Sumo Armoured LBPV - Tata Motors Customer Care

Owner’s Manual & Service Manual 

for 

TATA A SUMO 

LIGHT BULLET PROOF 

VEHICLE 4X4 

ISSUED BY 

PUNE

FOREWORD 

Thank you for selecting TATA LIGHT BULLET PROOF VEHICLE 

(4x4 ) of your choice. 

We welcome you to the world of advanced automotive engineering 

in a form especially suited to our operating conditions. 

This book gives you all the information necessary for making 

your ownership of the vehicle, a thoroughly satisfying experience. 

Should you need any special technical assistance, please 

contact us. 

Please note that by adhering to the correct operating procedures 

and scheduled maintenance, you can obtain the maximum 

performance from your vehicle. 

We request you to go through the book and derive many miles 

of motoring pleasure. 

We provide safe, high quality, high performance 

vehicles. In order to maintain the level of 

performance and reliability in the vehicle, it is 

important that only TATA MOTORS genuine 

accesories are to be fitted. Any accessory that is 

fitted or modification that is carried out can hamper 

the safety and performance of the vehicle besides 

depriving you of your warranty benefits. 

Use of genuine parts, designed and manufactured 

to our exacting standards, are the best way to 

maintain your vehicle in peak operating condition. 

Please do not use substitutes. They always prove 

costlier in the long run. 

Failure to use genuine parts can invalidate any 

future warranty claims. 

The information and specifications given in this 

book are valid as on the date of printing. TATA 

MOTORS LTD. reserves the right to make changes 

in design and specifications and/or to make 

additions to or improvements in this product without 

obligation to install them on products previously 

sold. 

(The contents given in this book are subject to change without notice, not binding and are for illustration purpose only.) 

iii

Contents 

Vehicle Identification .............. vi 

Vehicle details ............................ 1 

Warranty ..................................... 2 

Friendly notes 

Do's .............................................. 4 

Don’ts ........................................... 7 

Handling 

Location of aggregate 

serial numbers..............................8 

Keys.........................................................10 

Doors...........................................................10 

Rear view mirrors,Sunvisor .........11 

Seats.......................................................12 

First Aid Box & Fire 

Extinguisher..............................12 

Seat belt....................................13 

Vehicle tools and jack.................14 

Driving Controls..........................15 

iv 

Gear Shift Lever, Parking Brake, 

Spare Wheel.............................16 

Instruments Cluster/Instruments...17 

Steering lock cum 

ignition switch ....................... 20 

Combination switch.....................21 

Windsheild Wiper / Washer.........22 

Interior Lamps ...........................22 

Front Tow Hook.........................23 

Hazard Warning Switch, 

Tail Lamp. Registration Plate 

Lamp........................................24 

Front / Rear Fog lamps............. 25 

Head Lamp Levelling Switch, & 

High Mounted Stop Lamp.......... 26 

ECU,Towing Hook & Foot step.....27 

Roof Hatch & Observation 

Window ................................. 28 

Gun Port,Ventilator & 

Battery Isolator Switch.............. 29 

Engine compartment light, 

Bonnet opening and closing..,.... 30 

Turbocharger............................. 31 

Pre-silencer............................... 32 

Power steering ......................... 32 

Heating, Ventillation & 

Air Conditioning ....................... 35 

‘G’ Conscious pressure 

reducing valve........................... 37 

Preparing the vehicle for drive....38 

Driving, gear shifting ................ 41 

Driving Instructions, Braking ..... 42 

Stopping/starting the engine 

& Fuel economy........................ 43 

4x4 operation. ...........................44 

Vehicle maintenance 

Engine Compartment...................46 

Air Filter ................................... 47 

Engine Cooling system ............. 48

Contents 

Changing engine oil 

and oil filter ............................. 49 

Water Draining Procedure 

from Sedimenter........................50 

Fuel & Filter draining, 

Priming Pump / Pear Pump.........51 

Gear box Oil Checking/Changing..52 

Transfercase Oil Checking / 

Changing...........................................53 

Front / Rear Axle Oil Checking / 

Changing...........................................54 

Bleeding clutch system............... 55 

Brake system, Bleeding the 

brake system ........................... 56 

Brake adjustment....................... 58 

Adjustment of Parking brake....... 59 

Wheels and tyres....................... 60 

External Repair Kit ...................,.62 

Non-Skid Chains ........................63 

Tyre Rotation ......................... 63 

Battery...........................................64 

Head Lamp Adjustment................65 

Head lamp bulb replacement...... 67 

Bulb specifications..................... 68 

Fuses.......................................................69 

Care and cleaning of vehicle ... 70 

Preservation & De-preservation.. 73 

Special Operation Conditions .... 81 

Fuels, Lubricants, Coolants 

Fuels, Lubricants ...................... 82 

Coolants .................................. 83 

Recommended, oils & lubricant. 84 

Vehicle Data 

Technical Specifications............. 85 

Preliminary Trouble Shooting ..88 

Lubrication and Maintenance 

schedule 

Lubrication points ..................... 96 

Special instructions ................... 98 

Lubrication & Maintenance 

schedule.................................................99 

Vehicle record 

Service performed................... 102 

Repairs carried out.................. 104 

Abbreviations ......................... 106 

v

Vehicle identification 

Photographs 

TATA LIGHT BULLET PROOF VEHICLE 4 X 4 - DIFFERENT VIEWS 

vi

Vehicle details 

VERSION 

DESCRIPTION 

TATA LIGHT BULLET 

PROOF VEHICLE 4X4 

WITH 115PS 4SP DICOR 

ENGINE 

TATA LBPV 4X4 WITH 4SP DICOR ENGINE, 115PS, POWER STEERING, 

BUCKET SEAT, 6 SEATER, BHARAT STAGE III 

1

Warranty 

Terms and condition 

We WARRANT the TATA LBPV 

4X4 vehicles and parts thereof 

manufactured by us to be free from 

defect in material and workmanship, 

subject to the following terms and 

conditions : 

1. This warranty shall be for 24 

months or 20,000 kms 

whichever expires first from the 

date of delivery of the vehicle. 

2. Our obligation under this 

warranty shall be limited to 

repairing or replacing, free of 

charge, such parts of the 

vehicle which, in our opinion, 

are defective, on the vehicle 

being brought to us or to our 

dealers within the warranty 

period. The parts so repaired 

or replaced shall also be 

warranted for quality and 

workmanship but such warranty 

shall be warranted for quality 

and workmanship but such 

warranty shall be co-terminus 

with this original warranty. 

3. Any part which is found to be 

defective and is replaced by 

us under the warranty shall be 

our property. 

4. As for such parts as tyres, 

batteries, transfer case, rubber 

parts, electrical equipment, 

power steering equipment, A.C. 

equipment not manufactured by 

us but supplied by other 

parties, this warranty shall not 

apply, but buyers of the vehicle 

shall be entitled to, so far as 

permissible by law, all such 

rights as we may have against 

such parties under their 

warranties in respect of such 

parts. 

5. This warranty shall not apply if 

the vehicle or any part thereof 

is repaired or altered otherwise 

than in accordance with our 

standard repair procedure, or 

by any person other than our 

sales or service establishments, 

our authorised dealers, subdealers 

or service centres in 

WARRANTY 

any way so as , in our 

judgement which shall be final 

and binding, to effect its 

reliability, nor shall it apply if, 

in our opinion which shall be 

final and binding the vehicle is 

subjected to misuse, 

negligence, improper or 

inadequate maintenance or 

accident or loading in excess 

of such carrying capacity as 

certified by us, or such 

services as prescribed in our 

Owner’s Manual and Service 

Book are not carried out by 

the buyer through our sales or 

service establishments, our 

authorised dealers or their 

sub-dealers or service centres. 

6. This warranty shall not cover 

normal wear and tear or any 

inherent normal deterioration of 

the vehicle or any of its parts 

arising from the actual use of 

the vehicle or any damage due 

to negligent or improper 

operation or storage of the 

vehicle. This warranty shall not 

2

Warranty 

Terms and condition 

apply to normal maintenance 

services viz. oils & fluid 

changes, head lamps 

focussing, fastener 

retightening, wheel balancing, 

tyre rotation, adjustment of 

valve clearance, fuel timing, 

ignition timing and 

consumables like bulbs, fuel 

filters and oil filters etc. This 

warranty shall not apply to any 

damage or deterioration caused 

by environmental pollution or 

bird droppings. This warranty 

shall not apply to V-belts, hoses 

and gas leaks in case of air 

conditioned vehicle. Slight 

irregularities not recognised as 

affecting the function or quality 

of the vehicle or parts, such 

as slight noise or vibration, 

defects appearing only under 

particular or irregular 

operations are item considered 

characteristic of the vehicle. 

7. This warranty shall be null and 

void if the vehicle is subjected 

to abnormal use such as 

rallying, racing or participation 

in any other competitive sports. 

This warranty shall not apply 

to any repairs or replacements 

as a result of accident or 

collision. 

8. This warranty is expressly in 

lieu of all warranties, whether 

by law or otherwise, expressed 

or implied, and all other 

obligations or liabilities on our 

part and we neither assume nor 

authorise any person to 

assume on our behalf, any 

other liability arising from the 

sale of the vehicle or any 

agreement in relation thereto. 

9. The buyer shall have no other 

rights except those set out 

above and have, in particular, 

no right to repudiate the sale, 

or any agreement or to claim 

any reduction in the purchase 

price of the vehicle, or to 

demand any damages or 

compensation for losses, 

incidental or indirect, or 

inconvenience or consequential 

WARRANTY 

damages, loss of vehicle, or 

loss of time, or otherwise, 

incurred or accrued. 

10. Any claim arising from this 

warranty shall be recognised 

only if it is notified in writing 

to us or to our concerned 

dealer without any delay soon 

after such defect as covered 

any ascertained under this 

warranty. 

11. This warranty shall stand 

terminated if the vehicle is 

taransferred or otherwise 

alienated by the buyer without 

our prior written consent. 

12. We reserve our rights to make 

any change or modification in 

the design of the vehicle or its 

parts or to introduce any 

improvement therein or to 

incorporate in the vehicle any 

additional part or accessory at 

any time without incurring any 

obligation to incorporate the 

same in the vehicles previously 

sold. 

3


4 

Do's 

1. Use recommended oils and 

lubricants only. 

2. Change oil in engine, gear box, 

transfer case, steering system, 

front live axle and rear axle at 

prescribed intervals. 

3. Use only genuine oil filter and 

fuel filter elements. Replace 

them at regular intervals as 

prescribed. 

4. Clean air filter element 

regularly. Replace filter 

element when service indicator 

shows red band even after 

cleaning the filter element. 

5. Ensure periodic servicing as 

per maintenance schedule. 

6. Insist on use of genuine cobranded 

spare parts. 

7. Ensure that caps of auxiliary 

tank and radiator are firmly 

fitted to keep the cooling 

system pressurised and to 

Do’s 

maintain coolant level. Always 

use radiator cap only of 1.0 

kg/cm2 (14 PSI), for 

replacement. 

8. check tyres for damage from 

time to time and remove any 

foreign bodies embedded in 

treads. 

When replacing tyres, have the 

wheels balanced. Keep grease, 

oil and fuel away from the 

tyres. In case of uneven tyre 

wear get the vehicle attended 

to by any of our authorised 

service set-ups. 

9. Maintain correct tyre 

pressure 

10. Check battery every week and 

top up electrolyte level. Keep 

battery terminals clean and 

cable joints tight. Apply 

vaseline/petroleum jelly on 

terminals. Use distilled water 

only for topping up.


Do's 

11. Observe correct polarity when 

connecting battery terminals. 

12. Disconnect alternator/battery 

terminals, ECU connections 

while carrying out any 

welding on the vehicle. 

13. Avoid panic braking. Use 

lower gears while descending 

gradients. 

14. Start moving the vehicle always 

in the 1st gear to avoid premature 

clutch wear. 

15. Keep both brake pedal and 

parking brake properly 

adjusted. 

16. Before engaging reverse 

gear, ensure that the vehicle 

has come to a stop, declutch, 

wait for a few seconds and then 

shift into reverse gear. 

17. When parking on slopes, use 

wheel chocks, apply parking 

brake and keep vehicle in low 

gear. 

Do’s 

18. In case of emergency parking 

or breakdown on road, pull 

the hazard warning switch to 

flash all the blinker lights to 

warn other road users. 

19. Release parking brake before 

driving off. 

20. Release the ignition key as 

soon as engine starts. 

21. Retighten wheel mounting nuts 

after 100 km of every wheel 

change. 

Tightening Torque : 12-15 mkg. 

22. Use only recommended FUSES 

and always keep spare fuses 

in the box. 

23. Inspect the engine belts 

replace, if found torn, cracked, 

worn or soaked in oil. 

5


Do's 

24. Ensure doors are properly 

closed. 

25. Insulation in the cab room 

should be kept-up in good 

condition. 

27. Vehicle has a turbocharged 

engine, keep engine in idlling 

speed for atleast a minute 

after starting and also before 

stopping it, to protect the 

turbo charger against damage 

due to oil starvation. 

Air conditioning system : 

1. Whenever vehicle is parked in 

the sun, drive with ventilator 

open for a few minutes to blowoff 

for hot air before switching 

on A.C. 

2. Keep all gun port, ventilator, 

roof hatch closed, when AC 

system is working. 

Do’s 

3. During stop and go city 

driving use lower gears to 

obtain efficient cooling. 

4. If you feel irritation in the eyes 

due to smoke or during long 

drive, stop AC and ventilate for 

half a minute by opening 

ventilator. 

5. Before stopping the engine first 

switch-off AC and then the 

blower. 

6. During off-season operate the 

air conditioner a few times 

every month to lubricate 

components. 

6


Dont's 

1. Do not use Clutch Pedal as 

Foot Rest. This will reduce 

clutch life. Avoid clutch riding. 

2. Do not Coast vehicle in 

Neutral and engine switchedoff 

position. This is a safety 

hazard. 

3. Do not run engine without 

Radiator Cap. Use genuine 

Cap only, to keep system 

pressurised. 

4. Do not overtighten engine oil 

filter. 

5. Vehicle has a turbocharged 

engine, do not stop the 

engine at once, allow it to run 

at idling speed for atleast 1 

minute. Also do not accelerate 

engine till the engine oil 

pressure has built up. 

6. Do not open HP system under 

any condition. It should be 

handled by trained professional 

only. (i.e. HP Pump, Rail, 

Injector, HP lines) 

7. Do not clean Engine 

Compartment with high 

pressure water jet. It can cause 

Malfunctioning of electronic 

components. Cleaning can be 

done with high pressure air. 

8. Do not clean air filter cartidge 

with high pressure air. 

Air conditioning system : 

Dont's 

1. Do not cause heating of AC 

pipe (where fitted), while 

welding / brazing in its 

vicinity. 

2. Do not open any hose / pipe 

points of AC system, where 

fitted. 

3. Do not put your hand inside 

the condenser fan when the 

grille is removed. Disconnect 

power supply to fan and switch 

off engine before any 

maintenance work, where 

applicable. 

7

Handling 

Location of aggregate serial mumbers 

Chassis number on frame Engine Number Gear box number ( G-76) 

XXXXXXX 

Transfer case number (4x4) 

Rear axle number (Spicer) 

Front live axle number (4x4) 

8

Handling 

Location of aggregate serial mumbers 

Body shell number plate (under 

bonnet) 

9

Handling 

Doors 

1 

Key (Two Nos.) 

Two identical keys have been provided 

for operation of steering lock cum 

ignition switch, for locking and 

unlocking of driver’s and co-driver’s 

side door, glove box, fuel tank flap and 

rear door. 

10 

Locking and Unlocking of Doors 

From outside : To unlock the door 

turn key anticlockwise and swing 

handle (1) upwards. To lock the door 

turn key clockwise. 

From inside : Lift knob (2) and then 

only pull handle (3) in the door panel 

to unlock the door. To lock the door 

press knob (2). 

In case knob (2) is pressed with 

door open, it will get released 

automatically when door is closed. 

The co-driver’s side door and rear 

door can be opened from outside as 

well as inside but locking is from 

inside by pressing knob 2. The rear 

door can be opened and locked from 

inside.

Handling 

Rear view mirrors, Sunvisors 

Sun visors 

Rear view mirror 

Rear view mirrors - outside 

Rear view mirrors 

Rear view mirrors are fitted on driver’s 

side door and co-driver’s side door. 

They can be adjusted to the desired 

positions by hand. The mirror can be 

folded backwards for convenience 

when the vehicle is to be driven 

through narrow passages. 

An additional adjustable rear view 

mirror is fitted inside the cab. Mirrors 

can be adjusted with the lever provided 

inside the cab on the doors. 

Rear view mirror in cabin 

Sunvisors 

Two adjustable sun visors are provided 

inside the cab to prevent sun glare. 

