Modifications

1. INTRODUCTION OF GC MAX CIRCULAR NO – 3WH 187 DATE : 20/08/2007

• Usable Tray width increased from 1290 mm to 1410 mm.

• Center to center distance of headlamp / blinkers increased – More wider visibility of roads.

• Socket for fitment of mobile charger / cigarette lighter added on dashboard. – Additional feature.

• Neutral color of plastic parts / handle bar changed to Black. – To improve aesthetics

• Bottle holder bolted on RH support (below driver seat) - Additional feature

Continued ….

Air filter clogging and low oil pressure alarm indication control system.- Safety feature to enhance engine performance.

2. BAFFLE FITMENT IN FUEL TANK CIRCULAR NO : 3WH - 192

DATED : 05/09/2007

To take care of fuel spillage from plastic fuel tank and fuel tank cap coming out in locked position, we have started fitment of baffle, inside the fuel tank on GC MAX and MEGA.

3. INTRODUCTION OF MODIFIED GRILL AIR DUCT CIRCULAR NO : 3WH 197

4. INTRODUCTION OF MODIFIED FUEL TANK STRAP DATED : 27-09-2008

5. INTRODUCTION OF MODIFIED CYLINDER HEAD

• Introduction of modified GRILL AIR DUCT for MEGA MAX – to prevent water entry in air filter during rain. To prevent entry of water inside the grill, it is modified to direct the rain water downwards.

OLD

• Introduction of modified fuel tank strap with M8 stud for MEGA MAX & GC MAX -To take care of brakeage of fuel tank strap, it’s threading is changed to M8.

Continued …

Introduction of modified cylinder head for GC MAX & MEGA MAX. To take care of the problem of cylinder head bridge cracking, we have implemented modified cylinder head in which relief valve position is changed.

6. Driver Seat assembly with Reduced Length CIRCULAR NO : 3WH 198 DATED : 27.09.2007

Introduction of Driver seat assembly with reduced length for GC MAX & GC CNG MAX.

We have implemented Driver seat assembly with reduced length, to facilitate easy operation of reverse lever. Length of seat is reduced by 60mm. (The length of seat 871mm is reduced to 811mm.

7. Introduction of Splash Guard CIRCULAR NO : 3WH 200

8. Introduction of dust cover for wheel bearing DATED : 13.11.2007

9. Introduction of dashboard with additional holes

Introduction of Splash guard for GC Max and Mega Max >To protect engine from mud and dust, splash guard on engine is implemented on GC Max.

Introduction of dust cover for wheel bearing (sealed) - To avoid dust entry inside sealed bearing, we have provided dust cover for GC Max, Mega Max, GC CNG Max and Mega CNG. This will help to further enhance the life of bearing.

Dust Seal

Continued …

Introduction of dashboard with additional holes at end for GC Max and GC CNG Max

- For better fitment, trim has provided additional fixing with screw at both ends.

Introduction of Sealed Bearing in Differential CIRCULAR NO : 3WH 201 DATED : 08.11.2008

Introduction of sealed bearing in differential assembly. To prevent possibility of water entry inside the differential housing,

sealed bearing for differential is implemented on GC Max and Mega Max.

Sealed bearing for differential housing

Continued … CIRCULAR NO : 3WH 201

Implementation Of New Door Lock Set Commonisation of driver cabin of GC CNG Max with GC Max.

For better door lock operations, lock position and it’s linkages are modified.

NEW OLD

Continued …Commonisation of driver cabin of GC CNG Max with GC Max.Fitment of Head lamp Brackets With Bolts Instead of Spot Welding

Commonisation of driver cabin of GC CNG Max with GC Max. > We have commonised the driver cabin of GC CNG Max with GC Max.

Fitment of head lamp brackets with bolts instead of spot welding to Chassis, on GC CNG MAX and GC MAX > As a process improvement, we have started fitment of head lamp bracket with bolts.

Introduction Of Jack Assembly. Introduction of modified gear shifter housing & Cover for Reverse Switch

Introduction of jack assembly without handle (AN221004) and Tool kit complete (BB221005) for GC MAX > As a regular change, we have implemented new jack (without handle) and commonised Mega tool kit with GC Max. To operate the jack Tommy bar provided in tool kit is to be used.

CIRCULAR NO :202

DATED : 01.11.2007

Introduction of head light assembly with new rubber cap to avoid water / dust entry for GC Max & Mega Max.

Continued …Introduction of head light assembly with new rubber cap.

