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LP 613 EURO-II
TATA Motors LP 613 EURO-II User Manual
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Edition : XLI/NE/J-2007/001-500
Ta
t
a
LP
/
LPT 613 EURO-II
Operat
or
’
s Ser
vice Book
(
The con
tents given in this book are not binding;
are subject to change without
notice and are for illustration purposes only)
International Business (CVBU)
Mumbai, INDIA
2
Table of Contents
Default Chapter
3
Table of Contents
3
General Information
6
About Tata LP/LPT
6
Euro-II
6
Environmental Protection
9
Environment Protection
10
Important Tips for Driver
11
Tips for Maintenance
14
Body Building
15
Wheel Arch Dimensions
15
Position of Roof Luggage Carrier
15
Outrigger for Door Post
15
Polyamide (PA) Nylon Tubing for Air Brake
19
Preventive Maintenance for PA Nylon Tubing
19
Guidelines and Precautions for Nylon (PA) Tubing
20
Welding and Gas Cutting
20
Hot Objects
21
Sharp Objects
21
Loose Fitments
22
Misuse
22
Tube Fitment
23
Additional Fitments
24
Rear under Run Protection Device (RUPD)
24
Side under Run Protection Device (SUPD)
24
SUPD Alternate Proposal 2
29
Rear View Mirror - LP / LPT Versions
32
Wiping System
34
Additional Provisions (Electrical)
34
Additional Provisions (Electrical)
35
Lighting and Signalling
35
End Outline Marker Lamps
35
Rear Fog Lamp
35
Vehicle Overview
38
2 Vehicle Handling
39
Vehicle Identification
39
Vehicle View
39
Know Your Vehicle
39
Chassis Type Designation
40
Location of Aggregate Numbers
43
Instrument Panel
45
Switches, Gauges & Indicators
46
Fuel Gauge
46
Coolant Temperature Gauge
46
Air Pressure Gauges
46
SERV Indicator
47
GLOW Indicator
47
Low Air Pressure Indicator (Red)
47
High Beam Indicator
48
Parking Brake Indicator
48
Battery Charging Indicator
48
Low Oil Pressure Indicator
48
Exhaust Brake Indicator
49
Hazard Warning Indicator
49
Glow Plug Indicator (Amber)
49
ABS Indicators
49
Seat Belt Indicator
50
Exhaust Brake Isolator Switch
50
Front Fog Lamp Switch
50
Head Lamp Levelling Switch
50
Rear Fog Lamp Switch
51
Mechanical Stop Light Switch
51
Electric Service Indicator Switch
51
Air Dryer Heater
51
Battery Cut off Switch
52
Steering Lock Cum Ignition Switch
52
Combination Switch
54
Head Lights
54
Turn Signals
54
Light Switch
55
Hazard Warning Switch
55
Windshield Wiper and Washer
56
Driving Controls
57
Hand Brake (Parking Brake)
57
KSB Unit (for Euro II Vehicles)
58
Opening/Closing of Front Centre Flap
58
Turbocharger
59
Charge Air Cooler (Euro II)
60
Clutch Booster
61
Cab Tilting
62
To Raise the Cab
63
To Lower the Cab
65
Heating
67
Blower Regulator
67
Air Distribution Control
67
Driver Seat & Seat Belt
68
Driver Seat Adjustment
68
Seat Belt Arrangement
69
Fastening the Belt
69
Releasing the Belt
69
Belt Adjustment
69
3 Driving
70
Starting the Engine
71
Driving
71
Gear Shifting, Breaking
72
Driving
72
Speed
73
Load
73
Brakes
73
Parking the Vehicle
73
Engine Exhaust Brake
74
Hand Brake System
74
Isolator Switch (Exhaust Brake)
74
Stopping the Engine
75
Lubricating Exhaust Brake Linkages
75
Special Operating Conditions
76
Flame Start System (BERU)
76
Fuel Economy
78
Operation in Hilly Terrains
78
4 Maintenance Procedure
79
Air Intake System
80
Maintenance of Dry Type Air Filter
