ALLCV

Service Manual
Diaphragm Clutch
21.02 DIAPHRAGM CLUTCH

CONTENTS

GROUP - 21

DIAPHRAGM CLUTCH

Section Subject Page No.

21.0 General ..................................................................................................................... 21.03

21.0.0 Diaphragm Clutch Type and Sl. No. .............................................................................. 21.03
21.0.1 Design and Operation ........................................................................................................... 21.03
21.0.2 Description of Leading Components ............................................................................... 21.05
21.0.3 Data ............................................................................................................................................... 21.06
21.0.4 Clutch Preliminary Checks ................................................................................................... 21.08

21.1 To Remove and refit diaphragm Clutch from vehicle ................................ 21.09

21.2 To Overhaul ............................................................................................................ 21.10

21.2.0 Disassembly ................................................................................................................................. 21.10
21.2.1 Assembly ...................................................................................................................................... 21.12

21.3 Hydraulic system ................................................................................................... 21.14

21.3.0 Master Cylinder ........................................................................................................................ 21.14
21.3.0.0 Description......................................................................................................................... 21.14
21.3.0.1 Removal ............................................................................................................................... 21.14
21.3.0.2 Dismantling ........................................................................................................................ 21.14
21.3.0.3 Examination ....................................................................................................................... 21.15
21.3.0.4 Assembling ......................................................................................................................... 21.16
21.3.0.5 Clutch Pedal Free Play ................................................................................................. 21.16
21.3.1 Slave Cylinder ............................................................................................................................ 21.17
21.3.1.0 Removal ............................................................................................................................... 21.17
21.3.1.1 Dismantling ........................................................................................................................ 21.17
21.3.1.2 Examination ....................................................................................................................... 21.17
21.3.1.3 Assembling ......................................................................................................................... 21.18
21.3.1.4 Slave Cylinder Push Rod Stand out ....................................................................... 21.18
21.3.1.5 Bleeding the System ....................................................................................................... 21.18
21.3.1.6 Procedure ........................................................................................................................... 21.18

21.4 Tightening torques ................................................................................................ 21.19

21.5 Recommended lubricants ..................................................................................... 21.19

21.6 Filling capacity ....................................................................................................... 21.19

21.7 Maintenance programme ...................................................................................... 21.19

 DIAPHRAGM CLUTCH 21.03

21.0 GENERAL

21.0.0 Diaphragm Clutch Type and Sl. No.

Manufacturers make is punched on the cover

plate.

21.0.1 Design and Operation

Diaphragm clutch design consists of the

following parts.

1. Clutch Cover

2. Pressure plate

3. Diaphragm Spring

4. Fulcrum rings

5. Fulcrum rivets

6. Rivets to attach drive straps to clutch

cover and pressure plate

7. Drive straps

Fig. 1 Representative Diagram - Diaphragm Spring Clutch

21.04 DIAPHRAGM CLUTCH

Function
The flywheel is bolted firmly to the
crankshaft. As there are 2 friction surfaces
i.e. Flywheel face and Pressure plate face, the
torque is transmitted through these surfaces
based on the co-efficient friction(m). In the
case of the cover assembly the torque
transfer is from the flywheel into the cover, ,
which is bolted to the flywheel. Through the
drive straps, into the pressure plate and to
the facing on the clutch disc.

Fig. 2
The diaphragm spring clamps the pressure
plate against the clutch disc to achieve
positive lock-up with the flywheel. The
clutch disc transmits the entire engine torque
to the transmission via a splined connection
to the transmission input shaft. Fig - 2

When the driver depresses the clutch pedal,,

the release bearing actuates the diaphragm
spring. The diaphragm spring is supported
on a fulcrum ring attached to the clutch
cover. The diaphragm spring pivots on this
fulcrum ring, so that the outside diameter
moves away from the pressure plate. This
causes the preloaded drive straps to pull
the pressure plate away from the clutch disc,
interrupting torque transmission. When the
driver releases the clutch pedal, the outer
portion of the diaphragm spring acts on the
pressure plate which clamps the clutch disc
between the pressure plate and the flywheel.

