SERVICE CIRCULAR

TATA MOTORS
SC/2023/310 Model : TATA ACE HT+ BSVI Phase II Group: 00 Dec 2023

All Dealers / TASSs’

Subject: Introduction of TATA ACE HT+ BSVI Phase II

We are pleased to inform you about introduction of TATA ACE HT+ BSVI Phase II vehicle.
This vehicle is fitted with new powerful 800CC DICOR TCIC ENGINE, Direct Injection Common Rail Diesel
engine with 26.0 kW & 85 Nm torque with dry type Air filter which meets the Bharat stage VI RDE norms.

Representative photo of the vehicle is shown below:

VCBC Details:

SN LOB VC No. Chassis Type VC Description

1 SCV 55458522000R 559025 TATA ACE HT+ D CLB BSVI, 800CC TCIC DICOR,
MECHANICAL STEERING, GBS 65-5/5.07, BANJO
REAR AXLE (4.88) ,13” TYRES, 900 kg
PAYLOAD,DOMESTIC

CUSTOMER CARE (COMMERCIAL VEHICLE BUSINESS UNIT)

(As per policy of Tata Motors to continuously improve their products, the company reserves the right to make changes
of any nature on vehicles and aggregates without any obligation to incorporate them on previous vehicle)
We are enclosing herewith following details:
 Technical specifications (Annexure-1)
 Warranty and Free Service schedule (Annexure-2)
 Service & Maintenance Schedule (Annexure-3)
 Recommended Oil & Lubricants (Annexure-4)
 Special tools (Annexure-5)

Annexure – 1
Technical Specification
Engine
Engine Model TATA 800CC DICOR TCIC ENGINE, BS-VI (800CCDI04)
Bore / Stroke 78 mm x 83.5mm
Engine Capacity 798 cc
Max. Engine Output 26.0 kw @3750 rpm
Max. Torque 85 Nm@1750-2750 rpm
Engine Model 800CCDI04
Compression Ratio 16:01
Coolant Water & Ethylene Glycol ratio 40:60, Premixed
Engine Oil Capacity 2.90 Litre(Green)+ Service (2.6L)
Firing Order 1-2
Capacity Of Cooling System 4.8 liters
No Of Cylinders 2 inline
Air Filter Dry type

CLUTCH
Engine Clutch Type Single plate dry friction diaphragm type
Type of Actuation Cable operated with manual wear adjustment.

GEARBOX
Model GBS 65-5/5.07
Synchromesh on all forward gears,
Gearbox Type
Sliding mesh for reverse gear
No. of gears 5-Forward 1-Reverse

FRONT AXLE Rigid beam construction

REAR AXLE
Rear Axle Model Banjo Rear Axle
Rear Axle Ratio 4.88

FUEL TANK
Capacity 30 litres
 Electrical Specification
Audio warning Yes (Buzzer for high-temperature warning)
Battery 12V, 55Ah

Combi Switch Provided with self-cancelling turn signals and hazard warning switch

Exclusive Electrical Items

Horn Single Horn
Audio Warning Yes (Buzzer for high-temperature warning)
Digital Clock (Quartz) Yes (Available in cluster)
STARTER_MOTOR 12 V, 1.1 KW
ALTERNATOR CAPACITY Alternator -75A
1. EMS ECU with inbuilt Starter Motor Protection Strategy.
EMS 2. Sensors: e.g. Tmap, Crankshaft, Camshaft, Injector, Coolant temperature,
Exhaust Temp sensors, Delta Pressure sensor, NOx sensor, RPAS sensors,
Contact less speedo sensor
CAB
CAB Description: Full forward control steel shell- Modular Cabin
Roof Lining Yes
Side Doors Yes
Individual driver and co-driver seats with vinyl and head rests.
Seat Type Bucket seats with seat belts.
Sliding and folding arrangement available for driver seat.
Ventilation Natural
CABIN_SEATS 2 Seats
CAB_BODY Monocoque structure

WHEELS AND TYRES

No. Of Wheels/Tyres(NO_OF_TYRES) Front -2 Rear -2 Spare-1
Unladen and Laden:
Tyre Pressure Front – 3.5 Kg/sq.cm (50 psi)
Rear – 3.5 kg/sq.cm (50 psi)
Tyres 155 R13 LT 8PR Radial Tubeless Tyres

FRAME

Ladder type cranked frame with inverted hat section long members &
FRAME Description:
welded cross members. Depth: 122mm (max.) Width: 63mm (max.)

