Acom18 01GB

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
OPERATORS MANUAL
DCF 80100, DCT 80100
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, Operators manual DCF 80100, DCT 80100
ACOM18.01GB
ACOM18.01GB
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

Fuel filter, change, page 12
1 Engine
Fuel prefilter
Fuel filter
R*
R*
* Change every 1000 h or

every 12 months.
Valve clearance
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/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
Coolant, level check
Coolant, freezing point
Coolant, change
1.6 Air intake and exhaust

outlet, page 23
Turbo
Drive belts
R*
Drive belt, replace, page 33

Drive belt tensioner, check
(engine option Volvo), page
34
For volume and grade, see

section F Technical data.
every 48 months.
See Maintenance manual

ACOM18.01GB
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 testing (engine option

Volvo), page 29
The oil must always be

changed the first time at
500h.

page 30
* The oil change interval

can be extended from 500h
to 1000h with approved
documented oil samples at
1000h, 1250h and 1500h.
Engine oil changed every 12
months.
Fuel with sulphur content
>0.3% (3000 ppm):

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*

every 12 months.
1.6.7 Crankcase ventilation,

page 25
Visual check for damage or

corrosion.
NOTE
Never unplug connectors
unnecessarily, risk of
impurities entering the
connector.
ACOM18.01GB
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.

Fuel prefilter, draining of

condensation water, page
10

every 12 months.
Fuel prefilter, change, page

11

Fuel filter, change, page 12
1 Engine
Fuel prefilter
Fuel filter
R*
R*

every 12 months.
AdBlue tank
C / R*
Clean and change the filter

24:e months.
AdBlue tank, cleaning

(engine option Volvo
TAD871VE), page 13
Filter AdBlue pump unit
R*

every 24 months.
Filter AdBlue pump unit,

replace (engine option
Volvo TAD871VE), page 18
Strainer AdBlue pump unit
R*

every 24 months.
Filter AdBlue pump unit,

Filter level sensor AdBlue

tank
R*

every 24 months.
Filter in AdBlue pump tank,

* First time at 1000 h, then

every 2000:e h.
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/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.
C / R*
* Replace as required or
48:e months.
Drive belt, check, page 33
Turbo
Drive belts
C / R*
C / R*
Belt tensioner
Coolant, level check
Coolant, freezing point
Coolant, change
1.6 Air intake and exhaust

outlet, page 23
R*
Drive belt, replace, page 33

Drive belt tensioner, check
(engine option Volvo), page
34
For volume and grade, see

section F Technical data.
every 48 months.

ACOM18.01GB
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.

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.

page 30
Engine oil changed every 12

months.
Filter crankcase ventilation
Connectors
R*
R*
R*

every 12 months.
1.6.7 Crankcase ventilation,

page 25
Visual check for damage or

corrosion.
NOTE
Never unplug connectors
unnecessarily, risk of
impurities entering the
connector.
ACOM18.01GB
1 Engine Engine
1 Engine
Engine, description
Engine, component location
Volvo TAD851VE
6
7
8
9
3
14
11
12
13
10
019719
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
ACOM18.01GB
1 Engine Engine
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
019718
1 Engine Engine
Engine, component location

Volvo TAD871VE
5
7
8
9
10
11
12
13
14
15
019015
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
ACOM18.01GB
1 Engine Engine
2
1
10
11
019016
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
1 Engine Fuel system
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.
Machine in service position, see section B Safety.
Remove the protective plug from the bleed nipple (position 1).
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.
Bleed the fuel system by pumping with the hand pump (position 2)
until fuel free of air emerges from the bleed hose.
Close the bleed nipple while fuel is flowing out of the hose.
Wait for 15 seconds, then repeat Steps 4 5.
Remove the hose and tighten the bleed nipple by 3.5 Nm.
Refit the protective plug on the bleed nipple.
Start the engine and allow it to idle for approximately 5 minutes

before increasing the speed.
019005
1. Bleed nipple
2. Hand pump
ACOM18.01GB
10
1 Engine Fuel prefilter
1.2.3 Fuel prefilter

