warranty policy vehicle sep 2008

AL Warranty (Vehicles)

1

Warranty Policy &

Procedures

For Vehicles

ASHOK LEYLAND LIMITED

Technical Service Group

Marketing Division,

Nandanam

Chennai

September 2008


2

FOREWORD

The Warranty policy of Ashok Leyland covering the terms of warranty offered for

various models of vehicles marketed by AL in India and the procedure to be followed in

administering the Policy is given in this Manual.

This manual contains the latest information on AL’s warranty policy and any further

revision to the policy will be communicated to the recipients of manual for updation.

Information on Free Services offered by AL on various models of vehicles is also

included in this Manual.

In this manual wherever the word ‘Dealer’ is used, it shall also include ‘Authorised

Service Centre’ whether appointed AL or by a Dealer.

Ashok Leyland Limited

Marketing Division

Technical Service Group

Chennai

Dated: September 2008


3

UPDATION OF AMENDMENTS

This Manual contains the updated information on warranty policy as on September 2008

.

On each page, in the left hand bottom corner the month and year of issue are printed. In

this issue, all pages will show “Issue: September 08 /0”, the numeral ‘0’ denoting first

issue.

Any future amendments to the policy will be issued in the form of a “Warranty Policy

Amendment”. This amendment sheet bearing the Section and Page Number can be

inserted in place of the relevant Section/Page that has been superseded.

For example, the first amendment to page 3-1 if done in October 2006 will show at left

hand bottom corner “Issue: Oct 06/1” and will replace the page 3-1 bearing the notation

“Issue: Oct 06/0”.

The Amendment Record appearing after the “Table of Contents” will be updated by the

recipient.Any amendment to this manual will be issued by DGM – Technical Service

THIS MANUAL IS MEANT ONLY FOR PRIVATE CIRCULATION

FOR THE USE OF AL DEALERS / AUTHORISED SERVICE CENTRES

AND AL PERSONNEL.

Wherever the term ‘Dealer(s)’ occurs, it shall be read as Dealers / Authorised Service

Centres


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TABLE OF CONTENTS

Section Title From To

Warranty Terms

1 Applicable to MDV’s / ICV’s 2 4

Warranty Policy

2 Warranty Period 5 -

3 Scope of Warranty 6 -

4 Responsibility for rendering warranty attention 7 -

5 Disposal of failed components 8 -

6 Submission of Claims / Documentation 9

7 Settlement of Claims 10

8 Ancillary Claims 11

9 Spare Parts Claims 12

10 Goodwill Claims 13 14

11 Float Claims 15

12 Replacement of parts on unsold vehicles 16

13 Campaign repairs / replacement 17

Warranty Procedure

14 Sequential action in handling warranty complaints 18 20

15 Permissible Gross Vehicle Weight 21 26

Technical Guidelines

16 Criteria for acceptance of warranty claims 27

17 Criteria for acceptance of warranty claims – AL 28 46

18 Technical guidelines for warranty decision - ANC 47 50


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19 Non-warranty items 51

20 Limits for acceptance of claims on ‘wear & tear’

components

52

Ancillary Claims

21 Procedure for claiming 53 54

22 List of proprietary items with warranty period varying

from AL warranty period

55 -

23 Supplier Code/Identification/Destination of failed

parts

56 76

Preparation of Claims

24 Time Limit for submission of claims 77 -

25 Completion of Warranty Claim – Main &Ancillary 78 89

25.1 Completion of Warranty Labour Claim 90 91

26 Product Complaint Codes & Fault codes 92 122

Labour Charges

27 Repair Operation Time schedule 123 135

28 Flat Rate schedule for machining jobs 136 138

Disposal of Failed Components

29 Despatch of failed AL items 139

Settlement of Claims

30 Mode of Settlement 140 -

31 Payments for parts replaced 141 -

32 Payments of Labour charges 142 -

33 Manhour rate 143

34 Payment of Labour Charges to Sub-dealers/ALHRCs 144

35 Payment of Incidental Expenses for services rendered 145


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outside the dealer workshop

Free Service Policy & Procedure

36 Eligibility /Periodicity for Free Services 146 147

37 Time Limit for availing Free Services 148

38 Labour charges for Free Services payable to dlrs 149

39 Schedule of labour charges to Dealers for Free Services 150 151

40 Schedule of labour charges payable to Sub-

dealer/ALHRCS for Free Services

152

41 Oil change during PDI 153

42 Basic price of recommended Oils to be filled during

PDI

154

Miscellaneous

43 Abbreviations 155 156


1

WARRANTY POLICY & PROCEDURES AMENDMENT RECORD

Existing Replaced By

Sl No Page No Issue Page No Issue Circular Reference


2

1. ASHOK LEYLAND WARRANTY

Applicable To MDV Range

ASHOK LEYLAND LIMITED (AL)

warrants each vehicle sold by it to be

free from defects in material and

workmanship subject to the following

terms and conditions:

1. The period of warranty shall be 18

months from the date of sale or

1,50,000 KMs, whichever is earlier.

For Taurus Tipper, the period of

warranty shall be 18 months from

the date of sale or 3000 hours of

operation, whichever is earlier.

2. The warranty extends to the first

registered owner of the vehicle

only or (in the absence of

registration) to the first commercial

user of the vehicle. In the event of

transfer or any alienation otherwise

of the vehicle during the period

mentioned in Clause 1 above, the

warranty shall stand terminated

unless prior written consent of

Ashok Leyland is obtained.

3. In the event of any defect being

discovered within the period

mentioned in Clause 1 above, the

defective part is returned to the

nearest AL Dealer workshop,

freight paid, within 7 days

4. The obligation under warranty

shall be limited to either repairing

or replacing free of charge such

parts of the vehicle as are deemed

to be defective in the opinion of AL

and shall not extend to

consequential losses. The replaced

part shall become the property of

AL.

5. For proprietary parts not

manufactured by AL such as Fuel

Injection Equipment, Electrical

Equipment, Tipping Equipment,

Brake components, Instruments,

Batteries, Tyres and tubes the

warranty terms of the respective

supplier will be applicable.

6. The buyer shall have no other right

except those expressly stated herein

and have in particular no right to

repudiate the sale, or any

agreement, or to claim any

reduction in the purchase price of

the vehicle or to demand any

damages or compensation for

incidental or consequential losses

such as loss of use of vehicle, loss

of time, inconvenience or damage

to personal property, commercial

loss such as loss of revenue etc.,

during the period when the vehicle

is undergoing service / warranty

repairs.

7. The customer will be responsible

for


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* the cost of non-durable

materials (lubricants, fuel,

grease, filters, etc.,), rubber

items, liners (clutch, brake), soft

trims, upholstry and paint

coatings.

* The cost of maintenance and

lubrication operations.

* The cost of repairs made

necessary by normal wear &

tear, accidents or improper use

not authorised by AL or by

improper storage or negligence.

* The cost of on-road repairs,

towing, parking and insurance.

* The cost of repairs, caused by

damage due to fire, flood,

earthquake or such natural

calamities or by civil

disturbance.

8. The warranty shall become null

and void:

* If the vehicle is used in ways

not recommended by the

company, if any features of the

vehicle are modified, if the

vehicle is repaired or

disassembled, even partially, by

persons not belonging to AL’s

authorised workshop, if the

vehicle is fitted with body of

design, size, position and

mounting other than what is

prescribed by AL, if the

overhang is extended in excess

of the original specification

given in the Operator Manual,

if the failure of the tractor is

due to faulty design / coupling

of the trailer (in the case of

tractor trailer combination) or if

the vehicle is loaded beyond its

carrying capacity as certified by

AL.

* If the fuel injection pump

calibration figures are altered or

the relative seals tampered

with, if unsuitable lubricants or

fuels or coolants are employed

or non-genuine spare parts are

fitted.

* If the Free Services are not

carried out.

* If the recommended

maintenance practice is not

followed.

9. When a part is replaced under the

terms of warranty the benefits of

the warranty shall apply to the

replacement part for the reminder

of warranty period stated in Clause

1 and not beyond.

10. AL reserves the right to modify the

technical specifications of and

introduce improvements to its

vehicles at any time and is under

no obligation to apply such

modification or improvements to

vehicles produced at an earlier

date.


4

11. This warranty is in lieu of and

excludes all conditions,

warranties, liabilities expressed or

implied, whether in common law

statute or otherwise in relation to

all vehicles, whether covered by

warranty or not.


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2. WARRANTY PERIOD

The Warranty period for various models of vehicles is -

MDV/ICV 18 months from the date of sale or 1,50,000 KMs,

whichever is earlier.

For Taurus Tipper 18 months from the date of sale or

3000 hours of operation, whichever is earlier.

SPECIAL VEHICLES As per contract of sale


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3. SCOPE OF WARRANTY

Warranty covers the repair/replacement of the failed parts. Both parts and labour for

replacing/repairing are free of charge to the customer.

Warranty does not apply to failures due to normal wear and tear. The norms for

acceptance of claims under warranty for wear and tear items like bearings, clutch discs,

etc. are given in Section 19.

Warranty does not apply to spring leaves, glass, rubber, items like fan belts, hoses, etc

unless specifically agreed to in the sale contract. A list of non-warranty items is given in

Section 18

Warranty does not cover consequential damages, incidental expenses such as towing

(special trips to recover a broken down vehicle) or any loss, monetary or otherwise

claimed for the period vehicle was off road.

The customer will be liable to pay only the cost of consumables for any work carried out

under the terms of warranty. However, where oil replacement is required on account of

overhaul of Engine, Gearbox and Rear axle, the same shall be carried out Free of cost to

customer. This will not include topping-up of ‘Oils’.

Dealer shall make available in his workshop all the tools and equipment, including

Special Maintenance Tools, required to carry out repairs/replacement.

If it becomes necessary, the Dealer shall render attention at a location away from his

workshop.


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4. RESPONSIBILITY FOR RENDERING WARRANTY ATTENTION

Warranty attention is rendered by the accredited Dealers of AL. Dealers are not

authorised to make or publish any warranty on behalf of AL other than the terms

offered by AL in the Warranty Card.

Dealer shall extend warranty attention to all vehicles reporting with a complaint within

the terms of warranty whether or not the vehicle has been sold by him.

Dealer shall carry out warranty repairs/replacement within the shortest possible time in

order to ensure that vehicle downtime is kept at the minimum. Dealer shall adhere to

the time limits laid down by AL for carrying out warranty attention.

Dealer shall use parts from his stock for carrying out replacements.

No Dealer shall collect a deposit for any warranty attention unless the failure is

clearly due to misuse and AL has approved the collection of deposit.


8

5. RETURN OF FAILED COMPONENTS

All failed components replaced under warranty are the property of AL and have to be

returned to AL.

The procedure for returning the components is given in Section 29


9

6. SUBMISSION OF CLAIM/DOCUMENTATION

A Warranty Claim shall be completed for all failures accepted under warranty. All

Warranty Claims shall be prepared and submitted to AL online within 15 days from the

date of completion of the warranty job.

Every dealer shall be provided a Login ID by AL. AL shall make available online the

status on ‘acceptance’ or ‘return’ of the claim. For each returned claim, the Dealer shall

be provided an error log pointing out the field in which the error has occurred and the

nature of the error. The Dealer shall correct the errors and upload the claim again under

a different file name. The 15 day time limit includes correction of errors by the Dealer.

Dealer shall maintain all the relevant records namely Vehicle inward register, Job card,

Parts Indent, Customer bill, Parts invoice for components procured locally, Labour

invoice for outsourced jobs, Gate pass and these shall be presented to AL’s

representative at the time of audits.

Dealer shall obtain the signature of the Customer in the job card as evidence of

satisfactory completion of the job.


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7. SETTLEMENT OF CLAIM

Dealer shall be paid the cost of repairs / replacement.

Settlement will be effected in the form of cheque or ECS or book adjustment.

Please refer to Section 31 to 35 for valuation of claims, pay order details, etc.


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8. ANCILLARY CLAIM

AL will accept claims on account of failure of all ancillary supplies except in the case of

identified suppliers (given in Section 21) who will render warranty attention directly or

through their own dealer network.

Dealer shall submit a claim for the failure of any component supplied by ancillary

suppliers and follow the procedure for return of failed material as given in Section 29.


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9. SPARE PARTS CLAIM

Spare parts supplied by AL Spare Parts Department that may fail after fitment to a

vehicle will be covered by the provisions of AL warranty if the investigation proves that

the failure is due to defective material or manufacturing process.

The period of warranty shall be six months from the date of fitment or 32,000 KMs or one

year from the date of invoice for supply of parts, whichever is earlier.

The other conditions governing the eligibility for warranty attention will be the same as

those for components fitted on vehicles.

Benefits of Warranty do not apply if

- The part is not fitted in the workshop of an authorised AL Dealer.

- Old or worn out allied/mating parts have been the cause of failure

- The parts are sold across the counter by Dealer/stockist and fitted by the customer

For failures accepted within warranty, Dealer shall submit a Warranty Claim as per

procedure in Sections 24 to 28.


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10. GOODWILL CLAIMS

If a Dealer feels that a claim beyond the terms of warranty deserves special

consideration, he should obtain the approval of AL

Goodwill is split into 2 categories Technical and Commercial.

Technical goodwill – Failure occurring due to product issues after warranty period

For failures falling between 18 months and 24 months from date of sale – parts value at

NDP and labour charges as per ROT by dealer.

Commercial goodwill : Commercial Necessity

When servicing dealer is the selling dealer

Total claim value shall be split between AL Dealer and customer (1/3 each)

Customer shall provide a letter requesting for goodwill and his consent to pay his share.

Dealer shall forward the customers letter along with his recommendation and his

consent to bear his portion of expenditure.

AL , customer and dealer to share 1/3 portion of claim – Parts at MRP, relevant labour

charges at 1.5 times of ROT value. – Failed materials to be preserved and sent when

called for inspection. Customer to be charged at 1./3 of value of bill. Claim to AL for 1/3

portion of above value.

When servicing dealer is not the selling dealer

Servicing dealer to communicate to customer in writing cause of failure and submit an

estimate for repairs. AL SE to communicate to RSE covering the territory or selling

dealer who will confirm if goodwill consideration has to be extended.


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Customer to provide letter requesting for goodwill and his consent to pay his share to

the selling dealer. Selling dealer to forward customers letter alongwith his

recommendation and consent to bear his portion of the total expenditure and accept the

debit note being raised by AL. The remaining 1/3 value to be borne by AL

Servicing dealer will be reimbursed the cost of repair covered under goodwill in full by

AL. labour charges wil be at 1.5 times the ROT.

AL service HQ shall raise debit notes on concerned dealers every month for the 2/3rd

value of claims to be borne by them.


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11. FLOAT CLAIMS

Dealers are expected to use parts from their stock for carrying out warranty repairs /

replacement. However, it is possible that AL may provide an assembly or component

for warranty replacement to enable quick completion of repairs.

In case AL provides the parts for replacement from out of its float stock the Dealer shall

submit a Warranty Claim and will be reimbursed the labour charges only.

The Dealer shall raise a ‘F’ type warranty claim .

The Dealer shall provide suitable space for safe storage of float units / components

belonging to AL. Usage of any float item shall be approved by the AL SE.


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12. REPLACEMENT OF PARTS ON UNSOLD CHASSIS

Dealer shall attend to failures if any on unsold chassis as directed by AL and submit a

‘Warranty Claim’ online. In such cases, in the pre-sale flag field, the Dealer should enter

‘Y’.

Replacements / repairs arising out of shortage or due to accidents shall not be claimed

through a Warranty Claim. Such expenditure shall be claimed in the form a bill or debit

note and submitted to Sales Administration.

In the case of pre-sale warranty claims, reimbursement against parts will be on the same

basis as Warranty Claims and reimbursement of labour charges will be 1.75 times that of

warranty labour charges.


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13. CAMPAIGN REPAIRS / REPLACEMENT OF PARTS

AL Service will identify the need for any campaign repair / replacement.

The products to be covered under the campaign will also be identified by AL and

intimated to the Dealer. Each campaign will be assigned a code by AL.

It is the general practice of AL to provide the parts required to be replaced on a

campaign basis. In such cases, the labour charges will be reimbursed to the Dealer at

predetermined rates by AL. Dealer will submit a Warranty Claim for parts consumed

and labour carried out.

In case the Dealer is directed to procure and fit any part for campaign replacement, AL

will reimburse the cost on submission of a Warranty Claim supported by bills.


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14. SEQUENTIAL ACTION IN HANDLING WARRANTY COMPLAINTS

When a complaint on a vehicle is reported to the Dealer by a customer and the customer

requests warranty attention.

1) The Dealer shall check the following

- Name of the first registered owner

- Date of Sale / Registration

- Record of Free Services carried out

- If the vehicle is covered under AMC

- Kms / Hours run

from the RC Book, Free Service Folder containing the warranty card and odometer /

hourmeter to ensure whether the benefits of warranty can be extended.

2) If the vehicle is within warranty period, the following shall be ascertained

- Complaint as reported exists

- No unauthorised modification has been carried out

- The complaint is not due to overloading, i.e., the vehicle has not been

loaded beyond the permissible GVW given in Section 15.1 or due to any

other abuse.

- The complaint is not due to poor maintenance or the result of an

accident.

3) The technical guidelines for acceptance of warranty claim are given in Section 17.

The technical guidance of the AL Service Engineer/Regional Service Engineer can

be got, where required.

In any case, warranty attention shall not be delayed.

4) If the failure has to be attended under warranty, the dealer can view the Warranty

History of the chassis through the Warranty site provided by AL. Dealer has to

record on the Job card the Engine and Chassis number of the vehicle attended

under Warranty. The cost of repairs shall be assessed, i.e., cost of replacement of

parts and labour charges.


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5) If the cost of repairs is less than Rs. 25,000/- the Dealer shall straightaway carry out

the repairs.

6) If the cost of repairs exceeds Rs. 25,000/- the Dealer shall contact the AL SE / RSE

and carry out repairs on obtaining his approval. When seeking such approval, the

Dealer shall submit a written estimate of the value of parts to be replaced; the

estimate shall list the part numbers expected to be replaced and their Retail Price.

7) Dealer shall use parts from his stock for warranty replacement.

In case, a part is not readily available with the Dealer, he must place a Vehicle Off

Road (VOR) Order on the nearest Spare Parts Warehouse. It shall be the

responsibility of the Dealer to ensure that parts are received and warranty repairs /

replacement is carried out within the shortest possible time.

8) If repairs are carried out under warranty, the Dealer shall submit a Warranty Claim

to AL within 15 days from the date of completion of repairs.

Procedure for completing the Warranty Claim and the Warranty Labour Claim is

given in Section 24 and 28.

10) No deposit shall be collected from any customer for attending to a complaint

within Warranty

11) The failed material has to be packed and handed over to designated transport

contractor following the procedure for despatch of failed components given in

Section 29.

12) All Warranty Claims shall be submitted online and settlement will be effected by

the AL Regional Office.


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CLAIM PROCESSING SEQUENCE

Vehicle Reports to Dealer Workshop

With Complaint

Record Verification

Within

Warranty

Investigate

the Cause

If Manufacturing

Defect Assess the Cost

If not due to

Manufacturing Defect Repair on chargeable basis

Beyond Warranty Repair on

chargeable basis

IF deserving Recommend for Goodwill

consideration to RO

UPTO Rs.25000 /- Repair

More Than Rs.25000 / -Refer to AL SE / RSE

IF Approved Repair under

Warranty

IF not Approved Repair on

chargeable basis

If Accepted Repair under

Warranty

Prepare Claim

& Dispatch

Failed Parts

Submit Claim online

Processing of Claim at RO

Payment to Dealer


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1. PERMISSIBLE GROSS VEHICLE WEIGHT

Vehicle Nomenclature GVW / GCW (Kg)

PASSENGER

CHEETAH 176" WB ALPSV 4/100 14660 (9.00 x 20 - 14 PR);

15430 (10.00 x 20 - 16PR)


15430 (10.00 x 20 - 16PR)


15430 (10.00 x 20 - 16PR)


15430 (10.00 x 20 - 16PR)

VIKING 193" WB ALPSV 4/90 14660 (9.00 x 20 - 14 PR);

15430 (10.00 x 20 - 16PR)


15430 (10.00 x 20 - 16PR)


15430 (10.00 x 20 - 16PR)


15430 (10.00 x 20 - 16PR)


15430 (10.00 x 20 - 16PR)


15430 (10.00 x 20 - 16PR)


15430 (10.00 x 20 - 16PR)


15430 (10.00 x 20 - 16PR)


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15430 (10.00 x 20 - 16PR)

12 M FE H Series BS II ALPSV 4/86 16200(10 R 20 Radial)




12 M FE H Series BS II ALPSV4/114 16200(10 R 20 Radial)

12 M FE H Series BS II ALPSV4/117 16200(10 R 20 Radial)

12M R”I” Bus Luxura ALPSR 3/28 16200(22.5 – 16 PR)


15430 (10.00 x 20 - 16PR)


15430 (10.00 x 20 - 16PR)

Viking SLF 222” WB ALPSV 4/85 14660

VIKING CNG BS III 222" WB ALPSV 5/8 15430- with std brakes;

16200- with uprated brakes

VIKING 222" WB ALPSV 4/99 15430

CHEETAH 203" WB ALPSV 3/32 14660

Tarmac 11M coach (FE) ALPSR 5/2 13000

Enviro LF Bus ALPSR 5/2 16200

Vestibule Bus ALPSA 1/6 22000

Double Decker ALPSV 4/6 16200

12M Panther ALPSV 3/23 16200 10 R 20

12M Panther ALPSV 3/31 16200 10R 20

12M Enviro ALPSR 5/4 16200 10R 20


23


Lynx ALPSV3/40 11000


Stag ALPSV3/21 7500

Stag ALPSV3/22 7500

Stag ALPSV3/25 7500

Stag ALPSV3/26 7500

Stag ALPSV3/70 7500

Stag ALPSV3/71 7500

Stag ALPSV3/72 7500

Lynx ALPSV3/45 7500

Lynx ALPSV3/46 7500

Stag CNG ALPSV3/50 7500

Stag CNG ALPSV3/51 7500


GOODS

Comet 1611 1611 16200

1613S SG1613H/1 16200

1612 170.5" WB 1612 16200

PARCEL CARRIER - 185" WB 1612/3 16200

PARCEL CARRIER - 210" WB 1612/4 16200

CG1613 - 170.5" WB CG1613H 16200

1613H 185" WB 1613H 16200

SPL GOODS / REFUELLER 210"

WB

CG1613H/1 16200


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SPL GOODS - 222" WB 4/51GS 16200

1616H 185" WB Drill Rig 1616H 16200

12 m Goods 244" WB 1613 H/2 16200

SFC 1613 170.5"WB SG 1613 H 16200

1112 1112/1 11900

1112 1112/2 11900

1112 1112/3 11900

1112 1112/4 11900

1112 1112/5 11900

1112 1112/6 11900

1112 1112/7 11900

1112 tipper with cabin 1112/8 11900

912 912/1-912/5

912/7-912/9

9700

Ecomet 912 tipper with cabin 912/10 9700

Ecomet 912 tipper with cabin 912/6 9700

Ecomet 912 912E3 -912E3/3 9700

Ecomet 912 912E3/4- 912E3/7 9700

1112 1112E3, E3/1-3/3 11900

1112 1112E3/4-3/7 11900

2214 (6x2) 180" WB 2214/1S 25000

2214 (6x2) 198" WB 2214/2S 25000

2214 super (6x2) 180” WB 2214/18S 25000

2214 super (6x2) 198” WB 2214/27S 25000


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2514 (6x2) 240”WB 2514H 25000

2516H (6x2) 180" WB 2516H/2T 25000

2516H (6x2) 198" WB 2516H/3T 25000

2516H (6x4) 180" WB 2516H/2 25000

2516H (6x4) 198" WB 2516H/3 25000

2516H (6x4) 150" WB (RMC) 2516H/4C 25000

2518H (6x2) 180" WB 2518H/2 25000

2518H (6x2) 198" WB 2518H/3 25000

2516H (6x2) 180" WB 2516H3/2T 25000

2516H (6x2) 198" WB 2516H3/3T 25000

2516H (6x4) 180" WB 2516H3/2C 25000

2516H (6x4) 198" WB 2516H3/3 25000

2516H (6x4) 150" WB (RMC) 2516H3/4C 25000

3121 (8x2) 205” WB 3121 31000

TIPPER

TIPPER 115" WB CT1613H/2 16200

TIPPER 142" WB CT1613H/1 16200

TIPPER 142"WB CT1613/2S 16200

SFC TIPPER - 150"WB ST 1613H 16200

1616T – 142” WB CT 1616 16200

1616T – 115”WB CT 1616/1 16200

1616ST – 150”WB 1616ST 16200

Taurus HD 2516 Mining Tipper 2516MT/1 25000

2516H (6x4) 150" WB 2516H3/4 25000


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TRACTOR

3015 TT 130” WB 3015TT 30200

3516 TT 130” WB 3516 35200

3516 TT 130” ARTIK 35.16H

3516H3 TRACTOR ARTIK 35.16H3 35200

4921H (6x4) Tractor 4921H 49000

4018H3 TRACTOR ARTIK 40.18H3 40200


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16. CRITERIA FOR ACCEPTANCE OF WARRANTY CLAIMS

Technical guidelines for acceptance of complaints under warranty for AL items – sec 17

and ancillary supplies (those that have to be referred to the suppliers directly) are

separately given in Section 18

The list of non-warranty items appear in Section 19 .

Although ‘wear and tear’ components do not enjoy the benefits of warranty, on a few

selected components, limits have been prescribed for acceptance of their failure within

the terms of warranty. These items are listed in Section 19 alongwith the prescribed

limits.


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17. GUIDELINES FOR WARRANTY CLAIM DECISION (AL)

S.No Components Nature of failure Decision Remarks

1 Engine Assembly

Any major failure on

Drive – away chassis

Accept

Replace Engine assembly and end

the failed Engine assembly as it is

to AL for investigation.

2 Gear Box Assembly Any major failure on

Drive-away chassis

Accept Replace Gearbox assembly and

send failed Gear Box assembly as

it is to AL for investigation.

1. ENGINE CRANKCASE

Crankcase Blow hole Accept

Crankcase Crack Accept 1. If the crack is along the cross

hole, in the bore.

2. Provided the complaint is

not due to

overheating/thermal

distortion.

Reject 1. If the cooling system is not

maintained properly ie.

Thermostat/Radiator cap

missing or inadequate

airflow across the radiator.

2. Non –usage of anti-freeze

Compound in cold weather

operations.

3. If the crankcase top surface

grooved / cracked due to

prolonged operation after

gasket blowing.

Cylinder head studs Broken Accept Provided it is not due to over

tightening.

Cylinder Liner Crack Accept

only the

affected

liner

Provided the cylinder head had

not been dismantled earlier

Reject 1. If recommended oil filter

element is not used.

2. If correct grade of oil is not

used.

3. If Engine oil not changed at

the specified intervals.

4. If a gasket of lesser thickness

had been used.


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5. If cylinder head nuts are found

loose.

6. If Air cleaner is not

maintained as specified.

7. If deposit of dust is found

inside the inlet manifold.

8. If Engine found overheated.

9. If FIP seals are tampered.

10. If Injector is dribbling or

having glow opening

pressure.

11. If piston scuffing is found/

12. If the liner shows excess wear.

Camshaft Key Shearing due to

seizure of cam bush

Accept If the seizure of cam bush is not

due to faulty lubrication.

Flywheel housing Crack appearing near

mounting flange

Reject If due to

1. Loose mounting bolts

2. Improper engine mounting

or whipping of propeller

shaft.

Crack near starter

motor mounting

Reject 1. If due to starter hitting the

axle beam.

2. If due to loose starter

mounting studs / nuts.

3. If evidence of external

damage is seen.

2. CYLINDER HEAD

Cylinder Head Blow hole / crack Accept 1. If the crack is not due to

overheating / mishandling.

2. If the damage is due to valve

seat falling off.

Reject 1. If the excessive scale

formation in the water

passage is noticed.

2. If signs of overheating

noticed.

Engine Valve Breakage Accept Provided :

1. Engine was not opened

earlier.

2. FIP is not tampered with.

Injector was not found

dribbling.

3. Not consequential to entry


30


of foreign particles.

4. No excessive carbon

formation resulting in valve

sticking.

5. There was no change of

over-running of the vehicle.

6. Valve timing is correct.

7. No valve stamping marks

noticed on piston.

8. There is no sign of seizure of

tappet, rocker lever.

9. There is no sign of bent push

rod, breakage of valve

springs split cone etc,

10. Tappet clearance is checked

and found correct on other

cylinders.

Push Rod Bent / Broken Accept Provided valve tappet clearance

is adjusted regularly as per

recommendation.

Valve timing is correct

Tappet Broken Accept If valve timing is OK and correct

grade of oil was used.

Valve spring collar and

split cones

Breakage Accept Provided the tappet clearance is

periodically checked.

Valve spring Breakage Accept If FIP is not tampered with

Rocker Arm Broken Accept 1. If the FIP is not tampered

with

2. IF the valve timing is

correct.

Ball end screw Worn / Nut working

loose

Accept

Valve guide Broken / Cracked Accept Provided correct grade of engine

oil is used.

Cylinder head gasket Blown Accept Provided

1. Cylinder head has not been

dismantled earlier and

retorqueing of cylinder head

nuts carried out during 8000

kms service.

2. All free services availed by

the customer.

3. No signs of overheating due


31


to loss of coolant

4. Incorrect liner protection.

Reject 1. Signs of overheating found

due to maintenance factors.

2. Thermostat removed.

3. CRANKSHAFT

Crankshaft Breakage and crack Reject 1. If signs of unsatisfactory

lubrication (luish marks on

journal, indicating oil

starvation) noticed both on

bearings on crankshaft

2. If FIP calibration and cutting

in rpm altered.

3. If Engine is run with

damaged damper pulley.

4. If the crankshaft has been

reground by the customer.

5. If the thrust washer at one

end found seized due to

insufficient end float.

Worn out / Scored Reject 1. If the improper grade .

contaminated lub oil is used.

2. If due to improper filtration

(non genuine oil filter

element, improper assy of

filter element or chocked

filter element)

3. If diesel dilution with lub oil

is observed.

Breakage at gear end Accept Provided the front end drive

alignment is OK and the

recommended PTO is used.

Adaptor bolt breakage Accept If the locking plate is found intact

Damper pulley Rubber shearing off Accept

Leaky Accept If there is no sign of any external

damage

Flywheel ring gear

teeth breakage

Teeth chipping off Reject If due to bad usage by continuous

cranking.

Engine rear oil seal Leak Accept For acceptance limits refer Sec. 19

4. PISTON / CON ROD

Piston Breakage Accept Provided –

1. No overheating and

scuffing marks on any


32


piston including failed

piston.

2. No foreign material

inside the cylinder. Injectors

are in good condition and

spray pattern is in order.

Gudgeon Pin Circlip Dislodged / Broken Accept Provided –

1. No scuffing marks on piston

due to overheating.

2. No sign of seizure on

corresponding small end

bush

Piston Ring Broken / Seizure Accept 1. If the engine has not been

opened by the customer

earlier.

2. If the cooling / lubrication

system is in order.

3. If no excessive carbon

formation, indicating faulty

injectors / incorrect

lubrication.

Piston Ring Broken / Seizure Reject 1. If inlet manifold indicated

dust entry.

2. If the liners show excess

wear.

Con rod SE bush Pitting / breakage Accept Provided engine oil used is of the

correct grade, FIP is not

tampered.

Con rod Breakage / Splitting

through oil hole

Accept

Reject

Provided –

1. The corresponding piston

and con rod has not been

removed earlier.

2. No hydraulic lock caused

due to entry of water

through inlet manifold

causing con rod to bend /

break.

If FIP seals have been tampered.

Con rod bolt Stretching and

fracturing

Accept If injection pump seal has not

been tampered with


33


Bearing shells Rotation Reject 1. If non-genuine filter is used

and filter is clogged.

2. If foreign material is found

blocking the oil passage.

3. If improper grade of oil is

used.

4. If oil change was not done at

the specified interval.

5. If the air cleaner is not


6. If injection pump seal has

been tampered with.

Rotation Accept 1. Provided the en gine has not

been opened up earlier by

the customer and has been


2. If only one part of bearing

has failed and condition of

other bearings are good.

3. If bearing notches found

broken.

5. TIMING CASE

Idler Bolt Breakage / Working

loose

Accept Provided front timing cover was

not opened earlier.

6. WATER PUMP

Water Pump Water leakage Accept If due to faulty machining of

impeller casing or blow hole.

Bearing noise /

breakage

Accept

Reject

Provided bearings are lubricated

properly.

For acceptance limits refer sec. 19

If the bearing failure is due to

normal wear.

Key shearing Accept 1. Provided bearings have not

seized due to faulty lubrication .

2. Hub nut is intact.

Fan Blade Blades shearing off at

rivet holes

Accept 1. Provided no impact with

Radiator or stay rod

2. Provided engine not cranked

forcibly by using the fan

blade.

3. Provided water pump


34


bearing condition

satisfactory.

Polypropylene fan Breakage Accept 1. Provided no impact with

Radiator stay rod.

2. Provided engine not cranked

forcibly by using the fan

blade.

3. Provided water pump

bearing condition

satisfactory.

7. OIL PUMP

a) Oil pump drive

shaft

Tongue breakage Accept Provided:

1. The engine was not opened

earlier.

2. Oil pump gears not

sticky/jammed.

3. no entry of foreign particles

observed

4. condition of oil is in order

5. binding of helical gear in the

thrust housing.

b) Oil pressure gauge

pipe (bundy pipe)

Broken / Damaged Accept Provided clamps are in position

and the pipe is not fouling with

another component.

c) Lub. Oil delivery

and suction pipes

Crack Accept Provided the engine was not

opened earlier.

No external impact on sump

bottom.

8. FUEL PUMP /

INJECTORS

FIP Drive Coupling plates crack

/ breakage

Accept If the alignment is OK and not

tampered with

9. FILTERS

Oil filter body & Cover Leakage / Blow hole Accept If not due to mishandling

10. ENGINE MOUNTING

a) Metacone

mounting

Rubber material

getting damaged and

plate breaking

Accept If the mounting bolts are in tact.


b) Engine front

mounting pad

Rubber shearing Accept If the mounting bolts are not

loose.

