GMI-248

DIRECTOR GENERAL BORDER ROADS

GENERAL MAINTENANCE INSTRUCTION NO. 248

ON OPERATION AND MAINTENANCE OF

MEDIUM RECOVERY VEHICLE 4X4 STALLION ASHOK LEYLAND

INTRODUCTION:-

(a)                   Medium Recovery Veh Model Stallion 4x4 Make Ashok Leyland Chassis having Wheel base 4200 mm fitted with Ashok Leyland HA57L135/5 model BSIII norms diesel engine developing 135 kW at 2400 rpm, 6 speed synchromesh gear box including one over drive speed and power steering with Wrecker Equipment.

(b)                   This GMI gives the technical specification and know how on the operation, maintenance and repair procedure of aggregates of model vehicles, to ensure maximum performance and safe/satisfactory operation. Assuming that the technicians in the workshop are fully conversant with the repair and maintenance practices of commercial vehicles in general, the repair procedures out lined in this GMI emphasizes the special features of this product. Compliance with procedures given in this GMI will enable to desire the maximum service from the Ashok Leyland diesel vehicles.

(c)                   To prolong the life of Medium Recovery Veh Model Stallion 4x4, to prevent frequent break downs and to reduce maintenance cost, the periodic maintenance must be carried out according to the ‘Periodic Maintenance Schedule’ described in this GMI. Periodic Maintenance is essential for preventing troubles and accidents to ensure satisfaction and safety. Daily care and inspection is also essential for prolonging the operating life of the vehicle and for safe driving. It also reduces the wear and tear on the vehicle, prolongs its life, give more mileage, failure of the guide lines given below can result in personal injury or serious damage to the vehicle. All information and instruction in the GMI is based on the latest owner’s manual and service booklet.

AIM:-     The instructions are issued as guidelines for schedule of preventive maintenance, lubrication of Medium Recovery Veh Model Stallion 4x4 manufactured by M/s Ashok Leyland Ltd for regular attention to keep the vehicle in good mechanical condition which must be strictly followed.

ACTION BY:-

a)	User unit:     To carryout periodic inspection and monitor regular/periodical Maintenance as laid down in this instruction and to record the tasks done in log book.
b)	Field Workshop:
	i)	To carryout and monitor maintenance schedule and oil changes as per periodical maintenance laid down in the maintenance instruction and to check the record of maintenance including lubrication.
	ii)	To advise the user unit in respect of any lapse noticed.
c)	Mobile Maintenance Team:    To ensure that proper maintenance is carried out and submit report accordingly to Task Force Commander and OC Wksp for their necessary action.

DETAILS:-

This instruction includes the following aspects:-

	Operating Procedure – DO’s and Don’ts.	Appendix  ‘A’
	Periodic Maintenance schedule .	Appendix  ‘B’
	Technical Specification.	Appendix  ‘C’
	Recommended Lubricants/Filling Capacities/ Tyre Pressure chart.	Appendix ‘D’

          

                                                                                                           (M B Negi)

                                                                                                           EE (E&M) SG

                                                                                                           Joint Director (Tech)

                                                                                                           For Dir Gen Border Roads

                                                                                                          

                                                                                                                                   Appendix ‘A’

OPERATING PROCEDURE

Electronic Diesel control system (EDC)

1.      Electronic Diesel Control system (EDC) is provided to meet the demands of lowering of harmful exhaust gas emissions keeping in view the importance on fuel injection and engine management system with regard to the following:-

a)	High fuel injection line pressure.
b)	Water/coolant temperature dependant fuel quantity delivery for starting.
c)	Control of close idling speed
d)	Determined fuel quantity and timing in engine start phase to suit geographical/climatic conditions.
e)	Integral timing function adjusting start of delivery as a function of engine speed to meet the emission norms.
f)	Regulated fuel quantity in reference to load and engine speed.
g)	Metered fuel quantity to control and maintain free acceleration smoke.

2.      In Electronic Diesel Control system (EDC), the driver has no direct control over the injected fuel quantity through the accelerator pedal. EDC system is also capable of data exchange with other electronic systems such as Automatic transmission through CAN. (Control Area Network).

