warranty details

Edition : XLI/NE/J-2007/001-500

TataLP / LPT 613 EURO-II

Operator’s Service Book

(The contents given in this book are not binding; are subject to change without

notice and are for illustration purposes only)

International Business (CVBU)Mumbai, INDIA

iii

Dear Customer,

We are pleased to hand over your Tata LP/LPT 613 EURO-II Vehicle,manufactured by Tata Motors where QUALITY is the watchword and majorattention is paid even to minor details at all stages of manufacture of yourvehicle.

PLEASE DO READ THIS BOOK. It helps you to know your vehicle better, to ensureyour vehicle is ready for operation at all times and to obtain better performanceat optimum operating costs.

All lubricating and maintenance tasks are to be carried out at the specifiedservice intervals.

Some of the items / accessories / features shown / given in this book may notbe fitted on your vehicle, but they are applicable for other versions of vehicles.

For any further assistance, please contact the nearest Tata Diesel Vehicle Dealeror Our Office at following address.

Tata Motors LimitedInternational Business CVBU (Customer Support)Shah House, Shivsagar estate,Worli, Mumbai - 400 018,India.Ph No. : (009122) 6757 7239 / 7200Fax No. : (009122) 6757 7275E - Mail : [email protected]

We wish you good luck and prosperity.

v

1. General

1.1 About Tata LP/LPT 613 EURO-II ................................................ 3

1.2 Environment protection .......................................................... 5

1.3 Important tips for driver .......................................................... 7

1.4 Tips for maintenance .............................................................. 10

1.5 Body building ............................................................................. 11

1.6 Additional fitments .................................................................. 20

1.7 Additional provisions (electrical) ....................................... 30

2. Vehicle Handling

2.1 Vehicle identification .............................................................. 37

2.2 Location of aggregate numbers ......................................... 41

2.3 Instrument panel ...................................................................... 43

2.4 Switches, gauges & indicators .............................................. 44

2.5 Driving controls ......................................................................... 55

2.6 Turbocharger .............................................................................. 57

2.7 Charge air cooler ....................................................................... 58

2.8 Clutch booster ........................................................................... 59

2.9 Cab tilting .................................................................................... 60

2.10 Heating ......................................................................................... 65

2.11 Driver seat & seat belt ............................................................ 66

CONTENTS

vi

3. Driving

3.1 Starting the engine .................................................................. 71

3.2 Driving ......................................................................................... 72

3.3 Stopping the engine ............................................................... 75

3.4 Special operating conditions ............................................... 76

3.5 Fuel economy ............................................................................. 78

3.6 Do it yourself .............................................................................. 79

4. Maintenance procedure

4.1 Air intake system ...................................................................... 83

4.2 Fuel system ................................................................................. 85

4.3 Lubrication system .................................................................. 87

4.4 Cooling system. ......................................................................... 89

4.5 Clutch ............................................................................................ 92

4.6 Gearbox ........................................................................................ 94

4.7 Propeller shaft ........................................................................... 95

4.8 Front axle & rear axle ............................................................... 96

4.9 Power steering .......................................................................... 97

4.10 Brake system ........................................................................... 101

4.11 Springs ....................................................................................... 114

4.12 Centre flap ................................................................................ 115

4.13 Tilt cab ....................................................................................... 116

4.14 Wheels and tyres .................................................................... 117

4.15 Electricals .................................................................................. 121

4.16 Preservative treatment ....................................................... 128

4.17 Care and cleaning .................................................................. 131

vii

5. Technical information

5.1 Technical specifications ...................................................... 135

5.2 Aggregate filling capacities .............................................. 140

5.3 Lubrication points ................................................................. 141

5.4 Tightening torques ................................................................ 143

6. Fuel, lubricants and coolants

6.1 Fuel .............................................................................................. 149

6.2 Lubricants ................................................................................. 150

6.3 Coolant ...................................................................................... 152

7. Service recommendations

7.1 Special instructions .............................................................. 155

7.2 PDI ............................................................................................... 156

7.3 Service schedule .................................................................... 159

7.4 Record of services performed .......................................... 168

7.5 Record of repairs performed ............................................. 170

1

1. GENERAL

1.1 About Tata LP/LPT 613 EURO-II ..........................3

1.2 Environment protection ....................................5

1.3 Important tips for driver ....................................7

1.4 Tips for maintenance ....................................... 10

1.5 Body building ...................................................... 11

1.6 Additional fitments ........................................... 20

1.7 Additional provisions (electrical) ................ 30

3

TATA LP/LPT 613 EURO-II fullforward control chassis in truck & busversions are available with followingoptions :

● 3.8 meter wheel base for truck& bus.

● Tilt cabin chassis with / with outload body for trucks.

● Cowl chassis with windshieldglass / cowl chassis with frontend structure only for bus.

● LHD versions.

● Engines conforming to Euro IInorms with matching powertrain.

● Various colour combinations forcabin/ load body in truck version.

● With / with out power take offand provision for power take offin truck.

● Fuel tank capacity 120 litres.

● Diagonal ply / radial ply tyres forboth truck & bus versions.

Optional fitments include

● Engine cold start device

● Cab heating

● Driver seat belt warning device

● Front fog lamps

● Rear under run protectiondevice/ side under runprotection device for trucks.

These incorporate well provenfeatures of TATA vehicles to giveeconomic life cycle cost, high

reliability and ease ofmaintenance.

Short wheel base and narrow widthgives them high maneuverability,ideal for all applications.

TATA 697 TCIC direct injectionengines are fitted with dry typecylinder liners for long life and easyoverhaul.

Vehicles meeting Euro II norms arefitted with rotary type fuel injectionpump, turbocharger, air after cooler,high capacity dry type air filter, etc.

A radiator auxiliary tank is providedfor convenient coolant filling.

Good visibility, hydraulic powersteering, 5 speed synchromesh gearbox with remote shift arrangement,hydraulically actuated clutch, selfcancellation turn signals lever, tintedwind shield glass, etc. enhancedriving comfort.

S Cam full air brake system withair dryer, nylon brake pipes and loadconscious relief valve in rear brakecircuit makes driving more safe.Service brakes are supplemented byengine exhaust brake, coupled withservice brake operation. Thisenhances life of brake linings, brakedrums & tyres.

Provision for ABS brakes.

An exhaust brake isolator switchhas been provided on instrumentpanel. Exhaust brake can be madeinoperative whenever required bymeans of this switch.

1.1 About TATA LP/LPT 613 EURO-II General

4

Steering is provided with steeringlock cum ignition switch as asafety and security of the vehicle.Engine is started and stopped bymeans of this switch. Battery cut offswitch in bus version providesadditional safety for electrical system.

Wide centre flap at front enableseasy access to points of dailymaintenance.

Tilt cabin with torsion bar assistanceon truck version enable effortlessoperation of cabin tilting / lowering.It also provides ample space to reachengine / power train for inspection /maintenance.

Exhaust system with bigger silencerconsiderably reduces noise level.Different versions of exhaust pipinglay out are available to meet countryspecific regulations.

Proper and timely maintenanceand servicing as recommended inthis book will ensure trouble-freeoperation over long life.

1.1 About TATA LP/LPT 613 General

5

Environmental protection

TATA MOTORS is committed toproduce vehicles usingenvironmentally sustainabletechnologies. A number offeatures have been incorporated inTata vehicles which have beendesigned to ensure environmentalcompatibility throughout their lifecycle. We would like to inform youthat your vehicle meets appropriateenvironmental norms and this isbeing regularly validated at allstages of manufacturing .

As a user, you too can protectenvironment by operating yourvehicle in a proactive manner. A lotdepends on your driving style andthe way you maintain your vehicle.We are giving below a few tips foryour guidance.

Driving

● Avoid frequent and violentacceleration.

● Do not carry any unnecessaryweight as it overloads theengine.

● Avoid using devices requiringhigh power consumption duringslow traffic conditions.

● Monitor fuel consumptionregularly and if it shows a risingtrend, get it attended at Tataauthorised workshop.

● Switch off engine during longstops at traffic jams or signals. Ifsituation demands that engine

1.2 Environmental protection General

be kept running, avoid frequentrevving up of engine. Also avoidfrequent stopping andrestarting, if uncalled for.

● It is not necessary to rev up theengine before turning it off as itunnecessarily burns fuel.

● Shift to higher gears as soon aspossible. Use each gear upto2/3rd of its maximum enginespeed. A chart indicating gearshifting speed is given in themanual.

Maintenance of the vehicle

● Ensure that recommendedmaintenance is carried outregularly at Tata authorisedworkshops.

● As soon as you see any leakagesof oil, fuel, air or coolant get itattended immediately.

● Use only recommended gradesof lubricants and clean/uncontaminated fuels.

● Get your vehicle checked foremission periodically by Tataauthorised workshop.

● Ensure that fuel filter, air filter, oilfilter, breathers are periodicallychecked and if required, replacethe same by only genuine parts.

● Do not pour used oils orcoolants into sewage drains,garden soil or open streams.Dispose used filters andbatteries in compliance withcurrent legislation.

6

● Do not allow unauthorisedagencies to tamper enginesettings or to carrymodifications on the vehicle.

● Never allow the vehicle to runout of fuel, which results inmisfiring of engine.

● Parts like brake liners, clutchdisc may contain asbestos. Usevacuum cleaner for cleaningthese parts. Do not usecompressed air for cleaningthese parts which may spreaddust in atmosphere.

While carrying out servicing orrepairs pay keen attention tofollowing parts which can affectexhaust emissions.

1. Fuel injection pump, injectors/nozzles.

2. Air intake and Exhaust systemespecially for leakages.

3. Cylinder head for valve leakage.

4. All filters such as air, oil and fuelfilters.

5. Turbo charger (Euro II)

6. Air after cooler (Euro II)

1.2 Environmental protection General

This book contains furtherinformation on driving precautionsand maintenance care leading toenvironment protection. Pleasefamiliarise yourself with theseaspects before driving.

7

1.3 Important tips for driver General

1. Use only recommended oils andlubricants.

2. Always use recommendedantifreeze agents in coolingsystem to avoid deterioration ofengine components due tocorrosion. After filling coolant, fitauxiliary tank cap firmly, to keepcooling system pressurised.

3. Maintain correct tyre pressure toensure better tyre life.

4. Always fit genuine radiator capfor pressurised cooling system.

5. New tyres do not givemaximum grip straight away andshould therefore be run-in atmoderate speeds for first 100km. This will help to make tyreslast longer.

6. New brake linings must alwaysbe run-in, they do not haveoptimum friction propertiesduring first 200 kms.

7. Avoid mixing of different gradeof lubricants or clutch fluidsduring top up.

8. Run the engine in low idlingspeed for atleast three minutesafter starting and beforeshutting off. (Applicable forturbocharged engine)

9. Always start moving the vehiclein first gear.

10. Operate engine in correcttemperature range i.e. between60OC & 100OC.

11. Engine oil / coolant levels haveto be checked daily. Drain waterfrom fuel water separator daily.

12. In case of air lock in fuel system,bleeding should be done onhigh pressure side of fuel filters,drain manifold and highpressure lines. Ensure that liftpump operation is satisfactoryand proper fuel delivery takesplace while bleeding out air.

13. Avoid cranking of engine formore than 30 seconds. A gap of2 minutes should be leftbetween successive attempts.

14. Check battery every week andtop up electrolyte, if necessary.Keep battery terminals clean andcable joints tight. Apply vaseline/petroleum jelly on terminals.

15. Watch service indicator of drytype air filter (Euro II). Indicationof same is given on instrumentcluster. If it blinks continuouslythen clean the air filter housingand replace primary cartridge.

16. Observe correct polarity whileconnecting alternator terminalsand battery cables.

17. For operating vehicles inextremely cold climates andhigh altitudes contact Tataauthorised workshop to seekadvice.

18. Do not use kerosene as fuel. Itreduces engine and fuel pumplife.

8


19. Do not use clutch pedal as a footrest when driving. This will causepremature clutch lining wear.

20. Do not coast vehicle i.e. drivewith engine switched off. This isdangerous and affects life ofgear box.

21. Do not fit bigger size tyres. Donot over or under inflate tyres.This reduces tyre life.

22. Do not top up coolant in auxiliarytank by pouring cold coolant inhot engine. Cylinder head maycrack.

23. Do not overfill engine oil insump. This may cause enginesmoking and high engine oilconsumption.

24. Do not engage ignition key instarting position, after theengine has fired. Release itimmediately. If not, starterpinion and / or flywheel ringgear will be damaged.

25. Do not run alternator with outbattery or disconnect any lead ofalternator while engine isrunning.

26. Do not keep accelerator at fullthrottle during engine cranking.After starting, run engine at idlespeed till such time oil pressurebuilds up.

27. Do not clean exposed paintedsurface or windscreen withpetroleum products i.e. diesel,kerosine & petrol, etc.

28. When air / fuel / oil filtercartridges are replaced, destroyold cartridges to prevent theirreuse.

29. Ensure that air intake hoses arefree from punctures, cuts anddamages.

30. Always fasten seat belt whiledriving. Same is applicable forco-passenger, wherever seatbelt is provided.

31. Do not use mobile phone whiledriving.

32. Do not adjust seat belt whiledriving.

33. For first 2000 kms, restrict speedlimit to 60 kmph in top gearwith 1500 kg pay load.

34. Avoid panic braking.

35. Drive on lower gears on steepdown gradient, thus avoidingexcessive braking & brake overheating.

36. Primary lock lever on drive awaychassis is secured with bolt andnut as safety precaution.Replace this with a pad lock. Thiswill enable cab tilting only afterunlocking pad lock. Fitment ofpad lock will avoid unauthorisedtilting of cabin.

37. Ensure gear shifting lever in 2ndgear position before tilting/lowering cab.

38. Disconnect alternator terminalsbefore carrying out any weldingwork on chassis/body.

9

39. Engagement / disengagementof power take off (optionalfitment on trucks) needs to bedone only when gear lever is inneutral position & enginerunning at idling speed.

40. Engine exhaust brake isolatorswitch has to be kept ON always,unless & until exhaust brakeisolation is required.

41. Radial tyres are to be balancedwhenever they are removedfrom wheel rims. Balancingweights should not exceedmaximum permissible limits.


10

1.4 Tips for maintenance General

1. Use only recommended filtersfor air intake, engine oil and fuelsystem. Replace them atrecommended intervals.

2. Before building the body, studyrecommended body buildingpractices.

3. Disconnect alternator terminals,while carrying out electricalwelding.

4. Never use water alone in thecoolant system. Always usemixture of 50% clean water and50% antifreeze agent fortopping up and for change.Always carry a five litres can ofproperly mixed coolant fortopping up enroute, if necessary.

5. Get the cause of low engine oilpressure investigated at Tataauthorised workshop.

6. Any change in clutch pedal freeplay is to be immediatelyinvestigated.

7. Get your vehicle serviced at Tataauthorised workshop atrecommended intervals.

8. Use only recommended gradesof oils for all aggregates.

9. All services / repairs to be carriedout at Tata authorised workshopsonly.

10. Do not reinforce chassis frame,

springs or axles for carryinghigher payload. It will result inpremature failure of aggregatesand deprive you of warrantybenefits.

11. Dust accumulated in radiator finsshould be cleaned by blowingcompressed air at low pressurefrom inner side of radiator.Please do not clean withpressurized water jet as it willdeform radiator fins.

Helping you to obtain efficient trouble-free service from your

TATA DIESEL VEHICLE is our business.

11

1.5 Body building General

Body building guidelines

It is important to ensure that the bodyis fitted to chassis in such a way thatthe load imposed is transmittedcorrectly. At the same time the rigidlymounted body must flex with theframe. Care should be taken toensure that body and chassis arecompatible. An example of badselection would be the constructionin which a short body is made on along wheel base. In this case, itbecomes necessary to shortenchassis rear overhang toaccommodate body. As a resultcentre of gravity moves forward anda greater load than that desirable isimposed on front axle.

It is also essential that carefulconsideration be given to movementor modification of electrical wiring,electrical equipments, brakeconnections, brake piping, extensionof chassis rear over hang, relocationof chassis components to ensuregood performance in operation.

Post to waist rail joints

Gusset plates are welded toU-channel / Z-channel waist rail.

The welding of the gusset to thewaist rail should be intermittent.

Wheel arch dimensions

To accommodate wheels, side frameis formed to a suitable shape calledwheel arch.

To prevent tyre fouling with body onbad roads, recommended dimensionsof wheel arch should be maintained.

Position of roof luggage carrier(for LP model)

Roof luggage carrier should be placedto get the centre of gravity ahead ofrear axle centre line (min . 500 mm).Height of roof luggage carrier shouldbe minimum in order to reduce windresistance.

Outrigger for door post

When a door has to be located at aplace where cross bearers cannot bemounted due to positioning ofchassis aggregates at that location,outrigger assembly should be madefor door post.

12

Notes

1. Keep body weight minimumby selecting proper materialsand designs. This will save fueland increase tyre life.

2. Use curved window glass, avoidsharp corners and protrudingout destination boards toreduce wind resistance.

3. Select body dimensions,seating space and gangwaywidth to comply with currentgovernment regulations.

4. Ensure ease of removal andassembly of various aggregateslike gearbox, suspension,battery, spare wheel etc.Provide flaps/cut outs forservicing.

5. De-rust, phosphate and applyprimer to the body skeletonbefore fixing panels.

6. Use zinc plated hardware ofstandard quality for variousbody joints.

7. Protect instrument panel,steering wheel, driver’s /co-driver ’s seats, clutch fluidcontainers, hoses etc. fromdamage while carrying outstructural work.

8. Do not drill or weld chassisframe or remove any rivet. Donot use chassis or leaf spring aselectrical earthing point duringwelding.

9. Do not clamp bus body crossbearers to chassis crossmembers.

10. No body mountings should foulwith any chassis aggregate orframe cross member.

11. Avoid practice of cuttingchassis cross member formounting of ‘U’ bolts.

12. Do not extend chassis rearoverhang.

13. Avoid eccentric mounting ofcross bearers.

14. Do not use balata packing morethan 6 mm thick for crossbearer mounting. This willresult in premature perishingand damage to chassis longmember. In case thickerpacking is required, use steelplates to compensatealongwith 6 mm balata packing.

15. Avoid ‘U’ bolts touching chassislong members. This should bedone by using aluminium alloypacking between ‘U’ boltbottom radius and longmember bottom flange.

16. As far as possible, avoid postlocation over wheel arch.

17. No modification to front faceof cowl should be attemptedwhich would restrict air flow tothe radiator and air cleaner.Reducing the height/width ofcentre flap or closing louversprovided on cowl front faceare to be avoided.


13

18. No restriction should be placedbeneath the remote mountedair filter. Provide sufficientclearance for fitment andremoval of air cleaner.

19. Air intake hoses are not to bedisturbed during bodybuilding. However, if hoses areremoved for any reason, coverturbocharger / air after coolerand intake manifold openingswith suitable plastic caps toavoid dust foreign particlesentry, till such time hoses areconnected back. Clampsshould be properly tightenedduring this operation.

20. Do not reroute air intake,coolant and fuel lines.

21. Do not keep auxiliary tank capopen so as to avoidcontamination of coolant withdust and foreign material.

22. Disconnect battery andalternator connections beforestarting any electrical weldingon chassis/body.

23. Protect radiator / air aftercooler from weld spatters andexternal mechanical hitting,which might damage the coreof radiator / air after cooler.

24. Protect auxiliary tank fromweld spatters and mechanicaldamage. Use proper cover toprotect radiator and auxiliarytank during welding in theirvicinity.

25. Do not use suspension springpack for earthing or to checkcontinuity while carrying outarc welding. Welding spatterswill lead to breakage of springleaves.

26. Additional air connections foraccessories like air horn, etc. tobe taken only from port 24(auxiliary port) of systemprotection valve. Suchconnections should not betaken from either service brakecircuits or parking brake circuit.

27. Provide suitable hinged flapson the body skirt to facilitatedraining of air tanks and todrain water from fuel waterseparator.

28. Do not allow body builder todrill holes on chassis frame orextend rear overhang.

29. Do not flash alternator leads tocheck for current flow.

30. Do not mask head lamp lenswith black paint. If done, thiswill reduce head lamp lightintensity.


14

Body building

Load body should be mounted withthe help of ‘U’ bolts and must not befixed on to the chassis with the helpof bolts and nuts by drilling holes inchassis frame. This weakens thechassis frame which is liable to crack.

Do not reinforce, weld or drill holesin the chassis frame. Use six ‘U’ boltsto fasten the runners on either sideof chassis long member. Tighten ‘U’bolts nuts (M 16 x 1.5, - 8.8 quality)to 22 mkg. torque.

1. Hex. nuts M 16 x 1.5, -8.8 quality2. Plate washer3. Wooden runner4. Steel runner5. ‘U’ bolt 16 Ø6. Chassis long member7. Aluminium alloy packing

‘U’ Boltfastening with

steel runner

Section - AA

‘U’ Boltfastening withwooden runner

Section - AA

CANVASPACKING

A typical method in which the bodyshould be mounted on chassis isshown in figure.


15

Polyamide (PA) nylon tubing forair brake

Your vehicle is fitted with latestgeneration polyamide (PA) nylontubing for air brake.

PA material is preferred for thisapplication for :

● Excellent chemical resistance(against fuel, battery acid,hydraulic oils etc.)

● Dimensional stability and impactresistance (against gravel throwfrom tyres).

● Suitable working temperature is- 40ºC to 100ºC constantworking and upto 130º C peaks.

● PA is 7 to 8 times lighter thanmetal.

● Eliminates rusting problem, givesmuch lower leakage.

● Rust particles are not generated(like in metal tubes) and thusprotects valves etc.

Preventive maintenance for PAnylon tubing

● Check whether all clamps are inplace and suitably tightened.

● Check whether spiral cover is inplace.

● Check that all end fittings areproperly assembled.

● Check that PA tubes followrouting as per original vehicle.

● Check that PA tubes is notrubbing against any other objecton the vehicle such as frame,bracket or connectors.

● In case of repair, use only plasticcoated clamps for clamping of PAtubes.

● Ensure that PA tube is nottouching :

(a) Hot objects such as exhaustpipe

(b) Sharp objects such asbrackets or sheet metal parts.

(c) Moving objects such aspropeller shaft.


16

Guidelines and precautions fornylon (PA) tubing.

