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Tata's World Truck: the secrets revealed
Eliot Lobo looks at the contribution of some of the suppliers who helped make Tata's new trucks the impressive vehicles they are.
he launch of four configurations and two power nodes, 280 hp and 380 hp, marks the culmination of the first phase of Tata Motors’ World Truck development. The top end of 560 hp that MD Prakash Telang announced at the press launch will probably be introduced only in a later phase by 2012. The engine that powers the 4028S 4×2 and 4928S 6×4 tractors and 3128T 8×4 cargo truck is the Cummins ISBe 270 derated somewhat to 266 hp @ 2500rpm and 970 Nm @ 1200–1600rpm. This 6.7-litre engine with single-piece head, four valves per cylinder, 1600 bar common-rail fuel system, and wastegate turbocharger, was first introduced in early 2005 at Euro 4. It superseded Cummins’ 5.9-litre Euro 3 engine, which interestingly had been based on a platform developed by the European Engine Alliance (EEA) – the erstwhile three-way joint venture between Cummins, Iveco, and New Holland – using the design technology of Cummins’ legendary B-series engine. Since July 2008 the EEA is wholly owned by Fiat Powertrain Technologies (FPT), Tata’s other engine supplier for the World Truck. For markets outside Europe, Cummins developed Euro 3 ratings of the 6.7-litre engine later in 2007 as part of its Worldwide Common Platform (WWCP) strategy, of which 270 hp/1020 Nm is the top of the slate presently available in India. Autocar Professional learns that Cummins is working on a few ratings lower down the scale. The ISBe is the first fully electronic, commonrail-fuelled heavy duty engine to be seriesproduced in India, although the components are still mostly imported — for example the engine blocks and heads come from Brazil, and are only machined at Tata Cummins’ (TCL) plant in Jamshedpur. The fuel system hardware is from Bosch, and the electronic control module (ECM) and software from Cummins. TCL has a localisation target of 90 percent by 2012. The 6.7-litre engine carries forward the performance and fuel-efficiency advantages for which the 5.9-litre Euro 3 ISBe was famous worldwide. (These were based purely on the
28 Autocar Professional 15 June 2009
Bosch Body control module
Tata Ficosa Automotive ORVMs
Tata AutoComp ACSI & Interior Plastics Division SMC and plastic parts Tata Toyo Radiator
Rane TRW Steering gears Tata Visteon Automotive Headlamp cluster, fog lamp SKF India Front wheel-end
Gabriel India Primary & cabin shock absorbers
Fiat Powertrain Technologies Engine Eaton.autocarpro. RSB Group Propshaft Kalyani Hayes Lemmerz Wheels HV Axles. Mann + Hummel Air intake system Blaupunkt Radio Continental Automotive Components India Intelligent instrument cluster Grupo Antolin Pune Interior soft trims ISRI-TJC Seats. Voith Retarder Knorr-Bremse. sleeper berths Tata Cummins. Meritor HVS India Axles Metalsa Chassis frame www. WABCO Air brake system Cummins Exhaust Exhaust system Jost India Auto Components Fifth wheel Williams Controls Electronic throttle control & Knorr-Bremse Integrated pedal unit Spicer India. ZF Gearbox Telma.COVER STORY Tata Yazaki Autocomp Wiring harness Calsonic HVAC Tata AutoComp Systems Interior Plastics Division Cockpit Fleetguard Filters.in TACO Hendrickson Suspensions Inverted bogie suspension 15 June 2009 Autocar Professional 29 .
