I

Features

Construction & Operation

3-5

Installation & Maintenance

6-9

Service Problems & Solutions

10 - 11

Norms of Warranty Acceptance

12 -16

Pressure Plate Assembly Repair Procedure

17 - 22

Clutch Disc Assembly Repair Procedure

23 - 24

Dimension Specifications

25

Spare Parts Kit

26 - 27

Technical Specifications

28 - 29

Features
Push type Fit and Forget, no release bearing setting required
(unlike pull type) and hence easy to maintain.
Cast cover simple and robust. It is exclusively designed for 330 dia and not just an
upgrade of today's 310 dia.
Coil spring design most ideal for the Indian market - can be repaired easily at low cost.
Unique lever design and high lever ratio to provide low release loads and hence low
pedal effort.
Nine Needle Roller Bearings provide smooth and easy operation. No hassle of
loose needles.
Release bearing contacts collector ring with flat face, prevents grooving of the release
bearing which is a major problem with other designs.
No compromise on weight. Pressure plate of adequate mass ensures that the heat
absorption capacity is right to keep the ceramic buttons cool.
Cover design with large openings and the turbulence effect of springs ensures
adequate cooling to spring and buttons.
Suitable for both cummins and 697 turbo engines.

Fig.No. 1

8
7

2
3

6 5 4
9 Bolts
Bolts at 345 PCD numbered
1 to 9 for Flywheel with 12 holes

Clutch Construction
330 Dia Lipe clutch assembly is of the Push type, Dry disc design. Unlike pull type, this is
fit and forget type.

Fig.No. 2

CAST COVER
PRESSURE PLATE
PRESSURE PLATE PIN
EYE BOLT PIN
ADJUSTING NUT
EYE BOLT
LOCK NUT
RETRACTOR SPRING
DAMPER SPRING

LEVER

HUB
HUB SPLINE
HUB RIVET

COLLECTOR RING
PRESSURE SPRING

CERAMIC BUTTON

HOLD DOWN BOLT

Clutch Operation
When the clutch pedal is depressed the Release bearing assembly is pushed towards the
Flywheel. This results in retraction of pressure plate which relieves the Flywheel and the
pressure plate of the Disc Assembly.
Full disengagement occurs when the release bearing is actuated 10 to 12mm. Releasing
the clutch pedal allows the release bearing to travel back towards the transmission,
slowly re-engaging the clutch.

Clutch Release Action (Refer Fig. No. 3)

A : Pedal depressed.
B : Pedal linkage actuated.
C : Master cylinder link actuated.
D : Master cylinder piston in
E : Hydraulic fluid pressurised.
F : Slave cylinder piston pushes the clutch shifter fork.
G : Fork pushes the release bearing towards flywheel
H : Release bearing pushes the lever.
I : Pressure plate lifted by action of lever movement.
J : As a result of pressure plate lift which relieves the flywheel & pressure plate of the
driven disc & clutch is released.
Full disengagement occurs when the release bearing is actuated10 to12mm.Releasing
the pedal allows the release bearing to travel back towards the transmission slowly
re-engaging the clutch.
Lining Wear
K : As lining wears the pressure plate moves in this direction, towards the flywheel.
L : Through action of lever and linkages this causes the release bearing to move in the
direction 'L' as shown
M : As a result of lining wear the slave cylinder piston moves in the direction 'M' shown.

Fig.No. 3

Sequence Of Operation

Installation and Maintenance

1)Flywheel preparation
Ensure the Flywheel friction face is free of cracks, scouring, dishing and taper.
If found necessary, remove the Flywheel for re-work or replacement.
Check the condition of Pilot Bearing, replace if found damaged.
2) Checks for Flywheel
Check the run out of Flywheel - Clutch housing mounting surface with respect to
Flywheel housing .See Fig. No. 4
Over machining of the flywheel can cause fouling of the DP with the Flywheel
Mounting bolts
The centre line or Axis of the Engine, Flywheel, Flywheel housing, Clutch, Clutch housing
and transmission shall be common to these units with a permissible variation of not more
than 0.2 mm.
If the Flywheel is reworked by re-grinding the Friction Face, it is necessary to re-qualify the
thread depth to ensure that the Clutch mounting bolts do not bottom.
Check runout of Clutch housing bore dimention in respective with Flywheel Face.
(required within 0.2)
Fig.No. 4
FLYWHEEL HOUSING
INDICATOR
RUNOUT
0.008 MAX
0.20MM

ENGINE FLYWHEEL

FOR S.A.E. BELL Nos 1, 2 & 3

FLYWHEEL HOUSING

FLYWHEEL HOUSING

INDICATOR
RUNOUT
0.008 MAX
0.20MM

ENGINE FLYWHEEL

FOR S.A.E. BELL Nos 1, 2 & 3

FLYWHEEL HOUSING

INDICATOR
RUNOUT
0.001 MAX
0.03MM
1

/2CLUTCH DISC DIA.

