tata sumo light bullet proof vehicle 4x4

Owner’s Manual & Service Manualfor

TATATATATATTTTTA SUMOA SUMOA SUMOA SUMOA SUMO

LIGHT BLIGHT BLIGHT BLIGHT BLIGHT BULLET PRULLET PRULLET PRULLET PRULLET PROOF OOF OOF OOF OOF VEHICLE 4X4VEHICLE 4X4VEHICLE 4X4VEHICLE 4X4VEHICLE 4X4

ISSUED BY

PUNE

FOREWORD

Thank you for selecting TATA LIGHT BULLET PROOF VEHICLE

(4x4 ) of your choice.

We welcome you to the world of advanced automotive engineering

in a form especially suited to our operating conditions.

This book gives you all the information necessary for making

your ownership of the vehicle, a thoroughly satisfying experience.

Should you need any special technical assistance, please

contact us.

Please note that by adhering to the correct operating procedures

and scheduled maintenance, you can obtain the maximum

performance from your vehicle.

We request you to go through the book and derive many miles

of motoring pleasure.

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

We provide safe, high quality, high performance

vehicles. In order to maintain the level of

performance and reliability in the vehicle, it is

important that only TATA MOTORS genuine

accesories are to be fitted. Any accessory that is

fitted or modification that is carried out can hamper

the safety and performance of the vehicle besides

depriving you of your warranty benefits.

Use of genuine parts, designed and manufactured

to our exacting standards, are the best way to

maintain your vehicle in peak operating condition.

Please do not use substitutes. They always prove

costlier in the long run.

Failure to use genuine parts can invalidate any

future warranty claims.

The information and specifications given in this

book are valid as on the date of printing. TATAMOTORS LTD. reserves the right to make changes

in design and specifications and/or to make

additions to or improvements in this product without

obligation to install them on products previously

sold.

Vehicle Identification .............. vi

Vehicle details ............................ 1

Warranty ..................................... 2

Friendly notes

Do's .............................................. 4

Don’ts ........................................... 7

Handling

Location of aggregate

serial numbers..............................8

Keys.........................................................10

Doors...........................................................10

Rear view mirrors,Sunvisor .........11

Seats.......................................................12

First Aid Box & Fire

Extinguisher..............................12

Seat belt....................................13

Vehicle tools and jack.................14

Driving Controls..........................15

Gear Shift Lever, Parking Brake,

Spare Wheel.............................16

Instruments Cluster/Instruments...17

Steering lock cum

ignition switch ....................... 20

Combination switch.....................21

Windsheild Wiper / Washer.........22

Interior Lamps ...........................22

Front Tow Hook.........................23

Hazard Warning Switch,

Tail Lamp. Registration Plate

Lamp........................................24

Front / Rear Fog lamps............. 25

Head Lamp Levelling Switch, &

High Mounted Stop Lamp.......... 26

ECU,Towing Hook & Foot step.....27

Roof Hatch & Observation

Window ................................. 28

Gun Port,Ventilator &

Battery Isolator Switch.............. 29

Engine compartment light,

Bonnet opening and closing..,.... 30

Turbocharger............................. 31

Pre-silencer............................... 32

Power steering ......................... 32

Heating, Ventillation &

Air Conditioning ....................... 35

‘G’ Conscious pressure

reducing valve........................... 37

Preparing the vehicle for drive....38

Driving, gear shifting ................ 41

Driving Instructions, Braking ..... 42

Stopping/starting the engine

& Fuel economy........................ 43

4x4 operation. ...........................44

Vehicle maintenance

Engine Compartment...................46

Air Filter ................................... 47

Engine Cooling system ............. 48

Contents

iv

Contents

v

Changing engine oiland oil filter ............................. 49

Water Draining Procedurefrom Sedimenter........................50

Fuel & Filter draining,Priming Pump / Pear Pump.........51

Gear box Oil Checking/Changing..52

Transfercase Oil Checking /Changing...........................................53

Front / Rear Axle Oil Checking /Changing...........................................54

Bleeding clutch system............... 55

Brake system, Bleeding the

brake system ........................... 56

Brake adjustment....................... 58

Adjustment of Parking brake....... 59

Wheels and tyres....................... 60

External Repair Kit ...................,.62

Non-Skid Chains ........................63

Tyre Rotation ......................... 63

Battery...........................................64

Head Lamp Adjustment................65

Head lamp bulb replacement...... 67

Bulb specifications..................... 68

Fuses.......................................................69

Care and cleaning of vehicle ... 70

Preservation & De-preservation.. 73

Special Operation Conditions .... 81

Fuels, Lubricants, Coolants

Fuels, Lubricants ...................... 82

Coolants .................................. 83

Recommended, oils & lubricant. 84

Vehicle Data

Technical Specifications............. 85

Preliminary Trouble Shooting ..88

Lubrication and Maintenanceschedule

Lubrication points ..................... 96

Special instructions ................... 98

Lubrication & Maintenance

schedule.................................................99

Vehicle record

Service performed................... 102

Repairs carried out.................. 104

Abbreviations ......................... 106

Vehicle identification Photographs

TATA LIGHT BULLET PROOF VEHICLE 4 X 4 - DIFFERENT VIEWS

vi

1

VERSION DESCRIPTION

TATA LIGHT BULLET TATA LBPV 4X4 WITH 4SP DICOR ENGINE, 115PS, POWER STEERING,PROOF VEHICLE 4X4 BUCKET SEAT, 6 SEATER, BHARAT STAGE IIIWITH 115PS 4SP DICORENGINE

Vehicle details

2

WARRANTY

We WARRANT the TATA LBPV4X4 vehicles and parts thereofmanufactured by us to be free fromdefect in material and workmanship,subject to the following terms andconditions :

1. This warranty shall be for 24months or 20,000 kmswhichever expires first from thedate of delivery of the vehicle.

2. Our obligation under thiswarranty shall be limited torepairing or replacing, free ofcharge, such parts of thevehicle which, in our opinion,are defective, on the vehiclebeing brought to us or to ourdealers within the warrantyperiod. The parts so repairedor replaced shall also bewarranted for quality andworkmanship but such warrantyshall be warranted for qualityand workmanship but suchwarranty shall be co-terminuswith this original warranty.

3. Any part which is found to bedefective and is replaced byus under the warranty shall beour property.

4. As for such parts as tyres,batteries, transfer case, rubberparts, electrical equipment,power steering equipment, A.C.equipment not manufactured byus but supplied by otherparties, this warranty shall notapply, but buyers of the vehicleshall be entitled to, so far aspermissible by law, all suchrights as we may have againstsuch parties under theirwarranties in respect of suchparts.

5. This warranty shall not apply ifthe vehicle or any part thereofis repaired or altered otherwisethan in accordance with ourstandard repair procedure, orby any person other than oursales or service establishments,our authorised dealers, sub-dealers or service centres in

any way so as , in ourjudgement which shall be finaland binding, to effect itsreliability, nor shall it apply if,in our opinion which shall befinal and binding the vehicle issubjected to misuse,negligence, improper orinadequate maintenance oraccident or loading in excessof such carrying capacity ascertified by us, or suchservices as prescribed in ourOwner’s Manual and ServiceBook are not carried out bythe buyer through our sales orservice establishments, ourauthorised dealers or theirsub-dealers or service centres.

6. This warranty shall not covernormal wear and tear or anyinherent normal deterioration ofthe vehicle or any of its partsarising from the actual use ofthe vehicle or any damage dueto negligent or improperoperation or storage of thevehicle. This warranty shall not

Warranty Terms and condition

3

WARRANTY

apply to normal maintenanceservices viz. oils & fluidchanges, head lampsfocussing, fastenerretightening, wheel balancing,tyre rotation, adjustment ofvalve clearance, fuel timing,ignition timing andconsumables like bulbs, fuelfilters and oil filters etc. Thiswarranty shall not apply to anydamage or deterioration causedby environmental pollution orbird droppings. This warrantyshall not apply to V-belts, hosesand gas leaks in case of airconditioned vehicle. Slightirregularities not recognised asaffecting the function or qualityof the vehicle or parts, suchas slight noise or vibration,defects appearing only underparticular or irregularoperations are item consideredcharacteristic of the vehicle.

7. This warranty shall be null andvoid if the vehicle is subjectedto abnormal use such as

rallying, racing or participationin any other competitive sports.This warranty shall not applyto any repairs or replacementsas a result of accident orcollision.

8. This warranty is expressly inlieu of all warranties, whetherby law or otherwise, expressedor implied, and all otherobligations or liabilities on ourpart and we neither assume norauthorise any person toassume on our behalf, anyother liability arising from thesale of the vehicle or anyagreement in relation thereto.

9. The buyer shall have no otherrights except those set outabove and have, in particular,no right to repudiate the sale,or any agreement or to claimany reduction in the purchaseprice of the vehicle, or todemand any damages orcompensation for losses,incidental or indirect, orinconvenience or consequential

damages, loss of vehicle, orloss of time, or otherwise,incurred or accrued.

10. Any claim arising from thiswarranty shall be recognisedonly if it is notified in writingto us or to our concerneddealer without any delay soonafter such defect as coveredany ascertained under thiswarranty.

11. This warranty shall standterminated if the vehicle istaransferred or otherwisealienated by the buyer withoutour prior written consent.

12. We reserve our rights to makeany change or modification inthe design of the vehicle or itsparts or to introduce anyimprovement therein or toincorporate in the vehicle anyadditional part or accessory atany time without incurring anyobligation to incorporate thesame in the vehicles previouslysold.

Warranty Terms and condition

4

1. Use recommended oils andlubricants only.

2. Change oil in engine, gear box,

transfer case, steering system,

front live axle and rear axle at

prescribed intervals.

3. Use only genuine oil filter andfuel filter elements. Replace

them at regular intervals as

prescribed.

4. Clean air filter elementregularly. Replace filter

element when service indicator

shows red band even after

cleaning the filter element.

5. Ensure periodic servicing as

per maintenance schedule.

6. Insist on use of genuine co-branded spare parts.

7. Ensure that caps of auxiliarytank and radiator are firmlyfitted to keep the cooling

system pressurised and to

maintain coolant level. Alwaysuse radiator cap only of 1.0kg/cm2 (14 PSI), forreplacement.

8. check tyres for damage from

time to time and remove any

foreign bodies embedded in

treads.

When replacing tyres, have the

wheels balanced. Keep grease,oil and fuel away from thetyres. In case of uneven tyre

wear get the vehicle attended

to by any of our authorised

service set-ups.

9. Maintain correct tyrepressure

10. Check battery every week and

top up electrolyte level. Keep

battery terminals clean and

cable joints tight. Apply

vaseline/petroleum jelly on

terminals. Use distilled water

only for topping up.

Friendly notes Do’s

Do's

5

11. Observe correct polarity whenconnecting battery terminals.

12. Disconnect alternator/batteryterminals, ECU connectionswhile carrying out anywelding on the vehicle.

13. Avoid panic braking. Uselower gears while descendinggradients.

14. Start moving the vehicle alwaysin the 1st gear to avoid prematureclutch wear.

15. Keep both brake pedal andparking brake properlyadjusted.

16. Before engaging reversegear, ensure that the vehiclehas come to a stop, declutch,wait for a few seconds and thenshift into reverse gear.

17. When parking on slopes, usewheel chocks, apply parkingbrake and keep vehicle in lowgear.

18. In case of emergency parking

or breakdown on road, pullthe hazard warning switch toflash all the blinker lights to

warn other road users.

19. Release parking brake beforedriving off.

20. Release the ignition key assoon as engine starts.

21. Retighten wheel mounting nuts

after 100 km of every wheel

change.

Tightening Torque : 12-15 mkg.

22. Use only recommended FUSESand always keep spare fusesin the box.

23. Inspect the engine beltsreplace, if found torn, cracked,worn or soaked in oil.

Do's


6

24. Ensure doors are properly

closed.

25. Insulation in the cab room

should be kept-up in good

condition.

27. Vehicle has a turbochargedengine, keep engine in idllingspeed for atleast a minuteafter starting and also beforestopping it, to protect the

turbo charger against damage

due to oil starvation.

Air conditioning system :

1. Whenever vehicle is parked in

the sun, drive with ventilator

open for a few minutes to blow-

off for hot air before switching

on A.C.

2. Keep all gun port, ventilator,

roof hatch closed, when ACsystem is working.

3. During stop and go citydriving use lower gears to

obtain efficient cooling.

4. If you feel irritation in the eyes

due to smoke or during long

drive, stop AC and ventilate for

half a minute by opening

ventilator.

5. Before stopping the engine first

switch-off AC and then the

blower.

6. During off-season operate the

air conditioner a few times

every month to lubricate

components.


Do's

7

7. Do not clean EngineCompartment with highpressure water jet. It can causeMalfunctioning of electroniccomponents. Cleaning can bedone with high pressure air.

8. Do not clean air filter cartidgewith high pressure air.

Air conditioning system :

1. Do not cause heating of ACpipe (where fitted), whilewelding / brazing in itsvicinity.

2. Do not open any hose / pipepoints of AC system, wherefitted.

3. Do not put your hand inside

the condenser fan when the

grille is removed. Disconnect

power supply to fan and switch

off engine before any

maintenance work, where

applicable.

1. Do not use Clutch Pedal asFoot Rest. This will reduceclutch life. Avoid clutch riding.

2. Do not Coast vehicle inNeutral and engine switched-off position. This is a safetyhazard.

3. Do not run engine withoutRadiator Cap. Use genuineCap only, to keep systempressurised.

4. Do not overtighten engine oilfilter.

5. Vehicle has a turbochargedengine, do not stop theengine at once, allow it to runat idling speed for atleast 1minute. Also do not accelerateengine till the engine oilpressure has built up.

6. Do not open HP system underany condition. It should behandled by trained professionalonly. (i.e. HP Pump, Rail,Injector, HP lines)

Dont's

Friendly notes Dont's

8

Transfer case number (4x4) Front live axle number (4x4)Rear axle number (Spicer)

Chassis number on frame Engine Number Gear box number ( G-76)

Handling Location of aggregate serial mumbers

XXXXXXX

9

Body shell number plate (under

bonnet)

Handling Location of aggregate serial mumbers

10

Key (Two Nos.)Two identical keys have been provided

for operation of steering lock cum

ignition switch, for locking and

unlocking of driver’s and co-driver’s

side door, glove box, fuel tank flap and

rear door.

Locking and Unlocking of DoorsFrom outside : To unlock the door

turn key anticlockwise and swing

handle (1) upwards. To lock the door

turn key clockwise.

From inside : Lift knob (2) and then

only pull handle (3) in the door panel

to unlock the door. To lock the door

press knob (2).

In case knob (2) is pressed withdoor open, it will get releasedautomatically when door is closed.

The co-driver’s side door and rear

door can be opened from outside as

well as inside but locking is from

inside by pressing knob 2. The rear

door can be opened and locked from

inside.

Handling Doors

1

11

Sunvisors

Two adjustable sun visors are provided

inside the cab to prevent sun glare.

Rear view mirrors - outside Rear view mirror in cabin

Rear view mirrors

Rear view mirrors are fitted on driver’s

side door and co-driver’s side door.

They can be adjusted to the desired

positions by hand. The mirror can be

folded backwards for convenience

when the vehicle is to be driven

through narrow passages.

An additional adjustable rear view

mirror is fitted inside the cab. Mirrors

can be adjusted with the lever provided

inside the cab on the doors.

Handling Rear view mirrors, Sunvisors

Rear view mirror

Sun visors

12

Seats for Rear Passengers

Handling Seats

Driver and Co-driver Seat :

Adjustable type driver ’s seat is

provided. To Achieve correct position

for proper driving, lift handle (2) to slide

the seat either forward or backward.

