Volvo Veb
Volvo Veb
Volvo Veb
Trucks
Group
250-610
PV776-TSP0250610/2
Foreword
The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to February 2000.
The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplementary service bulletins will be issued to cover the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a reference to an V.S.T. (Volvo Standard Times).
Service procedures which do not include an operation number in the title are for general information and no reference is made to an V.S.T.
The following levels of observations, cautions and warnings are used in this Service
Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to
have the vehicle or component function in the manner intended.
Caution: Indicates an unsafe practice where damage to the product could occur.
Warning: Indicates an unsafe practice where personal injury or severe damage to the
product could occur.
Danger: Indicates an unsafe practice where serious personal injury or death could occur.
Contents
General .................................................................................................... 3
VOLVO Engine Brake (VEB) ................................................................. 3
Tools ........................................................................................................ 5
VOLVO Engine Brake, Special Tools ..................................................... 5
Other special equipment ..................................................................... 6
Design and Function ............................................................................. 7
Engine Brake ......................................................................................... 7
Exhaust Brake ..................................................................................... 7
Compression Brake ............................................................................. 7
Control Valve (VEB) ............................................................................ 8
Camshaft (VEB) .................................................................................. 9
Exhaust Rocker Arms (VEB) ............................................................. 10
Non-Return Valve (VEB) ................................................................... 10
Rocker Arm Plunger .......................................................................... 11
Engine Operation ............................................................................ 11
Compression Braking ...................................................................... 11
Engine Braking .................................................................................. 12
Control System, D12 and D12 A .................................................... 12
Exhaust Brake ................................................................................. 13
Compression Brake ......................................................................... 14
Induction Phase .............................................................................. 14
Decompression pPhase .................................................................. 14
Troubleshooting ...................................................................................
Engine Brake, Fault Tracing ................................................................
VEB Diagnosis and Troubleshooting .................................................
Electrical Troubleshooting .................................................................
Special tools: J41132 ....................................................................
Connecting test equipment .............................................................
Voltage measurement .....................................................................
Resistance measurement ...............................................................
Mechanical Troubleshooting ..............................................................
Conditions .......................................................................................
VEB Troubleshooting, Order to Follow ..............................................
1 ......................................................................................................
2 ......................................................................................................
3 ......................................................................................................
4 ......................................................................................................
VEB Fault Symptoms ........................................................................
Fault symptom 1 ..............................................................................
Fault symptom 2 ..............................................................................
Fault symptom 3 ..............................................................................
Fault symptom 4 ..............................................................................
Fault symptom 5 ..............................................................................
Fault symptom 6 ..............................................................................
Fault symptom 7 ..............................................................................
Low Engine Braking Effect (VEB) .....................................................
Check Before the Test: ....................................................................
Test Equipment, Installation ............................................................
Test-driving and Measuring .............................................................
Brake Test .......................................................................................
Evaluation of the Brake Test ...........................................................
Engine Brake, Checking ......................................................................
15
15
15
16
16
16
17
17
18
18
19
19
19
19
19
20
20
20
20
20
20
20
20
21
21
21
21
22
26
27
1
29
30
32
36
40
46
49
49
51
53
Operation Numbers
Group 25
General
General
VOLVO Engine Brake (VEB)
Successful troubleshooting of the VOLVO engine brake system requires information regarding system design and knowledge of how the different components function in
relation to each other.
W2002155
1
2
3
Camshaft
Shutter
Exhaust pressure governor
4
5
6
Rocker arm
Control valve
Oil pipe
The description, operation and service of the Volvo Engine Brake is detailed as follows:
The Troubleshooting section is subdivided into Electrical
Troubleshooting and Mechanical Troubleshooting.
Refer to this information along with the description and
operation information when performing troubleshooting.
Group 25
Tools
Tools
VOLVO Engine Brake, Special Tools
Servicing the Volvo Engine Brake (VEB) requires the following special tools. The tools
are available from the Parts Department of Volvo Truck North America, Inc. Unless otherwise noted, all tool numbers are preceded by 999. Please specify the complete part
number when ordering. Tools with part numbers beginning with J are available only
from Kent-Moore.
W2002194
9996465
9998338
9812327
Memory cassette
9989876
Dial indicator
9996716
Drift
9998339
9996956
9998342
9998190
Measuring instrument
9998344
9998333
9998364
9808001
Bolt
9999696
Magnetic base
Group 25
Tools
W2003381
J-385001000 Cartridge
J-3850060A Adapter
9510060 Multimeter
W2002195
J-35616-20
Jumper wires
9999708
J-42472
J- 39200
1159794
J- 41132
Group 25
W2000702
1
2
Camshaft
Shutter
3
4
5
6
Control valve
Oil pipe
The Volvo Engine Brake consists of two different systems, the exhaust brake and the compression brake.
