SUMMER VOCATIONAL TRAINING REPORT AT

BHANDARI MOTORS PVT LTD.

INTRODUCTION

Bhandari Motors Pvt Ltd. is located at Sodepore station road, B.T.Road, Kolkata- 700118. This is a ISO 9001:2008 Certified Workshop of TATA MOTORS. It has over 130 branches all over India specially in the metropolitan cities like Kolkata ,Delhi ,Mumbai,Pune. It covers about 30acres of square area.This Workshop is the SALES & SERVICE centre of all TATA Commercial Vehicles and is the biggest in the West Bengal. Everyday about 60-80 vehicles enter for servicing, cleaning, paint job. Also it is known for sales and after-sales purposes, everyday about 100-120 LCVs are being sold and also 10-20 MCVs are being assembled in the ASSEMBLY SECTION.

WE ARE THE STUDENTS OF MCKV INSTITUTE OF ENGINEERING OF AUTOMOBILE DEPARTMENT(AUE) {2012-2016}, WENT TO THE TRAINING CENTRE AS INSTRUCTED BY OUR T.P.O. MR.KAUSHIK HAZRA. WE MET OUR TRAINING HEAD MR.AVIJIT DAS AND STARTED OUR TRAINING FROM AS GUIDED BY TRAINING-HEAD SIR.

FIRST DAY AT TRAINING

TOPICS• PRE-DELIVERY INSPECTION (P.D.I)• IDENTIFICATION OF ALL RANGE OF TATA C.V. MODELS. (LCV, MCV &

HCV)• NOMENCLATURE OF TATA CHASSIS & ENGINES• DIAGNOSIS AND TROUBLESHOOTING TO POOR-PICKUP PROBLEM• TROUBLESHOOTING & DIAGNOSIS OF HIGH FUEL CONSUMPTION

PROBLEM• TROUBLESHOOTING OF MALFUNCTIONING OF BRAKING PROBLEM• VALVE-TAPPET CLEARENCE AND ADJUSTMENT• FUEL INJECTION PUMP TIMING- THE PROCESS• IDENTIFICATION & WORKING OF SENSORS IN BS-II,BS-III & BS-IV

ENGINE

AUTOMOTIVE SENSORS AND ARRAYSHERE WE ARE VIEWING THE WIRING DIAGRAM OF THE AUTOMOTIVE VEHICLES SUCH AS FUSE BOX,ECU,COMMON RAIL, BATTERY CUT OF SWITCH,SENSORS…

IDENTIFICATION OF TATA C.V. MODELS

• LIGHT COMMERCIAL VEHICLES: TATA ACE,ACE HT,ACE-ZIP,SUPER ACE,TATA MAGIC, TATA ACE-MEGA, TATA WINGER, TATA VENTURA, TATA IRIS, TATA MEGA, TATA XENON(pickup)

• MEDIUM COMMERCIAL VEHICLES- TATA 407( EX,EX2), TATA 709(EX,EX2), TATA 9.17,TATA 16.13, TATA16.12, 16.13C,16.12C (C- CUMMINS)

• HEAVY COMMERCIAL VEHICLES- TATA 16.13, TATA 25.18c,TATA 25.28c TATA 31.18c,TATA 37.23c,TATA 35.18c, TATA 40.18,TATA 49.23, TATA 21.28K TATA 25.28K, TATA 31.28K

HCV TATA 25.18

HCV TATA 35.18

MCV TATA 16.13LCV TATA ACE HT-MODEL

COMPARISON BETWEEN CUMMINS 6BTA & 6CTA

6BTA TCIC

• BORE=102mm• STROKE=120mm• PARENT BORE• 12VALVE (DOHC)• INJECTOR OUTSIDE &

VERTICALLY DOWNWARD• ENGINE HEAD SEPARATE FOR

EACH CYLINDER

6CTA TCIC

• BORE=107 mm• STROKE=124mm• WET LINER• 24 VALVE• INJECTOR INSIDE• ENGINE HEAD IS CONTINIOUS

THROUGHOUT THE ENGINE BLOCK

BS II Cummins Engine 6BTA5.9TCIC (B-series)

BS III Cummins Engine 6CTA5.9 TCIC (C-series)

LIST OF SENSORS & ACTUATORS IN BS-III AND BS-IV ENGINE

SENSORS & ACTUATORS1. MP ROP2. ACCELERATOR PEDAL MODULE (APM)3. NEEDLE LIFT SENSOR4. ENGINE SPEED SENSOR5. VEHICLE SPEED SENSOR6. WHEEL SPEED SENSOR7. FUEL TEMP. SENSOR8. WATER IN FUEL SENSOR9. AMF SENSOR10.WATER TEMPERATURE SENSOR 11. FUEL-METERING UNIT12.PIEZO-INJECTOR

