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CONTENTS
1.
VOLVO D13 ENGINE ............................................................................................................................ 3
1.1
SYSTEM OVERVIEW..................................................................................................................... 3
1.2
ENGINE OVERVIEW...................................................................................................................... 6
1.3
ENGINE OIL ................................................................................................................................... 7
1.3.1
General.................................................................................................................................... 7
1.3.2
Oil Quality ................................................................................................................................ 7
1.3.3
Oil Change Intervals................................................................................................................ 8
1.3.4
Oil Filters ................................................................................................................................. 9
1.3.5
Synthetic Lubrication ............................................................................................................... 9
1.3.6
Oil Viscosity ............................................................................................................................. 9
1.3.7
Oil Additives............................................................................................................................. 9
1.3.8
Oil Consumption...................................................................................................................... 9
1.3.9
Oil Change............................................................................................................................. 10
1.3.10
Oil Filters Change.................................................................................................................. 10
1.3.11
Checking The Oil Level .........................................................................................................11
1.4
POWER PLANT ASSEMBLY REMOVAL..................................................................................... 11
1.5
POWER PLANT ASSY. INSTALLATION...................................................................................... 14
1.6
ENGINE MOUNTS ....................................................................................................................... 14
2.
DETROIT DIESEL SERIES 60 ENGINE ............................................................................................. 16
2.1
DDEC VI SYSTEM........................................................................................................................ 16
2.2
HARNESSES................................................................................................................................ 16
2.3
ENGINE OVERVIEW.................................................................................................................... 17
2.4
DDEC VI SENSORS..................................................................................................................... 18
2.5
PREVOST INSTALLED SENSORS ............................................................................................. 19
2.6
MOTOR CONTROL MODULE (MCM).......................................................................................... 19
2.7
COMMON POWERTRAIN CONTROLLER (CPC) ....................................................................... 19
2.8
DDEC VI DIAGNOSTICS.............................................................................................................. 19
2.8.1
Diagnostic system ................................................................................................................. 19
2.8.2
Check Engine Telltale Light (AWL) ....................................................................................... 20
2.8.3
Stop Engine Warning Light (RSL) ......................................................................................... 20
2.8.4
Stop Engine Override Switch (SEO) ..................................................................................... 20
2.8.5
Diagnostic Data Link (DDL) Connectors ............................................................................... 20
2.9
READING DIAGNOSTIC CODES - FLASHING LIGHT METHOD: ............................................. 20
2.10 DDEC VI CPC DIAGNOSTIC CODES LIST ................................................................................. 21
2.11 DDEC VI MCM DIAGNOSTIC CODES LIST ................................................................................ 28
2.12 ENGINE OIL LEVEL ..................................................................................................................... 39
2.13 ENGINE OIL AND FILTER CHANGE ........................................................................................... 40
2.14 RECOMMENDED ENGINE OIL TYPE ......................................................................................... 41
2.15 POWER PLANT ASSEMBLY REMOVAL..................................................................................... 41
2.16 POWER PLANT ASSY. INSTALLATION...................................................................................... 45
2.17 JAKE BRAKE................................................................................................................................ 45
2.18 ENGINE MOUNTS ....................................................................................................................... 45
3.
ELECTRONIC FOOT PEDAL ASSEMBLY (EFPA) & THROTTLE POSITION SENSOR ................ 46
4.
ENGINE TROUBLESHOOTING GUIDE............................................................................................. 47
5.
SPECIFICATIONS............................................................................................................................... 49
5.1
SERIES 60 ENGINE ..................................................................................................................... 49
5.2
VOLVO D13 ENGINE ................................................................................................................... 50
PA1561
SECTION 01: ENGINE
1
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Summary of Contents for Volvo D13
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Page 1: Table Of Contents
SECTION 01: ENGINE CONTENTS VOLVO D13 ENGINE ..........................3 SYSTEM OVERVIEW........................3 ENGINE OVERVIEW........................6 ENGINE OIL ........................... 7 1.3.1 General............................ 7 1.3.2 Oil Quality ..........................7 1.3.3 Oil Change Intervals........................ 8 1.3.4 Oil Filters ..........................9 1.3.5 Synthetic Lubrication ....................... 9 1.3.6... - Page 2 ........................12 FIGURE BELT TENSIONER VALVE ) ................14 FIGURE ENGINE COMPARTMENT H COACHES TYPICAL ..............15 FIGURE VOLVO ENGINE POWER PLANT CRADLE INSTALLATION )............16 FIGURE VEHICLE INTERFACE HARNESS GENERAL APPLICATION SHOWN 2007 ................ 18 FIGURE DETROIT DIESEL SERIES...
