VOLVO TRUCKS INDIA

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Purpose of TFAR
 Guidance
Approval / feedback
 Technical Feedback
Type of TFAR
 Truck Chassis
Subject/Complaint
coolant level low signal coming in IC.
Report Number 694100-2-2025-67580 Report Date 10-May-2025 Prepared By vecvjharsuguda
Dealer ID 694100-2 Dealer Name VSPC-Jharsuguda
Customer Name Ajantha Mining PVT LTD Customer Contact Person VESLY
Workshop/Site-Location GOCP,MCL,Garjanbahal Customer Contact Number 9566606723
Chassis Model with Axle Configuration FM(4) 460 8x4 BS6 Body CuM & Application 20.3 cum RB HYVA
Chassis No 8-979516 Reg. Number AV-109 Date of Delivery 08-Feb-2023
Date of failure 04-May-2025 Repair Order No. 6244 Repair Date 15-May-2025
Failure Mileage kms 197319 Age in Months 27 Engine Hrs. 14508
Function Group 211 Causal Part No. VO 23617410 Description Inlet valve
Defect Code Group 1 NOISE/ VIBRATION Defect Code 11-KNOCKING NOISE AND IMPACT NOISE
Spare parts warranty No Spare parts invoice details Spare parts fitment date 2028-05-01
Driveline Warranty No GDR No NA

Repair Estimate Summary

Material Cost 1584295.60 Labor Cost 32486.58 Other Cost 0.00

Road Details

Type of road surface (Asphalt, Soil Gravel, Sharp stones etc. SOIL
Dust Condition (Heavy Slight, etc.,) SLIGHT
Approx. Gradient of the Road (required for engine and wheel Hub failures 1:16
Undulation on the Road( Heavy,Slight, Lot of pot holes, large Bumps, etc.) SLIGHT
Was the vehicle travelling Uphill or Downhill (required for engine and wheel hud failures NO

Load Details

Type of load carried OVER BURDEN Permitted Technical GCW 49 GCW during failure 48

Available information on the load types and GCW's handled by the vehicle earlier which could have caused the failure

NA

Aggregate details

Details of the concerned failed Aggregate ( Engine, Gearbox, Rear Axle, Diffeerential, Rear Axle, Diff. carrier, steering gear, Turbocharger, Superstructure Hydraulic parts etc.)
Aggregate NA Aggregate Part No. NA Aggregate Sr. No. NA

Interview with the Driver ( Applicable for all driveline related failures)

Driver Name SHAVOM KUMAR Training details on the related variant Site training by VECV

Drivers description on the happening of the failure:

coolant level low signal coming in IC.

Technical Explination of complaint (Dealer comment):

After complaint we check and observed that,
1.As per complaint Engine derated & coolant level low signal showing in instrument cluster.
2.We check the coolant level in expansion tank, found that physically coolant level low.
3.After we check the dipstick excessive engine oil showing in dipstick.
4.After removed oil sump we found coolant mix with engine oil.
5.After removed valve cover We found coolant mix with engine oil.
6.After removed sump found that coolant mixed with engine oil & coolant coming from outside of the 2ND no liner.
7.Then engine overhaul found that :-
8.Then we removed the Injectors and found that 2nd no cylinder Injector tip broken (Photo attached).
9.Then we removed the Cylinder head and found that 2nd no cylinders 1nos Inlet Valve broken The Broken particles of the valve gone into the combustion chamber & consequently damages cylinder head, liner, piston, Injector, Valves.
10.Then we checked 1st to 6th cylinder liner found scoring marks. Photos attached.
11.Then we checked 1st to 6th pistons found scoring marks. Photos attached.
12.Then we checked All main bearing found scoring mark. Photos attached.
13.Then we checked All big-end bearing found scoring mark. Photos attached.
14.Then we checked All camshaft bearing found scoring mark. Photos attached.
15.Then we checked Oil pump housing found scoring mark. Photos attached.
16.Then we checked 2nd no connecting rod cap found scoring mark. Photos attached.
17.Also observed dip scoring mark in the oil pump.
18.Engine SL no-2234965 and oil pump SL no-17643.Photos attached.
19.S4119 Campaign carried out at DB Bangalore Date- 26/10/2024 Lds order no-1501,KM-144690,Eh-10586.
20.AdBlue system is working

