Clutch & Transmission.pptx

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1. Technician Level 2 – Module 2 Clutch & Transmission Systems - LCV

2. Introduction Participant Name Dealership Name Location Experience in Tata Motors (In years & months) Specialization in which Models / Aggregates Hobbies 6/11/2014 TML 2

3. Program Objectives At the end of this module the participants will be able to : Understand the construction and types of Gear Boxes used in LCV range of Vehicles State the differences and characteristics of each type of Gear Boxes Perform Overhauling of GBS-380 & GBS-550 Gear Boxes Perform Overhauling of Transaxle – TA -70 Perform Maintenance Checks and Adjustments Perform Overhauling of 280 mm Dia Clutch Perform Important Adjustments & Settings on Clutch – 280 mm Dia & 330 mm Dia 6/11/2014 TML 3

4. Program Agenda Introduction to LCV Gear Boxes Introduction to GBS - 27 Gear Box Introduction to -GBS-40 Gear Box Introduction to GBS - 380 Gear Box Introduction to GBS-76 Gear Box Introduction to- GBS-550 Gear Box Introduction to TA - 70 Transaxle (FRT WD- Winger ) Transmission Overhauling GBS- 380 GBS-550 TA -70 Clutch System Overhauling 280 mm Dia Clutch 330 mm Dia Push Type Clutch 6/11/2014 TML 4

5. (GBS-27, GBS-40, GBS-76, GBS-380, GBS-550 & TA 70) Introduction to LCV Gear Boxes 6/11/2014 TML 5

6. General Information Introduction to GBS-27 6/11/2014 TML 6

7. GBS – 27- General Information Weight : 82 Kgs. Filling Capacity: 3.2 Ltrs . Description: Specification: Model: GBS-27-5-7.36 Ratios: 7.36 (three different ratios) Features: Synchro Mesh for 5 forward gears Sliding mesh for reverse gear Maximum torque of 27 mkg Weight of the Gear Box : 82 Kgs. Filling Capacity: 3.2 ltrs . 6/11/2014 TML 7

8. GBS-27- Numbering System 6/11/2014 TML 8 GBS-27-5/7.36 Transmit 27 mKg . of Torque Five Speed First Gear Ratio

9. GBS – 27 Gear Ratios 6/11/2014 TML 9 Gear Ratios in Different Gears: Gear Gear Ratio Gear Ratio Euro I Gear Ratio Turbo EX GBS-27 -5 -7.36 GBS-27 -5 -7.36 GBS-27 -5 -7.36 1 st 7.36 7.36 6.17 2 nd 3.98 4.38 3.34 3 rd 2.26 2.48 1.89 4 th 1.39 1.58 1.32 5 th 1.0 1.00 1.00 Reverse 6.67 6.67 5.58

10. GBS – 27 - Application Tata 407 –LP/LPT-Turbo Ex . Tata 709 – LP/LPT/SFC Turbo Ex . ( BSII) 6/11/2014 TML 10

11. General Information Introduction to GBS-40 6/11/2014 TML 11

12. GBS – 40- General Information Weight of the Gear Box: 57 Kgs. Filling Capacity: 5.2 ltrs Description: Specification: Model: GBS-40-5-7.51 Ratios: 7.51 Features: Synchro Mesh for 5 forward gears Sliding mesh for reverse gear Maximum torque of 40 mkg Weight of the Gear Box: 57 Kgs. Filling Capacity: 5.2 ltrs . Gearbox Oil - SAE 80W90 grades with 7% Anglomol 6/11/2014 TML 12

13. GBS-40 – Numbering System 6/11/2014 TML 13 GBS-40-5/7.51 Transmit 40 mKg . of Torque Five Speed First Gear Ratio

14. GBS-40 -Gear Ratios Gear Ratios in Different Gears: 6/11/2014 TML 14 Gear Gear Ratio No. of Teeth Gear Ratio No. of Teeth 712 EX 912 EX Driveshaft Teeth 18 Drive shaft Teeth 17 1 st 6.34 38/11 7.51 39/11 2 nd 3.37 32/18 3.99 32/18 3 rd 2.11 26/22 2.5 26/22 4 th 1.28 20/28 1.51 20/28 5 th 1.00 17/36 1.00 17/36 Reverse 6.93 6.93