Introduction of head light assembly with new rubber cap to avoid water / dust entry for GC Max & Mega Max.

To prevent water/ dust entry inside the head lamp through rubber cap, it

is modified as shown below

OLD NEW

Modification in Engine Mounting Cradle.

Modification in engine mounting cradle of GC MAX and MEGA MAX. > To strengthen engine mounting bracket on cradle to avoid its cracking, reinforcement is added as shown.

CIRCULAR NO : 205

DATED : 04.12.2008

OLD NEW

ReinforcementNo reinforcement

Modification in handle bar assembly

Modification in handle bar assembly for RE DIESEL, GC MAX, MEGA MAX and GC CNG MAX.

To avoid excess play in gear control tube and ring gear indicator, fitment of ring gear indicator on gear control tube with dowel pin is started.

CIRCULAR NO : 206

DATED :11.12.2007

HOLE IS PROVIDED FOR SPRING CLIP

SPRING CLIP PROVIDED IN HANDLE BAR

Implementation of hand brake lever of Mega MAX

Implementation of hand brake lever of Mega MAX (BB151001) on GC

MAX & GC CNG MAX

For commonisation, fitment of hand brake lever of Mega (BB151001) is started on GC MAX and MEGA MAX.

OLD NEW

CIRCULAR NO : 208

DATED : 8/12/2008

continued …Introduction of Coupler Instead of Bullet terminal for Cable Assembly Cabin light .

Introduction of coupler instead of Bullet Terminal for cable Assembly cabin light of GC max and MEGA MAX.

To improve the electrical connectivity with better, positive connection, cabin light harness is provided with coupler instead of bullets.

Continued …Introduction of needle bearing in place of ball bearing for camshaft

Introduction of needle bearing in place of ball bearing for camshaft of RE-DIESEL / GC MAX/ MEGA MAX. - As a regular change, we have

implemented needle bearing in place of ball bearing for camshaft of . Due to difference in diameter of needle bearing and ball bearing, cover

crank case is modified.

Hole –dia for needle bearing is reduced

Continued …

OLD NEW

Induction hardening done at camshaft

Needle bearing

Fitment of Connecting Rod forged from Preforged Preforms.

As a regular improvement, we have started fitment of connecting rods forged from forged preforms (Preforged shape changed from turning to hot forging) for GC MAX and Mega MAX

  The identification on web of the shaft is as follows.

Manufactured in :- Oct.07     :   X2/07 Nov.07    :   Y1/07, Y2/O7 & so on. Dec.07    : Z1/07, Z2/07 & so on Jan’08 : O1/08, O2/08 & so on. Depending on lot order

quantity

CIRCULAR NO : 209

DATED : 24.12.2007

Provision of Fuel Tank Guard.

Provision of fuel tank guard for GC MAX- DAC vehicle - We have started sending guard fuel tank for GC MAX -DAC vehicle with its fasteners in

accessories box sent along with the vehicle, effective from Dec 18,2007

Location of the guard is similar to existing one fitted from the factory on

GC Max.

CIRCULAR NO : 210

DATED : 22.01.2008

Guard fuel tank

Modification on Chassis assemblyImprovement in ED Painting Process in all 3 Wheeler models

Modification on Chassis assembly of GC MAX / Mega Max

We have implemented following improvements on chassis assembly of GC Max and Mega Max.

1) Cup cross tube added in chassis assembly. 2) Trailing arm bracket collar deleted. 3) Excess welding reduction of trailing arm brackets.

CIRCULAR NO : 211

DATED : 22.01.2007

Cup from inside welded Extrusion deleted Excess Extrusion deleted welding deleted

Continued …Clamp added for tail lamp branch, accelerator, stop cable and clutch cable

Clamp added for tail lamp branch, accelerator, stop cable and clutch cable

Clamps Added

Continued…Improvement in ED Painting Process in all 3 Wheeler Models

We have made certain changes in the ED painting process internally.

Due to this new process component paint color has become gray instead of black. (Before finish paint)

Introduction of modified D’com cable

As an improvement, we have implemented modified D’com cable with following changes

RE DIESEL, GC MAX and MEGA MAX. 1) End cap diameter is increased to 8 mm from 6 mm 2) Length of nut near dashboard is reduced to 19 mm from 24 mm.

