s e r v i c e m a n u a l clutch servo vg3286 / vg3287 e r v i c e m a n u a l clutch servo vg3286 /...

24
Commercial Vehicle Systems Service Manual Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions

Upload: buinga

Post on 12-May-2018

221 views

Category:

Documents


2 download

TRANSCRIPT

Page 1: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

C o m m e r c i a l V e h i c l e S y s t e m s

S e r v i c e M a n u a l Clutch ServoVG3286 / VG3287

Description/Function

Servicekit

Serviceinstructions

Page 2: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

Disclaimer

The information contained in this document is intended for the exclusive use of trained persons within the commercial vehicle industry, and must not be passed on to any third party.

All recommendations regarding products and their servicing or usage are with reference to Knorr-Bremse products and should not be considered applicable to products from other manufacturers.

This information does not purport to be all-inclusive and no responsibility is assumed as a result of its use. We cannot accept any liability nor offer any guarantee regarding data accuracy, completeness or timeliness. The information does not represent any guarantee or ensured characteristics of the Products or Systems described.

No liability can be accepted based on the information, its use, recommendations or advice provided. In no event may we be held liable for any damage or loss except in the case of wilful intent or gross negligence on our part, or if any mandatory legal provisions apply.

Any legal disputes arising from the use of this information shall be subject to German law.

Note: If service work is carried out on the vehicle, it is the responsibility of the workshop to ensure the vehicle is fully tested and in full functional order before the vehicle is returned into service. Knorr-Bremse accepts no liability for problems caused as a result of appropriate tests not being carried out.

This disclaimer is an English translation of a German text, which should be referred to for all legal purposes.

Page 3: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

Contents

Safety and Environment Guidelines 4

1 Overview 7

1.1 ClutchServoComponents. . . . . . . . . . . . . . . . . . 7

1.2 ProductidentificationandavailableServiceKit. . . . . . . . . . . . 8

2 General Information 9

2.1 Lubricant. . . . . . . . . . . . . . . . . . . . . . . 9

2.2 TorqueRequirements . . . . . . . . . . . . . . . . . . . 9

3 Description and Function 10

3.1 ClutchServoSectionedView. . . . . . . . . . . . . . . . . 10

3.2 DescriptionofOperation. . . . . . . . . . . . . . . . . . . 11

4 Removing the Clutch Servo from the Gearbox 12

5 Disassembly Process for Booster Cylinder 13

6 Disassembly Process for Control Unit 15

7 Assembly Process for Booster Cylinder 17

8 Assembly Process for Control Unit 21

9 Refitting the Clutch Servo to the Gearbox 23

Page 4: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

Safety and Environment Guidelines

Note: The safety advice listed below is applicable to general service and diagnostic work on pneumatic systems. Also observe any recommendations from the axle or vehicle manufacturer concerning towing, jacking-up and securing the vehicle.

Before and during working on or around compressed air systems and devices, the following precautions should be observed:

1 Always wear safety glasses when working with air pressure.

2 Never exceed the vehicle manufacturer’s recommended air pressures.

� Never look into air jets or direct them at anyone.

� Never connect or disconnect a hose or line containing pressure; it may whip as air escapes.

5 When removing or servicing a product, ensure all pressure related to the specific system it is contained in has been depleted to 0 bar. Be aware that if the vehicle is equipped with an air dryer system, it can also contain air pressure along with its purge reservoir, if fitted, even after pressure has been drained from the other reservoirs.

6 If it is necessary to drain the air pressure from reservoirs, etc., keep away from brake actuator push rods and levers since they may move as system pressure drops. On vehicles fitted with air suspension, it is advised when undertaking such work, to support the chassis from sudden lowering and therefore prevent any possibility of being trapped between the chassis and axle or ground.

7 Park the vehicle on a level surface, apply the parking brakes, and always chock the wheels as depleting vehicle air system pressure may cause the vehicle to roll.

8 When working under or around the vehicle, and particularly when working in the engine compartment, the engine should be shut off and the ignition key removed. Where circumstances require that the engine be running, EXTREME CAUTION should be taken to prevent personal injury resulting from contact with moving, rotating, leaking, heated or electrically charged components. Additionally, it is advisable to place a clear sign on or near the steering wheel advising that there is work in progress on the vehicle.

