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Owners Manual & Service Manual




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.

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. TATA MOTORS 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. iii

(The contents given in this book are subject to change without notice, not binding and are for illustration purpose only.)

Vehicle Identification .............. vi Vehicle details ............................ 1 Warranty ..................................... 2 Friendly notes Do's .............................................. 4 Donts ........................................... 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 iv 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

Changing engine oil and oil filter ............................. 49 Water Draining Procedure from 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 Maintenance schedule Lubrication points ..................... 96 Special instructions ................... 98 Lubrication & Maintenance schedule.................................................99 Vehicle record Service performed................... 102 Repairs carried out.................. 104 Abbreviations ......................... 106

Vehicle identification




Vehicle details

We WARRANT the TATA LBPV 4X4 vehicles and parts thereof manufactured by us to be free from defect in material and workmanship, subject to the following terms and conditions : 1. This warranty shall be for 24 months or 20,000 kms whichever expires first from the date of delivery of the vehicle. Our obligation under this warranty shall be limited to repairing or replacing, free of charge, such parts of the vehicle which, in our opinion, are defective, on the vehicle being brought to us or to our dealers within the warranty period. The parts so repaired or replaced shall also be warranted for quality and workmanship but such warranty shall be warranted for quality and workmanship but such warranty shall be co-terminus with this original warranty. 3. Any part which is found to be defective and is replaced by us under the warranty shall be our property.

Terms and condition

any way so as , in our judgement which shall be final and binding, to effect its reliability, nor shall it apply if, in our opinion which shall be final and binding the vehicle is subjected to misuse, negligence, improper or inadequate maintenance or accident or loading in excess of such carrying capacity as certified by us, or such services as prescribed in our Owners Manual and Service Book are not carried out by the buyer through our sales or service establishments, our authorised dealers or their sub-dealers or service centres. This warranty shall not cover normal wear and tear or any inherent normal deterioration of the vehicle or any of its parts arising from the actual use of the vehicle or any damage due to negligent or improper operation or storage of the vehicle. This warranty shall not


4. As for such parts as tyres, batteries, transfer case, rubber parts, electrical equipment, power steering equipment, A.C. equipment not manufactured by us but supplied by other parties, this warranty shall not apply, but buyers of the vehicle shall be entitled to, so far as permissible by law, all such rights as we may have against such parties under their warranties in respect of such parts. This warranty shall not apply if the vehicle or any part thereof is repaired or altered otherwise than in accordance with our standard repair procedure, or by any person other than our sales or service establishments, our authorised dealers, subdealers or service centres in 5. 6.

apply to normal maintenance services viz. oils & fluid changes, head lamps focussing, fastener retightening, wheel balancing, tyre rotation, adjustment of valve clearance, fuel timing, ignition timing and consumables like bulbs, fuel filters and oil filters etc. This warranty shall not apply to any damage or deterioration caused by environmental pollution or bird droppings. This warranty shall not apply to V-belts, hoses and gas leaks in case of air conditioned vehicle. Slight irregularities not recognised as affecting the function or quality of the vehicle or parts, such as slight noise or vibration, defects appearing only under particular or irregular operations are item considered characteristic of the vehicle. This warranty shall be null and void if the vehicle is subjected to abnormal use such as rallying, racing or participation in any other competitive sports. This warranty shall not apply to any repairs or replacements as a result of accident or collision. This warranty is expressly in lieu of all warranties, whether by law or otherwise, expressed or implied, and all other obligations or liabilities on our part and we neither assume nor authorise any person to assume on our behalf, any other liability arising from the sale of the vehicle or any agreement in relation thereto. The buyer shall have no other rights except those set out above and have, in particular, no right to repudiate the sale, or any agreement or to claim any reduction in the purchase price of the vehicle, or to demand any damages or compensation for losses, incidental or indirect, or inconvenience or consequential

Terms and condition

damages, loss of vehicle, or loss of time, or otherwise, incurred or accrued. 10. Any claim arising from this warranty shall be recognised only if it is notified in writing to us or to our concerned dealer without any delay soon after such defect as covered any ascertained under this warranty. 11. This warranty shall stand terminated if the vehicle is taransferred or otherwise alienated by the buyer without our prior written consent. 12. We reserve our rights to make any change or modification in the design of the vehicle or its parts or to introduce any improvement therein or to incorporate in the vehicle any additional part or accessory at any time without incurring any obligation to incorporate the same in the vehicles previously sold. 3


8. 9.

Friendly notes
1. Use recommended oils and lubricants 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 and fuel filter elements. Replace them at regular intervals as prescribed. 4. Clean air filter element regularly. 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 cobranded spare parts. 7. Ensure that caps of auxiliary tank and radiator are firmly fitted to keep the cooling system pressurised and to 4

maintain coolant level. Always use radiator cap only of 1.0 kg/cm2 (14 PSI), for replacement. 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 the tyres. In case of uneven tyre wear get the vehicle attended to by any of our authorised service set-ups. 9. Maintain pressure correct tyre


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
11. Observe correct polarity when connecting battery terminals. 12. Disconnect alternator/battery terminals, ECU connections while carrying out any welding on the vehicle. 13. Avoid panic braking. Use lower gears while descending gradients.

18. In case of emergency parking or breakdown on road, pull the hazard warning switch to flash all the blinker lights to warn other road users. 19. Release parking brake before driving off. 20. Release the ignition key as soon as engine starts. 21. Retighten wheel mounting nuts after 100 km of every wheel change. Tightening Torque : 12-15 mkg. 22. Use only recommended FUSES and always keep spare fuses in the box. 23. Inspect the engine belts replace, if found torn, cracked, worn or soaked in oil.


14. Start moving the vehicle always in the 1st gear to avoid premature clutch wear. 15. Keep both brake pedal and parking brake properly adjusted. 16. Before engaging reverse gear, ensure that the vehicle has come to a stop, declutch, wait for a few seconds and then shift into reverse gear. 17. When parking on slopes, use wheel chocks, apply parking brake and keep vehicle in low gear.

Friendly notes
24. Ensure doors are properly closed. 25. Insulation in the cab room should be kept-up in good condition. 27. Vehicle has a turbocharged engine, keep engine in idlling speed for atleast a minute after starting and also before stopping 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 blowoff for hot air before switching on A.C. Keep all gun port, ventilator, roof hatch closed, when AC system is working. 3.

During stop and go city driving use lower gears to obtain efficient cooling. 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. Before stopping the engine first switch-off AC and then the blower. During off-season operate the air conditioner a few times every month to lubricate components.






Friendly notes
1. Do not use Clutch Pedal as Foot Rest. This will reduce clutch life. Avoid clutch riding. Do not Coast vehicle in Neutral and engine switchedoff position. This is a safety hazard. Do not run engine without Radiator Cap. Use genuine Cap only, to keep system pressurised. Do not overtighten engine oil filter. Vehicle has a turbocharged engine, do not stop the engine at once, allow it to run at idling speed for atleast 1 minute. Also do not accelerate engine till the engine oil pressure has built up. Do not open HP system under any condition. It should be handled by trained professional only. (i.e. HP Pump, Rail, Injector, HP lines) 2. 7.

Do not clean Engine Compartment with high pressure water jet. It can cause Malfunctioning of electronic components. Cleaning can be done with high pressure air. Do not clean air filter cartidge with high pressure air. Do not cause heating of AC pipe (where fitted), while welding / brazing in its vicinity. Do not open any hose / pipe points of AC system, where fitted. 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. 7




Air conditioning system : 1.


4. 5.




