GMI - 234

DIRECTOR GENERAL BORDER ROADS

GENERAL MAINTENANCE INSTRUCTION NO 234

OF

TATA - 407 TURBO VEHICLE

1.           INTRODUCTION:-Tata -407 Turbo vehicle is fitted with 4 SPTC engine, turbo charger, dry type air filter and cylinder liners for long life and easy for over haul. A radiator auxiliary tank is provided for convenient water filling. A tailor made power train with matched gear ratios provide good acceleration, fast pick up and over all fuel economy. Five speed synchromesh gear box,  ‘S’ cam full air brake system on front and rear wheels, independent hydraulic brakes, an electric isolator switch has been provided on control panel for exhaust brake. The steering is provided with lock cum ignition switch as a safety against theft.

  Maintenance is the most important factor for enhancing the life and keeping the vehicle in good working conditions. Preventive maintenance is more economical than corrective repairs. Be sure to maintain the maintenance schedule as given in this GMI for running in period and later in regular intervals, respectively.

  This GMI as guide line describes procedures of maintenance, lubrication, handling, checking and adjustment. It will help the driver to realize peak performance through effective, economical and safe operation.

2.           AIM: The instructions are issued as guide lines for schedule of preventive maintenance, lubrication of Tata – 407 turbo charged vehicle for regular attention to keep the vehicle in good mechanical running condition and it must be strictly followed.

 

3.           ACTION BY

     

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

4.           Details  The details of maintenance and lubrication with their periodicity are as      under:-

a)	Do and Don’ts	:	Appx ‘A’
b)	Maintenance turbo charger	:	Appx ‘B’
c)	Lubricants	:	Appx ‘C’
d)	Service instruction	:	Appx ‘D’
e)	Technical data	:	Appx ‘E’

 5.          Please ack receipt.

		(Hari Prakash)
		SE (E&M) FS
		Dir (Tech)
Distributions		for Dir Gen Border roads
Normal

				Appx- ‘A’
DO’s AND DON’TS
	Do’s
1.	Use recommended lubricants only.
2.	Change oil in engine, gear box and rear axle at prescribed intervals with recommended oil.
3.	Use only genuine filter cartridge.
4.	Clean air cleaner regularly.
5.	Use only genuine parts
6.	Use recommended anti-freezing coolant in specified ratios.
7.	Always maintain correct tyre pressure.
8.	Check battery level and top up if necessary.
9.	Keep battery terminal clean and cable joint tight. Apply Vaseline/ petroleum jelly on terminals.
10.	Disconnect all alternator terminals while carrying out any welding work on the vehicle
11.	Ensure periodic servicing to keep the vehicle fit.
12.	Avoid panic braking during first 500 Kms.
13.	Check the tyre for damage, remove and fit timely.
14.	Keep the grease, oil and fuel away from the tyres.
15.	Whenever bonnet is opened for work, check its proper locking when closed.
16.	Start the vehicle always in first gear to avoid premature clutch wear.
17.	Keep foot and hand brakes properly adjusted.
18.	Drive at steady speed between 60-70 km for better fuel average and longer aggregate life.
19.	When parking on slope use wheel chocks apply hand brake and keep vehicle in gear.
20.	Watch service indicator of dry type air filter regularly, when it shows red band in engine stopped condition. Replace the old primary cartridge by new one.
21.	If air filter cartridge is replaced, destroy the old cartridge to prevent its reuse.
22.	Ensure / check that air intake hoses are free from puncture, cuts and damages etc.
23.	Keep engine in idling condition for at least one minute after just starting the engine and also before stopping it, to protect the turbo charger from getting damaged due to oil starvation.
24.	Use wheel chocks, while carrying out any repairs to the vehicle to prevent vehicle from undesired rolling.
25.	Always use seat belt while driving the vehicle for your safety.
	DON’TS
1.	Don’t use clutch pedal as foot rest while driving, this will cause premature clutch facing wear.
2.	Don’t keep clutch padel half pressed while shifting gears, this will reduce synchronizing cone life as well as clutch facing life.
3.	Don’t run vehicle with engine switch off or in neutral gear, this is dangerous
4.	Don’t weld or drill holes in chassis frame.
5.	Don’t rein force chassis frame spring or axles for carrying higher pay load.
6.	Don’t remove thermostat, if got defective replace it with new one
7.	Don’t top up radiator while engine is hot. This may cause cylinder head to crack.
8.	Don’t preload bearing while adjusting wheel bearings, set them to prescribed axle play, this will increase bearing and tyre life.
9.	Don’t fit large size tyre and don’t over or under inflate tyres. This will reduce tyre life.
10.	Don’t push/press starter button when engine is running. This will damage starter pinion and fly wheel ring gear.
11.	Don’t run the alternator without battery.
12.	Don’t disconnect any load of alternator, with engine running.
13.	Don’t over fill clutch fluid container, as it may spill with clutch usages.
14.	Don’t use kerosene as fuel under normal operating conditions; this will cause faster wear of fuel injection equipment
15.	Don’t disconnect hand brake, this will become safety hazard.
16.	Don’t idle the vehicle for stops over one minute, this will save fuel.
17.	Don’t drive in drunken condition.
18.	Don’t use tyre gaiter, this will result in imbalance of wheel and steering wobble.
19.	Don’t remove exhaust brake, brake lining life is improved with the use of the exhaust brake.
20.	Don’t apply any lubricant to the butterfly valve shaft of the exhaust brake unit and surface of ‘S’ cam in brake assembly.
21.	When brake drum are removed for any servicing, don’t apply grease between contact surface of ‘S’ cam profile and roller.
22.	Don’t attempt to clean the air dryer (cartridge and filter). Replace the cartridge and filter every two years.
23.	Don’t clean secondary cartridge of air filter. Replace it after three changes of primary cartridge or after two years.
24.	Don’t use mobile phone while driving the vehicle for safety of yourself and other road users.
			Appx- ‘B’

