SERVICE CIRCULAR

TATA MOTORS
SC/ 2023 / 306 Model : T.11 ULTRA 160HP BS6 Phase 2 Group : 00 Dec 2023

All Dealers / TASSs’,

We are pleased to inform introduction of T.11 Ultra with 33WB

Representative picture of the vehicle is given below -

We are enclosing the following details:

 Chassis type designation (Annexure - 1)
 Warranty and Free Service Schedule (Annexure - 2)
 Technical Specifications (Annexure - 3)
 Salient Features (Annexure - 4)
 BS6 Phase 2 Vehicle Exhaust System and New Sensor (Annexure - 5)
 GDCU and FOTA Flashing (Annexure - 6)
 Cruise Control Function (Annexure - 7)
 Instrument cluster New feature addition (Annexure - 8)
 Service and Maintenance Schedule (Annexure - 9)
 Recommended Oil and Lubricants (Annexure - 10)
 Special Tool List (Annexure - 11)
 EMS Diagnostic Software Details (Annexure - 12)

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)
 Annexure – 1

Chassis type designation:

Model Chassis barrel VC No.
T.11 ULTRA DCR33CBC 160B6M6 784089 55476733000R

Annexure – 2
WARRANTY AND FREE SERVICE SCHEDULE
2.1 Warranty:
Model Vehicle Warranty Engine Warranty
36 months from the date of sale OR
T.11 Ultra BS6 Phase 2 Same as Vehicle Warranty
3,00,000 Km whichever expires earlier

2.2 Free Service Schedule:

Below free services are applicable at the interval given below:
Sr.
Service Km covered (± 2000) Days (± 60)
No
1 Free PDI At the time of delivery of vehicle
2 Free Wheel Alignment 3,000 to 5,000 Km NA
3 First Free Service 60,000 Km < 365 Days (1 Year)
4 Second Free Service 120,000 Km < 730 Days (2 Year)
5 Third Free Service 180,000 Km < 1095 Days (3 Year)
 Annexure – 3
TECHNICAL SPECIFICATIONS
Vehicle Model 33 WB CBC
VC No 55476733R
Chassis Type 784089
ENGINE
Engine Model 3.3L BS6 Phase 2
Engine Type 4 cylinder Inline, Coolant cooled, Turbo- intercooled CRDI Engine
Bore and Stroke 100 mm X 105 mm
Engine Capacity 3300 CC
Max Torque Power Mode :- 475 Nm@1600 -2000 rpm
Max Power 160 PS @ 2600 RPM
Firing Order 1-3-4-2
Turbo Charger Electronically Actuated
HP Pump M/s Bosch CR system
Max Fuel System Pressure 2000 Bar
Air Filter Dry type
Fuel Filter Twin type filter with water separator
Oil Filter Full Flow Paper Type
Engine Fan Type Electronically actuated Viscous Fan
Fuel Tank Capacity 90 Ltr, HDPE Plastic fuel tank
Exhaust System After Treatment System with DEF Tank
CLUTCH
Outside diameter of clutch 330 mm
Engine Clutch Type Dry, single plate
Type of Actuation Hydraulically actuated
GEARBOX
Gear box Model Gearbox Description: G550 Cable shift
No. of gears 6 Forward 1 Reverse
Gear Ratios 1st – 6.9 , 2nd- 4.02 , 3rd- 2.39 , 4th- 1.46 , 5th- 1.00 , 6th – 0.84, Rev- 6.37
PROPELLER SHAFT
Type SPL 70
REAR AXLE
Rear Axle Description TATA RA 1068HD Non-THU
Rear Axle Type & Model Banjo type, single reduction hypoid gears, fully floating axle shafts.
Rear Axle Ratio 4.125 : 1 (33/8)
Rear Axle Make TATA make
FRONT AXLE
Front Axle Description 10.4 T FRONT AXLE "R"ASSY WITH DRUM AIR BRAKE
Hub Bearing Type Non THU
Axle Make TATA make
ELECTRICAL
Battery & Alternator Capacity 12V 100AH, Alternator 120A
Starter Motor 2.2 kW with TCO.
Head Lamp 2 No's Clear lens High and Low Beam
Horn Single High Tone
EMS MD1CS018 (Bosch CR System)
 Vehicle Model 33 WB CBC

