Service Note

Volvo Truck Corporation

Gothenburg, Sweden Trucks
Date Group No. Edition Page

3.02 253 19 011(26)

Engine brake
Fault finding
D9A, D12D

Engine braking, search for

breakdowns
Checklist O

T2019344

Summary
Description of the operation
Engine braking, troubleshooting issues
Comments on the Engine Brake list, troubleshooting

TSP161290
FRA10384 French
Page 2

Description of operation

T2019468
Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 3(26)

List of components
Component Description
A14 Control unit, EMS (Engine Control Unit)
A16 ECS control unit (electronically controlled air suspension)
A17 Control unit, VECU (vehicle control unit)
A19A/A19C Control Unit, GECU (gear selector)
A21 Control unit, EBS (Electronic Brake System)
A24 Control unit, trailer information module without ABS
A27 Control unit, LCM (outside lighting)
A33Tachograph
B04 Sensor, engine speed, crankshaft
B12 Sensor, tachograph/speed indicator
B13–20 Sensor, wheel speed
B25 Sensor, accelerator pedal
B29 Attitude sensor, rear axle, left side
B37 Sensor, pressure and temperature of boosted air
B38 Sensor, oil pressure and temperature
B55–58 Sensor, air pressure in the suspension blower
F41 Fuse, engine solenoid valves, electric feed pump
S07 Switch, engine brake
S24 Control lever, speed limiter
S58 Position contact, clutch pedal, NO
S59 Position contact, brake pedal, NO
XO5 Trailer connector, 7 pins, 24 S
Y37 Electrovane block, engine brake/pressure regulator on exhaust (ATR)
Y39 Electovalve, VEB (Volvo engine brake)
Page 4

For troubleshooting, it is important to well Electric control of the engine brake

understand the system and follow the order of re- The power of engine braking is determined by the re-
search indicated in the checklist to avoid driver settings. The power is different for
to replace intact parts. the various combinations of engine braking.

Engine brake
There are different types of engine brakes.
to say that different systems can be combined
depending on the desired engine braking power on
the vehicle.

Engine brakeATR

• The engine brake ATR (Aviation pressure regulator - regu-

Pressure sensor on exhaust) consists of
only from one side, in the pipe
exhaust after the turbocharger, which aug-
the back pressure of the exhaust during the
braking on exhaust.
The engine is running more difficultly and the vehicle is
thus hindered.
For a more detailed description, see 'Regulator'
pressure on exhaust (ATR)" page 10.

Engine brake EPGC

• The engine brake EPGC (Exhaust Pressure Governor)

Compression — Compression and pressure regulator
sion on exhaust) is identical to ATR when it
This is the engine braking function. The designa-
Section C indicates that the engine is equipped with a brake of
compression but it is only used for
lower the engine speed during downshifts.
EPGC is only used on equipped vehicles.
feet of an 'I-shift' gearbox, when not
does not want to have the Volvo VEB engine brake.

Engine brake VCB

• The engine brake VCB (Volvo Compression Brake —

Volvo compression brake consists of rocker-
special tools for exhaust valves,
of a special camshaft with additional cams
comments as well as a control valve
for the oil pressure in the rocker arm shaft.
For a more detailed technical description, see
Compression brake
The braking power of the compression brake
on the engine is obtained as follows:

• The exhaust valve opens, allowing out-

pull the air during the admission time, for
to have a larger amount of air to compress
my during compression time.
• The exhaust valve opens just before
the dead point high in the compression time
sionet 'burst' the compression to reduce the
power of working time.
The VCB brake alone is only used on the
engines with turbocompound.

Engine brake VEB

• The engine brake VEB (Volvo Engine Brake - brake

Volvo engine consists of two systems, ATR.
and VCB.
The operation is identical to that of the brake.
VCB with, as a difference, the ATR regulator which
increase the back pressure in the system
exhaust. This back pressure reinforces the
power of the compression brake.
Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 5(26)

ATR/EPGC On a tractor that is not equipped with ABS function,

the lighting cable of the trailer must be connected to
Switch (S07) the trailer hitch (X05) on the tractor so that the
auxiliary brake can function.

ATR/EPGC with a brake

Control lever (S24)

T0008637
Two positions.

