Related Manuals for Volvo D13J
Summary of Contents for Volvo D13J
- Page 1 Driver's Handbook VOLVO D13J Engine Operator's Manual PREVH, PREVX, B13R, 9700 USCAN...
- Page 2 Volvo Bus Corporation Göteborg, Sweden Order number: 89166953 ©2014 Volvo Bus Corporation, Göteborg, Sweden All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior...
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Page 3: Table Of Contents
On-Call Assistance......................27 Introduction..........................27 Fuel ............................28 Engine Oil ..........................29 Engine Operation .......................30 Engine Overview, D13J Left Side View ................33 Engine Overview, D13J Right Side View................34 Exhaust Emissions and Aftertreatment Diesel Particulate Filters (DPFs)......35 Exhaust Aftertreatment System ..................37 DPF Systems ........................39 Selective Catalytic Reduction (SCR) ................40 Aftertreatment Hydrocarbon Dosing System..............43... - Page 4 Engine Maintenance Intervals....................55 Engine Gaseous Emission Control Systems ..............56 Emissions Control System Warranty .................57 Engine Gaseous Emissions Control System Warranty ............58 Federal Emission Requirements ..................59 Emission Control System Warranty — California.............59 Emissions Control System Warranty .................62 Emission Green House Gas Component Warranty (If Equipped) ........64 Engine Brake..........................65 Engine Components, Service Schedules................66 Cooling System........................67...
- Page 5 Safety Information IMPORTANT: Before driving this vehicle, DANGER be certain that you have read and that you fully understand each and every step Danger indicates an unsafe practice that of the driving and handling information could result in serious personal injury or in this manual.
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Page 7: Volvo Engines
Be sure to read and follow these labels to prevent damage to the vehicle, personal injury or even death. Information in this manual refers to VOLVO components and VOLVO drivetrain. For detailed information on non-VOLVO drivetrains contact your nearest Prevost Service Center. - Page 8 Note: Illustrations are used for reference only and may differ slightly from the actual vehicle, however, key components addressed in this manual are represented as accurately as possible. VOLVO Bus Corporation reserves the right to make changes at any time or to change specifications or design without notice and without incurring obligation.
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Page 9: General
VOLVO Engines 3 General The Federal Clean Air Act, Section 203 (a) (3), states the following concerning the removal of air pollution control devices or modification of a certified engine to a non-certified configuration: CAA, Section (a) (3) (A) prohibits any person from removing or rendering inoperative any... -
Page 10: Federal Emission Requirements
VOLVO Engines Federal Emission Requirements This section covers the requirement of the United States Clean Air Act which states: The manufacturer shall furnish with each new motor vehicle or motor vehicle engine such written instructions for the maintenance and use of the vehicle or engine by the ultimate purchaser as may be reasonable and necessary to assure the proper functioning of emission control devices and systems. -
Page 11: Tampering With Exhaust Emission Control Systems Prohibited
4 Any person who operates a fleet of motor vehicles following its sale and delivery to the ultimate purchaser. Note: For specifics of the prohibited vehicle/engine modifications refer to the Volvo Bus or Prevost documentation. Noise Emissions Prevost warrants to the first person who purchases this vehicle for purposes other than... - Page 12 VOLVO Engines Noise Control System, Operator Inspection and Maintenance Requirements A Noise Control System Maintenance Log is located in this manual. This log should be used to document all Noise Control System related maintenance, whether the maintenance results from a specific noise control system inspection, or a deficiency identified during another general maintenance event.
- Page 13 VOLVO Engines 7 Tampering with Noise Control System Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...
- Page 14 VOLVO Engines Regulatory Compliance Acts that constitute tampering with the Noise Shielding and Insulation Devices: Removing or rendering inoperative the engine and/or transmission noise deadening panels, shields or insulating materials. Removing or rendering inoperative any vehicle body mounted sound insulation components and/or shields (fender shields, skirts, wheel housing splash shields, etc.).
