CHAPTER -1

INTRODUCTION

Automobiles need maintenance from time to time. Like humans are required
to maintain hygiene, similarly automobiles also need to be kept clean.
Automobiles have to run on dirty roads and in a polluted environment. They
run on uneven roads with potholes and other obstructions, and are therefore
subjected to loads which damage them. Therefore, there is a need for regular
maintenance and servicing of automobiles, which is usually done in auto
workshops or auto service stations.
In this Unit, you will understand the concept of vehicle maintenance
and servicing. All the services should be availed before expiry of above
mentioned km/hrs or days whichever occurs earlier. You can avail the free
labour services at any of TASS (TATA Motors Authorized Service Station)
If you require any assistance, please contact any of our Dealer or TASS
(TATA Authorized Service Station) or State Service Office or Customer
Assistance Centre (CAC).
 CHAPTER-2
COMPANY PROFILE

2.1 DETAILS OF THE ORGANISATION:

Company Name : TATA MOTORS SUSEE
Show room & Workshop: 49/50, New Bye Pass Road,
Bangalore - Chennai Highway, Vellore-632004.
Phone Showroom: 93447 21609
Service: 93447 21689
Email: accounts@susee.org
GSTIN: 33AAJCS2331LST001
Tata motors play a vital role in the community. I chose this
organization because. I find their mission to be important and relevant to my
career goals.

Figure No: 2.1 Photograph of the company

2
2.2 INDUSTRY PROFILE:
One of the biggest and fastest-growing industries worldwide is the
automotive industry, which is also one of the largest in India. Tata Motors
Vellore Susee group was started in 2012. Since its inception, it has
established itself as a prominent Truck dealer in Tamil Nadu. The Vellore
showroom has a Tata trained sales team that assists customers in choosing
the right Truck. The showroom offers Sales, Service, Spares - designed to
offer customers a complete solution. The facility with its trained staff and
state of the art facilities aspires to offer unparalleled experience to new and
existing customers. Susee Motors (India) Private Limited is the sole
authorised dealer for Tata vehicles in the Vellore, Thiruvannamalai and
Kanchipuram districts of Tamil Nadu since January 2012. The 'Susee
Group', which traces its origin to a business dealing with trading of
pulses/grains started in the late 1930s by Mr. Subramania Nadar and Ms.
Seeniyammal, is an established name in the auto dealership space in Tamil
Nadu. The group currently has five subgroups-belonging to the descendants
of the promoters; all of these operate under the 'Susee" brand, but have no
operational or financial linkages.

2.3 SUB-BRANCHES OF THE COMPANY:

 Thiruvannamalai
 Kanchipuram
 Arakonnam
 Tirupattur
 Vaniyambadi

3
2.4 PRODUCTS & SERVICES OF THE COMPANY:
 Tata Ace Gold Petrol
 Tata Ace Gold Diesel
 Tata Ace Gold CNG
 Tata Intra V10, 20, 30& 50
 Tata Yodha Pickup
 Tata Venture

4
 CHAPTER - 3
MAINTENANCE CHECKUP

This chapter on general maintenance may be one of the most

applicable for the average person to care for his or her own vehicle. We'll
discuss the vehicle owner's manual, vehicle fluids, fuses, belts and hoses,
vehicle lighting, and the air filter.

Fig.No: 3.1Vehicle Owner's Manual

All vehicles are different and the owner's manual for each make and
model is the most useful reference for maintenance and repair of that specific
vehicle. Despite the fact that it can often look thick, complicated, and boring
on the surface, vehicle owners should become familiar and comfortable with
the owner's manual. They're not so bad once they're finally opened.
The owner's manual will have a maintenance chart. The chart will
include such information as when to change the oil, rotate tires, replace the
air filter, inspect fuel cap and lines, change other fluids (transmission fluid,
etc.) and other maintenance issues. Your vehicle may have different

5
maintenance requirements at 30,000 miles, 90,000 miles, 150,000 miles and
at other intervals as indicated specifically in your owner's manual.
Being familiar with the maintenance chart in your owner's manual can
help you save money when taking your car to the mechanic for maintenance
checks. Sometimes the repair shop will suggest additional services that aren't
necessary.
If you don't have the owner's manual for your car then you may be
able to find one online by using Google or another search engine. Search the
website for the make of the vehicle. You could also try your local library.

