1

“INDUSTRIAL TRAINING AT VE COMMERCIAL VEHICLE”

A

Project Report

submitted

in partial fulfilment

for the award of the Degree of

Bachelor of Technology

in Department of Mechanical Engineering

by

Amit Prasad

020712001

Under the supervision of

Dr. M.P. Singh

[ H.O.D.]

Department of MechanicalEngineering

JaganNath University

Jaipur

Jan-july 2016

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Candidate Declaration

I, Amit Prasad, hereby declare that the work presented in this report

entitled“ Industrial training at VE commercial vehicle” in partial

fulfillment of the requirements for the award of Degree of Bachelor of

Technology, submitted in the Department of Mechanical Engineering at

JaganNath University, Jaipur, is an authentic record of my own work under

the supervision of Dr.M.P. Singh.

I also declare that the work embodied in the present project report is my

original work/extension of the existing work and has not been copied from

any Journal/thesis/book, and has not been submitted by me for any other

Degree/Diploma.

(Amit Prasad )

Enrollment No. 020712001

Date: 1 june 2016

3

Certificate of the Supervisor

This is to certify that the project report entitled “ Industrial Training at

VE commercial vehicle”submitted by Amit Prasad for the award of

Degree of Bachelor of Technology in the Department of Mechanical

Engineeringof JaganNath University, Jaipur, is a record of authentic work

carried out by him/her under my/our supervision.

The matter embodied in this project report is the original work of the

candidate and has not been submittedfor the award of any other degree or

diploma.It is further certified that he/she has worked with me/us for the

required period in the Department ofMechanical Engineering, JaganNath

University, Jaipur.

Dr. M.P.Singh

Date: 1 June 2016

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Acknowledgements

I would like to express my sincere gratitude to my project guide & professor

“Dr. M.P.Singh [H.O.D.]” for giving me the opportunity to work on this

topic. It would never be possible for us to take thisproject to this level

without his innovative ideas and his relentless support and encouragement.

Amit Prasad

1204001

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CONTENT

Chapter 1: Introduction

1.1- Introduction: Indian Automobile Industry 10

1.2- Market Share 12

Chapter 2: About Volvo Eicher Collaboration

2.1- Company profile 13

2.2- Basic Information 13

2.3- Overview 14

2.4- Volvo Trucks India 15

2.5- Vission& Mission 16

2.6- Company Description 17

2.7- Business Area Of Volvo Eicher Motors Ltd. 19

2.8- VE Commercial Vehicle Ltd. 19

2.9- Royal Enfield 19

2.10- Eicher Motors ltd. 20

Chapter 3: Pre-Delivery Inspection

3.1- Cabin 38

3.2- Chasis and Body 38

3.3- Engine Compartment (in off condition) 40

3.4- Engine Compartment (in operating condition) 41

3.5- Under Vehicle 42

3.6- Tyre 43

3.7- Road Test 44

3.8- Final Test 45

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3.9- Inspection And Maintenance Schedule 49

Chapter 4: Case Study of Maintenance And Inspection of a Bus

4.1- Bus Inspection Work Sheet 52

4.2- Equipment Repair and Parts Order 52

4.3- Preventive Maintenance oil Change Service 53

4.4- Preventive Maintenance 12000/24000/48000 mile service 59

4.5- Personnel Utilization 60

4.6- Bus Driver Sign-in Sheet 63

4.7- Driver Reported Bus defect log 63

4.8- Inspection and Maintenance Sheet 68

4.9- Using Some Advanced Tools 72

Refrences

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ABSTRACT

VE Commercial Vehicles Limited is a 50:50 joint venture between the Volvo Group

(Volvo) and Eicher Motors Limited (EML). It is a partnership that brings together Global

leadership in technology, quality, safety and environmental care, along with the deep

knowledge and understanding of the Indian Commercial Vehicle (CV) market. VE

Commercial Vehicles Ltd. (VECV) owes its inception to the compelling intent of driving

modernization in commercial transportation, in India and other developing markets. India

is an emerging country with huge potential. The domestic economy is now growing at

around 8-9% per annum and India’s importance in global terms is being reinforced by

rapidly rising exports and domestic consumption. At a time when numbers of a slowdown

and overheating in the Indian economy have started gaining momentum, the Indian rupee

sprang a surprise by pushing the GDP figure past the trillion-dollar (42,00,000 crore)

mark.

The automotive industry is at the centre of India’s new global dynamic. The domestic

market expanding rapidly as incomes rise and consumer credit becomes more widely

available. Manufacturer’s product lines are being continually expanded, as is the local

automotive manufacturing base. Expectation are high that India can develop as a global

hub for vehicle manufacturers and as an outsourcing centre that offers the global

automotive industry solution high up the automotive value chain.

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LIST OF FIGURES

Chapter-2

2.1- Eicher commercial Vehicle 26

2.2- Eicher Engineering Components 27

2.3- Eicher Engineering Services 27

2.4- Eicher Product Variety 31

2.5- Eicher Buses 31

2.6- Eicher Pro Series Model 35

Chapter-3

3.1- Inspection of Pro Series Vehicle 46

3.2- Detecting Air Filter Fault while Inspection 46

3.3- Mounting of Body after Dispatching 47

3.4- Vehicle Ready after Inspection to Dispatch 48

3.5- Inspection & Maintenance 51

Chapter-4

4.1- Maintenance & Inspection Sheet 68

4.2- Vehicle Inspection Sheet 69

4.3- Customer Instant Feedback Sheet 70

4.4- Old Parts Delivery Note 71

4.5- Tech Tool Kit 72

4.6- About Tech Tool Software Version 73

4.7- Manual Selection For Searching a Model 74

4.8- Operating the Vehicle Using Tech Tool 74

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LIST OF CHARTS

1.1- Market Share Of LCVs in India 12

1.2- Market Share Of MHCVs in India 12

2.1- Eicher Motors In Various Fields 28

2.2- Eicher CV Business 29

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Chapter-1 INTRODUCTION

1.1 Indian Automobile Industry

India is an emerging country with huge potential. The domestic economy is now growing

at around 8-9% per annum and India’s importance in global terms is being reinforced by

rapidly rising exports and domestic consumption. At a time when numbers of a slowdown

and overheating in the Indian economy have started gaining momentum, the Indian rupee

sprang a surprise by pushing the GDP figure past the trillion-dollar (42,00,000 crore)

mark.

The automotive industry is at the centre of India’s new global dynamic. The domestic

market expanding rapidly as incomes rise and consumer credit becomes more widely

available. Manufacturer’s product lines are being continually expanded, as is the local

automotive manufacturing base. Expectation are high that India can develop as a global

hub for vehicle manufacturers and as an outsourcing centre that offers the global

automotive industry solution high up the automotive value chain.

India eyes 25 million automotive jobs.

India's GDP is set to double over the next decade

In percentage terms, the automotive industry's contribution should also

double.

In dollar terms, the sector's contribution is set to quadruple to some $145bn

With the world’s second largest and fastest-growing population, there is no denying

India’s potential in both economic and population terms and the effect it will have on the

auto industry in the years to come. The country is already off to a good start, with a well-

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developed components industry and a production level of 1 million four-wheeled vehicles

a year, plus a further 5 million two- and three-wheelers.

The automotive industry in India grew at a computed annual growth rate (CAGR) of 11.5

percent over the past five years, the Economic Survey 2011-12 tabled in parliament on

2nd July’10 said. The industry has a strong multiplier effect on the economy due to its

deep forward and backward linkages with several key segments of the economy, a

finance ministry statement said. The automobile industry, which was plagued by the

economic downturn amidst a credit crisis, managed a growth of0.7 percent in 2011-12

with passenger car sales registering 1.31 percent growth while the commercial vehicles

segment slumped 21.7 percent.

Indian Automobile industry can be divided into three segments i.e. two wheeler, three

wheeler &four wheeler segment. The domestic two-wheeler market is dominated by

Indian as well as foreign players such as Hero Honda, Bajaj Auto, Honda Motors, TVS

Motors, and Suzuki etc. MarutiUdyog and Tata Motors are the leading passenger car

manufacturers in the country. And India is considered as strategic market by Suzuki,

Yamaha, etc. Commercial Vehicle market is catered by players like EICHER Motors,

Ashok Leyland, Volvo, Force Motors, Tata Motors etc.

Key Facts:

• India ranks 12th in the list of the worlds top 15 automakers

• Contributes 5% to the GDP

• Production of four wheelers in India has increased from 9.3 lakh units in 2003-04 to

88 lakh units in 20011-12

• Targeted to be of $ 145 Billion by 2016

• Exports increased from 88,000 units in 2002-03 to 5,80,000 units in 2011-12

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1.2 Market share�

�

1.1 Market share of Light commercial vehicles in India.

�

1.2 Market share of Medium and Heavy Commercial Vehicles in India.

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Chapter-2

ABOUT VOLVO EICHER COLLABORATION

2.1 Company Profile: -

VE COMMERCIAL VEHICLES manufactures a range of commercial vehicles with

GVW of 5 to 11 tons. It has been outperforming the industry for the past six years. The

sales growth in its LCV segment has been higher than that of the industry. In technical

and financial collaboration with Mitsubishi Motors Corporation of Japan, EML started

manufacturing the CANTER range of vehicles in 1986 at its plant at Pithampur in Central

India. The plant is a "state-of-the-art" facility with an integrated capacity of around 20000

vehicles per annum.

