TATA Motors LP 613 EURO-II Operator Service Book Download

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1.6 Additional fitments

General

ITEM NO. 3b - PROPOSAL - B

ITEM NO. - 4

ITEM NO. - 5

102

105

(TYP)

MATERIAL - SHEET 1 THK. D 513 SS : 4010

10 DIA

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

10 DIA

150

100

(TYP)

MATERIAL - SHEET 1 THK. D 513 SS : 4010

ITEM NO. 3a - PROPOSAL - A

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

LENGTH OF SIDE PANEL

Summary of Contents for LP 613 EURO-II

Page 1: ...7 001 500 Tata LP LPT 613 EURO II Operator s Service Book The contents given in this book are not binding are subject to change without notice and are for illustration purposes only International Business CVBU Mumbai INDIA ...

Page 2: ...ing 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 Intern...

Page 3: ...tional fitments 20 1 7 Additional provisions electrical 30 2 Vehicle Handling 2 1 Vehicle identification 37 2 2 Location of aggregate numbers 41 2 3 Instrument panel 43 2 4 Switches gauges indicators 44 2 5 Driving controls 55 2 6 Turbocharger 57 2 7 Charge air cooler 58 2 8 Clutch booster 59 2 9 Cab tilting 60 2 10 Heating 65 2 11 Driver seat seat belt 66 CONTENTS ...

Page 4: ...ure 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 5: ... 5 3 Lubrication points 141 5 4 Tightening torques 143 6 Fuel lubricants and coolants 6 1 Fuel 149 6 2 Lubricants 150 6 3 Coolant 152 7 Service recommendations 7 1 Special instructions 155 7 2 PDI 156 7 3 Service schedule 159 7 4 Record of services performed 168 7 5 Record of repairs performed 170 ...

Page 6: ... 1 1 About Tata LP LPT 613 EURO II 3 1 2 Environment protection 5 1 3 Important tips for driver 7 1 4 Tips for maintenance 10 1 5 Body building 11 1 6 Additional fitments 20 1 7 Additional provisions electrical 30 ...

Page 7: ...nd 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 type air filter etc A radiator auxiliary tank is provided for convenient coolant filli...

Page 8: ...nce 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 ser...

Page 9: ... Switch off engine during long stops at traffic jams or signals If situation demands that engine 1 2 Environmental protection General be kept running avoid frequent revving up of engine Also avoid frequent stopping and restarting if uncalled for 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...

Page 10: ...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 forleakages 3 Cylinderheadforvalveleakage 4 All filters such as air oil and fuel filters 5 Turbo charger Euro II 6 Air after cooler Euro II 1 2 Environmental protection General This book contai...

Page 11: ...rate engine in correct temperature range i e between 60O C 100O C 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 bleedi...

Page 12: ... 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 ...

Page 13: ...osition 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 1 3 Important tips for driver General ...

Page 14: ... Tata authorised workshop 6 Any change in clutch pedal free play is to be immediately investigated 7 Get your vehicle serviced atTata authorised workshop at recommended intervals 8 Use only recommended grades of oils for all aggregates 9 All services repairs to be carried out atTata authorised workshops only 10 Do not reinforce chassis frame springs or axles for carrying higher payload It will res...

Page 15: ...ake connections brake piping extension of chassis rear over hang relocation of chassis components to ensure good performance in operation 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 To accommodate wheels side frame is formed to a suitable shape called wheel arch To prev...

Page 16: ...ring as electrical earthing point during welding 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 thic...

Page 17: ...hanical hitting which might damage the core of radiator air after cooler 24 Protect auxiliary tank from weld spatters and mechanical damage Use proper cover to protect radiator and auxiliary tank during welding in their vicinity 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 Addition...

Page 18: ...se 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 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 U Bolt fastening with steel runner Section AA U Bolt fastening with wooden runner Section AA CANVAS PACKING A typical meth...

Page 19: ...t particles are not generated like in metal tubes and thus protects valves etc 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 Check that PA tubes is not rubbing against any other object on the v...

Page 20: ...e time of welding and gas cutting This will avoid welding spatter and molten metal from falling on the PA tubes and creating a hole in the PA tube 1 5 Body building General CoverPAtubebeforegascutting Unprotected areas while welding may damage PA tube Cover PA tube before welding Unprotected areas while gas cutting may damage PA tube ...

Page 21: ...do not come in contact with sharp objects This will avoid cutting of PA tubes PAtubesshouldnottouchsharpobjects Follow original routing of PA tubes 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 AvoidPAtubetotouchexhaustpipe Do not light fire near PA tube ...

Page 22: ...y building General 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 Avoid loose fitting of PA tube ...

Page 23: ...nal routing of PA tube z Take care that PA tubes are not forcibly bent or fitted z Use plastic coated clamps z Use both hands while fitting PA tube This will avoid twisting and kinking of PA tube Kinked tube Do not tighten nut without holding PA tube Hold PA tube before tightening nut Twisted tube ...

Page 24: ...dy customers have to ensure fitment of SUPD when they do body building Please refer fitment details of SUPD LOAD BODY BOTTOM OF FLOOR OVER ALL LENGTH H D G B P2 P1 E J A C FitmentofSUPDonLPTversion A Rear under run protection device RUPD This device is factory fitted on truck version Rear under run protection device fitted on vehicle LPT ...

Page 25: ... than or equal to 300 mm measured from front face of rear tyre 4 4 Dimension G should be greater than or equal to 100 mm 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 cro...

