Core Manual Table of Contents

Transcription

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

2 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 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 1 Table of Contents 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 1 Table of Contents 07 / 15 Page 46-1 Range Housing Kit 07 / 15 Page 1 Table of Contents 11 / 14 Page 84 Loaded Cylinder Kit / Loaded Overhaul Kit 11 / 14 Page 2 through 2-2 General 11 / 14 Page 1 Table of Contents 07 / 14 Page 2 through 2-5 General 07 / 14 Page 3 New Exchange Cores 07 / 14 Page 32 Turbo Chargers 07 / / 17 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Index Page 1

3 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 1 Table of Contents 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 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 / / 17 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Index Page 1-1

4 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 Volvo Way Hagerstown, MD 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). 07 / 17 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 2

5 General 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. 06 / 16 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 2-1

6 General 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 Create a CMS shipment. 3. Contact Yellow Roadway Consolidated (YRC) to schedule a pickup. Dealers in US and Canada call YRC at IMPORTANT REMINDERS 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 , Engine Data Label (Oct 2013) 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 11 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 2-2

7 5. Prepare your shipment for pick up General 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 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 , select prompt #2 for assistance. 6. Once shipment has been inspected by the Core Hub, if the shipment has exceptions a notification will be sent to your 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 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 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 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. 11 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 2-3

8 General 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 = Delivery Note + Case Label) 1- Pallet of Cylinder Heads (CMS shipment no = Delivery Note + Case Label) 1- Major Unit (Engine) (CMS shipment no = Delivery Note + Case Label) 1- Pallet of Brake Shoes (CMS shipment no = Delivery Note + Case Label) 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 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 07 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 2-4

9 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 notification of the completed inspection. Volvo Trucks will not be responsible for return freight charges. 11 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 2-5

10 New Exchange Cores Section 1 Cores New to Exchange Program 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% 07 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 3

11 Complete Engines 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. 03 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 4

12 Complete Engines Section 2 Complete Engines (Function Group 2102) Return Packaging The core should be returned on the same engine stand as the Exchange Component was delivered on, with the plastic sheeting. Ensure ID tag is right side up. Units equipped with an EGR bracket must be returned with this bracket in place to ensure no damage to the EGR. Cleaning Charges The returned core must be clean from grime and oil. If the procedure is not followed, a cleaning charge will be applied to your account. MARKINGS New Engines (Example) TD120A TD120A = Engine Model 302 = Last three digits of engine production number = Engine serial number Remanufactured Engines The marking is placed in the same position as on new models, but has changed its appearance. The engine is still identified by the last three digits in the production number however. There may also be a sign with an Exchange part number, if so, this number should be used as identification. DEDUCTION DESCRIPTION VALUE Engine Crankshaft (Broken) $1,200 Engine Head(s) - Missing or Damaged $1,000 Engine - Cores w / out Engine Brake in exchange for core w / Engine Brake $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 03 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 5

13 Basic Long Block Engines Section 3 Basic Long Block Engines (Function Group 2102) CORE INSTRUCTIONS The returned core must meet the following requirements: 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. The unit must be complete and assembled. Core is not damaged by non-operational causes such as rust, rough handling or fire. This assembly does not contain: Starter motor Alternator Turbo Water pump Injection system Oil filter Oil filter holder Flywheel Pulleys Induction manifold Exhaust manifold 09 / 13 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 6

14 Basic Long Block Engines Return Packaging The core should be returned on the same engine stand as the Exchange Component was delivered on with the plastic sheeting. Ensure unit ID tag is right side up. Failure to package the unit properly will result in a $750 deduction from your account. Cleaning Charges The returned core must be clean from grime and oil. If the procedure is not followed, a cleaning charge will be applied to your account. MARKINGS New Engines (Example) TD120A TD120A = Engine Model 302 = Last three digits of engine production number = Engine serial number Remanufactured Engines The marking is placed in the same position as on new models, but has changed its appearance. The engine is still identified by the last three digits in the production number however. There may also be a sign with an Exchange part number, if so this number should be used as identification. 01 / 12 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 7