3.      EDC system is sub divided into the following:

        

a)	Sensors – Detects the eng operating conditions and the driver’s demand. They convert physical variables in to electrical signals.
b)	Electronic Control unit (ECU) – Processes the information received from the sensors. It controls the actuators through electrical output signals. It also provides interfaces with other systems like diagnostic tool, ABS etc.
c)	Actuators – Convert the electrical signal from the ECU in to physical variable.

4.      Benefits of Turbo charging:

a)	Lower fuel consumption.
b)	Lower emission.
c)	Better Torque characteristics.
d)	Lower weight and a smaller engine package.
e)	Lower engine noise.
f)	Altitude compensating.

Dual Brake system

5.      The Dual Brake system is a split system of Air brakes to actuate front and rear foundation brakes separately/ independently, thereby ensuring partial braking for the veh, in case of failure in air system in any of these circuits (front or rear). Advantages of Dual brake system are as under:-

        

a)	Ensures better safety.
b)	Doubles the reliability of the brake system.
c)	Response time is reduced (viz) reduced stopping distance and reduced stopping time.
d)	Increased reservoir capacity:
	i)	More number of safe brake applications.
	ii)	Better condensation of water and oil.
	iii)	Ensures supply of clean dry air to brake valve and Brake chamber.
	iv)	Hence, increased life of brake system components.
e)	Pneumatic system is split in to independent sub systems.
	i)	Front axle brake system.
	ii)	Rear axle brake system.
	iii)	Spring actuated mechanical hand brake system.
	iv)	Auxiliary system.
f)	Provides a third braking system available to the driver even in the unlikely event of failure of both the primary and secondary brakes.
g)	There is no panic situation for the driver. Safe braking is always available under his foot pedal.
h)	Provides for spring actuated mechanical hand brakes. This can hold the veh in a gradient of 270. This also provides for safer surer hand brake in the place of conventional mechanical hand brake.
j)	Auxiliary equipments like Air horns are isolated from the main brake system, which ensures better safety. Failure in auxiliary system can not affect main system.
k)	Low pressure warning switches are provided in each circuit, which indicates to the driver the failure in any of the sub-system.

6.      Advantages of Diaphragm Clutch:

a)	Reduced clutch pedal effort.
b)	Optimum clamping load maintained regardless of wear on clutch disc.
c)	Uniform clamping load over facing.
d)	Diaphragm spring unaffected by centrifugal forces as in the case of coil springs.
e)	Compact and fewer parts.
f)	Better dynamic balance due to rotational symmetry.
g)	High fatigue life of diaphragm spring.

Do’s

1.	Check for engine oil pressure at engine idling condition minimum oil pressure should be 1.0 kg/Cm2.
2.	Idle the engine for 2 minutes after starting the engine.
3.	Idle the engine for 2 minutes before switching off the engine.
4.	Periodic cleaning of crank case breather is necessary to allow free flow of oil from turbo charger outlet.
5.	Before applying the exhaust brake, change to appropriate gears suitable to the vehicle speed and road condition.
6.	While exhaust brake is in use remove the leg from the accelerator pedal for reducing the fuel supply and engine speed.
7.	Service brake can be used in conjunction with the exhaust brake. Check for air and exhaust leaks and arrest suitably for ensuring efficient operation.
8.	Exhaust brake to be used only during downhill operation.
9.	Always use approved lubricants as recommended.
10.	Ensure Clutch pedal free play between 4 to 7 mm.
11.	Fleet guard fuel filtering system consists of a strainer (fitted before feed pump) and a fuel filter cum water separator. (fitted at pressure side before FIP).
12.	Drain cock provided in water separator should be hand tightened fully. Never use any spanner for rotating the drain cock.
13.	Check fan belt tension at regular intervals and adjust as needed. Check for any abnormal wear and damage in pulleys/belt including pulley alignment.
14.	Replace the fan belt if it is frayed or pieces of material missing or longitudinal cracks intersect with transverse cracks.
15.	Remove dust deposit weekly by squeezing the dust evacuator valve provided in dry type air cleaner and dust evacuator valve also be replaced immediately if it is torn, cracked, remains open or missing.
16.	Always use recommended radiator pressure cap to avoid leakage.
17.	Always refill the radiator with recommended coolant.
18.	After long storage before starting the engine, fill-up the oil feed hole of the turbocharger with clean engine oil to ensure lubrication during start-up.
19.	Sump heater and Flange heater should be operated only during sub-zero temperature operation. The extent of duration that these should be kept on will depend on the actual sub zero ambient temperature experienced.
20.	Turbocharger needs CLEAN ENGINE OIL and CLEAN AIR (from the Air Filter) for its proper functioning and durability.

