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axlesystems-new-file-220726142848-efdba20f.pptx
- 1. Technician Level 2(LOB Bus) – Module 3 Axle Systems
- 2. Introductions 7/26/2022 TML 2 Pleaseintroduce yourself loud and clear including your details for: Participant Name Dealership Name Location Experience in Tata Motors (In years & months) Hobbies What Bonds you with TATA MOTORS
- 3. Program Objective 7/26/2022 TML3 At the end of this module the participants will be able to: Perform basic checks on the Axle Systems Perform preventive maintenance on Axle Systems Dismantle & Assemble Axle Systems Perform inspection of components
- 4. Program Agenda 7/26/2022 TML4 ZF RL 85 A – Low Floor Front Axle – Introduction – Preventive Maintenance – Inspection & Adjustment – Dismantling & Assembly Meritor FH 946 – Low Floor Front Axle – Introduction – Preventive Maintenance – Inspection & Adjustment – Dismantling and Assembly ZF RL 75 E – Independent Front Axle – Introduction – Preventive Maintenance – Inspection & Adjustment – Dismantling & Assembly
- 5. Low Floor FrontAxle 7/26/2022 TML 5 ZF RL 85 A
- 6. Technical Specifications 7/26/2022 TML6 Model ZF RL 85 A Type Low floor front axle with disc brake Suspension Air Suspension Rim Size 22.5” Vehicle Models fitted with this axle LPO 1623 CNG RE LE LPO 1624 RELE LPO 1625 CNG RELE LPO 1925 CNG HYBRID R – Rated L – Load 85 – 8.5 Tonnes A – Series
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- 8. Cross-sectional view ofwheel hub 7/26/2022 TML 8
- 9. Tightening Torques 7/26/2022 TML9 Hub Socket Head Screws 30.0 mkg Hub Clamping nut socket head screws 0.2 mkg Hub cover socket head screws 2.3 mkg Brake caliper socket head screws 62.0 mkg Steering lock stop screw 39.0 mkg Track lever fastening hex head screws 75.0 mkg Tie rod ball joint nut 30.0 mkg Anti roll bar ball joint nut 22.0 mkg Spring carrier fastening screw 67.5 mkg Bracket on Axle casing socket head screw 62.0 mkg Longitudinal & 'V' rod mtg. Hex screw at Axle 44.0 mkg Longitudinal & 'V' rod mtg. Hex screw at module 44.0 mkg Draglink ball joint nut at Pitman arm 25-28 mkg Draglink ball joint nut at steering arm 46.0 mkg
- 10. Greasing Points 7/26/2022 TML10 Greasing Interval : 90,000 kms Grease to be used : Castrol Spherol EPL2 Grease 1) Steering knuckle bearing (above) 2) Steering knuckle bearing (below)
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- 13. Knorr Bremse DiscBrakes 7/26/2022 TML 13
- 14. Knorr Bremse DiscBrakes 7/26/2022 TML 14
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- 17. Practical Exercise Pleasefollow the instructions of the trainer Exercise Name – Disassembly of Axle Duration – 90 mins 7/26/2022 TML 17
- 18. Practical Exercise Pleasefollow the instructions of the trainer Exercise Name – Overhauling of Caliper Duration – 120 mins 7/26/2022 TML 18
- 19. Practical Exercise Pleasefollow the instructions of the trainer Exercise Name – Inspection of Axle and Disc Components Duration – 90 mins 7/26/2022 TML 19
- 20. Practical Exercise Pleasefollow the instructions of the trainer Exercise Name – Assemble and install Axle system Duration – 120 mins 7/26/2022 TML 20
- 21. Low Floor FrontAxle 7/26/2022 TML 21 Meritor FH 946
- 22. Identification The axlemodel number identification plate is located on the axle center 7/26/2022 TML 22
- 23. Technical Specifications Model MeritorFH 946 Type Low floor front axle with disc brake Suspension Air Suspension Rim Size 22.5” Vehicle Models fitted with this axle LPO 1623 CNG RE LE LPO 1624 RELE 7/26/2022 TML 23
- 24. Greasing Points 7/26/2022 TML24 1) Steering knuckle bearing (above) 2) Steering knuckle bearing (below)
- 25. Exploded view ofHub assembly 7/26/2022 TML 25
- 26. Special Tools Bush retainerand removal tool kit Tool Used for Guide Sleeve, Dust Excluder, Retainer & Bushes, Housing &Visual Wear Indicator Replacement 7/26/2022 TML 26
- 27. Special Tools Measurement adaptertool (frame lift) Tool Used for Checking Slide Pin Bush Wear 7/26/2022 TML 27
- 28. Special Tools Oval guidebush fitting tool Tool Used for Guide Sleeve, Dust Excluder, Retainer & Bushes 7/26/2022 TML 28
- 29. Special Tools 7/26/2022 TML29 King Pin Bushing Service Kit, King Pin Reamer Kit Removal & Disassembly of King Pin
- 30. Practical Exercise Pleasefollow the instructions of the trainer Exercise Name – Disassembly of Axle Duration – 90 mins 7/26/2022 TML 30
- 31. Practical Exercise Pleasefollow the instructions of the trainer Exercise Name – Overhauling of Caliper Duration – 120 mins Video 7/26/2022 TML 31 Please select audio track 6 for English
- 32. Practical Exercise Pleasefollow the instructions of the trainer Exercise Name – Inspection of Axle and Disc Components Duration – 90 mins 7/26/2022 TML 32
- 33. Practical Exercise Pleasefollow the instructions of the trainer Exercise Name – Assemble and install Axle system Duration – 120 mins 7/26/2022 TML 33
- 34. Independent Front Axle 7/26/2022TML 34 ZF RL 75 E
- 35. Technical Specifications Model ZFRL 75 E (Max load is 7.5 tonnes) Type Low floor front axle with disc brake Suspension Air Suspension Rim Size 22.5” Vehicle Models fitted with this axle LPO 1628 Hi-Deck - DIVO R – Rated L – Load 75 – 7.5 Tonnes E – Series 7/26/2022 TML 35
- 36.
- 37. Cross-sectional view ofwheel hub 7/26/2022 TML 37
- 38. Tightening Torques 7/26/2022 TML38 Component Torque Control Arm Pin Hex. Nut 100 mkg Lower control Arm castle Nut (at strg. knuckle carrier bolt) 60 mkg Tie rod arm castle Nut (at steering knuckle) 110 mkg Tie rod castle nut (at steering arm) 30 mkg Hub clamping nut tightening screw 6.5 mkg Brake caliper mtg bolt (on strg. knuckle carrier) 27.5 mkg
- 39. Greasing Points Greasing Interval: 90,000 kms Grease to be used : Castrol Spherol EPL2 Grease 1) Steering knuckle bearing (above) 2) Steering knuckle bearing (below) 3) Control arm (above) 7/26/2022 TML 39
- 40. Special Tools Listof special tools is given in the attached PDF 7/26/2022 TML 40
- 41. Practical Exercise Pleasefollow the instructions of the trainer Exercise Name – Disassembly of Axle Duration – 90 mins 7/26/2022 TML 41
- 42. Practical Exercise Pleasefollow the instructions of the trainer Exercise Name – Inspection of Axle and Disc Components Duration – 90 mins 7/26/2022 TML 42
- 43. Practical Exercise Pleasefollow the instructions of the trainer Exercise Name – Assemble and install Axle system Duration – 120 mins 7/26/2022 TML 43
- 44.