ASHOK LEYLAND CG 1613 H Instruction manual

DIRECTOR GENERAL BORDER ROADS
GENERAL MAINTENANCE INSTRUCTION NO 223
OF
ASHOK LEYLAND WATER TRUCK 9 KL CAPACITY
INTRODUCTION: - Ashok Leyland CG 1613 H 4330 MM (170.5”) WB chassis fitted with Hino WO 6 DTI
(BSII) diesel engine turbo charged,6 cylinder, water cooled developing 132 Ps@ 2400 RPM,24 V starting
alternator,5 speed synchromesh gear box power steering, exhaust brake spare wheel carrier and rim, and
water tanker of 9 KL capacity with pravity spray with 7 Nos tyres 1000 X20 PR PP nylon, the regular
servicing and maintenance are essential for optimal usurer of which to achieve maximum life for planning
and lamely repair to arrest defect from developing into major one; which s minimising the down time and
production losses. This GMI covers the periodical maint and lubrication schedule of vehicles for regular
maint to keep the vehicles as good mechanical condition.
AIM :- Instruction are issued as guidelines for schedule of preventive maintenance, lubrication of water
truck manufacture by Ashok Leyland for regular attention to keep the vehicle in good mechanical
condition and it must be strictly followed.
ACTION BY
USER UNIT: - To carryout periodic maintenance as laid down in this instruction and enter the all
task/record in concerned log book of vehicles.
FIELD WORKSHOP
(a) To check the maintenance, lubrication task are actually carried out by the user unit as per
Log book record.
(b) Advise user unit in respect of any discrepancies/short coming noticed.
DETAILS :-
(i) Maintenance Instruction - Appendix ‘A’
(ii) Hints for driver - Appendix ‘B’
(iii) Technical data - Appendix ‘C’
(iv) Recommended lubricants - Appendix ‘D’
(Hari Prakash)
SE (E&M) FS
Dir (Tech)
Distribution for Dir Gen Border Roads
Normal

Appx ‘A’
Maintenance Instruction
To get maximum service life from your vehicle, always make a habit to carry out simple check,
periodic check, general check and maintenance of vehicles. These checks and inspections are carried out
time to time will ensure minimum operating cost and maximum uptime of your vehicles:-
Check engine oil level top up if necessary.
Check coolent level top up if necessary.
Drain condensate from air tanks.
Check the vacuum indicator provide on the instrument panel for the appearance of red band.
Check water separator for collected water and drain if necessary. If water separator is not drained
periodically, fuel contaminates with water enter the FIP and injectors effecting performance and
damaging the fuel system.
Check tyre wear and pressure, if necessary inflate to the specified pressure
Check brakes
Check all light, warning indicators and wind screen wipers are in functioning condition.
Check oil level of steering gear box.
Check the battery electrolyte level, if necessary top up using distilled water at rest and cold.
Check the exhaust system visually, if exhaust is excessively smoky or engine is noisy refer vehicle
to nearest workshop for necessary check up.
Periodically check and ensure that the radiator cowl is intact, and replace a defective thermostat or
a missing header tank filler cap immediately as other wise the efficiency of cooling system would
be affected and this will be damage the engine.
Check all gauges fitted on instrument pannel are proper functioning.
Check all lights and electric connections, if found loose light it properly.
Fill up diesel tank at the end of each working day to reduce water condensation in the tanks.
Disconnect the propeller shaft while towing the vehicle for the long distance.
Drain air tank once in a week to drain water and oil sediments from the system.
Disconnect alternator/battery electric connection while carrying out welding work on the vehicle.