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Page 3: Volvo D13 Engine
Section 01: ENGINE 1. VOLVO D13 ENGINE provide input to the EMS: • Ambient Air Temperature Sensor 1.1 SYSTEM OVERVIEW • Ambient Pressure sensor NOTE • Boost Air Pressure (BAP) Sensor The “Premium Tech Tool” (PTT) is the • Camshaft Position (Engine Position) Sensor preferred tool for performing diagnostic work. - Page 4 Section 01: ENGINE to the diaphragm causes the diaphragm to EGR Temperature Sensor deflect and the amplifier to produce an electrical The EGR temperature sensor detects exhaust signal proportional to the deflection. gas temperature for EGR system. The sensor modifies a voltage signal from the control unit. The Ambient (Atmospheric) Pressure Sensor is The modified signal returns to the control unit as built into the Engine Management System...
- Page 5 Section 01: ENGINE temperature coefficient, which means the sensor air temperature increases. resistance will decrease as the engine oil Intake Manifold (Boost) Temperature temperature increases. Sensor is located in the intake manifold. The Engine Oil Temperature Sensor is located in the oil pan. Intake Manifold Pressure Sensor The Intake Manifold Pressure Sensor contains a Exhaust Temperature Sensor (DPF Sensors)
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Page 6: Engine Overview
For additional information concerning Volvo D13 engine components or engine-related components, consult Volvo Trucks Canada or Volvo Trucks North America Web Site under: Parts & Service. On Volvo web site, you will find detailed service procedures for parts replacement, repair and maintenance. -
Page 7: Engine Oil
1.3.2 Oil Quality Volvo North America recognizes engine oils that meet or exceed the standards given by American Petroleum Institute (API) for the oil classifications listed in this manual. Only oils licensed to carry the API... -
Page 8: Oil Change Intervals
EO-O Premium Plus (or VDS-4) diesel engine oil is mandatory for use in all 2007 emission compliant Volvo engines. Chassis equipped with a 2007 emission compliant engine, which can be identified by the presence of a Diesel Particulate Filter (DPF), also require the use of Ultra Low Sulfur Diesel (ULSD) fuel. -
Page 9: Oil Filters
These oils may be used 1.3.8 Oil Consumption in Volvo engines, provided they meet the quality Once the engine is stopped, check the oil level levels specified on the previous pages, that is: daily. -
Page 10: Oil Change
WARNING Volvo-branded oil filters are designed to provide the proper level of filtration and protection for Volvo engines. Filters that do When draining the oil, use the proper tools not meet the same stringent requirements and keep away as far as possible. Raise the may cause unsatisfactory results. -
Page 11: Checking The Oil Level
Section 01: ENGINE FIGURE 6: ENGINE OIL FILLING TUBE FIGURE 5: OIL FITER REPLACEMENT FIGURE 7: ENGINE OIL LEVEL DIPSTICK • Start the engine and check for leaks around the oil filter housing and filters. 1.4 POWER PLANT ASSEMBLY REMOVAL •... -
Page 12: Figure 8: Belt Tensioner Valve
Section 01: ENGINE 9. Disconnect and remove the air intake duct WARNING mounted between the turbocharger outlet and the air cooler inlet. Due to the heavy load of the rear bumper 10. Disconnect and remove section of coolant assembly, it must be adequately supported pipe assembly mounted between the radiator before attempting to remove it. - Page 13 Section 01: ENGINE 19. From under the vehicle, disconnect the 34. On partition wall, disconnect connector C397 propeller shaft as detailed in Section 09, located between engine compartment and under heading "Propeller Shaft Removal". main power compartment. 20. On vehicles equipped with an automatic 35.
