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TATA LIGHT BULLET PROOF VEHICLE 4X4 WITH 4SP DICOR ENGINE, 115PS, POWER STEERING, BUCKET SEAT, 6 SEATER, BHARAT STAGE III
Citation preview
Owner’s Manual & Service Manualfor
TATATATATATTTTTA SUMOA SUMOA SUMOA SUMOA SUMO
LIGHT BLIGHT BLIGHT BLIGHT BLIGHT BULLET PRULLET PRULLET PRULLET PRULLET PROOF OOF OOF OOF OOF VEHICLE 4X4VEHICLE 4X4VEHICLE 4X4VEHICLE 4X4VEHICLE 4X4
ISSUED BY
PUNE
FOREWORD
Thank you for selecting TATA LIGHT BULLET PROOF VEHICLE
(4x4 ) of your choice.
We welcome you to the world of advanced automotive engineering
in a form especially suited to our operating conditions.
This book gives you all the information necessary for making
your ownership of the vehicle, a thoroughly satisfying experience.
Should you need any special technical assistance, please
contact us.
Please note that by adhering to the correct operating procedures
and scheduled maintenance, you can obtain the maximum
performance from your vehicle.
We request you to go through the book and derive many miles
of motoring pleasure.
iii(The contents given in this book are subject to change without notice, not binding and are for illustration purpose only.)
We provide safe, high quality, high performance
vehicles. In order to maintain the level of
performance and reliability in the vehicle, it is
important that only TATA MOTORS genuine
accesories are to be fitted. Any accessory that is
fitted or modification that is carried out can hamper
the safety and performance of the vehicle besides
depriving you of your warranty benefits.
Use of genuine parts, designed and manufactured
to our exacting standards, are the best way to
maintain your vehicle in peak operating condition.
Please do not use substitutes. They always prove
costlier in the long run.
Failure to use genuine parts can invalidate any
future warranty claims.
The information and specifications given in this
book are valid as on the date of printing. TATAMOTORS LTD. reserves the right to make changes
in design and specifications and/or to make
additions to or improvements in this product without
obligation to install them on products previously
sold.
Vehicle Identification .............. vi
Vehicle details ............................ 1
Warranty ..................................... 2
Friendly notes
Do's .............................................. 4
Don’ts ........................................... 7
Handling
Location of aggregate
serial numbers..............................8
Keys.........................................................10
Doors...........................................................10
Rear view mirrors,Sunvisor .........11
Seats.......................................................12
First Aid Box & Fire
Extinguisher..............................12
Seat belt....................................13
Vehicle tools and jack.................14
Driving Controls..........................15
Gear Shift Lever, Parking Brake,
Spare Wheel.............................16
Instruments Cluster/Instruments...17
Steering lock cum
ignition switch ....................... 20
Combination switch.....................21
Windsheild Wiper / Washer.........22
Interior Lamps ...........................22
Front Tow Hook.........................23
Hazard Warning Switch,
Tail Lamp. Registration Plate
Lamp........................................24
Front / Rear Fog lamps............. 25
Head Lamp Levelling Switch, &
High Mounted Stop Lamp.......... 26
ECU,Towing Hook & Foot step.....27
Roof Hatch & Observation
Window ................................. 28
Gun Port,Ventilator &
Battery Isolator Switch.............. 29
Engine compartment light,
Bonnet opening and closing..,.... 30
Turbocharger............................. 31
Pre-silencer............................... 32
Power steering ......................... 32
Heating, Ventillation &
Air Conditioning ....................... 35
‘G’ Conscious pressure
reducing valve........................... 37
Preparing the vehicle for drive....38
Driving, gear shifting ................ 41
Driving Instructions, Braking ..... 42
Stopping/starting the engine
& Fuel economy........................ 43
4x4 operation. ...........................44
Vehicle maintenance
Engine Compartment...................46
Air Filter ................................... 47
Engine Cooling system ............. 48
Contents
iv
Contents
v
Changing engine oiland oil filter ............................. 49
Water Draining Procedurefrom Sedimenter........................50
Fuel & Filter draining,Priming Pump / Pear Pump.........51
Gear box Oil Checking/Changing..52
Transfercase Oil Checking /Changing...........................................53
Front / Rear Axle Oil Checking /Changing...........................................54
Bleeding clutch system............... 55
Brake system, Bleeding the
brake system ........................... 56
Brake adjustment....................... 58
Adjustment of Parking brake....... 59
Wheels and tyres....................... 60
External Repair Kit ...................,.62
Non-Skid Chains ........................63
Tyre Rotation ......................... 63
Battery...........................................64
Head Lamp Adjustment................65
Head lamp bulb replacement...... 67
Bulb specifications..................... 68
Fuses.......................................................69
Care and cleaning of vehicle ... 70
Preservation & De-preservation.. 73
Special Operation Conditions .... 81
Fuels, Lubricants, Coolants
Fuels, Lubricants ...................... 82
Coolants .................................. 83
Recommended, oils & lubricant. 84
Vehicle Data
Technical Specifications............. 85
Preliminary Trouble Shooting ..88
Lubrication and Maintenanceschedule
Lubrication points ..................... 96
Special instructions ................... 98
Lubrication & Maintenance
schedule.................................................99
Vehicle record
Service performed................... 102
Repairs carried out.................. 104
Abbreviations ......................... 106
Vehicle identification Photographs
TATA LIGHT BULLET PROOF VEHICLE 4 X 4 - DIFFERENT VIEWS
vi
1
VERSION DESCRIPTION
TATA LIGHT BULLET TATA LBPV 4X4 WITH 4SP DICOR ENGINE, 115PS, POWER STEERING,PROOF VEHICLE 4X4 BUCKET SEAT, 6 SEATER, BHARAT STAGE IIIWITH 115PS 4SP DICORENGINE
Vehicle details
2
WARRANTY
We WARRANT the TATA LBPV4X4 vehicles and parts thereofmanufactured by us to be free fromdefect in material and workmanship,subject to the following terms andconditions :
1. This warranty shall be for 24months or 20,000 kmswhichever expires first from thedate of delivery of the vehicle.
2. Our obligation under thiswarranty shall be limited torepairing or replacing, free ofcharge, such parts of thevehicle which, in our opinion,are defective, on the vehiclebeing brought to us or to ourdealers within the warrantyperiod. The parts so repairedor replaced shall also bewarranted for quality andworkmanship but such warrantyshall be warranted for qualityand workmanship but suchwarranty shall be co-terminuswith this original warranty.
3. Any part which is found to bedefective and is replaced byus under the warranty shall beour property.
4. As for such parts as tyres,batteries, transfer case, rubberparts, electrical equipment,power steering equipment, A.C.equipment not manufactured byus but supplied by otherparties, this warranty shall notapply, but buyers of the vehicleshall be entitled to, so far aspermissible by law, all suchrights as we may have againstsuch parties under theirwarranties in respect of suchparts.
5. This warranty shall not apply ifthe vehicle or any part thereofis repaired or altered otherwisethan in accordance with ourstandard repair procedure, orby any person other than oursales or service establishments,our authorised dealers, sub-dealers or service centres in
any way so as , in ourjudgement which shall be finaland binding, to effect itsreliability, nor shall it apply if,in our opinion which shall befinal and binding the vehicle issubjected to misuse,negligence, improper orinadequate maintenance oraccident or loading in excessof such carrying capacity ascertified by us, or suchservices as prescribed in ourOwner’s Manual and ServiceBook are not carried out bythe buyer through our sales orservice establishments, ourauthorised dealers or theirsub-dealers or service centres.
6. This warranty shall not covernormal wear and tear or anyinherent normal deterioration ofthe vehicle or any of its partsarising from the actual use ofthe vehicle or any damage dueto negligent or improperoperation or storage of thevehicle. This warranty shall not
Warranty Terms and condition
3
WARRANTY
apply to normal maintenanceservices viz. oils & fluidchanges, head lampsfocussing, fastenerretightening, wheel balancing,tyre rotation, adjustment ofvalve clearance, fuel timing,ignition timing andconsumables like bulbs, fuelfilters and oil filters etc. Thiswarranty shall not apply to anydamage or deterioration causedby environmental pollution orbird droppings. This warrantyshall not apply to V-belts, hosesand gas leaks in case of airconditioned vehicle. Slightirregularities not recognised asaffecting the function or qualityof the vehicle or parts, suchas slight noise or vibration,defects appearing only underparticular or irregularoperations are item consideredcharacteristic of the vehicle.
7. This warranty shall be null andvoid if the vehicle is subjectedto abnormal use such as
rallying, racing or participationin any other competitive sports.This warranty shall not applyto any repairs or replacementsas a result of accident orcollision.
8. This warranty is expressly inlieu of all warranties, whetherby law or otherwise, expressedor implied, and all otherobligations or liabilities on ourpart and we neither assume norauthorise any person toassume on our behalf, anyother liability arising from thesale of the vehicle or anyagreement in relation thereto.
9. The buyer shall have no otherrights except those set outabove and have, in particular,no right to repudiate the sale,or any agreement or to claimany reduction in the purchaseprice of the vehicle, or todemand any damages orcompensation for losses,incidental or indirect, orinconvenience or consequential
damages, loss of vehicle, orloss of time, or otherwise,incurred or accrued.
10. Any claim arising from thiswarranty shall be recognisedonly if it is notified in writingto us or to our concerneddealer without any delay soonafter such defect as coveredany ascertained under thiswarranty.
11. This warranty shall standterminated if the vehicle istaransferred or otherwisealienated by the buyer withoutour prior written consent.
12. We reserve our rights to makeany change or modification inthe design of the vehicle or itsparts or to introduce anyimprovement therein or toincorporate in the vehicle anyadditional part or accessory atany time without incurring anyobligation to incorporate thesame in the vehicles previouslysold.
Warranty Terms and condition
4
1. Use recommended oils andlubricants only.
2. Change oil in engine, gear box,
transfer case, steering system,
front live axle and rear axle at
prescribed intervals.
3. Use only genuine oil filter andfuel filter elements. Replace
them at regular intervals as
prescribed.
4. Clean air filter elementregularly. Replace filter
element when service indicator
shows red band even after
cleaning the filter element.
5. Ensure periodic servicing as
per maintenance schedule.
6. Insist on use of genuine co-branded spare parts.
7. Ensure that caps of auxiliarytank and radiator are firmlyfitted to keep the cooling
system pressurised and to
maintain coolant level. Alwaysuse radiator cap only of 1.0kg/cm2 (14 PSI), forreplacement.
8. check tyres for damage from
time to time and remove any
foreign bodies embedded in
treads.
When replacing tyres, have the
wheels balanced. Keep grease,oil and fuel away from thetyres. In case of uneven tyre
wear get the vehicle attended
to by any of our authorised
service set-ups.
9. Maintain correct tyrepressure
10. Check battery every week and
top up electrolyte level. Keep
battery terminals clean and
cable joints tight. Apply
vaseline/petroleum jelly on
terminals. Use distilled water
only for topping up.
Friendly notes Do’s
Do's
5
11. Observe correct polarity whenconnecting battery terminals.
12. Disconnect alternator/batteryterminals, ECU connectionswhile carrying out anywelding on the vehicle.
13. Avoid panic braking. Uselower gears while descendinggradients.
14. Start moving the vehicle alwaysin the 1st gear to avoid prematureclutch wear.
15. Keep both brake pedal andparking brake properlyadjusted.
16. Before engaging reversegear, ensure that the vehiclehas come to a stop, declutch,wait for a few seconds and thenshift into reverse gear.
17. When parking on slopes, usewheel chocks, apply parkingbrake and keep vehicle in lowgear.
18. In case of emergency parking
or breakdown on road, pullthe hazard warning switch toflash all the blinker lights to
warn other road users.
19. Release parking brake beforedriving off.
20. Release the ignition key assoon as engine starts.
21. Retighten wheel mounting nuts
after 100 km of every wheel
change.
Tightening Torque : 12-15 mkg.
22. Use only recommended FUSESand always keep spare fusesin the box.
23. Inspect the engine beltsreplace, if found torn, cracked,worn or soaked in oil.
Do's
Friendly notes Do’s
6
24. Ensure doors are properly
closed.
25. Insulation in the cab room
should be kept-up in good
condition.
27. Vehicle has a turbochargedengine, keep engine in idllingspeed for atleast a minuteafter starting and also beforestopping it, to protect the
turbo charger against damage
due to oil starvation.
Air conditioning system :
1. Whenever vehicle is parked in
the sun, drive with ventilator
open for a few minutes to blow-
off for hot air before switching
on A.C.
2. Keep all gun port, ventilator,
roof hatch closed, when ACsystem is working.
3. During stop and go citydriving use lower gears to
obtain efficient cooling.
4. If you feel irritation in the eyes
due to smoke or during long
drive, stop AC and ventilate for
half a minute by opening
ventilator.
5. Before stopping the engine first
switch-off AC and then the
blower.
6. During off-season operate the
air conditioner a few times
every month to lubricate
components.
Friendly notes Do’s
Do's
7
7. Do not clean EngineCompartment with highpressure water jet. It can causeMalfunctioning of electroniccomponents. Cleaning can bedone with high pressure air.
8. Do not clean air filter cartidgewith high pressure air.
Air conditioning system :
1. Do not cause heating of ACpipe (where fitted), whilewelding / brazing in itsvicinity.
2. Do not open any hose / pipepoints of AC system, wherefitted.
3. Do not put your hand inside
the condenser fan when the
grille is removed. Disconnect
power supply to fan and switch
off engine before any
maintenance work, where
applicable.
1. Do not use Clutch Pedal asFoot Rest. This will reduceclutch life. Avoid clutch riding.
2. Do not Coast vehicle inNeutral and engine switched-off position. This is a safetyhazard.
3. Do not run engine withoutRadiator Cap. Use genuineCap only, to keep systempressurised.
4. Do not overtighten engine oilfilter.
5. Vehicle has a turbochargedengine, do not stop theengine at once, allow it to runat idling speed for atleast 1minute. Also do not accelerateengine till the engine oilpressure has built up.
6. Do not open HP system underany condition. It should behandled by trained professionalonly. (i.e. HP Pump, Rail,Injector, HP lines)
Dont's
Friendly notes Dont's
8
Transfer case number (4x4) Front live axle number (4x4)Rear axle number (Spicer)
Chassis number on frame Engine Number Gear box number ( G-76)
Handling Location of aggregate serial mumbers
XXXXXXX
9
Body shell number plate (under
bonnet)
Handling Location of aggregate serial mumbers
10
Key (Two Nos.)Two identical keys have been provided
for operation of steering lock cum
ignition switch, for locking and
unlocking of driver’s and co-driver’s
side door, glove box, fuel tank flap and
rear door.
Locking and Unlocking of DoorsFrom outside : To unlock the door
turn key anticlockwise and swing
handle (1) upwards. To lock the door
turn key clockwise.
From inside : Lift knob (2) and then
only pull handle (3) in the door panel
to unlock the door. To lock the door
press knob (2).
In case knob (2) is pressed withdoor open, it will get releasedautomatically when door is closed.
The co-driver’s side door and rear
door can be opened from outside as
well as inside but locking is from
inside by pressing knob 2. The rear
door can be opened and locked from
inside.
Handling Doors
1
11
Sunvisors
Two adjustable sun visors are provided
inside the cab to prevent sun glare.
Rear view mirrors - outside Rear view mirror in cabin
Rear view mirrors
Rear view mirrors are fitted on driver’s
side door and co-driver’s side door.
They can be adjusted to the desired
positions by hand. The mirror can be
folded backwards for convenience
when the vehicle is to be driven
through narrow passages.
An additional adjustable rear view
mirror is fitted inside the cab. Mirrors
can be adjusted with the lever provided
inside the cab on the doors.