2.2 Basic Information

Company Name: VE Commercial Vehicles Ltd. (A Volvo Group and Eicher

Motors joint venture)

Business Type: Manufacturer

Eicher Sells: Gears, Gearbox, Transmission, Agriculture Gearbox,

Planetary Gearbox, Axle, PTO Gearbox, Worm Gearbox

Eicher Buys: forgings, Gear Cutters

Address: S.V.Road

Number of Employees: Above 1000 People

Year Established: 1971

Main Markets: 1. South America 2. Eastern Asia

. 3. Southeast Asia . 4. Africa.

. 5. North America

Total Annual Sales Above US$100 Million

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Factory Information

Management Certification: ISO 9001:2008 ISO/TS 16949

Contract Manufacturing: OEM Service Offered Design Service Offered Buyer

2.3 Overview

VE Commercial Vehicles Limited is a 50:50 joint venture between the Volvo Group

(Volvo) and Eicher Motors Limited (EML). It is a partnership that brings together Global

leadership in technology, quality, safety and environmental care, along with the deep

knowledge and understanding of the Indian Commercial Vehicle (CV) market. VE

Commercial Vehicles Ltd. (VECV) owes its inception to the compelling intent of driving

modernization in commercial transportation, in India and other developing markets.

Key Facts

VE Commercial Vehicles Limited (VECV) is a 50:50 joint venture between the Volvo

Group and Eicher Motors Limited, and is headquartered at New Delhi. This joint venture

came into effect in July 2008.

VECV is a leading full-range commercial vehicle player in India.

ETB, completed 25 years of operations in India in the month of June 2011. The first

Eicher truck was rolled out from its manufacturing plant in Pithampur, Madhya Pradesh

in 1986 and over the past 25 years, the products have got endorsement from happy

customers of over 300,000 vehicles.

Dec 2007: Signing of Letter of Intent

Dec 2007: Signing of Letter of Intent

Jan 2010: Launch of VE-series of Eicher HD trucks

Jan 2010: Launch of VE-series of Eicher HD trucks

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2.4 Volvo Trucks India: Sales And After Sales Support Of Volvo Trucks In India:

Volvo Trucks in India is synonymous with the mining and the construction industries.

They have been tried and tested for operations in extreme conditions, reliable and robust

performance and maximum productivity. Over the years Volvo Trucks has built up an

elite customer base having over 100 vehicles in their fleet operating at various mining

sites across India. The customers vouch by the high reliability and productivity and have

expanded business operations at a fast pace with quick return on investments. Being the

customer’s best business partner, Volvo Trucks extend support to customers’ right

through the life-cycle of the products with a wide network of service and parts centres

and on site assistance.

Eicher Trucks and Buses (ETB) has a strong presence in the L/MD segment with a

dominant share in the 5T-12T truck segment. Eicher’s 21-69 seater buses have a growing

presence in the LD school bus, staff and route-permit segments. ETB has also made

strong inroads into heavy-duty trucks segment of 16T-40T with their “VE” series of Fuel

Efficient heavy-duty trucks.

Eicher Engineering Components (EEC), the automotive component division of

VECV,came into existence in 1992.

Eicher Engineering Solutions (EES) was set up in 1997, as a center of excellence to

provide design, development and consulting expertise in the field of engineering services.

It has two main business areas – EES Inc. (US) and EES Gurgaon (Delhi).

The state-of-the-art plant in Pithampur has access to top line manufacturing processes

which includes cab weld shop with robotic welding, CED paint shop, integrated testing

facilities, 100% hot test facility for engines and a lean and scalable manufacturing set up.

The plant has an annual production capacity of 48,000 units.

In 2010, in a global first initiative, VECV announced an investment of 2,880MINR

(million Indian rupees) in its Pithampur plant for the production and final assembly of the

Volvo Group’s new global VE Powertrain.

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The manufacturing set up in Thane houses state-of-the-art machines which include

Gleason Conifex machines for straight bevel gear, Pfauter, Liebherr, Mitsubishi (CNC)

and Cleveland Hobbing machines, latest heat treatment facilities and CNC bore and

Cylindrical grinding machines.

The Plant in Dewas, Madhya Pradesh houses technologically advanced machines and

equipment which includes a battery of Mitsubishi CNC Hobbing machines, fellow

shaping machines, Reishauer Gear Grinder RZ400, Shaving Cutter Re-sharpening

machine from Gleason Hurth, state-of-the-art Continuous Gas Carburising Furnace (from

Aichelin) – fully PLC controlled with robotics for Press Quenching and PLC Controlled

Sealed Quench Furnaces (with hot oil quenching for reduced distortions).

VECV has over 3000 employees across its different divisions in India.

2.5 Vision & Mission

Vision

To be recognised as the industry leader driving modernization in commercial

transportation in India and the developing world.

Mission

VECV aims to continuously improve transportation efficiency in India and developing

markets, thereby reducing logistics costs for goods and people – leading to higher

enablement of specialization in manufacturing, agriculture and services, thereby

increasing the nation’s economic activity and productivity.

We choose to do this in a sustainable manner by having the safest, most durable and

efficient products in the market;

We care for our customers holistically by offering not just trucks and buses, but also

the best service and soft products to enable him to be most profitable;

We work with the driver community to enhance their productivity and overall working

environment;

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We ensure a level of quality and innovation that will continue to set standards in the

commercial transportation industry;

Going Forward

VECV aims to emerge as an Industry leader in driving modernization in commercial

vehicle transportation in India and the developing world by bring about improvement in

transport efficiencies.

In the near course, VECV will strengthen each of its product brands as leaders in their

respective segment through innovative products and expansion of its existing network

spanning the geographical expanse of the country.

2.6 Company description

VE Commercial Vehicles Limited owes its inception to the compelling intent of driving

modernization in commercial transportation, in India and other developing markets.

As a 5050 joint venture between the Volvo Group (Volvo) and Eicher Motors Limited

(EML), VE Commercial Vehicles (VECV) incorporates unique abilities to be able to do

so. The organization brings together global leadership in technology along with deep

knowledge and experience of the Indian commercial vehicle (CV) market.

As a company, VECV includes the complete range of Eichers commercial vehicles,

components and engineering design businesses as well as the sales and distribution of

Volvo trucks. Thus, each of its business units is already well-established and backed by a

sizable customer base.

VECVs portfolio of commercial vehicles includes two product brands with absolutely

different market positions yet complementing segment synergies. Eicher Trucks & Buses

have a wide offering in the mass market, 5T40T range while Volvo Trucks command a

strong presence in the premium, high-performance, heavy duty segments from 25T49T.

With a formidable presence in the existing light and medium duty segments, VECVs

main focus is on increasing the penetration and market share of its heavy duty products.

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Thus, its investments in design, development, manufacturing, systems, distribution and

services are largely oriented towards creating a stronger position in the heavy duty

market.

VECV is going all-out to gear itself in becoming a proactive solutions and service

provider meeting all customer needs. This it will do by strengthening each of its product

brands as leaders in their respective segments. In the near course, VECV will offer an

even more innovative line-up of technologically advanced and ergonomically aesthetic

products. Volvos widespread distribution network will facilitate the export of these

products to countries world over and will help VECV bolster its presence in more than 26

countries to where it currently exports. With an improved thrust on retail network

development and after sales service, VECV will soon come to be recognized as a lean

organization capable of setting new benchmarks in response times.

It is important for VECV, that its growth must also have a positive influence on the

industry it serves; ensuring that the industry becomes more efficient, environment

friendly, offers safer products and manufactures products that are driver friendly. And

this dictum of being the differentiator not only reflects in VECVs approach in the market

place but also in its internal workplace moving it to becoming a preferred employer in the

industry.

VE Commercial Vehicles has over 4000 employees with a sales & support network that

spreads across more than 300 points across the country. Companies industrial base

includes an integrated commercial vehicle factory in Pithampur producing Eicher trucks

& buses along with factories in Thane, Gurgoan and Dewas dedicated to manufacturing

gear boxes and gear box assemblies.

VECV is jointly managed by Volvo and EML with shared management and equal

representation rights on the board of Directors. All management positions are appointed

by the board. Mr. Par Ostberg (Chairman, Trucks Asia, Volvo Group) is VECVs

chairperson while Mr. Siddhartha Lal is the Managing Director and CEO.

Operational since July 2008, VE Commercial Vehicles is headquartered at New Delhi

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2.7 Business areas of Volvo Eicher Motors Limited

Eicher Motors Limited comprises of the automotive businesses of the EicherGroup . The

business activities of the company are carried out by its constituent Business Units, each

covering a product category as described below.

