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Transcript of Maruti Services
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A
TRAINING REPORT
AT
HMT LTD, PINJORE
SUBMITTED TO :
DEPARTMENT OF MECHANICAL ENGINEERING
In the partial fulfillment for the award of
DIPLOMA IN MECHANICAL ENGEERING
As prescribed by state of board of technical education Haryana.
SUPERVISED BY: SUBMITTED BY:
Mr. V.K. Grover Rajat Khurana
Manager Roll No. 0903917068
HMT Ltd., Pinjore Mech. Engg. (5th Sem.)
Jan Nayak Choudhary Devi Lal Polytechnic
Barnala Road, SIRSA-125055
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ACKNOWLEDGEMENT
I would like to express my gratitude to all these who gave me the possibility to
complete this training. I want to thank to Department of Mechanical
Engineering for giving me the permission to commence this training in this
training in the First instance, to do necessary work for training report & to use
the Department sources.
I am further more to thank to Mr. Sanjeev Kalra, Principal, Rajendra
Polytechnic , Phulkan (Sirsa) to enurrage to go ahead.
I am deeply indefinite to my supervisor Mr. Jaswant Ray Sharma , Shakti
Motors Sirsa. Who help, inspiring suggestion and in trust help me in all the
time of training work.
Especially, I would like to give me a special thanks to my parents, whose love
enabled me to complete this training. Last but not least, I am behold to Er.
Mahabir Pansia, H.O.D. Department of Mechanical Engineering. For his
unconditional aid & ignition.
Buta Singh
Roll No. 0909717008
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CONTENTS
S. No. Title Page
No.
1 Maruti Introduction 1-2
2 Maruti Models 3-5
3 Engine 6
4 Alto Gasket 7-8
5 Alto Gear Box 9-10
6 Alto Clutch Parts 11
7 Alto Breaking System 12-13
8 Cooling System 14-15
9 Alto Clutch Plate 16-17
10 Air Filter & Battery 18
11 Carburetor Parts 19
12 Pump 19
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MARUTI SUZUKI
INTRODUCTION
The introduction of the Maruti 800 in 1983, marked the beginning of a
revolution in the Indian automobile industry. Maruti Udyog brought in the
latest technology then available, more fuel-efficient cars, and brought down the
prices of cars in India. This led to the creation of a huge market for all car
segments as the Indian middle class grew in size. This in-turn brought in more
players to this segment. A number of auxiliary car parts making units were
setup as most car manufacturers realised it was more cost effective to make
their car parts in India rather than import them. Maruti's most major influence
was in helping the component industry in the country because of its emphasis
on localization and indegenisation. As in the beginning that sector hadn't grown
much, Maruti had to start a dozen joint ventures with Indian entrepreneurs. It
got them foreign collaborations, that led to collaborations for other
manufacturers so that over a period of time the whole component industry was
able to upgrade itself and improve its quality. Leading to a major existing
export potential in vehicle components. It also brought in better methods of
financing that allowed more people, who given their income levels could not
afford to buy a car on their own, to buy cars.[6] It still remains the leader notonly in terms of market share but also in customer satisfaction surveys - it has
consistently topped J. D. Power quality surveys, including 2005.
Maruti Suzuki India is a publicly listed automakerin India. It is a leading four-
wheelerautomobilemanufacturerin South Asia. Suzuki Motor Corporation of
http://en.wikipedia.org/wiki/Automakerhttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Automobilehttp://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Suzukihttp://www.marutisuzuki.com/maruti-cars-home.aspxhttp://en.wikipedia.org/wiki/Automakerhttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Automobilehttp://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Suzuki -
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Japan holds a majority stake in the company. It was the first company in India
to mass-produce and sell more than a million cars. It is largely credited for
having brought in an automobile revolution to India. It is the market leader in
India. On 17 September 2007, Maruti Udyog was renamed to Maruti Suzuki
India Limited. The company's headquarters remain in Gurgaon, nearDelhi.
Maruti Udyog Limited (MUL) was established in February 1981, though the
actual production commenced in 1983. Through 2004, Maruti has produced
over 5 Million vehicles. Marutis are sold in India and various several other
countries, depending upon export orders. Cars similar to Marutis (but not
manufactured by Maruti Udyog) are sold by Suzuki in Pakistan and otherSouth
Asian countries.