15 Basic Long Block Engines D11 Engines D12 Engines 01 / 12 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 8

16 Basic Long Block Engines D13 Engines D16 Engines 01 / 12 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 9

17 Basic Long Block Engines Engine Component Identification Valve Cover Upper Timing Cover Lower Timing Cover Drive Device Head Block Flywheel Housing Rear of Crankshaft 01 / 12 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 10

18 Basic Long Block Engines Engine Component Identification Upper Timing Cover Flywheel Housing Drive Device Lower Timing Cover Block Oil Pan Oil Cooler Cover Upper Timing Cover Flywheel Housing Lower Timing Cover 01 / 12 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 11

19 Basic Long Block Engines Engine Component Identification Rocker Arms Shaft Rocker Arms Exhaust Injector Intake Camshaft Tower Camshaft Camshaft Gear 01 / 12 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 12

20 Basic Long Block Engines HOLE IN BLOCK CRACKED BLOCK THROWN ROD 01 / 12 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 13

21 Basic Long Block Engines CRACKED PAN RAIL ATTEMPTED PAN RAIL REPAIR 01 / 12 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 14

22 Basic Long Block Engines Core Deductions DEDUCTION DESCRIPTION VALUE 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 09 / 13 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 15

23 Short Block Engines Section 4 Short Block Engines (Function Group 2105) CORE INSTRUCTIONS The returned core must meet the following requirements: The block must have no visible cracks or holes. The unit must be complete and assembled. Core is not damaged by non-operational causes such as rust, rough handling or fire. Return Packaging Pack 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 Charges The returned core must be clean from grime and oil. If the procedure is not followed, a cleaning charge will be applied to your account. DEDUCTION DESCRIPTION VALUE Engine Crankshaft (Broken) $1,200 Engine Cylinder Block - Cracked or Broken. $2,000 Engine - Disassembled Cores 50% of Core Value Engine - Improperly Drained of Oil and / or Antifreeze $300 Engine - Cores Damaged Beyond Repair Scrap Engine - All Other Missing or Damaged Items Dealer Net 03 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 16

24 Cylinder Heads Section 5 - All Cylinder Heads (Function Group 2111) 11L, 12L, 13L and 16L (Slab type) Any Style Cylinder Head other than Slab Type 08 / 11 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 17

25 Slab Type Cylinder Heads Slab Type Cylinder Head Indentification D11 D12 D13 D16 08 / 11 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 18

26 Slab Type Cylinder Heads Slab Type Cylinder Head Parts Indentification Cam Tower Spring Valve Rotator 08 / 11 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 19

27 Slab Type Cylinder Heads 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. Head Type Minimum Thickness D11, D12, D13, D *If your cylinder head has been previously remanufactured by VOLVO Reman the minimum thickness requirement will be waived and accepted for full credit. 04 / 16 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 20

28 Slab Type Cylinder Heads Two Examples of Acceptable Volvo Slab Cylinder Heads with Minor Deck Damage Minor pitting to the deck surface consists of small areas of slight damage Two Examples of a $500 Deduction on Volvo Slab Cylinder Heads with Major Deck Damage Major pitting to the deck surface consists of excessive damage over large areas See deduction page (23) Imprint from a broken valve stem 08 / 11 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 21

29 Slab Type Cylinder Heads Example of a SCRAP Volvo Slab Cylinder Head with a hole in the combustion surface Damage resulting in a hole through combustion surface renders CYLINDER HEAD scrap. (All heads) Example of a SCRAP Volvo Slab Cylinder Head with a cracked cam rail 08 / 11 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 22

30 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) Slab Type Cylinder Heads SLAB CYLINDER HEAD 11L, 12L, 13L, 16L DEDUCTIONS Springs Missing or Damaged (Each) $6 Valves Missing or Damaged (Each) $25 Cam Tower (Slab Heads) Missing / Damaged Tower $200 Cracks Between Counterbore & Injector Sleeve Scrap Under Minimum Head Thickness Dimension (Non-Volvo Reman) Scrap Major Deck Damage (Slab Heads) $500 Hole Through Combustion Surface Scrap Cracked Cam Rail (Slab Heads) Scrap Damaged by Non-Operational Causes Scrap Disassembled Core 50% ALL CYLINDER HEADS OTHER THAN SLAB TYPE (LEGACY) Damaged by Non-operational Causes (Rust, Rough Handling, Fire) Scrap Disassembled Core Scrap Broken Casted Features Scrap Major Deck Damage Scrap Hole Through Combustion Surface Scrap Cracks Between Counterbore & Injector Sleeve Scrap 01 / 17 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 23

