Volvo D11F Operator'S Manual And Maintenance Instructions Download Page 108

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104

Maintenance and Service

Lubrication Chart Notes

Spring hanger:

Use a lithium-based grease with specification API NLGI

No. 2. When lubricating the

left

and

right

sides of the

front

springs, lift

the axle off of the floor, suspend the frame with axle stands and lower the
axle. The spring bushings are now in the position where grease can be
added to the contact surfaces.

Slack adjuster and brake cam:

Use a lithium-based grease with EP

additives to specification API NLGI No. 2.

If the brake cam seal does not purge, make sure the inner seal does not purge
into the brake drum and onto the brake linings.

Steering gear:

Use a lithium-based grease with specification API NLGI

No. 2. Only use a hand-operated grease gun. The high pressure from an
air-operated grease gun will damage the seal.

Grease

Automatic Transmission
Fluid

Hub Oil

Manual Transmission Oil

Engine Oil

Rear Axle Oil

Steering Fluid

Brake Fluid

Auxiliary Axle(s)

Coolant

Hydraulic Oil

Windshield Washer Fluid

USA22978.bk.book Page 104 Wednesday, July 9, 2008 9:09 AM

Summary of Contents for D11F

Page 1: ...Volvo Trucks Driving Success R OPERATOR S MANUAL VEHICLE MAINTENANCE VN VHD Volvo d11fand d13f engines ...

Page 2: ......

Page 3: ... Engine Overview D11F and D13F Right Side View 40 Engine Storage 41 Engine Storage 41 Maintenance and Service 42 Maintenance Hazards 42 Engine Components Service Schedules 43 Cooling System 44 Fuel System 49 Engine Oil 57 Engine Air Filter 63 Diesel Particulate Filters If Equipped 65 Fan and Auxiliary Drive Belts 66 Turbocharger and Charge Air Cooler 68 Fuel System Service 70 Transmission Clutch a...

Page 4: ...ervice Check List 111 Preventive Maintenance 112 Service Charts 115 Scheduled Services 116 Repair Record 118 Tire Record 119 Fuel and Oil Record 120 Literature 121 Engine Data 121 Service Assistance and Manuals 122 Index 123 ...

Page 5: ...mer The service information contained in this manual gives the owner important information about maintaining the vehicle but is not intended as a substitute for the Preventive Maintenance Service Manual and must not be regarded as such The National Highway Traffic Safety Administration NHTSA and Volvo Trucks North America should be informed immediately if you believe that the vehicle has a defect ...

Page 6: ...ld result in serious personal injury or death The danger label is in white type on a black background with a black border A warning label directs the operator s attention to unsafe practices which could result in personal injury or severe damage to the vehicle The warning label is in black type on a gray background with a black border A caution label directs the operator s attention to unsafe prac...

Page 7: ...mation in this manual refers to Volvo components and Volvo drivetrain There is also certain information regarding the Cummins engine For detailed information on the Cummins engine or non Volvo engines and or drivetrains contact your nearest Volvo Truck dealer Establish a Preventive Maintenance Program with the help of your local Volvo Truck dealer A Preventive Maintenance Program makes it possible...

Page 8: ...n advice and instructions which will enable you to get the operating economy and performance that you expect from this quality vehicle All information illustrations and specifications contained in this manual are based upon the latest product information available at the time of publication If any questions arise concerning the current status of Federal or state laws the appropriate Federal or sta...

Page 9: ...anufacturer or dealer may take such action after sale and delivery of the vehicle to the ultimate purchaser The law provides a penalty of up to 10 000 for each violation Canada The same conditions that apply in the USA apply to Canada with one exception After the vehicle is sold to a retail customer that is the end user the jurisdiction controlling the emission control devices becomes the province...

Page 10: ...ncluding diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE If an emission related part of your engine is defective the part will be repaired or replaced by Volvo Trucks North America This is your emission control system DEFECTS WARRANTY OWNER S WARRANTY RESPONSIBILITIES As the motor vehicle engine owner you are responsible for the performance of the required maintenance listed in this man...