ENGINE FLYWHEEL

ENGINE FLYWHEEL

INDICATOR
RUNOUT
0.005 MAX
0.13MM

Excessive run out can cause Chatter, Vibration problem in the vehicle leading to clutch failure.

Fig.No. 5

20.6mm MIN
3.2/4.7mm

9.6/9.5mm

Flywheel Bolt Hole

3) Setco
Clutch/ Lipe
Mounting
Clutch Disc Assembly is part marked and identified
Pressure Plate side".Clutch Disc Assembly should be installed as
shown in Fig.6
Before Clutch Disk Assembly is installed smear the hub splines
with high melting point grease of the following specification,
Shell Multiservice Grease,
Industrial Multipurpose Grease
Marketed by: Bharat Shell Ltd.,
Under Licence of :
Shell International Petroleum Corporation Co. Ltd. London
Improper grease can cause dryness in the contact surface causing
more wear and tear .
Fit 2 off guide screws on Flywheel and put the Clutch Disc
Assembly and Pressure Plate Assembly over the Alignment tool and
2 guide screws.
Fit Pressure Plate Assembly on Flywheel using 7 Spring Washers
and Bolts and finger tighten. Remove guide screw and fit the
remaining 2 Bolts with Spring Washers.
Tighten the clutch mounting bolts in the sequence shown in Fig.
7 to a torque of 47/54 Nm.

Fig.No. 7

1
3
5

6
4
2 9 7

9 Bolts.
Bolt Tightening
Sequence

Fig.No. 6

Long Boss
Pressure Plate
Side

Caution:
Remove Hold down bolts!
There are 3 numbers of factory fitted Hold down bolts with washers and these are provided
for transit purpose and also to nullify the clamp load while removing the cover assembly from
the Flywheel.
1) During fitment of clutch on to the vehicle these Hold down bolts should be removed
after the cover assembly is screwed on to Flywheel and before removal of Alignment Tool.
Coil Springs apply the Clamp load only when the Hold Down bolts are removed.
2) During removal of clutch from the vehicle, fit the Hold Down Bolts to the Cover
assembly before removal of Alignment Tool and before dismantling the clutch from the Fly
wheel. This will ensure that the clutch setting is not disturbed and clutch is not damaged
during transit.

Clutch Housing with Clutch Release Fork

Apply High melting Point Grease,over the contact surface
between Release Bearing Washer and Collector Ring ('H' point in fig 8)
Lubricate Spherical Bearing of clutch release fork with high melting point grease
(Point `X'- Fig.8 ) and between clutch release fork and Release bearing (Point`Y`of Fig. 8 ).
Failure to lubricate in time will lead to premature wear..
Fig.No. 8

Other Lubrication Points

Hub splines
Clutch pedal linkages.
Slave cylinder linkages.
Master cylinder linkages

Service Problems & Solutions

PROBLEMS

SOLUTIONS

CHATTER
1.
2.
3.
4.
5.
6.

Loose, broken or worn engine mounts

Pedal linkage worn
Loose or cracked clutch housing
Spring shackles and mountings loose or worn
Misalignment
Oil or grease on facings

7. Warped or bent Clutch Disc Assembly

8. Improper disc facing thickness
9. Worn pilot bearing
10. Wrong spring pressure in cover assembly
11. Release levers not parallel
12. Glazed facing/pressure plate
13. Clutch disc bent with pressure plate contact on
inner diameter of clutch facing during
engagement

1.
2.
3.
4.
5.
6.

Tighten or replace
Replace linkage
Tighten or replace
Tighten or replace
Re-align
Install new Clutch Disc Assembly and
correct oil leak
7. Install new Clutch Disc Assembly
8. Replace
9. Replace
10. Replace with proper cover assembly
11. Recheck installation
12. Replace new Clutch Disc Assembly and
Pressure Plate Assembly
13. Replace new Clutch Disc Assembly

AGGRESSIVE
1. Worn or loose pedal linkage
2. Excessive backlash in power train
3. Warped Clutch Disc Assembly
4. Worn hub splines
5. Worn splines on input shaft
6. Improper facing material
7. Loose cerametallic button facing
8. Burned cerametallic button facing

1.
2.
3.
4.
5.
6.
7.
8.