31 Injector Rocker Arm Section 6 Injector Rocker Arm (Function Groups 2145 & 2371) CORE INSTRUCTIONS The returned core must meet the following requirements: Core is not damaged by non-operational causes such as rust, rough handling or fire. Core must have no visible cracks. 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 24

32 Crankshafts Section 7 Crankshafts (Function Group 2161) NOTE: Rod bearings, main bearings and thrust washers are included. CORE INSTRUCTIONS The returned core must meet the following requirements: 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. Core is not damaged by non-operational causes such as rust, rough handling or fire. 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 25

33 Injection Pumps / Unit Injector Section 8 Injection Pumps / Unit Injector (Function Group 2361) CORE INSTRUCTIONS The returned core must meet the following requirements: It is complete and assembled. Core is not damaged by non-operational causes such as rust, rough handling or fire. 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 26

34 Injectors Section 9 Injectors (Function Group 2371 & 2374) CORE INSTRUCTIONS The returned core must meet the following requirements: The unit must be complete. Core is not damaged by non-operational causes such as rust, rough handling or fire. 01 / 17 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 27

35 Turbo Chargers Section 10 Turbo Chargers (Function Group 2551) CLICK HERE TO RETURN TO TABLE OF CONTENTS. 08 / 11 Page 28

36 Turbo Chargers Complete VGT Turbo: Full Core Credit Band Clamps Speed Sensor Actuator / SRA 08 / 11 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 29

37 Turbo Chargers Incomplete VGT Turbo: Missing or damaged Speed Sensor Missing or damaged Actuator / SRA Missing Speed Sensor Missing Actuator / SRA Missing name plate is acceptable IF unit can be identified as a genuine core. 08 / 11 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 30

38 Turbo Chargers Complete Waste Gate Turbo Waste Gate: deduction if missing CLICK HERE TO RETURN TO TABLE OF CONTENTS. 08 / 11 Page 31

39 Turbo Chargers 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 DESCRIPTION DEDUCTION VALUE Missing Band Clamps $40 each Missing or damaged Speed Sensor (when applicable) $45 Missing or damaged Actuator / SRA (when applicable) $75 Missing nameplate and non-branded Scrap Missing or damaged Waste Gate Assembly (when applicable) $75 Broken propeller / Broken Shaft No Deduction Cracked or Broken Housings Scrap 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. 1. Check for Volvo stamped into the housing 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 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 32

40 Water Pumps / Coolant Pump / Bearing Housing Section 11 Water Pumps / Coolant Pump / Bearing Housing (Function Group 2621) CORE INSTRUCTIONS The returned core must meet the following requirements: Core is not damaged by non-operational causes such as rust, rough handling or fire. It is complete and assembled with pulleys and drive. It shows no visible cracks. It must be drained of fluid. CLICK HERE TO RETURN TO TABLE OF CONTENTS. 02 / 10 Page 33

41 Water Pumps / Coolant Pump / Bearing Housing WATER PUMP MARKINGS TYPE 1 TYPE 2 F4, FL4, B10R 3 CONNECTIONS IN DIFFERENT DIRECTIONS SPECIAL MODELS WITH GEAR DRIVE WITH V-SHAPED CONNECTION D12 / D12A / D12B F16, FH16 BEARING HOUSING D SERIES BEARING HOUSING 07 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 34

42 Thermostat / Viscous Fans Section 12 Thermostat / Viscous Fans (Function Group 2631) CORE INSTRUCTIONS The returned core must meet the following requirements: Core is not damaged by non-operational causes such as rust, rough handling or fire. 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 35

43 Control Units Section 13 Control Units (Function Group 2841) CORE INSTRUCTIONS The returned core must meet the following requirements: Core is not damaged by non-operational causes such as rust, rough handling or fire. It is complete and assembled. 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 36