Business Area Products

VE Commercial Vehicles Ltd - Eicher Trucks & Buses, Volvo Trucks,

Gears & Shafts

Motorcycles - Royal Enfield

2.8 VE COMMERCIAL VEHICLES LTD

It manufactures a range of commercial vehicles with GVW of 5 to 11 tons. It has been

outperforming the industry for the past six years. The sales growth in its LCV segment

has been higher than that of the industry. In technical and financial collaboration with

Mitsubishi Motors Corporation of Japan, EML started manufacturing the CANTER range

of vehicles in 1986 at its plant at Pithampur in Central India. The plant is a "state-of-the-

art" facility with an integrated capacity of around 20000 vehicles per annum.

2.9 ROYAL ENFIELD

Royal Enfield, manufacturers of the renowned range of Bullet motorcycles, has pioneered

manufacture of motorcycles in India. It has a wide range of high powered bikes in its

stable to deliver a ‘unique motorcycling experience’ to its rider. Presently Royal Enfield

is producing six different models ranging from 300cc to 600cc.All the products are

manufactured indigenously in its manufacturing plant in Chennai, which has an annual

installed capacity of manufacturing 39,000 motorcycles.

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2.10 Eicher Motors

2.10.1 Company Overview

Eicher Motors Limited is an India-based company engaged in the business of automobile

products and related components. The Company’s product range includes commercial

vehicles (Eicher and Volvo trucks), motorcycles, and components, including gears and

engineering solutions. The Company operates in the leisure cruiser segment with engine

capacity of 350 circuit current and above. During the year ended December 31, 2009, the

Company sold 51,955 motorcycles .In 2009, the Company introduced Classic bike in the

two categories of 350cc and 500cc. The Classic bikes are powered by a single cylinder

500 cc unit construction engine (UCE) supported by electronic fuel injection (EFI). The

UCE has an integrated assembly for the engine, gear box and clutch to reduce friction.

Eicher Motors' subsidiaries include VE Commercial Vehicles Limited, Eicher

Engineering Solutions, Inc., Hoff Automotive Design Company and Hoff Technology

Service Company.

Eicher Motors operates in three segments: Commercial Vehicles, Two Wheelers, and

Components of engineering products, as well as in the publication of city map and travel

guides. Its commercial vehicle plant is located at Dhar, MP. The company manufactures

motorcycles at a plant at Thiruvottiyur, TN, promoted under the brand Royal Enfield. The

company’s engineering component plants - located at Gurgaon, Haryana and Dewas, MP

- manufacture gears, gear boxes, and other components The company is also involved in

management consultancy services and customized. It has a joint venture agreement with

Volvo AB. The company has a strong network of 142 dealers distributed across India.

Eicher Motors is present in over 40 countries across the world. Most of the exports are to

South Asia, West Asia, and African countries

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2.10.2 AN OVERVIEW

Eicher began its business operations in 1959 with the roll out of India's first

tractor. Today the Eicher Group is a significant player in the Indian automobile

industry with a gross sales turnover of over Rs. 13,700 million in the year 2002-

03.

The Eicher Group has diversified business interests in manufacturing & marketing

of Tractors, Commercial Vehicles, Automotive Gears, Motorcycles, and exports

of vehicles, aggregates and components. Eicher has also invested in the potential

growth areas of Management Consultancy Services. The activities of the Group

are divided into the following business units covering all the business interests.

EICHER LIMITED

Subsidiary Companies Products

EICHER MOTORS LIMITED - Commercial Vehicles

EICHER TRACTORS - Tractors

ROYAL ENFIELD - Motorcycles

EICHER DEMM - Gears

EICHER INTERNATIONAL LTD - Exports

ECS LTD. – Management Consultancy

GOOD EAREH PUBLICATIONS - City Maps, Travels Guides

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2.10.3 EICHER MOTORS LIMITED

Eicher Motors Limited (EML) was incorporated in 1982 and introduced its first product,

the Canter, a 6 ton GVW truck manufactured at its state of the art plant at Pithampur,

Indore in collaboration with Mitsubishi Motors Corporation, Japan, in 1986. The

maiden offering soon created a strong customer base for itself.

From a single 6 Ton GVW truck in 1986, our range today extends from 5T to 16T

GVW trucks and the Skyline and Voila range of Buses. All our products can be offered

in BS II compatible options. We also have arguably the best CNG technology in the

world in our CNG Buses. Pioneering the concept of Built Up vehicles in the country,

we make products that consistently deliver high value to our customers and are

increasingly becoming the preferred option for all CV users, not only in India but

overseas too. Eicher CVs today have significant presence in more than 20 countries

across the world.

In India, Eicher Motors has consistently outperformed the industry in terms of growth

and currently holds over 30% market share in the 6T-11T GVW segments. In the 9T

GVW segment, Eicher Motors continues to be the leader with more than 50% market

share. Our well-equipped workshops result in faster turnaround of service. A network of

more than 4500 Eicher trained private mechanics, over 133 authorized sales and service

centres, and easy availability of genuine parts across more than 300 authorized spares

outlets means less downtime and increased opportunities for our customers to earn.

Eicher Motors is now poised to further consolidate its position in the CV industry by

entering into the Medium & Heavy Commercial Vehicle segments. Strategic plans are

in place to ensure necessary investments in technology and training to constantly

sharpen our development and manufacturing edge. EML is totally committed to

fulfilling the vision of being one of the top 3 CV manufacturers in the country by giving

customers what they want: vehicles that are safe, fuel efficient, easy to maintain,

enhance driver comfort and in turn productivity. Vehicles that deliver value by

providing low cost of ownership and increased profitability to our customers.

Eicher has over 5000 employees located in 10 manufacturing facilities and 24

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marketing offices all around the country. The Group has around 950 vendors supplying

components and sub-assemblies which testify to the strength of the vendor base. The

Group's products are brought to the customer through its network of around 800 dealers

distributed across the length and breadth of the country.

THE EML ADVANTAGE

-Technological Expertise

-Extensive Network

-Customized Applications

-Efficient cost of ownership

-Exports

-Vehicle Financing

Technological Expertise

EML products are manufactured at the Company's plant in Pithampur, near Indore,

Madhya Pradesh, India. The company has absorbed the technology and has successfully

indigenised the vehicles.

To ensure that we continue to create products that offer unique advantages and benefits

to our customers, Eicher Motors Limited has set up a Product Development group,

consisting of competent engineers. The team has developed several successful vehicles

and variants, an achievement made possible by the use of the latest Computer Aided

Design and Computer Aided Engineering (CAD-CAE) software like NASTRAN and

FEM analysis packages.

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Extensive Network

Eicher Motors Limited provides its customers the benefit of an extensive sales and

service network, customised solutions and an efficient cost of ownership.

Our manufacturing capabilities are backed by a sales and service network of over 133

EML authorised sales & service centers and more than 300 authorised spares outlets.

The three-tier service network consists of:

• Authorised distributors in metros and cities.

• 133 Authorised Service Centre's.

• Over 4500 company trained private mechanics.

Service highlights:

• Eicher Genuine Spares - available across all Eicher dealerships, service

centres, spares distributors, satellite service outlets and retail outlets.300

authorized spares outlets throughout the country.

• A strong and wide dealer network

• Grass-root level penetration through training to popular local mechanics,

currently numbering over 4500 nationwide.

• Fully equipped modern workshops for fast and experienced service.

• Driver-Safety training programmes for drivers of corporate and institutional

customers.

• Free vehicle check-up camps, organised regionally.

• A Comprehensive Service Audit System, which oversees the physical

infrastructure, ensures understanding and compliance with the system and

provides training and technical updates.

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Customized Applications

Eicher specializes in offering ready-to-use custom-built application vehicles to

suit customer needs, in addition to the normal range of vehicles. Adaptation of

product specifications to suit local regulations and norms is an integral part of the

process.

All Eicher exports to the Middle East meet Gulf Council Countries(GCC)

specifications, have power steering and air-conditioned cabins. A breakthrough in

our record as solution providers came when Eicher developed a cargo deck of a

composite material of Wood and Steel, called Met wood. Met wood is lighter and

more elegant, and vehicles fitted with these have more load capacity and yield

higher fuel efficiency. We also specially manufacture Commuter and Tourist

Buses suited for African markets. Our Commuter buses are designed for larger

passenger carrying capacities and to withstand tough road conditions.

Efficient Cost of Ownership

Eicher vehicles not only prove to be safe but also a profitable business

investment. This is a result of the engineering, maintenance and safety features

built-into each Eicher vehicle. We call this the efficient cost of ownership of an

Eicher vehicle.

Some of the highlights are:

• A Tilt able Cab for easy reach during routine and periodic service check-

ups.

• An Automated Exhaust Braking system that activates the brakes

automatically on deceleration, allowing for more driver control.

• A collapsible steering wheel.

• Adjustable seats for ergonomic comfort, thus reducing road fatigue.

