A B C D E F G

II III
ASHOK FIRST ANGLE PROJECTION
COMPUTERISED DRAWING DIN
ER- E
ALTERATIONS

IX
E
DO NOT CHANGE MANUALLY

AD

FF
DAT

GR

SU
I B CLUTCH SWITCH SETTING

LEYLAND
07 HOSE (F1996650) TO BE
ROUTED AS PER ROUTED IN
ADDED.
CLUTCH SWITCH SETTING 03.05.17 C
THE DRAWING ADDED IN LIST OF CTQ'S
CLUTCH PEDAL ASSY KM/KSD

CLUTCH HYDRAULIC FLUID REMOTE

RESERVOIR (F8002960)

CLUTCH SWITCH
BRAKE PEDAL

ALUMINIUM MASTER CYLINDER

(N0000999)
CLUTCH PEDAL
WABCO PART NUMBER : FN500600
BIL PART NUMBER : FN500400
This design is strictly private and confidential. It is the

not be used, copied or reproduced in part or whole

exclusive property of Ashok Leyland Ltd.,and must

without the Company's written permission.

CLUTCH PEDAL
FES FLOOR ASSY
CLUTCH PEDAL HEIGHT C
FES FLOOR ASSY FROM FLOOR = 170±10mm MASTER CYLINDER ASSEMBLY ARRANGEMENT IN
ARRANGEMENT OF CLUTCH PEDAL ASSEMBLY ON FES DETAIL 'A' CLUTCH PEDAL ASSEMBLY

IV V
PEDAL ASSY HOSE(F8612950) FROM MASTER CYLINDER MUST BE
ROUTED THROUGH THIS HOLE OF FES ASSY
TIGHTENING
+ TORQUE 24±5Nm
200mm LENGTH SIDE OF BUNDYPIPE (B3633001) 06
C TO BE ROUTED FROM FRONT OF THE VEHICLE

CLUTCH PEDAL C
FREE PLAY F
R

mm
08

10
MASTER CYLINDER AND FREE

5-
PLAY STOPPER BOLT ARRANGEMENT
FREE PLAY SETTING IN
DETAIL 'C' CLUTCH PEDAL ASSY

+
SPLIT PIN TO BE
LENGTH OF FREE PLAY STOPPER BOLT(F7872320)
C ASSEMBLED AS SHOWN,
PROJECTION = 15±2mm (ADJUSTABLE BOLT)
HYDRAULIC AND BUNDY PIPE ROUTING FROM THE AFTER FITTING THE
MASTER CYLINDER
MASTER CYLINDER DETAIL 'E' DETAIL 'F'

VI LENGTH OF FREE PLAY STOPPER BOLT(F7872320)

PROJECTION = 15±2mm (ADJUSTABLE BOLT) CLUTCH PEDAL VII MASTER CYLINDER
VIII
ASHOK LEYLAND LTD.
TECHNICAL CENTRE, VELLIVOYAL CHAVADI

PEDAL STOPPER BOLT

DETAIL 'N' CAP(F1292915) MUST BE
CAPPED ON BOLT

PEDAL STOPPER BOLT (F7872320)

ENSURE THAT CLUTCH SWITCH CLUTCH PEDAL AT HOME POSITION
PLUNGER SHOULD CONTACT
WITH CLUTCH PEDAL SURFACE 7. 5mm
5-1 PEDAL STOPPER BOLT
15.
C (F7872320)
SWITCH BRACKET SHOULD MOUNTED
PLUNGER
m
m G
ON THE STEARING COLUMN BRACKET 0
CLUTCH SWITCH CLOSED CONDITION 3
-
PLUNGER SHOULD BE COMPRESSED BY 5
MIN 1.3MM TO MAX 7MM AT CLUTCH C 2 DRAWING NOT VALID WITHOUT
M PEDAL HOME POSITION.TO MEET THE MAXIMUM CLUTCH PEDAL TRAVEL
ALPLM WATERMARK IN THIS SPACE
ABOVE CONDITION THE GIVEN 180±10mm
DIMENSION (15.5-17.5mm) TO BE PEDAL ASSEMBLY
MET.
ARRANGEMENT
DRAWN/ CHECKED/ MED APPROVAL/ APPROVED/ STDS APP/
DATE DATE DATE DATE DATE
P.V K.M SUNILRAJ K.S.D ----
N CLUTCH PEDAL AT FULLY PRESSED CONDITION 25-30mm OF GAP SHOULD BE MAINTAINED BETWEEN C
21.03.2017 21.03.2017 21.03.2017 21.03.2017 --------