11

Handling 

Seats 

1. Seat Reclining Adjustment Lever 

2. Seat Adjustment (Forward/Backward) Lever 

Driver and Co-driver Seat : 

Adjustable type driver’s seat is 

provided. To Achieve correct position 

for proper driving, lift handle (2) to slide 

the seat either forward or backward. 

Once the desired position is achieved, 

push down the handle to lock the seat. 

Adjust the backrest to desired position 

using the lever(1) on right handside 

of backrest. Release the lever to lock 

it. 

12 

Seats for Rear Passengers 

Seats for rear passengers : 

Two seats are provided on both side 

for two persons to seat. Storage space 

is available below seat squabs.

Handling 

Seat belts 

1. Anchor 2. Webbing 3. Tongue 4. Buckle 5. Release button 

Seat Belt : 

The vehicle has been fitted with three 

point belt for extra safety for driver . 

Fastening the belt 

Insert belt tongue into buckle, a 

positive locking ‘click’ indicates correct 

and safe assembly. 

Releasing the belt 

Press the release button, the tongue 

will be ejected clear of the looking 

mechanism within the buckle. 

Belt adjustment 

When the vehicle is at rest, adjust the 

length of belt to suit convenience. 

Insert belt tongue in buckle. A positive 

click indicates correct assembly. 

Adjust length of the belt to suit you 

and fasten. The lap section should be 

comfortably tight, the diagonal sections 

should be adjusted so that a flat hand 

will just pass between the chest and 

the strap. 

13

Handling 

Seat belts, Tools 

To tighten (shorten) the belt 

Pull free end of webbing through 

adjuster until required adjustment is 

achieved. 

To loosen (lengthen) the belt 

Tilt the adjuster by means of the grip 

and slide it along the strap until suitably 

adjusted. 

CAUTION 

The belt is designed for use of 

only one person. 

The belt should at all times be 

adjusted and used in accordance 

with the instructions and no 

excessive slackness in the belt 

should be evident 

Avoid twisting the straps during 

use. 

Webbing must not be allowed to 

chafe against sharp edges on 

seat or bodywork. 

Do not make any alterations or 

additions to the belt. If in doubt, 

consult the authorised dealer. 

Belt that have been cut, frayed, 

damaged or have been stressed 

through impact, should be 

replaced. 

To clean, an occasional wipe with 

warm soapy water will maintain the 

webbing in a clean condition. Do 

not use bleach or dye under any 

circumstances. 

Periodic inspection of the 

installation will ensure safe and 

reliable service of the seat belt. 

Vehicle Jack & Tools 

Tool bag with tools, jack and handle 

are kept below the drivers seat. 

14

Handling 

Driving Controls 

Driving Control - TATA LIGHT BULLET PROOF VEHICLE 4x4 

1. Steering Wheel 

2. Instrument Cluster 

3. Combi-switch 

4. Ignition cum steering lockswitch 

5. Bonnet opening lever 

6. Accelerator pedal 

7. Brake pedal 

8. Clutch pedal 

9. Parking Brake 

10. Jack 

11. Gear shifting lever 

15

Handling 

Gear Shifting Lever, Parking Brake & Spare wheel 

2 

1 

Gear shift lever knob 

Gear Shift Lever : 

The different gear positions are 

markedon the knob. The 5th gear (an 

overdrive) has been provided to obtain 

better fuel economy while driving on 

highways. 

16 

1. Parking brake released 

2. Parkeing brake applied 

Parking Brake (Floor mounted) : 

The Parking brake is mounted on floor 

between RH door and driver’s seat. 

To apply the parking brake, pull lever 

full up. To release it, pull the lever up 

slightly, press the release button and 

push the lever down. 

Ensure parking brake is released 

before driving the vehicle. Indication 

is given on instrument cluster. 

Spare wheel 

Spare Wheel 

Spare wheel is located behind driver 

and co-driver seat. 

To remove the spare wheel, loosen 

spare wheel strap by operating 

ratchet. After loosening strap, remove 

hook and take out the spare wheel.

Handling 

Instrument cluster 

5 6 7 8 9 10 

11 

4 

3 

12 

2 

1 

13 

15 

14 

Instrument cluster 

17

Handling 

1. Fuel gauge 

18 

It indicate the apporximate level of 

fuel in tank. 

Fill up the tank with recommended 

diesel fuel well in advance, before 

the needle touches ‘E’ mark on the 

gauge. 

2. CHECK ENGINE 

Indicator 

This lamp indicates engine 

condition, when a malfunctioning 

occurs in engine OR EMS, this 

lamp indicates as below : 

i. Come ‘ON’ when key is in ‘IGN’ 

position and goes ‘OFF’ after 

starting engine. 

ii. Remains ‘ON’ in engine 

running if malfuctioning occurs. 

3. Glow plug indicator 

light (Amber) 

CHECK 

ENGINE 

In the ‘ON’ position, the glow plug 

controller switches on the glow plugs 

and glow plug indicator comes ‘ON’. 

After a few seconds depending on 

the ambient temperature, the 

indicator light only goes ‘OFF’ 

indicating that the engine can be 

started. 

If the glow plug indicator does not 

go ‘OFF’ automatically, get the 

electrical system of your vehicle 

checked. 

4. High beam indicator 

(Blue) 

5. Battery charging 

indicator light. (Red) 

It comes on when ignition key is 

turned to position ‘ON’ and must 

go ‘OFF’ when the engine starts 

running. if continues to glow, then 

it has to be checked at authorised 

dealer. 

6. Turn signal indicator 

(Left) (Green) 

7. Speedometer 

It indicate vehicle speed in km/h 

8. Odometer registers total distance 

covered by the vehicle in km. 

9. Turn signal indicator 

(Right) (Green) 

10. Oil pressure 

indicator light (Red) 

Instruments 


turned to position ‘ON’ and goes 

off as soon as the required oil 

pressure has developed after the 

engine has started. If the light 

continues to glow when the 

engine is running, it indicated low 

oil level in engine oil sump, or a 

fault in the lubrication or electrical 

system. 

Continued running of the engine 

when the oil pressure indicator 

light is on, may damage the 

engine.

Handling 

Instruments 

11. Brake fluid level / 

parking brake 

indicator: (Red) 

This indicator light is used for both 

the functions. When ignition is ON 

position the lamp will glow. Thus 

it shows bulb is OK. 

After the engine has started, 

light will go Off automatically. The 

light will remain ON, if the break 

fluid level is low or the parking 

brake is applied. 

12. Water in Fuel 

Sedimenter Indicator 

Whenever water in fuel sedimenter 

indicator glows in instrument 

cluster, the water need to be 

drained from fuel sedimenter. 

(Refer Page 50) 

13.Coolant temperature gauge 

( 0 C) Red band of this gauge 

indicates engine overheating. 

P 

14. Four wheel drive high 

indicator light (4x4) 

(Green) 

4WDH 


turned to position’ON’ and goes 

‘OFF’ after a few seconds. The 

light glows continuously 

when four wheel drive high mode 

is selected for vehicle driving. 

17. Four wheel drive low 

indicator light (4x4) 

(Green) 

4WDL 


turned to position ‘ON’ and goes 

off after a few seconds. The light 

glows continuously when four 

wheel drive low mode is selected 

for vehicle driving. 

19

Handling 

Steering lock cum ignition switch 

Steering lock cum ignition Switch 

Steering lock ignition switch 

Steering is provided with steering lock 

cum ignition switch 

 

 

 

20 

To lock steering while parking the 

vehicle as safety against theft. 

To start and stop the engine. 

To switch on and off the electrical 

system other than listed below. 

Steering lock cum ignition switch key 

positions 

Horn, parking lamps, engine 

inspection lamp, hazard warning 

switch, headlamp, map reading 

lamp, black out head lamp/ stop 

lamp / parking lamp and roof light 

convoy lamp,tail lamp,side 

indicator, Blinker stop light. 

 

To switch on and off accessories 

only. 

The switch is located on the steering 

column support and has the following 

key positions : 

LOCK 

Key can be inserted or taken out only 

in this position. Steering gets locked 

only after the key is withdrawn from 

the switch. After withdrawing the key 

from the switch ensure that steering 

is locked by turning steering wheel 

clockwise and anticlockwise. 

To unlock the steering, insert the key 

into the switch and turn it clockwise. 

If any difficulty arises in unlocking turn 

the steering wheel a little clockwise or 

anticlockwise while turning the key. 

ACC 

By turning the key to ‘ACC’ position 

power supply to accessories is 

switched on.

Handling 

ON 

By turning the key to this position all 

remaining electrical systems become 

operative and fuel guage, temperature 

gauge, battery charging indicator, low oil 

pressure indicator, parking brake/low 

brake fluid indicators, Check Engine, 

Water Seperator will come ÒN’. 

In case of 4x4 vehicle in addition to 

above 4WDH & 4WDL lamps will come 

on and goes off after a few seconds. 

In ‘ON’ position, glow plug indicator 

lights up. After a few seconds, depeding 

on the ambient temperature, the 

indicator light only goes off indicating 

that the engine can be started. 

START 

Turn the key further clockwise to start 

position (spring loaded) to operate 

starter motor. As soon as the engine 

starts release the ignition key, so that key 

can come back to ‘ON’ position and 

starter motor disengages. Vehicle is 

driven in this position. By turning the 

ignition key from ‘ON’ position to ‘ACC’ 

32 3 

4 1 

Combination switch - Turn signals, High/Low 

beam and High Flash 

or ‘LOCK’ position engine can be 

stopped. 

Combination switch 

The combination switch is mounted on 

steering column. It’s right side lever 

operates turn signals, 

Turn Signals 

Moving the combination switch lever in 

sideways direction operates the turn 

signals : 

Position ‘3’ 

Position ‘4’ 

- Turn signal left 

- Turn signal right 

The lever returns to neutral position 

automatically when the steering 

wheel is returned to straight ahead 

position. 

The combination switch lever can be 

operated up and down to select the 

headlight beam as follows : 

Position 1 

Position 2 

Combination switch 

- High beam 

- High beam flash 

High Beam Flash (No.2 position) 

High beam flash will be ‘ON’ as long 

as lever is held in position `2’ . This is 

spring loaded position and can be 

used in day time also for giving signal 

to the on coming traffic. 

21

Handling 

Windshield Wiper / Washer & Interior Lamp 

POSITION FOR 

WASH-ON 

Windshield wiper/washer operating lever 

Winshield wiper / washer 

The combination switch lever mounted 

on the left side operates the windshield 

wipers and washer : 

Position : 

‘OFF’- Wiper motor switched ‘OFF’ 

‘INT’ - Wiper sweeps intermittently 

‘LO’ - Low speed of wiper motor 

‘HI’ 

- High speed of wiper motor To 

operate windshield washer, lift 

the lever. The winshield washer 

will remain in operation as long 

as the lever is held in this 

position. 

Interior Lamp Location 

Interior Lamps : 

A interior lamp is fitted near inside 

rear view mirror for illunination. The 

individual ‘ON / OFF’ switch is provided 

on the lamp itself. 

This lamp is controlled by a door 

switch. This lamp comes ‘ON’ if any 

one door is open. Door switches are 

fitted on RHS/LHS door and tailgate. 

22

Handling 

Interior Lamps & Front Tow Hook 

Door Control Switch 

Interior Lamp 

Interior Lamp Door Control Switch- Tailgate 

FrontTowing Hook 

Door Control Switch 

Front Towing Hook : 

Front tow hook is below front bumper 

for vehicle towing. 

Towing Procedure : 

Make sure that, the vehicle is in neutral 

condition and in 4X2 mode while 

towing. Maximum driving speed 40 

kmph. 

Interior Lamp Door Control Switch 

23

Handling 

Hazard warning switch,Tail Lamp & Registration Plate Lamp 

Hazard warning switch 

Hazard warning switch 

This can be operated without ignition 

‘ON’. Pull the hazard warning switch 

(red knob) on the nacelle behind the 

steering wheel, all side indicator lights 

will flash simultaneously to warn the 

other road users about any hazardous 

condition of the vehicle. Depress 

the knob again to switch ‘OFF’ the 

hazard function. 

Rear Tail Lamp 

Tail Lamp : 

The tail lamp assembly incorporates 

the following : 

1. Rear Stop Lamp 

2. Rear Direction Indicator 

3. Reverse Light 

4. Rear Parking Lamp 

Registration Plate Lamp 

Registration Plate Lamp : 

Two concealed lamp are provided for 

illumination of the rear registration plate. 

24

Handling 

Front & Rear Fog Lamps 

2 

1 

Front Fog Lamp 

Front and Rear Fog Lamps : 

The front fog lamps are provided on 

the front chassis frame to improve 

thevisibility in foggy weather. The front 

fog lamp can be switched ‘ON’ by 

pushing the switch once with the 

headlamp ‘ON’ till the parking brake is 

switched ‘OFF;. The rear fog lamp 

willswitch ‘OFF’ if parking lamps are 

switched ‘OFF’ and will not come ‘ON’ 

Rear Fog Lamp 

again with parking lamp ‘ON’ until 

deliberately switched ‘ON’ again. 

The switch for front fog lamp is an 

‘ON / OFF’ type switch. The rear fog 

lamp has the in-built tell tale indicating 

lamps for indicating the fog lamp 

operation. 

1. Switch for Rear Fog Lamp 

2. Switch for Front Fog Lamp 

25

Handling 

Head Lamp Levelling Switch & High Mounted Stop Lamp 

Headlamp Leveling Switch 

Head Lamp Leveling Switch (if fitted): 

A headlamp leveling switch is provided 

at the LH side of the steering column 

on dash board. 

As and when required headlamp leveling 

setting is done by rotating the 

knob to select one of the level marked 

in the switch depending upon the loading 

of vehicle. 

Switch 

Position 

O 

Loading Condition 

Unladen + Driver/Driver 

+ Co-driver 

1 Driver + Co-driver + All 

seats occupied 

2 Laden + All seats 

occupied 

3 Laden + All seats 

occupied + permissible 

luggage load 

High Mounted Stop Lamp 

High Mounted Stop Lamp: 

High mounted stop lamp is located on 

tail gate and it glows whenever service 

brake is applied in additional to 

two stop lamps. 

26

Handling 

ECU, Rear Towing Hook & Rear Foot Step 

ECU 

ECU : 

DICOR engine common rail system 

consist of ECU, sensors and 

actuators. The ECU receives input 

from various sensors located on the 

engine and the vehicle to decide the 

injected quantity and injection timing 

best suited for the engine to work with 

maximum efficiency and safety ECU 

is fitted inside the engine compartment 

Rear Central Towing Hook 

Rear Central Towing Hook : 

Rear central towing hook with locking 

arrangement has been provided for 

towing the trailor. 

Rear Foot Step 

Rear Foot Steps : 

Rear foot steps on RHS/LHS has been 

provided for ease of entering in or 

alighting from rear compartment. 

27

Handling 

Roof Hatch, Oservation Window and Gun Port 

1 

Roof Hatch (Optional Fitment) 

Roof Hatch : 

The roof hatch is provided for 

observation and firing front & rear. 

Roof Hatch Lock 

1. Handles 

Roof Hatch Lock: 

To open the roof hatch, first unlock the 

the latch knob by using key. Rotate the 

latch knob and push the hatch doors 

upwards. 

For closing the hatch doors, pull the 

handle swhich are provied on the doors 

from inside. 

1. Obeservation Window 

2. Gun port on rear door 

Observation Window With Gun 

Ports: 

Observation window (1) with gun port (2) 

is provided on tail gate door. 

28

Handling 

Gun Port, Ventilator & Battery Isolator Switch 

Gun port 

Gun Port : 

Gun ports are provided on the front 

left door, middle both doors, tail gate 

and LH & RH side windows at rear. 

Opening the gun port, press the knob 

and rotate in either direction. 

Gun ports are used to place gun for 

firing. 

Ventilator 

Ventilator : 

Battery Isolator Switch 

Battery Isolator Switch : 

Ventilator is located on the roof above 

driver & co-driver. 

Ventilator is provided for fresh air 

intake, when HVAC is not working. 

Battery Isolator Switch: 

This switch is provided near the gear 

shift lever to isolate the battery from 

electrical system when required. Battery 

Battery is connected to the starter and 

other circuitry through isolator switch. 

This is to be switched OFF while 

carrying out any work on the vehicle 

and also when the vehicle is parked 

for long duration to avoid battery 

drainage. This will also prevent any 

inadvertent short circuits during 

repairs. 

29

Handling 

Engine compartment light, Bonnet Opening / Closing 

1. Engine compartment light 

2. Engine compartment light switch 

Engine compartment light : 

To operate engine compartment light 

pull switch (2) 

Bonnet opening and closing : 

To open bonnet pull lever (1) This will 

release the bonnet lock. To open fully, 

lift the additional lock lever located on 

the bonnet centre with the help of 

finger. Use the bonnet stay rod to keep 

the bonnet open. 