Don’ts

1.	Do not run the engine with low oil pressure and low oil level.
2.	Do not put the engine under full load immediately after starting.
3.	Do not switch off the engine under full load/through gears.
4.	Do not run the engine with blocked, punctured, aged, deformed hose/ pipe connections from the air cleaner to the turbo charger and turbo charger to the inlet manifold.
5.	Do not open / repair the turbo charger, contact authorized service centre.
6.	Do not accelerate the engine immediately after start. Idle the engine for at least two minutes after start and before the engine is stopped.
7.	Do not depress the clutch after applying the exhaust brake as this will make the exhaust brake ineffective.
8.	Do not press the accelerator pedal after applying the exhaust brake.
9.	Do not allow exceeding the recommended speeds for respective gears after applying the exhaust brake.
10.	Never raise engine speed with exhaust brake applied during actual driving.
11.	Do not continuously operate the starter motor for more than 10 seconds at a time. Wait for 30-60 seconds before trying again.
12.	Do not over tension the Belt and do not apply oil/grease or paint on pulley grooves.
13.	Do not start the engine when the air cleaner indicator shows ‘RED BAND’. Clean air cleaner and start.
14.	Never operate the engine, if the restriction indicator is either broken or missing.
15.	Do not open the oil separator cap as there is no serviceable path inside is available.
16.	Never open the pressure cap when the radiator is hot.
17.	Do not park/leave the veh with ignition switch in ‘ON’ position.

                                                                                                       

                                                                                                                                    Appendix ‘B’