VC No 55476733R
Chassis Type 784089
WHEELS & TYRES
No. Of Tyres Front - 2, Rear-4, Spare-1
Tyre Size 235/75 R 17.5 Radial Tubeless
Wheel Rims 6.75 X 17.5
FRAME
Ladder type heavy duty frame with riveted/bolted cross members Side members
Frame Description are of channel section Depth -220 mm (max) Flange Width -60mm Thickness
5mm
BRAKES
Service Brakes Dual circuit full air S-Cam brake , Non ABS
Front Brakes Drum Brake, Dia 325 X 155 mm
Rear Brakes Drum Brake, Dia 325 X 155 mm
Parking brake Description Hand operated, Spring actuated parking Brake acting on rear wheels
STEERING
Type Integrated hydraulic power assisted
Ratio 20.2:1
Steering Gear Box Recirculating Ball type
SUSPENSION
Front Suspension Parabolic leaf spring
Rear Suspension Semi elliptical at rear with semi elliptical auxiliary springs
Shock Absorber Hydraulic double acting telescopic type at front only
Main Chassis Dimensions in
mm
Vehicle Overall Height 2470
Vehicle Overall Length 6385
Vehicle Overall Width 2205
Ground Clearance ~185
Minimum Turning Circle Dia. 10800
Wheel Base 3310
PERFORMANCE
Max. Geared speed 80 KMPH (Restricted through Speed Limit Function)
Max. Gradeability at rated
31%
GVW
WEIGHT in Kg
Gross Vehicle Weight (GVW) 11280
Kerb Weight (Unladen Weight) 3280
Max Payload 8000
Max. Permissible FAW 3890
Max Permissible RAW 7390
 Annexure – 4
SALIENT FEATURES

SN Descriptions Photo

3.3L Engine
 3.3L Engine with 160PS
1
 FE mode switch for better fuel
economy

Particulate Matter Sensor

2  For monitoring of soot value in
exhaust

GDCU – Gateway Domain Controller

Unit
 Prevents unauthorized access to
3 vehicle CAN network
 Performs FOTA function.
Flashing of vehicle various
ECUs remotely.

Telematics
 Fleet Management Solution
4  Track and Trace
 Driving Behavior
 Vehicle Performance

Steering Wheel switches and

controls (if applicable)

5  Volume and play list controls

 Phone call pick up – hang up
facility

Cruise control Function (if applicable)

 Helps driver to maintain a
6 suitable vehicle speed without
keeping foot on the accelerator
pedal.
 Low Viscous Rear Axle Oil
7 TMGO ProFE LL 80W90 Axle Oil
 Enhanced oil change interval
 Reduction in TCO

8 LED Tail Lamps (if applicable)

Air Deflector Mounting Provision

 Total 8 , M8 tapped holes
9  Better FE
 Annexure – 5
BS6 Phase 2 Vehicle Exhaust System and New Sensor

New Sensor / Actuator

Sr. no. Description Image
PM sensor

1 It is used to monitor the collection efficiency of particulate

matter trap (DPF) in the exhaust gas system of a diesel
engine. It is used to measure soot quantity getting escaped
through DPF.

HOT EGR Valve

2 EGR at low temperature is required for more reduction of

engine out NOx. Thermal management is critical for BS 6
applications at cold condition and part load operating
conditions for SCR conversion. Hot EGR Valve helps to
provide hot EGR gas at cold condition.
 Annexure – 6
GDCU and FOTA Flashing
 GDCU stands for Gateway Domain Controller Unit. It acts as gateway between various CAN
network ECUs/controllers
 It prevents unauthorized access to vehicle’s CAN network.
 GDCU Enables FOTA (Firmware Over The Air) function. Any vehicle ECU can be flashed
remotely without visit to any workshop.
Architecture of GDCU and FOTA function

 Updated Calibration firmware released on PLM server, gets transferred to UV server.

 From UV server, Cloud CVP (Connected Vehicle Platform) transfers firmware to particular
chassis TCU. Updated firmware gets stored in memory of GDCU.
 Driver will get intimation on instrument cluster by FOTA Tell Tale lamp about new
software available.
 Pre-Conditions for FOTA flashing are to be satisfied to initiate process.
o Hand Brake Engaged
o Engine RPM = 0 , Vehicle speed = 0
o IGN – ON
o Battery Voltage – 12V
 Once pre-conditions are satisfied, drive has to press Hazard switch 4 times
(ON-OFF-ON-OFF) within 10 sec to start software update.
 After driver authentication, GDCU will flash particular ECU.

 Cluster will display following ID which denote which ECU being updated

Vehicle ECU ID on cluster

EMS (Bosch) 06
EMS (Delph) 01
GDCU 20
TCU 25
Cluster 08/09
VECU 13
  Flashing status and progress will be displayed on screen.
o FOTA STARTED text message shall appear only once for 4 Secs
o TIME : XXXMINS text message shall appear for 4 Secs
o Cluster screen will go blank and ECU ID for which FOTA is initiated will be displayed.
o Cluster will display FOTA-XX-XXX% percentage completion of software update
o During FOTA in progress, FOTA tell-tale will keep on blinking

 After successful flashing FOTA SUCCESS message will display on screen. Driver can drive the
vehicle. If software update is unsuccessful then FOTA FAIL - ECU NOT OK or
FOTA FAIL - ECU OK message will display on screen.
 If FOTA fails then previous version flashing will be initiated with message on screen as FOTA
ROLLBACK along with status and progress. Either ROLLBACK SUCCESS or
ROLLBACK FAIL message will appear accordingly.