9 When working on vehicles equipped with air suspension, to guard against injury due to unexpected downward movement of the chassis caused by sudden pressure loss in the suspension system, ensure that the vehicle chassis is mechanically supported with a ‘prop’ between the chassis and the axle or between the chassis and the ground.

10 Examine all pipework for signs of kinks, dents, abrasion, drying out or overheating. Be aware that kinks in pipework may result in air pressure being trapped in the pipework and associated equipment. Replacement hardware, tubing, hose, fittings, etc. must be of equivalent size, type and strength as original equipment and be designed specifically for such applications and systems. Check the attachment of all pipework; it should be installed so that it cannot abrade or be subjected to excessive heat.

11 Components with stripped threads or damaged/corroded parts must be replaced completely. Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle or component manufacturer.

12 Never attempt to install, remove, disassemble or assemble a device until you have read and thoroughly understood the recommended procedures. Some units contain powerful springs and injury can result if not properly dismantled and reassembled. Use only the correct tools and observe all precautions pertaining to use of those tools.

1� Before removing any device note its position and the connections of all pipework so that the replacement/serviced device can be properly installed. Ensure that adequate support or assistance is provided for the removal/installation of heavy items.

1� Only use genuine replacement parts, components and kits as supplied by Knorr-Bremse or the vehicle manufacturer. Only use the recommended tools as specified in related service instructions.

15 The serviced or replaced product must be checked for correct function and effectiveness.

16 If products have been dismantled, serviced or replaced, whose performance could affect braking performance or system behaviour, this should be checked on a roller dynamometer. Bear in mind that a lower performance may be experienced during the bedding-in phase if new brake pads/linings and/or brake discs/drums have been fitted.

17 Prior to returning the vehicle to service, make certain that all components and the complete brake systems are leak free and restored to their proper operating condition.

Safety and Environment Guidelines

Page 5: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

5

Safety and Environment Guidelines

Welding

To avoid damage to electronic components when carrying out electrical welding, the following precautions should be observed:

1 In all cases, before starting any electrical welding, remove all connections from any electronic control units or modules, noting their position and the order in which they are removed.

2 When re-inserting the electrical connectors (in reverse order) it is essential that they are fitted to their correct assigned position - if necessary this must be checked by PC Diagnostics.

Disposal of Waste Equipment by Business Users in the European UnionThis symbol on the product, packaging or in user instructions, indicates that this product must not be disposed of with other general waste. Instead, it is your responsibility to dispose of the waste electrical and electronic parts of this product by handing them over to a company or organisation authorised for the recycling of waste electrical and electrical equipment. For more information about arrange-ments for waste equipment disposal please contact your Knorr-Bremse distributor or local Knorr-Bremse representative.

Page 6: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

6

Page 7: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

7

1

1

2 34 5

6

7

8 910 11

12 13

14 15

21

16

1718

19 2021 20

1918

22

2324

2526

27 28

2930

31

Overview

1.1 Clutch Servo Components

1 Overview

1 Retaining Ring2 Locking Plug� O-Ring� Ring5 Grooved Ring6 Control Piston7 Compression Spring8 Sleeve9 Retaining Ring10 O-Ring11 Valve Seat12 Valve Head

1� Compression Spring1� Bush15 O-Ring16 Main Housing17 Compression Spring18 Slide Ring19 Grooved Ring20 Disc21 Retaining Ring22 Push Rod Assembly2� Piston2� Grooved Ring

25 Guide Ring26 O-Ring27 Disc28 Retaining Ring29 Bellows�0 Flange�1 Screw (�x)

Page 8: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

8

1

KNORR-BREMSE

XXXXXXXXXXXXX

XXXXX XXXXX

KNORR-BREMSE

XXXXXXXXXXXXX

XXXXX XXXXX

Overview

1.2 Product Identification and available Service Kit

Use only genuine Knorr-Bremse parts!

The following service kit is available :

Description Contents Comments

Service Kit 1, �, �, 5, 6, 8, 10, 12, 15, 18, 19, 2�, 25, 26, 29 includes grease

Type of Clutch Servo Knorr-BremsePart no.

