Tata 613

Edition : XLI/NE/J-2007/001-500

TataLP / LPT 613 EURO-II

Operators Service Book

(The contents given in this book are not binding; are subject to change without

notice and are for illustration purposes only)

International Business (CVBU)Mumbai, INDIA

iii

Dear Customer,

We are pleased to hand over your Tata LP/LPT 613 EURO-II Vehicle,manufactured by Tata Motors where QUALITY is the watchword and majorattention is paid even to minor details at all stages of manufacture of yourvehicle.

PLEASE DO READ THIS BOOK. It helps you to know your vehicle better, to ensureyour vehicle is ready for operation at all times and to obtain better performanceat optimum operating costs.

All lubricating and maintenance tasks are to be carried out at the specifiedservice intervals.

Some of the items / accessories / features shown / given in this book may notbe fitted on your vehicle, but they are applicable for other versions of vehicles.

For any further assistance, please contact the nearest Tata Diesel Vehicle Dealeror Our Office at following address.

Tata Motors LimitedInternational Business CVBU (Customer Support)Shah House, Shivsagar estate,Worli, Mumbai - 400 018,India.Ph No. : (009122) 6757 7239 / 7200Fax No. : (009122) 6757 7275E - Mail : [email protected]

We wish you good luck and prosperity.

v1. General

1.1 About Tata LP/LPT 613 EURO-II ................................................ 3

1.2 Environment protection .......................................................... 5

1.3 Important tips for driver .......................................................... 7

1.4 Tips for maintenance .............................................................. 10

1.5 Body building ............................................................................. 11

1.6 Additional fitments .................................................................. 20

1.7 Additional provisions (electrical) ....................................... 30

2. Vehicle Handling

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

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

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

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

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

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

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

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

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

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

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

CONTENTS

vi

3. Driving

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

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

3.3 Stopping the engine ............................................................... 75

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

3.5 Fuel economy ............................................................................. 78

3.6 Do it yourself .............................................................................. 79

4. Maintenance procedure

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

vii

5. Technical information

5.1 Technical specifications ...................................................... 135

5.2 Aggregate filling capacities .............................................. 140

5.3 Lubrication points ................................................................. 141

5.4 Tightening torques ................................................................ 143

6. Fuel, lubricants and coolants

6.1 Fuel .............................................................................................. 149

6.2 Lubricants ................................................................................. 150

6.3 Coolant ...................................................................................... 152

7. Service recommendations

7.1 Special instructions .............................................................. 155

7.2 PDI ............................................................................................... 156

7.3 Service schedule .................................................................... 159

7.4 Record of services performed .......................................... 168

7.5 Record of repairs performed ............................................. 170

11. GENERAL

1.1 About Tata LP/LPT 613 EURO-II ..........................3

1.2 Environment protection ....................................5

1.3 Important tips for driver ....................................7

1.4 Tips for maintenance ....................................... 10

1.5 Body building ...................................................... 11

1.6 Additional fitments ........................................... 20

1.7 Additional provisions (electrical) ................ 30

3TATA LP/LPT 613 EURO-II fullforward control chassis in truck & busversions are available with followingoptions :

3.8 meter wheel base for truck& bus.

Tilt cabin chassis with / with outload body for trucks.

Cowl chassis with windshieldglass / cowl chassis with frontend structure only for bus.

LHD versions.

Engines conforming to Euro IInorms with matching powertrain.

Various colour combinations forcabin/ load body in truck version.

With / with out power take offand provision for power take offin truck.

Fuel tank capacity 120 litres.

Diagonal ply / radial ply tyres forboth truck & bus versions.

Optional fitments include

Engine cold start device

Cab heating

Driver seat belt warning device

Front fog lamps

Rear under run protectiondevice/ side under runprotection device for trucks.

These incorporate well provenfeatures of TATA vehicles to giveeconomic life cycle cost, high

reliability and ease ofmaintenance.

Short wheel base and narrow widthgives them high maneuverability,ideal for all applications.

TATA 697 TCIC direct injectionengines are fitted with dry typecylinder liners for long life and easyoverhaul.

Vehicles meeting Euro II norms arefitted with rotary type fuel injectionpump, turbocharger, air after cooler,high capacity dry type air filter, etc.

A radiator auxiliary tank is providedfor convenient coolant filling.

Good visibility, hydraulic powersteering, 5 speed synchromesh gearbox with remote shift arrangement,hydraulically actuated clutch, selfcancellation turn signals lever, tintedwind shield glass, etc. enhancedriving comfort.

S Cam full air brake system withair dryer, nylon brake pipes and loadconscious relief valve in rear brakecircuit makes driving more safe.Service brakes are supplemented byengine exhaust brake, coupled withservice brake operation. Thisenhances life of brake linings, brakedrums & tyres.

Provision for ABS brakes.

An exhaust brake isolator switchhas been provided on instrumentpanel. Exhaust brake can be madeinoperative whenever required bymeans of this switch.

1.1 About TATA LP/LPT 613 EURO-II General

4Steering is provided with steeringlock cum ignition switch as asafety and security of the vehicle.Engine is started and stopped bymeans of this switch. Battery cut offswitch in bus version providesadditional safety for electrical system.

Wide centre flap at front enableseasy access to points of dailymaintenance.

Tilt cabin with torsion bar assistanceon truck version enable effortlessoperation of cabin tilting / lowering.It also provides ample space to reachengine / power train for inspection /maintenance.

Exhaust system with bigger silencerconsiderably reduces noise level.Different versions of exhaust pipinglay out are available to meet countryspecific regulations.

Proper and timely maintenanceand servicing as recommended inthis book will ensure trouble-freeoperation over long life.

1.1 About TATA LP/LPT 613 General

5Environmental protection

TATA MOTORS is committed toproduce vehicles usingenvironmentally sustainabletechnologies. A number offeatures have been incorporated inTata vehicles which have beendesigned to ensure environmentalcompatibility throughout their lifecycle. We would like to inform youthat your vehicle meets appropriateenvironmental norms and this isbeing regularly validated at allstages of manufacturing .

As a user, you too can protectenvironment by operating yourvehicle in a proactive manner. A lotdepends on your driving style andthe way you maintain your vehicle.We are giving below a few tips foryour guidance.

Driving

Avoid frequent and violentacceleration.

Do not carry any unnecessaryweight as it overloads theengine.

Avoid using devices requiringhigh power consumption duringslow traffic conditions.

Monitor fuel consumptionregularly and if it shows a risingtrend, get it attended at Tataauthorised workshop.

Switch off engine during longstops at traffic jams or signals. Ifsituation demands that engine

1.2 Environmental protection General

be kept running, avoid frequentrevving up of engine. Also avoidfrequent stopping andrestarting, if uncalled for.

It is not necessary to rev up theengine before turning it off as itunnecessarily burns fuel.

Shift to higher gears as soon aspossible. Use each gear upto2/3rd of its maximum enginespeed. A chart indicating gearshifting speed is given in themanual.

Maintenance of the vehicle

Ensure that recommendedmaintenance is carried outregularly at Tata authorisedworkshops.

As soon as you see any leakagesof oil, fuel, air or coolant get itattended immediately.

Use only recommended gradesof lubricants and clean/uncontaminated fuels.

Get your vehicle checked foremission periodically by Tataauthorised workshop.

Ensure that fuel filter, air filter, oilfilter, breathers are periodicallychecked and if required, replacethe same by only genuine parts.

Do not pour used oils orcoolants into sewage drains,garden soil or open streams.Dispose used filters andbatteries in compliance withcurrent legislation.

6 Do not allow unauthorisedagencies to tamper enginesettings or to carrymodifications on the vehicle.

Never allow the vehicle to runout of fuel, which results inmisfiring of engine.

Parts like brake liners, clutchdisc may contain asbestos. Usevacuum cleaner for cleaningthese parts. Do not usecompressed air for cleaningthese parts which may spreaddust in atmosphere.

While carrying out servicing orrepairs pay keen attention tofollowing parts which can affectexhaust emissions.

1. Fuel injection pump, injectors/nozzles.

2. Air intake and Exhaust systemespecially for leakages.

3. Cylinder head for valve leakage.

4. All filters such as air, oil and fuelfilters.

5. Turbo charger (Euro II)

6. Air after cooler (Euro II)

1.2 Environmental protection General

This book contains furtherinformation on driving precautionsand maintenance care leading toenvironment protection. Pleasefamiliarise yourself with theseaspects before driving.

71.3 Important tips for driver General

1. Use only recommended oils andlubricants.

2. Always use recommendedantifreeze agents in coolingsystem to avoid deterioration ofengine components due tocorrosion. After filling coolant, fitauxiliary tank cap firmly, to keepcooling system pressurised.

3. Maintain correct tyre pressure toensure better tyre life.

4. Always fit genuine radiator capfor pressurised cooling system.

5. New tyres do not givemaximum grip straight away andshould therefore be run-in atmoderate speeds for first 100km. This will help to make tyreslast longer.

