04:01-02

Issue 2 en

Clutch and clutch control

Function and work description

© Scania CV AB 1999-10, Sweden

1 585 411
Contents

Contents
Function description General ............................................................3
Servomaster .....................................................4
Slave cylinder ..................................................6
Hose routing and connections .........................9

Work Description Renewing the servomaster.............................13

Checking the disc wear .................................15
Renewing the slave cylinder..........................16
Renewing the clutch ......................................19
Checking the pressure plate...........................20
Checking the diaphragm spring.....................23
Bleeding the hydraulic system ......................24

Troubleshooting Clutch and clutch control ..............................31

© Scania CV AB 1999, Sweden

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 General

Function description
Clutch control

General
The Scania clutch control system is hydraulic
and self-adjusting. It consists of two main
components, a compressed-air fed master
cylinder (servomaster) and a pull-type slave
cylinder with integrated release bearing. On
trucks equipped with EK power take-off, the
slave cylinder is mounted separately and the
release bearing is integrated in the clutch cover.
The system requires little pedal force which
gives good comfort and performance.

1 Position of the servomaster

2 Position of the master cylinder

© Scania CV AB 1999, Sweden

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Servomaster

Servomaster
The servomaster is actuated by the clutch pedal.
When the clutch pedal is depressed a pushrod
7 acts on an air valve 6 in the servomaster. The
air valve opens and compressed air forces the
hydraulic piston 9 downwards, which presses
the hydraulic fluid out to the slave cylinder. The
hydraulic connection 1 is restricted on some
clutches in order to reduce the flow in the
system and thus counteract vibration in the
clutch pedal.

© Scania CV AB 1999, Sweden

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 Servomaster

Servomaster, overview figure

1 Hydraulic connection to slave cylinder

2 Connection to fluid reservoir
3 Connection for ventilation hose
4 Air piston
5 Rubber bellows
6 Air valve, servo valve
7 Push rod to clutch pedal
8 Compressed air connection
9 Hydraulic piston

© Scania CV AB 1999, Sweden

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Slave cylinder

Slave cylinder Slave cylinder on vehicles without EK power

take-off
The slave cylinder is a pull-type, mounted on the
inside of the clutch housing, around the gearbox
input shaft. The moving part 3 of the slave
cylinder is connected to the diaphragm spring 5
of the clutch with a retaining ring 1. When the
slave cylinder is pressurized by the servomaster,
its moving part moves pulling the diaphragm
spring with it, and declutching occurs.
The connection between the clutch and the slave
cylinder consists of a retaining ring positioned
on the nose of the slave cylinder 8. When fitting
the gearbox, the retaining ring will snap into the
thrust washer 7 for the diaphragm spring,
locking the slave cylinder and the diaphragm
spring together.

1 Retaining ring
2 Release bearing
3 Slave cylinder, moving part
4 Slave cylinder, fixed part
5 Diaphragm spring
6 Retainer for thrust washer
7 Thrust washer
8 Nose

© Scania CV AB 1999, Sweden

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 Slave cylinder

On vehicles equipped with EK power take-off,

the slave cylinder is mounted on a separate
bracket outside the clutch housing. The release
bearing is actuated via a lever and is integrated
in the clutch cover.

Slave cylinder on vehicles with EK power take-off

1 Slave cylinder
2 Lever
3 Release bearing, integrated in clutch housing

© Scania CV AB 1999, Sweden

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Clutch, overview figure

Clutch, overview figure

1 Flywheel
2 Clutch disc
3 Pressure plate
4 Slave cylinder
5 Diaphragm spring
6 Clutch cover

© Scania CV AB 1999, Sweden

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 Hose routing and connections

Hose routing and connections

There are several different configurations of

hose routing and connections.

Hose routing between servomaster and fluid

reservoir.

Older configuration on trucks and buses

• The older configuration has a bleed nipple
on the slave cylinder and is bled like a
conventional hydraulic system. The bleed
nipple 1 is positioned above the hydraulic
line 2 to the servomaster.

Older configuration.
1 Bleed nipple
2 Hydraulic line to servomaster

© Scania CV AB 1999, Sweden

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Hose routing and connections

Configuration on trucks built after 9907

• The system is self bleeding and there is no

bleed nipple on the slave cylinder. Self
bleeding is possible due to the fact that both
the hydraulic line from the slave cylinder to
the servomaster and the hose from the
servomaster to the fluid reservoir are routed
upwards. All bleeding of the system is
carried out via the fluid reservoir. After
working on the system, bleeding is carried
out by using a special tool to pressurize the
fluid reservoir with compressed air.