Once the desired position is achieved,

push down the handle to lock the seat.

Adjust the backrest to desired position

using the lever(1) on right handside

of backrest. Release the lever to lock

it.

Seats for rear passengers :

Two seats are provided on both side

for two persons to seat. Storage space

is available below seat squabs.

1. Seat Reclining Adjustment Lever

2. Seat Adjustment (Forward/Backward) Lever

13

Seat Belt :

The vehicle has been fitted with three

point belt for extra safety for driver .

Fastening the belt

Insert belt tongue into buckle, a

positive locking ‘click’ indicates correct

and safe assembly.

Releasing the belt

Press the release button, the tongue

will be ejected clear of the looking

mechanism within the buckle.

Belt adjustment

When the vehicle is at rest, adjust the

length of belt to suit convenience.

Insert belt tongue in buckle. A positive

click indicates correct assembly.

Handling Seat belts

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

Adjust length of the belt to suit you

and fasten. The lap section should be

comfortably tight, the diagonal sections

should be adjusted so that a flat hand

will just pass between the chest and

the strap.

14

Handling Seat belts, Tools

To tighten (shorten) the belt

Pull free end of webbing throughadjuster until required adjustment isachieved.

To loosen (lengthen) the belt

Tilt the adjuster by means of the gripand slide it along the strap until suitablyadjusted.

CAUTION

l The belt is designed for use of

only one person.

l The belt should at all times be

adjusted and used in accordance

with the instructions and no

excessive slackness in the belt

should be evident

l Avoid twisting the straps during

use.

l Webbing must not be allowed to

chafe against sharp edges on

seat or bodywork.

l Do not make any alterations or

additions to the belt. If in doubt,

consult the authorised dealer.

l Belt that have been cut, frayed,

damaged or have been stressed

through impact, should be

replaced.

l To clean, an occasional wipe with

warm soapy water will maintain the

webbing in a clean condition. Do

not use bleach or dye under any

circumstances.

l Periodic inspection of the

installation will ensure safe and

reliable service of the seat belt.

Vehicle Jack & Tools

Tool bag with tools, jack and handle

are kept below the drivers seat.

15

Handling Driving Controls

Driving Control - TATA LIGHT BULLET PROOF VEHICLE 4x4

1. Steering Wheel

2. Instrument Cluster

3. Combi-switch

4. Ignition cum steering lockswitch

5. Bonnet opening lever

6. Accelerator pedal

7. Brake pedal

8. Clutch pedal

9. Parking Brake

10. Jack

11. Gear shifting lever

16

Spare wheelGear shift lever knob 1. Parking brake released

2. Parkeing brake applied

Handling Gear Shifting Lever, Parking Brake & Spare wheel

Gear Shift Lever :

The different gear positions are

markedon the knob. The 5th gear (an

overdrive) has been provided to obtain

better fuel economy while driving on

highways.

Parking Brake (Floor mounted) :

The Parking brake is mounted on floorbetween RH door and driver’s seat.

To apply the parking brake, pull leverfull up. To release it, pull the lever upslightly, press the release button andpush the lever down.

Ensure parking brake is releasedbefore driving the vehicle. Indication

is given on instrument cluster.

Spare Wheel

Spare wheel is located behind driver

and co-driver seat.

To remove the spare wheel, loosen

spare wheel strap by operating

ratchet. After loosening strap, remove

hook and take out the spare wheel.

1

2

17

Handling Instrument cluster

Instrument cluster

5 6 7 8 9 10

11

13

14

3

1

4

2

12

15

18

1. Fuel gauge

It indicate the apporximate level of

fuel in tank.

Fill up the tank with recommended

diesel fuel well in advance, before

the needle touches ‘E’ mark on the

gauge.

2. CHECK ENGINEIndicator

This lamp indicates engine

condition, when a malfunctioning

occurs in engine OR EMS, thislamp indicates as below :

i. Come ‘ON’ when key is in ‘IGN’

position and goes ‘OFF’ after

starting engine.

ii. Remains ‘ON’ in engine

running if malfuctioning occurs.

3. Glow plug indicatorlight (Amber)

In the ‘ON’ position, the glow plug

controller switches on the glow plugs

and glow plug indicator comes ‘ON’.

After a few seconds depending on

the ambient temperature, the

indicator light only goes ‘OFF’

indicating that the engine can be

started.

If the glow plug indicator does not

go ‘OFF’ automatically, get theelectrical system of your vehiclechecked.

4. High beam indicator(Blue)

5. Battery chargingindicator light. (Red)

It comes on when ignition key is

turned to position ‘ON’ and must

go ‘OFF’ when the engine starts

running. if continues to glow, then

it has to be checked at authorised

dealer.

6. Turn signal indicator(Left) (Green)

7. SpeedometerIt indicate vehicle speed in km/h

8. Odometer registers total distance

covered by the vehicle in km.

9. Turn signal indicator(Right) (Green)

10. Oil pressureindicator light (Red)


turned to position ‘ON’ and goes

off as soon as the required oil

pressure has developed after the

engine has started. If the light

continues to glow when the

engine is running, it indicated low

oil level in engine oil sump, or a

fault in the lubrication or electrical

system.

Continued running of the enginewhen the oil pressure indicatorlight is on, may damage theengine.

Handling Instruments

CHECKENGINE

19

4WDH

4WDL

11. Brake fluid level /parking brakeindicator: (Red)

This indicator light is used for both

the functions. When ignition is ON

position the lamp will glow. Thus

it shows bulb is OK.

After the engine has started,

light will go Off automatically. The

light will remain ON, if the break

fluid level is low or the parking

brake is applied.

12. Water in FuelSedimenter Indicator

Whenever water in fuel sedimenter

indicator glows in instrument

cluster, the water need to be

drained from fuel sedimenter.

(Refer Page 50)

13.Coolant temperature gauge

(0C) Red band of this gauge

indicates engine overheating.

Handling Instruments

P14. Four wheel drive high

indicator light (4x4)(Green)


turned to position’ON’ and goes

‘OFF’ after a few seconds. The

light glows continuously

when four wheel drive high mode

is selected for vehicle driving.

17. Four wheel drive lowindicator light (4x4)(Green)


turned to position ‘ON’ and goes

off after a few seconds. The light

glows continuously when four

wheel drive low mode is selected

for vehicle driving.

20

Steering lock cum ignition switch key

positions

Handling Steering lock cum ignition switch

Steering lock cum ignition Switch

Steering lock ignition switch

Steering is provided with steering lock

cum ignition switch

r To lock steering while parking the

vehicle as safety against theft.

r To start and stop the engine.

r To switch on and off the electrical

system other than listed below.

Horn, parking lamps, engine

inspection lamp, hazard warning

switch, headlamp, map reading

lamp, black out head lamp/ stop

lamp / parking lamp and roof light

convoy lamp,tail lamp,side

indicator, Blinker stop light.

r To switch on and off accessoriesonly.

The switch is located on the steeringcolumn support and has the followingkey positions :

LOCK

Key can be inserted or taken out only

in this position. Steering gets locked

only after the key is withdrawn from

the switch. After withdrawing the key

from the switch ensure that steering

is locked by turning steering wheel

clockwise and anticlockwise.

To unlock the steering, insert the key

into the switch and turn it clockwise.

If any difficulty arises in unlocking turn

the steering wheel a little clockwise or

anticlockwise while turning the key.

ACC

By turning the key to ‘ACC’ position

power supply to accessories is

switched on.

21

ON

By turning the key to this position all

remaining electrical systems become

operative and fuel guage, temperature

gauge, battery charging indicator, low oil

pressure indicator, parking brake/low

brake fluid indicators, Check Engine,

Water Seperator will come ̀ ON’.

In case of 4x4 vehicle in addition to

above 4WDH & 4WDL lamps will come

on and goes off after a few seconds.

In ‘ON’ position, glow plug indicator

lights up. After a few seconds, depeding

on the ambient temperature, the

indicator light only goes off indicating

that the engine can be started.

START

Turn the key further clockwise to start

position (spring loaded) to operate

starter motor. As soon as the engine

starts release the ignition key, so that key

can come back to ‘ON’ position and

starter motor disengages. Vehicle is

driven in this position. By turning the

ignition key from ‘ON’ position to ‘ACC’

Position ‘3’ - Turn signal left

Position ‘4’ - Turn signal right

The lever returns to neutral position

automatically when the steering

wheel is returned to straight aheadposition.

The combination switch lever can be

operated up and down to select the

headlight beam as follows :

Position 1 - High beam

Position 2 - High beam flash

High Beam Flash (No.2 position)

High beam flash will be ‘ON’ as long

as lever is held in position ̀ 2’ . This is

spring loaded position and can be

used in day time also for giving signal

to the on coming traffic.

Handling Combination switch

Combination switch - Turn signals, High/Low

beam and High Flash

32 3

4 1

or ‘LOCK’ position engine can be

stopped.

Combination switch

The combination switch is mounted on

steering column. It’s right side lever

operates turn signals,

Turn Signals

Moving the combination switch lever in

sideways direction operates the turn

signals :

22

Windshield wiper/washer operating lever

POSITION FORWASH-ON

‘HI’ - High speed of wiper motor To

operate windshield washer, lift

the lever. The winshield washer

will remain in operation as long

as the lever is held in this

position.

Handling Windshield Wiper / Washer & Interior Lamp

Winshield wiper / washer

The combination switch lever mounted

on the left side operates the windshield

wipers and washer :

Position :

‘OFF’- Wiper motor switched ‘OFF’

‘INT’ - Wiper sweeps intermittently

‘LO’ - Low speed of wiper motor

Interior Lamps :

A interior lamp is fitted near inside

rear view mirror for illunination. The

individual ‘ON / OFF’ switch is provided

on the lamp itself.

This lamp is controlled by a door

switch. This lamp comes ‘ON’ if any

one door is open. Door switches are

fitted on RHS/LHS door and tailgate.

Interior Lamp Location

23

Handling Interior Lamps & Front Tow Hook

Door Control Switch

Interior Lamp Door Control Switch

Door Control Switch

Interior Lamp Door Control Switch- TailgateFrontTowing Hook

Front Towing Hook :

Front tow hook is below front bumper

for vehicle towing.

Towing Procedure :

Make sure that, the vehicle is in neutral

condition and in 4X2 mode while

towing. Maximum driving speed 40

kmph.

Interior Lamp

24

Rear Tail Lamp

Tail Lamp :

The tail lamp assembly incorporates

the following :

1. Rear Stop Lamp

2. Rear Direction Indicator

3. Reverse Light

4. Rear Parking Lamp

Registration Plate Lamp :

Two concealed lamp are provided for

illumination of the rear registration plate.

Registration Plate Lamp

Hazard warning switch

This can be operated without ignition

‘ON’. Pull the hazard warning switch

(red knob) on the nacelle behind the

steering wheel, all side indicator lights

will flash simultaneously to warn the

other road users about any hazard-

ous condition of the vehicle. Depress

the knob again to switch ‘OFF’ the

hazard function.

Handling Hazard warning switch,Tail Lamp & Registration Plate Lamp

Hazard warning switch

25

1. Switch for Rear Fog Lamp

2. Switch for Front Fog Lamp

Handling Front & Rear Fog Lamps

Front and Rear Fog Lamps :

The front fog lamps are provided on

the front chassis frame to improve

thevisibility in foggy weather. The front

fog lamp can be switched ‘ON’ by

pushing the switch once with the

headlamp ‘ON’ till the parking brake is

switched ‘OFF;. The rear fog lamp

willswitch ‘OFF’ if parking lamps are

switched ‘OFF’ and will not come ‘ON’

Front Fog Lamp Rear Fog Lamp

again with parking lamp ‘ON’ until

deliberately switched ‘ON’ again.

The switch for front fog lamp is an

‘ON / OFF’ type switch. The rear fog

lamp has the in-built tell tale indicating

lamps for indicating the fog lamp

operation.

21

26

Handling Head Lamp Levelling Switch & High Mounted Stop Lamp

Head Lamp Leveling Switch (if fitted):

A headlamp leveling switch is provided

at the LH side of the steering column

on dash board.

As and when required headlamp lev-

eling setting is done by rotating the

knob to select one of the level marked

in the switch depending upon the load-

ing of vehicle.

Headlamp Leveling Switch

High Mounted Stop Lamp:

High mounted stop lamp is located on

tail gate and it glows whenever ser-

vice brake is applied in additional to

two stop lamps.

High Mounted Stop Lamp

Switch Loading ConditionPosition

O Unladen + Driver/Driver

+ Co-driver

1 Driver + Co-driver + All

seats occupied

2 Laden + All seats

occupied

3 Laden + All seats

occupied + permissible

luggage load

27

Rear Central Towing Hook

Rear Central Towing Hook :

Rear central towing hook with locking

arrangement has been provided for

towing the trailor.

Handling ECU, Rear Towing Hook & Rear Foot Step

ECU :

DICOR engine common rail system

consist of ECU, sensors and

actuators. The ECU receives input

from various sensors located on the

engine and the vehicle to decide the

injected quantity and injection timing

best suited for the engine to work with

maximum efficiency and safety ECU

is fitted inside the engine compartment

ECU Rear Foot Step

Rear Foot Steps :

Rear foot steps on RHS/LHS has been

provided for ease of entering in or

alighting from rear compartment.

28

Handling Roof Hatch, Oservation Window and Gun Port

1. Obeservation Window

2. Gun port on rear doorRoof Hatch (Optional Fitment) Roof Hatch Lock

1. Handles

1

Observation Window With GunPorts:

Observation window (1) with gun port (2)is provided on tail gate door.

Roof Hatch :

The roof hatch is provided for

observation and firing front & rear.

Roof Hatch Lock:

To open the roof hatch, first unlock thethe latch knob by using key. Rotate thelatch knob and push the hatch doorsupwards.

For closing the hatch doors, pull thehandle swhich are provied on the doorsfrom inside.

29

Handling Gun Port, Ventilator & Battery Isolator Switch

Ventilator

Ventilator :

Ventilator is located on the roof above

driver & co-driver.

Ventilator is provided for fresh air

intake, when HVAC is not working.

Gun port

Gun Port :

Gun ports are provided on the front

left door, middle both doors, tail gate

and LH & RH side windows at rear.

Opening the gun port, press the knob

and rotate in either direction.

Gun ports are used to place gun for

firing.

Battery Isolator Switch

Battery Isolator Switch:

This switch is provided near the gear

shift lever to isolate the battery from

electrical system when required. Battery

Battery Isolator Switch :

Battery is connected to the starter and

other circuitry through isolator switch.

This is to be switched OFF while

carrying out any work on the vehicle

and also when the vehicle is parked

for long duration to avoid battery

drainage. This will also prevent any

inadvertent short circuits during

repairs.

30

Engine compartment light :

To operate engine compartment light

pull switch (2)

Bonnet opening and closing :

To open bonnet pull lever (1) This will

release the bonnet lock. To open fully,

lift the additional lock lever located on

the bonnet centre with the help of

finger. Use the bonnet stay rod to keep

the bonnet open.

1. Engine compartment light

2. Engine compartment light switch

For closing the bonnet, disengage the

stay rod, clamp it properly and press

down the bonnet till it is fully shut.

Ensure that the bonnet is fullylocked driving off.

In case of failure of cable attached to

lever (1) bonnet lock can be opened by

inserting a screw driver from the top

centre position of grille through a slot

provided behind it on the sheet metal

and by pressing the lock plate toward

your left. Push upward the additional

lock lever at your right and lift the bonnet

while the lock plate is kept pressed with

the help of a screw driver.