6
 CHAPTER - 4
MAINTENANCE DETAILS

4.1 PREVENTIVE MAINTENANCE

Periodic maintenance is essential for ensuring long trouble free
performance. Have your vehicle serviced regularly from TATA MOTORS
authorized service centre. There is a large network of TATA MOTORS
Authorized Service Centre's to help you with their professional servicing
expertise. Scheduled maintenance information is provided which makes
tracking routine service easy.
The following checks can be carried out between the recommended
scheduled maintenance services. Take help of our authorized service centre
for assistance.
 Engine oil level
 Engine coolant level Brake fluid level
 Washer fluid level (if applicable)
 Battery electrolyte level Tyre inflation pressure including spare wheel.
Several maintenance procedures can be done only by a qualified
service technician with special tools. If improper maintenance held by you
during the warranty period, it may affect warranty coverage. If you're un-
sure about any servicing or maintenance procedure, have it done by TATA
MOTORS Authorized workshop.

4.2 SPRING AND SUSUPENSION

The suspension system is made of a few primary components,
including shock absorbers, coil springs, struts, leaf springs, and the tires
that’s right, your tires are actually part of the suspension system.

7
 Shock absorbers are long, tube-shaped pistons filled with liquid (and
sometimes with gas too). They support the springs by compressing and
lengthening to reduce the impact from a bump or dip in the road.
 Coil springs are placed near the shock absorber and take much of the
impact from bumps and dips in the road.
 Struts have a shock absorber and a spring in one assembly. Struts
provide structural support for your vehicle. Not all vehicles have
struts, and ones that do, typically only have them on one axle.
 Leaf springs are made up of multiple plates of slightly curved metal
those are clamped together. They are installed on a vehicle to help
minimize vertical vibration and are mainly found on vehicles with
solid rear axles.
 Tires are the only car suspension components in your suspension
system that touches the ground. Your tires take much of the impact
from road bumps and dips, transferring it to the shocks and/or struts.

Fig.No:4.1 Suspension System

8
4.3 SPARK PLUG
Spark plug plays a significant role in the combustion process in your
car’s engine. It ignites the air/fuel mixture and creates an explosion to power
up your engine. Regardless of the cutting-edge technology in your vehicle,
your car cannot start without a spark plug. However, car owners tend to
overlook its maintenance which later causes significant engine problems.
Read on to know simple maintenance tips for your spark plug and signs of a
damaged spark plug

Fig.No:4.2 Spark Plugs

4.3.1 TIPS TO MAINTAIN THE LONGEVITY OF SPARK PLUGS

A spark plug is located in the combustion chamber and keeps your car
engine going with very little maintenance. Since it is necessary to oversee its
maintenance, here are several ways to check on your spark plugs.
1. Choose a Suitable Spark Plug for Your Car:
Copper, Platinum, and Iridium are the three different types of spark
plugs available in the market. While copper plugs have high conductivity,
they come at a low price and short life span. Comparatively, platinum and

9
iridium are expensive and offer high performance in the long. However, the
best fit always depends on the design of your car engine.
2. Clean the Spark Plug and Electrodes Regularly:
The best way to maintain your car’s spark plugs is to clean off the dirt
on them regularly. You can perform this task at home with the proper
guidelines. To clean the spark plug, you will need a socket wrench, thinner
liquid, a toothbrush, and sandpaper. Make sure you remove the plug
carefully from its terminal with a socket wrench and soak it in petrol, diesel,
or isopropyl alcohol solution.
3. Check the Spark Gap:
The gap between the central and side electrodes should be appropriate
to make your spark plugs function smoothly. If the gap is less, the spark will
be weak and cause the engine to work poorly. However, the plug will not
make a spark if the gap is too big. Therefore, it is essential to check the gap
before mounting it in the combustion chamber using a coin-type gap
measure.
4. Clean the Mounting Area:
A frequent combustion process can build up debris and oil in the
mounting area, causing the spark plug to get misaligned. Therefore, it is
essential to clean the mounting area often to avoid malfunctioning. You can
use a compressed gun to clean the accumulated dirt.
5. Spray the Cavity around The Central Electrode:
Accumulation of debris can cause a misfire in the engine. Use a plug
cleaner in the cavity around the central electrode to get rid of unwanted
material like porcelain dust. Make sure you hold the plug face downward
while spraying the cavity.

