Owner’s Manual

Ni n Seth
Execu ve Director – LCV

Dear Customer,
Thank you for choosing our product. We are proud to have you in the Ashok Leyland family.
This Owner’s Manual has been prepared to acquaint you with the opera on and maintenance of your new
vehicle. Care has been taken to include as much useful informa on as possible.
You are requested to read this manual carefully before opera ng the vehicle. For your convenience, we
have provided a "Record of Maintenance" in this manual.
We, in Ashok Leyland are engaged in con nuously improving our products and it is therefore likely that
some of the specifica ons, dimensions or design referred to herein may change over a period of me.
In order to get op mum performance from your vehicle, we would urge you to get all service and repairs
done at the workshops of Ashok Leyland’s channel partners and use only Genuine Spare Parts.
We have put in considerable efforts to ensure the accuracy of the contents of this book and shall be thank-
-ful for any comments you may have to improve the same.

Yours sincerely
ASHOK LEYLAND LTD
Chennai
(Ni n Seth)
 FOREWORD

First of all, thank you for placing your confidence in one of our vehicles. We are sure you will not regret your choice. This owners
manual contains all the informations you need to know on the range of performances of your vehicle, as well as advice for driving it,
which no doubt you will find very useful. We advice you to read carefully before operating the vehicle. Your dealer has already
carried out a detailed pre-delivery check-up, to make sure that the vehicle is in perfect working condition.

We stress the importance of contacting your AL dealer whenever the vehicle needs any attention, including periodical check-ups
and maintenance operations or repairs, etc., as your dealer is an expert in its care, with specialized personnel and equipment.

VERY IMPORTANT
In order that both you and the other occupants can bene t from safe driving of the vehicle, we recommend that you follow these
rules:
• Do not drive while under the influence of alcohol or drugs.
• Observe the speed limits indicated in each case, and taking into account extreme conditions such as rain, fog,
snow, ice, etc.
• Use the seat belts in accordance with the regulations.
• Ashok Leyland Ltd. accepts no responsibility for the consequences of failing to comply with this warning.
• Keep Owner’s Manual in the vehicle at all times.
• This book will help you to understand the vehicle better, maximize uptime of the vehicle & obtain better
performance at optimum cost.
• The recommended routine maintenance servicing along with any running repairs that may be required, should be
entrusted to a AL dealer to ensure that only latest methods and genuine parts are used for the continued
reliability, safety and performance of the vehicle.
• Some of the items / accessories / features shown / given in this book may not be fitted on your vehicle, but they
are applicable for other versions of PARTNER.
Ref No: OM T/613/18/100; Version: V001
 READING OF THE MANUAL

This manual has been prepared to provide the user with the necessary information on the maintenance of ASHOK LEYLAND
PARTNER. It is hoped that this will also enable them to acquire working knowledge of the vehicle. Ashok Leyland Ltd. reserves the
right to change the procedures, material specification, dimensions, or design of the vehicles shown described referred herein at any
time and without prior notice in accordance with the company's policy of constant product improvement.

Every reasonable effort is made to ensure that this manual is accurate. Before driving your vehicle for the first time, carefully read
this Owners’ Manual so as to familiarize yourself with all the controls and maintenance requirements, to assist you in the safe
operation of your vehicle.

IMPORTANT
Throughout this manual we have used the symbol followed by the word WARNING/CAUTION. This indicates the presence of
a hazard which may cause the possibility of a personal injury or other damage and must be followed precisely.

CAUTION: This is also used throughout the manual to indicate the presence of a hazard that could cause possible minor injury to
yourself or components. Therefore the procedures must be followed carefully.
NOTE. This indicates additional helpful information. In both cases, their contents must be read carefully.

In the event of the Vehicle being sold, please ensure that this manual is left in the vehicle for the reference of the new owner.

No part of this publication may be translated, restructured or reproduced without the consent of ASHOK LEYLAND LTD.

ASHOK LEYLAND LTD. reserves the right to alter totally or partially (without prior warning) any of the data and specifications
contained in this publication.
The data contained in this publication are those that are currently applicable.
 TRANSFER OF OWNERSHIP

TRANSFEROR
Name:
Contact No.:
Address:

TRANSFEREE
Name:
Contact No.:
Address:

Reg . No
Engine No.:
VIN No.:
Date of Transfer:
 VEHICLE DETAILS

REGISTRATION NO GEARBOX NO

VEHICLE MODEL REAR AXLE NO

CHASSIS NO BATTERY NO

ENGINE NO
TYRE NO

DATE OF SALE
SOLD BY

OWNER' S DETAILS

OWNER NAME

ADDRESS

PH NO
CONTENTS

1. WARRANTY AND SERVICE ................................................................................................1

2. INSTRUMENT AND CONTROLS ....................................................................................... . . . . . 13

3. PRE-DRIVING CHECKS AND ADJUSTMENTS .................................................................. . . . . 25

4. STARTING AND DRIVING ................................................................................................. . . . . . . 33

5. APPEARANCE AND INTERIOR CARE............................................................................... . . . . . 41

6. IN CASE OF EMERGENCY ............................................................................................... . . . . . . 47

7. TECHNICAL INFORMATION.............................................................................................. . . . . . . 55

8. MAINTENANCE AND DO-IT YOURSELF ........................................................................... . . . . . 67

 1. WARRANTY AND SERVICE

CHAPTER 1
1. WARRANTY AND SERVICE
1.1 Warranty Terms .............................................................................................................................................. 3
2
1.1.1 Terms of Warranty .................................................................................................................................. 32
1.1.2 Service policy ........................................................................................................................................ 4
1.1.3 Scope of Warranty ................................................................................................................................. 4
1.1.4 Non-Warranty Items ............................................................................................................................... 5

1.2 Service schedule ............................................................................................................................................ 6

1

1.1 Warranty Terms
1.1.1 Terms of Warranty
Ashok Leyland Limited (AL) warrants
each vehicle sold by it to be free from
defects in material and workmanship
subject to the following terms and
conditions:
1. The period of warranty shall be 2
Years from date of sale 100, 000kms
for the vehicle whichever is earlier.
2. The warranty extends to the first
registered owner of the vehicle
only or (in the absence of
registration) to the first commercial
user of the vehicle. In the event of
transfer or any alienation
otherwise of the vehicle during the
period mentioned in Clause 1
above, the warranty shall stand
terminated unless prior written
consent of Ashok Leyland is
obtained.
3. In the event of any defect being
discovered within the period
mentioned in clause 1 above,
the defective part is returned to
the nearest AL Dealer
workshop, freight paid, within 7
days.
4. The obligation under warranty
shall be limited to either repairing
or replacing free of charge such
parts of the vehicle as are deemed
to be defective in the opinion of AL
and shall not extend to
consequential loses. The replaced
part shall become the property of
AL.
5. For proprietary parts not
manufactured by AL such as
Fuel Injection Equipment,
Electrical Equipment,
Instruments, Batteries, Tyres
the warranty terms of the
respective supplier will be
applicable.
6. The buyer shall have no other right
except those expressly stated
herein 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
incidental or consequential losses
such as loss of use of vehicle,
1. WARRANTY AND SERVICE
loss of time, inconvenience or
damage to personal property,
Commercial loss such as loss of
1
revenue etc., During the period when
the vehicle is undergoing service /
warranty repairs.
7. The customer will be responsible
for
* The cost of non-durable
materials (lubricants, fuel,
grease, filters, etc.), rubber
items, liners (clutch, brake), soft
trims, upholstery and paint
coatings.
* The cost of maintenance and
lubrication operations.
* The cost of repairs made
necessary by normal wear and
tear, accidents or improper use
not authorised by AL or by
improper / storage or
negligence.
3
 1. WARRANTY AND SERVICE
* The cost of on-road repairs,
1 towing
insurance.
parking and
* The cost of repairs caused by
damage due to fire, food,
earthquake or such natural
calamities or by civil
disturbances.
8. The warranty shall become null
and void:
* If the vehicle is used in ways
not recommended by the
company, if any features of the
vehicle are modified, if the
vehicle is repaired or
disassembled, even partially,
by persons not belonging to
AL’s authorized workshop, if
the vehicle is fitted with body of
design, size, position and
mounting other than what is
prescribed by AL, if the
overhang is extended in
excess of the original
specification or if the vehicle is
loaded beyond its carrying
capacity as certified by AL.
* If the fuel injection equipments
calibration figures are altered
or the relative seals tampered
with, if unsuitable lubricants
4
or fuels or coolants are
employed or non-genuine
spare parts are fitted.
* If the recommended
maintenance practice is not
followed.
9. When a part is replaced under the
terms of warranty the benefits of
the warranty shall apply to the
replacement part for the remainder
of the 12 months period.
10. AL reserves the right to modify the
technical specifications and
introduce improvement to its
vehicles at any time and is under
no obligation to apply such
modifications or improvements to
vehicles produced at an earlier
date.
11. This warranty is in lieu of and
excludes all conditions warranties
liabilities expressed or implied,
whether in common law statute or
otherwise in relation to all vehicle,
whether covered by warranty or
not.
1.1.2 Service policy
Ashok Leyland endeavors to secure
excellence of materials and
workmanship and this section covers
the service policy of AL.
The service policy has three elements
that you need to understand, viz.,
1. AL’s Warranty terms
2. Dealer’s Service obligations
3. Owner’s maintenance
responsibilities
1.1.3 Scope of Warranty
It is absolutely essential to avail the Pre
Delivery inspection and other claim
any benefit under the terms of warranty.
The terms of warranty are given in the
following pages.
 1. WARRANTY AND SERVICE
1.1.4 Non-Warranty Items 8. Fasteners except main bearing
The warranty terms are a precise
statement of AL’s intention to cover the
cap bolts, con rod bolts,
differential bearing cap mounting
bolts.
1
replacement / repair cost, on a
9. Parts recommended to be
standard and agreed basis, of any
replaced during routine
product failure resulting from defective maintenance.
material or sub-standard workmanship
during the manufacturing process. 10. Consumable items such as lube
oil, grease, anti-corrosion / anti-
Hence any replacement arising out of
freeze compound etc.
normal wear and tear of the following
items will not be the subject of a
warranty claim:
1. Gaskets (other than Cylinder Head
Gasket).
2. Rubber components such as
cylinder kit, wiper blades and floor
mats.
3. Bulbs and lamp covers.
4. Fuses.
5. Upholstery including seat cushions
and covers.
6. Glass items (other than
windscreen glass).
7. Suspension pins and bushes.

5
 1. WARRANTY AND SERVICE
1.2 Service schedule
1
Recommendation (Kms)

100000

110000

120000
40000

70000
20000

60000

80000

90000
50000
10000

30000
5000
Frequency
OPERATION Activity
kms

Engine
Air element (Primary) (As and
1 Replace 60000 – – – – – – R – – – – – R
when red band appears)
2 Air element (Secondary) Replace 120000 – – – – – – – – – – – – R

3 Engine coolant (level, Leakage) Replace 80000 – I I I I

R I I I R I I I I

4 Engine oil and oil Replace 10000 – R R R R R R R R R R R R

5 Fuel filter & Pre-filter element Replace 10000 – R R R R R R R R R R R R

6 Timing chain Inspect 10000 – I I I I I I I I I I I I

7 Alternator belt tension Inspect 10000 – I I I I I I I I I I I I

8 EGR valve Inspect 10000 – I I I I I I I I I I I I

9 Fuel lines and connections leakage Inspect 10000 – I I I I I I I I I I I I

Intake and Exhaust system (Noise,

10 Inspect 10000 – I I I I I I I I I I I I
Leakage)

11 Inspect exhaust smoke level Inspect 10000 – I I I I I I I I I I I I

6
 1. WARRANTY AND SERVICE

Recommendation (Kms)
1

100000

110000

120000
10000

20000

30000

40000

50000

60000

70000

80000

90000
Frequency

5000
OPERATION Activity
kms

Inspect & Tighten

a) Oil sump bolts

b) Fuel mounting brackets

c) Air cleaner mounting

d) Starter motor mounting

12 e) Turbocharger mounting Tighten 10000 – T T T T T T T T T T T T

f) Exhaust manifold mounting

g) Inlet manifold mounting

h) Oil pressure adapter

i) Cylinder head cover mounting

j) Fuel

Clutch

Clutch pedal linkages for greasing

13 Inspect 10000 – I I I I I I I I I I I I
(Re-greasing if necessary)

14 Clutch pedal play Inspect 10000 – I I I I I I I I I I I I

7
 1. WARRANTY AND SERVICE

1 Recommendation (Kms)

120000
110000
100000
40000
30000
20000

70000
50000

60000

80000

90000
10000
Frequency

5000
OPERATION Activity
kms

Gear Box

15 Transmission oil (level, leakage) Replace 40000 – I I I R I I I R I I R I

16 Vehicle speed sensor (mounting) Inspect 10000 – I I I I I I I I I I I I

Gear box mounting bolt (Tighten if

17 Inspect 10000 – I I I I I I I I I I I I
necessary)

Suspension

Condition of leaf spring (Front &

Rear) spacer, rubber mount, Bump
18 Inspect 10000 – I I I I I I I I I I I I
stop, Spring seat & bushes (if
necessary)

