1930 - 2005

Lucas Indian Service Ltd

Specialists in auto-electrical solutions and diesel injection systems
 INTRODUCTION:

Lucas Indian Service Limited is a fully owned subsidiary of Lucas-TVS and

is responsible for all aftermarket activities covering the whole range of
Auto Electrical and Fuel Injection products manufactured by the Lucas-TVS
group.

The core activities can be broadly classified as:

 After Sales Service.

 Sales and distribution of Spare parts.
 Lucas Care – A Preventive Maintenance Program.
 Recon.
 Training.
 Campaigns.
 Lucas Indian Service--Milestones:
1930 - LIS is registered as a limited company in Bombay.
1960 - LIS ignition coil factory is established.
1968 - LIS becomes a subsidiary of Lucas-TVS.
1972 - LIS is established in all four metros.
1977 - Marketing of Lispart products commences.
1980 - Completed 50 years of Service - Golden Jubilee
1985 - Promoted – I N E L – a joint venture with Kokusan Denki Co Ltd, Japan
to manufacture Electronic Ignition Systems.
1990 - Several marketing tie-ups for Lispart products.
1994 - Manufacturing of Solenoid switches commences.
1995 - Marketing of Horns commences.
1996 - Marketing of Halogen Bulbs commences.
2000 - Introduction of Automotive Lightings in the Range.
2002- “Endura” range of MF Batteries launched.
2003 – “Lucas Care” Program launched.
2004 – Launched TQM (Total Quality Management) programme
 Lucas-TVS – AN OVERVIEW

Lucas-TVS

Delphi-TVS AE LIS IJL INEL

AE - AUTO ELECTRICALS
PADI - 1961
REWARI - 1991
PONDICHERRY - 1995
Delphi-TVS - FUEL INJECTION - 1990
LIS - LUCAS INDIAN SERVICE - 1930
INEL - INDIA NIPPON ELECTRICALS - 1986
[JV with Kokusan Denki]
IJL - INDIA JAPAN LIGHTING - 1997
[JV with Koito]
 TVS Group Company:

 Currently the Group encompasses companies engaged in manufacturing,

distribution and service of automotive parts.

 Turnover – Rs 12,500 corers (approx).

 Largest exporter of automotive components from India (over Rs 220 corers).

 Lucas Indian Service (LIS) is a part of the TVS Group of companies and a
wholly owned subsidiary of Lucas-TVS.
 LIS Network:

Sales Dealer Accounts - approx 1200

Service Dealer Accounts – over 350 Regional Office

Branch Office

Institutional Accounts Including Dealers

Nationalized Transport Corporation - over 200

 LIS Locations:

JALANDHAR

GURGAON
DELHI
GHAZIABAD
LUCKNOW GUWAHATI
JAIPUR

RANCHI
INDORE RAIPUR
AHMEDABAD
CALCUTTA
NAGPUR BHUBANESWAR
MUMBAI
PUNE
HYDERABAD

GOA

CHENNAI
Regional Offices - 3
Branches - 19
Coil Factory at Chennai
 Electrical Components Of Vehicle:

Battery

 Alternator

 Starter Motor

 Ignition System

 Wiper Motor

 Others
 Purpose of Battery:

 Provide Electrical energy to the Vehicle electrical system.

Supply power to the starter and ignition system to crank the engine.

 Supply extra power when the vehicle load exceed the supply from the
alternator.

 Acts as a voltage stabilizer in the electrical system.

 Maintenance Tips for Battery:
 Secure the battery firmly on the cradle.

 Ensure the cable terminals tightly fitted on the battery posts.

 Do not hammer down terminals onto posts.

 Keep the battery top clean and dry.

 Clean the terminals and the posts regularly to avoid corrosion.

 Apply Petroleum jelly / Vaseline on the terminals and posts.

never apply grease.
 Top up only with distilled water and maintain the level corresponding to
the maximum level, never add Acid.
 Keep vent plugs tightly closed.
 Ensure the fan belt tension.
Rusted battery bkt.& Grease applied on terminals
Checking Battery Specific Gravity Using Hydro Meter:

Hydrometer Specific Gravity Checking

Specific Gravity Value :-

1.270-1.240 (Yellow Region)– Fully Charged
1.240-1.200 (Blue Region) – 70% Charged
1.200- and below (Red Region) – Needs Recharge
 Testing Battery Using High Rate Discharge Tester (HRD):
HRD Connection

HRD Operation HRD Reading HRD OK Indication

 ALTERNATOR:

 An Alternator is a machine that converts mechanical energy to

Electrical energy

 The Alternator output is used to charge the battery.