Advantages of Diaphragm Clutch

In the diaphragm spring clutch, the lever
portion performs the release function. In
spite of the high clamp load requirements,
the diaphragm spring's unique characteristic
curve provides the low release loads
demanded by today's comfort-minded
drivers. Finally, when coupled with an
appropriately tuned cushion segment in the
clutch disc, the diaphragm spring clutch offers
excellent engagement performance and
exceptional start-up comfort.

1. Reduced clutch pedal effort

2. Optimum clamping load maintained

regardless of wear on the clutch disc.
 DIAPHRAGM CLUTCH 21.05

3. Uniform clamping load over facing

4. Diaphragm spring unaffected by

centrifugal forces as in the case of coil
springs.

5. Compact and fewer parts.

6. Better dynamic balance due to

rotational symmetry.

7. High fatigue life of diaphragm spring.

21.0.2 Description of Leading Components

Cover - made of pressed steel, and form

in such a way as to allow for the assembly
of the diaphragm spring and pressure plate
internally.

Driving Straps - connects the cover to

the pressure plate. And is design in such a
way as to allow for the retraction of the
pressure plate during clutch release.

Diaphragm Spring - made from spring

steel with between 16 to 24 fingers
depending on design. Fingers are to allow
for the in and out movement of spring
during clutch engagement and disengagement.
The outer ring applies the clamping force.

Pressure plate - made of high quality cast

iron to reduce wear on the friction surface,
and of sufficient mass to absorb the heat
generated during clutch engagement.
Included is a pivot point on which the
diaphragm acts.

Rivets (Conventional) - There are

normally 6 rivets to secure the pressure
plate to the driving strap and drive strap to
cover (3 each)

Fulcrum Rivet - This is a special rivet and

is used to secure the diaphragm to the
cover in such a way, that the diaphragm is
still able to pivot.

Pivot Rings - These are special wire rings

welded to form a circle and are to act as
pivots for the diaphragm spring.
21.06 DIAPHRAGM CLUTCH

21.0.3 Data

Sl. No. Figure Description Value

Type - Single plate dry type Diaphragm

Clutch - Hydraulically operated

1 Master cylinder diameter (1) 7/8"

(AS type)

2 Slave cylinder diameter (2) 7/8"

3 Clutch pedal play (X) 1/8"

4 Clutch plate diameter (3) 310 mm

5 Clutch plate thickness - free (X1) 10.8 ± 0.5 mm

without load
Clutch plate thickness - clamped (X1) 10.0 ± 0.3 mm
with load
Change clutch plate when (X1) 6.6 mm

6 Diaphragm spring force

a. Fitted condition (P1) 840 ± 30 kg
b. Peak (P2) 940 ± 30 kg
 DIAPHRAGM CLUTCH 21.07

Sl. No. Figure Description Value

7 Lift of pressure plate for 12 mm 2.0 mm

travel of finger (X2) (minimum)

8 Finger tip run out less than or equal to 0.8 mm

Finger thickness more than or equal to 3.4 mm

10 Thickness of pressure plate

Max. skimming allowed (X5) 1.00 mm

NOTE: Do not skim as assembly. Pressure plate

has to be removed and then skimmed.

11 Slave Cylinder Push Rod standout

(with new flywheel, disc and cover assembly) 158 ± 7 mm.

12 Ensure push rod is to be flushed

inside the jaw end.
21.08 DIAPHRAGM CLUTCH

21.0.4 Clutch Preliminary Checks

It is mandatory to carry out few preliminary check on Clutch before dismounting from the vehicle. The
following cause and effects can lead to overhauling decision.

