Dongfeng KL Clutch booster assembly 1608010-L0310

As a core component of the Dongfeng KL’s clutch actuation system, this assembly delivers powerful pneumatic boosting to reduce driver fatigue. It features a dual-chamber boosting structure with a maximum working pressure of 0.8MPa, providing a boosting ratio of 1:5—converting 300N of pedal force into 1500N of clutch release force. This significantly lightens the clutch pedal load (reducing force by 60% compared to non-boosted systems), making it easier for drivers to operate the clutch during frequent gear shifts (e.g., in urban traffic or loading/unloading scenarios). The assembly’s response time is ≤ 0.2 seconds from pedal depression to boost activation, ensuring immediate clutch engagement/disengagement—critical for smooth gear changes and preventing transmission wear in heavy-duty operations (max payload: 49 tons for Dongfeng KL)

The clutch booster’s body is constructed from high-strength aluminum alloy (ADC12) with a sandblasted surface treatment, offering excellent impact resistance (able to withstand 500N axial force without deformation) and lightweight properties (total weight: 3.2kg, 15% lighter than cast iron alternatives). The internal piston uses a nitrile rubber (NBR) seal ring with a teflon coating, ensuring airtightness (air leakage rate ≤ 1mL/min at 0.8MPa) and smooth movement even after 500,000+ operating cycles. Additionally, the assembly’s input rod is chrome-plated (thickness 10-15μm) to resist corrosion and wear, while the dust cover (made of EPDM rubber) prevents dust, water, and oil from entering the internal chamber—extending the assembly’s service life in harsh working environments (e.g., construction sites, muddy roads)

Engineered to withstand extreme operating conditions, this clutch booster assembly has a wide operating temperature range of -40℃ to +120℃, ensuring stable performance in frigid northern China winters (where temperatures drop below -30℃) and hot southern summers (exceeding 40℃). The internal lubricating grease (high-temperature synthetic type) maintains viscosity even at 120℃, preventing piston jamming due to grease hardening or evaporation. For vibration resistance, the assembly’s mounting brackets use rubber bushings (vibration absorption rate ≥ 70% at 10-500Hz), reducing the transfer of engine and road vibrations to the clutch actuation components—testing shows no performance degradation after 1000 hours of vibration testing (200Hz frequency, 3g acceleration), avoiding premature failure caused by fatigue

This clutch booster assembly fully complies with China’s GB 16897-2010 “Brake Systems of Motor Vehicles” (extending to clutch boosting systems) and European ECE R13 standards, ensuring it meets global safety requirements for performance and durability. Each unit undergoes 100% factory testing, including: ① pressure leakage tests (at 1.0MPa for 5 minutes); ② stroke accuracy checks (tolerance ≤ ±0.5mm); ③ high/low temperature cycling tests (100 cycles of -40℃ to +120℃). Installation is straightforward: it comes with all necessary hardware (4 M10×30 bolts, lock washers) and a detailed manual with dimensional diagrams (overall size: 280mm × 150mm × 120mm) to guide positioning. The assembly also features a built-in inspection port for checking internal air pressure, allowing technicians to diagnose issues (e.g., air leakage) without disassembling the entire unit—reducing maintenance time and costs for fleet operators. It is backed by a 24-month warranty, covering defects in materials or workmanship