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Introduction to Buses & Engine Systems.pptx

The document provides an introduction to Tata Motors buses and engine systems. It discusses the objectives of the training program which are to understand Tata bus models, CNG fuel systems, and maintenance of CNG engines. The agenda covers an introduction to rear-engine and front-engine buses, an overview of compressed natural gas (CNG) and gas engine terminology, and details on the Cummins 6B5.9G and 3.8/5.7 SGI CNG engine systems including specifications and maintenance.

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Technician Level 2 (LOB Bus) – Module 1 Introduction to TATA Motors Buses & Engine Systems
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
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
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
Introduction to Tata Motors Buses 7/26/2022 TML 5
Rear Engine Buses 7/26/2022 TML 6
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
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
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
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
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
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
Front Engine Buses 7/26/2022 TML 13
Classification of Front Engine Buses 7/26/2022 TML 14 Bus Floor Height 650mm Mini/Midi 900 mm LPO 1618/62 LP 712/42 FESLF 1618/63 Products offered by TML CNG Diesel LP 909/49 LP 912/49 LP 407/34 LPO 1512/55 LPO 1613/55 LPO 1616/55 LPO 1613/55
LPO 1618 FE SLF 7/26/2022 TML 15 Aggregate Specification Engine Cummins 6BT AA Gearbox G600 Rear Axle TATA 109 RR Front Axle Reverse Elliot I Beam Steering Hydraulic Power Steering Brakes Full S-Cam Air Brakes (Front & Rear) Wheels and Tyres 11R22.5 Radial Suspension System Front: Weveller Suspension Rear : Pneumatic Suspension Electrical System 24 Volts,90 Ampere Multiplexing System
LPO 1613 CNG BS IV 7/26/2022 TML 16 Aggregate Specification Engine 5.7 SGI CNG BS IV Gearbox G600 Rear Axle TATA 109 RR Front Axle Reverse Elliot I Beam Steering Hydraulic Power Steering Brakes Full S-Cam Air Brakes (Front & Rear) Wheels and Tyres 11R22.5 Radial Suspension System Front: Weveller Suspension Rear : Pneumatic Suspension Electrical System 24 Volts,90 Ampere Multiplexing System
Vehicle Walk Around 7/26/2022 TML 17
Introduction to CNG 7/26/2022 TML 18
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
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
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
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
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
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
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
Engine Systems - CNG 7/26/2022 TML 26
Cummins 6B 5.9 G (B Gas Plus) 7/26/2022 TML 27
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
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)
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
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
Engine Views 1. Flywheel housing 2. Heated oxygen sensor 3. Exhaust adapter 4. Turbocharger 5. Spark plug wire Coolant outlet 6. Coolant inlet 7. Lubricating oil filter 8. Lubricating oil drain Exhaust Manifold Side View 7/26/2022 TML 32
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
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
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
Air Exhaust System Waste Gate Actuator 7/26/2022 TML 36
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
Lubricating System 7/26/2022 TML 38
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
Lubricating System 7/26/2022 TML 40
Cooling System 7/26/2022 TML 41
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)
Cooling System 7/26/2022 TML 43
Fuel System 1. Fuel inlet hose 2. Fuel Inlet 3. Pressure Regulator 4. Fuel house 5. Fuel shutoff valve 6. Screen pack 7. Gas mass flow sensor 8. Fuel housing 9. Fuel Jumper hose 10. Fuel control valve 11. Air/fuel mixer 12. Throttle actuator 13. Intake manifold 14. Intake valve. 15. Air/Fuel supply housing 7/26/2022 TML 44
Fuel System 7/26/2022 TML 45
Fuel System 7/26/2022 TML 46
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
Ignition System 7/26/2022 TML 48 ECM Combined On Plus Engines Spark Reference Spark Timing 300 Volts
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
Ignition System 7/26/2022 TML 50
Engine Familiarization Tata 5.7 SGI CNG BS IV 7/26/2022 TML 51
Tata 5.7 SGI CNG BS IV 7/26/2022 TML 52
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
New Components in BS IV Engine 7/26/2022 TML 54
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
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
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
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
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
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
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
Fuel System 7/26/2022 TML 62
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
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
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
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
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
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
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
Ignition System 7/26/2022 TML 70 Cam Position Sensor Coil On Plug Engine Control Module
Maintenance & Repair Cummins 6B 5.9 G (B Gas Plus) 7/26/2022 TML 71
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
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
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
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
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
Maintenance & Repair Tata 5.7 SGI CNG BS IV 7/26/2022 TML 77
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
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
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
All The Best! 7/26/2022 TML 81