30 

Bonnet Opening lever 

For closing the bonnet, disengage the 

stay rod, clamp it properly and press 

down the bonnet till it is fully shut. 

Ensure that the bonnet is fully 

locked driving off. 

In case of failure of cable attached to 

lever (1) bonnet lock can be opened by 

inserting a screw driver from the top 

centre position of grille through a slot 

provided behind it on the sheet metal 

Additional lock lever 

and by pressing the lock plate toward 

your left. Push upward the additional 

lock lever at your right and lift the bonnet 

while the lock plate is kept pressed with 

the help of a screw driver.

Handling 

Fresh 

Air in 

Turbocharger 

Compressor 

Wheel 

Turbocharger is an efficient 

supercharging device used in our 

engine. It makes use of thermal energyof 

engine exhaust gases to run a turbine 

which in turn drives a compressor to 

force air uner pressure into the inlet 

manifold. 

Pressure oil 

from engine 

Oil drain to engine 

Exhaust 

gas out 

Turbine Wheel 

Assembly 

Lubrication of Turbocharger : 

The rotor assembly of the 

turbocharger is supported by two 

floating lead bronze sleeve bearings 

in the bearing housing. These bearings 

are lubricated with the finest filtered 

and cooled oil from the lubrication 

Turbocharger 

system of the engine. There is a heat 

shield arrangement. provided between 

the gas chamber of the turbine nd the 

bearing housing to avoid heating of 

the bearings. 

Maintenance of Variable Geometry 

Turbocharger 

1. Tighten the following fasteners at 

PDI and thereafter at specified 

intervals. 

Turbocharger mounting 

Intercooler mounting 

Turbocharger hose connections 

& its mountings 

Intercooler hose connections 

and its mountings 

2. Check intercooler fins for any dust 

accumulations and clean by 

compressed air at at specified 

intervals. 

3. Check end play of turbocharger 

shaft and radial clearance between 

turbine wheel and housing at 

specified intervals. 

31

Handling 

Pre-silencer & Power steering 

1. RESERVOIR 

2. PUMP 

3. POWER STG.GEAR BOX 

4. FREE PLAY ADJUSTER 

5. LOCK NUT 

Pre-silencer: 

The construction of Presilencer consists 

of a cylindrical outer jacket, inside to 

which cylindrical perforated pipe & baffle 

are welded to it. As Exhaust gases 

passes through it expansion of gases 

occurs. At the both ends of presilencer 

triangular flanges are provided for the 

fitment of front & middle pipe assemblies. 

32 

Power steering - schematic circuit 

POWER STEERING 

Power steering is fitted for lighter 

steering effort and easy 

manoeuvrability. The system consists 

of steering gear box, hydraulic pump 

and hydraulic reservoir suitably 

mounted and connected by piping. 

Pump drive is through ‘V’ belt from 

engine. Power assistance is available 

during normal functioning of the 

power steering system. 

In case of any failure in hydraulic 

system, the steering can be 

operated mechanically with 

increased steering effort for 

bringing the vehicle to a repair 

station.

Handling 

Power steering hydraulic reservoir 

Procedure for oil filling and 

bleeding the power steering 

system. 

(Ensure that the reservoir is totally 

cleaned before starting the work.) 

1. Fill the reservoir nearly full. 

Crank the engine for 10 seconds 

without, if possible, allowing it 

to start. If the engine does start, 

shut off immediately. 

Check and refill the reservoir. Repeat 

at least three times, each time 

checking and refilling the reservoir. 

2. Check for any leakage in the 

system and if noticed take 

corrective action. 

3. Start the engine and steer the 

vehicle from full left to full right 

turn 3-4 times. Add fluid, if 

necessary to maintain the level up 

to the filter top. 

4. With the engine at steady speed, 

check for bubble / foaming in the 

fluid. If present it indicates that 

air is geting sucked into the 

system. Check the suction line / 

fittings and correct if necessary. 

5. Once the system is bled properly 

and free from foaming, there 

should not be appreciable change 

in fluid level in the reservoir, when 

the engine is started / stopped 

repeatedly. Top up or remove 

excess fluid so that the final level 

is at ‘H’ mark on dipstick. 

Power steering 

6. Now the system is ready for 

driving. 

CAUTION 

Do not allow the fluid level to drop 

significantly or run out of the 

reservoir during the above 

operation. This may induce air into 

the system. 

Do not start the engine without fluid 

in the power steering system. This 

will result in serious damage to the 

pump. 

NOTICE 

Always use recommended brand 

of fluid from closed container. Any 

dirty fluid poured in the system will 

result in damage to pump / gear. 

33

Handling 

Power Steering Belt tension 

Free play adjustment 

Ensure that vehicle is in straight ahead 

position. Remove tie rod ball joint on 

pitman arm. Hold sector shaft adjuster 

screw with 6 mm hexagonal key and 

loosen lock nut. Hold pitman arm and 

turn sector shaft adjuster screw 

clockwise till there is just no play of 

pitman arm. Tighten lock nut of 

adjuster screw without distrubing its 

position by holding with hex key. Turn 

steering wheel through its full 

movement and ensure that sector 

shaft movement is smooth throughout 

its range. Refit the tie rod ball joint to 

pitman arm. For any other complaints, 

get the system checked and rectified 

at our authorised workshops. 

For adjusting the power steering belt 

tension please refer page no.51. 

34 

Power steering pump belt tension 

Check : 

Check the conditions of belts on the 

engine. Examine the edge of the belt 

for cracks or fraying. 

Check the tension of the belt by 

pushing on it with your thumb 

Alternator/Power Steering belt as 

shown in Figure. 

The belts should have deflection of 8 

to 10 mm. (X). 

If the belt tension is not proper, get it 

attended at the nearest TATA 

Authorised Workshop.

Handling 

Heating,Ventilation & Air Conditioning 

C. Air Direction Control Knob : 

The air flow can be changed by turning 

the switch (C) to the desired direction. 

A 

D 

B 

E 

C 

Towards face 

Towards face and feet 

Towards feet 

HEATING, VENTILATION & AIR 

CONDITIONING : (if installed) 

A. Temperature Control Knob : 

The air temperature in the vehicle can 

be controlled by operating the 

temperature control knob (A) at the left 

hand side of the control panel. The 

temperature can be increased by 

rotating the knob towards the red 

segment and decreased by rotating it 

towards the blue segment. 

B. Blower Speed Regulation Knob 

: 

The ventilation system has a four 

speed blower. The blower speeds can 

be regulated to any one of the following 

speeds by operating the knob (B) at 

the centre of the control panel. 

1. LOW 2. MEDIUM 3. HIGH VERY 

HIGH 

Towards feet and windshield 

(Recommended for clearing 

fogging on windshield) 

Air demist / defrost windshield 

(Recommended for clearing 

heavy fog and snow) 

D. A.C. ON/OFF Switch : 

The A.C. can be switched 'ON' by 

pressing the switch (D) on the A.C. 

control panel provided the blower is 

ÒN' and the engine is running. The 

indicator lamp will show that the A.C. 

is ÒN'. 

35

Handling 

Heating,Ventilation & Air Conditioning 

E. Air Circulation Switch : 

In HVAC version to put air circulation 

mode in recirculation, press switch 

'E'. The indicator lamp will show air 

circulation is in recirculation. 

To put vehicle in Fresh mode release 

switch 'E'. Indicator lamp will be 

'OFF'. 

In recirculation mode, air inside the 

vehicle is circulated again and again. 

In Fresh mode, air is taken from 

atmosphere and circulated in the 

vehicle. Recirculation mode can be 

used 

While driving in dusty condition 

To avoid traffic pollution 

To get quick cooling/heating as 

required. 

Whenever discomfort is felt switch air 

circulation mode to fresh. 

NOTICE 

1. The A.C. can be switched ÒN' only 

if the blower is 'ON' and engine is 

running. When A.C. is switched 'ON' 

engine idling RPM increases 

marginally, to adjust to the A.C. 

compressor load. When desired 

temperature is achieved A.C. trips 

'OFF' automatically. 

2. The A.C. compressor gets 

switched 'OFF' automatically when 

engine gets overheated. The A.C. is 

automatically switched 'ON' when the 

engine cools down. 

Normal Cooling : 

A.C. 

Knob 'B' 

Knob 'C' 

- ON 

- Desired speed position 

- Towards face 

Switch 'E' - Suitably as explained 

Quick Cooling : 

If your car is left in the sun with window 

closed, inside temperature increases. 

To achieve quick cooling effect, open the 

windows briefly while you operate the air 

conditioner, with air circulation switch is 

in Fresh mode, fan at higher speed and 

air direction towards 'FACE'. All vents to 

be opened completely. 

Once temperature inside has come 

down sufficiently, close the windows and 

change air circulation suitably to fresh/ 

recirculation. 

36

Handling 

“G” Conscious pressure reducing valve for brakes 

“G” Conscious pressure 

reducing valve for brakes 

This valve consists of a barrel with 

one inlet and one outlet. A steel 

ball is kept rolling free in the barrel. 

When the brakes are applied the 

brake fluid going to rear wheel 

cylinders passes through this valve 

around the steel ball and goes out 

from other end to rear wheel 

cylinders. As the brakes are applied 

and vehicle decelerates, the free 

rolling ball moves forward due to 

its momentum and closes the port 

stopping the further supply of brake 

fluid to rear wheel cylinders. This 

ensures that cylinder pressure is 

limited to a value which avoids 

wheel locking. 

To achieve the specific cutout point 

the valve body is mounted on 

vehicle at 26 0 angle so that the ball 

has to climb some slope before 

closing the outlet port. 

37

Handling 

Preparing the vehicle for the drive 

Fuel tank fillerneck 

Check the following regularly, 

particularly before starting on a 

long journey. 

1. Fuel level in tank 

38 

Top up if required with correct 

diesel fuel, secure cap and lock 

the flap. 

1.Engine oil filler Cap 

2. Engine oil level 

2. Dip Stick 

Check engine oil level before 

starting the engine or at least 20 

minutes after stopping the engine. 

Top up if oil level is less than 

midway between upper and lower 

marks on the dipstick. 

The oil level should not exceed the 

'MAX’ mark. USE ONLY THE 

GENUINE CO- BRANDED OILS. 

Coolant Tank 

3. Coolant level 

With the engine cool, check the 

coolant in the no loss tank. The level 

should be between the 'FULL' and 

'MIN' marks. if the level is 

below the 'MIN' mark, top up with the 

genuine co-branded coolant. Bring 

the level upto the 'FULL' mark. The 

level must not exceed the 'FULL' 

mark. If the coolant level drops with 

in a short time after replenishing, 

there may be a leak in the system.

Handling 


Rectify the leakage and top up 

radiator also. Use recommended 

coolant. 

If no leak can be found inspection 

should be carried out at a Authorised 

service outlet. 

NOTICE 

Always use radiator cap only of 1.0 

kg/cm 2 (14 psi), ifrequired to be 

replaced. 

4. Ensure battery electrolyte level is 

10-12 mm above top of battery 

plates. Top up with distilled water if 

required (NOT ACID). 

Keep battery terminals clean and 

tight. Apply petroleum jelly / vaseline 

on terminals for protection against 

corrosion. Secure cover provided 

over positive terminal. 

5. Check all lights, horn, 

gauges,switches and wiper for 

proper functioning. 

6. Check condition and tension of 

belts. ADJUST tension if necessary. 

Checking belts tension 

7. Check leakages of coolant, fuel 

and oil at all joints of hoses and 

pipes and rectify, if any. If coolant 

leakage is noticed, rectify the 

leakages and top up radiator also 

with recommended coolant. 

8. Check level of brake fluid in 

plastic container. Top up if 

necessary. Do not overfill. Use 

only GENUINE CO-BRANDED 

brake fluid. 

1. Brake fluid Container 

2. Clutch fluid Container 

9. Check level of clutch fluid in 

plastic container. Top up if 

necessary. Do not overfill as this 

would result in spillage during clutch 

operation. Use only GENUIN 

CO-BRANDED clutch fluid. 

10. Check level of water in Windshield 

washer reservoir, located in the 

engine compartment near the fuse 

box. Top up with clean water if 

required. 

39

Handling 


B 

Gear box oil filler plug (G-76) Rear axle oil filler plug Transfer case 

A. Drain plug B. Oil level plug 

40 

Do not use soap solution. 

11. Level of gear box oil 

Periodically check gear box oil 

level. 

12.Level of front live axle oil (4x4) 

Periodically check front live axle oil 

level. 

13.Level of rear axle oil 

Periodically check rear axle oil 

level. 

14.Check condition of wiper 

blades, replace if rubber profile 

is damaged. 

15.Check level of oil in steering 

gear box. 

16.Check oil level in power steering 

hydraulic tank, where applicable. 

17.Check and correct tyre inflation 

pressure (with cold tyres). 

18.Level of transfer case oil (4x4) 

Periodically check oil level 

A 

CAUTION 

Do not use impact wrench to 

remove or install level / filling plug 

or drain plug since this will damage 

threads in the transfer case cover. 

19. Clean transfer case breather 

regularly for 4x4 vehicle.

Driving 

Before Driving 

Check 

 

 

 

 

 

Adjust 

 

 

Ensure 

 

 

 

 

Coolant level 

Engine oil level 

Tyre pressure 

Brake and clutch fluid level 

Doors are firmly closed 

Driver seat 

Rear view mirrors 

Gear shift lever is in neutral 

position. 

All switches and lamps are 

working. 

Brake fail indicator is 'OFF' 

Fuel level indicated in fuel 

gauge is above reserve 

mark. 

Gear lever knob (G-76 gear box) 

Start the engine and observe that : 

(Where turbocharged engine is fitted, 

run engine in low idle speed for 

atleast 1 minute and do not 

accelerate the engine till the engine 

oil pressure is built up.) 

Low oil pressure indicator light goes 

'OFF' 

Battery charging indicator light goes 

'OFF' 

Driving & Gear Shifting 

4 WDH and 4 WDL indicator lights 

go off in 2H mode in case of 4x4 

vehicle. 

VEHICLE IS NOW READY FOR A 

DRIVE 

DO NOT ALLOW VEHICLE TO ROLL 

BACK ON GRADIENTS. 

During Running-in period 

i.e. first 2,000 km. of operation : 

Do not exceed the following vehicle 

speeds : 

For 4x4 vehicles 

Gear 

Speed in km/hr. 

4x2 4x4 (low) 

1st to 2nd 20 10 

2nd to 3rd 35 14 

3rd to 4th 50 - 

4th to 5th 75 - 

41

Driving Instructions 

Driving , Gear Shifting, Braking 

 

 

 

42 

Avoid rapid acceleration and 

prolonged high speed runnings of 

the engine. 

Avoid sudden braking. 

Retighten wheel nuts to 12-15 mkg 

torque after first 100 km of running 

of a new vehicle and after every 

wheel change. 

Driving instructions 

 

 

 

 

DRIVE SAFELY AND JUDICIOUSLY 

REMEMBER SAFETY FIRST. 

Depress clutch pedal fully before 

shifting gears. This will ensure 

longer synchro cone life. 

For smooth starting of vehicle 

without jerks, synchronise 

release of clutch pedal with 

pressing of accelerator pedal. 

Start the vehicle in first gear only. 

Change gears at appropriate 

speeds and do not lug the engine 

by too early shifting to higher 

gear at low speeds. 

Recommended speeds for gear 

changes ( For 4x4 vehicles) 

 

 

 

Gear 

Speed in km/hr. 

4x2 4x4 (low) 

1st 22 10 

2nd 40 15 

3rd 60 - 

4th 70 - 

5th 85 - 

Engage reverse gear, only when 

vehicle is stationary. 

To engage reverse gear, move 

ear shift lever to extreme left and 

push it forward. 

Depress clutch pedal fully before 

engaging the reverse gear. Wait 

for a few seconds then engage 

the gear. If the gear shifting does 

not occur, then release the clutch 

pedal, once again press the 

clutch pedal and engage the 

reverse gear. 

Braking 

 

 

 

 

 

While braking on turns apply 

brakes gently. 

Before driving down a long steep 

gradient, reduce vehicle speed 

by changing to lower gear. 

Do not ride the brakes as they 

may overheat and their 

performance may be impaired. 

Do not use half engaged clutch 

to hold the vehicle on up 

gradient as this will result in 

premature clutch failure. 

After driving through pockets of 

water, apply the brake a few 

times at low speed to get rid of 

moisture inside the brake drums. 

When it begins to rain, reduce 

vehicle speed and avoid sudden 

braking.


Engine Starting & Stopping and Fuel Economy 

Starting the engine : 

Before starting 

1. Apply parking brake. 

b. Ensure gear lever in neutral. 

