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

2. Introductions
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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
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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
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 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
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ZF RL 85 A

6. Technical Specifications
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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
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8. Cross-sectional view of wheel hub
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9. Tightening Torques
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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
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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
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12. Special Tools
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13. Knorr Bremse Disc Brakes
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14. Knorr Bremse Disc Brakes
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15. Special Tools
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16. Special Tools
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17. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Disassembly of Axle
Duration – 90 mins
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18. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Overhauling of Caliper
Duration – 120 mins
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19. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Inspection of Axle and
Disc Components
Duration – 90 mins
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20. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Assemble and install
Axle system
Duration – 120 mins
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21. Low Floor Front Axle
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Meritor FH 946

22. Identification
 The axle model number identification plate is located on the axle center
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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
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24. Greasing Points
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1) Steering knuckle bearing (above)
2) Steering knuckle bearing (below)

25. Exploded view of Hub assembly
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26. Special Tools
Bush retainer and removal tool kit
 Tool Used for Guide Sleeve, Dust Excluder, Retainer & Bushes, Housing &Visual Wear Indicator
Replacement
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27. Special Tools
Measurement adapter tool (frame lift)
 Tool Used for Checking Slide Pin Bush Wear
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28. Special Tools
Oval guide bush fitting tool
 Tool Used for Guide Sleeve, Dust Excluder, Retainer & Bushes
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29. Special Tools
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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
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31. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Overhauling of Caliper
Duration – 120 mins Video
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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
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33. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Assemble and install
Axle system
Duration – 120 mins
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34. Independent Front Axle
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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
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36. Components of Axle
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37. Cross-sectional view of wheel hub
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38. Tightening Torques
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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)
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40. Special Tools
 List of special tools is given in the attached PDF
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41. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Disassembly of Axle
Duration – 90 mins
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42. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Inspection of Axle and
Disc Components
Duration – 90 mins
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43. Practical Exercise
 Please follow the instructions of the trainer
Exercise Name –
Assemble and install
Axle system
Duration – 120 mins
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44. All The Best!