INSUFFICIENT RELEASE
1. Broken or loose engine mounts
2. Worn or loose pedal linkage
3. Excessive idle speed
4. Loose or worn facing
5. Improper facing material
6. Warped or bent Clutch Disc Assembly
7. Worn hub splines
8. Worn or rusty splines on input shaft
9. Worn pilot bearing
10.Worn or misaligned drive pins
11.Insufficient release bearing travel
12.Misalignment of gear box
13.Stuck / jammed clutch disc

1. Replace or tighten
2. Replace or tighten
3. Adjust to Manufacturer's specification
4. Install new Clutch Disc Assembly
5. Install proper Clutch Disc Assembly
6. Install new Clutch Disc Assembly
7. Replace with new Clutch Disc Assembly
8. Clean or replace
9. Replace
10. Replace or re-align
11. Repair or replace linkage
12. Re-align properly
13. Grease the spline of hub & shaft

10

Replace or tighten
Adjust or replace worn parts
Install new Clutch Disc Assembly
Install new Clutch Disc Assembly
Replace shaft
Install proper Clutch Disc Assembly
Install new Clutch Disc Assembly
Install new Clutch Disc Assembly

PROBLEMS
HARD PEDAL
1. Worn pedal linkage
2. Binding in pedal linkage (Rod or cable)
3. Excessive spring pressure in Cover Assembly
4. Defective pilot bearing / bush Clutch Disc
Assembly and spline shaft
5. Gear box not aligned properly

SLIPPAGE
1. Oil or grease on facing
2.
3.
4.
5.
6.
7.

Loose or worn facing

Flywheel burned, cracked or dished
Insufficient pressure on pressure plate
Binding in pedal linkage
Improper facing material
Incorrect flywheel depth

8. Incorrect disc thickness

9. Inadequate free play of clutch pedal
10.Worn/damaged Pressure Plate Assembly
VIBRATION
1. One or More Units in power strain is out of
balance
2. Worn spline shaft
3. Worn crankshaft bearings
4. Worn drive pins or slots
5.
6.
7.
8.
9.

11

Worn or loose engine mounts

Loose or out of balance universal joint
Clutch out of balance
Worn disc splines
Clutch facing damaged

SOLUTIONS

1. Replace with new linkage

2. Lubricate, adjust or replace
3. Install proper Cover Assembly
4. Replace pilot bearing / bush Clutch Disc
Assembly and spline shaft
5. Realign Gear box

1. Install new Clutch Disc Assembly and

Correct oil leak
2. Install new Clutch Disc Assembly
3. Replace or re-grind to manufacturer's specification
4. Install new Cover Assembly
5 Lubricate and adjust
6. Use correct facing or replace Clutch Disc Assembly
7. Grind flywheel to manufacturer's
specifications or replace
8. Install new Clutch Disc Assembly
9. Adjust free play
10 Replace new Pressure Plate assembly.

1. Replace faulty component

2. Replace
3. Replace
4. Replace drive pin, Flywheel and/or intermediate
plate
5. Replace or tighten
6. Tighten or replace, check for balance.
7. Install balanced unit
8. Replace Clutch Disc Assembly
9. Replace new Clutch Disc Assembly

Norms of Warranty Acceptance

In a number of claims from the field on 330 dia clutches our analysis shows that these claims
should not have been accepted by the dealers. These can be classified as:
A)Clutch found ok. B) Burnt or overheated clutch
Part A
Checks to be carried on the vehicle before clutch is removed.
On many occasions the clutches are returned under warranty with complaint of slippage and
/or juddering. On many occasions, these clutches returned under warranty are found okay on
inspection and nothing is found wrong. The clutch characteristics are also found satisfactory,
suggesting that the problem is elsewhere and clutch is not the cause.
For example: Cause of slippage could be due to inadequate power from the engine due to
choked filters or faulty FIP setting, or juddering can also be caused by stuck release bearing or
the jammed brakes, stuck master/slave cylinders etc., but still the clutch is removed and
returned under warranty.
Whenever slippage or juddering is reported it is suggested that the complete vehicle clutch
system is checked to ensure satisfactory working of the clutch linkages, clutch hydraulics as per
the check list below, in addition to checking the engine filtration and FIP systems as well as the
brake system.
Checks To Be Done On Vehicle Before Removing The Clutch

Checks To Be Done

Corrective Action.

1.Check for smooth engagement and

smooth return of pedal.

1.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,

2.Should be 5 to 10 mm. If not, adjust the

pedal linkages to get the required play.

