Registered Address: Ashok leyland Ltd., No.

1, Sardar Patel Road, Guindy, Chennai - 600 032,

Ph. no.: 044 2220 6000 | Website: international.ashokleyland.com | email: [email protected]
* Conditions apply. Refer to operator manual for details.
 FOREWORD
Dear Customer,
Thank you for choosing our product. We are proud to have you in the Ashok Leyland family.
This Operator Manual has been prepared to acquaint you with the operation and maintenance of
Oyster bus fitted with Euro - III Norms Engine. Care has been taken to include as much useful information as
possible. You are requested to read this manual carefully before operating the vehicle. For your convenience, we have
given a provision for “Record of Maintenance” in this manual.
We, in Ashok Leyland, are engaged in continuously improving our products and it is therefore likely that some of the
specifications, dimensions, design, procedures, recommended practices referred to herein may change over a period of
time without prior notice and will be made available in the subsequent publications as required.
Some of the items, accessories and features shown in this book may not be available on your vehicle, but they are
applicable for other versions of the vehicles.
In order to get optimum performance from your vehicle, we would urge you to get all services and repairs done at the
workshops of Ashok Leyland’s channel partners and use only Genuine Spare Parts.
We have put in considerable efforts to ensure the accuracy of the contents of this book and shall be thankful for any
comments you may have to improve the same. Please write to:

AFTER MARKET - TECHNICAL LITERATURE

No.1, Sardar Patel Road, Guindy, Chennai, India - 600 032. Website: international.ashokleyland.com

PUB. NO. OM: OYSTER BUS:1523:0916:150:10

 CONTENTS

CHAPTER 1 - ATTENTION OWNERS 1.01 CHAPTER 4 - DASHBOARD, CONTROLS AND

OPERATING GUIDELINES 4.01
Vehicle Warranty 1.02
Dashboard Overview 4.02
Exhaust Emission 1.03
Instrument Panel 4.05
Service Policy 1.04
Gauges 4.06
Safety Tips 1.06 LCD Screen Display Details 4.08
Leyparts 1.08 Warning Indicators 4.11
Record of Maintenance 1.10 Controls 4.14
Exhaust Brake 4.16
Combination Switch 4.17
CHAPTER 2 - VEHICLE IDENTIFICATION 2.01
Steering System 4.21
Identification of Vehicle 2.02
Ignition Switch 4.22
Identification of Units 2.03 Engine Start / Stop Procedure 4.23
Operating Instruction For Seat Controls 4.25
Economical Driving 4.27
CHAPTER 3 - TECHNICAL SPECIFICATIONS 3.01
Check Before Driving 4.27
Weekly Checks 4.28
 CONTENTS
Do’s & Don’ts 4.30 CHAPTER 6 - MAINTENANCE AND LUBRICATION 6.01

On Spot Recovery 4.32 Maintenance Schedule 6.02

Tips To Improve Mileage 4.35 Maintenance Procedure 6.16

General 6.16
Tips To Improve Tyre Life 4.36
Engine 6.17
Diaphragm Clutch - Valeo 6.43
CHAPTER 5 - BUS BODY FEATURES 5.01
Gear Box 6.44
Vehicle Layout for School Bus 5.02
Propeller Shaft 6.45
Seating Layout for School Bus 5.03
Rear Axle 6.47
Seating Layout for Executive Bus 5.04 Front Axle 6.47
Safety Features 5.05 Power Steering 6.49
Interiors 5.09 Brake System 6.50

Exteriors 5.14 Parabolic Suspension 6.55

Electrical System 6.56
Video Surveillance System (Optional) 5.19
Wheels And Tyres 6.58
AC Control Panel 5.20
Filling Capacities 6.64
Control Panel Description 5.20
Recommended Lubricants 6.65
Display Description 5.20 Filling Points 6.66
Storage of Vehicles 5.24 Greasing Points 6.68
 CONTENTS

CHAPTER 7 - TROUBLE SHOOTING 7.01

Trouble Shooting - Engine 7.02

Turbocharger 7.10

Clutch 7.12

Gear Box 7.13

Rear Axle 7.13

Front Axle And Steering 7.14

Brake System 7.16

Electrical - Batteries 7.19

 ABOUT THE MANUAL
This manual gives information about the vehicle as intended and under the conditions foreseen by Ashok Leyland during normal operation, routine
service and maintenance.

All information, procedures, illustrations, specification provided in this manual can change anytime without prior notice as a part of continuous
improvements and most of which are shown for illustrative purpose only.

Safety Precautions

Throughout this manual, the reader can find symbols like “WARNING”, “CAUTION” and “NOTE” followed by specific instructions. Please read the
instructions before performing any operation.

WARNING CAUTION NOTE

CAUTION is used to indicate the presence

WARNING is used to indicate the presence
of a hazard that could cause minor or
of a hazard that could cause serious NOTE is intended to provide and stress on
moderate personal injury or damage to
personal injury. To avoid or reduce the risk, few important informations.
vehicle. To avoid or reduce the risk, the
the procedures must be followed precisely.
procedures must be followed precisely.
1. Attention Owners 1

Vehicle Warranty 1.02

Exhaust Emission 1.03
Service Policy 1.04
Safety Tips 1.06
Leyparts 1.08
Record Of Maintenance 1.10
 VEHICLE WARRANTY 4. The obligation under warranty shall personal property, commercial loss
1 be limited to either repairing or such as loss of revenue etc., During
Terms of Warranty replacing free of charge such parts of the period when the vehicle is
the vehicle as are deemed to be undergoing service / warranty
Ashok Leyland Limited (AL) warrants each repairs.
defective in the opinion of AL and
vehicle sold by it to be free from defects
shall not extend to consequential 7. The customer will be responsible for
in material and workmanship subject to
loses. The replaced part shall
the following terms and conditions: * The cost of non-durable
become the property of AL.
1. The period of warranty shall be 2 years materials (lubricants, fuel,
5. For proprietary parts not grease, filters, etc.), rubber
from the date of sale or 1,00,000 km
manufactured by AL such as Fuel items, liners (clutch, brake),
whichever is earlier.
injection Equipment, Electrical soft trims, upholstery and paint
2. The warranty extends to the first equipment, Brake components, coatings.
registered owner of the vehicle only Instruments, Batteries, Tyres , * The cost of maintenance and
or (in the absence of registration) to Tubes, AC Equipments, Doors lubrication operations.
the first commercial user of the and other body accessories the
vehicle. In the event of transfer or warranty terms of the respective * The cost of repairs made
any alienation otherwise of the supplier will be applicable. necessary by normal wear and
vehicle during the period mentioned tear, accidents or improper use
6. The buyer shall have no other right not authorised by AL or by
in Clause 1 above, the warranty shall
except those expressly stated herein improper / storage or
stand terminated unless prior
and have in particular no right to negligence.
written consent of Ashok Leyland is
repudiate the sale, or any
obtained. * The cost of on-road repairs,
agreement, or to claim any
3. In the event of any defect being towing parking and insurance.
reduction in the purchase price of
discovered within the period the vehicle or to demand any * The cost of repairs caused by
mentioned in clause 1 above, the damages or compensation for damage due to fire, flood,
defective part is returned to the incidental or consequential losses earthquake or such natural
nearest AL Dealer workshop, freight such as loss of use of vehicle, loss of calamities or by civil
paid, within 7 days. time, inconvenience or damage to disturbances.
1.02 ATTENTION OWNERS
8. The warranty shall become null and * If the recommended EXHAUST EMISSION
void: maintenance practice is not 1
* If the vehicle is used in ways followed. Operators must also carry out preventive
maintenance to ensure that smoke levels
not recommended by the 9. When a part is replaced under the
are not exceeded.
Company, if any features of the terms of warranty the benefits of the
vehicle are modified, if the warranty shall apply to the Check the Following aspects and rectify
vehicle is repaired or replacement part for the remaining if necessary: (Please refer page no. 6.02
disassembled, even partially, AL warranty period. for recommended maintenance
by persons not belonging to schedule)
10. AL reserves the right to modify the
AL’s authorised workshop, if 1. Injectors for correct opening
technical specifications and pressure and spray characteristics.
the vehicle is fitted with body introduce improvement to its
of design, size, position and vehicles at any time and is under no 2. Fuel Injection Pump for correct fuel
mounting other than what is obligation to apply such delivery and idling speed.
prescribed by AL, if the modifications or improvements to 3. Fuel filters for blockage / damage
overhang is extended in excess vehicles produced at an earlier date.
of the original specification 4. Injection timing - in case of excess
given in the Operator Manual, 11. This warranty is in lieu of and smoke in exhaust.
as certified by AL. excludes all conditions warranties 5. Cleanliness of diesel and diesel tank
liabilities expressed or implied, 6. Valve clearance
* If the fuel injection pump whether in common law statute or
calibration figures are altered otherwise in relation to all vehicle, 7. Air Cleaner element for clogging
or the relative seals tampered whether covered by warranty or not. 8. Engine breather for choking
with, lubricants or fuels or
coolants are used other than 9. Silencer/exhaust pipe for blockage
recommended ones, or 10. General condition of Engine (piston/
non-genuine spare parts are rings/valves) to be checked as when
fitted. necessary.
11. Proper functioning of pump and
injectors.
ATTENTION OWNERS 1.03
 SERVICE POLICY and agreed basis, of any product failure
CAUTION resulting from defective material or
1
The fuel settings of the FIP should never Ashok Leyland endeavors to secure sub-standard workmanship during the
be tampered. Use always low sulphur excellence of materials and workmanship manufacturing process. Hence any
and this section covers the service policy replacement arising out of normal wear
diesel fuel (Euro III Fuel) Use always
of AL. and tear of the following items will not be
genuine filter inserts. Use always the
the subject of a warranty claim:
correct grade of engine oil and change The service policy has three elements that
engine oil as recommended. you need to understand, viz., 1. Gaskets (other than Cylinder Head
Gasket)
1) AL’s Warranty terms
2. Rubber components such as fan
2) Dealer’s Service obligations
belts, hoses, oil seals, master
3) Owner’s maintenance responsibili cylinder kit, slave cylinder kit, wiper
ties blades, floor mats.
Scope of Warranty 3. Bulbs and lamp covers
It is absolutely essential to avail the Pre 4. Fuses
Delivery inspection and other Free
5. Upholstery including seat cushions
Services offered by AL to claim any
and covers
benefit under the terms of warranty
6. Glass items (other than windscreen
The terms of warranty are given in the
glass)
following pages. A list of wear and tear
items not covered under warranty is listed 7. Suspension pins and bushes
for ready reference. 8. Cowl
Non-Warranty Items 9. Fasteners except main bearing cap
The warranty terms are a precise bolts, con rod bolts, differential
statement of AL’s intention to cover the bearing cap mounting bolts
replacement / repair cost, on a standard

1.04 ATTENTION OWNERS

10. Parts recommended to be replaced Wear and Tear’ components under warranty
during routine maintenance 1
11. Consumable items such as lub oil, Benefits of warranty will apply up to the limit specified for wear and tear items listed
grease, anti-corrosion / anti-freeze below. It is to be understood that the life of these components depends on the nature of
compound etc. operation and duty cycle and only if the failure is premature in relation to these,
warranty replacement has to be effected. In any case, the benefits of warranty will not
NOTE apply beyond the limits stated.
Component Limit (in Kms / Months)
For proprietary parts not manufactured
by AL such as Fuel injection Equipment, Clutch Facing 32000 kms / 9 months
Electrical equipment, Brake components, Brake Lining 16000 kms / 6 months
Instruments, Batteries, Tyres, Tubes,
AC Equipments, Doors and other body Bearings 32000 kms / 9 months
accessories the warranty terms of the Oil seals 32000 kms / 9 months
respective supplier will be applicable.
Ball joints 32000 kms / 9 months
Fan belt 16000 kms / 6 months
UJ 32000 kms / 9 months
Clutch cylinders 16000 kms / 6 months
Cables 16000 kms / 6 months
Plastic and rubber components 6 months
Cab trim components 6 months
Electricals 6 months
Spring leaves 16000 kms / 6 months (provided suspension
not tampered)
Shock absorber 10,000 km / 3 months

ATTENTION OWNERS 1.05

 SAFETY TIPS Hill Driving While vehicle is in down hill
1 While going down a hill, always use the - Do not coast downhill with the
Safe driving is possible with total same gear as would have been used for transmission in neutral
concentration and involvement of the climbing it. Never drive downhill with
driver. Safety is more important than your engine switched off or gear in - Do not coast downhill with clutch
neutral position. Control the speed by disengaged.
Speed. Though innumerable skills can be
identified to expertise on safe driving staying in the correct gear to avoid - Do not coast the vehicle i.e., drive
techniques, only some of them are excessive use of brakes, which can lead to with engine switched off.
furnished here which can certainly reduce ‘Brake Fading’. The brakes fade as a result - Do not change gear unnecessarily.
the possibility of accidents if practiced. of excessive heating, causing temporary
brake failure. When allowed to cool, the - Ensure correct gear with vehicle
Wearing Seat Belt motion.
brakes will function normally again. Never
exceed the maximum rated speed by - Do not switch off exhaust brake at
selection of appropriate gears. Avoid down hills.
down shifting at high speeds which may - Do not accelerate while vehicle is in
cause engine over racing. downhill.
While parking on a hill, place wheel chock
S
PRES

- If air pressure is low in service brakes

3
4 2

1R

or wooden blocks under the wheels, in due to air leak use hand brake valve
addition to hand brake. Make sure to gradually to stop the vehicle.
remove such blocks from the road before
Always wear seat belt while driving. This
leaving. NOTE
safety feature reduces the chances of
personal injury in case of any accident by For emergency, use Graduated Hand Brake
securing the driver/co-driver firmly on if service brake got failed.
seat, preventing him to come away and
hit with steering, dash board or even with
windshield glass.

1.06 ATTENTION OWNERS

Skidding Tyre Failure Parking Your Vehicle
Skidding is the condition when one or If the front tyre bursts, the vehicle will Before leaving your vehicle, always put 1
more wheels lose road grip, causing tend to pull towards the side of the burst. the parking brakes on and the gear in low
involuntary movement of the vehicle in A rear burst will cause the vehicle to or reverse position. Never leave your
the direction other than intended. It is vibrate heavily. vehicle with engine running. Always put
normally caused by high speed, excessive on parking lights if vehicle is parked on a
In these cases, keep a firm grip on
or sudden braking, rapid acceleration, busy roadside.
steering wheel and try to steer straight
harsh braking etc. Oil, loose sand, snow
ahead. Apply brakes very softly till the Whenever you halt, make a habit of
and wet road surfaces are primary causes
speed is considerably reduced and then checking and cleaning wind screen, lights,
of skidding. Bald tyres and incorrect tyre
pull your vehicle to the side of the road. reflectors and rear view mirrors. Don’t
pressure increase this hazard. For correct
forget to check the tyre.
tyre pressure refer chapter 6.
Use of Cell Phone
Don’t apply brakes violently on slippery
It is dangerous to use cell phone while
roads to avoid skidding.
driving. It affects the concentration and
control on driving adversely. Please park
your vehicle off the road safely while
using cell phone.

ATTENTION OWNERS 1.07

 Driving in Adverse Environment - Do not inhale dust from clutch or
OTHER SAFETY TIPS
1 Driving through deep water may wet the brake lining, or blow dusts from these
- Modification to the vehicle in any units. It is injurious for health.
brake and adversely affect the
form (i.e. drilling or welding on frame,
performance. To dry it quickly, apply - Stay alert while driving. When you are
adding extra leaf in suspension,
change in leading dimensions etc.), tired take enough rest before driving
brakes softly a few times while
is strictly prohibited as it can affect on long trips, especially on hilly
maintaining safe road speed till the terrains.
the safety and economical aspect
braking ability returns to normal. adversely. Please adhere strictly to - If you find anything wrong or unsafe,
Drive slow in fog. Always drive at a speed body building guidelines. get it replaced / repaired before
that allows you to stop within the distance - Before commencing journey, ensure that commencing your journey. Never take
of your visibility. Use fog light for better the headlights, signal lights and brake a chance, it may prove too costly.
visibility. lights are clean and operating properly. - Do not park / leave the vehicle with
- Keep engine and its surrounding Ignition switch on.
area clean and free from leakages / - Do not drink and drive at any cost.
spillages of any inflammable liquid.
- Do not use personal entertainment
- Do not open radiator cap when the
systems through earphones. Use the
engine is hot. The boiling water can
vehicle infotainment system.
splash over you and cause serious burns.
- Bring the vehicle to the side of the - Do not transport or store hazardous or
road if low air pressure warning is flammable materials in the cabin.
heard. - Obey and abide by all traffic rules and
- If the vehicle is required to be lifted regulations.
(using jack), park the vehicle on level
and hard surface only. Use parking
brake and wheel chock to prevent
accidental rolling.

1.08 ATTENTION OWNERS

 1

LEYPARTS® is the original spare part for Reliable, efficient and economic operation Whenever repair work is carried out
Ashok Leyland vehicles and aggregates. of your Ashok Leyland vehicle depends on always demand usage of LEYPARTS®. To
the soundness of the components which ensure this, entrust repair jobs to Ashok
- LEYPARTS® stands for
go into making it. LEYPARTS® are the same Leyland Dealers and Authorized Service
• Life components which are used to build your Centers (ASC) so as to avail advantages of
• Economy Ashok Leyland Vehicle, i.e. LEYPARTS®
• Yield “What we fit is what we sell”
• Performance
It is highly probable that spare parts
• Availability beyond the umbrella of Ashok Leyland may
• Range not carry all quality & reliability aspects
• Tested required for optimum performance of
your Ashok Leyland vehicle. Hence usage
• Satisfaction
of those spare parts may be detrimental
LEYPARTS® offers to the required Reliability, Efficiency and
 A comprehensive range of genuine Economy of the vehicle irrespective of
spare parts for Ashok Leyland the repair workmanship. Moreover the
applications required for after sales replacement parts supplied to the market
support, by the OE approved vendors may not carry
 Emergency parts support through its the OE specifications as in LEYPARTS®. For
Vehicle Off Road service, meeting requisite safety and emission
requirements always use LEYPARTS®.
 Customized repair kits for all service
requirements, and

ATTENTION OWNERS 1.09

 RECORD OF MAINTENANCE
1
Complaint Attending Dealer’s Seal
Date Kms Work Carried out Remarks
Reported/Observed and Signature

PDI

5000

10000

15000

20000

25000

30000

1.10 ATTENTION OWNERS

 RECORD OF MAINTENANCE
1
Complaint Attending Dealer’s Seal
Date Kms Work Carried out Remarks
Reported/Observed and Signature

35000

40000

45000

50000

55000

60000

65000

ATTENTION OWNERS 1.11

 RECORD OF MAINTENANCE
1
Complaint Attending Dealer’s Seal
Date Kms Work Carried out Remarks
Reported/Observed and Signature

70000

75000

80000

85000

90000

95000

100000

1.12 ATTENTION OWNERS

2. Vehicle Identification
Identification of Vehicle 2.02
2
Identification of Units 2.03
 IDENTIFICATION OF VEHICLE

Manufacturer’s plate is fitted in all the vehicles. It shall show Vehicle Identification
Number (VIN), Gross Vehicle Weight, Gross Combination Weight (for applicable models),
2 TYPE
APPROVAL
VIN MB1XXXXXXXXXXXXXX
Axle loads, Chassis Type, Engine Type, Rear axle ratio and Engine number.
GROSS VEHICLE GROSS COMBINATION
WEIGHT (kgs) WEIGHT (kgs)
AXLE
LOADS(kgs) 1 2 3 4

CHASSIS ENGINE
VIN plate is riveted on the left hand side cross member near rear wheel.
TYPE TYPE
REAR AXLE ENGINE
RATIO NUMBER
Punch mark is on the left hand side of the frame at rear end cross member.

These two locations are easily accessible.

2.02 VEHICLE IDENTIFICATION

 IDENTIFICATION OF UNITS
Engine Diaphragm Clutch (Valeo) Synchromesh Gear Box (ZF S5-36 OD)
IDENTIFICATION
PLATE

FILLER PLUG

The gear box serial number and type are

The type and serial number are punched
punched on the name plate provided
The engine serial number is punched on on the driving plate. on the top side of the casing (Selector
the LH side rear top corner of crankcase housing side).
below cylinder head.

VEHICLE IDENTIFICATION 2.03

 Rear Axle (Meritor) RS120 Power Steering Gear (ZF) Alternator (Lucas Tvs)

2
x
xxx x
xxx

Serial number is punched on the housing Model and serial number sticker placed
at rectangular arm top area LH side. For For power steering gears identification
on top of the alternator stator body.
drive head, serial number is punched on plates are fixed on steering gear box.
the carrier RH rib, looking from the top on Starter Motor (Bosch)
the chassis. CB18 - CRS Fuel Injection Pump
Front Axle (A48 Beam with A36 Wheel End)

24V
XX-XX
BOSCH
XXX
XXX
X XXX
XXXX
05BOX 603
54099
55051
India
Made in

BOSCH XX-XX 24V

X XXX XXX XXX

550515409905BOXXXXX
Made in India 603

Model and serial number sticker placed

Model and serial number plate placed on on RH side on starter motor body.
Type and serial number are punched on Center of the RH side pump body.
the center portion of axle beam.
2.04 VEHICLE IDENTIFICATION
 3. Technical Specifications

The Model & Aggregate Details covered in the following pages helps you to identify the aggregates
fitted on your vehicle type / nomenclature. The technical data about vehicle performance, weight,
leading dimensions are also furnished.