15. GBS-40 - Application LP/LPT/SFC 712 LPT912 Turbo EX LPT/LP 1109 Turbo EX 6/11/2014 TML 15 LPT/LP 1112 Turbo EX

16. General Information Introduction to GBS-76 6/11/2014 TML 16

17. GBS-76- General Information Weight of the Gear Box: 57 Kgs. Filling Capacity: 1.6 ltrs . Description: Specification: Model: GBS-76 -5-3.87 Ratios: 3.87 Features: Synchro Mesh for 5 forward gears Sliding mesh for reverse gear Maximum torque of 16 mkg Weight of the Gear Box: 57 Kgs. Filling Capacity: 1.6 ltrs . Gearbox Oil - SAE 80W90 with 7% Anglamol 6097 by weight / API GL 4 76 indicates the center distance between main and counter shaft 6/11/2014 TML 17

18. GBS-76 – Numbering System 6/11/2014 TML 18 76 mm (For illustration purpose only)

19. GBS-76 –Gear Ratios Gear Ratios in Different Gears: 6/11/2014 TML 19 Gear Gear Ratio 1 st 3.87 & 4.1 2 nd 2.36 3 rd 1.37 4 th 1.00 5 th 0.82 Reverse 3.4

20. GBS-76 - Application Xenon All Models 207 DI BS III EX 6/11/2014 TML 20

21. General Information Introduction to GBS-380 6/11/2014 TML 21

22. GBS-380- General Information Weight of the Gear Box: 64.5 Kgs . Filling Capacity: 2.7 ltrs . Description: Specification: Model: GBS-380-5-4.9 Ratios: 4.9 & 5.19 Features: Synchro Mesh for 5 forward gears Sliding mesh for reverse gear Maximum torque of 38 mkg Weight of the Gear Box: 64.5 Kgs. Filling Capacity: 2.7 ltrs . Lubricant Grade : SAE 80W90 with 7% Anglamol 6097 by weight / API GL 4 6/11/2014 TML 22

23. GBS-380 – Gear Ratios 6/11/2014 TML 23 Gear Ratios in Different Gears: Gear Gear Ratios Number of Teeth ( Main & Counter shaft For 407 Turbo –Euro-1 For 407 Turbo Ex –Euro -II For 407 Turbo –Euro-1 For 407 Turbo Ex –Euro -II 1 st 4.9 5.19 37/13 38/13 2 nd 2.84 3.01 33/20 32/19 3 rd 1.79 1.89 27/26 23/24 4 th 1.24 1.32 21/29 22/33 5 th 1.00 1.00 - 18/36 Rev 4.77 5.05 36/13 36/13

24. GBS-380- Application Tata LP-407/410 -12 S eater Tata -407 /410 SFC 6/11/2014 TML 24

25. General Information Introduction to GBS-550 6/11/2014 TML 25

26. GBS-550-General Information Aluminium housing Filling Capacity: 5.8 Litres Drain & Fill: 5.7 Litres Description: Specification: Model: GBS-550-6- 6.9 (overall reduction) Ratios: 6.9 (Overall reduction) Features : G-550 – 6 speed with full remote gear shifting Synchro Mesh for 6 forward gears & 1Reverse 1st & 2nd Gear with double Synchro cone 3rd, 4th & 6th Gear Synchronizer on Counter Shaft 6th Gear is Over Drive for Better KMPL Maximum torque of 550 Nm Aluminium housing for light weight Filling Capacity: 5.8 litres. Drain & Refill: 5.7 litres Lubricant Grade : SAE 80W90 with 7% Anglamol 6097 by weight / API GL 4 6/11/2014 TML 26

27. GBS-550- Gear Ratios 6/11/2014 TML 27 Gear Ratios in Different Gears: Gear Shift Pattern: Gear Ratio (6.9 Ratio Version) Gears Number of Teeth Reduction Ratio Overall Reduction Ratio 1 st 39/11 3.545 6.904 2 nd 33/16 2.063 4.016 3 rd 27/22 1.227 2.39 4 th 21/28 0.75 1.461 5 th 37/19 1.947 1 6 th 25/58 0.431 0.84 Rev 24/11 x 36/24 2.18 x 1.5 6.373 2 1 3 6 5 4 N R

