Core Manual Table of Contentss7d9.scene7.com/.../Volvo/Regulatory/REMAN_CORE_MANUAL.pdf · Core Manual Table of Contents ... property of Volvo Trucks if disposition of this material

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REVISION INDEX ................................................................................................................................... Index Page 1General............................................................................................................................................................................. 2Section 1 Cores New to Exchange Program ......................................................................................................... 3Section 2 Complete Engines (Function Group 2102) ......................................................................................... 4Section 3 Basic Long Block Engines (Function Group 2102) .......................................................................... 6Section 4 Short Block Engines (Function Group 2105) ...................................................................................16Section 5 Cylinder Heads (Function Group 2111) .............................................................................................17Section 6 Injector Rocker Arm (Function Groups 2145 & 2371) ...................................................................24Section 7 Crankshafts (Function Group 2161) ...................................................................................................25Section 8 Injection Pumps / Unit Injector (Function Group 2361) .................................................................26Section 9 Injectors (Function Group 2371 & 2374) .........................................................................................27Section 10 Turbo Chargers (Function Group 2551) ..........................................................................................28Section 11 Water Pumps / Coolant Pump / Bearing Housing (Function Group 2621) ............................33Section 12 Thermostat / Viscous Fans (Function Group 2631) .....................................................................35Section 13 Control Units (Function Group 2841) ..............................................................................................36Section 14 Alternators (Function Group 3211) ...................................................................................................37Section 15 Starter Motors (Function Group 3311) ............................................................................................38Section 16 Clutch Kits (Function Group 4111) ..................................................................................................39Section 17 Clutch Cylinder / Actuator / Slave Cylinder (Function Group 4139) ........................................40Section 18 Pressure Plates (Function Group 4112) .........................................................................................41Section 19 Clutch Discs / Driven Plates (Function Group 4117) ..................................................................42Section 20 Transmissions / Gear Boxes (Function Groups 4311, 4312) ....................................................43Section 21 Air Compressors (Function Group 5611) .......................................................................................47Section 22 Brake Chamber / Cylinders (Function Group 5641) ....................................................................48Section 23 Steering Gears (Function Group 6422) ..........................................................................................49Section 24 Steering Pumps / Servo Pumps (Function Group 6453)............................................................50Section 25 Instrument Clusters (Function Group 3811) ..................................................................................51Section 26 Connecting Rods (Function Group 2164) .....................................................................................52Section 27 Loaded Cylinder Kit (Function Group 2131 / 2139) ................................................................55-1Section 28 Loaded Overhaul Kit (Function Group 2131 / 2139) ..............................................................55-2Section 29 EGR Valves – Volvo D12 Series Engines (Function Group 2548) ...........................................56Section 30 EGR Cooler (Function Group 2932) ...............................................................................................58Section 31 Diesel Oxidation Catalyst (Function Group 2587) ........................................................................67Section 32 DPF Filters (Function Group 2587) .................................................................................................68Section 33 DEF Pump (Function Group 2581) ..................................................................................................75Section 34 Driving Devices (Function Group 2159) ..........................................................................................79Section 35 Radiators (Function Group 2611) .....................................................................................................80Section 36 Actuators (Function Group 2559) ....................................................................................................81Section 37 Radios (Function Group 3981) .........................................................................................................82Section 38 Oil Pumps – Volvo D12 Series Engines (Function Group 2211) ..............................................83Section 39 Flywheels (Function Group 2166) ....................................................................................................84

Core Manual Table of ContentsThis guide includes exchange and core number cross over listings and is designed to ensure that returned cores meet acceptance requirements for condition, packaging and cleaning. Additionally, information is included to assist in identifying core markings. Refer to the Parts Operations Manual, Chapter 11, for complete policies and procedures for Volvo Reman cores.

To view a specific section, click on any of the blue links below. To Return to Table of Contents, click on the Volvo Reman Logo on any page or click on the link at bottom of page.

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Revisions

PAGE NUMBER PRODUCT REV. DATE

Page 84 Flywheels 08 / 17

Page 2 General 07 / 17

Page 84 Flywheels 06 / 17

Page 23 Cylinder Heads 01 / 17

Page 27 Injectors 01 / 17

Page 46 through 46-1 Transmissions 01 / 17

Pages 77 EGR Coolers 12 / 16

Pages 76 through 77 EGR Coolers 08 / 16

Page 57 EGR Valves 07 / 16

Page 2-1 General 06 / 16

Pages 77-78 DEF Pump 04 / 16

Page 20 Slab Type Cylinder Heads 04 / 16

Pages 55-1 through 55-2 Loaded Cylinder Kit & Loaded Cylinder Overhaul Kit 01 / 16

Page 27 Injectors 11 / 15

Page 1 Table of Contents 10 / 15

Page 52 through 55 Connecting Rods 10 / 15


Page 55-1 Loaded Cylinder Kit 10 / 15

Page 55-2 Loaded Cylinder Overhaul Kit 10 / 15

Page 56 EGR Valves – Volvo D12 Series Engines 10 / 15

Page 58 EGR Cooler 10 / 15

Page 67 Diesel Oxidation Catalyst 10 / 15

Page 68 through 74 DPF Filters 10 / 15

Page 75 DEF Pump 10 / 15

Page 79 Driving Devices 10 / 15

Page 80 Radiators 10 / 15

Page 81 Actuators 10 / 15

Page 82 Radios 10 / 15

Page 83 Oil Pumps – Volvo D12 Series Engines 10 / 15


Page 46-1 Range Housing Kit 07 / 15


Page 84 Loaded Cylinder Kit / Loaded Overhaul Kit 11 / 14

Page 2 through 2-2 General 11 / 14


Page 2 through 2-5 General 07 / 14

Page 3 New Exchange Cores 07 / 14

Page 32 Turbo Chargers 07 / 14

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Revisions

PAGE NUMBER PRODUCT REV. DATE

Page 33 Water Pumps / Coolant Pump / Bearing Housing 07 / 14

Page 40 Clutch Cylinder / Actuator / Slave Cylinder 07 / 14

Page 68 DPF Filters 07 / 14

Page 83 Oil Pumps – Volvo D12 Series Engines 07 / 14

Page 7 Short Block Engines 03 / 14

Pages 3 & 4 Complete Engines 03 / 14

Page 51 Radios 03 / 14

Page 50 Acutators 03 / 14

Page 49 Radiators 03 / 14

Pages 37 through 43 DPF Filters 03 / 14

Page 27 Steering Pumps / Servo Pumps 03 / 14

Page 8-6 Slab Type Cylinder Heads 03 / 14


Page 23-3 Transmission / Gear Boxes 12 / 13

Page 13-4 Turbo Chargers 09 / 13

Pages 5, 6-8 Basic Long Block Engines 09 / 13

Page 23-3 Transmissions / Gear Boxes 08 / 13

Page 23-1 through 23-3 Transmissions / Gear Boxes 05 / 13

Page 48 Driving Device 09 / 12

Page 44-47 DEF Pump 02 / 12

Page 23 through 23-2 Transmissions / Gear Boxes 02 / 12

Page 35-7 through 35-8 EGR Coolers 02 / 12

Page 3 through 4 Engines 01 / 12

Page 5 through 6-8 Basic Long Block Engines 01 / 12

Page 35-1 through 35-4 EGR Coolers 12 / 11

Page 13 through 13-4 Turbo Chargers 08 / 11

Page 8-3 Cylinder Heads 05 / 11

Page 8 through 8-3 Cylinder Heads 01 / 11

Page 36 Diesel Oxidation 09 / 10

Page 37 DPF Filters 09 / 10

07 / 17 Page 2CLICK HERE TO RETURN TO TABLE OF CONTENTS.

