Adding Reinforcement and Cross member to increase chassis frame strength(dmn14140). PROPOSED CHASSIS FOR CLA (6X4) LITE

Transcription

1 Vehicle(s) affected CLA (DS42) Tractor Head Component(s) affected Chassis Frame Problem Cause Urgency Remedy Chassis long member crack on RH side near fuel tank and Left long member bent vertically and horizontally. (Vehicle model designed for rated load i.e. 49 Ton) Long member cracking has various contribution factors such as Road condition, Overloading of vehicle, Fifth wheel kingpin offset changes by customer, Types of trailer used, Location of C.G. of load on trailer, changes in frame, suspension and fifth wheel by customer. Urgent Adding Reinforcement and Cross member to increase chassis frame strength(dmn14140). EXISTING CHASSIS FOR CLA (6X4) LITE LONG MEMBER FAILURE AREA PROPOSED CHASSIS FOR CLA (6X4) LITE New added Support BKT. Assly. (PT. NO ) New Added L BKT. For Support BKT. Assly. LH and RH side (PT. NO /0574) New Added C-Reinforcement LH and RH side (PT. NO /0480) ANDREAS BUG TECHNICAL BULLETIN DOC. NO. 124 REVISION-01 1/10

2 LONG MEMBER CRACKING - CONTRIBUTING FACTOR VEHICLE OVERLOADING ROAD CONDITION N LONG MEMBER CRACKING CHANGES IN FRAME, SUSPENSION AND FIFTH WHEEL BY CUSTOMER FIFTH WHEEL KINGPIN OFFSET CHANGE BY CUSTOMER LOCATION OF C.G. OF LOAD ON TRAILER TYPES OF TRAILER USED S.NO. DESCRIPTION PROCEDURE OF ASSEMBLY: SERVICE KIT MTIPL PART NO. QTY./ VEH. 1 Service kit for CLA49.220(6X4)LITE C-Reinforcement LH/RH 3 L Bkt. Support Bkt. Assly LH/RH / / Support BKT. ASSY Bolt M14X1.5X35 M MAN183-B Bolt M14X1.5X45 M MAN183-B Bolt M14X1.5X50 M MAN183-B Bolt M14X1.5X55 M MAN183-B NUT M14X Spacer 2mm Thick E 1E Step 1 :- Disconnect inlet-outlet fuel line connections from water separator, Air inlet-outlet connections from air drayer,purge tank and quadraple valve. Also disconnect air inlet-outlet connections of single tank mounted on chassis. TECHNICAL BULLETIN DOC. NO. 124 REVISION-01 2/10

3 Step 2:- Remove air tank MTG. BKT. (PT. NO ); Air drayer, Purge tank,compressor Pipe at U bend, Quadraple valve MTG. BKT. (PT. NO ); Water separator MTG. BKT. PT. NO ); Spare wheel MTG. BKT. (PT. NO ) and L MTG. BKT. for wire harness (PT. NO ) as per figure 1. Remove Vehicle front FIGURE 1 Step 3:- Remove 6 nos. of rivets in RH side nearby exiting holes of water separator MTG. BKT.and 4 Nos. of rivets in LH side nearby exiting holes of air tank MTG. BKT. as shown in figure 2. Water separator MTG. BKT. existing holes Vehicle Front Air tank MTG. BKT. existing holes Vehicle Front Remove rivets (6 nos.) Remove rivets (4 nos.) RH (SIDE VIEW) FIGURE 2 LH (SIDE VIEW) TECHNICAL BULLETIN DOC. NO. 124 REVISION-01 3/10

4 Step 4:- New Ø15.5 one hole to be drilled throughout on chassis long member and reinforcement in both LH and RH side above the tubular crossmember (fourth crossmember from vehicle front) mounting as shown in figure Ø15.5 One hole to be drilled Tubular crossmember(fourth crossmember from vehicle front) Vehicle front LH SIDE VIEW SHOWN RH SIDE VIEW MIRROR OF LH FIGURE 3 Step 5:- On LH side of chassis assemble C-Reinforcement LH (PT. NO ) from inside of long member and L MTG. BKT. For support BKT. Assy LH (PT.NO ) from outside of long member along with Air tank MTG. BKT. as shown in section A-A (Refer figure 4) Air Tank MTG. BKT. (PT. NO ) M14X1.5X M A- MAN183-B1 QTY.2Nos QTY.2 Nos. SECTION A-A TECHNICAL BULLETIN DOC. NO. 124 REVISION-01 4/10

