TATA LPT 613 User Manual
Tata
LP / LPT 613 EURO-II
Operator’s Ser vice Book
(The contents given in this book are not binding; are subject to change without
notice and are for illustration purposes only)
Edition : XLI/NE/J-2007/001-500
International Business (CVBU)
Mumbai, INDIA
Dear Customer,
We are pleased to hand over your Tata LP/LPT 613 EURO-II Vehicle,
manufactured by Tata Motors where QUALITY is the watchword and major
attention is paid even to minor details at all stages of manufacture of your
vehicle.
PLEASE DO READ THIS BOOK. It helps you to know your vehicle better, to ensure
your vehicle is ready for operation at all times and to obtain better performance
at optimum operating costs.
All lubricating and maintenance tasks are to be carried out at the specified
service intervals.
Some of the items / accessories / features shown / given in this book may not
be fitted on your vehicle, but they are applicable for other versions of vehicles.
For any further assistance, please contact the nearest Tata Diesel Vehicle Dealer
or Our Office at following address.
Tata Motors Limited
International Business CVBU (Customer Support)
Shah House, Shivsagar estate,
Worli, Mumbai - 400 018,
India.
Ph No. : (009122) 6757 7239 / 7200
Fax No. : (009122) 6757 7275
E - Mail : telcoexp@tatamotors.com
We wish you good luck and prosperity.
iii
CONTENTS
1. General
1.1 About Tata LP/LPT 613
1.2 Environment protection .......................................................... 5
1.3 Important tips for driver .......................................................... 7
1.4 Tips for maintenance ..............................................................10
1. 5 Body building .............................................................................1 1
1.6 Additional fitments..................................................................20
1.7 Additional provisions (electrical) .......................................30
2. Vehicle Handling
2.1 Vehicle identification..............................................................37
2.2 Location of aggregate numbers .........................................41
2.3 Instrument panel ......................................................................43
2.4 Switches, gauges & indicators..............................................44
EURO-II ................................................ 3
2.5 Driving controls ......................................................................... 5 5
2.6 Turbocharger..............................................................................57
2.7 Charge air cooler .......................................................................58
2.8 Clutch booster ........................................................................... 59
2.9 Cab tilting ....................................................................................60
2.10 Heating.........................................................................................65
2. 11 Driver seat & seat belt ............................................................6 6
v
3. Driving
3.1 Starting the engine ..................................................................71
3.2 Driving .........................................................................................7 2
3.3 Stopping the engine ...............................................................75
3.4 Special operating conditions...............................................76
3.5 Fuel economy ............................................................................. 78
3.6 Do it yourself ..............................................................................79
4. Maintenance procedure
4.1 Air intake system ......................................................................83
4.2 Fuel system ................................................................................. 85
4.3 Lubrication system ..................................................................87
4.4 Cooling system. .........................................................................89
4.5 Clutch............................................................................................92
4.6 Gearbox........................................................................................94
4.7 Propeller shaft ...........................................................................95
4.8 Front axle & rear axle...............................................................9 6
4.9 Power steering ..........................................................................97
4.10 Brake system ........................................................................... 101
4.11 Springs .......................................................................................114
4.12 Centre flap................................................................................115
4.1 3 Tilt cab .......................................................................................11 6
4.1 4 Wheels and tyres .................................................................... 11 7
4.15 Electricals..................................................................................121
4.16 Preservative treatment .......................................................128
4. 17 Care and cleaning.................................................................. 131
vi
5. Technical information
5.1 Technical specifications...................................................... 135
5.2 Aggregate filling capacities .............................................. 140
5.3 Lubrication points ................................................................. 1 41
5.4 Tightening torques ................................................................ 143
6. Fuel, lubricants and coolants
6.1 Fuel..............................................................................................149
6.2 Lubricants................................................................................. 150
6.3 Coolant ...................................................................................... 152
7. Service recommendations
7.1 Special instructions .............................................................. 155
7.2 PDI...............................................................................................156
7.3 Service schedule ....................................................................159
7.4 Record of services performed .......................................... 168
7.5 Record of repairs performed ............................................. 1 70
vii
1. GENERAL
1.1 About Tata LP/LPT 613
EURO-II .......................... 3
1.2 Environment protection....................................5
1.3 Important tips for driver .................................... 7
1.4 Tips for maintenance....................................... 1 0
1. 5 Body building ......................................................11
1.6 Additional fitments...........................................20
1.7 Additional provisions (electrical)................30
1
1.1 About TAT A LP/LPT 613 EURO-II General
TATA LP/LPT 613 EURO-II full
forward control chassis in truck & bus
versions are available with following
options :
● 3.8 meter wheel base for truck
& bus.
