DIRECTOR
GENERAL BORDER ROADS
GENERAL
MAINTENANCE INSTRUCTION NO 231
OF
INTRODUCTION
1. Tata model LP 709/38 (4x2) 32 seater, Wheel base 3800 mm
Fitted with Tata 497 TCIC turbocharged 89 HP (66.3 KW @ 2400 rpm BS 11 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 Mini Bus 709 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’
|
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c)
|
Special
operating system
|
:
|
Appx
‘C’
|
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d)
|
Periodic
service
|
:
|
Appx
‘D’
|
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e)
|
Service
schedule
|
:
|
Appx
’E’
|
|
f)
|
Tech
specifications
|
:
|
Appx
‘F’
|
5. Please ack receipt.
|
|
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(VK Sharma)
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|
|
|
EE (E&M) NFSG
|
|
|
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Joint
Director (Technical)
|
|
Distribution
|
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for
Dir General Border roads
|
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Normal
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Appendix’A’
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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 output
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
|
Ambient temp up to Dig C
|
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’
|
|
|
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||
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Lubricant
|
Specification
|
||
|
Engine Oil
|
:
|
SAE 15W-40 APICF4 + and MB 228.1 specification.
|
|
|
Rear axle oil
|
:
|
SAE 85W-90 with 7% Anglamol – 6043 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’
SPECIAL
SPERATING SYSTEM
Precautions
are to be observed when the vehicle operating at high altitudes and low ambient
temp. Because of low atmospheric pressure, which reduces the oxygen content at
high altitude, it is necessary to make certain adjustment in the fuel injection
pump output to prevent black smoke caused by unburned fuel emitting from the
engine.
High
altitude operation
Vehicle
output decreases due to reduction in atmospheric pressure and density. To
ensure and optimum operation of the engine at these conditions, it is necessary
to reduce fuel supply to cylinders and to prevent black smoke caused by
unburned fuel emitting from engine.
Cold
Starting oil
To
permit starting of vehicle at very low outside temps, the vehicle is also
provided with a ‘start pilot’ switch.
|
Operation in hilly
terrains
|
||||
|
1. To ensure
steering linkage and brakes are to be kept in Order.
|
||||
|
2. Proper gear should be used during climbing
or descending.
|
||||
|
3. Engine should
not be disengaged or switched off while descending on the downhill gradients.
|
||||
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4. Drain air tanks every work to remove
condensed water.
|
||||
|
5. Change brake and Clutch fluid in the system
every six months.
|
||||
|
6. Drain water from fuel water separators.
|
||||
|
7. Vehicle should
be greased at frequent intervals to prevent formation of rust on the exposed
surfaces.
|
||||
|
|
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 hose, 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
etc.
|
||||
|
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. C heck 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 Kms.
|
||
|
General
|
|
|
||
|
Wash
vehicle
|
:
|
5000 Kms.
|
||
|
Engine
|
:
|
|
||
|
1. Check coolant level, top up if necessary
|
:
|
Daily.
|
||
|
2. Check
engine oil level in sump
|
:
|
Daily.
|
||
|
3. Check
fuel level in tank
|
:
|
Daily.
|
||
|
4. Check and rectify leakage of oil, fuel and
coolant
|
:
|
Daily.
|
||
|
5. Change engine oil in sump
|
:
|
15,000 Kms.
|
||
|
6. Change of oil filter
|
:
|
15,000 Kms.
|
||
|
7. Clean pre-filter at feed pump
|
:
|
5000 Kms.
|
||
|
8. Clean strainer in fuel tank
|
:
|
10,000 Kms.
|
||
|
9. Check valve clearance and adjust if
necessary
|
:
|
10,000 Kms.
|
||
|
10. Check
and tighten of all nut and bolts
|
:
|
5000 Kms.
|
||
|
11. Check
condition of fan belt, replace if defective
|
:
|
5000 Kms.
|
||
|
12. Change
fuel filter element first at
|
:
|
10,000 Kms.
|
||
|
13. Change
both fuel element
|
:
|
20,000 Kms.
|
||
|
14. Clean
breather
|
:
|
20,000 Kms.
|
||
|
15. Lubricate
water pump with grease and lubricate accelerator linkage with oil can
|
:
|
5000 Kms.
|
||
|
16. Change
coolant
|
:
|
80,000 Kms Or two years. (whichever is
earlier)
|
||
|
17. Remove
and check thermostat for correct functioning
|
:
|
40,000 Kms.