General

This manual has been compiled in an attempt to provide guidelines for branches, subsidiaries and distributors in evaluating credit for returned cores. The text and pictures represent general conditions since not every situation can be covered with the array of parts and components involved in the Remanufacturing Program. Use common sense and good judgment in core evaluation.

Cores are the lifeline of the remanufacturing business. It is important that cores be evaluated properly to insure that you have made a profit on the full transaction, and that they be packaged in a manner that will eliminate shipping damage.

Cores purposely assembled out of scrap and / or old style parts will not be accepted as core returns. Cores must be complete. To receive full credit, they must include all of the material included in the remanufactured part. Credit will be reduced for damaged and missing components.

The remanufactured exchange program is a one-for-one exchange of like part numbers. Branches, Subsidiaries and Distributors purchasing remanufactured basic engines or components from another Branch, Subsidiary or Distributor must make sure that there has not already been a core returned against that component. It is important that each shipment of returned cores include the correct forms properly filled out to identify the components. Over-returns (cores returned in excess of purchases) may be purchased at an outright price at the request of the customer, or “Like” cores will be returned freight collect. You will be notified of over-returns. Over-returns will become the property of Volvo Trucks if disposition of this material is not ascertained within 30 days. Disposition of material rejected for scrap or over-returns must be indicated on the core return paper work. Core returns can be submitted and tracked through CMS.

Hazardous materials of any kind are not returnable under any circumstances. Volvo Trucks shall be indemnified and held harmless for any and all hazardous materials shipped by a dealer. In the event such a shipment should occur the dealer making the shipment shall incur all costs associated with the disposal of the hazardous material. Disposal will be handled in accordance with EPA regulations.

Volvo Trucks reserves the right to make final decisions on all returned cores and credit allowances.

EFFECTIVE IMMEDIATELY

These instructions supersede all previous instructions and must be adhered to.It is very important that you follow all core policies and procedures outlined in this section. Failure to comply with these policies will result in no credit or a reduction in credit.

Shipping Instructions:All cores must be fully assembled and they should be packaged in the original shipping box. Core credit will be denied on any core damaged by improper handling and / or packaging. One Pallet = One Shipment no. (Each pallet must include a unique CMS shipment no./delivery note as well as a clearly visible case label)The proper core return paperwork must be included with each shipment of cores. Delay in receiving these forms will result in a delay of the credit process.

Core Returns SHIP TO address:

Volvo Group Trucks C Dock – Core Hub 13403 Volvo Way Hagerstown, MD 21742 US Freight Policy:• The total BOL (Bill of Lading) may consist of 1 or more CMS Shipments.• Each Bill of Lading weighing 1000 pounds or more, combined, must be shipped using YRC Freight collect. There is no limit

to the number of returns that you are permitted to ship, as long as each return meets the 1000 pound weight requirement.• Returns weighing less than 1000 pounds, combined, may be shipped using the freight carrier of your choice and must be

shipped at dealers cost (pre-paid).

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General

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PACKAGING POLICY: Separation of product will shorten the time involved in receiving your core credits. Prepare the shipment, as you would like to receive it. These requirements are to insure that your return is processed in an expedient manner and that you receive the full value of your return. This is not intended to be all-inclusive and items that are not referenced should be approached with common sense and the realization that remanufacturing wants to produce a quality product at a reasonable price.• All pallets/containers CANNOT exceed 42” length x 48” width x 37” height.• All pallets/containers used must be on a two-way skid that can be accessed by forks from both sides.• Each pallet or container CANNOT exceed 1,200 LBS with the exception of major unit pallets.• The common L size Volvo emballage stacked 4 sides high fits within this limit. • Each pallet requires a case label that is clearly visible on the outside and the delivery note placed in a packing slip sleeve.• These restrictions will be enforced for all brake, mixed container and legacy cylinder head returns.• Shipments received after October 31, 2014 not meeting these requirements will be returned unprocessed at

the dealer’s expense.“One Pallet = One CMS Return Document (“CMS Shipment #”) Policy:• Each pallet must include a CMS shipment no./delivery note specific to the contents of the pallet/carton.PREPARING THE CORE SHIPMENT:When preparing items for shipment and placing them into a shipping container, remember to place heavy items on the bottom and place lighter items on top. Cores damaged from improper packing could result in debit.• Major Unit components (engines, transmissions, carriers) must be claimed on a separate CMS shipment number.

Engines, Carriers, Transmissions should be returned on a metal stand, if applicable, or on a two way skid, shrink wrapped and safely secured. o One Pallet = One CMS Return Document (“CMS Shipment number”) Each pallet must include a CMS shipment number/delivery note specific to its contents. o Cores must be drained free of all fluids to prevent hazardous and costly spills in transit. Any damages related to spills due to improperly drained engines will be the shipping dealer’s responsibility. o Improperly drained engines will result in a reduced core credit (see core credit deductions).

• Cylinder Heads must be claimed on a separate CMS shipment number. o One Pallet = One CMS Return Document (“CMS Shipment number”) Each pallet must include a CMS shipment number/delivery note specific to its contents. o Legacy Cylinder Heads - may be returned in VEMB (emballage) not to exceed 4 layers high or stacked on a pallet, maximum of 24, securely strapped and stretch wrapped. o Slab type Cylinder Heads – return in original wooden (coffin) box, or on a two way skid, shrink wrapped and safely secured.

• Mixed Cartons must contain the required paperwork (Delivery note & Case Labels). o Paperwork attached to each carton should be for the components inside that carton only. o One Pallet = One CMS Return Document (“CMS Shipment number”) Each pallet must include a CMS shipment number/delivery note specific to its contents. o Carton style containers must be securely closed to prevent pilferage or damage. Items should never be shipped lying loose in a container with the opening unsecured. Secure carton lid using banding or stretch wrap. o Please no nails or screws. o It is preferred parts be kept segregated by part type when consolidating into shipping container (package oil pumps with oil pumps, etc.) Use good judgment and common sense. o Arrange items to minimize movement within the packaging utilized. Whenever possible, place largest/heaviest cores on the bottom and smaller/lighter cores on top. o Mixed Cartons may not contain major units, cylinder heads or brake shoes.