Additional lock lever

Handling Engine compartment light, Bonnet Opening / Closing

Bonnet Opening lever

31

Handling Turbocharger

Turbocharger

Turbocharger is an efficient

supercharging device used in our

engine. It makes use of thermal energyof

engine exhaust gases to run a turbine

which in turn drives a compressor to

force air uner pressure into the inlet

manifold.

Lubrication of Turbocharger :

The rotor assembly of the

turbocharger is supported by two

floating lead bronze sleeve bearings

in the bearing housing. These bearings

are lubricated with the finest filtered

and cooled oil from the lubrication

system of the engine. There is a heat

shield arrangement. provided between

the gas chamber of the turbine nd the

bearing housing to avoid heating of

the bearings.

Maintenance of Variable GeometryTurbocharger

1. Tighten the following fasteners at

PDI and thereafter at specifiedintervals.

l Turbocharger mounting

l Intercooler mounting

l Turbocharger hose connections

& its mountings

l Intercooler hose connections

and its mountings

2. Check intercooler fins for any dust

accumulations and clean by

compressed air at at specifiedintervals.

3. Check end play of turbocharger

shaft and radial clearance between

turbine wheel and housing atspecified intervals.

Pressure oil

from engine

Fresh

Air in

Exhaust

gas out

Oil drain to engineTurbine Wheel

Assembly

Compressor

Wheel

32

Pre-silencer:

The construction of Presilencer consists

of a cylindrical outer jacket, inside to

which cylindrical perforated pipe & baffle

are welded to it. As Exhaust gases

passes through it expansion of gases

occurs. At the both ends of presilencer

triangular flanges are provided for the

fitment of front & middle pipe assem-

blies.

Handling Pre-silencer & Power steering

POWER STEERING

Power steering is fitted for lightersteering effort and easymanoeuvrability. The system consistsof steering gear box, hydraulic pumpand hydraulic reservoir suitablymounted and connected by piping.Pump drive is through ‘V’ belt fromengine. Power assistance is available

during normal functioning of thepower steering system.

In case of any failure in hydraulicsystem, the steering can beoperated mechanically withincreased steering effort forbringing the vehicle to a repairstation.

1. RESERVOIR

2. PUMP

3. POWER STG.GEAR BOX

4. FREE PLAY ADJUSTER

5. LOCK NUT

Power steering - schematic circuit

33

Handling Power steering

Power steering hydraulic reservoir

Procedure for oil filling andbleeding the power steeringsystem.

(Ensure that the reservoir is totallycleaned before starting the work.)

1. Fill the reservoir nearly full.Crank the engine for 10 secondswithout, if possible, allowing itto start. If the engine does start,shut off immediately.

Check and refill the reservoir. Repeatat least three times, each timechecking and refilling the reservoir.

2. Check for any leakage in thesystem and if noticed takecorrective action.

3. Start the engine and steer thevehicle from full left to full rightturn 3-4 times. Add fluid, ifnecessary to maintain the level upto the filter top.

4. With the engine at steady speed,check for bubble / foaming in thefluid. If present it indicates thatair is geting sucked into thesystem. Check the suction line /fittings and correct if necessary.

5. Once the system is bled properlyand free from foaming, thereshould not be appreciable changein fluid level in the reservoir, whenthe engine is started / stoppedrepeatedly. Top up or removeexcess fluid so that the final levelis at ‘H’ mark on dipstick.

6. Now the system is ready fordriving.

CAUTION

Do not allow the fluid level to dropsignificantly or run out of thereservoir during the aboveoperation. This may induce air intothe system.

Do not start the engine without fluidin the power steering system. Thiswill result in serious damage to thepump.

NOTICE

Always use recommended brandof fluid from closed container. Anydirty fluid poured in the system willresult in damage to pump / gear.

34

Power steering pump belt tensionCheck :

Check the conditions of belts on the

engine. Examine the edge of the belt

for cracks or fraying.

Check the tension of the belt by

pushing on it with your thumb

Power Steering Belt tensionHandling

Free play adjustment

Ensure that vehicle is in straight ahead

position. Remove tie rod ball joint on

pitman arm. Hold sector shaft adjuster

screw with 6 mm hexagonal key and

loosen lock nut. Hold pitman arm and

turn sector shaft adjuster screw

clockwise till there is just no play of

pitman arm. Tighten lock nut of

adjuster screw without distrubing its

position by holding with hex key. Turn

steering wheel through its full

movement and ensure that sector

shaft movement is smooth throughout

its range. Refit the tie rod ball joint to

pitman arm. For any other complaints,

get the system checked and rectified

at our authorised workshops.

For adjusting the power steering belt

tension please refer page no.51.

Alternator/Power Steering belt as

shown in Figure.

The belts should have deflection of 8

to 10 mm. (X).

If the belt tension is not proper, get it

attended at the nearest TATA

Authorised Workshop.

35

Handling Heating,Ventilation & Air Conditioning

HEATING, VENTILATION & AIRCONDITIONING : (if installed)

A. Temperature Control Knob :The air temperature in the vehicle can

be controlled by operating the

temperature control knob (A) at the left

hand side of the control panel. The

temperature can be increased by

rotating the knob towards the red

segment and decreased by rotating it

towards the blue segment.

B. Blower Speed Regulation Knob:The ventilation system has a four

speed blower. The blower speeds can

be regulated to any one of the following

speeds by operating the knob (B) at

the centre of the control panel.

1. LOW 2. MEDIUM 3. HIGH VERY

HIGH

C. Air Direction Control Knob :The air flow can be changed by turning

the switch (C) to the desired direction.

Towards face

Towards face and feet

Towards feet

Towards feet and windshield

(Recommended for clearing

fogging on windshield)

Air demist / defrost windshield

(Recommended for clearing

heavy fog and snow)

D. A.C. ON/OFF Switch :

The A.C. can be switched 'ON' by

pressing the switch (D) on the A.C.

control panel provided the blower is

`ON' and the engine is running. The

indicator lamp will show that the A.C.

is ̀ ON'.

A

B

C

D E

36

Handling Heating,Ventilation & Air Conditioning

E. Air Circulation Switch :

l In HVAC version to put air circulation

mode in recirculation, press switch

'E'. The indicator lamp will show air

circulation is in recirculation.

To put vehicle in Fresh mode release

switch 'E'. Indicator lamp will be

'OFF'.

l In recirculation mode, air inside the

vehicle is circulated again and again.

In Fresh mode, air is taken from

atmosphere and circulated in the

vehicle. Recirculation mode can be

used

l While driving in dusty condition

l To avoid traffic pollution

l To get quick cooling/heating as

required.

Whenever discomfort is felt switch air

circulation mode to fresh.

Normal Cooling :

A.C. - ON

Knob 'B' - Desired speed position

Knob 'C' - Towards face

Switch 'E' - Suitably as explained

Quick Cooling :

If your car is left in the sun with window

closed, inside temperature increases.

To achieve quick cooling effect, open the

windows briefly while you operate the air

conditioner, with air circulation switch is

in Fresh mode, fan at higher speed and

air direction towards 'FACE'. All vents to

be opened completely.

Once temperature inside has comedown sufficiently, close the windows andchange air circulation suitably to fresh/recirculation.

NOTICE

1. The A.C. can be switched ̀ ON' only

if the blower is 'ON' and engine is

running. When A.C. is switched 'ON'

engine idling RPM increases

marginally, to adjust to the A.C.

compressor load. When desired

temperature is achieved A.C. trips

'OFF' automatically.

2. The A.C. compressor getsswitched 'OFF' automatically whenengine gets overheated. The A.C. isautomatically switched 'ON' when theengine cools down.

37

Handling “G” Conscious pressure reducing valve for brakes

“G” Conscious pressurereducing valve for brakes

This valve consists of a barrel with

one inlet and one outlet. A steel

ball is kept rolling free in the barrel.

When the brakes are applied the

brake fluid going to rear wheel

cylinders passes through this valve

around the steel ball and goes out

from other end to rear wheel

cylinders. As the brakes are applied

and vehicle decelerates, the free

rolling ball moves forward due to

its momentum and closes the port

stopping the further supply of brake

fluid to rear wheel cylinders. This

ensures that cylinder pressure is

limited to a value which avoids

wheel locking.

To achieve the specific cutout point

the valve body is mounted on

vehicle at 260 angle so that the ball

has to climb some slope before

closing the outlet port.

38

Handling Preparing the vehicle for the drive

Fuel tank fillerneck Coolant Tank

Check the following regularly,particularly before starting on along journey.

1. Fuel level in tank

Top up if required with correct

diesel fuel, secure cap and lock

the flap.

2. Engine oil level

Check engine oil level before

starting the engine or at least 20

minutes after stopping the engine.

Top up if oil level is less than

midway between upper and lower

marks on the dipstick.

The oil level should not exceed the

'MAX’ mark. USE ONLY THE

GENUINE CO- BRANDED OILS.

3. Coolant level

With the engine cool, check the

coolant in the no loss tank. The level

should be between the 'FULL' and

'MIN' marks. if the level is

below the 'MIN' mark, top up with the

genuine co-branded coolant. Bring

the level upto the 'FULL' mark. The

level must not exceed the 'FULL'

mark. If the coolant level drops with

in a short time after replenishing,

there may be a leak in the system.

1.Engine oil filler Cap 2. Dip Stick

39

1. Brake fluid Container

2. Clutch fluid ContainerChecking belts tension


7. Check leakages of coolant, fuel

and oil at all joints of hoses and

pipes and rectify, if any. If coolant

leakage is noticed, rectify the

leakages and top up radiator also

with recommended coolant.

8. Check level of brake fluid in

plastic container. Top up if

necessary. Do not overfill. Use

only GENUINE CO-BRANDED

brake fluid.

9. Check level of clutch fluid in

plastic container. Top up if

necessary. Do not overfill as this

would result in spillage during clutch

operation. Use only GENUIN

CO-BRANDED clutch fluid.

10. Check level of water in Windshield

washer reservoir, located in the

engine compartment near the fuse

box. Top up with clean water if

required.

Rectify the leakage and top up

radiator also. Use recommended

coolant.

If no leak can be found inspection

should be carried out at a Authorised

service outlet.

NOTICE

Always use radiator cap only of 1.0

kg/cm2 (14 psi), ifrequired to be

replaced.

4. Ensure battery electrolyte level is

10-12 mm above top of battery

plates. Top up with distilled water if

required (NOT ACID).

Keep battery terminals clean and

tight. Apply petroleum jelly / vaseline

on terminals for protection against

corrosion. Secure cover provided

over positive terminal.

5. Check all lights, horn,

gauges,switches and wiper for

proper functioning.

6. Check condition and tension of

belts. ADJUST tension if necessary.

40


Gear box oil filler plug (G-76) Rear axle oil filler plug Transfer case

A. Drain plug B. Oil level plug

B

A

Do not use soap solution.

11. Level of gear box oil

Periodically check gear box oil

level.

12.Level of front live axle oil (4x4)

Periodically check front live axle oil

level.

13.Level of rear axle oil

Periodically check rear axle oil

level.

14.Check condition of wiperblades, replace if rubber profileis damaged.

15.Check level of oil in steeringgear box.

16.Check oil level in power steeringhydraulic tank, where applicable.

17.Check and correct tyre inflationpressure (with cold tyres).

18.Level of transfer case oil (4x4)

Periodically check oil level

CAUTION

Do not use impact wrench to

remove or install level / filling plug

or drain plug since this will damage

threads in the transfer case cover.

19. Clean transfer case breather

regularly for 4x4 vehicle.

41

Gear lever knob (G-76 gear box)

Driving Driving & Gear Shifting

Before Driving

Check

l Coolant level

l Engine oil level

l Tyre pressure

l Brake and clutch fluid level

l Doors are firmly closed

Adjust

l Driver seat

l Rear view mirrors

Ensure

l Gear shift lever is in neutralposition.

l All switches and lamps areworking.

l Brake fail indicator is 'OFF'

l Fuel level indicated in fuelgauge is above reservemark.

Start the engine and observe that :

(Where turbocharged engine is fitted,

run engine in low idle speed for

atleast 1 minute and do not

accelerate the engine till the engine

oil pressure is built up.)

Low oil pressure indicator light goes

'OFF'

Battery charging indicator light goes

'OFF'

4 WDH and 4 WDL indicator lights

go off in 2H mode in case of 4x4

vehicle.

VEHICLE IS NOW READY FOR A

DRIVE

DO NOT ALLOW VEHICLE TO ROLL

BACK ON GRADIENTS.

During Running-in period

i.e. first 2,000 km. of operation :

Do not exceed the following vehicle

speeds :

For 4x4 vehicles

Gear Speed in km/hr.

4x2 4x4 (low)

1st to 2nd 20 10

2nd to 3rd 35 14

3rd to 4th 50 -

4th to 5th 75 -

42

Driving Instructions Driving , Gear Shifting, Braking

l Avoid rapid acceleration and

prolonged high speed runnings of

the engine.

l Avoid sudden braking.

l Retighten wheel nuts to 12-15 mkg

torque after first 100 km of running

of a new vehicle and after every

wheel change.

Driving instructions

DRIVE SAFELY AND JUDICIOUSLY

REMEMBER SAFETY FIRST.

l Depress clutch pedal fully before

shifting gears. This will ensure

longer synchro cone life.

l For smooth starting of vehicle

without jerks, synchronise

release of clutch pedal with

pressing of accelerator pedal.

l Start the vehicle in first gear only.

l Change gears at appropriate

speeds and do not lug the engine

by too early shifting to higher

gear at low speeds.

Braking

l While braking on turns applybrakes gently.

l Before driving down a long steepgradient, reduce vehicle speedby changing to lower gear.

l Do not ride the brakes as theymay overheat and theirperformance may be impaired.

Do not use half engaged clutchto hold the vehicle on upgradient as this will result inpremature clutch failure.

l After driving through pockets of

water, apply the brake a few

times at low speed to get rid of

moisture inside the brake drums.

l When it begins to rain, reduce

vehicle speed and avoid sudden

braking.

Recommended speeds for gear

changes ( For 4x4 vehicles)

l Engage reverse gear, only when

vehicle is stationary.

l To engage reverse gear, moveear shift lever to extreme left andpush it forward.

l Depress clutch pedal fully beforeengaging the reverse gear. Waitfor a few seconds then engagethe gear. If the gear shifting doesnot occur, then release the clutchpedal, once again press theclutch pedal and engage thereverse gear.

Gear Speed in km/hr.

4x2 4x4 (low)

1st 22 10

2nd 40 15

3rd 60 -

4th 70 -

5th 85 -

43

charger, till its speed is fully reduced

and also allow the unit to cool down.

Above precautions will ensure

satisfactory life and performance from

the turbocharger.

Fuel Economy :

a. Drive smoothly, accelerate

gradually and anticipate stops.

b. Best fuel consumption is obtained

at low engine speeds in the

highest possible gear without

labouring the engine.

c. Driving with accelerator pedal fully

depressed means using

excessive fuel.

d. Do not allow the engine to labour

by too early high gear changes.

Change to lower gear when

engine no longer runs smoothly

e. If possible do not idle the engine

for more than 5 minutes. Switch

‘OFF’ the engine.

Driving Instructions Engine Starting & Stopping and Fuel Economy

f. Do not ride clutch. Do not use

clutch pedal as foot rest.

g. When changing from 4H/4L to 2H

of transfer case, 2H free wheeling

should be done . If 2H free

wheeling is not done the hub locks

of front hub are remain locked

causing unnecessary rotation of

front drive components and this

consumes more fuel.