- Page 15 VOLVO Engines 9 Exhaust System WARNING Hot engine! Avoid all movable parts or hot engine parts, exhaust gases, and/or fluids. A hot engine, exhaust, and/or fluids can cause burns. Maintenance Make sure the exhaust system is intact. Inspect for damage, misalignment and/or leakage.
- Page 16 VOLVO Engines Regulatory Compliance Acts that constitute tampering with the Air Intake/Air Induction System: Removing or rendering inoperative air intake/induction system components (filter, filter housings, ducts, etc.). Engine Control, EGR and Fuel Systems Acts that constitute tampering with Engine Control, EGR and Fuel Systems:...
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Page 17: Safety Information
VOLVO Engines 11 Safety Information Proper Maintenance Procedure DANGER Before working on a vehicle, set the parking brakes, place the transmission in neutral, and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. - Page 18 VOLVO Engines WARNING DO NOT attempt to repair or service this vehicle without having sufficient training, correct service literature and the proper tools. Failure to follow this could lead to personal injury or making your vehicle unsafe. WARNING Diesel engine exhaust and some of its constituents are known to the state of California to...
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Page 19: During Maintenance
VOLVO Engines 13 During Maintenance Remove key from ignition while working on vehicle or engine. DO NOT allow unauthorized personnel on, around or in the vehicle when maintenance or repair is being performed. • When operating the engine in an enclosed area, vent the exhaust to the outside. -
Page 20: Compressed Air And Water
Asbestos Information Note: The VOLVO engine and replacement parts for it shipped from the factory are asbestos free. VOLVO recommends the use of only genuine VOLVO spare parts. Never use any parts that contain or are thought to contain asbestos. Exposure to asbestos fibers can create serious health risks, including death. -
Page 21: Injury Prevention
VOLVO Engines 15 Injury Prevention Burn Prevention Engine Parts WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or fluid can cause serious burns. WARNING DO NOT raise the engine hood if you see or hear steam or coolant escaping from the engine compartment. - Page 22 VOLVO Engines Coolant WARNING Coolant may be combustible. Coolant leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up coolant spills immediately. W0001527 To prevent personal injury, use suitable, properly positioned ladder to reach and remove the filler cap.
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Page 23: Fire Or Explosion Prevention
VOLVO Engines 17 Batteries WARNING Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion. WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. - Page 24 VOLVO Engines W0001526 DANGER DO NOT service any part of the fuel system while smoking or in the presence of flames, sparks or hot surfaces. Failure to follow these precautions can result in fire, which can cause serious injury or death.
- Page 25 VOLVO Engines 19 The engine should not be operated in an area where combustible gases are suspected to be in the air. These could be drawn into the engine through the engine air intake system and could cause the engine to over speed with possible serious damage to the engine and bodily injury or property damage.
- Page 26 VOLVO Engines Respiratory Hazard Prevention DANGER Exhaust gases contain carbon monoxide. Always run the engine outdoors or use a properly vented exhaust hose. Prolonged or excessive exposure may cause serious illness or death. WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.
- Page 27 VOLVO Engines 21 Crushing or Cutting Prevention DANGER Before working on a vehicle, set the parking brakes, place the transmission in neutral and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death.
- Page 28 VOLVO Engines Climbing Up and Down DANGER Always use a three-point stance (one foot and two hands or two feet and one hand) whenever climbing up or down. Failure to follow this warning can result in serious personal injury or death.
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Page 29: Engine Damage Prevention
VOLVO Engines 23 Engine Damage Prevention Before Starting the Engine DANGER Before working on a vehicle, set the parking brakes, place the transmission in neutral and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. - Page 30 VOLVO Engines Starting Aids DANGER DO NOT use ether or other combustible starting aids on any engine equipped with a preheater. If the engine is equipped with a preheater, introduction of ether or similar starting aids could cause a fire or explosion resulting in severe property damage, serious personal injury or death.