Page 26: ...CREW M10x20 IS17130 8 8 ITEM NO 2 3 ITEM NO 5 ITEM NO 1 C E D THIS SURFACE SHOULD BE INSIDE THE MAX WIDTH OF VEHICLE AND SHOULD NOT BE MORE THAN 120 mm INSIDE ITEM NO 6 HEX FLANGED SCREW M10x20 IS17130 8 8 10 2 0 2 0 2 0 STEEL CROSS RUNNER ITEM NO 8 C MATERIAL SHT 4 THK DD 1079 SS 4013A ITEM NO 2 AND 3 NOT SHOWN 20 20 20 VIEW FROM D VIEW FROM E SECTION CC ALTERNATE FOR SECTION BB SECTION BB MATERI...

Page 27: ... 45 34 5 R4 5 460 5 TYP 5 TYP MATERIAL SHT 1 6 THK D513 SS 4010 DETAILS X SECTION AA 2 R1 5 10 105 2 R3 50 35 15 MATERIAL SHT 1 6 THK D513 SS 4010 ITEMNO 4 MATERIAL SHT 1 6 THK D513 SS 4010 R3 46 15 18 230 2 SLOTS 13 x 18 13 15 33 125 65 ITEMNO 5 MATERIAL SHT 1 6 THK D513 SS 4010 150 5 R3 5 10 41 R4 5 ...

Page 28: ... 20 35 R5 R10 R10 R5 R5 34 10 PITCH ITEM NO 7 ITEM NO 8 CENTRE LINE OF ITEM NO 9 CENTRE LINE OF ITEM NO 9 OVERALL LENGTH 6 ITEMNO 8 12 R3 TYP 105 126 105 R15 R6 R6 R10 33 5 R4 R6 MATERIAL SHT 1 THK D513 SS 4010 ITEMNO 9 30 WELD NUT M10 IS 8856 50 65 115 2 HOLES 12 5 DIA H11 MATERIAL SHT 2 THK DD 1079 SS 4013A ...

Page 29: ...ting to wooden runner b Two alternate sections for panel item no 3 1 6 Additional fitments General A B B C C WOODEN RUNNER FRONT OF VEHICLE 340 ITEM NO 1 ITEM NO 2 ITEM NO 4 ITEM NO 3 100 540 980 BOTTOM OF SIDE WALL OF LOAD BODY GROUND SECTIONAL VIEW BB F VIEW FROM A F 10 MAX WIDTH OF LOAD BODY AVERAGEHEIGHT MEASURED ON DIFFERENT LOAD BODIES ITEM NO 3 WOODEN RUNNER ...

Page 30: ...8x20 BRT WASHER 8 4 SPRING WASHER B8 HEX NUT M8 ITEM NO 3a ITEM NO 3b Note Refer item no 3a 3b 4 and 5 ITEMNO 2 MATERIAL ANGLES 45x45x3 THK Fe 410W A IS 2062 ITEMNO 1 MATERIAL SHEET 2 THK DD 1079 SS 4013A DIMN TO SUIT WOODEN CROSS MEMBER REF CROSS SECTION FF 6 HOLES 11 DIA 72 40 240 250 85 85 40 R5 TYP 15x450 45 230 D D PLATE 3 THK 3x30x30 E E 150 4 HOLES 12 DIA 20 478 SECTION EE SECTION DD ...

Page 31: ...5 TYP 15 MATERIAL SHEET 1 THK D 513 SS 4010 10 DIA 45 MATERIAL SHEET 3THK Fe410 1079 SS 4013A 20 45 25 10 DIA 150 40 100 30 20 R2 35 R5 TYP 20 MATERIAL SHEET 1 THK D 513 SS 4010 ITEM NO 3a PROPOSAL A MATERIAL RECTANGULAR TUBE 100x25x1 5 THK MINIMUM HF YST 210 IS 4923 LENGTH OF SIDE PANEL ...

Page 32: ...us will be fitted with rear view mirror Please refer section CC and section DD on page 29 1 6 Additional fitments General C Rear view mirror LP LPT versions BUSBODY TRUCKBODY B DETAILS OF A 6 8 5 0 7 0 16 5 2 3 3 3 X 1070 C C D D DETAILS OF B ASSY REAR VIEW MIRROR R H 1008 10 Y 0 center line of vehicle BUSBODY TRUCK CAB 210 6 4 0 Z 20 A X 1070 X 0 ...

Page 33: ...ne each at driver side and co driver side RUBBERPADTOP BRACKET TOP SLEEVE FOR FRAME SL CSK SCREW M6x20 4 8 WASHER C 6 4 SPR st 130 SECTION DD 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 RUBBERPADBOTTOM BRACKET BOTTOM SECTION CC Mirror for custom built cab ...

Page 34: ...panel below the wind screen with suitable mounting bracket 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 properl...

Page 35: ...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 ...

Page 36: ...AX 2100 MAX 1500 MAX V U 100 MIN 1500 MAX 2300 MAX H 350 MIN 250 MIN 1000 MAX UP TO 1800 UP TO 2500 3000 MAX 500 MIN 4000 MAX 4000 MAX 1 0 0 0 M A X 1500 MAX 2000 MAX 400 MAX VIEW Y 250 MIN 250 MIN MAX UPTO HEAD LAMP TOP SURFACE UP TO 1200 C A B C D E End out line marker lamp G H Side indicator lamp I J K L M N Side marker lamp Side retro reflector P O Front Fog lamp R Rear Fog lamp S T Head lamp ...

Page 37: ...TE FUSE 10A PARKING LAMP ON O P FRO COMBI SWITCH FUSE 10A CONNECTIONS TO BE TAKEN FROM THIS POINT 5W END OUT LINE MARKER LAMP RH FRONT 0 75 Sq mm GREY 0 75 Sq mm GREY 0 5 Sq mm BROWN 0 5 Sq mm BROWN 5W 5W SIDE MARKER LAMP LH FRONT SIDE MARKER LAMP LH MIDDLE 0 5 Sq mm BROWN SIDE MARKER LAMP LH REAR END OUTLINE MARKER LAMP LH REAR 0 5 Sq mm BROWN 0 5 Sq mm BROWN 0 75 Sq mm GREY 0 5 Sq mm GREY NOTES ...