 After FOTA COMPLETE message, tell-tale FOTA lamp will disappear from cluster.

Do’s Dont’s
Regularly check for this tell-tale indication Do not crank vehicle during software update
in progress.
Educate the drivers to keep a watch for the tell- Do not turn off ignition during software
tale and guide them to authorize through hazard update in progress
switch
Follow pre-condition requirement Do not cut-off battery / Do not turn off
battery switch during software update
Perform the software update when vehicle is Do not perform software update if battery
parked in safe location and safe condition voltage level is low
DO not leave vehicle unallocated while
software update is in -progress

Sample Images of FOTA message and progress:-

Message Display Message Display

ROLLBACK
FOTA STARTED SUCCESS

FOTA FAIL – FOTA COMPLETE

ECU NOT OK

FOTA ROLLBACK 02
ROLLBACK 013%
 Annexure – 7
Cruise Control Function

 Cruise Control function helps driver to maintain a suitable vehicle speed without keeping foot on the
accelerator pedal.
 Cruise control function can be set ON or OFF by rotating left knob

 When cruise control is ON, Tell-tale lamp will glow in instrument cluster.
 Speed can be increased or decreased by 1 Km/hr by rotating knob in front of INC (Increase) and DEC
(Decrease)
 To cancel cruise control temporarily, press either brake pedal or clutch pedal.
 Cruise control can be resumed by pressing RES (Resume) button.

Preconditions to start cruise control function

o Desired constant vehicle speed is above 40km/ph
o Vehicle is in 4th or 5th gear.

Temporary Disengagement of cruise control

o Brake pedal or Clutch pedal is pressed
o Speed falls below 30 km/h, when travelling uphill
o Gear is changed

Automatic Disengagement of cruise control

o Vehicle speed is below 30 km/h.
o Low engine speed (< 1000 rpm )
o Vehicle speed sensor is disconnected or tampered or non-functional
 Annexure – 8
Instrument Cluster New Feature Addition

It will illuminate for approx. 3 sec when ignition is switched ‘ON’.

FOTA (Firmware-
update Over The This Indicator Turns "ON" when Firmware Over The Air Update (FOTA) is
Air) Available & process initiation required. This Indicator will start "blinking"
once the FOTA activity is initiated.

Cruise Control
It will illuminate when cruise control function in ‘ON’.
Function
 Annexure – 9
SERVICE AND MAINTENANCE SCHEDULE
9.1 Service Operations to be performed by Customer –
Service Operations to be performed by Customer for 3.3L NewGen
SN OPERATION FREQUENCY
1 Check engine oil and coolant level. Top up, if necessary. Daily
Carry out visual inspection of vehicle for fuel leakages, traces of oil / fluid on ground, if
2 Daily
any.
Check air filter service indicator for the red band. Contact nearest TATA Motors
3 Authorised Workshop if red band appears. Daily
Note - Please do not clean air filter element.
Check ‘water in fuel’ indicator on instrument cluster. Drain water sediments from water
4 Daily
separator if indicator on instrument cluster is continuously ON.

5 Check ‘Low DEF level’ indicator on instrument cluster. Top up DEF if required Daily
Check for proper functioning of switches, gauges, warning lamps on instrument cluster,
6 Daily
buzzers, all lights, other electrical controls.
7 Check for proper functioning of service brake, parking brake, LCRV and exhaust brake. Daily
Drive Belts - Inspect the belts weekly. Check the belt for intersecting cracks. Attend, if
8 Weekly
required.
Air Tanks and Reservoirs - Open the drain cock on the air tank to drain any moisture
9 accumulated in the air system. If oil is present, the air compressor system must be Weekly
checked at TATA Motors authorised workshop.
10 Check Exhaust After treatment System housing for burn marks / damages. Weekly
11 Check tyre pressure including spare wheel, inflate tyres to specified pressure if necessary. Weekly
12 Check clutch, power steering oil level. Top up, if necessary. Monthly
Check tyres for any abnormal tyre wear. If tyre wear noticed, wheel alignment to be Monthly / 5000
13
checked immediately. Km
Rotate the tyres as per recommendation. In case any abnormal tyre wear observed,
14 Every 20000 Km
rotation to be carried out immediately for better tyre life.
15 Check the wheel alignment. Every 20000 Km
16 Check head lamp focusing. Adjust if necessary. As required
17 Check Windshield Washer water level. Top up, if necessary As required
18 Wash the vehicle As required
Monthly / 5000
19 Lubricate all chassis grease nipple points, if required
Km
20 Check engine lamp error on cluster to be reported to CAC Daily
21 Low DEF indication on cluster, top up DEF with Tata Motors Genuine DEF. As required