In the VEB, both systems operate at the same time.
Exhaust Brake
The exhaust pressure governor includes a shutter,
mounted in the exhaust side of the turbocharger. This
shutter, which is connected to the exhaust pressure governor plunger, restricts the exhaust gas flow when
activated. Braking is achieved during the exhaust stroke
by the backpressure created when the exhaust gas flow
is blocked.
Compression Brake
The compression brake controls the opening of exhaust
valves during the engine compression and combustion
(operating) stroke. This creates backpressure in the
combustion chamber which, in turn, has a braking effect.
On engines with compression brakes, the camshaft has
two extra lobes on each exhaust cam profile. The lift
height of the extra lobes is very low compared to that of
normal exhaust lobes. To enable the extra lobes to open
the exhaust valves, the exhaust rocker arms are arranged in a manner which reduces valve clearance
during the braking sequence.
Group 25
T2007789
Fig. 1: Engine in operation, the control valve solenoid valve not activated
T2007788
Fig. 2: VEB engine braking, the control valve solenoid valve activated
8
Group 25
T2006835
Oil inlet
Solenoid valve
Plunger
Spring
Oil outlet
Oil chamber
Camshaft (VEB)
On engines with a compression brake, the camshaft has
an induction lobe (1) and decompression lobe (2) in addition to the normal exhaust lobe (3) on each cam profile
for the exhaust valves. The induction and decompression
lobe lift height is 0.8 mm (0.032 in.) above the basic circle, which is equivalent to about 1.1 mm (0.043 in.) at
the valve bridge. The induction lobe is positioned to
open the exhaust valves at the end of the intake stroke
and hold them open at the beginning of the compression
stroke. The decompression lobe is positioned to open
the exhaust valves at the end of the compression stroke.
The valve clearance must be zero for the induction and
decompression lobes to open the exhaust valves.
T2006826
Induction lobe
Decompression lobe
Exhaust lobe
Group 25
T2006827
Spring tab
Non-return valve
Rocker arm plunger
Shims
W2000704
T2006834
10
Plunger
Spring
Ball
Rocker arm plunger
Spring
Group 25
Engine Operation
When the engine is operating, there is reduced oil pressure through the control valve to the rocker arm shaft,
and the rocker arm non-return valve (1) is open. Oil can
flow freely through the non-return valve in both directions. Therefore, no oil pressure is built up between the
rocker arm plunger (2) and the rocker arm.
The set valve clearances are great enough to prevent
the cam shaft induction and decompression lobes from
opening the exhaust valves.
The valve mechanism operates as it would on an engine
without a compression brake. That is, only the exhaust
lobe opens the exhaust valves.
T2006828
Non-return valve
Rocker arm plunger
Compression Braking
During compression braking, an oil pressure of at least
200 kPa (29 psi) is delivered to the rocker arm shaft as
the control valve does not reduce the oil pressure.
The pressure in the rocker arm non-return valve (1) increases enough to move the plunger in the non-return
valve from its rest position, and the ball now functions as
a non-return valve. Pressure builds up between the
rocker arm plunger (2) and the rocker arm. The plunger
moves out and forces the rocker arm roller against the
lobes on the camshaft. The valve clearance is eliminated
and the lift height on the induction and decompression
lobes is sufficient to open the exhaust valves. The rocker
arm plunger is equipped with a pressure-limiting valve
(3). When oil pressure between the rocker arm plunger
and the rocker arm becomes too high, the pressurelimiting valve opens and oil can exit through the hole in
the bottom of the plunger. The opening pressure of the
pressure-limiting valve is governed by the force of the
valve spring.
T2006836
Non-return valve
Rocker arm plunger
Pressure-limiting valve
11
Group 25
Engine Braking
Control System, D12 and D12 A
With the complete release of the accelerator pedal, the
engine brake is activated according to the selection made
on the dash board, but only if certain conditions are met:
Accelerator pedal must be fully released (fuel injection must not occur).
Temperature measured at
outlet of cooling pump
p/n 8155799
43 C (110 F)
p/n 3985349
67 C (158 F)
As an additional option, the engine brake may be enabled automatically if the vehicle exceeds a specified
cruise control limit. If this option is selected, the engine
brake may be applied at a selectable speed from 6.4 to
32 km/h (4 to 20 mph) above the cruise control set
speed.
12
W2000877
Group 25
Switches
On the dash the switches for the engine brake have different configurations. With the two dual-position
switches, the brake system is activated by placing one of
the switches in ON position. The HI/LO switch, in the HI
position, selects both the exhaust brake and the compression brake (Volvo engine brake or VEB). In the LO
position, only the exhaust brake is selected.