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Page 31: Electric And Electronic Systems
VOLVO Engines 25 Electric and Electronic Systems WARNING Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion. W0001526 Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. -
Page 32: Reporting Safety Defects
VOLVO Engines Electronic Engine Control System DANGER The engine uses high voltage to the electronic unit injectors. DO NOT come in contact with the unit injector terminals while the engine is running. An electric shock can cause an involuntary muscle spasm and cause loss of balance and falls leading to severe personal injury or death. -
Page 33: Canada
24 hours a day at 1 800 463 7738. Introduction The US2010 VOLVO D13J engines meet the very stringent new emissions standards which apply to all heavy-duty diesel engines built after January 1, 2010 for on-highway coaches. The new standards for US 2010 requires 83% reduction in nitrogen oxides (NOx). This represents a total reduction of 99% of all emissions from original levels. -
Page 34: Fuel
VOLVO Engines Fuel CAUTION Diesel engines for US 2010 vehicles are designed to operate only with ultra low sulfur diesel (ULSD) fuel. Use of fuel other than ULSD will reduce the efficiency and durability of the engine, permanently damage the advanced emission control systems, reduce fuel economy and possibly prevent the engine from running at all. -
Page 35: Engine Oil
EO-O Premium Plus (or VDS-4) diesel engine oil is mandatory for use in all US 2010 emission compliant VOLVO engines. Chassis equipped with a US 2010 emission compliant engine, which can be identified by the presence of an Aftertreatment Selective Catalytic Reduction (SCR) system, also require the use of ultra low sulfur diesel (ULSD) fuel. -
Page 36: Engine Operation
VOLVO Engines Engine Operation DANGER Do not use ether or other combustible starting aids in any VOLVO engine. Introduction of ether or similar starting aids could cause a fire or explosion resulting in severe property damage, serious personal injury or death. - Page 37 VOLVO Engines 31 Engine Shutdown System Stopping the Engine Allow the engine to slow down and idle for 3 to 5 minutes before shutting it off. This allows the turbo to slow down and the cooling system to dissipate the engine heat. Switch the engine off by turning the ignition key to the B, or OFF, position.
- Page 38 VOLVO Engines The engine shut-down system will automatically derate or stop the engine when one or more of the systems listed below reaches a critical stage: • High Coolant Temperature • Low Oil Pressure • Low Coolant Level • High Crankcase Pressure •...
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Page 39: Engine Overview, D13J Left Side View
VOLVO Engines 33 Engine Overview, D13J Left Side View W2006034 D13J Engine Note: Illustration is used for reference only and may differ slightly from the actual vehicle. 1. Breather Tube 9. Fuel Filter 2. Intake Manifold 10. Hand-Priming Pump 3. Air Compressor 11. -
Page 40: Engine Overview, D13J Right Side View
VOLVO Engines Engine Overview, D13J Right Side View W2006035 D13J Engine Note: Illustration is used for reference only and may differs slightly from the actual vehicle. 17. Exhaust Manifold 24. Venturi Pipe 18. Valve Cover 25. Oil Filters 19. Intake Air Heater (IAH) optional 26. -
Page 41: Exhaust Emissions And Aftertreatment Diesel Particulate Filters (Dpfs)
VOLVO Engines 35 Exhaust Emissions and Aftertreatment Diesel Particulate Filters (DPFs) General Emissions Control Compliance: The Federal Clean Air Act, Section 203 (a) (3), states the following concerning the removal of air pollution control devices or modification of a certified engine to a non-certified configuration: “The following acts and the causing thereof are prohibited:... - Page 42 VOLVO Engines Exhaust Emissions and Aftertreatment DPF with Vertical SCR Catalyst W2081002 1. Diffuser AssemblyAftertreatment 2. Catalytic Converter 3. DEF Injection Nozzle 4. Diesel Particulate Filter (DPF) 5. Diesel Oxidation Catalyst (DOC) 6. DEF Pump 7. Aftertreatment Control Module 8. Aftertreatment DEF Tank...