Master cylinder Clutch pedal

reservoir empty travel restricted

DIFFICULT TO
ENGAGE GEAR

Clutch worn or drive

Improper Engine idle
plate sticking on the
Bleeding speed too fast
maindrive splines

Fig. 3 Cause and Effect Diagram - Difficult to engage gear

Clutch Pedal Release Clutch

Pressure
setting wrong mechanism assembly Clutch plate
build up on
without free not contaminated worn
hydraulic
play. disengaging with oil

CLUTCH
SLIPPING

Excessive
Vehicle Clutch disc skimming of Diaphragm
overloaded glazed pressure spring weak
plate /
flywheel

Fig. 4 Cause and Effect Diagram - Clutch Slipping

 DIAPHRAGM CLUTCH 21.09

Release Warped or
Release Diaphragm
bearing broken Excessive
bearing spring finger
requires pressure pedal travel
seized. broken
lubrication plate

CLUTCH
HARD

Clutch
Air lock in
assembly Diaphragm Bend in
Oil level low hydraulic
contaminated spring weak clutch plate
system
with oil

Fig. 5 Cause and Effect Diagram - Clutch Hard

21.1 TO REMOVE AND REFIT

DIAPHRAGM CLUTCH FROM
VEHICLE

To remove gear box from vehicle disconnect

propeller shaft connection, connection parts
and remove the gear box assembly carefully.

Unscrew bolts holding the clutch assembly to

the engine flywheel and withdraw the clutch
assembly.

Perform the above in reverse order to refit

the clutch assembly.

Use Special Tool 0201006 -

Centraliser Clutch ZF Gear Box.
21.010 DIAPHRAGM CLUTCH

21.2 TO OVERHAUL

21.2.0 Disassembly

Inspection of the Assembly Before

Taking Out From Flywheel

Check the space available (3) between the

cover housing and diaphragm spring (2)

If the gap (3) available is less than 0.78

mm @ max disc wear or more than 7.94
mm max @ diaphragm finger sagging
condition then the clutch assembly has to be
taken out.
Fig. 1
Fig - 1

Inspection of Cover Assembly Fitted

on Special Tool 0202001 - Fixture
Diaphragm

Mount the assembly on to the fixture (2)

Check the height of the finger tips (1) from

the base of the fixture as shown.

If necessary change pressure plate or

diaphragm spring.

Fig - 2
Fig. 2
Inspection of Diaphragm Spring

Diaphragm Spring
Measure the run out on the finger tips. The
run out on the finger tips should not to
exceed 1.0 mm

Measure the wear on the finger tips (x)

The minimum thickness of the finger tips (1)

is not to be less than 2.05 mm.

Fig - 3

Inspection of Pressure Plate, Strap

and Fulcrum Ring Fig. 3

Pressure Plate
Measure the wear on the pressure plate
friction (1) surface. The dimensions should be
as shown in figure.

Strap
The straps (3) should be in good condition
on visual inspection

Fulcrum rings
Shake the assembly lightly. No metallic
rattling sound indicating the breakage of
fulcrum ring (4) should be heard.

Fig - 4 Fig. 4
 DIAPHRAGM CLUTCH 21.011

Removal of Pressure Plate and

Strap

One end of strap (1) riveted to cover (2)

and other end to pressure plate (4).

Make suitable marking on cover and

pressure plate for reassembling in same
position.

Place the assembly on the fixture (3) and

tighten the diaphragm spring (5) using the
handle (6). Fig. 5

Drill out the four rivets (7) one by one.

During drilling care should be taken to see

that the strap holes are not enlarged.

Remove cover (2) with Diaphragm (5) and

pressure plate (4).

Fig - 5

Removal of Pressure Plate From

Strap Fig. 6

Place the pressure plate (1) on the fixture

as shown Drill out the four rivets (2).

Caution: During drilling, drill should not touch the

pressure plate.

Fig - 6

Removal of Diaphragm From Cover

Place the assembly on the fixture (1) so

that rivets seat on the bunks. Fig. 7

Tighten the diaphragm spring (3) using the

handle.

Drill out the rivets.

Repeat for other 6 rivets (2).

Caution: While drilling drill bit should not touch

the cover.

Fig - 7
21.12 DIAPHRAGM CLUTCH

21.2.1 Assembly

Pressure Plate To Strap Riveting

Place the rivets on rivet supports (1) and

keep the straps (2) in position.

Place the pressure plate (3) over the straps

such that the rivets enter the holes.