9.2 Service Operations to be performed at Workshop:

Check by
Sr. Frequency Customer
Operation PDI
No. (Km)
D W M
D=Daily, W=Weekly, M=Monthly, P=PDI, *=whichever is earlier
1 ENGINE
Drain off Engine oil while hot. Change engine oil and oil filter. Clean drain plug & 60,000 Km OR
1.1
engine breather. Check engine oil pressure. 1 Year*
Check condition of drive belts for water pump, alternator, fan, steering visually.
1.2 60,000 Km W P
Replace, if necessary.
 Check all drive belts for free rotation / damage:
(a) Water pump, (b) Belt Tensioner pulley, (c) Belt Idler pulley, (d) Fan pulley,
1.3 60,000 Km
(e) Alternator pulley, (f) AC belt tensioner (If fitted), (g) AC compressor pulley
(If fitted). Change if necessary.

1.4 Drive belts are to be compulsory replaced 120,000 Km

Check if red band appears on air filter Service indicator or 'Air filter clogging'
1.5 indicator on instrument cluster is ON. 60,000 Km D P
(Note - Please do not clean air filter element with air)
If red band appears on service indicator, replace primary filter element. Replace
1.6 secondary (Safety filter) during every 3rd replacement of primary filter. 60,000 Km
(Note - Please do not clean air filter element with air)

Check proper sealing of air intake and exhaust system by checking hose & pipe
1.7 60,000 Km
condition / proper tightness of clamps. Replace any defective item, if required.

Check / replace if required pipes & hoses of engine lubrication / fuel / coolant /
1.8 60,000 Km
windshield washing system.
1.9 Check cylinder head valve clearance & adjust, if necessary. 60,000 Km
Check for external clogging of radiator, intercooler, and condenser (If fitted),
1.10 60,000 Km
clean if necessary with compressed air & water.
1.11 Check coolant concentration and top up coolant, if required. 60,000 Km
Drain cooling system - Reverse flush. Check thermostat for proper operation.
240,000 Km
1.12 Refill system with fresh coolant. Use mixture of clean water & recommended anti-
OR 2 Year*
freeze agent in specified ratio.
240,000 Km
1.13 Replace cooling system hoses and radiator rubber pads for radiator mounting.
OR 2 Year*
1.14 Check thermostat working & fan operation. 60,000 Km
Check for radiator mounting rubber bush. Replace, if required. Check & tighten
1.15 60,000 Km
radiator mounting.
1.16 Check and tighten engine mounting rubber, if required. 60,000 Km

Check mounting of engine speed sensor, boost pressure sensor, air intake
1.17 60,000 Km
temperature sensor, coolant temperature sensor, vehicle speed sensor.

De-coupling element (Cylinder head cover bolts) to be checked for bolt loose and
1.18 60,000 Km
oil leakages. Change if necessary.
Check oil traces for seepages and leakages from oil sump gasket and change if
1.19 60,000 Km
necessary.

1.20 Check cylinder head cover gasket condition for leakage and change if necessary. 60,000 Km

1.21 Oil sump mounting bolts pre-tightening 60,000 Km

Check for ECU errors with diagnostic system based on error indication in cluster,
1.22 60,000 Km
if any.
1.23 Check DOC- POC (EGP) housing for burn marks / damages / abnormalities 60,000 Km W P
1.24 DEF tank neck filter to be replaced. 60,000 Km
1.25 DEF line to be checked for leakages and to be changed if required. 60,000 Km
1.26 DPF ash cleaning 240,000 Km
2 FUEL SYSTEM
2.1 Drain water sediments from fuel filter cum water separator. 60,000 Km D P
2.2 Replace both pre and main fuel filter element. 60,000 Km
2.3 Flush and clean fuel tank. Clean strainer unit and refit. 120,000 Km
3 CLUTCH
3.1 Check for free play movement of clutch pedal. Adjust if necessary. 60,000 Km
 Gear Shifting - Drive the vehicle by shifting all gears to ensure clutch functioning
3.2 (engagement, disengagement and torque transmission) and replace appropriate 60,000 Km
components if found defective.
3.3 Replace clutch fluid & carry out bleeding of system. 120,000 Km
Bleeding of clutch actuation system, In case of any complaints please check /
3.4 60,000 Km
replace affected parts.
3.5 Overhaul clutch master, slave cylinder / clutch booster. 120,000 Km
4 GEAR BOX
4.1 Change oil in Gear Box. Drain while hot. Clean drain plug & breather. 120,000 Km
5 PROPELLER SHAFT
Check Propeller shaft splines for excessive wear and noise. Replace, if
5.1 60,000 Km
necessary.
6 FRONT AND REAR AXLE

6.1 THU Bearing fitted Axle

Inspection of front / rear hubs (wheel)

1. Check for any abnormal noise.
2. Check bearing hub play
(Spec:-Hub play less than 120 micron) 60,000 Km OR
6.1.1
3. Check grease leakage for front and oil leakage for rear by opening the HUB 1 Year*
CAP
4. Check for any water ingress by removing the Hub Cap
(DO NOT DISTURB THE UNITIZED BEARING AND INTEGRATED SEAL)