Welding and gas cutting

Cover PA tube with suitable objectsuch as metal sheet at the time ofwelding and gas cutting. This willavoid welding spatter and moltenmetal from falling on the PA tubesand creating a hole in the PA tube.


Cover PA tube before gas cutting

Unprotected areas while weldingmay damage PA tube

Cover PA tube before welding

Unprotected areas while gas cuttingmay damage PA tube

17


Clamp PA tubes properly to avoid coming in contact with hot objects

Sharp objects

Take care that PA tubes do not come in contact with sharp objects. This willavoid cutting of PA tubes.

PA tubes should not touch sharp objects Follow original routing of PA tubes

Hot objects

Take care that PA tubes do not touch hot objects such as exhaust pipe. This willavoid burning or melting of PA tube.

Avoid PA tube to touch exhaust pipe Do not light fire near PA tube

18

Loose fitments

Do not allow loose fitting of PA tube.


Ensure proper clamping of PA tubes

Misuse

Do not step or hang on connected PA tube. Doing so, will lead to damage ofPA tube at the clamps or near end fitting, resulting in leakage.

Do not step on or hang on to PA tube

Avoid loose fitting of PA tube

19


Tube Fitment

In case refitting of PA tube is required

Follow original routing of PAtube.

Take care that PA tubes are notforcibly bent or fitted.

Use plastic coated clamps.

Use both hands while fitting PAtube. This will avoid twisting andkinking of PA tube.

Kinked tube

Do not tighten nut without holding PAtube

Hold PA tube before tightening nut

Twisted tube

20

1.6 Additional fitments General

B) Side under run protection device (SUPD)

Note : While the SUPD is fitted as OE on vehicles with OE load body, customershave to ensure fitment of SUPD when they do body building. Please referfitment details of SUPD.

LOAD BODYBOTTOM

OF FLOOR

OVER ALL LENGTH

H

D

G

B

P2P1E J

A C

Fitment of SUPD on LPT version

A) Rear under run protection device (RUPD)

This device is factory fitted on truck version.

Rear under run protection device fitted on vehicle (LPT)

21

NOTE :

1. For all other technicalrequirements of sideprotection device ref.IS:14682:1999.

2. Pitch ‘P1’, ‘P2’, ……..shouldnot be more than1650 mm.

3. Dimn ‘H’ is as measured onthe load bodiesmanufactured by otherthan Tata Motors suppliedload body.

4. As per the regulations,following Dimensions needto be maintained withinthe specified values.

4.1 Dimension ‘A’ shouldbe less than or equal to300 mm measuredfrom front tyre rearface (for LPT vehicles)or less than or equal to100 mm. measuredfrom rear wall of cab incase of SFC vehicles.

4.2 Dimension ‘B’ shouldbe less than or equal to550 mm measuredfrom ground.

4.3 Dimension ‘C’ shouldbe less than or equal to300 mm measuredfrom front face of reartyre.

4.4 Dimension ‘G’ shouldbe greater than orequal to 100 mm.

4.5 Dimension ‘D' shouldbe less than or equal to350 mm measuredfrom lower most faceof floor structure.

4.6 Dimension ‘E’ and ‘J’should be less than orequal to 120 mm.

5. Painting or powder coatingto be done for rustprevention.

6. All the members as shownin drg. are with minimumcross sections and thicknessrequired.

7. Item no. 8 to be added atthe both ends to coveritem no. 7, to be welded toboth side guard panels.

8. # This dimensions (460 mmof item no. 1) to bechanged to meetregulations given in sl. no.4.2 (dimension `B') and 4.5(dimension `D').

9. Long side guards can beprovided with two pieceswith overlapping and withsuitable backing plate orlongitudinal gap ofmaximum 25 mm isallowed.


22


SUPD Proposal 1

Note : Please refer page numbers 23 to 24 for details of item no. 1 to itemno. 9 & for alternate proposals.

ASSY. SUPPORT SIDE GUARD

MA

X. W

IDTH

OF

LOA

D B

OD

Y

B

B

2 WELD NUTSM10

ITEM NO. 4

HEX. FLANGED SCREWM10x20-IS 17130-8.8

ITEM NO. 2 & 3

ITEM NO. 5

ITEM NO. 1

CE

D

THIS SURFACE SHOULD BEINSIDE THE MAX. WIDTH OFVEHICLE AND SHOULD NOT BEMORE THAN 120 mm INSIDE.

ITEM NO. 6HEX. FLANGED SCREWM10x20-IS 17130-8.8

10

20

2 0

20

STEEL CROSS RUNNER

ITEM NO. 8

C

MATERIAL - SHT. 4 THK.DD 1079 SS: 4013A

( ITEM NO. 2 AND 3 NOT SHOWN)

2020

20

VIEW FROM - D

VIEW FROM - E

SECTION - CC

ALTERNATE FORSECTION - BB

SECTION - BB

MATERIAL - SHT. 2.5 THK.DD 1079 SS: 4013A

9656

50

50

23


ITEM NO. 1 ITEM NO. 2 AND 3 (RH & LH)

`X'

R3 (TYP)

11 D

IA (T

YP)

A A

15= =

1535 15

45

34.5 R4.5460

#

5 (T

YP)

5 (TYP)

MATERIAL - SHT 1.6 THK. D513 SS: 4010

DETAILS -`X'

SECTION - AA

2

R1.5

10

105

2

R3

50

35

15


ITEM NO. 4


R3

46

15

18

230

2 SLOTS 13 x 18

131533

125 65

==

ITEM NO. 5


150

5R3

5

10

41

R4.5

24

ITEM NO. 7


ITEM NO. 6

MATERIAL - SHT. 1 THK. D513 SS:4010

(OVERALL LENGTH -12)

105

20

20

35R5 R10

R10R5R5

3410PITCH

ITEM NO. 7

ITEMNO. 8

CEN

TRE

LIN

E O

F IT

EM N

O. 9

CEN

TRE

LIN

E O

F IT

EM N

O. 9

OVERALL LENGTH

6

ITEM NO. 8

12

R3(TYP)

105

126

105R15

R6

R6

R1033.5

R4

R6

MATERIAL - SHT. 1 THK. D513 SS:4010

ITEM NO. 9

30

WELD NUT M10-IS: 8856

50

65

115

2 HOLES 12.5 DIA-H11

MATERIAL - SHT. 2 THK. DD 1079 SS:4013A

25

Note : Refer page number 26 for section CC and section FF. Details of itemno. 1 to item no. 4 are given on page number 26 and 27.

SUPD ALTERNATE PROPOSAL - 2 :a) with mounting to wooden runnerb) Two alternate sections for panel (item no. 3)


A

B

B

C

C

WOODEN RUNNER

FRONT OF VEHICLE

340

ITEMNO .-1

ITEM NO .-2

ITEM NO .-4

ITEMNO .-3

100

540

980

BOTTOM OF SIDE WALL OF LOAD BODY

GROUND

SECTIONAL VIEW - BB

F

VIEW FROM -A

F

10

MA

X.

WID

THO

F LO

AD

BO

DY

AVERAGE HEIGHTMEASURED ONDIFFERENT LOADBODIES.

ITEM NO .-3

WOODEN RUNNER

26


SECTION - CCPROPOSAL - A

SECTION - FF

SECTION - CCPROPOSAL - B

HEX. BOLT M10x100BRT. WASHER 10.5SPRING WASHER B10HEX. NUT M10

WOODEN CROSSMEMBER

4x30x30

HEX. SCREW M8x20BRT. WASHER 8.4SPRING WASHER B8HEX. NUT M8

ITEM NO. 3a ITEM NO. 3b

Note - Refer item no. 3a, 3b, 4 and 5.

ITEM NO. 2

MATERIAL - ANGLES 45x45x3 THK. Fe 410W A IS : 2062

ITEM NO. 1

MATERIAL - SHEET 2 THK. DD 1079 SS:4013A

# DIMN. TO SUIT WOODEN CROSS MEMBER( REF- CROSS SECTION -FF )

6 HOLES 11 DIA.

#72

40

#240

250

85 85 40

R5(TYP)

15x450

45

230

D

DPLATE 3 THK.

3x30x30

E E

150

4 HOLES 12 DIA

20

478

SECTION - EESECTION - DD

27


ITEM NO. 3b - PROPOSAL - B

ITEM NO. - 4 ITEM NO. - 5

102

105

R5(TYP)

15

MATERIAL - SHEET 1 THK. D 513 SS : 4010

10 DIA

45

MATERIAL - SHEET 3THK. Fe410 -1079 SS : 4013A

20

45

25

10 D

IA

150

4010

0

30

20

R2

35

R5(TYP)

20

MATERIAL - SHEET 1 THK. D 513 SS : 4010

ITEM NO. 3a - PROPOSAL - A

MATERIAL - RECTANGULAR TUBE 100x25x1.5 THK (MINIMUM) HF YST 210 IS : 4923

LENGTH OF SIDE PANEL

28

Note : Rear view mirror will be supplied as a kit with cowl and faceless chassisand should be fitted during body building. Factory built cab and bus will be fittedwith rear view mirror. Please refer section -CC and section - DD on page 29.


C) Rear view mirror - LP / LPT versions

BUS BODYTRUCK BODY

B

DETAILS OF ̀ A'

68

50

70

16.5

2 3

3 3

(X=

- 1

070)

C

C

D

D

DETAILS OF `B'

ASSY. REARVIEW MIRROR R.H.

100810

(Y=

0)

(cen

ter

line

of

veh

icle

)

BUS BODYTRUCK CAB

2 1 0

64

0

(Z=20)

`A'

(X=

- 1

070)

(X=

0)

29

Rear view mirror - LP / LPT versions


For LCVs there will be two plain mirrors one each at driver side andco-driver side.

RUBBER PAD TOP

BRACKET TOP

SLEEVE FOR FRAME

SL. CSK SCREW M6x20 - 4.8WASHER C 6.4 SPR. st 130

SECTION - DD

SL. CSK SCREW M6x20 - 4.8WASHER C 6.4 SPR. st 130

SL. CSK SCREW M8x30 - 4.8SPR. WASHER B8DOME CAP NUT M8

RUBBER PAD BOTTOM

BRACKET BOTTOM

SECTION - CC

Mirror for custom built cab

30

D) WIPING SYSTEM

GUIDELINES FOR FITMENT OF WIPERSYSTEM BY BODY BUILDERS

1. Wiper system components(wiper motor, wheel box,wiper arm and blade, linkages)are supplied along with thedrive away chassis and theseare recommended for use onthe built up vehicle. However,the windscreen and themounting of the wheel boxesshould be appropriatelydecided to match wipersystem regulation as stipulatedin AISO 11-2001 for A, B, Cwiping zone arearequirements.

2. Wiper motor to be mountedpreferably near the centre ofthe panel below the windscreen with suitable mountingbracket.

4. Wheel boxes to be fitted withsuitable mountingarrangement on both sides, insuch a way that the wipingpattern obtained meets theregulatory requirements ofAISO11-2001.

5. The path of link rodmovement, during wipingsystem operation, should befree from any obstacles toensure free movement.

6. Wiper arm and bladeassembly should be properlytightened on the wheel boxto ensure proper pressing of

rubber edge of blade againstthe wind screen.

7. Wiper system should bebalanced and it is to beensured that there is nopossibility of entangling /locking of linkages or foulingof wiper blade with rubberbeading.

1.7 Additional provisions (electrical) General

31

LIGHTING AND SIGNALLING

Guidelines for fitment of endoutline marker lamp, side markerlamp, side retro-reflector, sideindicator, front fog lamps andrear fog lamp, head lamps, taillamp assembly and side retro-reflector during body building(refer figure)

For factory built load body all theabove fitments come as OE, exceptfog lamps.

Front and rear fog lamps are optionaland only provision is given.

1. End outline marker lamps: A, B,C, D, E and F in the sketch are typicalsix locations of End outline markerlamps. Normally four lamps are fitted,two for the front (white light) andtwo for the rear ( red light ). The rearlamps can be fitted at locationssuitably to be visible from the rearof the vehicle. Visibility for both frontand rear lamps is defined ashorizontal spread about the lamp axisof minimum +/- 80 deg and thevertical spread of minimum 5 degabove and minimum 21 deg belowthe axis of the lamp. They arenormally mounted near the top ofthe vehicle; the height should besuch that it is minimum 200 mmabove the parking lamp. From thesides of the vehicle, the lampsshould be fitted at a distance lessthan 400 mm. Refer figure. Thewattage of the lamps should be 5watts.

2. Side ( turn ) indicator lamps : Gand H are the typical locations ofside indicator (turn indicator) lamps.The height restrictions of the lampare given in the figure. The wattageof the lamp should be normally 10watts.

3. Side marker lamps & Sideretro-reflectors: I,J,K,L,M and N arethe typical locations of side marker

lamps and side retro reflectors. Theseare to be fitted on all vehicles ofoverall length more than 6 meters.The distance restrictions are given inthe figure. The side marker lampand side retro reflector may beseparately fitted or can both beincluded in a single package. Thewattage of side marker lamp shouldbe 5 watts. The distance restrictionsare given in the figure. Refer figurefor circuit diagram.

4. Front fog lamps: P and Q are thetypical locations of the front foglamps. The distance restriction fromthe sides of the vehicle and theheight are given in the figure forFront and Rear fog lamps. Thewattage of the lamps should be 55watts each. Refer figure for circuitdiagram.

5. Rear fog lamp: R is a typicallocation of the rear fog lamp. Thedistance restrictions from thelongitudinal centre line of thevehicle and from the side of thevehicle are given in the figure forFront and Rear fog lamps. The rearfog lamp is to be fitted on thedriver’s side of the vehicle typicallyas shown in the figure. The wattageof the lamp should be 21 watts. Refercircuit schematic.

6. Head lamps: The head lamps aresupplied along with the vehiclesfrom the factory. The distancerestrictions for mounting of thelamps during body building are givenin the figure .

7. Tail lamps: The tail lampassemblies are fitted as part offactory supplies on our vehicles. Theassembly consists of rear positionlamp, stop lamp, rear retro-reflector,reversing lamp and turn indicator.The distance restrictions formounting the lamp assembly aregiven in the figure .


32


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MAX. UPTO HEAD LAMP TOP SURFACE

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33

1.7 Additional provisions (electrical) GeneralC

ON

NEC

TIO

N S

CH

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TIC

FO

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IDE

MA

RK

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AM

PS

/ EN

D O

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AR

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ON

TSI

DE

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IDD

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MA

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END

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0.5

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RO

WN

0.75

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0.5

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0.5

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m B

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0.5

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m B

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0.5

Sq. m

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0.75

Sq

. mm

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0.75

Sq

. mm

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35

2. Know Your Vehicle

2.1 Vehicle identification ................................................... 37

2.2 Location of aggregate numbers ............................... 41

2.3 Instrument panel ........................................................... 43

2.4 Switches, gauges & indicators ................................... 44

2.5 Driving controls .............................................................. 55

2.6 Turbocharger ................................................................... 57

2.7 Charge air cooler ........................................................... 58

2.8 Clutch booster ................................................................ 59

2.9 Cab tilting ......................................................................... 60

2.10 Heating .............................................................................. 65

2.11 Driver seat & seat belt .................................................. 66

37

2.1 Vehicle identification Know Your Vehicle

LPT 613 - Full forward control truck with tilt cab (RHS view)

LPT 613 - Full forward control truck with tilt cab (LHS view)

38


FULL FORWARD CONTROL CHASSIS WITH 3800mm 381 325 LPT 613/38CAB AND WITHOUT LOAD BODY, TRUCKVERSION WITH 697TCIC BHARAT STAGE-IIENGINE, WITH FULL AIR S’CAM BRAKEWITH HEATING AND DEMISTING,3800mm W.B.

FULL FORWARD CONTROL CHASSIS WITH 3800mm 381 327 LPT 613/38CAB AND WITHOUT LOAD BODY, TRUCKVERSION WITH 697TCIC EURO-II / BHARATSTAGE-II ENGINE, WITH FULL AIR S’CAMBRAKE, 3800mm W.B.

LP VERSIONS

FULL FORWARD CONTROL CHASSIS 3800mm 381 224 LP 613/38WITHOUT FACE BUS VERSION WITH697TCIC EURO-II / BHARAT STAGE-IIENGINE WITH FULL AIR S’CAMBRAKE 3800mm W.B.

FULL FORWARD CONTROL CHASSIS WITH 3800mm 381 225 LP 613/38COWL BUS VERSION WITH 697TCICEURO-II / BHARAT STAGE-II ENGINEWITH FULL AIR S’CAM BRAKE WITHHEATING AND DEMISTING ,3800mm W.B.

CHASSIS TYPE DESIGNATION

Description Wheel Chassis Salesbase type designation

LPT VERSIONS

39


LP 6

13

CH

ASS

IS W

ITH

CO

WL

38

WB

EU

RO

- II (

LHD

)

40


LPT

61

3 C

HA

SSIS

WIT

H C

AB

AN

D L

OA

D B

OD

Y 3

8 W

B E

UR

O- I

I (LH

D)

41

2.2 Location of aggregate numbers Know Your Vehicle

Chassis number - LHD

1. Chassis number plate

2. Cab /Cowl number plate

2

1

Engine number plate location

Engine number plate

Cab / Cowl number plate

Chassis number plate

42

2.2 Location of aggregate numbers Know Your Vehicle

Gearbox number Rear axle number plate

Power steering gearbox number plate Front axle number plate

43

2.3 Instrument panel Know Your Vehicle

1. Low air pressure indicator

2. High beam indicator

3. Exhaust brake indicator

4. Parking brake indicator

5. Front fog lamp indicator

6. Fuel gauge

7. Speedometer with odometer

8. Coolant temperature gauge

9. Low oil pressure indicator

10. Battery charging indicator

11. Seat belt indicator

12. Hazard warning indicator

13. ABS indicator (If fitted)

14. Rear fog lamp indicator

15. Air filter service indicator

16. Glow plug indicator

17. Air pressure gauge (II)

18. Air pressure gauge (I)

19. Exhaust brake isolator switch

20. Front fog lamp switch

21. Blank

22. ABS switch (If fitted)

23. Head lamp leveling knob

24 . Blank

25. Rear fog lamp switch

26. Engine compartment lampswitch

Instrument panel

1

2

4

5

3

6 7 8

910 11

12 13

14 15

1617

1819 20 21 22 23 24 25 26

44

Air pressure gauges

Two air pressure gauges have beenprovided, one each for front and rearbrake circuits. Vehicle should not bedriven till a minimum air pressure of5.6 bar is reached in both air tanks.Regulated cut out air pressure is7.4 ± 0.2 bar and cut in pressure is6.2 bar min.

2.4 Switches, gauges & indicators Know Your Vehicle

Fuel gauge

Fuel gauge indicates the level offuel in tank. It is electrically operated.Fuel level is indicated on gaugethrough a sensing unit mounted onfuel tank.

Speedometer

It indicates vehicle speed in kmphand also the distance covered byvehicle in km. This is driven by aflexible shaft connected to theoutput shaft of gear box. High beamindicator is also provided onspeedometer dial.

Coolant temperature gauge

Temperature gauge indicates coolanttemperature. It senses coolanttemperature through a transducermounted on upper cooling line.When gauge needle touches redband on dial it indicates engine overheating.

If overheating is observed & coolantlevel in auxiliary tank found to below, stop engine and allow it to cooldown. Top up coolant water mixturein 1:1 ratio through auxiliary tankfiller neck.

Cylinder head may crack, if coolantmixture is topped up when engineis hot.

Air pressure gauge

Speedometer

Fuel gauge

Coolant temperature gauge

45

SERV indicator

When it glows, it indicates that theAir cleaner filter is choked. Filterneeds to be cleaned/ replaced.When the ignition key is in ONposition, before starting the enginethis indicator should glow

GLOW indicator

This indicator is used to indicate thefunctioning of Flame start system.When the ignition key is in ONposition, before starting the engine,if the engine coolant temperature isless than 20OC, wait to crank till theindicator glow continuously andproceed to crank the engine oncethe indicator start blinking. If theengine coolant temperature is morethan 20OC, the indicator blinkscontinuously i.e. ready to start.

Front fog lamp indicatorThis indicator will glow only whenFront fog lamp is switched on.


Rear fog lamp indicator

This indicator will glow when rear foglamp is switched ON.

Low air pressure indicator (Red)

Two low pressure (LP) switches oneeach for front & rear brake circuits areconnected at dual brake valve. Whenpressure in any one or both thecircuits is less than specified value,these switches activate low airpressure indicator.

Low air pressure indicator

Rear fog lamp indicator

SERV indicator

GLOW indicator

Front fog lamp indicator

46

High beam indicator

When it glows, it indicates that thehead lights high beams are on. It isprovided in speedometer dial.

Parking brake indicator

This indicator comes ON whenparking brake is applied and goesOFF when it is released. It will alsoglow when air pressure in parkingbrake circuit is less than 4.6 bar.


Battery charging indicator

When it glows, it indicates thatbattery is not getting charged, i.e.during idling or when alternator isdefective with normal enginerunning. When ignition key is in ONposition, before starting the enginethis indicator should glow.

Low oil pressure indicator

This indicator glows when ignitionkey is in ON position before startingengine. It should go off after startingthe engine, when oil pressure builds up.

If indicator continues to glow evenafter the engine has started, stopthe engine, trace out the fault inlubrication system / electricalconnections and rectify.

Side indicators

Side indicator with arrow pointingtowards left will glow, when combilever is moved for LH indication.Similarly side indicator with arrowpointing towards right will glow, whencombi lever is moved for RH indication.

High beam indicator

Parking brake indicator

Low oil pressure indicator

Battery charging indicator

Side indicators

47


Exhaust brake indicator

This indicator comes ON whenexhaust brake is in operation

Hazard warning indicator

It comes 'ON' when hazard warninglights are switched 'ON' to warn theother road users about thehazardous condition of vehicle.

Glow plug indicator (Amber)

It glows when the ignition key isturned to position ‘ON’ and after a fewseconds it goes ‘OFF’ indicating thatengine can be started.

If glow plug indicator light does notgo off automatically, get it checked.

ABS Indicators (if fitted)

ABS indicator light on instrumentcluster illuminates approx. for 5 sec.when the ignition key is turned to‘ON’ position. This is normal andindicates the system is performing aself check. If the light does notilluminate when ignition is ‘ON’ orremains illuminated after initial selfcheck and while driving or flashes,fault may exist in the ABS system.

In this case also the normal brakingsystem is still effective and can ableto provide normal stopping ability.

