TATA LPT 613 User Manual

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Page 1

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

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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 : [email protected]

We wish you good luck and prosperity.

iii

Page 3

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

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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

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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

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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

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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.

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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.

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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.

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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)

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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.

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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.

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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.

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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.

Page 15

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.

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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.

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.

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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.

Page 18

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.

Page 19

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.

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.

Page 20

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

Page 21

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

Page 22

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

Page 23

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

Page 24

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

OVER ALL LENGTH

P2P1EJ

BOTTOM

OF FLOOR

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.

Page 25

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.

Page 26

1.6 Additional fitments General

SUPD Proposal 1

STEEL CROSS RUNNER

2 WELD NUTS

ITEM NO. 4

HEX. FLANGED SCREW

M10x20-IS 17130-8.8

M10

ITEM NO. 2 & 3

ITEM NO. 5

ITEM NO. 1

LOAD BODY

MAX. WIDTH OF

THIS SURFACE SHOULD BE INSIDE THE MAX. WIDTH OF VEHICLE AND SHOULD NOT BE MORE THAN 120 mm INSIDE.

HEX. FLANGED SCREW

M10x20-IS 17130-8.8

ITEM NO. 8

ITEM NO. 6

ASSY. SUPPORT SIDE GUARD

SECTION - BB

MATERIAL - SHT. 4 THK.

DD 1079 SS: 4013A

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.

Page 27

1.6 Additional fitments General

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

`X'

105

460 #

11 DIA (TYP)

MATERIAL - SHT 1.6 THK. D513 SS: 4010

5 (TYP)

DETAILS -`X'

34.5

SECTION - AA

R3 (TYP)

5 (TYP)

R4.5

R1.5

MATERIAL - SHT 1.6 THK. D513 SS: 4010

ITEM NO. 4

MATERIAL - SHT 1.6 THK. D513 SS: 4010

230

125

2 SLOTS 13 x 18

ITEM NO. 5

5R3

150

R4.5

MATERIAL - SHT 1.6 THK. D513 SS: 4010

Page 28

1.6 Additional fitments General

ITEM NO. 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

R5 R10

R10

3410

10520

R15

R10

(TYP)

MATERIAL - SHT. 1 THK. D513 SS:4010

105

33.5

105

126

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

115

WELD NUT M10

-IS: 8856

2 HOLES 12.5 DIA-H11

Page 29

1.6 Additional fitments General

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

FRONT OF VEHICLE

WOODEN RUNNER

BODY

OF LOAD

MAX. WIDTH

ITEM NO .-3

VIEW FROM -A

WOODEN RUNNER

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.

Page 30

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.

#72

(TYP)

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

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

250

ITEM NO. 3a

ITEM NO. 3b

SECTION - CC

PROPOSAL - B

ITEM NO. 2

230

3x30x30

#240

4 HOLES 12 DIA

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

SECTION - DD

PLATE 3 THK.

150

15x45

SECTION - EE

478

Page 31

1.6 Additional fitments General

ITEM NO. 3a - PROPOSAL - A

LENGTH OF SIDE PANEL

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

ITEM NO. 3b - PROPOSAL - B

MATERIAL - SHEET 1 THK. D 513 SS : 4010

ITEM NO. - 4 ITEM NO. - 5

10 DIA

40100

10 DIA

150

(TYP)

105

102

(TYP)

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

MATERIAL - SHEET 1 THK. D 513 SS : 4010

Page 32

1.6 Additional fitments General

C) Rear view mirror - LP / LPT versions

BUS BODY

TRUCK BODY

BUS BODY

TRUCK CAB

`A'

210

640

(Z=20)

(X= - 1070)

(X= 0)

ASSY. REAR

VIEW MIRROR R.H.

100810

(Y= 0) (center line of vehicle)

DETAILS OF `B'

(X= - 1070)

16.5

DETAILS OF `A'

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

Page 33

1.6 Additional fitments General

Rear view mirror - LP / LPT versions

Mirror for custom built cab

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

SL. CSK SCREW M6x20 - 4.8

WASHER C 6.4 SPR. st 130

SL. CSK SCREW M8x30 - 4.8 SPR. WASHER B8 DOME CAP NUT M8

BRACKET BOTTOM

RUBBER PAD BOTTOM

SECTION - CC

RUBBER PAD TOP

BRACKET TOP

SLEEVE FOR FRAME

SL. CSK SCREW M6x20 - 4.8

WASHER C 6.4 SPR. st 130

SECTION - DD

Page 34

1.7 Additional provisions (electrical) General

D) WIPING SYSTEM

GUIDELINES FOR FITMENT OF WIPER SYSTEM BY BODY BUILDERS

1. Wiper system components (wiper motor, wheel box, wiper arm and blade, linkages) are supplied along with the drive away chassis and these are recommended for use on the built up vehicle. However, the windscreen and the mounting of the wheel boxes should be appropriately decided to match wiper system regulation as stipulated in AISO 11-2001 for A, B, C wiping zone area requirements.

2. Wiper motor to be mounted preferably near the centre of the panel below the wind screen with suitable mounting bracket.

rubber edge of blade against the wind screen.

7. Wiper system should be balanced and it is to be ensured that there is no possibility of entangling / locking of linkages or fouling of wiper blade with rubber beading.

4. Wheel boxes to be fitted with suitable mounting arrangement on both sides, in such a way that the wiping pattern obtained meets the regulatory requirements of AISO11-2001.

5. The path of link rod movement, during wiping system operation, should be free from any obstacles to ensure free movement.

6. Wiper arm and blade assembly should be properly tightened on the wheel box to ensure proper pressing of

Page 35

1.7 Additional provisions (electrical) General

LIGHTING AND SIGNALLING Guidelines for fitment of end

outline marker lamp, side marker lamp, side retro-reflector, side indicator, front fog lamps and rear fog lamp, head lamps, tail lamp assembly and side retroreflector during body building

(refer figure) For factory built load body all the

above fitments come as OE, except fog lamps.

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

1. End outline marker lamps: A, B, C, D, E and F in the sketch are typical six locations of End outline marker lamps. Normally four lamps are fitted, two for the front (white light) and two for the rear ( red light ). The rear lamps can be fitted at locations suitably to be visible from the rear of the vehicle. Visibility for both front and rear lamps is defined as horizontal spread about the lamp axis of minimum +/- 80 deg and the vertical spread of minimum 5 deg above and minimum 21 deg below the axis of the lamp. They are normally mounted near the top of the vehicle; the height should be such that it is minimum 200 mm above the parking lamp. From the sides of the vehicle, the lamps should be fitted at a distance less than 400 mm. Refer figure. The wattage of the lamps should be 5 watts.

2. Side ( turn ) indicator lamps : G and H are the typical locations of side indicator (turn indicator) lamps. The height restrictions of the lamp are given in the figure. The wattage of the lamp should be normally 10 watts.

3. Side marker lamps & Side retro-reflectors: I,J,K,L,M and N are

the typical locations of side marker

lamps and side retro reflectors. These are to be fitted on all vehicles of overall length more than 6 meters. The distance restrictions are given in the figure. The side marker lamp and side retro reflector may be separately fitted or can both be included in a single package. The wattage of side marker lamp should be 5 watts. The distance restrictions are given in the figure. Refer figure for circuit diagram.

4. Front fog lamps: P and Q are the typical locations of the front fog lamps. The distance restriction from the sides of the vehicle and the height are given in the figure for Front and Rear fog lamps. The wattage of the lamps should be 55 watts each. Refer figure for circuit diagram.

5. Rear fog lamp: R is a typical location of the rear fog lamp. The distance restrictions from the longitudinal centre line of the vehicle and from the side of the vehicle are given in the figure for Front and Rear fog lamps. The rear fog lamp is to be fitted on the driver’s side of the vehicle typically as shown in the figure. The wattage of the lamp should be 21 watts. Refer circuit schematic.

6. Head lamps: The head lamps are supplied along with the vehicles from the factory. The distance restrictions for mounting of the lamps during body building are given in the figure .

7. Tail lamps: The tail lamp assemblies are fitted as part of factory supplies on our vehicles. The assembly consists of rear position lamp, stop lamp, rear retro-reflector, reversing lamp and turn indicator. The distance restrictions for mounting the lamp assembly are given in the figure .

