Mahindra TORRO 25 Workshop Manual
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Mahindra TORRO 25 Workshop Manual

Mahindra TORRO 25 Workshop Manual

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MAHINDRA & MAHINDRA LTD.
TORRO 25
WORKSHOP MANUAL
(In continuation with TRUXO 25 WM)
[Part No. 6003AAR0003PB]
MAHINDRA MAHINDRA LTD.
TRUCK AND BUS DIVISION.
PUNE

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  • Page 1 MAHINDRA & MAHINDRA LTD. TORRO 25 WORKSHOP MANUAL (In continuation with TRUXO 25 WM) [Part No. 6003AAR0003PB] MAHINDRA MAHINDRA LTD. TRUCK AND BUS DIVISION. PUNE...
  • Page 2 Mahindra & Mahindra Ltd. Truck and Bus Division. Chinchwad, Pune. Reproduction or translation of the whole or part of the TORRO 25 Workshop Manual without our written approval is prohibited. Subject to modification in design, specification & equipment. Printed by : SAWKAR ART SERVICE, PUNE Tel.
  • Page 3 TORRO 25 INTRODUCTION PREFACE This workshop manual is prepared for TORRO 25 in continuation with TORRO 25Cargo assuming that the technician working on TORRO 25 is fully conversant with general automobile practices and trained at Extramile, Pune. This will boost the confidence of the customer with respect to quality repairs through skilled manpower with less downtime.
  • Page 5 TORRO 25 INTRODUCTION CONTENTS INTRODUCTION ......................................7 DIFFERENTIAL ......................................23 BRAKES ........................................75 HYDRAULICS ....................................... 91...

  • Page 7: Vehicle Overview

    TORRO 25 INTRODUCTION VEHICLE OVERVIEW (Refer Fig. 1, 2 & 3) Fig. 1 Fig. 2 Fig. 3...
  • Page 8 TORRO 25 INTRODUCTION COMPARISON OF SPECIFICATION SR. NO. MODEL TORRO 25CARGO TORRO 25TIPPER GVW (Kgs) 25000 25000 WEIGHTS (Kgs) 1.01 Front axle (Laden) 6000 6000 1.02 Rear axle (Laden) 19000 19000 DIMENSIONS (MM) 2.01 Wheel base 5000 / 5350 4250 2.02...
  • Page 9 INTRODUCTION TORRO 25 SR. NO. MODEL TORRO 25CARGO TORRO 25TIPPER CLUTCH Diaphragm type, Single plate Single plate, Diaphragm spring, 4.01 Type dry, Push type clutch dry, Push type clutch 4.02 Facing dia (mm) 380 - Organic material 395 - Organic material...
  • Page 10 TORRO 25 INTRODUCTION SR. NO. MODEL TORRO 25CARGO TORRO 25TIPPER WHEELS & TYRES 9.01 Rim size 7.5"×20" 7.5"×20" 10×20-16PR 9.02 Tyre (Front) 10×20-16PR / 10R20 - 16PR 10R20 (optional) FRAME 10.01 Section / Thickness Parallel / 285×70×9.5 Parallel / 285×70×9.5 10.02...
  • Page 11 INTRODUCTION TORRO 25 SR. NO. MODEL TORRO 25CARGO TORRO 25TIPPER FUEL TANK 15.01 Type Steel rectangular Steel rectangular 417 Ltrs 15.02 Capacity (Litres) 250L (Optional 250L, 350L) CAB/COWL 16.01 Type Sl cab Day cab 16.02 Cab / cowl length 2270 1675 16.03...
  • Page 12 DIFFERENTIAL TORRO 25 WORKSHOP MANUAL (In continuation with TORRO 25 WM)

  • Page 14: Table Of Contents

    TORRO 25 DIFFERENTIAL & REAR AXLE CONTENTS General information ....................................26 Specifications ........................................ 27 Special tools ........................................28 Tightning torque ......................................34 Disassembly ........................................Removal of differential carrier from the axle housing ........................35 Disassembly of differential / interaxle assembly ..........................35 Removal of inter axle differential assembly ............................

  • Page 15: General Information

    DIFFERENTIAL & REAR AXLE TORRO 25 1. GENERAL INFORMATION TORRO 25 is equipped with meritor MT 1495 tendam series of axle. Both the axles are fitted with differential unit, so both are live axles. They are connected with interaxle shaft fitted in between two differential unit (Refer Fig.

  • Page 16: Specifications

    TORRO 25 DIFFERENTIAL & REAR AXLE 2. SPECIFICATIONS SR. NO. DESCRIPTION SPECIFICATION Oil grade SAE 85W140 with 6.5% Anglomol by weight of API GL5 Oil filling capacity 31.5 Litrs. (17 + 14.5 Litrs.) Oil change interval First at 500 Hrs & then after every 1500 Hrs.

  • Page 17: Special Tools

    DIFFERENTIAL & REAR AXLE TORRO 25 3. SPECIAL TOOLS TOOL NAME PART NO SHAPE OF THE TOOL USAGE OF THE TOOL Inner bearing puller 7006AAQ0004ST pinion front & rear Side bearing 7006AAQ0005ST adjuster Differential side bearing puller 7006AAQ0006ST (LH & RH) common...
  • Page 18 TORRO 25 DIFFERENTIAL & REAR AXLE TOOL NAME PART NO. SHAPE OF THE TOOL USAGE OF THE TOOL Removing sleeve 7006AAQ0007ST use with 8ST & 9ST Pinion inner bearing cup 7006AAQ0008ST remover Pinion outer bearing cup 7006AAQ0009ST remover Interaxle rear...
  • Page 19 DIFFERENTIAL & REAR AXLE TORRO 25 TOOL NAME PART NO. SHAPE OF THE TOOL USAGE OF THE TOOL Interaxle flange cage pinion outer 7006AAQ0011ST bearing cup remover Differential side 7006AAQ0012ST bearing installer Pinion inner 7006AAQ0014ST bearing installer Interaxle rear bearing cone...
  • Page 20 TORRO 25 DIFFERENTIAL & REAR AXLE TOOL NAME PART NO. SHAPE OF THE TOOL USAGE OF THE TOOL Interaxle front bearing cone 7006AAQ0017ST installer Rear flange pinion inner & 7006AAQ0018ST outer cup installer Interaxle differential rear 7006AAQ0019ST bearing cup installer...
  • Page 21 DIFFERENTIAL & REAR AXLE TORRO 25 TOOL NAME PART NO. SHAPE OF THE TOOL USAGE OF THE TOOL Interaxle differential front 7006AAQ0021ST bearing cup installer Installer sleeve 7006AAQ0022ST use with 19 & 20ST Interaxle differential oil seal 7006AAQ0024ST installer Input shaft bearing...
  • Page 22 TORRO 25 DIFFERENTIAL & REAR AXLE TOOL NAME PART NO. SHAPE OF THE TOOL USAGE OF THE TOOL Interaxle Input shaft front bearing 7006AAQ0035ST puller (Big) Rear pinion inner cage bearing 7006AAQ0036ST cup remover Pinion cage outer bearing 7006AAQ0039ST cup installer...