Inspect shock absorber (Oil

19 Inspect 10000 – I I I I I I I I I I I I
leakage, if necessary)

Inspect “U” clamp bolts (Tighten if

20 Inspect 10000 – I I I I I I I I I I I I
necessary)

Hydraulic Brakes

Brake / Clutch (level, leakage)

21 Replace 20000 – – R – R – R – R – R – R
DOT4

Brake hoses for damage / Leakage

22 Inspect 10000 – I I I I I I I I I I I I
(Replace if necessary)

23 Lubricate brake pedal linkages Inspect 10000 – I I I I I I I I I I I I

8
 1. WARRANTY AND SERVICE

Recommendation (Kms)
1

100000

110000

120000
Frequency

20000

30000

40000

50000

60000

70000

80000

90000
10000
OPERATION Activity

5000
kms

24 Lining inspection Inspect 10000 – I I I I I I I I I I I I

25 Wheel cylinder assembly Inspect 40000 – – – – – – – – – –

26 Rear brake drum & shoes wear Inspect 10000 – I I I I I I I I I I I I

Parking brake cable (Tighten if

27 Inspect 10000 – I I I I I I I I I I I I
required)

Vacuum booster mounting (Tighten

28 Inspect 10000 – I I I I I I I I I I I I
if required)

Front Axle

29 Wheel alignment Inspect 10000 – I I I I I I I I I I I I

30 Wheel bearing play check Inspect 10000 – I I I I I I I I I I I I

Wheel bearing greasing (Check for

31 Replace 40000 – – – – R - - - R - - - R
grease leakage)

Rear Axle

32 Rear Axle Oil (level, leakage) Replace 40000 – – – – R - - - R - - - R

33 Breather Clean 10000 – C C C C C C C C C C C C

9
 1. WARRANTY AND SERVICE

1 Recommendation (Kms)

120000
100000

110000
10000

40000

50000

60000

80000
20000

70000

90000
30000
Frequency

5000
OPERATION Activity
kms

Propeller Shaft

34 Check the condition of UJ seal Inspect 10000 – I I I I I I I I I I I I

Check of the UJ play (Replace if

35 Inspect 10000 – I I I I I I I I I I I I
Excessive play)

Check propeller shaft bolt torque

36 Inspect 10000 – I I I I I I I I I I I I
(Tighten if required)

Wheels & Tyres

37
38 Tyre pressure Inspect Daily I I I I I I I I I I I I I

38
39 Tyre wear Inspect 5000 I I I I I I I I I I I I I

39
40 Tyre rotation Inspect 10000 – I I I I I I I I I I I I

40
41 Wheels (damage) Inspect 10000 – I I I I I I I I I I I I

Steering (Power)

Oil in power steering container

41
42 Replace 80000 – I I I I I I I R I I I I
(Level, leakage)

42
43 Steering wheel free play Inspect 10000 – I I I I I I I I I I I I

Steering gear box mounting,

43
44 pitman arm, drag link, tie rod Inspect 10000 – I I I I I I I I I I I I
(Tighten if necessary)

10
 1. WARRANTY AND SERVICE

Recommendation (Kms)
1

110000

120000
10000

20000

30000

40000

50000

60000

70000

80000

90000

10000
Frequency

5000
OPERATION Activity
kms

44
45 Ball joint play in tie rod Inspect 10000 – I I I I I I I I I I I I

Steering hoses for leakage /

45 Inspect 10000 – I I I I I I I I I I I I
damage (Power steering)

46 Steering Tie rods (damage / wear) Inspect 10000 – I I I I I I I I I I I I

47 Grease steering column Replace 10000 I R R R R R R R R R R R R

Electricals

Battery electrolyte, gravity

48 (level, leakage add the distilled Inspect 10000 – I I I I I I I I I I I I
water if necessary)

49 Head lamp aiming and focus Inspect 10000 – I I I I I I I I I I I I

Water level in wind screen washer

50 Inspect Daily I I I I I I I I I I I I I
container

General

Apply the grease on door latches,

51 Replace 10000 – R R R R R R R R R R R R
tail gate hinges

I – Inspect, C – Clean, OMJ/A – Overhauling with major kit/Adjust, R – Replace, T– Tightening to recommended torque

11
 2. INSTRUMENT AND CONTROLS

CHAPTER

2. INSTRUMENT AND CONTROLS

2.1 Dashboard............................................................................................................................................14
2
1

2.2 Instrument cluster .................................................................................................................................15

2.3 Instrument gauges ................................................................................................................................ 16
2.4 Windshield wiper switch.........................................................................................................................19
2.5 Headlight, dimmer and turn signal switch ................................................................................................19
2.6 Headlight levelling switch.......................................................................................................................20
2.7 Hazard warning switch ..........................................................................................................................21
2.8 Exhaust brake switch.............................................................................................................................21
2.9 Tiltable steering.....................................................................................................................................21
2.10 Horn........................................................................................................................................... . . . . . . . 22
2.11 12V Outlet..................................................................................................................... . . . . . . . . . . . . . . . . . 22
2.12 Interior light or cabin light......................................................................................................................22
2.13 Tail lamp.......................................................................................................................... . . . . . . . . . . . . . . . 22
2.14 Cab Tilting Procedure...........................................................................................................................22
2.14.1 Opening the cabin.......................................................................................................................23
2.14.2 Closing the cabin.........................................................................................................................23
2.15 Glove box................................................................................................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

13
 2. INSTRUMENT AND CONTROLS
2.1 Dash board

1 2

Exhaust Brake Switch HLLD Switch Hazard Warning Switch

14
 2. INSTRUMENT AND CONTROLS
2.2 Instrument cluster

2
1

15
 2. INSTRUMENT AND CONTROLS
2.3 Instrument gauges
Speedometer
The speedometer indicates vehicle
Procedure to change the MODE
1. To change from Odo to Trip A
press mode knob for less than 1
sec.
To increment hour
digits and AM/PM, press and
release the mode knob.
3. Pressing the set knob for less

2
speed in km/hr.
1 press mode knob for less than 1
Odometer/Trip meter and Clock
• The odometer records the total
distance the vehicle has been
driven.
• The trip meter records the
distance of individual trips.
• Digital clock displays the time.
When the ignition switch is turned
to “ON”, the display shows any
one of the four types of indication;
odometer, trip meter A, trip meter B
and clock as shown.
than 1 sec will cause hour to
2. To change from Trip A to Trip B
set and minute will be
indicating the minute setting
sec.
mode.
3. To change from Trip B to Clock
4. While minute digits are
press mode knob for less than 1
press and release the mode
sec.
knob to increment the minute
4. To change from Clock to Odo digits.
press mode knob for less than 1
5. Pressing the set knob for less
sec.
than 1 sec will cause minute to
set and then minute digit will
Procedure to set Tripmeter stop and the clock is
1. To reset the Trip A value, select set.
Trip A screen and press set
knob for more than 3 sec. Fuel Gauge
2. To reset the Trip B value, select
Trip B screen and press set
knob for more than 3 sec.
The tripmeter can show upto
9999.9 km.

Procedure to set the Clock The display indicates the

1. Press the mode switch till clock APPROXIMATE fuel level in the
screen appears. tank.

2. In clock screen by pressing the

set key, hour digits will start

16

Note electrical system. Have the system
repaired promptly.
indicates empty as shown in the Low oil pressure indicator – Red
light
7.8
24.8
This light warns of low engine oil
45.8
comes on during normal driving, pull
68.8 off the road in a safe area, stop the
engine immediately and call AL LCV
90 Dealer.
WARNING
Checking bulbs Running the engine with the Low
oil pressure indicator on could
Apply the parking brake and turn the cause serious damage to the
ignition key to "ON" without starting engine.
the engine. The following lights will
come on: Note
The Low oil pressure indicator is not
designed to indicate a low oil level.
Use the dipstick to check the oil level.
If any light fails to come on, it
may indicate an open circuit in the
2. INSTRUMENT AND CONTROLS
See "Engine oil" in the "Maintenance
and Do-it-yourself" section.
High coolant temperature
indicator – Red light
2
1
The light indicates when the engine
temperature is high.
If the light indicates , stop the vehicle
safely as soon as possible. If the
engine is overheated, continued
operation of the vehicle may
seriously damage the engine. see“
In case of emergency “ section for
immediate action required.
WARNING
Do not remove the radiator cap
while the engine is hot. Otherwise,
there is a danger of being burned
by the coolant which is likely to
erupt from the radiator.
Charge indicator – Red light
17
 2. INSTRUMENT AND CONTROLS
If the light comes on while the engine
is running, it may indicate that there
is something wrong with the charging
system. Turn the engine off and
check the alternator belt. If the belt is
1 2 loose, broken, missing or if the light
remains on, contact your AL LCV
Dealer immediately.
WARNING
Do not continue driving if the belt
is loose, broken or missing. This
may cause severe harden brake
pedal and continuous battery
discharging.
Parking brake/Low brake
indicator – Red light
P travel.
This light functions for both the
parking brake or low brake in
the system.
The light comes on when the parking
brake is applied or brake level in
reservoir is below Min level.
18
If the light comes on while the engine
is running with the parking brake
not applied, stop the vehicle and
check the brake level. Add
brake as necessary. See "Brake
level" in the "Maintenance and
Do-it-yourself” section.
WARNING
If the level is below the MIN mark
on the brake reservoir, do not
drive until the brake system has
been checked at a AL LCV Dealer.
Note
Pressing the brake pedal with
the engine stopped and/or low
brake level could increase
your stopping distance and require
greater pedal effort as well as pedal
Water in fuel indicator – Amber
light
If the light comes on while the engine
is running, it warns that you need to
drain the water from the fuel .
See "Fuel in the "Maintenance
and Do-it-yourself" section. Fail
to drain water can cause serious
damage to the engine.
Turn signal/hazard indicator
The light when the turn signal
switch lever or hazard switch is
turned on.
High beam indicator – Blue light
This light comes on when the
headlight high beam is on, and goes
off when the low beam is selected.
Service lamp – Red light

If the light comes on while the engine
is running, it indicates that there is
something wrong with the engine
electronic control system.
2. INSTRUMENT AND CONTROLS
If the low vacuum indicator light
comes on, it warns poor braking
operation. Contact your AL LCV
Dealer to rectify.

CAUTION 2
1
2.4 Windshield wiper switch
• If the light comes on while
driving, slow down until the
light goes out.
• If the light remains still on
Note
contact your nearest AL LCV
Dealer. Do not operate the wipers if
L the windshield is dirty, it may
Malfunction indicator – Amber scratch/damage the glass.
light

Windshield wiper switch with 2.5 Headlight, dimmer and

washer turn signal switch
Move the lever back to operate the Lighting
If the light comes on, it warns that wiper.
emission from vehicle are not at
acceptable levels. Contact your AL Pull the lever towards you to spray
LCV Dealer to rectify. windscreen washer

Low vacuum indicator – Red

WARNING
To avoid possible injury, do not
operate controls by reaching
through the steering wheel.

19
 2. INSTRUMENT AND CONTROLS
Turning the switch to the below Flashing headlight 2.6 Headlight levelling switch
position:

1 2
The parking, tail, license plate and
instrument lights will come on.

Turning the switch to the below

position:
Pulling the lever toward you will turn The projected angle of the headlights
on the headlight main beam. may change with the condition and
load. This switch is used to adjust
Turn signal - Green light the projected angle to the proper
level.
Headlights will come on and all the
Adjust the switch knob by referring to
other lights remain on.
the following examples:
To select the high beam, push the
Switch Loading
lever down. Pull it back to select the
low-beam. position condition
0 Driver
1 Driver + Load

Move the lever front and back to

signal the turning direction. When
the turn is completed, the turn
signals cancel automatically.