80
Replacement of Air Filter Primary Cartridge
80
Charge Air Cooler (CAC)
81
Fuel System
82
Fuel Water Separator Cum Primer
82
Fuel Filter Change
82
Fuel System Bleeding
83
Lubrication System
84
Changing Engine Oil / Oil Filter
84
Cooling System
86
Cleaning of Cooling System
87
Fan Belt Tension Adjustment
88
Clutch Pedal Adjustment
89
Clutch Fluid Filling and Bleeding
90
Gear Box Oil Checking
91
Gear Box Oil Change
91
Link Rod Adjustment
91
Turning Tube Adjustment
91
Propeller Shaft
92
Front Axle & Rear Axle
93
Hub Greasing and Adjustment
93
Rear Axle Oil Change
93
Power Steering
94
Filling Oil in Steering Tank
94
Bleeding the Steering System
94
Oil Level Check-Up When Engine Stopped
94
Oil Level Check-Up with the Engine Running (Power Steering)
95
Filter Change (Power Steering)
95
Power Steering Pump Belt Tension Adjustment
96
Sector Shaft Play Adjustment
97
Brake System
98
S Cam Full Air Brakes
98
Adjustment of Service Brakes/Slack Adjusters
101
Releasing Automatically Applied Parked Bake
102
Adjustment of Brake Pedal Free Play
103
Adjustment of Stop Light Switch
103
Adjustment of Exhaust Brake
103
Load Conscious Pressure Reducing Valve
104
Anti Lock Brake System (ABS)
105
ABS Activation
105
Safety Tips While Driving with ABS
106
Brake System Routine Checks
107
System Protection Valve (SPV)
108
Opening Pressures
108
Closing Pressures
108
Dual Brake Valve (DBV)
109
Brake Chambers
109
Slack Adjusters
109
Graduated Hand Brake Valve
109
Springs
111
Anti Roll Bars (Bus Chassis)
111
Wheel Alignment
111
Shock Absorbers Check
111
Cable Adjustment on Centre Flap Locking Mechanism
112
Tilt Cab Torsion Bar Adjustment
113
Wheels and Tyres
114
Wheel Changes
114
Operating the Winch Type Spare Wheel Carrier
115
Wheel Balancing
115
Type Pressure
116
Tyre Rotation
116
Inflating Tyres with Air from Air Dryer
117
Electricals Maintenance
118
Alternator Belt Tension Adjustment
118
Bulb Replacement and Alignment of Head Lamps
119
Head Lamp Focusing
120
Bulb Specifications
123
Fuse Box and Relay Cover
124
Fuses
124
Preservative Treatment
125
Vehicle Storage
125
Preparing the Engine after Long Term Storage
127
Care and Cleaning
128
Protection against Corrosion
128
Under Body Maintenance
128
Technical Specifications
130
5 Technical Information
130
Aggregate Filling Capacities
135
Lubrication Points
136
Tightening Torques
138
Tightening Torques
139
Tightening Torques
140
6 Fuel, Lubricants and Coolants
141
Fuel
141
Lubricants
141
Coolant
141
Fuel
142
Lubricants
143
Coolant/Antifreeze
143
Oil Viscosity Recommendations
144
Rear Axle Oil
144
Lubrication for Clutch Disc Splines
144
Coolants
145
Power Steering Oil
145
Lubricant Specifications Chart
145
7 Service Recommendations
146
Regular Maintenance
147
Special Instructions
147
Pdi
148
Service Schedule
151
Record of Services Performed
160
Electricals - Index and Symbols
165
Electrical Diagrams
166
Connector Details
180
4
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TATA Motors LP 613 EURO-II Specifications
General
Brand
TATA Motors
Model
LP 613 EURO-II
Category
Utility Vehicle
Language
English
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TATA Motors LPT 613 EURO-II
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