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To assist you in maintaining your vehicle as per recommended Use of genuine parts, designed and manufactured
to our exacting standards, are the best way to
schedule, we have a widespread network of dealers and service maintain your vehicle in peak operating condition.
centres. The list is included in this book for your convenience. Please do not use substitutes. They always prove
costlier in the long run.
Should you need any special assistance, please call on our Authorised
Failure to use genuine parts can invalidate any future
Dealer.
warranty claims.
Please note that by adhering to the correct operating procedures
and by availing the scheduled maintenance services at our The information and specification given in this book
authorised service centres, you can obtain the maximum are valid as on the date of printing. Tata Motors
performance from your vehicle. reserves the right to make changes in design and
specifications and / or to make additions to or
We request you to go through the book and drive many miles
improvements in this product without obligation to
of motoring pleasure. install them on products previously sold.
v
Environmental Protection
• Avoid frequent
accelerations.
and violent
• Ensure that recommended • Never allow the vehicle to run out of
fuel.
maintenance is carried out on the
• Do not carry any unnecessary weight
on the vehicle as it overloads the
vehicle regularly at our Authorised
Service Outlets.
• Parts like brake liners, clutch disc should
be vacuum cleaned. Do not use the
engine. Avoid using devices requiring compressed air for cleaning these parts
high power consumption during slow • As soon as you see any leakages of oil
or fuel in the car, get it attended
which may spread the dust in the
traffic condition. atmosphere.
immediately.
vi
Environmental Protection
vii
Driving instruction 4 X4 Operation
36A
Driving instruction 4 X4 Operation
The limited slip differential provided in In 4H mode, the transmitted engine Free Wheeling of Front Hub
the rear axle takes care of such torque and vehicle speed remain After shifting from 4H to 2H, for effecting
situations. The clutch lock arrangement the same as in 2H. However, when free wheeling of front wheels, direction
provided internally, ensures that in case you shift to 4L mode engine torque of vehicle motion needs to be changed. If
one wheel loses traction and begins to is multiplied and vehicle moves at the vehicle was moving forward in 4H then
slip, a locking action takes place which low speed in the same gears with bring it to halt and engage reverse gear of
prevents differential action and both increased traction. 4L mode is main gear box. (If it was moving reverse in
wheels turn at the same speed. provided for negotiating sharp 4H mode then stop it, and then engage
gradients or driving through loose forward gear of main gear box.) After
Thus unnecessary spinning of one wheel
soil/sand. stopping and changing the gear the
is avoided and torque is transmitted to
both wheels, thus assisting the vehicle to 2. Shifting from 2H to 4H vehicle must travel in opposite direction
traverse loose terrain. However during Turn the selector knob from 2H to for a minimum of three meters, before
normal driving, the differential action 4H position. 4H indicator on free wheeling takes place.
takes place in the same manner as in a instrument panel will light up. 4. Shifting from 4H to 4L
standard differential. Changing from 2H to 4H can be Stop the vehicle. Press clutch pedal.
1. Four Wheel Drive Operation done at any speed upto 65 km/h (40 Turn the selector knob from 4H to 4L
In 2-H mode, only the rear two mph). No pressing of clutch pedal is position. 4L indicator light on
wheels of the vehicle are powered required. instrument panel will blink few times
by the engine and the front wheels and remain on.
are merely pushed. By shifting to 3. Shifting from 4H to 2H
Turn the selector knob from 4H to 5. Shifting from 4L to 4H
four wheel drive mode (4H or 4L)
the rear as well as the front axles 2H position. 4H indicator on Stop the vehicle. Press clutch pedal.
get geared to the engine through instrument panel will go off. Turn the selector knob from 4L to 4H
transfer case and transmit the Changing from 4H to 2H can be done position. 4H indicator light on
engine power to all four wheels. This at any speed upto 65 km/h (40 mph). instrument panel will blink few times
gives the vehicle increased traction. No pressing of clutch pedal is and will remain on.
required.
36B
Warranty Terms and conditions
We WARRANT each TATA SUMO SE+ / warranty shall be co-terminus with sales or service establishments, our
TOURIN / CARRIER vehicles & parts thereof this original warranty. authorised dealers, service centres or
manufactured by us to be free from defect service points in any way so as, in our
3. Any part which is found to be
in material and workmanship, subject to judgement which shall be final and
defective and is replaced by us under
the following terms & conditions: binding, to effect its reliability, nor
the warranty shall be our property.
shall it apply if, in our opinion which
1. This warranty shall be for 18 months
4. As for such parts as tyres, batteries, shall be final and binding the car is
from the date of sale of the vehicle,
electrical equipment, fuel injection subjected to misuse, negligence,
irrespective of the distance covered.
Howerver, for the vehicles used for
T Y
equipment, etc. not manufactured by
us but supplied by other parties, this
improper or inadequate maintenance
or accident or loading in excess of
N
commercial applications (including
warranty shall not apply, but buyers such carrying capacity as certified by
those used for hire or reward viz
those operating with a yellow
number plate), the warranty shall be
R A
of the car shall be entitled to, so far
as permissible by law, all such rights
us, or such services as prescribed in
our Owner’s Manual and Service Book
R
as we may have against such parties are not carried out by the buyer
limited to 18 months or 50,000 kms,
under their warranties in respect of through our sales or service
2.
whichever occurs earlier.
Our obligation under this warranty
shall be limited to repairing or
replacing, free of charge, such parts WA such parts. Our Dealers/TASC’s will
assist the purchaser in taking up the
complaint with the respective
manufacturers and their decision on
establishments, our authorised
dealers or service centres or service
points.
6. This warranty shall not cover normal
of the car which, in our opinion, are the warranty will be final.
wear and tear or any inherent normal
defective, on the vehicle being
5. This warranty shall not apply if the deterioration of the car or any of its
brought to us or to our dealers within
car or any part thereof is repaired or parts arising from the actual use of
the period. The parts so repaired or
altered otherwise than in accordance the car or any damage due to
replaced shall also be warranted for
with our standard repair procedure negligent or improper operation or
quality and workmanship but such
or by any person other than from our storage of the car. This warranty shall
1
Warranty Terms and conditions
not apply to normal maintenance competitive sport. This warranty shall 10. Any claim arising from this warranty
services like oils & fluid changes, head not apply to any repairs or shall be recognised only if it is notified
lamps focussing, fastener replacement as a result of accident in writing to us or to our authorised
retightening, wheel balancing, tyre or collision. dealer without any delay soon after
rotation, adjustment of valve such defect as covered and
8. This warranty is expressly in lieu of
clearance, fuel timing, ignition timing ascertained under this warranty.
all warranties, whether by law or
and consumables like bulbs, fuel
otherwise, expressed or implied, and 11. This warranty shall stand terminated
filters and oil filters etc. This warranty
shall not apply to any damage or
deterioration caused by Y
all other obligations or liabilities on
T
our part and we neither assume, nor
if the vehicle is transferred or
otherwise alienated by the buyer
N
authorise any person to assume on without our prior written consent.
environmental pollution or bird
our behalf, any other liability arising
droppings. This warranty shall not
apply to V-belts, hoses and gas leaks
R A
from the sale of the car or any
agreement in relation thereto.