Do not operate starter for more than 15 seconds at a time and wait for 30 to 60 second before
trying again.
Do not add cold water to hot engine as this can lead to crack in crankcase and other associated
parts.
Fuel pump setting should not be tempered.
Check wheel nut torques after driving 150 kms or 250kms regularly.
Do not apply radial tyres and cross ply tyres on the same axle. Tyre on the same axle must be of
the same type and nominal size.
Check radiator hoses and clamps for leakages and tightness.
Check fan belt tension and adjust if necessary.
Drain cooling system and fill recommended coolent every 20,000 Kms or 2 years which ever is
earlier.
Check lever control valve, if found excessive play in control lever unit must be replaced or over
hauled. Excessive play indicates probable bear on the cam, pin, plunger face or a week or
distorted plunger return spring.
Check and tighten front and rear engine mounting/other peripheral bolts.
Check and tighten cylinder head nut and bolt for correct torque in correct sequence if found loose.
Change engine oil and oil filter element. First change at 16000 Km, there after every 16000 Km.
Clean oil cooler.
Check engine oil pressure (min 1 Kg/Cm² at idling and 80 degree C engine Temp.
Replace fuel filter element, Primary every 16000 km and secondary element at first time 24000
km there after every 16000 km.
Clean full fuel pumps Stainer every 8000 km.
Lubricate accelerator linkages every 8000 km and pedal shaft etc.
Check FIP control lever return spring.
Check and tighten FIP mounting.
Check and clear air cleaner primary element. Replace air cleaner primary element after two
consecutive cleaning.
Replace air cleaner safety element (at the time of 3rd replacement of primary element or once in a
year whichever earlier).

Check restriction indicator, if necessary clean the element.
Check air inlet hose for any puncture/damage.
Check turbo charger mounting.
Check exhaust manifold and silencer for leakage and tightness.
Lubricate gear shaft ball joint periodically and weekly.
Lubricate propeller shaft UJ cross and splines periodically and weekly. Also check UJ cup for wear
and replace it if found burn out.
Lubricate centre joint bearing periodically and weekly.
Check and tighten propeller shaft flange bolts periodically and weekly.
Check oil level of rear axle, top up if necessary.
Lubricate track rod/drag link ball joint of front axle periodically and weekly.
Lubricate the king pin and check play, adjust if necessary.
Check wheel alignment and adjust if necessary.
Check ‘I’ bold ‘U’ bolts tightness and spring clip fitment helper spring bracket, spring shackle
periodically.
Check shock observer, rod pads, mounting brackets, bolts and nuts.
Lubricate shackle pin weekly.
Check steering gear box oil level and leakage, top up if necessary.
Check steering wheel free play and adjust if necessary.
Always block vehicle wheels and stop engine while working under vehicle.
Check pneumatic hand brake for proper functioning daily.
Check compressed air build up on air gauge (8.25 Kg/Cm²) daily.

Appx ‘B’
HINTS FOR DRIVER FOR SAFE DRIVING:-
Safe driving is possible with total concentration and involvement of the driver. Safety is more important
than speed.
Firstly check the vehicle for road worthiness.
Check that all the safety equipment and fire extinguisher are in good working condition.
Always wear seat belt while driving. This safety feature reduces the Chance of personal injury.
While going down a hill, always use the same gear as would have been used for climbing it.
Never drive down hill with your engine switch off or gear in neutral position.
Control the speed by staying in the correct gear to avoid excessive use of brakes.
Avoid down shifting at high speeds which may cause engine over racing.
While parking on a hill, place wheel chock or wooden block under the wheels in addition to hand brake.
Don’t use vehicle with bald tyres and incorrect tyre pressure, may cause of skidding of vehicle.
Don’t apply brake violently on slippery road to avoid skidding.
Never leave vehicle with engine running, always put on parking lights if vehicle is parked on busy road
side.
When you are halt, make a habit of checking and cleaning wind screen, lights, reflectors, rear view mirrors
and tyres.
Don’t use cell phone while driving, it effect the concentration and control on driving adversely. Please park
the vehicle off the road safely while using cell phone.
If vehicle drive in deep water may wet the brake and adversely affect the performance. To dry it quickly,
apply brakes softly a few times while maintaining safe road speed till the braking ability return to normal.
Drive slow in Fog, use fog light for better visibility.
Do not leave the vehicle unattended.
Always drive on approved route.
Do not allow passenger to travel in the vehicle.
Modification to the vehicle in any form (i.e. drilling or welding on frame, adding extra leaf in suspension) is
strictly prohibited as it can affect the safety and economical aspect adversely.
Do not coast down hill with the transmission in neutral, or with clutch disengaged.