Location of aggregate serial mumbers

Chassis number on frame

Engine Number

Gear box number ( G-76)


Transfer case number (4x4)

Rear axle number (Spicer)

Front live axle number (4x4)


Location of aggregate serial mumbers

Body shell number plate (under bonnet)



Key (Two Nos.) Two identical keys have been provided for operation of steering lock cum ignition switch, for locking and unlocking of drivers and co-drivers side door, glove box, fuel tank flap and rear door.

Locking and Unlocking of Doors From 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 with door open, it will get released automatically when door is closed.

The co-drivers 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.



Rear view mirrors, Sunvisors

Sun visors

Rear view mirror Rear view mirrors - outside Rear view mirrors Rear view mirrors are fitted on drivers side door and co-drivers 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. Rear view mirror in cabin Sunvisors Two adjustable sun visors are provided inside the cab to prevent sun glare.




1. Seat Reclining Adjustment Lever 2. Seat Adjustment (Forward/Backward) Lever

Seats for Rear Passengers

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. 12

Seats for rear passengers : Two seats are provided on both side for two persons to seat. Storage space is available below seat squabs.


Seat belts

1. Anchor Seat Belt :

2. Webbing

3. Tongue Releasing the belt

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.

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.

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.


To tighten (shorten) the belt Pull free end of webbing through adjuster until required adjustment is achieved. To loosen (lengthen) the belt Tilt the adjuster by means of the grip and slide it along the strap until suitably adjusted. Do not make any alterations or additions to the belt. If in doubt, consult the authorised dealer. Belt that have been cut, frayed, damaged or have been stressed through impact, should be replaced. 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. Periodic inspection of the installation will ensure safe and reliable service of the seat belt.

Seat belts, Tools

The belt is designed for use of only one person. 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 Avoid twisting the straps during use. Webbing must not be allowed to chafe against sharp edges on seat or bodywork.

Vehicle Jack & Tools Tool bag with tools, jack and handle are kept below the drivers seat.



Driving Controls

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Driving Control - TATA LIGHT BULLET PROOF VEHICLE 4x4

Steering Wheel Instrument Cluster Combi-switch Ignition cum steering lockswitch Bonnet opening lever Accelerator pedal Brake pedal Clutch pedal Parking Brake Jack Gear shifting lever 15


Gear Shifting Lever, Parking Brake & Spare wheel

2 1

Gear shift lever knob

1. Parking brake released 2. Parkeing brake applied

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 floor between RH door and drivers seat. To apply the parking brake, pull lever full up. To release it, pull the lever up slightly, press the release button and push the lever down. Ensure parking brake is released before 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.


5 6 7 8 10

Instrument cluster

11 4 3 2 12




Instrument cluster 17

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.
CHECK 2. CHECK ENGINE ENGINE Indicator This lamp indicates engine condition, when a malfunctioning occurs in engine OR EMS, this lamp 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.

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 the electrical system of your vehicle checked. 4. High beam indicator (Blue) 5. Battery charging indicator 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. Speedometer It 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 pressure indicator 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 engine when the oil pressure indicator light is on, may damage the engine.

3. Glow plug indicator light (Amber) In the ON position, the glow plug controller switches on the glow plugs and glow plug indicator comes ON. 18

11. Brake fluid level / parking brake indicator: (Red)

14. Four wheel drive high 4WDH indicator light (4x4) (Green) It comes on when ignition key is turned to positionON 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 low indicator light (4x4) (Green)

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 Fuel Sedimenter 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 ( 0 C) Red band of this gauge indicates engine overheating.

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.



Steering lock cum ignition switch

To switch on and off accessories only. The switch is located on the steering column support and has the following key 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.

Steering lock cum ignition Switch Steering lock ignition switch Steering is provided with steering lock cum ignition switch To lock steering while parking the vehicle as safety against theft. To start and stop the engine. To switch on and off the electrical system other than listed below. 20

Steering lock cum ignition switch key positions 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.

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

Combination switch
Position 3 Position 4 - Turn signal left - Turn signal right

2 3

The lever returns to neutral position automatically when the steering wheel is returned to straight ahead position. The combination switch lever can be operated up and down to select the headlight beam as follows : Position 1 Position 2 - High beam - High beam flash

Combination switch - Turn signals, High/Low beam and High 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.

or LOCK position engine can be stopped. Combination switch The combination switch is mounted on steering column. Its right side lever operates turn signals, Turn Signals Moving the combination switch lever in sideways direction operates the turn signals :



Windshield Wiper / Washer & Interior Lamp


Windshield wiper/washer operating lever 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 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.

Interior Lamp Location

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 Lamps & Front Tow Hook

Door Control Switch

Interior Lamp

Interior Lamp Door Control Switch- Tailgate

FrontTowing Hook Front Towing Hook : Front tow hook is below front bumper for vehicle towing. Towing Procedure :

Door Control Switch

Make sure that, the vehicle is in neutral condition and in 4X2 mode while towing. Maximum driving speed 40 kmph.

Interior Lamp Door Control Switch



Hazard warning switch,Tail Lamp & Registration Plate Lamp

Hazard warning switch 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 hazardous condition of the vehicle. Depress the knob again to switch OFF the hazard function. 24

Rear Tail Lamp Tail Lamp : The tail lamp assembly incorporates the following : 1. 2. 3. 4. Rear Stop Lamp Rear Direction Indicator Reverse Light Rear Parking Lamp

Registration Plate Lamp

Registration Plate Lamp : Two concealed lamp are provided for illumination of the rear registration plate.


Front & Rear Fog Lamps

Front Fog Lamp 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

Rear Fog Lamp

1. Switch for Rear Fog Lamp 2. Switch for Front 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.



Head Lamp Levelling Switch & High Mounted Stop Lamp

Switch Loading Condition Position 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

Headlamp Leveling Switch 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 leveling setting is done by rotating the knob to select one of the level marked in the switch depending upon the loading of vehicle.

High Mounted Stop Lamp High Mounted Stop Lamp: High mounted stop lamp is located on tail gate and it glows whenever service brake is applied in additional to two stop lamps.



ECU, Rear Towing Hook & Rear Foot Step

ECU 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

Rear Central Towing Hook Rear Central Towing Hook : Rear central towing hook with locking arrangement has been provided for towing the trailor.

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.



Roof Hatch, Oservation Window and Gun Port


Roof Hatch (Optional Fitment) Roof Hatch : The roof hatch is provided for observation and firing front & rear.

Roof Hatch Lock 1. Handles

Roof Hatch Lock: To open the roof hatch, first unlock the the latch knob by using key. Rotate the latch knob and push the hatch doors upwards. For closing the hatch doors, pull the handle swhich are provied on the doors from inside.

1. Obeservation Window 2. Gun port on rear door

Observation Window With Gun Ports: Observation window (1) with gun port (2) is provided on tail gate door.



Gun Port, Ventilator & Battery Isolator Switch

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.

Ventilator Ventilator : Ventilator is located on the roof above driver & co-driver. Ventilator is provided for fresh air intake, when HVAC is not working. 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 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. 29


Engine compartment light, Bonnet Opening / Closing

1. Engine compartment light 2. Engine compartment light switch 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. 30

Bonnet Opening lever 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 fully locked 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

Additional lock lever

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.

Pressure oil from engine

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 Geometry Turbocharger 1. Tighten the following fasteners at PDI and thereafter at specified intervals. Turbocharger mounting Intercooler mounting Turbocharger hose connections & its mountings Intercooler hose connections and its mountings 2. Check intercooler fins for any dust accumulations and clean by compressed air at at specified intervals. 3. Check end play of turbocharger shaft and radial clearance between turbine wheel and housing at specified intervals. 31

Fresh Air in

Exhaust gas out

Compressor Wheel

Oil drain to engine

Turbine Wheel Assembly

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


Pre-silencer & Power steering

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 assemblies.