28. GBS-550- Application Tata Star Bus Ultra Tata -1109/1112 6/11/2014 TML 28

29. General Information Introduction to Transaxle-TA-70 6/11/2014 TML 29

30. TA-70- General Information Aluminium Housing Filling Capacity: 2.1 Liter (Gears) & 1.4 Liter ( Differential) Description: Specification: Model: TA-70 – 5.69 & 4.84 Ratios: 5.69 & 4.84 Final Drive Ratio: 4.11 Features: Synchro Mesh for 5 forward gears & Sliding mesh for 1Reverse Maximum torque of 190 Nm Aluminium housing for light weight Filling Capacity: 2.1 Liter (Gears) & 1.4 Liter ( Differential ) Oil Used: 75W 90 Gears & 85 W 140 Differential 6/11/2014 TML 30

31. TA-70- Gear Ratios Gear Ratios in Different Gears: 6/11/2014 TML 31 TC Engines NA Engines Gears No. of Teeth Drop down Ratio 31/24 Gear Ratio Gear Ratio CWP No. of Teeth Drop down Ratio 32/23 Gear Ratio Gear Ratio CWP FD Ratio Lay Shaft I/P Shaft Lay Shaft I/P Shaft 1 45 12 1.29 4.84 19.91 45 11 1.39 5.69 23.39 4.11 2 35 19 1.29 2.38 9.78 37 17 1.39 3.03 12.45 4.11 3 30 24 1.29 1.61 6.64 31 22 1.39 1.960 8.06 4.11 4 30 34 1.29 1.140 4.68 33 34 1.39 1.35 5.55 4.11 5 24 37 1.29 0.84 3.44 29 37 1.39 1.09 4.48 4.11 R 38 11 1.29 4.46 18.34 38 11 1.39 4.81 19.75 4.11 RI 23  

32. TA-70- Transaxle Layout 6/11/2014 TML 32

33. TA-70 - Application Tata Winger 6/11/2014 TML 33

34. GBS-380 Transmission Overhauling 6/11/2014 TML 34

35. Removal of Transmission from the Vehicle Transmission – GBS-380 6/11/2014 TML 35

36. Transmission Removal Steps & Procedures from the Vehicle Special Tools Required for the purpose Removal of GBS-380 from the Vehicle 6/11/2014 TML 36 Transmission Removal from the Vehicle- GBS-380

37. Dismantling the Gear Box GBS-380 6/11/2014 TML 37

38. Dismantling of GBS-380 Dismantling the sub assemblies of GBS-380 Inspection of Components Reassembling the GBS-380 Dismantling & Assembly of GBS-380 6/11/2014 TML 38 Dismantling, Inspection & Assembly of GBS-380

39. GBS-550 Transmission Overhauling 6/11/2014 TML 39

40. Dismantling the Gear Box GBS-550 6/11/2014 TML 40

41. Dismantling of GBS-550 Dismantling the sub assemblies of GBS-550 Inspection of Components Reassembling the GBS-550 Special Tools required for Overhauling Dismantling & Assembly of GBS-550 6/11/2014 TML 41 Dismantling, Inspection & Assembly of GBS-550

42. TA -70 Transaxle Overhauling 6/11/2014 TML 42

43. Removal of Transaxle from the Vehicle Transaxle –TA-70 6/11/2014 TML 43

44. Special Tools & Equipment's 6/11/2014 TML 44 Sl No Picture Special Tool Number Usage 1 Installing the taper roller bearing use the bearing seat pusher special tool 2 Removing Taper roller bearing seat 3 Pinion Pre-loading shim selection special tool 4 Differential Threaded ring tightening Special tool

45. Special Tools & Equipment's 6/11/2014 TML 45 Sl No Picture Special Tool Number Usage 5 Drop down Gear lock 6 Locking Counter shaft 7 5 th gear puller special tool

