Gc Max Modification

1. INTRODUCTION OF GC MAX CIRCULAR NO – 3WH 187 DATE : 20/08/2007 ,[object Object],[object Object],[object Object],[object Object],[object Object]

Continued …. ,[object Object]

2. BAFFLE FITMENT IN FUEL TANK CIRCULAR NO : 3WH - 192 DATED : 05/09/2007 ,[object Object]

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 ,[object Object],OLD ,[object Object]

Continued … ,[object Object]

6. Driver Seat assembly with Reduced Length CIRCULAR NO : 3WH 198 DATED : 27.09.2007 ,[object Object],[object Object],[object Object]

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 ,[object Object],[object Object],Dust Seal

Continued … ,[object Object],[object Object]

Introduction of Sealed Bearing in Differential CIRCULAR NO : 3WH 201 DATED : 08.11.2008 ,[object Object],[object Object],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. ,[object Object],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 ,[object Object],[object Object],[object Object]

Introduction Of Jack Assembly. Introduction of modified gear shifter housing & Cover for Reverse Switch ,[object Object],CIRCULAR NO :202 DATED : 01.11.2007 ,[object Object]

Continued … Introduction of head light assembly with new rubber cap. ,[object Object],[object Object],OLD NEW

Modification in Engine Mounting Cradle . ,[object Object],CIRCULAR NO : 205 DATED : 04.12.2008 OLD No reinforcement NEW Reinforcement

Modification in handle bar assembly ,[object Object],[object Object],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 ,[object Object],[object Object],[object Object],CIRCULAR NO : 208 DATED : 8/12/2008 OLD NEW

continued … Introduction of Coupler Instead of Bullet terminal for Cable Assembly Cabin light . ,[object Object],[object Object]

Continued … Introduction of needle bearing in place of ball bearing for camshaft ,[object Object],[object Object],[object Object],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. ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],CIRCULAR NO : 209 DATED : 24.12.2007

Provision of Fuel Tank Guard. ,[object Object],[object Object],[object Object],CIRCULAR NO : 210 DATED : 22.01.2008 Guard fuel tank

Modification on Chassis assembly Improvement in ED Painting Process in all 3 Wheeler models ,[object Object],[object Object],[object Object],[object Object],[object Object],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 ,[object Object],Clamps Added

Continued… Improvement in ED Painting Process in all 3 Wheeler Models ,[object Object],[object Object]

Introduction of modified D’com cable ,[object Object],[object Object],[object Object],[object Object],Length of nut reduced to 19 mm from 24 mm Dia. of end cap increased to 8mm from 6 mm CIRCULAR NO : 215 DATED : 31.01.2008

Reverse Switch mounting is changed from Cover Gear Shifter to Cover Gear Box. Greasing arrangement for rear axle bearings ,[object Object],[object Object],CIRCULAR NO : 3WH/ TI/03 DATED : 08.05.2008 Based on field feedback we have re-introduced greasing arrangement for rear axle bearing of GC MAX , MEGA MAX OLD NEW

Greasing Arrangement of Rear Axle Bearing. ,[object Object],[object Object],CIRCULAR NO: 3WH/TI/04 DATE : 17.04.2008 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Continued… ,[object Object],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. NRB with proper seal lip Oil seal lip cut

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 … ,[object Object],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 ,[object Object],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 Holding Spring Strut LH Pin Ratchet

Modified air filter bracket ,[object Object],[object Object],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 ,[object Object],CIRCULAR NO : 3WH/ TI/07 DATED :29.05.2008 Part no. of Governor Lever-2 (BA122038) remains same. ,[object Object],[object Object]

Tray Mounting Bracket ,[object Object],[object Object],[object Object],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 process Current: 170 to180Amps Voltage - 20 to 25 V Tack weld at 4 points

Gc Max Modification

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