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Page 14: Power Plant Assy. Installation
Section 01: ENGINE FIGURE 9: ENGINE COMPARTMENT H3 COACHES (TYPICAL) 01193 1.5 POWER PLANT ASSY. INSTALLATION It is recommended that new rubber mounts be installed at each major overhaul. To install a power plant assembly, follow the NOTE same procedure as in "Power Plant Assembly Removal"... -
Page 15: Figure 10: Volvo Engine Power Plant Cradle Installation
Section 01: ENGINE FIGURE 10: VOLVO ENGINE POWER PLANT CRADLE INSTALLATION DRY TORQUES REFERENCE DESCRIPTION Lbf-ft SCREW, CAP HEXAGONAL HEAD M8 – 1.25 G8.8 SCREW, CAP HEXAGONAL HEAD M8 – 1.25 G10.9 SCREW, CAP HEXAGONAL HEAD M10 – 1.5 G10.9 SCREW, CAP HEXAGONAL HEAD M12 –... -
Page 16: Detroit Diesel Series 60 Engine
Section 01: ENGINE 2. DETROIT DIESEL SERIES 60 ENGINE system has a chassis-mounted control unit for vehicle engine management, the Common The DDC series 60 engine is a 6-cylinder, four- Powertrain Controller (CPC). The connection to cycle, 14.0 liters Detroit Diesel series 60 engine, the vehicle is made via a CAN interface which equipped with an electronic control system digitally transmits the nominal values (e.g. -
Page 17: Engine Overview
Section 01: ENGINE 2.3 ENGINE OVERVIEW 1- Starter motor 2- Oil pan drain plug 3- Primary fuel-filter/water- separator 4- MCM (DDEC VI Electronics) 5- Secondary fuel filter shutoff valve 6- Secondary fuel filter 7- Fuel pump 8- Air compressor 9- Engine oil filling tube 10- Bosch alternators (2) 11- Engine oil dipstick 12- EGR delta pressure sensor... -
Page 18: Ddec Vi Sensors
Section 01: ENGINE 24- Water pump 25- EGR cooler 26- Oil filter (2) 27- Crankcase breather tube 28- EGR tube FIGURE 12: DETROIT DIESEL 2007 SERIES 60 ENGINE (TYPICAL) 01179 • Engine Pressure Sensor (EOP 2.4 DDEC VI SENSORS Sensor): Senses gallery oil pressure for •... -
Page 19: Prevost Installed Sensors
Section 01: ENGINE 2.5 PREVOST INSTALLED SENSORS 2.7 COMMON POWERTRAIN CONTROLLER (CPC) • Engine Coolant Level Sensor (ECL Sensor): Senses coolant level for engine The CPC is the interface between the MCM and protection (mounted on coolant surge tank). the vehicle/equipment for engine control and manages other vehicle/equipment functions. -
Page 20: Check Engine Telltale Light (Awl)
Section 01: ENGINE problem solving in the form of a code. The MCM 2.8.3 Stop Engine Warning Light (RSL) and CPC continuously perform self diagnostic This light, also mounted on the telltale light checks monitor other system panel, illuminates to indicate that a major engine components. -
Page 21: Active/Inactive Codes
Section 01: ENGINE Active Codes: Codes that are currently keeping the Check Engine or Stop Engine telltale light illuminated. Active codes are flashed via the Stop Engine Light when checked with the stop-engine-override switch. Inactive Codes: These are all the codes logged in the CPC, which have previously occurred, (whether or not they are currently turning on the Stop or Check Engine Light). - Page 22 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2113 Vehicle Speed Sensor Circuit Failed High 2113 Vehicle Speed Sensor Circuit Failed Low 2113 VSS Anti Tamper Detection via Virtual Gear Ratio 2113 VSS Anti Tamper Detection via Fixed Frequency Device 2113 VSS Anti-Tamper Detection via ABS Vehicle Speed...
- Page 23 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2123 Coolant Temperature Very High 2124 Coolant Level Low 2124 Coolant Level Circuit Failed High 2124 Coolant Level Circuit Failed Low 2124 Coolant Level Very Low 2125 Battery Voltage Very Low 2125 Battery Voltage High 2125...
- Page 24 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2135 J1939 Cruise Control Enable Switch Signal from Source #1 is erratic 2135 J1939 Cruise Control Enable Switch Signal from Source #1 is missing 2135 J1939 Cruise Control Enable Switch Signal from Source #2 is erratic 2135 J1939 Cruise Control Enable Switch Signal from...
- Page 25 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2144 J1939 Cruise Control Accelerate Switch Signal from Source #3 is erratic 2144 J1939 Cruise Control Accelerate Switch Signal from Source #3 is missing 2145 J1708 Data Link Failure 2145 CPC2 Hardware Failure 2615 J1939 DM1 Message from Transmission is missing 2151...
- Page 26 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2615 MCM Fault Code Table Inconsistant - Upgrade MCM Software 2153 J1939 Data Link Failure 2211 Digital Output 4 09 Circuit Failed High 2211 Digital Output 4 09 Circuit Failed Low 2212 Digital Output 3 17 Circuit Failed High 2212...