46. Transmission Removal Steps & Procedures from the Vehicle Removal of TA-70 from the Vehicle 6/11/2014 TML 46 Transaxle Removal from the Vehicle- TA-70

47. Dismantling the Transaxle( Winger) TA-70 6/11/2014 TML 47

48. Dismantling the TA-70 –Transaxle (Winger) Mount the Gear box on the stand Remove the selector lever Remove the Reverse gear selecting cable Remove the Speedo cable 6/11/2014 TML 48

49. Dismantling the TA-70 –Transaxle (Winger) Remove the retain plug, Spring & Ball of 5th Gear Selector Shaft Unscrew the Hex bolts & separate rear cover from the Transaxle housing

50. Dismantling the TA-70 –Transaxle (Winger) Tap gently and pull out 5th gear shifter shaft along with shifter fork and shifting sleeve Remove 3 retainer bolts from ½, ¾ and reverse shifter shafts Take out springs and balls 6/11/2014 TML 50

51. Dismantling the TA-70 –Transaxle (Winger) Push out double Spring pin from1/2 – 3/4 shifter link , 5th Reverse shifter link Compress the spring on the selector shaft and pull out the plastic half locks Pull out the selector shaft from the housing 6/11/2014 TML 51

52. Dismantling the TA-70 –Transaxle (Winger) Bush with step is towards gear shift lever Bush without step is towards selector finger 6/11/2014 TML 52

53. Dismantling the TA-70 –Transaxle (Winger) Lock the 5th gear on the counter shaft and loosen the lock nut and take it out With the help of special tool puller the 5th gear on the counter shaft and take out Spacer sleeve needle bearing washer Synchronizer body, retainer spring & synchronizer ring. Remove the snap ring on the main shaft and pull out the snap ring from the main shaft. 6/11/2014 TML 53

54. Dismantling the TA-70 –Transaxle (Winger) Remove the spring pin of ½ and ¾ shifting lever Take out reverse gear shifting liver 6/11/2014 TML 54

55. Dismantling the TA-70 –Transaxle (Winger) Remove the Reverse Gear switch Unscrew all hexagonal bolts from gear box rear housing and take out NOTE : DO NOT HAMMER THE HOUSING TAP GENTLY WITH MALLET TO SEPERATE 6/11/2014 TML 55

56. Dismantling the TA-70 –Transaxle (Winger) Push out the spring pin and rotate the ¾ shifter shaft Pull out the shifter shaft Remove the fork The same procedure should be followed for removing the shifter shaft and fork for the ½ shifter shaft Hold the Main shaft, Counter shaft and Reverse shaft together and take it out from the housing 6/11/2014 TML 56

57. Dismantling the TA-70 –Transaxle (Winger) Dismantle 1-7, Clean and Inspect all the components. Replace worn out and damaged parts To remove the clutch shaft press the sleeve on the input shaft & and pull the clutch shaft 6/11/2014 TML 57 Lay shaft Washer Needle bearing Spring O ring Dowel Clutch shaft Ball bearing Circlip Washer Spacer Needle bearing 5 th Gear Synchronizer ring Retainer spring Synchronizer sleeve Washer Lock nut

58. Dismantling the TA-70 –Transaxle (Winger) Dismantle 4th gear, Reverse gear with shifter with 3rd gear, 2nd gear, 1st gear and reduction gear one by one with snap rings synchronizer assembly and spline washer Remove snap ring, spacer & ball bearing from speedo pinion end NOTE : Please take care of spline washers, snap rings and Synchronizer rings during dis assembly as they are different 6/11/2014 TML 58

59. Dismantling the TA-70 –Transaxle (Winger) Remove the drop down gear cover Lock the drop down gear with the special tool as shown in the figure. Loosen the lock nut on pinion shaft and remove the nut. Remove the special tool. Unscrew the hexagonal bolts shown with red arrow mark (Intermediate gear box housing to Clutch housing) Push out the Pinion shaft and dis-assemble the pinion shaft 6/11/2014 TML 59

60. Dismantling the TA-70 –Transaxle (Winger) Combination gear : This gear works as shifter sleeve for 3rd and 4th gear and Reverse gear on main shaft Synchro cone Gap: 1st & 2nd = 1.2mm: 3rd,4th,5th-= 1.1mm 6/11/2014 TML 60 Groove on shifter sleeve should be towards 2 nd gear