W3002827
The engine brake switches are on some truck models replaced by a single three-position switch. As with the
switches above it also regulates the engine brake for the
cruise control.
The three position switch has the following selection:
1
2
3
T2006953
Exhaust Brake
During exhaust braking, control pressure of about 752
kPa (109 psi) activates the exhaust pressure governor.
The exhaust pressure governor plunger is activated and
the shutter connected to the plunger restricts the flow of
exhaust gases out of the cylinders.
Restricting the flow of exhaust gases creates a back
pressure between the shutter and the piston crowns.
This provides a braking effect on the pistons as the exhaust valves open.
The higher the engine speed during exhaust braking, the
greater the braking effect.
T2006832
13
Group 25
Compression Brake
The exhaust brake is always engaged with the compression brake. This is because the compression brake
induction phase fully utilizes the backpressure created
by the exhaust brake in the exhaust manifold.
Induction Phase
The induction phase begins at the end of the intake
stroke and continues slightly into the compression stroke.
The piston travels downward toward bottom dead center
and the camshaft induction lobe opens the exhaust
valves long enough to fill the cylinder with the backpressure created by the exhaust brake in the exhaust
manifold.
When the induction lobe closes the exhaust valves, the
cylinder has a backpressure at the start of the compression stroke. This backpressure increases compression
considerably during the compression stroke which, in
turn, creates a powerful braking effect when the piston
moves upward.
T2006830
Decompression pPhase
At the end of the compression stroke, as the piston approaches top dead center, the camshaft decompression
lobe opens the exhaust valves and releases the pressure
from the cylinder. Shortly before bottom dead center, the
ordinary exhaust lobe opens the exhaust valves. During
the exhaust stroke, a backpressure is created in the exhaust manifold. This has a braking effect because the
exhaust pressure governor shutter is closed.
T2006831
14
Group 25
Troubleshooting
Troubleshooting
Engine Brake, Fault Tracing
V776200820SM
Specifications, VE D12
284610, PV776TSP128229
Engine Control System, VE D12
WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving or hot engine parts. A hot engine
can cause serious burns or can permanently damage
test equipment.
280600, PV776TSP105620/1
Fault Codes, Engine Electronic Control
Unit
WARNING
Always wear appropriate eye protection to prevent the
risk of eye injury due to contact with engine debris or
fluids.
CAUTION
Always clean the engine before servicing and keep
the compression brake components clean during all
service and repair procedures. Lack of cleanliness
during service and repair work could result in a fault
or malfunction of the compression brake system.
15
Group 25
Troubleshooting
Electrical Troubleshooting
W2002196
16
Group 25
Troubleshooting
Voltage measurement
Conditions:
Engine running
Engine brake switch in the ON position
Selector switch in the HI position
Throttle pedal in idle position
Voltage Measurement
Intended Value
Probable Cause
Faulty connection
2:9
B+
Faulty harness
Resistance measurement
Ignition off
Service
Manual
Resistance Measurement
Intended
Value
PV776280600SM
Electronic Controls, VE D12, D12 A,
D12 B
Probable Cause
Faulty connection
Faulty harness
2:9
13 16
Faulty harness
2:9
7.5 9.5
17
Group 25
Troubleshooting
Mechanical Troubleshooting
Conditions
The electrical troubleshooting has been carried out,
Exhaust brake
Compression brake
Test 1
Test 2
Test 1
Test 3
Test 4
Test 5
Carry out the tests on the exhaust brake and compression brake in numerical order according to the
above diagram, when either one of the brake systems does not work.
If both brake systems work, but give poor braking effect, see Low Engine Braking Effect (VEB) page 21.
18
Service procedures not contained in this information are to be found in the service information for
the VOLVO D12 engine under the respective group.
Test 2
Group 25
Troubleshooting
1
Begin troubleshooting by attempting to establish which of
the brake systems is faulty (exhaust brake, compression
brake, or both systems).
2
Verify that the following preconditions for exhaust braking are satisfied, with the switch(es) on the instrument
panel in the ON/LOW (exhaust brake only) positions.
3
Verify that the following preconditions for VEB (exhaust
braking and compression braking) are satisfied, with
the switches on the instrument panel in the ON/HI (exhaust brake and compression brake, VEB) positions.
Note: An additional option is to have the VEB enable automatically if the vehicle exceeds a specified cruise
control limit. If this option is selected, the VEB will automatically engage at a selectable speed approximately
6.4 to 32 km/h (4 to 20 mph) above the set cruise control speed.
4
Always begin with electrical troubleshooting, unless
a fault in the electrical system can be completely
ruled out.
