ALMDV

Service Manual
Clutch (CS380)
22.02 CLUTCH (CS380)

CONTENTS

GROUP - 22

CLUTCH ASSEMBLY (CS380)

Section Subject Page No.

22.0 Clutch Assembly (CS380) ......................................................................................... 22.03

22.0.0 Data and Specifications ................................................................................................................ 22.03
22.0.1 Trouble Shooting ............................................................................................................................. 22.04

22.1 Overhaul ........................................................................................................................ 22.05

22.1.0 Dismounting ...................................................................................................................................... 22.05
22.1.1 Disassembly ........................................................................................................................................ 22.06
22.1.2 Assembly ............................................................................................................................................. 22.06
22.1.3 Mounting ............................................................................................................................................. 22.08

22.2 Clutch Booster Arrangement ................................................................................... 22.09

22.3 Clutch Booster (CB) .................................................................................................. 22.14

22.3.0 About Clutch Booster ............................................................................................................................ 22.14
22.3.1 Cross section of Clutch Booster ....................................................................................................... 22.14
22.3.2 Principle of Operation ........................................................................................................................... 22.14
22.3.3 Dismantling Procedure ........................................................................................................................... 22.16
22.3.4 Assembling Procedure ............................................................................................................................ 22.18

22.4 Do’s and Don’ts during Servicing .......................................................................... 22.21

22.5 Inspection of Parts During Servicing .................................................................... 22.22

22.6 Trouble Shooting ........................................................................................................ 22.23

22.7 Special Tools ................................................................................................................ 22.23

22.8 Tightening Torques .................................................................................................... 22.24

22.9 Recommended Lubricants ......................................................................................... 22.24

22.11 Maintenance programme ........................................................................................... 22.24

22.10 Filling capacity ............................................................................................................ 22.24

PUB. NO. SM:ZFS9109&Clutch(CS380):816:0405:XA75:11

 CLUTCH (CS380) 22.03

22.0 CLUTCH ASSEMBLY (CS380)

22.0.0 Data and Specifications

Material Molded Non-Asbestos

Type Dry single plate with damper spring

Outside diameter 380 mm
Inside diameter 220 mm
Thickness (One side liner) 5.0 mm
Inspection and Repair Data
Rivet head depth 2.2 - 2.8 mm (limit 0.1 mm)
Clutch disc misalignment/faceout 0 - 0.7 mm (limit 0.7 mm)
Clearance between clutch disc hub
and transmission input shaft spline 0.05 - 0.15 mm (limit 0.3 mm)

Pressure plate warpage Less than 0.1 mm (limit 0.5 mm)

Pressure plate thickness 23 mm (limit 22 mm)

Compression spring free length 92.9 (limit 88.3)

Compression spring squareness (limit 5.0 mm)
Compression spring setting load at
the specified setting length 1285 N at 59. 6 mm (limit 1181.3 N at 59.6 mm)
Flywheel faceout 0 - 0.1 mm (limit 0.15 mm)

1. Clutch disc hub

2. Rivet
3. Clutch facing
4. Clutch plate
5. Damper spring
6. Clutch cover
7. Release lever pin
8. Release lever support
9. Release lever support nut
10. Torsion spring
11. Release lever
12. Pressure plate
13. Spring seat
14. Compression spring
15. Strap plate
16. Friction washer
17. Strap plate bolt
18. Lock plate

Fig. 1 Clutch
22.04 CLUTCH (CS380)