3. Insert the key in steering cum 

ignition lock and turn it to ‘ON’ 

position. 

4. Press the clutch pedal fully. 

5. Now crank the engine. 

6. If the engine does not start turn 

the key to ‘OFF’ position and 

try after 30 seconds. 

NOTICE 

After starting run the engine in 

low idle speed for at least 30 sec. 

Do not press accelerator pedal 

while starting the engine to avoid 

damage to turbocharger. 

Stopping the engine : 

Before switching ‘OFF’ the engine, run 

the engine idle for atleast 30 seconds 

and then switch ‘OFF’. This will allow 

the engine oil to lubricate the turbo- 

charger, till its speed is fully reduced 

and also allow the unit to cool down. 

Above precautions will ensure 

satisfactory life and performance from 

the turbocharger. 

Fuel Economy : 

a. Drive smoothly, accelerate 

gradually and anticipate stops. 

b. Best fuel consumption is obtained 

at low engine speeds in the 

highest possible gear without 

labouring the engine. 

c. Driving with accelerator pedal fully 

depressed means using 

excessive fuel. 

d. Do not allow the engine to labour 

by too early high gear changes. 

Change to lower gear when 

engine no longer runs smoothly 

e. If possible do not idle the engine 

for more than 5 minutes. Switch 

‘OFF’ the engine. 

f. Do not ride clutch. Do not use 

clutch pedal as foot rest. 

g. When changing from 4H/4L to 2H 

of transfer case, 2H free wheeling 

should be done . If 2H free 

wheeling is not done the hub locks 

of front hub are remain locked 

causing unnecessary rotation of 

front drive components and this 

consumes more fuel. 

H. Depending on traffic conditions 

a constant speed should be 

maintained 

The vehicle uses more fuel, 

every time you speed up or slow 

down. 

I. Avoid hard braking, abrupt 

cornering and rapid acceleration. 

43


Location of 4x4 Selector switch 

Transfer Case and Transfer Case 

nselector Electric Switch : 

On four wheel drive vehicles 

transfer case is fitted after the gear 

box for driving front live axle along 

with rear axle. 

The following 3 positions are 

provided on selector switch : 

2H Only rear wheels are driven and 

transfer case operates at 1:1 

ratio. 

44 

Automatic Hub Lock 

4H All four wheels are driven and 

transfer case operates at 1:1 

ratio. 

4L 

All four wheels are driven and 

transfer case operates at 2.48:1 

speed reduction ratio. 

Automatic hub locks (4x4) 

While driving in 2H mode this 

mechanism on the front axle hub 

allows the hub to free wheel. This 

4x4 Operations 

avoids the unnecessary spinning of 

front axle drive components and 

results in fuel saving, reduced noise 

and longer component life. 

As soon as 4H or 4L mode is 

selected the hub gets automatically 

connected to front drive line to 

increase the traction. 

Instructions for 4x4 operation 

1. With ignition ‘ON’ 4WDH & 

4WDL indicator lights on panel 

should glow for a few seconds 

onlyd then go off. 

CAUTION 

While in 2H mode, continuous 

illumination of 4WDL & 4WDH 

lights indicate electrical fault like 

short or open circuit. Do not 

march the vehicle in this case. 

2. Shifting from 2H to 4H : Turn 

the selector knob from 2H to 4H 

position. 4WDH indicator on 

instrument panel will light up.


Changing from 2H to 4H can be 

done at any speed upto 65 km/h. 

No pressing of clutch pedal is 

required 

3. Shifting from 4H to 2H : Turn 

the selector knob from 4H to 2H 

position. 4WDH indicator on 

instrument panel will go off. 

Changing from 4H to 2H can be 

done at any speed upto 65 

km/h. No pressing of clutch pedal 

is required. 

Free wheeling of front hub : After 

shifting from 4H to 2H, for effecting 

free wheeling of front wheels, 

direction of vehicle motion needs 

to be changed. If in4H mode the 

vehicle was moving forward then 

stop it, wait and then engage 

reverse gear of main gear box. If it 

was moving reverse in 4H mode 

then stop it, wait and then engage 

forward gear of main gear box. 

(After stopping and changing the 

gear the vehicle must travel in 

opposite direction for a minimum 

of three meters, before free 

wheeling takes place.) 

4. Shifting from 4H to 4L 

Stop the vehicle. Press clutch 

pedal. Turn the selector knob from 

4H to 4L position. 4WDL indicator 

light on instrument panel will blink 

a few times and remain on. 

5. Shifting from 4L to 4H 

Stop the vehicle. Press clutch 

pedal. Turn the selector knob from 

4L to 4H position. 4WDH indicator 

light on instrument panel will blink 

a few times and remain on. 

CAUTION 

In case of malfunctioning in 

shifting from 4H to 4L or 4L to 

4H, respectively 4L or 4H 

indicator light will flash 

continuously, Do not march the 

vehicle in such a case. 

4x4 Operations 

Do not use 4H or 4L modes 

continuously on dry and hard 

surfaced road except for 

checking operations. 

Limited Slip Differential : 

A standard differential delivers torque 

equally to each wheel. In case one 

wheel loses traction and begins to 

spin, the differential distributes the 

rotary speed unequally but with same 

torque. This can cause the wheel with 

good traction to slow down or stop 

while the wheel which lost traction 

rotates with increased speed. Such a 

situation can prevent the vehicle from 

moving. The limited slip differential 

provided in the rear axle takes care 

of such situations. The clutch lock 

arrangement provided internally, 

ensures that in case one wheel loses 

traction and begins to slip, a locking 

action takes place which prevents 

differential action and both wheels turn 

at the same speed. 

45

Vehicle Maintenance 

Engine Compartment 

ENGINE COMPARTMENT 

1. Fuse Box 

2. Power Steering Fluid Container 

3. Brake Fluid Container 

4. Clutch Fluid Container 

5. Engine Oil Filler Cap 

6. Dip Stick 

7. Air Filter 

8. Air Pre-cleaner 

9. Radiator Cap 

10. Engine Coolant Tank 

11. Windshield Washer Fluid Container 

46


Air Filter 

Air Filter : 

The air filter element should be 

periodically cleaned.Replace the air 

filter element with a new one when the 

service indicator shows red band 

even after cleaning. 

Always use genuine air filter element. 

Air filter for SUMO Armoured DICOR 

diesel engine is located at LH side of 

engine compartment. 

Replacement of Air Filter Element : 

a) Disconnect air filter from hose. 

Declamp and remove the air 

filter. 

b) Remove the cover of the air filter. 

c) Remove the air filter element. 

d) Clean it gently by tapping. Clean 

air filter cover and air ducting. 

e) Check element for puncture or pin 

holes by light source. 

f ) If found OK install paper filter 

element. Fit the cover and tighten 

air filter screws at the place and 

fit the clamps back. 

g) Clean the hose connecting the air 

filter to turbocharger pipe. Reset 

the indicator by pressing the 

rubber cap,red band will disappear 

from Service Indicator. 

On starting the engine, if red band 

continues to appear, replace the 

paper filter element. 

Air Filter 

Reset the indicator by pressing the 

rubber cap, red band will disappear 

from Service Indicator. 

On starting the engine, if red band 

continues to appear, replace the 

paper filter element. 

47


Engine Cooling System 

Engine Coolant Tank 

Engine Cooling System : 

If engine overheating occurs, there could 

be a fault in the cooling system which 

may be on account of : 

1. Less coolant in the cooling system 

or dirt / scale having accumulated 

inside cooling water passages 

especially in the radiator core. 

2. Choking of radiator passages due 

to foreign material or damages. 

3. Defective thermostat. 

48 

Radiator Cap 

4. Defective coolant temp. sensor. 

5. Coolant leakage. 

6. Radiator cap not sealing properly. 

7. A.C. condenser fan not working 

8. Excessive refrigerant charging in 

the A.C. system. 

Prevention of Rust Formation : 

To prevent rust formation in the radiator 

use premixed recommended anti-freeze 

coolant. 

This is sufficient to operate the vehicle 

upto - 40 0 C. 

Replacing Engine Coolant : 

The cooling system should be 

completely drained and refilled with new 

coolant at specified intervals. 

1. Ensure engine and radiator are 

cool enough to touch. 

2. Remove the radiator cap. 

3. Loosen drain plug on the bottom 

of radiator. Remove cylinder block 

drain plug from engine block. 

4. Remove the auxiliary tank from its 

holder and drain the coolant. 

5. Flush radiator and block with clean 

water and close the drain plugs. 

6. Pour the premixed coolant into 

radiator until it is full. 

7. Fill the auxiliary tank upto high 

mark. 

8. Ensure no leakage in the system.


Changing Engine Oil & Oil Filter 

Oil Sump drain plug 

Engine oil filler 

1.Engine oil filler Cap 2. Dip Stick 

Changing of Engine Oil and Oil 

Filter : 

Change the oil and oil filter at specified 

intervals. (Engine oil and oil filter 

may be changed earlier for sandy/ 

dusty operating conditions) 

Changing of oil and oil filter requires 

access from underneath the vehicle. 

Vehicle should be raised on a hydraulic 

lift of a service station or should be 

on a service pit. 

1. Run the engine until it reaches 

normal operating temperature. 

Then shut it off. 

2. Open the bonnet and remove 

engine oil filler cap. Remove the 

drain plug of the oil sump from the 

bottom of the engine. Drain the oil 

into an appropriate container. 

3. Remove the oil filter with the help 

of special wrench. The removed oil 

filter should not be reused and 

hence should be destroyed to avoid 

recycling of the same. Used filter 

and oil should be disposed in 

compliance with the current 

legislation. 

4. Smear a little fresh engine oil on 

rubber gasket of new engine oil filter. 

Hand tighten the engine oil filter fully 

and further half turn with special 

tool. Do not over tighten engine oil 

filter as this may damage oil filter & oil 

may leak out. 

49


Water Draining Procedure from Sedimenter 

5. Before filling in fresh oil in the 

engine, clean the drain plug and 

apply sealant on threads. 

6. Refit the drain plug using a new 

sealing washer. Tighten drain plug 

to 5 mkg. torque. 

7. Fill, recommended quantity of 

fresh engine oil in the crank case 

and secure the oil filler cap in its 

place. 

8. Start the engine and run for a few 

minutes. The engine oil pressure 

indicator lamp should go ‘off’ after 

starting the engine. 

9. Check for engine oil leakages. 

10.Stop the engine and recheck 

engine oil level after a few 

minutes. If necessary add oil to 

bring the level to the upper mark 

on the dipstick. 

NOTICE 

Use of reclaimed oil is not 

recommended. 

Water Sedimenter 

Water draining Procedure from 

Sedimenter : 

The water sedimenter is part of the 

Fuel filtration system, fitted to the 

chassis frame, near fuel tank below 

the vehicle. It is used in the fuel 

supplying system in order to reduce 

the water content in the fuel provided 

to the DICOR system. 

A water sensor is fitted to the water 

sedimenter in order to indicate to the 

driver that the sedimenter has to be 

drained. Whenever water in fuel 

sedimenter Indicator glows in 

instument cluster, the water need to 

be drained from the sedimenter. 

Water drain operation to be done on 

both filter and sedimenter. 

Procedure : 

1. Stop the engine, and wait until 

pressure stabilizes. 

2. Unclip one of the hydraulic 

connections (either inlet or outlet) 

and the electric connector of the 

water sensor. 3 Place a container 

underneath the water sedimenter. 

3. Place a container underneath the 

water sedimenter. 

4. Unscrew the water sensor about 

2 - 3 turns 

50


Fuel & Filter Draining & Priming / Pear Pump 

5. Wait until all the water has 

drained out of the water 

sedimenter. 

6. As soon as the flow is free of 

water, screw the water sensor to 

the required torque. 

7. Clip the hydraulic connector and 

the electric connector to the 

water sensor. 

Fuel & Filter Draining : 

Loosen drain plugs by 1-2 turn and 

drain out water and other sediments 

from fuel filter bowls depending on 

operating conditions to ensure that no 

water is allowed to enter the fuel 

system. 

Priming / Pear Pump 

Priming Pump / Pear Pump : 

This is used for priming the fuel 

manually after overhauling of the 

engine or after refitment of fuel lines 

or after changing either fule filter or 

sedimenter Pump the fuel by means 

of priming pump / pear pump until all 

air in the fuel line removed. Before 

cranking the engine ensure that there 

is no air in the fuel system. 

CAUTION 

Do not loosen the HP lines of 

DICOR system for bleeding the air 

from fuel system. 

51


1. Gear Box Oil Level / Filler Plug 

2. Gear Box Oil Drain Plug 

Gear Box Oil 

Checking of Oil Level : 

1. Clean the oil level plug and 

surrounding area. 

2. Remove the oil level plug and check 

whether oil is dripping out.Oil level 

must not be below the filler plug. 

Add oil to bring it tothe level. 

3. Tighten oil level plug to 2-3 mkg. 

torque. 

Changing Oil in Gear Box : 

1. Let the engine idle for about 5 min. 

in neutral, so that the gear box oil 

is warmed up. 

2. Clean the oil level plug, drain plug 

and surrounding area. 

3. Place a container under gear box 

to collect the oil. 

4. Remove the drain plug and let the 

oil drain out. 

5. Also remove the oil level plug. 

6. Tighten the oil drain plug and fill new 

recommended oil through oil level 

plug and tighten the oil drain plug 

oil level plug to 2-3 mkg. torque. 

Checking & Changing oil in Gear Box 

52


Checking & Changing oil in Transfer Case 

1. Transfer case Oil Level / Filler Plug 

2. Transfer case Oil Drain Plug 

Checking Oil Level of Transfer Case 

NOTICE 

Before checking or removing the 

oil, warming up of the transfer case 

is necessary. This should be done 

by driving the vehicle for some time 

in 4x4 mode. 

Checking of Oil levels : 



2. Remove the oil level plug and 

check whether oil is dripping out. 

3. If oil is not dripping out, oil level 

must be below the required level. 

Add oil to bring it to the level when 

it starts dripping out. 

4. Tighten oil level plug. Tightening 

torque of oil level plug is 2 to 3 

mkg. 

Changing of Transfer Case Oil 



2. Place a container to collect oil, 

under transfer case. 



4. Remove the oil level plug. 

5. Tighten oil drain plug and fill new 

recommended oil through oil level 

plug, till it begins to drip out. 

6. Tighten oil level plug. Tightening 

torque of oil drain plug is 2 to 3 

mkg. 

53


Checking & Changing oil in Front / Rear Axle 

3. Tighten oil level plug to 2 to 3 mkg. 

torque. 

2 

1. Differential Oil Level / Filler Plug 

2. Differential Oil Drain Plug 

Checking Oil Level in Front / Rear 

Axle : 



2. Remove the oil level plug and check 

whether oil is dripping out. 

Oil level must be below the required 

level. Add oil to bring it to the level, 

when it starts dripping out. 

1 

Changing Oil in Front Axle/Rear 

Axle 



2. Place a container under Front/ 

Rear axle to collect the oil. 



4. Also remove the oil level plug. 

5. Tighten the oil drain plug and fill 

new recommended oil through oil 

level plug till it begin to drip. 

6. Tighten oil drain and oil level plugs 

to 2 to 3 mkg. torque. 

54




Bleeding clutch system 

A dry friction, single disc, diaphragm 

type clutch has been fitted, which is 

actuated hydraulically. 

The procedure for bleeding the 

system is as follows : 

a. Ensure that fluid level in clutch 

fluid container is upto maximum 

level. 

Bleeding clutch slave cylinder 

b. Remove dust cap from slave 

cylinder bleed screw and clean 

the screw thoroughly. Attach 

bleeding tube to bleed screw and 

place other end of tube in a 

clean glass jar containing 

sufficient clutch fluid to submerge 

tube end. 

c. Pump clutch pedal twice or thrice 

slowly throughout its stroke and 

Bleeding clutch system 

by holding clutch pedal in 

depressed condition, loosen 

bleed screw on slave cylinder, 

Watch for air bubbles in glass jar. 

d. Retighten bleed screw on slave 

cylinder and repeat the process 

until air bubbles cease to appear 

at the end of tube in glass jar, 

allowing only fluid to flow. 

e. After completing bleeding 

operation, ensure that bleed 

screw on slave cylinder is fully 

tightened. Replace dust cap on 

the bleed screw. 

During bleeding process keep 

a watch on fluid level in 

container and top-up. 

55


Brakes, Bleeding the brake system 

Brake system 

The dual circuit service brake system 

operated through the tandem master 

cylinder is designed such that one 

circuit will continue to provide braking 

action if the other circuit fails. This 

vehicle is fitted with disc brakes at front 

and drum brakes at rear. 

56 

Stopping the vehicle after loss of the 

brake fluid in one circuit will require 

more pedal presssure and pedal travel 

than normal. Also stopping distance 

will be longer. 