BRAKES
Brake Drum Diameter Drum brakes 228mm dia.
Front Brakes Disc brakes
Service Brakes Vacuum assisted dual circuit hydraulically actuated
BRAKE_TYPE Hydraulic Brake
Parking brake Description Cable operated mechanical linkages acting on rear wheels
BRAKE_PIPE_LINES Yes
VACCUM_BOOSTER 7 inch booster with TMC

STEERING
STEERING_TYPE Mechanical, variable ratio
Steering Gear Box Mechanical Gearbox
Steering column Non-Adjustable Type.

SUSPENSION
SUSPENSION_TYPE Parabolic leaf spring at front and semielliptical leaf spring at rear
Antiroll Bar Provided at front.
Front SUSPENSION Parabolic leaf spring
Rear SUSPENSION Semi-elliptical leaf spring
Shock Absorber Hydraulic double acting telescopic type
Spring Span 1040 +/-3mm(Front),1060+/-3mm(Rear)

Vehicle_Dim_Performance
Main Chassis Dimensions
Ground Clearance 160
Height of Centre of gravity (mm) Unladen -579; Laden - 641
Minimum Turning Circle Dia. 9.25m
Minimum Turning Clearance Circle Dia. 10.25m
Overall Height (Unladen) 1858
Track Front 1310
Track Rear 1343

PERFORMANCE
Environmental & Operating Conditions Operating temperature range: -10 to 50 deg.cet.
Max. speed 80 kmph

WEIGHT
Gross Vehicle
Weight(GROSS_COMBINATION_WT)
1950 (FAW-947; RAW-1003)
Kerb Weight(UNLADEN_WT) 1050 (FAW-665: RAW-385)

OTHER SPECS Items

VEH_APPLN Pickup
SALES_DESIGNATION TATA ACE HT+ D CLB BSVI
Drive Options RHD
EMMISSION_NORMS BS-VI
FACE Fully Forward
FUEL Diesel
Fuel Tank Capacity 30 Liters
Urea Tank Capacity 10.5 Liters
FUEL TANK Material Plastic
 Annexure - 2
Warranty and Free Service schedule

2.1 Warranty:
Warranty for the vehicle shall be for a period of 2 years from the date of sale of the vehicle, or 72,000 kms
of its running whichever expires earlier.

2.2 Free Service Schedule

Vehicle is eligible for Free Labour Services and wheel alignment apart from Pre-Delivery Inspection (PDI) at the following intervals:

Sr No Service Type Kms. (± 500) Days (± 15)

1 PDI At the time of delivery of vehicle
3 1st free service 10,000 Kms. 240 Days (8 Months)
4 2nd free service 20,000 Kms 480 Days (16 Months)
5 3rd free service 30,000 Kms. 730 Days (24 Months)

Annexure – 3
Service and Maintenance Schedule
Service Operations to be performed by Customer
(In case of any abnormality vehicle should be taken to TATA MOTORS Authorized workshop for proper attention)
Sr Operation Frequency
No
Check service indicator on air filter for the red band.
1 Contact nearest TATA MOTORS Authorised workshop if red band appears Daily
Note - Please do not clean air filter element.