22.0.1 Trouble Shooting

Symptom Possible Cause Remedy/Prevention
Clutch dragging Clutch disc distorted or warped. Replace clutch disc.
Release lever incorrectly adjusted. Adjust release lever.
Transmission input shaft worn. Replace input shaft and check clutch hub
for excessive wear. If worn, replace disc.
Check flywheel-housing alignment.
Clutch slipping Release lever and release bearing clearance
incorrectly adjusted. Adjust clearance.
Clutch disc facing gummed with oil or grease. Replace facing or disc assembly
Release bearing worn. Replace bearing
Clutch pedal free-play incorrectly adjusted. Adjust free-play
Compression spring weak Replace compression spring
Clutch facing worn. Replace facing or disc assembly.
Vehicle vibrates Improper engine idling. Adjust idling.
when starting. Clutch control incorrectly adjusted. Adjust clutch control
Clutch disc facing gummed with oil or grease. Replace facing or disc assembly.
Glazed flywheel friction surface. Unglazed flywheel surface with coarse
emery cloth, stroking parallel to machining
lines.
Clutch disc distorted or warped. Replace disc.
Improper clutch cover tightening. Tighten bolts.
Flywheel housing misalignment. Replace flywheel housing.
Release lever incorrectly adjusted. Adjust release lever.
Noisy clutch Release bearing worn or dried. Replace release bearing.
Pilot bearing worn. Replace pilot bearing.
Clutch disc distorted or warped. Replace clutch disc.
Flywheel housing misalignment. Replace flywheel housing.
Transmission input shaft or clutch disc
spline worn. Clean and lubricate or replace.
Release lever incorrectly adjusted. Adjust release lever.
Insufficient lubrication of pedal and its
accessories. Lubricate.
Insufficient lubrication of release bearing hub. Lubricate.
Transmission input shaft retainer rusted or
soiled. Clean or replace if rusted.
Clutch pedal free-play incorrectly adjusted. Adjusted free-play.
Clutch pedal can Clutch control incorrectly adjusted. Adjust clutch control.
not be depressed. Insufficient lubricant release bearing hub. Lubricate.
 CLUTCH (CS380) 22.05

1. Pilot bearing
2. Clutch facing
3. Disc assembly
4. Rivet
5. Pressure plate
6. Spring seat
7. Compression spring
8. Friction washer
9. Clutch cover
10. Strap plate bolt
11. Release lever
12. Bushing
13. Release lever pin
14. Torsion spring
15. Cotter pin
16. Plain washer
17. Release lever support
18. Release lever support nut
19. Lock plate
20. Lock plate mounting bolt
21. Cover assembly fitting bolt
Fig. 2 - Exploded View

22.1 OVERHAUL

22.1.0 Dismounting

1. Remove the Clutch Cover and Disc

- Install the four pressure plate fixing bolts

and plain washers through the clutch
cover into the tapped holes in the
pressure plate.

Use special tool Pressure Plate Fixing Bolt

(9010-10700) and Plain Washer (9260-
10240)
Fig. 3

Fig - 3

2. Tighten the bolts in diagonal direction

alternately and evenly to the compress
the compression springs and release
pressure plate tension.

3. Loosen the fitting bolts.

22.06 CLUTCH (CS380)

22.1.1 Disassembly

1. Disassemble the Clutch Cover

- Before removing the special tools and the

strap plate bolt, compress the clutch
cover to release the compression spring
tension.

- Slowly release the press.

Fig - 4

NOTE: Before disassembling, make aligning Fig. 4

marks on the clutch cover and
pressure plate.

Fig - 5

2. Disassemble The Release Lever

Assembly

- Remove the split pin, release lever pin

and release lever.

Fig - 6

22.1.2 Assembly Fig. 5

1. Replace the clutch facing.

1. Drill off the rivets with a 5 mm diameter

drill.

NOTE: Do not remove the clutch facing with a

tapping rod and a hammer or a press.

2. Remove the old facing.

3. Place the new facing on the clutch plate

and insert the rivets into the holes so
that the facing is held in position. (Secure
Fig. 6
the rivets with adhesive tape to prevent
loosing them.)

4. Using a suitable riveter, rivet the new

facing. In order to distribute pressure
evenly, rivet in diagonal direction
alternately.

5. Using a dial gauge, check the

misalignment of the clutch disc after
riveting.

Fig - 7

Fig. 7
 CLUTCH (CS380) 22.07

2. Replace the Pilot Bearing

- Remove the pilot bearing.
Using special tool - Pilot Bearing Puller
(09650-1970) and Sliding Hammer
(09420-1442).
Fig - 8
- Using a suitable tapping rod, install the
pilot bearing.
NOTE: After installing the pilot bearing, ensure
that it rotates smoothly.
Fig - 9
Fig. 8
3. Install the Release Lever
1. Assemble the release lever, release lever
support and torsion spring, then install
the release lever assembly on the
pressure plate.
NOTE: Do not coat any grease on the bushing.
Coat lithium base grease to the sliding
part between the clutch release lever and
the pressure plate.
Fig - 10

4. Install the Clutch Cover

1. Install the clutch cover in position
according to the aligning marks, Compress Fig. 9
the clutch cover to relieve the
compression spring tension.
NOTE: When compressing the clutch cover, be
sure to hook up the torsion springs
between clutch cover and release lever.
When compression the clutch cover, pull
the release lever support up through the
holes in the clutch cover.
Be sure to insert the compression spring
upper seats in the pressure cover.

