Reported by : Ashish Kumar Thakur(PSE NGP+CHP) Site visit : 26th Nov,14 Location : Gouri-1 Customer : Avtar & Co

FLEET DETAILS SNOCUSTOMERMODEL (PC 24)CHIDDODHYVA BODY SLNODATE OF INSPECTION HMR/KMS 1Avtar & CoFMX 440 8X4(manual Gearbox) rock body PDI done but not yet updated in LDS(delivered-Nov- 14) 10THB Nov Ehrs/2680 Kms 2Avtar & CoFMX 440 8X4(manual Gearbox) rock body PDI done but not yet updated in LDS(delivered-Nov- 14) 10THB Nov Ehrs/2672 kms 3Avtar & CoFMX 440 8X4(manual Gearbox) rock body PDI done but not yet updated in LDS(delivered-Nov- 14) 10THB Nov Ehrs/2521 kms 4Avtar & CoFMX 440 8X4(manual Gearbox) rock body PDI done but not yet updated in LDS(delivered-Nov- 14) 09THB Nov Ehrs/2698 kms 5Avtar & CoFMX 440 8X4(manual Gearbox) rock body PDI done but not yet updated in LDS(delivered-Nov- 14) 10THB Nov Ehrs/2539 kms 6Avtar & CoFMX 440 8X4(manual Gearbox) rock body THB Nov-1455 Ehrs/1480 kms 7Avtar & CoFMX 440 8X4(manual Gearbox) rock body THB Nov-1459 Ehrs/1517 Kms 8Avtar & CoFMX 440 8X4(manual Gearbox) rock body THB Nov-1465 Ehrs/1652 Kms 9 Avtar & CoFMX 440 8X4(manual Gearbox) rock body THB Nov-14

OBSERVATIONS DURING THE INSPECTION SNOCHIDEHRS/ KMS COMPLAINTCAUSECORRECTIVE ACTION hmr /2680 kms Stroke length = 32 mm (Y1-101 & Y2-69) Clutch ‘Y’ value sticker missing on RH side driver door panel. Driver complaint for excessive wobbling & shock kick off upon the steering wheel while vehicle travels undulations. Un-availability of inhibitor valve likewise used to perform in classic platform /Missing procedure in impact also. Sticker of y value missed out. Un-availability of damper valve in steering cylinder HP hose pipe both inlet & return. Argus raised by TS > issue is open. As a local suggestion Y value measured & jotted upon clutch & RH door corner panel itself. Problem persisting (issue – open) hmr/ 2672 kms Stroke length = 32 mm (Y1-101 & Y2-69) Clutch ‘Y’ value sticker missing on RH side driver door panel. Driver complaint for excessive wobbling & shock kick off upon the steering wheel while vehicle travels undulations Un-availability of inhibitor valve likewise used to perform in classic platform /Missing procedure in impact also. Sticker of y value missed out. Un-availability of damper valve in steering cylinder HP hose pipe both inlet & return. Argus raised by TS > issue is open. As a local suggestion Y value measured & jotted upon clutch & RH door corner panel itself. Problem persisting (issue – open) hmr /2521 kms Stroke length = 32 mm (Y1-101 & Y2-69) Clutch ‘Y’ value sticker missing on RH side driver door panel. Driver complaint for excessive wobbling & shock kick off upon the steering wheel while vehicle travels undulations Un-availability of inhibitor valve likewise used to perform in classic platform /Missing procedure in impact also. Sticker of y value missed out. Un-availability of damper valve in steering cylinder HP hose pipe both inlet & return. Argus raised by TS > issue is open. As a local suggestion Y value measured & jotted upon clutch & RH door corner panel itself. Problem persisting (issue – open) hmr / 2698 kms Stroke length = 32 mm (Y1-101 & Y2-69) Clutch ‘Y’ value sticker missing on RH side driver door panel. Driver complaint for excessive wobbling & shock kick off upon the steering wheel while vehicle travels undulations Un-availability of inhibitor valve likewise used to perform in classic platform /Missing procedure in impact also. Sticker of y value missed out. Un-availability of damper valve in steering cylinder HP hose pipe both inlet & return. Argus raised by TS > issue is open. As a local suggestion Y value measured & jotted upon clutch & RH door corner panel itself. Problem persisting (issue – open) hmr / 2539 kms Stroke length = 32 mm (Y1-101 & Y2-69) Clutch ‘Y’ value sticker missing on RH side driver door panel. Driver complaint for excessive wobbling & shock kick off upon the steering wheel while vehicle travels undulations Un-availability of inhibitor valve likewise used to perform in classic platform /Missing procedure in impact also. Sticker of y value missed out. Un-availability of damper valve in steering cylinder HP hose pipe both inlet & return. Argus raised by TS > issue is open. As a local suggestion Y value measured & jotted upon clutch & RH door corner panel itself. Problem persisting (issue – open)

