Engine Brake Fault Tracing PDF
Engine Brake Fault Tracing PDF
Engine Brake Fault Tracing PDF
T2019344
This information covers fault tracing the VEB (Volvo Engine Brake) for the Volvo D12D
engine.
Contents
General Guide to Fault Tracing page 2
System Overview page 3
Checklist O, Engine Brake page 10
Engine Brake, Fault Tracing page 12
Illustrations are used for reference only, and may differ slightly from the actual
engine version. However, key components addressed in this information are repre-
sented as accurately as possible.
PV776-TSP187872 USA13254
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 2(21)
You must read and understand the precautions and guidelines in Service Informa-
tion, group 20, "General Safety Practices, Engine" before performing any procedure.
If you are not properly trained and certified in a procedure, ask your supervisor for
training before you perform it.
System Overview
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When fault tracing, it is important to understand the function of the system and
to follow the fault tracing sequence in the checklist to avoid replacing non-
defective components.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 4(21)
Component list
Component Description
A12 Control unit, ABS
A14 Control unit, EECU (engine electronic control unit)
A17 Control unit, VECU (vehicle electronic control unit)
A27 Control unit, LCM (external lighting)
B04 Sensor, engine speed, crankshaft
B13-18 Sensor, wheel speed
B25 Sensor, accelerator pedal
B37 Sensor, intake manifold pressure and temperature
B38 Sensor, oil pressure and oil temperature
B68 Sensor, road speed
F80 Fuse, engine solenoid valves, or fuel pump
S07 Switch, engine brake
S58 Position switch, clutch pedal, NC at rest
Y37 Air valve unit (AVU), engine brake/exhaust pressure governor (EPG)
Y39 Solenoid/control valve, VCB (Volvo Compression Brake)
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 5(21)
For a more detailed description of the EPG function, see The position of the Engine brake
Exhaust Pressure Governor (EPG) page 7. switch
The exhaust valve opens immediately before the Engine speed exceeds 900 rpm; engine speed sen-
sor, B04 (deactivates < 800 rpm).
turn of the compression stroke and punctures the
compression in order to reduce the effect with the Speedometer (B68) indicates a speed greater than
5 km/h (3 mph).
working stroke.
ABS wheel sensor (B13-18) indicates NO wheel
lockup (ABS non-active).
Electrical control of engine brake
The engine brake power is determined by the drivers
settings. The power varies for different combinations of
engine brakes.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 6(21)
Three positions. (J1939 and J1708/J1587) to the engine ECU (A14). The
engine ECU then sends a signal (-) to the sole-
noid/control valve (Y39) for increased oil pressure in the
The position of the Engine brake
rocker arm shaft and a PWM signal (Pulse Wide Modu-
switch
lated) to the AVU (Y37). Both the control valves are
0 (switched off) 0% supplied voltage via fuse F80.
1 50 % Requirements
2 100 % Clutch pedal (S58) is NOT depressed.
Accelerator pedal (B25) released.
Engine speed exceeds 1100 rpm*; engine speed
sensor, B04 (deactivates < 1000 rpm).
Speedometer (B68) indicates a speed greater than
5 km/h (3 mph).
Oil temperature (B38) greater than 55 C (131 F).
Intake manifold pressure (B37) less than 50 kPa
(7.25 psi).
ABS wheel sensor (B13-18) indicates NO wheel
lockup (ABS non-active).
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The exhaust pressure governor has three functions: Start and heat retention
For functional description and fault tracing of the exhaust
To keep the engine warm when idling. pressure governor during start and heat retention, refer
to Service Information, group 25, EPG, Fault Tracing,
To function as exhaust brake on down gradients. Checklist E.
Compression Brake
Solenoid/Control Valve
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The solenoid/control valve has the task of regulating the A: When the engine is running the piston (3) partly
oil pressure to the rocker arm mechanism. covers the outlet (5), which results in reduction of oil
pressure to approximately 100 kPa (14.5 psi) after the
The inlet (1), which is connected to the lubricating oil solenoid valve. This oil pressure is sufficient for lubrica-
passage in the cylinder block, always has system oil tion of the camshaft bearings and the rocker arm
pressure. The outlet (5) is connected to the rocker arm mechanism.
shaft. The compression brake is activated by the sole-
noid valve (2), which is controlled from the EECU. B: With compression braking, voltage to the solenoid
valve (2) opens a draining passage. The oil in the oil
space (6) flows out through the draining passage, allow-
ing the spring (4) to push the piston (3) to the side. This
means the outlet (5) becomes free and the oil pressure
from the gallery connection provides the rocker arm shaft
with full oil pressure more than 200 kPa (29 psi).
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 9(21)
W2004196
The camshaft (1) on an engine with VCB has, in addition B: With compression braking, the solenoid/control
to the ordinary exhaust cam (2), a charge cam (3) and a valve increases the oil pressure to > 200 kPa (29 psi).
decompression cam (4) on each exhaust cam lobe.