Page 36

1.7 Additional provisions (electrical) General

UP TO 1200

250 (MIN)

TYPICAL LOAD BODY (OF DIFFERENT

HEIGHTS)

HEAD LAMPS & TAIL LAMP ASSEMBLIES ON MCVs/HCVs/LCVs

MAX. UPTO HEAD LAMP TOP SURFACE

250 (MIN)

2300 (MAX) 1500 (MAX)

★

100 (MIN)

✤

500 (MIN)

UP TO

✤

LAMPS / SIDE RETRO REFLECTORS, SIDE INDICATOR LAMPS, FRONT & REAR FOG LAMPS,

GUIDE LINES TO BODY BUILDERS FOR FITMENT OF END OUTLINE MARKER LAMPS SIDE MARKER

400 (MAX)

2100 (MAX)

★

1500 (MAX)

✤

400

(MAX)

1000

(MAX)

4000 (MAX)

3000 (MAX)

1800

UP TO

★

VIEW 'Y'

2000 (MAX) 1500 (MAX)

✤★

2500

1000 (MAX) 250 (MIN)

350 (MIN)

- Side retro reflector

A. B. C. D. E. - End out line marker lamp

G. H. - Side indicator lamp

I. J. K. L. M. N . - Side marker lamp /

P. O. - Front Fog lamp

R. - Rear Fog lamp

S. T. - Head lamp

U. V. - Tail lamp assembly

VIEW 'X'

not permit to maintain

dimension marked with `✤', it

Note : If vehicle structure dose

may be increased to respective

dimension marked with `H'.

are applicable for bus body applications also.

1) This is a typical truck with load body . The fitment requir ement for the various lamps

2) Refer attached notes.

Page 37

1.7 Additional provisions (electrical) General

0.5 Sq. mm BROWN

LAMP LH REAR

LAMP RH REAR

END OUTLINE MARKER

0.5 Sq. mm WHITE

0.5 Sq. mm BROWN

RH REAR

SIDE MARKER LAMP

* END OUT LINE

0.5 Sq. mm BROWN

0.75 Sq. mm WHITE

RH MIDDLE

0.75 Sq. mm WHITE

0.5 Sq. mm BROWN0.5 Sq. mm BROWN

RH FRONT

0.75 Sq. mm WHITE

MARKER LAMP RH FRONT

0.5 Sq. mm GREY

0.5 Sq. mm BROWN 0.5 Sq. mm BROWN

0.5 Sq. mm BROWN

0.75 Sq. mm GREY

0.75 Sq. mm GREY 0.75 Sq. mm GREY

0.5 Sq. mm BROWN 0.5 Sq. mm BROWN

LH REAR

SIDE MARKER LAMP

LH MIDDLE

SIDE MARKER LAMP

LH FRONT

SIDE MARKER LAMP

* END OUT LINE

MARKER LAMP RH FRONT

FUSE 10A

CONNECTIONS TO BE

TAKEN FROM THIS POINT

CONNECTION SCHEMATIC FOR SIDE MARKER LAMPS / END OUTLINE MARKER LAMPS - REAR

'PARKING LAMP ON'

O/P FRO COMBI SWITCH

during body building.

NOTES :

2) All earthing connections should be on frame or body at suitable locations.

1) This is a schematic and is to be used as guide line for connecting side marker lamps / end out line marker lamps-rear

Page 38

2. Know Y our Vehicle

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

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

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

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

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

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

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

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

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

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

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

Page 39

2.1 Vehicle identification Know Your V ehicle

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

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

Page 40

2.1 Vehicle identification Know Your V ehicle

CHASSIS TYPE DESIGNATION

Description Wheel Chassis Sales

base type designation

LPT VERSIONS

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

FULL FORWARD CONTROL CHASSIS WITH 3800mm 381 327 LPT 613/38 CAB AND WITHOUT LOAD BODY, TRUCK VERSION WITH 697TCIC EURO-II / BHARAT STAGE-II ENGINE, WITH FULL AIR S’CAM BRAKE, 3800mm W.B.

LP VERSIONS

FULL FORWARD CONTROL CHASSIS 3800mm 381 224 LP 613/38 WITHOUT FACE BUS VERSION WITH 697TCIC EURO-II / BHARAT STAGE-II ENGINE WITH FULL AIR S’CAM BRAKE 3800mm W.B.

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

Page 41

2.1 Vehicle identification Know Your V ehicle

LP 613 CHASSIS WITH COWL 38 WB EURO- II (LHD)

Page 42

2.1 Vehicle identification Know Your V ehicle

LPT 613 CHASSIS WITH CAB AND LOAD BODY 38 WB EURO- II (LHD)

Page 43

2.2 Location of aggregate numbers Know Your Vehicle

1. Chassis number plate

2. Cab /Cowl number plate

Engine number plate

Cab / Cowl number plate

Engine number plate location

Chassis number - LHD

Chassis number plate

Page 44

2.2 Location of aggregate numbers Know Your Vehicle

Power steering gearbox number plate Front axle number plate

Gearbox number Rear axle number plate

Page 45

2.3 Instrument panel Know Your V ehicle

6 7 8

2 3 4 5

19 20 21 22 23 24 25 26

Instrument panel

1. Low air pressure indicator

2. High beam indicator

3. Exhaust brake indicator

4. Parking brake indicator

5. Front fog lamp indicator

6. Fuel gauge

7. Speedometer with odometer

8. Coolant temperature gauge

9. Low oil pressure indicator

10. Battery charging indicator

11. Seat belt indicator

12. Hazard warning indicator

13. ABS indicator (If fitted)

10 12

11 13 15

14. Rear fog lamp indicator

15. Air filter service indicator

16. Glow plug indicator

17. Air pressure gauge (II)

18. Air pressure gauge (I)

19. Exhaust brake isolator switch

20. Front fog lamp switch

21. Blank

22. ABS switch (If fitted)

23. Head lamp leveling knob 24 . Blank

25. Rear fog lamp switch

26. Engine compartment lamp switch

Page 46

2.4 Switches, gauges & indicators Know Your V ehicle

Fuel gauge

Fuel gauge indicates the level of fuel in tank. It is electrically operated. Fuel level is indicated on gauge through a sensing unit mounted on fuel tank.

Coolant temperature gauge

Tempera ture gauge indic ates coolant

Fuel gauge

Coolant temperature gauge

temperature. It senses coolant temperature through a transducer mounted on upper cooling line. When gauge needle touches red band on dial it indicates engine over heating.

If overheating is observed & coolant level in auxiliary tank found to be low, stop engine and allow it to cool down. T op up c oolant water mixture in 1:1 ratio through auxiliary tank filler neck.

Cylinder head may crack, if coolant mixture is topped up when engine is hot.

Speedometer

Air pressure gauge

Speedometer

It indicates vehicle speed in kmph and also the distance covered by vehicle in km. This is driven by a flexible shaft connected to the output shaft of gear box. High beam indicator is also provided on speedometer dial.

Air pressure gauges

Two air pressure gauges have been provided, one each for front and rear brake circuits. Vehicle should not be driven till a minimum air pressure of

5.6 bar is reached in both air tanks. Regulated cut out air pressure is

7.4 ± 0.2 bar and cut in pressure is

6.2 bar min.

Page 47

2.4 Switches, gauges & indicators Know Your Vehicle

SERV indicator

When it glows, it indicates that the Air cleaner filter is choked. Filter needs to be cleaned/ replaced. When the ignition key is in ON position, before starting the engine this indicator should glow

SERV indicator

GLOW indicator

This indicator is used to indicate the functioning of Flame start system. When the ignition key is in ON position, before starting the engine, if the engine coolant temperature is

GLOW indicator

less than 20OC, wait to crank till the indicator glow continuously and proceed to crank the engine once the indicator start blinking. If the engine coolant temperature is more than 20OC, the indicator blinks continuously i.e. ready to start.

Front fog lamp indicator

Low air pressure indicator

Rear fog lamp indicator

Front fog lamp indicator

This indicator will glow only when Front fog lamp is switched on.

Low air pressure indicator (Red)

Two low pressure (LP) switches one each for front & rear brake circuits are connected at dual brake valve. When pressure in any one or both the circuits is less than specified value, these switches activate low air pressure indicator.

Rear fog lamp indicator

This indicator will glow when rear fog lamp is switched ON.

Page 48

2.4 Switches, gauges & indicators Know Your V ehicle

High beam indicator

When it glows, it indicates that the head lights high beams are on. It is provided in speedometer dial.

