Clutch CL-6127J-01 CL-1

ClutchJL430

Structure and working principles of clutch CL-2

1. Clutch structure
2. Working principles of clutch
Data and technical specifications of clutch CL-4
1. Clutch facing
2. Repair criteria
3. Fastening torque
Troubleshooting CL-6
1. Incomplete disengagement of clutch disc
2. Clutch skidding
3. Vehicle shaking when startup
4. Noising of clutch
5. Clutch pedal unable to be stepped on
6. The spring force of clutch pedal changed
Dismantlement and assembly of clutch CL-8
1. Dismantlement of clutch compressing disc assembly and clutch disc
2. Dismantlement of clutch compressing disc assembly
3. Dismantlement of disengaging lever assembly
4. Dismantlement of clutch housing
5. Replace clutch facing
6. Replace the guide bearing
7. Driven disc of clutch
8. Clutch compressing disc
9. Flywheel
10. Compression spring
11. Assembly of clutch compressing disc assembly
12. Adjustment
13. Assembly of clutch housing
14. Assembly of clutch assembly
Inspection and repair CL-17
CL-2 Clutch CL-6127J-01

Structure and working principles of clutch

Clutch is an assembly in the transmission system of an automobile. Its driving part is connected to the engine's
flywheel and its driven part is connected to the gearbox. Its main function is to transmit or isolate driving forces for the
convenience of stable startup and gearshift of an automobile and prevent overloading of power train. A clutch is required
to engage smoothly and gently and disengage rapidly and thoroughly. It shall operate easily and conveniently and can
transmit forces reliably.

1. Clutch structure

1Adjusting nut, clutch disc disengaging lever 6Spring, disengaging lever 11. Spring, compressing disc
2Clutch cover 7Spring leaf, adjusting screw 12. Spring, compressing disc
3Gasket ring, clutch disengaging lever 8Straight pin 13Spring seat, compressing disc
4Spring assembly, clutch disengaging lever 9Adjusting screw, disengaging lever 14compressing disc
5Spring suspension ring, clutch disengaging lever 10disengaging lever assembly 15Straight pin
 Clutch CL-6127J-01 CL-3

2. Working principles of clutch

When the clutch cover is fixed to the flywheel with bolt,

the screw compression springs distributed in circle will
press the compressing disc to the flywheel, and press the
driven disc in the middle, thus making the clutch
engaged.

To disengage, the disengaging bearing pushes the

disengaging lever pivoting around the fulcrum, its outer
part moves backward with the drawing force of the
disengaging bolt on the compressing disc to act against
the force of compression spring, thus withdraw the
pressing force on the driven disc to disengage the clutch.
Flywheel
Clutch cover
Disengaging bolt
Clutch pedal
Disengaging lever
Disengaging bearing
Clutch shaft
Disengaging fork
Clutch friction plate
Clutch compressing disc
Compression spring
Disengaging fork arm
CL-4 Clutch CL-6127J-01

Data and technical specifications of clutch

1. Clutch facing
Model: JL430IC
Friction plate material Asbestos cord winding facing
Structure Dry single plate screw spring (with damping spring)
Outer diameter 430mm
Inner diameter 250mm

2. Repair criteria
Nominal Repair Repair Abrasion
Item size criteria limit limit Inspection method Remarks
(mm) (mm) (mm) (mm)
Less than
Runout - - 1.5
1.0
Driven
Friction plate
disc of 1.6 - - 0.3 Upper part of rivet
thickness (one side)
clutch
Less than
Spline side clearance - - 0.5
0.2
Planeness of friction Less than
- 0.4 -
Compre surface 0.12
ssing Taper of friction Less than
- 0.2 -
disc of surface 0.1
clutch Compressing disc
24 - - 22
thickness
Spring Free length (ten coils) 74 - - 72
of
16,600 When compressed
clutch Elastic force (10 coils) - - 510
636N to 44 mm
compre
ssing Less than
Pitch (10 coils) - - - In free condition
disc 1.5
Height of gasket ring To the surface of the
- 70 - -
Diseng of disengaging lever flywheel
aging End face runout of
lever gasket ring of the - 0.4 - -
and lever
disenga Clearance between
- 0.15 - 0.3
ging fork shaft and bearing
fork Free stroke of rocker
shaft arm of disengaging - 3~5 - -
fork shaft
Planeness of flywheel Less than
- 0.4 -
Flywhe friction surface 0.12
el Allowable reduction
- - - 2
of flywheel thickness
 Clutch CL-6127J-01 CL-5

