................................10 CHECK CLUTCH WEAR MFZ 430 ........................................... 24
CLUTCH SERVO.......................................................................12 CHECK CLUTCH WEAR (VALEO 405 / 430 DTP) ................... 26
PULLED DIAPHRAGM SPRING CLUTCH (MFZ WITH TECHNICAL DATA FOR CLUTCH PRESSURE PLATE OR
CONCENTRIC SLAVE CYLINDER) ..........................................14 CLUTCH PLATE ....................................................................... 28
PULLED DIAPHRAGM SPRING CLUTCHES (MFZ)
The MFZ clutch is particularly flat in construction. It is not pushed The advantages of the diaphragm spring clutch lie in its higher
but pulled when released. speed resistance, higher contact pressure and lower release
The release bearing (1) is inset in the diaphragm spring tongues force.
of the pressure plate and constantly runs with this play-free Activation is hydraulic via master and slave cylinders.
during operation, on activation the release bearing pulls the
slotted tongues outward. In modern vehicles no adjustment of clutch play is required.
The diaphragm spring is supported under force on the very Adjustment is automatic. The wear on the clutch can be checked
narrow housing (3) and presses on the inner diameter of the through the clutch housing inspection hole.
contact plate (2).
TKU001
CLUTCH ACTIVATION MFZ 330 / 362 / 395 / 430
The MFZ 330, 362 has a concentric slave cylinder with pulled MFZ 330
clutch activation.
M Diaphragm spring clutch
The MFZ 395, 430 has a clutch servo with wear indicator. F Flat flywheel
All clutch variants are asbestos-free single plate dry clutches with Z Pull release
automatic adjustment, torsion dampers and predampers. 330 External diameter of friction surface in mm
1. Flywheel
2. Clutch plate
3. Clutch pressure plate
4. Concentric slave cylinder with release bearing
5. Clutch bell
6. Hydraulic line
7. Clutch master cylinder
8. Clutch pedal
Clutch activation with hydraulic/pneumatic support
1. Clutch
2. Clutch servo
3. Hydraulic line
4. Master cylinder with header tank
5. Pedal stop
6. Air reservoir
7. Air line
CLUTCH MASTER CYLINDER
The master cylinder is connected to the clutch pedal and 1. Pressure spring
transfers the foot power applied to this to the slave cylinder 2. Piston
acting on the clutch release lever or the clutch servo. 3. Secondary sleeve
4. Stop plate
When the clutch pedal is pressed, via piston rods (6) and piston 5. Protective gaiter
(2) a pressure is generated which displaces the fluid volume 6. Piston rod
through connection B and the connecting line into the slave 7. Blocking ring
cylinder and here in turn moves the piston with piston rod by the 8. Primary sleeve
distance necessary to release the clutch.
Connections:
When the foot power is reduced or the clutch pedal released, A Header tank
the spring (1) presses the pistons (2) and piston rods (6) back B Control line
to the starting position.
Via connection A, any volume changes or fluid losses

occurring in the header tank are compensated.
On fluid loss check the system for leaks immediately.
CLUTCH SERVO
The clutch servo is used to assist the pedal power when 1. Control piston
activating the clutch. 2. Pressure spring
3. Outlet
The clutch servo is activated hydraulically and supported by 4. Inlet
compressed air. 5. Channel
6. Servo piston
When the clutch is activated, by means of the pedal, master 7. Pressure rod
cylinder pressure is generated in the hydraulic system. 8. Pressure spring
This pressure acts via control connection 4 on the control 9. Vent screw
piston (1) and working piston (11). 10. Guide ring
The control piston (1) is pushed to the left against the pressure 11. Working piston
spring (2), closes outlet (3) and opens inlet (4) so that the 12. Cylinder chamber
compressed air from the storage container can enter via
connection 1 and inlet (4) and impact the servo piston.
Connections:
The air pressure on the servo piston (6) therefore builds up 1 Energy supply (compressed air)
proportional to the pressure at connection 4 and hence the foot 4 Control connection (hydraulics)
force until the clutch release force is achieved. 31 Vent (compressed air)
The working piston (11) and pressure rod (7) now extend and 32 Vent (hydraulics)
activate the clutch.
When the pedal force is reduced and the hydraulic pressure