12. We reserve our rights to make any
change or modification in the design
R
in case of air conditioned cars. Slight of the car or its parts or to introduce
irregularities not recognised as 9. The buyer shall have no other rights any improvement therein or to
affecting the function or quality of
the vehicle or parts, such as slight
noise or vibration, defects appearing
only under particular or irregular WA 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
incorporate in the car any additional
part or accessory at any time without
incurring any obligation to
incorporate the same in the car
operations are items considered the car, or to demand any damages previously sold.
characteristic of the vehicle. or compensation for losses, incidental
or indirect, or inconvenience or
7. This warranty shall be null and void
consequential damages, loss of car,
if the car is subjected to abnormal
or loss of time, otherwise, incurred or
use such as rallying, racing or
accrued.
participation in any other
2
Friendly notes Do’s
1. Use genuine co-branded oils and 8. Check tyres for damage from time to
lubricants only. time and remove any foreign bodies
embedded in threads.
2. Change oil in engine, gear box, In case of tyre replacement or repairs
transfer case, steering system, front due to puncture, have the wheel
live axle and rear axle at prescribed balanced. Keep grease, oil and fuel
intervals. away from the tyres. In case of
uneven tyre wear get the vehicle
3. Use only genuine oil filter and fuel
attended to by any of our authorised
filter elements. Replace them at
service set-ups.
regular intervals.
Dos
9. Maintain correct tyre pressure.
4. Clean air filter element regularly.
Replace filter element when service 10. Check battery every week and top
indicator shows red band even after up electrolyte level. Keep battery
cleaning the filter element. terminals clean and cable joints tight.
Apply vaseline / petroleum jelly on
5. Ensure periodic servicing as per terminals. Use distilled water only for
maintenance schedule. topping up.
6. Insist on use of genuine spare parts. 11. Observe correct polarity when
connecting battery terminals.
7. Ensure that caps of auxiliary tank
and radiator are firmly fitted to keep 12. Disconnect alternator terminals
the cooling system pressurised and while carrying out any welding on
to maintain coolant level. Always use the vehicle.
genuine radiator cap only of 1.0
kg/cm2 (14 PSI), for replacement. 13. Avoid panic braking. Use lower gears
while descending gradients.
3
Friendly notes Do’s
14. Start the vehicle always in the 1st 22. Retighten wheel mounting nuts after
gear to avoid premature clutch wear. 100 km of very wheel change.
Tightening Torque : 12 -15 mkg.
15. Keep both foot and parking brakes
properly adjusted. 23. Use only recommended FUSES and
always keep spare fuses in the box.
16 Before engaging reverse gear,
ensure that vehicle is has come to a 24. In case of engine not starting first
stop, declutch, wait for a few seconds check the fuse of fuel injection
and shift into reverse gear. pump solenoid.
Dos
17. When parking on slopes, use wheel 25. Inspect the engine timing belt at
chocks, apply parking brake and keep every 48,000 km. and replace, if found
vehicle in low gear. torn, cracked, worn or soaked in oil.
18. In case of emergency parking or 26. Ensure doors are properly closed.
breakdown on road, pull the hazard
warning switch to flash all the blinker 27. If your vehicle has a turbocharged
lights to warn other road users. engine, keep engine at idling speed
for atleast a minute after starting and
19. Release parking brake before also before stopping it, to protect the
driving off. turbocharger against damage due to
oil starvation.
20. Crank the engine only when glow
plug indicator light is ‘OFF’.
4
Friendly notes Dont’s
1. Do not crank the engine when glow 8. If your vehicle has a turbocharged
plug indicator light is ‘ON’. engine, do not stop the engine at
once, allow it to run at idling speed
2. Do not start the vehicle if Brake Fail for atleast 1 minute. Also do not
indicator is ‘ON’. accelerate engine till the engine oil
pressure has built up.
3. Do not use Clutch Pedal as Foot
Rest. This will reduce clutch life. 9. 4 x 4 vehicles : Do not drive in 4H or
4L mode for long on hard paved
4. Do not Coast vehicle in Neutral and
surface except for checking the
engine switched-off position. This is a
operation.
safety hazard.
Donts 5.
6.
Do not run engine without Radiator
Cap. Use genuine Cap only, to keep
system pressurised.
5
Handling Location of chassis and aggregate serial numbers
6
Handling Location of aggregate serial numbers
Rear axle number ( Telco ) Rear axle number ( Spicer ) Body shell number plate
7
Handling Doors
3 2
Key Locking and Unlocking of Doors In case knob (2) is pressed with door
open, it will get released automatically
A key has been provided for operation of From outside : To unlock the door turn key when door is closed.
steering lock cum ignition switch, for anticlockwise and swing handle (1) The co-driver’s side door and middle doors
locking and unlocking of driver’s side door, upwards. To lock the door turn key can be opened from outside as well as inside
glove box, fuel tank flap and rear door. clockwise. but locking is from inside by pressing knob
2. The rear door can be opened and locked
From Inside : Lift knob (2) and then only pull from inside.
handle (3) in the door panel to unlock the
door. To lock the door press knob (2). Window winding
8
Handling Rear view mirror, seats
Sunvisors
Rear view mirror - outside Rear view mirror in cabin Driver’s seat
Seats
Sun visor Rear view mirror
Driver’s seat & Co-driver’s seat
Two adjustable sun visors are provided Rear view mirror is fitted on driver’s side
inside the cab to prevent sun glare. door. It can be adjusted to the desired Adjustable type seat is provided for driver
positions by hand. The mirror can be folded and co-driver (in few version soft
backwards for convenience when the cushioned comfortable bench seat is
vehicle is to be driven through narrow provided at front by the side of driver seat
passages. for two passengers). The driver seat is
An additional adjustable rear view mirror is fitted with lever and handle, to adjust the
fitted inside the cab. seat.
The seat can be adjusted in forward and
backward directions.
9
Handling Seats
To achieve correct position for proper a cushion bench 60:40 split seat has been Seats at rear
driving, lift the handle (2) and slide the provided for the middle passengers. Any
Two rows of seats, single or double are
seat either forward or backward. Once the one of the split can be folded by releasing
provided at rear for passengers. These
desire position is achieved push down the the latch, on the backrest simultaneously.
seats can be folded for carrying bulkier
handle to lock the seat. Turn the lever (1) For more luggage space or to access front
baggages as per procedure given below:
to adjust backrest to the desired position. facing third row seat, the folded middle
Release the lever to lock it. seat can be somersaulted further. 1. Lift the seat squab and hold against
For fixing the rear seat back upright, just backrest.
Do not adjust seat while driving. 2. Engage strap with the hook on seat
push back the seat in position. It will get
Middle seats locked by itself. squab.