5 Third cross member from vehicle front A B C Vehicle front 300 DETAILS OF LH SIDE ASSEMBLY (SIDE VIEW) FIGURE 4 Step 6:- Mount Air dryer MTG. BKT. and spare wheel MTG. BKT. On existing position as shown in Section B-B (Refer figure 4). Use washer (PT. NO ) in place of long spacer (PT. NO ). A B C WASHER 17X32 QTY. - 2 Nos. M14X1.5X M MAN183-B1 QTY.2 Nos QTY.2 Nos. Air Dryer, Purge tank, Quadraple valve MTG.BKT. (PT. NO ) WASHER 17X32 QTY. - 2 Nos. SECTION B-B TECHNICAL BULLETIN DOC. NO. 124 REVISION-01 5/10

6 Step 7:- Mount L BKT. For wire harness on exiting position in LH side as shown in section C-C (Refer figure 4). M14X1.5X M MAN183-B1 QTY. 1 Nos QTY. 1Nos. L-BKT. For Wire Harness (PT. NO ) SECTION C-C. Step 8:- Complete remaining bolting in LH side as shown in figure 5 (Refer figure 4 for location of holes). Vehicle Front FIGURE 5 (LH SIDE VIEW) M14X1.5X M MAN183-B1 QTY. 4 Nos QTY.4 Nos. TECHNICAL BULLETIN DOC. NO. 124 REVISION-01 6/10

7 Step 9 :- On RH side of chassis assemble C-Reinforcement RH (PT. NO ) from inside of long member and L MTG. BKT. For support BKT. Assy RH (PT. NO ) from outside of long member along with Water separator MTG. BKT.As shown in section D-D (Refer figure 6) Water Separator MTG. BKT. (PT.NO ) M14X1.5X M MAN183-B1 QTY. 2 Nos M14x M MAN183- B1 QTY. 2 Nos. SECTION D-D E D Vehicle front Third cross member from vehicle front E D 450 DETAILS OF RH SIDE ASSEMBLY (SIDE VIEW) FIGURE 6 TECHNICAL BULLETIN DOC. NO. 124 REVISION-01 7/10

8 Step 10 :- Complete remaining RH side bolting except existing mounting hole of L BKT for wire harness as shown in figure 7 (Refer figure 6 for holes location). Existing mounting hole of L BKT for wire harness Vehicle Front M14X1.5X M MAN183-B1 QTY. 6 Nos QTY. 6 Nos. FIGURE 7 (SIDE VIEW) Step 11 :- Mount L BKT. For wire harness on exiting position in RH side as shown in section E-E (Refer figure 6). L BKT for Wire Harness (PT. NO ) M14X1.5X M MAN183-B1 QTY.1 No QTY. 1No. SECTION E-E TECHNICAL BULLETIN DOC. NO. 124 REVISION-01 8/10

9 Step 12 :- Insert support BKT. Assy (PT. NO ) from front and assemble as shown in figure 7. Vehicle front M14X1.5X M MAN183-B1 QTY.10 Nos.(LH+RH) View X (Refer figure 8) Third cross member from vehicle front 400 FIGURE 7 (SIDE VIEW) Support BKT. Assy (PT. NO ) VIEW X FIGURE 8 TECHNICAL BULLETIN DOC. NO. 124 REVISION-01 9/10

10 Step 13:- Bolt to be assembled at new drilled hole (both LH and RH side) as shown in figure 9. M14X1.5X M MAN183-B1 QTY. 2 Nos M14X1.5-10, QTY. 2 Nos. Vehicle Front F SECTION F-F Tubular crossmember (Fourth crossmember from vehicle front) LH SIDE VIEW SHOWN RH SIDE VIEW MIRROR OF LH FIGURE 9 F Step 14:- Reconnect all fuel line connections of water separator, Air connections of Air dryer, Compressor Pipe,Purge tank and Quadraple valve. Reconnect all air connections of single tank mounted on chassis. NOTE: - Bolt Tightening Torque M Quality : 310 N-m TECHNICAL BULLETIN DOC. NO. 124 REVISION-01 10/10