) And like its predecessor. rated at 266 hp and 970 Nm at BS3. Certified for Euro 3 and Euro 4 in a range of ratings. and variable-geometry turbo. The result is smoother and more fuel-efficient performance. four valves per cylinder. but the programme has been kept in limbo for over a year now after the Cursor 9 was inserted into the equation in what would appear to be part of a quid pro quo that opens up Iveco’s distribution and service networks in Latin America and Eastern Europe to Tata. But since electronics and the sophisticated common-rail fuel system are novelties in the industry in India. is upgradable to BS4 and BS5 using SCR. Cummins’ Interact (the ‘I’ in ISBe) electronic intelligence system enables “drive-by-wire” electronic throttle control and multiplexing. is presently available in selectivecatalytic-reduction-(SCR)-optimised Euro 4 and 5 ratings of 420 hp @ 1550–2100rpm and 1900 Nm @ 1050–1550rpm. having just completed a similar programme for its own. ABS.in Cummins ISBe. the Cursor 9 (technical code name F2C E2681B*B) www. Originally introduced by Iveco in Europe in 2006 as the C87 designed specifically for industrial and agricultural applications. went into volume production at SFH. The fact is. Fiat Powertrain Technologies’ joint venture in Chongqing.COVER STORY high injection pressures of its common-rail injection system. can simply be activated inside the calibration. The customer buzz following the World Truck launch is that a 310 hp version is shortly going to be offered on a 40-tonne tractor. Tata’s original choice for this performance class was Cummins’ 160kg-lighter 8. The 10. The 10.7-litre six-cylinder inline engine with overhead camshaft. Bosch common-rail fuel system.8-litre ISMe was the first heavy duty engine in its class designed for a life-to-overhaul of one million kilometres. Cummins India had developed and begun productionising two Euro 3 ratings – 340 hp and 375 hp – of the Euro 4 WWCP generation of this engine in 2007. Starting from 150 hp. it is now built in China by Xi’an Cummins Engine Company. which yield a big advantage in fuel economy at the vehicle level. delivers its peak output at 1600–1900rpm and 2500 Nm @ 1000–1575rpm. FPT Cursor 13 is most likely to be Tata’s top-end engine choice for Euro 4 and 5 export markets.” Lambert said. This 8. For TCL. and 450 hp/2100 Nm. and Holset variable-geometry turbocharger. made its world on-highway debut only this March on the Genlyon range of trucks from SAIC Iveco Hongyan Commercial Vehicle Co (SIH) based on Iveco’s Stralis. this engine delivers a fuel economy advantage at the vehicle level as well. the engine has been certified to Euro 3 and designed to be upgraded to Euro 4 and Euro 5 with no hardware modification. by contrast. Using Cummins’ vehicle electronic programming system VEPS. This 12. lower emissions. Cummins’ ISLe. Also available are two Euro 4 ratings of 410 hp/2000 Nm and 440 hp/2080 Nm. The 380 hp/1500 Nm rating was developed for Tata in Bangalore by Bosch Ltd. Bosch EDC-controlled unit injectors. “For example cruise control and road speed governing. was Tata’s original choice for the 380 hp node. Autocar Professional learns that the next higher power node in the World Truck portfolio is 420 hp. In the SIH Genlyon the engine is presently available in two ratings of 270 hp and 400 hp @ 1800–2100rpm and 1300 Nm and 1600 Nm @ 1100–1800rpm. Weighing in at 865 kg. TCL has just launched a major campaign to train Tata Motors’ service technicians. The Cummins alternative is the new 13-litre ISZ. The development of heat exchangers that 15 June 2009 Autocar Professional 31 . and added protection against powertrain wear. Cummins’ 50:50 joint venture with Shaanxi Automobile Group Co. Moreover. corresponding to the top available Euro 4 rating of FPT’s Cursor 13 F3B. A regular laptop with Cummins InSite diagnostic software and a couple of special connectors are the only tools the service technician needs to download and analyse fault codes.9-litre ISLe. the lower rating with a fixedgeometry turbo. whose solution to meet the OEM’s specifications for driveability in these two applications involved reducing the rail pressure to 1400 bar. developed and produced by Dongfeng Cummins Engine Co in Wuhan. just one week before the launch of the World Truck. and available (for the Chinese market) in ratings of up to 545 hp. In addition. because it is electronic and several useful features can be programmed into it. originally planned around Cummins’ ISMe but now designated as “above 380 hp” and very likely to include FPT’s European Cursor 10 F3A at Euro 5 in 2015. now offered as 370 hp/1550 Nm option. customers can actually modify some parameters in the calibration of the electronic control module (ECM) to suit what they want for their vehicle applications. The engine ECM accepts inputs from all powertrain components – electronic transmission (if available).9-litre inline sixcylinder engine with four valves per cylinder. and ASR (antislip regulation) – via a high-speed data link. sensors throughout the engine continually send data to the ECM for self-diagnosis and protection. the customer can do that when the truck gets to the end of the line. which both simplifies wiring and allows data signals to be carried through to the smart instrument cluster and driver controls. and responds exactly to requested adjustments in torque or engine speed for gearchanging or wheelspin correction. Cummins India engineering vice-president Mike Lambert told Autocar Professional in an interview last year.autocarpro. and the company’s presentation to the media did indeed specify a 370 hp/1550 Nm ISLe as optional on the 3138K and 4938S. The four-axle 3138 tipper and the 4938 semitrailer tractor displayed at the launch are powered by a 380 hp Chinese-built Cursor 9 engine from SAIC Fiat Powertrain Hongyan Co (SFH).3-litre Cursor 10. the range of power ratings extends all the way up to 560 hp. marrying the ISBe to the vehicle was a challenging experience because this was the first time it was dealing with an electronic engine that can communicate with other electronically controlled systems on the vehicle and support onboard diagnostics. The 420 hp Euro 3 version produces its peak output at 1900rpm and peak torque of 2010 Nm at 1200rpm.
