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Volvo Trucks. Driving Progress Volvo Trucks. Driving Progress heavy Heavy facts Facts Genuine Volvo Parts Genuine Volvo Parts Clutch Clutch The clutch operates in a very dusty and hot environment; it should be able to withstand a working temperature of The clutch of a truck operates in a very dusty and hot environment. It has to withstand a working temperature of upto up to 0300° C. To achieve optimal function and performance, the components must be designed, dimensioned and 300 C. To achieve optimal function and performance, the components of a clutch must be designed, dimensioned and tested together as an integrated part of the driveline. tested together as an integrated part of the driveline. The Volvo Genuine Clutch is designed for optimum performance The Volvo Genuine Clutch is gear designed forand optimum to provide smooth start, easy shifting a long performance service life. –The withmain smooth starts, gentle gear shifting and a long service life. components in the clutch

are: The main components in the clutch system are: • Pressure plate • • Pressure plate Disc • • Disc Release bearing for manual transmission or • Release bearing for manual transmission/CCA Concentric Clutch Actuator (CCA) for I-Shift (Concentric Clutch Actuator) I-Shift • Clutch Value Unit (CVU) for for I-Shift • CVU (Clutch Valve Unit) for I-Shift. Components Components The pressure plate is the key component of a clutch that The pressurethe plate is the Then, key component that modulates the torque. modulates torque. the actuation system pushes the Then, the actuation system pushes the diaphragm spring, moving diaphragm spring, moving the pressure plate. The disc should the plate. The disc able power to manage up sliding. to 4.4 bepressure able to manage upto 4.4should tons ofbepress without tons of press power without sliding. The disc allows the driver The disc allows the driver to start the vehicle smoothly, safely to start vehicle smoothly, safely and comfortably

in all situations, and the comfortably in all situations, both with and without load. It both with and without load. It contains five main components: contains five main components 1.• Shock Shockabsorbing absorbingspring spring 2.• Hub Hub 3.• Lining Lining 4.• Friction Frictiondevice device 5.• Steel Steelsegments segments FEATURES FEATURES BENEFITS BENEFITS Complete exchange clutches ready to fit. • Complete ready to fit clutch Tested to handle torque into gearbox and protect driveline • Tested to handle torque into gearbox and protect driveline • • • • 1• year factoryand warranty unlimited mileage. Gearbox enginewith configured and balanced jointly •• No Nounexpected unexpectedcosts costs––increased increasedsecurity. security Gearbox and engine configured and balanced jointly. • • • • • Minimum downtime for installation. Minimum downtime for installation Minimum risk of damage to other parts of the driveline. Minimum risk of

damage to other parts of the driveline Smooth Smoothoperation. operation No noise. No noise Excellent drivability. Excellentdriver drivability Excellent comfort. • Excellent driver comfort 2015-06-11 ENG Version 01 1 (2) Heavy Facts Genuine Volvo Parts heavy facts specifications: its main components are glass fibre, phenol binders, organic fibres, rubber, charcoal and copper thread. Genuine Volvo Parts The facing material has a variety of different properties that The task of the clutch is to translate the torque from the engine meets the requirements such as environmental impact, density to the transmission with minimum loss of efficiency. Moreover, it for gear, shift quality, rotational speed for capacity to burst has to be able to disconnect the engine from the transmission has a varietyfriction of different properties that shall be fulfilled:damping speed, coefficient at different temperatures, Technical description and the rest of the transmission system, when

required. environmental impact, density for gear shiftdriving quality,distance rotationaland capacity at different temperatures, Disengagement of the clutch disc, when gears are shifted is speed for capacity to burst speed, friction coefficient at different The task of the clutch is to transfer the torque from the engine to the additional wear resistance at different temperatures. It is made an important part of its functionality. If the clutch is not fully temperatures, damping capacity at different temperatures and transmission with minimum loss of efficiency. Moreover, it has to be from asbestos-free material, riveted to the disc disengaged, when the gear is shifted, there will be high forces driving distances, and finally additional wear resistance at able to disconnect the engine from the transmission and the rest of • Fiction devices in Itthe clutch disc adds friction in the hub unit and into gearbox, giving levels and wear on different temperatures. is made from asbestos-free

material, thethe transmission system,high whenstress required to do so. increasing Disengagement peaks when it runs through the driveline dampens the vibration theofgears, shafts synchronisers in it; reducing thepart lifeofofitsthe riveted to the disc. the clutch discand when gears are shifted is an important vibration area, thus prolonging lifetime of in thethe transmission transmission • Friction devices in the clutch disc willthe add friction hub functionality.components If the clutch is not fully disengaged when the gear is • and Steeldampen segments placed in between and the unit the are vibration peaks when it the runsdisc through shifted, there will be high forces into the gearbox, giving high stress the driveline area, prolonging the the lifetime of the levelsdifference and increasing wear on the gears, shafts and synchronizers Thisthus is to ensure that torque ramps up materialvibration facing it. The transmission. in it; reducing the lifetime of the transmission’s