Power steering - schematic circuit POWER STEERING Power steering is fitted for lighter steering effort and easy manoeuvrability. The system consists of steering gear box, hydraulic pump and hydraulic reservoir suitably mounted and connected by piping. Pump drive is through V belt from engine. Power assistance is available during normal functioning of the power steering system. In case of any failure in hydraulic system, the steering can be operated mechanically with increased steering effort for bringing the vehicle to a repair station.


Check and refill the reservoir. Repeat at least three times, each time checking and refilling the reservoir. 2. Check for any leakage in the system and if noticed take corrective action. Start the engine and steer the vehicle from full left to full right turn 3-4 times. Add fluid, if necessary to maintain the level up to the filter top. With the engine at steady speed, check for bubble / foaming in the fluid. If present it indicates that air is geting sucked into the system. Check the suction line / fittings and correct if necessary. Once the system is bled properly and free from foaming, there should not be appreciable change in fluid level in the reservoir, when the engine is started / stopped repeatedly. Top up or remove excess fluid so that the final level is at H mark on dipstick. 6.

Power steering
Now the system is ready for driving.


Power steering hydraulic reservoir Procedure for oil filling and bleeding the power steering system. (Ensure that the reservoir is totally cleaned before starting the work.) 1. Fill the reservoir nearly full. Crank the engine for 10 seconds without, if possible, allowing it to start. If the engine does start, shut off immediately.


CAUTION Do not allow the fluid level to drop significantly or run out of the reservoir during the above operation. This may induce air into the system. Do not start the engine without fluid in the power steering system. This will result in serious damage to the pump. NOTICE Always use recommended brand of fluid from closed container. Any dirty fluid poured in the system will result in damage to pump / gear.



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.

Power Steering Belt tension

Power steering pump belt tension Check : 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

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.



Heating,Ventilation & Air Conditioning

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'. 35

HEATING, VENTILATION & AIR CONDITIONING : (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.

E. Air Circulation Switch : 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'. 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 While driving in dusty condition To avoid traffic pollution To get quick cooling/heating as required. Whenever discomfort is felt switch air circulation mode to fresh. NOTICE

Heating,Ventilation & Air Conditioning

Normal Cooling : A.C. - ON

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 gets switched 'OFF' automatically when engine gets overheated. The A.C. is automatically switched 'ON' when the engine cools down.

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 come down sufficiently, close the windows and change air circulation suitably to fresh/ recirculation.



G Conscious pressure reducing valve for brakes

G Conscious pressure reducing 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.



Preparing the vehicle for the drive

Fuel tank fillerneck

Check the following regularly, particularly before starting on a long journey. 1. Fuel level in tank Top up if required with correct diesel fuel, secure cap and lock the flap.

1.Engine oil filler Cap

2. Engine oil level

2. Dip Stick

Coolant Tank
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.

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.


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.

Preparing the vehicle for the drive

Checking belts tension

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.

1. Brake fluid Container 2. Clutch fluid Container

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.



Preparing the vehicle for the drive

B A Gear box oil filler plug (G-76)

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. 40

Rear axle oil filler plug

14.Check condition of wiper blades, replace if rubber profile is damaged. 15.Check level of oil in steering gear box. 16.Check oil level in power steering hydraulic tank, where applicable. 17.Check and correct tyre inflation pressure (with cold tyres). 18.Level of transfer case oil (4x4) Periodically check oil level

Transfer case A. Drain plug

B. Oil level plug

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.

Before Driving Check Coolant level Engine oil level Tyre pressure Brake and clutch fluid level Doors are firmly closed Adjust Driver seat Rear view mirrors Ensure Gear shift lever is in neutral position. All switches and lamps are working. Brake fail indicator is 'OFF' Fuel level indicated in fuel gauge is above reserve mark. Gear lever knob (G-76 gear box)
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'

Driving & Gear Shifting

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 -


Driving Instructions
Avoid rapid acceleration and prolonged high speed runnings of the engine. Avoid sudden braking. Retighten wheel nuts to 12-15 mkg torque after first 100 km of running of a new vehicle and after every wheel change.

Driving , Gear Shifting, Braking

Recommended speeds for gear changes ( For 4x4 vehicles) Braking While braking on turns apply brakes gently. Before driving down a long steep gradient, reduce vehicle speed by changing to lower gear. Do not ride the brakes as they may overheat and their performance may be impaired. Do not use half engaged clutch to hold the vehicle on up gradient as this will result in premature clutch failure. After driving through pockets of water, apply the brake a few times at low speed to get rid of moisture inside the brake drums. When it begins to rain, reduce vehicle speed and avoid sudden braking.

Gear 1st 2nd 3rd 4th 5th

Driving instructions

Speed in km/hr. 4x2 4x4 (low) 22 10 40 15 60 70 85 -

Engage reverse gear, only when vehicle is stationary. To engage reverse gear, move ear shift lever to extreme left and push it forward. Depress clutch pedal fully before engaging the reverse gear. Wait for a few seconds then engage the gear. If the gear shifting does not occur, then release the clutch pedal, once again press the clutch pedal and engage the reverse gear.

Depress clutch pedal fully before shifting gears. This will ensure longer synchro cone life. For smooth starting of vehicle without jerks, synchronise release of clutch pedal with pressing of accelerator pedal. Start the vehicle in first gear only. Change gears at appropriate speeds and do not lug the engine by too early shifting to higher gear at low speeds.


Driving Instructions
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-

Engine Starting & Stopping and Fuel Economy

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. 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 be maintained The vehicle uses more fuel, every time you speed up or slow down. I. Avoid hard braking, abrupt cornering and rapid acceleration.


Driving Instructions

4x4 Operations
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.

Location of 4x4 Selector switch Transfer Case and Transfer Case nselector 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 are provided on selector switch : 2H Only rear wheels are driven and transfer case operates at 1:1 ratio. 44

Automatic Hub Lock 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. Automatic hub locks (4x4) While driving in 2H mode this mechanism on the front axle hub allows the hub to free wheel. This

Driving Instructions
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.

4x4 Operations
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. 45

Vehicle Maintenance ENGINE COMPARTMENT

Engine Compartment

1. 2. 3. 4. 5. 6. 46

Fuse Box Power Steering Fluid Container Brake Fluid Container Clutch Fluid Container Engine Oil Filler Cap Dip Stick

7. 8. 9. 10. 11.

Air Filter Air Pre-cleaner Radiator Cap Engine Coolant Tank Windshield Washer Fluid Container

Vehicle Maintenance
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. Air Filter 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. 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.

Air Filter
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.


Vehicle maintenance

Engine Cooling System

This is sufficient to operate the vehicle upto - 400C. Replacing Engine Coolant : The cooling system should be completely drained and refilled with new coolant at specified intervals. 1. Ensure engine and radiator are cool enough to touch. 2. Remove the radiator cap. 3. Loosen drain plug on the bottom of radiator. Remove cylinder block drain plug from engine block. 4. Remove the auxiliary tank from its holder and drain the coolant. 5. Flush radiator and block with clean water and close the drain plugs. 6. Pour the premixed coolant into radiator until it is full. 7. Fill the auxiliary tank upto high mark. 8. Ensure no leakage in the system.

Engine Coolant Tank

Engine Cooling System : If engine overheating occurs, there could be a fault in the cooling system which may be on account of : 1. Less coolant in the cooling system or dirt / scale having accumulated inside cooling water passages especially in the radiator core. 2. Choking of radiator passages due to foreign material or damages. 3. Defective thermostat.

