A Survey Report on

AUTOMOTIVE SERVICE’S
(UJJWAL AUTOMOTIVE)

By
Mr. Yojit Lokhande Mr. Yash Pachpute
Mr. Shrikant Kalgane Mr. Paras Naik
Mr.Gurudev Keware
Guided By
Prof. Pravin Surwade

Department of Mechanical Engineering

K.K.WAGH INSTITUTE OF ENGINEERING
EDUACTION AND RESEARCH, NASHIK
[2022-2023]
K.KWagh Institute of Engineering Education & Research

CERTIFICATE

This is to Certify that Yojit Lokhande, Yash Pachpute, Shrikant Kalgane,

Paras Naik, Gurudev Keware students of Second Year (Mechanical Engineering)
were examined in the PBL entitled as AUTOMOTIVE SERVICE’S(UJJWAL
AUTOMOTIVE).

Prof.P.B.Surwade
(Project Guide) Examiner

Introduction:

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We visited Ujjwal Automotives the Authorized workshop of TATA. It was a short
survey for 4 to 5 days about the Automobile Services. Main objective of our survey
was to learn new things about engine management systems and new updated
electronic systems used in the vehicles. In these survey our objective was to learn
and gain knowledge about daily updates and new terms defined in vehicles. Here
we also noted about the various tools used and special tool kits required for repair.
We also observe the various sensors used in the vehicles and understood about
their function and work in brief.

About (Ujjwal Automotives):

Ujjwal Automotives is the Authorized workshop of the TATA Motors Pvt. Ltd. It
is near the DMART, Adgaon, Nashik, Maharashtra 422007. This workshop
provides services to commercial vehicles manufactured by Tata Motors. These
workshop has 20-25 workers including the Manager and mechanics. Here repaired
of all the Heavy Commercial Vehicles (HCV) and Light Commercial vehicles
(LCV’s) is done.
It is good infrastructure with different bays for the work. Here they have all new
technology required for the repair of new electric as well as diesel and petrol
engines. 3D wheel alignment and balancing system is also introduced here with
new system.
Ujjwal Automotives provides various services such as:
1. Vehicle cleaning and washing.
2. Vehicles Electric and electronic
diagnostics.
3. Vehicle Diagnostics with new
upgraded system
4. 3D wheel alignment and
balancing.
5. Engine servicing.
6. On road breakdown services

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 Fig: Services provided by workshop.

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 Survey Details:

As Ujjwal Automotives is authorized workshop of Tata motors. These

workshop has total 17 bays with well finished and well equipped tools required
for the repair. All rules and safety precautions were taken into the
consideration.
First of all we visited to the manager’s cabin an understood all about the outline
of the workshop and management of workshop. Management of workshop was
divided in three different categories which consist of Warranty Section, Sales
and spare, Repair and maintenance department. Then average daily visit of
vehicles to the workshop was near about the 30 to 35 vehicles in a day.
According to the bay the work was allotted to all the mechanics depending upon
vehicle type.

Job Card Creation:First of all after entering the workshop the Job card is
created of the vehicle on which the problem of vehicle is described in short. Job
card contains all data about the estimation of bill, pre and post checkup of
vehicle done by the following mechanic is described and after compilation of
the job it should be about the parts required and fitted. After completion of job
it should be filled again by the mechanic supervisor about the time required to
complete the job and part required for the repairs. Lubricant details and charges
should be also fill along with it.

Fig: Job Card sample

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Bay Details:

The structure of workshop was divided in into total 17 working bays as follow:
Bay No 1 to 7:
Bay 1 to 7 were provided for the LCV’s for general servicing of vehicles related
to engine, gearbox, clutch plate or electronic diagnostics system. Here general
servicing of vehicle which means the change of oil, oil filter, ail filter was

