Call Toll Free - Ace Manufacturing
Contents
1. ENGINE HP amp TORQUE 35 IN SEOUENCE BY HORSEPOWER NOTE RATE VARIABLE HORSEPOWER ENGINES TO HIGHEST HORSEPOWER TORQUE ENGINE RPM TORQUE RPM ca dea Siw ET wo 1 99 hm ew wm 00 ato wo wo uo 1 9 casso 1 100 o o 69 o CUM M11 330E oee 1 86 no IT INOHOL Y dH ANIDNA 36 Call Toll Free 1 800 325 6138 IN SEOUENCE BY HORSEPOWER NOTE RATE VARIABLE HORSEPOWER ENGINES TO HIGHEST HORSEPOWER TORQUE ENGINE RPM TORQUE RPM so too _ SA mm o 150 5600 oee o 560 600 gt GRAF RS 000 _ ENGINE HP TORQUE o e e gt 7 4 gt ha D e P x E H s r www ACE MFG com 0 1 YN m ii cK ES fe 37 IN SEOUENCE BY HORSEPOWER NOTE RATE VARIABLE HORSEPOWER ENGINES TO HIGHEST HORSEPOWER TORQUE ENGINE RPM TORGUE RPM aman EE AAA 0 e Tse eo o 6 em ee J oo wo um mhemm2. ENGINE HP amp TORGUE r www ACE MFG com a e Fa 17 Wes JON f 4 A i A 4 0 e i i 4 4 4 IN SEOUENCE BY HORSEPOWER NOTE RATE VARIABLE HORSEPOWER ENGINES TO HIGHEST HORSEPOWER TORQUE ENGINE HP RPM TORGUE RPM MACK EM6 250L 1750 1190 1020 MACK E7 250 MECH 1950 1200 1 co o 5 MACK EM7 250 MECH 250 1020 MACK EM7 250L 250 1020 CAT 3116 GM MD 250 1560 SERIES 50 8 5L IL 4 250 1200 CAT 3066 260 1350 CUM 1 10 260 1200 CUM L 10 STC 12CGA 1200 CUM L 10 STC 12CGB 9 1200 VOLVO 260E 300AE 7 7 8 7 1080 5 8 6 CUM L10 270 1300 CUM 1 10 270 1400 CUM FORM 270 270 1300 CUM FLEET 270 270 1100 CAT 3116 275 1560 CAT 3116 GM MD 275 1560 INTL 530 275 1300 MACK EM7 275 MECH 1250 MACK EM7 275 V MAC 1250 SERIES 50 8 5L 1 L 4 1200 WE F INOHOL Y dH ANIDNA 34 Call Toll Free 1 800 325 6138 IN SEOUENCE BY HORSEPOWER NOTE RATE VARIABLE HORSEPOWER ENGINES TO HIGHEST HORSEPOWER TORQUE ENGINE RPM TORGUE RPM HP 28020001050 eo va it c a Pa e E 7 D Ni cet Ch p pe T E e D s f gt ve A Let pa 4 4 y a v a 4 ae l a www ACE MFG com 5 Se we
3. SLIM HILNTI da mem CALL TOLL FREE 1 800 325 6138 Phone 573 468 4181 Fax 573 468 5584 22 Call Toll Free 1 800 325 6138 This clutch installation kit includes the following Clutch Housing Gasket e Shift Lever Housing Gasket e Front Bearing Cover Gasket Bearing w Snap Ring Inner Retaining Ring Pilot Bearing Outer Retaining Ring e Cross Shaft Bushings e Front Bearing Cover e Standard Release Yoke e 2 Torque Brake e 2 10 Spline Input Shaft CALL TOLL FREE 1 800 325 6138 ACE MANUFACTURING amp PARTS CO INC 300 Ramsey Sullivan MO 63080 Phone 573 468 4181 Fax 573 468 5584 www ACE MFG com n E 5 2 0 23 gt tn A de Clutch Installation Tool Kit Part ATK 200 Clutch Adjustment Gauge Disc Alignment Shaft Clutch Alignment Pins Shaft Removal Tool and Flywheel Gauge CALL TOLL FREE 1 800 325 6138 LIM TOOL NOILVTIVISNI ACE MANUFACTURING 8 PARTS CO INC 300 Ramsey Sullivan MO 63080 Phone 573 468 4181 Fax 573 468 5584 24 Call Toll Free 1 800 325 6138 A Y VIDA AAA 0 CLUTCH INSTALLATIO GUIDELINES Tech Tip You must have a minimum of 5 16 distance from the friction surface face of your flywheel to the top of the bolthead that holds the flywheel to the crankshaft If it is less than 5 16 you need a NEW flywheel E Z RIDER
4. CUM N14 435E 1650 DD 8V92TAC 1250 CUM 444 1400 CUM NTC444XT 444 2100 1400 400 400 400 410 410 410 410 410 410 410 410 410 410 420 425 425 425 425 425 427 430 430 430 430 430 430 430 430 430 435 435 435 435 435 435 435 CUM N14 435E 435 440 444 444 a o tae d WW h b 4 a tee A A a f 1 L fi TK ap www ACE MFG com ENGINE HP amp TORQUE 39 INOHOL Y dH ANIDNA LR l dei 2 jis 4 DE 1 i I o o IN SEOUENCE BY HORSEPOWER NOTE RATE VARIABLE HORSEPOWER ENGINES TO HIGHEST HORSEPOWER TORQUE ENGINE HP RPM TORQUE RPM 2100 1250 1300 450 1900 1420 1300 2100 1350 1500 2100 1350 1500 4 2100 1460 1200 1800 1460 1200 1900 1495 1300 SERIES 92 12 1L V 8 450 2100 1425 1200 1650 1560 1650 1550 1450 1550 1550 1550 1550 1550 1450 1550 1650 1650 1650 1750 1750 1330 1200 1250 1200 1100 1200 1200 1200 1200 1200 1200 1200 1750 1200 1200 1200 1200 1300 3406 CAT MACK E 7 454 CUM N14 469E CUM N14 CELECT 12 CDJ DD 12 7L 2100 1800 2100 1700 2100 1800 2100 1800 2100 1800 2100 2100 2100 1800 1800 2100 2100 2100 1430 1400 2100 1430 1400 1800 1800 2100 1800 1900 al al Ala o Ol OO P m o BIE NIN Ojo T gt N o SERIES 60 12 7L 1 L 6 430 470 SERIES 60 1
5. C Bs Manufacturing amp Parts Co American Made Clutches Since 1967 E Z RIDER MW li iz id li IEAVY DUTY CLUTCHES FOR ALL MEDIUM HEAVY DUTY VEHICLES By Ace Manufacturing amp Parts Co VisitSOunAWebsite WWWAGE MFG com METSAS AN 181 e Fax 573 468 5584 A 4 Po SF A wei de 4 gg OF CONTENTS gt Benefits amp Features Cryogenic Treated Disc Springs Friction Material Comparison Determining Proper Clutches E Z Clutch Selection Guide 7 Medium Duty Clutches ne e e e eno e e 8 67 a 9 Heavv Dutv Clutches o ei ei eo EDNA eo 10 04 agak rr e O 11 WAN X2 OO DIINO men mmen g 12 10 02 SDNNIO ist UU 13 15 12 SPA N E E E 14 9 1912707176 Flywheels ci Ae o e ro EE E DONC AGO GON 15 a e PEO A o 16 17 DOO no 18 ei PP A 18 N Uu MACK Pe o nee eena 19 N m 0 20 21 24 9 IN UE tel RE Ve nno 25 28 0 2 kr 29 30 gt 6 216 81 5 16 m Adjustment NIAIMENANCE MIS E 31 0 Engine Horsepower amp Torque Ratings e 32 40 Quick Reference aaa aan kaaa aa aaa aa aaa kakaa aa aaa aa aaa aa aaa aa aaa aa aaa aa aaa ka aaa kaaa kaaa RR REAR aaa 41 2 Call Toll Free 1 800 325 6138 l A Nr e Ma sm y i r EG sno gt mo
