DIRECTOR
GENERAL BORDER ROADS
GENERAL
MAINTENANCE INSTRUCTION NO 235
OF
TATA BUS -1510 (4x2)
INTRODUCTION
1. Tata Bus model
LP/LPO1510 (4x2) 52 seater, Wheel base 5195 mm Fitted with Tata 697 TCIC turbocharged
129 HP (95 KW @ 2400 rpm for fixed fan and 96 KW @ 2400 rpm for viscous fan) BS
II engine, 131 HP (98 KW@ 2400 rpm) BS III engine.
2. This GMI gives the technical specifications
and know how on the maintenance and repair procedures of aggregates of the
model vehicle. 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 you to derive the maximum service from the Tata diesel vehicles.
3. To prolong the life of your vehicle and
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 trouble and accidents to ensure your
satisfaction and safety. Daily care and inspection is essential for prolonging
the operating life of the vehicle and for safe driving, it also reduce the wear
and tear on your vehicle, prolongs its life, give more mileage, failure of the
guide lines below can result in personal injury or serious damage to the
vehicle. All information and instruction in this GMI is based on the latest
Owner’s manual and service booklet.
AIM:- The instruction are issued as guide
lines for schedule of preventive maintenance, lubrication of Tata Bus LP/LPO 1510
(4x2) 52 seater manufactured by Tata motors for regular attention to keep the
vehicle in good mechanical condition and it must be strictly followed:-.
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)
|
Special
instruction
|
:
|
Appx ‘A’
|
|
b)
|
Oil &
Lubricant
|
:
|
Appx ‘B’
|
|
c)
|
Maintenance
of Turbocharger
|
:
|
Appx ‘C’
|
|
d)
|
Periodic
service
|
:
|
Appx ‘D’
|
|
e)
|
Service
schedule
|
:
|
Appx ’E’
|
|
f)
|
Tech
specifications
|
:
|
Appx ‘F’
|
5. Please ack receipt.
|
|
(Hari Prakash)
|
|
|
SE (E&M) FS
|
|
|
Dir (Tech)
|
|
Distribution
|
for Dir Gen Border roads
|
|
Normal
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|
|
|
Appendix-‘A’
|
SPECIAL INSTRUCTION:- Precautions are to be observed when vehicle is operating
at high altitudes and low ambient temperatures. Because of low atmospheric
pressure, which reduces the oxygen content at high altitudes, It is necessary
to take the special maintenance of vehicle and their engines, Similarly, the
lubrication, fuel and cooling system have to be properly attended. The vehicle
out put decreases due to reduction in atmospheric pressure and density. To
ensure an optimum operation of the vehicle at these conditions, it is necessary
to reduce fuel supply to cylinders
FUEL:- High speed diesel confirming to IS
1460 OR DIN 51601 OR equivalent is recommended to be used as fuel. At very low
temperature fluidity of diesel may become insufficient due to paraffin
separation. It is therefore necessary to mix supplementary fuel with summer or
winter grade diesel.
|
Ambient
temp up to Deg˚
|
Percentage
|
|
|
Summer diesel
|
Supplementary fuel
|
|
|
Above 0
|
100
|
0
|
|
0 to -10
|
70
|
30
|
|
-10 to -15
|
50
|
50
|
|
Winter
|
||
|
0 to -15
|
100
|
-
|
|
-15 to -20
|
70
|
30
|
|
-20 and below
|
50
|
50
|
Care
should be taken that diesel and supplementary fuel are thoroughly mixed before
filling.
COOLANT:- Antifreeze must be used in any
climate for both freeze and boiling point protection. Don’t use more than 50%
antifreeze in the mixer.
|
To be used for
|
Grade/specification
|
Brand endorsed by Tata Engineering
|
|
|
Castrol
|
Bharat Petroleum
|
||
|
Cooling system motors.
|
Non-Amino base.
|
Castrol long life coolant.
|
MAK Tata super cool.
|
Appx’B’
|
Lubricant
|
Specification
|
|
|
Engine
Oil
|
:
|
SAE
15W-40 APICF4 + and MB 228.1 specification.
|
|
Rear
axle oil
|
:
|
SAE
85W-140 with 6.5% Anglamol – 99 by weight and API GL Specification.