10
4.4 GEAR BOX

Fig.No:4.3 Gear Box

4.4.1 MAINTAINENANCE OF GEARBOX

1. Perform a Regular Inspection of the gearbox:
A regular inspection helps you identify minor concerns and identify
the onset of any major issues. It enables you to resolve them on time, and in
a way, and to a considerable extent, maintain operational efficiency. So,
inspect the gearbox for oil leaks on the output and input shafts. Besides, look
for discoloration of the paint that perhaps signifies overheating. Furthermore,
listen to the gearbox and inspect it for excess vibration.
2. Monitor the Temperature of the Gearbox:
Overheating or sudden changes in the temperature may affect the
performance of the gearbox. Hence, consistent and maintaining the
necessary temperature levels plays a critical role in ensuring efficient
gearbox operations. In this view, monitor the temperature of the gearbox

11
with the help of an infrared gun. A sudden change in the temperature may be
pointing towards the onset of significant concern.
3. Lubricate the Gearbox Regularly:
Lubrication constitutes a very critical part of the overall maintenance
activity. Connect with Top Gear’s experts to know what lubrication and
additives are appropriate for the gearbox, and use it as per Top Gear’s
specifications. Keep the gearbox well hydrated with the lubricant appropriate
and crucial for efficient operations.
4. Ensure proper alignment of the Gearbox with the Equipment:
Proper alignment of the gearbox with the equipment is very important.
Appropriate couplings should be used for doing so, without creating an
interference fit between mating parts.
5. Check the Gearbox for Dirt and Dust:
Often, gearboxes operate in and encounter a lot of dirt and dust while
in operation. To avoid dirt and dust accumulation, overheating, and the entry
of contaminants in the gearbox, ensure that you keep it as clean as possible.
Have the gearbox undergo regular cleaning to keep the gearbox as clean as
possible.
6. Observe for Gearbox Vibrations:
Doing a vibration analysis is crucial, especially when the gearbox
operates in a commotion. A consistent vibration indicates the quality of the
gear train and the bearings. An increase in the vibration signifies a critical
concern.

4.5 AIR FILTER

Air filters are devices used to remove airborne particles, pollutants,
and microorganisms hazardous to health and the ecosystem. In industrial
facilities, air filters preserve the quality of products and materials and protect
critical equipment from damage. Cleanroom environments are heavily

12
dependent on air filters to control particle count. Exhaust and stack gases are
filtered and cleaned before releasing them into the atmosphere.

Fig.No:4.4 Air Filters

Air filters effectively remove dust, dirt, smoke, aerosols, odors,
viruses, molds, bacteria, toxic gases, and other particles and pollutants that
could exist in ambient air. These pollutants cause and aggravate respiratory
illnesses, skin disorders, allergies, and other illnesses.

4.5.1. Working of Air Filters

Air filters work by drawing unclean surrounding air to pass through
their filter medium with fine openings. The unwanted particles larger than
those openings are trapped inside the filter medium and are separated from
the passing air. The air leaves the filter with significantly reduced particle
content. Air filters increase their filtration efficiency as particles form a layer
in the upstream side of the filter media; this aids in screening other particles.
The filter medium is replaced regularly to prevent it from clogging or
blinding and restricting airflow.

13
4.6. COOLING SYSTEM
The engine in your car works best at a high temperature. When the
engine is cold, components wear out easily, emits more pollutants, and the
engine becomes less efficient. Thus, another important task of the cooling
system is to allow the engine to warm up as quickly as possible, and then to
maintain a constant engine temperature. The main function of a cooling
system is to ensure that the engine runs at its optimum operating
temperature. If the cooling system or any part of it fails, it will overheat the
engine, which can lead to many serious issues.