DETAIL 'M'
MATERIAL
THE BRACKET AND PEDAL STOPPER BOLT
CLUTCH PEDAL TRAVEL SETTING OF CLUTCH (ADJUSTABLE BOLT) -----
CLUTCH SWITCH ASSY DETAIL 'G'
HEAT TREATMENT

PEDAL ASSY ----

SURFACE
PROTECTION
-----
SPECIAL INSTRUCTIONS/NOTE: BILL OF MATERIALS REMARKS
FOR 3718 & 3118LA VEHICLE FITTED WITH 380DIA SETCO CLUTCH
APPEARANCE ITEM ER-DIN DATE
THIS DRG.CONTAINS ( 8 C CRITICAL - S SAFETY 7 + IMPORTANT ) CHARACTERISTICS
YES NO 37582 10.03.2017
DESCRIPTION
& ZF 9S/8SGB WITH G45 FES & G45 CAB ASSY

UNLESS OTHERWISE SPECIFIED OPERATING PEDAL UNIT ASSY INSTALLATION DRAWING

ASHOK FINISHED WEIGHT(APPROX) REF.PT.NO. ----
TOLERANCES REFER IS:2102; MEDIUM FOR MACHINING AND COARSE FOR FABRICATION
--- Kgs S/A.PT.NO. PART
A 6 F 0 4 8 0 0 C
SURFACE PROTECTION TO MEET THE REQUIREMENT OF ALS.268.03 ----
SURFACE FINISH AS PER METRIC SCREW THREADS SHALL CONFORM TO THE LIMITS SHARP EDGES TO BE REMOVED
SCALE SUPERSEDES ----
NO.
AND TOLERANCES SPECIFIED IN THE CURRENT IS:4218 DIMENSIONS ARE IN MM
A0
IS:3073(CLA VALUE)
LEYLAND CLASS 6g EXTERNAL OR 5H INTERNAL. DO NOT SCALE DRAWING NTS SPEC.NO. ALOP137 SHEET NO 1 OF 3
 A B C D E F G
ASHOK FIRST ANGLE PROJECTION
COMPUTERISED DRAWING DIN
ER- E
ALTERATIONS

IX
E
DO NOT CHANGE MANUALLY

AD

FF
DAT

GR

SU
FASTENERS TO FIT CLAMP

IX
(F6M01200) COMES UNDER CLUTCH SWITCH SETTING
09 ELECTRICAL SWITCH SPEC ADDED.
LEYLAND CLUTCH SWITCH SETTING 03.05.17 C
ADDED IN LIST OF CTQ'S
KM/KSD

TIGHTENING TORQUE = 30±5Nm

+
200mm LENGTH SIDE OF BUNDYPIPE TIGHTENING TORQUE = 30±5Nm
HOSE ROUTING TO BE ROUTED ALONG
(B3633001) TO BE ROUTED FROM WITH CLAMP (F6M01200) WHICH IS
I DETAIL 'D'
FRONT OF THE VEHICLE J MOUNTED ON HORN MOUNTING BRACKET

K
13
H
XV CLUTCH BOOSTER
This design is strictly private and confidential. It is the

not be used, copied or reproduced in part or whole

exclusive property of Ashok Leyland Ltd.,and must

without the Company's written permission.

