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Introduction to Buses & Engine Systems.pptx
1. Technician Level 2 (LOB Bus) – Module 1
Introduction to TATA Motors Buses & Engine Systems
2. Introduction
Please introduce yourself loud and clear including your details for:
Participant Name
Dealership Name
Location
Experience in Tata Motors (In years & months)
Hobbies & What Bonds you with TATA MOTORS
7/26/2022 TML 2
3. Program Objective
At the end of this module the participants will be able to:
Recall the bus models manufactured by Tata Motors in India
Understand how CNG is used as a fuel in Automobiles
Identify the various components used in CNG Engines
Perform maintenance and repair of CNG Engines
Perform basic fault finding on CNG Engines
7/26/2022 TML 3
4. Program Agenda
Introduction to Tata Motors Buses
– Rear Engine Buses
– Front Engine Buses
CNG
– Introduction to CNG
– Gas engine terminology
– Alternative fuels & New features
Engine Systems - CNG
– Salient Features & Technical Specifications
Cummins 6B5.9G (B Gas Plus)
3.8 / 5.7 SGI CNG BS IV
Maintenance & Repair
– Cummins 6B5.9G (B Gas Plus)
– 3.8 / 5.7 SGI CNG BS IV
7/26/2022 TML 4
7. Classification of Rear Engine Buses
7/26/2022 TML 7
Bus Floor Height 400mm 650mm 1200 mm
LPO 1628/61
RESLF 1618/63
RELE 1623/63
RELE 1624/63
RELE 1618/63
Products offered by TML
CNG
Diesel
RESLF 1623/63
RELE 1623/63
8. LPO 1623 CNG Non AC
7/26/2022 TML 8
Aggregate Specification
Engine BGas+ 230 Cummins BS3
Gearbox ALLISON’S Automatic Transmission
Rear Axle TATA 109 RR
Front Axle Meritor FH946
Steering Hydraulic Power Steering
Brakes
Full S-Cam Air Brakes (Front &
Rear)
Wheels and Tyres 11R22.5 Radial
Suspension System
Pneumatic Suspension at Front
and Rear
Electrical System
24 Volts,90 Ampere Multiplexing
System
9. 1628 HI - DECK
7/26/2022 TML 9
Aggregate Specification
Engine ISBe3 285H.P. Diesel Engine
Clutch Single Plate 430 mm Pull Type
Gearbox ZF S6-1000 BO
Rear Axle 109 RR
Front Axle ZF Independent (RL 75 E)
Brakes Disc (Front), Drum (Rear)
Suspension
Pneumatic Suspension at Front
and Rear
Wheels and Tyres 11R22.5-16PR
Fuel Tank 400 Litres
Electrical Systems
24 Volts,90X2 Amps, Multiplexing
System
10. 1623 HI DECK
7/26/2022 TML 10
Aggregate Specification
Engine Tata Cummins BS2
Clutch 380 Dia push type
Gearbox G-600 with Power Shift
Rear Axle RA 109 RR
Front Axle ZF RL 75E
Brakes
Disc (front), S Cam Drum
(Rear) with ABS
Suspension WIL Rear Air suspension
Steering System ZF Power steering
Fuel Tank 400 Litres
Electrical Systems
24 Volts,90X2 Amps,
Multiplexing System
11. LPO 1924 RESLF
7/26/2022 TML 11
Aggregate Specification
Engine ISBe 242 HP Cummins BS III
Gearbox Allison Automatic Transmission
Rear Axle TATA 109 RR
Suspension System
Pneumatic suspension at front &
rear
Wheels and tyres 295/80R22.5 Radial
FUEL TANK 200 liters
Steering Hydraulic power steering
Brakes
Dual circuit, full air S-CAM brake
system
Electrical System
24 Volts, 90ampX2, Multiplexing
System
12. LPO 1624 RELE
7/26/2022 TML 12
Aggregate Specification
Engine ISBE 242 HP BS3 DIESEL
Gearbox Allison Automatic Transmission
Rear axle TATA 109RR
Front Axle Meritor FH 946
Steering Hydraulic Power Steering
Brakes
Full S-Cam Air Brakes (Front &
Rear)
Suspension
Pneumatic Air Suspension with
Anti Roll Bar
Wheels and tyres 11R22.5 Radial
Fuel Tank 150 Liters
Electrical System
24V, 90 Ampere Multiplexing