Radiator Cap
4. 5. 6. 7. 8. Defective coolant temp. sensor. Coolant leakage. Radiator cap not sealing properly. A.C. condenser fan not working Excessive refrigerant charging in the A.C. system.

Prevention of Rust Formation : To prevent rust formation in the radiator use premixed recommended anti-freeze coolant.


Vehicle maintenance

Changing Engine Oil & Oil Filter

Oil Sump drain plug

Engine oil filler

1.Engine oil filler Cap 2. Dip Stick

Changing of Engine Oil and Oil Filter : Change the oil and oil filter at specified 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 hydraulic lift of a service station or should be on a service pit.

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 & oil may leak out. 49

Vehicle maintenance
5. Before filling in fresh oil in the engine, clean the drain plug and apply sealant on threads. 6. Refit the drain plug using a new sealing washer. Tighten drain plug to 5 mkg. torque. 7. Fill, recommended quantity of fresh engine oil in the crank case and secure the oil filler cap in its place. 8. Start the engine and run for a few minutes. The engine oil pressure indicator lamp should go off after starting the engine. 9. Check for engine oil leakages. 10.Stop the engine and recheck engine oil level after a few minutes. If necessary add oil to bring the level to the upper mark on the dipstick. NOTICE Use of reclaimed oil is not recommended.

Water Draining Procedure from 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 :
Water Sedimenter

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 from Sedimenter : 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
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.

Fuel & Filter Draining & Priming / Pear Pump

CAUTION Do not loosen the HP lines of DICOR system for bleeding the air from fuel system.

Priming / Pear Pump

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. 51

Vehicle maintenance

Checking & Changing oil in Gear Box

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.

1. Gear Box Oil Level / Filler Plug 2. Gear Box Oil Drain Plug

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. 52

Vehicle maintenance

Checking & Changing oil in Transfer Case

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 3 mkg. 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.

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.


Vehicle maintenance

Checking & Changing oil in Front / Rear Axle

3. Tighten oil level plug to 2 to 3 mkg. torque. 1 Changing Oil in Front Axle/Rear Axle 1. Clean the oil level plug, drain plug and surrounding area. 2. Place a container under Front/ Rear axle to collect the oil.

1. Differential Oil Level / Filler Plug 2. Differential Oil Drain Plug

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.

Checking Oil Level in Front / Rear Axle : 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. 54

Vehicle maintenance

Bleeding clutch system

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. 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.


1. Brake Fluid Container 2. Clutch fluid Container 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.

Bleeding clutch slave cylinder

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. Pump clutch pedal twice or thrice slowly throughout its stroke and



Vehicle maintenance

Brakes, Bleeding the brake system

Bleeding front calliper Bleeding the brake system 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. 56 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. If the brake pedal becomes spongy, this may be due to air in the hydraulic brake system. Whenever any repair/overhaul or disconnecting of any brake pipe is done, or level of brake fluid has fallen so low that air has been drawn into master cylinder, it is necessary to bleed the system to remove the trapped air.

Vehicle maintenance

Bleeding the brake system

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 keep the 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, 57

Bleeding rear wheel cylinder Proceed as follows for bleeding the brake system : a. Clean all dirt from around the fluid container. Remove cap and topup fluid upto the maximum level. Remove dust cap at each bleed screw and clean the area around it. Attach the bleed tube to the front left calliper bleed screw and



1. Brake Fluid Container 2. Clutch fluid Container 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

Vehicle maintenance
causing dangerous deterioration of the rubber seals. Never, under any circumstances, use the fluid which has been bled out from the system to topup the container. It may be aerated, have too much moisture content and /or is contaminated. Always use recommended brand of brake fluid. As brake fluid absorbs moisture from the atmosphere, we recommend changing of brake fluid in the system annually. Take care to see that the brake fluid is not spilled on the paint work. 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 rear brake shoes or linings, check and adjust brakes after 500 km run. For adjusting rear wheel brake shoes proceed as follows : 1. 2. Put chocks on front wheels. Jack up rear axle. Release parking brake. Ensure that parking brake cable is slack. Place the gear shift lever in neutral position. Loosen the adjusting screws of both brake shoes so that the wheel is absoultely free to rotate. 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.

Brake adjustment


4. 5.


Adjusting the rear brakes 1. Adjusting screw 2 & 3 To increase or reduce the clearance between brake shoe and drum 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.


Brake adjustment : The front wheels are fitted with disc brakes. These are self adjusting, therefore need no adjustment. The rear wheel brakes can, however 58 4.

Vehicle maintenance
5. 6. Adjust both brake shoes of the other wheel as described above. Operate brake pedal twice/ thrice, simultaneously rotating both rear wheels, for checking proper application and release of brakes. Re-adjust, if necessary. Remove front wheel chocks. Test drive vehicle for checking proper brake function. Parking brake handle (Floor mounted) 1. Parking brake released 2. Parking brake applied 4. Tighten the adjusting screw till rear wheels start jamming and cannot be rotated. Release the parking brake and ensure that wheels are rotating freely. Hold the adjusting screw 1

Adjustment of parking brake

1 2 2

7. 8. 9.

Parking Brake Brake adjustment (Floor mounted) : Adjust that all four rear brake shoes have been properly adjusted. 1. 2. 3. Put chocks on front wheels. Jack up the rear axle. Loosen the lock nut. Pull the parking brake lever up to 5th notch.

Parking brake linkage adjustment 1.Check nut 2. Parking brake nut


in this position and tighten the lock nut. Operate parking brake few times to ensure proper operation.


Vehicle maintenance

Wheels and tyres

Jack location at front 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. 60

Jack location at rear 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.

Tightening wheel nuts 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 LADEN 31 36 41 58

Check and maintain the above recommended tyre pressure in all terrain & environment conditions.

Vehicle maintenance
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. 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. 2. 3. 4. Permissible imbalance for tyre with rim=250 gm-cm max. Permissible balance weight for tyre with rim=140 gm max. Relocate the tyre if the weight required to balance is more than 140 gm. 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. Do not use more than one balance weight on one side.

Wheels and tyres

Run-flat : Run-flat is fitted on the rims inside tyres to drive the vehicle when tyres deflated due to bullet firing.



Vehicle maintenance

Wheels and tyres

External Repair kit (Optional): This repair system enables quick roadside 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 outside. It automatically seals the puncture 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. 62

Repair kit consists of 1. 2. 3. 4. 5. 6. Anchor seal plug. Marking chalk Rotary cutter 6mm Dia. Hand Ratchet (Right/ left) Insert tool. Special cement

2. Carry out the anchor seal following 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.

Repair procedure (Refer manufactures instruction) 1. Remove the penetrating object from the tyre.

Vehicle maintenance
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 maintained before fitment of nonskid chains on tyres 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 (longitudinally) on level floor 2) Drive the vehicle on laid chains 3) Wrap the chains on tyre. 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.

Wheels and tyres

Schematic diagram - Tyre rotation 63

Vehicle maintenance

Battery & Battery Isolator Switch

. 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 and remove 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 vehicles 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.

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. 64

Vehicle maintenance

Battery Isolator Switch & Head Lamps

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 inadvertant short circuits during repairs. 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

Head lamp adjustment

No light should fall above these lines i.e. in 'Dark zone' Thereafter lateral adjustment is done by adjusting the knob at bottom of headlamp so that contour of low beam coincides with contour formed by horizontal and inclined line below Dark zone When properly adjusted, most brightly illuminated area will be just below the intersection point 'A' of these two lines. The Second headlamp is adjusted in a similar manner without disturbing the position of the vehicle and the screen. Now switch 'ON' high beam. They will be symmetrical above point. 'A' and 'B' of intersection of vertical lines and horizontal lines. It is possible that high beams may not be exactly symmetrical but for this reason headlamps should not be realigned. Perferably, the alignment should be done in the dark. No masking of headlamps with black paint is required. If done, this will reduce the intensity of lights.