Position of Engine brake

the switch
0 (stop) 0%
1 100%

Electric command T5013265

When the switch is in position 1, the engine brake If the vehicle is equipped with a retarder, the brake mo-
is activated when the accelerator pedal (B25) is re- the engine works the same way with the retarder
released. but the two-position switch is replaced by a
The information coming from the switch and the pedal control lever for the retarder (S24).
accelerator goes through the vehicle's control unit
cube (A17), by the data buses (J1939 and
J1708/J1587) to reach the engine control unit The brake lever has a number
The engine control unit then sends a si- different positions based on tech characteristics
PWM (Pulse Wide Modulated - with modulation of vehicle techniques. The ATR regulator is active at
pressure width) at the control valve (Y37) which all the braking positions of the lever of com-
sends a maximum pilot pressure (750 kPa) to the reg. send.
lateurATR. The power supply to the valve of
command goes through fuse F41.
For the pilot pressure going to the ATR regulator following
the different braking powers, see the characteristics of
Conditions technical risks.
• The clutch pedal (S58) is not pressed.
• The engine speed is above 900 rpm (Cap-
Position of Auxiliary brake
diet killer, B04)
lever of com-
• The speed sensor (B12) indicates a speed of-
send
less than 5 km/h.
• ABS/EBS wheel sensors (B13–20) 0 (stop) No auxiliary brake
do not indicate wheel lock.
• The gear lever is not in the neutral position A Automatic progressive adjustment
(dead point). (A19A: Geartronic/Powertronic, A19C:
I-shift) 1 40%

Braking reduction 2 70%

If the vehicle is equipped with the electronic system of 3 100 %
EBS braking (Electronic Brake System) of a suspension.
pneumatic spring, a load indicator1check if B Maximum braking force1
the vehicle is loaded or empty.
If the vehicle is empty, the auxiliary brake is stopped for 1
Applies only to automatic gearboxes
avoid rear wheel locking during braking with
the auxiliary brake.

1 EBS: B29 Air suspension: B55–58

Page 6

Speed regulation for braking

Electric command
When the control lever is in one of the positions
braking, the engine brake is activated by releasing the pedal
accelerator pedal (B25).
Note: Exception in position A, see 'Progressive Adjustment'
automatic auxiliary brake system” page 6.
The information coming from the control lever and the
accelerator pedal goes through the control unit
of the vehicle (A17), by the data buses (J1939 and
J1708/J1587) to reach the engine control unit
(A14). The engine control unit then sends a si-
PWM (Pulse Width Modulated - with modulation of
pulse width) at the control valve (Y37) which
sends a maximum pilot pressure (750 kPa) to the regulator
pressure sensor on exhaust at all the
positions. The power supply of the valve of com-
send passes through the fuse F41.
T5013266
Automatic progressive brake adjustment In position A, the Brake Cruise function (speed regulation of
auxiliaries brake test) can be used by pushing down the
button "SET +/-" on the engine brake lever when the
When the throttle control lever is at the desired speed is reached. This speed is then saved.
position A, the ATR regulator is only activated in kept in the vehicle's control unit and the
pressing the brake pedal (S59). auxiliary brakes are activated when the speed is reduced
When braking in position A, a PWM (Pulse Width Modulation) signal
released. The accelerator pedal must be released and the
Modulated — pulse width modulation part The slow contact must not be activated.
from the engine control unit to the control valve
sends which, in turn, sends a pilot pressure to the
ATR regulator. This pilot pressure varies (50–750 kPa) Braking reduction
according to the depression of the brake pedal in order to If the vehicle is equipped with the electro-braking system
adapt the engine braking power to the specific needs Unique EBS (Electronic Brake System) where the
braking force. air suspension, a load indicator2veri-
The information on brake pedal depression indicate whether the vehicle is loaded or empty.
are sent on the data bus and indicate the The load indicator reduces the braking power.
braking power requested at the control unit when the vehicle is empty. This function aims to
of the vehicle for the engine control unit. to avoid the rear wheels from locking during braking
swimming with auxiliary brakes. The braking reduction
Auxiliary brake at 40 — 100 % is controlled by the PWM signal sent from the unit of
motor command to the control valve of the regulator
The braking power is regulated using teurATR. The signal determines the pilot pressure that must
different pilot pressures at the ATR regulator. The then- to be sent to the regulator ATR.
braking force requested (lever position of
command) is sent to the engine control unit On tractors that are not equipped with the system
which, in turn, sends a PWM signal (Pulse Width Modulation) ABS, the trailer's lighting cable must be bran-
marked - pulse width modulation) to the What at the trailer hitch (X05) on the tractor for
control valve. that the auxiliary brakes can operate.

Maximum braking power

Position B (exists only on vehicles with 2
EBS: B29 Pneumatic suspension: B55-58
automatic transmission) is spring-mounted.
When the control lever is brought to the position
The maximum auxiliary braking is in service and the box
the automatic gears are set to free position
swimming
The braking position on the gearbox means
that the gearbox will downshift to an exact engine speed
to achieve better braking power with a
Higher engine regime. This situation remains active.
as long as the accelerator pedal or the pedal
the clutch is not pressed down or that other conditions
the actions are not modified.