2 Check for proper functioning of lights, turn indicators, horn, switches, gauges, Daily
warnings in Instrument Cluster, buzzers and other electrical controls.
3 First Aid kit is provided in your vehicle. Check and regularly update Weekly
4 Check condition of shock absorber for leakage and breakage. Replace, if necessary Weekly
5 Check the performance of brakes by applying & releasing, when engine is running. Daily
Get it adjusted from TATA Authorised Workshop if required.
6 Check engine oil level on dipstick in sump. If necessary, top up with recommended Weekly
brand of oil
7 Check coolant level in auxiliary tank. Top-up if necessary, with mixture of clean soft Weekly
water and Ethylene Glycol in 60:40 ratio
8 Check for leakage of oil, fuel, clutch fluid, air and coolant if any Weekly
9 Check and top up DEF level in DEF Tank to full level, If Low level indicator light Based on Instrument Cluster DEF level
comes ON in Cluster. (Use Tata Genuine DEF only) information
Weekly or when Water in Fuel indicator
10 Loosen drain plug of fuel filter & drain off water glows in Instrument Cluster

11 Check tyre pressure. Inflate tyres to specified pressure, if necessary Weekly

12 Check wheel mounting nuts and tighten if necessary. (Also after 100 km of wheel As mentioned
change)
13 Check oil level in brake and steering. If necessary, top up with recommended brand Monthly / 5000 Kms
of oil
14 Check tyres for any abnormal tyre wear. If tyre wear noticed, wheel alignment is Monthly / 5000 Kms
required.
15 Check water level in windscreen washer container & top up, if necessary. As required
16 Wash the vehicle As required
17 Grease with grease gun (Where grease nipple is provided) Monthly
Service Operations to be Performed at Workshop
D=Daily, W=Weekly, M=Monthly, P=PDI, *=whichever is earlier, # =refer chapter After treatment system
Sr OPERATION FREQUENCY (In Kms.)
No
1 ENGINE
Drain off engine oil while hot. Clean drain plug
Change engine oil and oil filter (Vehicle running in normal operating 10,000 Kms. or 8 Months*
conditions)
Change engine oil and oil filter (Vehicle running in Unfavourable Driving Check oil levels frequently and top up as
condition) required.
Customers are suggested to follow this oil change frequency for better vehicle Oil change interval of such appli- cations to be
perform- ance if vehicle is operating in Unfavourable Driving condition such done at every 4 months or 5,000 kms of vehicle
1.1 as:- running, whichever is earlier.
• Driving in dense traffic condition where vehicle speed is limited if vehicle is continuously running in unfavorable
• Start stop cycles where vehicle required to start and stop frequently like driving # condi- tions
Garbage tip- pers, vegetable supply, courier delivery, etc.
• Driving frequently with Max speed less than 15 kms for long period
• Vehicle driven in over load condition ,abnormal vehicle usage like towing
application
• Frequently driving in high dust environment, hilly area.
1.2 Check all belts condition for any wear and tear. Replace, if required 10,000 Kms. or 8 Months*
1.3 Check / replace pipes and hoses of engine lubrication, fuel, coolant, wind 10,000 Kms. or 8 Months*
shield washing system, hydraulic system (clutch / brakes / steering), if
required
1.4 Check air intake and exhaust system for noise, leakages or defects. Rectify, if 10,000 Kms. or 8 Months*
neces- sary
1.5 Check engine mounting for looseness and damage to mounting 10,000 Kms. or 8 Months*
1.6 Check If red band appears on air filter service indicator 10,000 Kms. or 8 Months*
Sr OPERATION FREQUENCY (In Kms.)
No
40,000 Kms. or 36 months nor- mal operation,
20,000 Kms. or 12 months in dusty operation or
Replace air filter element. when red band appears on serv- ice indicator*
1.7
Note: Please don’t clean air filter element

