Service Information: Correction of setting of clutch travel sensor

Vehicles O500RS/RSD

Installing clutch pedal sensor to engage gears

This information has instructions to install the clutch pedal sensor to engage gears aiming not to allow the driver to perform gear change without the clutch being completely disconnected.

Safety:

Before staring the vehicle intervention, check that all necessary safety measures are fulfilled.

Involved parts

Quant... Part number.........Description

1............ A 002 540 30 45............Clutch pedal sensor

1............ A 634 291 05 40............Sensor support (approach)

3............. N 910105008016...........M8x3 Screw

1............ A 634 320 01 27............Crossing lever

2............ N 910105006026...........M6x12 Screw

1............ A 386 429 79 40............Valve fixing support

1............ N 913023014003...........M14x1.5 Nut

1............ A 005 997 12 36............Electro-pneumatic valve

2............ N 000000001155...........M8x60 Screw

2............ N 913023008003...........SW13 Nut

2............ A 000 997 47 34............Connection screw

2............. A 000 994 14 48............Retaining clip

2............ A 000 994 01 47............Sealing ring

2............ A 005 997 89 72............Connection

2............ A 000 994 01 03............Pressure ring

2............ A 001 987 50 46............Sealing ring

1............ A 000 987 49 27............Synthetic pipe

1............ A 382 545 56 26............4V Connector

1............ A 001 546 01 35............Covering

3............ A 693 545 34 80............Sealing seal

1............ A 000 545 62 80............Cavity plug

3............ A 009 545 47 26............End piece

2............ A 376 545 73 28............End piece

1............ A 382 545 85 28............End piece

2............ A 695 545 90 28............End piece

1............ A 695 545 84 28............End piece

1............ A 384 545 85 26............End piece

3............ ----------------------............Eye end piece M6

1............ A 384 542 71 19............Auxiliary mini-contactor with diode

2............ A 002 545 08 34............Auxiliary mini-contactor with diode

2............ A 695 545 71 01............Connector

1............ A 384 545 71 28............Connector



To remove the clutch pedal sensor, check link in the end of the document.

B29.10-0040-01

B29.10-0041-01

Vehicles with clutch pedal sensor installed

1 Install sensor fixing support (1) using screws (2), with 30 Nm torque.

2 Install the sensor crossing lever (3) on the clutch pedal using the screws (4), with 12 Nm torque.

The lever (3) needs re-work (cut on the low tab according to specification).

B29.10-0042-01

3 Fixing clutch pedal sensor (5) on support (6).

The sensor must be assembled carefully and adjusted with maximum distance of 3 mm (a) from the crossing lever (3).

B29.10-0043-06

Vehicles without clutch pedal sensor installed

1 Prepare electric harness according to diagram on the side.

The cable gauges used on this installation must be larger than 0.75 mm2 according to standard DIN 7251-6 and must have the length necessary for each body involved. We recommend the use of a plastic covering to protect the cables.

Subtitles for the picture on the side:

 5 - Pedal sensor

 7 - Fuse

 8 - Contactor

 9 - Connector

 10 - Electro-pneumatic valve

B29.10-0044-01

2 Install fuses (7) and the contactor (8), on the vehicles power plant.

B29.10-0045-01

B29.10-0046-01

3 Cut 3.5 mm (C) on side tab of the valve fixing support (11).

After re-work, remove the burrs and apply paint for local protection.

4 Install fixing support (11) on electro-pneumatic valve on PU valve compartment, using a nut (12).

B29.10-0047-01

5 Fix electro-pneumatic valve (10) on the support, using two screws (13) and two nuts (14), with 30 Nm torque.

B29.10-0049-01

B29.10-0050-01

6 Install the pneumatic pipes replacing the original ones:

 Disconnect the outlet original pipes 2.1 (F) from the pressure regulating valve (15) and connect on the electro-pneumatic valve (10) outlet 2.2 (E), making connection between the gear drive valve (16) inlet 1.2(G) to the electro-pneumatic valve outlet 2.2 (E).

 Assemble the pipe, the two connectors and connect it to pressure regulating valve (15) outlet 2.1 (F) and to electro-pneumatic (10) inlet 1.1 (D) .

B29.10-0048-01

7 Install electric connector (17) on the electro-pneumatic valve.

8 Test the system:

 1 - Test if the electric installation and the sensor are working. Actuate the clutch pedal until full disconnection and listen to the specific noise of contactor and electro-pneumatic valve action.

 2 - After the first step being completely successful, with the vehicle in movement perform the clutch pre-drive and try to perform the gear change, which will not happen due to the sensor non-actuation in the middle pedal position.

 3 - After the second step being completely successful, with the vehicle still in movement, perform the total clutch pre-drive and try to perform the gear change, which may happen due to the sensor actuation in this position.

 4 - Repeat items 2 and 3.