  • Page 23: Tightning Torque

    DIFFERENTIAL & REAR AXLE TORRO 25 TOOL NAME PART NO. SHAPE OF THE TOOL USAGE OF THE TOOL Rear differential flange oil seal 7006AAQ0044ST installer TIGHTNING TORQUE SR.NO. PART THREAD SIZE (DIA×PITCH) TORQUE VALUE (Nm) Pinion check nut M42×15×2 814 - 1085 Pinion cover mounting bolts M12×1.5...

  • Page 24: Disassembly

    TORRO 25 DIFFERENTIAL & REAR AXLE DISASSEMBLY DISASSEMBLY OF DIFFERENTIAL / INTERAXLE ASSEMBLY : REMOVAL OF DIFFERENTIAL CARRIER FROM THE 11. Loosen the thrust screw jam nut & remove the thrust AXLE HOUSING : screw from the side of the carrier (Refer Fig. 3).
  • Page 25 DIFFERENTIAL & REAR AXLE TORRO 25 16. Remove the pinion cover along with the gasket from the differential cage by unscrewing the mounting bolts (Refer Fig. 9). Fig. 6 14. Keep the differential assembly in vertical position in the stand (Refer Fig. 7).
  • Page 26 TORRO 25 DIFFERENTIAL & REAR AXLE 18. Loosen the inter axle cage bolts. 21. Take the shim pack aside (Refer Fig. 13). 19. Keep the differential unit in vertical position. Check all the mounting bolts are removed from the inter axle cage assembly. By using the long tomy bar or hydraulic lifter lift the inter axle assembly vertically upwards.
  • Page 27 DIFFERENTIAL & REAR AXLE TORRO 25 24. The inter axle drive assembly is as shown in the 27. Remove the retainer snap ring from the input figure (Refer Fig. 16). shaft (Refer Fig. 19 & 20). Fig. 16 Fig. 19 25.
  • Page 28 TORRO 25 DIFFERENTIAL & REAR AXLE 29. Take out the helical drive gear. It will easily slide 31. Remove clutch collar from the input shaft (Refer on the shaft (Refer Fig. 22). Fig. 25). Fig. 22 Fig. 25 30. Remove the thrust washer from the input shaft 32.
  • Page 29 DIFFERENTIAL & REAR AXLE TORRO 25 33. Take away the flange (Refer Fig. 28). 36. Now the input shaft is free from any assembly (Refer Fig. 31). Fig. 28 Fig. 31 34. Remove bearing cage from the input shaft. If required use hydraulic press for removal of bearing cage (Refer Fig.

  • Page 30: Removal Of Inter Axle Differential Assembly

    TORRO 25 DIFFERENTIAL & REAR AXLE REMOVAL OF INTER AXLE DIFFERENTIAL ASSEMBLY 39. Separate the two half by tapping by mallet (Refer Fig. 35). 37. Mark the differential upper & lower half with a straight line correct alignment while assembling (Refer Fig. 32 & 33).

  • Page 31: Removal Of Crown Pinion Assembly

    DIFFERENTIAL & REAR AXLE TORRO 25 REMOVAL OF CROWN PINION ASSEMBLY : 43. Mark the RH & LH side bearing cap so that while assembling it is easier to match the mating parts. 44. Remove the quarter pin from both the caps.
  • Page 32 TORRO 25 DIFFERENTIAL & REAR AXLE 50. Separate the case halves. If required use soft mallet to loosen the parts (Refer Fig. 46 & 47). Fig. 43 47. Lift the crown assembly by using the tommy bar or by hydraulic lifter (Refer Fig. 44).
  • Page 33 DIFFERENTIAL & REAR AXLE TORRO 25 53. Remove four star gears, thrust washer along with 56. Take away the crown ring gear from half by spider cross (Refer Fig. 49). loosining the mounting bolts (Refer Fig. 51). Fig. 49 Fig. 51 54.

  • Page 34: Removal Of Pinion Assembly From Differential Cage

    TORRO 25 DIFFERENTIAL & REAR AXLE REMOVAL OF PINION ASSEMBLY FROM 59. Hammer on the pinion shaft by using mallet in DIFFERENTIAL CAGE : between the pinion shaft or use hydraulic press for removal of pinion assembly. Care has to take 57.
  • Page 35 DIFFERENTIAL & REAR AXLE TORRO 25 62. Remove the spacer from the housing (Refer Fig. 64. Remove the inner bearing cup, outer bearing cup 57). by using the special tool (Refer Fig. 60). Check the number of shims (Refer Fig. 61) & thickness (Refer Fig.

  • Page 36: Dismantling Pinion Assembly

    TORRO 25 DIFFERENTIAL & REAR AXLE DISMANTLING PINION ASSEMBLY : PINION ASSEMBLY : 65. Remove bearing spacer. Before assembly clean the housing with kerosene compressed air. 66. Remove the pinion lower bearing by using the bearing puller (Refer Fig. 63).

  • Page 37: Shim Pack Thickness Calculation For A New Drive Pinion

    DIFFERENTIAL & REAR AXLE TORRO 25 SHIM PACK THICKNESS CALCULATION FOR A NEW 69. Find the pinion cone (PC) variation number on DRIVE PINION the drive pinion you’ll replace. Record the number. The pinion cone number can be one of If a new crown wheel and Pinion is used, the depth of the following values (Refer Fig.

  • Page 38: Shim Pack Thickness Calculation

    TORRO 25 DIFFERENTIAL & REAR AXLE TABLE 1 - SHIM PACK THICKNESS CALCULATION EXAMPLES SHIM SIZE (MM) Old shim pack thickness. 0.760 – 0.050 = 0.710 Old PC number, PC + 0.05 mm standard shim pack thickness. 0.710 + 0.130 = 0.840 New PC number, PC + 0.13 mm...
  • Page 39 DIFFERENTIAL & REAR AXLE TORRO 25 76. Install the lower bearing on the pinion (Refer Fig. 79. Insert the pinion from the bottom & pass through 70). the gear (Refer Fig. 73 & 74). Fig. 70 Fig. 73 77. Install the upper bearing cone (Refer Fig. 71).