● Tilt cabin chassis with / with out
load body for trucks.
● Cowl chassis with windshield
glass / cowl chassis with front
end structure only for bus.
● LHD versions.
● Engines conforming to Euro II
norms with matching power
train.
● Various colour combinations for
cabin/ load body in truck version.
● With / with out power take off
and provision for power take off
in truck.
● Fuel tank capacity 120 litres.
reliability and ease of
maintenance.
Short wheel base and narrow width
gives them high maneuverability,
ideal for all applications.
TATA 697 TCIC direct injection
engines are fitted with dry type
cylinder liners for long life and easy
overhaul.
Vehicles meeting Euro II norms are
fitted with rotary type fuel injection
pump, turbocharger, air after cooler,
high capacity dry typ e air filte r, et c.
A radiator auxiliary tank is provided
for convenient coolant filling.
Good visibility, hydraulic power
steering, 5 speed synchromesh gear
box with remote shift arrangement,
hydraulically actuated clutch, self
cancellation turn signals lever , tinted
wind shield glass, etc. enhance
driving comfort.
● Diagonal ply / radial ply tyres for
both truck & bus versions.
Optional fitments include
● Engine cold start device
● Cab heating
● Driver seat belt warning device
● Front fog lamps
● Rear under run protection
device/ side under run
protection device for trucks.
These incorporate well proven
features of TATA vehicles to give
economic life cycle cost, high
S Cam full air brake system with
air dryer, nylon brake pipes and load
conscious relief valve in rear brake
circuit makes driving more safe.
Service brakes are supplemented by
engine exhaust brake, coupled with
service brake operation. This
enhances life of brake linings, brake
drums & tyres.
Provision for ABS brakes.
An exhaust brake isolator switch
has been provided on instrument
panel. Exhaust brake can be made
inoperative whenever required by
means of this switch.
3
1.1 About TAT A LP/LPT 613 General
Steering is provided with steering
lock cum ignition switch as a
safety and security of the vehicle.
Engine is started and stopped by
means of this switch. Battery cut off
switch in bus version provides
additional safety for electrical system.
Wide centre flap at front enables
easy access to points of daily
maintenance.
Tilt cabin with torsion bar assistance
on truck version enable effortless
operation of cabin tilting / lowering.
It also provides ample space to reach
engine / power train for inspection /
maintenance.
Exhaust system with bigger silencer
considerably reduces noise level.
Different versions of exhaust piping
lay out are available to meet country
specific regulations.
Proper and timely maintenance
and servicing as recommended in
this book will ensure trouble-free
operation over long life.
4
1.2 Environmental protection General
Environmental protection
TATA MOTO RS is committed to
produce vehicles using
environmentally sustainable
technologies. A number of
features have been incorporated in
Tata vehicles which have been
designed to ensure environmental
compatibility throughout their life
cycle. We would like to inform you
that your vehicle meets appropriate
environmental norms and this is
being regularly validated at all
stages of manufacturing .
As a user, you too can protect
environment by operating your
vehicle in a proactive manner. A lot
depends on your driving style and
the way you maintain your vehicle.
We are giving below a few tips for
your guidance.
Driving
● Avoid frequent and violent
acceleration.
● Do not carry any unnecessary
weight as it overloads the
engine.
● Avoid using devices requiring
high power consumption during
slow traffic conditions.
● Monitor fuel consumption
regularly and if it shows a rising
trend, get it attended at Tata
authorised workshop.
