Commercial Vehicle Mechanic Training

About the Commercial Vehicle Mechanic Training

In 2024, the Indian commercial vehicle market continues to see significant innovation and expansion, with a focus on electric mobility and higher payload capacities. Models like the Tata Ace EV and Ashok Leyland Dost+ demonstrate the growing trend toward cleaner, more efficient vehicles for urban logistics. At the same time, there is still strong demand for diesel-powered light commercial vehicles like the Tata Intra V10 and Mahindra Jeeto Plus, especially in regions that require durability and higher load capacity for local delivery operations. Whether you are a beginner or experienced, our courses will help you gain proficiency in the latest ICE Engine service techniques and industry standards. Contact +91-9952749533. On site training available at Neyveli, Panruti, Cuddalore. Tamil Nadu India 607805. Training will be done on Tata ace old model engines. Ashok leyland engines 909.

Our Courses

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Training Vehicle 120HP Lorry Engine 3

Model: Heavy Duty Truck with 120 HP Engine (e.g., Tata LPK 1618 or Ashok Leyland 1618)

Engine Power: 120 HP
Engine Type: 4-Cylinder, Turbocharged Diesel Engine
Engine Displacement: 5.0L-6.0L (approx.)
Fuel System: Common Rail Direct Injection (CRDI)
Transmission: 6-Speed Synchromesh Gearbox
Torque: ~400 Nm
Fuel Tank Capacity: 120-150 liters
Cooling System: Water-cooled
Max Speed: 90-100 km/h
Brakes: Air Brakes with Dual Circuit
Tires: 8.25 x 20 (Front & Rear)
Dimensions:
- Length: 7000 mm
- Width: 2500 mm
- Height: 3000 mm
Gross Vehicle Weight: 16 tons
Weight: 7,000-8,000 kg
Ground Clearance: 230 mm
Target Use: This vehicle can be used for training on advanced truck engine systems, air braking systems, suspension, cargo handling, and heavy-duty engine diagnostics. It also helps in understanding larger commercial vehicle operations, including load management and maintenance.

Training Engine - Tata ACE 25 HP Engine 4

Tata ACE 25 HP Engine – Training Vehicle

Model: Tata ACE or similar mini-truck

Engine Power: 25 HP
Engine Type: 2-Cylinder, Direct Injection Diesel Engine
Engine Displacement: 700-800 cc
Fuel System: Diesel Fuel Injection
Transmission: 4-Speed Constant Mesh Gearbox
Torque: ~55 Nm
Fuel Tank Capacity: 20-30 liters
Cooling System: Air-cooled
Max Speed: 60-70 km/h
Brakes: Mechanical Drum Brakes (front and rear)
Tires: 145 R12
Dimensions:
- Length: 3800 mm
- Width: 1500 mm
- Height: 1700 mm
Payload Capacity: 600 kg
Gross Vehicle Weight: 1.8 tons
Weight: 800-1000 kg
Ground Clearance: 160 mm
Target Use: Ideal for basic vehicle mechanics and engine training, with a focus on small commercial vehicles. Students can learn the basics of small diesel engines, maintenance routines, and how to troubleshoot common issues in compact vehicles used for urban transport and last-mile connectivity.

Course Syllabus:

Week 1: Introduction to Diesel Engines and Diesel Mechanic Tools

Overview of Diesel Engines:
- Principles of internal combustion engines
- Diesel vs. gasoline engines: Differences and applications
- Engine cycles (4-stroke and 2-stroke)
- Basic diesel engine components: Block, pistons, crankshaft, camshaft, cylinder head, etc.
Tools of the Trade:
- Introduction to essential diesel mechanic tools
- Use of diagnostic tools and equipment
- Proper use and maintenance of hand tools, power tools, and lifting equipment

Week 2: Diesel Engine Components and System Functions

Engine Components:
- Pistons, cylinders, and crankshaft design
- Valve train: Valves, push rods, camshaft, and rocker arms
- The role of the cylinder head, gaskets, and seals
Understanding Engine Systems:
- Fuel system components (fuel tanks, lines, pumps, injectors)
- Air intake and exhaust systems
- Lubrication and cooling systems