3
The detailed technical specification of all the aggregates are given in the subsequent pages.
 TECHNICAL SPECIFICATION
Engine H6E3N118 Euro3, 6 Cylinder CRS Engine
Power 118kW (160HP) @ 2400 rpm
Torque 550 Nm @ 1500 rpm
Bore 104 mm
3 Stroke 113 mm
Air filter (Fleet Guard) Twin element dry type with pre cleaner
Fuel filter cum water separator is fitted at the pressure side before FIP and fuel
Fuel filter (Fleet Guard)
strainer is fitted before feed pump
FIP CB18 - CRS (Bosch) Fitted with EDC-17
Firing order 1-4-2-6-3-5
Tappet clearance Intake - 0.30 mm (0.012”), Exhaust - 0.45 mm (0.018”)
Cooling system type Circulating pump (Centrifugal) type, Forced circulation by volute pump
Cooling Fan Viscous Fan Clutch
Drive Poly V - Belt
Air Compressor Water cooled compressor,230cc

3.02 TECHNICAL SPECIFICATIONS

 TECHNICAL SPECIFICATION
Clutch Diaphram - Valeo make
Facing Diameter 380mm
Facing thickness 10 mm
Lining type F510
Clamping Load 1086 Kg 3

Clutch Withdrawal Gear Hydraulic actuation with booster arrangement

Gear Box ZF 5-36 OD GEAR BOX

No.Of Speeds 5 Forward + 1 Reverse
Gear Ratios I - 5.96, II - 3.05, III - 1.62, IV - 1, V - 0.78, Rev - 6.67
Gear Shifting Mechanism Mechanical

Propeller Shaft 1550 SERIES

No.of Shafts 2
Type of centre Bearing Rubber mounted

TECHNICAL SPECIFICATIONS 3.03

 TECHNICAL SPECIFICATION
Rear Axle Fully floating single reduction carrier MERITOR , RS120
Differential Hypoid
Capacity 5.3 T
Ratio 4.1:1
3 Wheel bolts 6

Front Axle A48 Forge ‘I’ Section reverse Elliot with A36 Wheel End
Capacity 3.7 T
Wheel bolts 6

Frame Ladder type bolted frame

Section (HxWxT) 185 x 65 x 6.15 mm (DxWxT)
No. of cross members 6

3.04 TECHNICAL SPECIFICATIONS

 TECHNICAL SPECIFICATION
Front - Suspension Parabolic leaf spring
Capacity 1650 kg
Span 1448 mm
Shock Absorbers Front and Rear
3

Rear - Suspension Parabolic leafspring

Capacity 2250 kg
Span 1524 mm

Steering System ZF Power steering

Drive LHD
Ratio 18.3: 1
Wheel Dia 451 mm

TECHNICAL SPECIFICATIONS 3.05

 TECHNICAL SPECIFICATION
Brake System Full Air Dual Line - Non Asbestos - ABS
Braking Area Front sq.cm. 1120 sq cm
Braking Area Rear sq.cm. 1360 sq cm
Lining Thickness Front mm 12.7mm
3 Lining Thickness Rear mm 12.7mm
Parking Brake Graduated Hand Control Valve on rear wheels only
Exhaust Brake Butterfly type

Electrical System
System Voltage 24V
Battries 2 x 12V, 150 Ah (20hr Rating)
Alternator Capacity 120A x 24V (2880W)
Starter Motor 4.5KW pre-engaged type (Bosch)
Instrument cluster Integrated instrument cluster
Isolater Switch Single pole - Isolater Switch

3.06 TECHNICAL SPECIFICATIONS

 TECHNICAL SPECIFICATION
Wheel Tyres
No. of Tyres Front : 2 Rear : 4
Spare 1
Tyre Size 235/75 R17.5 Radial Tubeless Tyres
Rim Size 6.75 x 17.5” – 131.5 mm offset 3

Performance data
Max. powered speed (km/hr) 106 Kmph
Max. Gradeability (Restart) 30%
Minimum Turning Circle Diameter 16m
Minimum Swept Circle Diameter 9.25m
Major Dimension (mm)
Wheel base 4200
Front overhang 1315
Rear overhang 2450
Overall Chassis Length 7965

TECHNICAL SPECIFICATIONS 3.07

 TECHNICAL SPECIFICATION
Overall Chassis Width 2230
Overall Chassis Height W/O Canopy 2060
Front track 1885
Rear track 1713
3 Min. Ground clearance 180
Angle of approach (Laden Chassis) 12°
Angle of departure (Laden Chassis) 9°
Weights (Kg) Laden Unladen (Chassis)
Front Axle 3700 2010
Rear Axle 5300 1120
Total 9000 3130

3.08 TECHNICAL SPECIFICATIONS

 TECHNICAL SPECIFICATION
Special Features
Aluminium Radiator with Charge Air cooler
Pendant type pedals with electronic Accelerator
Frame mounted Change Speed Operation
Exhaust Brake 3

Push to fit connector for Air piping

Chassis mounting AC Compressor
Clutch Booster Arrangement
Automatic Slack Adjuster
Parabolic leaf spring Suspension
Anti roll bar fitted on Front and Rear
Front overhang door
High capacity AC compressor

TECHNICAL SPECIFICATIONS 3.09

3

3.10 TECHNICAL SPECIFICATIONS

4. DASHBOARD, CONTROLS AND
OPERATING GUIDELINES
Dashboard Overview 4.02
Instrument Panel 4.05
Gauges 4.06
LCD Screen Display Details 4.08
Warning Indicators 4.11
Controls 4.14
4
Exhaust Brake 4.16
Combination Switch 4.17
Steering System 4.21
Ignition Switch 4.22
Engine Start / Stop Procedure 4.23
Operating Instruction For Seat Controls 4.25
Economical Driving / Check Before Driving 4.27
Weekly Checks 4.28
Do’s & Don’ts 4.30
On Spot Recovery 4.32
Tips To Improve Mileage 4.35
Tips To Improve Tyre Life 4.36
 DASHBOARD OVERVIEW

1. LH Dashboard
2. LH Dashboard Switch
3 3. Centre dash board
1 4
4. RH dash board
5. RH dash board switch
6. AC control unit
7. Gear shift knob
2
8. Steering wheel
4

5
6
7

4.02 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

 LH DASHBOARD AND CONTROLS

5 6

ISOLATOR

60 80
40
km/h
20
ROOF LAMP
L.H
ROOF LAMP
R.H
CO DRIVE LAMP
AC SWITCH

4
1/2

E
F
EDC
HAZARD
ENGINE DIGNOSTICS ABS
ISOLATOR

7 8 9 10 11
1 2 3 4
7. LH interior lamp
1. Isolator switch
8. RH interior lamp
2. Engine Diagnostic switch
9. Co - Driver lamp
3. ABS switch
10. AC switch
4. Hazard switch
11. OBD connector
5. Flick value
6. ORVM Joystick

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.03

 RH DASHBOARD AND CONTROLS

1 2 3 4

MIXTRAX

12V USB

BAND/
DIMMER
TRACK MAX

V1/V2 MENU - +

USB 12 V

AUTO

4
E
DRIVER FAN DRIVER LAMP
EXTERNAL
DESTINATION
BOARD ITS
CLOSE

SPHEROS

V1/V2 MENU
OPEN

7 6 5 8 9 10 11 12 13

1. WIFI antenna 6. Door Open / Close button 11. Destination Display Board ON/OFF Switch
2. Music player 7. LCD monitor 12. ITS Switch
3. USB charger 8. Driver Fan 13. AC control Unit
4. 12 V charger 9. Driver Lamp
5. Door Open / Close lamp 10. External Isolator

4.04 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

 1. Panel Indicators LH
1 2 3
2. Panel Indicators middle
3. Panel Indicators RH
4. RPM Meter
5. Temperature gauge
6. Air pressure Gauge Rear
7. Air pressure Gauge Front
8. Fuel Gauge
9. Speedo meter 4

SET MODE

9 8 7 6 5 4

1 2 3

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.05

 Fuel Gauge RPM Meter
GAUGES

Speedometer 15 20
10 25
rpm x 100
1/2
80 30
60 100 5

40 km/h 120
0 90
35
20 140 E F C

160 60 120
0 1/2

E F
Fuel gauge indicates approximate amount of
fuel remaining in the tank. RPM meter indicates the engine speed in
4
• F indicates Full tank. revolutions per minute.
Speedometer indicates the vehicle speed in • 1/2 indicates Half tank. The best possible performance / fuel economy
kilometers per hour (km/h). • E indicates Empty tank.
will be obtained if the engine speed is kept
WARNING all time within the “Economy” sector. This
is indicated by the green band in the rpm
When low fuel telltale is ON, fill the meter provided in the instrument panel. It is
fuel tank immediately. advisable to always operate the vehicle within
this Green Band.
CAUTION

A minimum fuel quantity 15 litres in CAUTION

rectangular tank is to be maintained to Do not operate the engine below 1000
avoid situations of air lock. Air lock or RPM. Failure to comply could lead to
frequent dry cranking of engine may result severe engine damage.
in damages to fuel injection equipment.

4.06 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

Air Pressure Gauge Before moving the vehicle, ensure that the If the gauge temperature is
The vehicle is equipped with two air pressure air pressure is built up to 6 bar to release the above 102°C, high engine coolant
gauges. parking brake. temperature warning is displayed
The low pressure warning buzzer which is to indicate that the coolant
fitted on instrument panel will beep if the air temperature has exceeded the
6 pressure drops below 4.5 bar or the parking normal working temperature.
brake is on.
In case of air leak in front or rear circuits, the WARNING
particular gauge connected to such circuit will
show comparatively low or nil air pressure. In
Operate the cluster controls and
such case the vehicle can be driven cautiously information display only when the
0 12 at lower speed with single circuit to the vehicle is stationery. Concentrate on the
bar nearest Workshop. road while driving, as the driver is totally
responsible for the vehicle and road safety. 4
• Pressure gauge 1 indicates the air Temperature Gauge
pressure of the front air tank CAUTION

Do not drive the vehicle, if the high

6 90 engine coolant warning telltale is ON.
C
2 Wait for sometime until the coolant
temperature reduces, and then open the
60 120 coolant tank and top‐up with water.
Never remove the radiator cap when the
0 12 engine is hot. The engine coolant may be
bar Temperature gauge shows the temperature of under high pressure and temperature, so
the engine coolant when the ignition key is in wait for the engine to cool down before
• Pressure gauge 2 indicates the air ON position. adding the coolant. Failure to comply
pressure of the rear air tank
could cause severe burns.

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.07

 LCD SCREEN DISPLAY DETAILS
DISPLAY MODES CASE DISPLAY STATUS FUNCTION

All segments on for

Screen – 01 5±0.5 seconds only Initialization screen during every ignition on.
(self test time)

Main ODO meter If Set button is pressed for less than 3 seconds the screen will jump to next screen.
Screen – 02*
(default) with AMT If Mode button is pressed for less than 3 seconds the screen will jump to the screen 13.

4 If Set button is pressed for less than 3 seconds the screen will jump to next screen.
Main ODO meter
Screen – 03 If Mode button is pressed for less than 3 seconds the screen will jump to screen 13 if
(default) W/O AMT
GSAS is Disabled else to screen 14.

Date Main ODO If Set button is pressed for less than 3 seconds the screen will jump to the next screen.
Screen – 04
meter If Mode button is pressed for less than 3 seconds the screen will jump to Previous screen.

If Set button is pressed for less than 3 seconds the screen will jump to the next screen.
Screen – 05 TRIP A KM If Mode button is pressed for less than 3 seconds the screen will jump to Previous screen.
If Set button is pressed for greater than 3 seconds Trip - A resets to 0 Km

Note : * Not Applicable

4.08 DASHBOARD, CONTROLS AND OPERATING GUIDELINES
 LCD SCREEN DISPLAY DETAILS
DISPLAY MODES CASE DISPLAY STATUS FUNCTION

If Set button is pressed for less than 3 seconds the screen will jump to the next screen.
Fuel Economy TRIP
Screen – 06 If Mode button is pressed for less than 3 seconds the screen will jump to Previous screen.
A
Trip - A Fuel economy becomes Zero on resetting to Trip - A in previous screen.

If Set button is pressed for less than 3 seconds the screen will jump to the next screen.
Screen – 07 TRIP B KM If Mode button is pressed for less than 3 seconds the screen will jump to Previous screen.
If Set button is pressed for greater than 3 seconds Trip - B resets to 0 Km
4
If Set button is pressed for less than 3 seconds the screen will jump to the next screen.
Fuel Economy TRIP
Screen – 08 If Mode button is pressed for less than 3 seconds the screen will jump to Previous screen.
B
Trip - A Fuel economy becomes Zero on resetting to Trip - B in previous screen.

If Set button is pressed for less than 3 seconds the screen will jump to the next screen.
Screen – 09 Distance to Empty
If Mode button is pressed for less than 3 seconds the screen will jump to Previous screen.

If Set button is pressed for less than 3 seconds the screen will jump to the next screen.
Screen – 10 Battery Voltage
If Mode button is pressed for less than 3 seconds the screen will jump to Previous screen.

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.09

 LCD SCREEN DISPLAY DETAILS
DISPLAY MODES CASE DISPLAY STATUS FUNCTION

This screen will be displayed only if the AdBlue feature is enabled.

Screen – 11 AdBlue Level* If Set button is pressed for less than 3 seconds the screen will jump to the next screen.
If Mode button is pressed for less than 3 seconds the screen will jump to Previous screen.

This screen will be displayed only if the AdBlue feature is enabled.

Screen – 12 Hour Meter If Set button is pressed for less than 3 seconds the screen will jump to the next screen.
If Mode button is pressed for less than 3 seconds the screen will jump to Previous screen.

4 This screen will be displayed only if the AdBlue feature is enabled.

Screen – 13 Diagnostic Code If Set button is pressed for less than 3 seconds the screen will jump to the screen 2 if
GSAS is disabled & AMT is enabled or screen 3 if GSAS is disabled & AMT is disabled
or screen 14 if GSAS is enabled & AMT is disabled.

This screen will be displayed only if the AdBlue feature is enabled.

If Set button is pressed for less than 3 seconds the screen will jump to the screen 3.
Screen – 14 GSAS Compliance
This screen will be visible only in Manual Transmission vehicles & GSAS feature is
enabled.

If any mode button or set button is pressed for greater than 3 seconds the screen will
Screen – 15 Soft ware Revision
jump to screen 2 if AMT is enabled or screen 3 if AMT is disabled.

Note: * Not applicable

4.10 DASHBOARD, CONTROLS AND OPERATING GUIDELINES
 WARNING INDICATORS
Telltale Name Colour Functions
Left arrow indicator flashes when the left turn indicator is turned ON. If the turn
Turn left Indicator Green indicator is flashing at a faster rate than normal, it indicates that one or more
bulbs have failed in the left side. Buzzer will be ON when the telltale is ON.

Front Fog Lamp Green Illuminates when the front fog lamp is turned ON.

Rear Fog Lamp Amber Illuminates when the rear fog lamp is turned ON.
4
Illuminates if the battery is not being charged by alternator when engine is
Battery not charging Red running, along with TT buzzer also will be turned on. Contact nearest authorised
Ashok Leyland Service Centre for further assistance.

Differential Lock* Yellow Illuminates when the differential lock is engaged.

Cab Tilt* Red Illuminates when the cab is not locked properly.

Exhaust Brake Amber Illuminates when exhaust brake is ON.

Note: * Not applicable

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.11
 WARNING INDICATORS
Telltale Name Colour Functions

Illuminates when the air filter is blocked. Contact nearest authorised Ashok
Air Filter Red
Leyland Service Centre for further assistance.

Gear High Range* Green Illuminates when gear is selected more than 4 (only in 9 speed gear vehicle).

Illuminates if engine oil pressure falls below the critical value. If the Telltale is ON
Low Engine Oil Pressure Red during engine running Contact nearest authorised Ashok Leyland Service Centre
4 for further assistance.

High Beam Blue Illuminates when the head lamp high beam is turned ON.

Illuminates continuously until the driver fastens the seat belt upon ignition.
Seat Belt Red Buzzer will be ON when vehicle is driven without fastening the seat belt and goes
OFF when the seat belt is fastened.

Illuminates when the brake pressure is above 5 bar and when the parking brake
Park brake engaged Red
is engaged and goes OFF once it is disengaged.

Illuminates when pressure falls below 4.5 bar in any of the pressure gauge.
Low Air Pressure Red
Buzzer will be ON when the telltale is ON.

Note : * Not applicable

4.12 DASHBOARD, CONTROLS AND OPERATING GUIDELINES
 WARNING INDICATORS
Telltale Name Colour Functions

ABS Tractor* Yellow Illuminates when there is malfunction in the tractor ABS.

Illuminates when the load body is raised. When the load body is not laid down
Load Body* Red
properly at 20 kmph then buzzer is ON in cluster.

Hazard Red Illuminates when the hazard switch is ON.

ABS Trailer* Yellow Illuminates when there is malfunction in the trailer ABS. 4

PTO* Yellow Illuminates when the Power Take‐Off (PTO) solenoid is engaged.
Right arrow indicator flashes when the right turn indicator is turned ON. If the
Turn Right Green turn indicator is flashing at a faster rate than normal, it indicates that one or
more bulbs have failed in the right side. Buzzer will be ON when the telltale is ON.
• Illuminates when the flange heater is functioning
• Flange heater operates when the coolant temperature is below around -10
Air Pre - Heater* Amber
degree Celsius
• Telltale operates after ignition is ON for 20-30 sec, then during cranking 20-30 sec
• If the vehicle speed is above the over speed threshold continuously for 5
seconds, then the telltale will be ON and once the vehicle speed is less than
Over Speed Red the threshold , telltale shall be OFF
• Overspeed threshold limit is 120kmph
Note : * Not applicable
DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.13
 CONTROLS Instrument gauges illumination 2. Brake pedal
During night driving the Instrument gauge Please press the brake pedal gently, when
Hazard warning switch dials are back lit, using Head lamp switch. the vehicle requires braking. Avoid fierce
If the vehicle is momentarily Hand brake valve (flick type) braking, unless it is an emergency.
stopped for any reason put 3. Clutch pedal
on the Hazard warning It disconnects the drive from engine to
switch. All directional transmission. Whenever gear shifting is
indicators on front and rear required depress the clutch pedal. It is
side of the vehicle will harmful to rest the leg on the clutch pedal

OFF ON
simultaneously flicker on. while the vehicle is running, as it would
damage the clutch components.
4 It indicates other road users that the
vehicle is not in operating condition.
ABS switch Whenever the vehicle is parked the hand 2
brake valve to be actuated for applying
Use piano switch in dashboard
parking brakes. To apply lift the lock-
to on or off ABS, after inserting 1
ABS
ing collar and move the knob to ‘ON’
the ignition key. position. Similarly for releasing lift the 3
locking collar and move the knob to ‘OFF’
Isolator switches position. The hand brake valve can also be
Battery isolator switches used for emergency application of brake.
enable battery supply to be 1. Accelerator pedal
CAUTION
cut instantly. Vital in an Gradually increase the acceleration and
emergency and also very try to drive the vehicle in a steady speed Do not use clutch pedal as foot rest
useful during vehicle storage of about 50 kmph. Do not accelerate
to ensure electrical isolation. during gear shifting.

4.14 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

 EXHAUST BRAKE - LAYOUT

Cab Lap Switch

Exhaust Brake Solenoid

HI
LO
INT

OFF
INT
TIME
S

F
MAN
UP

R OFF
L

Combination IN
OU
T
Switch
4
LOI
H

T
IN

3B
F
OF
TIM T
E

er
IN

h Boost
S

To Clutc
F
N
MA
UP

Exhaust
Brake Control

Au
x. Air
Ma Tan
in A k
ir T
ank Port 24

PV
Exhaust

QS
Brake Assy
22
1

24

A 21 QSPV Air Dryer

23

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.15

 EXHAUST BRAKE –– Check for air, exhaust leaks and also Micro Switch
defective electrical connection and
The exhaust brake is an auxiliary brake rectify for ensuring efficient
system to be used mainly during operation.
continuous braking on long descending
DON’TS
hilly gradients as well on level roads.
–– Do not depress the clutch as this will
With this arrangement the regular
make the exhaust brake in effective.
friction type wheel brakes are subjected
to less wear and tear and kept cool for –– Do not exceed the recommended
A micro switch is located on the brake
emergency use without excessive heating speeds for respective gears.
4 pedal. This gets activated at the beginning
of brake drums. –– Do not press accelerator pedal. of the pedal stroke and energises the
DOS solenoid to release air pressure to
CAUTION exhaust brake.
–– Before applying exhaust brake,
change to appropriate gears Never raise engine speed with exhaust
brake applied during actual driving.
suitable to the vehicle speed and
road condition.
–– While switching ON the exhaust
brake, remove the leg from
accelerator. Service brake can be
used in conjunction with the
exhaust brake for emergency
stopping of the vehicle.

4.16 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

 COMBINATION SWITCH
The combination switch is a multifunction Wipers Low Speed Wipe
switch mounted on the steering column.
The wipers can be operated at different
Combination Switch Controls ‐ Wiper Side
(Left Hand Stalk) speeds by rotating the knob to the required
mode. The wipers operate when the ignition
key is in ON position. OFF
INT
INC PULL UP
1. Low speed wipe LO
HI DEC
OFF
ON

2. Intermittent wipe
OFF
INT
LO
RES INC PULL UP 3. High speed wipe
LO
HI DEC
OFF
ON 4
Wipers OFF
This mode can be selected by rotating the
centre rotary knob to the LO position.

The combination switch controls the following

functions OFF

RES INT
INC PULL UP
1. Wipers LO
HI DEC
OFF
ON

2. Washer
3. Cruise control
4. Exhaust brake
In this position, the wipers are non operational.

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.17

 Intermittent Speed Wipe High Speed Wipe Washer (Self return)

OFF OFF
OFF
INT
INT INT RES INC PULL UP
INC PULL UP INC PULL UP LO
RES OFF
LO LO DEC ON
OFF OFF HI
HI DEC ON HI DEC ON

INT HI

4 • This mode can be selected by rotating the This mode can be selected by rotating the • The washer can be operated by lifting the
centre rotary knob to the INT position. centre rotary knob downwards to the HI
position. combination switch upwards, when the
• The wipers operate intermittently in this ignition key is in ON or ACC position.
mode.
NOTE • Upon activation, the wipers will perform a
• This mode can be used during drizzling or
misty weather conditions. Never operate the wiper when front single wiping operation.
cab hood is in Open Condition
• The combination switch automatically
Also dry Running is not recommended returns back to home position.

NOTE

Do not run the windscreen washer dry as

the motor will be damaged.

4.18 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

Exhaust Brake Combination Switch Controls ‐ Lighting Side • Along with the parking lamp, the tail
(Right Hand Stalk) lamp, the license plate lamp and the Back
light on the instrument cluster will light
1. Parking lamp up.
2. Head lamp low beam • The parking lamp can be switched ON,
OFF 3. Head lamp high beam even when the ignition is switched OFF.
INT
RES

4. Turn indicators
INC PULL UP
LO
OFF

CAUTION
HI DEC ON

5. Passing light
6. Front fog lamp Ensure that the parking lamp is OFF,
7. Rear fog lamp when the vehicle is left unattended for
a longer period.
The exhaust brake is engaged by pulling the Parking Lamp
4
Head Lamp Low Beam
combination switch whenever the vehicle is
travelling downhill.

OFF

S
PASP) OFF OFF
(U
L S OFF
R PASP)
(U
L
R

• Turn the outer rotary knob clockwise to

the first position to turn ON the parking When the ignition key is in ON position, rotate
lamp.
the outer rotary knob in clockwise direction to
second position to turn ON low beam mode.

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.19

 Head Lamp High Beam Turn Indicator The passing light can be turned ON by pulling
the lever upwards. The parking light can
OFF be switched ON, even when the ignition is
S
PASP) OFF switched OFF.
(U
L
R
Front Fog Lamp
OFF

S
PASP) OFF
(U
L
R OFF

S
PASP) OFF
(U
L
R
• When the head lamp is in low beam • Move the outer rotary knob upwards and
4
position, push the combination switch to downwards to turn ON the left and right
turn ON high beam. indicators (both front and rear) respectively.

• The head lamp high beam can be switched • The turn indicator can be operated only
when the ignition key is in ON position.
ON, even when the ignition is switched
• Rotate the inner rotary knob anti‐
OFF. Passing Light
clockwise to turn ON the front fog lamp
and rotate it in the same direction to turn
OFF the lamp.

• The front fog lamp is ON when the parking

OFF
lamp is ON.
S
PASP) OFF
(U
L
R

4.20 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

Rear Fog Lamp
NOTE STEERING SYSTEM

The rear fog lamp should be turned Steering Wheel and Horn Pad
ON only when visibility is very poor.

OFF

S
PASP) OFF
(U
L
R

2
• Rotate the inner rotary knob clockwise to 1 4
turn ON the rear fog lamp and the knob
automatically returns back to the normal
1. Horn pad
position
2. Steering wheel
• Rotate the knob in the same direction to
turn OFF the lamp. Steering wheel has a horn pad at the centre.
• The rear fog lamp is ON when the head
lamps are turned ON.