3.Check for full travel of the pedal to the

bottom of the floor.
4.Start the engine and check at what point
of pedal travel the clutch is released
and engaged.

3.There should be no obstructions like

foot rest etc.
4.Clutch engagement and disengagement
should take place between to 2/3 rd
the pedal travel.

5.Check for the movement of master

and slave cylinders.

5.Movement should be smooth and

should not be sticky.

6.Check if bleeding of hydraulic cylinders

are done.

6.Bleed the system if pedal spongy.

7.Check for the stroke of the slave cylinder

by depressing the clutch pedal fully.

7.Should be 10 to 12 mm at the slave cylinder

rod which can be easily checked with a scale.

12

Part B
Burnt clutch facing and over heated and burnt pressure plate assemblies.
This is an example of burnt clutch disc and button fully worn. Fig.9
Over heated & heat cracked Pressure Plate Fig.10
Fig.No. 9

Fig.No. 10

Factors That Result In Burnt - Pressure Plate/Clutch Disc

The major cause of clutch failure is attributed to EXCESSIVE HEAT. The heat generated
between the flywheel, Disc Assembly and pressure plate is high enough to cause the metal to
flow and the friction material to be destroyed resulting in the failure of the clutch.
When a clutch is fully engaged, during normal running of vehicle, Heat or Wear is practically
nonexistent. But, during the moment of engagement (when the clutch is picking up the load),it
generates considerable heat. A slipping clutch will generate sufficient heat that leads to
destruction.
Proper training of drivers and mechanics can go a long way toward extending clutch life.
Anyone who drives the truck, whether on or off highway, should be taught how to operate the
vehicle properly.
The most critical points to cover in driver training programs are:
Learning to start vehicle in the FIRST gear,
Proper clutch engagement,
Recognizing clutch malfunctions,
The most important points that can affect clutch performance are:
1) Starting The Vehicle In The Proper Gear.
Driver can burn the clutch trying to start in the higher gears with a partially or fully loaded
vehicle and more so up a gradient. An empty truck can be started satisfactorily in a higher gear
than when partially or fully loaded.

13

Drivers should be shown what is the right gear to be used for safe starts when the truck is
empty or loaded. With the diesel powered trucks he should select the gear where the vehicle
moves smoothly with an idling engine or if necessary with just enough throttle to prevent
stalling the engine.
After the clutch is fully engaged, the engine should be accelerated to near governed speed for
the up-shift into the next higher gear.
2) Gear Shifting Techniques
Many drivers up-shift into the next gear - or even skip-shift into a higher gear - before the
vehicle has reached the proper speed. This type of shifting is almost as damaging as starting off
in a higher gear, resulting in excessive burnt clutch.
3) Excessive Vehicle Overload
Ceramic clutches are designed with reasonably high factor of safety to prevent slippage at
higher GVW / GCW. But if the overload is excessive, and if the total gear reduction in the
power train is not sufficient to handle excessive overloads, the clutch will suffer, particularly on
steep gradients resulting in burnt overheated clutch.
4) Riding The Clutch Pedal
This practice is very destructive to the clutch since a partial clutch engagement permits slippage
and excessive heat. Riding the clutch pedal will also put a constant thrust load on the release
bearing, which can thin out the lubricant and also cause excessive wear on the pads. Release
bearing failures can be attributed to this type of operation.
5) Holding The Vehicle On An Incline With A Slipping Clutch
This practice of using the clutch to do the job normally expected of the wheel brakes also
results in burnt overheated clutch.
6) Coasting With The Clutch Released And Transmission In Gear
This procedure can cause high Clutch disc R.P.M. It can result in bursting or throwing the facing
off the clutch discs. Clutch disc speeds of over 10,000 R.P.M. have been encountered in such
cases.
7) Engaging Clutch In Lower Gears While Coasting
This procedure can result in tremendous shock loads and possible damage to the clutch, as
well as the entire drive-train.
8) Reporting Erratic Clutch Operation Promptly
Drivers should report erratic clutch operations as soon as possible to give the maintenance
personnel a chance to make the necessary inspection, clutch adjustment, linkage adjustments.
lubrication, etc., thereby avoiding possible clutch failures and breakdowns while on the road.
The importance of free-pedal travel should be brought to the driver's attention as well as the
mechanic.

14

OKAY CLUTCHES
On many clutches returned under warranty, complaint reported is Clutch slippage. But on
examination the clutch is found to be in good condition. In these cases it is possible the cause
for slippage is not the clutch. The clutch should be fitted back and the right reason for slippage
established.
n The following illustrations show cases where the clutch is considered to be in good
condition and claims should not be accepted.