Page 11: ...rucks North America dealership there will be no charge for labor Volvo Trucks North America s obligation under this warranty is limited to the repair or replacement at Volvo Trucks North America s option of any part s of the Emission Control Systems of such engine and or vehicle found to be defective upon examination by Volvo Trucks North America and provided that such part s were returned to Volv...

Page 12: ...Electronic Control Module g EGR Mixer h EGR Cooler i EGR Control Valve j Crankcase Breather k Diesel Particulate Filter DPF Assembly l DPF Components 앫 Aftertreatment Fuel Injector AFI 앫 AFI Shutoff Valve 앫 Discharge Recirculation Valve 앫 Pre Catalyst Temp Sensor 앫 Post Catalyst Temp Sensor 앫 Downstream DPF Temp Sensor 앫 Differential Pressure Sensor m Sensors 앫 Engine Timing Speed flywheel 앫 Engin...

Page 13: ...y authorized VOLVO repair facility at his place of business with no charge for parts and labor including diagnosis using VOLVO parts for any part of the emission control systems covered by this warranty and found defective 2 In an Emergency In an emergency where an authorized VOLVO facility is not available repairs may be performed at any available service establishment or by the owner using any r...

Page 14: ...ct to parts other than VOLVO parts however the use of non VOLVO parts does not invalidate the warranty on other components unless non VOLVO parts cause damage to warranted parts 5 Maintenance and Maintenance Records The vehicle owner is responsible for the performance of all required maintenance specified in this manual VOLVO will not deny a warranty claim solely because there is no record of main...

Page 15: ...eve they are entitled under the California Emission Control Systems Warranty they should contact Volvo Trucks North America Warranty Administration 336 393 2000 The address and telephone number of each Regional Office is in your vehicle owner s package Owners in need of additional assistance or information concerning the California Emission Control Systems Warranty may also contact Volvo Trucks No...

Page 16: ...TEMS SERVICE RECORD DATE KM MILES SERVICE PERFORMED SERVICED BY __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ ...

Page 17: ...ty is limited to the repair or replacement at Volvo Trucks North America s option of any part s of the Emission Control Systems of such engine and or vehicle found to be defective upon examination by Volvo Trucks North America and provided that such part s were returned to Volvo Trucks North America or its nearest authorized Dealer within a reasonable period of time Qualifications and Limitations ...

Page 18: ... Harness f Electronic Control Module g EGR Mixer h EGR Cooler i EGR Control Valve j Crankcase Breather k Diesel Particulate Filter DPF Assembly l DPF Components 앫 Aftertreatment Fuel Injector AFI 앫 AFI Shutoff Valve 앫 Discharge Recirculation Valve 앫 Pre Catalyst Temp Sensor 앫 Post Catalyst Temp Sensor 앫 Downstream DPF Temp Sensor 앫 Differential Pressure Sensor m Sensors 앫 Engine Timing Speed flywh...

Page 19: ...se of the vehicle or engine by the ultimate purchaser as may be reasonable and necessary to assure the proper functioning of emission control devices and systems This section also covers the requirements of the emissions regulations promulgated under the Motor Vehicle Safety Act in Canada TAMPERING WITH GASEOUS EMISSION CONTROL SYSTEMS PROHIBITED The Federal Clean Air Act prohibits the removal or ...

Page 20: ...for the life of the vehicle Noise Control System Operator Inspection and Maintenance Requirements A Noise Control System Maintenance Log is located in this manual This log should be used to document all Noise Control System related maintenance whether the maintenance results from a specific noise control system inspection or a deficiency identified during another general maintenance event If addit...

Page 21: ...oling fan system 앫 Removal of the cooling fan shroud 앫 Removal or rendering inoperative of the air cleaner or air intake in line silencer 앫 Removal of the sound deadening material from the hood or cab tunnel 앫 Removal or rendering inoperative of the engine speed governor so as to allow engine speed to exceed the manufacturer s specifications 앫 Removal of splash shields located inside the wheel hou...

Page 22: ...ngage at any time without warning Anyone near the fan when it turns on could be seriously injured Maintenance Visually inspect cooling system components for damage and or misalignment Primary system components requiring noise related inspection include fan blades fan clutch fan shroud fan ring and recirculation shields Check fan blades fan ring fan shroud belt tensioner and recirculation shields f...