6. New brake linings must alwaysbe run-in, they do not haveoptimum friction propertiesduring first 200 kms.

7. Avoid mixing of different gradeof lubricants or clutch fluidsduring top up.

8. Run the engine in low idlingspeed for atleast three minutesafter starting and beforeshutting off. (Applicable forturbocharged engine)

9. Always start moving the vehiclein first gear.

10. Operate engine in correcttemperature range i.e. between60OC & 100OC.

11. Engine oil / coolant levels haveto be checked daily. Drain waterfrom fuel water separator daily.

12. In case of air lock in fuel system,bleeding should be done onhigh pressure side of fuel filters,drain manifold and highpressure lines. Ensure that liftpump operation is satisfactoryand proper fuel delivery takesplace while bleeding out air.

13. Avoid cranking of engine formore than 30 seconds. A gap of2 minutes should be leftbetween successive attempts.

14. Check battery every week andtop up electrolyte, if necessary.Keep battery terminals clean andcable joints tight. Apply vaseline/petroleum jelly on terminals.

15. Watch service indicator of drytype air filter (Euro II). Indicationof same is given on instrumentcluster. If it blinks continuouslythen clean the air filter housingand replace primary cartridge.

16. Observe correct polarity whileconnecting alternator terminalsand battery cables.

17. For operating vehicles inextremely cold climates andhigh altitudes contact Tataauthorised workshop to seekadvice.

18. Do not use kerosene as fuel. Itreduces engine and fuel pumplife.


19. Do not use clutch pedal as a footrest when driving. This will causepremature clutch lining wear.

20. Do not coast vehicle i.e. drivewith engine switched off. This isdangerous and affects life ofgear box.

21. Do not fit bigger size tyres. Donot over or under inflate tyres.This reduces tyre life.

22. Do not top up coolant in auxiliarytank by pouring cold coolant inhot engine. Cylinder head maycrack.

23. Do not overfill engine oil insump. This may cause enginesmoking and high engine oilconsumption.

24. Do not engage ignition key instarting position, after theengine has fired. Release itimmediately. If not, starterpinion and / or flywheel ringgear will be damaged.

25. Do not run alternator with outbattery or disconnect any lead ofalternator while engine isrunning.

26. Do not keep accelerator at fullthrottle during engine cranking.After starting, run engine at idlespeed till such time oil pressurebuilds up.

27. Do not clean exposed paintedsurface or windscreen withpetroleum products i.e. diesel,kerosine & petrol, etc.

28. When air / fuel / oil filtercartridges are replaced, destroyold cartridges to prevent theirreuse.

29. Ensure that air intake hoses arefree from punctures, cuts anddamages.

30. Always fasten seat belt whiledriving. Same is applicable forco-passenger, wherever seatbelt is provided.

31. Do not use mobile phone whiledriving.

32. Do not adjust seat belt whiledriving.

33. For first 2000 kms, restrict speedlimit to 60 kmph in top gearwith 1500 kg pay load.

34. Avoid panic braking.

35. Drive on lower gears on steepdown gradient, thus avoidingexcessive braking & brake overheating.

36. Primary lock lever on drive awaychassis is secured with bolt andnut as safety precaution.Replace this with a pad lock. Thiswill enable cab tilting only afterunlocking pad lock. Fitment ofpad lock will avoid unauthorisedtilting of cabin.

37. Ensure gear shifting lever in 2ndgear position before tilting/lowering cab.

38. Disconnect alternator terminalsbefore carrying out any weldingwork on chassis/body.

939. Engagement / disengagementof power take off (optionalfitment on trucks) needs to bedone only when gear lever is inneutral position & enginerunning at idling speed.

40. Engine exhaust brake isolatorswitch has to be kept ON always,unless & until exhaust brakeisolation is required.

41. Radial tyres are to be balancedwhenever they are removedfrom wheel rims. Balancingweights should not exceedmaximum permissible limits.


10

1.4 Tips for maintenance General

1. Use only recommended filtersfor air intake, engine oil and fuelsystem. Replace them atrecommended intervals.

2. Before building the body, studyrecommended body buildingpractices.

3. Disconnect alternator terminals,while carrying out electricalwelding.

4. Never use water alone in thecoolant system. Always usemixture of 50% clean water and50% antifreeze agent fortopping up and for change.Always carry a five litres can ofproperly mixed coolant fortopping up enroute, if necessary.

5. Get the cause of low engine oilpressure investigated at Tataauthorised workshop.

6. Any change in clutch pedal freeplay is to be immediatelyinvestigated.

7. Get your vehicle serviced at Tataauthorised workshop atrecommended intervals.

8. Use only recommended gradesof oils for all aggregates.

9. All services / repairs to be carriedout at Tata authorised workshopsonly.

10. Do not reinforce chassis frame,

springs or axles for carryinghigher payload. It will result inpremature failure of aggregatesand deprive you of warrantybenefits.

11. Dust accumulated in radiator finsshould be cleaned by blowingcompressed air at low pressurefrom inner side of radiator.Please do not clean withpressurized water jet as it willdeform radiator fins.

Helping you to obtain efficient trouble-free service from your

TATA DIESEL VEHICLE is our business.

11

1.5 Body building General

Body building guidelines

It is important to ensure that the bodyis fitted to chassis in such a way thatthe load imposed is transmittedcorrectly. At the same time the rigidlymounted body must flex with theframe. Care should be taken toensure that body and chassis arecompatible. An example of badselection would be the constructionin which a short body is made on along wheel base. In this case, itbecomes necessary to shortenchassis rear overhang toaccommodate body. As a resultcentre of gravity moves forward anda greater load than that desirable isimposed on front axle.

It is also essential that carefulconsideration be given to movementor modification of electrical wiring,electrical equipments, brakeconnections, brake piping, extensionof chassis rear over hang, relocationof chassis components to ensuregood performance in operation.

Post to waist rail joints

Gusset plates are welded toU-channel / Z-channel waist rail.

The welding of the gusset to thewaist rail should be intermittent.

Wheel arch dimensions

To accommodate wheels, side frameis formed to a suitable shape calledwheel arch.

To prevent tyre fouling with body onbad roads, recommended dimensionsof wheel arch should be maintained.

Position of roof luggage carrier(for LP model)

Roof luggage carrier should be placedto get the centre of gravity ahead ofrear axle centre line (min . 500 mm).Height of roof luggage carrier shouldbe minimum in order to reduce windresistance.

Outrigger for door post

When a door has to be located at aplace where cross bearers cannot bemounted due to positioning ofchassis aggregates at that location,outrigger assembly should be madefor door post.

12

Notes

1. Keep body weight minimumby selecting proper materialsand designs. This will save fueland increase tyre life.

2. Use curved window glass, avoidsharp corners and protrudingout destination boards toreduce wind resistance.

3. Select body dimensions,seating space and gangwaywidth to comply with currentgovernment regulations.

4. Ensure ease of removal andassembly of various aggregateslike gearbox, suspension,battery, spare wheel etc.Provide flaps/cut outs forservicing.

5. De-rust, phosphate and applyprimer to the body skeletonbefore fixing panels.

6. Use zinc plated hardware ofstandard quality for variousbody joints.

7. Protect instrument panel,steering wheel, drivers /co-driver s seats, clutch fluidcontainers, hoses etc. fromdamage while carrying outstructural work.

8. Do not drill or weld chassisframe or remove any rivet. Donot use chassis or leaf spring aselectrical earthing point duringwelding.

9. Do not clamp bus body crossbearers to chassis crossmembers.

10. No body mountings should foulwith any chassis aggregate orframe cross member.

11. Avoid practice of cuttingchassis cross member formounting of U bolts.

12. Do not extend chassis rearoverhang.

13. Avoid eccentric mounting ofcross bearers.

14. Do not use balata packing morethan 6 mm thick for crossbearer mounting. This willresult in premature perishingand damage to chassis longmember. In case thickerpacking is required, use steelplates to compensatealongwith 6 mm balata packing.

15. Avoid U bolts touching chassislong members. This should bedone by using aluminium alloypacking between U boltbottom radius and longmember bottom flange.

16. As far as possible, avoid postlocation over wheel arch.

17. No modification to front faceof cowl should be attemptedwhich would restrict air flow tothe radiator and air cleaner.Reducing the height/width ofcentre flap or closing louversprovided on cowl front faceare to be avoided.


13

18. No restriction should be placedbeneath the remote mountedair filter. Provide sufficientclearance for fitment andremoval of air cleaner.

19. Air intake hoses are not to bedisturbed during bodybuilding. However, if hoses areremoved for any reason, coverturbocharger / air after coolerand intake manifold openingswith suitable plastic caps toavoid dust foreign particlesentry, till such time hoses areconnected back. Clampsshould be properly tightenedduring this operation.

20. Do not reroute air intake,coolant and fuel lines.

21. Do not keep auxiliary tank capopen so as to avoidcontamination of coolant withdust and foreign material.

22. Disconnect battery andalternator connections beforestarting any electrical weldingon chassis/body.

23. Protect radiator / air aftercooler from weld spatters andexternal mechanical hitting,which might damage the coreof radiator / air after cooler.