Fig.No. 11

Loose Damper Springs

Loose damper Spring on Lipe / Setco clutches is
not a defect and the discs should be fitted back
and Warranty should not be accepted.
Crack between the rivets of ceramic
buttons.
Hair line Cracks on the button between the
rivets or slight chipping of ceramic material on
the button face are quite normal and this is not
considered a defect. These clutch discs should
be fitted back and not accepted under warranty.
Uneven contact.
On many occasions the clutch disc is returned
under warranty at early kms with complaint of
uneven contact. It is quite normal for clutch
discs which are not fully bedded in to show
higher peripheral wear. These cases should not
be returned under warranty.
Glazed or Bluish colored lining surface.
It is quite normal for ceramic button to turn
bluish on use. The clutch disc in these cases is
considered in good and usable condition and
these cases should not be returned under
warranty.

15

Warranty is acceptable for manufacturing defects but given below

are few photographs which show the cases of warranty claims
which have to be rejected. All repairing cases and burnt cases
should not be claimed under warranty
Clutch disc Facing Fully Burnt,
Driver foot Riding on Clutch pedal.
nd
Starting vehicle in 2 or higher gear.
Heat damage to all mating surfaces.

Clutch Disc bent.

Mishandling of the disc while
removing from vehicle. This is not a
manufacturing defect.

Repaired clutch disc worn out /burnt

/broken etc.
One rivet-head is on the flywheel side
and the other rivet-head is on pressure
plate side. This indicate clutch disc is
repaired and not as per manufacturers
specification

16

Procedure of Reconditioning of 330 Dia Clutch

a) Need for reconditioning
Check for cracks, unevenness, over heating and scoring marks on Flywheel and Clutch Pressure Plate.
The Clutch Pressure Plate and Flywheel must be replaced if friction face is severely heat cracked or it is warped
in excess of 1mm in case of flywheel or 0.8 mm in case of Pressure Plate or if there is excessive wear in the
drive slots.

b) Schematic layout of clutch assembly

CAST COVER
PRESSURE PLATE
PRESSURE PLATE PIN
EYE BOLT PIN
ADJUSTING NUT
EYE BOLT
LOCK NUT
RETRACTOR SPRING
DAMPER SPRING

LEVER

HUB
HUB SPLINE
HUB RIVET

COLLECTOR RING
PRESSURE SPRING

CERAMIC BUTTON

17

HOLD DOWN BOLT

Pressure Plate dismantling procedure

Fig.No. 12

There are two suggested methods of

Holding cover assembly - Flywheel
or Arbour Press
1) Flywheel Or Base Plate
Place cover assembly and Clutch Disc
Assembly on the flywheel or special
fixture and clamp using the 9 flange bolts.
Remove the three Hold down bolts and
locknuts from the cover assembly Now
slowly release the 9 bolts. See Fig. 12.
Remove cast iron cover and nine
pressure springs.See Fig. 13. Remove
circlip and washers from the pressure
plate pins, Remove the release levers,
dismantle the eye bolt pins from the
eyebolts and adjusting nuts from
eyebolts. Now press or knock out the
needle bearings in the eyebolts and
pressure plate.

MOUNTING BOLT

TOGGLE TOOL

Fig.No.13

2) Arbour Press
Place cover assembly and Clutch disc onto the above and clamp cover to arbor base .
Remove the three Hold down bolts and locknuts from the cover assembly. Now slowly
release the arbor press.
NOTE:

While dismantling care should be taken to mark the position of Pressure Plate with respect to
cover and Flywheel, to facilitate reassembly in their original position, otherwise it may lead to
unbalanced assembly. If a major component like cover or pressure plate is replaced, it is
necessary to balance the complete assembly before installation on the vehicle. The maximum
out of balance should be 36 gm-cm. Whenever replacement of smaller components like
release levers, release lever supports, pressure springs etc., becomes necessary due to wear
or breakage, these should be replaced in sets, otherwise the assembly is likely to be
imbalanced.
Inspection And Reconditioning
After the cover assembly has been stripped, clean all parts thoroughly.
Inspect all parts. Discard components with visual defects i.e. worn or damaged.
But remember If in doubt replace with new.

18

A. Pressure Plate
1) The Pressure plate must be replaced if Friction Face is severely heat checked or it is warped
in excess of 0.8mm or if there is excessive wear in the drive slots
Note: To check if there is excessive wear, locate part in a ring cover, refer to section B para 2
Cast iron cover.
Provided none of the above apply then the Pressure plate can be re-faced and used by regrinding a maximum of 0.8mm from the face. Fit ground steel washers of the thickness of the
removed material between the springs and the Pressure Plate, in order to have no
deterioration in clutch performance for improved performance.
Referring to Fig. 14 Dimension 'C' is the distance from the friction face to the top of the
pressure plate pin.
`C` dimension as new
= 38.4 mm
`C` Dimension after grinding = 37.6 mm
Over machining of Pressure Plate can cause decrease in the clamp load leading to clutch
slippage.