Fig - 11 & 12

Fig. 10

Fig. 12 Fig. 11
22.08 CLUTCH (CS380)

2. Temporarily tighten the release lever

support nuts.

NOTE: Coat the spherical seat of the clutch

cover and threaded section of the release
lever support with a small amount of
anti-seizure agent.

Fig - 13

3. Install the four pressure plate fixing bolts

with the plain washers through the clutch Fig. 13
cover into the tapped holes in the
pressure plate.

Use special tool - Pressure Plate Fixing

Bolt (9010-10700) and Plain Washer
(9260-10240)

Fig - 14

4. Install the strap plate bolt with the

friction washer and lock washer.

Fig. 14
Fig - 15

22.1.3 Mounting

1. Install the Clutch Disc on the

Flywheel

- Insert an aligning arbor or splined input

shaft through the clutch disc hub and into
the flywheel pilot bearing to position the
clutch disc.

Use Special Tool Clutch Aligning Arbor Fig. 15

(09662-1200).

Fig - 16

Fig. 16
 CLUTCH (CS380) 22.09

22.2 CLUTCH BOOSTER ARRANGEMENT

Stage 1 : Bearing Assy

1. Clean the Bearing seating surface in Clutch

throw out sleeve.

2. Press the Clutch throw out bearing to

Clutch throw out sleeve.

3. Screw the Union to the bottom of the

sleeve.

4. Fix the retainer spring using 2 nos. long bolt

to the Sleeve.
Fig. 1
Fig - 1

Stage 2 : Clutch Booster fitment

1. Fix the Clutch Booster Mounting bracket –

Front to the Gear box using 4 nos. long
bolts.

Fig - 2

2. Mount the clutch Booster to the Clutch

Booster Mounting bracket – Front using 2
nos nuts with washers.

3. Insert plain washer in the clutch booster rear

mounting bolt Fig. 2

Fig - 3

4. Align the clutch booster rear mounting

bracket to the clutch booster rear mounting
bolt.

5. Tighten the Clutch booster rear mounting

bolt with nut.

6. Fix the clutch booster rear mounting bracket

to the gear box using bolt.

Fig - 4

Fig. 3

Fig. 4
22.10 CLUTCH (CS380)

Stage 3 : Gear box & Clutch Housing

Assy

1. Fix the 10 nos clutch housing mounting

studs in the Gear box.

2. Position the clutch housing on the studs

(10nos)

3. Pull out the clutch housing to appro. 15mm

& screw the nyloc nut to the outer studs as
shown in figure.

Fig - 5
Fig. 5

4. Tighten the 2 nuts gradually until clutch

housing rear face butts with the gear box.

Fig - 6

Fig. 6

Torque tighten the inner 8 nos nyloc nuts

and outer 2 nos nyloc nuts to 270 ± 10
Nm

Fig - 7, 8 & 9

Fig. 7

Fig. 9 Fig. 8
 CLUTCH (CS380) 22.11

Stage 4 : Clutch Housing Assy

1. Clean the cross shaft seating area

thoroughly.

2. Insert the Clutch cross shaft through the

cross shaft bore. (Spline should expose in
LH side of clutch housing)

3. Press the Key in the cross shaft.

4. Insert the Clutch operating lever into the

cross shaft & position the clutch operating
lever in the key. Fig. 10

5. Tighten the clutch operating lever with Pinch

bolt.

6. Fix the inspection window cover (top &

bottom) to the clutch housing.

7. Fix the greaser assy in the hole provided in

the bottom cover.

8. Fix the grease nipple 2 nos in both sides of

the Clutch rocking shaft.

Fig - 10
Fig. 11
Stage 5 : Clutch Housing Assy

1. Insert the Bearing assy to the gear box

input shaft cover & position it with Clutch
operating lever.

Fig - 11

2. Connect the Nylon pipe to the Union in the

sleeve & Greaser in the bottom Cover.