20

2.7 Hazard warning switch
Hazard warning switch
Hazard warning switch
Push the switch on to warn other
drivers when you stop or park under
emergency conditions. All turn
Rear Fog Switch
2.8 Exhaust brake switch
Exhaust brake switch
2. INSTRUMENT AND CONTROLS
Exhaust brake switch 2.9 Tiltable Steering
The exhaust brake switch is
located in the instrument panel.
2
Push to ON, the exhaust brake
indicator light in the instrument panel 1
illuminates. This indicates that the
exhaust brake is in operation.
Use the exhaust brake, when
frequent brake operation is required,
for example, when driving on down
hill grades (Using the engine brake).
Steering adjustable lever provided
CAUTION for adjusting steering position.
2.10 Horn
Do not use the exhaust brake
when driving on wet or slippery
HLLD Switch surfaces, because
Hazard Warning doing so could
Switch
lock the wheels.
When the clutch or accelerator pedal
is depressed, the exhaust brake will
not operate.
To sound the horn press the horn pad
of the steering wheel. The horn can
be operated with the any position of
ignition switch.
21
 2. INSTRUMENT AND CONTROLS
2.11 12V Outlet
1 2
12 V outlet can be used for mobile
charging and cigarette lighter.
2.12 Interior light or cabin light
The switch has two position “ON or
OFF”. The light comes ON when it is
turned to ON position and vice verse.
22
2.13 Tail lamp
Turn signal light (1) comes ON when
the turn signal switch is activated.
Brake lights (2) comes ON when the
brake pedal is pressed or headlight
is switched ON.
Reverse light (3) comes on when
gear is shifted to reverse.
2.14 Cab Tilting Procedure
The cabin is designed to tilt open to
access the engine compartment.
WARNING
• Never Perform the cabin tilting
or closing operation during
strong winds.
• Before tilting the cabin, make
sure that:
• Ensure the vehicle is parked on
the level surface.
• Check that the front of the
vehicle is clear of persons of
objects.
• Ensure that all doors are fully
closed.
CAUTION
Make sure that there are no
loose objects inside the cabin
compartment.
 2. INSTRUMENT AND CONTROLS

2.14.1 Opening the cabin 2. Hold the lever (1) in this position
while moving the open and close
lever (2) outward.

2
1

3. Tilt the cab to its maximum

position and apply the safety
latch.
2.14.2 Closing the cabin

WARNING
1. Remove the safety pin (4) in the
• Take care not to trap your rear side.
or hands when closing
• Place the gear lever in the N the cabin. 2. Lift the lock (6) and release it,
(Neutral) position. holding the handle of cabin.
• Always check that the cabin is
• Apply the Parking brake. closed and locked securely. 3. Pull the cab down with suf
force to ensure that it closes
• Ensure that all doors are fully correctly.
closed.
4. Push the open and close lever
1. Pull the lever (1) outwards to (2) inward until it is heard to click
release the cab catches . in to place.

23
 2. INSTRUMENT AND CONTROLS

2.15 Glove box

1 2

To open the glove box press the latch

lever. To close it push the lid until it
latches securely.

WARNING
Never drive with glove box lid
open, it could cause injury if an
accident occurs.

24
 3. PRE-DRIVING CHECKS AND ADJUSTMENTS

CHAPTER

3. PRE-DRIVING CHECKS AND ADJUSTMENTS

3.1 Key ......................................................................................................................................................26
3.2 Door locks ............................................................................................................................................26
3.2.1 Locking the doors with key ............................................................................................................26
3.2.2 Locking the doors without key .......................................................................................................26 3
1
3.2.3 Fuel cap with key ..................................................................................................................27
3.3 Seats ...................................................................................................................................................27
3.3.1 Forward and backward .................................................................................................................27
3.3.2 Reclining .....................................................................................................................................28
3.3.3 Tilting the seats ............................................................................................................................28
3.4 Window ................................................................................................................................................28
3.4.1 Window adjustment ......................................................................................................................28
3.4.2 Rear view window ........................................................................................................................28
3.5 Seat Belts.............................................................................................................................................28
3.5.1 Seat belt maintenance ..................................................................................................................30
3.6 3-Point type with retractor ......................................................................................................................30
3.6.1 Fastening the belts .......................................................................................................................30
3.6.2 Unfastening the belts ....................................................................................................................30
3.6.3 Checking seat belt operation .........................................................................................................30
3.6.4 Shoulder belt for Co-driver ............................................................................................................31
3.7 Parking brake lever ...............................................................................................................................31
3.8 Outside rear view mirror ........................................................................................................................31
3.9 Inside rear view mirror ...........................................................................................................................31

25
 3. PRE-DRIVING CHECKS AND ADJUSTMENTS
3.1 Key
0000
1 3
Record the key number on the key
plate/metal tag and keep it in a safe
place, The vehicle comes with a pair
of identical keys. Keep the spare
keys in a safe place. If you lose your
keys, contact your AL LCV Dealer for
duplicates by using the key number.
CAUTION
Do not leave the ignition key
inside the vehicle when leaving
the vehicle.
26
3.2 Door locks
3.2.1 Locking the doors with key
To lock the door from outside the
vehicle, insert the key and turn the
top of the key anticlockwise.
To unlock the door from outside the
vehicle, insert the key and turn the
top of the key clockwise.
3.2.2 Locking the doors without
key
A latch and lock knob is provided
on the inside of the driver / co-driver
side of the door to facilitate the safe
opening and closing for entry and
exiting the vehicle.
To open the door from inside, insert
a from the side gap provision
on the latch lever and pull the lever
gently, this action opens the lock and
further pushing opens the door.
To close and lock the door, from
inside, pull the door while lifting the
lever gently and release while the
door is with the body the lever
locks the door in position. To prevent
the door from opening accidently,
Push the lock knob down, To open
lift the lock knob and lift the latch and
push the door.
Note
The driver's door cannot be locked
from the outside without a key.
Use the key to lock the door. This
is to prevent the door lock from
accidentally being locked with the
key inside the vehicle.
 3. PRE-DRIVING CHECKS AND ADJUSTMENTS

Note
WARNING CAUTION
After adjustment, be sure that the
Before opening the door, always Fuel may be under pressure. Turn seat is securely locked by slightly
look for and avoid oncoming the cap one-half turn and wait for rocking the seat.
traf any “hissing” sound to stop, to
prevent fuel from spraying out and
3.2.3 Fuel cap with key possible personal injury. 3.3.1 Forward and backward

Proto bracket
Filter Fuel Filter
Bracket
Note
3
1
Tupe

Return hose Use only a genuine AL fuel cap

Pre-filter
as a replacement. It has a built-in
Fuel Tank
safety valve needed for proper
operation of the fuel system. An
incorrect cap can result in a serious
malfunction and possible injury.

The fuel tank is located on the Right Pull the lever up and hold it while you
hand side of the vehicle. slide the seat forward or backward
The fuel cap is located on the 3.3 Seats to the desired position. Release the
top of the fuel tank. Seat Adjustment lever to lock the seat in position.

The fuel cap can be unlocked by

using the key provided. WARNING
Do not adjust the driver's seat
while driving. The seat may move
suddenly and could cause loss of
control of the vehicle.

27
 3. PRE-DRIVING CHECKS AND ADJUSTMENTS
3.3.2 Reclining
1 3
Pull the lever up and lean back until
the desired angle is obtained. To
bring the seatback forward again,
pull the lever and move your body
forward. The seatback will move
forward.
WARNING
The seat back should not be
reclined any more than needed
for comfort. Seat belts are most
effective when the passenger sits
well back and straight up in the
seat. If the seat back is reclined,
the risk of sliding under the lap belt
and being injured is increased.
28
3.3.3 Tilting the seats
Move the lever to tilt down the seat
back.
3.4 Window
3.4.1 Window adjustment
Raise or lower the door window by
turning the handle located on the
door panel.
3.4.2 Rear view window
Rear window glass
Weather strip
Rear view window is provided in the
rear of the cabin for better visibility
and accessibility for the co-driver to
the cargo deck area.
3.5 Seat Belts
Precautions On Seat Belt Usage
Note
AL strongly encourages you and
your co-driver to buckle up every
time you drive. Your chances of
being injured in an accident and/or
the severity of injury may be greatly
reduced if you are wearing your seat
belt and it is properly adjusted.

WARNING
Seat belts are designed to bear
upon the bony structure of the
body, and should be worn low
across the front of the pelvis, or
the pelvis, chest and shoulders, as
applicable; wearing the lap section
of the belt across the abdominal
area must be avoided. Serious
injury can occur if seat belt is not
worn properly.
u show no damage and continue
3. PRE-DRIVING CHECKS AND ADJUSTMENTS
WARNING
• No or additions
should be made by the user
which will either prevent the
seat belt adjusting devices
from operating to remove
slack, or prevent the seat belt
assembly from being adjusted
to remove slack.
• Seat belts should be adjusted
as as possible,
consistent with comfort, to
provide the protection for which
they have been designed. A
slack belt will greatly reduce
the protection afforded to the
Wearer.
Note
• Care should be taken to avoid
contamination of the webbing with
polishes, oils and chemicals, and
particularly battery acid. Cleaning
may safely be carried out using
mild soap and water. The belt
should be replaced if webbing
becomes frayed, contaminated or
3
1
damaged.
• It is essential to replace the entire
assembly after it has been worn in
a severe impact even if damage
to the assembly is not obvious.
• All seat belt assemblies including
retractors and attaching hardware
should be inspected after any
collision at your AL LCV Dealer.
AL recommends that all seat
belt assemblies in use during a
collision be replaced unless the
collision was minor and the belts
to operate properly. Seat belt
assemblies not in use during a
collision should also be inspected
and replaced if either damage or
improper operation is noted.
29
 3. PRE-DRIVING CHECKS AND ADJUSTMENTS
3.5.1 Seat belt maintenance
• To clean the seat belt
webbings, apply a mild
soap solution or any solution
recommended for cleaning
upholstery or carpets. Then
brush it, wipe with a cloth and
allow it to dry in the shade. Do
3 not allow the seat belts to retract
1 until they are completely dry.
• If dirt builds up in the shoulder belt
guide of the seat belt anchors,
the seat belts may retract slowly.
Wipe the shoulder belt guide with
a clean, dry cloth.
• Periodically check to see that
the seat belt and the metal
components such as buckles,
retractors, wires and
anchors work properly. If loose
parts, deterioration, cuts or other
damage on the webbing is found,
the entire belt assembly should
be replaced.
30
3.6 3-Point type with retractor
3.6.1 Fastening the belts
1. Adjust the seat.
2. To fasten the seat belt, sit
up straight and well back in
the seat, pull the latch plate
attached to the seat belt across
your body and press it into the
buckle until you hear a “click”
sound.
3. Position the lap belt portion low
on the hips as shown.
4. Pull the shoulder belt portion
toward the retractor to take up
extra slack.
WARNING
• The seat belt should rest on the
middle of the shoulder. It must
not rest against the neck.
• Make sure that the seat belt is
not twisted in any way.
3.6.2 Unfastening the belts
To unfasten the belt, push the red
“PRESS” button on the buckle and
allow the belt to retract.
3.6.3 Checking seat belt operation
Your seat belt retractors are
designed to lock belt movement by
two separate methods:
1. When the belt is pulled quickly
from the retractor.
2. When the vehicle slows down
rapidly.
To increase your in the
belts, check the operation as follows:
Grasp the shoulder belt and pull
quickly forward. The retractor

should lock and restrict further belt
movement.
If the retractor does not lock during
these checks or if you have any
question about belt operation contact
your AL LCV Dealer.
3.6.4 Shoulder belt for Co-driver
Shoulder Belt
Shoulder belt is provided in the
co-driver area for co-driver safety.
3. PRE-DRIVING CHECKS AND ADJUSTMENTS
3.7 Parking brake lever
To apply: Press the button and pull
the lever up.
To release: Push the button and
pull the lever up slightly, and lower
completely. Before driving, be sure
the parking brake warning light goes
out.
3.8 Outside rear view mirror
Adjust the outside rear view mirror so
that you can just see the side of your
vehicle in the mirror.
3.9 Inside rear view mirror
3
1
You can adjust the inside rear view
mirror by hand so as to see the rear
of your vehicle in the mirror.
To adjust the mirror move the mirror
up, down or sideways by hand to
obtain the best view.
CAUTION
Be careful when judging the size
or distance or other object seen in
the mirror.
31
 4. STARTING AND DRIVING

CHAPTER

4. STARTING AND DRIVING

4.1 Break-In schedule .................................................................................................................................34
4.2 Before starting the engine......................................................................................................................34
4.3 Precautions when starting and driving ....................................................................................................34
4.3.1 Exhaust gas (Carbon Monoxide) ...................................................................................................34
4.3.2 To help prevent damage ...............................................................................................................35
4.3.3 Care when driving ........................................................................................................................35