6. www ACE MFG com 15 1 2 x 2 8 Spring 7 Flywheel Bore TORQUE PLATE LD DISC STYLE PEDAL PART NUMBER COMMENTS 1250 3600 dd SR ES DUAL EZ208391 77B 1250 3600 ES TMS 107391 77B Co Ft Organic 8 Springs Co Ft STD 107391 82B 1400 4000 TORQUE PLATE LD DISC STYLE PEDAL PART NUMBER COMMENTS Ceramic 8 Spring Available With 1400 3600 A Pad Co Ft pau DUAL EZ208391 81B Ceramic 8 Spring 1400 3600 4 Pad Co Ft STD 107391 81B 5383 ALNA AAVJH lt L SI Ace Mfg amp Parts Co manufactures the parts shown above Spicer is a registered trademark of Dana Corp E Z Rider is a registered trademark of Ace Mfg amp Parts Co Inc Sullivan MO USA 1 2 Call Toll Free 1 800 325 6138 15 1 2 x 2 10 Spring 8 5 Flywheel Bo 1450 A000 aa Ba DUAL EZ208391 78B 1450 4000 Organic 10 Spring 107391 78B Co Ft Ceramic 10 Spring Available With 1650 3600 A Pad Co Ft DUAL EZ208391 74B Ceramic 10 Spring 1650 3600 A Pad Co Ft STD 107391 74B Ceramic 10 Spring Available With Ceramic 10 Spring 1860 4000 A Pad Co Ft STD 107391 93B 15 1 2 HEAVY DUTY CLUTCHES Ace Mfg 8 Parts Co manufactures the parts shown above Spicer is a registered trademark of Dana Corp zu ES lo ap www ACE MFG com A i N N 222 7 Spring 10 Flywheel Bor d Ceramic 7 Spring With 1700 3600 A Pad Co Ft az DUAL EZ208925 82B Cer
7. EEO Y a E Z RIDER lt By Ace Manufacturing amp Parts Co Heavy Duty Clutches Flywheels amp Clutch Accessories No cores to handle Because we are the manufacturer only new parts and assemblies are used E Z Rider clutch units are manufactured and assembled in the U S A at our Sullivan Missouri St Louis facility e The Ace E Z Rider series clutch has the easiest pedal action of any new clutch on the market Ace maintains a number of design and process patents to achieve the soft pedal Dual adjust feature Every Ace clutch incorporates the E Z adjust feature and the manual adjust capability e Disc springs Every Ace E Z Rider clutch unit is shipped with disc that contain chrome silicon valve quality steel disc springs that have been cryogenically treated A patented process that is exclusive to Ace This process has eliminated spring failures e Friction Material Ace offers asbestos free woven organic proprietary sintered copper and iron materials of high friction properties which results in low wear and high reliability Test results show increased clutch life and less wear to the mating parts with the iron based buttons e Fiber Brake Spacer Shipped free of charge in every new Ace clutch unit The spacer is essential to achieve brake sgueeze when the flywheel has been resurfaced e State of the art assembly Unlike the competition every
8. ONLY use an 8 spring disc B If flywheel bore is 8 5 use a 10 spring disc C If flywheel bore is 10 use a 7 spring 6 spring VCT or a 9 spring Mack Only D If you have a 10 flywheel bore DO NOT USE ORGANIC FACING The facing I D will extend into the flywheel bore opening not having full facing contact NA DAT HJINTI I Vv SECTION A A 6 Call Toll Free 1 800 325 6138 s t s a a ee E Z Clutch Selection Guide CLUTGH MODELS TO USE BY FLYWHEEL BORE SIZE All 14 clutches use 8 spring disc assemblies and can be used only with 7 flywheel bore size Disc types will vary and are designed to be used with a specific flywheel bore size Shown below are the E Z RIDER and STANDARD clutch models designed for each bore size 7 7 25 lu bi Standard Clutch choices BORE 107390 77 A 0 a 107391 77B 107391 818 107391 82B 8 Spring Disc 8 5 8 562 BORE Standard Clutch choices 107391 74B 107391 78B 107391 93B 10 E Z CLUTCH GUIDE 9 750 BORE Standard Clutch choices 107925 82B 107935 51 Mack 7 amp 9 Spring Disc For non standard reguirements and or selection of the specific model for a vehicle follow the clutch selection procedure in the catalog E Z Rider is a registered trademark of Ace Mfg amp Parts Co Inc Sullivan MO USA a 0 c