High beam indicator

Parking brake indicator

This indicator comes ON when parking brake is applied and goes OFF when it is released. It will also glow when air pressure in parking brake circuit is less than 4.6 bar.

Parking brake indicator

Battery charging indicator

When it glows, it indicates that battery is not getting charged, i.e. during idling or when alternator is defective with normal engine running. When ignition key is in ON position, before starting the engine

Battery charging indicator

Low oil pressure indicator

Side indicators

this indicator should glow.

Low oil pressure indicator

This indicator glows when ignition key is in ON position before starting engine. It should go off after starting the engine, when oil pressure builds up.

If indicator continues to glow even after the engine has started, stop the engine, trace out the fault in lubrication system / electrical connections and rectify.

Side indicators

Side indicator with arrow pointing towards left will glow, when combi lever is moved for LH indication. Similarly side indicator with arrow pointing towards right will glow, when combi lever is moved for RH indication.

Page 49

2.4 Switches, gauges & indicators Know Your Vehicle

Exhaust brake indicator

This indicator comes ON when exhaust brake is in operation

Exhaust brake indicator

Hazard warning indicator

Glow plug indicator

ABS indicator

Hazard warning indicator

It comes 'ON' when hazard warning lights are switched 'ON' to warn the other road users about the hazardous condition of vehicle.

Glow plug indicator (Amber)

It glows when the ignition key is turned to position ‘ON’ and after a few seconds it goes ‘OFF’ indicating that engine can be started.

If glow plug indicator light does not go off automatically, get it checked.

ABS Indicators (if fitted) ABS indicator light on instrument

cluster illuminates approx. for 5 sec. when the ignition key is turned to ‘ON’ position. This is normal and indicates the system is performing a self check. If the light does not illuminate when ignition is ‘ON’ or remains illuminated after initial self check and while driving or flashes, fault may exist in the ABS system.

In this case also the normal braking system is still effective and can able to provide normal stopping ability.

In this condition it is recommended to taking your vehicle to the nearest Dealer / service outlet and get your vehicle attended as soon as possible if the warning light stays on.

Page 50

2.4 Switches, gauges & indicators Know Your V ehicle

Seat belt indicator

It comes ‘ON’ when seat belt is not fasten or belt tongue is not locked in to buckle.

Seat belt indicator

Exhaust brake isolator switch

Exhaust brake can be made inoperative, by exhaust brake isolator switch, whenever required.

Exhaust brake isolator switch

Engine compartment switch

Provided to switch ON the bulb located in engine compartment for inspection purpose.

Engine compartment switch

Front fog lamp switch

Head lamp leveling knob

Front fog lamp switch:

This switch is provided to switch on Front fog lamps. Front fog lamps are operative only when the park lamps are switched ON.

Head lamp levelling switch

A motorized head lamp levelling arrangement with the setting knob is provided near the instrument panel.

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

Page 51

2.4 Switches, gauges & indicators Know Your Vehicle

Rear fog lamp switch:

This switch is provided to switch on Rear fog lamps. Rear fog lamps are operative only when the park lamps along with Head lamps (Hi beam/ Low beam) or Front fog lamps are switched ON.

Rear fog lamp switch

Mechanical stop light switch

A mechanical stop light switch is mounted above brake control lever. Whenever brake pedal is depressed for applying brakes, stop light switch comes into operation and lights at rear tail lamp glow. This also activates

Mechanical stop light switch

engine exhaust brake solenoid valve for exhaust brake application.

Electric service indicator switch

This switch is provided on air cleaner. Switch contact takes place only when the filter get chocked.

Electric service indicator switch

Air dryer heater

This heater is a part of air dryer assy. This heater is provided to heat the moisture if any in the air brake lines. This heater gets switched ON at 70 C of air temperature and OFF at 290 C automatically.

Page 52

2.4 Switches, gauges & indicators Know Your V ehicle

Battery cut off switch

Bus chassis is provided with battery cut off switch to isolate battery from electrical system when required.

Battery is connected to starter motor and other circuits through isolator switch. This is to be switched off

Battery isolator switch

Steering lock cum ignition switch-key positions

while carrying out any electrical work on the vehicle and also when vehicle is parked for long duration.

STEERING LOCK CUM IGNITION SWITCH Position of key Steering Electricals Clockwise direction

‘LO CK’ without key Locked All OFF ‘L OCK’ with key Locked All OFF ‘ACC’ with key Unlocked ACC ON ‘ON’ with key Unlocked ACC + IG ON ‘START’ with key Unlocked IG + ST ON

Anti-clockwise direction

’ON’ with key Unlocked ACC + IG ON ‘ACC’ with key Unlocked ACC ON ‘L OCK’ with key Unlocked All off ‘LO CK’ without key Locked All off

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

Page 53

2.4 Switches, gauges & indicators Know Your V ehicle

Steering lock cum ignition switch

It is located on right hand side of steering column. It has following positions.

‘LOCK’ Position

Key can be inserted or removed in this position only. Steering wheel gets locked, only when key is removed.

‘ACC’ Position

Steering lock cum ignition switch with key (LHD)

Steering gets unlocked in this position. Only accessories are ON.

‘ON’ Position

By turning the key to position ON, low oil pressure lamp, battery charging indicator lamp, parking brake indicator lamp (if applied), fuel gauge and temperature gauge are switched on. Other electrical systems are ready for operation. If none of the above warning indicators /gauges are working the chances are that the fuse for engine and gauges is blown off in which case engine will not start.

‘START’ Position

Turn the key further clockwise to start position to operate starter motor. This is a spring return position.

As soon as the engine starts, release ignition key so that the key can come back to ON position and starter motor disengages.

Page 54

2.4 Switches, gauges & indicators Know Your Vehicle

POSITION FOR FLASH (HIGH BEAM)

POSITION FOR LOW BEAM

POSITION FOR HIGH BEAM

POSITION FOR WASH-ON

POSITION FOR LEFT

POSITION FOR RIGHT

Combination switch

Combination switch (LHD)

HAZARD WARNING SWITCH

Combination switch

Combi switch is mounted on steering column. It has 2 levers.

One lever is for operating turn signals, head lamps, parking lamps and number plate lamps. This lever is mounted on RH side on RHD vehicles and LH side on LHD vehicles.

Head lights

Position 1 - Low beam Position 2 - High beam Position 3 - High beam (flash)

Turn signals

Position 4 - Turn signal right Position 5 - Turn signal left Self cancellation turn signal

arrangement is provided. When turn signal option is used, this lever will return to neutral position on its own when steering wheel is brought back to straight ahead position.

INT

OFF

Page 55

2.4 Switches, gauges & indicators Know Your Vehicle

Lights

Lights are operated by turning the

OFF

OFF POSITION

'PL' POSITION

knob of this lever as indicated below

First notch (PL position)

Parking lights, instrument panel lights, number plate lights, control backlights and top marker lights are switched ‘ON’.

'HL' POSITION

Light switch

Note :

High beam flash (No. 3 position) High beam will be ‘ON’ as long as

lever is held in position '3' irrespective of the knob position. T his is spring loaded position and can be used in day time for giving signal to on coming traffic.

OFF

Hazard warning switch

Second notch (HL position)

In addition to parking, instrument panel, control backlights, number plate lights and top marker lights, headlights are also switched ON.

OFF-position

All lights are switched off in this position.

Hazard warning switch

Combi switch assembly also has a switch for operating hazard warning device.

To switch ON hazard warning, pull the knob located behind steering wheel. All turn signals lights will flash simultaneously to warn other road users about the hazardous condition of vehicle.

Push back this knob to original position when hazard warning requirement is over.

Page 56

2.4 Switches, gauges & indicators Know Your V ehicle

POSITION FOR WASH-ON

INT

OFF

Wiper motor operating lever (LHD)

Windshield washer water reservoir

Windshield wiper and washer

The lever on other side is for operating windshield wiper and washer. This lever is located on LH side on RHD vehicle and RH side in LHD vehicle.

Position

‘OFF’ - Wiper motor

switched ‘OFF’

‘INT’ - Wiper sweeps

intermittently

‘LO’ - Low speed of

wiper motor

‘HI’ - High speed of

wiper motor

T o operat e windshield washer, lift the lever. Windshield washer will remain in operation as long as the lever is held in this position.

