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Gc Max Modification

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Gc Max Modification

  1. 1. Modifications
  2. 2. 1. INTRODUCTION OF GC MAX CIRCULAR NO – 3WH 187 DATE : 20/08/2007 <ul><li>Usable Tray width increased from 1290 mm to 1410 mm. </li></ul><ul><li>Center to center distance of headlamp / blinkers increased – More wider visibility of roads. </li></ul><ul><li>Neutral color of plastic parts / handle bar changed to Black. – To improve aesthetics </li></ul><ul><li>Bottle holder bolted on RH support (below driver seat) - Additional feature </li></ul><ul><li>Socket for fitment of mobile charger / cigarette lighter added on dashboard. – Additional feature. </li></ul>
  3. 3. Continued …. <ul><li>Air filter clogging and low oil pressure alarm indication control system.- Safety feature to enhance engine performance. </li></ul>
  4. 4. 2. BAFFLE FITMENT IN FUEL TANK CIRCULAR NO : 3WH - 192 DATED : 05/09/2007 <ul><li>To take care of fuel spillage from plastic fuel tank and fuel tank cap coming out in locked position, we have started fitment of baffle, inside the fuel tank on GC MAX and MEGA. </li></ul>
  5. 5. 3. INTRODUCTION OF MODIFIED GRILL AIR DUCT CIRCULAR NO : 3WH 197 4. INTRODUCTION OF MODIFIED FUEL TANK STRAP DATED : 27-09-2008 5. INTRODUCTION OF MODIFIED CYLINDER HEAD <ul><li>Introduction of modified GRILL AIR DUCT for MEGA MAX – to prevent water entry in air filter during rain. To prevent entry of water inside the grill, it is modified to direct the rain water downwards. </li></ul>OLD <ul><li>Introduction of modified fuel tank strap with M8 stud for MEGA MAX & GC MAX -To take care of brakeage of fuel tank strap, it’s threading is changed to M8. </li></ul>
  6. 6. Continued … <ul><li>Introduction of modified cylinder head for GC MAX & MEGA MAX. To take care of the problem of cylinder head bridge cracking, we have implemented modified cylinder head in which relief valve position is changed. </li></ul>
  7. 7. 6. Driver Seat assembly with Reduced Length CIRCULAR NO : 3WH 198 DATED : 27.09.2007 <ul><li>Introduction of Driver seat assembly with reduced length for GC MAX & </li></ul><ul><li>GC CNG MAX. </li></ul><ul><li>We have implemented Driver seat assembly with reduced length, to facilitate easy operation of reverse lever. Length of seat is reduced by 60mm. (The length of seat 871mm is reduced to 811mm. </li></ul>
  8. 8. 7. Introduction of Splash Guard CIRCULAR NO : 3WH 200 8 . Introduction of dust cover for wheel bearing DATED : 13.11.2007 9. Introduction of dashboard with additional holes <ul><li>Introduction of Splash guard for GC Max and Mega Max >To protect engine from mud and dust, splash guard on engine is implemented on GC Max. </li></ul><ul><li>Introduction of dust cover for wheel bearing (sealed) - To avoid dust entry inside sealed bearing, we have provided dust cover for GC Max, Mega Max, GC CNG Max and Mega CNG . This will help to further enhance the life of bearing. </li></ul>Dust Seal
  9. 9. Continued … <ul><li>Introduction of dashboard with additional holes at end for GC Max and GC CNG Max </li></ul><ul><li>- For better fitment, trim has provided additional fixing with screw at both ends. </li></ul>
  10. 10. Introduction of Sealed Bearing in Differential CIRCULAR NO : 3WH 201 DATED : 08.11.2008 <ul><li>Introduction of sealed bearing in differential assembly. </li></ul><ul><li>To prevent possibility of water entry inside the differential housing, sealed bearing for differential is implemented on GC Max and Mega Max . </li></ul>Sealed bearing for differential housing
