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T
he launch of four configurations and
two power nodes, 280 hp and 380 hp,
marks the culmination of the first
phase of Tata Motors’ World Truck Bosch
development. The top end of 560 hp Body control module
that MD Prakash Telang announced at the press
launch will probably be introduced only in a later
phase by 2012.
The engine that powers the 4028S 4×2 and
4928S 6×4 tractors and 3128T 8×4 cargo truck is
the Cummins ISBe 270 derated somewhat to
266 hp @ 2500rpm and 970 Nm @ 1200–1600rpm. Tata Ficosa
This 6.7-litre engine with single-piece head, four Automotive
valves per cylinder, 1600 bar common-rail fuel ORVMs
system, and wastegate turbocharger, was first
introduced in early 2005 at Euro 4.
It superseded Cummins’ 5.9-litre Euro 3
engine, which interestingly had been based Tata AutoComp
on a platform developed by the European ACSI & Interior
Engine Alliance (EEA) – the erstwhile three-way Plastics Division
joint venture between Cummins, Iveco, and SMC and plastic
New Holland – using the design technology of parts
Cummins’ legendary B-series engine. Since July
2008 the EEA is wholly owned by Fiat Powertrain
Technologies (FPT), Tata’s other engine supplier Tata Toyo
for the World Truck.
Radiator
For markets outside Europe, Cummins
developed Euro 3 ratings of the 6.7-litre engine
later in 2007 as part of its Worldwide Common
Platform (WWCP) strategy, of which 270 hp/1020
Rane TRW
Nm is the top of the slate presently available in
Steering
India. Autocar Professional learns that Cummins gears
is working on a few ratings lower down the scale.
The ISBe is the first fully electronic, common-
rail-fuelled heavy duty engine to be series-
produced in India, although the components
Tata Visteon
Automotive
are still mostly imported — for example the Headlamp cluster,
engine blocks and heads come from Brazil, and fog lamp
are only machined at Tata Cummins’ (TCL) plant
in Jamshedpur. The fuel system hardware is
from Bosch, and the electronic control module SKF India
(ECM) and software from Cummins. TCL has a Front
localisation target of 90 percent by 2012. wheel-end
The 6.7-litre engine carries forward the
performance and fuel-efficiency advantages
for which the 5.9-litre Euro 3 ISBe was famous MRF Gabriel India
worldwide. (These were based purely on the Tyres Primary & cabin shock absorbers
28 Autocar Professional 15 June 2009 www.autocarpro.in
COVER STORY
Tata Yazaki
Autocomp Calsonic
Wiring harness HVAC
Tata AutoComp Systems Blaupunkt Continental Automotive Grupo Antolin Pune ISRI-TJC
Interior Plastics Division Radio Components India Interior soft trims Seats, sleeper berths
Cockpit Intelligent instrument cluster
Fleetguard Filters,
Mann + Hummel
Air intake system
Williams Controls
Electronic
throttle control
Tata Cummins, &
Fiat Powertrain Knorr-Bremse, Knorr-Bremse
Technologies WABCO Integrated pedal unit
Engine Air brake system
high injection pressures of its common-rail made its world on-highway debut only this
injection system, Cummins India engineering March on the Genlyon range of trucks from SAIC
vice-president Mike Lambert told Autocar Iveco Hongyan Commercial Vehicle Co (SIH)
Professional in an interview last year.) And like its based on Iveco’s Stralis. Weighing in at 865 kg, the
predecessor, this engine delivers a fuel economy engine has been certified to Euro 3 and designed
advantage at the vehicle level as well, because it to be upgraded to Euro 4 and Euro 5 with no
is electronic and several useful features can be hardware modification.