When wind shield washer is actuated, wipers are also switched on. Wind shield washer water reservoir is accessible after opening centre flap. Top up reservoir with clean water regularly. Do not use soap solution. In cold climates, Use methanol and water in the ratio 50:50 to avoid water freezing. Please refer chapter no. 6.3 for details of recommended antifrost and ratio for varying ambient temperatures.

Do not operate windshield washer more than ten seconds at a time.

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

Page 57

2.5 Driving controls Know Your Vehicle

Driving controls LHD

1. Accelerator pedal

2. Brake pedal

3. Clutch pedal

4. Parking brake

5. Gear shift lever

Hand brake valve

6. Steering wheel

7. Combiswitch lever (Lights)

8. Instrument panel

9. Steering lock cum ignition switch

10. Combiswitch lever (Wiper/

washer)

Hand brake (parking brake)

Hand brake is integral with spring brake actuator on rear axle. Spring brake chamber piston ram acts

directly on push rod assembly of brake chamber.

A. Brake applied B. Brake released A to B Gradual application.

Page 58

2.5 Driving controls Know Your Vehicle

KSB unit (for Euro II vehicles)

KSB unit is a cold start throttle advance mechanism. It is an integral part of fuel injection pump.

KSB unit

- Provides necessary advance in lower throttle operation during cold condition.

KSB unit

- Allows a normal dynamic timing during regular operation.

- Reduces white smoke, misfiring in cold start and part throttle operation.

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

Opening/closing of front centre flap

Pull to open the bonnet - LHD

For opening centre flap, a lever as shown has been provided. For LHD vehicles it is located on LH side above clutch pedal. To open centre flap, pull this lever and lift centre flap.

A stay rod has been provided to keep centre flap open position. To close centre flap, remove stay rod. Slowly drop centre flap and press it down to make sure that it is locked.

Page 59

2.6 Turbocharger Know Your Vehicle

Turbocharger (Euro II) Lubrication of the turbocharger

Rotor assembly of turbocharger is supported by two floating lead bronze sleeve bearings in the bearing housing. These bearings are lubricated with finest filtered and cooled oil from lubrication system. There is a heat shield arrangement provided between turbine housing and bearing housing to avoid heating of the bearings.

Advantages of turbocharger

Turbocharged engine has following advantages over naturally aspirated engine of same size and weight.

1. Increased power is obtained with the same engine dimensions thereby increasing the power to weight ratio. Thus, the engine is lighter and payload value of the vehicle is improved.

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

3. Turbocharger reduces black smoke in the exhaust.

4. Loss of engine power at higher altitudes is much less making it ideal under all operating conditions. Especially in hilly areas, payload capacity is further improved by this aspect.

5. Turbocharger acts as an additional silencer on exhaust side, thus reducing engine noise.

Maintenance of turbocharger

No adjustments or repairs are to be carried out on the turbocharger. In case of doubtful performance from

the engine because of malfunctioning of turbocharger, take your vehicle to T ata authorised workshop .

Following precautionary measures should be taken to obtain trouble free performance.

1. During regular engine inspection, look carefully for any oil leakage at the oil inlet banjo connection on bearing housing. Do not run engine unless leakage at this point is rectified.

2. Do not stop the engine suddenly as it may damage rotor bearings. Allow engine to idle for atleast 3 minutes before switching it off. Similarly, do not increase engine speed suddenly.

Run the engine at low idle speed for atleast 3 minutes after starting to build up oil pressure before increasing engine speed.

3. Since the speed of rotor assembly is tremendously high, (nearly 1,00,000 rpm) it requires finest filtered oil. Therefore, ensure cleanliness of engine oil by adhering to regular schedules of engine oil and oil filter cartridge change intervals.

4. As the unfiltered dust particles entering compressor housing may prove dangerous, make sure that there is no leakage in air intake system and that air filter elements are in good condition and sealings are perfect.

5. Insist on use of only recommended grade of engine oil, genuine engine oil filter and air filter cartridges.

Page 60

2.7 Charge air cooler Know Your Vehicle

Charge air cooler (Euro II)

TURBOCHARGER

EXHAUST INLET

Charge air cooler

Advantages of charge air cooler

Hot air coming out of turbo charger flows through charge air cooler and gets cooled before entering intake manifold, thus increasing density of intake air for better combustion.

Charge air cooler is mounted in front of radiator .

Page 61

2.8 Clutch booster Know Y our V ehicle

Clutch Booster

Hydraulic clutch actuation system with pneumatically operated clutch booster has been provided to reduce clutch pedal effort.In this system, clutch booster replaces the function of clutch slave cylinder. Compressed air connection to operate clutch booster has been tapped from port No. 24 of system protection valve. Output rod of clutch booster is connected to clutch release fork. When there is no force on clutch pedal, push rod (5), pistons (3 & 4) are in stand still position due to the force exerted by return springs (6 &

8). When pedal is pressed to disengage clutch, clutch fluid under pressure enters throught port no. 4 and acts on piston (3). due to this piston (3) moves leftwards. At the same time fluid under pressure acts on controlling piston (2) due to which piston (2) moves leftwards to close air outlet and to open air inlet (1) compressed air

Port 1. Inlet port (for compressed air) Port 3. Vent (for compressed air) Port 4. Control port (for clutch fluid)

2. Piston

3. Piston

4. Piston

5. Push rod

6. Return spring

7. Wind pipe

8. Return spring A. B. Cavity C. D. Cavity

flows into air cylinder via wind pipe (7). Piston (4) moves leftwards and exert force on piston (3) which in turn pushes output rod to actuate push rod (5). The force on piston (4 & 3) is proportional to the pressure exerted by clutch fluid on piston (2). When pedal is released to engage clutch, clutch fluid pressure drops to zero. By the action of return spring (8) and air pressure at cavity B, piston (2) moves rightwards to close air inlet and to open air outlet. Compressed air in cavity D is exhausted to atmosphere. Return springs (6 & 8) bring back pistons (2 & 4) to stand still position and hence push rod (5) retracts to its original position.

Technical Data

Operating pressure : Clutch fluid 4 Mpa, compressed air 0.8 Mpa Max. pressure : Clutch fluid 12 Mpa, compressed air 1 Mpa Operating Temp. range -40OC to +80OC.

Page 62

2.9 Cab tilting Know Your V ehicle

RELEASED POSITION BEFORE TILTING

Cab tilting and locking lever arrangement

RELEASED AND TILTED POSITION

1. Cam lever handle

2. Cam lever

3. Primary locking lever handle

4. Primary locking lever

5. Secondary locking lever

6. Connecting link - LH

7. Connecting link - RH

8. Cab mounting mechanism

9. Mounting pin

10. Mounting hook

11. Rubber pad

12. Torsion bar

13. Cab stay

14. Releasing lever

Page 63

2.9 Cab tilting Know Your V ehicle

Cab Tilting

Truck version of 613 vehicle is provided with tilt cab. For tilting the cab proceed as follows :

To raise the cab

Hand brake valve

1. Park vehicle on level ground in straight ahead condition and apply parking brake.

2(A) Put the gear shifting lever in

second gear. (sketch position No. (2))

Note : Remove or secure all loose items in the vehicles. Close all the doors.

2(B) Remove p adlo ck or b olt a n d nut

from primary locking lever. (sketch position No. (3))

Page 64

2.9 Cab tilting Know Your V ehicle

3. Hold primary locking lever ad pull

cam lever handle to release primary locking lever from locked condition. (sketch position No. (4))

4. Raise primary locking lever handle to horizontal positions. Mounting pins of cab mounting mechanism get released from mounting hooks. (sketch position No. (5))

5. Pull secondary locking lever to

release it from locking condition

and hold. Slightly raise cab to clear secondary locking lever from it’s hook. (sketch position No. (6))

6. Raise cab to maximum position.

At this position cab stay locks automatically. Cab is retained safely in max. titled condition by the stay. Torsion bar assists in easy tilting of cab.

Page 65

2.9 Cab tilting Know Your V ehicle

To lower the cab

1. Holding cab, press cab stay releasing lever and slightly lower cab. Linkage gets released from straight position. (sketch position No. (7))

2. Lower cab till cab gets seated on rubber pads. Secondary locks lever gets automatically locked in its hook. (sketch position No. (8))

3. Push down primary locking lever

till it locks on the cam lever. (sketch position No. (9))

Page 66

2.9 Cab tilting Know Your V ehicle

4. After locking, make sure that the cab is fully secured with the mounting hooks. (sketch position No. (10))

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

Page 67

2.10 Heating Know Your Vehicle

Slot A

Slot C

Heating control

Heating control (Optional)

Heating system is provided for comfortable driving. Heating system can be operated as per need.