For acceptance limits refer Sec.

19.


35


11. OIL COOLER

Oil Cooler Leaky Accept Crack at brazing joints or pipe

12. RADIATOR

a) Radiator Leaky Accept

Reject

Provided

1. Not due to any external

damages.

2. Not due to loose mountings.

3. Conditions of radiator

rubber mountings is ok

If repaired at unauthorised

workshop

b) Coolant tank Crack / Leak Accept 1. If the tank mountings is tight.

2. If no external hit

13. DIPSTICK

Dipstick Broken Accept

Reject

If the failure is due to soldering

giving way.

If due to mishandling.

14. AIR CLEANER

Filtration ineffective Accept Provided –

Dust particles are found in inlet

manifold / inlet pipings in spite of

1. Maintaining specified oil in

bowl to the correct level.

2. Bowl rubber seal is in good

condition

3. Rubber beading between

stack pipe and wire mesh in

good condition (in case of

remote mtd air cleaner )

Disintegration of wire

mesh

Accept If wire mesh broken pieces are

found in oil inspite of proper air

cleaner maintenance.

Leakages through air

cleaner

Accept Provided -

The leaks are established from

spot welding on top cover (in

case of direct mounted air

cleaner) and from spot welding /

soldering in body (in case of

remote mounted air cleaner).

15. CLUTCH DISC

a) Clutch back Cracked / Reject 1. If the vehicle had been


36


plate face plate glazed/broken

Accept

found without

recommended pedal play.

2. If there are signs of

overheating /slippage

If the crack emanates from the

slots

b) Clutch Disc Torsion spring

breakage/loose

Liner cracked /

disintegrated

Hub rivets

loose/broken

Accept

Accept

Accept

If the linings are intact and wear

is normal.

For acceptance limits refer Sec.

19.

1. If there are no signs of

overheating / slippage

2. If wear and tear is normal

and failure is highly

premature.

For acceptance limits refer sec. 19.

If there are no signs of

overheating/slippage

c) Clutch Pressure

plate spring

Loss of tension /

Permanent set

Accept If there are no signs of

overheating and slippage

d) Clutch withdrawal

bearing

Noisy / sticky Accept

Reject

For acceptance limits refer Sec 19.

1. If due to inadequate

lubrication.

2. If due to clutch riding

3. If due to wrong clutch pedal

play adjustment.

e) Diaphragm clutch Diaphragm tip

breakage

Tip wear

Pressure plate crack

Accept

Reject

Accept

1. If clutch release bearing is not

fouling with diaphragm tip

(for mechanical actuation)

2. If no modification carried out

on clutch release bearing.

1. If clutch riding is observed.

2. If clutch rod setting is

incorrect.

1. If no clutch slip is observed.

2. If cover assembly to flywheel


37


Straps breakage

Accept

bolts are tight

3. If clutch free play is

maintained.

16. GEAR BOX

a) Main shaft Breakage Accept Provided oil condition is

satisfactory.

b) Pinion shaft Teeth breakage Accept Provided –

1. Gear shift lever setting is

ok.

2. Pinion shaft end float

adjustment is ok

3. The bearing condition is

ok .

c) Gear wheel Teeth breakage

Bush seizure

Accept

Accept

Provided –

1. clutch system adjusted

properly and gear shift

mechanism is in order.

2. no evidence of crash

engagement of gear

3. the vehicle has not

bogged down

4. gearbox not opened

earlier

5. lubrication and condition

of bushes are ok.

6. Mating gear is ok.

1. If the oil level is

maintained and there is

no contamination.

2. If gearbox oil change has

been done as per

maintenance schedule.

Provided the gearbox has not

been opened earlier.

d) Locking screw

of counter shaft

washer

Loosening Accept Provided the gearbox has not

been opened earlier.

e) Gear casing Crack Reject

1. If due to improper engine

mounting.

2. If bottom support given


38


Accept

by the customer

3. If any signs of external

damage is seen.

1. If due to consequential

damage to gear teeth.

f) Bearing Defective / failed Accept

Reject

2. If the gearbox was not

opened earlier.

3. If the level and grade of

oils is in order.

If the failure is due to normal

wear and tear.

g) Synchroniser

rings

Worn out Accept

Reject

For acceptance limits refer Sec. 19

1. If wrong grade of oil

used and oil change is

not carried out as per

schedule.

2. condition of clutch is bad

3. If declutching is not

carried out while shifting

gears.

4. If gearbox is dismantled by

unauthorised workshop

h) Gear shift ball

joints

Normal wear

Premature shake

Reject

Accept

If maintenance Ok.

For acceptance limits refer

sec 19.

i) ZF transmatic

Electronic unit

Defective Reject 1. If the electrical

connection to transmatic

system are tampered.

17. PROPELLER

SHAFT

2.

a) Propeller Shaft Tube bent / twisted Accept 3. Provided vehicle not

overloaded.

4. Vehicle had not got bogged

down .

5. Provided flange

mounting bolts are not

loose.

b) Prop shaft yoke and

stub shaft

Breakage Accept 1. If the lubrication is ok

2. IF vehicle has ot got

bogged down


39


3. Provided vehicle not

overloaded.

4. Flange mounting bolts

are tight

If broken into two with

splines in tact.

c) U J Cross Breakage Accept As above

Maintenance is ok and wear

is normal.


Sec. 19

d) C J Bearing Pitting / noisy Accept 1. If lubrication is ok

2. If there is no

misalignment / bend in

prop shaft.

18. REAR AXLE

a) Crown / Pinion

Teeth pitted / broken Accept

Reject

1. If the unit was not

dismantled earlier.

2. If oil changes as well as

brand of oil are to the

specification.

3. If back lash is within the

limits.

4. If the vehicle not

overloaded.

5. If not misused in

operation.

If maintenance is not satisfactory.

b)Crown wheel bolts Shearing Accept Provided –

1. Free services are carried

out at dealer point

2. Unit not tampered earlier

3. Vehicle not overloaded

4. Maintenance / oil change

is regular

5. Tightness of bolts had

been checked at 16000

kms service

vehicle had not got bogged

down.

c) Differential bearings Rollers and races

pitted /broken

Accept

Provided –

1. Diff. oil is not

contaminated.


40


Reject

2. differential unit is not

dismantled earlier

outside.

3. correct lubricant and

change scheduled

adopted by customer

4. Recommended Preload

adjustment done at 16000

kms service

If the failure was due to normal

wear and if the maintenance is

not satisfactory.

d) Differential Cage

Bevel Wheels and Bevel

pinions or trunnion

Breakage Accept

1. If it is due to failure of

thrust washers, thrust

washer locking pegs.

2. If oil condition is ok

3. IF no oil starvation

4. If no overheating

If there is no evidence of wheel

spinning

e) Axle shaft Breakage Accept Provided –

1. Springs are not

recambered

2. extra spring leaves not

added.

3. No overloading on the

vehicle

the failure is not consequential to

the vehicle getting bogged down.

f) Diff input shaft

bearing

Rollers and races

pitted/ broken

Accept Provided –

1. General maintenance is

ok

2. No alteration in

suspension and chassis

3. Not due to oil starvation

4. Not due to normal wear

and tear

5. Not overloaded.

g) Axle casing Cracked / bent Accept

Provided –

1. Suspension h as not been

modified with extra


41


Reject

leaves in the spring assy

2. Not dismantled earlier to

carry out any

modification.

1. Any modification done to

overload the vehicle.

If general maintenance is poor.

h) Wheel studs Thread chipped / stud

broken

Rotation

Accept

Accept

(as above)

1. If wheel studs are

tightened to specified

torque.

2. If it is due to shearing of

locking peg.

If wheel studs are tightened to

specified torque.

i) Wheel bolt Rotation / Breakage Accept If bolts have not been over

tightened.

j) Wheel Bearings Races or rollers pitted/

scored/ discoloured

Accept

Reject

For acceptance limits refer Sec. 19

1. correct grade of lub/change

period not maintained.

2. If hub greasing done by


3. Failure due to normal wear

and tear.

k) Brake drum Cracked / broken

Accept 1. Examine for any external

impact and make sure that

the failure is not due to

mishandling.

2. If drum does not show excess

wear.

l) Output shaft

snap ring (Hippo /

Taurus differential )

Cir clip coming out

from its groove

Accept

If inter axle propeller shaft free

on splines

19 FRONT AXLE

a) “I” Beam Cracked Accept If there is no evidence of any

external impact

Bent / Cracked Reject 1. If the investigations confirm

that the vehicle was involved

in an accident or was

overloaded.


42


2. If suspension altered to carry

overload.

b) King pin /bushes Premature wear Reject If due to lack of lubrication or

excessive kingpin play.

Breakage Accept If lub oil / adjustments are okay.

c) Axle arm Crack Reject If due to accident

d) Wheel bearings Races or rollers pitted

/ scored/ discoloured

Accept For acceptance limits refer Sec 19.

Reject 1. If correct grade of lub /

change period not

maintained.

2. If hub greasing done by


3. Failure due to normal wear

and tear

e) Drums Broken / crack Accept Provided –

1. not due to mishandling

2. not due to impact

3. if the wear is normal

f) Wheel studs Rotation Accept Provided wheel nuts are

tightened to specified torque.

g) Wheel bolts Rotation / Breakage Accept ( as above )

h) Drag link /tie rod ball

joint dies

Work Accept If lubricants is regularly carried

out


i) Ball pin Broken Accept 1. If not due to accident

2. If lubrication is carried out

regularly.


20 STEERING

a) Steering mounting

studs

Breakage Accept If it is not due to loose nut or due

to any impact.

b) Inner column Breakage Reject If it is due to external impact or

accident

c) Steering bearings Pitting Accept If it is not due to lack of

lubrication /correct grade of lub

oil is used.

d) Rocker shaft hosur Pitting Accept 1. If not due to lack of

lubricating oil / correct grade

of lub oil is used.

2. If the steering box is not

opened earlier.

e) Cam & Roller Pitting Accept - do -


43


f) Steering wheel Crack Accept

g)Steering gear housing Blow hole Accept

21 BRAKES

a) Brake liner Wear Reject If the wear is normal for the

operating conditions

Cracked / hardened /

glazed

Accept If the operating conditions are

normal and there is no sign of

excessive heating.

For limits of acceptance refer sec,

19

b) Brake carrier Crack Accept Provided

Mounting bolts are secured

properly.

22 SUSPENSION AND

FRAME

a) Frame long member Bent / cracked Reject 1. If body / chassis mounting

bolts loose

2. If body mounting not as per

recommendation

3. If unauthorised welding on

the side members is done

4. If unauthorised welding on

the side members done

5. If unauthorised overhand

extension is done

6. If spring buffer fouling

/hitting the lower flange of

side members due to faulty

suspension .

7. If the vehicle has been

overloaded.

8. If any modification done to

overload the vehicle.

b)Cross Member Crack Accept If not due to accident of

impact.

Reject If the mounting bolts were

found loose

c) Spring brackets Crack Reject 1. If extra leaves added and

recambered.


44


2. If due to loose bolts

3. IF due to overloading

4. If due to external hitting

5. If due to misalignment of

spring assembly

6. If due to worn out shackle

pin and bushes

d) Spring Assy Loss of Camber /

spring leaf breakage

Accept For acceptance limits refer sec. 19

Reject 1. If springs have been

recambered and leaves

added.

2. If rubber buffer not provided

3. If due to overloading of

vehicle beyond RLW

4. If spring bolts are loose

5. If shackles bushes are not

lubricated or excessively

worn out.

6. If shackle brackets are

excessively worn out giving

side play between spring

eyes and bracket.

7. If due to abnormally bad

terrain

8. If due to bad driving habits.

e) Shcakle pin Worn out / Broken Reject 1. If due to improper

lubrication.

2. If due to poor locking of

shackle pin

f) Bell crank lever / Tie

rods

Crack / Breakage Accept IF not due to overloading and

unauthorised modification

g)Torque stabilizers Breakage Reject 1. If due to improper

maintenance.

2. If not due to external hits.

h) Shock absorber Leaky / shaft broken Accept Provided springs are not

tampered/modified.


sec. 19

i)Spring eye bolt Breakage Accept Provided it is not due to

external hits.

j) Weveller suspension Cracked Accept For acceptance limits refer


45


rubber pads sec. 19

k) Air bellows Cracked / cut Accept If the crack / cut is not due to

external stone hits.


sec. 19.

i) Rear spring seat

(scammel suspension)

Breakage Accept 1. If no extra leaves are added.

2. If mounting bolts are tight.

m)Radius rod bush /

pins/ mounting

bolts

Breakage Accept If all other radius rod / mounting

bolts are found to the specified

torque and split pins are intact.

n) Bogie bracket Crack Accept If mounting bolts are found

tightened to specified torque

o) Bogie bracket bearing Seizure Accept If oil is present in the housing to

the correct level

p) Anti roll bar Broken Accept 1. If the suspension is not

altered.

2. If it is not due to external

impact

23 ACCESSORIES

a) Spare wheel carrier Breakage / crack Accept If no sign of external hitting.

b) Fuel tank Leakage Accept 1. If no external damage

2. If not due to loose mounting

and vibration.

c) Silencer flexible pipe Crack Accept If not due to loose mounting

d) Wheel rims Broken / cracked Accept 1. If the wheel stud seating

position is not damaged.

2. If no external impact

3. If vehicle is not overloaded.

. Reject 1. If wheel mounting holes are

elongated.

2. If wheel nuts are loose

3. If failure is due to over

tightening

e) Speedo cable /

Throttle cable

Breakage Accept If the routing / clamping of

the cable is found in order.

24 ELECTRICALS

a) Switches and gauges Defective Accept 1. If no ingress of water

2. If not tampered

3. For acceptance limits refer

sec. 19

Reject If there is sign of any external

damage and mishandling .

b) Wiper Motor Defective Accept 1. If no fouling / loose fitments


46


found in the wiper linkages.

2. If wiper wiring connections

are found tight.

c) Wiring harness Burnt Accept Provided –

1. The wiring looms had been

properly clamped and all

connections / sockets / joints

are kept tight.

2. If no part of the wiring loom

is left open leading to short

circuiting.

d) Electronic flasher Defective Accept If the unit is already not

tampered.

e) Horn Not functioning Accept If the nut is already not

tampered.

25 CAB / DASH BOARD

a) Door glass winding Malfunctions Accept Provided it is not due to external

hits

b) Torsion bar Breakage Accept As above

Misalignment Accept Realignment to be tried before

replacement by a new one .

c) CSO Lock release

cable

Breakage Accept If the cable is properly secured.

d) CSO Lock housing

on telescopic gear

shift

Breakage Reject If the cab tilting instructions are

not followed.

e) Cab tilt key housing Cracks Reject If the key is used to lift the cab

f) Glove box lid Cracks Accept If no external hits are noticed

g) windshield glass Crumbles Accept If not due to accident. For

acceptance limits refer Sec. 19

Waviness Accept For acceptance limits refer sec 19

Vision blurred or any

manufacturing defect

Accept For acceptance limits refer sec 19

h) Cab front panel

oddie fastener

Not working Accept

i) Driver seat

mechanism

Ratchet teeth

damaged or restricted

movement

Accept If no misuse is observed

j) Door lock / remote

lock

Not opening or

locking

Accept For acceptance limits refer sec. 19

k) Cab painting Fading / blistering Accept Repainting of affected area only

l) Dash Board panel. Cracks Accept If it is not due to misuse.


47


Seat belt. Door

pads/sun visor

18. GUIDELINES FOR WARRANTY CLAIM DECISION (ANCILLARY)


1 ENGINE

FUEL PUMP /

INJECTOR

a) FIP cam box Leak / Back leak Accept Refer the claim to MICO

b) Bottom end plugs

– FIP

Leak Accept If the failure is not due to improper

handling.

Refer the claim to MICO

c) Injector body Leaking / crack Accept If not due to mishandling / improper

tightening by customer. Refer claim

to MICO

d) Injector High

pressure pipes

Leaking / cracked Accept

2 ENGINE

ACCESSORIES

a) Turbocharger

turbine shaft

Seizure Accept Provided –

1. Lub oil specification is OK

2. Filter change and oil change has

been periodical

3. Not subjected to overheating

4. The TC was not opened earlier

5. Air cleaner element is not

choked

6. Starting and stopping procedure

had been followed.

b) Turbocharger

glands

Oil leak and excess

engine oil being

pumped through the

exhaust manifold

Accept - as above -

c) Turbocharger

body

Crack Reject If mounting bolts are loose. If

exhaust tail pipe is stressing TC body

If any alteration in exhaust system.

3. REAR AXLE

a) Crown / Pinion Teeth pitted / broken

wear

Accept 1. If the unit was not dismantled

earlier.

2. If oil changes as well as brand of


48


oil are to specification

3. If pinion bearing preload is in

order

4. If backlash is within limits

5. If vehicle is not overloaded

6. If not misused in operation

b)Pressed/

Welded axle

Bend Reject 1. If overloaded.

2. If rar suspension has been

tampered with by addition of

spring leaves.

c) Pressed /Welded

axle

Cracking at brake

carrier /mounting

flange area

Accept …..

4. BRAKES

a) Spring brake

chamber

Crack Accept Provided –

1. Not due to fouling

2. Not due to stone hit. In such

cases refer to M/s Sundaram

Clayton

3. Not due to loose mounting bolts

b) Needle Roller

bearings / Nylon

bushes

Worn or rotated Accept If proper lubrication schedule is

provided

Reject In case of normal wear and tear

c) Expander unit

(Brakes)

Sticky / not working Accept Provided not tampering done by

unauthorised persons

d) Pneumatic valves

/ cylinder

Leak / sticky Accept If regular maintenance is carried for

air filter, air compressor and

draining of air tank. Only kits have

to be changed.


5 POWER

STEERING

a) Power steering Steering Hard Accept If hard steering is due to Piston seal

leakage ijn the gearbox

b) Steering pump Seizure, pressure not

building up

Accept 1. If oil is not contaminated in the

system

2. If correct grade of oil is used

3. If filter is not missing or


49


chocked.

6 ELECTRICALS

Starter Defective Accept 1. If starter switch is found

defective leading to starter

failure.

2. If no loose connection found in

starter terminals

3. If the failure is not due to

continuous cranking or misuse

For all defects refer the complaint to

the concerned supplier /dealer

Alternator Defective Accept If cable connections to alternator are

found secure.

For all defects refer the complaint to

the concerned supplier / dealer .

7 A/C SYSTEM

1) Compressor Not working Accept

2) Condensor Fan

Motor

Grounded / Burnt Accept

3) Condensor Fan

blade

Broken / Bent Accept 1. If not due to external damage /

mishandling

2. If it is due to loose mounting

4) Evaporator /

Blower motor

Grounded /Burnt Accept

5) Evaporator /

Blower wheel

Broken / bent Accept 1. If not due to loose mounting

6) Receiver Tank /

Refriegerant

Line

1. If no welding is carried out on

the tank.

2. If not due to external damage.

7) Pressure switches

(Low & High )

Not working Accept

8) Thermostat Not working Accept

9) Suction,

Discharge

Service valve

Expansion

Receiver

Tank valves

Malfunctioning Accept If settings have not been tampered

with

10) Magnetic Clutch Malfunctioning Accept If settings have not been tampered

with

8. TIPPING GEAR

1) PTO drive shaft Breakage from the slot Reject 1. If loaded beyond the rated load


50


2. Loose mountings

2) Swash plate

pump

Noisy Reject 1. If loaded beyond rated load.

2. Contaminated hydraulic fluid or

incorrect / inadequate fluid

used.

3. Loose mounting of the unit

3) Piston Piston crack in Ram

assy

Reject As stated above

If any external damage to ram assy

observed.

Improper mounting of ram assy by

body builder

Improper distribution of load

4) Trunnion arm Breakage Reject If loaded beyond rated load.

Loose mounting bolts


51

19. NON-WARRANTY ITEMS

The warranty terms are a precise statement of AL’s intention to cover the replacement or

repair cost, on a standardised and agreed basis, of any product failure resulting from

defective material or substandard workmanship during the manufacturing process.

However, the following items will not be the subject of a warranty daim :

1. Gaskets (other than Cylinder Head Gasket)

2. Rubber components such as wiper blades, floor mats

3. Bulbs and lamp covers

4. Fuses

5. Upholstry including seat cushions and covers

6. Glass items (other than windscreen glass)

7. Suspension pins and bushes

8. Cowl

9. Fasteners except main bearing cap bolts, con rod bolts, differential bearing cap

mounting bolts

10. Parts recommended to be replaced during routine maintenance

11. Consumable items such as lub oil, grease, anti-corrosion/ anti-freeze compound etc.

However, where oil replacement is required in Engine, Gearbox and Rear axle on

account of overhaul under warranty, the same shall be carried out Free of cost to

customer. This will not include topping-up of ‘Oils’.

12. In the case of vehicles supplied Fully Built, Warranty benefits as agreed to in the

specific sale contract will be applicable.


52

20. GUIDELINES FOR ACCEPTANCE OF ‘WEAR & TEAR’ COMPONENTS

UNDER WARRANTY

The components listed below are of ‘wear and tear’ nature. Premature failures of these

may be accepted up to the limits specified. It is to be understood that the life of these

components depends on the nature of operation and duty cycle and only if the failure is

premature in relation to these, warranty replacement has to be effected.

Component Limit (in Kms / Months)

Clutch Facing 32,000 km / 6 months

Brake Lining 16,000 km / 3 months

Bearings 72,000 km / 12months

Oil seals 72,000 km / 12 months

Ball joints 72,000 km / 12 months

Fan belt 32,000 km / 6 months

UJ 72,000 km / 12 months

Clutch cylinders 50,000 km / 12 months

Cables 32,000 km / 6 months

Plastic and rubber components 12 months

Cab trim components 12 months

Electricals 12 months

Spring leaves 16,000 km (provided

suspension not tampered)

Shock absorber 32,000 km / 6 months

Air suspension (bellow / leaf spring/ leveling

valve)

1,00,000 km / 12 months


53

21. PROCEDURE FOR CLAIMING – ANCILLARY SUPPLIES

Warranty offered by AL covers all the components, both Works made and supplies by

ancillary manufacturers, fitted on products supplied by AL subject to variation in the

warranty period in the case of specified items mentioned in Section 21.

Warranty attention on account of failure of all parts supplied by ancillary manufacturers

will be rendered by AL Dealers and Warranty Claim submitted to AL.

A list of supplier codes and identification mark for various items also appears later in

Section 22.

For each supplier, a separate Warranty Claim has to be submitted and no two items shall

be clubbed in one Claim.

However, in the case of the following suppliers, the Dealer will prefer a claim directly on

the respective supplier or his Dealer for any warranty attention that may be required.

1. Fuel Injection Equipment supplied by MICO

2. Electrical equipment supplied by LUCAS and MICO

3. Supplies by Sundaram Clayton

4. Turbocharger of Turbo Energy Limited

5. Power Steering equipment (ZF and RANE make)

6. Supplies by Automotive Axles Ltd in case of failures relating to replacement Axle

Casing


54

7. Tipping equipment supplied by Hyva, UT and Wipro.

8. Batteries (all OE makes)

9. Tyres (all OE makes)

The Warranty period offered by the above suppliers, where it varies from vehicle

warranty, is given separately in Section 21. The decision of the above supplier on

extending warranty attention shall be final.

The technical guidelines for acceptance of claims are given in Section 17.

Upon inspection of the failed material received by AL, AL reserves the right to reverse a

claim if

- Defect as mentioned in the claim does not exist

- Failed material returned are found to be either non-genuine or if any component is

missing

- Parts are received in a damaged condition due to improper packing thereby not

allowing a proper investigation

- Parts are received in a rusted condition due to non-application of rust preservative

coatings

- Wrong parts are received or mating parts do not match, e.g. Crown Wheel & Pinion

- Parts are not received within 45 days from the date of claim approval.

If it becomes necessary AL will reverse the claim and recover the value of claim settled.

However, failed material sent to AL will not be returned.


55

22. WARRANTY PERIOD FOR PROPRIETARY ITEMS VARYING FROM AL’S

WARRANTY PERIOD

Sl. Component /

Unit

Name of the

Supplier

Kms / Period

1 F.I.E. MICO 12 months from date of sale of

vehicle

2 Foot brake

components

Sundaram Clayton

Ltd

24 months or 200000 km with

Airdrier from date of sale of

vehicle, whichever is earlier

12 months or 100000 km without

Airdrier from date of sale of

vehicle, whichever is earlier

3 Tipping Gear UT, WIPRO, HYVA,

EDBRO

18 months from date of sale of

vehicle or 3000 hrs of operation

4 Battery Various 12 months from date of sale of

vehicle


56

23 SUPPLIER’S CODE AND IDENTIFICATION

Part / Unit Supplied Supplier

Code Supplier Name Identification

ENGINE

Air Blast Heat Exchanger 1536 Asian Radiator ASIAN

Air blast oil cooler 5473 Halgona Radiators Halgona

Air duct hose 3887 Sam Plastics SAM

Air Filter 1712 India Filters INDIA FILTER

Air Filter 2041 Luminous Autolight Luman (2041)

Air Filter 2711 Southern Pressings Name Plate

Air Filter P066 Fleet Guard Name sticker

All Filters 0586 Lumax Industries Lumax

All joints 2374 Perfect Circle Victor Ltd VICOR

All joints 3957 Talbros Automotive Components TALBROS

Dry Type Air Cleaner 6977 Fleet Guard Name sticker

All Joints 0714 Sankar Sealing System Sankar

All Joints 1559 Banco Products Banco

Bottom cover 1894 Karnataka Precision Inds. 1894

Bottom Cover 3892 Unimech Industries UI

Bump stop S/A 3105 Buyer’s Engineers BE

Bump stop S/A 2929 Vapi Rubber Industrial VI

Camshaft Bush 1309 Copper Alloy Industries C

Camshaft Bush 2433 Rapsri Engg. Industries R

Charge Air Cooler 6972 Young Industries CAC

Charge Air Cooler 7057 Zios Charge Air Coolers P Ltd.,

Pune

ZIOS

Charge Air Cooler 5009 Alkraft P Ltd., Chennai Alkraft

Cogged Belt 0477 Hilton Rubber Limited HILTON

Cogged Belt 1507 Fenner India Fenner

Con rod bearings 1547 Gabriel India Ltd, GB

Con Rod SE Bush 1209 Bimetal Bearings BM

Con Rod SE Bush 1926 Kiroloskar Oil Engines KOEL

Con Rod SE Bush 1547 Gabriel India GB

Con Rod Bearings 1209 Bimetal Bearing Ltd BM

Con Rod Bearings 1926 Kirloskar Oil Engines Ltd KOEL

Crankshaft 2556 Shardlow India Ltd., Shardlow

Crankshaft Adaptor 4013 Abhijat Industries 4013

Crankshaft adaptor 1894 Karnataka Precision Inds. 1894

Cylinder Gasket 402/412 2972 Talbros Automotive TALBROS


57



Cylinder Head Gasket 3957 Talbros Automotive TALBROS

Cylinder Head Gasket 1559 BANCO Products India (P) BANCO

Cylinder Head Gasket 2374 Perfect Circle Victor Ltd., VICTOR

Cylinder Head Gasket 0714 Sankar Sealing System SANKAR

Cylinder Liner 1076 Auto Liners 1076

Cylinder Liner 4086 Bharat Auto Enterprise 4086

Cylinder Liner 3091 Bharat Industries 3091

Cylinder Liner 3091 Bharat Industries 3091

Cylinder Liner 3114 Centricast Foundries 3114

Cylinder Liner 3146 Chukkappalli Auto Components 3146

Cylinder Liner 3147 Chukkappalli Finance 3147

Cylinder Liner 3155 Chukkappalli Industries 3155

Cylinder Liner 4214 Emkeyen Enterprises 4214

Cylinder Liner 0372 Engineering Marketing and

Inspection

372

Cylinder Liner 1827 Instruments and Controls 1827

Cylinder Liner 2053 Machinekraft 2053

Cylinder Liner 0633 Malayil Electro Castings 633

Cylinder Liner 2293 Pearlite Liners (P) Ltd, 2293

Cylinder Liner 0685 Sleeves India 685

Cylinder Liner 2504 Sunas Engineering 2504

Cylinder Liner 2021 City liners Agencies (P) Ltd., 2021

Cylinder Liner 2038 Liners India Ltd., 2038

Damper Pulley 1077 Autolec manufacturing and

Marketing

A

Damper Pulley 1366 Dampers India DI

Dipstick 3547 Lakshmi Industrial Plastics lakshmi

Driving Belt 1387 Dunlop India Ltd Dunlop

Dry type air cleaner 6977 Fleet-Guard Filters I Ltd FE

Engine Fail Safe System 4027 Aries Electronics ARIES

Engine Mounting Pad 0650 Madras Rubber Products MRP

Engine Mounting Pad 2642 Sundaram Industries SIR

Engine Mounting Pad 2929 Vapi Rubber Industrial VI

Engine Rear Mounting 3105 Buyer’s Engineers BE

Fan Belt 0477 Roulunds Codan (I) Ltd Roulunds

Fan Belt 4197 BMF Belting Limited BMF

Fan Belt 1507 Fenner India Ltd FENNER

Fan Belt X517 Beijing Automotives(China make) Chinese letters BJ

FIP 2132 Motor Industries Co. Ltd. MICO


58



FIP & Injector 2132 Motor Industries Co. Ltd. MICO

Flywheel 1580 Ghatge Patil Industries Ltd. GPI

Gudgeon Pin 1456 Escorts Ltd MAHLE

Gudgeon Pin 1733 India Pistons Ltd IPL(1733)

Gudgeon Pin 2562 Shriram Pistons and Rings Ltd., USHA 2562

Heat Exchanger 1536 Asian Radiator ASIAN

Heat Exchanger 2860 Universal Heat Exchangers UHE

Impeller 2217 NF (P) Limited NF

Impeller 3683 Precision Engg. Works PEW

Inlet/Ex. Valves 2562 Shriram Pistons and Rings Ltd., USHA (PNo)

Inlet/Ex. Valves 1913 Karmobiles Ltd. KVL (PNo)

Inlet/Exhaust Valve 1450 Engine Valves Ltd, EVL

Main bearing 1209 Bimetal Bearing Ltd BM

Main bearing 1547 Gabriel India Ltd GB

Main bearing 1926 Kirloskar Oil Engines KOEL

Metacone Mounting 4610 Buyer’s Engineers, BE

Metacone Mounting 1753 Industrial Rubber Products IRP

Metacone Mounting 3209 Mechan Engineering P. Ltd. VIR

Metacone Mounting 3105 Meenakshi Mouldings P. Ltd 3105

Metacone Mounting 2929 Vapi Rubber Industrial VI

Oil Cooler 1536 Asian Radiator ASIAN

Oil Cooler 2860 Universal Heat Exchangers UHE

Oil Cooler 2862 Universal Radiators Ltd UR

Oil Cooler 3208 Manickam Radiators MANICKAM

Oil Cooler 6957 Voras Excluisve Tools Pvt. Ltd

Oil Cooler - Case 4125 English Tools and Casting Pvt. Ltd. ETC

Oil Filter Element 4667 Mikroflo Filters MIKROFLO

Oil Filter Element 2379 Purolator India Limited 2379

Oil Filter Element 1133 Ashra Consultants (P) Ltd. 1133 (PNo.)

Water Separator 5098 Engine Tech. Systems (I) Pvt. Ltd. Engine Tech

Fuel Water Separator 6977 Fleet Guard Fleet Guard

Oil Seal 1507 Fenner India Ltd KOS 1988

Oil Seal Gaco GACO

Oil Seal 2649 Super Seals SS

Oil Seal 3359 MRP Auto Rub P. Ltd MRP

Piston 1456 Escorts Ltd, MAHLE

Piston 1733 India Piston Ltd, IPL(1733)

Piston (370/401/6.65) 2562 Shriram Pistons USHA


59



Piston rings 1591 Goetze India Ltd, GOETZE

Piston rings 1733 India Piston Ltd IPL(1733)

Pistons/Rings 2562 Shriram Pistons and Rings Ltd., USHA 2562

Plastic Fan 4313 Govel Plastics (P) Ltd, GOVEL

Plastic Fan 4005 Ampson Plastics P. Ltd AP

Push Rod 3928 Ghaziabad Precision Products Ltd GPP

Push Rod 4722 Pal Dahle (P) Ltd PD

Push rod 1083 Autopal Manufacturing Co. AUTOPAL

Radiator 1558 BANCO Products India (P) BANCO

Radiator 1652 Halgona Radiators, HALGONA

Radiator 1735 India Radiator Ltd, IRL

Radiator 1930 Klipco private Ltd Klipco

Radiator 4575 Madras Heat Transfer MHTP

Radiator 5864 Premier Radiator PREMIER

Radiator 2862 Universal Radiators Ltd UR

Radiator (680TC) 1536 Asian Radiator ASIAN

Radiator 6009 GS Radiators Limited GS Radiators

Radiator 6326 Teksons Limited, Mumbai Teksons

Radiators Aluminum 6244 TATA Toyo Ltd. Pune TATA TOYO

Radiator 1930 Clipco Inds CLIPCO

Radiator 5009 Alkraft ALKRAFT

Shroud Radiator 6017 Sakthi Fiberglass & Fabricators SAKTH

Radiator Mounting Bush 4902 Taylor Rubber Industry TRI

Rocker Lever bush 1926 Kirloskar Oil Engines KOEL

Small End bush-conrod 1926 Kirloskar Oil Engines KOEL

Small end bush-conrod 1209 Bimetal Bearing Ltd BM

Starter Ring 4356 Hindustan Ring Gears HRG

Starter Ring 4547 Lasco Engineering Co. LASCO

Starter ring 1734 India Piston Repco IRP

Tappet 1077 Autolec 1077

Tappet 2350 Engine Components 2350

Tappet 4375 Han Tools 4375

Thermostat 4558 Tribology India Pvt. Ltd WAX or TRIBOLOGY

Thermostat 2948 Western Thompson, WESTERN

Thermostat 3157 Caltherm thermostats CALTHERM

Thermostat (Hino) 2943 Wax Thermostats P Ltd, WAX or TRIBOLOGY

Turbocharger 4970 Turbo Energy Ltd., TEL

Valve Guide 1450 Engine Valves Ltd EVL


60



Valve Guide 4689 Speed Valves Industries 4689

Valve Guide 4634 Sridhar Technocrafts 4634

Valve Guide 3611 Madhu Machine Tools 3611

Valve Guide 2293 Pearlite liners 2293

Valve Guide 3382 MASP Funktioning 3382

Valve inlet/exhaust 1913 Kar Mobiles Limited KVL

Valve Seat 2381 Perfect Alloy Comp. 2381

Valve Spring 2631 Stumpp Schuele Somappa GREEN

Valve Spring 4089 The Bombay Co.Ltd BROWN & WHITE BAND

Viscous Clutch 3030 Amalgamations Valeo Clutch Ltd Valeo

Viscous Fan Clutch 6483 Borgwarner

Viscous Damper 2168 Mechnaar Engg. Pvt.Ltd. M

Viscous Fan Clutch 6483 Borgwarner Cooling Systems India

P Ltd.

