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 & Coolant over flowing from coolant tank breather pipe.
Report Number 691210-2-2025-70769 Report Date 14-Aug-2025 Prepared By skhurshid2
Dealer ID 691210-2 Dealer Name VSPC-Singrauli 3
Customer Name KCCL AMLORI Customer Contact Person Rasvind Chauhan
Workshop/Site-Location AMLORI Customer Contact Number 8879140732
Chassis Model with Axle Configuration FM(4)-B 460 8X4 BS6 Body CuM & Application 20.3 cum RB HYVA
Chassis No 8-985304 Reg. Number DPV-996 Date of Delivery 26-Dec-2023
Date of failure 10-Aug-2025 Repair Order No. 15739 Repair Date 14-Aug-2025
Failure Mileage kms 185014 Age in Months 20 Engine Hrs. 12066
Function Group 2111 Causal Part No. 23762967 Description CYLINDER HEAD
Defect Code Group 8 BREAKAGE Defect Code 82-MATERIAL CRACK
Spare parts warranty No Spare parts invoice details Spare parts fitment date 0000-00-00
Driveline Warranty Yes GDR No

Repair Estimate Summary

Material Cost 568766.67 Labor Cost 12611.25 Other Cost 17438.96

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 NA
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 NA

Load Details

Type of load carried Coal OB Permitted Technical GCW 49 GCW during failure NA

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

NAA

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 XXXX Aggregate Part No. XXXXX Aggregate Sr. No. XXXXX

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

Driver Name rajkumar viswakrma Training details on the related variant VECV TRAINING

Drivers description on the happening of the failure:

coolant level low & Coolant over flowing from coolant tank breather pipe.

Technical Explination of complaint (Dealer comment):

>As per driver complaint coolant level low.

> Checked the vehicle as per customer complaint and found coolant level low & Coolant over flowing from coolant tank breather pipe.
> Checked notification in IC found nothing.
> Then connect Tech tool found EMS- P256000 Engine Coolant level low, no sub type information (Inactive )
> Then check all point found no ant hose and cooling line no any leakage
> Then check the thermostat valve working properly
> Then check the tank pressure cap found good condition .
> Then replace the pressure cap and coolant top-up vehicle running but problem same
> Then check the coolant pump and drive belts found good condition.
> The air compressor head seemed fine but I changed the air compressor and tried running the vehicle but the propeller
was still the same
> Then connect the tech tool and test the cylinder compression test found 4 & 5th no cylinder compression week.
> Then remove the turbocharger and exhaust manifold found exhaust line coolant
> Then rotted the crank shaft found 4th cylinder coolant coming.
> Then dismantle the engine head found coolant in cylinder in 4th, 5th.
> Then check the engine head no any other external hitting mark
> Then check the engine head found 2,3,4,5,& 6th cylinder head crack

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

EMS- P256000 Engine Coolant level low, no sub type information (Inactive )
Is the causal part a recently modified one NA

If Yes, kindly provide more details about the modification:

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

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
DPV-996
CHASSIS ID 8-985304
EH-12066, KM-185014
SNAP-01
SNAP-02
SNAP-03
SNAP-05
SNAP-06
SNAP-07
SNAP-08
SNAP-09
SNAP-10
SNAP-11
FAIL PARTS CPN-23477606, SL NO, 232571646
1st cylinder exhaust valve condition
1st cylinder Inlet valve condition
2nd cylinder exhaust valve condition
2nd cylinder Inlet valve condition
3rd cylinder exhaust valve condition
3rd cylinder Inlet valve condition
4th cylinder exhaust valve condition
4th cylinder Inlet valve condition
5th cylinder exhaust valve condition
5th cylinder Inlet valve condition
6th cylinder exhaust valve condition
6th cylinder Inlet valve condition

Probable Cause of Failure

Suspecting that this failure is happened due material quality or processing defect.