1.8 Check for any wear on the timing belt 10,000 Kms. or 8 Months*
1.9 Check cylinder head valve clearance and adjust, if necessary 40,000 Kms.
1.10 Check coolant concentration and top up coolant, if required 10,000 Kms. or 8 Months*
1.11 Drain cooling system - Change coolant. Use mixture of clean soft water and 1,00,000 Kms. or 4 Years*
coolant in 60:40 ratio
1.12 Check intercooler & radiator external clogging. Clean with compressed air & 40,000 Kms. or 2 Years*
water, if necessary
Check and top up DEF level in DEF Tank to full level, If Low level indicator Whenever the indication comes on the
1.13 light comes ON in Cluster. (Use Tata Genuine DEF only) (DEF not to be Instrument cluster
taken out of DEF tank to check)
1.14 Replace timing belt 1,60,000 Kms. or 36 Months*
1.15 Replace alternator belt 1,00,000 Kms. or 12 Months*
1.16 Replace Turbocharger compressor outlet hose 40,000 Kms. or 2 Years*
1.17 Replace Intercooler inlet hose 40,000 Kms. or 2 Years*
2 FUEL FILTERS
2.1 Drain water from fuel filters. Whenever the indication comes on the Instrument 10,000 Kms. or 8 Months*
cluster
2.2 Change fuel filter element 80,000 Kms. or fuel filter clog in- dication lamp
on cluster*
Sr OPERATION FREQUENCY (In Kms.)
No
2.3 Clean strainer in fuel pump module inside the fuel tank 40,000 Kms
3 CLUTCH
3.1 Check for free play movement of clutch pedal. Adjust if necessary 10,000 Kms. or 8 Months*
3.2 Check for clutch noise and vibration during clutch engagement / dis- 40,000 Kms
engagement at all gears
 Check for pressure plate (wear / thermal cracks) and diaphragm condition and
3.3 replace if necessary. Check release fork, bushes and bearing (noise). Check During clutch disc change
clutch / release fork mountings
4 GEAR BOX
4.1 Check and tighten gear box mounting bolts 10,000 Kms. or 8 Months*
4.2 Change oil in gear box. Clean breather on gear box 80,000 Kms.
5 REAR AXLE
5.1 Change oil in rear axle. Clean breather on rear axle 1,00,000 Kms.
6 PROPELLER SHAFT
6.1 Check propeller shaft UJ cross and sliding yoke. Replace, if required 10,000 Kms. or 8 Months*
7 SUSPENSION
7.1 Check torque at front and rear spring pivots, ‘U’ bolt, shock absorbers front 10,000 Kms. or 8 Months*
and rear anti- roll bar. Tighten if necessary
7.2 Check condition of rear leaf spring bushes. Replace, if necessary 10,000 Kms. or 8 Months*
7.3 Check front & rear leaf spring leaves for damage and breakage. Replace, if 10,000 Kms. or 8 Months*
necessary
7.4 Check condition of front & rear shock absorber for leakage and breakage. 10,000 Kms. or 8 Months*
Replace, if necessary
Sr OPERATION FREQUENCY (In Kms.)
No
7.5 Check the condition of shock absorber bushes, Replace if necessary 10,000 Kms. or 8 Months*
7.6 Check the condition of front and rear anti roll bar bushes for damage. 10,000 Kms. or 8 Months*
Replace, if neces- sary
7.7 Check the condition of front and rear anti roll bar link for damage. Replace, if 10,000 Kms. or 8 Months*
necessary
7.8 Change spring bushes 40,000 Kms.
7.9 Check the condition of front & rear bump stoppers for damage. Replace, if 10,000 Kms. or 8 Months*
necessary
8 BRAKES
8.1 Check front brake pad / disc for wear and replace if required 10,000 Kms. or 8 Months*
8.2 Check rear brake liner / drum for wear and replace if required 10,000 Kms. or 8 Months*
8.3 Check brake hoses and pipes for leakage, damage and replace if necessary 10,000 Kms. or 8 Months*
8.4 Check brake pedal travel and correct if necessary by bleeding the brake 10,000 Kms. or 8 Months*
system
8.5 Replace brake fluid 40,000 Kms. or 2 Years*
8.6 Overhaul TMC / front caliper and wheel cylinder & replace the seal & rubber 40,000 Kms. or 2 Years*
parts
8.7 Check parking brake cable & tighten if required 10,000 Kms. or 8 Months*
9 MECHANICAL STEERING
9.1 Check tie rod ends for looseness, damage or wear 10,000 Kms.
9.2 Check and adjust steering wheel free play 40,000 Kms.
10 WHEELS AND TYRES
10.1 Check tyre pressure, inflate tyres to specified pressure, if necessary. Educate 10,000 Kms. or 8 months*
customer on recommended tyres pressures
10.2 Rotate the tyres as per recommendation. 10,000 Kms. or 8 months*
10.3 Check wheel alignment
Sr OPERATION FREQUENCY (In Kms.)
No
(Note - Alignment to be checked even after changing any suspension & 10,000 Kms. or if any abnormal tyre wear
steering linkage parts) noticed*
10.4 Check wheel mounting nuts and tighten if required 10,000 Kms. or 8 months*
11 ELECTRICALS
Check proper functioning of lights, switches, gauges, warning lamps in
11.1 instrument cluster, wiper and other electrical buzzers 10,000 Kms. or 8 months*