programmed into it. In the SIH Genlyon the engine is presently
“For example cruise control and road speed available in two ratings of 270 hp and 400 hp @
governing, which yield a big advantage in fuel 1800–2100rpm and 1300 Nm and 1600 Nm @
economy at the vehicle level, can simply be 1100–1800rpm, the lower rating with a fixed-
activated inside the calibration. Moreover, the geometry turbo. The customer buzz following
customer can do that when the truck gets to the World Truck launch is that a 310 hp version is
the end of the line. Using Cummins’ vehicle shortly going to be offered on a 40-tonne tractor.
electronic programming system VEPS, customers The 380 hp/1500 Nm rating was developed for
can actually modify some parameters in the Tata in Bangalore by Bosch Ltd, whose solution to
Cummins ISBe, rated at 266 hp and 970 Nm at
calibration of the electronic control module BS3, is upgradable to BS4 and BS5 using SCR.
meet the OEM’s specifications for driveability in
(ECM) to suit what they want for their vehicle these two applications involved reducing the rail
applications,” Lambert said. pressure to 1400 bar.
For TCL, marrying the ISBe to the vehicle was Tata’s original choice for this performance
a challenging experience because this was the class was Cummins’ 160kg-lighter 8.9-litre ISLe,
first time it was dealing with an electronic engine and the company’s presentation to the media
that can communicate with other electronically did indeed specify a 370 hp/1550 Nm ISLe as
controlled systems on the vehicle and support optional on the 3138K and 4938S. The fact is,
onboard diagnostics. Cummins’ Interact (the ‘I’ Cummins India had developed and begun
in ISBe) electronic intelligence system enables productionising two Euro 3 ratings – 340 hp and
“drive-by-wire” electronic throttle control and 375 hp – of the Euro 4 WWCP generation of this
multiplexing, which both simplifies wiring and engine in 2007, but the programme has been
allows data signals to be carried through to the kept in limbo for over a year now after the Cursor
smart instrument cluster and driver controls. 9 was inserted into the equation in what would
The engine ECM accepts inputs from appear to be part of a quid pro quo that opens up
all powertrain components – electronic Iveco’s distribution and service networks in Latin
transmission (if available), ABS, and ASR (anti- America and Eastern Europe to Tata.
slip regulation) – via a high-speed data link, Autocar Professional learns that the next
and responds exactly to requested adjustments higher power node in the World Truck portfolio
in torque or engine speed for gearchanging or is 420 hp, originally planned around Cummins’
wheelspin correction. The result is smoother ISMe but now designated as “above 380 hp” and
and more fuel-efficient performance, lower Cummins’ ISLe, now offered as 370 hp/1550 Nm very likely to include FPT’s European Cursor 10
emissions, and added protection against option, was Tata’s original choice for the 380 hp F3A at Euro 5 in 2015.
powertrain wear. In addition, sensors throughout node. The 10.8-litre ISMe was the first heavy duty
the engine continually send data to the ECM for engine in its class designed for a life-to-overhaul
self-diagnosis and protection. of one million kilometres. Certified for Euro 3
A regular laptop with Cummins InSite and Euro 4 in a range of ratings, it is now built
diagnostic software and a couple of special in China by Xi’an Cummins Engine Company,
connectors are the only tools the service Cummins’ 50:50 joint venture with Shaanxi
technician needs to download and analyse fault Automobile Group Co. The 420 hp Euro 3 version
codes. But since electronics and the sophisticated produces its peak output at 1900rpm and peak
common-rail fuel system are novelties in the torque of 2010 Nm at 1200rpm. Also available are
industry in India, TCL has just launched a two Euro 4 ratings of 410 hp/2000 Nm and
major campaign to train Tata Motors’ service 440 hp/2080 Nm. The 10.3-litre Cursor 10, by
technicians, having just completed a similar contrast, is presently available in selective-
programme for its own. catalytic-reduction-(SCR)-optimised Euro 4 and
The four-axle 3138 tipper and the 4938 5 ratings of 420 hp @ 1550–2100rpm and 1900
semitrailer tractor displayed at the launch are Nm @ 1050–1550rpm, and 450 hp/2100 Nm.
