SRV: CIR: 36: 2019

November 1, 2019

To,

ALL VEHICLE DEALERS/AUTHORIZED SERVICE CENTERS

Sub: BS-VI Readiness

India will be leapfrogging from BS4 to BS6 from, April 1, 2020. While the earlier emission norms
were implemented progressively, BS VI will be implemented simultaneously across India. Ashok
Leyland will assist in preparing you for this changeover progressively over next few months.
Following communication is a brief on what to expect.

BS VI Architecture

Emission Standards

PM 50%
g/kW.h Migration to BS VI entails substantial
0.02 reductions in key Emission elements of
BSIV
Particulate Matter (PM), Nitrides of Oxygen
0.01
(NOx) and Hydrocarbons.
BSVI
1.5 While NOx will have the sharpest decrease
CO NOx
0% 0.4 3.5 by 88.6% to 0.4 g/kW.h, Hydrocarbons will
89%
0.13
have a decrease of 72% and Particulate
Matters a decrease of 50%.
Carbon Monoxide will be at same levels as
0.46 BS IV.

HC 72%

Ashok Leyland’s Emission Control Strategy

Ashok Leyland will be extending the successful combination of iEGR and Diesel Oxidation
Catalyst (DOC) to BS VI. Addition of Diesel Particulate Filter (DPF) and Selective Catalytic
reduction (SCR) System will ensure compliance to BS VI emission norms. While the EGR and
SCR combination reduces NOx, PM will be filtered by DPF.
Key Changes in BS VI

BS IV BS VI

Ashok Leyland’s BS VI vehicles would be fitted with the following important aggregates:

Engine Management System

● Electronic Diesel Control System (Updated version of BS IV)
● Common Rail System (Updated version of BS IV)
● iEGR (Same as BS IV)

Exhaust After Treatment System (EATS)

● After Treatment Control Unit (ACU) and additional Sensors
● Diesel Oxidation Catalyst (DOC)
● Diesel Particulate Filter (DPF)
● Selective Catalytic Reduction (SCR)
● Ammonia Slip Catalyst (ASC)
● Controller Area Network (CAN) enabled Instrument Cluster

Diesel Particulate Filter is cleaned or “Regenerated” periodically.

● Accumulated PM in the form of soot is burned off regularly during vehicular operations
● In certain operating conditions, regeneration may not happen during the normal running of the
vehicle. Such situations will call for performing Regeneration process in vehicle stationary
condition which generates high tail-pipe temperatures. Temperature in certain conditions can
be as high as 700 deg C and workshops need to be equipped for removal of the exhaust
gases. Annexure1 lists down the requirement for this setup.
● Accumulated ash over a period beyond certain levels cannot be burnt and in such situations,
DPF needs to be removed and cleaned. DPF cleaning frequency in normal operating
conditions depends on the quality of oil and fuel; so at-site cleaning of DPF is not
recommended. Framework on DPF cleaning and replacement will be shared shortly.

BS VI Readiness

The addition of BS VI specific new technology components (EATS, CAN enabled instrument
cluster, On Board Diagnostics - OBD) and introduction of modular vehicle architecture in M&HV
trucks with a few new aggregates call for creation of additional facilities, procurement of special
equipment and SMTs and Upgradation of skills. These activities need to be completed by our
channel partners by February 2020.
Infrastructure
● One service bay to be earmarked and equipped to handle regeneration and marked as
“REGENERATION BAY” (Refer Annexure 1 for details)
● Special Maintenance Tools to handle Modular architecture related changes and new
aggregates (Refer Annexure 2 for list of tools)
● AdBlue storage facility – Sale of AdBlue in workshops is expected to increase considerably
and hence a proper storage area needs to be planned such that AdBlue is not stored under
direct sunlight and has a properly covered & ventilated surrounding (Refer Annexure 3 for
storage guidelines)

Diagnostic Equipment
● Availability of tablet based diagnostic tool – minimum one per workshop.
● Upgrading the current BS IV diagnostic tools available in workshop for handling BS VI
● Availability of Wi-Fi with sufficient strength
o Connectivity for online data transfer through tablet based diagnostic tool.
o Online access for Service & parts related information

Training
● Availability of trained SAs, TAs, floor supervisors, technicians and electricians in all
workshops. Please nominate sufficient number of employees to the programs and ensure that
100 % of the productive staffs are trained by March 2020.
● Each workshop should have at least one BS VI Champion & one Electronics Champion
who would be mentored by AL for Skill Upgradation.
● Body Builder – All the body builders in the respective area should be trained on BS VI specific
requirement and precautions. Training content will be provided, and training will be imparted
by AL to dealer team.
● Customer and Driver – Understanding of the Instrument Cluster information by the driver will
be very critical for optimum performance of BS VI and as such driver training becomes very
important. Will share the training content for customer / driver separately. At the time of
vehicle delivery, all customers and drivers should be trained based on the training content
and this will be mandatory

Parts
● Minimum stock levels for identified spares is being asessed and will be shared shortly.