In this condition it is recommendedto taking your vehicle to the nearestDealer / service outlet and get yourvehicle attended as soon as possibleif the warning light stays on.

Exhaust brake indicator

ABS indicator

Glow plug indicator

Hazard warning indicator

48

Exhaust brake isolator switch

Exhaust brake can be madeinoperative, by exhaust brakeisolator switch, whenever required.

Engine compartment switch

Provided to switch ON the bulblocated in engine compartment forinspection purpose.

Front fog lamp switch:

This switch is provided to switch onFront fog lamps. Front fog lamps areoperative only when the park lampsare switched ON.


Head lamp levelling switchA motorized head lamp levellingarrangement with the setting knob isprovided near the instrument panel.

This switch has 4 positions viz. 0, 1, 2and 3. Appropriate levelling positioncan be set depending on the load.

Seat belt indicator

It comes ‘ON’ when seat belt is notfasten or belt tongue is not locked into buckle.

Exhaust brake isolator switch

Engine compartment switch

Head lamp leveling knob

Seat belt indicator

Front fog lamp switch

49


Rear fog lamp switch:

This switch is provided to switch onRear fog lamps. Rear fog lamps areoperative only when the park lampsalong with Head lamps (Hi beam/Low beam) or Front fog lamps areswitched ON.

Mechanical stop light switch

A mechanical stop light switch ismounted above brake control lever.Whenever brake pedal is depressedfor applying brakes, stop light switchcomes into operation and lights atrear tail lamp glow. This also activatesengine exhaust brake solenoid valvefor exhaust brake application.

Electric service indicator switchThis switch is provided on air cleaner.Switch contact takes place onlywhen the filter get chocked.

Air dryer heaterThis heater is a part of air dryer assy.This heater is provided to heat themoisture if any in the air brake lines.This heater gets switched ON at 70 Cof air temperature and OFF at 290 Cautomatically.

Rear fog lamp switch

Mechanical stop light switch

Air dryer heater

Electric service indicator switch

50

STEERING LOCK CUM IGNITION SWITCH

Position of key Steering Electricals

Clockwise direction

‘LOCK’ without key Locked All OFF

‘LOCK’ with key Locked All OFF

‘ACC’ with key Unlocked ACC ON

‘ON’ with key Unlocked ACC + IG ON

‘START’ with key Unlocked IG + ST ON

Anti-clockwise direction

’ON’ with key Unlocked ACC + IG ON

‘ACC’ with key Unlocked ACC ON

‘LOCK’ with key Unlocked All off

‘LOCK’ without key Locked All off

(ACC = Accessories)(IG = Ignition)(ST = Start)


Battery cut off switch

Bus chassis is provided with batterycut off switch to isolate battery fromelectrical system when required.

Battery is connected to starter motorand other circuits through isolatorswitch. This is to be switched offwhile carrying out any electrical workon the vehicle and also when vehicleis parked for long duration.

Battery isolator switch

Steering lock cum ignition switch-key positions

51

Steering lock cum ignition switch

It is located on right hand side ofsteering column. It has followingpositions.

‘LOCK’ Position

Key can be inserted or removed inthis position only. Steering wheel getslocked, only when key is removed.

‘ACC’ Position

Steering gets unlocked in thisposition. Only accessories are ON.

‘ON’ Position

By turning the key to position ON, lowoil pressure lamp, battery chargingindicator lamp, parking brakeindicator lamp (if applied), fuel gaugeand temperature gauge are switchedon. Other electrical systems areready for operation. If none of theabove warning indicators /gauges areworking the chances are that thefuse for engine and gauges is blownoff in which case engine will notstart.

‘START’ Position

Turn the key further clockwise to startposition to operate starter motor. Thisis a spring return position.

As soon as the engine starts, releaseignition key so that the key can comeback to ON position and starter motordisengages.


Steering lock cum ignition switch withkey (LHD)

52

Combination switch

Combi switch is mounted onsteering column. It has 2 levers.

One lever is for operating turnsignals, head lamps, parking lampsand number plate lamps. This lever ismounted on RH side on RHD vehiclesand LH side on LHD vehicles.

Head lights

Position 1 - Low beam

Position 2 - High beam

Position 3 - High beam (flash)

Turn signals

Position 4 - Turn signal right

Position 5 - Turn signal left

Self cancellation turn signalarrangement is provided. When turnsignal option is used, this lever willreturn to neutral position on its ownwhen steering wheel is brought backto straight ahead position.


Combination switch

POSITION FOR WASH-ON

POSITION FOR FLASH

(HIGH BEAM)

N

POSITION FOR LOW

BEAM

POSITION FOR

HIGH BEAM

POSITION FOR LEFT

HAZARD WARNING SWITCH

POSITION FOR RIGHT

HI

LO

INT

OFF

Combination switch (LHD)

1

2 5

34

53


Lights

Lights are operated by turning theknob of this lever as indicated below

First notch (PL position)

Parking lights, instrument panellights, number plate lights, controlbacklights and top marker lights areswitched ‘ON’.

Second notch (HL position)

In addition to parking, instrumentpanel, control backlights, numberplate lights and top marker lights,headlights are also switched ON.

OFF-position

All lights are switched off in thisposition.

Note :

High beam flash (No. 3 position)

High beam will be ‘ON’ as long aslever is held in position '3'irrespective of the knob position. Thisis spring loaded position and can beused in day time for giving signal toon coming traffic.

Hazard warning switch

Combi switch assembly also has aswitch for operating hazard warningdevice.

To switch ON hazard warning, pullthe knob located behind steeringwheel. All turn signals lights will flashsimultaneously to warn other roadusers about the hazardous conditionof vehicle.

Push back this knob to originalposition when hazard warningrequirement is over.

Light switch

OFF OFF POSITION

'PL' POSITION

'HL' POSITION

Hazard warning switch

ON

OFF

54


Windshield wiper and washer

The lever on other side is foroperating windshield wiper andwasher. This lever is located on LHside on RHD vehicle and RH side inLHD vehicle.

Position

‘OFF’ - Wiper motor

switched ‘OFF’

‘INT’ - Wiper sweeps

intermittently

‘LO’ - Low speed of

wiper motor

‘HI’ - High speed of

wiper motor

To operate windshield washer, lift thelever. Windshield washer will remainin operation as long as the lever isheld in this position.

When wind shield washer isactuated, wipers are also switchedon. Wind shield washer waterreservoir is accessible after openingcentre flap. Top up reservoir withclean water regularly. Do not usesoap solution. In cold climates, Usemethanol and water in the ratio50:50 to avoid water freezing. Pleaserefer chapter no. 6.3 for details ofrecommended antifrost and ratio forvarying ambient temperatures.

Do not operate windshield washermore than ten seconds at a time.

Wiper motor operating lever (LHD)

HI

POSITION FOR WASH-ON

LO

INT

OFF

Use methanol and water in the ratio50:50 to avoid water freezing.

Windshield washer water reservoir

55

2.5 Driving controls Know Your Vehicle

Hand brake (parking brake)

Hand brake is integral with springbrake actuator on rear axle. Springbrake chamber piston ram actsdirectly on push rod assembly ofbrake chamber.

A. Brake applied

B. Brake released

A to B Gradual application.

1. Accelerator pedal2. Brake pedal3. Clutch pedal4. Parking brake5. Gear shift lever

Hand brake valve

B

A

6. Steering wheel7. Combiswitch lever (Lights)8. Instrument panel9. Steering lock cum ignition switch10. Combiswitch lever ( Wiper/

washer)

Driving controls LHD

678

5

4

1

2

3

10

9

56

2.5 Driving controls Know Your Vehicle

KSB unit (for Euro II vehicles)

KSB unit is a cold start throttleadvance mechanism. It is an integralpart of fuel injection pump.

KSB unit

- Provides necessary advance inlower throttle operation duringcold condition.

- Allows a normal dynamic timingduring regular operation.

- Reduces white smoke, misfiringin cold start and part throttleoperation.

During normal running of engine,24 V supply continues to KSB unitthrough thermo switch.

Opening/closing of front centreflap

For opening centre flap, a lever asshown has been provided. For LHDvehicles it is located on LH sideabove clutch pedal. To open centreflap, pull this lever and lift centre flap.

A stay rod has been provided to keepcentre flap open position. To closecentre flap, remove stay rod. Slowlydrop centre flap and press it down tomake sure that it is locked.

KSB unit

Pull to open the bonnet - LHD

57

2.6 Turbocharger Know Your Vehicle

Turbocharger (Euro II)

Lubrication of the turbocharger

Rotor assembly of turbocharger issupported by two floating leadbronze sleeve bearings in thebearing housing. These bearings arelubricated with finest filtered andcooled oil from lubrication system.There is a heat shield arrangementprovided between turbine housingand bearing housing to avoid heatingof the bearings.

Advantages of turbocharger

Turbocharged engine has followingadvantages over naturally aspiratedengine of same size and weight.

1. Increased power is obtained withthe same engine dimensionsthereby increasing the power toweight ratio. Thus, the engine islighter and payload value of thevehicle is improved.

2. A turbocharged engine has alower specific fuel consumption,so the vehicle consumes less fuel.

3. Turbocharger reduces blacksmoke in the exhaust.

4. Loss of engine power at higheraltitudes is much less making itideal under all operatingconditions. Especially in hillyareas, payload capacity is furtherimproved by this aspect.

5. Turbocharger acts as an additionalsilencer on exhaust side, thusreducing engine noise.

Maintenance of turbocharger

No adjustments or repairs are to becarried out on the turbocharger. Incase of doubtful performance from

the engine because ofmalfunctioning of turbocharger, takeyour vehicle to Tata authorised workshop.

Following precautionary measuresshould be taken to obtain troublefree performance.

1. During regular engine inspection,look carefully for any oil leakageat the oil inlet banjo connectionon bearing housing. Do not runengine unless leakage at thispoint is rectified.

2. Do not stop the engine suddenlyas it may damage rotor bearings.Allow engine to idle for atleast3 minutes before switching it off.Similarly, do not increase enginespeed suddenly.

Run the engine at low idle speedfor atleast 3 minutes after startingto build up oil pressure beforeincreasing engine speed.

3. Since the speed of rotor assemblyis tremendously high, (nearly1,00,000 rpm) it requires finestfiltered oil. Therefore, ensurecleanliness of engine oil byadhering to regular schedules ofengine oil and oil filter cartridgechange intervals.

4. As the unfiltered dust particlesentering compressor housingmay prove dangerous, make surethat there is no leakage in airintake system and that air filterelements are in good conditionand sealings are perfect.

5. Insist on use of onlyrecommended grade of engineoil, genuine engine oil filter andair filter cartridges.

58

2.7 Charge air cooler Know Your Vehicle

Charge air cooler (Euro II)

Advantages of charge air cooler

Hot air coming out of turbo chargerflows through charge air cooler andgets cooled before entering intakemanifold, thus increasing density ofintake air for better combustion.

Charge air cooler is mounted in frontof radiator.

Charge air cooler

-TURBOCHARGEREXHAUST INLET

59

Clutch BoosterHydraulic clutch actuation systemwith pneumatically operated clutchbooster has been provided toreduce clutch pedal effort.In thissystem, clutch booster replaces thefunction of clutch slave cylinder.Compressed air connection tooperate clutch booster has beentapped from port No. 24 of systemprotection valve.Output rod of clutch booster isconnected to clutch release fork.When there is no force on clutchpedal, push rod (5), pistons (3 & 4)are in stand still position due to theforce exerted by return springs (6 &8).When pedal is pressed to disengageclutch, clutch fluid under pressureenters throught port no. 4 and actson piston (3). due to this piston (3)moves leftwards.At the same time fluid underpressure acts on controlling piston(2) due to which piston (2) movesleftwards to close air outlet and toopen air inlet (1) compressed air

Port 1. Inlet port (forcompressed air)Port 3. Vent (forcompressed air) Port 4.Control port (for clutchfluid)2. Piston3. Piston4. Piston5. Push rod6. Return spring7. Wind pipe8. Return springA.B. CavityC.D. Cavity

flows into air cylinder via wind pipe(7).Piston (4) moves leftwards andexert force on piston (3) which inturn pushes output rod to actuatepush rod (5). The force on piston (4& 3) is proportional to the pressureexerted by clutch fluid on piston (2).When pedal is released to engageclutch, clutch fluid pressure dropsto zero. By the action of returnspring (8) and air pressure at cavityB, piston (2) moves rightwards toclose air inlet and to open airoutlet. Compressed air in cavity Dis exhausted to atmosphere. Returnsprings (6 & 8) bring back pistons(2 & 4) to stand still position andhence push rod (5) retracts to itsoriginal position.Technical DataOperating pressure : Clutch fluid 4Mpa, compressed air 0.8 MpaMax. pressure : Clutch fluid 12 Mpa,compressed air 1 MpaOperating Temp. range -40OC to+80OC.

1A 8 B3

C 2 7

10

5 34

6 4

D

2.8 Clutch booster Know Your Vehicle

60

1. Cam lever handle2. Cam lever3. Primary locking lever handle4. Primary locking lever5. Secondary locking lever6. Connecting link - LH7. Connecting link - RH

8. Cab mounting mechanism9. Mounting pin10. Mounting hook11. Rubber pad12. Torsion bar13. Cab stay14. Releasing lever

12

13

14

RELEASED AND TILTED POSITION

2.9 Cab tilting Know Your Vehicle

Cab tilting and locking lever arrangement

3 68 7 9

4

2

1

510 11

RELEASED POSITION BEFORE TILTING

61


Cab Tilting

Truck version of 613 vehicle isprovided with tilt cab. For tilting thecab proceed as follows :

To raise the cab

1. Park vehicle on level ground instraight ahead condition andapply parking brake.

2(A) Put the gear shifting lever insecond gear. (sketch positionNo. (2))

Note : Remove or secure all looseitems in the vehicles. Close all thedoors.

2(B) Remove padlock or bolt and nutfrom primary locking lever.(sketch position No. (3))

3

2

Hand brake valve

B

A

1

62


4

6

3. Hold primary locking lever ad pullcam lever handle to releaseprimary locking lever fromlocked condition. (sketch positionNo. (4))

4. Raise primary locking leverhandle to horizontal positions.Mounting pins of cab mountingmechanism get released frommounting hooks. (sketch positionNo. (5))

5. Pull secondary locking lever torelease it from locking conditionand hold. Slightly raise cab toclear secondary locking leverfrom it’s hook. (sketch positionNo. (6))

6. Raise cab to maximum position.At this position cab stay locksautomatically. Cab is retainedsafely in max. titled condition bythe stay. Torsion bar assists in easytilting of cab.

5

63


To lower the cab

1. Holding cab, press cab stayreleasing lever and slightly lowercab. Linkage gets released fromstraight position. (sketch positionNo. (7))

2. Lower cab till cab gets seated onrubber pads. Secondary lockslever gets automatically locked inits hook. (sketch position No. (8))

3. Push down primary locking levertill it locks on the cam lever.(sketch position No. (9))

9

8

7

64


104. After locking, make sure that the

cab is fully secured with themounting hooks. (sketch positionNo. (10))

5. Fit back padlock or bolt and nuton primary locking lever.(sketch position No. (11) & (12))

12

11

65

Slot - 'B' Air Distribution Control

Air directed towards chestand legs

Air directed towards legs,chest and windscreen

Air directed towards legs andwindscreen

2.10 Heating Know Your Vehicle

Demist : Switch-off heater. Direct airflow towards windscreen for arequired period.

Defrost : Switch-on heater. Direct airflow towards windscreen for arequired period.

Slot - 'C' - Closing and opening of legvent

- Leg vent closed

- Leg vent open

Heating control (Optional)

Heating system is provided forcomfortable driving. Heating systemcan be operated as per need.

The cab heat can be regulated bycontrolling air flow rate of theblower.

Three knobs A, B, C as given beloware used to operate the system.

Slot - 'A' Blower Regulator

Blower off

Blower slow speed

Blower medium speed

Blower high speed

Note : Though slot B is shown for airat leg, slot ‘C’ to decide leg will beopen or close.

Heating control

Slot C Slot C

Slot A Slot B

66

2.11 Driver seat & seat belt Know Your Vehicle

** Precautions

Cab heating system - operates usingengine hot coolant. Hence, if enginecoolant temperature overshootsspecified limit, shut off the engineand rectify the fault.

** Do not leave the vehicle keepingheater and engine in runningmode as it may cause extensiveheating inside the cab. There isno thermostatic control in the cabheating system to shut-offengine, blower and heater.

Maintenance

1. Check hoses joints for leakage.Tighten, if necessary.

2. Check hoses for cracks. Replace,if required. If there is a loss ofcoolant, replenish coolantmixture in auxiliary tank.

3. If blower is not working, checkfuse, if blown, replace.

Driver seat adjustment

Lever 1 : Lever for adjusting backrest.

Lever 2 : Lever for adjusting seatheight at rear.

Lever 3 : Lever for horizontalmovement of seat.

Lever 4 : Lever for adjusting seatheight at front.

Note : Please ensure that the seat islocked after making necessaryadjustments.

Driver seat adjustment

1

23

4

67

2.11 Driver seat & seat belt Know Your Vehicle

Seat belt arrangement

1. Anchor 2. Webbing 3. Tongue 4. Buckle 5. Release button

Seat belt

On truck versions three point belt fordriver/co-driver and lap belt forpassenger sitting in middle provided.

On bus versions, three point belt fordriver seat is provided.

Fastening the belt

Insert belt tongue into buckle. Apositive locking ‘click’ indicatescorrect assembly.

Releasing the belt

Press the release button. The tonguewill be ejected clear of the lockingmechanism within the buckle.

Belt adjustment

When the vehicle is at rest, adjustlength of the belt to suitconvenience and observe that thebelt is locked.

Lap belt (middle passenger)

Adjust length of belt in the tongueto suit convenience. Insert belttongue in buckle. A positive clickindicates correct assembly. To release,press the release button. The tonguewill be ejected from the buckle.

Precautions :

● The belt is designed for use ofonly one person.

● It is not intended for childrenbelow 10 years.

● Avoid twisting the strap.

● Webbing must not be allowed tochafe against sharp edges.

● Do not make any alterations.

● Belts that have been cut, frayed,damaged or have been stressedthrough impact, should bereplaced.

● After vehicle collision if any, beltanchorage points should bechecked.

● An occasional wipe with warmsoapy water will maintain thewebbing in a clean condition. Donot bleach or dye.

● Periodic inspection of the seatbelts will ensure safe and reliableservice.

● Before moving the vehicleensure that belt is properlylocked and beeper is off. (wherefitted).

3

5

4

1

2

3

4

LHD

69

3. Driving

3.1 Starting the engine, .......................................................... 71

3.2 Driving ................................................................................... 72

3.3 Stopping the engine ........................................................ 75

3.4 Special operating conditions ....................................... 76

3.5 Fuel economy ..................................................................... 78

3.6 Do it yourself ....................................................................... 79

71

1. Ensure that parking brake isapplied.

2. Move gear shift lever to neutralposition.

3. Insert ignition key in steeringlock cum ignition switch.Steering wheel will be in lockedcondition. Turn the key to “ACC”position. Steering wheel getsunlocked, and accessories will beON.

4. Turn the key further to ONposition. Lamp of batterycharging indicator, low oilpressure will come on.

5. Do not press the acceleratorpedal. Turn the key furtherclockwise to “START” position(spring loaded) to operate startermotor. As soon as engine starts,release ignition key so that keycan come back to ON positionand starter motor disengages.

6. If engine misfires and stops, waitfor 2 minutes before operatingstarter motor once again. Thispractice should be strictlyadhered to, otherwise it willdamage starter motor.

7. Once engine starts, lamps ofbattery charging indicator andlow oil pressure should go off.

8. Allow engine to warm up - untilcooling system temperaturereaches at least 40o C.

9. Release parking brake.

10. Now the vehicle is ready tomove.

3.1 Starting the engine Driving

Steering lock cum ignition switch-keypositions

Steering lock cum ignition key

72

1st to 2nd 12 12

2nd to 3rd 23 23

3rd to 4th 37 40

4th to 5th 62 67

Gear

Speed in kmph

StandardGearbox

OptionalGearbox

Driving, Gear shifting, Breaking

DRIVE SAFELY AND JUDICIOUSLYRemember SAFETY FIRST.

Do not keep driving till you areovercome by fatigue. The reflexes ofa tired driver are not as they shouldbe.

1. Before you drive, ensure thatvehicle is in a road-worthycondition. Especially checksteering system, tyres, brakes,clutch etc.

2. Release parking brake.

3. Depress clutch pedal fullybefore shifting gears. Forsmooth starting of vehiclewithout jerks, synchroniserelease of clutch pedal withpressing of accelerator pedal.

4. Gear Shifting

Vehicle should be started infirst gear only.

Engaging position for variousgears are shown on gear knob.Change gears at appropriatespeed and do not lug theengine by too early high gearchanges at low speed.

Reverse gear should only beengaged when vehicle has beenbrought to a complete stop.

Approximate speeds for gearchange.

5. While driving, left foot must notrest on clutch pedal. This causesabnormal wear of clutch liningsdue to clutch slippage.

6. Slowing down the vehicleshould be achieved by changingdown to lower gears.

7. Maintain a steady speed, avoidquick acceleration and suddenbraking. High speed driving savesyou a little time but increasesfuel and oil consumption. It alsocauses faster tyre wear.

3.2 Driving Driving

Gear lever knob

42R

1 3 5

73

3.2 Driving Driving

We, therefore, recommended todrive in fifth gear at a steady speedof about 70 kmph. Optimum fuelconsumption is achieved at thisspeed

CAUTION DURING RUNNING INPERIOD

During first 2,000 km. observefollowing speed and load limits.

Speed

Not more than 70 kmph in top gearand correspondingly lesser in lowergears.

Load

Gross vehicle weight should notexceed 2/3 of max. recommendedgross vehicle weight.

Brakes

Avoid panic braking during first500 kms. Drive in lower gears whennegotiating steep down gradient,thus avoiding excessive braking andbrake drum over heating.

8. Application of brakes

Brake application should begradual to avoid fast wear ofbrake linings, brake drums andtyres. Brake should not beapplied too violently on aslippery road, since the vehiclemay then start skidding.

When driving down a long steepgradient, reduce vehicle speedby shifting to lower gear.Engine will provide a braking

effect. Do not ride brakes. Thiswill lead to over heating of brakedrums and linings resulting inlow brake efficiency.