  11. 11. Continued … CIRCULAR NO : 3WH 201 Implementation Of New Door Lock Set Commonisation of driver cabin of GC CNG Max with GC Max. <ul><li>For better door lock operations, lock position and it’s linkages are modified. </li></ul>NEW OLD
  12. 12. Continued … Commonisation of driver cabin of GC CNG Max with GC Max. Fitment of Head lamp Brackets With Bolts Instead of Spot Welding <ul><li>Commonisation of driver cabin of GC CNG Max with GC Max. > We have commonised the driver cabin of GC CNG Max with GC Max. </li></ul><ul><li>Fitment of head lamp brackets with bolts instead of spot welding to </li></ul><ul><li>Chassis, on GC CNG MAX and GC MAX > As a process improvement, we have started fitment of head lamp bracket with bolts. </li></ul>
  13. 13. Introduction Of Jack Assembly. Introduction of modified gear shifter housing & Cover for Reverse Switch <ul><li>Introduction of jack assembly without handle (AN221004) and Tool kit complete (BB221005) for GC MAX > As a regular change, we have implemented new jack (without handle) and commonised Mega tool kit with GC Max. To operate the jack Tommy bar provided in tool kit is to be used. </li></ul>CIRCULAR NO :202 DATED : 01.11.2007 <ul><li>Introduction of head light assembly with new rubber cap to avoid water / dust entry for GC Max & Mega Max. </li></ul>
  14. 14. Continued … Introduction of head light assembly with new rubber cap. <ul><li>Introduction of head light assembly with new rubber cap to avoid water / dust entry for GC Max & Mega Max. </li></ul><ul><li>To prevent water/ dust entry inside the head lamp through rubber cap, it is modified as shown below </li></ul>OLD NEW
  15. 15. Modification in Engine Mounting Cradle . <ul><li>Modification in engine mounting cradle of GC MAX and MEGA MAX. > To strengthen engine mounting bracket on cradle to avoid its cracking, reinforcement is added as shown. </li></ul>CIRCULAR NO : 205 DATED : 04.12.2008 OLD No reinforcement NEW Reinforcement
  16. 16. Modification in handle bar assembly <ul><li>Modification in handle bar assembly for RE DIESEL, GC MAX, MEGA MAX and GC CNG MAX . </li></ul><ul><li>To avoid excess play in gear control tube and ring gear indicator, fitment of ring gear indicator on gear control tube with dowel pin is started. </li></ul>CIRCULAR NO : 206 DATED :11.12.2007 HOLE IS PROVIDED FOR SPRING CLIP SPRING CLIP PROVIDED IN HANDLE BAR
  17. 17. Implementation of hand brake lever of Mega MAX <ul><li>Implementation of hand brake lever of Mega MAX (BB151001) on GC </li></ul><ul><li>MAX & GC CNG MAX </li></ul><ul><li>For commonisation, fitment of hand brake lever of Mega (BB151001) is started on GC MAX and MEGA MAX. </li></ul>CIRCULAR NO : 208 DATED : 8/12/2008 OLD NEW
  18. 18. continued … Introduction of Coupler Instead of Bullet terminal for Cable Assembly Cabin light . <ul><li>Introduction of coupler instead of Bullet Terminal for cable Assembly cabin light of GC max and MEGA MAX . </li></ul><ul><li>To improve the electrical connectivity with better, positive connection, cabin light harness is provided with coupler instead of bullets. </li></ul>
  19. 19. Continued … Introduction of needle bearing in place of ball bearing for camshaft <ul><li>Introduction of needle bearing in place of ball bearing for camshaft of </li></ul><ul><li>RE-DIESEL / GC MAX/ MEGA MAX . - As a regular change, we have implemented needle bearing in place of ball bearing for camshaft of . </li></ul><ul><li>Due to difference in diameter of needle bearing and ball bearing, cover crank case is modified. </li></ul>Hole –dia for needle bearing is reduced
  20. 20. Continued … OLD NEW Induction hardening done at camshaft Needle bearing