24. Protect auxiliary tank fromweld spatters and mechanicaldamage. Use proper cover toprotect radiator and auxiliarytank during welding in theirvicinity.

25. Do not use suspension springpack for earthing or to checkcontinuity while carrying outarc welding. Welding spatterswill lead to breakage of springleaves.

26. Additional air connections foraccessories like air horn, etc. tobe taken only from port 24(auxiliary port) of systemprotection valve. Suchconnections should not betaken from either service brakecircuits or parking brake circuit.

27. Provide suitable hinged flapson the body skirt to facilitatedraining of air tanks and todrain water from fuel waterseparator.

28. Do not allow body builder todrill holes on chassis frame orextend rear overhang.

29. Do not flash alternator leads tocheck for current flow.

30. Do not mask head lamp lenswith black paint. If done, thiswill reduce head lamp lightintensity.


14

Body building

Load body should be mounted withthe help of U bolts and must not befixed on to the chassis with the helpof bolts and nuts by drilling holes inchassis frame. This weakens thechassis frame which is liable to crack.

Do not reinforce, weld or drill holesin the chassis frame. Use six U boltsto fasten the runners on either sideof chassis long member. Tighten Ubolts nuts (M 16 x 1.5, - 8.8 quality)to 22 mkg. torque.

1. Hex. nuts M 16 x 1.5, -8.8 quality2. Plate washer3. Wooden runner4. Steel runner5. U bolt 16 6. Chassis long member7. Aluminium alloy packing

U Boltfastening with

steel runner

Section - AA

U Boltfastening withwooden runner

Section - AA

CANVASPACKING

A typical method in which the bodyshould be mounted on chassis isshown in figure.


15

Polyamide (PA) nylon tubing forair brake

Your vehicle is fitted with latestgeneration polyamide (PA) nylontubing for air brake.

PA material is preferred for thisapplication for :

Excellent chemical resistance(against fuel, battery acid,hydraulic oils etc.)

Dimensional stability and impactresistance (against gravel throwfrom tyres).

Suitable working temperature is- 40C to 100C constantworking and upto 130 C peaks.

PA is 7 to 8 times lighter thanmetal.

Eliminates rusting problem, givesmuch lower leakage.

Rust particles are not generated(like in metal tubes) and thusprotects valves etc.

Preventive maintenance for PAnylon tubing

Check whether all clamps are inplace and suitably tightened.

Check whether spiral cover is inplace.

Check that all end fittings areproperly assembled.

Check that PA tubes followrouting as per original vehicle.

Check that PA tubes is notrubbing against any other objecton the vehicle such as frame,bracket or connectors.

In case of repair, use only plasticcoated clamps for clamping of PAtubes.

Ensure that PA tube is nottouching :

(a) Hot objects such as exhaustpipe

(b) Sharp objects such asbrackets or sheet metal parts.

(c) Moving objects such aspropeller shaft.


16

Guidelines and precautions fornylon (PA) tubing.

Welding and gas cutting

Cover PA tube with suitable objectsuch as metal sheet at the time ofwelding and gas cutting. This willavoid welding spatter and moltenmetal from falling on the PA tubesand creating a hole in the PA tube.


Cover PA tube before gas cutting

Unprotected areas while weldingmay damage PA tube

Cover PA tube before welding

Unprotected areas while gas cuttingmay damage PA tube

17


Clamp PA tubes properly to avoid coming in contact with hot objects

Sharp objects

Take care that PA tubes do not come in contact with sharp objects. This willavoid cutting of PA tubes.

PA tubes should not touch sharp objects Follow original routing of PA tubes

Hot objects

Take care that PA tubes do not touch hot objects such as exhaust pipe. This willavoid burning or melting of PA tube.

Avoid PA tube to touch exhaust pipe Do not light fire near PA tube

18

Loose fitments

Do not allow loose fitting of PA tube.


Ensure proper clamping of PA tubes

Misuse

Do not step or hang on connected PA tube. Doing so, will lead to damage ofPA tube at the clamps or near end fitting, resulting in leakage.

Do not step on or hang on to PA tube

Avoid loose fitting of PA tube

19


Tube Fitment

In case refitting of PA tube is required

z Follow original routing of PAtube.

z Take care that PA tubes are notforcibly bent or fitted.

z Use plastic coated clamps.

z Use both hands while fitting PAtube. This will avoid twisting andkinking of PA tube.

Kinked tube

Do not tighten nut without holding PAtube

Hold PA tube before tightening nut

Twisted tube

20

1.6 Additional fitments General

B) Side under run protection device (SUPD)

Note : While the SUPD is fitted as OE on vehicles with OE load body, customershave to ensure fitment of SUPD when they do body building. Please referfitment details of SUPD.

LOAD BODYBOTTOM

OF FLOOR

OVER ALL LENGTH

H

D

G

B

P2P1E J

A C

Fitment of SUPD on LPT version

A) Rear under run protection device (RUPD)

This device is factory fitted on truck version.

Rear under run protection device fitted on vehicle (LPT)

21

NOTE :

1. For all other technicalrequirements of sideprotection device ref.IS:14682:1999.

2. Pitch P1, P2, ..shouldnot be more than1650 mm.

3. Dimn H is as measured onthe load bodiesmanufactured by otherthan Tata Motors suppliedload body.

4. As per the regulations,following Dimensions needto be maintained withinthe specified values.

4.1 Dimension A shouldbe less than or equal to300 mm measuredfrom front tyre rearface (for LPT vehicles)or less than or equal to100 mm. measuredfrom rear wall of cab incase of SFC vehicles.

4.2 Dimension B shouldbe less than or equal to550 mm measuredfrom ground.

4.3 Dimension C shouldbe less than or equal to300 mm measuredfrom front face of reartyre.

4.4 Dimension G shouldbe greater than orequal to 100 mm.

4.5 Dimension D' shouldbe less than or equal to350 mm measuredfrom lower most faceof floor structure.

4.6 Dimension E and Jshould be less than orequal to 120 mm.

5. Painting or powder coatingto be done for rustprevention.

6. All the members as shownin drg. are with minimumcross sections and thicknessrequired.

7. Item no. 8 to be added atthe both ends to coveritem no. 7, to be welded toboth side guard panels.

8. # This dimensions (460 mmof item no. 1) to bechanged to meetregulations given in sl. no.4.2 (dimension `B') and 4.5(dimension `D').

9. Long side guards can beprovided with two pieceswith overlapping and withsuitable backing plate orlongitudinal gap ofmaximum 25 mm isallowed.


22


SUPD Proposal 1

Note : Please refer page numbers 23 to 24 for details of item no. 1 to itemno. 9 & for alternate proposals.

ASSY. SUPPORT SIDE GUARD

MA

X. W

IDTH

OF

LOA

D B

OD

Y

B

B

2 WELD NUTSM10

ITEM NO. 4

HEX. FLANGED SCREWM10x20-IS 17130-8.8

ITEM NO. 2 & 3

ITEM NO. 5

ITEM NO. 1

CE

D

THIS SURFACE SHOULD BEINSIDE THE MAX. WIDTH OFVEHICLE AND SHOULD NOT BEMORE THAN 120 mm INSIDE.

ITEM NO. 6HEX. FLANGED SCREWM10x20-IS 17130-8.8

10

20

2 0

20

STEEL CROSS RUNNER

ITEM NO. 8

C

MATERIAL - SHT. 4 THK.DD 1079 SS: 4013A

( ITEM NO. 2 AND 3 NOT SHOWN)

2020

20

VIEW FROM - D

VIEW FROM - E

SECTION - CC

ALTERNATE FORSECTION - BB

SECTION - BB

MATERIAL - SHT. 2.5 THK.DD 1079 SS: 4013A

9656

50

50

23


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

`X'

R3 (TYP)

11 D

IA (T

YP)

A A

15= =

1535 1

5

45

34.5 R4.5460

#

5 (T

YP)

5 (TYP)

MATERIAL - SHT 1.6 THK. D513 SS: 4010

DETAILS -`X'

SECTION - AA

2

R1.5

10

105

2

R3

50

35

15


ITEM NO. 4


R3

46

15

18

230

2 SLOTS 13 x 18

13153

3

125 65

==

ITEM NO. 5


150

5R3

5

10

41

R4.5

24

ITEM NO. 7


ITEM NO. 6

MATERIAL - SHT. 1 THK. D513 SS:4010

(OVERALL LENGTH -12)

105

20

20

35R5 R10

R10R5R5

3410PITCH

ITEM NO. 7

ITEMNO. 8

CEN

TRE

LIN

E O

F IT

EM N

O. 9

CEN

TRE

LIN

E O

F IT

EM N

O. 9

OVERALL LENGTH

6

ITEM NO. 8

12

R3(TYP)

105

126

105R15

R6

R6

R1033.5

R4

R6

MATERIAL - SHT. 1 THK. D513 SS:4010

ITEM NO. 9

30

WELD NUT M10-IS: 8856

50

65

115

2 HOLES 12.5 DIA-H11

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

25

Note : Refer page number 26 for section CC and section FF. Details of itemno. 1 to item no. 4 are given on page number 26 and 27.