Page 23: ...ring with the Exhaust System Removing or rendering inoperative exhaust system components such as the pipes clamps etc Air Intake Air Induction System Maintenance Make sure the air intake system is intact Inspect components for damage misalignment and or leakage Primary system components requiring noise related inspection include the air cleaner housing air cleaner element turbocharger charge air c...

Page 24: ...ive or modifying the engine control system such as the ECU EGR system components or fuel system components in order to allow the engine to operate outside of the manufacturer s specifications is not allowed and violates both warranty and legislation Noise Control Log NOISE CONTROL SYSTEM MAINTENANCE LOG DATE MILEAGE MAINTENANCE PERFORMED MAINTENANCE FACILITY ...

Page 25: ...d VHD Similar 1 Transmission Type and Gear Pattern This information is located in the visor 2 VIN GAWR Located in the door frame B pillar 3 VIN Major Components Located in the door frame B pillar 4 Vehicle Noise Emission Located in the door frame B pillar ...

Page 26: ...nd circuit breakers with the same current amperage Increasing fuse or circuit breaker rating may result in electrical circuit overheating and possible fire On sleeper models equipped with fluorescent lighting there is a 3 AMP maximum fuse located in the lighting fixture ...

Page 27: ...d The vehicle has an electrical center located in the middle of the dash under the top cover Since the function of some fuses or relays may change for the vehicle application refer to the list of functions that is attached beneath each panel VN Fuse and Relay Center VHD Fuse and Relay Center ...

Page 28: ... Hydrocarbon vapors can enter the air intake and over speed the engine causing severe engine damage and or an explosion and fire Serious personal injury or death could occur Never try to operate or work on this vehicle while under the influence of alcohol Your reflexes can be affected by even a small amount of alcohol Drinking and operating this vehicle can lead to an accident causing serious pers...

Page 29: ... are in place and properly secured 앫 Never put maintenance fluids into glass containers since glass containers can break 앫 Report all problems in a timely manner before they threaten the safety of operating the vehicle 앫 DO NOT work on the engine while it is running 앫 Make sure protective locks and covers are in their proper place 앫 DO NOT use high amperage electronic starting devices for jump sta...

Page 30: ...s free Volvo recommends the use of only genuine Volvo spare parts Never use any parts that contain or are thought to contain asbestos Exposure to asbestos fibers can create serious health risks including death Fluid Penetration Always use a piece of paper or cardboard when checking for a leak Escaping fluid under high pressure even a pin hole sized leak can penetrate body tissue causing serious in...

Page 31: ...ng fluid and steam may be blown out under pressure if the cap is taken off too soon which can cause personal injury and damage to engine components DO NOT touch any part of the engine while it is hot Allow the engine to cool before any repair or maintenance is performed on the engine Relieve all pressure in air oil fuel or cooling systems before any lines fittings or related items are disconnected...

Page 32: ...r cap slowly to relieve pressure Oils Hot engine Keep yourself clear of all hot engine parts and or fluids A hot engine and or fluid can cause serious burns Hot oil can cause severe burns DO NOT allow hot oil to contact the skin When changing oil wear protective gloves Batteries Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid...

Page 33: ...res The operator of this vehicle is urged to check the tires of the vehicle to determine if there are any limitations Fire or Explosion Prevention The diesel engine will operate on any fuel which enters the cylinder whether it is from the injectors or from the air intake system Therefore if any solvent is used to flush out the air cleaner element the engine may over speed during start up Engine da...

Page 34: ... the engine and bodily injury or property damage Make provisions for shutting off the engine intake air or fuel supply to stop the engine if there is an over speed on start up after performing repair or maintenance on it Contact your nearest Volvo Truck dealer for any necessary air conditioning testing or repairs All fuels most lubricants and some coolant mixtures are flammable Diesel fuel is flam...

Page 35: ...ederal and local regulations Oil and fuel filters should be properly installed and housing covers tightened to the proper torque when being changed Starting Aids DO NOT use ether or other combustible starting aids on any engine equipped with a preheater If the engine is equipped with a preheater introduction of ether or similar starting aids could cause a fire or explosion resulting in severe prop...