AIR FILTER REPLACED DETAILS-
LDS ORDER NO- 2556, Date-18-03-2025, KM-185360, HMR-13581.
LDS ORDER NO- 2321, Date-12-02-2025, KM-175410, HMR-12847.
LDS ORDER NO- 1941, Date-12-12-2024, KM-160505, HMR-11737.
LDS ORDER NO- 1619, Date-04-11-2024, KM-150376, HMR-10813.
LDS ORDER NO- 1265, Date-09-09-2024, KM-133934, HMR-9757.
LDS ORDER NO- 834, Date-11-06-2024, KM-117546, HMR-8407.
LDS ORDER NO- 636, Date-07-04-2024, KM-97797, HMR-7260.
LDS ORDER NO- 388, Date-15-02-2024, KM-82339, HMR-6250.
LDS ORDER NO- 137, Date-01-12-2023, KM-65720, HMR-4867.

Fault codes registered in vehicle (Including Active and Inactive Faults)

Active-P021900,P02E697 Inactive- P029900 All DTCs list attached
Is the causal part a recently modified one NO

If Yes, kindly provide more details about the modification:

NA
Is this a repeat failure No Is yes, provide relavant details NO
Relavant Argus No. If any NO Relavant DQR No. If any NO Relavant MQR No. If any NO
Relavant QJ No. If any NO

Affected Vehicle details

Chassis No Model Body No Date of Delivery Date of Failure Mileage Kms Engine hrs Parts Sl.no
-- -- -- -- -- -- -- --

Area(Photos Where required/Applicable)

Photo Area Description/Remarks
1.CH ID 8-979516, Front View.
2. RHS VIEW.
3. LHS VIEW.
4. KM-197319 & HMR-14508.
5.Engine derated,Engine over speed signal show in the IC.
6.coolent level low signal show in IC.
7.Coolent drop in marking area
8.
9.Top View of Cylinder head.
10.2nd cylinder inlet valve broken view.
11.2nd cylinder inlet valve broken view.
12.Botam View of Cylinder head.
13.Botam view off 2nd cylinder inlet valve broken view.
14.Botam view off 2nd cylinder inlet valve broken view.
15.2nd cylinder all valve View.
16.2nd cylinder inlet valve broken View.
17.2nd cylinder all valve locks found ok.
18.2nd cylinder Injector tip broken View .and SL no:-S177962328
19.All piston cooling jet found ok.
20.Oil pump found scoring mark. sl no-17643
21.All main bearing found scoring mark.
22.All big-end bearing.
23.2nd cylinder connecting rod found scoring mark.
24.1st cylinder piston View.
25.2nd cylinder piston View.
26.3rd cylinder piston View.
27.4th cylinder piston View.
28.5th cylinder piston View.
29.6th cylinder piston View.
30.1st cylinder liner found scoring marks.
31.2nd cylinder liner found scoring marks.
32.3rd cylinder liner found scoring marks.
33.4th cylinder liner found scoring marks.
34.5th cylinder liner found scoring marks.
35.6th cylinder liner found scoring marks.
36.2nd no cylinder liners long view.
37.All cylinder liners long view.
38.2nd no cylinder liner O-rings view.
39.All cylinder liner O-rings view.
40.All Camshaft bearing found scoring mark.
41.Chassie id-8-979516,Engine sl no-2234965.

Probable Cause of Failure

NO

Corrective Action/Suggestions

NO

Service and Repair History of the vehicle (Relevant to the failure)

S.No.
Job Card No.
Date
Mileage Kms
Engine Hrs.
 Job carried out Remarks
1LDS ORDERNO- 282220-Apr-202519413114239Basic service.
2LDS ORDERNO- 250607-Mar-202518244213316Basic service.
3LDS ORDERNO- 215522-Jan-202516944112409Basic service.
4LDS ORDERNO- 190710-Dec-202415719711503Basic service.
5LDS ORDERNO- 154026-Oct-202414469010586Basic service.
6LDS ORDERNO- 126509-Sep-20241339349757Basic service.
7LDS ORDERNO- 107314-Jul-20241248528872Basic service.
8LDS ORDERNO- 73003-May-20241048417705Basic service.
9LDS ORDERNO- 40719-Feb-2024833006309Basic service.
10LDS ORDERNO- 20619-Dec-2023680075130Basic service.
11LDS ORDERNO- 11208-Mar-20224300120Basic service