Fuel prefilter, draining of condensation water
NOTE
NOTE
The water separator should be drained of water when necessary
or at least every 50 operating hours.
017831
Position a receptacle under the fuel prefilter.
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.
Remove the water separator (position 2) from the fuel prefilter

(position 1) by turning in accordance with the figure.
Clean the water separator and refit it on the filter.
Close the drain tap.
Bleed the fuel system, see Fuel system, bleeding, page 9.
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
11
Fuel prefilter, change
NOTE
Clean the fuel prefilter and water separator externally.
Drain the fuel prefilter (position 1) of fuel and water by opening the
drain tap (position 4). Collect any fuel in a receptacle.
Disconnect the connector (position 3) for the water separator.
Remove the water separator (position 2) from the old filter.
Remove the fuel prefilter (position 1) from the filter holder, use a
filter removal tool. Collect any fuel in a receptacle.
Clean the water separator internally.
Lubricate the gasket on the new fuel prefilter using diesel fuel.
Fit a new O-ring on the water separator and moisten it with diesel
fuel.
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.
019006
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
ACOM18.01GB
12
Fuel filter, change
NOTE
1
Clean the fuel filter externally. Clean around the filter as well.
NOTE
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
Remove the filter cover (position 1) from the filter housing (position
4).
Remove the filter insert (position 3) and O-ring (position 2) from

the filter cover.
Replace the O-ring, moisten the new O-ring in order to prevent

it from turning.
Fit the new filter insert in the cover. Make sure that the filter insert
is fitted correctly in the cover.
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.
Bleed the fuel system, see Fuel prefilter, draining of condensation

water, page 10.
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
13
AdBlue tank, cleaning (engine option Volvo

TAD871VE)
NOTE
Read the safety instructions for AdBlue before starting work, see
section B Safety.
1d
1b
Drain the AdBlue tank into a receptacle.

The drain plug for the AdBlue tank can be accessed from the
underside of the machine.
1c
3
4
018998
1a
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.
Release the rubber gasket that seals the AdBlue filling point
against the cover plate by pressing it in behind the cover plate
(position 1).
Loosen the tensioning strap (position 4) that secures the console

with the tank.
Release the console by loosening the 4 screws (position 5) that

attach the lower console to the side console.
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
1. AdBlue filling
2. Console AdBlue tank
3. Drain point AdBlue tank
4. Tensioning strap
5. Screws for the console
ACOM18.01GB
14
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.
018199
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.
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
15
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
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.

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
ACOM18.01GB
16
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.
019001
1. Drain plug
2. Gasket
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.
018199
ACOM18.01GB
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.

Check coolant level.
018837
33
34
ACOM18.01GB
18
Filter AdBlue pump unit, replace (engine option

Volvo TAD871VE)
NOTE
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.
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.
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.
There may be AdBlue residue in the filter housing. Position a

receptacle under the filter cover.
Screw off the filter cover from the pump (position 1). A 27 mm
spanner can be used to facilitate the process.
Remove the equalisation unit (position 2).
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.
Install the new filter insert and then the equalisation unit.
Finally, screw on the filter cover, tighten to tightening torque 20

(+5) Nm
10
018207
1. Filter cover
2. Equalisation unit
3. Filter insert
ACOM18.01GB
19
Filter in AdBlue pump tank, replace (engine

option Volvo TAD871VE)
NOTE
section B Safety.
1d
1b
Drain the AdBlue tank into a receptacle.