61. Dismantling of TA-70 Dismantling the sub assemblies of TA-70 Inspection & Adjustments Reassembling the TA-70 On Vehicle Repair Procedures Dismantling & Assembly of TA-70 6/11/2014 TML 61 Dismantling, Inspection & Assembly of TA-70

62. Clutch System 6/11/2014 TML 62

63. Clutch System – LCV – Application Matrix 6/11/2014 TML 63 Sr. No. Parameters 215 Dia. Clutch 240 Dia. Clutch 280 Dia. Clutch 310 Dia. Clutch 330 Dia. Clutch 352 Dia. Clutch 380 Dia. Clutch 1 Supplier Valeo 207 DI / Xenon Rx - Exedy Xenon 3L - LUK India LUK India Setco Setco Setco Setco 2 Type Single type dry friction diaphragm type Single type dry friction diaphragm type Single type dry friction diaphragm type Single plate dry friction diaphragm type A. Booster Assisted Single plate dry friction diaphragm type A. Booster Assisted Single plate dry friction diaphragm type Single plate dry friction Push type 3 Type of Actuation Push type Push type Push type Booster Assisted Push Type Pneumatic Booster Push Type Pull Type Push Type 4 Models 1. Winger A1. Xenon 2.2L BSIV (DOM.) A2. Xenon 3.0L (DOM.) C1. 207 DI EX BS II/III/IV C2. 207 DI RX C3. Xenon Pickup C4. SFC 407 CNG BSIII C5. LP 407 BSII C6. SFC 407 BSIII A1. 407 Facelift BS III A2. LPT/SFC 407 BS III A3. SFC 407 Pickup BS II A4. LP/LPT/SFC 407 BSII A5. LPK 407 BS II/III A6. Tata 410 EX A7. LP 709 BS II/III A8. LP 909 BSII/III A9. LP 709 EX BSII (Reinforced) A10. SFC 407 CNG BSIV B1. SFC 407 Pickup BS II A1. LPK 909 BS III A2. SFC 909 EX BS III A3. SFC 712 EX BS III A4. LP/LPT 712 EX BS III A5. LPT 709 BS III A6. LPT 909 BS III A7. LPT 909 H EX2 BS III A8. LP 709 BS III B1. LP 712 BS IV Ac1. Starbus ULTRA BS III Ac.2. Tata ULTRA BS III Bc1. LPO 9.6T Y1, 12V Bc2. LPO 9.6T Y1, NG Bc3. LPT 1109 CRDi BSIII Bb4. LPT 1109 Bs III Ba. LPO 1613 BSIV A1. LPT 1613 A2. LPT 1616 A3. SE 1613 A4. SK 1613 A5. SE 1616 A6. SK 1616 A7 LPK 1616 B1. LPO 1612C B2. 1610/ 1616/ 1612C/ 1612C RE B3. 4018C B4. 3015C LPK 2518TC LPT 2518TC

64. Types of Clutch 6/11/2014 TML 64 Diaphragm Clutch Hydraulic Clutch Actuation Hydraulic & Air Clutch Actuation Spring Clutch

65. Types of Clutch 6/11/2014 TML 65 Clutch plate type Clutch pressure plate Release bearing Ceramic Spring Type Oil Lubricated Organic Diaphragm Type Grease Lubricated Self Lubricated

66. Clutch System Overhauling Clutch System -280 mm Dia. 6/11/2014 TML 66

67. Clutch System -280 Dia- Construction Single Disc Dry Clutch Diameter : 280 mm Pressure Plate Assembly : Diaphragm Spring Type Clutch release Bearing : Self Centering Type Clutch Actuation : Hydraulic Master/Slave Cylinder Clutch Adjustment : Self- Adjusting 6/11/2014 TML 67