Handling Rear view mirrors, Sunvisors
Rear view mirror
Sun visors
12
Seats for Rear Passengers
Handling Seats
Driver and Co-driver Seat :
Adjustable type driver ’s seat is
provided. To Achieve correct position
for proper driving, lift handle (2) to slide
the seat either forward or backward.
Once the desired position is achieved,
push down the handle to lock the seat.
Adjust the backrest to desired position
using the lever(1) on right handside
of backrest. Release the lever to lock
it.
Seats for rear passengers :
Two seats are provided on both side
for two persons to seat. Storage space
is available below seat squabs.
1. Seat Reclining Adjustment Lever
2. Seat Adjustment (Forward/Backward) Lever
13
Seat Belt :
The vehicle has been fitted with three
point belt for extra safety for driver .
Fastening the belt
Insert belt tongue into buckle, a
positive locking ‘click’ indicates correct
and safe assembly.
Releasing the belt
Press the release button, the tongue
will be ejected clear of the looking
mechanism within the buckle.
Belt adjustment
When the vehicle is at rest, adjust the
length of belt to suit convenience.
Insert belt tongue in buckle. A positive
click indicates correct assembly.
Handling Seat belts
1. Anchor 2. Webbing 3. Tongue 4. Buckle 5. Release button
Adjust length of the belt to suit you
and fasten. The lap section should be
comfortably tight, the diagonal sections
should be adjusted so that a flat hand
will just pass between the chest and
the strap.
14
Handling Seat belts, Tools
To tighten (shorten) the belt
Pull free end of webbing throughadjuster until required adjustment isachieved.
To loosen (lengthen) the belt
Tilt the adjuster by means of the gripand slide it along the strap until suitablyadjusted.
CAUTION
l The belt is designed for use of
only one person.
l The belt should at all times be
adjusted and used in accordance
with the instructions and no
excessive slackness in the belt
should be evident
l Avoid twisting the straps during
use.
l Webbing must not be allowed to
chafe against sharp edges on
seat or bodywork.
l Do not make any alterations or
additions to the belt. If in doubt,
consult the authorised dealer.
l Belt that have been cut, frayed,
damaged or have been stressed
through impact, should be
replaced.
l To clean, an occasional wipe with
warm soapy water will maintain the
webbing in a clean condition. Do
not use bleach or dye under any
circumstances.
l Periodic inspection of the
installation will ensure safe and
reliable service of the seat belt.
Vehicle Jack & Tools
Tool bag with tools, jack and handle
are kept below the drivers seat.
15
Handling Driving Controls
Driving Control - TATA LIGHT BULLET PROOF VEHICLE 4x4
1. Steering Wheel
2. Instrument Cluster
3. Combi-switch
4. Ignition cum steering lockswitch
5. Bonnet opening lever
6. Accelerator pedal
7. Brake pedal
8. Clutch pedal
9. Parking Brake
10. Jack
11. Gear shifting lever
16
Spare wheelGear shift lever knob 1. Parking brake released
2. Parkeing brake applied
Handling Gear Shifting Lever, Parking Brake & Spare wheel
Gear Shift Lever :
The different gear positions are
markedon the knob. The 5th gear (an
overdrive) has been provided to obtain
better fuel economy while driving on
highways.
Parking Brake (Floor mounted) :
The Parking brake is mounted on floorbetween RH door and driver’s seat.
To apply the parking brake, pull leverfull up. To release it, pull the lever upslightly, press the release button andpush the lever down.
Ensure parking brake is releasedbefore driving the vehicle. Indication
is given on instrument cluster.
Spare Wheel
Spare wheel is located behind driver
and co-driver seat.
To remove the spare wheel, loosen
spare wheel strap by operating
ratchet. After loosening strap, remove
hook and take out the spare wheel.
1
2
17
Handling Instrument cluster
Instrument cluster
5 6 7 8 9 10
11
13
14
3
1
4
2
12
15
18
1. Fuel gauge
It indicate the apporximate level of
fuel in tank.
Fill up the tank with recommended
diesel fuel well in advance, before
the needle touches ‘E’ mark on the
gauge.
2. CHECK ENGINEIndicator
This lamp indicates engine
condition, when a malfunctioning
occurs in engine OR EMS, thislamp indicates as below :
i. Come ‘ON’ when key is in ‘IGN’
position and goes ‘OFF’ after
starting engine.
ii. Remains ‘ON’ in engine
running if malfuctioning occurs.
3. Glow plug indicatorlight (Amber)
In the ‘ON’ position, the glow plug
controller switches on the glow plugs
and glow plug indicator comes ‘ON’.
After a few seconds depending on
the ambient temperature, the
indicator light only goes ‘OFF’
indicating that the engine can be
started.
If the glow plug indicator does not
go ‘OFF’ automatically, get theelectrical system of your vehiclechecked.
4. High beam indicator(Blue)
5. Battery chargingindicator light. (Red)
It comes on when ignition key is
turned to position ‘ON’ and must
go ‘OFF’ when the engine starts
running. if continues to glow, then
it has to be checked at authorised
dealer.
6. Turn signal indicator(Left) (Green)
7. SpeedometerIt indicate vehicle speed in km/h
8. Odometer registers total distance
covered by the vehicle in km.
9. Turn signal indicator(Right) (Green)
10. Oil pressureindicator light (Red)
It comes on when ignition key is
turned to position ‘ON’ and goes
off as soon as the required oil
pressure has developed after the
engine has started. If the light
continues to glow when the
engine is running, it indicated low
oil level in engine oil sump, or a
fault in the lubrication or electrical
system.
Continued running of the enginewhen the oil pressure indicatorlight is on, may damage theengine.
Handling Instruments
CHECKENGINE
19
4WDH
4WDL
11. Brake fluid level /parking brakeindicator: (Red)
This indicator light is used for both
the functions. When ignition is ON
position the lamp will glow. Thus
it shows bulb is OK.
After the engine has started,
light will go Off automatically. The
light will remain ON, if the break
fluid level is low or the parking
brake is applied.
12. Water in FuelSedimenter Indicator
Whenever water in fuel sedimenter
indicator glows in instrument
cluster, the water need to be
drained from fuel sedimenter.
(Refer Page 50)
13.Coolant temperature gauge
(0C) Red band of this gauge
indicates engine overheating.
Handling Instruments
P14. Four wheel drive high
indicator light (4x4)(Green)
It comes on when ignition key is
turned to position’ON’ and goes
‘OFF’ after a few seconds. The
light glows continuously
when four wheel drive high mode
is selected for vehicle driving.
17. Four wheel drive lowindicator light (4x4)(Green)
It comes on when ignition key is
turned to position ‘ON’ and goes
off after a few seconds. The light
glows continuously when four
wheel drive low mode is selected
for vehicle driving.
20
Steering lock cum ignition switch key
positions
Handling Steering lock cum ignition switch
Steering lock cum ignition Switch
Steering lock ignition switch
Steering is provided with steering lock
cum ignition switch
r To lock steering while parking the
vehicle as safety against theft.
r To start and stop the engine.
r To switch on and off the electrical
system other than listed below.
Horn, parking lamps, engine
inspection lamp, hazard warning
switch, headlamp, map reading
lamp, black out head lamp/ stop
lamp / parking lamp and roof light
convoy lamp,tail lamp,side
indicator, Blinker stop light.
r To switch on and off accessoriesonly.
The switch is located on the steeringcolumn support and has the followingkey positions :
LOCK
Key can be inserted or taken out only
in this position. Steering gets locked
only after the key is withdrawn from
the switch. After withdrawing the key
from the switch ensure that steering
is locked by turning steering wheel
clockwise and anticlockwise.
To unlock the steering, insert the key
into the switch and turn it clockwise.
If any difficulty arises in unlocking turn
the steering wheel a little clockwise or
anticlockwise while turning the key.
ACC
By turning the key to ‘ACC’ position
power supply to accessories is
switched on.
21
ON
By turning the key to this position all
remaining electrical systems become
operative and fuel guage, temperature
gauge, battery charging indicator, low oil
pressure indicator, parking brake/low
brake fluid indicators, Check Engine,
Water Seperator will come ̀ ON’.
In case of 4x4 vehicle in addition to
above 4WDH & 4WDL lamps will come
on and goes off after a few seconds.
In ‘ON’ position, glow plug indicator
lights up. After a few seconds, depeding
on the ambient temperature, the
indicator light only goes off indicating
that the engine can be started.
START
Turn the key further clockwise to start
position (spring loaded) to operate
starter motor. As soon as the engine
starts release the ignition key, so that key
can come back to ‘ON’ position and
starter motor disengages. Vehicle is
driven in this position. By turning the
ignition key from ‘ON’ position to ‘ACC’
Position ‘3’ - Turn signal left
Position ‘4’ - Turn signal right
The lever returns to neutral position
automatically when the steering
wheel is returned to straight aheadposition.
The combination switch lever can be
operated up and down to select the
headlight beam as follows :
Position 1 - High beam
Position 2 - High beam flash
High Beam Flash (No.2 position)
High beam flash will be ‘ON’ as long
as lever is held in position ̀ 2’ . This is
spring loaded position and can be
used in day time also for giving signal
to the on coming traffic.
Handling Combination switch
Combination switch - Turn signals, High/Low
beam and High Flash
32 3
4 1
or ‘LOCK’ position engine can be
stopped.
Combination switch
The combination switch is mounted on
steering column. It’s right side lever
operates turn signals,
Turn Signals
Moving the combination switch lever in
sideways direction operates the turn
signals :
22
Windshield wiper/washer operating lever
POSITION FORWASH-ON
‘HI’ - High speed of wiper motor To
operate windshield washer, lift
the lever. The winshield washer
will remain in operation as long
as the lever is held in this
position.
Handling Windshield Wiper / Washer & Interior Lamp
Winshield wiper / washer
The combination switch lever mounted
on the left side operates the windshield
wipers and washer :
Position :
‘OFF’- Wiper motor switched ‘OFF’
‘INT’ - Wiper sweeps intermittently
‘LO’ - Low speed of wiper motor
Interior Lamps :
A interior lamp is fitted near inside
rear view mirror for illunination. The
individual ‘ON / OFF’ switch is provided
on the lamp itself.
This lamp is controlled by a door
switch. This lamp comes ‘ON’ if any
one door is open. Door switches are
fitted on RHS/LHS door and tailgate.
Interior Lamp Location
23
Handling Interior Lamps & Front Tow Hook
Door Control Switch
Interior Lamp Door Control Switch
Door Control Switch
Interior Lamp Door Control Switch- TailgateFrontTowing Hook
Front Towing Hook :
Front tow hook is below front bumper
for vehicle towing.
Towing Procedure :
Make sure that, the vehicle is in neutral
condition and in 4X2 mode while
towing. Maximum driving speed 40
kmph.
Interior Lamp
24
Rear Tail Lamp
Tail Lamp :
The tail lamp assembly incorporates
the following :
1. Rear Stop Lamp
2. Rear Direction Indicator
3. Reverse Light
4. Rear Parking Lamp
Registration Plate Lamp :
Two concealed lamp are provided for
illumination of the rear registration plate.
Registration Plate Lamp
Hazard warning switch
This can be operated without ignition
‘ON’. Pull the hazard warning switch
(red knob) on the nacelle behind the
steering wheel, all side indicator lights
will flash simultaneously to warn the
other road users about any hazard-
ous condition of the vehicle. Depress
the knob again to switch ‘OFF’ the
hazard function.
Handling Hazard warning switch,Tail Lamp & Registration Plate Lamp
Hazard warning switch
25
1. Switch for Rear Fog Lamp
2. Switch for Front Fog Lamp
Handling Front & Rear Fog Lamps
Front and Rear Fog Lamps :
The front fog lamps are provided on
the front chassis frame to improve
thevisibility in foggy weather. The front
fog lamp can be switched ‘ON’ by
pushing the switch once with the
headlamp ‘ON’ till the parking brake is
switched ‘OFF;. The rear fog lamp
willswitch ‘OFF’ if parking lamps are
switched ‘OFF’ and will not come ‘ON’
Front Fog Lamp Rear Fog Lamp
again with parking lamp ‘ON’ until
deliberately switched ‘ON’ again.
The switch for front fog lamp is an
‘ON / OFF’ type switch. The rear fog
lamp has the in-built tell tale indicating
lamps for indicating the fog lamp
operation.
21
26
Handling Head Lamp Levelling Switch & High Mounted Stop Lamp
Head Lamp Leveling Switch (if fitted):
A headlamp leveling switch is provided
at the LH side of the steering column
on dash board.
As and when required headlamp lev-
eling setting is done by rotating the
knob to select one of the level marked
in the switch depending upon the load-
ing of vehicle.
Headlamp Leveling Switch
High Mounted Stop Lamp:
High mounted stop lamp is located on
tail gate and it glows whenever ser-
vice brake is applied in additional to
two stop lamps.
High Mounted Stop Lamp
Switch Loading ConditionPosition
O Unladen + Driver/Driver
+ Co-driver
1 Driver + Co-driver + All
seats occupied
2 Laden + All seats
occupied
3 Laden + All seats
occupied + permissible
luggage load
27
Rear Central Towing Hook
Rear Central Towing Hook :
Rear central towing hook with locking
arrangement has been provided for
towing the trailor.
Handling ECU, Rear Towing Hook & Rear Foot Step
ECU :
DICOR engine common rail system
consist of ECU, sensors and
actuators. The ECU receives input
from various sensors located on the
engine and the vehicle to decide the
injected quantity and injection timing
best suited for the engine to work with
maximum efficiency and safety ECU
is fitted inside the engine compartment
ECU Rear Foot Step
Rear Foot Steps :
Rear foot steps on RHS/LHS has been
provided for ease of entering in or
alighting from rear compartment.
28
Handling Roof Hatch, Oservation Window and Gun Port
1. Obeservation Window
2. Gun port on rear doorRoof Hatch (Optional Fitment) Roof Hatch Lock
1. Handles
1
Observation Window With GunPorts:
Observation window (1) with gun port (2)is provided on tail gate door.
Roof Hatch :
The roof hatch is provided for
observation and firing front & rear.
Roof Hatch Lock:
To open the roof hatch, first unlock thethe latch knob by using key. Rotate thelatch knob and push the hatch doorsupwards.
For closing the hatch doors, pull thehandle swhich are provied on the doorsfrom inside.
29
Handling Gun Port, Ventilator & Battery Isolator Switch
Ventilator
Ventilator :
Ventilator is located on the roof above
driver & co-driver.
Ventilator is provided for fresh air
intake, when HVAC is not working.
Gun port
Gun Port :
Gun ports are provided on the front
left door, middle both doors, tail gate
and LH & RH side windows at rear.
Opening the gun port, press the knob
and rotate in either direction.
Gun ports are used to place gun for
firing.
Battery Isolator Switch
Battery Isolator Switch:
This switch is provided near the gear
shift lever to isolate the battery from
electrical system when required. Battery
Battery Isolator Switch :
Battery is connected to the starter and
other circuitry through isolator switch.
This is to be switched OFF while
carrying out any work on the vehicle
and also when the vehicle is parked
for long duration to avoid battery
drainage. This will also prevent any
inadvertent short circuits during
repairs.
30
Engine compartment light :
To operate engine compartment light
pull switch (2)
Bonnet opening and closing :
To open bonnet pull lever (1) This will
release the bonnet lock. To open fully,
lift the additional lock lever located on
the bonnet centre with the help of
finger. Use the bonnet stay rod to keep
the bonnet open.
1. Engine compartment light
2. Engine compartment light switch
For closing the bonnet, disengage the
stay rod, clamp it properly and press
down the bonnet till it is fully shut.
Ensure that the bonnet is fullylocked driving off.
In case of failure of cable attached to
lever (1) bonnet lock can be opened by
inserting a screw driver from the top
centre position of grille through a slot
provided behind it on the sheet metal
and by pressing the lock plate toward
your left. Push upward the additional
lock lever at your right and lift the bonnet
while the lock plate is kept pressed with
the help of a screw driver.