System
19. CNG Fuel System Layout
7/26/2022 TML 19
COOLA
C
R EF UELLIN G
VA LVE
P R ES S UR E
GA UGE
HIGH
P RES S URE
REGULATOR
LOW
P R ES S UR E
R EGULA TOR
GA S S HUT OF F S OLEN OID
VA LVE
A / F (EGO)
C ON TR OLLER
OVER S P EED
C ON TR OLLER
COOLAN
HIGH
P RES S URE
FILTER
EN GIN E
C A R B UR ETTOR
C HA S S IS F R A M E
1/2" DIA
1/2" DIA
COO
COOLANT LI NE
TO ATM OS P HERE
TO ATM OS P HERE
CATALYTIC
CONVERTER
C HA S S IS F R A M E
8 N OS . C N G
C YLIN D ER S
LP FI LTER
AND LOW
P RES S URE
GAUGE
TIMER
20. CNG Fuel System Technology Overview
Technology Title
CNG Fuel System for Automotive application
Value Opportunity
CNG fuel system helps in saving running cost by 20 - 40 %
Additional business due to adoption of CNG by different cities
Technology Benefit
Less emission, and hence low pollution (helps minimize global warming)
Cost effective transportation as running cost is less as compared with Diesel
Noise reduction due to low knocking level as compared with Diesel
Abundance availability
7/26/2022 TML 20
21. CNG Fuel System Technology Overview contd.
Roadblocks
Limited exposure / lesser R&D in India
More initial and maintenance cost
Safety aspects
Fuel availability across the cities
High investment in CNG storage and transportation infrastructure
Technology Description
In this fuel system, Compressed Natural Gas (CNG) is used as fuel for IC engine to propel the
vehicle. This may be a used as either dedicated or bi-fuel system.
This system comprises of High Pressure Storage, different pressure regulating devices, filters,
& safety controls in addition to the necessary piping for fuel (CNG) supply to engine.
There are many electrical devices in the system to make the system work (i.e. control of fuel
flow rate & pressure based on demand) for engine.
7/26/2022 TML 21
22. Gas Engine Terminology
Stoichiometric Combustion: The chemically perfect ratio of air and fuel to be burned in the
engine.
Lean-Burn Combustion: Excess air enters the combustion chamber with the fuel.
Excess Air Ratio (Lambda): A measure of the excess air that is present (AF/AF Stoichiometric).
Detonation (Knock): Occurs when combustion is not controlled. Fuel auto-ignites after the
spark event. This results in very high temperatures and pressure, capable of causing extensive
engine damage.
Pre-Ignition: Similar to detonation, but in this case the fuel ignites before the spark. The result
is the same, multiple flame fronts and eventual engine damage.
Hydrocarbon Fuel: Fuel composed mainly of carbon, hydrogen. May contain other trace
elements.
Methane Index: A measure of the quality of gas. Methane index increases with the
percentage of Methane.
Natural Gas: Pipeline quality gas. Methane index greater that 75-80. When natural gas is
mentioned in this training, we are referring to pipeline gas. Cummins are not currently
designed to operate on bio-gas, digester gas, or landfill gas.
7/26/2022 TML 22
23. Combustion
Combustion is the chemical reaction between Carbon, Hydrogen & Oxygen that produces
heat.
– C and H provided by hydrocarbon fuel
– Air is needed to provide oxygen
– Some energy is compulsory to start the combustion
According to the Air/Fuel, the reaction can be rich, stoichiometric or lean.
7/26/2022 TML 23
24. Types of combustion
Deflagration:
This is normal combustion whose flame
propagation speed is below the speed of
sound.