Adjusting head lamps focus with the help of screen The vehicle should be parked 10 meters away from screen with its centre in line with central vertical line on screen, and screen at right angle to longitudinal axis of the vehicle. The vehicle should be in unloaded condition with no sag in suspension springs and all tyres equally inflated.Head lamp leveling switch should be kept on O position. 66

On the marked up screen as shown in figure, area above horizontal and inclined lines (shaded) is called 'Dark zone' and the area below it is called 'The illuminated zone'. Each headlamp is aligned individually by masking the other headlamp. Headlamp is first adjusted for proper height of low beam by adjusting head lamp leveling motor shaft if required. Light from low beam should fall below horizontal and inclined lines.

Vehicle maintenance

Head lamp bulb replacement

Removal of cable socket 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 locking ring Realign headlamp beam after replacing bulb Do not clean the reflector as it will cause damage to mirror-finished surface. Do not replace bulb with dirty or oily hands, since oil will evaporate due to bulb heat and stain the reflector.

Removal headlamp bulb


Vehicle maintenance BULB SPECIFICATION


Bulb specifications


Head Lamp Bulb Parking Lamp Bulb Direction Indicator Lamp Bulb Side Repeater Bulb Tail Lamp Bulb High mounted stop lamp Reversing Lamp Bulb Number Plate Lamp Bulb 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/ Parking Light Indicator Bulb,4WDL & 4WDHIndicator Bulb, Check Engine Indicator Bulb, Water in fuel indicator Bulb Gauge Illumination Lamp Interior Lights Engine Compartment Lamp Front Fog Lamps Rear Fog Lamps

Head Lamp Head Lamp/Tail Lamp Head lamp/Tail lamp Side Indicators Tail Lamp Tail Lamp Tail Lamp Number Plate

12 V 12 V 12 V 12 V 12 V 12 V 12 V 12 V

60/55 W 4/5 W 21 W 5W 10 W 21 W 21 W 10/5 W

Instrument Cluster

12 V


Instrument Cluster Roof Engine Compartment Front Bumper Tail Lamp

12 V 12 V 12 V 12 V 12 V

3.4 W 10 W 21 W 55 W 21 W


Vehicle maintenance
In case of a fault in the electrical system check the respective fuse. The particulars of the consumers served by each fuse and amperage are printed on the fuse box cover. The fuse link can be identified for amperage by colour codes : 1. Fuse link - Red - 10 Amps 2. Fuse link - Blue - 15 Amps 3. Fuse link - Light brown - 5 Amps 4. Fuse link - Yellow - 20 Amps Fuse /relay box in engine compartment (If fitted) 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. 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 protection short circuit

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.

If flasher circuit is short circuited or overloaded (more than 110 W) flasher will shut off. It can be reset by 69

Vehicle maintenance
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 : 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. 70 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. Seat belt Clean 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. 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.

Care and cleaning of vehicle

Cleaning exterior of the vehicle Dirt or any other foreign material on the painted surface may result in : Faded paint. Rust on body due to deteriorated paint film. Rust due to scratches 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 : Flush underside of body and wheel housing with pressurised water to remove mud and debris. Use plenty of water to loosen and remove dirt. Remove dirt and mud from

Vehicle maintenance
bodyexterior with running water. Use a soft sponge, brush with water. Do not use hard material
which can scratch the paint. 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. Once dirt has been completely removed, wash off with running hose water. 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. Waxing the vehicle exterior After washing the vehicle, waxing and polishing are recommended to protect and beautify the paint. Use only good quality waxes and polishes. When using waxes and polishes, the precautions specified by the manufacturers should be observed. Chrome-plated parts should also be waxed. Protection against corrosion The following cause corrosion : Moisture trapped in body cavities. Dirt and salts collected in hollows on the underside of the vehicle. Removal of paint and protective coatings from the exterior and underside of the vehicle. Corrosion preventive measures have been incorporated in your vehicle. You can avoid corrosion of your vehicle by performing some simple periodic maintenance :

Care and cleaning of vehicle

Repair chips and scratches in the paint as soon as you discover them. Inspect and clean the drain holes in the bottom of the doors and body. 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. Use a high-pressure spray to clean the underside of your vehicle. This is especially important in areas near chemical and other industries. Have corrosion preventive coatings done on the underside of your vehicle. Preventive coatings such as the Dinitrol-3850 are available in the market.


Vehicle Maintenance
Cleaning of Glasses : For the internal face of the glass (polycarbonate) 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 blowing with clean filtered air, preferably ionised to minimise static attraction. 2. Wash with tepid water / detergent (e.g. Teepol or a domestic household detergent) solution and dry using clean gloves cloths. 3. Rub lightly to remove stubborn marks with soft glove cloth impregnated with 50% v/v isopropyl alcohol or ethanol in water followed by through washing with water / detergent. Change cloth frequently. 72 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.

Care and cleaning of vehicle

Wipe the PC Hi-tech (anti-scratch plastic) 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 solvents (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 with the inside face of window. Wipe the inside face of the window with the hand, whether glove or not. The inside face of the window should not be 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

Preservation & De-preservation

WORK GUIDELINE FOR PRESERVATION AND DE-PRESERVATION OF SUMO ARMOURED VEHICLE IN DIFFERENT 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 engines 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 73

Vehicle Maintenance

Preservation & De-preservation

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 its 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. 74

Vehicle Maintenance

Preservation & De-preservation

11 12 13 14 15 16 17

18 19 20 21

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. Wash and wax the body surface. Apply vinyl/Weather protestant on leather surfaces, tyres, and other rubber components. Keep off the wiper blades from wind shield glass or take off and preserve separately. Seal the tailpipe and any other openings to prevent entry of mice or other rodents. Particularly care to be taken to plug the fire wall openings in to the cabin to prevent rodents. To avoid engine bearing damage due to acid in the engine oil, change the engine oil and oil filter. 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 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. Make sure you have adequate insurance on the vehicle to cover for fire, theft and vandalism or any avalanches or storm condition etc. Open both front and rear hatch if it is inside parking & keep it partial open when parked outside or open to atmosphere. Make sure that 4 x 4 is not engaged.


Vehicle Maintenance

Preservation & De-preservation

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 3 4 5 6 7 8 Bring the battery to full charge before storing it. If the battery is in a vehicle, it is often best to disconnect the negative battery cable. Install and keep terminal protectors in place and keep the battery clean. Store the battery in as cool of a location as possible. Monitor the battery on a regular basis. 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. 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. 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. 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 -32C (-25F) A fully-charged battery will not freeze until the temperature is below -54C (-65F). Monitor the stored battery regularly by checking the built-in hydrometer or OCV.