PERIODIC MAINTENANCE SCHEDULE

S/ No	Operation	Daily	Weekly	Every Kms					Remarks
				1000	5000	10000	20000	30000
A	ENGINE
1	Check and tighten Cylinder head bolt.					*
2	Check and adjust valve clearance .					*
3	Check Compression pressure.						*
4	Check engine mounting front and rear/other  peripheral bolts and tighten if necessary .				*
5	Check engine oil level and top up if required.	*
6	Change engine oil and oil filter element.					*			Every 5000 Kms for HAA/Desert area.
7	Clean oil cooler.								During every O/H.
8	Check fan belt tension and adjust if necessary.		*
9	Check coolant level and top up if required.	*
10	Check fan mounting bolt tightness and tighten if necessary.			*
11	Check water pump bearing for abnormal sound.					*
12	Drain Cooling system, clean and fill recommended coolant.							*
13	Replace rubber hose for coolant pump.								As required.
14	Check injection timing and fuel feed pump operation.					*
15	Replace fuel inline strainer and fuel cum water separator.					*
16	Adjust fuel injector  nozzle pressure.					*
17	Clean fuel feed pump strainer.					*
18	Injection pump assy for O/H.							*
19	Clean fuel tank strainer.						*
20	Replace fuel hose.							*	Every 2 years.
21	Check intake and exhaust manifold mounting nut tightness and tighten if necessary.					*
22	Check and rectify exhaust gas leakage at silencer and exhaust pipe.			*
23	Check exhaust pipe mounting  and tighten if necessary.			*
24	Clean Air cleaner primary element.								If Restriction Indicator shows Red band.
25	Replace Air cleaner primary element.								After 2 consecutive cleaning.
26	Replace Air cleaner safety element.								At the time of 3rd replacement of primary element.
	EDC (Electronic Diesel Control)
27	Check tightness of mating connectors &  engine speed sensor and clean.				*
28	Check function of EDC & sensors with diagnostic tool.							*
B	CLUTCH
1	Lubricate clutch operating pedal shaft, clutch withdrawal lever and clutch withdrawal bearing.		*
2	Check clutch pedal free play to 5 mm.		*
3	Check oil level in reservoir and top up.				*
4	Change oil in clutch reservoir.								Every 40000 km.
5	Check clutch disc wear.					*
C	GEAR BOX AND AUX GEAR BOX
1	Check oil level & top up if necessary.		*
2	Change oil when hot. Refill to correct level.						*		Every 1 year.
3	Check and replace reaction rod ball joints.							*
4	Check and tighten all mounting bolts of gear box and auxiliary gear box.		*
5	Clean and re fit breather of gear box and auxiliary gear box.				*
D	PROPELLER SHAFT
1	Lubricate UJ Cross, Propeller shaft splines and tightness of propeller shaft bolts.		*
E	REAR AXLE
1	Check oil level and top up if necessary.		*
2	Check the tightness of axle  shaft nuts and drive head.		*
3	Repack the hub with recommended grease and adjust hub end play.					*
4	Change oil when hot. Refill to correct level.						*		Every 1 year.
5	Check and adjust end play of hub if necessary.				*
6	Check and adjust preload.						*
7	Clean the breather.				*
F	FRONT AXLE
1	Check oil level and top up if necessary.		*
2	Check the tightness of drive head.		*
3	Repack the hub with recommended grease and adjust hub end play.					*
4	Change oil when hot. refill to correct level.						*		Every 1 year.
5	Check and adjust wheel alignment if necessary  and check max cut.				*
6	Check and adjust preload.						*
7	Lubricate track rod ball joints.		*
8	Drag link socket to be preloaded.						*
9	Socket assy to be replaced.								Replace socket at 40000 km.
G	OTHER ITEMS
1	Lubricate brake wedges on front axle and ‘S’ camshaft on rear axle.				*
2	Check brake liner for wear and replace if necessary.					*
H	STEERING GEAR
1	Check oil level in reservoir and top up if required.				*
2	Lubricate drag link ball joints.				*
3	Check steering mounting bolts/ nuts.				*
4	Change Hyd oil and filter cartridge.							*	Every 1 year.
J	SUSPENSION
1	Lubricate front and rear spring shackle pins.			*
K	CHASSIS
1	Check the chassis cross members and side members for loose bolts or rivets and tighten.				*
L	CABIN
1	Replace cabin mounting bush.							*	Every 2 year.
M	MISC
1	Check  tyre pressure and inflate.		*
2	Check battery electrolyte level  and top up if required.		*
3	Check tightness of all clips/clamps of hoses and tighten if required.				*

