Boss LHD Ohb - Draft 1

BOSS TRUCK LHD
Operator Hand Book

FOREWORD
Dear Customer,
Thank you for choosing our product. We are proud to have you in the Ashok Leyland family.
This Operator Manual has been prepared to acquaint you with the operation and maintenance of BOSS 815 & 1223
fitted with Euro IV CRS Engines. Care has been taken to include as much useful information as possible. You are
requested to read this manual carefully before operating the vehicle. For your convenience, we have given a provision for
“Record of Maintenance” in this manual.
We, in Ashok Leyland, are engaged in continuously improving our products and it is therefore likely that some of the
specifications, dimensions, design, procedures, recommended practices referred to herein may change over a period of
time without prior notice and will be made available in the subsequent publications as required.
Some of the items, accessories and features shown in this book may not be available on your vehicle, but they are applicable
for other versions of the vehicles.
In order to get optimum performance from your vehicle, we would urge you to get all services 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 thankful for any
comments you may have to improve the same. Please write to:
EXPORTs - SERVICE
No.1, Sardar Patel Road, Guindy, Chennai – 600 032. India
Pub. No. EX - OM: Boss - E4 :1015

VEHICLE DATA SHEET
Name of the Customer : ................................................ Battery Details
Address : ................................................ Make & Serial No. 1. : ....................................................
................................................ 2. :.....................................................
Phone No. : ................................................
Date of Sale & Registration. : ................................................
Tyre Details
Registration No. : ................................................
Front RH : ................................................................
Name of the Selling Dealer : ................................................
Dealer Address & Code : ................................................
Front LH : ................................................................
................................................
Vehicle Model : ................................................ Rear RH inner : ................................................................
VIN : ................................................ Rear RH outer : ................................................................
Engine No. : ................................................ Rear LH inner : ................................................................
Fully built vehicles Rear LH outer : ................................................................
Type : ................................................ Spare : ................................................................
Capacity / Span : ................................................ . Certified by
Manufacturer of Body : ................................................
Body No. : ................................................ Ashok Leyland RSO..................................
Warranty terms and vehicle features are explained at the time of delivery.
Signature of the Customer Signature of the Selling Dealer & Stamp

Did You Know?
Ashok Leyland
is having over 461 touch points
across the length and breadth of the country
to know more turn overleaf

Did You Know?
Ashok Leyland is the first Indian company to Ashok Leyland is

- Receive BS IV – OBD II Certification for commercial vehicle - the Market leader in the Passenger segment
engines - Strengthening Indian logistics since 1948
- Introduce full air brakes in the commercial vehicle segment - Carrying over 70 million people every day
- Introduce multi-axle trucks - Exporting commercial vehicles to more than 30 countries
- Introduce plug-in CNG hybrid bus - Market leader in the Marine Diesel engines segment in India
- Introduce power steering in the commercial vehicle segment
- Introduce Common rail diesel engine for a commercial vehicle
- Introduce multi-point fuel injection (MPFI) system for CNG
engines used in buses
- Develop in-line fuel pump engine compliant to BS III norms Ashok Leyland is India’s first automotive manufacturer
- Present hybrid electric commercial vehicle - To be awarded the ISO 9001 certification
- To be awarded the ISO 9002 certification
- To be awarded the QS 9000 certification
Ashok Leyland is the largest - To be awarded the ISO 14001 certification
- Manufacturer of CNG buses in the world
- Supplier of logistics defence vehicles to the Indian army
Ashok Leyland is India’s first commercial vehicle manufacturer

Ashok Leyland is the only Indian manufacturer of - To be awarded the TS 16949 Corporate Certification
- Double-decker buses - To receive the BS 7799 certification for information security
- Vestibule buses management system
contents
Chapter 1 -Attention Owners Chapter 4 - Instruments and Controls
)) Terms of warranty (Chassis) )) Instrument Panel

)) Instruments
)) Exhaust Emission
)) Controls
)) Service policy
)) Combination switch for Cargo cab
)) Safety tips )) Pedal Controls for Cargo Models
)) Hill Driving )) Cab Lifting for Cargo Models
)) About Leyparts )) Warning Lights
)) Service Products )) Cargo cab

)) Operating instruction for Seat controls
)) Record of maintenance
)) Engine Starting / Stopping
Chapter 2 - Vehicle Identification )) Check before driving
)) On the spot recovery
)) Identification of vehicle )) Guidelines to Operate the Tipper for First Time
)) Operating instructions for Tipper
)) Identification of units
)) Operating Guidelines
Chapter 3 - Technical Specifications )) Tips To Improve Mileage & Tyre Life
contents
Chapter 5 -Body Building Instructions Chapter 7 - Trouble shooting
)) General guidelines )) Engine
)) Precautions during body building Turbocharger
)) Body / Equipment installation )) Clutch
)) Storage of vehicles )) Gear box
)) Coach builders drawing )) Rear axle
)) Front axle & steering

Chapter 6 - Maintenance and Lubrication
)) Brake system
)) Maintenance schedule )) Electrical system
)) Maintenance procedure Battery
)) Filling capacity Alternator
)) Recommended lubricants Starter motor

1. Attention Owners
)) Terms of warranty (Chassis)
)) Exhaust Emission
)) Service policy
)) Safety tips
)) About Leyparts
)) Record of maintenance
nearest AL Dealer workshop, freight of time, inconvenience or damage to
Terms of Warranty
1 paid, within 7 days personal property, commercial loss such
ASHOK LEYLAND LIMITED (AL) warrants as loss of revenue etc., during the period
each vehicle sold by it to be free from 4. The obligation under warranty shall be when the vehicle is undergoing service /
defects in material and workmanship limited to either repairing or replacing warranty repairs.
subject to the following terms and free of charge such parts of the 7. The customer will be responsible for
conditions:
vehicle as are deemed to be defective in the cost of non-durable materials
1. The period of warranty shall be as per (lubricants, fuel, grease, filters, etc.,),
the opinion of AL and shall not extend to
the terms expressed by our dealer rubber items, liners (clutch, brake), soft
consequential losses. The replaced part
during order finalization. trims, upholstery and paint coatings.
shall become the property of AL.
2. The warranty extends to the first * The cost of maintenance and
5. For proprietary parts not manufactured lubrication operations.
registered owner of the vehicle only or by AL such as Fuel Injection Equipment,
(in the absence of registration) to the Electrical Equipment, Tipping * The cost of repairs made
first commercial user of the vehicle. In Equipment, Brake components, necessary by normal wear & tear,
Instruments, Batteries, Tyres and tubes accidents or improper use not
the event of transfer or any alienation
the warranty terms of the respective authorised by AL or by improper
otherwise of the vehicle during the storage or negligence.
supplier will be applicable.
period mentioned in Clause 1 above,
6. The buyer shall have no other right * The cost of on-road repairs,
the warranty shall stand terminated towing, parking and insurance.
except those expressly stated herein
unless prior written consent of
and have in particular no right to * The cost of repairs, caused by
Ashok Leyland is obtained. repudiate the sale, or any agreement, damage due to fire, flood, earthquake
3. In the event of any defect being or to claim any reduction in the or such natural calamities or by civil
discovered within the period purchase price of the vehicle or to disturbance.
demand any damages or compensa- 8. The warranty shall become null and
mentioned in Clause 1 above, the
tion for incidental or consequential void:
defective part is returned to the losses such as loss of use of vehicle, loss
1.02 ATTENTION OWNERS
* If the vehicle is used in ways not 10. AL reserves the right to modify the 1. Injectors for correct opening pressure
recommended by the company, if any technical specifications and introduce and spray characteristics. 1
features of the vehicle are modified, if improvements to its vehicles at any
2. Fuel Injection Pump for correct fuel
the vehicle is repaired or disassembled, time and is under no obligation to apply
even partially, by persons not belonging delivery and idling speed.
such modification or improvements
to AL’s authorised workshop, if the to vehicles produced at an earlier 3. Fuel filters for blockage / damage
vehicle is fitted with body of design, date. 4. Injection timing - in case of excess
size, position and mounting other than
11. This warranty is in lieu of and excludes smoke in exhaust.
what is prescribed by AL, if the overhang is
extended in excess of the original all conditions warranties liabilities 5. Cleanliness of diesel and diesel tank
specification given in the Operator express or implied, whether in common
law statute or otherwise in relation 6. Valve clearance
Manual, or if the vehicle is loaded
beyond its carrying capacity as certified to all vehicles, whether covered by 7. Air Cleaner element for clogging
by AL. warranty or not.
8. Engine breather for choking
* If the fuel injection pump Exhaust Emission 9. Silencer/exhaust pipe for blockage
calibration figures are altered or
the relative seals tampered with, if Non adherence to the above mentioned 10. General condition of Engine (piston/
unsuitable lubricants or fuels or cool- "Free Acceleration" smoke limit is violation rings/valves) to be checked as when
ants are employed or non-genuine of the said rule. necessary.
spare parts are fitted. It is therefore imperative that operators The fuel settings of the FIP
* If the recommended maintenance check the exhaust emission levels on should never be tampered
practice is not followed. their vehicles at intervals of 15,000 kms, with.
Operators must also carry out preventive CAUTION
Use always low sulphur diesel
9. When a part is replaced under the maintenance to ensure that smoke levels fuel.
terms of warranty the benefits
are not exceeded. Use always the correct grade
of the warranty shall apply to the
Check the Following aspects and rectify if of engine oil and change
replacement part for the remainder of
necessary: (Please refer Chapter no. 6 for engine oil and oil filter as
the AL Warranty period not beyond
that. recommended maintenance schedule) recommended.
ATTENTION OWNERS 1.03

sub-standard workmanship during the Wear and Tear’ components under warranty
SERVICE POLICY
1 manufacturing process. Hence any Benefits of warranty will apply up to the
Ashok Leyland endeavors to secure replacement arising out of normal wear limit specified for wear and tear items
excellence of materials and workmanship and tear of the following items will not be listed below.
and this section covers the service policy the subject of a warranty claim: It is to be understood that the life of these
of AL. 1. Gaskets (other than Cylinder Head Gasket) components depends on the nature of
The service policy has three elements operation and duty cycle and only if the
2. Rubber components such as fan belts, failure is premature in relation to these,
that you need to understand, viz., hoses, oil seals, master cylinder kit, slave warranty replacement has to be effected.
1) AL’s Warranty terms cylinder kit, wiper blades, floor mats. In any case, the benefits of warranty will
2) Dealer’s Service obligations not apply beyond the limits stated.
3. Bulbs and lamp covers
Component Limit
3) Owner’s maintenance responsibilities 4. Fuses
Clutch Facing 15,000 km/3 months
Scope of Warranty 5. Upholstery including seat cushions Brake Lining 15,000 km/3 months
It is absolutely essential to avail the Pre and covers Bearings 30,000 km/6months
Delivery inspection and other scheduled 6. Glass items (other than windscreen glass) Oil seals 30,000 km/6 months
Services offered by AL to claim any
7. Suspension pins and bushes Ball joints 30,000 km/6 months
benefit under the terms of warranty
8. Cowl Fan belt 30,000 km/6 months
The terms of warranty are given in the
UJ 30,000 km/6 months
following pages. A list of wear and tear 9. Fasteners except main bearing cap
items not covered under warranty is bolts, con rod bolts, differential bearing Clutch cylinders 30,000 km/6 months
listed for ready reference. cap mounting bolts Cables 15,000 km/3 months
Non-Warranty Items 10. Parts recommended to be replaced Plastic & rubber 6 months
during routine maintenance Cab trim 6 months
The warranty terms are a precise
statement of AL’s intention to cover the Electricals 6 months
11. Consumable items such as lub oil,
replacement / repair cost, on a grease, anti-corrosion / anti-freeze Spring leaves 1 0 , 0 0 0 k m ( p rov i d e d
standard and agreed basis, of any product compound etc. suspension not tempered)
failure resulting from defective material or Shock absorber 30,000 km / 6 months

– If the vehicle is subjected to overloading Wearing Seat Belt
Tipper
/ unauthorized modification / abuse Always wear seat belt while driving. This safe- 1
The period of warranty for the tipping of equipment (e.g. misalignment of ty feature reduces the chances of personal
equipment shall be 12 months from the body due frequent pushing of vehicle) / injury in case of any accident by securing the
date of sale of end customer or 2000 hrs accidental damages. driver/co-driver firmly on seat, preventing
of operation whichever occurs earlier. – If the cleanliness of the hydraulic circuit him to come away and hit with steering, dash
Any replacement / repairs arising out of is not maintained. board or even with windshield glass.
normal wear & tear of the components – If the PTO is not disengaged after the HILL DRIVING
will not be the subject of a warranty claim. tipping operation.
While going down a hill, always use the
Limited warranty components:
SAFETY TIPS same gear as would have been used for
Benefits of warranty will be limited to the climbing it. Never drive downhill with
Safe driving is possible with total
specified period given below from the concentration and involvement of the your engine switched off or gear in
date of sale to the end customer for the driver. Safety is more important than neutral position. Control the speed by
following components: Speed. Though innumerable skills can staying in the correct gear to avoid
– All rubber items like hoses, seals, 'O' be identified to expertise on safe driving excessive use of brakes, which can lead
rings, etc. – 12 months from the date of techniques, only some of them are to ‘Brake Fading’. The brakes fade as a
furnished here which can certainly reduce result of excessive heating, causing
sale to end customer.
the possibility of accidents if practiced. temporary brake failure. When allowed
– Load body Paint defects (Mfg. defects to cool, the brakes will function normally
like mismatch / fading / blistering, etc.) again. Never exceed the maximum rated
- 6 months from the date of sale to end speed by selection of appropriate gears.
customer. Avoid down shifting at high speeds which
may cause engine over racing.
The warranty shall become null and void:
While parking on a hill, place wheel chock
– If the recommended maintenance or wooden blocks under the wheels, in
SS
activities are not performed. PRE
addition to hand brake. Make sure to

– If the recommended lubricants are not remove such blocks from the road before
PRESS
used. leaving.

DON’TS Skidding Parking the Vehicle
1 Dont's while vehicle is in down Skidding is the condition when one or Before leaving the vehicle, always put the
the hill. more wheels lose road grip, causing parking brakes on and the gear in low or
involuntary movement of the vehicle in reverse position. Never leave your vehicle
Do not coast downhill with the
with engine running. Always put on
transmission in neutral the direction other than intended. It is parking lights if vehicle is parked on a
Do not coast downhill with clutch normally caused by high speed, excessive busy roadside.
disengaged. or sudden braking, rapid acceleration, Whenever you halt, make a habit of
Do not coast the vehicle i.e., drive harsh braking etc. Oil, loose sand, snow checking and cleaning wind screen, lights,
with engine switched off. and wet road surfaces are primary causes reflectors and rear view mirrors. Don’t
of skidding. Bald tyres and incorrect tyre forget to check the tyre.
Do not change gear unnecessarily.
pressure increase this hazard. For correct Use of Cell Phone
Ensure choose correct gear with tyre pressure refer Chapter - 6. It is dangerous to use cell phone while
vehicle motion.
Don’t apply brakes violently on slippery driving. It affects the concentration and
Switch on exhaust brake and use roads to avoid skidding. control on driving adversely. Please park
exhaust brake. your vehicle off the road safely while
Tyre Failure using cell phone.
Do not accelerate while vehicle is
in downhill. If the front tyre bursts, the vehicle will Driving in Adverse Environment
tend to pull towards the side of the burst Driving through deep water may wet
If air pressure is low in service
(Not applicable for vehicles having power the brake and adversely affect the
brakes due to air leak use hand
steering). A rear burst will cause the performance. To dry it quickly, apply
brake valve gradually to stop the
vehicle to vibrate heavily. brakes softly a few times while maintaining
vehicle.
safe road speed till the braking ability
For emergency use Graduated In these cases, keep a firm grip on steering
returns to normal.
parking brake when service wheel and try to steer straight ahead.
Drive slow in fog. Always drive at a speed
brake got failed. Apply brakes very softly till the speed is
NOTE that allows you to stop within the distance
considerably reduced and then pull the of your visibility. Use fog light for better
vehicle to the side of the road. visibility.

While Loading the Hazardous Goods Bulk Liquid or Liquefied Gases
Transportation of Hazardous
Vehicles - Stop the engine and place wheel chocks 1
Goods
Packed goods on both sides of the rear wheels.
Before Loading Hazardous Goods
Vehicles - Stop the engine and place the wheel - Do not smoke or carry matches/
chocks on both sides of the rear wheels. lighters.
- Check the vehicle for road-worthiness.
- Do not smoke or carry matches/ - Connect the earthing cable first and
- Check that all the safety equipment and lighters. then the loading hoses.
fire extinguishers are in good working
- Load the vehicle uniformly to equally - When loading is completed, check
condition.
distribute the load on all the wheels. for leaks, rectify if any, disconnect
- Collect "Transport Emergency Card" hoses, earthing cable, remove wheel
(Termcard) and "Instructions To Driver" - Keep the bung of the drums upwards. chocks and then only start the vehicle
of concerned hazardous product and - Keep the articles in the vehicles such (Use protective equipment wherever
ensure that they are kept in the drivers that they do not move within the required).
cabin and discard any other Termcards. vehicle during transportation. Vehicle Loaded with Hazardous Goods
In the case of an empty tanker - Do not load food stuff and other - Do not leave the vehicle unattended.
reporting for loading, check whether: general cargo along with hazardous
- Do not park the vehicle in a thickly
- the tank is clean or not goods.
populated area.
- the previous load was the same prod- - Load heavy articles at bottom and
lighter articles over them. - Always drive on approved route.
uct or different.
- Do not load leaky containers/drums. - Do not allow passengers to travel in the
- the tank has been thoroughly cleaned vehicle.
by following proper procedure (e.g., - Do not over load the vehicle.
washing, steaming and then purging - After loading, secure the load with rope
with nitrogen), if previous load was a after covering with tarpaulin.
different product (particularly, in the
case of incompatible products).

During Transportation of Hazardous While Off-loading the Hazardous Goods Emergency Procedures
1 goods Vehicle The driver should take the following
Driver of the vehicle to ensure that: Packed goods actions in an emergency.
- He understands the nature of the - Stop the engine and place the wheel In the event of an accident, leakage or
hazardous goods and also knows the chocks on both sides of the rear fire
action to be taken by him in an emergency wheels, using four wheel chocks. - Stop engine, apply hand-brake and
involving his vehicle / product. - Remove unwanted people from vicinity. wheel chocks.
- The information (Termcard and - Do not smoke or carry matches / lighters. - Ensure that Termcard is removed
Instructions in writing) given to him is from the vehicle and kept safely and is
kept in the cabin of the vehicle and is - Do not drop the articles form the
available for reference.
available at all times during transportation. vehicle.
He should carry Termcard only for the - Keep people away from the area.
Bulk Liquid or Liquefied Gases
particular substance being transported - Stay upwind, mark road and warn other
- Stop the engine and place the wheel
and discard any other Termcards. road users.
chocks on both sides of the rear
- Precautions are taken for preventing wheels. - If necessary, evacuate people within a
fires, explosion or escape of hazardous radius of 250 metres
- Do not smoke or carry matches/
goods. lighters. - Do not allow smoking, naked lights
- He parks the vehicle under his control and Avoid sparks.
- Connect the earthing cable first and
in a safe area whenever required and then the unloading hoses. - Inform the nearest Police station
not to leave it unattended. through a messenger giving precise
- When unloading is completed
- He reports any accident involving his details of location of accident, number
disconnecthoses,earthingcable,remove
vehicle to the nearest police station of injured persons, etc.
wheel chocks and then only start the
and then to the consignor, the haulier vehicle. (Use protective equipment - Inform the Consignor/Consignee and
and the customer. wherever required). your Employer.
- Give First-aid to the injured.

- Give priority to protecting life and contaminated area with plenty of Large Fire
environment and preventing injury water and prevent it from entering - Inform the nearest Fire Brigade 1
and not to salvaging of product. sewers.
- Stop vehicular traffic on the road,
- Ensure that the vehicle is attended - Inform the nearest Fire Brigade evacuate people in the area.
constantly by you or your assistant. through a messenger giving name
The ignition key should be available of the Cargo, precise details of the
with you. accident location, number of injured Other Safety Tips
persons etc. - Modification to the vehicle in any
In the Event of Leakage / Spillage of
Product - Try to stop the leakage, if possible, form (i.e. drilling or welding on frame,
using non-sparking tools and personal adding extra leaf in suspension, change
- If possible, move vehicle to an open
protective equipment. in leading dimensions etc.), is strictly
ground, away from populated areas.
- Keep the Fire Extinguishers in readiness. prohibited as it can affect the safety
- Absorb the spilt liquid in sand, earth or and economical aspect adversely.
saw-dust and remove it to a safe area - Ensure adequate ventilation.
Please adhere strictly to body building
for disposal by burying or burning. - Stop vehicular traffic on the road, guidelines provided on Chapter - 5.
Prevent liquid from entering sewers or evacuate people in the area (within a
radius of 250 metres), if necessary. - Before commencing journey, ensure
any other water sources.
that the headlights, signal lights and
- In case of spillage of pesticides, In the Event of a Fire brake lights are clean and operating
decontaminate the area by soaking Small Fire properly.
with 10% sodium carbonate or 5% - Use portable Fire extinguishers, sand - Keep engine and its surrounding
caustic soda. or earth and extinguish the fire. area clean and free from leakages /
- If it is a non-corrosive liquid product, - Inform the nearest Fire Brigade, if spillages of any inflammable liquid.
try to collect the leaky liquid in sound required. - Do not open radiator cap when the
closeable steel drums and transfer the
- Stop vehicular traffic on the road, engine is hot. The boiling water can
liquid to a salvage tank if available.
evacuate people in the area, if splash over you and cause serious
- If it is a liquefied gas, flush the necessary. burns.

- Bring the vehicle to the side of the It is very likely that spare parts other
1 road if low air pressure warning is than Leyparts would not carry all quality
heard. aspects matching Leyparts. Therefore in
Leyland vehicles and aggregates. all likely-hood usage of those spare parts
- If the vehicle is required to be lifted
(using jack), park the vehicle on level Leyparts will not yield the required reliability,
and hard surface only. Use parking * Stands for quality, reliability, ready efficiency and economy of the vehicle
brake and wheel chock to prevent fitment and long term economy. irrespective of the repair workmanship.
accidental rolling. More so the parts supplied to the
* Stands for comprehensive range of
- Do not inhale dust from clutch or market by the OE approved
genuine spare parts for Ashok Leyland
brake lining, or blow dusts from these vendors may not carry the OE
applications required for after sales
units. It is injurious for health. specifications as in Leyparts. Also
support.
- Drivers must turn their Tanker at for meeting safety and emission
* Offers better value for money requirements use of Leyparts is
curves, at a speed well below the
normal vehicle turning speed as they * Offers dedicated parts support recommended. For guaranteed genuine
are prone to roll over due to liquid through its Vehicle Off Road Service Leyparts always buy from authorised
surge and comparatively high Centre Dealers/Service Centres or Retailers.
* Offers comprehensive repair kits
of gravity. Always demand usage of Leyparts
- While driving tractor – trailer vehicles * Is made available through a wide whenever repair work is carried out. To
please ensure the secured connection network across India consisting of ensure this, entrust repair jobs to Ashok
of service/relay emergency brakes. The reliable, efficient and economic Leyland Dealers and Authorised Service
- Stay alert, driving when you are tired operation of a vehicle depends on the Centres (ASC) so as to avail advantages
is dangerous. Take enough rest on soundness of the components which go of Leyparts.
long trips, especially on hilly terrains. into the making of it. Leyparts carries
- If you find anything wrong or the same OE Standards with respect
unsafe, get it replaced / repaired before to Manufacturing processes, Material,
commencing your journey. Never take dimensions, strength and tolerances,
a chance, it may prove too costly. Since, “What We Fit is What We Sell”

RECORD OF MAINTENANCE
1
Complaint Work Attending Dealer's
Date Kms Remarks
Reported/Observed Carried out Seal and Signature
PDI
5000
10000
20000
30000
40000
50000
60000
70000
80000
90000

RECORD OF MAINTENANCE
1
Complaint Work Attending Dealer's
Date Kms Remarks
Reported/Observed Carried out Seal and Signature
100000
110000
120000
130000
140000
150000
160000
170000
180000
190000
200000

2. Vehicle Identification
)) Identification of vehicle
)) Identification of units
Body builder’s plate is fitted in all the Vin - Punching & Manufacturer Plate
IDENTIFICATION OF VEHICLE
vehicles with load body, which are in the Location
Manufacturer’s Plate form of drive away chassis. The body
builder’s plate, typically shown above is
firmly attached by welding in a conspicuous
2
MB1AUR1A0
DPYH2684
TYPE
APPROVAL XXXXXXXX VIN MB1AUR1A0DPYHXXXX and readily accessible position on a part
GROSS VEHICLE
WEIGHT (kgs) XXXX GROSS COMBINATION
WEIGHT (kgs) XX which is normally not likely to be replaced
AXLE
LOADS
(kgs) 1 XXXX 2 XXXX 3 XX 4 XX during use. It shall show clearly and
CHASSIS
XXXXXXXX ENGINE
XXXXXXXX
indelibly the following information in the TYPE
APPROVAL XXXXXXXX
GROSS VEHICLE
WEIGHT (kgs) XXXX
VIN MB1AUR1A0DPYHXXXX
GROSS COMBINATION
WEIGHT (kgs) XX
TYPE 1 XXXX 2 XXXX 3 XX 4 XX

AXLE
TYPE
order listed.
(kgs)
LOADS
CHASSIS
TYPE XXXXXXXX ENGINE
TYPE XXXXXXXX
ENGINE
DAHZ10XXXX
ENGINE
DAHZ10XXXX
X.XX:X
REAR AXLE
REAR AXLE
RATIO X.XX:X NUMBER
MADE IN INDIA
NUMBER
1. Ashok Leyland Part number
RATIO MADE IN INDIA
2. Body builder name code. VIN number is punched on LH frame side

Manufacturer’s plate is fitted in all the member near rear spring rear bracket.
3. Loading span in Feet
vehicles. It shall show Vehicle Identification Manufacturer’s plate is located on LH
Number (VIN), Gross Vehicle Weight, 4. Manufacturing Date code
For Cab chassis vehicle, body builder has frame side member behind rear spring
Gross Combination Weight (for applicable rear bracket.
models), Axle loads, Chassis Type, Engine to ensure the fittment of body builder’s
plate adhering to the above guidelines. Body Builder’s Plate Location
Type, Rear axle ratio and Engine number.
Vehicle Identification Number (VIN) Every unit fitted on the vehicle is
replaces the Chassis Number. identified with its type and serial number.
Body Builder’s Plate When referring to any problems or while
ordering spare parts, the operators are TO
F
ON E
requested to quote always the aggregate FR HICL AOT
VE
AOT
11200
11200
WAPL 13
type and serial number. This will help in
D19
17FT HS
D
WAPL 1 identifying the vehicle immediately and
6 4 20
13
3D19
17FT HSD effect supply of correct spare parts.
6 4 20
13 Body builder’s plate is located on front LH
side of the load body.
2.02 VEHICLE INDENTIFICATION