11 76

Vehicle Maintenance
12 13

Preservation & De-preservation

1 2 3 4 5 1 2 3

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%. 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 0 0 0 0 21 C - 27 C (70 F - 80 F) 8 Months 270C - 320C (800F - 900F) 4 Months 0 0 0 0 32 C - 38 C (90 F - 100 F) 2 Months 380C OR More (1000F OR More) 30 Days Chart applies to fully-charged batteries only AT HILLY SNOW ALL/COLD CLIMATE AREA: Apart from above mentioned points, below mentioned points are specific for cold climate area preserving, Remove battery from vehicle and keep it in battery maintained area. Apply thick layer of antirust on all open surface area. Place the transmission gear selector in Reverse or First. Put 4x2 mode gear selector. Release the Park Brake. Lubricate door, trunk, hood and other moving metal parts with silicone lubricant. GENERAL INSPECTION BEFORE RETRIVAL OF PRESERVED VEHICLE: Over all condition of vehicle. Paint condition. Rusting marks on body as well as on chassis components. 77

Vehicle Maintenance

Preservation & De-preservation

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 ) 78

Vehicle Maintenance
10 11 12 13 14 15 1 2

Preservation & De-preservation

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. After 2 minutes in idling accelerate further to ensure that engine is running up to fly up rpm. Drive vehicle in Pre selective first gear for 15 min. 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) Check vehicle by driving in each gear ensuring all aggregates are functioning properly. Confirm for 4 x 4 high/low operation. Vehicles at cold climate area or a hilly area an attention towards following things apart from above mentioned points need to be given. 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. Wherever snow is concentrated over a surface needs to be cleaned and make rust free surface. Vehicle to be inspected for affected areas where snow was accumulated and any damaged components to be replaced. All fuel lines and water passages to be made ice free and if required damaged pipes or rubber hoses need to be replaced. Fuel tank to be made empty and made ice, water, moisture free and fresh fuel need to be filled up.


3 4 5 6


Vehicle Maintenance

Preservation & De-preservation

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
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 -20 0 C ( With recommended fuel & oil) 2. Altitude : 2500 meters and ambient temp. upto -200C ( With recommended fuel & oil)

Special Operating Conditioning

Recommendations for operating under special conditions : 1. Air filter : Cleaning of air filter cleaner element For dusty operating conditions cleaning 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 whichever is earlier. (Existing frequency for normal operating conditions is 10000 kms) 81

Fuels, lubricants, coolants

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 :
Ambient temperature upto 0 C upto 0 0 to -10 -10 to -15 Ambient temperature upto 0 C upto -15 -15 to -20 -20 and below Percentage Summer grade diesel 100 70 50 Percentage Winter grade diesel 100 70 50 Supplementary fuel 0 30 50 Supplementary fuel 0 30 50

Fuels, lubricants
Care should be taken that diesel and supplementary fuel are thoroughly mixed before filling. Lubricants Recommended lubricants conform to the following specifications : 1. SAE 15 W40 to API CF 4+ 2. 75 W 90 GL-4 Syn. oil Engine 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. 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 :


Vehicle maintenance
Ambient temperature 0C 0 and above 0 to -18 -18 and -40 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. Engine oil grade SAE 15W40 SAE 0W30 SAE 0W40

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).


Recommended oils, lubricants and filling capacities




Castrol GDT 15W/40 For Summer 500 SAE 0 W 40 For Winter -200 Golden Cruiser Premium 1400 M Frostox SFD 12 HP Thanda Raja P HP Gear EP 75W90 CASTROL Sythetic 75W90 HP-Automatic Transmission CASTROL Transpower TQ Fluid Type A HP-ATF Dextron II D CASTROL Transpower TQ HP Gear Oil XP 85W140 GL5 with friction modifier 40819 CASTROL Extreme Pressure 85W140 Super Duty Brake Fluid DOT - 3 / DOT - 4 CASTROL Universal Brake Fluid DOT - 3 HP Multipurpose Grease-2 Castrol AP-2 grease Dinitrol Wuerth Terostat 8590 Kit Form Terostat 930 Iftex Clean System D DENSOIL-6 SUNISONO.5GS

6.5 Litres


13 Litres 1.6 Litres 1.2 Litres 1.4 Litres 2.2 Litres for Rear # 1.2 Litres for Front As required As required

310 ml Cartridge 250 ml pack * -

* Add to Diesel as per the dosage recommended by M/s IFTEX # For Tata Motors Rear axle - 1.9 Litres


Vehicle Data
ENGINE Model Type TATA 3.0 L DICOR BS-III Water cooled, Direct injection, Common Rail, Turbocharged Intercooled Diesel engine with crankcase breather and relief valve. 4 inline 97 mm x 100 mm 2956 cc 84.9 kw @ 3050 rpm as per CMVR 115(9) 1996 300 N-m at 1600 ~ 2200 rpm as per CMVR 115(9) 1996 17.5 : 1 1-3-4-2 Max. 6.5 litres / Min. 5.5 Litres 320 kg (Dry) 2480 Single plate dry friction diaphragm type with hydraulic actuation. 240 mm 452 sq. cm. (approximately) Ratio FRONT LIVE AXLE Type Ratio REAR AXLE Type TRANSFER CASE Type Ratio GEAR BOX Type No of gears Gear ratios

Technical Specification
G-76-5/4.1 with overdrive sychromesh on all gears. 5 Forward, 1 Reverse 1st 4.10 2nd 2.22 3rd 1.37 4th 1.00 5th 0.77 Rev. 3.75 With electric shift arrangement mounted on gear box. 4x2 high - Ratio - 1:1 4x4 high - Ratio - 1:1 4x4 Low - Ratio - 1 : 2.48 Single reduction, salisbury type with limited slip differential hypoid gears & semi-floating axle shafts. 4.55 (41/9) Independently suspended with automatic hub lock 4.55 (41/9)

No. of cylinders Bore / Stroke Capacity Max. engine output Max. torque Compression ratio Firing order Engine oil capacity Weight of Engine Radiator frontal area CLUTCH Type Outside diameter of clutch lining Friction area


Vehicle Data
STEERING Type Steering Wheel BRAKES Service brakes Power Steering 380 mm dia. Vacuum assisted indepedent hydraulic brakes on front & rear through tandem master cylinder.Vacuum pump mounted on engine 282 dia disc brake 295 dia. auto adjuster drum brake Floor mounted Cable operated mech. linkages acting on rear wheels. Ladder type cranked frame with boxed section long members and welded cross members 110 mm (maximum) 60 mm Tow hook at front, Provision of central towing hook at rear Double wishbone type with torsion bar springs. Semi-elliptical leaf springs. Hydraulic double acting telescopic type at front and rear. At both front and rear.

Technical Specification
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

Front Rear Parking brake FRAME Type

Depth Width Tow Hook SUSPENSION Type Front Rear Shock Absorber Antiroll bar



Technical Specification


Preliminary Trouble Shooting

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 ENGINE 1. Engine not cranking CAUSE Battery dead, Loose or dirty battery connections Air in the fuel system EMS fuse blown Water sedimenter filled up with water Coolant level low Hose collapse / torn Low engine oil level Radiator cap not sealing properly 4. Charging indicator continuously remains ON Battery not getting charged due to loose belt drive Faulty alternator Cut off relay is not working ACTION TO BE TAKEN Get battery checked&/or charged Clean and tighten battery connections Press pear pump for air removal Check leakages Replace the fuse Drain water from sedimenter. Top up coolant, check and correct leakages Get the hose replaced Add oil Fit the radiator cap correctly Get the belt tension adjusted replace belt if broken Replace it. Replace it

2. Engine cranks but does not start

3. Engine overheats


Preliminary Trouble Shooting

PROBLEM OBSERVED 5. Poor pickup CAUSE Loose contact of electrical connectors Blocked fuel filter Clogged air filter Alternator electrical connection plug out Intercooler hose collapse or loosen Accelerator pedal module defective Loose belt Belt glazed ACTION TO BE TAKEN Get defect rectified. Clean / replace fuel filter element Clean / replace fuel filter element Check and make proper connections Check and make proper fitment of hose Get defect rectified Get belt tension adjusted Get belt replaced

6. Does not accelerate 7. Belt squeal CLUTCH 1. Clutch does not get disengaged 2. Clutch pedal goes too low 3. Clutch pedal return sluggish