Service brakes are vacuum assisted. 

In case of failure of vacuum, the 

vehicle can still be stopped, however 

with a higher effort. 

Bleeding front calliper 

Bleeding the brake system 

If the brake pedal becomes spongy, 

this may be due to air in the hydraulic 

brake system. 

Whenever any repair/overhaul or 

disconnecting of any brake pipe is 

done, or level of brake fluid has 

fallen so low that air has been 

drawn into master cylinder, it is 

necessary to bleed the system to 

remove the trapped air.


Bleeding rear wheel cylinder 

Proceed as follows for bleeding the 

brake system : 

a. Clean all dirt from around the fluid 

container. Remove cap and topup 

fluid upto the maximum level. 

b. Remove dust cap at each bleed 

screw and clean the area around 

it. 

c. Attach the bleed tube to the front 

left calliper bleed screw and 



place the other end in a clean jar 

containing sufficient fluid to 

submerge the end of the tube. 

d. Pump the brake pedal 3-4 times 

slowly throughout its stroke and 

by holding the pedal depressed, 

loosen the bleed screw and watch 

for air bubbles in the glass jar. 

e. Re-tighten the bleed screw and 

release the brake pedal. Repeat 

the process until bubbles cease 

Bleeding the brake system 

to appear at the end of bleed 

tube, allowing only fluid to flow. 

f. Replace the dust cap on bleed 

screw. 

Repeat the same procedure (steps 'a' 

to 'f') on the front right calliper, rear 

left wheel cylinder followed by rear 

right wheel cylinder. 

After completion of bleeding, apply 

the brake several times and check for 

any leakage at joints and bleed 

screws. 

During the bleeding process keep 

the following points in mind : 

1. Ensure that the fluid level in the 

fluid container does not fall low 

enough to cause air to be drawn 

into the hydraulic system. 

2. Maintain absolute cleanliness. 

The brake system must be kept 

entirely free from petrol, kerosene 

or any form of mineral oil, as 

mineral contamination spreads 

rapidly in the hydraulic system, 

57


causing dangerous deterioration 

of the rubber seals. 

3. Never, under any circumstances, 

use the fluid which has been bled 

out from the system to topup 

the container. It may be 

aerated, have too much moisture 

content and /or is contaminated. 

4. Always use recommended brand 

of brake fluid. 

5. As brake fluid absorbs moisture 

from the atmosphere, we 

recommend changing of 

brake fluid in the system annually. 

6. Take care to see that the brake 

fluid is not spilled on the paint 

work. 

Brake adjustment : 

The front wheels are fitted with disc 

brakes. These are self adjusting, 

therefore need no adjustment. 

The rear wheel brakes can, however 

58 

be adjusted. Due to wear on the brake 

shoe linings the clearance between 

rear brake shoe linings and the brake 

drum increases. This must be 

adjusted after every 5,000 km if 

required : After installing new rear 

brake shoes or linings, check and 

adjust brakes after 500 km run. 

For adjusting rear wheel brake 

shoes proceed as follows : 

1. Put chocks on front wheels. 

2. Jack up rear axle. Release 

parking brake. Ensure that 

parking brake cable is slack. 

Place the gear shift lever in 

neutral position. 

3. Loosen the adjusting screws of 

both brake shoes so that the 

wheel is absoultely free to rotate. 

4. Now turn the adjusting screw of 

one of the brake shoes till brake 

begins to bind i.e. the brake shoe 

touches the brake drum. 

Brake adjustment 

Adjusting the rear brakes 

1. Adjusting screw 

2 & 3 To increase or reduce the 

clearance between brake 

shoe and drum 

Now turn the adjusting screw in 

the opposite direction just upto the 

point when wheel can be rotated 

freely. 

Adjust the other brake shoe of the 

same wheel in the manner 

described above.


5. Adjust both brake shoes of the 

other wheel as described above. 

6. Operate brake pedal twice/ thrice, 

simultaneously rotating both rear 

wheels, for checking proper 

application and release of brakes. 

7. Re-adjust, if necessary. 

8. Remove front wheel chocks. 

9. Test drive vehicle for checking 

proper brake function. 

Parking Brake Brake adjustment 

(Floor mounted) : 

Adjust that all four rear brake shoes 

have been properly adjusted. 

1. Put chocks on front wheels. 

2. Jack up the rear axle. 

3. Loosen the lock nut. Pull the 

parking brake lever up to 5th 

notch. 

2 

Parking brake handle (Floor mounted) 

1. Parking brake released 

2. Parking brake applied 

4. Tighten the adjusting screw till 

rear wheels start jamming and 

cannot be rotated. 

5. Release the parking brake and 

ensure that wheels are rotating 

freely. Hold the adjusting screw 

1 

Adjustment of parking brake 

1 

Parking brake linkage adjustment 

1.Check nut 2. Parking brake nut 

in this position and tighten the 

lock nut. Operate parking brake 

few times to ensure proper 

operation. 

2 

59


Wheels and tyres 

Jack location at front Jack location at rear Tightening wheel nuts 

Wheels and Tyres 

Always use only recommended size 

wheel rims and tyres. Use of rims and 

tyres not recommended by us may 

have adverse effect on vehicle safety 

and further more, could infringe on 

motor vehicle regulations. 

Wheel change 

When changing wheels use the jack 

provided with the vehicle. 

60 

Jack should be placed below chassis 

long member behind front wheel for 

changing front tyres and before rear 

wheel at rear axle as shown for rear 

tyres. 

Wheel alignment 

If uneven tyre wear is noticed, get the 

vehicle examined and attended by 

TATA MOTORS authorised Service 

Outlet. Periodically check and maintain 

correct tyre pressure to obtain longer 

tyre life. 

Recommended tyre pressure 

(with cold tyres) 

For LT 245 / 70 R 16 ALL TERRAIN 

TYRES 

LT 245 / 70 R 16 

Front(psi) 

Rear(psi) 

UNLADEN 31 41 

LADEN 36 58 

Check and maintain the above 

recommended tyre pressure in all terrain 

& environment conditions.


Check tyres for damage from time to 

time and remove any foreign bodies 

(nails/stones, metal chips etc.) 

embedded in treads. 

While fitting wheels on the vehicle make 

sure that wheel bolts are free from dust, 

scratches, dirt, dents etc. 

Do not oil wheel bolts and nuts. 

Wipe off any adhering oil. 

Tightening torque of : 12-15 mkg 

wheel nuts. 

Retighten wheel nuts after 100 km of 

every wheel change. 

New tyres do not give maximum grip 

straightaway and should therefore 

be run-in at moderate speed for the 

first 100 km. This will help to make 

the tyres last long. 

To avoid damage to tyres and wheels, 

drive slowly over speed breakers/ 

bumps/rough roads. 

Wheel balancing : 

Wheels of your vehicle are balanced. 

The same should be maintained when 

repairing a tyre or tube and replacing the 

tyre or rim. 

Replacing a tyre/ rim : 

When the tyre or rim is changed the 

wheel should be properly balanced on a 

machine after inflating to the specified 

value as per the following norms. 

1. Permissible imbalance for tyre with 

rim=250 gm-cm max. 

2. Permissible balance weight for tyre 

with rim=140 gm max. 

3. Relocate the tyre if the weight required 

to balance is more than 140 gm. 

4. Balance weights are available 

from 10 gm to 90 gm in steps of 10 

gm and from 80 to 140 gm in steps 

of 20 gm. 

5. Do not use more than one balance 

weight on one side. 

Run-flat : 


Run-flat is fitted on the rims inside 

tyres to drive the vehicle when tyres 

deflated due to bullet firing. 

61



External Repair kit (Optional): 

This repair system enables quick roadside 

puncture fixing without having to 

demount the wheel from the vehicle. 

The specifically shaped rubber repair 

plug with its special adhesive coating 

is inserted in the tread injury from outside. 

It automatically seals the puncture 

channel. The repair plug, with its 

specific shape, acts like an anchor. It 

hooks itself on the tyre inside while 

completely plugging the puncture 

channel, and sealing the tyre. 

62 

Repair kit consists of 

1. Anchor seal plug. 

2. Marking chalk 

3. Rotary cutter 6mm Dia. 

4. Hand Ratchet (Right/ left) 

5. Insert tool. 

6. Special cement 

Repair procedure (Refer manufactures 

instruction) 

1. Remove the penetrating object from 

the tyre. 

2. Carry out the anchor seal following 

the enclosed instructions 

provided with kit. 

3. Finally inflate the tyre - the job is 

safely done. 

4. The repair plug self – vulcanizes 

by the heat generated in he tyre 

under working condition. 

Caution : It is advisable to inspect 

the tyre internally for secondary 

damage.



Non skid chains : (If required) 

Non skid chains are used on tyre to 

get better traction and drivability in 

snow or marshy area. 

Fitment procedure of these chains on 

tyre is given below : 

1) Check for proper pressure in tyres. 

1) Lay down the chains (longitudinally) 

on level floor 

2) Drive the vehicle on laid chains 

3) Wrap the chains on tyre. 

4) Adjust the chain locking 

5) Clamp the toggle clamp 

6) Ensure tight fitment of chains 

7) Run for one or two Kms. 

8) Adjust the chain locking. 

NOTE : Tyre pressure to be maintained 

before fitment of nonskid 

chains on tyres 

Tyre rotation 

Tyre rotation is recommended for 

achieving identical wear on each tyre. 

It is also advisable to change rotating 

direction to relieve tyres of continual 

one way rotation. Regular rotation of 

tyres also will prevent abnormal wear. 

The sketch indicates a suggested 

sequence of tyre rotation Rotate tyres 

at specified intervals or earlier 

depending on operation. 

Schematic diagram - Tyre rotation 

63


Battery & Battery Isolator Switch 

Battery 

Battery : 

Battery is fitted near the gear shift lever 

& in between driver & co driver seat. 

Battery is located in box & bolted 

cover. 

Check the battery for proper 

electrolyte level and corrosion on the 

terminals. 

1. Check the battery for electrolyte 

level against the marking on the 

battery outer case. 

64 

2. . Check the battery terminals for 

corrosion (a white or yellowish 

powder). To remove it, cover the 

terminals with a solution of baking 

soda. It will bubble up and turn 

brown. 

3. When this stops wash it off with 

plain water. Dry off the battery with 

a cloth or paper towel. 

4. Coat the terminal with petroleum 

jelly to prevent future corrosion. 

Use a proper spanner to loosen and 

remove cables from the terminals. 

Always disconnect the negative (- 

ve) cable first and reconnect it last. 

Clean the battery terminals with a 

terminal cleaning tool or wire brush. 

Reconnect and tighten the cables, 

coat the terminals with petroleum jelly. 

Ensure that battery is securely 

mounted. 

If you need to connect the battery to 

a charger, disconnect both cables to 

prevent damage to the vehicle’s 

electrical system. 

NOTICE 

During normal operation, the battery 

generates gas which is explosive in 

nature, a spark or open flame can 

cause the battery to explode 

causing very serious injuries. 

Keep all sparks & open flames and 

smoking materials away from the 

battery. 

Getting electrolyte in your eyes or 

on the skin can cause severe burns. 

Wear protective clothing and a face 

shield or have a skilled technician 

to do the battery maintenance. 

The battery contains sulphuric acid 

(electrolyte) which is poisonous and 

highly corrosive in nature 

Battery Isolator Switch: 

This switch is provided near the gear 

shift lever to isolate the battery from 

electrical system when required.


Battery Isolator Switch & Head Lamps 

Battery Isolator Switch 

Battery is connected to the starter and 

other circuitry through isolator switch. 

This is to be switched OFF while 

carrying out any work on the vehicle 

and also when the vehicle is parked 

for long duration to avoid battery 

drainage. This will also prevent any 

inadvertant short circuits during 

repairs. 

Headlamps 

The headlamps provides two types of 

light beams; a high beam to give 

maximum light well ahead of vehicle, 

and a low beam which is shorter and 

lower so that it will not dazzle the 

oncoming drivers can be used in low 

visibility area. 

The headlamp also incorporates a 

parking light. 

The headlamps must be properly 

aligned in order to obtain maximum 

road safety, proper road illumination 

and reduced glare to oncoming traffic. 

It is recommended to check alignment 

of headlamp beams periodically and 

whenever headlamp bulbs are 

replaced, by means of a headlamp 

aligner or with the help of a screen as 

shown in figure . 

65


Adjusting head lamps focus with 

the help of screen 

The vehicle should be parked 10 

meters away from screen with its 

centre in line with central vertical line 

on screen, and screen at right angle 

to longitudinal axis of the vehicle. The 

vehicle should be in unloaded 

condition with no sag in suspension 

springs and all tyres equally 

inflated.Head lamp leveling switch 

should be kept on ‘O’ position. 

66 

On the marked up screen as shown in 

figure, area above horizontal and inclined 

lines (shaded) is called 'Dark zone' and 

the area below it is called 'The illuminated 

zone'. 

Each headlamp is aligned individually 

by masking the other headlamp. 

Headlamp is first adjusted for proper 

height of low beam by adjusting head 

lamp leveling motor shaft if required. 

Light from low beam should fall below 

horizontal and inclined lines. 

Head lamp adjustment 

No light should fall above these lines 

i.e. in 'Dark zone' Thereafter lateral 

adjustment is done by adjusting the 

knob at bottom of headlamp so that 

contour of low beam coincides with 

contour formed by horizontal and 

inclined line below ‘Dark zone’ 

When properly adjusted, most brightly 

illuminated area will be just below the 

intersection point 'A' of these two 

lines. 

The Second headlamp is adjusted in 

a similar manner without disturbing the 

position of the vehicle and the screen. 

Now switch 'ON' high beam. They will 

be symmetrical above point. 'A' and 

'B' of intersection of vertical lines and 

horizontal lines. It is possible that 

high beams may not be exactly 

symmetrical but for this reason 

headlamps should not be realigned. 

Perferably, the alignment should be 

done in the dark. 

No masking of headlamps with 

black paint is required. If done, this 

will reduce the intensity of lights.


Head lamp bulb replacement 

Removal of cable socket Removal of locking ring Removal headlamp bulb 

Head lamp bulb replacement 

Raise the bonnet of the vehicle. 

Remove the rear protective cover. Pull 

out cable socket from bulb. Remove 

lock ring holding the bulb and remove 

the bulb. 

Install new bulb, properly locating it 

in the housing. Fit back locking ring, 

cable socket and protective cover. 

Realign headlamp beam after 

replacing bulb 

Do not clean the reflector as it will 

cause damage to mirror-finished 

surface. Do not replace bulb with 

dirty or oily hands, since oil will 

evaporate due to bulb heat and 

stain the reflector. 

67


Bulb specifications 

BULB SPECIFICATION 

DESCRIPTION LOCATION SPECIFICATION 

Head Lamp Bulb Head Lamp 12 V 60/55 W 

Parking Lamp Bulb Head Lamp/Tail Lamp 12 V 4/5 W 

Direction Indicator Lamp Bulb Head lamp/Tail lamp 12 V 21 W 

Side Repeater Bulb Side Indicators 12 V 5 W 

Tail Lamp Bulb Tail Lamp 12 V 10 W 

High mounted stop lamp Tail Lamp 12 V 21 W 

Reversing Lamp Bulb Tail Lamp 12 V 21 W 

Number Plate Lamp Bulb Number Plate 12 V 10/5 W 

Warning & Illumination Lamps, Head Lamp Bulbs (Main beam), 

Turn Indicator Bulb, Battery Charging Indicator Bulb,Glow 

Plug Indicator Bulb, Low Oil Pressure Indicator Bulb, Barake/ Instrument Cluster 12 V 2 W 

Parking Light Indicator Bulb,4WDL & 4WDHIndicator Bulb, 

Check Engine Indicator Bulb, Water in fuel indicator Bulb 

Gauge Illumination Lamp Instrument Cluster 12 V 3.4 W 

Interior Lights Roof 12 V 10 W 

Engine Compartment Lamp Engine Compartment 12 V 21 W 

Front Fog Lamps Front Bumper 12 V 55 W 

Rear Fog Lamps Tail Lamp 12 V 21 W 

68


Fuse /relay box in engine 

compartment (If fitted) 

Fuse box : 

In order to protect the cable harness 

and other equipments from damage 

in case of short circuit and overloads, 

fuse links are provided. 

Fuse box is located in engine 

compartment at RH side. 

In case of a fault in the electrical 

system check the respective fuse. The 

particulars of the consumers served 

by each fuse and amperage are 

printed on the fuse box cover. The fuse 

link can be identified for amperage 

by colour codes : 

1. Fuse link - Red - 10 Amps 

2. Fuse link - Blue - 15 Amps 

3. Fuse link - Light brown - 5 Amps 

4. Fuse link - Yellow - 20 Amps 

While fitting fuse box cover ensure 

that cover knob rests in the slot 

provided inside fuse box. 