The engine serial number is punched on Front Axle (A36/A48)
IDENTIFICATION OF UNITS
LH side top rear of crankcase, behind Fuel
H4E4SD95E - CRS Engine Injection Pump.
Diaphragm Clutch
2
XX
XXXXXX
XX
XXXXXX
330 mm DIA DIAPHRAGM CLUTCH 380 mm DIA DIAPHRAGM CLUTCH

The front axle serial number and type of
Number is punched on the cover plate. front axle are punched on center of axle
Synchromesh Gear Box (ZF) beam.
The engine serial number is punched on
Rear Axle (Meritor)
LH side top rear of crankcase, behind Fuel IDENTIFICATION
PLATE
Injection Pump.
H6E4SD165E - CRS Engine
x
xxx x
xxx
XXXXXXXX
XXXXXXXX
The gear box serial number and type are

punched on the name plate provided on Type and serial number are punched on
selector housing side. the name plate riveted at left hand side of
the axle housing.
VEHICLE IDENTIFICATION 2.03

Rear Axle (AAM) CB18 - CRS Fuel Injection Pump Alternator (Bosch)
BOSCH XX-XX 24V
X XXX XXX XXX GENERATOR
550515409905BOXXXXX
Made in India 603
X XXX XXX XXX

XXXXXXXX
Rear axle serial number and AL spec

of rear axle are punched on LH side top as CB28 - CRS Fuel Injection Pump Model and serial number name plate
shown in above figure. placed rear side of alternator rear body.
Steering Gearbox Starter Motor (Bosch)
Pump
24V
XX-XX
BOSCH
XXX
XXX
X XXX
XXXX
05BOX 603
54099
55051
India
Made in
X XXX XXX XXX

XXXXXXXX
BOSCH XX-XX 24V
X XXX XXX XXX
Model and serial number plate placed on 550515409905BOXXXXX

Made in India 603
Steering Box
Center of the RH side pump body.
Identification plates are fixed on steering
Model and serial number name sticker
gear box.
placed as shown above.
2.04 VEHICLE INDENTIFICATION

3. Technical Specifications
The Model vs Aggregate Matrix covered in the following pages helps you to identify the
aggregates fitted on your vehicle type / nomenclature. The technical data about vehicle
performance, weight, leading dimensions are also furnished.
The detailed technical specification of all the aggregates are given in the subsequent pages.
Vehicles TECHNICAL SPECIFICATION
AGGREGATE BOSS 815 E-IV 3400 / 3900WB BOSS 1223 E-IV 4500 / 5100WB
Engine-Type H4E4SD110 E - IV H6E4SD165 Euro-IV
Power 150 HP @ 2400rpm 230 HP(165kW) @2500rpm
Torque 520 Nm @1400-2000 rpm 800 Nm @1400-1800 rpm
Bore X Stroke 104 X 113 mm 104 X 113
3
Engine rpm 2400 2500
Displacement 3.8L 5.7L
compression ratio 17.7:1 17.4:1
Air filter Twin element dry type with pre cleaner
Pre-filter cum water separator is fitted on the low pressure side and dual filter on the
Fuel filter
high pressure side.
Common Rail System (CRS) - CB18 Common Rail System (CRS) - CB28
Fuel Injection Pump
(Bosch) fitted with EDC 17. (Bosch) fitted with EDC 17.
Firing order 1-3-4-2 1-4-2-6-3-5
Tappet clearance Intake - 0.30mm, Exhaust - 0.45 mm
Cooling system type Circulating pump type, Forced circulation by volute pump
Cooling Fan Viscous cooling fan Viscous cooling fan - 610mm Fan Dia
Drive Poly 'v' belt drive
Air Compressor Gear Driven, 230 CC - Water Cooled
3.02 TECHNICAL SPECIFICATION

Clutch - Type Single dry plate,push type clutch with power assistance Diaphram
Facing Diameter 330 mm 380 mm
Lining type Schaeffler B8805 -Asbestos free Organic lining
Clutch Withdrawal Gear Hydraulic actuation
3
Gear Box - Type ZF S6-36 gearbox
No.Of Speeds 6 Forward + 1 Reverse
Gear Ratios I - 6.93, II - 3.79, III - 2.36, IV - 1.51, V - 1.0, VI - 0.84, Reverse - 6.22
Gear Shifting Mechanism Cable shifting Operation
Propeller Shaft - Type SPL 70 Series with 120 serrated flange SPL 100 Series with 120 serrated flange
No.of Shafts 2
Type of centre Bearing Rubber mounted
AAM - Fully floating , Single reduction Meritor - Fully floating, Single reduction
Rear Axle - Type
cast hypoid gear with ABS cast hypoid axle - ABS
Differential Hypoid
Capacity 7.6 T 8.2 T
Ratio 3.7:1 (Optional 4.1:1) 3.7:1
Wheel bolts 6 nos 8 nos
TECHNICAL SPECIFICATION 3.03

A36 Axle non driven Reverse Elliot, I
Front Axle - Type F48 axle, non driven reverse Elliot, I section
section with ABS
Capacity 3.6T 4.8 T
Wheel bolts 6 nos 8 nos
3 Frame - Type Bolted construction constant width over chassis
Section (HxWxT) 200 x 60 x 5 mm 204 x 63 x 7 mm
No. of cross members 8 cross member 10 cross member
Front - Suspension - Type Parabolic leaf springs , shock absorbers and anti roll bar
Capacity 1418 kg/Spring 4200 Kg
Span 1700mm 1700mm
Shock Absorbers Front and Rear Front and Rear
Rear - Suspension - Type Parabolic leaf springs , shock absorbers and anti roll bar
Capacity 3100 kg/Spring 8200 Kg
Span 1700mm
Steering System - Type ZF - Integral power assisted recirculating ball and nut type.
Drive LHD
Ratio 14.4 - 16.6:1 Variable Ratio (ZF)
Wheel Dia 446mm

Full air - dual line SCAM Brakes with
Brake System - Type Full air - dual line SCAM Brakes with ABS ABS (Optinal - Full air Dual line Caliper
Operated Disc Brake)
Braking Area Front & Rear 1360 cm2
Lining Thickness Front & Rear 10mm
3
Parking Brake Spring actuated , pneumatic (on rear only)
Electrical System - Type
System Voltage 24V System
Battries 150 Amp hr - 2X12V
Alternator Capacity 85 Amps (BOSCH)
Starter Motor 3.5 kW 24V (BOSCH) 4.5 kW 24V (BOSCH)
Instrument cluster - Type NGC Ecocluster
Isolater Switch Single Pole
Wheel Tyres - Type
No. of Tyres Front : 2 Rear : 4 & Spare: 1
Tyre Size 225/75 R17.5 245/70 R19.5 (GOOD YEAR)
Rim Size 6.75x17.5 6.75X19.5

Performance data
Max. Powered speed (km/hr) 111kmph
Max. Speed km/h 100 kmph @ 2400 rpm 122 Kmph @ 2500 rpm
Max.Running Gradeability % 32.3
3 Max. Restart Gradeability % 28.2 25%
Turning Circle Diameter Curb to Curb 12.25m 14m 14.80m 16.60m
Turning Circle Diameter Wall to Wall 13.35m 15m 16.98m 18.34m
Major Dimension (mm)
Wheel base 3440 3940 4500 5100
Front overhang 1225 1225 1225 1225
Rear overhang 1770 2075 2020 2420
Overall Chassis Length 6435 7240 7745 8745
Angle of approach (Chassis with Bumper) 17 Deg 16.5 Deg 18.3 Deg 18.3 Deg
Angle of departure (Chassis) 12.2 Deg 10.7 Deg 14.2 Deg 12.7 Deg
Ramp Break over angle 18.2 Deg 15.7 Deg 10 Deg 8 Deg
Overall Chassis Width 2200 2297
Front track 1905 1845
Rear track 1674 1740
Min. Ground clearance 168 200
Frame Height from ground (Laden) 830 910

Chassis Weights kg:
Front Axle 2180 2206 2643 2677
Rear Axle 1240 1256 1476 1485
Total Curb Weight (Chassis) 3420 3462 4119 4162
GVW 8200 8500 11990 11990 3

4. Instruments & Controls
)) Instrument Panel And Controls
)) Gauges
)) Warning Indicators
)) Instruments And Controls
)) Body Builder's Guidelines For EEA
)) LCD Display Screen - EEA
)) Combination Switch
)) Ignition Switch
)) Engine Start / Stop Procedure
)) Cab Exteriors
)) Cab Tilting Guidelines
)) Parking Brake
)) Economical Driving
)) Daily Checks
)) Weekly Checks
)) Do’s & Don’ts
)) Tips To Improve Mileage
Instrument panel AND CONTROLS
1. Combination switch LH
ON/OFF . ON/DOOR . ON/OFF
2. Instrument panel
3. Combination switch RH
4. Switches
5. A/C controls / Ventilation
control
6. Dummy blank
1 2 3 4 5 6 7 8 9
7. Adjustable vents - Middle
8. Storage box / fuse box 4
cover
9. Adjustable vents - Corner
R
L
OFF S
INT
TIME
HI
LO
INT
10. Steering wheel
MAN OFF
11. Horn
UP
F
12. Ignition Switch

3 5
R 1
24 V
2 4 6
13. Gear shift lever

14. Cup holder
10 11 12 13 14 15 16 17 15. Coin Box
16. Storage compartment
17. 24v socket
INSTRUMENTS & CONTROLS 4.03

Instrument panel
18 19 20 18. Panel Indicator LH
19. Panel Indicator Centre
20. Panel Indicator RH
21. RPM Meter
22. Temperature Gauge
23. LCD Display
24. Air Pressure Gauge Rear
25. Air Pressure Gauge Front
4 26. Fuel Gauge
27. Speedo Meter
28. Dummy
29. LED Dome Light
27 26 25 24 23 22 21 30. Sun Visor
18 19 20
28
O
N/
O
FF
.O
N/
DO
O
R
.O
N/
O
FF
29
30
4.04 INSTRUMENTS & CONTROLS

GAUGES −− F indicates Full tank. The best possible performance / fuel
−− 1/2 indicates Half tank. economy will be obtained if the engine
Speedometer speed is kept all time within the
−− E indicates Empty tank. “Economy” sector. This is indicated by the
80 green band in the rpm meter provided in
60 100 When low fuel telltale is ON, the instrument panel. It is advisable to
40 km/h 120 fill the fuel tank immediately. always operate the vehicle within this
WARNING
20 140 Green Band.
0 160 A minimum fuel quantity 15 Do not operate the engine
litres in rectangular tank is to
1/2
below 1000 RPM. Failure to

be maintained to avoid
E F
comply could lead to severe
CAUTION
situations of air lock. Air lock CAUTION
or frequent dry cranking of engine damage.

4
Speedometer indicates the road surface engine may result in damages
speed of the vehicle in kilo meters Pressure Gauge
to fuel injection equipment.
per hour (km/h). The vehicle is equipped with two air
RPM Meter pressure gauges.
Fuel Gauge
15 20
6
10 25
rpm x 100
1/2
5 30
0 90
35
C
E F 0 12
60 120
bar
Fuel gauge indicates approximate amount RPM meter indicates the engine speed in −− Pressure gauge 1 indicates the air
of fuel remaining in the tank. revolutions per minute. pressure of the front air tank

Temperature Gauge Do not drive the vehicle, if the
6 high engine coolant warning
2 CAUTION
telltale is ON. Wait for
90 sometime until the coolant
C temperature reduces, and
then open the coolant tank
0 12 and top‐up with water.
bar 60 120 Never remove the radiator cap
when the engine is hot. The
−− Pressure gauge 2 indicates the air engine coolant may be under
high pressure and temperature,
pressure of the rear air tank Temperature gauge shows the temperature
so wait for the engine to cool
4 Before moving the vehicle, ensure that of the engine coolant when the ignition
down before adding the
key is in ON position.
the air pressure is built up to 6 bar to coolant. Failure to comply
If the gauge temperature is could cause severe burns.
release the parking brake.
above 102°C, high engine
The low pressure warning buzzer which is coolant temperature warning
fitted on instrument panel will beep if the is displayed to indicate that
the coolant temperature has
air pressure drops below 4.5 bar or the exceeded the normal working
parking brake is on. temperature.
In case of air leak in front or rear circuits, Operate the cluster controls
the particular gauge connected to such and information display only
circuit will show comparatively low or nil when the vehicle is stationery.
WARNING
air pressure. In such case the vehicle can Concentrate on the road while
be driven cautiously at lower speed with driving, as the driver is totally
responsible for the vehicle
single circuit to the nearest Workshop.
and road safety.

WARNING INDICATORS
Telltales Description Color Glowing Type Input Type
Exhaust Brake Amber Continuous Active High
Air Filter Blocked Red Continuous Active Low
Turn Left Green Blinking At Rate Of Flasher Input Active High

4
Rear Fog Amber Continuous Active High
Cab Tilt Red Continuous Active Low
Front Fog Green Continuous Active High
Active Low (Effective Resistance

Battery Not Charging Red Continuous
Should Be Equivalant To 3W)
High Range Gear

Green Continuous Active Low
Indicator

WARNING INDICATORS
Low Oil Pressure Red Continuous Active Low
High Beam Blue Continuous Active High
Seat Belt Red Continuous Active Low

4
Park Brake Red Continuous Active Low
Load Body Tipping Red Continuous Active Low
When Both Rh & Lh Indicators

Hazard Red Continuous
Are On Turn, On Hazard Telltale
ABS Amber Continuous Active Low
ABS1 Amber Continuous Active Low

WARNING INDICATORS
Air Pre-Heater Amber Continuous Active High
Turn Right Green Blinking At Rate Of Flasher Input Active High
Refer (Sheet 2 Of 3 Si.No.6 ) Air Pressure

Low Air Pressure Red Continuous
Gauge Details
4
High Temperature Refer (Sheet 2 Of 3 Si.No.5) Temperture
Red Continuous
Warning Gauge Details
Low Fuel Level Refer (Sheet 2 Of 3 Si.No.4) Fuel Gauge

Amber Continuous
Warning Details
Low Adblue Warning Red Continuous Can Message
Amt Failure Red Continuous Can Message
Amt Warning Amber Continuous Can Message

WARNING INDICATORS
Over Speed Red Continuous Internal Logic
Water In Fuel Amber ----- +Ve & -Ve Input Will Be From ECU
Immobilizer Red ----- +Ve & -Ve Input Will Be From ECU
4
Diagnostic Lamp 12V Red ----- +Ve & -Ve Input Will Be From ECU
Diagnostic Lamp 24V Red ----- +Ve & -Ve Input Will Be From ECU
MIL Amber ----- +Ve & -Ve Input Will Be From ECU

INSTRUMENTS AND CONTROLS EEA provides efficient diagnostics
functionality. E/E system is capable of
Analog Inputs
detecting the electrical diagnostics like
short to battery, short to ground and open
Digital Inputs Power Outputs load errors. It protects the vehicle from
Frequency Inputs short circuits through its internal logic
EDS
modules.
BCU
ABS
A unique, state-of-the-art Electrical and
Electronics (E/E) architecture has been
CAN - 1
CAN - 2 established for our commercial vehicles
PTO
CAN - 3
named as “Ashok Leyland Vehicle
Electronics Distributed Architecture” 4
OTHER ECU’S (ALVEDA TM)
CLUSTER
CAN - D
DIAGNOSTICS ALVEDA Components:
Body Control Unit (BCU) - Acts as an
interface to inputs, outputs & Electronic
Power Outputs
control units
MUX Multiplexer (Mux) - Drives rear electrical
loads & communicates with BCU on CAN
Electronic Cluster - Acts as Human-
CAN 1 Power Train CAN (EMS ECU, ABS ECU) Machine Interface (HMI)
CAN 2
CAN 3 MUX CAN (Rear Nodes)
CAN D

Body controller Instrument Cluster
BCU processes all input signals from This is a complete CAN based Electronic
switches and sensors and drives the front Instrument Cluster that replaces all the
mechanical gauges with Stepper Motor
loads, it communicates with MUX on CAN
Driven Gauges which improves the
to control the rear loads. It communicates reliability. The Instrument Cluster has 34
to Cluster on CAN for display of messages, Telltales driven by LED’s and pictogram on
Telltale and gauges. It also serves as a the Monochrome LCD display. Trip
gateway to the other electronic units in Information (Distance, fuel Economy) and Night view of cluster
the network. It acts as a Single point Diagnostics Information of all ECUs ALVEDA CAN Network
diagnostic interface to all the ECUs connected in the network is displayed.
CAN 1 : Power Train CAN- ECUs like EDC
(Engine ECU, MUX, Instrument Cluster, The HMI is through the 2 Push Buttons ECU, ABS ECU, and AMT ECU are
4 AMT and ABS ECU) connected in the (SET & Mode) on the Instrument Cluster connected to BCU via power
network through CAN. BCU performs (used for resetting the trip meter, date & train CAN. These ECU’s are
electrical load management and in Time settings, LCD Brightness settings & responsible for controlling the
Scrolling between different pages of LCD). power train of the vehicle.
vehicle network management. It not only
Gear Shift Advisory System which is CAN 2 : Infotainment CAN -Instrument
drives the load but also detects the available as integral part of cluster Cluster and Telematics unit are
electrical diagnostics like short to battery, provides advice to the driver for connected to BCU via
short to ground and open load errors. improving the driving pattern. Infotainment CAN. These ECUs
Multiplexing Unit (MUX) display information to the driver.
CAN 3 : MUX CAN for Rear Nodes -
MUX is an electronic Control Unit that Multiplexing unit is connected to
controls all rear tractor and trailer & BCU via MUX CAN to
tipper loads. It Communicates with the communicate with the rear loads
of tractor, trailer & Tipper’s.
BCU through CAN. It not only drives the
CAN 4 : Diagnostics CAN - This CAN is
load but also detects the electrical used for flashing the ECUs and
diagnostics like short to battery, short to for connecting diagnostic tool
ground and open load errors. Day Light view of cluster for ECU diagnostic in the vehicle.

BODY BUILDER'S GUIDELINES FOR EEA −− Ensure the fuse (Maxi, MUX and BCU) 10 - 12 Nm (for M8 Bolt).
connections of EEA system are −− Connectors of the BCU must be
−− Before and during welding undisturbed. connected or disconnected only
a. Switch off the battery isolator −− To power BCU, MUX and cluster when the power is switched off /
b. Disconnect the BCU (4) connectors minimum 20 volts is required at its Ignition switch is in OFF position.
and MUX (1) connector. corresponding terminals −− Trouble shooting should be done only
c. Avoid falling of hot weld spatters −− Emergency start is available (pressing at AL authorised service / Dealer’s
on wiring harnesses, BCU, & MUX. ignition start & emergency start point. Carry out the trouble shooting
d. Do not disturb the clamps of switch) simultaneously. of EEA along with its testing tool.
Wiring harness. Disconnecting
Do’s & Don’ts −− Continuity check on the wiring
BCU connectors (4) and MUX
harness with opened connector ends
connector (1) is allowed only at DO's
(no power supply to BCU, MUX & 4
AL authorised Dealer’s service −− Care needs to be taken while cluster) can be done if it is found
point. removing the battery connection extremely essential & unavoidable.
−− Do not disturb/remove the ground during body building & reconnect the Care must be taken not to damage
connection provided at two places terminals with correct polarity. the terminals, pins and rubber seals.
(chassis, starter motor negative to −− Check the battery condition regularly −− Attempt verification / checking of EEA
engine block). & keep the batteries in healthy parts including wiring harness after
−− Do not disturb/remove the ground condition. confirming & clearing identified
connection provided on all sensors.
−− Ensure proper connectivity of BCU, mechanical troubles as there might
The ground connections to be
MUX & Cluster along with Sensor be a wrong lead of EEA malfunction
provided as similar to the connections due to effect of mechanical troubles
connections.
provided by the manufacturer.
−− Do not remove/cut/ add any wires −− Keep the ignition switch in OFF −− Advise drivers on OBD - (on board
condition while removing the battery diagnostics menu screens)
of architecture wire harness.
from the vehicle. −− Run EEA system always with batteries
Unprescribed extension or
intermediate splices are not permitted. −− Ensure the tightening torque is connected.
achieved on mounting the BCU, MUX.

−− Ensure all connectors are positioned Don’ts output pins are considered for
properly and well connected. Positive −− Electrical tapping is not allowed on designated load current. During such
locking to be ensured. EEA system. Tapping should not be cases, the additional loads can be
−− Ensure the proper fitment of 20A taken as this can severely affect the connected from the separate fuse
fuse for BCU, MUX provided in the performance of the BCU, MUX & provided in the chassis main fuse box.
fuse box. Spare fuses are available on cluster. This has to be done at AL service \
the wire harness (inside polythene Dealer’s point only. This is to avoid
−− Care should be taken while washing
cover of main wiring harness). the damage on the wire harness
the vehicle. Do not direct jet of water
provided by the manufacturer.
−− Ensure the ignition switch and on to the BCU, MUX and other
battery isolator switch are in OFF electrical components. −− Never change (increase or decrease)
condition when the vehicle is parked. the fuse rating provided in the CAB/
−− Diagnostic and USB connector should
4 −− After ignition is turned off, allow Chassis fuse box.
not be left hanging loose and should
40 secs “after-run” before removing be handled with care. −− Do not change the mounting position
the power from the battery (i.e.) of the BCU, MUX and its mounting
−− USB connector has to be utilised only
switching off Isolator switch. panel.
for data logging.
−− Whenever error is recorded in the −− No undue pressure to be applied on
−− Avoid using USB connector for
BCU and same error is rectified , it is to the BCU, MUX during service.
charging the mobile phones & for
advised to turn off the ignition once Music players. −− Do not touch the pins of the BCU,
to reset the error. Without resetting MUX & cluster to avoid damage due
−− No higher wattage loads to be
the error status, BCU and MUX shall to electro static discharge.
connected \ replaced on existing
not provide desired output. −− Never attempt to connect negative
electrical loads which will affect the
performance of the normal operation battery cable to positive terminal of
of the corresponding electrical loads. battery and positive battery cable to
negative terminal of battery. This will
−− Mid tapping (load output side) on
damage EEA system electrical &
wire harness is not acceptable as the
electronic units.
wire harness cross section and

−− Do not test (continuity check) of BCU,
MUX pins with multimeter.
−− Developed EEA wiring harness is
provided with prewired connectors
to avoid any disturbances and mis
connection unless it is induced.
Discourage frequent connection and
disconnection of connectors. This
would lead to malfunction of BCU,
MUX and sensors of EEA system.
−− Do not use heavy tools / spanners /
screw drivers to remove the BCU, 4
MUX connectors & sensors. Consider
the guidelines of engineering
sketches for fitment & removal.
−− While coiling or ending of cables /
wires avoid sharp bends or folding.

LCD SCREEN DISPLAY DETAILS
DISPLAY MODES CASE DISPLAY STATUS FUNCTION
All Segments On For 5 ± 0.5

Boot Screen Seconds Only (Self Test Time Initialization Screen Every Ignition On.
Which Is Configurable)
Set Button If Pressed <3 Sec. Screen Will Jump To

Screen 12.
4
Screen - 01 Mode Button If Pressed <3 Sec The Screen Will Jump To
Default Screen Amt Screen Main Odo Meter The Next Screen.
Segment 1 & 2-Gear Display. Segment 3-Gradient Assist
(If Amt (Default) Segment 4-Crawler(C). Segment 6-Power (P) / Economy
Feature Enabled) (E) / Super Power Mode (S).
Gear Message Is Not There, Than Display '__' At Gear
Position

Screen - 02 Screen 01.
Real Time Digital Clock Mode Button If Pressed <3 Sec The Screen Will Jump To
Default Screen
5 0.5 Seconds Only The Next Screen.
(If Amt Set Button To Be Pressed For >3Sec. To Enter Into Clock
Main Odo Meter (Default)
Feature Disabled) Setting Mode.
(Refer Rtc Setting Procedure)

Screen 02.
Date Mode Button If Pressed <3 Sec The Screen Will Jump To
Screen - 03 The Next Screen.
Main Odo Meter (Default) Set Button To Be Pressed For >3Sec. To Enter Into Date
Setting Mode.
(Refer Rtc Setting Procedure)

Real Time Digital Clock Screen 02.
Screen - 04 Mode Button If Pressed <3 Sec The Screen Will Jump To 4
(Default) Trip A Km The Next Screen.
Set Button If Pressed >3 Sec Trip A Reset

Screen - 05
Fuel Economy Trip A Mode Button If Pressed <3 Sec The Screen Will Jump To
The Next Screen.

Screen 05.
Real Time Digital Clock
(Default) Trip B Km
The Next Screen.
Set Button If Pressed >3 Sec Trip B Reset

Screen - 07
Fuel Economy Trip B Mode Button If Pressed <3 Sec The Screen Will Jump To
The Next Screen.

Screen 07.
Screen - 08 Distance To Empty
Mode Button If Pressed <3 Sec The Screen Will Jump To
4 The Next Screen.

Screen 08.
Screen - 09 Battery Voltage
Screen 01

Screen - 10
Screen 09.
(If Adblue Adblue Level
Feature Enabled)
The Next Screen.

Screen - 11
Hour Meter Mode Button If Pressed <3 Sec The Screen L Jump To
The Next Screen.

Screen 11.
Real Time Digital Clock
Diagnostic Code
Screen 01 If Amt Feature Enabled.
Will Jump To Screen 02 If Amt Feature Disabled.
Mode Button And Set Button Pressed >5 Sec The
Screen.
Screen - 13 Software Revision Will Jump To Screen 01 If Amt Feature Enabled.
Will Jump To Screen 02 If Amt Feature Disabled. 4
(Applicable From All Screens) Time Out Of 3 ± 0.5 Sec.

COMBINATION SWITCH Wipers OFF Intermittent wiping time adjustment
The combination switch is a multifunction

switch mounted on the steering column.
Wipers S
HI
S
INT
TIME
HI
LO
MAN INT LO
TIME INT MAN
The wipers can be operated at different

UP INT
UP
F OFF OFF
speeds by rotating the knob to the
F
OFF INT - F
required mode. The wipers operates
when the ignition key is in ON position.
Wiper button has 4 positions. In this position, wiper is in OFF condition. Intermittent wiping time can be
4 1. OFF : wiper is in OFF condition selected from slow to fast by turning
Intermittent Speed Wipe
the rotary ring as in the fig. The wiping
2. INT : Intermittent wipe interval is the shortest in the position F
3. LO : Low speed wipe (Wiping will be fast).
4. HI : High speed wipe S

HI
INT
LO
MAN
UP TIME INT
F OFF
INT HI
S TIME
LO
INT MAN
UP INT
F OFF
INT - F
Turn the rotary switch as in above fig.
Wiping will be intermittent and not
continuous.
The wiping interval is the longest in
the position S (Wiping will be slow).

Low Speed Wipe Windshield washer Turn signals
Move the lever perpendicularly towards
the steering wheel axis to switch the turn
HI
signals ON.
S
INT
LO
MAN HI
UP TIME INT S
INT
LO
OFF MAN
F UP TIME INT
R
F OFF
LO L
OF
F
R
At this position, the wiping speed is slow Windshield wipers and washer are active
and continuous. when the ignition is turned "ON". 4
High Speed Wipe Push the switch at the end of the control
lever to turn on the washer. The washer
pump will operate until you release the
switch.
HI
S
INT
LO
MAN
UP TIME INT
F OFF
HI
At this position, the wiping speed is High

and continuous.