• Brake Shoe guidelines. o One Pallet = One CMS Return Document (“CMS Shipment number”) Each pallet must include a CMS shipment number/delivery note specific to its contents. o Brake Shoe Packing: Pallets of brake shoes must be packed securely to ensure safety. Brake shoe pallets CANNOT exceed 1200 LBS. o Using L type Emballage is preferred, but never more than 4 layers high. o Brake shoes stacked (nested) on an open pallet (48x48) and secured with stretch wrap is acceptable, but should not be more than 4 layers high. o Cardboard (Gaylord) packaging or original brake shoe packaging is also acceptable, but completed skid must be secured with stretch wrap.


General

IMPORTANT REMINDERS

11 / 14 Page 2-2

Canadian Dual-Dealers ONLY• Only shipments from your Volvo dealer code may be on a single BOL.

• Multiple truck brands on the same BOL is a violation of US Customs law.

• You will need to schedule a pickup and receive a YRC Pro number for your Volvo shipments.

Canadian Dealers returning any engine core. When calling YRC to schedule your pick-up. Be prepared to provide YRC with necessary engine data for EPA documents required to clear customs. Dealer name, dealer code, address, and phone number; CMS Shipment #, and the following information from the engine label (data plate):

• Engine part number

• Engine build date

• Engine serial number

• Engine family name

*In case of a missing or unreadable engine data label, dealer will first acquire a replacement engine data label, before creating the core return.

Refer to FIELD SERVICE BULLETIN 210-001, Engine Data Label (Oct 2013)

IMPORTANT REMINDERS• If the shipment size and or weight require the use of a pallet, be sure that material-handling equipment can be used. Pallets

should not have cracked or broken boards prior to shipment.• Items shipped on pallets must be securely strapped / stretch wrapped to the pallet to prevent shifting and movement during

transit.• Cores MUST be complete and assembled to be applicable for the maximum credit allowance.• A reduction in credit allowance will be made for cores returned with damaged or missing components.

o Excess rusty or dirty cores are subject to a deduction.• All cores are subject to an External Visual Inspection. Any discrepancies will be verified by a second inspector.• HAZARDOUS MATERIALS:

o Hazardous materials of any kind are not returnable under any circumstances. Mack Trucks shall be indemnified and held harmless for any and all hazardous materials shipped by a dealer. In the event such a shipment should occur, the dealer making the shipment shall incur all costs associated with the disposal of the hazardous material. Disposal will be handled in accordance with EPA regulations.

Core Return Process:1. Check your Open Eligibility in CMS. • Log in with user name and password. • If you do not know your password please call the dealer help desk at 1-877-278-6586.2. Create a CMS shipment.3. Contact Yellow Roadway Consolidated (YRC) to schedule a pickup. Dealers in US and Canada call YRC at 888-610-8249

4. Click on “ready for pick” up in CMS • Click on “get tracking no” • Select shipping terms from drop-down menu • Input YRC provided Pro. no./shipping ref. • Click “send”

Canadian Dealers

• Print 2 copies of each Delivery Note. (1-in/on each pallet, 1-attached to BOL)

• The Delivey Note will also serve as Customs invoice and MUST be complete.

• Ensure that the following information is complete for EACH core listed on EVERY Delivery Note: • Country of Origin “orig”

• Core value “ext.value”• If any cores are missing either “orig” or “ext.value” on the Delivery Note, contact Volvo

Core Return Dealer Support at 1-800-573-6225, select prompt #2 for assistance.


5. Prepare your shipment for pick up • Print documents Bill of Lading – provide to YRC driver Case Labels – affix label to outside of the pallet Delivery Note - Each pallet must include a CMS shipment no./delivery note specific to its contents which may be placed, either inside or placed in a packing slip sleeve attached to outside of container

General

11 / 14 Page 2-3

6. Once shipment has been inspected by the Core Hub, if the shipment has exceptions a notification email will be sent to your email address indicating that the inspection is complete and ready for your review and confirmation. • A shipment that has no exceptions will not require action by dealer and will be completed without notification.7. Review and confirm the shipment inspection results within 48 hours. • Disputes can be made during this time in CMS and sent for review. • If you would like the core returned to you, select RETURN TO DEALER and provide the preferred carrier, account number and the amount of insurance if desired. • If CMS receives no response within 48 hours, the shipment will be confirmed on behalf of the dealer.8. CMS shipment is marked complete.9. CMS shipment is processed for crediting.10. Core credits are issued for all eligible cores with matching core groups.

Inspection Guidelines: • All returned cores must be completely assembled. Disassembled cores are unacceptable and will be subject to a 50% deduction. You may request a core to be returned to you within 48 hours of receiving email notification of completed inspection. Volvo Trucks will not be responsible for return freight charges. • All cores must be qualifying units that are included within the Exchange System. Non-qualifying cores will be rejected, if you wish to have them returned to you freight collect you may request a core to be returned to you within 48 hours of receiving email notification of completed inspection. Volvo Trucks will not be responsible for return freight charges. • All core returns must be free from outside damage (fire, water, collision, or due to shipping or rough handling). Damaged cores will be rejected, if you wish to have them returned, you may request a core return within 48 hours of receiving email notification of the completed inspection. Volvo Trucks will not be responsible for return freight charges. • The Core Hub will attach photos to CMS inspection results for all Major Units (engines, transmissions, carriers) with deductions from missing or damaged parts. Photos of all other cores that have been re-identified or that have deductions may be available by request.


A TYPICAL CORE RETURN may consist of 1 pallet or multiple pallets. Each pallet is referred to as a CMS shipment.

Example Core Return:1- Mixed Carton (CMS shipment no 51308 = Delivery Note + Case Label)1- Pallet of Cylinder Heads (CMS shipment no 51311 = Delivery Note + Case Label)1- Major Unit (Engine) (CMS shipment no 51309 = Delivery Note + Case Label)1- Pallet of Brake Shoes (CMS shipment no 51310 = Delivery Note + Case Label)

• All four CMS shipments are picked up by carrier as a single RETURN and transported to the Core Hub on 1- Bill Of Lading (BOL)

• combined into a single “Return” (BOL), means weight is combined to satisfy the freight policy

• palletized separately

• each created as its own CMS shipment

• each has its own “Delivery Note” & “Case Label”

• delivery note may be placed, either inside or placed in a packing slip sleeve attached to outside of container.

• carriers should be palletized separately

• multiple legacy Cylinder heads may be packaged in emballage as safety standards permit

General

07 / 14 Page 2-4


General

Cores that are not covered within this manual:Any cores returned to the Core Hub, that are not covered within this manual will, at the discretion of Volvo Trucks, be received by the Core Hub and “accepted” “as removed”.

Damages to returned Cores that are not covered within this manual:Assessed damages to Cores that are not covered within this manual, and that render the core unusable, will, at the discretion of Volvo Trucks, be received by the Core Hub and “scraped” with appropriate deductions assessed.

IMPORTANT REMINDER • All core returns must be free from outside damage (fire, water, collision, or due to shipping or rough handling). Damaged cores will be rejected, if you wish to have them returned, you may request a core return within 48 hours of receiving email notification of the completed inspection. Volvo Trucks will not be responsible for return freight charges.

