FSB 237-021v2

Volvo Trucks North
America
Greensboro, NC USA
Field Service Bulletin
Trucks
Date
This Field Service Bulletin (FSB) replaces VOLVO bulletin
“Exhaust Rocker Compression Brake Piston, Repair”,
PV729-FSB 213–002_V (USA138519491) dated 01/2017.
6.2021
Group
No.
213 002
Release
Page
02
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Exhaust Rocker Compression Brake Piston,
Repair
VN, VAH, VHD, VT
FSB 213-002, Exhaust Rocker Compression Brake
Piston, Repair
(June 2021)
For VOLVO VN, VAH, VHD, and VT trucks built from 01/01/2007 to 07/06/2020, a repair
procedure and new tools have been created to repair the exhaust rocker compression brake
pistons. In some instances the exhaust rocker piston cap screw may become loose and back
out causing loss of engine compression, or a mechanical injector Diagnostic Trouble Code
(DTC).
There are two repair strategies outlined in this document. The first and updated repair
strategy is to replace the rocker arms with updated parts. The updated rocker arms contain a
welded piston cap which reduces failure rate and increases longevity of the repair. This
repair strategy is to be used on all under warranty repairs.
Note: If the vehicle is out of warranty, either repair strategy is acceptable.
The second repair requires the removal of the exhaust rocker piston, removal of the exhaust
rocker piston cap and internal components for cleaning. Ensure the rocker arm and exhaust
rocker compression brake piston are recorded as a pair during this repair procedure for
proper installation. After cleaning, the internal components are re-installed, thread locker
(LOCTITE 638) is applied to the cap, and the cap is tightened with special tooling to ensure
the proper torque is applied. See the repair parts section for special tooling part numbers.
Follow one of the repairs procedures outlined in this Field Service Bulletin (FSB) to repair the
vehicle.
PV776-FSB213-002_V
USA156922222
Volvo Trucks North America
Field Service Bulletin
Date
6.2021
Group
No.
Release
213
002
02
Repair procedure
Decommissioning the Truck for Repair
You must read and understand the precautions and guidelines in Service Information,
group 20, "General Safety Practices, Engine" before performing this procedure. If you are
not properly trained and certified in this procedure, ask your supervisor for training before
you perform it.
Note: Information is subject to change without notice. Illustrations are used for reference
only and can differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.
Repair 1 – Replacing the Exhaust Rockers with updated parts.
Required Parts
Item
Description
Part Number
1
Exhaust Rockers
See impact for VIN Specific Part Number
1 Remove and replace the rocker arm as per Impact operation 2145-03-02-01 Rocker Arm,
Replacement.
Repair 2 – Repairing Exhaust Rockers
Required Tools
Item
Description
Part Number
1
Retainer Tool
88800569
2
Assembly Tool
88800564
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Volvo Trucks North America
Field Service Bulletin
Date
6.2021
Group
No.
Release
213
002
02
1 Park the vehicle on a flat and level surface.
2 Apply the parking brake.
3 Place the transmission in neutral or park.
4 Chock the front wheels..
W7086748
5 Disconnect the cable from the battery’s negative terminal.
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Volvo Trucks North America
Field Service Bulletin
Date
6.2021
Group
No.
Release
213
002
02
Exhaust Rocker Compression Brake Piston Repair
Note: Do not use air impact tools for any part of this repair procedure.
1 Remove the exhaust rocker compression brake piston from the rocker arm.
Note: Record the rocker arm and the exhaust rocker compression brake piston as a
matched pair for installation purposes.
2 Place the Retainer Tool (part number 88800569) in a vise as shown in the figure below.
Note: Do not secure the tool in the vise at this time.
W2118927
3 Measure the diameter of the exhaust rocker compression brake piston to determine the
appropriate tool opening to be used in this repair procedure.
Note: The exhaust rocker compression brake piston diameter will be dimension (A) 28
mm (1.10 in) or (B) 30 mm (1.18 in).
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Volvo Trucks North America
Field Service Bulletin
Date
6.2021
Group
No.