A cushion bench seat has been provided 3. Fold the seat stand.
for the middle passengers. In few versions,
10
Handling Seats
1 2 3
Slide the knob and fold the seat Press the knob and pull Front facing rear seat
the seat to its position
4 5 6
Rear jump seat Total luggage space where front facing Luggage space where rear
seat is removed & middle seat folded jump seats are folded
11
Handling Seats
1 2 3
For folding back, pull the strap Lift the lever and fold the seat further For detaching seat, operate two levers
as shown in figure to get maximum luggage space provided on wheel house area and pull it out
The vehicle has been fitted with three When the vehicle is at rest, adjust the Pull free end of webbing through adjuster
point active belt for extra safety for driver, length of the belt to suit convenience. until required adjustment is achieved.
co-driver and passengers on middle seat. Insert belt tongue in buckle. A positive click
indicates correct assembly. To loosen (lengthen) the belt.
Fastening the belt Adjust length of the belt to suit you and Tilt the adjuster by means of the grip and
fasten. The lap section should be slide it along the strap until suitably
Insert belt tongue into buckle, a positive comfortably tight, the diagonal sections adjusted.
locking ‘ click ’ indicates correct and safe should be adjusted so that a flat hand will
assembly. pass between the chest and the strap. Lap belt for middle passengers of front
Releasing the belt. bench seat.
Press the release button, the tongue will Middle passenger is provide with lap belt.
be ejected clear of the locking mechanism Adjust length of belt to suit convenience.
within the buckle.
13
Handling Seat belts, Tools
14
Handling Jack & Tools and Dashboard
15
Handling Instrument cluster
4 5 6 7 8 9
10
11
3
2
1 12
Instrument Cluster
16
Handling Gauges & Indicators
LOCK
❒ to switch on and off the electrical The switch is located on the steering column
system other than listed below. support and has the following key positions:
18
Handling Steering lock cum ignition switch, Combination switch
ON Combination switch
By turning the key to this position all The combination switch is mounted on
remaining electrical systems become steering column. It’s right side lever operates
operative and lamps of battery charging turn signals, headlamps and parking lights,
indicator, low oil pressure will come on. 3 number plate lights and instrument panel
4 light.
In case of 4x4 vehicle in addition to above 1
4WDH & 4WDL lamps will come on and goes Turn Signals
off after a few seconds. 5 2
Moving the combination switch lever in
In ‘ON’ position, the glow plug controller sideways direction operates the turn signals:
switches on the glow plugs and glow
indicator lights up. After a few seconds,
Combination Switch Position ‘4’ - Turn signal left
depending on the ambient temperature,
the indicator light only goes off indicating Position ‘5’ - Turn signal right
START
that the engine can be started. Glow plugs
remain on for few seconds and switches off Turn the key further clockwise to start The lever returns to neutral position
automatically. position (spring loaded) to operate starter automatically when the steering wheel is
motor. As soon as the engine starts release returned to straight ahead position.
As a safety feature glow plugs are the ignition key, so that key can come back
automatically switched off after a lapse of to ‘ON’ position and starter motor
certain time if the engine is not started to disengages and glow plug is switched off.
conserve battery. Vehicle is driven in this position. By turning
the ignition key from
In this case to start the engine repeat the ‘ON’ position to ‘ACC’ or ‘LOCK’ position
operation by first going to ‘ACC’ or ‘LOCK’ engine can be stopped.
position.
19
Handling Combination switch
OFF - Position.
Lights are operated by turning the knob of Head lights are also switched ‘ON’, in
combination switch as indicated below: addition to parking lights, number plate
lights and controls backlights.
First notch (P L position)
20
Handling Windshield wiper/washer, Hazard warning switch
The combination switch lever mounted on ‘LO’ - Low speed of To operate the system, pull the switch located
the leftside operates the windshield wipers wiper motor behind the steering wheel. Indicator light will
and washers : come ‘ON’ in instrument cluster and all turn
‘HI’ - High speed of signal lights will flash simultaneously to warn
wiper motor other road users about the hazardous
Position
To operate windshield washer, lift the lever. condition of the vehicle.
‘OFF’ - Wiper motor The windshield washer will remain in
switched ‘OFF’ operation as long as the lever is held in this
position.
‘INT’ - Wiper sweeps
intermittently
21
Handling Roof lamp
Loading Switch
Conditions Position/
Marks
assigned
Unladen + One person 0
person in driver seat
Driver + Co-driver 0
Driver + Co-driver + 0
All the seats farthest
to rear occupied
All the seats occupied 1
Laden (All seats
Headlamp Leveling Switch occupied + Luggage
Roof lamp 1. Lamp off in boot space to achive 2
2. Door control mode Headlamp Leveling Switch (if provided) : permissible load on the
3. Lamp on A motorized headlamp leveling rear axle)
arrangement with the setting knob
Driver + evenly distributed
Roof lamp provided on the dashboard.
load in the boot to obtain 3
As and when required, headlamp leveling permissible load on
This lamp assembly is mounted in the setting is done by rotating the knob to corresponding axle
middle of compartment. Its switch has 3 select one of the levels marked in the switch
positions : (1) OFF, (2) DOOR CONTROL depending upon the loading conditions
(3) ON. of the vehicle.
When the switch is in Door Control position,
lamp will glow as soon as door is opened
and stops glowing after door is closed.
22
Handling Engine compartment light, Bonnet
23
Handling Driving controls
1. Steering Wheel *
2. Instrument Cluster
3. Combination Switch
4. Head Lamp Leveling Switch
5. Steering Lock cum Ignition Switch
6. Bonnet Opening Lever
7. Clutch Pedal
8. Brake Pedal
9. Accelerator Pedal
10. Gear Shift Lever
11. Horn Pad
12. Glove Box
* Four spoke steering wheel for vehicles
with Power Steering
Driving Control
24
Handling Driving controls , Spare wheel
Gear shift lever knob & shifting pattern Parking brake handle : Floor mounted Spare wheel
Gear shift lever ( GBS - 76 gear box ) The parking brake is mounted on floor Spare Wheel
It is floor mounted. The different gear between RH door and driver’s seat.
Spare wheel is mounted on tubular
positions are marked on the knob. The 5th To apply the parking brake, pull lever full up. structure at rear door.
gear, ( an overdrive ) has been provided to To release it, pull the lever up slightly, press
obtain better fuel economy while driving on Wheel spanner provided with the vehicle
the release button and push the lever down.
highways. can be used to loosen and tighten the bolts
Ensure parking brake is released before of the spare wheel mounting.
driving the vehicle.
The spare wheel mounting pin has a hole to
lock the spare wheel with a pad lock.
25
Handling Turbocharger (if fitted)
28
Handling Power steering
Power steering (if fitted) 2. Check for any leakage in the system
and if noticed take corrective action.
Power steering is fitted for lighter steering
effort and easy manoeuvrability. The system 3. Start the engine and steer the vehicle
consists of steering gear box, hydraulic from full left to full right turn 3-4 times.
pump and hydraulic reservoir suitably Add fluid if necessary to maintain the
mounted and connected by piping. Pump level up to the filter top.
drive is through ‘V’ belt from engine. Power
assistance is available during normal 4. With the engine at steady speed check
functioning of the power steering system. for bubble / foaming in the fluid. If
present it indicates that air is getting
sucked into the system.