19
Group 25
Troubleshooting
Fault symptom 5
Poor braking effect from the exhaust brake
Fault symptom 1
Probable fault:
Fault symptom 2
Neither the exhaust brake nor the compression
brake functions
This indicates a fault in the electrical system. The control
signal is not reaching the exhaust pressure governor and
the control valve solenoid valves.
Carry out electrical troubleshooting.
Fault symptom 3
The exhaust brake functions, but not the compression brake
Probable fault:
Fault symptom 6
Poor braking effect from the engine brake (exhaust
brake and compression brake)
Probable fault:
Fault symptom 7
The compression brake engages but will not disengage
If the compression brake remains engaged with full effect even though the accelerator pedal is depressed, this
is due to the control valve plunger remaining in theVEB
positionand directing full system oil pressure out to the
rocker arms.
Fault symptom 4
The compression brake functions, but not the exhaust brake
Probable fault:
20
Group 25
Troubleshooting
To obtain good test results, the exhaust pressure governor should be disabled when checking the function of
the compression brake.
Route the 36-pin breakout box into the cab and secure.
Check that both the exhaust brake and engine brake are
functioning by test-driving the truck.
If the engine sound changes and there is a noticeable braking effect, the compression brake does
function.
Group 25
Troubleshooting
T2008019
Press
one more time.
The display should now show six temperature values,
one for each cylinder, with no. 1 cylinder shown on the
extreme left of the display.
The instrument will now measure temperature continuously.
Brake Test
T2008010
T2008011
once.
Press
The display should now show the text Temp. Display.
22
Group 25
Troubleshooting
T2008013
T2008012
once.
View the measurement instrument, wait for the temperature to rise and begin to stabilize.
Press
once.
Note: Remember the engine brake will remain active until switched OFF.
Store the measurement values by pressing
When terminals 2 and 11 of the 36-pin breakout box
are bridged, the compression brake will activate anytime the VEB control switch is in the ON position,
regardless of status. The compression brake will remain ON until the control switch is moved to the OFF
position. While the engine brake is activated, do not
depress the accelerator or clutch. If the accelerator is
depressed, engine damage may result. If the clutch is
depressed a loss of power steering assist may occur.
Be prepared to switch off the engine brake at any time.
Failure to do so may result in personal injury or death.
23
Group 25
Troubleshooting
10
T2008011
T2008021
Press
and the first stored measurement value is displayed. The identification letter A appears before the
measurement value.
or
By pressing
values on the display.
T2008014
Press
until the text Temp. Evaluation is shown on
the display.
24
Group 25
Troubleshooting
11
13
The results from the third, and if necessary, the fourth
and fifth measurements are produced in the same way
as with measurements one and two.
By pressing , it is possible to move between 10 measurement values and 5 differences.
14
Note the measurement results and remember that a fully
charged back-up battery retains the stored measurement
values in the instrument for max. 20 minutes after the
external voltage supply has been broken. If possible, do
not break the voltage supply to the instrument before all
the measurement results have been noted.
T2008022
By pressing
again, the difference between measurement values B and A is shown.
or
By pressing
values on the display.
15
12
T2008015
Hold
pressed in (approx. 2 seconds), when all measurement results have been noted, until the text Temp.
Evaluation is shown on the display.
16
T2008020
Press
once.
T2008023
Press
play.
Group 25
Troubleshooting
17
When the switch(es) are moved from position OFF to positions ON/HI, the oil pressure in the rocker arm shaft
should rise to min. 2 bar (29 psi).
If the oil pressure does not exceed 2 bar (29 psi), the
control valve is faulty.
Note: Low oil pressure in the rocker arm shaft may also
be due to excessive wear in the rocker arm bushing
and/or rocker arms which result in excessive oil pressure
loss. See Rocker Arm Roller, Checking page 46.
The temperature increase for each individual cylinder
should be between 90 C and 130 C (194 F and 266 F)
in order to be certain that the compression brake on
each cylinder is functioning properly.
T2008024
By holding
pressed in for approximately 2 seconds
until the display shows the text Temperature, the instrument leaves the back-up mode and all the stored
measurement values are cleared.
18
Disconnect the electrical plug for the external voltage
supply.
Note: Switch the instrument off by holding
pressed in
for approx. 2 seconds when the display shows the text
Temp. Evaluation or Temp. Display, after the external
supply contact has been broken.
26
Group 25
Troubleshooting
2531-06-02-01
Engine Brake, Checking
WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving or hot engine parts. A hot engine
can cause serious burns or can permanently damage
test equipment.
Note: Before carrying out the following procedure, read
the troubleshooting general information in Engine Brake,
Fault Tracing page 15.