powered by a 380 hp Chinese-built Cursor 9 Starting from 150 hp, the range of power
engine from SAIC Fiat Powertrain Hongyan Co ratings extends all the way up to 560 hp,
(SFH). This 8.7-litre six-cylinder inline engine corresponding to the top available Euro 4 rating
with overhead camshaft, four valves per cylinder, of FPT’s Cursor 13 F3B. This 12.9-litre inline six-
Bosch common-rail fuel system, and Holset cylinder engine with four valves per cylinder,
variable-geometry turbocharger, went into Bosch EDC-controlled unit injectors, and
volume production at SFH, Fiat Powertrain variable-geometry turbo, delivers its peak output
Technologies’ joint venture in Chongqing, just at 1600–1900rpm and 2500 Nm @ 1000–1575rpm.
one week before the launch of the World Truck. The Cummins alternative is the new 13-litre ISZ,
Originally introduced by Iveco in Europe developed and produced by Dongfeng Cummins
in 2006 as the C87 designed specifically for Engine Co in Wuhan, and available (for the
industrial and agricultural applications, the FPT Cursor 13 is most likely to be Tata’s top-end Chinese market) in ratings of up to 545 hp.
Cursor 9 (technical code name F2C E2681B*B) engine choice for Euro 4 and 5 export markets. The development of heat exchangers that
www.autocarpro.in 15 June 2009 Autocar Professional 31
COVER STORY
would manage the massive charge air and engine the programme. It will supply these in six
cooling requirements of these powerful engines configurations including, for the first time in
was entrusted to Tata Toyo Radiator (TTR). The India, a vertical model for the 3138K.
company responded with an aluminium radiator Director Manoj Solanki told Autocar
that has a thinner core and is both lighter and Professional last month that initial deliveries of
cheaper than conventional designs, directly 30–60 a month for the World Truck could rapidly
contributing to improved fuel efficiency and grow to “10,000 next year, or even 20,000”, even
reduced operating costs. as CEIL transitions into an entity that will be 100
Besides, being thinner, it requires less coolant percent owned by Cummins Emission Solutions
than the conventional designs, in which higher (CES) ahead of the advent of BS4 emissions
cooling demands are typically met by increasing legislation in April 2010.
the thickness of the core. Reducing the size of CES is the leader in emission solutions for
the radiator meant reducing the heat exchange medium and heavy duty on-highway truck
surface, and hence the challenge was to get better manufacturers in the Euro 4 and 5 markets
efficiency from a smaller surface area. worldwide, ahead of other big names like Emcon,
“We achieved this by enhancing the geometry Tenneco, Cornaglia, and Eberspächer.
of the core for better heat exchange efficiency. Wearing his CES shirt, so to speak, Solanki
Using our past experience, we simulated the revealed that eight prototype SCR systems
actual conditions under which the entire system airfreighted in from China would be installed on
consisting of the radiator, intercooler (which we test vehicles with Cummins engines by the first
also developed), and various other components week of June. “Combining a CES system with a
would be used, and optimised the design and Cummins engine allows Tata Cummins (ISBe) or
configuration to arrive at this solution,” TTR’s Cummins India (ISLe, ISMe) to tune the entire
Ravi Chidambar said. system, with the SCR aftertreatment controlled
Asked what his engineers’ main challenge by the engine ECM,” he explained.
was, the CEO of this joint venture between Tata “For a non-Cummins engine the strategy is
AutoComp Systems, T.Rad Co of Japan (a major to have a separate dosing control unit, which
supplier of heat exchangers to Iveco and Hino), links the SCR system to the ECM and allows
and Mitsubishi Corporation Nonferrous (supplier CES to maintain control on the system and its
of aluminium to both Tata Toyo and T.Rad), cited performance. We’re trying to make it plug-and-
Tata’s far more exacting durability targets for play, because in these situations our interactions
the World Truck compared to other vehicles for will be limited by the ECM.”