68. Clutch System -280 Dia- Components Sl No. Assembly Pressure Plate Clutch Plate Clutch Actuation 1 Pressure Plate Side Plate Clutch Pedal 2 Diaphragm Rivets Facing Rivet Adjusting Eccentric Pin 3 Fulcrum Ring Facing Clutch Release Fork 4 Cover Damper Spring Brake Cum Clutch Fluid Container 5 Diaphragm Spring Hub Clutch Master Cylinder 6 Rivets Intermediate Plate Clutch Slave Cylinder 7 Straps Washer Bleeding Nipple 8 Carrier Plate Push Rod 9 Segment Clutch Pedal Stop 10 Rivet 11 Washer 12 Wave Washer 6/11/2014 TML 68

69. Clutch System –Pressure Plate Assembly Specification 6/11/2014 TML 69 Sl No Description – Pressure Plate Unit Value New Condition Worn Condition 1 Clutch Plate Diameter mm Ø 281 Ø 281 2 Minimum Clamp Load N 8150 ( Mean Curve) 7250 (Mean Curve) 3 Release Load (NEW) N Max. 2400 Max .2640 4 Release Load (WORN) N Max.2950 Max.3250 5 Release Bearing Dia mm Ø 64 Ø 64 6 Lift of Pressure plate for 10 mm travel mm 1.7 1.7 7 Set Height when new mm 52.5 + 1.5 52.5 + 1.5 8 Finger tip run out mm 0.8 max 1.2 max 9 Overall Clutch size mm Max. 334.5 Max. 334.5 10 Dowel hole size/PCD/Nos. mm/mm/nos. 8.025+0.05/ Ø 313.995/3X 8.025+0.05/ Ø 313.995/3X

70. Clutch System –Pressure Plate Assembly Specification 6/11/2014 TML 70 Sl No Description - Pressure Plate Unit Value New Condition Worn Condition 11 Mounting hole size/PCD/Nos. mm/mm/nos. 8.7 + 0.1 / Ø 314.07/3X 8.7 + 0.1 / Ø 314.07/3X 12 Diaphragm type - Goose neck Goose neck 13 Total clutch height mm 60.5 + 0.2 60.5 + 0.2

71. Clutch System – Clutch Disc Assembly Specification 6/11/2014 TML 71 Sl No Description – Clutch Disc Assembly Unit Value New Condition Worn Condition 1 Outer Diameter (Facing) mm Ø 280 + 1 Ø 280 + 1 2 Inner Diameter (Facing) mm Ø 165 + 0.5/1 Ø 165 + 0.5/1 3 Clutch Plate thickness (New) mm 10.3 10.3 4 Clutch Plate thickness (Worn) mm 7.5 7.5 5 Facing Material - Valeo F 510 Valeo F 510 6 Max. Torque/Max . Twist angle mKg / deg 52/4.6° 47/4.6° 7 Number of Stages Nos Single Single 8 Level Dimension mm 6.5 + 1 8.5 + 1 9 Hub Length mm 35 + 0.5 8.5 + 1/1.5 10 Spline - A 10×28×35 DIN 5464/65 A 10×28×35 DIN 5464/65

72. Clutch Actuation System & Components Clutch Actuation Mechanism : Hydraulically operated clutch has been fitted on this vehicle. Hence the clutch is adjusted automatically. Basic adjustment of the clutch control mechanism is necessary after the pedals have been worked on or after the removal of the master cylinder. 6/11/2014 TML 72 1 Clutch Pedal 2 Adjusting Pin 3 Clutch Release Fork 4 Clutch Fluid Container 5 Clutch Master Cylinder 6 Clutch Slave Cylinder 7 Bleeding Nipple 8 Push Rod 9 Lock Nut

73. Clutch Actuation System & Components 6/11/2014 TML 73 Slave Cylinder Master Cylinder Master cylinder is having fluid bottle and attached to pedal. It compresses the oil and raises pressure up to 55 bar and send to slave cylinder Slave cylinder is attached to clutch fork and actuated by pressure developed in master cylinder

74. Clutch Booster Mechanism In order to reduce the clutch pedal effort, 70mm dia clutch booster assy is introduced in place of hydraulic clutch slave cylinder. Clutch booster is a pneumatic assisted clutch slave cylinder . 6/11/2014 TML 74 Model Clutch Pedal Travel (mm) Clutch Booster Travel (mm) 709 110 10 - 12 mm 909 110 10 - 12 mm 1109 110 10 - 12 mm Y1 100 10 - 12 mm 1613 152 20 - 22 mm 2518 124 20 - 22 mm