Combustion start under control (spark or
fuel injection)
Pre-ignition
As the percentage of propane increases
over 1.7%, overall NG octane rating (burn
temperature) is reduced.
Ignition occurs at lower temperature due
to reduced octane rating.
Occurs before spark event.
7/26/2022 TML 24
25. Types of combustion
Detonation, Knocking or Auto Ignition:
Ignition via ‘hot spots’ from previous
combustion cycle.
Propagation speed supersonic
Start of combustion not controlled
Colliding flame fronts produce
characteristic ‘knock’
Occurs after the spark event.
Causes: High cylinder pressure &temperature,
rich A/F mixture & advanced timing
7/26/2022 TML 25
28. Cummins 6B 5.9 G (B Gas Plus) Engine
7/26/2022 TML 28
Parameter Marking Decoding
Engine Model BG+ 230 BS IV B Gas Plus 230 HP BS IV
Rated HP 230 @ 2800 RPM 230 HP @ 2800 RPM
Engine Sr. No. 62954879 -
Month & Year of Mfg. 12-10 December 2010
Appl No. M-S042133 Application Number
29. Engine Specifications
7/26/2022 TML 29
Description Specification
Displacement 5.88 L (359 in3)
Configuration In-line 6 cylinder
Bore mm (in) 102 (4.02)
Stroke mm (in) 120 (4.72)
Weight Kg (lbs) 413 (911) (Dry)
Rated Horsepower 230
Rated Speed (rpm) 2800
Firing Order 1-5-3-6-2-4
Crankshaft Rotation CLOCKWISE (viewed from front of engine)
Spark Plug Gap 0.508 mm (0.020 in)
Overhead Adjustment
- Intake valve 0.305 mm (0.012 in)
- Exhaust valve 0.610 mm (0.024 in)
30. Engine Views
1. Front engine mount
2. Fuel housing
3. Gear housing
4. Gas mass flow sensor
5. Mixer inlet pressure
sensor
6. Intake elbow
7. Throttle actuator
8. Exhaust back
pressure sensor
9. Spark plug wire
10. Ignition coil
11. Electronic control
module (ECM)
12. Engine lifting bracket
13. OEM connectors (23-
pin and 31-pin)
14. Ignition control
module (ICM)
15. Fuel inlet fitting
16. Primary fuel pressure
sensor
17. Low pressure
regulator
18. Starter
19. Flywheel housing
20. Lubricating oil pan
21. Fuel filter oil drain
22. Fuel filter
23. Engine oil
pressure/temp sensor
24. Fuel control valve
25. Air compressor
Intake Manifold Side View
7/26/2022 TML 30
31. Engine Views
1. Ignition control module (ICM)
2. Intake manifold pressure or temperature
sensor
3. OEM connectors (23-pin and 31-pin)
4. Engine lifting bracket
5. Heated oxygen sensor
6. Flywheel housing
7. Flywheel
Flywheel End View
7/26/2022 TML 31
33. Engine Views
1. Alternator
2. Ignition coil
3. Exhaust back
4. pressure sensor
5. Fuel jumper tube
6. Fuel filter
7. Fuel filter oil drain
8. Lubricating oil pan
Front End View
7/26/2022 TML 33
34. Air Intake System
1. Intake air inlet to turbocharger
2. Turbocharger air to charge air cooler
3. Charge air cooler
4. Fuel-air mixer
5. Intake manifold
6. Intake valve
Specifications - Air Intake System
Maximum Intake Restriction (clean air filter
element) 254 mm H2O [10.0 in H2O]
Maximum Intake Restriction (dirty air filter
element) 635 mm H2O [25.0 in H2O]
7/26/2022 TML 34
35. Air Exhaust System
1. Exhaust valve
2. Exhaust manifold
3. Turbocharger Exhaust Inlet
4. Turbocharger exhaust outlet
5. Waste-gate Closed
6. Waste-gate open
Specifications - Exhaust System
Maximum Exhaust Back Pressure with
catalyst 152 mm Hg [6 in Hg]
7/26/2022 TML 35
37. Air Exhaust System
Catalyst
The Catalyst used in the Exhaust Catalytic
Convertor is of two way type.