The cab heat can be regulated by controlling air flow rate of the blower .

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

Slot - 'A' Blower Regulator

Blower off Blower slow speed Blower medium speed Blower high speed

Note : Though slot B is shown for air at leg, slot ‘C’ to decide leg will be open or close.

Slot B

Slot C

Slot - 'B' Air Distribution Control

Air directed towards chest and legs

Air directed towards legs, chest and windscreen

Air directed towards legs and windscreen

Demist : Switch-off heater. Direct air flow towards windscreen for a required period.

Defrost : Switch-on heater. Direct air flow towards windscreen for a required period.

Slot - 'C' - Closing and opening of leg vent

- Leg vent closed

- Leg vent open

Page 68

2.11 Driver seat & seat belt Know Your V ehicle

Driver seat adjustment

Lever 1 : Lever for adjusting back

rest.

Driver seat adjustment

** Precautions

Cab heating system - operates using engine hot coolant. Hence, if engine coolant temperature overshoots specified limit, shut off the engine and rectify the fault.

* * Do not leave the vehicle keeping

heater and engine in running mode as it may cause extensive heating inside the cab. There is no thermostatic control in the cab heating system to shut-off engine, blower and heater.

Lever 2 : Lever for adjusting seat

height at rear .

Lever 3 : Lever for horizontal

movement of seat.

Lever 4 : Lever for adjusting seat

height at front.

Note : Please ensure that the seat is locked after making necessary adjustments.

Maintenance

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

2. Check hoses for cracks. Replace, if required. If there is a loss of coolant, replenish coolant mixture in auxiliary tank.

3. If blower is not working, check fuse, if blown, replace.

Page 69

2.11 Driver seat & seat belt Know Your V ehicle

3 5 4

LHD

Seat belt arrangement

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

Seat belt

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

On bus versions, three point belt for driver seat is provided.

Fastening the belt

Insert belt tongue into buckle. A positive locking ‘click’ indicates correct assembly.

Releasing the belt

Press the release button. The tongue will be ejected clear of the locking mechanism within the buckle.

Belt adjustment

When the vehicle is at rest, adjust length of the belt to suit convenience and observe that the belt is locked.

Lap belt (middle passenger)

Adjust length of belt in the tongue to suit convenience. Insert belt tongue in buckle. A positive click indicates correct assembly. To release, press the release button. The tongue will be ejected from the buckle.

Precautions :

● The belt is designed for use of

only one person.

● It is not intended for children

below 10 years.

● Avoid twisting the strap.

● Webbing must not be allowed to

chafe against sharp edges.

● Do not make any alterations.

● Belts that have been cut, frayed,

damaged or have been stressed through impact, should be replaced.

● After vehicle collision if any, belt

anchorage points should be checked.

● An occasional wipe with warm

soapy water will maintain the webbing in a clean condition. Do not bleach or dye.

● Periodic inspection of the seat

belts will ensure safe and reliable service.

● Before moving the vehicle

ensure that belt is properly locked and beeper is off. (where fitted).

Page 70

3. Driving

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

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

3.3 Stopping the engine........................................................ 7 5

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

3.5 Fuel economy..................................................................... 7 8

3.6 Do it yourself....................................................................... 7 9

Page 71

3.1 Starting the engine Driving

1. Ensure that parking brake is applied.

2. Move gear shift lever to neutral position.

3. Insert ignition key in steering lock cum ignition switch. Steering wheel will be in locked condition. Turn the key to “ACC” position. Steering wheel gets unlocked, and accessories will be ON.

Steering lock cum ignition key

4. Turn the key further to ON position. Lamp of battery charging indicator, low oil pressure will come on.

5. Do not press the accelerator pedal. Turn the key further clockwise to “START” position (spring loaded) to operate starter motor. As soon as engine starts, release ignition key so that key can come back to ON position and starter motor disengages.

Steering lock cum ignition switch-key positions

6. If engine misfires and stops, wait for 2 minutes before operating starter motor once again. This practice should be strictly adhered to, otherwise it will damage starter motor.

7. Once engine starts, lamps of battery charging indicator and low oil pressure should go off.

8. Allow engine to warm up - until cooling system temperature reaches at least 40o C.

9. Release parking brake.

10. Now the vehicle is ready to move.

Page 72

3.2 Driving Driving

Engaging position for various gears are shown on gear knob. Change gears at appropriate speed and do not lug the

engine by too early high gear changes at low speed.

135

Gear lever knob

Driving, Gear shifting, Breaking

DRIVE SAFELY AND JUDICIOUSLY Remember SAFETY FIRST.

Do not keep driving till you are overcome by fatigue. The reflexes of a tired driver are not as they should be.

1. Before you drive, ensure that vehicle is in a road-worthy condition. Especially check steering system, tyres, brakes, clutch etc.

2. Release parking brake.

3. Depress clutch pedal fully before shifting gears. For smooth starting of vehicle without jerks, synchronise release of clutch pedal with pressing of accelerator pedal.

4. Gear Shifting

Vehicle should be started in first gear only.

Reverse gear should only be engaged when vehicle has been brought to a complete stop.

Approximate speeds for gear change.

Speed in kmph

Gear

Standard

Gearbox

Optional

Gearbox

1st to 2nd 12 12

2nd to 3rd 23 23

3rd to 4th 37 40 4th to 5th 62 67

5. While driving, left foot must not rest on clutch pedal. This causes abnormal wear of clutch linings due to clutch slippage.

6. Slowing down the vehicle should be achieved by changing down to lower gears.

7. Maintain a steady speed, avoid quick acceleration and sudden braking. High speed driving saves you a little time but increases fuel and oil consumption. It also causes faster tyre wear.

Page 73

3.2 Driving Driving

We, therefore, recommended to drive in fifth gear at a steady speed of about 70 kmph. Optimum fuel consumption is achieved at this speed

CAUTION DURING RUNNING IN PERIOD

During first 2,000 km. observe following speed and load limits.

Speed

Not more than 70 kmph in top gear and correspondingly lesser in lower gears.

Load

Gross vehicle weight should not exceed 2/3 of max. recommended gross vehicle weight.

Brakes

Avoid panic braking during first 500 kms. Drive in lower gears when negotiating steep down gradient, thus avoiding excessive braking and brake drum over heating.

effect. Do not ride brakes. This will lead to over heating of brake drums and linings resulting in low brake efficiency.

9. Parking the vehicle Apply parking brake. Keep

engine in low idling speed at least for three minutes (Turbo charged engine). Switch off engine. Remove key from steering lock cum ignition switch. While parking on slopes, place wheel chokes to prevent vehicle rolling. Engage forward gear if it is likely to roll in the reverse direction or vice versa.

8. Application of brakes Brake application should be

gradual to avoid fast wear of brake linings, brake drums and tyres. Brake should not be applied too violently on a slippery road, since the vehicle may then start skidding.

When driving down a long steep gradient, reduce vehicle speed by shifting to lower gear. Engine will provide a braking

Page 74

3.2 Driving Driving

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

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

Isolator switch (Exhaust brake)

Hand brake valve A. Brake released B. Brake applied A to B Gradual application

Hand brake system

Hand brake is integral with spring brake actuator on rear axle. Spring brake chamber piston ram acts directly on push rod assembly of brake chamber.

Engine exhaust brake

Exhaust brake operation is coupled with service brake. Whenever brake pedal is depressed for applying brakes, exhaust brake also gets applied and indicator lamp (E) comes ON instrument panel.

Stop light switch provides signals both for rear tail lamps as well as for exhaust brake solenoid valve.

In certain situations like starting of vehicle on an upgradient, simultaneous acceleration and partial braking of vehicle are required. Isolator switch can be used to cut off air supply to exhaust brake air cylinder, by putting it in off (disengaged) position. Isolator switch should be put ON (engaged), as soon as isolation requirement is over.

Solenoid valve opens, allowing compressed air to flow to exhaust brake air cylinder, thus operating exhaust brake butterfly valve.