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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 yourselfloud 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 theend 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  Introductionto 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
  • 5.
    Introduction to TataMotors Buses 7/26/2022 TML 5
  • 6.
  • 7.
    Classification of RearEngine 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 CNGNon 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 7/26/2022TML 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 7/26/2022TML 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 7/26/2022TML 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
  • 13.
  • 14.
    Classification of FrontEngine Buses 7/26/2022 TML 14 Bus Floor Height 650mm Mini/Midi 900 mm LPO 1618/62 LP 712/42 FESLF 1618/63 Products offered by TML CNG Diesel LP 909/49 LP 912/49 LP 407/34 LPO 1512/55 LPO 1613/55 LPO 1616/55 LPO 1613/55
  • 15.
    LPO 1618 FESLF 7/26/2022 TML 15 Aggregate Specification Engine Cummins 6BT AA Gearbox G600 Rear Axle TATA 109 RR Front Axle Reverse Elliot I Beam Steering Hydraulic Power Steering Brakes Full S-Cam Air Brakes (Front & Rear) Wheels and Tyres 11R22.5 Radial Suspension System Front: Weveller Suspension Rear : Pneumatic Suspension Electrical System 24 Volts,90 Ampere Multiplexing System
  • 16.
    LPO 1613 CNGBS IV 7/26/2022 TML 16 Aggregate Specification Engine 5.7 SGI CNG BS IV Gearbox G600 Rear Axle TATA 109 RR Front Axle Reverse Elliot I Beam Steering Hydraulic Power Steering Brakes Full S-Cam Air Brakes (Front & Rear) Wheels and Tyres 11R22.5 Radial Suspension System Front: Weveller Suspension Rear : Pneumatic Suspension Electrical System 24 Volts,90 Ampere Multiplexing System
  • 17.
  • 18.
  • 19.
    CNG Fuel SystemLayout 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 SystemTechnology 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 SystemTechnology 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 isthe 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
  • 26.
    Engine Systems -CNG 7/26/2022 TML 26
  • 27.
    Cummins 6B 5.9G (B Gas Plus) 7/26/2022 TML 27
  • 28.
    Cummins 6B 5.9G (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 TML29 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. Frontengine 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. Ignitioncontrol 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
  • 32.
    Engine Views 1. Flywheelhousing 2. Heated oxygen sensor 3. Exhaust adapter 4. Turbocharger 5. Spark plug wire Coolant outlet 6. Coolant inlet 7. Lubricating oil filter 8. Lubricating oil drain Exhaust Manifold Side View 7/26/2022 TML 32
  • 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
  • 36.
    Air Exhaust System WasteGate Actuator 7/26/2022 TML 36
  • 37.
    Air Exhaust System Catalyst TheCatalyst 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
  • 38.
  • 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
  • 40.
  • 41.
  • 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)
  • 43.
  • 44.
    Fuel System 1. Fuelinlet hose 2. Fuel Inlet 3. Pressure Regulator 4. Fuel house 5. Fuel shutoff valve 6. Screen pack 7. Gas mass flow sensor 8. Fuel housing 9. Fuel Jumper hose 10. Fuel control valve 11. Air/fuel mixer 12. Throttle actuator 13. Intake manifold 14. Intake valve. 15. Air/Fuel supply housing 7/26/2022 TML 44
  • 45.
  • 46.
  • 47.
    Fuel System Test FuelData 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
  • 48.
    Ignition System 7/26/2022 TML48 ECM Combined On Plus Engines Spark Reference Spark Timing 300 Volts
  • 49.
    Capacitive Discharge Ignitionwith 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
  • 50.
  • 51.
    Engine Familiarization Tata 5.7SGI CNG BS IV 7/26/2022 TML 51
  • 52.
    Tata 5.7 SGICNG BS IV 7/26/2022 TML 52
  • 53.
    Engine Specifications 7/26/2022 TML53 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
  • 54.
    New Components inBS IV Engine 7/26/2022 TML 54
  • 55.
    Cylinder Head  BS-IVhas 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-IVhas 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  Individualrunners 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  IMseparate 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  Boschelectronic 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 ExhaustSystem 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 TML61 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
  • 62.
  • 63.
    Fuel System High PressureParts:  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 FlowValve  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 7/26/2022TML 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 forlonger 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 toDC 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
  • 70.
    Ignition System 7/26/2022 TML70 Cam Position Sensor Coil On Plug Engine Control Module
  • 71.
    Maintenance & Repair Cummins6B 5.9 G (B Gas Plus) 7/26/2022 TML 71
  • 72.
    Instructions for practicalexercise  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 practicalexercise  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 practicalexercise  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 practicalexercise  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 practicalexercise  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
  • 77.
    Maintenance & Repair Tata5.7 SGI CNG BS IV 7/26/2022 TML 77
  • 78.
    Instructions for practicalexercise  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 practicalexercise  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 practicalexercise  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
  • 81.