Fig.No:4.5 Engine Cooling System

Have you ever imagined what would happen if your engine cooling
system did not work properly? Overheating can cause cylinder head gaskets
to explode and even crack engine blocks if the problem is serious enough.
And all this heat must be fought. If the heat cannot be removed from the
engine, the pistons are literally welded to the inside of the cylinders. Then
you just must throw the engine away and buy a new one. So, you should take
care of your engine cooling system and learn how it works

14
 CHAPTER -5
SAFETY RULES AND EQUIPMENTS

5.1 BASIC GENERAL INDUSTRY SAFETY RULES

1. Keep work areas clean. Proper housekeeping alone can go a long way in
preventing injuries. Injuries such as slips, trips, falls, lacerations, sprains,
strains, etc., can be reduced by keeping work areas organized and clean.
2. Use the proper tool for the job. Avoid the first impulse to use whatever
tool (or object) is around you to get a work task done. Using the wrong tool
for the job can result in an injury or damage to the tool, which can lead to an
injury in the future.
3. Always wear the proper PPE for the work task. The lack of PPE, or the
use of improper PPE, leads to many injuries in the workplace. PPE is the last
line of defense when protecting yourself from the hazards of your work. If
you come into contact with a hazard when not wearing the correct PPE, the
injury will be more severe than if you were wearing it.
4. Never work on live equipment. Working on energized equipment is an
unsafe act that can result in serious injuries or fatalities. Always follow
proper lock-out/tag-out procedures prior to performing any maintenance or
repair work on equipment.
5. Make sure chemicals are properly labeled and stored. OSHA issues many
citations regarding hazard communication every year. Improper labeling and
storage can lead to injuries or property loss due to fires, corrosion, etc.
6. Communicate hazards to other personnel. Never assume that a coworker
understands the hazards of a task, especially if they are new or new to the
task. When work plans or conditions change, take the necessary time to
inform others of the impacts the changes have on safety.

15
7. Stop work when needed to address hazards. Always stop work to take the
time to get hazards addressed to make it safe to continue the task. Whether
you need to involve other personnel, such as a supervisor, or you need to
take time to get the right tool for the job, always take the time to do so.

5.2 SAFETY EQUIPMENTS

5.2.1 SAFETY GLASSES
The important industrial safety equipment worn by workers, safety
glasses protect from severe damage caused to the eyes while performing
welding or soldering tasks or from the dust and debris produced by certain
power tools. They are worn while operating lathe machines to avoid
projectiles from entering the eyes.

5.2.2 HEARING PROTECTION

Several industrial activities produce higher levels of noise. Daily or
frequent exposure to such types of increased noises can cause hearing
impairment or hearing loss. Using earplugs can be of great help in
safeguarding against these extreme noises.

16
5.2.3 SAFETY GLOVES
They protect the workers’ hands from chemicals, sharp objects,
sensitive materials and extreme temperatures. Look for gloves with proper
fitting, which must be compatible with the material and suitable for the
concerned tasks.

17
5.2.4 FACE SHIELD
A face shield protects the workers’ faces when using lathes and
similar machinery or equipment as it produces plenty of flying chips. They
are comfortable and easy to use and can be flipped upwards when not in use.

5.2.5 SAFETY HELMETS

These safeguard the most fragile and highly important part of the
human body- the brain. Safety helmets provide protection against fatal
incidents that commonly take place in industrial work areas.

18
5.2.6 SAFETY SHOES
The resilient shoes protect the workers feet from potential injuries that
occur from any heavy machines and equipment hitting the feet, sharp objects
that lacerate the feet and burns to name a few. Safety shoes are more
comfortable, provide a firm grip and relieve pain from standing for several
hours at work in factories.