the SCR systems will initially be imported from China. cited Tata’s far more exacting durability targets for the World Truck compared to other vehicles for which they had developed radiators. Cummins Filtration is the global leader in filtration. ahead of other big names like Emcon. startability. Reducing the size of the radiator meant reducing the heat exchange surface. T. and various other components would be used.” Tata’s orders for air intake systems. if we see the volumes for SCR going up suddenly. we may advance our plans to set up manufacturing here. Cummins’ value package on the World Truck includes turbochargers. according to marketing head Tarun Dham.autocarpro. it is expected to localise the design with gears sourced from Ashok Leyland and housings sourced from Jaya Hind. being thinner. Tenneco. from air inlet to turbo inlet.000”. The Cummins ISBe is mated to the ZF Ecomid 9S1110 OD gearbox or Tata’s own G1400. Asked what his engineers’ main challenge was. exhaust mufflers. where CES started producing them this April. and optimised the design and configuration to arrive at this solution. sister company of MAN Force Trucks. while ZF is initially importing its transmission from a plant in France. a vertical model for the 3138K. the programme.” TTR’s Ravi Chidambar said. the 50:50 joint venture that Cummins Filtration had with Cummins India till recently. and Eberspächer. or even 20. which links the SCR system to the ECM and allows CES to maintain control on the system and its performance.” While the mufflers are supplied from CEIL’s Daman facility. Cummins Exhaust (CEIL). We’re trying to make it plug-andplay.COVER STORY would manage the massive charge air and engine cooling requirements of these powerful engines was entrusted to Tata Toyo Radiator (TTR). This 50:50 joint venture between Cummins Filtration and Pune-based Perfect Sealing Systems. It is also in discussions to provide Fleetguard coolants as first fill.” he said. and gradeability in maximum detail at the earliest stage of engagement with the OEM. air intake and filtration systems. the application approval process it used on the World Truck programme is standard practice worldwide for new truck developments but unique in the Indian context in that it directly captures the “voice of the customer” and clearly elicits the requirements in terms of application.Rad). we simulated the actual conditions under which the entire system consisting of the radiator. in which higher cooling demands are typically met by increasing the thickness of the core. which Eaton uses to search its database 15 June 2009 Autocar Professional 33 . For Eaton. there will be minor changes in terms of tooling and customisation to suit each model. GVW. Besides. and Mitsubishi Corporation Nonferrous (supplier of aluminium to both Tata Toyo and T. this was the first time our products would go on trucks exported around the world. The latter presently has three nine-speed transmissions on the World Truck — the FS 10309 and FSO 10309 (overdrive). “Another was to develop aesthetic designs in plastics that would withstand extremes of temperature and still meet Tata’s stringent life requirements — after all. duty cycle. Besides engines.” he explained. the CEO of this joint venture between Tata AutoComp Systems.in Fleetguard Filters MD Niranjan Kirloskar with Cummins India CMD Anant Talaulicar at the launch in Mumbai. and FFPL is the exclusive supplier of all the wet filtration products for the Cummins ISBe and ISMe on the World Truck. is Tata’s exclusive source for Euro-3-spec acoustic mufflers for www. and the FS 15409. intercooler (which we also developed). CES is the leader in emission solutions for medium and heavy duty on-highway truck manufacturers in the Euro 4 and 5 markets worldwide. and fuel additive technology for engine-powered systems of all kinds. it requires less coolant than the conventional designs. he pointed out. with the SCR aftertreatment controlled by the engine ECM. The emphasis was on commonisation to reduce costs. The company responded with an aluminium radiator that has a thinner core and is both lighter and cheaper than conventional designs. “Combining a CES system with a Cummins engine allows Tata Cummins (ISBe) or Cummins India (ISLe.Rad Co of Japan (a major supplier of heat exchangers to Iveco and Hino). while Eaton has been contracted to supply its Fuller transmissions for the Cursor 9 and higherpowered engine applications. because in these situations our interactions will be limited by the ECM. exhaust. “The OEM’s marketing and engineering organisations fill out an application approval form. so to speak. even as CEIL transitions into an entity that will be 100 percent owned by Cummins Emission Solutions (CES) ahead of the advent of BS4 emissions legislation in April 2010. Designing a system for BS4 and BS5 requirements was one peculiar challenge for Fleetguard. while the radiator and intercooler will be the same across models. Wearing his CES shirt. directly contributing to improved fuel efficiency and reduced operating costs. ISMe) to tune the entire system. “For a non-Cummins engine the strategy is to have a separate dosing control unit. Interestingly. Solanki revealed that eight prototype SCR systems airfreighted in from China would be installed on test vehicles with Cummins engines by the first week of June. Director Manoj Solanki told Autocar Professional last month that initial deliveries of 30–60 a month for the World Truck could rapidly grow to “10.” Solanki said. and emission solutions. adding that this would be at Cummins’ megasite at Phaltan near Pune. its other erstwhile licensee for this model. for the first time in India. terrain. has so far supplied Tata’s alpha and beta requirements from its Nandur plant near Pune. coolant. “However. It will supply these in six configurations including. but production supplies will come from its Jamshedpur facility beginning September. “We achieved this by enhancing the geometry of the core for better heat exchange efficiency. Cornaglia. and hence the challenge was to get better efficiency from a smaller surface area. Using our past experience. “Hence. a variant of the 10309 specially developed for the heavy tipper. have been split 50:50 between Fleetguard Filters (FFPL) and Mann + Hummel across all applications.000 next year.