  • Page 40: Crown Wheel Assembly

    TORRO 25 DIFFERENTIAL & REAR AXLE 81. Install the upper bearing on the pinion (Refer Fig. CROWN WHEEL ASSEMBLY : 76 & 77). 84. Fit the lower half to the ring gear (Refer Fig. 79). Fig. 76 Fig. 79 85. Assemble the bottom sun gear along with the thrust washer (Refer Fig.
  • Page 41 DIFFERENTIAL & REAR AXLE TORRO 25 86. Check the backlash of the gears (Refer Fig. 81). 89. Assemble the top half and torque both the left and right hubs (Refer Fig. 84). Fig. 81 Fig. 84 87. Assemble four star gears & upper sun gear with washers along with the cross (Refer Fig.

  • Page 42: Preloading Of The Pinion Bearing

    TORRO 25 DIFFERENTIAL & REAR AXLE 92. Lift the crown assembly & insert in the 95. Adjust the backlash for used set 0.20 – 0.46 mm diffrerential cage (Refer Fig. 87). & for new set adjustthe backlash up to 0.20 –...

  • Page 43: Inter Axle Assembly

    DIFFERENTIAL & REAR AXLE TORRO 25 INTER AXLE ASSEMBLY : 104. Fit the oil seal in the cage (Refer Fig. 94). 102. Install the bearing on the shaft by using the bearing installer (Refer Fig. 91 & 92). Fig. 94 105.
  • Page 44 TORRO 25 DIFFERENTIAL & REAR AXLE 107. Install the flange on the cage & tightened the nut 109. Insert thrust washer (Refer Fig. 100). (Refer Fig. 97 & 98). Fig. 100 Fig. 97 110. Slide helical gear on the input shaft.
  • Page 45 DIFFERENTIAL & REAR AXLE TORRO 25 114. Align this inter axle assembly on the input shaft NOTE with the bolt head towards the rear.Engage the teeth of the pinion with the teeth on the helical Do not use removed thrust washer.

  • Page 46: Assembly Of Inter Axle Differential In The Housing

    TORRO 25 DIFFERENTIAL & REAR AXLE ASSEMBLY OF INTER AXLE DIFFERENTIAL IN THE 119. Install the old shim pack on the housing HOUSING : (Refer Fig. 111). 116. Install the bearing on the in put shaft gear (Refer Fig. 108).
  • Page 47 DIFFERENTIAL & REAR AXLE TORRO 25 122. Adjust the end play up to 0.05-0.20 mm vertically 125. Fit the inter axle shift fork assembly. Use proper by using shims.Add shims to increase end play & sealent & tight the mounting bolts (Refer Fig.

  • Page 48: Dismantling Of Rear Rear Differential Assembly

    TORRO 25 DIFFERENTIAL & REAR AXLE DISMANTLING OF REAR REAR DIFFERENTIAL 134. Take away the pinion assembly from the housing ASSEMBLY : (Refer Fig. 120). 128. Remove the differential assembly from the axle housing as per the process given in the first axle removal.
  • Page 49 DIFFERENTIAL & REAR AXLE TORRO 25 139. Remove the upper bearing,oil seal from top by tapping from inner side (Refer Fig. 126 & 127). Fig. 123 137. Remove the bearing spacer (Refer Fig. 124). Fig. 126 Fig. 124 Fig. 127 138.

  • Page 50: Inspection

    TORRO 25 DIFFERENTIAL & REAR AXLE 142. Remove the bearing from pinion (Refer Fig. 132). Fig. 129 141. Remove the circlip & washer of tail pinion pilot Fig. 132 bearing (Refer Fig. 130 & 131). INSPECTION Inspect pinion for any abnormal wear on the teeth, bearings &...

  • Page 51: Assembly

    DIFFERENTIAL & REAR AXLE TORRO 25 ASSEMBLY 145. Assemble the washer & circlip of tail pinion pilot bearing (Refer Fig. 135 & 136). Before assembly clean the housing carefully with kerosene & compressed air. 143. Install the bearing on the pinion by using the special tool (Refer Fig.
  • Page 52 TORRO 25 DIFFERENTIAL & REAR AXLE 147. Install both the bearing cups in the cage by using 149. Install the upper pinion bearing in the bearing installer (Refer Fig. 138 & 139). cage (Refer Fig. 141 & 142). Fig. 138 Fig.
  • Page 53 DIFFERENTIAL & REAR AXLE TORRO 25 151. Install the washer (Refer Fig. 144). Fig. 147 Fig. 144 155. Keep the same shim pack, if you are using the same unit. If you are replacing the unit then use 152. By using oil seal installer fit the oil seal in the cage same pattern of shim selection as per first axle (Refer Fig.

  • Page 54: Crown Wheel Assembly

    TORRO 25 DIFFERENTIAL & REAR AXLE CROWN WHEEL ASSEMBLY : 159. Check the backlash of the gears (Refer Fig. 152). 157. Fit the lower half to the ring gear (Refer Fig. 150). Fig. 152 160. Assemble four star gears along with washers and Fig.

  • Page 55: Differential Assembly

    DIFFERENTIAL & REAR AXLE TORRO 25 DIFFERENTIAL ASSEMBLY : 164. Lift the crown assembly by using the tommy bar or by hydraulic lifter & fit in the hosing (Refer Fig. 158 & 159). Fig. 155 162. Fit the case halves. Use mallet for fitment as per the mark (Refer Fig.
  • Page 56 TORRO 25 DIFFERENTIAL & REAR AXLE 166. Assemble two bearing caps & adjusting rings. 168. Adjust the thrust pad screw (Refer Fig. 163). Keep the assembly of bearing cap & adjuster ring of left and right seperately (Refer Fig. 161).

  • Page 57: Install And Adjust Ring Gear Thrust Bolt

    DIFFERENTIAL & REAR AXLE TORRO 25 INSTALL AND ADJUST RING GEAR THRUST BOLT New Gearing - Correct Pattern Procedure Paint six ring gear teeth 180° apart with marking compound and roll the gear to obtain a contact 169. Thread thrust screw into the carrier until firm pattern.
  • Page 58 TORRO 25 DIFFERENTIAL & REAR AXLE Adjust Contact Pattern If the pattern is too close to the root of the gear tooth, add pinion shims. Move pinion away from the ring gear. If necessary, adjust the contact pattern by moving the (Refer Fig.