which they had developed radiators. While the mufflers are supplied from CEIL’s
The emphasis was on commonisation to Fleetguard Filters MD Niranjan Kirloskar with Daman facility, the SCR systems will initially
reduce costs, he pointed out. “Hence, while the Cummins India CMD Anant Talaulicar at the be imported from China, where CES started
radiator and intercooler will be the same across launch in Mumbai. Besides engines, Cummins’ producing them this April. “However, if we see
models, there will be minor changes in terms of value package on the World Truck includes the volumes for SCR going up suddenly, we may
tooling and customisation to suit each model.” turbochargers, air intake and filtration systems, advance our plans to set up manufacturing
Tata’s orders for air intake systems, from air exhaust mufflers, and emission solutions. here,” Solanki said, adding that this would be at
inlet to turbo inlet, have been split 50:50 between Cummins’ megasite at Phaltan near Pune.
Fleetguard Filters (FFPL) and Mann + Hummel The Cummins ISBe is mated to the ZF Ecomid
across all applications. Designing a system for 9S1110 OD gearbox or Tata’s own G1400, while
BS4 and BS5 requirements was one peculiar Eaton has been contracted to supply its Fuller
challenge for Fleetguard, according to marketing transmissions for the Cursor 9 and higher-
head Tarun Dham. “Another was to develop powered engine applications. The latter presently
aesthetic designs in plastics that would withstand has three nine-speed transmissions on the World
extremes of temperature and still meet Tata’s Truck — the FS 10309 and FSO 10309 (overdrive),
stringent life requirements — after all, this was and the FS 15409, a variant of the 10309 specially
the first time our products would go on trucks developed for the heavy tipper.
exported around the world,” he said. Interestingly, while ZF is initially importing
This 50:50 joint venture between Cummins its transmission from a plant in France, it is
Filtration and Pune-based Perfect Sealing expected to localise the design with gears sourced
Systems, has so far supplied Tata’s alpha and from Ashok Leyland and housings sourced from
beta requirements from its Nandur plant near Jaya Hind, sister company of MAN Force Trucks,
Pune, but production supplies will come from its its other erstwhile licensee for this model.
Jamshedpur facility beginning September. For Eaton, the application approval process it
Cummins Filtration is the global leader in used on the World Truck programme is standard
filtration, exhaust, coolant, and fuel additive practice worldwide for new truck developments
technology for engine-powered systems of all but unique in the Indian context in that it directly
kinds, and FFPL is the exclusive supplier of all the captures the “voice of the customer” and clearly
wet filtration products for the Cummins ISBe and elicits the requirements in terms of application,
ISMe on the World Truck. It is also in discussions terrain, duty cycle, GVW, startability, and
to provide Fleetguard coolants as first fill. gradeability in maximum detail at the earliest
Cummins Exhaust (CEIL), the 50:50 joint stage of engagement with the OEM.
venture that Cummins Filtration had with “The OEM’s marketing and engineering
Cummins India till recently, is Tata’s exclusive organisations fill out an application approval
source for Euro-3-spec acoustic mufflers for form, which Eaton uses to search its database
www.autocarpro.in 15 June 2009 Autocar Professional 33
COVER STORY
CHASSIS
The six-rod inverted bogie suspensions for
the tandem rear axles on the 49-tonne tractors
and 31-tonne tipper and cargo truck were
indigenously designed and 100 percent localised B D Singh points out a Spicer propshaft on 4028 This is the same series presently used in the USA,
by TACO Hendrickson Suspensions (THSL) in Pune tractor. The company’s shafts are also standard Brazil, and Europe, which Rane TRW Steering
to meet Tata’s demanding cost targets. on the heaviest-duty 3138 tipper. Systems in Chennai has adapted for India.