● Switch off engine during long
stops at traffic jams or signals. If
situation demands that engine
be kept running, avoid frequent
revving up of engine. Also avoid
frequent stopping and
restarting, if uncalled f or.
● It is not necessary to rev up the
engine before turning it off as it
unnecessarily burns fuel.
● Shift to higher gears as soon as
possible. Use each gear upto
2/3rd of its maximum engine
speed. A chart indicating gear
shifting speed is given in the
manual.
Maintenance of the vehicle
● Ensure that recommended
maintenance is carried out
regularly at Tata authorised
workshops.
● As soon as you see any leakages
of oil, fuel, air or coolant get it
attended immediately .
● Use only recommended grades
of lubricants and clean/
uncontaminated fuels.
● Get your vehicle checked for
emission periodically by Tata
authorised workshop.
● Ensure that fuel filter, air filter, oil
filter, breathers are periodically
checked and if required, replace
the same by only genuine parts.
● Do not pour used oils or
coolants into sewage drains,
garden soil or open streams.
Dispose used filters and
batteries in compliance with
current legislation.
5
1.2 Environmental protection General
● Do not allow unauthorised
agencies to tamper engine
settings or to carry
modifications on the vehicle.
● Never allow the vehicle to run
out of fuel, which results in
misfiring of engine.
● Parts like brake liners, clutch
disc may contain asbestos. Use
vacuum cleaner for cleaning
these parts. Do not use
compressed air for cleaning
these parts which may spread
dust in atmosphere.
While carrying out servicing or
repairs pay keen attention to
following parts which can affect
exhaust emissions.
1. Fuel injection pump, injectors/
nozzles.
2. Air intake and Exhaust system
especially for leakages.
This book contains further
information on driving precautions
and maintenance care leading to
environment protection. Please
familiarise yourself with these
aspects before driving.
3. Cylinder head for valve leakage.
4. All filters such as air, oil and fuel
filters.
5. Turbo charger (Euro II)
6. Air after cooler (Euro II)
6
1.3 Important tips for driver General
1. Use only recommended oils and
lubricants.
2. Always use recommended
antifreeze agents in cooling
system to avoid deterioration of
engine components due to
corrosion. After filling coolant, fit
auxiliary tank cap firmly, to keep
cooling system pressurised.
3. Maintain correct tyre pressure to
ensure better tyre life.
4. Always fit genuine radiator cap
for pressurised cooling system.
5. New tyres do not give
maximum grip straight away and
should therefore be run-in at
moderate speeds for first 100
km. This will help to make tyres
last longer.
6. New brake linings must always
be run-in, they do not have
optimum friction properties
during first 200 kms.
7. Avoid mixing of different grade
of lubricants or clutch fluids
during top up.
8. Run the engine in low idling
speed for atleast three minutes
after starting and before
shutting off. (Applicable for
turbocharged engine)
9. Always start moving the vehicle
in first gear.
10. Operate engine in correct
temperature range i.e. between
60OC & 100OC.
11. Engine oil / coolant levels have
to be checked daily. Drain water
from fuel water separator daily.
12. In case of air lock in fuel system,
bleeding should be done on
high pressure side of fuel filters,
drain manifold and high
pressure lines. Ensure that lift
pump operation is satisfactory
and proper fuel delivery takes
place while bleeding out air.
13. Avoid cranking of engine for
more than 30 seconds. A gap of
2 minutes should be left
between successive attempts.
14. Check battery every week and
top up electrolyte, if necessary.
Keep battery terminals clean and
cable joints tight. Apply vaseline/
petroleum jelly on terminals.
15. Watch service indicator of dry
type air filter (Euro II). Indication
of same is given on instrument
cluster. If it blinks continuously
then clean the air filter housing
and replace primary cartridge.
16. Observe correct polarity while
connecting alternator terminals
and battery cables.
17. For operating vehicles in
extremely cold climates and
high altitudes contact Tata
authorised workshop to seek
advice.
18. Do not use kerosene as fuel. It
reduces engine and fuel pump
life.