Hose routing of the self-bleeding system.

1 Left-hand drive vehicle
2 Right-hand drive vehicle

© Scania CV AB 1999, Sweden

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 Hose routing and connections

Newer configuration on buses

• The bleed nipple 2 is positioned below the
hydraulic line 1 to the servomaster. The
system is bled like a conventional
hydraulic system

1 Hydraulic line routing and connection

2 Bleed nipple position on buses

On trucks with EK power take-off

• The bleed nipple is positioned on the slave
cylinder. The system is bled like a conven-
tional hydraulic system, using the bleed
nipple.

1 Position of bleed nipple on trucks equipped

with EK power take-off.

© Scania CV AB 1999, Sweden

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 © Scania CV AB 1999, Sweden
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 Renewing the servomaster

Work Description
Renewing the servomaster
Removal
Depressurize the system.

! WARNING!

Wear protective goggles. Hydraulic fluid

is corrosive and can cause permanent
eye damage.

1 Remove hose 2 to the fluid reservoir and

fold it upwards so the fluid does not drain
from the reservoir.
2 Remove the ventilation hose 3.
3 Remove the hydraulic hose 4 to the slave
cylinder. Plug both the hose and the
connections to the cylinder.

1 Retaining nuts
2 Hose to fluid reservoir
3 Ventilation hose
4 Hydraulic hose to slave cylinder

© Scania CV AB 1999, Sweden

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Renewing the servomaster

4 Remove the panel below the steering wheel.

5 Remove the union for the air supply hose 7.

Note: Use a counterhold when loosening the

union.

6 Remove the three retaining nuts 1 for the

servomaster.
7 Remove the lock pin 6 and the parallel
pin 5.
5 Parallel pin
6 Lock pin
7 Air supply hose

Alternative position for the air supply hose on

trucks built after 9912.
Fitting

Specifications

Tightening torque
Union, air supply hose 20 Nm

• Refit the servomaster in reverse order.

Note: Use a counterhold when tightening the

union for the air supply hose.

© Scania CV AB 1999, Sweden

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 Checking the disc wear

Disc wear

Check

Special tools

Number Designation Illustration Tool board

99 315 Gauge F1

To check disc wear, the measurement must be

taken directly on the disc. Remove the
protection cover over the inspection opening on
the bottom of the flywheel housing. Use gauge
99 315 and measure through the inspection
opening in the flywheel housing as shown in the
illustration.
A new disc is 10 mm thick and has a wear limit
of 7 mm. It may be difficult to reach the disc
with the gauge in some cases. If so, turn the
crankshaft using turning tool 99 309.

04_0458

© Scania CV AB 1999, Sweden

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Renewing the slave cylinder

Renewing the slave

cylinder

Removal

Vehicles without EK power take-off

1 Remove the gearbox, refer to Main group 5,
Manual gearbox, Removal and fitting.
2 Clean around the pipe connections.
3 Loosen the pipe grommet on the clutch
housing. Remove the pipes inside the clutch
housing. Older versions of trucks and buses
have two pipes. Plug the pipe connections to Slave cylinder, truck, newer version.
prevent dirt entering the hydraulic system.

Slave cylinder, bus and older trucks.

4 Remove the retaining bolts and the slave

cylinder.

Note: The slave cylinder cannot be overhauled,

renew as a complete unit.

Removal of the slave cylinder.

© Scania CV AB 1999, Sweden

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 Renewing the slave cylinder

Fitting

Vehicles without EK power take-off

Specifications

Tightening torques
Slave cylinder 22 Nm
Pipe 30 Nm

1 Screw the slave cylinder onto the clutch

housing.
2 Fit the pipes and torque tighten them.
3 Screw the grommet onto the clutch housing.
4 Fit the gearbox, refer to Main group 5,
Manual gearbox, Removal and fitting.

© Scania CV AB 1999, Sweden

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Renewing the slave cylinder

Vehicles with EK power

take-off

Removal and fitting

The slave cylinder is mounted on a bracket on
the outside of the clutch housing.