Appendix ‘C’
RECOMMENDED LUBRICANTS
Aggregates
Asoka Leyland specification
Abient
temp
°C
Co-branded
lubricants
Approved
lubricants
Change period in Kms
Gulf oil India
IOC
Bharat stage II & III Diesel
engine Hino (6DTI & 6ET)
engine
API CH-4+MB 228.3+VDS 3
-15 and
above
Super fleet LE max
SAE 15W-40
Servo pride
ALT 15W-40
First oil change period at 16,000 Km & there after
every 24,000 Kms for city and Ghat operation.
36,000 Kms for long haul operation. 24,000 Kms
or 500 hrs which ever is earlier
BSII AL 412 TC AC & BSII &III
HA4CTI diesel engine
API CH-4+MB 228.3+VDS 3
-15 and
above
Super fleet LE max
SAE 15W-40
Servo pride
ALT 15W-40
For long haul operation
Oil change at every 16,000 KM
Gear box constant mesh
Steering gear box (Mannual)
Gear box synchromesh
API GL-4 with specified
additive
>0
>0
>0
Gear XP MAX SAE
90
SERVO GEAR
ALT 90
AL
40,000
RANE
72,000
ZF
40,000
Power steering
General motors type A suffix
A
-
Power steering fluid
Max
Servo power
steer ALT
RANE
80,000/1 year
ZF
Rear axle spiral and pinion
API GL-4 (OR) MIL-L-2105
(OR) IS 1118-EP TYPE GL-
4
>30
Gear EP Max SAE
140
Servo Gear
ALT 140
8T/ 10T
24,000
Rear axle hypoid drive
API GL 5 with specified
additive
-12 and
above
Gear DB Max
85W140
Servo gear
super ALT
85W-140
Q109,RS145,RS120,R149.5
R160, SQR10960SHO, C100
48,000 Kms
Wheel bearing
IS 12203
-
Crown Max RR3
Servo gem ALT
-
48,000
Engine water pump, Gear shift
ball joints,S cam shaft & slack
adjuster (front & rear) shackle
pin
IS12203
-
MP Grease Max
NLGI 2
Servo grease
ALT
-
Weekly

Accelerator pedal ball joints,
Accelerator control shaft (Pedal
end & crankcase rear)
-
8000
Clutch pedal, Brake pedal,
Relay shaft & ball joints (clutch
withdrawal),clutch withdrawal
sleeve & liner, Centre bearing
joint, Propeller shaft UJ cross,
Drag line& track rod, King pin
-
Weekly/8000
Ram base, Ram cross head
Tees, Tipper body hinger,5th
wheel coupling.
-
Daily
Tipping unit
IS 10522
-
Harmony
AW Max ISO VG 32
Servo hydraulic
ALT 32
WIPRO,UT,HYVA
6 months
Hydraulic clutch
Hydraulic brake
FM VSS 116-Dot 3 (OR) IS
8654
-
Brake fluid Max Dot
3
Servo power
brake ALT
-
40,000
ENGINE COOLENT
Aggregate
Asoka ley land
specification
Ambient Temp
°C
Gulf oil India
IOC
Change period in
KMs
All AL/Hino engines with brass –copper radiator
JIS K 2234-94
Class 2 and
plus
>0
20 % Euro cool Max
Every 75,000 Kms
All AL/Hino engines with Aluminum radiator
50 % Euro cool Max
Every 75,000 Kms