7
1.3 Important tips for driver General
19. Do not use clutch pedal as a foot
rest when driving. This will cause
premature clutch lining wear.
20. Do not coast vehicle i.e. drive
with engine switched off. This is
dangerous and affects life of
gear box.
21. Do not fit bigger size tyres. Do
not over or under inflate tyres.
This reduces tyre life.
22. Do not top up coolant in auxiliary
tank by pouring cold coolant in
hot engine. Cylinder head may
crack.
23. Do not overfill engine oil in
sump. This may cause engine
smoking and high engine oil
consumption.
24. Do not engage ignition key in
starting position, after the
engine has fired. Release it
immediately. If not, starter
pinion and / or flywheel ring
gear will be damaged.
25. Do not run alternator with out
battery or disconnect any lead of
alternator while engine is
running.
26. Do not keep accelerator at full
throttle during engine cranking.
After starting, run engine at idle
speed till such time oil pressure
builds up.
27. Do not clean exposed painted
surface or windscreen with
petroleum products i.e. diesel,
kerosine & petrol, etc.
28. When air / fuel / oil filter
cartridges are replaced, destroy
old cartridges to prevent their
reuse.
29. Ensure that air intake hoses are
free from punctures, cuts and
damages.
30. Always fasten seat belt while
driving. Same is applicable for
co-passenger, wherever seat
belt is provided.
31. Do not use mobile phone while
driving.
32. Do not adjust seat belt while
driving.
33. For first 2000 kms, restrict speed
limit to 60 kmph in top gear
with 1500 kg pay load.
34. Avoid panic braking.
35. Drive on lower gears on steep
down gradient, thus avoiding
excessive braking & brake over
heating.
36. Primary lock lever on drive away
chassis is secured with bolt and
nut as safety precaution.
Replace this with a pad lock. This
will enable cab tilting only after
unlocking pad lock. Fitment of
pad lock will avoid unauthorised
tilting of cabin.
37. Ensure gear shifting lever in 2nd
gear position before tilting/
lowering cab.
38. Disconnect alternator terminals
before carrying out any welding
work on chassis/body.
8
1.3 Important tips for driver General
39. Engagement / disengagement
of power take off (optional
fitment on trucks) needs to be
done only when gear lever is in
neutral position & engine
running at idling speed.
40. Engine exhaust brake isolator
switch has to be kept ON always,
unless & until exhaust brake
isolation is required.
41. Radial tyres are to be balanced
whenever they are removed
from wheel rims. Balancing
weights should not exceed
maximum permissible limits.
9
1.4 Tips for maintenance General
1. Use only recommended filters
for air intake, engine oil and fuel
system. Replace them at
recommended intervals.
2. Before building the body, study
recommended body building
practices.
3. Disconnect alternator terminals,
while carrying out electrical
welding.
4. Never use water alone in the
coolant system. Always use
mixture of 50% clean water and
50% antifreeze agent for
topping up and for change.
Always carry a five litres can of
properly mixed coolant for
topping up enroute, if necessary.
5. Get the cause of low engine oil
pressure investigated at Tata
authorised workshop.
6. Any change in clutch pedal free
play is to be immediately
investigated.
springs or axles for carrying
higher payload. It will result in
premature failure of aggregates
and deprive you of warranty
benefits.
11. Dust accumulated in radiator fins
should be cleaned by blowing
compressed air at low pressure
from inner side of radiator.
Please do not clean with
pressurized water jet as it will
deform radiator fins.
7. Get your vehicle serviced at T at a
authorised workshop at
recommended intervals.
8. Use only recommended grades
of oils for all aggregates.
9. All services / repairs to be carried
out at Tata authorised workshops
only.
10. Do not reinforce chassis frame,
Helping you to obtain efficient trouble-free service from your
TATA DIESEL VEHICLE is our business.