19
 CHAPTER – 6
DASHBOARD INDICATORS

6.1 DASHBOARD INDICATOR LIGHTS

The instrument panel on your dashboard has multiple gauges and
indicators. These may include the fuel gauge, speedometer, tachometer, oil
pressure, and engine temperature. Most are self-explanatory the speedometer
measures your speed, etc. The one that may not be self-explanatory is the
tachometer, which indicates engine speed in revolutions per minute (RPM).
It often has a red zone which you should never exceed.
In the previous chapter we checked all the vehicle lighting which
included the dashboard symbols. Now we will discuss what these symbols
mean. As always, a better resource to learn the meaning of each dashboard
symbol for a specific vehicle is the owner’s manual for that vehicle. The
ones that are included in each vehicle will vary by make and model.
Dashboard lights can be red, orange (or yellow) and blue. Generally when a
red light comes on while driving, it means you should immediately pull over
safely and call a tow truck. However there are some exceptions some lights
which are generally red can be yellow or orange, and some red lights can be
fixed immediately Orange or yellow lights generally indicate that there is a
problem with your vehicle, but it is safe to drive to a repair facility or your
home residence to investigate further. This also has some exceptions. It is
always best to consult the owner’s manual for a particular vehicle.

6.2. LIST OF GENERAL SYMBOLS

6.2.1 Airbag Light or Supplemental Restraint Warning Light:
Red, Orange or Yellow. Whenever this light illuminates the air bag
system senses a problem, which could be a safety issue. It does not

20
necessarily mean that the airbags will not work. The airbags might or might
not still deploy during an accident. The light means that there is a part of the
airbag system that may not work.

6.2.2 Anti-Lock Brakes Light:

Orange or yellow light. This indicates a failure in the anti-lock brake
(ABS) system and anti-lock brakes are disabled. The purpose of the ABS is
to allow steering control of a vehicle while braking and to avoid skidding
during a panic stop. If this light is on, then normal conventional brake
function will continue. If it’s on in the event of a panic stop then the vehicle
will skid. Have the vehicle serviced.

6.2.3 Brake Light:

Red light, immediately pull over safely and have the vehicle towed (or
disengage the parking brake if applicable). This light indicates that there is
something wrong with the brakes. There could be a low brake fluid level,
there could be a hydraulic brake failure, or the parking brake is engaged.

6.2.4. Change Oil Soon:

Orange or yellow light. This light indicates that routine oil change and
maintenance is due. It’s based on revolutions of the crankshaft, which is
even more accurate than basing routine oil changes on mileage.
21
6.2.5 Check Engine Light:
Red or yellow light. There is a problem with the vehicle emissions and
the vehicle’s computer will have diagnostic trouble codes (DTCs) which will
be retrieved when the vehicle is inspected. The light may come on and then
off. If there are any performance issues with the way the vehicle is driving,
then pull over and have it towed. If the light comes on and stays on, or
comes on and then flashes during acceleration, then immediately pull over
safely and have it towed to a shop.

6.2.6 High Beam Indicator or Brights:

Usually blue, but can be red on older vehicles. This indicates that your
brights are on.

6.2.7 Low Coolant Level Light:

Red, Orange or yellow light. This light indicates that the engine
coolant level is low, which could be due to a leak. It is still safe to drive as
long as the engine temperature light is not on. In some vehicles the first
symbol above, the thermometer symbol, can also be a temperature light.

22
(Remember from Chapter 2 that the coolant level should not be checked
while the engine is hot). Some vehicles can have a blue thermometer symbol.
Consult the owner’s manual for its description.

6.2.8 Low Fuel Light:

Yellow or Orange. This light indicates that fuel is low. It could also be
a simple round light that illuminates when the fuel gauge is nearing empty.

6.2.9 Low Oil Level Light:

Yellow or Orange. The oil level is low. Refill the oil as soon as
possible and bring the vehicle to a shop to see why it was low.

6.2.10. Low Oil Pressure or Engine Oil Pressure Light:

Red light (immediately pull over safely). Once you pull over you
could check your oil level and add oil if it’slow. If the light continues
illuminated then you should have your vehicle towed to a facility.
Catastrophic engine failure will occur if the oil pressure is low. Repairs for
these damages can be very expensive.

23
6.2.11 Parking Brake Light:
Red light. The parking brake is engaged or not fully released. Release
it completely before driving.

