ACOM18_01GB
Short Description
ACOM18_01GB...
Description
Empty container handler 8-10 tonnes SUPPLEMENT TAD851VE Stage 3a/Tier 3 TAD871VE Stage 4/Tier 4f
Publ. no ACOM18.01GB Operator's manual in original
OPERATOR’S MANUAL
DCF 80–100, DCT 80–100
Contents Preventive maintenance Preventive maintenance ...................................................................................................... 1 Service schedule Volvo TAD851VE ................................................................................... 1 Service schedule Volvo TAD871VE ................................................................................... 3 Engine.................................................................................................................................... 5 Engine, description ............................................................................................................ 5 Engine, component location Volvo TAD851VE .................................................................. 5 Engine, component location Volvo TAD871VE .................................................................. 7 Fuel system........................................................................................................................ 9 Fuel system, bleeding ........................................................................................................ 9 Fuel prefilter ................................................................................................................ 10 Fuel prefilter, draining of condensation water .................................................................. 10 Fuel prefilter, change ........................................................................................................ 11 Fuel filter, change ............................................................................................................ 12 AdBlue tank, cleaning (engine option Volvo TAD871VE)................................................. 13 Filter AdBlue pump unit, replace (engine option Volvo TAD871VE) ................................ 18 Filter in AdBlue pump tank, replace (engine option Volvo TAD871VE) ........................... 19 Air intake and exhaust outlet............................................................................................ 23 Exhaust outlet, component location Volvo TAD851VE................................................ 23 Exhaust outlet, component location Volvo TAD871VE................................................ 24 Crankcase ventilation.................................................................................................. 25 Crankcase filter, replace (engine option Volvo TAD871VE)............................................. 25 Cooling system ................................................................................................................ 26 Cooling fan .................................................................................................................. 26 Visco fan, description ............................................................................................. 26 Coolant........................................................................................................................ 26 Coolant, change............................................................................................................... 26 Lubrication system ........................................................................................................... 29 Oil testing (engine option Volvo) ................................................................................. 29 Oil and oil filter, change ................................................................................................... 30 Oil level, check (engine option Volvo) .............................................................................. 32 Oil level, check................................................................................................................. 32 Frame, body, cab and accessories ................................................................................... 33 Heating, ventilation and air conditioning .......................................................................... 33 AC compressor ........................................................................................................... 33 Drive belt, check ..................................................................................................... 33 Drive belt, replace................................................................................................... 33 Drive belt tensioner, check (engine option Volvo)................................................... 34 Handling .............................................................................................................................. 35 Error codes ...................................................................................................................... 35 Error code tables......................................................................................................... 35 Error codes machine........................................................................................................ 35 Error codes engine........................................................................................................... 35 Technical data..................................................................................................................... 45 Data ................................................................................................................................. 45 Volumes ........................................................................................................................... 46 Oils and lubricants, recommendation............................................................................... 48
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
1
C Preventive maintenance
Preventive maintenance Service schedule Volvo TAD851VE Service
Object, action
500h, 1500h, 2500h, etc.
1000h, 3000h, 5000h, etc.
2000h, 4000h, 6000h, etc.
C*
R**
R**
Comment
Reference
*Drain the water/impurities. Change the filter earlier if an error code is shown.
Fuel prefilter, draining of condensation water, page 10
** Change every 1000 h or every 12 months.
Fuel prefilter, change, page 11
Change the filter earlier if an error code is shown.
Fuel filter, change, page 12
1 Engine Fuel prefilter
Fuel filter
R*
R*
* Change every 1000 h or every 12 months. Valve clearance
C*
C
* First time at 1000 h, then every 2000:e h. After engine replacement or engine overhaul, check/adjust at 250 h.
Air intake and exhaust outlet Air filter main cartridge
C/R
Air filter safety cartridge
C / R*
C
C/R
C/R
Check of indicator, change on indication.
C / R*
C / R*
* Change every other time the main cartridge is replaced.
C*
* Check every 2000 h or every 24 months.
Must be performed by a service technician authorised by Volvo.
C / R*
* Replace as required or every 2000 h or every 48:e months.
Drive belt, check, page 33
C / R*
Belt tensioner
C
C
C
Coolant, level check
C
C
C
Coolant, freezing point
C
C
C
Coolant, change
1.6 Air intake and exhaust outlet, page 23
C
Turbo
Drive belts
Must be performed by a service technician authorised by Volvo.
R*
Drive belt, replace, page 33 Drive belt tensioner, check (engine option Volvo), page 34
For volume and grade, see section F Technical data. * Change every 8000 h or every 48 months.
Supplement, Operator’s manual DCF 80–100, DCT 80–100
See Maintenance manual See Maintenance manual
ACOM18.01GB
2
C Preventive maintenance – Preventive maintenance
Service
Object, action Engine oil and oil filter
500h, 1500h, 2500h, etc.
1000h, 3000h, 5000h, etc.
2000h, 4000h, 6000h, etc.
R*
R*
R*
Comment
Reference
For volume and quality, see section Technical data, page 45.
Oil and oil filter, change, page 30
Fuel with sulphur content 0.3% (3000 ppm):
Oil and oil filter, change, page 30
Sulphur content 0.3-0.5%: change every 250h or at least every 12 months. Sulphur content >0.5%: change every 125h or at least every 12 months. Filter crankcase ventilation Connectors
R*
R*
R*
* Change every 1500 h or every 12 months.
1.6.7 Crankcase ventilation, page 25
C
Visual check for damage or corrosion.
-
NOTE Never unplug connectors unnecessarily, risk of impurities entering the connector.
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
3
C Preventive maintenance – Preventive maintenance
Service schedule Volvo TAD871VE Service
Object, action
500h, 1500h, 2500h, etc.
1000h, 3000h, 5000h, etc.
2000h, 4000h, 6000h, etc.
C*
R**
R**
Comment
Reference
*Drain the water/impurities. Change the filter earlier if an error code is shown.
Fuel prefilter, draining of condensation water, page 10
* Change every 1000 h or every 12 months.
Fuel prefilter, change, page 11
Change the filter earlier if an error code is shown.
Fuel filter, change, page 12
1 Engine Fuel prefilter
Fuel filter
R*
R*
* Change every 1000 h or every 12 months. AdBlue tank
C / R*
Clean and change the filter every 2000 h or every 24:e months.
AdBlue tank, cleaning (engine option Volvo TAD871VE), page 13
Filter AdBlue pump unit
R*
* Change every 2000 h or every 24 months.
Filter AdBlue pump unit, replace (engine option Volvo TAD871VE), page 18
Strainer AdBlue pump unit
R*
* Change every 2000 h or every 24 months.
Filter AdBlue pump unit, replace (engine option Volvo TAD871VE), page 18
Filter level sensor AdBlue tank
R*
* Change every 2000 h or every 24 months.
Filter in AdBlue pump tank, replace (engine option Volvo TAD871VE), page 19
C
* First time at 1000 h, then every 2000:e h.
Must be performed by a service technician authorised by Volvo.
Valve clearance
C*
After engine replacement or engine overhaul, check/adjust at 250 h. Air intake and exhaust outlet Air filter main cartridge
C/R
Air filter safety cartridge
C
C/R
C/R
Check of indicator, change on indication.
C / R*
C / R*
* Change every other time the main cartridge is replaced.
C*
* Check every 2000 h or every 24 months.
Must be performed by a service technician authorised by Volvo.
C / R*
* Replace as required or every 2000 h or every 48:e months.
Drive belt, check, page 33
Turbo
Drive belts
C / R*
C / R*
Belt tensioner
C
C
C
Coolant, level check
C
C
C
Coolant, freezing point
C
C
C
Coolant, change
1.6 Air intake and exhaust outlet, page 23
C
R*
Drive belt, replace, page 33 Drive belt tensioner, check (engine option Volvo), page 34
For volume and grade, see section F Technical data. * Change every 8000 h or every 48 months.
Supplement, Operator’s manual DCF 80–100, DCT 80–100
See Maintenance manual See Maintenance manual
ACOM18.01GB
4
C Preventive maintenance – Preventive maintenance
Service
Object, action Engine oil and oil filter
500h, 1500h, 2500h, etc.
1000h, 3000h, 5000h, etc.
2000h, 4000h, 6000h, etc.
R*
R*
R*
Comment
Reference
For volume and quality, see section Technical data, page 45.
Oil and oil filter, change, page 30
The oil must always be changed the first time at 500h.