3. Fastening torque
Item Fastening torque (N.M)
Clutch cover connecting bolt 3252
Clutch cover Engine side 3252
connecting bolt Gearbox side 142186
Disengaging fork fastening bolt 1621
Fastening bolt of transmission shaft 220250
CL-6 Clutch CL-6127J-01

Troubleshooting

Common troubles of the clutch include skidding, improper disengagement and abnormal noises. As the clutch is
driven by the clutch operating mechanism , clutch troubles are directly caused by the clutch operating mechanism in
many cases. After the troubles of the control system are eliminated, focus on the quality and installing conditions of the
clutch to find the cause of trouble.

Symptoms Possible causes Repair/preventive measures

Incomplete disengagement of clutch Deformation or distortion of the clutch
disc disc
Improper adjustment of the disengaging
lever
Abrasion of transmission input shaft
Replace the clutch disc
Adjust the disengaging lever
Replace the input shaft, and check
whether the clutch hub is over
abrasive. If yes, replace the clutch
disc. Check whether the flywheel
housing is properly aligned.

Improper adjustment of clearance

Clutch skidding between disengaging lever and Clearance adjustment
disengaging bearing
The clutch facing is stained with oil or Replace clutch facing or clutch
lubricating grease assembly
Abrasion of disengaging bearing Replace the bearing
Improper adjustment of the free stroke of
Adjust the free stroke
clutch pedal
Weak strength of compression spring Replace compression spring
Abrasion of clutch facing Replace facing or clutch assembly

Improper adjustment of idle speed of

Vehicle shaking when startup
engine
Improper adjustment of clutch operating
mechanism
The clutch facing is stained with oil or
lubricating grease
The friction surface of flywheel is
polished
Deformation or distortion of the clutch
disc
Incorrect fastening of clutch cover
Malalignment of the flywheel housing
Improper adjustment of disengaging
lever
Adjust idle speed
Adjust clutch operating mechanism
Replace clutch facing or clutch
assembly
Use coarse emery cloth to make the
flywheel surface coarse, the rub lines
shall be parallel with the machining
lines.
Replace the clutch disc
Fasten the bolt
Replace the flywheel housing
Adjust disengaging lever

Noising of clutch Abrasion or dry friction of disengaging Replace the disengaging bearing
 Clutch CL-6127J-01 CL-7

bearing
Guide bearing is worn out Replace the guide bearing
Deformation or distortion of the clutch
Replace the clutch
disc
Malalignment of the flywheel housing Replace the flywheel housing
Abrasion of transmission input shaft or
Clean, lubricate or replace
clutch spline
Improper adjustment of disengaging
Adjust disengaging lever
lever
Insufficient lubrication of clutch pedal
Lubricate
and its accessories
Insufficient lubrication of shaft sleeve of
Lubricate
disengaging bearing
The closing ring of transmission input
Clean or replace rusty part
shaft gets rusty or dirty
Improper adjustment of the free stroke of
Adjust clutch operating mechanism
clutch pedal

Clutch pedal unable to be stepped Improper adjustment of clutch operating

Adjust clutch operating mechanism
down mechanism
Insufficient lubrication of shaft sleeve of
Lubricate
disengaging bearing

The spring force of clutch pedal Inflow of air in clutch hydraulic control
Discharge the air
changed pipe
CL-8 Clutch CL-6127J-01

Dismantlement and Assembly of Clutch

1. Dismantle clutch compressing disc assembly and clutch disc.

Warnings
Mind not to drop on your feet when dismantling
clutch compressing disc assembly and clutch disc.

2. Dismantle clutch compressing disc assembly

Press out the clutch cover to realease the tension of the compression
spring before dismantling special tool and input shaft bolt.
Release the compressor slowly.
Note: Make alignment mark for clutch cover and compressing
disc before dismantlement.

3. Dismantle disengaging lever assembly

Dismantle the straight pin connecting disengaging lever
and compressing disc.

Remove the retainer ring, then dismantle the bracing straight

pin of the fork of stay disengaging lever.