|
||
|
18. Check
and replace radiator rubber hoses
|
:
|
80,000 Kms.
|
||
|
Clutch
|
|
|
||
|
1. Check level of brake fluid in plastic
container
|
:
|
1000 Kms.
|
||
|
2. Lubricant clutch pedal pivot pins
|
:
|
1000 Kms.
|
||
|
3. Check and
tighten mounting clutch master cylinder and slave cylinder
|
:
|
5,000 Kms.
|
||
|
4. Remove clutch
release for support bearing apply, tight coat of grease and refit
|
:
|
40,000 Kms.
|
||
|
5. Check clutch
fluid in clutch system and bleed the system
|
:
|
40,000 Kms.
|
||
|
6. Dismantle/clean,
inspect and re-assemble clutch master cylinder and slave cylinder of clutch
actuation mechanism
|
:
|
80,000 Kms.
|
||
|
Gear Box
|
|
|
||
|
1. Check oil level in gear box, top up if
necessary
|
:
|
5,000 Kms.
|
||
|
2. Change oil in gear box (First in 10,000 Km)
than
|
:
|
72,000 Kms.
|
||
|
3. Clean breather in gear box
|
:
|
80,000 Kms.
|
||
|
4. Check gear box
mounting and tighten up if necessary
|
:
|
5,000 Kms.
|
||
|
Suspension
|
|
|
||
|
1. Grease the king
pin, tie rod ball joint, drag link ball joint, front spring pins & rear
spring pins
|
:
|
1000 Kms.
|
||
|
2. Check condition
of shock absorber , bushes, replace if necessary
|
:
|
10,000 Kms.
|
||
|
3. Check wheel alignment if necessary
|
:
|
40,000 Kms.
|
||
|
4. Check shock absorber, replace if defective
|
:
|
20,000 Kms.
|
||
|
5. Dismantle front
and rear springs, clean and apply graphite grease, check and if necessary
replace eye bushes
|
:
|
40,000 Kms.
|
||
|
6 Check and tighten of nuts of spring pins,
‘U’ bolt of front and rear springs
|
:
|
1000 Kms.
|
||
|
Front axle
|
|
|
||
|
1. Change
grease in front hub, adjust bearing play, replace damage/worn out parts
|
:
|
20,000 Kms.
|
||
|
Rear Axle
|
|
|
||
|
1. Check
oil level in rear axle, top up if necessary
|
:
|
5,000 Kms.
|
||
|
2. Change
oil in rear axle (For first 10,000 Km) than
|
:
|
72,000 Kms.
|
||
|
3. Change grease in rear hub, adjust
bearing play. Replace damage/worn out parts
|
:
|
20,000 Kms.
|
||
|
Wheel & Tyre
|
|
|
||
|
1. Check tyre pressure
|
:
|
Daily.
|
||
|
2. Tyre rotation
|
:
|
5,000 Kms.
|
||
|
3. Check wheel mounting nuts and tighten if
necessary
|
:
|
1000 Kms.
|
||
|
Propeller Shaft
|
|
|
||
|
1. Grease
propeller shaft ‘U’ joint, sliding yokes and centre bearing
|
:
|
1000 Kms.
|
||
|
2. Check
and tighten the propeller shaft centre bearing bracket mounting bolt
|
:
|
5,000 Kms.
|
||
|
Brakes-‘S’ Cam full
air brakes
|
|
|
||
|
1. Check
air dryer functioning, if there is condensed water/oil in the exhaust ,
replace the air dryer – desiccant cartridge and filter
|
:
|
Weekly/2,000 Kms.
|
||
|
2. Grease slack adjusters and cam shaft buses
|
:
|
Weekly/2,000 Kms.
|
||
|
3. Lubricate brake chamber fork and pin,
leakage of foot brake, ball joint of exhaust brake linkage
|
:
|
Weekly/2,000 Kms.
|
||
|
4. Check
brake system for any leakage, rectify if necessary
|
:
|
Weekly/2,000 Kms.
|
||
|
5. Check
brake lining wear
|
:
|
10,000 Kms.
|
||
|
6. Check proper functioning engine exhaust
brake and slackness in linkages
|
:
|
10,000 Kms.