Oil testing (engine option Volvo), page 29
* The oil change interval can be extended from 500h to 1000h with approved documented oil samples at 1000h, 1250h and 1500h.
Oil and oil filter, change, page 30
Engine oil changed every 12 months. Filter crankcase ventilation Connectors
R*
R*
R*
* Change every 1500 h or every 12 months.
1.6.7 Crankcase ventilation, page 25
C
Visual check for damage or corrosion.
-
NOTE Never unplug connectors unnecessarily, risk of impurities entering the connector.
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
5
1 Engine – Engine
1 Engine Engine, description Engine, component location Volvo TAD851VE 6
5
7 8 9
1
2
3 14
11
12
13
10
019719
4
1. Intercooler
8. Dipstick, transmission oil
2. Water cooler
9. Dipstick, engine oil
3. Condenser
10. Oil cooler
4. Transmission oil cooler
11. Fuel filter
5. Temperature sensor
12. Oil filter
6. Filling point, engine oil
13. Control unit, engine (D793)
7. Filling point transmission oil
14. Pressure sensor
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
6
1 Engine – Engine
4
3
2
5
6
7
8
9
10
11
1. Valve cover
7. Exhaust cooler (EGR)
2. Sensor, coolant level (B7590)
8. Turbo
3. Filling point, coolant
9. Oil sump
4. Expansion tank
10. Compressor
5. Fuel prefilter
11. Alternator
6. Starter motor
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
019718
1
7
1 Engine – Engine
Engine, component location Volvo TAD871VE 5
6
7 8 9
1
2
3
10
11
12
13
14
15
019015
4
1. Intercooler
9. Dipstick, engine oil
2. Water cooler
10. Crankcase ventilation
3. Condenser
11. Oil cooler
4. Transmission oil cooler
12. Pressure sensor
5. Temperature sensor
13. Fuel filter
6. Filling point, engine oil
14. Oil filter
7. Filling point transmission oil
15. Control unit, engine (D793)
8. Dipstick, transmission oil
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
8
1 Engine – Engine
4
3
2 1
6
7
8
9
10
11 019016
5
1. Valve cover
7. Exhaust cooler (EGR)
2. Sensor, coolant level (B7590)
8. Turbo
3. Filling point, coolant
9. Oil sump
4. Expansion tank
10. Compressor
5. Fuel prefilter
11. Alternator
6. Starter motor
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
1 Engine – Fuel system
9
1.2 Fuel system Fuel system, bleeding
NOTE Read the safety instructions for the fuel system before starting work, see section B Safety. The fuel system must be bled, e.g. after replacing the fuel filter, if the fuel is run empty and after long periods of downtime.
2
Machine in service position, see section B Safety.
2
Remove the protective plug from the bleed nipple (position 1).
3
Open the bleed nipple two turns and connect a transparent fuel-resistant hose to the bleed nipple. Route the open end of the hose into a receptacle.
4
Bleed the fuel system by pumping with the hand pump (position 2) until fuel free of air emerges from the bleed hose.
5
Close the bleed nipple while fuel is flowing out of the hose.
6
Wait for 15 seconds, then repeat Steps 4 – 5.
7
Remove the hose and tighten the bleed nipple by 3.5 Nm.
8
Refit the protective plug on the bleed nipple.
9
Start the engine and allow it to idle for approximately 5 minutes before increasing the speed.
019005
1
1
1. Bleed nipple 2. Hand pump
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
10
1 Engine – Fuel prefilter
1.2.3 Fuel prefilter Fuel prefilter, draining of condensation water
NOTE Read the safety instructions for the fuel system before starting work, see section B Safety.
NOTE The water separator should be drained of water when necessary or at least every 50 operating hours.
1
2
017831
3
1
Machine in service position, see section B Safety.
2
Position a receptacle under the fuel prefilter.
3
Open the drain tap (position 3) on the underside and allow the condensation water to drain out. Close the cock when pure fuel without water is draining out.
4
Remove the water separator (position 2) from the fuel prefilter (position 1) by turning in accordance with the figure.
5
Clean the water separator and refit it on the filter.
6
Close the drain tap.
7
Bleed the fuel system, see Fuel system, bleeding, page 9.
8
Turn on the system voltage and start the engine. Check that the filter is sealed.
1. Fuel prefilter 2. Water separator 3. Drain tap
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
11
1 Engine – Fuel prefilter
Fuel prefilter, change
NOTE Read the safety instructions for the fuel system before starting work, see section B Safety.
1
1
Machine in service position, see section B Safety.
2
Clean the fuel prefilter and water separator externally.
3
Drain the fuel prefilter (position 1) of fuel and water by opening the drain tap (position 4). Collect any fuel in a receptacle.
4
Disconnect the connector (position 3) for the water separator.
5
Remove the water separator (position 2) from the old filter.
6
Remove the fuel prefilter (position 1) from the filter holder, use a filter removal tool. Collect any fuel in a receptacle.
7
Clean the water separator internally.
8
Lubricate the gasket on the new fuel prefilter using diesel fuel.
9
Fit a new O-ring on the water separator and moisten it with diesel fuel.
2
Fit the water separator on the new fuel prefilter.
NOTE Do not fill the new fuel filter with fuel prior to installation. There is a risk of impurities entering the fuel system and causing malfunctions or damage.
3
019006
4
10
Fit the new fuel prefilter on the filter holder. Tighten in accordance with the instructions on the filter.
1. Fuel prefilter 2. Water separator
11
Connect the connector for the water separator.
12
Bleed the fuel system, see Fuel prefilter, draining of condensation water, page 10.
13
Turn on the system voltage and start the engine. Check the sealing integrity.
3. Wiring, water separator 4. Draining
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
12
1 Engine – Fuel prefilter
Fuel filter, change
NOTE Read the safety instructions for the fuel system before starting work, see section B Safety. 1
Machine in service position, see section B Safety.
2
Clean the fuel filter externally. Clean around the filter as well.
1
NOTE
2
Be prepared to collect up some diesel. The filter housing is full of diesel and there is a risk of spillage when the cover is removed.
019707
3 4
3
Remove the filter cover (position 1) from the filter housing (position 4).
4
Remove the filter insert (position 3) and O-ring (position 2) from the filter cover.
5
Replace the O-ring, moisten the new O-ring in order to prevent it from turning.
6
Fit the new filter insert in the cover. Make sure that the filter insert is fitted correctly in the cover.
7
Lower the filter insert with cover fitted into the filter housing. Carefully tighten the cover and check that the O-ring does not turn. If necessary, lubricate the O-ring again.
8
Bleed the fuel system, see Fuel prefilter, draining of condensation water, page 10.
9
Start the engine and check the sealing integrity.
Volvo TAD851VE / TAD871VE 1. Filter cover 2. O-ring
Tighten to a tightening torque of 25 Nm.
3. Filter insert 4. Filter housing
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
13
1 Engine – Fuel prefilter
AdBlue tank, cleaning (engine option Volvo TAD871VE)
NOTE Read the safety instructions for AdBlue before starting work, see section B Safety.
1d 1b
Machine in service position, see section B Safety.
2
Drain the AdBlue tank into a receptacle. The drain plug for the AdBlue tank can be accessed from the underside of the machine.
2
1c
3 4
018998
1a
1
AdBlue tank 1a 1b 1c 1d 2 3 4
Filler cap Filler pipe with strainer Filler spigot O-ring Tank unit Drain plug and seal ring Filter on tank unit 3
Position a jack or similar as support under the console for the AdBlue tank.
4
Release the rubber gasket that seals the AdBlue filling point against the cover plate by pressing it in behind the cover plate (position 1).
5
Loosen the tensioning strap (position 4) that secures the console with the tank.
6
Release the console by loosening the 4 screws (position 5) that attach the lower console to the side console.
7
Lower the AdBlue tank so that you can access the connector for the tank unit through the hole in the cover plate for the AdBlue filling point.
1
2
5
4
019008
3
1. AdBlue filling 2. Console AdBlue tank 3. Drain point AdBlue tank 4. Tensioning strap 5. Screws for the console
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
14
1 Engine – Fuel prefilter
8
2
Mark and detach the hose connections for AdBlue from the tank unit (position 1). Protect the machine from leakage by isolating the AdBlue hoses with a plastic bag. Note the locations so that the hoses are connected correctly.