Additional lock lever
Handling Engine compartment light, Bonnet Opening / Closing
Bonnet Opening lever
31
Handling Turbocharger
Turbocharger
Turbocharger is an efficient
supercharging device used in our
engine. It makes use of thermal energyof
engine exhaust gases to run a turbine
which in turn drives a compressor to
force air uner pressure into the inlet
manifold.
Lubrication of Turbocharger :
The rotor assembly of the
turbocharger is supported by two
floating lead bronze sleeve bearings
in the bearing housing. These bearings
are lubricated with the finest filtered
and cooled oil from the lubrication
system of the engine. There is a heat
shield arrangement. provided between
the gas chamber of the turbine nd the
bearing housing to avoid heating of
the bearings.
Maintenance of Variable GeometryTurbocharger
1. Tighten the following fasteners at
PDI and thereafter at specifiedintervals.
l Turbocharger mounting
l Intercooler mounting
l Turbocharger hose connections
& its mountings
l Intercooler hose connections
and its mountings
2. Check intercooler fins for any dust
accumulations and clean by
compressed air at at specifiedintervals.
3. Check end play of turbocharger
shaft and radial clearance between
turbine wheel and housing atspecified intervals.
Pressure oil
from engine
Fresh
Air in
Exhaust
gas out
Oil drain to engineTurbine Wheel
Assembly
Compressor
Wheel
32
Pre-silencer:
The construction of Presilencer consists
of a cylindrical outer jacket, inside to
which cylindrical perforated pipe & baffle
are welded to it. As Exhaust gases
passes through it expansion of gases
occurs. At the both ends of presilencer
triangular flanges are provided for the
fitment of front & middle pipe assem-
blies.
Handling Pre-silencer & Power steering
POWER STEERING
Power steering is fitted for lightersteering effort and easymanoeuvrability. The system consistsof steering gear box, hydraulic pumpand hydraulic reservoir suitablymounted and connected by piping.Pump drive is through ‘V’ belt fromengine. Power assistance is available
during normal functioning of thepower steering system.
In case of any failure in hydraulicsystem, the steering can beoperated mechanically withincreased steering effort forbringing the vehicle to a repairstation.
1. RESERVOIR
2. PUMP
3. POWER STG.GEAR BOX
4. FREE PLAY ADJUSTER
5. LOCK NUT
Power steering - schematic circuit
33
Handling Power steering
Power steering hydraulic reservoir
Procedure for oil filling andbleeding the power steeringsystem.
(Ensure that the reservoir is totallycleaned before starting the work.)
1. Fill the reservoir nearly full.Crank the engine for 10 secondswithout, if possible, allowing itto start. If the engine does start,shut off immediately.
Check and refill the reservoir. Repeatat least three times, each timechecking and refilling the reservoir.
2. Check for any leakage in thesystem and if noticed takecorrective action.
3. Start the engine and steer thevehicle from full left to full rightturn 3-4 times. Add fluid, ifnecessary to maintain the level upto the filter top.
4. With the engine at steady speed,check for bubble / foaming in thefluid. If present it indicates thatair is geting sucked into thesystem. Check the suction line /fittings and correct if necessary.
5. Once the system is bled properlyand free from foaming, thereshould not be appreciable changein fluid level in the reservoir, whenthe engine is started / stoppedrepeatedly. Top up or removeexcess fluid so that the final levelis at ‘H’ mark on dipstick.
6. Now the system is ready fordriving.
CAUTION
Do not allow the fluid level to dropsignificantly or run out of thereservoir during the aboveoperation. This may induce air intothe system.
Do not start the engine without fluidin the power steering system. Thiswill result in serious damage to thepump.
NOTICE
Always use recommended brandof fluid from closed container. Anydirty fluid poured in the system willresult in damage to pump / gear.
34
Power steering pump belt tensionCheck :
Check the conditions of belts on the
engine. Examine the edge of the belt
for cracks or fraying.
Check the tension of the belt by
pushing on it with your thumb
Power Steering Belt tensionHandling
Free play adjustment
Ensure that vehicle is in straight ahead
position. Remove tie rod ball joint on
pitman arm. Hold sector shaft adjuster
screw with 6 mm hexagonal key and
loosen lock nut. Hold pitman arm and
turn sector shaft adjuster screw
clockwise till there is just no play of
pitman arm. Tighten lock nut of
adjuster screw without distrubing its
position by holding with hex key. Turn
steering wheel through its full
movement and ensure that sector
shaft movement is smooth throughout
its range. Refit the tie rod ball joint to
pitman arm. For any other complaints,
get the system checked and rectified
at our authorised workshops.
For adjusting the power steering belt
tension please refer page no.51.
Alternator/Power Steering belt as
shown in Figure.
The belts should have deflection of 8
to 10 mm. (X).
If the belt tension is not proper, get it
attended at the nearest TATA
Authorised Workshop.
35
Handling Heating,Ventilation & Air Conditioning
HEATING, VENTILATION & AIRCONDITIONING : (if installed)
A. Temperature Control Knob :The air temperature in the vehicle can
be controlled by operating the
temperature control knob (A) at the left
hand side of the control panel. The
temperature can be increased by
rotating the knob towards the red
segment and decreased by rotating it
towards the blue segment.
B. Blower Speed Regulation Knob:The ventilation system has a four
speed blower. The blower speeds can
be regulated to any one of the following
speeds by operating the knob (B) at
the centre of the control panel.
1. LOW 2. MEDIUM 3. HIGH VERY
HIGH
C. Air Direction Control Knob :The air flow can be changed by turning
the switch (C) to the desired direction.
Towards face
Towards face and feet
Towards feet
Towards feet and windshield
(Recommended for clearing
fogging on windshield)
Air demist / defrost windshield
(Recommended for clearing
heavy fog and snow)
D. A.C. ON/OFF Switch :
The A.C. can be switched 'ON' by
pressing the switch (D) on the A.C.
control panel provided the blower is
`ON' and the engine is running. The
indicator lamp will show that the A.C.
is ̀ ON'.
A
B
C
D E
36
Handling Heating,Ventilation & Air Conditioning
E. Air Circulation Switch :
l In HVAC version to put air circulation
mode in recirculation, press switch
'E'. The indicator lamp will show air
circulation is in recirculation.
To put vehicle in Fresh mode release
switch 'E'. Indicator lamp will be
'OFF'.
l In recirculation mode, air inside the
vehicle is circulated again and again.
In Fresh mode, air is taken from
atmosphere and circulated in the
vehicle. Recirculation mode can be
used
l While driving in dusty condition
l To avoid traffic pollution
l To get quick cooling/heating as
required.
Whenever discomfort is felt switch air
circulation mode to fresh.
Normal Cooling :
A.C. - ON
Knob 'B' - Desired speed position
Knob 'C' - Towards face
Switch 'E' - Suitably as explained
Quick Cooling :
If your car is left in the sun with window
closed, inside temperature increases.
To achieve quick cooling effect, open the
windows briefly while you operate the air
conditioner, with air circulation switch is
in Fresh mode, fan at higher speed and
air direction towards 'FACE'. All vents to
be opened completely.
Once temperature inside has comedown sufficiently, close the windows andchange air circulation suitably to fresh/recirculation.
NOTICE
1. The A.C. can be switched ̀ ON' only
if the blower is 'ON' and engine is
running. When A.C. is switched 'ON'
engine idling RPM increases
marginally, to adjust to the A.C.
compressor load. When desired
temperature is achieved A.C. trips
'OFF' automatically.
2. The A.C. compressor getsswitched 'OFF' automatically whenengine gets overheated. The A.C. isautomatically switched 'ON' when theengine cools down.
37
Handling “G” Conscious pressure reducing valve for brakes
“G” Conscious pressurereducing valve for brakes
This valve consists of a barrel with
one inlet and one outlet. A steel
ball is kept rolling free in the barrel.
When the brakes are applied the
brake fluid going to rear wheel
cylinders passes through this valve
around the steel ball and goes out
from other end to rear wheel
cylinders. As the brakes are applied
and vehicle decelerates, the free
rolling ball moves forward due to
its momentum and closes the port
stopping the further supply of brake
fluid to rear wheel cylinders. This
ensures that cylinder pressure is
limited to a value which avoids
wheel locking.
To achieve the specific cutout point
the valve body is mounted on
vehicle at 260 angle so that the ball
has to climb some slope before
closing the outlet port.
38
Handling Preparing the vehicle for the drive
Fuel tank fillerneck Coolant Tank
Check the following regularly,particularly before starting on along journey.
1. Fuel level in tank
Top up if required with correct
diesel fuel, secure cap and lock
the flap.
2. Engine oil level
Check engine oil level before
starting the engine or at least 20
minutes after stopping the engine.
Top up if oil level is less than
midway between upper and lower
marks on the dipstick.
The oil level should not exceed the
'MAX’ mark. USE ONLY THE
GENUINE CO- BRANDED OILS.
3. Coolant level
With the engine cool, check the
coolant in the no loss tank. The level
should be between the 'FULL' and
'MIN' marks. if the level is
below the 'MIN' mark, top up with the
genuine co-branded coolant. Bring
the level upto the 'FULL' mark. The
level must not exceed the 'FULL'
mark. If the coolant level drops with
in a short time after replenishing,
there may be a leak in the system.
1.Engine oil filler Cap 2. Dip Stick
39
1. Brake fluid Container
2. Clutch fluid ContainerChecking belts tension
Handling Preparing the vehicle for the drive
7. Check leakages of coolant, fuel
and oil at all joints of hoses and
pipes and rectify, if any. If coolant
leakage is noticed, rectify the
leakages and top up radiator also
with recommended coolant.
8. Check level of brake fluid in
plastic container. Top up if
necessary. Do not overfill. Use
only GENUINE CO-BRANDED
brake fluid.
9. Check level of clutch fluid in
plastic container. Top up if
necessary. Do not overfill as this
would result in spillage during clutch
operation. Use only GENUIN
CO-BRANDED clutch fluid.
10. Check level of water in Windshield
washer reservoir, located in the
engine compartment near the fuse
box. Top up with clean water if
required.
Rectify the leakage and top up
radiator also. Use recommended
coolant.
If no leak can be found inspection
should be carried out at a Authorised
service outlet.
NOTICE
Always use radiator cap only of 1.0
kg/cm2 (14 psi), ifrequired to be
replaced.
4. Ensure battery electrolyte level is
10-12 mm above top of battery
plates. Top up with distilled water if
required (NOT ACID).
Keep battery terminals clean and
tight. Apply petroleum jelly / vaseline
on terminals for protection against
corrosion. Secure cover provided
over positive terminal.
5. Check all lights, horn,
gauges,switches and wiper for
proper functioning.
6. Check condition and tension of
belts. ADJUST tension if necessary.
40
Handling Preparing the vehicle for the drive
Gear box oil filler plug (G-76) Rear axle oil filler plug Transfer case
A. Drain plug B. Oil level plug
B
A
Do not use soap solution.
11. Level of gear box oil
Periodically check gear box oil
level.
12.Level of front live axle oil (4x4)
Periodically check front live axle oil
level.
13.Level of rear axle oil
Periodically check rear axle oil
level.
14.Check condition of wiperblades, replace if rubber profileis damaged.
15.Check level of oil in steeringgear box.
16.Check oil level in power steeringhydraulic tank, where applicable.
17.Check and correct tyre inflationpressure (with cold tyres).
18.Level of transfer case oil (4x4)
Periodically check oil level
CAUTION
Do not use impact wrench to
remove or install level / filling plug
or drain plug since this will damage
threads in the transfer case cover.
19. Clean transfer case breather
regularly for 4x4 vehicle.
41
Gear lever knob (G-76 gear box)
Driving Driving & Gear Shifting
Before Driving
Check
l Coolant level
l Engine oil level
l Tyre pressure
l Brake and clutch fluid level
l Doors are firmly closed
Adjust
l Driver seat
l Rear view mirrors
Ensure
l Gear shift lever is in neutralposition.
l All switches and lamps areworking.
l Brake fail indicator is 'OFF'
l Fuel level indicated in fuelgauge is above reservemark.
Start the engine and observe that :
(Where turbocharged engine is fitted,
run engine in low idle speed for
atleast 1 minute and do not
accelerate the engine till the engine
oil pressure is built up.)
Low oil pressure indicator light goes
'OFF'
Battery charging indicator light goes
'OFF'
4 WDH and 4 WDL indicator lights
go off in 2H mode in case of 4x4
vehicle.
VEHICLE IS NOW READY FOR A
DRIVE
DO NOT ALLOW VEHICLE TO ROLL
BACK ON GRADIENTS.
During Running-in period
i.e. first 2,000 km. of operation :
Do not exceed the following vehicle
speeds :
For 4x4 vehicles
Gear Speed in km/hr.
4x2 4x4 (low)
1st to 2nd 20 10
2nd to 3rd 35 14
3rd to 4th 50 -
4th to 5th 75 -
42
Driving Instructions Driving , Gear Shifting, Braking
l Avoid rapid acceleration and
prolonged high speed runnings of
the engine.
l Avoid sudden braking.
l Retighten wheel nuts to 12-15 mkg
torque after first 100 km of running
of a new vehicle and after every
wheel change.
Driving instructions
DRIVE SAFELY AND JUDICIOUSLY
REMEMBER SAFETY FIRST.
l Depress clutch pedal fully before
shifting gears. This will ensure
longer synchro cone life.
l For smooth starting of vehicle
without jerks, synchronise
release of clutch pedal with
pressing of accelerator pedal.
l Start the vehicle in first gear only.
l Change gears at appropriate
speeds and do not lug the engine
by too early shifting to higher
gear at low speeds.
Braking
l While braking on turns applybrakes gently.
l Before driving down a long steepgradient, reduce vehicle speedby changing to lower gear.
l Do not ride the brakes as theymay overheat and theirperformance may be impaired.
Do not use half engaged clutchto hold the vehicle on upgradient as this will result inpremature clutch failure.
l After driving through pockets of
water, apply the brake a few
times at low speed to get rid of
moisture inside the brake drums.
l When it begins to rain, reduce
vehicle speed and avoid sudden
braking.
Recommended speeds for gear
changes ( For 4x4 vehicles)
l Engage reverse gear, only when
vehicle is stationary.
l To engage reverse gear, moveear shift lever to extreme left andpush it forward.
l Depress clutch pedal fully beforeengaging the reverse gear. Waitfor a few seconds then engagethe gear. If the gear shifting doesnot occur, then release the clutchpedal, once again press theclutch pedal and engage thereverse gear.
Gear Speed in km/hr.
4x2 4x4 (low)
1st 22 10
2nd 40 15
3rd 60 -
4th 70 -
5th 85 -
43
charger, till its speed is fully reduced
and also allow the unit to cool down.
Above precautions will ensure
satisfactory life and performance from
the turbocharger.
Fuel Economy :
a. Drive smoothly, accelerate
gradually and anticipate stops.
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. If possible do not idle the engine
for more than 5 minutes. Switch
‘OFF’ the engine.
Driving Instructions Engine Starting & Stopping and Fuel Economy
f. Do not ride clutch. Do not use
clutch pedal as foot rest.
g. When changing from 4H/4L to 2H
of transfer case, 2H free wheeling
should be done . If 2H free
wheeling is not done the hub locks
of front hub are remain locked
causing unnecessary rotation of
front drive components and this
consumes more fuel.
H. Depending on traffic conditions
a constant speed should bemaintained
The vehicle uses more fuel,
every time you speed up or slow
down.
I. Avoid hard braking, abrupt
cornering and rapid acceleration.
Starting the engine :
Before starting
1. Apply parking brake.
b. Ensure gear lever in neutral.
3. Insert the key in steering cum
ignition lock and turn it to ‘ON’
position.
4. Press the clutch pedal fully.
5. Now crank the engine.
6. If the engine does not start turn
the key to ‘OFF’ position and
try after 30 seconds.