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Page 43: Exhaust Aftertreatment System
VOLVO Engines 37 Exhaust Aftertreatment System DANGER The DPF/SCR shield should not be removed while the vehicle is in use. Also, only remove the shield, once the vehicle is out of use and the SCR/DPF is sufficiently cooled. Failure to follow these... - Page 44 There are multiple methods of reducing these emissions. VOLVO has selected to use a Diesel Oxidation Catalyst (DOC) with a catalyzed diesel particulate filter. The other uses a diesel particulate filter of a different kind without a DOC and in its place uses a combustion chamber to heat the exhaust mixture thus causing active regeneration.
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Page 45: Dpf Systems
VOLVO Engines 39 DPF Systems The VOLVO systems chemically alters soot by high heat into a harmless gas which passes out through the stack pipe. At these high temperatures, the process is relatively rapid (10–12 minutes). Eventually, the filter must be removed to permit clearing away of the ash with special equipment. -
Page 46: Selective Catalytic Reduction (Scr)
VOLVO Engines Selective Catalytic Reduction (SCR) Selective Catalytic Reduction (SCR) is an emissions-reduction technology with the ability to deliver near-zero emissions of nitrogen oxides (NOx), a smog-causing pollutant and greenhouse gas. SCR's performance has been proved in millions of miles of real-world truck operations in other countries, as well as in long-term field tests in the U.S. - Page 47 VOLVO Engines 41 SCR Surface Temperatures Position Thickness of at exhaust at exhaust Heat Insulation temperature of 350 temperature 450 °C (662 °F) at the °C (842 °F) at the SCR-muffler inlet SCR-muffler inlet Casing – all round Muffler filled 75 °C (167 °F)
- Page 48 The VOLVO SCR system is simple and effective, with few components. It consists of a Aftertreatment DEF tank positioned near the standard diesel tank, plus a Aftertreatment DEF pump, Aftertreatment DEF Dosing unit and SCR catalyst. The advantage of using DEF is that it enables the engine to use less EGR -- and higher oxygen levels -- for better combustion, while meeting the EPA near-zero NOx emissions requirement of 0.2 g/hp-hr...
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Page 49: Aftertreatment Hydrocarbon Dosing System
VOLVO Engines 43 Aftertreatment Hydrocarbon Dosing System W2064634 The aftertreatment hydrocarbon dosing system is a part of the exhaust aftertreatment system and is used to increase the exhaust gas temperature (EGT) needed for the aftertreatment system. The dosing system allows diesel fuel to be injected into the exhaust system of the engine to increase the amount of hydrocarbon (HC) released. -
Page 50: Diesel Exhaust Fluid (Def)
VOLVO Engines Diesel Exhaust Fluid (DEF) Diesel Exhaust Fluid (DEF) is a reactant that's key to the SCR process. It's a nontoxic, aqueous solution of 32.5% urea and 67.5% water. Urea is a compound of nitrogen that turns to ammonia when heated. It is used in a variety of industries, perhaps most commonly as a fertilizer in agriculture. - Page 51 VOLVO Engines 45 Things to know about spilled Diesel Exhaust Fluid (DEF) If urea solution comes into contact with the skin, rinse with plenty of water and remove contaminated clothing. If urea solution comes into contact with the eyes rinse for several minutes and call for medical help if necessary.
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Page 52: Aftertreatment Control Module (Acm)
VOLVO Engines Aftertreatment Control Module (ACM) W2038621 The ACM controls the following components in the exhaust aftertreatment system: • Aftertreatment DEF Dosing Unit • Aftertreatment DEF Tank Heater Valve • Aftertreatment DEF Line Heaters • Aftertreatment DEF Pump • Aftertreatment DEF Return Valve •... -
Page 53: Smart Nox Sensor
VOLVO Engines 47 Smart NOx Sensor W9000948 The Smart NOx- sensor is used to monitor the emission reduction system. Two NOx sensors are needed for US 2010 vehicles. One sensor is positioned on the DPF/muffler outlet, the other on the exhaust pipe after the SCR-muffler on the SCR-muffler outlet (vertical version). - Page 54 VOLVO Engines W2081003 NOx Sensor Locations for Vertical SCR...