The company annually exports more than 30,000 cars and has an extremely
large domestic market in India selling over 500,000 cars annually. Maruti 800,
till 2004, was the India's largest selling compact car ever since it was launched
in 1983. More than a million units of this car have been sold worldwide so far.
Currently, Maruti Alto tops the sales charts.
Suzuki Motor Corporation, the parent company, is a global leader in mini and
compact cars for three decades. Suzukis technical superiority lies in its ability
to pack power and performance into a compact, lightweight engine that is clean
and fuel efficient.
The company vouches for customer satisfaction. For its sincere efforts it has
been rated (by customers)first in customer satisfaction among all car makers in
India for seven years in a row in annual survey by J D Power Asia Pacific.
Maruti Suzuki was born as a government company, with Suzuki as a minor
partner, to make a peoples car for middle class India. Over the years, the
product range has widened, ownership has changed hands and the customer has
http://en.wikipedia.org/wiki/September_17http://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/Gurgaonhttp://en.wikipedia.org/wiki/Delhihttp://en.wikipedia.org/wiki/Pakistanhttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/2004http://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/September_17http://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/Gurgaonhttp://en.wikipedia.org/wiki/Delhihttp://en.wikipedia.org/wiki/Pakistanhttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/2004http://en.wikipedia.org/wiki/Maruti_Alto -
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evolved. What remains unchanged, then and now, is Marutis mission to
motorise India.
TYPES OF MODELS
Sales of automobiles
Maruti 800
Maruti Zen Estilo
In the order they were launched:
1. Maruti 800: Launched 1983. Largest selling car in India, until 2004.
Cheapest car in India. 3 Face-Lifts.(P)
2. Maruti Omni: Launched 1984. 2 Face-Lifts.(P)
3. Maruti Gypsy: Launched 1985.(P)
4. Maruti Wagon-R:Launched 1999, 2 Face-Lifts.(P)5. Maruti Alto: Launched 2000. Currently the largest selling car in India. 1
Face-Lift.({{Tooltip|P|Petrol
6. Maruti Versa(2003-) (P)
7. Maruti Zen Estilo(2005-) (P)
8. Maruti Suzuki Swift 1 very small face-lift(2006- ) (P & D)
9. Maruti Suzuki SX4 (May 2007- ) (P & D)
10.Maruti Grand Vitara Sports Utility Vehicle Launched in (July 2007- ).
Imported(P)
11. Maruti DZiRE Sedan Version of swift launched in (March 2008- ) (P)
Upcoming models in 2008
http://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Maruti_Omnihttp://en.wikipedia.org/wiki/Maruti_Gypsyhttp://en.wikipedia.org/wiki/Maruti_Wagon-Rhttp://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Maruti_Versahttp://en.wikipedia.org/wiki/Maruti_Zen_Estilohttp://en.wikipedia.org/wiki/Maruti_Suzuki_Swifthttp://en.wikipedia.org/wiki/Maruti_Suzuki_SX4http://en.wikipedia.org/wiki/Maruti_Grand_Vitarahttp://en.wikipedia.org/wiki/Maruti_DZiREhttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Maruti_Omnihttp://en.wikipedia.org/wiki/Maruti_Gypsyhttp://en.wikipedia.org/wiki/Maruti_Wagon-Rhttp://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Maruti_Versahttp://en.wikipedia.org/wiki/Maruti_Zen_Estilohttp://en.wikipedia.org/wiki/Maruti_Suzuki_Swifthttp://en.wikipedia.org/wiki/Maruti_Suzuki_SX4http://en.wikipedia.org/wiki/Maruti_Grand_Vitarahttp://en.wikipedia.org/wiki/Maruti_DZiRE -
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1. Suzuki Splash
2. Suzuki A-Star
Future Maruti Suzuki Plans
1. Maruti Omni Face-Lift in 2009
2. New Mini-SUV in 2010 Likely to be a four-door Jimny.
3. New Luxury Sedan in 2010 Likely to be a production version of the
Kizashi.