- Page 27 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2244 J1939 Engine Retarder Selection Signal Erratic 2245 Remote Accelerator Pedal Supply Voltage Out of Range 2245 Remote Accelerator Pedal Circuit Failed High 2245 Remote Accelerator Pedal Circuit Failed Low 2311 PTO CC+ and CC- Switches Pressed Simultaneously 2615...
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Page 28: Ddec Vi Mcm Diagnostic Codes List
Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 3695 2334 DPF Regen Inhibit MUX Switch Message Not Received this Ign Cycle 3696 2335 DPF Regen Force MUX Switch Message Contains Data Error Indicator 3696 2335 DPF Regen Force MUX Switch Message Contains SNV Indicator 3696 2335... - Page 29 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1212 Engine Coolant Outlet Temperature Circuit Failed Low 1212 Engine Coolant Outlet Temperature Circuit Failed High 1212 Coolant Temperature High 1212 Coolant Temperature / Engine Oil Temperature Plausibility Fault 1212 Engine Coolant Sensor (OUT), General Temp. Plausibility Error 1213 Intake Air Throttle Valve Closure Detection- Positive Torque 1213...
- Page 30 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed High 1615 MU_ISP_T_TBD2_SRH Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed Low 1615 MU_ISP_T_TBD3_SRL Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed High 1615 MU_ISP_T_TBD3_SRH 1615...
- Page 31 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1615 Volute Shut Off Valve, Shorted to Battery 1615 Volute Shut Off Valve, Open Load 1615 Function 30 Circuit Failed Low 1615 Function 30 Circuit Failed High 1615 Function 30 Circuit Failed Open 1615 Function 31 Circuit Failed Low 1615...
- Page 32 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1334 Fan Stage 1 Circuit Failed Open 1242 Injector Cylinder #1 Needle Control Valve Abnormal Operation 1242 Injector Cylinder #1 Needle Control Valve Abnormal Rate of Change Injector Cylinder 1, Nozzle Control Valve or Spill Control Valve, Jammed 1242 Closed Injector Cylinder 1, Nozzle Control Valve or Spill Control Valve, Jammed...
- Page 33 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1253 Injector Cylinder #7 Needle Control Valve Abnormal Rate of Change 1253 Injector Cylinder #7 Needle Control Valve, Valve Shorted Circuit 1253 Engine Smoothness Control / Cylinder #7 Value Out of Range 1254 Injector Cylinder #8 Needle Control Valve Abnormal Operation 1254...
- Page 34 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1172 1425 Turbocharger Compressor Inlet Temperature Circuit Failed High 1172 1425 Coolant Temp/Compressor Inlet Temp Plausibility Error Turbocharger Compressor Inlet Temp. Sensor, General Temp. Plausibility 1172 1425 Error 1176 1431 Turbocharger Compressor Inlet Pressure Circuit Failed Low 1176 1431 Turbocharger Compressor Inlet Pressure Circuit Failed High...
- Page 35 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 2629 1513 Turbocharger Out Temperature, Temperature Too Low (High Box) Turbocharger Compressor Outlet Temp. Sensor, General Temp. Plausibility 2629 1513 Error 2630 1514 Charge Air Cooler Outlet Temperature Circuit Failed Low 2630 1514 Charge Air Cooler Outlet Temperature Circuit Failed High...
- Page 36 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 3050 1525 Engine Air Flow Out of Range Low 3050 1525 Active Regen Temp Out of Range Low 3058 1615 EGR System Parametrization Failure 3064 1615 DPF System Parametrization Failure 3242 1531 DOC Inlet Temperature Circuit Failed Low 3242...
- Page 37 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 3509 1631 Multiplexer 1 Channel 2, Shorted High 3510 1632 Multiplexer 2 Channel 1, Shorted High 3510 1632 Multiplexer 2 Channel 2, Shorted High 3511 1633 Multiplexer 3 Channel 1, Shorted High 3511 1633 Multiplexer 3 Channel 2, Shorted High...
- Page 38 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 3661 1613 Injector Cylinder #3 Spill Control Valve Abnormal Operation Injector Cylinder #3 Spill Control Valve ("Amplifier") Abnormal Rate of 3661 1613 Change 3661 1613 Injector Cylinder #3 Spill Control Valve ("Amplifier"), Valve Shorted Circuit 3662 1614 Injector Cylinder #4 Spill Control Valve Abnormal Operation...