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Page 55: Aftertreatment Inducement Screens
VOLVO Engines 49 Aftertreatment Inducement Screens Aftertreatment DEF Tank Level - Driver Warning & Inducement Aftertreatment DEF tanks are sized to have The vehicle instrument cluster has an no less than two times the diesel fuel tank aftertreatment DEF tank level gauge. -
Page 56: Aftertreatment Def Quality - Driver Warning & Inducement
VOLVO Engines Aftertreatment DEF Quality - Driver Warning & Inducement Lamp Status Triggers Driver Information Display Screen Good DEF Quality None None Poor DEF Quality DTC SCR performace low Initially Detected Engine derate in < xxx mins W2029417 Poor DEF Quality DTC... - Page 57 VOLVO Engines 51 Exit conditions for DEF Quality "8 Km/h (5 mph) road speed limit" Inducement: Next 1 Engine Starts: Return to 25% torque reduction until there is a proper DEF quality evaluation. If poor DEF quality is detected during the next monitoring cycle then 8 Km/h (5 mph) is resumed after the vehicle is stationary for 20 minutes.
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Page 58: Aftertreatment Tampering - Driver Warning & Inducement
VOLVO Engines Aftertreatment Tampering - Driver Warning & Inducement When the SCR tampering fault is active for one or more hours a new Driver Information Display screen appears. The text changes for the Driver Information Display (DID) screen associated with this fault are listed in the table below. - Page 59 VOLVO Engines 53 Driving with Active Fault SCR system fault for + 4 hours Engine in derate 5 Mph at next stop W2029417 W3031200 Active tampering DTC SCR system fault iniatilly detected + 4 hours Speed limited of operation AND eitrher: to 5 Mph.
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Page 60: Misfilling Diesel Or Aftertreatment Def Tanks
VOLVO Engines SCR Tampering Aftertreatment Control Module (ACM) Disconnected Aftertreatment Inlet NOx sensor disconnected Aftertreatment Oulte NOx sensor disconnected DEF Pump Disconnected DEF Dosing Valve Disconnected DEF Tank Level Sensor Disconnected DEF Dosing valve or line blocked. DEF Pump pressure build up failure... -
Page 61: Warranty And Maintenance
VOLVO Engines 55 Warranty and Maintenance Exhaust Aftertreatment System Maintenance The vehicle must be taken to an authorized Prevost Service Center to remove the ash from the Aftertreatment Diesel Particulate Filter and clean the Aftertreatment Doser. Emissions Maintenance 1. If owner's manual recommends Aftertreatment DPF replacement within useful life, the manufacturer must pay for the replacement;... -
Page 62: Engine Gaseous Emission Control Systems
WARRANTY MAINTENANCE GASEOUS EMISSION CONTROL SYSTEMS WARRANTY Prevost warrants the Emission Control Systems on each new VOLVO diesel engine in a new Prevost coach to comply with all United States Federal and Canadian emissions regulations applicable at the time of manufacture of the engine, and to be free from defects... -
Page 63: Emissions Control System Warranty
VOLVO Engines 57 Emissions Control System Warranty The following engine components are covered by the supplemental emissions control system warranty policy as required by the Federal code of emission regulations. • 1 Engine Turbocharger Assembly Aftertreatment DPF Differential • Pressure Sensor... -
Page 64: Engine Gaseous Emissions Control System Warranty
VOLVO Engines • Aftertreatment DEF Heated Lines 18. Exhaust Gas Piping (from • Turbocharger to Aftertreatment System) Aftertreatment DEF Quality Sensor 17. Instrument Cluster (Repair of Microprocessor) Engine Gaseous Emissions Control System Warranty The emission warranty for the diesel particulate filter and SCR Systems covers defects in workmanship only. -
Page 65: Federal Emission Requirements
4 Any person who operates a fleet of motor vehicles following its sale and delivery to the ultimate purchaser. Note: For specifics of the prohibited vehicle/engine modifications refer to the VOLVO Body Builders documentation . Emission Control System Warranty — California The California Air Resources Board and Prevost. - Page 66 State of California) Prevost warrants the Emission Control Systems on each new VOLVO diesel engine in a new Prevost coach to comply with all State of California emissions regulations applicable at the time of manufacture of the...