  • Page 59: Installation Of Differential Assembly To Its Housing

    DIFFERENTIAL & REAR AXLE TORRO 25 If the pattern is concentrated at the heel (too far up the 10. INSTALLATION OF DIFFERENTIAL tooth), move the ring gear toward the pinion to ASSEMBLY TO ITS HOUSING decrease backlash. (Refer Fig. 170) 180.

  • Page 60: Shim Pack Thickness Calculation For A New Drive Pinion

    TORRO 25 DIFFERENTIAL & REAR AXLE 11. SHIM PACK THICKNESS CALCULATION 185. Find the pinion cone (PC) variation number (Refer FOR A NEW DRIVE PINION Fig. 173) on the drive pinion you’ll replace. Record the number. The pinion cone number can be one If a new crown wheel and Pinion is used, the depth of of the following values.
  • Page 61 DIFFERENTIAL & REAR AXLE TORRO 25 12. SHIM PACK THICKNESS CALCULATION TABLE 1 - EXAMPLES SHIM SIZE (MM) Old shim pack thickness. 0.760 – 0.050 = 0.710 Old PC number, PC + 0.05 mm standard shim pack thickness. 0.710 + 0.130 = 0.840 New PC number, PC + 0.13 mm...

  • Page 62: Trouble Shooting

    TORRO 25 DIFFERENTIAL & REAR AXLE 13. TROUBLE SHOOTING SR. NO. SYMPTOM PROBABLE CAUSE REMEDY Oil leaks Oil leaks from companion flange Oil overcharge Correct quantity ● ● Worn or damaged oil seal Replace ● ● Oil leaks from differential carrier and housing...
  • Page 63 DIFFERENTIAL & REAR AXLE TORRO 25 SR.NO. SYMPTOM PROBABLE CAUSE REMEDY Continuous Poor adjustment of final drive gear Adjust or replace ● ● abnormal noise backlash or tooth contact or during drive worn teeth Poor preload adjustment of final Adjust or replace ●...
  • Page 64 BRAKES TORRO 25 WORKSHOP MANUAL (In continuation with TORRO25 WM)
  • Page 66 TORRO 25 BRAKES CONTENTS Brake circuit ..............................78 Specifications .............................. 79 Tightning torque ............................81 View of automatic load sensing valve assembly ................ 83 Auto load sensing valve (ALSV) ......................84 Function ................................ 86 Operation ..............................86 Auto load sensing valve : Fitment on the vehicle ..............87...

  • Page 67: Brake Circuit

    BRAKES TORRO 25 1. BRAKE CIRCUIT (Refer Fig. 1) Fig. 1...

  • Page 68: Specifications

    TORRO 25 BRAKES 2. SPECIFICATIONS SR.NO. ITEM DESCRIPTION SPECIFICATION Brake pedal Brake pedal full stroke 95 mm Air compressor Air compressor type Water cooled Stroke 46 mm Displacement 230 cc Max pressure 10 bar Drive Gear Cooling type Water Lubricant type...
  • Page 69 BRAKES TORRO 25 STANDARD TIPPER SR.NO. ITEM DESCRIPTION SPECIFICATION Spring brake actuator Type Pneumatic Max working pressure 10 bar Normal working stroke 35-45 mm Max working stroke 57 mm Effective diaphragm area 24 inch Spring hold of pressure 4.3+/-0.4 bar...

  • Page 70: Tightning Torque

    TORRO 25 BRAKES 3. TIGHTNING TORQUE / SERVICE STANDARDS SERVICE SR. NO. DESCRIPTION NOMINAL VALUE STANDARDS (mm) Brake pedal Brake pedal play Pedal installed length Stop lamp switch installation clearance Pedal full working stroke 95 mm Pedal to fork bore clearance...
  • Page 71 BRAKES TORRO 25 STANDARD TIPPER SERVICE SR. NO. DESCRIPTION NOMINAL VALUE STANDARDS (mm) Brake chamber Normal working stroke 35 - 45 mm Stand out stroke 72 mm Spring brake actuator Normal working stroke 35 - 45 mm Stand out stroke...
  • Page 72 TORRO 25 BRAKES 4. VIEW OF AUTO LOAD SENSING VALVE ASSEMBLY (ALSV) (Refer Fig. 2) Fig. 2...

  • Page 73: Auto Load Sensing Valve (Alsv)

    BRAKES TORRO 25 AUTO LOAD SENSING VALVE (ALSV) (EXPLODED VIEW) (Refer Fig. 3) Fig. 3...
  • Page 74 TORRO 25 BRAKES MAIN ASSEMBLY : AUTO LOAD SENSING VALVE (Refer Fig. 3) Components SR. NO. DESCRIPTION SR. NO. DESCRIPTION Upper body Seal Sealing ring Diaphragm retainer Body Lower body Valve Dust seal Spring Clamp ring Sealing ring Collet Dust cap...

  • Page 75: Function

    BRAKES TORRO 25 FUNCTION The Automatic Load Sensing Valve (ALSV) has been The applied pressure is thus regulated in proportion to designed to regulate the braking force on a particular vehicle spring deflection. As the effective area of the axle in proportion to the load on that axle, and is...
  • Page 76 TORRO 25 BRAKES LINK ACTUATION MECHANISM Fig. 4 Fig. 5 SR. NO. PART NUMBER DESCRIPTION 7708AAQ00030N Automatic load sensing valve (150 mm) 7715EAQ00060N ALSV MTG bracket 7715EAQ00030N Verticle link rod (Dia. 8) 7708AAQ00010N Arm assembly (105 mm) SF0201099 Screw hex M12×1, 5×20×8, 8×GR...

  • Page 77: Setting Procedure

    BRAKES TORRO 25 AUTO LOAD SENSING MECHANISM CONSIST OF 1. Link rod mechanism 2. Auto load sencing valve Link rod mechanism consist of vertical link rod, actuating arm assembly & rubber pad. Adjustment : LCRV lever angle setting to be done at 14 ±2.5...

  • Page 78: Troubleshooting

    TORRO 25 BRAKES TROUBLESHOOTING SYMPTOM PROBABLE CAUSE ACTION Excessive wear of brake lining/ Obstruction in returning of slack adjuster during brake release. brake drum over heating/ brake pulling ● Control arm misalignment with Correct the mis-alignment by the anchor bracket and loosening the nut of the chamber stretched during fixing.
  • Page 79 BRAKES TORRO 25 STANDARD TIPPER NOTES...
  • Page 80 HYDRAULICS TORRO 25 WORKSHOP MANUAL (In continuation with TORRO 25WM)
  • Page 82 TORRO 25 HYDRAULICS CONTENTS General information ..............................94 Specifications ................................100 Tightening torque ..............................100 Removal of tipper body from the vehicle ...................... 101 Assembly sequence ..............................101 Tail gate opening & locking mechanism adjustment ................. 103 Air cylinder ................................... 104 Removal from vehicle ..............................