PERIODIC MAINTENANCE SCHEDULE

S/ No	Operation	Daily	Weekly	Monthly	Once in
					3 Months	6 Months	a year
N	BRAKE SYSTEM
1	Check mounting bolts/nuts for tightness and tighten if required.				*
2	Check for air leakage in all the  lines, joints and assys.	*
	Single Cylinder compressor
3	Check inlet hose for deterioration and renew, if required.			*
4	Check Compressor performance and go for overhaul, if required (Build up time at 1600 rpm: 6 minutes. (Max) for 65 ltrs, 10 minutes (Max) for 100 ltrs. If exceeds the limit, then unit requires O/H)				*
5	Clean Cylinder head and decarbonise Inlet/Delivery pipe lines. O/H using cylinder head repair kit.						*
	Air Dryer
6	Check for moisture/water collection in the reservoir. If water collection is noticed, replace the Desiccant cartridge.			*
7	Check for performance. Pressure differential should not exceed 1.3 bar.				*
	Quadruple system protection valve
8	Check the gaiter condition and replace, if necessary.				*
9	Drain sensing tank and watch for pressure drop in the gauges to detect Non return valve leak.					*
	Reservoir
10	Drain the reservoirs and check for moisture/water collection in the reservoir. If water collection is noticed, replace the Desiccant cartridge in Air Dryer.			*
	Dual Brake Valve
11	Check for free movement of the plunger.			*
12	Check gaiter for damage/deterioration, replace Gaiter if necessary.				*
	R6 Relay valve & Trailer control valve
13	Apply and release the brakes and check for free exhaust. Check for performance.				*
	Load sensing valve
14	Check and adjust the setting  angle.						*
	Wedge brake actuator
15	Check for uniform application and release of brakes.			*
	Spring brake actuator
16	Lubricate Fork and pin.  Check for free movement of push rod  by applying  and releasing brakes.			*
17	Check the condition of breather tube and ensure clips are secured properly at both ends.				*
	Quick Release valve (Diaphragm)
18	Check for uniform exhaust by applying and releasing brakes.			*
	Slack Adjuster
19	Lubricate using recommended grease.		*
20	Apply the Brakes and check for the angle between the arm and push rod is 900. Adjust the brakes if required and ensure the angle is 900.			*
	Graduated hand control valve
21	Check lever for proper locking in brakes ‘ON/OFF’ positions.				*
22	Check Gaiter and Knob for damage and replace if required.					*
	Shut off Cock
23	Check for proper operation of the valve.				*
24	Check for blockage of vent hole. (if applicable)					*
	Palm coupling
25	Replace the rubber sealing ring.						*
	Exhaust Brake assy
26	Lubricate the linkages and check slackness.			*
27	Check performance and free movement of Butterfly valve.				*
	Brake Chamber
28	Lubricate Fork and pin. Check for free movement of push rod by applying and releasing the brakes.			*
	Low Pressure Indicator switch
29	Check for proper working of Beeper.	*
	Stop light switch
30	Check for proper working of stop lights.	*
	Hose assy
31	Check for crack/deterioration/rubbing marks.				*

Note:

a)      Overhaul the all above units of Brake system using recommended repair kits and replacement of Desiccant cartridge in the Air Dryer once in two years.

b)      Ensure that the angle between the push rod and the slack adjuster is 90⁰ or + 5⁰ and – 0⁰, if the angle is less than 90⁰ then the push rod travel is more and needs immediate adjustment of brakes.

c)      While overhauling Exhaust Brake assy, the foot control valve/Air exhaust brake valve/magnetic valve also must be overhauled to ensure trouble free operation of exhaust brake system.

d)      Do not lubricate the pivot pin joints in the housing of butterfly valve shaft and the bushes.

Appendix ‘C’