 The inbuilt Rectifier converts the A.C output to D.C.

 The inbuilt Regulator controls the output and it depends on

the battery charge status .

 The capacity of the Alternator for a vehicle is decided based on

the total electrical loads of the vehicle.
SINGLE FLOW COOLING:

External Fan Alternator:

 DOUBLE FLOW COOLING:
Internal Fan Alternator:

Advantages:-
1. Better efficiency due to heat dissipation by two fans provided in the Rotor.
2. Less weight and compact in Size.
3. Low operation noise.
 FEATURES OF ALTERNATOR SYSTEM:

 Rotating magnetic field (Rotor)

 Stationary out put winding (Stator).

 Solid state Bridge Rectifier.

 Built-in Electronic Voltage Regulator.

No moving parts. Precise and reliable.
 Higher operating speed.

 Self limiting in current output.

 Integral Vacuum pump for brake system (Optional).

 Ventilated and fan cooled.

 PRINCIPLE OF OPERATION – ALTERNATOR:

 Initial excitation of Rotor field from battery through charge

warning lamp creates magnetic flux in the Rotor.
 Rotor rotation produces rotating magnetic flux.

 A.C. output induced in Stator winding.

 Rectification by Positive & Negative main diodes for battery

charging.

 Rectification by Auxiliary diodes for field excitation. of Rotor field.

 Output controlled by the in-built Regulator.

EXTERNAL FAN ALTERNATOR WITH VACUUM PUMP – EXPLODED VIEW:
INTERNAL FAN ALTERNATOR – EXPLODED VIEW:
 CHECKING BELT TENSION:

3 2

1. Crank Shaft Pulley

2. Alternator
3. Water Pump
 CHECKING EXTERNAL WIRING:

5 4
6 3
2

1. Alternator. 4. Ign. Switch

2. Battery 5. Charge Warning lamp
3. Fuse Link 6. Radio Suppression Capacitor
 TESTING ALTERNATOR OUTPUT:

 Put Clamp Meter

6 5 on the negative
4 cable of the
battery.
 Connect Volt Meter
10 3 9 to B+ on alternator
2 and chassis.

 Switch on all
7 electrical loads
except Heater and
Wiper motor.
1
8  Run Alternator at
maximum engine
1. Alternator 6. Charge Warning lamp r.p.m. and read
2. Battery 7. Ammeter Ammeter and Volt
Meter.
3. Fuse Link 8. Volt Meter
4. B+Lead 9. Switch Electrical Load
5. Ign. Switch 10. Radio suppression capacitor
 ALTERNATOR DO’S AND DONT’S:

DO’s Don'ts
Observe correct Polarity when refitting Don’t run the Alternator without the
vehicle Battery, or slave Battery to aid Battery in the system
starting. Always Battery (-) to earth.
Use Multi meter or test lamp to check Don’t flash the Alternator output leads
continuity of wiring. to check output.

Keep the Engine off when you Don’t disconnect Battery cable or
disconnect or reconnect wiring during charging system wiring while the
electrical service. Engine is running
Isolate Alternator while carrying out Don’t use high voltage instrument like
electric welding on the vehicle. Meggar on Alternator or wiring for
insulation check.
Use special tester for checking Don’t run Alternator integral with
electronic Regulator and Multimeter for Vacuum pump without oil for more
Diodes than a minute.
 Factors Affecting Product Life:

 Alternator:
 Loose and excess fan belt tension.
 Fused warning lamp bulb.
 Discharged Battery.
 Loose Battery positive wire & warning lamp socket connection.
 Carrying out welding operation w/o disconnecting battery connection.

Note: By strictly adhering the above points the damages to the alternator
can be avoided result in increased product life.
 Alternator Testing (on Vehicle) using Clamp Meter:

Battery Open Circuit Voltage Alternator Charging Current.