Suitable for a wide variety of multiaxle The superior features of the TRW system
applications, this design improves the vehicle’s include faster steering ratios for improved lock-
stability and braking performance. Other crucial to-lock turns compared to existing gear designs,
advantages over current systems, particularly lower internal gear friction for better return-to-
in Indian operating conditions, include ease of centre response, and a reduced package size for
serviceability and better ride quality (a function increased wheel cut, according to P B Rajan, GM
of the rubber bolsters at the spring ends, which (marketing) of Rane TRW Steering Systems in
also act as effective rebound stoppers). Chennai.
The first of its kind in India, the 48-tonne “This model delivers the highest torque
suspension on the 3138K is THSL’s heaviest- per unit weight in the world,” he told Autocar
duty model. A lighter 26 tonne (plus 15 percent Professional. “It has automatic poppets and
overload capacity) version is available on the advanced rotary valves for user comfort and
4938S and 4928S, and the 3128T offers the provides power assistance from lock to lock even
additional options of a regular 26-tonne model while the vehicle is stationary.”
or a 19-tonne-plus-30-percent. Rajan cited the tight lead time for submission
The front axles on all models are suspended of special prototype parts and Tata’s stiff cost
by means of parabolic leaf springs, believed targets as specific challenges his engineers faced
to be from a Korean supplier even though, Meritor’s MS14-160 axle will soon feature on in developing this product.
interestingly, THSL’s parent company 3128T. Tandem version could go on tractors. The air brake systems for truck and trailer
Hendrickson International is the world leader come from Knorr-Bremse and WABCO, the two
in this type of springs. leading suppliers worldwide. The former’s scope
Parabolic springs deliver far superior ride of supply includes the air processing unit (APU),
characteristics to the conventional multileaf foundation brakes and actuators, trailer brake
variety, and will continue to be used on the front system, and ABS for truck and trailer.
axles even when air suspensions from THSL The Knorr system is designed for a brake
make their appearance on the World Truck as circuit pressure of 10 bar, as against the 8.1 bar
early as next year for export models. “Although systems that go onto Tata’s existing range. It is
air suspensions on front and rear axles are ideal, able to deliver higher braking torques at the
OEMs even in Europe save costs by matching the wheel ends using similar-sized, albeit more
frequencies of the parabolic front suspension robust and reliable, actuators that have actually
with those of the rear air-ride system,” an Autocar been validated at pressures of above 10 bar,
Professional source said. according to sales, marketing, and business
The twin-steer systems on the 3138K and development head Anirban Mukherjee.
3128T are variants of the Servocom 8099 twin- The APU ensures better air management,
circuit power steering gears from ZF Lenksysteme higher reliability, and longer service life than
GmbH. For single-steer applications with lighter the traditional air dryer by integrating this
front axle loads such as tractors that will be used function with an oil separator and multicircuit
for long-distance haulage, tip-trailers, bulkers, This 26-tonne version of TACO Hendrickson’s protection valve into a single unit. Interestingly,
and reefers, Tata has chosen TRW Automotive’s 6-rod tandem bogie suspension is standard on 49- it constitutes the mechanical basis for one
latest THP-series from Europe rated at 175 bar. tonne tractors and optional on 3128 cargo truck. of Knorr’s most recent innovations: the EAC
36 Autocar Professional 15 June 2009 www.autocarpro.in
COVER STORY
INTERIORS
Grupo Antolin Pune is Tata’s exclusive source for
soft trim parts, i.e., the headliners and fabric
trims for the doors, sides, and rear of the cab. For
this company, which is supplying “more than 20”
part numbers from its Ranjangaon plant near
Pune, the World Truck was a significant challenge
because it was now dealing with parts of “huge
truck” proportions, according to GM (marketing)
Ajay Apte.
“For the first time an Indian truck was being
developed with a trim level that compared
to those sold in Europe. For us, maintaining
tolerances and fit and finish across such
large dimensions was a herculean task,” he
reminisced. GA Pune supplies headliners with
integrated lamp bezels, speaker grills, and
air vents, which will be added on at a small
subassembly warehouse the company is setting
up in Jamshedpur preparatory to the commercial
launch of the trucks.