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• An aerodynamic design and a highly fuel efficient engine, that make it the

most fuel efficient vehicle in its class.

Exports

Eicher Motors markets its range of Commercial Vehicles and customized

applications to over 28 countries across the world.

Vehicle Financing

Eicher has arrangements with a number of key Non Banking Financial Companies

and Financial Institutions to help our customers to avail finance for the purchase

of vehicles. Eicher also provides customer finance through Auto Finance

Company, a division of EML.

Eicher Motors Limited

Fig 2.1 Eicher Commercial vehicle

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Fig 2.2 Eicher Engineering Component

Fig 2.3 Engineering Services

2.10.4 EICHER COMMERCIAL VEHICLES

The Commercial vehicle division was established in 1986 in collaboration with

Mitsubishi Motors Japan and is one of the leading manufacturers of commercial vehicles

in India having capacity of manufacturing 38,000 Commercial vehicles.

The Product range includes 5 ton, 7 ton, 9 ton, 11 ton, 16 ton & 25 ton GVW categories

trucks, tipper, trailers; Bus range includes City buses, School bus, luxury coach, Intercity

CWC, Nova 200; Ready-To-Use application vehicles - Around 85 RTU built vehicles to

suit a diverse range of applications.

The manufacturing plant equipped with state-of-art facilities with stringent quality

control norms - practices like Kaizen, Just-in-time, TQM and TQC etc. and State of the

art R&D set up helping the commercial vehicles unit to serve their customers better.

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Pie chart 2.1 Eicher motors in various fields

Diagram showing diversifications in various fields by Eicher Motors Limited with

their percentage and capital distribution.

2.10.5 EICHER’S CV BUSINESS

Eicher is the third largest player in the Indian Commercial Vehicles market:

– It leads in the LCV segment with 27% market share in domestic 5-12T cargo segment

in FY 16.

– It is gaining momentum in the HCV segment with successful launch of 16T, 25T,

Tipper and Passenger segments and 1.8% domestic cargo market share in FY 16 implying

a growth of 32.9% in sales volume over FY 15.

Eicher’s CV business is well positioned to tap the incumbent growth in the CV industry

owing to its:

–Established track record and stronghold in LCV segment

–Strong brand equity, an established Marketing and Distribution Network and cost

competitive R&D and manufacturing base providing a ready platform for foray in HCV

segment.

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Eicher – the third largest player in the industry – is well set to leverage its dominant

presence in LCV segment to gain significant market share in the fast growing HCV

Segment

With the introduction of new products and upgrading of existing products across the

range, Eicher poised for higher volumes.

EICHER CV BUSINESS – AN OUTLOOK

Pie chart 2.2 Eicher CV Business

Industry on Fast Track

• CV industry (5T & above) has grown by 25.4% with 355,761 vehicle s sold in FY 16

over last year.

• Improving road infrastructure creating market opportunities for high performance

products.

Strong Position in LCV Segment

• Strong position in LCV segment with market share of 27% in 5 -12T domestic cargo

segment.

• Absence from Sub 5T category leaves significant room for further expanding the

product portfolio.

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• Established track record and Brand Equity, recognized for superior product

quality/specifications.

Ready Platform for Successful HCV Foray

• Successfully launched 16T, 25T, Tipper and Passenger segments with an indigenously

designed product range.

• Various success stories in segments and geographies, that would be replicated pan-India

with expanding sales & marketing infrastructure and focused marketing push.

• New products on the verge of being launched, providing significant opportunity to

capture wider spectrum of the market and expanding customer segments.

• Incumbent Brand Equity to facilitate successful foray into lucrative HCV market.

Sales and Marketing Infrastructure

• Strong dealer network in West, Central and South India

• Strengthening the dealership network, primarily to increase geographical coverage

• Sales & Marketing setup was historically more focused on LCV. Significant progress

made to gear up the same to cater to HCV segment.

Low Cost Manufacturing and Product Development

• Established R&D infrastructure and proven skill set.

• Proven capability to develop new products in short timeframe and at minimal

development cost, giving crucial time to market and cost advantage.

• Constantly evolving supply chain management with robust supplier base.

• Optimized manufacturing set-up with a good mix of “Make and Buy”.

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Management and Engineering Skill Set

• Qualified and motivated management with established track record of change

management, business integration and new product development.

• Strong engineering and product development skills.

2.10.6 Product Range of Eicher Motors Ltd.

LEADING THE WAYTO Profitability

Leveraging 25 years of local presence and international Partnerships to drive

Modernization in the Indian transportation industry.

Trucks Buses Special Applications Non-Automotive Engines

Fig 2.4 Eicher Product variety

The Eicher range of Buses & Chassis is a contemporary offering of superior vehicle

performance with safety features, superior comfort and redefined styling. The range

comprises of:

Fig 2.5 Eicher buses

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Buses

Eicher Offers a wide range of options in the Buses. There are two range of Built up buses

- Skyline &Starline with a seating capacity starting from 16 seater till 65 seater. As per

the requirement of the customers, Eicher also offers a wide range of chassis starting from

a 12 seater capacity till the 65 seater Capacity. Eicher buses are trusted by the customers

for the best in class fuel efficiency.

School Buses

Eicher introduced “SKYLINE - The First Safe School Bus” in India, developed in

association with IRTE (Institute of Road Traffic Education) in the year 1996, thereby

pioneering the concept of School Bus. The school bus specific features have now become

a norm in the industry. Apart from being safest the popular Skyline school bus is now

available in enhanced features, superior aesthetics & increased passenger comfort.

\

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Staff Buses

Eicher Skyline has made staff commutation as comfortable as it can be. Aesthetic

superiority, high passenger comfort & Economical performance has made this bus class

apart. The faith of customers & industry is reflected with the fact that Skyline Executive

was awarded with CV-Apollo Award 2010 for “LCV" Bus of the year.

City Buses

The latest offering from Eicher - the Rear Engine Semi Low Floor (RESLF) bus has been

developed in line with the guidelines laid down by the Ministry of Urban Development as

applicable to Mass Urban Transportation needs. This offering has been received with lot

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of optimism & excitement by various State Transport Undertakings, City Administrations

and Municipal Bodies across India. Eicher also offers a wide range of products in the

Mini, Midi and Heavy buses for City Bus Deployment. The products have been designed

to suit the frequent start-stop duty cycle of intra city operations.

Route Permit Buses

Eicher Offers a wide range of chassis for Route permit (Stage Carriage) deployments.

Eicher products are well suited for the unique requirement of the route permit application,

which necessitates a frequent start-stop operation, overload and rugged usage.

Trucks

Eicher manufactures a range of Haulage (5 T- 31T), Tipper (8T to 25T), Articulated

Tractor (40 T) and Special Applications trucks.

Eicher Trucks are built to deliver low ‘Total Cost-of-Ownership’. The Eicher haulage

trucks’ range includes the E2 Plus series of 5T-13T Light & Medium Duty Trucks

(LMD) – tagged as “Mileage KaBadshah” and VE Series of Fuel efficient Heavy Duty

Trucks (HD) of 16T-31T. Designed for superior performance with better fuel economy,

higher rated payload and faster turnaround these trucks have low operating cost and, high

reliability leading to higher profits.

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Fig 2.6 Eicher Pro Series Model

Tipper

Eicher Terra series of 16T & 25T offer enhanced value to customers in areas which are

critical to a tipper operating economics. The USP of Eicher Tippers is their better uptime

and pulling power, stronger aggregates, and the ability to run more number of trips. Terra

tippers offer enhanced benefits which accrues from the results of extensive research done

by the company in the market understanding of the usage pattern and various duty cycle

of its operation. The range makes a significant and positive effect on the operators’

productivity and profitability by offering better fuel economy.

Articulated Tractor

Eicher 40.40 (Articulated Tractor) from the VE series is built to “Deliver More!” Fitted

with Cummins Engine of 132.5 Kw, Max Torque of 650 Nm and the ET-80 gear box, the

optimized power and torque benefits come along with the High Fuel Efficiency, stronger

aggregates which offer high reliability and durability. The soft suspended Cabin offers

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higher driving comfort which means faster turnaround and more trips leading to higher

revenues.

Special Applications

Eicher produces an efficient range of Special Application trucks which have been

envisioned and developed to suit the specific requirements of:

Special Applications

Eicher produces an efficient range of Special Application Vehicles which are used as for

various applications as Troop Carriers, Garbage Tippers, Water Containers, Mild Steel

Container & Ambulances.

Eicher Ambulance is a state of art van with all facilities pertaining for an emergency

medical vehicle. Vehicle is equipped with on board equipments not just for safe and swift

transfer of patients but also for providing emergency medical aid.

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Mild Steel Container

Ready to use from day 1, Eicher MS container options are unique with respect to fine

engineering design and flexibility requirements. Engineered design, Fine workmen-ship

and rugged but light in weight are few features of Eicher containers offered with 18

months of warranty on container.