75. Safety Procedures & Cautions to be Followed Never blow compressed over the clutch plates to clean them. Clutch linings should not be replaced individually – Entire clutch disc to be replaced with genuine parts. Ensure clutch facing material is not contaminated with oil or grease to prevent unnecessary slippage of clutch 6/11/2014 TML 75

76. Checks to be done on the vehicle before Clutch Removal Sl No Checks to Be Done Corrective Action 1 Check for smooth engagement and smooth return of pedal Pedal return should be smooth and there should be no stick slip. Ensure the presence of pedal return spring. Ensure that the pedal linkages and bushes are greased. 2 Check the pedal free play Should be 2 to 3mm. If not adjust the pedal linkages to get the required play. 3 Check for full travel (As per drawing specification) of the pedal to the bottom of the floor. There should be no obstructions like foot rest etc. 4 Start the engine and check what point of pedal travel the clutch is released and engaged Clutch engagement and disengagement should take place between to 2/3 rd the pedal travel 5 Check the movement of master and slave cylinders. Movement should be smooth and should not be sticky 6 Check if bleeding of hydraulic cylinders are done. Bleed the system if pedal is spongy 7 Check for the stroke of the slave cylinder by depressing the clutch pedal fully 6/11/2014 TML 76

77. Clutch System Removal Procedure from Vehicle Removal Of Clutch Actuation Mechanism Dismantling Of Master Cylinder Dismantling Of Slave Cylinder Inspection of Clutch Components Inspection Of Master Cylinder Inspection Of Slave Cylinder Assembling Of Master Cylinder Assembly Of Slave Cylinder Installation Of Clutch On Vehicle Clutch System Overhauling – 280 mm Dia 6/11/2014 TML 77 Clutch System Overhauling – 280 mm Dia

78. General Maintenance of Clutch System Maintenance of clutch includes adjustment of pedal stopper bolt, checking oil level and bleeding the system for defect free operation on clutch actuation mechanism and periodic lubrication Driving: Following driving conditions will affect performance of clutch Clutch Riding Using clutch pedal as foot rest by keeping foot constantly on pedal while driving will cause partial clutch disengagement. It will result in slipping of the clutch disc and premature failure of the clutch. Permitting the clutch to slip too long Half clutch driving and thereby permitting the clutch purposely to slip too long will have the same result as clutch riding Sudden clutch engagement at higher engine speed specially while moving out stranded vehicle will cause severe instantaneous clutch loading, resulting in clutch slippage and burning of the lining. Starting the vehicle in first gear under such conditions will avoid such a problem. Always start vehicle in first gear. 6/11/2014 TML 78

79. General Maintenance of Clutch System Operating Conditions: Vehicles operating on shorter runs, city operations, off highway and operations in hilly terrains are obviously subjected to more number of clutch operations and thereby higher clutch wear. Clutch Disengagement And Disengagement Test During the above test, when vehicle is in motion, depress clutch pedal fully without changing accelerator pedal position. If engine speed increases immediately, perfect clutch disengagement is indicated. Further, release the clutch pedal suddenly. If the vehicle moves forward with a little jerk, perfect clutch engagement is indicated   Caution : This test should be carried out with utmost care because sudden release of clutch might cause heavy jerk and damage to clutch lining. 6/11/2014 TML 79

80. General Maintenance of Clutch System Clutch Slippage Test: The following methods are used to confirm clutch slippage: Drive vehicle in 1 st or 2 nd gear at maximum speed corresponding to that gear. With accelerator pedal fully pressed, apply brake gradually with left foot. If engine stalls, it means that clutch does not slip Drive loaded vehicle in3rd gear on level ground and let vehicle speed drop down to approximately 15 kmph / 9mph. Now press accelerator pedal full. With slipping clutch, vehicle speed will not pick up and also clutch burning smell will be felt. If this does not occur and vehicle picks up speed. It indicates that clutch does not slip. 6/11/2014 TML 80

