DIRECTORATE GENERAL BORDER ROADS
GENERAL MAINTENANCE INSTRUCTIONS
NO: 218
ON
ASHOK
LEYLAND HAULAGE CG 1613H
AND
TIPPER CT 1613/H1
Introduction:
1. Ashok Leyland Haulage CG 1613H and
Tipper CT 1613H/1 has been designed to ensure case of access to mechanical
components. This will enable you to carry out a number of simple
maintenance. Ashok Leyland Haulage CG
1613H and Tipper CT 1613H/1, 6 cylinder water cooled 4 stroke diesel engines
with direct fuel injection. The engine employs re-entrant combustion chambers
which features a specially shaped combustion chamber in the piston crown.
2. The Shape of the combustion chamber
allows full use of the energy contained in the fuel, because the cooling
surfaces are comparatively small in relation to the volume of the combustion
chamber whilst the air swirls ensures that air and fuel are mixed uniformly.
Aim
3. To lay down the details of periodical
maintenance and Lubrication and hints for safe operation and towing of Ashok
Leyland Haulage CG 1613H and Tipper CT 1613H/1 medium duty vehicles to achieve
enhance life.
Action
by:-
a)
|
User
Unit
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To
carry out regular/periodical maintenance as laid down in this Instruction and
enter the tasks in log book.
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b)
|
Field
Workshop
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i)
|
To
check the maintenance and lubrication actually carried out as per log book.
record during the inspection and repairs of the eqpt.
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ii)
|
Advise
user units in respect of any discrepancy/short coming noticed.
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Details
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a)
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Technical Specification Data.
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Appx
‘A’
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b)
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Periodical Service schedule.
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Appx
‘B’
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c)
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Recommended lubricants & engine
coolant chart.
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Appx
‘C’
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d)
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Hints for safe operation and towing.
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Appx
‘D’
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4.
|
Please
ack receipt.
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(Hari Prakash)
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SE (E&M)
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Dir
(Tech)
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Dated
: Jul 2008
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For
Dir Gen Border Roads
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Appx- ‘A’
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TECHNICAL
SPECIFICATION
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Model
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|||||
Engine
|
:
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HINO
HA 6D TI 2D MARK-II BS-II.
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No.
of Cylinders (Vertical in Line)
|
:
|
6.
|
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Working
Cycle
|
:
|
4
Stroke Diesel.
|
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Cooling
System
|
:
|
Forced
Circulation by Volute Pump.
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|||
Fan
Belt Tension
|
:
|
10-15
mm .
|
|||
Bore
x Stroke
|
:
|
104
x 113 mm.
|
|||
Firing
Order
|
:
|
1-4-2-6-3-5.
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Direction
of Rotation
|
:
|
Counter
Clockwise viewed from flywheel opens at 82º ± 2º C.
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Thermostat
Type
|
:
|
Single
thermostat wax type. (bottom by pass)
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Compression
Ration
|
:
|
17.5:1
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Max
out put
|
:
|
132
ps/97 kw@2400 rpm.
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Max
Torque
|
:
|
(430
Nm) 43.8 Kgm @ 1200-1600 rpm.
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Fuel
Filter
|
:
|
1.11
Dual filter (Both Micro Filter with coil type paper element)
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Governor
|
:
|
Mechanical,
engine speed control.
|
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Nozzle
opening pressure
|
:
|
247-261
bar.
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Fuel
Injection timing
|
:
|
1.30±
0.02 mm plunger lift at TDC with No. 1. Cylinder on compression stroke.
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Compression
pressure
|
:
|
29-32
Kg/Cm²@280 rpm.
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Alternator
|
:
|
Lucas
TVS 24V, 55 Amp Belt driven.
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Starter
motor
|
:
|
Lucas
TVS 24V-GBS 5, Axial drive.
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Air
Filter
|
:
|
Twin
element dry type.
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Front Axle
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|||||
Axle
Capacity (Kg)
|
:
|
5460
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Slack
adjuster
|
:
|
Mannual.
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Rear Axle
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|||||
Axle
Capacity
|
:
|
10200
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Axle
Ration
|
:
|
6.167
: 1
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Slack
Adjuster
|
:
|
Mannual.
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Suspension
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|||||
Type
|
:
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Semi-elliptic
laminated multi leaf with centre belt arrangement.
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Leaf
width (mm)
|
:
|
Front
76, Rear 80.
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Shock
absorbers
|
:
|
Double
acting telescopic on front axle only.