In case of any failure in hydraulic system,
the steering can be operated Check the suction line / fittings and
mechanically with increased steering correct if necessary.
effort for bringing the vehicle to a repair Power steering fluid dip stick
station. 5. Once the system is bled properly and
free from foaming, there should not be
appreciable change in fluid level in the
Procedure for oil filling and bleeding 1. Fill the reservoir nearly full. Crank the reservoir, when the engine is started /
the power steering system. engine for 10 seconds without, if stop repeatedly. Top up or remove
possible, allowing it to start. If the excess fluid so that the final level is at
(Ensure that the reservoir is totally cleaned engine does start, shut off ‘H’ mark on dipstick.
before starting the work.) immediately.
6. Now the system is ready for driving.
Check and refill the reservoir. Repeat atleast
three times, each time checking and refilling
the reservoir.
29
Handling Power steering
Note
Always use recommended brand of fluid Power steering pump belt drive arrangement
from closed containers. Any dirty fluid
poured in the system will result in damage
to pump/gear.
31
Preparing the vehicle for the drive
Note :
Always use radiator cap only of 1.0
kg / cm2 (14 psi), if required to be
replaced.
Brake fluid container Clutch fluid container Windshield washer fluid container
8. Check level of brake fluid in plastic 9. Check level of clutch fluid in plastic 10. Check level of water in Windshield
container. Top up if necessary. container. Top up if necessary. Do not washer reservoir. Top up with clean
Do not overfill. overfill as this would result in spillage water if required.
during clutch operation.
Use only genuine co-branded brake Use good quality cleaning solvent
fluid. Use only genuine co-branded clutch available in the market in the ratio as
fluid. specified by its manufacturer.
33
Preparing the vehicle for the drive
1
2 2
Gear box oil filler plug Rear axle oil filler plug 1.Transfercase oil level plug 2. Drain plug
11. Level of gear box oil 16. Check and correct tyre inflation 18. Clean transfer case breather
Periodic check gear box oil level. pressure ( with cold tyres ). regularly (4X4 vehicles)
12. Level of rear axle oil
17. Level of transfercase oil (4X4)
Periodically check rear axle oil level. periodically check transfer case oil
level.
13. Check condition of wiper blades,
replace if rubber profile is damaged. Donot use impact wrench to
remove or install level/filling
14. Check level of oil in steering gear box, plug or drain since this will
where applicable.
damage threads in the transfer
15. Check oil level in power steering
case cover.
hydraulic tank, where applicable.
34
Driving, gear shifting, braking
Check
l Low oil pressure indicator light goes
l Coolant level ‘OFF’
l Engine oil level l Battery charging indicator light goes
l Tyre pressure ‘OFF’
l Brake and clutch fluid level l DO NOT CRANK ENGINE WHEN GLOW
PLUG INDICATOR IS ‘ON’
l Doors are firmly closed
l ENSURE THAT PARKING BRAKE IS
Adjust RELEASED (INDICATOR LAMP ‘OFF’)
l Driver seat l VEHICLE IS NOW READY FOR A
l Rear view mirrors DRIVE.
35
Driving instruction Driving, gear shifting, braking
During running - in period Driving Instructions l Engage reverse gear, only when
i.e. first 2,000 km of operation : vehicle is stationary.
DRIVE SAFELY AND JUDICIOUSLY.
Do not exceed the following vehicle l Depress clutch pedal fully before
REMEMBER SAFETY FIRST.
speeds: engaging the reverse gear. Wait for a
l Depress clutch pedal fully before few seconds then engage the gear. If
Gear NA TC
shifting gears. This will ensure longer gear shifting does not occur, then
First - 25 - 30 synchro cone life. release the clutch pedal, once again
Second 15 45 15 55
l For smooth starting of vehicle press the clutch pedal and engage
Third 25 75 25 90 without jerks, synchronise release of the reverse gear.
Fourth 30 100 35 120 clutch pedal with pressing of
Fifth 40 Max 45 Max accelerator pedal.
speed speed l Start the vehicle in first gear only.
l Avoid rapid acceleration and l Change gear at appropriate speed
prolonged high speed running of the and do not lug the engine by too
engine. early shifting to higher gear at low
speeds.
l Avoid sudden braking.
l Retighten wheel nuts to 12-15 mkg. Recommended speeds for gear changes
torque after first 100 km of running Gear Speed in km/hr.
of a new vehicle and after every wheel 1st to 2nd 20
change.
2nd to 3rd 35
3rd to 4th 60
4th to 5th 80
36
Driving instruction Driving, gear shifting, braking
37
Starting & Driving Driving Safety
38
Starting & Driving Driving Safety
Side indicator/Hazard warning when subjected to extreme conditions, triangle must be at least 50 meters
such as high speed, high load and high behind the car in the same lane of traffic.
Ensure that all side indicators/hazard
outside temperature. Do not use worn
warning lights are always in working
or bald tyres on front wheels. Increase the distance to 150 meters on a
condition and they are used when
highway or if a bad/hill top obscures the
required.
view
First Aid Kit :
Horn First aid kit is provided in your car. This is
for use in case of minor injuries. It is to be
Ensure the horn is working properly. Hort
regularly checked for any disintegration
provides safety to other road users by
and should be updated with regularly.
alerting your presence.
1) Engine sump drain plug 2) Oil filter Before filling in fresh oil in the engine, refill
A) Engine oil filling neck
the sump drain plug using a new sealing
B) Engine oil deep stick
Changing engine oil washer. Tighten drain plug to 4 mkg
torque.
Change engine oil in the crankcase at
recommended interval. Engine oil should be Fill in specified quantity of fresh engine
drained while it is hot. Unscrew engine oil in the engine crankcase. Start engine
sump drain plug and allow oil to drain out and run for a few minutes. Stop the engine
fully. and re-check oil level after approx. 20
minutes. Top up if oil level is less than
Changing oil filter midway between upper and lower marks
on the dipstick.
Unscrew and remove engine oil filter with
the help of special tool, if necessary. Engine * Fill the new oil filter with fresh engine
oil filter is a spin-on type and cannot be oil.
40
Vehicle maintenance Air Filter
41
Vehicle maintenance Fuel system
Changing fuel filter element Priming fuel system Fan belt tension checking
Changing fuel filter element Priming fuel system Fan belt tension adjustment
Unscrew drain plug and drain fuel from Unscrew fuel lift pump plunger knob. Pull Check the conditions of belts on the
fuel bowls. Remove fuel filter with top cover and push it 10-14 times (30-40 times if fuel engine Examine the edge of the belt for
from mounting bracket. tank has been completely emptied). cracks or fraying.
