Shepard-Thomason Co.

BRAKE & CLUTCH REBUILDING EQUIPMENT

R83 EC LC CLUTCH SETTING/TESTING TABLE

Operating Instructions Part Identification

901 LESLIE STREET, LA HABRA, CA. 90631 TEL.: 714/773-5539 FAX: 714/773-5827

OPERATING INSTRUCTIONS Shepard-Thomason Clutch Tables INSTALLATION

CAUTION: Machine is top heavy. Remove from crate, with caution near point of installation. Unpack all tooling and accessories. Check for damage and shortages. Report damage to carrier immediately. Advise factory, within 10 days of receipt, of any shortages. Wipe machine clean. Position machine with control valves, mounted on one of the legs, to the planned operator position. Connect air line to connection ahead of air filter located on rear leg, to the left of operator's position. Air supply line should be minimum of 3/8" (95 mm) inside diameter. Air supply should be 125 psi (8.8 kg/sq cm) minimum. Machine regulators have been set at the factory at 120 psi (i.4 kg/sq cm). Adjust as required for the clutch being rebuilt. Before putting clutch or machine and accessories on table, activate air valves. Valve on operator's left, left side of front leg, operates the three (3) clamp cylinders located around the outside of the table. Lifting the handle should cause the air cylinder rods to extend. Pushing the handle down, towards the floor, should cause the rods to retract. Valve on top or on right side of table controls the center pulldown shaft. CAUTION: This is a large cylinder that exerts high forces. Do not use except in direct pulldown.

Always be sure clamp washer is fully engaged in groove, and that pulldown is always parallel to table top. Failure to do so could cause the pulldown shaft to bend or fracture. NEVER POSITION ANY PART OF YOUR BODY ABOVE PULLDOWN SHAFT WHEN UNIT IS UNDER LOAD. A DAMAGED PULLDOWN SHAFT COULD SEPARATE UNDER LOAD AND CAUSE SEVERE DAMAGE . Clean three (3) adjusting screws, part no. 40-020, and place on (1) in the hole in the rod of each of the three (3) clamp air cylinders. The adjusting screw has a knurled nut which rests on top of the cylinder rod. This nut is used to raise or lower the top of the adjusting screw so that the top clamps can be set parallel to the table top. Start with the nut against the head end of the adjusting screw.

Units With Digital Displays Carefully remove packing materials around display units. Check display units to be sure they are in proper locations. Open door (2 plastic wing screws) on loadcell display unit (one on left) and check to be sure all four (4) of the boards are forced back into their installed positions. Vibration from shipping sometimes causes the boards to move slightly forward out of position.

Probes Carefully remove packing materials around display unit. Plug in power cord(s) - 220 volt only. - 1_ Press power button on the side of the digital display unit(s). Read gauge instruction manual(s) carefully before operating. CAUTION: CAUTION: Always keep spacer pads on secured in position as severe damage to the linear measuring gauges could result. Probes and/or loadcells are precision measuring instruments and should be cared for accordingly. To reduce chance of damage, the end of the liftoff gauges should be set so that it is no higher above the gauge pad than required. In general .100 to .125 above pad is adequate.

MAINTENANCE This machine is designed and built to give years of service with minimum maintenance. Daily: Wipe pulldown shaft and lubricate with medium weight (30 w) oil or WD-40 or equivalent from the top of the table up about 5" (12.7 cm) and under the table between the shaft guide bushings. Blow grit out of table slots and lubricate as above. This is especially critical if clutches contain abrasive shot from the clutch cleaning operations. Weekly: Check and fill lubricator, part no. 40-061, with clean, non-detergent oil, preferably SAE 10 or lighter. The rate of oil delivering has been set at the factory and should need no adjustment. Under continuous 5 day - 8 hour use, the plastic bowl should required filling about once per month. Too little oil will shorten the life of the 0-rings and seals in the air cylinders and valves. To fill while under pressure, remove the fill plug at the top of the lubricator and pour the oil into bowl through the fill port only. Drain the filter unit, part no., 40-060, by pushing the shaft at the bottom of the filter to one side while the unit is under air pressure. Hold to one side until all the water is drained from the filter bowl. Observe manufacture's cautions for the filter, lubricators and regulators as per enclosed instructions. Air Valves: Long life will be achieved provided filter and lubricator are maintained. Specify machine serial number and valve when ordering. Cleanliness is extremely important when servicing. Allow no dirt or foreign material to enter valve when servicing. Air cylinders: Standard parts kits are available for convenient replacement of wearable parts (see below). Be careful to avoid introducing any dirt or chips into the cylinder during repair operations, as well as damaging piston, piston rod, cylinder tube and seals.

OPERATION INSTRUCTIONS Setup - Unit Without Liftoff Or Load Tester Place the proper set of spacer pads, part no. 40-080, three (3) required, under the pressure plate. Spacer pads located 120 apart and should be near the center of the pressure plate. Adjust cover clamps to clamp as close to the clutch mounting holes as possible. Place clutch on top of pads being careful to closely center. Place centering cone on centering shaft and center clutch. CAUTION Remove centering cone before clamping clutch or damage to clutch diaphragm will result. Position the shifting lever, part no. 40-059, until it is about the middle of it's travel. Position the cover clamps, clamping buttons over clutch cover flange, over the clamp support. Place the pin, part no. 40012, through the clamp and clamp support. Cover clamp should be in a near level position when the clamp is touching the clutch cover flange. All clamps should be set the same and the pin should be in the same location in all three of the cover clamp supports. Adjust each of the adjusting screws, part no. 40-020, so that each of the cover clamps are about 1/16" above the cover flange in the unclamped position. Move shifting lever back and forth. In the back position, the cover clamps should clear the cover flange so the clutch can readily be removed from the setting table. In the "in" position, the clamps should hit the sides of the cover - centering the clutch. Remove the centering cone. Raise lever on left valve and clamp the cover assembly. Check to verify that the cover mounting surface is flush with table. The clutch cover is now in the "vehicle installed position". Pull the valve handle on top of table moving the center shaft to the full down position. Note groove in center shaft that is just below top of the clutch diaphragm fingers. Push valve handle forward raising shaft. Place bearing ring over shaft and insert C-washer in shaft groove. Pull valve handle carefully and slowly depressing diaphragm. Stop if diaphragm depresses too much.