Knorr-BremseDate of Manufacturer

Page 9: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

9

2General Information

2.1 Lubricant

2 General Information

2.2 Torque Requirements

Part Number Discription Quantity

I9069� Silicon Grease 25g

Thread Size Description Torque Spanner Size (mm)

M8 Mounting Bolts refer to vehicle manufacturer`s recommendations

_

M8 Bleed Screws 10 Nm Hexagon key (9 mm)

M1� Hydraulic �5 Nm Hexagon key (19 mm)

M16 Pneumatic �5 Nm Hexagon key (22 mm)

Page 10: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

10

3

21

12

3 4 6 7 8 9 10 11 12 13 14 155 16 17

18 19 20 21 20 19 18 22 23 24 25 27 26 28 2930

31

Description and Function

3.1 Clutch Servo Sectioned View

3 Description and Function

Hydraulic Port

Pneumatic Port

Exhaust Port

Hydraulic Chambers

Pneumatic Chambers

1 Retaining Ring2 Locking Plug� O-Ring� Ring5 Grooved Ring6 Control Piston7 Compression Spring8 Sleeve9 Retaining Ring10 O-Ring11 Valve Seat12 Valve Head

1� Compression Spring1� Bush15 O-Ring16 Main Housing17 Compression Spring18 Slide Ring19 Grooved Ring20 Disc21 Retaining Ring22 Push Rod Assembly2� Piston2� Grooved Ring

25 Guide Ring26 O-Ring27 Disc28 Retaining Ring29 Bellows�0 Flange�1 Screw

Page 11: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

11

3Description and Function

3.2 Description of Operation

As the driver allows the clutch pedal to lift, hydraulic pressure decreases and the control piston (6) moves under the influence of compression spring (7) and of pressurized air. However, since the valve head (12) is not able to move, due to being in contact with the valve seat (11), a gap is created between control piston (6) and valve head (12) and air is released to the exhaust port. As both hydraulic and pneumatic pressure decrease, the push rod assembly (22) moves backwards and hence the clutch starts to engage. If the driver holds the clutch pedal at any mid position, hydraulic pressure stops decreasing. Air pressure will however continue to decrease resulting in a reduction in force on the control piston. The latter will therefore eventually move forward until it reaches the valve head (12) and the exhaust of air is stopped. At this point, the clutch is therefore only partly engaged.

If the driver subsequently allows the clutch pedal to lift further, the above process will be repeated until hydraulic pressure becomes zero. When this happens, the control piston (6) moves fully backwards and the gap between control piston (6) and valve head (12) is continuously open. The clutch is then fully engaged.

Clutch Engaging Phase(Driver releases the clutch pedal)

Clutch Disengaging Phase(Driver pushes the clutch pedal)

As the driver pushes the clutch pedal, hydraulic pressure increases on both the push rod assembly (22) and the control piston (6). At a certain pressure, the control piston (6) overcomes the compression spring (7) and moves forward, therefore exhaust gap between control piston (6) and valve head (12) is closed. As the valve head (12) continues to move it is lifted from valve seat (11), pressurized air can therefore enter the pneumatic space and act on piston (2�); thus assisting the forward load on the push rod and helping the driver to disengage the clutch (servo effect). When the driver stops pushing the clutch pedal further, hydraulic pressure no longer increases. However, the gap between valve head (12) and valve seat (11) is still open and air pressure continues to rise, eventually moving the control piston (6) backwards until the gap between valve head (12) and valve seat (11) is closed. No further increase of air pressure therefore takes place, an equilibrium state is reached and the push rod assembly (22) stops moving. Depending on the height of the clutch pedal, the clutch is therefore partly disengaged. Further pushing of the clutch pedal will repeat the above process. Full depression of the clutch pedal will of course fully disengage the clutch

Page 12: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

12

4

M8

M8

M8

M14M16

M8

Removing the Clutch Servo from the Gearbox

4 Removing the Clutch Servo from the Gearbox

1Before starting work on the vehicle please refer to the “Safety and Environment Guidelines“ - see Page �.

2 Vent the system air pressure using reservoir drainage points.

� Disconnect hydraulic and pneumatic lines.

�Disconnect the push rod of the device from the push rod of the gearbox - refer to vehicle manufacturer`s recommendations.

5 Unscrew and remove the four M8 mounting bolts and remove device.

Step Service task

!

Mounting Bolts

Mounting BoltsHydraulic Connection

Mounting Bolts

Mounting Bolts

Pneumatic Connection

Page 13: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

1�

5

�0�1

2229

�0

28

29

�0

27

26

2�

Disassembly Process for Booster Cylinder

!