1 Slave cylinder position on vehicles with EK power take-off.

© Scania CV AB 1999, Sweden

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 Renewing the clutch

Renewing the clutch

Removal

Special tools

Number Designation Illustration Tool board

98 747 Guide pins F1

99 204 Mandrel D4
99 205 Sleeve

1 Remove the gearbox, refer to Main group 5,

Manual gearbox, Removal and fitting.

2 Remove bolts 7 and 8.

3 Fit the guide pins 98 747 in the bolt holes.
4 Fit the mandrel 99 204 with the sleeve
99 205 in the centre of the disc.
5 Remove the clutch cover and the clutch disc
by alternately loosening the remaining bolts.
6 Clean the flywheel and check it for thermal
cracks and wear.
7 Check the pressure plate, refer to Checking
the pressure plate.

© Scania CV AB 1999, Sweden

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Renewing the clutch

Checking the pressure plate

Specifications

Maximum concavity
Pressure plate 1 mm

Check the friction surface of the pressure plate

for heat damage.
If the friction surface of the pressure plate has
deep thermal cracks or blueing that may
sometimes be obvious as a movement of the
material, the clutch cover should not be re-used.
The method of machining or grinding the
friction surface of the pressure plate should not
be used, as this affects the clamping force.
Heat, caused by incorrect use of the clutch, will
often lead to the friction surface of the pressure
plate distorting and becoming concave.
The concavity is not detrimental if the same
clutch cover and disc are refitted. However,
when renewing discs it is advisable to check
how deep this concavity is.
If, by measuring as shown in the illustration, it is
found that dimension B is greater than 0.6 mm,
there is an increased risk of rapid disc wear in
the future.
If the distortion or wear, dimension B, is greater
than approx. 1 mm, the clutch cover should be Checking the pressure plate.
renewed.

© Scania CV AB 1999, Sweden

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 Renewing the clutch

Fitting

Specifications

Tightening torque
Clutch cover 47 Nm

Special tools

Number Designation Illustration Tool board

98 747 Guide pins F1

99 204 Mandrel D4
99 205 Sleeve

1 Fit the mandrel 99 204 into the flywheel

bearing. Fit the sleeve 99 205 to the mandrel
and fit the disc onto the sleeve.

Note: Turn the disc as illustrated.

Fitting the disc, arrow towards the flywheel.

2 Fit guide pins 98 747 in the threaded holes
7 and 8. Place the clutch cover on the guide
pins.

IMPORTANT! To enable the clutch cover to lie

completely flat and even against the contact
surface of the flywheel, the guide edges of the
clutch cover and flywheel must be thoroughly
cleaned.

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Renewing the clutch

3 Tighten the bolts 1-6 in the order shown in

the illustration, so that the guide edge of the
clutch cover mates evenly all around with
the guide edge A of the flywheel.

4 Remove the guide pins and fit bolts 7 and 8.

5 Check that the clutch cover sits completely
flat and even against the contact surface of
the flywheel.
6 Torque tighten bolts 1-8 to 47 Nm in the
order shown in the illustration.
7 Check tighten all the bolts to 47 Nm.
8 Remove the mandrel and the sleeve.
9 Check the diaphragm spring, refer to
Checking the diaphragm spring.
10 Fit the gearbox, refer to Main group 5,
Manual gearbox, Removal and fitting.

© Scania CV AB 1999, Sweden

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 Renewing the clutch

Checking the diaphragm spring

Specifications

Maximum deviation from the flat

Diaphragm spring fingers 1 mm

If the diaphragm spring fingers deviate too much

from the flat when the clutch cover is fitted to
the flywheel, vibration can occur in the release
bearing.
The different heights of the diaphragm spring
fingers are probably caused by a break in the
diaphragm spring or by the bolts for the clutch
cover being tightened to different torques.
Check as follows, that the diaphragm spring
fingers do not deviate more than 1 mm from the
flat due to other causes.
1 Screw the clutch cover onto the flywheel.
2 Fit the clutch cover and torque tighten the
bolts to 47 Nm.
3 Using a rule and a sliding caliper, it is
possible to determine the greatest deviation
from the flat position of the thrust washer.
If the deviation is greater than 1 mm the clutch
cover should be renewed, provided that the
cause of the deviation cannot be attributed to
faults that can be rectified i.e. incorrect fitting.