6.1.2 Hub greasing is not required on THU bearing fitted vehicle. NA

6.2 Non THU Bearing fitted Axle

1st at 120,000
Change grease in front & rear hubs. Dismantle and clean bearings and other Km & then
6.2.1
components. Adjust the hub play. Replace affected parts, if required. Every 180,000
Km
6.3 Change oil in rear axle. Drain while hot. Clean drain plug and breather. 300,000 Km
7 Air BRAKES
Check for proper functioning of service brake, parking brake, LCRV and exhaust
7.1 60,000 Km D P
brake (if applicable).
During tyre rotation (with the wheels removed), Check for front & rear brakes
7.2 uneven wear of brake linings and grease spilling on linings or past hub seals. 60,000 Km
Check all springs of brake shoe for no elongation. Attend, if necessary.
Drain off air from all tanks. If condensed water is found, replace air drier
7.3 60,000 Km W P
desiccant cartridge.

Check for oil droplets / excessive oil accumulation (slight traces of oil are
acceptable) at air drier exhaust port. If yes, then carry out following activities: (a)
7.4 Check / replace compressor piston rings, (b) clean compressor head (c) Check / 60,000 Km
replace compressor outlet pipe in case of carbon formation, (d) clean oil
separator.

Check for air dryer outlet pressure difference between cut-off and cut-in, which
7.5 60,000 Km W P
should be within 0.6 bar to 1.3 bar.
Exhaust Brake (If applicable) - Check pneumatic cylinder and hose condition,
7.6 replace if required. For leakage of exhaust gas through flange joints of exhaust 60,000 Km
brake assembly, tighten the screws
Inspect torque plate, cam shaft, shoe assembly, dust shield, chamber bracket
7.7 120,000 Km
assembly, roller and fulcrum pin. Replace if required.
Conduct brake system routine checks I (Check for leakage, switches and 240,000 Km
7.8 D P
Gauges, brake pressure fill up time). OR 2 Years*
 Conduct brake system routine checks II (Check opening / closing pressure of 240,000 Km
7.9
SPV, check valves for leakage, damage etc.) OR 2 Years*
Dismantle and overhaul pneumatic aggregates of brake system. Clean / inspect 240,000 Km
7.10
& replace parts if necessary. OR 2 Years*
240,000 Km
7.11 Replace air drier desiccant cartridge and filter of air dryer / DDU.
OR 2 Years*

7.12 Check and adjust pole wheel sensor (ABS) air gap. 60,000 Km

7.13 Check hill hold assist controller body for leakage. 60,000 Km

8 SUSPENSION

8.1 Check anti roll bar bush, Cab spring eye bushes, replace if required. 60,000 Km

Check suspension. Attend, if required - Leaf springs for damage / sagging / bush
8.2 wear out / U-bolt suspension arm & steering knuckle supports & rear leaf spring 60,000 Km
arm. suspension bump stopper
Check shock absorbers for leak / damage. Check shock absorber bush, replace if
8.3 60,000 Km W P
required.
8.4 Check antiroll bar for damage / bush wear out. 60,000 Km
9 POWER STEERING
9.1 Check steering pipelines connections for leakages and rectify if any. 60,000 Km
9.2 Check power steering hydraulic limiter valve setting and peak pressure. 60,000 Km
Check steering wheel play & check for proper condition of ball joints & rubber
9.3 boots of tie rod / drag link for looseness, damage, excess wear, dislodging etc. 60,000 Km
Replace if necessary.

9.4 Drain off hydraulic oil of power steering. Replace filter cartridge. Fill in fresh oil. 120,000 Km

10 WHEELS AND TYRES

Once in 2
10.1 Check tyre pressure; inflate tyres to specified pressure, if necessary.
weeks
10.2 Rotate the tyres as per recommendation. 20,000 Km

During every
wheel change
10.3 Check for wheel nut tightness, for specified torque. & 100 Km
after wheel
change

20,000 Km OR
Check wheel alignment. (Note - Wheel alignment to be done even after changing if any
10.4
related suspension & steering linkage parts) abnormal tyre
wear noticed*

11 ELECTRICALS
Check proper functioning of switches, gauges, lights, blinkers, warning lamps in
11.1 60,000 Km D P
instrument cluster.

Check battery mountings, Clean battery posts and terminals, tighten terminals &
smear petroleum jelly. Check battery cells with cell tester and specific gravity of
11.2 60,000 Km P
electrolyte with hydrometer. Check electrolyte level in battery and top up if
necessary.
11.3 Check horn mounting and functioning. Adjustment to be done if required. 60,000 Km P
11.4 Check head lamp focusing. Adjust if necessary. 60,000 Km D P
Check all electrical system health: Ensure usage of genuine fuses with correct
11.5 rating, All ECU, DC-DC converter, telematics device, earthing connections, 60,000 Km
proper routing / clamping of wiring, intactness of grommets.
 At every wheel
11.6 ABS wheel sensors & connectors for fitment.
change
After every
11.7 Check sensors & connectors for cleanliness & secure fitment.
wash
12 CAB & LOAD BODY

Check for any paint peeling, rusting & damage to body panels & structure all
12.1 60,000 Km P
around & underneath.