9. 2RSNR RING GEAR AF673GB222 15 FLAT FLYWHEEL 10 BORE DOWEL HOLE TIMING MARK 6 METRIC BOLT HOLES USE 9 SPRING CLUTCH BEARING AB197S 6306 2RSNR 20 RING GEAR 118 TEETH RING GEAR AF673GB222 15 FLAT FLYWHEEL 10 BORE DOWEL HOLE TIMING MARK 6 METRIC BOLT HOLES USE 9 SPRING CLUTCH BEARING AB197S 6306 2RSNR 20 RING GEAR 117 TEETH RING GEAR 673GB35 MACK E7 E TECH SERIES FLYWHEELS MACK YUVLSIAVN STIIAMATI 14 FLAT FYWHEEL 7 BORE 9 MOUNTING BOLT HOLES USE 8 SPRING CLUTCH BEARING AB195 6205 17 RING GEAR 137 TEETH RING GEAR 1800777C1 14 FLAT FYWHEEL 7 BORE 8 MOUNTING BOLT HOLES USE 8 SPRING CLUTCH BEARING AB195 6205 17 RING GEAR 138 TEETH RING GEAR AF1815440C1 14 FLAT FLYWHEEL 7 BORE 10 MOUNTING BOLT HOLES USE 8 SPRING CLUTCH BEARING AB190 6206 OR AB199 6305 17 RING GEAR 138 TEETH RING GEAR AF1800777C1 14 FLAT FLYWHEEL 7 BORE 12 MOUNTING BOLT HOLES USE 8 SPRING CLUTCH BEARING AB190 6206 OR AB199 6305 17 RING GEAR 138 TEETH RING GEAR AF1815440C1 NAVISTAR 1 3 INTERNATIONAL 6 9 INTERNATIONAL NAVISTAR DT466 NAVISTAR 1 3 INTERNATIONAL NAVISTAR DT466E Call Toll Free 1 800 325 6138 CH Ki Clutch Accessories Drive Pin 14 Flywheel 6 per card MABBP I 2 Brake Spacer 6 per card 15885 TI 1 75 Brake Spacer 6 per card bm 1 75 2 pc Hinge Clutch Brake
10. Ace clutch unit is shipped as a serialzed matched unit and digitally recorded to the specific a serial number e Mack application As part of the E Z Rider series we offer EZ208935 51 and the EZ208935 51H heavy duty version of the Mack 9 spring clutch unit New 9 spring units have typically been reserved exclusive to the Mack dealer program E Z RIDER e Cast cover replacement Ace offers a cast cover replacement for the medium duty stamped steel throw away clutch e Training and fieldwork Ace will provide training and hold clutch clinics free of charge Our techs will happily troubleshoot an installation or failure e Warranty All Ace clutch units offer 12 months and unlimited mileage warranty against defects in material and workmanship Fa w Z e 1 Get A Ad i sg 7 4 S4 PA gt 4 Te 4 d B F x NT PAN dif PA 4 4 wW i m 1 4 i kal H d 4 U www ACE MFG com oo Cryogenic Treated Disc Springs A patented process exlusive to Ace EZ Rider Clutches One of the many selling features of Ace s 7 E Z Rider series clutch units is an exclusive patented process of Cryo treating our disc springs Unlike most clutch manufacturers and rebuilders we start with a chrome silicon valve quality spring With the combination of higher quality steel and cryo treating we have virtually eliminated d
11. MOUNTING BOLT HOLES USE 8 SPRING CLUTCH CUMMINS BEARING AB197 6306 L10 M11 DRIVE PINS NOT INCLUDED 17 RING GEAR 103 TEETH RING GEAR AF4797 SNIAWWn92 ST334HMA 14 LL O Call Toll Free 1 800 325 6138 15 FLAT FLYWHEEL 10 BORE 6 MOUNTING BOLT HOLES USE 7 SPRING CLUTCH BEARING AB197 6306 17 RING GEAR 103 TEETH RING GEAR AF4797 15 FLAT FLYWHEEL 10 BORE 8 MOUNTING BOLT HOLES USE 7 SPRING CLUTCH BEARING AB197 6306 RING GEAR AF4797 17 RING GEAR 103 TEETH 14 FLYWHEEL 7 BORE 8 MOUNTING BOLT HOLES USE 8 SPRING CLUTCH BEARING AB190 6206 RING GEAR AF3903309 173 TEETH CUMMINS NT855 N14 CUMMINS M11 CUMMINS 5 9 B FLYWHEELS CUMMINS 15 FLAT FLYWHEEL 10 BORE 12 MOUNTING BOLT HOLES USE 7 SPRING CLUTCH BEARING AB197 6306 20 RING GEAR 118 TEETH RING GEAR AF5166664 DETROIT SERIES 60 14 FLYWHEEL 7 BORE 8 MOUNTING BOLT HOLES USE 8 SPRING CLUTCH BEARING AB195 6205 17 RING GEAR 138 TEETH RING GEAR AF5116302 DETROIT 8 2 14 FLAT FLYWHEEL 7 BORE 8 MOUNTING BOLT HOLES USE 8 SPRING CLUTCH BEARING AB190 6206 17 RING GEAR 138 TEETH RING GEAR AFE6HZ6384A adOJ LIOALIO STITHMA TA 18 Call Toll Free 1 800 325 6138 www ACE MFG com 1 A fe 15 FLAT FLYWHEEL 10 BORE 20 RING GEAR 118 TEETH USE 9 SPRING CLUTCH 675 amp 676 BEARING AB197S 6306
12. PROCEDURE Cont Once the external parts are in tune with the clutch record the measured amount of free pedal movement in the vehicle log This is the normal standard pedal travel for this vehicle Then if and when the clutch again needs adjustment it should be adjusted back to this standard Example If pedal travel standard is 2 the clutch may need adjustment when wear has reduced it to about 1 of travel INSTALLER SHOULD CAREFULLY CHECK TO VERIFY THAT THERE IS 1 8 OF FREE TRAVEL BETWEEN THE YOKE AND THE WEAR PADS AND A MINIMUM OF 1 2 TO 9 16 OF SPACE BETWEEN THE BEARING AND THE CLUTCH BRAKE fas i EE EE i DEM LNIWLSAFrAV HINTI E Z Rider is a registered trademark of Ace Mfg amp Parts Co Inc Sullivan MO USA 3 D Call Toll Free 1 800 325 6138 Maintenance Tips IT IS IMPORTANT TO NOTE THAT THESE ARE GENERAL GUIDELINES ONLY AND THAT THE INSTALLER SHOULD ALWAYS REFER TO THE VEHICLE MAINTENANCE MANUAL FOR SPECIFIC DETAILS Only high temperature grease should be used for clutch bearing housing and linkage lubrication Do not use chassis lubricant for clutch lubrication Refer to the vehicle maintenance manual for lubricant specifications 2 Lubricate the clutch release bearing each time the chassis is lubricated 3 When lubricating the clutch apply lubricant to each fitting on the clutch housing 4 Every point in the clutch linkage must be lubricated i