Step Service task

1 Clean the outside of the clutch servo to prevent entry of dirt.

2 Clamp the body in a vice to provide proper support for the disassembly (Fig.1).

�Remove screws (�1) and remove flange (�0).CAUTION: Pre-tensioned spring is under the flange; while unscrewing, maintain hand pressure on the push rod assembly (22) (Fig.2).

�Detach push rod assembly (22) from bellows (29). Use a tool with a round profile in order to avoid damage to the bellows (Fig. �).

5 Detach bellows (29) from flange (�0) (Fig. � and 5).

6 Remove retaining ring (28) and detach disc (27) (Fig. 6 and 7).

7 Remove O-ring (26) and detach push rod assembly (22) from piston (2�) (Fig. 8 and 9).

Fig.1 Fig.2 Fig.�

Fig.� Fig.5 Fig.6

Fig.7 Fig.8 Fig.9

!

5 Disassembly Process for Booster Cylinder

Page 14: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

1�

5

2�

25 2�

21

18

19

20

21

1819

20

Disassembly Process for Booster Cylinder

8 Detach guide ring (25) and grooved ring (2�) from piston (2�) (Fig. 10 and 11).

9Remove compression spring (17) to gain access to the seals between the hydraulic and pneumatic sides.

10 Remove retaining ring (21) (Fig. 12).

11 Remove slide ring (18) (Fig 1�).

12 Remove grooved ring (19) and disc (20) (Fig. 1�).

1� Remove second retaining ring (21) (Fig. 15).

1� Remove second grooved ring (19) and disc (20) (Fig. 16).

15 Remove second slide ring (18) (Fig 17).

Step Service task

Fig.10 Fig.11 Fig.12

Fig.1� Fig.1� Fig.15

Fig.16 Fig.17

Page 15: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

15

6

5

1

6

2�

6

Disassembly Process for Control Unit

Fig.18 Fig.19 Fig.20

Fig.22 Fig.2�Fig.21

6 Disassembly Process for Control Unit

Step Service task

1 Clean the outside of the clutch servo to prevent entry of dirt.

2 Clamp the body in a vice to provide proper support for the disassembly process (Fig. 18).

� Remove retaining ring (1) (Fig. 19).

�Remove locking plug (2) using suitable grips. DO NOT use a spanner to break the plug free, because the housing or the plug can easily be damaged (Fig. 20).

5 Remove plastic ring (�) (Fig. 21)..

6 Remove control piston (6) (Fig. 22).

7 Remove grooved ring (5) with a suitable tool taking care not to damage the cylinder bore (Fig. 2�).

!

!

Page 16: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

16

6

8

1�

1�15

10

1112

7

9

Disassembly Process for Control Unit

Step Service task

8 Remove compression spring (7) (Fig. 2�).

9 Remove sleeve (8) with a suitable tool (Fig. 25). Do not damage the sealing surface

10Remove retaining ring (9) from the groove inside the control cylinder. Use a small circlip clamp.Do not damage the sealing surface (Fig. 26).

11Remove O-ring (10) and valve seat (11) as an assembly, valve head (12), compression spring (1�), bush (1�) and O-ring (15) with a suitable tool (Fig. 27 - �1). Do not damage the sealing surface

Fig.25

Fig.27 Fig.28 Fig.29

Fig.�0 Fig.�1

Fig.2� Fig.26

sealingsurface

Page 17: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

17

7

18 18

19

18 19

20

21

20

21

19

20

21 22

18

18

20

2019

21

19

Assembly Process for Booster Cylinder

Step Service task

! All parts included in the service kit must be changed, even if no visible damage can be seen on the old parts ! Use only the grease provided in the kit

Fig.2 Fig.�

Fig.� Fig.5

Fig.6 Fig.7 Fig.8

7 Assembly Process for Booster Cylinder

1Clean all the sealing surfaces from dirt and grease with a dry piece of cloth or paper and ensure they are free of damage. Note the correct alignment and orientation of each component (Fig. 1).

2Grease slide ring (18) evenly and place it in the housing with the “crowns“ pointing upwards (Fig. 2). Ensure it is properly seated (Fig. �).

�Grease grooved ring (19) and place it in the bore, so that the groove fits over the “crown“ points of the slide ring (18) (Fig. �).

� Grease disc (20) and place it on grooved ring (19) (Fig. 5).