The drain plug for the AdBlue tank can be accessed from the
underside of the machine.
1c
3
4
018998
1a
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
Position a jack or similar as support under the console for the

AdBlue tank.
Release the rubber gasket that seals the AdBlue filling point
against the cover plate by pressing it in behind the cover plate.
Loosen the tensioning strap (position 4) that secures the console

with the tank.
Release the console by loosening the 4 screws (position 5) that

attach the lower console to the side console.
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
1. AdBlue filling
2. Console AdBlue tank
3. Drain point AdBlue tank
4. Tensioning strap
5. Screws for the console
ACOM18.01GB
20
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.
018199
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.
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
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
3. Filler spigot
4. O-ring
5. Tank unit
ACOM18.01GB
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.
019001
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
ACOM18.01GB
22
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.
018199
Fill the tank with AdBlue. Refit the filler cap.

32
Check coolant level.
018837
30
31
ACOM18.01GB
1 Engine Air intake and exhaust outlet
23
1.6 Air intake and exhaust outlet

Exhaust outlet, component location
Volvo TAD851VE
1
5
2
1. End pipe
4. Heat protection
2. Silencer
5. Gateway control visco fan
019716
3. Exhaust pipe
ACOM18.01GB
24
1 Engine Air intake and exhaust outlet
Exhaust outlet, component location

Volvo TAD871VE
13
14
12
10
11
10
9
6
5
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
019017
1 Engine Crankcase ventilation
25
1.6.7 Crankcase ventilation

Crankcase filter, replace (engine option Volvo
TAD871VE)
1
Clean around the filter.
Remove the filter cover manually.
Remove the filter insert.
Replace the O-ring.
Fit the new filter insert.
Turn and tighten the filter cover.
019010
1. Filter cover
2. Filter insert
3. O-ring
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
Open the filler cap on the expansion tank carefully until a slight
resistance is felt and allow any overpressure to be vented away.
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!
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)
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
27
1 Engine Coolant
Position a receptacle under the drain points on the radiator and

engine. For cooling system volume, see section F Technical data.
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.
Check that all coolant drains out.
019009
1. Drain point, radiator
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.
Remove the thermostat and flush out the thermostat housing.
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.
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.
If impurities still remain after flushing for a long time, a radiator

cleaner can be used for cleaning, contact Cargotec Service.
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.
Start the engine.

Check that the water valve in the cab is fully open so that the
heating system is bled.
ACOM18.01GB
Stop the engine after approximately one hour and check the
coolant level, top up if necessary.
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.
019011
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).
ACOM18.01GB
30
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.
Position a receptacle under the engine's drain point for engine oil.
For volume, see section F Technical data.
Remove the drain plug from the engine and drain the engine of oil.
Clean around the oil filter.
007317
ACOM18.01GB
Carefully remove the filter cover (position 1).
Remove the O-ring (position 2) and filter insert (position 3).
Allow the oil to drain from the filter into the receptacle.
8
31
Fit a new O-ring on the cover.
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
ACOM18.01GB
32
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
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.
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.
019011
A. Position for filling point

B. Filling point
C. Oil dipstick
ACOM18.01GB
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
Raise the hood.
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
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.
ACOM18.01GB
34
9 Frame, body, cab and accessories AC compressor
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.
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.
Remove the drive belt.
Check that the belt pulleys are clean and undamaged.
Fit the new drive belt.
Fit the socket and socket wrench again and remove the drift.
Carefully release the belt tensioner so that the belt is tensioned
once again.
Check that the drive belts are correctly aligned and that they can
be pressed down 34 mm.
10
Start the engine and perform a function check.
018727
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.
Check that the tension lever stop is not touching the moulded stop
lugs on the belt tensioner housing.
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
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.
Measure the distance between the belt tensioner's spring housing

and the tension lever, the clearance must not exceed 3 mm.
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

speed.
WARNING
51/7
P02E699

speed.
WARNING
51/12
P02E601

speed.
WARNING
51/13
P02E697

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
WARNING
94/12
P253901
WARNING
94/18
P008A00
Low fuel pressure. Reduced output and torque.
WARNING
ACOM18.01GB
36
5 Handling Error code tables

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.

system, page 29
98/5
P250A13
Sensor oil level engine.

system, page 29
98/18
P108600
Low oil level engine.

system, page 29
100/1
P052400
Oil pressure too low. Reduced engine power or engine

is turned off.