BW

Viscous Fan Clutch P105 Behr India Ltd Behr

Water Pump Seal 1507 Fenner India Ltd. Fenner

Water Pump Seal 1085 Automotive Industrial Seals (P) Ltd. AIS

AL Pump 5090 Alpump

Water Pump Seal 1014 AVON AVON

Air Cleaner 2041 Luman Auto Light (P) Ltd. LUMAN

Air Cleaner (1312) 2711 Southern Pressings P. Ltd SPTC

Air Compressor Hose 5984 Ranflex Braided Compressor Hose RANFLEX

Bush - FIP Supt. 1209 Bimetal Bearings Ltd BM

Bush - FIP/PS 1209 Bimetal Bearings Ltd BM

Cam Gear 5324 Elforge Ltd. EFL

Camshaft 1198 Bharat Forge Ltd. BFL

Con Rod 1198 Bharat Forge Ltd. Pune BFL

Crank Gear 5324 Elforge Ltd. EFL

Damper 3368 Hodek Engineering Works H

Drive Pulley 1077 Autolec Manufacturing &

Marketing Pvt. Ltd.

A

Exhaust Manifold 3231 Eltex Pvt. Ltd. ELTEX

Fan Hub 3368 Hodex Engineering Works H

FIP Gear 5324 Elforge Ltd. EFL

Idler Shaft 5324 Elforge Ltd EFL

Inter Bush 1209 Bimetal Bearings Ltd, BM

Inter Gear 5324 Elforge Ltd. EFL

Nozzle Clamp 5324 Elforge Ltd. EFL

Oil Cooler 2391 Poona Shims Pvt. Ltd. POSH


61



Oil Pressure Switch 3235 MVD Auto Components FUSI

OP Driven Gear 5324 Elforge Ltd EFL

OP Gear 5324 Elforge Ltd EFL

PMP Pulley 1077 Autolec Manufacturing and

Marketing Pvt. Ltd.

A

Power Steering Gear 5324 Elforge Ltd. EFL

Pulley 2168 Mechnarr Engs. (P) Ltd. ME

Pulley Compressor 1077 Autolec manufacturing &

Marketing Pvt. Ltd.

A

Pulley Tensioner 1077 Autolec manufacturing &

Marketing Pvt. Ltd.

A

Radiator 6009 G S Radiators Ltd GS

Ring Gear 1734 India Piston Repco IPR

S. Shaft 5324 Elforge Ltd. EFL

Sender Unit 2372 Premier Instruments & Controls PRICOL

Thermostat 5192 Caltherm (P) Ltd. CAL

Timing Case Inner 1878 Jaya Hind Ind. Ltd J

Timing Case Outer 1878 Jaya Hind Ind. Ltd J

Water Pump 5090 AL Pump Pvt. Ltd. ALPUMP

DAT Tank 6921 Time Packaging TPL

Dearation Tank 5703 Milton Plastics MILTON

Deareation Tank 5098 Engine Tech. Systems (I) Pvt. Ltd. EnginTech

Exhaust Pipe 5959 RAS Metal Fabricators RAS

Turbocharger 4970 Turbo Energy TEL

CLUTCH

Clutch disc P095 Setco Automotive SETCO

Clutch Housing 1051 Ashok Iron Works AIW

Clutch Plate 1031 Amalgamation Repco Ltd, AMREP

Clutch Plate 2088 Mahindra & Mahindra Ltd, M & M

Clutch Plate 2435 Rane Brake Linings RBL

Clutch Plate 1305 Clutch Auto Limited CA

Clutch Spring 0678 Nagappa Springs (P) Ltd WHITE COLOUR

Clutch Spring 2631 Stumpp Schule Somappa Colour Code

Clutch Spring 4600 Machs Spring Pvt. Ltd. Colour Code

Cover Assembly 2435 Rane Brake Linings RBL

Clutch Withdrawal Bearing 4809 Swathantra Jain SWATHANTRA

Diaphragm Clutch Hindustan Composites HF

Wearing Plate 2435 Rane Brake Linings RBL


62



Clutch Withdrawal Plate 4425 Janus Auto

Clutch 6422 Texpin Bearings Ltd. TEXPIN

Clutch Withdrawal Brg. 5177 RMP Bearing Ltd. RMP

Clutch Disc 4318 Setco SETCO

Clutch booster X006 Wabco Products WABCO

GEAR BOX

Gearbox Casing 1051 Ashok Iron Works AIW

Marine Gear Box 1580 Ghatge Patil Industries Ltd, GPI

Marine PTO 4217 Easun Machine Tool Name Plate

PTO Unit 1580 Ghatge Patil Industries Ltd, GPI

Speed Change Casing 1051 Ashok Iron Works AIW

PROPELLER SHAFT

Propeller Shaft 3773 GNA Udyog Ltd GNA

Propeller Shaft, UJ Cross 2088 Mahindra Sona Ltd, MSL

Propeller Shaft, UJ Cross 4981 Hindustan Hardy Spicer HHSL

Prop. Shaft “T” Series 3441 Spicer India Ltd (HHSL) spicer

CJ Brg. 9812 Hardy Spicer Hardy Spicer

Prop. Shaft “T” Series 3441 Spicer India Ltd (HHSL) spicer

AXLES

Axle Arm 1653 AM Forge Ind. Ltd. AMF

Axle Beam 1653 Amforge Industries Ltd. Amforge

Axle Casing 4003 Axles India Limited, AIL

Axle Casing 4018 Automotive Axles Limited. AAL

Axle Shaft 1616 Gurunanak Auto Enterprises GNA

Thrust Bearings FA90 6422 Texspin

Axle Shaft 2556 Shardlow India Ltd Shardlow

CWP 1195 Bharat Gear Ltd, BGL

CWP R149 / Q109 /SQR 109

/ C100

4018 Automotive Axles Limited. AAL

Oil Seal Rear Hub 5484 Hitech Arai Ltd HTA

Thrust bearing (FA90) 6422 Texspin Bearings Ltd., Texspin

Rear Axle Casing 4018 Automotive Axles Ltd AAL

Rear Wheel Bolt 6840 STL STL

BRAKE

Air Compressor, 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)


63



Air Filter 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Air Hose Assembly 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Air Reservoir 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Brake Chamber 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Brake Chamber X006 Wabco Products Ltde WABCO

Brake Drum 1051 Ashok Iron Works AIW

Brake Drum 1137 Aqura AQ

Brake Drum 5200 CPC Ltd. CPC

Brake Drum 8412 Ennore Foundries EF

Brake Drum 4219 Eskayaar Industries E

Brake Drum 1580 Ghatge Patil Industries Ltd. 1580

Brake Drum 5655 Lamina Foundries Ltd LM

Brake Drum 6736 Mak Auto (P) Ltd. M

Brake Drum 3630 Mak Industries M

Brake Drum 5903 PSG & Sons Charities PSG

Brake Drum 0938 Rangamma Steels and Malleables 0938

Brake Drum 6812 RVS Industries (P) Ltd. RVS

Brake Drum 6835 Samir Castings (P) Ltd. SAM

Brake Drum 2679 Shivaji Iron Works SW

Brake Drum 6842 Sandfit Foundries P Ltd SP

Brake Drum 5655 Lamina Foundries LF

Brake Drum 2027 Vindya Vasini VV

Brake Drum Casting 8412 Ennore Foundries EF

Brake Drum Casting 1210 Binny Engineering Ltd. BEL

Brake Drum Casting 2747 Jaiswal Neco Auto Castings Ltd. JNL

Brake Drum Casting 1421 Sandfit Foundries SF

Brake Drum Casting 4648 Nelcast NC

Brake Drum Casting 0776 Autocast ACL

Brake Front 1223 Brakes India Ltd, BI Part No

Brake Frt LH/RH 4018 Automotive Axles Limited. AAL

Brake Lining 3607 Sundaram Brake Linings SB

Brake Rear 1223 Brakes India Ltd, BI Part No

Brake Rear LH/RH 4018 Automotive Axles Limited. AAL

Double Check Valve 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Dual Brake Valve 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Graduated Flick Valve 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Hand Brake Valve 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Low Pressure Warning 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)


64



Switch

Pneumatic Wind off

connection

2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Pressure Regulator Valve 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Slack Adjuster 2035 Haldex India Lted HALDEX

Slack Adjuster 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Slack Adjsuter 2035 Haldex Inds HALDEX

Slack Adjuster 2077 Madras Engg Inds MEI

Slack Adjuster 2733 ANG Auto (P) Ltd ANG

Stop Light Switch 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

System Protection valve 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

Unloader Valve 2639 Sundaram Clayton Ltd CLAYTON(CD-TVS)

BEARINGS

Bearing 1041 Antifriction Bearing Corporation ABC

Bearing 2333 FAG Precision BearingsLimited NORMA

Bearing 1740 HMT Bearings Limited HMT

Bearing 0664 National Engineering Industries

Ltd

NBC

Bearing 2224 Needle Roller Bearing, NRB

Bearing 1064 SKF Bearing India Ltd. SKF

Bearing 3854 Tata Timken TIMKEN

Bearing 4505 Karnataka Ball Bearings JAY

Bearing P070 Orbit bearing P070

FASTENERS

Fasteners 3186 Dev Fasteners DEV

Fasteners 1609 G K W Limited GKW

Fasteners 0442 Gujarat Metal Form GML

Fasteners 2335 Precision Fasteners Ltd UNBRACO

Fasteners 4756 Right Tight Fastners RTF

Fasteners 2568 Simmonds Marshall SM

Fasteners 2640 Sundaram Fasteners Ltd TVS

Rear Wheel Bolt 6840 Sterling Tools Ltd STL

Wheel Bolt 2335 Precision Fasteners Ltd, UNBRACO

Wheel Bolt 2640 Sundaram Fasteners Ltd, TVS

Wheel Bolt 2703 Sterling Tools Limited STL

Wheel Bolt/Nut 0550 Kuduma Fasteners KFL

Wheel Cone 2150 Micro Turns


65



STEERING

Ball Joint 0749 QH Talbros QH TALBROS

Ball Joint 0817 Rane Madras (Mysore) RANE

Ball Joint LH / RH 5374 Elgi Auto Parts Ltd ELGI

Power Steering and steering

UJ

2430 TRW Steering Systems RANE

Power Steering assembly X278 Hubei Forni HF

Power Steering Hydraulic

Pump

2907 Vickers Sperry of India Ltd, VICKERS

Steering Bevel Box 0207 APT Engineering APT

Steering 2429 Rane (Madras) Limited, RANE

Steering Pump 4529 Dynamatic Technologies P. Ltd. DOWTY

Steering Wheel 3211 Emdet Engineers EMDET

Steering Wheel 0293 Coolwels Automobile Engineers COOLWELS

Steering wheel 4869 Standard Auto Industries SAI

Steering Wheel 0293 Coolwels Automobile Engineers CAE

Steering Wheel Cover 2075 Mahindra Sona Ltd. MSL

Steering wheel for Power

Steering

1753 Industrial Rubber products IRP

Steering ZF 4992 ZF Steering Gear India Ltd. ZF India

Track Rod 5374 Elgi Auto Parts Ltd. ELGI

Wheel Assembly Steering 5850 Premium Moulding and Pressings PMP

Steering Column Assy 1616 GNA Udyog Ltd. GNA

SUSPENSION

Buffer 2929 Vapi Rubber Industrial VI

King Pin Bush 2433 Rapsri Engg. Industries R

Leaf Spring 1647 Jai Parabolic Springs Ltd JSPL

Leaf Spring 5798 Madras suspensions UIE

Levelling Valve X006 WABCO Wabco

Rr. Spg. Buffer 3105 Buyer’s Engineers BE

Shock Absorber 1455 Escorts Ltd. ESCORTS

Shock absorber 1551 Gabriel India Ltd. GABRIEL

Shock absorber 1679 Hydraulics Limited ARMSTRONG

Shock absorber 5970 Quantitech Inds KONI

Shock absorber 2164 Renowned Auto Products RAP

Silent Block Bush 3926 VIR Rubber Products VIR

Spring Eye Bush 0826 Patel Brass Works PBW

Spring Front 1086 Auto Pins India Ltd SIROCCO or SSL


66



Spring Leaf 1855 Jamuna Auto Industries JAI

Spring Leaf 2792 Torsion Products Ltd TVS TORSION

Spring Rear, Spring Front 1715 India Leaf Spring Manufacturing

Co. Ltd.

ISCO or ILA

Spring Rear, Spring Front 1877 Jonas Woodhead and Sons (India)

Ltd

WOODHEAD

Springs 2631 Stump Scheuele Somappa GREEN COLOUR BAND

Thrust washer 2433 Rapsri Engg. Industries R

Air Bellows (12 M) 5970 Resistoflex Dynamics P Ltd CONTITECH

Front Spring Assy 1715 India Leaf Spring ICS

Front Spring Assy. 5572 Jai Parabolic Springs Ltd JPS

Rear Spring Assy 1715 India Leaf Spring ICS

Rear Spring Assy. 5572 Jai Parabolic Springs Ltd JPS

Stabilizer Bar 5195 Coventry Spring & Engg. CS

Air Duct Hose 3887 Samplastics SAM

Air Bellow 5970 Resisto Flex CONTITECH

Levelling Valve X006 Wabco Inds WABCO

FES & CHASSIS

Aren Control & Nylon Hose 3547 Lakshmi Industrial Plastics lakshmi

Arens Control 4857 Shah Udyog 4857

Cabin Rear Buffer 3105 Buyer’s Engineers BE

Control cable 4857 Shah Udyog 4857

Diesel Tank 2074 Madras Radiators andPressings MRP

Diesel Tank 4836 Vijay Associates VA

Diesle Tank 1451 Imperial Graphics Imperial

Fuel Tank 3037 Anupama Fabricators AF

Fuel Tank P083 Prabha Auto components Prabha

Fuel Tank 2127 JMC Industries JMA

Fuel Tank (3516) 5571 Jayalakshmi Auto Products

Fuel Tank Cap 6555 Auto Engineers (India) PAVANA

Fuel Tank 2074 Madras Radiator & Pressing Ltd. MRP

Fuel Tank 2488 Ragam Metal Products Pvt. Ltd. RMP

Fuel Tank 5950 Pallavi Metals (P) Ltd. PML

Fuel Tank 6025 Standard Metal Works SM

Fuel Tank 6703 Kailash Auto Builders Ltd. SEL

Fuel Tank 2127 JMC Industries, New Delhi

Fuel Tank 3516 5571 Jayalakshmi Auto Products, Hosur JAYA

FES 2074 Madras Radiators andPressings MRP


67



FES 3028 Autofab Pvt. Ltd. Autofab

FES 2328 Prabha Industries PI

FES 2488 Ragam Metal Products Ragam

FES 0617 Impipe India P. Ltd. IMPIPE

Rear Cab Mounting Rubber 1753 Industrial Rubber Products IRP

Rear Cab Mounting Rubber 1085 Automotive Industrial Seals AIS

Reflector 2032 Lumax Industries Ltd. LUMAX

Reflector RED 0586 Lumax Industries Ltd. LUMAX

Silencer 1451 Imperial Graphics IG

Silencer Flex Pipe 2991 Zaver Chand & Co., FLEXICAB

Silencer Muffler 6579 Diamond Bucket Industries Diamond Bucket

Muffler Assy 5558 ABM Tools ABM

Muffler Assy. 2621 Standard Structurals SS

Silencer Turbo 2621 Stnadard Structurals SS

Silencer Turbo 5558 ABM Tools ABM

Tyre Inflator Hose 1439 ELGI Equipments Ltd. ELGI

Wind Screen 0517 Indrad Auto Components Ltd INDRAD AUTO

Weather Strip 0202 Anand Nishikawa Co. Ltd.

Bracket Assy RR View 6439 We Two & Co.

Bracket Assy Wiper Motor 0517 Indrad Auto Components

Buzzer 1480 Electron India ELECTRON

Cab Lock 6872 Spot Electro Tech

Cab Lock Assy 1084 Automotive Ancillary AAS

Cab Lock Assy. 5220 Crystal cabs (P) Ltd. CCP

Cab Lifting Pump 5387 Deccan Hydraulics (P) Ltd.

Clamp Jack Stowage FT 4196 Balaa Works BW

Clamp Jack Stowage RR 4196 Balaa Works BW

Co-driver seat 1957 Krishna Fabrication Ltd. KFL

Driver Seat 6603 Ersleln Geniuen India

Col. Lower 6252 Supreme Industries Ltd. SIL

Control Rod Assy 1084 Automotive Ancillary AAS

Control Rod Assy 5220 Crystal cabs (P) Ltd. CCP

Cover Speedo 5377 Devi Polymers (P) Ltd. DPL

Cover Steering 5850 Premium Moulding & Pressings

Ltd

PMP

Door Latch 6004 Reinz Talbros Ltd. REINZ

Door Lock 6741 Monoclick Systems M

Door Lock 5696 Mullgaonkar Engg. Works MULGOANKAM


68



Door Lock 6726 Metaloid Corporation METALOID

Driver Seat Krishna Fabrication Ltd. KUSHY

Driver Seat 5358 Foam Products Seat Division

Driver Seat 6603 Erste Ingenieure P Ltd Er

Fairing FT Bumper LH 6421 VIP Industries Ltd. VIP

Fairing FT Bumper RH 6421 VIP Industries Ltd. VIP

Fender Cargo Cab 6118 Sun Vaccum Formers (P) Ltd. SUN

Front Grill 6252 Supreme Industries Ltd. SIL

Gaiter Stg Column 1753 Industrial Rubber Products IRP

Glove Box Large 6252 Supreme Industries Ltd. SIL

Handle Cab Release 2125 Modern General Industry MGI

Handle W/S Wash 6118 Sun Vaccum Formers (P) Ltd. SUN

Hing - Glove Box LH 6439 We Two & Co. WTC

Hinge - Glove Box RH 6439 We Two & Co. WTC

Hook Assy - Cab lock 5220 Crystal cabs (P) Ltd. CCP

Hook Assy. - Cab lock 1084 Automotive Ancillary AAS

Instrument Panel 6066 Saks Ancillaries (P) Ltd. SAKS

Instrument Panel RH/LH 5377 Devi Polymers (P) Ltd. DPL

Insulator Assy - Rad supp. 1084 Automotive Ancillary AAS

LH door Regulator Assy 6004 Reinz Talbros Ltd. REINZ

Lock Assy 6004 Reinz Talbros Ltd. REINZ

Mirror LH 6439 We Two & Co. WTC

Mirror RH 6439 We Two & Co. WTC

Pad Torsion Bar Regulator

Assy

5856 Plastic Industries PI

Rear View Mirror 5098 Engine Tech. Systems Pvt. Ltd. Engine Tech

Regulator Assy - Cab lock 5037 Autarkey Auto Prods.(P) Ltd. A

Relay Head Light 5370 Fourth Generation Engg.(P) Ltd. FOURTH GEN

RH door 6004 Reinz Talbros Ltd. REINZ

Runner 6004 Reinz Talbros Ltd. REINZ

Scuff Plate Rear LH/RH 4313 Govel Plastics (P) Ltd. GP

Shroud - Steering 4313 Govel Plastics (P) Ltd. GP

Shroud Steering Column

Upper LH/RH

6252 Supreme Industries Ltd. SIL

Spring pedal Return Brake 5006 Accurate Spring Products ASP

Spring Pedal Return Clutch 5006 Accurate Spring Products

Stabiliser Bar 1086 Auto Pins (P) Ltd. SIRRACCO

Stack Pipe Assembly 6322 Universal Fibre Glass Ind. UFG

Striker Pin 6004 Reinz Talbros Ltd. REINZ


69



Striker Pin 0485 Index Auto Components I

Striker Pin 6944 Universal Flexibles (P) Ltd UF

Torsion Bar RH/LH 1086 Auto Pins (P) Ltd. SIRRACCO

Torsion Bar RH/LH 5195 Coventry Spring & Engg. CS

Wheel Assy Steering 5850 Premium Moulding & Pressings

Ltd

PMP

Wind Screen 3367 Hindustan Safety Glass Works Ltd.

Wind Screen Glass 2192 Sekurit Saint - Gobain India Ltd. ATUL TUF

Window Winding

Mechanism

8603 Prince Metal Works PMW

Wiper Arm 5104 Bombay Commercial Syndicate BCS

Wiper Blade 5104 Bombay Commercial Syndicate BCS

ELECTRICALS

Accessory Kit 2026 Lucas TVS Ltd LUCAS TVS

Air Buzzer 2698 IQ Infotech Sticker with System

Alternator 2026 Lucas TVS Ltd LUCAS TVS

Alternator 4094 Best & Crompton Engineering Ltd. BEACON

Assy, of Air Horn 1439 ELGI Equipments Ltd ELGI

Assymetric Lamp 0585 Lumax Industries Limited LUMAX

Baffle Plate 1084 Automotive Ancillary Services AAS

Beeper 2698 System and Dimension System & Dimension

Beeper 4859 Sri Charan Enterprises Sri Charan

Beeper 1480 Electron India Ltd Electron

Beeper Unit 2040 Luxong Luxong

Buzzer 1480 Electron India Ltd, Electron

CNG DC Convertor 2054 Mekhale Electronics ME

Combination Switch 4714 Perfect Electric Concern Pvt. ZEUS

Combination Switch 2036 Brytax Auto BRYTEX

Combination Switch 2041 Luminous Autolite Pvt.Ltd LUMAN

Combination Switch 1075 Auto Electric Enterprises AEE

Combination Switch 0813 Rajan Auto Ancillaries RAJAN

Combination Switch 0962 Shutam Electric SHUTAM

Combination Switch 0369 Electron electricals Lakshmi

Dashboard gauge P063 Minda Stoneridge Minda

Dynamo (IE/ME) 2026 Lucas TVS Ltd LUCAS TVS

Electronic Flasher 4557 Textech Electronic Industry TEXTEK

Flasher 0813 Rajan Auto Ancillaries RAJAN

Flasher 2036 Brytax Auto BRYTEX


70



Flasher Lamp 2036 Lumax Auto Pvt.Ltd LUMAX

Flasher Unit 1759 JMA Industries Ltd, HELLA

Flasher Unit 2032 Lumax Industries Ltd, LUMAX

Fuse Box 0369 Eltron Electricals lakshmi

Hazard Warning Switch 1759 JMA Industries Ltd, HELLA

Head Lamp 0585 Lumax Industries Limited LUMAX

Head Lamp 1759 JMA Industries Ltd, HELLA

Head lamp 2026 Lucas TVS Ltd LUCAS TVS

Head Lamp - Goods 1760 JMA Industries Ltd, HELLA INDIA

Head Lamp - Passenger 1760 JMA Industries Ltd, HELLA INDIA

Head Lamp assy 2698 System Dimensions Sticker with System

Head Lamp Assy. 3101 Batra Associates Ltd BATRA

Horn 24V 1883 Roots India Limited ROOTS

Horn 24V 4040 Padmini Engineering Pvt. Ltd PADMINI

Horn 1759 JMA Industries Ltd, HELLA

Horn 2026 Lucas TVS Ltd LUCAS TVS

Horn 4615 Munchur Industries Pvt. Ltd FER

Horns P037 Nikko Auto NIKKO

Horns 5727 MINDA MINDA

Horn 4589 Munchur Udyog, Mangalore MUNCHUR

Horn P037 NIKKO Auto NIKKO

Horn/Dipper Switch 1084 Automotive Ancillary Services AAS

Isolator Switch 2029 IGSA Switch IGSA

Junction Box 1075 Auto Electric Enterprises AEE

Low Pressure Indicator 2698 IQ Infotech Sticker with System

Low Pressure Indicator 4859 Sricharam Enterprises SRICHARAM

Low Pressure Indicator 1480 Electron India Ltd, ELECTRON

Low Pressure Warning

Lamp

0323 Devi Enterprises Devi

Pressure Transducer 2372 Premier Inustrument Control PIC

Rear Lamp 2032 Lumax Industries Ltd. LUMAX

Regulator (IE/ME) 2026 Lucas TVS Ltd LUCAS TVS

Reverse Light Switch 3256 Electromags ELECTROMAG

Side & Flasher lamp 1084 Automotive Ancillary Services AAS

Side Lamp 2032 Lumax Industries Ltd. LUMAX

Side Lamp 2036 Lumax Auto Pvt.Ltd. LUMAX

Side Lamp 1759 JMA Industries Ltd. HELLA

Solenoid Valve 6821 Rotex Technical Services P. Ltd. ROTED


71



Solenoid Valve 1214 Blue Star PRECISION

Starter Motor 4094 Best & Crompton Engineering Ltd. BEACON

Starter Motor 2026 Lucas TVS Ltd LUCAS TVS

Starter Relay 2062 Tyco Tyco

Switch 0369 Eltron Electricals Lakshmi

Tail Lamp 2032 Lumax Industries Ltd. LUMAX

Tail Lamp 1759 JMA Industries HELLA

Tail Lamp 2041 Luminous Auto Light LUMEN

Warning Lamp 0323 Devi Industries 323

Wiper Arm Assy. 4078 Bombay Commercial Syndicate BCS

Wiper Motor 2026 Lucas TVS Ltd LUCAS TVS

Wiper Motor 4334 Prabha Engg. PRABHA

Wiper Motor (Ecomet) 0517 Mitsubha Sical L Ltd., Mitsuba

Wiper Motor Switch 4714 Perfect Electric Concern Pvt. ZEUS

Wiper Motor Switch 1075 Auto Electric Enterprises AEE

Wiper Switch

ON/OFF(12/24 Volt)

1158 PMP Auto Industries Ltd PMP

Wiring Assy - Ignition 6066 Saks Ancillaries (P) Ltd SAKS

Wiring Assy - Rear lamp

connection.

6066 Saks Ancillaries (P) Ltd SAKS

Wiring Assy Battery 6066 Saks Ancillaries (P) Ltd. SAKS

Wiring Assy Cab Catch 6066 Saks Ancillaries (P) Ltd SAKS

Wiring Assy Centre- 6066 Saks Ancillaries (P) Ltd SAKS

Wiring Assy Engine 6066 Saks Ancillaries (P) Ltd SAKS

Wiring Assy Ingnition

connection


Wiring Assy Int Bunk Lamp 6066 Saks Ancillaries (P) Ltd SAKS

Wiring Assy LH Instrument 6066 Saks Ancillaries (P) Ltd SAKS

Wiring Assy Main-RHD 12

V


Wiring Assy Rear 6066 Saks Ancillaries (P) Ltd SAKS

Wiring Assy RH Inst Panel 6066 Saks Ancillaries (P) Ltd SAKS

Wiring Assy Roof Marker 6066 Saks Ancillaries (P) Ltd SAKS

DASHBOARD INSTRUMENTS

Air Pressure gauge 1770 VDO I Ltd VDO

Air Pressure gauge 2372 Premier Instruments & Controls

Ltd,

PRICOL

Air Pressure gauge 4009 Autometers Ltd AUTOMETER


72



Air Pressure gauge 2169 TAFE Accessories Ltd TAL

Ammeter 2169 TAFE Accessories Ltd TAL

Ampere meter 1770 VDO India VDO

Ampere meter 2372 Premier Instruments & Controls

Ltd.

PRICOL

Ampere meter 4009 Autometers Ltd. AUTOMETER

Electronic Hour Meter 5052 Ayyappa Agencies GIC

Flasher Switch 1084 Automotive Ancillary Services AAS

Fuel Tank Indicator 4009 Autometers Limited AUTOMETER

Fuel Tank Indicator 2013 Leo Machine Products LEO

Fuel gauge 2169 TAFE Accessories Ltd TAL

Gauges 2169 Tafe Access Ltd TAL

Gauges 6653 Indication Instruments Ltd VEETHREE

H.W. Switch 0369 Eltron Electricals lakshmi

Hazard Warning

Switch

0369 Eltron Electricals lakshmi

Ignition Starter switch 1770 International Instruments Limited YENKAY

Ignition Switch 4537 K.Lakshmanan KL Sticker

Ignition Switch 0813 Rajan Auto Ancillaries RAJAN

Ignition Switch 4714 Perfect Electric Concern Pvt. ZEUS

Ignition Switch 0369 Eltron Electricals LAKSHMI

Instrument Panel 0677 Phoenix Plasts Company PPC

Instrument Panel

Gauges

2169 TAFE Access Ltd. Chennai TAL

Low Air Pressure

switch

1770 International Instruments Ltd YENKAY

Oil Pressure gauge 1770 VDO India VDO

Oil Pressure Gauge 2372 Premier Instruments & Controls

Ltd,

PRICOL

Oil Pressure Gauge 4009 Autometers Ltd, AUTOMETER

Oil Pressure Gauge 2169 TAFE Accessories Ltd TAL

Oil Pressure switch 1770 VDO India VDO

Panel Light Switch 0369 Eltron Electricals Lakshmi

Piano Key Switch 1075 Auto Electric Enterprises AEE

Piano key switch 4714 Perfect Electric Concern Pvt. ZEUS

Piano switch 1770 VDO India VDO

Pilot Lamp and Holder 1480 Electron India Ltd

Pull & Push Switch 1158 PMP Auto Industries Ltd PMP

Pull Push Switch 0813 Rajan Auto Ancillaries RAJAN


73



Pull Push Switch 4537 K.Lakshmanan KL Sticker

Pull Push Switch 2036 Brytax Auto BRYTEX

Push Switch 4864 Switch Auto 4864

Push switch(Starter) 2026 Lucas TVS Ltd LUCAS TVS

RPM Cable 1770 VDO India VDO

RPM Cable 2372 Premier Instruments & Controls

Ltd

PRICOL

RPM Cable 4009 Autometers Ltd AUTOMETER

RPM Indicator & Bulb 1770 VDO India VDO

RPM Indicator & Bulb 2372 Premier Instruments & Controls

Ltd

PRICOL

RPM Indicator & Bulb 4009 Autometers Ltd AUTOMETER

Speedo cable 4009 Autometers Ltd AUTOMETER

Speedo cable 2372 Premier Instruments & Controls

Ltd

PRICOL

Speedo cable 1770 VDO India VDO

Speedo cable (Lynx) 6011 Remsons Auto Industries Remson

Speedometer 1770 VDO India VDO

Speedometer 2372 Premier Instruments & Controls

Ltd

PRICOL

Speedometer 4009 Autometers Ltd AUTOMETER

Speedometer 1770 VDO India Limited VDO

Speedometer 2169 TAFE Accessories Ltd., TAL

Starter Push Switch 2036 Brytax Auto BRYTEX

Starter Push Switch 3547 Lakshmi Industrial Plastics LIP

Starter Switch 0369 Eltron Electricals Lakshmi

Switch WS Washer 0517 Indrad Auto Components IndRad Auto

Temperature gauge 2169 TAFE Accessories Ltd TAL

Tail Lamp Switch 1759 JMA Industries Ltd, HELLA

Temp. Sensor 2372 Premier Instruments & Controls

Ltd

PRICOL

Temp. Sensor 2169 TAFE Accessories Ltd TAL

Temp. Sensor 4009 Autometers Ltd AUTOMETER

Temperature Switch 3902 RICO RICO

Toggle Type Switch 4428 Essen Engg. Company ESSEN

Water temp.gauge 1770 VDO India VDO

Wiper motor switch 1770 VDO India VDO

Bush Self Cancellation 4714 Perfect Electric Concern (P) Ltd. ZEUS

Combination Switch 2041 Luman Auto Light (P) Ltd. LUMAN


74



Combination Switch 0962 Shutham India Shutham

Courtesy Lamp 2032 Lumax Industries Ltd. LUMAX

Flasher Unit 2041 Luman Auto Light (P) Ltd. LUMAN

Front Direction

Indicator &Assy

LH/RH

2041 Luman Auto Light (P) Ltd. LUMAN

Front Directional

Indicator

2032 Lumax Industries Ltd. LUMAX

Fuel Guage 4714 Perfect Electric Concern (P) Ltd. ZEUS

Fuse Box 4714 Perfect Electric Concern (P) Ltd. ZEUS

Hazard Warning

Switch

2036 Brytax Auto Ind. Ltd. BrytaX

Hazard Warning

Switch


Head Lamp 2032 Lumax Industries Ltd. LUMAX

Head Lamp 2041 Luman Auto Light (P) Ltd. LUMAN

Head Lamp 5370 Fourth Generation Fourthgen

Head Lamp Relay 2036 Brytax Auto Ind. Ltd. BrytaX

HW Switch 4714 Perfect Electric Concern (P) Ltd. ZEUS

Ignition Switch 2041 Luman Auto Light (P) Ltd. LUMAN

Interior Lamp Assy 2032 Lumax Industries Ltd. LUMAX

Lamp Assy Roof

Marker

2032 Lumax Industries Ltd. LUMAX

Lamp Assy Roof

Marker


Lamp Assy Side Flasher 2032 Lumax Industries Ltd. LUMAX

Lamp Assy Side

Marker


Micro Switch

(Hightemp)

1917 Kaycee Industries Ltd KAYCEE

Oil Pressure Gauge 4714 Perfect Electric Concern (P) Ltd. ZEUS

Oil Pressure Gauge 6653 Indication Instruments Ltd VEETHREE

Pressure Transducer 4714 Perfect Electric Concern (P) Ltd. ZEUS

Rear Lamp Assy. 2041 Luman Auto Light (P) Ltd. LUMAN

Relay Head Light 2041 Luman Auto Light (P) Ltd. LUMAN

Relay starter 2026 Lucas Indian Services LIS

Reverse Light Switch 3235 MVD Auto Components FUSI

Sender Unit 4714 Perfect Electric Concern (P) Ltd. ZEUS

Sensor INT Gauge 4714 Perfect Electric Concern (P) Ltd. ZEUS


75



Side & Tail Lamp

Switch

2036 Brytax Auto Ind. Ltd BrytaX

Switch 2041 Luman Auto Light (P) Ltd. LUMAN

Switch Assy 2026 Lucas Indian Services LIS

Switch Assy Ignition 4714 Perfect Electric Concern (P) Ltd. ZEUS

Switch Assy Steering

Horn

4714 Perfect Electric Concern (P) Ltd. ZEUS

Switch Bulb Test 4714 Perfect Electric Concern (P) Ltd. ZEUS

Switch Cab Latch 4714 Perfect Electric Concern (P) Ltd. ZEUS

Switch Cab Latch 2041 Luman Auto Light (P) Ltd. LUMAN

Tail Lamp 2032 Lumax Industries Ltd. LUMAX

Warning Lamp 5017 Accu Spark Engineers A

Wiper Motor 0517 Indrad Auto Components MITUSUBA

Wiper Motor 4334 Prabha Industries PRABHA

Wiper Switch 2041 Luman Auto Light (P) Ltd. LUMAN

WS Washer Unit 24V 0517 Indrad Auto Components IndRad Auto

BATTERY

Battery 1032 Amco Batteries Limited AMCO

Battery 1297 Chloride India Limited EXIDE

Battery 4921 UB MEC Batteries Ltd MEC

Battery 2305 Amara Raja Batteries Ltd AMARAN

Battery (Goods) 2613 Standard Batteries STANDARD SF

Battery - 12V 2230 Tudor India Ltd. Prestolite

WHEELS & TYRE

Tyre 1044 Apollo Tyres Ltd APOLLO

Tyre 1280 Ceat Tyre of India Ltd CEAT

Tyre 1388 Dunlop India Ltd, DUNLOP

Tyre 1593 Goodyear India Limited, GOODYEAR

Tyre 1758 J.K. Industries, JK

Tyre 2076 Madras Rubber Factory MRF

Tyre 8720 Modi Rubber Limited, MODI

Tyre 2346 Premier Tyres Limited, PREMIER

Tyre 3941 Vikrant Tyres, VIKRANT

Tyres 1215 Bombay Tyres International MODISTONE

Wheel disc 2949 Wheels India Limited, WIL

Wheel disc 4208 Kalyani Lammerg KLL


76



TIPPING UNIT

Tipping gear 0473 Dantel Edbro fitment of PL

Haulwell

Dantel

Tipping gear 2869 Usha Telehoist Ltd., UT

Tipping gear WIPRO WIPRO

Tipping gear P004 Hyva HYVA

Tipping Hyd pump P119 Inter Pump Hydraulics India Pvt

Ltd

PZB

ACCESSORIES

Hydraulic Jacks 1769 International Industries Pvt. Ltd INTERNATIONAL

Sea Water Pump 4288 Stork Pumps India Ltd. STORK

Seawater Pump 2944 Water Supply Specialities WASP


77

24 TIME LIMIT FOR SUBMISSION OF CLAIMS

Immediately upon completion of repairs, the dealer shall complete the relevant

Warranty details and submit the same online.