3
Set Multimeter to measure Amps and
connect it to terminals 2 and 11 on the
36pin breakout box. This supplies
battery voltage and measures current
draw to the brake circuit (exhaust
brake only).
4
An audible click should be heard
from the exhaust brake solenoid valve
when the multimeter is connected.
5
If no click is heard from the exhaust
brake solenoid valve, and the exhaust
brake measurement 1 results were
OK, replace the HI/LO switch. Otherwise, proceed to step 6.
6
Disconnect the connector on the exhaust brake solenoid valve.
7
Bridge terminals 3 and 10 on the
breakout box.
8
Set Multimeter to measure Amps and
connect it to terminals 2 and 11 on the
36pin breakout box.
9
A faint click should be heard from the
compression brake solenoid valve
when the multimeter is connected.
W2002218
27
Group 25
Troubleshooting
Measurement 2
Measurement 4
1
Bridge terminals 2 and 11 on the 36
pin breakout box.
1
Set Multimeter to measure Voltage.
2
Disconnect the 2-pin connector at the
exhaust brake solenoid valve and connect the J42472 breakout harness
between the solenoid valve and the
wiring harness.
3
Set multimeter to measure Voltage
and connect it to pins 1 and 2 on the
compression brake connector at the
upper timing gear cover.
Intended value: B+
4
If the intended value is correct, remove the valve cover and carry out
Measurement 3.
5
If the intended value is not correct,
carry out Measurement 4.
Measurement 3
1
Set multimeter to measure Ohm ( ).
2
Measure between 1 and 2 on the compression brake solenoid valve.
Intended value: 20 2
3
If the intended value is correct, check
the cables between the compression
brake solenoid valve and the connector at the upper timing gear cover.
4
If the intended value is not correct, replace the compression brake solenoid
valve.
28
2
Measure between alternate ground
and pin 1 in the connector for the control valve solenoid valve at the upper
timing gear cover.
Intended value: B+
3
If the value is not correct, check the
wire to pin 1 in the connector for the
control valve at the upper timing gear
cover and to pin 2 at the EB connector
including the engine brake switch(es).
Make repairs and retest.
4
If the value is correct, measure between alternate battery supply and pin
2 in the connector for the control valve
solenoid at the upper timing gear
cover.
Intended value: B+
5
If the value is correct, clean and inspect both pins and sockets at the
connector for the control valve solenoid. Repeat measurement 1.
6
If the value is not correct, check the
wire from pin 2 in the connector for the
control valve at the upper timing gear
cover to its ground location, including
compression brake coolant temperature switch.
Group 25
Troubleshooting
2533-06-02-01
Solenoid Valve, Compression
Brake, Checking
Test 1
1
T2007704
WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving or hot engine parts. A hot engine
can cause serious burns or can permanently damage
test equipment.
WARNING
Always wear appropriate eye protection to prevent the
risk of eye injury due to contact with engine debris or
fluids.
Note: Before carrying out the following procedure, read
the troubleshooting general information in Engine Brake,
Fault Tracing page 15.
T2007740
29
Group 25
Troubleshooting
2531-06-02-02
Exhaust Brake, Electronic
Checking
Test 2
1
W2002231
2
Test-drive the vehicle and allow it to
reach operating temperature.
3
Activate the engine brake by making
sure the switch(es) on the instrument
panel are in the ON/HI position and
the conditions for engine braking are
satisfied.
4
When the oil pressure has stabilized
record the gauge reading during engine brake operation.
The pressure should be at least 2 bar
(29 psi).
5
Repeat the test a number of times to
confirm the measurement reading.
6
Replace the control valve if the measured pressure is below 2 bar (29 psi)
and the rocker arms, nozzles for lubricating the ball sockets, bushings and
other components on the rocker arm
bridge are not damaged.
30
Measurement 1
1
Move the switch(es) on the instrument
panel to ON/LOW (exhaust brake only)
positions.
2
Bridge terminals 3 and 10 on the
breakout box. Doing so energizes the
EECU power supply relay by providing
a ground to the coil side of the relay.
3
Set Multimeter to measure Amps and
connect it to terminals 2 and 11 on the
36pin breakout box. This supplies
battery voltage and measures current
draw to the brake circuit (exhaust
brake only).
4
An audible click should be heard
from the exhaust brake solenoid valve
when the multimeter is connected.
5
The multimeter should show 0.7 0.1
Amp.
Group 25
Troubleshooting
6
If no click is heard from the exhaust
brake solenoid valve, or if the multimeter does not show the value 0.7 0.1
Amp, proceed to the next measurement.