|
||
|
7 Check brake torque plate mounting bolt
and tighten up if necessary
|
:
|
10,000 Kms.
|
||
|
8. Check
hoses for damage replace if necessary
|
:
|
20,000 Kms.
|
||
|
9. Check condition of brake valves, exhaust
flap in dual brake valve, nylon breather tube and clip of spring brake
actuator
|
:
|
20,000 Kms.
|
||
|
10. Check mounting bolt of brake chambers,
and other all mounting bolts
|
:
|
20,000 Kms.
|
||
|
11. Grease fulcrum pin bushes, cam shaft
bushes and roller ends
|
:
|
At the time of
replacing linings.
|
||
|
12. Complete
over haul of foundation brake
|
:
|
Every second brake
shoe re-lining or as required.
|
||
|
Steering
|
|
|
||
|
1. Check
oil level in steering gear box, top up if necessary
|
:
|
10,000 Kms.
|
||
|
2. check
and adjust steering wheel free play
|
:
|
40,000 Kms.
|
||
|
3. Change
oil in steering gear box
|
:
|
80,000 Kms.
|
||
|
4. Check and tighten if necessary ‘U’ joint
on steering spindle, steering gear box and its mounting bracket bolts joints
of pitman arms, drag link and tie rod
|
:
|
5,000 Kms.
|
||
|
Electrical
|
|
|
||
|
1. Check and tighten mounting bolt of
alternator, Starter motor, wiper motor, battery mounting bolt all electrical
connections and head lamp mounting screw
|
:
|
5,000 Kms.
|
||
|
2. Check battery cell and specific gravity
of electrolyte, recondition battery if necessary
|
:
|
40,000 Kms.
|
||
|
3. Check
head lamps focus, adjust if necessary
|
:
|
5,000 Kms.
|
||
|
4. Check electrolyte level in battery and
add distilled water if necessary
|
:
|
5,000 Kms.
|
||
|
5. Clean
battery post and terminals and apply petroleum jelly
|
:
|
1000 Kms.
|
||
|
6. Lubricate bushing of starter motor and
wiper motor linkages
|
:
|
20,000 Kms.
|
||
|
Body and
miscellaneous
|
|
|
||
|
1. Lubricate accelerator linkages, door
hinge, door latches, bonnet hinge, bonnet stay rod, bonnet opening cable
|
:
|
1000 Kms.
|
||
|
2. Apply
grease to door lock inner racket and pawl
|
:
|
40,000 Kms.
|
||
|
3. Check
door for proper opening and closing if required adjust striker assembly
|
:
|
10,000 Kms.
|
||
|
4. Check
mounting bolt of driver cabin, driver and co-driver seat
|
:
|
5,000 Kms.
|
||
|
Turbo charge and
dry type air filter
|
|
|
||
|
1. Tighten all fasteners on turbo charger,
air filter mounting and air duct hose connections
|
:
|
5,000 Kms.
|
||
|
2. Check
air filter indicator, if found ‘Red’ clean air filter housing and replace primary
cartridge
|
:
|
Daily.
|
||
|
3. Remove
and clean dust bowl of dry type air filter
|
:
|
2,000 Kms.
|
||
|
4. Check
air filter hoses for damage and replace if necessary
|
:
|
5,000 Kms.
|
||
|
|
|
Appx ‘F’
|
|
|
Technical Data
|
|
||
|
Engine
|
|
||
|
Model
|
:
|
Tata 497 TCIC (BS-II) fuel efficient.
|
|
|
Type
|
:
|
Water cooled direct injection diesel engine
with inter cooler.
|
|
|
No of cylinder
|
:
|
4 in line.
|
|
|
Bore stroke
|
:
|
97 mm x 128 mm.
|
|
|
378 cc . (LP/LPT)
|
|||
|
Max engine out put
|
:
|
66.3 Kw (90Ps) @ 2400rpm.
|
|
|
Max torque
|
:
|
325 Nm (31 Kgm) @ 1300-1600 rpm.
|
|
|
Compression ratio
|
:
|
17.5:1.
|
|
|
Firing order
|
:
|
1-3-4-2.
|
|
|
Air filter
|
:
|
Dry type.
|
|
|
Oil filter
|
:
|
Full flow paper type.