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.21

 IGNITION SWITCH LOCK ON

Switch position
CK AC
LO

C
ON STAR
T
When the ignition key is in ON position,
In this position, electrical systems are functions like wipers and combination
disabled except a few like parking lamps, switch are activated.
4 hazard warning indicators and horn.
Ignition key barrel START
The ignition key barrel is located on the −− Insert or remove the ignition key only
right side of the steering column. in this position.
Before starting the engine, check whether ACC
the gear is in neutral position else engage
the gear lever in the neutral position.
The ignition key barrel has four positions
1. LOCK
2. ACC Turning the ignition key to START position
3. ON activates all vehicle functions and the
engine is ready for use.
4. START Once the engine is started, the engine will
Turning the ignition key to ACC position not crank again (Anti-cranking) while
running, even if the ignition key is turned
will switches on all electrical accessories.
to START position.
4.22 DASHBOARD, CONTROLS AND OPERATING GUIDELINES
 ENGINE START / STOP PROCEDURE −− Crank engine (10 secs maximum)
CAUTION until it starts.
Before starting ensure that the gear is in Do not operate the starter motor for −− Check oil pressure - minimum 0.5 Kg/
neutral position and the parking brake is more than 10 seconds continuously. cm² at idling.
applied.
If the engine does not start, wait for 30
To reduce transmission drag on cold CAUTION
seconds before the next crank.
vehicles, depress the clutch pedal.
Do not leave the ignition key in ON To obtain trouble free and long life
position, if the engine is not running. from the turbo charger, keep the
NOTE
Failure to comply will lead to battery engine in idling rpm immediately after
If it is required to start the vehicle in discharge. starting and before stopping, for about
a garage or workshop, ensure that Idle the engine always about 2 minutes 2 minutes
4
adequate ventilation is provided. after starting and before switching off After starting the engine proceed slowly
the engine. and keep engine at an average speed until
Engine Start Procedure
normal operating temperature is reached.
Do not switch-off the engine through
1. Insert the ignition key into the By this method it is possible to obtain:
gears
ignition key barrel located on the
−− Optimum oil flow throughout the
right hand side of the steering
WARNING lubrication circuit
column. Turn the key to start
position. −− Exhaust gases within the specified
Do not remove the ignition key from limit.
2. Turning this key further will crank the the ignition lock until the vehicle is
stationary, since it is not possible to −− Fuel economy.
engine. After starting the engine
release the key immediately. steer the vehicle, if the key is removed.

To warm-up engine
−− Switch on the ignition.
−− Do not depress the accelerator pedal.
DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.23
 Engine Stop Procedure GEAR SHIFT PATTERN ZF S5 36 OD

R 2 4

CK AC
C
LO

ON
STA
RT

1 3 5
The gearshift arrangement for ZF
The ignition key provided with the vehicle
synchromesh gearbox is shown above.
is used to start and stop the engine.
4
NOTE

Always remove the ignition key while

leaving the vehicle. Avoid rough
handling.

4.24 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

 Sliding Adjustment Front Side Height Adjustment
OPERATING INSTRUCTION FOR SEAT
CONTROLS (Forward & Backward) (Up & Down)

DRIVER SEAT

LIFT

LIFT LIFT

LIFT LIFT
LIFT

LIFT LIFT
LIFT
LIFT LIFT
LIFT
LIFT

LIFT LIFT LIFT LIFT

LIFT LIFT LIFT

4
1. Lift up the lever to activate front side
1. Lift up the lever to activate sliding height adjustment.
Seat with seat belt provision is provided, the mechanism. 2. Adjust the seat up or down as required.
seat is designed to have following adjustments 2. Move the seat forward or backward as 3. Then, release lever to lock at desired
to have improved driving comfort for the required. position.
driver. 3. Then, release lever to lock at desired
1. Sliding Adjustment position.

2. Front Side Height Adjustment

3. Rear Side Height Adjustment
4. Backrest Reclining Adjustment
5. Weight Adjustment

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.25

 Rear Side Height Adjustment Backrest Reclining Adjustment Weight Adjustment
(Up & Down) (To & Fro) (Up & Down)

LIFT

LIFT

LIFT LIFT
LIFT LIFT
LIFT LIFT
LIFT LIFT

LIFT LIFT
LIFT

4 1. Lift up the lever to activate rear side 1. Lift reclining lever upwards 1. Rotate the knob clock wise or anti-clock
height adjustment. wise.
2. Adjust backrest angle to desired level.
2. Adjust the seat up or down as required. 3. Release lever to lock. 2. This will increase or decrease the seat
stiffness.
3. Then, release lever to lock at desired
position. NOTE 3. This adjustment is done based on Driver’s
weight to have better riding comfort.
Cushioned seats are not standard
fitment. WARNING
Knitted type seats are also available
with above adjustments, without Never attempt to adjust the driver seat
weight adjustment. while the vehicle is in motion. Failure
to comply will lead to loss of control,
resulting in accidents.
Ensure that the seat is securely locked
in position after adjustment.

4.26 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

 ECONOMICAL DRIVING developed, approximately 80% of the CHECK BEFORE DRIVING
maximum rated speed.
The following suggestions should be 3. On downgrades To get maximum service life from your
considered; vehicle please carry out the simple
Engage suitable gear and avoid excessive checks and inspections detailed on the
1. Reduce engine speed brake wear. following pages. These simple checks and
This is very important and applies Abrupt acceleration and braking results inspections will ensure minimum
particularly to vehicles that travel in a waste of energy, greater stress on operating cost and maximum uptime of
long distances on highways. The best mechanical components, faster wear of your vehicles.
possible performance / fuel economy will be brakes and tyres. Avoid such bad driving Checks Before Each Journey
obtained if the engine speed is kept at habits!
all time within the “Economy” sector,
4
namely around the maximum torque
speed. This is indicated by the green
band in the rpm meter provided in the
instrument panel. It is advisable to always
operate the vehicle within this green
band.
2. On upgrades
Select the gear best suited to the
1. Use dipstick to check engine oil level.
gradient, and remember that high
average speeds and optimum fuel Top up through filler cap.
economy depend on your driving skills
and correct use of the transmission.
On upgrades keep the engine speed
over that at which maximum torque is
DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.27
 If red band appears replace the WEEKLY CHECKS
primary filter element
5. Check water separator for collected 1. The new power steering reservoir is
water and drain if necessary. If water a transparent one, hence the oil
MAX separator is not drained periodically, level can be visually checked
MIN
fuel contaminates with water, enters without removing the cap.
the fuel injection pump and injectors Minimum and maximum levels are
affecting performance and damaging embossed on the reservoir. With
the fuel system. engine switched off and wheels in
COOLANT LEVEL Also check: straight ahead position, the oil level
should be at the top reference mark.
1. Tyre conditions. If necessary top up after removing
2. Check coolant level. Top up through
4 2. Operation of service & parking rakes. the cap.
filler cap.
3. Operation of lights, warning
indicators and windscreen wipers.
MAX

MIN

POWER STEERING RESERVOIR

3. Drain condensate from air tanks.
4. Check the vacuum indicator provided
on the instrument panel for the
appearance of red band.
4.28 DASHBOARD, CONTROLS AND OPERATING GUIDELINES
 6. Check fluid level in the clutch
reservoir, the fluid level should be at
the Max mark on the reservoir.
Check for any leaks, rectify it and
topup if necessary.

Under inflation Correct inflation

Never exceed maximum permissible

load on each axle (This however
should not affect total vehicle
2. Check the battery electrolyte level,
weight).
if necessary, top up using distilled
5. Also check the exhaust system 4
water with batteries at rest and
cold. visually. If exhaust is excessively
smoky or engine is noisy refer to an
3. Operate jack a few times under no
authorised Dealer for necessary
load to check and preserve its
checkups.
efficiency.
4. Check tyre wear and pressure
AKE FLUD
BR DO
LY T3

N
EO

-D
REMOVING US

OT
(don’t forget the spare wheel!).

4
FR
OM
A
SEALED CONT
ORE
If necessary, inflate to the specified PB
EF
CA

AIN
N
EA

E
R
CL

pressure (Refer Chapter - 6). If

WARNING

MAX

pressure is low, tyres tend to wear MIN

on the outer treads. Check toe-in

and camber in case of abnormal
wear.

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.29

 DO’S & DON’TS - For coolant topping up, use only - Disconnect alternator / battery
premixed coolant (Eurocool LL Max electrical connection while carrying
Do’s 50 & Servo Kool ALT) directly. Do not out welding work on the vehicle.
- Periodically check and ensure that dilute with plain or demineralised - Maintain electrolyte level in the
the radiator cowl is intact, and water for top up. battery using distilled water.
replace a defective thermostat or a
missing header tank filler cap - Fill up diesel tank at the end of each - Drain water separator as & when
immediately as otherwise the working day to reduce water required.
efficiency of cooling system would condensation in the tanks.
be affected and this will damage the - Before towing the vehicle,
engine. disconnect the propeller shaft while
4 - Check radiator stay bracket towing the vehicle for a long
mounting bolts for tightness. Check distance. Also mechanically wind off
the silent block bush in stay rod and the rear spring brake chamber while
replace if found defective. towing.
- To obtain a trouble free and - Park the vehicle on a level and hard
enhanced engine life, maintain the ground when lifting (Jacking) the
air cleaner as per recommended vehicle. Apply hand brake as well as
maintenance procedure. chock the wheels.
- After starting the engine, check for - Drain air tank once in a week to
proper functioning of all instrument drain water and oil sediment from
gauges and lights. the system.
- Remember that wheel hubs are to - Check tyre pressure and ensure it is
be packed with grease. as per recommendations.

4.30 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

Don’ts - Fuel pump setting should not be - Do not attempt to dismantle spring
- Do not weld or drill holes on chassis tampered with. brake actuator without proper
frame. - Do not coast down hill with the special tools.
- Do not extend chassis frame/cabin transmission in neutral, or with the - Do not tamper the air pressure
as this can lead to premature clutch disengaged. settings in the unloader valve (8.25
failures. - Do not coast the vehicle i.e. drive Kg/cm²). Otherwise this can result in
with engine switched off. This will inefficient brake/excess tyre wear.
- Do not reinforce chassis frame and
do not load the vehicle more than affect gear box life. - Do not accelerate engine after
its rated GTW. - Do not run the vehicle with leakages starting as well as before stopping,
- Maintain original suspension and do of air, fuel, oil and water. keep the engine at idling RPM for
4
not add additional leaves and do not minimum 2 minutes. This can
- Do not ride the clutch pedal as it
recamber springs as recambering prevent damage to turbo charger.
leads to premature wear of clutch
will result in frequent spring
plate and other associated - Do not switch off ignition key switch
failures.
components. when the engine is in running
- Do not operate starter for more condition, this will cause white
than 15 seconds at a time and wait - Do not move the vehicle before the
smoke
for 30 to 60 seconds before trying low pressure warning buzzer stops
again. beeping (set to stop beeping
between 6.0 and 6.4 Kg/cm²).
- Do not add cold water to a hot
Otherwise premature wear of brake
engine as this can lead to crack in
linings would take place due to
crankcase and other associated
partial brake binding.
parts.

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.31

 ON SPOT RECOVERY Fuse box consists of 37 fuses for circuit
operations and six spare fuses. The lamps/
FUSE BOX DETAILS units protected by the fuses and the cor-
MICRO RELAYS
responding fuse ratings are indicated on
the fuse box cover.
PARK LAMP WIPER HIGH FRONT FOG

Fuses Replacement/checking
HEAD LAMP RELAY RELAY LAMP
DUMMY HIGH BEAM DUMMY RATING : 12A/24V
RATING :15A/24V RATING : 15A/24V
RATING :15A/24V

HORN WIPER LOW

RELAY RELAY
HEAD LAMP
DUMMY LOW BEAM RATING :15A/24V RATING : 12A/24V DUMMY
RATING :15A/24V DUMMY

BUS BODY ELECTRICAL FUSES

TOP MAR. LAMP
DRIVER COMP.

FRONT & REAR

SPARE FUSE

SPARE FUSE

SPARE FUSE

SPARE FUSE

SPARE FUSE

SPARE FUSE
DRIVER FAN

SUPPLY 1
EXTRA SW+

EXTRA SW+
SUPPLY
LAMP

EXTRA B+
LAMP RH
INT ROOF

INT ROOF

SUPPLY

4
LAMP lH
10A

10A

10A

15A

15A

15A

15A

10A

10A
5A

5A

5A

5A

5A
-

-
The fuses mounted in the fuse holders of
CHASSIS ELECTRICAL FUSES fuse box are located near the dashboard.
HIGH BEAM LH FRONT INDI. LH FRONT PARK LH STOP LIGHT SW HORN
To check or replace a fuse remove the
10A 5A 5A 5A
WIPER MOTOR
10A cover. Fuses can be checked without re-
moving from their position.
HIGH BEAM RH FRONT INDI. RH FRONT PARK RH STOP LH SWITCH
10A 5A 5A 5A 10A
LOW BEAM LH REAR PARK LH WIPER MOTOR

Refit the cover after replacement/checking.

REAR INDI. LH STOP RH
LOW AND HIGH
5A 5A 5A 20A
10A
LOW BEAM RH REAR INDI. LH REAR PARK RH DRIVER SEAT

Relays
REVERSE SW
10A 5A 5A 5A 5A
FR FOG LAMP LH CLUSTER PARK HEAD LAMP SW HEAD LAMP
HAZARD
10A 15A
ILLUMINATION
5A
INST CLUSTER
5A
LEVELLING
5A The following relays are fitted in electrical
system
FR FOG LAMP RH FLASHER AIR DRIER
GAUGES -
10A 15A
5A 5A

CHASSIS ELECTRICAL RELAYS

1. Horn, ignition relay,
2. Directional indicators and hazard
warning lamps,
IGINTION IGINTION BODY
RELAY 1 RELAY 2 LOADS
RELAY
RATING :50A/24V RATING :50A/24V
DUMMY RATING :50A/24V DUMMY DUMMY
3. Head lamps, Parking & Wiper relay

4.32 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

WHEEL CHANGING - Tyres on the same axle must be Wind off the release bolt anticlockwise.
of the same type and nominal When the vehicle is to be stored for peri-
When replacing road wheels ensure that size. The wheel size, tyre size, ods exceeding one month, the following
the following items are clean and free type and speed/load rating as
procedure must be adopted to prevent
from paint, rust, foreign matter etc, fitted to the vehicle as original
damage to the brake shoe and drum as-
- Mating faces of the hub flange. equipment should be fitted to
the model question. semblies,
- Wheel nut threads. - Park the vehicle in the storage
PARKING BRAKE ACTUATOR WINDING OFF
- Wheel bolt threads. area chock the
Ensure that the wheel nuts are torque
Bearing
Stem Plug
- wheels and release the Parking
brake controls.
tightened progressively and diametrically Dust seal
Gaiter

to recommendation. - Completely drain the air 4

reservoir.
Whenever a road wheel has been
Lock nut

Push rod assembly

- Wind off the Parking brake.
removed or replaced, the wheel nut O ring Bearing
Integral seal Flange
- Place a suitable notice on the
torques should be checked and torqued if
windscreen in front of the driver
necessary after driving a further 250 km
facing inward stating “Brake
(150 mile). actuator released. Do not drive.
When replacing tyres on wheel and tyre WARNING No brakes”.
assemblies ensure that the recommenda- Before moving the vehicle apply
Winding off the spring parking brake
tions below are followed. chamber immobilises the parking the brakes by winding in the
- Do not mix radial tyres and cross brake mechanism. Do not attempt release bolts or resetting the
ply tyres on the same axle. to wind off the bolt without suitably parking brake actuator and
chocking the road wheels before hand. recharge the system with air.
- Do not fit radial tyres to the front
axle when crossply tyres are
fitted to the rear axles
DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.33
 Front towing eye Vehicle that require breakdown recovery Unladen vehicle
must be towed as follows:
Disconnect the propeller shaft from the
rear yoke and secure if engine assistance
A B is not required or remove the propeller
shaft completely if engine assistance is
required for air pressure, alone.
Laden vehicle
May use a suspended lift/tow with the
Should a rigid tow bar with no lifting or the bumper removed and the chains attached
4 Move lever to mid position and lift out. towing requires the front axle to be lifted, to the axle beam. Prior to lifting a wood-
Replace pin in position (A or B) and press en sleeper should be positioned under-
down the lock. the vehicle must be either unloaded and a
side of the chassis front cross member to
crane lift used directly under the front axle. avoid damage.
Towing recovery
CAUTION
CAUTION
If neither of these alternatives are
possible then a suspended lift/tow is Cantilever type systems are not
recommended because of the
permitted but only on good roads at a
excessive bending loads they impose
max speed of 30 kmph. on chassis side members.

If some air supply is available connect via

coupling if no air pressure is available,
chock the wheels and wind off the spring
brake.

4.34 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

 TIPS TO IMPROVE MILEAGE

1. Fill diesel in reputed single filling station

2. Fill at early morning or late evening to get high density fuel
3. Don’t allow diesel to get condensate
4. Check and drain water separator regularly
5. Check and maintain recommended engine idling rpm
6. Don’t idle engine for long duration in signals
7. Don’t clutch ride
8. Avoid sudden pick up and panic braking 4
9. Check and maintain recommended tyre pressure
10. Check wheels for free rotation – brake binding
11. Shift appropriate gear for appropriate speeds
12. Always drive vehicle in the green band on Engine rpm meter
13. Always maintain recommended loads (Don’t overload)
14. Check for any restriction in air intake
15. Use recommended lubricants
16. Maintain vehicle in an authorized dealer point
17. Check and arrest air leaks.
18. Clean radiator and air cooler fins.
19. Maintain correct fan belt tension.

DASHBOARD, CONTROLS AND OPERATING GUIDELINES 4.35

 TIPS TO IMPROVE TYRE LIFE

1. Maintain recommended tyre pressure

2. Don’t overload the vehicle
3. Check and remove small stones or materials struck in between tyre lugs and ribs
4. Have proper tyre rotation as recommended.
5. Don’t use sharp tools to remove and refit tyres
6. Don’t mix different tyre sizes
7. Check shackle pin and bushes at regular intervals
4
8. Don’t rechamber leaf springs
9. Adjust brakes evenly on all wheels
10. Check u-bolts and leaves for misalignment
11. Carryout wheel alignment at regular intervals
12. Avoid spinning your wheels in roads
13. Avoid panic braking
14. Maintain even wear on pair wheels

4.36 DASHBOARD, CONTROLS AND OPERATING GUIDELINES

5. Bus Body Features
Vehicle Layout For School Bus 5.02
Seating Layout For School Bus 5.03
Seating Layout For Executive Bus 5.04
Safety Features 5.05
Interiors 5.09
Exteriors 5.14
Video Surveillance System (Optional) 5.19
AC Control Panel 5.20
Control Panel Description 5.20
5
Display Description 5.20
Storage Of Vehicles 5.24
 VEHICLE LAYOUT FOR SCHOOL BUS

5.02 BUS BODY FEATURES

 SEATING LAYOUT FOR SCHOOL BUS

Company has all rights to change Seating layout to comply with Region’s vehicle registration, Regulations Seating Capacity - 33+1
& Customers requirement, please contact dealer for any information

BUS BODY FEATURES 5.03

 SEATING LAYOUT FOR EXECUTIVE BUS

Company has all rights to change Seating layout to comply with Region’s vehicle registration, Regulations Seating Capacity - 33+1
& Customers requirement, please contact dealer for any information

5.04 BUS BODY FEATURES

 First Aid Box
SAFETY FEATURES
ON
Electrical isolation switch
60 80
40
km/h
20
FIRST AID BOX

1/2

E
F
EDC
HAZARD
ENGINE DIGNOSTICS ABS
ISOLATOR

The door is provided with emergency exit knob

inside the Door. First aid box is located at next to passenger door.
1 2 3 Whenever there is an emergency press ON knob
to open glass and pull down the red handle to
Three electrical isolation switches were provided
open the door.
to avoid any accidental short circuit and damages.
1. Main Isolator Switch Out side door
2. External Isolator Switch
3. Internal Isolator Switch 5
These switches are provided in the driver control
panel area (Dashboard RH side).
Emergency exit Door (Optional) It consists of plaster, bandage roll, cotton roll,
Inside door external use antiseptic cream.
Emergency Exit
NOTE

Replenish the items as and when used and

The door is provided with emergency exit knob expired.
outside the Door.
Whenever there is an emergency brake glass WARNING
and twist handle to open the door.
Always check expiry date before use.

BUS BODY FEATURES 5.05

 Passenger seat belt (Optional) Fire Detection and suppression system FDSS tubing is ideal for fire detection in buses
(optional) as it tolerates the vibration, dirt, temperature
extremes of the environments in which the
Fire Detection suppression system ensure
buses operate. Also, as the system in the
vehicles and passengers remain safe during
Oyster is pneumatically operated, here-by
fire hazard. Transit bus plays a major role in
they don’t require much power from the
providing daily transit to commuters while
vehicle to operate and do not place additional
reducing the vehicle congestion on roads and
strain on the vehicle’s electrical system.
highways.
Fire Extinguisher
The impact of a fire in a Luxury or school bus
is wide ranging. Just a few issues surrounding
Seat belts are provided on all passenger seats bus fires include passenger safety, costs to
which has both chest and abdominal hold to city or school, loss of passenger capacity, FIRST AID BOX

rest passenger on position. disruption of traffic and public relations

Hatch door issues.
5 Fire Detection & Suppression System offer a
unique approach to fire protection of many
at the fire prone areas of the vehicles. FDSS
Fire Extinguisher is located next to first aid box.
systems detect fire using the proprietary red
Fire-trace Detection Tubing (FDT). This heat
sensitive polymer tubing is pressurized and
reacts to the heat and radiant energy of fire
EMERGENCY
EXIT HATCH
PULL HANDLE AND LIFT THE

and bursts where sensor is provided near FDT

which is heat sensitive, thus activating the fire
suppression system.
Pull the red knob to open the door at
emergencies.

5.06 BUS BODY FEATURES

 EMERGENCY HAMMER
Steel headed hammer are fitted as shown.
Pull to break the plastic holder to take out hammer and break the glasses at emergency.

Hammer near to window. Hammer near to rear windscreen.

5
1 2 3
HAM
MER

PULL BREAK EXIT

BUS BODY FEATURES 5.07

 Driver Seat Belt movement provided his movements are not
abrupt.
The belt mechanism is affected by the vehicle’s
changes of attitude and it may lock in the
following cases:
S
PRES - Sudden braking or acceleration
- Vehicle driving on a slope

3
R

1R
L

2
- When cornering
3
4

1R
2

CAUTION
To fasten the belt, insert the coupling tang in
The belt should not be twisted but should
Always wear seat belt while driving. This safety the buckle until it clicks.
correctly adhere to the driver’s hips (but
feature reduces the chances of personal injury
not to his abdomen to prevent him from
in case of any accident by securing the driver
slipping forward).
firmly on seat, preventing him to come away
5 and hit with steering, dash board or even Regularly ensure that bolts securing the
with windshield glass. If the seat belt is not anchorage points are fully tightened and
fastened when the ignition switch is turned
S
PRES that the belt is not cut or frayed.
to the ON position, the seat belt warning light

3
4

1R
2
will remain on until the belt is fastened. If the WARNING
system does not operate correctly, consult an
authorized AL Dealer. In the event of a serious accident, renew
To unfasten the belt, press the button located the seat belt even if it does not appear to
The vehicle is preset for the application of
on the top side of the buckle. be damaged.
belts with automatic roll up facility and three
anchorage sockets. Do not make alterations to the belt as this
The belt does not need to be adjusted by hand
could result in mechanism malfunction.
These sockets (threaded holes) are generally as it adjusts itself automatically to the optimum
covered with plastic plugs. length for the driver allowing him freedom of
5.08 BUS BODY FEATURES
 INTERIORS

1. Speaker
2. Roof lamp
1
3. Motion sensor (Optional)
4. CC Camera (Optional)

10 8 5. Hammer

2 6. Passenger Seat
3 4 7. Passenger Seat Belt
5
8. Hatch door
9. Floor
6
10. AC Louvres
5

BUS BODY FEATURES 5.09

 Sun Visor Driver Seat
INTERIOR FEATURES
Driver compartment

Rollable sun visor is provided at the front of

the driver to avoid sun glare from front side. High cushioned driver seat provided the seat
The sun visor can be set at any height as per can be adjusted back & forth and also up &
Partition is provided to separate drivers area the driver’s requirement. Pull the sun visor down based on the requirement.
from passenger compartment. Sufficient downwards and stop at the required height. USB Charger port
space is provided in the driver’s compartment The sun visor is guided by guide rods and it has
5 for comfort & free movement. stoppers to position the same at the required
height. To unwind, gently pull and leave it.