NOTICE
After starting run the engine in
low idle speed for at least 30 sec.
Do not press accelerator pedal
while starting the engine to avoid
damage to turbocharger.
Stopping the engine :
Before switching ‘OFF’ the engine, run
the engine idle for atleast 30 seconds
and then switch ‘OFF’. This will allow
the engine oil to lubricate the turbo-
44
Automatic hub locks (4x4)
While driving in 2H mode this
mechanism on the front axle hub
allows the hub to free wheel. This
Location of 4x4 Selector switch
4H All four wheels are driven and
transfer case operates at 1:1
ratio.
4L All four wheels are driven and
transfer case operates at 2.48:1
speed reduction ratio.
Transfer Case and Transfer Casenselector Electric Switch :
On four wheel drive vehicles
transfer case is fitted after the gear
box for driving front live axle along
with rear axle.
The following 3 positions areprovided on selector switch :
2H Only rear wheels are driven and
transfer case operates at 1:1
ratio.
Driving Instructions 4x4 Operations
Automatic Hub Lock
avoids the unnecessary spinning of
front axle drive components and
results in fuel saving, reduced noise
and longer component life.
As soon as 4H or 4L mode is
selected the hub gets automatically
connected to front drive line to
increase the traction.
Instructions for 4x4 operation
1. With ignition ‘ON’ 4WDH &
4WDL indicator lights on panel
should glow for a few seconds
onlyd then go off.
CAUTION
While in 2H mode, continuous
illumination of 4WDL & 4WDH
lights indicate electrical fault like
short or open circuit. Do not
march the vehicle in this case.
2. Shifting from 2H to 4H : Turn
the selector knob from 2H to 4H
position. 4WDH indicator on
instrument panel will light up.
45
Driving Instructions 4x4 Operations
Changing from 2H to 4H can be
done at any speed upto 65 km/h.
No pressing of clutch pedal is
required
3. Shifting from 4H to 2H : Turn
the selector knob from 4H to 2H
position. 4WDH indicator on
instrument panel will go off.
Changing from 4H to 2H can be
done at any speed upto 65
km/h. No pressing of clutch pedal
is required.
Free wheeling of front hub : After
shifting from 4H to 2H, for effecting
free wheeling of front wheels,
direction of vehicle motion needs
to be changed. If in4H mode the
vehicle was moving forward then
stop it, wait and then engage
reverse gear of main gear box. If it
was moving reverse in 4H mode
then stop it, wait and then engage
forward gear of main gear box.
(After stopping and changing the
gear the vehicle must travel in
opposite direction for a minimum
of three meters, before free
wheeling takes place.)
4. Shifting from 4H to 4L
Stop the vehicle. Press clutch
pedal. Turn the selector knob from
4H to 4L position. 4WDL indicator
light on instrument panel will blink
a few times and remain on.
5. Shifting from 4L to 4H
Stop the vehicle. Press clutch
pedal. Turn the selector knob from
4L to 4H position. 4WDH indicator
light on instrument panel will blink
a few times and remain on.
CAUTION
In case of malfunctioning in
shifting from 4H to 4L or 4L to
4H, respectively 4L or 4H
indicator light will flash
continuously, Do not march the
vehicle in such a case.
Do not use 4H or 4L modes
continuously on dry and hard
surfaced road except for
checking operations.
Limited Slip Differential :
A standard differential delivers torque
equally to each wheel. In case one
wheel loses traction and begins to
spin, the differential distributes the
rotary speed unequally but with same
torque. This can cause the wheel with
good traction to slow down or stop
while the wheel which lost traction
rotates with increased speed. Such a
situation can prevent the vehicle from
moving. The limited slip differential
provided in the rear axle takes care
of such situations. The clutch lock
arrangement provided internally,
ensures that in case one wheel loses
traction and begins to slip, a locking
action takes place which prevents
differential action and both wheels turn
at the same speed.
46
Vehicle Maintenance Engine Compartment
1. Fuse Box
2. Power Steering Fluid Container
3. Brake Fluid Container
4. Clutch Fluid Container
5. Engine Oil Filler Cap
6. Dip Stick
7. Air Filter
8. Air Pre-cleaner
9. Radiator Cap
10. Engine Coolant Tank
11. Windshield Washer Fluid Container
ENGINE COMPARTMENT
47
Air Filter :
The air filter element should be
periodically cleaned.Replace the air
filter element with a new one when the
service indicator shows red band
even after cleaning.
Always use genuine air filter element.
Air filter for SUMO Armoured DICOR
diesel engine is located at LH side of
engine compartment.
Replacement of Air Filter Element :
a) Disconnect air filter from hose.
Declamp and remove the air
filter.
b) Remove the cover of the air filter.
c) Remove the air filter element.
d) Clean it gently by tapping. Clean
air filter cover and air ducting.
e) Check element for puncture or pin
holes by light source.
f ) If found OK install paper filter
element. Fit the cover and tighten
air filter screws at the place and
fit the clamps back.
g) Clean the hose connecting the air
filter to turbocharger pipe. Reset
the indicator by pressing the
rubber cap,red band will disappear
from Service Indicator.
On starting the engine, if red band
continues to appear, replace the
paper filter element.
Reset the indicator by pressing the
rubber cap, red band will disappear
from Service Indicator.
On starting the engine, if red band
continues to appear, replace the
paper filter element.
Air Filter
Vehicle Maintenance Air Filter
48
Engine Cooling System :
If engine overheating occurs, there couldbe a fault in the cooling system whichmay be on account of :
1. Less coolant in the cooling systemor dirt / scale having accumulatedinside cooling water passagesespecially in the radiator core.
2. Choking of radiator passages dueto foreign material or damages.
3. Defective thermostat.
4. Defective coolant temp. sensor.
5. Coolant leakage.
6. Radiator cap not sealing properly.
7. A.C. condenser fan not working
8. Excessive refrigerant charging inthe A.C. system.
Prevention of Rust Formation :
To prevent rust formation in the radiatoruse premixed recommended anti-freezecoolant.
This is sufficient to operate the vehicleupto - 400C.
Replacing Engine Coolant :
The cooling system should becompletely drained and refilled with newcoolant at specified intervals.
1. Ensure engine and radiator arecool enough to touch.
2. Remove the radiator cap.
3. Loosen drain plug on the bottomof radiator. Remove cylinder blockdrain plug from engine block.
4. Remove the auxiliary tank from itsholder and drain the coolant.
5. Flush radiator and block with cleanwater and close the drain plugs.
6. Pour the premixed coolant intoradiator until it is full.
7. Fill the auxiliary tank upto highmark.
8. Ensure no leakage in the system.
Engine Coolant Tank Radiator Cap
Vehicle maintenance Engine Cooling System
49
Changing of Engine Oil and OilFilter :
Change the oil and oil filter at speci-
fied intervals. (Engine oil and oil filter
may be changed earlier for sandy/
dusty operating conditions)
Changing of oil and oil filter requires
access from underneath the vehicle.
Vehicle should be raised on a hydrau-
lic lift of a service station or should be
on a service pit.
Oil Sump drain plug
1. Run the engine until it reaches
normal operating temperature.
Then shut it off.
2. Open the bonnet and remove
engine oil filler cap. Remove the
drain plug of the oil sump from the
bottom of the engine. Drain the oil
into an appropriate container.
3. Remove the oil filter with the help
of special wrench. The removed oil
filter should not be reused and
hence should be destroyed to avoid
recycling of the same. Used filter
and oil should be disposed in
compliance with the current
legislation.
4. Smear a little fresh engine oil on
rubber gasket of new engine oil filter.
Hand tighten the engine oil filter fully
and further half turn with special
tool. Do not over tighten engine oil
filter as this may damage oil filter & oilmay leak out.
Vehicle maintenance Changing Engine Oil & Oil Filter
Engine oil filler 1.Engine oil filler Cap 2. Dip Stick
50
Water Sedimenter
A water sensor is fitted to the water
sedimenter in order to indicate to the
driver that the sedimenter has to be
drained. Whenever water in fuel
sedimenter Indicator glows in
instument cluster, the water need to
be drained from the sedimenter.
Water drain operation to be done on
both filter and sedimenter.
Procedure :
1. Stop the engine, and wait until
pressure stabilizes.
2. Unclip one of the hydraulic
connections (either inlet or outlet)
and the electric connector of the
water sensor. 3 Place a container
underneath the water sedimenter.
3. Place a container underneath the
water sedimenter.
4. Unscrew the water sensor about
2 - 3 turns
Water draining Procedure fromSedimenter :
The water sedimenter is part of the
Fuel filtration system, fitted to the
chassis frame, near fuel tank below
the vehicle. It is used in the fuel
supplying system in order to reduce
the water content in the fuel provided
to the DICOR system.
Vehicle maintenance Water Draining Procedure from Sedimenter
5. Before filling in fresh oil in theengine, clean the drain plug andapply sealant on threads.
6. Refit the drain plug using a newsealing washer. Tighten drain plugto 5 mkg. torque.
7. Fill, recommended quantity offresh engine oil in the crank caseand secure the oil filler cap in itsplace.
8. Start the engine and run for a fewminutes. The engine oil pressureindicator lamp should go ‘off’ afterstarting the engine.
9. Check for engine oil leakages.
10.Stop the engine and recheckengine oil level after a fewminutes. If necessary add oil tobring the level to the upper markon the dipstick.
NOTICE
Use of reclaimed oil is not
recommended.
51
5. Wait until all the water has
drained out of the water
sedimenter.
6. As soon as the flow is free of
water, screw the water sensor to
the required torque.
7. Clip the hydraulic connector and
the electric connector to the
water sensor.
Fuel & Filter Draining :
Loosen drain plugs by 1-2 turn and
drain out water and other sediments
from fuel filter bowls depending on
operating conditions to ensure that no
water is allowed to enter the fuel
system.
Priming Pump / Pear Pump :
This is used for priming the fuel
manually after overhauling of the
engine or after refitment of fuel lines
or after changing either fule filter or
sedimenter Pump the fuel by means
of priming pump / pear pump until all
air in the fuel line removed. Before
cranking the engine ensure that there
is no air in the fuel system.
Priming / Pear Pump
Vehicle maintenance Fuel & Filter Draining & Priming / Pear Pump
CAUTION
Do not loosen the HP lines of
DICOR system for bleeding the air
from fuel system.
52
Gear Box Oil
Checking of Oil Level :
1. Clean the oil level plug and
surrounding area.
2. Remove the oil level plug and check
whether oil is dripping out.Oil level
must not be below the filler plug.
Add oil to bring it tothe level.
3. Tighten oil level plug to 2-3 mkg.
torque.
Changing Oil in Gear Box :
1. Let the engine idle for about 5 min.
in neutral, so that the gear box oil
is warmed up.
2. Clean the oil level plug, drain plug
and surrounding area.
3. Place a container under gear box
to collect the oil.
4. Remove the drain plug and let the
oil drain out.
5. Also remove the oil level plug.
6. Tighten the oil drain plug and fill new
recommended oil through oil level
plug and tighten the oil drain plug
oil level plug to 2-3 mkg. torque.
Vehicle maintenance Checking & Changing oil in Gear Box
1. Gear Box Oil Level / Filler Plug
2. Gear Box Oil Drain Plug
53
Checking of Oil levels :
1. Clean the oil level plug and
surrounding area.
2. Remove the oil level plug and
check whether oil is dripping out.
3. If oil is not dripping out, oil level
must be below the required level.
Add oil to bring it to the level when
it starts dripping out.
4. Tighten oil level plug. Tightening
torque of oil level plug is 2 to 3mkg.
Changing of Transfer Case Oil
1. Clean the oil level plug, drain plug
and surrounding area.
2. Place a container to collect oil,
under transfer case.
3. Remove the drain plug and let the
oil drain out.
4. Remove the oil level plug.
5. Tighten oil drain plug and fill new
recommended oil through oil level
plug, till it begins to drip out.
6. Tighten oil level plug. Tightening
torque of oil drain plug is 2 to 3
mkg.
Vehicle maintenance Checking & Changing oil in Transfer Case
1. Transfer case Oil Level / Filler Plug
2. Transfer case Oil Drain Plug
Checking Oil Level of Transfer Case
NOTICE
Before checking or removing the
oil, warming up of the transfer case
is necessary. This should be done
by driving the vehicle for some time
in 4x4 mode.
54
Checking Oil Level in Front / RearAxle :
1. Clean the oil level plug and
surrounding area.
2. Remove the oil level plug and check
whether oil is dripping out.
Oil level must be below the required
level. Add oil to bring it to the level,
when it starts dripping out.
3. Tighten oil level plug to 2 to 3 mkg.
torque.
Changing Oil in Front Axle/RearAxle
1. Clean the oil level plug, drain plug
and surrounding area.
2. Place a container under Front/
Rear axle to collect the oil.
3. Remove the drain plug and let the
oil drain out.
4. Also remove the oil level plug.
5. Tighten the oil drain plug and fill
new recommended oil through oil
level plug till it begin to drip.
6. Tighten oil drain and oil level plugs
to 2 to 3 mkg. torque.
Vehicle maintenance Checking & Changing oil in Front / Rear Axle
1. Differential Oil Level / Filler Plug
2. Differential Oil Drain Plug
1
2
55
Bleeding clutch system
A dry friction, single disc, diaphragm
type clutch has been fitted, which is
actuated hydraulically.
The procedure for bleeding the
system is as follows :
a. Ensure that fluid level in clutch
fluid container is upto maximum
level.
1. Brake Fluid Container
2. Clutch fluid Container
b. Remove dust cap from slave
cylinder bleed screw and clean
the screw thoroughly. Attach
bleeding tube to bleed screw and
place other end of tube in a
clean glass jar containing
sufficient clutch fluid to submerge
tube end.
c. Pump clutch pedal twice or thrice
slowly throughout its stroke and
Bleeding clutch slave cylinder
by holding clutch pedal in
depressed condition, loosen
bleed screw on slave cylinder,
Watch for air bubbles in glass jar.
d. Retighten bleed screw on slave
cylinder and repeat the process
until air bubbles cease to appear
at the end of tube in glass jar,
allowing only fluid to flow.
e. After completing bleeding
operation, ensure that bleed
screw on slave cylinder is fully
tightened. Replace dust cap on
the bleed screw.
During bleeding process keep
a watch on fluid level in
container and top-up.
Vehicle maintenance Bleeding clutch system
56
Brake system
The dual circuit service brake system
operated through the tandem master
cylinder is designed such that one
circuit will continue to provide braking
action if the other circuit fails. This
vehicle is fitted with disc brakes at front
and drum brakes at rear.
Stopping the vehicle after loss of the
brake fluid in one circuit will require
more pedal presssure and pedal travel
than normal. Also stopping distance
will be longer.
Service brakes are vacuum assisted.
In case of failure of vacuum, the
vehicle can still be stopped, however
with a higher effort.
Bleeding the brake system
If the brake pedal becomes spongy,
this may be due to air in the hydraulic
brake system.
Whenever any repair/overhaul ordisconnecting of any brake pipe isdone, or level of brake fluid hasfallen so low that air has beendrawn into master cylinder, it isnecessary to bleed the system toremove the trapped air.
Bleeding front calliper
Vehicle maintenance Brakes, Bleeding the brake system
57
Proceed as follows for bleeding thebrake system :
a. Clean all dirt from around the fluid
container. Remove cap and top-
up fluid upto the maximum level.
b. Remove dust cap at each bleed
screw and clean the area around
it.
c. Attach the bleed tube to the front
left calliper bleed screw and
Bleeding rear wheel cylinder
place the other end in a clean jar
containing sufficient fluid to
submerge the end of the tube.
d. Pump the brake pedal 3-4 times
slowly throughout its stroke and
by holding the pedal depressed,
loosen the bleed screw and watch
for air bubbles in the glass jar.
e. Re-tighten the bleed screw and
release the brake pedal. Repeat
the process until bubbles cease
to appear at the end of bleed
tube, allowing only fluid to flow.
f. Replace the dust cap on bleed
screw.
