DIRECTORATE GENERAL BORDER ROADS

GENERAL MAINTENANCE INSTRUCTION : 207

ON
TATA 407 TRUCK
1. INTRODUCTION

Tata 407 Truck is a 1 Ton Army Rating Vehicle, with short wheel base. This
vehicle is ideal for use on hill roads.

The 407 vehicle is highly reliable and economical provided it is systematically

maintained in accordance with the laid down instructions.

2. ACTION BY

a) USER UNIT

i) Carry out the maintenance of the vehicle fag complying with the
instructions as laid down
ii) Enter the maintenance task in the log book

b) FIELD WKSP (GREF)

i) To check the records of maintenance and lubrication of the vehicle

in the log book during its inspection and enter repair record if
carried out, as per maintenance schedule given in the instruction.

ii) Advise user unit in respect of any discrepancy/short comings

noticed.

3. DETAILS

a) Routine service & maintenance check - Apxx ‘A’

driving instructions and cautions during running in period.

b) Recommended lubricants, coolants and their - Appx ‘B’

aggregate filling capacities.

c) Technical specifications - Appx ‘C’

4. please ack receipt.

Sdxxxxxxx
(Hans Raj)
SE (E&M), SG
Director (Tech)
Dated: 13 Aug 1999 For Dir Gen Border Roads

Distribution :-

Normal
 Appendix ‘A’ to GMI No. 207

ROUTINE SERVICE & MAINTENANCE VEHICLE,

DRIVING INSTRUCTIONS AND CAUTION DURING
RUNNING IN PERIOD

1. ROUTINE SERVICE & MAINTENANCE

1. Daily

(i) Check engine oil level in sump. If necessary top up with recommended
brand of oil

(ii) Check water level in radiator. Top up if necessary with clean water.
Secure radiator cap.

(iii) Check for oil leakage, rectify if necessary

(iv) Check fuel level in tank and secure fuel tank cap. Rectify fuel leakage if
any.

(v) Check tyre inflation pressure

(vi) Check brakes

(vii) Check functioning of lights, gear, wiper, blinkers, switches and gauges.

2. After every 1,000 km of operation

(i) Check engine oil level in sump. If necessary, top up with recommended
brand of oil

(ii) Check water level in radiator. Top up if necessary with water and secure
radiator cap.

(iii) Check and rectify leakage of oil, fuel and water if found/noticed.

(iv) Lubricate with oilcan, Accelerator, linkages and brake cable, door hinges,
clutch pedal pivot pins

(v) Grease with grease gun

(a) Propeller shaft ‘U’ joints (3), Propeller shaft, Propeller shaft center
bearing (1)

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(b) King pins (4), Tie rod ball joints (2), Drag link ball joints (2)

(c) Front spring pins (6)

(d) Rear spring pins (6)

(vi) Check level of brake fluid in plastic containers for brake and clutch. Top
up if necessary.

(vii) Check condition of oil level in air cleaner bowl. Top up if necessary.

(viii) Check and tighten if necessary ‘U’ bolts of front and near springs.

(ix) Check wheel nuts and tighten if necessary.

(x) Check battery mountings, clean battery posts and terminals, tighten
terminals and gear Vaseline/petroleum jelly

Note: - In case any abnormal conditions are observed during driving, stop the
vehicle and report for assistance to the nearest Tata Diesel Vehicle Dealer.

3. Driving Instructions

(i) Ensure your vehicle in road worthy condition before you drive.

(ii) Especially check the steering system, tyres, brakes and clutch.

(iii) Check parking brake

(iv) Check smooth starting of vehicle without jerks, Pully, clutch pedal

(v) Always start the vehicle in first gear.

(vi) Always change gears at appropriate speeds and don’t lup the engine by top
early high gear changes at low speeds.

(vii) Always maintain steady speed, avoid quick acceleration and sudden
braking. High speed driving saves little time out increase fuel and oil
consumption. Therefore this vehicle suggest to drive in the fifth gear at a steady
speed of about 0 to 60km ph. Optimum fuel economy is achieved at this speed.

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4. CAUTION DURING RUNNING IN PERIOD

During the first 2000 Km observe the following speed condition limits: -

(i) The speed of this vehicle not more than 60 km ph into gear and
correspondingly lesser in lower gears.

(ii) The gross vehicle weight should not exceed 3.5 tones

(iii) Avoid panic braking during first 500 km. Drive in lower gear when
negotiating stage down gradient, thus avoiding excessive braking and brake
overheating. Brake application should be gradual to avoid fast wear of brake
linings, brake drums and tyres.
 Appendix –‘C’ to GMI No.207

TECHNICAL SPECIFICATIONS DATA

Model : TATA 497 SP

Type : high speed, water cooled, naturally aspirated,

high pressure direct injection diesel engine with dry
liners.