Spare fuse cartridges are provided 

inside the fuse boxes. 

Always use fuses of correct rating. 

Do not use a wire in place of fuse. 

Flasher with short circuit 

protection 

If flasher circuit is short circuited or 

overloaded (more than 110 W) flasher 

will shut off. It can be reset by 

Fuses 

momentarily centering the indicator 

arm of combi switch. 

If flasher is shutting off or fuse is 

blowing off repeatedly the flasher 

circuit should be checked for short 

circuit. Check the flasher separately 

for its functioning. 

69


Care and cleaning of the vehicle 

70 

CAUTION 

When cleaning the interior / exterior 

of the vehicle, NEVER USE volatile 

solvents such as thinner, petrol or 

any other cleaning materials such 

as bleaches or strong household 

detergents. These materials may be 

poisonous or flammable and their 

improper use may cause personal 

injury or damage to the vehicle. 

Cleaning of vehicle interior : 

Upholstery 

Prepare a solution of soap or 

neutral detergent mixed with warm 

water. Apply solution with a sponge 

or soft cloth and let it soak for a 

few minutes to loosen dirt. Wipe 

the surface with a clean, damp 

cloth to remove dirt and soap 

solution. If some dirt still remains 

on the surface, repeat the 

procedure. 

Floor mats ( If fitted) 

Dirt can be removed from the mats 

with water and a mild soap. Use a 

brush to help loosen dirt. After dirt 

is loosened, wash the mat 

thoroughly with water and dry it in 

the shade. 

Seat belt 

Clean the seat belt with a mild soap 

and water only. No bleach or dye 

should be used as this may weaken 

the belt fabric. The belt should be 

allowed to dry in the shade. 

Carpets (if fitted) 

Remove dirt as much as possible 

by using a vacuum cleaner. Rub 

the stained area with clean cloth 

made damp with soap to absorb 

the stain and remove the soap. 

Repeat until the stain is removed. 

You can use commercially 

available carpet cleaner. In this 

case, carefully follow the 

manufacturer's instructions and 

precautions. 

Care and cleaning of vehicle 

Cleaning exterior of the vehicle 

Dirt or any other foreign material on 

the painted surface may result in : 

Faded paint. 

Rust on body due to deteriorated 

paint film. 

Rust due to scratches 

Body rust due to contact with 

damp dirt trapped in the body. 

Therefore it is important that your 

vehicle is always kept clean and 

free from dirt in order to maintain 

the paint in a good condition and 

to protect the entire body against 

corrosion. 

Washing 

When washing the vehicle, follow the 

instructions given below : 

Flush underside of body and wheel 

housing with pressurised water to 

remove mud and debris. Use plenty 

of water to loosen and remove dirt. 

Remove dirt and mud from


bodyexterior with running water. 

Use a soft sponge, brush with 

water. Do not use hard material 

which can scratch the paint. 

Wash the exterior with water, lightly 

rubbing with sponge or soft cloth. 

The sponge or cloth should be 

frequently soaked in water. 

CAUTION 

When using commercial wash 

products precautions specified by the 

manufacturers should be observed. 

Do not use strong household 

detergents or soaps. 

Once dirt has been completely 

removed, wash off with running hose 

water. 

After rinsing, wipe the body lightly 

with wet chamois or cloth and allow 

the body to dry in the shade. 

WARNING 

After washing, check that the brakes 

are dry. If brakes are not dry, dry them 

by gently, repeatedly applying while 

driving at low speed. 

Waxing the vehicle exterior 

After washing the vehicle, waxing and 

polishing are recommended to 

protect and beautify the paint. 

Use only good quality waxes and 

polishes. 

When using waxes and polishes, the 

precautions specified by the 

manufacturers should be observed. 

Chrome-plated parts should also 

be waxed. 

Protection against corrosion 

The following cause corrosion : 

Moisture trapped in body cavities. 

Dirt and salts collected in hollows on 

the underside of the vehicle. 

Removal of paint and protective 

coatings from the exterior and 

underside of the vehicle. 

Corrosion preventive measures 

have been incorporated in your vehicle. 

You can avoid corrosion of your vehicle 

by performing some simple periodic 

maintenance : 


Repair chips and scratches in the 

paint as soon as you discover them. 

Inspect and clean the drain holes in 

the bottom of the doors and body. 

Check the floor coverings for 

dampness. Carpets and floor mats 

remain for a long time, especially 

in winter. This can eventually cause 

the floor panel to corrode. 

Use a high-pressure spray to clean 

the underside of your vehicle. This 

is especially important in areas near 

chemical and other industries. 

Have corrosion preventive coatings 

done on the underside of your 

vehicle. Preventive coatings such 

as the Dinitrol-3850 are available in 

the market. 

71


Cleaning of Glasses : 

For the internal face of the glass (polycarbonate) 

it is not recommended to 

use cleaning agents, since they could 

affect the optical quality of the 

product. Because of the above, we 

recommend using only water and damp 

cloth. In any case avoid cleaning 

glasses under direct sunlight. 

1. Remove grit particles, etc by blowing 

with clean filtered air, preferably 

ionised to minimise ‘static’ 

attraction. 

2. Wash with tepid water / detergent 

(e.g. Teepol or a domestic household 

detergent) solution and dry 

using clean gloves cloths. 

3. Rub lightly to remove stubborn 

marks with soft glove cloth impregnated 

with 50% v/v isopropyl 

alcohol or ethanol in water followed 

by through washing with water / 

detergent. Change cloth frequently. 

72 

Dry with lights strokes, with a clean, 

dry soft glove cloth. Fresh paint, 

grease and wet sealant may be 

similarly treated. 

Minimise the effects of hairline 

scratches and minor abrasions 

using very mild automobile cleaner 

polish. 


DO NOT 

Wipe the PC Hi-tech (anti-scratch plastic) 

inside surface with dry, dirty rags and/ 

or any abrasive clothes which may 

scratch the splash shield. 

Try to remove marks or dirt with sharp 

object or razor blade. 

Stick any labels or stickers to the inside 

face. 

Wipe the inside face with dry, dirty rags. 

Allow any subsequent exposure to solvents 

(other than as above). 

Scrape the surface to remove marks, 

frost etc with any sharp instrument. 

Allow any abrasive cleaner, steel wool or 

similar material to come into contact with 

the inside face of window. 

Wipe the inside face of the window with 

the hand, whether glove or not. 

The inside face of the window should not 

be allowed to come into contact with other 

organic materials containing plasticisers 

or solvents e.g. Flexible PVC, 

‘Screenvin” solvent based protective 

lacquers etc.


Preservation & De-preservation 

WORK GUIDELINE FOR PRESERVATION AND DE-PRESERVATION OF SUMO ARMOURED VEHICLE IN 

DIFFERENT CLIMATIC CONDITIONS 

STORAGE PREPARATION OF VEHICLE: 

Choose a place preferably closed cool, dark and dry. But many a times getting such an ambience is not possible. If 

the vehicle needs to be stored outside, it should be covered with a quality cover which has thick, multi-layered fabric. 

Following precautions can help in keeping the vehicle in good condition. 

PRESERVATION (07 Days or less): 

1 Vehicle shall be empty and no load inside cabin or load body shall be kept. 

2 Increase Tire pressures by 10 psi over the specified (placard) pressures to avoid flat spots or damage to the 

tire leading to permanent set deformation. 

3 Disconnect the battery terminals inside engine compartment as well as in passenger compartment. 

4 Make sure that fuel quantity inside tank is at minimum level. 

5 If the engine’s coolant service life time limit will be exceeded while the vehicle is in storage, drain and refill the 

cooling system with the recommended coolant mixture. 

6 The coolant mixture must protect against freezing down to the lowest expected temperature 

7 Make sure that vehicle is in 4 x2 mode. 

AT HILLY / SNOW FALL / COLD CLIMATE AREA: 

1 In cold atmosphere area vehicle shall be parked preferably inside enclosed area. If such area is not available 

then park the vehicle in such a place where snow fall is less. Put antirust element on surface which is open to 

atmosphere. 

2 Cover the vehicle with car cover where the snow fall is in control. 

3 Put hand brake in on condition to arrest the vehicle slippage or park the vehicle in plain area with chokes 

73



74 

COASTAL AREA: 

1 Apply antirust to all open body area 

DE-PRESERVATION (Beyond 07 days): 

In addition to above short term storage precautions following steps needs to be taken: 

1 Make sure the vehicle is clean, waxed, and chrome polished before putting it into storage. 

2 Drive the vehicle for about 10 Km after adding the stabilizer/antirust/anticorrosion agent in fuel system, Cooling 

system ,lubricating systems and brake oils (Long storage fuel additives available in local market is called 

stabilizer). 

3 Normally it’s best to leave the tank full. However, if the vehicle will be stored in an enclosed location where gas 

fumes could be a problem, empty the tank about half way 

4 Open the Injectors and pour about a teaspoon of oil into each cylinder and fit it back. This will help coat the 

cylinders to prevent rust. Also pour oil into the intake, this lubricates the engine and the exhaust system from 

the inside deterring rust formation. 

5 Place desiccant packs in various locations inside the car; also place moth balls in various locations inside; 

make sure the air is on the “re-circulate” setting; open the glove box and other interior storage locations; cover 

any areas that might be exposed to sunlight. 

6 Drain the cooling system fluid and fill fresh appropriate coolant in system. 

7 Seal off engine openings such as engine air intake, exhaust out let pipe with absorbent cotton to keep moisture 

out. 

8 Remove the battery and clean its top with a mixture of baking soda and water. Apply grease on the terminals 

and preserve separately. 

9 Loose the drive-belts to take the pressure off of the pulley bearings.



10 Support the vehicle on jack-stands or blocks. This will take the weight off of the wheel bearings and suspension 

components. Also if possible remove the wheels and tires, lower the tyre pressure slightly, and store them flat 

and out of sunlight area. 

11 Wash and wax the body surface. 

12 Apply vinyl/Weather protestant on leather surfaces, tyres, and other rubber components. 

13 Keep off the wiper blades from wind shield glass or take off and preserve separately. 

14 Seal the tailpipe and any other openings to prevent entry of mice or other rodents. 

15 Particularly care to be taken to plug the fire wall openings in to the cabin to prevent rodents. 

16 To avoid engine bearing damage due to acid in the engine oil, change the engine oil and oil filter. 

17 Leather care: You do not to need to apply a leather conditioner to maintain suppleness in the leather. To clean 

the leather use a damp, soft cloth, taking care not to soak the leather. Small dirt particles can be abrasive and 

damaging to leather surfaces and should be removed promptly. Do not use saddle soap, polishes, oils, 

cleaning fluids, solvents, detergents or ammonia-based cleaners 

18 Place any written reminders on what may be needed after the vehicle is removed from storage where it will be 

easily seen such as the top of the instrument panel, on the steering wheel, etc. 

19 Make sure you have adequate insurance on the vehicle to cover for fire, theft and vandalism or any avalanches 

or storm condition etc. 

20 Open both front and rear hatch if it is inside parking & keep it partial open when parked outside or open to 

atmosphere. 

21 Make sure that 4 x 4 is not engaged. 

75



76 

BATTERY STORAGE GUIDELINES: 

1 Any time a battery will be stored unused for an extended period of time (over 30 days), certain precautions will 

help assure that the battery will not be damaged and will be ready for use when needed. 

2 Bring the battery to full charge before storing it. 

3 If the battery is in a vehicle, it is often best to disconnect the negative battery cable. 

4 Install and keep terminal protectors in place and keep the battery clean. 

5 Store the battery in as cool of a location as possible. 

6 Monitor the battery on a regular basis. 

7 Bring the battery to full charge before it is stored. This is the best insurance against internal damage due to 

remaining in a discharged state for a long period of time, and against freezing in extremely cold weather. 

8 If possible disconnect the negative battery cable if the battery is in a vehicle (this is must to prevent battery 

discharge as well fire accidents). This will prevent parasitic drains in the vehicle system from discharging the 

battery at a faster rate. If the negative battery cable cannot be disconnected, more frequent monitoring and 

charging will be needed. 

9 To prevent accidental discharge, install terminal protectors on exposed terminals. Keep the battery free of dust, 

dirt, moisture, and conductive materials like damp cardboard that could allow the battery to discharge slowly 

through external paths. 

10 Cool temperatures retard the internal reactions that cause self discharge and internal grid corrosion. Find the 

coolest storage location that will not cause the battery to freeze. A battery that is kept at a 65% SOC or higher 

will not freeze until the temperature is below -32°C (-25°F) A fully-charged battery will not freeze until the 

temperature is below -54°C (-65°F). 

11 Monitor the stored battery regularly by checking the built-in hydrometer or OCV.



12 If a battery is stored in a vehicle with the cables connected, check the battery SOC every 30 days. Recharge 

the battery fully whenever the SOC falls below 65%. 

13 When stored on the shelf or in a vehicle with the negative cable disconnected, a battery that begins storage at 

full charge will require recharge on the following schedule, depending on the estimated average storage 

temperature : 

AVERAGE STORAGE TEMPERATURE 

RECHARGE FULLY AT 

21 0 C OR Below (70 0 F OR Below) 12 Months 

21 0 C - 27 0 C (70 0 F - 80 0 F) 8 Months 

27 0 C - 32 0 C (80 0 F - 90 0 F) 4 Months 

32 0 C - 38 0 C (90 0 F - 100 0 F) 2 Months 

38 0 C OR More (100 0 F OR More) 30 Days 

Chart applies to fully-charged batteries only 

AT HILLY SNOW ALL/COLD CLIMATE AREA: 

1 Apart from above mentioned points, below mentioned points are specific for cold climate area preserving, 

2 Remove battery from vehicle and keep it in battery maintained area. 

3 Apply thick layer of antirust on all open surface area. 

4 Place the transmission gear selector in Reverse or First. Put 4x2 mode gear selector. Release the Park Brake. 

5 Lubricate door, trunk, hood and other moving metal parts with silicone lubricant. 

GENERAL INSPECTION BEFORE RETRIVAL OF PRESERVED VEHICLE: 

1 Over all condition of vehicle. 

2 Paint condition. 

3 Rusting marks on body as well as on chassis components. 

77



4 Levels like radiator coolant, engine oil, Gear box oil, axle oil, power steering oil etc… 

5 Condition of tyre. (Any depletion happens). 

6 Fuel tank condition (inside/Outside). 

RETRIVING PRESERVED VEHICLE: 

1 Check battery condition & electrolyte level. Check for battery serviceability and if it is in serviceable condition, 

send it for servicing. 

2 Remove air filter element & clean it. 

3 Check water separator. If water level indicator is showing high level then empty the water separator. 

4 Remove fuel filters for inspection and if dirty clean it, also clean the entire fuel line. This will ensure removal of 

any blockages / water particles / any rusted chip if present inside. 

5 If any contamination is observed in levels of engine oil, coolant, gear box oil, power steering oil, rear axle oil 

etc... Than then flush the entire contaminated level. After flushing refill oil or coolant. 

6 Clean the rusted surface where traces of corrosion are observed. Traces may be observed at electrical 

connections like fuse/Starter motor/alternator/connectors/ relays/ etc… These traces required to be cleaned to 

ensure proper voltage supply throughout the circuit. 

7 Remove all brake drums/ Pads and clean the rusted surface where traces of corrosion are observed. Before 

fitting back ensure for no moisture content within system. 

8 Do hand priming of fuel line & ensure that fuel is supplied up to injectors, fuel lines and its solenoid for free 

movement and free working. 

9 Connect properly charged battery to vehicle and crank the engine for 5 seconds to know about any abnormality 

in engine noise after cranking. Repeat cranking for 2/3 times to ensure further cranking can be done. Than 

crank the engine till it get started. (Do not crank engine for more than 20 sec, because battery cable may be 

heated and can cause fire ) 

78



10 When vehicle is started let the engine run in idle condition up to 2 minutes to ensure proper oil supply inside the 

engine and to attain the ambient temp of all parts. 

11 After 2 minutes in idling accelerate further to ensure that engine is running up to fly up rpm. 

12 Drive vehicle in Pre selective first gear for 15 min. 

13 During driving apply brake from 60 kmph up to 30 kmph. Repeat it for @ 10 - 20 cycles (This is to ensure 

proper brake liner to drum contact and make it moisture/dust free) 

14 Check vehicle by driving in each gear ensuring all aggregates are functioning properly. 

15 Confirm for 4 x 4 high/low operation. 

AT HILLY / SNOW FALL / COLD CLIMATE AREA: 

1 Vehicles at cold climate area or a hilly area an attention towards following things apart from above mentioned 

points need to be given. 

2 A rubber component, Plastic components, rubber hoses needs to be checked for its proper hardness and if 

crack generated are mores replace the components. All rubber parts like seal, beeds “O” rings etc to be 

changed with new, since there is a chance of aging due to presence of ozone in atmosphere. 