TECHNICAL SPECIFICATION

Description	:		Stallion 4x4 MRV BS III.
Engine
Model.	:		HA57L135/5.
Type.	:		Diesel 4 stroke, 6 cylinder water cooled, direct injection, in line overhead valve, Turbocharged with inter cooler.
Maximum output.	:		135 KW @ 2400 rpm.
Maximum torque.	:		66 kgm (660 Nm) @ 1600-1800 rpm.
Bore x Stroke.	:		104 x 113 mm.
Displacement.	:		5.76 ltrs.
Compression ratio.	:		17.5 +0.5 : 1.
Firing Order.	:		1-4-2-6-3-5.
Direction of Rotation.	:		Counter clockwise viewed from fly wheel.
Compression Pressure.	:		Maximum - 29 – 32 kg/cm2 @ 280 rpm. Minimum - 24 kg/cm2 @ 280 rpm.
Idling revolution.	:		600 + 50 rpm.
Engine weight. (with oil)	:		530 kg.
Cold starting aids.	:		Flange heater and sump heater.
Turbocharger.	:		With wastegate, Make TEL.
Fuel Injection pump.	:		BOSCH  Model VP37 Rotary Type (Distributor), Electronic Control unit – EDC 15VM + 2.V9.
Injector Nozzle opening Pressure.	:		270 – 278 bar.
Injection timing.	:		0.6 mm  + 0.02 mm plunger lift at TDC with No 1 cylinder at compression stroke.
Injection Nozzle type.	:		Multi hole Nozzle. (first Injector NBF)
Tappet/Valve clearance (when cold)
Intake.	:		0.30 mm (0.012”)
Exhaust.	:		0.45 mm (0.018”)
Valve Timing
Intake opens.	:		310 before TDC.
Intake closes.	:		430 after BDC.
Exhaust opens.	:		710 before BDC.
Exhaust closes.	:		290 after TDC.
Lubrication  System
Eng oil pump type and Drive.	:		Full forced pressure feed by gear pump and drive by timing gear.
Eng oil Cooler.	:		Multi plates type (No. of Plates-8), Water cooled.
Maximum Eng oil pressure.	:		4.5/4.8 kg/Cm2 at full load. 1.2/1.6 kg/Cm2 at Eng idling.
Minimum Eng oil pressure.	:		1.0 kg/Cm2 at Eng idling.
Cooling  System
Coolant pump type and Drive.	:		Forced circulation by volute pump, 55 mm dia ball and roller bearing and drive by Poly V-belt, Impeller diameter – 100 mm.
Thermostat.	:		Twin thermostat, wax type, bottom by pass system, opens at 820 + 20C.
Maximum cooling temperature permissible.	:		950C.
Clutch
Make.	:		Amalgamations Valceo /Luk India.
Type.	:		Single plate dry type Diaphragm clutch- Hydraulically operated.
Outside diameter.	:		383 mm.
Inside diameter.	:		220 mm.
Clutch  face thickness with load.	:		10 mm.
No. of Rivets.	:		36.
Clutch Booster.	:		Make - Wabco TVS/Brakes India. Stroke 85 mm, Type 3”  version.
Gear Box Main.	:		Make - Ashok Leyland Ltd.
Model, Type.	:		ZF S6-36 MK II, Synchromesh type.
No. of gears.	:		6 forward and 1 reverse.
Gear Ratios. (Forward)
1st	:		6.93 : 1
2nd	:		4.43 : 1
3rd	:		2.63 : 1
4th	:		1.51 : 1
5th	:		1 : 1
Over drive.	:		0.84 : 1
Reverse.	:		6.22 : 1
PTO output speed ratio.	:		1.05 : 1
PTO operation.	:		Electro pneumatic switch operated from driver’s cabin.
Gear Box Auxiliary	:		Make – Ashok Leyland Ltd.
Ratios.	:		High – 1:1, Low – 2.15:1
Operation.	:		Electro pneumatic switch operated from driver’s cabin.
Propeller Shaft
Gear Box to Auxiliary Gear Box.	:		1600 Series.
Auxiliary Gear Box to Front axle.	:		1600 Series.
Auxiliary Gear Box to Rear axle.	:		1600 Series.
Axles- Front & Rear
Make, Mode.l	:		Meritor HVS India/Ashok Leyland Ltd, Pressed banjo type- RS 145.
Type- Front.	:		Fully floating pressed type drive axle with steerable ends , Cap- 7500 Kg, Over slung.
Type- Rear.	:		Fully floating  with differential lock, Cap- 10200 Kg, Over slung.
Differential ratio.	:		6.83:1.
Suspension
Front Spring.	:		Semi elliptical  multi leaf – progressive.
Rear Spring.	:		Semi elliptical multi leaf with helper.
No. of Leaves.	:		Front – 15, Rear -  16 (main), 4 (helper), 2 (packing)
Span/length of spring eyes.	:		Front – 1650 mm, Rear – 1524 mm.
Leaf width.	:		Front – 76.2  mm, Rear - 76.2 mm.
Shock absorber Front & Rear.	:		Make – Gabriel/Hydraulics, Type - Double acting telescopic.
Wheels
Rim size.	:		B 10 x20.
Tyre size.	:		14.00 x 20, 18 PR, Qty -05 Nos.
Brakes
Service brake.	:		Make – Brakes India Ltd for Front & Meritor HVS India/ Brakes India Ltd for Rear, Type - Air Brake Dual  line.
Parking brake.	:		Pneumatic type.
Exhaust Brake.	:		Make – Wabco TVS, Type - Butterfly type actuated by air pressure.
Steering	:		ZF Power steering/Rane TRW steering.
Type.	:		Integral Power Steering.
System pressure.	:		130 bar.
Drive.	:		Engine driven.
Steering wheel diameter.	:		500 mm.
Electrical system
Battery.	:		12 V x 130 AH- Qty 02 Nos.
Alternator. (Max. output)	:		24V, 55 Amps, Make – BOSCH/LUCAS.
Starter Motor.	:		24V, Pre-engaged, Make – BOSCH/LUCAS.