Page 38: ... 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: ...37 2 1 Vehicle identification KnowYourVehicle LPT 613 Full forward control truck with tilt cab RHS view LPT 613 Full forward control truck with tilt cab LHS view ...

Page 40: ...K 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 C...

Page 41: ...39 2 1 Vehicle identification KnowYourVehicle LP 613 CHASSIS WITH COWL 38 WB EURO II LHD ...

Page 42: ...40 2 1 Vehicle identification KnowYourVehicle LPT 613 CHASSIS WITH CAB AND LOAD BODY 38 WB EURO II LHD ...

Page 43: ... 2 2 Location of aggregate numbers KnowYourVehicle Chassisnumber LHD 1 Chassisnumberplate 2 Cab Cowlnumberplate 2 1 Enginenumberplatelocation Engine number plate Cab Cowl number plate Chassis number plate ...

Page 44: ...42 2 2 Location of aggregate numbers KnowYourVehicle Gearboxnumber Rearaxlenumberplate Powersteeringgearboxnumberplate Frontaxlenumberplate ...

Page 45: ... indicator 11 Seat belt indicator 12 Hazard warning indicator 13 ABS indicator If fitted 14 Rear fog lamp indicator 15 Air filter service indicator 16 Glow plug indicator 17 Air pressure gauge II 18 Air pressure gauge I 19 Exhaust brake isolator switch 20 Front fog lamp switch 21 Blank 22 ABS switch If fitted 23 Head lamp leveling knob 24 Blank 25 Rear fog lamp switch 26 Engine compartment lamp sw...

Page 46: ...ph 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 Coolant temperature gauge Temperature gauge indicates coolant temperature It senses coolant temperature through a transducer mounted on upper cooling line When gauge needle touches red band on dial it indicates engin...

Page 47: ...e indicator start blinking If the engine coolant temperature is more than 20O C the indicator blinks continuously i e ready to start Front fog lamp indicator This indicator will glow only when Front fog lamp is switched on 2 4 Switches gauges indicators KnowYourVehicle Rear fog lamp indicator This indicator will glow when rear fog lamp is switched ON Low air pressure indicator Red Two low pressure...

Page 48: ...tion key is in ON position before starting the engine 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 theengine whenoilpressurebuildsup If indicator continues to glow even after the engine has started stop the engine trace out the fault in lubrication system electrical connections ...

Page 49: ...rs 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 s...

Page 50: ... only when the park lamps are switched ON 2 4 Switches gauges indicators KnowYourVehicle 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 Seat belt indicator It comes ON when seat belt is not fastenorbelt tongu...

Page 51: ...top light switch comes into operation and lights at rear tail lamp glow This also activates 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 Air dryer heater This heater is a part of air dryer assy This heater is provided to heat the moisture if any ...

Page 52: ...ey Unlocked All off LOCK without key Locked All off ACC Accessories IG Ignition ST Start 2 4 Switches gauges indicators KnowYourVehicle 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 while carrying out any el...

Page 53: ...rake 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 retur...

Page 54: ...ignals 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 2 4 Switches gauges indicators KnowYourVehicle Combinationswitch POSITION FOR WASH ON POSITION FOR FLASH HIGH BEAM N POSITION FOR LOW...

Page 55: ...sition 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 This is spring loaded position and can be used in day time for giving signal to on coming traffic 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 wh...

Page 56: ...ever 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 ...

Page 57: ... on push rod assembly of brake chamber A Brake applied B Brake released A to B Gradual application 1 Accelerator pedal 2 Brake pedal 3 Clutch pedal 4 Parking brake 5 Gear shift lever Handbrakevalve B A 6 Steering wheel 7 Combiswitch lever Lights 8 Instrument panel 9 Steering lock cum ignition switch 10 Combiswitch lever Wiper washer DrivingcontrolsLHD 6 7 8 5 4 1 2 3 10 9 ...

Page 58: ...ld 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 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 positio...

Page 59: ... 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 yourvehicletoTataauthorisedworkshop 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...

Page 60: ...rge 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 Charge air cooler TURBOCHARGER EXHAUST INLET ...

Page 61: ... 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 p...

Page 62: ... 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 12 13 14 RELEASEDANDTILTEDPOSITION 2 9 Cab tilting KnowYourVehicle Cabtiltingandlockingleverarrangement 3 6 8 7 9 4 2 1 5 10 11 RELEASED POSITION BEFORE TILTING ...

Page 63: ...raise the cab 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 padlock or bolt and nut from primary locking lever sketch position No 3 3 2 Handbrakevalve B A 1 ...

Page 64: ...ting 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 ...

Page 65: ...lightly 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 9 8 7 ...

Page 66: ...ting KnowYourVehicle 10 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 12 11 ...

Page 67: ...riod Slot C Closing and opening of leg vent Leg vent closed Leg vent open 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 spe...

Page 68: ...em to shut off engine blower and heater Maintenance 1 Check hoses joints for leakage Tighten if necessary 2 Check hoses for cracks Replace if required If there is a loss of coolant replenish coolant mixture in auxiliary tank 3 If blower is not working check fuse if blown replace Driver seat adjustment Lever 1 Lever for adjusting back rest Lever 2 Lever for adjusting seat height at rear Lever 3 Lev...

Page 69: ...st 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 ...

Page 70: ...69 3 Driving 3 1 Starting the engine 71 3 2 Driving 72 3 3 Stopping the engine 75 3 4 Special operating conditions 76 3 5 Fuel economy 78 3 6 Do it yourself 79 ...