10
1.5 Body building General
Body building guidelines
It is important to ensure that the body
is fitted to chassis in such a way that
the load imposed is transmitted
correctly. At the same time the rigidly
mounted body must flex with the
frame. Care should be taken to
ensure that body and chassis are
compatible. An example of bad
selection would be the construction
in which a short body is made on a
long wheel base. In this case, it
becomes necessary to shorten
chassis rear overhang to
accommodate body. As a result
centre of gravity moves forward and
a greater load than that desirable is
imposed on front axle.
It is also essential that careful
consideration be given to movement
or modification of electrical wiring,
electrical equipments, brake
connections, brake piping, extension
of chassis rear over hang, relocation
of chassis components to ensure
good performance in operation.
Position of roof luggage carrier
(for LP model)
Roof luggage carrier should be placed
to get the centre of gravity ahead of
rear axle centre line (min . 500 mm).
Height of roof luggage carrier should
be minimum in order to reduce wind
resistance.
Outrigger for door post
When a door has to be located at a
place where cross bearers cannot be
mounted due to positioning of
chassis aggregates at that location,
outrigger assembly should be made
for door post.
Post to waist rail joints
Gusset plates are welded to
U-channel / Z-channel waist rail.
The welding of the gusset to the
waist rail should be intermittent.
Wheel arch dimensions
T o accommodate wheels , side frame
is formed to a suitable shape called
wheel arch.
To pr even t tyre fouling with body on
bad roads, recommended dimensions
of wheel arch should be maintained.
11
1.5 Body building General
Notes
1. Keep body weight minimum
by selecting proper materials
and designs. This will save fuel
and increase tyre life.
2. Use curved window glass, avoid
sharp corners and protruding
out destination boards to
reduce wind resistance.
3. Select body dimensions,
seating space and gangway
width to comply with current
government regulations.
4. Ensure ease of removal and
assembly of various aggregates
like gearbox, suspension,
battery, spare wheel etc.
Provide flaps/cut outs for
servicing.
5. De-rust, phosphate and apply
primer to the body skeleton
before fixing panels.
9. Do not clamp bus body cross
bearers to chassis cross
members.
10. No body mountings should foul
with any chassis aggregate or
frame cross member.
11. Avoid practice of cutting
chassis cross member for
mounting of ‘U’ bolts .
12. Do not extend chassis rear
overhang.
13. Avoid eccentric mounting of
cross bearers.
14. Do not use balata packing more
than 6 mm thick for cross
bearer mounting. This will
result in premature perishing
and damage to chassis long
member. In case thicker
packing is required, use steel
plates to compensate
alongwith 6 mm balata packing.
6. Use zinc plated hardware of
standard quality for various
body joints.
7. Protect instrument panel,
steering wheel, driver ’s /codriver’s seats, clutch fluid
containers, hoses etc. from
damage while carrying out
structural work.
8. Do not drill or weld chassis
frame or remove any rivet. Do
not use chassis or leaf spring as
electrical earthing point during
welding.
12
15. Avoid ‘U’ bolts touching chassis
long members. This should be
done by using aluminium alloy
packing between ‘U’ bolt
bottom radius and long
member bottom flange.
16. As far as possible, avoid post
location over wheel arch.
17. No modification to front face
of cowl should be attempted
which would restrict air flow to
the radiator and air cleaner.
Reducing the height/width of
centre flap or closing louvers
provided on cowl front face
are to be avoided.
1.5 Body building General
18. No restriction should be placed
beneath the remote mounted
air filter. Provide sufficient
clearance for fitment and
removal of air cleaner.
19. Air intake hoses are not to be
disturbed during body
building. However, if hoses are
removed for any reason, cover
turbocharger / air after cooler
and intake manifold openings
with suitable plastic caps to
avoid dust foreign particles
entry, till such time hoses are
connected back. Clamps
should be properly tightened
during this operation.
20. Do not reroute air intake,
coolant and fuel lines.
21. Do not keep auxiliary tank cap
open so as to avoid
contamination of coolant with
dust and foreign material.
22. Disconnect battery and
alternator connections before
starting any electrical welding
on chassis/body.
23. Protect radiator / air after
cooler from weld spatters and
external mechanical hitting,
which might damage the core
of radiator / air after cooler.