4
4.3.4 Engine cold start period ................................................................................................................35
4.3.5 Loading the baggage ....................................................................................................................35 1
4.3.6 When the road is wet or under winter conditions.............................................................................35
4.4 Ignition switch .......................................................................................................................................36
4.5 Starting the engine ................................................................................................................................36
4.6 Driving with manual transmission ...........................................................................................................36
4.6.1 Driving the vehicle ........................................................................................................................36
4.6.2 Driving precautions.......................................................................................................................37
4.6.3 Suggested shift-up speeds............................................................................................................37
4.7 Parking.................................................................................................................................................37
4.8 Precautions when driving.......................................................................................................................38
4.8.1 Driving uphill ................................................................................................................................39
4.8.2 Driving downhill............................................................................................................................39
4.9 Cold weather driving..............................................................................................................................39
4.10 Corrosion protection ............................................................................................................................39

33
 4. STARTING AND DRIVING
4.1 Break-In schedule • Fasten seat belts and ask 4.3 Precautions when starting
co-driver to do likewise. and driving
these recommendations for the • Do not place hard or heavy 4.3.1 Exhaust gas (Carbon
future reliability and economy of your objects on either the front or rear Monoxide)
new vehicle. parcel shell to prevent injury in
the event of a sudden stop. WARNING
• Do not accelerate hard in top
gear. • Check the operation of warning • Do not breathe exhaust
lights when key is turned to the gases; they contain
• Avoid quick starts and full "ON“ position. colorless and odorless
acceleration. carbon monoxide. Carbon
• Avoid hard stops as much as WARNING monoxide is dangerous. It
possible. can cause unconsciousness

4 •
km.
4.2 Before starting the engine
• Make sure the area around the
vehicle is clear.
• adequately.
oil, coolant and brake.
• Check that all windows and light
lenses are clean.
• Visually inspect tires for their
appearance and condition. Also
check tire pressure for proper
• Lock all doors.
The driving characteristics of
your vehicle can be changed
remarkably by any additional
load. Your driving style and
speed have to be adjusted
accordingly. Especially when
carrying heavy loads, your
speed must be reduced
or death.
• If you suspect that exhaust
fumes are entering the
vehicle, drive with all
windows fully open, and
have the vehicle inspected
immediately.
• Do not run the engine in
closed spaces such as a
garage.
• Do not park the vehicle with
the engine running for any
extended length of time.
• It is not advisable to sit
for any length of time in
a parked vehicle with the
engine running and A/C ON.

• Adjust inside and outside mirrors.

34

4.3.2 To help prevent damage
CAUTION
• Keep your engine tuned
up. Malfunctions in the fuel
injection or electrical systems
can cause over rich fuel
into the engine, causing it to
overheat.
WARNING
Do not keep driving if the
engine or if noticeable
loss of performance or other
unusual operating conditions
are detected. Have the vehicle
inspected promptly by an
authorized AL LCV Dealer.
4. STARTING AND DRIVING
(coupling devices, roof baggage
CAUTION
carriers, etc.) will change the
driving characteristics of the vehicle
• Avoid driving with an extremely
low fuel level. Running out of considerably. Driving style and
fuel could cause the vehicle speed must be changed according
to not start due to air lock or to the circumstances.
engine to or damage
4.3.6 When the road is wet or
the catalytic converter.
under winter conditions
• Do not race the engine while
• Avoid quick acceleration and
warming it up.
sudden braking.
• Do not push or tow your vehicle
• Avoid sharp turns or lane
to start the engine.
4
changes.
4.3.3 Care when driving • Suf distance to be
1
Driving your vehicle to the maintained from the vehicle in
circumstances is essential for your front.
safety and comfort. As a DRIVER, • When water covers the road
you should be the one who knows surface in puddles, small
best how to drive in the given streams, etc, REDUCE SPEED
circumstances. to prevent aquaplaning which will
4.3.4 Engine cold start period cause skidding and loss of control
(worn tires increase this risk).
Due to the higher engine speeds
when the engine is cold, extra
caution must be exercised when
selecting gear during engine
warm-up period after starting the
engine.
4.3.5 Loading the baggage
Loads and their distribution and
the attachment of equipment
35
 4. STARTING AND DRIVING

4.4 Ignition switch

CAUTION
Do not keep the ignition switch in
“ON” or “ACC” position for longer
time, if it is not followed leads to
complete battery drain.
"ON" Normal operating position.
CAUTION
Do not crank the engine for more
than 15 seconds at a time. If
the engine does not start, wait
30 seconds and remove the key
before cranking again otherwise
the starter could be damaged.

0000
The switch includes the anti-theft
4 steering lock device.
"LOCK" Normal parking position
The ignition key can only be removed
at this position .
This position turns on the ECU and
fuel pump.
4.6 Driving with manual
transmission
"START" This position starts the
engine. As soon as the engine has
started, release the key immediately.
It will automatically return to the "ON"
position.

To lock the steering wheel, remove 4.5 Starting the engine

the key. To unlock the steering
wheel, insert the key and turn it
gently while rotating the steering
wheel slightly right and left .
"ACC" (Accessories) This position
activates electrical accessories such
as the radio, instrument cluster lamp
when the engine is not running.
1. Move the gearshift lever to "N"
(Neutral).
2. Ensure that the service lamp is 4.6.1 Driving the vehicle
off before starting the vehicle.
1. Depress the clutch pedal to the
3. Start the engine. and move the gearshift
lever to the "1" or "R" position.
4. Keep the engine idle for atleast
30 seconds. Do not accelerate 2. Slowly depress the accelerator
the engine immediately after pedal, releasing the clutch pedal
starting to avoid damage to the at the same time.
turbocharger.

36

4.6.2 Driving precautions
To change gears, fully depress the
clutch pedal, then move the gearshift
lever. After shifting, release the
clutch slowly.
If it is dif to move the shift lever
into Reverse or 1st, shift into Neutral,
then release the clutch pedal and
shift into Reverse or 1st again.
CAUTION
• Do not rest your foot on the
clutch pedal while driving. This
may cause clutch damage.
• Stop your vehicle completely
before shifting into reverse.
• When you are shifting from
one gear to another, be certain
to press the clutch pedal all
the way to the to avoid
clashing or chipping the gears.
4. STARTING AND DRIVING
road conditions, the weather and
CAUTION
individual driving habits.
• Avoid abrupt starts and
acceleration for your safety. Gear Change Km/hr
• When quick acceleration is 1st to 2nd 10
required for some reason, shift
to a lower gear and accelerate
2nd to 3rd 20
until the vehicle reaches the
maximum speed in each gear.
Do not exceed the speed 3rd to 4th 35
limit of any gear. Pay special
attention when accelerating or 4th to 5th 50
4
when shifting into a lower gear
on slippery surfaces. Sudden The listed refer to potential 1
acceleration or down shifting speed ranges for each gear. The
could cause the wheels to skid
speed at which you drive, however,
and result in loss of control.
should conform to all territory laws,
• Keep the engine idle for atleast and to the condition which will permit
20 seconds before switching safe operation.
off the engine, this will allow
engine oil to lubricate the
turbocharger. 4.7 Parking
4.6.3 Suggested shift-up speeds CAUTION
The following provides suggested
Do not park the vehicle over
speed ranges for shifting into a
materials such as dry
higher gear. These suggestions
grass, waste paper or rags, as
relate to fuel economy and vehicle
they may burn easily.
performance. Actual shift ranges
should be adjusted for
Safe parking procedures require that
the parking brake be set and the
37
 4. STARTING AND DRIVING
gearshift lever placed in the proper
position.
1. Firmly apply the parking brake.
2. When parking, make sure the
gear shift lever for manual
transmission vehicles is in 1st
gear or “R” (Reverse).
3. Turn the ignition key to the
"LOCK" position and remove
the key.
4 WARNING
Never leave the engine running
while the vehicle is unattended.
When parked on a sloping driveway.
Turn the wheels so the vehicle will
not roll into the street in case it
moves.
1 3
Uphill or Downhill
no curb
2 • Always park your vehicle where it
Uphill with curb
38
• HEADED DOWNHILL: 1
Turn the wheels into the curb,
allow the vehicle to move forward
until the curb side wheel gently
touches the curb. Then set the
parking brake.
• HEADED UPHILL: 2
Turn the wheels away from the
curb and allow the vehicle to
move back until the curb side
wheel gently touches the curb.
Then set the parking brake.
• HEADED UPHILL OR
DOWNHILL, NO CURB: 3
Turn the wheels toward the side of
the road so the vehicle will move
away from the center of the road
if it moves. Then set the parking
brake.
When leaving your vehicle
unoccupied:
• Always remove the ignition key -
even in your own garage.
• Close all windows completely and
lock all doors.
can be seen, at night, park in a
well lit area.
• Do not leave valuables on view to
tempt a thief. Always take your
valuables with you. If you must
leave something in your vehicle,
lock it in the glove box or hide it
out of sight.
• Do not leave the vehicle
documents in your vehicle. In the
unfortunate event of your vehicle
being stolen the documents will
only help a thief to sell the vehicle.
• Do not leave articles on a roof
rack as they are particularly
vulnerable. If possible, remove
them from the rack and lock them
in the glove box in the vehicle.
• Do not leave the spare key in the
vehicle - keep it in a safe place in
your home.
• Do not leave a note of your
vehicle key number in the vehicle.
A thief may break into the vehicle,
note the key number and return
with a key to enter and drive the
vehicle.
4.8 Precautions when driving
1. Driving with vacuum assisted
brake:
The brake booster aids braking
by using engine vacuum. If

the engine stops or the drive
belt is broken, you can stop the
vehicle by depressing the brake
pedal. However, greater foot
pressure on the brake pedal will
be required to stop the vehicle
and the stopping distance will be
longer.
2. Wet brakes:
• When the vehicle is washed
or driven through water, the
brakes may get wet. As a
result, your braking distance
will be longer and the vehicle
may pull to one side during
braking.
• To dry brakes, drive the
vehicle at a safe speed while
lightly pressing the brake
pedal to heat-up the brakes.
Do this until the brakes return
to normal. Avoid driving the
vehicle at high speeds until
the brakes function correctly.
3. Avoid resting your foot on the
brake pedal while driving. This
will overheat the brakes, wear
out the brake linings and pads
faster and reduce mileage.
4. To help save the brakes and
to prevent the brakes from
overheating, before going down
a slope or long grade, reduce
speed and downshift to a lower
gear.
5. While driving on a slippery
surface, be careful when
braking, accelerating or
downshifting. Abrupt braking
actions or sudden acceleration
could cause the wheels to skid.
4.8.1 Driving uphill
When starting on a steep grade,
it is sometimes dif to operate
both the brake and clutch. Use the
parking brake to hold the vehicle.
Do not slip the clutch. When ready
to start, slowly release the parking
brake while depressing accelerator
pedal and releasing the clutch.
4.8.2 Driving downhill
The engine braking action is effective
for controlling the vehicle while
descending hills. The gearshift lever
should be placed in the lower speed
position prior to descending.
4.9 Cold weather driving
Battery
If the battery is not fully charged
during extremely cold weather
4. STARTING AND DRIVING
conditions, the battery may
freeze and damage the battery. To
maintain maximum ef , the
battery should be checked regularly.
For details, see "Battery" in the
“Maintenance and Do-it-yourself”
section.
4.10 Corrosion protection
Chemicals used for road surface
de-icing are extremely corrosive
and will accelerate corrosion and
4
the deterioration of underbody
components such as the exhaust 1
system, fuel and brake lines, brake
cables, pan and fenders.
Note
In winter, the underbody must be
cleaned periodically. For more
detailed. information concerning
cleaning the exterior to protect it
from corrosion, please refer to the
"Appearance and interior care" of
this Manual.
For additional protection against
rust and corrosion, which may be
required in some areas, consult your
local AL LCV Dealer.
39
 5. APPEARANCE AND INTERIOR CARE
CHAPTER

5. APPEARANCE AND INTERIOR CARE

5.1 Cleaning exterior and interior .................................................................................................................42
5.1.1 Washing ......................................................................................................................................42
5.1.2 Removing spots ...........................................................................................................................42
5.1.3 Underbody ...................................................................................................................................42
5.1.4 Cleaning glasses..........................................................................................................................42
5.1.5 Cleaning interior ...........................................................................................................................43
5.1.6 Seat belts ....................................................................................................................................43
5.2 Protecting against corrosion...................................................................................................................43
5.2.1 Environmental factors the rate of corrosion: .....................................................................43
5.2.2 To protect your vehicle from corrosion:...........................................................................................43
5.3 Precautions for electronic diesel control system (EDC) during welding operation .......................................44
5