Page 75

3.3 Stopping the engine Driving

Operating instructions

1. Ensure air pressure in the system is above 5 bar .

2. Change to lower gear appropriate to road conditions. Exhaust brake is very effective below 40 kmph speed.

3. Do not depress clutch as this would render exhaust brake ineffective.

4. Press brake pedal fully when vehicle is to be brought to a stop.

Lubricating exhaust brake linkages

1. Every 9,000 km. a few drops of oil should be applied to ball pins of outer linkages and friction surface.

2. Butterfly valve shaft, which is made of heat resistant material,

should not be lubricated,

since the lube oil would cause seizing of the butterfly valve in its housing.

shut off valve and fuel supply is cut off. Engine will stop. This shut off timer is aborted in case you turn ignition key again to ON position within 5 seconds.

5. Turn the key to “lock” position.

6. Take out key from steering lock cum ignition switch. Slightly turn steering wheel clockwise or anti clockwise (max. 180o), till click sound is heard, to make sure that steering wheel is locked.

Stopping the engine

After parking the vehicle in safe place.

1. Release accelerator pedal.

2. Move gear shift lever to neutral position.

3. Apply parking brake.

4. Turn ignition key to ACC position. A timer will switch on fuel stop solenoid for about 5 seconds which operates fuel

Page 76

3.4 Special operating conditions Driving

Flame start system (BERU):

Flame start system is provided for convenient starting at cold conditions by heating the intake air by means of burning the diesel in air intake manifold.

● Pre-glow time of just 20~45

seconds

● Trouble-free starting even at

BERU heater controller

T emperature transducer

Flame glow plug

low temperatures

● Post glow (after starting the

engine) time of up to 3 minutes

The flame start control unit controls the supply of current to the indicator light, flame glow plugs and solenoid valve. It evaluates the signals from starter motor in Ignition ON position via Temperature transducer (BERU) in alternator running condition.

The pre-glow phase commences when the ignition is switched on at temperature below the system stop temperature.

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

Once the pre – glow time has passed the indicator lights starts to flash. This indicates to the operator that the engine can be started. Power continues to be supplied to the flame glow plugs. If the engine is not started during this period, the flame start control unit switches off the flame glow plugs and the indicator light.

If the vehicle is started during ready to start period, then the flame start control unit activates the solenoid valve. The fuel then flows through the open solenoid valve, across the

Page 77

3.4 Special operating conditions Driving

hot heater rod of the flame glow plug, evaporates and ignites.

The post heating operation begins once the start procedure has ended. The duration is determined by the engine temperature (coolant water) when the post heating commences. Power continues to be supplied to the flame glow plugs, the solenoid valve remain open and indicator light goes off.

If the start procedure is unsuccessful, then the solenoid valve and flame glow plugs are shut off, the ignition must be switched off before attempting to restart. Where temperature exceeds the system stop temperature, the indicator light immediately starts flashing to indicate start ready, after the ignition has been switched on.

No power is supplied to the flame glow plug and the solenoid valve.

Page 78

3.5 Fuel economy Driving

Fuel Economy

a. Drive smoothly, accelerate

gradually, avoid harsh acceleration.

b. Best fuel consumption is

obtained at low engine speeds in the highest possible gear without labouring the engine.

c. Driving with accelerator pedal

fully depressed means using excessive fuel.

d. Do not allow the engine to

labour by too early high gear changes. Change to lower gear when engine no longer runs smoothly.

e. Switch ‘OFF’ engine when

stopping for long duration of time.

f. Do not ride clutch. Do not

use clutch pedal as foot rest.

g. Do not allow leakage or spillage

of diesel. h. Always drive in correct gears. i. Do not over load the vehicle. j. Maintain correct tyre pressure. k. Always keep vehicle and engine

in good condition.

Operation in hilly terrains

In hilly terrain and where the atmosphere is very humid, following precautions should be taken.

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

Note :

Diesel and clutch fluid, both being hygroscopic, absorb moisture from atmosphere.

● Drain air tanks every day to

remove water.

● Drain water from fuel water

separator.

● Vehicle should be greased every

day to prevent formation of rust on the exposed moving surfaces. Servicing and maintenance should be done as specified.

● Use same gear selection while

ascending and descending the same slope.

Caution : Operating engine beyond high idle speed can cause severe engine damage. When descending a steep gradient, use a combination of transmission gears and exhaust brake or service brake to control vehicle and engine speed.

● Use lower gears and brake

cautiously on wet and slippery roads.

Ensure that steering linkages and brakes are in order and proper gears are used during climbing and

Page 79

4. Maintenance Procedure

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 80

4.1 Air intake system Maintenance

Slit for dust

separation

Dust bowl

Primary cartridge

Plastic cover

Atmospheric air from intake duct

Schematic details of dry type air filter

Maintenance of dry type air filter

(Vehicle with Euro II engine) Dry type air filter with an inbuilt

cyclonic vane type pre-cleaner is fitted. For vehicles operating under normal conditions evacuator valve (of air filter) is required to be checked once every 2,000 km. This should be done more often, if vehicle operates in dusty conditions, viz. off highway operation, mining areas, construction sites, etc.

While reassembling, care must be taken to ensure that evacuator valve is assembled in the bottom most position and slit opening is pointing towards ground.

When service indicator glows, on instrument panel. Clean air filter housing and primary cartridge.

Electric

service

indicator

Air to turbo charger

Cyclonic pre-cleaner

Secondary cartridge

Replacement of air filter primary cartridge

a) Remove cover of air filter. b) Remove primary cartridge

(element). c) Clean air filter housing, air ducts. d) Replace old primary cartridge by

new one. e) Fit the cover. On starting the

engine, if service indicator on the

instrument cluster continues to

blink take your vehicle to nearest

Ta ta authorised workshop. f) Do not clean secondary

cartridge. Replace it after three

changes of primary cartridge or

after 2 years, whichever is earlier.

Page 81

4.1 Air intake system Maintenance

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

Inspection

If engine experiences a turbocharger failure or any other occasion where oil or debris has entered into CAC, the CAC must be cleaned.

Charge air cooler

Cleaning with solvent

Remove CAC from vehicle. Visually inspect CAC for cracks, holes

and damage. Inspect tubes, fins and w elds f or tear,

breakage or other damage.

Cleaning

Flush CAC internally first with trichloro ethane (solvent) in the opposite direction of normal air flow. Shake the CAC and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris.

Caution : Do not use caustic cleaners to clean CAC. Damage to CAC will result.

After the CAC has been thoroughly cleaned of all oil and debris with solvent, wash CAC internally with industrial soap solution to remove remaining solvent. Rinse thoroughly with clean water .

Cleaning with hot water/compress air

Blow compressed air into the CAC in the opposite direction of normal air flow until the CAC is dry internally.

Page 82

4.2 Fuel system Maintenance

Fuel water separator cum primer:-

It is fitted in between fuel tank and FIP. It separates water particles in fuel. Fuel passes over funnel like cone in water separator and water being heavier than fuel, so water gets collected at the bottom of the

Fuel water separator cum primer

bowl. To remove water from the bowl loose the primer then loose the drain plug , Water starts dropping from drain plug. Once water is completely drained from the water separator. Tighten the drain plug and primer. It is recommended that water in the separator be drained at least once a week.

Fuel filter change

1. Bleeding screw on banjo bolt

2. Drain plugs

1. Remove filter bowls by removing two bolts given on filter cover.

2. Clean the bowls.

3. Fit new elements in bowls a) Felt type element in primary

filter bowl.

b) Coil type micro element in

secondary filter bowl.

4. Replace O - rings on filter cover.

5. Assemble primary & secondary filter bowls to the cover. Tighten bolts to 2 mkg torque.

6. Fill diesel in filter bowls by operating feed pump primer .

7. Bleed fuel system and start engine.

Page 83

4.2 Fuel system Maintenance

If performance of engine is affected due to presence of air in fuel system (commonly known as air lock), it can be rectified by bleeding fuel system.

Fuel system bleeding

1. Ensure no leakage in fuel line.

2. Bleeding air in fuel line upto filter

- Loosen outlet banjo of fuel filter.

- Prime the circuit by using hand primer.

- Tighten banjo after completely bleeding air.

3. Bleeding air after FIP

- Loosen overflow banjo on FIP. This ensures FIP is filled with fuel.

- Prime the circuit by using hand primer.

- Tighten overflow banjo after completely bleeding air.