3
018199
1
1. Connection AdBlue 2. Connection coolant for tank heating 3. Connection ventilation hose 9
Clamp the hoses for tank heating together (position 2) using hose clamp pliers or similar in order to avoid coolant leakage when the hoses are detached.
10
Mark and detach the hoses for the tank heating from the tank unit. Note the locations so that the hoses are connected correctly.
1
2
11
Release the AdBlue tank by fully loosening the tensioning strap and removing the jack and console.
12
Remove the filler cap (position 1) and filler pipe with strainer (position 2).
NOTE If it is difficult to remove the filler pipe, then detach the filler spigot (3 screws) and press the pipe forward from the inside. Rinse the strainer for the filler pipe.
018999
13
1. Filler cap 2. Filler pipe with strainer
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
15
1 Engine – Fuel prefilter
Lower the filler cap and filler pipe in a water bath. Allow them to remain for at least two minutes.
014226
14
Example figure
NOTE Make sure that the filler pipe with strainer and filler spigot is removed before the tank unit is removed. 15
3
Undo the 3 screws that attach the filler spigot in the tank. Check that the O-ring fitted between spigot and tank is intact. Undo the hose clamp that attaches the tank unit in the tank and angle and lift the unit from the tank.
5 16
Protect the electrical connections by packing them into a bag. Check the filter, clean if necessary. To change, see Filter in AdBlue pump tank, replace (engine option Volvo TAD871VE), page 19.
NOTE Always change a damaged filter.
019000
17
1. Filler cap
Then check that the tank is completely drained of water. 18
Refit and attach the tank unit in the tank.
19
Refit the O-ring and filler spigot. Make sure that the O-ring is fitted in place and tighten the 3 screws that attach the spigot in the tank.
20
Refit the filler pipe and filler cap.
2. Filler pipe with strainer 3. Filler spigot
Flush the tank with hot water for at least ten minutes.
4. O-ring
NOTE When refitting the spigot, it is important that it is correctly rotated.
018813
1
2
4
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
16
1 Engine – Fuel prefilter
21
Fit the drain plug, use a new gasket. Tighten to a tightening torque of 30 Nm.
NOTE Only use gaskets that can withstand AdBlue.
1
019001
2
1. Drain plug 2. Gasket
2
22
Check that the ventilation hose (position 3) is not clogged. Blow it clean using compressed air if necessary. Pay attention that AdBlue does not come into contact with the electrical connection. Make sure that the ventilation hose emerges under the tank.
23
Lift the AdBlue tank back into its place. Lift it up far enough so that you can access the connector for the tank unit through the hole in the cover plate for the AdBlue filling point. Use a jack if necessary.
24
Plug in the electrical connector for the tank unit
25
Connect the hoses for the tank heating (position 2) to the tank unit in accordance with the marking.
26
Connect the hose connections for AdBlue (position 1) to the tank unit in accordance with the marking.
27
Remove the blocking from the hoses for tank heating.
28
Fit the console with its 4 attaching bolts. Secure the AdBlue tank by tightening the tensioning strap around the tank and the console.
3
018199
1
1. Connection AdBlue 2. Connection coolant for tank heating 3. Connection ventilation hose
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
1 Engine – Fuel prefilter
17
29
Fit the tensioning strap back in the buckle in accordance with the series of figures.
30
Pull the rubber gasket in front of the cover plate so that it seals between the cover plate and the AdBlue filling point.
31
Check that the drain plug is tightened correctly.
32
Fill the tank with AdBlue. Refit the filler cap. Start the engine and check the sealing integrity. Check coolant level.
018837
33 34
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
18
1 Engine – Fuel prefilter
Filter AdBlue pump unit, replace (engine option Volvo TAD871VE)
NOTE Read the safety instructions for AdBlue before starting work, see section B Safety.
CAUTION Wait at least two minutes after switching off the engine before removing the hoses for AdBlue so that the after-treatment system has time to drain and depressurise.
3
1
Machine in service position, see section B Safety.
2
The AdBlue pump unit is located on the left-hand side of the machine in front of the AdBlue tank. The filter cover on the pump (position 1) can be accessed from the underside of the machine.
3
Inspect the area around the filter cover for leakage. AdBlue leakage gives off a white precipitate. If there are signs of leakage, clean with hot water and check what could be causing the leakage.
4
There may be AdBlue residue in the filter housing. Position a receptacle under the filter cover.
5
Screw off the filter cover from the pump (position 1). A 27 mm spanner can be used to facilitate the process.
6
Remove the equalisation unit (position 2).
7
Remove the old filter insert (position 3). To pull out the filter, use the puller included with the filter kit by first pressing it into the filter hole until it clicks.
8
Install the new filter insert and then the equalisation unit.
9
Finally, screw on the filter cover, tighten to tightening torque 20 (+5) Nm
10
Start the engine and check the sealing integrity.
018207
2
1
1. Filter cover 2. Equalisation unit 3. Filter insert
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
19
1 Engine – Fuel prefilter
Filter in AdBlue pump tank, replace (engine option Volvo TAD871VE)
NOTE Read the safety instructions for AdBlue before starting work, see section B Safety.
1d 1b
Machine in service position, see section B Safety.
2
Drain the AdBlue tank into a receptacle. The drain plug for the AdBlue tank can be accessed from the underside of the machine.
2
1c
3 4
018998
1a
1
AdBlue tank 1a 1b 1c 1d 2 3 4
Filler cap Filler pipe with strainer Filler spigot O-ring Tank unit Drain plug and seal ring Filter on tank unit
1
2
5
4
Position a jack or similar as support under the console for the AdBlue tank.
4
Release the rubber gasket that seals the AdBlue filling point against the cover plate by pressing it in behind the cover plate.
5
Loosen the tensioning strap (position 4) that secures the console with the tank.
6
Release the console by loosening the 4 screws (position 5) that attach the lower console to the side console.
7
Lower the AdBlue tank so that you can access the connector for the tank unit through the hole in the cover plate for the AdBlue filling point.
019008
3
3
1. AdBlue filling 2. Console AdBlue tank 3. Drain point AdBlue tank 4. Tensioning strap 5. Screws for the console
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
20
1 Engine – Fuel prefilter
8
2
Mark and undo the hose connections for AdBlue (position 1) from the tank unit, protect the machine from leakage by isolating the AdBlue hoses with a plastic bag. Note the locations so that the hoses are connected correctly.
3
018199
1
1. Connection AdBlue 2. Connection coolant for tank heating 3. Connection ventilation hose 9
Clamp the hoses for tank heating together (position 2) using hose clamp pliers or similar in order to avoid coolant leakage when the hoses are detached.
10
Mark and detach the hoses for the tank heating from the tank unit. Note the locations so that the hoses are connected correctly.
11
Release the AdBlue tank by fully loosening the tensioning strap and removing the jack and console.
NOTE Make sure that the filler pipe with strainer and filler spigot is removed before the tank unit is removed. 12
1
2
3
4 5
Undo the 3 screws that attach the filler spigot (position 3) in the tank. Check that the O-ring (position 4) fitted between spigot and tank is intact. Undo the hose clamp that attaches the tank unit (position 5) in the tank and angle and lift the unit from the tank. Protect the electrical connections by packing them into a bag.
019000
13
1. Filler cap 2. Filler pipe with strainer 3. Filler spigot 4. O-ring 5. Tank unit
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
1 Engine – Fuel prefilter
21
14
Remove the filter from the tank unit.
15
Flush clean the AdBlue pipes on the tank unit using hot water.
16
Fit the new filter on the tank unit. Refit and attach the tank unit in the tank.
18
Refit the O-ring and filler spigot. Make sure that the O-ring is fitted in place and tighten the 3 screws that attach the spigot in the tank.
19
Refit the filler pipe and filler cap.
018222
17
Tank unit filter
NOTE
018813
When refitting the spigot, it is important that it is correctly rotated.
20
Fit the drain plug, use a new gasket. Tighten to a tightening torque of 30 Nm.
NOTE Only use gaskets that can withstand AdBlue.
1
019001
2
1. Drain plug 2. Gasket 21
Lift the AdBlue tank back into its place. Lift it up far enough so that you can access the connector for the tank unit through the hole in the cover plate for the AdBlue filling point. Use a jack if necessary.
22
Plug in the electrical connector for the tank unit
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
22
1 Engine – Fuel prefilter
2
23
Connect the hoses for the tank heating (position 2) to the tank unit in accordance with the marking.
24
Connect the hose connections for AdBlue (position 1) to the tank unit in accordance with the marking.