'C'

Fig.No. 14

Procedure For Regrinding ,Machining Pressure Plate.

After re-facing, ensure that the face runout of Pressure Plate is max. 0.5 mm at 254 mm
diameter.
Check the run out of Pressure Plate with Pressure Plate mount on the re-grinding blocks
and pins.
Remove needle bearings. Use 3 nos re-grinding blocks and pins. See fig.15 & 16 for
machining / grinding set up.
Fig.No. 15

19

Fig.No. 16

B. Cast Iron Cover

1) Must be replaced if any cracks are present or drive blocks are worn or cover is distorted or
damaged.
2) The 330 dia pressure plate is driven by engagement of driving slots to mating drive blocks in
the cover. A check on the wear between the driving surfaces of the ring cover and the pressure
plate slots should be carried out. There should be not less than 0.10mm or more than 0.25mm
movement between drive blocks and slots.
0.1 - 0.25 mm

0.1 - 0.25 mm

VIEW- A
0.1 - 0.25 mm

LUG

PRESSURE PLATE

C. Pressure Spring
All pressure springs to be checked for load at working height and for free length. Limits of
acceptance as below:
Acceptance norm
Load @ 38.86 mm.
Free Length

Pressure spring
122 kg.
71 mm min

Springs should be discarded if distorted and heat affected.

NOTE: Always replace Springs as a set
D. Parts Inspection
Needle bearings: Always replace the Pressure Plate and Eye bolt needle bearings using a
suitable tool. It is important that the part number on the bearing cage is against the flat face or
shoulder of the fitting tool. This prevents damage to the bearing cage when fitting.
Always replace Retractor springs and Retaining Clips.
If worn damaged or loose replace Eye Bolts, adjusting nuts, Release Lever, Pressure Plate Pins
& Eye Bolt Pins.

20

E. Flywheel
Check for cracks, unevenness, over heating and scoring marks.
The Flywheel must be replaced if friction face is severely cracked or it is warped in excess
of 1mm.
If required the Clutch resting surface can be machined/ground up to 1mm. Grinding should be
done over entire friction face and up to diameter 'D'. In any case, dimension 'D' must be
maintained with in specified limit . Reduce spigot length also by the same amount.
If heat or surface cracks or grooves or contact surface convex are apparent after resurfacing to
the minimum thickness the flywheel must be discarded.
The face runout of Flywheel is max. 0.254mm at 254mm Radius.
SEE
DETAIL A

365.030.03

41.260.25(BEFORE MACHING)

40.260.25 ( AFTER MACHING)

C

DIA 'D'
354.25
DETAIL A
30
20.25
R1.520.25

v) Clutch Release Bearing

Check Clutch Release Bearing for wear overheating marks, for free movement. Replace if
necessary.
vi) Needle Bearing
Always replace the Pressure Plate and Eyebolt Needle Bearings using a suitable tool. It is
important that the part number on the Bearing cage is against the flat face or shoulder of the
fitting tool. This prevents damage to the bearing cage when fitting.
NOTE: Always replace retractor springs and retaining clips. If worn damaged or loose replace
eye bolts, adjusting nuts, release lever, pressure plate pins&eye bolt pins. Apply high
temperature grease on all pivot points/pins/bearings.
If the needle roller bearing of the Pressure Plate is damaged ,then the Pressure Plate along with
needle roller bearing should be replaced as a set.(Part no. of Pressure Plate and Needle
Bearing sub-assembly is 2724 2540 0109)
F. Assembly Procedure
Clutch Cover Assembly
Assembly can be done using either on a Flywheel or a Special Fixture.

21

1) Place new Clutch Disc(New Clutch Disc thickness 10.80.2) assembly on a Special Fixture
or Flywheel (on Clutch Disc check for Flywheel side/Pressure Plate side, follow as per
instruction). This will act as a gauge plate for setting the Release Levers.
2) Place Pressure Plate on top of the Driven Disc
3) Assemble the Eyebolts, adjusting nuts, Release Levers, Retractor Springs, Retaining clips and
Pressure Plate and Eyebolt pins.
4) Place the Pressure Springs & Ground steel washer of correct quantity over the spring bosses
on the Pressure Plate (always replace Pressure springs as a set)

5) The cover can now be pressed into position, taking care to engage the driving blocks into the
mating slots of the pressure plate and the adjusting nuts / eyebolts in the holes on the ring cover
as the springs are compressed. Ensure that the springs are seated correctly.
6)When the Pressure Plate cover has been put into position, the locknuts can be fitted. Now
the assembly is ready for setting lever height.