|
|
Gear
box oil
|
:
|
SAE
80W-90 with 7% Anglamol -6097 by weight and APGL 4 Specification.
|
|
Power
steering oil
|
:
|
Dextron
IID.
|
|
Clutch
fluid
|
:
|
SAE
J 1703 F DOT 3 Plus or DOT 4.
|
|
Coolant
|
:
|
Non
Amino Base.
|
|
Chassis/wheel
bearing grease
|
:
|
Li
base grease NLG1 3.
|
|
Clutch/Clutch
release bearing sleeve clutch disc splines
|
:
|
High
temp lithium base grease.
|
|
Brake
pneumatic equipment
|
:
|
Multipurpose
grease (Consistency No. 2).
|
Appx ‘C’
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 (nearly1,
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 grades of E/oil as well as genuine engine oil
filter, air filter cartridges.
Appx ‘D’
PERIODIC
SERVICE
|
1.
|
Wash
and clean the vehicle thoroughly.
|
|
2.
|
Check
the vehicle pulling LH/RH wobbling self centering, Acceleration etc.
|
|
3.
|
Check
abnormal noise in Engine.
|
|
4.
|
Check
engine oil level, Top up if necessary.
|
|
5.
|
Check
for any leakage from engine side.
|
|
6.
|
Check
hose, clamps & pipes at all locations in air intake system.
|
|
7.
|
Check
all hoses, clamp and pipe at all location in cooling system.
|
|
8.
|
Check
for leakage of gear oil.
|
|
9.
|
Check
for proper fitment of gear shift lever rubber boots.
|
|
10.
|
Check
level of clutch and brake fluid, Top up if necessary.
|
|
11.
|
Check
clutch/brake/pedal free play.
|
|
12.
|
Check
for leakage in clutch/brake circuit.
|
|
13.
|
Check
for fitment of split pins at drag link ball joints, tie rod ball joints &
stub axles.
|
|
14.
|
Check
for fitment of grease nipple at stub axles, shackle pins, pivot pin, Ball
joint
|
|
15.
|
Check
for leakage of front axle & rear axle oil.
|
|
16.
|
Check
tightness of propeller shaft centre bearing bracket mounting nut & bolts.
|
|
17.
|
Check
for any air leakage from the air circuit.
|
|
18.
|
Check
fitment of split pins at the mounting bolts of Anchor plants, brake chambers,
push rod etc.
|
|
19.
|
Check
for fitment of all grease nipples.
|
|
20.
|
Check
power steering oil level in reservoir.
|
|
21.
|
Check
for leakage in the hydraulic circuit.
|
|
22.
|
Check
for steering wheel free play (axle and radial)
|
|
23.
|
Check
for fitment of split pin at steering shaft.
|
|
24.
|
Check
any leakage in the fuel system.
|
|
25.
|
Check
coolant level in the transparent auxiliary tank.
|
|
26.
|
Check
coolant level in the non transparent auxiliary tank, top up if low.
|
|
27.
|
Check
for any leakage of coolant.
|
|
28.
|
Check
functioning of all bulbs.
|
|
29.
|
Check
proper functioning of blinkers, horn, head lamps, parking light, reverse
light wiper system,
washer system etc.
|
|
30
|
Check
tightness of electrical connection at battery, starter motor, alternator
& starter relay.
|
|
31.
|
Check
all fuses.
|
|
32.
|
Check
all the earth point for looseness.
|
|
33.
|
Check
for functioning of all gauges/meters/warning lamps.
|
|
34.
|
Check
connectors in all the circuits.
|
|
35.
|
Check
for proper opening and closing of doors.
|
|
36.
|
Check
functioning of door locks, latches and windows.
|
|
37.
|
Check
and tighten hand loose fasteners.
|
|
38.
|
Check
for any breakage, bends, and failure of any component/assy/unit.
|
|
39.
|
Lubricate
with oil can all linkages and other points.
|
|
40.
|
Grease
with grease gun all the grease points.
|
Appx ‘E’
Service Schedule
|
S/No
|
Description
|
|
Frequency in Km
|
|
|
General
|
||||
|
01.
|
Wash
vehicle
|
:
|
9000
Kms
|
|
|
Engine
|
||||
|
01.
|
Check coolant level, top up if
necessary
|
:
|
Daily
|
|
|
02.