Repair Estimate

Material Cost

S.No. Part no Description Qty Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
1VO 22164943DE-CARBONIZING KIT161894.1661,894.161811,140.9573,035.1109
2VO 21581522GASKET KIT172058.3172,058.311812,970.5085,028.8109
3VO 24247097MAIN BEARING KIT32478.577,435.71181,338.438,774.1409
4VO 24247101MAIN BEARING KIT32478.577,435.71181,338.438,774.1409
5VO 24247105MAIN BEARING KIT12478.572,478.5718446.142,924.7109
6VO 24618469BIG-END BEARING KIT62746.1116,476.66182,965.8019,442.4609
7VO 24124156THRUST WASHER KIT15807.095,807.09181,045.286,852.3709
8VO 24124132CAMSHAFT BEARING KIT13025.653,025.6518544.623,570.2709
9VO 24124130CAMSHAFT BEARING KIT62375.0814,250.48182,565.0916,815.5709
10VO 23762967CYLINDER HEAD1500672500,672.001890,120.96590,792.9609
11VO 3092340SEALANT12989.682,989.6818538.143,527.8209
12VO 23284156LOCKING FLUID11400.191,400.1918252.031,652.2209
13VO 85141044CLEANING AGENT11181.231,181.2318212.621,393.8509
14OL 23068345SVOLVO ENGINE OIL VDS-4.5401867,440.00181,339.208,779.2009
15VO 23764239CYLINDER LINER KIT667884.87407,309.221873,315.66480,624.8809
16VO 23606950CONNECTING ROD143810.3343,810.33187,885.8651,696.1909
17VO 20532891GASKET1590.62590.6218106.31696.9309
18VO 21532258SEALING RING1181.73181.731832.71214.4409
19VO 21282255GASKET11065.131,065.1318191.721,256.8509
20VO 24118272SEALING STRIP14208.774,208.7718757.584,966.3509
21VO 20824906OIL PUMP148736.5548,736.55188,772.5857,509.1309
22VO 994451FLANGE SCREW349.22147.661826.58174.2409
23VO 984740FLANGE SCREW441.65166.601829.99196.5909
24VO 23759508OIL FILTER KIT- STEP E22345.434,690.8618844.355,535.2109
25VO 24137737FILTER KIT - Step E14799.394,799.3918863.895,663.2809
26VO 24633960FILTER KIT12742.962,742.9618493.733,236.6909
27VO 21794321ADJUSTING SCREW3672.652,017.9518363.232,381.1809
28VO 1677396HEXAGON NUT3114.21342.631861.67404.3009
29VO 24429533CONNECTION PIPE11496.731,496.7318269.411,766.1409
30VO 21344774FLANGE SCREW6128.09768.5418138.34906.8809
31VO 23000879PIPE33488.1710,464.51181,883.6112,348.1209
32VO 23000870PIPE33488.1710,464.51181,883.6112,348.1209
33IN2 24754666COOLANT-VCS2 210L42183.597,710.78181,387.949,098.7209
34VO 24309482INJECTOR172442.5972,442.591813,039.6785,482.2609
35VO 990810FLANGE SCREW181.481.401814.6596.0509
36VO 948211CABLE TIE628.4170.401830.67201.0709
37VO 983472CABLE TIE54.4222.10183.9826.0809
38VO 23248736GASKET13115.883,115.8818560.863,676.7409
39VO 23949026VALVE BRIDGE134973,497.0018629.464,126.4609
40VO 3183207VALVE CALIPER11949.791,949.7918350.962,300.7509
41VO 990232FLANGE SCREW1866.36866.3618155.941,022.3009
42VO 24476465WIRES14216.974,216.9718759.054,976.0209
Total 1,342,623.40 Total 1,584,295.61

