SESSION – 1

CHASSIS ASSEMBLYChassis Assembly consists of 16 stages:

1. Frame loading

2. Front axle mounting

3. Rear axle mounting

4. Axle torqueing

5. Silencer mounting

6. Chassis turnover operation

7. Fuel tank mounting

8. Engine mounting

9. Radiator mounting

10. Oil filling

11. Cab mounting

12. Electrical

13. Wheel mounting

14. Wheel torqueing

15. Vehicle starting

16. Off track

All these stages complete the assembling of the chassis into the system.

After the frame, front and rear axle are loaded, the axle undergoes torquing which is checked by the torque checking machine. The silencer is mounted on the axle. Till now, the whole setup, i.e., the axles and the frame is upside down. So, the next operation is chassis turnover operation. A big machine which can carry around 8000kgs, has two pulleys with a hook that helps with this operation. The chassis is turned over by this machine.

Soon after this, the fuel tank, the engine and the radiator is mounted. The engine oil is filled and the cab is mounted. The mounting of the cab is done by two carriers. The movement of these carriers is achieved with the help of PLCs. The whole drive is divided into 6 zones. And the drive is designed such that no two carriers are present in the same zone. The carrier then mounts the cab on to the setup with the help of pendants.

The electrical system of the vehicle is checked and placed. The wheel is mounted using a pneumatic device so that the weight of the wheel(120kgs) becomes lesser. The wheel also undergoes torqueing so as to maintain equal torque on both wheels. Thus, making the vehicle more balanced. The vehicle is then started and sent for testing off track.

SESSION 2

REAR AXLE ASSEMBLY

There are twelve stages in this arrangement of the rear axle and it also has sub stages where the hub to the axle are made.

Stage 1:

Load axle casting are added and their left and right position are ensured they are correct

Stage 2:

Brakes are added to them using the bolts and nuts

Stage 3:

The tighten of the bolts and nuts using the torqueing technique with the desired amount of torque.

Stage 4:

Inner rings and Inner bearing are assembled on the beam having differentiator.

Stage 5:

The grease are applied and the hub is added to the beam.

Stage 6:

Tightening of the hub is done.

Stage 7 & 8:

Applying the torque and tighten the nuts and remove the excess bolts and nuts.

Stage 9:

Assembling the brake drum and tighten them with wheel nuts.

Stage 10:

Assembling the axle shaft and tighten with the spring washers and nuts.

Stage 11 & 12:

Punching the axle serial and spec number on the beam.