41
 5. APPEARANCE AND INTERIOR CARE
5.1 Cleaning exterior and When it is necessary to park outside,
interior park in a shady area or protect the
In order to maintain the appearance
of your vehicle, it is important to take
proper care of it.
5 In the following cases, please wash
your vehicle as soon as possible to
protect the paint surface.
• After driving on coastal roads.
• When things such as soot,
bird droppings, tree sap, metal
particles or insects get on the
paint surface.
• When dust or mud builds up on
the surface.
Whenever possible, store or park
your vehicle inside a garage or in a
covered area.
42
vehicle with a body cover.
5.1.1 Washing
Wash dirt off with a wet sponge and
plenty of water. Clean the vehicle
thoroughly using a mild soap or
detergent (a special vehicle soap or
general purpose dish washing liquid)
mixed with clean, lukewarm (never
hot) water.
CAUTION
• Do not use strong household
soap, strong chemical
detergents,
solvent.
gasoline or
• Do not wash the vehicle
in direct sunlight or while
the vehicle body is hot, as
the surface may become
water-spotted.
Rinse the vehicle thoroughly with
plenty of clean water.
Inside seams and folds
on the doors, hatches and hood
are particularly endangered by the
effects of road salt. Therefore, these
areas must be regularly cleaned.
Take care that drain holes in the
lower edge of the door are open.
Spray water under the body and in
the wheel to loosen the dirt and wash
it away.
A damp cloth can be used to dry the
vehicle to avoid water spot.
5.1.2 Removing spots
Remove tar and oil spots, industrial
dust, insects and tree sap as quickly
as possible from the surface of the
paint to avoid lasting damage or
straining. Special cleaning products
are available at your AL LCV dealer
or any automotive accessories store.
5.1.3 Underbody
In areas where road salt is used in
winter, it is necessary to clean the
underbody regular in order to prevent
dirt and salt from building up and
causing corrosion on the underbody
and suspension.
5.1.4 Cleaning glasses
Using glasses cleaner, remove
smoke and dust from the glass
surface. It is normal for glasses to be
coated with a after the vehicle is
parked in the hot sun. Glass cleaner

and soft clothes easily remove this
When cleaning the inside of the
windows, do not use any sharp-edge
tools or abrasive cleaners or
chlorine-based disinfectant cleaners.
(These may damage the electrical
conductors or rear window defogger
elements.)
5.1.5 Cleaning interior
Occasionally remove loose dust
form the interior trim, plastic parts
and seat using a vacuum cleaner or
soft brush. Before using any fabric
protector, read the manufacturers
recommendations. Some fabric
protectors contains chemicals that
stain or bleach the seat material.
• Never use benzine, thinner or any
similar material.
• Never use fabric protectors
unless recommended by the
manufacturer.
5.1.6 Seat belts
The seat belts can be cleaned
by wiping them with a sponge
dampened in a mild soap solution.
Allow the belts to dry completely
before using them. Do not allow wet
5. APPEARANCE AND INTERIOR CARE
belts to roll up in the reactor. NEVER especially those areas where the
use bleach, dye or chemical solvents temperatures stay above freezing
since these may severely weaken and where atmospheric pollution
the seat belt webbing. exists and road salt is used.
5.2 Protecting against Temperature
corrosion A temperature increase will
Most common factors contributing to accelerate the rate of corrosion
vehicle corrosion: to those parts which are not well
1. The accumulation of ventilated.
moisture-retaining dirt and Air pollution
debris in body panel sections,
cavities, and other areas. Industrial pollution, the presence of
salt in the air in coastal areas, or
2. Damage to paint and other
protective coatings caused by heavy road salt use will accelerate
gravel and stone chips or minor the corrosion process. Road salt will
traf accidents.
5.2.1 Environmental factors
the rate of
also accelerate the disintegration of
paint surface. 5
5.2.2 To protect your vehicle from
corrosion: corrosion:
Moisture
• Wash and wax your vehicle often
The accumulation of sand, dirt and to keep the vehicle clean.
water on the underside of the body
• Always check for minor damage
will accelerate corrosion. Floor to the paint and repair it is as soon
section which have snow and ice as possible.
trapped under the matting will
• Keep drain holes at the bottom
not dry.
of the doors and tailgate open to
Relative humidity avoid water accumulation.
Corrosion will be accelerated in • Check the underbody. If
areas of high relative humidity, any sand, dirt, or salt has
43
 5. APPEARANCE AND INTERIOR CARE
accumulated, wash it off with
water as soon as possible.
WARNING
Never allow water or other liquids
to come in contact with electronic
components inside the vehicle.
Chemicals used for road surface
de-icing are extremely corrosive.
They accelerate corrosion and
deterioration of underbody
components such as the exhaust
system, fuel and brake lines, brake
cables, pan and fender.
5
In winter, the underbody must be
cleaned periodically.
For additional protection against
rust and corrosion, which may be
required in some areas, consult your
local AL LCV Dealer.
5.3 Precautions for electronic
diesel control system (EDC)
during welding operation
Extreme care to be taken while
assembling the body on the chassis
with respect to the ECU.
General
44
1. The ECU should be disconnected
from the harness and a dummy cap /
cover with plastic bags should be put
on the ECU connector. There should
be no ingress of water through the
wiring harness on the ECU.
2. The ECU as such should be
covered in a box so that if any
washing is done, the ECU will be
protected.
3. Maximum cleanliness in the
work area and the tools should be
employed. Check to see if the ECU
has become dirty during the body
building phase especially at the
connector end and pins. Use a soft
clean & dry paint brush to remove
the dust.
4. For connecting and disconnecting
the ECU from the wiring harness,
Follow the recommendations of AL.
5. ECUs must be connected or
disconnected to the wiring harness
only when the ignition is OFF.
6. No undue pressure should be
applied on the ECU during the
connector assembly process.
EDC system
Have a clear space in front of the
EDC panel cover for easy removal
and of electrical / electronic
parts of EDC panel.
Instructions
1. Before and during welding
- Disconnect battery terminals (First
remove the negative terminal and
then remove the positive terminal of
12V supply).
- Disconnect Two connectors of
the ECU and have the panel cover
- Do not use Accelerator Pedal as a
support during body building.
- Avoid falling of any sharp / Heavy
objects on the accelerator pedal
module and its connecting wire.
2. Before connecting the engine
wiring harness. the battery
terminals (Both positive and negative
terminals) are to be disconnected.
3. Make sure that the lock of the
connectors are properly.
4. Wrap insulation tape where-ever
the taping has been taken. Make

sure that no part of the wire is left
un-insulated.
Do’s and Dont’s for Body builders
1. Electrical tapping not allowed from
EDC wiring. Tapping should NOT be
taken as this can severely affect the
performance of the ECU and sensor.
2. Care should be taken while
washing the vehicle. Do not splash
water directly on to the ECU,
accelerator pedal sensors and other
electrical components.
3. Diagnostic connector should not
be left hanging loose and should be
handled with care.
5. APPEARANCE AND INTERIOR CARE
7. No intermittent connector in
the EDC wiring system should be
practiced.
8. Keep the ignition “Switch
Off” while removing the battery
connections in the vehicle.
9. Correct tightening torques should
be used for mounting the ECU .
10. Mounting position of the ECU
should not be changed.
11. ECU must be connected or
disconnected only when the power
is switched off / ignition switch is in
off position.

12. No undue pressure to be applied

5
4. Reverse polarity protection:
Care needs to be taken while on the ECU during servicing.
removing the battery connection
during body building or otherwise to
reconnect the terminals in correct
polarity.
5. Check the battery condition
regularly and keep the batteries in
healthy condition.
6. Ensure proper connectivity of
ECU / sensor connectors with wiring
harness.

45
 6. INCASE OF EMERGENCY
CHAPTER

6. IN CASE OF EMERGENCY
6.1 Flat tire.................................................................................................................................................48
6.1.1 Stopping the vehicle .....................................................................................................................48
6.1.2 Jack and Jack handle location.......................................................................................................48
6.1.3 Fire Extinguisher Location.............................................................................................................48
6.1.4 Spare wheel carrier ......................................................................................................................48
6.1.5 Blocking wheels ...........................................................................................................................49
6.1.6 Jacking up and removing tire.........................................................................................................49
6.1.7 Installing wheel ............................................................................................................................51
6.2 If engine overheats................................................................................................................................52
6.3 Towing..................................................................................................................................................52
6.4 Driving Instructions................................................................................................................................53

6
1

47
 6. INCASE OF EMERGENCY
6.1 Flat tire
If you have a tire, follow the
instructions
6.1.1 Stopping the vehicle
1. Safely move the vehicle off the
road away from traf
2. Turn on the hazard warning
.
3. Park on a level surface and
apply the parking brake. Shift
the manual transmission into
reverse.
4. Turn off the engine.
5. Place advance warning triangle
Min 50m behind the vehicle.
6
WARNING
Never change tires when
the vehicle is on a slope or
soft uneven ground. This is
dangerous.
48
6.1.2 Jack and Jack handle
location
The jack, jack handle and Tool kit
are located on the panel behind the
driver seat.
1. Jack mounted by bolt.
2. Jack rod mounted by snap
clips welded in cab rear panel.
3. Tool kit vertically mounted and
locked by belt assembly clamp.
6.1.3 Fire Extinguisher Location
6.1.4 Spare wheel carrier
2820 Wheel base
Jack rod
accessibility
in Rear Side
Removal procedure:
Spare wheel carrier is provided on
the rear side of the frame.
• Loosen the M14 lock nuts from
mechanism.
• Insert jack rod through frame last
cross member and ensure Jack
rod slot portion has been locked
in mechanism.
• After locking, rotate the jack
rod anti clock wise to move tire
downwards.
• Same procedure is followed in
reverse for assembly. In addition
to following the below points.

Before tyre lifting, spare wheel
mechanism bottom plate bolt to be
inserted in to wheel rim two holes.
After tyre lifting, Mechanism bottom
plate bolt to be align with spare wheel
mounting bracket holes. Which is
mentioned by letter 2.
3320 Wheel base
Removal procedure:
Spare wheel carrier is provided on
the rear side of the frame.
• Loosen the M14 lock nuts from
mechanism.
• Insert jack rod through frame LH
side member and ensure Jack rod
slot portion has been locked in
mechanism.
• After locking, rotate the jack
rod anti clock wise to move tire
downwards.
• Same procedure is followed in
reverse for assembly. In addition
to following the below points.
Before tyre lifting, spare wheel
mechanism bottom plate bolt to be
inserted in to wheel rim two holes.
After tyre lifting, Mechanism bottom
plate bolt to be align with spare wheel
mounting bracket holes. Which is
mentioned by letter 3.
CAUTION
Be careful not to loosen the
hanger nut excessively, otherwise
the hanger will fall suddenly.
6.1.5 Blocking wheels
6. INCASE OF EMERGENCY
Place suitable blocks at both
the front and back of the wheel
diagonally opposite the tire.
Note
It is recommended that the wheels
of the vehicle be chocked, and that
no person should remain inside the
vehicle that is being jacked.
6.1.6 Jacking up and removing
tire
WARNING
To help avoid personal injury,
carefully read the caution label
attached to the jack body and
the following instructions.
1. Place the jack directly under
6
1
the jack-up point as shown, so
that top of the jack contacts
the vehicle at the jack up point.
Having located the jack head
use the handle provided for
jacking up the vehicle.
49
 6. INCASE OF EMERGENCY

50

Note
The jack should be used on
level ground wherever
possible. Jack rod used for
remove the wheel nut with the
help of wrench wheel nut.
WARNING
Never jack up the vehicle
more than necessary.
2. Loosen each wheel nut
one or two turns by turning
counterclockwise with the wheel
nut wrench.
Note
Do not remove the wheel nuts
until the tire is off the ground.
3. Carefully raise the vehicle until
the tire clears the ground.
Remove the wheel nuts, and
then remove the tire.
Note the following points while
jacking.
• Never get under the vehicle
while it is supported only by
the jack; use a vehicle support
stand.
• Use the jack provided with your
vehicle. The jack is designed
only for lifting your vehicle
during a tire change.
• Use the correct jack up points;
never use any other part of the
vehicle for jack support.
• Do not start or run engine while
vehicle is on the jack.
• Do not allow passengers to
stay in the vehicle while it is on
the jack.
• Do not raise the vehicle using a
bumper jack.
6.1.7 Installing wheel
6. INCASE OF EMERGENCY
1. Clean any mud or dirt from the
surface between the wheel and
hub.
2. Carefully put the wheel on and
tighten the wheel nuts
tight.
3. With the wheel nut wrench,
tighten wheel nuts alternately
and evenly until they are tight.
4. Lower the vehicle slowly until
the tire touches the ground.
Then, with the wheel nut
wrench, tighten the wheel nuts
securely in the sequence as
illustrated.
• As soon as possible tighten
the wheel nuts.
• Adjust tire pressure.
Tire pressures are shown on the
tire placard af to the driver's
6
1
side lock pillar.
5. Securely store the spare tire
and jacking equipment in the
vehicle.
51
 6. INCASE OF EMERGENCY
6.2 If engine overheats
WARNING
To avoid the danger of being
burned, never remove the
coolant reservoir cap while the
engine is still hot.
If the high coolant temperature
6 indicator comes on while driving
1. Park the vehicle, apply the
parking brake and move the
gear lever to Neutral.
2. Switch off the air conditioning (if
Open all the windows.
3. Tilt the cab. For details,
see“Chapter 2 Instrument and
controls” Do not stop the
engine (unless the belt is
broken).
52
4. Check whether the radiator fan
operates. The radiator hoses
and radiator should not leak
water. If coolant is leaking or
the cooling fan does not run,
stop the engine and contact the
nearest AL LCV Dealer.
WARNING
Be careful not to allow your
hands, hair or clothing to
come into contact with the
fan, belts, or other moving
parts.
5. If none of these faults are
detected when the engine is
running, Switch off the ignition
and wait until the engine cools
down, check the coolant level in
6.
the reservoir tank.
If the level is low, remove the
reservoir cap and add coolant to
MAX level of the reservoir tank.
Then reinstall the cap.
Note
Never water in cooling
system. It comes with premixed
solution of coolant and water.
7. If, after the system,
no leaks are detected, run
the engine and check for high
coolant temperature indicator.
Close the cab and proceed.
If the lamp glows switch off the
engine and contact AL LCV
Dealer.
WARNING
Use only recommended coolant
grade.
6.3 Towing
CAUTION
Never try to start the vehicle by
towing it; when the engine starts,
the forward surge could cause
the vehicle to collide with the tow
vehicle.
1. AL recommends to use a
recovery van for towing the
vehicle.
2. Before towing, ensure that the
Front axle, Steering system,
Gear box and differential are in
good condition.