R  turn signal - lever up. Move the Headlight flasher / Low and high beam
lever as shown in above fig for changing
Right turn.
R
L
OFF R
L
OFF
R
L OFF Side marker lights on. In this
L position, Side marker Lamps are
illuminated.
4 L For high and low beam operation, lift the
 turn signal - lever down. Move lever UP as in image. Headlights High
the lever as shown in above fig for beam is on until you release the lever.
Left turn.
R For permanent high beam, Press the lever
Side marker lamps and low beam L
down. Pull the lever to the initial position
OFF to change over to the low beam.
R
L
OFF
Low beam (and/or high beam) ON
OFF
Turn the rotary end of the lever to switch
on head lamp. Low beam is selected by
default.
OFF : Lights off. In this position, Instrument
panel Back lights are OFF condition.

IGNITION SWITCH LOCK ON
Switch position
CK AC
LO
C
ON STAR
T
When the ignition key is in ON position,
In this position, electrical systems are functions like wipers and combination
disabled except a few like parking lamps, switch are activated.
Ignition key barrel hazard warning indicators and horn. 4
START
The ignition key barrel is located on the −− Insert or remove the ignition key only
right side of the steering column. in this position.
Before starting the engine, check whether ACC
the gear is in neutral position else engage
the gear lever in the neutral position.
The ignition key barrel has four positions
1. LOCK
2. ACC Turning the ignition key to START position
3. ON activates all vehicle functions and the
engine is ready for use.
4. START Once the engine is started, the engine will
Turning the ignition key to ACC position not crank again (Anti-cranking) while
running, even if the ignition key is turned
will switches on all electrical accessories.
to START position.

ENGINE START / STOP PROCEDURE Do not operate the starter To warm-up engine
motor for more than 10 seconds −− Switch on the ignition.
Before starting ensure that the gear is in
continuously. −− Do not depress the accelerator pedal.
neutral position and the parking brake is CAUTION
If the engine does not start, −− Crank engine (10 secs maximum)
applied.
wait for 30 seconds before the until it starts.
To reduce transmission drag on cold
next crank.
vehicles, depress the clutch pedal. −− Check oil pressure - minimum 0.5 Kg/
Do not leave the ignition key
cm² at idling.
If it is required to start the in ON position, if the engine is
vehicle in a garage or workshop, not running. Failure to comply To obtain trouble free and long
ensure that adequate will lead to battery discharge. life from the turbo charger,
NOTE
ventilation is provided. Idle the engine always about 2 CAUTION
keep the engine in idling rpm
4 minutes after starting and immediately after starting and
Engine Start Procedure before switching off the before stopping, for about
1. Insert the ignition key into the engine. 2 minutes
ignition key barrel located on the Do not switch-off the engine
After starting the engine proceed slowly
right hand side of the steering through gears
and keep engine at an average speed until
column. Turn the key to start normal operating temperature is reached.
position. Do not remove the ignition
By this method it is possible to obtain:
key from the ignition lock until
2. Turning this key further will crank the −− Optimum oil flow throughout the
the vehicle is stationary, since
engine. After starting the engine WARNING
lubrication circuit
it is not possible to steer the
release the key immediately.
vehicle, if the key is removed. −− Exhaust gases within the specified
limit.
−− Fuel economy.

Engine Stop Procedure ENGINE COLD START GUIDELINES 5. Solenoid circuit resistance to be 90
milli-ohm maximum @+20°C as per IS
A cold start device is required to start 13226.
an engine at adversely low ambient 6. Alternator: Bosch 85 Amps to be used
conditions. Ashok Leyland engines are which is already used for Russian
capable of starting up to -10 deg °C application.
without cold start device. Fuel System
With grid heater AL engines can be
CK AC
C
LO
ON
1. Use Nylon fuel pipe which will have
STA
RT
started till -25 deg °C. advantage of thermal insulation
However a cold starting device is required property.
for ambient conditions lesser than -25° C. 2. Fuel filters should be close to engine
The ignition key provided with the vehicle
Starting System to get warmed up fast.
is used to start and stop the engine. 4
1. For cold sub-zero condition higher 3. Based on AL cold start experience, it is
Always remove the ignition key recommended to use ATF+0.4%
while leaving the vehicle. Avoid Amp-hr. battery is recommended to
reduce internal resistance of battery NO- NOx Additive to prevent fuel
NOTE rough handling. coagulation.
and provide higher voltage to ensure
higher cranking speed. Air Intake System
2. Battery should be close to starter The engine is equipped with an intake
motor to maintain minimum cable grid heater to heat the intake air to aid
length thereby to reduce the starting the engine in cold weather
resistance. conditions. (beyond -10 °C)
3. Ensure battery to be minimum 80% Grid heater requirements:
state of charge in all the cells i.e., 1. Supply voltage for preheating is 24
specific gravity of electrolyte: 1.28. volts.
4. Total Cable Resistance of starter 2. Preheating time should not be more
circuit to be 1.7 milli-ohm maximum than 30 seconds.
@ +20°C (approx.) as per IS 13226. 3. After engine start-up, the air inlet

heater can be activated for an 3. From cylinder block / coolant elbow.
extended post heat cycle. The grid Do’s & Don’ts for Cold start operation
heater will operate for an additional
Do’s
15 seconds (post heat) in order to
have a smooth running of engine. 1) Monitor the oil pressure and coolant
temperature gauges frequently.
Cooling System
2) After starting a cold engine, increase
For extremely cold operating conditions,
the engine speed (rpm) slowly to
a 60/40 mixture (coolant/water ratio) can
provide adequate lubrication to the
be used.
bearings and to allow the oil pressure
Exhaust System to stabilize.
The SCR system requires a reagent called 3) Check all rubber parts weekly: hoses,
‘Ad-blue’ to be injected in the exhaust tires, and fan drive belts.
4 stream to reduce emissions to meet the
4) Check all electrical wiring and
Emission norms.
connections for any fraying or for
This reagent has a limitation with respect damaged insulation.
to operation at sub-zero temperature.
Don’ts:
The freezing point specified for Ad-blue
is -11˚C and would require additional 1) Using starting fluid (like ether) to help
heating kits. These kits require the engine start the engine could cause a fire
coolant to circulate through the Ad-Blue or explosion, resulting in personal
tank to prevent it from freezing. Three injury, property damage and severe
locations have been identified for tapping engine damage. Do not use starting
the engine coolant for circulation as fluid to start this engine.
mentioned below: 2) Avoid smoking when checking battery
1. From thermostat housing above the electrolyte levels.
by-pass 3) Electrolyte is an acid and can cause
2. From thermostat housing below the personal injury if it contacts skin or
by-pass eyes.

GRID HEATER CIRCUIT DIAGRAM - ECU CONTROLLED SYSTEM GEAR SHIFT LEVER
3 5
R 1
2 4 6
Gear Shift Pattern

4
R 1 3 5
2 4 6
Grid Heater Operation ECU will not switch ON the Grid
1) If Driver turns the ignition Key Switch, Heater.
ECU Switches ON the Grid Heater for 3) If Coolant temp is more than -10 deg Engage gear speeds mechanically by the
30 Sec (Pre-Glow) and 15 Sec C; ECU will not switch ON the Grid gearshift lever with the clutch pedal
(Post Glow) along with tell-tale Heater. depressed.
indication through instrument cluster.
2) If Battery Voltage is less than 16 V;

STEERING WHEEL ADJUSTMENT Steering Adjustment Horn Pad
The steering column height and reach of
the steering wheel can be adjusted.
1. Pull the lever to unlock the steering
column
2. Adjust the steering wheel to the R
L
OFF S
INT
TIME
HI
LO
INT
desired position. Steering wheel can

MAN OFF
UP
F
be tilted towards the driver and away R 1

3 5
5
3
6
1
from driver as well as pulled axially up

R
2 4 6
Lever and down as indicated by arrow

marks in the image.
4 Horn pad is located at the centre of
3. Lock the steering column in position
Steering wheel.
by pushing the lever down.
4. Ensure the steering column is locked
in position before driving.
Adjust the steering wheel only

5
3
6
1
4
R
when the vehicle is stationary

5
3
6
1
4
R
and when the parking brake is

WARNING engaged. Failure to comply will
lead to accidents
Steering column
The steering column is designed as
telescopic and tiltable type to reduce
fatigue while driving.

BATTERY Battery Circuit Breaker (Isolater Switch) FUSE BOX & RELAYS
Fuse box consists of fuses for circuit
operations and spare fuses for emergency
requirements. The lamps/units protected
by the fuses and the corresponding fuse
OFF ON
ratings are indicated on the fuse box
A B
cover.
OFF
ON
OFF
ON
Position A: circuit breaker OFF

Check the battery condition, electrolyte
level and tightness of the ground screw. Position B: circuit breaker ON 4
When disconnecting the battery Never shut the engine off by
terminals, be sure to disconnect first the the battery circuit breaker -
negative ("–") terminal. Proceed with care this could damage the
during removal of battery terminals not CAUTION electrical equipment and
to cause short-circuit between "+" battery alternator.
terminal and vehicle ground. After
cleaning and careful connection of
terminals connect the positive terminal
("+") to the battery circuit breaker.
Replace the discharged battery with a
battery of the same capacity, voltage,
ampere load and size.
The used battery must be
disposed off with regard to
WARNING environmental regulations.

FUSES AND RELAYS LAYOUT
HEAD HEAD DUMMY

F48 15A
LAMP LAMP
HIGH LOW F47 15A
BEAM BEAM
R14
SPARE 15A
R25 R26
SPARE 40A
AIR REAR FOG F46 15A
CONDITIONER LAMP F25 F26 F27 F28 F29 F30
STOP PARKING WIPER RELAY CONTROLLER
F45 20A
LAMP LAMP INTERMITTENT - 10A 30A 40A 10A 10A
MODULE R7 R8 F44 20A
R23 R24 R13 DUMMY
SPARE 30A
MIRROR
SPARE 10A
F43 15A F19 F20 F21 F22 F23 F24
HEATER
WIPER HORN POWER
F42 -
4 HIGH WINDOW 10A 10A 10A 10A 10A 10A DUMMY ABS
MOTOR -
PASSENGER UP
R5 R6 F41 -
EX
BRAKE
R21 R22 R12 STARTER ACCESSORIES
SPARE 10A
F40 5A
SPARE 25A
RELAY RELAY F13 F14 F15 F16 F17 F18 R28 R27
EDC EDC POWER
F39 -
BRAKE AC WINDOW 15A 5A 10A 10A - 10A
REQUEST MOTOR - R3 R4 F38 15A
PASSENGER
R19 R20 DOWN R11 IGNITION IGNITION
F37 10A F7 F8 F9 F10 F11 F12
SPARE 20A
SPARE 5A
RELAY 1 RELAY 2
WIPER WASH POWER F36 30A
LOW PUMP WINDOW 20A 5A 25A 15A 5A 5A
MOTOR- R1 R2 F35 5A
DRIVER UP
R17 R18 R10 F49 F50 F51 F52 F53 F54

F34 30A F1 F2 F3 F4 F5 F6
SPARE 15A
SPARE 5A
FRONT SCR POWER F33 -

FOG HEATER WINDOW - 5A 10A 10A 10A 10A 10A 10A 10A 5A 5A 40A
LAMPS MOTOR- F32 -
DRIVER DOWN
R15 R16 R9 F31 30A NOTICE: USE ONLY DEFINED FUSES AND RELAY

Fuses & Relays SWITCH LEVELLING
Head lamp dipped beam vertical

orientation is ensured by AL for the
chassis. Dipped beam plate is fixed near
chassis identification plate, indicating the
0 1 2 3
set value for initial beam inclination.
However the head lights & beam
Above image shows removal of fuse box
Switch Control for Levelling Motor orientation should be checked and
cover to access fuses and relays.
Head lamp dipped beam shall always adjusted by authorized dealers whenever 4
be tilted downwards, under all loading head lamp is replaced during
conditions (empty / laden), to avoid glare maintenance.
to vehicles coming in opposite direction.
This is achieved with the help of Head
24V
lamp levelling motor & switch

arrangement.
Levelling motor is used to tilt the dipped
beam downwards and it is operated by a
Fuses and relays are shown in the above switch from dashboard.
image. LX models will have EDC Always keep the switch in ‘0’ position in
Diagnostic request switch and EDC unladen condition. Refer TABLE for
Diagnostic socket beside fuses and relays. levelling switch position in laden
condition.

CAB FEATURES Pedals And Controls Cabin Door Key
BOSS cabin is a factory built twin seater

day cab. Comfortable driver seat,
ergonomically located controls, generous
stowage space, excellent visibility and
ventilation are some of the salient A
features of the cab. The BOSS cab spells
new levels of comfort and safety.
CAB INTERIORS
Cluster instrument panel C B
18 19 20 The cabin door key provided with the
4
The pedal position & arrangement are vehicle is used to lock and unlock the
shown in the illustration. doors.
A. Accelerator pedal The doors can be locked or unlocked
using the cabin door key. For unlocking
B. Brake pedal
the driver side door, insert the key in
C. Clutch pedal vertical position, turn to clockwise and
again back to original vertical position to
BOSS
27
cabin
26
is provided
25
with
24 23
ergonomically
22 21 unlock the door. For locking, turn the key
designed cluster instrument panel. The anti clockwise and then back to original
instrument panel houses air pressure vertical position and remove the key.
gauges, water temperature gauge, fuel
gauge, speedometer & engine rpm meter.
Also it has battery charge indicator, low oil
pressure warning light, parking brake
indicator, head lamp indicator & LH/RH
directional indicators.

Fuel Tank Key Cup holder Coin Box
R
L
HI
OFF S LO
INT
INT
TIME
MAN OFF
UP
F
3 5
R 1
24 V
2 4 6
Fuel tank key allows the driver to lock and To slide the holder out, push it and Pull it to open. Never put paper and other
unlock the fuel tank cap. release. After use, slide it back. flammable objects in the ashtray - danger 4
Sun visors Do not use the cup holder if of fire.
the vehicle is in motion. Storage Compartment
Do not use the cup holder to
NOTE
hold other objects.
Sun visors are situated above the

windshield in the cabin ceiling.
They can be tilted as desired. Use to store documents and small
Adjust the sun visors to protect you articles.
against sun glare.

Inner door lock Ensure the doors are locked Doors and Steps
LOCK properly before starting the
WARNING
vehicle to avoid accidental
opening of doors during
UNLOCK
motion.
Ensure the path of door
opening is clear from
B
obstruction.
A
To Lock A. Speakers : Provided on doors for audio.

4 Pull the door grab handle to close the B. Door pouch : Provided to keep
door Press the lock button to lock (small magazines and other articles.
size) the door securely. Cabin Door
To Unlock The cabin doors are designed to open 90°
Pull and unlock the lock button wide allowing the driver and codriver to
(small size). enter and exit the vehicle easily.
Pull the lever below lock button gently to Ensure that fingers and hands
open the door do not get trapped while
Hold the door grab handle and push CAUTION closing the door.
gently to open the door.
Cabin light will glow
continuously, if the doors are
NOTE not closed properly.

Fixed Steps Door Handles Manual Window Controls
The door handles are used to close the Rotate the window regulator handle
Fixed steps are provided at a lower height
door from inside.
to reduce the effort while entering and Clockwise to raise the glass and 4
exiting the vehicle. The door handles also act as an extension anti-clockwise to lower the glass.
of the armrest, providing the driver added
Grab handle
comfort while driving.
Cabin Rear Windows
Two grab handles each are provided on

the left and right-hand sides of the door The rear window behind the driver and
entry to reduce the driver and codriver’s co-driver’s seat provides rear view of the
effort during cabin entry and exit. vehicle.

Doom Lighting Windshield Seat controls
1
2
O
N/O
FF
.O
N/D
3
O
O
R
.O
N/O
FF
1 3
2
1. Cabin light switch
• A single piece laminated windshield is 1. Horizontal Adjustment
4 2. Door switch pasted on the cabin for better visibility. 2. Height And Slope Adjustment
3. Cabin light switch 3. Backrest Adjustment
Do not drive with a damaged
• The cabin light is turned ON and OFF windshield. Replace it Storage compartment
using the cabin light switch. immediately at an authorised
CAUTION
• When the door switch is pressed the Ashok Leyland Service Centre.
cabin light illuminates whenever any
one of the door is opened and
automatically turns off when the
door is closed.
Do not use the interior lights
for extended hours when the The storage compartment as seen in
CAUTION
vehicle is stationary. Failure above image is available below the
to comply will lead to battery co-driver seat, which carries tools and
discharge. jack rod. Lift the co-driver seat to access
the storage space.

Ventilation Deflect the fins (item 5) at air vents to 3. Heater valve control knob - regulation
II III IV
change the angle of airflow. The air of temperature of the airflow.
volume emitted from individual vents is 4. Regime of air circulation.
I controlled by thumb wheels (item 6).
Window Defogging (if Heating opted):
Item 5 & 6 are shown in the next page
)) (item 1) fully to position IV.
If heating is Opted:
)) (item 3) to extreme left.
The cabin is heated by the radiator hot
coolant. )) (item 2) to position .
1 4 2 3 The heater is controlled by heater control )) Set the regime of air circulation to
elements on the instrument board. fresh mode
Ventilation (Heating as an Option): )) Close air vents by thumb wheels.
1. Heater fan control.
By turning the heating control knob Windshield Defrosting (if Heating opted): 4
(item 3) you will regulate volume of cold 2. Airflow direction control,
and hot air flowing into the cab (turn the )) (item 1) fully to position IV.
control knob to the red zone to supply the to crew heads. )) (item 3) to extreme left.
hot air). )) (item 2) to position .
Use the control knob (item 1) to adjust )) Set the regime of air circulation to
the fan speed and thus the air volume to crew feet and heads.
fresh mode
circulating through the system. The
airflow speed can be set in four steps. )) Close air vents by thumb wheels.
The control knob of the airflow direction to crew feet.
(item 2) allows you to change the
direction of airflow (way of cabin to feet, windshield and side
heating). windows.
Push the button(item4) to turn ON/OFF
the regime of circulating air in the cabin to windshield and side windows.
(Recirculation/Fresh)

ON/OFF . ON/DOOR . ON/OFF
5 5 5 5
R
L
HI
OFF S LO
INT
INT
TIME
MAN OFF
UP
F
3 5
R 1
24 V
2 4 6
5 5 5 5
When windows are still being fogged (for Ventilation: Maximum heating (if Heating opted):
example in rainy weather), it is necessary: )) (item 1) to desired position. )) (item 1) to position IV.
)) (item 1) to position II or III. )) (item 3) to extreme right. )) (item 3) to extreme left.
)) (item 2) to position . )) (item 2) to position (or to desired )) (item 2) to position .
)) (item 3) if necessary, turn on heating. position). )) Switch on the regime of air
Optimum heating (if Heating opted): circulation to fresh mode.
)) (item 1) to position II or III.
)) (item 3) to desired heating output.
)) (item 2) to position .

CAB EXTERIORS Front lid Raise the front lid.
Take strut out of holder (item A) and
Mirrors 1
insert the strut end in hole (item B) to
B
secure the lifted front lid.
A
Closing the front lid
B N
LY
BRA KE FLUD
D OT
Raise the front lid slightly.
O
SE
3
-D
R EMOVI NG U
OT
4 FRO
M
A SEALE D CON
ORE
EF
PB
CA
N
TA
EA NE
I
CL R
WAR NIN G
MAX
MIN
D MIN
MAX
A
Unhook strut from hole and put it in
C 2 holder (item A).
Tilt the front lid in the vertical position
and push its lower edge until it clicks into
Opening the front lid lock (item 2). 4
When the front lid snaps in, you can hear it.
A. Proximity mirror Push the front lid in its lower part, press
the release lever (item 1) to lift.
B. Rear view mirror You should check a proper
C. Wide vision mirror front lid locking whenever you
Before driving your vehicle, the mirrors CAUTION move off
must be checked and if necessary
adjusted to give the best possible
rearward vision.

Hydraulic cabin tilting Insert jack rod into lever of the hydraulic
Boss vehicle is provided with effortless pump. Actuate the jack rod to operate the
cab tilting mechanism. Hydraulic tilting is pump and tilt the cab. Hydraulic locks of
provided to ensure smooth and effortless the rear location will open and cabin
cabin tilting. starts to tilt itself.
The cabin must be tilted fully to its tilted
position. A partial tilting is not allowable
for entering beneath the cabin.
Cab is provided with a free fall
The above image shows the lever position in last 10 degree during tilting
for cabin lowering as well as vehicle WARNING
this happens after complete
4 tilting of cab). Exercise caution
driving position.
and do not work under the
cabin while tilting.
Cabin lowering
Rotate the hydraulic pump lever
clockwise to tilt the cab. Lever position in Turn the hydraulic pump lever into anti
Up arrow indicates that the cab will be clockwise position downwards.
tilted. Down arrow indicates that the cab Pump until locks of the rear location are
will be lowered and ready for driving. closed (cabin rests down in place and is
Always drive the vehicle keeping the lever locked).
in the downward arrow position.

CAB TILTING GUIDELINES
Caution
Switch off engine: Engine to be switched off before and during cab tilting
Apply parking brake

4
Keep doors closed before tilting. During cab tilt there should not be any external restriction
Keep the gears in neutral before tilting

R1 3 5
N
2 4 6
Tilt on even surface: Cabin to be tilted when vehicle is in even surface.
Rotate the cab tilt pump lever clock wise as in image to lift the cabin.

CAB TILTING GUIDELINES
Rotate the cab tilt pump lever anti clockwise as in image to lower the cabin
X
Keep the cab tilt pump lever anti clockwise as in image during driving
4 Do not stand in front of the cabin while tilting

X
Do not work under partially tilted cabin
Do not work under cabin while lowering
Check proper locking after lowered the cab. Do not drive with cab lock warning light ON in instrument panel

EXTERIOR LIGHTING −− Front direction indicator - indicates Roof Marker Lamps
the turning direction to other vehicles.
Head Lamp Assembly
Check alignment of head
lamps regularly. In case of
NOTE
poor focusing contact an
authorised Ashok Leyland
Service Centre.
Avoid driving the vehicle with

poor head lamp illumination. −− Roof marker lamps provided on
WARNING
either side of the cabin roof and load 4
body top indicates height and width
Side Direction indicator
1 Head lamp of the vehicle to the approaching
Right and left Side Direction indicator traffic.
2 Front direction indicator
indicate the turning direction of the
3 Side Direction indicator −− Always ensure that the roof marker
vehicle to other vehicles. Side Direction
lamps are in working condition.
The head lamp assembly comprises of indicator are positioned on either side of
low beam and high beam. Head lamp also the vehicle. LH / RH turn indication is
incorporates parking lights. achieved by front direction indicator and
Side Direction indicator lamp.
−− High beam - The high beam is for
providing maximum illumination well
ahead of the vehicle.
−− Low beam - The low beam is for
providing illumination for a shorter
distance.

PARKING BRAKE Move the parking brake lever forward to Winding off the spring parking
release the parking brake (Before the brake chamber immobilizes
It is mounted in the Centre console. To parking position is achieved, you have to
apply parking brake, move the control to the parking brake mechanism.
overcome a point of pressure resistance WARNING
Do not attempt to wind off the
ON position and the locking collar will and then the lever is automatically
engage automatically. To release parking bolt without suitably chocking
secured in the parking position). the road wheels before hand.
brake, Lift the locking collar and move the
control to OFF position then release the The use of parking brake When the vehicle is to be stored for
locking collar. during driving is dangerous periods exceeding one month, the following
Parking brake is also called as graduated WARNING
and will lead to loss of control procedure must be adopted to prevent
hand control valve. It can be used in case and skidding. Apply the damage to the brake shoe and drum
of emergency conditions when foot parking brake only in case of assemblies,
4 brakes fails to work. In case of such urgent need. −− Park the vehicle in the storage area
emergency, use the parking brake valve It is not allowed to drive the chock the wheels and release the
slowly to stop the vehicle. vehicle when the indicator Parking brake controls.
Position of the parking brake lever light of minimum air pressure
glows. −− Completely drain the air reservoir.
Parking position:
−− Wind off the Parking brake.
Parking Brake Actuator Winding Off −− Place a suitable notice on the
Vehicle Front
windscreen in front of the driver
Bearing
Stem Plug facing inward stating "Brake actuator
Dust seal released. Do not drive. No brakes".
Gaiter
Before moving the vehicle apply the brakes
by winding in the release bolts or resetting
OFF Lock nut
ON
Push rod assembly the parking brake actuator and recharge
the system with air.
Move the parking brake lever backward Integral seal Flange
Bearing
‘O’ring
to apply the parking brake.

BUMPER attach the towing bar. When towing the Wheel Chock
vehicle ensure engine at stand still and no
gear engaged, propeller shaft disconnected,
spring brake chamber released.
Disconnecting the propeller shaft
Wheel choke is fitted in RUPD (Rear under 4

All metal high quality bumper protects protection device) Bracket as shown in
frontal chassis components against any above image.
minor accidental damages.
TOWING Secure the vehicle against motion.
Dismount bolts fixing the propeller shaft
to the axle final drive housing flange.
Attach the propeller shaft to the vehicle
frame in a suitable manner.
After the vehicle towing and repair have
been accomplished, remount the propeller
shaft to the axle final drive housing flange
again and tighten the nut.
Tow hook is bolted to LH frame side member
behind the bumper. Use the hook to

WINDSHIELD WASHER & WIPERS To assure good wiping, wash the rubber ECONOMICAL DRIVING
blades with glass washing agent regularly.
Fluid container On the wiper arm there are washer jets. Fuel economy and long life
The jets can be adjusted with a needle. Careful use of the vehicle will result in:
The whole wiper arm body jets can be
−− Improved fuel economy
moved freely along the arm.
−− Reduced wear and tear of major
components yet obtaining optimum
Do not use wipers to wipe dry
glass - they may scratch it. performance in keeping within the
NOTE
limits imposed by currently effective
4 regulations.
The windshield washer container is The following suggestions should be
situated in the RH side of front bumper as
considered;
shown in the above image.
Add water with glass washer solvent 1. Reduce engine speed
agent to the container as required.
This is very important and applies
Wipers
particularly to vehicles that travel long
distances on highways. The best possible
performance / fuel economy will be
obtained if the engine speed is kept at all
time within the “Economy” sector, namely
around the maximum torque speed. This
is achieved by driving within 1200 to 1700
RPM band of engine speed.

2. On upgrades DAILY CHECKS
Select the gear best suited to the To get maximum service life from your
gradient, and remember that high vehicle please carry out the simple checks
average speeds and optimum fuel and inspections detailed as said in the
economy depend on your driving skills following pages.
MAX
and correct use of the transmission.

These simple checks and inspections will MIN
On upgrades keep the engine speed over ensure minimum operating cost and
that at which maximum torque is maximum uptime of your vehicles.
developed, approximately 80% of the
maximum rated speed. Checks before each journey 2. Check coolant level. Top up through
filler cap. Coolant level to be between
3. On downgrades MIN & MAX. 4
Engage suitable gear and avoid excessive
brake wear.
Abrupt acceleration and
braking results in a waste of
CAUTION
energy, greater stress on
mechanical components,
faster wear of brakes and
tyres. Avoid such bad driving 1. Use dipstick to check engine oil level.
habits! Top up through filler cap.
3. Drain condensate from air tanks.
4. Check the vacuum indicator provided
on air intake pipe for the appearance
of red band.