H. Depending on traffic conditions

a constant speed should bemaintained

The vehicle uses more fuel,

every time you speed up or slow

down.

I. Avoid hard braking, abrupt

cornering and rapid acceleration.

Starting the engine :

Before starting

1. Apply parking brake.

b. Ensure gear lever in neutral.

3. Insert the key in steering cum

ignition lock and turn it to ‘ON’

position.

4. Press the clutch pedal fully.

5. Now crank the engine.

6. If the engine does not start turn

the key to ‘OFF’ position and

try after 30 seconds.

NOTICE

After starting run the engine in

low idle speed for at least 30 sec.

Do not press accelerator pedal

while starting the engine to avoid

damage to turbocharger.

Stopping the engine :

Before switching ‘OFF’ the engine, run

the engine idle for atleast 30 seconds

and then switch ‘OFF’. This will allow

the engine oil to lubricate the turbo-

44

Automatic hub locks (4x4)

While driving in 2H mode this

mechanism on the front axle hub

allows the hub to free wheel. This

Location of 4x4 Selector switch

4H All four wheels are driven and

transfer case operates at 1:1

ratio.

4L All four wheels are driven and

transfer case operates at 2.48:1

speed reduction ratio.

Transfer Case and Transfer Casenselector Electric Switch :

On four wheel drive vehicles

transfer case is fitted after the gear

box for driving front live axle along

with rear axle.

The following 3 positions areprovided on selector switch :

2H Only rear wheels are driven and

transfer case operates at 1:1

ratio.

Driving Instructions 4x4 Operations

Automatic Hub Lock

avoids the unnecessary spinning of

front axle drive components and

results in fuel saving, reduced noise

and longer component life.

As soon as 4H or 4L mode is

selected the hub gets automatically

connected to front drive line to

increase the traction.

Instructions for 4x4 operation

1. With ignition ‘ON’ 4WDH &

4WDL indicator lights on panel

should glow for a few seconds

onlyd then go off.

CAUTION

While in 2H mode, continuous

illumination of 4WDL & 4WDH

lights indicate electrical fault like

short or open circuit. Do not

march the vehicle in this case.

2. Shifting from 2H to 4H : Turn

the selector knob from 2H to 4H

position. 4WDH indicator on

instrument panel will light up.

45

Driving Instructions 4x4 Operations

Changing from 2H to 4H can be

done at any speed upto 65 km/h.

No pressing of clutch pedal is

required

3. Shifting from 4H to 2H : Turn

the selector knob from 4H to 2H

position. 4WDH indicator on

instrument panel will go off.

Changing from 4H to 2H can be

done at any speed upto 65

km/h. No pressing of clutch pedal

is required.

Free wheeling of front hub : After

shifting from 4H to 2H, for effecting

free wheeling of front wheels,

direction of vehicle motion needs

to be changed. If in4H mode the

vehicle was moving forward then

stop it, wait and then engage

reverse gear of main gear box. If it

was moving reverse in 4H mode

then stop it, wait and then engage

forward gear of main gear box.

(After stopping and changing the

gear the vehicle must travel in

opposite direction for a minimum

of three meters, before free

wheeling takes place.)

4. Shifting from 4H to 4L

Stop the vehicle. Press clutch

pedal. Turn the selector knob from

4H to 4L position. 4WDL indicator

light on instrument panel will blink

a few times and remain on.

5. Shifting from 4L to 4H

Stop the vehicle. Press clutch

pedal. Turn the selector knob from

4L to 4H position. 4WDH indicator

light on instrument panel will blink

a few times and remain on.

CAUTION

In case of malfunctioning in

shifting from 4H to 4L or 4L to

4H, respectively 4L or 4H

indicator light will flash

continuously, Do not march the

vehicle in such a case.

Do not use 4H or 4L modes

continuously on dry and hard

surfaced road except for

checking operations.

Limited Slip Differential :

A standard differential delivers torque

equally to each wheel. In case one

wheel loses traction and begins to

spin, the differential distributes the

rotary speed unequally but with same

torque. This can cause the wheel with

good traction to slow down or stop

while the wheel which lost traction

rotates with increased speed. Such a

situation can prevent the vehicle from

moving. The limited slip differential

provided in the rear axle takes care

of such situations. The clutch lock

arrangement provided internally,

ensures that in case one wheel loses

traction and begins to slip, a locking

action takes place which prevents

differential action and both wheels turn

at the same speed.

46

Vehicle Maintenance Engine Compartment

1. Fuse Box

2. Power Steering Fluid Container

3. Brake Fluid Container

4. Clutch Fluid Container

5. Engine Oil Filler Cap

6. Dip Stick

7. Air Filter

8. Air Pre-cleaner

9. Radiator Cap

10. Engine Coolant Tank

11. Windshield Washer Fluid Container

ENGINE COMPARTMENT

47

Air Filter :

The air filter element should be

periodically cleaned.Replace the air

filter element with a new one when the

service indicator shows red band

even after cleaning.

Always use genuine air filter element.

Air filter for SUMO Armoured DICOR

diesel engine is located at LH side of

engine compartment.

Replacement of Air Filter Element :

a) Disconnect air filter from hose.

Declamp and remove the air

filter.

b) Remove the cover of the air filter.

c) Remove the air filter element.

d) Clean it gently by tapping. Clean

air filter cover and air ducting.

e) Check element for puncture or pin

holes by light source.

f ) If found OK install paper filter

element. Fit the cover and tighten

air filter screws at the place and

fit the clamps back.

g) Clean the hose connecting the air

filter to turbocharger pipe. Reset

the indicator by pressing the

rubber cap,red band will disappear

from Service Indicator.

On starting the engine, if red band

continues to appear, replace the

paper filter element.

Reset the indicator by pressing the

rubber cap, red band will disappear

from Service Indicator.

On starting the engine, if red band

continues to appear, replace the

paper filter element.

Air Filter

Vehicle Maintenance Air Filter

48

Engine Cooling System :

If engine overheating occurs, there couldbe a fault in the cooling system whichmay be on account of :

1. Less coolant in the cooling systemor dirt / scale having accumulatedinside cooling water passagesespecially in the radiator core.

2. Choking of radiator passages dueto foreign material or damages.

3. Defective thermostat.

4. Defective coolant temp. sensor.

5. Coolant leakage.

6. Radiator cap not sealing properly.

7. A.C. condenser fan not working

8. Excessive refrigerant charging inthe A.C. system.

Prevention of Rust Formation :

To prevent rust formation in the radiatoruse premixed recommended anti-freezecoolant.

This is sufficient to operate the vehicleupto - 400C.

Replacing Engine Coolant :

The cooling system should becompletely drained and refilled with newcoolant at specified intervals.

1. Ensure engine and radiator arecool enough to touch.

2. Remove the radiator cap.

3. Loosen drain plug on the bottomof radiator. Remove cylinder blockdrain plug from engine block.

4. Remove the auxiliary tank from itsholder and drain the coolant.

5. Flush radiator and block with cleanwater and close the drain plugs.

6. Pour the premixed coolant intoradiator until it is full.

7. Fill the auxiliary tank upto highmark.

8. Ensure no leakage in the system.

Engine Coolant Tank Radiator Cap

Vehicle maintenance Engine Cooling System

49

Changing of Engine Oil and OilFilter :

Change the oil and oil filter at speci-

fied intervals. (Engine oil and oil filter

may be changed earlier for sandy/

dusty operating conditions)

Changing of oil and oil filter requires

access from underneath the vehicle.

Vehicle should be raised on a hydrau-

lic lift of a service station or should be

on a service pit.

Oil Sump drain plug

1. Run the engine until it reaches

normal operating temperature.

Then shut it off.

2. Open the bonnet and remove

engine oil filler cap. Remove the

drain plug of the oil sump from the

bottom of the engine. Drain the oil

into an appropriate container.

3. Remove the oil filter with the help

of special wrench. The removed oil

filter should not be reused and

hence should be destroyed to avoid

recycling of the same. Used filter

and oil should be disposed in

compliance with the current

legislation.

4. Smear a little fresh engine oil on

rubber gasket of new engine oil filter.

Hand tighten the engine oil filter fully

and further half turn with special

tool. Do not over tighten engine oil

filter as this may damage oil filter & oilmay leak out.

Vehicle maintenance Changing Engine Oil & Oil Filter

Engine oil filler 1.Engine oil filler Cap 2. Dip Stick

50

Water Sedimenter

A water sensor is fitted to the water

sedimenter in order to indicate to the

driver that the sedimenter has to be

drained. Whenever water in fuel

sedimenter Indicator glows in

instument cluster, the water need to

be drained from the sedimenter.

Water drain operation to be done on

both filter and sedimenter.

Procedure :

1. Stop the engine, and wait until

pressure stabilizes.

2. Unclip one of the hydraulic

connections (either inlet or outlet)

and the electric connector of the

water sensor. 3 Place a container

underneath the water sedimenter.

3. Place a container underneath the

water sedimenter.

4. Unscrew the water sensor about

2 - 3 turns

Water draining Procedure fromSedimenter :

The water sedimenter is part of the

Fuel filtration system, fitted to the

chassis frame, near fuel tank below

the vehicle. It is used in the fuel

supplying system in order to reduce

the water content in the fuel provided

to the DICOR system.

Vehicle maintenance Water Draining Procedure from Sedimenter

5. Before filling in fresh oil in theengine, clean the drain plug andapply sealant on threads.

6. Refit the drain plug using a newsealing washer. Tighten drain plugto 5 mkg. torque.

7. Fill, recommended quantity offresh engine oil in the crank caseand secure the oil filler cap in itsplace.

8. Start the engine and run for a fewminutes. The engine oil pressureindicator lamp should go ‘off’ afterstarting the engine.

9. Check for engine oil leakages.

10.Stop the engine and recheckengine oil level after a fewminutes. If necessary add oil tobring the level to the upper markon the dipstick.

NOTICE

Use of reclaimed oil is not

recommended.

51

5. Wait until all the water has

drained out of the water

sedimenter.

6. As soon as the flow is free of

water, screw the water sensor to

the required torque.

7. Clip the hydraulic connector and

the electric connector to the

water sensor.

Fuel & Filter Draining :

Loosen drain plugs by 1-2 turn and

drain out water and other sediments

from fuel filter bowls depending on

operating conditions to ensure that no

water is allowed to enter the fuel

system.

Priming Pump / Pear Pump :

This is used for priming the fuel

manually after overhauling of the

engine or after refitment of fuel lines

or after changing either fule filter or

sedimenter Pump the fuel by means

of priming pump / pear pump until all

air in the fuel line removed. Before

cranking the engine ensure that there

is no air in the fuel system.

Priming / Pear Pump

Vehicle maintenance Fuel & Filter Draining & Priming / Pear Pump

CAUTION

Do not loosen the HP lines of

DICOR system for bleeding the air

from fuel system.

52

Gear Box Oil

Checking of Oil Level :

1. Clean the oil level plug and

surrounding area.

2. Remove the oil level plug and check

whether oil is dripping out.Oil level

must not be below the filler plug.

Add oil to bring it tothe level.

3. Tighten oil level plug to 2-3 mkg.

torque.

Changing Oil in Gear Box :

1. Let the engine idle for about 5 min.

in neutral, so that the gear box oil

is warmed up.

2. Clean the oil level plug, drain plug

and surrounding area.

3. Place a container under gear box

to collect the oil.

4. Remove the drain plug and let the

oil drain out.

5. Also remove the oil level plug.

6. Tighten the oil drain plug and fill new

recommended oil through oil level

plug and tighten the oil drain plug

oil level plug to 2-3 mkg. torque.

Vehicle maintenance Checking & Changing oil in Gear Box

1. Gear Box Oil Level / Filler Plug

2. Gear Box Oil Drain Plug

53

Checking of Oil levels :


surrounding area.

2. Remove the oil level plug and

check whether oil is dripping out.

3. If oil is not dripping out, oil level

must be below the required level.

Add oil to bring it to the level when

it starts dripping out.

4. Tighten oil level plug. Tightening

torque of oil level plug is 2 to 3mkg.

Changing of Transfer Case Oil



2. Place a container to collect oil,

under transfer case.


oil drain out.

4. Remove the oil level plug.

5. Tighten oil drain plug and fill new

recommended oil through oil level

plug, till it begins to drip out.

6. Tighten oil level plug. Tightening

torque of oil drain plug is 2 to 3

mkg.

Vehicle maintenance Checking & Changing oil in Transfer Case

1. Transfer case Oil Level / Filler Plug

2. Transfer case Oil Drain Plug

Checking Oil Level of Transfer Case

NOTICE

Before checking or removing the

oil, warming up of the transfer case

is necessary. This should be done

by driving the vehicle for some time

in 4x4 mode.

54

Checking Oil Level in Front / RearAxle :


surrounding area.

2. Remove the oil level plug and check

whether oil is dripping out.

Oil level must be below the required

level. Add oil to bring it to the level,

when it starts dripping out.

3. Tighten oil level plug to 2 to 3 mkg.

torque.

Changing Oil in Front Axle/RearAxle



2. Place a container under Front/

Rear axle to collect the oil.


oil drain out.

4. Also remove the oil level plug.

5. Tighten the oil drain plug and fill

new recommended oil through oil

level plug till it begin to drip.

6. Tighten oil drain and oil level plugs

to 2 to 3 mkg. torque.

Vehicle maintenance Checking & Changing oil in Front / Rear Axle

1. Differential Oil Level / Filler Plug

2. Differential Oil Drain Plug

1

2

55

Bleeding clutch system

A dry friction, single disc, diaphragm

type clutch has been fitted, which is

actuated hydraulically.

The procedure for bleeding the

system is as follows :

a. Ensure that fluid level in clutch

fluid container is upto maximum

level.


2. Clutch fluid Container

b. Remove dust cap from slave

cylinder bleed screw and clean

the screw thoroughly. Attach

bleeding tube to bleed screw and

place other end of tube in a

clean glass jar containing

sufficient clutch fluid to submerge

tube end.

c. Pump clutch pedal twice or thrice

slowly throughout its stroke and

Bleeding clutch slave cylinder

by holding clutch pedal in

depressed condition, loosen

bleed screw on slave cylinder,

Watch for air bubbles in glass jar.

d. Retighten bleed screw on slave

cylinder and repeat the process

until air bubbles cease to appear

at the end of tube in glass jar,

allowing only fluid to flow.

e. After completing bleeding

operation, ensure that bleed

screw on slave cylinder is fully

tightened. Replace dust cap on

the bleed screw.

During bleeding process keep

a watch on fluid level in

container and top-up.

Vehicle maintenance Bleeding clutch system

56

Brake system

The dual circuit service brake system

operated through the tandem master

cylinder is designed such that one

circuit will continue to provide braking

action if the other circuit fails. This

vehicle is fitted with disc brakes at front

and drum brakes at rear.

Stopping the vehicle after loss of the

brake fluid in one circuit will require

more pedal presssure and pedal travel

than normal. Also stopping distance

will be longer.

Service brakes are vacuum assisted.

In case of failure of vacuum, the

vehicle can still be stopped, however

with a higher effort.

Bleeding the brake system

If the brake pedal becomes spongy,

this may be due to air in the hydraulic

brake system.

Whenever any repair/overhaul ordisconnecting of any brake pipe isdone, or level of brake fluid hasfallen so low that air has beendrawn into master cylinder, it isnecessary to bleed the system toremove the trapped air.