Check for proper functioning of doors, seat, and sun visors. Check body for
12.2 60,000 Km P
unusual noise.

12.3 Replace cab tilt oil. (If applicable) 120,000 Km

13 AIR CONDITIONING (If Applicable)
13.1 Clean air filter (wire mesh) & inner filter. 60,000 Km W P
13.2 Replace air filter (wire mesh) & inner filter, if necessary 60,000 Km
13.3 Clean condenser with high pressure water. 60,000 Km
14 GENERAL
Check & top up levels of:
1. Engine oil
14.1 60,000 Km D P
2. Engine coolant
3. Windshield washer tank (As required)
Check & top up oil levels of:
1. Gear Box oil
14.2 60,000 Km P
2. Rear Axle oil
3. Tilt Cab (If applicable)
14.3 Check & top up oil levels of: 1. Clutch oil 2. Steering oil 60,000 Km M P
Check for / Rectify the leakages of-
1. Oil (at Engine / Clutch / Gear Box / air conditioning (If fitted) / shock absorbers
/ Rear axle/ power steering)
2. Fuel at tank, pipelines & engine
14.4 60,000 Km D P
3. Engine coolant
[Link] exhaust
5. Pneumatic (brake system)
[Link] lines
14.5 Check and tighten all fasteners if necessary as per the check list # 60,000 Km
14.6 Wash the vehicle. As Required
14.7 Grease as per the list ## 60,000 Km M P
14.8 Conduct road test for vehicle handling and functioning of aggregates. 60,000 Km
14.5 # Checking of fasteners required Periodical Checking and Tightening
Engine peripherals : Engine mounting & accessories mountings, all clamps, fuel
tank brackets, all fasteners on turbocharger, air filter mounting, radiator
a 60,000 Km
mounting, thermostat, exhaust gas processor, exhaust pipe mounting hangers &
brackets, air duct hose connections.
Driveline: Clutch housing, clutch booster, mounting of clutch master cylinder and
b slave cylinder, gear box mounting, gear shift mechanism, propeller shaft coupling 60,000 Km
flange, centre bearing bracket, rear axle carrier housing mounting studs.
Steering: Steering gear box bracket mounting bolts, pitman arm, drag link, tie
c 60,000 Km
rod, relay arm, steering column.
Suspension : Anti roll bar mounting, shock absorber mounting, leaf springs ‘U’
d 60,000 Km
bolts, nuts of spring wedge bolts, spring hanger bracket & slide support bracket
Brakes : Spring actuators & other brake valves mountings, pneumatic lines,
e anchor plate, air tanks mounting, air line clamps, exhaust brake valve mounting 60,000 Km
bolts, relay valve mounting, solenoid valve mounting, modulator valve mounting.
Electricals : Starter motor, alternator, battery mounting bolts, wiper motor,
f 60,000 Km
switches & gauges, head lamp, tail lamp, blinker lamp.
g Wheels & Tyres: wheel mounting nuts, mounting of spare wheel carrier. 60,000 Km
Cab - Cab mountings, mounting of cab lock and cab springs, Seats, RVM, door
h 60,000 Km
hinges, door locks, door striker plates, body mountings.
General: Apart from above please check visually any other fasteners for
i 60,000 Km
loosening.
14.7 ## List of items required periodic Greasing

a Clutch : Clutch release bearing, clutch cross shaft, clutch pedal bush 60,000 Km M P
b Front Axle : King pin 60,000 Km M P
Prop shaft : UJ cross joints, sliding yoke (also check the condition of rubber
c 60,000 Km M P
boot), centre bearing (Wherever applicable)
Steering : Steering tie rod ends, ball joints, drag links, centre link, idler arm,
d 60,000 Km M P
spindle / sleeves, column
e Brake: Front and rear Brake S-camshaft bushes. 60,000 Km M P
Lubricate with oil can:
Pinion bushing of starter motor and wiper & motor linkages. Door hinges, outer
f 60,000 Km M P
door handle, door latches, dove tails & striker plates, bonnet stay rod, pivot pins
& luggage box door