a. In case of a failure in the
Front axle or steering system,
remove the bumper and put
suitable packing cushion (E.g
old tyre) between tow chain
and cab.
b. In case of a failure in the
gearbox remove the propeller
shaft and tow the vehicle.
c. In case of a failure in the
differential/rear axle, remove
the spare wheel and the
towing chain. Put suitable
packing cushion (E.g old tyre)
between tow chain and load
body.
3. Switch on hazard warning lights.
4. To avoid crash with the towing
vehicle use rigid tow bar. Do not
use rope or cable.
5. Release the parking brake and
place the gear lever in the
neutral position before starting
to tow the vehicle.
6. In case of failure of brakes, use
parking brake to stop the vehicle
while towing.
Note
When towing the vehicle with the
front wheels on the ground, turn
the ignition key to the ACC position
and secure the steering wheel in the
straight ahead position with a rope
or similar device.
6. INCASE OF EMERGENCY
6.4 Driving Instructions
1. If the oil pressure warning light
comes on while driving,
move the vehicle safely off the
road, apply the hand brake
and move the gear lever to N
(Neutral) position. Turn off the
engine. Contact the nearest AL
LCV Dealer to repair the fault.
2. Attention must also be paid to
the battery warning light
when driving. If it lights up
continuously during driving, this
6
1
means that the alternator is not
charging the battery, in this case
the fault must be repaired as
soon as possible as the battery
may be drained by later engine
starts.
53
 7. TECHNICAL INFORMATION

CHAPTER

7. TECHNICAL INFORMATION
7.1 Lubrication charts..................................................................................................................................56
7.2 Lubrication Points .................................................................................................................................57
7.3 Vehicle ..............................................................................................................................58
7.3.1 Vehicle Plate ............................................................................................................58
7.3.2 Engine serial number....................................................................................................................58
7.3.3 Clutch..........................................................................................................................................58
7.3.4 Gear Box .....................................................................................................................................58
7.3.5 Rear Axle.....................................................................................................................................58
7.3.6 Power steering pump....................................................................................................................59
7.3.7 Tire placard..................................................................................................................................59
7.4 Technical ...........................................................................................................................60

7
1

55
 7. TECHNICAL INFORMATION
7.1 Lubrication charts
When follow the procedure instructed in the "Maintenance and Do-it-yourself" section.

RECOMMENDED OILS AND LUBRICANTS WITH FILLING CAPACITY

Ashok Leyland Gulf oil Cobranded Capacity

Aggregate Replacement KM
Lubricant (in liters/gms)

Engine Gulf NxG 9.5 W/Filter 10000

Gear Box KINETIC ALK32 Gulf Gear TX 80W90 40000

Power Steering Gulf Power Steering NxG 1.5 Lit 80000

Rear Axle Gulf Axle NxG 5.2 Lit 40000

ENGINE COOLANT

For Non A/C Version Gulf Eurocool Dura Max 11 Lit 80000 Km / 1 year

Brake / Clutch Fluid Gulf Brake Fluid Plus NxG 1 Lit 20000

GREASE

Propeller shaft UJ cross & spline ends 12 gms 10000/Monthly

Front Axle 200 gms 40000

7 Clutch pedal, Brake pedal, Spare wheel carrier, Steering

wheel, Drag link, track rod and door hinges
Gulf Crown CSC NxG
As required 10000/Monthly

Steering Column 35 gms 10000/Monthly

First 5000 Kms & then
King Pin As required
Every 10,000 Kms/Months

56
 7. TECHNICAL INFORMATION

7.2 Lubrication Points

7
1

57
 7. TECHNICAL INFORMATION
7.3 Vehicle 7.3.2 Engine serial number 7.3.4 Gear Box
7.3.1 Vehicle Plate
The vehicle plate is
XXXX
af as shown in the below XX

It shall show Vehicle

number (VIN), Gross vehicle weight,
Gross combination weight, Axle
loads, Chassis type, Engine type,
Rear axle ratio and Engine number. XXXXXX

The engine serial number is punched The number is punched on the RH

on the LH side rear bottom of the end portion of front casing.
cylinder block below the oil 7.3.5 Rear Axle
7.3.3 Clutch MODE L
ME R ITOR T M
AL1-3200Q-2383
S E R IAL NO 12C 2-00014-H0011

R AT IO 4.56 DAT E AUG 12

Mfd. B y : Automotive Axles Ltd., Mys ore India

Vin Plate
ME R ITOR TM

MODE L AL1-3200Q-2383

S E R IAL NO 12C 2-00014-H0011

R AT IO 4.56 DAT E AUG 12

Mfd. B y : Automotive Axles Ltd., Mys ore India

7
Axle serial number is punched on
The number is located on the disc right side of near banjo housing
cover. cover backside of rear axle.

58
 7. TECHNICAL INFORMATION
7.3.6 Power steering pump

Power steering pump number is

located in the body of the pump at
the rear side.
7.3.7 Tire placard
The cold tire pressures is shown on
the tire placard.

6 - Tyre

Tyre Pressure
TYRE SIZE
7.50 X 16 LT - 16 PR
Kg/cm2
(P.S.I)
2.45
7
1
UNLADEN (35)
FRONT
4.21
LADEN (60)
2.45
UNLADEN (35)
REAR
6.32
LADEN (90)

59
 7. TECHNICAL INFORMATION

ZD30 387 (EURO-III)

87 kW @ 2750 RPM

320 Nm @ 1350-2600 RPM

Diaphragm, Push type, Single dry plate, Non Pre-damper

60
 7. TECHNICAL INFORMATION

280 mm

Kinetic
Fully syncronised 5 speed gearbox Manual

1st - 5.256; 2nd - 3.045;3rd-1.651;4th- 1;5th-0.747;

Rev-5.388
3.4 Litres

No. of Shafts (6 Tire) Wheel Base 3320 mm Double

7
1

61
 7. TECHNICAL INFORMATION

AXLES
Front Rigid Axle
Rear Fully floating, Single speed, Hypoid gears
Rear axle Ratio 4.56:1
Oil Capacity 5.2 Litres
STEERING
Type Hydraulic Assisted Power Steering
Ratio 19.8:1 (PS)
Steering wheel dia 400 mm
Turning Circle Diamater (TCD) (6 - Tire) WB 3320 mm 14800 mm
BRAKES
Service Brakes Vacuum assisted hydraulically actuated brake
Front Brakes Drum – 320 mm x 90 mm
Rear Brakes Drum – 320 mm x 90 mm
EXHAUST BRAKE

7 Type valve with vacuum assisted

FRAME
Type Ladder C construction with riveted & bolted joints

62
 7. TECHNICAL INFORMATION

Frame Dimensions Width – 752 mm max., Height – 170 mm max.

SUSPENSION
Asymmetric Parabolic, overslung suspension with
Front Double acting Shock Absorbers

Semi elliptic (main), Overslung suspension with Double

Rear
acting shock Absorber
Shock absorber Hydraulic double acting telescopic type
FUEL TANK
Capacity 90L

ELECTRICAL SYSTEMS
System voltage 12 V
Alternator capacity 70 Amp Non.Ac

Battery 12V 75Ah

Windscreen wiper Twin speed with intermittent

PERFORMANCE
Maximum Speed 95 kmph 7
1
Maximum Gradeability at rated GVW ) 28%
WHEELS & TIRES
No of wheels 6+1
Front Single

63
 7. TECHNICAL INFORMATION

Rear Twin
Spare Single
Tire size 7.5 x 16 - 16 PR
Rim 5.5F-16

TYRE PRESSURE
UNLADEN
Front 35 Psi
Rear 35 Psi
LADEN
Front 60 Psi
Rear 90 Psi

64
 7. TECHNICAL INFORMATION
Dimenssions
Vehicle Type LONGER WHEEL BASE - 3320 (Partner 7.2T)
Load Body Type Cab chassis Drop Side Deck (DSD)
Variants LES-CC LES
Unladen Front Axle Weight 1385 1437
Unladen Rear Axle Weight 882 1192
Unladen Gross Vehicle Weight 2267 2629
WEIGHTS (in kg) Front Axle Weight 2085 2086
Rear Axle Weight 5115 5114
Gross Vehicle Weight 7200 7200
Rated Payload (in kg) 4933 4571
Wheel Base (‘C’ ) 3320 mm
Overall Length 5865 mm 5990 mm
Overall Height 2240 mm
Overall Width 1850 mm 2060 mm
Front Track 1570 mm
OVER All
Rear Track 1492 mm
DIMENSIONS
Turning Circle Diameter (TCD) 13.5 m

7
Turning Cicle Clearance Diameter (TCCD) 14.8 m
Min. Ground Clearance (Laden @Rear Axle) 220 mm
1
Front Overhang 985 mm
Rear Overhang 1560 mm 1685 mm

65
 8. MAINTENANCE AND DO-IT YOURSELF

CHAPTER

8. MAINTENANCE AND DO-IT YOURSELF

8.1 Maintenance Requirements ...................................................................................................................69
8.2 Maintenance Precautions ......................................................................................................................69
8.3 General Maintenance ............................................................................................................................70
8.4 Check locations ....................................................................................................................................71
8.5 Engine oil .............................................................................................................................................72
8.5.1 Checking engine oil level ..............................................................................................................72
8.5.2 Changing engine oil and oil ....................................................................................................73
8.6 Engine cooling system...........................................................................................................................74
8.6.1 Checking coolant level..................................................................................................................75
8.6.2 Changing engine coolant ..............................................................................................................75
8.7 Fuel ..............................................................................................................................................76
8.7.1 Draining water..............................................................................................................................76
8.7.2 Changing fuel .......................................................................................................................76
8.7.3 Bleeding the fuel system ...............................................................................................................76
8.8 Air .................................................................................................................................................77
8.9 Emission control system ........................................................................................................................77
8.9.1 Exhaust emission control system...................................................................................................77
8.9.2 Maintenance recommendation ......................................................................................................78
8.10 Drive belt ............................................................................................................................................78
8.11 Power steering ............................................................................................................................78
8.12 Windscreen reservoir (If equipped) ................................................................................................79
8.13 Wiper blades.......................................................................................................................................79
8
8.14 Brake / Clutch level ......................................................................................................................80

67
 8. MAINTENANCE AND DO-IT YOURSELF
8.15 Brake conditions .................................................................................................................................80
8.16 Battery................................................................................................................................................81
8.17 Fuses .................................................................................................................................................82
8.18 Lights bulbs ........................................................................................................................................83
8.18.1 Headlamp................... .................................................................................................................83
8.18.2 Rear Fog lamp................................................................................................................ . . . . . . . . . 84
8.19 Bulbs..................................................................................................................................................84
8.19.1 Replacement procedures ............................................................................................................84
8.20 Wheels and tyres ................................................................................................................................ 85