Catalyst Muffler
The substrate material used is Palladium,
Platinum & Rhodium.
7/26/2022 TML 37
39. Lubricating System
Oil Specifications:
Oil Pressure:
– Low Idle (minimum allowable) : 69 kPa [10 psi]
– At rated speed (minimum allowable) : 207 kPa [30 psi]
– Pressure Regulator valve opening pressure : 499 kPa [65 psi]
– Filter By pass Valve Opening pressure : 138 kPa [20psi]
Oil Capacity:
– Standard Oil Pan:
– High: 14.2 liter [15 quart]
– Low : 12.4 liter [13 quart]
– Total System Capacity : 15.1 liter [16 quart]
The Oil grade to be used is SAE 15W40 GEO (Gas Engine Oil). A sulfated ash limit of 0.6 percent
has been placed on all engine lubricating oils recommended for use in Cummins® natural gas
engines. Higher ash oils can cause valve and/or piston damage and lead to excessive oil
consumption and degradation of the catalyst.
7/26/2022 TML 39
42. Cooling System
Specifications - Cooling System
Coolant Capacity (engine only): 10.5 liters [11.1 qt.]
Engine Coolant Temperature: 600to 1000 C [1400 to 2120 F]
Standard Modulating Thermostat Range: 820 to 930 C [1800 to 1990 F]
7/26/2022 TML 42
Water Quality
Calcium Magnesium
(Hardness)
Maximum 170 ppm as
(CaCO3 + MgCO3)
Chloride 40 ppm as (Cl)
Sulfur 100 ppm as (SO4)
47. Fuel System
Test Fuel Data Input (See notes at right)
Location (Description) Cert. fuel
Methane CH4 90.02 %
Ethane C2H6 4.03 %
Propane C3H8 1.76 %
Butane C4H10 0.01 %
Pentane C5H12 0.01 %
Hexane C6H14 0.00 %
Heptane C7H16 0.00 %
Octane C8H18 0.00 %
Carbon Dioxide CO2 0.00 %
Nitrogen N2 3.99 %
Oxygen O2 0.00 %
Sum of Components 100.00 %
Methane Number: 89.76 PASS (Minimum Methane Number: 80)
Higher Heating Value (BTU/Std. Cu. Ft) 1024.50 PASS (Min. Higher Heating Value = 975 BTU/Std.
Cu. Ft.)
Note: Both MN and HHV Criteria must be met to pass a given fuel!
7/26/2022 TML 47
Notes:
1. Fuel requirements for automotive spark
ignited gas engines only.
2. Fuel as delivered to engine regardless if
liquid or gaseous
3. Maximum allowable sulfur content =
0.001% Weight.
4. Landfill gas and gas with chlorine
additives are not permitted
5. Fuel shall not contain water, dust, sand,
dirt, oils or any substance that can harm
engine operation
49. Capacitive Discharge Ignition with Coil Packs
7/26/2022 TML 49
Voltage will build in the
Secondary windings until it
is high enough to force the
electrons across the spark
plug electrode gap
53. Engine Specifications
7/26/2022 TML 53
Description Specification
Model 697 CNG BS-IV
Engine 697 NA CNG
Model 697 NA CNG Bharat Stage IV. Water cooled,
Type Stoichiometric, Naturally Aspirated, CNG engine.