4
If the intended value is not correct,
check the wire between pin 1 in the
connector for the exhaust brake solenoid valve and pin 2 at connector EB,
including the engine brake switch(es).
Measurement 2
Measurement 4
1
Bridge terminals 2 and 11 on the 36
pin breakout box in addition to the
connections in measurement 1.
1
Note: A functional diode allows current to flow in one direction only.
Connect the J-42472 2-pin breakout
harness to the exhaust brake solenoid
only.
2
Disconnect the 2-pin connector at the
exhaust brake solenoid valve and connect the J42472 breakout harness
between the solenoid valve and the
wiring harness.
3
Set multimeter to measure Voltage.
Measure between pins 1 and 2 on the
breakout harness. Intended value: B+
(battery positive voltage ~12V).
4
If the intended value is correct, replace
the exhaust brake solenoid valve.
5
If the intended value is not correct,
carry out Measurement 3.
Measurement 3
1
Set multimeter to measure Voltage.
2
Measure between alternate ground
and pin 1 in the breakout harness.
Intended value: B+
3
If the intended value is correct, check
the cable from pin 2 in the connector
for the exhaust brake solenoid valve to
ground.
31
Group 25
Troubleshooting
2531-06-02-03
Exhaust Brake, Mechanical
Checking
2
Verify correct air regulator valve is
used with the proper system. The exhaust brake requires the 7.5 bar
regulator, while the EPG utilizes a 2.3
bar regulator.
3
WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving or hot engine parts. A hot engine
can cause serious burns or can permanently damage
test equipment.
WARNING
W2002198
W2002234
T2007700
Group 25
Troubleshooting
Test 2
1
Check that the air hoses are not
twisted or blocked.
Replace damaged hoses.
2
T2007701
If the exhaust pressure governor shutter does not move, remove the air
hose from the exhaust pressure governor and activate the exhaust brake
solenoid valve again.
T2007953
6
If no air comes out of the hose, carry
out Test 2.
If air comes out of the hose, carry out
Test 3.
33
Group 25
Troubleshooting
Test 3
Test 4
1
Check that the hoses are not twisted
or blocked.
Replace damaged hoses.
999 6465
999 8333
T2007707
Connect the pressure gauge to the exhaust pressure governor hose and
activate the exhaust brake solenoid
valve.
Note: The pressure in the hose should
be 7.5 0.3 bars (109 4.4 psi).
2
If the
carry
If the
carry
999 6465
999 8333
W2002211
3
If the pressure is within the tolerances,
the quick release valve is faulty and
should be replaced.
34
Group 25
Troubleshooting
Test 5
1
Remove the exhaust pipe from the
shutter housing.
2
W2002212
W2002189
V776250600SM
Intake and Exhaust
Systems, VE D12
4
Activate the exhaust brake solenoid
valve.
8
Pressure not OK:
35
Group 25
Troubleshooting
2533-06-02-02
Oil Pressure, Compression
Brake, Checking
T2007703
Check if the exhaust pressure governor shutter seals against the shutter
housing.
6
If the shutter does not seal against the
housing, replace or overhaul the exhaust pressure governor according to
the procedures found in:
Service
Manual
V776250600SM
Intake and Exhaust
Systems, VE D12
7
If the shutter seals against the housing, remove the exhaust pressure
governor and check the shutter and
shutter housing.
36
WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving or hot engine parts. A hot engine
can cause serious burns or can permanently damage
test equipment.
WARNING
Always wear appropriate eye protection to prevent the
risk of eye injury due to contact with engine debris or
fluids.
Group 25
Troubleshooting
T2008278
T2006731
9998338
5
3
Remove the valve cover stud located
between no. 4 and 5 injector solenoids.
J-41203
T2008279
Group 25
Troubleshooting
W2002200
W2002199
10
W2002213
T2007003
38
30 3 Nm
(22 2 ft-lb)
9998339
Group 25
Troubleshooting
Testing
Removal
1
Set the control switches to the OFF
position (VEB disabled). Start the engine and measure the rocker arm shaft
oil pressure. The pressure should be
approximately 1 bar (14.5 psi).
1
Set the parking brake. Remove the
pressure gauge and oil pressure hose
from the cab. Cut the oil hose free
from the cable ties and disconnect the
pressure gauge.
2
If the pressure fluctuates or is under
0.5 bar (7.25 psi) or over 1.5 bar
(21.75 psi), the control valve is faulty.
T2006731
CAUTION
With older engines avoid damage to the valve cover
and internal injector cable harness by making sure the
mounting screws do not unscrew from the cylinder
head during removal. Do not use impact tools to remove the nuts securing the valve cover.
3
Remove the oil pressure hose from
connector 9998338. Pull the oil pressure hose through the valve cover and
remove the oil seal.