Troop Carrier

Its about Determination and Conquering the spirit, Eicher vehicles deliver on these.

Water Tanker

Low operating cost, efficient and durable water tankers. Fully built Water Tankers

options available in 3.5 KL, 5KL, 6KL & 9KL

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Chapter-3 PRE DELIVERY INSPECTION

CHECKS TO BE CARRIED DURING PDI

3.1 CABIN

3.1.1CABIN EXTERIOR

Check distortion and damage of body panels

Check painting, rusting and flaws on body panels.

Check all doors, hood and other parts for proper spacing at top and bottom, front

and rear.

Check for all doors and mirrors installed properly.

Check for security of the cab mounting.

3.1.2CABIN INTERIOR

Check seats, interior trims and head lining are installed properly.

Check seats, interior trims and head lining for damage and abrasion.

Check painting, rusting and flaws.

Check for drip and seepage of adhesive.

3.2 BODY AND CHASIS

3.2.1 HYDRAULIC TILT MECHANISM

Check for any leakage in the system.

Check for the oil level in the pump & fill upto top level.

Check for the tightening of mounting bolt.

3.2.2 REAR CAB SUSPENSION

Check for any leakage in the system.

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Check if the latch is operating while pumping.

3.2.3OPERATION OF DOORS,LOCKS AND WINDOWS

Check door operation for closing and opening.

Check operation of the door lock from both inside and outside the vehicle.

Check the windows for the ease of operation and tight fit against weather strip.

3.2.4 OPERATION OF LAMPS AND SWITCHES

Check operation of all lamps and switches

Headlamps

Turn signal and hazard warning

Tail, clearance lamps, stop, backup, and licence plate lamps.

Other warning lamps and switches.

3.2.5 OPERATION OF WINDSHIELD WIPER AND WASHER

Check operation of the wiper in all ranges.

Check the washer for operation and the nozzle for clogging.

Check the water level in the washer tank.

3.2.6OPERATION OF HORN ELECTRICAL EQUIPMENT

Check the operation of horn.

3.2.7 REFLECTION OF MIROR

Check the mirrors for reflection and stain.

3.2.8 CLUTCH RESERVOIR TANK FLUID LEVEL

Check the fluid level in the reservoir tank. The fluid level should be between the

min. and max. levels. (If the level is too low, check for fluid leaks.)

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3.3ENGINE COMPARTMENT

(IN ENGINE OFF CONDITION)

3.3.1 RADIATOR COOLANT LEVEL

Check the coolant level in the de aeration tank. If the level is too low, check for

coolant leaks.

3.3.2 ENGINE OIL LEVEL

Check the oil level. The oil should be in the specified range.

3.3.3 POWER STEERING OIL LEVEL (VEHICLE WITH POWER

STEERING)

Check the oil level in the oil tank.

Note: when the check is made, the front wheels should be placed in straight-

ahead position.

3.3.4 FUEL LEAKS FROM FUEL SYSTEM

Check the fuel system for leakage from fuel feed pump, fuel filter, injection

pump, injection nozzle, piping.

3.3.5 AIR INTAKE LINE

Check tightness of turbocharger/intercooler air hoses.

Check tightness of turbocharger/intercooler air pipes.

Check tightness of intercooler mounting bolts.

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3.3.6 EXHAUST MANIFOLD TIGHTNESS

Check that the exhaust manifold is correctly tightened. If the mounting nuts are

loose, tighten them to specification.

Check the tightness of turbocharger mounting bolts.

Check for oil leakage at turbocharger in and out.

Check tightness of oil supply pipe bolts.

Check leakage of wastage hose.

3.3.7 INSTALLED CONDITION OF ELECTRICAL EQUIPMENT

Check that the starter and alternator are installed properly.

Check the wiring connections for tightness. If the wiring is in contact with other

parts, correct it by proper clamping.

3.3.8 DRY TYPE AIR CLEANER

Check the indicator for chocking. Clean the element if found choked.

3.4 ENGINE COMPARTMENT

( IN ENGINE OPERATING CONDITON)

3.4.1 ENGINE STARTING PERFORMANCE

Check to see if the engine starts smoothly.

Check operation of the key switch and starter.

3.4.2 COOLANT, AIR AND OIL LEAKAGE FROM CYLINDER HEAD

AND ROCKER CASE

Check for coolant and air leaks from the cylinder head.

Check for oil leaks from the rocker case or cylinder head cover.

3.4.3 OPERATION OF ACCELERATING LINKAGE

Check the accelerator pedal for sticking, binding and full return.

Check for abnormal engine noise.

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3.4.4 EXHAUST GAS CONDITION AND NOISE

After the engine has warmed up, check that black smoking is not emitted at

idling, medium and high speeds.

Check for abnormal noise.

3.5 UNDER VEHICLE

3.5.1 ENGINE OIL LEAKS FROM OIL PAN AND OILCOOLER

Check for oil leaks from the engine oil pan, oil cooler and oil filter mounting

area.

3.5.2 ENGINE SUPPORT BOLTS TIGHTNESS

Check that the engine mounting bolts are tightened to specifications

Tighten them to specifications as specified in shop manual.

3.5.3 FLUID LEAKS FROM CLUTCH LINES

Check that the pipes and hoses are not in contact with other parts.

3.5.4 AIR LEAKS FROM BRAKE LINES

Check the brake pipe lines for leakage.

Check the pipes and hoses are not in contact with other parts.

3.5.5 OIL LEVEL IN STEERING GEAR BOX, TRANSMISSION AND

REAR AXLE HOUSING

Remove the inspection plug(filter plug) and check that the oil is at the brim.

Steering gear box

Transmission

Axle housing

3.5.6 FLUID LEAK FROM SHOCK ABSORBER

Check the shock absorber for fluid leaks.

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3.5.7 FUEL LEAKS FROM FUEL TANK

Check for fuel leaks from the drain plug of the fuel tank and the pipe

connections.

3.5.8 SUSPENSION SHACKLE PIN LOCK BOLTS AND U-BOLTNUTS

TIGHTNESS

Check that the shackle pin lock bolts and U-bolt nuts are correctly tightened.

3.5.9 PROPELLER SHAFT FLANGE YOKE BOLTS TIGHTNESS

Check the flange yoke bolt tightness.

3.5.10 DIFFERENTIAL CARRIER ATTACHING BOLTS TIGHTNESS

Check the bolts attaching differential carrier to axle housing for tightness.

3.5.11 ELECTRICAL CONNECTION AND ROUTING

Check the battery cable and other electrical connection for tightness.

3.5.12 BODY MOUNTING BOLTS AND NUTS TIGHTNESS

Check the body mounting bolts and nuts for tightness.

3.6 TYRE (INCLUDING SPARE TYRE)

Check the tyre pressure while the tyres are cold.

Check for stone, pebbles and other foreign objects caught in the tread grooves,

remove them.

Check that the spare tyre is installed properly.

Front and rear wheel nuts tightness.

Check the exhaust pipe and muffler installation and connection for looseness.

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3.7 ROAD TEST

3.7.1 ENGINE STOPPING CONDITION

Turn the starter switch to “ACC” and check stopping of engine smoothly.

3.7.2 SERVICE BRAKE OPERATION

Inspect pedal play and stroke.

Check that brake operation is smooth and positive.

Check oil leakage from supply pipe of compressor.

Check water leakage at inlet/outlet hoses of compressor

3.7.3 PARKING BRAKE OPERATION

Inspect the operation of graduated hand control valve, braking effect, return and

buzzer.

Check for wind-off nut of spring brake actuator.

3.7.4 CLUTCH OPERATION

Check the operation of clutch in all driving ranges.

Check clutch pedal play.

3.7.5 TRANSMISSION OPERATION

Check the operation of transmission and gearshift lever in all ranges.

Check the control linkage for looseness.

3.7.6 STEERING WHEEL PLAY AND OPERATION

Place the steering wheel in straight-ahead position and check for the play.

Check the steering wheel for ease of operation, stability and returnability.

3.7.7 GAUGES AND WARNING LAMPS FUNCTION

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Inspect that all gauges and warning lamps are functioning properly, i.e.

speedometer, air pressure gauge, fuel gauge, water temperature gauge and

warning lamps.

3.7.8 NOISE

Check for noise in each of the brakes, clutch, engine, transmission, steering

system, propeller shaft, differential and others.

3.8 FINAL STEPS

3.8.1 VEHICLE WASHING

Clean the vehicle exterior and interior. Then wash the body exterior with water.

Lubricate all greasing points.

3.8.2 TOOL SET

Verify that the tool sets are on the vehicle.

3.8.3 INSTALLATION OF LICENCE PLATES

Install the licence plate.