Week 3: Diesel Engine Fuel Systems

Fuel Systems Overview:
- Types of diesel fuel systems: Single and multi-point injection
- Understanding the common rail fuel injection system
- Diesel pumps and fuel injectors: Types and functions
Fuel System Maintenance:
- Replacing fuel filters and fuel lines
- Troubleshooting fuel system failures
- Adjusting fuel pump timing

Week 4: Diesel Engine Troubleshooting and Diagnostics

Introduction to Diagnostics:
- Basic engine diagnostics and failure symptoms
- Tools for diagnostics: Multimeter, compression gauge, scan tools
- Interpreting diagnostic trouble codes (DTCs) from engine management systems
Common Diesel Engine Problems:
- Poor starting, misfires, power loss
- High fuel consumption and smoke issues
- Diagnostic flowcharts for common diesel engine problems

Week 5: Turbochargers, Superchargers, and Intercoolers

Turbocharging and Supercharging:
- Understanding forced induction in diesel engines
- Components of turbocharging and supercharging systems
- Turbocharger maintenance and troubleshooting
Intercoolers:
- The role of intercoolers in cooling compressed air
- Common intercooler failures and fixes

Week 6: Cooling and Lubrication Systems

Cooling System Overview:
- Diesel engine cooling mechanisms (radiators, water pumps, thermostats)
- Identifying coolant leaks and solving overheating problems
- Importance of proper coolant maintenance
Lubrication System:
- Types of lubricants for diesel engines
- Oil changes and monitoring oil pressure
- Troubleshooting lubrication problems (oil sludge, pressure drops)

Week 7: Diesel Engine Emissions and Environmental Regulations

Emission Control Systems:
- Diesel Particulate Filters (DPF)
- Selective Catalytic Reduction (SCR) and Exhaust Gas Recirculation (EGR) systems
- Common emission control issues and repairs
Understanding Environmental Standards:
- EPA and EU emissions standards for diesel engines
- Impact of diesel engine emissions on the environment
- Maintenance to comply with environmental regulations

Week 8: Clutch, Transmission, and Drive train Systems

Clutch Systems:
- Understanding clutch operation in diesel-powered vehicles
- Clutch failure symptoms and repairs
- Hydraulic vs. mechanical clutch systems
Transmission and Drive train:
- Manual vs. automatic transmission systems
- Torque converters and gearbox designs
- Transmission fluid checks and maintenance

Week 9: Diesel Engine Overhaul and Rebuilding

Engine Overhaul:
- When and why to rebuild a diesel engine
- Steps in engine disassembly and inspection
- Measuring tolerances and replacing worn components (pistons, rings, bearings)
Rebuilding Process:
- Reassembling the engine block, cylinder head, and valves
- Testing the rebuilt engine for leaks and performance

Week 10: Advanced Diagnostics and Electronic Control Systems

Modern Diesel Engine Electronics:
- Introduction to Engine Control Modules (ECM) and Electronic Control Units (ECU)
- Role of sensors and actuators in modern diesel engines
- Diagnosing electronic control failures
Advanced Diagnostics:
- Using advanced diagnostic tools (oscilloscopes, scanners)
- Troubleshooting sensor failures (oxygen, temperature, pressure sensors)

Week 11: Preventive Maintenance and Service Schedules

Routine Maintenance Practices:
- Regular checks for wear and tear (filters, oils, hoses, belts)
- Scheduled oil changes and fluid replacements
- Developing a preventive maintenance checklist for diesel engines
Maintenance Log and Service Records:
- Importance of maintaining service records
- Understanding warranty requirements and maintenance contracts

Week 12: Final Hands-on Project and Assessment

Practical Application:
- Hands-on experience with real diesel engines (disassembly, troubleshooting, rebuilding)
- Working with diagnostics, emissions testing, and fuel systems
Final Assessment:
- Written exam covering the entire syllabus
- Practical exam: Demonstrating diagnostic and repair skills on diesel engines

ONLINE and Onsite Class Room courses for - International students training on Google meet / zoom call to +91-9952749533