At high pressure, the piston (11) overcomes the spring
Each rocker arm (5) includes a non-return valve (7) and (14), which means that the spring (12) can push the ball
a rocker arm piston (8). A spring tab (6) holds the rocker (13) towards the seat. The oil, above the rocker arm pis-
arm in its resting position against the valve bridge. The ton (8), can no longer flow past the ball and therefore
non-return valve clearance is adjusted with the help of pushes on the rocker arm piston (8), so that the piston
shim (9) which is situated on the valve bridge. pushes down and eliminates the valve clearance.
The non-return valve (7) consists of a piston (11) and When the camshafts extra brake cams (3) and (4) fur-
spring (14), spring (12) and ball (13). ther affect movement of the rocker arm, the exhaust
valves are pushed down and compress (force more air
A: Under normal engine operation, the sole- into the cylinder with the help of the back pressure in the
noid/control valve reduces the oil pressure. exhaust during the compression stroke) and decompres-
sion respectively (release compression during the power
At reduced oil pressure of 100 kPa (14.5 psi), the piston
stroke).
(11) will not move out of its rest position, because the oil
So that the pressure above the rocker arm piston does
pressure is not sufficient to overcome the spring force
not push back into the rocker arm shaft when the valve
(14). The pistons pin holds the ball (13) away from the
opens, there is a pressure limiting valve (10).
seat, which allows the oil to flow in both directions
through the non-return valve. This prevents excess oil
pressure building up above the rocker arm piston (8).
Have the fault codes related to the engine brake been corrected?
Action:
Does the displayed status conform to the actual position of the switch?:
Switch Status
Position 1 (EPG)
Do EPG and VCB solenoid valves function when activated by VCADS Pro?
Does accelerator pedal idling switch indicator light up when pedal is depressed ... and go off when pedal is released?
Road test Check the following requirements (for the engine brake to become active) during test driving:
Does the displayed status conform to the position of the clutch pedal?
Is EPG solenoid valve indicator lit in switch position 1 when prerequisites are met?
Are VEB and EPG solenoid valve indicators lit in switch position 2 when prerequisites are met?
Action:
Does the AVU receive correct air pressure (over 7.5 bar / 110 psi)?
Are the air hoses correctly clamped and free from kinks or damage?
Does the EPG receive correct air pressure at 100% activation (approx. 7.5 bar/110 psi)?
Action:
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 11(21)
Action:
Action:
Action:
Are the draining hole and draining passage free from debris?
Action:
Is the clearance between the rocker arm piston and valve bridge within specifications?
Action:
Are the spring and the non-return valves piston free from defects?
Are the non-return valves ball and spring free from defects?
Action:
Notes:
2531-20-03-01 2
5
Check that the hoses are properly
connected and do not leak.
6
Empty the compressed air system and
remove gauge and test nipple. Re-
move fitting from test nipple and install
fitting into AVU and connect supply
hose.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 13(21)
2
Remove the exhaust pipe by the EPG
and check that shutter disc is not dam-
aged.
3
Connect the PC tool to the vehicles
data link connector, if this has not al-
ready been done.
4
Using VCADS Pro, begin Start and
heat retention function, test; activate
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EPG at 30% (corresponds to the same
Check that the EPG receives the cor- 9996465 air pressure as with warm-hold func-
rect control pressure: remove the air 9998333 tion) and at 100 % (corresponds to full
hose from the EPG and connect pres- control pressure, exhaust brake).
sure gauge 9996465 and nipple
9998333 to the hose.
5
8
Connect the PC tool to the vehicles
data link connector, if this has not al-
ready been done.
9
Using VCADS Pro, run the Engine
brake function test.
psi).
WARNING
11
If the control pressure is not within EPG shutter may move without warning. Keep hands
specifications and the supply pressure away from EPG shutter during activation. Failure to
to the AVU is the same as the system do so can result in personal injury.
air pressure approximately 8.3 bar
(120 psi) replace the AVU. Check that the shutter reaches its end
positions by activating and shutting off
the EPG using the PC tool.
12
Remove the gauge and test nipple. NOTE: The stroke travel (A) should be
Connect air hose to EPG. 29 33 mm (1.15 1.30 in.).
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 14(21)
6 3
If stroke travel is not within specifica-
tions, replace or overhaul EPG; refer
to Service Information, group 25.
CAUTION
Use a hand wrench to loosen the valve cover nuts;
this will help prevent the studs from loosening from
the cylinder head and thus damaging the valve cover
and the unit injectors wiring harness. DO NOT USE
AN AIR TOOL.
4
Temporarily remove the hose.
5
Remove the second stud (counting
from left front of engine) so hose can
be routed through valve cover.
6
Route the oil pressure hose from out-
side and in through the valve cover
W2004197
where the stud was removed.
Remove the second bolt on the rocker
arm shaft (as viewed from the front of
the engine).
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 15(21)
7 13
Carefully route the hose into the cab. 9998496
J39200
Alternate 1: 9998339
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Alternate 2:
14
8
Test drive the vehicle and bring to op-
Secure the hose so that it will not be
erating temperature. Activate VCB and
damaged by the rocker arms.
note pressure after it stabilizes.
