MASALAH, GEJALA DAN

PEMECAHANNYA
PADA KOPLING
 RESERVE TANK

1. Structure and Function CONNECT DISCONNECT

MASTER CYLINDER

1) Clutch control system CLUTCH PEDAL RELEASE CYLINDER

(1) Release cylinder

CONNECT DISCONNECT
This system converts oil RESERVE TANK
AIR TANK

pressure, fed from the main

MASTER CYLINDER
cylinder into mechanical force. CLUTCH PEDAL

CLUTCH BOOSTER
(COMPRESSED
AIR)

CONNECT DISCONNECT
RESERVE TANK
VACUUM TANK

MASTER CYLINDER

CLUTCH PEDAL

CLUTCH BOOSTER(VACUUM)
(2)Master cylinder

Producing oil pressure and operating the release cylinder or

clutch booster.

VALVE RETURN SPRING

PUSH ROD PISTON STOPER BOLT RETURN SPRING

 (3)Clutch booster (vacuum servo)
VALVE SPRING
DIAPHRAGM PLATE
VALVE BODY
POPPET VALVE SPRING
The main part consists POPPET VALVE ASSEMBRY
of the three components DIAPHRAGM ASSEMBLY
as the power cylinder, RELAY VALVE SPRING

control valve, and a POWER

PISTON
hydraulic cylinder. ASSEMBLY DUST COVER
PUSH ROD
REAR HYDORAULIC PISTON
CYLINDER
SHELL CYLINDER BODY
FRONT CYLINDER SHELL
DIAPHRAGM RETURN SPRING

PEDAL IS DEPRESSED PEDAL IS RELEASED

ATOMSPHERIC PRESSURE

FROM MASTER
TO MASTER
CYLINDER
CYLINDER
TO VACUUM TANK TO VACUUM TANK
 (4)Clutch booster (air servo)

The main part consists of the same three components as the

vacuum servo type.
EXHAUST PORT
DIAPHRAGM & STEM ADAPTER
AIR BLEEDER
RELAY VALVE SECTION
RELAY VALVE PISTON

POPPET VALVE
POWER CYLINDER SECTION
COMPRESSED AIR
POPPET VALVE SPRING
RETURN SPRING
VENTILATION HOLE
CYLINDER SHELL

POWER PISTON
HYDRAULIC CYLINDER SECTION
HYDRAULIC PISTON CUP
PUSH ROD
RETURN SPRING HYDRAULIC PISTON
FROM MASTER CYLINDER SEAL RETAINER
 EXHAUST EXHAUST

FROM AIR TANK

ATMOSPHRIC PRESSURE

FROM CLUTCH MASTER CYLINDER TO CLUTCH MASTER CYLINDER

COMPRESSED AIR

PEDAL IS DEPRESSED PEDAL IS RELEASED

2) Clutch disc
Maintaining uniform contact with the flywheel and pressure
plate.
The friction face smoothly transmits torque - and at the same
time preventing deformation and damage to the clutch plate
itself.
The damper springs are designed to absorb and alleviate
impact when torque is suddenly transmitted from the rear axle.
CLUTCH FACING
CUSHION PLATE

CLUTCH PLATE

SPLINE HUB

DAMPER SPRING
3) Clutch unit
Constantly transmitting force from the engine to the transmission.
(1)Coil spring type

Deformation against centrifugal force is prevented by the

spring guide.

CLUTCH COVER
CLUTCH DISC RELEASE LEVER
SUPPORT NUT
PILOT BEARING RETURN SPRING
RELEASE BEARING
SHIFT BLOCK

RETURN SPRING
FLYWHEEL SHIFT FORK
CLUTCH SPRING
SPRING SEAT
PRESSURE PLATE
(2)Diaphragm spring type

The springs allow a variety of spring coefficients to be

obtained through the suitable selection of plate thickness and
height.

CLUTCH COVER

DIAPHRAGM SPRING

SHIFT BLOCK

PILOT BEARING

CLUTCH DISC RETURN SPRING

SHIFT FORK
FLYWHEEL
PRESSURE PLATE
 2. Troubleshooting

1. Clutch slip

Trouble Causes Chart

Clutch disc Clutch control

Facing wear No play in the master cylinder

Oil stuck to facing No play in release lever part

Decreased friction coefficient due to heat Faulty return (all control parts)

Clutch slip
Riding the clutch Pressure plate wear, damage, or deformation

Frequent half-clutching Flywheel wear, damage, or deformation

Clutch spring deterioration

Driving-related causes Clutch unit-related causes

Cause diagnosis
Clutch disc

Friction coefficient drop due to heat

The facing friction coefficient drops when the Ubun type facing
surface temperature rises.

Large
Friction coefficient

High
Temperature (ºC)

Wear Volume Versus Temperature (Example)

Furthermore, as the temperature increases, the amount
of facing wear also increases rapidly.

Large
Wear volume

High
High Temperature (ºC)

Wear Volume Versus Temperature (Example)

 2.Faulty declutching

Trouble Causes Chart

Clutch control (fluid pressure/air Clutch control

pressure-related causes) (mechanical causes)

Air mixed into clutch fluid Pedal height is too low

Faulty master cylinder cap seal Excessive play in master cylinder part
Faulty clutch booster air pressure Excessive play in release lever part
Faulty clutch booster air seal Faulty sliding of release bearing hub
Faulty clutch booster cap seal

Faulty declutching
Faulty pilot bearing Excessive clutch disc vibration
Excessive flywheel deformation Sticky clutch disc
Excessive pressure plate deformation Faulty spring sliding
Uneven release lever height Faulty conical shape

Clutch unit-related causes Clutch disc-related causes

Inspection sheets
CLUTCH-001
CLUTCH SLIPPING
Chassis No: Country:
Engine No : TR. No :

NATURE OF DEFECT
1 When does the trouble occur?
(1) Start running Running at constant speed km/hr ml/hr
Shifting up from gear to gear
Shifting down from gear to gear
(2) With load Without load

INSPECTION ITEMS
1 Kind of clutch disk Semi mold Combination Ceramic

2 Does the driver put his foot on the clutch pedal?

Always Sometimes Only when sifting

3 Can the driver fully step on the clutch pedal? (Is driving seat position suitable)
Yes No

4 Does the driver take a long time for half clutch as compared with other drivers?
Yes No

5 Which gear is applied when the vehicle starts? gear

6 How is the operating power to disengage the clutch? Heavy Light

Please state if there is any difference compared to other vehicle
Maker Model Booster With Without

7 Adjustment of push rod play at top pedal mm in