25. Do not use suspension spring
pack for earthing or to check
continuity while carrying out
arc welding. Welding spatters
will lead to breakage of spring
leaves.
26. Additional air connections for
accessories like air horn, etc. to
be taken only from port 24
(auxiliary port) of system
protection valve. Such
connections should not be
taken from either service brake
circuits or parking brake circuit.
27. Provide suitable hinged flaps
on the body skirt to facilitate
draining of air tanks and to
drain water from fuel water
separator .
28. Do not allow body builder to
drill holes on chassis frame or
extend rear overhang.
29. Do not flash alternator leads to
check for current flow.
30. Do not mask head lamp lens
with black paint. If done, this
will reduce head lamp light
intensity.
24. Protect auxiliary tank from
weld spatters and mechanical
damage. Use proper cover to
protect radiator and auxiliary
tank during welding in their
vicinity.
13
1.5 Body building General
CANVAS
PA CKING
Section - AA
‘U’ Bolt
fastening with
wooden runner
1. Hex. nuts M 16 x 1.5, -8.8 quality
2. Plate washer
3. Wooden runner
4. Steel runner
5. ‘U’ bolt 16 Ø
6. Chassis long member
7. Aluminium alloy packing
Body building
Load body should be mounted with
the help of ‘U’ bolts and must not be
fixed on to the chassis with the help
of bolts and nuts by drilling holes in
chassis frame. This weakens the
chassis frame which is liable to crack.
Do not reinforce, weld or drill holes
in the chassis frame. Use six ‘U’ bolts
to fasten the runners on either side
of chassis long member. Tighten ‘U’
bolts nuts (M 16 x 1.5, - 8.8 quality)
to 22 mkg. torque.
Section - AA
‘U’ Bolt
fastening with
steel runner
A typical method in which the body
should be mounted on chassis is
shown in figure.
14
1.5 Body building General
Polyamide (PA) nylon tubing for
air brake
Your vehicle is fitted with latest
generation polyamide (PA) nylon
tubing for air brake.
PA material is preferred for this
application for :
● Excellent chemical resistance
(against fuel, battery acid,
hydraulic oils etc.)
● Dimensional stability and impact
resistance (against gravel throw
from tyres).
● Suitable working temperature is
- 40ºC to 100ºC constant
working and upto 130º C peaks.
● PA is 7 to 8 times lighter than
metal.
● Eliminates rusting problem, gives
much lower leakage.
● Rust particles are not generated
(like in metal tubes) and thus
protects valves etc.
● Check that PA tubes is not
rubbing against any other object
on the vehicle such as frame,
bracket or connectors.
● In case of repair, use only plastic
coated clamps for clamping of PA
tubes.
● Ensure that PA tube is not
touching :
(a) Hot objects such as exhaust
pipe
(b) Sharp objects such as
brackets or sheet metal parts.
(c) Moving objects such as
propeller shaft.
Preventive maintenance for PA
nylon tubing
● Check whether all clamps are in
place and suitably tightened.
● Check whether spiral cover is in
place.
● Check that all end fittings are
properly assembled.
● Check that PA tubes follow
routing as per original vehicle.
15
1.5 Body building General
Guidelines and precautions for
nylon (PA) tubing.
Welding and gas cutting
Cover PA tube with suitable object
such as metal sheet at the time of
welding and gas cutting. This will
avoid welding spatter and molten
Unprotected areas while welding
may damage PA tube
Cover PA tube before welding
metal from falling on the PA tubes
and creating a hole in the PA tube.
Unprotected areas while gas cutting
may damage PA tube
Cover PA tube before gas cutting
16
1.5 Body building General
Hot objects
Take care that PA tubes do not touch hot objects such as exhaust pipe. This will
avoid burning or melting of PA tube.
Avoid PA tube to touch exhaust pipe Do not light fire near P A tube
Clamp PA tubes properly to avoid coming in contact with hot objects
Sharp objects
Take care that PA tubes do not come in contact with sharp objects. This will
avoid cutting of PA tubes.