USB charger port is available at the side panel

between each seats.

5.10 BUS BODY FEATURES

Passengers seat LED interior saloon strip lamp

For executive bus

For school bus LED lights one for driver comportment another Fire retardant, marine quality plywood is used
four LED lights are provided in passenger area as base floor material and vinyl flooring is
to illuminate the same during night. provided as the primary layer.
Flooring Saloon mirror

For executive bus

Comfortable cushioned seats are provided for
passengers.
For School bus Saloon view mirror is also fitted inside the bus
to observe the passenger movement inside
and around bus middle door. The mirror can
be swivel at all directions.
BUS BODY FEATURES 5.11
 Speakers LCD monitor (Optional) AC louvres

Speakers are part of the public address system Monitor is available in dashboard to have all AC louvres are placed over passenger seats.
and fitted on the roof. camera views.
Vent window
Camera Internal (Optional) MP3 player

Provision is made on all windows for venting

Three cameras are fixed inside the vehicle MP3 player fitted on dash board. (Optional fitment).
above driver door, In middle of driver
compartment and at rear passenger saloon.

5.12 BUS BODY FEATURES

 FLOOR PANEL - SERVICE DOORS

2
5

1. Gear box lid for service

2. Fuel float lid for service

BUS BODY FEATURES 5.13

 EXTERIORS
FRONT REAR
1
2
2
1
3
3

13
4

5
4
12

5
6
8
7
6
5 8

11
10 9 7

1. Pilot Lamp 8. Fog lamp (Optional) 1. Rear camera (Optional) 5. RH tail lamp
2. Front camera (Optional) 9. Headlamp with High beam 2. Pilot lamp rear (Optional) 6. Rear bumper
3. Windshield glass 10. Headlamp low beam 3. Windshield glass 7. Number plate
4. LH Rear View mirror 11. Child foot step (Optional) 4. Reflector (Optional) 8. RH tail lamp
5. Wiper 12. Reflector
6. Front grill 13. RH rear view mirror
7. LH Indicator

5.14 BUS BODY FEATURES

 EXTERIORS
1. Front Pilot lamp
RH
2. Front passenger door
3. Side fender lamp
4. Window glass
5. RH side camera (Optional)
6. Emergency door (Optional)
7. Diesel tank door
8. Battery access door
9. Stop board (Optional)
10. Driver foot step
5 4 3 2 1
11. Driver door
LH 12. LH side camera (Optional)
5

12 11 10 9 8 7 6

BUS BODY FEATURES 5.15

 please insert the key to the lock and turn the
EXTERIOR FEATURES
key to the left side and take it out. Then the
Passenger Door door will be locked from outside.

NOTE

In the doors there is a system to inform

the obstacles preventing the door working.
While the door is closing if it faces any
obstacles ( Like one passenger can be
squeeze between door wings..etc) it will be
Please insert the key to the locked door hand opened automatically.
clip part which is outside the door. (no 3). Please
EMERGENCY MEASURES
turn the key to the right side and open the door
lock. Turn the revolving handle (photo 4) as in
the drawing to the right side. When the arrow
5 direction as in position 6 in the drawing, you
should be sure that the door lock has been
opened (unlocked). The open/close buttons are
on the left side of the photo. In case of pushing
button number 2 on the bottom part, the closed
door will be opened. In case of pushing the
button number 1 on upper part of the drawing,
it will close the opened door.
Door is provided for the smooth entry & exit of - In case of danger (fire, accident etc) if the
the passengers. Door slide open outside and So as to lock the door, when the door is in door can not be opened from the command
they are electro-pneumatically operated by closed situation, revolving handle should button, then please use the emergency valve
the driver from his cabin. be turned to the opposite side of clock, like which has been shown in Figure A, that is
direction of arrow 5 position in drawing,
inside the bus and upper part of the door.

5.16 BUS BODY FEATURES

The emergency valve should be turned to the Rear View Mirrors level of power steering reservoir. Wire mesh
direction which has been shown by arrows on are provided on the flap to ensure proper air
it (clock wise), then make the air zevacuated circulation.
and then push the door to the outside and Flap door Battery
make the passengers leave the bus.
Driver Door

Rear view mirrors are fitted in the bus to

enable the driver to view other vehicles and
objects behind and around the vehicles. The
objects appearing in the mirror are closer
than they appear in the mirror.
Front Bonnet grill

Flap door with gas strut support and lock is

5
provided for battery. Battery can be accessed
On the LH side of Driver seat driver door is through this flap.
provided. This allows the driver to alight from
the vehicle at ease and also to climb in the
vehicle without much effort. A bottle holder is
also fitted in the door

Front grill is supported with gas struts for

easy opening and closing to check & inspect
engine related points, radiator and CAC, oil
BUS BODY FEATURES 5.17
 Wiper washer unit Steps to open flap door lock Camera - External (Optional)

Four external cameras are fitted, one above front

Wiper - washer unit to fill the water 1. Insert key to the hole windshield glass, one above rear windshield
whenever required. glass, one above driver door and one near RHS
Flap Door fuel Tank last window glass.
Child foot step (Optional)
5

2. Rotate to open and Close the flap door

assembly.
Flap door is provided for fuel filling.
Auto retractable foot step is available for ease
entry and exit.

5.18 BUS BODY FEATURES

 VIDEO SURVEILLANCE SYSTEM (OPTIONAL)
Camera Camera PIR Camera Camera
video input 2 video input 7 motion sensor video input 6 video input 5 Camera
video input 3

Camera
video input 4

Camera
video input 1

5
LCD
video input

RFID reader

Door trap
sensor

BUS BODY FEATURES 5.19

 AC CONTROL PANEL
Control panel description Display description

1. Display A. Room temperature

2. Auto Button B. Outside temperature
3. Fresh Air/ Circulating Air ( NOT USED ) C. Active mode (Auto)
4. Blower Speed button D. Error signalization
5. Status light at buttons 2, 3 & 4 E. Air recirculation is on ( NOT USED )
6. Button DOWN F. Heating is on
7. Button UP G. Air-conditioning system is on
8. ON/OFF Button H. Blower speed

5.20 BUS BODY FEATURES

 USAGE
Air-conditioning and heating are only active in auto mode! To use all modes in full scope, activate after turning on the control panel the auto mode.
To save energy, you can switch to manual mode, where the temperature can be manually changed by the regulation of the fan.
Turn control panel on/off

Press button shortly until the standard screen appears

Turn ON

Press button shortly until the display turns off

Turn OFF
Press and hold button pressed for 2 seconds, until “OFF” appears on the screen. The
climatic control is now fully turned off

Activate the AUTO mode

The AUTO mode can only be activated if the vehicle’s engine is running.
5
Press button shortly. The status LED next to the button and “AUTO” on the screen
Activate / Terminate:
show that the AUTO function is active.

If the AUTO mode is deactivated, the blower is automatically controlled by the SC600
Adjust blower speed
Press button shortly – the LED next to the button starts to flash. Now the blower
speed can be adjusted.

Activate Press button to increase speed.

Press button to decrease speed.

The currently set blower speed can be read in the display

BUS BODY FEATURES 5.21

 Press the button again to confirm the setting.
Confirm setting
If the setting is not confirmed, the LED stops flashing after 3 seconds and the new setting remains.

Terminate Hold button pressed for 3 seconds until the icon disappears.

ADJUST TEMPERATURE

Press button to increase temperature.

Press button to decrease temperature.

The passenger compartment temperature can be varied within the values 15°C and 28°C

REHEAT/ DEHUMIDIFY (OPTIONAL)

Additional mode, only with installed roof heating (AC & roof heating) applicable.

Press buttons , If “nA” appears on the display, this function is not applicable.
5
Activate

READ OUT ERRORS

Press buttons and , and hold them pressed for a few seconds until F001 is
indicated.
Activate The menu for system fault analysis opens.
The count shows the frequency of error occurrence.

Press buttons to scroll through error messages.

5.22 BUS BODY FEATURES

 Press buttons and , and hold them pressed for a few seconds until the
Terminate
standard screen appears

Error description In the case of a system error, the warning icon for error messages appears on the display

LIST OF ERROR MESSAGES

Error message on the display Description Cause Remedy
F001 w/o function

F003 Error servo motor 1 (flaps)

5
F017 Error, ice temperature sensor

F019 Error room temperature sensor Contact the service

F020 Error ambient temperature sensor

F022 Error, condenser pressure sensor

F025 High/Low pressure error

Icing on evaporator panels. Wait until the icing on panels
F026 Icing error
totally disappears.
BUS BODY FEATURES 5.23
 b) Anticorrosive oil should be liberally sprayed b) The masking tapes used in preparation of
STORAGE OF VEHICLES
over rocker levers, push rods, plunger springs. storage should be removed.
Whenever vehicles are in storage proper care c) Ensure that sensors / actuators and other c) The sump should be completely drained of
should be taken as detailed below: components of the EDC system including the corrosion inhibiting oil and refilled with
Storage over a short period (3 months and wiring harness are protected properly. the recommended engine oil.
below) d) The lubricating system should be drained and d) The filter elements should be cleaned and the
• The vehicle must be thoroughly washed, replenished with corrosion inhibiting oil. injectors checked for the correct pressure
including the under-chassis to remove any e) It is advisable that the cooling system be setting and spray characteristics.
deposits of mud as this will lead to corrosion. drained completely. A board should be e) The complete electrical circuit, especially
• The vehicle should be parked in a covered suitably displayed to indicate that the the charging circuit should be checked for
area, on a plain hard surface. cooling system has been drained in order correctness of connections. Starter solenoid
• The bat ter y terminals should be to avoid accidental starting of the engine. points and battery terminals should be
disconnected. f) It is advisable to drain the fuel tank and fuel cleaned. Starter motor and alternator
filters to avoid formation of gum deposits brushes should be checked for proper
• The engine should be started and run for a few contact with commutator.
minutesatleastonceaweek.Itisadvisablethat and the possibility of difficult starting later.
the vehicle is jacked-up and the gears engaged g) All the openings like intake manifold, exhaust f) Ensure that sensors / actuators and other
so that complete oil circulation is effected in tail pipe, engine breather pipe, fuel tank vent components of the EDC system including
5
the gearbox and differential too. hole, etc. should be completely sealed with wiring harness are in order.
Storage over a prolonged period (above 3 masking tape. g) The engine should be cranked till the engine
months) h) The vehicle should be jacked-up and oil pressure builds upto around 2 kg/cm².
supported on suitable props under the axles. Then start engine and ensure that the
a) The battery should be removed from the specified oil pressure is attained.
chassis and prepared for storage in a dry i) The use of parking brake should not be
place. The battery should be topped-up resorted to, for arresting the movement of h) The oil levels in other units like Gearbox,
with distilled water and charged at regular the vehicle - instead, chocks must be used. Differential and Steering Box should be
intervals. Alternatively, the acid from the checked and topped up. In case of vehicles
Recommissioning of vehicle after long storage
battery should be drained dry and stored, fitted with power steering, the hydraulic
a) The cooling system should be flushed system should be bled free of air bubbles
however ensuring that the acid is refilled to
completely and refilled with recommended and topped up with the correct grade of
the correct level and density and recharged coolant. Additives like anticorrosive oil and
at the time of recommissioning the battery. hydraulic fluid in the reservoir.
antifreeze compound may be added in the
correct proportion.
5.24 BUS BODY FEATURES
6. Maintenance and Lubrication
Maintenance Schedule 6.02
Maintenance Procedure 6.16
General 6.16
Engine 6.17
Diaphragm Clutch - Valeo 6.43
Gear box 6.44
Propeller Shaft 6.45
Rear Axle 6.47
Front Axle (A36) 6.47
Power Steering 6.49
Brake System 6.50
Parabolic Suspension 6.55
6
Electrical System 6.56
Wheels and Tyres 6.58
Filling Capacities 6.64
Recommended Lubricants 6.65
Filling Points 6.66
Greasing Points 6.68
 MAINTENANCE SCHEDULE

* Maintenance Schedule that follows is for normal road operating conditions.

* More frequent attentions will be necessary to vehicles working under adverse conditions such as city applications or ghat / hilly terrains.
Key to Maintenance schedule
 - Applicable to specific maintenance interval, given as column heading

Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
I H SERIES EURO III ENGINE
A General
1 Check and adjust valve clearance on cold engine 80
2 Check and tighten front and rear engine mounting / other peripheral bolts 10
3 Check vibration pulley for any damages and replace if necessary 80
6
B Lubrication system
1 Check and top up engine oil if necessary. Also check oil leakages at the time of top up 
2 Change engine oil and oil filter element 20
C Cooling System
1 Visually inspect cooling fan / drive for any damages and replace/rectify 
2 Inspect fan clutch / hub for dust if necessary clean 40

6.02 MAINTENANCE AND LUBRICATION

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
3 Check and tighten fan mounting bolts  40
Check coolant level and top up if necessary . Also check for coolant leakages at the time
4 
of top up

5 Check radiator hoses and clamps for leakages and tightness  

6 Check fan belt tension / condition and adjust / replace if necessary  20

7 Check radiator stay rod and radiator mounting bolts  40 or 1 year whichever is earlier

8 Drain cooling system and fill recommended coolant. 40 or 1 year whichever is earlier

Replace cooling system hoses, clips and radiator rubber pads for radiator mounting &
9 40 or 1 years whichever is earlier
stay rod. To be replaced along with coolant change.
D Fuel System

1 Replace Main fuel filter element 20 6

2 Replace protect fuel filter element 20

3 Check water separator and drain if necessary 

4 Check fuel tank mounting strap for tightness and replace rubber packing if damaged  40 or 1 years whichever is earlier

5 Clean Fuel tank and clean suction stainer 40 or 1 years whichever is earlier

6 Check and replace fuel hoses if necessary 80

MAINTENANCE AND LUBRICATION 6.03

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
E Air intake and exhaust
Check vacuum indicator and replace primary filter element - Whenever the vacuum
1 
indicator shows red band
At the time of every third replacement of pri-
2 Replace air cleaner secondary filter element
mary filter element
3 Check air inlet hose for any puncture/damage and replace if required 10 Monthly
4 Check for any blockage / breakage at rain hood assembly 10 Monthly
5 Check Turbocharger mounting  40
6 Check charge air cooler for any blockage of fins and clean the cooler if necessary (2.5 kg/cm2)  40 or 1 years whichever is earlier
7 Check charge air cooler hoses for any damage  10
8 Check exhaust manifold and silencer for leaks and tightness  40
9 Check intake and exhaust manifold mounting fasteners  40
F Electronic Diesel Control (EDC 17)
6 1 Check functioning of EDC and sensors with diagnostic tool 40 or 1 years whichever is earlier
2 Check tightness of all mating connectors and ensure they are connected properly  40
3 Check and secure wiring harness away from temperature zones on the engine/vehicle  40
4 Check functioning of EDC and sensors with diagnostic tool  80
5 Check tightness of engine speed sensors and clean the sensor tip for any dirt/dust deposits  40
6 Check functioning of warning EDC light 

6.04 MAINTENANCE AND LUBRICATION

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
II CLUTCH
A Lubrication
1 Lubricate clutch operating pedal shaft  Monthly
2 Lubricate clutch withdrawal lever  Monthly
3 Lubricate clutch withdrawal bearing sleeve  Monthly
4 Lubricate clutch linkages  Monthly
B Maintenance
1 Check clutch pedal free play and adjust if necessary  As required
2 Check clutch fluid level, top up if necessary  Monthly
3 Overhaul clutch master As required
4 Check stand out & replace clutch disc if necessary As required
6
5 Change clutch fluid 40
C Clutch Booster
1 Check for any leaks in the joints - both air and hydraulic Monthly
2 Check for tightness of mtg. bolts, fork and bleeding screw Monthly
3 Clean the exhaust valve in case it is soiled Monthly
4 Overhaul the booster unit 80 or 1 years whichever is earlier

MAINTENANCE AND LUBRICATION 6.05

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
III SYNCHROMESH GEAR BOX
A Lubrication
1 Lubricate gear shift ball joints  Monthly
2 Check oil level , top up and clean breather Monthly
3 Change oil when hot. Refill upto correct level 40
B Maintenance
1 Check for correct operation of gear shift linkage and setting  10
2 Check tightness of clutch housing mounting bolts  20
3 Check and tighten output flange nut  20
IV PROPELLER SHAFT
A Lubrication
1 Lubricate propeller shaft UJ cross  Monthly
2 Lubricate centre joint bearing (other than sealed bearing)  Monthly
6 3 Lubricate propeller shaft splines  Monthly
B Maintenance
1 Check and tighten propeller shaft flange bolts 
2 Check centre bearing for oil seal leakage Monthly
3 Check and tighten centre bearing housing bolts 10 Monthly
4 Check and tighten centre bearing housing bracket mounting bolts 10 Monthly
5 Check UJ cross and cup for wear and replace if found worn out. 10 Monthly
6 Check for spline wear and replace propeller shaft if found worn out 10 Monthly

6.06 MAINTENANCE AND LUBRICATION

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
V REAR AXLE
1 Check oil level and top up 
2 Change oil (drain oil when hot) . Refill upto correct level For hypoid gear drive head 40 or 1 years whichever is earlier
Repack the hubs with recommended grease. Check the condition of hub bearings and
3 40 or 1 years whichever is earlier
change if necessary, Adjust hub end play.
VI FRONT AXLE
1 Lubricate drag link ball joints  Monthly
Repack the hubs with recommended grease. Check the condition of hub bearings and
2 40 or 1 years whichever is earlier
change if necessary, Adjust hub end play
3 Lubricate king pins  Monthly
4 Check wheel alignment and adjust if necessary  Monthly
5 Check and tighten thrust cover bolts Monthly
6 Check king pin vertical play & adjust if necessary Monthly
6
7 Check king pin lateral play. Replace bush if necessary Monthly
VII BRAKE SYSTEM
A General
1 Check pneumatic hand brake for proper functioning 
2 Check service brake for proper functioning & for air leakage and rectify if any 
3 Check compressed air buildup on air gauge (8.25 kg/cm²) 
4 Check and tighten all brake valve mounting bolts 40 or 1 years whichever is earlier

MAINTENANCE AND LUBRICATION 6.07

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
B Air Compressor (Water cooled 230cc)
1 Clean compressor fins from oil sludge and dust Monthly
2 Check for leakages in lub oil connection and rectify if any. Monthly
3 Check compressor Inlet & delivery rubber hoses and pipes for deterioration and renew, if required 20 Monthly
4 Check & tighten cylinder head mounting bolts and end cover bolts for correct torque values. 40 Monthly
5 Check for leak through oil seal and rectify if any Monthly
6 Check for carbon deposit in delivery pipe and clean. 40 or 1 years whichever is earlier
7 Overhaul the assembly 80 or 2 years whichever is earlier
C Graduated Hand Control Valve
1 Check rubber gaiter is in good condition and replace if required 40
2 Operate the lever and check for proper functioning 10
6 3 Remove exhaust filter, clean and refit 40
4 Overhaul the assembly or 2 years whichever is earlier
D Dual brake valve
1 Check for free movement of pin in pedal & plunger.  10
2 Check & Tighten exhaust check screw 40
3 Check boot for deterioration & change if required 40
4 Overhaul the assembly 80 or 2 years whichever is earlier

6.08 MAINTENANCE AND LUBRICATION

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
E Air Dryer
Check for moisture/ water collection in the Reservoirs. If water collection is noticed,
1 
replace the Desiccant cartridge.
2 Check for correct pressure setting (8.25 kg/cm²)  Monthly
3 Remove inlet filter, clean and refit 40
4 Check & tighten all screws in the assy for correct torque value 40
5 Overhaul the unit using recommended Repair Kit. Replace Desiccant Cartridge 80 or 2 years whichever is earlier
F Quadruple System Protection Valve
1 Check rubber gaiter is in good condition and replace if required Monthly
Drain Sensing Reservoir and watch for any pressure drop in the gauge to detect Non
2 Return Valve leak. If pressure drop is noticed, clean and reassemble the Non Return Monthly
Valve of respective element. Check for joint leaks.
3 Overhaul the assembly 80 or 2 years whichever is earlier
G Air Reservoir
6
1 Drain condensate 
2 Check drain valve and replace if required 20
3 Check air tank mounting, pipe clamps and tighten if necessary 20
H Relay valve
1 Apply & release the brake and check for free exhaust and replace if required 20
2 Check for proper function, remove & clean filter 40
3 Overhaul the unit 80 or 2 years whichever is earlier

MAINTENANCE AND LUBRICATION 6.09

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
I Front Brake Chamber
1 Check the travel of push rod and adjust the brake with minimum travel 40
2 Check clamp ring bolt and mounting bolt tightness for its correct torque value 40
3 Dismantle and clean. Change diaphragm and seal assembly on all chambers 80 or 2 years whichever is earlier
J Automatic Slack adjuster
1 Lubricate the S cam shaft  Monthly
2 Lubricate the slack adjuster with grease- For haldex only Monthly
3 Check S cam bush play and replace the bush if required (Clearance should not exceed 0.5 mm) Monthly
4 Check the tightness of anchor brackets and retighten to specification if necessary Monthly
5 Check for correct axial play (0.3 to 0.8 mm) of adjuster on S cam and adjust if necessary Monthly
6 Overhaul the unit When De- adjustment Torque Falls Below 18 Nm As required
6
K Spring Brake Actuator - Rear
1 Check clamp ring bolt and mounting bolt tightness for its correct torque value 40
2 Overhaul the assy with recommended repair kit 80 or 2 years whichever is earlier
L Brake Shoes
Check brake lining for wear and replace if necessary, During replacement check brake
1 Monthly
drum and rectify defects if any.