OBSERVATIONS DURING THE INSPECTION SNOCHIDEHRS/ KMS COMPLAINTCAUSECORRECTIVE ACTION Driver complaint for excessive wobbling & shock kick off upon the steering wheel while vehicle travels undulations. Un-availability of damper valve in steering cylinder HP hose pipe both inlet & return. Problem persisting (issue – open) Driver complaint for excessive wobbling & shock kick off upon the steering wheel while vehicle travels undulations. Un-availability of damper valve in steering cylinder HP hose pipe both inlet & return. Problem persisting (issue – open) Driver complaint for excessive wobbling & shock kick off upon the steering wheel while vehicle travels undulations. Un-availability of damper valve in steering cylinder HP hose pipe both inlet & return. In order to arrest the complaint replaced the HP hose along with the adaptor containing (valve) from classic platform vehicle rectifying the issue. Rectified at ehrs – 51 & kms – 1384 / on -26 th,nov Driver complaint for excessive wobbling & shock kick off upon the steering wheel while vehicle travels undulations. Un-availability of damper valve in steering cylinder HP hose pipe both inlet & return. Problem persisting (issue – open)

DETAILED REPORT ON COMPLAINT CUSTOMER/DRIVER COMPLAINTPOINT OF ERRUPTION OF SYMPTOMS OCCURENCES OF SYMPTOMS STATUS OF VEHICLE * Driver complained for excessive steering wobbling & excess of vibration causing un-stability of vehicle together with driver fatigue. Symptoms are erupted when ever vehicle passes over un-even road surface, even minor undulation, pot holes or stony surfaces. Actual road conditions – satisfactory. Type of material – OB Gradient – 1:16 Eruption of symptom – both in laden & un-laden condition Each & every trips (loading to un-loading point ) With lead of 6km’s(up+ down) CHID /923073/923074/923075/ – wobbling is evident but vehicle still running. * Last 4 vehicle BD/customer stopped the vehicles as driver complained for excessive wobbling as compared to other vehicles (923283/923240/923241/923722) CREDENTIALS INSPECTED BOTH ON IMPACT & PHYSICAL FITTED PART UPON PC24 & CLASSIC PLATFORM CREDENTIALSCLASSIC PLATFORM (FM 400/FMX 440/FM 480) PC 24 PLATFORM (FMX 440 8x4)DIFFERENCE AS PER IMPACT (FG646)Same steering cylinder in all variant with similar part no & specifications (part no: - steering cylinder, HP hose ) Specification of steering cylinder is totally same, but difference in part no of cylinder superseded to , HP hose, no valve Difference in steering (1)Steering cylinder part no. (2) HP hose part no. (3) Absence of valve. AS PER PHYSICAL /ACTUAL FITTMENT Steering cylinder part no fitted onto vehicle - steering cylinder.HP hose, valve /smaller steering cylinder dia /leeser inclination Steering cylinder part no fitted – HP hose – Damper valve - absent Absence of damper valve – Same stroke & same specification but due to change in intermediate arm inclination of cylinder differ. Different part no.

ROOT CAUSE ANALYSIS SHEET & COMPARISION CLASSIC PLATFORM (FM 400, FM 480)NEW PLATFORM (FMX 440 8X4) *During inspection observed that stroke of steering cylinder to be same as that of PC 24 platform trucks. Length of cylinder from ball joint found to be 740 mm when tyre in straight ahead portion, On dismantling found 36 no socket hexagonal adaptor tightened after hexagonal nut of HP hose pipe. Adaptor contained the spring loaded valve & an orifice with 4 holes causing varied flow & spring loaded valve acting as a damper damping road surface shocks & vibration effect upon steering system. Steering cylinder part no fitted onto vehicle - steering cylinder.HP hose, valve /smaller steering cylinder dia /lesser inclination During inspection observed that stroke of steering cylinder to be same as that of classic platform. Length of cylinder from ball joint found to be 740 mm when tyre in straight ahead portion, but observed the steering cylinder to be fitted at lesser inclination due to change in intermediate arm. Change in outer dia of cylinder. Fitment of hose pipe in different direction. Absence of damper valve & orifice which would varied flow & spring loaded valve acting as a damper damping road surface shocks & vibration effect upon steering system. Steering cylinder part no fitted – HP hose – Damper valve - absent Causal part – valve – ( classic platform p no) In order to have correct tread & nut size need to replace hose also

CORRECTIVE ACTION TAKEN: (1)Dismantled the steering cylinder HP inlet & return hose pipe from steering cylinder & detailed checked for variation of flow by blowing out air through hose pipe fitted with Adaptor containing valve. (2) Observed the varied flow & resistance in flow while blowing air which was not observed In case of PC 24 hose pipe, where flow could be felt direct & without any hindrance. (3) Detailed the adaptor - observed the spring loaded valve for damping shock permitted in flow of steering oil & an orifice for permitting varied oil flow in & out of the steering cylinder both inlet & return HP hoses. (4) Finally fitted the same hose & adaptor of classic platform onto the PC 24 vehicles - where the male part of adaptor easily fitted onto the steering cylinder but hexagonal nut protruding towards aluminum servo pipe got tightened to male tread of the pipe to about 7-8 treads only without any leak or damage of hose.

TRIAL FEEDBACK & MODIFICATION SNAPS: Driver feedback after trial – no wobbling & Vibration effect upon steering. Inspected both in loaded & un-loaded condition. Feedback of driver trainer – No vibration & wobbling effect No of trips taken on inspection date during trial – 5 trips Current status of issue - resolved Status of vehicle – running with same modification from 26 th till 27 th Nov,14