9. Parking the vehicle

Apply parking brake. Keepengine in low idling speed atleast for three minutes (Turbocharged engine). Switch offengine. Remove key fromsteering lock cum ignitionswitch. While parking on slopes,place wheel chokes to preventvehicle rolling. Engage forwardgear if it is likely to roll in thereverse direction or vice versa.

74

Hand brake system


Engine exhaust brake

Exhaust brake operation is coupledwith service brake. Whenever brakepedal is depressed for applyingbrakes, exhaust brake also getsapplied and indicator lamp (E) comesON instrument panel.

Stop light switch provides signals bothfor rear tail lamps as well as forexhaust brake solenoid valve.

Solenoid valve opens, allowingcompressed air to flow to exhaustbrake air cylinder, thus operatingexhaust brake butterfly valve.

Since exhaust opening is restricted,road wheels will drive engine, whichwill act as a compressor (resistor),thus retarding vehicle speed.

Use of engine exhaust brake resultsin increased life of brake linings,brake drums & tyres.

Isolator switch (Exhaust brake)

In certain situations like starting ofvehicle on an upgradient,simultaneous acceleration and partialbraking of vehicle are required.Isolator switch can be used to cut offair supply to exhaust brake aircylinder, by putting it in off(disengaged) position. Isolator switchshould be put ON (engaged), as soonas isolation requirement is over.

3.2 Driving Driving

Hand brake valve

A. Brake released

B. Brake applied

A to B Gradual application

75

3.3 Stopping the engine Driving

Operating instructions

1. Ensure air pressure in the systemis above 5 bar.

2. Change to lower gearappropriate to road conditions.Exhaust brake is very effectivebelow 40 kmph speed.

3. Do not depress clutch as thiswould render exhaust brakeineffective.

4. Press brake pedal fully whenvehicle is to be brought to astop.

Lubricating exhaust brakelinkages

1. Every 9,000 km. a few drops ofoil should be applied to ball pinsof outer linkages and frictionsurface.

2. Butterfly valve shaft, which ismade of heat resistant material,should not be lubricated,since the lube oil would causeseizing of the butterfly valve inits housing.

Stopping the engine

After parking the vehicle in safeplace.

1. Release accelerator pedal.

2. Move gear shift lever to neutralposition.

3. Apply parking brake.

4. Turn ignition key to ACCposition. A timer will switch onfuel stop solenoid for about 5seconds which operates fuel

shut off valve and fuel supply iscut off. Engine will stop. This shutoff timer is aborted in case youturn ignition key again to ONposition within 5 seconds.

5. Turn the key to “lock” position.

6. Take out key from steering lockcum ignition switch. Slightly turnsteering wheel clockwise or anticlockwise (max. 180o), till clicksound is heard, to make sure thatsteering wheel is locked.

76

3.4 Special operating conditions Driving

Flame start system (BERU):

Flame start system is provided forconvenient starting at coldconditions by heating the intake airby means of burning the diesel in airintake manifold.

● Pre-glow time of just 20~45seconds

● Trouble-free starting even atlow temperatures

● Post glow (after starting theengine) time of up to 3 minutes

The flame start control unit controlsthe supply of current to the indicatorlight, flame glow plugs and solenoidvalve. It evaluates the signals fromstarter motor in Ignition ON positionvia Temperature transducer (BERU)in alternator running condition.

The pre-glow phase commenceswhen the ignition is switched on attemperature below the system stoptemperature.

The indicator light comes on steadyand power is fed to flame glow plug.

Once the pre – glow time has passedthe indicator lights starts to flash. Thisindicates to the operator that theengine can be started. Powercontinues to be supplied to theflame glow plugs. If the engine is notstarted during this period, the flamestart control unit switches off theflame glow plugs and the indicatorlight.

If the vehicle is started during readyto start period, then the flame startcontrol unit activates the solenoidvalve. The fuel then flows throughthe open solenoid valve, across the

BERU heater controller

Temperature transducer

Flame glow plug

77

hot heater rod of the flame glowplug, evaporates and ignites.

The post heating operation beginsonce the start procedure has ended.The duration is determined by theengine temperature (coolant water)when the post heating commences.Power continues to be supplied tothe flame glow plugs, the solenoidvalve remain open and indicator lightgoes off.

If the start procedure is unsuccessful,then the solenoid valve and flameglow plugs are shut off, the ignitionmust be switched off beforeattempting to restart. Wheretemperature exceeds the systemstop temperature, the indicator lightimmediately starts flashing toindicate start ready, after the ignitionhas been switched on.

No power is supplied to the flameglow plug and the solenoid valve.

3.4 Special operating conditions Driving

78

3.5 Fuel economy Driving

Fuel Economy

a. Drive smoothly, accelerategradually, avoid harshacceleration.

b. Best fuel consumption isobtained at low engine speedsin the highest possible gearwithout labouring the engine.

c. Driving with accelerator pedalfully depressed means usingexcessive fuel.

d. Do not allow the engine tolabour by too early high gearchanges. Change to lower gearwhen engine no longer runssmoothly.

e. Switch ‘OFF’ engine whenstopping for long duration oftime.

f. Do not ride clutch. Do notuse clutch pedal as foot rest.

g. Do not allow leakage or spillageof diesel.

h. Always drive in correct gears.

i. Do not over load the vehicle.

j. Maintain correct tyre pressure.

k. Always keep vehicle and enginein good condition.

Operation in hilly terrains

In hilly terrain and where theatmosphere is very humid, followingprecautions should be taken.

Ensure that steering linkages andbrakes are in order and proper gearsare used during climbing and

descending. Make maximum use ofexhaust brake while descending.With a little pressing of brake pedal,exhaust brake first comes into action.This will relieve driver of fatigue andwill increase the life of tyres, brakelinings and brake drums.

Note :

Diesel and clutch fluid, both beinghygroscopic, absorb moisture fromatmosphere.

● Drain air tanks every day toremove water.

● Drain water from fuel waterseparator.

● Vehicle should be greased everyday to prevent formation of ruston the exposed movingsurfaces. Servicing andmaintenance should be done asspecified.

● Use same gear selection whileascending and descending thesame slope.

Caution : Operating engine beyondhigh idle speed can cause severeengine damage. When descending asteep gradient, use a combination oftransmission gears and exhaustbrake or service brake to controlvehicle and engine speed.

● Use lower gears and brakecautiously on wet and slipperyroads.

81

4. Maintenance Procedure

4.1 Air intake system ........................................................... 83

4.2 Fuel system ...................................................................... 85

4.3 Lubrication system ........................................................ 87

4.4 Cooling system. .............................................................. 89

4.5 Clutch ................................................................................ 92

4.6 Gearbox ............................................................................. 94

4.7 Propeller shaft ................................................................ 95

4.8 Front axle & rear axle .................................................... 96

4.9 Power steering ............................................................... 97

4.10 Brake system ................................................................ 101

4.11 Springs ............................................................................ 114

4.12 Centre flap .................................................................... 115

4.13 Tilt cab ............................................................................ 116

4.14 Wheels and tyres ........................................................ 117

4.15 Electricals ....................................................................... 121

4.16 Preservative treatment ............................................. 128

4.17 Care and cleaning ...................................................... 131

83

4.1 Air intake system Maintenance

Maintenance of dry type air filter(Vehicle with Euro II engine)

Dry type air filter with an inbuiltcyclonic vane type pre-cleaner isfitted. For vehicles operating undernormal conditions evacuator valve(of air filter) is required to bechecked once every 2,000 km. Thisshould be done more often, ifvehicle operates in dusty conditions,viz. off highway operation, miningareas, construction sites, etc.

While reassembling, care must betaken to ensure that evacuator valveis assembled in the bottom mostposition and slit opening is pointingtowards ground.

When service indicator glows, oninstrument panel. Clean air filterhousing and primary cartridge.

Replacement of air filter primarycartridge

a) Remove cover of air filter.

b) Remove primary cartridge(element).

c) Clean air filter housing, air ducts.

d) Replace old primary cartridge bynew one.

e) Fit the cover. On starting theengine, if service indicator on theinstrument cluster continues toblink take your vehicle to nearestTata authorised workshop.

f ) Do not clean secondarycartridge. Replace it after threechanges of primary cartridge orafter 2 years, whichever is earlier.

Schematic details of dry type air filter

Secondary cartridge

Slit for dustseparation Primary

cartridge

Atmospheric airfrom intake duct

Air toturbocharger

Dust bowl Plastic cover Cyclonic pre-cleaner

Electricservice

indicator

84

Charge air cooler (CAC)(with Euro II engine)

Inspection

If engine experiences a turbochargerfailure or any other occasion whereoil or debris has entered into CAC,the CAC must be cleaned.

Remove CAC from vehicle.

Visually inspect CAC for cracks, holesand damage.

Inspect tubes, fins and welds for tear,breakage or other damage.

Cleaning

Flush CAC internally first withtrichloro ethane (solvent) in theopposite direction of normal air flow.Shake the CAC and lightly tap on theend tanks with a rubber mallet todislodge trapped debris.

Caution : Do not use causticcleaners to clean CAC. Damage toCAC will result.

After the CAC has been thoroughlycleaned of all oil and debris withsolvent, wash CAC internally withindustrial soap solution to removeremaining solvent. Rinse thoroughlywith clean water.

Blow compressed air into the CAC inthe opposite direction of normal airflow until the CAC is dry internally.

4.1 Air intake system Maintenance

Charge air cooler

Cleaning with hot water/compress air

Cleaning with solvent

Charge air cooler

85

4.2 Fuel system Maintenance

Fuel filter change

1. Remove filter bowls byremoving two bolts given onfilter cover.

2. Clean the bowls.

3. Fit new elements in bowls

a) Felt type element in primaryfilter bowl.

b) Coil type micro element insecondary filter bowl.

4. Replace O - rings on filter cover.

5. Assemble primary & secondaryfilter bowls to the cover. Tightenbolts to 2 mkg torque.

6. Fill diesel in filter bowls byoperating feed pump primer.

7. Bleed fuel system and startengine.

Fuel water separator cumprimer:- It is fitted in between fuel tank andFIP.It separates water particles in fuel.Fuel passes over funnel like cone inwater separator and water beingheavier than fuel, so water getscollected at the bottom of thebowl.To remove water from the bowlloose the primer then loose thedrain plug ,Water starts dropping from drainplug.Once water is completely drainedfrom the water separator. Tightenthe drain plug and primer.It is recommended that water in theseparator be drained at least oncea week.

1. Bleeding screw on banjo bolt

2. Drain plugs

1

2

Fuel water separator cum primer

86

If performance of engine is affecteddue to presence of air in fuel system(commonly known as air lock), it canbe rectified by bleeding fuel system.

Fuel system bleeding

1. Ensure no leakage in fuel line.

2. Bleeding air in fuel line upto filter

- Loosen outlet banjo of fuelfilter.

- Prime the circuit by usinghand primer.

- Tighten banjo aftercompletely bleeding air.

3. Bleeding air after FIP

- Loosen overflow banjo on FIP.This ensures FIP is filled withfuel.

- Prime the circuit by usinghand primer.

- Tighten overflow banjo aftercompletely bleeding air.

4. Crank engine for few seconds. Ifengine still does not startproceed to next step.

5. Remove cylinder head cover &loosen high pressure line capnuts of all cylinders.

6. Crank engine till fuel coming outof high pressure lines is freefrom air. Tighten high pressureline cap nuts.

7. Start the engine.

4.2 Fuel system Maintenance

87

4.3 Lubrication system Maintenance

Changing engine oil / oil filter

Engine oil should be drained while itis still hot.

a. Unscrew sump drain plug andallow oil to drain out for20 minutes.

b. Unscrew drain plug of oil filter,drain out oil and refit drain plug.

c. Unscrew centre bolt andremove oil filter bowl, cleancentre bolt.

d. Clean the bowl thoroughly andreplace with a new genuinefilter cartridge.

e. Remove old ‘O’ ring in cover andinstall a new O’ ring.

f. During reassembly, first fill filterbowl with 1 litre of engine oiland thereafter reassemble filterbowl on top cover. Pour another1.5 litres of engine oil throughthe filler plug opening in thecover & then tighten filler plugwith a new sealing washer.

This is done to ensure that oilimmediately flows to bearingsand attains correct pressure,when engine is started. If thisinstruction is ignored, bearingsmay get damaged.

Oil filter must be kept clean toprotect engine componentsfrom rapid wear due to abrasion.

g. Oil filter centre bolt should betightened to 4 mkg torque.

Oil filter cartridge

Full flow engine oil filter assembly

1. Drain plug engine oil sump

2. Drain plug oil filter

3. Filler plug oil filter

12

3

88

4.3 Lubrication system Maintenance

h. Clean the drain plug of oil sumpand refit with a new sealingwasher, if necessary. Tightendrain plug to 4 to 6 mkg torque.

i. Fill in recommended quantity ofengine oil in sump.

j. Start engine and allow it to run fora few minutes and stop the engine.

k. After 20 minutes, check level ofoil on dipstick. It should be atupper mark. If not, top-up. Whenchecking oil level, vehicle shouldbe parked on level ground.

CAUTION

Make sure that only genuine oil filtercartridge is used.

i. Do not use filter with inferiorfiltering material which cannotproperly filter the engine oil.

ii. Do not use filter with improperdimensions which cannotprevent filtered oil gettingmixed with unfiltered oil.

Since it is extremely difficult todistinguish between genuine andnon-genuine filter cartridges, obtainthese only from Tata authorisedworkshop.

Discard used oil filter cartridge.

Filter cartridge should not becleaned or reused.

Change Engine Oil after every18000 kms or earlier depending onthe type of operation.

Use only recommended engine oilconforming to SAE 0W-40 APICH4 &MB228.3 specifications.

Engine oil dipstick

A. Minimum level

B. Maximum level

Engine oil dip stick

A

B

89

4.4 Cooling system Maintenance

Cooling system

A transparent radiator auxiliary tankis fitted between cabin rear wall andload body on LPT 613 vehicles. OnLP 613 this is fitted behind driverseat. Maximum & minimum levelsindicated on the body. It is fittedwith two identical caps withpressure cum vacuum relief valvehaving 0.5 bar pressure setting.Always top up coolant only throughfiller neck. Top cap should not bedisturbed.

Procedure for filling when thesystem is empty.

1. Ensure no water in vent pipes,drain vent pipes while draining/refilling.

2. Fill coolant mixture throughauxiliary tank filler neck.

3. Run engine for a few minutesand top up coolant mixture, ifrequired.

Add recommended coolant towater in ratio 1:1. If coolant startsboiling, it may be on account of :

i. Less coolant or dirt/scale havingaccumulated inside coolantpassages, especially in radiatorcore.

ii. Choking of radiator air passagesdue to foreign material ordamaged radiator fins.

iii. Loss of coolant by evaporationand leakage through defectiveauxiliary tank caps.

iv. Loose water pump drive belt.

v. Coolant leakage.Radiator drain plug

Radiator auxiliary tank filler neck(LPT)

Radiator auxiliary tank filler neck (LP)

90

Always use genuine auxiliary tankcap. A proper cap firmly fittedmaintains pressure in the coolingsystem and makes engine moreefficient by permitting a slightlyhigher operating temperature.Vacuum created in the system isrelieved by a valve provided in thecap. Descale and clean coolingsystem regularly.

Cleaning of cooling system.

This should be done at every80,000 km or every two yearswhichever is earlier.

While cleaning, the system is to betotally drained out. Coolant from ventpipes is to be drained out bydisconnecting these pipes fromauxiliary tank end side.

Fill the system with industrial soapsolution through filler cap in auxiliarytank.

Wait for 2 to 3 minutes to allow airto be vented and add solution tobring the level to the top.

Do not install filler cap.

Operate engine for 5 mins. with theflushing solution temperature above800 C. at maximum engine speed.

Stop engine and drain soap solution.

Fill system with clean water. Be sureto vent the engine for completefilling.

Do not install filler cap.

Again operate the engine for 5 mins.with water temperature above 800 Cat maximum engine speed.

Stop engine and drain water.

If water drained is still dirty, systemmust be flushed again until waterdrained out is clean.

Use a mixture of 50% water and 50%ethylene glycol non-amino baseantifreeze to fill cooling system.

Fill the system slowly to prevent airlocks. During filling air must bevented from the engine and radiator.

Wait for 2 to 3 minutes to allow theair to be vented and then addmixture to bring coolant level to thetop.

Install filler cap. Operate engine untilit reaches a temperature of 800 C, andcheck for coolant leaks.

Wait until the coolant temperaturereaches below 500 C. Check coolantlevel again to make sure the systemis full of coolant.


91


Fan belt tension adjustment

1. Loosen idler pulley flange nuts1, 2 and the tensioner rodmounting nut 3 as shown in thepicture, to release the fan idlerpulley arrangement.

2. Loosen the check nut A androtate adjusting nut B to get thedesired tension of fan belt.Slackness should be approx.20 mm at the centre of fan beltdrive, when checked by thumbpush.

3. Tighten check nut A withoutdisturbing the position ofadjusting nut B..

4. Without disturbing thearrangement, retighten nuts 1, 2& 3 as explained above.

5. Recheck belt tension andconfirm.

Fan belt tension adjustment

1,2. Idler pulley flange nuts

3. Tensioner rod mounting nut

A. Check nut

B . Adjusting nut

A

B

2

1

3

92

Clutch pedal adjustment

Hydraulically operated clutch hasbeen fitted on this vehicle.

Clutch pedal height adjustment isrequired only in case of componentrepairs/overhaul etc. Adjustment isnot required during normalmaintenance.

1. Loosen check nut on clutchmaster cylinder push rod.

2. Adjust the distance of 126 mmbetween master cylinder flangeface and the fork hole centre asshown in the figure.

3. Tighten push rod check nuts ofmaster cylinder withoutdisturbing adjusted length.

4. Adjust clutch pedal free playwith the help of stopper screwas shown in figure. Free play atclutch pedal should be between15 - 20 mm.

5. Operate clutch pedal a fewtimes to ensure desired clutchpedal free play.

6. Apply synthetic grease at allrotary joints.

Clutch pedal height adjustment &free play adjustment is needed to bedone at Tata authorised workshoponly.

4.5 Clutch Maintenance

Clutch pedal stopper screw

Clutch pedal height

A=126mm

Stopper screw

Check nut

M a s t e rcylinder

Clutch pedal

93

Clutch fluid filling and bleeding

Procedure for bleeding the systemgiven below :

i. Remove filler cap and fill theclutch fluid container with freshbrake fluid.

ii. Remove dust cap from slavecylinder bleed screw and cleanit thoroughly. Attach bleed tubeto the bleed screw and placeother end of the tube in a cleanglass jar containing sufficientbrake fluid to submerge the endof tube.

iii. Pump clutch pedal twice/thriceslowly throughout its stroke andby holding the pedal pressed,loosen bleed screw and watchair bubbles in glass jar.

iv. Retighten bleed screw andrepeat the same operation untilair bubbles cease to appearallowing only fluid to flow.

v. Replace dust cap on bleedscrew without fail.

4.5 Clutch Maintenance

3

6

4

5

7

1

82

9

220

mm

app

rox.

Schematic layout of clutch actuationmechanism

1. Clutch Pedal

2. Adjusting pin

3. Clutch release fork

4. Clutch fluid container

5. Clutch master cylinder

6. Clutch slave cylinder

7. Bleeding nipple

8. Master cylinder push rod

9. Clutch pedal stop

Filling clutch fluid

94

4.6 Gearbox Maintenance

Gear box oil checking

Check level of gear box oil. Top up ifnecessary.

Gear box oil change

Drain while hot.Fill the gear box with new oil.Capacity : 5.2 Litres

: 5.8 LitresRecommended oil

Grade SYN gear EP 75 W 90 GL 4 Gulfgrade.

Dimension ALink rod adjustmentEither increasing or decreasing thelength or link rod assembly canadjust dimension A. Loosen lock nutson both sides of connecting tube &adjust the length by turningconnecting tube with the help of DEspanner clockwise / anti clockwise.When desired dimension is achieved,tighten lock nuts on both sides & re-check dimension A. The adjustmentneeds to be carried out in installedcondition of link rod.Dimension BTurning tube adjustmentThis adjustment is to be carried outafter disconnecting ball joint fromgearshift lever. Loosen the lock nutfrom connecting flange & rotate balljoint clockwise /anti clockwise toobtain desired dimension. Tightenthe lock nut. Assemble ball joint nut.Re-check dimension of turning tubeassembly (Dimension B).Link measurement (in mm)Drive A BRHD 330 ± 1.5 1000 ± 2LHD 350 ± 1.5 986 ± 2

Gear box (GBS - 40)1. Oil drain plug2. Oil level plug

Remote gear shifting arrangement

A

B

95

Propeller shaft

Propeller shaft, U-joint cross bearingand sliding yoke should be regularlygreased. Failure to do so may resultin rapid wear and tear of the bearingsand centre bearing mountings.Periodically check and if necessary,tighten mountings of centre bearingbracket to 8 mkg torque.

When disconnecting propeller shaft,care must be taken to ensure thatarrow marks on rear propeller shaftand sliding yoke are aligned duringreassembly. Tighten coupling flangebolts to 7 mkg torque. When fittingpropeller shafts ensure all ‘U’-jointyokes are in one plane. In case ofundue vibrations noticed onpropeller shafts, take necessarycorrective action.

4.7 Propeller shaft Maintenance

U Joint yoke

Propeller shaft centre beaming

96

Rear axle oil level checking

Check level of rear axle oil. Top up ifnecessary.

Rear axle oil change

Drain while hot

Fill the rear axle with new oil.

Capacity : 2.75 litres

Recommended oil

Grade APIGL 5 SAE 85W-140 with7% Anglamol-6043 by weight.

Change rear axle oil first at 9000 km,then at 36,000 km and thereafter atevery 36,000 km.

Check front & rear hub play at every9000 kms & adjust, if necessary.

4.8 Front axle & rear axle Maintenance

Hub grease for front & rear hubs to bechanged at every 36000 kms.

Hub greasing and adjustment

Remove front and rear wheel hubs.Dismantle and clean bearing andother components. Re-pack withbearing grease.

Front hub : 250 gm/ hub

Rear hub : 450 gm / hub

Grade - Multi purpose grease No. 2

Adjust hub bearing play.