relieved, the control piston (1) is pushed to the right, closing
inlet (4) and opening outlet (3) and compressed air escapes to
the open via vent 31.
PULLED DIAPHRAGM SPRING CLUTCH (MFZ WITH CONCENTRIC SLAVE CYLINDER)
These clutches have a release unit with concentric slave cylinder The advantages of the concentric slave cylinder are:
mounted centrally in the gear bell housing. The release unit and No mechanical force transmission elements are required such as
slave cylinder form a complete unit on the gear input shaft. shaft with forks and bearings or rockers, release unit, guide
sleeve and external slave cylinder.
There is no friction in the shafts and rocker bearings so the
cylinder requires lower activation forces.
CHECKING THE CONCENTRIC SLAVE CYLINDER
1. Turn bearing inner ring "A" while pulling slightly, check for Removing the gearbox with concentric slave
smooth running and ease of operation. cylinder
2. Check seal, there is an outlet opening "B" for leaks on the Pull load ring down using wire "C“, wrap a loop of binding wire
underside of the slave cylinder (also for the gearbox shaft around load ring and pull together .
sealing ring).
NOTE:
If the connection cannot be released by itself under the force of
the preload spring, press the clutch pedal and pull the load ring
together.
Concentric slave cylinder Check clutch wear
1. Release bearing Dimension L for new clutch approx. 8.0 mm
2. Load ring Dimension L for worn clutch approx.11.0 mm
3. Connection for hydraulic line
4. Slave cylinder
5. Clamping pin
A Adjustment dimension new 113.0+1 mm
ADJUSTING THE CONCENTRIC SLAVE CYLINDER
The slave cylinder can be adjusted with two pairs of pliers. 2. Adjustment dimension (for use or repaired parts)
L = 132 - 133 mm
A Extend slave cylinder, enlarge dimension L
B Retract slave cylinder, reduce dimension L
1. Adjustment dimension (new clutch plate, pressure plate,
flywheel plate) L = 119 - 120 mm
CHECK CLUTCH WEAR MF 350
If the release lever has wandered maximum halfway to the edge "B" Lever position for new clutch plate
of inspection hole "C" (should be a vertical extension to the
release lever) the carrier plate must be replaced.
"A" Lever position for worn clutch plate
CHECK CLUTCH WEAR MFZ 430
1. Pressure plate Remove rubber cap from inspection hole; the release lever
2. Clutch plate with marker arrow and min or max marking (2) is visible.
3. Release unit For a new clutch plate, the max mark must align with the
4. Clutch housing marker arrow (1).
5. Fixing bolt for pressure plate On a worn clutch carrier plate, the release lever wanders
6. Flywheel plate back in the direction of the slave cylinder.
7. Release lever bearing By visual inspection the wear on the carrier plate can be
8. Release lever established at the release lever point.
9. Wear indicator If the release lever has reached the min mark, the carrier
10. Slave cylinder or clutch servo plate must be changed.
11. Torsion damping springs
12. Guide (pilot) bearing NOTE:
13. Rubber stopper for inspection hole If there is no MIN/MAX mark, the clutch plate must be replaced
14. Centring pin for pressure plate when the release lever has reached the rear edge of the
inspection hole.
CHECK CLUTCH WEAR (VALEO 405 / 430 DTP)
The clutch is adjusted automatically. WABCO

If the wear indicator projects (Ö) 30 mm from the housing of the
Wear indicator clutch slave cylinder, the clutch plate must be replaced.
For a new clutch plate, the wear indicator (Ö) lies on the
housing of the clutch slave cylinder. KNORR
If the wear indicator has reached the first notch (Ö) = single
Note: After replacing the clutch plate, press the wear indicator in plate clutch, the clutch plate must be replaced.
to the stop.
WABCO KNORR
TECHNICAL DATA FOR CLUTCH PRESSURE PLATE OR CLUTCH PLATE
Clutch pressure plate MFZ 330 Clutch plate MFZ 330
"Y" Release path .............................................. 10.0 - 12.0 mm "A" Thickness of clutch plate under no load......... 8.8 - 9.4 mm
Thickness of clutch plate under load .............. 8.5 - 8.8 mm
"X" Wear..................................................................... 14.0 mm
"B" Lining new ...................................................... 4.9 - 5.1 mm
Lining worn .................................................... 6.4 - 6.6 mm
Maximum wobble ............................................................ 0.5 mm

Permitted imbalance .......................................................... 200 g
"Y" Release path .............................................. 10.0 - 12.0 mm "A" Thickness of clutch plate under no load..... 10.4 - 10.8 mm
"X" Wear........................................................... 10.0 - 13.0 mm Thickness of clutch plate under load ............ 9.7 - 10.3 mm
"B" Lining new ...................................................... 3.0 - 5.0 mm
Lining worn .................................................... 5.0 - 7.0 mm

"X" Wear.................................................................... 15.0 mm "A" Thickness of clutch plate under no load..... 10.5 - 10.8 mm
"Y" Release path .............................................. 10.0 - 12.0 mm Thickness of clutch plate under load ............ 9.7 - 10.3 mm
"B" Lining new ...................................................... 3.0 - 5.0 mm
Lining worn .................................................... 5.0 - 7.0 mm

"X" Wear..................................................................... 14.0 mm "A" Thickness of clutch plate under no load..... 10.5 - 10.8 mm
"B" Lining new ....................................................5.4 (6 - 8) mm
Lining worn ............................................6.9 (7.5 - 9.5) mm

"X" Wear..................................................................... 16.0 mm "A" Thickness of clutch plate under no load..... 10.5 - 11.3 mm
"B" Lining new ...................................................... 8.9 - 9.1 mm
Lining worn ................................................ 10.4 - 10.6 mm


Clutch

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Training Document

Produced in January 2002 by

2003 MAN Nutzfahrzeuge Aktiengesellschaft

CONTENTS .................................................................................3 CHECKING THE CONCENTRIC SLAVE CYLINDER............... 16

Via connection A, any volume changes or fluid losses

When the pedal force is reduced and the hydraulic pressure

A Adjustment dimension new 113.0+1 mm

The clutch is adjusted automatically. WABCO

Clutch pressure plate MFZ 330 Clutch plate MFZ 330

Maximum wobble ............................................................ 0.5 mm

Maximum wobble ............................................................ 0.5 mm

Maximum wobble ............................................................ 0.5 mm

Maximum wobble ............................................................ 0.5 mm

Maximum wobble ............................................................ 0.5 mm

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