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Section 1 Cores New to Exchange Program

New Exchange Cores

NEW EXCHANGE CORES

Cores that are new to the VOLVO REMAN exchange program, (parts that have a core charge but are not yet available as “REMAN”), will be accepted with full credit if the core meets the following criteria:

CORE INSTRUCTIONS

• The Core must be complete and assembled.

• The Core is in suitable condition for Remanufacture.

• The Core is not damaged by non-operational causes such as rust, rough handling or fire.

DESCRIPTION DEDUCTION VALUE

Disassembled Core / Incomplete Core Scrap / 100%Condition unsuitable for Remanufacture Scrap / 100%Damaged by non-operational causes such as rust, rough handling or fire Scrap / 100%


Section 2 Complete Engines (Function Group 2102)

CORE INSTRUCTIONS

The returned core must meet the following requirements:

• Oil and water must be drained.

• Protective plugs must be transferred from Exchange Component to core.

• EGR unit must be protected during shipping by using the EGR bracket supplied on the replacement Exchange engine.

• The unit must be complete and assembled.

• Core is not damaged by non-operational causes such as rust, rough handling or fire.

Volvo Direct Ship Product (VDSP) Complete Engines are not stocked in a PDC; they are shipped directly from the manufacturing facility. VDSP Complete Engines are shipped without a starter motor, alternator, steering pump or EGR Valve. VDSP Engines must be returned as the part number ordered.

Complete Engines


Section 2 Complete Engines (Function Group 2102)

Return PackagingThe core should be returned on the same engine stand as the Exchange Component was deliveredon, with the plastic sheeting. Ensure ID tag is right side up. Units equipped with an EGR bracket mustbe returned with this bracket in place to ensure no damage to the EGR.

Cleaning ChargesThe returned core must be clean from grime and oil. If the procedure is not followed, a cleaningcharge will be applied to your account.

MARKINGS

New Engines(Example) TD120A 302 30040TD120A = Engine Model302 = Last three digits of engine production number30040 = Engine serial number

Remanufactured EnginesThe marking is placed in the same position as on new models, but has changed its appearance. Theengine is still identified by the last three digits in the production number however. There may also be asign with an Exchange part number, if so, this number should be used as identification.

DESCRIPTIONDEDUCTION VALUE

Engine Crankshaft (Broken) $1,200Engine Head(s) - Missing or Damaged $1,000Engine - Cores w / out Engine Brake in exchange for core w / Engine Brake $500Engine Cylinder Block - Cracked or Broken. No deduction for cracked D12 engine blocks only. $2,000Engine Cylinder Block - Thrown Rod (Includes Block and Crank Deduction) $3,200Engine - Complete Engines (Built up past 3 / 4 Engine) $300Engine - Disassembled Cores 50% of Core ValueEngine - Improperly Drained of Oil and / or Antifreeze $300Engine - Excessively Soiled or Rusty Cores Minimum $50Engine - Damaged Cores Beyond Repair ScrapEngine - Failure to Return Core on Steel Engine Stand $750Engine Stand - Missing Steel Engine Stand Parts Each $40Engine - All Other Missing or Damaged Items Dealer Net

Complete Engines


Section 3 Basic Long Block Engines (Function Group 2102)

CORE INSTRUCTIONS


• The block must have no visible cracks. Cracks are acceptable on D12 engine blocks only.

• It must be possible to turn the engine over manually or with the help of the starter motor.

• Oil and water must be drained.

• Protective plugs must be transferred from Exchange Component to core.



This assembly does not contain:

• Starter motor

• Alternator

• Turbo

• Water pump

• Injection system

• Oil filter

• Oil filter holder

• Flywheel

• Pulleys

• Induction manifold

• Exhaust manifold

Basic Long Block Engines


Return PackagingThe core should be returned on the same engine stand as the Exchange Component was delivered onwith the plastic sheeting. Ensure unit ID tag is right side up. Failure to package the unit properly willresult in a $750 deduction from your account.

Cleaning ChargesThe returned core must be clean from grime and oil. If the procedure is not followed, a cleaningcharge will be applied to your account.

MARKINGS

New Engines(Example) TD120A 302 30040

TD120A = Engine Model302 = Last three digits of engine production number30040 = Engine serial number

Remanufactured EnginesThe marking is placed in the same position as on new models, but has changed its appearance. Theengine is still identified by the last three digits in the production number however. There may also be asign with an Exchange part number, if so this number should be used as identification.



D11 Engines

D12 Engines



D13 Engines

D16 Engines



Engine Component Identification

Upper Timing Cover

Valve Cover

Drive Device

Lower Timing Cover

Flywheel Housing

Block

Rear of Crankshaft

Head



Block

Upper Timing Cover

Drive Device

Lower Timing Cover

Oil Pan

Flywheel Housing

Oil Cooler Cover

Lower Timing Cover

Upper Timing Cover

Flywheel Housing




Camshaft Tower

Camshaft CamshaftGear

Rocker Arms Exhaust Injector

Intake

Rocker Arms Shaft




HOLE IN BLOCK

CRACKED BLOCK

THROWN ROD



CRACKED PAN RAIL

ATTEMPTED PAN RAIL REPAIR



Core Deductions

DESCRIPTION DEDUCTIONVALUE

Engine Crankshaft (Broken) $1,200

Engine Head(s) - Missing or Damaged $1,000

Engine - Cores w / out Engine Brake in exchange for core w / Dynatard $500

Engine Cylinder Block - Cracked or Broken. No deduction for cracked D12 engine blocks only. $2,000

Engine Cylinder Block - Thrown Rod (Includes Block and Crank Deduction) $3,200

Engine - Complete Engines (Built up past 3 / 4 Engine) $300

Engine - Disassembled Cores 50% of Core Value

Engine - Improperly Drained of Oil and / or Antifreeze $300

Engine - Excessively Soiled or Rusty Cores Minimum $50

Engine - Damaged Cores Beyond Repair Scrap

Engine - Failure to Return Core on Steel Engine Stand $750

Engine Stand - Missing Steel Engine Stand Parts Each $40

Engine - All Other Missing or Damaged Items Dealer Net



CORE INSTRUCTIONS


• The block must have no visible cracks or holes.



Return PackagingPack the return short block with the marking turned to face upwards so that it is clearly visible when unpacking. The core should be returned on the same engine stand as the Exchange Component was delivered on. Ensure unit ID tag is right side up. Failure to package the unit properly will result in a $750 charge deduction from your account.

Cleaning ChargesThe returned core must be clean from grime and oil. If the procedure is not followed, a cleaning charge will be applied to your account.