Form the rivets (4) one by one using the

punch (5).

Forming diameter of rivets should be Fig. 8

between 11 - 11.5 mm using hydraulic press
of 8 - 10 Tons.

Fig - 8

Cover To Diaphragm Riveting

Locating of Diaphragm Spring With

Cover

Place the six guide screws on locating bunk.

Place one fulcrum ring so that the welded

portion comes in between rivets.
Fig. 9

Place the diaphragm spring over the ring.

Place another fulcrum ring (2) over the

diaphragm spring such that welded portion is
diametrically opposite to the other ring.

Place the cover housing so that the guide

screws pass through the holes.

Tighten the guide screws and take out the

sub-assembly.

Fig - 9
Fig. 10

Place six rivets on the rivet supports.

Place the sub-assembly such that the rivets

pass through the rivet holes in the cover.

Fig - 10

Form the rivets using the punch (1) and

hydraulic press. Forming diameter is to be
maintained between 11.5 - 12 mm.

Repeat for other six rivets.

Fig - 11 Fig. 11
 DIAPHRAGM CLUTCH 21.13

Final Riveting
Place the dowel pins in position.
Place the rivets (1) on the bunks.
Place the pressure plate (2) so that the
rivets pass through the strap holes.
Coat the diaphragm seating position with
molycoat grease. Position the cover and
diaphragm suitably so that the markings
made before dismantling matches. Tighten
the springs using the handle.
Fig - 12
Form the rivets one by one using the punch (1).
Forming diameter of the rivets is to be Fig. 12
maintained at 11.5 - 12 mm. Use by press
of 6 - 7 ton capacity.
Fig - 13

Inspection After Riveting

Mount the assembly on the fixture:
Check the height of the finger tips from the
base of the fixture as shown.
35.4 ± 1 mm - @ New condition
32.5 ± 1 mm - After machining the
pressure plate 0.8 mm.
Fig - 14
Fig. 13
INSTALLATION OF CLUTCH DISC
Ensure that the flywheel must be with the
face of clutch disc lettered as "Flywheel Side",
in the case of installing a new clutch disc.
Fig - 15
However in the case of refixing an old clutch
disc, the lettering may have disappeared and
hence check as below.
Hub tail (longer end of clutch plate hub) is
to be kept towards the rear (GB side).
The oil flinger on the clutch plate to be ensured
on the pressure plate side (i.e. G.B. side).
Fig - 16 Fig. 14

Fig. 16 Fig. 15
21.14 DIAPHRAGM CLUTCH

Fig.1 Master Cylinder - Cut Sectional View

21.3 HYDRAULIC SYSTEM Disconnect the outlet pipe connection from

the master cylinder.
21.3.0 Master Cylinder
Disconnect the push rod linkage from the
21.3.0.0 Description
clutch pedal. Remove the master cylinder
When the clutch pedal is depressed, the
mounting bolts/nuts. The master cylinder can
master cylinder push rod which is directly
now be taken out along with the push rod.
connected to the clutch pedal, pushes the
master cylinder piston sufficiently for the
21.3.0.2 Dismantling (Refer Fig - 2)
pressure seal to pass the cut off port.
Clean the master cylinder externally.
Further movement of the piston displaces
Unscrew the filler cap and drain-out any
fluid under pressure from the cylinder and
surplus fluid. Hold the master cylinder in a
transmits it through the hydraulic pipe to
vice fitted with soft jaws. Take care not
slave cylinder, which in turn operates the
to distort the barrel.
clutch release fork through the push rod.
When the clutch pedal is released, due to Remove the fluid reservoir mounting screws
the action of the clutch diaphragm fingers, (12) with the help of Phillips headed
the fluid from the slave cylinder is pumped screwdriver. Take out the fluid reservoir
back to the master cylinder. (11) from the master cylinder.
Remove the grommet (16) from the master
21.3.0.1 Removal
cylinder inlet port. Remove the push rod
Connect a bleed tube to the slave cylinder
(10). Remove the dust cover (9).
bleed screw after removing the rubber dust
Depress the piston (6) with the push rod
cap. Loosen the bleed screw by 1/2 to 3/4
and remove circlip (8). The internal parts
turn and pump out the clutch fluid into a
can now be removed in this order. Piston
suitable container by operating the clutch
with back seal (7), pressure seal (4), spring
pedal.
retainer (3) and piston return spring (2).
 DIAPHRAGM CLUTCH 21.15
1. MASTER CYLINDER BODY
2. SPRING
3. SPRING RETAINER
4. PRESSURE SEAL
5. SHIM
6. PISTON
7. BACK SEAL
8. CIRCLIP
9. DUST COVER
10. PUSH ROD
11. FLUID RESERVOIR BODY
12. SCREW
13. FILTER
14. SEALING WASHER
15. FILLER CAP ASSEMBLY
16. GROMMET