If red band appears replace the WEEKLY CHECKS With engine switched off and wheels
primary filter element. in straight ahead position, the oil
5. Check fuel filter cum water separator level should be at the top reference
for collected water and drain if mark. If necessary top up after
necessary. removing the cap.
If not drained periodically, fuel contaminates MAX
2. Check the battery electrolyte level, if
with water, enters the fuel injection pump necessary, top up.
MIN
and injectors affecting performance and 3. Check tyre wear and pressure
damaging the fuel system. (don’t forget the spare wheel).
6. Check:
−− Tyre conditions and Tyre pressure.
4 1. The new power steering reservoir is
−− Operation of service & parking
brakes. a transparent one. Hence the oil level
can be visually checked without
−− Operation of lights, warning indicators removing the cap. Minimum and
and windscreen wipers. maximum levels are embossed on the Under inflation Correct inflation
−− Cab secured in locks at rear. reservoir.
−− Fuel level in tank.
−− Fluid leakages.
INFLATION PRESSURE
MODELS TYRE FRONT REAR
KPA Kg/cm2 PSI KPA Kg/cm2 PSI
815 225/75 R17.5 620 6.33 90 586 6.00 85
1223 245/70 R19.5 760 7.73 110 690 7.00 100

If necessary, inflate to the specified DO’S & DON’TS directly. Do not dilute with plain or
pressure. If pressure is low, tyres tend to demineralized water for top up.
wear on the outer treads. Check toe-in Do’s −− Fill up diesel tank at the end of each
and camber in case of abnormal wear. −− Periodically check and ensure that working day to reduce water
Never exceed maximum permissible load the radiator cowl is intact, and condensation in the tanks.
on each axle (This however should not replace a defective thermostat or a −− Before towing the vehicle, disconnect
affect the total vehicle weight). missing header tank filler cap the propeller shaft. Also mechanically
4. Also check the exhaust system immediately as otherwise the wind off the rear spring brake
visually. If exhaust is excessively efficiency of cooling system would be chamber while towing.
smoky or engine is noisy refer to an affected and this will damage the
engine. −− Park the vehicle on a level and hard
authorised Dealer for necessary ground when lifting (Jacking) the
checkups. −− Check radiator stay bracket mounting vehicle. Apply hand brake as well as 4
5. Check fluid level in the clutch reservoir, bolts for tightness. Check the silent chock the wheels.
by lifting the front lid. The fluid level block bush in stay rod and replace if
found defective. −− Drain air tank once in a week to drain
should be at the Max mark on the water and oil sediment from the
reservoir. −− To obtain a trouble free and enhanced system.
engine life, maintain the air cleaner
LY
BR
AKE FLUD
DO
T3
as per recommended maintenance −− Check tyre pressure and ensure it is

N
EO
-D
REMOVING US
OT
as per recommendations.
4F
RO
MA
procedure.
SEALED CONT
ORE
EF
PB
CA
AIN
N
−−
EA
Disconnect alternator / battery

E
R
CL
WARNING
−− After starting the engine, check for

MAX
electrical connection while carrying

MIN
proper functioning of all instrument

gauges and lights. out welding work on the vehicle.
−− Remember that wheel hubs are to be −− Maintain electrolyte level in the
packed with grease. battery using distilled water.
−− For coolant topping up, use only −− Drain water from fuel filter cum water
Check for any leaks, rectify it and top-up separator as and when required.
if necessary. pre-mixed coolant (Eurocool LL Max 4)

Don’ts −− Do not run the vehicle with leakages −− Do not switch off ignition key switch
−− Do not weld or drill holes on chassis of air, fuel, oil and water. when the engine is in running
frame. −− Do not ride the clutch pedal as it condition, this will cause white
−− Do not extend chassis frame/cabin as leads to premature wear of clutch smoke.
this can lead to premature failures. plate and other associated
−− Do not reinforce chassis frame and do components.
not load the vehicle more than its −− Do not move the vehicle before the
rated GVW. low pressure warning buzzer stops
−− Maintain original suspension and do beeping (set to stop beeping
not add additional leaves and do not between 6.0 and 6.4 Kg/cm²).
recamber springs as recambering will Otherwise premature wear of brake
4 result in frequent spring failures. linings would take place due to partial
−− Do not operate starter for more than brake binding.
10 seconds at a time and wait for 30 −− Do not attempt to dismantle spring
to 60 seconds before trying again. brake actuator without proper
−− Do not add cold water to a hot engine special tools.
as this can lead to crack in crankcase −− Do not tamper the air pressure
and other associated parts. settings in the unloader valve
−− Fuel pump setting should not be (8.1 ± 0.2 Kg/cm²). Otherwise this
tampered with. can result in inefficient brake/excess
tyre wear.
−− Do not coast down hill with the
transmission in neutral, or with the −− Do not accelerate engine after
clutch disengaged. starting as well as before stopping,
−− Do not coast the vehicle i.e. Drive keep the engine at idling RPM for
with engine switched off. This will minimum 2 minutes. This can prevent
affect gear box life. damage to turbo charger.

TIPS TO IMPROVE MILEAGE TIPS TO IMPROVE TYRE LIFE
1. Fill diesel in reputed single filling station 1. Maintain recommended tyre pressure
2. Fill at early morning or late evening to get high density fuel 2. Don’t overload the vehicle
3. Don’t allow diesel to get condensate 3. Check and remove small stones or materials struck in
between tyre lugs and ribs
4. Check and drain water separator regularly
4. Have proper tyre rotation as recommended.
5. Check and maintain recommended engine idling rpm
5. Don’t use sharp tools to remove and refit tyres
6. Don’t idle engine for long duration in signals
6. Don’t mix different tyre sizes
7. Don’t clutch ride
7. Check shackle pin and bushes at regular intervals
8. Avoid sudden pick up and panic braking 4
8. Don’t re-chamber leaf springs
9. Check and maintain recommended tyre pressure
9. Adjust brakes evenly on all wheels
10. Check wheels for free rotation – brake binding
10. Check u-bolts and leaves for misalignment
11. Shift appropriate gear for appropriate speeds
11. Carry out wheel alignment at regular intervals
12. Always drive vehicle in the green band on Engine rpm meter
12. Avoid spinning your wheels in roads
13. Always maintain recommended loads (Don’t overload)
13. Avoid panic braking
14. Check for any restriction in air intake
14. Maintain even wear on pair wheels
15. Use recommended lubricants
16. Maintain vehicle in an authorized dealer point
17. Check and arrest air leaks.
18. Clean radiator and air cooler fins.
19. Maintain correct fan belt tension.
5. Body Building Instructions
)) General Guidelines
)) Precautions During Body Building
)) Body/Equipment Installation
)) Body Mounting Brackets
)) Bracket Positioning
)) Reflex Reflectors
)) Vehicle Side Protection Device
)) Rear Under Run Protection Device (Rupd)
)) Spray Suppression
)) Grab Handle
)) Braking System Performance
)) Storage Of Vehicles
)) Coach builders drawing

General Guidelines Wheel Arch Precautions during body building
Wheel arch to tyre clearance should be so
Ground Clearance provided as to avoid tyre fouling the wheel During bodybuilding the following
Keep dimensions as close as possible to arch even in extreme conditions. The precautions must be taken to avoid any
the specification in all cases, but make no recommended vertical clearance between undue damage to the various
change at all in the approach angle of any tyre top edge and the wheel hump inner components:-
vehicle fitted with an Ergonomic cab. surface is 225 mm as measured in laden Protection Of Piping & Wiring
Working Clearances condition. During welding, cutting, drilling or
Working clearance required by chassis Chassis Modification grinding operations on body work, all piping
and body part must be provided, e.g., Normally, flitches are provided on and electrical wiring should be kept well
drop arm movement, axle articulation, the frame only in the case of special clear of the immediate working area or
suspension movement, variation in applications to bring down stress levels. adequately covered to prevent damage.
propeller shaft drive lines, flexible pipes, No additional flitches should be added. Electrical Equipment
wheel arch clearance, bumper clearance Any modification to a system on the All electrical equipment like alternator,
etc. Life and reliability of units will be chassis should only be made on advice batteries, starter motor, wiper motor,
5
impaired if the above factors are not from Ashok Leyland Limited. etc. should be isolated from the circuit to
taken care of. avoid possible damage due to high
Safety And Legal Requirement
Batteries currents from welding equipments. The
Body builders should familiarise batteries may be preferably removed
A build up of explosive fumes could make themselves with statutory
covered batteries dangerous, so, don't from the vehicle whilst bodywork is being
requirements and be responsible for their carried out.
cover them without providing adequate adherence. However, if doubts exist on the
ventilation. The batteries require a understanding of practical application of
generous air flow, to prevent gas build regulations, assistance may be sought
up and to keep the cell temperature in from Ashok Leyland or Authorised Dealer.
control.
5.02 BODY BUILDING INSTRUCTIONS

Frame Body/Equipment installation 2. Frame mounted body attachment
brackets must not be welded to the
Successful body / equipment installation chassis long members or bolted through
depends on many factors. The most the top and / or bottom of side member
important is the correct type of mounting flanges.
of the body on the frame. Correctly
3. All attachment bolt must be secured with
installed bodies increase the effective
lock nuts or nuts with heavy duty lock
life of the vehicle, minimise accidents &
washers. No welding with chassis side
guard against failures. If faithfully
member is permissible.
employed, the methods described/ points
Any welding or drilling of holes on the given in this section will ensure the best 4. Body sub frame & mounting brackets
frame without the consent of AL is strictly possible mounting body. must be securely clamped to the frame
prohibited. Observe The Following: side members before drilling the frame
web or body runner for fixing bolts.
Welding precaution 1. The imposed loads from body to
chassis frame must be applied to the 5. Wherever dissimilar metals are used such
Serious structural damage can be caused
side members at equal or near equal as light alloy & steel, Zinc chromate paint 5
by improper use of welding equipment.
intervals along the chassis frame. or paste should be applied between the
Care must be taken to ensure that the
welding gun is not flashed off on the
spring leaves and that the earth clamp
is not attached to the spring. When
welding, the springs should be covered to
avoid weld splatter falling on the spring
surfaces. Springs should not be subjected
to sharp impacts.
Chassis - centre of gravity (CG)
BODY BUILDING INSTRUCTIONS 5.03

faces to minimise electrolytic corrosion. BODY MOUNTING BRACKETS Two Spring Bracket
Where practical, balata strip can be used
as an alternative. Single Spring Bracket
4
6. The rear most body mounting bracket 3
1
be mounted as close as possible to rear 1
3
most cross member. 4mm gap
5
7. CG of the body should be as low & as near 6
4 2
the centre of the vehicle as possible. 4mm gap 5 7
8. The body mounting should be designed 6
7
/ positioned in such a way that the
dismounting of body should not disturb 2 ILL. No. Description
or lead to breaking any electrical 1 Top bracket
wiring or brake pipes or any vehicle ILL. No. Description 2 Bottom bracket
equipment & components. 1 Top bracket 3 Spring
2 Bottom bracket 4 M16 Bolt
5 Raising the CG is inevitable when mount-
3 M16 Bolt 5 Washer
ing a body or equipment but all possible 4 Spring 6 M16 Nut
steps should be taken to minimise this 5 Washer 7 M12 Bolt
effect by mounting heavier parts of the 6 Washer It provides flexible connection, also known
body or equipment as symmetrically 7 M16 Nut as friction joints.
about the chassis frame as possible. It provides flexible connection, also Tensioning of the bolt, secures the body
known as friction joints. using friction.
Tensioning of the bolt, secures the body
using friction.
Torsionally flexible & semi-flexible super
structure requires flexible attachment at
first attachment point.

Semi-Flexible bracket Cleat Plate: Load Body Installation
Procedure for installing load body sub
1
frame assembly on Chassis:
1. Wipe the frame top face and sub
3 frame bottom face with cloth.
1
4 2 2. Place the load body aligning sub
5
frame assembly on chassis Frame
along sidewise.
6 3. Align the sub frame longitudinally
ILL. No. Description
2 with the help of stopper plate which
1 Cleat plate
ILL. No. Description is welded at rear end of the sub
2 Bolt & Nut
1 Top bracket frame.
It provides rigid connection, also known 4. Use U bolts to hold sub frame and
2 Bottom bracket
as clamp joints. Surface of the bolt is in frame tightly against each other to
3 M16 Bolt
4 Nut contact with the edge of the hole, secures avoid any gap.
the body. 5
5 M12 Bolt 5. Refer page 5.05 and install brackets
6 M12 Nut Torsionally flexible super structure and cleat plate.
It provides semi-flexible connection, also requires rigid attachment at mid to rear
portion of the body. 6. Repaint all the welded surface using
known as friction joints. black paint to protect against
Four bolt mounting and Two bolt mounting Torsionally semi-flexible super structure corrosion.
used in Boss models. requires rigid attachment at rear axle
position. 7. Remove the U-clamps after welding
Tensioning of the bolt, secures the body the brackets.
using friction.
Torsionally semi-flexible super structure
requires semi-flexible attachment at mid
& rear portion of the body.

Installation of spring brackets: Installation of Fixed brackets: Installation of Cleat Plate:
Spring brackets Top bracket Top brkt
4mm gap
4mm gap
Bottom Bottom
brkt brkt
Procedure:
Bolt the bottom portion on frame.
Bolt the bottom bracket on frame. Procedure: Tighten the bolts on frame with tightening
Align top pivot brackets using fasteners Bolt the bottom bracket on frame. torque of 120 Nm.
and springs as Shown. Align top pivot brackets using fastener as After torque tightening completely weld
Tighten the bolts on frame to 120 Nm shown. the top portion of the cleat to sub frame.
5
Maintain 4 mm gap between top & bottom Tighten the bolts on frame with tightening Loading / Unloading Instructions
bracket. torque of 120 Nm. 1. Place the loading material gently so
Then fasten M12 (spring) bolts against Maintain 4 mm gap between top & bottom that the load body floor sheet nor the
spring to maintain 1 mm gap between bracket. loading material gets damaged.
each coil (50mm total spring ht.). Fasten bolts with tightening torque of 120 2. Do not carry boulder stone or highly
Completely weld the top bracket to sub Nm. concentrated material on to the
frame. After torque tightening completely weld haulage load body.
the top bracket in the slot and on the top 3. Do not stack the loading material
of the bracket. beyond the certain height limit
(top roof structure), since it affects
the vehicle stability.

BRACKET POSITIONING
“A” Dimension
should not exceed
1000 mm I II* III II*
Max.450 mm
5
Max A A Max A A
550 mm 400 mm
4. Do not drag the material on the floor, 6. Stack the material on the load body
it will result in paint peel-off and uniformly to have equal weight
scratches which will lead to corrosion. distribution which will have good ride
5. Do not drop the loading material control.
from height.

REFLEX REFLECTORS VEHICLE SIDE PROTECTION DEVICE: REAR UNDER RUN PROTECTION DEVICE
(RUPD):
Reflex reflectors (white, amber and red) The Specification and Requirements for
used in commercial vehicles shall be Vehicle Side protection device (SUPD) The Specification and Requirements for
tested for compliance to the above used in commercial vehicles are covered Rear Under Run Protection Device (RUPD)
norms. White and amber colour reflectors in IS:14682-1999. It is applicable for all used in commercial vehicles are covered
are separate unit and red reflector is part trucks other than Tippers and Tractors. in IS:14812 - 2000. RUPD is applicable for
of tail lamp. This is an OE fitment for fully built all trucks other than Tippers and Tractors.
For fully built vehicles, Ashok Leyland (AL) vehicles only. For drive away chassis, This is an OE fitment.
will ensure fitment of reflex reflectors SUPD will be supplied as a kit and will RUPD is painted in yellow/White zebra
from vendors who have got their be fitted during body building. strips on the entire face of the device.
products approved to AIS 057 - 2005. Removal and refitment is necessary
For drive away chassis, during body building, during removal of spare tyre in vehicle
operators and body builders should fitted with rear bottom mounting spare
ensure fitment of reflex reflectors as per wheel carrier.
5 AIS 057 - 2005.

SPRAY SUPPRESSION: GRAB HANDLE BRAKING SYSTEM PERFORMANCE
Spray suppression system is introduced to Ministry of shipping, road transport &
reduce the pulverization of water thrown highways had notified new brake norms
upwards by the tyres of the vehicle in as per IS 11852 - 2001 effective from
motion. 1st April 2006 pertaining to commercial
The spray suppression system is made-up vehicles. Suitable modifications are
of mud guard, rain flaps and valances carried out in AL vehicles and braking
equipped with a spray suppression system performance is ensured as per IS
device. This device traps the water thrown 11852-2001.
up by tyres in motion and directs it
towards the ground. Also it reduces the
risk of small objects, in particular pebbles, Two grab handles are provided on the left
being picked up from the ground by the and right-hand sides of the door entry to
tyres and thrown upwards or side wards reduce the driver and codriver’s effort
towards other road users. during cabin entry and exit. 5

Storage of Vehicles Storage over a prolonged period d) The lubricating system should be
drained and replenished with
a) The battery should be removed from
Whenever vehicles are in storage corrosion inhibiting oil.
the chassis and prepared for
awaiting bodybuilding, proper care
storage in a dry place. The battery e) It is advisable that the cooling system
should be taken as detailed below:
should be topped-up with distilled be drained completely. A board
Storage over a short period water and charged at regular should be suitably displayed to
a) The vehicle must be thoroughly intervals. Alternatively, the indicate that the cooling system has
washed, including the under-chassis acid from the battery should be been drained in order to avoid
to remove any deposits of mud as this drained dry and stored, however accidental starting of the engine.
will lead to corrosion. ensuring that the recommended f) It is advisable to drain the fuel tank
b) The vehicle should be parked in a acid is refilled to the correct level and and fuel filters to avoid formation of
covered area, on a plain hard surface. recharged at the time of gum deposits and the possibility of
recommissioning the battery. difficult starting later.
c) The battery terminals should be
disconnected. b) The injectors should be removed and g) All the openings like intake manifold,
5 d) The engine should be started and run about 20 cc of corrosion inhibiting oil exhaust tail pipe, engine breather
(Shell Ensis oil SAE 10 or Castrol pipe, fuel tank vent hole, etc. Should
for a few minutes atleast once a Storage oil 301 or Servo Preserve 30)
week. It is advisable that the vehicle be completely sealed with masking
should be added through the injector tape.
is jacked-up and the gears engaged so hole. The engine should be cranked
that complete oil circulation is for about 30 seconds and the h) The vehicle should be jacked-up and
effected in the gearbox and differential injectors fitted back. supported on suitable props under
too. the axles.
c) Anticorrosive oil should be liberally
sprayed over rocker levers, push rods, i) The use of parking brake should not
plunger springs and tappets of Fuel be resorted to, for arresting the
Injection Pump. movement of the vehicle - instead,
chocks must be used.

Recommissioning Of Vehicle After Long f) The engine should be cranked
Storage (keeping the engine stop cable pulled)
a) The cooling system should be flushed till the engine oil pressure builds upto
completely and refilled with clean soft around 2 kg/cm². Then start engine
water. Additives like anticorrosive oil and ensure that the specified oil
and antifreeze compound may be pressure is attained.
added in the correct proportion. g) The oil levels in other units like
b) The masking tapes used in preparation Gearbox, Differential and Steering
of storage should be removed. Box should be checked and topped
up. In case of vehicles fitted with
c) The sump should be completely power steering, the hydraulic system
drained of the corrosion inhibiting oil and
should be bled free of air bubbles and
refilled with the recommended engine
topped up with the correct grade of
oil.
hydraulic fluid in the reservoir.
d) The filter elements should be
cleaned/replaced and the injectors 5
checked for the correct pressure
setting and spray characteristics.
e) The complete electrical circuit,
especially the charging circuit should
be checked for correctness of
connections. Starter solenoid
points and battery terminals should
be cleaned. Starter motor and
alternator brushes should be checked
for proper contact with commutator.

COACH BUILDER DRAWING FOR 815 - 3440 mm WB
FSM CROSS SECTION
1776 (OCL)
START OF LOAD BODY (740) 5
.4
R9
3
17
200
190
R2
LOAD BODY MOUNTING LOCATION 5
2135 935 670 975
2515 (OCH)
60
200
830
17deg
168 (MGC)
18.2de
g
1225 (FOH) 3440 (WB) 1770 (ROH)
L e ft v i e w
deg
Front view 12.2 1905 (FT)
2200 (OCW)
FC182014 @ "Y" View
X Y Z Z SUB FRAME FRAME
BT13908 @
"X"&"Z" View
2071
1406
1310
950 LOADBODY MOUNTING @ "Y"
LOADBODY MOUNTING @ "Z"

132
745
75 75
75
60
LOADBODY MOUNTING @ "X"
37.5
.5
2346 ±10
R6
1674 (RT)
51
.5
75
R6
51
2108
850
37.5
95
.5
R6
31
"Y"
"Z"
745
"X"
1258 849 821
1763
2343
Top view
COACH BUILDER DRAWING

START OF LOAD BODY (740)

1776
FSM CROSS SECTION
1 73
R2
5 4
9.
LOAD BODY MOUNTING LOCATION
190 R
200
2545 1025 920 1060
2515
200
60
830
15.7deg
168(MGC)
16.5d eg
1225 eg 3940 10.7d 2090
1905
Front view
2200
X Y Z Z L e ft v i e w
2071
1406
1310 FC182014 @ "Y" View SUB FRAME
950
745
BT13908 @ "Z" & "X" Viwe

105
FRAME
60
2345 ±10
LOADBODY MOUNTING @ "Y"
2108
1674
850
LOADBODY MOUNTING @ "X" LOADBODY MOUNTING @ "Z"
75 75
75 75
.5
745
37.5
R6
37.5
.5
51
.5
R6
R6
31
51
1258
1763
2343 849 821 "Y"
"X" "Z"
Top view

FSM CROSS SECTION
.45
START OF LOAD BODY (920) R9
1776
3
17
R2
190
204
5
LOAB BODY MOUNTING
3582
2390 - 2550 (OCH)
62
1378 825 1056 908 1366 549
g
910
200
18.3de
1740 REAR TRACK

9.75 1845 FRONT TRACK
deg
2346 OVERALL
g
de
.2
1225 FOH 4500 WB 2020 ROH
14
FRONT VIEW
SUB FRAME
FC182014
2782 X Y Z BT13909 @ "X"&"Z" View
1572
1463
1059
LOADBODY MOUNTING @ "Y"

580 LOADBODY MOUNTING @ "X"
LOADBODY MOUNTING @ "Z"
719
75
37.5 75 75 75
5
62
R6.
37.5
.5
2350±10
34
1744 RT
R6.5
R6
168
2108
854
51
51
"X"
719
"Y" "Z"
1318 849 821

1744
2584

START OF LOAD BODY (920)

1776
173
R2
LOAB BODY MOUNTING LOCATION FSM CROSS SECTION
4151
2390 - 2550 (OCH)
1378 815 1198 605 770 1391 924

.45
R9
204
190
204
5
g
18.3de
62
910
7.0
8de
200
1744 FRONT TRACK
g
12.7de
g
1225 (FOH) 5100 (WB) 2420 (ROH) 1840 REAR TRACK

2297 OVERALL WIDTH
FRONT VIEW LEFT VIEW
FC182014 SUB FRAME

FRAME
BT13909
X Y Z Z
LOADBODY MOUNTING @ "X" LOADBODY MOUNTING @ "Y"

2872
1572 LOADBODY MOUNTING @ "Z"
1463 75
1059 37.5
.5
75
R6
34
75 75 .5 37.5
R6
716
51
.5
1236
R6
51
62
"X"
2350±10
1744 RT
2108
"Y"
854
"Z"
206
716
1318 853 816

1744
2584
TOP VIEW

6. Maintenance & Lubrication
)) Maintenance schedule
)) Maintenance procedure
)) Filling capacity
)) Recommended lubricants
Maintenance schedule
ii Maintenance Schedule that follows is
for normal road operating conditions.
ii For Off Highway application (Tipper),
hourly maintenance schedule should be
followed in place of km schedule. The
following schedule can be converted
into hourly schedule (except for cases
mentioned in terms of hours) by using
the ratio of 1 hour of operation is
equivalent to 40 km.
For Eg. 10,000 km equals to 250 hrs.
ii More frequent attentions will be
necessary to vehicles working under
adverse conditions such as sand / gravel
pit work or under severe hilly terrains
/ projects.
Key to Maintenance schedule
6
ii Applicable to specific maintenance
interval, given as column heading
6.02 MAINTENANCE AND LUBRICATION

Every km x
Weekly
Daily
1000
PDI
MAINTENANCE ACTIVITY Remarks
I H4E4SD95 / H6E4SD165 E-IV CRS Engine
A General
1 Check and adjust valve clearance on cold engine 15
2 Check and tighten front and rear engine mounting / other peripheral bolts 10
3 Check compression pressure 60
4 Check and tighten cylinder head bolts for correct torque in correct sequence 60
B Lubrication system
1 Check and top up engine oil 3 6
2 Change engine oil and oil filter element (deep well sump with Spin on filter) 10
3 Clean oil cooler 60

Check engine oil pressure (min. 1 kg/cm² at idling and 80°C engine
4 3 3
temperature)
5 Check oil leakages, if any 3 10
MAINTENANCE AND LUBRICATION 6.03

Every km x
Weekly
Daily
1000
PDI
C Cooling System
1 Check and tight fan mounting bolts 3 10
2 Check coolant level and top up if necessary 3
3 Inspect fan clutch / hub for dust if necessary clean 40
4 Visually inspect cooling fan / drive for any damages and replace/rectify 3 40
5 Check radiator hoses and clamps for leakages and tightness 3 5
6 Check fan belt tension and adjust If necessary 3 10
7 Check radiator stay rod and radiator mounting bolts  15
8 Drain cooling system and fill recommended coolant.
Replace cooling system hoses and radiator rubber pads for radiator
9 50,000 km or 1 years whichever is earlier
mounting & stay rod
6
10 Replace coolant filter unit (To be replaced along with coolant change), if fitted.
D Fuel System
1 Replace fuel filter cum water separator 20
2 Replace main fuel filter unit 20
3 Check water separator and drain if necessary As and when required.
4 Check and tighten F.I.P. and fuel tank Mountings 30

Every km x
Weekly
Daily
1000
PDI
5 Check injection timing 30
6 Clean Fuel tank and suction strainer 50
7 Re-calibrate fuel pump 100
8 Check and replace fuel hoses if necessary 80
E Electronic Diesel Control
1 Check for engine full acceleration (Throttle response) 3
Check tightness of all mating connectors and ensure they are

2
connected properly
6
Check and secure wiring harness away from temp. zones on the
3 3 25
engine/vehicle
4 Check functioning of EDC and sensors with diagnostic tool 3 40

Check tightness of engine speed sensors and clean the sensor tip for
5 3 25
any dirt/dust deposits
6 Check functioning of warning EDC light 3