Fig - 12

Fig. 12
22.12 CLUTCH (CS380)

Fig. 13

Stage 6 : Outer Lever, Jaw end &

Push rod Assy

1. Mount the Clutch Housing & Gear Box Assy

on the Engine using 12 nos. long bolts with
plain & Spring washers.

2. Butt the Clutch Throw out Bearing on the

Clutch Finger by rotating the Clutch Rocking
Shaft.

3. Keeping the Throw Out Bearing in butting

position with clutch fingers fix the COP
Outer Lever vertically downwards & tighten
the Outer Lever with bolt.

4. Screw the Push rod with Lock nut in the

Jaw end threads & set the distance 163-
165 mm as shown in the figure.

5 Mount the Jaw End & Push Rod Assy on

the Outer Lever using the Anchor Pin by
keeping the Push Rod inside the Clutch
Booster Slave Cylinder and tighten the Assy
with M8 x 1.25 Nyloc Nut.

CAUTION: During fitment of gearbox to engine,

ensure that clutch rocking shaft is held
secure, so as to avoid rotation causing
popping out of clutch lever inner from
retainer spring in sleeve.

Fig - 13
 CLUTCH (CS380) 22.13

Fig. 14

Stage 7 : Pull Off Spring Assy

1. Fix the Anchor bracket in the Clutch Booster

bottom bolt.

2. Mount the Pull Off Spring between the

dimples of the Anchor Bracket and the
Anchor Pin.

Push Rod Setting Dimension

Checking:

The push rod stand out (from jaw end

centre to clutch booster mouth) to 108 to
110mm.

CAUTION: Push rod checking to be done after

fitment of pull off spring.

Before fitment of gearbox on to

engine, greasing to be done in all
grease nipple points.

Check for grease flow at both ends

of rocking shaft boss support in
clutch housing.
22.14 CLUTCH (CS380)

22.3 CLUTCH BOOSTER (CB)

22.3.0 About Clutch Booster

Is a hydro-pneumatic device for reducing

clutch pedal effort

Hydraulic circuit is for signal to the servo

valve

Hydraulic circuit acts as a backup system

Pneumatic circuit is for actuation

Fig. 1
Fig - 1

22.3.1 Cross section of Clutch Booster

Fig - 2

22.3.2 Principle of Operation

Fig - 3

The clutch booster is a combination of servo

valve, power cylinder hydraulic cylinder. The
supply of air to the power cylinder is
controlled by a servo valve. The servo valve
operates in response to hydraulic signal Fig. 2
generated by clutch pedal operation.

When the clutch pedal is pressed, Oil from

the master cylinder acts on the relay piston
to open the poppet valve. The poppet
valve admits air from the system protection
valve into the power cylinder. This makes
the power piston to move a hydraulic piston
and actuator. The actuator moves the clutch
operating lever, there by disengaging the
clutch.

During partial engagement (as in crowed city

traffic), the air supply to the power cylinder
is cutoff. The power piston is held in that
position by the air trapped in the power
cylinder circuit. There fore the driver
precisely controls the amount of declutching.

When the pedal is released, the air trapped

the power cylinder is vented into the
atmosphere through a non-return valve. This
enables the power piston and other linkages
to return their home position. The clutch is
now engaged.

The clutch booster operates like a

simple slave cylinder in the absence
of air supply. Fig. 3
 CLUTCH (CS380) 22.15

Fig. 4

Sl.No. Part Name Sl.No. Part Name

2-4 Assy Shell 32 Protector
5 O ring 36 Piston Relay
6 Collar 37 Packing cup
7 O ring 38 O ring
10-11 Assy push rod 39 Spring
12 O ring 40 O ring
13 Plate piston 41 Body Upper valve
14 Packing cup 42 Valve poppet
15 Spring 43 Spring
16 Nut 44 Gasket
17 Spring 46 Connector
20 Body 48 Screw
21 Pin Spring 51 Hyd piston
23 Retainer 52 Packing cup
24 Packing cup 53 Packing cup
25 Assy Retainer 54 Exhaust cover
26-28 Retainer 56 Guard
28 O ring 57 Bolt
29 Washer 58 Washer
30 Ring Retainer 59 Nut
31 Plug- Bld screw
22.16 CLUTCH (CS380)

22.3.3 Dismantling Procedure

1. Locate the Fixture (AFT 7714) in the vise

and locate the bolts (57) of the clutch
Booster in the fixture as shown in the
Figure. Remove the Guard (56) from groove.

