bbkjnjknlknjoknknklnjknhhoihihiohihihohohiohohohohoihhhohohhho

1. Technician Level 2 (LOB Bus) – Module 3
Axle Systems

2. Introductions
7/26/2022 TML 2
Please introduce 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 TML 3
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 TML 4
 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 Front Axle
7/26/2022 TML 5
ZF RL 85 A

6. Technical Specifications
7/26/2022 TML 6
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

7. Components of Axle
7/26/2022 TML 7

8. Cross-sectional view of wheel hub
7/26/2022 TML 8

9. Tightening Torques
7/26/2022 TML 9
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 TML 10
Greasing Interval : 90,000 kms
Grease to be used : Castrol Spherol EPL2 Grease
1) Steering knuckle bearing (above)
2) Steering knuckle bearing (below)

11. Special Tools
7/26/2022 TML 11

12. Special Tools
7/26/2022 TML 12

13. Knorr Bremse Disc Brakes
7/26/2022 TML 13

14. Knorr Bremse Disc Brakes
7/26/2022 TML 14

15. Special Tools
7/26/2022 TML 15

16. Special Tools
7/26/2022 TML 16

17. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Disassembly of Axle
Duration – 90 mins
7/26/2022 TML 17

18. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Overhauling of Caliper
Duration – 120 mins
7/26/2022 TML 18

19. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Inspection of Axle and
Disc Components
Duration – 90 mins
7/26/2022 TML 19

20. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Assemble and install
Axle system
Duration – 120 mins
7/26/2022 TML 20

21. Low Floor Front Axle
7/26/2022 TML 21
Meritor FH 946

22. Identification
 The axle model number identification plate is located on the axle center
7/26/2022 TML 22

23. Technical Specifications
Model Meritor FH 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 TML 24
1) Steering knuckle bearing (above)
2) Steering knuckle bearing (below)

25. Exploded view of Hub assembly
7/26/2022 TML 25

26. Special Tools
Bush retainer and 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 adapter tool (frame lift)
 Tool Used for Checking Slide Pin Bush Wear
7/26/2022 TML 27

28. Special Tools
Oval guide bush fitting tool
 Tool Used for Guide Sleeve, Dust Excluder, Retainer & Bushes
7/26/2022 TML 28

29. Special Tools
7/26/2022 TML 29
King Pin Bushing Service Kit, King Pin Reamer Kit
 Removal & Disassembly of King Pin

30. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Disassembly of Axle
Duration – 90 mins
7/26/2022 TML 30

31. Practical Exercise
 Please follow 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
 Please follow the instructions of the trainer
Exercise Name –
Inspection of Axle and
Disc Components
Duration – 90 mins
7/26/2022 TML 32

33. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Assemble and install
Axle system
Duration – 120 mins
7/26/2022 TML 33

34. Independent Front Axle
7/26/2022 TML 34
ZF RL 75 E

35. Technical Specifications
Model ZF RL 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. Components of Axle
7/26/2022 TML 36

37. Cross-sectional view of wheel hub
7/26/2022 TML 37

38. Tightening Torques
7/26/2022 TML 38
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
 List of special tools is given in the attached PDF
7/26/2022 TML 40

41. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Disassembly of Axle
Duration – 90 mins
7/26/2022 TML 41

42. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Inspection of Axle and
Disc Components
Duration – 90 mins
7/26/2022 TML 42

43. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Assemble and install
Axle system
Duration – 120 mins
7/26/2022 TML 43

44. All The Best!