6.10 MAINTENANCE AND LUBRICATION

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
2 Check & tighten brake carrier mounting bolts for correct torque values Monthly
3 Check S cam shaft / bushes, replace defective items, if any Monthly
M Stop Light Switch
1 Check for electrical connection Monthly
2 Check for correct operation by applying brakes. Replace if found defective Monthly
N Low Pressure Warning Switch
1 Check all electrical connections Monthly
2 Check operation of the switch by depleting the air and replace if necessary Monthly
O Exhaust Brake
1 Check pipe connections & tighten if necessary Monthly
2 Check for micro switch setting in brake pedal Monthly
3 Check Solenoid and Exhaust brake valve mountings, and tighten Monthly 6
4 Check mounting bold & tighten is necessary Monthly
5 Check pressure setting and adjuster if necessary 40
6 Overhaul the unit 80 or 2 years whichever is earlier

MAINTENANCE AND LUBRICATION 6.11

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
VIII POWER STEERING
1 Check steering gear box for oil leaks and level, top up if necessary  Monthly
2 Check for wear and tighten steering drop arm, drag link and track rod ends Monthly
3 Check tightness of steering box mounting fasteners Monthly
4 Lubricate drag link and trackrod ends Monthly
5 Check UJ fastener tightness Monthly
6 Change oil and oil filter (For ZF Models) 40 or 1 years whichever is earlier
7 Check power steering hydraulic limiter valve setting and peak pressure 80
8 Check steering wheel freeplay and adjust if necessary, ensure zero free play. 20
9 Check draglink / trackrod ball joint play (to be within 2 mm) 20 or 6 month whichever is earlier
IX CHASSIS FRAME
1 Check all joints and unions for oils, fuel, water or air leaks, Rectify the defect noticed  Monthly
6 2 Check the tightness of cross members to frame side members mounting bolts  Monthly
X SUSPENSION
1 Check “I” Bolts/”U” Bolts, spring clip fitment and spring shackle for tightness  Monthly
2 Check Torque values of all mechanical joints and mountings - Anti roll bar, shock absorber mountings  Monthly
3 Lubricate shackle pins
4 Check for excess play in Suspension spring end Bushes and replace if necessary Monthly
5 Check Anti roll bar bushes ( Replace if necessary) Monthly

6.12 MAINTENANCE AND LUBRICATION

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
XI ANTI - LOCK BRAKE SYSTEM (ABS)
1 Check and adjust pole wheel sensor (ABS) Air gap 40 or 1 Years whichever is earlier
XII WHEELS AND TYRES
1 Check tyre pressure & inflate as recommended 
2 Check for wheel nut tightness for specified torque Monthly
3 Rotate the tyre as recommended Monthly
XIII ELECTRICAL EQUIPMENT
1 Check fuel tank and fuel gauge sensing unit nuts for tightness Monthly
2 Check the battery electrolyte level. Top up if necessary with distilled water only  
3 Check all the electrical connections  Monthly
4 Check battery terminals. Apply petroleum jelly 
5 Check all lights, switches, gauges, wiper and horn for correct functioning, rectify if necessary 
6 Check battery cells - voltage and specific gravity, rectify if necessary Monthly 6
7 Tighten Head/Fog lamp mounting brackets, if provided Monthly
XIV FES & BODY
1 Lubricate Door hinges, Driver seat, Wiper arm linkages Monthly
2 Check condition of body mounting pads, replace if necessary  Monthly
3 Check condition of gaiters at gear lever and steering column  Monthly
4 Check and tighten all body/cabin mounting fasteners  Monthly
5 Vehicle washing and chassis greasing Monthly

MAINTENANCE AND LUBRICATION 6.13

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
XV Bus Body
Check and tighten all fasteners such as end sockets for grab rails and stanchion bar, seat
1  Monthly
frame, mirrors, window frames, flooring and floor wear strips, corner protective strips etc.
2 Clean complete underbody thoroughly and remove mud and dirt accumulated. Monthly
Inspect structural members, external as well as underbody for corrosion, damages,
3  Monthly
cracks, weld failures etc.
4 Ensure tightness of fasteners for integration of body with chassis.  Monthly
Check external and internal panelling for cracks, deformation, scoring, damages, paint
5  Monthly
deterioration or peeling off.
Inspect driver seat as well as passenger seats for tightness of anchoring, frame condition
6  Monthly
and functioning of seat mechanism.
Check windows and glasses for easy movement and ensure that seals are free from
7  Monthly
damages.
6 Check for signs of water leakage at front wind screen glasses, passenger windows and
8  Monthly
rear window glass, roof joints, doors etc
Check windscreen glass and other glasses and their frames for proper seating and not
9  Monthly
slipping out from beading.
Check all rubber components including beadings, grommets etc for ageing, cracks,
10  Monthly
tearings
Check all hinges, locks, sliding mechanisms, guide rails etc for smooth functioning and
11  Monthly
lubricate

6.14 MAINTENANCE AND LUBRICATION

 Every km
Weekly

x 1000
MAINTENANCE ACTIVITY Remarks

Daily
PDI
Check door mechanism and ensure proper movement. Correct door alignment wherever
12  Monthly
required.
Check for signs of rusting and treat with anti-corrosive paint wherever required after
13  Monthly
ensuring adequate cleaning of the area.

Apply anti-corrosive paint to under body including cross bearers, after thorough cleaning
14 40 or 1 Years whichever is earlier
and removing flaking paint and rust if any.

XVI Air Conditioning System

1 Ensure roof unit, condenser, fan mounting is proper and tighten Monthly

2 Check AC Compressor mounting in Frame and ensure properly tightened Monthly

3 Check for AC Compressor rubber mount condition and replace if required Monthly
Check AC Drive belts tension and adjust if necessary, ensure belt alignment during
4 20
adjustment
6
5 Replace AC drive belts condition and replace if necessary 20

6 Check AC Gas pressure Monthly

MAINTENANCE AND LUBRICATION 6.15

 MAINTENANCE PROCEDURE 1. GENERAL contact with the ground must be chocked.
Place the jack under the jacking point
Your vehicle has been designed to ensure Chassis Frame ensuring that the jack base is on level
ease of access to mechanical components. Modification to the vehicle chassis frame ground.
This will enable you to carry out a number
by welding, drilling, etc. is not permitted If it is necessary to get under the
of simple maintenance tasks.
as this could distort or weaken the chassis suspended vehicle to carry out any repairs
Please read the instructions carefully frame. or maintenance, additional supports
which will enable you to perform the
basic maintenance work by yourself. Check the chassis cross members and side must be used under the axle.
members for loose bolts or rivets. Loose Jack Usage (Mechanical)
Used engine oils
bolts should be tightened. For any major
* Avoid excessive contact, wash chassis frame work, contact authorised
thoroughly after contact. Ashok Leyland Dealers.
* Keep out of reach of children. Precautions for jack usage
WARNING Garage hoisting devices (trolley jacks,
etc.) must be applied in such a way that
Prolonged and repeated contact to damage to the steering linkage is avoided.
used engine oil may cause serious skin If necessary use wooden blocks for
disorders, including dermatitis and After positioning the jack under the
cushioning. Ensure that the underside of
6 cancer. vehicle the handle has to be rotated
the vehicle is clear of obstructions before
Protect the environment - It is illegal clockwise to raise the vehicle. To lower the
lowering the jack.
to pollute drains, water sources or soil. jack turn the handle in opposite direction
Use authorised waste disposal facilities, Before jacking up the vehicle first ensure slowly and lower the vehicle carefully to
including civic amenity sites and garages that it is standing on the level ground and the ground.
providing facilities for receipt of used oil. the parking brake is applied. Should it
If in doubt, contact your local authority be necessary to jack up the vehicle on a
for advice. slope or without the parking brake being
applied then the wheels remaining in

6.16 MAINTENANCE AND LUBRICATION

For Hydraulic Jack Usage: WHEELS AND TYRES 2. ENGINE
To raise the jack ensure that the valve The wheel nuts fitted to your vehicle
is closed (turned clockwise) using the are Metric Type. They are all right hand I. Lubrication System
slotted end of the multipurpose handle. threaded and have an integral washer as Use of recommended lubricants
Insert the jack handle into the pump and part of the nut assembly. and following appropriate draining
turn clockwise to engage. procedures at correct intervals as per the
Do not repaint the following areas : maintenance schedule is very important
NOTE * Areas under the wheel nuts for the maintenance of the vehicle.
* Contact faces between rear wheels For severe and adverse operating
The lift is variable and the rate can conditions, the regular maintenance
be controlled by the amount that the * Contact faces between wheels and intervals should be shortened suitably.
valve is opened. hub/ drum assemblies. Engine Oil
For engine Lubricants and brands
The jack can now be positioned under the of Lubricants, Refer Recommended
vehicle by pushing or pulling the handle. Lubricants Chart.
When positioned use a steady pumping
action to raise the vehicle as necessary, NOTE
to remove and replace a wheel. To lower
the jack remove the handle from the Engine oil additives should not be used
actuating mechanism and locate the Oil Pump.
slotted end onto the pump valve. Turn the 6
Type Pressure lubrication
valve anticlockwise slowly and lower the
vehicle carefully to the ground. Oil Pump Gear pump
Min. Allowable oil
1 kg/cm² (80°C)
pressure at idling
Max. oil pressure at 4.5-4.8 kg/cm²
full load (Hot Engine)
Full Flow - element
Oil Filter
type

MAINTENANCE AND LUBRICATION 6.17

 Oil level Oil and filter change
Before checking the oil level ensure that To drain the oil:-
the vehicle is standing on a level ground. Ensure that the vehicle is standing on level
Also allow 10 minutes for warm oil to ground and the engine is warm. Draining
CASE OIL COOLER

settle down in the sump. Withdraw the

of oil should be done within 10 minutes, Gasket, Outer
dipstick from the tube located on the LH
side of engine. With a clear lint free rag from shutdown. After positioning a Gasket, Inner

wipe the dipstick scale and re insert fully. suitable drain tray under the sump
remove the drain plug and drain the oil. Adaptor

Washer

CAUTION Spring Washer

Bolt, Hex

When completely drained install the Oil Filter

drain plug with new washers and

tighten securely. Renewal procedure for spin on oil filter

Spin on type oil filter 1 Smear Oil on the

‘O’ Ring

6 Withdraw the dipstick and note the level

on the scale and top up as necessary with 2 Hand Tighteining
new oil to recommended specification. Only

3 Rotate turn
to ensure proper
tightening

6.18 MAINTENANCE AND LUBRICATION

Remove the old filter using a filter wrench. II. Cooling System
Clean filter base (adaptor) and ensure The proper selection and use of coolant are very important to prevent corrosion of the
that the all old gaskets are removed.
cooling system and clogging of the radiator. Replace coolant as per the maintenance
Check the filter mounting adaptor for
schedule. Drain and fill the cooling system with a new coolant.
tightness.
Apply thin coat of clean engine oil to the Recommended Coolant : premixed
washer sealing surface of the new filter. Eurocool LL Max 50 & Servo Kool ALT 50 are pre mixed coolant (pre mixed with water
Do not use grease. at 50% ratio) and has been formulated with a view to offer extended service life. No
Carefully read the installation instructions addition of water is required.
printed on the outside of the filter to
determine the number of turns the filter Both the coolants are available in convenient pack sizes of 1, 3, 20, 50 lts & also as 210
must to be rotated past washer contact lt barrel.
for proper installation and washer
compression. Ashok Leyland Ambient Gulf Oil Indian Oil
Change Period (kms)
Specification Temp. India Corporation
Pre-fill the new filter with clean engine
oil. Spin on the new filter until the washer Every 50000 kms or
JIS K 2234 -94 Class2 Eurocool LL Servo Kool
makes contact with the sealing surface on >-35°C 1 Year whichever is
and Plus Plus MAX 50 ALT 50
the filter head. earlier
Mark a reference point on the filter and
head to identify the point that the sealing 6
washer first makes contact with the CAUTION
sealing surface of the head.
Rotate the filter by approx 3/4th number For topping up use only Eurocool LL Max 50 or SERVO KOOL ALT 50 directly. Do not
of turns past washer contact by hand dilute with plain or demineralised water for top up.
tightening.
Start the engine and check for oil leakage
around the sealing gasket and filter
assembly.
MAINTENANCE AND LUBRICATION 6.19
 Both the coolants are available in A loose fan belt result in
convenient pack sizes of 1, 3, 20, 50 lts & NOTE
a) Squeaking noise
also as 210 lt barrel. Misalignment of pulleys will produce
b) An undercharged battery
Water Pump (H Series Engine) noise & shorten the belt life.
c) Engine overheating
No frequent lubrication is required as H
Adjustment of the driving belt tension of 5. Mount the belt over pulleys and
Series engines are fitted with “integral
water pump (Poly V belt arrangement) ensure that the belt ribs are seated in
shaft and bearing” type water pumps
the respective pulley grooves.
with prepacked grease.
4 3 2
6. Tension the belt and tighten all the
Removal and Refitment of Fan Belt 1
fasteners.
- Open the bonnet
7. Run the engine for 3 to 5 minutes
- Dismount radiator side stay and with the applied tension to allow the
loosen radiator bottom mounting to sway belt to seat in the respective pulley
out a little to clear the cowl covering the 5
grooves properly. Reset tension.
fan. 8. Apply initial belt tension of 700N by
- Loosen alternator link bracket and Installation Procedure adjusting the alternator position.
loosen the fan belt fully. Inspect the 1. Loosen the necessary fasteners, 9. To ensure the applied tension,
pulleys for damage and wear. slacken the pulleys & remove the old measure it in the middle of span
6
- Replace the new fan belt and redo belt. between water-pump pulley and
the above in reverse. 2. Check pulley grooves for wear / alternator using electronic type
Tensioning of fan belt damage and replace the pulley if tension gauge.
A tight belt results in rapid wear of required. 10. Verify the initial tension after running
3. Clean the pulley grooves for debris the engine for 24 hours
a) Fan belt
and ensure not to apply oil or grease
b) Alternator and Water pump on the pulley grooves.
bearings 4. Check alignment of the pulleys.
6.20 MAINTENANCE AND LUBRICATION
Belt tension checking procedure DONT’s: Charge air cooler and Radiator core
• Hold the sensing head steadily • Don’t over tension the belt cleaning and fin repair
across the belt span within 5~10 mm • Don’t apply oil/grease or paint on When mud, debris, etc. are stuck up at
distance above the top surface of the pulley grooves the front of the radiator or charge air
belt. • Don’t fix the belt improperly aligned cooler core, the passage of cooling air is
• Tap the belt gently near the mid span impaired. Hence such matter should be
• Don’t use worn out belts
using a rod or with similar tool to removed completely by washing with
• Don’t pry the belt using sharp tools. water. Deformed fins also can impair
cause the belt span to vibrate.
Visually inspect the belt. cooling and these should be repaired.
• Check the required tension display on
the LCD panel on the tension meter. Replace cooling system rubber hoses.
 Check hoses for cracks, swelling or
• If a reading is not obtained check that
deterioration and replace if necessary.
the sensing head and ensure that it is
positioned properly. X Changing Coolant in Radiator
• Repeat the same procedure to 1. Do not loosen the drain plugs while
recheck. the engine is still hot. If you do so,
hot water can come out resulting in
DO’s:
personal injury. 6
• Check belt tension at regular intervals
NOTE 2. Stop the engine. Loosen-the radiator
and adjust as needed.
drain plug to drain the coolant.
• Check for any abnormal wear and Replace the belt if it is frayed or pieces
of material missing or Longitudinal Drainage will improve if you remove
damage in pulleys / Belt the cap from radiator.
cracks intersect with transverse cracks.
• Check for pulley alignment 3. Drain the complete system and
• Make belts free of fluffs and dirt\ tighten the radiator drain plug.

MAINTENANCE AND LUBRICATION 6.21

 4. Slowly feed coolant into the radiator Automatic Belt Tensioner accessories. Base designs vary. Some
through the filler until the radiator base components are very complicated
is full. When supplying coolant from and may include bracketry or conduits
a pail, pour it slowly to prevent air that carry engine coolant.
from mixing with the coolant. 2. Tension Spring: preloaded at the factory.
5. When the level of the coolant It provides force to tension the belt.
reaches the filler neck, squeeze the 3. Damping Mechanism: a composite
upper radiator hose two or three mechanism that smooths system
times. This will cause air inside the vibration. Tensioners with worn out
hose to be expelled, and the level of dampers need to be replaced.
the coolant will fall.
4. Arm: connects spring to tensioner
6. Properly close the radiator cap. pulley. Usually an aluminum casing.
7. To ensure that the air in the engine 5. Sealing Disk: attaches base to arm
and the piping is properly expelled, How a tensioner works: and prevents internal contamination.
set the engine speed slightly higher The automatic tensioner has a coil spring
than normal idling speed. Raise the 6. Pulleys/Bearings: are thermoplastic or
inside that applies just the right amount steel and may be grooved, flat or flat with
water temperature above 82°C,
of force against the belt to keep it tight. flanges. The key component of a pulley
then continue to idle the engine for
The tensioner also provides a little “give” is the bearing. For a pulley to function
another 10 minutes.
so it can absorb and cushion shock loads properly, the bearing must be properly
6 8. Stop the engine and after the engine
on the belt. The tensioner automatically lubricated. Do not attempt to put new
has cooled down sufficiently, check bearings in an old pulley.
the coolant in the radiator. Add compensates for wear and keeps the belt
under constant tension. 7. Dust Shield: protects bearing from
coolant to make up for any drop in
elements.
the coolant level. The spring loaded tensioner consists of
8. Bolt: connects pulley to arm.
eight parts:
1. Base: stationary part of the tensioner
that is bolted to engine block or other

6.22 MAINTENANCE AND LUBRICATION

The primary advantages of a automatic Radiator stay Rod & Cowl arrangement Radiator Cap
belt tensioner are: Do not run the vehicle without radiator
cowl. Ensure that the radiator cowl
1. Maintains its correct alignment to
mounting and fan blade clearance are in
the belt
proper order.
2. Automatically maintains correct
Check radiator stay bracket mounting
accessory belt tension
bolts for tightness. Also check the silent
3. Automatically dampens normal block bush in stay rod and replace if found
accessory system vibrations defective.
4. Eliminates need to adjust / re- The presence of the radiator cap prevents
Check radiator mounting bracket bolts for
tension belts loss of coolant, entry of foreign particles
tightness and the condition of the rubber and raises boiling point of coolant. The
5. Prevents belt slip (noise / excessive pads and replace if found defective. absent can lead to engine overheating
belt wear) and reduction in engine life.
6. Optimizes life of belt CAUTION
7. Provides for indication of correct Improper radiator mounting can result
belt length in radiator hose failures as well as core
8. Provides indication of excessive cracks at dip soldered joints of top and
belt stretch (replacement) bottom tanks.
6
9. Improves belt system alignment Do not clean the air filter elements.
10. Extends accessory system
component life

MAINTENANCE AND LUBRICATION 6.23

 Cooling Fan - Viscous III. Air Intake System
Maintenance of Air cleaner plays a major
role in engine performance and life. Poor
air cleaner maintenance will result in
complaints like excess liner wear, high
engine oil consumption, excess blow by
and poor pick up.
Maintenance and Servicing of Dry type
Air cleaner
Engine Cooling Fan with viscous clutch Following maintenance recommendations Replace primary filter element as soon as
works on the principle of fluid clutch. need to be strictly followed. vacuum indicator shows red band.
Handle the fan and fan clutch with care. * Remove dust deposit weekly by Replace the secondary filter element at
squeezing the dust evacuator valve. the time of every third replacement of
NOTE * Replace dust evacuator valve the primary filter element.
Do not paint the fan / clutch. Do not immediately if it is torn, cracked,
remains open or missing. NOTE
try to dismantle the clutch. The clutch
is a sealed unit. * Never operate the engine, if the The wing nut should be tightened
6 restriction indicator is either broken with hand alone. Excessive tightening
Check the bimetallic temp sensing coil for or missing. would damage the air cleaner.
any mud or dust. If the coil is covered with
mud or dust, the fan performance will be
erratic. Remove any mud / dust carefully
with a brush.

6.24 MAINTENANCE AND LUBRICATION

Guidelines for replacing the air filter Repeat the above step at the time of
change interval for safety element.

3. Remove the cover

5. Thoroughly clean the sealing surface
1. Life the lever as indicated on the
and the inside of the housing.
cover label

4. Twist the end of the filter to disen-

gage the seal. Gently remove the filter
element from the housing. Inspect the
element for the foreign material on the
2. Twist the cover to the left in the open sealing surface and potential marks of dust
position. at the clean air side.

MAINTENANCE AND LUBRICATION 6.25

 6. Insert the new element in the housing

9. Once the elements have been

changed, make sure that you reset
8. Twist the cover to the right and put into the restriction indicator.
7. Place the cover back on the housing. the closed position.
IMPORTANT
Make sure dust evacuator valve is oriented
Never pull the latch. Life the latch and
rotate the end cover for opening of air
cleaner. Ensure that the latch is sitting
in the slot. This condition only ensures
air cleaner end cover is properly fitted
with the air cleaner housing otherwise
6
end cover may fall of and damage.
Dust evacuator on the end cover
should always point vertically down.
Ensure that the arrow mark on air Also unlocked symbol marking on end
Also unlocked symbol marking on end cleaner housing matches with the locked cover should match with the marking
cover should match with the marking on symbol on air cleaner end cap. on air cleaner housing
air cleaner housing

6.26 MAINTENANCE AND LUBRICATION

FUEL SYSTEM –– Connect the Inlet ( ) & ( )
CAUTION
Outlet fuel pipes from the tank & to the
Fuel Tank Main filter as per the arrow. Indicated
A minimum fuel quantity 40 liters in
Remove the fuel tank from the vehicle. rectangular tank is to be maintained on Filter head
Thoroughly clean the inside surface and to avoid situations of air lock. Air lock –– Unscrew the air vent screw on both
strainer as given in the Maintenance or frequent dry cranking of engine the 'Protect. . Main Fuel filter and start
Schedule. may result in damages to fuel injection priming in main filter to drain out air.
−− Ensure the diesel tank cap rubber equipment.
–– Priming to be done till fuel flows freely
seal in good condition. Fuel Filters - Protect I Pre Filter
from the Air vent screw
Centre Bolt
Air Vent Screw
–– Tighten the Air vent screw as per the
Filter Cover recommended Torque of 7 – 9 Nm.
–– Crank the Engine & check for Leakages
Filter Bowl Installation Instructions of Insert
replacement Service :
–– Unscrew the centre bolt & Open the
top cover to replace Filter inserts.
6
Filter Bowl
–– While replacing the ne. filter insert
−− Clean the vent hole in diesel tank. make sure all the sealing rings are in
−− Tighten the diesel tank mounting Installation Instructions of New Filter position.
brackets because loose mounting may assembly on Vehicle :
develop crack in the chassis frame and –– Before placing the new insert into the
also the diesel suction pipe c a n –– Check Fuel filter for Physical damage filter bowl, remove the sludge screw
break frequently. at the bottom to get rid of the sludge
–– Mount the filter assy on Vehicle using deposited already & retighten it.
the appropriate mounting bolts / nuts.
MAINTENANCE AND LUBRICATION 6.27
 –– Clean & flush the bowl with clean diesel Filter Cover with Prime the fuel from the tank till fuel flows
before placing the new insert Hand Primer freely from the air vent screw.
Inlet
–– Tighten the Filter insert to the Filter Temperature Air Vent Screw Screw the air vent screw as per the
Sensor
head to a Torque of 15 + 5 Nm Ou
tle
t
recommended torque 7-9 Nm.
–– Start the Vehicle & Check for Leakages Crank the engine and check for leakages.
Do not try to repair the clogged unit Filter Insert
Do's
Fuel Filters - Main Filter cum Water
Ensure filter mounting M1. nut & bolt
Separator Water in Fuel Sensor
tighten properly.
Installation instruction of New fuel Ensure inlet & outlet pipes are not
assembly on the vehicles interchanged.
Check the fuel filter for physical damages Ensure 250 um strainer is installed in the
after taking from the bulk packing. tank and functioning properly during the
enter duration.
Mount the fuel filter assembly on the
vehicle using two M10 nut and bolts. Ensure that no leakage after cranking the
engine.
Connect the inlet ( ) and outlet ( )
6 fuel pipes as per the arrows indicated on Store the filter in room temperature and
Fuel filter cum water separator is fitted
behind the Cabin at LH side. the filter head. under only condition.
Connect temperature , water level sensor
connector to the respective vehicle wiring
harness mating connector.
Unscrew the air vent screw on the filter
head and start priming to drain out the air
from the spin –on.
6.28 MAINTENANCE AND LUBRICATION
Don't
Diesel

Don't use physically damaged filter for

assembly. Don't use hammer for
tightening or loosening air vent screw and
mounting fasteners. Don't install
the filter in tilted angle or horizontally.
Don't remove protective caps (on banjos)
X 270°

till fuel lines are connected. Don't

demount temperature sensor from hand
primer cover while replacing spin-on
filter. Do not fill the diesel into the new filter Once the filter insert is felt tight enough,
insert before assembling on to the filter turn the filter insert further by 270
Instruction for replacing spin-on at Service
head assembly. degrees.
Unscrew water sensor to drain fuel
completely from filter insert. Prime the filter head assembly with the
Remove the filter insert from the filter aid of hand pump.
head assembly.
Check the new filter insert for any physical

X
damage after removal from packing.
6
Apply film of SAE 30 to the seal ring of the
new filter insert as seen above.
Replace the water sensor seal ring by a
new one.
Assembly the water sensor with a torque
of 2 – 3 Nm. Screw the filter insert by hand up . to Don`t use wrenches. Use belt wrench for
the base in clockwise direction and hand de-mounting only.
tighten.