ISOMETRIC VIEW
X ENSURE HYDRAULIC FLUID DOT 4 TO BE FILLED
IN RESERVOIR UP TO MAX LEVEL, AFTER CLUTCH
BLEEDING

L 03 04 05
19 MAX
TIGHTENING TORQUE 10±3Nm
NOTE: + MIN
3/8" CLUTCH PIPE TO BE FREE FROM FOULING WITH FRAME ASSY 02
01
CLUTCH HOSE END TO CLUTCH
03 04
BOOSTER FITTING BOLT
06 TIGHTENING TORQUE = 24±5Nm
TIGHTENING TORQUE 10±3 Nm
DETAIL 'B'
DETAIL 'L'

XI XII XIII XIV

TIGHTENING TORQUE 10±3 Nm TIGHTENING TORQUE 10±3 Nm
TIGHTENING TORQUE
15 16 17 85±5 Nm
TIGHTENING TORQUE 10
85±5 Nm 10
14 14
11 04 05
17 16 15
11 04 05
ASHOK LEYLAND LTD.
TECHNICAL CENTRE, VELLIVOYAL CHAVADI

11 12 05

18 11 12 05
Tightening TIGHTENING P-CLAMP (F7874110) TO BE
18
Torque 10±3 Nm TORQUE 10±3 Nm CLAMPED ON ELECTRICAL SPEC P-CLAMP (F7874110) TO BE
DRAWING NOT VALID WITHOUT
ALPLM WATERMARK IN THIS SPACE
BRACKET(X0416810) ON CLAMPED ON ELECTRICAL SPEC
NOTE:
ENSURE 3/8" CLUTCH PIPE FREE FROM +
GEARBOX CROSS MEMBER BRACKET(X0416810) ON DRAWN/ CHECKED/ MED APPROVAL/ APPROVED/ STDS APP/
FOULING WITH GB MECHANICAL CSO ASSY DATE DATE DATE DATE DATE
GEARBOX CROSS MEMBER P.V K.M SUNILRAJ K.S.D ----
21.03.2017 21.03.2017 21.03.2017 21.03.2017 --------

DETAIL 'I' DETAIL 'J' MATERIAL

DETAIL 'H' DETAIL 'K' -----

HEAT TREATMENT

----
SURFACE
PROTECTION
-----
SPECIAL INSTRUCTIONS/NOTE: BILL OF MATERIALS REMARKS
FOR 3718 & 3118LA VEHICLE FITTED WITH 380DIA SETCO CLUTCH
APPEARANCE ITEM ER-DIN DATE
THIS DRG.CONTAINS ( 8 C CRITICAL - S SAFETY 7 + IMPORTANT ) CHARACTERISTICS
YES NO 37582 10.03.2017
DESCRIPTION
& ZF 9S/8SGB WITH G45 FES & G45 CAB ASSY

UNLESS OTHERWISE SPECIFIED OPERATING PEDAL UNIT ASSY INSTALLATION DRAWING

ASHOK FINISHED WEIGHT(APPROX) REF.PT.NO. ----
TOLERANCES REFER IS:2102; MEDIUM FOR MACHINING AND COARSE FOR FABRICATION
--- Kgs S/A.PT.NO. PART
A 6 F 0 4 8 0 0 C
SURFACE PROTECTION TO MEET THE REQUIREMENT OF ALS.268.03 ----
SURFACE FINISH AS PER METRIC SCREW THREADS SHALL CONFORM TO THE LIMITS SHARP EDGES TO BE REMOVED
SCALE SUPERSEDES ----
NO.
AND TOLERANCES SPECIFIED IN THE CURRENT IS:4218 DIMENSIONS ARE IN MM
A0
IS:3073(CLA VALUE)
LEYLAND CLASS 6g EXTERNAL OR 5H INTERNAL. DO NOT SCALE DRAWING 1:4 SPEC.NO. ALOP137 SHEET NO 2 OF 3
 A B C D E F G
ASHOK COMPUTERISED DRAWING DIN