25
Remove the blocking from the hoses for tank heating.
26
Fit the console with its 4 attaching bolts. Secure the AdBlue tank by tightening the tensioning strap around the tank and the console.
27
Fit the tensioning strap back in the buckle in accordance with the series of figures.
28
Pull the rubber gasket in front of the cover plate so that it seals between the cover plate and the AdBlue filling point.
29
Check that the drain plug is tightened correctly.
3
018199
1
1. Connection AdBlue 2. Connection coolant for tank heating 3. Connection ventilation hose
Fill the tank with AdBlue. Refit the filler cap. Start the engine and check the sealing integrity.
32
Check coolant level.
018837
30 31
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
1 Engine – Air intake and exhaust outlet
23
1.6 Air intake and exhaust outlet Exhaust outlet, component location Volvo TAD851VE
1 5
4
1
4
3
2 1. End pipe
4. Heat protection
2. Silencer
5. Gateway control visco fan
019716
1
3. Exhaust pipe
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
24
1 Engine – Air intake and exhaust outlet
Exhaust outlet, component location Volvo TAD871VE
1
13
14
1
12 10 11 10 9 6 5
8
4 2
3 1. End pipe
8. Silencer with catalyst (SCR)
2. Control unit after-treatment system (UDS)
9. NOx sensor after after-treatment
3. Water valve
10. Exhaust pipe
4. AdBlue pump unit
11. Injection unit, AdBlue
5. AdBlue tank
12. NOx sensor before after-treatment
6. Tank unit with sensor for level and temperature indication
13. Heat protection 14. Gateway error codes SCR and control visco fan
7. Sensor exhaust temperature
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
019017
7
1 Engine – Crankcase ventilation
25
1.6.7 Crankcase ventilation Crankcase filter, replace (engine option Volvo TAD871VE) 1
Machine in service position, see section B Safety.
2
Clean around the filter.
3
Remove the filter cover manually.
4
Remove the filter insert.
5
Replace the O-ring.
6
Fit the new filter insert.
7
Turn and tighten the filter cover.
8
Start the engine and check the sealing integrity.
1
3
019010
2
1. Filter cover 2. Filter insert 3. O-ring
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
26
1 Engine – Cooling system
1.7 Cooling system 1.7.5 Cooling fan Visco fan, description The machine is equipped with an engine-driven visco fan. An extra gateway, located to the right behind the driver's seat, controls the visco fan according to transmission cooling requirements.
14
018482
This gateway also controls error codes from the after-treatment system for Volvo TAD871VE.
14. Gateway in cab.
1.7.7 Coolant Coolant, change Draining 1
Machine in service position, see section B Safety
2
Open the filler cap on the expansion tank carefully until a slight resistance is felt and allow any overpressure to be vented away.
A
The filler cap has a position for venting out overpressure without the risk of the cap loosening. The position feels like a small notch when turning the cap.
WARNING C
The cooling system is pressurised. Steam or hot coolant may spray out. Risk of scalding/burn injuries!
B
019717
Open the filler cap very carefully when the engine is warm. Wait until the coolant has cooled down before topping up.
A. Position of the coolant container (expansion tank)
3
When the overpressure has been vented away, remove the filler cap from the cooling system's expansion tank.
B. Filling point C. Level marking MIN and MAX
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
27
1 Engine – Coolant
4
Position a receptacle under the drain points on the radiator and engine. For cooling system volume, see section F Technical data.
5
Open all drain points. Drain the coolant from the radiator and engine block with a drain hose. The drain point for the radiator is fitted centrally on the right-hand side of the radiator tank (in machine's travel direction). The drain point for the engine is fitted on the left-hand side of the engine block. Thread a drain hose onto the drain point.
6
Check that all coolant drains out.
019009
1
1. Drain point, radiator
1
2
NOTE
018641
Deposits that may be inside the cock/plug must be cleaned out; otherwise there is a risk that coolant may remain and cause freezing damage.
1. Drain hose
Allow the drain taps or plugs to remain open and ensure that the heating control knob is set to full heat during cleaning. 7
Insert a hose in the filler hole in the expansion tank and flush with clean water, until the water flowing out is clear.
8
Remove the thermostat and flush out the thermostat housing.
9
It is recommended to flush the cab heating circuit. Flush in the opposite flow direction to normal through the cab's heating coil. It is also recommended to detach the radiator hoses and flush the radiator in the opposite direction to the flow.
2. Drain point engine
Cleaning with coolant 1
Fill the cooling system, see Filling point, page 28. Use only recommended coolant, see section F Technical data.
2
Drain the cooling system after 1-2 days of operation.
NOTE In order to avoid dissolved materials settling in the cooling system, drain quickly, within 10 minutes, without the engine having been switched off for a long time. Remove the filler cap from the expansion tank and the lower radiator hose if necessary in order to increase the drain speed. 3
Immediately flush the system thoroughly with clean hot water in order to prevent dirt settling on the internal surfaces. Flush until fully clean water is running out. Check that the water valve in the cab is fully open during cleaning.
4
If impurities still remain after flushing for a long time, a radiator cleaner can be used for cleaning, contact Cargotec Service.
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
28
1 Engine – Coolant
NOTE Use only cleaning agents approved by the engine manufacturer. Follow the instructions on the packaging carefully.
Filling point 1
When the cooling system is completely free from impurities, close the drain points.
CAUTION Use approved coolant. Risk of engine damage and invalidated warranty if unapproved coolant is used. Only use coolant approved by the engine supplier when changing and topping up the coolant. 2
Fill new ready-mixed coolant of the correct type in the expansion tank until the level is in the centre of the sight glass. For volume and grade, see section F Technical data.
3
Start the engine. Check that the water valve in the cab is fully open so that the heating system is bled.
4
ACOM18.01GB
Stop the engine after approximately one hour and check the coolant level, top up if necessary.
Supplement, Operator’s manual DCF 80–100, DCT 80–100
1 Engine – Lubrication system
29
1.8 Lubrication system Oil testing (engine option Volvo) By taking an oil sample at 1000 h, 1250 h and 1500 h, it is possible to extend the change interval for engine oil to 1000 h. The new change interval only applies for the tested combination of engine type, engine oil, fuel quality and operating mode. If any of these parameters are changed then the interval must be identified by means of testing with a new series of oil samples. In order for the 1000 h change interval to apply, all of the conditions below must be met:
A MIN
MAX
•
Carry out and document service in accordance with Volvo Penta's service protocol for the engine.
•
Oil samples approved and carried out using the Volvo Penta Kit for oil analysis (can be ordered using part number 923944.2781).
•
Only Volvo Penta oil filters.
•
Only oil grade in accordance with section F Technical data.
•
Only ULSD fuel may be used.
B
019011
C
A. Oil dipstick location B. Oil filling C. Oil dipstick The filler pipe and dipstick for the engine oil are located under the hood.
Taking samples 1
Follow the instructions in the kit. The oil sample can be taken via oil filling (position B).
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
30
1 Engine – Lubrication system
Oil and oil filter, change
NOTE Read the safety instructions for the oil before starting work, see section B Safety. Run the engine to operating temperature.
2
Machine in service position, see section B Safety.
3
Position a receptacle under the engine's drain point for engine oil. For volume, see section F Technical data.
4
Remove the drain plug from the engine and drain the engine of oil.
5
Clean around the oil filter.
007317
1
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
1 Engine – Lubrication system
6
Carefully remove the filter cover (position 1).
7
Remove the O-ring (position 2) and filter insert (position 3).
1
Allow the oil to drain from the filter into the receptacle. 8
2
3
31
Fit a new O-ring on the cover.
9
Secure the new filter insert in the cover.
10
Then fit the filter cover with a new filter insert and O-ring in the filter housing and tighten to a torque of 40 Nm. Do not tighten the cover too hard, the threads may crack which can lead to leakage.
11
Once the oil has drained out, fit the oil plug with a new gasket. Tighten to a maximum tightening torque of 55 Nm.
NOTE Do not tighten the oil plug with higher tightening torque, the threads will be damaged. 12
Fill with engine oil to the correct level. Do not fill to above the MAX level. For volume and grade, see section F Technical data. Start the engine, allow it to run at idling speed. Check that the oil pressure is normal and that there is no leakage.
14
Switch off the engine, wait 5 minutes and check the oil level, see Oil and oil filter, change, page 30. Top up if necessary.