8
68

8.1 Maintenance
Requirements
Your AL vehicle has been designed
to have minimum maintenance
requirements with longer service
intervals to save your time and
money.
However, some day- to - day and
regular maintenance is essential
to maintain good mechanical
conditions as well as its emission
and engine performance.
It is the owner’s responsibility
to make sure that the
maintenance, as well as general
maintenance, is performed. As the
vehicle owner, you are the only one
who can ensure that your vehicle
receives the proper maintenance
care. You are a vital link in the
maintenance chain.
Scheduled maintenance
For your convenience, the required
scheduled maintenance items are
described and listed in a separate
section Warranty and service. You
must refer to that section to ensure
that necessary maintenance is
8. MAINTENANCE AND DO-IT YOURSELF
performed on your AL vehicle at
regular intervals.
General maintenance
General maintenance includes those
items which should be checked
during normal day-to-day operation
of the vehicle. They are essential if
your vehicle is to continue to operate
properly. It is your responsibility to
perform these procedures regularly
as prescribed. These checks or
inspections can be done by yourself
and your AL LCV Dealer.
Where to go for service
If service is required or your
vehicle appears to malfunction,
have the systems checked and
tuned by AL LCV Dealer. AL LCV
Dealer technicians are well-trained
specialists and are kept up to date
with the latest service information
through technical bulletins, service
tips, and in-dealers training
programs completely to
work on your vehicle. You can be
that your AL LCV Dealer
performs the best job to meet the
maintenance requirements on your
vehicle – in a reliable and economic
way. Refer to the list of Authorized
service centres at the end of the
manual.
8.2 Maintenance Precautions
Follow these precautions before
carrying out any inspection or
maintenance work on the vehicle.
Failure to follow these
recommendations could lead to
personal injuries or damage to the
vehicle.
• Park the vehicle on a level
surface, apply the parking brake
and block the wheels to prevent
any accidental movement of the
vehicle. Put the gearshift level in
N (neutral) position.
• Be sure to turn the ignition key
to the LOCK position when
performing any replacement or
repair and also disconnect battery
–ve terminal
• Do not work in the engine
compartment while the engine is
hot. Wait for the engine to cools 8
down.
69
 8. MAINTENANCE AND DO-IT YOURSELF
• If it is necessary to work with • The fuel
the engine running, keep hands,
clothes, hair and tools away
from the fan, belts and any other
moving parts.
• It is not recommended to work
while wearing loose clothing.
Remove any personal objects
such as rings, watch, etc. before
starting work on the vehicle.
• If the engine must be left running
in an enclosed space, it is
necessary to ensure that there is
adequate ventilation to facilitate
the escape of exhaust fumes.
• Never get under the vehicle while
it is only supported by the jack. If
it is necessary to work under the
vehicle, always use safety stands.
• Keep and sparks away
from the battery, fuel tank and
engine compartment.
• Additional electronic equipment
may negatively affect the
correct operation of the vehicle’s
electronic components. It is
therefore forbidden to use such
equipment provision in fuse box
8 for any addition connections. AL
does not accept responsibility for
the consequences of failing to
comply with this point.
70
and fuel lines should
be serviced by a AL LCV Dealer.
The fuel lines are subjected to
very high pressures, even when
the engine is not running.
• The engine oil and/or other
in the vehicle can damage the
environment. Always
local regulations for disposal of
vehicle
• Avoid direct contact with used
engine oil.
CAUTION
The owner should be aware that
incomplete or improper servicing
could cause incorrect operation,
which could affect the warranty
coverage. In case of doubt about
any servicing, contact AL LCV
Dealer.
8.3 General Maintenance
During the normal day-to-day
operation of the vehicle, general
maintenance should be performed
regularly as prescribed in this
section. If you detect any unusual
sounds, vibrations or smell, be sure
to check for the cause or contact
your AL LCV Dealer. In addition, you
should notify your AL LCV Dealer if
you think that repairs are required.
When performing any checks or
maintenance work, closely observe
the Maintenance precautions as
described later in this section.
Note
Additional information on the
following items with “*” is found
later in this section.
Exterior of vehicle
Lights*
Ensure that the headlights, brake
lights, side indicator lights and
reverse lights are functioning well.
Spare wheel*
Ensure that the spare wheel is
secured correctly in its proper
location.
Tyres*
Check and set the tyre pressure
(including the spare wheel) as per
Check for cuts or
excessive wear.
 8. MAINTENANCE AND DO-IT YOURSELF
Doors Steering wheel Check that they are not cut or worn,
etc.
Check that all the doors open and Check for free play, stiffness or
close correctly. Lubricate the locks, strange noises.
hinges, etc, if necessary. Windscreen washer (If
8.4 Check locations

Note equipped)

If you drive in industrial areas or Check the level in the reservoir.

on roads covered with salt or other Engine coolant*
corrosive materials, lubricate these
Check the coolant level when the
points frequently.
engine is cold.
Engine oil*
Windscreen wiper blades* XXXX
XX

Check the level on a surface

Check for breaks or wear and when the engine is hot (with off
whether areas of the windscreen condition).
remain dirty when the wipers are Brake / Clutch
used.
Check that the level is between
Battery* the “MAX” and “MIN” marks on the
reservoir.
Check that the level of electrolyte in
each cell and add distilled water if Power steering *
required. Check that the level is between the
“MAX” and “MIN” marks with the
Interior of vehicle Check for oil leaks from the following
engine cold.
locations:
Instrument panel
8
Seat belts
1. Engine oil dipstick (1)
Ensure that the gauges and audio (if Check that the buckles,
are operating correctly. retractors and adjustment devices 2. Engine oil (2)
function and are correctly installed. 3. Engine oil cap (3)

71
 8. MAINTENANCE AND DO-IT YOURSELF
4
3. Turn off the engine. Wait a few Note
minutes for the oil to drain
It is normal to add some engine oil
back into the sump.
between oil maintenance intervals
4. Tilt the cab (Refer cab tilting depending on the severity of
procedure in chapter 2) for operating conditions or depending
accessing the dipstick to check
on the property of the engine
the engine oil.
oil used. More engine oil is
5 5. Remove the dipstick and wipe it consumed by frequent acceleration
clean. Reinsert it all the way. / deceleration especially when the
6. Remove the dipstick again engine rpm is high.
1. Check for fuel leaks around the
fuel tank area (4). and check the oil level. It Consumption is likely to be higher
should be between the MIN and
2. Check the battery condition (5). when the engine is new.
MAX range. If the oil level is
8.5 Engine oil below MIN remove the oil
cap and pour recommended
8.5.1 Checking engine oil level oil through the opening until
reaches (MAX). Do not CAUTION

7. Recheck the oil level with the Oil level should be checked
dipstick. DAILY. Operating with insuf
8. Close the cab (Refer cab closing amount of oil can damage the
procedure in chapter 2). engine, and such damage is not
covered by the warranty.

1. Park the vehicle on a level

8 surface and apply the hand

brake.
2. Run the engine until it reaches
operating temperature.

72
 8. MAINTENANCE AND DO-IT YOURSELF
8.5.2 Changing engine oil and oil

WARNING
• Used oil must not be poured
into the ground, canals, rivers,
etc. It should be disposed of
at a rubbish tip having proper
facilities. We recommend
having your oil changed by AL
LCV Dealer. 5. Place a container under the Clean and re-install the drain
drain plug and the oil . plug. Securely tighten the drain
1. Park the vehicle on a horizontal plug with a wrench. Do not use
surface and apply the parking 6. Remove the drain plug with a
wrench and completely drain the excessive force.
brake.
oil then remove the oil as 7. Coat the seal of the new
2. Allow the engine to run shown in the with engine oil.
until it reaches its operating
temperature, then turn the
engine off.
3. Tilt the cab (Refer cab tilting
procedure in chapter 2).
4. Remove the oil cap.

8. Screw the oil into place by

hand until a slight resistance is
felt, and then tighten additionally
8
3/4th turn.

73
 8. MAINTENANCE AND DO-IT YOURSELF
9. engine with recommended
oil and install the cap. See the
“Technical Information“ section
for engine oil capacity.
WARNING
When adding oil, pull out the
dipstick until the seal is free
of its housing to allow air to
escape from the sump.
10. Start the engine. Check for
leakage around the drain plug
and oil . Authority for advice on disposal.
WARNING
• Prolonged and repeated
contact with used engine oil
may cause skin af such
skin cancer, dermatitis, etc.
• Try to avoid any contact
with the used engine oil. If
skin contact is made, wash
thoroughly with soap or hand
cleaner as soon as possible.
• Keep (used) engine oil out of
reach of children.
Protection of the environment
It is illegal to pollute drains, water
courses or soil. Use authorized
waste collection facilities and
garages providing facilities for
disposal of used oil and used oil
If in doubt, contact your Local
function. Therefore, additional
cooling system additives are not
necessary.
Never add water to the radiator.
Use only recommended pre-mixed
ethylene glycol base anti-freeze.
CAUTION
Never use any other types of
engine coolant since it could
damage the cooling system.
WARNING
Engine coolant is poisonous.
Therefore it should be kept in a
properly marked container and
out of reach of children.

11. Turn the engine off and wait

several minutes. Check the oil
level with the dipstick and add
engine oil, if necessary.
8 12. Close the cab (Refer the cab
closing procedure in chapter 2).
8.6 Engine cooling system
The engine cooling system is
at the factory with a high-quality, and
extended life engine coolant. The
high quality engine coolant contains
the solutions effective for
the anti-corrosion and the antifreeze

74

8.6.1 Checking coolant level
Check the coolant level in the
reservoir tank daily when the engine
is cold.
Tilt the cab (Refer cab tilting
procedure in chapter 2). And check,
if the coolant level is below the MIN
mark, add coolant recommended
by AL until it reaches MAX mark.
After or checking, close the
cab (Refer cab closing procedure in
chapter 2).
CAUTION
If the cooling system frequently
requires to add the coolant, have
it checked by AL LCV Dealer.
8. MAINTENANCE AND DO-IT YOURSELF
8.6.2 Changing engine coolant
Note
Major engine cooling system repairs
should be performed by AL LCV
Dealer. The service procedures
can be found in the appropriate AL
Service Manual. Improper servicing
can result in engine overheating.
WARNING
To avoid the danger of being burnt,
never change the coolant when
the engine is hot.
1. Loose the DAT cap and remove
the drain plug from radiator and
drain the coolant.
2. Flush the cooling system by
running clean water (without
foreign particles).
3. Install the drain plug to the
radiator.
4. See the “Technical information”
section for cooling system
capacity. Fill the reservoir tank
up to the MAX mark by slowly
pouring coolant to allow the air
to escape out of the system.
5. Install the DAT cap, start the
engine and let it run for several
minutes.
6. Stop the engine. After it
completely cools down, check
the coolant level and add
coolant in the reservoir tank up
to the MAX mark.
7. Check for any sign of leaks.
8
75
 8. MAINTENANCE AND DO-IT YOURSELF
8.7 Fuel For additional information, see
8.7.1 Draining water Bleeding the fuel system in this
section.
8.7.2 Changing fuel
1. Disconnect fuel lines from the
fuel
CAUTION
Plug the pipe to prevent fuel
from draining.
2. Tilt the cab (Refer cab tilting
procedure in chapter 2).
3. Loosen the air vent screw
(1) from the fuel (2) and
unscrew the hand primer (3)
and start pumping for the air to
escape from the system through
the bleed screw and tighten the
same when all air escapes out
of the system.

2. Remove the from the

Drain the water from the fuel mounting bracket on the
when the water in fuel indicator chassis frame.
comes on in the dashboard.
3. Remove fuel cartridge from
Follow the procedure as described the bowl by unscrewing the 4
below. bolts on the top cover plate.

1. Place an appropriate container 4. Install the new cartridge

and assemble back the top 4. Start the engine and make sure
(1) under the fuel . that there are no leaks in the
cover plate.
2. Loosen the drain plug (2) a connector or any other element
couple of turns. To avoid 5. Install the fuel on the frame. that has been handled.
dropping it, do not loosen the 8.7.3 Bleeding the fuel system 5. Close the cab (Refer cab closing
drain plug too much. procedure in chapter 2).
If air enters the fuel circuit on any
3. After draining the water occasion, or after an empty
completely, screw the drain plug
8 4.
back in place.
Bleed the air from the fuel
fuel tank or after replacing fuel
proceed as follows:
,

1. Ensure that there is suf

system.
fuel in the tank.