Page 71: ...pring 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 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 pr...

Page 72: ...pressing of accelerator pedal 4 Gear Shifting Vehicle should be started in first gear only 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 Reverse gear should only be engaged when vehicle has been brought to a complete stop Approximate speeds for gear change 5 While driving left foot ...

Page 73: ...plication 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 effect Do not ride brakes This will lead to over heating of brake ...

Page 74: ... air cylinder thus operating exhaust brake butterfly valve 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 In certain situations like starting of vehicle on an upgradient simultaneous accelerati...

Page 75: ...ial should not be lubricated since the lube oil would cause seizing of the butterfly valve in its housing 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 shut off valve and fue...

Page 76: ...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 glo...

Page 77: ...e 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 supp...

Page 78: ...tions should be taken Ensure that steering linkages and brakes are in order and proper gears are used during climbing and 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 bein...

Page 79: ...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: ...n service indicator glows on instrument panel Clean air filter housing and primary 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 vehi...

Page 81: ...ction 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 Blow compressed ...

Page 82: ...7 Bleed fuel system and start engine 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 bowl To remove water from the bowl loose the primer then loose the drain plug Water starts dropping from drain plug Once...

Page 83: ...fter 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...

Page 84: ...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 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 fi...

Page 85: ...s 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 Fil...

Page 86: ...ater 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 r...

Page 87: ...ns 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 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...

Page 88: ...djusting 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 Fanbelttensionadjustment 1 2 Idlerpulleyflangenuts 3 Tensionerrodmoun...

Page 89: ...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 adjustm...

Page 90: ...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 4 5 Clutch Maintenance 3 6 4 5 7 1 8 2 9 220 mm approx Schematiclayoutofclutchactuation mechanism 1 C...

Page 91: ...spanner clockwise anti clockwise When desired dimension is achieved tighten lock nuts on both sides re check 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 cloc...

Page 92: ...earing bracket to 8 mkg torque 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 4 7 Propel...

Page 93: ... 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 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 re...

Page 94: ... 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 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 ...

Page 95: ... 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...

Page 96: ...belt tension Belt tension is correct if it can be depressed by 20 mm with thumb pressure applied in the middle of its length 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 essen...

Page 97: ...th 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 Torque for sealing nut is 70 Nm This adjustment i...

Page 98: ...earest Tata authorised workshop Procedure for these checks explained in pages 110 112 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 a...

Page 99: ...102 4 10 Brake system Maintenance AIR BRAKE SYSTEM WITH ABS IF FITTED ...

Page 100: ...103 4 10 Brake system Maintenance SCHEMATIC LAYOUT OF DUAL CIRCUIT FULL AIR S CAM BRAKES WITH LCRV ...

Page 101: ... brake efficiency Procedure 1 Jack the wheels Release hand brake if it is in ON condition 2 Position a box spanner or a ring spanner 12 mm A F over the adjuster hexagon By depressing the locking sleeve turn adjuster screw clockwise until shoe begins to bind drum Then turn adjuster screw anticlockwise 270O Note It is possible to check clearance between the drum and lining by using a feeler gauge th...

Page 102: ... does not effect parking brake due to the action of system protection valve A mechanical wind off screw M16 x 1 5 is provided at the top of spring brake actuator to release automatically applied parking brake due to any reason To release rotate wind off screw up with a spanner against the tension of spring inside spring brake chamber till brakes are completely released Wind off screw has to be tur...

Page 103: ...mes properly Adjustment of exhaust brake There is no separate exhaust brake adjustment Stop light switch serves the function of providing signals both for rear tail brake lamps as well as for exhaust brake solenoid valve Precautions Check for proper functioning of exhaust brake at PDI and after every 10 000 Km With brake pedal fully released there should be no exhaust brake application If it is on...

Page 104: ... side of the frame and connected to rear axle with help of linkages Distance between axle and Chassis top varies with the load on vehicle This variation is sensed by the valve through the linkage connected to the axle and input air pressure to brake actuator is modulated Adjustment In unladen vehicle with or without load body Loosen screw B Rotate link A by sliding rubber connector over link C suc...

Page 105: ... due to the limit of tyre to road adhesion The ABS is addition to the basic brake system It is activated automatically every time the engine is started If there is a malfunction the system turns off automatically indicated by a ABS warning indicator on the dash board still the ordinary brake system continues to work ABS Activation ABS activation varies with various road surfaces i e the amount of ...

Page 106: ...ollowing distance 3 ABS does not reduce either time or stopping distance It only helps steering control during braking You should always keep a safe distance from other vehicles 4 ABS will not prevent skidding of a vehicle that results from changing direction abruptly such as trying to take a corner too fast or making a sudden lane change 5 ABS cannot prevent a loss of stability due to severe or s...

Page 107: ...ening pressure in the system protection valve will rise at first to a certain limit Then other circuit will follow and both will rise together f The low air pressure indicator should be off at the specified value 5 4 0 5 bar If not rectify g Continue to charge the system till cut out pressure 7 4 0 2 bar The unloader valve should cut out identified by a hissing noise h Stop engine The time taken f...

Page 108: ...wing checks of different brake valves keep the system healthy It is recommended once in 40 000 km and after each brake overhaul 2 1 System protection valve SPV A Opening pressures a Fail one service circuit say rear circuit port 21 by opening any pipe joints b Drain the healthy reservoir front below 4 bar and charge air at max engine speed c Note max pressure in the gauge of healthy circuit This i...

Page 109: ... brake OFF condition c Open inlet pipes one by one say 11 and check for leakages between primary and secondary chambers in brakes OFF and ON conditions Repeat with pipe 12 disconnected 2 3 Brake chambers a With brakes applied at full pressure check for leakages in front and rear brake chambers b Open service brake pipe 11 of spring brake actuator and check for leakages from spring brake chamber in...