Unscrew fuel filter bowl mounting bolt and Tighten fuel lift pump plunger knob. Start
replace bowl with element. engine and check for smooth running. Check the tension of the belt by pushing
it with your thumb. The belts shuld have
Replace fuel tank side filter element after If erratic fuel supply is still felt, check for deflection of 8 to 10 mm.
every 8,000 km and FIP side filter element air suction in fuel pipeline from fuel tank
after every 16,000 km. to FIP and rectify. If the belt tension is not proper, get it
Assemble fuel filter and fit it on mounting attended at the nearest authorised service
bracket. outlet.
42
Vehicle maintenance Bleeding clutch system
a. Ensure that fluid level in clutch fluid c. Pump clutch pedal twice or thrice
container is upto maximum level. slowly throughout its stroke and by
holding clutch pedal in depressed
condition, loosen bleed screw on slave
43
Vehicle maintenance Cooling system
44
Vehicle maintenance Brakes
Brake system Stopping the vehicle after loss of the brake If the brake pedal becomes spongy, this may
fluid in one circuit will require more pedal be due to air in the hydraulic brake system.
The dual circuit service brake system pressure and pedal travel than normal. Also
operated through the tandem master Whenever any repair / overhaul or
stopping distance will be longer.
cylinder is designed such that one circuit disconnecting of any brake pipe is done,
will continue to provide braking action if the Service brakes are vacuum assisted. In case or level of brake fluid has fallen so low
other circuit fails. This vehicle is fitted with of failure of vacuum, the vehicle can still be that air has been drawn into master
disc brakes at front and drum brakes at rear. stooped, however with a higher effort. cylinder, it is necessary to bleed the
system to remove the trapped air.
45
Vehicle maintenance Brakes
4. Always use recommended brand of Place the gear shift lever in neutral
brake fluid. position.
5. As brake fluid absorbs moisture from 3. Loosen the adjusting screws of both
the atmosphere, we recommend brake shoes so that the wheel is
changing of brake fluid in the system absolutely free to rotate.
annually. 4. Now turn the adjusting screw of one
6. Take care to see that the brake fluid is of the brake shoes till brake begins to
not spilled on the paint work. bind - i.e. the brake shoe touches the
brake drum.
Brake adjustment
Now turn the adjusting screw in the
The front wheels are fitted with disc brakes. opposite direction just upto the point
These are self adjusting, therefore need no when wheel can be rotated freely.
adjustment. The rear wheel brakes can,
however be adjusted. Due to wear on the Adjust the other brake shoe of the
brake shoe linings the clearance between same wheel in the manner described Adjusting the rear brakes
rear brake shoe linings and the brake drum above. 1. Adjusting screw
increases. This must be adjusted after every 5. Adjust both brake shoes of the other 2&3 To increase or reduce the
4,000 km if required : wheel as described above. clearance between brake
After installing new rear brake shoes or 6. Operate brake pedal twice/thrice, shoe and drum
linings, check and adjust brakes after 500 simultaneously rotating both rear
km run. wheel, for checking proper application
For adjusting rear wheel brake shoes and release of brakes.
proceed as follows : 7. Check and readjust parking brake, if
1. Put chocks on front wheels. necessary.
2. Jack up rear axle. Release parking 8. Remove front wheel chocks.
brake. Ensure that parking brake cable 9. Test drive vehicle for proper brake
is slack. function.
47
Vehicle maintenance Parking brake
48
Vehicle maintenance Wheels and tyres
Wheels and tyres Jack should be placed below chassis long Recommended tyre pressures :
Always use only recommended size wheel member behind front wheel for changing ( with cold tyres )
rims and tyres. Use of rims and tyres not front tyres and before rear wheel as shown.
For 195 R15 8PR LT Radial ply Tyres
recommended by us may have adverse
effect on vehicle safety and further more Wheel alignment At Unladen Laden
could infringe on motor vehicle regulations. If uneven tyre wear is noticed, get the At rated GVW
vehicle examined and attended by Tata Front 26 psi 26 psi
Wheel change Motors authorised workshop. Periodically (1.8 bar) (1.8 bar)
When changing wheels use the jack check and maintain correct tyre pressure
Rear 26 psi 54 psi
provided with the vehicle. to obtain longer tyre life.
(1.8 bar) (3.8 bar)
49
Vehicle maintenance Wheels and tyres
For 215/70 R15C Radial ply Tyres Do not oil wheel bolts and nuts. during removal of tyres. Check the balance
weight prior to removal of tyre, if found
At Unladen Laden Wipe off any adhering oil on bolts/nuts
loose, mark its location on the rim and refit
(Rated GVW) Tightening torque of wheel nuts :12-15 properly.
Front 44psi 44psi mkg.
Replacing a tyre / rim.
(3.0 bar) (3.0 bar) Retighten wheel nuts after 100 km of every
When the tyre or rim is changed the wheel
Rear 44 psi 46 psi wheel change.
should be properly balanced on a machine
(3.0 bar) (3.2 bar) New tyres do not give maximum grip after inflating to the specified value as per
straightway and should therefore be run- the following norms.
in at moderate speed for the first 100 km.
For LT 215/75 R15100/97 Tyres 1. Permissible imbalance for tyre with
This will help to make the tyres last long.
rim = 250 gm-cm max.
At Unladen Laden To avoid damage to tyres and wheels, drive
(Rated GVW) slowly over speed breakers/bumps / rough 2. Permissible balance weight for tyre
roads. with rim = 140 gm max.
Front 35 psi 35 psi
(2.4 bar) (2.4 bar) Wheel balancing 3. Relocate the tyre if the weight
required to balance is more than 140
Rear 35 psi 50 psi Wheels of your vehicle are balanced. The gm.
(2.4 bar) (3.5 bar) same should be maintained when
repairing a tyre or tube and replacing the 4. Balance weights are available from 10
Check tyres for damage from time to time tyre or rim. gm to 90 gm in steps of 10 gm and
and remove any foreign bodies (nails/ from 80 to 140 gm in steps of 20 gm.
Repairing a tyre / tube
stones, metal chips etc.) embedded in 5. Do not use more than one balance
treads. Mark suitably the tyre position (If original
weight on side.
colour dot mark is not visible) with respect
While fitting wheels on the vehicle make to valve stem hole to ensure that tyre is
sure that wheel bolts are free from dust, refitted in original location. Ensure that the
scratches, dirt, dents, etc. balancing weights are not disturbed
50
Vehicle maintenance Wheels and tyres, Electrical system
SPARE
FRONT
123
REAR
123
123
123 The head lamps must be properly aligned
123
12345678 1234567 in order to obtain maximum road safety,
12345678 1234567
12345678 1234567 proper road illumination and reduced glare
to oncoming traffic.
12345678 12345678
12345678 12345678
12345678 12345678 It is recommended to check alignment of
123
123
123 headlamp beams periodically and
123 SPARE
FRONT
REAR
746
reason headlamps should not be
realigned.
52
Vehicle maintenance Electrical system
53
Vehicle maintenance Electrical system
Bulb specifications
Description Location Type Specifications Qty.