Also for the first time in the world, the
company developed a special solution for the
side trims using knitted fabrics treated with
tandem version. It is also one of the suppliers of Jost India director and CEO Amarjeet Singh and 3M Scotchguard to ensure cleanability, Apte
TRBs for the differential. sales & marketing head G S Pradeep. The company pointed out. “GA uses a different, more expensive
The JSK36DV1, and JSK38DV50 and JSK38C1, meets Tata’s domestic and export requirements material in Spain. For India we had to come out
fifth wheel couplers on the 40- and 49-tonne for fifth wheels from Jamshedpur and Germany. with a cost-effective solution based on the same
tractors respectively are from Jost India Auto basic sandwich.”
Components, Tata’s exclusive supplier of this The high-end air-sprung or mechanically
critical device that connects truck to trailer. suspended driver and co-driver seats with
Designed for an imposed load of 20 tonnes integrated seat belts are a first on a truck in
the JSK36, with a two-inch kingpin, is the India. Designed and developed in Germany by
most widely used fifth wheel model in the Isringhausen GmbH, the world leader in driver’s
Asian market and one of Jost’s largest-selling seats for trucks, in a joint venture with Tata
worldwide. Johnson Controls Automotive (TJC), they have
The JSK38DV50 is a pressed version of the gone into limited production at a TJC facility in
JSK38C1 cast fifth wheel for an imposed load Pune till ISRI-TJC’s plant in Jamshedpur is set up.
of 28 tonnes that Tata has so far used on its The seat squabs can be adjusted for height,
existing 4923 model. “Since the Indian market fore and aft movement, and tilt; adjustable lower
traditionally prefers the pressed version, and upper lumbar supports and high-density
this development was undertaken for cost- foam and bolsters make for additional comfort.
optimisation,” G S Pradeep, senior sales and The seats are optionally fitted with a heater to
marketing manager for Jost India, explained. SKF bearings on the World Truck: top three are provide comfort in extreme cold conditions.
“It costs about 30 percent less, and has passed for steering and front axle application; bottom “The World Truck was conceived with a seating
all the standard life tests required to ensure four are for rear axle. system of global standards with respect to safety
reliability. More importantly it is reworkable, and comfort. The challenge was to design the
which is a vital requirement in the Indian market. seats keeping Indian road conditions in mind.
While the cast version is extremely strong, it That took an intensive R&D effort, following a
could possibly crack under the extreme abuse to global benchmarking exercise we did on truck
which fifth wheels are subjected here and cannot seating systems,” CEO Vinayak Lingayat said.
be welded or bent back into shape in the event,” The result is seats that not only meet the
he pointed out. stringent ECE norms concerning ergonomics
According to Pradeep, the JSK38C1 2J on one and occupational safety but also conform to
of the 4938 tractors displayed could be an option AIS regulations. A lot of effort has been made
on the World Truck for export markets, where to localise the design, but certain critical
the weight limits of semitrailer combinations are components will continue to be imported from
seldom exceeded and cast fifth wheels are usually Germany, he added.
preferred. The complete wiring harness that Tata Yazaki
An important feature of this model is Autocomp (TYA) designed and supplies for the
the interchangeable locking mechanism World Truck compares to that on any premium
that can accommodate both, two-inch and European truck, marketing head Prashant
3.5-inch kingpins, allowing the operator Gajendragadkar told Autocar Professional.
to switch the rated imposed load on the “The bus bar design drastically reduces the size
coupler to the maximum 36 tonnes for of the wire bundle coming into the fuse box for
which the JSK38 platform was originally LCD on Continental instrument cluster displays ease of handling, assembly, and maintenance. A
designed. menus and error messages in Hindi and English. single connection joins all vehicle applications
38 Autocar Professional 15 June 2009 www.autocarpro.in
COVER STORY