Annexure – 10
RECOMMENDED OIL AND LUBRICANTS
Sr. Fluid type /
Aggregates Quantity Recommended Brands
No. Grade
Engine oil 12.5 Ltr (Sump) + 1 Ltr SAE 5W30 Ultra- TATA MOTORS - TATA Motors Genuine
1 (including oil (Oil filter) = Total 13.5 premium Fully Synthetic Engine Oil 05W30
filter) Ltr Max Synthetic
Type 2 Ultra long TATA MOTORS – TATA Motors Genuine
2 Coolant 12 Ltr
life SS7721 Coolant (ULTRACOOL)
Gear Box SAE 80W90 Long TATA MOTORS - TATA Motors Genuine
3 5.7 Ltr
G550 6 Speed drain Gear Oil 80W90 LL
Rear Axle TATA MOTORS - TATA Motors Genuine
4 6.3 Ltr ProFE LL 80W90
RA 1068HD ProFE LL 80W90 Axle Oil
Power Steering TATA MOTORS – TATA Motors Genuine
5 3 Ltr Dexron II D
Oil Power Steering Oil
TATA MOTORS - TATA Motors Genuine
6 Clutch Fluid 350 ml DOT 4
Brake Fluid (DOT 4)
Axle with THU
Hub greasing is not
bearing:-
7.1 required for THU Not Applicable Not Applicable
Wheel bearing
bearing fitted vehicle.
grease

Axle with Non

THU Bearing:- Front Hub - 210 gm/hub TATA MOTORS - TATA Motors Genuine
7.2 Synthetic Grease
Wheel bearing Rear Hub - 285 gm/hub Synthetic Grease
grease
All Grease TATA MOTORS – TATA Motors Genuine
8 As required AP2 Grease
Nipples AP2 Grease
1. CASTROL – Hyspin AWH 15
Tilt cab cylinder
2. SHELL – Shell Tellus oil T15
9 oil (if 1.5 Ltr (Approx) Cab tilting oil 220
3. Exxon Mobil – Esso Tellus
applicable)
4. TOTAL – Equivis ZS 15
AUS-32 Urea TATA MOTORS – TATA Motors Genuine
10 DEF 18 L
Solution 32.5% DEF
 Annexure - 11
SPECIAL TOOL LIST

3.3L New Gen Engine Special Tools List

EMISSION
TOOL Existing Tool /
SN LOB APPLICABILI TOOL IMAGE PART NO Qty. APPLICATION Price
DESCRIPTION New Tool
TY

PULLER,
Truck BS4, BS6, 5507589
1 INJECTOR Existing Tool 1 1970
& Bus Phase 2 00702
REMOVAL

LOCKING
Truck BS4, BS6, 5507589
2 CAMSHAFT FOR Existing Tool 1 3033
& Bus Phase 2 00604
VALVE TIMIMG

CRANK SHAFT Truck BS4, BS6, 5507589

3 Existing Tool 1 335
LOCKING PIN & Bus Phase 2 00601

HP PUMP
SPROCKET Truck BS4, BS6, 2654589
4 Existing Tool 1 2793
REMOVAL & Bus Phase 2 03201
PULLER

ENGINE
COMPRESSION Truck BS4, BS6, 5507589
5 Existing Tool 1 1164
CHECKING & Bus Phase 2 00703
ADAPTER

LOCKING TIMING
Truck BS4, BS6, 5507589
6 CHAIN Existing Tool 2 294
& Bus Phase 2 00610
TENSIONER

BRACKET(LH
AND RH) ENGINE Truck BS4, BS6, 5507589
7 Existing Tool 2 3412
MOUNTING ON & Bus Phase 2 00607
REPAIR STAND
 ENGINE
Truck BS4, BS6, 2573589
8 OVERHAULING Existing Tool 1 41523
& Bus Phase 2 02401
STAND

FLYWHEEL Truck BS4, BS6, 5507589

9 Existing Tool 1 1035
LOCKING TOOL & Bus Phase 2 00644

Truck BS4, BS6, 5507589

10 SUPPORT RAIL Existing Tool 1 1803
& Bus Phase 2 00608

VALVE SPRING
Truck BS4, BS6, 2829589
11 COMPRESSOR Existing Tool 1 1377
& Bus Phase 2 00605
TOOL

PULLER FOR
Truck BS4, BS6, 5507589
12 PILOT CRANK Existing Tool 1 2926
& Bus Phase 2 00606
SHAFT BEARING

DRIFT FOR
FITMENT OF Truck BS4, BS6, 5507589
13 Existing Tool 1 814
PILOT BEARING & Bus Phase 2 00603
IN CRANK SHAFT

CLUTCH DISC
Truck BS4, BS6, 5507589
14 ALIGNMENT Existing Tool 1 917
& Bus Phase 2 00605
MANDREL TOOL

ASSEMBLY
SPECIAL TOOL Truck BS4, BS6, 5507589
15 Existing Tool 1 NA 5790
FOR TAPPET & Bus Phase 2 00112
GAP SETTING

MAIN BODY
WITH
HANDLE(SPL Truck BS4, BS6, 5507589
16 Existing Tool 1 1802
TOOL FOR & Bus Phase 2 00613
TAPPET GAP
SETTING)
 FEELER GAUGE
0.3MM THICK
Truck BS4, BS6, 5507589
17 FOR EXHAUST Existing Tool 1 429
& Bus Phase 2 00611
VALVE GAP
SETTING