Section 4 Short Block Engines (Function Group 2105)

DESCRIPTIONDEDUCTIONVALUE

Engine Crankshaft (Broken) $1,200Engine Cylinder Block - Cracked or Broken. $2,000Engine - Disassembled Cores 50% of Core ValueEngine - Improperly Drained of Oil and / or Antifreeze $300Engine - Cores Damaged Beyond Repair ScrapEngine - All Other Missing or Damaged Items Dealer Net

Short Block Engines


Section 5 - All Cylinder Heads (Function Group 2111)

11L, 12L, 13L and 16L (Slab type)

Any Style Cylinder Head other than Slab Type

Cylinder Heads


Slab Type Cylinder Head Indentification

D11

D13

D12

D16

Slab Type Cylinder Heads


Cam Tower

Spring

ValveRotator

Slab Type Cylinder Head Parts Indentification



All cores are subject to visual inspection only. Non-current heads are unacceptable for credit. Full credit will be issued on all VOLVO SLAB CYLINDER HEADS which are completely assembled with the valves, springs, rotators, etc., as well as meeting the minimum dimension for head thickness. Damage resulting in a hole through combustion surface renders cylinder head scrap (see below). All cylinder heads must meet a minimum thickness specification as listed on the below chart to be accepted for credit. All cylinder heads thinner than the below specification will be rejected.*

Example of a SCRAP Volvo Slab Cylinder Head with a crack between the counterbores

Below is a chart listing minimum thicknesses for cylinder head core returns.

*If your cylinder head has been previously remanufactured by VOLVO Reman the minimum thickness requirement will be waived and accepted for full credit.

HeadType

MinimumThickness

D11, D12, D13, D16 5.306”



Two Examples of Acceptable Volvo Slab Cylinder Heads with Minor Deck Damage

Two Examples of a $500 Deduction on Volvo Slab Cylinder Heads with Major Deck Damage

Minor pitting to the deck surface consists of small areas of slight damage

Major pitting to the deck surface consists of excessive damage over large areas

See deduction page (23)

Imprint from a broken valve stem



Example of a SCRAP Volvo Slab Cylinder Head with a hole in the combustion surface

Example of a SCRAP Volvo Slab Cylinder Head with a cracked cam rail

Damage resulting in a hole through combustion surface

renders CYLINDER HEAD scrap. (All heads)



SLAB CYLINDER HEAD 11L, 12L, 13L, 16L DEDUCTIONSSprings – Missing or Damaged (Each) $6Valves – Missing or Damaged (Each) $25Cam Tower (Slab Heads) – Missing / Damaged Tower $200Cracks Between Counterbore & Injector Sleeve ScrapUnder Minimum Head Thickness Dimension (Non-Volvo Reman) ScrapMajor Deck Damage (Slab Heads) $500Hole Through Combustion Surface ScrapCracked Cam Rail (Slab Heads) ScrapDamaged by Non-Operational Causes ScrapDisassembled Core 50%

ALL CYLINDER HEADS OTHER THAN SLAB TYPE (LEGACY)Damaged by Non-operational Causes (Rust, Rough Handling, Fire) ScrapDisassembled Core ScrapBroken Casted Features ScrapMajor Deck Damage ScrapHole Through Combustion Surface ScrapCracks Between Counterbore & Injector Sleeve Scrap

APPROXIMATE WEIGHT

438 lbs. (D11 Shipping weight with box)450 lbs. (D12 and D13 Shipping weight with box)480 lbs. (D16 Shipping weight with box)



Section 6 Injector Rocker Arm (Function Groups 2145 & 2371)

CORE INSTRUCTIONS



• Core must have no visible cracks.

Injector Rocker Arm


Section 7 Crankshafts (Function Group 2161)

NOTE: Rod bearings, main bearings and thrust washers are included.

CORE INSTRUCTIONS


• If it has no indications of serious radial cracks.

• It has no permanent discoloration (dark blue in appearance).

• Surface of the rod or main journals cannot be scored due to bearing failure.


Crankshafts


Section 8 Injection Pumps / Unit Injector (Function Group 2361)

CORE INSTRUCTIONS


• It is complete and assembled.


Injection Pumps / Unit Injector


Section 9 Injectors (Function Group 2371 & 2374)

CORE INSTRUCTIONS


• The unit must be complete.


Injectors

CLICK HERE TO RETURN TO TABLE OF CONTENTS.08 / 11 Page 28

Section 10 Turbo Chargers (Function Group 2551)

Turbo Chargers


Complete VGT Turbo: Full Core Credit

Band Clamps

Speed Sensor

Actuator / SRA

Turbo Chargers


Incomplete VGT Turbo: Missing or damaged Speed Sensor Missing or damaged Actuator / SRA

Missing Speed SensorMissing Actuator / SRA

Missing name plate is acceptable IF unit can be identified as a genuine core.

Turbo Chargers


Complete Waste Gate Turbo

Waste Gate: deduction if missing

Turbo Chargers

CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 32

DESCRIPTION DEDUCTION VALUEMissing Band Clamps $40 eachMissing or damaged Speed Sensor (when applicable) $45Missing or damaged Actuator / SRA (when applicable) $75Missing nameplate and non-branded ScrapMissing or damaged Waste Gate Assembly (when applicable) $75Broken propeller / Broken Shaft No DeductionCracked or Broken Housings Scrap

1. Check for “Volvo” stamped into the housing

2. Check Turbine Opening

11L - has 60mm wheel bore

13L - has a 68mm wheel bore

Use 2 ½” plastic pipe to determine if 13L.

2 ½” plastic pipe will not fit if 11L.

3. Check Blade Count

US07 - has 12 vanes (blades)

US10 - has 11 vanes (blades)

Hint: turn the wheel so that a vane is at 12 o’clock. If there is a vane at 6 o’clock

(directly opposite), then it is an ‘07.

07 / 14

CORE INSTRUCTIONS

The returned core must meet the following guidelines:

• The unit is complete and assembled.

• Like-for-like part numbers or accepted as part of a Core Clearing Group.

• Is a Genuine core, which can be identified by I.D. tag or Logo on compressor housing.

• Core is not damaged by non-operational causes such as rust, welding, torch, grinder, rough handling, or fire.

DEDUCTIONS

Turbo Chargers


Section 11 Water Pumps / Coolant Pump / Bearing Housing (Function Group 2621)

CORE INSTRUCTIONS



• It is complete and assembled with pulleys and drive.

• It shows no visible cracks.

• It must be drained of fluid.

Water Pumps / Coolant Pump / Bearing Housing


WATER PUMP MARKINGS

TYPE 1

SPECIAL MODELSWITH GEAR DRIVE

WITH V-SHAPED CONNECTION

D12 / D12A / D12B F16, FH16

TYPE 2 F4, FL4, B10R 3 CONNECTIONS INDIFFERENT

DIRECTIONS

Water Pumps / Coolant Pump / Bearing Housing

D SERIES BEARING HOUSING

BEARING HOUSING


Section 12 Thermostat / Viscous Fans (Function Group 2631)

CORE INSTRUCTIONS



Thermostat / Viscous Fans


Section 13 Control Units (Function Group 2841)

CORE INSTRUCTIONS




Control Units


Section 14 Alternators (Function Group 3211)

CORE INSTRUCTIONS




Alternators


Section 15 Starter Motors (Function Group 3311)

CORE INSTRUCTIONS




Starter Motors


Section 16 Clutch Kits (Function Group 4111)

CORE INSTRUCTIONS

Kit core returns will be credited by individual component. See below for breakdown.

• Unit must be complete.

• The disc centers must not be loose.

• No springs can be missing.