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Steering
|
|||||
Type
|
:
|
Integral
power steering.
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Angle
of steering column to frame
|
:
|
73°
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Electrical
system
|
:
|
24V
negative earth, 80AH (20h rating) 2x12V battery.
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Appx- ‘B’
PERIODICAL SERVICE SCHEDULE & RECOMMENDED LUBRICANT
CHART
1. PERIODICAL
MAINTENANCE ON ENGINE
DAILY
(a) Check engine
oil level, if the level only reaches to the lower mark of the dipstick, the
oil should be topped up without delay.
|
(b) Top up
coolant level and top up, if necessary.
|
(c) Fill up the
fuel tank at the end of each working day. Never wait until the tank is empty.
This would necessitate replacing of the entire fuel system.
|
(d) Clean the
engine at the day work.
|
(e) Check engine
oil pressure (Min 1 Kg/Cm² at idling and 80°C engine temperature.
|
(f) Check
restriction indicator, if necessary clean the element.
|
2. Maintenance schedule that follow for the
normal road operating conditions:-
a) For off
highways application (Tipper) hourly maintenance schedule should be followed
in place of Km schedules. The following schedule
can be converted into hourly schedule by using the ratio on 1 hour of
operation is equivalent to 40 km. For eg. 10,000 km equals to 40 hrs.
|
b) More frequent
attentions will be necessary to vehicles working under adverse conditions
such as sand/ Gravel pit work or under service hilly terrains/ projects.
|
c) Check and
tighten front and rear engine mounting/other peripheral bolts.
|
d) Check and
top up engine oil.
|
e) Check oil
leakages, if any.
|
f) Check and
tight fan mounting bolts.
|
g) Check
radiator hoses and clams for leakages and tightness.
|
h) Check fan
belt tension and adjust if necessary.
|
j) Check
radiator stay rod and radiator mounting bolts.
|
3. Change
engine oil and oil filter element (Long life filter housing/ element)
a) First
change at 16000 kms and thereafter every 24,000 Kms.
|
b)
Tipper application – First change at 16000 kms and thereafter every
24000 kms or 500 hrs, whichever is earlier.
|
c) Other application – First change at
16000kms and thereafter every 36000 kms.
|
4. Drain cooling
system and file recommended coolant:- 20000 kms or 2 years whichever is
earlier.
5. Fuel system
a) Primary element change
- 16000 Kms.
|
b) Secondary element change - First
24000 kms & thereafter every 16000 kms.
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Appx-
‘C’
RECOMMENDED
LUBRICANTS
|
Aggregates
|
Ashok Leyland specification
|
Ambient
temp°C
|
Co-branded lubricants
|
Approved lubricants
|
Change period in Kms.
|
|
|
Gulf oil
India
|
IOC
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|||||
|
Bharat stage II & III Diesel engine Hino (6DT1 & 6ET1)
|
API CH-4+MB 228.3+VDS 3
|
-15 and above
|
Super
fleet LE max SAE
15W-40
|
Servo pride ALT
15W-40
|
First oil change period at 16,000 Km &
there after every 24,000 Kms for city and Ghat operation. 36,000 Kms for long
haul operation. 24,000 Kms or 5000 hrs, whichever is earlier for tipper.
application with long life filter housing/element.
|
|
|
BSII AL 412 TC AC & BSII &III HA4CTI
diesel engine
|
API CH-4+MB 228.3+VDS 3
|
-15 and above
|
Super
Fleet
LE
max SAE
15W-40
|
Servo pride ALT
15W-40
|
For long haul operation
Oil change at every 16,000 Kms.
|
|
|
For tipper
10,000Km OR 250 Hrs of operation, (whichever
is earlier.)