4. New Swift in 2011
5. New Alto
http://en.wikipedia.org/wiki/Suzuki_Splashhttp://en.wikipedia.org/w/index.php?title=Suzuki_A-Star&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Maruti_Omni_Face-Lift_in_2009&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Mini-SUV_in_2010&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Luxury_Sedan_in_2010&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Swift_in_2011&action=edit&redlink=1http://en.wikipedia.org/wiki/Suzuki_Splashhttp://en.wikipedia.org/w/index.php?title=Suzuki_A-Star&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Maruti_Omni_Face-Lift_in_2009&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Mini-SUV_in_2010&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Luxury_Sedan_in_2010&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=New_Swift_in_2011&action=edit&redlink=1 -
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Maruti Alto Engine
All the Suzuki Alto's sold in the Netherlands have the same engine/platform. So
it is very cheap to maintain, because second hand parts can be found at almost
any junkyard and are cheap! The same car and engine are also sold as the
Daewoo Tico and in India as the Maruti 800. The F8B engine is also mounted
in the Suzuki Mightyboy and Suzuki Hatch.
General specification:
Engine code: F8B
Capacity: 796cc
Nominal bore: 68.5mm
Stroke: 72.0mm
Compression ratio: 8.7:1
Max power output: >29.5kW/39.5bhp @ 5500rpm
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Power output per litre: >37kW/49,7bhp
Power to weight ratio: 64,1bhp/ton (616Kg)
Max torque: 59 Nm @ 3000rpm
Torque per litre: 74,1Nm
Torque to weight ratio: 95,8Nm/ton
Intake 31.6mm Exhaust 27.6 (valve head diameter)
Rocker ratio: about 1.48
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Alto Gasket
In my earlier post, I did mention on the K6A engine that is install on Japan
Suzuki Alto (Please note that the Malaysia Suzuki Alto which is assemble from
India Suzuki factory is in difference engine), as it seem like this engine is
mainly for Japan domestic market requirement only, I'm not really expect to
find such an engine in Malaysia.
Than I found a post in a local auto forum, that one guy had swap this 2003
Suzuki Alto K6A engine to 1993 Suzuki Alto, which it originaly carry F6A
engine.
http://3.bp.blogspot.com/-9bAZQFZfwXg/TiOZbJyNAtI/AAAAAAAAA0U/ik625QdRr1s/s1600/K6A.jpghttp://3.bp.blogspot.com/-_M7YJPMgWws/TiOZgpRraHI/AAAAAAAAA0c/QPCU63lbJfI/s1600/p1070201l.jpg -
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And also some fact of K6A engine driven Suzuki Cappuccino.
The Suzuki Cappuccino is a small 2-door, 2-seater demountable hardtop
roadster produced by Suzuki Motor Corporation. The vehicle was designed to
meet Kei car specifications for lower tax and insurance in Japan. Weighing just
725 kg (1,598 lb), the Cappuccino is powered by a turbocharged, three-
cylinder, 657cc DOHC engine (just under the 660cc maximum displacement
allowed for a Kei car). Its dimensions also conformed to Kei car regulations on
length and width, being 3,295 mm (129.7 in) long and 1,395 mm (54.9 in) wide.
Front-rear weight distribution is claimed to be 50/50% when both seats are
occupied. Layout is front mid-engined and rear-wheel drive. The hood, roof,
roll bar and lower front guard panels are aluminium.
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Maruti Alto Gear Box
n an awe inspiring reflection of how popular Volkswagens award winning dual
clutch gearbox has been, Volkswagen has just sold its three and a half
millionth DSG Gearbox worldwide. DSG, is an acronym for Direct Shift
Gearbox, with Volkswagen being the very first manufacturer to introduce the
dual clutch system in a car gearbox which made gear shift times quicker, to suit
todays high performance car just fine.
The Direct-Shift Gearbox commonly abbreviated to DSG is an electronically
controlled dual clutch multiple-shaft manual gearbox, in a transaxle design -
without a conventional clutch pedal,and with full automatic, or semi-manualcontrol. The first actual Dual Clutch transmissions derived from Porsche in-
house development for 962 racing cars in the 80's.
Now, what exactly do the two clutches in the DSG gearbox do? The two
clutches let two gears to be selected at a single shot so that when the
transmission shifts, it needs only open one clutch and the other clutch can
remain closed, thus saving time. Quicker shifts means more rapid acceleration
and also a less jerky movement during gear shifting.