Every km x
Weekly
Daily
1000
PDI
II AIR INTAKE AND EXHAUST

Check vacuum indicator and replace primary filter element - whenever
1 3
the vacuum indicator shows redband"
At the time of every third replacement of
2 Replace air cleaner secondary filter element primary filter element
3 Check air inlet hose for any puncture/damage 3
Check for any blockage / breakage at rainhood assembly / Snockle
4 3
mtg bolts on cab
5 Check Turbocharger mounting 3 30
Check charge air cooler for any blockage of fins and clean the cooler
6 3 30
if necessary (2.5 kg/ cm2)
7 Check charge air cooler hoses for any damage 10
6
8 Check exhaust manifold and silencer for leaks and tightness 3 15
9 Check intake and exhaust manifold mounting fasteners 3 30
III CLUTCH
A Lubrication
1 Lubricate clutch operating pedal shaft 3 3 10
2 Lubricate clutch withdrawal lever 3 3 10

Every km x
Weekly
Daily
1000
PDI
3 Lubricate clutch withdrawal bearing sleeve 3 3 10
4 Lubricate clutch linkages 3 3 10
5 Repack grease in clutch withdrawal bearing At the time of clutch disc replacement.
B Maintenance
1 Check and adjust clutch pedal freeplay 3 As required
2 Check clutch fluid level, top up if necessary 3 10
3 Overhaul clutch master cylinder / Clutch booster 70
4 Check stand out & replace clutch disc if necessary As required.
5 Change clutch fluid 40 6
C Clutch Booster
Check for any leaks in the joints - both air and hydraulic / tighten the
1 3
mounting Bolts, fork and bleed screw
2 Clean the exhaust valve in case it is soiled 3
Once in a
3 Overhaul the unit using appropriate repair kit through ASC year

Every km x
Weekly
Daily
1000
PDI
IV SYNCHROMESH GEAR BOX

A Lubrication
1 Lubricate gear shift ball joints 3 3
2 Check oil level , top up and clean breather 10
3 Change oil when hot. Refill upto correct level 20 For intra city
4 Change oil when hot. Refill upto correct level 35 For inter city
5 Change oil when hot. Refill upto correct level - For Tippers. 500 hrs
B Maintenance
1 Check for correct operation of gear shift linkage and setting 10
2 Check tightness of clutch housing mounting bolts 15
6
3 Check and tighten output flange nut 20
V PROPELLER SHAFT
A Lubrication
1 Lubricate propeller shaft UJ cross 3 3 10
2 Lubricate centre joint bearing (other than sealed bearing) 3 3 10
3 Lubricate propeller shaft splines 3 3 10

Every km x
Weekly
Daily
1000
PDI
B Maintenance
1 Check and tighten propeller shaft flange bolts 3 3
2 Check centre bearing for oil seal leakage 10
3 Check and tighten centre bearing housing bolts 10
4 Check and tighten centre bearing housing bracket mounting bolts 10
5 Check UJ cross and cup for wear and replace if found worn out. 10
6 Check for spline wear and replace propeller shaft if found worn out 10
Check runout at 2" from weld at both the ends and also at centre of
7 15
tube, replace propeller shaft if runout exits 0.025"
VI REAR AXLE
A Lubrication
6
1 Check oil level and top up 3 10
2 Change oil when hot. Refill upto correct level 20
a For hypoid gear drive head (Meritor) 50
b For hypoid gear drive head (AAM) 50
3 Repack the hubs with recommended grease. 50
4 Check and Adjust pole wheel sensor (ABS) air gap 3 50

Every km x
Weekly
Daily
1000
PDI
B Maintenance
Check & adjust the hub end play. Check the condition of hub bearing,
1 3 15
change if necessary.
2 Check the tightness of driving head nuts and axle shaft nuts 15
3 Check the condition of differential bearings, Change if necessary 100
4 Check thrust screw clearance and adjust (for hypoid drive axles) 15
VII FRONT AXLE
Repack the hubs with recommended grease. Check the condition of
1 80
hub bearings and change if necessary. Adjust hub end play.
2 Lubricate king pins 3

6
3 Check wheel alignment and adjust if necessary 3 20
4 Check and tighten thrust cover bolts 20
5 Check stub axle vertical play & adjust if necessary 20
6 Check king pin lateral play. Replace bush if necessary 20

Every km x
Weekly
Daily
1000
PDI
VIII BRAKE SYSTEM

A. General
Check foot brake operation. Remove stopper bolt to ensure full line
1 3
pressure at the brake Chambers
2 Check pneumatic hand brake for proper functioning 3
3 Check service brake for proper functioning & for air leakage and rectify if any
4 Check compressed air buildup on air gauge (8.25 kg/cm²)
5 Check brake pedal clearance over brake valve and adjust if required 40
B Air Compressor (Water cooled - 230cc)
1 Check for leakages in lub oil connection and rectify if any. 15
2 Check for leakages in compressor cooling line and rectify if any. 15
Check compressor Inlet & delivery rubber hoses and pipes for 6
3 15
deterioration and renew if required
Check & tighten cylinder head mounting bolts & end cover bolts for
4 15
correct torque values.
5 Check for leak through oil seal and rectify if any 15
Remove cylinder head assembly and check for excessive carbon deposit
6 and reed valve rivet loosening, decarbonize cylinder head and overhaul if Every 1,00,000 km or 2 years whichever is earlier
necessary.

Every km x
Weekly
Daily
1000
PDI
7 Check for carbon deposit in delivery pipe and clean. 100

8 Check compressor coolant inlet and outlet pipes for leakages 15
9 Overhaul the assembly Every 1,00,000 km or 2 years whichever is earlier
C Unloader valve with tyre inflator
1 Check for correct pressure setting (8.25 kg/cm²) and adjust if required 15
2 Remove inlet filter, clean and refit 50
3 Check & tighten all screws in the assy for correct torque value 50
D Air Dryer (Wabco)
Check for moisture/ water collection in the Reservoirs. If water
1 3 10
collection is noticed, replace the Desiccant cartridge.
6
2 Check for performance. Pressure difference should not exceed 1.3 kg/cm². 10
3 Check for correct pressure setting (8.25 kg/cm²) 15
Overhaul the unit using recommended Repair Kit. Replace Desiccant
6 Every 1,00,000 km or 2 years whichever is earlier
Cartridge

Every km x
Weekly
Daily
1000
PDI
E Air Dryer
1
collection is noticed, replace
the Desiccant cartridge 10
3 Check for correct pressure setting 15
6 Check that the desiccant cartridge is being purged 50,000 km or 1 Year whichever is earlier.
7 Replace the desiccant cartridge Every 1,00,000 km or 2 years whichever is earlier
8 Service unloader valve mechanism and clean the silencer Every 1,00,000 km or 2 years whichever is earlier
6
F DDU
1 3 10
collection is noticed, replace the Desiccant cartridge.
3 Check for correct pressure setting (8.25 kg/cm²) 15

Every km x
Weekly
Daily
1000
PDI
6 Check rubber gaiter is in good condition and replace if required 10

First Overhaul at 150000 km or three years
Overhaul the unit using recommended Repair Kit. Replace Desiccant
7 whichever is earlier and thereafter Every
Cartridge
1,00,000 km or 2 years whichever is earlier
G Quadruple System Protection Valve
Drain Sensing Reservoir and watch for any pressure drop in the gauge
to detect Non Return Valve leak. If pressure drop is noticed, clean
2 10
and reassemble the Non Return Valve of respective element. Check
for joint leaks."
6 H Graduated Hand Control Valve
2 Operate the lever and check for proper functioning 10
3 Remove exhaust filter, clean and refit 50

Every km x
Weekly
Daily
1000
PDI
I Hand Brake Valve

2 Operate the lever and check for proper functioning 10
3 Remove exhaust filter, clean and refit 50
4 Service Hand brake valve 150000 km or 3 years whichever is earlier.
J Dual brake valve
1 Check for free movement of pin in pedal & plunger. 10
2 Check & Tighten exhaust check screw 50
3 Check boot for deterioration & change if required 50
K Foot brake valve
1 Check for free movement of pin in pedal & plunger. 10 6
2 Check & Tighten exhaust check screw 50
3 Check boot for deterioration & change if required 50
On treadle operated valves check the condition of the push rod boot
4 25,000 km or 6 months whichever is earlier.
and lubricate the treadly pivots and push rod / treadle joint
On pendant pedal operated valves check the condition of the push rod
5 Every 1,00,000 km or 2 years whichever is earlier
boot and lubricate the push rod / pendant pedal assembly connecting pin
6 Service Foot brake valve 150000 km or 3 years whichever is earlier.

Every km x
Weekly
Daily
1000
PDI
L Air Reservoir
1 Drain condensate 3
2 Check drain valve and replace if required 50
3 Check air tank mounting, pipe clamps and tighten if necessary 10
M Air Filter
1 Remove serviceable filter element, clean & refit 50
N Front Brake Chamber
1 Check the travel of push rod and adjust the brake with minimum travel 10
Check clamp ring bolt and mounting bolt tightness for its correct
2 50
torque value
6
Dismantle and clean. Change diaphragm and seal assembly on all
3 1,60,000 km or 2 years whichever is earlier
chambers
O Front Brake Chamber
Check clamp ring bolt and mounting bolt tightness for its correct
2 50
torque value
3 Dismantle and clean. Change diaphragm and seal assembly on all chambers 150000 km or 3 years whichever is earlier

Every km x
Weekly
Daily
1000
PDI
P Slack adjuster - Manual

1 Lubricate the slack adjuster/S cam shaft 3 3
2 Check worm shaft lock is functioning properly 10
Q Automatic Slack adjuster
1 Lubricate the S cam shaft 3 3
For Haldex make ASA once in 5000 km and

2 Lubricate the slack adjuster with grease
for MEI make ASA at the time of overhauling.
Check S cam bush play and replace the bush if required (Clearance
3 15
should not exceed 0.5 mm)
6
5 Check plastic insert & Peg Bolt for wear & replace if necessary 15
6 Check peg bolt tightness 15
Check for correct axial play (0.3 to 0.8 mm) of adjuster on S cam and
7 15
adjust if necessary
When De- adjustment Torque Falls Below

8 Overhaul the unit
18 Nm

Every km x
Weekly
Daily
1000
PDI
R Spring Brake Actuator - Rear

2 Check clamp ring bolt and mounting bolt tightness for its correct torque value 50
3 Overhaul the assy with recommended repair kit Every 1,00,000 km or 2 years whichever is earlier
S Spring Brake Actuator - Rear
2 Check clamp ring bolt and mounting bolt tightness for its correct torque value 50
3 Service Spring brake actuator with recommended repair kit 150000 km or 3 years whichever is earlier
T Brake Shoes
6
Check brake shoe clearance (0.010") and adjust slack adjuster if
1 3 10
necessary (Only manual slack adjusters)
Check brake lining for wear and replace if necessary, During
2 10
replacement check brake drum and rectify defects if any.
3 Check & tighten brake carrier mounting bolts for correct torque values 10
4 Check S cam shaft / bushes, replace defective items, if any 15

Every km x
Weekly
Daily
1000
PDI
U Exhaust Brake
1 Check pipe connections & tighten if necessary 15
2 Check mounting bolts & tighten if necessary 15
3 Check pressure setting and adjust if necessary 50
4 Overhaul the unit Every 1,00,000 km or 2 years whichever is earlier
W Quick Release Valve
1 Check for uniform exhaust by applying and releasing brakes 10
X Relay valve
1 Apply & release the brake and check for free exhaust and replace if required 15
6
2 Check for proper function, remove & clean filter 50
Y Relay Inversion Valve
1 Apply & release the brake and check for free exhaust and replace if required 15
2 Check for proper function, remove & clean filter 50

Every km x
Weekly
Daily
1000
PDI
Z Automatic Load Sensing valve

Check and adjust the setting angle of LSV as per the
1 15
recommendations
AA Double Check Valve
1 Overhaul the unit by replacing the seals Every 1,00,000 km or 2 years whichever is earlier
AB Hose assembly
1 Check for abrasion, damage and replace if required 10
2 Change hose assembly Every 1,00,000 km or 2 years whichever is earlier
AC Stop Light Switch
6
1 Check for electrical connection 10
2 Check for correct operation by applying brakes. Replace if found defective 10
AD Low Pressure Warning Switch
1 Check all electrical connections 10
2 Check operation of the switch by depleting the air and replace if necessary 10

Every km x
Weekly
Daily
1000
PDI
IX POWER STEERING
1 Check steering gear box for oil leaks and level, top up if necessary 3 10
2 Check for wear and tighten steering drop arm, drag link and track rod ends 10
3 Check tightness of steering box mounting fasteners 10
4 Lubricate drag link and track rod ends 3 10
5 Check UJ fastener tightness 40
6 Change oil and oil filter Every 50000 km or 1 years whichever is earlier
7 Check power steering hydraulic limiter valve setting and peak pressure 70 6
8 Check steering wheel freeplay and adjust if necessary, ensure zero free play. 30
X CHASSIS FRAME
Check all joints and unions for oils, fuel, water or air leaks, Rectify
1 3 10
the defect noticed
2 Check the tightness of cross members to frame side members mounting bolts 3 10

Every km x
Weekly
Daily
1000
PDI
XI SUSPENSION
Check "I" Bolts/"U" Bolts, spring clip fittment, Helper Spring brackets
1 3 10
and spring shackle for tightness
2 Check and tighten shock absorber, rubber pads, mounting bracket bolts and nuts 3 10
3 Lubricate shackle pins 3
XII WHEELS AND TYRES
1 Check tyre pressure & inflate as recommended 3
2 Check for wheel nut tightness for specified torque 10
3 Rotate the tyre as recommended 10
XIII INSTRUMENTS
1 Check fuel tank and fuel gauge sensing unit nuts for tightness 10
6
Check speedo meter cable, air and oil pressure gauge connecting
2 3 10
union for tightness
XIV FES & BODY
1 Lubricate Door hinges, Driver seat, Wiper arm linkages 10
2 Check condition of body mounting rubber pad, replace if necessary 3 10
3 Check condition of gaiters at gear lever and steering column 3 10

Every km x
Weekly
Daily
1000
PDI
4 Check and tighten all body/cabin mounting fasteners 3 10

5 Vehicle washing and chassis greasing 10
XV ELECTRICAL EQUIPMENT
1 Check the battery electrolyte level. Top up if necessary with distilled water only 3 3 10
2 Check all the electrical connections 3 3 10
3 Check battery terminals. Apply petroleum jelly 3 3 10
Check all lights, switches, gauges, wiper and horn for correct
4
functioning, rectify if necessary
5 Check battery cells - voltage and specific gravity, rectify if necessary 15
XVI CABIN
1 Check operation of seat adjuster mechanism and air hose connections 3 40 First at 6
2 Check for various locks/key doors alignment and window winders. 3 40 20,000
3 Lubricate latch pawl & check strap locking pin and cab latch at rear of cab. 3 40 kms and
subsequently
4 Check and lubricate cab tilt mechanism linkages and safety lock 3 40 every
5 Check operation of wind screen washer & wiper 3 40 40,000
6 Check alignment of doors, and adjust striker plate if necessary. 3 40 kms
7 Check steering wheel alignment in straight ahead position. 3 20

Every km x
Weekly
Daily
1000
PDI
8 Check wind screen glass and rubber are in good condition. 3 20

9 Check Rear view mirror adjustment 3
10 Check windscreen washer reservoir level and top up if necessary. 3
11 Head lamp alignment. 3 3 20
12 Check cab lock warning lamp and beeper 3 20
13 Replace cab tilt pump oil Every 1,00,000 km or 2 years whichever is earlier
XVII BODY
1 Lubricate Door hinges, Driver seat, Wiper arm linkages 3
2 Check and tighten all body mounting fasteners 3 20

MAINTENANCE PROCEDURE ENGINE Oil level
It is necessary to check the oil level before
Your vehicle has been designed to ensure 1. LUBRICATION SYSTEM each drive (the oil is consumed a little by
ease of access to mechanical components. Use of recommended lubricants and the vehicle operation).
This will enable you to carry out a number following appropriate draining procedures The vehicle must stand on level ground to
of simple maintenance tasks. at correct intervals as per the maintenance check the oil level.
schedule is very important for the Check the oil level before starting the
Please read the instructions carefully
maintenance of the vehicle. engine when the oil level is stabilized.
which will enable you to perform the
basic maintenance work by yourself. For severe and adverse operating
conditions, the regular maintenance
intervals should be shortened suitably.
Pull dipstick out, wipe it clean with a rag 6

and push it all the way.
Pull dipstick out again. The oil level is
correct when it is between marks on the
dipstick.
Add oil on time and not to allow the oil
level to drop below the MIN mark.
Always add the oil of the recommended
grade and specification.

Engine Oil Used engine oils Spin on type filter element
For engine lubricants and brands of
Avoid excessive contact, wash thoroughly
lubricants, refer recommended lubricants
after contact. Keep out of reach of
chart.
children.
To drain the oil
Engine oil additives should not
be used. Ensure that the vehicle is standing on
NOTE
level ground and the engine is warm.
Draining of oil should be done within
Oil Pump
10 minutes, from shutdown. After
Type Pressure lubrication positioning a suitable drain tray under the
sump, remove the drain plug and drain
Oil Pump Gear pump the oil.
Min. Allowable oil
1 kg/cm² (80°C) Removal and re fitment of
pressure at idling Case oil cooler
Noise shield to be carried out
Max. Oil pressure 4.5-4.8 kg/cm² during oil change and regular
NOTE
at full load (Hot Engine) maintenance.
Full Flow - element
Oil Filter
6 type When completely drained
install the drain plug with new Adapter
CAUTION washers and tighten securely.
Insufficient oil level will cause
damage to engine. Keep the
environment clean when Spin on oil ﬁlter
CAUTION
handling the oil.
Always use the approved
engine oil only. Renewal procedure for spin on oil filter

Carefully read the installation instructions COOLING SYSTEM
printed on the outside of the filter to
determine the number of turns the filter The proper selection and use of coolant
1 Smear Oil on the
must to be rotated past washer contact are very important to prevent corrosion
‘O’ Ring
for proper installation and washer of the cooling system and clogging of the
compression. radiator. Replace coolant as per the
Pre-fill the new filter with clean engine maintenance schedule.
2 Hand Tighteining oil. Recommended Coolant
Only Spin on the new filter until the washer Eurocool LL Max 50 & Servo Kool ALT
makes contact with the sealing surface on 50 are pre mixed coolant (pre mixed
the filter head. with water at 50% ratio) and has been
Mark a reference point on the filter and formulated with a view to offer extended
3 Rotate turn
to ensure proper head to identify the point that the sealing service life. No addition of water is
tightening washer first makes contact with the required.
sealing surface of the head. For coolant change interval, refer
Rotate the filter by half a turn past washer Maintenance Schedule. Both the coolants
contact. are available in convenient pack sizes of
Remove the old filter using a filter wrench. 1, 3, 20, 50 liters & also as 210 liters barrel.
Clean filter base (adaptor) and ensure Start the engine and check for oil leakage 6
around the sealing washer and filter For topping up use only
that the all old washers are removed.
assembly. Eurocool LL Max 50 or Servo
Check the filter mounting adaptor for Kool ALT 50 directly. Do not
tightness. CAUTION
dilute with plain or
Apply thread seal. demineralised water for top up.
Apply thin coat of clean engine oil to the
washer sealing surface of the new filter.
Do not use grease.

Water Pump −− Loosen alternator link bracket and Coolant filter (spin on type cartridge) is
“H” Series engines are fitted with “integral loosen the fan belt fully. Inspect the introduced in the cooling circuit. Replace
shaft and bearing” type water pumps with pulleys for damage and wear. coolant filter as per given in Maintenance
prepacked grease. −− Replace the new fan belt and redo Schedule.
Removal and Refitment of Fan Belt the above in reverse. Renewal procedure for spin on coolant
Tensioning of fan belt filter
−− Open the bonnet
A tight belt results in rapid wear of Remove the old filter using a filter wrench.
−− Loosen the Four bolts between the
Clean filter base (adaptor) and ensure
fan and fan clutch and remove the a) Fan belt
that the all old washers are removed.
bolts. b) Alternator and Water pump bearings
Check the filter mounting adaptor for
−− Now the fan will be free from the A loose fan belt result in tightness.
clutch and can move axially and radially.
a) Squeaking noise Apply thread seal.
−− Move the fan towards the engine and
b) An undercharged battery Apply thin coat of clean engine oil to the
lift it to the maximum such that there
will be gap created between the c) Engine overheating washer sealing surface of the new filter.
clutch and the fan. Do not use grease.
Coolant Filter (If fitted)
−− Loosen the fan belt; push the belt 1 Smear Oil on the
through the gap between fan pilot dia ‘O’ Ring
6 and the fan adaptor. Belt can be

removed in the gap between the fan
clutch shaft and fan pilot diameter. 2 Hand Tighteining
Only
−− Same procedure to be adopted for
refitting of the fan belt.
−− Thus the Fan belt can be removed Rotate 3/4th turn
3
and refitted easily without any to ensure proper
3/4 tightening
special tool.

Pre-fill the new filter with clean coolant. 1. Rotate the nut (2) anti-clockwise of 8. Apply initial belt tension of 700 N by
Spin on the new filter until the washer link rod (1). Loosen alternator bottom adjusting the alternator position.
makes contact with the sealing surface on mounting fasteners, slacken the 9. To ensure the applied tension,
the filter head. pulleys and then remove the belt (5). measure it in the middle of span
Mark a reference point on the filter and 2. Check pulley grooves for wear / between water-pump pulley and
head to identify the point that the sealing damage and replace the pulley if alternator using electronic type
required. tension gauge.
washer first makes contact with the
sealing surface of the head. 3. Clean the pulley grooves for debris and 10. Verify the initial tension after running
ensure not to apply oil or grease on the engine for 24 hours.
Rotate the filter, the number of turns past
the pulley grooves.
washer contact. Belt tension checking procedure
4. Check alignment of the pulleys.
Start the engine and check for coolant Misalignment of pulleys will produce −− Hold the sensing head steadily across
leakage around the sealing washer and noise and shorten the belt life. the belt span within 5-10 mm
filter assembly. distance above the top surface of the
5. Mount the belt over pulleys and
Adjustment of Fan Belt Tension (Poly V) belt.
ensure that the belt ribs are seated in
4 3 2 the respective pulley grooves. −− Tap the belt gently near the mid span
1 using a rod or with similar tool to
6. Tension the belt by rotating the nut
cause the belt span to vibrate.
(2) clockwise thus moving the adaptor
piece (3) and alternator away from the −− Check the required tension display on 6
engine. Tighten the outer lock nut (4) the LCD panel on the tension meter.
after achieving required belt tension. −− If a reading is not obtained check that
Also tighten the alternator bottom the sensing head and ensure that it is
fastener. positioned properly.
5 7. Run the engine for 3 to 5 minutes with −− Repeat the same procedure to
the applied tension to allow the belt recheck.
to seat in the respective pulley grooves
properly. Reset tension.

DO’S: Replace the belt if it is frayed 3. Drain the complete system and
−− Check belt tension at regular intervals or pieces of material missing tighten the radiator drain plug.
and adjust as needed. or longitudinal cracks intersect 4. Slowly feed coolant into the radiator
NOTE
−− Check for any abnormal wear and with transverse cracks. through the filler until the radiator is
damage in pulleys / belt full. When supplying coolant from a
Charge air cooler and Radiator core cleaning pail, pour it slowly to prevent air from
−− Check for pulley alignment and fin repair mixing with the coolant.
−− Make belts free of fluffs and dirt. When mud, debris, etc. are stuck up at 5. When the level of the coolant
DON’TS: the front of the radiator or charge air reaches the filler neck, squeeze the
−− Don’t over tension the belt cooler core, the passage of cooling air is upper radiator hose two or three
−− Don’t apply oil/grease or paint on impaired. Hence such matter should be times. This will cause air inside the
pulley grooves removed completely by washing with hose to be expelled, and the level of
−− Don’t fix the belt improperly aligned water. Deformed fins also can impair the coolant will fall.
cooling and these should be repaired.
−− Don’t use worn out belts 6. Properly close the radiator cap.
Replace cooling system rubber hoses.
−− Don’t pry the belt using sharp tools. 7. To ensure that the air in the engine
Check hoses for cracks, swelling or
deterioration and replace if necessary. and the piping is properly expelled,
 Changing Coolant in Radiator
set the engine speed slightly higher
than normal idling speed. Raise the
6 1. Do not loosen the drain plugs while water temperature above 82°C, then
continue to idle the engine for
X the engine is still hot. If you do so, hot
water can come out resulting in another 10 minutes.
personal injury. 8. Stop the engine and after the engine
2. Stop the engine. Loosen-the radiator has cooled down sufficiently, check
drain plug to drain the coolant. the coolant in the radiator. Add
Drainage will improve if you remove coolant to make up for any drop in
Visually inspect the belt. the cap from radiator. the coolant level.

Radiator stay Rod & Cowl arrangement Cooling Fan AIR INTAKE SYSTEM
Do not run the vehicle without
radiator cowl. Ensure that the radiator
cowl mounting and fan blade clearance
are in proper order.
Check radiator stay bracket mounting
bolts for tightness. Also check the silent
block bush in stay rod and replace if found
defective.
Check radiator mounting bracket bolts for
Engine Cooling Fan with viscous clutch
tightness and the condition of the rubber
works on the principle of fluid clutch.
pads and replace if found defective.
Handle the fan and fan clutch with care.
Improper radiator mounting
Do not paint the fan / clutch.
can result in radiator hose Do not try to dismantle the
CAUTION failures as well as core cracks clutch. The clutch is a sealed
NOTE
at dip soldered joints of top unit.
and bottom tanks. 6
Check the bimetallic temp sensing coil for
Radiator Cap any mud or dust. If the coil is covered with
mud or dust, the fan performance will be Maintenance of Air cleaner plays a
The presence of the radiator cap prevents major role in engine performance and
erratic. Remove any mud / dust carefully
loss of coolant, entry of foreign particles life. Poor air cleaner maintenance will
with a brush.
and raises boiling point of coolant. The result in complaints like excess liner wear,
absence can lead to engine overheating high engine oil consumption, excess blow
and reduction in engine life. by and poor pick up.

Maintenance and Servicing of Dry type Guidelines for replacing Air Filter
Air cleaner The restriction indicator mounted on your
Following maintenance recommendations
need to be strictly followed. Air Intake System indicates when your air
−− Remove dust deposit weekly by filter elements need changing.
squeezing the dust evacuator valve.
−− Replace dust evacuator valve
immediately if it is torn, cracked,
remains open or missing.
−− Never operate the engine, if the
restriction indicator is either broken −− Replace primary filter element as
or missing. soon as vacuum indicator shows red
band.
Do not clean the air filter
primary & secondary elements. 1. De-clamp the Top Cover from Air
CAUTION
Cleaner Housing.
6
−− Replace the secondary filter element
at the time of every third replacement
of the primary filter element.
Air cleaner is fitted on LH side of vehicle For opening or closing of the 2. Remove the Top Cover.
behind front wheel. Restriction indicator air cleaner, instructions given
is fitted on air cleaner outlet pipe as seen NOTE
on the sticker (pasted on air
in above image. cleaner) need to be followed.