Checking the diaphragm spring fingers.

© Scania CV AB 1999, Sweden

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Bleeding the hydraulic system

Hydraulic system

Bleeding the hydraulic

system using the bleed
nipple

Other tools

Number Designation Illustration Tool board

587 949 Replenishing equipment

99 405 Bleeding tool D6

! WARNING!

Wear protective goggles. Hydraulic fluid

is corrosive and can cause permanent
eye damage.

© Scania CV AB 1999, Sweden

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 Bleeding the hydraulic system

Bleeding without replenishing

equipment 587 949

IMPORTANT! Use hydraulic fluid of the type

SAE J 1703 D.O.T:3-4 Brake Fluid.

1 Connect a suitable container to the bleed

nipple 1 at the clutch housing.

IMPORTANT! Used brake fluid must be

discarded.

Bleeding container connected to the bleed

nipple 1 at the gearbox.

2 Fill with fluid up to the maximum level of

the fluid reservoir.

IMPORTANT! Ensure that the fluid reservoir

does not become empty during bleeding.

3 Pump the clutch pedal until a resistance is

felt. Keep the pedal depressed in its lowest
position. Alternatively, the system can be
pressurized using bleeding tool 99 405.
4 Open the bleed nipple at the clutch housing
and release the fluid/air mix by depressing
the clutch pedal.
5 Close the bleed nipple and release the clutch
pedal.
6 Repeat steps 2-5 until all the air has been
removed and only pure hydraulic fluid flows
from the bleed nipple.

© Scania CV AB 1999, Sweden

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Bleeding the hydraulic system

Bleeding using replenishing equipment

587 949

! WARNING!

Wear protective goggles. Hydraulic fluid

is corrosive and can cause permanent
eye damage.

IMPORTANT! Use hydraulic fluid of the type

SAE J 1703 D.O.T:3-4 Brake Fluid.

1 Fill the reservoir of the replenishing

equipment with hydraulic fluid. The
reservoir volume is 5 litres.
2 Connect the replenishing equipment
according to the illustrations and connect a
supply of compressed air.

Replenishing equipment connected to the

hydraulic fluid reservoir.

3 Fill and bleed the system by opening the

bleed nipple 1 on the gearbox. Repeat the
bleeding until all the air has been removed
and only pure hydraulic fluid flows from the
bleed nipple. The hydraulic system volume
is approximately 0.5 litres.

IMPORTANT! Ensure that the hydraulic fluid

reservoir does not become empty during
bleeding. Bleeding container of replenishing equipment
587 949 connected to bleed nipple 1 at the
gearbox.

© Scania CV AB 1999, Sweden

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 Bleeding the hydraulic system

Bleeding the hydraulic

system without the bleed
nipple

Special tools

Number Designation Illustration Tool board

99 405 Bleeding tool D6

! WARNING!

Wear protective goggles. Hydraulic fluid

is corrosive and can cause permanent
eye damage.

! WARNING!

The hydraulic fluid reservoir may be

pressurized to a maximum of 2 bar.

IMPORTANT! Use hydraulic fluid of the type

SAE J 1703 D.O.T:3-4 Brake Fluid.

1 Fill with fluid up to the maximum level of

the hydraulic fluid reservoir.
2 Connect the cap of the bleeding tool to the
hydraulic fluid reservoir. Ensure that the cap Fitting the cap of the bleeding tool.
is correctly secured in the threads.

© Scania CV AB 1999, Sweden

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Bleeding the hydraulic system

3 Connect the bleeding tool to a compressed

air supply. The tool is pre-set to 2 bar.
4 Build up a pressure of 2 bar. Keep the
reservoir pressurized for 20 seconds. The
bleeding tool is equipped with a hook to
allow the tool to be hung up whilst the
system is being pressurized.

Hanging up the bleeding tool

1 Hook

Pressurizing the hydraulic system

5 Release the pressure using the ventilating

valve on the bleeding tool. The air in the
system will rise as bubbles in the reservoir.

1 Ventilating valve

© Scania CV AB 1999, Sweden

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 Bleeding the hydraulic system

6 Repeat the procedure according to steps 4-5

five times, though with a reduced
pressurizing time.

IMPORTANT! Ensure that the hydraulic fluid

reservoir does not become empty during
bleeding.