019012
13
1. Filter cover 2. O-ring 3. Filter insert
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
32
1 Engine – Lubrication system
Oil level, check (engine option Volvo) Oil level, check
NOTE Read the safety instructions for the oil before starting work, see section B Safety. The engine's oil filler pipe (position B) and oil dipstick (position C) are located under the hood. 1
Machine in service position, see section B Safety.
2
The oil level must be checked when the oil is warm. The oil dipstick has two markings; the oil level should be between the two markings.
3
Top up as required with new engine oil (position B). For volume and grade, see section F Technical data).
A MIN
MAX
Do not fill to above the MAX level. 4
Fill - wait a moment - check the oil dipstick.
NOTE Work carefully when filling engine oil to prevent other fluids or particles from contaminating the oil. Other fluids or particles in the engine oil means a risk of engine damage.
B
019011
C
A. Position for filling point B. Filling point C. Oil dipstick
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
9 Frame, body, cab and accessories – Frame, body, cab and accessories
33
9 Frame, body, cab and accessories 9.4 Heating, ventilation and air conditioning 9.4.7 AC compressor Drive belt, check Check after operating when the belt is warm. 1
Machine in service position, see section B Safety.
2
Raise the hood.
3
It should be possible to press down the drive belt approx. 3-4 mm between the belt pulleys. Check that the belt does not have any intersecting cracks. Transverse cracks are acceptable, longitudinal cracks that are intersected by transverse cracks are not acceptable.
NOTE The belt tensioner is automatic.
IMPORTANT 008011
Always replace a drive belt that looks to be worn or has cracks. 4
Close the hood.
Drive belt, replace 1
Machine in service position, see section B Safety.
2
Loosen the belt tensioner by fitting a 1/2" square box wrench in the belt tensioner (position 1). Lift the wrench up and remove the drive belt.
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
34
9 Frame, body, cab and accessories – AC compressor
3
3
A 21 mm socket grip is moulded into the tensioner, use a socket wrench with a 21 mm socket pressed onto the socket wrench's barrel plug (position 1). Unload the belt tensioner by turning the belt tensioner (position 2) with the socket wrench.
4
When the tension lever is unloaded with the socket and the socket wrench, 2 holes align (position 3). Lock the tension lever by inserting a drift (see figure) or similar in both holes. The socket wrench and socket can now be removed.
5
Remove the drive belt.
6
Check that the belt pulleys are clean and undamaged.
7
Fit the new drive belt.
8
Fit the socket and socket wrench again and remove the drift. Carefully release the belt tensioner so that the belt is tensioned once again.
9
Check that the drive belts are correctly aligned and that they can be pressed down 3–4 mm.
10
Start the engine and perform a function check.
018727
2
1 1. Socket wrench with 1/2" sleeve socket 2. Belt tensioner
018701
3. Positioning of drift or similar
Drive belt tensioner, check (engine option Volvo) Check below for any replacement of the belt tensioner (see workshop manual) 1
Check that there are no cracks on the drive belt tensioner's wheels or levers.
2
Check that the tension lever stop is not touching the moulded stop lugs on the belt tensioner housing.
3
Check that the lower tension lever stop is in contact with the lower stop lug on the belt tensioner housing.
With drive belt removed
ACOM18.01GB
4
Check the belt tensioner for signs of wear and damage at the tension wheel and the tension lever, if there are signs of damage then the centre bearing may be worn out.
5
Measure the distance between the belt tensioner's spring housing and the tension lever, the clearance must not exceed 3 mm.
Supplement, Operator’s manual DCF 80–100, DCT 80–100
5 Handling – Handling
35
5 Handling 5.3 Error codes 5.3.3 Error code tables Error codes machine Code 462
Description
Action
Communication error with Stage 4 SCR Gateway in the cab.
STOP
Error codes engine Error codes Volvo TAD851VE and TAD871VE Display (SPN/FMI)
Supplier code
Description
Action
28/2
-
+ switches.
WARNING
29/2
-
Accelerator.
WARNING
29/3
-
Accelerator.
WARNING
29/4
-
Accelerator.
WARNING
29/5
-
Accelerator.
WARNING
51/3
P02E612
Sensor throttle position. Engine speed limited to idling speed.
WARNING
51/5
P02E613
Sensor throttle position. Engine speed limited to idling speed.
WARNING
51/7
P02E699
Sensor throttle position. Engine speed limited to idling speed.
WARNING
51/12
P02E601
Sensor throttle position. Engine speed limited to idling speed.
WARNING
51/13
P02E697
Sensor throttle position. Engine speed limited to idling speed. Engine difficult to start or does not start at all.
WARNING
91/0
P012085
Accelerator. Speed limitation.
WARNING
91/2
-
Accelerator.
WARNING
91/3
-
Accelerator.
WARNING
91/4
-
Accelerator.
WARNING
91/5
-
Accelerator.
WARNING
91/9
P012082
Accelerator.
WARNING
91/13
-
Accelerator.
WARNING
91/19
P012083
Accelerator. Speed limitation.
WARNING
94/0
P008B97
High fuel pressure.
WARNING
94/3
P253912
Fuel pressure sensor.
WARNING
94/5
P253913
Fuel pressure sensor.
WARNING
94/12
P253901
Fuel pressure sensor.
WARNING
94/18
P008A00
Low fuel pressure. Reduced output and torque.
WARNING
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
36
5 Handling – Error code tables
Error codes Volvo TAD851VE and TAD871VE Display (SPN/FMI)
Supplier code
Description
Action
97/0
P226985
Water in fuel.
WARNING: Drain the fuel prefilter, see Fuel prefilter, draining of condensation water, page 10
97/4
P226411
Sensor, water-in-fuel.
WARNING
97/12
P226401
Sensor, water-in-fuel.
WARNING
98/1
P250F00
Low oil level engine.
WARNING: Check the oil level in the engine. See 1.8 Lubrication system, page 29
98/4
P250A11
Sensor oil level engine.
WARNING: Check the oil level in the engine. See 1.8 Lubrication system, page 29
98/5
P250A13
Sensor oil level engine.
WARNING: Check the oil level in the engine. See 1.8 Lubrication system, page 29
98/18
P108600
Low oil level engine.
WARNING: Check the oil level in the engine. See 1.8 Lubrication system, page 29
100/1
P052400
Oil pressure too low. Reduced engine power or engine is turned off.
WARNING: Check the oil level in the engine. See 1.8 Lubrication system, page 29
100/3
P052012
Oil pressure sensor.
STOP
100/5
P052013
Oil pressure sensor.
STOP
100/18
P109300
Low oil pressure in engine. Reduced engine power or engine is turned off.
WARNING: Check the oil level in the engine. See 1.8 Lubrication system, page 29
102/0
P111800
Boost pressure too high. Reduced engine power.
STOP
102/3
P010512
Sensor, boost pressure. Reduced engine power.
STOP
102/5
P010513
Sensor, boost pressure. Reduced engine power.
STOP
102/16
P111600
High charge-air pressure.
STOP
105/0
P111A00
Boost temperature too high. Reduced engine power.
STOP
105/4
P011011
Sensor, boost temperature.
STOP
105/5
P011013
Sensor, boost temperature.
STOP
105/16
P111900
High boost temperature.
STOP
107/0
P10F800
Low pressure between air filter and turbo.
WARNING
107/3
P100712
Sensor air pressure intake.
WARNING
107/4
P100711
Sensor air pressure intake.
WARNING
107/5
P100713
Sensor air pressure intake.
WARNING
107/12
P100701
Pressure sensor air filter.
WARNING
108/5
P222613
Sensor air pressure.
WARNING
110/0
P021700
Coolant temperature too high. Reduced engine power.
STOP: Check the coolant level. See 6.2.5 Cooling system.
110/4
P011511
Sensor, coolant temperature. Engine hard to start.
STOP
110/5
P011513
Sensor, coolant temperature. Engine hard to start.
STOP
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
5 Handling – Error code tables
37
Error codes Volvo TAD851VE and TAD871VE Display (SPN/FMI)
Supplier code
Description
Action
110/16
P111E00
High coolant temperature.
STOP: Check the coolant level. See 6.2.5 Cooling system.
111/1
P256000
Low coolant level.
STOP: Check the coolant level. See 6.2.5 Cooling system.
111/3
P255612
Sensor, coolant level.
STOP
111/4
P255611
Sensor, coolant level.
STOP
111/5
P255613
Sensor, coolant level.
STOP
111/18
P111D00
Low coolant level.