No. Of Cylinders 6 inline
Bore / Stroke 97mm x 128mm
Capacity 5675 cc
Max. Engine Output 96 kw at 2500 rpm as per MOST/CMVR
Max. Torque 405 Nm @1250-1500
Compression Ratio 12.5:1
Firing Order 1-5-3-6-2-4
Air Filter Dry type remote mounted
Oil Filter Spin on filter
Fuel Filter Colasing oil and particulate filter and LP Filter
HP Gauge Plate mounted
55. Cylinder Head
BS-IV has different air inlet port
Spark plug center line is outward by 4mm
UWCL is different
Provision of gas rail in BS-IV head
7/26/2022 TML 55
56. Intake Manifold
BS-IV has separate IM and rocker arm cover
Individual runners for cylinders
Has provision for TMAP sensor & reference port
BS-IV has different throttle body. It can be fitted on any side as per requirement
Better air sealing capabilities
Metallic gaskets used for better sealing
7/26/2022 TML 56
57. Exhaust Manifold
Individual runners for cylinders
No clamps, bolts used directly for assembly
Better air sealing capabilities
Metallic gaskets used for better sealing
7/26/2022 TML 57
BS-IV
58. Head Cover
IM separate from rocker arm cover
No long bolts for assembly
Better oil sealing capabilities
Breather and oil filling facility
Different rocker arm assembly studs
Different gasket
7/26/2022 TML 58
59. Throttle Body
Bosch electronic throttle body for BS-IV
No cable operation
Fits on either side of intake manifold as per vehicle requirement
No mechanical setting required
7/26/2022 TML 59
60. Intake and Exhaust System
7/26/2022 TML 60
Air cleaner
Air throttle actuator
Inlet manifold
‘T’ map sensor
Injector
Coil on plug
HEGOS
Coolant Temp. sensor
Cam position sensor
Crank position sensor
Cat-Con Silencer
61. Catalytic Converter
7/26/2022 TML 61
Steel Plates
(Platinum / Palladium Coated)
To Silencer
Exhaust Gas from Engine
3 Way Conversion :-
1. Reduction : Nox
2. Oxidation : HC + O2
3. Oxidation ; CO + O2
N 2 + O2
H2 O+ CO2
CO2
Platinum Cat Convertor
Cat Convertor
Cat Convertor
Platinum / Palladium
Platinum / Palladium
63. Fuel System
High Pressure Parts:
5 nos. of CNG Cylinders (4 cylinder 135
Litter each capacity + one cylinder 110
litter at 200 kg/sq-cm) with
Safeties – Burst Disk, Excess Flow and
Fusible plug.
Seamless steel tubing for connecting all
cylinders
High pressure Fuel Filter
Receptacle or Refueling Valve
High pressure gauge
Three way valve
7/26/2022 TML 63
64. Fuel System
Excess Flow Valve
Cuts off gas flow at a pressure difference
over 650 Kpa (6.5 Bar).
At cut off position, the bypass flow of gas
through the valve does not exceed 0.05 cu.
m/min. at differential pressure of 10000
Kpa (100 Bar)
Pl. note: Before dismantling the excess flow
valve ensure that the cylinder is completely
empty
Burst Disc
Working pressure (kgf/sq cm) = 200
Bursting pressure (kgf/sq cm) = 300 / 330
Melting point of alloy in degree C= 100
(+4/-2)
7/26/2022 TML 64
65. Cylinder Valve Operation
7/26/2022 TML 65
vent line
Cylinder Valve
Excess flow valve limiter
Gas in and out hole
GAS IN GAS OUT
Excess flow valve limiter
66. Receptacle
Design for longer o-ring life as o-ring is not
in path of gas.
Maintenance requirement is nil however a
good practice is to replace O-ring after
every 300,000 kms or 5 yrs.
7/26/2022 TML 66
67. Three Way Valve
Position A : (Taper end of the knob pointing
towards the receptacle). Gas flows from
receptacle to cylinders, but flow to the
engine is blocked. As such the knob should
be kept at this position only while filling gas
into the cylinders.
Position B : (Taper end of the plastic knob
pointing upwards). Gas cylinders are cut off
both from receptacle and engine. The knob
should be kept at this position when the
vehicle is parked and not in operation.
Position C : (Taper end of the plastic knob
pointing towards the gas cylinder). Gas
flows from cylinder to the engine. As such
the knob should be kept at this position
when the vehicle is in operation.
Running
Parking
Filling
7/26/2022 TML 67
68. Ignition System
DC to DC Converter:
Ignition Control System and closed loop
lambda control system operates on 12V
supply
To provide 12V supply from the 24 volts
battery system DC to DC converter is
required
It is mounted under the dashboard in
driver cabin.