N
W
DO
3. Twist the end of the primary element 5. Insert the new Primary element in 7. Clamp the Top Cover back on the
to disengage the seal. Gently remove the housing. housing.
the primary element from the housing.
6
6. Place the Top Cover back on the 8. Once the elements have been
housing. Make sure dust evacuator changed, make sure that you reset
valve is oriented downwards. the restriction indicator.
4. Thoroughly clean the sealing surface
9. Same procedure has to be followed
and the inside of the Air Cleaner
for the safety element which can be
housing.
seen once the primary element is
removed. Safety element diameter is
smaller than the primary element.

TURBOCHARGER oil change as recommended in the Do’s
maintenance schedule. −− Use of specified grade of engine oil
3. Maintenance work has to be carried and oil filter and periodic change as
out regularly on the oil filter and air recommended in maintenance
filter system, as recommended in schedule.
maintenance schedule. −− Regular cleaning / change of air filter
4. Checks to be made on the oil, air and element according to maintenance
exhaust piping, as well as, on all other schedule.
connections and seals, to ensure that −− Check for oil pressure at engine idling
they are tight and no damage has condition minimum oil pressure
occurred. should be 1 kg/cm².
5. When carrying out maintenance −− Idle the engine for 2 minutes after
Initial running
work on the engine, the piping starting the engine.
Keep the engine at idling rpm for −− Idle the engine for 2 minutes before
minimum 2 minutes before moving the leading from or to the turbocharger
must be removed, and the pipe switching off the engine.
vehicle and before shutting off, to obtain
maximum life from the turbocharger. openings on the turbocharger to be −− Regularly checks the oil feed and
Do not run the vehicle at full load with oil closed. return pipes for leaks, air intake
pressure less than 1.5 kg/cm². 6. Prior to fixing turbocharger to the system pipes and hoses for leakage,
engine, fill the central housing with blockage and exhaust piping
Check all air ducts and gaskets for leak.
6 Repair any leaks before proceeding. Inlet clean engine oil and ensure that, all connections for leakages, blockage.
of air compressor must be free from dust pipes are thoroughly cleaned before −− Check the fuel injection system for
and contamination. connecting to the turbocharger. its proper functioning.
−− Close all the turbocharger openings
Maintenance Disassembly, servicing or with protective plugs when it is not in
1. Turbocharger and boost pressure overhauling of turbochargers use.
control valve do not require any NOTE
should be carried out only −− Contact Ashok Leyland dealer /
maintenance. through Ashok Leyland authorised centres for turbocharger
2. Adhere strictly to the periodic engine authorised dealers.
complaints / service.

Don’ts Benefits of Turbocharger 4. The clearances between the rotating
−− Don’t run the engine with low oil )) Lower fuel consumption parts are very close(in microns).
pressure. )) Lower emission 5. Turbocharger rotor assembly rotates
−− Don’t put the engine under full load at high speeds up to 1,00,000 rpm at
)) Better torque characteristics
immediately after starting. the rated engine power. Therefore
)) Lower weight and a smaller engine turbocharger rotating parts are
−− Don’t switch off the engine under full
)) Package balanced to very high accuracy for
load.
)) Lower engine noise optimum performance.
−− Don’t run the engine with leaky,
)) Altitude compensating 6. Since turbocharger compressor
restricted oil feed and drain pipes.
wheel is made of aluminum alloy
−− Don’t run the engine with blocked, For Enhancing Turbocharger Life
rotating at very high speeds, dust,
punctured, aged, deformed hose / Turbocharger needs CLEAN ENGINE OIL sand or any foreign particle entering
pipe connections from the air cleaner & CLEAN AIR (from the air filter.) For it’s in to the turbocharger compressor
to the turbocharger, turbocharger to proper functioning and durability for the housing will damage the compressor
charge air cooler and charge air following reasons. wheel blades, which will lead to
cooler to the inlet manifold. 1. Oil contaminated with dirt or foreign turbocharger failure.
−− Don’t run the engine with leaky material will wear the journals and 7. Damaged blades will lead to imbalance
connections, blocked, deformed journal seating area. in the rotor assembly resulting in
connections to the turbocharger 2. Dirt in the oil also blocks the oil holes shaft or bearing failure. 6
turbine inlet and from turbine outlet. in the journals (bearings) and bearing
−− Don’t tamper the fuel injection housing leading to oil starvation to
system the turbocharger.
−− Don’t dismantle the turbocharger, 3. Filtered oil at required pressure is
contact Ashok Leyland dealer / essential to lubricate and cool the
authorised service centre. journals.

FUEL SYSTEM FOR H4E4SD95 A minimum fuel quantity )) Connect the Inlet ( ) & ( ) Outlet
40 liters in rectangular tank is fuel pipes from the tank & to the Main
Fuel Tank filter as per the arrow. Indicated on
to be maintained to avoid
Remove the fuel tank from the vehicle.
CAUTION
situations of air lock. Air lock Filter head
Thoroughly clean the inside surface and or frequent dry cranking of )) Unscrew the air vent screw on both the
strainer as given in the Maintenance engine may result in damages 'Protect. . Main Fuel filter and start
Schedule. to fuel injection equipment. priming in main filter to drain out air.
−− Ensure the diesel tank cap rubber Fuel Filters - Protect I Pre Filter )) Priming to be done till fuel flows
seal in good condition. freely from the Air vent screw
Centre Bolt
Air Vent Screw )) Tighten the Air vent screw as per the
Filter Cover recommended Torque of 7 – 9 Nm.
)) Crank the Engine & check for Leakages
Filter Bowl
Installation Instructions of Insert
replacement Service :
)) Unscrew the centre bolt & Open the
top cover to replace Filter inserts.
6 Filter Bowl )) While replacing the ne. filter insert
−− Clean the vent hole in diesel tank. make sure all the sealing rings are in
−− Tighten the diesel tank mounting Installation Instructions of New Filter position.
brackets because loose mounting assembly on Vehicle :
)) Before placing the new insert into
may develop crack in the chassis )) Check Fuel filter for Physical damage the filter bowl, remove the sludge
frame and also the diesel suction pipe
)) Mount the filter assy on Vehicle using screw at the bottom to get rid of the
can break frequently.
the appropriate mounting bolts / nuts. sludge deposited already & retighten it.

)) Clean & flush the bowl with clean diesel Filter Cover with Screw the air vent screw as per the
before placing the new insert Hand Primer recommended torque 7-9 Nm.
Inlet
Crank the engine and check for leakages.
)) Tighten the Filter insert to the Filter Temperature Air Vent Screw
head to a Torque of 15 + 5 Nm
Sensor Ou
tle
Do's
t
Ensure filter mounting M1. nut & bolt
)) Start the Vehicle & Check for tighten properly.
Leakages Do not try to repair the Filter Insert
Ensure inlet & outlet pipes are not
clogged unit interchanged.
Fuel Filters - Main Filter cum Water Water in Fuel Sensor Ensure 250 um strainer is installed in the
Separator tank and functioning properly during the
Installation instruction of New fuel enter duration.
assembly on the vehicles Ensure that no leakage after cranking
Check the fuel filter for physical damages the engine.
after taking from the bulk packing. Store the filter in room temperature
Mount the fuel filter assembly on the and under only condition.
vehicle using two M10 nut and bolts. Don't
Connect the inlet ( ) and outlet ( ) Don't use physically damaged filter for
fuel pipes as per the arrows indicated on assembly.
the filter head. Don't use hammer for tightening or 6
Connect temperature , water level sensor loosening air vent screw and mounting
Fuel filter cum water separator is fitted connector to the respective vehicle wiring fasteners.
behind the Cabin at LH side. harness mating connector. Don't install the filter in tilted angle or
Unscrew the air vent screw on the filter horizontally.
head and start priming to drain out the air Don't remove protective caps (on banjos)
till fuel lines are connected.
from the spin –on. Don't demount temperature sensor from
Prime the fuel from the tank till fuel flows hand primer cover while replacing
freely from the air vent screw. spin-on filter.

Instruction for replacing spin-on at Service Prime the filter head assembly with the
Unscrew water sensor to drain fuel aid of hand pump.
completely from filter insert.
Remove the filter insert from the filter head
assembly.
X
Check the new filter insert for any
physical damage after removal from
packing.
Apply film of SAE 30 to the seal ring of the
new filter insert as seen above.
Replace the water sensor seal ring by a Screw the filter insert by hand up . to the Don`t use wrenches. Use belt wrench for
new one. base in clockwise direction and hand de-mounting only.
Assembly the water sensor with a torque tighten.
of 2 – 3 Nm.
Diesel
6
X 270°
Start the vehicle.

Once the filter insert is felt tight enough,
Do not fill the diesel into the new filter turn the filter insert further by 270
insert before assembling on to the filter degrees.
head assembly.

Fuel additive should not be Instructions for draining water from the
used. filter
CAUTION
Use good quality diesel. Use
always low sulphur diesel fuel .
Keep fuel clean and prevent
water from entering the fuel
System.
When filling the fuel tank in
the rain or snow care should
be taken not to allow water
in the fuel tan. Do not
forget to close the fuel tank
cap securely. Disconnect the end connectors of water
Check for leakages. Since the tip of the nozzle is sensor and vehicle wiring harness
Do's very sensitive extreme care to Unscrew the water level sensor in ant
be exercised in handling the clockwise direction by hand.
Ensure no leakage after mounting.
injection nozzles at all level. Let the water get drained from spin on
Ensure water sensor is tightened properly.
Do not use emery sheet or any filter.
Change the sealing ring of the water
hard material to clean the tip Collect water or water and diesel 6
sensor on every spin-on exchange.
of nozzles Emulsion from the drain pipe in a bin
Don't
After draining, Tighten back the Drain
Don't fill the Spin-on filter with diesel plug by rotating clock wise. Tightening
before mounting. torque 2 to 3 Nm or hand tighten.
Don't use wrenches for mounting. Connect the end connectors of the water
Don’t use spin-on sealing ring more than level sensor and vehicle wiring harness
one service interval. Crank the engine and check for the
leakages

Do's If Hand priming is not possible. Instructions for Loosening the filter from
Ensure water level sensor is tighten 1. Then Replace with New In-tank Strainer filter head.
properly. 2. Perform Hand Priming )) Demount the water level sensor from
the spin-on.
Ensure no leakages after mounting. 3. If the Problem Persists with Hand
Priming, Then Replace with new )) Unscrew spin-on filter from the filter
Don't head assembly by rotating
Hand Primer Head Assembly.
Don’t unscrew the water level sensor ant-clockwise direction using belt
Do's
completely. wrench.
Rotate Air vent screw in Anti-clockwise
Don't let the diesel drain out from the filter DO's
and clockwise direction while Loosening
while draining water. and Tightening respectively. Use the wrench on the ant-clock wise
Instructions to use Hand primer at direction and place the wrench on the
Don't
Service upper end of the bowl i.e. just below the
Do not repair the flap assembly in Hand seaming
During Air lock, loosen the Air vent screw primer Head Assembly.
Don't
and perform Hand priming till fuel comes
out of Air vent provision. Do not open the high pressure Do not put the wrench at the centre and
pipes to bleed air from the lower end of the bowl.
Re Tighten the Air vent screw at 7 + 2 Nm. system. Over tightening of the
NOTE Do not use the wrench in clockwise.
Fuel line will be filled with Fuel. vent screws will lead to the
failure of vent screws. Do not use the wench on the casting head.
6 Hand Primer
Tools used for mounting or demounting the serviceable parts
Air Vent Filter components Tightening torque Tools for mounting and demounting
15-20 Nm or 270° angle
Fuel Filter Insert Hand or Universal belt wrench
rotation after hand tight
Temperature Sensor 25-30 Nm Spanner: A/F 19 mm
Water level sensor 2-3 Nm Torque wrench or hand
Air vent Screw 7-9 Nm Spanner: A/F 10 mm

FUEL SYSTEM CRS
High pressure pump CB18-16/2 OFV

with metering unit and
sensor
integrated vane pump
PLV
hand primer and
water separator
ID>=8mm
NRV
ID>=6mm
ID>=3mm
Sensors Actuators Injector
ID>=8mm
CR12-16
ID>=8mm
High pressure
unit
Tank with stainer & EDC 17CV54 EDC 17 Low pressure
6
WORKING PRINCIPLE:
Fuel from tank flows through pre-filter and main filter to FIP. Over flow fuel flows back to diesel tank. High pressure fuel is pumped
by FIP to common rail and excess fuel flows back to tank. Electronic control unit (ECU) receives signal from sensors and actuates
actuators. Injector is opened once signal is sent from ECU. Rail pressure is sensed by rail pressure sensor and signal is fed to ECU.
In similar manner, ECU receives signals from all the sensors and controls FIP, Injector function to get correct quantity of fuel at
correct time.

Following are the critical components of −− To be disconnected during body
CRS system. building
1. High Pressure Pump −− To be avoided from electro static
discharge
Critical parts must be always protected.
Don't remove CRS pump &
injectors. CRS pump & injector
CAUTION
are very sensitive equipment.
For any defects report to the
nearest AL dealership
5. Electronic Control Unit (ECU)
2. Rail
3. Injectors
4. Sensors
6 )) Engine speed sensor
)) Pump camshaft speed sensor Electronic Control Unit and sensors
)) Fuel temperature sensor −− To be protected from moisture entry
)) Rail pressure sensor −− To be protected from electrical
)) Boost pressure sensor overstress
)) Accelerator pedal sensor −− High current .ow
−− Proper grounding for wiring
)) Coolant temperature sensor
harness
Injectors Wear of parts will lead to incorrect Don't
injection characteristics Don't damage the Nozzle tip. Electrical
INJECTOR
connector or High pressure connector
NUT while assembling or removing the
CONE injector from the engine.
WASHER
Don't allow the in injector to fall-of OR hit
with other component.
Don't use the same retainer ring after
removal.
SEAL RING Don't erase or damage the laser writing
Do’s on the injector.
Ensure proper protecting cap at below Use two spanners during Don’t try to assemble or remove
connections tightening or loosening of high electrical connections when ignition key is
CAUTION pressure pipe cap nuts. in 'ON' position.
−− High pressure connector
−− Back leak opening Don't try to dismount the HP connector
or nozzle body.
−− Electrical connector
−− Nozzle tip 6
Remove the protection caps only during
the time of assembly
Assemble all protection caps immediately
after removing the injector
CRI is very sensitive for

contamination / particles.
CAUTION

SELECTIVE CATALYTIC REDUCTION (SCR) Reaction in the catalytic convertor: converter housing. The shape of the
Scope hydrolysis pipe may vary depending
Ammonia reacts with nitric oxide and
on the vehicle. The injector nozzle and
This system is provided in all vehicle to oxygen to form nitrogen and water.
temperature sensor are located in the
treat engine exhaust to meet the Euro IV The non-toxic, colorless and odorless urea hydrolysis pipe.
emission norms. solution is available in many petrol
stations under the trade name of Do not attempt to bend
Function "AdBlue®". Vehicles with SCR systems Hydrolysis pipe.
CAUTION
have an extra tank for this purpose.
The SCR process (Selective Catalytic
Reduction) has proven itself for reducing SCR systems must be installed as compact
nitrogen oxide. By selectively adding the units in the exhaust silencer area. These
systems have emission control using SCR
reducing agent AdBlue® harmful nitrogen
technology and noise suppression in one
oxides are converted into harmless housing.
nitrogen and water in the catalytic
AdBlue® tank
convertor. Engine characteristics control
the SCR systems which reduces the The tank is made of tough plastic and has
nitrogen oxide emissions of diesel a volume of approximately 16 liters.
6 engines with maximum efficiency. Fill only AdBlue® in the
AdBlue® tank. Other fuels can
The reducing agent AdBlue® is an CAUTION damage the enter SCR system.
aqueous urea solution (32.5%). The
Hydrolysis pipe
solution is injected selectively into the
exhaust gas system using a dosing unit The hydrolysis pipe is made of high
(UDS = Urea Dosing System). quality stainless steel and is highly
durable. It is welded to the catalytic

Filling AdBlue® Malfunction Indicator Lamp (MIL) AdBlue® Level Gauge
The tank cap is fastened to the tank neck It shows any malfunction on vehicle level.
using a loop and secured against falling. Use OBD - Test device to read the error 3.3
The tank cap is secured with a lock. The code from control units. Adblue Level 1 50%
delivery includes 2 keys.
Adblue 0% 50% 100%

SET BUTTON
MODE BUTTON
AdBlue Tank level gauge shows actual

level of available AdBlue in tank. This
gauge is equipped with an reserve lamp,
Check AdBlue tank display first. Indicating to be refilled soon. Reserve
Appearance on vehicle may vary dependent lamp will glow below 7 litres. Additional
on type of vehicle. to this the MIL will also glow.
6
After filling, screw the tank caps back
onto the tank neck.
The tank cap is provided with
ventilation. The tank cap
CAUTION
should be replaced only with
original accessories with
ventilation.

Operation Disposal On Board Diagnostic (OBD)
The equipment can function without The SCR system partly consists of
failures and safely only if it is operated electronic components that require
and maintained properly special disposal. Always follow all the
environmental regulations.
Fill only AdBlue® in the
AdBlue® tank Other fuels can Leaked AdBlue® must be
CAUTION damage the entire CRS system. pumped into suitable containers
or covered with an absorbent
Safety instructions for operation CAUTION
material and removed and
Risk of burns The exhaust filled into containers for
OBD system is a monitoring and
system is very hot during inspection and disposal This
detection system which can alert the
operation Allow the system to container must be labelled
CAUTION
component or system failures that can
cool down completely before appropriately to prevent it
adversely affect emissions.
working on the C system from getting mixed with new
AdBlue®. Illuminates a dashboard light (malfunction
Maintenance must be carried Consult the local authorities Indicator lamp) to inform the driver of a
out by technicians who are on issues about waste fault.
NOTE trained in the field of automotive management. Provides standard and unrestricted
6 engineering. access for diagnosis and repair.
Do not dispose of AdBlue®
Use only demineralised water into surface water or the
for cleaning the filter (filler WARNING sewage system.
CAUTION neck). Do not use tap water.
Ensure that the external The consumption of AdBlue®
compressed air system is is about 4 to 5 % of fuel
depressurized. NOTE consumption.

FUEL SYSTEM FOR H6E4SD165 1. Maintenance
2. Fuel Tank Cap Filter inserts must be replaced at regular
Remove the fuel tank from the vehicle. intervals. For replacement period refer
Thoroughly clean the inside surface and 3. Fuel Sensor Unit
Maintenance Schedule.
strainer as per maintenance schedule. −
Renewal procedure for Fuel Filter
− Ensure the diesel tank cap rubber seal
develop crack in the chassis frame and
1 Smear Oil on the
− Clean the vent hole in diesel tank. frequently.
‘O’ Ring
3 1
2
2 Hand Tighteining
Only
Boss 815 - 105  3 Rotate 3/4th turn

2 to ensure proper
3/4 tightening
1
3 6
−
−
the old gasket material is completely
removed.
been designed to retain even the smallest
−
Boss 1223 - 208 

thin coat of clean engine oil to the

gasket sealing surface of the new Chassis pre-filter - FleetGuard Ventilating the system with the hand
filter. Press the gaskets firmly into the pump
gasket retainer groove while It is necessary to ventilate the filter if the
lubricating the sealing gasket. Do Not spin-on filter has been replaced and work
Use Grease. has been performed on the fuel line.
−− Pre-fill the new filter with clean fuel. Procedure
−− Spin on the new filter until the sealing 1. Turn off the engine.
gasket makes contact with the sealing
2. Undo the vent screw (3).
surface on the fuel filter head.
3. Pump with the hand pump (4) until
−− Mark a reference point on the filter
only fuel emerges from the vent
and head to identify the point that the
screw.
sealing gasket first makes contact with
the sealing surface of the head. 4. Re-tighten the vent screw. Apply
torque of 5-7 Nm. If fuel leak is seen
−− Rotate the filter 3/4 number of turns
after tightening, replace the sealing
past gasket contact.
washer.
−− Start the engine and check for fuel
leakage around the sealing gasket and Functional description
Over tightening may break
filter assembly. The PreLine filter system is installed in
6 the screw
the fuel line downstream of the fuel CAUTION
tank. Here, it separates water and

ultrafine particles from the diesel fuel
which flows through it, by virtue of its
multilayer media construction.
The separated water collects in beneath
the filter. The collected water is drained
off via the drain plug.

Draining the water from the water Changing the pre-filter Mounting the pre-filter system
collecting Filter
Only install undamaged
It is necessary to drain the collected water spin-on filters. The old spinon
if the water collecting vessel is full and NOTE filter may stuck to the filter
when the spin-on filter has been changed. head. Release the filter using a
suitable tool.
Fuel leakage contaminates
the environment. When To remove the spin-on filter, follow this
WARNING
working on the filter, place a procedure:
collecting vessel below the
1. Turn off the engine.
engine and dispose of
collected fuel properly. 2. Remove the old spin-on filter. 1. Look and align for mounting hole
3. Dispose of the old filter. spacings
2. Attach mounting flange to frame
To mount the spin-on filter, follow this with two screws.
procedure: 3. Disconnect the fuel line and attach
threaded couplings
1. Lubricate the seal. 4. Connect the fuel lines to the inlet
2. Screw on filter by hand until the seal and outlet.
is in contact with the joint. 5. Check the filter for leakage. 6
OPEN CLOSE
6. Check the entire filter for snug fit
3. Continue to screw filter by hand until (vibration free).
filter is tightly fitted (approx. ¾ turn). 7. Open the bleed screw.
8. Operate the hand pump and prime
Procedure: 4. Ventilate until air bubbles are no with fuel.
1. Undo drain plug and allow the water longer visible. 9. Actuate the pump until no more air
to drain off. 5. Carry out a leakage test. emerges from the bleed screw.
10. Close the bleed screw.
2. Re-tighten the drain plug. 11. Start the engine.

Diesel Bleeding Procedure 6. Loosen bleed screw on the main filter. 12. Ensure there is no leak anywhere in
the fuel line.
1. Ensure that diesel (min. 10 liters) is 7. Crank engine till fuel comes out of
available in the tank. If leakages are bleed screw but do not operate the
there arrest it and ensure there is no Do not open high pressure
starter motor for more than 10
blockage in the filter/pipe lines. lines for bleeding
seconds continuously. Wait 30 - 60 CAUTION
2. Open the vent screw (5) of pre-filter. seconds before next attempt.
Before bleeding ensure that
3. Operate the hand pump (8) and 8. Tighten bleed screw
1. Adequate diesel is available in fuel
prime with fuel. Do not operate the starter tank.
4. Actuate the pump until no more air motor for more than 10
emerges from the vent screw. CAUTION
seconds continuously. Wait 2. There are no damaged fuel pipes.
30 - 60 seconds before next
5. Close the vent screw. attempt. 3. The copper washer at all the joints
must be ok, otherwise priming takes
9. Crank engine till fuel leaks out of more time due to entry of air and
injector leak off connection (D) to the hence bleeding is not proper.
banjo on rail but do not operate the
starter motor for more than 10 4. The pipe fittings are tight.
seconds continuously. Wait 30 - 60 5. The suction strainer in fuel tank is
6
seconds before next attempt. clean.
10. Tighten leak off connection. 6. Both the fuel filters and their seals
11. Crank engine till engine starts but do are in good condition.
not operate the starter motor for
more than 10 seconds continuously.
Wait 30 - 60 seconds before next
attempt.

Fuel additives should not be
D used.
CAUTION Use good quality diesel. Use
A - Fuel inlet to Feed pump always low sulphur diesel fuel
(Euro IV Fuel) .Keep fuel clean
B - Feed pump outlet and prevent water from
C - CR pump inlet entering the fuel system.
D - Fuel return from When filling the fuel tank in
E injector and rail to pump the rain or snow care should
fuel return be taken not to allow water
in the fuel tank. Do not forget
E - Fuel return to tank to close the fuel tank cap
securely.
Since the tip of the nozzle is
C very sensitive, extreme care
to be exercised in handling
the injection nozzles at all
level. Do not use emery sheet
A or any hard material to clean 6
the tip of nozzles. Handling
Guidelines for high precision
CRS Components
B

While operating in the field extreme care
Fault Possible Cause Remedy should be taken when handling with CRS
Components.
Engine power output too Following are the critical components of
Filter capacity exhausted Replace filter
low CRS system.
1. High Pressure Pump
Connect the Filter inlet/ 2. Rail with RDS4.2
Filter inlet/outlet incor-
outlet so that the Filter 3. Injector
rectly connected to tubing.
No through flow after of functions properly 4. Sensors
The PreLine filter system
Engine speed sensor (DG6)
Leaky hose connections Pump camshaft speed sensor (DG6)
Check seals
or seal
Fuel temperature sensor (FTS)
Boost pressure sensor (LDF6T)
Accelerator pedal sensor (PWG3)
Maintenance Schedule Oil pressure sensor (ODFT)
Water temperature sensor (WTS)
Maintenance work Interval
6
5. Electronic Control Unit (EDC 16UC40)
Critical parts must be always protected.
Drain off water Depending on water volume or before freezing can occur
Don’t remove CRS pump &
Change spin-on filter Refer Maintenance schedule injectors. CRS pump &
CAUTION
injectors are very sensitive
equipment. For any defects
report to the nearest AL
dealership.

Typical damages due to handling
3 4 5 Causes Effects
Connectors damaged Leakage Investigation not possible
7
6 Particles inside the pump Functionality
MPROP damaged / any tampering Leakage Investigation not possible
1 8
1. Gear pump inlet

2. Gear pump outlet
3. Pump inlet connector
4. Back flow connector
6
5. HP Connector
6. Drive shaft
7. M-Prop Use two spanners during
tightening or loosening of
8. Camshaft speed sensor high pressure pipe cap nuts
CAUTION

Precautions during handling Injectors Wear of parts will lead to incorrect
Correct handling injection characteristics
NUT
Do not keep or even handle the pump INJECTOR

CONE
WASHER
applying forces on external components
like fittings, M-Prop, Overflow Valve.
CLAMP INJECTOR
Pay attention to ensure that there are
no contacts between hard materials and
critical parts like head’s covers and
SEAL RING
flanges.
Cleanliness on line Do’s
Ensure proper protection cap at below
Protective caps (especially from fittings)
connections
must be removed as late as possible,
−− High Pressure connector Use two spanners during
just before external circuit components tightening or loosening of high
assembly. −− Back leak opening
CAUTION
pressure pipe cap nuts
−− Electrical connector
Ensure the following environmental
−− Nozzle tip Don’t s
requirements:
6 Remove the protection caps only during Don’t damage the Nozzle tip, Electrical
Storage conditions connector or High pressure connector
the time of assembly
Temperature : - 30 to 60°C while assembling of removing the injector
Assemble all protection caps immediately
from the engine.
Relative humidity : 0 - 80% after removing the injector
Don’t allow the injector to fall-off OR hit
Protect from : Rain, Snow & Sunshine
with other component.
CRI is very sensitive for
Longest allowed Don’t use the same retainer ring after
contamination/particles
storage period : 1 year CAUTION
removal.