Labour cost

S.No. Operation No Description Qty. Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
121070-1Engine, remove4.88554,104.0018738.724,842.7209
221122-1Cylinder head, remove48553,420.0018615.604,035.6009
321124-1Cylinder head, install9.18557,780.50181,400.499,180.9909
421418-3Valve stem seal replace3.28552,736.0018492.483,228.4809
521311-3Cylinder liners and pistons, replace (All). Cylinder heads and oil pan removed6.58555,557.50181,000.356,557.8509
621706-1Oil sump, remove0.2855171.001830.78201.7809
721708-1Oil sump, install1.38551,111.5018200.071,311.5709
817010-2Connect-disconnect of diagnostic tool0.2855171.001830.78201.7809
921603-3Main bearings, replace (all). Oil sump removed2.98552,479.5018446.312,925.8109
Total 27,531.00 Total 32,486.58

Other cost

S.No. Description Qty. Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
Total 0.00 Total 0.00
Total cost of Repair( Material, Labor and Other cost) 1,616,782.19

Any Local solution or suggestion from the Field team for Prevention/ Quick resolution of Complaint

NO

ANNEXURES (Select the annexure attached)

17012-3 VCADS Pro Error Codes Test 1747634180_AV-109_DTC.pdf Compulsory for all failures having fault codes
17034-3 Vehicle information test
28486-3 Sensor Values History Report Compulsory for all failures related with the engine
20007-3: Engine protection data
28407-3 Sensor Values, Monitoring
20005-3: Fuel consumption data 1747634185_AV-109_FUEL_CONSUMPTION_DATA.pdf
28108-8 Engine ECU, check Compulsary for all failures related with the engine ECU
PDF file of the Repair history of the vehicle in LDS– complete 1746366116_Service_History_AV-109_PART_1.pdf Optional
Scan or Fax copy of the Last BS or AS (as applicable) checksheet Compulsary
Completely filled checksheets and Protocols as given in Impact/FAG in YVD for the complaint Compulsary

Additional Attachments

S.No. Attatchemnt
11746645131_WhatsApp_Video_2025-05-08_at_12.41.22_AM.mp4
21747629140_AV-109_Valve_checksheet.jpeg
31747634238_AV-109_GD_REPORT.pdf
41747634241_AV-109_ENGINE_OVER_SPEED.pdf
51747634238_AV-109_ENGINE_STATISTICS_DATA.pdf
61747634238_AV-109_ENGINE_PROTECTION_DATA.pdf

Oil & Fuel Sample Test Reports (Compulsory for all major engine related failures):

Sample Date Sent to ELF Mumbai


Dispatch Details of Failed Parts( Mandatory for critical failures/failures related to safety/failures related to performance)

Docket No Dispatch Date Courier Name Transporter Veh No.

Present Status of the vehicle

Present Status Breakdown Reason

Comments

S.No. Remarks By Date & Time TFAR Status
1vecvjharsuguda2025-05-10 10:26:04TFAR RAISED
2vecvjharsuguda2025-05-16 15:19:25TFAR RAISED
3Dear Tapash Da,
Kindly suggest.

BR
Ajantha Team		vecvjharsuguda2025-05-19 11:34:17TFAR RAISED
4Hi,

New direction given for TGW support. We need to raise TFAR Lite instead of main TFAR. Pls inform after draft the TFAR.		tpaul12025-05-20 16:25:40QUERY RAISED
5tpaul12025-06-04 18:24:17REPLY TO QUERY
6Dear Sir,

Subject vehicle reported Coolant level low signal in IC..

During checking found that coolant mixed with oil
due to 2nd liner crack & few DTC in active condition.
After dismantled of engine found 2nd no cylinder valves in broken condition. Cylinder head & 2nd no piston fully damaged due to valve stamping, two valves broken & another two bent of 2nd no cylinder. Injector tip of 2nd no was broken.
2nd no liner fully damaged & metal particle gone into all other liners & occurred scoring mark. Also particle mixed with oil & therefore bearings got score marks.

Please validate this case for TGW support.

BR Tapash,		tpaul12025-06-04 18:31:25TFAR FORWARDED
7The Inlet valve failure could be high landing force on the valve due to excess play over a period and combination of severe operating condition with steep gradient

During our visit to the customer site, we have seen that the vehicle operates in steep gradient and two engine failures reported in the same gradient

Since we do not have any open quality issue in this part, VTC will not consider this under TGW 		ahussain12025-10-30 10:51:49RETURNED
 
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