The completed claim correct in all respects must be submitted within 15 days from the

date of completion of repairs. Any claim accepted beyond 15 days from the date of

completion of repairs is liable for penalty at the following rates:

15 - 30 days from date of completion .. 25%

30 – 60 days from date of completion .. 50%

More than 60 days from date of completion.. 100%

AL shall provide a facility to dealers to view the status of claims online.


78

24. COMPLETION OF WARRANTY CLAIM - MAIN/ANCILLARY

Warranty claims have to be submitted online by Dealers and the fields to be filled in

are listed below:

Sl Field Description Filling Requirement Field

Width

Remarks

1 Dealer Code Mandatory 4 Servicing Dealer Code

2 Fin Year Mandatory 1 Financial Year

3 Claim Type Mandatory 1 Valid claim types are

A,B,C,D,F,O,P,L,M,N or K

4 Claim Sl No Mandatory 4 Serial Number

5 Claim Date Mandatory 11 DD-MMM-YYYY

6 Customer Type Mandatory 2 01-Private; 02-STU; 03-Project;

04-Dealer; 3-PEM

7 SE Code Mandatory for Float

Claims

4 SE code against which the

float part belongs

8 Selling Dealer Code Mandatory 4 Selling dealer code

9 Supplier Code Mandatory for Ancillary

claims

4 Supplier code

10 Chassis Number Mandatory 9 The field is not mandatory for

Engine claims

11 Engine Number Mandatory 9 Field width can be 10 in case

of Industrial / Marine engines

12 Regn Number Not mandatory Max allowed field width is 15

13 Complaint Code Mandatory 4

14 Fault Code Mandatory 2

15 Appl Code Mandatory 1 Valid codes are

A,B,C,D,E,F,G,H,I,J,K,L,M,P,S


79

16 Operating Condition Mandatory 1 Valid codes are 1,2,3,4,5,6,7

17 Load Type Mandatory 1 (P or T) The field is not

mandatory for Engine claims

18 Load Carried Mandatory 2 Tons in case of Goods and

No. of passengers in case of

Pass.

The field is not mandatory for

Engine claims

19 Settle Mode Mandatory 1 Cash or Parts

20 Date Sold Mandatory 11 DD-MMM-YYYY

21 Date Commissioned Mandatory 11 DD-MMM-YYYY

22 Date Failed Mandatory 11 DD-MMM-YYYY

23 Job Card No. Mandatory 15

24 Job Card Date Mandatory 11 DD-MMM-YYYY

25 Job Compl Date Mandatory 11 DD-MMM-YYYY

26 KM / Hrs per day Mandatory 3

27 KMs / Hrs Run Mandatory 6

28 KMs / Hrs Flag Mandatory 1 K or H

29 RECEIVED_FAILED_PART

S_ALONE

Mandatory 1 Y or N

30 Goodwill Flag Mandatory 1 Y or N

31 Goodwill Amount Non Mandatory (To be

used only for Goodwill

Claims where

expenditure is shared)

11 If amount is entered this will

be taken as the Claim payable

/ expenditure amount

32 Total Claimed Value Mandatory 11

33 Total Labour Value

Claimed

Mandatory 11

34 Total Parts Value Claimed Mandatory 11


80

35 Cause of Failure Mandatory 55

36 Investigation Findings Mandatory 55

37 Action Taken Mandatory 55

38 DEFECTIVE_PARTS_SENT

_TO

Not Mandatory for pure

labour

E1 - Ennore, H1 - Hosur 1, H2

- Hosur 2

39 Unit Sl No Mandatory for

Complaint codes 25, 26,

28 35, 42, 45, 47, 48 & 53

40 Complaint_Reported Mandatory 55 Complaint as reported by

Customer

41 From Location Mandatory if KMs one

way is filled

50 From location in case the

vehicle is attended at site

42 To Location Mandatory if KMs one

way is filled

50 To location in case the vehicle

is attended at site

43 KMs one way Not Mandatory 3 Distance one way

44 No. of trips Mandatory if KMs one

way is filled

1 No of trips made to the

location

45 Service Jeep used Mandatory if KMs one

way is filled

1 Y if mobile service jeep is

used, else N

46 Service Tax claimed Mandatory No

47 Presale Warranty Mandatory 1 Y or N

1Dealer Code Mandatory 4

2Fin Year Mandatory 1

3Claim Type Mandatory 1

4Claim Sl No Mandatory 4

5FAILED PART NUMBER Mandatory AL Part Number (Z999999X

in case of where AL does not


81

service failed part numbers.

The last character X can be 1

to 9)

6REPLACED PART

NUMBER

Mandatory AL Part Number (A999999X

in case of where AL does not

service replaced part numbers

or where the part is locally

procured. The last character

X can be 1 to 9)

7QUANTITY Mandatory

8RATE CLAIMED Mandatory

9AL SPARE PART INVNO Mandatory Bill number in case of local

purchase

10AL SPARE PART INVDT Mandatory DD-MMM-YYYY

11Part Description Mandatory for Z99

Failed Part number

1Dealer Code Mandatory 4

2Fin Year Mandatory 1

3Claim Type Mandatory 1

4Claim Sl No Mandatory 4

5REPAIR OPERATION

CODE

Mandatory 6

6LABOUR CLAIMED Mandatory

7REPAIR DESCRIPTION Mandatory for Misc

Codes (TR001A)


82

The claim has to be submitted to AL in Comma Separated Value (.csv) format and the

serial order of the fields given above should be maintained. Any number of claims can

be included in one file.

The Header file should contain 47 fields, Parts file 11 fields and Labour file 7 fields.

Every claim will have a minimum of 2 files. In case of Pure labour claims, there should

be 2 files viz., Header and Labour. In case of claims involving parts replacement, there

should be 3 files Header file, Parts file and Labour file.

The files naming should follow the logic given below

• First character should be ‘W’

• Next four characters should be dealer code

• Sixth character should be ‘H’ for header file, ‘P’ for Parts line and ‘L’ for labour

line

• Next six characters will be control number. This number should be same for all

the three files.

• Name of the file once loaded cannot be used again.

Selling Dealer:

Give the 4-character numeric code of the dealer who sold the vehicle. For direct sale

obtain code from AL Regional office.


83

Servicing Dealer Code:

The 4-character numeric code of the dealer who rendered the warranty attention.

Year Code:

For the year 2008 - 09, fill in ‘8’ as the year code. Use the same logic for subsequent

years.

Claim Type:

Choose the relevant claim type, viz.,

O - Main Claim - AL material (+ Labour)

A - Spare Parts - Ancillary material (+ Labour)

B - Campaign - Ancillary material (+ Labour)

C - Ancillary Claim - Material (+ Labour)

D - Float - Ancillary material (+ Labour)

F - Float - AL material (+ Labour)

N - Campaign - AL Material (+ Labour)

P - Campaign - Dealer Material (+ Labour)

S - Spare Parts (+ Labour)

M - Main Claim – Pure Labour

L - Ancillary Claim – Pure Labour


84

K - Campaign Claim – Pure Labour

Claim Sl. No.

Give 4-digit running claim serial number. Start with ‘0001’ for each financial year and do

not repeat the same number within a financial year.

Claim Date:

The date on which the claim is prepared. For example, 5th July 2005 should be filled as

‘05-Jul-05’.

Chassis Number:

The chassis number as punched on the identification plate.

Engine Number:

The engine number as punched on the chassis identification plate.

Unit Serial Number:

The serial number as punched on the corresponding failed unit.


85

Complaint Code:

The 4-character complaint code relevant to the root cause of failure alone. This is a very

vital information and utmost care has to be exercised in filling the correct complaint

code.

Every failure will have to be attributed to the root cause and all replaced components

have to be covered in one claim. In the event of replacement of AL made as well as

ancillary supplies becoming necessary, all the components have to be included in one

claim and the claim type shall be chosen depending on the component that is assessed to

have been the root cause of the failure.

The code ‘A0’ (General) – the 3rd and 4th characters in the complaint code – may be used

only in the extreme case where a suitable code is not available. .

The code 72A0 may be used only in case of scheduled services carried out under a

maintenance contract. For Breakdown failures, the relevant complaint code has to be

used.

Fault Code:

The 2-character fault code. This again is a vital information and requires utmost care in

completion.

The fault codes ZA to ZL, YA to YL, XA to XL, WA to WL and VA to VL (60 codes) may

be used only to denote the specific schedule service under a maintenance contract. The

fault code ‘EC’ has to be used only for Ecomet models where the wear and tear


86

components are replaced within the purview of the service. For breakdown failures,

relevant fault codes has to be used.

Date of Sale:

Fill the date from the sale record or invoice produced by customer.

Date of Comm:

The date of registration as appearing in the RC Book is the date of commissioning. For

off-highway vehicles, write the date based on the vehicle log maintained by customer.

Regn no:

The Vehicle Registration Number as appearing in the RC Book.

Date of Failure:

The date of failure based on information provided by the customer.

KMs/Hrs per day:

Fill in the figures elicited from customer and ensure that this is a fair indication for the

type of operation.

KMs / HRs flag

Write ‘K’ to denote KMs or ‘H’ to denote Hours


87

KMs/Hrs run:

Fill in the relevant figure and ensure that this is a fair indication for the period the

vehicle has been in operation for the type of operation. If the meter is non-functional,

make a reasonable estimate of the KM/hours run and do not merely mention ‘Meter non-

functional’, etc.

Supplier Make/Code for complaint causing failure:

Write the name of the supplier and the supplier code of the component whose failure is

the root cause of the complaint.

Customer Type:

Fill in the corresponding numeric code by referring to the legend at the bottom of the

claim, viz.,

01 - Private

02 - STU

03 - Project

Application:

Fill in the relevant alpha code from the list below


88

A - Passenger

B - Goods Haulage

C - Tipper

D - Tractor

E - Tanker

F - Container

G - Rig

M - Others

Operating Condition:

Fill in the relevant numeric code from the list below

1 - City

2 - Mofussil

3 - Project

4 - Ghat

7 - Others

Received Failed Parts alone from customer:

‘Y’ if the failed part was brought loose by the customer otherwise ‘N’.

Job Card No.:

The job Card number .


89

Job Card Date:

The Job Card date on which it was opened.

Date of completion of job:

The date on which the vehicle was made ready after warranty attention, i.e., the date on

which the Job Card was closed.

Failed Part Number:

The AL part number of the failed item.

In case an item is not serviced by AL (e.g UT) the part number should be filled as Z 99

999 99.

Replaced Part Number:

The AL part number of the ‘Leypart’ used for replacement.

If a locally purchased part is used for replacement then the part number should be filled

as A 99 999 99. In case of an item not serviced by AL, the part number should be filled as

Z 99 999 99.

Quantity:

The numbers off/set of replaced part. Where a part out of a set is used for replacement,

denote the actual number used.

AL Spare Parts Inv Ref/Dt:

Fill in the AL Invoice number under which the replaced component was procured. If a

locally purchased part is used, fill the local supplier’s invoice number; the invoice

document should be made available during audit by AL.


90

Amount Claimed:

The value of components replaced at the retail price

Cause of Failure:

Write , cause of failure as analysed,

Investigation Findings

Symptoms noticed, analysis carried out and resultant damage

Dealer shall prepare a report on the failure. Failure analysis reports, MICO test reports

(where required) and sketches / photographs should be made available to the ALSE.

Action Taken

How the complaint was resolved.

Complaint Reported

Failure as reported by customer

Repair Operation code:

The relevant operation code from these listed in Section 29 and 30 – Repair Operation

Time Schedule – of this manual.

If the Labour actual claim relates to a job done outside the workshop, the bills of the

service provider have to be made available to AL during audit.

Repair Description

Where code starting with ‘MC’ is used, provide description of the job carried out. Any

other special codes specified by AL the nature of job has to be mentioned.


91

Labour Value:

The product of the Total Time in Manhours and the approved hourly manhour rate.


92

26. PRODUCT COMPLAINT CODE

CODE PRODUCT COMPLAINT

01 CRANKCASE

01A0 GENERAL

01B1 BLOCK CASTING DEFECT-

BLOWHOLE/CRACK BELOW SWJ

AREA

01B2 BLOCK CASTING DEF-

BLOWHOLE/CRAK BETN

SWJ&REAR COVR

01B3 BLOCK CASTING DEF.-BLOWHOLE

ON SWJ OPNG.& BETN. SWJ


BLOWHOLE/CRACK BELOW FIP

MTG.


BLOWHOL/CRAK CONNTG OIL

GLRY&SWJ


BLOWHOLE/CRACK AT TAPPET

BORE


BLOWHOLE/CRACK@TAPPET

COVER AREA

01B8 BLOCK CASTING DEFECT -

BLOCKAGE IN WATER PASSAGE

01B9 BLOCK MACHINING DEFECT

01C3 BLOCK SURFACE CRACK

01D0 CYLINDER PARENT BORE CRACK

01D1 CYLINDER PARENT BORE

DISTORTION

01D2 MAIN PARENT BORE CRACK

01D4 CRACKS OTHER AREAS

01D5 BLOCK CRACK AT WATER JACKET

WELCH PLUG AREA

01D6 BLOCK CRACK AT ENGINE

MOUNTING AREA

01E0 CYLINDER LINER CRACK AT

COLLAR AREA

01E1 CYL. LINER CRACK

CIRCUMFERENTIAL - MIDDLE OF


LINER

01E2 CYLINDER LINER CRACK

VERTICAL

01E3 CYLINDER LINER FLAME

ARRESTER

01E4 CYLINDER LINER OTHER

COMPLAINTS

01F0 CAMSHAFT JOURNALS

01F1 CAMSHAFT LOBE

01F2 CAMSHAFT BUSHES

01F3 CAMSHAFT BUSH PARENT BORE

01F4 CAMSHAFT TIMING GEAR

01F5 CAMSHAFT THRUST

PLATE/WASHER

01F6 CAMSHAFT GEAR MOUNTING SET

SCREW

01F7 CAMSHAFT GEAR MOUNTING KEY

01F8 CAMSHAFT SHIMS

01F9 CAMSHAFT REAR END PLATE/'O'

RING

01G0 IDLER GEAR

01G1 IDLER GEAR BOLT/NUT/SPLIT PIN

01G2 IDLER GEAR SPINDLE

01G3 IDLER GEAR BUSH

01G4 IDLER GEAR THRUST

WASHER/PLATE

01G5 ACCESSORY DRIVE GEAR (POWER

STEERING)

01G6 ACCESSORY DRIVE GEAR BUSH

FRONT

01G7 ACCESSORY DRIVE GEAR BUSH

REAR

01G8 IDLER GEAR SPINDLE MOUNTING

FASTENERS

01H0 PUSH ROD

01H1 TAPPET

01I0 MAIN BEARING

01I1 MAIN BEARING CAP

01I2 MAIN BEARING CAP BOLT

01I3 MAIN BEARING CAP BOLT AREA

IN CRANKCASE


93


01J0 OIL RELIEF VALVE

01K0 TIMING BACK PLATE

01K1 TIMING CASE (STANDARD)/FRONT

COVER

01K2 TIMING CASE OIL SEAL / GASKET

01K3 TIMING CASE OIL SUPPLY NOZZLE

01K4 FIP GEAR

01K5 FIP GEAR BUSH

01K6 FIP GEAR SHIM

01K7 TIMING CASE SUITABLE FOR

POWER STEERING

01K8 FIP FRONT SUPPORT BRG /

SUPPORT BRKT

01K9 TIMING CASE GASKETS

01L0 STUD STRIPPING ON CRANKCASE

01M0 STUD BREAKAGE BLOCK END

01M1 STUD BREAKAGE NUT END

01M2 CYLINDER HEAD BOLTS

01N0 WATER DRAIN PLUG

01P0 SIDE WATER RAIL

01P1 SIDE WATER RAIL DEFLECTOR

01P2 CRANKCASE FRONT COVER

01P3 CRANKCASE REAR COVER

01P4 CRANKCASE WELCH

PLUG/CLOSING BALLS

01P5 CRANKCASE SIDE COVER

01Q1 ENGINE FAILURES DUE TO

FOREIGN MATERIAL

01R0 CRANK CASE GASKETS/SEALS.

01R1 CRANKCASE 'O' RINGS

01R2 CRANKCASE SIDE COVER GASKET

01S0 ENGINE BREATHER CUM OIL

SEPARATOR

01T1 ALTERNATOR MOUNTING

BRACKET

01T2 ALTERNATOR ADJUSTING LINK

02 CYLINDER HEAD

02A0 GENERAL

02B1 CYL HEAD CASTING DEFECT

02B2 CYL HEAD MACHINING DEFECT


02B3 CYL HEAD CORE PLUG/ WELCH

PLUG

02C0 CYL HEAD CRACK AT VALVE

SEAT/INJ.HOLE

02C1 CYL HEAD ANGULAR OIL HOLE

CRACK

02C2 CYL.HEAD SURFACE CRACKS

02C3 CYL.HEAD CRACK OTHER AREAS

02D0 VALVE FAILURE AT STEM

02D1 VALVE FAILURE AT HEAD/FACE

02D2 VALVE FAILURE AT RADIUS

02D3 VALVE OTHER FAILURES

02E0 VALVE SEAT

02E1 VALVE GUIDE

02E2 VALVE COLLAR

02E3 VALVE SPILT CONES

02E4 VALVE SPRINGS

02E5 VALVE CAP

02E6 VALVE STEM SEAL

02E7 VALVE SPRING SEAT

BOTTOM/ABUTMENT WASHER

02F0 ROCKER SHAFT

02F1 ROCKER BRACKET

02F2 ROCKER ARM

02F3 ROCKER BUSH

02F4 BALL END

02G0 VALVE COVER

02G1 CYLINDER HEAD COVER

02G2 OIL FILLER CAP

02G3 CYLINDER HEAD COVER GASKET

02H0 HEAD GASKET BLOWING FROM

CULOT TO RUBBER RINGS

02H1 HEAD GASKET BLOWING

BETWEEN CYLINDERS

02H2 HEAD GASKET BLOWING AT SIDE

ENDS

02H3 HEAD GASKET BLOWING AT

OTHER AREAS

02I0 INJECTOR SLEEVES

02I1 INJECTOR COOLING JET SLEEVE


94


02J0 VALVE LEAK

02K0 INLET MANIFOLD

02K1 INLET MANIFOLD ELBOW

02K2 INLET MANIFOLD MOUNTING

FASTENERS

02K3 EXHAUST MANIFOLD MOUNTING

FASTENERS

02K4 EXHAUST ELBOW/DISTANCE PIECE

02L0 EXHAUST MANIFOLD

02M0 GASKETS/ 'O' RINGS

02M1 WELCH PLUG

03 FLYWHEEL AND HOUSING

03A0 GENERAL

03B0 FLYWHEEL HOUSING

03C0 FLYWHEEL

03C1 FLYWHEEL MOUNTING BOLTS

03C2 FLYWHEEL TIMING MARK

03C3 FLYWHEEL DRIVING PEG

03D0 FLYWHEEL FACE PLATE

03E0 ADAPTOR

03E1 CRANKSHAFT ADAPTOR BOLTS

03F0 FLYWHEEL SPIGOT BEARING

03F1 HSG - FLYWHEEL SPIGOT BRG

03G0 RING GEAR

04 CRANKSHAFT

04A0 GENERAL

04B0 CRANKSHAFT WITH FLANGE (FOR

SPLIT TYPE OIL SEAL)

04B1 CRANKSHAFT -REGULAR 3 PIECE

STANDARD

04B2 UNDERSIZE CRANKSHAFT-

REGULAR

3PIECE(RECONDITIONED)

04C0 CRANKSHAFT GEAR

04C1 CRANKSHAFT THRUST WASHER

04C2 GEAR OIL PUMP DRIVE ON

CRANKSHAFT

04C3 KEY - CRANKSHAFT OIL PUMP

DRIVE GEAR

04D0 DAMPER PULLEY


04D1 VISCOUS DAMPER

04D2 KEY FOR DAMPER/CRANKSHAFT

PULLEY

04D3 MOUNTING BOLTS FOR VISCOUS

DAMPER

04D4 DAMPER/CRANKSHAFT PULLEY

FASTENING BOLT/NUT

04E0 OIL SEAL SPLIT TYPE

04E1 OIL SEAL FULL CIRCLE

04E2 OIL SEAL CARRIER

04E3 SLEEVE FOR OIL SEAL ON

CRANKSHAFT

04F3 OIL PLUG ON CRANK SHAFT

IVECO

05 PISTON AND CONNECTING ROD

05A0 GENERAL

05B4 PISTON

05B5 PISTON COOLING NOZZLES

05C4 RINGS

05D0 GUDGEON PIN

05D1 CIRCLIP

05E0 CONNECTING ROD BOLT

05E1 CONNECTING ROD NUT

05E2 SPLITPIN-CONNECTING ROD NUT

05F0 CON ROD BREAKAGE AT I

SECTION

05F1 CON ROD BREAKAGE THROUGH

RIFLE HOLE

05F2 CON ROD BREAKAGE ACROSS

BOLT HEAD SEATING

05F3 CON ROD OTHER FAILURES

05F4 CON ROD SERRATION

05F5 CONNECTING ROD SMALL END

BREAKAGE

05G0 CONNECTING ROD BEARING

05H0 CONNECTING ROD BUSH

06 WATER PUMP

06A0 GENERAL

06B0 THERMOSTAT HOUSING

06B1 THERMOSTAT HOUSING 'O' RING


95


06C0 THERMOSTAT

06D0 IMPELLER

06E0 INSERT

06F0 WATER PUMP SEAL

06G0 WATER PUMP SHAFT

06H2 WATER PUMP SEALED BEARING

06H3 WATER PUMP TAPERED ROLLER

BEARING

06I0 IMPELLER CASING

06I1 LEAK @ JOINTS-W/P AREA(EXCL.

LEAK FROM W/P ITSELF)

06J0 PULLEY HUB

06J1 PULLEY FAN HUB SPACER

06K0 PULLEY

06L0 FAN

06L1 FAN CLUTCH ASSY - VISCOUS

06M0 FAN BELT

06N0 IDLER PULLEY

06N1 IDLER PULLEY BEARING

06N2 IDLER PULLEY MOUNTING

BRACKET

06N3 IDLER PULLEY MOUNTING

BRACKET FASTENERS

06N4 AUTO BELT TENSIONER

06P1 REMOTE FAN DRIVE BEARING

06P2 RFD FAN BELT-CRANKSHAFT TO

IDLER

06P3 REMOTE FAN IDLER BEARING

06P4 RFD FAN BELT-IDLER TO FAN

07 FUEL PUMP AND INJECTORS -

INLINE VERSION

07A0 GENERAL

07B0 BACK LEAK

07B1 CALIBRATION ERROR /EXCESS

FUEL CONS. /POOR PICK UP

07C0 FUEL PUMP FLYWHEEL

07C1 FUEL PUMP TIMING

07C2 FUEL PUMP TIMER

07C3 FUEL PUMP TIMER BOLTS

07C4 FIP MOUNTING BRACKET


07C5 TIMER OIL SEAL

07C6 SLEEVE FOR TIMER OIL SEAL

07C7 TIMER DRAIN HOSE

07C8 TIMER DRAIN HOSE

ADAPTER/CLIPS

07C9 TIMER HOUSING

07D1 FUEL PIPES - FEED PUMP INLET

07D2 FUEL PIPES - FEED PUMP TO FILTER

07D3 FULE PIPES - FILTER TO FIP

07E0 INJECTOR PIPES

07F0 LEAK OFF PIPES

07F1 FLEXIBLE DIESEL RETURN PIPE

07G0 FIP CAMSHAFT

07H0 BEARING

07I0 INTERMEDIATE BEARING

07J0 PUMP ELEMENT

07J1 DELIVERY VALVE

07J2 DELIVERY VALVE HOLDER

07J3 QUADRANT LOOSE

07J4 PLUNGER SPRING

07J5 ROLLER TAPPET

07K0 CONTROL RACK

07L0 GOVERNOR ASSEMBLY

07L1 SUPPLEMENTARY IDLING

ADJUSTING SCREW

07L2 FIP SEALS

07M0 FEED PUMP - PIN FOLLOWER

07M1 HAND PRIMING PUMP

07M2 FEEDPUMP OIL SEAL/'O' RING

07M3 FEED PUMP - ROLLER FOLLOWER

07N0 INJECTOR OPENING PRESSURE

07N1 INJECTOR DRIBBLING

07N2 INJECTOR BODY

07N3 INJECTOR OTHER COMPLAINTS

07N4 NOZZLE

07N5 NOZZLE CAP NUT

07N6 INJECTOR SEALS/O RINGS

07N7 INJECTOR CLAMP

07N8 INJECTOR MOUNTING STUDS

07N9 INJECTOR WASHER


96


07P0 OFF LEVER CABLE/ARENS

CONTROL CABLE

07P1 ENGINE SHUT OFF SOLENOID

SWITCH

07P2 ENGINE SHUT-OFF CYLINDER

07Q0 FLEXIBLE DRIVE ASSEMBLY

07Q1 RESITEX PLATE – COUPLING

07Q2 FIP BALL JOINTS

07R0 ACCELERATOR LINKAGES

07R1 ACCELERATOR CABLE

07R2 ACCELERATOR KICKDOWN

ARRANGEMENT

07S1 OIL PIPE TO TIMER/PUMP

08 OIL PUMP AND SUMP

08A0 GENERAL

08B0 OIL PUMP HOUSING

08C0 OIL PUMP SHAFT BOTTOM

08C1 OIL PUMP SHAFT TOP

08C2 OIL PUMP GEAR

08C3 OIL PUMP SPIRAL GEAR ON TOP

SHAFT

08C4 OIL PUMP THRUST CAP

08C5 OIL PUMP SPIRAL GEAR ON

CAMSHAFT

08C6 OIL PUMP DRIVE GEAR – HINO

08C7 OIL PUMP SHAFT SQUARE DRIVE

COUPLING -ANDORIA TYPE

08D0 OIL PUMP DELIVERY PIPE

08E0 SUCTION BRANCH

08E1 STRAINER

08F0 1 IN 1 PUMP DRIVE SHAFT

08F1 1 IN 1 PUMP SUCTION PIPE

08F2 1 IN 1 PUMP DELIVERY PIPE

08F3 1 IN 1 PUMP OTHER COMPLAINTS

08G0 SUMP

08G1 SUMP GASKET

08G2 DRAIN PLUG - OIL SUMP

08H0 DIPSTICK

08H1 DIPSTICK GUIDE

09 FILTERS


09A0 GENERAL

09B0 FUEL FILTER ELEMENT 0.5 LITRE

09B1 FUEL FILTER ELEMENT 1.1 LITRE

09B2 FUEL FILTER COVER

09B3 FEED PUMP FILTER / STRAINER

(BANJO TYPE)

09B4 FUEL FILTER BOWL

09B5 OVER FLOW VALVE

09B6 FUEL FILTER MOUNTING BRACKET

09B7 FASTENERS - FUEL FILTER

MOUNTING BRACKET

09B8 FUEL FILTER CUM WATER

SEPERATOR

09B9 MUD STRAINER

09C0 OIL FILTER ELEMENT

09C1 OIL FILTER BOWL

09C2 OIL FILTER HEAD

09C3 OIL FILTER VALVES

09C4 OIL FILTER BOTTOM CONICAL

SPRING

09C5 OIL FILTER BOWL CENTRE

STEM/BOLT

09C6 OIL FILTER BOWL O RING

09C7 OIL FILTER BOTTOM O RING

09D0 AIR CLEANER DRY TYPE:ENGINE

MOUNTED

09D1 AIR CLEANER WET TYPE

09D2 WIRE MESH

09D3 WING SCREW

09D4 OUTER FELT SEAL -ENGINE

MOUNTED AIRCLEANER

09D5 INNER SEAL-FILT.ELEMENT TO

TUBE-ENG MTD AIRCLEANER

09D7 PRE FILTER

09D8 AIR CLEANER MOUNTING

FASTENERS-ENGINE MT

09D9 AIRCLEANER SEAL-TOPCOVR TO

FILT.ELEMNT(TBLR ENTRY)