TURBO CHARGERTHIS IS A BSII TURBOCHARGER ALONG WITH EXTERNAL WASTE GATE WITH ACTUATOR FOR 6 CYLINDER ENGINE OF TATA 35.18

Engine- CUMMINS 6BTA 5.9 BSIII POWER-172HPTORQUE-680nmWITH INTERCOOLER

DRUM BRAKE ASSEMBLY OF FRONT WHEEL OF TATA 407 EX2 (POWER STEERING)

DRUM BRAKE ASSEMBLY OF REAR WHEEL OF A TATA 16.13c COMPONENTS

1. BRAKE SHOE2. S-CAM ALONG WITH

BRAKE ACTUATOR3. WHEEL SPINDLE4. RETRACTING SPRING5. ADJUSTING SPRING 6. BRAKE DRUM7. BACK PLATE AND WHEEL

BEARINGS

ANTILOCK BRAKING SYSTEMASSEMBLY

• PREVENTS VEHICLE SKIDDING• PREVENT TRACTOR-TRAILER JACK-KNIFING• REDUCES STOPPING DISTANCE• IMPROVES STABILITY AND STEERABILITY• INCREASE THE LIFE OF TYRE, BRAKES&

SUSPENSION

ABS COMPONENTS• WHEEL SPEED SENSOR• POLE WHEEL• CONNECTING WIRES• MODULATOR VALVE• ECU

FIP TIMING

• BRING THE CYLINDER 1 IN TDC POSITION• IF FIRST TWO VALVES ARE FREE, THEN ITS IN COMPRESSION STROKE• A PIN IS PRESENT IN FIP WHICH CONNECTS WITH CAM SHAFT• OPEN THE ADJUSTING NUT OF FIP AND INSERT DIAL GAUGE INDICATOR• CHECK THAT THE TIMING IS 1.08mm(CUMMINS)• CHECK THAT THE FIP FOLLOWS THE FIP TIMING BY ROTATING THE VIBRATION DAMPER• OPEN THE ADJUSTING SCREW & INSERT THE DIAL GAUGE INDICATOR• MOVE THE FIP GEAR SIDE WAYS AND SET 0 MARK WHRE THE INDICATOR STOPS

MOVING• ROTATE CLOCKWISE 1-REVOLUTION AND CHECK THE ACTUL TIMING OF FIP• IF IT NEEDS TO ADVANCE THEN FIT THE FIP TOWARDS THE BLOCK AND FOR RETARED

FIT THE FIP AWAY FROM THE BLOCK

• FIP TIMING = 1.08mm • DIAL GAUGE =.01mm(L.C)• ALL TOTAL=.01 * 100 DIV = 1.00mm

DIAGNOSIS STEPS • CHECKING AIR-FILTER, IF IT IS OK THEN

CHECK THE MAP(mass-air flow) SENSOR AND THEN THE INTAKE MANIFOLD.

• CHECK THE FUEL FILTERS AND FUEL LINE OF THE FUEL SYSTEM.

• CHECK THE VALVE-TAPPET CLEARENCE ADJUSTMENT.

• CHECK THE FRINGE HEIGHT OF THE CLUTCH AND CLUTCH PLATE.

• CHECK THE F.I.P. TIMING OF THE FUEL INJECTION PUMP AND ADJUST IT

POOR PICKUP PROBLEM

INSPECTING OVER TATA 4.07EX2• PROBLEM- HIGH FUEL CONSUMPION,AIR

LEAKAGE IN INTAKE MANIFOLD

• SOLUTION: 1.REPLACEMENT OF FINE AND COARSE AIR FILTER2. REPLACEMENT OF PRIMARY AND SECONDARY FUEL FILTER 3. CHECKING AND ADJUTMENT OF VALVE CLEARENCE

INSPECTING OVER A TATA 7.15c (4X4)BSIII

• PROBLEM- INACCURATE BRAKING AND LARGE STOPPING DISTANCE

• SOLUTION- REPLCEMENT OF BRAKE LINING BY RIVETING PROCESS

• CHECKING OF BRAKE LINE AND COMPRESSOR

INSPECTING OVER A TATA 9.12 BS IV

• PROBLEM- POOR PICKUP

• SOLUTION- FUEL STRAINER REPLACED,NOZZLE REPAIR, TAPPET ADJUSTMENT,PROPER CLUTCH ADJUSTMENT.

BS(IV) PROBLEMS

1. VEHICLE WILL NOT START IF THE AIR GAP IN THE ENGINE SPEED SENSORS IS NOT = 0.75mm

2. VEHICLE WILL NOT START IF THE PRV COUNT IS NOT=15 (PRV= PRESSURE RELEASE VALVE)

CONCLUSION

• We have enjoyed our summer training at BHANDARI MOTORS PVT LTD Works, learnt many things which may will be needed in future.

THANK YOU

QUESTIONS???