76
 8. MAINTENANCE AND DO-IT YOURSELF
8.8 Air Note to penalties for any
Place the hose back with arrow made to the emission control
Replacing the air
mark towards the element. systems after delivery,
Replace the air element on
With this emission control system
appearance of a red band in the
5. Reset the indicator by pressing built into AL, the discharge of
service indicator present in the
it on the top again after pollutants has been reduced
housing.
replacement of the substantially.
element.
These pollutants are primarily
WARNING hydrocarbons, nitrogen oxides and
carbon monoxides.
• Do not run the engine without
the air-cleaner as it also Hydrocarbons and nitrogen
performs as a extinguisher oxides when exposed to sunlight
when the engine under certain conditions produce
photochemical smog.
8.9 Emission control system
Carbon monoxide is toxic when
1. The air is located at left The control of automotive air highly concentrated in the air.
side of vehicle which is below pollution largely depends upon the 8.9.1 Exhaust emission control
the co-driver seat. development of effective emission system
control systems.To meet this
2. Remove the hose clip and unclip Exhaust gas recirculation (EGR)
the housing. demand, AL been making consistent
system (If equipped)
and continuous efforts towards the
3. Take out the element further development of such devices. The purpose of the EGR system is
4. Replace with new and genuine to direct burnt gas into the intake
Your AL vehicle is equipped with
element and place back all manifold so that it re-enters the
emission control devices which

8
the components. engine combustion chambers.
are designed and built to provide
emission performance levels This system controls the engine
required by Indian design rules. In combustion temperature, thus
some States owners may be subject reducing NOx emissions.

77
 8. MAINTENANCE AND DO-IT YOURSELF
8.9.2 Maintenance
recommendation
Please make your contribution
to clean air in our environment
by operating the vehicle within
the prescribed load limits and by
maintaining the emission control
system in accordance with our
recommendations.
To maintain the original quality built
into the emission control system
we recommend that the system
be maintained by your AL LCV
Dealer who uses only Genuine AL
Replacement Parts, The use of
other parts which may be inferior
to genuine AL parts could lead to a
reduction in the effect of the system,
8.10 Drive belt
Water pump alternator
and Compressor belt
A the MAX and MIN marks
8
Dummy pulley
Drive belt auto tensioner
78
WARNING
Be sure the ignition key is in the
LOCK position.
Visually inspect the belt for signs
of unusual wear, cuts, fraying or
looseness. If the belt is in poor
condition or loose, have it replaced
3. If the level is below the
or adjusted by AL LCV Dealer.
lowest mark (MIN), add power
Note steering up to the highest
mark (MAX).
Have the belts checked regularly for
condition and tension in accordance Note
with the maintenance schedule.
When checking the power steering
level, prevent dust or dirt from
entering the reservoir.
8.11 Power steering The power steering will not operate
correctly if the quantity of is
The power steering level must
insuf or if the is dirty. Use
be checked when the engine is cold.
only recommended power steering
1. Tilt the cab (Refer cab tilting For details see “Capacities and
procedure in chapter 2). recommended oil and lubricants” in
2. Check that the level is between the “Technical Information” section.
 8. MAINTENANCE AND DO-IT YOURSELF
8.12 Windscreen 8.13 Wiper blades not form when rinsing with clear
reservoir (If equipped) water.
Wiper blades replacement
• Clean the blade by wiping it with a
Wiper cloth soaked in a washer solution
blades or a mild detergent. Then rinse
the blade with clear water. If the
windscreen is still not clear after
cleaning the blades and using the
wiper, replace the blades.

WARNING
When waxing the front panel of
Check the level in the reservoir the vehicle, be careful not to
1. Pull the wiper arm up.
and add if necessary. let wax get into the windscreen
2. Push the lock pin, then remove washer nozzles which could
In the winter season, add a the wiper blade. cause them to clog or create
windscreen washer anti-freeze.
3. Insert the new wiper blade to the improper windscreen washer
wiper arm. operation.
CAUTION
4. Return the wiper arm to its
Do not substitute engine original position. CAUTION
antifreeze coolant for windscreen
washer solution. This may If the windscreen is not clear after Make sure the wiper blade
damage the paint. using the windscreen washer, or contacts the glass otherwise the
if the wiper blade chatters when arm may be damaged because of
running, wax or other material may wind pressure.
be on the blade or windscreen.
• Clean the outside of the
windscreen with a washer
8
solution or a mild detergent. The
windscreen is clean if beads do

79
 8. MAINTENANCE AND DO-IT YOURSELF
8.14 Brake / Clutch level • Low quality may damage 8.15 Brake conditions
the brakes and reduce braking
ef . Parking brake

MAX • If the has to be topped up

MIN frequently, the system must be
checked by AL LCV Dealer.
• Do not spill onto painted
MAX
surfaces since it will damage the
paintwork. Wash immediately
MIN

with water if this happens.

1. Check the brake / clutch CAUTION

level in the reservoir from
opening located on the right side
of the dashboard.
2. The level must be between
the MAX and MIN marks on
the reservoir. If it is below the
MIN mark or if the low brake
/ clutch indicator comes
on, add brake / clutch
recommended by AL up to the
MAX mark.
CAUTION
Use new brake / clutch Low
8
quality or dirty could cause
problems in the brake / clutch.
Brake / Clutch absorbs Periodically check the retention
moisture. This makes it ineffective capacity of the hand brake by
in operation. Don’t leave it parking the vehicle on a steep hill
uncapped for a long time. and braking the vehicle with the
parking brake only. If it does not hold
WARNING satisfactorily, visit AL LCV Dealer.
Brake / Clutch is poisonous Brake bleeding procedure
and must therefore always be kept
Whenever air bubbles present in the
in its original container and stored
brake lines, it is essential to bleed the
out of reach of children.
system.
1. Attach bleed tube to the
bleed screw (As per bleeding
sequence shown in the

80
 8. MAINTENANCE AND DO-IT YOURSELF
Brake pedal the “-” negative battery terminal
cable to prevent the battery from
discharging.

2. Place the other end of the

tube in a bleeder bottle,
containing suf brake
If the brake pedal suddenly goes
to submerge the end of the tube.
down further than normal, the pedal
3. Start the engine and depress the feels “spongy” or the vehicle seems
brake pedal 3 to 4 times with an to take longer to stop, visit AL LCV WARNING
interval of 3 to 4 seconds.
Dealer immediately.
4. Hold the pedal in depressed • Do not expose the battery to
condition and open the bleed 8.16 Battery or electrical sparks.
screw by 1/2 to 3/4 of a turn. Hydrogen gas generated by
• Keep the battery surface clean battery action is explosive.
5. Repeat the action until bubbles and dry. Any corrosion should
of air comes out of the system. be washed off with a solution of • Do not allow electrolyte to
baking soda and water. contact your skin, eyes,
6. Close the bleed screw fabrics, or painted surfaces on
immediately. • Make sure that the terminal the car.
connections are cleaned and
securely tightened.
• Check that the battery is secured.
• Clean and apply neutral Vaseline
on battery terminal.
• If the vehicle is not to be used
8
for 30 days or longer, disconnect

81
 8. MAINTENANCE AND DO-IT YOURSELF
The affected circuits are shown on
WARNING
the back of the fuse box lid.
• Do not touch or rub your eyes 1. Be sure the ignition key in the
after touching a battery or “LOCK” position.
battery cap. Thoroughly wash
your hands. If the acid contacts 2. Open the fuse box cover and
your eyes, skin or clothing, remove the fuse
immediately with water for 3. If the fuse is open, replace it with
at least 15 minutes and seek a new fuse.
medical attention.
4. If a new fuse blows out again,
• Keep the battery out of the 1. Remove the cell plugs using a have the electrical system
reach of children. suitable tool. checked and repaired by AL
2. Add distilled water up to the LCV Dealer.
Maintenance free MAX level.
This battery needs no regular 3. Check the level by looking CAUTION
checking of the electrolyte level or directly above the cell, as
illustrated. Never use a fuse of lower or higher
the addition of distilled water. current rating than that
4. Tighten the cell plugs. on the fuse box cover.
However, to prevent possible
damage, the level should be
checked at least once a month.
CAUTION
Do not battery cells.
Check the electrolyte level in each
Excessive electrolyte may leak
cell. It should be between the MAX
out of the battery during charging,
and MIN lines. If electrolyte level is
and may cause paint damage.
below MIN mark, add only distilled
water to bring the level to the MAX
mark in each cell. Do not
8.17 Fuses

8 If the electrical equipment does not

operate, check for a blown out fuse.

82
 8. MAINTENANCE AND DO-IT YOURSELF
One fuse box is located in the lower given on H/L mounting bracket.
Tighten the lamp assembly with
CAUTION
part of the glove box.
fasteners.
• Do not touch the glass of a
2. Place the side panel. halogen bulb with your hands
8.18 Lights bulbs or with dirty gloves; use a
8.18.1 Headlamp clean cloth. If it is accidentally
Note touched, clean it with cotton
While installing make sure the head soaked in alcohol.
lamp bulb is free from scratches or • Always use bulbs of the
dirt. power.
• It is not necessary to adjust
A the height of the headlamp
after replacing bulbs. When an
adjustment needs to be made,
visit AL LCV Dealer.
• Do not leave the headlights unit
Removal procedure without its glass and its rubber
protector for a long time.
1. Remove the side panel and
remove the bolts of head lamp. • Dust, damp, smoke, etc, may
affect its operation.
2. Disconnect the electrical
connections. (Behind the • Remove the bulb just before
assembly) its replacement.

3. Remove the grommet.

4. Take out the head lamp from the
inner panel.

Fitment procedure 8
1. Insert the head lamp assembly.
Align the four mounting holes

83
 8. MAINTENANCE AND DO-IT YOURSELF
8.19 Bulbs 8.19.1 Replacement procedures 8.20 Wheels and tyres
If you have a tyre, see “In case
Power
ITEM of emergency” section.
(W)
Tyre pressure
Head lamp
Periodically check the tyre pressure
Low beam 55 (including spare).COLD tyre
High beam 60 pressures are shown on the tyre
Front side lights placard af to the driver’s side
centre pillar or for details, see
Parking light 5 “Wheels and tyres” in the “Technical
information” section.
Turn signal light 21
Incorrect tyre pressure may
Rear combination lights
adversely affect tyre life and vehicle
Turn signal light 21 handling. Insuf pressure can
Remove
Park/brake light 5/21 lead to an overheating of the tyre
Fit and subsequent internal damage.
Reverse light 21 At high speeds, this could result in
Rear licence light 10 All other lights are either type A, B, C tread separation and even bursting
or D. of the tyre.
Outer body lights
Side turn light 21 When replacing a bulb, remove CAUTION
the lens and/or cover.
Interior lights When changing or replacing tyres,
be sure all four tyres are of the
Front 10
same type (i.e., summer, all
season or snow) and construction.

8 Tyre rotation
AL recommends that tyres be rotated
for every 10,000 km. See “Flat tyre”

84

in the “In case of emergency “section
for tyre replacing procedures.
Tyre Rotation - 6 Tyre
• After rotating the tyres, adjust the
tyre PRESSURE.
• Incorrect tyre selection,
care or maintenance can affect
the vehicle’s safety with risk of
accident and injury. If any doubt,
consult your AL LCV Dealer or
the tyre manufacturer.
Tyre wear and damage
Tyres should be periodically
inspected for wear, cracking,
bulging, or objects caught in the
tread. If excessive wear, cracks,
bulging, or deep cuts are found, the
tyre should be replaced.
8. MAINTENANCE AND DO-IT YOURSELF
The original tyres have a built-in
tread wear indicator. When the wear
indicator is visible, the tyre should
be replaced.
Changing tyres and wheels
Note
When replacing a tyre, use the same
size, speed rating and load carrying
capacity as originally equipped.
Recommended types and sizes are
shown in “Wheels and tyres” in the
“Technical information” section.
If the wheels are changed for
any reason, always replace with
wheels which have the same offset
dimension.
Wheels of a different offset
could cause early tyre wear,
possibly degraded vehicle handling
characteristics and/or interference
with the brake discs/drums. Such
interference can lead to decreased
braking ef and/or early brake
pad/shoe wear.
WARNING
Do not install a deformed wheel or
tyre even if it has been repaired.
Such wheels or tyres could have
structural damage and could fail
without warning.
8
85
 8. MAINTENANCE AND DO-IT YOURSELF

Wheel Base 3320 2820

Caster angle 2.5°±0.5 2.5°±0.5

Camber 0.5°±30' 0.5°±30'

Total toe ( min to max) 1-3 mm 1-3 mm

(0.03 - 0.11) inch (0.03 - 0.11) inch

Wheel alignment

Incorrect wheel alignment affects

vehicle handling and tyre life.
Whenever uneven tyre wear is
noticed contact the nearest AL LCV
Dealer.
Care of wheels
• Wash the wheels when washing
the vehicle to maintain their
appearance.
• Clean the inner side of the wheels
when the wheel is changed or
the underside of the vehicle is
washed.
• Do not use abrasive cleaners
when washing the wheels.

8 • Inspect wheel rims regularly for

dents or corrosion. This may
cause loss of pressure or damage
the tyre bead.

86
 No.1 Sardar Patel Road,
Guindy, Chennai 600 032
Email : lcvccc@ashokleyland.com
Publication No: OM T/613/18/100