Bleeding front calliper

Vehicle maintenance Brakes, Bleeding the brake system

57

Proceed as follows for bleeding thebrake system :

a. Clean all dirt from around the fluid

container. Remove cap and top-

up fluid upto the maximum level.

b. Remove dust cap at each bleed

screw and clean the area around

it.

c. Attach the bleed tube to the front

left calliper bleed screw and

Bleeding rear wheel cylinder

place the other end in a clean jar

containing sufficient fluid to

submerge the end of the tube.

d. Pump the brake pedal 3-4 times

slowly throughout its stroke and

by holding the pedal depressed,

loosen the bleed screw and watch

for air bubbles in the glass jar.

e. Re-tighten the bleed screw and

release the brake pedal. Repeat

the process until bubbles cease

to appear at the end of bleed

tube, allowing only fluid to flow.

f. Replace the dust cap on bleed

screw.

Repeat the same procedure (steps 'a'

to 'f') on the front right calliper, rear

left wheel cylinder followed by rear

right wheel cylinder.

After completion of bleeding, apply

the brake several times and check for

any leakage at joints and bleed

screws.

During the bleeding process keepthe following points in mind :

1. Ensure that the fluid level in the

fluid container does not fall low

enough to cause air to be drawn

into the hydraulic system.

2. Maintain absolute cleanliness.

The brake system must be kept

entirely free from petrol, kerosene

or any form of mineral oil, as

mineral contamination spreads

rapidly in the hydraulic system,

Vehicle maintenance Bleeding the brake system


2. Clutch fluid Container

58

causing dangerous deterioration

of the rubber seals.

3. Never, under any circumstances,

use the fluid which has been bled

out from the system to top-

up the container. It may be

aerated, have too much moisture

content and /or is contaminated.

4. Always use recommended brand

of brake fluid.

5. As brake fluid absorbs moisture

from the atmosphere, we

recommend changing of

brake fluid in the system annually.

6. Take care to see that the brake

fluid is not spilled on the paint

work.

Brake adjustment :

The front wheels are fitted with disc

brakes. These are self adjusting,

therefore need no adjustment.

The rear wheel brakes can, however

be adjusted. Due to wear on the brake

shoe linings the clearance between

rear brake shoe linings and the brake

drum increases. This must be

adjusted after every 5,000 km if

required : After installing new rearbrake shoes or linings, check andadjust brakes after 500 km run.

For adjusting rear wheel brakeshoes proceed as follows :

1. Put chocks on front wheels.

2. Jack up rear axle. Release

parking brake. Ensure that

parking brake cable is slack.

Place the gear shift lever in

neutral position.

3. Loosen the adjusting screws of

both brake shoes so that the

wheel is absoultely free to rotate.

4. Now turn the adjusting screw of

one of the brake shoes till brake

begins to bind i.e. the brake shoe

touches the brake drum.

Adjusting the rear brakes

1. Adjusting screw

2 & 3 To increase or reduce the

clearance between brake

shoe and drum

Vehicle maintenance Brake adjustment

Now turn the adjusting screw in

the opposite direction just upto the

point when wheel can be rotated

freely.

Adjust the other brake shoe of the

same wheel in the manner

described above.

59

Parking brake handle (Floor mounted)

1. Parking brake released

2. Parking brake applied

5. Adjust both brake shoes of the

other wheel as described above.

6. Operate brake pedal twice/ thrice,

simultaneously rotating both rear

wheels, for checking proper

application and release of brakes.

7. Re-adjust, if necessary.

8. Remove front wheel chocks.

9. Test drive vehicle for checking

proper brake function.

Parking Brake Brake adjustment(Floor mounted) :

Adjust that all four rear brake shoes

have been properly adjusted.

1. Put chocks on front wheels.

2. Jack up the rear axle.

3. Loosen the lock nut. Pull the

parking brake lever up to 5th

notch.

4. Tighten the adjusting screw till

rear wheels start jamming and

cannot be rotated.

5. Release the parking brake and

ensure that wheels are rotating

freely. Hold the adjusting screw

in this position and tighten the

lock nut. Operate parking brake

few times to ensure proper

operation.

Parking brake linkage adjustment

1.Check nut 2. Parking brake nut

Vehicle maintenance Adjustment of parking brake

2

1

1

2

60

Wheels and Tyres

Always use only recommended size

wheel rims and tyres. Use of rims and

tyres not recommended by us may

have adverse effect on vehicle safety

and further more, could infringe on

motor vehicle regulations.

Wheel change

When changing wheels use the jack

provided with the vehicle.

Jack location at front Jack location at rear Tightening wheel nuts

Jack should be placed below chassis

long member behind front wheel for

changing front tyres and before rear

wheel at rear axle as shown for rear

tyres.

Wheel alignment

If uneven tyre wear is noticed, get the

vehicle examined and attended by

TATA MOTORS authorised Service

Outlet. Periodically check and maintain

correct tyre pressure to obtain longer

tyre life.

Vehicle maintenance Wheels and tyres

Recommended tyre pressure(with cold tyres)

For LT 245 / 70 R 16 ALL TERRAIN

TYRES

LT 245 / 70 R 16

Front(psi) Rear(psi)

UNLADEN 31 41

LADEN 36 58

Check and maintain the above

recommended tyre pressure in all terrain

& environment conditions.

61

Check tyres for damage from time to

time and remove any foreign bodies

(nails/stones, metal chips etc.)

embedded in treads.

While fitting wheels on the vehicle make

sure that wheel bolts are free from dust,

scratches, dirt, dents etc.

Do not oil wheel bolts and nuts.

Wipe off any adhering oil.

Tightening torque of : 12-15 mkg

wheel nuts.

Retighten wheel nuts after 100 km of

every wheel change.

New tyres do not give maximum grip

straightaway and should therefore

be run-in at moderate speed for the

first 100 km. This will help to make

the tyres last long.

To avoid damage to tyres and wheels,

drive slowly over speed breakers/

bumps/rough roads.


Wheel balancing :

Wheels of your vehicle are balanced.

The same should be maintained when

repairing a tyre or tube and replacing the

tyre or rim.

Replacing a tyre/ rim :

When the tyre or rim is changed the

wheel should be properly balanced on a

machine after inflating to the specified

value as per the following norms.

1. Permissible imbalance for tyre with

rim=250 gm-cm max.

2. Permissible balance weight for tyre

with rim=140 gm max.

3. Relocate the tyre if the weight required

to balance is more than 140 gm.

4. Balance weights are available

from 10 gm to 90 gm in steps of 10

gm and from 80 to 140 gm in steps

of 20 gm.

5. Do not use more than one balance

weight on one side.

Run-flat :

Run-flat is fitted on the rims inside

tyres to drive the vehicle when tyres

deflated due to bullet firing.

62


External Repair kit (Optional):

This repair system enables quick road-

side puncture fixing without having to

demount the wheel from the vehicle.

The specifically shaped rubber repair

plug with its special adhesive coating

is inserted in the tread injury from out-

side. It automatically seals the punc-

ture channel. The repair plug, with its

specific shape, acts like an anchor. It

hooks itself on the tyre inside while

completely plugging the puncture

channel, and sealing the tyre.

Repair kit consists of

1. Anchor seal plug.

2. Marking chalk

3. Rotary cutter 6mm Dia.

4. Hand Ratchet (Right/ left)

5. Insert tool.

6. Special cement

Repair procedure (Refer manufac-tures instruction)

1. Remove the penetrating object from

the tyre.

2. Carry out the anchor seal follow-

ing the enclosed instructions

provided with kit.

3. Finally inflate the tyre - the job is

safely done.

4. The repair plug self – vulcanizes

by the heat generated in he tyre

under working condition.

Caution : It is advisable to inspect

the tyre internally for secondary

damage.

63

Non skid chains : (If required)

Non skid chains are used on tyre to

get better traction and drivability in

snow or marshy area.

Fitment procedure of these chains on

tyre is given below :

1) Check for proper pressure in tyres.

1) Lay down the chains (longitudi-

nally) on level floor

2) Drive the vehicle on laid chains

3) Wrap the chains on tyre.

4) Adjust the chain locking

5) Clamp the toggle clamp

6) Ensure tight fitment of chains

7) Run for one or two Kms.

8) Adjust the chain locking.

NOTE : Tyre pressure to be main-

tained before fitment of nonskid

chains on tyres


Schematic diagram - Tyre rotation

Tyre rotation

Tyre rotation is recommended for

achieving identical wear on each tyre.

It is also advisable to change rotating

direction to relieve tyres of continual

one way rotation. Regular rotation of

tyres also will prevent abnormal wear.

The sketch indicates a suggested

sequence of tyre rotation Rotate tyres

at specified intervals or earlier

depending on operation.

64

Vehicle maintenance Battery & Battery Isolator Switch

Battery

Battery :

Battery is fitted near the gear shift lever

& in between driver & co driver seat.

Battery is located in box & bolted

cover.

Check the battery for proper

electrolyte level and corrosion on the

terminals.

1. Check the battery for electrolyte

level against the marking on the

battery outer case.

.2. Check the battery terminals for

corrosion (a white or yellowish

powder). To remove it, cover the

terminals with a solution of baking

soda. It will bubble up and turn

brown.

3. When this stops wash it off with

plain water. Dry off the battery with

a cloth or paper towel.

4. Coat the terminal with petroleum

jelly to prevent future corrosion.

Use a proper spanner to loosen andremove cables from the terminals.

Always disconnect the negative (-ve) cable first and reconnect it last.

Clean the battery terminals with a

terminal cleaning tool or wire brush.

Reconnect and tighten the cables,

coat the terminals with petroleum jelly.

Ensure that battery is securely

mounted.

If you need to connect the battery to

a charger, disconnect both cables to

prevent damage to the vehicle’s

electrical system.

NOTICE

During normal operation, the battery

generates gas which is explosive in

nature, a spark or open flame can

cause the battery to explode

causing very serious injuries.

Keep all sparks & open flames and

smoking materials away from the

battery.

Getting electrolyte in your eyes or

on the skin can cause severe burns.

Wear protective clothing and a face

shield or have a skilled technician

to do the battery maintenance.

The battery contains sulphuric acid

(electrolyte) which is poisonous and

highly corrosive in nature

Battery Isolator Switch:

This switch is provided near the gear

shift lever to isolate the battery from

electrical system when required.

65

Headlamps

The headlamps provides two types of

light beams; a high beam to give

maximum light well ahead of vehicle,

and a low beam which is shorter and

lower so that it will not dazzle the

oncoming drivers can be used in low

visibility area.

The headlamp also incorporates a

parking light.

The headlamps must be properly

aligned in order to obtain maximum

road safety, proper road illumination

and reduced glare to oncoming traffic.

It is recommended to check alignment

of headlamp beams periodically and

whenever headlamp bulbs are

replaced, by means of a headlamp

aligner or with the help of a screen as

shown in figure .

Vehicle maintenance Battery Isolator Switch & Head Lamps

Battery is connected to the starter and

other circuitry through isolator switch.

This is to be switched OFF while

carrying out any work on the vehicle

and also when the vehicle is parked

for long duration to avoid battery

drainage. This will also prevent any

inadvertant short circuits during

repairs.

Battery Isolator Switch

66

Adjusting head lamps focus withthe help of screen

The vehicle should be parked 10meters away from screen with itscentre in line with central vertical lineon screen, and screen at right angleto longitudinal axis of the vehicle. Thevehicle should be in unloadedcondition with no sag in suspensionsprings and all tyres equallyinflated.Head lamp leveling switchshould be kept on ‘O’ position.

On the marked up screen as shown infigure, area above horizontal and inclinedlines (shaded) is called 'Dark zone' andthe area below it is called 'The illuminatedzone'.

Each headlamp is aligned individuallyby masking the other headlamp.Headlamp is first adjusted for properheight of low beam by adjusting headlamp leveling motor shaft if required.Light from low beam should fall belowhorizontal and inclined lines.

No light should fall above these linesi.e. in 'Dark zone' Thereafter lateraladjustment is done by adjusting theknob at bottom of headlamp so thatcontour of low beam coincides withcontour formed by horizontal andinclined line below ‘Dark zone’

When properly adjusted, most brightlyilluminated area will be just below theintersection point 'A' of these twolines.

The Second headlamp is adjusted ina similar manner without disturbing theposition of the vehicle and the screen.

Now switch 'ON' high beam. They willbe symmetrical above point. 'A' and'B' of intersection of vertical lines andhorizontal lines. It is possible thathigh beams may not be exactlysymmetrical but for this reasonheadlamps should not be realigned.

Perferably, the alignment should bedone in the dark.

No masking of headlamps withblack paint is required. If done, thiswill reduce the intensity of lights.

Vehicle maintenance Head lamp adjustment

67

Head lamp bulb replacement

Raise the bonnet of the vehicle.

Remove the rear protective cover. Pull

out cable socket from bulb. Remove

lock ring holding the bulb and remove

the bulb.

Install new bulb, properly locating it

in the housing. Fit back locking ring,

cable socket and protective cover.

Removal of cable socket Removal of locking ring Removal headlamp bulb

Realign headlamp beam afterreplacing bulb

Do not clean the reflector as it willcause damage to mirror-finishedsurface. Do not replace bulb withdirty or oily hands, since oil willevaporate due to bulb heat andstain the reflector.

Vehicle maintenance Head lamp bulb replacement

68

Vehicle maintenance Bulb specifications

DESCRIPTION LOCATION SPECIFICATION

Head Lamp Bulb Head Lamp 12 V 60/55 W

Parking Lamp Bulb Head Lamp/Tail Lamp 12 V 4/5 W

Direction Indicator Lamp Bulb Head lamp/Tail lamp 12 V 21 W

Side Repeater Bulb Side Indicators 12 V 5 W

Tail Lamp Bulb Tail Lamp 12 V 10 W

High mounted stop lamp Tail Lamp 12 V 21 W

Reversing Lamp Bulb Tail Lamp 12 V 21 W

Number Plate Lamp Bulb Number Plate 12 V 10/5 W

Warning & Illumination Lamps, Head Lamp Bulbs (Main beam),

Turn Indicator Bulb, Battery Charging Indicator Bulb,Glow

Plug Indicator Bulb, Low Oil Pressure Indicator Bulb, Barake/ Instrument Cluster 12 V 2 W

Parking Light Indicator Bulb,4WDL & 4WDHIndicator Bulb,

Check Engine Indicator Bulb, Water in fuel indicator Bulb

Gauge Illumination Lamp Instrument Cluster 12 V 3.4 W

Interior Lights Roof 12 V 10 W

Engine Compartment Lamp Engine Compartment 12 V 21 W

Front Fog Lamps Front Bumper 12 V 55 W

Rear Fog Lamps Tail Lamp 12 V 21 W

BULB SPECIFICATION

69

Fuse box :

In order to protect the cable harness

and other equipments from damage

in case of short circuit and overloads,

fuse links are provided.

Fuse box is located in engine

compartment at RH side.

In case of a fault in the electricalsystem check the respective fuse. Theparticulars of the consumers servedby each fuse and amperage areprinted on the fuse box cover. The fuselink can be identified for amperageby colour codes :

1. Fuse link - Red - 10 Amps2. Fuse link - Blue - 15 Amps3. Fuse link - Light brown - 5 Amps4. Fuse link - Yellow - 20 Amps

While fitting fuse box cover ensure

that cover knob rests in the slot

provided inside fuse box.

Spare fuse cartridges are provided

inside the fuse boxes.

Always use fuses of correct rating.Do not use a wire in place of fuse.

Flasher with short circuitprotection

If flasher circuit is short circuited or

overloaded (more than 110 W) flasher

will shut off. It can be reset by

momentarily centering the indicator

arm of combi switch.