  • Page 83: General Information

    HYDRAULICS TORRO 25 1. GENERAL INFORMATION Fig. 1 HYDRAULICS (Refer Fig. 2) Fig. 2...
  • Page 84 TORRO 25 HYDRAULICS TIPPING CYLINDER P.T.O. (HYVA) This is hydraulic cylinder used for lowring and tipping A P.T.O. (Refer Fig. 5) (Power Take Off ) is an auxillary gear operation of tipper body. (Refer Fig. 3) box mounted on the transmission. Its function is to transmit the power from rotation of the engine.

  • Page 85: Idle Condition

    HYDRAULICS TORRO 25 PT VALVE (HYVA) AIR CONTROL VALVE The PT Valve is mounted on the hydraulic tank (Refer Air Control Valve is mounted in the cabin close to driver Fig. 7). PT valve delivers 220 liters of oil per minute.
  • Page 86 TORRO 25 HYDRAULICS IDLE CONDITION WITH PTO ENGAGED Fig. 10 TIPPING FUNCTION Fig. 11...
  • Page 87 HYDRAULICS TORRO 25 PRESSURE RELEIF FUNCTION Fig. 12 LOWERING FUNCTION Fig. 13...
  • Page 88 TORRO 25 HYDRAULICS HYFIX PROCEDURE FOR TIPPING AND LOWERING OF TIPPER BODY Hyfix clamp mounted underneath the body, stops rattling of the empty tipper body on the chassis and thus prevents damage to the chassis, structural part and sub- frame and reduce the noise nuisance (Refer Fig. 14).

  • Page 89: Specifications

    HYDRAULICS TORRO 25 SPECIFICATIONS SR. NO. TIPPER BODY & HYDRAULICS SPECIFICATION Tipper body with tail gate operated along with body 4915×2340×1400 mm (Internal) for 16 m 6210×2518×2406 mm (External) Tipper body with tail gate operated along with body 4895×2340×1230 mm (Internal) for 14 m 6210×2518×2406 mm (External)

  • Page 90: Removal Of Tipper Body From The Vehicle

    TORRO 25 HYDRAULICS 4. REMOVAL OF TIPPER BODY FROM THE 5. ASSEMBLY SEQUENCE VEHICLE Lift the tipper body by using crane. The rope hooks provided on the side panel for lifting. Park the vehicle on the level road,apply hand brake &...
  • Page 91 HYDRAULICS TORRO 25 Three numbers of outriger brackets to be fitted as follows (Refer Fig. 18) : Fig. 18 The spring to be compressed till the solid length and released as follows : Outrigger Released by 10 mm Outrigger Released by 8 mm A.

  • Page 92: Tail Gate Opening & Locking Mechanism Adjustment

    TORRO 25 HYDRAULICS 6. TAIL GATE OPENING & LOCKING 16. Locking Pin used for holding CAM and Tie Rod assembly should be mounted at a distance of MECHANISM ADJUSTMENT 101mm from Rod of Hammer Assembly (Refer Fig. 21). 14. Pin of Profile Plate Assembly which passes through CAM should be mounted at a distance of 120 mm with respect to rod of hammer assembly (Refer Fig.

  • Page 93: Air Cylinder

    HYDRAULICS TORRO 25 18. Tight the Nut, such that there should be no gap 7. AIR CYLINDER between Hinge and hood (Refer Fig. 23). REMOVAL FROM VEHICLE 21. Park the tipper on good, firm and even ground(Refer Fig. 25). Fig. 23 19.
  • Page 94 TORRO 25 HYDRAULICS 23. Lift the cylinder and install the prop (Refer Fig. 27 & 28). Fig. 30 26. Disconnect the cylinder hose after releasing the Fig. 27 hydraulic pressure. Collect the spillage oil in a tray (Refer Fig. 31).
  • Page 95 HYDRAULICS TORRO 25 28. Remove the bolt of one bracket and slide cylinder mounting bracket from the cradle (Refer Fig. 33). Fig. 33 29. Slide the cylinder away from the bracket with help of tyre lever (Refer Fig. 34). Fig. 34 30.

  • Page 96: Tipping Cylinder (Exploded View)

    TORRO 25 HYDRAULICS TIPPING CYLINDER (EXPLODED VIEW) (FE 129-3-03850-001A-K1609-HD3-HC) Fig. 36 SR. NO. DESCRIPTION SR. NO. DESCRIPTION Tipping cylinder Slider 110 FE 129-3-03850-001A-K1609-HD3-HC Liftring 110 Packset Piston S 091-1525-HD3-HC Base Pin round head grooved 6×15 MM Seal bottom plate O-ring piston top 091...

  • Page 97: Cylinder Disassembly

    HYDRAULICS TORRO 25 CYLINDER DISASSEMBLY 34. Detorque the cap end cover bolts and remove (Refer Fig. 40). 31. Clean the cylinder external surface and keep cylinder in a clear place or on V block (Refer Fig. 37). Fig.40 35. Install four long bolt with the lock plates to remove the cap end cover (Refer Fig.
  • Page 98 TORRO 25 HYDRAULICS 37. Tap the Third stage piston rod out. Remove piston 40. Remove Second stage Dia 110 piston rod out from bearing (Refer Fig. 43). Cylinder (Refer Fig. 46). Fig.43 Fig.46 38. Remove third stage Dia 91 piston rod out from 41.

  • Page 99: Inspection

    HYDRAULICS TORRO 25 INSPECTION CYLINDER ASSEMBLY 43. Check all the three stages of the cylinder outer Clean the cylinder outer surface and apply small layer of surface for any scoring marks / band. grease. 44. Check the bottom lock plate condition.
  • Page 100 TORRO 25 HYDRAULICS 48. Assemble (110 Dia tube S/A) 2nd Stage 51. Assemble the 3rd stage piston bearings. Use (Refer Fig. 51). sufficient grease. Slide the 3rd stage tube fully inside the 2nd ,1st & outer tube (Refer Fig. 54).
  • Page 101 HYDRAULICS TORRO 25 55. Assemble rod eye and lock by tightening the grub screw. (hand tight) (Refer Fig. 60 & 61). Fig. 57 Fig. 60 Fig. 58 54. Assemble the lock plate & bolts. Tighten equally. Fig. 61 (Refer Fig. 59)

  • Page 102: Disassembly Of The Seals From The Piston

    TORRO 25 HYDRAULICS 62. Remove rod bearings from all tubes (L Shape) DISASSEMBLY OF THE SEALS FROM THE PISTON (Refer Fig. 64). (Refer Fig. 62) 56. Remove wipers from the tubes. 57. Remove rod bearings from all tubes’ shape 58. Remove back up rings & O rings.