Air in the hydraulic system Less fluid in the master cylinder Air in the hydraulic system Less fluid in the master cylinder Blocking of vent in clutch fluid Bottle

Bleed the system Get the clutch fluid filled Bleed the system Get the clutch fluid filled Open the cap from the bottle & clean the breather hole, if Clogged


Preliminary Trouble Shooting

PROBLEM OBSERVED GEAR BOX 1. Hard gear shifting / crash engagement 2. Gear shifts but vehicle does not move REAR AXLE & FRONT AXLE 1. Loss of lubricant (Oil) Breather hole clogged Differential cover gasket torn Pinion oil seal damaged Insufficient oil Incorrect lubricant used Excess play in crown wheel pinion Clean the breather hole on the axle housing Get replaced Get replaced Get the oil filled Drain, flush and get correct lubricant filled Adjust the play Clutch does not disengage properly 4 X 4 sensor connections loosen Get the clutch hydraulic system attended Make proper sensor connections CAUSE ACTION TO BE TAKEN

2. Differential housing overheating

3. Noise from axle BRAKES 1. Poor brakes

Insufficient brake fluid. Air in the system Malfunction of automatic adjuster Vacuum leakage

Get the brake fluid filled Bleed the system Check & rectify auto adjuster mechanism or replace. Rectify the leakage


Preliminary Trouble Shooting

PROBLEM OBSERVED CAUSE Brake fluid contamination Brake fluid, grease, oil or water on pad /drum Worn brake lining/pad Excessive worn drums at rear soft or weak hose Air in the system Oil on the lining/pad One side shoe (pad) worn Loose brake anchor plate Wheel adjustment disturbed Unequal tyre pressure One side brake pipe clogged Improperly adjusted parking brake brake fluid container breather hole clogged No brake pedal free play/brake pedal not returning fully Defective tandem master cylinder ACTION TO BE TAKEN Replace the brake fluid Replace the leaking line, bleed the system. Clean pad/lining. replace seals if leaking Get the liners/pad replaced Replace rear drums Check & replace Bleed the system Clean the pad lining Get the shoe pad replaced Tighten the bolts Adjust Adjust Get the brake line cleaned & bleed the system Get correctly adjusted Clean the hole on the container Adjust brake pedal Replace/rectify tandem master cylinder 91

2. Spongy pedal 3. Brake pulling to one side

4. Brake grab

Preliminary Trouble Shooting

PROBLEM OBSERVED CAUSE Brake fluid contamination 5. Brake Squeal Defective brake lining/pad Glazed lining/pad Loose rivets Wrong lining/pad Shoe return spring broken Front pads / Antisqueal shims rubbing on the disc ACTION TO BE TAKEN Replace brake fluid along with tandem master cylinder and wheel cylinder. Replace Clean or replace lining/pad Install rivets properly Install correct lining/pad Replace Get corrected

STEERING SYSTEM 1. Hard steering Less fluid in the power steering tank Air in the system Loose pump belt Improper wheel alignment Improper tyre inflation pressure Get the fluid topped up to correct level Get the air removed by bleeding the system Get the belt correctly adjusted Set proper wheel alignment Set proper inflation pressure

2. One side vehicle pulling


Preliminary Trouble Shooting

PROBLEM OBSERVED ELECTRICAL & AIR CONDITIONING 1. No lights on the dash board after turning on the ignition key Battery terminal got disconnected Battery completely dead Get the battery properly connected 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 Replace the fuse if blown Get the connection properly tightened Tighten the relay correctly Get the defective component replaced from Authorized workshop CAUSE ACTION TO BE TAKEN

2. Non functioning electrical accessories such as power windows, head lamps, fuel tank flap, wiper and washer etc

Blown fuse in the circuit Loose connectors Circuit relay loose the mounting Defective components

AIR CONDITIONING 1. Fan motor does not operate Blown fuse Faulty connection Faulty motor Faulty or poor Faulty fan switch Replace fuse and correct any wiring short Properly connect poor connections Replace motor if no conductance Replace resistor block if defective connection at resistor Replace switch 93

Preliminary Trouble Shooting

PROBLEM OBSERVED 2. Motor operates but air flow is minimum 3. Insufficient cooling, Air flow normal and compress operating 4. Demist or defrost not working WIPERS 1. Narrow streaks are left on the wind shield making it hard to see 2. The wiper blade jumps across the windshield and makes a lot f noise (Un-smooth operation) Foreign matter has attached to the blade or No proper contact of wiper blade with wind shield glass and wiper blade does not move smoothly across the surface but vibrates, noisily and bounces. Rubber deformed Deformed wiper blade / arm Clean the edge of the blade. If streaks still appear, replace the blade edge of the blade is worn out. Clean the wind shield. If jumping persists replace the blade. CAUSE Obstruction at evaporator inlet Air leak Faulty thermostat Incorrect refrigerant quantity or or defect in system aggregates or defective thermosensor Loose electrical connections ACTION TO BE TAKEN Clean evaporator Correctly seal Adjust or replace thermostat Get the defect rectified at nearest authorized service centre

Get proper connections

3. The wipe leaves large un-wiped spots. 4. The blade does not contact with the wind shield surface evenly, leaving a large un-wiped surface. 94

Replace the blade Replace wiper blade / arm

Preliminary Trouble Shooting

PROBLEM OBSERVED WHEELS AND TYRES 1. Excessive tyre wear Improper inflation pressure Disturbed steering geometry Adjust steering geometry Check and set proper inflation pressure CAUSE ACTION TO BE TAKEN


Lubrication points
Lubrication points : The lubrication points listed below and shown on next page require greasing or an oil level check and topping up. No. Description
1. 2. 3. 4. 5. 6. 7. 8. 9. Engine Front hub Front Axle C.V. Joint Power steering tank Steering spindle and sleeve Transfer case Propeller shaft (Rear yoke) Rear axle Rear hub

Grease / oil
Oil level Pack grease Pack grease Oil level 1 Grease nipple Oil level 1 Grease nipple Oil level Pack grease 1 Grease nipple Oil level 4 grease nipples 2 Grease nipples

10. Front Propeller shaft Rear yokes 11. Gear box 12. Rear spring suspension Rear 13. Rear spring suspension Front

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


Lubrication points (4x4 vehicle) LUBRICATION POINTS


Special instructions
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. This chapter contains charts showing lubrication points and the lubrication & maintenance schedule. 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. The vehicle is entitled to pre-delivery service with free labour. It is an important condition of our policy that no warranty claims shall be entertained by us 6. unless all services upto the time of the claim arising 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. 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.

2. 3.

4. 5.



OPERATION Service Operations to be performed by Driver GENERAL 1. Check engine oil level in sump, Top up, if necessary. 2. Check coolant level in auxiliary tank, top-up, if 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 fluid and coolant, if any. 4 Check tyre pressure. Inflate tyres to specified pressure, if necessary. 5 Check level of brake fluid in containers, top up, if necessary. 6 Grease with grease gun : (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 & releasing, when engine is running. Get it adjusted from Authorized Workshop if required. 8 Check oil level in power steering tank & top up if necessary 9 Check headlamps, gauges & instruments for proper functioning. Get it rectified if necessary 10 Check exhaust system. Get it rectified, if necessary. 11 Check condition of wiper blades for crack damage, etc. replace if necessary.

OPERATION 12 Clean the vehicle from inside & outside Note : Do not wash DICOR system components with forced water 13 Check Air Filter service indicator. If RED BAND appears, clean the filter cartridge. Replace filter element when service indicator shows red band even after cleaning the filter element. 14 Wheel balancing 15 Wheel alignment (Steering geometry) must be done.