Page 110: ... diameters are recommended upto repair size II of 329 mm Drums should not be used beyond 330 mm dia as there will be no service braking or parking brake left due to cam roll over Before that drums should be discarded 6 Any extra air connection to auxiliaries like air horn should be taken from exhaust brake circuit only and not from parking brake circuit or service brake circuits 7 Graduated hand b...

Page 111: ... spring packs at every 72000 kms Clean apply graphite grease reassemble Check eye bushes replace if necessary Anti roll bars bus chassis Check anti roll bar mountings at every 9000 kms tighten if necessary Check condition of bushes and replace if necessary Wheel alignment Check toe in at every 36000 kms adjust if necessary Specified toe in 0 to 3 mm Shock absorbers Check condition of shock absorbe...

Page 112: ...ing it is necessary to fix the outer cable with out slackness Cable outer first part is between release lever and toggle lock RHS To adjust slackness on first part of cable loosen lock nut 2 and tighten adjustment nut 1 till the desired stiffness is achieved Tighten lock nut 2 firmly Cable outer second part is between the toggle lock RHS LHS To adjust slackness on second part of cable loosen lock ...

Page 113: ...ng out and resistance while lowering Adjustment procedure follows Place adjusting block A on the LHS end spline of torsion bar so as to align the midway of oblong hole 1 with locking bolt hole 2 Tighten lock bolt 3 to hand tight Loosen the lock nut 4 on adjusting screw and tighten screw 5 in order to achieve 3mm gap between adjusting screw and block Tighten lock nut 4 firmly Tighten lock bolt 6 of...

Page 114: ...ndition there is a rise in pressure after vehicle has travelled some distance and tyres get hot Tyre pressure should not be corrected under these conditions because if tyre pressure is corrected at this stage it will result in under inflation when it cools down It is good practice to have best tyres on front axle for operational safety of the vehicle However it is essential to match size of the ty...

Page 115: ...ng Wheels of your vehicle are balanced for better ride comfort and longer tyre life Balancing needs to be done whenever tyre is removed from rim 1 Permissible imbalance for tyre with rim 500 gm cm max 2 Total balance weight should be within 240 gms on each side 3 Relocate the tyre if the weight required to balance is more than 240 gm 4 Do not use more than one balance weight on one side 5 Tube val...

Page 116: ...tches indicate suggested sequence of tyre rotation Rotate tyre every 9 000 km or earlier depending on operation Type pressure LP LPT 613 At rated Unladen GVW LPT LP Front 90 psi 50 psi 35 psi 6 3 bar 3 5 bar 2 4 bar Rear 90 psi 35 psi 35 psi 6 3 bar 2 4 bar 2 4 bar 4 14 Wheels and tyres Maintenance Tyre rotation all tyres rib type REAR RIGHT REAR LEFT SPARE Tyre rotation Front tyres rib type rear ...

Page 117: ...hichever is provided from tyre inflating valve and start the engine After the condensed water and oil that may be present in the system have been completely expelled connect hose to the tyre inflating valve and nipple of the hose to the tyre tube nozzle Run the engine at fast idling speed Disconnect hose and check tyre pressure 4 14 Wheels and tyres Maintenance Connectinghosetotyretubenozzle Conne...

Page 118: ...djust belt tension as per following procedure a Loosen bottom mounting bolt of alternator b Loosen bolt holding upper mounting of alternator to the clamping piece c Loosen lock nut d Adjust belt tension by turning adjusting nut and by moving alternator away from engine e Tighten lock nut and the bolt holding clamping piece to alternator f Tighten bottom mounting bolt g Recheck belt tension 4 15 El...

Page 119: ...and swivel the head lamp assembly sideways on the hinges Remove rubber cap from rear of head lamp Push out cable socket from bulb Replace with new bulb taking care for proper fitment and lock the bulb with lock ring Refit cable socket with bulb on the head lamp and press it in position Note Do not clean the reflector as it will cause damage to mirror finished surface Do not replace bulb with dirty...

Page 120: ...by adjusting the dipped beams unlike other head lamps where main beams are adjusted e Head Lamp Focusing Park unloaded vehicle with no sag in suspension springs and all tyres equally inflated 10 m away from the screen with it s center in line with the central vertical line on the screen at right angles to longitudinal axis of the vehicle Keep the leveling switch at 0 position On the marked up scre...

Page 121: ...rly aligned the most brightly illuminated area will be below the intersection point A of two lines The second head lamp can be adjusted in a similar manner without disturbing the position of the vehicle and the screen Operate the leveling switch to 1 2 3 positions ensure symmetrical movement of cut off beams vertically Focusing should be done preferably in the dark The Dark Zone and the area below...

Page 122: ...ark Zone When properly aligned most brightly illuminated area will be just below the intersection A of two lines Head lamp on other side is adjusted in a similar manner without disturbing the position of vehicle and screen Now switch ON main beam lights They will be symmetrical above points of intersection point A B of vertical lines and horizontal line It is possible that main beams may not be ex...

Page 123: ...ts Head lamp HL 24 V 4 W 2 Tail lamp G 24 V 10 W 2 Number plate G 24 V 10 W 2 Reverse indicator lights Tail lamp RL 24 V 21 W 2 Battery charging indicator light Instrument panel 24 V 2 W 1 Low oil Pressure indicator light Instrument panel 24 V 2 W 1 Parking brake indicator light Instrument panel 24 V 2 W 1 Gauge illumination light Instrument panel 24 V 2 W 7 Driver compartment light Cab roof 24 V ...