Head lamp.	:		70/75W – 02 Nos.
Fog lamp.	:		70W – 02 Nos.
Revolving lamp.	:		70W – 01 No.
Pilot lamp.	:		LED, 02 Nos.
Performance data
First Gear speed. (Max)	:		11 Km/hour.
Sixth Gear speed. (Max)	:		93 Km/hour.
Reverse Gear speed .	:		12 Km/hour.
Maximum gradeability. (solo)	:		25 0.
Turning circle diameter.	:		16.7 mtr.
Braking efficiency.	:		4x4 – 43%, 4x2 – 40%.
Maximum draw bar pull.	:		7.5 Ton – 4x4 low, 4.4 Ton - 4x4 high.
Gross power to weight ratio. (solo)	:		12.6 kw/T.
Cross country towing.	:		10 Tons. (Max)
Parking Brake performance. (solo)	:		250.
Over turning angle.	:		200.
Mud Tracking.	:		430 mm.
Water wading.	:		760 mm.
Unladen weights (with wrecker Eqpt)
Front Axle.	:		6310 Kg.
Rear Axle.	:		4415 Kg.
Total.	:		10725 Kg.
Laden weight	:		4.5 Ton. Normal operation (Lift & Move)	7 Ton Limited operation*
Front Axle.	:		5125 Kg.	4020 Kg.
Rear Axle.	:		10100 Kg.	13705 Kg.
Total. (Gross vehicle weight)	:		15225 Kg.	17725 Kg.
Pay Load.	:		4500 Kg.	7000 Kg.
* With limited speed of 15 kmph on plain roads.
Major dimensions
Wheel base.		:	4200 mm.
Front overhang. (with bumper)		:	1770 mm.
Front overhang. (on chassis, without bumper)		:	1485 mm.
Rear overhang. (on vehicle)		:	1420 mm.
Rear overhang. (on chassis)		:	885 mm.
Front wheel Track.		:	2030 mm.
Rear  wheel Track.		:	2060 mm.
Angle of approach.		:	28 0.
Angle of departure.		:	33 0.
Ground clearance.		:	Front /Rear - 360 mm.
Overall length. (Max)		:	7390 mm.
Overall height. (Max)		:	3400 mm.
Overall Width. (Max)		:	2500 mm.
Superstructure Details
Crew cabin.		:	Provided behind driver’s cabin with seating bench to seat 4 people.
Wrecker Equipment.		:	Twin boom with manual slewing and having facility for manual lowering and lifting.  Manually swiveling for angular pulls
Boom specification.		:	Twin boom suitably strengthened for recovery operation.  The boom length and height will be such that it will enable lifting of major assy and suspend ‘B’ vehicles up to 7.5 Tons. On suspended tow veh causalities up to 12 Tons class. Radius of boom 4156 mm. Hook lifting capacity at a clear reach of 450 mm will be not less than 7.5 tons for each boom and with boom locked 12 tons on rear jacks.  Lift and move at minimum reach of 450 mm from rear most position of the veh, for suspended tow, with booms locked will be 4.5 ton on cross country and 7 tons for level road at 15 kmph.
Maximum rear of boom.		:	Sides – 3500mm, Rear – 450mm.
Clear lift of boom @ max reach.		:	2500 mm.
Maximum lift capacity @ max reach.		:	2.5 Ton.
Clear lift of boom @ min reach.		:	5000 mm.
Boom projection in stowed condition.		:	450 mm from rear most position of the veh.
Boom height in stowed condition.		:	3400 mm.
Angle of slew.		:	1500 for each boom.
Wrecker Platform overall dimension (including crew cabin)
Max length.		:	5470 mm.
Max width.		:	2500 mm.
Height above veh frame.		:	2025 mm.
Weight of wrecker eqpt without platform.		:	3575 Kg. (Approx)
Weight of counter weight as front bumper.		:	450 Kg.
Boom cabin size.		:	Steel 14 dia, 6 x 36 IWRC 1960, IS 2262 ; 100 mtrs long per boom.
Cable breaking capacity.		:	More than 1.75 time load lift capacity. (13900 Kg)
Safety device for over loading.		:	Slipping clutch (adjustable) set to 7.5 Ton.
Outrigger jacks .		:	Manually retractable outrigger jacks with locking arrangement.
Controls.		:	Controls for service drums will be provided on both LH and RH at the rear of the veh for ease of operation. The veh accelerator controls will also be duplicated on LH and RH at the rear of the veh.
Line Pull Switch
Quantity.		:	Qty 02 Nos.
Type.		:	Line pull type, mechanically operated and capable of exerting straight pull from rear and side of the veh.
Capacity.		:	7.5 Ttons (each winch)
Winching speed.		:	3.3 meter per minute @ 4 Ton load. (max)
Winch cable size.		:	14 mm dia.
Cable breaking capacity.		:	Not less than 1.75 times winch pull capacity.
Device for cleaning and lubrication.		:	Cleaning and manual lubrication of rope.
Swiveling search light
Type.		:	Detachable and swiveling type search lights (2 Nos) are provided, on top of Wrecker frame to cater for illumination up to 100 mtr. One more portable search light with 100 mtr cable is provided, interchangeable with Swiveling search light.
Transmission Assy
Type.		:	A suitable winch reversing transmission assy is provided for clock wise & anti clock wise simultaneously.