MAINTENANCE AND LUBRICATION 6.29

 water sensor is tightened properly. Instructions for draining water from the
Change the sealing ring of the water filter
sensor on every spin-on exchange.
Don't
Don't fill the Spin-on filter with diesel
before mounting.
Don't use wrenches for mounting.
Don’t use spin-on sealing ring more than
one service interval.
Start the vehicle.
CAUTION

Fuel additive should not be used. Use Disconnect the end connectors of water
good quality diesel. Use always low sensor and vehicle wiring harness
sulphur diesel fuel . Keep fuel clean Unscrew the water level sensor in ant
and prevent water from entering the clockwise direction by hand.
fuel System. Let the water get drained from spin on
When filling the fuel tank in the rain or filter.
6 snow care should be taken not to allow Collect water or water and diesel
water in the fuel tan. Do not forget to Emulsion from the drain pipe in a bin
close the fuel tank cap securely. After draining, Tighten back the Drain
Since the tip of the nozzle is very plug by rotating clock wise. Tightening
torque 2 to 3 Nm or hand tighten.
sensitive extreme care to be exercised
Check for leakages. in handling the injection nozzles at all Connect the end connectors of the water
level. Do not use emery sheet or any level sensor and vehicle wiring harness
Do's
hard material to clean the tip of nozzles Crank the engine and check for the
Ensure no leakage after mounting. Ensure leakages
6.30 MAINTENANCE AND LUBRICATION
Do's If Hand priming is not possible. Instructions for Loosening the filter from
Ensure water level sensor is tighten 1. Then Replace with New In-tank Strainer filter head.
properly. 2. Perform Hand Priming 1. Demount the water level sensor from
the spin-on.
Ensure no leakages after mounting. 3. If the Problem Persists with Hand
Priming, Then Replace with new 2. Unscrew spin-on filter from the
Don't filter head assembly by rotating
Hand Primer Head Assembly.
Don’t unscrew the water level sensor ant-clockwise direction using belt
Do's
completely. wrench.
Rotate Air vent screw in Anti-clockwise
Don't let the diesel drain out from the DO's
and clockwise direction while Loosening
filter while draining water. and Tightening respectively. Use the wrench on the ant-clock wise
Instructions to use Hand primer at direction and place the wrench on the
Don't
Service upper end of the bowl i.e. just below the
Do not repair the flap assembly in Hand seaming
During Air lock, loosen the Air vent screw primer Head Assembly.
Don't
and perform Hand priming till fuel comes
out of Air vent provision. NOTE Do not put the wrench at the centre and
lower end of the bowl.
Re Tighten the Air vent screw at 7 + 2 Nm. Do not open the high pressure pipes Do not use the wrench in clockwise.
Fuel line will be filled with Fuel. to bleed air from the system. Over
tightening of the vent screws will lead Do not use the wench on the casting head.
Hand Primer to the failure of vent screws. 6
Tools used for mounting or demounting the serviceable parts
Air Vent Filter components Tightening torque Tools for mounting and demounting
15-20 Nm or 270° angle
Fuel Filter Insert Hand or Universal belt wrench
rotation after hand tight
Temperature Sensor 25-30 Nm Spanner: A/F 19 mm
Water level sensor 2-3 Nm Torque wrench or hand
Air vent Screw 7-9 Nm Spanner: A/F 10 mm
MAINTENANCE AND LUBRICATION 6.31
 FUEL SYSTEM CRS

High pressure pump CB18-16/2 OFV

with metering unit and
sensor
integrated vane pump

PLV
hand primer and
water separator

ID>=8mm
NRV

ID>=6mm

ID>=3mm
ID>=8mm
Sensors Actuators Injector
CR12-16

ID>=8mm
High pressure
unit
Tank with stainer & EDC 17CV54 EDC 17 Low pressure

WORKING PRINCIPLE:
Fuel from tank flows through pre-filter and main filter to FIP. Over flow fuel flows back to diesel tank. High pressure fuel is pumped by
FIP to common rail and excess fuel flows back to tank. Electronic control unit (ECU) receives signal from sensors and actuates actua-
tors. Injector is opened once signal is sent from ECU. Rail pressure is sensed by rail pressure sensor and signal is fed to ECU. In similar
manner, ECU receives signals from all the sensors and controls FIP, Injector function to get correct quantity of fuel at correct time.

6.32 MAINTENANCE AND LUBRICATION

Following are the critical components of To be disconnected during body building
CRS system.
To be avoided from electro static discharge
1. High Pressure Pump
Critical parts must be always protected.

CAUTION
Don't remove CRS pump & injectors.
CRS pump & injector are very sensitive
equipment. For any defects report to
the nearest AL dealership
5. Electronic Control Unit (ECU) Injectors
INJECTOR

NUT

CONE
2. Rail WASHER

3. Injectors
4. Sensors
6
–– Engine speed sensor
–– Pump camshaft speed sensor Electronic Control Unit and sensors SEAL RING
–– Fuel temperature sensor To be protected from moisture entry
Do’s
–– Rail pressure sensor To be protected from electrical overstress Ensure proper protecting cap at below
–– Boost pressure sensor High current .ow connections
–– Accelerator pedal sensor
Proper grounding for wiring harness −− High pressure connector
–– Coolant temperature sensor −− Back leak opening
MAINTENANCE AND LUBRICATION 6.33
 −− Electrical connector Don't On Board Diagnostic (OBD)
−− Nozzle tip Don't damage the Nozzle tip. Electrical
Remove the protection caps only during connector or High pressure connector
the time of assembly while assembling or removing the
injector from the engine.
Assemble all protection caps immediately
after removing the injector Don't allow the in injector to fall-of OR hit
with other component.
CAUTION Don't use the same retainer ring after
removal.
CRI is very sensitive for contamination /
particles. Don't erase or damage the laser writing OBD system is a monitoring and detec-
on the injector. tion system which can alert the compo-
Wear of parts will lead to incorrect injec-
tion characteristics Don’t try to assemble or remove electrical nent or system failures that can adversely
connections when ignition key is in 'ON' affect emissions.
position.
Illuminates a dashboard light (malfunction
Don't try to dismount the HP connector Indicator lamp) to inform the driver of a
or nozzle body. fault.

CAUTION Provides standard and unrestricted ac-

6
cess for diagnosis and repair.
Use only demineralised water for
cleaning the filter (filler neck). Do
not use tap water. Ensure that the
CAUTION
external compressed air system is
Use two spanners during tightening or depressurized.
loosening of high pressure pipe cap nuts.

6.34 MAINTENANCE AND LUBRICATION

 Fault Possible Cause Remedy
CB18

C Engine power output too

Filter capacity exhausted Replace filter
low

Connect the Filter inlet/

Filter inlet/outlet incor-
outlet so that the Filter
rectly connected to tubing.
No through flow after of functions properly
The PreLine filter system
Leaky hose connections
Check seals
B or seal

A Maintenance Schedule
D
Maintenance work Interval
6
A - Fuel inlet to Feed pump Drain off water Depending on water volume or before freezing can occur
B - Feed pump outlet
Change spin-on filter Refer Maintenance schedule
C - Fuel return from injector and rail to
pump fuel return
D - Cam shaft sensor

MAINTENANCE AND LUBRICATION 6.35

 While operating in the field extreme care 3 4 5
should be taken when handling with CRS
Components. 7
6
Following are the critical components of
CRS system.
2
1. High Pressure Pump
2. Rail with RDS4.2 1 8
3. Injector
1. Gear pump inlet
4. Sensors 2. Gear pump outlet CAUTION
Engine speed sensor (DG6) 3. Pump inlet connector
Pump camshaft speed sensor (DG6) 4. Back flow connector Use two spanners during tightening
5. HP Connector or loosening of high pressure pipe cap
Fuel temperature sensor (FTS) nuts.
6. Drive shaft
Boost pressure sensor (LDF6T)
7. M-Prop
Accelerator pedal sensor (PWG3) 8. Camshaft speed sensor
Oil pressure sensor (ODFT)
Water temperature sensor (WTS)
Typical damages due to handling
6 5. Electronic Control Unit (EDC 16UC40)
Critical parts must be always protected. Causes Effects
Connectors damaged Leakage Investigation not possible
CAUTION
Particles inside the pump Functionality
Don’t remove CRS pump & injectors. MPROP damaged / any tampering Leakage Investigation not possible
CRS pump & injectors are very sensitive
equipment. Any defects report to the
nearest AL dealership.
6.36 MAINTENANCE AND LUBRICATION
Precautions during handling Injectors Wear of parts will lead to incorrect injec-
Correct handling tion characteristics
NUT

Do not keep or even handle the pump INJECTOR

CONE
WASHER
applying forces on external components
like fittings, M-Prop, Overflow Valve.
CLAMP INJECTOR
Pay attention to ensure that there are
no contacts between hard materials
and critical parts like head’s covers and
SEAL RING
flanges.
Do’s
Cleanliness on line
Ensure proper protection cap at below
Protective caps (especially from fittings) connections
must be removed as late as possible, −− High Pressure connector
just before external circuit components −− Back leak opening CAUTION
assembly. −− Electrical connector Use two spanners during tightening or
Ensure the following environmental −− Nozzle tip loosening of high pressure pipe cap nuts
requirements: Remove the protection caps only during Don’t s 6
Storage conditions the time of assembly
Don’t damage the Nozzle tip, Electrical
Assemble all protection caps immediately connector or High pressure connector
Temperature : - 30 to 60°C
after removing the injector
while assembling of removing the injector
Relative humidity : 0 - 80%
CAUTION from the engine.
Protect from : Rain, Snow & Sunshine
Don’t allow the injector to fall-off OR hit
Longest allowed CRI is very sensitive for contamination/ with other component.
storage period : 1 year particles
Don’t use the same retainer ring after removal.

MAINTENANCE AND LUBRICATION 6.37

 Don’t erase or damage the laser writing SENSORS AND SWITCHES
(IMA code) on the injector.
Don’t try to assemble or remove electri-
cal connectors when ignition key is in ‘ON’
position.
Don’t try to dismount the HP connector
or nozzle body.
Rail pressure sensor (RDS)
Assemble all the protection caps immedi-
ately after rail is removed
Do’s
Remove protection cap inlet/outlet con-
nectors only during assembly.
RDS to be protected from entry of any for-
eign residue

6 Don’ts
Don’t try to dismount rail pressure sensor
(RDS) & Pressure limiting valve (DBV)
1. Boost Pressure Sensor 6. Fuel Temperature Sensor
Don’t allow the rail to fall-off OR hit with 2. Accelerator Pedal Sensor 7. Rail Pressure Sensor
other component
3. Engine Speed Sensor 8. Vehicle Speed Sensor
Don’t try to assemble or remove RDS 4. Camshaft Speed Sensor 9. Brake Signal Switch
electrical connectors when ignition key is
in ‘ON’ position. 5. Coolant Temperature Sensor 10. Clutch Signal Switch

6.38 MAINTENANCE AND LUBRICATION

1. Boost Pressure Sensor The Sensor serves to measure demand 4. FIP Camshaft Speed Sensor
from the driver and communicates to
the ECU. It detects the pedal position
by means of potentiometer sensor and
transfers this information to the ECU in
terms of Voltage. It consists of two poten-
tiometer sensors for measuring the posi-
tion of accelerator pedal module from
0% travel position to 100% travel posi-
tion. The second sensor is incorporated
as redundant and reports error in case
Function and Working The sensor serves of malfunction of the first sensor. Voltage Cam speed sensor is an inductive type. It
to measure the absolute intake manifold across redundant sensor is almost half of is mounted on the FIE .Electric pulses are
pressure. The pressure Sensor Element the first sensor. generated when the formed slot inside
consists of a Silicon diaphragm, which 3. Engine Speed Sensor the pump passes through sensor axis.
contains Piezo resistive Semiconduc- 5. Coolant Temperature Sensor
ENGINE SPEED SENSOR
tor. The Pressure acts on the diaphragm
causes change in electrical resistance in FLANGED SCREW
Circuit thus change in Output voltage. SENSOR MTG PLATE

2. Accelerator Pedal Sensor

FLYWHEEL HOUSING 6

It is a thermistor, mounted on coolant

return line from cylinder head. A semi
Engine speed sensor is an inductive type. conductor material changes its resistance
It is mounted on the flywheel housing. when exposed to variable temperature
Electric pulses are generated when the
source. Resistance decrease as temperature
formed slots on the flywheel pass through
Increase (NTC type).
the sensor axis.
MAINTENANCE AND LUBRICATION 6.39
 6. Fuel Temperature Sensor 8. Vehicle Speed Sensor This information is used by the ECU to
activate the limp home mode in case of
A1 A2 defective accelerator pedal sensor (Pedal
stuck Pressing brake implies this condi-
tion).
10. Clutch Signal Switch (If fitted)

It is a thermistor, mounted on FIP. A semi A1 A2

conductor material changes its resistance
when exposed to variable temperature
source. Resistance decrease as temperature Working on proximity principle, produces
Increase (NTC type). 6 or 8 pulses per revolution, pulse output
7. Rail Pressure Sensor is used for calculating the distance travel
and speed of the vehicle.
9. Brake Signal Switch
It is mounted on the clutch pedal to de-
tect whether clutch is pressed or not.
Sensor Hybrid
6

The switch is of electro-pneumatic type.

Switch is mounted on the dual-control
The rail contains a pressurised supply of
brake valve. It indicates the altered volt-
diesel fuel ready for the injectors to use;
age level from the switch and output is
when the pressure in the rail drops the
fed to ECU as information. Switch oper-
sensor signals this to the ECU and pres-
ates for pressure greater than 0.5 Bar.
sure (via the pump) is restored.
6.40 MAINTENANCE AND LUBRICATION
SENSORS Don’ts Electronic Control Unit
−− Don’t drop the sensor
−− Do not Hammer the sensor while
fitting
−− Avoid moisture (water traces) near to
the sensors
−− Do not short circuit the connector
pins while the sensor is functioning.
−− Sensors should not be kept near Hot
Do’s
medium or objects with Temp > 120 ºC.
−− Sensors must be removed from its
−− Sensors should not be kept near any
packing just prior to installation
strong Magnetic Materials.
−− Specified tightening torque should be −− To be protected from moisture entry
−− None of the application guidelines
maintained −− To be protected from electrical
should be deviated (Air gap, tightening overstress (EOS)
−− Replace any damaged O-Ring. torque etc) −− High current flow
−− Clean and grease O-Ring prior to −− Proper grounding for wiring harness
installation with mineral oil-based −− To be disconnected during body
grease. building 6
−− Storage temperature to be main- −− To be avoided from electro static
discharge (ESD)
tained at -20ºC to 50ºC
−− To be protected from handling
damages
−− To be stored properly (storage temp:
-20ºC to 50ºC)

MAINTENANCE AND LUBRICATION 6.41

 V. Turbocharger 2. Adhere strictly to the periodic engine Do’s
Compressed Air to Engine
Intet Manifold
oil change as recommended in the • Use of specified grade of engine oil
maintenance schedule. and oil filter and periodic change as
3. Maintenance work has to be carried recommended in maintenance schedule.
out regularly on the oil filter and air • Regular cleaning / change of air filter
filter system, as recommended in element according to maintenance
maintenance schedule. schedule.
4. Checks to be made on the oil, air and • Check for oil pressure at engine idling
exhaust piping, as well as, on all other
1.
2.
Air Outlet from Compressor
Back Plate condition minimum oil pressure
3. Compressor Wheel connections and seals, to ensure that
4. Thrust Bearing should be 1 kg/cm².
5.
6.
Center Bearing Housing
Turbine Wheel they are tight and no damage has
7. Journals TURBOCHARGER WITH WASTEGATE
occurred. • Idle the engine for 2 minutes after
Initial running starting the engine.
5. When carrying out maintenance work
Keep the engine at idling rpm for on the engine, the piping leading • Idle the engine for 2 minutes before
minimum 2 minutes before moving the from or to the turbocharger must be switching off the engine.
vehicle and before shutting off, to obtain removed, and the pipe openings on • Regularly checks the oil feed and
maximum life from the turbocharger. Do the turbocharger to be closed. return pipes for leaks, air intake
not run the vehicle at full load with oil 6. Prior to fixing turbocharger to the system pipes and hoses for leakage,
pressure less than 1.5 kg/cm². engine, fill the central housing with blockage and exhaust piping
6
Check all air ducts and gaskets for leak. clean engine oil and ensure that, all connections for leakages, blockage.
Repair any leaks before proceeding. Inlet pipes are thoroughly cleaned before • Check the fuel injection system for its
of air compressor must be free from dust connecting to the turbocharger. proper functioning.
and contamination. Disassembly, servicing or overhauling • Close all the turbocharger openings with
Maintenance of turbochargers should be carried out protective plugs when it is not in use.
1. Turbocharger and boost pressure only through Ashok Leyland authorised
• Contact Ashok Leyland dealer /
control valve do not require any dealers.
authorised centres for turbocharger
maintenance. complaints / service.
6.42 MAINTENANCE AND LUBRICATION
Don’ts 3. DIAPHRAGM CLUTCH - VALEO
assembled condition of clutch assembly on
the flywheel, the diaphragm spring gets almost
• Don’t run the engine with low oil flattened exerting clamping force on the clutch
pressure. Diaphragm Clutch plate through clutch pressure plate. Thus the
• Don’t put the engine under full load diaphragm trying to regain the conical shape
immediately after starting. exerts even pressure on to the pressure plate.
• Don’t switch off the engine under full When clutch pedal effort is removed, the
load. diaphragm spring returns back by its tension
and makes the pressure plate to engage with
• Don’t run the engine with leaky, clutch plate. Clutch pedal returns with the help
restricted oil feed and drain pipes. of the return spring.
• Don’t run the engine with blocked, HYDRO-PNEUMATIC ACTUATION
punctured, aged, deformed hose / Hydro-pneumatic system with booster
pipe connections from the air cleaner arrangement consists of master cylinder,
to the turbocharger, Turbocharger The diaphragm clutch mainly consists of the reservoir and clutch booster inter
to charge air cooler and charge air following parts. connected by bundy pipe and flexible
cooler to the inlet manifold. 1. Cover plate hoses. The master cylinder is mounted
2. Fulcrum ring right behind the clutch pedal and the
• Don’t run the engine with leaky clutch booster on the side of the gearbox.
connections, blocked, deformed 3. Diaphragm spring
connections to the turbocharger 4. Fulcrum ring
CAUTION 6
turbine inlet and from turbine outlet. 5. Pressure plate
• Don’t tamper the fuel injection 6. Drive straps Ensure that the clutch pedal lever is
system 7. Rivet - Diaphragm physically stopped before its extreme
8. Rivet - Cover end by proper adjustment of stopper
• Don’t dismantle the turbocharger, screw to avoid failure by jamming of
contact Ashok Leyland dealer / 9. Allen bolts
seal inside master cylinder.
authorised service centre. 10. Spring washer
The following procedure is to be followed
In diaphragm clutch, the clamping force is for hydraulic clutch actuation adjustment.
provided by diaphragm spring. Under the

MAINTENANCE AND LUBRICATION 6.43

 CLUTCH BOOSTER SETTING Refer following instructions for wear 4. GEAR BOX
JAW END
indicator adjustment on clutch booster.
CLUTCH BOOSTER
Synchromesh Gear box (ZF)
MOUNTING POSITION:
DELIVERY POSITION: Rod & washer are moves back by
the piston when mounting

Washer Body of
(Self locking) wear indicator IDENTIFICATION
PLATE

Rod
COP LEVER OUTER

113±5 mm
CLUTCH BOOSTER MOUNTING
FILLER PLUG
INTIALIZED POSITION: WORN POSITION :
Washer pushed along the rod Wear stroke of clutch
Release travel 15 to 18 mm unit body of wear indicator
position 0

Clutch pedal free play - 4 to 7 mm. This The ZF transmission is an OE/Optional

dimension has to be maintained by fitment. The gear selection is done
adjusting pedal stopper bolt. through gear shift lever mounted on L
Set clutch booster push rod 5 mm inside the frame. The design of the transmission and
jaw end as shown, before assembling jaw the shift control rods for transmitting the
end on to COP lever outer. Assemble COP shifting forces assists easy and accurate
lever outer one serration backward from shifting of the gears in all situations.
6 vertical (7.5° approx. inclined) on to rocking Refer the above instrutions given in the For filling capacity & recommended
shaft as shown; with clutch release bearing
butting on to cover assy. finger tips. fig. for wear indicator adjustment on lubricants Refer Chapter 6.
Distance from bracket face to jaw end clutch booster. For change period refer maintenance
center as shown is 113 ± 5 mm. Reset the wear indicator to zero position. schedule.
Booster push rod travel for clutch release When wear stroke of clutch as shown in
- 15 to 18 mm. NOTE
After replacment of new clutch assy, fig becomes 28 mm due to clutch disc
Please ensure the clutch booster setting wear, replace the clutch disc. Drain oil while hot. Fill recommended
dimension 113 ± 5 mm. grade of oil.

6.44 MAINTENANCE AND LUBRICATION

Draining the oil Clean Transmission Breather 5. PROPELLER SHAFT
Drain the oil when the transmission is at The transmission oil heats up while
operating temperature. When you need the vehicle is in motion. This creates
to drain the oil, always do so immediately
after the vehicle has been driven. an overpressure which is continuously
relieved by the transmission breather
To drain the oil, unscrew and remove drain
plug on the underside of transmission provided on selector housing.
and, if an auxiliary unit is fitted, also Always ensure that this valve functions
remove its oil drain plug. correctly. The breather valve must be
Before reinserting plug, remove any cleaned at regular interval (remove if
attached debris from the magnet and fit necessary)
the plug with a new sealing ring.
Filling the Transmission with Oil and
checking the oil level
Park the vehicle on level ground before Two / Three propeller shafts are fitted
filling the transmission with oil or checking in between the gearbox and rear
the oil level. Clean the area around the oil axle supported by a centre bearing at
filler hole before opening it.
the centre. The front shaft has a fixed
joint near the gear box and rear end is
NOTE
supported on the centre bearing with 6
Fill the transmission with recommend- a splined stub shaft to take up the rear
ed grade of oil. propeller shaft. The rear shaft consists of
a fixed joint at rear end and a slip joint at
CAUTION the front end.
Alignment of propeller shafts.
Less oil in the transmission can cause
transmission damage. Too much oil The propeller shafts are balanced to avoid
can lead to gearbox overheating. vibration and whipping. Arrow marks are

MAINTENANCE AND LUBRICATION 6.45

 provided on yoke and tube for proper 3. Still if any bearing cup assemblies fail For Slip Joint:
alignment and balance. Further ensure to purge, then by using brass hammer 1. Apply grease gun pressure to lube
yokes of front and rear propeller shafts sharply strike yoke on inboard and fitting until grease appears at the
are in the same plane when fitted. outboard lug ears once, to firmly seat pressure relief valve (or hole in
Lubrication Procedure bearing and relieve tension across the plug at the slip yoke end of the
span. Rotate shaft 180° and repeat splines).
For a longer and trouble free life of
procedure on opposite inboard and
propeller shaft UJ and slip joints are to 2. Now cover the pressure relief hole
outboard lug ears.
be lubricated periodically, as described with your finger and continue to
below. 4. Now apply grease gun pressure and apply pressure until grease appears
purge all four bearing until fresh at the slip yoke seal.
Refer Chapter 6 for propeller shaft
grease is seen at all four seals.
lubrication schedule. For Centre bearing (other than sealed
5. If striking lug does not cause purging, bearings)
For UJ:
remove snap ring (or capscrews as
1. While greasing, ensure grease is Apply grease gun pressure to lube fitting
the case may be) in lug ears of the
coming out (purging) from all four until grease appear at the pressure relief
bearings that are not purging and
seals of each UJ lugs. This flushes valve.
repeat step 3. If all four bearing
abrasive contaminants from each purge fresh grease refit snap rings (or
bearing assembly and ensures proper capscrews to the specified torque).
6 filling of all four bearing.
6. If the bearing still do not purge,
2. If any of the seal fail to purge, try remove the UJ from the yoke and
to move the driveshaft from side to determine the cause of blockage.
side simultaneously apply grease
gun pressure. This allows greater
clearance on the thrust end of the
bearing assembly that is not purging.