According to vice-president S Raghunathan a tandem version. though Tata and Eaton are now applicating Roadranger 10. Axle partner Meritor HVS India is gearing up to supply its MS14-160 hypoid axle. Another Meritor axle the OEM is presently testing for the World Truck is the two-speed MS-240 for 4×2 tractors and 6×2 and 8×2 rigids. But Singh is proud of the end result: “All vehicle validations so far have qualified the customer’s expectations. and sealed universal joints as the salient features of his company’s products. which Tata is expected to fit on the 3128T 8×2 cargo truck going by the fact that it is already used by MAN Force on its 4×2 and 6×2 rigid trucks for the domestic and export markets. RTO 16910 twin-countershaft model will go into severe service and off-highway applications. An 18-inch crown wheel. With a torque capacity of 1750 Nm the singlecountershaft 10309.” he explained.” GM (corporate strategy) Rajnikant Behera said. low NVH.” Pavan Pattada. We had the option of either looking for a different product. In line with the company’s worldwide manufacturing strategy the transmissions will initially be imported from China.and 16-speed could make their way onto Tata’s “above 380 hp” models for export. . India head of Eaton’s Truck Group. driveline angle. not least because of the number of design iterations they had to perform without falling behind on Tata’s strict sample and supply timeline. the number of hours the vehicle is going to be operated in each gear. or working on an existing family to meet the requirements. While Spicer is contracted to supply “approximately 25” designs with varying torque capacities for the full spectrum of applications.and 13-speed twin countershaft transmissions in “above 380 hp” applications. “As part of the application approval we studied the duty cycle.COVER STORY house models for severe-service applications. Our new shafts are both lighter and cheaper for the same transferrable torque. “Models similar to the ones we have developed are already in use in similar applications abroad. could still fit into some applications above 380 hp. Poland. Meeting these expectations was a challenge for Spicer’s engineers. RSB has developed six designs for five World Truck models in the 31-.” Pattada said. 15 June 2009 Autocar Professional 35 for the available transmissions that best fit the application. ZF Ecomid 9-speed is mated to Cummins ISBe. despite the contrasting requirements of these applications. Among the technical highlights of the Spicer products that chief operating officer B D Singh points out are their “lubed-for-life” service-free joints. Germany. The RSB shafts are based on designs developed by its technology partner Eugen Klein GmbH in Esslingen. We’ve had this discussion for each vehicle configuration. “Tata’s requirement was that the durability and performance of the shafts under Indian vehicle utilisation conditions be enhanced — in particular. The next critical link in the driveline – the propeller shaft – comes from Spicer India and the RSB Group. and 49-tonne classes that it will begin supplying as soon as these models go into commercial production. etc.in Eaton 10309 series (above) will make way for Roadranger 10. is in the choice of the overdrive version for the tractors. The difference. the MS141495. the MT28-160. We then present these options to the OEM. presently imported from Poland. and the 3138K on the other. and other design enhancements give this model a 30 percent higher torque capacity than MHVSIL’s other available axle in this load class. and increased torque capacity at reduced component weight resulting in lower axial forces on the slip joints and increased durability compared to the shafts it supplies for Tata’s legacy truck models. and then progressively localised as volumes pick up. on the one hand. China. which is used both on. Eaton displayed its 10-speed RTO 16910B-DM3 transmission at last year’s Auto Expo and a variant of this could very well be out on the roads in a year. 40-. The result of this process so far has been the selection of the 10309 model for the 4038S and 4938S.” he told Autocar Professional. in which the lower gears have been strengthened because the vehicle will be operated for longer periods in those gears.and off-highway. ZF Ecosplit 12. He cited face serrated mountings. and the development of a new directdrive variant designated 15409 for the tipper. we also suggest ways to compensate for those minuses by means of changing the axle ratio. explained to Autocar Professional. we decided to do the latter. they needed highly statically and dynamically balanced shafts for highspeed applications and improved corrosionresistance. Of course. Rilsan-coated sliders with metallic dust covers. tyre size. Eaton is the only independent supplier worldwide of this extremely robust design. the largest on the market.e. “In Brazil the European players often choose the twin-countershaft solution over their own inwww. and then sit and discuss with them the pluses and minuses of each. Together with Tata. he explains. i.” Pattada pointed out. where they are assembled from parts supplied out of Eaton plants in Brazil. and India.and 13-speed twincountershaft models for off-highway applications using the 420 hp Cummins ISMe.autocarpro. will also be available to Tata.