Headlights Headlamp Halogen 12V 60 / 55 W 2
Turn indicator light Front D 12 /1 12V 21 W 2
Tail lamp D 12 /1 12V 21 W 2
Stop lights Tail lamp D 12 /1 12V 21 W 2
Parking lights Head lamp M 12 /4 12 V 4W 2
Tail Lamp M 12 /6 12 V 10W 2
Registration number plate lights Near number light M 12 /6 12 V 10W 2
Reverse indicator lights Tail lamp D 12 /1 12 V 21W 2
Warning and illumination lamps Instrument Cluster
Head light (Main beam) “ BA 9S 12 V 2W 1
Turn indicators “ BA 9S 12 V 2W 2
Battery charging indicator “ BA 9S 12 V 2W 1
Glow plug indicator “ BA 9S 12 V 2W 1
Low oil pressure indicator “ BA 9S 12 V 2W 1
Brake fail/Parking brake indicator “ BA 9S 12 V 2W 1
Gauge illumination lights “ BA 9S 12 V 3.4W 4
Check engine indicator “ BA 95 12 V 2W 1
(on NA BS - III only)
Roof lamp Cab roof K 12 V 10 W 1
Engine compartment light Engine compartment D12/1 12V 21W 1
54
Vehicle maintenance Electrical system
Fuse box Fuse box location Fuse box location - Below glove box
1. Fuse link - Red -10 Amps Flasher with short circuit protection
Fuses 2. Fuse link - Blue -15 Amps
3. Fuse link - light brown -5 Amps If flasher circuit is short circuited or
In order to protect the cable harness and 4. Fuse link - Yellow -20 Amps overloaded (more than 110 W) flasher will
other equipments from damage in case of 5. Fuse link - White -25 Amps shut off. It can be reset by momentarily
short circuit and overloads, fuse links are 6. Fuse link - Green -30 Amps centering the indicator arm of combi
provided in the fuse box. 7. Fuse link - Orange -40 Amps
switch.
While fitting fuse box cover ensure that
In case of a fault in the electrical system cover knob rests in the slot provided inside If flasher is shutting off or fuse is blowing
check the respective fuse. The particulars of the fuse box. off repeatedly the flasher circuit should
the consumers served by each fuse and Spare fuse links are provided inside the be checked for short circuit.
amperage are printed on the fuse box cover. fuse box.
The fuse link can be identified for amperage Check the flasher separately for its
Always use fuses of correct rating. Do not functioning.
by color codes :
use wire in place of fuse.
55
Vehicle maintenance Care and cleaning of vehicle
Care and cleaning of the vehicle ● Upholstery ● Rust on body due to deteriorated paint
film.
Prepare a solution of soap or neutral
Caution ● Rust due to scratches.
detergent mixed with warm water.
Apply solution with a sponge or soft ● Body rust due to contact with damp
When cleaning the interior / exterior of the
cloth and let it soak for a few minutes to dirt trapped in the body.
vehicle, NEVER USE volatile solvents such as
thinner, petrol or any other cleaning materials loosen dirt. Wipe the surface with a
such as bleaches or strong household clean, damp cloth to remove dirt and Therefore it is important that your vehicle
detergents.These materials may be poisonous soap solution. If some dirt still remains is always kept clean and free from dirt in
or flammable and their improper use may on the surface, repeat the procedure. order to maintain the paint in a good
cause personal injury or damage to the condition and to protect the entire body
● Carpets
vehicle. against corrosion.
Remove dirt as much as possible by
using a vacuum cleaner. Rub the stained Washing
Cleaning of vehicle interior area with clean cloth made damp with
● Floor mat soap to absorb the stain and remove the When washing the vehicle, follow the
soap. Repeat until the stain is removed. instructions given below.
Dirt can be removed from the mat with
water and mild soap. Use a brush to help You can use commercially available ● Flush underside of body and wheel
loosen dirt. After dirt is loosened, wash carpet cleaner. In this case, carefully housing with pressurised water to
the mat thoroughly with water and dry follow the manufacturer’s instructions remove mud and debris. Use plenty of
it in the shade. and precautions. water to loosen and remove dirt.
● Seat belt Cleaning exterior of the vehicle ● Remove dirt and mud from body
exterior with running water. Use a soft
Clean the seat belts with a mild soap Dirt or any other foreign material on the sponge, brush with water. Do not use
and water only. No bleach or dye painted surface may result in : hard material which can scratch the
should be used as this may weaken
● Faded paint. paint.
the belt fabric. The belts should be
allowed to dry in the shade.
56
Vehicle maintenance Care and cleaning of vehicle
● Wash the exterior with water, lightly Washing the vehicle exterior avoid corrosion of your vehicle by
rubbing with sponge or soft cloth. The performing some simple periodic
sponge or cloth should frequently After washing the vehicle, waxing and pol- maintenance :
soaked in water. ishing are recommended to protect and
beautify the paint. ● Repair chips and scratches in the paint
as soon as you discover them.
Caution ● Use only good quality waxes and
polishes. ● Inspect and clean the drain holes in
When using commercial wash products the bottom of the doors and body.
precautions specified by the manufacturer ● When using waxes and polishes, the
precautions specified by the ● Check the floor coverings for
should be observed. Do not use strong dampness. Carpets and floor mats
household detergents or soaps. manufacturers should be observed.
remain damp for a long time, especially
● Once dirt has been completely ● Chrome plated parts should also be in winter. This can eventually cause the
removed, wash off with running hose waxed. floor panels to corrode.
water. Protection against corrosion ● Use a high pressure spray to clean the
● After rinsing, wipe the body lightly underside of your vehicle. This is
The following cause corrosion : especially important in areas near
with wet chamois or cloth and allow
the body to dry it in the shade. chemical and other industries.
● Moisture trapped in body cavities.
● Have corrosion preventive coatings
Warning ● Dirt and salts collected in hollows on done on the underside of your vehicle
the underside of the vehicle. using Tata Motors co-branded anti
After washing, check that the brakes are dry. If
Removal of paint and protective corrosive treatment.
brakes are not dry,dry them by gently,repeatedly ●
applying while driving at low speeds. coatings from the exterior and
underside of the vehicle.
57
Fuel, lubricants, coolants Fuel, lubricants
Fuel Lubricants
High speed diesel conforming to IS 1460 or DIN 51601 or equivalent
Recommended lubricants conform to the following specifications:
is recommended to be used as fuel.
At very low temperature fluidity of diesel may become insufficient 1. SAE 15W40 to API CF4+ - Engine oil
due to paraffin separation. It is therefore, necessary to mix 2. ATF Type A or 80w90 with
supplementary fuel with summer or winter grade diesel. The
7% anglemol - Gearbox oils
supplementary fuel to be used is kerosene or aviation turbine fuel.
3. APIGL 5 - Rear axle and mechanical
Ratios for mixing of supplementary fuel and diesel are shown in
steering gear box oils
table:
Please use only recommended brands for good performance.
Ambient Percentage
temperature upto Summer Supplementary
0
C grade diesel fuel The oil change periods recommended in maintenance schedule
should be adhered to.
upto 0 100 0
0 to -10 70 30 Use of reclaimed oil is not recommended.