  21. 21. Fitment of Connecting Rod forged from Preforged Preforms. <ul><li>As a regular improvement, we have started fitment of connecting rods forged from forged preforms (Preforged shape changed from turning to hot forging) for GC MAX and Mega MAX </li></ul><ul><li>  </li></ul><ul><li>The identification on web of the shaft is as follows. </li></ul><ul><li>Manufactured in :- </li></ul><ul><li>Oct.07     :   X2/07 </li></ul><ul><li>Nov.07    :   Y1/07, Y2/O7 & so on. </li></ul><ul><li>Dec.07    : Z1/07, Z2/07 & so on </li></ul><ul><li>Jan’08 : O1/08, O2/08 & so on. Depending on lot order quantity </li></ul>CIRCULAR NO : 209 DATED : 24.12.2007
  22. 22. Provision of Fuel Tank Guard. <ul><li>Provision of fuel tank guard for GC MAX- DAC vehicle - We have started sending guard fuel tank for GC MAX -DAC vehicle with its fasteners in </li></ul><ul><li>accessories box sent along with the vehicle, effective from Dec 18,2007 </li></ul><ul><li>Location of the guard is similar to existing one fitted from the factory on GC Max . </li></ul>CIRCULAR NO : 210 DATED : 22.01.2008 Guard fuel tank
  23. 23. Modification on Chassis assembly Improvement in ED Painting Process in all 3 Wheeler models <ul><li>Modification on Chassis assembly of GC MAX / Mega Max </li></ul><ul><li>We have implemented following improvements on chassis assembly of GC Max and Mega Max. </li></ul><ul><li>1) Cup cross tube added in chassis assembly. </li></ul><ul><li>2) Trailing arm bracket collar deleted. </li></ul><ul><li>3) Excess welding reduction of trailing arm brackets. </li></ul>CIRCULAR NO : 211 DATED : 22.01.2007 Cup from inside welded Extrusion deleted Excess Extrusion deleted welding deleted
  24. 24. Continued … Clamp added for tail lamp branch, accelerator, stop cable and clutch cable <ul><li>Clamp added for tail lamp branch, accelerator, stop cable and clutch cable </li></ul>Clamps Added
  25. 25. Continued… Improvement in ED Painting Process in all 3 Wheeler Models <ul><li>We have made certain changes in the ED painting process internally. </li></ul><ul><li>Due to this new process component paint color has become gray instead of black. (Before finish paint) </li></ul>
  26. 26. Introduction of modified D’com cable <ul><li>As an improvement, we have implemented modified D’com cable with following changes </li></ul><ul><li>RE DIESEL, GC MAX and MEGA MAX. </li></ul><ul><li>1) End cap diameter is increased to 8 mm from 6 mm </li></ul><ul><li>2) Length of nut near dashboard is reduced to 19 mm from 24 mm. </li></ul>Length of nut reduced to 19 mm from 24 mm Dia. of end cap increased to 8mm from 6 mm CIRCULAR NO : 215 DATED : 31.01.2008
  27. 27. Reverse Switch mounting is changed from Cover Gear Shifter to Cover Gear Box. Greasing arrangement for rear axle bearings <ul><li>Reverse switch mounting of GC MAX and MEGA MAX is changed from cover gear shifter to cover gear box. </li></ul><ul><li>To provide more rigid fixing to reverse switch to avoid reverse light glowing in neutral, mounting position of reverse switch is changed from gear shifter cover to gear box cover. </li></ul>CIRCULAR NO : 3WH/ TI/03 DATED : 08.05.2008 Based on field feedback we have re-introduced greasing arrangement for rear axle bearing of GC MAX , MEGA MAX OLD NEW