44 Alternators Section 14 Alternators (Function Group 3211) CORE INSTRUCTIONS The returned core must meet the following requirements: Core is not damaged by non-operational causes such as rust, rough handling or fire. It is complete and assembled. 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 37

45 Starter Motors Section 15 Starter Motors (Function Group 3311) CORE INSTRUCTIONS The returned core must meet the following requirements: Core is not damaged by non-operational causes such as rust, rough handling or fire. It is complete and assembled. 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 38

46 Clutch Kits 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. Core is not damaged by non-operational causes such as rust, rough handling or fire CLUTCH KIT KIT CORE NUMBER Front Disc Core Rear Disc Core Exchange Clutch Core CLUTCH KIT KIT CORE NUMBER Release Bearing Core Exchange Clutch Core 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 39

47 Clutch Cylinder / Clutch Actuator Section 17 Clutch Cylinder / Actuator / Slave Cylinder (Function Group 4139) CORE INSTRUCTIONS The returned core must meet the following guidelines: It must be complete and assembled. Core is not damaged by non-operational causes such as rust, rough handling or fire. 07 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 40

48 Pressure Plates Section 18 Pressure Plates (Function Group 4112) CORE INSTRUCTIONS The returned core must meet the following requirements: It must be complete and assembled. Core is not damaged by non-operational causes such as rust, rough handling or fire. There must be no cracks in the plate or housing. 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 41

49 Clutch Discs / Driven Plates Section 19 Clutch Discs / Driven Plates (Function Group 4117) CORE INSTRUCTIONS The returned core must meet the following requirements: 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. Core is not damaged by non-operational causes such as rust, rough handling or fire. 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 42

50 Transmissions / Gear Boxes Section 20 Transmissions / Gear Boxes (Function Group 4311) Mechanical CORE INSTRUCTIONS The returned core must meet the following requirements: It must be cleaned, complete and assembled. Core is not damaged by non-operational causes such as rust, rough handling or fire. 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 Packaging The 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 debited to your account. Cleaning Charges The returned core must be clean from grime and oil. If the procedure is not followed, a cleaning charge will be applied. 02 / 11 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 43

51 Transmissions / Gear Boxes Auto-Mechanical / I-SHIFT Oil Filter Housing and Filter included Volvo Reman I-Shift Complete Top Cover Assembly with Electronic Control Module included Clutch Control Actuator (CCA) included Solenoid, Harness and Lines included Volvo Reman I-Shift Basic Oil Filter Housing and Filter included No Top Cover Assembly with Electronic Control Module included No Clutch Control Actuator (CCA) included No Solenoid, Harness and Lines included Oil Filter Housing and Filter included No Range Assembly included Volvo Reman I-Shift Short No Top Cover Assembly with Electronic Control Module included No Clutch Control Actuator (CCA) included No Solenoid, Harness and Lines included 12 / 12 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 44

52 Transmissions / Gear Boxes 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 Transmissions to avoid deductions Plastic bonnet must be installed for core return on Short Transmission to avoid deducations CLICK HERE TO RETURN TO TABLE OF CONTENTS. 05 / 13 Page 45

53 Transmissions / Gear Boxes CORE PART NUMBER GROUPING - CORES WITHIN GROUP ARE INTERCHANGEABLE COMPLETE TRANSMISSIONS MODEL AT2512C GROUP # AMT MODEL ATO2512C GROUP # AMT MODEL ATO3112C GROUP # AMT MODEL AT2612D GROUP # AMT MODEL ATO2612D GROUP # AMT MODEL ATO3112D STD OR HD GROUP # AMT BASIC TRANSMISSIONS MODEL AT2612D GROUP # AMT MODEL ATO2612D GROUP # AMT STAND ALONE SHORT TRANSMISSIONS MODEL AT2612D GROUP # AMT MODEL ATO2612D GROUP # AMT STAND ALONE HD COMPLETE TRANSMISSIONS MODEL AT2612D GROUP # AMT 001 HD MODEL ATO2612D GROUP # AMT 002 HD HD BASIC TRANSMISSIONS MODEL AT2612D HD GROUP # AMT 010 HD MODEL ATO2612D HD GROUP # AMT 011 HD MODEL ATO3112D STD OR HD GROUP # AMT 012 HD HD SHORT TRANSMISSIONS MODEL AT2612D HD GROUP # AMT 016 HD MODEL ATO2612D HD GROUP # AMT 017 HD MODEL ATO3112D STD OR HD GROUP # AMT 015 HD / 17 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 46