09E0 AIR INTAKE HOSE - FLEXIBLE

HOSE PVC


97


09E1 AIR INTAKE PIPES - METALLIC

09F0 REMOTE MOUNTED AIR CLEANER-

OIL BATH

09F1 REMOTE MOUNTED AIR CLEANER

MOUNTING BRACKET


ELEMENT


RUBBER SEAL OUTER


RUBBER SEAL INNER

09F5 AIRCLEANER DRY TYPE:REMOTE

MOUNTED-PRIMARY ELEMENT

09F6 AIR CLEANER DRY TYPE:REMOTE

MOUNTED-SAFETY ELEMENT

09F7 VACUUM INDICATOR

09F8 HOSE CONNECTION TO VACUUM

INDICATOR

09G0 STACK PIPE ARRANGEMENT

CARGO

09G1 UPPER SUPPORT - STACK PIPE

09G2 LOWER SUPPORT- STACK PIPE

09G3 BELLOWS - STACK PIPE

09G4 ELBOW TUBE ON FENDER FOR

STACK PIPE

09G5 ELBOW TUBE FITMENT ON

FENDER

09G6 HOSE - ELBOW TUBE TO

AIRCLEANER

09G7 HOSES - AIR CLEANER TO INLET

MANIFOLD

09G8 HOSE CLIPS - AIR INTAKE SYSTEM

09H0 CHARGE AIR COOLER

09H1 CHARGE AIR COOLER BELLOW

HOSE

09H2 CHARGE AIR COOLER STRAIGHT

HOSE

09H3 CHARGE AIR COOLER MOUNTING

AREA

09H4 HEAT SHIELD FOR CONNECTION

PIPE TO INLET MANIFOLD


10 COMPRESSOR

10A0 GENERAL

10A1 CRANKCASE

10C0 CYLINDER HEAD

10C1 CYLINDER HEAD GASKET

10C2 VALVES

10C3 CYLINDER HEAD OTHER FAILURES

10D0 CRANKSHAFT

10D1 COMPRESSOR GEAR

10D2 COMPRESSOR GEAR MTG NUT

10D3 COMPRESSOR GEAR KEY

10D4 COMPRESSOR DRIVING FLANGE -

REAR END

10D5 COMPRESSOR DRIVE PULLEY

10D6 COMPRESSOR FRONT OIL SEAL

10E0 PISTON

10E1 RINGS

10E2 GUDEON PIN/CIRCLIP

10F0 CONNECTING ROD

10F1 CON ROD BEARING

10F2 CON ROD BUSH

10F3 CON ROD BOLT/NUT

10G0 END COVER

10H0 COMPRESSOR OUTLET PIPE

10H1 HOSE CONNECTION

10H2 OIL FEED PIPE

10H3 OIL RETURN PIPE

10H4 DUMMY PLUG IN INLET

MANIFOLD

10I0 WATER INLET LINE

10I1 WATER OUTLET LINE

10J0 OIL COOLER NIPPLE

11 OIL COOLER / HEAT EXCHANGER

11A0 GENERAL

11B0 HEAT EXCHANGER – MARINE

11C0 OIL COOLER END BRAZING JOINT

LEAK

11C1 OIL COOLER LEAK THROUGH O

RINGS

11C2 OIL COOLER TUBES/PLATES


98


11C3 OIL COOLER ZINC ANODES

11C4 OIL COOLER OTHER FAILURES

11D0 OIL COOLER BODY/CASING

11E0 OIL COOLER WATER INLET LINE

11E1 OIL COOLER WATER OUTLET LINE

11F0 AIR BLAST OIL COOLER TUBES

11F1 AIR BLAST OIL COOLER BODY

JOINTS

11F2 FLEXIBLE HOSE FOR AIR BLAST OIL

COOLER

11F3 TRANSFER BLOCK FOR OIL

COOLER

11G0 OIL COOLER 'O' RINGS

11G1 OIL COOLER SEALING GASKET

11H0 OIL FILTER ADAPTOR -SPIN ON

TYPE

12 TURBO CHARGER

12A0 GENERAL

12D0 BEARINGS HOUSING

12D1 TURBINE SHAFT

12D2 TURBINE HOUSING

12D3 COMPRESSOR HOUSING

12D4 COMPRESSOR WHEEL

12D5 BACK PLATE

12D6 PISTON RING

12D7 HEAT SHIELD

12D8 TURBOCHARGER OTHER

FAILURES

12D9 TURBINE WHEEL

12E0 OIL FEED PIPE

12E1 OIL DRAIN PIPE

12E2 AIR INLET PIPE

12E3 TURBOCHARGER INLET HOSES

12E4 BOOST PRESSURE CONTROL

VALVE

12E5 BOOST PRESSURE PIPE

12F0 THRUST BEARING

12F1 OIL DEFLECTOR

12G0 TURBO CHARGER WASTE GATE

MECHANISM


13 ENGINE MOUNTING

13A0 GENERAL

13B0 ENGINE MOUNTING FRONT X

MEMBER (STANDARD)

13B1 C 45 FRONT X MEMBER -

ENG.MTG.HOLE AREA

13B2 C 45 FRONT X MEMBER - RIVET

AREA

13B3 C 45 FRONT X MEMBER - END

GUSSET AREA

13C0 ENGINE MOUNTING PAD FRONT

13D0 METACONE MOUNTING FLANGE

BREAKAGE

13D1 METACONE MOUNTING RUBBER

SEPARATION

13E0 SUPPORT BRACKET FRONT

(LH/RH)

13E1 SUPPORT BRACKET REAR (LH/RH)

13E2 ENGINE MOUNTING BRACKET ON

FLYWHEEL HOUSING(LH/RH)

13F0 ENGINE MOUNTING BRACKET ON

CRANKCASE –IVECO

13F1 INSULATOR

13F2 FASTENERS- ENGINE MTG

BRACKET ON CRANKCASE

13F3 ENGINE MOUNTING FASTENER-

BRACKET TO INSULATOR

13F4 FASTENER- FRAME SIDE MEMBER

TO INSULATOR

14 RADIATOR

14A0 GENERAL

14B0 TOP TANK JOINT LEAK

14B1 BOTTOM TANK JOINT LEAK

14B2 CORE TUBE LEAK

14B3 TOP INLET ELBOW LEAK

14B4 BOTTOM INLET ELBOW LEAK

14B5 MAKE UP LINE LEAK

14B6 DE-AERATION LINE LEAK

14B7 DE-AERATION TANK

14B8 RADIATOR FRAME

14B9 RADIATOR OTHER FAILURES


99


14C0 STAY ROD/BRACKET

14C1 RADIATOR MOUNTING BRACKET

LH & RH (C45)

14D1 RADIATOR TOP HOSE

14D2 RADIATOR BOTTOM HOSE

14D3 HOSES OTHERS

14D4 HOSE CLIPS - COOLING SYSTEM

14E0 WATER PIPE ELBOW

14F0 ONE WAY VALVE - NON RETURN

VALVE

14F1 NON RETURN VALVE BRASS

ADAPTOR

14G0 NO LOSS COOLING SYSTEM

14H0 RADIATOR PRESSURE CAP

14H1 RADIATOR FILLER CAP

14I0 RADIATOR COWL

14I1 RADIATOR COWL FASTENERS

14I2 RUBBER O RING - RADIATOR

COWL

14I3 FAN RING

14I4 JUBILEE CLIP FOR HOLDING THE

RUBBER RING

15 VE / VP FUEL INJECTION

EQUIPMENT

15A0 GENERAL

15B0 BACK LEAK

15B1 CALIBRATION ERROR /EXCESS

FUEL CONS. /POOR PICK UP

15C0 FUEL PUMP TIMING

15D0 FUEL PIPES

15E1 INJECTOR PIPES

15F0 LEAK OFF PIPES

15G0 FIP COUPLING MALE PIECE

15G1 FIP COUPLING FEMALE PIECE

15G2 FIP COUPLING INTERMEDIATE

ADAPTOR

15G3 DRIVE SHAFT SEALING RING

15G4 FIP DRIVE SHAFT

15G5 FIP DRIVE SHAFT CLAW

15G6 FIP DRIVE SHAFT KEY


15G7 TOOTHED GEAR - GOVERNOR

DRIVE GEAR

15G8 CROSS DISC

15G9 FIP DRIVE SHAFT BUSH

15H1 VANE PUMP

15H2 VANE PUMP BACK PLATE

15J1 ROLLER RING – ROLLERS

15J2 ROLLER RING - ROLLERS SEATING

RING

15K0 CAM PLATE

15K1 K SHIM

15L1 KSB UNIT

15L2 TIMER PISTON

15L3 TIMER PISTON O RING

15L4 TIMER ACTUATING PIN

15M0 PLUNGER RETURN SPRING

15M1 DISTRIBUTOR PUMP PLUNGER

15M2 PLUNGER - FOOT WASHER

15M3 DISTRIBUTOR HEAD

15M4 DELIVERY VALVE

15M5 DISTRIBUTOR HEAD 'O' RING

15M6 BLEEDER SCREW - TIMING CHECK

AREA

15M7 CONTROL COLLAR - PLUNGER

ASSY

15N0 STARTING LEVER

15N1 TENSIONING LEVER

15N2 STOP LEVER

15N3 ACCELERATOR LEVER

15N4 ACCELERATOR LEVER BUSH

15N5 ACCELERATOR - O RING

15N6 SHUT OFF PLUNGER

15N7 SHUT OFF SPRING

15P0 OVER FLOW BANJO

15P1 PRESSURE RELIEF VALVE

15Q0 GOVERNOR SPRING

15Q1 FLY WEIGHT ASSY

15Q2 FULCRUM LEVER

15Q3 GOVERNOR SHAFT

15Q4 GOVERNOR DRIVEN GEAR


100


15Q5 SLIDING SLEEVE - GOVERNOR

ASSEMBLY

15V0 SHUT-OFF SOLENOID

15W1 MPC CASING - O RING

15W2 MPC – CASING

15W3 MPC- DIAPHRAGM

15W4 MPC UNIT - OTHER FAILURES

15Y0 PUMP – CASING

VP (BS III) FUEL INJECTION EQUIPMENT

15L5 TIMER SOLENOID

15Q6 FUEL TEMPERATURE SENSOR

15Q7 HDK UNIT

16 CNG COMPLAINTS : OTHER

THAN ENGINE

16A0 GENERAL

16B0 SAFETY VALVE(BURST

DISC/FUSIBLE ALLOY)

16B1 RECEPTACLE

16B2 GAS ON/OFF VALVE (TEL)

16B3 FIRST STAGE REGULATOR

16B4 SECOND STAGE REGULATOR

16B5 LOW PRESSURE SOLENOID

16B6 HIGH PRESSURE PIPES (GAS)

16B7 GAS VALVE IN CYLINDER

16B8 GAS VENT LINE

16B9 1" CNG HOSE TO CARBURRETOR

16C0 CARBURRETOR

16C1 3 WAY SOLENOID

16C2 SPEED GOVERNOR RELAY

16C3 VACUUM SWITCH

16C4 AIR - GAS MIXTURE

16C6 IGNITION COIL

16D0 DISTRIBUTOR ROTOR

16D1 DISTRIBUTOR BEARING

16D2 DISTRIBUTOR DRIVESHAFT

16D3 DISTRIBUTOR MOUNTING

BRACKET

16D4 SPARK PLUG

16D5 HIGH TENSION CABLE(IG. COIL TO

DIST.)


16D6 SPARK PLUG CABLE

16D7 DISTRIBUTOR

16E0 24 V TO 12 V CONVERTOR

16E1 IGNITION COIL

16E2 TRIGGER BOX

16E3 DISTRIBUTOR PICK UP CABLE

16F0 OXYGEN SENSOR

16F1 CATALYTIC CONVERTOR

16F2 FUEL CONTROL VALVE

16F3 COMMANDER

16F4 RELAY- COMMANDER

16F5 LAMDA CONTROL SYSTEM (LCS)

16F6 LCS PROGRAMME NOT HOLDING

16F7 STEPPER MOTOR

16G0 GAS CYLINDER

16G1 GAS PRESSURE GAUGE

(MANOMETER)

16G2 POTENTIOMETER(SENSOR UNIT

FOR GAS PR.GG)

16G3 GAS LEVEL LED INDICATOR

16G4 CYLINDER STORAGE VALVE

16H0 IGNITION WIRING HARNESS

16K0 3 STAGE REGULATOR

16K1 IDLING SOLENOID (3 STAGE

REGULATOR)

16K2 HP SOLENOID (3 STAGE

REGULATOR)

16K3 SENSITIVITY SCREW ADJUSTMENT

(3 STAGE REGULATOR)

16L0 3/2 VALVE

16L1 PE SWITCH

16L2 PLASTIC TUBE (IGNITION KILL)

16L3 RELAY IGNITION KILL SYSTEM

17 ELECTRONIC DIESEL CONTROL

17A0 GENERAL

17A1 DC - DC CONVERTER

17B1 ELECTRONIC CONTROL UNIT

(ECU)

17B2 ENGINE SPEED SENSOR

17B3 COOLANT TEMPERATURE SENSOR


101


17B4 BOOST PRESSURE SENSOR

17B5 INSTRUMENTED INJECTOR

17B6 ACCELERATOR PEDAL SENSOR

17B7 VECHICLE SPEED SENSOR

17B8 BRAKE SWITCH

17B9 CLUTCH SWITCH

17D1 HOLD ON RELAY (12 V)

17D2 MAIN RELAY (24 V)

17D3 IGNITION RELAY (24 V)

17D4 DIODE

17E1 ELECTRICAL SHORT CIRCUIT - 5A

CIRCUIT


CIRCUIT


CIRCUIT

17E4 ELECTRICAL SHORT CIRCUIT -

BATTERY CABLE CIRCUIT

17E5 EDC WIRING HARNESS

17F1 FIP SOLENOID (ELAB)

17F2 TIMER SOLENOID

17F3 FIP ACTUATOR

17G1 IDLING SPEED ADJUSTMENT

17G2 STARTING QUANTITY

ADJUSTMENT

17G3 LIMITING QUANTITY

ADJUSTMENT

17G4 VEHICLE SPEED ADJUSTMENT

21 AXIAL CLUTCH, CLUTCH DISC &

CLUTCH ACTUATION

MECHANISM

AXIAL CLUTCH

21A0 GENERAL

21D0 BACK PLATE/ PRESSURE PLATE

21E0 DRIVING PLATE ( PART OF COVER

ASSEMBLY)

21F0 CLUTCH SPRINGS

21G0 LEVER

21G1 ECCENTRIC PIN

21G2 BRACKET


21G3 BUSH

21G4 PRESSURE PAD

21G5 CLUTCH FINGER

SETTING/LUBRICATION

21G6 LEVER RETAINING SPRING

21H0 WITHDRAWAL PLATE

CLUTCH DISC

21B0 LINER

21B1 LINER / CERAMIC BUTTON RIVETS

21C1 CUSHION SPRINGS

21C2 HUB RIVETS

21C3 CLUTCH CENTRE HUB

21C4 RETAINER / CARRIER PLATE

21C5 CERAMIC BUTTONS

CLUTCH ACTUATION

MECHANISM

21I0 WITHDRAWAL BEARING

21I1 WITHDRAWAL BEARING HOUSING

21I2 LUB PIPE - WITHDRAWAL

BEARING HOUSING

21J0 WITHDRAWAL SLEEVE

21J1 RETAINER SPRING - WITHDRAWAL

SLEEVE

21K0 CLUTCH ROCKING SHAFT

21K1 CLUTCH OPERATING LEVER ON

GEAR BOX

21K2 CLUTCH OPERATING PEDAL

21K3 CLUTCH PLAY ADJUSTING ROD

21L0 SLAVE CYLINDER

21L1 PUSH ROD - SLAVE CYLINDER

21M0 MASTER CYLINDER

21M1 RESERVOIR

21M2 RESERVOIR CAP

21N1 HYDRAULIC LINE – FLEXIBLE

21N2 HYDRAULIC LINE- METALLIC

21P0 FLUID FLYWHEEL

21Q0 AIR SYSTEM -CLUTCH ACTUATION

22 DIAPHRAGM CLUTCH

22A0 GENERAL

22C0 DIAPHRAGM TIP WEAR


102


22C1 DIAPHRAGM TIP BREAKAGE

22C2 DIAPHRAGM TIP RUN OUT

22C3 DIAPHRAGM SETTING HEIGHT

22D1 COVER HOUSING

22E0 PRESSURE PLATE

22F0 CONNECTING RIVETS

22F1 CONNECTING RIVET - PRESSURE

PLATE

22F2 CONNECTING RIVET - COVER

ASSEMBLY

22G0 DRIVE STRAP KIT

22H0 RELEASE BEARING

22I0 FULCRUM RING DIGGING

26 ALGB 13 GEARBOX

26A0 GENERAL

26B0 GEAR CASING

26C0 MAIN SHAFT

26C1 COUNTER SHAFT

26C2 REVERSE SHAFT

26C3 PINION SHAFT

26C4 MAINSHAFT FIXED ELEMENTS

PLAY

26D0 FIRST SPEED GEARS

26D1 SECOND SPEED GEARS

26D2 THIRD SPEED GEARS

26D3 FOURTH SPEED GEARS

26D4 REVERSE GEARS

26D5 CONSTANT MESH GEAR

26E0 NEEDLE ROLLER BEARING FIRST

SPEED

26E1 SLEEVE FOR FIRST SPEED GEAR

26E2 SECOND SPEED BUSH

26E3 THIRD SPEED BUSH

26E4 FOURTH SPEED BUSH

26E5 NEEDLE ROLLER BEARING

REVERSE GEAR

26E6 SLEEVE FOR REVERSE GEAR

26F0 SPIGOT BEARING

26F1 PINION SHAFT BEARING

26F2 MAIN SHAFT REAR BEARING


26F3 COUNTER SHAFT FRONT BEARING

26F4 COUNTER SHAFT REAR BEARING

26F5 PINION SHAFT BALL BEARING

26G0 SLIDING/FIXED DOG CLUTCH

26H0 MAINSHAFT THRUST WASHER

26H1 COUNTERSHAFT THRUST WASHER

26I0 PINION SHAFT BRACKET

26I1 PINION SHAFT BEARING CIRCLIP

26J0 OIL SEAL

26K0 MAINSHAFT REAR NUT

26K1 COUNTERSHAFT SPECIAL

NUT/SPLIT PIN

26K2 IDLER SPINDLE LOCK PLATE

26K3 COUNTERSHAFT REAR BEARING

LOCK PLATE/BOLT

26L0 SPEED CHANGE CASING

26L1 TOP COVER

26M0 SPEED CHANGE SPINDLE 1ST AND

REVERSE

26M1 SPEED CHANGE SPINDLE 2ND

AND 3RD SPEED

26M2 SPEED CHANGE SPINDLE 4TH AND

5TH SPEED

26N0 SPEED CHANGE FORK 1ST AND

REVERSE

26N1 SPEED CHANE FORK 2ND AND 3RD

SPEED

26N2 SPEED CHANGE FORK 4TH AND

5TH SPEED

26N3 PINCH BOLT FOR FORKS

26N4 INTERLOCKING PIN/BALL/SPRING

26P0 SPEED CHANGE LEVER HOUSING

26P1 SPEED CHANGE LEVER BOTTOM

HALF

26P2 GEAR LEVER TOP

26P3 SPEED CHANGE LEVER OTHER

PARTS

26Q0 SPEEDO DRIVE UNIT

26Q1 SPEEDO DRIVE GEAR

26Q2 REVERSE WARNING SWITCH


103


26R0 OVER SPEED GEAR DISTANCE

PIECE

26R1 DISTANCE PIECE IN LIEU OF PTO

GEAR

26R2 PRESENCE OF FOREIGN MATERIAL

26S0 CLUTCH HOUSING

26S1 CLUTCH HOUSING STUD

28 ZF S5-36 AND S6-36 GEARBOX /

OVER DRIVE GEARBOX

28A0 GENERAL

28B0 GEAR CASING – MAIN

28B1 GEAR CASE – FRONT

28C1 COUNTER SHAFT

28C2 REVERSE SPINDLE

28C3 PINION SHAFT

28C4 MAIN SHAFT FAILURE AT OUTPUT

FLANGE END

28C5 M/S CIRCLIP GROOVE @ 4&5TH

GEAR(S6)/3&4TH GEAR(S5)

28C6 MAIN SHAFT OTHER FAILURES

28D0 1ST SPEED GEARS

28D1 2ND SPEED GEARS

28D2 3RD SPEED GEARS

28D3 4TH SPEED GEARS


28D5 REVERSE GEARS

28D6 CONSTANT MESH GEAR

28D7 OVER DRIVE GEAR

28E0 NEEDLE ROLLER BEARING 1ST

SPEED GEARS

28E1 NEEDLE ROLLER BEARING 2ND

SPEED GEARS

28E2 NEEDLE ROLLER BEARING 3RD

SPEED GEARS

28E3 NEEDLE ROLLER BEARING 4TH

SPEED GEARS

28E4 NEEDLE ROLLER BEARING 5TH

SPEED GEARS

28E5 NEEDLE ROLLER BEARING

REVERSE GEAR


28E6 SLEEVE FOR NEEDLE ROLLER

BRG.3RD GEAR

28E7 SLEEVE FOR NEEDLE ROLLER

BRG.REVERS GEAR

28F0 SPIGOT BEARING – MAINSHAFT

28F1 PINIONSHAFT BEARING

28F2 MAINSHAFT REAR BEARING

28F3 COUNTER SHAFT FRONT BEARING

28F4 COUNTER SHAFT REAR BEARING

28F5 SPIGOT BEARING SLEEVE

28G1 SLIDING DOG CLUTCH

28G4 LOCKING RING

28G5 BALL PIN

28G6 SPRING

28G7 PLUNGER/PRESSURE PIECE

28H0 PINIONSHAFT COVER

28H1 PINIONSHAFT BRG SNAP RING

28I1 GB REAR END OIL SEAL LEAK

28I2 GB FRONT END OIL SEAL LEAK

28J0 MAIN SHAFT REAR NUT

28J1 REVERSE SPINDLE LOCK WASHER

28K0 FORK 1ST AND REVERSE GEARS

28K1 FORK 2ND AND 3RD GEARS

28K2 FORK 4TH AND 5TH GEARS

28K3 FORK REVERSE GEAR (S636)

28K4 FORK 1ST AND 2ND GEARS (S636)

28K5 FORK 3RD AND 4TH GEARS (S636)

28K6 FORK 5TH AND 6TH GEARS (S636)

28K7 SELECTOR PAD

28K8 PIVOT SCREW

28K9 FORK - OVERDRIVE GEAR

28L0 SELECTOR PLATE 1ST AND

REVERSE

28L1 SELECTOR PLATE 2ND AND 3RD

28L2 SELECTOR PLATE 4TH AND 5TH

28L3 SELECTOR PLATE REVERSE

GEAR(S636)

28L4 SELECTOR PLATE 1ST AND

2ND(S636)

28L5 SELECTOR PLATE 3RD AND 4TH


104


(S636)


(S636)

28L7 SELECTOR PLATE FOR OVERDRIVE

GEAR

28M0 REVERSE SELECTOR SHAFT

28N0 SELECTOR HOUSING

28N1 NEEDLE ROLLER BEARING

SELECTOR HOUSING

28N2 OUTER LEVER

28N3 SELECTOR LEVER

28N5 SELECTOR SHAFT

28N6 ROLLER PINS

28N7 SELECTOR OTHER PARTS

28N8 DETEND PLUNGER @ GB CASING

FOR REVERSE GEAR

28N9 DETENT PUNGER@ GB CASING FOR

REVERSE GEARS


28Q2 SPEEDO WORM GEAR

28Q3 SPEEDO PINION GEAR

28Q4 SPEEDO PINION SHAFT

28R0 FILLER ELBOW

28R1 BREATHER

28S0 CLUTCH HOUSING


28T0 SYNCHRO RING 1&2 (S6) 1(S5)

28T1 SYNCHRO RING 3&4(S6)2&3(S5)


28T3 SYNCHRO CONE 1&2(S6)1&R(S5)

28T4 SYNCHRO CONE 3&4(S6)2&3(S5)


28T6 SYNCHRO HUB 1&2(S6)1&R(S5)

28T7 SYNCHRO HUB 3&4(S6)2&3(S5)

28T8 SYNCHRO HUB 5&6(S6)4&5(S5

REFER TO 36 CODE SERIES FOR

REMOTE GEAR SHIFT PARTS.

FOR CARGO REMOTE SHIFTING

MECHANISM REFER 66 SERIES.

29 ALGB4 GEAR BOX



(S636)

28L7 SELECTOR PLATE FOR OVERDRIVE

GEAR

28M0 REVERSE SELECTOR SHAFT

28N0 SELECTOR HOUSING

28N1 NEEDLE ROLLER BEARING

SELECTOR HOUSING

28N2 OUTER LEVER

28N3 SELECTOR LEVER

28N5 SELECTOR SHAFT

28N6 ROLLER PINS

28N7 SELECTOR OTHER PARTS

28N8 DETEND PLUNGER @ GB CASING

FOR REVERSE GEAR

28N9 DETENT PUNGER@ GB CASING FOR

REVERSE GEARS


28Q2 SPEEDO WORM GEAR

28Q3 SPEEDO PINION GEAR

28Q4 SPEEDO PINION SHAFT

28R0 FILLER ELBOW

28R1 BREATHER

28S0 CLUTCH HOUSING


28T0 SYNCHRO RING 1&2 (S6) 1(S5)



28T3 SYNCHRO CONE 1&2(S6)1&R(S5)



28T6 SYNCHRO HUB 1&2(S6)1&R(S5)

28T7 SYNCHRO HUB 3&4(S6)2&3(S5)

28T8 SYNCHRO HUB 5&6(S6)4&5(S5

REFER TO 36 CODE SERIES FOR

REMOTE GEAR SHIFT PARTS.



29 ALGB4 GEAR BOX


105


29A0 GENERAL

29B0 GEAR CASING

29C0 MAIN SHAFT

29C1 COUNTER SHAFT

29C2 REVERSE SHAFT

29C3 PINION SHAFT

29D0 1ST SPEED GEARS

29D1 2ND SPEED GEARS

29D2 3RD SPEED GEARS


29D4 REVERSE GEARS

29D5 CONSTANT MESH GEARS

29D6 IDLER GEAR ON REVERSE SHAFT

29E0 1ST SPEED THRUST SLEEVE

29E1 2ND SPEED BEARING SLEEVE

29E2 3RD SPEED BEARING SLEEVE

29E3 4TH SPEED BEARING SLEEVE

29E4 REVERSE GEAR BEARING SLEEVE

29F0 PINIONSHAFT BALL BEARING

29F1 PINIONSHAFT ROLLER BEARING

29F2 MAINSHAFT BEARING

29F3 COUNTERSHAFT BEARING

29G0 SLIDING/FIXED DOG CLUTCH

29H0 MAINSHAFT THRUST WASHER

29H1 COUNTERSHAFT THRUST WASHER

29I0 PINIONSHAFT HOUSING

29I1 PINIONSHAFT CIRCLIP

29I2 CLUTCH THROW OUT BEARING

29I3 CLUTCH THROW OUT SEAL

29J0 OIL SEAL

29K0 MAIN SHAFT REAR NUT

29K1 COUNTERSHAFT SPECIAL SET

SCREW

29L0 SPEED CHANGE CASING

29M0 SPEED CHANGE SPINDLE 1ST AND

REVERSE

29M1 SPEED CHANGE SPINDLE 2ND

AND 3RD GEARS

29M2 SPEED CHANGE SPINDLE 4TH AND

5TH GEARS


29M3 SPEED CHANGE SPINDLE

CONSTANT MESH GEARS

29N0 SPEED CHANGE FORK 1ST AND

REVERSE

29N1 SPEED CHANGE FORK 2ND AND

3RD SPEED

29N2 SPEED CHANGE FORK 4TH AND

5TH SPEED

29N3 SPEED CHANGE FORK CONSTANT

MESH GEARS

29N4 SELECTOR ARM SHAFT

29N5 PINCH BOLT

29Q0 ZF LINKAGES IN LIEU OF CSO

29R0 SPEEDO METER PINION

29R1 INSTRUMENT DRIVE HOUSING

29R2 INSTRUMENT DRIVING SPINDLE

BRACKET

31 ECOMET 6HP600 GEARBOX

31A0 GENERAL

31B0 CLUTCH DISC

31C0 HYDRAULIC VALVE BODY

31D0 SOLENOID

31E0 INDUCTIVE TRANSMITTER

31F0 RELAY

31G0 ELECTRONIC CONTROL UNIT

31H0 RANGE SELECTOR

31I0 ZF CABLE

31J0 HOSUR WIRING

31L0 PTO

31M0 OIL LEAK

31N0 ACCELERATOR INTERLOCK

31P0 OIL TEMPERATURE GAUGE

31Q1 LOAD SENSOR

32 ALLISON HT 750 DRG GEAR BOX /

MT 643

32A0 GENERAL

32B0 MODULATOR

32D0 LOCKUP CLUTCH

32E0 TORQUE CONVERTER

32E1 TORQUE CONVERTER OIL SEAL


106


34 AUXILIARY GEAR BOX

34A0 GENERAL

34B0 GEAR CASING

34C0 GEARS

34D0 SHAFTS

34E0 BEARINGS

34F0 MOUNTING

34G0 OIL SEALS

34H0 OTHER COMPONENTS

35 POWER TAKE OFF

SIDE MOUNTED - CONSTANT

MESH GEAR BOX

35A0 GENERAL

35B0 OPERATING LEVER INNER AL PTO

35B1 OPERATING LEVER OUTER AL PTO

35B2 OPERATING LINKAGES (CABIN)

35C0 HOUSING AL PTO

35D0 GEARS AL PTO

35D1 SLIDING DOG

35D2 FORKS

35D3 SPINDLE

35D4 BUSHES

35D5 OTHER PARTS

35E0 CLUTCH DISC

35F0 SWITCH

35G0 SOLENOID VALVE

35H0 BEARINGS

35I0 OIL SEALS/SEAL RINGS

SIDE MOUNTED - ZF PTO

35K0 SHIFT CYLINDER BODY

35K1 SPRING SHIFT CYLINDER

35K2 SELECTOR SHAFT

35K3 SELECTOR FORK

35K4 PISTON SHIFT CYLINDER

35K5 O' RING

35K6 SHIFT CYLINDER COVER

35K7 INTERMEDIATE GEAR

35K8 INTERMEDIATE GEAR NEEDLE

ROLLER BEARING

35K9 INTERMEDIATE SHAFT


35L0 TAPER ROLLER BEARINGS

35L1 OUTPUT SHAFT

35L2 OUTPUT GEAR

35L3 OUTPUT SHAFT NUT

35L4 DRIVE GEAR KEY

35L5 BRACKET FOR INPUT SHAFT

35L6 INPUT SHAFT GEAR

35L7 DISTANCE PIECE - PTO TO GEAR

CASING

REAR MOUNTED PTO - ZF

35M0 NRB FOR INPUT SHAFT

35M1 PTO HOUSING

35M2 ACTUATOR SHAFT

35M3 WEAR PAD

35M4 COLLARED BUSH

35M5 ACTUATOR LEVER

35M6 GEARS

35M7 SHAFTS

35M8 BEARINGS

35M9 CIRCLIP

PTO ACTUATION

35N0 CONTROL VALVE

35N1 FLEXIBLE PIPELINES

35N2 METALLIC PIPELINES

35N3 ACTUATING CYLINDER FOR REAR

MOUNTED PTO

35N4 EXTERNAL MECHANICAL

LINKAGE FOR ALGB13

36 GEAR BOX REMOTE SHIFTINGS



36A0 GENERAL

36B0 SPEED CHANGE LEVER BOTTOM

HALF

36B1 SPEED CHANGE LEVER BRACKET

AT FLYWHEEL HOUSING


AT FRAME


AT EXHAUST MANIFOLD


107


36C0 CONTROL TUBE

36D0 OPERATING SHAFT

36E0 BALL JOINT REACTION ROD

36E1 BALL JOINT GEAR SHIFT LEVER

36F0 REACTION ROD

36G0 UNIVERSAL JOINT ASSEMBLY

36H0 KNUCKLE

36I0 CONNECTION FLANGE

36J0 BEARING HOUSING

36K0 HOUSING FOR SPEED CHANGE

LEVER

36L0 CONNECTION PIECE

36M0 GEAR LEVER REMOTE TYPE

36N0 SPHERICAL BEARING

36P0 SHACKLE

36Q1 GEAR SHIFT LEVER GAITER

41 PROPELLER SHAFT

41A0 GENERAL

41B0 PROPELLER SHAFT TUBE FRONT

41B1 PROPELLER SHAFT TUBE MIDDLE

41B2 PROPELLERSHAFT TUBE REAR

41C0 YOKE

41D0 STUB SHAFT

41E0 UNIVERSAL JOINT CROSS

41E1 UNIVERSAL JOINT STRAP- SIL

VERSION

41E2 UNIVERSAL JOINT STRAP BOLTS-

SIL VERSION

41F0 CENTRE JOINT BEARING

ORDINARY

41F1 CENTRE JOINT BEARING RUBBER

CUSHION TYPE

41F2 CENTRE BEARING MOUNTING

BRKT/BOLTS - PUNCHED FRAME

41F3 MUDFLINGER - RUBBER CUSHION

TYPE BEARING

41F4 CENTRE BEARING HOUSING

41G0 COMPANION FLANGE

41G1 FASTENERS - PROPELLERSHAFT

FLANGE


41G2 GREASE NIPPLE

41H0 PROPELLER SHAFT INTER AXLE

41I0 PROPELLER SHAFT PTO

41J0 PROPELLER SHAFT 4 X 4 GEAR BOX

TO AGB

41J1 PROPELLER SHAFT AGB TO REAR

AXLE

41J2 PROPELLER SHAFT AGB TO FRONT

AXLE

41K0 LAY RUB COUPLING

42 DIFFERENTIAL GROUP

42A0 GENERAL

42B0 AXLE TUBE LH/RH

42B1 AXLE CASING/TUBE END

THREADS/CHECK NUT

42B2 AXLE CASING DOME WELDING

CRACK

42B3 AXLE CASING SEAM WELDING

CRACK

42B4 AXLE CASING BRAKE CHAMBER

MOUNTING BRACKET CRACK

42B5 AXLE CASING SPRING SEAT

WELDING

42B6 AXLE CASING OTHER FAILURES

42B7 AXLE CASING SPINDLE

42B8 AXLE CASING BRAKE CARRIER

FLANGE

42B9 AXLE CASING INTEGRAL BOTTOM

CLAMPS

42C0 AXLE SHAFT SPLINES CHIPPING

42C1 AXLE SHAFT BREAKAGE AT

SPLINE END

42C2 AXLE SHAFT BREAKAGE AT

FLANGE END

42C3 AXLE SHAFT BREAKAGE AT STEM

AREA

42C4 SPRING DOWEL AXLE SHAFT

42D0 DIFF CARRIER (NOSE BRG.AREA)

42D1 DIFF CARRIER (SIDE BRG.AREA)

42D2 DIFFERENTIAL BEARING

CAP/BOLT


108


42D3 DIFFERENTIAL CARRIER OTHER

FAILURES

42D4 DIFFERENTIAL CARRIER JOINT

LEAKAGE

42E0 CROWN WHEEL PINION 43/7




42E4 CROWN WHEEL PINION 37/6 (R149)

42E5 CROWN WHEEL PINION 37/7 (C100)

42E7 CWP 6.83 Q109/RS 145

42E8 CWP 6.17 Q109/ RS 145/DANA

42E9 CWP 5.83 Q109 / RS145

42F3 CROWN WHEEL PINION 38/15

42F4 CROWN WHEEL PINION 38/17

42F5 CROWN WHEEL PINION 4.56 : 1



42F8 CWP 6.83 R149

42F9 CWP R158

42G0 CWP 6.5 : 1 DANA

42G1 CWP 5.57 : 1 DANA

42G2 CWP SQR109 / DANA DSHO44 FIRST

AXLE

42G3 CWP SQR109 / DANA DSHO44

SECOND AXLE

42H0 PINION TAPER ROLLER BEARING

42I0 CROWN WHEEL TAPER ROLLER

BRG.