5 Grease retaining ring (21) and fit to the housing with a suitable tool (Fig. 6).

6 Grease disc (20) and place it on retaining ring (21) (Fig. 7).

7 Grease grooved ring (19) and place it on disc (20) with the groove upwards (Fig. 8).

Fig.1

Page 18: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

18

7

17

18

19

26

2�

2�

2�

1821

22

2�

2�

Assembly Process for Booster Cylinder

!

Step Service task

8Grease slide ring (18) and place it in the bore so that the “crowns“ point downwards and fit in the groove of the grooved ring (19) (Fig.9). Ensure it is properly seated (Fig.10).

9 Grease retaining ring (21) and fit to the housing with a suitable tool (Fig. 11).

10 Grease the whole inner surface of the booster cylinder (Fig. 12).

11 Place compression spring (17) in the housing (Fig. 1�).

Note: Parts 22-30 have to be separately assembled

12Grease grooved ring (2�) and fit to piston (2�) so that the grooved side of the ring is as shown in (Fig.1�).

1� Grease O-ring (26) and fit to piston (2�) (Fig. 15).

1� Fit the piston assembly on the push rod assembly (22) as shown in (Fig.16).

Fig.9 Fig.10 Fig.11

Fig.12 Fig.1� Fig.1�

Fig.15 Fig.16

Page 19: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

19

7

1729

�0

27

2525

2�

28

22

Assembly Process for Booster Cylinder

!

Step Service task

15 Grease guide ring (25) and fit to the piston assembly (Fig. 17).

16 Attach disc (27) to the piston assembly so that it fits into the recess of guide ring (25) (Fig. 18).

17 Fit retaining ring (28) in the groove on push rod assembly (22) to secure the piston assembly (Fig. 19).

18

Attach bellows (29) to flange (�0). Use a round-headed tool to avoid damage to the bellows (Fig. 20 and Fig.21).CAUTION: If the two parts are not correctly assembled or bellows is damaged, dirt can enter the booster cylinder and the lifetime of the device will be shortened

19 Grease push rod assembly (22) and place it in the housing (Fig. 22).

20 By compressing the spring (17), push the piston assembly to its end position (Fig. 2�).

Fig.17 Fig.18 Fig.19

Fig.20 Fig.21 Fig.22

Fig.2�

!

29

�0

Page 20: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

20

7

�1

�0

�1

�0

2222

2222

Assembly Process for Booster Cylinder

Step Service task

21Hold the piston in this position and re-grease the inner surface of the booster cylinder. (Fig. 2�). After re-greasing, DO NOT let the piston assembly come fully out of the cylinder

22Attach the flange and bellows assembly to the piston assembly and fix flange (�0) to the housing with screw (�1) x� (Fig.25).

2� Expose the threaded end of the push rod assembly (22) (Fig. 26 - Fig. 27).

!

Fig.2� Fig.25 Fig.26

Fig.27

Page 21: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

21

8

11

10

1�1�

12

151�2

5

6

10

8

7

911

121�

1�15

910

11

Assembly Process for Control Unit

sealing surface

!

Step Service task

1Clean all the sealing surfaces from dirt and grease with a dry piece of cloth or paper and ensure they are free of damage. Note the correct alignment and orientating of each component (Fig. 28).

2 Grease the inner surfaces of the control cylinder evenly (Fig. 29)

�Grease O-ring (15) and carefully place it in the control cylinder. Check if part is properly seated by visual inspection (Fig. �0).

�Grease bush (1�) and place it in the control cylinder so that the larger diameter side touches the O-ring (15) (Fig. �1).

5 Insert compression spring (1�) in the control cylinder so that it sits on bush (1�) (Fig. �2).

6Grease and place valve head (12) in the control cylinder; the smaller diameter portion slides inside the compression spring (1�) (Fig. ��).

7Grease and attach O-ring (10) to valve seat (11), grease both parts and place in the control cylinder as shown in (Fig ��).

8Fit retaining ring (9) in the groove inside the control cylinder while valve seat (11) is pushed to its end position. Take care not to damage the sealing surface Check carefully if retaining ring (9) is securely seated in the groove (Fig. �5).

!

8 Assembly Process for Control Unit

co

ntro

l cylin

de

r

Fig.29 Fig.�0Fig.28

Fig.�1 Fig.�2

Fig.�� Fig.�5Fig.��

Page 22: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

22

8

7

6

8

2

1

2

5

Assembly Process for Control Unit

!