6.2.12. Turn Signals and Hazard Light Display:

These will only illuminate when a turn signal (left or right) or the
hazard lights (both simultaneously) are turned on. If one stays on instead of
blinking in rhythm or blinks slower or quicker than usual then there is a
problem. One of the bulbs may need to be replaced or there is something
wrong with the circuit.

6.2.13 Voltage Light:

Red Light (pull over safely and get it towed). If this particular light
illuminates while you’re on the freeway then you may be able to proceed to
the next exit. This light indicates that voltage is below the minimum
specification and your vehicle will stop running once the battery dies. Safely
pulling over and having the vehicle towed is even more important at night
since you’ll lose the use of your headlights, which tend to drain the battery

24
even quicker. Some of the samples are yellow; in this case you should still
treat it as a red light.

6.2.14 Seat Belt Light:

Red light. This means that the driver and/or passenger do not have
their seat belts fastened. Put on your seatbelts before continuing to drive.
They want you to understand that when you get behind the wheel
you’repotentially putting people in danger. Ideally, seat belts would be more
like the harnesses used in roller coasters, which include two shoulder straps
and a middle fastening device at the chest. The cross-over shoulder strap
isn’t very effective in comparison. It is designed that way for commercial
purposes and to account for common human behavior. It’s easier and quicker
to have one buckle where the belt can be pulled over and fastened in one
quick motion while the person is just getting into the car. While the
conventional seat belt isn’t 100% efficient, it is potentially the most
important safety feature of the vehicle because it keeps the body harnessed
and kept in the seat. Wear your seat belt.

25
 CHAPTER- 7
SERVICE PROCEDURE

7.1 COMMON ACTIVITIES IN WORKSHIP

You may have noticed that authorized automobile service centres
adopt certain procedures during the service of a vehicle. In this session, we
will discuss the common activities done in the service centre. One of the
most important part is job card and its filling procedure. Common Activities
in the Workshop
 Job card and its filling procedure
 Washing of vehicle and Washing Procedure
 Engine minor tune up
 Oil replacement
 Checking of battery—electrolyte level and top-up
 Clutch and brake-free play and their adjustment
 Lighting system, its various parts and
 their checking
 Identification of greasing points of wheelers and
 procedure of greasing
 Checking of tyre inflation and procedure of inflation
 Job Card and Its Filling Procedure.

When a vehicle owner enters the service centre, he or she is attended

by the supervising engineer. The customer informs about the vehicle defect.
After getting feedback from the vehicle owner or driver regarding defects of
the vehicle, the supervising engineer in a service station or workshop
inspects it. The defects pointed out or listed are noted down in a standard
format, which is called the job card or work order.

26
 In order to indicate his satisfaction with the diagnosis made by the
supervising engineer, the customer of the vehicle signs the job card before
the repairs on the vehicle are started. Work is then assigned to the concerned
person to carry out repairs and the supervisor signs the job card too. The
work order or job card is prepared.

7.2 CONTENTS OF A STANDARD JOB CARD

The following the list of information normally found in a standard job card:
 Job card number
 Name, address and phone number of the service
 centre
 Name, address and phone number of the customer
 Details of vehicle, such as make, model, registration
 number, chassis number, engine number, date of
 sale, kilometres’ reading, receiving date and time,
 delivery date and time by the service centre
 Checklist before trial
 Customer’s observation
 Job to be done
 Estimated cost in rupees for the customer and
 insurance company
 Labour required
 Name of the mechanic
 Name and signature of the supervisor
 Customer’s authorisation for repair and
 their signature
 Acknowledgement
 Filling the Job Card

27
A standard job card is shown below.

Fig.No: 7.1 Standard Job Card

7.3 PRE-DELIVERY INSPECTION (PDI) REPORT

A pre-delivery inspection is an inspection carried out, either by a
purchaser or seller, prior to the final delivery of the product. It is used in
several industries.

28
Fig.No: 7.2 Pre-Delivery Inspection (PDI) Sheet
 CHAPTER- 8
CONCLUSION

The work experiences i encountered during the internship allowed me

to develop the service skills. I think I still require to work on my practical
skills. But, the overall experience was positive, and everything. I learned
would be useful in my future career in this field.
APPENDIX