Fig. 2 Exploded View of Master Cylinder Assembly (AS Type)

Remove the spring (2) from the spring UNDER NO CIRCUMSTANCE SHOULD
retainer (3). Remove the spring retainer (3) THE HOLES BE POKED WITH A SHARP
from the piston. Remove the pressure seal INSTRUMENT
(4), shim (5) from the piston. Remove the
back seal (7) from the piston groove 21.3.0.3 Examination
carefully stretching it over the end flange Examine the bore of the master cylinder. If
using either by fingers or by using a blunt it is not scored, ridged or corroded and is
edged screw driver or brass rod. smooth to touch, the master cylinder can
be rebuilt using parts from Leyparts master
Discard all the rubber parts and seal shim.
cylinder repair kit. If there is the slightest
Clean all the other parts and master cylinder
doubt as to the condition of the bore, a
body thoroughly in fresh brake and clutch
new master cylinder assembly must be
fluid or alcohol and place them on the clean
fitted.
tray or sheet of paper.
It is recommended that a new piston is
NEVER CLEAN THE MASTER CYLINDER
fitted at every overhaul. If you should use
OR INTERNAL PARTS WITH DIESEL,
the same piston, ensure that the piston is
KEROSENE OR PETROL.
free from rust, ridges and burrs and all the
Ensure that the recuperating hole and the recuperating holes in the piston are clear.
feed hole visible through the inlet port of If the recuperating holes are blocked the
master cylinder are clean by blowing with blocks can be removed by blowing dry
dry compressed air. compressed air.
Remove the filler cap assembly (15) from If in doubt replace the piston. Ensure that
the reservoir. Remove the filter (13) from the piston return spring is in good
the filler cap after taking out the baffle. condition. Renew if necessary.
Ensure that the breather hole in the filler cap WHEN EVER THE MASTER CYLINDER IS
is clean after removing the small cap on the SERVICED, USING PARTS FROM GENUINE
top. LEYPARTS REPAIR KIT IS STRONGLY
Clean the filter (13) by blowing dry RECOMMENDED.
compressed air. Clean the reservoir in
isopropylene alcohol.
21.16 DIAPHRAGM CLUTCH

21.3.0.4 Assembling 14. Fix the screw (12) and tighten them
Once properly inspected, assemble the to a torque of 5.6/6.8 Nm.
master cylinder as follows. 15. Place the filter on the reservoir.
1. Dip the piston (6), back seal (7), seal 16. Fit a new rubber gasket and the
shim (5), pressure seal (4), spring baffle on to the filler cap. And also
retainer (3) in fresh hydraulic fluid. assemble the small cap on to the
2. Lubricate the cylinder bore liberally top.
with fresh hydraulic fluid. 17. Screw in the filler cap assembly on
3. Using fingers only, fit the back seal (7) to the fluid reservoir (11). Now,
on to the piston groove in such a the master cylinder can be fitted on
way that the seal lip is facing towards to the vehicle.
the stem end of the piston.
Fit the master cylinder on to the vehicle in the
4. Fit seal shim (5), pressure seal (4) the reverse order of removal.
seal lip facing the spring, on the stem
end of the piston. Reconnect the outlet pipe connections.
5. Fit the spring retainer (3) in such a
way that the prongs are towards the 21.3.0.5 Clutch Pedal Free Play
seal and ensure it is well seated on Adjust the clutch pedal free play by adjusting stopper
the stem. bolt on the clutch pedal to achieve the recommended
free play (Refer page 21.06).
6. Dip the spring (2) in fresh hydraulic
fluid and fit one end of the spring on It is essential that the free play is checked regularly
to the spring retainer (3). and corrected as necessary.