Conditions
See 'Conditions' page 5.
Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 7(26)

VCB On a tractor that is not equipped with the ABS system, the
the trailer's lighting cable must be connected to the
Switch (S07) trailer hitch (X05) on the tractor for the brake
auxiliary can function.

VCB with a gearbox to-

automatic and/or a speed bump
Control lever (S24)

T0008637
Two positions.

Position of Engine brake

the switch
0 (stop) 0%
1 100 %

Electric command
When the switch is in position 1, the engine brake
is activated by releasing the accelerator pedal (B25).
The information coming from the switch and the pedal T5013279
accelerator do not go through the vehicle's control unit
Control lever for VCB with gearbox
vehicle (A17), by the data buses (J1939 and
J1708/J1587) to go to the engine control unit automatic tests.
The engine control unit sends a signal (-)
at the control valve (Y39) to increase the pressure
in the rocker arm axis. The power supply
the control valve passes through fuse F41.

Conditions
• The clutch pedal (S58) is not pressed down.
• The engine speed exceeds 1000 rpm (Sensor of
diet B04).
• The speed sensor (B12) indicates a speed of-
less than 5 km/h.
• The ABS/EBS wheel sensors (B13–20)
do not indicate wheel blockage.
• The gear lever is not in the neutral position.
(dead point). (A19A: Geartronic/Powertronic, A19C:
I-shift
• The oil temperature is above 55 C
• The boost pressure is below 50
T5013265
kPa
Control lever for VCB with box of vi-
Braking reduction automatic tests and speed bumps.
If the vehicle is equipped with the electro-braking system
Unique EBS (Electronic Brake System) If the vehicle is equipped with a retarder, the brake mo-
pneumatic suspension, a load indicator3verify the engine works in the same way with the retarder
Check if the vehicle is loaded or empty. but the "2 position" switch is replaced by the
If the vehicle is empty, the charge indicator shows that brake controller (S24).
VCB is not activated. This feature is meant to prevent
the rear wheel locking during braking with the brake The control lever of the retarder may have a
auxiliary. different name of positions according to the characteristics
vehicle technical specifications. VCB is active at all
the braking positions of the control lever.
3 EBS: B29 Air suspension: B55–58
Page 8

Position of Auxiliary brake Speed regulation for braking

communication lever See 'Speed Regulation for Braking' page 6.
send
0 (stop) No auxiliary brake Brake reduction
See "Braking Reduction" page 7.
A Automatic progressive adjustment
1 40% /1100% 2
VEB
1
2 70%
1
Switch (S07)
3 100%
3
B Maximum braking power

1
Applies to VCB with brake
2
Applies to VCB without speed bump
3
Applies only to automatic gearboxes

Electric command
When the control lever is in one of the positions
of braking, the engine brake is activated when the pedal
the accelerator (B25) is released.
T0008058

N.B. Exception in position A, see 'Progressive Adjustment' Three positions.

automatic auxiliary brake system" page 8.
The information coming from the control lever and the Note: The '3-position' switch only concerns
The accelerator pedal goes through the control unit. manual gearboxes.
of the vehicle (A17), by the data buses (J1939 and
J1708/J1587) to reach the engine control unit Position of Engine brake
(A14). The engine control unit then sends a si- the switch
signal (-) to the control valve (Y39) to increase
the oil pressure in the rocker arm shaft. 0 (stop) 0%
The power supply of the control valve
goes through the fuse F41. 1 50%
2 100%
Automatic progressive brake adjustment
auxiliaries
When the engine brake control lever is at the Electric command
position A, VCB is activated only by pressing the When the switch is in position 1, VCB is activated
brake pedal (S59). by releasing the accelerator pedal (B25). At the same time
When braking in position A, a signal is sent from the unit. The ATR regulator is activated with a pressure.
from the engine control to the control valve. VCB reduced to have an auxiliary braking power of 50
is active or inactive depending on the braking power of- %.
demanded. The required braking power depends
from the depression of the brake pedal. When the switch is in position 2 VCB is activated
Information on brake pedal depression by releasing the accelerator pedal (B25). At the same
are sent on the data bus and indicate the time, the ATR regulator is activated with a pressure
requested braking power to the control unit maximum to achieve an auxiliary braking power of
of the vehicle for the engine control unit. 100 %.
The information coming from the switch and the pedal
Auxiliary brake at 40 - 100 % accelerator does not pass through the vehicle control unit
The braking power of VCB is always 100 vehicle (A17), via the data buses (J1939 and
%, when braking is requested with VCB. J1708/J1587) to reach the engine control unit
The different levels of braking are regulated using The engine control unit then sends a si-
of the different braking powers of the retarder. Gain (-) at the control valve (Y39) to increase
the oil pressure in the rocker arm shaft is a signal
PWM (Pulse Width Modulation)
Maximum braking power from the actuator to the control valve of the ATR regulator
See 'Maximum braking power' page 6. The power supply to the two valves
the command goes through fuse F41.
Conditions
See 'Conditions' page 7. Conditions
See "Conditions" page 7.