If flasher is shutting off or fuse is

blowing off repeatedly the flasher

circuit should be checked for short

circuit. Check the flasher separately

for its functioning.

Vehicle maintenance Fuses

Fuse /relay box in engine

compartment (If fitted)

70

l Floor mats ( If fitted)Dirt can be removed from the mats

with water and a mild soap. Use a

brush to help loosen dirt. After dirt

is loosened, wash the mat

thoroughly with water and dry it in

the shade.

l Seat beltClean the seat belt with a mild soap

and water only. No bleach or dye

should be used as this may weaken

the belt fabric. The belt should be

allowed to dry in the shade.

l Carpets (if fitted)

Remove dirt as much as possible

by using a vacuum cleaner. Rub

the stained area with clean cloth

made damp with soap to absorb

the stain and remove the soap.

Repeat until the stain is removed.

You can use commercially

available carpet cleaner. In this

case, carefully follow the

manufacturer's instructions and

precautions.

Vehicle maintenance Care and cleaning of vehicle

Cleaning exterior of the vehicle

Dirt or any other foreign material on

the painted surface may result in :

l Faded paint.

l Rust on body due to deteriorated

paint film.

l Rust due to scratches

l Body rust due to contact with

damp dirt trapped in the body.

Therefore it is important that your

vehicle is always kept clean and

free from dirt in order to maintain

the paint in a good condition and

to protect the entire body against

corrosion.

Washing

When washing the vehicle, follow the

instructions given below :

l Flush underside of body and wheel

housing with pressurised water to

remove mud and debris. Use plenty

of water to loosen and remove dirt.

l Remove dirt and mud from

Care and cleaning of the vehicle

CAUTION

When cleaning the interior / exterior

of the vehicle, NEVER USE volatile

solvents such as thinner, petrol or

any other cleaning materials such

as bleaches or strong household

detergents. These materials may be

poisonous or flammable and their

improper use may cause personal

injury or damage to the vehicle.

Cleaning of vehicle interior :

l Upholstery

Prepare a solution of soap or

neutral detergent mixed with warm

water. Apply solution with a sponge

or soft cloth and let it soak for a

few minutes to loosen dirt. Wipe

the surface with a clean, damp

cloth to remove dirt and soap

solution. If some dirt still remains

on the surface, repeat the

procedure.

71

Vehicle maintenance Care and cleaning of vehicle

Waxing the vehicle exterior

After washing the vehicle, waxing and

polishing are recommended to

protect and beautify the paint.

l Use only good quality waxes and

polishes.

l When using waxes and polishes, the

precautions specified by the

manufacturers should be observed.

l Chrome-plated parts should also

be waxed.

Protection against corrosion

The following cause corrosion :

l Moisture trapped in body cavities.

l Dirt and salts collected in hollows on

the underside of the vehicle.

l Removal of paint and protective

coatings from the exterior and

underside of the vehicle.

Corrosion preventive measureshave been incorporated in your vehicle.

You can avoid corrosion of your vehicle

by performing some simple periodic

maintenance :

l Repair chips and scratches in the

paint as soon as you discover them.

l Inspect and clean the drain holes in

the bottom of the doors and body.

l Check the floor coverings for

dampness. Carpets and floor mats

remain for a long time, especially

in winter. This can eventually cause

the floor panel to corrode.

l Use a high-pressure spray to clean

the underside of your vehicle. This

is especially important in areas near

chemical and other industries.

l Have corrosion preventive coatings

done on the underside of your

vehicle. Preventive coatings such

as the Dinitrol-3850 are available in

the market.

bodyexterior with running water.

Use a soft sponge, brush with

water. Do not use hard material

which can scratch the paint.

l Wash the exterior with water, lightly

rubbing with sponge or soft cloth.

The sponge or cloth should be

frequently soaked in water.

CAUTION

When using commercial wash

products precautions specified by the

manufacturers should be observed.

Do not use strong household

detergents or soaps.

l Once dirt has been completely

removed, wash off with running hose

water.

l After rinsing, wipe the body lightly

with wet chamois or cloth and allow

the body to dry in the shade.

WARNING

After washing, check that the brakes

are dry. If brakes are not dry, dry them

by gently, repeatedly applying while

driving at low speed.

72

Cleaning of Glasses :

For the internal face of the glass (poly-

carbonate) it is not recommended to

use cleaning agents, since they could

affect the optical quality of the

product. Because of the above, we

recommend using only water and damp

cloth. In any case avoid cleaning

glasses under direct sunlight.

1. Remove grit particles, etc by blow-

ing with clean filtered air, preferably

ionised to minimise ‘static’

attraction.

2. Wash with tepid water / detergent

(e.g. Teepol or a domestic house-

hold detergent) solution and dry

using clean gloves cloths.

3. Rub lightly to remove stubborn

marks with soft glove cloth impreg-

nated with 50% v/v isopropyl

alcohol or ethanol in water followed

by through washing with water /

detergent. Change cloth frequently.

Dry with lights strokes, with a clean,

dry soft glove cloth. Fresh paint,

grease and wet sealant may be

similarly treated.

Minimise the effects of hairline

scratches and minor abrasions

using very mild automobile cleaner

polish.

DO NOTDO NOTDO NOTDO NOTDO NOT

Wipe the PC Hi-tech (anti-scratch plas-tic) inside surface with dry, dirty rags and/

or any abrasive clothes which may

scratch the splash shield.

Try to remove marks or dirt with sharp

object or razor blade.

Stick any labels or stickers to the inside

face.

Wipe the inside face with dry, dirty rags.

Allow any subsequent exposure to sol-vents (other than as above).

Scrape the surface to remove marks,frost etc with any sharp instrument.

Allow any abrasive cleaner, steel wool or

similar material to come into contact withthe inside face of window.

Wipe the inside face of the window withthe hand, whether glove or not.

The inside face of the window should notbe allowed to come into contact with other

organic materials containing plasticisers

or solvents e.g. Flexible PVC,‘Screenvin” solvent based protective

lacquers etc.

Vehicle Maintenance Care and cleaning of vehicle

73

Vehicle Maintenance Preservation & De-preservation

WORK GUIDELINE FOR PRESERVATION AND DE-PRESERVATION OF SUMO ARMOURED VEHICLE INDIFFERENT CLIMATIC CONDITIONS

STORAGE PREPARATION OF VEHICLE:

Choose a place preferably closed cool, dark and dry. But many a times getting such an ambience is not possible. If

the vehicle needs to be stored outside, it should be covered with a quality cover which has thick, multi-layered fabric.

Following precautions can help in keeping the vehicle in good condition.

PRESERVATION (07 Days or less):

1 Vehicle shall be empty and no load inside cabin or load body shall be kept.

2 Increase Tire pressures by 10 psi over the specified (placard) pressures to avoid flat spots or damage to the

tire leading to permanent set deformation.

3 Disconnect the battery terminals inside engine compartment as well as in passenger compartment.

4 Make sure that fuel quantity inside tank is at minimum level.

5 If the engine’s coolant service life time limit will be exceeded while the vehicle is in storage, drain and refill the

cooling system with the recommended coolant mixture.

6 The coolant mixture must protect against freezing down to the lowest expected temperature

7 Make sure that vehicle is in 4 x2 mode.

AT HILLY / SNOW FALL / COLD CLIMATE AREA:

1 In cold atmosphere area vehicle shall be parked preferably inside enclosed area. If such area is not available

then park the vehicle in such a place where snow fall is less. Put antirust element on surface which is open to

atmosphere.

2 Cover the vehicle with car cover where the snow fall is in control.

3 Put hand brake in on condition to arrest the vehicle slippage or park the vehicle in plain area with chokes

74

COASTAL AREA:

1 Apply antirust to all open body area

DE-PRESERVATION (Beyond 07 days):

In addition to above short term storage precautions following steps needs to be taken:

1 Make sure the vehicle is clean, waxed, and chrome polished before putting it into storage.

2 Drive the vehicle for about 10 Km after adding the stabilizer/antirust/anticorrosion agent in fuel system, Cooling

system ,lubricating systems and brake oils (Long storage fuel additives available in local market is called

stabilizer).

3 Normally it’s best to leave the tank full. However, if the vehicle will be stored in an enclosed location where gas

fumes could be a problem, empty the tank about half way

4 Open the Injectors and pour about a teaspoon of oil into each cylinder and fit it back. This will help coat the

cylinders to prevent rust. Also pour oil into the intake, this lubricates the engine and the exhaust system from

the inside deterring rust formation.

5 Place desiccant packs in various locations inside the car; also place moth balls in various locations inside;

make sure the air is on the “re-circulate” setting; open the glove box and other interior storage locations; cover

any areas that might be exposed to sunlight.

6 Drain the cooling system fluid and fill fresh appropriate coolant in system.

7 Seal off engine openings such as engine air intake, exhaust out let pipe with absorbent cotton to keep moisture

out.

8 Remove the battery and clean its top with a mixture of baking soda and water. Apply grease on the terminals

and preserve separately.

9 Loose the drive-belts to take the pressure off of the pulley bearings.


75

10 Support the vehicle on jack-stands or blocks. This will take the weight off of the wheel bearings and suspension

components. Also if possible remove the wheels and tires, lower the tyre pressure slightly, and store them flat

and out of sunlight area.

11 Wash and wax the body surface.

12 Apply vinyl/Weather protestant on leather surfaces, tyres, and other rubber components.

13 Keep off the wiper blades from wind shield glass or take off and preserve separately.

14 Seal the tailpipe and any other openings to prevent entry of mice or other rodents.

15 Particularly care to be taken to plug the fire wall openings in to the cabin to prevent rodents.

16 To avoid engine bearing damage due to acid in the engine oil, change the engine oil and oil filter.

17 Leather care: You do not to need to apply a leather conditioner to maintain suppleness in the leather. To clean

the leather use a damp, soft cloth, taking care not to soak the leather. Small dirt particles can be abrasive and

damaging to leather surfaces and should be removed promptly. Do not use saddle soap, polishes, oils,

cleaning fluids, solvents, detergents or ammonia-based cleaners

18 Place any written reminders on what may be needed after the vehicle is removed from storage where it will be

easily seen such as the top of the instrument panel, on the steering wheel, etc.

19 Make sure you have adequate insurance on the vehicle to cover for fire, theft and vandalism or any avalanches

or storm condition etc.

20 Open both front and rear hatch if it is inside parking & keep it partial open when parked outside or open to

atmosphere.

21 Make sure that 4 x 4 is not engaged.


76

BATTERY STORAGE GUIDELINES:

1 Any time a battery will be stored unused for an extended period of time (over 30 days), certain precautions will

help assure that the battery will not be damaged and will be ready for use when needed.

2 Bring the battery to full charge before storing it.

3 If the battery is in a vehicle, it is often best to disconnect the negative battery cable.

4 Install and keep terminal protectors in place and keep the battery clean.

5 Store the battery in as cool of a location as possible.

6 Monitor the battery on a regular basis.

7 Bring the battery to full charge before it is stored. This is the best insurance against internal damage due to

remaining in a discharged state for a long period of time, and against freezing in extremely cold weather.

8 If possible disconnect the negative battery cable if the battery is in a vehicle (this is must to prevent battery

discharge as well fire accidents). This will prevent parasitic drains in the vehicle system from discharging the

battery at a faster rate. If the negative battery cable cannot be disconnected, more frequent monitoring and

charging will be needed.

9 To prevent accidental discharge, install terminal protectors on exposed terminals. Keep the battery free of dust,

dirt, moisture, and conductive materials like damp cardboard that could allow the battery to discharge slowly

through external paths.

10 Cool temperatures retard the internal reactions that cause self discharge and internal grid corrosion. Find the

coolest storage location that will not cause the battery to freeze. A battery that is kept at a 65% SOC or higher

will not freeze until the temperature is below -32°C (-25°F) A fully-charged battery will not freeze until the

temperature is below -54°C (-65°F).

11 Monitor the stored battery regularly by checking the built-in hydrometer or OCV.


77

12 If a battery is stored in a vehicle with the cables connected, check the battery SOC every 30 days. Recharge

the battery fully whenever the SOC falls below 65%.

13 When stored on the shelf or in a vehicle with the negative cable disconnected, a battery that begins storage at

full charge will require recharge on the following schedule, depending on the estimated average storage

temperature :

AVERAGE STORAGE TEMPERATURE RECHARGE FULLY AT

210C OR Below (700F OR Below) 12 Months

210C - 270C (700F - 800F) 8 Months

270C - 320C (800F - 900F) 4 Months

320C - 380C (900F - 1000F) 2 Months

380C OR More (1000F OR More) 30 Days

Chart applies to fully-charged batteries only

AT HILLY SNOW ALL/COLD CLIMATE AREA:

1 Apart from above mentioned points, below mentioned points are specific for cold climate area preserving,

2 Remove battery from vehicle and keep it in battery maintained area.

3 Apply thick layer of antirust on all open surface area.

4 Place the transmission gear selector in Reverse or First. Put 4x2 mode gear selector. Release the Park Brake.

5 Lubricate door, trunk, hood and other moving metal parts with silicone lubricant.

GENERAL INSPECTION BEFORE RETRIVAL OF PRESERVED VEHICLE:

1 Over all condition of vehicle.

2 Paint condition.

3 Rusting marks on body as well as on chassis components.


78

4 Levels like radiator coolant, engine oil, Gear box oil, axle oil, power steering oil etc…

5 Condition of tyre. (Any depletion happens).

6 Fuel tank condition (inside/Outside).

RETRIVING PRESERVED VEHICLE:

1 Check battery condition & electrolyte level. Check for battery serviceability and if it is in serviceable condition,

send it for servicing.

2 Remove air filter element & clean it.

3 Check water separator. If water level indicator is showing high level then empty the water separator.

4 Remove fuel filters for inspection and if dirty clean it, also clean the entire fuel line. This will ensure removal of

any blockages / water particles / any rusted chip if present inside.

5 If any contamination is observed in levels of engine oil, coolant, gear box oil, power steering oil, rear axle oil

etc... Than then flush the entire contaminated level. After flushing refill oil or coolant.

6 Clean the rusted surface where traces of corrosion are observed. Traces may be observed at electrical

connections like fuse/Starter motor/alternator/connectors/ relays/ etc… These traces required to be cleaned to

ensure proper voltage supply throughout the circuit.

7 Remove all brake drums/ Pads and clean the rusted surface where traces of corrosion are observed. Before

fitting back ensure for no moisture content within system.

8 Do hand priming of fuel line & ensure that fuel is supplied up to injectors, fuel lines and its solenoid for free

movement and free working.

9 Connect properly charged battery to vehicle and crank the engine for 5 seconds to know about any abnormality

in engine noise after cranking. Repeat cranking for 2/3 times to ensure further cranking can be done. Than

crank the engine till it get started. (Do not crank engine for more than 20 sec, because battery cable may be

heated and can cause fire )


79

10 When vehicle is started let the engine run in idle condition up to 2 minutes to ensure proper oil supply inside the

engine and to attain the ambient temp of all parts.

11 After 2 minutes in idling accelerate further to ensure that engine is running up to fly up rpm.

12 Drive vehicle in Pre selective first gear for 15 min.

13 During driving apply brake from 60 kmph up to 30 kmph. Repeat it for @ 10 - 20 cycles (This is to ensure

proper brake liner to drum contact and make it moisture/dust free)

14 Check vehicle by driving in each gear ensuring all aggregates are functioning properly.

15 Confirm for 4 x 4 high/low operation.

AT HILLY / SNOW FALL / COLD CLIMATE AREA:

1 Vehicles at cold climate area or a hilly area an attention towards following things apart from above mentioned

points need to be given.