13. fem wo un AA o wn teso INOHOL Y dH ANIDNA 38 Call Toll Free 1 800 325 6138 IN SEOUENCE BY HORSEPOWER NOTE RATE VARIABLE HORSEPOWER ENGINES TO HIGHEST HORSEPOWER TORQUE ENGINE HP RPM RPM 0 40 SERIES 60 12 7 1L 6 40 180 1450 1200 SERIES 60 12 7 1L 6 40 21000 1450 1200 SERIES 60 12 7 1L 6 1450 1200 SERIES 92 12 11 V8 40 2100 1320 1200 CAT C 12 410 1600 1450 1200 CAT C 12 40 180 1550 1200 CAT C 12 410 2100 1550 1200 CUM N14 410 410 2100 1450 1200 CAT 3406E 94 Ap 1600 1550 1200 CAT 3408 40 19000 1460 1200 DD 12 71 45 2100 1400 1200 428 es 428 es AA IE 480 480 80 EE 430 480470 CUM N14 STC 12 CEE CUM N14 STC 12 CEG CUM N14 CELECT 12 CEN CAT 3406E CAT C 12 RCVBUS 1450 1200 CAT 3406B 1450 CAT 3406C 1550 CAT 3406C 1650 MACK E7 427 1560 CUM N14 CELECT 12 CDC 1450 CUM N14 CELECT 12 CEP 1550 DD 12 7L 1450 DD 12 7L 430 470 1550 SERIES 60 12 7L 1 L 6 4380 1800 1450 SERIES 60 12 7L 1 L 6 430 2100 1450 SERIES 60 12 7L 1 L 6 1450 SERIES 60 12 7L 1 L 6 1450 CAT 3406E 94 45 100 1650 440 IEA 1200 1200 1200 1250 1100 1300 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1650 1200 1200 1200 1200 1200 1200 1200 1300 1500 1500
14. to install the spacer without removing the clutch and clutch brake Cut a V shape on the fiber so it can be twisted and slipped onto the input shaft from the side Be sure to cut the bottom of the V smaller than the O D of the input shaft so it won t fall off during operation see schematic 2 You should now be able to twist the fiber and fit it over the input shaft between the clutch brake and the transmission flange You can now proceed to reset the clearance between the bearing lid and clutch brake at 1 2 to 9 16 with the internal clutch adjuster Schematic 1 Recommended Openings we For 2 Shafts O D O D 2 0 I D 1 5 For 1 3 4 Shafts LD OD 1 75 Schematic 2 LD 1 25 NOILVTIVISNI HLNTI 1 3 4 Fiber Part No A153 2 Fiber Part No A148 E Z Rider is a registered trademark of Ace Mfg 8 Parts Co Inc Sullivan MO USA 26 Call Toll Free 1 800 325 6138 www ACE MFG com FOR E Z RIDER 14 amp 15 5 TWO PLATE CLUTCHES 1 14 amp 15 5 A new pilot bearing should be used Before installing pilot A Ni GENERAL CLUTCH INSTALLATION GUIDELINES 14 amp 15 5 Check condition of flywheel If it is cracked or warped resurface or replace flywheel Surface must be smooth or premature clutch failure can occur Flywheel depth must be 2 937 for 14 two plate clutches The 15 5 clutch uses a flat flywheel REMEMBER Machining the f
15. 1 T As YAA 20539 898 108991998 Rrotaos 06 00666 2062919991 TO mere _ www ACE MFG com QUICK REFERENCE CLUTCH PART NUMBER DESCRIPTION EZ208925 82B EZ208925 82H EZ208391 74B EZ107237 8CB EZ108050 59B EZ208935 51H FLYWHEEL PART NUMBER DESCRIPTION AF1821915C91 AF23509709 AF1818214C91 AF1265875 AF530GB3170 AF1810855C93 AF3921263 AF3071615 AF4P4797 AF3016495 ON1T13S OL 14 12 Call Toll Free 1 800 325 6138 www ACE MFG com Peo em 2 Manufacturing amp Parts Co American Made Clutches Since 1967 Our 118 000 square foot manufacturing and distribution facility is located 60 miles southwest of St Louis in Sullivan Missouri Ace has been providing the highest guality clutches clutch parts and assemblies to the heavy duty industry for over 40 years SALES SUPPORT DIRECTORY Robbin Thayer Sales amp Marketing Manager 573 468 4181 ext 142 573 468 5584 rthayer ace mfg com Craig Callaway Technical Representative Cell 636 432 2191 573 468 5584 clutchtech live com Technical Representative 573 468 4497 asettles ace mfg com For high quality be AMR low cost American made E Z RIDER Clutches CALL 1 800 325 6138 or visit our website www ace mfg com mm ANT TAN 468 5584 rmoreno ace mfg com I mI IA U
16. 14 8 15 5 Start bell housing cap screws and tighten progressively to the torgue recommended by the vehicle manufacturer 17 14 8 15 5 Release bearing has been pre packed with grease from the factory 18 14 amp 15 5 Install clutch linkage See Clutch Adjustment Procedure 28 Call Toll Free 1 800 325 6138 E Z RIDER CLUTCH ADJUSTMENT PROCEDURE NOTE E Z RIDER clutches are adjusted at the factory to original equipment specifications and should require very little internal adjustment to achieve proper release and engagement The clutch must not be adjusted to accommodate thin or worn flywheels or worn linkage yoke and or cross shaft bushings or to accommodate other drive train deficiencies Adjustment for such purposes will either cause the clutch to not function properly or will cause early clutch failure and will be apparent on factory inspection of warranty claims and therefore will void the manufacturer warranty THIS PROCEDURE COVERS BOTH 14 AND 15 1 2 CLUTCHES STEP 1 After clutch installation check the clearance between the yoke tips and wear pads on bearing housing for 1 8 clearance This determines pedal freeplay See lllustration Adjust the clutch linkage to increase or decrease the yoke to bearing clearance NEVER USE THE INTERNAL CLUTCH ADJUSTMENT FOR THIS PURPOSE STEP 2 Check for proper clutch brake and bearing gap of 1 2 to 9 16 If the gap is not with