Brake reduction
On an empty vehicle, VCB is out of service but the
ATR regulator remains active. Furthermore, see 'Reduction'
braking" page 7.
Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 9(26)

VEB with a gearbox at- Automatic progressive brake adjustment

automatic and/or a speed bump auxiliaries
When the control lever of the retarder is at the
Control lever (S24) position A, ATR and VCB are only activated in
pressing the brake pedal (S59).
During braking in position A, signals are sent from
the engine control unit to the control valve
(Y37) as well as the control valve (Y39).

• The control valve (Y37) sends, in turn,

a pilot pressure to the ATR regulator. This pres-
pilot pressure varies (50–750 kPa) depending on the depth
from the brake pedal.

• VCB is active or inactive depending on the power of

braking requested. The braking power of-
command depends on the depression of the pedal
brake.
Information on the depression of the brake pedal
are sent to the data bus and indicate the
braking force requested at the control unit
of the vehicle for the engine control unit.
T5013265
If the vehicle is equipped with a retarder or a gearbox Auxiliary brake at 40 - 100%
of automatic speeds, the engine brake works
The braking power depends on the different pre-
in the same way as the speed bump but
pilot actions going to the ATR regulator. The power of
The 'three position' switch is replaced by the lever.
of the brake control (S24). braking requested (position of the control lever) is
sent to the engine control unit which, in turn,
sends a PWM signal (Pulse Width Modulated - to mo-
The control lever of the retarder has a number pulse width modulation) to the control valve.
different positions depending on the tech characteristics
vehicle techniques. VCB is active in all positions except for position 1.
VCB is active at positions A, 2, 3 and B.
ATR is active in all braking positions of the le- Maximum braking power
control valve, with different pilot pressures. See 'Maximum braking power' page 6.

For the pilot pressure going to the ATR regulator Conditions

the different braking forces, see the characteristics See 'Conditions' page 7.
technical wristbands.
Speed regulation for braking
Position of the Auxiliary brake See 'Speed Regulation for Braking' page 6.
lever of com-
send Braking reduction
On an empty vehicle, VCB is out of service but ATR
0 (stop) No auxiliary brake is active. Furthermore, see 'Braking Reduction' page
7.
A Automatic progressive adjustment
1 40%
2 70%
3 100%
B Maximum braking power1

1
Applies only to automatic gearboxes

Electric command
See 'Electric Command' page 8.
Page 10

Pressure regulator on exhaust (ATR)

T2019326
(Does not apply to engines with turbochargers) Starting and maintaining heating
pound) For the description of the operation and the search for
The exhaust pressure regulator has two functions problems concerning the pressure regulator on escape-
power at startup and maintenance of heating, see
25324–6 "Pressure regulator on exhaust, re-
• Keep the engine idling hot. "Troubleshooting" (Checklist E).

• Act as a brake on the exhaust during descents. Brake on exhaust

The pressure regulator on the exhaust is placed in When ATR is active, the panel (2) strangles the passage.
direct connection with the turbine casing of the turbocharger exhaust gases in the reed box(1). A
seur. The pressure regulator on the exhaust is back pressure is created in the exhaust pipe.
composed of a flapper box (1), a shutter (2) and a If the engine is equipped with the Volvo VEB engine brake.
pneumatic cylinder (3). Compressed air ar- (Volvo Engine Brake), the compression brake is activated
pneumatic system of the vehicle and is regulated simultaneously.
through the control valve for ATR(4) that does not allow- If the engine is equipped with a retarder, the retarder
be a reduced pressure at the pressure regulator on is activated simultaneously.
exhaust. The valve, of the PWM type, regulates progressively.
measuring pressure in a range of 50 to 750 kPa.
In normal operation, the control valve for
ATR(4) is closed. The panel(2) is then fully
open and the exhaust gases pass freely.
Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 11(26)

Compression brake

Control valve

T2019494
The control valve is designed to regulate the pressure. At the engine training, the piston (3) covers by-
oil going to the rocker mechanism. Particularly the output(5), the oil pressure drops to
about 100 kPa after the control valve. This
The inlet(1), which is connected to the lubrication oil channel Oil pressure is sufficient for the lubrication of the bearings.
In the cylinder block, it is always at oil pressure camshaft gear and rocker arm mechanism.
of the system. The output (5) is connected to the rocker arm axis.
The compression brake is activated by the solenoid valve (2). B: During engine braking, the solenoid valve (2) is activated.
itself activated by the control unit. tension and open the drainage channel. The oil in the
room(6) passes through the drainage channel and the spring
(4)can push back the piston(3). The output(5)is then
cleared and the oil from the gallery reaches the rocker shaft
tires with a maximum pressure.
Page 12