2 A rubber component, Plastic components, rubber hoses needs to be checked for its proper hardness and if

crack generated are mores replace the components. All rubber parts like seal, beeds “O” rings etc to be

changed with new, since there is a chance of aging due to presence of ozone in atmosphere.

3 Wherever snow is concentrated over a surface needs to be cleaned and make rust free surface.

4 Vehicle to be inspected for affected areas where snow was accumulated and any damaged components to be

replaced.

5 All fuel lines and water passages to be made ice free and if required damaged pipes or rubber hoses need to

be replaced.

6 Fuel tank to be made empty and made ice, water, moisture free and fresh fuel need to be filled up.


80

COASTAL AREA:

1 Vehicle to be inspected for rusty surface and rusted surface area to be made rust free.

2 Surface area where thickness of that component is rusted more than 50 %, than repainting of that surface is

required to be done.


81

Vehicle Maintenance Special Operating Conditioning

Special Operating Conditions :

1. Operating on dusty/sandy roads.

2. Operating on hilly terrain with dusty

conditions.

3. Operating on muddy and melted

snow roads.

4. Operating frequently above 2000

m. of altitude.

5. Possible mixing of impurities in the

fuel due to operating conditions.

The vehicle is fitted with 3L DICOR

engine can be used satisfactorily

under the following conditions :

1. Altitude : Mean Sea level / ambient

temp. up to -200C ( With

recommended fuel & oil)

2. Altitude : 2500 meters and

ambient temp. upto -200C ( With

recommended fuel & oil)

Recommendations for operatingunder special conditions :

1. Air filter :

Cleaning of air filter cleaner element

For dusty operating conditions clean-

ing of air filter element need to be

carried out when ever red band

appears on the indicator. Cleaning of

air filter element should be carried out

by tapping the element gently so that

the dust could fall off.

Air filter element may be changed :

If the red band appears on the

Service Indicator continuously. OR

If visually it is observed to be covered

with mud / dust which can not be

cleaned effectively.

2. Engine oil and oil filter :

For special operating conditions of

vehicle, change oil and oil filter at

every 5000 kms or 3 months which-

ever is earlier. (Existing frequency for

normal operating conditions is 10000

kms)

82

The oil change periods recommended in maintenance

schedule should be adhered to.

Use of reclaimed oil is not recommended.

Engine oil : Qty : 6.5 Litres

Recommended grades of engine oil conforming to Multigrade

oil 15W40 API-CF4 specifications and range of ambient

temperatures at which these can be used are given below :

Fuels, lubricants, coolants Fuels, lubricants

Fuels :

High speed diesel conforming to IS 1460 or DIN 51601 or

equivalent is recommended to be used as fuel.

At very low temperatures fluidity of diesel may become

insufficient due to paraffin separation. It is therefore,

necessary to mix supplementary fuel with summer or winter

grade diesel. The supplementary fuel to be used is kerosene

or aviation turbine fuel

Ratios for mixing of supplementary fuel and diesel are shown

in table :

Percentage

Summer Supplementary

grade diesel fuel

upto 0 100 0

0 to -10 70 30

-10 to -15 50 50

Ambienttemperature upto

0C

Care should be taken that diesel and supplementary fuel

are thoroughly mixed before filling.

Percentage

Winter Supplementary

grade diesel fuel

upto -15 100 0

-15 to -20 70 30

-20 and below 50 50

Ambient

temperature upto0C

Lubricants

Recommended lubricants conform to the following

specifications :

1. SAE 15 W40 to API CF 4+ Engine oil

2. 75 W 90 GL-4 Syn. oil Gearbox oils

3. SAE 85 W 140 API GL-036 B Rear axle

(with additive 6.5 % Angalmol

99 by weight) and friction

modifier 40819.

Please use only recommended brands for good

performance.

83

Vehicle maintenance Lubricants

Ambient temperature 0C Engine oil grade

0 and above SAE 15W40

0 to -18 SAE 0W30

-18 and -40 SAE 0W40

Running in oil

In the first 2000 km of operation of a new or reconditioned

engine, any one of the running in oils listed below should

be used :

Autolube 30 : (HP)

Gear box oil (for GBS-76)

75W90 GL4 Syn. oil

Transfer case oil :

Recommended lubricant - Type A, Suffix A specifications,

e.g. Castrol TQ Gear oil capacity-1.2 liters.

Rear axle, live front axle oil :

Use oils conforming to APIGL 5 specifications. SAE 90 oil

should be used upto -90C and SAE 85 W 140 -400C.

Brake and clutch fluid

Brake fluid conforming to IS : 8654/DOT 3 is

recomnmended.

Spicer propeller shaft (where applicable)

Lubricate slip joint with NLGI-2 grade grease.

Lubrication of steering spindle and sleeve

Lubricate steering spindle and sleeve with Molikote grease

or mobiltac NC grease, at specified intervals.

Coolants :

Presence of dirt in the coolant chokes up passages in the

radiator, cylinder head and cylinder block, thereby causing

insufficient cooling of engine.

To prevent rust information and freezing of coolant inside

the passages of radiator, cylinder block and cylinder head,

use genuine co-branded premixed coolant (ready to use).

84

Recommended oils, lubricants and filling capacities

PLEASE USE ONLY FOLLOWING GENUINE OILS, COOLANTS , LUBRICANTS , ANTI RUST & SOUND DEADENING COATS,

WINDSCREEN SEALANT, ADHESIVES & FUEL ADDITIVES BRANDED BY TATA MOTORS FOR OPTIMUM PERFORMANCE

ITEM COMPANY BRAND QTY

ENGINE OIL CASTROL Castrol GDT 15W/40 For Summer 500 6.5 Litres

HPCL SAE 0 W 40 For Winter -200

COOLANT (Premixed) SUNSTAR Golden Cruiser Premium 1400 MHENKEL TEROSON Frostox SFD 12 13 Litres

HPCL HP Thanda Raja P

GEAR BOX (G-76) HPCL HP Gear EP 75W90 1.6 LitresCASTROL CASTROL Sythetic 75W90

TRANSFER CASE OIL HPCL HP-Automatic Transmission 1.2 LitresCASTROL CASTROL Transpower TQ Fluid Type A

POWER STEERING OIL HPCL HP-ATF Dextron II D 1.4 LitresCASTROL CASTROL Transpower TQ

REAR AXLE / HPCL HP Gear Oil XP 85W140 GL5 with friction modifier 40819 2.2 Litres for Rear #FRONT LIVE AXLE CASTROL CASTROL Extreme Pressure 85W140 1.2 Litres for Front

BRAKE / CLUTCH FLUID HP CL Super Duty Brake Fluid DOT - 3 / DOT - 4 As requiredCASTROL CASTROL Universal Brake Fluid DOT - 3

WHEEL BEARING & CHASSIS HPCL HP Multipurpose Grease-2 As requiredPropeller shaft joints, Sliding CASTROL Castrol AP-2 greaseYokes, Vacuum Booster

ANTI RUST TREATMENT DINITROL Dinitrol —& SOUND DEADENING WUERTH Wuerth —

WIND SCREEN SEALANT ANCHEMCO Terostat 8590 Kit Form —

METAL & PLASTIC ADHESIVE ANCHEMCO Terostat 930 310 ml Cartridge

DIESEL ADDITIVE IFTEX Iftex Clean System D 250 ml pack *

A.C.COMPTRESSOR SUBROS DENSOIL-6 -SUNOILCO SUNISONO.5GS

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

85

ENGINE

Model TATA 3.0 L DICOR BS-III

Type Water cooled, Direct injection,

Common Rail, Turbocharged

Intercooled Diesel engine with

crankcase breather and relief valve.

No. of cylinders 4 inline

Bore / Stroke 97 mm x 100 mm

Capacity 2956 cc

Max. engine output 84.9 kw @ 3050 rpm as per CMVR

115(9) 1996

Max. torque 300 N-m at 1600 ~ 2200 rpm as per

CMVR 115(9) 1996

Compression ratio 17.5 : 1

Firing order 1-3-4-2

Engine oil capacity Max. 6.5 litres / Min. 5.5 Litres

Weight of Engine 320 kg (Dry)

Radiator frontal area 2480 sq.cm.

CLUTCH

Type Single plate dry friction diaphragm

type with hydraulic actuation.

Outside diameter of 240 mm

clutch lining

Friction area 452 sq. cm. (approximately)

GEAR BOX

Type G-76-5/4.1 with overdrive

sychromesh on all gears.

No of gears 5 Forward, 1 Reverse

Gear ratios 1st 4.10

2nd 2.22

3rd 1.37

4th 1.00

5th 0.77

Rev. 3.75

TRANSFER CASE

Type With electric shift arrangementmounted on gear box.

Ratio 4x2 high - Ratio - 1:1

4x4 high - Ratio - 1:1

4x4 Low - Ratio - 1 : 2.48

REAR AXLE

Type Single reduction, salisbury type with

limited slip differential hypoid gears

& semi-floating axle shafts.

Ratio 4.55 (41/9)

FRONT LIVE AXLE

Type Independently suspended with

automatic hub lock

Ratio 4.55 (41/9)

Vehicle Data Technical Specification

86


STEERING

Type Power Steering

Steering Wheel 380 mm dia.

BRAKES

Service brakes Vacuum assisted indepedent hydraulicbrakes on front & rear through tandemmaster cylinder.Vacuum pump mountedon engine

Front 282 dia disc brake

Rear 295 dia. auto adjuster drum brake

Parking brake Floor mounted Cable operated mech.linkages acting on rear wheels.

FRAME

Type Ladder type cranked frame with boxedsection long members and weldedcross members

Depth 110 mm (maximum)

Width 60 mm

Tow Hook Tow hook at front, Provision of centraltowing hook at rear

SUSPENSION

Type Front Double wishbone type with torsion barsprings.

Rear Semi-elliptical leaf springs.

Shock Absorber Hydraulic double acting telescopic typeat front and rear.

Antiroll bar At both front and rear.

WHEELS AND TYRES

Tyres a ) LT 245 / 70 R16 113S BF

b ) 245 / 70 R16 111S ZVRL - MRF

Wheel rims 6.5 J x 16 Steel rims

No of wheels Front - 2, Rear - 2, Spare - 1

FUEL TANK

Capacity 65 litres

ELECTRICAL SYSTEM

System Voltage 12 Volts (–ve earth)

Alternator Capacity 150 Amps

Battery 12 Volts, 80A/Hr

PERFORMANCE

Max. speed at rated GVW 85kmph

Max. gradeability at rated GVW 360

WEIGHTS (KG) - Tolerances as per INTEREUROPE STVZO

Complete vehicle kerb

weight as per ISO:1176 3050 (FAW-1400,RAW-1650)

(with spare wheel & tool)

Gross Vehicle Weight 3510 (FAW-1440,RAW-2070)

Max.Permissible FAW 1440

Max.Permissible RAW 2070

Max. permissible trailer 750

capacity (Unbraked)

PASSENGER CAPACITY

Driver +5

87


VEHICLE DIMENSION

88

PRELIMINARY TROUBLESHOOTING :

(These tips are given for your guidance and preliminary jobs to be done in an emergency situation. In normal case, the

problems should be attended in an Authorized Workshop by following the repair procedures given in Workshop Manual)

PROBLEM OBSERVED CAUSE ACTION TO BE TAKEN

ENGINE

1. Engine not cranking Battery dead, • Get battery checked&/or charged

Loose or dirty battery connections • Clean and tighten battery

connections

2. Engine cranks but does not start Air in the fuel system • Press pear pump for air removal

• Check leakages

EMS fuse blown • Replace the fuse

Water sedimenter filled up • Drain water from sedimenter.

with water

3. Engine overheats Coolant level low • Top up coolant, check and

correct leakages

Hose collapse / torn • Get the hose replaced

Low engine oil level • Add oil

Radiator cap not sealing properly • Fit the radiator cap correctly

4. Charging indicator continuously Battery not getting charged • Get the belt tension adjusted

remains ‘ON’ due to loose belt drive replace belt if broken

Faulty alternator • Replace it.

Cut off relay is not working • Replace it

Preliminary Trouble Shooting

89


5. Poor pickup Loose contact of electrical • Get defect rectified.

connectors

Blocked fuel filter • Clean / replace fuel filter element

Clogged air filter • Clean / replace fuel filter element

Alternator electrical connection • Check and make proper

plug out connections

Intercooler hose collapse or loosen • Check and make proper fitment of

hose

6. Does not accelerate Accelerator pedal module defective • Get defect rectified

7. Belt squeal Loose belt • Get belt tension adjusted

Belt glazed • Get belt replacedCLUTCH

1. Clutch does not get disengaged Air in the hydraulic system • Bleed the system

Less fluid in the master cylinder • Get the clutch fluid filled

2. Clutch pedal goes too low Air in the hydraulic system • Bleed the system

Less fluid in the master cylinder • Get the clutch fluid filled

3. Clutch pedal return sluggish Blocking of vent in clutch fluid • Open the cap from the bottle

Bottle & clean the breather hole, if

Clogged


90


GEAR BOX

1. Hard gear shifting / Clutch does not disengage • Get the clutch hydraulic system

crash engagement properly attended

2. Gear shifts but vehicle 4 X 4 sensor connections loosen • Make proper sensor connections

does not move

REAR AXLE & FRONT AXLE

1. Loss of lubricant (Oil) Breather hole clogged • Clean the breather hole on the

axle housing

Differential cover gasket torn • Get replaced

Pinion oil seal damaged • Get replaced

2. Differential housing overheating Insufficient oil • Get the oil filled

Incorrect lubricant used • Drain, flush and get correct

lubricant filled

3. Noise from axle Excess play in crown wheel pinion • Adjust the play

BRAKES

1. Poor brakes Insufficient brake fluid. • Get the brake fluid filled

Air in the system • Bleed the system

Malfunction of automatic adjuster • Check & rectify auto adjuster

mechanism or replace.

Vacuum leakage • Rectify the leakage


91


Brake fluid contamination • Replace the brake fluid

Brake fluid, grease, oil or water • Replace the leaking line, bleed

on pad /drum the system. Clean pad/lining.

replace seals if leaking

Worn brake lining/pad • Get the liners/pad replaced

Excessive worn drums at rear • Replace rear drums

soft or weak hose • Check & replace

2. Spongy pedal Air in the system • Bleed the system

3. Brake pulling to one side Oil on the lining/pad • Clean the pad lining

One side shoe (pad) worn • Get the shoe pad replaced

Loose brake anchor plate • Tighten the bolts

Wheel adjustment disturbed • Adjust

Unequal tyre pressure • Adjust

One side brake pipe clogged • Get the brake line cleaned &

bleed the system

4. Brake grab Improperly adjusted parking brake • Get correctly adjusted

brake fluid container breather hole • Clean the hole on the container

clogged

No brake pedal free play/brake • Adjust brake pedal

pedal not returning fully

Defective tandem master cylinder • Replace/rectify tandem master

cylinder


92


Brake fluid contamination • Replace brake fluid along with tandem

master cylinder and wheel cylinder.