  28. 28. Greasing Arrangement of Rear Axle Bearing. <ul><li>Please refer our circular no. 3WH 218 dated 12.3.08 on re-introduction of </li></ul><ul><li>Grease nipple arrangement. </li></ul>CIRCULAR NO: 3WH/TI/04 DATE : 17.04.2008 <ul><li>Dismantling and Modification </li></ul><ul><li>Remove the rear axle. </li></ul><ul><li>Note : If required, replace the bearings. Pl. note that use of sealed </li></ul><ul><li>bearings in this trailing arm is must. </li></ul><ul><li>2) Remove needle roller bearing of rear axle with the help of special tool </li></ul><ul><li>37221706. </li></ul><ul><li>3) Cut the lip of rubber seal of the bearing (inner side only) using sharp </li></ul><ul><li>tool as shown in picture </li></ul>
  29. 29. Continued… <ul><li>Caution: Only one side of seal is to be cut (inner side). This will allow grease to enter inside NRB . </li></ul>4) Drill the hole of dia.4.5mm. on hub near back plate. Tap it for M6X1.Refer drawing in Annex-I for location of drill on hub. NRB with proper seal lip Oil seal lip cut
  30. 30. Continued… Drilling and tapping to be done on hub at this point. Please remove all metallic burr inside the hub by cleaning the hub with kerosene. Caution : Do not forget to re grease the bearings. 1) Fix the grease nipple. Grease Nipple
  31. 31. Continued … <ul><li>2) Lubricate the NRB with RR3 grease and press it in trailing arm with the Help of special tool. (Rubber seal damage side should be inside.) </li></ul>Rubber seal damaged side Sealed ball bearing 3) Please fit oil seal (part no. 24171024) inside the trailing arm at ball bearing side. Oil seal (24171024) to be fitted
  32. 32. Introduction of Auto Adjuster Brake System <ul><li>Introduction of Auto Adjuster brake system on all RE models. Please refer our earlier circular no. 3WH:213 dated 22.01.2008 through which we have communicated the implementation of this system on RE 2S </li></ul>CIRCULAR NO :3WH/TI/04 DATED : 10.05.2008 Pinion Wheel cylinder Spring Shoe Clamp Pin Pivot Shoe Spring Strut LH Spring Shoe Holding Plate Strut Front Spring Strut LH holding
  33. 33. Continued… Plate Ratchet Pinion Spring Main Plate Strut Front Spring Strut LH Holding Spring Strut LH Pin Ratchet
  34. 34. Modified air filter bracket <ul><li>1) Modified air filter bracket for GC Max and Mega Max </li></ul><ul><li>As an improvement to enhance the life of bracket, it is modified and made in single piece. </li></ul>CIRCULAR NO : 3WH/TI/06 DATED : 25.05.2008 Old New Bracket air filter mtg. is made single piece. Bracket Air filter welded to support bracket with spot welding instead of CO2 welding
  35. 35. Improvement for Governor lever –2 Introduction of modified stop cable, Cover Governor lever and Governor lever 3 <ul><li>To prevent oil leakage from governor lever –2 induction hardening is added </li></ul>CIRCULAR NO : 3WH/ TI/07 DATED :29.05.2008 Part no. of Governor Lever-2 (BA122038) remains same. <ul><li>Introduction of modified stop cable, cover governor lever and Governor lever 3 on RE DIESEL, GC MAX and MEGA MAX </li></ul><ul><li>Stop cable with fixed end is implemented for operational consistency on RE DIESEL, GC MAX & MEGA MAX. This has further modified the cover governor and governor lever 3. </li></ul>
  36. 36. Tray Mounting Bracket <ul><li>PROBLEM REPORTED FROM FIELD : Cracking at tray mounting bracket (front) </li></ul><ul><li>MODIFICATION IMPLEMENTED : Tack welding at four points on tray </li></ul><ul><li>mounting bracket </li></ul>CIRCULAR NO : 3WH/PUG/08-09/05 DATED : 17.06.2008 ACTION TO BE TAKEN IN FIELD : 1) Loosen / remove the tray mounting bracket bolts. 2) Remove the Dunlop packing of front tray mounting brackets. 3) Remove the paint of tray mounting bracket at welding location. 4) Tack welds the bracket. Ensure 10 mm weld run at 4 points as shown in figure.
  37. 37. Continued … Parameters for welding process Current: 170 to180Amps Voltage - 20 to 25 V Tack weld at 4 points

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