• The clutch disc must have no damage to the splines in the center.

• There must be no cracks in the pressure plate.

• The unit is to be returned in the packaging supplied together with the Exchange Unit.


Clutch Kits

3919067 CLUTCH KIT KIT CORE NUMBER 851039608112600 Front Disc 8118600 Core

8112601 Rear Disc 8118601 Core

8112602 Exchange Clutch 8118602 Core

3919079 CLUTCH KIT KIT CORE NUMBER 851039618112340 Release Bearing 8118340 Core

8112597 Exchange Clutch 8118597 Core


Section 17 Clutch Cylinder / Actuator / Slave Cylinder (Function Group 4139)

CORE INSTRUCTIONS


• It must be complete and assembled.


Clutch Cylinder / Clutch Actuator


Section 18 Pressure Plates (Function Group 4112)

CORE INSTRUCTIONS




• There must be no cracks in the plate or housing.

Pressure Plates


Section 19 Clutch Discs / Driven Plates (Function Group 4117)

CORE INSTRUCTIONS


• The clutch disc must be complete and assembled.

• The clutch disc must not be cracked.

• The clutch disc must have no damage to the splines in the center.

• The disc center must not be loose.

• No springs can be missing.


Clutch Discs / Driven Plates


Section 20 Transmissions / Gear Boxes (Function Group 4311) Mechanical

CORE INSTRUCTIONS


• It must be cleaned, complete and assembled.


• The transmission is to be emptied of oil (see below re: Cleaning Charges).

• The core is to be returned in the same packaging material the Exchange Component was delivered.

• The transmission housing must have no visible cracks.

• It must be possible to turn the input shaft by hand with the gear engaged.

Return PackagingThe core should be returned using the same packaging the Exchange Component was delivered in.Ensure unit ID tag is right side up. Failure to package the unit properly may result in a charge debitedto your account.

Cleaning ChargesThe returned core must be clean from grime and oil. If the procedure is not followed, a cleaningcharge will be applied.

Transmissions / Gear Boxes


Oil Filter Housing and Filter included Top Cover Assembly

with Electronic Control Module included

No Top Cover Assembly with

Electronic Control Module included

No Top Cover Assembly with

Electronic Control Module included

Clutch Control Actuator (CCA) included

Solenoid, Harness and Lines

included

Volvo Reman I-Shift Complete

Volvo Reman I-Shift Basic

Volvo Reman I-Shift Short

Oil Filter Housing and Filter included

Oil Filter Housing and Filter included

No Solenoid, Harness and Lines

included

No Solenoid, Harness and Lines

included

Auto-Mechanical / I-SHIFT

No Range Assembly included

No Clutch Control Actuator (CCA) included

No Clutch Control Actuator (CCA) included



Plastic Bonnet must be installed for core return

on Transmissions to avoid deductions

Top Assembly cover must be installed for core return

on Basic and Short Transmissions to avoid deductions

Plastic bonnet must be installed for core return on Short Transmission to avoid deducations



CORE PART NUMBER GROUPING - CORES WITHIN GROUP ARE INTERCHANGEABLE


COMPLETE TRANSMISSIONS

MODEL AT2512C GROUP # AMT 001 8500914485009831

MODEL ATO2512CGROUP # AMT 0028500914585009832

MODEL ATO3112CGROUP # AMT 0038500914785009833

MODEL AT2612DGROUP # AMT 00485009221850098518513180485131807

MODEL ATO2612DGROUP # AMT 005850092228500985285131805 85131808

MODEL ATO3112D STD OR HDGROUP # AMT 00685009223851318068502657985026582

BASIC TRANSMISSIONSMODEL AT2612DGROUP # AMT 0108501943185019437

MODEL ATO2612DGROUP # AMT 0118501943385019439

STAND ALONE850194178501941985019421

SHORT TRANSMISSIONSMODEL AT2612DGROUP # AMT 0168501943285019438

MODEL ATO2612DGROUP # AMT 0178501943485019440

STAND ALONE850194188501942085019422

HD COMPLETE TRANSMISSIONSMODEL AT2612DGROUP # AMT 001 HD8502635185026349

MODEL ATO2612DGROUP # AMT 002 HD8502635285026350

HD BASIC TRANSMISSIONSMODEL AT2612D HDGROUP # AMT 010 HD8502643785026435

MODEL ATO2612D HDGROUP # AMT 011 HD8502643885026436

MODEL ATO3112D STD OR HDGROUP # AMT 012 HD8502643985026755 85019435

HD SHORT TRANSMISSIONSMODEL AT2612D HDGROUP # AMT 016 HD8502644485026442

MODEL ATO2612D HDGROUP # AMT 017 HD8502644585026443

MODEL ATO3112D STD OR HDGROUP # AMT 015 HD850264468502675685019436

CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 46-101 / 17

CORE DEDUCTIONS

DESCRIPTIONDEDUCTION VALUE

Return of a “C” Model against a purchase of a “D” Model or Other Returns which are Non like-for-like Model ( AT for an ATO or an ATO for an AT) $1500

Return of a “D” Model against a purchase of a “C” Model (Contact required for proper credit) $0Broken, Cracked or Missing Bell Housing $600Broken, Cracked or Missing Main Case $1000Broken, Cracked or Missing Range Housing ( Complete and Basic only) $1000Broken, Cracked or Missing Top Cover Assembly (TCU) $2500Improperly Drained Transmission $300Failure to Return with shipping covers (Basic and Short only) $50 ea.Excessively Soiled or Rusty Core Minimum $50Disassembled Core ½ Core ChargeFire Damage ScrapAll Other Missing or Damaged Items Dealer NetReturns of Std model for an HD of the same model, except ATO3112D model.(AT2612D for a AT2612D HD or a ATO2612D for a ATO2612D HD) $500

*All Volvo Reman Transmissions must be returned safely on a steady skid or stand. There will be no credit given for the return of a 2512 or 2612 Series Transmission against the purchase of a 3112 series.


07 / 15 Page 46-1CLICK HERE TO RETURN TO TABLE OF CONTENTS.

(Function Group 4312)

CORE INSTRUCTIONS


• Kit must be returned with all 4 pieces shown (Ring Gear, Engaging Rings and Synchronizer Ring) in the picture above to receive credit

Range Housing Kit

DESCRIPTION DEDUCTION VALUE1 or more missing parts 100%

Synchronizer RingEngaging Ring (Drum/Hub)

Engaging RingRing Gear


Section 21 Air Compressors (Function Group 5611)

CORE INSTRUCTIONS



• The crankshaft is not broken. (It can be turned.)

• The housing has no visible cracks or holes.


Air Compressors


Section 22 Brake Chamber / Cylinders (Function Group 5641)

CORE INSTRUCTIONS




• The housing has no visible cracks or holes.

MARKINGS

TYPE 1 MAXIBRAKE (Membrane in rear

part, thick stainless rod)

MGM-MODEL (Membrane in front part,

thin rod)

DBA (Unic) AP (Unic)

Brake Chamber / Cylinders


Section 23 Steering Gears (Function Group 6422)

CORE INSTRUCTIONS



• There must be no visible cracks in the housing.