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


A

B

B

C

C

WOODEN RUNNER

FRONT OF VEHICLE

340

ITEMNO .-1

ITEM NO .-2

ITEM NO .-4

ITEMNO .-3

100

540

980

BOTTOM OF SIDE WALL OF LOAD BODY

GROUND

SECTIONAL VIEW - BB

F

VIEW FROM -A

F

10

MA

X.

WID

THO

F LO

AD

BO

DY

AVERAGE HEIGHTMEASURED ONDIFFERENT LOADBODIES.

ITEM NO .-3

WOODEN RUNNER

26


SECTION - CCPROPOSAL - A

SECTION - FF

SECTION - CCPROPOSAL - B

HEX. BOLT M10x100BRT. WASHER 10.5SPRING WASHER B10HEX. NUT M10

WOODEN CROSSMEMBER

4x30x30

HEX. SCREW M8x20BRT. WASHER 8.4SPRING WASHER B8HEX. NUT M8

ITEM NO. 3a ITEM NO. 3b

Note - Refer item no. 3a, 3b, 4 and 5.

ITEM NO. 2

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

ITEM NO. 1

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

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

6 HOLES 11 DIA.

#72

40

#240

250

85 85 40

R5(TYP)

15x45045

230

D

DPLATE 3 THK.

3x30x30

E E

150

4 HOLES 12 DIA

20

478

SECTION - EESECTION - DD

27


ITEM NO. 3b - PROPOSAL - B

ITEM NO. - 4 ITEM NO. - 5

102

105

R5(TYP)

15

MATERIAL - SHEET 1 THK. D 513 SS : 4010

10 DIA

45

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

20

45

25

10 D

IA

150

4010

0

30

20

R2

35

R5(TYP)

20

MATERIAL - SHEET 1 THK. D 513 SS : 4010

ITEM NO. 3a - PROPOSAL - A

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

LENGTH OF SIDE PANEL

28

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


C) Rear view mirror - LP / LPT versions

BUS BODYTRUCK BODY

B

DETAILS OF ` A'

68

50

70

16.5

2 3

3 3

(X=

- 1

070)

C

C

D

D

DETAILS OF `B'

ASSY. REARVIEW MIRROR R.H.

100810

(Y=

0)

(cen

ter

line

of

veh

icle

)

BUS BODYTRUCK CAB

2 1 0

64

0

(Z=20)

`A'

(X=

- 1

070)

(X=

0)

29

Rear view mirror - LP / LPT versions


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

RUBBER PAD TOP

BRACKET TOP

SLEEVE FOR FRAME

SL. CSK SCREW M6x20 - 4.8WASHER C 6.4 SPR. st 130

SECTION - DD

SL. CSK SCREW M6x20 - 4.8WASHER C 6.4 SPR. st 130

SL. CSK SCREW M8x30 - 4.8SPR. WASHER B8DOME CAP NUT M8

RUBBER PAD BOTTOM

BRACKET BOTTOM

SECTION - CC

Mirror for custom built cab

30

D) WIPING SYSTEM

GUIDELINES FOR FITMENT OF WIPERSYSTEM BY BODY BUILDERS

1. Wiper system components(wiper motor, wheel box,wiper arm and blade, linkages)are supplied along with thedrive away chassis and theseare recommended for use onthe built up vehicle. However,the windscreen and themounting of the wheel boxesshould be appropriatelydecided to match wipersystem regulation as stipulatedin AISO 11-2001 for A, B, Cwiping zone arearequirements.

2. Wiper motor to be mountedpreferably near the centre ofthe panel below the windscreen with suitable mountingbracket.

4. Wheel boxes to be fitted withsuitable mountingarrangement on both sides, insuch a way that the wipingpattern obtained meets theregulatory requirements ofAISO11-2001.

5. The path of link rodmovement, during wipingsystem operation, should befree from any obstacles toensure free movement.

6. Wiper arm and bladeassembly should be properlytightened on the wheel boxto ensure proper pressing of

rubber edge of blade againstthe wind screen.

7. Wiper system should bebalanced and it is to beensured that there is nopossibility of entangling /locking of linkages or foulingof wiper blade with rubberbeading.

1.7 Additional provisions (electrical) General

31

LIGHTING AND SIGNALLING

Guidelines for fitment of endoutline marker lamp, side markerlamp, side retro-reflector, sideindicator, front fog lamps andrear fog lamp, head lamps, taillamp assembly and side retro-reflector during body building(refer figure)

For factory built load body all theabove fitments come as OE, exceptfog lamps.

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

1. End outline marker lamps: A, B,C, D, E and F in the sketch are typicalsix locations of End outline markerlamps. Normally four lamps are fitted,two for the front (white light) andtwo for the rear ( red light ). The rearlamps can be fitted at locationssuitably to be visible from the rearof the vehicle. Visibility for both frontand rear lamps is defined ashorizontal spread about the lamp axisof minimum +/- 80 deg and thevertical spread of minimum 5 degabove and minimum 21 deg belowthe axis of the lamp. They arenormally mounted near the top ofthe vehicle; the height should besuch that it is minimum 200 mmabove the parking lamp. From thesides of the vehicle, the lampsshould be fitted at a distance lessthan 400 mm. Refer figure. Thewattage of the lamps should be 5watts.

2. Side ( turn ) indicator lamps : Gand H are the typical locations ofside indicator (turn indicator) lamps.The height restrictions of the lampare given in the figure. The wattageof the lamp should be normally 10watts.

3. Side marker lamps & Sideretro-reflectors: I,J,K,L,M and N arethe typical locations of side marker

lamps and side retro reflectors. Theseare to be fitted on all vehicles ofoverall length more than 6 meters.The distance restrictions are given inthe figure. The side marker lampand side retro reflector may beseparately fitted or can both beincluded in a single package. Thewattage of side marker lamp shouldbe 5 watts. The distance restrictionsare given in the figure. Refer figurefor circuit diagram.

4. Front fog lamps: P and Q are thetypical locations of the front foglamps. The distance restriction fromthe sides of the vehicle and theheight are given in the figure forFront and Rear fog lamps. Thewattage of the lamps should be 55watts each. Refer figure for circuitdiagram.

5. Rear fog lamp: R is a typicallocation of the rear fog lamp. Thedistance restrictions from thelongitudinal centre line of thevehicle and from the side of thevehicle are given in the figure forFront and Rear fog lamps. The rearfog lamp is to be fitted on thedrivers side of the vehicle typicallyas shown in the figure. The wattageof the lamp should be 21 watts. Refercircuit schematic.

6. Head lamps: The head lamps aresupplied along with the vehiclesfrom the factory. The distancerestrictions for mounting of thelamps during body building are givenin the figure .

7. Tail lamps: The tail lampassemblies are fitted as part offactory supplies on our vehicles. Theassembly consists of rear positionlamp, stop lamp, rear retro-reflector,reversing lamp and turn indicator.The distance restrictions formounting the lamp assembly aregiven in the figure .


32


No

te :

If ve

hic

le s

truc

ture

dos

en

ot p

erm

it t

o m

ain

tain

dim

ensi

on m

arke

d w

ith

`

', it

may

be

incr

ease

d t

o re

spec

tive

dim

ensi

on m

arke

d w

ith

`H

'.

GU

IDE

LIN

ES T

O B

OD

Y B

UIL

DER

S FO

R F

ITM

ENT

OF

END

OU

TLIN

E M

AR

KER

LA

MP

S SI

DE

MA

RK

ERLA

MP

S / S

IDE

RET

RO

REF

LEC

TOR

S, S

IDE

IND

ICA

TOR

LA

MP

S, F

RO

NT

& R

EAR

FO

G L

AM

PS,

HEA

D L

AM

PS

& T

AIL

LA

MP

ASS

EMB

LIES

ON

MC

Vs/

HC

Vs/

LCV

sTY

PIC

AL

LOA

D B

OD

Y (

OF

DIF

FER

ENT

HEI

GH

TS)

B

AY

400

(MA

X)

2100 (MAX)

1500 (MAX)

VU

100 (MIN)

1500 (MAX)

2300 (MAX)

H

350 (MIN)

250 (MIN)

1000 (MAX)

UP

TO

1800

UP

TO

2500

3000

(MA

X)

500 (MIN)

4000

(MA

X)

4000

(MA

X)

1000

(MAX)

1500 (MAX)

2000 (MAX)

400

(MA

X)

VIE

W '

Y'

250 (MIN)

250 (MIN)

MAX. UPTO HEAD LAMP TOP SURFACE

UP TO 1200

C

A. B

. C. D

. E.

-En

d o

ut

line

mar

ker

lam

pG

. H.

-Si

de

ind

icat

or

lam

pI.

J. K

. L. M

. N.