|
Check engine oil level in sump
|
:
|
Daily
|
|
|
03.
|
Check fuel level in tank
|
:
|
Daily
|
|
|
04.
|
Check and rectify leakage of oil,
fuel and coolant
|
:
|
Daily
|
|
|
05.
|
Change engine oil in sump
|
:
|
36,000 Kms
|
|
|
06.
|
Change of oil filter
|
:
|
36,000 Kms
|
|
|
07.
|
Clean pre-filter at feed pump
|
:
|
9000 Kms
|
|
|
08.
|
Clean strainer in fuel tank
|
:
|
18,000 Kms
|
|
|
09.
|
Check valve clearance and adjust if
necessary
|
:
|
9,000 Kms
|
|
|
10.
|
Check and tighten of all nut and
bolts
|
:
|
9000 Kms
|
|
|
11.
|
Check condition of fan belt, replace
if defective
|
:
|
9000 Kms
|
|
|
12.
|
Change fuel filter element first at
|
:
|
18,000 Kms
|
|
|
13.
|
Change both fuel element
|
:
|
36,000 Kms
|
|
|
16.
|
Change coolant
|
:
|
72,000 or Two years.
(whichever is earlier)
|
|
|
17.
|
Remove and check thermostat for
correct functioning
|
:
|
72000 Kms
|
|
|
18.
|
Check and replace radiator rubber
hoses
|
:
|
72,000 Kms
|
|
|
|
Clutch
|
|
||
|
01.
|
Check level of clutch fluid level
container & top up
|
:
|
9000 Kms
|
|
|
02.
|
Lubricant clutch pedal pivot pins
|
:
|
9000 Kms
|
|
|
03.
|
Check and tighten mounting clutch
master cylinder and slave cylinder
|
:
|
9,000 Kms
|
|
|
06.
|
Dismantle/clean, inspect and
re-assemble clutch master cylinder and slave cylinder of clutch actuation
mechanism
|
:
|
72,000 Kms
|
|
|
|
Gear Box
|
|
||
|
01.
|
Check oil level in gear box, top up
if necessary
|
:
|
9,000 Kms
|
|
|
02.
|
Change oil in gear box (First in
10,000 Km) than
|
:
|
72,000 Kms
|
|
|
03.
|
Clean breather in gear box
|
:
|
72,000 Kms
|
|
|
04.
|
Check gear box mounting and tighten
up if necessary
|
:
|
18,000 Kms
|
|
|
|
Suspension
|
|
||
|
01.
|
Grease
the king pin, tie rod ball joint, drag link ball joint, front spring pins
& rear spring pins
|
:
|
9000 Kms
|
|
|
02.
|
Check condition of shock absorber ,
bushes, replace if necessary
|
:
|
18,000 Kms
|
|
|
03.
|
Check wheel alignment if necessary
|
:
|
18,000 Kms
|
|
|
04.
|
Check shock absorber, replace if
defective
|
:
|
18,000 Kms
|
|
|
05.
|
Dismantle front and rear springs,
& cabin mounting clean and apply graphite grease, check and if necessary
replace eye bushes
|
:
|
72,000 Kms
|
|
|
06.
|
Check and tighten of nuts of spring
pins, ‘U’ bolt of front and rear springs
|
:
|
9000 Kms
|
|
|
|
Front axle
|
|
||
|
01.
|
Change
grease in front hub, adjust bearing play, replace damage/worn out parts
|
:
|
18,000
Kms
|
|
|
|
Rear Axle
|
|
||
|
01.
|
Check
oil level in rear axle, top up if necessary
|
:
|
9,000
Kms
|
|
|
02.
|
Change
oil in rear axle (For first 10,000 Km) than
|
:
|
72,000
Kms
|
|
|
03.
|
Change
grease in rear hub, adjust bearing play. Replace damage/worn out parts
|
:
|
18,000
Kms
|
|
|
|
Wheel & Tyre
|
|
||
|
01.
|
Check
tyre pressure
|
:
|
Daily
|
|
|
02.
|
Tyre
rotation
|
:
|
9,000
Kms
|
|
|
03.
|
Check
spare when carrier and tighten if necessary
|
:
|
18000
Kms
|
|
|
|
Brakes-‘S’ Cam full air brakes
|
|
||
|
01.