STOP: Check the coolant level. See 6.2.5 Cooling system.
131/3
P047012
Pressure sensor exhaust gases. Engine brake, low performance.
WARNING
131/5
P047013
Pressure sensor exhaust gases. Engine brake, low performance.
WARNING
131/12
P047001
Pressure sensor exhaust gases.
WARNING
157/0
P008800
Fuel pressure, too high. Reduced engine power.
WARNING
157/1
P008700
Fuel pressure, too low. The engine can be switched off.
WARNING
157/4
P019011
Pressure sensor fuel. Reduced engine power.
WARNING
157/5
P019013
Pressure sensor fuel. Reduced engine power.
WARNING
157/7
P019062
Pressure sensor fuel. Reduced engine power.
WARNING
157/12
P019001
Pressure sensor fuel. Reduced engine power.
WARNING
157/14
P00C600
Pressure sensor fuel. The engine turns over but does not start.
WARNING
157/16
P114700
Fuel pressure, high. Reduced engine power.
WARNING
158/2
P05611F
Voltage feed Control unit engine (D7940). Uneven torque.
WARNING
158/3
-
Voltage feed Control unit engine (D7940).
WARNING
158/4
-
Voltage feed Control unit engine (D7940).
WARNING
172/4
P00D911
Ambient temperature sensor. Engine difficult to start at low temperatures.
WARNING
172/5
P00D913
Ambient temperature sensor. Engine difficult to start at low temperatures.
WARNING
173/0
P242800
Exhaust temperature too high. Reduced engine power.
WARNING
173/16
P112E00
High exhaust temperature.
WARNING
175/0
P029800
Oil temperature too high. Reduced engine power.
STOP
175/4
P019511
Sensor, oil temperature. Speed limitation.
STOP
175/5
P019513
Sensor, oil temperature.
STOP
175/16
P112500
High oil temperature.
STOP
190/0
P021900
Engine speed too high. Engine speed is limited.
WARNING
190/16
P119D00
Engine speed too high.
WARNING
411/3
P040912
Pressure sensor exhaust gas recirculation (EGR).
WARNING
411/5
P040913
Pressure sensor exhaust gas recirculation (EGR).
WARNING
411/12
P040901
Pressure sensor exhaust gas recirculation (EGR).
WARNING
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
38
5 Handling – Error code tables
Error codes Volvo TAD851VE and TAD871VE Display (SPN/FMI)
Supplier code
Description
Action
412/0
P112100
EGR temperature too high. Reduced engine power.
WARNING
412/4
P040A11
Temperature sensor exhaust gas recirculation (EGR).
WARNING
412/5
P040A13
Temperature sensor exhaust gas recirculation (EGR).
WARNING
412/12
P040A01
Temperature sensor exhaust gas recirculation (EGR).
WARNING
412/16
P112200
EGR temperature higher than normal. Reduced engine power.
WARNING
626/2
-
Start button
WARNING
626/3
P100212
Relay, preheating. Engine difficult to start at low temperatures.
WARNING
626/4
P100211
Relay, preheating. Engine difficult to start at low temperatures.
WARNING
626/5
P100213
Relay, preheating. Engine difficult to start at low temperatures.
WARNING
628/2
P060741
Memory error in Control unit engine (D7940). Engine does not start.
WARNING
628/2
-
Memory error in Control unit engine (D7940). Engine does not start.
WARNING
628/12
-
Memory error in Control unit engine (D7940). Engine does not start.
WARNING
629/12
-
Memory error in Control unit engine (D7940). Engine does not start.
WARNING
630/2
-
Memory error in Control unit engine (D7940). Engine does not start.
WARNING
630/12
-
Memory error in Control unit engine (D7940). Engine does not start.
WARNING
636/7
P001676
Camshaft speed sensor. The engine takes longer to start than normal or does not start at all.
WARNING
636/8
P034038
Speed sensor camshaft. The engine takes longer to start than normal.
WARNING
636/9
P034031
Speed sensor camshaft. The engine takes longer to start than normal.
WARNING
637/2
P03351F
Crankshaft speed sensor. The engine takes longer to start than normal. Reduced torque.
WARNING
637/8
P033538
Crankshaft speed sensor. The engine takes longer to start than normal. Reduced torque.
WARNING
637/9
P033531
Crankshaft speed sensor. The engine takes longer to start than normal. Reduced torque.
WARNING
639/2
U001088
Control unit engine (D7940), communication error CAN bus drivetrain (J1939).
WARNING
Engine shut-off: the engine cannot be started. Engine running: the engine can only be stopped by using the emergency stop. 639/2
-
Control unit engine (D7940), communication error CAN bus drivetrain (J1939).
WARNING
Engine shut-off: the engine cannot be started. Engine running: the engine can only be stopped by using the emergency stop.
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
5 Handling – Error code tables
39
Error codes Volvo TAD851VE and TAD871VE Display (SPN/FMI)
Supplier code
639/9
-
Description
Action
Control unit engine (D7940), communication error CAN bus drivetrain (J1939).
WARNING
Engine shut-off: the engine cannot be started. Engine running: the engine can only be stopped by using the emergency stop. 641/0
P004577
Variable turbo geometry too high value. Reduced engine power.
WARNING
641/2
P256214
Actuator variable turbo geometry. Reduced engine power.
WARNING
641/3
P006E17
Actuator variable turbo geometry. Reduced engine power.
WARNING
641/5
P004513
Actuator variable turbo geometry. Reduced engine power.
WARNING
641/6
P004519
Actuator variable turbo geometry. Reduced engine power.
WARNING
641/9
U010C00
Actuator variable turbo geometry. Reduced engine power.
WARNING
641/11
P004592
Actuator variable turbo geometry. Reduced engine power.
WARNING
641/17
P112B00
Variable turbo geometry temperature higher than normal. Reduced engine power.
WARNING
647/3
P048012
Electromagnetic clutch cooling fan. Cooling fan drive locked at 100%.
WARNING
647/4
P048011
Electromagnetic clutch cooling fan. Cooling fan drive not working, risk of overheating.
WARNING
647/5
P048013
Electromagnetic clutch cooling fan. Cooling fan drive locked at 100%.
WARNING
651/3
P020112
Injector cylinder 1. The engine has reduced power output.
WARNING
651/4
P020111
Injector cylinder 1. The engine has reduced power output.
WARNING
651/5
P020113
Injector cylinder 1. The engine has reduced power output.
WARNING
652/3
P020212
Injector cylinder 2. The engine has reduced power output.
WARNING
652/4
P020211
Injector cylinder 2. The engine has reduced power output.
WARNING
652/5
P020213
Injector cylinder 2. The engine has reduced power output.
WARNING
653/3
P020312
Injector cylinder 3. The engine has reduced power output.
WARNING
653/4
P020311
Injector cylinder 3. The engine has reduced power output.
WARNING
653/5
P020313
Injector cylinder 3. The engine has reduced power output.
WARNING
654/3
P020412
Injector cylinder 4. The engine has reduced power output.
WARNING
654/4
P020411
Injector cylinder 4. The engine has reduced power output.
WARNING
654/5
P020413
Injector cylinder 4. The engine has reduced power output.
WARNING
655/3
P020512
Injector cylinder 5. The engine has reduced power output.
WARNING
655/4
P020511
Injector cylinder 5. The engine has reduced power output.
WARNING
655/5
P020513
Injector cylinder 5. The engine has reduced power output.
WARNING
656/3
P020612
Injector cylinder 6. The engine has reduced power output.
WARNING
656/4
P020611
Injector cylinder 6. The engine has reduced power output.
WARNING
656/5
P020613
Injector cylinder 6. The engine has reduced power output.
WARNING
677/3
P061512
Start relay on the starter motor. Engine does not start.
WARNING
677/4
P061511
Start relay on the starter motor. Engine does not start.
WARNING
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
40
5 Handling – Error code tables
Error codes Volvo TAD851VE and TAD871VE Display (SPN/FMI)
Supplier code
Description
Action
677/5
P061513
Start relay on the starter motor. Engine does not start.
WARNING
677/6
P061519
Start relay on the starter motor. Engine does not start.
WARNING
679/3
P009012
Fuel pressure regulator (MPROP). Reduced engine power.
WARNING
679/4
P009011
Fuel pressure regulator (MPROP). Reduced engine power.
WARNING
679/5
P009013
Fuel pressure regulator (MPROP). Reduced engine power.