Page 124: ... ECU RELAY BLUE FRONT FOG LAMP RELAY YELLOW ABS RELAY GREEN ACC RLY YELLOW HEAD LAMP L B RLY YELLOW STOP LIGHT RELAY BLACK 12V HOLD RLY BLACK ECU RELAY II YELLOW AIR DRYER HEATER 10A ACC 20A HEAD LAMP RELAY COIL 5A PARK RH 5A FRONT FOG LAMP 10A DC DC CONVERTER 15A WARNING LAMP ABS 5A RADIO 5A PARK LH 5A ENGINE STOP 5A IGN SUPPLY ABS 5A HORNROOF ENG LAMP 10A GAUGES 5A TURN 5A ADD SUPPLY BATTERY 5A ...

Page 125: ...essure from time to time The paint needs no special maintenance if the vehicle has been thoroughly cleaned before laying it up Caution Grease nipples must be carefully cleaned prior to greasing and the same applies to grease cups screw plugs before they are unscrewed Engine storage Short term Note This procedure describes the method of preparing an engine for short term 1 to 6 months storage Run e...

Page 126: ...hing procedure a second time Run engine at high idle until coolant temperature reaches 70O C Stop the engine Drain oil from sump Install drain plug and fill sump to high level mark on dipstick with preservative oil Note Lubricating system preservative oil must meet Military Specification MIL L 21260 Type PE 30 I SAE 30 Disconnect fuel supply tube at fuel filter and keep injector return tube at a c...

Page 127: ...ne Remove intake manifold cover and visually inspect the lower valve stem area for presence of rust An accumulation of rust requires disassembly and rebuild of cylinder head Install drive belt Remove plug from main oil rifle drilling and flush preservative oil from the engine by pumping 4 litres of light mineral oil into oil rifle Rotate crankshaft three or four revolutions as the engine is flushe...

Page 128: ...ffective for such washing Wash load body in shade when body is not hot to touch To protect box sections from corrosion apply DINTROL 3850 rust preventive compound in the box section of all sides panels floor tail gate and bottom cross member through drain holes provided for the purpose Be careful when transporting chemical cleansers fertilizers etc If a spill or leak is noticed care must be taken ...

Page 129: ...133 5 Technical Information 5 1 Technical specifications 135 5 2 Aggregate filling capacities 140 5 3 Lubrication points 141 5 4 Tightening torques 143 ...

Page 130: ... Ratio 17 5 1 Firing Order 1 5 3 6 2 4 Air Filter Dry type remote mounted Oil Filter Full flow paper type Fuel Filter Two stage pre and fine filtration Fuel Injection Pump Rotary type Timing With automatic advance built in FIP Governor Centrifugal type variable speed Capacity of Cooling System 20 litres Crankcase Oil Capacity Max 14 litres Min 12 litres Weight of Engine 450 kg Dry Radiator Frontal...

Page 131: ...ir S Cam brake ABS system with valve silencer and suitable for 40 deg ambient for LPT Dual circuit full air S Cam brake Fitment of ABS Optional For LP Brake Drum Diameter 325 mm Lining Area Front 1236 sq cm Rear 1236 sq cm Total 2472 sq cm Parking Brake Spring actuated parking brake acting on rear wheels Engine Exhaust Brake Coupled with service brake For LP FRAME Ladder type frame with rivetted b...

Page 132: ... Wheel Rims 6 00 G x 16 SDC No of Wheels Front 2 Rear 4 Spare 1 FUEL TANK Capacity 120 litres CAB All steel full forward control cowl Heating Demisting optional For LP All steel full forward control driver s cab with tilting arrangement with torsion bar assistance Heating demisting optional LPT ELECTRICAL SYSTEMS For LP OPTION I OPTION II System Voltage 12 Volts 24 Volts Alternator Capacity 65 Amp...

Page 133: ...mm 3400 3800 Minimum Turning 14 15 4 Clearance Circle Dia in m as per IS 9435 Minimum Turning Circle 12 3 13 5 Dia in m as per IS 9435 MAIN CHASSIS DIMENSIONS AS PER IS 9435 mm LP LPT Wheel Base 3400 3800 3800 Track Front 1650 1650 1650 Track Rear 1577 1577 1577 Overall Length 6425 7125 6860 Max Width 2140 2140 2125 Overall Height Unladen 2550 2550 2341 Front Overhang 1275 1275 1275 Loading platfo...

Page 134: ...issible GVW 7500 7500 SPECIAL FEATURES For LP Complete Vehicle its aggregates meet the latest EEC ECE GOST norms Relevant items are suitable for cold country application SPECIAL FEATURES For LPT Complete Vehicle its aggregates meet the latest EEC ECE GOST norms Relevant items are suitable for cold country application Provision for Engine block heater fitment Vehicle meets all Russian homologation ...

Page 135: ... System 3 litre Cooling System 20 litre Tyre pressure Front Rated GVW 90 psi 6 3 bar Unladen 50 psi 3 5 bar LPT 35 psi 2 4 bar LP Clutch Hydraulic System 1 1 litre Front hub grease 250 gm per hub Rear Axle 2 75 litre Tyre pressure Rear Rated GVW 90 psi 6 3 bar Unladen 35 psi 2 4 bar Rear hub grease 450 gm per hub Fuel tank 120 litre Water pump grease 80 gm Oil bath air filter 1 2 litres if fitted ...

Page 136: ...bed in tabular form 5 3 Lubrication points Technical Information Caution Grease nipples must be carefully cleaned prior to greasing and the same applies to grease cups screw plugs before they are unscrewed For greasing use only high pressure grease guns 1 2 3 4 5 6 7 8 9 10 11 18 12 13 14 15 16 17 ...