4. Crank engine for few seconds. If engine still does not start proceed to next step.

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

6. Crank engine till fuel coming out of high pressure lines is free from air. Tighten high pressure line cap nuts.

7. Start the engine.

Page 84

4.3 Lubrication system Maintenance

Changing engine oil / oil filter

Engine oil should be drained while it is still hot.

a. Unscrew sump drain plug and

allow oil to drain out for 20 minutes.

b. Unscrew drain plug of oil filter,

drain out oil and refit drain plug.

c. Unscrew centre bolt and

Full flow engine oil filter assembly

1. Drain plug engine oil sump

2. Drain plug oil filter

3. Filler plug oil filter

remove oil filter bowl, clean centre bolt.

d. Clean the bowl thoroughly and

replace with a new genuine filter cartridge.

e. Remove old ‘O’ ring in cover and

install a new O’ ring.

f. During reassembly, first fill filter

bowl with 1 litre of engine oil and thereafter reassemble filter bowl on top cover . Pour another

1.5 litres of engine oil through the filler plug opening in the cover & then tighten filler plug with a new sealing washer.

Oil filter cartridge

This is done to ensure that oil immediately flows to bearings and attains correct pressure, when engine is started. If this instruction is ignored, bearings may get damaged.

Oil filter must be kept clean to protect engine components from rapid wear due to abrasion.

g. Oil filter centre bolt should be

tightened to 4 mkg torque.

Page 85

4.3 Lubrication system Maintenance

h. Clean the drain plug of oil sump

and refit with a new sealing washer, if necessary. Tighten drain plug to 4 to 6 mkg torque.

i. Fill in recommended quantity of

engine oil in sump.

j. Start engine and allow it to run for

a few minutes and stop the engine.

Engine oil dip stick

Engine oil dipstick A. Minimum level B . Maximum level

k. After 20 minutes, check level of

oil on dipstick. It should be at upper mark. If not, top-up. When checking oil level, vehicle should be parked on level ground.

CAUTION

Make sure that only genuine oil filter cartridge is used.

i. Do not use filter with inferior

filtering material which cannot properly filter the engine oil.

ii. Do not use filter with improper

dimensions which cannot prevent filtered oil getting

mixed with unfiltered oil.

Since it is extremely difficult to distinguish between genuine and non-genuine filter cartridges, obtain these only from Tata authorised workshop.

Discard used oil filter cartridge. Filter cartridge should not be

cleaned or reused.

Change Engine Oil after every 18000 kms or earlier depending on the type of operation.

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

Page 86

4.4 Cooling system Maintenance

Cooling system

A transparent radiator auxiliary tank is fitted between cabin rear wall and load body on LPT 613 vehicles. On LP 613 this is fitted behind driver seat. Maximum & minimum levels indicated on the body. It is fitted with two identical caps with pressure cum vacuum relief valve

Radiator auxiliary tank filler neck (LP)

Radiator auxiliary tank filler neck (LPT)

Radiator drain plug

having 0.5 bar pressure setting. Always top up coolant only through filler neck. Top cap should not be disturbed.

Procedure for filling when the system is empty.

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

2. Fill coolant mixture through auxiliary tank filler neck.

3. Run engine for a few minutes and top up coolant mixture, if required.

Add recommended coolant to water in ratio 1:1. If coolant starts boiling, it may be on account of :

i. Less coolant or dirt/scale having

accumulated inside coolant passages, especially in radiator core.

ii. Choking of radiator air passages

due to foreign material or damaged radiator fins.

iii. Loss of coolant by evaporation

and leakage through defective auxiliary tank caps.

iv. Loose water pump drive belt. v. Coolant leakage.

Page 87

4.4 Cooling system Maintenance

Always use genuine auxiliary tank cap. A proper cap firmly fitted maintains pressure in the cooling system and makes engine more efficient by permitting a slightly higher operating temperature. Vacuum created in the system is relieved by a valve provided in the cap. Descale and clean cooling system regularly.

Cleaning of cooling system.

This should be done at every 80,000 km or every two years whichever is earlier.

While cleaning, the system is to be totally drained out. Coolant from vent pipes is to be drained out by disconnecting these pipes from auxiliary tank end side.

Fill the system with industrial soap solution through filler cap in auxiliary tank.

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

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

Stop engine and drain water. If water drained is still dirty, system

must be flushed again until water drained out is clean.

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

Fill the system slowly to prevent air locks. During filling air must be vented from the engine and radiator .

Wait for 2 to 3 minutes to allow the air to be vented and then add mixture to bring coolant level to the top.

Install filler cap. Operate engine until it reaches a temperature of 800 C, and check for coolant leaks.

Wait until the coolant temperature reaches below 500 C. Check coolant level again to make sure the system

is full of coolant. Do not install filler cap. Operate engine for 5 mins. with the

flushing solution temperature above 800 C. at maximum engine speed.

Stop engine and drain soap solution. Fill system with clean water. Be sure

to vent the engine for complete filling.

Do not install filler cap.

Page 88

4.4 Cooling system Maintenance

Fan belt tension adjustment 1,2.Idler pulley flange nuts

3. Tensioner rod mounting nut A. Check nut B . Adjusting nut

1. Loosen idler pulley flange nuts 1, 2 and the tensioner rod mounting nut 3 as shown in the picture, to release the fan idler pulley arrangement.

2. Loosen the check nut A and

Fan belt tension adjustment

rotate adjusting nut B to get the desired tension of fan belt. Slackness should be approx. 20 mm at the centre of fan belt drive, when checked by thumb push.

3. Tighten check nut A without disturbing the position of adjusting nut B..

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

5. Recheck belt tension and confirm.

Page 89

4.5 Clutch Maintenance

A=126mm

Stopper screw

Master

Check nut

Clutch pedal

Clutch pedal height

Clutch pedal stopper screw

cylinder

Clutch pedal adjustment

Hydraulically operated clutch has been fitted on this vehicle.

Clutch pedal height adjustment is required only in case of component repairs/overhaul etc. Adjustment is not required during normal maintenance.

1. Loosen check nut on clutch master cylinder push rod.

2. Adjust the distance of 126 mm between master cylinder flange face and the fork hole centre as shown in the figure.

3. Tighten push rod check nuts of master cylinder without disturbing adjusted length.

4. Adjust clutch pedal free play with the help of stopper screw as shown in figure. Free play at clutch pedal should be between 15 - 20 mm.

5. Operate clutch pedal a few times to ensure desired clutch pedal free play.

6. Apply synthetic grease at all rotary joints.

Clutch pedal height adjustment & free play adjustment is needed to be done at Tata authorised workshop only.

Page 90

4.5 Clutch Maintenance

Clutch fluid filling and bleeding

Procedure for bleeding the system given below :

i. Remove filler cap and fill the

clutch fluid container with fresh brake fluid.

ii. Remove dust cap from slave

cylinder bleed screw and clean it thoroughly. Attach bleed tube to the bleed screw and place

Filling clutch fluid

other end of the tube in a clean glass jar containing sufficient brake fluid to submerge the end of tube.

220mmapprox.

4 6

Schematic layout of clutch actuation mechanism

1. Clutch Pedal

2. Adjusting pin

3. Clutch release fork

4. Clutch fluid container

5. Clutch master cylinder

6. Clutch slave cylinder

7. Bleeding nipple

8. Master cylinder push rod

9. Clutch pedal stop

iii. Pump clutch pedal twice/thrice

slowly throughout its stroke and by holding the pedal pressed, loosen bleed screw and watch air bubbles in glass jar.

iv. Retighten bleed screw and

repeat the same operation until air bubbles cease to appear allowing only fluid to flow.

v. Replace dust cap on bleed

screw without fail.

Page 91

4.6 Gearbox Maintenance

Gear box oil checking

Check level of gear box oil. Top up if necessary.

Gear box oil change

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

: 5.8 Litres

Recommended oil

Gear box (GBS - 40)

1. Oil drain plug

2. Oil level plug

Remote gear shifting arrangement

Grade SYN gear EP 75 W 90 GL 4 Gulf grade.

Dimension A Link rod adjustment

Either increasing or decreasing the length or link rod assembly can adjust dimension A. Loosen lock nuts on both sides of connecting tube & adjust the length by turning connecting tube with the help of DE spanner clockwise / anti clockwise. When desired dimension is achieved, tighten lock nuts on both sides & recheck dimension A. The adjustment needs to be carried out in installed condition of link rod.

Dimension B Turning tube adjustment

This adjustment is to be carried out after disconnecting ball joint from gearshift lever. Loosen the lock nut from connecting flange & rotate ball joint clockwise /anti clockwise to obtain desired dimension. Tighten the lock nut. Assemble ball joint nut. Re-check dimension of turning tube assembly (Dimension B).