Step Service task

9 Grease sleeve (8) and place it in the control cylinder with “crowns“ pointing upwards (Fig. �6).

10Place compression spring (7) in the control cylinder, larger diameter end fitting within “crowns“ of sleeve (8) (Fig. �7).

11Place control piston (6) in the cylinder with smaller diameter end fitted inside compression spring (7) (Fig. �8).

12Grease grooved ring (5) and place it on control piston (6) with grooved side pointing upwards (Fig. �9).

1�Grease and attach O-ring (�) to locking plug (2), grease both parts again and mount ring (�) on locking plug (2). Ring (�) must snap on locking plug (2) (Fig. �0).

1�Place locking plug assembly in the control cylinder so, that ring (�) pushes grooved ring (5) in the cylinder (Fig. �1).

15 While pushing locking plug (2) in the cylinder, fit retaining ring (1) in the groove (Fig. �2).

Fig.�6 Fig.�7 Fig.�8

Fig.�9 Fig.�0 Fig.�1

Fig.�2

CAUTION: Test the clutch servo ONLY when it is securely mounted to the gearbox with the correctly torqued mounting bolts - see section 9 !

!

grooved side

Page 23: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

2�

9

M8

M8

M8

M14M16

M8

M8

Refitting the Clutch Servo to the Gearbox

1 Reconnect the push rod and adjust the position - refer to vehicle manufacturer`s recommendations.

2 Tighten the four M8 mounting bolts - refer to vehicle manufacturer`s recommendations.

� Reconnect hydraulic and pneumatic lines. For tightening torques - see section 2.2.

� Do the bleeding process carefully - refer to vehicle manufacturer`s recommendations.

5 After the bleeding process tighten the bleed screw carefully. For tightening torque - see section 2.2 .

6Check all fittings and seals for leakage using soap and water while engaging and disengaging the clutch several times. There must be no leakage!

Step Service task

!

!

Mounting Bolts

Mounting BoltsHydraulic Connenction

Mounting Bolts

Mounting Bolts

Pneumatic Connenction

Bleed Screws

9 Refitting the Clutch Servo to the Gearbox

Page 24: S e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 e r v i c e M a n u a l Clutch Servo VG3286 / VG3287 Description/Function Service kit Service instructions Disclaimer The information

C o m m e r c i a l V e h i c l e S y s t e m s

Knorr-Bremse Systeme für Nutzfahrzeuge GmbH Moosacher Straße 80 80809 Munich Germany Tel: +49 89 3547-0 Fax: +49 89 3547-2767www.knorr-bremseCVS.com

This

docu

men

t is

subj

ect t

o al

tera

tion

with

out n

otice

and

ther

efor

e a

prin

ted

copy

may

not

be

the

late

st re

visio

n. P

leas

e ch

eck

our w

ebsit

e w

ww.

knor

r-bre

mse

CVS.

com

for t

he la

test

upd

ate

or c

onta

ct y

our l

ocal

Kno

rr-Br

emse

repr

esen

tativ

e.

The

figu

rativ

e m

ark “

K” a

nd th

e tra

dem

arks

KNO

RR a

nd K

NORR

-BRE

MSE

are

regi

ster

ed in

the

nam

e of

Kno

rr-Br

emse

AG.

Add

itiona

l ter

ms

and

cond

itions

app

ly; p

leas

e re

fer t

o ou

r web

site

knor

r-bre

mse

CVS.

com

und

er th

e “D

ocum

enta

tion”

ta

b. N

ote:

If s

ervic

e w

ork

is ca

rried

out

on

a ve

hicle

as

a re

sult

of in

form

atio

n ta

ken

from

this

docu

men

t, it

is th

e re

spon

sibilit

y of

the

wor

ksho

p to

ens

ure

the

vehi

cle is

fully

test

ed a

nd in

full f

unct

iona

l ord

er b

efor

e th

e ve

hicle

is re

turn

ed in

to

serv

ice. K

norr-

Brem

se a

ccep

ts n

o lia

bility

for p

robl

ems

caus

ed a

s a

resu

lt of

app

ropr

iate

test

s no

t bein

g ca

rried

out

.Cop

yrig

ht 2

010

© K

norr-

Brem

se A

G –

all r

ight

s re

serv

ed, i

nclu

ding

indu

stria

l pro

perty

righ

ts a

pplic

atio

ns. K

norr-

Brem

se A

G re

tain

s an

y po

wer

of d

ispo

sal,

such

as

for c

opyin

g an

d tra

nsfe

rring

. Rel

ease

d 06

/201

0

Sweden Knorr-BremseSystem for Tunga Fordon ABMalmöTel: +46 40 680 5880Fax: +46 40 937490 SwitzerlandKnorr-BremseSysteme für Nutzfahrzeuge GmbHBassersdorf Tel: +41 44 888 77-55Fax: +41 44 888 77-50