Press the bushing of the composite bearing out of the hole of

straight pin on disengaging lever. Reuse of the dismantled
bushing is not allowed. Replacement of new part is required.
 Clutch CL-6127J-01 CL-9

4. Dismantlement of clutch housing

1. Clutch housing assembly 2Bushing 3Tabular plug 4Disengaging fork 5 Flat key
6Clutch ventilation cover assembly 7Rubber gasket, clutch ventilation cover
8Assembly of disengaging fork w/ pin 9Disengaging bearing assembly 10 Seal
washer
11Hose joint 12Lubrication hose, disengaging bearing 13Grease cup seat 14Grease cup cover
Dismantle lubrication hose and hose joint of disengaging bearing, seal washer and grease cup base;
Dismantle fastening bolt of disengaging fork and disengaging fork shaft;
Draw the disengaging fork shaft out from the end with fork arm
Remove disengaging bearing and disengaging fork from the bearing cover of transmission input shaft;
Press bushing and plug out of the bracing holes of the disengaging fork shaft located at the two sides of the clutch
cover. The bushing shall be replaced. Reuse is not allowed.

5. Replace clutch facing

Use drill with a diameter of 5mm to drill out the rivet.
Caution: Do not use iron rod, hammer or compressor to
dismantle clutch facing.
Dismantle old facing.
Place new facing on the clutch disc, plug the rivet into the hole to fix
the position. (use adhesive tape to fix the rivet in case of missing).
Use rivet machine and punch with the same dimension of the rivet
head and base to rivet down the new facing. To ensure equal
distribution of pressure, the rivets are symmetrically distributed at
the edge of clutch. Diameter Punch
Rivet
Clutch disc
Facing
CL-10 Clutch CL-6127J-01
 Clutch CL-6127J-01 CL-11

6. Replace the guide bearing

Use slide hammer to draw out guide bearing.
Use proper copper rod to install guide bearing.
Note: Make sure that the guide bearing is running smoothly after
installation.

7. Driven disc of clutch

Check the runout of clutch driven disc:
Repair criteria less than 1.0mm
Abrasion limit 1.5mm

Check whether there is breakage of damping spring and corrugated

sheet. If yes, replace driven friction plate assembly of the clutch.

Measure thickness A from the surface of driven disc to the rivet head:
Normal size: 1.6mm
Abrasion limit : 0.3mm

Measure the spline side clearance between spline hub and spline
shaft of driven disc:
Repair criteria:less than 0.2mm
Abrasion limit: 0.5mm

8. Compressing disc of clutch

Measure the planeness of clutch compressing disc:
Repair criterialess than 1.0mm
Repair limit 1.0mm
CL-12 Clutch CL-6127J-01

Measure the thickness of compressing disc:

When Dimension A in the figure is less than rated dimension
of 2mm due to abrasion or repair, replace the compressing disc.
Normal sizeA=24.0mm
Abrasion limit 22.0mm

9. Flywheel
Measure the planeness of the flywheel surface:
Repair criteria less than 1.0mm
Repair limit 0.4mm

Measure flywheel end face dimension H:

Normal size: 24.5mm
Abrasion limit 22.5mm

10. Compression spring

Measure the free length of compression spring:
Normal size: 74mm
Limit 72mm

Measure the tension of compression spring (when compressed to 44mm):

Repair criteria 1.0mm
Service limit 510N

Measure the inclinatio of compression spring:

Repair criteria less than 1.0mm
 Clutch CL-6127J-01 CL-13

1Clutch compressing disc spring 2Round wire snap ring

3. Spring suspension ring, disengaging lever 4Disengaging lever spring 5Clutch cover
6Clutch compressing disc 7Disengaging lever bushingbushing
8Straight pin 9Straight pin 10Disengaging lever bushingbushing
11Spring leaf, adjusting screw 12. Adjusting screw 13Adjust nut
14Disengaging lever 15Disengaging lever gasket
16Compressing disc spring 17Compressing disc spring base
X Six locations marked with X
Rivet down
Counterweight hole
Max. aperture
Max. depth
Clear the scrap iron after counterweighing
When reassembling, apply a layer of lubricating grease on the surface between shaft and bushingbushing.

11. Assemble clutch compressing disc assembly

Press the disengaging lever bushingbushing into the disengaging lever
hole, and apply a thin layer of lubricating grease on the inner surface
of the bushingbushing.
CL-14 Clutch CL-6127J-01
 Clutch CL-6127J-01 CL-15

Assemble disengaging lever stay fork and straight pin in the

disengaging lever hole, fix the ends of the straight pin with retainer
rings.

Use straight pin to assemble the disengaging lever assembly to the

compressing disc.

Place compressing disc on the compressor.

Install two suits of compression springs onto compressing disc.
Caution: when installing red springs, the locations of the springs
in each section are fixed, and the locations between each section
are symmetrical.