3.8.4 ACCESSORIES

Head lamp bulbs - one

First Aid kit – one

Chock - two

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FIG 3.1 INSPECTION OF PRO SERIES VEHICLE

FIG 3.2 DETECTING AIR FILTER FAULT WHILE INSPECTION

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FIG 3.3 MOUNTING OF BODY FOR DISPATCHING

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FIG 3.4 VEHICLE READY AFTER INSPECTION TO DISPATCH

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3.9 Inspection And Maintenance Schedule

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51

Fig 3.5 Inspection & Maintenance Schedule

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Chapter-4 CASE STUDY OF MAINTENANCE AND INSPECTION OF A BUS

4.1 BUS INSPECTION WORK SHEET

The mechanic shall use this form to inspect each school bus. After completing the

information on the top of the sheet, the defects are to be noted by placing an X in the Needs

Repair column by the respective item. After repairs to each defective item have been

completed, the mechanic shall place a check mark in the OK column for that item. If defects

cannot be repaired the day of inspection, the mechanic for his own use shall complete a

Defect List. The mechanic shall refer to the Defect List the next day he is at the school and

repair these defective items, if parts are available, before inspecting another bus. The

mechanic shall record his inspection time on the form and turn in daily the 30-Day School

Bus Inspection Work Sheet to the designated person. The designated person shall file the

30-Day School Bus Inspection Work Sheet in the individual bus maintenance history file

after keying inspection data and labor into the computer.

4.2 EQUIPMENT REPAIR AND PARTS ORDER

The mechanic shall record his service truck subshop number on the Shop location, the

vehicle number, work source code, mileage, make, and model of the vehicle, and the

correct date. A list of repairs completed shall be entered on the Repairs Performed Section.

Labour shall be recorded (to the nearest tenth of an hour) for each type of repair. (Only one

type of repair may be entered on a line). The mechanic shall enter his mechanic number

beside all labor time entered on each line of the repair order. The mechanic, or designated

person, shall record the remaining pertinent information needed: All inventory used; DOT -

computer number, manufacturer's number, description, and cost for all non-inventory (direct

charge) items, and/or sublet repairs.

When the job is completed, the mechanic shall sign the form and turn it over to the

designated person for review and for all data to be entered into the computer. This form

shall be filed in an individual vehicle cost record file by a designated person. All travel

time from school to school or bus-to- bus etc. is to be charged on the Equipment Repair and

Parts Order. Charge actual time of repair for each specific repair performed to a vehicle.

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4.3 PREVENTIVE MAINTENANCE OIL CHANGE SERVICE 4.3.1 Preventive Maintenance 12,000- Mile Service

The 12,000-mile preventive maintenance service is a garage-performed activity. It is the

first mileage-based scheduled preventive maintenance after the lubrication, oil, and filter

change. The following procedures and instructions refer to the 12,000-mile service and

the Preventive Maintenance 12,000/24,000/48,000 Service Work Order. These service

procedures are to be followed every 12,000 miles for the entire service life of all vehicles.

This service is similar to that described in the section on 30-day inspection and is

performed even if the vehicle has been previously inspected during the month. The

purpose of this preventive maintenance is to detect any defects in order that repairs can be

made before returning the bus to service. The engine compartment shall be inspected

before the engine is washed in order that oil leaks may be more easily detected.

Engine and battery compartments are to be washed at each 12,000-mile preventive

maintenance service. This will maintain relatively clean engine compartments and allow oil

leaks to be detected more easily on regular 30-day inspections. Also, battery compartment

service will be much easier if a regular cleaning procedure is used.

Although 12,000 miles has been established as a maximum interval at which to perform

this preventive maintenance service, you may want to use more frequent mileage intervals

based upon factors such as terrain, road conditions, urban routes, etc. which may require

more frequent servicing of your bus fleet.

Each mechanic is to record labor only for duties actually performed and the defect

list/work order file is to be reviewed for the vehicle being serviced prior to performing the

preventive maintenance due.

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Road Test

During the road test, the mechanic must be observant for proper operation of all

components of the vehicle. Any defect should be noted. Also, the results of the following

items shall be noted on the work order.

Travel Angle

Observation, by using both side mirrors, should indicate the bus travel angle in relation to

the road or centerline. A bus that appears to be running somewhat sideways (rear axle not

tracking on a straight line with the front axle) could indicate either a misalignment of the

axle to the springs or possibly a broken or bent spring center bolt.

Steering Gear Check

While traveling very slowly in the bus garage parking area or some similar safe place,

slowly turn the steering wheel to its extreme left, back to its extreme right, and then again to

the straight ahead position. Observe any roughness, looseness, or other defect.

This vehicle service is to be recorded on a Preventive Maintenance Oil Change Service form

by the mechanic performing the service. This form is to be turned in daily to the appropriate

person. The Preventive Maintenance Oil Change Service form is to be processed

Equipment Repair and Parts Order. While driving along the road, ease bus to the right

until right wheel leaves the pavement, then slowly to the left until bus returns to the

pavement. Observe if any shimmy or lost motion can be detected.

Load Test

While traveling uphill, or simply slowing down to a point allowing for acceleration while

still in high gear, accelerate the vehicle in a loaded condition and observe performance.

Brake Test

Each vehicle is required to have its brakes tested by using a brake test meter or equivalent

test meter. This test is to be conducted on a dry paved road which is as level as possible

for local terrain. The test is made by making a panic stop at 20 mph after having set the

brake meter on test. The minimum score allowed is 60% for an unloaded vehicle. Any

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score less than 60% requires additional testing and proper brake system repair to enable the

vehicle to be returned to service. You shall not operate any vehicle which does not pass the

brake test.

Panic Stop

While traveling in a safe area, make a panic brake application (without sliding wheels).

Observe braking action and after vehicle has come to a stop, observe engine idle.

Acceleration

While traveling at a speed that would allow heavy acceleration in high gear, observe

engine pings and knocks as well as engine performance.

Transmission Automatic

Observe operation of transmission and record the up and down shift points on the

12,000-mile service form. Also note if gear changes are not normal.

After Road Test

Park vehicle in a clean dry area and observe five minutes later for leaks from any

component.

Tune Up

Perform the following and replace defective items as required. For all gasoline equipped

vehicles, refer to service manual for specifications and requirements.

Vehicle Service Manual

May be obtained by ordering the desired manual from the dealer awarded the state bid

for the respective vehicle model year. Contact the parts department of the bidding dealer

for additional information.

Battery &Compartment

Clean compartment area and make any necessary repairs. Paint (brush) inside of

compartment and tray with corrosion resistant metal seal. Lubricate tray slides. Clean

battery and cable terminals. Install felt battery terminal protector rings and reconnect

cables. Felt protector rings will be more effective if soaked in EP-90 lubricant prior to

installation. If a battery terminal sealer is desired, use high heat paint. Do not use petroleum-

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based lubricant. Equipment required: a battery terminal puller and battery terminal spreader.

Fuel System Test

Fuel Filters

If fuel filters have a replaceable element, fuel/water separator, drain, clean, and install new

element, inspect flex hoses and tubing, replace if necessary.

Electrical System

Starting and charging system tests are performed with a volt amp tester connected at the

battery. With the engine cranking (but not starting), tester meter readings are observed for

the number of amperes of current used and battery terminal voltage during starter

operation. This test provides performance serviceability information for starter motor and

battery.

Alternator test

The alternator output test is performed with the engine running at a speed great enough to

produce maximum output and the tester switch in output test position. The battery load is

increased by decreasing the resistance in the tester carbon pile rheostat until the maximum

ampere rate of current is observed on the tester amp meter.

Voltage regulator

The voltage regulator test is performed with the engine running at the same speed and the

tester switch in the voltage test position. This places a resistor in series with the battery,

simulating a fully charged battery. The regulated voltage is obtained by observing the

maximum voltage on the tester volt meter.

Diode Stator

The diode stator test is performed with the engine running and the tester switch in the

diode stator position. If the test indicates a defect, it will be necessary to disassemble the

alternator to determine if the defect is a diode or the stator. Follow instructions of your test

equipment.

Residual Current Test

With the engine and all electrical components turned off and the negative battery cable

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disconnected, place a milliampere meter in series with the circuit and observe meter

reading. Observing polarity, connect one lead to the negative battery terminal and the other

to the negative cable. A meter reading greater than 100 milliamperes indicates current

leakage through some component of the electrical system. The proper component is located

by the process of elimination (dirty or wet battery will allow current to travel along the case

to ground through the battery tray). Alternators with integrated (internal) voltage

regulators will have a residual current draw of approximately 50 milliamperes.

Engine Drive Belts

Inspect for condition and proper adjustment of belt.

Cooling System test

Using a pump type pressure tester installed on radiator filler pipe, pressurize system and

observe for leaks. Using the same tester, test operation of radiator pressure cap. Visually

inspect radiator hoses, water pump, and other components (coolant recovery tank) for

defects. Inspect radiator support and support mounting bolts and insulators.

Conditioner test

Test the coolant system level with an engine coolant system test kit. If conditioner is

needed, use a conditioner per specifications. This test is extremely critical for proper

diesel engine maintenance. The test shall be conducted utilizing a Coolant Test Kit or

equivalent kit. The coolant conditioner controls the buildup of scale with the cooling

system of diesel engines.