10.8 0.2

53.0 0.2

85

Fig.No. 17

365 h8

7) The lever heights are set by turning the adjusting nuts while at the same time holding the
locknuts with a spanner (See fig.17). The position of the 3 levers in the case of 330 dia clutch
with a cast iron cover is checked from the flat surface of flywheel or arbor press to top of the
collector ring at minimum three points.
This dimension should be 53 mm +/- 0.2 mm. And run out of fingers within 0.4 mm. This
dimension can also be verified by checking the dimension of 32.0 mm +/- 0.2 mm from the
top face of cover raised lugs up to the collector ring.
8) Having adjusted the Collector ring to the specified height, hold the adjusting nuts in
position using the 2 slots and tighten up the locknuts to the required 12kgm torque. Recheck
the collector ring heights to ensure they have not moved.
NOTE: Before releasing the Clutch from the assembly fixture fit the three hold down bolts.
Now the Clutch Assembly can be removed from the flywheel safely.
22

Driven Disc Assembly Repairing Procedure

It is not recommended to use ceramic button riveting in the field due to inadequate facilities.
It is recommended that once the buttons are worn, the complete Clutch Disc Assembly
needs to be replaced, However, should there be premature wear on the buttons and it is
absolutely necessary to rivet buttons in the field, a makeshift fixture/tool has been designed.
Procedure
Inspection of Clutch Disc Assembly
1) Check splines of Clutch Disc Assembly Hub. The Clutch Disc Assembly should slide easily
on drive shaft, but should not have play and wobble.
2) For inspecting torsion damper mechanism,
clamp Clutch Disc Assembly on mandrel,
Fig.No. 18
Hold mandrel in vice and rotate Clutch disc by
hand holding it at it's edge. If there is radial play
or wear of torsion damper mechanism or if the
torsion springs are distorted, the Clutch Disc
Assembly must be replaced. (refer fig. 18)
3) Check ceramic buttons for wear, inadequate
contact, burning marks and oil contamination.
Buttons with any of the above defects or worn
out up to rivet head must be replaced.
Removal of Ceramic Buttons
1) Remove all rivets carefully by drilling with
12.0 mm drill into flaring side of rivet and punch
out remaining portion of the rivet with suitable
punch.(Refer Fig. No.19)

Fig.No. 19

Note : While drilling rivets, care should be taken

that the drilled hole does not become oval /
oblong. Also ensure that the Clutch Disc
Assembly is adequately supported during drilling and punching out the rivets.
Ensure that the Torsion Plate Assembly is flat, if necessary straighten it on suitable surface
plate carefully.

23

Mount Torsion Plate assembly on mandrel and check plate for face run out using dial gauge.
If necessary realign the Torsion Plate Assembly using straightening fork. refer fig. 20
(Maximum face run- out 0.6 mm)
Fig.No.20

Riveting :
Clean the surface area where buttons are to be riveted.
Put new buttons on both sides of Torsion Plate and align.
Clamp in Fixture, align for riveting and hand tighten.
Locate head of rivet on anvil suitably located in base plate. Support other end of
the disc to ensure that Disc Assembly is flat.
By means of 4 Ton Hydraulic Press flare the two rivets one at a time.
Fig.No.21

Ensure that the buttons are riveted flush against the disc No gaps are permissible and no
feeler gauge should pass after riveting.
Ensure Clutch Disc Assembly is square to the splines and run out of the Clutch Disc
Assembly should not exceed 0.6 mm.
Fig.No.22

Before refitting Clutch Disc Assembly in vehicle, ensure that the friction material is free
from oil & grease contamination. Ensure that the splines of hub are greased.