Spec: 12.0 to 13.0 volts Value depends on Elec. Load,

Engine RPM and Battery charge status.
 Alternator Testing (on Vehicle) using Clamp Meter:

Charging Voltage without Load Charging Voltage with Load

Spec: 14.0 ± 0.2 volts Readings may vary depends

Depends on Battery charge status on Battery charge status
 Fault Diagnosis (On Vehicle) – Alternator:

[Link]. Defect Procedures Check Points Corrective Actions

1. Remove the battery

1. Connect a voltmeter If the voltage is found from the vehicle for
across the Alaternator between 14.2 ± 0.4 bench charging.
positive and negative volts 2. Check for any leakage
Frequent discharge of terminals. on the vehicle wiring.
1
battery 2. Switch OFF all the vehicle
If the voltage is below
loads. Tighten / Replace fan
the above reading
3. Raise the engine speed to belt.
check for loose / worn-
about 2500 rpm. Remove the Alternator
If the fan belt is found
from the vehicle for
OK
further inspection.
If the bulb does not Check & replace the WL
1. Remove the WL socket
Warning lamp does not glows circuit fuse or bulb.
from the Alternator,
2 glow when the ignition Remove the Alternator
2. Ground the Warning Lamp
switch is ON If the bulb glows from the vehicle for
wire (Wiring Harness Side)
further inspection.
Check the WL ciruit
1. Remove the WL socket If the bulb glows wiring on the vehicle.
from the Alternator, brightly and goes of Check for defective
Warning bulb glows dim
2. Use a separate WL bulb after starting dasboard panel or WL
3 when the ignition switch
and connect between the bulb holder.
is ON
Alternator WL terminal and Remove the Alternator
the battery positive If the bulb glows dim from the vehicle for
further inspection.

Contd..
 Fault Diagnosis (On Vehicle) – Alternator:

[Link]. Defect Procedures Check Points Corrective Actions

1. Remove the WL socket from
the Alternator. Check for loose fan belt if
WL bulb glows while 2. Use a separate WL bulb and found OK, Remove the
4 If the bulbs glows
the vehicle is running connect between the Alternator Alternator from the vehicle
WL terminal and the battery for further inspection.
positive
1. Remove the WL socket from Remove the Alternator
the Alternator. If the bulb flickers from the vehicle for further
WL bulb flickers while 2. Use a separate WL bulb and inspection.
5
the vehicle is running connect between the Alternator
If the flickering not Check and rectify the WL
WL terminal and the battery
found wiring
positive
Remove the Alternator
If the voltage is more
Battery gases and Connect a voltmeter across the from the vehicle for further
than 14.2 ± 0.4 volts
6 excess lose of battery positive and negative inspection.
electrolyte terminals If found within the Check the battery for
above reading internal damage

Note: By strictly following the above procedures the removal of OK units

from the vehicle can be avoided.
 1930 - 2005

Lucas Indian Service Ltd

Specialists in auto-electrical solutions and diesel injection systems
 Starter Motor :

 A Starter motor is a machine that converts electrical energy to

mechanical energy.

 The Starter output is used to crank the engine.

 The Starter motor gets supply from the battery.

 When the Starter solenoid switch getting energized, the pinion

engages with the flywheel ring gear and rotates the same.

 The starter performance depends on the battery charge status

and the voltage drop in the starting circuit.
 CLASSIFICATION OF STARTER MOTOR :

 Based on voltage of operation - 12V & 24V starters.

 Based on construction - Axial, Pre-engaged, Inertial starters.

 Based on field system - Wound field, Permanent Magnet.

 Based on method of transmission - Direct drive & Geared.

Based on application - 2Wlr, Car, Commercial, Tractor, Off-high way..

 AXAIL STARTER INERTIA STARTER

PRE ENGAGED STARTER

GEAR REDUCTION STARTER

GEAR REDUCTION STARTER

 Gear Reduction Starter Motor :

Concept:

High speed machine which employs a gear mechanism to

achieve reduction in speed and high torque.

Types of Gear reduction:

Planetary reduction (Epicyclic Gear) – coaxial

Offset gear reduction (Spur Gear) – biaxial

 NEED OF GEAR REDUCTION STARTER:
 Normally vehicle fly wheel gear ratios is 15:1.(between pinion and ring
gear). Larger diameter ring gears cause installation problems especially in
transverse engines.
To achieve overall weight reduction the size of the flywheel is reduced.
To obtain a worthwhile reduction in starter size it becomes necessary to increase the
armature speed for the same out [Link] necessary engine starting torque at the
drive pinion is obtained through the use of a gear mechanism.