Link measurement (in mm) Drive A B

RHD 330 ± 1.5 1000 ± 2 LHD 350 ± 1.5 986 ± 2

Page 92

4.7 Propeller shaft Maintenance

Propeller shaft

Propeller shaft, U-joint cross bearing and sliding yoke should be regularly greased. Failure to do so may result in rapid wear and tear of the bearings and centre bearing mountings. Periodically check and if necessary, tighten mountings of centre bearing bracket to 8 mkg torque.

Propeller shaft centre beaming

U Joint yoke

When disconnecting propeller shaft, care must be taken to ensure that arrow marks on rear propeller shaft and sliding yoke are aligned during reassembly. Tighten coupling flange bolts to 7 mkg torque. When fitting propeller shafts ensure all ‘U’-joint yokes are in one plane. In case of undue vibrations noticed on propeller shafts, take necessary corrective action.

Page 93

4.8 Front axle & rear axle Maintenance

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

Hub greasing and adjustment

Remove front and rear wheel hubs. Dismantle and clean bearing and other components. Re-pack with bearing grease.

Front hub : 250 gm/ hub

Rear axle

1. Oil drain plug

2. Oil level plug

Rear axle oil level checking

Check level of rear axle oil. Top up if necessary.

Rear axle oil change

Drain while hot Fill the rear axle with new oil. Capacity : 2.75 litres

Recommended oil

Grade APIGL 5 SAE 85W-140 with 7% Anglamol-6043 by weight.

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

Check front & rear hub play at every 9000 kms & adjust, if necessary .

Rear hub : 450 gm / hub Grade - Multi purpose grease No. 2 Adjust hub bearing play . Front hub : 0.01 / 0.06 mm Rear hub : 0.04 / 0.1 mm Tubular spacer with shims provided

in between bearings for front and rear hubs to control hub play .

This operation is needed to be carried out at Tata authorised workshops only.

Front hub

Remove front hub cap, fill with ¾th full wheel bearing grease and refit at every 9000 kms.

Page 94

4.9 Power steering Maintenance

Then turn steering wheel several times from lock to lock so that air escapes from the system. Keep watching oil level. Add oil immediately when oil level drops.

Keep adding oil till the level remains at upper mark on dipstick and air bubbles are no longer visible in oil

Power steering tank

OIL FILLING AND BLEEDING Filling oil in steering tank

Steering gear and pump are filled through filler neck on oil tank. For initial filling and for oil changes it will be of advantage to remove the tank cover and to add hydraulic oil upto edge of tank. Engine can then be cranked with starter motor for a while (not more than 10 seconds at a stretch) to fill entire hydraulic system with oil. Since oil level in tank will drop rapidly, keep adding oil to avoid pump sucking air.

tank when steering wheel is turned. If above instructions are observed, oil

level in tank should not raise by more than approx. 1-2 cm when engine is shut off.

Shut off engine and lower front axle.

Oil level check-up when engine stopped

Add enough oil in tank until oil level is approx. 1-2 cm above upper mark. Start engine and run it at idling speed. Check oil level in dipstick. Oil level should be between minimum and maximum levels.

Bleeding the steering system

When steering gear is filled to the extent that short cranking of engine will not cause oil level to drop below top mark on oil dipstick, engine can be started.

Jack up front axle, start engine, run at idle speed for some time, thus allowing air to escape from the system. Oil level must be watched during this process. Oil must be topped up immediately if the level drops.

Page 95

4.9 Power steering Maintenance

Oil level check-up with the engine running

With engine running, oil level will drop slightly, since oil requires a pressure of appox. 2-4 bar to overcome flow resistance when

Power steering tank A. Bottom level B. To p level

flowing through the system. Add enough oil to keep oil at upper mark. Stop engine. Oil level should not raise more than 1-2 cm. A higher oil level indicates that there is air in the system.

Filter change

a. Unscrew closing plug from cover

of oil tank and remove tank cover.

b. Pull out used filter cartridge.

When pulling out, keep bore of filter cartridge closed so that no dirty oil could flow back into tank.

c. Lubricate filter carrier and insert

new filter cartridge with metal collar in upward direction.

d. Crank engine for a short period

with starter motor, so that oil level will drop. Then bleed the system.

Replace oil/oil filter at every 80,000 kms. Bleed the system and check performance with test equipment.

Page 96

4.9 Power steering Maintenance

Power steering pump belt tension adjustment

Checking and adjustment of steering pump belt tension.

a. Loosen bolt holding upper

mounting of steering pump to the clamping piece.

b. Loosen steering pump pivot pin

nut.

c. Loosen the locknut & adjust belt

tension by rotating the adjusting

Checking power steering pump belt tension

nut.

d. Check belt tension. Belt tension

is correct, if it can be depressed by 20 mm with thumb pressure applied in the middle of its length.

1. Lock nut

2. Adjusting nut

3. Clamping bolt

4. Clamping piece

e. Tighten clamping piece bolt, lock

nut and pivot pin nut for locking the pump in position.

Power steering linkages

In case of excessive free play, check steering linkages for looseness and get the defect rectified immediately. Periodical inspection of steering linkages is essential for driving safety.

Page 97

4.9 Power steering Maintenance

Sector shaft play adjustment

If play is noticed on drop arm or input

Sector shaft play adjustment A. Sealing nut B. Adjuster screw

shaft of steering gear box, it is to be adjusted as given below :

● Bring steering wheel to SAP

(Straight Ahead Position).

● Sealing nut is to be loosened in

anticlockwise direction by holding adjuster screw in place with a screw driver.

● Rotate adjuster screw with

screwdriver in anticlockwise and check for play on drop arm. Play will increase.

● Again rotate adjuster screw in

clockwise direction till the play disappears on drop arm, holding the sealing nut in place.

● Turn adjuster screw clockwise

another half turn. Hold it in place with a screw driver and lock sealing nut.

100

T orque f or sealing nut is 70 Nm. This adjustment is usually required

after a coverage of 100,000 kms.

Page 98

4.10 Brake system Maintenance

S Cam full air brakes

S cam brakes are fully air operated brakes. Brake actuators at front and rear axles are externally mounted outside the foundation brake assemblies.

Air is fed to brake actuators through dual brake valve (Operated by brake pedal), proportional to braking requirements.

Push-rods of brake actuators act on slack adjusters, which convert linear motion into circular motion of cam shaft. S-shaped cam portion of shaft expands brake shoes against drums, thus applying brakes.

S cam is of equal displacement design, resulting in equal wear of leading and trailing shoes.

Brake system provides safe and reliable braking. Brake circuit consisting of various pneumatic components is shown in schematic layout.

Service brakes consist of two separate circuits. One for front wheels and the other for rear wheels.

In the unlikely event of failure of any one circuit, other circuit remains still operative and guarantees a certain degree of braking for the vehicle.

One of the auxiliary outlet of system protection valve is connected through a graduated hand brake valve to spring brake chamber portion, integral with rear brake actuator.

air pressure, thus releasing parking brake. For parking / emergency braking, hand brake valve is operated for depleting air to atmosphere, thus applying parking brakes.

Second auxiliary outlet of system protection valve is connected to exhaust brake air cylinder through exhaust brake solenoid valve which is coupled with service brake pedal operation through stop light switch.

Exhaust brake isolator switch is provided on instrument panel which can be used to cut off exhaust brake, isolating exhaust brake whenever required e.g. while starting the vehicle on steep up gradient.

An air dryer cum unloader valve is fitted between air compressor and system protection valve alongwith purge tank. Air dryer ensures clean and dry air in the brake system, resulting in enhanced life of brake valves.

Note :

Do not attempt to clean air dryer desiccant cartridge and filter.

Replace desiccant cartridge and filter after every 2 years.

To conduct brake system routine service check - I prescribed at every 18,000 km and routine checks - II prescribes at every 36,000 km contact nearest Tata authorised workshop.

Procedure for these checks explained in pages 110-112.

During normal running, inside springs are kept in compressed condition by

101

Page 99

4.10 Brake system Maintenance

102

AIR BRAKE SYSTEM WITH ABS (IF FITTED)

Page 100

4.10 Brake system Maintenance

103

SCHEMATIC LAYOUT OF DUAL CIRCUIT FULL AIR S-CAM BRAKES WITH LCRV