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.

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
WARNING
107/5
P100713
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
37

Display
(SPN/FMI)
Supplier
code
Description
Action
110/16
P111E00
High coolant temperature.

111/1
P256000
Low coolant level.

111/3
P255612
Sensor, coolant level.
STOP
111/4
P255611
STOP
111/5
P255613
STOP
111/18
P111D00
Low coolant level.

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
WARNING
157/7
P019062
WARNING
157/12
P019001
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
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
WARNING
411/12
P040901
WARNING
ACOM18.01GB
38

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
WARNING
412/12
P040A01
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

temperatures.
WARNING
626/5
P100213

temperatures.
WARNING
628/2
P060741
Memory error in Control unit engine (D7940). Engine does

not start.
WARNING
628/2

not start.
WARNING
628/12

not start.
WARNING
629/12

not start.
WARNING
630/2

not start.
WARNING
630/12

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

WARNING
637/9
P033531

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

WARNING

the emergency stop.
ACOM18.01GB
39

Display
(SPN/FMI)
Supplier
code
639/9
Description
Action

WARNING

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
WARNING
641/5
P004513
WARNING
641/6
P004519
WARNING
641/9
U010C00
WARNING
641/11
P004592
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
WARNING
651/5
P020113
WARNING
652/3
P020212
WARNING
652/4
P020211
WARNING
652/5
P020213
WARNING
653/3
P020312
WARNING
653/4
P020311
WARNING
653/5
P020313
WARNING
654/3
P020412
WARNING
654/4
P020411
WARNING
654/5
P020413
WARNING
655/3
P020512
WARNING
655/4
P020511
WARNING
655/5
P020513
WARNING
656/3
P020612
WARNING
656/4
P020611
WARNING
656/5
P020613
WARNING
677/3
P061512
Start relay on the starter motor. Engine does not start.
WARNING
677/4
P061511
WARNING
ACOM18.01GB
40

Display
(SPN/FMI)
Supplier
code
Description
Action
677/5
P061513
WARNING
677/6
P061519
WARNING
679/3
P009012
Fuel pressure regulator (MPROP). Reduced engine

power.
WARNING
679/4
P009011

power.
WARNING
679/5
P009013

power.
WARNING
679/7
P228D72

power.
WARNING
729/5
P054013
Preheating element. Engine difficult to start at low

temperatures.
WARNING
729/6
P054070

temperatures.
WARNING
729/7
P05407F

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

cannot be started.
WARNING
970/5
P100113

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
WARNING
1188/5
P024313
WARNING
1239/14
P009400
Fuel leakage, minor.
WARNING
1347/7
P06279C
Fuel pressure pump. Reduced engine power.
WARNING
1485/7
P068573
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
WARNING
1761/12
P203A01
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

WARNING
ACOM18.01GB
41

Display
(SPN/FMI)
Supplier
code
2017/9
Description
Action
U014100
Control unit engine (D7940) communication error CAN

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
WARNING
2791/5
P040313
WARNING
2791/6
P040312
WARNING
2791/7
P040371
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
WARNING
3216/5
P220013
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
WARNING
3216/13
P220093
WARNING
3216/14
P22001C
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

power.
WARNING
3226/7
P225F00

power.
WARNING
3226/9
U029E00

power.
WARNING
3226/12
P22FE00
WARNING
ACOM18.01GB
42

Display
(SPN/FMI)
Supplier
code
Description
Action
3226/13
P229E93
WARNING
3226/14
P229E1C
WARNING
3241/4
P054411
Sensor exhaust temperature 1.
WARNING
3241/5
P054415
WARNING
3241/12
P054401
Sensor exhaust temperature 1
WARNING
3241/19
P054486
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

the tank.
WARNING
3363/5
P20B113

the tank.
WARNING
3364/17
P207F9A
Incorrect AdBlue quality.
WARNING
3464/3
P02E012
Actuator motor throttle.
WARNING
3464/4
P02E011
WARNING
3464/5
P02E013
WARNING
3464/7
P02E09C
WARNING
3464/10
P02E07C
WARNING
3464/12
P02E09B
WARNING
3468/2
P018564
Fuel temperature manifold.
WARNING
3468/4
P018511
Fuel temperature sensor.
WARNING
3468/5
P018513
WARNING
3468/12
P018501
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
43