starting from day one”. albeit more robust and reliable. Tandem version could go on tractors. The Knorr system is designed for a brake circuit pressure of 10 bar. and will continue to be used on the front axles even when air suspensions from THSL make their appearance on the World Truck as early as next year for export models. higher reliability. By means of an electropneumatic control the driver can either engage the regular ratio or step the propshaft input down through the reduction. It is able to deliver higher braking torques at the wheel ends using similar-sized.” he told Autocar Professional. marketing. OEMs even in Europe save costs by matching the frequencies of the parabolic front suspension with those of the rear air-ride system. Parabolic springs deliver far superior ride characteristics to the conventional multileaf variety. foundation brakes and actuators. according to sales. and the 3128T offers the additional options of a regular 26-tonne model or a 19-tonne-plus-30-percent. Brazil. trailer brake system. this design improves the vehicle’s stability and braking performance. The company’s shafts are also standard on the heaviest-duty 3138 tipper. and ABS for truck and trailer. which also act as effective rebound stoppers). This is the same series presently used in the USA.in . The air brake systems for truck and trailer come from Knorr-Bremse and WABCO. interestingly. The first of its kind in India. for instance. which Rane TRW Steering Systems in Chennai has adapted for India. Tata has chosen TRW Automotive’s latest THP-series from Europe rated at 175 bar. The front axles on all models are suspended by means of parabolic leaf springs.1 bar systems that go onto Tata’s existing range. and reefers. For single-steer applications with lighter front axle loads such as tractors that will be used for long-distance haulage. it constitutes the mechanical basis for one of Knorr’s most recent innovations: the EAC www. THSL’s parent company Hendrickson International is the world leader in this type of springs. actuators that have actually been validated at pressures of above 10 bar. and business development head Anirban Mukherjee. and a reduced package size for increased wheel cut. This improves the flexibility of usage and yields better fuel efficiency and operating economics. This 26-tonne version of TACO Hendrickson’s 6-rod tandem bogie suspension is standard on 49tonne tractors and optional on 3128 cargo truck. adjacent to the crown wheel. he is convinced the market will absorb the additional cost without fuss because the value it offers is “readily realisable in terms of fuel efficiency. GM (marketing) of Rane TRW Steering Systems in Chennai. The former’s scope of supply includes the air processing unit (APU). according to P B Rajan. The superior features of the TRW system include faster steering ratios for improved lockto-lock turns compared to existing gear designs. The APU ensures better air management. CHASSiS The six-rod inverted bogie suspensions for the tandem rear axles on the 49-tonne tractors and 31-tonne tipper and cargo truck were indigenously designed and 100 percent localised by TACO Hendrickson Suspensions (THSL) in Pune to meet Tata’s demanding cost targets.” Raghunathan told Autocar Professional in an interview a few months ago. tip-trailers. So even though this axle is more expensive. Other crucial advantages over current systems. 36 Autocar Professional 15 June 2009 B D Singh points out a Spicer propshaft on 4028 tractor. Meritor’s MS14-160 axle will soon feature on 3128T. bulkers. “It has automatic poppets and advanced rotary valves for user comfort and provides power assistance from lock to lock even while the vehicle is stationary. believed to be from a Korean supplier even though.COVER STORY A design that has already been proved in Brazil and Mexico for over seven years now.” Rajan cited the tight lead time for submission of special prototype parts and Tata’s stiff cost targets as specific challenges his engineers faced in developing this product. as against the 8. lower internal gear friction for better return-tocentre response. include ease of serviceability and better ride quality (a function of the rubber bolsters at the spring ends. and longer service life than the traditional air dryer by integrating this function with an oil separator and multicircuit protection valve into a single unit. “This model delivers the highest torque per unit weight in the world. The twin-steer systems on the 3138K and 3128T are variants of the Servocom 8099 twincircuit power steering gears from ZF Lenksysteme GmbH. you’re negotiating a steep gradient. A lighter 26 tonne (plus 15 percent overload capacity) version is available on the 4938S and 4928S. and Europe. this axle has a planetary gear reduction built into the differential itself.” an Autocar Professional source said. “Although air suspensions on front and rear axles are ideal. particularly in Indian operating conditions. and then switch to economy mode when you’re at grade.autocarpro. the 48-tonne suspension on the 3138K is THSL’s heaviestduty model. “Typically you can operate in power mode when. Interestingly. Suitable for a wide variety of multiaxle applications. the two leading suppliers worldwide.