Camshaft and exhaust rocker arms

T2019493
The camshaft on an engine equipped with the VEB brake B: During compression braking, the control valve
includes, in addition to the normal escape cam (2), causes the oil pressure to rise to
a compression cam(3) and a decompression cam the oil system pressure.
pressure(4) on each exhaust cam. At this high pressure, the piston moves.
sort(12) can then push the ball(13) from its seat.
In each rocker arm (5) there is an anti-backflow valve. The oil, above the rocker piston (8) cannot
tour(7) and a rocker arm piston(8). A spring blade then pass through the ball and push the rocker arm piston back
(6) keeps the rocker arm in its resting position against nut(8), which is sunk and eliminates the valve play.
the valve rocker. The clearance at the valves is adjusted with When the additional braking cams of
the adjustment blade (9) located on the valve rocker. the camshaft(3)and(4)act on the movement of the
The check valve (7) consists of a piston (11), rocker arm, the exhaust valves are recessed
of a spring (12) and a ball (13). to achieve a compression (pushing out a more
large quantity of air in the cylinder using the
A: At the engine test bench, the control valve back pressure in the exhaust pipe at the time
lowers the oil pressure. decompression) respectively a decompression (re-
With this low pressure in the rocker arm axis, the release of compression during work time.
the piston(11) is pressed down by the spring. The tip of the p...
A pressure limiter prevents the pressure at-
you press the ball(13) against its seat, the oil can the top of the rocker arm piston returning to the axis of
So pass in both directions through the non-return valve. rockers at the valve opening.
No oil pressure is created above the piston
of the rocker (8).
At this position, the exhaust valves are not
not affected by the additional cams on the shaft
camshaft.
Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 13(26)

Fault finding

After having carried out

• the grouping of the basic data

• the list of fault codes

• the control of parameters

, the result of the tests (recommended in the docu-
reflection on the symptoms) is used to make oneself
an idea of the vital functions of the engine. Compare
the results of all the information in order to have
a solid foundation to continue the research work
of failures listed in this checklist.
As a defect can affect several systems
During these themes, it is important to execute the VCADS tests.
indicated to eliminate or confirm certain
causes of failure as soon as possible.
Page 14

Engine brake, search for Troubleshooting

pannes
Description of operation

Vehicle Chassis number Mileage Client

Yes No

1 "Fault Codes, Report" page 17

Have the fault codes related to the engine brake been repaired? . . . . . . . . . . . . . . . . . .
Intervention
2 Auxiliary brakes, test
Does the state indication correspond to the current position of the switch?
Switch "2-3" positions
Position 1
Position 2 (VEB only)
Control lever '4-6' positions
1 2 3
Position A .................................................
1 2 3
Position 1 ..................................................
2 3
Position 2 ...................................................
2 3
Position 3 ...................................................
1 3
Position B ...................................................
Speed regulation for braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SET - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SET + . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Does the solenoid valve ATR work?

Is the VCB solenoid valve working?
Is the control lever or switch electrically powered from the unit?
vehicle order?
Does the engine control unit send a signal to the regulator control valve?
ATR? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Is the idle contact on the accelerator pedal disabled?

Test drive
During the test drive, verify the following conditions (for the engine brake to be active):

Position of the accelerator pedal %

measured
Does the position of the accelerator pedal correspond to 0%? ...
Does the state indication correspond to the current position of the brake pedal? ...
4
Does the state indication correspond to the position of the clutch pedal? ....
Is the fuel flow rate 0 l/h?

1
Concerning the engines with VCB and automatic transmission
2
Concerning engines with ATR/VEB/VCB, retarder, manual gearbox
3
Regarding the engines with ATR/EPGC/VEB/VCB, retarder, automatic transmission
4
Concerning engines with manual transmission
Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 15(26)

Is the engine regime above the limit to activate the braking function?
concerned?
Is the vehicle speed greater than 5 km/h?
Is the oil temperature above 55 C? . . . . . . . . . . . .1. . . . . . . . . .
Is the boost pressure lower than 50 kPa? . . . . . . . . . . . . . 1. . .
Is the ABS or EBS system inactive? ...
Is the ABS or EBS system inactive?
2
Is the 'neutral position' inactive? .................................
Does the requested braking power correspond to the braking power?
chosen?
Does the gearbox shift to the downshift position (control lever)
in position B)? 3 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Does the state indication correspond to the braking reduction? 5. . . . . . . . . . . . . .
Intervention
3 Air supply to the pressure regulator on the exhaust and to the electro-
valves, control” page 17

Control valve . . . . . . kPa

Does the control valve receive an exact air pressure (about 700 kPa)?
Are the air hoses correctly tightened, intact, and not pinched?