17. 2 7L 1 L 6 430 470 SERIES 60 12 7L 1L 6 SERIES 60 12 7L 1L 6 CAT 3406 CAT 3406E CAT 3406E CAT 3406E CAT 3406E DD 8V92TA CUM TWIN TURBO NTC 475 CAT 3406E 94 DD 12 71 AJAJIA NININ Dojo 1 NIN oi oi BIE NIN a N 6 T gt N al Es A N N al al a O1 5 ojo CUM N14 500 MACK E9 500 al O o CUM N14 500E 500 2100 CUM N14 500E 2100 1750 CAT 3406E 94 500 1800 CAT 3406 2100 CAT 3406 2100 CAT 3406 500 2100 SERIES 60 12 7L 1 L 6 1800 SERIES 60 12 7L 1 L 6 2100 SERIES 92 12 1L V8 500 2100 CAT 3406 510 1600 CUM N14 525 1800 CUM KT 525 1983 525 2100 2100 1800 550 2100 CUM KTA 600 1983 _ 60 2100 o 600 2100 CUM SIGNATURE 60 60 2100 Call Toll Free 1 800 325 6138 ledium Dut Owick Reference Medium DUTY QUICK Nererence EZ107237 4CB 107237 8 N10713751CE MU129044 37 DSCB M129044 6F5 N10723722CE MU129044 37DSCB M1290446F5NSP 0 2 ARA N1076835CE MU127747DSCB M1277476F5 rr 1 0 2659 E ar o 0 00 ees doma mw Heavy Duty Quick Re eziosoassz 811491 NioBossse 12740008 Messe ezosoa __ Wees 12 00088 3006065966 METEO I AI R eessen Niosos059 MUI27SSGOSCE 3 06 096 0661 1 2266991778 1899 778 mens DS 059665 _ 11 6 9
18. 430 1500 GM 6 5L TURBO 180 3400 360 1700 CAT 3116 85 2600 520 1560 CAT 3116G 85 2600 495 1560 CAT 3116 85 2200 520 1560 FORD 7 3L NATASP 85 3000 360 1400 CAT 3126 90 2200 520 1440 CUM 6BTA5 9 90 2500 475 1600 FD 1060 190 2500 475 1600 FORD 7 3L TURBO 190 3000 395 1400 GM 6 5 L TURBO 190 3400 385 1700 INTL DT 408 190 2600 485 1800 INTL T444E 190 2600 485 1500 MACK E3 190 MECH CAT 90 2500 475 1300 3116 95 2200 521 1560 INTL DT 466 195 2400 520 1600 CAT 3116 MD 200 2600 520 1560 CAT 3208T MD 200 2000 620 1400 200 2600 495 1560 200 2600 520 1560 CAT 3126 210 2200 605 1440 CAT 3126 210 2400 520 1440 CUM 6BTA5 9 210 2500 520 1600 CUM 6CT8 3 210 2200 605 1500 FD 1060 210 2500 485 1600 FD 1060 210 2300 520 1600 FD 1460 210 2200 605 1300 INTL DT 408 210 2600 1800 INTL DT 466 2400 1600 wech INOHOL Y dH ANIDNA 32 Call Toll Free 1 800 325 6138 A 4 el IN SEQUENCE BY HORSEPOWER NOTE RATE VARIABLE HORSEPOWER ENGINES TO HIGHEST HORSEPOWER TORQUE ENGINE RPM TORGUE RPM EE ET TE 6838968998 oe om 60 00 oos am 560 155 ou es mn 660 un wm 1 1 om GG mmm UR a none ja 2m om 1600 cwm oo w oo w oee 1 70 10 505200 800 120 1 em 50 68 om 140 46 1 em uo 8 20 om am 6
19. Co Ft 6525598203 DUAL EZ108063 59A Ceramic 8 Springs A Pad Co Fi 107063 59A 1400 3600 ph TON Sealed Pilot Bearings ligh Performa cri ICE Elastomer VITO J Excellent Resistance To Petro Chemicals Fluids Extreme Temperaturas a NOW A Minimum Requirement By all O E MI S far 5 hito ka IDO Le le with the SIHILNTI ALNA AAVSH Vb Ace Mfg amp Parts Co manufactures the parts shown above Spicer is a registered trademark of Dana Corp E Z Rider is a registered trademark of Ace Mfg amp Parts Co Inc Sullivan MO USA 10 Call Toll Free 1 800 325 6138 Ceramic 8 Springs IC i 3 Pad Co Ft Ceramic 8 Springs VER SC 3 Pad Co Ft 1150 3600 Organic 8 Springs EZ Co Ft Organic 8 Springs 1150 3600 EE Ceramic 8 Springs 4 Pad Co Ft Ceramic 8 Springs 4 Pad Co Ft Ceramic 8 Springs 4 Pad Co Ft Ceramic 8 Springs 4 Pad Co Ft STD STD STD DUAL STD DUAL STD DUAL STD DUAL STD 107034 61B 107034 82B EZ108050 59B 107050 59B EZ108050 69B 107050 69B E7108034 61B Available With Iron Button Heavy Duty Plate Available With Iron Button Heavy Duty Plate Standard Plate Available With Iron Button Standard Plate Ace Mfg amp Parts Co manufactures the parts shown above Spicer6 is a registered trademark of Dana Corp E Z Rider is a registered trademark of Ace Mfg amp Parts Co Inc Sullivan MO USA Wi ym Ei 1
20. Heavy Duty Clutches CLUTH INSTALLATION ACE MANUFACTURING amp PARTS CO INC 300 Ramsey Sullivan MO 63080 Phone 573 468 4181 Fax 573 468 5584 www ACE MFG com a N 1 F P 2 CLUTCH INSTALLATION GUIDELINES Does your new clutch need a clutch brake spacer Our E Z RIDER clutches are pre adjusted at the factory Therefore no adjustment should be reguired at the time of installation However if the flywheel has been reground and or the transmission flange is worn you may need to use a fiber spacer in conjunction with the new clutch brake you are installing with the clutch On vehicles with this type of wear the common complaint at time of installation is can t get the clutch brake to sgueeze The solution could be to use the 1 8 fiber brake washer Or you may need to replace the flywheel Before deciding that however we suggest you install the spacer to see if that solves the problem One is included with this clutch for that purpose If you do not need it discard or save for future installations To use the spacer slide the fiber washer onto the input shaft next to the transmission before the clutch brake itself is put on Then install the clutch and set the linkage per your usual procedure see schematic 1 If the clutch and the transmission are already installed without the spacer and you are having release problems it may be possible