Also, since Dual Clutch gearboxes are lighter than conventional automatic
gearboxes, they are inherently more efficient, thus delivering fuel savings. In
India, models such as the Skoda Laura, Skoda Superb, the Altoi A4, the 2011
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Volkswagen Passat are a few models where Volkswagens DSG gearbox is
being used currently. In due course of time, smaller Volkswagen group cars in
India like the Volkswagen Polo and the Skoda Fabia may also get the DSG
gearbox.
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Alto Clutch parts
We have wide range of clutch plate items available for American , European ,J
apanese,and Korea Vehicles,
O,D range from 160mm-430mm.
2,More than 1,000 kinds of models, if you require by OEM No.,or Dakin No.,V
aleo No.,Sachs No.,Asco No.,
LUK No., etc. We can quote you in no time, we can guarantee our clutch disc t
o be high standard.
3,We can develop according to customers' drawings or samples.
4,Material:High quality non-asbestos clutch facing. High quality toque spring
with material 60 Si2Mn,Forged clutch hubs , Anti-rust paper and oil.
5,High standard heat treatment system for progressing.
6,Steady force transmission , Reliable transfer torque.
7,Excellent radiative performance.
8,Long service life , low wear and tear , Noiseless.
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Alto Braking System
Differential & Gear Parts
One of the most important car parts, these axles join the front two
wheels of your car. The positioning of the front axle can significantly change
the wheel base, for example if it is mounted under the cab instead of ahead the
cab, as most commonly done in commercial vehicles, the wheel base can be
reduced to quite an extend. Our front axles designed for cars like tata indica,
maruti suzuki and other cars are made to fit all the models and can also be made
to your exact specifications. Some of the axle types are shaft assembly ( both
for rh and lh drive), joint assembly wheel side and joint assembly differential
side.
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Our company is also engaged in the manufacturing of rim, web & welded shoe
for various automobiles.
6 types of rims & 7 types of webs are manufactured for different leading
vehicles viz. Maruti800, Zen, Alto, Van, Swift, Esteem, Tata Indica,
Bajaj Rickshaw, Mahindra Logan, Tata Economy Car (Rs. 1 lacs) & etc. .
Web developed for Mahindra Logan has full shaving as like fine blanked
component on its welding face & anchor point. .
Pad plate developed for Maruti 800 for its front disk brake is having full
shaving on its two lugs with dimension between the two maintained
within +/-0.05mm. .
Each rim has lancing, dimpling & radius bending operations which are to
be maintained within close dims. .
Progressive tools have been developed for four types of rims and four
types of web. .
Shoe welding can be done in house on projection welding machines. .
A fully developed & tested set-up for shoe welding, coining & piercing is
ready with CSPL.
Our company is one of the main sources to supply these items in quantities to
Bosch. Currently, our company is short-listed supplier by Bosch for supplying
Rim, Webs for Alto.
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The Car Cooling System
When a car engine is running there are continuous explosions in the cylinders of
the engine. We know for a fact that fire creates heat, these explosions create a
lot of heat within the engine. If the heat is not controlled it can damage the
engine and cause it to cease. For this reason every car has a cooling system. The
cooling system on a car is managed by a radiator and some other components.
All cars today are liquid cooled. There are passages around the engine and thecylinders. The cooling system circulates coolant through those passages in the
engine. The liquid absorbs the heat from the engine as it passes through.
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In earlier times cars were cooled by passing water around those passages. Cars
operate in very different conditions across the world. From well over 100 F in
desserts to below freezing temperatures in snow. The liquid that is used to cool
the engine cannot evaporate or freeze because if it does the cooling system will
not work and the engine will overheat until it ceases. As a result the fluid used
to cool the engine is a mixture of water and ethylene glycol which is called
coolant. This mixture has a boiling point that is much higher than that of water
at 235 F, and has a freezing point that is well below that of the freezing point of
water at -55 C. In addition to this there is a pressurised radiator cap. The boiling
temperature of any liquid goes up when it is pressurised, as a result the
pressurised radiator cap increases the boiling point of the coolant. If the
temperature exceeds the boiling point the fluid will flow out of the radiator cap
through a valve. The spring pressure of the cap determines how much
maximum pressure of the cooling system. The coolant flows through the
overflow pipe into the bottom of the overflow tank. Once the radiator cools
back down vacuum is created in the cooling system that opens another spring
loaded valve that pulls the coolant back into the system.