 The higher speed of the starter armature, resulting in smaller size for a given power
output and permanent magnet field is used to obtain the weight reduction.

 The gear arrangement in the starter can be either spur gears with an offset
output shaft or an epicyclic (planetary) gears with an inline arrangement.
 ADVANTAGES OF GEAREDUCTIONSTARTER:

 Improved cold starting (upto – 30 deg c)

 Less weight and size.

 Higher power to weight ratio.

 Direct interchangeable with conventional starters.

 Less vibration and noise.

CONSTRUCTIONAL FEATURES - OPTIONAL DESIGNS:
OVERHANG TYPE:

FRONT NOSE TYPE

Exploded View-Gear Reduction Starter Motor:
 FEATURES – STARTER MOTOR:
 SOLENOID SWITCH
 Drive pinion engaged prior to energizing the motor.
Less wear and tear of pinion.
 Drive pinion disengaged after de-energizing the motor.
Easy pinion retraction.
 ROLLER CLUTCH ASSEMBLY ON PINION
 Armature disengaged from pinion while engine drives the motor soon
after the engine start.
Prevents over running of starter.
 SERIES PARALLEL FIELD
 Reduce starter internal resistance.
Improves motor torque.
 COPPER IMPREGNATED GRAPHITE BRUSHES
 Provide path for adequate current flow.
Improves starter performance.
STARTER MOTOR (Direct Drive) – EXPLODED VIEW:
 VOLTAGE DROP ON TOTAL CIRCUIT:

1. Crank engine.
Record “V1”.
Should read 10.5v.

2. Crank engine.
Record “V2”.
Should read 10v.

3. “V1” – “V2”
Should not exceed 1 v.

4. If the above value exceeds

1Volt check for high
resistance on insulated
and earth line.
 VOLTAGE DROP ON POSITIVE LINE:

1. Connect Volt meter across

battery “+” and starter
“B” terminal.

2. Crank the engine.

3. Meter reading should not

exceed 0.25 volt. Excessive

reading indicate high
resistance.
 VOLTAGE DROP ON EARTH LINE:

1. Connect Volt meter across

battery negative and starter
“E” terminal.

2. Crank the engine.

3. Meter reading should not

exceed 0.25 volt. Excessive
reading indicate high
resistance.
 Testing Cranking Current Using Clamp Meter:

Clamp-Meter Connection Cranking Current

 Factors Affecting Product Life:

 Starter Motor:

 Discharged Battery (Battery specific gravity should be

1.250 in all cells)
 Poorly Soldered battery terminals.
 Excess cable length result in increased voltage drop.
 Loose battery terminals and starter cables.
 Oxidized terminals and posts. (Clean them regularly and apply
petroleum jelly).
 Prolonged cranking of engine.
 Faulty Ignition Switch.

Note: By strictly adhering the above points the damages to the

Starter can be avoided result in increased product life.
 Fault Diagnosis (On Vehicle) – Starter Motor

[Link]. Defect Procedures Check Points Corrective Actions

If the voltage is found
between 14.2 ± 0.4 volts,
connect the battery positive Check the wiring
and the starter solenoid between starter and
terminal using a external ignition switch.
Vehicle not starting 1. Connect a voltmeter cable. If the starter motor
1 (Engine not rotating, across the battery positive found working.
Starter sluggish) and negative terminals. Remove the starter
If the motor is not working motor for further
investigation.
Clean battery terminals
Check for dirty / oxidised
and posts, apply
battery terminals and posts.
petroleum jelly.
Remove the starter
If the voltage is found
motor for further
between 10.0 ± 0.5 votls
investigation.
Check for voltage drop
Connect the voltmeter in the starting circuit
Tik-Tik noise from the across the starter solenoid (Poorly soldered battery
2
starter motor and battery negative and cable with terminal,
If the voltage is found below
crank the engine. excess length of battery
the above reading
positive and negative
cables, improper
earthing of battery
negative cable.