OPTIONAL SETUP If predetermined setting blocks are used proceed as follows: Remove clutch assembly. Raise center shaft. Place proper setting block on top of table around center shaft. Place bearing ring and C-washer on shaft. (In the proper groove.) Lower shaft until bearing ring is tight against setting block. If it is not tight, raise shaft and lower adjustable shaft stop. When bearing ring is tight, raise adjustable shaft stop until tight. Raise shaft and remove setting block.

OPERATING INSTRUCTIONS Setup - Unit with Liftoff and/or Load Tester CAUTION The gauge pads resting on the load cells are the primary setting pads and must absorb the full plate load for accurate results. The gauge pads over the liftoff probes are not to be used as the gauge pads when using the load cell gauge pads. They are for protecting the probe spindle and for securing the probe in position. They must be thinner than the load cell gauge pads. The center of the load cell gauge pad must be under the clutch pressure plate or tipping will occur resulting in erratic readings. Operation Position load cells such that the center of the load cell will be under pressure plate. Secure with the two socket cap screws. Lightly tighten screws as over tightening could restrict operation of load cell. Be sure all load cells are at the same radius. Select proper gauge pads and place on top of each load cell over the two aligning pins. Use table as a standard clutch setting table. Read plate pressure after clutch has been "broken in". Function The load from all three load cells are summed by the digital unit and displayed on the readout when the channel selector is set at 0. For analysis, the pressure of any individual load cell may be read by setting the channel selector to either 1, 2 or 3 depending on which load cell you would like to read.

NOTE: When the load cells are in a non-loaded condition, i.e. when no weight is on them, the digital display should read 0 to 5 lbs. If the reading is beyond that range, recalibrate the unit as follows. Turn system on. Select channel 1. With load cell number 1 at zero physical load, adjust balance control (Bal) number 1 to zero reading. Move red calibration switch for channel 1 to up position. Note meter reading. It should agree with the following settings: #1 #2#3If necessary, adjust span to correct. Return switch to down position. Switch selector to channel 2 and repeat and so on with 3. When finished, reset to 0 position. Meter reading will be the sum of individual channel cal valves. System is now ready to use.

LOADCELLS POSITIONED UNDER PRESSURE PLATE AS IN FIG. 1 FOR BEST RESULTS.

LOADCELLS POSITIONED AS IN FIG. 2 WILL ALSO PRODUCE ACCURATE READINGS

LOADCELLS POSITIONED AS IN FIG. 3 WILL RESULT IN ERRATIC READINGS

LOADCELLS POSITIONED AS IN FIG. 4 COULD BE DAMAGED BY COVER DURING CLAMPING

Liftoff Tester Probes must be positioned so they are located under the pressure plate. To position, loosen slightly, the hex screw in front of the probe at the top of the table and move the probe in or out radically, until at the desired location. Repeat for the other two probes. Probe Height Setting With display unit operating, zero all three displays, place a flat plate over one of the probes and observe reading. If reading is above or below the range of expected liftoff, move the probe assembly until acceptable reading is reached. Operation With clutch clamped on the table, move the lever on each of the three digital display units (Sony) to the left to 000 each of the displays. Displays should all read 000. Set Pulldown Height Machine is supplied with an adjustable spacer and an adjustable pulldown stop. The adjustable spacer is placed over the pulldown shaft before the C-washer is placed on the shaft. The adjustable pulldown stop is under the table (see Fig. 1) and is needed to limit the downward movement of the pulldown shaft. To set pulldown height, move pulldown shaft to full up position. Measure with a scale from the table top to one of the groove edges on the pulldown shaft. Switch the valve so the pulldown shaft goes down and stops at the adjustable stop. Repeat measurement above. Return shaft to the "Up" position and adjust the adjustable pulldown stop (see Fig. 1) until proper pulldown is achieved. Several tries may be necessary to achieve exact setting. Move pulldown shaft to "Up" position. Place adjustable spacer on top of clutch over pulldown shaft. Place C-washer in slot just above adjustable spacer. Adjust spacer until it just touches the C-washer. Moving the pulldown shaft to the full down position should depress the clutch fingers proper pulldown. Digital display now read plate lift. Display and table slide are marked to show corresponding position of reading. To remove clutch, push valve handle to center shaft forward. Remove C-washer and adjustable spacer. Remove clutch by lifting straight up. Do not slide, as pressure plate may hit the side of the probes and cause damage.

Center pulldown cylinder force versus regulator air pressure (in pulldown) 6" cylinder with 1 3/8" Rod. Note: Pulldown force is Theoretical and does not account for pressure losses caused by

4000 3000 2000 1000 0 friction. 20 40 60 80 100 120 140 160