  • Page 103: Inspection

    HYDRAULICS TORRO 25 65. Remove rod seals (Refer Fig. 67). 8. ROD SEAL ASSEMBLY 73. Assemble the rod seals ( make kidney shape for Insertion) (Out tube, First & second Stage. Ensure direction of lip. Lip should always face pressure side (Refer Fig.
  • Page 104 TORRO 25 HYDRAULICS 75. Assemble O rings & back up ring for all stages 78. Apply clean white grease on the seal area. (O ring, (Back up ring towards out side) (Refer Fig. 70). rod seal, bearings & wiper) (Refer Fig. 73 & 74) Fig.

  • Page 105: Mounting Of The Cylinder

    HYDRAULICS TORRO 25 MOUNTING OF THE CYLINDER 81. Slide the bracket into the cross members. Align fastening holes (Refer Fig. 77) of the bracket and 79. Mount one of cylinder mounting bracket (Refer Fig. the cross member. Use specified screws, washers 75) on to the cross members.

  • Page 106: Air Control Valve

    TORRO 25 HYDRAULICS 85. Remove the plug (Refer Fig. 78) from the oil inlet 92. Repeat the reverse procedure to fit the air control and connect the cylinder to the hydraulic system. valve in the cabin. Connect the hose to the inlet with sufficient loop, so that it is not obstructing the movement of the 10.
  • Page 107 HYDRAULICS TORRO 25 PT VALVE (EXPLODED VIEW) (Refer Fig. 81) Fig. 81 SR. NO. DESCRIPTION SR. NO. DESCRIPTION SR. NO. DESCRIPTION Housing Spring Bonded seal Aluminium head Retaining ring Straight coupling Spring disk ‘O’ Ring Blind plug Plunger Quadring Blind plug...

  • Page 108: Pto Pump And Pto

    TORRO 25 HYDRAULICS 11. PTO PUMP AND PTO 99. Loosen the nut of PTO (Refer Fig. 85). REMOVAL FROM VEHICLE 96. Lock the hydraulic tank knob, so that the oil does not fall out from the hydraulic tank. (Refer Fig. 82) Fig.
  • Page 109 HYDRAULICS TORRO 25 Fig. 88 Fig. 91 102. Remove the drain plug on gear box and drain the 104. Take out the shims from gear box countershaft rear gear oil (Refer Fig. 89). end. (Refer Fig. 92) Fig. 89 Fig. 92 103.

  • Page 110: Pto Pump

    TORRO 25 HYDRAULICS 12. PTO PUMP (EXPLODED VIEW) (Refer Fig. 93) Fig. 93 SR. NO. DESCRIPTION SR. NO. DESCRIPTION Body Circlip Cover Lock ring Screw Roller bearing Washer Support shaft Driver shaft Roller bearing Driven shaft Oil rings Housing ‘O’ ring...

  • Page 111: Disassembly

    HYDRAULICS TORRO 25 DISASSEMBLY 108. Make the two halves seperate by using mallet. Do not use hammer (Refer Fig. 97 & 98). 105. Loosen the adoptors of hydraulic pipe connection. (Refer Fig. 94) Fig. 97 Fig. 94 106. Loosen the allen bolts (8 Nos.) (Refer Fig. 95) Fig.
  • Page 112 TORRO 25 HYDRAULICS 110. Take out drive shaft & driven shaft from the 112. Take out support shaft gear along with gear by housing (Refer Fig. 100 & 101). removing snap ring (Refer Fig. 103). Fig. 100 Fig. 103 113. Remove the housing spacer along with oil seal (Refer Fig.

  • Page 113: Inspection

    HYDRAULICS TORRO 25 115. Remove the support shaft oil seal (Refer Fig. 106). 121. Fit the ‘O’ ring in the housing (Refer Fig. 108). Fig. 106 Fig. 108 INSPECTION 122. Fit the thrust plate in the housing. Ensure backup ring fitted (red color) in the thrust plate 116.
  • Page 114 TORRO 25 HYDRAULICS 124. Fit the housing of support shaft on the driver and 127. Fit the gear on the support shaft (Refer Fig. 114 & driven shaft (Refer Fig. 111). 115). Fig. 114 Fig. 111 125. Insert the snap ring (Refer Fig. 112).

  • Page 115: Pto

    HYDRAULICS TORRO 25 13. PTO (EXPLODED VIEW) (Refer Fig. 117) Fig. 117 SR. NO. DESCRIPTION SR. NO. DESCRIPTION Housing Shaft seal (50×72×8) Driven gear Z 22 Gasket Deep groove NR6010 bearing Stud (M12×60l) Needle roller bearing (BK 3020) Hex nut (M12)

  • Page 116: Dismantling

    TORRO 25 HYDRAULICS DISMANTLING 136. Take out the packing (Refer Fig. 120). 132. Remve the PTO pump away from PTO. 133. Remove air connection knob from PTO & plastic plug. 134. Disconnect PTO from gear box. (Refer Fig. 118) Fig. 120 137.
  • Page 117 HYDRAULICS TORRO 25 139. Make the flange & housing seperately by using 142. Take out the needle roller bearing away from mallet (Refer Fig. 123 & 124). housing (Refer Fig. 126). Fig. 123 Fig. 126 143. Turn the PTO over to drive gear.

  • Page 118: Inspection

    TORRO 25 HYDRAULICS 145. Take out drive gear from the housing OPERATION CHECK LIST : (Refer Fig. 129). WARNING Do not engage or disengage the PTO with out pressing the clutch pedal. If not the drive gear internal splines will get wornout.

  • Page 119: Pto Pump Mounting Bolt Torque

    HYDRAULICS TORRO 25 PTO PUMP MOUNTING BOLT TORQUE (Refer Fig. 131 & 132) Fig. 131 Fig. 132...

  • Page 120: Hyfix

    TORRO 25 HYDRAULICS 14. HYFIX (Refer Fig. 133) Fig. 133 SR. NO. DESCRIPTION SR. NO. DESCRIPTION Hyfix assembly Pin-2 Power block (Rubber pad) Pin-1 Compresion plate Frame Pin-3 Mounting eye Locking plate Hook Hyfix pivoting Securing pin Stud with nut...