Front hub : 0.01 / 0.06 mm

Rear hub : 0.04 / 0.1 mm

Tubular spacer with shims providedin between bearings for front andrear hubs to control hub play.

This operation is needed to be carriedout at Tata authorised workshopsonly.

Front hub

Remove front hub cap, fill with ¾thfull wheel bearing grease and refit atevery 9000 kms.

Rear axle

1. Oil drain plug

2. Oil level plug

2

1

97

4.9 Power steering Maintenance

OIL FILLING AND BLEEDING

Filling oil in steering tank

Steering gear and pump are filledthrough filler neck on oil tank. Forinitial filling and for oil changes it willbe of advantage to remove the tankcover and to add hydraulic oil uptoedge of tank. Engine can then becranked with starter motor for a while(not more than 10 seconds at astretch) to fill entire hydraulic systemwith oil. Since oil level in tank willdrop rapidly, keep adding oil to avoidpump sucking air.

Bleeding the steering system

When steering gear is filled to theextent that short cranking of enginewill not cause oil level to drop belowtop mark on oil dipstick, engine canbe started.

Jack up front axle, start engine, runat idle speed for some time, thusallowing air to escape from thesystem. Oil level must be watchedduring this process. Oil must betopped up immediately if the leveldrops.

Then turn steering wheel severaltimes from lock to lock so that airescapes from the system. Keepwatching oil level. Add oilimmediately when oil level drops.

Keep adding oil till the level remainsat upper mark on dipstick and airbubbles are no longer visible in oiltank when steering wheel is turned.

If above instructions are observed, oillevel in tank should not raise by morethan approx. 1-2 cm when engine isshut off.

Shut off engine and lower front axle.

Oil level check-up when enginestopped

Add enough oil in tank until oil levelis approx. 1-2 cm above upper mark.Start engine and run it at idlingspeed. Check oil level in dipstick. Oillevel should be between minimumand maximum levels.

Power steering tank

98


Oil level check-up with theengine running

With engine running, oil level willdrop slightly, since oil requires apressure of appox. 2-4 bar toovercome flow resistance whenflowing through the system. Addenough oil to keep oil at upper mark.Stop engine. Oil level should notraise more than 1-2 cm. A higher oillevel indicates that there is air in thesystem.

Filter change

a. Unscrew closing plug from coverof oil tank and remove tank cover.

b. Pull out used filter cartridge.When pulling out, keep bore offilter cartridge closed so that nodirty oil could flow back into tank.

c. Lubricate filter carrier and insertnew filter cartridge with metalcollar in upward direction.

d. Crank engine for a short periodwith starter motor, so that oil levelwill drop. Then bleed the system.

Replace oil/oil filter at every80,000 kms. Bleed the system andcheck performance with testequipment.

Power steering tank

A. Bottom level

B. Top level

AB

99


Power steering pump belttension adjustment

Checking and adjustment of steeringpump belt tension.

a. Loosen bolt holding uppermounting of steering pump tothe clamping piece.

b. Loosen steering pump pivot pinnut.

c. Loosen the locknut & adjust belttension by rotating the adjustingnut.

d. Check belt tension. Belt tensionis correct, if it can be depressedby 20 mm with thumb pressureapplied in the middle of itslength.

e. Tighten clamping piece bolt, locknut and pivot pin nut for lockingthe pump in position.

Power steering linkages

In case of excessive free play, checksteering linkages for looseness andget the defect rectified immediately.Periodical inspection of steeringlinkages is essential for driving safety.

Checking power steering pump belttension

1. Lock nut

2. Adjusting nut

3. Clamping bolt

4. Clamping piece

3

12

4

100


Sector shaft play adjustment

If play is noticed on drop arm or inputshaft of steering gear box, it is to beadjusted as given below :

● Bring steering wheel to SAP(Straight Ahead Position).

● Sealing nut is to be loosened inanticlockwise direction byholding adjuster screw in placewith a screw driver.

● Rotate adjuster screw withscrewdriver in anticlockwise andcheck for play on drop arm. Playwill increase.

● Again rotate adjuster screw inclockwise direction till the playdisappears on drop arm, holdingthe sealing nut in place.

● Turn adjuster screw clockwiseanother half turn. Hold it in placewith a screw driver and locksealing nut.

Torque for sealing nut is 70 Nm.

This adjustment is usually requiredafter a coverage of 100,000 kms.

Sector shaft play adjustment

A. Sealing nut

B. Adjuster screw

B

A

101

4.10 Brake system Maintenance

air pressure, thus releasing parkingbrake. For parking / emergencybraking, hand brake valve is operatedfor depleting air to atmosphere, thusapplying parking brakes.

Second auxiliary outlet of systemprotection valve is connected toexhaust brake air cylinder throughexhaust brake solenoid valve whichis coupled with service brake pedaloperation through stop light switch.

Exhaust brake isolator switch isprovided on instrument panel whichcan be used to cut off exhaust brake,isolating exhaust brake wheneverrequired e.g. while starting thevehicle on steep up gradient.

An air dryer cum unloader valve isfitted between air compressor andsystem protection valve alongwithpurge tank. Air dryer ensures cleanand dry air in the brake system,resulting in enhanced life of brakevalves.

Note :

Do not attempt to clean air dryerdesiccant cartridge and filter.

Replace desiccant cartridge and filterafter every 2 years.

To conduct brake system routineservice check - I prescribed at every18,000 km and routine checks - IIprescribes at every 36,000 kmcontact nearest Tata authorisedworkshop.

Procedure for these checksexplained in pages 110-112.

S Cam full air brakes

S cam brakes are fully air operatedbrakes. Brake actuators at front andrear axles are externally mountedoutside the foundation brakeassemblies.

Air is fed to brake actuators throughdual brake valve (Operated by brakepedal), proportional to brakingrequirements.

Push-rods of brake actuators act onslack adjusters, which convert linearmotion into circular motion of camshaft. S-shaped cam portion of shaftexpands brake shoes against drums,thus applying brakes.

S cam is of equal displacementdesign, resulting in equal wear ofleading and trailing shoes.

Brake system provides safe andreliable braking. Brake circuitconsisting of various pneumaticcomponents is shown in schematiclayout.

Service brakes consist of twoseparate circuits. One for frontwheels and the other for rear wheels.

In the unlikely event of failure of anyone circuit, other circuit remains stilloperative and guarantees a certaindegree of braking for the vehicle.

One of the auxiliary outlet of systemprotection valve is connectedthrough a graduated hand brakevalve to spring brake chamberportion, integral with rear brakeactuator.

During normal running, inside springsare kept in compressed condition by

102


AIR

BR

AK

E SY

STEM

WIT

H A

BS

(IF

FIT

TED

)

103


SCH

EMA

TIC

LAY

OU

T O

F D

UA

L C

IRC

UIT

FU

LL A

IR S

-CA

M B

RA

KES

WIT

H L

CR

V

104

Adjustment of service brakes/slack adjusters

In order to ensure efficient operation,4 wheel brakes must be set duringevery lining change or wheneverbrake drum open for maintenance.

All normal setting should be madeonly by means of adjuster screw toslack adjuster. Brake adjustment is tobe done when drums are cold andnot when they are hot. Improperbrake adjustments can cause brakegrabbing, more air consumption orlow brake efficiency.

Procedure

1. Jack the wheels. Release handbrake if it is in ON condition.

2. Position a box spanner or a ringspanner (12 mm A/F) over theadjuster hexagon. Bydepressing the locking sleeve,turn adjuster screw clockwiseuntil shoe begins to bind drum.Then turn adjuster screwanticlockwise 270O

Note

It is possible to check clearancebetween the drum and lining byusing a feeler gauge throughinspection hole after removingrubber grommet.


1. Adjuster screw

2. Locking sleeve

2

1

Position of slack adjuster

POSITION AT ZEROSTROKE

POSITION WHEN ADJUSTMENTREQUIRED(in brakes applied condition)

105

Hand brake (parking brake)


Parking brake adjustment

No separate adjustment is required.Service brake adjustment holds goodfor hand brake also.

Releasing automatically appliedparking brake

If there is air leakage in parking brakecircuit, parking brake gets appliedautomatically. Air leakage in anyother circuit (front, rear and exhaustbrake) does not effect parking brakedue to the action of systemprotection valve. A mechanical ‘windoff’ screw (M16 x 1.5) is provided atthe top of spring brake actuator torelease automatically applied parkingbrake due to any reason.

To release, rotate wind off screw upwith a spanner against the tension ofspring (inside spring brake chamber)till brakes are completely released.

Wind off screw has to be turned backto original position, soon aftermechanical wind off requirement isover and before vehicle is put onroad again.


Hand brake valve

A. Brake released

B. Brake applied

A to B Gradual application

Spring brake actuator

Mechanical wind off screw for handbrake

1

106


2. Loosen check nut on pedalstopper screw located near stoplight switch. Adjust stopperscrew such that brake pedal freeplay travel is between 3 to 6 mm.

3. Tighten check nut of stopperscrew without disturbing stopperscrew.

4. Operate brake pedal a few timesto ensure desired brake pedalfree play.

5. Adjust stop light switch.

Adjustment of stop light switch

1. Ensure that brakes are inreleased condition.

2. Install stop light switch so thatthe plunger is pressed by about3 mm when assembled.

3. Operate brakes a few times, tomake sure that stop lightindication comes properly.

Adjustment of exhaust brake

There is no separate exhaust brakeadjustment. Stop light switch servesthe function of providing signals bothfor rear tail brake lamps as well as forexhaust brake solenoid valve.

Precautions

Check for proper functioning ofexhaust brake at PDI and after every10,000 Km. With brake pedal fullyreleased, there should be no exhaustbrake application. If it is on, readjuststop light switch suitably. Exhaustbrake application can be made outfrom the distinct change in enginenoise.

Adjustment of brake pedal freeplay

Adjust brake pedal free play as below :

1. Ensure brakes are in releasedcondition.

1. Dual brake valve

2. Push rod

3. Stop light switch

4. Brake pedal

5. Pedal stopper screw(Adjacent to stop light switch)

FIRE WALL

4

2

91 mm

1

3

AB

A. Stop light switch

B. Pedal stopper screw

107


Load conscious pressurereducing valve (If ABS is notfitted)

This valve is located in rear brakecircuit and regulates supply ofpressurised air to rear brakechambers depending on the load onrear axle.

This enables rear brake actuationproportional to the load on rear axleand avoids wheel locking in partiallyloaded conditions.

The valve is mounted on the RH sideof the frame and connected to rearaxle with help of linkages.

Distance between axle and Chassistop varies with the load on vehicle.This variation is sensed by the valvethrough the linkage connected tothe axle and input air pressure tobrake actuator is modulated.

Adjustment

In unladen vehicle (with or withoutload body) Loosen screw 'B'. Rotatelink 'A' by sliding rubber connectorover link 'C' such that Point 'P' ondial 'D' coincides with point 'Q'.Tighten the screw 'B'.

Adjustment of LCRV should be doneas per valve setting data given onthe sticker, located near windshieldwasher water reservoir.

108

Anti Lock Brake System (ABS)(if fitted)

ABS combined with the traditionalhydraulic brake system prevents thewheel from locking while braking bymaking use of most of road to tyregrip. It also ensures better controland stability of vehicle while braking.

How ABS works

ABS essentially consists of anElectronic Control Unit (ECU) whichreads signals from the sensors fittedto each wheel and identifies the onewhich is likely to lock. (Wheels willtend to lock when the speed ofrotation of any one wheel becomestoo low in relation to the vehiclespeed.) It tells an Electronic ControlUnit (ECU) to reduce, maintain orincrease the pressure on themodulator valve in order to preventthe wheel from locking. The ABScomes into play when the vehicle isbraked heavily during emergency orroad surface is wet or slippery.

The driver feels modulation ofair pressure (some sound frommodulator valve)

This is absolutely Normal. Thisshould not be interpreted as afault in the brakes. On thecontrary it’s the indication thatthe ABS is working. This is anintentional warning to the driver thata wheel or wheels are tending tolock due to the limit of tyre to roadadhesion. The ABS is addition to thebasic brake system. It is activatedautomatically every time the engineis started. If there is a malfunction

the system turns off automaticallyindicated by a ‘(ABS)’ warningindicator on the dash board, still theordinary brake system continues towork.

ABS Activation

ABS activation varies with variousroad surfaces i.e. the amount oftraction your tyre have on aparticular surface. On dry surface youwill need more pedal effort toactivate ABS. However you may feelABS activates immediately if you tryto stop on snow, ice or slipperysurface.

ABS Indicators


The ABS is self check. Ifany thing goes wrongthe ABS warning indicator comes onthe instrument panel. When youswitch on the Ignition the ABS lightturns ON but should go out afterabout 5 seconds. If the light fails togo or the lighting up of the warninglight when the engine is running orthe light comes at any other time, itindicates there is a fault in the ABSonly. In this case also the normalbraking system is still effective andis able to provide normal stoppingability.

In this condition it is recommendedto take your vehicle to the nearestauthorized Dealer / service outletand get your vehicle attended assoon as possible if the warning lightstays on.

109

Safety tips while driving withABS

1) During a hard braking or whenthe road grip is poor, you willfeel an audible noise in thesystem. This is absolutelyNormal and it’s the indicationthat your ABS is rapidlymodulator air pressure. Do notrelease the brake pedal, thisdefeats the purpose of ABS.Keep firm steady pressure onthe brake pedal so as not tointerrupt the braking action aslong as you steer away fromthe hazard.

2) ABS prevents the wheel fromlocking but it does not increaseactual tyre to road grip. Henceeven if your vehicle is fittedwith ABS, maintain a safefollowing distance.

3) ABS does not reduce eithertime or stopping distance, Itonly helps steering controlduring braking. You shouldalways keep a safe distancefrom other vehicles.

4) ABS will not prevent skiddingof a vehicle that results fromchanging direction abruptlysuch as trying to take a cornertoo fast or making a suddenlane change.

5) ABS cannot prevent a loss ofstability due to severe or sharpsteering wheel movement.Always steer moderately whilebraking hard.


6) ABS requires a little longerstopping distance than avehicle with conventionalbrake system on a loose oruneven surface, such as gravelor snow. Slow down and allowa safe following distance.

7) ABS serves to increase yourcontrol over the vehicle not toenable you to go faster.

110


Brake system routine checks

1. Routine checks - I

a. It is very essential that brakesystem is kept trim at all timesand periodic checks areconducted so that vehicles withbrake system defects are not runon road. The following procedureis recommended for a generalcheck once in 20,000 km. andafter each brake overhaul. Formaintenance data, refer tospecifications.

b. Place chocks on both front andrear wheels.

c. Remove drain plugs and exhaustall air tanks. Drain water andassemble back drain plugs.Deplete air in spring brakes byapplying, releasing hand brakevalve. Keep hand brake in ‘OFF’position.

d. Turn vehicle ignition to ‘ON’. Thelow air pressure and hand brakeindicators should glowimmediately. The pressuregauges should read zero. If not,rectify.

e. Run the engine at full speed tocharge the system. The airpressure in one of the servicetanks (the circuit having slightlylesser opening pressure in thesystem protection valve) will riseat first to a certain limit. Thenother circuit will follow and bothwill rise together.

f. The low air pressure indicatorshould be off at the specifiedvalue (5.4 + 0.5 bar). If not, rectify.

g. Continue to charge the systemtill ‘cut-out’ pressure (7.4 + 0.2bar). The unloader valve shouldcut out (identified by a hissingnoise).

h. Stop engine. The time takenfrom zero to cut out pressureshould not exceed specifiedpump up time. If it takes more,check for leakages in brakesystem and rectify. Also opencompressor head, check fordefects and rectify.

i. After pressure in the systemstabilises, the drop in air pressure(due to leakage if any) withbrakes ‘OFF’ should not exceedspecified value. Otherwise,rectify.

j. Apply service brakes and hold.The pressure in both circuits willdrop by a small amount andstabilises. The drop in airpressure (due to leakage, if any)with brakes ‘ON’ should bewithin limits.

k. Make a few brake applications tobring down air pressure. When‘cut in’ pressure is reached, thecompressor charges the systemagain till ‘Cutout’ pressure isreached. Put off the engine.

111


l. Jack up the rear axle. Rotatewheels manually. Apply handbrake. It will not be possible torotate wheels. Hand brakeindicator appears on panel.Release hand brake. Wheels willbe free to rotate again. There willbe a small pressure drop in boththe reservoirs. Now hand brakewarning signals should be off.

m. Lower down rear axle.

n. Apply service brakes and checkthat rear tail lamp glow.

o. Put exhaust brake piano switchin ‘ON’ position. Start the engineand apply brake pedal. Exhaustbrake indication appears on thepanel along with distinct changein engine noise which indicatesthe application of exhaust brake.

p. Take road test for :

i. Efficient braking

ii. Absence of grabbing/pullingto one side

iii. Absence of brake squealingand rectify defects if any.

iv. Check that hand brake andexhaust brake are alsofunctioning properly.

2. Routine checks - II

In addition to routine checks - 1,the following checks of differentbrake valves keep the systemhealthy. It is recommended oncein 40,000 km. and after eachbrake overhaul.

2.1 System protection valve(SPV)

A. Opening pressures

a. Fail one service circuit say rearcircuit (port 21) by opening anypipe joints.

b. Drain the healthy reservoir(front) below 4 bar and chargeair at max. engine speed.

c. Note max. pressure in the gaugeof healthy circuit. This is theopening pressure of SPV port 21,connected to failed rear circuit.

d. Repeat a, b and c for other circuit(port 22).

e. With all circuits healthy, build upair pressure till cut out. Openconnector at SPV port 23 toatmosphere. Pressure in theservice tanks will fall to around4 bar. Run engine at max. speedand note the stabilized gaugepressure (either front or reargauge). This is the openingpressure of SPV port 23.

f. Repeat (e) for SPV port 24.

B. Closing pressures

a. With full pressure in the air tanks,slowly leak out any circuit, sayrear (port 21) to zero. Thepressure in the other circuit (port22) falls to a certain value andstabilizes. This is the closingpressure of SPV port 22.

b. Repeat (a) for closing pressure ofport 21.

112


c. For checking closing pressure ofport 23, 24 pressure gaugesshould be connected in theircircuits. Leak out air in eitherfront (22) or rear tanks (21). Notedown closing pressure of SPVport 23 and 24 after pressuregets stabilized.

d. Note down closing pressures ofSPV port 21/22 with air leakedout to zero in hand brake circuit(port 23). These closing pressureswill be different from those at (a)and (b).

e. Repeat (d) with air leaked out tozero in exhaust brake circuit(24).

2.2 Dual brake valve (DBV)

a. With full pressure in air tanks,check for leakage from exhaustport of DBV with :

i. Brakes in released condition.

ii. Partial braking and

iii. Full braking

b. Open the outlet pipes 21 and 22and check for leakage in brakeOFF condition.

c. Open inlet pipes one by one say11 and check for leakagesbetween primary and secondarychambers in brakes OFF and ONconditions. Repeat with pipe 12disconnected.

2.3 Brake chambers

a. With brakes applied at fullpressure, check for leakages infront and rear brake chambers.

b. Open service brake pipe 11 ofspring brake actuator and checkfor leakages from spring brakechamber into service brakechamber and from non-pressureplate side of spring brakechamber.

c. Check that ‘mechanical wind off’is functional in spring brakeactuator.

d. Check for any hole elongationand wear on push rod fork andpin.

2.4 Slack adjusters

a. Check that slack adjusters arefunctional and adjustment ispossible without sticking.

b. Check for any hole elongationand wear in bushes.

2.5 Graduated hand brake valve

a. Check leakage from exhaust portin brake ON and OFF condition.

b. Check lever for proper locking, inbrakes ON and OFF condition.

113

FRIENDLY SERVICE TIPS

1. Braking performance will dropdown after brake chamber pushrod travel of 45 mm in brakesapplied condition. (Anglebetween push rod and centreline of slack adjuster will be lessthan 90o.) Please do adjustservice brakes before 45 mmtravel.

2. When drums are removed forservicing, do not apply greasebetween contact surfaces of Scam profile and rollers. Theyshould be left dry for properrolling action. But only roller endswhich sit into shoe web are tobe greased lightly.

3. When using repair size brakedrums and linings ensure thatdrum diameters and brake liningsizes are same on the opposite sideof the same axle.

4. Do not attempt to clean air dryer(cartridge & filter). Replace theold ones with new cartridge andfilter every two years.

5. Brake drum diameters arerecommended upto repair size IIof 329 mm. Drums should notbe used beyond 330 mm dia. asthere will be no service brakingor parking brake left, due to camroll over. Before that, drumsshould be discarded.

6. Any extra air connection toauxiliaries like air horn should betaken from exhaust brake circuitonly and not from parking brakecircuit or service brake circuits.

7. Graduated hand brake valve canbe used along with exhaustbrake isolator switch forsimultaneous acceleration andpartial braking of vehicle incertain situations like startmoving the vehicle on steepupgradient.

8. For brake system service checksat every 20,000 & 40,000 km.contact Tata authorisedworkshop.

9. Please take care of nylon tubes,see that they,

a. Do not come in contact withhot objects.

b. Do not rub against sharpedges.

c. Do not have kinks, folds ortwist.

d. Are not exposed to weldingspatters etc.

10. Always use genuine nylon tubes,for safety reasons.


114

4.11 Springs Maintenance

Springs

U-bolt nuts and check nuts of front/rear springs should be regularlytightened with a torque wrench orwith a socket wrench and a handleof atleast 60 cm length. Specifiedtorques are given below :

‘U’ bolt nuts : 21 mkg

‘U’ bolt check nuts : 21 mkg

Dismantle front / rear spring packs atevery 72000 kms. Clean, applygraphite grease & reassemble. Checkeye bushes & replace, if necessary.

Anti roll bars (bus chassis)

Check anti roll bar mountings atevery 9000 kms & tighten, ifnecessary. Check condition of bushesand replace, if necessary.

Wheel alignment

Check toe-in at every 36000 kms &adjust, if necessary. Specified toe-in0 to 3 mm.

Shock absorbers

Check condition of shock absorbers/ shock absorber bushes at every9000 km & replace, if necessary.

Tightening spring ‘U’ bolt at front axle

115

Cable adjustment on centre flaplocking mechanism.

● Centre flap is locked by twopiece toggle locks fixed on frontend of fire wall on LH & RHsides.

● Centre flap gets locked when itis lowered and pressed gentlyagainst fire wall.