No of cylinders : 4 in line

Bore/Stroke : 97/100 mm

Capacity : 2356 rpm

Maximum engine output : 600 rpm

Maximum operating speed : 3500 rpm

Idling speed : 600 rpm

Maximum : 16.0 mkg (157 km) at 2200 rpm

Firing order (From F.W end) : 1-3-4-2

Compression Ratio : 17:1

Compression pressure at 150–200rpm: Atleast 20 bar

Maximum permissible compression : 1.5 bar

pressure between any two cylinder

Air filter : Oil bath type

Oil filter : Full flow paper type

Fuel filter : Single stage find filteration

Fuel injection pump : Inline type – MICS

Governor : Centrifugal type variable speed RSV

Fuel injection begins : 15 degree before TDC

Timing : Automatic advance

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Opening pressure of nozzles

(a) New nozzles : 200 + 10 bar

(b) Used nozzles : 180 bar at least

Maximum permissible variation in injection : 5 bar

nozzle pressure

Inlet valve clearance : 0.2 0 mm Cold or moderately warm engine,

Exhaust valve clearance : 0.30 mm (Cooling system temp max 50 0C)

Weight of Engine : 270 Kg (Dry)

Cooling water temperature : 85 0 C to 95 0 C

Cooling system pressure : 0.5 bar

Radiator frontal area : 2533 Cm2

Maximum oil pressure (New engine) : 5.2 +- 0.5 bar

Min oil pressure for used engine : 2.5 bar at Max speed 0.5 bar at idling speed

Clutch

Model : TATA 240 diaphragm type, Dry friction

type single plate

Outside diameter of clutch facing : 240 mm

Friction area (both sides) : 527 Sq. cm (approx)

Thickness of facing 4.6 mm Pressure plate side 3.4 mm

Fly wheel side

Clutch actuation : Hydraulic

Gear Box

Model : TATA GBS –18 gear box, synchromesh on

all forward gears and sliding on reverse gear

No of gears : 5 forward and 1 reverse

Gear ratios : Ist 6.01:1

2nd 3.46 : 1

3rd 1.97 : 1

4th 1.37 : 1

5th 1.00 : 1

Reverse 5.69 : 1 …….P/3

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Rear Axle

Model : TATA 407 Rear Axle

Type : Single speed hypoid gears, fully floating

axle shaft

Ratio : 4.525:1(37/8)

Front axle : Forged 1 beam, reverse elliot type

Steering : Mannual steering constant ratio

recalculating ball and nut type with
universal joints.

Ratio : 22.5 : 1

Steering wheel diameter : 425 mm

Parking Brake : Cable operated, mechanical brake acting

on rear wheels only

Service brake : Vaccum assisted hydraulic, duel circuit

brake with tandem master cylinder

Suspension

Type :semi-elliptical multi-leaf springs at front

and rear

Wheel Alignment data

Toe in (measured on wheel rim) : 0 to 3 mm

Caster : 2 0 – 30 0 (+ ve)

Camber : 1 0 + ve

King pin inclination : 9 0 – 30 ’ +- 10

Wheel lock angle : 41 0 +- 1 0

Electric system

System voltage : 12 V, - ve warth

Alternator capacity : 12V/38 Amp

Battery : 1 No. 12 V 70 Ah capacity

Wiper motor : 12 V/17 W, two speed

 Appendix ‘B’ to GMI No.207

RECCOMMENDED LUBRICANTS, COOLANTS AND THEIR AGGREGATE FILLING CAPACITIES FOR TATA

VEHICLE MODEL – 407

S/No Description Periodicity of changes & top Ambient Temp 0C Lubricants to be used Capacities in Ltrs Remarks
up at KM

Oil Filter

1 2 3 4 5 6 7 8

1. Engine 18000 (Servo + 5 and above SAE 30 Engine Oil sump Servo pride 30 to
Pride 30) be changed at
The engine oil recommended for 9000 - 10 to +20 SAE 20E/20 Max – 8 Ltrs 18000 Kms &
use on TATA Diesel Vehicle should or 9000 (Other other grades at
conform to specifications of HIL-I- grades) - 20 to 0 SAE 10W Min – 6 Ltrs 9000 Kms
2104 c and grade selected according
to range of ambient temperature - 20 & below SAE 5W Oil Filter – 1 Ltr

2. Gear Box 18000 - - Servo Trans Fluid ‘A’ 2.90 Ltrs

3. Rear Axle 18000 - - Servo Gear Super – 90 1.50 Ltrs

4. Steering gear box 9000 - - -do- 0.50 Ltr

5. Wheel boaring Every 10000 - - Servo Grease HP Front hub – 140 gms

Rear hub – 300 gms

6. Chassis application As and when - - -do- -

required

7. Clutch As and when - - Servo grease rolar -

required
Clutch release bearing, release for
support bearing

8. Brake & Clutch hydraulic system Top up as and - Operation upto 40 J/1703 B/P -
0
when required C

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1 2 3 4 5 6 7 8

9. Coolants 1. Bharat Sherol B (DP) 13 Ltrs

2. Calf Esulsil NA (Perosil)
The anti-corrosion agents (oils) 3. HP Radiator protractor
recommended for use in the cooling 4. Castrol Cooledge SL (Indrol)
system are mentioned under Col 6 5. Veedol – Aeulcut 4 tide water
6. Servo cut – 5 (ICC)
7. Aqua clear engine (Add 60 (60)
cc of the oil for the entinr cooling
system and when replenishing the
water, add 5 cc per litre of water

10. Anti freeze agent should be added Upto Castrol Anti – Freeze Do not intermix
to the water in the cooling system as ambient different brand of
per data which depends on ambient Temp (cc) (Water) Anti-Freeze-Agent Anti-freeze agent.
temperature. Anti Freeze agent
Minus 10 80 20 affective up to –40 0C
Minus 20 66 34 Do not drain cooling
Minus 30 56 54 (44) system.
Minus 40 10 50