3 Wherever snow is concentrated over a surface needs to be cleaned and make rust free surface. 

4 Vehicle to be inspected for affected areas where snow was accumulated and any damaged components to be 

replaced. 

5 All fuel lines and water passages to be made ice free and if required damaged pipes or rubber hoses need to 

be replaced. 

6 Fuel tank to be made empty and made ice, water, moisture free and fresh fuel need to be filled up. 

79



COASTAL AREA: 

1 Vehicle to be inspected for rusty surface and rusted surface area to be made rust free. 

2 Surface area where thickness of that component is rusted more than 50 %, than repainting of that surface is 

required to be done. 

80


Special Operating Conditioning 

Special Operating Conditions : 

1. Operating on dusty/sandy roads. 

2. Operating on hilly terrain with dusty 

conditions. 

3. Operating on muddy and melted 

snow roads. 

4. Operating frequently above 2000 

m. of altitude. 

5. Possible mixing of impurities in the 

fuel due to operating conditions. 

The vehicle is fitted with 3L DICOR 

engine can be used satisfactorily 

under the following conditions : 

1. Altitude : Mean Sea level / ambient 

temp. up to -20 0 C ( With 

recommended fuel & oil) 

2. Altitude : 2500 meters and 

ambient temp. upto -20 0 C ( With 

recommended fuel & oil) 

Recommendations for operating 

under special conditions : 

1. Air filter : 

Cleaning of air filter cleaner element 

For dusty operating conditions cleaning 

of air filter element need to be 

carried out when ever red band 

appears on the indicator. Cleaning of 

air filter element should be carried out 

by tapping the element gently so that 

the dust could fall off. 

Air filter element may be changed : 

If the red band appears on the 

Service Indicator continuously. OR 

If visually it is observed to be covered 

with mud / dust which can not be 

cleaned effectively. 

2. Engine oil and oil filter : 

For special operating conditions of 

vehicle, change oil and oil filter at 

every 5000 kms or 3 months whichever 

is earlier. (Existing frequency for 

normal operating conditions is 10000 

kms) 

81

Fuels, lubricants, coolants 

Fuels : 

High speed diesel conforming to IS 1460 or DIN 51601 or 

equivalent is recommended to be used as fuel. 

At very low temperatures fluidity of diesel may become 

insufficient due to paraffin separation. It is therefore, 

necessary to mix supplementary fuel with summer or winter 

grade diesel. The supplementary fuel to be used is kerosene 

or aviation turbine fuel 

Ratios for mixing of supplementary fuel and diesel are shown 

in table : 

Ambient 

Percentage 

temperature upto Summer Supplementary 

0 

C grade diesel 

fuel 

upto 0 100 0 

82 

0 to -10 70 30 

-10 to -15 50 50 

Ambient 

Percentage 

temperature upto Winter Supplementary 

0 

C grade diesel 

fuel 

upto -15 100 0 

-15 to -20 70 30 

-20 and below 50 50 

The oil change periods recommended in maintenance 

schedule should be adhered to. 

Use of reclaimed oil is not recommended. 

Engine oil : 

Fuels, lubricants 

Care should be taken that diesel and supplementary fuel 

are thoroughly mixed before filling. 

Lubricants 

Recommended lubricants conform to the following 

specifications : 

1. SAE 15 W40 to API CF 4+ Engine oil 

2. 75 W 90 GL-4 Syn. oil Gearbox oils 

3. SAE 85 W 140 API GL-036 B Rear axle 

(with additive 6.5 % Angalmol 

99 by weight) and friction 

modifier 40819. 

Please use only recommended brands for good 

performance. 

Qty : 6.5 Litres 

Recommended grades of engine oil conforming to Multigrade 

oil 15W40 API-CF4 specifications and range of ambient 

temperatures at which these can be used are given below :


Ambient temperature 0 C 

Running in oil 

Engine oil grade 

0 and above SAE 15W40 

0 to -18 SAE 0W30 

-18 and -40 SAE 0W40 

In the first 2000 km of operation of a new or reconditioned 

engine, any one of the running in oils listed below should 

be used : 

Autolube 30 : (HP) 

Gear box oil (for GBS-76) 

75W90 GL4 Syn. oil 

Transfer case oil : 

Recommended lubricant - Type A, Suffix A specifications, 

e.g. Castrol TQ Gear oil capacity-1.2 liters. 

Rear axle, live front axle oil : 

Use oils conforming to APIGL 5 specifications. SAE 90 oil 

should be used upto -9 0 C and SAE 85 W 140 -40 0 C. 

Brake and clutch fluid 

Lubricants 

Brake fluid conforming to IS : 8654/DOT 3 is 

recomnmended. 

Spicer propeller shaft (where applicable) 

Lubricate slip joint with NLGI-2 grade grease. 

Lubrication of steering spindle and sleeve 

Lubricate steering spindle and sleeve with Molikote grease 

or mobiltac NC grease, at specified intervals. 

Coolants : 

Presence of dirt in the coolant chokes up passages in the 

radiator, cylinder head and cylinder block, thereby causing 

insufficient cooling of engine. 

To prevent rust information and freezing of coolant inside 

the passages of radiator, cylinder block and cylinder head, 

use genuine co-branded premixed coolant (ready to use). 

83

Recommended oils, lubricants and filling capacities 

PLEASE USE ONLY FOLLOWING GENUINE OILS, COOLANTS , LUBRICANTS , ANTI RUST & SOUND DEADENING COATS, 

WINDSCREEN SEALANT, ADHESIVES & FUEL ADDITIVES BRANDED BY TATA MOTORS FOR OPTIMUM PERFORMANCE 

ITEM COMPANY BRAND QTY 

ENGINE OIL CASTROL Castrol GDT 15W/40 For Summer 50 0 6.5 Litres 

HPCL SAE 0 W 40 For Winter -20 0 

COOLANT (Premixed) SUNSTAR Golden Cruiser Premium 1400 M 

HENKEL TEROSON Frostox SFD 12 13 Litres 

HPCL HP Thanda Raja P 

GEAR BOX (G-76) HPCL HP Gear EP 75W90 1.6 Litres 

CASTROL CASTROL Sythetic 75W90 

TRANSFER CASE OIL HPCL HP-Automatic Transmission 1.2 Litres 

CASTROL CASTROL Transpower TQ Fluid Type A 

POWER STEERING OIL HPCL HP-ATF Dextron II D 1.4 Litres 

CASTROL CASTROL Transpower TQ 

REAR AXLE / HPCL HP Gear Oil XP 85W140 GL5 with friction modifier 40819 2.2 Litres for Rear # 

FRONT LIVE AXLE CASTROL CASTROL Extreme Pressure 85W140 1.2 Litres for Front 

BRAKE / CLUTCH FLUID HP CL Super Duty Brake Fluid DOT - 3 / DOT - 4 As required 

CASTROL CASTROL Universal Brake Fluid DOT - 3 

WHEEL BEARING & CHASSIS HPCL HP Multipurpose Grease-2 As required 

Propeller shaft joints, Sliding CASTROL Castrol AP-2 grease 

Yokes, Vacuum Booster 

ANTI RUST TREATMENT DINITROL Dinitrol — 

& SOUND DEADENING WUERTH Wuerth — 

WIND SCREEN SEALANT ANCHEMCO Terostat 8590 Kit Form — 

METAL & PLASTIC ADHESIVE ANCHEMCO Terostat 930 310 ml Cartridge 

DIESEL ADDITIVE IFTEX Iftex Clean System D 250 ml pack * 

A.C.COMPTRESSOR SUBROS DENSOIL-6 - 

SUNOILCO SUNISONO.5GS 

* Add to Diesel as per the dosage recommended by M/s IFTEX # For Tata Motors Rear axle - 1.9 Litres 

84

Vehicle Data 

ENGINE 

Model 

Type 

No. of cylinders 

Bore / Stroke 

Capacity 

Max. engine output 

Max. torque 

TATA 3.0 L DICOR BS-III 

Water cooled, Direct injection, 

Common Rail, Turbocharged 

Intercooled Diesel engine with 

crankcase breather and relief valve. 

4 inline 

97 mm x 100 mm 

2956 cc 

Compression ratio 17.5 : 1 

Firing order 1-3-4-2 

Engine oil capacity 

Weight of Engine 

Radiator frontal area 

CLUTCH 

Type 

Outside diameter of 

clutch lining 

Friction area 

84.9 kw @ 3050 rpm as per CMVR 

115(9) 1996 

300 N-m at 1600 ~ 2200 rpm as per 

CMVR 115(9) 1996 

Max. 6.5 litres / Min. 5.5 Litres 

320 kg (Dry) 

2480 sq.cm. 

Single plate dry friction diaphragm 

type with hydraulic actuation. 

240 mm 

452 sq. cm. (approximately) 

GEAR BOX 

Type 

G-76-5/4.1 with overdrive 

sychromesh on all gears. 

No of gears 5 Forward, 1 Reverse 

Gear ratios 1st 4.10 

2nd 2.22 

3rd 1.37 

4th 1.00 

5th 0.77 

Rev. 3.75 

TRANSFER CASE 

Type 

With electric shift arrangement 

mounted on gear box. 

Ratio 4x2 high - Ratio - 1:1 

4x4 high - Ratio - 1:1 

4x4 Low - Ratio - 1 : 2.48 

REAR AXLE 

Type 

Single reduction, salisbury type with 

limited slip differential hypoid gears 

& semi-floating axle shafts. 

Ratio 4.55 (41/9) 

FRONT LIVE AXLE 

Type 

Independently suspended with 

automatic hub lock 

Ratio 4.55 (41/9) 

Technical Specification 

85

Vehicle Data 

STEERING 

Type 

Steering Wheel 

BRAKES 

Service brakes 

Front 

Rear 

Parking brake 

FRAME 

Type 

Depth 

Width 

Tow Hook 

86 

Power Steering 

380 mm dia. 

Vacuum assisted indepedent hydraulic 

brakes on front & rear through tandem 

master cylinder.Vacuum pump mounted 

on engine 

282 dia disc brake 

295 dia. auto adjuster drum brake 

Floor mounted Cable operated mech. 

linkages acting on rear wheels. 

Ladder type cranked frame with boxed 

section long members and welded 

cross members 

110 mm (maximum) 

60 mm 

Tow hook at front, Provision of central 

towing hook at rear 

SUSPENSION 

Type Front Double wishbone type with torsion bar 

springs. 

Rear Semi-elliptical leaf springs. 

Shock Absorber Hydraulic double acting telescopic type 

at front and rear. 

Antiroll bar At both front and rear. 


WHEELS AND TYRES 

Tyres 

a ) LT 245 / 70 R16 113S BF 

b ) 245 / 70 R16 111S ZVRL - MRF 

Wheel rims 

6.5 J x 16 Steel rims 

No of wheels Front - 2, Rear - 2, Spare - 1 

FUEL TANK 

Capacity 

65 litres 

ELECTRICAL SYSTEM 

System Voltage 12 Volts (–ve earth) 

Alternator Capacity 150 Amps 

Battery 

12 Volts, 80A/Hr 

PERFORMANCE 

Max. speed at rated GVW 

85kmph 

Max. gradeability at rated GVW 36 0 

WEIGHTS (KG) - Tolerances as per INTEREUROPE STVZO 

Complete vehicle kerb 

weight as per ISO:1176 3050 (FAW-1400,RAW-1650) 

(with spare wheel & tool) 

Gross Vehicle Weight 3510 (FAW-1440,RAW-2070) 

Max.Permissible FAW 1440 

Max.Permissible RAW 2070 

Max. permissible trailer 750 

capacity (Unbraked) 

PASSENGER CAPACITY 

Driver +5

Vehicle Data 


VEHICLE DIMENSION 

87

Preliminary Trouble Shooting 

PRELIMINARY TROUBLESHOOTING : 

(These tips are given for your guidance and preliminary jobs to be done in an emergency situation. In normal case, the 

problems should be attended in an Authorized Workshop by following the repair procedures given in Workshop Manual) 

88 

PROBLEM OBSERVED CAUSE ACTION TO BE TAKEN 

ENGINE 

1. Engine not cranking Battery dead, • Get battery checked&/or charged 

Loose or dirty battery connections • Clean and tighten battery 

connections 

2. Engine cranks but does not start Air in the fuel system • Press pear pump for air removal 

• Check leakages 

EMS fuse blown 

• Replace the fuse 

Water sedimenter filled up 

• Drain water from sedimenter. 

with water 

3. Engine overheats Coolant level low • Top up coolant, check and 

correct leakages 

Hose collapse / torn 

• Get the hose replaced 

Low engine oil level 

• Add oil 

Radiator cap not sealing properly • Fit the radiator cap correctly 

4. Charging indicator continuously Battery not getting charged • Get the belt tension adjusted 

remains ‘ON’ due to loose belt drive replace belt if broken 

Faulty alternator 

• Replace it. 

Cut off relay is not working • Replace it



5. Poor pickup Loose contact of electrical • Get defect rectified. 

connectors 

Blocked fuel filter 

• Clean / replace fuel filter element 

Clogged air filter 

• Clean / replace fuel filter element 

Alternator electrical connection • Check and make proper 

plug out 

connections 

Intercooler hose collapse or loosen • Check and make proper fitment of 

hose 

6. Does not accelerate Accelerator pedal module defective • Get defect rectified 

7. Belt squeal Loose belt • Get belt tension adjusted 

Belt glazed 

• Get belt replaced 

CLUTCH 

1. Clutch does not get disengaged Air in the hydraulic system • Bleed the system 

Less fluid in the master cylinder • Get the clutch fluid filled 

2. Clutch pedal goes too low Air in the hydraulic system • Bleed the system 

Less fluid in the master cylinder • Get the clutch fluid filled 

3. Clutch pedal return sluggish Blocking of vent in clutch fluid • Open the cap from the bottle 

Bottle 

& clean the breather hole, if 

Clogged 

89


90 


GEAR BOX 

1. Hard gear shifting / Clutch does not disengage • Get the clutch hydraulic system 

crash engagement properly attended 

2. Gear shifts but vehicle 4 X 4 sensor connections loosen • Make proper sensor connections 

does not move 

REAR AXLE & FRONT AXLE 

1. Loss of lubricant (Oil) Breather hole clogged • Clean the breather hole on the 

axle housing 

Differential cover gasket torn • Get replaced 

Pinion oil seal damaged 

• Get replaced 

2. Differential housing overheating Insufficient oil • Get the oil filled 

Incorrect lubricant used 

• Drain, flush and get correct 

lubricant filled 

3. Noise from axle Excess play in crown wheel pinion • Adjust the play 

BRAKES 

1. Poor brakes Insufficient brake fluid. • Get the brake fluid filled 

Air in the system 

• Bleed the system 

Malfunction of automatic adjuster • Check & rectify auto adjuster 

mechanism or replace. 

Vacuum leakage 

• Rectify the leakage



Brake fluid contamination 

Brake fluid, grease, oil or water 

on pad /drum 

Worn brake lining/pad 

Excessive worn drums at rear 

soft or weak hose 

• Replace the brake fluid 

• Replace the leaking line, bleed 

the system. Clean pad/lining. 

replace seals if leaking 

• Get the liners/pad replaced 

• Replace rear drums 

• Check & replace 

2. Spongy pedal Air in the system • Bleed the system 

3. Brake pulling to one side Oil on the lining/pad • Clean the pad lining 

One side shoe (pad) worn 

• Get the shoe pad replaced 

Loose brake anchor plate 

• Tighten the bolts 

Wheel adjustment disturbed • Adjust 

Unequal tyre pressure 

• Adjust 

One side brake pipe clogged • Get the brake line cleaned & 

bleed the system 

4. Brake grab Improperly adjusted parking brake • Get correctly adjusted 

brake fluid container breather hole • Clean the hole on the container 

clogged 

No brake pedal free play/brake • Adjust brake pedal 

pedal not returning fully 

Defective tandem master cylinder • Replace/rectify tandem master 

cylinder 

91



Brake fluid contamination • Replace brake fluid along with tandem 

master cylinder and wheel cylinder. 