• Nut on output shaft must be screwed into shaft.

• The core must be returned in the same packaging material as the Exchange Component is delivered.

• Plastic plugs must be transferred.


Nut

Steering Gears


Section 24 Steering Pumps / Servo Pumps (Function Group 6453)

CORE INSTRUCTIONS




Steering Pumps / Servo Pumps


Section 25 Instrument Clusters (Function Group 3811)

CORE INSTRUCTIONS


1. Core must be returned in original carton with packing material that reman unit was shipped in.

2. Cores are allowed on a strict like-for-like basis.

3. Core is complete and not disassembled.

4. Core is not damaged by non-operational causes such as rust, rough handling or fire.

Instrument Clusters

NEW # REMAN #8510202485102029 8510200685102011 85102022 8510202585102007

85001106850002248500022585000226850002278500022885000232


Section 26 Connecting Rods (Function Group 2164)

Connecting Rods

11L CONNECTING ROD

D12 CONNECTING ROD

CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 52-110 / 15

Connecting Rods

13L CONNECTING ROD

16L CONNECTING ROD


Connecting Rods

CONNECTING ROD AND CAP mustmatch and seated with the bolts to be acceptable.

Spun and damaged bores renderCONNECTING ROD scrap.

Spun or damaged wrist pin bores render

a connecting rod scrap and therefore

are unacceptable for core credit.

Excessively damaged and burned thrust walls are unacceptable for core credit.


Connecting Rods

Bent connecting rods are unacceptableand no credit will be given for cores

returned in this condition.

Burned rods from excessive heat andexcessively rusted rods are rendered

scrap and unacceptable for credit.


Connecting Rods

CORE INSTRUCTIONS


• Connecting rod and cap must match and be seated with the bolts to be acceptable. Mismatched rod and cap are unacceptable.

• Core must be free of spun and damaged bores.

• Rods must not be bent or burned.

Returning Connecting Rods

• Extreme care must be taken when packing connecting rod cores for return. Rods which are damaged in shipping due to improper packing are unacceptable.

DEDUCTIONS

• If rod is damaged beyond repair, rod is scrap.

PART # REMAN # CORE # DESCRIPTION21405253 (NEW EXCHANGE) N/A 85019220 11L CONNECTING ROD20412200 85001360 85007360 D12 CONNECTING ROD20876840 (NEW EXCHANGE) N/A 85007362 13L CONNECTING ROD20898595 (NEW EXCHANGE) N/A 85019292 16L CONNECTING ROD21527863 (NEW EXCHANGE) N/A 85019587 16L CONNECTING ROD


Section 27 Loaded Cylinder Kit (Function Group 2131 / 2139)

Loaded Cylinder Kit

CORE INSTRUCTIONS

Cores must be returned in original packaging to avoid deduction. Proper handling of the crown is necessary to prevent damage to ring grooves. DO NOT RETURN LINER WITH CORE.

In order to ensure the proper credit is given, be sure to distinguish clearly on the core return paperwork whether the credit requested is for a single Loaded Cylinder or for a Loaded Cylinder Overhaul kit. Use of the proper core part number listed below is the best way to ensure the correct credit is given.

(D12D single loaded cylinder pictured)

REMAN PART # CORE PART # DESCRIPTION85125028 85125048 D12C Loaded Cylinder Kit85125029 85125049 D12D Loaded Cylinder Kit85146556 85146557 D11 EPA 07/10 Loaded Cylinder Kit85146622 85146623 D13 EPA 07 Loaded Cylinder Kit85146626 85146627 D13 EPA 10 Loaded Cylinder Kit85146631 85146632 D16 EPA 04/07 Loaded Cylinder Kit85146663 85146664 D16 EPA 10 Loaded Cylinder Kit

LOADED CYLINDER KIT

***Please see Connecting Rods section for further damage criteria

DEDUCTIONS

DESCRIPTION DEDUCTION VALUE PER CYLINDER

BENT, BURNT, SPUN DAMAGED ROD*** $120

RUSTY OR DAMAGED PISTON CROWN $50

FAILURE TO RETURN IN ORIGINAL PACKAGE $50

MISSING / DAMAGED WRIST PIN $5

SPUN/DMG BORES REJECTED

EXCESSIVE RUST REJECTED

MISMATCH CAP & ROD REJECTED


Section 28 Loaded Cylinder Overhaul Kit (Function Group 2131 / 2139)

Loaded Cylinder Overhaul Kit

CORE INSTRUCTIONS

Cores must be returned in original packaging to avoid deduction. Proper handling of the crown is necessary to prevent damage to ring grooves. DO NOT RETURN LINER WITH CORE.

In order to ensure the proper credit is given, be sure to distinguish clearly on the core return paperwork whether the credit requested is for a single Loaded Cylinder or for a Loaded Cylinder Overhaul kit. Use of the proper core part number listed below is the best way to ensure the correct credit is given.

REMAN PART # CORE PART # DESCRIPTION85125018 85125045 D12C Loaded Cylinder Overhaul Kit85125020 85125046 D12D Loaded Cylinder Overhaul Kit85146672 85146674 D11 EPA 07/10 Loaded Cylinder Overhaul Kit85146679 85146680 D13 EPA 07 Loaded Cylinder Overhaul Kit85146683 85146684 D13 EPA 10 Loaded Cylinder Overhaul Kit85146687 85146688 D16 EPA 04/07 Loaded Cylinder Overhaul Kit85146692 85146693 D16 EPA 10 Loaded Cylinder Overhaul Kit

LOADED CYLINDER OVERHAUL KIT

***Please see Connecting Rods section for further damage criteria

DEDUCTIONS

DESCRIPTION DEDUCTION VALUE PER CYLINDER

BENT, BURNT, SPUN DAMAGED ROD*** $120

RUSTY OR DAMAGED PISTON CROWN $50

FAILURE TO RETURN IN ORIGINAL PACKAGE $50

MISSING / DAMAGED WRIST PIN $5

SPUN/DMG BORES REJECTED

EXCESSIVE RUST REJECTED

MISMATCH CAP & ROD REJECTED


Section 29 EGR Valves – Volvo D12 Series Engines

ACCEPTABLE

CORE INSTRUCTIONS

Criteria applies to all EGR Valves:


• Cut or spliced harnesses are acceptable.


NOTE: Only the valve assemblies need to be returned. Do not return piping and clamping.