4
T2007708
Group 25
5
Tighten the rocker arm bridge bolts in
two steps:
1 Torque to 15 Nm (11 ft-lb).
2 Tighten both bolts an additional
90 .
6
Clean the threaded hole in the cylinder
head where the valve cover stud was
removed. Clean the valve cover stud
bolt and apply locking fluid. Torque the
stud to 48 8 Nm (35 6 ft-lb).
Troubleshooting
15 Nm
(11 ft-lb)
2515-06-02-01
Exhaust Temperature, Checking
J-41203
48 8 Nm
(35 6 ft-lb)
WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving or hot engine parts. A hot engine
can cause serious burns or can permanently damage
test equipment.
WARNING
Always wear appropriate eye protection to prevent the
risk of eye injury due to contact with engine debris or
fluids.
8
Install the valve cover.
Installation
9
1
Set the parking brake.
T2007003
30 3 Nm
(22 2 ft-lb)
10
Test run engine and check for oil leaks.
W2002214
Disconnect the pipe from the air compressor and remove the intake pipe
between the air cleaner and turbocharger.
40
Group 25
Troubleshooting
3
Remove bolts and spacers fastening
the heat shield to the exhaust manifold.
4
Disconnect the air compressor discharge line and lay aside.
5
Unbolt the oil supply line at the turbo
only.
T2008047
Insert the temperature sensors between the exhaust manifold and the
cylinder head.
Insert the temperature sensors far
enough that the guide pins are against
the edge of the exhaust manifold.
9998342
8
Tighten the exhaust manifold bolts.
9
Tighten the oil supply line at the turbo.
10
Connect the air compressor discharge
line.
11
Secure the temperature sensor cables
with cable ties away from the exhaust
manifold and to avoid damage during
testing.
Route the cables into the cab for connection to the measuring instrument.
12
Install the intake pipe between the air
cleaner and the turbocharger. Connect
the pipe to the air compressor.
41
Group 25
13
Make sure that the ignition key is in
the OFF position.
Troubleshooting
17
14
Clean the area around the EECU and
harness connectors.
15
Disconnect the EB harness (lower harness) from the EECU and connect the
36-pin breakout box between the EB
harness and the EECU.
Make sure the harness connectors are
properly pressed together. Do not
force the connectors together.
16
Route the 36-pin breakout box into the
cab and secure.
W2002215
T2008016
42
9998190
9812327
Group 25
Troubleshooting
T2008010
T2008017
Connect the collation unit electrical cable to the cigarette lighter socket and
turn the ignition key to ON position.
T2008018
Connect the collation unit to the measurement instrument and plug in the
numbered electrical connectors from
the temperature sensors to the numbered positions in the collation unit
connection panel.
9998364
43
Group 25
Troubleshooting
Removal
1
Set the parking brake. Take the measurement instrument and temperature
sensor electrical cables out of the cab.
2
Remove the cable ties and the electrical sensor cables.
CAUTION
In order to prevent personal injury, always wear safety
glasses when working with compressed air.
10
Remove the 2 bolts fastening the oil
drain back tube to the turbo.
3
Disconnect the pipe from the air compressor and remove the intake pipe
between the air cleaner and turbocharger.
11
Remove the 4 bolts mounting the
turbo to the exhaust manifold and lift
off the turbo.
4
Remove the 4 mounting bolts and lift
away the air filter housing.
12
Remove the exhaust manifold mounting bolts and lift the manifold away
from the engine.
5
Disconnect the oil supply line to the air
compressor at the oil filter housing
and remove the line clamp.
13
Remove all of the temperature sensors.
14
6
Remove the 2 bolts attaching the
lower charge air cooler pipe to the
turbo and the bolt supporting the lower
end of the pipe.
7
Pry the charge air cooler pipe away
from the turbo and remove the end
adapter for more clearance.
8
Remove the shutter housing turbo
clamp. Move the shutter housing away
from the turbo and let it rest on the
frame.
9
Blow all debris away from the area
where the turbocharger oil supply line
enters the oil filter base. Remove the 2
bolts fastening the supply line to the
turbocharger and remove the line.
Note: Cover the open hole in the oil
filter base to prevent debris from
entering.
44
T2007717
Group 25
Troubleshooting
15
17
W2002224
48 8 Nm
(35 6 ft-lb)
Glue the new gaskets onto the exhaust manifold with the correct side
facing the manifold.
Note: The marking MANIFOLD SIDE
should be turned toward the exhaust
manifold.
16
18
Note: Make sure that all gasket surfaces on the turbocharger are free of
gasket material and clean. Make sure
that there is nothing inside the exhaust
manifold or air piping e.g. debris from
a previous failure.