P A tubes should not touch sharp objects Follow original routing of PA tubes
17
1.5 Body building General
Loose fitments
Do not allow loose fitting of PA tube.
Avoid loose fitting of PA tube
Ensure proper clamping of PA tubes
Misuse
Do not step or hang on connected PA tube. Doing so, will lead to damage of
PA tube at the clamps or near end fitting, resulting in leakage.
Do not step on or hang on to PA tube
18
1.5 Body building General
Tube Fitment
In case refitting of PA tube is required
z Follow original routing of PA
tube.
z Take care that PA tubes are not
forcibly bent or fitted.
Do not tighten nut without holding PA
tube
Hold PA tube before tightening nut
Twisted tube
z Use plastic coated clamps.
z Use both hands while fitting PA
tube. This will avoid twisting and
kinking of PA tube .
Kinked tube
19
1.6 Additional fitments General
A) Rear under run protection device (RUPD)
This device is factory fitted on truck version.
Rear under run protection device fitted on vehicle (LPT)
B) Side under run protection device (SUPD)
LOAD BODY
D
B
OVER ALL LENGTH
AC
G
P2P1EJ
BOTTOM
OF FLOOR
H
Fitment of SUPD on LPT version
Note : While the SUPD is fitted as OE on vehicles with OE load body, customers
have to ensure fitment of SUPD when they do body building. Please refer
fitment details of SUPD.
20
1.6 Additional fitments General
NOTE :
1. For all other technical
requirements of side
protection device ref.
IS:14682:1999.
2. Pitch ‘P1’, ‘P2’, ……..should
not be more than
1650 mm.
3. Dimn ‘H’ is as measured on
the load bodies
manufactured by other
than Tata Motors supplied
load body.
4. As per the regulations,
following Dimensions need
to be maintained within
the specified values.
4.1 Dimension ‘A’ should
be less than or equal to
300 mm measured
from front tyre rear
face (for LPT vehicles)
or less than or equal to
100 mm. measured
from rear wall of cab in
case of SFC vehicles.
4.2 Dimension ‘B’ should
be less than or equal to
550 mm measured
from ground.
4.3 Dimension ‘C’ should
be less than or equal to
300 mm measured
from front face of rear
tyre.
4.5 Dimension ‘D' should
be less than or equal to
350 mm measured
from lower most face
of floor structure.
4.6 Dimension ‘E’ and ‘J’
should be less than or
equal to 120 mm.
5. Painting or powder coating
to be done for rust
prevention.
6. All the members as shown
in drg. are with minimum
cross sections and thickness
required.
7. Item no. 8 to be added at
the both ends to cover
item no. 7, to be welded to
both side guard panels.
8. # This dimensions (460 mm
of item no. 1) to be
changed to meet
regulations given in sl. no.
4.2 (dimension `B') and 4.5
(dimension `D').
9. Long side guards can be
provided with two pieces
with overlapping and with
suitable backing plate or
longitudinal gap of
maximum 25 mm is
allowed.
4.4 Dimension ‘G’ should
be greater than or
equal to 100 mm.
21
1.6 Additional fitments General
SUPD Proposal 1
STEEL CROSS RUNNER
2 WELD NUTS
B
B
ITEM NO. 4
HEX. FLANGED SCREW
M10x20-IS 17130-8.8
M10
ITEM NO. 2 & 3
ITEM NO. 5
ITEM NO. 1
C
20
20
LOAD BODY
MAX. WIDTH OF
10
20
C
D
THIS SURFACE SHOULD BE
INSIDE THE MAX. WIDTH OF
VEHICLE AND SHOULD NOT BE
MORE THAN 120 mm INSIDE.
E
HEX. FLANGED SCREW
M10x20-IS 17130-8.8
ITEM NO. 8
ITEM NO. 6
ASSY. SUPPORT SIDE GUARD
96
50
SECTION - BB
MATERIAL - SHT. 4 THK.
DD 1079 SS: 4013A
56
50
ALTERNATE FOR
SECTION - BB
MATERIAL - SHT. 2.5 THK.