24

Dimension Specification

Driven
Disc Assembly

Pressure Plate

Description

Nominal

Facing assembly thickness

(when independent)

10.8

VALUE
mm

Flatness
Hub spline play in
rotating direction
Gap between ring cover
and Pressure plate Slots
Height from friction face to the
top of the Pressure Plate pin
Minimum free length of
pressure Springs
Pressure Plate Lever height
(A) From Flywheel face
upto the Collector Ring
(B) From top of the cover
raised lug upto the collector
ring

Limit/
Correction
Tolerance And Remark
mm

6.8

Replace

0.60

Correct or
Replace
Replace

0.10
38.4

53.0
32.0

0.25

Replace

37.6

Replace

71

Replace

0.2
0.2

Adjust
Adjust

Tightening Torque Table

Part to be tightened
Clutch
Cover

25

Clutch Cover mounting bolt

Pressure Plate eye bolt lock nut

Thead size O.D. Tightening torque

Nm(Kgfm)
x Pitch (mm)
M8 X 50
47 to 54 (4.7 to 5.4)
110 to 120 (11-12)

Spare Parts Kits For 330mm Coil Type Clutch

Sr.No Description

Telco PartNo.

AC001-L1897.
Pressure Plate with needle bush 2724 2540 0109
Pressure Plate
Needle Bush

2724 2540 3002

B.

AKN-L2316. lever kit Release

2724 2540 0111

Release lever

2724 2540 5103

Eye Bolt with needle bearing

2724 2540 0110

Eyebolt

Needle Bearing

Eye Bolt Pin

3
3

Retainer ring

2724 2540 4301

Lock nut

2724 2540 6502

Adjusting nut

2724 2540 6503

Pressure Plate pin

2724 2540 6705

10

Retractor Spring

2724 2540 8703

11

Washer

2724 2540 9002

C.

AKN-L3217. AssemblyRelease
Lever with Eye Bolt

2724 2540 0112

Eye Bolt with needle bearing

2724 2540 0110

Eyebolt

Needle Bush

2724 2540 3001

Release lever

2724 2540 5103

Eye Bolt Pin

2724 2540 6704

7
8
6
11

26

1
6

2724 2540 3001

2724 2540 6704

10

Quantity
per set

2,3
4

9
11

5
1

Sr. No

Description

Telco Part No.

Quantity per se

C002-L1898. Cover (Finished)

2724 2540 3701

X011-L0678.Cotter Pin

2724 2540 6706

C023-L1881. Collector Ring

2724 2540 8601

C005-L1898. Pressure Spring

2724 2540 8704

AKN L1908.Hold down Bolt Kit.

2754 2540 0120

H-1

Hold down bolt

2754 2540 3201

H-2

Washer

2724 2540 9203

H-2

H-1

CERAMIC CLUTCH DISC

Sr. No

Description

Telco Part No.

AKN-L2318. Disc Facing Kit

2724 2520 0111

I-a

Ceramic Button

2724 2520 6304

12

I-b

Button Rivet

2724 2520 7402

12

I-a

I-b

27

Quantity per set

Technical Specification

13"/330mm - Push Type-Coil Spring-Cast

Cover-Ceramic Clutch

Recommended Torque
Ratings with

Ceramic lining - 106 Kgm

Type of Clutch

Dry Disc, Direct Pressure Less Pedal Effort.

Type of Service

Automotive Truck, Tractor,Tipper, Bus.

Clutch Disc Facing Area

Ceramic Button 464 Sq cm

Pressure Springs

9 nos - Cylindrical type

Release Bearing Load

Maximum 250 kg

Release Bearing Travel

10-12mm

Wear Adjustment

Sufficient adjustment must be provided in pedal

linkage to allow full wear travel.

Bell Housing &

Fly wheel type

As per Customer specification

Clutch Disc Assembly

Spring Dampened, spline sizes as per Customer specification

Friction Facing Material

Ceramic, Miba buttons - MD 562

Clutch Lever System

Pressed 3 Lever arrangement

Weight

Cover Assembly : 20 kg
Disc Assembly : 3.7 Kg

IMPORTANT :
For maximum clutch life, all highway vehicles should have a minimum gradeability of 15 % and
for off highway vehicles 30% is recommended. Vehicle Specification should be submitted to
SETCO Lipe for Qualified Engineering Recommendation.

28

60

30

30

TA

TA

896

29

30

-L1
02R
C0

30

30

60

30

10.8 0.2

53.0 0.2

Kgf
Kgf

Clamp Load Assembly

Clamp Load in wom condition
AT 7.36 mm
Release Load ( Max.)
Release travel at Bearing
Wear travel at Bearing

Kgf
mm
mm

Units

COVER ASSEMBLY DATA

85

250
10-12
19

1113
900

Value

Units

cm2
mm
Kgm
Deg.

DISC ASSEMBLY DATA

Number of Buttons
Button material
Total lining Area
Rivet Depth on Each Side
Torsional capacity of Disc
Torsional Angle Each Direction

12
MD 562
464
2
106
4.25

Value

330 Push Type Coil Spring Ceramic Clutch With Cast Cover

365 h8