Going forward, we shall be sharing with you, detailed communications on maintenance

practices, troubleshooting guidelines, SMT usage guidelines, aggregate specifications and other
relevant information to help you equip yourself for the upcoming technological changes.

Regards
for Ashok Leyland

Devakaruppaiah B
Head – Technical Service
Annexure 1 – Regeneration Bay
The workshops need to be equipped for removal of the exhaust gases (with temperatures as
high as 700 Deg C.) to maintain safe working environment. For performing Regeneration,
workshops are required to have a dedicated work bay with Exhaust Extraction System along
with good ventilation preferably located in the corner having open area in the front and on the
sides.
Following is an itemised list for accessorising the Regeneration Bay along with indicative costs

Description Cost, INR ##

Exhaust Extraction System (EES) capable of handling 700
3,25,000
to 500 deg C (Indicative)
Engine bay with 200 deg C extraction system 1,60,000
Venting for taking the gas out of the workshop from EES Actuals **
Barricade for the EATS (for trucks) 5,000
Pedestal Industrial fan 10,000
Exhaust fan 7,500
Fire extinguishers 6,000
Thermal gloves 4,000
Contactless thermometer 3,000
Thermal insulator (Mat) 10,000
## Costs are indicative and under negotiations.
** Costs shall vary based on Workshop layout and Bay location.
Annexure 2 – List of SMTs

Sl No Proposed SMTs Aggregate

1 Tablet based Diagnostic Tool Vehicle
2 Refractometer for checking adblue quality EATS
3 Tool for Exhaust Manifold tightening - UJ Engine
4 Spring brackets fasteners tightening in NRS – UJ Suspension
5 Unitized Bearing removal Circlip Plier Front/Rear Axle
6 Installer FA99 GGB King pin Bush Front Axle
7 Remover FA99 GGB King pin bush Front Axle
8 Tool for Constant Pressure Clip removal Radiator
9 Relay/Micro Relay removal tool Electrical
10 EATS assembly R & R Fixture - Cummins - Sangam Exhaust
11 Steering linkages Removal Tool - MBP / BUS Steering
12 Fixture for Removal & fitment of Vetri EATS Exhaust
EATS Sangam assy mounting fixture with wheel (Mounting
13 Exhaust
trolley for Sangam EATS)
14 AdBlue tank levelling sensor removal & Refitment Exhaust
15 SCR Tank neck filter removal Exhaust
16 FIP Drive Housing - timing tool for Delphi FIE Engine
17 Relay drop arm removal puller Steering
18 Drag link ball joints removal puller - ICV Truck Steering
19 Shackle Pin Removal Tool Suspension
20 Bogie Bracket Removal Trolley -MBP Suspension
21 NGC Cabin front damper bottom bush removal tool – MBP Cabin
22 Support base for 6MT86 Gearbox Gearbox
23 EATS assembly R & R Fixture - Albonair Exhaust
24 6MT86 Gear Box Tools Gearbox
Annexure 3 – AdBlue Storage & Handling
Storage
In order to avoid any compromise to the quality of the AdBlue during transportation and storage, the
following conditions should be taken into account:
● Protect from direct sunlight. The AdBlue containers or barrels should be stored under shade in a well-
ventilated shed structured.
● In order to protect AdBlue from air-borne contaminants, appropriately-sealed containers should be
used.
● Shelf life of AdBlue depends on storage temperature.
o 25 to 30 deg C 12 months
o 30 to 35 deg C 6 months

Handling
AdBlue is corrosive in nature. Hence metal containers should not be used for storage and filling including
the pump.
Keep AdBlue equipment clean and free of dirt and dust.
If equipment needs be cleaned or rinsed internally, use demineralized water or AdBlue – don’t use tap
water.
Ad Blue contamination with fuel, oil, grease, water, dust, dirt, metal or detergent is detrimental and to be
avoided. Hence do not use common container, cans for storage and refilling of oil, fuel, coolant and
water.
The components of the filling and emptying equipment should be emptied, cleaned and closed off after
use, in order to prevent contamination of AdBlue from the surroundings. Hoses, in particular, should be
dedicated and closed after every use, and handled and stored in a controlled manner.
Don’t refill previously used AdBlue containers as they may have been contaminated.
Don’t fill AdBlue tank with anything other than AdBlue. There is no substitute for AdBlue.
Use of impure AdBlue or other liquids like water may cause gradual degrading and subsequent clogging
of the catalyst resulting in costly replacement of parts, reduced efficiency and lost time.

Fin