6
Engine brake at 40%, ATR . kPa
Engine braking at 50%, ATR 7 . kPa
6
Engine brake at 70%, ATR . kPa
Engine brake at 100%, ATR . . kPa
Does the ATR regulator receive exact air pressure? . . . . . . . . . . . . . . . . . . . . . . . . . .
Intervention
4 Braking on exhaust, course, control
Can the ATR regulator flap move freely?
Is the disc of the shutter intact?
Does the shutter axis reach its limit positions?
Intervention

1
Concerning the engines with VEB
2
Concerning engines with an automatic gearbox with the selector in drive position.
3
Concerning the engines with ATR/EPGC, automatic transmission, and retarder
4
Regarding engines with VEB/VCB, automatic transmission
5
Concerns only vehicles with charge indicators
6
Concern only vehicles with a 5-6 position control lever
7
Concerns only vehicles with a 3-position switch.
Page 16

5 D9A: "Camshaft axis, oil pressure measurement" page 19

D12D: "Rocker arm shaft, oil pressure measurement" page 19
When the engine brake is activated, is the oil pressure in accordance with the specifications?
techniques?

Oil pressure in the axis of kPa

rockers.

Intervention
6 Camshaft, oil leaks, control
Are the caps in the rocker arm axis properly tightened? . . . . . . . . . . . . . .
Are the rocker arm bolts properly tightened?
Intervention
7 Rocker arm bushings, control
VEB rocker arm ring
Is the game compliant with the technical specifications?
Rocking arm roller ring VEB
Is the game in compliance with the technical specifications?
Intervention
8 VCB control valve, control
Is the drainage hole and the drainage channel perfectly clean?
Does the solenoid valve open correctly?
Are the seals intact?
Intervention
9 VCB rocker arm valve, control
Are the spring and the piston of the check valve intact?
Can the piston of the check valve move freely? .............
Is the ball and the spring of the non-return valve intact?
Can the rocker arm piston move freely?
Intervention
Remarks

Document filled out by Dealer Date

Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 17(26)

Comments on the engine brake list, search for

pannes
17012-6 Control valve
Fault codes, report 1
Before starting the troubleshooting, the codes
Defects related to the engine brake must be repaired.

50008-6
Auxiliary brakes, test
When checking the operation of the brakes, it is necessary to
possible to determine if the defect affects the command
electric pressure regulator on escape

1
Connect the PC to the diagnostic socket
vehicle tick, if this operation is not
not done yet.
Execute the test 'Auxiliary brakes,'
test.
Follow the VCADS instructions.

2
Check that all results are no-
drink and finish the test.

T2019381

25330-6 Note: Empty the pneumatic system

before unplugging the hose
9992976
9996465
Air supply to the regulator air inlet of the control valve
send.
700 kPa

pressure tester on Check that the control valve

exhaust and to the electro- receives an exact pressure in bran-
sing the pressure gauge 9996465 and a
valves, control connector 9992976 to the supply hose
of the control valve air.
Special tools: 9992976, 9996465, 9998333 Load the pneumatic system to
approximately 700 kPa. The pressure must be
identical to the system pressure
in the vehicle.
If the pressure going to the solenoid valves
is different from the pressure of the sys-
check the air hoses
in accordance with 'Flexible and rac-
cords" page 17.

2
Reconnect the air hose to the valve of
order.

Hoses and fittings

3
Check that the air hoses are not
not damaged, pinched, or bent.

4
Check that the hoses are not
loose.
Page 18

ATR 8
Reattach the air hose to the regulator
5 ATR.

25317-2
Brake on exhaust,
course, control
1
Check that the air pressure of the sys- 700 kPa
The theme is around 700 kPa.

2
Connect the PC to the diagnostic outlet.
vehicle registration, if this operation is not
not done yet.
Start the test 'Start Function'
rage and maintaining heating, test
and activate ATR at 30% (corresponds to
the same air pressure as that of
heating maintenance) and at 100%
(corresponds to a maximum pressure).

3
Listen if the regulator flap is
move.

T2019382 4
Verify that the ATR regulator receives 9996465 Drop the exhaust pipe at
a pilot pressure. 9998333 regulator level and verify
Unplug the air hose from the regulator that the disc of the shutter is not in-
teardown and connect the pressure gauge damaged.
9996465 and a fitting 9998333 at
flexible.
5

6
Connect the PC to the diagnostic socket
yes, if this operation is not already
done.
Start the auxiliary brakes test,
test" and activate the engine brake.