Turkey Knorr-BremseSysteme für Nutzfahrzeuge GmbHFindikli - IstanbulTel: +90 212 293-4742Fax: +90 212 293-4743

United Kingdom Knorr-Bremse Systems for Commercial Vehicles Ltd.BristolTel: +44 117 9846-100Fax: +44 117 9846-101

A m e r i c a

Brazil Knorr-BremseSistemas para Veículos Comerciais Brasil Ltda.São Paulo Tel: +55 11 5681 1104Fax: +55 11 5686 3905

USA Bendix Commercial Vehicle Systems LLC Elyria, OH Tel: +1 440 329-9100Fax: +1 440 329-9105

A s i a – A u s t r a l i a

AustraliaKnorr-Bremse Australia Pty. Ltd. Granville NSWTel: +61 2 8863-6500Fax: +61 2 8863-6510

China Knorr-Bremse Brake Equipment (Shanghai) Co. Ltd. ShanghaiTel: +86 21 3858-5800Fax: +86 21 3858-5900

China Knorr-Bremse Asia Pacific (Holding) LimitedTruck Brake Systems DivisionHong Kong Tel: +852 3657-9800Fax: +852 3657-9901

India Knorr-BremseSystems for Commercial Vehicles India Private Ltd.PuneTel: +91 20 6674-6800Fax: +91 20 6674-6899

Japan Knorr-Bremse Commercial Vehicle Systems Japan Ltd.SaitamaTel: +81 49 273-9085Fax: +81 49 282-8601

Korea Knorr-Bremse Korea Ltd. Truck Brake DivisionSeoul Tel: +82 2 2273-1182Fax: +82 2 2273-1184

Europe – Africa Austria Knorr-Bremse GmbHSysteme für NutzfahrzeugeMödling Tel: +43 2236 409-436Fax: +43 2236 409-434

BelgiumKnorr-Bremse Benelux B.V.B.A.Heist-op-den-BergTel: +32 1525 7900Fax: +32 1524 9240

Czech RepublicKnorr-Bremse Systémy pro uzitková vozidla, CR, s.r.o.Straz nad NisouTel: +420 482 363-611Fax: +420 482 363-711

France Knorr-Bremse Systèmes pour Véhicules Utilitaires France S.A.Lisieux CedexTel: +33 2 3132 1200Fax: +33 2 3132 1303

Germany Hasse & Wrede GmbH Berlin Tel: +49 30 9392-3101Fax: +49 30 7009-0811

Germany Knorr-Bremse Systeme für Nutzfahrzeuge GmbH Munich Tel: +49 89 3547-0 Fax: +49 89 3547-2767 HungaryKnorr-Bremse Fékrendszerek Kft.Kecskemét Tel: +36 76 511 100Fax: +36 76 481 100

ItalyKnorr-Bremse Sistemi per Autoveicoli Commerciali S.p.A.Arcore Tel: +39 039 6075-1Fax: +39 039 6075-435

Netherlands Knorr-Bremse Benelux B.V.B.A.Mydrecht Tel: +31 297 239-330Fax: +31 297 239-339

PolandKnorr-Bremse Polska SfN Sp. z o.o.WarsawTel: +48 22 887-3870Fax: +48 22 531-4170

Russia Knorr-Bremse RUS Nizhniy NovgorodTel: +7 8312 57-6661Fax: +7 8312 57-6791

Russia Knorr-BremseSysteme für Nutzfahrzeuge GmbHMoscowTel: +7 495 234-4995Fax: +7 495 234-4996

South Africa Knorr-Bremse S.A. Pty. Ltd. Kempton Park Tel: +27 11 961-7800Fax: +27 11 975-8249

SpainBost Ibérica, S.L.Irun (Guipuzcoa) Tel: +34 902 100-569Fax: +34 943 614-063

Y093009-EN-000