7. Now push the piston assembly spring

leading into the bore.

8. Depress the piston slightly by push

rod (10) and fit circlip (8).

9. Check the piston for free movement

when depressed.

10. Smear the inside of dust cover (9)

with vegetable based rubber grease
and fit it on to the master cylinder.
Ensure its lip is well seated on the
cylinder groove.

11. Smear vegetable based rubber grease

on the push rod stem seating in the
piston and on the eye hole.

12. Dip the rubber grommet (16) in fresh

hydraulic fluid and fit it on to the
master cylinder inlet port.

13. Fit the hydraulic fluid reservoir body

(11) with the fluid nozzle in the
rubber grommet and align the
mounting holes with the mounting
threaded holes on the master cylinder
body.
 DIAPHRAGM CLUTCH 21.17

1. SLAVE CYLINDER BODY

2. SPRING
3. GLAND SEAL
4. PISTON
5. CIRCLIP
6. DUST COVER
7. BLEED SCREW
8. DUST CAP
Fig. 3 Exploded View of Slave Cylinder

21.3.1 SLAVE CYLINDER 5. The internal parts can be removed in

Slave cylinder is a simple construction this order. Piston with seal (3) and
consisting of a cast iron body incorporating piston return spring (2).
a piston and seal.
6. Remove the gland seal (3) from the
The slave cylinder flange is mounted to the piston groove carefully with fingers or
clutch housing bracket. When the clutch with a blunt edged brass rod or
pedal is depressed, fluid in the master connector.
cylinder is forced under pressure into slave
7. Discard all the rubber parts. Clean
cylinder, actuating its push rod, which
all the parts and the cylinder body
operates the clutch mechanism.
throughly in fresh hydraulic fluid or
isopropylene alcohol and place them
21.3.1.0 Removal
on a clean tray or on a clean sheet
Connect a bleed tube to the slave cylinder
of paper.
bleed screw after removing its dust cap.
Loosen the bleed screw 1/2 to 3/4 turn and NEVER CLEAN THE SLAVE CYLINDER
pump out the hydraulic fluid into a suitable OR INTERNAL PARTS WITH MINERAL
container by operating the clutch pedal. OIL LIKE KEROSENE, DIESEL OR
PETROL.
Disconnect the Hose Banjo/Banjo bolt
connection. Loosen and remove the
21.3.1.2 Examination
mounting bolts. Now, take out the slave
cylinder for overhauling. Examine the bore of the slave cylinder. If
it is not scored, ridged or corroded and is
21.3.1.1 Dismantling (Refer Fig - 3) smooth to touch, the slave cylinder can be
rebuilt using parts from genuine Leyparts
1. Hold the slave cylinder in a vice fitted
repair kit. If there is the slight doubt as
with soft jaws, taking care not to
to the condition of the bore, a new slave
distort the barrel.
cylinder assembly must be fitted.
2. Unscrew and remove the bleed screw
Examine the piston, it should be free from
(7).
rust, ridges and burrs. If in doubt replace
3. Remove dust cover (6). the piston.

4. Depress the piston (4) and remove Ensure that the piston return spring is in
the circlip (5). good condition. If necessary replace.
21.18 DIAPHRAGM CLUTCH