Fig - 5

2. Loosen the connector (46) by spanner and

remove it. Remove Gasket (44) from Fig. 5
connector, spring (43) and poppet (42).

Fig - 6

3. Loosen the 3 screws (48) with screw driver

and remove the Upper valve body (41).
Remove collar (6) ‘O’ ring (40) and spring
(39).

Fig - 7

4. Removal of individual part.

Fig. 6
Fig - 8

5. Pull the Relay piston (36) slowly in the

upward direction by hand.

Loosen and remove the Hexagonal nut (59)

with Spanner and washer (58) and slowly lift
the cast iron body (20) in the upward
direction thro the bolt.(57)

Fig - 9

Fig. 7

Fig. 9 Fig. 8
 CLUTCH (CS380) 22.17

6. Remove spring (17) from the shell (2-4)

Remove the power piston assy (10-16)
slowly by hand. Remove shell (2-4) and
bolts (57).

Fig - 10

7. Clamp the push rod (10-11) of the power

piston assembly (10-16) in the vise. Loosen
the nut (16) with Box spanner and Remove
washer (15) ‘O’ Ring (12), pushrod (10-11).

Fig - 11 Fig. 10

8. Removal of individual part.

Fig - 12

9. Clamp cast iron body in the vise as shown.

Remove ‘O’ ring (5). Remove circlip (30) by
circlip plier. Remove washer (29), ‘O’ ring
(28), Retainer (23), Packing cup (24) and
Retainer Assy (23).

Fig - 13
Fig. 11
10. Remove the Hydraulic piston (51) from the
bore by bore pushing it from the rear side.
Remove cap (32) from Bleed screw (31).
Loosen bleed screw (31) and Exhaust cover
(54) with spanner and remove them.
Remove pin (21) by hand.

Fig - 14

Fig. 12

Fig. 14 Fig. 13
22.18 CLUTCH (CS380)

22.3.4 Assembling Procedure

1. Pick cast iron Body (20) and apply Red

Rubber grease Throughout the bore.

Fig - 15

2. Apply Sealant on the Exhaust cover (54)

thread and assemble. Assemble Bleed screw
(31) and tighten to the specified torque.
Assemble protector (32) on the Bleed
screw.
Fig. 15
Torque:
Bleed screw : 6.9 - 12.7 Nm
Exhaust : 14.7 - 19.6 Nm.

Fig - 16

3. Retainer Assembly

Assemble ‘O’ring (28) in the groove of the

Retainer assy (26-28). Apply Red rubber
grease on the OD and in the ID of the
Retainer assy.
Fig. 16

Assemble Retainer (23), cup (24), Retainer

assy (26-28), washer (29). Assemble circlip
(30) with circlip plier (internal) in the circlip
groove.

Fig - 17

4. Hydraulic Piston Assembly

Assemble cup (52,53) in the Hydraulic piston

(51) using the tool (AFT 7715) Apply Red
rubber grease On the OD of the cups.
Fig. 17

Assemble Hydraulic piston in the bore.

Assemble pin (21) in the hole.

Refer Fig. for direction of cups.

Fig - 18

Fig. 18
 CLUTCH (CS380) 22.19

5. Power Piston Assembly

Assemble cup (14) on the power piston

(13) groove.

Assemble ‘O’ ring (12) in pushrod (10-11)

and locate power piston assembly on the
pushrod. Locate washer (15) over push rod
(10-11) thread. Assemble nut (16) and
tighten to specified torque.

Torque:
Dia 70,90 : 19.6 - 29.4 Nm
Dia 105 : 24.5 - 34.3 Nm

After tightening, punch on the push rod (10-

11) thread and Nut (16) contact surface at
two points opposite to each other.

Fig - 19

6. Locate the Fixture (AFT 7714) in the vise.

Locate 4 Bolts (57) on the fixture. Assemble
the shell (2-4) over the bolts as shown.
Apply Lithium Grease evenly through out the
Fig. 19
bore. Assemble power piston assy (10-16)
into the bore. Locate spring (17) on the
power piston.