|
Check
for proper function of brakes
|
:
|
Daily
|
|
|
02.
|
Drain
off condensed water from Air tank
|
:
|
9,000
Kms
|
|
|
03.
|
Check
if necessary tighten (1) mounting of air tanks (Air line clamps)
|
:
|
9,000
Kms
|
|
|
04.
|
Check
and adjust brake free pedal free play
|
:
|
9,000
Kms
|
|
|
05.
|
Check
brake system for leaks and rectify, if necessary
|
:
|
9,000
Kms
|
|
|
06.
|
Check
for proper functioning engine exhaust brake,
|
:
|
9,000
Kms
|
|
|
07.
|
Check
brake rubber hoses/air pipe for damages/leaks and replace if necessary
|
:
|
18,000
Kms
|
|
|
08.
|
Dismantle
pneumatic aggregates of brakes system, clean inspect and replace parts if
necessary
|
:
|
72,000
Kms
|
|
|
09.
|
Grease
with grease gun brake pedal bushing brake double level slack adjuster and cam
shaft bushes
|
:
|
9,000
Kms
|
|
|
10.
|
Check brake plate mounting bolts and
tighten if necessary
|
:
|
9,000
Kms
|
|
|
11.
|
Check
condition of gaiter in different brake valves, exhaust flap in dual brake
valve
|
:
|
18,000
Kms
|
|
|
12.
|
Check
mounting bolts of brake chamber, different valve mountings air tank mounting
air cylinders mounting
|
:
|
18,000
Kms
|
|
|
13
|
Check
service brake, parking brake and adjust if necessary
|
:
|
36,000
Kms
|
|
|
|
Steering
|
|
||
|
01.
|
Check
oil level in power steering Hyd tank, top up if necessary
|
:
|
9,000
Kms
|
|
|
02.
|
check
and adjust steering wheel free play
|
:
|
9,000
Kms
|
|
|
03.
|
Drain
hyd oil of power steering replace filter and cartridge
|
:
|
72,000
Kms
|
|
|
|
Electrical
|
|
||
|
01.
|
Check
and tighten mounting bolt of alternator, Starter motor, wiper motor, battery
mounting bolt all electrical connections and head lamp mounting screw
|
:
|
9,000
Kms
|
|
|
02.
|
Check
battery cell and specific gravity of electrolyte, recondition battery if
necessary
|
:
|
18,000
Kms
|
|
|
03.
|
Check
head lamps focus, adjust if necessary
|
:
|
9,000
Kms
|
|
|
04.
|
Check
electrolyte level in battery and add distilled water if necessary
|
:
|
9,000
Kms
|
|
|
05.
|
Clean
battery post and terminals and apply petroleum jelly
|
:
|
9000
Kms
|
|
|
|
Bus Body and miscellaneous
|
|
||
|
01.
|
Check
all body U-bolts and tighten
|
:
|
9000
Kms
|
|
|
02.
|
Check
the space of the U-bolt for dislocation or cracking replace if necessary
|
:
|
9,000
Kms
|
|
|
03.
|
Check and if necessary tighten
mounting of body bonnet, hinges, tie member mounting dove tail bottom dove
tail bracket stop, door hinges, door locks, dove tail striker plates mounting
of the driver seat
|
:
|
9,000
Kms
|
|
|
04.
|
Check
doors for proper opening & closing. Adjust striker plate if necessary.
|
:
|
9,000
Kms
|
|
|
05
|
Check
condition of driver seat rubber stops buffers shock absorber & bushes
replace if necessary.
|
:
|
9,000
Kms
|
|
|
06
|
Check
proper sliding of window glass
|
:
|
9,000
Kms
|
|
|
07
|
Grease
with grease gun (1) sliding rails of driving seat (2) Jack knife door’s
bearings
|
:
|
9,000
Kms
|
|
|
08
|
Lubricate
with oil can Pivot of driver’s seat
|
:
|
9,000
Kms
|
|
|
|
Turbo charge and dry type air filter
|
|
||
|
01.
|
Tighten
all fasteners on turbo charger, air filter mounting and air duct hose
connections
|
:
|
9,000
Kms
|
|
|
02.