Assemble disengaging lever spring and adjusting screw spring leaf

onto disengaging lever.
Caution: disengaging lever springs with disengaging lever gasket
rings and suspension rings shall be installed with interval.

Place the clutch cover on the compressing disc and pressurize with
compressor.
Cautions: a) When assemble cover and compressing disc, align
with the marks
b) Align compression spring with a round rod.

Use compressor to press compressing disc cover till the screw thread
end of the stay fork comes to the surface, then screw adjusting nut.
Cautions: a) The work platform supporting the compressing disc
shall not contact with the cover;
b) Apply heavy-load bearing lubricating grease between
the cover and the screw thread.
CL-16 Clutch CL-6127J-01

Use disengaging lever suspension spring to install disengaging

bearing gasket ring.

Process dynamic balancing test after successfully assembling clutch

compressing disc assembly:
Dynamic balancing value: less than 700 mgm
 Clutch CL-6127J-01 CL-17

12. Adjust
Adjust height and end face runout of end face of disengaging lever gasket ring;
Height of end face of disengaging lever gasket ring:
Against flywheel friction surface 70mm
End face runout of disengaging lever gasket ring: less than 0.4mm

After proper adjustment of the height, knock the disengaging

lever and lever gasket ring slightly with wooden hammer,
then recheck the height and end face runout of disengaging
lever gasket ring: make sure that they are within prescribed ranges.

After adjustment, screw down the adjusting nut.

13. Assemble clutch housing

Joint clutch and transmission

Press the bushingbushing and plug of the clutch fork into the holes
on clutch housing, and apply a layer of lubricating grease on the
inner surface of the bushingbushing.

Fill the oil chamber in the inner chamber (sliding hole) of

disengaging bearing with lubricating grease,then assemble fork
and disengaging bearing to the bearing sleeve of the input shaft.

Insert the disengaging fork shaft into the inner hole of

bushing from the outside of clutch housing, then install flat key,
insert fork and bushing, screw down fork fastening bolt.
CL-18 Clutch CL-6127J-01

Joint lubrication hose of disengaging bearing sliding sleeve, assemble

hose joint, seal washer, grease cup base and grease cup cover.
Caution: fill the grease cup cover with lubricating grease before
screwing it to the grease cup seat.

14. Assemble clutch assmebly

Use the shaft for assembly (special tool) to assemble clutch cover assembly and driven disc to the flywheel.
Cautions: a) On the special tool, the convex side of the driven disc shall face the compressing disc.
b) The connecting bolts of the cover shall be screwed down in crossing order.
 Clutch CL-6127J-01 CL-19

Inspection and repair

Unit: mm
Inspection item Standard value Limit value Solution Inspection method

Depth of rivet head 2.2~2.8 0.1 Replace the clutch

more than
Runout of clutch disc 0~1.3 Replace
1.3

The facing is stained

with lubricating oil
Replace clutch disc
Rivets are loosened
- - assembly when Visual inspection
Damping springs are
necessary.
loosened or damaged

Clearance between
Replace clutch disc
clutch disc hub and
0.05~0.15 0.5 or transmission
transmission input
input shaft
shaft

End face runout of Regrind the friction

Less than 0.1 0.5
compressing disc surface or replace

Taper of friction Regrind the friction

Less than 0.1 0.2
surface surface or replace

Compressing disc
30 28 Replace
thickness

The friction surface of

compressing disc is Regrind the friction
- - Visual inspection
abraded or surface or replace
coarse
CL-20 Clutch CL-6127J-01

Unit: mm
Inspection item Standard value Limit value Solution Inspection method

Free length of
92.1 86.5 Replace
compression spring

Perpendicularity of co
- 5.0 Replace
mpression spring

Elastic force of
compression spring
564~636N 510N Replace
(when compressed to
44mm)

End face runout of Regrind the friction

0~1.0 0.2
flywheel surface or replace

Allowable reduction of
- - 2
flywheel thickness
The friction surface of
Regrind the friction
compressing disc is
- - surface or replace Visual inspection
abraded or
when necessary
coarse

Abnormal running of Replace when

- -
guide bearing necessary

Height of disengaging
74 72 Adjust
lever gasket ring
End face runout of
disengaging lever 0.4 - Adjust or replace
gasket ring
Clearance between
0.15 0.3 Adjust or replace
fork shaft and bearing
Clutch CL-6127J-01 CL-21