5. Brake Squeal Defective brake lining/pad • Replace 

Glazed lining/pad 

• Clean or replace lining/pad 

Loose rivets 

• Install rivets properly 

Wrong lining/pad 

• Install correct lining/pad 

Shoe return spring broken • Replace 

Front pads / Antisqueal shims • Get corrected 

rubbing on the disc 

STEERING SYSTEM 

1. Hard steering Less fluid in the power steering • Get the fluid topped up to 

tank 

correct level 

Air in the system 

• Get the air removed by bleeding 

the system 

Loose pump belt 

• Get the belt correctly adjusted 

2. One side vehicle pulling Improper wheel alignment • Set proper wheel alignment 

Improper tyre inflation pressure • Set proper inflation pressure 

92



ELECTRICAL & AIR CONDITIONING 

1. No lights on the dash board after Battery terminal got disconnected • Get the battery properly connected 

turning on the ignition key Battery completely dead • Get the battery charged 

• Get the alternator & charging circuit 

checked 

• Check battery cut off switch, make it 

ON if it is OFF 

• Check for parking lamp fuse 

2. Non functioning electrical Blown fuse in the circuit • Replace the fuse if blown 

accessories such as power 

windows, head lamps, fuel Loose connectors • Get the connection properly tightened 

tank flap, wiper and washer etc Circuit relay loose the mounting • Tighten the relay correctly 

Defective components 

• Get the defective component 

replaced from Authorized workshop 

AIR CONDITIONING 

1. Fan motor does not operate Blown fuse • Replace fuse and correct any 

wiring short 

Faulty connection 

• Properly connect poor connections 

Faulty motor 

• Replace motor if no conductance 

Faulty or poor 

• Replace resistor block if defective 

connection at resistor 

Faulty fan switch 

• Replace switch 

93



2. Motor operates but air flow Obstruction at evaporator inlet • Clean evaporator 

is minimum Air leak • Correctly seal 

Faulty thermostat 

• Adjust or replace thermostat 

3. Insufficient cooling, Air flow Incorrect refrigerant quantity or • Get the defect rectified at nearest 

normal and compress operating or defect in system aggregates authorized service centre 

or defective thermosensor 

4. Demist or defrost not working Loose electrical connections • Get proper connections 

WIPERS 

1. Narrow streaks are left on the Foreign matter has • Clean the edge of the blade. If 

wind shield making it hard to see attached to the blade or streaks still appear, replace the blade 

edge of the blade is worn out. 

2. The wiper blade jumps across No proper contact of wiper blade • Clean the wind shield. If jumping 

the windshield and makes a lot with wind shield glass and wiper persists replace the blade. 

f noise (Un-smooth operation) 

blade does not move smoothly 

across the surface but vibrates, 

noisily and bounces. 

3. The wipe leaves large un-wiped Rubber deformed • Replace the blade 

spots. 

4. The blade does not contact with Deformed wiper blade / arm • Replace wiper blade / arm 

the wind shield surface evenly, 

leaving a large un-wiped surface. 

94



WHEELS AND TYRES 

1. Excessive tyre wear Disturbed steering geometry • Adjust steering geometry 

Improper inflation pressure 

• Check and set proper inflation 

pressure 

95

Lubrication points 

Lubrication points : The lubrication points listed below 

and shown on next page require greasing or an oil 

level check and topping up. 

No. Description 

NOTE : Grease nipples must be carefully cleaned prior to 

greasing and the same applies to grease cups/screw plugs 

before they are unscrewed. 

* During Overhauls 

96 

Grease / oil 

1. Engine Oil level 

2. Front hub Pack grease 

3. Front Axle C.V. Joint Pack grease 

4. Power steering tank Oil level 

5. Steering spindle and sleeve 1 Grease nipple 

6. Transfer case Oil level 

7. Propeller shaft (Rear yoke) 1 Grease nipple 

8. Rear axle Oil level 

9. Rear hub Pack grease 

10. Front Propeller shaft Rear yokes 1 Grease nipple 

11. Gear box Oil level 

12. Rear spring suspension Rear 4 grease nipples 

13. Rear spring suspension Front 2 Grease nipples

Lubrication points (4x4 vehicle) 

LUBRICATION POINTS 

97

Special instructions 

1. The vehicle has been built to give you thousands 

of kilometres of economical and trouble-free 

performance. This is however, possible only if this 

vehicle is systematically maintained and operated 

strictly according to the instructions contained in 

this book. 

2. This chapter contains charts showing lubrication 

points and the lubrication & maintenance schedule. 

3. Besides the lubrication & maintenance schedule 

chart detailing the service operations to be 

performed, free PDI Coupon (perforated) is 

incorporated on one sheet. This coupon should be 

detached and sent to Customer Support, 

Passenger Car Division, Tata Motors Limited, 

Survey No. 15 & 15 A, PCNTDA, KD-03, Chikhali, 

Pune - 410501 by the servicing dealer after the 

service is performed. The servicing dealer should 

fill up details of chassis particulars on the inside 

cover page. 

4. The vehicle is entitled to pre-delivery service with 

free labour. 

5. It is an important condition of our policy that 

no warranty claims shall be entertained by us 

unless all services upto the time of the claim 

arising have been performed on the vehicle. 

Failure to carry out the services listed in this book 

can cause considerable damage to the vehicle and 

inconvenience to you. It is, therefore, in your own 

interest to get the vehicle serviced as per schedule. 

6. For any technical advice concerning your vehicle, 

please contact the nearest Authorised Dealer or 

our Customer Support Representative or write to : 

Customer Support, 

Passenger Car Division, 

Tata Motors Limited, 

Survey No. 15 & 15 A, PCNTDA, 

KD-03, Chikhali, Pune - 410501 

While washing the vehicle with water hose, cover up 

head lamps and other electrical items and gauges to 

avoid ingress of water. 

98

LUBRICATION & MAINTENANCE SCHEDULE 

OPERATION 

FREQUENCY IN 

DURATION 

FREQUENCY IN 

KM 

OPERATION 

FREQUENCY IN 

DURATION 

FREQUENCY IN 

KM 

Service Operations to be performed by Driver 

GENERAL 

1. Check engine oil level in sump, Top up, if necessary. Daily 

2. Check coolant level in auxiliary tank, top-up, if Daily 

necessary with mixture of clean soft water and 

recommended anti-freeze additive in specified ratio. 

3 Check and get rectified leakage of oil, fuel, brake Weekly 

fluid and coolant, if any. 

4 Check tyre pressure. Inflate tyres to specified Weekly 

pressure, if necessary. 

5 Check level of brake fluid in containers, top up, Monthly 

if necessary. 

6 Grease with grease gun : Monthly 

(Where grease nipple is provided). 

Tie rod ball joints, Draglink ball joints, Idler arm ball 

joints, front & Rear spring pins, Propeller shaft & 

steering spindle 

7 Check the performance of brakes by applying & Monthly 

releasing, when engine is running. Get it adjusted 

from Authorized Workshop if required. 

8 Check oil level in power steering tank & top up if Monthly 

necessary 

9 Check headlamps, gauges & instruments for proper Daily 

functioning. Get it rectified if necessary 

10 Check exhaust system. Get it rectified, if necessary. Monthly 

11 Check condition of wiper blades for crack damage, Daily 

etc. replace if necessary. 

12 Clean the vehicle from inside & outside Monthly 

Note : Do not wash DICOR system components 

with forced water 

13 Check Air Filter service indicator. If RED BAND Daily 

appears, clean the filter cartridge. Replace filter 

element when service indicator shows red band 

even after cleaning the filter element. 

14 Wheel balancing Whenever tyre is 

removed from wheel rim. 

15 Wheel alignment (Steering geometry) must be done. Monthly 10000 km 

on road 

5,000 km 

off road 

16 Check water level in windscreen washer container Daily 

& top up if necessary 

17 Lubricate all grease nipples Monthly 10,000 

18 Tighten all fasteners: front grill, & fuel lines, engine, Monthly 10,000 

radiator mtg., radiator hose, turbocharger mounting, 

inter cooler mounting fasteners turbocharger hose 

connections/its mountings & inter-cooler hose 

connection / its mountings prop. shaft centre bearing. 

bracket / mounting bolts, U-bolts & nuts of springs, 

joints of pitman arm, tie rods, steering gear box & 

its mtg. bracket, vacuum & hydraulic line connections, 

head lamp mtg., wheel mtg. nuts, drivers cab seats 

mountings, axle shaft mtg., anti roll bar mtg.,vacuum 

booster & tandem master cylinder mountings, rear 

anchor plate mtg., , fuel tank mtgs. 

99


OPERATION 

FREQUENCY IN 

DURATION 

FREQUENCY IN 

KM 

OPERATION 

FREQUENCY IN 

DURATION 

FREQUENCY IN 

KM 

Service Operations to be performed at Workshop 

ENGINE 

1 Change coolant in cooling system 2 years 40,000 

2 Change engine oil & oil filter cartridge 6 months 10,000 

3 Change water sedimenter 2 years 50,000 

5 Drain water in sedimenter / Fuel filter 5000 

Whenever umbrella shape lamp glows 

6 Change fuel filter 1 Years 20000 

7 Cooling and heater: check & rectify hoses for clog Monthly 

and damage (radiator & condenser fins blocking due 

to dirt / dust etc.) 

8 Check alternator belt and A/C compressor belt adjust 6 Months 10,000 

tension if required, change if damaged 

9 Change / replace all drive belts 2 years 40,000 

10 Replace air cleaner element 

1 year for normal operation, 6 months for Dusty 

roads10,000 for normal operation, 5000 for Dusty 

roads 

11 Check & adjust tappet clearance 1 year 10,000 

12 Inspect vacuum hose connection and rectify if Monthly 5,000 

necessary 

13 Change / replace all vacuum hoses 2 years 40,000 

14 Check Turbo charger hose & Rectify if necessary Monthly 5,000 

15 Check & ensure normal working of engine using 5,000 

diagnostic equipment ( Whenever check engine 

lamp glows on OR at every vehicle servicing) 

LOW PRESSURE FUEL SYSTEM 

1 Check low pressure fuel lines for leakage & rectify 6 months 5,000 

2 Clean strainer in fuel tank 1 Year 10,000 

3 Remove drain plug fuel tank and drain off sediments 1 Year 40,000 

BRAKES 

1 Check level of brake fluid in containers, top up Daily 

if necessary 

2 Check service & parking brakes, adjust if necessary 3 Months 5,000 

3 Check front brake & rear brake linings, Replace if 6 Months 15,000 

necessary 

4 Change brake fluid in the brake system and bleed 1 years 20,000 

the system 

5 Overhaul the vacuum booster assembly using 1 years 30,000 

recommended repair kit and diaphragm. 

6 Dismantle, clean, inspect and re-assemble tandam 1 years 30,000 

master cylinder of brake system. 

GEAR BOX 

2 Check oil level in Gear Box. 3 Months 5,000 

3 Change oil in the Gear Box. 1 year 15,000 

4 Check and Clean breather on Gear box 1 year 15,000 

TRANSFER CASE 

1 Check oil level in transfer case, top up if necessary 3 Months 5,000 

2 Change oil in transfer case (First 10,000 km) 1 year 45,000 

4 Check & tighten if necessary, transfer case mounting 6 months 5,000 

screw 

100


OPERATION 

FREQUENCY 

IN DURATION 

FREQUENCY 

IN KM 

OPERATION 

FREQUENCY IN 

IN DURATION 

FREQUENCY 

IN KM 

LIVE FRONT AND REAR AXLE 

1 Check oil level in live front axle and live rear axle, 3 Months 5,000 

top up if necessary 

2 Change oil in live Front axle & Rear axle (FIRST 10,000) 1 years 15,000 

3 Change grease in front hubs & adjust bearing play 1 years 30,000 

Replace damaged / worn parts. 

4 Clean breather on live front axle and rear axle. 6 months 

POWER STEERING & SUSPENSION 

1 Check and tighten if nessary. “U” joints on steering 6 months 

spindle. Steering gear box and mounting bracket 

bolts joints of pitman arm, drag link and tie rod. 

2 Check & adjust steering wheel free play 6 months 

3 Check oil level in P.S. tank & top up if neccessary. 3 months 5,000 

4 Change oil in steering gear box. 2 years 30,000 

5 Check belt tension & adjust if necessary 6 Months 10,000 

6 Check condition of rubber bushes of a) Anti-roll bar 1 Year 30,000 

b) Upper wish bone c) Lower wish bone 

7 Check tightening torque of suspension fasteners 5,000 

ELECTRICALS 

1 Check battery voltage, charge the battery externally Weekly 

if necessory 

2 Apply graphite grease on starter motor pinion bushing 6 months 15,000 

3 Grease the wiper motor linkages 6 months 15,000 

CAB 

1 Apply grease on door latches, door lock striker, bonnet Monthly 

opening lever, lock plate tail gate hinges & door lock 

inner ratchet 

Change oil in live Front axle & Rear axle (FIRST 10,000) 

WHEELS & TYRES 

1 Tyre rotation. 6 Monthly 5,000 

AIR CONDITIONING SYSTEM (wherever fitted) 

1 Check torque of bolts on brackets & AC compressor Monthly 

2 Check compressor belt, adjust tension, Replace if Monthly 

necessary. 

3 Check bubbles in receiver drier for refrigerant level Monthly 

4 Check for leak of gas / oil from pipes, joints, Monthly 

compressor shaft seal & cylinder head 

5 Clean condenser with high pressure water Monthly 

6 Check fan speeds for proper air flow Monthly 

7 Check system pressure with gauges. Recharge if Monthly 

necessary 

8 Clean evaporator from its face to remove dust, Monthly 

foreign objects etc. 

9 Replace AC compressor belt 2 Years 45,000 

HEATING / DEMISTING SYSTEM 

1 Check hose joints of heating system for leakage. Monthly 

Tighten if necessary 

2 Check hoses of heating system for cracks. Replace Monthly 

if required 

3 Check blower for proper functioning. Check fuse. Monthly 

Replace if found blown. 

RUBBER / NYLON HOSES & FLEXIBLE PIPES 

1 Check hoses & pipes of air / fuel / coolant / brake / 1 year 

clutch / air conditioning / wind screen washing system 

for joint tightness and damage. Replace, if necessary. 

101

Record of services performed 

Recommended Odometer Repair Servicing Dealer's 

Service Date reading Order Signature and 

Km. No. Stamp 

At Km. 

PDI 

Chassis No................................ 



Km. No. Stamp 

45,000 

50,000 

5,000 

10,000 

15,000 

20,000 

25,000 

30,000 

35,000 

40,000 

55,000 

60,000 

65,000 

70,000 

75,000 

80,000 

85,000 

90,000 

102

Record of services performed 

Chassis No................................ 



Km. No. Stamp 

95,000 

1,00,000 



Km. No. Stamp 

1,45,000 

1,50,000 

1,05,000 

1,10,000 

1,15,000 

1,20,000 

1,25,000 

1,30,000 

1,35,000 

1,40,000 

1,55,000 

1,60,000 

1,65,000 

1,70,000 

1,75,000 

1,80,000 

1,85,000 

1,90,000 

103

Record of repairs carried out 

Chassis No................................ 

Date 

Odometer 

reading (km) 

Repair 

Order No. 

Particulars of Repair 

Servicing Dealer's Signature & Stamp 

104

Record of repairs carried out 

Chassis No................................ 

Date 

Odometer 

reading (km) 

Repair 

Order No. 

Particulars of Repair 

Servicing Dealer's Signature & Stamp 

105

ABBREVIATIONS 

AC 

ACC 

Amp 

Br 

Brg 

Air conditioning 

Accessories 

Ampere 

Branch 

Bearing 

IGN 

Kg 

km 

Km/h 

Ignition 

Kilogram 

Kilometer 

Kilometer per hour 

RAW 

RCSM 

RH 

RM 

RPM 

Rear Axle Weight 

Regional Customer Support 

Manager 

Right Hand 

Regional Manager 

Revolution Per Minute 

cc 

Cm 

Cubic centimeter 

Centimeter 

LH 

Max 

Left Hand 

Maximum 

Sec 

Sq. cm. 

Seconds 

Square Centimeter 

Dia 

EGR 

Diagonal 

Exhaust Gas Recirculation 

Min 

mkg 

mm 

Mtg 

Minimum 

Meter per Kilogram 

Milimeter 

Mounting 

TASC 

TASP 

Tata Motors Authorised 

Service Centre 

Tata Motors Authorised 

Service Point 

FAW 

Fig 

Front Axle Weight 

Figure 

No 

Number 

V 

Volts 

FIP 

gm 

Fuel Injection Pump 

Gram 

PDI 

PSI 

PUC 

Pre-delivery Inspection 

Pounds per Square Inch 

Pollution Under Control 

W 

Wt 

Watts 

Weight 

GVW 

Cross Vehicle Weight 

106

At the time of delivery of vehicle please ensure that 

Pre-delivery inspection has been carried out as per details 

given in the SERVICE SCHEDULE. 

Chassis No................................... 

Engine No. .................................... 

Gear Box No. ................................ 

Sig. of customer ....................................... 

WORK DONE TO MY SATISFACTION 

PDI 

FREE 

LABOUR 

L - 

TATA SUMO 4X4 ARMOURED 

Speedo Reading ....................................... Km. seal O.K. / Broken 

R.O. No. ........................................................... Date ..................................... 

Dealer's / Authorised Service Centre's 

Stamp & Signature ................................................................................... 

107

108

Sumo Armoured LBPV - Tata Motors Customer Care

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