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|
Gear box constant mesh
Steering gear box (Mannual)
Gear box synchromesh
|
API GL-4 with specified additive
|
>0
>0
>0
|
Gear XP
MAX
SAE
90
|
SERVO GEAR ALT 90
|
AL
|
40,000
|
|
RANE
|
72,000
|
|||||
|
ZF
|
40,000
|
|||||
|
Power steering
|
General motors type A suffix A
|
-
|
Power
Steering
fluid Max
|
Servo power steer ALT
|
RANE
|
80,000/1 year
|
|
ZF
|
||||||
|
Rear axle spiral Bevel and pinion
|
API GL-4 (OR) MIL-L-2105 (OR) IS 1118-EP
TYPE GL-4
|
>30
|
Gear EP
Max
SAE
140
|
Servo Gear ALT 140
|
8T/ 10T
|
24,000
|
|
Rear axle hypoid drive
|
API GL 5 with specified additive
|
-12 and above
|
Gear
DB Max
85W140
|
Servo gear super ALT 85W-140
|
Q109,RS145,RS120,R149.5
R160,SQR10960SHO,C100
|
48,000 Kms
|
|
Wheel bearing
|
IS 12203
|
-
|
Crown
Max
RR3
|
Servo
gem ALT
|
-
|
48,000
|
|
Engine water pump, Gear shift ball joints, S
camshaft & slack adjuster (front & rear) shackle pin
|
IS12203
|
-
|
MP
Grease
Max
NLGI
2
|
Servo grease ALT
|
-
|
Weekly
|
|
Accelerator pedal ball joints, Accelerator
control shaft(Pedal end & crankcase rear)
|
-
|
8000
|
||||
|
Clutch pedal, Brake pedal, Relay shaft &
ball joints (clutch withdrawal),clutch withdrawal sleeve & liner, Centre
bearing joint, Propeller shaft UJ cross, Drag line& track rod, King pin
|
-
|
Weekly/
8000
|
||||
|
Ram base, Ram cross head Tees, Tipper body
hinges, 5th wheel coupling.
|
-
|
Daily
|
||||
|
Tipping unit
|
IS 10522
|
-
|
Harmo
ny
AW Max
ISO
VG
32
|
Servo hydraulic ALT 32
|
WIPRO,UT,HYVA
|
6 months
|
|
Hydraulic clutch, Hydraulic brake
|
FM VSS 116-Dot 3 (OR) IS 8654
|
-
|
Brake
Fluid
Max
Dot
3
|
Servo power brake
ALT
|
-
|
40,000
|
|
# Specification and change period
applicable for special, arduous duty & Army applications refer service
manual.
Note : Do not mix lubricants of different
brands/ Grades.
|
||||||
ENGINE
COOLENT
Aggregate
|
Ashok leyland specification
|
Ambient Temp °C
|
Gulf oil India
|
IOC
|
Change period #
( Kms)
|
All AL/Hino engines with brass – copper
radiator
|
JIS K 2234-94 Class 2 and plus
|
>0
|
20 %
Euro cool Max
|
-
|
Every 75,000 Kms
|
All AL/Hino engines with Aluminum radiator
|
50 % Euro cool Max
|
-
|
Every 75,000 Kms
|
||
Note: Do not mix lubricants of different
brands/oil.
|
|||||
Appx
‘D’
HINTS
FOR SAFE OPERATION AND TOWING
(a) Do not accelerate the engine immediately
after start. Idle the engine for at least two minutes after start and before
the engine is stopped.
(b) Don’t
open the turbocharger your self. As the turbocharger is precision build,
assembled and tested by highly skilled personnel. We do not recommended opening
of the turbocharger for servicing by unauthorized persons. However, if need be
please contact turbo energy Ltd. Service centers for assistance for servicing
turbo chargers.
(c) Don’t
run the engine with low oil pressure.
(d) Don’t
put the engine under full load immediately after starting.
(e) Regular
change of engine oil/oil filter.
(f) Regular
change/cleaning of air filter element.
(g) Check
for oil pressure at engine of engine idling condition.
(h) Idle
the engine for two minute, after starting the engine.
(j) Idle
the engine for two minutes before switching off the engine.
(k) Periodic
cleaning of crankcase breather is necessary to allow free flow of oil from
turbocharger outlet.
(l) Regularly
check all air, oil and exhaust connection for leaks and abnormal dust/oil/carbon
build up.
(m) Do
not use response (or) petrol (or) any other mineral oil to clean the cylinders
and their internal parts.
(n) Damaged
and badly worn components must be renewed.
(o) Also
check once a week the tightness of all nuts and bolts.
(p) Lubricants
as per schedule all the greasing points on the vehicles.
(q) Ensure
periodic servicing as per maintenance schedule.
(r) Maintain
correct type pressure.
(s) Check
battery every week and top up electrolyte levels. Keep battery terminals clean
and cable joints tight. Apply Vaseline/petroleum jelly in terminals, use
distilled water only for topping up.
(t) Observe
correct polarity when connecting bty terminals.
(u) Disconnect
alternator terminals while carrying out any welding on the vehicle.
(v) Keep
both foot and parking brake properly adjusted.
_______
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