Corrective Action/Suggestions

Need to replace the mentioned part

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
1---13-Dec-202313865913basic servicebasic service done
2---01-Feb-2024349081871basic service basic service done
3---15-Mar-2024499462702basic service basic service done
4---07-May-2024655503640basic service basic service done
5-----26-Jun-2024814034653basic service basic service done
6----23-Aug-2024954185594basic service basic service done
7---11-Oct-20241080136483basic service basic service done
8---14-Nov-20241174687123basic service basic service done
9---11-Dec-20241252027659basic service basic service done
10----11-Jan-20251384898255basic service Coolant replace
11---09-Feb-20251433108829basic service basic service done
12----12-Mar-20251520439436basic service basic service done
13----18-Apr-202516203110150basic service basic service done
14----02-Jun-202517333411053basic service basic service done
15----30-Jul-202518395411974basic service basic service done
16---

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 23762967 CYLINDER HEAD 1500672500,672.00525,033.60525,705.6009
2VO 21510072 CYLINDER HEAD GASKET 115435.5215,435.525771.7816,207.3009
3VO 23759508 OIL FILTER KIT 22345.434,690.865234.544,925.4009
4VO 24124132CAMSHAFT BEARING KIT 13025.653,025.655151.283,176.9309
5VO 24124130CAMSHAFT BEARING KIT 62375.0814,250.485712.5214,963.0009
6VO 21344774 FLANGE SCREW6128.09768.54538.43806.9709
7VO 276948O-RING KIT6473.252,839.505141.982,981.4809
Total 541,682.55 Total 568,766.68

Labour cost

S.No. Operation No Description Qty. Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
121126-2 Cylinder head, replace 12.585510,687.50181,923.7512,611.2509
Total 10,687.50 Total 12,611.25

Other cost

S.No. Description Qty. Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
1IN2 24754666 42183.597,710.78181,387.949,098.7209
2OL 23068345S 381867,068.00181,272.248,340.2409
Total 14,778.78 Total 17,438.96
Total cost of Repair( Material, Labor and Other cost) 598,816.89

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

NA

ANNEXURES (Select the annexure attached)

17012-3 VCADS Pro Error Codes Test 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
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 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
11754811200_WhatsApp_Video_2025-08-10_at_12.26.18_PM.mp4
21754811200_WhatsApp_Video_2025-08-10_at_12.38.42_PM.mp4
3
4
5
6

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 Rectified & Running Reason Waiting for approval

Comments

S.No. Remarks By Date & Time TFAR Status
1Dear Jayanta ji,

validate this case under warranty please check and approve

3C Following

C1:- coolant level low & Coolant over flowing from coolant tank breather pipe.
C2:- Check and found Engine head crack
C3:- Need to replace Engine head,

Thanks & Regards
Vijay Pandey 		skhurshid22025-08-14 12:50:29TFAR RAISED
2Hi,

please add coolant change history, service history		jjadav2025-08-16 21:40:08QUERY RAISED
3Dear Jayanta ji,

Coolant replace EH-8255, KM-138489, and other service history attached in Service and Repair History of the vehicle.

Thanks & Regards
Vijay Pandey 		skhurshid22025-08-17 10:38:48REPLY TO QUERY
4Dear Jacob,

Above mentioned vehicle reported with the complaint of Engine Head Crack at 12066EH. Attached service history FYR to refer the coolant service history done as per schedule. NO external hitting mark observed over there or abnormalities found. Request you to please suggest further.		jjadav2025-08-17 10:59:45TFAR FORWARDED
5jjadav2025-08-17 11:23:36REPLY TO QUERY
6Dear Jacob,

Above mentioned vehicle reported with the complaint of Engine Head Crack at 12066EH. Attached service history FYR to refer the coolant service history done as per schedule. NO external hitting mark observed over there or abnormalities found. On further inspection found oil leakage from valve steam seal from 3rd, 4th, 5th and 6th cylinder which causes oil to entered into cylinder causes high temperature inside the combustion chamber leads to head to be cracked. Request you to please suggest further.		jjadav2025-08-17 11:24:37TFAR FORWARDED
7Hello All

Cylinder head cracks are connected with pressure and temperature building inside the combustion chamber.
oil leak may not directly contribute to this failure. the engine load (% if time the engine load is above 90%) is around 6-8% which is high.

we see that in jun and jul month manual gears have been utilized more than automatic gears as gear usage can contribute to temperature increase in cylinder.

since this case is outside warranty this case is not supported under warranty and TGW.

Regards

Jacob		jmathew12025-08-18 16:40:47RETURNED
 
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