Check battery mountings, Clean battery posts and terminals. Tighten

terminals & smear petroleum jelly. Check battery condition like voltage,
11.2 10,000 Kms. or 8 months*
specific gravity and electrolyte level. Check with indicator on battery
(wherever available)
11.3 Check head lamp focusing. Adjust if necessary. (Additionally to be done after 10,000 Kms. or 8 months*
every bulb change)
Check electrical system health: Ensure usage of genuine fuses with correct
rating, con- dition of fuse and relay holding base, Extra load tapping from
11.4 10,000 Kms. or 8 months*
unauthorized point, earthing connections, proper routing / clamping of wiring,
intactness of grommets
11.5 All ground points should be checked 10,000 Kms. or 8 months*
12 BODY
12.1 Under body inspection for any external under body damages 10,000 Kms. or 8 Months*
12.2 Body panel inspection for paint rust, panel crack, lock working 10,000 Kms. or 8 Months*
12.3 Check cab mounting bushes 10,000 Kms. or 8 Months*
13 EXHAUST SYSTEM
13.1 Check and top up DEF level in DEF Tank to full level, if Low level indicator Based on Instrument Cluster DEF level
light comes ON. Use Tata Genuine DEF only information
Sr OPERATION FREQUENCY (In Kms.)
No
14 GENERAL
14. Check & top up levels of: 10,000 Kms. or 8 Months*
1 1. Engine oil, 2. Engine coolant, 3. Windshield washer tank (As required)
14. Check & top up levels of: 10,000 Kms. or 8 Months*
2 1. Gear box oil 2. Rear axle oil
Check & top up levels of:
14. 1. steering oil 10,000 Kms. or 8 Months*
3 2. Brake oil

Check for any the leakages of :

1. Oil (at engine / gear box / shock absorbers / rear axle / steering / brakes)
14.
2. Fuel tank and pipelines 3. Engine coolant, 10,000 Kms. or 8 Months*
4
4. Engine exhaust, 5. Hydraulic circuit (Brake)