NOTE: While assembling power piston, press in

tilted condition, level it after entry and press
again.

Fig - 20

7. Assemble ‘O’ring (5) on the body and apply

Lithium grease on the O ring. Locate the
body (20) on the shell (2-3) thro the bolts
Fig. 20
(57). Assemble washers (58) and the nut
(59) on the bolt and tighten to the specified
torque.

Torque:
Dia 70, 90 : 14.7 - 19.6 Nm
Dia 105 : 19.6 - 29.4 Nm.

Fig - 21

Fig. 21
22.20 CLUTCH (CS380)

8. Relay Piston Assembly

Assemble cup (37)-2 nos in the Relay piston

(36) grooves with tool (AHW 7083/ 7082)
and assemble ‘O’ ring (38) in the groove.
Apply red rubber grease on the cups. Apply
silicon grease on the ‘O’ ring.

Fig - 22

9. Press Relay piston assy (36) into the bore

Assemble Spring (39) on the Relay piston.
Assemble Gasket (40) in the valve body Fig. 22
(41) groove. Assemble ‘O’ ring (7) in the
valve body. Locate collar (6) in the shell
pipe. Locate valve body (41) over the cast
iron body (20) and tighten it with 3 nos of
screws (48) to specified torque

Torque : 3.9 - 5.9 Nm

Ensure proper seating of collar (6), ‘O’ ring

(7).

Fig - 23
Fig. 23
10. Assembly poppet (42) the valve body port.
Locate Spring (43) on poppet. Assemble
Gasket (44) in the Connector (46) and
tighten the connector on the valve body to
the specified torque. Assemble pin (21) in
the CI body port. Assemble Guard (56) on
the CI body groove.

Ensure proper seating of poppet spring (43)

smaller dia of spring to seat on the poppet
face.

Torque : 19.6- 29.4 Nm.

Fig. 24

Fig - 24
 CLUTCH (CS380) 22.21

22.4 DO’S AND DON’TS DURING

SERVICING

Do’s

1. Follow the Sequence as per the Assembling

and Dismantling procedure.

2. Tighten the parts to the recommended

torque only. Refer assembly procedure

3. Ensure ‘O’ rings, Gaskets and cups are

seated properly on the groove without
twisting.

4. Ensure proper seating of collar (6) and

‘O’ring (7) in upper valve body (41).

5. Ensure the cups assembled on Hydraulic

piston and Relay piston are in the correct
direction. (refer figure in CB Assembly
procedure).

6. Ensure the presence of stainer in MC

reservoir

7. Assembling and dismantling area must be

free from dusts.

8. For wiping of parts use only lint free cloth.

9. Keep the hands clean and dry, during

assembling or dismantling of clutch Booster.

10. Use clutch oil as per recommendation.

Don‘ts

1. Do not use Bearing grease, mineral grease

or mineral oil

2. Do not have petrol, Diesel, Engine oil, Gear

box oil, Bearing grease etc at the clutch
booster servicing area (scrap the Rubber
parts if they get mixed with the above
mentioned items).

3. Do not loosen the connector while

disconnecting the air hose.

4. Do not disturb the Actuation rod stroke

setting.

5. Do not pour Hydraulic oil in Exhaust cover

port.
22.22 CLUTCH (CS380)

22.5 INSPECTION OF PARTS DURING

SERVICING

1. Cup (Hydraulic Piston), Part No. 52

Check packing lips for damage or wear.

Fig - 1

2. Relay piston, Part No. 37 Fig. 1

Check defects such as Rust, Damages, etc.,

Replace the part if found defective.

Fig - 2

3. Hydraulic piston, Part No. 51

Check defects such as Damages or worn
surface. Replace the part if found defective. Fig. 2

Fig - 3

4. Cast iron body (Part No. 21)

Check for Rust, Damages on the internal
surface of the Cylinder. Check for damages
inside the bore and correct with #80C or
finer Emery paper. Ensure the orifice passage
is clear. Fig. 3

Fig - 4

5. Push rod (Part No. 10-11)

Check defects such as Damages or Rust on
surface. Replace the part if found with play.