7
Activate the ATR regulator.
The test verifies the different positions
of the percentage of engine braking that
before the technical characteristics of
vehicle.
Check the pilot pressure on the gauge.
meter and note this pressure in the
checklist.
If the pilot pressure is not within range
within the tolerances (in accordance with
T2013094
to the technical characteristics) and if Check that the shutter reaches its position mini. 29 mm
the supply pressure at the valve limited actions by activating and deactivating
of the order is not identical to the the regulator ATR.
air pressure of the system: The race(A) must be at least 29
mm.
• Check the connectors at the point.
due to bad contact, the oxidation-
or damaged pins.
• If the connectors are intact,
replace the valve of com-
send.
Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 19(26)

25305-8 25305-8
Rocking arm shaft, measurement of Rocker arm shaft, measurement of
the oil pressure oil pressure
These indications apply only to D9A! These indications apply only to D12D!
For the D12D, see 'Rocker arm shaft, measurement' For the D9A, see "Rockershaft, measurement of"
from oil pressure" page 19. the oil pressure" page 19.

Special tools: 9996591, 9998339, 9998493 Special tools: 9998338, 9998339

1
Remove the rocker cover.
Note: Use a ratchet wrench to
prevent the bolts from being loosened
from the cylinder head and prevent damage
the rocker cover as well as the makes-
cable harness of the injector pumps.

T2019464
1
Unscrew the cap located on the edge. 9996591
rear on the right side of the cylinder head.
Assemble the fitting 9996591.

2
Connect the oil hose 9998493 to 9998493
connector 9996591.

3
Lower the cabin. T2007708
Remove the rear screw that secures the sup-
4 rocker arm shaft between the 5th and
Bring the hose into the cabin. 9998339 6th rockers.
Connect the pressure gauge 9998339.

5
Bring the vehicle to a test location 200–400 kPa
adequate.
Activate the VEB brake and let the vehicle-
be careful to roll with engine braking until
that the pressure has stabilized at
the manometer.
Note and assess. Check that the presence-
the oil pressure is 200–400 kPa.
Repeat the test several times for
to have a reliable result.

6
Restore the vehicle to a state of
market.
Page 20

3 5

T2019461

Pass the hose from the outside to

through the rocker cover, where the
goujon has been removed. Connect it.
flexible at the banjo fitting of the specialized tool
cial.
T2019460

Assemble the connection 9998338. 9998338 Attach the hose so that it

70 Nm cannot be damaged by
Note: Assemble the tool's flexible hose the rockers.
seal and check that the connection and the
flexible are well cleared from the rockers
tightening the screw to the specified torque 6
from 70 Nm. Then remove the hose. Check that the flexible is correct. 20±2 Nm
positioned and, with caution,
put on the rocker cover.
4 Tighten the rocker cover at the torque
Remove the second peg (starting from 20±2 Nm.
from the front on the left side). This
surgery is necessary in order to
pass the flexible of the special tool 7
by the rocker cover.

T2019462

Push the seal into place for the

flexible in the hole on the cover
rocker
Pass the flexible through the hatch
in the right march.

Note: Attach the hose so that it does not

do not be damaged by tipping
read the cabin.

8
Lower the cabin.
Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 21(26)

9 21451-4
Pass the hose through the cabin. 9998339
Connect the pressure gauge 9998339. Rocker arm bushings, control
Special tools: 9998511, 9999696
10 Other special equipment: 9989876
Bring the vehicle to a testing location 200–400 kPa
adequate. VCB rocker arm ring
Activate the VEB brake and let the vehicle
slow down using engine braking until 1
that the pressure has stabilized on
the manometer.
Collect and note. Check that the pres-
The oil pressure is 200–400 kPa.
Redo the test several times to get
a reliable result.

11

T2012845

Clamping diagram, valve cover

Restore the vehicle to a state of 40±3 Nm T2019598

market. 20±2 Nm Place the magnetic support 9999696 9999696

with the dial comparator 9989876
N.B. 9989876 for the me- key
sure comes just above the
• Switch the blocking product on rocker arm ring (on the rocker arm
the stud and tighten to the torque of who is not found on one of the
40±3 Nm camshaft.

• Tighten the rocker cover, in

the order indicated in the illustration, at 2
torque of 20±2 Nm. Tilt the rocker so that the most
a large part of the oil film should be eliminated
born on the upper surface of the axis of
21496-2 rockers.
Set the dial gauge to zero.
Rocker arm shaft, leaks
oil, control
1
Check that the caps at the ends
the rocker arm axis are
correctly tightened and that they are not
not damaged.