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Page 39: Engine Oil Level
Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 4227 1324 Electrostatic Oil Separator Circuit Failed Open 4227 1615 Oil Separator Circuit Failed Low 4227 1615 Oil Separator Circuit Failed High 4227 1615 Oil Separator, Max. Duration Time Reached 1241 Smart Remote Actuator 5 (VGT), Temperature Fault 4228 1241... -
Page 40: Engine Oil And Filter Change
Section 01: ENGINE 2.13 ENGINE OIL AND FILTER CHANGE 2. Reinstall the drain plug. 3. Remove the spin-on filter cartridge using a 1/2" drive socket wrench and extension. MAINTENANCE 4. Dispose of the used oil and filter in an Both the engine oil and filter should be environmentally responsible manner... -
Page 41: Recommended Engine Oil Type
Section 01: ENGINE NOTE MAINTENANCE COLD WEATHER STARTING The proper selection of the engine oil grade Engine oil temperature should be checked will ease cold weather starting (refer to the every 25,000 miles (40 000 km) to determine lubrication and servicing schedule for the oil cooler efficiency. -
Page 42: Figure 20: Engine Compartment
Section 01: ENGINE 3. Drain the engine cooling system. Refer to 13. Disconnect fan-clutch electrical Section 05 under "Draining Cooling connector. COOLING System". 14. Disconnect the radiator fan drive shaft. 15. Disconnect the small heater hose located on the cylinder head at the back of the engine. 16. - Page 43 Section 01: ENGINE pressure regulator output. The pressure regulator is mounted in the upper section of engine compartment backwall accessible through the engine compartment R.H. side door. 29. On vehicles equipped with an electrically operated cold-starting aid, disconnect the delivery hose from the starting-aid cylinder solenoid valve.
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Page 44: Figure 21: Engine Compartment H 3 Coaches ( Typical )
Section 01: ENGINE FIGURE 21: ENGINE COMPARTMENT H3 COACHES (TYPICAL) 01177 FIGURE 22: ENGINE COMPARTMENT VIP (TYPICAL) 01178 PA1561... -
Page 45: Power Plant Assy. Installation
Section 01: ENGINE 2.17 JAKE BRAKE 2.16 POWER PLANT ASSY. INSTALLATION Refer to both "The Jake Brake Troubleshooting To install a power plant assembly, follow the and Maintenance Manual" and "Installation same procedure as in "Power Plant Assembly Manual for Model 797 Engine Brakes" for Removal"... -
Page 46: Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor
Section 01: ENGINE 3. ELECTRONIC FOOT PEDAL ASSEMBLY the CPC will signal diagnostic codes of 21-12 for idle error and 21-23 for wide-open throttle error. (EFPA) & THROTTLE POSITION SENSOR The Electronic Foot Pedal Assembly (EFPA) connects the accelerator pedal to a Throttle Position Sensor (TPS). -
Page 47: Engine Troubleshooting Guide
Section 01: ENGINE 4. ENGINE TROUBLESHOOTING GUIDE START go to does the is the engine engine step 2 rotate ? starting ? note 1 plug the Diagnostics Data Reader DDR into the receptacle does the red or momentarily depress the go to "Stop Engine"... - Page 48 Section 01: ENGINE step 3 with diagnostic code in hand, contact your note 1 Detroit Diesel service REFERENCES center -Operator's Manual chap. 3,4 & 8 -Detroit Diesel pamphlet "DDEC III/IV diagnostic codes and MPSI reader functions" -8V92 series engine, switch is located in service compartment note 1 plug the Diagnostics Data...
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Page 49: Specifications
Section 01: ENGINE 5. SPECIFICATIONS 5.1 SERIES 60 ENGINE Make ............................Detroit Diesel Type ....................... Diesel four cycle/in-line engine Description ...................... Turbo/Air to air charge cooled No. of cylinders ............................. 6 Operating range ........................1200-2100 RPM Maximum RPM............................2100 CAUTION To avoid possible engine damage, do not use single grade (Monograde) lubricants in Detroit Diesel four-cycle Series 60 engines, regardless of API classification. -
Page 50: Volvo D13 Engine
Make .........................Detroit Diesel # 23507545 Prevost number..........................550630 NOTE For primary and secondary fuel filters, refer to Specifications in section 03. 5.2 VOLVO D13 ENGINE Make ............................Volvo Powertrain Type ............................Diesel four cycle Description ...................... Turbo/Air to air charge cooled No. of cylinders .........................12.8 L inline 6 Recommended cruise speed range ..................1300-1500 RPM... - Page 51 Section 01: ENGINE NOTE For primary and secondary fuel filters, refer to Specifications in section 03. PA1561...