SHOWER TEST MODIFICATION AND ANALYSES OF LEAKAGES

ASSIGNMENT 3. ANALYSES AND RECTIFICATION OF LEAKAGES IN THE VEHICLE

AIM: To analyse the LEAKAGES in vehicle ARIA and their RECTIFICATION

EQUIPMENT:

1. Shower area 2. Supply pipe 3. Motor 4. Nozzles 5. Blower

SHOWER TEST AREA SPECIFICATION: Shower Test Indicruz TCF Technical Parameters Riser Pitch Nozzle Pitch Nozzle Spray angle Flow rate per nozzle Water pressure at Nozzle Length of booth Test time

I.S-11865 revision 2006 400 mm 400 mm 60 deg 15 lpm +/- 15% 2 bar +/- 15%

Equipment Specification 400 mm 400 mm 60 deg 15lpm +/- 10% 2 bar +/- 10%

NA NA Additional Fitures

5.4 m 3 min

( Rain And Light Sensor Testing)

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MOTOR SPECIFICATIO SP ECIFICATION N :Manufactured by- Kirloskar Brothers Ltd. Type- SP- IHM S no.- A0DAJF0366





IMP.DIA.mm-134.0 HEAD RANGE m-9.0-18 m -9.0-18.0 .0 Lps-4.5 RPM-2800 CAPACITY RANGE lps- 6.2-1.5 kW/HP -1.5/2.0 OVERALL EFF. %-34.0 INS B 50Hz 3 Ph CONN S 415V A 3.9 DUTY S1 INDUCTION MOTOR

About Shower testing 1. What is a shower test? Checking the leakage inside the cabinet 2. Why shower test is needed? To check and ensure that there is no water leakage inside the cabinet 3. How is the shower test performed? Vehicle is kept under the shower for 3 minutes and VISUALLY CHECKED from INSIDE for a LEAKAGE from windshields, glass door pads, windows, firewall, tailgates etc.





3. 4. 5. 6. 7.

Start wipers Enter the vehicle in the shower testing booth. Stop vehicle in the shower for 3 minutes. Visually check for leakages closely. Check whether the wiper blades are over shouting on the wind shield. 8. If a leakage is found mark on the history card for rework. 9. If no leakage is found allow vehicle to dry on platform.

PREPARATION OF VEHICLE FOR SHOWER TEST: 1. Ensure Door beading is fitted properly and no sealing gap in BIW. 2. Ensure doors and windows are fitted properly. 3. Ensure Sealant application as per specification.

ACCEPTED NORMS/ STANDARD: STANDARD : No water leakage inside the CAB.





THE COMMON PROBLEMS: 1. Water leakage through TAILGATE OR SEATBELTS due to improper fitting of the TAILGATE BEADING. 2. Water leakage through inner BEADING of the DOORS due to DOOR SASH PROBLEM. 3. Water leakage through the INNER BEADING of the FRONT DOORS due to improper use of SEALANT for the ROOF.

ANALYSES OF PROBLEMS : PROBLEM Leakage through the TAILGATE or SEATBELTS

REASON Improper fitting of the tailgate BEADING

Leakage through Inner BELT of the doors

Improper sealant filling

CAUSE Tailgate and roof joint left open hence loose tailgate beading 1. Sealant not continuosly applied on the roof 2. No checking in the BIW shop for Sealant application 3. Roof of the cab too high for the operators to apply sealant in a proper manner





through TAILGATE glass Water leakage through WINDSHIELD GLASS Leakage through QUARTER GLASS Front and Rear

filling by the OPERATOR Improper SEALENT filling by the OPERATOR Improper SEALENT filling by the OPERATOR BIW joints mismatch

Improper Inspection Change in operators

Change in operators

SOLUTIONS: PROBLEM Leakage through the TAILGATE or SEATBELTS

SOLUTION Beating of joints suggested to be done regularly Proper pressing of TAILGATE beading before fixing Leakage through Inner BELT of Change in sealant filling the doors procedure Proper Instructions given to the operator Strict follow up in BIW shop advised Water leakage through door door sash No permanent solution Temporarily fixed by pulling door inwards

Water leakage through TAILGATE glass

Instructions given to the operator Follow up taken by supervisors







Leakage through QUARTER GLASS Front and Rear

Instructions given to the operator Follow up taken by supervisors

CONCLUSION: Reduction in cases of shower leakages . On the spot rectification to enable further processes on the vehicle.

SHOWER TEST MODIFICATION AND ANALYSES OF LEAKAGES

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