MAINTENANCE OF TURBO CHARGER:-

            As there is no mechanical drive connection between engine and the turbo charger, apart from the engine inspection at regular intervals, no additional or particular maintenance service are required for the turbo charger unit, therefore, no adjustments or repair to be carried out on the turbo charger, in case of doubtful performance from the engine because of malfunctioning of the turbo charger. In that condition take the vehicle in nearest authorized dealer.

           

            However following precautionary measures are to be taken to obtain trouble free performance.

1.         During regular engine inspection, look carefully for any oil leakage at the oil banjo connection on the turbo charger bearing housing.

2.         Don’t stop the engine suddenly as it may damage turbo charger rotor bearings, allow engine to idle for some time before switching it off. Similarly don’t increase engine speed suddenly. Run the engine in low idle speed for at least one minute after starting and ensure the engine oil pressure has build up.

3.         Since the speed of the turbocharger rotor assy is tremendously high (nearly 1,00,000 rpm) is requires finest filtered oil which comes from the engine lubrication system. Therefore ensure cleanliness of the engine oil by adhering to regular schedule of engine oil and oil filter cartridge change intervals.

4.         As the unfiltered dust particles coming is to the turbocharger/compressor may prove dangerous, make sure that there is no leakage is the air intake system and the air filter element is in good condition and sealing are perfect.  

5.         Use only recommended grade of E/oil as well as genuine engine oil filter, air filter cartridges.

			Appx- ‘C’
Lubricants:-
To be use for	Castrol	BP	Indian Oil
Engine Oil	Castrol Rx Super Max 15W-40	Tata BP C3MG 15W-40
Synchromesh gear box	Castrol Hypoy LL 80 W 90	Telco Spirol S 80 W 90
Rear axle	Castrol Hypoy B 80 W 140	Telco Spirol HD 80 W 140
Wheel bearing	Castrol AP Grease	Telco univex – A Grease
Steering gear box	Castrol Hypoy B	Bharat Spirol HD - 90	Servo gear super-90
Cooling system	Castrol long life coolant	Telco Super Kool

     

(a)        Gear box Oil:- Change at every 10,000 Kms

(b)        Oil change frequency for Rear axle: - Change the oil at first 10,000 Km there after every 40,000 Kms.

(c)        Steering gear box: - Change Oil SAE 90 should be used at 9ºC and –SAE 75 should be used bet 9ºC and minus 40ºC at every 80,000 Kms.

(d)        Engine Oil:- Oil change first at 10,000Kms and thereafter also every 10,000 Kms.