42J0 PINION NOSE BRG/SPIGOT BRG

42K0 DIFFERENTIAL CAGE LH/RH

42K1 DIFFERENTIAL CAGE BOLTS

42K2 CROWN WHEEL TO CAGE BOLT

42K3 BEVEL WHEEL AND PINION

42K4 TRUNNION

42K5 THRUST WASHER

42K6 ADJUSTING NUT WORKING LOOSE

42K7 LOCKING PLATE

42K8 THRUST BUTTON – CROWN

42K9 RING SCREW LOCKING DOWEL


42M0 PINION OIL SEAL

42M1 COMPANION FLANGE

42M2 COMPANION FLANGE NUT

42N0 OUTPUT SHAFT

42N1 OUTPUT SHAFT BEARING

42N2 OUTPUT SNAP RING

42N3 OUTPUT SHAFT SEAL

42P0 INPUT SHAFT

42P1 INPUT SHAFT BEARING

42P2 INPUT SHAFT SEAL

42Q0 THIRD DIFFERENTIAL UNIT

42Q1 THIRD DIFFERENTIAL LOCK

42Q2 MAIN DIFFERENTIAL LOCK

42Q3 DIFFERENTIAL LOCK ACTUATING

CYLINDER

42R0 TWO SPEED AXLE

42S0 RETRACTABLE AXLE

42U0 DUMMY AXLE CASING 6 X 2

VERSION

45 REAR AXLE HUB GROUP

45A0 GENERAL

45B0 REAR HUB

45B1 REAR HUB CHECK NUT

45C0 DRIVING FLANGE

45D0 BRAKE DRUM CIRCUMFERENTIAL

CRACK

45D2 BRAKE DRUM CRACK ACROSS THE

WIDTH

45D3 BRAKE DRUM - OTHER FAILURES

45E0 REAR WHEEL OUTER BEARING

45F0 REAR WHEEL INNER BEARING

45G0 DISTANCE PIECE

45H0 HUB OIL SEALS

45I0 REAR WHEEL STUDS

45I1 WHEEL NUT - STUD VERSION

45I2 LOCKING PEG SHEARING

45J0 REAR WHEEL BOLTS

45J1 WHEEL CONES DIGGING ON

BRAKE DRUM

45J5 WHEEL NUT - BOLT VERSION


109


45K0 BRAKE SHOE

45L0 BRAKE LINING

45M0 PULL OFF SPRING

45M1 BRAKE SHOE RETAINING SPRING

45M2 WEARING PAD

45N0 BRAKE CAM SHAFT

45N1 CAMSHAFT HOUSING/BRACKET

45N2 NEEDLE ROLLER BEARING/BUSH

45N3 ABUTMENT BLOCK

45N4 ABUTMENT BLOCK RETAINING

PLATE/BOLTS

45N5 CAMSHAFT WASHER

45N6 CAMSHAFT CIRCLIP

45N7 CAM END ROLLER

45N8 ANCHOR END ROLLER

45N9 SHOE ROLLER RETAINER CLIP

45Q0 COVER TUBE

45R0 DUST COVER

45S0 TORQUE PLATE/BRAKE CARRIER

ASSEMBLY

45S1 BRAKE CARRIER MOUNTING

BOLTS

45S3 BRAKE EXPANDER ASSEMBLY

45S4 ANTI ROTATION CLIP

45S5 RUBBER BOOT FOR EXPANDER

ASSEMBLY

45U0 ANCHOR PIN

45U1 ANCHOR PIN BUSH

45U2 GUIDED ADJUSTER BRAKE -

UNIQUE PARTS

45V0 WHEEL CYLINDER

45V1 MASTER CYLINDER

45V2 RESERVOIR

45V3 HYDRAULIC PIPES/HOSES

45V4 BRAKE CHAMBER - MASTER

CYLINDER ACTUATION

45W0 HAND BRAKE CABLE

45W1 BRACKET FOR HB CABLE

45W2 HAND BRAKE BOOT

47 FRONT AXLE


47A0 GENERAL

47B0 I BEAM CRACK BETN.SPG.PAD @

TOP SURFACE

47B1 I BEAM CRACK BETN.SPG.PADS @

BOT.SURFACE

47B2 I BEAM CRACK BETN.SPRING PAD

AND KP BOSS

47B3 I-BEAM CRACK AT I BOLT

MOUNTING HOLE

47B4 I-BEAM CRACK AT KING PIN BOSS

AREA

47B5 I-BEAM OTHER FAILURES

(INCLUDING BEND AND TWIST)

47C0 AXLE ARM

47D0 KING PIN

47D1 KING PIN BUSHES

47D2 KING PIN SEALS

47D4 KING PIN THRUST BEARING

47E0 FRONT HUB

47F0 BRAKE DRUM -

CIRCUMFERENTIAL CRACK

47F2 BRAKE DRUM CRACK ACROSS THE

WIDTH

47F3 BRAKE DRUM - OTHER FAILURES

47G0 FRONT WHEEL OUTER BEARING

47H0 FRONT WHEEL INNER BEARING

47I0 DISTANCE PIECE

47I1 CASTLE NUT/SPLIT PIN

47J0 HUB SEALS

47K0 FRONT WHEEL STUDS

47K1 WHEEL NUT - STUD VERSION

47K2 LOCKING PEG SHEARING

47L0 FRONT WHEEL BOLTS

47L1 WHEEL NUT - BOLT VERSION

47M0 FRONT BRAKE SHOE

47N0 BRAKE LINING

47P0 PULL OFF SPRING

47P1 BRAKE SHOE RETAINING SPRING

47P2 WEARING PAD

47Q0 BRAKE CAMSHAFT


110


47Q1 CAMSHAFT HOUSING/BRACKET

47Q2 NEEDLE ROLLER BEARING/BUSH

47Q3 ABUTMENT BLOCK

47Q4 ABUTMENT BLOCK RETAINING

PLATE/BOLTS

47Q5 CAMSHAFT WASHER

47Q6 CAMSHAFT CIRCLIP

47Q7 CAM END ROLLER

47Q8 ANCHOR END ROLLER

47Q9 SHOE ROLLER RETAINING CLIP

47S0 COVER TUBE

47T0 DUST COVER

47U0 TORQUE PLATE/BRAKE CARRIER

ASSEMBLY

47U1 BRAKE CARRIER MOUNTING

BOLTS

47U3 BRAKE EXPANDER ASSEMBLY

47U4 ANTI ROTATION CLIP

47U5 BRAKE EXPANDER RUBBER BOOT

47V0 WHEEL CYLINDER

47V1 HYDRAULIC PIPE/HOSES

47W0 ANCHOR PIN

47W1 ANCHOR PIN BUSH

48 FRONT DRIVING AXLE (4X4) WITH

MAGIRUS ENDS

48A0 GENERAL

48E0 FRONT AXLE DIFFERENTIAL UNIT

48F0 FRONT AXLE SHAFT OUTER

48F1 FRONT AXLESHAFT NEEDLE BRG

48F2 OILSEAL -FRONT AXLESHAFT

48H0 4X4 FRONT HUB

48H1 HUB OIL SEAL

48I0 FRONT AXLE CASING

48I1 STUB AXLE

48I2 DRIVING FLANGE

48L1 DRIVING SHAFT

48L2 YOKE ASSEMBLY

48M1 STEERING ARM

48M2 TRACK ARM

48M3 KINGPIN NEEDLE ROLLER BRG


48M4 OILSEAL –KINGPIN

48N0 FAILURES DUE FOREIGN MATL

48P0 BRAKE SPIDER

48P1 BRAKE SHOE

48P2 BRAKE SHOE RETAINING SPRING

48P3 BRAKE GUIDE SCREW

48P4 BRAKE SHOE RETAINING CLIP

48P5 BRAKE DRUM

50 STEERING

50A0 GENERAL

50D0 RANE STEERING ROCKER SHAFT

50D1 RANE INNER COLUMN /RIGID STG

50D2 RANE INNER COLUMN UJ

APPLICATION

50D3 RANE STEERING BOX HOUSING

50D4 RANE STG TAPER ROLLER BRG

50D5 RANE OUTER TUBE

50D6 RANE DROP ARM

50D7 RANE STEERING COLUMN BUSHES

50D8 RANE MAIN NUT ASSEMBLY

50D9 RANE STEERING OTHER PARTS

50E0 STEERING BEVEL BOX

50G0 POWER STG PUMP SHAFT/GEAR

(VANE TYPE)

50G1 POWER STEERING PUMP (VANE)

50G2 POWER STEERING PUMP KEY

50G3 POWER STG PUMP GEAR MTG SET

SCREW

50G4 POWER STEERING UJ CROSS SHAFT

50G5 POWER STG OTHER COMPLAINTS

50G6 POWER STG PUMP DRIVE PULLEY

50G7 POWER STG PUMP DRIVE BELT

50G8 POWER STEERING OIL SEAL

50H0 STEERING WHEEL

50I0 STEERING LEVERS

50I1 STEERING LEVER BOLTS

50I2 TRACK ROD LEVER

50J0 DRAG LINK

50J1 TRACK ROD

50J2 STEERING PLAY ADJUSTMENT


111


50J3 DRAG LINK SOCKET

50J4 DRAG LINK BALL PIN

50J5 DRAG LINK SOCKET PINCH BOLT

50J6 TRACK ROD SOCKET

50J7 TRACK ROD BALL PIN

50J8 TRACK ROD SOCKET PINCH BOLT

50K0 STEERING BOX MOUNTING STUDS

50K1 STG.MTG BRKT-FRAME MTG TYPE

50K2 STG.MTG BRKT-OUTRIGGER TYPE

50K3 PWR STG BOX INPUT SHAFT SEAL

50K4 POWER STG BOX ROCKER SHAFT

SEAL

50K5 POWER STG BOX LIMITER VALVE

50L0 UNIVERSAL JOINT CROSS

50M3 POWER STEERING RESERVOIR

50M4 POWER STEERING HOSES

50M5 POWER STEERING OIL FILTER

50M6 POWER STG.RESERVOIR

MOUNTING BRACKET

50M7 POWER STEERING METALLIC PIPES

50N0 STEERING OUTER COLUMN

SUPPORT BRACKET

50P0 STEERING COLUMN ASSEMBLY

(CARGO)

52 BRAKES

52A0 GENERAL

52B0 AIR PIPES

52B1 AIR HOSES

52C0 AIR TANK/SENSING TANK

52C1 AUXILLARY TANK

52C2 AIR TANK BRACKET

52D0 AIR INLINE FILTER

52F0 UNLOADER VALVE WITH TYRE

INFLATOR

52G0 STOP LIGHT SWITCH

52H0 BRAKE CHAMBER FRONT

52I0 SLACK ADJUSTER AND LINKAGES

52I1 AUTOMATIC SLACK ADJUSTER

52J0 BRAKE OPERATING PEDAL STD

52J1 BRAKE OPERATING PEDAL C45


52K0 E2 BRAKE VALVE

52K1 SYSTEM PROTECTION VALVE

52K2 GRADUATED HAND CONTROL

VALVE

52L0 SPRING BRAKE CHAMBER REAR

52M0 QUICK RELEASE VALVE

52M1 RELAY VALVE

52M2 TC2 VALVE

52M3 TRAILER CONTROL VALVE

52N0 PALM COUPLING SERVICE LINE

52N1 PALM COUPLING EMERGENCY

LINE

52P0 LOW PRESSURE WARNING

SWITCH

52Q0 EXHAUST BRAKE VALVE - SLIDING

TYPE

52Q1 EXHAUST BRAKE VALVE -

BUTTERFLY TYPE

52Q2 BALL JOINT FOR BUTTERFLY

VALVE LEVER

52Q3 EXHAUST BRAKE - SOLENOID

VALVE

52Q4 EXHAUST BRAKE FOOT OPERATED

SWITCH ON FLOOR

52Q5 EXHAUST BRAKE FOOT OPERATED

SWITCH ON PEDAL

52Q6 EXHAUST BRAKE OPERATING

CYLINDER

52Q7 ISOLATOR SWITCH FOR EXHAUST

BRAKE

52R0 AIR PRESSURE REDUCER VALVE

52S0 AIR DRIER

52S1 AUTO DRAIN VALVE

52S2 DRYING AND DISTRIBUTION UNIT

53 FRAME AND SUSPENSION

53A0 GENERAL

53A1 DIFFERENCE IN WHEEL BASE

53A2 FRAME HEIGHT VARIATION/TWIST

53B0 FRAME BEND/BUCKLING

53B1 SUB FRAME


112


53B2 TURN TABLE BEAM (ARTIC)

53B3 OUTRIGGER/END GUSSETS

53B4 TRACTA SAURER COUPLING (VEST

BUS)

53B5 FRAME FLITCH INTERNAL

53B6 FRAME FLITCH EXTERNAL

53C0 FRAME CRACK FRONT X MEMBER

GUSSET AREA

53C1 FRAME CRACK 2ND X MEMBER

BOLT HOLES

53C2 FRAME CRACK BET. FSRB AND 2ND

X MEMBER

53C3 FRAME CRACK CJ BRG X MEMBER

GUSSET AREA

53C4 FRAME CRACK RSFB X MEMBER

GUSSET AREA

53C5 FRAME CRACK RSRB X MEMBER

GUSSET AREA

53C6 FRAME CRACK REAR SPRING

BUFFER AREA

53C7 FRAME CRACK AT FRONT SPRING

FRONT BRACKET AREA

53C8 FRAME CRACK @ HELPER

SPG.FRONT BRKT.AREA

53C9 FRAME CRACK @ HELPER

SPG.REAR BRKT.AREA

53D0 FRAME CRACK STG.MOUNTING

BRACKET AREA

53D1 FRAME CRACK OUTRIGGER

MTG.BRACKET AREA

53D2 FRAME CRACK AT FUEL TANK

MTG.AREA

53D3 FRAME CRACK AT TRUNNION

MTG.AREA

53D4 FRAME CRACK AT OTHER AREA

53D5 FRAME CRACK AT CABIN REAR

SUPPORT AREA

53D6 FRAME CRACK DUE TO BODY

BUILDING DEFECT

53E0 CENTRE BEARING X MEMBER

53E1 TUBULAR X MEMBER


53E2 CROSS MEMBER OTHERS

53E3 SOLE MEMBER

53E4 REAR SPRING FRONT X MEMBER

(STANDARD)

53E5 REAR SPRING FRONT X MEMBER -

FULL DEPTH

53E6 REAR SPRING MIDDLE X MEMBER

(2516)

53E7 REAR SPRING REAR X MEMBER

53E8 FRONT CROSS MEMBER

53E9 SECOND CROSS MEMBER

53F0 U BOLT/I BOLT

53F1 SPRING U CLAMP

53G0 FRONT SPRING MAIN LEAF

53I0 REAR SPRING MAIN LEAF

53K0 HELPER SPRING

53L0 SHOCK ABSORBER FRONT

53L1 SHOCK ABSORBER REAR

53M0 SHOCK ABSORBER BRACKET

FRONT

53M1 SHOCK ABSORBER BRACKET REAR

53N0 SPRING BRACKETS FRONT SPRING

53N1 SPRING CHAIR REAR SPRING

53N2 SPRING BRACKET REAR SPRING

53N3 HELPER BRACKET

53N4 HELPER BRACKET WEAR PADS

53N5 HANGER BRACKET WEAR PADS

53P0 SPRING BUFFERS FRONT

53P1 SPRING BUFFERS REAR

53Q0 SPRING SHACKLE

53Q1 SHACKLE PIN

53Q3 SPRING EYE BOLT

53Q4 SPRING EYE BUSH - FRONT SPRING

FRINT

53Q5 SPRING EYE BUSH - FRONT SPRING

REAR

53Q6 SPRING EYE BUSH - REAR SPRING

FRONT BUSH

53Q7 SPRING EYE BUSH - REAR SPRING

REAR BUSH


113


53Q8 SPRING EYE BUSH - REAR MOST

SPRING REAR BUSH

53Q9 SHACKLE PIN - MAV REAR

53R0 BELL CRANK LEVER

53R1 V SEAL FOR SHACKLE PIN

53S0 TIE RODS

53S1 LINK ARMS

53S2 METALLASTIC BUSHES

53S3 SPHERICAL BEARINGS

53T0 TORQUE STABILIZER

53T1 ANTI ROLL BAR

53U0 RADIUS ROD

53U1 RADIUS ROD BRACKETS/BOLTS

53U2 RADIUS ROD BUSHES

53U3 SILENT BLOCK BUSH

53V0 CROSS TUBE

53W0 BOGIE CROSS SHAFT

53W1 BOGIE BRACKET

53X0 AIR SUSPENSION BELLOW –FRONT

53X1 AIR SUSPENSION BELLOW –REAR

53X2 LEVELLING VALVES

53X5 AIR SUSPENSION BEAM

53X6 REAR LOCATION LINK -AIR

SUSPENSION

53X7 PANHARD ROD

53X8 CROSS BEARER -AIR SUSPENSION

53X9 AIR SUSPENSION PIPES

53Y0 FRAME CRACK AT FRONT SPRING

REAR BRACKET

53Z0 WEWELLER RUBBER ELEMENTS

53Z1 WEWELLER SPRINGS -FRONT 4"

53Z2 WEWELLER SPRINGS –REAR

53Z3 FRONT WEVELLER BRACKETS

53Z4 REAR WEVELLER BRACKETS

53Z5 PARABOLIC SPRINGS

53Z6 AUTOROLA FRONT SUSPENSION

53Z7 AUTOROLA REAR SUSPENSION

53Z8 WEWELLER SPRING - FRONT 3"

55 ACCESSORIES

55A0 GENERAL


55B0 SPARE WHEEL CARRIER

55B1 SPARE WHEEL CARRIER

OPERATING CABLE

55B2 SPARE WHEEL CARRIER BRACKET

55C0 WHEEL DISC DEFECTS -

MTG.HOLES AREA

55C1 WHEEL DISC DEFECTS - FIXED

FLANGE AREA

55C2 WHEEL DISC DEFECTS - WELDED

AREA

55C3 WHEEL DISC DEFECTS - LOCKING

RING AREA

55D0 TYRES AND TUBES

55E0 FUEL TANK

55E1 FUEL TANK GAUGE MECHANICAL

55E2 FUEL TANK GAUGE ELECTRICAL -

AT FUEL TANK

55E3 FUEL TANK MOUNTING

55E4 WATER SEPARATOR -

MECHANICAL TYPE

55E5 FUEL TANK CAP

55E6 FUEL TANK CAP LOCK

55F0 SILENCER

55F1 SILENCER INLET/OUTLET PIPES

55F2 EXHAUST PIPE MOUNTING

BRACKET(AT F/W HOUSING AREA)

55F3 SILENCER MOUNTING CLAMPS

55F4 TAIL PIPE MOUNTING BRACKET

55F5 TAIL PIPE CLAMPS

55G0 EXHAUST FLEXIBLE PIPE

55G1 EXHAUST PIPE LINE CARGO

55H0 CAB BODY STRUCTURE CRACK

55H1 CAB FLOOR CRACK

55H2 ERGOMATIC CAB

55H3 CAB OTHER FAILURES

55H4 BONNET

55H5 BONNET INSULATION

55H6 BONNET SEALING RUBBER

55I0 FRONT END STRUCTURE

(810/STAG)


114


55J0 FRONT END STRUCTURE (SFC)

55J1 SEMI FORWARD CONTROL

BONNET

55J2 SEMI FORWARD CENTRE LOCK

55J3 SEMI FORWARD CONTROL

BONNET HINGES

55J4 INTEGRAL BUS BODY STRUCTURE

55J5 SFC CAB MOUNTING LONG

MEMBER (LH/RH)

55J6 SEMI FORWARD CONTROL CAB

MOUNTING BRACKET.

55J7 A POST – SFC

55K0 TIPPING BODY TAIL GATE

55L0 DUMPER BODY

55M0 FULLY BUILT CABIN

55N0 BUMPER AND ITS MOUNTING

55P0 GRILLE

55P1 GRILLE HINGES

55P2 GRILLE LOCK

55P3 GRILL LOCKING MECHANISM

55P4 FRONT OPENING PANEL STAY

ROD

55P5 STAY ROD GROMMET

55Q0 FRONT WINDSCREEN GLASS


RUBBER


RUBBER

55Q3 REAR VIEW MIRROR LH / RH

55Q4 REAR VIEW MIRROR MOUNTING

BRACKET LH / RH

55R0 CAB MOUNTING BRACKET

55S0 PANTHER FRP FRONT PANEL

55S1 PANTHER FES STEEL STRUCTURE

55T0 HYDRAULIC JACK

55U0 WIPER MOTOR

55V0 DRIVERS SEAT

55V1 DRIVER SEAT ADJUSTING

MECHANISM

55W0 C45 CAB


55W1 G45 MARK II

55W2 G45 MARK III

55X0 MUD GUARD

55X1 REAR UNDER RUN PROTECTION

DEVICE (RUPD)

55X2 LATERAL PROTECTION DEVICE

(LPD/SUPD)

55Y0 RUBBER CONES/MOUNTING

BRACKET

55Z0 AC DRIVE IDLER PULLEY

55Z1 AC DRIVE IDLER PULLEY

MOUNTING BRACKET

55Z2 AC UNIT DRIVE IDLER PULLEY

BEARING

55Z3 ENGINE TO IDLER PULLEY DRIVE

BELT

55Z4 FAN BELT TENSIONER

ARRANGEMENT IN IDLER PULLEY

55Z5 AC COMPRESSOR MOUNTING

BRACKET

56 CARGO CAB

56A0 GENERAL

56B0 CAB PANEL FLOOR

56C0 CAB PANEL FRONT

56D0 CAB PANEL ROOF

56E0 CAB DOOR

56E1 DOOR LOCK MECHANISM

56E2 CAB LOCKING MECHANISM

56E3 STRIKER PIN FOR CABLOCK

56E4 ANTIRATTLE SPRING IN CABLOCK

56E5 HANDLE -DOOR LOCK

56E6 KEY -DOOR LOCK

56E7 LOCK BARREL

56E8 REMOT LOCK-DOOR

56F0 WIND SCREEN & VISOR

56F1 WIND SCREEN WASHER

56G0 DOOR GLASS

56G1 QUARTER GLASS/QUARTER GLASS

LOCK

56G2 WINDOW WINDING MECHANISM


115


56I0 TORSION BAR

56I1 TORSION BAR PAD

56J0 CAB MOUNTING BRACKET FRONT

56J1 CAB MOUNTING BOLT - CAB TO

BRACKET

56J2 CAB MOUNTING BOLT - BRACKET

TO CHASSIS

56K0 FUSE MODULE

56L0 SEATS

56M0 CAB PAINT

56M1 CAB PAINT UNDER BODY

56N0 CAB MOUNTING BUSH FRONT

56N1 CAB MOUNTING BUSH REAR

56P0 FENDER

56P1 BUMPER

56P2 GRILLE

57 ELECTRICALS

57A0 GENERAL

57B0 BATTERY

57B1 BATTERY CARRIER/FITMENT

DEFECT

57B2 MAIN CABLE

57B3 BATTERY ISOLATOR SWITCH

57C0 WIRING

57C1 FUSE BOX

57C2 FUSE - CAPSULE TYPE

57C3 FUSE - BLADE TYPE

57D0 STARTER MOTOR AUXILIARY

FIELD COIL

57D1 STARTER MOTOR COMMUTATOR

SOLDERING

57D2 STARTER MOTOR CLUTCH SLIP

57D3 STARTER MOTOR PINION END

CUSHIONING

57D4 STARTER MOTOR OTHER

COMPLAINTS

57D5 STARTER RELAY

57E0 ALTERNATOR REGULATOR

57E1 ALTERNATOR ROTOR

57E2 ALTERNATOR DIODE


57E3 ALTERNATOR BRUSHES

57E4 ALTERNATOR STATOR

57E5 ALTERNATOR FUSE

57E6 ALTERNATOR KEY/KEYWAY

57E7 ALTERNATOR CHARGING

57E8 ALTERNATOR OTHER

COMPLAINTS

57F0 DYNAMO

57G0 REGULATOR

57H0 HEAD LAMP

57H1 HEAD LAMP RELAY

57H2 CAB INTERIOR LAMP

57I0 TAIL LAMP

57J0 PARKING/SIDE INDICATOR LAMP

57K0 PILOT LAMP

57L0 LAMPS OTHERS

57M0 AIR CONDITIONING UNIT

57N0 SOLENOID

57P0 OIL PRESSURE TRANSDUCER

57Q0 STARTER MOTOR SOLENOID

58 DASH BOARDS

58A0 GENERAL

58B0 COMBINATION SWITCH

58C0 KEY TYPE SWITCH

58D0 INDICATOR SWITCH

58E0 STARTER BUTTON

58F0 AIR PRESSURE BUZZER

58F1 HAZARD WARNING SWITCH

58G0 FLASHER UNIT STANDARD

58G1 FLASHER UNIT ELECTRONIC

58G2 FLASHER INDICATOR ON PANEL

BOARD - CARGO

58G3 MAIN BEAM INDICATOR

58H0 HORN

58I0 SPEEDO METER

58J0 SPEEDO CABLE

58K1 ELECTRICAL TEMPERATURE

GAUGE

58L0 MECHANICAL OIL PRESSURE

GUAGE


116


58L1 OIL PRESS GAUGE FLEX. PIPE

58L2 ELECTRICAL OIL PRESSURE

GAUGE

58L3 BUNDY PIPE OIL PRESSURE GAUGE

58M0 AIR PRESSURE GAUGE

58N0 AMPERE METER

58N1 VOLTMETER

58N2 CLUSTER INST. PANEL-GLASS /

SEALING RING / HOUSING

58P0 RPM INDICATOR DIGITAL

58P1 RPM INDICATOR DIAL TYPE

58Q0 ELECTRONIC HOUR METER

58R0 PULL AND PUSH SWITCH - HEAD

LAMP

58R1 PULL AND PUSH SWITCH -

IGNITION

58S0 PIANO TYPE SWITCH

58T0 PARKING BRAKE WARNING LAMP

(PANEL BOARD)

58U0 WATER SEPARATOR LEVEL

WARNING LAMP

58V0 BULB TESTING SWITCH

58W0 LOW AIR PRESSURE ALARM

58X0 LOW OIL PRESSURE WARNING

LAMP

58X1 LOW OIL PRESSURE SWITCH

58X2 FUEL TANK GAUGE ON

DASHBOARD

58Y0 CAB SEATING WARNING LAMP

58Z1 ELECTRICAL TEMPERATURE

SENSOR

58Z2 REVERSE LIGHT – TIPPER

58Z3 REVERSE BEEPER

60 TRAILER UNIT

60A0 GENERAL

60B0 MAHINDRA OWEN AXLE

60B1 TRAILER INDIA AXLE

60B2 TRAILER AXLE OTHER MAKE

60C0 MAHINDRA OWEN FRAMES

60C1 TRAILER INDIA FRAMES


60C2 TRAILER FRAME OTHER MAKE

60D0 MAHINDRA OWEN 5TH

WHEEL/SUB FRAME

60D1 TRAILER INDIA 5TH WHEEL/SUB

FRAME

60D2 HAULWEL 5TH WHEEL/SUB

FRAME

60D3 OTHER MAKE 5TH WHEEL/SUB

FRAME

60E0 TURN TABLE KINGPIN

60E1 KINGPIN OFFSET

61 TIPPING UNIT

61A0 GENERAL

61B0 HOSES/PIPE

61C0 RAMS PISTON/RINGS

61C1 PIVOT PINS

61C2 TRUNNION ARM

61C3 TRUNNION ARM MOUNTING X

MEMBER

61C4 OIL SEALS

61D0 INNER/OUTER LEVERS

61E0 PUMPS

61F0 HYDRAULIC TANK

61F1 BREATHER- HYDRAULIC TANK

61G0 VALVE

61H0 POWER TAKE OFF U/T

61H1 PNEUMATIC OPERATING SWITCH -

PTO

61H2 PUSH PULL CABLE

61H3 SOLENOID SWITCH

61I0 PTO OPERATING LEVER (CABIN)

61J0 SUB-FRAME ASSEMBLY

61J1 LOAD BODY RUBBER BUFFER

61K0 FRONT END TIPPING SYSTEM

62 MARINE / INDUSTRIAL ENGINE

62A0 GENERAL

62B0 SEA WATER PUMP

62C0 ENGINE MOUNTING

62D0 CLUTCH ASHOK

62D1 CLUTCH KPC


117


62D2 CLUTCH GPL

62D3 ASHOK CLUTCH FORWARD

62D4 ASHOK CLUTCH REVERSE

62D5 BACK PLATE

62D6 CLUTCH FINGER ASSEMBLY

62D7 WITHDRAWAL ASSEMBLY

62D8 WITHDRAWAL SLEEVE

62D9 WITHDRAWAL BEARING HOUSING

62E0 GEAR CASING ASHOK

62E1 GEAR CASING KPC

62E2 GEAR CASING GPL

62E3 ASHOK END COVER

62E4 FRONT OIL SEAL

62E5 REAR OIL SEAL

62F0 GEARS ASHOK GEAR BOX

62F1 GEARS KPC GEAR BOX

62F2 GEARS GPL GEAR BOX

62F3 LAYSHAFT FORWARD GEAR

62F4 LAYSHAFT REVERSE GEAR

62F5 IDLER GEAR

62F6 IDLER GEAR BUSH

62G0 SHAFT ASHOK GEAR BOX

62G1 SHAFT KPC GEAR BOX

62G2 SHAFT GPL GEAR BOX

62G3 INPUT SHAFT FORWARD – ASHOK

62G4 INPUT SHAFT REVERSE – ASHOK

62G5 LAYSHAFT – ASHOK

62G6 OUTPUT SHAFT FLANGE – ASHOK

62H0 BEARING ASHOK GEAR BOX

62H1 BEARING KPC GEAR BOX

62H2 BEARING GPL GEAR BOX

62H3 BEARING - FORWARD INPUT

SHAFT – ASHOK

62H4 BEARING - REVERSE INPUT SHAFT

– ASHOK

62H5 BEARING LAYSHAFT FRONT

62H6 BEARING LAYSHAFT REAR

62I0 GEAR SHIFT ASHOK

62I1 GEAR SHIFT KPC

62I2 GEAR SHIFT GPL


62I3 SELECTOR SHAFT - ASHOK

62I4 SELECTOR FORK - ASHOK

62I5 SELECTOR LEVER - ASHOK

62J0 COUPLING

62K0 PROPELLER

64 SUPER STRUCTURE FOR GOODS /

DEFENCE VEHICLES

64A0 SUPER STRUCTURE GENERAL

64B0 WATER PUMP

64C0 PNEUMATIC VALVES

64D0 PNEUMATIC CYLINDER (ACCL.