14. Check and tighten all fasteners if necessary as per the check list # 10,000 Kms. or 8 Months*
5
14. Wash the vehicle. 10,000 Kms. or 8 Months*
6
14. Grease as per the list ## 10,000 Kms. or 8 Months*
7
14. Conduct road test for vehicle handling and functioning of aggregates, 10,000 Kms. or 8 Months*
8 abnormal noise as well as customer complaints
14. Check error code with suitable diagnostic tool. Rectify, if necessary 10,000 Kms. or 8 Months*
9
14.10 Take road test and Check for Proper functioning of GSA and ECO Switch 10,000 Kms. or 8 Months*
function (if ap- plicable)
14. # Check list of fasteners requiring periodic checking & tightening
5
a Engine : Engine mounting & accessories mountings, air filter mounting, fuel 10,000 Kms. or 8 Months*
tank mount- ing, engine hood insulation mounting, radiator mounting.
Sr OPERATION FREQUENCY (In Kms.)
No
b Driveline : Clutch housing, gear box mounting, propeller shaft coupling 10,000 Kms. or 8 Months*
flange, rear axle shaft mounting
c Electricals : Starter motor, alternator, wiper motor mounting bolts 10,000 Kms. or 8 Months*
d Steering : Steering gear box, Joints of pitman arm, steering arm, tie rod. 10,000 Kms. or 8 Months*
e Suspension : Leaf spring pivots, ‘U’ bolt, shock absorber, front & rear bump 10,000 Kms. or 8 Months*
stopper mounting fasteners
f Brakes : Brake pipeline clamps, master cylinder mounting, brake drum 10,000 Kms. or 8 Months*
mounting
g Wheels & Tyres : Wheel mounting nuts (also once after 100 km after each 10,000 Kms. or 8 Months*
wheel re- placement), mounting of spare wheel carrier
h Body : Driver cab & load body mounting 10,000 Kms. or 8 Months*
i Exhaust system : Rubber hanger, DEF Tank mounting, catcon mountings, 10,000 Kms. or 8 Months*
DEF injector mounting
j General : Apart from above please check visually any other fasteners for 10,000 Kms. or 8 Months*
loosening.
 14.7 ## List of points requiring periodic greasing
a Front axle: King pin 10,000 Kms. or 8 Months*
b Body : door latches / slider, door locks, door check stop, tailgate hinges 10,000 Kms. or 8 Months*
15 TIPPING HYDRAULIC SYSTEM (if applicable)
15.1 Check level of hydraulic fluid & top up if necessary. Trace and rectify oil Weekly
leakage if any
15.2 Grease with grease gun at all greasing points of cylinder, load body, body Monthly
lock, safety stay rod, tail gate hinge & tailgate locking mechanism
15.3 Clean breather element with compressed air Monthly
Sr OPERATION FREQUENCY (In Kms.)
No
15.4 Check the dumping time with recommended pay load If it exceeds the Every 4 Months
specified value, then check the control valve, cylinder & pump. Replace with
the repair kit if necessary
15.5 Check and tighten the pump mounting, drive shaft from PTO to pump, Every 4 Months
hydraulic tank mounting, sub-frame mounting, mounting of body lock
15.6 Change hydraulic oil and oil filter Every 12 Months

Annexure – 4
Recommended Oils and Lubricants

Sr Aggregates Quantity Fluid Type / Grade Recommended Brands

No
1 Engine oil with 2.6 Litres* Fully Synthetic Untra Premium Oil TATA MOTORS - TATA Motors Genuine Oil
oil filter 5W30 (SS6596) BU Engine Oil 5W30 (SS6596) BU
2 Coolant 5.4 Litres Coolant Type2 Ultra Long Life SS7721, TATA MOTORS - Ultra Cool Engine Coolant
For Non AC(stan- Ratio Coolant & Water-40:60% (Extra Long Life)
dard) - 4.8 Litres
3 Gear box 1.5 Litres SAE 80W90 Long drain TATA MOTORS - TATA Motors Genuine
Gear Oil 80W90 LL
4 Rear Axle 1.45 Litres SHELL SPIRAX 80W90 HD SHELL - Shell Spirax 80W90 HD
5 Brake Fluid 0.5 Litres DOT4 TATA MOTORS - TATA Genuine Brake Fluid
(DOT 4)
6 All Grease As required AP2 Grease TATA MOTORS - TATA Genuine AP2
Nipples Grease
7 DEF 12.6 Litres TATA Genuine DEF (Diesel Exhaust TATA MOTORS - TATA Genuine Diesel
Fluid) Exhaust Fluid
8 Hydraulic tipping 10 Litres 68 Grade Hydraulic oil CASTROL - Castrol Hyspin VG 68
system (If BPCL - Bharat Hydrol 68
applicable) IOCL - Servo System 68
VEEDOL (Tide Water) - Autorbrio 68
Chemoleums - Erato 46 AW
* For Fresh Engine, 2.9L Engine oil to be filled

Annexure – 5
New Special tools Details

Special tools are carryover, pls refer SC_2023_201 and workshop manual