7/26/2022 TML 68
69. Coil On Plug - Pencil coil BAE 403
7/26/2022 TML 69
• coil body
• high voltage spring
• rubber boot
• coil connector
• coil fixing bracket
1. LV
Connector
2. Coil Head
3. HV Diode on
secondary
winding
4. Magnets
5. Magnetic
core
6. Iron jackets
7. HV Spring
8. Rubber boot
72. Instructions for practical exercise
Trainer:
– Divide the group into 4 teams
– Brief the trainees on the CNG Cylinder and Valve
– Make them inspect each component
Trainees:
– Follow the instructions of the trainer
– Inspect the CNG Cylinder and Valve
Objective:
– To identify and inspect the CNG Cylinder and the parts of the
cylinder valve
Practical Exercise
7/26/2022 TML 72
Exercise Name-
Inspection of CNG
Cylinder & Valve
Duration –30 Mins
73. Instructions for practical exercise
Trainer:
– Divide the group into 4 teams
– Brief the trainees on the CNG HP Components
– Make them inspect each component
Trainees:
– Follow the instructions of the trainer
– Inspect the CNG HP Components
Objective:
– To identify and inspect the CNG HP Components
Practical Exercise
7/26/2022 TML 73
Exercise Name-
Inspection of CNG HP
Components
Duration – 60 Mins
74. Instructions for practical exercise
Trainer:
– Divide the group into 4 teams
– Brief the trainees on the CNG LP Components
– Make them inspect each component
Trainees:
– Follow the instructions of the trainer
– Inspect the CNG LP Components
Objective:
– To identify and inspect the CNG LP Components
Practical Exercise
7/26/2022 TML 74
Exercise Name-
Inspection of CNG LP
Components
Duration – 60 Mins
75. Instructions for practical exercise
Trainer:
– Divide the group into 4 teams
– Brief the trainees on the Ignition system components
– Make them inspect each component
Trainees:
– Follow the instructions of the trainer
– Inspect the Ignition system components
Objective:
– To identify and inspect the Ignition system components
Practical Exercise
7/26/2022 TML 75
Exercise Name-
Inspection of Ignition
system components
Duration – 120 Mins
Video of Ignition
System
76. Instructions for practical exercise
Trainer:
– Divide the group into 4 teams
– Brief the trainees on Spark plug inspection and testing
– Make them inspect each component
Trainees:
– Follow the instructions of the trainer
– Inspect & test the spark plug
Objective:
– To Inspect & test the spark plug
Practical Exercise
7/26/2022 TML 76
Exercise Name- Spark
plug inspection and
testing
Duration – 60 Mins
78. Instructions for practical exercise
Trainer:
– Divide the group into 4 teams
– Brief the trainees on the CNG HP Components
– Make them inspect each component
Trainees:
– Follow the instructions of the trainer
– Inspect the CNG HP Components
Objective:
– To identify and inspect the CNG HP Components
Practical Exercise
7/26/2022 TML 78
Exercise Name-
Inspection of CNG HP
Components
Duration – 60 Mins
79. Instructions for practical exercise
Trainer:
– Divide the group into 4 teams
– Brief the trainees on the Ignition coil inspection and testing
– Make them inspect each component
Trainees:
– Follow the instructions of the trainer
– Inspect and test Ignition coil
Objective:
– To Inspect and test Ignition coil
Practical Exercise
7/26/2022 TML 79
Exercise Name- Ignition
coil inspection and
testing
Duration – 60 Mins
80. Instructions for practical exercise
Trainer:
– Divide the group into 4 teams
– Brief the trainees on the Common Rail
– Make them inspect each component
Trainees:
– Follow the instructions of the trainer
– Inspect the Common Rail
Objective:
– To Inspect the Common Rail
Practical Exercise
7/26/2022 TML 80
Exercise Name-
Inspection of Common
Rail
Duration – 60 Mins