54 Transmissions / Gear Boxes CORE DEDUCTIONS DEDUCTION DESCRIPTION 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) $0 Broken, Cracked or Missing Bell Housing $600 Broken, Cracked or Missing Main Case $1000 Broken, Cracked or Missing Range Housing ( Complete and Basic only) $1000 Broken, Cracked or Missing Top Cover Assembly (TCU) $2500 Improperly Drained Transmission $300 Failure to Return with shipping covers (Basic and Short only) $50 ea. Excessively Soiled or Rusty Core Minimum $50 Disassembled Core ½ Core Charge Fire Damage Scrap All Other Missing or Damaged Items Dealer Net Returns 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. 01 / 17 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 46-1

55 Range Housing Kit (Function Group 4312) Ring Gear Engaging Ring Engaging Ring (Drum/Hub) Synchronizer Ring CORE INSTRUCTIONS The returned core must meet the following requirements: Kit must be returned with all 4 pieces shown (Ring Gear, Engaging Rings and Synchronizer Ring) in the picture above to receive credit DESCRIPTION DEDUCTION VALUE 1 or more missing parts 100% 07 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 46-1

56 Air Compressors Section 21 Air Compressors (Function Group 5611) CORE INSTRUCTIONS The returned core must meet the following requirements: It must be complete and assembled. The crankshaft is not broken. (It can be turned.) The housing has no visible cracks or holes. Core is not damaged by non-operational causes such as rust, rough handling or fire. 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 47

57 Brake Chamber / Cylinders Section 22 Brake Chamber / Cylinders (Function Group 5641) CORE INSTRUCTIONS The returned core must meet the following requirements: It must be complete and assembled. Core is not damaged by non-operational causes such as rust, rough handling or fire. 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) 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 48

58 Steering Gears Section 23 Steering Gears (Function Group 6422) Nut CORE INSTRUCTIONS The returned core must meet the following requirements: It must be complete and assembled. 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. Core is not damaged by non-operational causes such as rust, rough handling or fire. 02 / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 49

59 Steering Pumps / Servo Pumps Section 24 Steering Pumps / Servo Pumps (Function Group 6453) CORE INSTRUCTIONS The returned core must meet the following requirements: It must be complete and assembled. Core is not damaged by non-operational causes such as rust, rough handling or fire. 03 / 14 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 50

60 Instrument Clusters Section 25 Instrument Clusters (Function Group 3811) CORE INSTRUCTIONS The returned core must meet the following requirements: 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. NEW # REMAN # / 10 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 51

61 Connecting Rods Section 26 Connecting Rods (Function Group 2164) 11L CONNECTING ROD D12 CONNECTING ROD 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 52

62 Connecting Rods 13L CONNECTING ROD 16L CONNECTING ROD 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 52-1

63 Connecting Rods Spun and damaged bores render CONNECTING ROD scrap. CONNECTING ROD AND CAP must match and seated with the bolts to be acceptable. 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. 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 53

64 Connecting Rods Bent connecting rods are unacceptable and no credit will be given for cores returned in this condition. Burned rods from excessive heat and excessively rusted rods are rendered scrap and unacceptable for credit. 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 54

65 Connecting Rods CORE INSTRUCTIONS The returned core must meet the following requirements: 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 # DESCRIPTION (NEW EXCHANGE) N/A L CONNECTING ROD D12 CONNECTING ROD (NEW EXCHANGE) N/A L CONNECTING ROD (NEW EXCHANGE) N/A L CONNECTING ROD (NEW EXCHANGE) N/A L CONNECTING ROD 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 55

66 Loaded Cylinder Kit Section 27 Loaded Cylinder Kit (Function Group 2131 / 2139) 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. LOADED CYLINDER KIT REMAN PART # CORE PART # DESCRIPTION D12C Loaded Cylinder Kit D12D Loaded Cylinder Kit D11 EPA 07/10 Loaded Cylinder Kit D13 EPA 07 Loaded Cylinder Kit D13 EPA 10 Loaded Cylinder Kit D16 EPA 04/07 Loaded Cylinder Kit D16 EPA 10 Loaded Cylinder Kit 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 ***Please see Connecting Rods section for further damage criteria (D12D single loaded cylinder pictured) 01 / 16 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 55-1