“Before we designed this wheel. In fact we already supply these wheels to Daimler. Knorr has kicked off the exercise of designing the first EBS electronic braking system. An interesting safety feature of this system is the park/shunt valve on the trailer.” The high-performance wheel-ends from SKF on the front axles of the 4028 and 4928 tractors each consist of two optimised premium taperedroller bearings (TRBs).and three-axle semitrailers from Tata International DLT that Tata Motors will offer with its tractors.in Kodlikeri with a hi-spec 10-stud steel disc wheel. This parking brake cannot be released unless the trailer is once again www. and high-temperature lithium-based grease for increased regreasing intervals. and then Tata Daewoo. Knorr-Bremse CEO Venkat Potturu with APU on 3128T. Autocar Professional learns. Bangalore. As for the peculiar challenges KHL faced designing and manufacturing the wheels for this project. The EAC combines the functions of the APU with electronics that intelligently reduce compressor fuel consumption unlike conventional air processing systems that operate independently of the drive situation. which he said poses lots of challenges that need to be taken account of while designing the wheels for this application. and the vehicles in these areas are often very heavily overloaded. the World Truck models produced at the Tata Daewoo plant in Gunsan. For the first time in India the hand brake valve has been designed with a trailer check function that senses when a trailer is coupled to the towing vehicle and automatically applies the trailer brakes as well. Measurements on various European road circuits have indicated potential fuel savings of several hundred litres per year using EAC.COVER STORY coupled to a tractor and there is pressure in the palm coupling. we have supported a unitised bearing for the first time in an application like the steering link to omit grease leakage and spillover in the vehicle and into the environment. revealed to Autocar Professional. the company supported HV Axles on the prototype development of its HR210 hub reduction axle with a wheel-end TRB. Kalyani Hayes Lemmerz is Tata’s single source of these wheels for domestic and Korean production. and a deep-groove ball bearing for the 15 June 2009 Autocar Professional 37 electronic air control system. and also developed the kingpin seal especially for the World Truck. not only in India but also outside the country. “As a part of our drive towards sustainability and environment-friendly products and solutions. Africa. will also roll on KHL wheels. Kodlikeri singled out the mining area in particular.” he told Autocar Professional. For the heavy duty tippers and construction vehicles. director of SKF India’s automotive business unit.autocarpro. which is used to activate the spring brake when the trailer is uncoupled from the tractor. “In such a case Tata’s decision to go in for 20-inch rims is appropriate. Knorr’s 325mm S-cam drum brake has already been validated by Tata and it is awaiting approval for samples of a 410mm version it has supplied. For one there are practically no normal roads. which should be ready for testing and validation in the next six months for a Tata vehicle that will only be rolled out in 2012. our engineers spent lot of time in the mines to understand the product application. and Southeast Asia. MD Prakash Kodlikeri reckons that Tata will first market the World Truck in nonEuropean countries just to establish the product. In fact Knorr has also developed separate brake systems with ABS for the two. a pinionclass TRB. Having already developed and begun exporting disc brake components. though the foundation brakes on the front and rear axles on the launch vehicles were from Meritor HVS India associate KTMS and the TVS Group’s Brakes India respectively. In addition. KHL had the wheels for the World Truck specially tested at its parent Hayes Lemmerz International’s European test facility in Germany. from our plant in Pune. and for centre-axle drawbar trailers that the OEM is also planning to introduce later. .” Ranjan Kar. Korea. he pointed out: “We initially supplied Daewoo. because of which the maintenance of the tyre/ wheel assembly in such areas needs special consideration. Every World Truck that Tata produces will roll out on steel wheels from Kalyani Hayes Lemmerz (KHL) in Pune. and Iveco in Europe. two premium hub seals developed by SKF Sealing Solutions.” Interestingly. for which Knorr sees possibilities on Tata’s export models in the next couple of years. I must say that our wheels last for more than 10 years in such areas and are performing very satisfactorily. This solution will be launched on the tipper series in September. and exports large numbers of this type to Europe. SKF India is the sole supplier of the front wheel end for these applications. it will shortly begin supplying 24-inch wheels homologated for and approved by Tata Motors for this application. Volvo. Below: Knorr ABS 6 Premium on World Truck. KHL is already the sole supplier of these wheels to Volvo India for the FM400 and Mercedes-Benz India for the Actros. it is now working with Tata on disc brakes that will be introduced on the World Truck in the next two years. Concurrently.