81. Important Settings & Adjustments Clutch Pedal Height & Free Play Adjustment: Clutch pedal free play is due to clearance between plunger & push rod of master cylinder. This cannot be adjusted. It is built in design feature. Loosen lock nut for master cylinder push rod fork. Slide back dust cover. Rotate master cylinder push rod till desired height of pedal is achieved. Tighten lock nut for push rod fork. Check pedal stroke. It should be 130 mm. If not adjust pedal stroke with pedal travel adjusting screw( Stopper Bolt) & lock it with lock nut. 6/11/2014 TML 81

82. Important Settings & Adjustments Clutch Pedal Height & Free Play Adjustment 6/11/2014 TML 82 Clutch Pedal Cl pedal Adj. screw Cl release fork Reservoir Master Cylinder Slave cylinder Bleeding pt. Push Rod Lock Nut Cl Pedal height adjustment Measured with a scale

83. Clutch Release Bearing Lubrication 6/11/2014 TML 83 Felt Pad Oiling photo Greasing type CRB Fill oil this point.

84. Clutch Fluid Filling & Bleeding The System Fill the Container with clean brake fluid. Connect the S/ Cyl . bleeding nipple with the tube to a glass jar with fluid. Press the clutch pedal 3 to 4 time to full stroke, watch the fluid level in container & keep adding. Hold the pedal pressed, loosen the S/ cyl , bleeding screw till all air bubble expel. Tighten the nipple. Repeat sl.no 3 & 4 till the air bubble cease to appear. NOTE : Ensure that the fluid level in container does not fall below ‘MIN’ marking throughout the bleeding operation. If it drops down to ‘MIN’ marking, top up with brake fluid up to ‘MAX’ marking. 6/11/2014 TML 84 Clutch Master Cylinder Clutch Slave Cylinder

85. Clutch System Overhauling Clutch System - 330 mm Dia . 6/11/2014 TML 85

86. 330 Dia Clutch Adjustment The lever height are set by turning the adjusting nuts while at same time holding the lock nut with a spanner. The position of the three lever in the case of 330 dia clutch with a cast iron cover is check from the flat surface of the flywheel or arbor press to top of the collector ring at minimum three point. This dimension should 53mm +/-0.2mm and run out of finger within 0.4 mm. This dimension can also be verified by checking the dimension of 32 mm +/- 0.2 mm from the top face of cover raised lugs up to the collector ring . 6/11/2014 TML 86

87. Clutch Overhauling - 330 mm Clutch Remove cast iron cover & 9 pressure spring. Remove circlip & washer from the pressure plate pins. Remove the release levers, dismantle the eye bolt pins from the eye bolts & adjusting nuts from eyebolts. Press or knock out the needle bearings in the eyebolts & pressure plate. 6/11/2014 TML 87 Mounting Bolt Toggle Tool Acceptance norm Pressure spring Load @ 38.86 mm 122 kg Free Length 71 mm/min

88. Clutch Specification - 330 dia 6/11/2014 TML 88 Description Nominal Value (mm) Limit Tolerance (mm) Correction and Remark Driven Disc Assembly Facing assembly thickness (when independent) 10.8 6.8 Replace Flatness 0.60 Correct or Replace Hub spline play in rotating direction Replace Pressure Plate Gap between ring cover and Pressure plate Slots 0.10 0.25 Replace Height from friction face to the top of the Pressure Plate pin 38.4 37.6 Replace Minimum free length of pressure Springs 71 Replace Pressure Plate Lever height (A) From Flywheel face up-to the Collector Ring (B) From top of the cover raised lug up-to collector ring. 53.0 32.0 ± 0.2 ± 0.2 Adjust Adjust

89. Clutch Specification - 330 dia 6/11/2014 TML 89 Tightening Torque Part to be tightened Thread size O.D. x Pitch (mm) Tightening torque Nm ( Kgfm ) Clutch Clutch Cover mounting bolt M8 X 50 47 to 54 (4.7 to 5.4) Cover Pressure plate eye bolt lock nut 110 to 120 (11 - 12)

90. All The Best!!! 6/11/2014 TML 90