WARNING
679/7
P228D72
Fuel pressure regulator (MPROP). Reduced engine power.
WARNING
729/5
P054013
Preheating element. Engine difficult to start at low temperatures.
WARNING
729/6
P054070
Relay, preheating. Engine difficult to start at low temperatures.
WARNING
729/7
P05407F
Relay, preheating. Engine difficult to start at low temperatures.
WARNING
729/12
P054001
Preheating element. Engine difficult to start at low temperatures.
WARNING
970/3
P100112
Stop-button on engine. The engine is switched off and cannot be started.
WARNING
970/4
P100111
Stop-button on engine. The engine is switched off and cannot be started.
WARNING
970/5
P100113
Stop-button on engine. The engine is switched off and cannot be started.
WARNING
970/11
P100192
Stop-button on engine. Engine cannot be started.
WARNING
970/14
P100190
Stop-button on engine. Engine cannot be started.
WARNING
1188/3
P024312
Actuator intercooler pressure control.
WARNING
1188/4
P024311
Actuator intercooler pressure control.
WARNING
1188/5
P024313
Actuator intercooler pressure control.
WARNING
1239/14
P009400
Fuel leakage, minor.
WARNING
1347/7
P06279C
Fuel pressure pump. Reduced engine power.
WARNING
1485/7
P068573
Voltage feed Control unit engine (D7940).
WARNING
1639/3
P052612
Sensor fan speed. The cooling fan does not disengage.
WARNING
1668/2
U008088
Engine control unit (D7940) communication error.
WARNING
1761/3
P203A12
Level sensor AdBlue tank.
WARNING
P203A86 1761/5
P203A13
Level sensor AdBlue tank.
WARNING
1761/12
P203A01
Level sensor AdBlue tank.
WARNING
P203A86 1761/17
P114500
AdBlue level, below normal level.
WARNING
1761/18
P203F00
AdBlue-level, low. Reduced engine power.
WARNING
2000/9
U010000
Control unit engine (D7940) communication error CAN bus drivetrain (J1939).
WARNING
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
5 Handling – Error code tables
41
Error codes Volvo TAD851VE and TAD871VE Display (SPN/FMI)
Supplier code
2017/9
Description
Action
U014100
Control unit engine (D7940) communication error CAN bus drivetrain (J1939).
WARNING
2036/9
U117100
Communication error with machine.
WARNING
2659/10
P04007C
EGR system.
WARNING
2659/18
P04009C
EGR system, low flow.
WARNING
2791/2
P048613
EGR position sensor. Reduced engine power.
WARNING
2791/3
P041A12
EGR unit. Reduced engine power.
WARNING
2791/4
P041A11
EGR unit. Reduced engine power.
WARNING
2791/5
P040313
EGR unit. Reduced engine power.
WARNING
2791/6
P040312
EGR unit. Reduced engine power.
WARNING
2791/7
P040371
EGR unit. Reduced engine power.
WARNING
2791/9
U010A00
Communication error between EGR unit and Control unit engine (D7940). Reduced engine power.
WARNING
2791/11
P040392
EGR valve. Reduced engine power.
WARNING
2791/12
P040341
EGR valve. Reduced engine power.
WARNING
2791/17
P114E00
EGR valve, temperature higher than normal. Reduced engine power.
WARNING
3031/0
P24FF00
AdBlue-temperature too high.
WARNING
3031/4
P205A11
Temperature sensor AdBlue tank.
WARNING
3031/5
P205A13
Temperature sensor AdBlue tank.
WARNING
3031/12
P205A86
Temperature sensor AdBlue tank. Reduced engine power.
WARNING
P205A01 3216/2
P220064
NOx sensor inlet catalytic converter
WARNING
3216/3
P220012
NOx sensor inlet catalytic converter
WARNING
3216/5
P220013
NOx sensor inlet catalytic converter
WARNING
3216/9
U029D00
NOx sensor inlet catalytic converter Reduced engine power.
WARNING
3216/11
P225D00
NOx sensor inlet catalytic converter Reduced engine power.
WARNING
3216/12
P22FB92
NOx sensor inlet catalytic converter
WARNING
3216/13
P220093
NOx sensor inlet catalytic converter
WARNING
3216/14
P22001C
NOx sensor inlet catalytic converter
WARNING
3226/2
P229E64
NOx sensor outlet catalytic converter.
WARNING
3226/3
P229E12
NOx sensor outlet catalytic converter. Reduced engine power.
WARNING
3226/5
P229E13
NOx sensor outlet catalytic converter. Reduced engine power.
WARNING
3226/7
P225F00
NOx sensor outlet catalytic converter. Reduced engine power.
WARNING
3226/9
U029E00
NOx sensor outlet catalytic converter. Reduced engine power.
WARNING
3226/12
P22FE00
NOx sensor outlet catalytic converter.
WARNING
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
42
5 Handling – Error code tables
Error codes Volvo TAD851VE and TAD871VE Display (SPN/FMI)
Supplier code
Description
Action
3226/13
P229E93
NOx sensor outlet catalytic converter.
WARNING
3226/14
P229E1C
NOx sensor outlet catalytic converter.
WARNING
3241/4
P054411
Sensor exhaust temperature 1.
WARNING
3241/5
P054415
Sensor exhaust temperature 1.
WARNING
3241/12
P054401
Sensor exhaust temperature 1
WARNING
3241/19
P054486
Sensor exhaust temperature 1.
WARNING
3361/12
P204F93
Metering valve AdBlue. Reduced engine power.
WARNING
3361/12
P208A86
AdBlue pump. Reduced engine power.
WARNING
3363/3
P20B112
Heating valve AdBlue tank. Risk that AdBlue freezes in the tank.
WARNING
3363/4
P20B111
Heating valve AdBlue tank. Risk that AdBlue freezes in the tank.
WARNING
3363/5
P20B113
Heating valve AdBlue tank. Risk that AdBlue freezes in the tank.
WARNING
3364/17
P207F9A
Incorrect AdBlue quality.
WARNING
3464/3
P02E012
Actuator motor throttle.
WARNING
3464/4
P02E011
Actuator motor throttle.
WARNING
3464/5
P02E013
Actuator motor throttle.
WARNING
3464/7
P02E09C
Actuator motor throttle.
WARNING
3464/10
P02E07C
Actuator motor throttle.
WARNING
3464/12
P02E09B
Actuator motor throttle.
WARNING
3468/2
P018564
Fuel temperature manifold.
WARNING
3468/4
P018511
Fuel temperature sensor.
WARNING
3468/5
P018513
Fuel temperature sensor.
WARNING
3468/12
P018501
Fuel temperature sensor.
WARNING
3468/16
P016800
Fuel temperature too high. Reduced engine power.
WARNING
3509/3
P06B017
Voltage feed sensor A.
WARNING
3509/4
P06B016
Voltage feed sensor A.
WARNING
3510/3
P06B317
Voltage feed sensor B.
WARNING
3510/4
P06B316
Voltage feed sensor B.
WARNING
3511/3
P06E617
Voltage feed sensor C.
WARNING
3511/4
P06E616
Voltage feed sensor C.
WARNING
3597/3
P065712
AdBlue pump unit voltage feed A. No AdBlue additive.
WARNING
3597/4
P065711
AdBlue pump unit voltage feed A. No AdBlue additive.
WARNING
3598/3
P266912
AdBlue pump unit voltage feed B. Risk that AdBlue freezes.
WARNING
3598/4
P266911
AdBlue pump unit voltage feed B. Risk that AdBlue freezes.
WARNING
4334/4
P204A11
Pressure sensor AdBlue. Reduced engine power.
WARNING
4334/5
P204A13
Pressure sensor AdBlue. Reduced engine power.
WARNING
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
5 Handling – Error code tables
43
Error codes Volvo TAD851VE and TAD871VE Display (SPN/FMI)
Supplier code
4354/3
Description
Action
P20B912
Hose heater A AdBlue. Risk that AdBlue freezes in the hose.
WARNING
4354/4
P20B911
Hose heater A AdBlue. Risk that AdBlue freezes in the hose.
WARNING
4354/5
P20B913
Hose heater A AdBlue. Risk that AdBlue freezes in the hose.
WARNING
4355/3
P20BD12
Hose heater B AdBlue. Risk that AdBlue freezes in the hose.
WARNING
4355/4
P20BD11
Hose heater B AdBlue. Risk that AdBlue freezes in the hose.
WARNING
4355/5
P20BD13
Hose heater B AdBlue. Risk that AdBlue freezes in the hose.