67 Loaded Cylinder Overhaul Kit Section 28 Loaded Cylinder Overhaul Kit (Function Group 2131 / 2139) 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. LOADED CYLINDER OVERHAUL KIT REMAN PART # CORE PART # DESCRIPTION D12C Loaded Cylinder Overhaul Kit D12D Loaded Cylinder Overhaul Kit D11 EPA 07/10 Loaded Cylinder Overhaul Kit D13 EPA 07 Loaded Cylinder Overhaul Kit D13 EPA 10 Loaded Cylinder Overhaul Kit D16 EPA 04/07 Loaded Cylinder Overhaul Kit D16 EPA 10 Loaded Cylinder Overhaul Kit 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 ***Please see Connecting Rods section for further damage criteria 01 / 16 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 55-2

68 EGR Valve - Volvo D12 Series Engines Section 29 EGR Valves Volvo D12 Series Engines CORE INSTRUCTIONS Criteria applies to all EGR Valves: Unit must be complete. Cut or spliced harnesses are acceptable. Core is not damaged by non-operational causes such as rust, rough handling or fire. NOTE: Only the valve assemblies need to be returned. Do not return piping and clamping. ACCEPTABLE 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 56

69 EGR Valve - Volvo D12 Series Engines NOT ACCEPTABLE DO NOT RETURN PIPING AND CLAMPING DEDUCTIONS DESCRIPTION DEDUCTION VALUE NON GENUINE $ / 16 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 57

70 EGR Coolers Section 30 EGR Cooler 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 58

71 EGR Coolers D-12D US04 Coolant Ports Exhaust Ports Coolant Bleed Screw Housing Mounting Tab CLICK HERE TO RETURN TO TABLE OF CONTENTS. 12 / 11 Page 59

72 EGR Coolers Housing Protective plugs shipped on Dex Part # DEX CLICK HERE TO RETURN TO TABLE OF CONTENTS. 12 / 11 Page 60

73 EGR Coolers D-16D US04 Exhaust Port Coolant Port Exhaust Port Mounting Bolts Coolant Bleed Screw Mounting Brackets Coolant Port Protective plugs shipped on Dex Part # DEX CLICK HERE TO RETURN TO TABLE OF CONTENTS. 12 / 11 Page 61

74 EGR Coolers D-11, D-13, D-16 US07 US10 Coolant Ports Mounting Pin Exhaust Ports Coolant Bleed Screw Housing Compression Pads CLICK HERE TO RETURN TO TABLE OF CONTENTS. 12 / 11 Page 62

75 EGR Coolers Protective plugs shipped on new and Dex parts Extra protective plug included on DEX part #s DEX, DEX, DEX Protective plugs shipped on new and Dex parts Broken weld on coolant port CLICK HERE TO RETURN TO TABLE OF CONTENTS. 12 / 11 Page 63

76 EGR Coolers Examples of unacceptable cores: Bent / Damaged Exhaust Port Bent / Damaged Coolant Port 12 / 11 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 64

77 EGR Coolers Examples of unacceptable cores: Bent / Damaged Coolant Port APPROXIMATE WEIGHT Note: Weight may vary based on usage. D-11 Shipping weight with box-37lbs D-12 Shipping weight with box-19lbs without housing, 26lbs with housing attached D-13 Shipping weight with box-40lbs D-16 Shipping weight with box-43lbs 08 / 16 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 65

78 EGR Coolers The returned core must meet the following guidelines: 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. Note: Do not return piping or clamping hardware. DESCRIPTION Missing Compression Pads. (except D12D) Unacceptable - Bent or Damaged Exhaust Ports. Unacceptable - Bent or Damaged Coolant Ports. DEDUCTION VALUE $25 each REJECTED REJECTED 12 / 16 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 66