Repeat the same procedure (steps 'a'
to 'f') on the front right calliper, rear
left wheel cylinder followed by rear
right wheel cylinder.
After completion of bleeding, apply
the brake several times and check for
any leakage at joints and bleed
screws.
During the bleeding process keepthe following points in mind :
1. Ensure that the fluid level in the
fluid container does not fall low
enough to cause air to be drawn
into the hydraulic system.
2. Maintain absolute cleanliness.
The brake system must be kept
entirely free from petrol, kerosene
or any form of mineral oil, as
mineral contamination spreads
rapidly in the hydraulic system,
Vehicle maintenance Bleeding the brake system
1. Brake Fluid Container
2. Clutch fluid Container
58
causing dangerous deterioration
of the rubber seals.
3. Never, under any circumstances,
use the fluid which has been bled
out from the system to top-
up the container. It may be
aerated, have too much moisture
content and /or is contaminated.
4. Always use recommended brand
of brake fluid.
5. As brake fluid absorbs moisture
from the atmosphere, we
recommend changing of
brake fluid in the system annually.
6. Take care to see that the brake
fluid is not spilled on the paint
work.
Brake adjustment :
The front wheels are fitted with disc
brakes. These are self adjusting,
therefore need no adjustment.
The rear wheel brakes can, however
be adjusted. Due to wear on the brake
shoe linings the clearance between
rear brake shoe linings and the brake
drum increases. This must be
adjusted after every 5,000 km if
required : After installing new rearbrake shoes or linings, check andadjust brakes after 500 km run.
For adjusting rear wheel brakeshoes proceed as follows :
1. Put chocks on front wheels.
2. Jack up rear axle. Release
parking brake. Ensure that
parking brake cable is slack.
Place the gear shift lever in
neutral position.
3. Loosen the adjusting screws of
both brake shoes so that the
wheel is absoultely free to rotate.
4. Now turn the adjusting screw of
one of the brake shoes till brake
begins to bind i.e. the brake shoe
touches the brake drum.
Adjusting the rear brakes
1. Adjusting screw
2 & 3 To increase or reduce the
clearance between brake
shoe and drum
Vehicle maintenance Brake adjustment
Now turn the adjusting screw in
the opposite direction just upto the
point when wheel can be rotated
freely.
Adjust the other brake shoe of the
same wheel in the manner
described above.
59
Parking brake handle (Floor mounted)
1. Parking brake released
2. Parking brake applied
5. Adjust both brake shoes of the
other wheel as described above.
6. Operate brake pedal twice/ thrice,
simultaneously rotating both rear
wheels, for checking proper
application and release of brakes.
7. Re-adjust, if necessary.
8. Remove front wheel chocks.
9. Test drive vehicle for checking
proper brake function.
Parking Brake Brake adjustment(Floor mounted) :
Adjust that all four rear brake shoes
have been properly adjusted.
1. Put chocks on front wheels.
2. Jack up the rear axle.
3. Loosen the lock nut. Pull the
parking brake lever up to 5th
notch.
4. Tighten the adjusting screw till
rear wheels start jamming and
cannot be rotated.
5. Release the parking brake and
ensure that wheels are rotating
freely. Hold the adjusting screw
in this position and tighten the
lock nut. Operate parking brake
few times to ensure proper
operation.
Parking brake linkage adjustment
1.Check nut 2. Parking brake nut
Vehicle maintenance Adjustment of parking brake
2
1
1
2
60
Wheels and Tyres
Always use only recommended size
wheel rims and tyres. Use of rims and
tyres not recommended by us may
have adverse effect on vehicle safety
and further more, could infringe on
motor vehicle regulations.
Wheel change
When changing wheels use the jack
provided with the vehicle.
Jack location at front Jack location at rear Tightening wheel nuts
Jack should be placed below chassis
long member behind front wheel for
changing front tyres and before rear
wheel at rear axle as shown for rear
tyres.
Wheel alignment
If uneven tyre wear is noticed, get the
vehicle examined and attended by
TATA MOTORS authorised Service
Outlet. Periodically check and maintain
correct tyre pressure to obtain longer
tyre life.
Vehicle maintenance Wheels and tyres
Recommended tyre pressure(with cold tyres)
For LT 245 / 70 R 16 ALL TERRAIN
TYRES
LT 245 / 70 R 16
Front(psi) Rear(psi)
UNLADEN 31 41
LADEN 36 58
Check and maintain the above
recommended tyre pressure in all terrain
& environment conditions.
61
Check tyres for damage from time to
time and remove any foreign bodies
(nails/stones, metal chips etc.)
embedded in treads.
While fitting wheels on the vehicle make
sure that wheel bolts are free from dust,
scratches, dirt, dents etc.
Do not oil wheel bolts and nuts.
Wipe off any adhering oil.
Tightening torque of : 12-15 mkg
wheel nuts.
Retighten wheel nuts after 100 km of
every wheel change.
New tyres do not give maximum grip
straightaway and should therefore
be run-in at moderate speed for the
first 100 km. This will help to make
the tyres last long.
To avoid damage to tyres and wheels,
drive slowly over speed breakers/
bumps/rough roads.
Vehicle maintenance Wheels and tyres
Wheel balancing :
Wheels of your vehicle are balanced.
The same should be maintained when
repairing a tyre or tube and replacing the
tyre or rim.
Replacing a tyre/ rim :
When the tyre or rim is changed the
wheel should be properly balanced on a
machine after inflating to the specified
value as per the following norms.
1. Permissible imbalance for tyre with
rim=250 gm-cm max.
2. Permissible balance weight for tyre
with rim=140 gm max.
3. Relocate the tyre if the weight required
to balance is more than 140 gm.
4. Balance weights are available
from 10 gm to 90 gm in steps of 10
gm and from 80 to 140 gm in steps
of 20 gm.
5. Do not use more than one balance
weight on one side.
Run-flat :
Run-flat is fitted on the rims inside
tyres to drive the vehicle when tyres
deflated due to bullet firing.
62
Vehicle maintenance Wheels and tyres
External Repair kit (Optional):
This repair system enables quick road-
side puncture fixing without having to
demount the wheel from the vehicle.
The specifically shaped rubber repair
plug with its special adhesive coating
is inserted in the tread injury from out-
side. It automatically seals the punc-
ture channel. The repair plug, with its
specific shape, acts like an anchor. It
hooks itself on the tyre inside while
completely plugging the puncture
channel, and sealing the tyre.
Repair kit consists of
1. Anchor seal plug.
2. Marking chalk
3. Rotary cutter 6mm Dia.
4. Hand Ratchet (Right/ left)
5. Insert tool.
6. Special cement
Repair procedure (Refer manufac-tures instruction)
1. Remove the penetrating object from
the tyre.
2. Carry out the anchor seal follow-
ing the enclosed instructions
provided with kit.
3. Finally inflate the tyre - the job is
safely done.
4. The repair plug self – vulcanizes
by the heat generated in he tyre
under working condition.
Caution : It is advisable to inspect
the tyre internally for secondary
damage.
63
Non skid chains : (If required)
Non skid chains are used on tyre to
get better traction and drivability in
snow or marshy area.
Fitment procedure of these chains on
tyre is given below :
1) Check for proper pressure in tyres.
1) Lay down the chains (longitudi-
nally) on level floor
2) Drive the vehicle on laid chains
3) Wrap the chains on tyre.
4) Adjust the chain locking
5) Clamp the toggle clamp
6) Ensure tight fitment of chains
7) Run for one or two Kms.
8) Adjust the chain locking.
NOTE : Tyre pressure to be main-
tained before fitment of nonskid
chains on tyres
Vehicle maintenance Wheels and tyres
Schematic diagram - Tyre rotation
Tyre rotation
Tyre rotation is recommended for
achieving identical wear on each tyre.
It is also advisable to change rotating
direction to relieve tyres of continual
one way rotation. Regular rotation of
tyres also will prevent abnormal wear.
The sketch indicates a suggested
sequence of tyre rotation Rotate tyres
at specified intervals or earlier
depending on operation.
64
Vehicle maintenance Battery & Battery Isolator Switch
Battery
Battery :
Battery is fitted near the gear shift lever
& in between driver & co driver seat.
Battery is located in box & bolted
cover.
Check the battery for proper
electrolyte level and corrosion on the
terminals.
1. Check the battery for electrolyte
level against the marking on the
battery outer case.
.2. Check the battery terminals for
corrosion (a white or yellowish
powder). To remove it, cover the
terminals with a solution of baking
soda. It will bubble up and turn
brown.
3. When this stops wash it off with
plain water. Dry off the battery with
a cloth or paper towel.
4. Coat the terminal with petroleum
jelly to prevent future corrosion.
Use a proper spanner to loosen andremove cables from the terminals.
Always disconnect the negative (-ve) cable first and reconnect it last.
Clean the battery terminals with a
terminal cleaning tool or wire brush.
Reconnect and tighten the cables,
coat the terminals with petroleum jelly.
Ensure that battery is securely
mounted.
If you need to connect the battery to
a charger, disconnect both cables to
prevent damage to the vehicle’s
electrical system.
NOTICE
During normal operation, the battery
generates gas which is explosive in
nature, a spark or open flame can
cause the battery to explode
causing very serious injuries.
Keep all sparks & open flames and
smoking materials away from the
battery.
Getting electrolyte in your eyes or
on the skin can cause severe burns.
Wear protective clothing and a face
shield or have a skilled technician
to do the battery maintenance.
The battery contains sulphuric acid
(electrolyte) which is poisonous and
highly corrosive in nature
Battery Isolator Switch:
This switch is provided near the gear
shift lever to isolate the battery from
electrical system when required.
65
Headlamps
The headlamps provides two types of
light beams; a high beam to give
maximum light well ahead of vehicle,
and a low beam which is shorter and
lower so that it will not dazzle the
oncoming drivers can be used in low
visibility area.
The headlamp also incorporates a
parking light.
The headlamps must be properly
aligned in order to obtain maximum
road safety, proper road illumination
and reduced glare to oncoming traffic.
It is recommended to check alignment
of headlamp beams periodically and
whenever headlamp bulbs are
replaced, by means of a headlamp
aligner or with the help of a screen as
shown in figure .
Vehicle maintenance Battery Isolator Switch & Head Lamps
Battery is connected to the starter and
other circuitry through isolator switch.
This is to be switched OFF while
carrying out any work on the vehicle
and also when the vehicle is parked
for long duration to avoid battery
drainage. This will also prevent any
inadvertant short circuits during
repairs.
Battery Isolator Switch
66
Adjusting head lamps focus withthe help of screen
The vehicle should be parked 10meters away from screen with itscentre in line with central vertical lineon screen, and screen at right angleto longitudinal axis of the vehicle. Thevehicle should be in unloadedcondition with no sag in suspensionsprings and all tyres equallyinflated.Head lamp leveling switchshould be kept on ‘O’ position.
On the marked up screen as shown infigure, area above horizontal and inclinedlines (shaded) is called 'Dark zone' andthe area below it is called 'The illuminatedzone'.
Each headlamp is aligned individuallyby masking the other headlamp.Headlamp is first adjusted for properheight of low beam by adjusting headlamp leveling motor shaft if required.Light from low beam should fall belowhorizontal and inclined lines.
No light should fall above these linesi.e. in 'Dark zone' Thereafter lateraladjustment is done by adjusting theknob at bottom of headlamp so thatcontour of low beam coincides withcontour formed by horizontal andinclined line below ‘Dark zone’
When properly adjusted, most brightlyilluminated area will be just below theintersection point 'A' of these twolines.
The Second headlamp is adjusted ina similar manner without disturbing theposition of the vehicle and the screen.
Now switch 'ON' high beam. They willbe symmetrical above point. 'A' and'B' of intersection of vertical lines andhorizontal lines. It is possible thathigh beams may not be exactlysymmetrical but for this reasonheadlamps should not be realigned.
Perferably, the alignment should bedone in the dark.
No masking of headlamps withblack paint is required. If done, thiswill reduce the intensity of lights.
Vehicle maintenance Head lamp adjustment
67
Head lamp bulb replacement
Raise the bonnet of the vehicle.
Remove the rear protective cover. Pull
out cable socket from bulb. Remove
lock ring holding the bulb and remove
the bulb.
Install new bulb, properly locating it
in the housing. Fit back locking ring,
cable socket and protective cover.
Removal of cable socket Removal of locking ring Removal headlamp bulb
Realign headlamp beam afterreplacing bulb
Do not clean the reflector as it willcause damage to mirror-finishedsurface. Do not replace bulb withdirty or oily hands, since oil willevaporate due to bulb heat andstain the reflector.
Vehicle maintenance Head lamp bulb replacement
68
Vehicle maintenance Bulb specifications
DESCRIPTION LOCATION SPECIFICATION
Head Lamp Bulb Head Lamp 12 V 60/55 W
Parking Lamp Bulb Head Lamp/Tail Lamp 12 V 4/5 W
Direction Indicator Lamp Bulb Head lamp/Tail lamp 12 V 21 W
Side Repeater Bulb Side Indicators 12 V 5 W
Tail Lamp Bulb Tail Lamp 12 V 10 W
High mounted stop lamp Tail Lamp 12 V 21 W
Reversing Lamp Bulb Tail Lamp 12 V 21 W
Number Plate Lamp Bulb Number Plate 12 V 10/5 W
Warning & Illumination Lamps, Head Lamp Bulbs (Main beam),
Turn Indicator Bulb, Battery Charging Indicator Bulb,Glow
Plug Indicator Bulb, Low Oil Pressure Indicator Bulb, Barake/ Instrument Cluster 12 V 2 W
Parking Light Indicator Bulb,4WDL & 4WDHIndicator Bulb,
Check Engine Indicator Bulb, Water in fuel indicator Bulb
Gauge Illumination Lamp Instrument Cluster 12 V 3.4 W
Interior Lights Roof 12 V 10 W
Engine Compartment Lamp Engine Compartment 12 V 21 W
Front Fog Lamps Front Bumper 12 V 55 W
Rear Fog Lamps Tail Lamp 12 V 21 W
BULB SPECIFICATION
69
Fuse box :
In order to protect the cable harness
and other equipments from damage
in case of short circuit and overloads,
fuse links are provided.
Fuse box is located in engine
compartment at RH side.
In case of a fault in the electricalsystem check the respective fuse. Theparticulars of the consumers servedby each fuse and amperage areprinted on the fuse box cover. The fuselink can be identified for amperageby colour codes :
1. Fuse link - Red - 10 Amps2. Fuse link - Blue - 15 Amps3. Fuse link - Light brown - 5 Amps4. Fuse link - Yellow - 20 Amps
While fitting fuse box cover ensure
that cover knob rests in the slot
provided inside fuse box.
Spare fuse cartridges are provided
inside the fuse boxes.
Always use fuses of correct rating.Do not use a wire in place of fuse.
Flasher with short circuitprotection
If flasher circuit is short circuited or
overloaded (more than 110 W) flasher
will shut off. It can be reset by
momentarily centering the indicator
arm of combi switch.
If flasher is shutting off or fuse is
blowing off repeatedly the flasher
circuit should be checked for short
circuit. Check the flasher separately
for its functioning.
Vehicle maintenance Fuses
Fuse /relay box in engine
compartment (If fitted)
70
l Floor mats ( If fitted)Dirt can be removed from the mats
with water and a mild soap. Use a
brush to help loosen dirt. After dirt
is loosened, wash the mat
thoroughly with water and dry it in
the shade.
l Seat beltClean the seat belt with a mild soap
and water only. No bleach or dye
should be used as this may weaken
the belt fabric. The belt should be
allowed to dry in the shade.
l Carpets (if fitted)
Remove dirt as much as possible
by using a vacuum cleaner. Rub
the stained area with clean cloth
made damp with soap to absorb
the stain and remove the soap.