XVIII
FIRST ANGLE PROJECTION ALTERATIONS ER- E

IX
XVII

E
DO NOT CHANGE MANUALLY

AD

FF
DAT

GR

SU
XVI
CLUTCH SWITCH SETTING
CLUTCH BOOSTER PUSHROD WITH ADDED.
LEYLAND WELDED JAWEND CLUTCH SWITCH SETTING 03.05.17 C
ADDED IN LIST OF CTQ'S
CLUTCH BOOSTER PUSHROD WITH KM/KSD
CLUTCH BOOSTER WEAR INDICATOR WELDED JAWEND
"ZERO SETTING" AT NOMINAL
CONDITION
CLUTCH BOOSTER WEAR INDICATOR

PIN AND SPLIT

PIN ARRANGEMENT

INPUT SHAFT COVER

This design is strictly private and confidential. It is the

ISOMETRIC VIEW
not be used, copied or reproduced in part or whole
exclusive property of Ashok Leyland Ltd.,and must

ENSURE FITMENT OF CLUTCH BOOSTER ENSURE FITMENT OF CLUTCH BOOSTER

without the Company's written permission.

SUCH THAT AIR EXHAUST PORT IS IN SUCH THAT AIR EXHAUST PORT IS IN
DOWNWARD DIRECTION + DOWNWARD DIRECTION
100±4
CLUTCH BOOSTER C AFTER INSERTING THE +
STANDOUT DIMENSION 19-22mm CLUTCH BOOSTER RELEASE TRAVEL AT C
CLUTCH PEDAL FULLY PRESSED CONDITION SPLIT PIN FOLD THE SPLIT
PIN AS SHOWN IN PIC
CWG ASSY AT NOMINAL CONDITION CWG ASSY AT RELEASED CONDITION

XIX
LIST OF CTQ'S
DESCRIPTION SPEC REFERENCE REFERENCE
SHEET NO
CLUTCH DISC STOPPING TIME 4Sec max - -
CLUTCH BOOSTER STANDOUT 100±4mm SHEET 3 XVI
CLUTCH RELEASE STROKE 19-22mm SHEET 3 XVII
CLUTCH PEDAL FREE PLAY 5-10mm SHEET 1 V
CLUTCH PEDAL TOTAL TRAVEL 180±10mm SHEET 1 VII
PEDAL STOPPER BOLT PROJECTED LENGTH 25-30mm SHEET 1 VIII
FREE PLAY STOPPER BOLT PROJECTED LENGTH 15±5mm SHEET 1 V
CLUTCH PEDAL HEIGHT FROM FLOOR 170±10mm SHEET 1 II
HYDRAULIC RESERVIOR OIL DOT 4 SHEET 2 X
HYDRAULIC RESERVIOR OIL LEVEL Max Level SHEET 2 X
ONCE WEAR STROKE 38mm IS
CLUTCH SWITCH SETTING (PLUNGER COMPRESSION)
REACHED, REPLACE THE CLUTCH DISC 15.5-17.5 mm SHEET 1 VI
AT PEDAL HOME POSITION
19 B3628809 HOSE FROM PIPE TO BOOSTER ASSY- 800 MM 1 SHEET 2
18 F0830910 CLIP 2 SHEET 2
17 L4111200 Standard Washer - Single Coil - M12 2 SHEET 2
16 L3021218 Standard Nut - Hex - M12 X 1.5 FP X 10.8mm LONG X GR 8 2 SHEET 2
ASHOK LEYLAND LTD.

15 L2021235 Standard Screw - Hex - M12 X 1.5 FP X 35mm LONG X GR 8.8 2 SHEET 2
14 X0416810 L BRACKET 2 SHEET 2
TECHNICAL CENTRE, VELLIVOYAL CHAVADI