|
|
|
Fuel filter
|
:
|
Two stage pre-and fine filtration.
|
|
|
Fuel injection pump
|
:
|
Rotary type.
|
|
|
Governor
|
:
|
Mechanical.
|
|
|
Capacity of cooling system
|
:
|
17 Ltrs.
|
|
|
Crank case oil capacity
|
:
|
Max 9 Ltrs, Min 7 Ltrs.
|
|
|
Engine weight
|
:
|
390 Kg. (dry)
|
|
|
Radiator frontal area
|
:
|
2414 Sq cm.
|
|
|
Engine oil filter cap
|
:
|
01 Ltrs.
|
|
|
Clutch
|
|
||
|
Type
|
:
|
Single plate dry friction type.
|
|
|
Out side diameter of clutch lining
|
:
|
280 mm.
|
|
|
Friction area
|
:
|
798 Sq cm.
(Appx)
|
|
|
Clutch hydraulic system for vehicle with
‘S’ cam brakes
|
:
|
0.15 Ltrs.
|
|
|
.GEAR
|
:
|
GBS 27 Synchromesh.
|
|
|
No of gears
|
:
|
5 Forward, 1 reverse.
|
|
|
Gear ratio First
|
:
|
6.17
|
|
|
2 nd
|
:
|
3.34
|
|
|
3 rd
|
:
|
1.89
|
|
|
4 th
|
:
|
1.33
|
|
|
5th
|
:
|
1
|
|
|
Reverse
|
:
|
5.6
|
|
|
REAR
|
|
||
|
Type
|
:
|
Single reduction, hypoid gears, fully
floated axle shafts.
|
|
|
Ratio
|
:
|
3.875 (31/8)
|
|
|
Rear axle oil cap
|
:
|
2.75 Ltrs.
|
|
|
NT
|
:
|
Heavy duty forged 1 beam reverse Elliot
type.
|
|
|
STEERING
|
|
||
|
Type
|
:
|
Variable ratio steering.
|
|
|
Steering gear box
|
:
|
Reciprocating ball type
|
|
|
Ratio
|
:
|
35-40:1.
|
|
|
Power assisted
|
:
|
Integral hydraulic power assisted.
(optional)
|
|
|
Capacity
|
:
|
1 Ltr.
|
|
|
FRAME
|
:
|
(a) Ladder type frame with riveted/bolted
cross members.
|
|
|
|
(b) Side member are of channel section.
|
||
|
Depth : 200 mm .(max)
|
|||
|
Width 60mm.
|
|||
|
SUSPENSION
|
|
||
|
Type
|
:
|
Semi elliptical spring.
|
|
|
Spring span
|
:
|
Front 1450 mm.
|
|
|
Rear 1620 mm.
|
|||
|
Leaf width
|
:
|
Front 70mm.
|
|
|
Rear 70mm.
|
|||
|
Shock absorber
|
:
|
Hydraulic double acting telescopic type at
front and rear.
|
|
|
WHEEL AND TYRES
|
|
|
|
Tyres size
|
:
|
7.50x16-16 PR.
|
|
Tyre pressure Laden
|
:
|
Front - 6.2 (Kgs/sq cm)
|
|
Rear - 5.8 (Kgs/sq cm)
|
||
|
Fuel tank capacity
|
:
|
160 Ltrs.
|
|
CAB
|
:
|
All steel full forward control cowl (LP).
|
|
ELECTRICAL SYSTEM
|
|
|
|
Voltage
|
:
|
12 V.
|
|
Alternator
|
:
|
65 Amp.
|
|
Battery
|
:
|
12 V 120 AH.
|
|
Wind screen wiper
|
:
|
17 W-2 speed & intermittent wipe.
|
|
Wind screen washer
|
:
|
Electrically operated.
|
|
CHASSIS DIMENSION
|
|
|
|
Wheel base
|
:
|
3800 mm.
|
|
Track front
|
:
|
6550 mm.
|
|
Track rear
|
:
|
1577 mm.
|
|
Overall length
|
:
|
7125 mm.
|
|
Max width
|
:
|
2140 mm.
|
|
Overall height
|
:
|
2550 mm.
|
|
Grease front hub
|
:
|
140 gms.
|
|
Rear hub
|
:
|
300 gms.
|
|
Water pump
|
:
|
80 gms.
|
__________
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