Contd..
 Fault Diagnosis (On Vehicle) – Starter Motor
[Link]. Defect Procedures Check Points Corrective Actions
If the voltage is found between Remove the starter motor
10.0 ± 0.5 votls for further investigation.
Connect the voltmeter across
Check for voltage drop or
No response from Starter the starter solenoid and
3 If the voltage is found below open circuit in the solenoid
motor during cranking battery negative and crank
the above reading or zero circuit (Wiring between
the engine.
voltage observed ignition switch and Starter
solenoid).
Use Hydrometer to check the If the Hydrometer reading is
specific gravity of the battery below 1.210 in any one of the Remove the battery for
in all cells. cell bench charging, check and
Press the push button on the solder the battery cables
Starter motor does not
HRD. If the voltmeter reads with the terminals.
4 rotates when the engine is
below 11.0 volts
hot. Use the battery High Rate
If the battery chage status is
Discharge tester (HRD)
found to be satisfactorly (To Remove the starter motor
be confirmed by the above for further investigation.
tests).
Remove the wire from Starter
If the voltage found even after Replace ignition switch or
solenoid, connect the
releasing the ignition switch check for any wiring defect
Starter motor continues to voltmeter between the wire
5 run even after releasing and the battery negative.
the ignition switch Operate the ignition switch Remove the starter motor
If no voltage is found
( Repeat the exercise for 5 - for further investigation.
10 times).

Note: By strictly following the above procedures the removal of OK units

from the vehicle can be avoided.
 FRONT WIPER MOTOR:

1. CABLE ASSEMBLY
WITH SOCKET

2. ROTARY LINK
1
3. MOTOR
2
3
ARRANGEMENT OF FRONT WIPER MOTOR ASSY:

1 2 3
4 5

1. ROTARY LINK ASSY 4. ARMATURE ASSEMBLY

5. YOKE AND BRG. ASSY.
2. GEAR BOX ASSY
6. THRUST SCREW &
3. GEAR BOX & BRUSH LOCK NUT ASSY.
PLATE ASSY.
 REAR WIPER MOTOR:

1. MOTOR. 3. ROTARY LINK.

2. GEAR BOX ASSEMBLY.
 REAR WIPER MOTOR ASSY:

3 6
1 2

1. ARMATURE ASSLY 4. WORM WHEEL ASSLY. 6. GEAR BOX &

BRUSH PLATE ASSLY.
2. YOKE & BRG. ASSLY.
5. DRIVE MECHANISM ASSY
3. THURST SCREW&
LOCK NUT
 Maintenance Tips for Wiper Motor:

 Ensure all electrical connections are in good condition.

 Always keep the wind screen clean.

 Do not operate the wiper on dry wind screen.

 Check the free movement of wiper links at regular intervals.

 Worn out or perished blades should be replaced immediately.

 Product Details:
Product
Model
Alternator Starter Front Wiper Rear Wiper

Indica 26021189 26925263 26071204 26971281

Indica (D) 26021319 26925264A 26071204 26971281

Indigo 26021320 26925264A 26071204 26971281

Indigo (D) 26021287 26925264A 26071204 26971281

Marina 26021138 26925264A 26071204 26971281

Marina (D) 26021287 26925264A 26071204 26971281

Sumo 26021123 26925121A 26071169 26971281

Sumo Delux 26021143 26925121A 26071169 NA

Spacio 26021292 26925113A 26071169 NA

26925121A /
Safari 26021284 26071174 26071175
26925271A
Safari (D) 26021261 26925121A 26071174 26071175

Safari DICOR 26021366 26925113A 26071174 26071175

WARRANTY HANDLING PROCEDURE
WARRANTY HANDLING PROCEDURE:
VMD / CUSTOMER

LIS BRANCH LIS DEALER

Check the failed unit,Verify document

claim form / WCIR
RC Book.

Physical inspection of components

for damages and fix liability..

If Accepted If Rejected

Carry out repair jobs and Rectify the unit on chargeable

Deliver to customer / OEMD basis/Return the unit with
with investigation report. rejection letter.

Failure analysis report to Lucas-TVS

 Format to be Enclosed with the Failed Part
WARRANTY COMPLAINT INVESTIGATION REPORT
INFORMATION TO BE PROVIDED BY VEHICLE / ENGINE MANUFACTURER's SERVICE DEALERS

Customer - Name & Address Veh. Reg. No.