Specifications
1.Radiator fan motor, Fan motor, Blower motor, Electrical fan motor for
MARUTI ESTEEM FM35
2.OE N/D
NAME:Radiator fan motor, Fan motor, Blower motor, Electrical fan
motor
1.Application: MARUTI ESTEEM FM35
2.OE N/D
3.Volt: 12V
4.Certification:ISO9001:2000
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Alto Clutch
We provide clutch plates that are forged out of high grade materials. These
clutch plates are supplied with asbestos based or asbestos free clutch facings, to
suffice you requirements. A wide orange of clutch plates are available for
different makes of cars. There is also a provision to cater to the customized
requirements for individual needs. Along with it, we also have a complete range
of clutch parts, namely bearings, clutch arms and clutch fork.
automobile clutch release bearingclutch bearing,automotive bearingclutch
partstruck bearing ,With Car Maruti Alto.
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Various types and sizes of automobile clutch release bearings available for
Europe, Japan,
Korea and America automobiles .
Capable of developing customer's designation and samples.
We offer SKF number for you .
our company fully introduces ISO9001 and TS16949 international standard.
By the past years efforts, we have already established a comprehensive
integrated quality control system, with QC engineers inspecting goods at every
stage of the manufacturing process.
With high-quality material and advanced technology,the qualities of the
products have get continuous promotion and have got the praise of customers.
We offer our customers:
1) High quanlity bearing
2) competitive price
3) prompt delivery
4) good service
In addition, special bearings are also produced as per customers requirements
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Air Filter and Battery
A few car upkeep work tend to be not so difficult to become carried out through
somebody along with fairly small specialized understanding. Car restore
providers that may be carried out along with no less than resources as well as
knowhow consist of altering the fatigue, changing a good air conditioning filter,
looking at as well as altering essential oil, looking at as well as leading upward
tranny liquid, as well as looking at electric battery, ignite attaches along with
other electric products.
A few of these points seem very complex in order to somebody who has in no
way done an automobile prior to. However, dont allow the actual unfamiliar
frighten a person. Determining the issue is the toughest a part of carrying out
car restore providers; maintaining an automobile taken care of is usually easier.
http://www.forerunner405gps.com/maintaining-car-air-filter-battery.htmlhttp://www.forerunner405gps.com/maintaining-car-air-filter-battery.html -
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Carburetor Parts
To cater to the segment, which has cars that were launched with carburetors
(maruti suzuki 800, Alto, omni, gypsi, zen/ alto), we supply a complete
range of parts. Some of them are: needle valve assembly, float, jet
(primary and secondary), gasket kit, membrane assembly accelerator
pump, float chamber cover, throttle body, spring, carburetor repair kit,
pump body accelerator, power valve kit, insulating gasket, washer and
valve assembly solenoid (solenoid watch).
Pumps 01
Our range of auto pumps viz water pump assembly, pulley water
pump, belt water pump, fuel pump assembly (along with diaphragm) and oil
pump assembly are carefully manufactured and thoroughly tested, in oder to
prevent any leakage or over heating of the engine. These components not only
prevent accidental damage but if properly maintained, also enhance the
efficiency of the vehicle.
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CONCLUSION
On an average more than 73% people feel that the prices are affordable whereas
17% do not agree, 74% believe that attractive discounts are offered whereas
26% are not satisfied with the discounts offered. 20%
said that the test drives are not offered and 15% said that post sales follow ups
are not done regularly whereas 85% said that they were done regularly, but
people feel that Maruti Suzukis the peoples car as it is satisfactory on all other
parameters: knowledgeable sales persons, employees spent enough time before
and during sales, display of merchandise is attractive, availability of product,
variety of merchandize, vehicle in good condition, affordable prices, attractive
discounts are offered, dcor of the waiting area is pleasing, responds to
complaints quickly, service at Maruti service station is excellent, careful with
personal information and is value for money .
The overall opinion about Maruti is very good.