21. amic 7 Spring 1700 3600 4 Pad Co Ft STD 107925 82B Ceramic 9 Spring Mack Only 1700 3600 DUAL EZ208935 51 Available With 4 Pad Co Ft Iron Button Ceramic 9 Spring 1700 3600 4 Pad Co Ft 107935 51 Mack Only Mack Only Available With Iron Button Ceramic 9 Spring 6 Pad Co Ft 5383 ALNA AAVJH lt L SI Ace Mfg amp Parts Co manufactures the parts shown above Spicer is a registered trademark of Dana Corp 14 Call Toll Free 1 800 325 6138 www ACE MFG com 1 T TAMA A 15 FLAT FLYWHEEL 10 BORE 12 MOUNTING BOLT HOLES USE 7 SPRING CLUTCH BEARING AB197 6306 20 RING GEAR 113 TEETH RING GEAR AF4N2514 3406 3406E 14 FLAT FLYWHEEL 7 BORE 10 MOUNTING BOLT HOLES USE WITH 8 SPRING CLUTCH BEARING AB199 6305 OR AB190 6206 RING GEAR AF9L8113 RING GEAR 968113 17 RING GEAR 134 TEETH 14 FLAT FLYWHEEL 7 BORE 8 MOUNTING BOLT HOLES 1 DOWEL PINHOLE BEARING AB190 6206 2RS 17 RING GEAR 134 TEETH RING GEAR 7W5095 3116 3126 FLYWHEELS CATERPILLAR 14 POT FLYWHEEL 7 BORE 6 MOUNTING BOLT HOLES CUMMINS USE 8 SPRING CLUTCH NT855 BEARING AB197 6306 SMALL CAM DRIVE PINS NOT INCLUDED BIG CAM 17 RING GEAR 103 TEETH RING GEAR AF4797 15 FLAT FLYWHEEL 8 5 BORE 6 MOUNTING BOLT HOLES USE 10 SPRING CLUTCH BEARING AB197 6306 17 RING GEAR 103 TEETH RING GEAR 4797 CUMMINS NT855 N14 14 POT FLYWHEEL 7 BORE 8
22. artensite It is believed the cryogenic process causes atoms to diffuse or migrate to these voids and fill them creating a more homogenious grain structure that aids in improved properties SINIIdS 3570 DINTOOLAD We also use this process for all our tools such as dies punches drills taps broaches and cutting inserts Depending on the parts being treated Ace recognizes a 50 300 percent increase in performance life of our tools JA Call Toll Free 1 800 325 6138 Manufacturing amp Parts Co American Made Clutches Since 1967 More aggressive higher torgue low wear Cons Rough on mating surfaces Better heat resistance smoother engagement than ceramic good wear easy on mating surfaces Cons Lower coefficient than ceramic lower torgue than ceramic Iron Base Smooth engagements light medium duty excellent on mating surfaces not recom mended for 300 HP engines FRICTION MATERIAL Cons Low torque Woven Non Asbestos Organic SA QI www ACE MFG com 4 RS 9 Determining The Proper Clutch For Your Vehicle 1 Determine the size of the clutch 14 or 15 5 2 If 15 5 then measure the center flywheel opening Dimension A in the illustration Approximate flywheels sizes 7 8 5 or 10 3 Determine engine torque at current settings See Page 32 Torque Chart A If flywheel bore is 7
23. en depressing the pedal to end of stroke The feeler gauge must be tightly clamped between the bearing and the clutch brake See lllustration This verifies the contact of the bearing to the clutch brake The clutch brake will be sgueezed if the total pedal stroke slightly exceeds the movement required to move the yoke fork 5 8 to 11 16 the combined total of the 1 8 clearance between yoke tips and wear pads and the 1 2 9 16 brake sgueeze gap IN THE EVENT THE BRAKE IS NOT BEING SOUEEZED DO NOT CHANGE THE 1 2 9 16 GAP FOR THE CLUTCH BRAKE OR THE 1 8 CLEARANCE FOR THE BEARING HOUSING CONSULT THE VEHICLE MANUFACTERER SERVICE MANUAL In analyzing the reasons for the brake not being sgueezed other things to check for are A Worn linkage components or yoke and cross shaft bushings If necessary replace those components B Improper linkage assembly Verify that linkage is assembled in the correct hole locations C Pedal stroke To adjust raise the upper and or lower the lower pedal stops NOTE MAXIMUM BRAKE SQUEEZE IN CAB OF TRUCK SHOULD NOT EXCEED 1 FROM THE END OF PEDAL STROKE IF IT DOES IT CAN BE ADJUSTED BY A Changing pedal stops in cab to reduce total pedal stroke B Increasing 1 8 yoke to bearing setting to lower sgueeze This will increase free pedal travel CLUTH ADJUSTMENT continued qe a 6 29 www ACE MFG com E Z RIDER CLUTCH ADJUSTMENT
24. he center plate should move up and down freely on the pins 6 14 Only Install front clutch disc center plate and rear disc as marked 7 14 Only Insert alignment shaft through both clutch discs making sure it enters the pilot bearing NOTE If an old pilot shaft with worn splines is used to align clutch disc transmission pilot shaft may damage clutch hubs during installation of transmission 14 Only Position cover assembly onto the pilot shaft and guide towards flywheel mounting surface making sure the cover fits into the flywheel pilot Start cap screws K rey ae e Pa p i ge y n l ai g g a pi ka e A gt A ES na si Ze 7 4 s d i i A ey 1 A CLUTH INSTALLATION 21 A Pug s 5 a Ki a ei e 3 a A a a 4 A vi 4 M _ 4 a S A 4 o gt mn GENERAL CLUTCH INSTALLATION GUIDELINES Cont FOR E Z RIDER 14 amp 15 5 TWO PLATE CLUTCHES 9 15 5 Only Insert alignment shaft through bearing housing Install rear disc center plate and front disc on alignment shaft Move clutch housing towards flywheel making sure cover fits into flywheel pilot 14 amp 15 5 Only Install the cap screws that fasten the clutch housing on the flywheel Tighten the cap screws to the specified to