For this company.” G S Pradeep. allowing the operator to switch the rated imposed load on the coupler to the maximum 36 tonnes for which the JSK38 platform was originally designed.and 49-tonne tractors respectively are from Jost India Auto Components. explained. An important feature of this model is the interchangeable locking mechanism that can accommodate both. It is also one of the suppliers of TRBs for the differential. the world leader in driver’s seats for trucks. is the most widely used fifth wheel model in the Asian market and one of Jost’s largest-selling worldwide. the World Truck was a significant challenge because it was now dealing with parts of “huge truck” proportions. The seat squabs can be adjusted for height. sides. “Since the Indian market traditionally prefers the pressed version. The company meets Tata’s domestic and export requirements for fifth wheels from Jamshedpur and Germany. For us. speaker grills. and air vents. which is a vital requirement in the Indian market.” he reminisced. The complete wiring harness that Tata Yazaki Autocomp (TYA) designed and supplies for the World Truck compares to that on any premium European truck. according to GM (marketing) Ajay Apte. GA Pune supplies headliners with integrated lamp bezels. “The World Truck was conceived with a seating system of global standards with respect to safety and comfort. Also for the first time in the world. fifth wheel couplers on the 40. “For the first time an Indian truck was being developed with a trim level that compared to those sold in Europe. The challenge was to design the seats keeping Indian road conditions in mind. i.” he pointed out. two-inch and 3. marketing head Prashant Gajendragadkar told Autocar Professional. they have gone into limited production at a TJC facility in Pune till ISRI-TJC’s plant in Jamshedpur is set up. “It costs about 30 percent less. SKF bearings on the World Truck: top three are for steering and front axle application. and has passed all the standard life tests required to ensure reliability. Designed and developed in Germany by Isringhausen GmbH.COVER STORY inTERiORS tandem version. Designed for an imposed load of 20 tonnes the JSK36.” The high-end air-sprung or mechanically suspended driver and co-driver seats with integrated seat belts are a first on a truck in India. Apte pointed out. in a joint venture with Tata Johnson Controls Automotive (TJC). LCD on Continental instrument cluster displays menus and error messages in Hindi and English. but certain critical components will continue to be imported from Germany. and tilt. More importantly it is reworkable. That took an intensive R&D effort. which will be added on at a small subassembly warehouse the company is setting up in Jamshedpur preparatory to the commercial launch of the trucks. “GA uses a different. the company developed a special solution for the side trims using knitted fabrics treated with 3M Scotchguard to ensure cleanability. According to Pradeep. senior sales and marketing manager for Jost India. this development was undertaken for costoptimisation. A lot of effort has been made to localise the design. The JSK38DV50 is a pressed version of the JSK38C1 cast fifth wheel for an imposed load of 28 tonnes that Tata has so far used on its existing 4923 model.” CEO Vinayak Lingayat said. bottom four are for rear axle.autocarpro. “The bus bar design drastically reduces the size of the wire bundle coming into the fuse box for ease of handling. which is supplying “more than 20” part numbers from its Ranjangaon plant near Pune. fore and aft movement.. For India we had to come out with a cost-effective solution based on the same basic sandwich. with a two-inch kingpin. Tata’s exclusive supplier of this critical device that connects truck to trailer. it could possibly crack under the extreme abuse to which fifth wheels are subjected here and cannot be welded or bent back into shape in the event. maintaining tolerances and fit and finish across such large dimensions was a herculean task. and JSK38DV50 and JSK38C1. 38 Autocar Professional 15 June 2009 Jost India director and CEO Amarjeet Singh and sales & marketing head G S Pradeep. and rear of the cab. adjustable lower and upper lumbar supports and high-density foam and bolsters make for additional comfort. The seats are optionally fitted with a heater to provide comfort in extreme cold conditions. While the cast version is extremely strong. The JSK36DV1.in . The result is seats that not only meet the stringent ECE norms concerning ergonomics and occupational safety but also conform to AIS regulations. A single connection joins all vehicle applications www. he added.e. where the weight limits of semitrailer combinations are seldom exceeded and cast fifth wheels are usually preferred. Grupo Antolin Pune is Tata’s exclusive source for soft trim parts. more expensive material in Spain.5-inch kingpins. the headliners and fabric trims for the doors. the JSK38C1 2J on one of the 4938 tractors displayed could be an option on the World Truck for export markets. following a global benchmarking exercise we did on truck seating systems. assembly. and maintenance.