|
Check
air filter indicator, if found ‘Red’ clean air filter housing and replace
primary cartridge
|
:
|
Daily
|
|
|
03
|
Check
air filter hoses for damage and replace if necessary
|
:
|
9,000
Kms
|
|
|
|
|
Appx ‘F’
|
|
Technical
Data
|
|
|
|
Engine
|
|
|
|
Model
|
:
|
Tata 697
TCIC (BS-II) fuel efficient
|
|
Type
|
:
|
Water
cooled direct injection diesel engine
|
|
No of
cylinder
|
:
|
6 in line
|
|
Bore stroke
|
:
|
97 mm x 128
mm (5675 cc)
|
|
Max engine
out put
|
:
|
(95 KW @
2400 rpm for fixed fan and 96 KW @ 400 rpm for viscous fan BS II engine, 131
HP (98 KW@ 2400 rpm) BS III engine.
|
|
Max torque
|
:
|
410 Nm @ 1400-1700 rpm
|
|
Compression
ratio
|
:
|
17.5:1
|
|
Firing
order
|
:
|
1-5-3-6-2-4
|
|
Air filter
|
:
|
Dry type
|
|
Oil filter
|
:
|
Full flow
paper type
|
|
Fuel filter
|
:
|
Two stage
fine filtration
|
|
Fuel
injection pump
|
:
|
Rotary type
MICO
|
|
Governor
|
:
|
Centrifugal
type variable speed
|
|
Capacity of
cooling system
|
:
|
20 Ltrs
|
|
Crank case
oil capacity
|
:
|
Max 14
Ltrs, Min 12 Ltrs
|
|
Engine
weight
|
:
|
450 Kg(dry)
|
|
Radiator
frontal area
|
:
|
2760 Sq cm
|
|
Clutch
|
|
|
|
Type
|
:
|
Single
plate dry friction type
|
|
Out side
diameter of clutch lining
|
:
|
310 mm,330
mm
|
|
Friction
area
|
:
|
1180 Sq
cm/(Appx),1030 Sq cm/(Appx)
|
|
GEAR
|
:
|
GBS 40
|
|
No of gears
|
:
|
5 Forward ,
1 reverse
|
|
Type
|
:
|
Synchromesh
on all forward gears and constant mesh reverse gear
|
|
Gear ratio - First
|
:
|
7.51
|
|
2 nd
|
:
|
3.99
|
|
3 rd
|
:
|
2.50
|
|
4 th
|
:
|
1.51
|
|
5th
|
:
|
1.00
|
|
Reverse
|
:
|
6.93
|
|
REAR
|
|
|
|
Type
|
:
|
Single
reduction, hypoid gears, fully floated axle shafts
|
|
Ratio
|
:
|
5.285:1(37/7)
Standard, 5.8571 (41/7) Optional
|
|
FRONT
|
:
|
Heavy duty
forged 1 beam reverse Elliot type
|
|
STEERING
|
|
|
|
Type
|
:
|
Power
steering
|
|
Ratio
|
:
|
20.2:1
|
|
FRAME
|
:
|
(a) Ladder
type frame with riveted/ bolted cross members Side member are of channel
section
|
|
|
|
Depth : 223
mm (max)
|
|
|
|
Width : 60mm
|
|
SUSPENSION
|
|
|
|
Type
|
:
|
Semi
elliptical leaf spring at front and rear, Optional Pneumatic suspension
|
|
Spring span
|
:
|
Front 1450
mm
|
|
|
:
|
Rear 1600
mm
|
|
Leaf width
|
:
|
Front 70mm
|
|
|
:
|
Rear 80mm
|
|
Shock
absorber
|
:
|
Hydraulic
double acting telescopic type
|
|
WHEEL
AND TYRES
|
|
|
|
Tyres size
|
:
|
9.00x20-14PR(LPO),10.00x20
16 PR(LP)
|
|
Wheel Rim
|
:
|
7.00x20
|
|
No of
wheels
|
:
|
Front-2,
rear-4 spare-1
|
|
Fuel tank
capacity
|
:
|
250 Ltrs
|
|
CAB
|
:
|
All steel
full forward control cowl
|
|
ELECTRICAL
SYSTEM
|
|
|
|
Voltage
|
:
|
24V
|
|
Alternator
|
:
|
55/60Amp,45
Amp
|
|
Battery
|
:
|
2x150Ah,
2x120 Ah
|
|
Wind screen
|
:
|
Electrically
operated
|
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