						Appx-‘D’
Service instruction
This vehicle has been built to give you thousands of km of economical and trouble free performance. This is possible only if the vehicle is systematically maintained and operated strictly as per instruction given in GMI.
PDI Service
Following jobs are to be performed at PDI.
1.	Wash & clean the vehicle thoroughly.
2.	Road test the vehicle, check for proper functioning of engine, clutch, transmission aggregates, steering brakes etc.
3.	Check pulling of RH/LH wobbling, self centering, acceleration etc.
4.	Static test: Start engine & check for Idling rpm & Max rpm. (any abnormal noise) service brake air pressure, water temp, operation of exhaust brake system etc.
5.	Check engine oil level.
6.	Check for any leakage from engine oil, gear box oil, clutch and brake fluid, and rear axle oil.
7.	Check all hose, clamp pipe for broken/damage.
8.	Check for proper fitment of gear shift lever rubber boots.
9.	Check level of clutch and brake fluid.
10.	Check clutch/brake pedal free play.
11.	Check for fitment of split pins at drag link ball joints, Tie rod ball joints, and stub axles.
12.	Check for fitment of grease nipple at stub axle, shocker pins, pivot pins, Ball joint etc.
13.	Check tightness of centre bearing bracket mounting nut & bolt.
14.	Check for any air leakage in the brake circuit.
15.	Check steering wheel free play. (axial and radial)
16.	Check for fitment of split pin at steering shaft.
17.	Check any leaking in fuel system.
18.	Check coolant level in transparent auxiliary tank & non transparent auxiliary tank top up if found low.
19.	Check functioning of all tight circuit, bulbs, blinkers, horn, head lamp, parking light, reverse light, griper motor and washer system.
20.	Check battery connections, Starter motor, Alternator and starter relay.
21.	Check all fuses.
22.	Check all earth joints for looseness.
23.	Check for proper functioning of all gauges/meters/warming lamps.
24.	Check for proper function of opening of door, door lock, latches and windows.
25.	Check and tighten hand loose fastness.
					Appx- ‘E’
Technical Data
Engine
Model		:		Tata 497 SP Turbo.
Type		:		Water cooled direct injection pump diesel engine.
No of cyl		:		4 in line.
Bore/Stroke		:		97 mm x 100 mm.
Compression ratio		:		19 : 1.
Firing order		:		1-3-42.
Air filter		:		Dry type.
Oil filter		:		Full flow paper type.
Fuel filter		:		Two stage pre and fine filtration.
FIP		:		inline type-mico.
Cap of cooling		:		13 Liters.
Crank case oil cap		:		Max 7 Ltrs & Min 5 Ltrs.
Clutch		:		Single plate dry friction type.
Clutch lining		:		240 mm.
Gear box		:		GBS-18 gear box synchromesh.
No of gear		:		5 forward and 1 reverse.
Rear axle		:		Single reduction, lipoid gear fully floating axle shafts.
Front axle		:		Heavy duty forged I beans, reverse Eliot type.
Steering		:		Manual steering.
Steering gear box		:		Recirculation ball type with rack and sector.
Brake		:		Vacuum assisted dual circuit hydraulic with tandem master cylinder.
Parking brake		:		Hand operated.
Engine exhaust brake		:		Coupled with service brake.
Frame		:		Ladder type frame with riveted/cooled cross members, side: members are of channel section.
				Depth   : 150 mm. (Max)
				Width   : 55 mm.
Suspension		:		Semi elliptical lead spring at front and rear.
Spring Span		:		Front 1220 mm.
		:		Rear 1370 mm.
Leaf width		:		Front 70 mm.
		:		Rear 70 mm.
Shock absorbers		:		Hyd double acting Telescopic type at front and rear.
Wheel and tyres		:		7.00 X 16 – 16 PR Diagonal ply.
Fuel Tank		:		60 Liter cap.
Cab/Cowl		:		All steel semi forward control drivers cab. (Standard)
Electrical system		:		12 Volt.
Alternator Cap		:		35 Amp.
Battery		:		12270 AH Cap.
Wind screen wiper		:		17 W, two speed & intermittent wipe.
Wind screen washer		:		Electrically operated.
Chassis dimension
Wheel base		:		3100 mm.
Max width		:		2140 mm.
Overall length (without load body		:		5375 mm.
Overall length (with load body)		:		5605 mm.
Overall height		:		2300 mm.
Minimum turning circle dia		:		12 mm.
Minimum turning circle clearing		:		13.4 mm.

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