21.3.1.3 Assembling operation. Ensure that no dirt or grit

enters the system, especially at the fluid
1. Dip piston (4) and gland seal (3) in
reservoir.
fresh hydraulic fluid.
All equipment to be used must be entirely
2. Using fingers only fit the gland seal
free from mineral oil like diesel, kerosene
(3) on to the piston (4) in such a
etc to avoid contamination as it will
way that it sits squarely in the piston
deteriorate the rubber seals.
groove (the flat face of the seal
towards the push rod end of the NEVER, UNDER ANY CIRCUMSTANCES,
piston). USE THE FLUID WHICH HAS BEEN
BLEED FROM THE SYSTEM TO TOP UP
3. Lubricate the bore of the slave
THE FLUID RESERVOIR. AS IT MAY BE
cylinder (1) liberally with fresh hydraulic
AERATED, HAVE TOO MUCH
fluid.
MOISTURE CONTENT AND/OR BE
4. Fit the spring on to the piston stem. CONTAMINATED.
5. Insert the piston assembly into the
21.3.1.6 Procedure
bore with the other end of spring
leading into the bore. Before commencing to bleed, follow the
essential precautions. To bleed the clutch
6. Depress the piston (4) and fit circlip
system, first carefully clean all dirt from
(5).
around the fluid reservoir cap. Remove the
7. Check the piston for free movement filler cap, fill the reservoir with hydraulic
when depressed. fluid to the “MIN” marking level.
8. Smear inside of the dust cover lip Remove the slave cylinder bleed screw dust
with vegetable based rubber grease cap and clean it. Attach the bleed tube to
and fit it on to the cylinder. the bleed screw and place the other end
of the tube in a glass jar containing
9. Fit bleed screw (7) and dust cap (8).
sufficient hydraulic fluid to submerge the
DO NOT USE CHASSIS GREASE end of the tube.
Refit the slave cylinder assembly in the Open the bleed screw ½ to ¾ turn
reverse order of removal, and connect the sufficient to allow the fluid to flow freely.
hose with banjo, banjo bolt and new Depress the clutch pedal slowly throughout
gaskets. the full stroke of the pedal and allow it to
return slowly to its stop.
21.3.1.4 Slave Cylinder Push Rod Stand out
There should be an interval of three or
Refer page 21.07 for adjusting slave cylinder
four seconds before making the next
push rod stand out.
stroke. This action should be repeated
until bubbles of air cease to appear at the
21.3.1.5 Bleeding the System
end of the bleed tube. Close the bleed
The process of removing air from the
screw immediately after the last downward
hydraulic pipe line and cylinders is known
stroke of the pedal. Whilst the pedal is
bleeding and is necessary whenever any part
thus held, securely tighten the bleed screw
of the system has been disconnected or the
and remove the tube. Replace the dust
level of fluid in the fluid reservoir has been
cap on the bleed screw.
allowed to fall so low that air has been
drawn in to the system. When seals are Ensure that the fluid level in the fluid
worn, it is possible for air to enter the reservoir does not fall low enough to cause
cylinder with out any sign of fluid leaking, air to be drawn into the system through
causing a spongy pedal which is the usual the bleeding operation.
indication of air in the system. ALWAYS USE HEAVY DUTY
It is vital that absolute cleanliness is HYDRAULIC FLUID AS RECOMMENDED
maintained throughout the entire bleeding TO MEET THE ABOVE REQUIREMENT
 DIAPHRAGM CLUTCH 21.19

21.4 TIGHTENING TORQUES

Spanner Kgm lb.ft

Size

310 mm Cover assembly mounting bolts (M8) 13 mm 2.9 21

21.5 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

21.6 FILLING CAPACITY

Aggregates Filling Capacity Change Period

(l) (km)
Hydraulic Clutch
Clutch Hydraulic System 1 40000

21.7 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 operating pedal shaft bush G 1 ✓ ✓ ✓
2. Lubricate clutch withdrawal lever G 1 ✓ ✓ ✓
3. Lubricate clutch withdrawal bearing sleeve G 1 ✓ ✓ ✓
B. Maintenance
1. Check and adjust clutch pedal free ✓ As
play. Refer page 6.38 required
2. Check master / slave cylinder for leakages ✓ ✓
3. Check pipes for leakages ✓ ✓
4. Check level and top up hydraulic fluid in ✓ Refer
reservoir of master cylinder lubricant
chart.
5. Overhaul clutch master / slave cylinder 72
6. Check stand out & replace clutch disc if necessary As
required.