Repeat until the stain is removed.
You can use commercially
available carpet cleaner. In this
case, carefully follow the
manufacturer's instructions and
precautions.
Vehicle maintenance Care and cleaning of vehicle
Cleaning exterior of the vehicle
Dirt or any other foreign material on
the painted surface may result in :
l Faded paint.
l Rust on body due to deteriorated
paint film.
l Rust due to scratches
l Body rust due to contact with
damp dirt trapped in the body.
Therefore it is important that your
vehicle is always kept clean and
free from dirt in order to maintain
the paint in a good condition and
to protect the entire body against
corrosion.
Washing
When washing the vehicle, follow the
instructions given below :
l Flush underside of body and wheel
housing with pressurised water to
remove mud and debris. Use plenty
of water to loosen and remove dirt.
l Remove dirt and mud from
Care and cleaning of the vehicle
CAUTION
When cleaning the interior / exterior
of the vehicle, NEVER USE volatile
solvents such as thinner, petrol or
any other cleaning materials such
as bleaches or strong household
detergents. These materials may be
poisonous or flammable and their
improper use may cause personal
injury or damage to the vehicle.
Cleaning of vehicle interior :
l Upholstery
Prepare a solution of soap or
neutral detergent mixed with warm
water. Apply solution with a sponge
or soft cloth and let it soak for a
few minutes to loosen dirt. Wipe
the surface with a clean, damp
cloth to remove dirt and soap
solution. If some dirt still remains
on the surface, repeat the
procedure.
71
Vehicle maintenance Care and cleaning of vehicle
Waxing the vehicle exterior
After washing the vehicle, waxing and
polishing are recommended to
protect and beautify the paint.
l Use only good quality waxes and
polishes.
l When using waxes and polishes, the
precautions specified by the
manufacturers should be observed.
l Chrome-plated parts should also
be waxed.
Protection against corrosion
The following cause corrosion :
l Moisture trapped in body cavities.
l Dirt and salts collected in hollows on
the underside of the vehicle.
l Removal of paint and protective
coatings from the exterior and
underside of the vehicle.
Corrosion preventive measureshave been incorporated in your vehicle.
You can avoid corrosion of your vehicle
by performing some simple periodic
maintenance :
l Repair chips and scratches in the
paint as soon as you discover them.
l Inspect and clean the drain holes in
the bottom of the doors and body.
l Check the floor coverings for
dampness. Carpets and floor mats
remain for a long time, especially
in winter. This can eventually cause
the floor panel to corrode.
l Use a high-pressure spray to clean
the underside of your vehicle. This
is especially important in areas near
chemical and other industries.
l Have corrosion preventive coatings
done on the underside of your
vehicle. Preventive coatings such
as the Dinitrol-3850 are available in
the market.
bodyexterior with running water.
Use a soft sponge, brush with
water. Do not use hard material
which can scratch the paint.
l Wash the exterior with water, lightly
rubbing with sponge or soft cloth.
The sponge or cloth should be
frequently soaked in water.
CAUTION
When using commercial wash
products precautions specified by the
manufacturers should be observed.
Do not use strong household
detergents or soaps.
l Once dirt has been completely
removed, wash off with running hose
water.
l After rinsing, wipe the body lightly
with wet chamois or cloth and allow
the body to dry in the shade.
WARNING
After washing, check that the brakes
are dry. If brakes are not dry, dry them
by gently, repeatedly applying while
driving at low speed.
72
Cleaning of Glasses :
For the internal face of the glass (poly-
carbonate) it is not recommended to
use cleaning agents, since they could
affect the optical quality of the
product. Because of the above, we
recommend using only water and damp
cloth. In any case avoid cleaning
glasses under direct sunlight.
1. Remove grit particles, etc by blow-
ing with clean filtered air, preferably
ionised to minimise ‘static’
attraction.
2. Wash with tepid water / detergent
(e.g. Teepol or a domestic house-
hold detergent) solution and dry
using clean gloves cloths.
3. Rub lightly to remove stubborn
marks with soft glove cloth impreg-
nated with 50% v/v isopropyl
alcohol or ethanol in water followed
by through washing with water /
detergent. Change cloth frequently.
Dry with lights strokes, with a clean,
dry soft glove cloth. Fresh paint,
grease and wet sealant may be
similarly treated.
Minimise the effects of hairline
scratches and minor abrasions
using very mild automobile cleaner
polish.
DO NOTDO NOTDO NOTDO NOTDO NOT
Wipe the PC Hi-tech (anti-scratch plas-tic) inside surface with dry, dirty rags and/
or any abrasive clothes which may
scratch the splash shield.
Try to remove marks or dirt with sharp
object or razor blade.
Stick any labels or stickers to the inside
face.
Wipe the inside face with dry, dirty rags.
Allow any subsequent exposure to sol-vents (other than as above).
Scrape the surface to remove marks,frost etc with any sharp instrument.
Allow any abrasive cleaner, steel wool or
similar material to come into contact withthe inside face of window.
Wipe the inside face of the window withthe hand, whether glove or not.
The inside face of the window should notbe allowed to come into contact with other
organic materials containing plasticisers
or solvents e.g. Flexible PVC,‘Screenvin” solvent based protective
lacquers etc.
Vehicle Maintenance Care and cleaning of vehicle
73
Vehicle Maintenance Preservation & De-preservation
WORK GUIDELINE FOR PRESERVATION AND DE-PRESERVATION OF SUMO ARMOURED VEHICLE INDIFFERENT CLIMATIC CONDITIONS
STORAGE PREPARATION OF VEHICLE:
Choose a place preferably closed cool, dark and dry. But many a times getting such an ambience is not possible. If
the vehicle needs to be stored outside, it should be covered with a quality cover which has thick, multi-layered fabric.
Following precautions can help in keeping the vehicle in good condition.
PRESERVATION (07 Days or less):
1 Vehicle shall be empty and no load inside cabin or load body shall be kept.
2 Increase Tire pressures by 10 psi over the specified (placard) pressures to avoid flat spots or damage to the
tire leading to permanent set deformation.
3 Disconnect the battery terminals inside engine compartment as well as in passenger compartment.
4 Make sure that fuel quantity inside tank is at minimum level.
5 If the engine’s coolant service life time limit will be exceeded while the vehicle is in storage, drain and refill the
cooling system with the recommended coolant mixture.
6 The coolant mixture must protect against freezing down to the lowest expected temperature
7 Make sure that vehicle is in 4 x2 mode.
AT HILLY / SNOW FALL / COLD CLIMATE AREA:
1 In cold atmosphere area vehicle shall be parked preferably inside enclosed area. If such area is not available
then park the vehicle in such a place where snow fall is less. Put antirust element on surface which is open to
atmosphere.
2 Cover the vehicle with car cover where the snow fall is in control.
3 Put hand brake in on condition to arrest the vehicle slippage or park the vehicle in plain area with chokes
74
COASTAL AREA:
1 Apply antirust to all open body area
DE-PRESERVATION (Beyond 07 days):
In addition to above short term storage precautions following steps needs to be taken:
1 Make sure the vehicle is clean, waxed, and chrome polished before putting it into storage.
2 Drive the vehicle for about 10 Km after adding the stabilizer/antirust/anticorrosion agent in fuel system, Cooling
system ,lubricating systems and brake oils (Long storage fuel additives available in local market is called
stabilizer).
3 Normally it’s best to leave the tank full. However, if the vehicle will be stored in an enclosed location where gas
fumes could be a problem, empty the tank about half way
4 Open the Injectors and pour about a teaspoon of oil into each cylinder and fit it back. This will help coat the
cylinders to prevent rust. Also pour oil into the intake, this lubricates the engine and the exhaust system from
the inside deterring rust formation.
5 Place desiccant packs in various locations inside the car; also place moth balls in various locations inside;
make sure the air is on the “re-circulate” setting; open the glove box and other interior storage locations; cover
any areas that might be exposed to sunlight.
6 Drain the cooling system fluid and fill fresh appropriate coolant in system.
7 Seal off engine openings such as engine air intake, exhaust out let pipe with absorbent cotton to keep moisture
out.
8 Remove the battery and clean its top with a mixture of baking soda and water. Apply grease on the terminals
and preserve separately.
9 Loose the drive-belts to take the pressure off of the pulley bearings.
Vehicle Maintenance Preservation & De-preservation
75
10 Support the vehicle on jack-stands or blocks. This will take the weight off of the wheel bearings and suspension
components. Also if possible remove the wheels and tires, lower the tyre pressure slightly, and store them flat
and out of sunlight area.
11 Wash and wax the body surface.
12 Apply vinyl/Weather protestant on leather surfaces, tyres, and other rubber components.
13 Keep off the wiper blades from wind shield glass or take off and preserve separately.
14 Seal the tailpipe and any other openings to prevent entry of mice or other rodents.
15 Particularly care to be taken to plug the fire wall openings in to the cabin to prevent rodents.
16 To avoid engine bearing damage due to acid in the engine oil, change the engine oil and oil filter.
17 Leather care: You do not to need to apply a leather conditioner to maintain suppleness in the leather. To clean
the leather use a damp, soft cloth, taking care not to soak the leather. Small dirt particles can be abrasive and
damaging to leather surfaces and should be removed promptly. Do not use saddle soap, polishes, oils,
cleaning fluids, solvents, detergents or ammonia-based cleaners
18 Place any written reminders on what may be needed after the vehicle is removed from storage where it will be
easily seen such as the top of the instrument panel, on the steering wheel, etc.
19 Make sure you have adequate insurance on the vehicle to cover for fire, theft and vandalism or any avalanches
or storm condition etc.
20 Open both front and rear hatch if it is inside parking & keep it partial open when parked outside or open to
atmosphere.
21 Make sure that 4 x 4 is not engaged.
Vehicle Maintenance Preservation & De-preservation
76
BATTERY STORAGE GUIDELINES:
1 Any time a battery will be stored unused for an extended period of time (over 30 days), certain precautions will
help assure that the battery will not be damaged and will be ready for use when needed.
2 Bring the battery to full charge before storing it.
3 If the battery is in a vehicle, it is often best to disconnect the negative battery cable.
4 Install and keep terminal protectors in place and keep the battery clean.
5 Store the battery in as cool of a location as possible.
6 Monitor the battery on a regular basis.
7 Bring the battery to full charge before it is stored. This is the best insurance against internal damage due to
remaining in a discharged state for a long period of time, and against freezing in extremely cold weather.
8 If possible disconnect the negative battery cable if the battery is in a vehicle (this is must to prevent battery
discharge as well fire accidents). This will prevent parasitic drains in the vehicle system from discharging the
battery at a faster rate. If the negative battery cable cannot be disconnected, more frequent monitoring and
charging will be needed.
9 To prevent accidental discharge, install terminal protectors on exposed terminals. Keep the battery free of dust,
dirt, moisture, and conductive materials like damp cardboard that could allow the battery to discharge slowly
through external paths.
10 Cool temperatures retard the internal reactions that cause self discharge and internal grid corrosion. Find the
coolest storage location that will not cause the battery to freeze. A battery that is kept at a 65% SOC or higher
will not freeze until the temperature is below -32°C (-25°F) A fully-charged battery will not freeze until the
temperature is below -54°C (-65°F).
11 Monitor the stored battery regularly by checking the built-in hydrometer or OCV.
Vehicle Maintenance Preservation & De-preservation
77
12 If a battery is stored in a vehicle with the cables connected, check the battery SOC every 30 days. Recharge
the battery fully whenever the SOC falls below 65%.
13 When stored on the shelf or in a vehicle with the negative cable disconnected, a battery that begins storage at
full charge will require recharge on the following schedule, depending on the estimated average storage
temperature :
AVERAGE STORAGE TEMPERATURE RECHARGE FULLY AT
210C OR Below (700F OR Below) 12 Months
210C - 270C (700F - 800F) 8 Months
270C - 320C (800F - 900F) 4 Months
320C - 380C (900F - 1000F) 2 Months
380C OR More (1000F OR More) 30 Days
Chart applies to fully-charged batteries only
AT HILLY SNOW ALL/COLD CLIMATE AREA:
1 Apart from above mentioned points, below mentioned points are specific for cold climate area preserving,
2 Remove battery from vehicle and keep it in battery maintained area.
3 Apply thick layer of antirust on all open surface area.
4 Place the transmission gear selector in Reverse or First. Put 4x2 mode gear selector. Release the Park Brake.
5 Lubricate door, trunk, hood and other moving metal parts with silicone lubricant.
GENERAL INSPECTION BEFORE RETRIVAL OF PRESERVED VEHICLE:
1 Over all condition of vehicle.
2 Paint condition.
3 Rusting marks on body as well as on chassis components.
Vehicle Maintenance Preservation & De-preservation
78
4 Levels like radiator coolant, engine oil, Gear box oil, axle oil, power steering oil etc…
5 Condition of tyre. (Any depletion happens).
6 Fuel tank condition (inside/Outside).
RETRIVING PRESERVED VEHICLE:
1 Check battery condition & electrolyte level. Check for battery serviceability and if it is in serviceable condition,
send it for servicing.
2 Remove air filter element & clean it.
3 Check water separator. If water level indicator is showing high level then empty the water separator.
4 Remove fuel filters for inspection and if dirty clean it, also clean the entire fuel line. This will ensure removal of
any blockages / water particles / any rusted chip if present inside.
5 If any contamination is observed in levels of engine oil, coolant, gear box oil, power steering oil, rear axle oil
etc... Than then flush the entire contaminated level. After flushing refill oil or coolant.
6 Clean the rusted surface where traces of corrosion are observed. Traces may be observed at electrical
connections like fuse/Starter motor/alternator/connectors/ relays/ etc… These traces required to be cleaned to
ensure proper voltage supply throughout the circuit.
7 Remove all brake drums/ Pads and clean the rusted surface where traces of corrosion are observed. Before
fitting back ensure for no moisture content within system.
8 Do hand priming of fuel line & ensure that fuel is supplied up to injectors, fuel lines and its solenoid for free
movement and free working.
9 Connect properly charged battery to vehicle and crank the engine for 5 seconds to know about any abnormality
in engine noise after cranking. Repeat cranking for 2/3 times to ensure further cranking can be done. Than
crank the engine till it get started. (Do not crank engine for more than 20 sec, because battery cable may be
heated and can cause fire )
Vehicle Maintenance Preservation & De-preservation
79
10 When vehicle is started let the engine run in idle condition up to 2 minutes to ensure proper oil supply inside the
engine and to attain the ambient temp of all parts.
11 After 2 minutes in idling accelerate further to ensure that engine is running up to fly up rpm.
12 Drive vehicle in Pre selective first gear for 15 min.
13 During driving apply brake from 60 kmph up to 30 kmph. Repeat it for @ 10 - 20 cycles (This is to ensure
proper brake liner to drum contact and make it moisture/dust free)
14 Check vehicle by driving in each gear ensuring all aggregates are functioning properly.
15 Confirm for 4 x 4 high/low operation.
AT HILLY / SNOW FALL / COLD CLIMATE AREA:
1 Vehicles at cold climate area or a hilly area an attention towards following things apart from above mentioned
points need to be given.
2 A rubber component, Plastic components, rubber hoses needs to be checked for its proper hardness and if
crack generated are mores replace the components. All rubber parts like seal, beeds “O” rings etc to be
changed with new, since there is a chance of aging due to presence of ozone in atmosphere.
3 Wherever snow is concentrated over a surface needs to be cleaned and make rust free surface.
4 Vehicle to be inspected for affected areas where snow was accumulated and any damaged components to be
replaced.
5 All fuel lines and water passages to be made ice free and if required damaged pipes or rubber hoses need to
be replaced.