6.46 MAINTENANCE AND LUBRICATION

Maintenance Procedure 6. REAR AXLE 7. FRONT AXLE
Replacement of UJ kit alone is
recommended.

CAUTION
Repairs on propeller shaft like replacement
of Yokes, Tube, Stub shaft etc requires
high level sophisticated equipment and
processes. Also dynamic balancing of x
xxx x
xxx

the unit to very tight limits is essential

for satisfactory performance. As such
field repair of these components is NOT A48 beam with A36 Wheel ends
recommended.
Replacement of Sealed Centre Bearing Description
The crown wheel and pinion, lapped
“When servicing a propeller shaft in for proper tooth contact and supplied The front axle consists of an I-section axle
the field with a new centre bearing, it is as a set is not interchangeable with beam, to which the stub axle is connected
necessary to fill the entire cavity around the another set. Set numbers are etched on at each end. The stub axle carries wheel
bearing with waterproof grease to shield hub and drum assemblies. The axle beam
the crown wheel and pinion for proper
the bearing from water and contaminants. is suspended on load springs which are 6
identification.
attached to the vehicle chassis frame.
Hub end play : 0.001” to 0.004” Shock absorbers are fitted to dampen the
Check hub play at PDI and during effect of the road springs
subsequent grease changing intervals. Front to Rear Axle Alignment
The thrust axis of the Vehicle (rear axle)
must be correctly aligned with the front
axle otherwise an adverse effect on the
rest of the steering geometry will result.
MAINTENANCE AND LUBRICATION 6.47
 Toe-in King pin lubrication
When a vehicle is travelling in the straight The King pins are mounted in the axle
ahead direction, the front wheels should beam and are located by double cotter
be parallel. pins on each side in the case of 6T front
axle. Always wipe the nipples clean
of grease and road dirt before filling
the grease. Always use the specified
lubricant. Grease has to be pumped in
through top / bottom grease nipple.
With reference to the above illustration
it can be seen that a vehicle with a
misaligned thrust axis will have to be
steered to counteract the uneven thrust.
This will result in difficult steering and
potentially dangerous handling. On rear wheel drive vehicles the front wheels FA36 Front Axle
The wear on the front tyres will be uneven normally splay out. Therefore to counteract
and severe. this, a ‘toe-in’ is specified. The illustration
Where axle misalignment is detected shows the toe-in on front wheels.
6 the rear axle suspension and location Toe-in is measured at the rim of the wheels,
assemblies should be thoroughly checked two measurements being taken at the
for wear and damage and corrected as same point, the vehicle having moved half
necessary. the circumference of the wheel between
measurements. Toe-in is adjusted by
altering the effective length of the track rod.
The recommended toe-in is 0-2mm when
measured at wheel rim toe-in valve should
be 0-0.9mm.
6.48 MAINTENANCE AND LUBRICATION
Lubricate king pins every week. 8. POWER STEERING

CAUTION MAX

MIN

It is important to ensure that the specified

hub end-float (0.001” - 0.004”) for the
wheel bearing exists at all times. Under
no circumstances it is permissible for a POWER STEERING RESERVOIR
zero end-float condition to exist, as this
will preload the wheel bearings, and cause
premature failure. Fill the reservoir nearly full. Crank the
The power steering reservoirs are to be engine for 10 seconds without allowing
regularly checked for oil level and to be the engine to start. If the engine starts,
topped up as required. shut it off immediately. Check and refill
For filling capacity & recommended the reservoir. Repeat atleast three times,
lubricants Refer Chapter 6. each time checking and refilling the
For change period refer maintenance reservoir.
schedule. Start the engine and check for oil
Check the condition of steering drop arm, leakages, if noticed shut off the engine
drag link and track rod ends visually for immediately and take corrective action, 6
any damage. to arrest the leakage.
Check for any unusual shake in steering
linkages.
Procedure for oil filling

MAINTENANCE AND LUBRICATION 6.49

 9. BRAKE SYSTEM Service brakes achieved through the live circuit, thus
providing the necessary secondary
The two Service Reservoirs are connected
The Dual Brake system is a split system braking.
to the Brake Chambers and Spring
of brakes actuating the front and rear Brake Chambers, at Front and Rear Emergency and Parking Brakes
axles separately there by ensuring partial axles, through a Dual Brake Valve. The
braking for the vehicle during failure of One of the secondary outlets of the
Slack Adjusters convert the longitudinal
either Front or Rear brakes. System Protection Valve is connected to
movement of the Brake Chamber /
the Spring Brake portion of the Spring
The System Spring Brake Chamber push rod to one
Brake Chamber at rear axle through a
rotation of the ‘S’ Cam shaft of the
The Air Compressor, driven by the Engine, Graduated Hand Control Valve.
foundation brakes. Independent low air
draws air from the Engine inlet manifold During normal running of the vehicle,
pressure switches and warning buzzers
and compressed air is pumped into the pressurised air from system Protection
are provided to warn during appropriate
sensing Reservoir through the DDU/Air Valve flows to Spring Brake portion of
occasions.
Dryer/Unloader Valve. The Unloader the Spring Brake Chamber through
Valve ensures the unidirectional flow of When the Dual-Brake Valve treadle is
Hand Control Valve and keeps the Spring
filtered air into the system apart from depressed, compressed air from the
Brakes released. For Parking / Emergency
regulating the system pressure. The Service Reservoirs is fed into the brake
braking, Hand Control Valve is operated
Quadruple System Protection Valve has actuators at front and Rear axles through
for depleting air from the Spring Brake
four independent delivery lines from a the secondary and primary deliveries of
6 Chamber thereby applying spring brakes.
single inlet, two of which are preferentially the Dual brake Valve. The foundation
charged for the service braking, the third brakes are actuated through the Slack
line is utilised for parking brakes and the Adjusters. On release of the treadle,
fourth for auxiliaries like air suspension, the air, from the actuators is exhausted
exhaust brakes, air horn, etc. through the Dual Brake Valve thus
releasing the brakes.
During accidental failure of either front
or rear brake circuits, partial braking is
6.50 MAINTENANCE AND LUBRICATION
AUTOMATIC SLACK ADJUSTER works on the principle of clearance of adjusting the brakes, to compensate
sensing and adjust for the excess for lining wear, is fitted to the splined end
clearance between the brake lining and of the cam shaft.
brake drum automatically. The brake is actuated by air chamber push
Check brake lining periodically for wear rod connected to the slack adjuster.
and replace if necessary.
Ensure that no manual brake adjustment
is done (Except during brake lining
change) as the vehicle is fitted with
Automatic brake adjuster.
The Slack Adjuster is a link between S-cam brakes
the brake chamber or actuator and the
Description
foundation brake camshaft. It transforms
and multiplies the force developed by The ‘S’ Cam roller follower brake is of
the chamber into a torque that applies sound rugged construction combining
the brakes via the brake camshaft. Slack simplicity with strength, designed for
adjusters provide a quick, easy method of use on heavy commercial vehicles. The
brake is operated by a ‘S’ form cam which 6
adjusting brakes to compensate for brake
lining wear. is an integral part of the cam shaft, the
shaft being mounted on derlin bushes
The excess clearance between the brake
in the chamber brackets and spider. The
lining and the brake drum (due to the
expanding force at the ‘S’ cam is applied
wear of brake lining or brake drum) to be
to the shoes through rollers seated
adjusted automatically to have effective
between shoes webs. A slack adjuster,
braking. Automatic slack adjuster (ASA)
which provides a quick and easy method

MAINTENANCE AND LUBRICATION 6.51

 Lining inspection –– Examine shoe linings for wear
CAUTION regularly
Access to view the linings is through the
inspection holes provided in the dirt Check brake lining periodically for Don’ts
shield. The inspection holes are protected wear and replace if necessary. –– Use Vacuum cleaner to remove dust
by rubber grommets. After checking Failure to replace the linings/shoes at use a damp rag.
running clearances/lining thickness, the correct time may result in damage –– Actuate the brake at the time of
always replace the grommets to avoid dirt to the shoes and drums and impaired lining replacement.
and water ingress. brake efficiency.
Recommended Lubricants
Ensure that no manual brake
At roller end shoe resting lugs and shoe
adjustment is done (Except during
hold down clip - Multipurpose Grease. For
brake lining change) for the vehicles
fitted with Automatic brake adjuster. specifications by various companies, refer
Recommended lubricant chart.
Always fit new shoes in pairs on both
sides of the vehicle. When fitting new
shoes check the condition of shoe return
springs and change if necessary.
Do’s
6 Lining Wear
–– Reset shoe to drum clearances after
Brake shoes should be replaced when fitting new shoes.
the lining material is worn to a minimum –– Inspect bores and seatings for
thickness of 5 mm (0.2”). damage when servicing
–– Unwind the spring brake chambers
screw fully and after assembling
the shoes wind in the screw.

6.52 MAINTENANCE AND LUBRICATION

 Major Components * Optimum stopping distance
Anti-Lock Brake System (ABS)
* Reduced tire wear.
The braking system of any vehicle must be
Driver Tips:
capable of slowing and stopping the vehicle
* Under panic braking conditions, press
safely with in reasonable limits without
hard on the brakes and continue to
wheel lock up under all circumstances of hold it down.
load. Wheel Speed
Pole Wheel
Sensors * While ignition is switched on, ensure
During braking, wheels lock if the brake the ABS warning lamp comes on and
force applied is more than the friction goes off.
between the road & tyre. * If the ABS warning lamp stays on,
get system checked by an authorized
The ABS braking system is capable of service center after completing the
slowing and stopping the vehicle within trip.
reasonable limits without wheel lock up ECU Modulator Valve
* ABS does not come in to action unless
under all circumstances of load, which wheel is about to lock during brake
ensures improved safety. Incorporation * Pole Wheel, Wheel speed sensors &
application.
of ABS modulates the air pressure in the cables.
* Electronic Control Unit. * Always drive carefully and keep safe
brake actuator to prevent the wheel lock distance.
and provide precise vehicle control during * Solenoid operated modulator valves.
* Do not drive aggressively or over 6
over-braking and under different loading Advantages
speed, as there is ABS in the vehicle.
conditions. * Improved vehicle Stability
* Braking an ABS vehicle on sand, gravel
* Prevents vehicle pulling by avoiding and loose snow, the vehicle stability
Anti-Lock Brake System (ABS) is an electronic
front wheel lock. is ensured with a longer stopping
system, an add on to the existing dual
* Prevents vehicle swinging by avoiding distance.
line air brake system, used to prevent the rear wheel lock
vehicle skidding during wheel lock under * Do not switch of f the ignition
* Steer while brake - Helps driver to steer
all circumstances of Load, Tyre/road slip while driving. This makes ABS non-
around obstacles during panic braking
coefficient. on slippery roads. operational.

MAINTENANCE AND LUBRICATION 6.53

 AIR PIPING LAYOUT

FOR
TYPE 12 DOOR

EXHAUST
BRAKE
SOLENOID

REAR SPRING BRAKE CHAMBERS

TYPE 14/16

6.54 MAINTENANCE AND LUBRICATION

 10. PARABOLIC SUSPENSION Visually check the spring assemblies for Don’ts
cracked or broken leaves or loose clamps,
Do not remove the shock absorber as it
misalignment within the mounting
results in more oscillations because of the
brackets caused by worn or damaged
friction between the springs is less.
spring eye bushes and excessive wear or
distortion. Check the mounting brackets –– Do not add semi-elliptic leaves
for cracking damage or distortion, loose
–– Do not re-camber the leaf spring
Front Leaf Spring Assembly rivets or excessively worn rebound
pins. Check shock absorbers for leaks –– Don’t remove center pads.
or damages and for security of the –– Don’t add additional conventional leafs
mountings.
–– Don’t heat with gas welding torch or
ADVANTAGES: with any other means.
1. Improved Suspension
2. Light Weight
3. Long Fatigue Life
Rear Leaf Spring Assembly
Do’s and Don’ts
Do’s 6
At PDI and once in every 8000 km check
suspension joints/linkage for security Replace broken leaf with correct part
damage or wear, report any defects. number leaf spring to avoid damage/
For convenience, this operation may be breakage of other leaves.
carried out in the same time as that of
suspension bracket and springs eye bolt –– Torque center bolt nut properly
torque checks.

MAINTENANCE AND LUBRICATION 6.55

 11. ELECTRICAL SYSTEM • When charging the batteries from an • Connect jumper positive lead to
external source ensure that the area vehicle battery positive.
Battery around the battery is well ventilated • Ensure jumper lead terminal does
and protected against any naked not touch carrier or other vehicle
flame or heat source. The use of metalwork.
‘Boost charger’ should be avoided
• Connect jumper negative lead, to
and should only be used with the
vehicle frame atleast 300 mm (12 Ins)
battery removed from the vehicle.
from vehicle battery. Ensure a good
• Always disconnect the earth lead connection is made to vehicle frame.
from the battery negative terminal
• Start vehicle. When running, ensure
when working on the vehicle.
Maintenance engine speed does not exceed 1000
Check and apply petroleum jelly to rev/min (for fast idle).
Remove the caps and check the Specific battery terminals - every week
Gravity of each cell, with a hydrometer. • Then disconnect negative jumper
Specific gravity readings at 27°C (Fully Remove the caps and check the Specific from slave battery first, then vehicle.
charged) will be 1.230/1.240. For other Gravity of each cell, with a hydrometer
• Disconnect positive from vehicle.
temperatures above 27°C add 0.007, once in every 16000 km.
If using two vehicles do not allow
and below 27°C subtract 0.007 for every Use of slave battery for starting their bodies/chassis to touch. Always
10°C. Check and apply petroleum jelly to To avoid damage to the vehicle charging disconnect the negative lead first.
6
battery terminals. system, it is important to observe the Since hydrogen gas is always present,
Service Precautions following procedure, when using jumper sparks or flame should not be allowed
• Ensure that the correct battery leads to start vehicle having discharged near the battery. When using jumper
polarity is maintained since reversed batteries. leads the cables should always be
battery or charger connections will • Ensure electrolyte level is above the attached, as described above, to
damage the alternator rectifier. top of the plates. avoid sparks near a vehicle battery.
Never disconnect the battery whilst • Switch off all vehicle load/systems.
engine is running.
6.56 MAINTENANCE AND LUBRICATION
Fuse Box • Refit the bulb locking ring and push and the other the dipped beam which
the sealing cover into place. is shorter and lower. One of the primary
A Fuse Box is fitted under the dashboard.
requirements of the dipped beam is
It consists of 12 fuses for circuit operation • Reconnect the plugs to the headlamp
that it does not cause any glare on the
and two spare fuses. For more detailed and sidelamp bulbs.
oncoming traffic.
information refer chapter 4.
• Locate the upper mounting onto the
Head lamp replacement adjusting screw, hook the spring onto
the centre lower bracket and refit the
The head lights should be checked and
retaining screw.
adjusted to ensure good illumination. It
must be done by authorised dealer. Head Lamp Setting
• Apply the parking brake and remove
the grille.
• Loosen the retaining screw and pull
the headlamp forward. Unhook the
spring from the centre lower bracket
and twist the assembly to unhook the
upper mounting from the adjusting
screw. 6
• Disconnect the plugs from the
headlamp and integral side lamp
bulb.
• Remove the sealing cover, the locking The headlamp provides two types of light
ring and the bulb. beams – one the main beam which gives
maximum light well ahead of vehicle
• Fit a new bulb into the headlamp.

MAINTENANCE AND LUBRICATION 6.57

 12. WHEELS AND TYRES Tyres
General Maintenance
Wheels Tyres require very little maintenance, to
The wheel nuts fitted to your vehicle give a long life and avoid costly failure.
are all right hand threaded and have The following suggestions are offered to
an integral washer as part of the nut avoid premature failure:
assembly.
1. Check tyre pressure DAILY. Always
check when the tyres are cold to
avoid error, as pressure builds up
4. Lift the wheel into position, noting in due to high temperature of tyres in
the case of twin rear wheels that the
tyre valve of the inner wheel should operation.
project through the aperture in the 2. Do not over inflate to compensate
rim of the outer wheel diametrically for overloading. Over inflation does
opposite the valve in the latter. not add to the load carrying capacity
5. Refit all wheels nuts tightening them of the tyres. It only reduces the
Do not repaint the following areas : lightly, then, selecting diametrically road contact thus rendering braking
opposite nuts in rotation, go over unsafe.
* Areas under the wheel nuts all the nuts in turn and tighten.
6
* Contact faces between rear wheels Recommended tightening torque for
* Contact faces between wheels and wheel nut
hub/ drum assemblies. kgm lb.ft. Nm
Removal and fitment of wheels 38 - 40 280 - 295 380 - 400
1. Slacken the nuts on the wheels 6. Remove the jack and go over all nuts
affected, (wheel nuts are RH) again in the same way.
Under inflation Correct inflation
2. Jack up the axle, remove the wheel 7. Re-check the tightness of wheel nuts
nuts and lift the wheel off. daily for the first week.
3. Grease the wheel stud threads.
6.58 MAINTENANCE AND LUBRICATION
3. Do not underinflate to allow for 4. The correct alignment of road 7. Check for slow leaks whenever there
pressure build up. The tyre design wheels is important. The rear wheels is a definite drop in pressure (say 5 per
allows for normal build up. Running should be exactly parallel, whilst the day) and repair the leak immediately.
a tyre in under-inflated condition front wheels should also be set and If the leak is due to valves replace the
causes maintained as per Toe-in specified. valve pin if required.
A small error in this alignment may
CAUTION 8. If excessive build up occurs (over 15
cause excessive tread wear on the
psi) it can definitely be attributed to
Always check tyre inflation pressure in front tyres.
cold condition. Pressure will inevitably overloading, overspeeding, under
rise as the tyres heat up while running. 5. Wheel nuts should be checked for inflation or combination of these.
Do not reduce tyre pressure for getting tightness whenever a wheel has been
Take corrective action as necessary. Ensure
an increased reading while the vehicle removed and refitted for any purpose
is on run. that valve caps are fitted on all tyres and
after the first run.
that they are screwed in finger tight.
Overheating of tyre due to excessive 6. Oil and grease are particularly
flexing. harmful to rubber, paraffin being
Low inflation pressure can reduce life almost instantaneous in its effect. Any
of a tyre quickly by destroying the tyre oil which may be thrown on the tyre
structure, due to over heating. Tyre should be removed at the earliest by 6
should not be used for greater loads than a rag, dipped in a little petrol.
their maximum carrying capacity. Running
on under inflated or overloaded tyre also TYRE PRESSURE CHART
results in increased fuel consumption due Tyre Size Position Inflation pressure when cold
to the increased rolling resistance.
Front Axle
235/75 R17.5 7.38 Kg/cm² 105 Psi 7.2 bar
Rear Axle

MAINTENANCE AND LUBRICATION 6.59

 RECOMMENDED TYRE ROTATION Alternate Tyre Normal Wear Front Tyre Irregular Wear

Tyre Normal Wear

In the event of alternate normal tyre wear In the event of front tyre irregular wear
follow the above shown tyre rotation pat- follow the above shown tyre rotation pat-
In the event of normal type wear follow tern.
tern.
the above shown tyre rotation pattern.

6.60 MAINTENANCE AND LUBRICATION

Rear tyre Irregular Wear Check tyre condition and tread depth,
report any defects, Inspects each tyre in-
cluding the spare, for cuts, bulges, dam-
age, signs of uneven wear and tread
depth. The tread depth should be mea-
sured across the width of the tyre at three
points around the tyre circumference.

WARNING

Unsafe tyres must be replaced immediately.

After flipping tyre sides insert the rim.
In the event of rear tyre irregular wear
follow the above shown tyre rotation pat- NOTE
tern. During every alternate rotation tyre to be
flipped i.e., de-mounted from the rim and
rotated, so that inner side will become
outer side.

Tyre wear differs depending upon the 6

load distribution, braking action and road
conditions. The spare tyre also will dete-
riorate if not in use. To off-set these char-
acteristics we recommend tyre rotation
periodically once in 8000 km (or once in
a month).
Remove the rim marking tyre side and flip
the tyre.
MAINTENANCE AND LUBRICATION 6.61
 TUBELESS TYRE PUNCTURE REPAIR 3. Using spiral cementing tool, pierce 5. Cement the injury thorougly by in-
PROCEDURE the tyre at the angle and direction of in- serting tool in the direction of the i n j u -
jury. ry.
In the event of tyre puncture need not to
demount the tyre.
1. Inspect the Tyre with approx. 25-psi
pres­sure and remove the object that
RUBBER SOLUTION

caused puncture.

4. Apply chemical vulcanizing cement 6. Leave Tool inside injury. Remove the
through the spiral cementing tool. blue poly of the phermacure carefully
without touching near the centre. With
inserting tool.
2. Find the angle & direction of the in- RUBBER SOLUTION

jury & Mark the injury.

6
MARKER

6.62 MAINTENANCE AND LUBRICATION

7. Apply chemical vulcanizing cement 9. Pull out the insertion tool. 11. If needed, cut the excess Pherma-
on the selected strips carefully. cure outside the Tyre. Inflate Tyre to
standard Working Pressure. If leakage
persists, apply another Phermacure.

RUBBER SOLUTION

10. The Repair is Complete.

8. Remove the spiral cementing Tool
from injury & push the phermacure
into the injury until only about 1/2 i n c h
of the phermacure remains outside.

MAINTENANCE AND LUBRICATION 6.63

 FILLING CAPACITIES
Engine (Including Oil Filter) H Series H6E3N118 12.5 l

Cooling system capacity H Series H6E3N118 22 approx.