Preventive Maintenance 12,000/24,000/48,000 Mile Service

The mechanic shall complete this form at 12,000-mile intervals for the service life of the

vehicle. After entering all requested information and completing the 12,000-mile service, the

mechanic shall turn the form over to the shop foreman/transportation director for review.

After keying the data into the computer, the form shall be filed in the Individual Vehicle

Maintenance History file for future reference.

Preventive Maintenance 24,000-Mile Service

The 24,000-mile preventive maintenance service is a garage-performed activity. After

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completing the 12,000-mile procedures, the following additional items shall be serviced every

24,000 miles.

Rear Brakes

If indicated by your operating conditions, this service may need to be performed at the

12,000-mile preventive maintenance interval. After rear of vehicle is raised from the floor

and before the wheel and drum assemblies are removed: Place safety stands under axle and

remove both wheel and drum assemblies. Inspect brake components for possible defects

(leaking wheel cylinders, etc.). Clean brake drum, shoes, and other components in a safe

and acceptable manner. Using a tire tread gauge that measures in 32nds of an inch,

measure the amount of brake lining above the rivet head, at the thickest point of each

brake shoe. Record the measurement of the thickest shoe, for each wheel, in the appropriate

space on the Preventive Maintenance 12,000/24,000/48,000 Work Order. On air brake

equipped buses which have cam ground or tapered lining, the measurement should be made

near the center of the brake shoe. Compare these measurements with the measurements from

the vehicle history to determine if the lining is still serviceable or needs to be replaced. If

brake lining thickness is acceptable, inspect for possible lining cracks, loose rivets,

defective brake shoe, etc. If brake lining thickness is unacceptable, replace brake lining.

Rebuild hydraulic brake wheel cylinders at any time brake lining is replaced (if needed).

Brake drums shall be turned to a smooth surface each time brake lining is replaced (if

needed). Inspect S-cam bushings. Replace if needed. If applicable, remove wheel bearings,

clean and inspect bearings and cups. Repack wheel bearings with lubricant which meets

vehicle manufacturer's specifications. Install inner wheel bearing and seal in hub. Install hub

and drum assembly. Replace with new drums if worn beyond OEM specificationsInstall

outer wheel bearing washer and nut, and adjust wheel bearings to specifications.

Alternator

Check tension belt pulley.

Starter Motor and Solenoid

Perform starter current draw test. Repair if needed to meet manufacturer's

specifications.

Tune Up Diesel

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Diesel engine shall be adjusted to meet manufacturer's specifications. Replace items as

necessary.

Automatic Transmission Filters and Fluid

Replace filters (internal & external) and fluid in automatic transmission. Automatic

transmission shift point test should be made with results recorded prior to removing fluid

and filter. This will allow for necessary valve body adjustments to be made when

transmission pan is removed. Fluid should be drained at normal operating temperature.

Remove transmission pan, fluid, and filters. Fluid that is in transmission pan should be

poured through a wire mesh screen in order to detect metal particles which might be in it.

Particles which are recovered should be analyzed to determine if additional repairs are

needed. After any needed adjustments or repairs are made, install new filters and

reinstall transmission pan. Replace transmission fluid following instructions outlined in

transmission service manual.

4.4 PREVENTIVE MAINTENANCE 12,000/24,000/48,000 MILE SERVICE

The mechanic shall complete this form at 24,000-mile intervals for the service life of the

vehicle. After entering all requested information and completing the service, the

mechanic shall turn the form over to the shop foreman/transportation director for review.

After all data is keyed into the computer, the form shall be filed in the Individual Vehicle

Maintenance History file for future reference.

Preventive Maintenance 48,000-Mile Service

The 48,000-mile preventive maintenance service is a garage-performed activity. After

completing the 24,000-mile procedure, the following additional items shall be serviced every

48,000 miles.

Air Dryer Replace desiccant cartridge and inspect all connections (fittings, hoses, etc.).

Engine Valve Adjustment

Engine valves adjustment not to exceed 48,000 miles or per manufacturer

recommendations is required. Valve adjustment frequency varies for each engine

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manufacturer. Refer to the respective manufacturer for correct specifications and valve

adjustment intervals.

Power Steering Filter and Fluid

Change the power steering filter and fluid in reservoir.

Differential

With differential at normal operating temperature, drain lubricant and strain through a

wire mesh screen to detect any metal particles which might be in lubricant. If no repairs

are needed, replace lubricant with proper type as specified by chassis manufacturer.

Lubricant should have EP (extreme pressure qualities). Synthetic lube draining not required.

Coolant System

Drain and flush the coolant system. Refill system with a proper mixture of water and glycol

based antifreeze solution and install the proper amount of coolant conditioner. Do not use

a soluble oil based cooling system additive. After refilling the coolant system, test the coolant

for the proper level of conditioner. If conditioner is needed, use an ethylene glycol based

or OEM recommended conditioner. For more information on conditioner testing.

Wheel Bearings

If equipped with out-board drums, remove all wheel bearings; clean, repack and bar test

wheel bearing.

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4.5 Personnel Utilization

An important factor in the effectiveness of a preventive maintenance program is the

ability and willingness of all transportation personnel to work together with one goal in

mind: a cost efficient and safe preventive maintenance program. The assignment of

personnel to specific daily job duties is essential for the preventive maintenance program

presented in this manual to be successful. The following section describes typical job

assignments for transportation personnel.

Personnel Assignments

The fuel truck driver's daily service (duties) will consist of the following routine: fuel

vehicles (fuel dispensed must be charged to the nearest tenth of a gallon on form TD-18B

Fuel Issue Ticket); and check oil, water, tires; and under hood observation. In addition to

the above routine, the fuel truck driver shall, if assigned, analyze and repair driver reported

bus defects on the day he is at the school as well as assist with 30-day inspections.

Example: minor repairs such as replacing fuses or light bulbs. The fuel truck driver shall

also obtain speedometer readings for each vehicle fueled.

The mechanic's daily service (duties) will consist of the following routine: analyze and repair

driver reported bus defects on the day he is at the school. The mechanic shall visit his

assigned schools to repair driver reported defects on the days designated by the shop

foreman/transportation director. After repairing reported defects, he will initiate his 30-

day bus inspection, which is the basic foundation of the preventive maintenance program.

(Refer to the detailed explanation in the 30-day inspection section.) On the days the

mechanic is at the garage, he will be performing routine preventive maintenance or forced

maintenance (unscheduled repairs) on vehicles assigned to him by the shop foreman or

transportation director.

Reporting of defect by drivers and repairing such defects: bus drivers are required to sign in

at each school where buses are terminated and indicate any defect detected on their bus on a

Driver's Sign- In Sheet. A designated person shall call the bus garage upon arrival of all buses

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at the school, giving a report on all defects reported by their drivers or e-mail/fax (if

available). The assigned person at the garage shall record on a Reported Bus Defect Log,

the reported defects by school along with the time they were reported. The assignment of

these defects to garage personnel will be as follows: the assigned person shall contact, by

radio, the fuel truck operators and mechanics who are already working in their respective

areas and give them a list, by bus number, of all reported defects in their area. If a mechanic

assigned to an area not serviced by a fuel truck on that day is working in the garage, the

foreman and/or transportation director shall give a list indicating the buses and their

defects as reported by the drivers. The mechanic shall then proceed into his area and

make such repairs and return to his assigned duties. The personnel, to whom such defects

are assigned, shall inspect and repair these defects as far as they can, provided they have the

necessary parts with them to do so.

All personnel to whom a defect has been assigned, who cannot repair said defect, shall

report that information along with any additional information that would be helpful in

repairing the defect to the garage by radio. The foreman or director will then decide the best

course of action to take in the same manner he would with any other defective bus.

Personnel, to whom defects have been assigned from the reported Driver Reported Bus

Defect Log, shall make a list of the defects by the bus number. This list of defects for each

bus with notations of corrections made shall be turned in at the parts department or

designated location, along with the Equipment Repair and Parts Order forms by the person

to whom they were assigned. The foreman and/or director shall check this Defect List

against the reported Bus Defect Log daily. Any defects not repaired shall be assigned to a

mechanic for repair, or the bus shall be scheduled to be brought to the garage for repairs.

The above procedures give specific guidelines for transportation personnel to pursue the

field portion of the preventive maintenance program.

The shop foreman and or director shall plan a work schedule for the coming day. In

planning this schedule, the buses due preventive maintenance service shall take priority

over other repairs. The shop foreman/transportation director shall consider any and all

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vehicles which are already at the garage awaiting repair, any defective vehicles which are

still operating but need repair (both those which can be repaired at the school and those

which will need to be brought to the garage), any other vehicles in the fleet which need

repair or preventive maintenance service, and any other work (tire repairs, component

parts, etc.) which needs to be done. Near the end of the workday, the foreman shall plan the

next day's work and discuss this plan and work schedule with the director. The director shall

make suggestions regarding the schedule. Together they shall arrive at a final plan for a

work schedule for the following day. This schedule will be subject to change due to defects

detected and road failures during the day.