Appendix ‘D’
TECHNICAL SPECIFICATION
Model
CG 1613 (H) 170.5” WB HAULAGE
Engine (Hino)
HINO HA6DTI2D MARK-II BS 2, 4 stroke, 6 cylinder diesel engine with
turbocharger and inter cooler
Bore & Stroke (mm)
104x113
Displacements (l)
5.759
Compression ratio
17.5:1
Max Output
132 ps/97 kw @ 2400 rpm
Max torque
(430 Nm) 43.8 Kgm @ 1200-1600 rpm
Firing order
1-4-2-6-3-5
Direction of Rotation
Counter clockwise viewed from Flywheel
Emission Standard
Meets Bharat Stage II mass emission norms
Cooling System
Forced circulation by volute pump
Drive
Cogged V-belt drive
Fan
Fan with viscous clutch, 520 mm Dia
Thermostat Type
Single thermostat wax type (bottom bypass) opens at 82 degree + 2
degree C
Lubricating system
Circulating pump, Pressurised Lubrication, driven by timing Gear
Oil Filter Type
Full Flow paper element
Oil Cooler Type
Plate Type Oil cooler (5 plates)
Fuel system
Injection Pump
Distributor type (VE) with Manifold pressure compensator (LDA)
(Optional hydraulic cold start injection advance –KSB)
Governor
Mechanical, engine speed control
Injector
Multi Hole Nozzle with bar filter
Feed Pump
Engine driven feed pump mounted on FIP timer cover
Fuel Filter
I, II Dual Filter (Both micro filter with coil type paper element)
Service Data
Nozzle opening pressure
247-261 bar
Fuel Injection timing
1.30+0.02mm plunger lift at TDC with No: 1 cylinder on Compression
stroke
Compression pressure
29 –32 kg/cm² @ 280rpm
Valve clearance
Intake –0.30mm, Exhaust –0.45mm
Electrical Equipment
Alternator
Lucas TVS 24 V, 55 Amps Belt driven
Starter Motor
Lucas TVS, 24V –GBS5, Axial drive
Air Filter
Twin element dry type
Clutch
Single plate dry type 14” four finger clutch (Non-Asbestos)
Actuation
Hydraulic
Facing dia (mm)
353
Wear Allowance per side
(in mm)
3.35
Gross frictional area
(cm²)`
1220

Gear Box
ZF S5 –36 Synchromesh
Gear ratios
1st
7.20 : 1
2nd
4.22 : 1
3rd
2.44 : 1
4th
1.52 : 1
5th
1.00 : 1
Reverse
8.05 : 1
Propeller shaft
1550 Series
No. of propeller shafts
2
Type of centre bearing
Self aligned
Rear Axle
Fully floating single speed hypoid gear (RS145)
Axle Capacity (kg)
10200
Axle ratio
6.167 : 1
Slack adjuster
Manual
Front Axle
Forged 1 –Section Reverse Elliot Type
Axle capacity (kg)
5460
Slack adjuster
Manual
Suspension
Regular
Type
Semi-elliptic laminated multi leaf with centre bolt arrangement
Leaf width (mm)
Front –76, Rear 80
Shock absorbers
Double acting telescopic on front axle only
Steering
ZF Power
Type
Integral power steering
Angle of steering column
to frame
73º
Electrical System
24 V negative earth, 80 Ah (20 h rating), 2x12V batteries
Brakes
Dual Line diaphragm operated 5 cam brake, flick valve operated
pneumatic hand brake on rear wheels only
Frame
All Steel Ladder Type bolted
No. of Cross Member
6
Frame Dimension (mm)
228.6x76.2x6.35 (depth X width X thickness)
Wheels and Tyres
Rim size
B 7” x 20”
Offset
157mm
Front tyre
10.00 x 20 16 PR
Rear tyre
10.00 x 20 16 PR
Front End Structure
G45 <LIII
Cabin (Tipper)

Performance data
Maximum speed (km/hr)
74.5
Maximum gradeability
(%)
21.40
Unladen Weights (kg)
Front Axle
2500
Rear Axle
1820
Total
4320
Laden Weights (kg)
Front Axle
6000
Rear Axle
10200
Total
16200
Major Dimension (mm)
Wheel base
4330
Front overhang
(including bumper)
1446
Rear overhang
1990
Overall length
7766
Overall width
2425
Front track
1963
Rear track
1816
Frame width
864
Laden height
970
Min. ground clearance
253
Turning circle radius
8750
FILLING CAPACITIES
In Litres
Engine (including Oil
Filter)
Hino HA DDTI2D 10.5
Cooling system capacity
Hino HA 6DTI 2D 19 Approx
Gear box
ZF-S5 36/S6-36 Synchromesh 6.5
ZF-S5-36/S6-36 Synchromesh with PTO 7.5
Rear Axle
RS145/Q109 13.0
Steering
Rane Power 4.0
ZF Power 4.5