Daily Daily


Weekly Weekly Monthly Monthly

Whenever tyre is removed from wheel rim. Monthly 10000 km on road 5,000 km off road


Monthly Daily Monthly Daily

16 Check water level in windscreen washer container & top up if necessary 17 Lubricate all grease nipples 18 Tighten all fasteners: front grill, & fuel lines, engine, radiator mtg., radiator hose, turbocharger mounting, inter cooler mounting fasteners turbocharger hose connections/its mountings & inter-cooler hose connection / 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 seats mountings, axle shaft mtg., anti roll bar mtg.,vacuum booster & tandem master cylinder mountings, rear anchor plate mtg., , fuel tank mtgs.

Daily Monthly Monthly 10,000 10,000



OPERATION Service Operations to be performed at Workshop ENGINE 1 Change coolant in cooling system 2 Change engine oil & oil filter cartridge 3 Change water sedimenter 5 Drain water in sedimenter / Fuel filter Whenever umbrella shape lamp glows 6 Change fuel filter 7 Cooling and heater: check & rectify hoses for clog and damage (radiator & condenser fins blocking due to dirt / dust etc.) 8 Check alternator belt and A/C compressor belt adjust tension if required, change if damaged 9 Change / replace all drive belts 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 12 Inspect vacuum hose connection and rectify if necessary 13 Change / replace all vacuum hoses 14 Check Turbo charger hose & Rectify if necessary 15 Check & ensure normal working of engine using diagnostic equipment ( Whenever check engine lamp glows on OR at every vehicle servicing)

OPERATION LOW PRESSURE FUEL SYSTEM 1 Check low pressure fuel lines for leakage & rectify 2 Clean strainer in fuel tank 3 Remove drain plug fuel tank and drain off sediments BRAKES 1 Check level of brake fluid in containers, top up if necessary 2 Check service & parking brakes, adjust if necessary 3 Check front brake & rear brake linings, Replace if necessary 4 Change brake fluid in the brake system and bleed the system 5 Overhaul the vacuum booster assembly using recommended repair kit and diaphragm. 6 Dismantle, clean, inspect and re-assemble tandam master cylinder of brake system. GEAR BOX 2 Check oil level in Gear Box. 3 Change oil in the Gear Box. 4 Check and Clean breather on Gear box TRANSFER CASE 1 Check oil level in transfer case, top up if necessary 2 Change oil in transfer case (First 10,000 km) 4 Check & tighten if necessary, transfer case mounting screw



2 years 6 months 2 years

40,000 10,000 50,000 5000 20000

6 months 1 Year 1 Year Daily 3 Months 6 Months 1 years 1 years 1 years

5,000 10,000 40,000

1 Years Monthly

5,000 15,000 20,000 30,000 30,000

6 Months 2 years

10,000 40,000

1 year Monthly 2 years Monthly

10,000 5,000 40,000 5,000 5,000

3 Months 1 year 1 year 3 Months 1 year 6 months

5,000 15,000 15,000 5,000 45,000 5,000



OPERATION LIVE FRONT AND REAR AXLE 1 Check oil level in live front axle and live rear axle, top up if necessary 2 Change oil in live Front axle & Rear axle (FIRST 10,000) 3 Change grease in front hubs & adjust bearing play Replace damaged / worn parts. 4 Clean breather on live front axle and rear axle. POWER STEERING & SUSPENSION 1 Check and tighten if nessary. U joints on steering spindle. Steering gear box and mounting bracket bolts joints of pitman arm, drag link and tie rod. 2 Check & adjust steering wheel free play 3 Check oil level in P.S. tank & top up if neccessary. 4 Change oil in steering gear box. 5 Check belt tension & adjust if necessary 6 Check condition of rubber bushes of a) Anti-roll bar b) Upper wish bone c) Lower wish bone 7 Check tightening torque of suspension fasteners ELECTRICALS 1 Check battery voltage, charge the battery externally if necessory 2 Apply graphite grease on starter motor pinion bushing 3 Grease the wiper motor linkages CAB 1 Apply grease on door latches, door lock striker, bonnet opening lever, lock plate tail gate hinges & door lock inner ratchet

OPERATION WHEELS & TYRES 1 Tyre rotation. AIR CONDITIONING SYSTEM (wherever fitted) 1 Check torque of bolts on brackets & AC compressor 2 Check compressor belt, adjust tension, Replace if necessary. 3 Check bubbles in receiver drier for refrigerant level 4 Check for leak of gas / oil from pipes, joints, compressor shaft seal & cylinder head 5 Clean condenser with high pressure water 6 Check fan speeds for proper air flow 7 Check system pressure with gauges. Recharge if necessary 8 Clean evaporator from its face to remove dust, foreign objects etc. 9 Replace AC compressor belt HEATING / DEMISTING SYSTEM 1 Check hose joints of heating system for leakage. Tighten if necessary 2 Check hoses of heating system for cracks. Replace if required 3 Check blower for proper functioning. Check fuse. Replace if found blown. RUBBER / NYLON HOSES & FLEXIBLE PIPES 1 Check hoses & pipes of air / fuel / coolant / brake / clutch / air conditioning / wind screen washing system for joint tightness and damage. Replace, if necessary.



3 Months 1 years 1 years 6 months 6 months

5,000 15,000 30,000

6 Monthly Monthly Monthly Monthly Monthly Monthly Monthly Monthly Monthly 2 Years Monthly Monthly Monthly


6 months 3 months 2 years 6 Months 1 Year

5,000 30,000 10,000 30,000 5,000


Weekly 6 months 6 months Monthly 15,000 15,000

1 year

Change oil in live Front axle & Rear axle (FIRST 10,000)

Record of services performed

Recommended Service Date At Km. PDI 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 Odometer Repair Servicing Dealer's reading Order Signature and Km. No. Stamp

Chassis No................................
Recommended Service Date 45,000 50,000 55,000 60,000 65,000 70,000 75,000 80,000 85,000 90,000 Odometer Repair Servicing Dealer's reading Order Signature and Km. No. Stamp


Record of services performed

Recommended Service Date 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 Odometer Repair Servicing Dealer's reading Order Signature and Km. No. Stamp

Chassis No................................
Recommended Service Date 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 Odometer Repair Servicing Dealer's reading Order Signature and Km. No. Stamp


Record of repairs carried out

Date Odometer reading (km) Repair Order No. Particulars of Repair

Chassis No................................
Servicing Dealer's Signature & Stamp


Record of repairs carried out

Date Odometer reading (km) Repair Order No. Particulars of Repair

Chassis No................................
Servicing Dealer's Signature & Stamp


AC ACC Amp Br Brg cc Cm Dia EGR FAW Fig FIP gm GVW 106 Air conditioning Accessories Ampere Branch Bearing Cubic centimeter Centimeter Diagonal Exhaust Gas Recirculation Front Axle Weight Figure Fuel Injection Pump Gram Cross Vehicle Weight IGN Kg km Km/h LH Max Min mkg mm Mtg No PDI PSI PUC Ignition Kilogram Kilometer Kilometer per hour Left Hand Maximum Minimum Meter per Kilogram Milimeter Mounting Number Pre-delivery Inspection Pounds per Square Inch Pollution Under Control Sec Seconds Sq. cm. Square Centimeter TASC TASP Tata Motors Authorised Service Centre Tata Motors Authorised Service Point Volts Watts Weight RAW RCSM RH RM RPM Rear Axle Weight Regional Customer Support Manager Right Hand Regional Manager Revolution Per Minute

V W Wt

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 ...................................................................................