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

1
 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

2
 Certificate of the Supervisor

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

VE commercial vehiclesubmitted 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 Indias 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 Indias new global dynamic. The domestic
market expanding rapidly as incomes rise and consumer credit becomes more widely
available. Manufacturers 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 Indias 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 Indias new global dynamic. The domestic
market expanding rapidly as incomes rise and consumer credit becomes more widely
available. Manufacturers 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 worlds second largest and fastest-growing population, there is no denying
Indias 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-

10
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 July10 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
customers 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. Eichers 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 Groups 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 nations 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 Companys 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
companys 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

22
 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.

23
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.

25
 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

26
 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.

27
 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 EICHERS 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.

Eichers 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.

28
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.

29
 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.

30
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

31
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.

32
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

33
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.

34
 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

35
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.

36
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

37
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.

38
 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.)

39
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.

40
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.

41
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.

42
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.

43
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

44
 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

45
 FIG 3.1 INSPECTION OF PRO SERIES VEHICLE

FIG 3.2 DETECTING AIR FILTER FAULT WHILE INSPECTION

46
FIG 3.3 MOUNTING OF BODY FOR DISPATCHING

47
FIG 3.4 VEHICLE READY AFTER INSPECTION TO DISPATCH

48
3.9 Inspection And Maintenance Schedule

49
50
Fig 3.5 Inspection & Maintenance Schedule

51
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.

52
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.

53
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

54
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-

55
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

56
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

57
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

58
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

59
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.

60
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

65
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

69
Fig 4.3. Customers 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, thats 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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