replaced or clean accordingly depends upon the type of vehicle. Also all general
checkup of the vehicle is also monitored using the Vehicle diagnostics tool.
After that if vehicle has some major problems related to the engine, gearbox,
brake or electronic system then it is further given to the bay no 5, 6 and 7. In
LCV’s the vehicles mostly visited was Intra V30, Intra V10, and Ace Gold
petrol and diesel variants. As we observed there mostly visited vehicles were
BS 6 and BS 4.
Engines used in these vehicles was 4 piston- cylinder and fuel used were Petrol,
CNG, Diesel engines and some of the vehicles were 2 piston- cylinder Diesel
engine and all engines were water cooled. Gearbox used was heavy duty 5
speed manufactured by Tata was used in all vehicles. Now a days the lubricant
used in the Bs-6 vehicle was 10W30 with high lubricating effects. Coolant used
was Tata green.
For the electronic diagnostics of vehicles the system was used were TDS Lite
system which diagnoses all about the problems in Vehicle system. Now in new

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BS 6 vehicles the ECU i.e. Electronic Control unit is used for the various
systems of vehicles such as fuel pressure control unit, steering system, and
Exhaust system were diagnosted using these TDS Lite and accordingly repair
was done. Clutch system used in all these vehicles were hydraulic clutch system
which was operated on the fluid name as DOT 3 or DOT 4 brake and clutch oil.
Bay No 8 and 9 (Denting and painting Section);
These bay was provided for the denting painting of
accidental vehicles. The operations carried out to
remove the dent was observed carefully. Using the
various types of heating, welding, grinding and
cutters the original shape was given to the
accidental vehicles. Welding types used here was
gas welding and MIG welding. For coloring the
compressor spray gun was used.

Fig: Gas welding

Bay No 10 (Wheel alignment and balancing);
These bay was especially provided for 3D wheel alignment and balancing of
LCV’s and HCV’s. Here for wheel alignment special ramp was provided to set
the gauge of wheels in precise manner. The 3D wheel alignment system
consists of 2 cameras with the oscillating pendulum sensors which gives the
precise measurements of the wheels and accordingly the wheels are adjusted
further.
The adjustment procedure for wheel alignment is as follows:
 Start at the rear, adjust the Chamber and adjust the toe. After that to the
front wheels, adjust the castor, adjust the chamber and finally front toe.
Providing all the adjusters are moving freely.

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  Lock the steering wheel in the straight ahead position and apply the
brake pedal depressor.
 Fit the measuring heads to the rear wheels and the center lines scale to
the front wheels and switch on the sensors.
 After collecting all the data using the sensors collect the misalignment of
wheels accordingly and again follow the procedure for precise
measurement and alignment.

Fig: 3D Wheel alignment Sensor

Bay No 11 to 17 (Quick service bay and HCV’s Bay):

These bays were provided for quick services, Heavy Commercial Vehicles
(HCV’s), buses and ambulances. Mostly visited HCV’s were 1109, 407, Tippers
like SIGNA 48.25tk, 4923 and many more. Buses visited was Marcopolo, Starbus,
Starbus Ultra, etc all of these variants were Diesel and CNG depending upon the
use of user.
Here engines used in these vehicles was 6 Cylinder, 8 Cylinder engines for heavy
duty and it was water cooled engines. As the tipper are having more heavy
operations since the engines used are also heavy.

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These all vehicles have 6 speed, 8 speed and 12 speed gearbox accordingly the use.
All of the HCV’s are used to carry heavy load hence speed required is less and
torque required is more. Hence, gears are designed in the manner that they gives
the greater torque and less speed. Tipper contains hydraulic pump to lift up the
load.

Quick services provided on these bay were:

1. Wheel greasing: In wheel greasing the bearings of wheels are lubricated
using the grease various types of grease were used for greasing was TATA
bearing grease, chassis grease, etc.
2. Electricals: Here Headlamp, tail lamp bulbs were checked and replaced.
Also all electrical repairs i.e. starter, alternator overhaul were done.
3. Other services: Services like tie rod joints replacement, steering wheel
replacement, and suspension check and accessory fitment was done.
4. Related to engine: Tappet adjustment, Engine oil change, Fuel filter
replacement, change of hoses, cylinder head gasket replacement, timing belt
replacement, FIP timing, alternator belt, fan belt replacement were done.
5. Gearbox and Clutch: Gear oil change, Clutch pedal free play setting, clutch
master and slave replacement, gear lever adjustment, etc.
6. Propeller Shaft: UJ cross replacement, central bearing bracket replacement
Fig: Eligible jobs for Quick service bay.