-Si

de

mar

ker

lam

p /

-Si

de

retr

o r

efle

cto

rP.

O.

-Fr

on

t Fo

g l

amp

R.

-R

ear

Fog

lam

pS.

T.

-H

ead

lam

pU

. V.

-Ta

il la

mp

ass

emb

ly

1)Th

is is

a ty

pic

al tr

uck

with

load

bod

y. Th

e fit

men

t req

uire

men

t for

the

vario

us la

mp

sar

e ap

plic

able

for b

us b

ody

app

licat

ions

als

o.2)

Refe

r att

ache

d n

otes

.

P O

H

DAB E

LM

IJ

K

C FVRU

N

VIE

W '

X'

XA

D

ST

PQ

33

1.7 Additional provisions (electrical) GeneralC

ON

NEC

TIO

N S

CH

EMA

TIC

FO

R S

IDE

MA

RK

ER L

AM

PS

/ EN

D O

UT

LIN

E M

AR

KER

LA

MP

S - R

EAR

* EN

D O

UT

LIN

EM

AR

KER

LA

MP

RH

FR

ON

T

SID

E M

AR

KER

LA

MP

RH

FR

ON

TSI

DE

MA

RK

ER L

AM

PR

H M

IDD

LESI

DE

MA

RK

ER L

AM

PR

H R

EAR

END

OU

TLIN

E M

AR

KER

LAM

P R

H R

EAR

0.5

Sq. m

m B

RO

WN

0.75

Sq

. mm

WH

ITE

0.5

Sq. m

m W

HIT

E

0.5

Sq. m

m B

RO

WN

0.5

Sq. m

m B

RO

WN

5W5W

5W

0.5

Sq. m

m B

RO

WN

0.5

Sq. m

m B

RO

WN 5W

0.75

Sq

. mm

WH

ITE

0.75

Sq

. mm

WH

ITE

FUSE

10A

'PA

RK

ING

LA

MP

ON

'O

/P F

RO

CO

MB

I SW

ITC

H

FUSE

10A

CO

NN

ECTI

ON

S TO

BE

TAK

EN F

RO

M T

HIS

PO

INT

5W * E

ND

OU

T LI

NE

MA

RK

ER L

AM

P R

H F

RO

NT

0.75

Sq

. mm

GR

EY0.

75 S

q. m

m G

REY

0.5

Sq. m

m B

RO

WN

0.5

Sq. m

m B

RO

WN

5W5W

SID

E M

AR

KER

LA

MP

LH F

RO

NT

SID

E M

AR

KER

LA

MP

LH M

IDD

LE0.5

Sq

. mm

BR

OW

N

SID

E M

AR

KER

LA

MP

LH R

EAR

END

OU

TLIN

E M

AR

KER

LAM

P L

H R

EAR

0.5

Sq. m

m B

RO

WN

0.5

Sq. m

m B

RO

WN

0.75

Sq

. mm

GR

EY0.

5 Sq

. mm

GR

EY

NO

TES

:

1)Th

is is

a s

chem

atic

and

is to

be

used

as

gui

de

line

for c

onne

ctin

g s

ide

mar

ker l

amp

s / e

nd o

ut li

ne m

arke

r lam

ps-

rear

durin

g bo

dy b

uild

ing.

2)A

ll ea

rthi

ng c

onne

ctio

ns s

houl

d b

e on

fram

e or

bod

y at

sui

tab

le lo

catio

ns.

5W

5W5W

35

2. Know Your Vehicle

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

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

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

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

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

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

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

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

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

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

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

37

2.1 Vehicle identification Know Your Vehicle

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

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

38


FULL FORWARD CONTROL CHASSIS WITH 3800mm 381 325 LPT 613/38CAB AND WITHOUT LOAD BODY, TRUCKVERSION WITH 697TCIC BHARAT STAGE-IIENGINE, WITH FULL AIR SCAM BRAKEWITH HEATING AND DEMISTING,3800mm W.B.

FULL FORWARD CONTROL CHASSIS WITH 3800mm 381 327 LPT 613/38CAB AND WITHOUT LOAD BODY, TRUCKVERSION WITH 697TCIC EURO-II / BHARATSTAGE-II ENGINE, WITH FULL AIR SCAMBRAKE, 3800mm W.B.

LP VERSIONS

FULL FORWARD CONTROL CHASSIS 3800mm 381 224 LP 613/38WITHOUT FACE BUS VERSION WITH697TCIC EURO-II / BHARAT STAGE-IIENGINE WITH FULL AIR SCAMBRAKE 3800mm W.B.

FULL FORWARD CONTROL CHASSIS WITH 3800mm 381 225 LP 613/38COWL BUS VERSION WITH 697TCICEURO-II / BHARAT STAGE-II ENGINEWITH FULL AIR SCAM BRAKE WITHHEATING AND DEMISTING ,3800mm W.B.

CHASSIS TYPE DESIGNATION

Description Wheel Chassis Salesbase type designation

LPT VERSIONS

39


LP 6

13

CH

ASS

IS W

ITH

CO

WL

38

WB

EU

RO

- II (

LHD

)

40


LPT

61

3 C

HA

SSIS

WIT

H C

AB

AN

D L

OA

D B

OD

Y 3

8 W

B E

UR

O- I

I (LH

D)

41

2.2 Location of aggregate numbers Know Your Vehicle

Chassis number - LHD

1. Chassis number plate

2. Cab /Cowl number plate

2

1

Engine number plate location

Engine number plate

Cab / Cowl number plate

Chassis number plate

42

2.2 Location of aggregate numbers Know Your Vehicle

Gearbox number Rear axle number plate

Power steering gearbox number plate Front axle number plate

43

2.3 Instrument panel Know Your Vehicle

1. Low air pressure indicator

2. High beam indicator

3. Exhaust brake indicator

4. Parking brake indicator

5. Front fog lamp indicator

6. Fuel gauge

7. Speedometer with odometer

8. Coolant temperature gauge

9. Low oil pressure indicator

10. Battery charging indicator

11. Seat belt indicator

12. Hazard warning indicator

13. ABS indicator (If fitted)

14. Rear fog lamp indicator

15. Air filter service indicator

16. Glow plug indicator

17. Air pressure gauge (II)

18. Air pressure gauge (I)

19. Exhaust brake isolator switch

20. Front fog lamp switch

21. Blank

22. ABS switch (If fitted)

23. Head lamp leveling knob

24 . Blank

25. Rear fog lamp switch

26. Engine compartment lampswitch

Instrument panel

1

2

4

5

3

6 7 8

910 11

12 13

14 15

1617

1819 20 21 22 23 24 25 26

44

Air pressure gauges

Two air pressure gauges have beenprovided, one each for front and rearbrake circuits. Vehicle should not bedriven till a minimum air pressure of5.6 bar is reached in both air tanks.Regulated cut out air pressure is7.4 0.2 bar and cut in pressure is6.2 bar min.

2.4 Switches, gauges & indicators Know Your Vehicle

Fuel gauge

Fuel gauge indicates the level offuel in tank. It is electrically operated.Fuel level is indicated on gaugethrough a sensing unit mounted onfuel tank.

Speedometer

It indicates vehicle speed in kmphand also the distance covered byvehicle in km. This is driven by aflexible shaft connected to theoutput shaft of gear box. High beamindicator is also provided onspeedometer dial.

Coolant temperature gauge

Temperature gauge indicates coolanttemperature. It senses coolanttemperature through a transducermounted on upper cooling line.When gauge needle touches redband on dial it indicates engine overheating.

If overheating is observed & coolantlevel in auxiliary tank found to below, stop engine and allow it to cooldown. Top up coolant water mixturein 1:1 ratio through auxiliary tankfiller neck.

Cylinder head may crack, if coolantmixture is topped up when engineis hot.

Air pressure gauge

Speedometer

Fuel gauge

Coolant temperature gauge

45

SERV indicator

When it glows, it indicates that theAir cleaner filter is choked. Filterneeds to be cleaned/ replaced.When the ignition key is in ONposition, before starting the enginethis indicator should glow

GLOW indicator

This indicator is used to indicate thefunctioning of Flame start system.When the ignition key is in ONposition, before starting the engine,if the engine coolant temperature isless than 20OC, wait to crank till theindicator glow continuously andproceed to crank the engine oncethe indicator start blinking. If theengine coolant temperature is morethan 20OC, the indicator blinkscontinuously i.e. ready to start.

Front fog lamp indicatorThis indicator will glow only whenFront fog lamp is switched on.


Rear fog lamp indicator

This indicator will glow when rear foglamp is switched ON.

Low air pressure indicator (Red)

Two low pressure (LP) switches oneeach for front & rear brake circuits areconnected at dual brake valve. Whenpressure in any one or both thecircuits is less than specified value,these switches activate low airpressure indicator.

Low air pressure indicator

Rear fog lamp indicator

SERV indicator

GLOW indicator

Front fog lamp indicator

46

High beam indicator

When it glows, it indicates that thehead lights high beams are on. It isprovided in speedometer dial.