-10 to -15 50 50
Engine oil
Ambient Percentage Recommended grades of engine oil conforming to SAE API CF4+
specifications and range of ambient temperature at which these
temperature upto Winter Supplementary
0
can be used are given below :
C grade diesel fuel
upto -15 100 0 Ambient temperature 0C Engine oil grade
-15 to -20 70 30
-10 and above SAE 15W/40
-20 and below 50 50
-20 TO 0 SAE 10W/30
Care should be taken that diesel and supplementary fuel are
-10 and below SAE 5W/20
thoroughly mixed before filling.
58
Fuel, lubricants, coolants Lubricants
59
Recommended oils, lubricants and filling capacities
PLEASE USE ONLY GENUINE ENGINE OILS, COLLANTS, LUBRICANTS, ANTI-RUST & SOUND DEADENING COATS,
WIND SCHREEN SEALANT, ADHESIVES & FUEL ADDITIVES BRANDED BY TATA MOTORS FOR OPTIMUM
PERFORMANCE OF YOUR TATA SUME SE+/TOURIN/CARRIER
ITEM COMPANY BRAND QTY
ENGINE OIL CASTROL Castrol GTD 15 W/40 6.8 Litres (NA engine)
HPCL HP Milcy Power 15 W/40 7.7 Litres (TC engine)
COOLANT SUNSTAR Golden Cruiser Premium 1400 M
ANCHEMCO Frostox SFD 12 Approx. 9-10 Litres
HPCL HP Thanda Raja P
GEAR BOX (G-76) HPCL HP-ATF 80 W 90 1.6 Litres
CASTROL Castrol Transpower TQ
STEERING OIL HPCL HP-ATF 1.4 Litres
CASTROL Castrol Transpower TQ
REAR AXLE / FRONT AXLE HPCL HP Gear Oil XP 85W 140 GLS 2.2 Litres for Dana Axle
CASTROL Castrol Extreme Pressure 85W 140
BRAKE FLUID HPCL HP Super Duty Brake Fluid DOT-3 As required
CASTROL Castrol Universal Brake Fluid DOT-3
AXLE / HUB GREASE CASTROL Castrol AP2 grease As required
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*
* Add to Diesel as per the dosage recommended by M/s IFTEX
# For TATA MOTORS Rear Axle - 1.9 Litres.
60
Technical specifications Engine
Engine
61
Technical specifications Clutch, Gear box, Transfer case, Axles
62
Technical specifications Axles, Steering, Brakes, Frames, Suspension
Brakes Frame
Service brakes : Vacuum assisted Type : Ladder type cranked frame
independent hydraulic with boxed section long
brakes on front and rear members and welded cross
through tandem master members
cylinder. Vacuum pump Depth : 110 mm ( maximum )
mounted on alternator. Width : 60 mm
Front : 262 dia. disc brake ( 4 x 2 ) Suspension
271 dia disc brake ( 4 x 4 )
Rear : 282 dia. drum brake Front ( 4 x 2 ) : Double wishbone type with
Parking brake : Cable operated mechanical coil springs.
linkages acting on rear Rear : Semi - elliptical leaf springs.
wheels. Shock Absorber : Hydraulic double acting
telescopic type at front and
LCRV (if fitted) : Load conscious pressure rear.
reducing valve and ‘O’ dead Antiroll bar : At both front and rear.
stroke booster provided
63
Technical specifications Wheels & tyres, Fuel tank, Electrical, Performance
Max gradeability
at rated GVW 24 % 28% 26% 25%
64
Technical specifications Chassis dimensions and Weights
65
Special instructions
1. The vehicle has been built to give you thousands of kilometers 4. These services can be satisfactorily performed only by one of
of economical and trouble-free performance. This is however, our Authorised Dealers’/TASC’s Workshops in India, irrespective
possible only if this vehicle is systematically maintained and of the dealer who sold the vehicle, provided the vehicle is sent
operated strictly according to the instructions contained in this to them at the kilometerages specified and that this service book
book. is produced before them.
The vehicle is entitled to pre-delivery service with free labour.
2. This chapter contains charts showing lubrication points and After the delivery of the vehicle, in the subsequent ‘4 free services’
the service schedule. labour would be free but materials, if any would be charged for.
● PDI - Pre Delivery Inspection All services, other than the above, must be paid for both for
● Daily materials and labours; material at prevailing rates for the quantity
consumed and labour at our scheduled rates available with our
● 5,000 km. Service at 5,000 - 5,500 km repeating
Authorised Dealers/TASCs/TASPs.
at every 10,000 km.
● 10,000 km. Service at 10,000 - 10,500 km repeating 5. In the event of a schedule Service not performed within specified
kilometers the respective coupons will be detached by the
at every 20,000 km.
Authorised Dealer’s Workshop when the vehicle is sent to them
● 20,000 km. Service at 20,000 - 20,500 km repeating next. Should a major service have been missed, all the works
at every 40,000 km. listed for such service must be performed when the vehicle is
● 40,000 km. Service at 40,000 - 40,500 km repeating taken next to one of our Authorised Dealer’s/ TASC’s Workshop.
at every 40,000 km. 6. It is an important condition of our sales policy that no warranty
claims shall be entertained by us unless all services upto time of
3. Besides the service schedule chart detailing the service
the claim arising have been performed on the vehicle by one of
operations to be performed Service Coupons (perforated) are
our Authorised Dealer’s / TASC’s/TASP’s Workshops.
incorporated on two sheets. These coupons should be
detached and sent to Customer Support, Passenger Car Division, Failure to carry out the services listed in this book can cause
Tata Motors, Pune - 411 018 by the servicing dealer after the considerable damage to the vehicle and inconvenience to you.
service is performed. The selling dealer should fill up details of It is, therefore, in your own interest to take your vehicle to one
chassis particulars on the inside cover page. of our Authorised Dealer’s, TASC’s, TASP’s, Workshop for servicing
66
Special instructions
67
Lubrication points
68
Record of service performed Chassis No. .........................................
Recommended Odometer Repair Servicing Dealer’s Recommended Odometer Repair Servicing Dealer’s
Service Date reading Order Signature and Service Date reading Order Signature and
km. No. Stamp km. No. Stamp
At km. At km.
45,000
PDI * 50,000
5,000 * 55,000
10,000 * 60,000
15,000 * 65,000
20,000 * 70,000
25,000 75,000
30,000 80,000
35,000 85,000
40,000 90,000
Recommended Odometer Repair Servicing Dealer’s Recommended Odometer Repair Servicing Dealer’s
Service Date reading Order Signature and Service Date reading Order Signature and
km. No. Stamp km. No. Stamp
At km. At km.
95,000 1,45,000
1,00,000 1,50,000
1,05,000 1,55,000
1,10,000 1,60,000
1,15,000 1,65,000
1,20,000 1,70,000
1,25,000 1,75,000
1,30,000 1,80,000
1,35,000 1,85,000
1,40,000 1,90,000
70
Record of repairs carried out Chassis No. .........................................