W2004200 16
If rocker arm shaft oil pressure is
Press the seal for the oil pressure
within specifications, remove valve
hose into the hole on the valve cover.
cover and test equipment.
11
17
Route and secure the oil pressure
Install rocker arm shaft bolt and 15 5 Nm
hose so that it will not be damaged
torque-tighten to 15 5 Nm (11 4 ft- (11 4 ft-lb),
when the hood is closed.
lb), then turn additional 120 5 . 120 5
12
Lower the hood.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 16(21)
T2012845
2
Check all rocker arm bolts in order to
T2019598
make sure that there is no oil leakage
Position magnetic stand 9999696 with 9999696
due to under-torqued bolts.
dial gauge 9989876 so that the dial 9989876
gauges measurement probe tip is lo-
cated above the middle of the rocker
arm bushing (on the rocker arm not in
contact with the camshaft).
3
Move the rocker arm, so that most of
the oil film is thinned out on the upper
side of the rocker arm shaft.
4
Reset the dial gauge.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 17(21)
5 8
C2002679
T2019598
Position bar tool 9998511 under the 9998511 Place dial indicator 9989876 in mag- 9999696
rocker arm, by the rocker arm shaft, netic stand 9999696. Put the magnetic 9989876
and push up the rocker arm. Note the stand on the rocker arm.
reading on the dial gauge.
Direct the probe tip of the dial gauge
Max. permitted clearance is 0.1 mm so that it lies horizontally against the
(0.0039 in.). In the case of clearance center of the roller.
greater than this, replace the rocker Set the dial gauge at 2 3 mm (0.080
and check the rocker arm shaft for 0.118 in.) tension.
wear.
NOTE: Make sure that the probe tip of
the dial gauge is set at tension and
6 can move in both directions.
Repeat the check on all other rocker
arm bushings.
9
T2007948
T2007950
Rotate the roller a few turns, so that
the oil film between the bushing and Put a screwdriver between the rocker
shaft is thinned out. arm and roller.
NOTE: If the roller jams and does not Push out the roller as far as possible
rotate freely, the rocker arm must be and read off the value on the dial test
replaced. indicator.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 18(21)
10 12
Check valve clearance between rocker
arm piston and valve bridge. Accept-
able clearance is 1.55 1.65 mm
(0.051 0.065 in.); for information on
adjusting valves, refer to Service Infor-
mation, group 21.
T2007951
11
T2019599
T2007792
3 5
With low oil pressure in the rocker arm
shaft, check:
T2019600
WARNING
Wear eye protection. Do not apply full shop air pres-
sure. There is risk of oil splash that can cause T2019601
personal injury.
The piston (1) in the control valve is in
active position (B), when the solenoid
is activated and the oil chamber (2) is
drained and the spring presses the
Control Valve piston to its end position.
4 When the engine is switched OFF,
If the engine oil is very contaminated, there is no oil pressure on either side
remove the control valve and clean it of the piston, so the piston should be
internally. at its end position (via the spring). If
the piston jams or sticks, the VCB can
become active for a short period after
starting.
It is highly unlikely that the piston (1)
has jammed or stuck in the driving po-
sition, i.e. the VCB is not active (A).
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 20(21)
7
During engine operation, the springs 1
force and oil pressure in the oil cham-
ber (2) hold the piston in the balance
position which reduces oil pressure.
2
Heat the plug (1) on VEB rocker cylin-
der 3 so that the locking fluid ceases
to grip. Remove the plug.
Non-return valve
3
Remove the spring (2) and the non-
return valve piston (3a) and check
spring and piston for damage.
4
Place the non-return valve piston (3a)
back in the piston bore. Push piston
forward and back to verify that piston
moves freely in piston bore.
5
Check the non-return valve ball (3b)
and spring (3c) by pressing the non-
return valve piston (3a) to end position
in order to feel whether there is a
spring tension. If no tension is felt, the
spring is faulty and should be replaced.
T2019602
1. Plug
2. Spring Rocker arm piston
3. Non-return valve 6
3a. Piston Push the non-return valve piston (3a)
3b. Ball to end position while pressing the
3c. Spring rocker arm forward (towards the
valves).
4. Rocker arm piston
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 3.2003 253 21 21(21)
7 10
When the rocker arm piston (4) con- If no faults were found, install spring
tacts the valve caliper, release the (2) and plug (1).
non-return valve piston (3a).
NOTE: Apply thread locking fluid to
plug before installation.
8
Push the rocker arm back (towards the
camshaft). Negative pressure will then 11
be created in the rocker arm piston (4). Check the remaining VEB rocker
arms: rotate the engine to the next
VEB marking and repeat steps 2 10.
9
Continue to hold the rocker arm
toward the camshaft. Release the neg-
ative pressure by pushing in the
non-return valve piston (3a). The
rocker arm piston (4) should drop to-
ward the valve caliper when negative
pressure is released. If piston does not
move freely, replace the rocker arm.