2
Tighten all the rocker arm bolts
factors to ensure that a possible
oil leak does not come from a seal-
insufficient torque of a bolt.
Page 22

3 5

C2002679

Place the dial gauge 9999696

9989876 in the magnetic support 9989876
T2019598 9999696. Put the magnetic support
Insert lever 9998511 just below the 9998511 tic on the rocker.
rocker arm, towards the rocker arm axis, and 0.08 mm Direct the measuring key of the com-
push the rocker upwards. dial gauge so that it is at
Raise the indication on the comparator the horizontal towards the center of the pebble.
to dial. Set a pre-tension of 2 to 3 mm
on the dial comparator.
The maximum allowed play is 0.08
mm. If the game is more important, rem- Note: Make sure that the me- key
place the rocker and check the axis of sure the dial comparator is
rockers. adjusted on the prestressing and that it
can move in both directions.
Check the other rocker arms in proce-
tooth in the same way.
6

Rocking lever pebble ring VCB

4

T2007948

Turntherollerafewturns
to eliminate the oil film between the
ring and the axis.

Note: If the roller jams, the rocker arm

T2007950
must be replaced.
Insert a screwdriver between the rocker arm
and the pebble.
Push the pebble back as far as possible and re-
lift the comparator indication to
dial.
Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 23(26)

7 25341-2
Control valve VCB,
control
Solenoid valve
1
Remove the solenoid valve from the valve of
order.

T2007951
With the help of a suitable blunt object, Maxi. 0.1 mm
push the pebble as far as possible towards
the inside. Raise at the same time
the indication of the dial comparator.
The maximum allowable play between the ring T2019599

and the shaft is 0.1 mm. If the play is Check that the drainage hole is not
larger, replace the rocker arm. not clogged on the solenoid valve.
Also check the drainage channel-
swimming on the control valve.
8

T2007792
Note: During the exchange of the rocker arm,
the new rocker arm ring will have to
be lubricated with motor oil.
Use a burette and pass it
point in the oil channel hole. T2019600
Rotate the roller while injecting To verify that the solenoid valve opens
the oil and ensure that the oil comes out correctly: block one of the or-
on both sides of the pebble.
openings and, with a nozzle, blow
in the other opening while activating
the solenoid valve.
Note: Do not blow with a pres-
maximum tension. Risk of projections
of oil.
Page 24

Control valve 6
4
If the engine oil is heavily polluted,
remove the control valve and the
clean internally.

5
If the oil pressure is low in
the rocker shaft, check

• The sealing joint between the

control valve and the cu-
lasse.
• The sealing joints in the
pipe between the valve of com-
send and the rocker arm axis.

T2019601
The piston in the valve of com-
command is in active position (B),
when the engine is off. None
oil pressure is not present
two sides of the piston, the spring
push the piston back to its re- position
pos.
If the piston jams, the VCB brake can
be active a moment after the start
rage.
It is very unlikely that the piston(1)
grip in the driving position, it is-
to say VCB is not active(A).
If a foreign object has entered
the space(2) behind the piston, the pis-
you may not be able to return to his
rest position. VCB will not be able to
so not to be activated (since the piston
cannot return to its position of
The control valve must
so it should be cleaned thoroughly.
Volvo Truck Corporation Date Group No. Edition Page
Service Note 3.02 253 19 01 25(26)

21441-2 1
Rocking valve VCB,
control

T2014923
Turntheenginetotopdeadcenter.
The top dead center (TDC) reference
the camshaft must come between the
marks on the bearing cap
before

2
Heat the plug(1), on the rocker-
tear, to eliminate the liquid from
blocking. Unscrew the cap.

Check valve
3
Place the spring(2) and the piston of
the non-return valve (3a), check them at
point of view damages.

T2019602
4
Reinsert the piston of the anti-
Cork
tour(3a). Move the piston of the
2. Spring back and forth check valve
to check that he can move freely
3. Check valve but without a great resistance.
3a. Piston
3b. Bill
3c. Spring 5
Check the ball of the check valve
4. Rocker arm piston (3b) and the spring (3c), by pushing it down
piston of the check valve (3a) to its
limit position to feel if he encounters
an elastic resistance.

Rocking Arm Piston

6
Push down the piston of the anti-
turn(3a) to its limit position while
pushing the rocker forward
(towards the valves).
When the rocker arm piston (4) reaches
hold its limit position, release it
piston of the non-return valve (3a).
Page 26

7 9
Push the rocker back Reinsert the spring(2). 1161056
(towards the camshaft). Put the cap back on with the pro-
A depression is created in the piston blocking fund (reference number
from the rocker arm (4). 1161056).

8 10
Release the depression by pushing down TurntheenginetotheVEBmark
the piston of the check valve (3a). follow and repeat points 2 to 8.
If the rocker arm piston (4) can be
move freely, he is going to fall against
the valve rocker arm when the depression-
sion disappears.