● Flap gets unlocked when releaselever (located above acceleratorpedal) is pulled back.

● Cable outer is of two part andinner is single piece with twolocking sieves.

● In order achieve proper lockingand unlocking, it is necessary tofix the outer cable with outslackness.

● Cable outer first part is betweenrelease lever and toggle lockRHS.

● To adjust slackness on first partof cable, loosen lock nut “2” andtighten adjustment nut “1” tillthe desired stiffness is achieved.

● Tighten lock nut “2” firmly.

● Cable outer second part isbetween the toggle lock RHS &LHS.

● To adjust slackness on secondpart of cable, loosen lock nut “2”and tighten adjusting nut “1” tilldesired stiffness is achieved.


4.12 Centre flap Maintenance

Outer cable first part

1. Adjustment nut

2. Lock nut

1

2

Outer cable second part

1. Adjustment nut

2. Lock nut

2

1

116

Tilt cab torsion bar adjustment

● In cab tilting system a, torsion baris incorporated to reduce theeffort while tilting out cab. Alsoto offer resistance while loweringthe cab to avoid sudden falling ofcabin.

● Torsion bar should be fitted/removed/adjusted only with thecabin in fully tilt out position.

● Torsion bar needs to adjusted, inorder to achieve the desirableeffort while tilting out andresistance while lowering.

Adjustment procedure follows.

● Place adjusting block “A” on theLHS end spline of torsion bar soas to align the midway of oblonghole “1” with locking bolt hole “2”

● Tighten lock bolt “3” to hand tight.

● Loosen the lock nut. “4” onadjusting screw and tightenscrew “5” in order to achieve3mm gap between adjustingscrew and block.


● Tighten lock bolt “6” of adjustingblock to 7 mkg.

4.13 Tilt cab Maintenance

Removal of adjusting block1. Oblong hole2. Locking bolt hole

4. Lock nut5. Adjustment screw6. Lock bolt of adjusting block

3. Locking bolt

117

4.14 Wheels and tyres Maintenance

Wheels and tyres

Tyres are to be examinedperiodically for damage, foreignobjects and wear.

You should look for :

● Bumps or bulges in treads orsides of tyre. Replace tyre if youfind either of these conditions.

● Cuts, splits or cracks in the sideof the tyre. Replace tyre if yousee the fabric or chord.

● Excessive tread wear.

Tyres can give satisfactory serviceonly if the load carried by each tyreand pressure is within specified limit.For this reason maximumrecommended GVW must never beexceeded as otherwise life of tyreswill be adversely affected.

Under inflation and over inflation areboth injurious to life of tyres.Therefore, correct tyre pressure mustbe maintained at all times. It ispossible that after initial inflation oftyres in cold condition, there is a risein pressure after vehicle has travelledsome distance and tyres get hot. Tyrepressure should not be correctedunder these conditions because iftyre pressure is corrected at thisstage, it will result in under inflationwhen it cools down.

It is good practice to have best tyreson front axle for operational safety ofthe vehicle. However, it is essential tomatch size of the tyres so that alltyres on the same axle have more orless same degree of wear. Fittingtyres of size other than specified willhave a number of adverse effectsand therefore should be avoided.

Wheel changes

When changing wheels observespecified tyre load capabilities andpressures.

Secure the vehicle to prevent rollingby using suitable wheel chokes.

The jack should be applied at frontaxle towards front, below spring pack(i.e. below 8th leaf ).

Never put the jack below thedifferential housing.

Specified tightening torque forwheel nuts is 35-40 mkg.

Jack location at front

Jack location at rear

118

Operating the winch type sparewheel carrierLoosen mounting nuts (2 Nos.)holding spare wheel to winch withwheel wrench.Lift ratchet-pawl and rotate winchspindle in counter clockwisedirection with wheel nut spannerand lower the saddle with sparewheel.Remove spare wheel from saddle.After repairing spare wheel, secure iton the saddle.Rotate winch spindle in clockwisedirection using wheel wrench. Alignsaddle studs with mounting hole onwinch.Tighten mounting nuts (2 Nos.) withwheel nut spanner.Wheel BalancingWheels of your vehicle are balancedfor better ride comfort and longertyre life. Balancing needs to be donewhenever tyre is removed from rim.1. Permissible imbalance for tyre

with rim = 500 gm-cm max.2. Total balance weight should be

within 240 gms on each side.3. Relocate the tyre if the weight

required to balance is more than240 gm.

4. Do not use more than onebalance weight on one side.

5. Tube valve should be positionedcentrally with respect to wheelrim valve cut-out.

While fitting wheels on the vehiclemake sure that wheel bolts are freefrom dust, scratches, dirt; dents, etc.Do not oil wheel bolts and nuts.


A -Winch spindleB -Spare wheel

B

A

Spare wheel mounting nuts

Ratchet-pawl

119

Tyre rotation

Tyre rotation is recommended forachieving identical wear on eachtyre. It is also advisable to changerotating direction to relieve tyres ofcontinual one way running. Regularrotation of tyres will also preventabnormal wear. Sketches indicatesuggested sequence of tyre rotation.

Rotate tyre every 9,000 km or earlierdepending on operation.

Type pressure

LP/ LPT 613

At rated UnladenGVW LPT LP

Front 90 psi 50 psi 35 psi

(6.3 bar) (3.5 bar) (2.4 bar)

Rear 90 psi 35 psi 35 psi

(6.3 bar) (2.4 bar) (2.4 bar)


Tyre rotation (all tyres rib type)

REAR RIGHT

REAR LEFT

SPARE

Tyre rotation (Front tyres rib type,rear & spare tyres lug type)

REAR RIGHT

REAR LEFT

SPARE

120

Inflating tyres with air from airdryer

Outlet pipe from air compressor isconnected to air dryer with in builttyre inflator cum unloader valve.

Air from tyre inflator can be used toinflate tyres during emergency.

For inflating tyres, unscrew wing nutor remove rubber cap (whichever isprovided) from tyre inflating valveand start the engine. After thecondensed water and oil that maybe present in the system have beencompletely expelled, connect hoseto the tyre inflating valve and nippleof the hose to the tyre tube nozzle.Run the engine at fast idling speed.

Disconnect hose and check tyrepressure.


Connecting hose to tyre tube nozzle

Connecting hose to tyre inflatingvalve

Removing rubber cap from tyreinflating valve

121

Alternator belt tensionadjustment

Belt tension should regularly bechecked and if necessary adjusted. Ifbelt tension is correct, it can bedepressed by 20 mm with thumbpressure applied on the middle of itslength.

If belt is loose (slack), i.e. it getsdepressed by more than 20 mm,adjust belt tension as per followingprocedure :

a. Loosen bottom mounting bolt ofalternator.

b. Loosen bolt holding uppermounting of alternator to theclamping piece.

c. Loosen lock nut.

d. Adjust belt tension by turningadjusting nut and by movingalternator away from engine.

e. Tighten lock nut and the boltholding clamping piece toalternator.

f. Tighten bottom mounting bolt.

g. Recheck belt tension.

4.15 Electricals Maintenance

1. Lock nut

2. Adjusting nut

3. Clamping bolt

4. Clamping piece

3

1

42

122


Bulb replacement and alignmentof head lamps

Head lamp system provides twotypes of light beams; a main beam togive maximum light well ahead ofthe vehicle, and a dipped beamwhich is shorter and lower so that itwill not dazzle on on-coming drivers,and can be used in low visibility area.

Separate filaments in a single bulbprovide main and dipped beams.

Head lamp also has a parking lamp.

Bulb replacement

Remove head lamps outer ring.Unscrew the screw and swivel thehead lamp assembly sideways on thehinges. Remove rubber cap from rearof head lamp. Push out cable socketfrom bulb. Replace with new bulbtaking care for proper fitment andlock the bulb with lock ring. Refitcable socket with bulb on the headlamp and press it in position.

Note :

Do not clean the reflector as it willcause damage to mirror finishedsurface. Do not replace bulb withdirty or oily hands since oil willevaporate due to the bulb heat andstain the reflector. After replacingbulb check head lamp alignment.

Halogen bulb is used for head lamps.Do not touch glass shell. It may resultin personal injury or damage to bulb

Removal of locking ring

Replacing head lamp bulb

123

Head lamp alignment

The head lights must be properlyaligned in order to obtain maximumroad safety as regards proper roadillumination and to reduce the glareon the oncoming traffic.

It is recommended to check thealignment of head lights periodicallyand whenever bulbs are replaced, bymeans of screen as shown in figure.

The head lamp alignment in thistype, asymmetrical dipped beams, isdone only by adjusting the dippedbeams unlike other head lampswhere main beams are adjusted.

e) Head Lamp Focusing

Park unloaded vehicle with no sag insuspension springs and all tyresequally inflated, 10 m away from thescreen with it’s center in line withthe central vertical line on the screenat right angles to longitudinal axis ofthe vehicle.

● Keep the leveling switch at ‘0’position.

● On the marked up screen, thearea above the horizontal andinclined lines (shaded) is called


Motorised head lamp

1. Vertical adjustment screw

2. Horizontal adjustment screw

3. Fine adjustment setting screw

12

3

124


Screen for adjusting head lamps focusing - LHD Vehicles

1500780 78012801

00

0 60

0*

B150 150A

RIGHT HAND TRAFFIC

DARK ZONE

CENTRE LINE OFHEAD LAMP

CENTRE LINE OFHEAD LAMP CENTRE LINE OF

VEHICLE

* = 825 mm with unladen vehicle.

Caution : Setting screw onmotor should be used for fineadjustment only, otherwisemotorised adjusting mechanismwill be damaged

● Lateral adjustment can be doneby adjusting screw at the otherend of bottom so that contourof the dipped beam coincideswith the contour formed byhorizontal & inclined lines below‘The Dark Zone’.

● When properly aligned the mostbrightly illuminated area will bebelow the intersection (point A)of two lines.

● The second head lamp can beadjusted in a similar mannerwithout disturbing the positionof the vehicle and the screen.

● Operate the leveling switch to ‘1’,‘2’ & ‘3’ positions & ensuresymmetrical movement of cut-off beams vertically.

Focusing should be done,preferably in the dark.

The Dark Zone’, and the areabelow it is called ‘TheIlluminated Zone’.

● Each lamp can be alignedindividually by masking theother lamp. The head lamp is firstadjusted for the proper height ofthe dipped beam by adjustingthe screw at it’s bottom belowmotor. The light from dippedbeam should fall below thehorizontal and inclined lines. Nolight should fall above theselines i.e., in ‘the dark zone’.

Head lamp levelling switch

125

Each lamp is aligned individually bymasking the other lamp. Head lampis first adjusted for proper height ofdipped beam by adjusting screw attop. Light from dipped beam shouldfall below horizontal and inclinedlines. No light should fall above theselines. i.e., in “The Dark Zone”.Thereafter lateral adjustment is doneby adjusting screw at bottom so thatcontour of dipped beam coincideswith the contour formed byhorizontal and inclined lines below“Dark Zone”. When properly aligned,most brightly illuminated area will bejust below the intersection A) of twolines.

Head lamp on other side is adjustedin a similar manner withoutdisturbing the position of vehicle andscreen. Now switch “ON” main beamlights. They will be symmetrical abovepoints of intersection (point A & B)of vertical lines and horizontal line.It is possible that main beams maynot be exactly symmetrical but forthis reason head lamps should not berealigned.

PREFERABLY, ALIGNMENTSHOULD BE DONE IN THE DARK

Caution :

No masking of head lamps with blackpaint is required. If done this willreduce head lamp intensity.


126

Bulb specifications

Description Location Type Specification Qty.

Headlights Headlamp H4 P43 24 V 60/55 W 2Instrument panel * 24 V 2 W 1

Turn indicator lights Front RL 24 V 21 W 2Tail lamp RL 24 V 21 W 2Instrument panel * 24 V 2 W 2Side indicator lamp * 12 V 21 W 2

Brake lights Tail lamp RL 24 V 21 W 2

Parking lights Head lamp HL 24 V 4 W 2Tail lamp G 24 V 10 W 2Number plate G 24 V 10 W 2

Reverse indicator lights Tail lamp RL 24 V 21 W 2

Battery chargingindicator light Instrument panel * 24 V 2 W 1

Low oil Pressureindicator light Instrument panel * 24 V 2 W 1

Parking brakeindicator light Instrument panel * 24 V 2 W 1

Gauge illuminationlight Instrument panel * 24 V 2 W 7

Driver compartment light Cab roof 24 V 10 W 1

Engine compartmentlight Engine compartment RL 24 V 21 W 1

* = These bulbs are capless.


127

Fuses

In order to protect cable harness andother equipments from damage incase of short circuit and overloads,glass cartridge fuses as per IS 2577 orSAEJ 554b are provided in fuse box .

In case of a fault in electrical systemcheck respective fuse. Particulars ofconsumers served by each fuse areprinted on fuse box cover.

Spare fuse cartridges are providedinside fuse box.

Always use fuses of correctrating. Do not use a wire in placeof fuse.


Fuse and relay box cover

WIRING DIAGRAMS ARE GIVEN FROM PAGE NO.173 TO188

FUSE BOX & RELAY COVER

H/LLEVELLINGMOTOR RLY

(YELLOW)

HORN RLY(YELLOW)

HEAD LAMPH/B RLY

(YELLOW)

REAR FOGLAMP

(YELLOW)

ECU RELAY(BLUE)

FRONT FOGLAMP RELAY

(YELLOW)

ABS RELAY(GREEN)

ACC RLY(YELLOW)

HEAD LAMPL/B RLY

(YELLOW)

STOP LIGHTRELAY

(BLACK)

12V HOLDRLY

(BLACK)

ECU RELAY-II(YELLOW)

AIR DRYERHEATER

10A

ACC 20A

HEAD LAMPRELAY COIL

5A

PARK RH5A

FRONT FOGLAMP

10A

DC-DCCONVERTER

15A

WARNINGLAMP ABS

5A

RADIO5A

PARK LH5A

ENGINESTOP 5A

IGN-SUPPLYABS5A

HORN ROOF,ENG. LAMP

10A

GAUGES5A

TURN 5A

ADD SUPPLYBATTERY

5A

ECU-ABS15A

REV-STOP 5A

WIPER5A

VEH. SPEEDSENSOR

5A

ADD SUPPLYIGNITION

5A

WATERSEPERATOR

10A

HEAD LAMPH/B RH

5A

HEAD LAMPL/B LH

5A

FIP TIMERDC-DC

10A

POWERSOCKET

5A

H/L LEV.RLY/FEEDPUMP 5A

HEAD LAMPH/B RH

5A

HEAD LAMPL/H RH

5A

ECU15A

AIR DRYERHEATERRELAY

(YELLOW)

WATERSEPERATOR

RELAY(YELLOW)

STARTERRELAY

ADDITIONALSUPPLY-IBATTERY

(5A MAX)

ADDITIONSUPPLY-IIIGNITION(5A MAX)

DIA

NO

STIC

CO

NN

ECTO

R

WIPER CONTROLLERFLASHER

Location of fuse and relay box

128

4.16 Preservative treatment Maintenance

Vehicle storage

Following protective treatmentwould be required for the vehicle incase body building is deferred orvehicle would be put in operationafter considerable storage or bodybuilding time would be fairly long.

Vehicle should be thoroughlywashed and lubricated. Check allpainted parts for damage and touchup, if necessary. Apply chromiumprotective paste on chromium platedparts. Grease springs and springsuspensions with anti-corrosivegrease.

If vehicle is to be laid up for morethan 6 months, drain off transmissionand rear axle oils when hot, aftervehicle has been driven for sometime and replace by anti corrosive oil.

Batteries should be serviced atregular intervals to keep them ingood condition. Batteries should bestored in a cool and dry room. Checkbattery condition every fortnight. Ifnecessary, recharge.

Vehicle should be jacked up to relievethe tyres of load. Tyres includingspare-wheel should have a pressureof approximately 0.5 to 1 kg / cm2.Check tyre pressure from time totime.

The paint needs no specialmaintenance if the vehicle has beenthoroughly cleaned before laying itup.

Caution : Grease nipples must becarefully cleaned prior to greasingand the same applies to grease cups/screw plugs before they areunscrewed.

Engine storage (Short term)

Note : This procedure describes themethod of preparing an engine forshort term. (1 to 6 months) storage.

Run engine at high idle until coolanttemperature reaches 700 C. Stop theengine.

Remove fuel tube to fuel filter andinjector return tube.

Note :Fuel system preservative oilmust meet Federal specificationVV-L-800C.

Fill two containers, one with dieseland the other with preservative oil.Put both fuel tubes into the containerof diesel.

Start the engine. When it is operatingsmoothly, put fuel supply tube intothe container of preservative oil.Remove injector return tube fromdiesel container. When preservativeoil flows from the tube, stop theengine.

Install fuel supply tube to fuel filter,and put a cap at the end on all otherfuel tubes.

Drain oil from sump and oil filter.Drain diesel from fuel filters. Installdrain plug in sump. Install filter bowls.Tighten according to specifications.

Note : Do not drain coolant fromcooling system.

129


Inspect the engine closely, and coverall openings with tape to prevent dirtand moisture from entering. Install awarning tag which alerts others of nooil in the engine and that it mustnot be started.

Store the engine /vehicle in a dryarea of even temperature.

Rotate crankshaft two or threerevolutions every 3 to 4 weeks usingengine barring tool.

Preparing the engine after shortterm storage.

Remove tapes from all openings, andremove warning tag. Refill oil filterwith clean W-40 oil, and fill oil panto high-mark on dipstick. Primelubrication system.

Use starter to crank engine for amaximum of 30 seconds with 2minute intervals until oil pressurebuilds up.

Use clean diesel to flushpreservative oil from fuel system, andfill fuel filters again. Prime and ventthe fuel system.

Engine storage (Long term)

This procedure describes themethod of preparing an engine forlong term (6 to 24 months) storage.

Note : If the engine has been storedfor 24 months, cooling system mustbe flushed with a solvent. Repeat theflushing procedure a second time.

Run engine at high idle until coolanttemperature reaches 70OC.

Stop the engine.

Drain oil from sump. Install drain plugand fill sump to high level mark ondipstick with preservative oil.

Note : Lubricating systempreservative oil must meet MilitarySpecification MIL-L-21260 Type PE30-I SAE 30.

Disconnect fuel supply tube at fuelfilter and keep injector return tube ata convenient place.

Note : Fuel system preservative oilmust meet Federal Specification VV-L-800C.

Fill two containers, one with dieseland the other with preservative oil.Put both fuel tubes into the containerof diesel.

Start the engine. When it is operatingsmoothly, put fuel supply tube intothe container of preservative oil.

Remove injector return tube fromdiesel container. When preservativeoil flows from the tube, stop the engine.

Connect fuel supply tube to fuel filter,and put a cap at ends of all other fueltubes.

Drain and flush the cooling system,using a water-soluble rust inhibitor.

Spray preservative oil into intake andthe exhaust ports of cylinder headand exhaust manifold.

Install exhaust manifold.

Remove rocker housing covers, andspray rocker levers, valve springs,valve stems, valve guides, and pushrods with preservative oil. Installrocker housing covers.

130


Spray preservative oil into intake portof air compressor and on all exposedmetal surfaces that are not painted.

Note : Use a preservative compoundthat meets Military Specification MIL-C-16137.C type P- 2 Grade 1 or 2.

Cover all openings with heavy paperand tape to prevent entrance of dirtand moisture.

Put a warning tag on the enginewhich contains following information :

Date the engine was prepared forstorage.

Crankshaft must not be rotated.

Coolant has been drained.

Engine must not be operated.

Store the engine / vehicle in a dryarea of even temperature.

Preparing the engine after Longterm storage

Remove paper and tape from allopenings. Remove warning tag.

Flush fuel system with clean dieselto remove preservative oil.

Rotate the water pump to make sureit hasn't rusted in place.

Rotate crankshaft two completerevolutions to make sure the pistonrings are free and no foreign objectsare in the engine.

Remove intake manifold cover andvisually inspect the lower valve stemarea for presence of rust.An accumulation of rust requiresdisassembly and rebuild of cylinderhead.

Install drive belt.

Remove plug from main oil rifledrilling and flush preservative oilfrom the engine by pumping 4 litresof light mineral oil into oil rifle.Rotate crankshaft three or fourrevolutions as the engine is flushed.Install the plug.

Remove the oil drain plug and allowpreservative oil to drain.

Remove oil filter. Install a new filter.

Pressure fill the engine with 15W40oil through the 1.8 inch pipe tap onthe side of oil filter housing directlybelow turbocharger oil supplyconnection. Use 2.07 bar to pressurefill the system with a minimum of3.6 litres.

Fill oil in sump upto maximum levelon dipstick.

Fill cooling system with a mixture of50% water and 50% ethylene-glycolantifreeze. Adjust valve clearance.

Tighten all cap-screws, plugs andfittings as necessary.

Caution : Make sure that the enginedoes not start when you crankengine.

Use starter to crank the engine for amaximum of 30 seconds, with twominute intervals, till such time oilpressure builds up.

131

4.17 Care and cleaning Maintenance

Protection against corrosion

Dampness, humid atmosphere, hightemperature, unattended chippedoff paint surface, accumulatedchemicals wet dust and road saltremains are the prime cause forcorrosion. Follow precaution givenbelow :

● Park vehicle in well ventilatedand dry place preferably undershade.

● Wash and wax the vehicleregularly.

● Clean dirt or chemicals onvehicle, when noticed.

● Paint touch up due to chippingoff scratch on paint surface.

● Washing under chassisfrequently if vehicle is beingdriven on salted road (coldweather)

● Ensure fitment of mud flaps.

Corrosion prevention for loadbodies

● To protect paint damage anddeformation of sheet metal, usewooden raft or rubber sheet ontop of floor panes and sidepanels of load body.

● Wash load body frequently. Forvehicles operating near coastalareas, underside of load bodyand wheel arches should bewashed at least once a month.High pressure water is effectivefor such washing. Wash load

body in shade when body is nothot to touch.

● To protect box sections fromcorrosion - apply “DINTROL -3850” rust preventive compoundin the box section of all sides,panels, floor, tail gate and bottomcross member through drainholes provided for the purpose.

● Be careful when transportingchemical, cleansers, fertilizers,etc. If a spill or leak is noticed,care must be taken toimmediately clean area. For suchapplications use additional coatof paints epoxy/chlorinated baseanti-corrosive paint.

