Repair and Periodic Maintenance of Ashok Leyland Guru 3270

Overhauling, servicing, and comprehensive re-conditioning of heavy-duty front-mounted Guru snow clearance V-blade and angling moldboard assembly of Ashok Leyland Guru 715 4x4 Truck 3270 deployed for alpine snow clearance operations across Mechanical Division Doda. Scope comprises dismantling worn-out lower scraper cutting edges and fabricating replacement heavy-duty cutting edge segments conforming to IS 2062:2011 Clause 5.2 Grade E250 structural steel specifications, including precision beveling, punch-drilling counter-sunk mounting holes, and applying wear-resistant hard-facing overlays along high-abrasion contact margins. Renewal of high-tensile Grade 8.8 countersunk plow bolts, prevailing torque lock nuts, and hardened reversible ground-skid wear shoes. Disassembly, chemical ultrasonic degreasing, honing, and complete seal renewal of twin double-acting hydraulic angling rams using heavy-duty polyurethane rod wipers, high-pressure piston cups, and nitrile O-ring sets rated for extreme sub-zero operation conforming strictly to IS 12207:2019 Clause 5.1 and IS 11170:2018 Clause 6.2 hydraulic standards. Servicing spring-trip safety relief mechanisms, replacing fatigued high-stress compression return springs, heat-treated alloy steel pivot hitch pins, and spherical bush mountings. Reassembly, precision torqueing, hydraulic pressure proof-testing at 190 bar working pressure, verifying zero external leakage, and executing dynamic angle articulation field trials to statutory mechanical engineering maintenance standards.

Comprehensive periodic servicing, overhaul, and preventive maintenance of full air dual-line pneumatic braking system, S-cam assemblies, and air generation circuit of Ashok Leyland Guru 715 4x4 Truck 3270 operating under severe high-altitude alpine snow clearance conditions. Scope encompasses removing all four wheel brake drums, inspecting friction surfaces for heat glazing, scoring, or ovality, and skimming drums within permissible engineering limits. Renewal of heavy-duty asbestos-free bonded brake friction linings with brass rivets on all four wheels to IS 11852:2018 Clause 5.2 standards. Overhauling S-cam shafts, replacing bronze support bushes, roller cam followers, return springs, and adjusting automatic slack adjusters. Dismantling and replacing two service diaphragm brake chambers complete with reinforced pushrods and mounting clamps. Servicing Wabco air dryer unit, replacing desiccant spin-on cartridge, renewing purge valve seals, and servicing automatic moisture drain valves. Inspecting wire-braided pneumatic lines, tightening fittings, inspecting brake pedal treadle valve travel, checking emergency spring brake chamber hold-off pressure, adjusting slack adjuster angular travel to certified OEM limits, performing air pressure build-up and decay leakage tests at 8.5 bar working pressure, verifying dual-circuit pressure split safety, and executing dynamic high-load stopping distance road trials to statutory commercial vehicle safety codes.

Complete disassembly, fluid renewal, inspection, and overhaul of drivetrain 6-speed synchromesh overdrive gearbox, 330mm single dry plate diaphragm clutch assembly, and rear hypoid drive differential axle of Ashok Leyland Guru 715 4x4 Truck 3270 under heavy snow plough duty. Scope entails draining degraded gear lubricants, flushing gearbox and differential casings to remove metal wear debris, and refilling 5.0 litres of SAE 80W-90 Extreme Pressure gear oil (API GL-4) in transmission and 6.0 litres of EP-90 hypoid gear oil conforming to IS 1118:2018 Clause 5.1 (API GL-5) in rear axle. Dismantling clutch housing to overhaul 330mm clutch pack, replacing driven plate with asbestos-free friction facings and torsional damper springs, heavy-duty pressure plate diaphragm assembly, and carbon-thrust release throw-out bearing. Checking flywheel face for run-out, setting release finger heights, and bleeding pneumatic-hydraulic clutch booster circuit. Inspecting transmission synchronizer brass cone rings for wear, verifying gearbox mainshaft bearing end-float, checking propeller shaft universal cross-joints for needle play, and repacking with EP grease. Renewing gearbox top cover synthetic gaskets, rear differential pinion oil seals, and axle shaft flange gaskets to IS 11170:2018 Clause 6.2. Completing reassembly, executing gear shifting trials across all forward and reverse ratios, and verifying smooth engagement under full load.

Disassembly, comprehensive overhaul, and precision rebuilding of heavy-duty front steering drive axle kingpins, tapered roller wheel hub bearings, and semi-elliptic leaf spring suspension assemblies of Ashok Leyland Guru 715 4x4 Truck 3270. Scope includes jacking and supporting front chassis, dismantling both steering knuckles, and extracting worn kingpins. Fitting OEM-grade kingpin overhaul kit comprising case-hardened alloy steel kingpins, precision phosphor-bronze bushes, hardened spherical thrust washers, and multi-lip grease seals to IS 11170:2018 Clause 6.2. Reaming bushes to precision fit, repacking wheel hubs with Lithium Complex EP-2 water-resistant grease conforming to IS 7623:2019 Clause 4.2, renewing inner and outer tapered roller hub bearings, and setting bearing end-play with dial indicator. Overhauling front and rear semi-elliptic leaf spring suspension, replacing worn bronze shackle bushes, spring eye pins, and heavy-duty U-bolts torqued to OEM specifications. Replacing two front double-acting hydraulic shock absorbers with heavy-duty rubber mounting grommets. Inspecting front leaf spring main and military wrap leaves for micro-cracks, checking front axle beam camber alignment, torqueing wheel nuts in criss-cross sequence, verifying zero kingpin lateral free-play, adjusting wheel alignment toe-in geometry, and executing dynamic suspension deflection load testing under full snow plough ballast to statutory highway maintenance standards.

Overhauling, servicing, fluid renewal, and precision recalibration of integral power steering system, hydraulic orbitrol steering box, and front mechanical steering linkage geometry of Ashok Leyland Guru 715 4x4 Truck 3270. Work encompasses draining degraded hydraulic steering fluid, chemical flushing of power steering reservoir, and refilling 4.0 litres of virgin anti-wear hydraulic oil ISO VG 68 conforming strictly to IS 10522:2019 Clause 6.1 specifications. Replacement of hydraulic return-line filter element and cleaning reservoir wire-mesh suction strainer. Overhauling steering box control valve assembly, replacing high-pressure spool seals, PTFE backup rings, and sector shaft oil seals to IS 11170:2018 Clause 6.2. Fabricating and replacing two wire-braided high-pressure flexible hydraulic steering hoses rated for 330 bar working pressure conforming to SAE 100R2 and IS 4854:2018 Clause 4.1 with swaged female swivel couplings. Replacing heavy-duty steering drag-link spherical joints, tie-rod ball ends, dust boots, and castle nuts with split pins. Checking power steering pump pressure relief valve cut-in rating, inspecting steering column universal joint needle bearings, torqueing pitman arm lock nut, inserting fresh stainless steel split cotter pins, adjusting steering gear backlash, setting front wheel toe-in tracking alignment, bleeding air by lock-to-lock sweeps, and verifying light, responsive steering effort under full front V-blade weight load.