components. smoothly as dissipates heat • Steel segments are placed in between the disc and the material • The steel in the shock absorbing spring is of extremely high facing it. This genuine is to ensure that the torque ramps smoothly, as The difference The stiffness of the spring is reduced while the material quality. The Volvo clutch is balanced anduptested to handle well as dissipating heat. strength is high; both of which are beneficial material properties torque transmission to the gearbox. Testing is carried out both • The steel in the shock-absorbing spring is of extremely high in this instance. Lower spring stiffness means that the vibration at a component level, by the supplier and in our own test The Volvo Genuine Clutch is balanced and tested to handle torque quality. The spring’s stiffness is reduced and its material strength can be moved out of driving RPMs. This is visualised in the peak laboratory. Thisgearbox. is followed byisfield testing of the transmission

to the Testing carried out both at atruck, com-in extreme is high: both of which are beneficial material properties in this below. Volvo’s spring stiffness is about 200-300 Nm / figure weather and road conditions, for atleast two years. ponent level, by the supplier, and in our own test laboratory. This instance. Lower spring stiffness means that the vibration peak degree engine type.This Thisiscan be compared is followed by field testing of the complete truck on our roads in can bedepending moved outon of the driving RPMs. visualized in the tofigure. 450 Nm / degree competition. vibration extreme weather and road conditions, for at least two years. Volvo’s springcompared stiffness istoabout 200-300If the Nm/degree, Service depending ontransmission the engine type. can be are This too high, thecompared result willtobe450 the peaks into the Nm/degreeoffrom our competitors. If the vibration intonoise. the breakdown gear wheels in transmission and apeaks rattling To guarantee Exchange

partshigh quality of repair and longer lifetime of the transmissiondue are to toothe high, the result be strength the breakdown Furthermore, quality of thewill steel, can beof component, it is recommended to have the following skills, gear wheels in transmission and a rattling noise. Furthermore, components are available as Volvo Exchange Parts. maintained. This is necessary in order to dampen ignition peaks Clutch competence, tools and equipment. due to the quality of the steel, strength can be maintained. This • Clutch kit for manual transmission: Includes pressure plate, from the engine. These peaks result is about 30% more torque • Access and ability to use recommended special tools to is necessary in order to dampen ignition peaks from the engine. disc and release bearing. than normal. If the spring cannot handle these peaks, there will ensure high quality repair These peaks result in about 30% more torque than normal: if • Clutch kit for I-Shift: Includes pressure plate

and disc. bethe severe wear on the ingoing gear wheels. • Ability to use Volvo Trucks service information in order to apply spring cannot handle these peaks, there will be severe wear • Pressure plate the correct and safe repair procedures on the ingoing gear wheels. • Disc • Use of VolvoClutch TrucksActuator). service information on all required parts • CCA (Concentric Vibration needed for repair to plan and perform the repair efficiently Normal engine To secure the best possible service, uptime and efficiency, fit the Service drive revs range genuine Volvo parts at a Volvo workshop by certified technicians. Volvo disc Technical description Competitors disc Engine vibration 0 RPM Comparison of vibration peak between a Volvo disc and other discs. The wear of the disc can be measured, based on measured play; a decision can then be taken as to whether or not the disc should Recommended additional parts be replaced. On manual transmissions, this measurement is made

manually, while with I-Shift the play is recorded when the truck is Replacing clutch is time-consuming. Consider replacement of connected to the Volvoparts TechTool. the complete package insteadtoofthe individual components; a After repair, theclutch vehicle is connected Volvo TechTool, and clutch the clutch parameters are reset. For the for I-Shift. kit for manual transmission ormanual a clutchgearboxes, kit plus CCA parameter is the number of gear changes, whereas for I-Shift it relates to the clutch wear. Recommended additional parts Thehub hubisissplined splined and and can and forth on on Replacing clutch parts is time-consuming. Consider replacement • •The can therefore thereforemove moveback back and forth theshaft. shaft. This This is is to torque during geargear shifting. the to minimize minimisedrag drag torque during shifting of the complete clutch package instead of individual components; • The lining is developed to match the Volvo’s vehicle specifications: a

clutch kit for manual transmission, or a clutch kit plus CCA for • The lining is developed to match the Volvo vehicle its main components being glass fiber, phenol binders, organic fibers, rubber, charcoal and copper thread. The facing material I-Shift replacements. www.volvotrucksindiacom Unit No. 502, 5th Floor, Southern Wing (Wing-B), Embassy Prime, Bagmane Techpark, C V Raman Nagar, Bengaluru - 560 093 Phone: +91 80 6788 7000, Fax: +91 80 6788 7124 For more information contact: vtimarketing@volvo.in Follow us on: / Volvo Trucks India 2 (2)