Length of nut reducedto 19 mm from 24 mm

Dia. of end cap increasedto 8mm from 6 mm

CIRCULAR NO : 215DATED : 31.01.2008

Reverse Switch mounting is changed from Cover Gear Shifter to Cover Gear Box.Greasing arrangement for rear axle bearings

Reverse switch mounting of GC MAX and MEGA MAX is changed from cover gear shifter to cover gear box.

To provide more rigid fixing to reverse switch to avoid reverse light glowing in neutral, mounting position of reverse switch is changed from gear shifter cover to gear box cover.

CIRCULAR NO : 3WH/ TI/03

DATED : 08.05.2008

OLD NEW

Based on field feedback we have re-introduced greasing arrangement for rear axle bearing of GC MAX , MEGA MAX

Greasing Arrangement of Rear Axle Bearing.

Please refer our circular no. 3WH 218 dated 12.3.08 on re-introduction of

Grease nipple arrangement.

CIRCULAR NO: 3WH/TI/04

DATE : 17.04.2008

A) Dismantling and Modification

1) Remove the rear axle.

Note : If required, replace the bearings. Pl. note that use of sealed bearings in this trailing arm is must.

2) Remove needle roller bearing of rear axle with the help of special tool 37221706.

3) Cut the lip of rubber seal of the bearing (inner side only) using sharp

tool as shown in picture

Continued…

Caution: Only one side of seal is to be cut (inner side). This will allow grease to enter inside NRB.

NRB with proper seal lip Oil seal lip cut

4) Drill the hole of dia.4.5mm. on hub near back plate. Tap it for M6X1.Refer drawing in Annex-I for location of drill on hub.

Continued…

Drilling and tapping to be done on hub at this point.

Please remove all metallic burr inside the hub by cleaning the hub with kerosene.

Caution : Do not forget to re grease the bearings.

1) Fix the grease nipple.

Grease Nipple

Continued …

2) Lubricate the NRB with RR3 grease and press it in trailing arm with the Help of special tool. (Rubber seal damage side should be inside.)

Rubber seal damaged side

Sealed ball bearing

3) Please fit oil seal (part no. 24171024) inside the trailing arm at ball bearing side.

Oil seal (24171024)to be fitted

Introduction of Auto Adjuster Brake System

Introduction of Auto Adjuster brake system on all RE models. Please refer our earlier circular no.3WH:213 dated 22.01.2008 through which we have communicated the implementation of this system on RE 2S

CIRCULAR NO :3WH/TI/04

DATED : 10.05.2008

Pinion Wheel cylinder

Spring Shoe Clamp

Pin Pivot Shoe

Spring Strut LH

Spring Shoe Holding

Plate Strut Front

Spring Strut LH holding

Continued…

Plate Ratchet Pinion Spring Main Plate Strut Front

Spring Strut LH HoldingSpring Strut LHPin Ratchet

Modified air filter bracket

1) Modified air filter bracket for GC Max and Mega Max

As an improvement to enhance the life of bracket, it is modified and made in single piece.

CIRCULAR NO : 3WH/TI/06

DATED : 25.05.2008

Old New

Bracket air filter mtg. is made single piece.Bracket Air filter welded to support bracket with spot welding instead of

CO2 welding

Improvement for Governor lever –2 Introduction of modified stop cable, Cover Governor lever and Governor lever 3

• To prevent oil leakage from governor lever –2 induction hardening is added

CIRCULAR NO : 3WH/ TI/07

DATED :29.05.2008

Part no. of Governor Lever-2 (BA122038) remains same.

• Introduction of modified stop cable, cover governor lever and Governor lever 3 on RE DIESEL, GC MAX and MEGA MAX

Stop cable with fixed end is implemented for operational consistency on RE DIESEL, GC MAX & MEGA MAX. This has further modified the cover governor and governor lever 3.

Tray Mounting Bracket

PROBLEM REPORTED FROM FIELD : Cracking at tray mounting bracket (front) MODIFICATION IMPLEMENTED : Tack welding at four points on tray mounting bracket

CIRCULAR NO : 3WH/PUG/08-09/05

DATED : 17.06.2008

ACTION TO BE TAKEN IN FIELD : 1) Loosen / remove the tray mounting bracket bolts. 2) Remove the Dunlop packing of front tray mounting brackets. 3) Remove the paint of tray mounting bracket at welding location. 4) Tack welds the bracket. Ensure 10 mm weld run at 4 points as shown in figure.

Continued …

Parameters for welding processCurrent: 170 to180AmpsVoltage - 20 to 25 V

Tack weld at 4 points