Release
213
002
02
4 Position the exhaust rocker compression brake piston in the retainer tool as shown in the
figure below. The appropriate opening sizes are (A) 28 mm (1.10 in) or (B) 30 mm (1.18
in).
Note: Ensure the exhaust rocker compression brake piston protrudes approximately 6.35
mm (0.25 in) above the surface of the tool.
W2118929
5 Secure the exhaust rocker compression brake piston and the retainer tool in the vise.
Note: Apply enough pressure to the jaws of the vise to prevent the exhaust rocker
compression brake piston from rotating inside the tool when torque is applied to the cap.
6 Using Assembly Tool (88800564) and hand tools, remove the cap from the exhaust rocker
compression brake piston housing.
Note: Do not use air impact tools for this repair procedure.
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Volvo Trucks North America
Field Service Bulletin
Date
6.2021
Group
No.
Release
213
002
02
7 Remove the internal components from the exhaust rocker compression brake piston
housing.
Note: The internal components of exhaust rocker compression brake piston are very
small and could be easily misplaced when the cap is removed.
W2118931
8 Using brake cleaner, clean the internal components and the threads on the cap. Store the
internal components and cap in a secure location for installation.
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Volvo Trucks North America
Field Service Bulletin
Date
6.2021
Group
No.
Release
213
002
02
9 Using compressed air, blow out the inside of the exhaust rocker compression brake piston
housing as shown.
W2118934
10 Ensure the drain hole in the bottom of the exhaust rocker compression brake piston
housing is clean and clear of any debris.
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Volvo Trucks North America
Field Service Bulletin
Date
6.2021
Group
No.
Release
213
002
02
11 Install the internal components in the exhaust rocker compression brake piston housing.
W2118935
12 Position the cap in the exhaust rocker compression brake piston housing, then rotate the
cap one full turn until it starts to thread.
Note: Due to pressure from internal spring compression, slight pressure on the cap is
required to ensure the cap turns smoothly in the exhaust rocker compression brake piston
housing.
13 Apply one drop of thread locker (LOCTITE 270) in (4) places (90 degrees from each
other) on the exhaust rocker compression brake piston cap.
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Volvo Trucks North America
Field Service Bulletin
Date
6.2021
Group
No.
Release
213
002
02
14 Using a hand tool and Assembly Tool (88800564), tighten the cap until it bottoms out in
the exhaust rocker compression brake piston housing.
Note: Use hand tools only, do not use air impact tools.
15 Using a torque wrench with Assembly Tool (88800564) tighten the cap to 30 ± 3 Nm (22 ±
2 ft-lb).
W2118937
16 Remove the exhaust rocker compression brake piston from the retainer tool.
17 Install the exhaust rocker compression brake piston in the rocker arm as previously
recorded.
18 Repeat steps 2 through 17 for the remaining exhaust rocker compression brake pistons
that require repair.
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Volvo Trucks North America
Field Service Bulletin
Date
6.2021
Group
No.
Release
213
002
02
Commissioning the Truck for Operation
1 Connect the battery cable to the negative (ground) terminal.
W3086758
2 Remove the wheel chocks.
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Volvo Trucks North America
Field Service Bulletin
Date
6.2021
Group
No.
Release
213
002
02
Reimbursement
This repair may be eligible for reimbursement if a
product failure was experienced within time and mileage
limits of the applicable Warranty coverage.
Reimbursement is obtained via the normal claim
handling process.
UCHP
Reimbursement
Claim Type (used only when uploading from the Dealer
Bus. Sys.)
01
Labor Code
Repair 1
Rocker Arm, Replacement
Repair 2
Primary Labor Code (Exhaust Rocker Compression Brake
Piston, Repair), per piston
Causal Part
2145-03-02-01
Varies 4.0 to 7.0 hrs.
2132-16-09-01
0.2 hrs.
Note: Use the part
number of your exhaust
rocker to file a claim.
VOLVO Trucks North America reserves the right to make any changes in design or to make
additions to or upon its products without incurring any obligations to install the same on
vehicles previously built.
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