Date Odometer Repair Particulars of Repair Servicing Dealer’s Signature & Stamp
reading (km) Order No.
71
Record of repairs carried out Chassis No. .........................................
Date Odometer Repair Particulars of Repair Servicing Dealer’s Signature & Stamp
reading (km) Order No.
72
Lubrication & Maintenance Service Schedule
1,00,000
20,000
30,000
40,000
60,000
10,000
35,000
70,000
55,000
15,000
25,000
95,000
45,000
50,000
65,000
80,000
85,000
90,000
75,000
5,000
SR. FREQUENCY
OPERATION
No. IN km
GENERAL
1. Wash the vehicle 5,000 •• •• •• •• • • •• • • • • • • • •
DIESEL NA ENGINE
2. Clean air cleaner filter element, change if red band appears on service indicator, even after cleaning 5,000 •• •• •• •• • • •• • • • • • • • •
3. Change coolant in cooling system 50,000 or two
years which
ever is earlier
• •
4. Change engine oil and filter cartridge At every 7500 Kms
5. Change fuel filter element (tank side) 10,000 •
• • • • • • • • •
6. Change both fuel filter elements 20,000 • • • • •
7. Drain water from Fuel filter 5,000 •• •• •• •• • • •• • • • • • • • •
8. Check timing belt, adjust tension if necessary, replace if defective 50,000 •
9. Replace timing belt 1,00,000 •
10. Check fan belt, adjust tension if necessary, replace if defective 10,000 • • • • • • • • • •
11. Replace fan belt 40,000 • •
DIESEL TURBO ENGINE (If fitted)
12. Clean air cleaner filter element, change if red band appears on service indicator, even after cleaning. 5,000 •• •• •• •• • • •• • • • • • • • •
13. Replace Air Filter element at 40,000 km in clean condition or at 25,000 km in dusty condition 40,000 • •
14. Change coolant in cooling system 50,000 or two
years which
ever is earlier
• •
15. Change engine oil and filter cartridge 10,000 • • • • • • • • • •
16. Change fuel filter element (tank side) 10,000 • • • • • • • • • •
17. Change both fuel filter elements 20,000 • • • • •
18. Drain water from Fuel filter 5,000 •• •• •• • • • • • • • • • • • • • •
19. Check timing belt, adjust tension if necessary, if replace if defective 50,000 •
73
Lubrication & Maintenance Service Schedule
1,00,000
20,000
30,000
40,000
60,000
10,000
35,000
70,000
55,000
15,000
25,000
95,000
45,000
50,000
65,000
80,000
85,000
90,000
75,000
5,000
SR. FREQUENCY
OPERATION
No. IN km
1,00,000
20,000
30,000
40,000
60,000
10,000
35,000
70,000
55,000
15,000
25,000
95,000
45,000
50,000
65,000
80,000
85,000
90,000
75,000
5,000
SR. FREQUENCY
OPERATION
No. IN km
40. Overhaul the following brake components and change the brake fluid in the system
1) Tandem Master Cylinder, 2) Front Caliper, 3) Rear Wheel Cylinders, 4) Clutch Master
40,000 • •
Cylinder & Slave Cylinder
ELECTRICALS
41. Check electrolyte level in battery, add distilled water if necessary 5,000 •• •• •• •• • • •• • • • • • • • •
42. Check Specific gravity of electrolyte and the charge of battery. 40,000 • •
43. Check headlamp focussing 20,000 • • • • •
BODY
44. Apply grease on door latches, door lock striker, bonnet opening lever and lock plate
AIR CONDITIONING SYSTEM (if fitted)
10,000 • • • • • • • • • •
45. Check for leak of gas / oil from pipes, joints, compressor shaft seal & cylinder head. 10,000 • • • • • • • • • •
46. Clean condensor with high pressure water 5,000 •• •• •• •• • • •• • • • • • • • •
47. Check fan operation for proper air flow 5,000 •• •• •• •• • • •• • • • • • • • •
48. Check compressor clutch operation 10,000 • • • • • • • • • •
49. Check system pressure with gauges 20,000 • • • • •
50. Check evapourate from its face to remove dust, foreign objects etc.
WHEELS & TYRES
30,000 • • •
51. Tyre rotation (check tyre pressure) 10,000 • • • • • • • • • •
75
ABBREVIATIONS
A E I
Abbreviations 76 EGR 28 Ignition Switch 18
Aggregate Numbering 6 Engine Air Filter 41 Indicators 17
Automatic hub lock 36A Engine Compartment Light 23 Instrument Cluster 16
Engine Oil Change 40 J
B Engine Oil Filter Change 40 Jack 15
Bonnet Opening & Closing 23 Environmental Protection vi
Brakes System 45 K
Branded Lubricants 60 F Key 8
Bulb Specifications 54 Fan Belt Tension 42
Four wheel drive 36B L
C Fuel Economy 37 Light’s 20
Cargo Body (Carrier) 14 Fuel System 42 Limited slip differential 36A
Catalytic converter 28 Fuel 58 Lubricants 58
Clutch System 43 Fuses 55 Lubrication Points 68
Combination Switch 19
Coolants 59 G P
Cooling Systems 44 Guages 17 Parking Brake 25
Gear Shifting 36 Parking Brake Adjustment 48
D Gear Shifting Lever 25 Power Steering 29
Do’s 3 Preparing the vehicle for the drive 31
Don’ts 5 H
Driving Controls 24 Hazard Warning Switch 21 R
Driving instructions 36 Head Lamp Adjustment 51 Rear View Mirror 9
Driving Safety 38 Head Lamp Bulb Replacement 53 Record of service performed 69
Head Lamps 51 Roof lamp 22
Head Lamp Leveling Switch 22
77
ALPHAB ETICAL INDEX
S
Seat Belt 13
Seats 9
Service Schedule 73
Spare Wheel 25
Special Instructions 66
Steering Lock cum ignition switch 18
Sun Visors 9
T
Technical Specifications 61
Tools 15
Turbocharger 26
Tyre Pressure 49
Tyre Rotation 51
V
Vehicle Care 56
W
Warranty- Terms & Conditions 1
Wheel alignment 49
Wheel Balancing 50
Wheel Change 49
Wheels & Tyres 49
Window Winding 8
Windshield Wiper / Washer 21
78
Chassis No. ...................................... At the time of delivery of vehicle, please ensure that
Engine No. .......................................
Gear Box No. ...................................
2 pre-delivery inspection has been carried out as per details
given in the SERVICE SCHEDULE.
PDI
At 10,000-10,500 km FREE Chassis No. ...................................... FREE
please bring your vehicle for this service as per details Engine No. .......................................
LABOUR LABOUR
given in the SERVICE SCHEDULE. Gear Box No. ...................................
TATASUMO SE+/Tourin/Carrier
Dealer's / Authorised Service Centre's TATASUMO SE+/Tourin/Carrier
Dealer's / Authorised Service Centre's
Stamp & Signature ......................................................................... Stamp & Signature .........................................................................
Chassis No. ......................................