Install the turbocharger with a new
mounting gasket onto the exhaust
manifold. Torque mounting nuts to
48 8 Nm (35 6 ft-lb).
19
Position the shutter housing and
exhaust piping onto the rear of the turbocharger. Install clamp and torque to
24 2 Nm (18 2 ft-lb).
20
Connect the oil return tube (using a
new gasket) to the turbocharger.
Torque bolts to 24 4 Nm
(18 3 ft-lb).
48 8 Nm
(35 6 ft-lb)
24 2 Nm
(18 2 ft-lb)
24 4 Nm
(18 3 ft-lb)
T2007724
Install 2 alignment dowels in the cylinder head to help position the manifold.
Install the exhaust manifold and the
corresponding bolts.
Note: Make sure that the sleeves are
properly positioned in the counterbore
of the manifold flange.
21
Install the oil supply tube with a new
seal and gasket. Torque bolts to
24 4 Nm (18 3 ft-lb).
24 4 Nm
(18 3 ft-lb)
Note: Make sure the port in the oil filter housing for the oil supply tube and
seal assembly is clean and smooth,
also before installing the supply tube,
pre-lubricate the turbo with clean engine oil.
45
Group 25
22
Connect the lower charge air cooler
pipe and adapter with new O-ring
seals to the turbo. Install and torque
the 3 charge air cooler pipe support
bolts to 24 4 Nm (18 3 ft-lb).
Troubleshooting
24 4 Nm
(18 3 ft-lb)
2145-06-02-02
Rocker Arm Roller, Checking
24 4 Nm
(18 3 ft-lb)
48 8 Nm
(35 6 ft-lb)
25
Install the air filter housing and all air
piping.
26
T2006672
W2002216
T2007948
9996956
Group 25
Troubleshooting
T2007949
9999876
9999696
T2007951
Max. 0.1 mm
(0.004 in)
T2007950
T2007792
48
Group 25
Service Procedures
Service Procedures
2145-04-04-02
Rocker Arm, Overhaul
T2007725
T2007727
9998344
2
4
Clean and check the rocker arm.
Make sure that all dirt is removed before assembling.
Note: If the rocker arm shaft bushing
or roller is damaged, the complete
rocker arm must be replaced.
T2007726
49
Group 25
Service Procedures
T2007730
T2007728
9996716,
9998344
0 0.1 mm
(0 0.003 in.)
T2007725
T2007729
50
Group 25
Service Procedures
2533-03-02-05
Solenoid Valve, Compression
Brake, Replacement
WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving or hot engine parts. A hot engine
can cause serious burns or can permanently damage
test equipment.
T2007792
WARNING
Always wear appropriate eye protection to prevent the
risk of eye injury due to contact with engine debris or
fluids.
1
Set the parking brake.
2
T2006731
51
Group 25
Service Procedures
CAUTION
With older engines, avoid damage to the valve cover
and injector cable harness by making sure the mounting screws do not unscrew from the cylinder head
during removal. Do not use impact tools to remove
the nuts securing the valve cover.
3
Clean the area round the solenoid
valve.
T2007732
T2007731
T2007736
12.2 Nm
(9 ft-lb)
Group 25
Service Procedures
2531-03-02-02
Control Valve, Engine Brake,
Replacement
WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving or hot engine parts. A hot engine
can cause serious burns or can permanently damage
test equipment.
T2007733
1.4 Nm
(1 ft-lb)
WARNING
Always wear appropriate eye protection to prevent the
risk of eye injury due to contact with engine debris or
fluids.
8
Install the valve cover.
1
Set the parking brake.
T2007003
30 3 Nm
(22 2 ft-lb)
T2006731
10
Test run engine and check for oil leaks.
Group 25
Service Procedures
T2007731
T2007734
T2007722
J41203
T2007794
54
12.2 Nm
(9 ft-lb)
Group 25
Service Procedures
10
T2007734
20 3 Nm
(15 2 ft-lb)
T2007733
1.4 Nm
(1 ft-lb)
11
Press the electrical cable clamp onto
the stud bolt.
Note: The electrical cable must be positioned on the outside of the valve
cover stud.
12
Install the valve cover.
13
T2007723
J41203
48 8 Nm
(35 6 ft-lb)
T2007003
30 3 Nm
(22 2 ft-lb)
14
Test run engine and check for oil leaks.
55
56
Operation Numbers
2145-04-04-02
2145-06-02-02
2515-06-02-01
2531-03-02-02
2531-06-02-01
2531-06-02-02
2531-06-02-03
2533-03-02-05
2533-06-02-01
2533-06-02-02
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49
46
40
53
27
30
32
51
29
36