Vehicle washing Bay:

Here after complete repair of vehicles, they were washed and clean.
Hydraulic lift was used to lift the vehicle up for washing it has overall
capacity to lift the load was maximum 2 tons.

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 Fig: Washing Area and Hydraulic lift.

Fig: Gear box assembly

Spares and sales section:

Spares and sales section was to provide the spares required for the vehicles during
the repairing of vehicles.

Sensors:
Sensor is a device that detects and responds to some type of input from the
physical environment. As there were many sensors used in the vehicles are listed
below:

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1. Crank Sensor: Crank sensor is most important sensor of any engine, it
monitors to set ignition timing, detect engine RPM and relative engine
speed.
2. Camshaft Sensor: The camshaft sensor enables the engine to control the
exact position of the crankshaft drive. This information is required to
calculate the injection point.
3. Speed Sensor: Speed sensor is used to measure the speed of the vehicle.
4. Common Rail pressure sensor: Common rail pressure sensor is located on
the fuel rail. Its function is to monitor the pressure in common rail.
5. Throttle Position sensor: It is used to measure the air intake of engine. It
located on butterfly spindle, so that it can monitor directly the position of
throttle.
6. Temperature Sensors: The engine coolant temperature sensor detects the
engine coolant temperature.

Fig: Sensors used in automobile

Tools:
Tools used for assembly and disassembly of vehicles were observed and
purpose of that tool was noted as follow:
1. Tools used for assembly and disassembly of vehicles were observed and
purpose was specific tool was learnt accordingly.
2. Ring Spanner: A type of spanner with a handle that has a hole of a
particular shape designed to grip a nut or bolt head
3. Open-ended and double-ended spanners:

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 4. Ratchet ring spanners: A ratchet spanner or wrench uses a mechanism
which allows an open-ended, flare or ring head to turn a fastener in one
direction but not the other while remaining fitted to the fastener head.
5. Box spanners: They're often used to remove fittings that are hard to
reach, such as deeply set nuts or spark plugs tucked away in a recess. The
box spanners come with a soft tool roll to make organization and
transport easier.
6. Ratchet wrench:
7. Oil filter and diesel fitter opener wrench: Function of oil filter and diesel
filter wrench is to open and tighten the oil filter and diesel filter.

Fig: Tool Box

Special tools:
Some of the special tools were also seen and their function is listed below in detail;
1. Feeeler Gauge: Feeler gauge is a measuring gauge having scale in mm. It is
used to measure the tappet setting of valves.
2. Flywheel locking pin: This tool is used to lock the flywheel to allow
torque to be applied to undo the crankshaft pulley fixing.

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3. Locking plate/ CAM Shafter locker: The camshaft holding and lock
tools help you get the right timing on the timing belt once it is replaced. The
timing of the engine valves is critical to the functioning of your engine.
Some models have a hydraulic timing belt tensioner that requires an extra
step in the removal and replacement of the timing belt.
4. Locking plate/ CAM Shaft Hub locker: The camshaft holding and lock
tools help you get the right timing on the timing belt once it is replaced.
5. FIP Gear locking: It is used to lock the cam shaft gear to fix the pulley on it.
6. Timing Rod FIP: It is used to lock the timing of fuel rotary pump while
replacement of timing belt.
7. Drift/ Install Liner: They are used to removal of piston liners of cylinder and
fixing it again.
8. Drift- Oil Pump Oil Seal/CUB: Oil seal press tool is used to press the oil
seals.

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 Fig: a) Feeler Gauge b) Timing rod FIP
c) Locking plate/camshaft locker d) Fly wheel locking pin

Safe Workshop practices:

1. Wheel Chocks
2. Inspection Pit
3. Use of safety Helmet
4. Safety Shoes
5. Use Of apron
6. Use of safety gloves,etc.
7. Collection And disposal of lubricants

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