7 Depress the clutch pedal ten times.

8 Repeat the bleeding twice according to steps
3-7.
9 Top up the hydraulic fluid reservoir to the
maximum level.
10 Depress the clutch pedal a further 10-15
times.
11 The hydraulic system should now be
sufficiently free from air for the clutch to
function. If not, repeat the bleeding until the
clutch functions.
12 Remove the tool.

Note: There may be a small amount of air still in

the hydraulic system after bleeding, but this
disappears during driving.

© Scania CV AB 1999, Sweden

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 © Scania CV AB 1999, Sweden
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 Troubleshooting

Troubleshooting

Clutch and clutch control Symptom

Vibration in the clutch pedal when it is
When the clutch malfunctions, the following depressed or released.
trouble shooting schedule can be used to help
identify the cause and carry out remedial action.
Cause
The position numbers in the text refer to the
illustration at the end of the trouble shooting Instability in the control valve of the
section. servomaster. Applies to servomasters with an
older date code than 9750.

Faults
Action
Replace the existing unrestricted union A at the
Symptom
hydraulic connection 1 of the servomaster, with
Vibration in the clutch pedal when it is held still a restricted union and fit a new O-ring.
with the foot, irrespective of position.

Cause
Burrs in the guide edge of the clutch cover or the
diaphragm spring not lying parallel to the
pressure plate.

Action
Remove the burrs from the guide edge of the
clutch cover. Refer to Main group 4, Fitting the
clutch and Checking the diaphragm spring.
A. Union
B. O-ring
C. Servomaster
D. Restriction

© Scania CV AB 1999, Sweden

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Troubleshooting

Symptom Symptom
The clutch begins to engage. Soft pedal movement, varying position for
clutch engagement or insufficient longitudinal
stroke at the slave cylinder.
Cause
1 Fluid leak from the servomaster, slave Cause
cylinder, hydraulic hose or its connections.
Air leaking into the hydraulic fluid.
2 Internal hydraulic leak in the servomaster
due to particles of dirt, or a swollen rubber
disc caused by contamination in the Action
hydraulic fluid.
• Check all connections.

Action • Check the hose routing between the

servomaster union 2 and the fluid reservoir.
1 Tighten or renew leaking components.
• Bleed the system.
2 Renew the servomaster.

© Scania CV AB 1999, Sweden

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 Troubleshooting

Symptom Symptom
Slow pedal movement, reduced or no servo The Retarder is unintentionally activated.
function.
Cause
Cause
The pedal return spring is too weak to hold the
• No compressed air supply to the pedal in the upper position.
servomaster.
• Internal air leakage from bleeding hose 3. Action
• Air leakage from rubber bellows 5 due to a Replace the spring and spring retainer. Use
damaged cover seal. conversion kit 550 552.

• Air leak from the cover retaining ring due to

a damaged O-ring.

Action
1 Check the air supply to the servomaster.
2 Renew the servomaster.

A. Spacing washer
B. Spring retainer
C. Attaching lug

© Scania CV AB 1999, Sweden

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Troubleshooting

Symptom Symptom
Cruise control or fixed engine speed function Air leaks from the connection 3 for the
temporarily deactivated. ventilation hose.

Cause Cause
Lock pin for push rod fastens in vertical position Internal air leakage in the servomaster.
and prevents the pedal from returning to the
upper position.
Action
Action
Renew the servomaster.
Check that the lock pin is of the correct type and
is fitted correctly according to the illustration.
Symptom
Air leaks out through rubber bellows 5 when the
servo master is not in operation.

Cause
• Crack in the valve seat for the servo valve 6
due to the head of the push rod 7 having
collided with the edge of the seat in the
servomaster.
• Crack in the valve seat for the servo valve 6
caused by striking of, or tightening without
using a counterhold, the union for
compressed air connection 8.

Action
• If possible, replace the pushrod with a
longer one.
Lock pin, clutch pedal
• Renew the servomaster.

© Scania CV AB 1999, Sweden

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 Troubleshooting

Servomaster, overview figure

1 Hydraulic connection to slave cylinder

2 Connection for fluid reservoir
3 Connection for ventilation hose
4 Air piston
5 Rubber bellows
6 Air valve, servo valve
7 Push rod to clutch pedal
8 Compressed air connection
9 Hydraulic piston

© Scania CV AB 1999, Sweden

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