Parking brake indicator

This indicator comes ON whenparking brake is applied and goesOFF when it is released. It will alsoglow when air pressure in parkingbrake circuit is less than 4.6 bar.


Battery charging indicator

When it glows, it indicates thatbattery is not getting charged, i.e.during idling or when alternator isdefective with normal enginerunning. When ignition key is in ONposition, before starting the enginethis indicator should glow.

Low oil pressure indicator

This indicator glows when ignitionkey is in ON position before startingengine. It should go off after startingthe engine, when oil pressure builds up.

If indicator continues to glow evenafter the engine has started, stopthe engine, trace out the fault inlubrication system / electricalconnections and rectify.

Side indicators

Side indicator with arrow pointingtowards left will glow, when combilever is moved for LH indication.Similarly side indicator with arrowpointing towards right will glow, whencombi lever is moved for RH indication.

High beam indicator

Parking brake indicator

Low oil pressure indicator

Battery charging indicator

Side indicators

47


Exhaust brake indicator

This indicator comes ON whenexhaust brake is in operation

Hazard warning indicator

It comes 'ON' when hazard warninglights are switched 'ON' to warn theother road users about thehazardous condition of vehicle.

Glow plug indicator (Amber)

It glows when the ignition key isturned to position ON and after a fewseconds it goes OFF indicating thatengine can be started.

If glow plug indicator light does notgo off automatically, get it checked.

ABS Indicators (if fitted)

ABS indicator light on instrumentcluster illuminates approx. for 5 sec.when the ignition key is turned toON position. This is normal andindicates the system is performing aself check. If the light does notilluminate when ignition is ON orremains illuminated after initial selfcheck and while driving or flashes,fault may exist in the ABS system.

In this case also the normal brakingsystem is still effective and can ableto provide normal stopping ability.

In this condition it is recommendedto taking your vehicle to the nearestDealer / service outlet and get yourvehicle attended as soon as possibleif the warning light stays on.

Exhaust brake indicator

ABS indicator

Glow plug indicator

Hazard warning indicator

48

Exhaust brake isolator switch

Exhaust brake can be madeinoperative, by exhaust brakeisolator switch, whenever required.

Engine compartment switch

Provided to switch ON the bulblocated in engine compartment forinspection purpose.

Front fog lamp switch:

This switch is provided to switch onFront fog lamps. Front fog lamps areoperative only when the park lampsare switched ON.


Head lamp levelling switchA motorized head lamp levellingarrangement with the setting knob isprovided near the instrument panel.

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

Seat belt indicator

It comes ON when seat belt is notfasten or belt tongue is not locked into buckle.

Exhaust brake isolator switch

Engine compartment switch

Head lamp leveling knob

Seat belt indicator

Front fog lamp switch

49


Rear fog lamp switch:

This switch is provided to switch onRear fog lamps. Rear fog lamps areoperative only when the park lampsalong with Head lamps (Hi beam/Low beam) or Front fog lamps areswitched ON.

Mechanical stop light switch

A mechanical stop light switch ismounted above brake control lever.Whenever brake pedal is depressedfor applying brakes, stop light switchcomes into operation and lights atrear tail lamp glow. This also activatesengine exhaust brake solenoid valvefor exhaust brake application.

Electric service indicator switchThis switch is provided on air cleaner.Switch contact takes place onlywhen the filter get chocked.

Air dryer heaterThis heater is a part of air dryer assy.This heater is provided to heat themoisture if any in the air brake lines.This heater gets switched ON at 70 Cof air temperature and OFF at 290 Cautomatically.

Rear fog lamp switch

Mechanical stop light switch

Air dryer heater

Electric service indicator switch

50

STEERING LOCK CUM IGNITION SWITCH

Position of key Steering Electricals

Clockwise direction

LOCK without key Locked All OFF

LOCK with key Locked All OFF

ACC with key Unlocked ACC ON

ON with key Unlocked ACC + IG ON

START with key Unlocked IG + ST ON

Anti-clockwise direction

ON with key Unlocked ACC + IG ON

ACC with key Unlocked ACC ON

LOCK with key Unlocked All off

LOCK without key Locked All off

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


Battery cut off switch

Bus chassis is provided with batterycut off switch to isolate battery fromelectrical system when required.

Battery is connected to starter motorand other circuits through isolatorswitch. This is to be switched offwhile carrying out any electrical workon the vehicle and also when vehicleis parked for long duration.

Battery isolator switch

Steering lock cum ignition switch-key positions

51

Steering lock cum ignition switch

It is located on right hand side ofsteering column. It has followingpositions.

LOCK Position

Key can be inserted or removed inthis position only. Steering wheel getslocked, only when key is removed.

ACC Position

Steering gets unlocked in thisposition. Only accessories are ON.

ON Position

By turning the key to position ON, lowoil pressure lamp, battery chargingindicator lamp, parking brakeindicator lamp (if applied), fuel gaugeand temperature gauge are switchedon. Other electrical systems areready for operation. If none of theabove warning indicators /gauges areworking the chances are that thefuse for engine and gauges is blownoff in which case engine will notstart.

START Position

Turn the key further clockwise to startposition to operate starter motor. Thisis a spring return position.

As soon as the engine starts, releaseignition key so that the key can comeback to ON position and starter motordisengages.


Steering lock cum ignition switch withkey (LHD)

52

Combination switch

Combi switch is mounted onsteering column. It has 2 levers.

One lever is for operating turnsignals, head lamps, parking lampsand number plate lamps. This lever ismounted on RH side on RHD vehiclesand LH side on LHD vehicles.

Head lights

Position 1 - Low beam

Position 2 - High beam

Position 3 - High beam (flash)

Turn signals

Position 4 - Turn signal right

Position 5 - Turn signal left

Self cancellation turn signalarrangement is provided. When turnsignal option is used, this lever willreturn to neutral position on its ownwhen steering wheel is brought backto straight ahead position.


Combination switch

POSITION FOR WASH-ON

POSITION FOR FLASH

(HIGH BEAM)

N

POSITION FOR LOW

BEAM

POSITION FOR

HIGH BEAM

POSITION FOR LEFT

HAZARD WARNING SWITCH

POSITION FOR RIGHT

HI

LO

INT

OFF

Combination switch (LHD)

1

2 5

34

53


Lights

Lights are operated by turning theknob of this lever as indicated below

First notch (PL position)

Parking lights, instrument panellights, number plate lights, controlbacklights and top marker lights areswitched ON.

Second notch (HL position)

In addition to parking, instrumentpanel, control backlights, numberplate lights and top marker lights,headlights are also switched ON.

OFF-position

All lights are switched off in thisposition.

Note :

High beam flash (No. 3 position)

High beam will be ON as long aslever is held in position '3'irrespective of the knob position. Thisis spring loaded position and can beused in day time for giving signal toon coming traffic.

Hazard warning switch

Combi switch assembly also has aswitch for operating hazard warningdevice.

To switch ON hazard warning, pullthe knob located behind steeringwheel. All turn signals lights will flashsimultaneously to warn other roadusers about the hazardous conditionof vehicle.

Push back this knob to originalposition when hazard warningrequirement is over.

Light switch

OFF OFF POSITION

'PL' POSITION

'HL' POSITION

Hazard warning switch

ON

OFF

54


Windshield wiper and washer

The lever on other side is foroperating windshield wiper andwasher. This lever is located on LHside on RHD vehicle and RH side inLHD vehicle.

Position

OFF - Wiper motor

switched OFF

INT - Wiper sweeps

intermittently

LO - Low speed of

wiper motor

HI - High speed of

wiper motor

To operate windshield washer, lift thelever. Windshield washer will remainin operation as long as the lever isheld in this position.

When wind shield washer isactuated, wipers are also switchedon. Wind shield washer waterreservoir is accessible after openingcentre flap. Top up reservoir withclean water regularly. Do not usesoap solution. In cold climates, Usemethanol and water in the ratio50:50 to avoid water freezing. Pleaserefer chapter no. 6.3 for details ofrecommended antifrost and ratio forvarying ambient temperatures.

Do not operate windshield washermore than ten seconds at a time.

Wiper motor operating lever (LHD)

HI

POSITION FOR WASH-ON

LO

INT

OFF

Use methanol and water in the ratio50:50 to avoid water freezing.

Windshield washer water reservoir

55

2.5 Driving controls Know Your Vehicle

Hand brake (parking brake)

Hand brake is integral with springbrake actuator on rear axle. Springbrake chamber piston ram actsdirectly on push rod assembly ofbrake chamber.

A. Brake applied

B. Brake released

A to B Gradual application.

1. Accelerator pedal2. Brake pedal3. Clutch pedal4. Parking brake5. Gear shift lever

Hand brake valve

B

A

6. Steering wheel7. Combiswitch lever (Lights)8. Instrument panel9. Steering lock cum ignition switch10. Combiswitch lever ( Wiper/

washer)

Driving controls LHD

678

5

4

1

2

3

10

9

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2.5 Driving controls Know Your Vehicle

KSB unit (for Euro II vehicles)

KSB unit is a cold start throttleadvance mechanism. It is an integralpart of fuel injection pump.