Page 137: ...12 Front spring suspension rear nipples 4 grease 13 Front hub Pack grease 14 Front spring suspension front nipples 2 grease 15 Engine oil level dipstick Oil level 16 Engine oil filling Oil level 17 Water pump bearing Pack grease 18 Manual steering gear box if fitted Oil level Also lubricate the following points not shown in the chart a Clutch release bearing sleeve felt pad Oiling b Clutch release...

Page 138: ...ts M8 0 6 11 Oil cooler bolts on crankcase M8 3 5 12 Timing gear housing on crankcase M10 4 5 13 Timing gear nut Injection pump M14 8 14 Timing gear housing cover M6 0 8 15 Bolt for timer on camshaft 30 16 Vibration damper lock bolt M24x1 5 50 to 55 17 Flywheel mounting bolts M12 10 18 Flywheel housing on crankcase M12 9 19 Oil pump to crankcase M8 3 20 Oil pump pressure relief valve 1 5 to 2 5 21...

Page 139: ...unting bolts 9 mkg 42 Propeller shaft coupling flange bolts 8 mkg 43 Nut holding coupling flange 30 to 36 mkg 44 Nut holding rear axle carrier assembly on beam 9 mkg HYDRAULIC POWER STEERING AND CHASSIS 45 Steering intermediate cover screw M10 3 mkg 46 Steering intermediate cover screw M 12 x 1 5 5 6 mkg 47 Steering intermediate cover screw M 14 x 1 5 9 2 mkg 48 Sealing nut 4 3 mkg 49 Oil drain pl...

Page 140: ...Rear with collar hex nut 63 Air brake chamber spring brake actuator mounting bolts M16 x 1 5 5 6 mkg Precaution Do not overtighten as it is likely to cause damage to brake chambers 64 Spring brake actuator mounting bracket to rear axle 4 6 mkg 65 Cam shaft bearing block to rear axle M10 4 6 mkg 66 Brake chamber mounting bracket to front torque plate 8 mkg Note When choosing torque wrench remember ...

Page 141: ...147 6 Fuel Lubricants and Coolant 6 1 Fuel 149 6 2 Lubricants 150 6 3 Coolant 152 ...

Page 142: ... injection systems it is extremely important that the fuel be kept clean and free of dirt or water Dirt or water in the system can cause severe damage to both injection pump and injection nozzles Use low sulphur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature Cloud point is the temperature at which wax crystals begin to form in diesel Viscos...

Page 143: ...dness or contain more than 100 ppm of either chloride or sulphate Specifications Use low silicate antifreeze which meets ASTM 4985 test GM6038M spec criteria or class II JIS K 2234 specification Use a 50 percent concentration level upto an ambient temperature 37O C for non amino base coolant For ambient temperature further low follow the guidelines below Antifreeze at 68 percent concentration prov...

Page 144: ...scosity recommendations for extreme climates Note Limited use of low viscosity oils may be used for easier starting and providing sufficient oil flow at ambient temperatures below 5O C However continuous use of low viscosity oils can decrease engine life due to wear Gear box oil Use multi grade oil conforming toSYN Gear EP 75 W 90 GL4 Gluf grade specifications Change oil first at 9000 km then at 3...

Page 145: ...T 4 Coolant Non Amino Base class II JIS K 2234 specification Chassis wheel Li base grease NLGI 2 Consistency No 3 bearing grease Clutch Clutch release Synthetic grease 365 TS 25205 P1 bearing Sleeve Clutch disc splines Brake pneumatic Synthetic grease 365 TS 25205 P1 equipment Windshield washer Methanol and water 50 50 water 6 3 Coolants Fuel Lubricants and Coolants Power steering oil Use Automati...

Page 146: ...153 7 Service Recommendations 7 1 Special instructions 155 7 2 PDI 156 7 3 Service schedule 159 7 4 Record of services performed 168 7 5 Record of repairs performed 170 ...

Page 147: ...al hours or litres of fuel consumed For example in case where vehicle is used as a stationery power source engine oil and oil filter cartridge should be changed after every 250 operational hours or after every 3 200 litres of fuel consumed PDI Service to be performed once only i e at the time of delivery of vehicle Every 1 000 km Type 2 Service at 9 000 9 500 km repeating at every 18 000 km Type 3...

Page 148: ...for our warranty Before commissioning the vehicle after body building it should be produced for inspection at Tata authorised workshop to ascertain that operational efficiency of the vehicle has not been impaired during body building Any damage the vehicle might have sustained during body building or arising out of bad storage or lack of proper care or inadequate maintenance will be rectified by t...

Page 149: ...es clamps pipes at all locations in cooling system 8 Check for leakages of gear box oil 9 Check for proper fitment of gear shift lever rubber boots 10 Check level of clutch fluid Acceptable if found between mid and max 11 Check clutch brake pedal free play 12 Check for leakages in clutch actuation circuit 13 Check for fitment of split pins at drag link ball joints tie rod ball joints Stub axles 14...

Page 150: ...sing of doors 32 Check functioning of door locks latches and windows 33 Check for any complaints on the cab fittings instrument panel glove box etc 34 Check and tighten hand loose fasteners 35 Check for any breakages bends failure of any component assembly unit 36 Any fouling between two components which may lead to leakages or other complaints Fouling of fuel lines brake pipes clutch pipes air in...

Page 151: ... oil in sump Drain off while hot Clean magnetic drain plug 18000 7 Clean engine oil filter housing and cover Replace oil filter cartridge and O ring 18000 8 Clean oil bath air filter Euro I and fill to correct level with recommended engine oil Check condition 9000 of sealing rings replace if necessary 9 Remove drain plugs of fuel filters Drain off sediments Bleed the fuel system 9000 D Dailyservic...