CONTROL)

64E0 HYDRAULIC VALVES

64F0 PRIMING UNIT

64G0 MONITOR

64H0 AIR LEAK

64I0 ELECTRICALS

64J0 CREW CABIN: BABBAR WRECKR

LRV

64J1 CREW CABIN: PERFECT

MFR.INDUSTRIES LRV

64K1 WINCH GEARBOX LRV

64K2 WINCH GEAR BOX OPERATING

LINKAGES

64L1 WRECKER BOOM LRV

64L2 BOOM/WINCH CABLE : LRV

64M0 MEASURING GAUGES (VENDOR)

64N0 WATER TANK

64N1 FOAM TANK

64N3 DEMISTER TANK/CONNECTION

64O1 DOOR SHUTTER

64O2 ALL PIPING AND PLUMBINGS

64O3 ALL HOSES / RUBBER ITEMS IN

CIRCUIT

64O4 ATTACHMENTS/ACCESSORIES

64P0 PTO ACTUATING MECH

(MANUAL)

64P1 EXHAUST PRIMING MECH

64P2 PROPELLER SHAFT FOR WATER

PUMP


118


64P3 ACTUATING LEVERS

64P4 CHAIN

64P5 OVER LOAD CLUTCH

64P6 PROPELLER SHAFT (PTO)

64Q0 PLASTIC/RUBBER ITEM (VENDOR)

64Q1 OTHER MOUNTINGS

64Q3 FIT AND FINISH

64R0 SERVICE DRUM ASSY

64R1 SERVICE DRUM RING GEAR

64R3 SERVICE DRUM CABLES

64S0 TOWING HITCH ASSY

64S1 STIFF LEG BLOSTER ASSY

64S2 OUT BOARD LEG ASSY

64S3 CABLE HOOK

64T0 MAST SHEAVE YOKE ASSY

64T1 BOOM SHEAVE YOKE ASSY

64T2 SERVICE PINION SHAFT ASSY

64T3 IDLER SPROCKET YOKE ASSY

64V1 BRAKE ASSCENTRIC ASSY

64W1 OPERATING LEVER ASSY

64X1 REAR JACK

64Z0 WRECKER PLAT FORM BODY

65 FULLY BUILT BUS

65A0 GENERAL

AIR CONDITIONING UNIT

RELATED

65B0 SLAVE ENGINE FOR AC UNIT

65B1 AC DUCTING IN PASSENGER

COMPARTMENT

65B2 AC UNIT COMPRESSOR

65B3 AC COMPRESSOR DRIVE BELT

65B4 AC UNIT EVAPORATOR

65B5 AC UNIT EVAPORATOR FAN /

BLOWER

65B6 AC UNIT EXPANSION VALVE

65B7 AC UNIT CONDENSOR

65B8 AC UNIT CONTROLS (SWITCHES &

RELAYS)

65B9 AC UNIT WIRING HARNESS

BODY STRUCTURE RELATED


65C0 FLOOR STRUCTURE AT

PASSENGER AREA

65C1 DRIVER SEAT PLATFORM AREA

65C2 SIDE STRUCTURE LH / RH

65C3 ROOF STRUCTURE

65C4 FRONT STRUCTURE

65C5 REAR STRUCTURE

65C6 FOOT STEP FRONT

65C7 FOOT STEP REAR

65C8 WHEEL ARCH FRONT LH/ RH

65C9 WHEEL ARCH REAR LH/ RH

65D0 DRIVER DOOR

65D1 EMERGENCY DOOR

65D2 PASSENGER DOOR

65D3 PNEUMATIC ACTUATION

MECHANISM FOR PASSENGER

DOOR

65D4 DOOR LOCK

65D5 DOOR HINGES

65D6 PASSENGER OVERHEAD LUGGAGE

COMPARTMENT

65D7 LUGGAGE COMPARTMENT -

UNDER BODY

65D8 INTEGRATION BETWN

BODY&OUTRIGGER @ REAR SUSPN

AREA

65D9 INTEGRATION BETWEEN BODY &

OUTRIGGER @ OTHER AREAS

65E0 WINDOW

65E1 WINDOW GLASS

65E2 WINDOW HANDLE

65E3 WINDOW LOCK

65E4 REAR WINDSCREEN GLASS

65E5 REAR WINDSCREEN GLASS

RUBBER

65E6 REAR WINDSCREEN APERTURE

65E7 ROOF VENTILATION DOOR

65E8 SUN VISOR - FRONT WINDSCREEN

GLASS

65E9 ROOF TAR MAT


119


65F0 PASSENGER SEAT

65F1 PASSENGER SEAT ADJUSTMENT

MECHANISM

66 CARGO CAB TILT & GEAR SHIFT

MECHANISM

66A0 GENERAL

66B0 GEAR LEVER SEATING

BLOCK/DISTANCE PIECE

66B1 GEAR LEVER CONNECTOR

FLANGE

66B3 SEALING PAD ASSEMBLY-FOR

FLOOR MOUNTED

66C0 GEAR SHIFT TELESCOPE NYLON

END BLOCK

66C1 TELESCOPIC LOCK RELEASE

CABLE

66C5 RELEASE CABLE PULLEY

66C6 RELEASE CABLE SPRING

66C7 RELEASE CABLE CAM

66C8 RELEASE CABLE SPINDLE

66D0 CAB TILT KEY HOUSING

66D1 CAB LIFTING : GENERAL

STALLION/LRV

66D2 CAB LIFTING PUMP STALLION/LRV

66D3 CAB LIFTING RAM STALLION/LRV

66E0 CONTROL ROD SUPPORT LH

66E1 CONTROL ROD SUPPORT RH

66F0 TELESCOPIC SPHERICAL BEARING


66F1 SPHERICAL BEARING -FLOOR

MOUNTED CSO

66G0 SELECTOR FORK DETENT SPRING

66G1 SELECTOR FORK DETENT BALL

66G2 DETENT PLATE

66G3 SELECTOR FORK NEEDLE ROLLER

BEARING

66H1 REMOTE OPERATING DOOR

CLOSING MECHANISM

66J0 CSO BRACKET –LOWER

66J1 CSO BRACKET –UPPER

66J2 GAITER FOR GEAR SHIFT LEVER

66J3 GEAR SHIFT LEVER

66J4 KNUCKLE FOR GEAR SHIFT LEVER

66J5 BALL JOINT AND NUT FOR GEAR

SHIFT LEVER

66J6 CSO TUBE ASSEMBLY

66J7 FORK SUPPORT LEVER

66J8 PIVOT SUPPORT BRACKET

66J9 GEARSHIFT ROD

72 AMC

72A0 AMC SCHEDULED SERVICE


120

26. FAULT CODE

CODE FAULT DESCRIPTION

AA ADRIFT/LOOSE

AB AIR BUBBLE

AC AIR LEAK

AD AIR LOCK

AE BEND/DEFORMED/DISTORTED

AF BLOCKED/CLOGGED

AG BROKEN/BURST/CRACKED

AH BURNT / MELTED / DISCOLOURED

AJ CASTING DEFECTS / POROUS

AK

CORRODED / CONTAMINATED /

WATER INGRESS

AL

EXCESS CLEARANCE / PLAY /

WORN

AM FITMENT DEFECT

AN FOREIGN MATERIAL

AP FOULING

AQ FUEL LEAK

AR GAS LEAK

AS IMPROPER WELDING/SOLDERING

AT MACHINING DEFECT

AU MAINTENANCE DEFECT

AV MALADJUSTED

AW MISALIGNED

AX MISMATCHED

AY NOISY/VIBRATION

AZ OIL LEAK

BA OPEN CIRCUIT

BB PEELED OFF/CHIPPING

BC POOR CONNECTION


BD ROTATED

BE SCORED/PITTED

BF SCUFFED/SEIZED/STIFF/HARD

BG SHORTAGE

BH SHORT CIRCUIT

BJ SHUDDER/JUDDER

BK WATER LEAK

BL WEAK

BM UNIDENTIFIED DEFECT

BN LACK OF LUBRICATION

PERFORMANCE RELATED FAULT CODES

To be used only when definite reasons are

Not Available

CA ENGINE OIL CONSUMPTION

CB ENGINE OIL THICKENING

CC ENGINE OVERHEATING

CD LOW ENGINE OIL PRESSURE

CE EXCESS ENGINE BLOWBYE

CF EXCESS FUEL CONSUMPTION

CG POOR PICKUP

CH

ENGINE NOT TAKING

LOAD/HUNTING

CJ TRANSMISSION NOISE

CK EXCESS TYRE WEAR

CL BRAKE PULLING

FAULT CODES FOR MISCELLANEOUS

ACTIVITIES

DA TRIAL FITMENT

EC ECOCARE REPLACEMENTS

FAULT CODES FOR AMC

Z0 PDI FOR AMC STU VEHICLES

ZA I YEAR FIRST SERVICE


121


ZB I YEAR SECOND SERVICE

ZC I YEAR THIRD SERVICE

ZD I YEAR FOURTH SERVICE

ZE I YEAR FIFTH SERVICE

ZF I YEAR SIXTH SERVICE

ZG I YEAR SEVENTH SERVICE

ZH I YEAR EIGHTH SERVICE

ZI I YEAR NINTH SERVICE

ZJ I YEAR TENTH SERVICE

ZK I YEAR ELEVENTH SERVICE

ZL I YEAR TWELFTH SERVICE

ZM I YEAR THIRTEENTH SERVICE

ZN I YEAR FOURTEENTH SERVICE

ZO I YEAR FIFTEENTH SERVICE

ZP I YEAR SIXTEENTH SERVICE

ZQ I YEAR SEVENTEENTH SERVICE

ZR I YEAR EIGHTEENTH SERVICE

ZS I YEAR NINETEENTH SERVICE

YA II YEAR FIRST SERVICE

YB II YEAR SECOND SERVICE

YC II YEAR THIRD SERVICE

YD II YEAR FOURTH SERVICE

YE II YEAR FIFTH SERVICE

YF II YEAR SIXTH SERVICE

YG II YEAR SEVENTH SERVICE

YH II YEAR EIGHTH SERVICE

YI II YEAR NINTH SERVICE

YJ II YEAR TENTH SERVICE


YK II YEAR ELEVENTH SERVICE

YL II YEAR TWELFTH SERVICE

YM II YEAR THIRTEENTH SERVICE

YN II YEAR FOURTEENTH SERVICE

YO II YEAR FIFTEENTH SERVICE

YP II YEAR SIXTEENTH SERVICE

YQ II YEAR SEVENTEENTH SERVICE

YR II YEAR EIGHTEENTH SERVICE

YS II YEAR NINETEENTH SERVICE

XA III YEAR FIRST SERVICE

XB III YEAR SECOND SERVICE

XC III YEAR THIRD SERVICE

XD III YEAR FOURTH SERVICE

XE III YEAR FIFTH SERVICE

XF III YEAR SIXTH SERVICE

XG III YEAR SEVENTH SERVICE

XH III YEAR EIGHTH SERVICE

XI III YEAR NINTH SERVICE

XJ III YEAR TENTH SERVICE

XK III YEAR ELEVENTH SERVICE

XL III YEAR TWELFTH SERVICE

XM III YEAR THIRTEENTH SERVICE

XN III YEAR FOURTEENTH SERVICE

XO III YEAR FIFTEENTH SERVICE

XP III YEAR SIXTEENTH SERVICE

XQ III YEAR SEVENTEENTH SERVICE

XR III YEAR EIGHTEENTH SERVICE

XS III YEAR NINETEENTH SERVICE


122


WA IV YEAR FIRST SERVICE

WB IV YEAR SECOND SERVICE

WC IV YEAR THIRD SERVICE

WD IV YEAR FOURTH SERVICE

WE IV YEAR FIFTH SERVICE

WF IV YEAR SIXTH SERVICE

WG IV YEAR SEVENTH SERVICE

WH IV YEAR EIGHTH SERVICE

WI IV YEAR NINTH SERVICE

WJ IV YEAR TENTH SERVICE

WK IV YEAR ELEVENTH SERVICE

WL IV YEAR TWELFTH SERVICE

VA V YEAR FIRST SERVICE

VB V YEAR SECOND SERVICE

VC V YEAR THIRD SERVICE

VD V YEAR FOURTH SERVICE

VE V YEAR FIFTH SERVICE

VF V YEAR SIXTH SERVICE

VG V YEAR SEVENTH SERVICE

VH V YEAR EIGHTH SERVICE

VI V YEAR NINTH SERVICE

VJ V YEAR TENTH SERVICE

VK V YEAR ELEVENTH SERVICE

VL V YEAR TWELFTH SERVICE


123

27. REPAIR OPERATION TIME SCHEDULE

CODE DESCRIPTION A B D E

EN100 COMPLETE OVERHAULING OF ENGINE ASSY

(INCLUDES R&R, DISMANTLING, CLEANING,

INSPECTION AND ASSEMBLING WITH NEW OR R/C

COMPONENTS-NA ENGINE)

42.0 43 80 31

EN105 R & R ENGINE ASSY 13.0 12 21 7

EN110 COMPLETE OVERHAUL OF SPARE/FLOAT ENGINE

(WITHOUT R&R)

29.0 31 59 24

EN115 ENGINE TESTING 3.0 3 4 3

EN120 DECARBONISING CYLINDER HEAD AND

REPLACING VALVE GUIDE

11.0 13.5 17 9

EN125 PRESSURE TEST CYLINDER HEAD 1.0 1 1 1

EN130 PRESSURE TESTING OF ENGINE BLOCK 1.0 1 1 1

EN135 RE-RINGING JOB 7.5 9.5 14 6.5

EN140 R & R CYLINDER HEAD GASKET 4.5 7 10 4

EN145 R & R BROKEN CYLINDER HEAD BOLT/ STUD 6.0 8 10 6

EN150 R & R ROCKER SHAFT ASSEMBLY AND ADJUST

VALVE CLEARANCE

2.0 2.5 3 1.5

EN155 R & R AND OH ROCKER ARM 2.5 3 3.5 2

EN160 ADJUST VALVE CLEARANCE 2.0 1.5 2 1.5

EN161 R&R TAPPET COVER GASKET 1.0 1.0

EN165 R & R VALVE STEM OIL SEAL 3.5 4 3.5

EN170 R & R TAPPETS AND ADJUST VALVE CLEARANCE 4.5 4 5 4

EN175 R & R SINGLE CYLINDER LINER AND PISTON 9.5 10.5 12 8

EN180 R & R TWO CYLINDER LINER AND PISTON 10.0 11.5 13 8.5

EN185 R & R THREE CYLINDER LINER AND PISTON 10.5 12.5 14 9

EN190 R & R FOUR CYLINDER LINER AND PISTON 11.0 13.5 15 9.5

EN195 R & R FIVE CYLINDER LINER AND PISTON 11.5 14.5 16

EN200 R & R SIX CYLINDER LINER AND PISTON 12.0 15.5 17

EN205 R & R WATER PUMP ASSY (INCLUDING R & R

RADIATOR AND HOSES)

2.5 2.5 4 2

EN210 R & R AND O/H WATER PUMP ASSY (INCLUDING R

AND R RADIATOR AND HOSES)

3.5 3.5 5 3.5

EN212 R & R COOLANT TEMPERATURE SENSOR 0.5 0.5

EN215 R & R RADIATOR ASSEMBLY INCLUDING HOSES 2.0 2 3 1.5

EN217 R & R AND CLEAN AFTER COOLER 2.0 2 2 2

EN220 R & R WATER HOSE (1 NOS HOSE) 0.5 0.5 0.5 0.5

EN225 R & R FAN ASSEMBLY 2.0 2 3 1.5

EN230 R & R VIBRATION DAMPER 3.0 3 3.5 3

EN235 R & R FAN PULLEY HUB 2.5 2.5 3 2.5


124


EN240 ADJUST BELT TENSION (PER BELT) 0.5 0.5 0.5 0.5

EN242 R&R BELT TENSIONER PULLEY 0.5 0.5

EN245 REPLACE BELT (PER BELT) 0.5 0.5 0.5 0.5

EN250 R & R ALTERNATOR BRACKET 0.5 1 1 0.5

EN255 R & R OIL PUMP ASSEMBLY ALONE AND REPLACE

NECESSARY PARTS

3.0 1.5 2 3

EN260 R & R OIL SUMP AND REPLACEMENT OF GASKETS 1.0 0.5 0.5 1

EN265 R & R OIL COOLER AND CHANGE ‘O’ RING 1.0 1 1 1

EN275 R & R ENGINE OIL FILTER/DRAIN AND REFILL OIL 0.5 0.5 0.5 0.5

EN280 R & R AIRCLEANER ASSY AND CLEAN/ REPLACE

ELEMENT

0.5 0.5 0.5 0.5

EN290 R & R AIR INTAKE HOSE (1 NOS HOSE) 0.5 0.5 0.5 0.5

EN295 R & R THERMOSTAT ASSY AND CHECK OPENING

TEMPERATURE

1.0 1 1 1

EN300 CHECK COMPRESSION IN ALL CYLINDERS 1.5 1.5 2 1.5

EN305 R & R CAMSHAFT ASSY AND REPLACE CAM

BUSHES (IN SITU)

5.0 7 8 4

EN310 R & R FLYWHEEL PILOT BEARING 4.0 4 13 3

EN315 R & R FLYWHEEL 4.0 4

EN320 R & R FLYWHEEL RING GEAR 5.0 5 13 4

EN325 R & R ENGINE REAR END OIL SEAL 6.0 4 13 3.5

EN330 R & R FLYWHEEL FACE PLATE 5.0 5 5

EN335 R & R FLYWHEEL HOUSING 7.0 7 7

EN337 R & R ENGINE SPEED SENSOR 0.5 0.5

EN340 R & R TIMING CASE OIL SEAL 4.5 4.5 4.5 3.5

EN345 R & R TIMING CASE AND REPLACE GASKET 4.0 4.5 4.5 3.5

EN350 R & R TIMING BACKPLATE INCLUDING

REPLACEMENT OF GASKETS, TIMING GEARS/

CRANKSHAFT GEAR

6.0 6 9 6

EN355 R & R TURBOCHARGER UNIT 3.0 3 3 2.5

EN360 CHECK AND RESET VALVE TIMING/REPLACE

BROKEN COMP. GEAR / GEAR TRAIN INSPECTION

6.0 6.5 7 6

EN365 R & R SIDE WATER RAIL/ R & R OIL COOLER IN

CASE OF

1.5 2 2 1.5

EN375 R & R INJECTOR 1.5 1.5 1.5 1.5

EN382 R & R INSTRUMENTED INJECTOR 0.5 0.5

EN385 R & R FIP AND RESET TIMING 3.5 2 2 3.5

EN386 R & R FIP SOLENOID (ELAB) 0.5 0.5

EN387 R & R TIMER SOLENOID 2.0 2

EN388 R & R FIP ACTUATOR 2.0 2

EN389 IDLING SPEED ADJUSTMENT 0.5 0.5


125


EN390 RESET FIP TIMING 1.0 1 1 1

EN391 STARTING QUANTITY ADJUSTMENT 0.5 0.5

EN392 LIMITING QUANTITY ADJUSTMENT 0.5 0.5

EN393 VEHICLE SPEED ADJUSTMENT 0.5 0.5

EN395 R & R FIP COUPLING (INCLUDING REPLACEMENT

OF FAILED PARTS)

4.5 3 4.5

EN400 R & R INJECTOR HIGH PRESSURE PIPE 0.5 0.5 0.5 0.5

EN405 R & R FIP SHUT-OFF SOLENOID SWITCH 0.5 0.5 0.5 0.5

EN406 R&R ARENS CONTROL CABLE 0.5 0.5

EN410 R & R ACCELERATOR CABLE 0.5 0.5 0.5

EN415 R & R ACCELERATOR PEDAL 1.0 1 1 1

EN417 R & R ACCELERATOR PEDAL SENSOR 0.5 0.5

EN420 R & R TIMING CASE AND REPLACE FIP DRIVE

GEAR

4.0 3.5 4

EN425 R & R FUEL FEED PUMP AND O/H INCLUDING

GASKET REPLACEMENT

1.0 1 1 2

EN430 R & R FUEL TANK AND CLEAN/RANDR FUEL LINES

AND CLEAN / R&R FUEL FILTER

2.0 2 2 2

EN435 BLEED FUEL SYSTEM 1.0 1 1 1

EN440 R & R FUEL LINE HOSE (1 NOS HOSE) 0.5 0.5 0.5 0.5

EN445 R & R ENGINE MOUNTING FRONT 4.0 4 4.5 3.5

EN450 R & R ENGINE MOUNTING REAR 1.5 1.5 2 1.5

EN455 R & R WATER COOLED HEAT EXCHANGER 1.5 1 2 1.5

EN460 R & R PRESSURE RELIEVE VALVE/BYPASS VALVES

AND INSPECT FOR PROPER SEATING

1.0 0.5 0.5 1

EN465 R & R BREATHER PIPE INCLUDING CLEANING 0.5 0.5 0.5 0.5

EN470 R & R INLET MANIFOLD 2.5 2.5 2.5 2.5

EN472 R & R BOOST PRESSURE SENSOR 0.5 0.5

EN475 R & R EXHAUST MANIFOLD 3.5 3.5 3.5 3.5

EN477 REMOVE BROKEN EXSHAUST MANIFOLD STUD 4.0 4.0

EN480 R & R SILENCER 0.5 0.5 0.5 0.5

EN490 R & R DC - DC CONVERTER 1.0 1

EN495 R & R ELECTRONIC CONTROL UNIT (ECU) 0.5 0.5

EN500 R & R HOLD ON RELAY (12 V) 1.0 1

EN505 R & R MAIN RELAY (24 V) 1.0 1

EN510 R & R IGNITION RELAY (24 V) 1.0 1

EN515 R & R DIODE 1.0 1

EN520 TROUBLE SHOOTING & EDC LINE SETTING - 5A

CIRCUIT

3.0 3


CIRCUIT

3.0 3


126



CIRCUIT

3.0 3

EN535 R & R FUSE - BATTERY CABLE CIRCUIT 1.0 1

EN540 ECU - ATMOSPHERIC PRESSURE SENSOR 0.5 0.5

EN600 CNG - R&R CARBURETOR AND REPLACEMENT OF

DIAPHRAGM

1.0

EN602 CNG - R&R 3 WAY SOLENOID 0.5

EN604 CNG - R&R SPEED GOVERNING RELAY 0.5

EN606 CNG - R&R DISTRIBUTOR ROTOR 0.5

EN608 CNG - R&R DISTRIBUTOR BEARING 2.0

EN610 CNG - R&R SPARK PLUG (6 PLUGS) 1.0

EN612 CNG - R&R HT CABLES 0.5

EN614 CNG - R&R 24V - 12V CONVERTOR 0.5

EN616 CNG - R&R IGNITION COIL 0.5

EN618 CNG - R&R TRIGGER BOX 0.5

EN620 CNG - R&R DISTRIBUTOR PICKUP COIL 0.5

EN622 CNG - OXYGEN SENSOR 0.5

EN624 CNG - R&R CATALYTIC CONVERTOR 2.0

EN626 CNG - R&R FCV 0.5

EN628 CNG - R&R OF COMMANDER AND RELAY VALVE 0.5

EN630 CNG - R&R OF GAS CYLINDER (PER BANK) 6.0

EN632 CNG - R&R SAFETY VALVE 0.5

EN634 CNG - R&R RECEPTACLE 1.0

EN636 CNG - R&R FILLER VALVE 1.0

EN638 CNG - FIRST STAGE REGULATOR 1.0

EN640 CNG - OVERHAUL SECOND STAGE REGULATOR

(INCL R&R)

3.0

EN642 CNG - LOW PRESSURE SOLENOID 1.0

EN644 CNG - R&R HIGH PRESSURE PIPE 0.5

EN646 CNG - R&R PRESSURE GAUGE 0.5

EN648 CNG - R&R VACUUM SWITCH 0.5

EN650 R&R FOR VERTICAL DISTRIBUTOR DRIVE 2.0

EN652 R&R ACELERAT0R CABLE 1.0

EN654 R&R GAS FILTER 0.5

EN656 R&R GAS HOSE 0.5

EN658 R&R CNG IGNITION WIRING HARNESS 3.0

EN660 R & R FIXED VENTURI MIXER 1.0

EN662 R & R IDLING SOLENOID VALVE 0.5

EN664 R & R HIGH PRESSURE SOLENOID VALVE 0.5

EN666 R & R AND OH 3 STAGE REGULATOR 2.0


127


EN668 R & R OF LAMDA CONTROL SYSTEM 0.5

EN670 PROGRAMMING OF LCS 0.5

EN672 R & R OF STEPPER MOTOR 0.5

EN674 R & R DUAL MODE SELECTOR SWITCH 0.5

EN676 R & R LCS WIRING 3.0

EN678 REGULATOR SENSITIVITY ADJUSTMENT 1.0

EN680 R & R PRESSURE TRANSDUCER 1.0

EN682 GAS LEAK CHECKING 1.0

EN684 R & R CYLINDER STORAGE VALVE 1.0

EN686 R & R 3/2 VALVE 1.0

EN688 R & R PE SWITCH 0.5

EN690 R & R RELAY & WIRING (IGNITION KILL SYSTEM) 0.5

EN692 R & R PLASTIC TUBE 0.5

EN694 R & R LCS 0.5

EN695 R&R LEAK OFF PIPE 0.5 0.5 0.5

CL100 R & R CLUTCH ASSY AND REPLACE DISC (INCL

GB100/G110)

5.0 5 6 3

CL110 R & R CLUTCH ASSY N O/H INCL. GB100/GB110 BUT

EXCL O/H OF WITHDRAWAL BRG (AXIAL &

DIAPHRAGM)

8.0 8 11 8

CL120 COMPLETE OVERHAUL OF SPARE/FLOAT CLUTCH

ASSEMBLY

3.0 3 5 3

CL130 R & R CLUTCH WITHDRAWAL BRG (INCL.

GB100/GB110)

4.0 4 7 3

CL140 R & R MASTER CYLINDER OVERHAUL BLEED

SYTEM AND ADJUST

2.5 2.5 4 2.5

CL150 R & R SLAVE CYLINDER O/H BLEED SYSTEM AND

ADJUST

2.0 2 2 2

CL160 R & R CLUTCH PEDAL 1.0 1 1 1

CL165 R & R CLUTCH SWITCH 0.5 0.5

GB100 R & R GEAR BOX ASSEMBLY-ALGB 3.0 3 5

GB110 R & R GEAR BOX ASSEMBLY-ZFGB 3.0 3 16 2.5

GB120 R & R GEAR BOX AND OVERHAUL (FOR GEAR

TEETH BREAKAGE, GEAR NOISE BUSH SEIZURE,

GEAR SLIP, OIL SEAL LEAKS, SHAFT DAMAGES &

END FLOAT ADJUSTMENTS) FOR ALGB

7.0 7 25

GB130 R & R GEAR BOX AND OVERHAUL (FOR GEAR

TEETH BREAKAGE, GEAR NOISE BUSH SEIZURE,

GEAR SLIP, OIL SEAL LEAKS, SHAFT DAMAGES &

END FLOAT ADJUSTMENTS) FOR ZF

7.5 7.5 28 7

GB140 OVERHAUL GEARBOX (INCLUDING SELECTOR 4.0 4 18


128


ASSEMBLY)-ALGB

GB150 OVERHAUL GEARBOX (INCLUDING SELECTOR

ASSEMBLY)-ZFGB

4.5 4.5 4.5

GB180 R & R CSO MECHANISM AND OVERHAUL BOTH

REMOTE AND DIRECT MOUNTED ARRANGEMENTS

1.0 1 1 1

GB190 R & R AND OVERHAUL SELECTOR MECHANISM 2.0 2 4 2

GB200 R & R KNUCKLE BALL JOINTS AND ADJUST

LINKAGES

1.0 1 1 1

GB210 R & R AND O/H SELECTOR TOP ASSY (BOTTOM

HALF)

1.0 1

GB220 R & R GEAR LEVER 0.5 0.5 0.5 0.5

GB230 R & R REVERSE LIGHT SWITCH 0.5 0.5 0.5 0.5

GB240 R & R GEARBOX (SIDE MOUNTED) PTO AND OH 3.5 3.5 3.5

GB250 R & R GEARBOX (REAR MOUNTED) PTO AND OH 2.0 2 3.5 2

GB260 R & R SPEEDO DRIVE ASSY AND REPLACE

NECESSARY PARTS

2.5 2.5 2.5 2.5

GB265 R & R VECHICLE SPEED SENSOR 0.5 0.5

GB270 R & R GB FRONT OIL SEAL 3.5 3.5 3.5 3.5

GB280 R & R FRONT/REAR OIL SEAL 2.5 2.5 2.5 2.5

GB290 R & R AUXILIARY GEARBOX AND O/H 8.0 8 8

GB300 R & R FRONT/REAR OIL SEAL IN AUXILIARY GEAR

BOX

1.5 1.5 1.5

GB310 R & R AGB MOUNTINGS/BUSHES 3.0 3 3

GB340 REPLACEMENT OF FRONT COVER GASKET - S536 /

S636

3.5 3.5 3.5

GB350 DRAIN OIL IN GEARBOX AND REFILL 0.5 0.5 0.5 0.5

GB360 CLEAN BREATHER IN GEARBOX AND REAR AXLE 0.5 0.5 0.5 0.5

GB361 R & R GEARSHIFT CABLE IN PANTHER 4.0 4.0 4.0

GB370 R&R & OVERHAUL OF ZF 9S/8S 109 GEARBOX 10.0 10.0

PS100 R & R AND O/H FRONT PROP. SHAFT ASSY 2.5 2.5 3 2

PS110 R & R FRONT PROP. SHAFT ASSY 1.0 1 1 1

PS120 R & R AND O/H REAR PROP. SHAFT ASSY 2.5 2.5 3 2

PS130 R & R REAR PROP. SHAFT ASSY 1.0 1 1 1

PS140 R & R AND O/H MIDDLE PROP. SHAFT ASSY 2.5 2.5

PS150 R & R MIDDLE PROP. SHAFT ASSY 1.0 1

PS160 R & R AND O/H INTER-AXLE PROP. SHAFT ASSY 2.5 2.5 3

PS170 R & R INTER-AXLE PROP. SHAFT ASSY 1.0 1 1

PS180 R & R PROPELLER SHAFT (INCLUDING YOKE AND

FLANGE) AND CHECK FOR BEND

2.0 2 2

PS190 R & R ONE CENTRE JOINT BEARING ASSY 2.0 2 2

PS200 R & R TWO (BOTH) CENTRE JOINT BEARING ASSY 4.0 4


129


PS210 R & R CENTRE JOINT BEARING RUBBER

MOUNTING (1 NOS)

2.0 2 2

PS220 R & R CENTRE JOINT BEARING RUBBER

MOUNTING (2 NOS)

4.0 4

PS250 R & R UJ CROSS ASSEMBLY - 1 NO. 1.5 1.5 1.5 1.5

RA100 R & R FIRST REAR AXLE CASING 8.0 8 16 7.5

RA110 R & R SECOND REAR AXLE CASING 8.0 8 16

RA120 R & R DIFF ASSY (2ND AXLE FOR TWIN-AXLE

VEHICLES

2.0 2 4

RA130 R & R DIFF ASSY (1ST AXLE) 2.5 2.5 5 2

RA140 R & R DIFF ASSY N O/H (2ND AXLE FOR TWIN-AXLE

VEH.)

7.0 7 9

RA150 OVERHAUL SPARE DIFFERENTIAL ASSY 5.0 5 7 4.5

RA160 R & R DIFF. ASSY N O/H FOR FORWARD REAR AXLE 7.5 7.5 12 6.5

RA170 R & R 3RD DIFF. ASSY N O/H 7.0 7 12

RA180 R & R CROWN WHEEL AND PINION AND ADJUST

BACKLASH

5.5 5.5 5 6

RA190 DIFF. PINION OIL SEAL REPLACEMENT 1.0 1 1.5 1

RA200 R & R INTER-AXLE SEAL AND BEARING IN 3RD

DIFFERENTIAL

2.5 2.5 4

RA210 R & R INNER/OUTER WHEEL BEARINGS (ONE SIDE) 2.5 2.5 4 2

RA220 R & R INNER/OUTER WHEEL BEARINGS (BOTH

SIDES)

5.0 5 8 4

RA230 R & R WHEEL BOLTS WITHOUT ANY

CONSEQUENTIAL DAMAGE (ONE SIDE)

3.0 3 5 2

RA240 R & R WHEEL BOLTS WITHOUT ANY

CONSEQUENTIAL DAMAGE (BOTH SIDES)

6.0 6 10 4

RA250 R & R TORQUE PLATE ASSY (PER SIDE) 3.5 3.5 5 2

RA260 R & R TORQUE PLATE ASSY (BOTH SIDES) 7.0 7 10 5

RA270 R AND R EXPANDER UNIT (PER SIDE) 3

RA280 R AND R EXPANDER UNIT (BOTH SIDES) 6

RA290 R & R BRAKE LINING (ONE SIDE) EXCLUDING

DRUM MACHINING

3.0 3 4.5 2

RA300 R & R BRAKE LINING (BOTH SIDES) EXCLUDING

DRUM MACHINING

6.0 6 9 4

RA310 R & R BROKEN AXLE SHAFT (ONE SIDE) 3.0 3 5 3

RA320 R & R BROKEN AXLE SHAFT (BOTH SIDES) 6.0 6 10 6

RA330 R & R AND O/H BRAKE CAMSHAFT ASSY ONE SIDE 2.5 2.5 5 2.5

RA340 R & R BRAKE DRUM IN CASE OF CRACK 1.0 1 2 1

RA350 R & R AND O/H SLACK ADJUSTER (ONE SIDE) 1.5 1.5 2.5 1.5

RA360 R & R HUB OIL SEAL ONE SIDE 3.0 3 5 2


130


RA370 R & R HUB OIL SEAL TWO SIDES 6.0 6 10 4

RA400 DRAIN OIL IN REAR AXLE AND REFILL (PER AXLE) 0.5 0.5 0.5 0.5

FA100 R & R FRONT AXLE BEAM AND CHECK FOR BEND

OR TWIST (INCLUDES JOB FA110)

12.5 12.5 20 12.5

FA110 REPLACE KING PIN AND BUSHES/ AXLE ARM (ONE

SIDE)

5.0 5 7 4

FA120 REPLACE KING PIN AND BUSHES/ AXLE ARM

(BOTH SIDES)

10.0 10 14 8

FA130 SHIM UP KINGPIN BOTH SIDES 1.0 1 1 1

FA140 R & R HUB OIL SEAL/ HUB BEARINGS ONE SIDE 2.5 2.5 5 2

FA150 R & R HUB OIL SEAL/ HUB BEARINGS TWO SIDES 5.0 5 10 4

FA160 R & R WHEEL BOLTS WITHOUT CONSEQUENTIAL

DAMAGE (ONE SIDE)

2.5 2.5 5 2

FA170 R & R WHEEL BOLTS WITHOUT CONSEQUENTIAL

DAMAGE (BOTH SIDES)

5.0 5 10 4

FA180 R & R BRAKE LINING ONE SIDE 2.5 2.5 5 2

FA190 R & R BRAKE LINING BOTH SIDES 5.0 5 10 4

FA200 R & R TORQUE PLATE ASSEMBLY (PER SIDE) 3.5 3.5 5 3

FA210 R & R TORQUE PLATE ASSEMBLY (BOTH SIDES) 7.0 7 10 6

FA220 R & R BRAKE DRUM IN CASE OF CRACK (ONE SIDE) 1.0 1 1.5 1

FA230 R & R BRAKE DRUM IN CASE OF CRACK (BOTH

SIDES)

2.0 2 3 2

FA240 R AND R EXPANDER ASSY (ONE SIDE) 2

FA250E R AND R EXPANDER ASSY (BOTH SIDES) 4

FA260 CHECK AND ADJUST WHEEL ALIGNMENT 1.0 1 1 1

FA270 R & R AND O/H BRAKE CAMSHAFT ASSY ONE SIDE 2.0 2 2.5 2

FA280 R & R AND O/H BRAKE CAMSHAFT ASSY BOTH

SIDES

4.0 4 5 4

FA290 R & R AND O/H SLACK ADJUSTER ONE SIDE 1.5 1.5 2 1

FA300 R & R AND O/H SLACK ADJUSTER BOTH SIDES 3.0 3 4 2

SU100 R & R FRONT SPRING ASSY INCLUDING

REPLACEMENT OF BUSHES & SHACKLE PINS

2.5 2.5 3 2

SU110 R & R REAR SPRING ASSY INCLUDE

REPLACEMENT OF BUSHES AND SHACKLE PINS

2.5 2.5 3 2

SU120 R & R FRONT/REAR HANGER BRACKET PER SIDE 2.0 2 2 2

SU130 R & R FRONT/REAR HANGER BRACKET BOTH

SIDES

4.0 4 4 4

SU140 R & R HELPER SPRING BRACKET PER SIDE 1.0 1 2 1

SU150 R & R HELPER SPRING BRACKET BOTH SIDES 2.0 2 4 2

SU160 R & R MAIN LEAF OR ANY OTHER LEAF PER

SPRING

3.0 3 4 3


131


SU170 REPLACEMENT OF U/I CLAMPS PER SPRING ASSY 1.5 1.5 2 1

SU180 R & R SPRING BUFFER ON CHASSIS (PER BUFFER) 0.5 0.5 0.5 0.5

SU190 R & R SPRING BUFFER ON SPRING ASSY (PER

BUFFER)