The following are maintenance record forms which are referred to in this section. They are

required to document the preventive maintenance program. These forms are to be properly

and thoroughly completed and filed in the appropriate assigned location. Transportation

Services staff members will review these records periodically during the year.

4.6 BUS DRIVER SIGN-IN SHEET

This form is utilized at the school each day for the drivers to record the bus number and

time ofarrival. Check the proper column if the bus is OK, record the number of students

transported, note any bus defects or problems which the driver knows need to be checked by

a mechanic, and sign the report. The designated person shall use this form as a record when

notifying the school bus garage of driver reported bus defects. A copy of this report shall

be picked up by the gas truck driver or mechanic (whoever is at the school that day) and

turned over to the designated person at the school bus garage. After reviewing the form, it

shall be filed in a School Bus Drivers Sign-In Sheet file.

4.7 Driver Reported Bus Defect Log

A designated person at the school bus garage shall record daily on this form the defects

called in from each school. The bus number, school, time of call, mechanical problem,

and the assigned mechanic shall be recorded for future reference. This form shall be used

to double check the Bus Drivers Sign-In Sheet defects in order that no defects are

overlooked. After comparing the two forms, this form shall be filed in a Reported Bus

Defect Log file.

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SERVICE CALL LOG

A designated person shall complete this form daily. The date, weather condition, bus

number, time of call, phone number call received from, nature of problem, and location

of vehicle shall be recorded at the time the service call is received. The time the mechanic

calls in (that the bus is back in service and what the actual problem was) will be recorded in

the proper columns. This form will be filed in a Bus Service Call Log file for future reference.

DEFECT LIST SHEET

For each bus involved, this sheet is to be turned in daily to the assigned person along with

the Equipment Repair and Parts Order form. This form shall be reviewed by the designated

person and compared with the Reported Bus Defect Log.

Note: The defect list sheet may be a copy of the driver sign-in sheet or a list of defects

the mechanic has been assigned to repair.

Fuel And Lubricant Issue Ticket

The fuel truck drivers shall complete the date, truck number, type fuel, bulk pump readings

(both), truck meter readings (both), and gallons used for each. Also, he will record the bus

number, quantity of gasoline/diesel fuel to the nearest tenth of a gallon and total quarts of oil

for each vehicle, on the assigned days of the week. The fuel truck driver will record

mileage for each vehicle fueled. The truck driver shall sign the form and turn it over to

the cost clerk. After keying the data into the computer, the cost clerk shall file it in a

designated file for future reference.

Note: All added oil is to be recorded on the Fuel and Lubricant Issue Ticket. Do not

record added oil on a equipment Repair and Parts Order form. Only oil change quantities

are to be recorded on aequipment Repair and Parts Order form. Also, all added oil is to be

keyed into the computer-using screen.

Individual Vehicle Maintenance History File

It is required that a separate folder be established to hold maintenance records for each

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vehicle in your fleet.

Work Order File

It is required that a folder be established to hold Equipment Repair and Parts Order forms

written in advance of vehicles coming to the garage for repairs.

Extra Bus Schedule (Assignment)

This form is to be completed by a designated person to record when and where the spares are

beingoperated. Not only does this form assist in recording use of spare buses, it also records

"down time" of your regular buses. This form is to be filed in an Extra Bus Schedule file for

future reference.

Service Vehicle Maintenance and Operation

Maintaining your service vehicle fleet is essential in order to provide proper

preventive maintenance service to your bus fleet. The following procedures shall be

followed for all service vehicles. The 6,000-mile oil change service shall not be

exceeded.

All garage service vehicles are to be maintained in good operating condition and

in a safe state of repair.

Lubricate and change oil and filter every 6000 miles or 12 months from date of last

oil change for all service vehicles. Engine should be at normal operating temperature

when oil is drained.

Service wheel bearings and inspect brake lining and components at 24,000 miles

for all service vehicles.

Inspect each vehicle once each year in accordance with the Division of Motor

Vehicles regulation.

Clean all service vehicles inside and out a minimum of once a month.

Body repair and repainting of service vehicles should be conducted as needed

according to the repainting procedures section.

All service vehicles: pickups, fuel trucks, wreckers, and tire trucks are recommended to be

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inspected each 30 days in the same manner utilizing the same 30-day inspection form as

school buses.

Vehicle Body Repair and Repainting Procedures

The appearance of each county's bus and service vehicle fleet has more effect on your

public relations than any other maintenance factor. While the appearance may or may not

affect safety, it does affect the manner in which the public views the mechanical

condition of your bus and service vehicle fleet. Driver attitudes and care of their assigned

vehicles are influenced considerably by the appearance of those vehicles. Pride in the

operation of your transportation fleet is very much dependent upon the appearance and

condition of the vehicles. Vehicles shall be repaired and repainted as needed. The

following preparation procedures are to be followed. These steps will greatly increase the

durability and life expectancy of your paint jobs.

Wash and clean vehicle with a cleaning agent.

Repair all exterior damage to vehicle.

Mask and paint with a good quality unleaded polyurethane paint. Make sure bus

is dry. Add a paint hardener catalyst into paint to increase paint life (if

recommended by paint manufacturer). Discarded Equipment, Supplies & Materials File

A file folder is required to hold authorizations of discarded equipment for future reference.

Keep in office until of no further administrative value.

Required Maintenance Record Documentation

The following are maintenance record forms which are required to document the

preventive maintenance program. These forms are to be properly and thoroughly

completed and filed in the appropriate assigned location. The Transportation Services staff

members will review periodically during the year. Transportation Services will furnish

upon request, a copy of the following forms to the bus staff:

Preventive Maintenance — Oil Change Service Work Order

Preventive Maintenance 12,000/24,000/48,000-Mile Service Work Order

Discarded Equipment, Supplies & Material

New Vehicle Service Work Order

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Equipment Repair and Parts Order

Fuel and Lubricant Issue Ticket

The following required forms or files ARE NOT FURNISHED by Transportation Services.

Either the sample presented, or a similar form which fills your particular needs, is required

to be used. All of the information requested on the samples presented must be included.

Sample Forms

Bus Driver Sign-In Sheet

Extra Bus Schedule (Assignment)

Reported Bus Defect Log

Service Call Log

Sample Files

Discarded Equipment, Supplies & Materials File (folder)

Extra Bus Schedule (Assignment) File (folder)

Individual Vehicle Cost Record File (folder)

Individual Vehicle Maintenance History File (folder)

Work Order File (folder)

All of the forms and file folders listed in this section are essential for proper documentation

of your preventive maintenance program. An explanation of each form listed above is

presented in the appropriate section of this manual.

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4.8 INSPECTION AND MAINTENANCE SHEET

Fig 4.1 Maintenance and inspection sheet

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Fig 4.2. Vehicle Inspection Sheet

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Fig 4.3. Customer’s Instant Feedback Sheet

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Fig 4.4. Old Parts Delivery Note

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4.9 USING SOME ADVANCED TOOLS

4.9.1 Tech-Tool

Tech-Tool(TT) is a tool that supports the repair and diagnostic process. It was

developed to make repair shop tasks easier and more efficient.TT can be used in

the repair shop, out in the field, at the roadside, or during test drives.TT is a

diagnostic application that covers the whole repair process through the use of

plug-inns. With TT you can diagnose , test, calibrate, and program a product. A

product could be a vehicle, engine or a machine. TT also provide functions for

updating the tool, communication with the product and other external

applications. The set of plug-inns, user authorization, and available language is

adjustable to provide every user with what they need.

Some facts about TECH-TOOL.

- It is an advanced technology that is used for diagnosing purpose for a

new/old/serviced/repaired vehicle.

- It is generally a software tool that detects the problem of the vehicle and

also describing the troubleshooting method to overcome the problem.

- Tech tool generally has to install in a laptop (I mention laptop here

because it is mobile and one has to use this tool must be move on place

to another, that’s why laptop is quite well suit) and connect it to ECU of

the vehicle that is to install in the drivers cabin.

- Most of the problem that is related with software can easily be solved out

through this tool.

- And it can only work in with the latest model of the commercial vehicle.

Fig 4.5. Tech Tool Kit

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4.9.2 The basic workflow in Tech Tool is the same for all Products:-

Identify a product

View information history

Diagnose a selected product

Test a selected product

Program a selected product

4.9.3 Compatible Software

Volvo Tech Tool (TT) 2.04.55 / VCADS Pro 3.04.55

Fig 4.6. About Tech Tool Software Version

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4.9.4 Process to Search For a Model using Tech-Tool

Fig 4.7. Manual selection for searching a model

Fig 4.8. operating the vehicle using Tech Tool

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REFERENCES

Primary Data:-

Eicher Office

www.eicherworld.com

www.scribd.com

www.vecv.in

en.wikipedia.org/wiki/Eicher_Motors

http://www.eicher.in/etb/manufacturing-facility

en.wikipedia.org/wiki/Automotive_industry_in_India

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