EGR Valve - Volvo D12 Series Engines


NOT ACCEPTABLE

DO NOT RETURN PIPING AND CLAMPING

EGR Valve - Volvo D12 Series Engines

DEDUCTIONS


NON GENUINE $100


Section 30 EGR Cooler

EGR Coolers


D-12DUS04

Coolant Bleed Screw Housing

Mounting Tab

Coolant Ports

Exhaust Ports

EGR Coolers


Protective plugs shipped on Dex Part # 20722340DEX

Housing

EGR Coolers


Protective plugs shipped on Dex Part # 20801814DEX

Exhaust Port

Coolant Port

Coolant PortCoolant Bleed Screw

Mounting Brackets

Mounting Bolts

Exhaust Port

D-16D US04

EGR Coolers


D-11, D-13, D-16US07 – US10

Compression Pads

Coolant Ports

Mounting Pin

Exhaust PortsCoolant Bleed Screw Housing

EGR Coolers


Protective plugs shipped on new and Dex parts

Extra protective plug included on DEX part #s 21480644DEX,

21480645DEX, 21480646DEX

Protective plugs shipped on new and Dex parts

Broken weld on coolant port

EGR Coolers


Examples of unacceptable cores:

Bent / Damaged Exhaust Port

Bent / Damaged Coolant Port

EGR Coolers


APPROXIMATE WEIGHT

Note: Weight may vary based on usage.D-11 Shipping weight with box-37lbsD-12 Shipping weight with box-19lbs without housing, 26lbs with housing attachedD-13 Shipping weight with box-40lbsD-16 Shipping weight with box-43lbs

Bent / Damaged Coolant Port

EGR Coolers

Examples of unacceptable cores:

CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 66


• Core is not damaged by non-operational causes such as rust, fire, or rough handling.

• Compression pads must be returned. *Except D12D* (Deduction if missing from unit or not returned in box with core part) NOTE: Compression pads can be taped securely to cooler.

• No visible exterior damage, bends, or cracks.

• Protective plugs must be transferred from purchase part to core part. (See illustrations for examples of plugs included in shipping.)

• No bent or damaged coolant or exhaust ports.

• No bent or broken mounting pins, brackets or bolts.

DESCRIPTION DEDUCTION VALUEMissing Compression Pads. (except D12D) $25 eachUnacceptable - Bent or Damaged Exhaust Ports. REJECTEDUnacceptable - Bent or Damaged Coolant Ports. REJECTED

Note: Do not return piping or clamping hardware.

12 / 16

EGR Coolers


Section 31 Diesel Oxidation Catalyst

Diesel Oxidation Catalyst (DOC)

CORE CRITERIA


CORE INSTRUCTIONS

• The core must be returned in the original packaging.

o Place dirty core into plastic bag that is provided for you.

o Insert into smaller box.

o Insert smaller box into larger outer box.

Component Indentification

Diesel Oxidation Catalyst


CORE CRITERIA

• Core is not damaged by non-operational causes such as rough handling or fire.

CORE INSTRUCTIONS

• The core must be returned in the original packaging. o Core must be returned in bag, inside original box.

Complete DPF & Filters

Section 32 Complete DPF & Filters

DPF FILTER


Stain on Outlet.Rust stain.No signs of soot on outlet.

Heavy soot on inlet.Soot completely plugs channels.

Oil on Outlet.Staining due to oil passing into filter.Oil is dry.

Section 32 Acceptable Clean and Return DPF Filters



Scrape on Ceramic.Ceramic surface rubbed by hard material in removal / shipping.Channels have plugs intact.

Bent Flanges.Flange has been bent in removal / shipping.

Fingerprint on Outlet.Spot appears to be soot on outlet and would normally be scrap.Spots are fingerprints from handling.




Oil on Outlet.Staining due to oil passing thru DPF.Oil is wet.


Soot on Inlet.Even coating of soot.

Soot on Inlet.Variations of soot on surface.

Clean on Outlet.No signs of soot on outlet.



Soot on Outlet.Soot showing on outlet indicates filter failure.

Soot on Outlet.Multiple locations of soot passing thru filter.

Ceramic Cracked.Large portion of ceramic cracked.Crack reveals open channels below plugs.

Section 32 Scrap Clean and Return DPF Filters



Ceramic Pushed out of Can.Ceramic is driven out of canning due to extremely highback pressure.

Filter Melted.Ceramic shows signs of abnormally high temperatures.Channels are melted.

Channels are Round.Ceramic channels are not square.Ceramic shows signs of abnormally high temperatures.




Swirl Pattern on Exhaust and / or Intake Surface.Sign of filter getting too hot and overheating.Soot on exhaust surface.Early stages of a melted filter.

Another Example of a Swirl Pattern on Exhaust and / or Intake Surface.Sign of filter getting too hot and overheating.No sign of soot on exhaust surface.Early stages of a melted filter.

Filter Sent in to Reman for Clean / Return Service.Identified as Scrap at the Reman Center and sent back to dealer.




Section 33 DEF Pump

DEF Pump


Mounting Points

Mounting Points

Mounting Points

DEF Pump


Caps

Caps

DEF Pump


CORE CRITERIA


• Broken fittings are acceptable.

• The core must be returned in the original packaging. o Core must be returned in bag, inside original box.

• Must be returned with all caps and covers.

• DEF pump should be free of any paint marks, writing, or paint.

APPROXIMATE WEIGHT

Note: Weight may vary based on usage.Shipping weight -8.5 lbs

DEF Pump


Broken Mounting Points ½ of Core Charge

Improper Packaging ½ of Core Charge

DEDUCTION


Section 34 Driving Device (Function Group 2159)

CORE CRITERIA


• The core must be returned in the original packaging.


Missing or Damaged Hub $30.00

Missing or Damaged Gear $30.00

Disassembled Core ½ of Core Charge

NEW PART # REMAN PART # CORE PART # CORE VALUE20838388 85013115 85019115 $150

APPROXIMATE WEIGHT

Note: Weight may vary based on usage.Shipping weight -10.75 lbs.

Driving Device


Section 35 Radiators (Function Group 2611)

CORE INSTRUCTIONS



• Core must be complete and assembled.

• Must not have broken or otherwise damaged tanks or brackets.

• Core is not damaged by physical or chemical effect of any corrosive substances in operating environment.

Radiators


Section 36 Actuators (Function Group 2559)

CORE INSTRUCTIONS


• Core is not damaged by non-operational causes such as rust, rough handling, fire, improper removal or improper protection while storing.


• Casting is not visibly cracked or damaged.

Actuators


Section 37 Radios (Function Group 3981)

CORE INSTRUCTIONS




• Core must be returned in the original shipping box.

Radios


Section 38 Oil Pumps – Volvo D12 Series Engines (Function Group 2211)

Oil Pumps – Volvo D12 Series Engines

CORE INSTRUCTIONS

Criteria applies to all D Series Oil Pumps:


• No visable cracks or damage to Housing.

• No visable damage to mating gears.



Section 39 Flywheels (Function Group 2166)

DESCRIPTION DEDUCTION

Core is damaged by non-operational causes such as rust, rought handling or fire Rejected

16L twin mass flywheel is not an acceptable core Rejected

Flywheels

ACCEPTABLE SINGLE MASS FLYWHEEL

UNACCEPTABLE - TWIN MASS FLYWHEEL (16L ONLY)

Single mass flywheel has one group of bolt holes around center.

16L twin mass flywheel has two sets of bolt holes around center of flywheel.

Documents

Core Manual Table of Contentss7d9.scene7.com/.../Volvo/Regulatory/REMAN_CORE_MANUAL.pdf · Core Manual Table of Contents ... property of Volvo Trucks if disposition of this material