Gear box ZF - Synchromesh 6.5 l

Rear axle Meritor RS120 7.5 l

Power Steering ZF power 2.0 to 2.5 l

Clutch master cylinder 0.3 l

Fuel tank 110 l

Front axle Hub Greasing A36 400gms per hub

Rear axle Hub Greasing RS120 375 ± 25gms per hub

6

6.64 MAINTENANCE AND LUBRICATION

 RECOMMENDED LUBRICANTS
Co-branded Lubri- Approved Lubri-
Ashok Leyland Minimum cant# cant#
Aggregate Ambient
Specification Temp. °C Indian Oil Corpora-
Gulf Oil India tion
API CI-4 + Gulf Super fleet LE Servo pride
Engines H Series - Euro III -20 Dura Max 15W-40 ALT plus 15W 40
MB 228.3+ VDS 3
Engine coolant JIS K 2234, class 2 - Gulf Euro cool Servo kool ALT 50
LL max 50
API GL-4 Gulf Gear XP Dura Max Servo Gear
Gear box Synchromesh (S5 36) -25 80W-90
SAE 80W 90 ALT 80W-90 (LL)
General Motors
Power Steering (ZF) -40 Gulf Power Steering Servo Transdex II
Type A Suffix A / Dura Max
Dextron II D
API GL5 Gulf Gear DB Dura Max Servo Gear Axle ALT
Rear Axle Hypoid Drive (Meritor RS120) -10 85W-140 85W-140
SAE 85W 140
Lithium complex Gulf Crown LX Dura Servoplex ALT 3
Wheel Bearing, Front & Rear Hub greasing based NLGI3 grease -20 Max NLGI 3 Grease
(or) IS 12203
Engine Water pump, Gear shift ball joints, S cam shaft &
slack adjuster (front & rear), Shackle pin.
6
Clutch pedal, Brake pedal, Relay shaft & ball joints Lithium complex Gulf MP Grease
(Clutch withdrawal), Clutch withdrawal sleeve & liner, based NLGI2 grease -20 Servo Grease ALT
(or) IS 12203 Max NLGI 2
Centre bearing joint, Propeller shaft UJ cross & splines,
Inter axle propeller shaft UJ cross, Drag link, track rod and
King pin
FM VSS 116 - Dot 3 Servo Power Brake
Hydraulic Clutch -40 Gulf Clutch Fluid Max ALT
(or) IS 8654
NOTE : Do not mix lubricants of different brands/grades.

MAINTENANCE AND LUBRICATION 6.65

 FILLING POINTS

4 2 3

5 1

6.66 MAINTENANCE AND LUBRICATION

 FILLING POINTS

1 2 3
H-SERIES DIESEL ENGINE ZF GEAR BOX (5S / 6S) REAR AXLE

4 5
STEERING OIL RESERVOIR CLUTCH OIL RESERVOIR DAT COOLANT FILLING

MAINTENANCE AND LUBRICATION 6.67

 GREASING POINTS

16 10 8 9 12 13 18 14 19

6 7 11 15

6.68 MAINTENANCE AND LUBRICATION

 GREASING POINTS

CLUTCH
CLUTCH OPERATING LEVER
DROP ARM ROCKING SHAFT

6 7 8 8
STEERING COLUMN POINT DRAG LINK FRONT END CLUTCH WITHDRAWAL CLUTCH WITHDRAWAL
BEARING SLEEVE GEAR

S-CAM SHAFT
SLACK ADJUSTER
KING PIN - TOP

6
HUB
GREASING

TRACK ROD KING PIN - BOTTOM

9 10 10 11
BALL JOINTS - FRONT AXLE FRONT AXLE DRAG LINK REAR END
GEAR SHIFT LINKAGE

MAINTENANCE AND LUBRICATION 6.69

 GREASING POINTS

UJ YOKE - FRONT UJ YOKE - REAR UJ YOKE - REAR

HUB BEARING

SLACK S-CAM SHAFT

UJ YOKE - FRONT ADJUSTER
SLIP JOINT
12 13 14 15
PROPELLER SHAFT - FRONT PROPELLER SHAFT - MIDDLE PROPELLER SHAFT - REAR REAR AXLE

REAR SPRING
FRONT SPRING FRONT BRACKET REAR SPRING BRACKET
FRONT BRACKET

REAR SHACKLE

16 18 19
FRONT SUSPENSION REAR SUSPENSION REAR SUSPENSION CLUTCH OPERATING
-ELLIPTICAL PEDAL SHAFT

6.70 MAINTENANCE AND LUBRICATION

7. Trouble shooting

Trouble Shooting - Engine 7.02

Turbocharger 7.10
Clutch 7.12
Gear Box 7.13
Rear Axle 7.13
Front Axle And Steering 7.14
Brake System 7.16
Electrical - Batteries 7.19

7
 TROUBLE SHOOTING - ENGINE
Symptom Possible Cause Remedy/Prevention
Engine overheating Coolant
* Insufficient coolant Add coolant
* Defective thermostat Replace the thermostat
* Overflow of coolant due to leakage of Repair
exhaust into cooling system
* Coolant leakage from cylinder head gasket Replace gasket.
* Defective coolant pump Repair or replace.

Radiator
* Clogged with rust and scale Clean radiator.
* Clogged with iron oxide due to leakage Clean coolant passage and correct exhaust
of exhaust into cooling system leakage.
* Clogged radiator core due to mud or Clean radiator.
other debris
* Defective radiator cap pressure valve Replace radiator cap
7 * In correct gap between radiator and fan Correct the gap
* Deration pipes blocked due to mud Clean and use coolant.
* CAC & Radiator fins out side for dust Clean.
deposit.
* Malfunctioning of thermo sensing fan Check and correct.

7.02 TROUBLE SHOOTING

 TROUBLE SHOOTING - ENGINE
Symptom Possible Cause Remedy/Prevention
Engine overheating Abnormal Combustion
* Poor fuel Use good quality fuel.
* Poor nozzle spray Replace nozzle.
Other problems
* Defective or deteriorated engine oil Change engine oil.
* Unsatisfactory operation of oil pump Replace or repair
* Insufficient oil Add oil.
* Brake drag Repair or adjust.
Excessive oil consumption Piston, cylinder liners and piston rings
* Wear of piston ring and cylinder liner Replace piston rings and cylinder liner.
* Worn, sticking or broken piston rings Replace piston rings and cylinder liner.
* Insufficient tension on piston rings Replace piston rings and cylinder liner.
* Unsuitable oil (viscosity too low) Change oil as required and replace piston
rings and cylinder liners.
* Incorrectly fitted piston rings (upside down) Replace piston rings.
* Gaps of piston rings in line with each Reassemble piston rings.
other
7
Valve and valve guides
* Worn valve stream Replace valve and valve guide
* Worn valve guide Replace valve guides.
* Incorrectly fitted valve stem seal Replace the stem seal.
* Excessive lubricant on rocker arm Check clearance of rocker arm and shaft.

TROUBLE SHOOTING 7.03

 TROUBLE SHOOTING - ENGINE
Symptom Possible Cause Remedy/Prevention
Excessive oil consumption Excess oil feed
* Defective oil level gauge Replace oil level gauge
* Oil level too high Drain excess oil.

Other problems
* Overcooled engine (low temperature wear) Warm up engine before moving vehicle.
Check cooling system .
* Oil leakage from miscellaneous parts Repair
Piston seizure Operation
* Abrupt stoppage of engine after running Operate engine properly.
at highspeed
* Hill climbing using unsuitable gear Select suitable gear

Oil
* Insufficient oil Add oil.
* Dirty oil Change oil.
* Poor quality oil Replace with proper engine oil.
* High oil temperature Repair
* Defective oil pump Repair oil pump.
7 * Reduced performance due to worn oil Repair oil pump.
pump
* Suction strainer sucking air Add oil and/or repair strainer.
Abnormal combustion See symptom:”Engine overheating”
Coolant See symptom:”Engine overheating”

7.04 TROUBLE SHOOTING

 TROUBLE SHOOTING - ENGINE
Symptom Possible Cause Remedy/Prevention
Lack of power Intake
* Clogged air cleaner Replace element.

Fuel and nozzle

* Poor nozzle spray Replace injector with new one
* Clogged nozzle with carbon Replace injector with new one
* Wear or seizure of nozzle Replace injector with new one
* Air in fuel system Repair and bleed air from fuel system.
* Clogged fuel filter Replace fuel filter element
* Use of poor fuel Use good quality fuel.

Abnormal combustion See symptom:”Piston Seizure”

Piston, cylinder liners and piston rings See symptom:”Excessive Oil Consumption”

Other problems
* Breakage of turbine or blower Repair
7
* EDC system defective Use diagnostic tool for trouble shooting
and rectify.

TROUBLE SHOOTING 7.05

 TROUBLE SHOOTING - ENGINE
Symptom Possible Cause Remedy/Prevention
Difficult starting engine Electrical system
* Discharged battery Charge battery
* Defective wiring in starter circuit Repair wiring of starter.
* Loose or open-circuit battery cable Tighten battery terminal connections or
replace battery cable.
Injection pump Repair

Air cleaner
* Clogged element Replace the element.
Fuel system
* No fuel in tank Supply fuel and bleed air from fuel
system.
* Clogged fuel line Clean fuel line.
* Air sucked into fuel system through Tighten fuel line connections.
fuel line connections.
* Clogged fuel filter Replace element
* Loose connection in high-pressure line 1. First loosen both sleeve nuts of high
pressure pipes.
2. Hand tighten both the sleeve nuts
7 to ensure that the seating of HP pipe is
proper.
3. Apply the specified torque.

* Water in fuel Drain and clean fuel system

7.06 TROUBLE SHOOTING

 TROUBLE SHOOTING - ENGINE
Symptom Possible Cause Remedy/Prevention
Difficult starting engine Nozzle
* Seized nozzle Replace injector with new one.

Oil system
* Oil viscosity too high Use proper viscosity oil, or install an oil
immersion heater and warm up oil.
Other problems
* Seized piston Replace piston, piston rings ,and liner.
* Seized bearing Replace bearing and /or crankshaft
* Reduced compression pressure Overhaul engine
* Ring gear damaged or worn pinion. Replace the ring gear and/or starter
* Check relays and fuses of EDC system Replace defective parts.
Rough idling Injection pump Repair
Nozzles
* Poor nozzle spray Replace injector with new one.
* Carbon deposit on nozzle tip Replace injector with new one
Engine
* Improper valve clearance Adjust valve clearance 7
* Improper contact of valve seat Replace or repair valve and valve seat.
* Idling speed too low Warm up engine.
* Compression pressure of cylinders Overhaul engine
markedly different from one another

TROUBLE SHOOTING 7.07

 TROUBLE SHOOTING - ENGINE
Symptom Possible Cause Remedy/Prevention
Engine does not start Fuel not reaching injection pump
* Fuel lines clogged or damaged Clean or replace fuel lines.
* Fuel filter clogged Clean or replace the filter elements.
* Air in fuel caused by improper Repair connections.
connections of fuel line between fuel tank
and feed pump.
* Filter incorporated in inlet side of feed Remove foreign material.
pump clogged

Nozzle faulty
* Fuel leakage caused by loosened nozzle Inspect and tighten it. If it is not OK,
clamp. replace injector with new one.
Excessive smoke Black smoke
* Bad nozzle fuel spray characteristics Check and correct them.
* Faulty booster sensor Check and replace.

7 White smoke
* Water in fuel Check and clean fuel lines.
* Faulty coolant temperature sensor Check and replace.
* Fuel starvation Check and correct.

7.08 TROUBLE SHOOTING

 TROUBLE SHOOTING - ENGINE
Symptom Possible Cause Remedy/Prevention
Engine always runs at high speed Accelerator pedal sensor sticky Check and replace.
Engine starts and stops Fuel lines clogged Clean or replace fuel lines.
Air in fuel caused by damaged fuel lines of Repair fuel lines or replace fuel lines and
improper connection of fuel lines. gaskets.
Engine has low power Pump
* Feed pressure too low Repair the feed pump located on the FIP.
* EDC system faulty Check with diagnostic tool and rectify.

Nozzle faulty Replace injector with new one.

* Fuel leakage from nozzle holder

TROUBLE SHOOTING 7.09

 TURBOCHARGER
COMPLAINTS
Cyclic Oil leak
Excessive Oil leak
CAUSES Engine Black Blue Turbo- sound from
engine from
lacks exhaust exhaust charger from com-
oil con- turbine
power smoke smoke noisy Turbo- pressor
sumption seal
chager seal
Clogged air filter element     
Obstructed air outlet duct to turbo
     
compressor
Obstructed intake manifold   
Air leak in duct from air cleaner to
  
compressor
Air leak in duct from compressor to Intake

manifold
Air leak at Intake manifold to engine
    
joint
Obstruction in exhaust manifold     
7 Obstruction in muffler or exhaust stack      
Gas leak In exhaust manifold to engine
joint   

Gas leak in turbine inlet to exhaust

manifold joint    

7.10 TROUBLE SHOOTING

 TURBOCHARGER
COMPLAINTS
Cyclic Oil leak
Excessive Oil leak
CAUSES Engine Black Blue Turbo- sound from
engine from
lacks exhaust exhaust charger from com-
oil con- turbine
power smoke smoke noisy Turbo- pressor
sumption seal
chager seal
Gas leak in ducting after the turbine outlet    
Obstructed turbocharger oil drain line 
Obstructed engine crankcase vent    
Turbocharger center housing sludged or
   
coked
FIP or fuel injectors incorrectly adjusted    
Engine camshaft timing Incorrect  
Worn engine piston rings or liners (blowby)  
Internal engine problem (valves pistons)      
Dirt on compressor wheel/diffuser vanes        
Damaged turbocharger        7

NOTE

If boost pressure is too high, possible cause will be boost pressure pipe / hose damaged or punctured and valve stuck in closed
position. If engine lacks power, possible cause may be the boost pressure control valve is stuck in open position.
TROUBLE SHOOTING 7.11
 CLUTCH
1. Insufficient free play
2. Excessive skimming of pressure plate/flywheel
3. Oily or worn out / glazed linings
Slipping
4. Weak or proken coil spring
5. Glazed surfaces of flywheel/pressure plate
6. Warped pressure plate

1. Clutch plate completely worn out to rivet head

2. Highly rated clutch pedal return spring
Hard 3. Withdrawal sleeve seized due to rust / dust / lack of lubrication
4. Warped broken pressure plate
5. Lack of lubrication of pedal and linkages

1. Loose rivets
2. Bend in clutch plate
Juddering 3. Torsion springs weak/broken
4. Oily clutch
5. Loose linkages

7
1. Insufficient free play
2. Cluth riding
Poor Life
3. Warped pressure plate
4. Clutch slipping

7.12 TROUBLE SHOOTING

 GEAR BOX
Grinding Noise when Changing Knocking when engaging
Noisy while travelling Gear change difficulties
gears clutch or during gear change
(Possible Causes) (Possible Causes) (Possible Causes) (Possible Causes)
Propeller shaft imbalanced /
Clutch not Separating Worn selector dogs Clutch not disengaging
misaligned
Bearings or teeth in Gear Box
Clutch not fully depressed Clutch plate bent Dog clutches worn
worn
Dog clutches worn / Synchro Propeller shaft centre bearing Clutch plate torsion springs Linkages jammed / needs
ring worn worn defective / weak adjustments
Selector forks or sliding pieces Propeller shaft splines / pieces insufficient lubrication
Selector forks or sliding
worn worn universal joints worn
Gear forcibly engaged Rear axle shaft bevel gear worn

REAR AXLE
Crown Wheel Noise Causes
Lack of lubrication, Less backlash in crown wheel and pinion, Wrong tooth contact
Humming Noise
in crown wheel.
7
Worn or damaged crown wheel and pinion or excess backlash, Worn out or
Noise when in straight ahead
damaged bearings.

Growling noise or noise when cornering only. Worn out or damaged differential gears / thrust washers.

TROUBLE SHOOTING 7.13

 FRONT AXLE AND STEERING
Complaints
Vehicle pulls
CAUSES Excessive
Steering one-side Steering
Play in the Hard Steering Tyre wear
Wander­ing during driv- shimmy
steering
ing /braking
Loose/worn out parts     
Binding on the inner column bush 
Lock of oil 
Pitting on the balls/worn track 
Excessive pre-loading of the inner

column bearing
Improper adjustment of rocker shaft   
Binding in the rocker shaft bush 
Excessive friction on the ball joints 
Loose or worn out parts/linkages   
Uneven braking action / Oval brake drum  
7 Improper wheel alignment  
Loose/worn out bearing    
Low/uneven tyre pressure     

7.14 TROUBLE SHOOTING

 FRONT AXLE AND STEERING
Complaints
Vehicle pulls
CAUSES Excessive
Steering one-side Steering
Play in the Hard Steering Tyre wear
Wander­ing during driv- shimmy
steering
ing /braking
Uneven, sagging, loose or broken
    
springs
King pin bush - lack of lubricant  
King pin bush worn out / loose cotter pin 
Hub End play improper  
Wheel disc run out / Frame bend   

TROUBLE SHOOTING 7.15

 BRAKE SYSTEM
Fault Possible Cause Remedy
Storage system
a. Excessive air build-up time* 1. Engine air filter element/air Clean air filter element /
ducting restricted or blocked. clean air ducting as instructed.
2. Defective compressor Check compressor performance
a. Excessive carbon and take appropriate remedial
buildup in compressor or action as instructed in service manual.
Cylinder head / discharge line.
b. Leaking compressor inlet
discharge valves.
c. Worn compressor.
b. Failure to attain normal 1. Excessive air system leakage Carry out pressure system test to
working pressure or retain locate and rectify leakage.
Normal working pressure
(should be 8.25 kg/cm²) 2. Defective unloader valve Carry out operating and leakage tests and take appropriate
remedial action.
Clean and adjust or renew defective safety valve.
Check compressor performance and take appropriate
remedial action as instructed in manual.

7 Use calibrated test gauge to check vehicle air system

supply, renew defective gauge as necessary.
NOTE

Correct air buildup time should be within 3 minutes at maximum engine speed

7.16 TROUBLE SHOOTING

 BRAKE SYSTEM
Fault Possible Cause Remedy
Service brake system
Brakes inoperative or i. Insufficient air pressure. Build air pressure.
insufficient application.
ii. Low foot brake valve Using test gauge fitted in
delivery pressure line fully apply foot brake valve and
compare input pressure with corresponding output
pressure. In each case input/output pressure should
be identical. A pressure variation indicates a defective
foot brake valve: overhaul foot brake valve; overhaul
foot brake valve as instructed in manual. Replace or
overhaul unit as instructed in Manual.
iii. Defective front brake Overhaul / Replace the front / rear brake
chambers and rear spring chamber.
brake chambers.
iv. Worn brake shoe linings Replace the brake shoe linings.
B. Brakes slow to release. i. Blocked exhaust port in Clear obstruction and clean exhaust
foot brake valve. port. 7
ii. Br. chamber seized. Overhaul brake chamber.
iii. Brake pedal/valve plunger Release and lubricate pedal joint/
sticking. valve plunger.

TROUBLE SHOOTING 7.17

 BRAKE SYSTEM
Fault Possible Cause Remedy
Service brake system
Brakes inoperative or i. Insufficient air pressure. Build air pressure.
insufficient application.
ii. Low foot brake valve Using test gauge fitted in
delivery pressure line fully apply foot brake valve and
compare input pressure with corresponding output
pressure. In each case input/output pressure should
be identical. A pressure variation indicates a defective
foot brake valve: overhaul foot brake valve; overhaul
foot brake valve as instructed in manual. Replace or
overhaul unit as instructed in Manual.
iii. Defective front brake Overhaul / Replace the front / rear brake
chambers and rear spring chamber.
brake chambers.
iv. Worn brake shoe linings Replace the brake shoe linings.
B. Brakes slow to release. i. Blocked exhaust port in Clear obstruction and clean exhaust
7 foot brake valve. port.
ii. Br. chamber seized. Overhaul brake chamber.
iii. Brake pedal/valve plunger Release and lubricate pedal joint/
sticking. valve plunger.

7.18 TROUBLE SHOOTING

 ELECTRICAL - BATTERIES
Fault Possible Cause Remedy
1. Old battery 1. Replace after testing
2. Infrequent driving 2. Charge by driving or by small bench charge periodically
3. Loose fan belt 3. Tighten / replace belt
4. Poor insulation of mountings 4. Check, clean battery top
1. Weak battery
5. Short circuit in wiring 5. Check as given below
6. Regulator set low 6. Get regulator set correctly
7. Plates sulphated 7. Recover by sulphation treatment
8. Loose terminal / corrosion 8. Clean terminals, tighten clamps.
II. Excessive topping
required (More than
1. Overcharging 1. Check, correct regulator setting
about 150 cc per
battery every fortnight)
ELECTRICAL - ALTERNATOR
Fault Possible Cause Remedy

1. Open circuit 1. Eliminate open circuit

2. Drained Battery 2. Recharge Battery. If charge is not holding investigate and
Battery not being replace. 7
charged / sufficiently 3. Alternator defective 3. Get alternator repaired
charged 4. Regulator defective 4. Replace regulator
5. V-belt loose 5. Re-adjust /replace V-belt

TROUBLE SHOOTING 7.19

 ELECTRICAL - ALTERNATOR
Fault Possible Cause Remedy
1. Drained Battery 1. Recharge Battery. If charge is not holdinginvestigate and
replace.
2. Regulator defective 2. Replace regulator
Generator warning 3. Generator warning lamp blown 3. Fit new bulb
4. Leads loose/defective 4. Replace leads/tighten connections
lamp not glowing when
5. Short circuit of positive diode in 5. Get alternator repaired
ignition switch closed. alternator
6. Carbon brushes worn 6. Replace carbon brushes
7. Oxide layer on collector ring/open 7. Get alternator repaired
circuit in excitation winding
1. Regulator defective 1. Replace regulator
2. V-belt loose 2. Re-adjust /replace V-belt
Generator warning 3. Lead defective / short circuit to 3. Replace lead/eliminate short circuit
ground
lamp lit up brightly at
4. Rectifier defective, collector rings 4. Get alternator repaired
high engine speed. fouled, short circuit in lead DF or
motor winding

1. Alternator defective 1. Get alternator repaired

2. Regulator defective 2. Replace regulator
7 Generator warning 3. Contact resistance in charging circuit 3. Eliminate contact resistance
lamp lights up less or in lead to generator warning lamp
brightly or glows when
engine is running.

7.20 TROUBLE SHOOTING

 ELECTRICAL - STARTING MOTOR
Fault Possible Cause Remedy

Battery discharged/weak Recharge / replace battery

Battery cable terminals loose / oxidised

Tighten terminals / clean
or ground connection poor

Starting motor terminals / brushes

Remove short circuit
Starting motor shaft shorted to ground
does not turn/ turns
slowly. Carbon brushes not seating against com-
Check / replace brushes
mutator/broken/oily

Starting/solenoid switch damaged Replace switch / get starter motor repaired

Excessive voltage drop in cables/loose

Check the cable and connectors
connection
7
Pinion bearing fouled and oil lightly Clean bearing point
Armature turns but
pinion does not mesh
with ring gear. Pinion bearing fouled aged, burrs
File off burrs and get the pinion / ring gears replaced
formed

TROUBLE SHOOTING 7.21

 ELECTRICAL - STARTING MOTOR

Battery discharged / weak Recharge / replace battery

Excessive voltage drop in cables/loose

Armature turns and Check the cable and connectors
connection
pinion meshes com-
pletely but engine is not
Pressure of carbon brushes on
cranked Check brushes, clean replace
commutators insufficient

Over running clutch slips Replace over running clutch

Starting motor
continues to run even
Starting switch defective Turn off engine immediately and check the switch
after starting switch is
released.
Pinion does not
de-mesh after engine Return spring weak / broken. Get starter motor repaired.
starts to operate.

7.22 TROUBLE SHOOTING

 Registered Address: Ashok leyland Ltd., No. 1, Sardar Patel Road, Guindy, Chennai - 600 032,
Ph. no.: 044 2220 6000 | Website: international.ashokleyland.com | email: [email protected]