KSB unit

- Provides necessary advance inlower throttle operation duringcold condition.

- Allows a normal dynamic timingduring regular operation.

- Reduces white smoke, misfiringin cold start and part throttleoperation.

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

Opening/closing of front centreflap

For opening centre flap, a lever asshown has been provided. For LHDvehicles it is located on LH sideabove clutch pedal. To open centreflap, pull this lever and lift centre flap.

A stay rod has been provided to keepcentre flap open position. To closecentre flap, remove stay rod. Slowlydrop centre flap and press it down tomake sure that it is locked.

KSB unit

Pull to open the bonnet - LHD

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2.6 Turbocharger Know Your Vehicle

Turbocharger (Euro II)

Lubrication of the turbocharger

Rotor assembly of turbocharger issupported by two floating leadbronze sleeve bearings in thebearing housing. These bearings arelubricated with finest filtered andcooled oil from lubrication system.There is a heat shield arrangementprovided between turbine housingand bearing housing to avoid heatingof the bearings.

Advantages of turbocharger

Turbocharged engine has followingadvantages over naturally aspiratedengine of same size and weight.

1. Increased power is obtained withthe same engine dimensionsthereby increasing the power toweight ratio. Thus, the engine islighter and payload value of thevehicle is improved.

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

3. Turbocharger reduces blacksmoke in the exhaust.

4. Loss of engine power at higheraltitudes is much less making itideal under all operatingconditions. Especially in hillyareas, payload capacity is furtherimproved by this aspect.

5. Turbocharger acts as an additionalsilencer on exhaust side, thusreducing engine noise.

Maintenance of turbocharger

No adjustments or repairs are to becarried out on the turbocharger. Incase of doubtful performance from

the engine because ofmalfunctioning of turbocharger, takeyour vehicle to Tata authorised workshop.

Following precautionary measuresshould be taken to obtain troublefree performance.

1. During regular engine inspection,look carefully for any oil leakageat the oil inlet banjo connectionon bearing housing. Do not runengine unless leakage at thispoint is rectified.

2. Do not stop the engine suddenlyas it may damage rotor bearings.Allow engine to idle for atleast3 minutes before switching it off.Similarly, do not increase enginespeed suddenly.

Run the engine at low idle speedfor atleast 3 minutes after startingto build up oil pressure beforeincreasing engine speed.

3. Since the speed of rotor assemblyis tremendously high, (nearly1,00,000 rpm) it requires finestfiltered oil. Therefore, ensurecleanliness of engine oil byadhering to regular schedules ofengine oil and oil filter cartridgechange intervals.

4. As the unfiltered dust particlesentering compressor housingmay prove dangerous, make surethat there is no leakage in airintake system and that air filterelements are in good conditionand sealings are perfect.

5. Insist on use of onlyrecommended grade of engineoil, genuine engine oil filter andair filter cartridges.

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2.7 Charge air cooler Know Your Vehicle

Charge air cooler (Euro II)

Advantages of charge air cooler

Hot air coming out of turbo chargerflows through charge air cooler andgets cooled before entering intakemanifold, thus increasing density ofintake air for better combustion.

Charge air cooler is mounted in frontof radiator.

Charge air cooler

-TURBOCHARGEREXHAUST INLET

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Clutch BoosterHydraulic clutch actuation systemwith pneumatically operated clutchbooster has been provided toreduce clutch pedal effort.In thissystem, clutch booster replaces thefunction of clutch slave cylinder.Compressed air connection tooperate clutch booster has beentapped from port No. 24 of systemprotection valve.Output rod of clutch booster isconnected to clutch release fork.When there is no force on clutchpedal, push rod (5), pistons (3 & 4)are in stand still position due to theforce exerted by return springs (6 &8).When pedal is pressed to disengageclutch, clutch fluid under pressureenters throught port no. 4 and actson piston (3). due to this piston (3)moves leftwards.At the same time fluid underpressure acts on controlling piston(2) due to which piston (2) movesleftwards to close air outlet and toopen air inlet (1) compressed air

Port 1. Inlet port (forcompressed air)Port 3. Vent (forcompressed air) Port 4.Control port (for clutchfluid)2. Piston3. Piston4. Piston5. Push rod6. Return spring7. Wind pipe8. Return springA.B. CavityC.D. Cavity

flows into air cylinder via wind pipe(7).Piston (4) moves leftwards andexert force on piston (3) which inturn pushes output rod to actuatepush rod (5). The force on piston (4& 3) is proportional to the pressureexerted by clutch fluid on piston (2).When pedal is released to engageclutch, clutch fluid pressure dropsto zero. By the action of returnspring (8) and air pressure at cavityB, piston (2) moves rightwards toclose air inlet and to open airoutlet. Compressed air in cavity Dis exhausted to atmosphere. Returnsprings (6 & 8) bring back pistons(2 & 4) to stand still position andhence push rod (5) retracts to itsoriginal position.Technical DataOperating pressure : Clutch fluid 4Mpa, compressed air 0.8 MpaMax. pressure : Clutch fluid 12 Mpa,compressed air 1 MpaOperating Temp. range -40OC to+80OC.

1A 8 B3

C 2 7

10

5 34

6 4

D

2.8 Clutch booster Know Your Vehicle

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1. Cam lever handle2. Cam lever3. Primary locking lever handle4. Primary locking lever5. Secondary locking lever6. Connecting link - LH7. Connecting link - RH

8. Cab mounting mechanism9. Mounting pin10. Mounting hook11. Rubber pad12. Torsion bar13. Cab stay14. Releasing lever

12

13

14

RELEASED AND TILTED POSITION

2.9 Cab tilting Know Your Vehicle

Cab tilting and locking lever arrangement

3 68 7 9

4

2

1

510 11

RELEASED POSITION BEFORE TILTING

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Cab Tilting

Truck version of 613 vehicle isprovided with tilt cab. For tilting thecab proceed as follows :

To raise the cab

1. Park vehicle on level ground instraight ahead condition andapply parking brake.

2(A) Put the gear shifting lever insecond gear. (sketch positionNo. (2))

Note : Remove or secure all looseitems in the vehicles. Close all thedoors.

2(B) Remove padlock or bolt and nutfrom primary locking lever.(sketch position No. (3))

3

2

Hand brake valve

B

A

1

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4

6

3. Hold primary locking lever ad pullcam lever handle to releaseprimary locking lever fromlocked condition. (sketch positionNo. (4))

4. Raise primary locking leverhandle to horizontal positions.Mounting pins of cab mountingmechanism get released frommounting hooks. (sketch positionNo. (5))

5. Pull secondary locking lever torelease it from locking conditionand hold. Slightly raise cab toclear secondary locking leverfrom its hook. (sketch positionNo. (6))

6. Raise cab to maximum position.At this position cab stay locksautomatically. Cab is retainedsafely in max. titled condition bythe stay. Torsion bar assists in easytilting of cab.

5

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To lower the cab

1. Holding cab, press cab stayreleasing lever and slightly lowercab. Linkage gets released fromstraight position. (sketch positionNo. (7))

2. Lower cab till cab gets seated onrubber pads. Secondary lockslever gets automatically locked inits hook. (sketch position No. (8))

3. Push down primary locking levertill it locks on the cam lever.(sketch position No. (9))

9

8

7

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104. After locking, make sure that the

cab is fully secured with themounting hooks. (sketch positionNo. (10))

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

12

11

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Slot - 'B' Air Distribution Control

Air directed towards chestand legs

Air directed towards legs,chest and windscreen

Air directed towards legs andwindscreen

2.10 Heating Know Your Vehicle

Demist : Switch-off heater. Direct airflow towards windscreen for arequired period.

Defrost : Switch-on heater. Direct airflow towards windscreen for arequired period.

Slot - 'C' - Closing and opening of legvent

- Leg vent closed

- Leg vent open

Heating control (Optional)

Heating system is provided forcomfortable driving. Heating systemcan be operated as per need.

The cab heat can be regulated bycontrolling air flow rate of theblower.

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

Slot - 'A' Blower Regulator

Blower off

Blower slow speed

Blower medium speed

Blower high speed

Note : Though slot B is shown for airat leg, slot C to decide leg will beopen or close.

Heating control

Slot C Slot C

Slot A Slot B

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2.11 Driver seat & seat belt Know Your Vehicle

** Precautions

Cab heating system - operates usingengine hot coolant. Hence, if enginecoolant temperature overshootsspecified limit, shut off the engineand rectify the fault.

** Do not leave the vehicle keepingheater and engine in runningmode as it may cause extensiveheating inside the cab. There isno thermostatic control in the cabheating system to shut-offengine, blower and heater.

Maintenance

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

2. Check hoses for cracks. Replace,if required. If there is a loss ofcoolant, replenish coolantmixture in auxiliary tank.

3. If blower is not working, checkfuse, if blown, replace.

Driver seat adjustment

Lever 1 : Lever for adjusting backrest.

