OVERHAULING OF LEAF SPRING ASSEMBLY

-

AIM:

OVERHAULING OF LEAF SPRING ASSEMBLY 

TOOLS REQUIRED

1. BOX SPANNER SET
2. RING SPANNER SET
3. DOUBLE END OPEN SPANNER SET
4. HYDRAULIC JACK
5. LONG SCREW DRIVER (-)
6. TORQUE WRENCH
7. MALLET

MATERIALS REQUIRED

1. KEROSENE OIL
2. COTTON WASTE
3. EMERY PAPER
4. GREASE
5. RUBBER BRUSHES
6. LUBRICANT
7. GRAPHITED OIL

PROCEDURE

1. Chock the wheels.

2. Jack up the frame and lift the vehicle just enough for the wheels to clear the ground.

3. Place a horse to support the frame and take out the jack.

4. Disconnect the shock absorber, if provided.

5. Remove the clamp bolt from the shackle.

6. Remove the spring fixing bolts and nuts all pads.

7. Put the jack to support the axles. And Remove the grease nipples.

8. Remove the shackle pins with the help of special tools.

9. Remove the leaf spring assembly from the axle.

10. Put up the spring in a press, measure the pre - camber.

11. Apply full load and observe the camber. This will be the negative camber.

12. Set the spring eyes at a higher plane on the press.

13. Measure the distance between the spring centre and the base plate.

14. Apply deflection load as per specification.

15. Again measure the distance between the spring centre and the base plate.

16. Calculate the deflection of the spring. ( difference between two readings.)

17. If the deflection is not as per recommendation, hold the spring in a vice firmly and remove the nuts and bolts from the spring, clips and release the vice slowly.

18. Then separate the spring leaves.

19. Inspect the spring leaves for crack or damage.

20. Clean the spring leaves with a thin oil; apply graphited oil and observe the crack.

21. Replace the faulty leaf.

22. Coat each leaf with graphite oil or grease, containing 10% graphite.

23. Assemble the springs.

24. Press new bushes into the front spring eyes and fix in position.

25. Straighten the clips, if distorted.

26. Check the parallelism of the spring. Reject if the first leaf not parallel.

27. Finally fit the clips and tighten up the nuts dead tight.

FITMENT

1. Place the spring perfectly on the spring saddle provided on the axles.

2. Drive in the shackle pin after aligning the spring eye into the hanger bracket using a soft mallet.

💠 Do not use fingers for aligning the spring leaf holes.

3. Fix and tighten the clamp bolts of the spring shackle and spring brackets.

4. Fix all pads and tighten slightly the U clamp bolt/ clamp bolt and nut using the special tool.

5. Release the jack.

6. Finally tighten the nuts of the clamp bolt/U bolt nuts to the recommended torque.

7. Fit back the grease nipple and lubricate.

ADDITIONAL HINTS FOR REAR SPRING OVERHAULING.

▪️ Carry out all the steps for removing the front spring. The following additional steps are also required.

▪️ Remove the axle U bolt with the help of special tools.

▪️ At the time of assembling, use special levers for tightening the U bolt clamps.

RESULT :

 OVERHAULING OF LEAF SPRING ASSEMBLY DONE SUCCESSFULLY.

Popular posts from this blog

INTRODUCTION TO ENGINE

-
Image
Engine : It acts as the power unit. The internal combustion engine is the most commonly used in automobiles. It is of two types ; (i) Spark ignition (ii) Compression ignition.         Both engines are called heat engines. A steam engine is an external combustion engine because the fuel is burned outside the engine. The principle of working of an external combustion engine is shown in the figure below. COMPARISON BETWEEN INTERNAL AND EXTERNAL COMBUSTION ENGINES      The internal combustion engine is an engine in which the combustion of a fuel occurs with an oxidizer (usually air) in a combustion chamber. In an internal combustion engine the expansion of the high temperature and pressure gases, which are produced by the combustion, directly applies force to a movable component of the engine, such as the pistons and by moving it over a distance, generate useful mechanical energy.          The internal combustion engine...
Read more

FOUR STROKE SPARK IGNITION (PETROL) ENGINE

-
Image
FOUR STROKE PETROL ENGINE MAIN PARTS 1. PISTON 2. CYLINDER 3. CONNECTING ROD 4. INLET VALVE 5. EXHAUST VALVE 6. SPARK PLUG 7. CRANK SHAFT 8. FLY WHEEL 9. CAM SHAFT CONSTRUCTION A four stroke petrol engine have a piston, connecting rod, crank shaft, inlet valve, exhaust valve and a spark plug. The connecting rod is used to connect the piston and crank shaft. The spark plug and valves are mounted in the cylinder head. Also the valves are operated by cam shaft which is connected to the crank. In this type of engines, there would be a power stroke for every two rotations of crank shaft. It is also known as otto cycle. Each full rotation of crank having two strokes. So one stroke is  180° rotation of flywheel. A four stroke petrol engine having the following strokes. WORKING Induction stroke : The crankshaft moves the piston downwards (TDC to BDC). The inlet valve is open and a mixture of fuel and air is sucked into the combustion chamber. It is also known suction stroke. In this strok...
Read more

MAJOR PARTS OF AN IC ENGINE

-
Image
ENGINE COMPONENTS 1. CYLINDER BLOCK      The cylinder block is the main body of the engine. Cylinder head is mounted on the cylinder block. It houses iniet and exhaus valves. Crank case is attached to the bottom of the cylinder block. Crank case supports the crank shaft. Oil pan is attached to the bottom of the crank case. Cylinder block contains large cylindrical holes called cylinder bore. The cylinders are accurately finished to accommodate pistons. The space above the piston inside the cylinder at TDC called the combustion chamber. Combustion of fuel inside this space, high pressure and temperature will be developed inside the cylinder. Therefore, it should be made of material which can resist high pressure and temperature (2800°C). In water jackets has around the cylinders for the circulation cooling water to absorb the temperature while running of an engine. 2. CYLINDER HEAD Cylinder head is a separate casting placed on top of the cylinder block by studs and nuts. I...
Read more