                                                                                                                                                

                                                                                                                                                  Appendix ‘D’

RECOMMENDED LUBRICANTS

S/No	Unit.	Ambient Temp.	IOC Grade Lubricant.
a)	Engine.	- 15 0C & above	Servo Pride XL 15W 40.
		- 30 0C & above	Servo Pride XL 10W 40.
b)	Gear Box. Synchromesh	- 15 0C & above	SAE 80W 140.
		- 30 0C to + 30 0C	SAE 75W 90.
		< 0 0C	Servo Gear HP 80W.
		> 0 0C	Servo Gear HP 90 (T).
c)	Power Steering.	--	Servo Trans Fluid ‘A’.
d)	Hydraulic Jack.	--	Servo System 68.
e)	Axles/Auxiliary Gear Box/Winch gear Box.	< 4 0C	Servo Gear Super 80W 90.
		> 4 0C	Servo Gear Super 85W 140.
f)	Clutch Master Cylinder.	--	Servo brake fluid super HD.
g)	General Chassis Lubrication.	--	Servo Grease MP. (Servo Gem RR3 for Wheel Bearings)

 Note: Do not mix two different types of oils.

FILLING CAPACITIES

S/No	Unit.	Capacity.
a)	Engine.	10.5 ltrs.
b)	Cooling System.	18.5 ltrs.
c)	Gear box Main ZF S6 36.	6.5 ltrs.
d)	Auxiliary Gear Box.	4.5 ltrs.
e)	Front Axle.	16 ltrs.
f)	Rear Axle.	16 ltrs.
g)	Power Steering.	4 ltrs.
h)	Clutch Hydraulic System/Clutch reservoir.	0.30 ltr/1.0 ltr.
j)	Fuel tank – 02 Nos.	160 ltrs each.

TYRE PRESSURE CHART

Tyre size.	Ply Rating.	Position.	Qty.	Tyre Pressure.
				Laden 4.5 Ton.	Laden 7.0 Ton.
14.00 x 20	18	Front Axle.	2	45 psi.	20 psi.
14.00 x 20	18	Rear Axle.	2	113 psi.	125 psi.
14.00 x 20	18	Spare.	1

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