● Check the condition of loadbody’s paint periodically for anychips or breakage creepage ofrust from paint damaged area.Give immediate attention forboth primer and finish painttouch-up work.

Under Body Maintenance

Corrosive materials on roadsaccumulate on under body of avehicle. If allowed to remain, thesematerials can cause deterioration ofunder body components such as fuellines, chassis frame, floor panels,exhaust system etc. Atleast onceevery year, preferably after a winter'sexposure, flush the under body withplain water. Complete under bodyneeds to be thoroughly washed priorto each maintenance inspection.

133

5. Technical Information

5.1 Technical specifications ............................................ 135

5.2 Aggregate filling capacities ..................................... 140

5.3 Lubrication points ....................................................... 141

5.4 Tightening torques ..................................................... 143

135

5.1 Technical specifications Technical Information

ENGINE

Model : TATA 697 TC/IC EURO-II

Type : Water cooled direct injection Diesel Enginewith Inter-cooler

No. of Cylinders : 6 inline

Bore / Stroke : 97 mm x 128 mm

Capacity : 5675 cc

Max. Engine Output : 95 kw @ 2400 rpm as per 80/1269/EEC asamended by 89/491/EEC(TUV)

Max. Torque : 416 Nm @ 1400-1700 rpm as per 80/1269/EEC as amended by 89/491/EEC(TUV)

Compression Ratio : 17.5 : 1

Firing Order : 1-5-3-6-2-4

Air Filter : Dry type , remote mounted

Oil Filter : Full flow paper type

Fuel Filter : Two stage pre and fine filtration

Fuel Injection Pump : Rotary type

Timing : With automatic advance built-in FIP

Governor : Centrifugal type variable speed

Capacity of Cooling System : 20 litres

Crankcase Oil Capacity : Max. 14 litres Min. 12 litres

Weight of Engine : 450 kg (Dry)

Radiator Frontal Area : 2860 sq cm

CLUTCH

: Single plate dry friction type

Outside diameter of : 310 mmclutch lining

Friction Area : 1030 sq cm (approximately)

GEAR BOX

Model : GBS 40 synchromesh

No. of gears : 5 Forward 1 Reverse

136


Gear Ratios : 1st-6.34 2nd-3.37 3rd-2.114th-1.28 5th-1.00 Rev-5.85With PTO Provision & PTO Fitment optional.for LPT

REAR AXLE

: Single reduction, hypoid gear, fully floatingaxle shafts.

Ratio : 3.111 : 1 (28/9)

FRONT AXLE

: Heavy duty Forged I beam reverse Elliot type

STEERING

Steering Gear Box : Power assisted hydraulic steering.

BRAKES

Service Brakes : Dual circuit full air S-Cam brake, ABS systemwith valve silencer and suitable for -40 deg.ambient (for LPT).

: Dual circuit full air S-Cam brake (Fitment ofABS - Optional) (For LP)

Brake Drum Diameter : 325 mm

Lining Area : Front - 1236 sq cmRear - 1236 sq cmTotal - 2472 sq cm

Parking Brake : Spring actuated parking brake acting on rearwheels

Engine Exhaust Brake : Coupled with service brake (For LP)

FRAME: Ladder type frame with rivetted/bolted cross

members Side members are of channelsectionDepth : 200 mm (max)Width : 60 mm with rear under-run protection

SUSPENSION

Type : Semi elliptical leaf spring at front and rearwith auxiliary springs at rear only.

137


LP LPTSpring Span : Front - 1450 mm Front - 1150 mm

Rear - 1620 mm Rear - 1220 mm

Leaf Width : Front - 70 mm Front - 70 mmRear - 70 mm Rear - 70 mm

Shock Absorber : Hydraulic double acting telescopic type atfront and rear

Antiroll Bar : At front & rear

WHEELS AND TYRES

Tyres : 7.50x16-16PR Diagonal ply (For LP)7.50R16-14PR Radial ply (optional) (For LP)7.50R16-14PR Radial ply (For LPT)

Wheel Rims : 6.00 G x 16 SDC

No. of Wheels : Front - 2 Rear - 4 Spare - 1

FUEL TANK

Capacity : 120 litres

CAB

: All steel full-forward control cowl. Heating &Demisting optional. (For LP)

: All steel full-forward control driver’s cab withtilting arrangement & with torsion barassistance. Heating & demisting (optional).(LPT)

ELECTRICAL SYSTEMS (For LP)

OPTION-I OPTION-II

System Voltage : 12 Volts 24 Volts

Alternator Capacity : 65 Amps 75 Amps

Battery : 12V,180 Ah 2x12V,120Ah

Wind Screen Wiper : 17 W - 2 speed and intermittent wipe

Wind Screen Washer : Electrically operated

ELECTRICAL SYSTEMS (For LPT)System Voltage : 24 Volts

Alternator Capacity : 75 Amps

138


Battery : 2X12V,180 Ah

Wind Screen Wiper : 17 W - 2 speed and intermittent wipe

Wind Screen Washer : Electrically operated, 5 litres bottle size

PERFORMANCE

Max. Geared Speed in : 112 kmphTop Gear (With Std.Rear Axle)

Max. Climbing Ability in : 31 %1st Gear (With std. GearBox and Rear Axle)

WHEEL BASE (mm) : 3400 3800

Minimum Turning 14 15.4Clearance Circle Dia.in m as per IS: 9435

Minimum Turning Circle : 12.3 13.5Dia in m as per IS:9435

MAIN CHASSIS DIMENSIONS AS PER IS 9435 (mm)

LP LPT

Wheel Base : 3400 3800 3800

Track Front : 1650 1650 1650

Track Rear : 1577 1577 1577

Overall Length : 6425 7125 6860

Max. Width : 2140 2140 2125

Overall Height (Unladen) : 2550 2550 2341

Front Overhang : 1275 1275 1275

Loading platform : - - 10.3area (sq m)

WEIGHTS (kg)

WHEEL BASE (mm) : 3400 3800

Bare chassis kerb weight : 2750 2775with Cowl (With sparewheel and tools) asper IS 9211

139


Complete chassis kerb : 3070weight with cab withoutloadbody (With sparewheel and tools) asper IS 9211

Complete chassis kerb : 3570weight with cab and loadbody (With spare wheelsand tools) as per IS 9211

Max.Permissible FAW : 2800 2800

Max.Permissible RAW : 4700 4700

Max.Permissible GVW : 7500 7500

SPECIAL FEATURES (For LP): Complete Vehicle & its aggregates meet the

latest EEC/ECE/GOST norms. Relevant itemsare suitable for cold country application.

SPECIAL FEATURES (For LPT): Complete Vehicle & its aggregates meet the

latest EEC/ECE/GOST norms. Relevant itemsare suitable for cold country application.

Provision for Engine block heater fitment.Vehicle meets all Russian homologationnorms as on April 2006.

Provision of flame glow plug to assist coldstart at -22 deg. centigrades.

Fog lamps.

Battery cut-off switch.

140

5.2 Aggregate filling capacities Technical Information

Eng

ine

oil

su

mp

=14

litr

es (m

ax.)

=12

litr

es (m

in.)

Eng

ine

oil

fil

ter

=2.

5 lit

re

Gea

r b

ox

= 5

.2 l

itre

s(w

ith

o

ut

PT

O)

5.8

litre

s (w

ith

PTO

Po

wer

Ste

erin

g S

yste

m =

3 l

itre

Co

olin

g S

yste

m =

20

litre

Tyre

pre

ssu

re F

ron

t

Rate

d G

VW

=90

psi

(6.

3 b

ar)

Un

lad

en=

50 p

si (

3.5

bar

) -

LPT

35 p

si (

2.4

bar

) -

LP

Clu

tch

Hyd

rau

licSy

stem

= 1

.1 l

itre

Fro

nt

hu

b g

reas

e =

250

gm

per

hu

b

Rea

r A

xle

= 2

.75

litre

Tyre

pre

ssu

re R

ear

Rate

d G

VW

= 9

0 p

si (

6.3

bar

)U

nla

den

= 3

5 p

si (

2.4

bar

)

Rear

hu

b g

reas

e =

450

gm

per

hu

b

Fuel

tan

k =

120

lit

reW

ater

pu

mp

gre

ase

= 8

0 g

m

Oil

bat

h a

irfi

lter

= 1

.2lit

res

(if

fitt

ed)

141

Lubrication pointsThe lubrication points illustrated below and respective points are described intabular form:

5.3 Lubrication points Technical Information

Caution :Grease nipples must be carefully cleaned prior to greasing and the same appliesto grease cups/screw plugs before they are unscrewed.For greasing, use only high pressure grease guns.

1

23

45

67

8

91

0

11

18

12

13

14

15

16

17

142

5.3 Lubrication points Technical Information

Sr. Description No. of PointsNo.

1. Power Steering fluid container Oil level2. a. Drag link 2 grease nipples

b. King pin 4 grease nipplesc. Tie rod ball joints 2 grease nipples

3. Gear box Oil level4. Propeller shaft centre bearing 1 Grease nipple5. a. Rear spring suspension front 2 grease nipples

b. Rear helper spring front (Truck) 2 Apply grease6. Rear wheel hub Pack grease7. a. Rear spring suspension rear 4 grease nipples

b. Rear helper spring bracket rear (Truck) 2 Apply grease8. Rear propeller shaft 2 grease nipples9. Rear axle Oil level10. Rear propeller shaft front end 1 grease nipple11. Propeller shaft front 1 grease nipple12. Front spring suspension rear nipples 4 grease13. Front hub Pack grease14. Front spring suspension front nipples 2 grease15. Engine oil level dipstick Oil level

16. Engine oil filling Oil level17. Water pump bearing Pack grease18. Manual steering gear box (if fitted) Oil level

Also lubricate the following points not shown in the chart:a. Clutch release bearing sleeve felt pad Oilingb. Clutch release fork support bearing Apply grease

and ball pin endc. Gear box linkages (except ball joints Pack grease

which are packed with grease for life)d. Accelerator linkages; pivot pins of Oiling

clutch and brake pedals; ball pinof exhaust brake linkage

e. Door latches, centre flap locking lever Apply greaseon front panel

f. Wiper motor linkages; pinion bushing Oilingof starter motor

g. Clutch actuation linkage, fuel injection Oilingpump linkages as well as other jointsof cab and body.

143

5.4 Tightening torques Technical Information

1. Main bearing cap bolts 5 ** = Further tightening by 900 to 1000

2. Con. rod bolts - M 14x1.25 5 ** = Further tightening by 900 to 1000

3. Cylinder head bolts 1st stage 6

2nd stage 9

3rd stage 12

4. Screw plug in cylinder head - M 30x1.5 10 to 20

5. Nozzle in nozzle holder 6

6. Cap nuts on high pressure lines 2 to 2.5

7. Rocker arm support bolts 11

8. Cylinder head cover bolts 2.5

9. Screw plug in crankcase - M18 8

10. Push rod chamber cover bolts - M8 0.6

11. Oil cooler bolts on crankcase - M8 3.5

12. Timing gear housing on crankcase - M10 4.5

13. Timing gear nut (Injection pump) - M14 8

14. Timing gear housing cover - M6 0.8

15. Bolt for timer on camshaft 30

16. Vibration damper lock bolt - M24x1.5 50 to 55

17. Flywheel mounting bolts - M12 10

18. Flywheel housing on crankcase- M12 9

19. Oil pump to crankcase - M8 3

20. Oil pump pressure relief valve 1.5 to 2.5

21. Oil sump screw - M 6 0.8

22. Oil sump screw- M 8 0.9

23. Oil sump drain plug 4 to 6

24. Fan on water pump hub - M8 3.5

25. Exhaust manifold bolts / nuts 3.5

26. Starter motor on flywheel housing (M10) 5

27. Clamping bolt for alternator - M10 4

28. Nut on alternator pulley - M14x1.5 3.5 to 4.5

144

29. Fuel filter bowl mounting bolts 2

30. Banjo bolt on leak off line 0.5 to 0.7

31. Centre bolt of oil filter housing 4

32. Oil filter cover on crankcase - M10 6

33. Oil pump cover on oil pump - M8 3

34. Suction pipe on oil pump cover - M8 3

TRANSMISSION

35. Transmission main shaft 30 to 36 mkg

36. Nut holding tail pinion coupling flange 30 to 36 mkg

37. Crown wheel mounting bolts 12 mkg

38. Differential side bearing cap bolt 16 mkg

39. For mounting differential case to cover 16 to 18 mkg

40. Bolts holding clutch assembly to flywheel 3 mkg

41. Clutch housing mounting bolts 9 mkg

42. Propeller shaft coupling flange bolts 8 mkg

43. Nut holding coupling flange 30 to 36 mkg

44. Nut holding rear axle carrier assembly on beam 9 mkg

HYDRAULIC POWER STEERING AND CHASSIS

45. Steering intermediate cover screw M10 3 mkg

46. Steering intermediate cover screw M 12 x 1.5 5.6 mkg

47. Steering intermediate cover screw M 14 x 1.5 9.2 mkg

48. Sealing nut 4 3 mkg

49. Oil drain plug 2.1 mkg

50. Counter nut 1.7 mkg

51. Ball joint at frame, pitman arm and drag link 14 to 18 mkg

52. Pitman arm to cross shaft 40 to 45 mkg

53. Shock absorber mounting bolts 10 mkg

54. 'U' bolt nuts Front axle 21 mkg

Rear axle 21 mkg

55. 'U' bolt check nuts Front axle 21 mkg

Rear axle 21 mkg

56. Wheel nuts 35 to 40 mkg


145

57. Bolts holding steering mountingbracket to long member 10 mkg

58. Bolts holding steering gearbox tomounting bracket 10 mkg

59. Nut holding Pitman arm to sector shaft 45 to 50 mkg

60. Rear spring helper brackets (Truck) 12 mkg

61. Rear spring hanger mounting bolts 12 mkg

62. Brake mounting bolts (M16 x 1.5)

Front 18 mkg. M16,(with castle nut and split pin) 9.5 mkg. M12

Rear 12.5 mkg.(Rear with collar hex nut)

63. Air brake chamber/spring brakeactuator mounting bolts (M16 x 1.5) 5 - 6 mkg. *

* Precaution : Do not overtighten as itis likely to cause damage to brake chambers

64. Spring brake actuator mounting bracketto rear axle 4.6 mkg.

65. Cam shaft bearing block to rear axle (M10) 4.6 mkg.

66. Brake chamber mounting bracket tofront torque plate 8 mkg.

Note : When choosing torque wrench, remember that is should not be subjectto torque exceeding three-fourth of its capacity. Before tightening, clean thethreads and apply a little oil.


147

6. Fuel, Lubricants and Coolant

6.1 Fuel ................................................................................. 149

6.2 Lubricants ..................................................................... 150

6.3 Coolant .......................................................................... 152

149

6.1 Fuel Fuel, Lubricants and Coolants

Fuel

High speed diesel conforming to IS 1460 or DIN 51601 or equivalent isrecommended to be used as fuel.

At very low temperature fluidity of diesel may become insufficient due toparaffin separation. It is therefore necessary to mix supplementary fuel withsummer or winter grade diesel.

Care should be taken that diesel and supplementary fuel are thoroughly mixedbefore filling.

Warning : Do not mix gasoline or alcohol with diesel. This mixture can causeexplosion.

Caution : Due to the precise tolerance of diesel injection systems, it isextremely important that the fuel be kept clean and free of dirt or water. Dirtor water in the system can cause severe damage to both injection pump andinjection nozzles.

Use low sulphur content fuel having a cloud point that is at least 10 degreesbelow the lowest expected fuel temperature. Cloud point is the temperatureat which wax crystals begin to form in diesel.

Viscosity of the fuel must be kept above 1.0 centistoke to provide adequatefuel system lubrication at 40O C.

Ambienttemperature upto

Deg. CSummer

grade dieselSupplementary

fuel

Percentage

Above 0

0 to -10

-10 to -15

100

70

50

0

30

50

Ambienttemperature upto

Deg. CWinter

grade dieselSupplementary

fuel

Percentage

0 to -15

-15 to -20

-20 and below

100

70

50

-

30

50

150

6.2 Lubricants Fuel, Lubricants and Coolants

Coolant/Antifreeze

Antifreeze must be used in anyclimate for both freeze and boilingpoint protection.

It broadens operating temperaturerange by lowering coolant freezingpoint and by raising its boiling point.Do not use more than 50 percentantifreeze in the mixture unlessadditional freeze protection isrequired. Never use more than 68percent antifreeze under anycondition.

Use soft water in coolant mixture,Contaminants in hard waterneutralise the corrosion inhibitorcomponents. Water must notexceed 300 ppm hardness or containmore than 100 ppm of eitherchloride or sulphate.

Specifications - Use low silicateantifreeze which meets ASTM4985 test (GM6038M spec.)criteria or class II JIS K 2234specification.

Use a 50 percent concentrationlevel upto an ambienttemperature -37OC for non-aminobase coolant.

For ambient temperature further lowfollow the guidelines below.Antifreeze at 68 percentconcentration provides maximumfreeze protection and must never beexceeded under any conditions.

Ethylene Glycol(Non-Amino base)

50% = -37O C

60% = -54O C

68% = -71O C

Concentration Testing -Antifreeze concentration must bechecked using a refractometer(such as Fleetguard Part No.CC2800)

Windscreen Washer Antifrost

Make : Antifrost - K

Concentration : 1:5 for 0O C

1:1 for -10O C

2:1 for -16O C

1:0 for -37O C

151

6.2 Lubricants Fuel, Lubricants and Coolants

Lubricating oilrecommendations/specifications

Oil performancerecommendations

Use of quality engine oil combinedwith appropriate oil drain and filterchange intervals are critical factors inmaintaining engine performanceand durability.

Use of a high quality SAE 0 W40heavy duty engine oil which meetsAPI CH4 and MB228.3 specificationsis recommended.

Oil viscosity recommendations

Use of multi-viscosity lubricating oilhas been found to reduce oilconsumption and improve enginecranking in cold temperatures whilemaintaining lubrication at highoperating temperatures.

While 0 W-40 oil is recommendedfor most climates, refer to theaccompanying table for oil viscosityrecommendations for extremeclimates.

Note : Limited use of low viscosityoils, may be used for easier startingand providing sufficient oil flow atambient temperatures below -5O C.However, continuous use of lowviscosity oils can decrease enginelife due to wear.

Gear box oil

Use multi-grade oil conformingtoSYN Gear EP 75 W-90 GL4 Glufgrade specifications.

Change oil first at 9000 km, then at36,000 km and thereafter at every36,000 km.

Rear axle oil

Use Multi-grade oil conforming toSAE 85W-140 grade with 7%Anglamol-A 6043 by weight and APIGL5 specifications.

Change oil first at 9000 km, then at36,000 km and thereafter at every36,000 km.

Lubrication for clutch discsplines

At the time of replacement orremounting of clutch disc, smearclutch disc splines with high tempSynthetic grease 365 TS 25205 P1for free movement of clutch discon drive shaft.

Ambient temperature & oil viscosity

15W-40

10W-30

15W-30

152

Lubricant specifications chart

Lubricant Specification

Engine oil SAE 0 W-40 API CH4 and MB 228.3 specifications.

Rear axle oil SAE 85W-140 grade with 7% Anglamol-A 6043 byweight and API GL5 specifications

Gear box oil SYN Gear EP 75 W-90 GL4 Gluf grade specifications.

Power steering oil Automatic transmission fluid ATF Type A Suffix A orDextron II D

Brake/clutch fluid SAE J 1703F DOT 3 plus or DOT 4

Coolant Non - Amino Base class II JIS K 2234 specification

Chassis/wheel Li base grease NLGI 2 (Consistency No. 3)bearing grease

Clutch

Clutch release Synthetic grease 365 TS 25205 P1bearing Sleeve,Clutch disc splines,

Brake pneumatic Synthetic grease 365 TS 25205 P1equipment

Windshield washer Methanol and water 50:50water

6.3 Coolants Fuel, Lubricants and Coolants

Power steering oil: Use Automatictransmission fluid conforming to ATFType A suffix A or Dextron II D.

Clutch fluid: Use clutch fluidconforming to SAE J 1703F DOT 3plus or DOT 4 specifications.

Grease: Use Synthetic grease 365TS 25205 P1.

153

7. Service Recommendations

7.1 Special instructions .................................................... 155

7.2 PDI ................................................................................... 156

7.3 Service schedule ......................................................... 159

7.4 Record of services performed ................................ 168

7.5 Record of repairs performed .................................. 170

155

7.1 Special instructions Service Recommendations

Regular maintenance

Maintenance schedules given in thisbook are meant for vehiclesoperating under normal conditions.In case operating conditions aresevere, certain operations may haveto be carried out more frequently andcertain other operations may have tobe introduced based on your ownexperience.

In case the engine has to operateeven when vehicle is stationery,18,000 km interval for regular engineoil and oil filter cartridge changeshould be carried out in terms ofoperational hours or litres of fuelconsumed. For example in casewhere vehicle is used as a stationerypower source, engine oil and oil filtercartridge should be changed afterevery 250 operational hours or afterevery 3,200 litres of fuel consumed.

PDI - Service to be performed onceonly i.e., at the time of delivery ofvehicle.

Every 1,000 km.

Type 2 Service at 9,000 - 9,500 km

repeating at every 18,000km.

Type 3 Service at 18,000 - 18,500km repeating at every36,000 km.



All periodical services to be carriedout at Tata authorised workshops.

Daily maintenance & maintenancescheduled at every 1000 kms to becarried out by driver.

156

1. Tata Diesel Vehicles have beenbuilt to give you thousands andthousands of miles of economicaland trouble free performance.This is, however, possible only ifvehicle is systematicallymaintained and operated strictlyaccording to the instructionscontained in this book.

2. During body building, specialcare should be exercised toensure that chassis is not affectedin any manner. Body should bemounted on chassis, through 'U'bolts without drilling holes onchassis frame. Particular attentionshould be paid to see that nounauthorised modifications and /or repair work are done onchassis or any parts thereof, asotherwise, it would not onlyaffect performance but alsovehicle would loose its eligibilityfor our warranty.

Before commissioning thevehicle after body building, itshould be produced forinspection at Tata authorisedworkshop to ascertain thatoperational efficiency of thevehicle has not been impairedduring body building. Anydamage the vehicle might havesustained during body building orarising out of bad storage or lackof proper care or inadequatemaintenance, will be rectified bythe inspecting workshop.