25. i 86969 2 200Hinge oben _ EN mans Oversized 2 po Hinge Clutch Brae o IE T Spring LoaceaAgusier OOO 1 75 Torque Limiting Brake A236BP A230EZ SPRING ADJUSTER SPRING ADJUSTER een A Pilot Bearing Viton Sealed for Mack 1 PC CLUTCH BRAKE CLUTCH BRAKE B201BP AB195BP AB197BP a ee SBP ABI nn STIH C 890 475 X10 SPLINE HO plot arr __ 2 0010 SPLINE 1180 NE es ATHTI50 ATHTI75 MM AT HT175A AB195SBP 819758 ATHT175X1 ER AT HT200 ma LI amp Em a A CLUTCH ACCESSORIES CS106C1094BP CSB12815BP IPS1659 CSF105C137BP LONG SHAFT BUSHING INPUT SHAFT 2 A148BP RELEASE YOKE BELL HOUSING BELL HOUSING 10 SPLINE W BUSHING FIBER DISC ACE MANUFACTURING amp PARTS CO INC 300 Ramsey Sullivan MO 63080 Phone 573 468 4181 Fax 573 468 5584 aw 3 B 1 4 j i e De y y www ACE MFG com bM ME cz Ba e po ANTA i ere e n Kit PR a ch Installatio Our BASIC Clut Part AK2200 Includes 1 CSF105C137 Fork 1 A240 2 Brake 4 CSB12915 Bushings Part AK2175 Includes 1 CSF105C137 Fork 1 A239 1 75 Brake 4 CSB12915 Bushings i 4 v y A e Our BASIC Clutch Installation Kit Part AK2201 Includes 1 CSF105C137 Fork 1 B201 2 2 Piece Clutch Brake 4 CSB12815 Bushings
26. in these tolerances the clutch needs adjusting If the clutch does need adjusting remove the lock strap and set the clearance between the bearing and clutch brake at 1 2 to 9 16 THIS DIMENSION IS CRITICAL DO NOT VARY EITHER OVER OR UNDER THESE DIMENSIONS UNDER ANY CIRCUMSTANCES Use the internal adjustment on the clutch to move the bearing Turn adjuster clockwise to move bearing towards transmission to decrease clearance or counter clockwise to move the bearing towards the engine to increase clearance If internal adjustment exceeds 4 notches either way the clutch may not release or may slip Put tension on the linkage to be sure bearing is stretched and no movement towards the engine is noticed Measure clutch brake and bearing gap with 1 2 9 16 gauge See lllustration Once the adjustment is set re install lock strap REMINDER The bearing must move a minimum of 1 2 or clutch will not release Eliminate lost motion before checking for 1 2 movement Lost motion is generally caused by loose or worn linkage or worn yoke or cross shaft bushings STEP 3 If internal clutch adjustment was made re verify the 1 8 clearance between the yoke tips and wear pads on bearing housing shown in Step 1 above If necessary re align linkage to obtain proper clearance See lllustration STEP 4 Re verify the clutch brake sgueeze by inserting 010 feeler gauge between bearing and clutch brake th
27. isc spring failure Our cryogenic process involves taking springs slowly down to 300f The temperature cycle is regulated by a computer controlled flow of nitrogen into the chamber where the parts are placed After the disc springs are returned to room temperature they are placed in a tempering furnace and tempered to a setting of 300f 400f A variety of improvements are gained such as stress relief wear resistance and fatigue life Testing reflects an increase in spring life from 2 to 5 times that of an untreated spring The cryogenic process most commonly applies to heat treated steels Heat treated steels are stronger and harder Heat treating is a process of heating the steel quenching in oil or water and draw tempering Steel is com prised of austenite grain which is soft and weak The quenching transforms the austenite into harder and stronger martensite The martensite becomes too brittle in this state for most heat treated steels By elevating the temperature again but to a lower than orignal temperature that it was originally tempered makes the martensite less brittle yet stronger and harder During this process the austenite is not completely changed into martensite The retained austenite may still make up more than 5 of the quenched and tempered structure in the steel By cryogenically treating the steel the aus i tenite is transformed into martensite so that the structure is 100 m