Page 36: ...death Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm Always work in a well ventilated space if the engine needs to be running and use a hose to route the exhaust to the outside Poisonous Substances Coolant is toxic risk of poisoning DO NOT drink coolant Use proper hand protection when handling Keep c...

Page 37: ...ny time without warning Anyone near the fan when it turns on could be seriously injured Never attempt adjustments or repairs while the engine is running see your authorized Volvo Truck dealer Inspect the fan blade assembly before service for cracks or loose mounting before starting the engine Never stand alongside a rotating fan assembly particularly at high fan speeds Wear protective glasses when...

Page 38: ...roper entry and exit procedures Always use a three point stance two hands and one foot or one hand and two feet whenever climbing up or down ENGINE DAMAGE PREVENTION Before Starting the Engine Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or d...

Page 39: ... and if in an enclosed area vent the exhaust to the outside Start the engine only from the driver seat in the cab Never start the engine by shorting across the starter motor terminals or batteries to start the engine as this could bypass the engine neutral start system as well as damage the electrical and electronic system Always start the engine according to the required engine starting procedure...

Page 40: ...r frayed wires Have all loose or frayed electrical wires tightened repaired or replaced before operating the vehicle Grounding Practices Proper grounding for vehicle and engine electrical and electronic systems is necessary for proper vehicle and engine performance and reliability Improper grounding will result in uncontrolled and unreliable electrical paths Uncontrolled engine electrical circuit ...

Page 41: ... electronic system when charging the batteries jump starting or performing electric welding on the vehicle See the vehicle Operator s Manual for correct procedures This engine is equipped with monitoring features that may cause reduced power or shutdown under certain conditions The power output monitoring and idling features can only be programmed and or changed with electronic service tools and p...

Page 42: ...t Investigations and Recalls may telephone the toll free hotline 1 800 333 0510 within Canada only or call 1 613 993 9851 from Ottawa region or outside Canada Contact Transport Canada by mail at Transport Canada ASFAD Place de Ville Tower C 330 Sparks Street Ottawa ON K1A 0N5 For additional road safety information please visit the Road Safety website at http www tc gc ca roadsafety menu htm Mexico...

Page 43: ...milar 1 Breather Tube 2 Intake Manifold 3 Air Compressor 4 Power Steering Pump 5 Fuel Pump 6 Engine Electronic Control Unit EECU 7 Fuel Filter 8 Fuel Water Separator 9 Fuel Filter 10 Hand Priming Pump 11 Crankcase Ventilator 12 Alternator 13 AC Compressor 14 Alternator AC Compressor Belt 15 Fan Coolant Pump Belt 16 EGR Mixing Chamber ...

Page 44: ...Shown D11F Engine Similar ENGINE STORAGE 17 Exhaust Manifold 18 Valve Cover 19 Engine Pre Heater Element Optional 20 Thermostat Housing 21 Belt Tensioner 22 Coolant Pump 23 Coolant Filter 24 Venturi Pipe 25 Oil Filters 26 Oil Pan 27 EGR Cooler 28 Turbocharger 29 Starter Motor 30 EGR Valve ...

Page 45: ...uel 4 Run the engine for two minutes around 1000 rpm Shut the engine down DO NOT drain the oil after this run 5 Check the coolant for proper levels of antifreeze and inhibitor SCA protection Service as necessary 6 Seal all engine openings using protective covers To return to service an engine preserved in this manner remove previously installed protective covers Check all fluid levels and if neces...

Page 46: ...xpected vehicle movement and can cause serious personal injury or death DO NOT attempt to repair or service this vehicle without having sufficient training correct service literature and the proper tools Failure to follow this could lead to personal injury or death or making your vehicle unsafe Read all safety information before working on the vehicle Refer to Proper Maintenance Procedure on page ...

