Directorate General Border Roads General Maintenance Instruction No. 204 General Maintenance Instruction No. 204
Directorate General Border Roads General Maintenance Instruction No. 204 General Maintenance Instruction No. 204
Directorate General Border Roads General Maintenance Instruction No. 204 General Maintenance Instruction No. 204
Sdx-x-x-x-
(S S Dogra)
EE (E&M)
Dty Director (Tech)
Dated : 13 Aug 1999 For Dir Gen Border Roads
GENERAL MAINTENANCE INSTRUCTION NO 204 ON MAHINDRA AND
MANINDRA 540 DP DIESEL VEHICLE
INSTRUCTION:
AIM
2. The aim of issuing this GMI is keep the vehicle working efficiently at all
time, minimise the breakdown and down time. This is achieved by ensuring regular
and periodical preventive maintenance, at every level.
ACTION BY
DETAILS
(Hans Raj)
SE (E&M), SG
Director (Tech)
For Dir Gen Border Roads
Appx-A
4. Check free play of clutch and brake paddle and re-adjust if it is less/more
than specified free play (Free play specified as 25 km)
5. Check all gauges on dash board and change if any of the gauge found
defective.
6. Check for correct functioning of foot brake and parking brake operation.
SAFTY TASK
4. Check Bty terminal and cable joint. Keep clean/tighten if it is dirty/loose and
use mineral jelly to protect them from corrosion.
6. Check shackle pins and bushes for damage and grease if required.
7. Check fan belt tension while pressed sagging should not increase 10mm. If
incorrect, tighten or replace fan belt.
10. Check air filter and service if vehicle deployed in dusty area.
Contd...P/3
-3-
MONTHLY TASK
3. Check the state of Rubber hose of air filter and change it if found perished.
4. Check tension of fan belt and replace if found worn out, damaged or
excessively sagging.
2. Drain engine oil and refill new engine oil of the specified specification as
per appendix attached.
4. Check fuel filter assy and drain the trapped water or sediments.
6. Check for any suspect noise from engine. Report to workshop if any
abnormal noise coming.
Contd...P/4
-4-
9. Check body mounting pad and change if found any unserviceable condition.
10. Check the steering connecting rod and tie rod boll joints snug and change
them if worn out.
Appx-D
Contd...P/5
-5-
Appx-E
Dont
2. Do maintain correct oil level in engine, gear box, rear axle, steering box,
master cylinder and oil bath air cleaner using specified grades of oil only.
5. Do check clutch pedal free play and brake pedal free play.
6. Do press clutch pedal fully when engaging gears. Always allow the clutch
pedal to return slowly and smoothly.
7. Do allow the starter pinion to come to rest before again attempting to start
the engine, otherwise the flywheel ring gear and pinion mt get damaged.
10. Do use only genuine oil filter and fuel elements. Replace them at
recommend intervals.
11. Do use only genuine MAHINDRA spares parts for all replacements.
12. Do maintain correct tyre pressure as per model specified in chart (Chock in
the morning).
13. Do check engine oil level in the sump everyday in the morning.
14. Do check battery every week and top up electrolyte level with distilled
water, Keep battery terminals clean and cable joints tight. Apply
Vaseline/petroleum jelly on terminals.
Contd...P/6
-6-
20. Do use the hazard warning with to flash all the blinker lights to warn other
road user, in case of emergency parking or brake down or road.
23. Do disconnect alternator terminals while carrying out any welding to the
vehicle.
24. Do power wash & lubricate (Service) your vehicle at every 2000 kms or
once a month.
25. Do fill up fuel tank (Diesel tank) completely every evening (after the days
work) to avoid condensation of vapour.
DONTs
1. Do not run the engine unless the gauge shows oil pressure or warning light
goes off.
3. Do not use clutch pedal as foot rest . This will reduce clutch life.
4. Do not run the engine with out radiator cap. Use genuine cap only, to keep
the system pressurized.
5. Do not continue to run the engine when the temperature gauge shows more
than 100 degree C.
8. Do not continue to run the engine, if black smoke is coming from the
exhaust.
10. Do not use cotton waste or any fluffy cloth when cleaning.
Contd...P/7
-7-
12. Do not use loose engine oil, always use oil from sealed tins.
13. Do not race or rev the engine especially when starting. This is destructive to
the engine and will not heat the engine quickly.
14. Do not run the engine with oil bath air cleaner removed or with the oil
container of the air cleaner empty. Maintain correct oil level at all times.
15. Do not run the engine, if the charging indicator light glows.
Appx-B
S/No Make & Type of Assy Capacity Periodicity of change at KM Ambient Temp Multi grade lub oil of
Veh/eqpt in Ltr IOC Ltd
Oil Filter
01 Jeep M&M 540 DP Engine 4.5000 Ist change 2000 2000
Diesel veh 2nd change 4000 there
after every 4000 4000 Multi Grade
Servo Pride 20W40
Or 15W40, 10W40
4000 Up to -70C
From 80C to 200C
Below - 200C 5W30
Air cleaner 0.5 (a) Ist change 1000 - -do- -do-
at
(b) Thereafter 2000 - -do- -do-
at every
Gear Box & transfer 3.2 Ist change 2000 - Upto - 260C from Servo Super 80W
case Thereafter 2000 every - -270C to -400C Servo Super 75W
Differential 1.2 Ist change 2000 - -do- -do-
Thereafter 2000 every -
Steering gear box 0.50 20,000 - (a) Winter Servo gear HP 90
(b) Summer Servo gear HP 140
Brake system .325 Check the level each - - -
2000
Wheel bearing - - - All Tem (a) EP-1 for chassis
Speedo meter cable - - - Servogram application
& Hand brake cable (b) Servogram EP-2 for wheel bearing
Appendix C to GMI No. 204 (contd)
S/No Make & Type of Assy Capacity Periodicity of change at KM Ambient Temp Multi grade lub oil of
Veh/eqpt in Ltr IOC Ltd
Oil Filter
Note: - The draining period should be reduced if excess water or sedimentation is observed while draining.
If filter elements are found clogged due to dirt of adulterated fuel before the normal change period, it should be
immediately replaced.
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