Engine No.
Chassis No.
Vehicle Make
Model
Mileage / Hrs
Vehicle Dealer - Name & Address [Link]
Dt. of Failure
Job Completion Dt.
Defective unit type
Mfg. Date

Vehicle Dealer Job No. Date: Sign:

VEHICLE DEALERS OBSERVATION ON DEFECTIVE UNITS (please tick appropriate box):
ALTERNATOR STARTER MOTOR
Warninglamp does not come when switch is 'ON' Starter does not engage
Warning Lamp continue to glow with engine 'ON' Starter engage; But doesn't crank the Engine.
Warning Lamp off; But battery low state of charge. Starter rotates; But the engine does not.
Warninglamp flashes, Ammeter flickers. Starter sluggish. Rotates very slowly.
Headlights suddenly becomes brighter or dim. Starter does not respond sometime.
Warninglamp glows dim. Starter continues to run even after switch is 'OFF'
Constant high output, bulb fuses or bright, Both starter & engine does not rotate
high consumption of battery distilled water. chattering noise heard from starter.

CONTD.
CONTD.

WIPER MOTOR DISTRIBUTOR OTHERS

Sluggish No pick up
Intermittent Vehicle jerking
Burnt Dist cover tracking/cracking

Wiper blade jerking Engine rotates, but does not start

Others Noisy operation

LIS DEALER / BRANCH OBSERVATION & ACTION TAKEN :

LIS Dealer/Branch Name: Job no: Date :

Test Report : Claim Status : Accepted Rejected If Rejected, give reasons :

Signature with Seal (Vehicle Dealer) Signature with Seal ( LIS Dealer / Branch)
 Date :
VEHICLE SYSTEM CHECKLIST
To be carried out before Removing the Component from the Vehicle

a. Vehicle Details
1 Vehicle Registration No 7 Customer complaint
2 Vehicle Chassis No 8 LIS Job Date
3 Vehicle Dealer Name 9 Starter Batch Code
4 Location 10 Date of Sale
5 Date of Complaint 11 Battery Make
6 KMs Reading

b. Is the Starter com plaint personally Yes No

experience by you.
c. Details of the Measurem ent Taken
SN PARAMETER SPECIFICATION MEASURED VALUES REMARKS
1 Battery OCV Min 12.3 V
C1 C2 C3 C4 C5 C6
2 Sp. Gravity in each cell 1270 ~ 1240

3 HRD Tester 150A/200A 10.5V to 9.5V

Battery Cables
4 Yes No
Soldered at Both Ends
Engine IDLE RPM picks
5 up while switching on
A/C Yes No
(I.e. FICD function OK or
Not.

CONTD.
CONTD.
Copper bracket intact &
6 Yes No
tight
Junction Box & Fly
7 Leads are OK (Indigo Yes No
Only)
Current Drawn by Glow Plug 1 Plug 2 Plug 3 Plug 4
8 Each Plug 15~18A
(All plugs < 80 Amps)
COLD HOT Value - COLD Value - HOT
Cranking Voltage at
9 Conduct HRD test on the battery again
Battery +ve End > 10.0 V > 10.1 V
(Refer Sl No : 3)
Cranking Voltage at Check for any loose connections /
10 > 9.7 V > 9.8V
Starter End Joints. Confirm the Soldering of Main
11 Solenoid Voltage > 9.3 V > 9.5 V Cables at 5 Points
Cranking current at Replace the Starter Motor if the results
12 145 ~ 170 A
Battery +ve End are not as per specification
Previous History and Action T aken

T ML Dealer / Branch LIS Branch / Dealer Checked By

Please follow the following steps for taking the above readings
1. T ake cranking current & voltage measurements both cold and hot conditions
(For hot condition, run the engine at 2000 RPM for 20 minutes or run the vehicle for 30 Kms
2. Disconnect FIP for taking cranking measurements
3. Crank the Engine for 4 to 5 Sec's. Ensure the glow plug timer switched off before cranking
4. Starter current to be checked only on the battery +ve cable and should be measured after 2 to 3 Seconds
of cranking under steady state condition. T he current should not be taken for analysis
THANK YOU …