  • Page 121: Hydraulic Tank Mounting

    HYDRAULICS TORRO 25 15. HYDRAULIC TANK MOUNTING (Refer Fig. 134) Fig. 134 ITEM CODES FOR SPARES SR. NO. DESCRIPTION QTY. SR. NO. DESCRIPTION QTY. Cradle mounting Hydraulic oil tank Return oil filter assembly Rubber base pad Breather assembly Rubber strap...

  • Page 122: Return Line Filter Assembly

    TORRO 25 HYDRAULICS 16. RETURN LINE FILTER ASSEMBLY Return line filter assembly is located on top of the hydraulic oil tank & adjacent to tipping valve. Oil from cylinder on its return path, (Cylinder Tipper Valve) flows to the tank through return line filter.

  • Page 123: Air Breather (Breather Filter Assembly)

    HYDRAULICS TORRO 25 17. AIR BREATHER ( BREATHER FILTER ASSEMBLY Breather Assembly As the name indicates, this helps the Hydraulic oil tank to ‘Breath in’ or ‘Breath out’ air, in order to maintain the atmospheric pressure inside tank, even when there is lower level of oil (in tipped condition) or higher level of oil (due to lowering down or heat generation in the system), in order to prevent any kind of deformation of tank.

  • Page 124: Location Of Return Line Filter And Breather Assembly

    TORRO 25 HYDRAULICS 18. LOCATION OF RETURN LINE FILTER AND BREATHER ASSEMBLY (Refer Fig. 137) Fig. 137...

  • Page 125: Greasing Points

    HYDRAULICS TORRO 25 19. GREASING POINTS (Refer Fig. 138) Fig. 138 SR. NO. DESCRIPTION Cylinder mounting bracket Cylinder piston eye Rear hinge greasing Tail door locking mechanism Tail door hinge Body prop Hyfix...

  • Page 126: Do's & Don'ts

    TORRO 25 HYDRAULICS 20. DO’S & DON’TS Don’ts Do’s Do not tamper the relief valve setting. Grease the mounting brackets & all pin every day. ● ● Do not open the cylinder, valve or pump by local ● Change the Hydraulic filter within the specified ●...

  • Page 127: Troubleshooting

    HYDRAULICS TORRO 25 21. TROUBLESHOOTING SYMPTOM PROBABLE CAUSE ACTION Valve works properly but • Broken air tube Check air tubes and replace as suddenly fails required Cylinder jerks when extending • Air in the system Bleed the pump by slightly...
  • Page 128 TORRO 25 HYDRAULICS SYMPTOM PROBABLE CAUSE ACTION • Cylinder is connected to • Connect cylinder to port ‘A’ wrong Valve port Air supply correct but tipping • Air control fault • Remove all air tubes except valve does rot gel actuated feed and exhaust.

  • Page 129: Operational / Abuse Failure

    HYDRAULICS TORRO 25 22. OPERATIONAL / ABUSE FAILURE SYMPTOM PROBABLE CAUSE ACTION 1. TIPPING CYLINDER Cylinder bent • Tipping on uneven ground Educate the operator • Running of vehicle by keeping Educate the operator body in tipping condition • Vehicle toppling in an accident...

  • Page 130: Hydraulic Pump

    TORRO 25 HYDRAULICS SYMPTOM PROBABLE CAUSE ACTION Piston eye coming out Poor locking arrangement Repair Cylinder base tube crack • Crack is on trunion side due to Educate the operator side loads • Crack is on all around trunion Educate the operator...
  • Page 131 HYDRAULICS TORRO 25 SYMPTOM PROBABLE CAUSE ACTION 4. TIPPER SUB-FRAME Sub frame crack • Crack develop due to not Tighten the subframe hardwares tightening mounting bolts regularly as specified • Crack due to improper loading Educate the operator pattern • Crack develops near welding joints...
  • Page 132 TORRO 25 HYDRAULICS NOTES...
  • Page 133 HYDRAULICS TORRO 25 NOTES...
  • Page 134 SUSPENSION BOGIE : WORKSHOP MANUAL...
  • Page 136 BOGIE SUSPENSION Bogie suspension is on alternate for link suspension fitted on MN 25 tipper It consist of 1. Leaf spring assembly 2. Bogie assembly 3. Torque rod Changes with respect to MN25 tipper with link suspension. Rear suspension – bogie as optional Rear leaf spring assy.
  • Page 137 SUSPENSION BOGIE 1. Centre link rod 1 No 2. Bracket 2 No 3. Suspension leaf 2 No 4. U Clamp 4 No 5. Trunion shaft 2 No 6. Torque rod 6 No 7. Bump stopper 4 No EXPLODED VIEW - BOGIE SUSPENSION Sr.
  • Page 138 BOGIE SUSPENSION 7402EAQ01420N Sub Assy Fwd Axle 7402EAQ01430N Sub Assy Rwd Axle 7402EAQ01400N Shim Torque Rod 2mm Thk As Required 7402EAQ01390N Shim Torque Rod 1mm Thk As Required 7402EAQ01410N Shim Torque Rod 3.15mm As Required 7402EAQ00920N Top Clamp Plate SF0202137 Screw Hex Fl M16x2x55x10.9...
  • Page 139 SUSPENSION BOGIE MN25 BOGIE TIPPER SERVICE SCHEDULE Parameters Frequency Torque value Check & tighten leaf spring First at PDI & then every 150 hrs 716 - 843 Nm U Bolt (4 nos) or weekly once Check & tighten torque rod First at PDI &...
  • Page 140 BOGIE SUSPENSION CONTENTS BOGIE DISMANTLING: LEAF SPRING ASSEMBLY ..........................9 TRUNION HOUSING REMOVAL ................................11 REMOVAL OF TRUNION METAL BUSH (2NOS) ..........................13 REMOVAL OF SIDE TORQUE ROD ................................14 REMOVAL OF CENTRE LINK ROD ................................15 REMOVAL OF ‘A’ BRACKET ..................................16 REMOVAL OF TRUNION SHAFT FROM ‘A’...
  • Page 141 SUSPENSION BOGIE...

  • Page 142: Bogie Dismantling: Leaf Spring Assembly

    BOGIE SUSPENSION Support the chassis at rear of the bogie & at front end BOGIE DISMANTLING: LEAF SPRING of the bogie. Take care while support that all the four ASSEMBLY corners of chassis supported properly by using screw Park the vehicle on a leveled road. Keep wheel choke jack.
  • Page 143 SUSPENSION BOGIE Loose the front & rear leaf spring top clamp. Loosen the U bolt (2 at each side). (Refer Fig. 9) (Refer Fig. 6) Fig. 9 Fig. 6 Fig. 10 Fig. 7 CAUTION Take away the top clamp bracket from front & back of Remove the U bolt from one side either LH or RH.