5. Brake Squeal Defective brake lining/pad • Replace

Glazed lining/pad • Clean or replace lining/pad

Loose rivets • Install rivets properly

Wrong lining/pad • Install correct lining/pad

Shoe return spring broken • Replace

Front pads / Antisqueal shims • Get corrected

rubbing on the disc

STEERING SYSTEM

1. Hard steering Less fluid in the power steering • Get the fluid topped up to

tank correct level

Air in the system • Get the air removed by bleeding

the system

Loose pump belt • Get the belt correctly adjusted

2. One side vehicle pulling Improper wheel alignment • Set proper wheel alignment

Improper tyre inflation pressure • Set proper inflation pressure


93


ELECTRICAL & AIR CONDITIONING

1. No lights on the dash board after Battery terminal got disconnected • Get the battery properly connected

turning on the ignition key Battery completely dead • Get the battery charged

• Get the alternator & charging circuit

checked

• Check battery cut off switch, make it

ON if it is OFF

• Check for parking lamp fuse

2. Non functioning electrical Blown fuse in the circuit • Replace the fuse if blown

accessories such as power

windows, head lamps, fuel Loose connectors • Get the connection properly tightened

tank flap, wiper and washer etc Circuit relay loose the mounting • Tighten the relay correctly

Defective components • Get the defective component

replaced from Authorized workshop

AIR CONDITIONING

1. Fan motor does not operate Blown fuse • Replace fuse and correct any

wiring short

Faulty connection • Properly connect poor connections

Faulty motor • Replace motor if no conductance

Faulty or poor • Replace resistor block if defective

connection at resistor

Faulty fan switch • Replace switch


94


2. Motor operates but air flow Obstruction at evaporator inlet • Clean evaporator

is minimum Air leak • Correctly seal

Faulty thermostat • Adjust or replace thermostat

3. Insufficient cooling, Air flow Incorrect refrigerant quantity or • Get the defect rectified at nearest

normal and compress operating or defect in system aggregates authorized service centre

or defective thermosensor

4. Demist or defrost not working Loose electrical connections • Get proper connections

WIPERS

1. Narrow streaks are left on the Foreign matter has • Clean the edge of the blade. If

wind shield making it hard to see attached to the blade or streaks still appear, replace the blade

edge of the blade is worn out.

2. The wiper blade jumps across No proper contact of wiper blade • Clean the wind shield. If jumping

the windshield and makes a lot with wind shield glass and wiper persists replace the blade.

f noise (Un-smooth operation) blade does not move smoothly

across the surface but vibrates,

noisily and bounces.

3. The wipe leaves large un-wiped Rubber deformed • Replace the blade

spots.

4. The blade does not contact with Deformed wiper blade / arm • Replace wiper blade / arm

the wind shield surface evenly,

leaving a large un-wiped surface.


95


WHEELS AND TYRES

1. Excessive tyre wear Disturbed steering geometry • Adjust steering geometry

Improper inflation pressure • Check and set proper inflation

pressure


96

Lubrication points

Lubrication points : The lubrication points listed below

and shown on next page require greasing or an oil

level check and topping up.

NOTE : Grease nipples must be carefully cleaned prior to

greasing and the same applies to grease cups/screw plugs

before they are unscrewed.

* During Overhauls

No. Description Grease / oil

1. Engine Oil level

2. Front hub Pack grease

3. Front Axle C.V. Joint Pack grease

4. Power steering tank Oil level

5. Steering spindle and sleeve 1 Grease nipple

6. Transfer case Oil level

7. Propeller shaft (Rear yoke) 1 Grease nipple

8. Rear axle Oil level

9. Rear hub Pack grease

10. Front Propeller shaft Rear yokes 1 Grease nipple

11. Gear box Oil level

12. Rear spring suspension Rear 4 grease nipples

13. Rear spring suspension Front 2 Grease nipples

97

Lubrication points (4x4 vehicle)

LUBRICATION POINTS

98

1. The vehicle has been built to give you thousands

of kilometres of economical and trouble-free

performance. This is however, possible only if this

vehicle is systematically maintained and operated

strictly according to the instructions contained in

this book.

2. This chapter contains charts showing lubrication

points and the lubrication & maintenance schedule.

3. Besides the lubrication & maintenance schedule

chart detailing the service operations to be

performed, free PDI Coupon (perforated) is

incorporated on one sheet. This coupon should be

detached and sent to Customer Support,Passenger Car Division, Tata Motors Limited,Survey No. 15 & 15 A, PCNTDA, KD-03, Chikhali,Pune - 410501 by the servicing dealer after the

service is performed. The servicing dealer should

fill up details of chassis particulars on the inside

cover page.

4. The vehicle is entitled to pre-delivery service with

free labour.

5. It is an important condition of our policy thatno warranty claims shall be entertained by us

unless all services upto the time of the claimarising have been performed on the vehicle.

Failure to carry out the services listed in this book

can cause considerable damage to the vehicle and

inconvenience to you. It is, therefore, in your own

interest to get the vehicle serviced as per schedule.

6. For any technical advice concerning your vehicle,

please contact the nearest Authorised Dealer or

our Customer Support Representative or write to :

Customer Support,Passenger Car Division,Tata Motors Limited,Survey No. 15 & 15 A, PCNTDA,KD-03, Chikhali, Pune - 410501

While washing the vehicle with water hose, cover up

head lamps and other electrical items and gauges to

avoid ingress of water.

Special instructions

99

LUBRICATION & MAINTENANCE SCHEDULE

Service Operations to be performed by Driver

GENERAL

1. Check engine oil level in sump, Top up, if necessary. Daily

2. Check coolant level in auxiliary tank, top-up, if Daily

necessary with mixture of clean soft water and

recommended anti-freeze additive in specified ratio.

3 Check and get rectified leakage of oil, fuel, brake Weekly

fluid and coolant, if any.

4 Check tyre pressure. Inflate tyres to specified Weekly

pressure, if necessary.

5 Check level of brake fluid in containers, top up, Monthly

if necessary.

6 Grease with grease gun : Monthly

(Where grease nipple is provided).

Tie rod ball joints, Draglink ball joints, Idler arm ball

joints, front & Rear spring pins, Propeller shaft &

steering spindle

7 Check the performance of brakes by applying & Monthly

releasing, when engine is running. Get it adjusted

from Authorized Workshop if required.

8 Check oil level in power steering tank & top up if Monthly

necessary

9 Check headlamps, gauges & instruments for proper Daily

functioning. Get it rectified if necessary

10 Check exhaust system. Get it rectified, if necessary. Monthly

11 Check condition of wiper blades for crack damage, Daily

etc. replace if necessary.

12 Clean the vehicle from inside & outside Monthly

Note : Do not wash DICOR system components

with forced water

13 Check Air Filter service indicator. If RED BAND Daily

appears, clean the filter cartridge. Replace filter

element when service indicator shows red band

even after cleaning the filter element.

14 Wheel balancing Whenever tyre is

removed from wheel rim.

15 Wheel alignment (Steering geometry) must be done. Monthly 10000 km

on road

5,000 km

off road

16 Check water level in windscreen washer container Daily

& top up if necessary

17 Lubricate all grease nipples Monthly 10,000

18 Tighten all fasteners: front grill, & fuel lines, engine, Monthly 10,000radiator mtg., radiator hose, turbocharger mounting,inter cooler mounting fasteners turbocharger hoseconnections/its mountings & inter-cooler hoseconnection / its mountings prop. shaft centre bearing.bracket / mounting bolts, U-bolts & nuts of springs,joints of pitman arm, tie rods, steering gear box &its mtg. bracket, vacuum & hydraulic line connections,head lamp mtg., wheel mtg. nuts, drivers cab seatsmountings, axle shaft mtg., anti roll bar mtg.,vacuumbooster & tandem master cylinder mountings, rear anchor plate mtg., , fuel tank mtgs.

OPERATION FREQUENCY IN

DURATION

FREQUENCY IN

KMOPERATION FREQUENCY IN

DURATION

FREQUENCY IN

KM

100


Service Operations to be performed at Workshop

ENGINE

1 Change coolant in cooling system 2 years 40,000

2 Change engine oil & oil filter cartridge 6 months 10,000

3 Change water sedimenter 2 years 50,000

5 Drain water in sedimenter / Fuel filter 5000

Whenever umbrella shape lamp glows

6 Change fuel filter 1 Years 20000

7 Cooling and heater: check & rectify hoses for clog Monthly

and damage (radiator & condenser fins blocking due

to dirt / dust etc.)

8 Check alternator belt and A/C compressor belt adjust 6 Months 10,000

tension if required, change if damaged

9 Change / replace all drive belts 2 years 40,000

10 Replace air cleaner element

1 year for normal operation, 6 months for Dusty

roads10,000 for normal operation, 5000 for Dusty

roads

11 Check & adjust tappet clearance 1 year 10,000

12 Inspect vacuum hose connection and rectify if Monthly 5,000

necessary

13 Change / replace all vacuum hoses 2 years 40,000

14 Check Turbo charger hose & Rectify if necessary Monthly 5,000

15 Check & ensure normal working of engine using 5,000

diagnostic equipment ( Whenever check engine

lamp glows on OR at every vehicle servicing)

LOW PRESSURE FUEL SYSTEM

1 Check low pressure fuel lines for leakage & rectify 6 months 5,000

2 Clean strainer in fuel tank 1 Year 10,000

3 Remove drain plug fuel tank and drain off sediments 1 Year 40,000

BRAKES

1 Check level of brake fluid in containers, top up Daily

if necessary

2 Check service & parking brakes, adjust if necessary 3 Months 5,000

3 Check front brake & rear brake linings, Replace if 6 Months 15,000

necessary

4 Change brake fluid in the brake system and bleed 1 years 20,000

the system

5 Overhaul the vacuum booster assembly using 1 years 30,000

recommended repair kit and diaphragm.

6 Dismantle, clean, inspect and re-assemble tandam 1 years 30,000

master cylinder of brake system.

GEAR BOX

2 Check oil level in Gear Box. 3 Months 5,000

3 Change oil in the Gear Box. 1 year 15,000

4 Check and Clean breather on Gear box 1 year 15,000

TRANSFER CASE

1 Check oil level in transfer case, top up if necessary 3 Months 5,000

2 Change oil in transfer case (First 10,000 km) 1 year 45,000

4 Check & tighten if necessary, transfer case mounting 6 months 5,000

screw

OPERATION FREQUENCY IN

DURATION

FREQUENCY IN

KMOPERATION FREQUENCY IN

DURATION

FREQUENCY IN

KM

101


LIVE FRONT AND REAR AXLE

1 Check oil level in live front axle and live rear axle, 3 Months 5,000top up if necessary

2 Change oil in live Front axle & Rear axle (FIRST 10,000) 1 years 15,000

3 Change grease in front hubs & adjust bearing play 1 years 30,000Replace damaged / worn parts.

4 Clean breather on live front axle and rear axle. 6 months

POWER STEERING & SUSPENSION

1 Check and tighten if nessary. “U” joints on steering 6 monthsspindle. Steering gear box and mounting bracketbolts joints of pitman arm, drag link and tie rod.

2 Check & adjust steering wheel free play 6 months

3 Check oil level in P.S. tank & top up if neccessary. 3 months 5,000

4 Change oil in steering gear box. 2 years 30,000

5 Check belt tension & adjust if necessary 6 Months 10,000

6 Check condition of rubber bushes of a) Anti-roll bar 1 Year 30,000b) Upper wish bone c) Lower wish bone

7 Check tightening torque of suspension fasteners 5,000

ELECTRICALS

1 Check battery voltage, charge the battery externally Weeklyif necessory

2 Apply graphite grease on starter motor pinion bushing 6 months 15,000

3 Grease the wiper motor linkages 6 months 15,000

CAB

1 Apply grease on door latches, door lock striker, bonnet Monthlyopening lever, lock plate tail gate hinges & door lockinner ratchet

WHEELS & TYRES

1 Tyre rotation. 6 Monthly 5,000

AIR CONDITIONING SYSTEM (wherever fitted)

1 Check torque of bolts on brackets & AC compressor Monthly

2 Check compressor belt, adjust tension, Replace if Monthlynecessary.

3 Check bubbles in receiver drier for refrigerant level Monthly

4 Check for leak of gas / oil from pipes, joints, Monthlycompressor shaft seal & cylinder head

5 Clean condenser with high pressure water Monthly

6 Check fan speeds for proper air flow Monthly

7 Check system pressure with gauges. Recharge if Monthlynecessary

8 Clean evaporator from its face to remove dust, Monthlyforeign objects etc.

9 Replace AC compressor belt 2 Years 45,000

HEATING / DEMISTING SYSTEM

1 Check hose joints of heating system for leakage. MonthlyTighten if necessary

2 Check hoses of heating system for cracks. Replace Monthly if required

3 Check blower for proper functioning. Check fuse. MonthlyReplace if found blown.

RUBBER / NYLON HOSES & FLEXIBLE PIPES

1 Check hoses & pipes of air / fuel / coolant / brake / 1 yearclutch / air conditioning / wind screen washing system for joint tightness and damage. Replace, if necessary.

OPERATION FREQUENCY

IN DURATION

FREQUENCY

IN KMOPERATION FREQUENCY IN

IN DURATION

FREQUENCY

IN KM

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

smg18991

Rectangle

102

Record of services performed Chassis No................................

Recommended Odometer Repair Servicing Dealer's

Service Date reading Order Signature and

Km. No. Stamp

At Km.

PDI

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000



Km. No. Stamp

45,000

50,000

55,000

60,000

65,000

70,000

75,000

80,000

85,000

90,000

103

Record of services performed Chassis No................................



Km. No. Stamp

95,000

1,00,000

1,05,000

1,10,000

1,15,000

1,20,000

1,25,000

1,30,000

1,35,000

1,40,000



Km. No. Stamp

1,45,000

1,50,000

1,55,000

1,60,000

1,65,000

1,70,000

1,75,000

1,80,000

1,85,000

1,90,000

104

Record of repairs carried out Chassis No................................

DateOdometer Repair

Particulars of Repair Servicing Dealer's Signature & Stampreading (km) Order No.

105

Record of repairs carried out Chassis No................................

DateOdometer Repair

Particulars of Repair Servicing Dealer's Signature & Stampreading (km) Order No.

106

AC Air conditioning

ACC Accessories

Amp Ampere

Br Branch

Brg Bearing

cc Cubic centimeter

Cm Centimeter

Dia Diagonal

EGR Exhaust Gas Recirculation

FAW Front Axle Weight

Fig Figure

FIP Fuel Injection Pump

gm Gram

GVW Cross Vehicle Weight

IGN Ignition

Kg Kilogram

km Kilometer

Km/h Kilometer per hour

LH Left Hand

Max Maximum

Min Minimum

mkg Meter per Kilogram

mm Milimeter

Mtg Mounting

No Number

PDI Pre-delivery Inspection

PSI Pounds per Square Inch

PUC Pollution Under Control

RAW Rear Axle Weight

RCSM Regional Customer Support

Manager

RH Right Hand

RM Regional Manager

RPM Revolution Per Minute

Sec Seconds

Sq. cm. Square Centimeter

TASC Tata Motors Authorised

Service Centre

TASP Tata Motors Authorised

Service Point

V Volts

W Watts

Wt Weight

ABBREVIATIONS

107

PDIFREE

LABOURL -

TATA SUMO 4X4 ARMOURED

At the time of delivery of vehicle please ensure that

Pre-delivery inspection has been carried out as per details

given in the SERVICE SCHEDULE.

Chassis No. ..................................

Engine No. ....................................

Gear Box No. ................................

WORK DONE TO MY SATISFACTION

Sig. of customer .......................................

Speedo Reading ....................................... Km. seal O.K. / Broken

R.O. No. ........................................................... Date .....................................

Dealer's / Authorised Service Centre's

Stamp & Signature ...................................................................................

tata sumo light bullet proof vehicle 4x4

Documents

aggregate serial mumbers

strong household detergents

tandem master cylinder

front tow hook

registration plate lamp

avoid sudden braking

paper filter element

red band appears