79 Diesel Oxidation Catalyst Section 31 Diesel Oxidation Catalyst Component Indentification Diesel Oxidation Catalyst (DOC) CORE CRITERIA Core is not damaged by non-operational causes such as rust, rough handling or fire. 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. 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 67

80 Complete DPF & Filters Section 32 Complete DPF & Filters DPF FILTER 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. 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 68

81 Complete DPF & Filters Section 32 Acceptable Clean and Return DPF Filters 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. 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 69

82 Complete DPF & Filters 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. 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 70

83 Complete DPF & Filters Section 32 Acceptable Clean and Return DPF Filters Soot on Inlet. Even coating of soot. Soot on Inlet. Variations of soot on surface. Clean on Outlet. No signs of soot on outlet. Oil on Outlet. Staining due to oil passing thru DPF. Oil is wet. 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 71

84 Complete DPF & Filters Section 32 Scrap Clean and Return DPF Filters 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. 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 72

85 Complete DPF & Filters Section 32 Scrap Clean and Return DPF Filters Ceramic Pushed out of Can. Ceramic is driven out of canning due to extremely high back 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. 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 73

86 Complete DPF & Filters Section 32 Scrap Clean and Return DPF Filters 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. 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 74

87 DEF Pump Section 33 DEF Pump 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 75

88 DEF Pump Mounting Points Mounting Points Mounting Points 02 / 12 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 76

89 DEF Pump Caps Caps 04 / 16 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 77

90 DEF Pump APPROXIMATE WEIGHT Note: Weight may vary based on usage. Shipping weight -8.5 lbs CORE CRITERIA Core is not damaged by non-operational causes such as rust, rough handling or fire. 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. DEDUCTION DESCRIPTION Broken Mounting Points Improper Packaging DEDUCTION VALUE ½ of Core Charge ½ of Core Charge 04 / 16 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 78

91 Driving Device Section 34 Driving Device (Function Group 2159) CORE CRITERIA Core is not damaged by non-operational causes such as rust, rough handling or fire. The core must be returned in the original packaging. DESCRIPTION DEDUCTION VALUE Missing or Damaged Hub $30.00 Missing or Damaged Gear $30.00 Disassembled Core ½ of Core Charge APPROXIMATE WEIGHT Note: Weight may vary based on usage. Shipping weight lbs. NEW PART # REMAN PART # CORE PART # CORE VALUE $150 CLICK HERE TO RETURN TO TABLE OF CONTENTS. 10 / 15 Page 79

92 Radiators Section 35 Radiators (Function Group 2611) CORE INSTRUCTIONS The returned core must meet the following requirements: Core is not damaged by non-operational causes such as rust, rough handling or fire. 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. CLICK HERE TO RETURN TO TABLE OF CONTENTS. 10 / 15 Page 80

93 Actuators Section 36 Actuators (Function Group 2559) CORE INSTRUCTIONS The returned core must meet the following requirements: Core is not damaged by non-operational causes such as rust, rough handling, fire, improper removal or improper protection while storing. Core must be complete and assembled. Casting is not visibly cracked or damaged. CLICK HERE TO RETURN TO TABLE OF CONTENTS. 10 / 15 Page 81

94 Radios Section 37 Radios (Function Group 3981) CORE INSTRUCTIONS The returned core must meet the following requirements: Core is not damaged by non-operational causes such as rust, rough handling or fire. Core must be complete and assembled. Core must be returned in the original shipping box. CLICK HERE TO RETURN TO TABLE OF CONTENTS. 10 / 15 Page 82

95 Oil Pumps Volvo D12 Series Engines Section 38 Oil Pumps Volvo D12 Series Engines (Function Group 2211) CORE INSTRUCTIONS Criteria applies to all D Series Oil Pumps: Unit must be complete. No visable cracks or damage to Housing. No visable damage to mating gears. Core is not damaged by non-operational causes such as rust, rough handling or fire. 10 / 15 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 83

96 Flywheels Section 39 Flywheels (Function Group 2166) 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. DESCRIPTION Core is damaged by non-operational causes such as rust, rought handling or fire 16L twin mass flywheel is not an acceptable core DEDUCTION Rejected Rejected 08 / 17 CLICK HERE TO RETURN TO TABLE OF CONTENTS. Page 84