AR25.20-B-0100F | Remove/install master cylinder | 12.02.16 |
Vehicle 979 with Cumbustion engine 612.983, 904.943, 904.970
B25.20-0030-09
1 Hydraulic clutch actuator sender cylinder
2 Cylinder spring (repair kit)
3 Gaskets, two pieces (repair kit)
4 Piston assembly (repair kit)
5 Expander ring (repair kit)
6 Bellows (repair kit)
7 Input connector ring for sender cylinder (repair kit)
8 Brake fluid reservoir (left side of panel)
9 Reservoir fastening screws in cab
10 Collar screws for fastening sender cylinder to pedal bracket
11 Complete cylinder actuator rod assembly
12 Collar nut for actuator rod adjustment
13 Actuator rod terminal (with ball joint)
14 Output tubing connection on sender cylinder
15 Sender cylinder output tubing
16 End tubing for transmission central declutching device
17 Tubing connection in transmission
18 Gearbox
Important preliminary information | Always follow the recommended personal safety measures to avoid accidents as well as the environmental protection measures. | ||
Hydraulic sender cylinder repair kit replacement shown here is applicable to all vehicles of the series, however, cylinder diameter and piston stroke vary according to vehicle cargo capacity, as indicated on the plastic identification strip that comes with the cylinder | In Vehicles 979.013/016, the hydraulic clutch sender cylinder allows repair kit replacement In Vehicles 979.046 the complete hydraulic sender cylinder must be replaced as there is no repair kit for this model. | ||
Cylinder components must only be washed with hydrated alcohol (pharmacy supply). Oil-derived products, such as gasoline, kerosene or Diesel fuel will damage rubber components. | |||
1 | Place the vehicle on flat and level ground that permits working safely. Chock the rear wheels to avoid the vehicle's unintentional rolling | ||
2 | Turn-off the master switch | As it deals with electronic vehicles, always follow the recommendations for this type of vehicles. | |
| Removal | ||
3 | Remove steering column cover to allow easy access to pedals | Refer to: Steering column removal and installation. | |
Danger! | Risk of poisoning by brake fluid ingestion Risk of injury by brake fluid contact with skin and eyes | Use only original containers for draining and storing brake fluid. Wear protective clothing and goggles. | |
4 | Protect lower section of cab against brake fluid leaks | Adequately line lower cab section, for brake fluid rests may always fall and cause damage to paint and other components. | |
5 | Drain brake fluid from clutch actuator system | Use adequate draining equipment. Refer to: Bleed air from clutch actuator. | |
Vehicle 979.013/016 | |||
Vehicle 979.046 | |||
6 | Disconnect output (14) and input (7) tubings from hydraulic sender cylinder (1). Fasten empty tubings temporarily under the dashboard | Handle brake fluid reservoir with care. Seal tubing ends with small plugs to avoid brake fluid leaks. | |
7 | Remove complete clutch pedal assembly | Vehicle 979.01/016 | |
Vehicle 979.046 | |||
Pedal assembly will come out with installed bracket and sender cylinder. | |||
8 | Fasten assembly by its bracket to a suitable base | ||
9 | Remove two collar screws (10) and withdraw hydraulic sender cylinder (1) from its bracket | For Vehicles 979.046 there is no repair kit for the sender cylinder, so it is not to be disassembled but replaced completely. | |
For Vehicles 979.013/016, a repair kit is available for the sender cylinder which is to be disassembled, cleaned and prepared for mounting corresponding components. | |||
10 | Remove plastic identification strip, protective bellows (6), expander ring (5), complete piston (4), spring (3), and connector ring (7) from cylinder (1) | Items (2), (3), (4), (5), (6), and (7), being part of the repair kit, are to be replaced. | |
| Clean | ||
Wash sender cylinder inner section with hydrated alcohol (pharmacy supply). If there are any signs of oxidation use a fine steel sponge. If oxidation cannot be eliminated, the complete hydraulic cylinder must be replaced | |||
11 | Clean all components | The rod ball joint must not be washed, it is to be cleaned with a clean, dry cloth and afterwards lubricated with specified grease. | |
| Check | ||
12 | Examine all components subject to wear or deformation, especially rod ball joint (11) and (13). Replace as necessary | ||
| Installation | ||
13 | Once cylinder (1) is in good condition, perfectly clean and lubricated with specified brake fluid, install new repair kit components in specified order | Vehicle 979.013/016 | |
Connecting expander ring (7) Return spring (3) (observe correct position) Complete piston (4) with mounted gaskets (3) Mount new expander ring (5) | |||
14 | Install the new plastic strip to identify the cylinder | ||
15 | Verify free piston (4) movement within cylinder (1) | ||
16 | Use long-lasting grease to lubricate contact area between rod and piston | Also lubricate actuator rod terminal joint (13). | |
17 | Install sender cylinder (1) on its bracket and tighten two collar screws (10) to specified torque | | |
18 | Mount new protective bellows (6) | ||
19 | Adjust rod play: Hold the rod with a spanner, loosen nut (12) on the thread and rotate rod (11) by hand until a stop is felt, then turn the rod slightly back and fix it with nut (12) | The hydraulic sender cylinder has a piston return spring, and play between rod and piston can be previously adjusted even without pressure. Final adjustment will be made after bleeding the hydraulic clutch actuator system | |
Installation of complete pedal assembly on main support | |||
20 | Mount complete pedal assembly with bracket on steering column main support and fasten it with collar bolts | | |
Vehicles 979.013/016. | |||
Vehicles 979.046. | |||
21 | Connect brake fluid feeder tubing to input (7) of hydraulic sender cylinder (1) | ||
22 | Connect and fasten output tubing (14) to sender cylinder Connect electric cables to clutch pedal switch | ||
23 | Fill clutch actuator system with brake fluid and bleed the system | Use adequate bleeding equipment. Refer to: Bleed air from clutch actuator system | |
24 | Confirm adjustment of sender cylinder (1) actuator rod (11) | Play between rod and piston. | |
Vehicle 979.013/016. | |||
Vehicle 979.046. | |||
25 | Install steering column cover to allow easy access to pedals | Refer to: Steering column removal and installation. | |
26 | Verify that everything is in order, remove protections from cab interior, turn on the main switch and take a test drive |
Pedals, bearing bracket
Número | Denominação | Vehicles 979.013/016 | Vehicles 979.046 | |||
BE29.10-B-1007-01D | Clearance F between actuation rod and the emitter cylinder piston, adjusted. | mm | 0,50 | 0,50 | ||
Pedals, bearing bracket
Número | Denominação | Vehicles 979.013/ 016 | Vehicles 979.046 | |||
BA29.10-B-1002-02C | Flange bolts, attaching the clutch pedal support to the main bracket | M8 | Nm | 21 | 21 | |
BA29.10-B-1010-02C | Bolts attaching the hydraulic clutch master cylinder | M6x1 | Nm | 9 | 9 | |
Produtos para reparos
Número | Denominação | Número de pedido |
BR00.45-B-1004-06A | Grease as per DBL 6888.00 | A 000 989 51 51 |
BR00.45-B-1007-06A | Grease DBL 6812.00 | Klueber Lubrification |
BR00.45-B-1011-06A | Brake fluid as per DBL 7760.30 (DOT 4) | - |
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