6 Fuel tank to be made empty and made ice, water, moisture free and fresh fuel need to be filled up.
Vehicle Maintenance Preservation & De-preservation
80
COASTAL AREA:
1 Vehicle to be inspected for rusty surface and rusted surface area to be made rust free.
2 Surface area where thickness of that component is rusted more than 50 %, than repainting of that surface is
required to be done.
Vehicle Maintenance Preservation & De-preservation
81
Vehicle Maintenance Special Operating Conditioning
Special Operating Conditions :
1. Operating on dusty/sandy roads.
2. Operating on hilly terrain with dusty
conditions.
3. Operating on muddy and melted
snow roads.
4. Operating frequently above 2000
m. of altitude.
5. Possible mixing of impurities in the
fuel due to operating conditions.
The vehicle is fitted with 3L DICOR
engine can be used satisfactorily
under the following conditions :
1. Altitude : Mean Sea level / ambient
temp. up to -200C ( With
recommended fuel & oil)
2. Altitude : 2500 meters and
ambient temp. upto -200C ( With
recommended fuel & oil)
Recommendations for operatingunder special conditions :
1. Air filter :
Cleaning of air filter cleaner element
For dusty operating conditions clean-
ing of air filter element need to be
carried out when ever red band
appears on the indicator. Cleaning of
air filter element should be carried out
by tapping the element gently so that
the dust could fall off.
Air filter element may be changed :
If the red band appears on the
Service Indicator continuously. OR
If visually it is observed to be covered
with mud / dust which can not be
cleaned effectively.
2. Engine oil and oil filter :
For special operating conditions of
vehicle, change oil and oil filter at
every 5000 kms or 3 months which-
ever is earlier. (Existing frequency for
normal operating conditions is 10000
kms)
82
The oil change periods recommended in maintenance
schedule should be adhered to.
Use of reclaimed oil is not recommended.
Engine oil : Qty : 6.5 Litres
Recommended grades of engine oil conforming to Multigrade
oil 15W40 API-CF4 specifications and range of ambient
temperatures at which these can be used are given below :
Fuels, lubricants, coolants Fuels, lubricants
Fuels :
High speed diesel conforming to IS 1460 or DIN 51601 or
equivalent is recommended to be used as fuel.
At very low temperatures fluidity of diesel may become
insufficient due to paraffin separation. It is therefore,
necessary to mix supplementary fuel with summer or winter
grade diesel. The supplementary fuel to be used is kerosene
or aviation turbine fuel
Ratios for mixing of supplementary fuel and diesel are shown
in table :
Percentage
Summer Supplementary
grade diesel fuel
upto 0 100 0
0 to -10 70 30
-10 to -15 50 50
Ambienttemperature upto
0C
Care should be taken that diesel and supplementary fuel
are thoroughly mixed before filling.
Percentage
Winter Supplementary
grade diesel fuel
upto -15 100 0
-15 to -20 70 30
-20 and below 50 50
Ambient
temperature upto0C
Lubricants
Recommended lubricants conform to the following
specifications :
1. SAE 15 W40 to API CF 4+ Engine oil
2. 75 W 90 GL-4 Syn. oil Gearbox oils
3. SAE 85 W 140 API GL-036 B Rear axle
(with additive 6.5 % Angalmol
99 by weight) and friction
modifier 40819.
Please use only recommended brands for good
performance.
83
Vehicle maintenance Lubricants
Ambient temperature 0C Engine oil grade
0 and above SAE 15W40
0 to -18 SAE 0W30
-18 and -40 SAE 0W40
Running in oil
In the first 2000 km of operation of a new or reconditioned
engine, any one of the running in oils listed below should
be used :
Autolube 30 : (HP)
Gear box oil (for GBS-76)
75W90 GL4 Syn. oil
Transfer case oil :
Recommended lubricant - Type A, Suffix A specifications,
e.g. Castrol TQ Gear oil capacity-1.2 liters.
Rear axle, live front axle oil :
Use oils conforming to APIGL 5 specifications. SAE 90 oil
should be used upto -90C and SAE 85 W 140 -400C.
Brake and clutch fluid
Brake fluid conforming to IS : 8654/DOT 3 is
recomnmended.
Spicer propeller shaft (where applicable)
Lubricate slip joint with NLGI-2 grade grease.
Lubrication of steering spindle and sleeve
Lubricate steering spindle and sleeve with Molikote grease
or mobiltac NC grease, at specified intervals.
Coolants :
Presence of dirt in the coolant chokes up passages in the
radiator, cylinder head and cylinder block, thereby causing
insufficient cooling of engine.
To prevent rust information and freezing of coolant inside
the passages of radiator, cylinder block and cylinder head,
use genuine co-branded premixed coolant (ready to use).
84
Recommended oils, lubricants and filling capacities
PLEASE USE ONLY FOLLOWING GENUINE OILS, COOLANTS , LUBRICANTS , ANTI RUST & SOUND DEADENING COATS,
WINDSCREEN SEALANT, ADHESIVES & FUEL ADDITIVES BRANDED BY TATA MOTORS FOR OPTIMUM PERFORMANCE
ITEM COMPANY BRAND QTY
ENGINE OIL CASTROL Castrol GDT 15W/40 For Summer 500 6.5 Litres
HPCL SAE 0 W 40 For Winter -200
COOLANT (Premixed) SUNSTAR Golden Cruiser Premium 1400 MHENKEL TEROSON Frostox SFD 12 13 Litres
HPCL HP Thanda Raja P
GEAR BOX (G-76) HPCL HP Gear EP 75W90 1.6 LitresCASTROL CASTROL Sythetic 75W90
TRANSFER CASE OIL HPCL HP-Automatic Transmission 1.2 LitresCASTROL CASTROL Transpower TQ Fluid Type A
POWER STEERING OIL HPCL HP-ATF Dextron II D 1.4 LitresCASTROL CASTROL Transpower TQ
REAR AXLE / HPCL HP Gear Oil XP 85W140 GL5 with friction modifier 40819 2.2 Litres for Rear #FRONT LIVE AXLE CASTROL CASTROL Extreme Pressure 85W140 1.2 Litres for Front
BRAKE / CLUTCH FLUID HP CL Super Duty Brake Fluid DOT - 3 / DOT - 4 As requiredCASTROL CASTROL Universal Brake Fluid DOT - 3
WHEEL BEARING & CHASSIS HPCL HP Multipurpose Grease-2 As requiredPropeller shaft joints, Sliding CASTROL Castrol AP-2 greaseYokes, Vacuum Booster
ANTI RUST TREATMENT DINITROL Dinitrol —& SOUND DEADENING WUERTH Wuerth —
WIND SCREEN SEALANT ANCHEMCO Terostat 8590 Kit Form —
METAL & PLASTIC ADHESIVE ANCHEMCO Terostat 930 310 ml Cartridge
DIESEL ADDITIVE IFTEX Iftex Clean System D 250 ml pack *
A.C.COMPTRESSOR SUBROS DENSOIL-6 -SUNOILCO SUNISONO.5GS
* Add to Diesel as per the dosage recommended by M/s IFTEX # For Tata Motors Rear axle - 1.9 Litres
85
ENGINE
Model TATA 3.0 L DICOR BS-III
Type Water cooled, Direct injection,
Common Rail, Turbocharged
Intercooled Diesel engine with
crankcase breather and relief valve.
No. of cylinders 4 inline
Bore / Stroke 97 mm x 100 mm
Capacity 2956 cc
Max. engine output 84.9 kw @ 3050 rpm as per CMVR
115(9) 1996
Max. torque 300 N-m at 1600 ~ 2200 rpm as per
CMVR 115(9) 1996
Compression ratio 17.5 : 1
Firing order 1-3-4-2
Engine oil capacity Max. 6.5 litres / Min. 5.5 Litres
Weight of Engine 320 kg (Dry)
Radiator frontal area 2480 sq.cm.
CLUTCH
Type Single plate dry friction diaphragm
type with hydraulic actuation.
Outside diameter of 240 mm
clutch lining
Friction area 452 sq. cm. (approximately)
GEAR BOX
Type G-76-5/4.1 with overdrive
sychromesh on all gears.
No of gears 5 Forward, 1 Reverse
Gear ratios 1st 4.10
2nd 2.22
3rd 1.37
4th 1.00
5th 0.77
Rev. 3.75
TRANSFER CASE
Type With electric shift arrangementmounted on gear box.
Ratio 4x2 high - Ratio - 1:1
4x4 high - Ratio - 1:1
4x4 Low - Ratio - 1 : 2.48
REAR AXLE
Type Single reduction, salisbury type with
limited slip differential hypoid gears
& semi-floating axle shafts.
Ratio 4.55 (41/9)
FRONT LIVE AXLE
Type Independently suspended with
automatic hub lock
Ratio 4.55 (41/9)
Vehicle Data Technical Specification
86
Vehicle Data Technical Specification
STEERING
Type Power Steering
Steering Wheel 380 mm dia.
BRAKES
Service brakes Vacuum assisted indepedent hydraulicbrakes on front & rear through tandemmaster cylinder.Vacuum pump mountedon engine
Front 282 dia disc brake
Rear 295 dia. auto adjuster drum brake
Parking brake Floor mounted Cable operated mech.linkages acting on rear wheels.
FRAME
Type Ladder type cranked frame with boxedsection long members and weldedcross members
Depth 110 mm (maximum)
Width 60 mm
Tow Hook Tow hook at front, Provision of centraltowing hook at rear
SUSPENSION
Type Front Double wishbone type with torsion barsprings.
Rear Semi-elliptical leaf springs.
Shock Absorber Hydraulic double acting telescopic typeat front and rear.
Antiroll bar At both front and rear.
WHEELS AND TYRES
Tyres a ) LT 245 / 70 R16 113S BF
b ) 245 / 70 R16 111S ZVRL - MRF
Wheel rims 6.5 J x 16 Steel rims
No of wheels Front - 2, Rear - 2, Spare - 1
FUEL TANK
Capacity 65 litres
ELECTRICAL SYSTEM
System Voltage 12 Volts (–ve earth)
Alternator Capacity 150 Amps
Battery 12 Volts, 80A/Hr
PERFORMANCE
Max. speed at rated GVW 85kmph
Max. gradeability at rated GVW 360
WEIGHTS (KG) - Tolerances as per INTEREUROPE STVZO
Complete vehicle kerb
weight as per ISO:1176 3050 (FAW-1400,RAW-1650)
(with spare wheel & tool)
Gross Vehicle Weight 3510 (FAW-1440,RAW-2070)
Max.Permissible FAW 1440
Max.Permissible RAW 2070
Max. permissible trailer 750
capacity (Unbraked)
PASSENGER CAPACITY
Driver +5
87
Vehicle Data Technical Specification
VEHICLE DIMENSION
88
PRELIMINARY TROUBLESHOOTING :
(These tips are given for your guidance and preliminary jobs to be done in an emergency situation. In normal case, the
problems should be attended in an Authorized Workshop by following the repair procedures given in Workshop Manual)
PROBLEM OBSERVED CAUSE ACTION TO BE TAKEN
ENGINE
1. Engine not cranking Battery dead, • Get battery checked&/or charged
Loose or dirty battery connections • Clean and tighten battery
connections
2. Engine cranks but does not start Air in the fuel system • Press pear pump for air removal
• Check leakages
EMS fuse blown • Replace the fuse
Water sedimenter filled up • Drain water from sedimenter.
with water
3. Engine overheats Coolant level low • Top up coolant, check and
correct leakages
Hose collapse / torn • Get the hose replaced
Low engine oil level • Add oil
Radiator cap not sealing properly • Fit the radiator cap correctly
4. Charging indicator continuously Battery not getting charged • Get the belt tension adjusted
remains ‘ON’ due to loose belt drive replace belt if broken
Faulty alternator • Replace it.
Cut off relay is not working • Replace it
Preliminary Trouble Shooting
89
PROBLEM OBSERVED CAUSE ACTION TO BE TAKEN
5. Poor pickup Loose contact of electrical • Get defect rectified.
connectors
Blocked fuel filter • Clean / replace fuel filter element
Clogged air filter • Clean / replace fuel filter element
Alternator electrical connection • Check and make proper
plug out connections
Intercooler hose collapse or loosen • Check and make proper fitment of
hose
6. Does not accelerate Accelerator pedal module defective • Get defect rectified
7. Belt squeal Loose belt • Get belt tension adjusted
Belt glazed • Get belt replacedCLUTCH
1. Clutch does not get disengaged Air in the hydraulic system • Bleed the system
Less fluid in the master cylinder • Get the clutch fluid filled
2. Clutch pedal goes too low Air in the hydraulic system • Bleed the system
Less fluid in the master cylinder • Get the clutch fluid filled
3. Clutch pedal return sluggish Blocking of vent in clutch fluid • Open the cap from the bottle
Bottle & clean the breather hole, if
Clogged
Preliminary Trouble Shooting
90
PROBLEM OBSERVED CAUSE ACTION TO BE TAKEN
GEAR BOX
1. Hard gear shifting / Clutch does not disengage • Get the clutch hydraulic system
crash engagement properly attended
2. Gear shifts but vehicle 4 X 4 sensor connections loosen • Make proper sensor connections
does not move
REAR AXLE & FRONT AXLE
1. Loss of lubricant (Oil) Breather hole clogged • Clean the breather hole on the
axle housing
Differential cover gasket torn • Get replaced
Pinion oil seal damaged • Get replaced
2. Differential housing overheating Insufficient oil • Get the oil filled
Incorrect lubricant used • Drain, flush and get correct
lubricant filled
3. Noise from axle Excess play in crown wheel pinion • Adjust the play
BRAKES
1. Poor brakes Insufficient brake fluid. • Get the brake fluid filled
Air in the system • Bleed the system
Malfunction of automatic adjuster • Check & rectify auto adjuster
mechanism or replace.
Vacuum leakage • Rectify the leakage
Preliminary Trouble Shooting
91
PROBLEM OBSERVED CAUSE ACTION TO BE TAKEN
Brake fluid contamination • Replace the brake fluid
Brake fluid, grease, oil or water • Replace the leaking line, bleed
on pad /drum the system. Clean pad/lining.
replace seals if leaking
Worn brake lining/pad • Get the liners/pad replaced
Excessive worn drums at rear • Replace rear drums
soft or weak hose • Check & replace
2. Spongy pedal Air in the system • Bleed the system
3. Brake pulling to one side Oil on the lining/pad • Clean the pad lining
One side shoe (pad) worn • Get the shoe pad replaced
Loose brake anchor plate • Tighten the bolts
Wheel adjustment disturbed • Adjust
Unequal tyre pressure • Adjust
One side brake pipe clogged • Get the brake line cleaned &
bleed the system
4. Brake grab Improperly adjusted parking brake • Get correctly adjusted
brake fluid container breather hole • Clean the hole on the container
clogged
No brake pedal free play/brake • Adjust brake pedal
pedal not returning fully
Defective tandem master cylinder • Replace/rectify tandem master
cylinder
Preliminary Trouble Shooting
92
PROBLEM OBSERVED CAUSE ACTION TO BE TAKEN
Brake fluid contamination • Replace brake fluid along with tandem
master cylinder and wheel cylinder.