FEELER GAUGE
0.25MM THICK
Truck BS4, BS6, 5507589
18 FOR INLET Existing Tool 1 429
& Bus Phase 2 00612
VALVE GAP
SETTING

INJECTER
SLEEVE Truck BS4, BS6, 5507589
19 Existing Tool 1 739
REMOVAL AND & Bus Phase 2 00615
FITMENT TOOL

DRIFT FOR
FITMENT Truck BS4, BS6, 5507589
20 Existing Tool 1 3583
OF & Bus Phase 2 00632
FRONT SEAL

DOLLY FOR
Truck BS4, BS6, 5507589
21 FITMENT OF Existing Tool 1 5681
& Bus Phase 2 00631
REAR OIL SEAL

PULLER
Truck BS4, BS6, 5507589
22 CRANKSHAFT Existing Tool 1 4587
& Bus Phase 2 00646
FRONT OIL SEAL

STRETCH BELT Truck BS4, BS6, 5507589

23 Existing Tool 1 784
FITMENT TOOL & Bus Phase 2 00638

TOOL, STRETCH Truck BS4, BS6, 5507589

24 Existing Tool 1 1146
BELT REMOVAL & Bus Phase 2 00635

Steering pump
pulley holder Truck BS4, BS6, 5412589
25 Existing Tool 1 905
(Removal of pulley & Bus Phase 2 01301
mtg. centre nut)
 OIL FILTER Truck BS4, BS6, 2870589
26 Existing Tool 1 1061
SPANNER & Bus Phase 2 01804

OIL SUMP &

SPACER BS4, BS6, 5507589
27 Existing Tool Truck 1 1207
SEALANT Phase 2 00623
REMOVAL TOOL

OIL SUMP
SEALANT BS4, BS6, 5507589
28 Existing Tool Bus 1 773
REMOVAL TOOL Phase 2 00627
FOR BUS

WEDGE FOR
SEALANT Truck BS4, BS6, 5424589
29 Existing Tool 1 1865
REMOVAL FROM & Bus Phase 2 00609
ENGINE

OIL SUMP Truck BS4, BS6, 5507589

30 Existing Tool 1 1113
REMOVAL TOOL & Bus Phase 2 00624

SPANNER FOR
TURBO
Truck
CHARGER
& Bus
MOUNTING 3
BOLT

BS4, BS6, 5530589

31 Existing Tool 1 1222
SPANNER FOR Phase 2 01401
AIR
COMPRESSOR
BOTTOM SIDE Bus
MTG. BOLT
REMOVAL &
FITMENT

FUEL INJECTION
Truck BS4, BS6, 5507589
32 PUMP REMOVAL Existing Tool 1 867
& Bus Phase 2 00625
TOOL

HIGH PRESSURE
Truck BS4, BS6, 5507589
33 SPROCKET Existing Tool 2 316
& Bus Phase 2 00619
LOCKING BOLTS
 FLYWHEEL
Truck BS4, BS6, 5507589
34 LOCKING TOOL Existing Tool 1 388
& Bus Phase 2 00634
PIN

HOLDER, FAN
Truck
PULLEY BS4, BS6, 5507589
35 Existing Tool & 1 701
(Fan Make – M/s Phase 2 00637
Bus
BorgWarner)

SPANNER FAN
ASSEMBLY Truck BS4, BS6, 5507589
36 Existing Tool 1 3444
(Fan Make – M/s & Bus Phase 2 03509
BorgWarner)

SPANNER (FAN
Truck
REMOVAL) BS4, BS6, 5507589
37 Existing Tool & 1 1184
(Fan Make – M/s Phase 2 00636
Bus
Mahle Behr)

Truck BS4, BS6, 5507589

38 Flywheel Holding Existing Tool 1 3206
& Bus Phase 2 00645

BS4, BS6, 5137589

39 AFT Unit Removal New Tool Truck 1 4301
Phase 2 02410
 Annexure - 12
EMS DIAGNOSTIC SOFTWARE DETAILS
All Workshops to ensure Garuda Hardware Kit available & Diagnostic Software is installed on Laptop to do
diagnostic of all vehicle.
PART NAME PART NUMBER PHOTO

Laptop based Software

210323999949
TDS - ICV, HCV, I&LCV, SCV & PICK UPS

TFS – ICV, HCV, I&LCV, SCV & PICK UPS 210323859941

Hardware Kit
GES -Garuda II-USB_ ENABLED_FULL_SET
Kit : 210324769907
(Garuda Hardware + USB
Cable + OBDII DLC Cable )

Hardware Child Parts

210324769908
GES - Garuda II – USB Cable

Hardware Child Parts

GES – Garuda II – OBD II – Cable 210324769909
(DLC CABLE )