DD 1079 SS: 4013A
202020
VIEW FROM - D
( ITEM NO. 2 AND 3 NOT SHOWN)
VIEW FROM - E
SECTION - CC
Note : Please refer page numbers 23 to 24 for details of item no. 1 to item
no. 9 & for alternate proposals.
22
1.6 Additional fitments General
ITEM NO. 1 ITEM NO. 2 AND 3 (RH & LH)
`X'
50
10
105
15
460 #
A
A
11 DIA (TYP)
MATERIAL - SHT 1.6 THK. D513 SS: 4010
==
15
15
35
15
5 (TYP)
DETAILS -`X'
34.5
SECTION - AA
R3 (TYP)
5 (TYP)
R4.5
2
35
R1.5
R3
45
2
MATERIAL - SHT 1.6 THK. D513 SS: 4010
ITEM NO. 4
46
R3
33
15
15
13
18
MATERIAL - SHT 1.6 THK. D513 SS: 4010
230
125
2 SLOTS 13 x 18
ITEM NO. 5
5R3
5
65
150
==
41
10
R4.5
MATERIAL - SHT 1.6 THK. D513 SS: 4010
23
1.6 Additional fitments General
ITEM NO. 6
6
CENTRE LINE
OF ITEM NO. 9
ITEM NO. 8
ITEM NO. 7
PITCH
OVERALL LENGTH
CENTRE LINE
OF ITEM NO. 9
ITEM
NO. 8
ITEM NO. 7
(OVERALL LENGTH -12)
MATERIAL - SHT. 1 THK. D513 SS:4010
ITEM NO. 9
35
R5 R10
20
R10
R5
R5
3410
10520
24
12
R15
R10
R6
R3
(TYP)
MATERIAL - SHT. 1 THK. D513 SS:4010
105
33.5
R6
105
126
R6
R4
65
30
50
MATERIAL - SHT. 2 THK. DD 1079 SS:4013A
115
WELD NUT M10
-IS: 8856
2 HOLES 12.5 DIA-H11
1.6 Additional fitments General
SUPD ALTERNATE PROPOSAL - 2 :
a) with mounting to wooden runner
b) Two alternate sections for panel (item no. 3)
A
FRONT OF VEHICLE
WOODEN RUNNER
F
F
BODY
OF LOAD
MAX. WIDTH
10
ITEM NO .-3
VIEW FROM -A
B
B
WOODEN RUNNER
C
C
BOTTOM OF SIDE WALL OF LOAD BODY
ITEM
NO .-1
ITEM
NO .-3
340
AVERAGE HEIGHT
100
MEASURED ON
DIFFERENT LOAD
BODIES.
980
540
ITEM NO .-2
ITEM NO .-4
GROUND
SECTIONAL VIEW - BB
Note : Refer page number 26 for section CC and section FF. Details of item
no. 1 to item no. 4 are given on page number 26 and 27.
25
1.6 Additional fitments General
HEX. BOLT M10x100
BRT. WASHER 10.5
SPRING WASHER B10
HEX. NUT M10
SECTION - FF
WOODEN CROSS
MEMBER
4x30x30
HEX. SCREW M8x20
BRT. WASHER 8.4
SPRING WASHER B8
HEX. NUT M8
SECTION - CC
PROPOSAL - A
Note - Refer item no. 3a, 3b, 4 and 5.
ITEM NO. 1
6 HOLES 11 DIA.
R5
#72
(TYP)
MATERIAL - SHEET 2 THK. DD 1079 SS:4013A
# DIMN. TO SUIT WOODEN CROSS MEMBER
( REF- CROSS SECTION -FF )
85
250
ITEM NO. 3a
85
ITEM NO. 3b
SECTION - CC
PROPOSAL - B
ITEM NO. 2
230
3x30x30
40
40
#240
4 HOLES 12 DIA
MATERIAL - ANGLES 45x45x3 THK. Fe 410W A IS : 2062
SECTION - DD
45
PLATE 3 THK.
150
20
D
D
EE
0
15x45
SECTION - EE
478
26
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