0.5 0.5 0.5 0.5

SU200 R & R SHOCK ABSORBER (PER SHOCK ABSORBER) 0.5 0.5 0.5 0.5

SU210 R & R SHOCK ABSORBER RUBBER BUSHES (BOTH) 1.0 1 1

SU220 R & R WEVELLER TYPE SPRING ASSY (PER SPRING) 2.0 2

SU230 R & R AIR SUSPENSION BELLOW (PER BELLOW) 3.0 3

SU240 R & R BOGIE (INCLUDING WHEEL REMOVAL) 9.0 9

SU250 R & R LEVELLING VALVE 1.0 1

SU260 R & R REAR LOCATION LINK (ONE SIDE) 7.0 7

SU270 R & R X BEARER BEAM 8.0 8

SU310 R AND R ANTI-ROLL BAR ASSEMBLY 1.0

SU330 R & R BELL CRANK LEVER 2.5 2.5

SU340 R & R TIE ROD 2.0 2

SU360 R & R LEVELVING VALVE AND OVERHAUL 2.0

ST100 R & R STEERING WHEEL 0.5 0.5 0.5 0.5

ST110 R & R STEERING BOX 2.5 2.5 2.5 2.5

ST120 R & R SECTOR SHAFT SEAL 2.0 2 2

ST130 R & R STEERING BOX AND O/H 5.5 5.5 5.5 5.5

ST140 REPLACEMENT OF STEERING COLUMN INNER

SHAFT/BUSHES

2.5 2.5 2.5 2

ST150 R & R AND O/H TRACK ROD/ DRAGLINK BALL

JOINT AND CHECK WHEEL ALIGNMENT

3.0 3 3 3

ST160 ADJUST STEERING CENTRE LOAD 0.5 0.5 0.5 0.5

ST170 R & R STEERING OUTRIGGER BRKT. 2.5 2.5 2.5

ST180 R & R STEERING UJ AND O/H 2.0 2 2 2

ST190 ADJUST MAX CUT SCREWS AND CHECK WHEEL

ALIGNMENT

2.0 2 2 2

ST200 DRAIN AND REFILL STEERING BOX OIL 0.5 0.5 0.5 0.5

ST210 R & R STEERING PUMP ASSY 3.0 3 3 3

ST220 R & R STEERING BOX ASSY (ZF/RANE) 3.0 3 3 3

ST230 PRESSURE SETTING AND MAX CUT ADJUSTMENT 2.0 2 2 2

ST240 R & R POWER RTEERING RESERVOIR 2.0 2 2 2

ST250 R & R POWER STEERING HOSE (1 NOS) 0.5 0.5 0.5 0.5

ST260 OVERHAULING & TESTING OF SPARE STEERING

BOX - HF

0.5 0.5 0.5

ST270 REPLACEMENTOF SIDE COVER SEALS (IN

VEHICLE) - HF

0.5

ST280 REPLACEMENT OF TOP COVER SEALS (IN

VEHICLE) - HF

0.5


132


ST290 REPLACEMENT OF SEALS ON SPARE STEERING

BOX - HF

0.5

ST300 OVERHAUL OF SPARE PUMP - HF 0.5

ST310 TESTING OF SPARE PUMP - HF 0.5

CH100 R & R CHASSIS ASSY COMPLETE/ RANDR CHASSIS

LONG

51.0 51 51

CH130 R & R FRONT CROSS MEMBER 5.5 5.5 7.5 5.5

CH140 R & R BUMPER (FRONT) 0.5 0.5 1 0.5

CH150 R & R TOW HOOK ASSY 1.0 1 1 1

CH160 R & R FLITCH BETWEEN FRONT SPRING BRACKET

PER SIDE

2.5 2.5 3 2.5

CH170 R & R TUBULAR CROSS MEMBER (PER CROSS

MEMBER)

5.0 5 2 5

CH180 R & R 2ND CROSS MEMBER 3.0 3 3

CH190 R & R CENTRE JOINT BEARING CROSS MEMBER 3.5 3.5 3.5

CH200 R & R REAR SPRING FRONT CROSS MEMBER 5.0 5 0.5 5

CH210 R & R REAR SPRING REAR CROSS MEMBER 5.0 5 5

CH220 R & R BOX FLITCH BETWEEN REAR SPRING

BRACKETS (PER SIDE)

1.5 1.5 1.5

CH230 R & R SHOCK ABSORBER BRACKET (TOP AND

BOTTOM)

1.0 1 1

CH240 R & R REAR MOST CROSS MEMBER 1.5 1.5 2.5 1.5

CH250 SERVICE WATER SEPARATOR 0.5 0.5 5 0.5

CH270 R & R SUB FRAME ASSEMBLY 30.0 30

CH280 R & R SPARE WHEEL CARRIER 0.5 0.5 0.5 0.5

CH290 R&R COUPLING BELLOW ASSY COMPLETE -

VESTIBULE

6.0

CH300 R&R DIESEL TANK BRACKET 2.5 2.5

TG100 R & R HYDRAULIC RAM AND O/H-FET 16.0 16 16

TG110 R & R HYDRAULIC RAM (TWO NO) AND O/H-UBT-

2516/2

16.0 16

TG120 R & R HYDRAULIC RAM (TWO NO) AND O/H-UBT

CO 3/10

16.0 16

TG130 R & R AND O/H CONTROL VALVE-FET 3.0 3 3 3

TG140 R & R AND O/H CONTROL VALVE-UBT 3.0 3 3

TG150 R & R AND O/H RELIEF VALVE 0.5 0.5 0.5 0.5

TG160 R & R AND OVERHAUL HYD. PUMP 4.0 4 4

TG170 DRAIN AND REFILL HYDRAULIC TANK 0.5 0.5 0.5 0.5

TG180 R & R AND CLEAN HYDRAULIC TANK 2.0 2 2 2

TG190 R & R AND O/H CONTROL LEVER ASSEMBLY 1.0 1 1 1

TG210 R & R CROSS HEAD 1.0 1 1 1


133


TG220 R & R HINGE BRACKETS (PER BRKT) 1.0 1 1 1

TG230 R & R PROPELLERSHAFT ASSEMBLY 1.0 1 1 1

TG240 R & R SUBFRAME-2516/2 30.0 30

TG250 R & R SUBFRAME-CO 3/10 20.0 20 20

TG260 R & R HOSE (PER HOSE) 0.5 0.5 0.5 0.5

TG270 R & R FIFTH WHEEL COUPLING 5.0 5

TG280 R & R FIFTH WHEEL COUPLING KING PIN 1.0 1

EL100 R & R STARTER MOTOR 0.5 0.5 0.5 0.5

EL110 R & R ALTERNATOR ASSY 0.5 0.5 0.5 0.5

EL120 R & R ALTERNATOR PULLEY (INCL. RANDR

ADJUSTMENT)

0.5 0.5 0.5 0.5

EL130 R & R BATTERY 0.5 0.5 0.5 0.5

EL135 R & R BATTERY ISOLATOR SWITCH 1.0 1

EL140 R & R BATTERY CARRIER 0.5 0.5 0.5 0.5

EL150 R & R HEADLIGHT ASSEMBLY 0.5 0.5 0.5 0.5

EL160 R & R HEAD LIGHT BULB (PER SIDE) 0.5 0.5 0.5 0.5

EL170 R & R HEADLIGHT RELAY 0.5 0.5 0.5 0.5

EL180 R & R COMBINATION SWITCH 0.5 0.5 0.5 0.5

EL190 R & R FLASHER UNIT 0.5 0.5 0.5 0.5

EL200 R & R HAZARD WARNING UNIT 0.5 0.5 0.5 0.5

EL210 R & R INDICATOR LAMP ASSY PER SIDE 0.5 0.5 0.5 0.5

EL220 R & R INDICATOR LAMP BULB 0.5 0.5 0.5 0.5

EL230 R & R BACK LIGHT ASSY 0.5 0.5 0.5 0.5

EL240 R & R BACK LIGHT ASSY BULB 0.5 0.5 0.5 0.5

EL250 R & R CAB INTERIOR LAMP 0.5 0.5 0.5 0.5

EL260 R & R BULB CAB INTERIOR LAMP 0.5 0.5 0.5 0.5

EL270 R & R ROOF MARKER LAMP 0.5 0.5 0.5 0.5

EL280 R & R STARTER SWITCH 0.5 0.5 0.5 0.5

EL290 R & R OTHER SWITCHES (PER SWITCH) 0.5 0.5 0.5 0.5

EL300 R & R HORN ASSY 0.5 0.5 0.5 0.5

EL310 R & R WIPER MOTOR 0.5 0.5 0.5 0.5

EL320 R & R WIPER ARM 0.5 0.5 0.5 0.5

EL330 R & R WIPER BLADE 0.5 0.5 0.5 0.5

EL340 R & R WIRING HARNESS 8.0 8 8 8

EL345 R & R EDC WIRING HARNESS 3.0 3

EL350 R & R AMMETER 0.5 0.5 0.5 0.5

EL360 R & R OIL PRESSURE GAUGE 0.5 0.5 0.5 0.5

EL370 R & R OIL PR. SWITCH (SENSOR UNIT FOR CARGO 0.5 0.5 0.5 0.5

EL380 R & R OIL PRESSURE GAUGE PIP 0.5 0.5 0.5 0.5

EL390 R & R SPEEDOMETER ASSY 0.5 0.5 0.5 0.5


134


EL400 R & R SPEEDOMETER CABLE 0.5 0.5 0.5 0.5

EL410 R & R WATER TEMPERATURE GAUGE 0.5 0.5 0.5 0.5

EL420 R & R WATER TEMPERATURE SENSOR 0.5 0.5 0.5 0.5

EL430 R & R AIR PRESSURE GAUGE 0.5 0.5 0.5 0.5

EL440 R & R AIR PRESSURE GAUGE PIPE 0.5 0.5 0.5 0.5

EL450 R & R FUEL GAUGE ON TANK/ DASHBOARD 0.5 0.5 0.5 0.5

EL460 R & R BULB OF INST. PANEL GAUGE/ WARNING

LAMPS (PER BULB)

0.5 0.5 0.5 0.5

EL465 DIAGNOSTIC LAMP 0.5 0.5

EL470 R & R FUEL TANK FLOAT UNIT (SENSOR) 0.5 0.5 0.5 0.5

EL490 R & R RPM / HOURMETER 0.5 0.5 0.5 0.5

EL500 R & R RPM / HOURMETER CABLE 1.0 1 1 1

EL510 R & R OIL GAUGE FLEXIBLE HOSE 0.5 0.5 0.5 0.5

EL520 R & R AIR GAUGE FLEXIBLE HOSE 0.5 0.5 0.5 0.5

EL530 R&R REVERSE BEEPER 0.5 0.5 0.5

BR100 R & R AIR LINE (1 PIPE / HOSE) 0.5 0.5 0.5 0.5

BR110 R & R AIR TANK ASSEMBLY 1.5 1.5 1.5 1.5

BR115 R & R BRAKE PEDAL 0.5 0.5 0.5 0.5

BR200 R & R AND O/H AIR COMPRESSOR-AL ENGINE 5.0 5 5 5

BR205 R & R AND O/H AIR COMPRESSOR-HINO ENGINE 3.5 3.5 3.5 3.5

BR210 R & R COMPRESSOR ASSY (INC RADIATOR) 2.5 2.5 2.5 2.5

BR215 CHECK AIRLINE FOR LEAKS AND RECTIFY 1.5 1.5 1.5 1.5

BR220 R & R D.B. VALVE 1.0 1 1 1

BR225 R & R AND O/H D.B. VALVE 1.0 1 1 1

BR227 R & R BRAKE SWITCH 0.5 0.5

BR230 R & R SYSTEM PROTECTION VALVE 0.5 0.5 0.5 0.5

BR235 R & R AND O/H SYSTEM PROTECTION VALVE 1.0 1 1 1

BR240 R & R UNLOADER VALVE AND O/H 1.5 1.5 1.5 1.5

BR245 R & R TC2 VALVE 1.0 1 1 1

BR250 R & R AND OVERHAUL TC2 VALVE 2.0 2 2 2

BR255 R & R RELAY VALVE 0.5 0.5 0.5 0.5

BR260 R & R AND OVERHAUL RELAY VALVE 1.0 1 1 1

BR265 R & R AIRLINE FILTER AND O/H 1.0 1 1 1

BR270 R & R STOP LIGHT SWITCH AND O/H 0.5 0.5 0.5 0.5

BR280 R & R AND O/H HAND CONTROL VALVE 2.5 2.5 2.5 2.5

BR285 R & R AND O/H MASTER CYLINDER 1.5 1.5 1.5 1.5

BR290 R & R LOW PRESSURE WARNING SWITCH 0.5 0.5 0.5 0.5

BR295 R & R EXHAUST BRAKE CONTROL VALVE 0.5 0.5 0.5 0.5

BR300 R & R AND OVERHAUL EXHAUST BRAKE

CONTROL VALVE

1.0 1.0 1.0 1.0


135


BR305 R & R EXHAUST BRAKE ASSEMBLY 0.5 0.5 0.5 0.5

BR310 R & R AND OVERHAUL EXHAUST BRAKE

ASSEMBLY

1.5 1.5 1.5 1.5

BR315 R & R COMPRESSOR HEAD AND OVERHAUL 2.0 2 2 2

BR320 R & R PALM COUPLING AND OVERHAUL 2.0 2 2 2

BR330 R & R DDU ASSEMBLY 0.5 0.5 0.5 0.5

BR340 OVERHAUL DDU ASSEMBLY 1.0 1.0 1.0 1.0

WL100 R & R WHEEL (ONE SIDE) 0.5 0.5 1 0.5

WL120 R & R EACH WHEEL DISC (INCL.WL100) 1.0 1 1.5 1

CB100 R & R CAB 10.0 10 10 10

CB110 R & R CAB MTG BRKT PER SIDE/ HINGE SUPPORT

BRKT

1.0 1 1

CB120 R AND R GRILLE 0.5 0.5 0.5

CB130 R AND R WINDSCREEN GLASS/BEADING 1.0 1 1

CB140 R AND R CAB TORSION BAR ASSY (RH) 1.0 1 1

CB150 R AND R CAB TORSION BAR ASSY (LH) 1.0 1 1

CB160 R AND R DOOR ASSEMBLY (PER SIDE) 1.0 1 1

CB170 RECTIFY DOOR GLASS WINDING MECHANISM

(PER DOOR)

0.5 0.5 0.5

CB180 RECTIFY DOOR LOCK MECHANISM (PER DOOR) 1.0 1 1

CB190 RECTIFY/REPLACE LOCK CYLINDER/KEY MECH

(PER LOCK)

1.0 1 1

CB200 GLS BDNG REPLMNT (PER GLS) EXT DOOR GLS

WNDSCR GLS

1.0 1 1

CB210 DOOR SLIDING GLASS/BEADING REPLACEMENT 1.0 1 1

CB220 DOOR ALIGNMENT (PER DOOR) 1.5 1.5 1.5

CB230 R AND R DRIVER SEAT 0.5 0.5 0.5

CB240 R AND R CO-DRIVER SEAT 0.5 0.5 0.5

CB250 REPLACE REARVIEW MIRROR 0.5 0.5 0.5

CB260 R&R CAB SUSPNSN (RR) BOTH SIDES FOR SLEEPR

CAB

2.0 2 2

CB270 R AND R CAB LIFTING PUMP (FOR SLEEPER CAB) 1.0 1 1

CB280 R & R WINDSCREEN WASHER COMPLETE ASSY 1.5 1.5 1.5

AS001 WEEKLY INSPECTION (TO BE CLAIMED / MONTH) 4.0 4 4 4

AS002 MONTHLY INSPECTION AS PER SCHEDULE 2.5 2.5 2.5 2.5

AS003 UNDER BODY WASHING AND LUBRICATION /

MONTHLY

4.0 4 4 4


136

28. FLAT RATE SCHEDULE FOR MACHINING JOBS

In Rupees


MC005 CRANKCASE LINE BORE 650.0 650 800 450

MC010 CRANKCASE MACHINE TOP SURFACE 350.0 350 400 300

MC015 CRANKSHAFT GRINDING - MAIN AND CON-ROD

JOURNALS

900.0 900 1000 750

MC025 CONROD BIGEND BORING (1 NO) 150.0 150 200 125

MC030 CONROD SMALL END BORING (1 NO) 60.0 60 60 40

MC035 CONROD BEND CHECKING 120.0 120 120 100

MC040 CRANK SHAFT LAPPING 150.0 150 150 150

MC045 CAMSHAFT GRINDING 150.0 150 150 150

MC050 CYL. HEAD SURFACE GRIND 225.0 225 225 225

MC055 RADIATOR FLUSHING AND PR TESTING

(INCLUDE. R

250.0 250 250 250

MC060 FIP CALIBRATION 300.0 300 300 300

MC065 INJ TESTING/ ADJUSTING OPENING PR / REPL 200.0 200 200 150

MC070 CL PR PLATE AND F/W FACING AND GRIND 100.0 100 100 100

MC075 BRAKE DRUM MACHINE TO SIZE (1 DRUM) 100.0 100 100 100

MC080 RECONDITIONING WHEEL DISC (ONE DISC) 750.0 750 750 750

MC085 SILENCER BOX CRACK REPAIR 250.0 250 250 250

MC090 SILENCER BOX MOUNTING BRACKET REPAIR 100.0 100 100 100

MC095 DIESEL TANK REPAIR 250.0 250 250 250

MC250 CRANKCASE LINE BORE 450 650 650 450

MC252 CRANKCASE MACHINE TOP SURFACE 300 350 350 400

MC254 CRANKSHAFT GRINDING – MAIN & CON ROD

JOURNALS

900 900 1000 750

MC256 CRANKSHAFT RENITRADE 1500 1500 1500 1750

MC258 CON ROD BIGEND BORING 125 150 150 200

MC260 CON ROD SMALL END BORING 40 60 60 60

MC262 CON ROD BEND CHECKING 100 120 120 120

MC264 CRANKSHAFT LAPPING 150 150 150 150

MC266 CAMSHAFT GRINDING 150 150 150 150

MC268 CYL HEAD SURFACE GRIND PER HEAD 225 225 225 225

MC270 RADIATOR FLUSHING & PRESSURE TESTING (INCL

R&R)

250 250 250 250

MC272 FIP CALIBRATION 300 300 300 300

MC274 INJ R&R & TESTING / ADJUSTING OPENING PRES 150 200 200 200

MC276 RADIATOR MINOR REPAIR, CORE LEAK, TANK

SOLDERING

150 150 150 150


137


MC290 INCIDENTAL CHARGES FOR AT SITE ATTENTION 250 250 250 250

MC291 CHARGES FOR TRANSPORTATION OF PARTS 100 100 100 100

MC300 WELDING DOME AREA CRACK IN REAR AXLE 500 500 500 500

MC301 SUB FRAME REPAIRING 5000 5000 5000 5000

MC302 CABIN FLOOR CRACK REPAIR 3000 3000 3000 3000

MC303 ALTERNATOR REPAIR 1500 1500 1500 1500

MC304 STARTER MOTOR REPAIR 5000 5000 5000 5000

MC305 CHASSIS CRACK WELD AND REPAIR 3000 3000 3000 3000

MC306 HOLE DRILLING IN CHASSIS OR CROSS MEMBER

PER SIDE

300 300 300 300

MC307 FABRICATION OF BRACKETS 1000 1000 1000 1000

MC308 TURBO CHARGER REPAIR / OVERHAUL 15000 15000 15000 15000

MC309 FIP REPAIR / OVERHAUL 15000 15000 15000 15000

MC310 RADIATOR REPAIR 500 500 500 500

MC311 CAC REPAIR 500 500 500 500

MC312 1613H FRAME REPAIR INCL PARTS 4500 4500 4500 4500

MC330 BELL CRANK LVR MACHINING 7 bus fitment 275 275 275 275

MC370 DDU REPAIR 3000 3000 3000 3000

MC510 VEH WASHING LUBNE & CHECKS AS PER POLICY 550 550 550 550

MC511 HUB GREASE FOR 4X2 HAULAGE 4 HUBS 1600 1600 1600 1600

MC512 HUB GREASE FOR 6X2 HAULAGE 6 HUBS 2400 2400 2400 2400

MC513 HUB GRESE TRACTOR 1 AXLE TRAILER 8 HUBS 3200 3200 3200 3200

MC902 2513 MK 1 TO MK II CONVERSION 775 775 775 775

MC903 CAMPAIGN MODFN FOR AIR TANK POSITION 500 500 500 500

MC904 STAG FITMENT OF BIGGER BRAKE CHAMBER 150 150 150 150

MC905 FRONT AXLE FASTENER TIGHTNESS CHECK 400 400 400 400

MC906 RH FLITCH REPLACEMENT MAV CAMPAIGN 800 800 800 800

MC907 LH FLITCH REPLACEMENT MAV CAMPAIGN 800 800 800 800

MC909 CNG CHECKING GAS LEAK IN DTC / PVT SECTOR 100 100 100 100

MC910 GSRTC CNG SAFETY CAMAPAIGN STAGE 1 180 180 180 180

MC911 4026 FLUWHEEL HOUSING MODIFICATION 6650 6650 6650 6650

MC912 GSRTC CNG SAFETY CAMAPAIGN STAGE 2 125 125 125 125

MC913 NEGATIVE FUSE LINK FITMENT DIESEL BUS 50 50 50 50

MC914 ADD ON WIRING HARNESS FOR CON SUP 75 75 75 75

MC915 MICO 4 ST RELAY STARTER 75 75 75 75

MC916 IVECO CNG CYL HEAD REPLACEMENT 1050 1050 1050 1050

MC917 OIL PUMP SHAFT 70 70 70 70

MC918 TCV FITMENT 280 280 280 280

MC919 CNG ACCELERATOR CABLE BKT MODIFICATION 250 250 250 250

MC920 CNG SAFETY CHECK GAS LEAK AND ELEC. 100 100 100 100


138


MC921 BOTH SIDE RR LEAF ADDITION 2518 MT(JNCL

PARTS)

- 6500 - -

MC922 CNG SAFETY CHECK GSRTC STAGE 3 80 - - -

MC924 SFC FES REINFORMCEMENT INCL PARTS 7000 7000 7000 7000

MC925 R&R FIP CAMPAIGN– RETAINING BKT 300 300 300 300

MC926 R&R FIP CAMAPAIGN – PRESALE VEHICLE 171 171 171 171

MC927 REFURBISHING FLOOD AFFECTED CHASSIS – VJW 182 182 182 182

MC928 SFC FES REINFORMCENET FOR PRESALE VEHICLE 3999 3999 3999 3999


139

29. DESPATCH OF FAILED ITEMS

All the failed items that are replaced under warranty have to be returned to AL, unless

specifically exempt by AL.

All the components that form part of claims accepted by AL will be displayed when the

dealer logs in with his user name and password to enable Dealer prepare the packing

list. The system will display the list of failed items to be returned to AL by the

designated plant in AL, viz., Ennore, Hosur1, Hosur2, etc.

In the event of a particular part not being available for returning, e.g., Anabond, quantity

of such item shall be entered in the ‘Perished Quantity’ field in the packing slip.

Similarly, in the case of a claim relating to fitment of a component that was not a part of

the original vehicle build, quantity of the components should be entered in the ’Short

fitment’ field in the packing slip.

The Dealer shall pack the failed items securely by adhering to the packing instructions

provided by AL and mark the destination of the consignments clearly, e.g., E1 for

Ennore. Individual components shall be tagged to identify the claim number.

AL shall arrange to pick up the consignments of failed components from the Dealerships

and transport them to the designated plants in AL. It shall be the responsibility of the

Dealer to pack the components and load them on to the transporter’s vehicle when the

transporter visits the outlet as per agreed schedule.

AL has dispensed with return of failed material from dealers of the following 6 states

J&K, Himachal Pradesh, Uttaranchal, Bihar, Jharkhand, and Assam. These dealers shall

store the failed material for a minimum period of 45 days from the time of successful

claim upload. Thereafter the material shall be defaced and scrapped. AL shall debit 5%

of the parts value computed against each claim towards salvage of parts . In case AL

demands return of material, dealer shall be issued a credit note for the 5% recovered in

claim settlement.

Upon receipt of a consignment in the manufacturing plants of AL, the Reliability Centre

in the plant will advise Dealer of shortages / damage to components.


140

30 MODE OF SETTLEMENT

Claims shall be submitted within 15 days from the date of completion of repairs by the

Dealer.

Claims accepted by AL will be approved for payment as soon as the failed material is

packed, handed over to the Transport and the GC Note number is keyed into the AL

System.

AL will prepare Pay Order for accepted Warranty Claims on the 5th, 15th and 25th of every

month.

Settlement to the Dealer by AL will be by way of a cheque or ECS or by book adjustment.


141

31 PAYMENT FOR PARTS REPLACED

Where Leyparts are used for warranty replacement, Dealers will be reimbursed the

UMRP of parts on the date of failure less dealer margin and taxes. This is the base rate

to which actual taxes plus Handling Charges (HC) will be added. If a locally purchased

item is used for warranty replacement, the dealer will be reimbursed the actual cost of

purchase of the locally purchased item not exceeding the cost (Base Rate + Taxes + HC)

of the Leypart.

Dealers will claim the UMRP as per the Parts Price List or the amendments issued from

time to time vide Parts Price Bulletins.

AL will calculate the payable value.

For each Pay Order the particulars of settlement listed below will be made available in

the cdb.ashokleyland.com site, which can be viewed or downloaded:

- Claim Number & date

- Chassis Number

- Date of Failure

- Date of Sale

- Type of Claim

- Part Number with description

- Quantity, Effective date of Price Bulletin

- Discount Percentage / Base Rate / Amount Taxes

- Handling Charges Percentage & Amount and

- the Payable Value


142

32. PAYMENT OF LABOUR CHARGES

Labour charges payable are the same for AL items as well as ancillary items.

The man-hour rate payable to various categories of Dealers is given in Section 37.

The Repair Operation Time Schedule for warranty jobs applicable to various models of

vehicles is given in Section 29.

For machining jobs, flats rates will be paid as per the schedule in Section 30.

Warranty labour charges shall be claimed by the Dealers, applying the man-hour rate

based on the Repair Operation Time Schedule. Where flat rates are applicable, the same

shall be claimed.


143

33. MANHOUR RATE APPLICABLE TO VEHICLE DEALERS

The rate per man-hour is based on the classification of Dealer workshop as ‘Metro’ or

‘Non Metro’.

The rate payable for ‘Metro’ dealers is Rs.75/- per man hour and the rate payable for

‘Non Metro’ Dealers is Rs.65/- per man hour.

Those located in the following cities are considered as ‘Metro’ Dealers and all others are

treated as ‘Non Metro’ Dealers:

Region City

North Delhi, Gurgaon, Faridabad, Jaipur,

Chandigarh

East Kolkata, Guwahati

West Mumbai, Ahmedabad

South Chennai, Bangalore, Secunderabad, Cochin

The rate payable to ALASCs is Rs.70 per man hour irrespective of the location of the

ALASC.

The labour rate for presale vehicle attention would be 75% extra.


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34. PAYMENT OF LABOUR CHARGES TO SUB-DEALERS/ALHRCS

In case sub-dealers render warranty attention, Dealers shall pay them at the following

rates without waiting for settlement from AL. These are the minimum rates

recommended by AL.

Dealer category Rate per man hour to be paid (Rs.)

Metro Dealer 56

Non Metro Dealer 49


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35. PAYMENT OF INCIDENTAL EXPENSES FOR SERVICE RENDERED

OUTSIDE THE DEALER WORKSHOP

Over and above the rates mentioned, in case it becomes necessary for a Dealer to carry

out warranty repairs on a vehicle outside the workshop, the Dealer will be paid:

i) Premium of 50% of the warranty labour rate or Rs.150/- whichever is higher

towards incidental expenses;

ii) Travel expenses at Rs.5/- per km if a Mobile Service Vehicle

is used and Re.2/- per km otherwise

Premium of 50% is not payable towards jobs outsourced by the Dealer, i.e., where ROT

codes starting with MC are used.

The relevant information with regard to location, distance, number of trips and whether

Mobile Service Vehicle was used has to be furnished by Dealer in the Warranty Claim

Header file.


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36. ELIGIBILITY/PERIODICITY OF FREE SERVICES

AL customers can avail free services offered by AL anywhere in India in any authorised

dealer’s workshop on production of the Free Service Coupon Book. Eligibility and

periodicity of Free Services for various products is given in the schedule appearing

below.

SCHEDULE GIVING ELIGIBILITY/PERIODICITYOF FREE SERVICES FOR

VARIOUS MODELS OF VEHICLES

Model PDI 8000 Kms 16000 Kms

Private Sector

MDV 4x2 and 4x4 Models Yes Yes Yes

MDV 6x4 and 6x2 Models Yes Yes Yes

ICV and LCV Models Yes Yes Yes

STUs and Project (Non Defence)*

MDV 4x2 and 4x4 Models Yes Yes No

ICV and LCV Models Yes Yes No

Project (Defence & Para Military)

MDV 4x2 and 4x4 Models - Chassis/CBU Yes No No


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ICV and LCV Models Yes No No

* Project (Non-defence) will cover sales to Police, Municipal Corporations,Fire Service

etc.


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37. TIME LIMIT FOR AVAILING FREE SERVICES

The time limit within which Free Services must be availed is given below.

MODEL 8000 Kms 16000 Kms

Number of days from the

date of Registration

MDV Haulage and Pass Models 45 90

LCV and ICV Haulage & Pass Models 55 90

Tractor and Tipper Models 60 120

Supplies to Govt/Educational Institutions 60 120


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38. LABOUR CHARGES PAYABLE TO DEALERS

Dealer should carry out all the jobs given in the check-list appearing on the reverses of

the free service coupons.

The customer’s signature with date shall be obtained on the free service coupons as

evidence of having carried out the service.

Labour charges payable to Dealers for carrying out Free Services is given in the schedule

referred to in Section 39.

Dealer shall submit Free Service bills online. The free service coupons after obtaining

the signature of AL SE shall be submitted to the Regional Office of AL.

In case it becomes necessary for a Dealer to carry out a Free Service at the customer’s

premises on Tippers a higher rate of labour charges will be allowed as mentioned in the

schedule in Section 39. However the time limit specified in Section 37 for carrying out

Free Services has to be adhered to in all cases.


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39. SCHEDULE OF LABOUR CHARGES PAYABLE TO DEALERS FOR

CARRYING OUT FREE SERVICES

MODEL LABOUR CHARGES

PDI 8000 Kms 16000 Kms

Private Sector

MDV 4x2 and 4x4 Models 550 700 800


LCV and. ICV Models 350 500 600

-

STUs & Project (Non-Defence)

MDV 4x2 and 4x4 Models 300 250 -

LCV and.ICV Models 200 175 -

-

Project (Defence & Para Military)

MDV 4x2 and 4x4 Models 550 - -

MDV 6x4 and 6x2 Models 550 - -


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For Free Services carried out on Tipper vehicles atsite, an additional sum of Rs 125/- per

service is payable

Project (Non-defence) will cover sales to Police, Municipal Corporation, Fire Service, etc.


152

40. LABOUR CHARGES PAYABLE TO SUB-DEALERS/ALHRCs FOR CARRYING

OUT FREE SERVICES

In case, sub-dealers or ALHRCs carry out free services, Dealers shall pay them at the

following rates without awaiting settlement from AL.

Model PDI 8000 Kms 16000 Kms



LCV and ICV 4x2 Models 280 400 480

For Free Services carried out on Tipper vehicles at-site, an additional sum of Rs 100/- per

service is payable


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41. OIL CHANGE DURING PDI

During PDI, the Dealer shall replace the factory filled oil as advised by AL from time to

time. .

For such oil replacement, the cost of oil plus taxes (actual incidence of Sales Tax,

Surcharge thereon, and Octroi / Entry Tax) will be reimbursed to Dealers on submission

of bills along with the coupons to the Regional Office.

The details of the basic price of recommended oils are given in Section 42.

ELIGIBILITY FOR FREE OIL CHANGE DURING PDI

MODEL ELIGIBLE FOR FREE OIL

CHANGE DURING PDI

(Yes/No)

Sale to Private Sector Yes

Sale to Project (Non-Defence) Sector No

Sale to STU sector No

Sale to Project (Defence* & Para Military Sector) Yes

Project (Non-defence) sector will cover sale to Police, Municipal Corporations, Fire

Service, etc.

* applicable only to chassis / fully built vehicles.


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42. BASIC PRICE OF RECOMMENDED OILS

Sl.

No.

Unit / Application Grade / Brand Rate (Rs

/Lit)

1 BS 2, 3 engine Superfleet LE Max 15W-40 168.00

2 BS 1 engine Superfleet Max 15W-40 151.00

3 Gas engine Gulfco 1049 Max 156.00

4 Coolant Eurocool Max 126.00

5 Hydraulic Clutch and Brake Fluid Brake Fluid Max DOT 3 188.00

6 Gearbox oil / Steering (Gear (Manual) Gear XP Max 90 150.00

7 Rear Axle Spiral drive Gear XP Max 140 138.00

8 Rear Axle Hypoid Drive Gear DB Max 85W-140 165.00

9 Power Steering Power Steering Fluid Max 141.00

10 Long Life Wheel bearing grease Crown Max RR 3 148.00

11 Grease various applications MP Grease Max 2 141.00

12 Tipping Unit Harmony AW Max 32 115.00

Rate given is the basic price of oil and dealers will be reimbursed applicable taxes

over and above the basic price.


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43. ABBREVIATIONS

AL - Ashok Leyland Limited

AL SE - Ashok Leyland Service Engineer

ALSC - Ashok Leyland Authorized Service Centre

CVCT - Comet, Viking, Cheetah, Tusker range

DGM - Deputy General Manager

GC - Goods Consignment

GVW - Gross Vehicle Weight

GTW - Gross Train Weight

HQ - Head Quarters

NDP - Net Dealer Price

O/H - Overhaul

PDI - Pre Delivery Inspection

PPR - Product Performance Report

RC - Registration Certificate

RLW - Registered Laden Weight

RO - Regional Office

ROT - Repair Operation Time

R & R - Remove & Refit


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RSE - Regional Service Engineer

STU - State Transport Undertaking

VOR - Vehicle Off Road

warranty policy vehicle sep 2008

Documents

warranty procedure

terms of warranty

warranty terms

al warranty period

warranty policy amendment

scope of warranty

warranty policy procedures

als warranty policy