Lever 2 : Lever for adjusting seatheight at rear.

Lever 3 : Lever for horizontalmovement of seat.

Lever 4 : Lever for adjusting seatheight at front.

Note : Please ensure that the seat islocked after making necessaryadjustments.

Driver seat adjustment

1

23

4

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2.11 Driver seat & seat belt Know Your Vehicle

Seat belt arrangement

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

Seat belt

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

On bus versions, three point belt fordriver seat is provided.

Fastening the belt

Insert belt tongue into buckle. Apositive locking click indicatescorrect assembly.

Releasing the belt

Press the release button. The tonguewill be ejected clear of the lockingmechanism within the buckle.

Belt adjustment

When the vehicle is at rest, adjustlength of the belt to suitconvenience and observe that thebelt is locked.

Lap belt (middle passenger)

Adjust length of belt in the tongueto suit convenience. Insert belttongue in buckle. A positive clickindicates correct assembly. To release,press the release button. The tonguewill be ejected from the buckle.

Precautions :

The belt is designed for use ofonly one person.

It is not intended for childrenbelow 10 years.

Avoid twisting the strap.

Webbing must not be allowed tochafe against sharp edges.

Do not make any alterations.

Belts that have been cut, frayed,damaged or have been stressedthrough impact, should bereplaced.

After vehicle collision if any, beltanchorage points should bechecked.

An occasional wipe with warmsoapy water will maintain thewebbing in a clean condition. Donot bleach or dye.

Periodic inspection of the seatbelts will ensure safe and reliableservice.

Before moving the vehicleensure that belt is properlylocked and beeper is off. (wherefitted).

3

5

4

1

2

3

4

LHD

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3. Driving

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

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

3.3 Stopping the engine ........................................................ 75

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

3.5 Fuel economy ..................................................................... 78

3.6 Do it yourself ....................................................................... 79

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1. Ensure that parking brake isapplied.

2. Move gear shift lever to neutralposition.

3. Insert ignition key in steeringlock cum ignition switch.Steering wheel will be in lockedcondition. Turn the key to ACCposition. Steering wheel getsunlocked, and accessories will beON.

4. Turn the key further to ONposition. Lamp of batterycharging indicator, low oilpressure will come on.

5. Do not press the acceleratorpedal. Turn the key furtherclockwise to START position(spring loaded) to operate startermotor. As soon as engine starts,release ignition key so that keycan come back to ON positionand starter motor disengages.

6. If engine misfires and stops, waitfor 2 minutes before operatingstarter motor once again. Thispractice should be strictlyadhered to, otherwise it willdamage starter motor.

7. Once engine starts, lamps ofbattery charging indicator andlow oil pressure should go off.

8. Allow engine to warm up - untilcooling system temperaturereaches at least 40o C.

9. Release parking brake.

10. Now the vehicle is ready tomove.

3.1 Starting the engine Driving

Steering lock cum ignition switch-keypositions

Steering lock cum ignition key

72

1st to 2nd 12 12

2nd to 3rd 23 23

3rd to 4th 37 40

4th to 5th 62 67

Gear

Speed in kmph

StandardGearbox

OptionalGearbox

Driving, Gear shifting, Breaking

DRIVE SAFELY AND JUDICIOUSLYRemember SAFETY FIRST.

Do not keep driving till you areovercome by fatigue. The reflexes ofa tired driver are not as they shouldbe.

1. Before you drive, ensure thatvehicle is in a road-worthycondition. Especially checksteering system, tyres, brakes,clutch etc.

2. Release parking brake.

3. Depress clutch pedal fullybefore shifting gears. Forsmooth starting of vehiclewithout jerks, synchroniserelease of clutch pedal withpressing of accelerator pedal.

4. Gear Shifting

Vehicle should be started infirst gear only.

Engaging position for variousgears are shown on gear knob.Change gears at appropriatespeed and do not lug theengine by too early high gearchanges at low speed.

Reverse gear should only beengaged when vehicle has beenbrought to a complete stop.

Approximate speeds for gearchange.

5. While driving, left foot must notrest on clutch pedal. This causesabnormal wear of clutch liningsdue to clutch slippage.

6. Slowing down the vehicleshould be achieved by changingdown to lower gears.

7. Maintain a steady speed, avoidquick acceleration and suddenbraking. High speed driving savesyou a little time but increasesfuel and oil consumption. It alsocauses faster tyre wear.

3.2 Driving Driving

Gear lever knob

42R

1 3 5

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3.2 Driving Driving

We, therefore, recommended todrive in fifth gear at a steady speedof about 70 kmph. Optimum fuelconsumption is achieved at thisspeed

CAUTION DURING RUNNING INPERIOD

During first 2,000 km. observefollowing speed and load limits.

Speed

Not more than 70 kmph in top gearand correspondingly lesser in lowergears.

Load

Gross vehicle weight should notexceed 2/3 of max. recommendedgross vehicle weight.

Brakes

Avoid panic braking during first500 kms. Drive in lower gears whennegotiating steep down gradient,thus avoiding excessive braking andbrake drum over heating.

8. Application of brakes

Brake application should begradual to avoid fast wear ofbrake linings, brake drums andtyres. Brake should not beapplied too violently on aslippery road, since the vehiclemay then start skidding.

When driving down a long steepgradient, reduce vehicle speedby shifting to lower gear.Engine will provide a braking

effect. Do not ride brakes. Thiswill lead to over heating of brakedrums and linings resulting inlow brake efficiency.

9. Parking the vehicle

Apply parking brake. Keepengine in low idling speed atleast for three minutes (Turbocharged engine). Switch offengine. Remove key fromsteering lock cum ignitionswitch. While parking on slopes,place wheel chokes to preventvehicle rolling. Engage forwardgear if it is likely to roll in thereverse direction or vice versa.

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Hand brake system

Hand brake is integral with springbrake actuator on rear axle. Springbrake chamber piston ram actsdirectly on push rod assembly ofbrake chamber.

Engine exhaust brake

Exhaust brake operation is coupledwith service brake. Whenever brakepedal is depressed for applyingbrakes, exhaust brake also getsapplied and indicator lamp (E) comesON instrument panel.

Stop light switch provides signals bothfor rear tail lamps as well as forexhaust brake solenoid valve.

Solenoid valve opens, allowingcompressed air to flow to exhaustbrake air cylinder, thus operatingexhaust brake butterfly valve.

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

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

Isolator switch (Exhaust brake)

In certain situations like starting ofvehicle on an upgradient,simultaneous acceleration and partialbraking of vehicle are required.Isolator switch can be used to cut offair supply to exhaust brake aircylinder, by putting it in off(disengaged) position. Isolator switchshould be put ON (engaged), as soonas isolation requirement is over.

3.2 Driving Driving

Hand brake valve

A. Brake released

B. Brake applied

A to B Gradual application

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3.3 Stopping the engine Driving

Operating instructions

1. Ensure air pressure in the systemis above 5 bar.

2. Change to lower gearappropriate to road conditions.Exhaust brake is very effectivebelow 40 kmph speed.

3. Do not depress clutch as thiswould render exhaust brakeineffective.

4. Press brake pedal fully whenvehicle is to be brought to astop.

Lubricating exhaust brakelinkages

1. Every 9,000 km. a few drops ofoil should be applied to ball pinsof outer linkages and frictionsurface.

2. Butterfly valve shaft, which ismade of heat resistant material,should not be lubricated,since the lube oil would causeseizing of the butterfly valve inits housing.

Stopping the engine

After parking the vehicle in safeplace.

1. Release accelerator pedal.

2. Move gear shift lever to neutralposition.

3. Apply parking brake.

4. Turn ignition key to ACCposition. A timer will switch onfuel stop solenoid for about 5seconds which operates fuel

shut off valve and fuel supply iscut off. Engine will stop. This shutoff timer is aborted in case youturn ignition key again to ONposition within 5 seconds.

5. Turn the key to lock position.

6. Take out key from steering lockcum ignition switch. Slightly turnsteering wheel clockwise or anticlockwise (max. 180o), till clicksound is heard, to make sure thatsteering wheel is locked.

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3.4 Special operating conditions Driving

Flame start system (BERU):

Flame start system is provided forconvenient starting at coldconditions by heating the intake airby means of burning the diesel in airintake manifold.

Pre-glow time of just 20~45seconds

Trouble-free starting even atlow temperatures

Post glow (after starting theengine) time of up to 3 minutes

The flame start control unit controlsthe supply of current to the indicatorlight, flame glow plugs and solenoidvalve. It evaluates the signals fromstarter motor in Ignition ON positionvia Temperature transducer (BERU)in alternator running condition.

The pre-glow phase commenceswhen the ignition is switched on attemperature below the system stoptemperature.

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

Once the pre glow time has passedthe indicator lights starts to flash. Thisindicates to the operator that theengine can be started. Powercontinues to be supplied to theflame glow plugs. If the engine is notstarted during this period, the flamestart control unit switches off theflame glow plugs and the indicatorlight.

Tata 613

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