- Page 67 VOLVO Engines 61 THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES AND REPRESENTATIONS OR CONDITIONS, STATUTORY OR OTHERWISE, EXPRESSED OR IMPLIED INCLUDING, BUT NOT LIMITED TO, IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
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Page 68: Emissions Control System Warranty
VOLVO Engines Emissions Control System Warranty The following engine components are covered by the supplemental emissions control system warranty policy as required by the California code of regulations. • 1 Engine Turbocharger Assembly Aftertreatment DPF Differential • Pressure Sensor Variable Geometry Turbo (VGT) - Page 69 VOLVO Engines 63 • Aftertreatment DEF Heated Lines 18. Exhaust Gas Piping (from • Turbocharger to Aftertreatment System) Aftertreatment DEF Quality Sensor 17. Instrument Cluster (Repair of Microprocessor)
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Page 70: Emission Green House Gas Component Warranty (If Equipped)
VOLVO Engines Emission Green House Gas Component Warranty (If Equipped) Critical Emissions-Related Maintenance Source of parts and repair: A repair shop or person of the owner’s choosing must maintain, replace, or repair emission control devices and systems per manufacturer's recommendations. -
Page 71: Engine Brake
VOLVO Engines 65 Engine Brake The engine brake is operated by the Engine Brake buttons on the steering wheel. It works together with the exhaust brake to provide two levels of braking power. There are three Engine Brake buttons on the steering wheel: OFF, (1) LOW and (2) HIGH. When the Engine Brake button (1) LOW is depressed, only the exhaust brake is engaged. -
Page 72: Engine Components, Service Schedules
VOLVO Engines Engine Components, Service Schedules Component Operation Km (Miles)/Maximum Months/Hours Engine Fuel Filter Change Each oil change * Water Separator Filter change Each oil change * Air Filter US Change 160 000 (100,000) or 12 months, 2010 whichever comes first... -
Page 73: Cooling System
Clean up coolant spills immediately. Failure to follow these precautions can cause serious illness or death. CAUTION Prevost and Volvo Bus Corporation does WARNING not recommend using plain water in the cooling system. Water alone is corrosive at engine operating temperatures and does DO NOT raise the engine hood if you see not provide adequate boiling protection. - Page 74 VOLVO Engines The main purpose of coolant is to transport heat from the hot parts of the engine to the radiator and to protect the cooling system from corrosion. In addition to this, the coolant must: • Protect against pitting and cavitation erosion damage of the water pump and cylinder liners.
- Page 75 VOLVO Engines 69 A well functioning and maintained cooling system is as important to the engine as performing regular oil changes or using good fuel. To get the best result use quality products and service the system at the correct intervals. Please read this section carefully.
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Page 76: Regular Coolant Change Interval
VOLVO Engines Regular Coolant Change Interval Coolant SCA level must be tested at least twice per year or whenever coolant loss occurs. For maximum coolant system efficiency, test the system at every engine oil change interval, every 1,000 hours or every 6 months (whichever comes first). For proper SCA levels, consult Service Manual. - Page 78 Last page Volvo Bus Corporation Göteborg, Sweden 89166953 English 9.2014...