Don’t erase or damage the laser writing SENSORS AND SWITCHES
(IMA code) on the injector.
Don’t try to assemble or remove electrical
connectors when ignition key is in ‘ON’
position.
Don’t try to dismount the HP connector
or nozzle body.
Rail pressure sensor (RDS)
Assemble all the protection caps
immediately after rail is removed
Do’s
Remove protection cap inlet/outlet
connectors only during assembly.
RDS to be protected from entry of any
foreign residue
Don’ts 6
Don’t try to dismount rail pressure sensor
(RDS) & Pressure limiting valve (DBV)
1. Boost Pressure Sensor 6. Fuel Temperature Sensor
Don’t allow the rail to fall-off OR hit with
other component 2. Accelerator Pedal Sensor 7. Rail Pressure Sensor
3. Engine Speed Sensor 8. Vehicle Speed Sensor
Don’t try to assemble or remove RDS
electrical connectors when ignition key is 4. Camshaft Speed Sensor 9. Brake Signal Switch
in ‘ON’ position. 5. Coolant Temperature Sensor 10. Clutch Signal Switch

1. Boost Pressure Sensor The Sensor serves to measure demand 4. FIP Camshaft Speed Sensor
from the driver and communicates to the
ECU. It detects the pedal position by
means of potentiometer sensor and
transfers this information to the ECU in
terms of Voltage. It consists of two
potentiometer sensors for measuring the
position of accelerator pedal module
from 0% travel position to 100% travel
position. The second sensor is
incorporated as redundant and reports
Function and Working The sensor serves error in case of malfunction of the first Cam speed sensor is an inductive type. It
to measure the absolute intake manifold sensor. Voltage across redundant sensor is mounted on the FIE .Electric pulses are
pressure. The pressure Sensor Element is almost half of the first sensor. generated when the formed slot inside
consists of a Silicon diaphragm, which 3. Engine Speed Sensor the pump passes through sensor axis.
contains Piezo resistive Semiconductor. 5. Coolant Temperature Sensor
ENGINE SPEED SENSOR
The Pressure acts on the diaphragm
causes change in electrical resistance in FLANGED SCREW
Circuit thus change in Output voltage. SENSOR MTG PLATE
2. Accelerator Pedal Sensor

6 FLYWHEEL HOUSING
It is a thermistor, mounted on coolant

return line from cylinder head. A semi
Engine speed sensor is an inductive type. conductor material changes its resistance
It is mounted on the flywheel housing. when exposed to variable temperature
Electric pulses are generated when the
source. Resistance decrease as temperature
formed slots on the flywheel pass through
Increase (NTC type).
the sensor axis.
6. Fuel Temperature Sensor 8. Vehicle Speed Sensor 0.5 Bar. This information is used by the
ECU to activate the limp home mode in
A1 A2 case of defective accelerator pedal sensor
(Pedal stuck Pressing brake implies this
condition).
10. Clutch Signal Switch (If fitted)
It is a thermistor, mounted on FIP. A semi A1 A2

conductor material changes its resistance
when exposed to variable temperature
source. Resistance decrease as temperature Working on proximity principle, produces
Increase (NTC type). 6 or 8 pulses per revolution, pulse output
7. Rail Pressure Sensor is used for calculating the distance travel
and speed of the vehicle.
9. Brake Signal Switch
It is mounted on the clutch pedal to
detect whether clutch is pressed or not.
Sensor Hybrid
6
The switch is of electro-pneumatic type.

Switch is mounted on the dual-control
The rail contains a pressurised supply of
brake valve. It indicates the altered
diesel fuel ready for the injectors to use;
voltage level from the switch and output
when the pressure in the rail drops the
is fed to ECU as information. Switch
sensor signals this to the ECU and
operates for pressure greater than
pressure (via the pump) is restored.

SENSORS −− Sensors should not be kept near Hot CLUTCH
medium or objects with Temp > 120 ºC.
−− Sensors should not be kept near any Diaphragm Clutch
strong Magnetic Materials. The diaphragm clutch mainly consists of
−− None of the application guidelines the following parts.
should be deviated (Air gap, tightening 1. Pressed steel cover
torque etc)
2. Diaphragm spring
Electronic Control Unit
N NN
I
3. Pressure plate
NN N NN
4. Driving straps
ININ
ININ
ININ
Do’s 5. Connecting rivets

−− Sensors must be removed from its
packing just prior to installation
−− Specified tightening torque should
be maintained
−− Replace any damaged O-Ring.
−− Clean and grease O-Ring prior to
installation with mineral oil-based −− To be protected from moisture entry
grease. −− To be protected from electrical 330 mm DIA DIAPHRAGM CLUTCH 380 mm DIA DIAPHRAGM CLUTCH
−− Storage temperature to be overstress (EOS)

6 maintained at -20ºC to 50ºC In diaphragm clutch, the clamping force is
−− High current flow
Don’ts −− Proper grounding for wiring provided by diaphragm spring. Under the
−− Don’t drop the sensor harness assembled condition of clutch assembly
−− Do not Hammer the sensor while −− To be disconnected during body on the flywheel, the diaphragm spring
fitting building gets almost flattened exerting clamping
−− Avoid moisture (water traces) near −− To be avoided from electro static force on the clutch plate through clutch
to the sensors discharge (ESD) pressure plate. Thus the diaphragm trying
−− Do not short circuit the connector −− To be protected from handling to regain the conical shape exerts even
pins while the sensor is functioning. damages pressure on to the pressure plate.

When clutch pedal effort is removed, the
diaphragm spring returns back by its
tension and makes the pressure plate to x
engage with clutch plate. Clutch pedal
returns with the help of the return spring.
Clutch booster stand out setting
Ensure the following dimensions for
clutch booster stand out setting COP
outer lever should be assembled when
the clutch withdrawal bearing touches
the cover assembly finger and after
assembly, maintain distance from clutch
booster mounting face of the bracket to
jaw end centre as 102.5 ± 0.4 mm.
As the disc wears off, the standout
reduces. Note For Stand Out:
Replace clutch disc when clutch booster Clutch Booster Stand Out (X) = 116.5 ± 0.4 mm
wear indicator becomes 31.87 mm. Booster Stroke = 13.5 -15 mm
Ensure Proper Clutch Bleeding 6
Refer following instructions for wear
indicator adjustment on clutch booster. Clutch Worn Out Stroke (Wear Stroke) = 14 mm
Clutch Booster Stand Out After Disc Worn Out (X) = 102.5 ± 0.4 mm
For Field Service:

When Clutch Stand Out (X) Becomes 102.5 ± 0.4 mm
(Due To Clutch Disc Wear) Replace The Clutch Disc

DELIVERY POSITION:
MOUNTING POSITION:
Rod & washer are moves back by
To Bleed the Hydraulic System escapes during slackening of bleeding
Washer Body of
the piston when mounting
Air will get into the hydraulic line if the screw (without any trace of air bubbles).
(Self locking) wear indicator
level of fluid in the master cylinder Finally tighten the bleed screw, remove
Rod reservoir is allowed to fall too low and the bleeding tube and refit the rubber cap
leaks develop in the pipe unions. As a on the bleed screw.
result the pedal will feel spongy or it may Fluid withdrawn during bleeding
require a pump action, or even become should be filtered and left to
completely inoperative. In such cases the NOTE stand for at least 24 hours
bleeding should be done, as follows: until it is clear of all air
Remove the filler cap from the reservoir bubbles. The fluid can then be
INTIALIZED POSITION:
Washer pushed along the rod
WORN POSITION :
Wear stroke of clutch and arrange to keep the fluid level topped used for topping up the
up throughout the bleeding operation. reservoir on future occasion.
unit body of wear indicator
position 0
Remove the cap from the bleed screw on

the booster and attach a transparent Checking and adding the fluid
rubber bleeding tube. Check the fluid level in circuit regularly.
Allow the free end of the tube to dip into LY
BR
AKE FLUD
DO
T3
N
EO
a clean glass containing hydraulic fluid.
-D
REMOVING US
OT
4F
RO
MA
SEALED CONT
ORE
EF
PB
CA
AIN
N
Depress the clutch pedal fully and allow it
EA
E
R
CL
WARNING
MAX
MIN
6 to return. Continue the same for 5 times

and then hold the pedal in depressed
Clutch booster stand out becomes condition. Slacken the bleed screw and
109 ± 0.5 mm. allow the oil in the system to escape. You
Reset the wear indicator to zero position. can find air bubbles in the escaping oil
Again when wear stroke of clutch as through the transparent tube. The fluid level must be between MIN and
shown in fig becomes 31.87 mm due to Tighten the bleeding screw and repeat MAX marks. If it drops below MIN mark,
clutch disc wear, replace the clutch disc. the above steps until you find pure oil add the fluid.

ZF GEAR BOX - S6-36 OD after the vehicle has been driven. Filling the Transmission with Oil and
To drain the oil, unscrew and remove the Checking the Oil Level
oil drain plug on the underside of Park the vehicle on level ground before
transmission and, if an auxiliary unit is
filling the transmission with oil or
fitted, also remove its oil drain plug.
Before reinserting plug, remove any checking the oil level. Clean the area
attached debris from the magnet and fit around the oil filler hole before opening it.
the plug with a new sealing ring.
Less oil in the transmission
When the vehicle is towed with can cause transmission
engine at standstill and no CAUTION
damage. Too much oil can
gear shifted, disconnect the lead to gearbox overheating.
CAUTION
propeller shaft (at the rear
The ZF transmission is an OE fitment. The axle) to avoid damage to
gear selection is done through gear shift gearbox due to insufficient
lever arrangement. The design of the Fill the transmission with
lubrication.
transmission and the shift control rods recommended grade of oil.
Do not start the engine when NOTE
for transmitting the shifting forces assists there is no oil in gearbox.
easy and accurate shifting of the gears in Never coast with the Clean Transmission Breather
all situations. transmission in neutral The transmission oil heats up while
For filling capacity & recommended Never coast with the clutch
lubricants refer lubrication chart. the vehicle is in motion. This creates 6
depressed an over. Pressure which is continuously
For change period refer maintenance Coasting with the transmission
schedule. relieved by the transmission breather
in neutral will cause friction
Drain oil while hot. Fill recommended grade between main shaft and provided on selector housing.
of oil. needle rollers resulting in lack Always ensure that this valve functions
Draining the oil of lubrication and extreme correctly. The breather valve must be
Drain the oil when the transmission is at difference in rotational speeds, cleaned at regular interval.
operating temperature. When you need there by damaging the
to drain the oil, always do so immediately transmission.

CABLE SHIFT SETTING 3. Adjust the length of the reaction rod Shift cable assembly gearbox end
by rotating the middle part to
Boss vehicles come with cable shift maintain the 176 mm setting of the Shift Cable Lock Nut
mechanism for easy and smooth gear select cable as shown in fig.
shifting. In case of any difficulty in gear Tighten the reaction rod locknuts
shifting, please report to authorised tightening torque 50 ± 5 Nm
service centre. However we have 4. Tighten the select cable lock nut
given few setting dimensions which can 60 ± 5 Nm Ball Joint
be checked during emergency 19
2+ Nut
requirements. 5. Tighten the ball joint nut 24 ± 3 Nm 1m

m
Select cable assembly setting at gearbox Shift cable assembly gearbox end
end Shift Cable
Support Bracket 1. Place the ball stud on outer lever as
350+5mm shown in fig.
2. Place the cable on the shift cable
mounting bracket by adjusting the
lock nuts.
Bolt and Washer
3. Set the distance 192 ± 1 as shown
6 from the bracket to the outer lever
hole (if required remove and rotate
the outer lever to attain this setting)
Reaction Rod Lock Nut
1. Place the shift cable mounting bracket and tighten the shift cable lock nut
onto clutch housing as shown in tightening torque 60 ± 5 Nm)
1. Place the ball stud on middle hole of
selector plate 1 figure. 4. Tighten the ball joint nut-tightening
2. Tighten the bracket with bolt torque 50 ± 10 Nm.
2. Place the cable on the select cable
mounting bracket using the lock nuts. tightening torque 50 ± 5 Nm

PROPELLER SHAFT Lubrication Procedure repeat procedure on opposite
For a longer and trouble free life of inboard and outboard lug ears.
propeller shaft UJ and slip joints are to be 4. Now apply grease gun pressure and
lubricated periodically as described purge all four bearing until fresh
below. grease is seen at all four seals.
Refer maintenance schedule for propeller 5. If striking lug does not cause
shaft lubrication schedule. purging, remove snap ring (or cap
For UJ: screws as the case may be) in lug ears
of the bearings that are not
1. While greasing, ensure grease is
purging and repeat step 3. If all
coming out (purging) from all four
four bearing purge fresh grease
seals of each UJ lugs. This flushes
Propeller shafts are fitted between the refit snap rings (or cap screws to the
abrasive contaminants from each
gearbox and rear axle supported by a specified torque).
bearing assembly and ensures proper
rubber mounted centre bearing at the filling of all four bearing. 6. If the bearing still do not purge,
centre. The front shaft has a fixed joint remove the UJ from the yoke and
near the gear box and rear end is supported 2. If any of the seal fail to purge, try to
determine the cause of blockage.
on the centre bearing with a splined stub move the drive shaft from side to side
simultaneously apply grease gun For Slip joint:
shaft to take up the rear propeller shaft.
The rear shaft consists of a fixed joint at pressure. This allows greater 1. Apply grease gun pressure to lube 6
rear end and a slip joint at the front end. clearance on the thrust end of the fitting until grease appears at the
bearing assembly that is not purging. pressure relief valve (or hole in the
Alignment of propeller shafts
3. Still if any bearing cup assemblies fail plug at the slip yoke end of the
The propeller shafts are balanced to avoid splines).
vibration and whipping. Arrow marks are to purge, then by using brass hammer
provided on yoke and tube for proper sharply strike yoke on inboard and 2. Now cover the pressure relief hole
alignment and balance. Further ensure outboard lug ears once, to firmly with your finger and continue to
yokes of front and rear propeller shafts seat bearing and relieve tension apply pressure until grease appears at
are in the same plane when fitted. across span. Rotate shaft 180° and the slip yoke seal.

Maintenance Procedure FRONT AXLE REAR AXLE
Replacement of UJ kit alone is recommended.
Repairs on propeller shaft
like replacement of Yokes,
CAUTION Tube, Stub shaft etc requires
high level sophisticated
equipment and processes.
Also dynamic balancing of the
unit to very tight limits is
essential for satisfactory
performance. As such field
repair of these components is
NOT recommended. Check the oil level and change the oil in
If you notice that tyre treads wear axle final drive housing during service
Replacement of Sealed Centre Bearing unevenly on the front axle, check and inspections.
When servicing a propeller shaft in the have the front axle geometry adjusted at Visually check the axle final drive
field with a new centre bearing, it is the authorized service station. housings for leaks. If you find any
necessary to fill the entire cavity around The life of shock absorbers and their leakage, have it repaired at the
6 the bearing with waterproof grease to function depend on the way of driving authorized service station.
shield the bearing from water and and kind of operation.
contaminants. Model Rear Axle Hub End Play
Front axle hub end play to be 0.025 mm
to 0.100 mm. 912 0.025 to 0.100 mm

POWER STEERING Procedure for oil filling If the oil needs to be refilled
too often, visit the authorized
Pump NOTE service station.
Keep the environment clean
MAX when handling the oil.
MIN
Fill the reservoir nearly full. Crank the

engine for 10 seconds without allowing
Steering Box
the engine to start. If the engine starts,
The power steering reservoirs are to be shut it of immediately. Check and refill the
regularly checked for oil level and to be reservoir. Repeat at least three times,
topped up as required. each time checking and refilling the
reservoir.
For change period refer maintenance
Start the engine and check for oil
schedule. leakages, if noticed shut of the engine
Check the condition of steering drop arm, immediately and take corrective action, 6
drag link and track rod ends visually for to arrest the leakage.
any damage. Check for any unusual shake Oil level to be maintained between MIN
in steering linkages. and MAX level as shown in above fig.
Do not run the engine when

there is no oil in the power
CAUTION steering reservoir.

BRAKE SYSTEM movement of the Brake Chamber / Spring Brake Chamber at rear axle through a
Brake Chamber push rod to rotary Graduated Hand Control Valve.
The Dual Brake system is simply a split movement of the 'S' Cam shaft of the During normal running of the vehicle,
system of brakes actuating the front and foundation brakes. Independent low air pressurised air from system Protection
rear axles separately hereby ensuring pressure warning lamps are provided in Valve flows to Spring Brake portion of the
partial braking for the vehicle during each circuit. Spring Brake Chamber through hand
failure of either Front or Rear brakes.
When the Dual-Brake Valve treadle is Control Valve and keeps the Spring Brakes
The System depressed, compressed air from the released. For Parking / Emergency
The Air Compressor, driven by the Engine, Service Reservoirs is fed into the brake braking, hand Control Valve is operated
draws air from the Engine inlet manifold actuators at front and Rear axles through for depleting air from the Spring Brake
and compressed air is pumped through the secondary and primary deliveries Chamber thereby applying spring brakes.
the DDU. The Unloader Valve ensures of the Dual brake Valve. The foundation
the unidirectional flow of filtered air into brakes are actuated through the Slack Before towing, Check that
the system apart from regulating the Adjusters. On release of the treadle, the spring loaded cylinders
system pressure. The DDU System the air, from the actuators is exhausted WARNING
of the parking brake are
Protection Valve has four independent through the Dual Brake Valve thus released.
delivery lines from a single inlet, two of releasing the brakes. Before releasing the parking
which are preferentially charged for the brake Ensure the vehicle is
service braking, the third line is utilized During accidental failure of either front held with chocks to prevent it
6 for parking brakes and the fourth for or rear brake circuits, partial braking is from rolling away.
auxiliaries like exhaust brakes. achieved through the live circuit, thus The spring loaded cylinders in
providing the necessary secondary the parking brake must be
Service brakes
braking. returned to their operational
The two Service Reservoirs are connected
Emergency and Parking Brakes state before operating the
to the Brake Chambers and Spring Brake
One of the secondary outlets of the vehicle again
Chambers, at Front and Rear axles,
through a Dual Brake Valve. The Slack System Protection Valve is connected to
Adjusters convert the longitudinal the Spring Brake portion of the Spring

S-cam brakes protected by rubber grommets. After Do's
The brake is operated by a '5' form cam checking running clearances / lining −− Reset shoe to drum clearances after
which is an integral part of the cam shaft, thickness, always replace the grommets fitting new shoes.
the shaft being mounted on derlin to avoid dirt and water ingress.
−− Inspect bores and seatings for
bushes in the chamber brackets and Lining Wear damage when servicing
spider. The expanding force at the '5' cam Brake shoes should replaced when the −− Unwind the spring brake chambers
is applied to the shoes through rollers lining material is worm to a minimum screw fully and after assembling the
seated between shoes webs. A slack thickness of 5 mm (0.2’’) shoes wind in the screw.
adjuster, which provides a quick and
easy method of adjusting the brakes, to Check brake lining periodically −− Examine shoe linings for wear
compensate for lining wear, is fitted to the for wear and replace if regularly
splined end of the cam shaft. necessary. Don'ts
CAUTION
The brake is actuated by air chamber Failure to replace the linings / −− Use Vacuum cleaner to remove dust
push rod connected to the slack adjuster. shoes at the correct time may use a damp rag.
result in damage to the shoes
Lining inspection −− Actuate the brake at the time of lining
and drums and impaired brake
replacement.
efficiency.
Ensure that no manual brake Recommended Lubricants
adjustment is done (Except At roller end shoe resting lugs and shoe
6
during brake lining change) hold down clip Multipurpose Grease. For
for the vehicles fitted with specifications by various companies, refer
automatic brake adjuster. Recommended lubricant chart.
Always fit new shoes in pairs on both Exhaust brake
sides of the vehicle. When fitting new The exhaust brake is an auxiliary brake
Access to view the linings is through shoes check the condition of shoe return system to be used mainly during
the inspection holes provided in the springs and change if necessary. continuous braking on long descending
dirt shield. The inspection holes are hilly gradients as well on level roads. With

this arrangement the regular friction type SUSPENSION At PDI and once in every 8000 km check
wheel brakes are subjected to less wear suspension joints/linkage for security
and tear and kept cool for emergency use Your vehicle is fitted with parabolic leaf damage or wear, report any defects.
without excessive heating of brake drums. springs. Proper and timely lubrication For convenience, this operation may be
(Graphite Grease) of spring leaves (inter carried out in the same time as that of
In the present system of exhaust brake, leaf) and tightening of U-bolts will ensure
control activates the exhaust brake when suspension bracket and springs eye bolt
safer driving and longer life from both torque checks.
the driver intends to slow down the springs and tyres.
vehicle by pressing the brake pedal. A Visually check the spring assemblies for
pedal position sensor positioned at the Parabolic Suspension cracked or broken leaves or loose clamps,
brake pedal energizes the solenoid valve misalignment within the mounting brackets
whenever the brake pedal is pressed and caused by worn or damaged spring eye
thus activating the exhaust brake. bushes and excessive wear or distortion.
A 'normally closed' type micro switch is Check the mounting brackets for cracking
used as a pedal position sensor. damage or distortion, loose rivets or
excessively worn rebound pins.
Front Leaf Spring Assembly
Check shock absorbers for leaks or damages
and for security of the mountings.
6 ADVANTAGES:
1. Improved Suspension
2. Light Weight
3. Long Fatigue Life
Rear Leaf Spring Assembly

Don'ts Do's ELECTRICAL SYSTEM Service Precautions
Do's −− Ensure that the correct battery
BATTERY polarity is maintained since reversed
Replace broken leaf with correct part
number leaf spring to avoid damage/ Maintenance battery or charger connections will
breakage of other leaves. Remove the caps and check the Specific damage the alternator rectifier.
Gravity of each cell, with a hydrometer. For Never disconnect the battery whilst
- Torque center bolt nut properly
engine is running.
- Always use proper height & torque Exide batteries Specific gravity readings at
27"C (Fully charged) will be 1.230/1.240. −− When charging the batteries from
for U-bolts
an external source ensure that the
Don'ts For other temperatures above 27"C add
area around the battery is well
0.007, and below 27"C subtract 0.007 for
Do not remove the shock absorber as it ventilated and protected against any
results in more oscillations because of every 10"C. For Amaron Batteries Specific naked fame or heat source. The use
the friction between the springs is less. gravity readings at 27"C (Fully charged) of 'Boost charger' should be avoided
will be 1.270 ± 0.005. and should only be used with the
(( Do not add semi elliptic leaves
Electrolyte level must always be battery removed from the vehicle.
(( Do not re-camber the leaf spring
maintained Inline with the bottom of the Check and apply petroleum jelly to
(( Don’t remove center pads.
vent hole. Incase of any drop in level add battery terminals every week
(( Don’t add additional conventional
distilled water. Never add acid. Remove the caps and check the Specific
leafs
Check and apply petroleum jelly to Gravity of each cell, with a hydrometer 6
(( Don’t heat with gas welding torch once in every 16000 km.
or with any other means. battery terminals, never apply grease.
The Alternator charging voltage setting
measured across the battery terminals
must be maintained at 14± 0.20 volts for
12 V system and 28± 0.40 volts for 24 V
system.

Use Of Slave Battery For Starting −− Then disconnect negative jumper
from slave battery first, then vehicle.
4 −− Disconnect positive from vehicle.
2 If using two vehicles do not allow
their bodies/chassis to touch. Always
- + disconnect the negative lead first.
24V Since hydrogen gas is always present,
sparks or flame should not be
allowed near the battery. When using
jumper leads the cables should
always be attached, as described
above, to avoid sparks near a vehicle
OFF
battery.
3 1
ON
Non-insulated parts of cable

1. Positive Cable −− Connect jumper positive lead to clamps must not touch each
2. Negative Cable vehicle battery positive.
other. The jumper cable
Ensure jumper lead terminal does not WARNING
3. Vehicle Battery connected to the positive
touch carrier or other vehicle
4. Slave Battery terminal of the battery must
metalwork.
6 To avoid damage to the vehicle charging not come in contact with the
−− Connect jumper negative lead, to vehicle ground because this
system, it is important to observe the vehicle frame at least 300 mm from
following procedure, when using jumper could lead to short circuit.
vehicle battery.
leads to start vehicle having discharged
−− Ensure a good connection is made to
batteries.
vehicle frame.
−− Ensure electrolyte level is above the
−− Start vehicle. When running, ensure
top of the plates.
engine speed does not exceed 1000
−− Switch off all vehicle load/systems. rev/min (for fast idle).

WHEELS AND TYRES Removal and fitment of wheels 6. Recommended tightening torque for
wheel nut for front and rear.
Always check the tyre pressure before M18 (6 wheel bolts) - 390 ± 10 Nm
you drive the vehicle. Remember also to
check the tyre condition. M20 (8 wheel bolts) - 530 ± 10 Nm
7. Remove the jack and go over all nuts
No cuts, bruises or other damages are again in the same way.
allowed on tyre treads or sides.
8. Re-check the tightness of wheel nuts
In case of the uneven wear of tyre treads daily for the first week.
on front axles, check and adjust the front
axle wheels geometry as required .
Protect tyres against oils and fuel. 1. Slacken the nuts on the wheels
affected, (wheel nuts are RH)
Always check tyre inflation
2. Jack up the axle, remove the wheel
pressure in cold condition.
nuts and lift the wheel off.
NOTE Pressure will inevitably rise as
the tyres heat up while running. 3. Grease the wheel stud threads.
4. Lift the wheel into position, noting in
The service life of tyres depends on:
the case of twin rear wheels that the
)) Way of driving and driving habits tyre valve of the inner wheel should 6
)) Correct tyres inflation project through the aperture in the

rim of the outer wheel diametrically
)) Vehicle operating conditions opposite the valve in the latter.
)) Geometry of front axle 5. Refit all wheels nuts, tighten them
lightly, then, selecting diametrically
)) Proper distribution of load on the
opposite nuts in rotation, go over all
load space.
the nuts in turn and tighten.

SPARE WHEEL CARRIER HYDRAULIC JACK TOWING
FRONT OF
VEHICLE
Hydraulic jack is located behind the driver

Spare wheel carrier is fitted at rear of the
seat.
vehicle at centre of frame as shown in the
At front axle, place the jack with its head Use the tow hook attach in the LH part of
above image.
guided through a hole in the metal sheet the frame side member.
guide situated under the leaf spring When towing the vehicle with the engine
ahead of the axle (see the figure). at standstill and no gear speed shifted in
On the rear axle, place the jack with its gearbox, disconnect the propeller shaft
6 head under the flat portion of the axle not to damage the gearbox due to
casing. insufficient lubrication and release the
spring-loaded Brake chamber.
The jack must stand firmly on
the firm sub grade. With the With the engine off, the power
WARNING
vehicle lifted, never start the steering is out of function. Use
engine. WARNING
only the tow bar to tow the
vehicle; other connection is
not permitted.

TUBELESS TYRE PUNCTURE REPAIR 3. Using spiral cementing tool, pierce 5. Cement the injury thorougly by
PROCEDURE the tyre at the angle and direction of inserting tool in the direction of the
injury. injury.
In the event of tyre puncture need not to
demount the tyre.
1. Inspect the Tyre with approx. 25-psi
pressure and remove the object that
RUBBER SOLUTION
caused puncture.
4. Apply chemical vulcanizing cement 6. Leave Tool inside injury. Remove the
through the spiral cementing tool. blue poly of the phermacure carefully
without touching near the centre.
With inserting tool.
2. Find the angle & direction of the RUBBER SOLUTION
injury & Mark the injury.