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.
WARNING
4354/5
P20B913

hose.
WARNING
4355/3
P20BD12
Hose heater B AdBlue. Risk that AdBlue freezes in the

hose.
WARNING
4355/4
P20BD11

hose.
WARNING
4355/5
P20BD13

hose.
WARNING
4356/3
P20C112
Hose heater C AdBlue. Risk that AdBlue freezes in the

hose.
WARNING
4356/4
P20C111

hose.
WARNING
4356/5
P20C113

hose.
WARNING
4366/14
P20B992

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
WARNING
4375/3
P208A12
WARNING
4375/4
P208A11
WARNING
4375/5
P208A13
WARNING
4375/12
P10AD13
WARNING
4375/14
P21CAA1
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

WARNING
4376/5
P20A013

WARNING
4376/7
P20A007

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
WARNING
5394/5
P204713
WARNING
ACOM18.01GB
44

Display
(SPN/FMI)
Supplier
code
Description
Action
5394/12
P204786
AdBlue injection unit.
WARNING
5394/14
P204773
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
WARNING
520244/5
P009B13
WARNING
520244/7
P009B73
WARNING
520244/12
P018F00
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
WARNING
520688/5
P11A413
WARNING
520688/16
P11A500
Exhaust temperature higher than normal.
WARNING
ACOM18.01GB
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
ACOM18.01GB
46
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
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.
ACOM18.01GB
48
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
-40
-30
-20
-10
+10
+20
+30
+40
-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

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
49
ACOM18.01GB
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. Cargotecs main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields.
Cargotecs 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

Acom18 01GB

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Empty container handler 8-10

DCF 80100, DCT 80100

Contents Preventive maintenance

Supplement, Operators manual DCF 80100, DCT 80100

Supplement, Operators manual DCF 80100, DCT 80100

*Drain the water/impurities.

Fuel prefilter, draining of

** Change every 1000 h or

Fuel prefilter, change, page

Change the filter earlier if an

Fuel filter, change, page 12

* Change every 1000 h or

* First time at 1000 h, then

Air intake and exhaust outlet

Air filter safety cartridge

Check of indicator, change

* Change every other

* Check every 2000 h or

Drive belt, check, page 33

Coolant, level check

Coolant, freezing point

1.6 Air intake and exhaust

Drive belt, replace, page 33

For volume and grade, see

Supplement, Operators manual DCF 80100, DCT 80100

See Maintenance manual

C Preventive maintenance Preventive maintenance

For volume and quality, see

Oil and oil filter, change,

Fuel with sulphur content

Oil testing (engine option

The oil must always be

Oil and oil filter, change,

* The oil change interval

Oil and oil filter, change,

Sulphur content 0.3-0.5%:

* Change every 1500 h or

1.6.7 Crankcase ventilation,

Visual check for damage or

Supplement, Operators manual DCF 80100, DCT 80100

C Preventive maintenance Preventive maintenance

Service schedule Volvo TAD871VE

*Drain the water/impurities.

Fuel prefilter, draining of

* Change every 1000 h or

Fuel prefilter, change, page

Change the filter earlier if an

Fuel filter, change, page 12

* Change every 1000 h or

Clean and change the filter

AdBlue tank, cleaning

Filter AdBlue pump unit

* Change every 2000 h or

Filter AdBlue pump unit,

Strainer AdBlue pump unit

* Change every 2000 h or

Filter AdBlue pump unit,

Filter level sensor AdBlue

* Change every 2000 h or

Filter in AdBlue pump tank,

* First time at 1000 h, then

After engine replacement