Page 152: ...lts n Water pump o Coolant temperature transducer p Air filter mounting q Exhaust manifold and muffler assembly 13 Check alternator fan belt condition and tension If necessary replace belt adjust 9000 14 Check and if necessary tighten the following a Push rod chamber cover b Timing gear cover c Cylinder head cover d Radiator mounting 18000 e Radiator hose connections f Fuel tank brackets g Fuel fi...

Page 153: ...tity 320000kmsor2yearswhicheverisearlier of anti freeze agent in specified ratio 24 Replace radiator rubber hoses 72000 25 Remove and clean exhaust outlet elbow exhaust butterfly valve shaft and refit Do not lubricate 72000 26 Check engine for trouble free operation colour of exhaust gases and nozzle operation 18000 27 Check end play of turbo charger shaft radial clearance between turbine wheel ho...

Page 154: ... GEAR BOX 1 Check oil level in gear box top up if necessary 9 000 O 2 Change oil in gear box also at first 9 000 km 36 000 3 Clean breather on gear box 72 000 4 Check tighten if necessary Gear box mounting screw 18 000 SUSPENSION 1 Grease with grease gum 9 000 O ii King pins 4 Tie rod ball joints 2 Drag link ball joints 2 iii Front spring pins 6 iv Rear spring pins 6 2 Check condition of shock abs...

Page 155: ...sary 9 000 REAR AXLE 1 Check oil level in rear axle top up if necessary 9 000 O 2 Change oil in rear axle Also at first 9000 km 36 000 3 Change grease in rear hub Adjust bearing play Replace damaged worn parts 36 000 4 Check rear hub bearing play and adjust if necessary 9 000 WHEELS TYRES 1 Check tyre pressure DAILY D 2 Check wheel mounting nuts and tighten if necessary 9 000 O 3 Check and tighten...

Page 156: ...and travel of brake chamber s push rod 9 000 Adjust service brakes if necessary for long route application 7 Check brake lining wear clearance with drum and travel of brake chamber s push rod 4 500 Adjust service brakes if necessary for city hilly cross country applications 8 Check for proper functioning of engine exhaust brake and slackness in linkages 9 000 9 Check brake torque plate mounting bo...

Page 157: ...nd camshaft bushes roller ends _ At the time of replacing linings 18 Dismantle pneumatic aggregates of brake system Clean inspect and replace parts if necessary 72 000 Apply grease to components while reassembling 19 Complete overhauling of foundation brake Everysecondbrakeshoereliningorasrequired 20 Air dryer replace desiccant cartridge and filter Everytwoyears STEERING 1 Check oil level in power...

Page 158: ...k electrical gadgets for proper functioning Rectify if necessary DAILY D 5 Check electrolyte level in battery and add distilled water if necessary 9 000 O 6 Check battery mountings clean battery posts and terminals 9 000 O tighten terminals and smear vaseline petroleum jelly 7 Lubricate with oil can Pinion bushing of starter motor and wiper and motor linkages 18 000 8 Check alternator carbon brush...

Page 159: ...and driver s co driver s seats HEATING DEMISTING SYSTEM wherever fitted 1 Check hose joints of heating system for leakage Tighten if necessary 9 000 2 Check hoses of heating system for cracks Replace if required 9 000 3 Check blower for proper functioning Check fuse Replace if found blown 9 000 RUBBER NYLON HOSES FLEXIBLE PIPES 4 Check hoses pipes of air fuel coolant brake clutch windscreen washin...

Page 160: ... 81 000 2 90 000 3 99 000 2 1 08 000 4 1 17 000 2 1 26 000 3 1 35 000 2 1 44 000 5 1 53 000 2 1 62 000 3 1 71 000 2 Recommended Service At km Type Date Odometer readingKms Repair Order No Servicing Dealer s Signature Stamp 7 4 Record of services performed Service Recommendations ...

Page 161: ...00 2 2 52 000 4 2 61 000 2 2 70 000 3 2 79 000 2 2 88 000 5 2 97 000 2 3 06 000 3 3 15 000 2 3 24 000 4 3 33 000 2 3 42 000 3 Recommended Service At km Type Date Odometer readingKms Repair Order No Servicing Dealer s Signature Stamp 7 4 Record of services performed Service Recommendations ...

Page 162: ...170 7 5 Record of repairs performed Service Recommendations Odometer Repair ServicingDealer s Date readingkm OrderNo ParticularsofRepair Signature Stamp ...

Page 163: ...171 7 5 Record of repairs performed Service Recommendations Odometer Repair ServicingDealer s Date readingkm OrderNo ParticularsofRepair Signature Stamp ...

Page 164: ...172 7 5 Record of repairs performed Service Recommendations Odometer Repair ServicingDealer s Date readingkm OrderNo ParticularsofRepair Signature Stamp ...

Page 165: ...173 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 1 of 16 ...

Page 166: ...174 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 2 of 16 ...

Page 167: ...175 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 3 of 16 ...

Page 168: ...176 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 4 of 16 ...

Page 169: ...177 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 5 of 16 ...

Page 170: ...178 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 6 of 16 ...

Page 171: ...179 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 7 of 16 ...

Page 172: ...180 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 8 of 16 ...

Page 173: ...181 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 9 of 16 ...

Page 174: ...182 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 10 of 16 ...

Page 175: ...183 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 11 of 16 ...

Page 176: ...184 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 12 of 16 ...

Page 177: ...185 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 13 of 16 ...

Page 178: ...186 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 14 of 16 ...

Page 179: ...187 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 15 of 16 ...

Page 180: ...188 4 15 Electricals Maintenance WIRING DIAGRAM LP LPT 613 EURO II Drg Part No 2641 5400 00 11 Sheet No 16 of 16 ...

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TATA Motors LP 613 EURO-II, Operator Service Book

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