28. lywheel past the 060 recommended moves the pressure plate away from the transmission In this event install a fiber spacer provided on the pilot shaft between the clutch brake and the transmission The release yoke in the bell housing may not align properly with the pressure plate release bearing housing Linkage adjustment may be reguired 114 amp 15 5 Inspect and dial indicate the mating surface of engine flywheel housing and clutch bell housing for alignment and also check flywheel run out CAUTION If misalignment is greater than limits recommended this will cause poor clutch release rapid wear on transmission pilot shaft and destruction of the clutch disc Excessive flywheel run out may cause severe vibration in vehicle drive line bearing into flywheel check freedom of movement on transmission pilot shaft 14 Only Drive pins in the flywheel should be replaced Check and be sure drive pin heads are square with the flywheel friction surface If drive pins are not replaced assume that they have turned The constant pounding of the center plate may have changed the position of the drive pins in the flywheel Play it safe Check them all 14 Only After the drive pins are installed and properly aligned position the center plate onto the drive pins and check the clearance with a feeler gauge Clearance should be 006 to 010 and be measured from the same side of the drive pin at each location T
29. n addition to the clutch housing 9 Exercise caution in lubricating the bearing as any excess lubricant will find its way onto the clutch facing 6 Adjust the clutch before the pedal clearance has disappeared Failure to do so will result in slippage and adjustment afterwards may not be effective f If the clutch is hydraulically assisted make sure the slave and master cylinders are functioning properly MAINTENANCE TIPS www ACE MFG com Eb s 31 Mime ENGINE HORSEPOWER amp TORQUE RATINGS The data listed herein has been compiled from vehicle manufacturers and other reliable sources of information and is correct to the best of our knowledge However Ace Manufacturing amp Parts Co Cannot assume any responsibility for the accuracy of or possible errors in this information or in any other current or future informative bulletins of this nature IN SEQUENCE BY HORSEPOWER NOTE RATE VARIABLE HORSEPOWER ENGINES TO HIGHEST HORSEPOWER TORQUE ENGINE HP RPM TORQUE RPM CUM 4BT3 9 105 2500 260 1700 CUM 4BTA3 9 120 2500 304 1700 GM 6 5L NATASP 155 3600 275 1700 CUM 6BT55 9 160 2500 400 1700 GM 6 5 L NATASP 60 3400 290 1700 FD 1060 160 2500 400 1600 INTL T444E 160 2600 400 1500 FORD 7 3 HI ALT 165 3000 325 1600 CAT 3116 HEUI 170 2200 420 1560 CAT 3116 MD 170 2600 420 1560 CAT 3126 175 2400 420 1440 FD 1060 175 2500 420 1600 INTL DT 408 175 2600 430 1800 INTL T444E 175 2600
30. rgue and the seguence specified by the manufacturer of the vehicle or transmission Cap screws should be Class 5 or greater 11 14 amp 15 5 Examine transmission pilot shaft for wear and replace if necessary Worn splines on pilot shaft will cause clutch to release improperly and may cause splined hubs in clutch disc to break out 12 14 amp 15 5 Inspect release bearing yoke and both cross shaft bushings in bell housing and replace if worn NOTE For proper clutch release release bearing housing on cover must squeeze clutch brake during clutch disengagement Worn parts in bell housing may prevent full movement of release bearing during operation of vehicle 13 14 amp 15 5 If clutch brake is to be used place on transmission pilot shaft 14 14 amp 15 5 Rotate release bearing housing on cover assembly until flat section is on top NOTE Bell housing cross shaft on some vehicles may be below center This reguires the flat section on release bearing to be in down position Note position on clutch when being removed 15 14 amp 15 5 Using extreme caution guide transmission through cover and disc assembly rotating bell housing shaft so that release yoke fingers are clear of the pads on the release bearing assembly WARNING Transmission must not hang or be forced into the clutch This can warp the clutch disc and prevent the clutch from releasing NOILVTIVISNI HLNTI 16
31. y monk 4 VA t www ACE MFG com Wi Past Yt 1 ey A e dE u NN y Heavy Duty Clutch for Medium Duty Truck 14 x 1 3 4 For 14 Flat Flywheel H D Cast Version of Stamped Steel SIHILNTI ALNA AAVJH Vb Chaco Available With prng EZ107915 1CB Iron Button 4 Pad Co Ft Mercedes Ceramic 8 Spring Available With 4 Pad Co Ft Iron Button Ace Mfg amp Parts Co manufactures the parts shown above Spicer is a registered trademark of Dana Corp E Z Rider is a registered trademark of Ace Mfg amp Parts Co Inc Sullivan MO USA Note These clutches are not adjusted for synchronized transmissions Call Toll Free 1 800 325 6138 Cc f CJ E E a me Heavy Duty Clutch for Medium Duty Truck 14 x 2 For 14 Flat Flywheel H D Cast Version of Stamped Steel Ceramic 8 Spring cl With Ceramic 8 apang CAER With The Medium Truck Heavy Duty Cluch DO YOU WANT NEW TECHNOLOGY EXTENDED MILEAGE STAMPED STEEL CLUTCH WITH CAST COVER LIMITED MILEAGE THROW AWAY CLUTCH 14 HEAVY DUTY CLUTCHES Ace Mfg amp Parts Co manufactures the parts shown above Spicer is a registered trademark of Dana Corp Note These clutches are not adjusted for synchronized transmissions www ACE MFG com 1150 3600 2 A a DUAL EZ108035 82B 0 1150 3600 CU ME STD 107035 82B Ceramic 8 Springs pen With 1400 3600 4 Pad
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