Fig - 5
Fig. 4
6. Shell Cylinder (Part No. 2-4)
Check the internal surface of the cylinder
shell and replace if it severely corroded,
rusted or dented enough to affect the
stroke of piston. Correct light corrosion,
rust and dents using emery paper (#500 -
600)

Fig - 6 Fig. 5

7. Rubber parts
When the clutch booster is disassembled for
regular maintenance, replace the rubber parts
with new one.
However, when disassembled after a short
time after regular maintenance need not
replace the rubber parts unless they have
defects such as wear, swelling or other Fig. 6
damages.
When the rubber parts are reused, clean
them by wiping with a cloth soaked in Iso
propyl alcohol.
 CLUTCH (CS380) 22.23

22.6 TROUBLE SHOOTING

Failures Causes Trouble Shooting

Oil leakage thro Exhaust cover Oil seal (24) damaged. Replace with new oil seal.

Oil leakage thro CB bore Hydraulic piston cup damage/ Replace with cup and
Hydraulic piston fallen Down. Hydraulic piston.

Increase in clutch pedal effort Low air pressure Maintain air pressure at a minimum
of 5 bar.

Jerking of clutch pedal CB without Spring arrangement. Mount CB with spring.

Less clutch pedal travel Oil not returning to MC properly. Check MC and service.

Clutch not disengaging fully Stroke less, Release bearing play less. Adjust the stroke and Release
bearing play

Pedal spongy Improper Bleeding, Oil level low. Bleed the system and fill the
reservoir with oil.

Engine raise Release bearing play less Adjust the Release bearing play.

22.7 SPECIAL TOOLS

Sl. No. Tool No. Tool Name Figure Application

1 AFT 7715 - 1 Assembling cone

For Assembling cup (52, 53)

in Hydraulic piston (51)

2 AFT 7715 - 2 Assembling cone

3 AHW 7083 Assembling cone

For Assembling cup (37)

in Relay piston (36)

4. AHW 7082 Assembling cone

5. AFT 7714 Assembling Fixture For location shell (2 - 4)

 22.24 CLUTCH (CS380)

22.8 TIGHTENING TORQUES Kgm lb.ft Nm

Cover assembly bolt 6.53 - 8.56 48 - 61 64 - 84
Strap plate bolt 4.00 - 5.00 29 - 36 39.2 - 49.0
Lock plate fitting bolt 1.2 - 1.8 9 - 13 11.8 - 17.7

22.9 RECOMMENDED LUBRICANTS

ASHOK
LEYLAND
GENUINE
LUBRICANTS
Ashok Sah
Indian Oil Hindustan Bharat Elf Karol Pennzoil Meguin
Aggregate Leyland Gulf Oil India IBP Castrol Petroleums
Corporation Petroleum Petroleum Lubricants Lubricants Quaker Oil India
Spec. IPOL
Clutch
MP ® Multi All MP IPOL MP Meguin
Operating Gulf MP Servo MAK
IS 12203 Grease Lex 2 purpose Purpose Grease MP Grease Grease Grease
Pedal Grease No.2 Grease MP UNIVEX A
No.2 Grease No.2 No. 2 No.2 No.2 MP 2
Shaft
FM VSS
Gulf Super Servo Brake MAK® Universal
Hydraulic 116 - Dot 3 H.D.Brake Heavy Duty IBP Brakopower IPOL Halt X
HD Brake Fluid Super Brake Brake -- --
Clutch* (or) Fluid Dot 3 Brake Fluid DOT-3 DOT-3 Dot 3
Fluid Dot 3 HD Fluid Fluid
IS 8654

* - TVS - Girling brake fluid can also be used 10-02-04

22.10 FILLING CAPACITY

Aggregates Filling Capacity

(l)
Clutch Hydraulic System 1.0

22.11 MAINTENANCE PROGRAMME

km x 1000
Lubricant

16000 km
8000 km
Weekly
No. of
points

Remarks
Every

Every
Every
Daily
PDI

A. Lubrication

1. Lubricate clutch withdrawal lever G 1 ✓ ✓ ✓

2. Lubricate clutch withdrawal bearing sleeve G 1 ✓ ✓ ✓

3. Lubricate clutch pedal G 1 ✓ ✓ ✓

B. Maintenance

1. Check clutch fluid level, top up if necessary ✓

2. Overhaul clutch master/booster cylinder 72

3. Check stand out & replace clutch disc

if necessary As required.

4. Replace clutch hydraulic fluid 40