13 B3633001 3/8 INCH CWG PIPE -2250MM LENGTH 1 SHEET 2

12 F3580810 Special Washer - MM - Plain - 7mm ID X 18mm OD X 2mm T 2 SHEET 2
11 L2010625 Standard Screw - Hex - M6 X 1 CP X 25mm LONG X GR 8.8 4 SHEET 2
10 F7874110 CLIP-HOSE SUPPORT 2 SHEET 2
CLUTCH BOOSTER WEAR INDICATOR SETTING 09 F6M01200 CLAMP WITH RUBBERIZED/PVC SLEEVE 1 SHEET 1
08 F8612950 HOSE ON MASTER CYLINDER 1 SHEET 1
07 F1996650 HOSE FOR REMOTE MOUNTED RESERVOIR ON 2214 1 SHEET 1
INSTRUCTIONS:- 06 N0000439 JUPITOR HOSE CLAMP 2 SHEET 1 DRAWING NOT VALID WITHOUT
1) ENSURE HOSE ROUTING TO BE DONE SUCH AS TO AVOID KINKING OF HOSE ALPLM WATERMARK IN THIS SPACE
05 L3010618 Standard Nut - Hex - M6 X 1 CP X 5.2mm LONG X GR 8 6 SHEET 1 & 2
2) AFTER CLUTCH BLEEDING,IN ENGINE ON CONDITION WITH CLUTCH PEDAL PRESSED CONDITION 04 L4110600 Standard Washer - Single Coil - M6 6 SHEET 1 & 2
SHIFT ALL GEARS INCLUDING REVERSE GEAR AND GEAR SHIFTING TO BE SMOOTH WIHTOUT DRAWN/ CHECKED/ MED APPROVAL/ APPROVED/ STDS APP/

GEAR CLASH NOISE 03 L2010615 Standard Screw - Hex - M6 X 1 CP X 15mm LONG X GR 8.8 4 SHEET 1 DATE
P.V
DATE
K.M
DATE
SUNILRAJ
DATE
K.S.D
DATE
----

02 F8434410 RESERVOIR MOUNTING BRACKET 1 SHEET 1 21.03.2017 21.03.2017 21.03.2017 21.03.2017 --------

3) CLUTCH DISC STOPPING TIME IS DEFINED AS THE TIME TAKEN TO STOP THE ROTATION OF THE MATERIAL

CLUTCH DISC AFTER FULLY PRESSING THE CLUTCH PEDAL 01 F8002960 CLUTCH FLUID RESERVOIR ASSY 1 SHEET 1 -----
HEAT TREATMENT

S.NO PART NUMBER DESCRIPTION QTY REFERENCE SHEET ----

SURFACE
PROTECTION
-----
SPECIAL INSTRUCTIONS/NOTE: BILL OF MATERIALS REMARKS
FOR 3718 & 3118LA VEHICLE FITTED WITH 380DIA SETCO CLUTCH
APPEARANCE ITEM ER-DIN DATE
THIS DRG.CONTAINS ( 8 C CRITICAL - S SAFETY 7 + IMPORTANT ) CHARACTERISTICS 1. REFER A1N04900 CWG INSTALLTION DRAWING FOR MORE DETAILS ABOUT CWG ASSY
YES NO 37582 10.03.2017
DESCRIPTION
& ZF 9S/8SGB WITH G45 FES & G45 CAB ASSY

UNLESS OTHERWISE SPECIFIED OPERATING PEDAL UNIT ASSY INSTALLATION DRAWING

ASHOK REF.PT.NO. ----
TOLERANCES REFER IS:2102; MEDIUM FOR MACHINING AND COARSE FOR FABRICATION 2. ENSURE CLUTCH BOOSTER WEAR INDICATOR SHOULD BE ZERO POSITION IN CLUTCH BOOSTER (REFER XVIII) FINISHED WEIGHT(APPROX)

--- Kgs S/A.PT.NO. PART

A 6 F 0 4 8 0 0 C
SURFACE PROTECTION TO MEET THE REQUIREMENT OF ALS.268.03 ----
SURFACE FINISH AS PER METRIC SCREW THREADS SHALL CONFORM TO THE LIMITS SHARP EDGES TO BE REMOVED
SCALE SUPERSEDES ----
NO.
AND TOLERANCES SPECIFIED IN THE CURRENT IS:4218 DIMENSIONS ARE IN MM
A0
IS:3073(CLA VALUE)
LEYLAND CLASS 6g EXTERNAL OR 5H INTERNAL. DO NOT SCALE DRAWING NTS SPEC.NO. ALOP137 SHEET NO 3 OF 3