6
MARKER

7. Apply chemical vulcanizing cement 9. Pull out the insertion tool. 11. If needed, cut the excess Phermacure
on the selected strips carefully. outside the Tyre. Inflate Tyre to
standard Working Pressure.
If leakage persists, apply another
Phermacure.
RUBBER SOLUTION
10. The Repair is Complete.

8. Remove the spiral cementing Tool
from injury & push the phermacure
into the injury until only about 1/2
inch of the phermacure remains
outside.

RECOMMENDED TYRE ROTATION Front Tyre Irregular Wear
Tyre Normal Wear
Remove the rim marking tyre sides and

In the event of front tyre irregular wear flip the tyre.
follow the above shown tyre rotation pat-
In the event of normal tyre wear follow tern.
the above shown tyre rotation pattern.
Rear Tyre Irregular Wear
Alternate Tyre Normal Wear
After flipping tyre side insert the rim.

During every alternate rotation
tyre to be flipped i.e.,
In the event of rear irregular wear follow
In the event of alternate normal tyre wear de-mounted from the rim and
the above shown tyre rotation pattern. NOTE
follow the above shown tyre rotation rotated, so that inner side will
pattern. become outer side.

Tyre wear differs depending upon the TYRE INFLATION PRESSURE
load distribution, braking action and road
conditions. The spare tyre also will MODELS TYRE SIZE FRONT REAR
deteriorate if not in use. To off-set these KPA Kg/cm2 PSI KPA Kg/cm2 PSI
characteristics we recommend tyre 815 225/75 R17.5 620 6.33 90 586 6.00 85
rotation periodically once in 8000 km
1223 245/70 R19.5 760 7.73 110 690 7.00 100
(or once in a month).
Check tyre condition and tread depth, RECOMMENDED LOADING PATTERN
report any defects, Inspects each tyre
including the spare, for cuts, bulges,
damage, signs of uneven wear and tread X X
depth. The tread depth should be
measured across the width of the tyre at
three points around the tyre
circumference. X X
Unsafe tyres must be replaced
immediately.
6
WARNING
   
Do not exceed the maximum allowable rated axle load.
Take care that the load is distributed correctly on the load space of the vehicle: place the
load to the centre of the load space
−− Place the load evenly on the whole load space
−− Keep a correct distribution of the weight (1/3rd to the front axle and 2/3rd to the
rear axle.)

CABIN painted by “cataphoresis + priming + 2. LUBRICATION
enamel” or “cataphoresis +
1. MAINTENANCE powders”,). Fastening elements such
−− Wash the vehicle at fixed intervals as bolts, washers, nuts and screws
with neutral surface-active products should be protected with suitable
and water so as to remove all traces rust preventive chemicals.
of corrosive agents (i.e. sand, salt etc,). −− Carry out the assembling operations
Avoid using brushes provided with with care (pay attention to
hard fibres or unclean wiping cloths interferences, make sure not to score
which may cause deep scoring or surfaces with screwdrivers etc.) Lubricate door locks, strap pivots and
tarnishing of the point. in order to avoid permanent damage hinges.
−− Blow dry by compressed air so as to to the paint film. As a general guide, lubricate any Sliding
thoroughly eliminate water pockets Sticker (Deco - strip) components (check straps, lock pawls,
which may have formed. with grease and pivoting components,
The application or removal of stickers
−− If necessary, polish the paint using (hinges, handles and check strap pivots),
(deco-strip) by means of cutting tools
the standard fine grain silicone with oil. Remember to lubricate the hood
(e.g., blades, knives etc.) May cause
pastes. hinges.
gashes in the paint film with consequent
−− Do not further drill the cab corrosion of the under-firm surface.
switchboard panel (e.g, bore for radio Grease 6
Cleaning of upholstery should
antenna connection) in order to avoid be by means of dry foams,
untimely tarnishing of inner and petrol, alcohol etc. Never use
outer surface. CAUTION
chlorinated solvent (trichloroeth
−− When fitting on further accessories: ylene, hyperchloride etc.
Use suitably painted and protected
items (e.g., external rearview mirrors, Apply grease sparingly to lock mechanism
drag foilers, sun Visors should be (both sides).

3. VEHICLE CARE Seat belts
Cleaning agents Clean them with a soap water solution.
As far as the cleaning agents or other The seat belts should be kept
chemical vehicle-care products are clean. Dirt would affect the
concerned, Please follow the directions function of retractor.
NOTE
when using them both for the vehicle
Before winding, the seat belts
interior or exterior.
must be perfectly dry.
The non-suitable cleaning agents may The seat belts must not be
impair the value of vehicle components. cleaned chemically.
Do not use the volatile agents (acetone,
diluents, gasoline), cleaning agents Vehicle Washing
(wash powders) and bleaching or other Use the lukewarm or cold water to wash
aggressive agents. the vehicle.
Take care that the ventilation is enough First wash off the dirt thoroughly.
when working in interior (vapours of
After washing off the dirt, use a soft
some agents are harmful to health).
sponge to clean the body with water and
Vehicle interior and exterior car-wash shampoo in ratio as mentioned
It is important to use correct cleaning on the packing.
6 agents and procedures (see instructions
Use plenty of water to rinse the vehicle
mentioned on cleaning agents) to
off after washing (do not allow the agents
preserve the interiors and exteriors value
of vehicle components. to dry on the body paint) and dry it out
with a chamois.
Plastic parts
Use wet rag to clean the plastic parts.
After a rough cleaning by wet rag, you can
apply the agents recommended.

FILLING CAPACITIES
BOSS 815
DESCRIPTION AGGREGATE QTY
Engine (Including Oil Filter) H4E4SD110 E - IV 12.5 
Cooling System Capacity H4E4SD110 E - IV 16 
Gear Box ZF - Synchromesh 6.5 
Rear Axle AAM 12.6" 6.5 
Power Steering ZF 4.5 
Clutch Master Cylinder 0.3 
Fuel Tank 105 
Adblue (Urea) Tank Cummins 16 
Cab Tilt System 0.4 
A36 Front Axle Hub Greasing 400gms/Hub
AAM 12.5" Rear Axle - Hub Greasing 400gms/Hub
BOSS 1223
Engine (Including Oil Filter) H6E4SD165 EURO-IV 18 
Cooling System Capacity H6E4SD165 EURO-IV 22 
Gear Box ZF - Synchromesh 6.5 
6
Rear Axle Meritor RS120 8
Power Steering ZF 4.5 
Clutch Master Cylinder 0.3 
Fuel Tank 208 
Adblue (Urea) Tank Cummins 35 
0.4 
A48 Front Axle Hub End Greasing 470gms/Hub
Meritor Rs120 - Rear Axle - Hub Greasing 450gms/Hub

RECOMMENDED LUBRICANTS
Co-branded Lubricant Approved Lubricant
Min. Ambient
Aggregate Gulf Oil India Indian Oil Corporation
Temp. °C
Gulf Super Fleet LE Dura Servo pride ALT plus
HA4CTI3K B PLATFORM (with spin on oil filter) 20
Max 15W-40 15W-40
Gulf Gear XP Servo Gear ALT 80W-90
Gear box Synchromesh (ZF S6-36) 25
Dura Max 80W-90 (LL)
Gulf Power Steering Dura
Power Steering (Rane TRW) 40 Servo Transdex II
Max
Gulf Gear DB Dura Max Servo Gear Axle ALT
Rear Axle Hypoid Drive AAM and Meritor 10
85W-140 85W-140
Engine Water pump, Gear shift ball joints, S cam shaft & slack adjuster
(front & rear), Shackle pin.
Accelerator pedal ball joints, Accelerator control shaft (Pedal end &
Crankcase rear)
20 MP Grease Max NLGI 2 Servo Grease ALT
Clutch pedal, Brake pedal, Relay shaft & ball joints (clutch withdrawal), Clutch
withdrawal sleeve & liner, Centre bearing joint, Propeller shaft UJ cross & splines,
6 Inter axle propeller shaft UJ cross, Drag link, track rod, Steering column spline
shaft and King pin
Hydraulic Clutch 40 Gulf Clutch Fluid Max Servo Power Brake ALT
Wheel bearing, front and Rear hub greasing 20 Gulf Crown Dura Max NLGI 3 Servo Grease Super 3
Cab tilt 30 Gulf Harmony HVI Plus-15 Servo System HVLP 15
Cab latch 20 Gulflex EP2 Servo Grease molex
# : Specification and change period applicable for special, arduous duty & army applications refer service manual. NOTE : Do not mix lubricants of different brands/grades.

7. Trouble shooting
)) Engine
)) Clutch & Gear Box
)) Rear Axle
)) Front Axle & Power Steering
)) Brake System
)) Electrical System
)
7
7.2 TROUBLE SHOOTING

TROUBLE SHOOTING - ENGINE
Symptom Possible Cause Remedy/Prevention
Engine overheating Coolant
* Insufficient coolant Add coolant
* Defective thermostat Replace the thermostat
* Overflow of coolant due to leakage Repair
of exhaust into cooling system
* Coolant leakage from cylinder head gasket Replace gasket.
* Defective coolant pump Repair or replace.
Radiator
* Clogged with rust and scale Clean radiator.
* Clogged with iron oxide due to Clean coolant passage and correct
leakage of exhaust into cooling system exhaust leakage.
* Clogged radiator core due to mud Clean radiator.
or other debris
* Defective radiator cap pressure valve Replace radiator cap
* In correct gap between radiator and fan Correct the gap
* Deration pipes blocked due to mud Clean and use coolant.
7
* CAC & Radiator fins out side for dust Clean.
deposit.
* Working of thermo sensing fan Check and correct.
TROUBLE SHOOTING 7.3

Abnormal combustion
* Reduced injection pressure Adjust injection pressure.
* Poor fuel Use good quality fuel.
* Poor nozzle spray Adjust or replace nozzle.
Other problems
* Defective or deteriorated engine oil Change engine oil.
* Unsatisfactory operation of oil pump Replace or repair
* Insufficient oil Add oil.
* Brake drag Repair or adjust.
Excessive oil
consumption Piston, cylinder liners and piston rings
* Wear of piston ring and cylinder liner Replace piston rings and cylinder liner.
* Worn, sticking or broken piston rings Replace piston rings and cylinder liner.
* Insufficient tension on piston rings Replace piston rings and cylinder liner.
* Unsuitable oil (viscosity too low) Change oil as required and replace
piston rings and cylinder liners.
* Incorrectly fitted piston rings (upside down) Replace piston rings.
* Gaps of piston rings in line with each other Reassemble piston rings.
7 Valve and valve guides
* Worn valve stream Replace valve and valve guide
* Worn valve guide Replace valve guides.
* Incorrectly fitted valve stem seal Replace the stem seal.
* Excessive lubricant on rocker arm Check clearance of rocker arm and shaft.

Excessive oil
consumption
Excess oil feed
* Defective oil level gauge Replace oil level gauge
* Oil level too high Drain excess oil.
Other problems
* Overcooled engine (low temperature wear) Warm up engine before moving vehicle.
Check cooling system.
* Oil leakage from miscellaneous parts Repair.
Piston seizure Operation
* Abrupt stoppage of engine after running Operate engine properly.
at highspeed
* Hill climbing using unsuitable gear Select suitable gear
Oil
* Insufficient oil Add oil.
* Dirty oil Change oil.
* Poor quality oil Replace with proper engine oil.
* High oil temperature Repair
* Defective oil pump Repair oil pump. 7
* Reduced performance due to worn oil pump Repair oil pump.
* Suction strainer sucking air Add oil and/or repair strainer.
Abnormal combustion See symptom:”Engine overheating”
Coolant See symptom:”Engine overheating”

Lack of power Intake
* Clogged air cleaner Clean element or replace element.
Fuel and nozzle
* Poor nozzle spray Adjust or replace injection nozzle
* Clogged nozzle with carbon Clean nozzle
* Wear or seizure of nozzle Replace nozzle
* Air in fuel system Repair and bleed air from fuel system.
* Clogged fuel filter Replace element
* Use of poor fuel Use good quality fuel.
Abnormal combustion See symptom:”Piston Seizure”
Piston, cylinder liners and piston rings See symptom.”Excessive Oil Consumption”
Other problems
* Breakage of turbine or blower Repair
* EDC system defective Use diagnostic tool for trouble shooting and
rectify.
Difficult starting
7 engine Electrical system
* Discharged battery Charge battery
* Defective wiring in starter circuit Repair wiring of starter.
* Loose or open-circuit battery cable Tighten battery terminal connections or replace
battery cable.

Injection pump Repair
Air cleaner
* Clogged element Clean the element or replace the element.
Fuel system
* No fuel in tank Supply fuel and bleed air from fuel system.
* Clogged fuel line Clean fuel line.
* Air sucked into fuel system through Tighten fuel line connections.
fuel line connections.
* Clogged fuel filter Replace element
* Loose connection in high-pressure line Tighten sleeve nut of high pressure line.
* Water in fuel Drain and clean fuel system
Nozzle
* Seized nozzle Replace nozzle
* Broken or fatigued nozzle spring Replace spring
Oil system
* Oil viscosity too high Use proper viscosity oil, or install an oil immersion
7
heater and warm up oil.
Other problems
* Seized piston Replace piston, piston rings ,and liner.

* Seized bearing Replace bearing and /or crankshaft
* Reduced compression pressure overhaul engine
* Ring gear damaged or worn Replace the ring gear and/or starter pinion.
* Check relays and fuses of EDC system Replace defective parts.
Rough idling Injection pump Repair
Nozzles
* Uneven injection pressure Adjust
* Poor nozzle spray Adjust or replace nozzle.
* Carbon deposit on nozzle tip Remove carbon
* Seized needle valve Replace nozzle
Engine
* Improper valve clearance Adjust valve clearance
* Improper contact of valve seat Replace or repair valve and valve seat.
* Idling speed too low Warm up engine.
7
* Compression pressure of cylinders Overhaul engine
markedly different from one another

TURBOCHARGER
High oil consumption
Oil leak from turbine

Engine Lacks power
Turbocharger noisy
compressor side
Oil leak from
Possible Cause
Black smoke
Blue Smoke
seal
Dirty air cleaner 3 3 3 3
Restricted compressor intake duct / piping 3 3 3 3 3
Restricted air duct from compressor to intake manifold 3 3 3
Air leak in pipe from air cleaner to turbocharger 3
Air leak in pipe from compressor to inlet manifold 3 3 3 3
Air leak from inlet manifold 3 3 3 3
Foreign object in exhaust manifold (from engine) 3 3 3 3 3
Restricted exhaust system 3 3 3
Exhaust manifold cracked, gaskets blown or missing 3 3 3
Gas leak at turbine inlet/exhaust manifold joint 3 3 3
7
Gas leak in exhaust piping 3
Restricted turbocharger oil drain line 3 3 3
Restricted/blocked/distorted crankcase breather 3 3 3

TURBOCHARGER
High oil consumption
Oil leak from turbine

Engine Lacks power
Turbocharger noisy
compressor side
Oil leak from
Possible Cause
Black smoke
Blue Smoke
seal
Turbocharger bearing housing sludged or coked 3 3 3
Fuel Injection System defective / incorrectly adjusted 3 3
Engine valve timing incorrect 3 3
Worn engine piston / piston rings / liners 3 3 3 3
Eroded valves and / or pistons 3 3 3 3 3
Excessive dirt build up on compressor wheel and housing 3 3 3 3 3 3
Boost pressure control swing valve / poppet valve
doesn’t ft close/damaged 3 3
Boost pressure pipe to actuator leaking / damaged 3
7 Piston ring sealing defective 3 3 3
Turbocharger journal (bearing) defective 3 3 3 3 3 3 3
Foreign body damage on compressor / turbine wheels 3 3 3 3
Insufficient oil supply to turbocharger 3 3 3 3

GEAR BOX
Grinding Noise when Knocking when engaging
Noisy while travelling Gear change difficulties
Changing gears clutch or during gear change
Propeller shaft
Clutch not Separating Worn selector dogs Clutch not disengaging
imbalanced / misaligned
Bearings or teeth in Gear
Clutch not fully depressed Clutch plate bent Dog clutches worn
Box worn
Dog clutches worn / Propeller shaft centre Clutch plate torsion Linkages jammed /
Synchro ring worn bearing worn springs defective / weak needs adjustments
Selector forks or sliding Propeller shaft splines / insufficient lubrication
Selector forks or sliding
pieces worn pieces worn universal joints worn
Rear axle shaft bevel
Gear forcibly engaged gear worn
REAR AXLE
Crown Wheel Noise Causes
Humming Noise Lack of lubrication, Less backlash in crown wheel and pinion, Wrong tooth contact in crown wheel.
7
Noise when in straight ahead Worn or damaged crown wheel and pinion or excess backlash, Worn out or damaged bearings.
Growling noise or noise when Worn out or damaged differential gears / thrust washers.
cornering only

FRONT AXLE AND STEERING
Symptom Complaints
Vehicle pulls
CAUSES Excessive
Hard Steering one-side Steering
Play in Tyre wear
Steering Wandering during driving shimmy
the steering
/braking
Loose/worn out parts 3 3 3 3 3
Binding on the inner column bush 3
Lock of oil 3
Pitting on the balls/worn track 3
Excessive pre-loading of the inner column bearing 3
Improper adjustment of rocker shaft 3 3 3
Binding in the rocker shaft bush 3
Excessive friction on the ball joints 3
Loose or worn out parts/linkages 3 3 3
Uneven braking action / Oval brake drum 3 3
Improper wheel alignment 3 3
Loose/worn out bearing 3 3 3 3
Low/uneven tyre pressure* 3 3 3 3 3
7 Uneven, sagging, loose or broken springs 3 3 3 3 3
King pin bush - lack of lubricant 3 3
King pin bush worn out / loose cotter pin 3
Hub End play improper 3 3
Wheel disc run out / Frame bend 3 3 3
7.12 ON THE SPOT RECOVERY

BRAKE SYSTEM
Fault Possible cause Remedy
Storage system
a. Excessive air build-up time* 1. Engine air filter element/air Clean air filter element /
ducting restricted or blocked. clean air ducting as instructed.
2. Defective compressor Check compressor performance
a. Excessive carbon and take appropriate remedial
buildup in compressor or action as instructed in service Manual.
Cylinder head / discharge line.
b. Leaking compressor inlet
discharge valves.
c. Worn compressor.
b. Failure to attain normal 1. Excessive air system leakage Carry out pressure system test to
working pressure or retain locate and rectify leakage.
Normal working pressure 2. Defective unloader valve Carry out operating and leakage
(should be 8.25 kg/cm²) tests and take appropriate remedial
action.
Clean and adjust or renew defective
safety valve.
Check compressor performance
and take appropriate remedial
action as instructed in manual. 7
Use calibrated test gauge to check
vehicle air system supply, renew
defective gauge as necessary.
* Note : Correct air buildup time should be within 3 minutes at maximum engine speed

BRAKE SYSTEM
Service brake system
Brakes inoperative or i. Insufficient air pressure. Build air pressure.
insufficient application.
ii. Low foot brake valve Using test gauge fitted in
delivery pressure line fully apply foot brake valve and
compare input pressure with
corresponding output pressure. In each
case input/output pressure should be
identical. A pressure variation indicates
a defective foot brake valve: overhaul
foot brake valve; overhaul foot brake
valve as instructed in manual. Replace
or overhaul unit as instructed in
Manual.
iii. Defective front brake Overhaul / Replace the front / rear
chambers and rear spring brake chamber.
brake chambers.
iv. Worn brake shoe linings Replace the brake shoe linings.
Brakes slow to release. i. Blocked exhaust port in Clear obstruction and clean exhaust
foot brake valve. port.
7 ii. Br. chamber seized. Overhaul brake chamber.
iii. Brake pedal/valve plunger Release and lubricate pedal joint/
sticking. valve plunger.

BRAKE SYSTEM
Brakes binding Air System malfunction Overhaul foot brake valve. See
i. Foot brake valve piston sticking manual.
ii. Leaking foot brake valve. Check foot brake valve for leakages and
if necessary, renew or overhaul as
instructed in Manual
iii. Defective brake shoe return Inspect brake shoe return spring and
renew as necessary.
Fierce brake application. i. Incorrect brake pedal Check brake pedal adjustment and if
adjustment. necessary, adjust.
ii. Incorrect or contaminated Renew brake shoe linings in both sides
brake shoe linings. of axle.
iii. Eccentric brake drums. Check brake drums for ovality: machine
or renew as necessary.
Parking brake system
a. Slow or poor hand brake i. Defective hand control Check operation of hand control valves
application valve. as instructed in manual, renew/
overhaul valve as necessary.
b. Brakes binding or Mechanical Malfunction :
slow to release i. Leak from spring brake Renew / overhaul spring brake actua-
tor 7
actuator taking special care during dismantling.
ii. Defective hand control Renew or overhaul hand control valve
valve. as instructed in manual.
iii. Damaged air pipe lines. Renew air pipes as necessary.
ON THE SPOT RECOVERY 7.15

ELECTRICAL - BATTERIES
Fault Possible Cause Remedy
1. Old battery 1. Replace after testing
2. Infrequent driving 2. Charge by driving or by small bench charge periodically
3. Loose fan belt 3. Tighten / replace belt
4. Poor insulation of mountings 4. Check, clean battery top
1. Weak battery
5. Short circuit in wiring 5. Check as given below
6. Regulator set low 6. Get regulator set correctly
7. Plates sulphated 7. Recover by sulphation treatment
8. Loose terminal / corrosion 8. Clean terminals, tighten clamps.
II. Excessive topping
required (More than
1. Overcharging 1. Check, correct regulator setting
about 150 cc per
battery every fortnight)
ELECTRICAL - ALTERNATOR
1. Open circuit 1. Eliminate open circuit

2. Drained Battery 2. Recharge Battery. If charge is not holding investigate and
7 Battery not being
charged / sufficiently 3. Alternator defective
replace.
3. Get alternator repaired
charged 4. Regulator defective 4. Replace regulator
5. V-belt loose 5. Re-adjust /replace V-belt

ELECTRICAL - ALTERNATOR
1. Drained Battery 1. Recharge Battery. If charge is not holdinginvestigate and
replace.
2.
Regulator defective 2. Replace regulator
Generator warning 3.
Generator warning lamp blown 3. Fit new bulb
4.
Leads loose/defective 4. Replace leads/tighten connections
lamp not glowing when
5.
Short circuit of positive diode in 5. Get alternator repaired
ignition switch closed. alternator
6. Carbon brushes worn 6. Replace carbon brushes
7. Oxide layer on collector ring/open 7. Get alternator repaired
circuit in excitation winding
1. Regulator defective 1. Replace regulator
2. V-belt loose 2. Re-adjust /replace V-belt
Generator warning 3. Lead defective / short circuit to 3. Replace lead/eliminate short circuit
ground
lamp lit up brightly at
4. Rectifier defective, collector rings 4. Get alternator repaired
high engine speed. fouled, short circuit in lead DF or
motor winding
1. Alternator defective 1. Get alternator repaired

2. Regulator defective 2. Replace regulator
Generator warning 3. Contact resistance in charging circuit 3. Eliminate contact resistance 7
lamp lights up less or in lead to generator warning lamp
brightly or glows when
engine is running.

ELECTRICAL - STARTER MOTOR
Battery discharged/weak Recharge / replace battery
Battery cable terminals loose / oxidised

Tighten terminals / clean
or ground connection poor
Starting motor terminals / brushes
Starting motor shaft shorted to ground Remove short circuit
does not turn/ turns
slowly. Carbon brushes not seating against com-
Check / replace brushes
mutator/broken/oily
Starting/solenoid switch damaged Replace switch / get starter motor repaired
Excessive voltage drop in cables/loose

Check the cable and connectors
connection
Pinion bearing fouled and oil lightly Clean bearing point

Armature turns but
pinion does not mesh
7 with ring gear.
Pinion bearing fouled aged, burrs
File off burrs and get the pinion / ring gears replaced
formed

ELECTRICAL - STARTER MOTOR
Battery discharged / weak Recharge / replace battery
Armature turns and

pinion meshes com- Excessive voltage drop in cables/loose Check the cable and connectors
pletely but engine is not connection
cranked
Pressure of carbon brushes on commu-
Check brushes, clean replace
tators insufficient
Over running clutch slips Replace over running clutch
Starting motor
continues to run even
Starting switch defective Turn off engine immediately and check the switch
after starting switch is
released.
Pinion does not
de-mesh after engine Return spring weak / broken. Get starter motor repaired. 7
starts to operate.

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BOSS TRUCK LHD

Operator Hand Book

Pub. No. EX - OM: Boss - E4 :1015

Signature of the Customer Signature of the Selling Dealer & Stamp

to know more turn overleaf

Ashok Leyland is the first Indian company to Ashok Leyland is

Ashok Leyland is India’s first commercial vehicle manufacturer

)) Terms of warranty (Chassis) )) Instrument Panel

)) Service Products )) Cargo cab

)) General guidelines )) Engine

)) Precautions during body building Turbocharger

)) Body / Equipment installation )) Clutch

)) Storage of vehicles )) Gear box

)) Coach builders drawing )) Rear axle

)) Front axle & steering

)) Maintenance schedule )) Electrical system

)) Maintenance procedure Battery

)) Filling capacity Alternator

)) Recommended lubricants Starter motor

ATTENTION OWNERS 1.03

1.04 ATTENTION OWNERS

addition to hand brake. Make sure to

ATTENTION OWNERS 1.05

1.06 ATTENTION OWNERS

ATTENTION OWNERS 1.07

1.08 ATTENTION OWNERS

ATTENTION OWNERS 1.09

1.10 ATTENTION OWNERS

ATTENTION OWNERS 1.11

1.12 ATTENTION OWNERS

TYPE 1 XXXX 2 XXXX 3 XX 4 XX

2. Body builder name code. VIN number is punched on LH frame side

2.02 VEHICLE INDENTIFICATION

330 mm DIA DIAPHRAGM CLUTCH 380 mm DIA DIAPHRAGM CLUTCH

The gear box serial number and type are

VEHICLE IDENTIFICATION 2.03

X XXX XXX XXX

Rear axle serial number and AL spec

X XXX XXX XXX

Model and serial number plate placed on 550515409905BOXXXXX

2.04 VEHICLE INDENTIFICATION

3.02 TECHNICAL SPECIFICATION

TECHNICAL SPECIFICATION 3.03

3.04 TECHNICAL SPECIFICATION

TECHNICAL SPECIFICATION 3.05

3.06 TECHNICAL SPECIFICATION

TECHNICAL SPECIFICATION 3.07

12. Ignition Switch

13. Gear shift lever

INSTRUMENTS & CONTROLS 4.03

4.04 INSTRUMENTS & CONTROLS

below 1000 RPM. Failure to

or frequent dry cranking of engine damage.

INSTRUMENTS & CONTROLS 4.05

4.06 INSTRUMENTS & CONTROLS

Exhaust Brake Amber Continuous Active High

Air Filter Blocked Red Continuous Active Low

Turn Left Green Blinking At Rate Of Flasher Input Active High

Rear Fog Amber Continuous Active High

Cab Tilt Red Continuous Active Low

Front Fog Green Continuous Active High

Active Low (Effective Resistance

High Range Gear