3. Tata authorised workshops areequipped with special tools andare manned by technicalpersonnel trained by us. Ourauthorised workshops are,therefore in a position to renderyou any expert advice andservice, your vehicle may need.Please give them an opportunityto serve you, so that you mayobtain economical and troublefree performance from yourvehicle.

4. For any technical adviceconcerning your vehicle pleasecontact nearest Tata authorisedworkshop.

7.2 PDI Service Recommendations

157


PDI SERVICE

Following jobs are to be performedat PDI.

1. Wash & clean the vehiclethoroughly.

2. Road test the vehicle. Check forproper functioning of engine,clutch, transmission aggregates,steering, brakes etc.

Check vehicle behaviour :pulling to LH/RH, wobbling, selfcentering, acceleration etc.

3. Static test : Start engine &check for : Idling rpm &maximum rpm (look for anyabnormal noise), service brakeair pressure, water temperature,operation of exhaust brakesystem etc.

4. Check engine oil level. Level isacceptable if found betweenmid and max mark.

5. Check for any leakages ofengine oil.

6. Check hoses, clamps & pipes atall locations in air intakesystem.

7. Check hoses, clamps & pipes atall locations in cooling system.

8. Check for leakages of gear boxoil.

9. Check for proper fitment ofgear shift lever rubber boots.

10. Check level of clutch fluid.Acceptable if found betweenmid and max.

11. Check clutch / brake pedal freeplay.

12. Check for leakages in clutchactuation circuit

13. Check for fitment of split pinsat drag link ball joints, tie rodball joints, Stub axles.

14. Check for fitment of greasenipples at all locations.

15. Check for leakages of rear axleOil.

16. Check tightness of centrebearing bracket mounting bolts.

17. Check for any air leakages inbrake circuit.

18. Check fitment of split pins atthe mounting bolts of torqueplates, brake chambers, pushrods etc.

19. Check for steering wheel freeplay (axial and radial).

check leakages of powersteering oil.

20. Check for fitment of split pin atsteering shaft.

21. Check for any leakages in thefuel system.

158

22. Check coolant level intransparent auxiliary tank. Levelis acceptable if it is foundbetween mid and max.

23. Check for any leakages ofcoolant.

24. Check functioning of all bulbs.

25. Check for proper functioning ofblinkers, horn, head lamp,parking light, reverse light,wiper system, washer systemetc.

26. Check tightness of electricalconnection at battery, startermotor, alternator & starter relay.

27. Check all fuses .

28. Check all the earth points forlooseness.

29. Check for functioning of allgauges / meters / warninglamps.

30. Check connectors in all thecircuits.

31. Check for proper opening andclosing of doors .

32. Check functioning of door locks,latches and windows.

33. Check for any complaints onthe cab fittings, instrumentpanel, glove box etc.

34. Check and tighten hand loosefasteners

35. Check for any breakages, bends,failure of any component /assembly / unit.

36. Any fouling between twocomponents which may lead toleakages or other complaints.Fouling of fuel lines, brakepipes, clutch pipes, air intakepipe, power steering hydraulicpipe, clutch / brake linkages,accelerator rod etc.

37. Lubricate with oil can linkagesand all other points asrecommended.

38. Grease with grease gun all thepoints as recommended.

39. Check for proper functioning ofcab tilt mechanism.

40. Check for proper functioning offront/rear fog lamps, Cabheating mechanism etc.(optional fitments).


159

7.3 Service sched

ule

Service Reco

mm

end

ation

s

1. Wash vehicle. 9,000 ● ● ● ● ● ● ● ●

ENGINE

1. Check oil level in the sump and top up, if necessary. Check oil leaks and rectify, if any. DAILY D ● ● ● ● ● ● ● ●

2. Check coolant level in auxiliary tank and top up, if necessary. Check coolant leakages and rectify, if any. DAILY D ● ● ● ● ● ● ● ●

3. Drain water trapped in fuel water separator. DAILY O ● ● ● ● ● ● ● ●

4. Check thermostat for proper functioning and replace if necessary. 18000 ● ● ● ●

5. Lubricate with oil can : Controls to fuel injection pump and exhaust brake linkage ball joints. 9000 O ● ● ● ● ● ● ● ●

Pinion bush of the starter motor.

6. Change oil in sump. Drain off while hot. Clean magnetic drain plug. 18000 ● ● ● ●

7. Clean engine oil filter housing and cover. Replace oil filter cartridge and 'O' ring. 18000 ● ● ● ●

8. Clean oil bath air filter (Euro I) and fill to correct level with recommended engine oil. Check condition 9000 ● ● ● ● ● ● ● ●

of sealing rings, replace if necessary.

9. Remove drain plugs of fuel filters. Drain off sediments. Bleed the fuel system. 9000 ● ● ● ● ● ● ● ●

D : Daily service to be performed by the driver/operator

O : Service to be performed at every 1000 kms by the driver/operator

W : Service to be performed weekly or at every 2000 kms. whichever is earlier bydriver / operator

SR.NO.

OPERATION FREQUENCYIN KM

DAILY

Ever

y 1,

000

km

9,00

0-9,

500

km

18,0

00-1

8,50

0 km

27,0

00-2

7,50

0 km

36,0

00-3

6,50

0 km

45,0

00-4

5,50

0 km

54,0

00-5

4,50

0 km

63,0

00-6

3,50

0 km

72,0

00-7

2,50

0 km

160

7.3 Service sched

ule

Service Reco

mm

end

ation

s


DAILY

Ever

y 1,

000

km

9,00

0-9,

500

km

18,0

00-1

8,50

0 km

27,0

00-2

7,50

0 km

36,0

00-3

6,50

0 km

45,0

00-4

5,50

0 km

54,0

00-5

4,50

0 km

63,0

00-6

3,50

0 km

72,0

00-7

2,50

0 km

10. Clean prefilter at feed pump and bleed the fuel system. 9000 ● ● ● ● ● ● ● ●

11. Check valve clearance (warm-up engine) and adjust, if necessary. 18000 ● ● ● ●

12. Check and if necessary, tighten the following :-(a) Injector pressure lines, (b) Leak off fuel line banjo bolts, (c) Heat exchanger bolts, (d) Oil 9000 ● ● ● ● ● ● ● ●

sump screws, (e) Oil pressure pipe union at heat exchanger, (f ) Exhaust manifold mountingbolts, (g) Turbocharger mounting fasteners, (h) Flywheel housing mounting bolts, (i) Clutchhousing mounting bolts, (j) Air cleaner mounting bolts, (k) Delivery valve holders, (l) Leak off lines(m) Engine mounting bolts, (n) Water pump, (o) Coolant temperature transducer, (p) Air filtermounting (q) Exhaust manifold and muffler assembly.

13. Check alternator / fan belt condition and tension. If necessary replace belt & adjust. 9000 ● ● ● ● ● ● ● ●

14. Check and if necessary, tighten the following :-(a) Push rod chamber cover, (b) Timing gear cover, (c) Cylinder head cover, (d) Radiator mounting 18000 ● ● ● ●

(e) Radiator hose connections, (f ) Fuel tank brackets, (g) Fuel filter bracket, (h) Fuel filter mountingbolts, (i) Air ducting hose connections, (j) Engine mounting bolts.

15. Check air cleaner service indicator on instrument cluster (Euro II). If it blinks continuously , DAILY D ● ● ● ● ● ● ● ● ●

clean air filter housing and replace primary cartridge.

16. Change air filter secondary cartridge. After every 3 replacements of primary cartridge

17. Check fuel level in fuel tank and secure fuel tank cap. DAILY D ● ● ● ● ● ● ● ●

18. Remove primary fuel filter bowl, clean and replace element. Bleed the system. 18000 ● ● ● ●

19. Remove secondary fuel filter bowl, clean and replace element. Bleed the system. 36000 ● ●

SR.NO.

161

7.3 Service sched

ule

Service Reco

mm

end

ation

s

SR.NO.


DAILY

Ever

y 1,

000

km

9,00

0-9,

500

km

18,0

00-1

8,50

0 km

27,0

00-2

7,50

0 km

36,0

00-3

6,50

0 km

45,0

00-4

5,50

0 km

54,0

00-5

4,50

0 km

63,0

00-6

3,50

0 km

72,0

00-7

2,50

0 km

20. Remove strainer in fuel tank, clean and refit. Bleed the system. 36000 ● ●

21. Remove engine breather cap, clean in kerosene. Blow air from outlet pipe. Replace gasket, 9000 ● ● ● ● ● ● ● ●

if necessary. Check and replace rubber hose, if necessary.

22. Remove injection nozzles. Test pressure and spray characteristics on nozzle testing equipment. 36000 ● ●

Do not disassemble nozzle, if found correct.

23. Drain cooling system - reverse flush. Refill system with fresh coolant. Add recommended quantity 320000 kms or 2 years whichever is earlier.

of anti freeze agent in specified ratio.

24. Replace radiator rubber hoses. 72000 ●

25. Remove and clean exhaust outlet elbow, exhaust butterfly valve, shaft and refit. (Do not lubricate). 72000 ●

26. Check engine for trouble-free operation (colour of exhaust gases and nozzle operation). 18000 ● ● ● ●

27. Check end play of turbo charger shaft & radial clearance between turbine wheel & housing (Euro II). 72000 ●

C L U T C H

1. Check level of clutch fluid in plastic containers. 9,000 O ● ● ● ● ● ● ● ●

Top up if necessary.

2. Check clutch pedal free play and adjust if necessary. (For highway operation vehicles, this check to 9,000 O ● ● ● ● ● ● ● ●

be done more often).

3. Remove grease cup for lubricating clutch release bearing. Replace 3/4 full with grease and tighten 9,000 ● ● ● ● ● ● ● ●

by a few turns.

4. Lubricate with oil can-clutch pedal pivot pins. 9,000 O ● ● ● ● ● ● ● ●

5. Tighten if necessary. Mounting of clutch master cylinder and slave cylinder. 9,000 ● ● ● ● ● ● ● ●

162

7.3 Service sched

ule

Service Reco

mm

end

ation

s


DAILY

Ever

y 1,

000

km

9,00

0-9,

500

km

18,0

00-1

8,50

0 km

27,0

00-2

7,50

0 km

36,0

00-3

6,50

0 km

45,0

00-4

5,50

0 km

54,0

00-5

4,50

0 km

63,0

00-6

3,50

0 km

72,0

00-7

2,50

0 km

SR.NO.

6. Remove clutch release fork support bearing. Apply light coat of 18,000 ● ● ● ●

recommended grease and refit.

7. Dismantle clean, inspect, replace kits and re-assemble clutch master cylinder 72,000 ●

and slave cylinder and bleed the system.

GEAR BOX

1. Check oil level in gear box, top up if necessary. 9,000 O ● ● ● ● ● ● ● ●

2. Change oil in gear box (also at first 9,000 km). 36,000 ● ● ●

3. Clean breather on gear box. 72,000 ●

4. Check & tighten if necessary.Gear box mounting screw. 18,000 ● ● ● ●

SUSPENSION

1. Grease with grease gum : 9,000 O ● ● ● ● ● ● ● ●

ii. King pins (4). Tie rod ball joints (2), Drag link ball joints (2).

iii. Front spring pins (6).

iv. Rear spring pins (6).

2. Check condition of shock absorber bushes, replace if necessary. 9,000 ● ● ● ● ● ● ● ●

3. Check wheel alignment and adjust if necessary. 36,000 ● ●

4. Check shock absorber, replace, if defective. 18,000 ● ● ● ●

5. Dismantle front and rear springs. Clean and apply graphite grease. 72,000 ●

Check and if necessary replace eye bushes.

163

7.3 Service sched

ule

Service Reco

mm

end

ation

s

SR.NO.


DAILY

Ever

y 1,

000

km

9,00

0-9,

500

km

18,0

00-1

8,50

0 km

27,0

00-2

7,50

0 km

36,0

00-3

6,50

0 km

45,0

00-4

5,50

0 km

54,0

00-5

4,50

0 km

63,0

00-6

3,50

0 km

72,0

00-7

2,50

0 km

6. Check and tighten if necessary : Anti roll bar mountings. Nuts of spring pins, 9,000 O ● ● ● ● ● ● ● ●

'U' bolts of front and rear springs.

FRONT AXLE

1. Change grease in front hub. Adjust bearing play. Replace damaged/worn parts. 36,000 ● ●

2. Check front hub bearing play and adjust if necessary. 9,000 ● ● ● ● ● ● ● ●

REAR AXLE

1. Check oil level in rear axle, top up if necessary. 9,000 O ● ● ● ● ● ● ● ●

2. Change oil in rear axle. (Also at first 9000 km) 36,000 ● ● ●

3. Change grease in rear hub . Adjust bearing play. Replace damaged/worn parts. 36,000 ● ●

4. Check rear hub bearing play and adjust if necessary. 9,000 ● ● ● ● ● ● ● ●

WHEELS & TYRES

1. Check tyre pressure DAILY D ● ● ● ● ● ● ● ●

2. Check wheel mounting nuts and tighten if necessary. 9,000 O ● ● ● ● ● ● ● ●

3. Check and tighten spare wheel carrier mountings. 9,000 ● ● ● ● ● ● ● ●

4. Tyre rotation. 9000 ● ● ● ● ● ● ● ●

PROPELLER SHAFT

1. Grease with grease gun : 9,000 O ● ● ● ● ● ● ● ●

Propeller shaft ‘U’ joints (3), Propeller shaft sliding yoke (1).Propeller shaft centre bearing (1).

2. Check & tighten the propeller shaft centre bearing bracket mounting bolts, coupling flange bolts. 9,000 ● ● ● ● ● ● ● ●

164

7.3 Service sched

ule

Service Reco

mm

end

ation

s

BRAKES - 'S' CAM FULL AIR BRAKES

1. Check brakes. DAILY D O ● ● ● ● ● ● ● ●

2. Check air dryer functioning by ensuring that no oil droplets or condensed water is thrown from Weekly / ● ● ● ● ● ● ● ●

exhaust port of the air dryer. If there is condensed water/oil in the exhaust, replace the air 2,000 kmdryer - desiccant cartridge and filter.

3. Grease with grease gun : Slack adjusters & cam shaft bushes. Weekly / ● ● ● ● ● ● ● ●

2,000 km

4. Lubricate with oil can : Brake chamber fork and pin, linkages Weekly / ● ● ● ● ● ● ● ●

of foot brake, ball joints of exhaust brake linkages. 2,000 km

5. Check brake system for leaks and rectify if necessary. Weekly / ● ● ● ● ● ● ● ●

2,000 km

6. Check brake lining wear, clearance with drum and travel of brake chamber’s push rod. 9,000 ● ● ● ● ● ● ● ●

Adjust service brakes if necessary. ( for long route application)

7. Check brake lining wear, clearance with drum and travel of brake chamber’s push rod. 4,500 ● ● ● ● ● ● ● ●

Adjust service brakes if necessary. (for city/hilly/cross country applications)

8. Check for proper functioning of engine exhaust brake and slackness in linkages. 9,000 ● ● ● ● ● ● ● ●

9. Check brake torque plate mounting bolts and tighten if necessary. 9,000 ● ● ● ● ● ● ● ●

(also at every

lining change)

10. Check hoses / nylon pipes for damages and replace if necessary. 18,000 ● ● ● ●

11. Check condition of gaiter in different brake valves, exhaust flap in dual brake valve, nylon breather 18,000 ● ● ● ●

tube and clips of spring brake actuator


DAILY

Ever

y 1,

000

km

9,00

0-9,

500

km

18,0

00-1

8,50

0 km

27,0

00-2

7,50

0 km

36,0

00-3

6,50

0 km

45,0

00-4

5,50

0 km

54,0

00-5

4,50

0 km

63,0

00-6

3,50

0 km

72,0

00-7

2,50

0 km

SR.NO.

165

7.3 Service sched

ule

Service Reco

mm

end

ation

s

SR.NO.


DAILY

Ever

y 1,

000

km

9,00

0-9,

500

km

18,0

00-1

8,50

0 km

27,0

00-2

7,50

0 km

36,0

00-3

6,50

0 km

45,0

00-4

5,50

0 km

54,0

00-5

4,50

0 km

63,0

00-6

3,50

0 km

72,0

00-7

2,50

0 km

12. Check mounting bolts of brake chambers, different valve mountings, 18,000 ● ● ● ●

air tank mountings, air line clamps and tighten if necessary.

13. Carry out brake system routine checks I 18,000 ● ● ● ●

14. Remove drum brakes. Inspect brake linings, brake drums etc. Rectify defects if any. 36,000 ● ●

15. Carry out brake system routine checks II 36,000 ● ●

16. Replace brake lining _ When worn upto indicator slot or1 mm over the rivets

17. Grease fulcrum pin bushes and camshaft bushes & roller ends. _ At the time of replacing linings

18. Dismantle pneumatic aggregates of brake system. Clean, inspect and replace parts if necessary. 72,000 ●

Apply grease to components while reassembling.

19. Complete overhauling of foundation brake Every second brake shoe relining or as required

20. Air dryer - replace desiccant cartridge and filter Every two years

STEERING

1. Check oil level in power steering hydraulic tank and top up, if necessary. 9,000 ● ● ● ● ● ● ● ●

Check hydraulic piping connections for leakages and rectify, if any.

2. Check power steering pump belt condition and tension. Adjust, if necessary. 9,000 ● ● ● ● ● ● ● ●

3. Drain off hydraulic oil of power steering. Replace filter cartridge & fill in fresh oil. Bleed the system. 72,000 ●

4. Check and tighten if necessary : ‘U’ joints on steering spindle. Steering gear box and its mounting 9,000 ● ● ● ● ● ● ● ●

bracket bolts joints of pitman arm, drag link and tie rod

166

7.3 Service sched

ule

Service Reco

mm

end

ation

s

ELECTRICALS

1. Check & tighten if necessary :Mounting bolts of alternator, starter motor and wiper motor. 9,000 ● ● ● ● ● ● ● ●

Battery mounting bolts.All electrical wire connections.Head lamp mounting screws.

2. Check battery cells with cell tester and specific gravity of 36,000 ● ●

electrolyte with hydrometer. Service battery if necessary.

3. Check head lamp focus. Adjust if necessary. 9,000 ● ● ● ● ● ● ● ●

4. Check electrical gadgets for proper functioning. Rectify if necessary DAILY D ● ● ● ● ● ● ● ●

5. Check electrolyte level in battery and add distilled water if necessary. 9,000 O ● ● ● ● ● ● ● ●

6. Check battery mountings, clean battery posts and terminals, 9,000 O ● ● ● ● ● ● ● ●

tighten terminals and smear vaseline/petroleum jelly.

7. Lubricate with oil can : Pinion bushing of starter motor and wiper and motor linkages. 18,000 ● ● ● ●

8. Check alternator carbon brushes and replace if necessary. 36,000 ● ●


DAILY

Ever

y 1,

000

km

9,00

0-9,

500

km

18,0

00-1

8,50

0 km

27,0

00-2

7,50

0 km

36,0

00-3

6,50

0 km

45,0

00-4

5,50

0 km

54,0

00-5

4,50

0 km

63,0

00-6

3,50

0 km

72,0

00-7

2,50

0 km

SR.NO.

167

7.3 Service sched

ule

Service Reco

mm

end

ation

s

BODY AND MISC

1. Lubricate with oil can : Accelerator linkages, door hinges, door latches Bonnet hinges, bonnet 9,000 O ● ● ● ● ● ● ● ●

stay rod, bonnet opening cable and locking lever and load body hinges.

2. Apply grease to door lock inner racket and pawl 36,000 ● ●

3. Check doors for proper opening & closing. If required adjust striker assembly. 9,000 ● ● ● ● ● ● ● ●

4. Check & tighten if necessary : Mounting of driver’s cab, load body 9,000 ● ● ● ● ● ● ● ●

to frame and driver’s/co-driver’s seats

HEATING / DEMISTING SYSTEM (wherever fitted)

1. Check hose joints of heating system for leakage. Tighten if necessary 9,000 ● ● ● ● ● ● ● ●

2. Check hoses of heating system for cracks. Replace if required 9,000 ● ● ● ● ● ● ● ●

3. Check blower for proper functioning. Check fuse. Replace if found blown. 9,000 ● ● ● ● ● ● ● ●

RUBBER / NYLON HOSES & FLEXIBLE PIPES

4. Check hoses & pipes of air / fuel / coolant / brake / clutch / windscreen washing systems 9,000 ● ● ● ● ● ● ● ●

for cracks / aging / deterioration. Replace, if necessary

SR.NO.


DAILY

Ever

y 1,

000

km

9,00

0-9,

500

km

18,0

00-1

8,50

0 km

27,0

00-2

7,50

0 km

36,0

00-3

6,50

0 km

45,0

00-4

5,50

0 km

54,0

00-5

4,50

0 km

63,0

00-6

3,50

0 km

72,0

00-7

2,50

0 km

168

PDI

9,000 2

18,000 3

27,000 2

36,000 4

45,000 2

54,000 3

63,000 2

72,000 5

81,000 2

90,000 3

99,000 2

1,08,000 4

1,17,000 2

1,26,000 3

1,35,000 2

1,44,000 5

1,53,000 2

1,62,000 3

1,71,000 2

RecommendedService

At km Type

Date Odometerreading Kms.

RepairOrderNo.

ServicingDealer's Signature

& Stamp

7.4 Record of services performed Service Recommendations

169

1,80,000 4

1,89,000 2

1,98,000 3

2,07,000 2

2,16,000 5

2,25,000 2

2,34,000 3

2,43,000 2

2,52,000 4

2,61,000 2

2,70,000 3

2,79,000 2

2,88,000 5

2,97,000 2

3,06,000 3

3,15,000 2

3,24,000 4

3,33,000 2

3,42,000 3

RecommendedService

At km Type

Date Odometerreading Kms.

RepairOrderNo.

ServicingDealer's Signature

& Stamp

7.4 Record of services performed Service Recommendations

170

7.5 Reco

rd o

f repairs p

erform

edService R

ecom

men

datio

ns

Odometer Repair Servicing Dealer’sDate reading km Order No. Particulars of Repair Signature & Stamp

171

7.5 Reco

rd o

f repairs p

erform

edService R

ecom

men

datio

ns


172

7.5 Reco

rd o

f repairs p

erform

edService R

ecom

men

datio

ns


173


WIRING DIAGRAMLP/LPT 613 EURO-IIDrg./Part No. 2641 5400 00 11Sheet No. 1 of 16

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