  • Page 144: Trunion Housing Removal

    BOGIE SUSPENSION Lift the leaf spring assembly by using proper lifter or chain pulley block. (Refer Fig. 12) Fig.14 Clean the grease observed on the trunion check nut. Fig. 12 (Refer Fig. 15) Keep the leaf spring away from working area. Check for any breakage of suspension leaf / centre bolt If any replace while assembly CATUION...
  • Page 145 SUSPENSION BOGIE Fig. 17 Fig. 20 Loosen the mounting bolt's (2 Nos) of the trunion NOTE checknut. (Refer Fig. 18) Replace the ‘O’ ring while assembly Take out the lock plate along with 'O' ring by using screw driver. (Refer Fig. 21) Fig.

  • Page 146: Removal Of Trunion Metal Bush (2Nos)

    BOGIE SUSPENSION By rotating the trunion housing clockwise & anti Using punch or screw driver remove grooved washer clockwise. (Refer Fig. 23) oil seal. (Refer Fig. 26) Fig. 23 Fig. 26 Take out the trunion housing from trunion shaft. (Refer Fig. 24) Fig.

  • Page 147: Removal Of Side Torque Rod

    SUSPENSION BOGIE Tap the copper cylindrical bearing from trunion bracket REMOVAL OF SIDE TORQUE ROD. & remove both the bearings. (Refer Fig. 29) Loosen the torque rod mounting from cross shaft link rod end take away the mounting bolt. (Refer Fig. 32) Fig.

  • Page 148: Removal Of Centre Link Rod

    BOGIE SUSPENSION Apply the same procedure for removal of other side of Remove both the caps from centre cross shaft the bogie. (Refer Fig. 37) REMOVAL OF CENTRE LINK ROD Loosen the link rod cover stud nut from both side of 'A' bracket.

  • Page 149: Removal Of 'A' Bracket

    SUSPENSION BOGIE REMOVAL OF ‘A’ BRACKET REMOVAL OF TRUNION SHAFT FROM ‘A’ BRACKET Loosen the 'A' bracket bolt fitted on chassis long member & bogie cross member. (Refer Fig. 40) After removing ‘A’ bracket remove dowl. (Refer Fig. 42) Fig. 42 Fig.

  • Page 150: Removal Of Bottom Wear Pad

    BOGIE SUSPENSION REMOVAL OF BOTTOM WEAR PAD. REMOVAL OF SIDE WEAR PAD Lift the leaf spring assembly by jack from one side. Loosen the mounting bolt fitted on the common (Refer Fig. 45) bracket for torque rod and both side & bottom wear pad.

  • Page 151: Removal Of Torque Rod Bracket

    SUSPENSION BOGIE REMOVAL OF TORQUE ROD BRACKET Loosen the bolts fitted on the axle housing. (Refer Fig. 50) Fig. 53 The bracket is fitted for bottom wear pad & torque rod as a combined set. (Refer Fig. 54) Fig. 50 Take out the upper bracket and mark for identification.

  • Page 152: Removal Of Torque Rod Bush

    BOGIE SUSPENSION Check the for slackness of the bracket with respect to On hydraulic press make arrangement for to remove dowl. (Refer Fig. 56) the bush from the torque rod, by slightly pressing down wards. (Refer Fig. 58) Fig. 56 Fig.

  • Page 153: Torque Rod Bracket

    SUSPENSION BOGIE Loosen the mounting bolts from housing center Remove the torque rod from the vehicle. (Refer Fig. 63) welded bracket & take it out. (Refer Fig. 60) Fig. 63 Fig. 60 Follow the same process for other side of the torque rod.

  • Page 154: Removal Of Bump Stopper

    BOGIE SUSPENSION Loosen the bolts from the bracket & disconnect the BUMP STOPPER BRACKET torque rod bracket fitted on the axle housing & take Loosen the four mounting bolts fitted along with away. While removing the bracket mark the postion as chassis.

  • Page 155: Trunion Shaft In 'A' Bracket

    SUSPENSION BOGIE FITMENT OF TRUNION SHAFT IN ‘A’ ‘A’ BRACKET ASSEMBLY BRACKET Fit the ‘A’ bracket on the chassis & apply the torque as specified. (Refer Fig. 73) Check ‘A’ bracket for any damage or breakage before fitment. (Refer Fig. 70) Fig.
  • Page 156 BOGIE SUSPENSION Apply small quantity of grease on the trunion shaft Fit lock plate on the shaft along with ‘O’ ring. Tap it gently from outside & trunion housing bearing from inside. on the lock plate to fit in the position. (Refer Fig. 78) (Refer Fig.

  • Page 157: Spring Assembly

    SUSPENSION BOGIE Fit the nut and apply the torque. (Refer Fig. 81) Apply torque to mounting bolts. (Refer Fig. 84) Fig.81 Fig. 84 Insert the lock bolt & tighten the nut. Apply the torque Check the trunion housing for free movement on the as specified.
  • Page 158 BOGIE SUSPENSION ASSEMBLY OF CENTRE CROSS SHAFT Fix it on the trunion along with the U bolt. Apply the torque to the U bolt nut as specified. (Refer Fig. 86) As per the marking kindly position the cross shaft. (Refer Fig. 89) Fig.

  • Page 159: Torque Rod Bracket

    SUSPENSION BOGIE CENTRAL TORQUE ROD. Tighten the nuts on the studs & apply the torque as specified. (Refer Fig. 92) Fit the torque rod bracket on the axle housing dome welded bracket. (Refer Fig. 94) Fig. 92 ASSEMBLY OF TORQUE ROD BRACKET Fig.

  • Page 160: Bottom Wear Pad

    BOGIE SUSPENSION Tighten the mounting bolt fitted on the common ASSEMBLY OF BOTTOM WEAR PAD. bracket for torque rod and both side & bottom wear Fit bottom wear pad at the location. (Refer Fig. 97) pad. (Refer Fig. 100) Fig. 97 Fig.

  • Page 161: Alsv Setting

    SUSPENSION BOGIE ALSV SETTING Maintaining the LCRV Angle 14deg +/-2.5degree in Vehicle Unladen condition. 127.8 +/-6mm (From Bogie Suspension Cross member Gusset Bottom to LCRV Rubber Bush Top) OR 178.8 +/-6mm (From Bogie Suspension Cross member Gusset Bottom to LCRV Rubber Bush Bottom) (Refer Fig.

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