WARNING
4356/3
P20C112
Hose heater C AdBlue. Risk that AdBlue freezes in the hose.
WARNING
4356/4
P20C111
Hose heater C AdBlue. Risk that AdBlue freezes in the hose.
WARNING
4356/5
P20C113
Hose heater C AdBlue. Risk that AdBlue freezes in the hose.
WARNING
4366/14
P20B992
Hose heater A AdBlue. Risk that AdBlue freezes in the hose.
WARNING
4374/0
P202D7A
AdBlue system, pressure leakage.
WARNING
4374/1
P208A92
AdBlue pump unit, motor speed too low. No AdBlue additive.
WARNING
4375/0
P10AD12
Motor AdBlue pump unit.
WARNING
4375/1
P10AD11
Motor AdBlue pump unit.
WARNING
4375/3
P208A12
Motor AdBlue pump unit.
WARNING
4375/4
P208A11
Motor AdBlue pump unit.
WARNING
4375/5
P208A13
Motor AdBlue pump unit.
WARNING
4375/12
P10AD13
Motor AdBlue pump unit.
WARNING
4375/14
P21CAA1
Motor AdBlue pump unit.
WARNING
4376/3
P20A012
Directional control valve AdBlue pump unit. AdBlue is not pumped back to the tank when the engine is switched off.
WARNING
4376/4
P20A011
Directional control valve AdBlue pump unit. AdBlue is not pumped back to the tank when the engine is switched off.
WARNING
4376/5
P20A013
Directional control valve AdBlue pump unit. AdBlue is not pumped back to the tank when the engine is switched off.
WARNING
4376/7
P20A007
Directional control valve AdBlue pump unit. AdBlue is not pumped back to the tank when the engine is switched off.
WARNING
4752/7
P245700
EGR cooler, temperature deviation.
WARNING
5016/4
P26E711
AdBlue pump unit voltage feed D.
WARNING
5392/31
P20E892
AdBlue pressure. Reduced engine power.
WARNING
5394/3
P204712
AdBlue injection unit. No AdBlue additive.
WARNING
5394/4
P204711
AdBlue injection unit. No AdBlue additive.
WARNING
5394/5
P204713
AdBlue injection unit. No AdBlue additive.
WARNING
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
44
5 Handling – Error code tables
Error codes Volvo TAD851VE and TAD871VE Display (SPN/FMI)
Supplier code
Description
Action
5394/12
P204786
AdBlue injection unit.
WARNING
5394/14
P204773
AdBlue injection unit. No AdBlue additive.
WARNING
5435/14
P204F94
AdBlue system.
WARNING
5485/14
P10CE97
AdBlue pump unit, no return flow.
WARNING
5765/10
P041A2A
EGR temperature sensor. Reduced engine power.
WARNING
520244/3
P009B12
Fuel pressure relief valve. Reduced engine power.
WARNING
520244/4
P009B11
Fuel pressure relief valve. Reduced engine power.
WARNING
520244/5
P009B13
Fuel pressure relief valve. Reduced engine power.
WARNING
520244/7
P009B73
Fuel pressure relief valve. Reduced engine power.
WARNING
520244/12
P018F00
Fuel pressure relief valve. Reduced engine power.
WARNING
520245/0
P016E00
Fuel pressure, too high. Reduced engine power.
WARNING
520245/1
P016F00
Fuel pressure, too low. Reduced engine power.
WARNING
520245/16
P228F00
Fuel pressure above normal level. Reduced engine power.
WARNING
520245/18
P228E00
Fuel pressure below normal level.
WARNING
520335/5
U300001
Control unit engine (D7940). Engine does not start.
WARNING
520416/9
U116F00
Communication error Control unit after-treatment system (UDS). No AdBlue additive.
WARNING
520688/0
P11A600
Exhaust temperature too high.
WARNING
520688/3
P11A412
Sensor exhaust temperature.
WARNING
520688/4
P11A411
Sensor exhaust temperature.
WARNING
520688/5
P11A413
Sensor exhaust temperature.
WARNING
520688/16
P11A500
Exhaust temperature higher than normal.
WARNING
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
F Technical data – Technical data
45
Technical data Data 1 Engine
Volvo TAD851VE
Volvo TAD871VE
185 kW between 1500 – 2200 rpm
185 kW between 1500 – 2200 rpm
1160 Nm at 1100 – 1400 rpm
1160 Nm at 1100 – 1500 rpm
Max. rotation speed
2200 rpm
2200 rpm
Number of cylinders
6 cylinders
6 cylinders
28 V / 110 A
28 V / 110 A
24 V (2x12 V / 135 Ah)
24 V (2x12 V / 145 Ah)
Power acc. to ISO 3046 (net power) Torque ISO 3046
Alternator, output System voltage, voltage – capacity
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
46
F Technical data – Technical data
Volumes Any deviation from this table must be approved in writing by Cargotec.
1.2 Engine, fuel system Fuel quality Volvo TAD851VE
Recommendation for Stage 3A/Tier 3 engines Diesel according to: EN590, ASTM D 975 No 1-D, ASTM D 975 No 2-D.
CAUTION Use only the fuel of approved quality. Risk of engine damage, warranty invalidated. Only fuel of a quality that is approved by the engine supplier may be used.
WARNING If fuel with a sulphur content higher than 0.3% (3000 ppm) is used then the engine oil and oil filter must be changed at more frequent intervals. Risk of engine damage! Change the engine oil and oil filter in accordance with the prescribed intervals. Fuel quality Volvo TAD871VE
Requirements for Stage 4/Tier 4f engines Diesel according to: EN590 ASTM D 975 No 1-D ASTM D 975 No 2-D
CAUTION Use only the fuel of approved quality. Risk of engine damage, warranty invalidated. Only fuel of a quality that is approved by the engine supplier may be used.
WARNING Engines of 3B and Tier 4i standard must only be run on diesel with ultra-low sulphur content, max. 0.0015% (15 ppm). Using fuels with a higher sulphur content damages the SCR system.
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
F Technical data – Technical data
47
1.2 Engine, fuel system AdBlue tank, volume Volvo TAD871VE AdBlue quality Volvo TAD871VE
1.8 Engine, lubrication system Oil volume incl. filter Oil type, quality
35 l AdBlue, according to ISO standard 22241. Volvo TAD851VE
Volvo TAD871VE
Total: 24 l
Total: 24 l
See Oils and lubricants, recommendation, page 48.
See Oils and lubricants, recommendation, page 48.
Supplement, Operator’s manual DCF 80–100, DCT 80–100
ACOM18.01GB
48
F Technical data – Technical data
Oils and lubricants, recommendation The service intervals specified by Cargotec in the maintenance manual require that oils are selected in accordance with the table below. The table indicates recommended viscosity for different oil types, and grades, depending on the outdoor temperature. Any deviation from this table must be approved in writing by Cargotec, and may mean changed service intervals.
Oil type, quality
°C
-40
-30
-20
-10
0
+10
+20
+30
+40
°F
-40
-22
-4
+14
+32
+50
+68
+86
104
1.8 Engine, lubrication system Volvo TAD851VE: VDS-32
SAE 5W/301 (engine oil)
Volvo TAD871VE: VDS-4
SAE 10W/30 (engine oil) SAE 15W/40 (engine oil)
1 Only
applies to synthetic or semi-synthetic engine oil.
2 If the fuel has a sulphur content higher than 1.0 percent by weight then oil with TBN >15 must be used.
VDS = Volvo Drain Specification TBN = Total Base Number
Engine oil
NOTE Oil filters must be changed in connection with oil change. Stage 3A/Tier 3 engines
WARNING Change intervals for engine oil and oil filter depend on the sulphur content in the fuel. Risk of engine damage! Change the engine oil and oil filter in accordance with the prescribed intervals.
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
49
ACOM18.01GB
Supplement, Operator’s manual DCF 80–100, DCT 80–100
last page
Cargotec improves the efficiency of cargo flows by offering solutions for the loading and unloading of goods on land and at sea – wherever cargo is on the move. Cargotec’s main daughter brands for cargo handling Hiab, Kalmar and MacGregor are global market leaders in their fields. Cargotec’s global network offers extensive services that ensure the continuous, reliable and sustainable performance of equipment.
Cargotec Sweden AB Torggatan 3 SE-340 10, Lidhult, Sweden tel. +46 372 260 00 fax +46 372 263 90 www.cargotec.com
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