Other prospects are body control modules (BCMs). While the pedal is already fully compatible with the Cummins and Iveco engines on the World Truck. The cluster also stores error information in itself. That wasn’t all: a special bulkhead was designed as an interconnector between the engine cabling and the dashboard wiring harness. According to GM (commercial vehicle) Hemal Shah. while the fuse box will remain the same. the technical sophistication of the product in the Indian truck market made the project particularly demanding. which it then displays either on the analog gauges (driven by high-precision electronic stepper motors). says it can easily be adapted for any engine or application requirement by simply programming the sensor according to the configuration of the ECM. or by the supplier of the ECM if the latter insists on being proprietary about its load circuit diagrams. This keeps the driver informed about the state of the vehicle so that he can act accordingly. This not only ensures ease of fitment on the vehicle but also enhances serviceability. such as fuel consumption.” he said. Using this information it calculates current driving and vehicle parameters. “Continental is the world leader in tachographs with a more than 95 percent share of the market.COVER STORY to the battery power through the bus. and appreciation for.” he said. This all-plastic suspended pedal uses a non-contact sensor that provides an electrical signal to the ECM in response to the driver’s demand for engine power. It was particularly difficult adapting a system architecture predominant in Europe and other developed www. “In LHD vehicles meant for export the bulkhead will simply be a mirror image of the present design. audible alerts. air brake tubing. This sleek new concept has helped reduce 75 circuits and liberates a large space for other aggregates. or as warning symbols (illuminated by LEDs). the world’s leading manufacturer of such pedals and the dominant supplier for BS3 truck programmes in India with an 80 percent share. But we finally achieved it in cooperation with Tata’s Engineering Research Centre. and sensors. Shah told Autocar Professional that Continental would supply tachographs for the World Truck in a later phase of market penetration.in Rishi and Rahul Kshetry of Taurus Flexibles with air brake coils on 4928S. This assembly saves space in the footwell by integrating the respective pedals with the foot brake valve.” he said. “The technical specifications have evolved since we first started in 2006. and situating the bulkhead so that the cabin and engine compartment connections could have a common interface point with the unique fuse box to suit all models in the World Truck programme. and individual functions are activated by insertion of a simple fuse. In addition. Shailendra Goswami. and leak-free compressor outlet pipes for World Truck. For brake and clutch actuation. supplied solely by Bosch for now. By this commonisation TYA has been successful in dramatically reducing the variety and thereby saving on resources like costs and time. The cluster evaluates digital and analog inputs from various sensors fed to it via a CAN bus that also networks the electronic control units around the vehicle. electrical coils.” he added. CMD of Williams’s India representative Pushkaraj Engineering Enterprises. and brake light switch in a single aluminium die-cast support structure. error messages received from various ECUs are displayed in the menu in English and Hindi. n 15 June 2009 Autocar Professional 39 PhotograPhy Ashley BAxter . The company supplies fuel lines. he revealed. The routing of the harness on the vehicle was developed with 60 different clamping options. Tata has chosen an integrated pedal unit (IPU) from Knorr-Bremse in keeping with its modularisation strategy. The cluster’s scalable architecture allows Tata to meet future demands for communication with tachographs and integrated telematics. Williams Controls WM542 electronic throttle pedal (above) and Knorr integrated pedal unit are emblematic of Tata’s modular approach. or as average mileage or “distance to empty” data on the TFT LCD panel in the centre. The electronic throttle control pedal is a WM542 model from Williams Controls. The intelligent electronic instrument cluster from Continental Automotive Components India was developed at Continental Automotive R&D locations in Germany and Romania. This is done either by Williams Controls itself. the low awareness of. and called for an intensive R&D effort. It is the first of its kind with contemporary European features to feature on a commercial vehicle in India. clutch master cylinder. countries to the Indian market even as the system requirements were continuously being upgraded in the last 2½ years. The complete design also involved preparing the circuit schematic and the fusing and earthing strategy. Each of these will operate on the same bulkhead and fuse box design. At the moment there are 11 distinct variants of the electrical system for the right-hand-drive vehicles that will be sold in India. which can be downloaded at the service station later by service personnel using diagnostic tools.autocarpro. seven of them in L1 (low-end) and L2 (high-end) versions.
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