5. Brake Squeal Defective brake lining/pad • Replace
Glazed lining/pad • Clean or replace lining/pad
Loose rivets • Install rivets properly
Wrong lining/pad • Install correct lining/pad
Shoe return spring broken • Replace
Front pads / Antisqueal shims • Get corrected
rubbing on the disc
STEERING SYSTEM
1. Hard steering Less fluid in the power steering • Get the fluid topped up to
tank correct level
Air in the system • Get the air removed by bleeding
the system
Loose pump belt • Get the belt correctly adjusted
2. One side vehicle pulling Improper wheel alignment • Set proper wheel alignment
Improper tyre inflation pressure • Set proper inflation pressure
Preliminary Trouble Shooting
93
PROBLEM OBSERVED CAUSE ACTION TO BE TAKEN
ELECTRICAL & AIR CONDITIONING
1. No lights on the dash board after Battery terminal got disconnected • Get the battery properly connected
turning on the ignition key Battery completely dead • Get the battery charged
• Get the alternator & charging circuit
checked
• Check battery cut off switch, make it
ON if it is OFF
• Check for parking lamp fuse
2. Non functioning electrical Blown fuse in the circuit • Replace the fuse if blown
accessories such as power
windows, head lamps, fuel Loose connectors • Get the connection properly tightened
tank flap, wiper and washer etc Circuit relay loose the mounting • Tighten the relay correctly
Defective components • Get the defective component
replaced from Authorized workshop
AIR CONDITIONING
1. Fan motor does not operate Blown fuse • Replace fuse and correct any
wiring short
Faulty connection • Properly connect poor connections
Faulty motor • Replace motor if no conductance
Faulty or poor • Replace resistor block if defective
connection at resistor
Faulty fan switch • Replace switch
Preliminary Trouble Shooting
94
PROBLEM OBSERVED CAUSE ACTION TO BE TAKEN
2. Motor operates but air flow Obstruction at evaporator inlet • Clean evaporator
is minimum Air leak • Correctly seal
Faulty thermostat • Adjust or replace thermostat
3. Insufficient cooling, Air flow Incorrect refrigerant quantity or • Get the defect rectified at nearest
normal and compress operating or defect in system aggregates authorized service centre
or defective thermosensor
4. Demist or defrost not working Loose electrical connections • Get proper connections
WIPERS
1. Narrow streaks are left on the Foreign matter has • Clean the edge of the blade. If
wind shield making it hard to see attached to the blade or streaks still appear, replace the blade
edge of the blade is worn out.
2. The wiper blade jumps across No proper contact of wiper blade • Clean the wind shield. If jumping
the windshield and makes a lot with wind shield glass and wiper persists replace the blade.
f noise (Un-smooth operation) blade does not move smoothly
across the surface but vibrates,
noisily and bounces.
3. The wipe leaves large un-wiped Rubber deformed • Replace the blade
spots.
4. The blade does not contact with Deformed wiper blade / arm • Replace wiper blade / arm
the wind shield surface evenly,
leaving a large un-wiped surface.
Preliminary Trouble Shooting
95
PROBLEM OBSERVED CAUSE ACTION TO BE TAKEN
WHEELS AND TYRES
1. Excessive tyre wear Disturbed steering geometry • Adjust steering geometry
Improper inflation pressure • Check and set proper inflation
pressure
Preliminary Trouble Shooting
96
Lubrication points
Lubrication points : The lubrication points listed below
and shown on next page require greasing or an oil
level check and topping up.
NOTE : Grease nipples must be carefully cleaned prior to
greasing and the same applies to grease cups/screw plugs
before they are unscrewed.
* During Overhauls
No. Description Grease / oil
1. Engine Oil level
2. Front hub Pack grease
3. Front Axle C.V. Joint Pack grease
4. Power steering tank Oil level
5. Steering spindle and sleeve 1 Grease nipple
6. Transfer case Oil level
7. Propeller shaft (Rear yoke) 1 Grease nipple
8. Rear axle Oil level
9. Rear hub Pack grease
10. Front Propeller shaft Rear yokes 1 Grease nipple
11. Gear box Oil level
12. Rear spring suspension Rear 4 grease nipples
13. Rear spring suspension Front 2 Grease nipples
97
Lubrication points (4x4 vehicle)
LUBRICATION POINTS
98
1. The vehicle has been built to give you thousands
of kilometres of economical and trouble-free
performance. This is however, possible only if this
vehicle is systematically maintained and operated
strictly according to the instructions contained in
this book.
2. This chapter contains charts showing lubrication
points and the lubrication & maintenance schedule.
3. Besides the lubrication & maintenance schedule
chart detailing the service operations to be
performed, free PDI Coupon (perforated) is
incorporated on one sheet. This coupon should be
detached and sent to Customer Support,Passenger Car Division, Tata Motors Limited,Survey No. 15 & 15 A, PCNTDA, KD-03, Chikhali,Pune - 410501 by the servicing dealer after the
service is performed. The servicing dealer should
fill up details of chassis particulars on the inside
cover page.
4. The vehicle is entitled to pre-delivery service with
free labour.
5. It is an important condition of our policy thatno warranty claims shall be entertained by us
unless all services upto the time of the claimarising have been performed on the vehicle.
Failure to carry out the services listed in this book
can cause considerable damage to the vehicle and
inconvenience to you. It is, therefore, in your own
interest to get the vehicle serviced as per schedule.
6. For any technical advice concerning your vehicle,
please contact the nearest Authorised Dealer or
our Customer Support Representative or write to :
Customer Support,Passenger Car Division,Tata Motors Limited,Survey No. 15 & 15 A, PCNTDA,KD-03, Chikhali, Pune - 410501
While washing the vehicle with water hose, cover up
head lamps and other electrical items and gauges to
avoid ingress of water.
Special instructions
99
LUBRICATION & MAINTENANCE SCHEDULE
Service Operations to be performed by Driver
GENERAL
1. Check engine oil level in sump, Top up, if necessary. Daily
2. Check coolant level in auxiliary tank, top-up, if Daily
necessary with mixture of clean soft water and
recommended anti-freeze additive in specified ratio.
3 Check and get rectified leakage of oil, fuel, brake Weekly
fluid and coolant, if any.
4 Check tyre pressure. Inflate tyres to specified Weekly
pressure, if necessary.
5 Check level of brake fluid in containers, top up, Monthly
if necessary.
6 Grease with grease gun : Monthly
(Where grease nipple is provided).
Tie rod ball joints, Draglink ball joints, Idler arm ball
joints, front & Rear spring pins, Propeller shaft &
steering spindle
7 Check the performance of brakes by applying & Monthly
releasing, when engine is running. Get it adjusted
from Authorized Workshop if required.
8 Check oil level in power steering tank & top up if Monthly
necessary
9 Check headlamps, gauges & instruments for proper Daily
functioning. Get it rectified if necessary
10 Check exhaust system. Get it rectified, if necessary. Monthly
11 Check condition of wiper blades for crack damage, Daily
etc. replace if necessary.
12 Clean the vehicle from inside & outside Monthly
Note : Do not wash DICOR system components
with forced water
13 Check Air Filter service indicator. If RED BAND Daily
appears, clean the filter cartridge. Replace filter
element when service indicator shows red band
even after cleaning the filter element.
14 Wheel balancing Whenever tyre is
removed from wheel rim.
15 Wheel alignment (Steering geometry) must be done. Monthly 10000 km
on road
5,000 km
off road
16 Check water level in windscreen washer container Daily
& top up if necessary
17 Lubricate all grease nipples Monthly 10,000
18 Tighten all fasteners: front grill, & fuel lines, engine, Monthly 10,000radiator mtg., radiator hose, turbocharger mounting,inter cooler mounting fasteners turbocharger hoseconnections/its mountings & inter-cooler hoseconnection / its mountings prop. shaft centre bearing.bracket / mounting bolts, U-bolts & nuts of springs,joints of pitman arm, tie rods, steering gear box &its mtg. bracket, vacuum & hydraulic line connections,head lamp mtg., wheel mtg. nuts, drivers cab seatsmountings, axle shaft mtg., anti roll bar mtg.,vacuumbooster & tandem master cylinder mountings, rear anchor plate mtg., , fuel tank mtgs.
OPERATION FREQUENCY IN
DURATION
FREQUENCY IN
KMOPERATION FREQUENCY IN
DURATION
FREQUENCY IN
KM
100
LUBRICATION & MAINTENANCE SCHEDULE
Service Operations to be performed at Workshop
ENGINE
1 Change coolant in cooling system 2 years 40,000
2 Change engine oil & oil filter cartridge 6 months 10,000
3 Change water sedimenter 2 years 50,000
5 Drain water in sedimenter / Fuel filter 5000
Whenever umbrella shape lamp glows
6 Change fuel filter 1 Years 20000
7 Cooling and heater: check & rectify hoses for clog Monthly
and damage (radiator & condenser fins blocking due
to dirt / dust etc.)
8 Check alternator belt and A/C compressor belt adjust 6 Months 10,000
tension if required, change if damaged
9 Change / replace all drive belts 2 years 40,000
10 Replace air cleaner element
1 year for normal operation, 6 months for Dusty
roads10,000 for normal operation, 5000 for Dusty
roads
11 Check & adjust tappet clearance 1 year 10,000
12 Inspect vacuum hose connection and rectify if Monthly 5,000
necessary
13 Change / replace all vacuum hoses 2 years 40,000
14 Check Turbo charger hose & Rectify if necessary Monthly 5,000
15 Check & ensure normal working of engine using 5,000
diagnostic equipment ( Whenever check engine
lamp glows on OR at every vehicle servicing)
LOW PRESSURE FUEL SYSTEM
1 Check low pressure fuel lines for leakage & rectify 6 months 5,000
2 Clean strainer in fuel tank 1 Year 10,000
3 Remove drain plug fuel tank and drain off sediments 1 Year 40,000
BRAKES
1 Check level of brake fluid in containers, top up Daily
if necessary
2 Check service & parking brakes, adjust if necessary 3 Months 5,000
3 Check front brake & rear brake linings, Replace if 6 Months 15,000
necessary
4 Change brake fluid in the brake system and bleed 1 years 20,000
the system
5 Overhaul the vacuum booster assembly using 1 years 30,000
recommended repair kit and diaphragm.
6 Dismantle, clean, inspect and re-assemble tandam 1 years 30,000
master cylinder of brake system.
GEAR BOX
2 Check oil level in Gear Box. 3 Months 5,000
3 Change oil in the Gear Box. 1 year 15,000
4 Check and Clean breather on Gear box 1 year 15,000
TRANSFER CASE
1 Check oil level in transfer case, top up if necessary 3 Months 5,000
2 Change oil in transfer case (First 10,000 km) 1 year 45,000
4 Check & tighten if necessary, transfer case mounting 6 months 5,000
screw
OPERATION FREQUENCY IN
DURATION
FREQUENCY IN
KMOPERATION FREQUENCY IN
DURATION
FREQUENCY IN
KM
101
LUBRICATION & MAINTENANCE SCHEDULE
LIVE FRONT AND REAR AXLE
1 Check oil level in live front axle and live rear axle, 3 Months 5,000top up if necessary
2 Change oil in live Front axle & Rear axle (FIRST 10,000) 1 years 15,000
3 Change grease in front hubs & adjust bearing play 1 years 30,000Replace damaged / worn parts.
4 Clean breather on live front axle and rear axle. 6 months
POWER STEERING & SUSPENSION
1 Check and tighten if nessary. “U” joints on steering 6 monthsspindle. Steering gear box and mounting bracketbolts joints of pitman arm, drag link and tie rod.
2 Check & adjust steering wheel free play 6 months
3 Check oil level in P.S. tank & top up if neccessary. 3 months 5,000
4 Change oil in steering gear box. 2 years 30,000
5 Check belt tension & adjust if necessary 6 Months 10,000
6 Check condition of rubber bushes of a) Anti-roll bar 1 Year 30,000b) Upper wish bone c) Lower wish bone
7 Check tightening torque of suspension fasteners 5,000
ELECTRICALS
1 Check battery voltage, charge the battery externally Weeklyif necessory
2 Apply graphite grease on starter motor pinion bushing 6 months 15,000
3 Grease the wiper motor linkages 6 months 15,000
CAB
1 Apply grease on door latches, door lock striker, bonnet Monthlyopening lever, lock plate tail gate hinges & door lockinner ratchet
WHEELS & TYRES
1 Tyre rotation. 6 Monthly 5,000
AIR CONDITIONING SYSTEM (wherever fitted)
1 Check torque of bolts on brackets & AC compressor Monthly
2 Check compressor belt, adjust tension, Replace if Monthlynecessary.
3 Check bubbles in receiver drier for refrigerant level Monthly
4 Check for leak of gas / oil from pipes, joints, Monthlycompressor shaft seal & cylinder head
5 Clean condenser with high pressure water Monthly
6 Check fan speeds for proper air flow Monthly
7 Check system pressure with gauges. Recharge if Monthlynecessary
8 Clean evaporator from its face to remove dust, Monthlyforeign objects etc.
9 Replace AC compressor belt 2 Years 45,000
HEATING / DEMISTING SYSTEM
1 Check hose joints of heating system for leakage. MonthlyTighten if necessary
2 Check hoses of heating system for cracks. Replace Monthly if required
3 Check blower for proper functioning. Check fuse. MonthlyReplace if found blown.
RUBBER / NYLON HOSES & FLEXIBLE PIPES
1 Check hoses & pipes of air / fuel / coolant / brake / 1 yearclutch / air conditioning / wind screen washing system for joint tightness and damage. Replace, if necessary.
OPERATION FREQUENCY
IN DURATION
FREQUENCY
IN KMOPERATION FREQUENCY IN
IN DURATION
FREQUENCY
IN KM
Change oil in live Front axle & Rear axle (FIRST 10,000)
102
Record of services performed Chassis No................................
Recommended Odometer Repair Servicing Dealer's
Service Date reading Order Signature and
Km. No. Stamp
At Km.
PDI
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
Recommended Odometer Repair Servicing Dealer's
Service Date reading Order Signature and
Km. No. Stamp
45,000
50,000
55,000
60,000
65,000
70,000
75,000
80,000
85,000
90,000
103
Record of services performed Chassis No................................
Recommended Odometer Repair Servicing Dealer's
Service Date reading Order Signature and
Km. No. Stamp
95,000
1,00,000
1,05,000
1,10,000
1,15,000
1,20,000
1,25,000
1,30,000
1,35,000
1,40,000
Recommended Odometer Repair Servicing Dealer's
Service Date reading Order Signature and
Km. No. Stamp
1,45,000
1,50,000
1,55,000
1,60,000
1,65,000
1,70,000
1,75,000
1,80,000
1,85,000
1,90,000
104
Record of repairs carried out Chassis No................................
DateOdometer Repair
Particulars of Repair Servicing Dealer's Signature & Stampreading (km) Order No.
105
Record of repairs carried out Chassis No................................
DateOdometer Repair
Particulars of Repair Servicing Dealer's Signature & Stampreading (km) Order No.
106
AC Air conditioning
ACC Accessories
Amp Ampere
Br Branch
Brg Bearing
cc Cubic centimeter
Cm Centimeter
Dia Diagonal
EGR Exhaust Gas Recirculation
FAW Front Axle Weight
Fig Figure
FIP Fuel Injection Pump
gm Gram
GVW Cross Vehicle Weight
IGN Ignition
Kg Kilogram
km Kilometer
Km/h Kilometer per hour
LH Left Hand
Max Maximum
Min Minimum
mkg Meter per Kilogram
mm Milimeter
Mtg Mounting
No Number
PDI Pre-delivery Inspection
PSI Pounds per Square Inch
PUC Pollution Under Control
RAW Rear Axle Weight
RCSM Regional Customer Support
Manager
RH Right Hand
RM Regional Manager
RPM Revolution Per Minute
Sec Seconds
Sq. cm. Square Centimeter
TASC Tata Motors Authorised
Service Centre
TASP Tata Motors Authorised
Service Point
V Volts
W Watts
Wt Weight
ABBREVIATIONS
107
PDIFREE
LABOURL -
TATA SUMO 4X4 ARMOURED
At the time of delivery of vehicle please ensure that
Pre-delivery inspection has been carried out as per details
given in the SERVICE SCHEDULE.
Chassis No. ..................................
Engine No. ....................................
Gear Box No. ................................
WORK DONE TO MY SATISFACTION
Sig. of customer .......................................
Speedo Reading ....................................... Km. seal O.K. / Broken
R.O. No. ........................................................... Date .....................................
Dealer's / Authorised Service Centre's
Stamp & Signature ...................................................................................
108