Page 47: ...pplemental Coolant Additive SCA 80 000 50 000 or 6 months Coolant Filter ELC US07 Change 240 000 150 000 15 2 500 Coolant Filter ELC Euro 4 Change No SCA requirement 240 000 150 000 or 12 months Valves Injectors All Engine Models Initial Adjust 200 000 125 000 12 2 500 Valves Injectors All Engine Models Adjust 400 000 250 000 24 5 000 Drive Belts VN Euro 4 Highway Change 500 000 300 000 or 36 mont...

Page 48: ...ressure if the cap is taken off too soon and can cause personal injury Coolant may be combustible Coolant leaked or spilled onto hot surfaces or electrical components can cause a fire Clean up coolant spills immediately Volvo Trucks North America does not recommend using plain water in the cooling system Water alone is corrosive at engine operating temperatures and does not provide adequate boilin...

Page 49: ...engine failures can be traced back to a problem in the cooling system If the coolant level is allowed to go below the bottom of the tank there is the risk of the engine shutting down See the operator s manual for more information on the warning functions Always dispose of coolant according to Federal or local regulations Take all used coolant to a recycling or waste collection center Coolant mixtu...

Page 50: ...free from bugs dirt leaves etc see Cleaning Charge Air Cooler and Radiator Package on page 68 for cleaning information Check the coolant level in the tank regularly Fill the tank as necessary with the correct coolant Inspection of the whole cooling system is important Check for swollen or deteriorated heater and radiator hoses loose hose clamps and connections and radiator leaks DO NOT work near t...

Page 51: ...h the coolant lifetime Regular Coolant Change Interval Replace the coolant every 400 000 km 250 000 miles 4 000 hours or every two years whichever comes first Coolant SCA level must be tested at least twice per year or whenever coolant loss occurs For maximum coolant system efficiency test the system at every engine oil change interval every 1 000 hours or every 6 months whichever comes first For ...

Page 52: ...itives SCA to extended life coolant Should the extended life coolant system become contaminated with regular coolant exceeding 10 of the system s total capacity or if SCA is added to extended life coolant drain the system and refill with new extended life coolant or regular coolant Extended Lift Coolant Filter Change Interval Hot engine Keep clear of all hot engine parts and fluids A hot engine an...

Page 53: ...T mix gasoline or alcohol with diesel oil fuel This mixture can cause an explosion and result in severe personal injury or death DO NOT remove the fuel tank cap near an open flame Diesel fumes are combustible and can cause an explosion or fire resulting in severe personal injury or death If a fuel leak is detected stop the engine immediately The vapors from hot fuel are highly flammable which may ...

Page 54: ...recommended by Volvo Trucks North America The proper selection of fuel is essential for good economy performance and engine life No 2D ULSD should be used when climatic conditions permit No 1D ULSD can be used during cold weather conditions Blends of No 1D and No 2D ULSD fuels can be used to suit various climatic conditions The use of lighter fuels grade No 1 D can reduce fuel economy Euro 4 Engin...

Page 55: ...rting conditions Fuel with a higher cetane value may be required for high altitude or cold weather operation Filtration Fuel should be clean and free of contamination Clean fuels should have no more than 0 05 of sediment and water Fuel Additives Fuel additives are generally not recommended or needed for fuels listed earlier Cetane improvers can be used as necessary Biocides may be needed to elimin...

Page 56: ... 앫 Emission control additives 앫 Detergents 앫 Combustion improvers 앫 Smoke suppressants 앫 Cold weather flow improvers Repair expenses resulting from malfunctions in the fuel system or with engine components when fuel enhancers have been used are not covered under warranty Some fuel additives can be used to provide temporary relief but they do not replace good fuel handling practices These products ...

Page 57: ...n the diesel fuel Used lubrication oil contains solids and acids from the combustion process that can severely corrode parts of the injection system resulting in reduced power and higher maintenance cost over time Alternative Fuels Alternative fuels can be of several different types There are vegetable based fuels aviation fuel and recycled petroleum based fuels that are used in combustion engines...

Page 58: ...ng filtering problems 앫 Keep the area around the fill cap clean Tilt the tank slightly toward the drain plug area so water and sediment can be easily drained Generally fuel contamination occurs as the result of improper fuel handling The most common types of contamination are water dirt and microbial growth black slime The formation of varnishes and gums resulting from poor fuel stability or long ...

Page 59: ...of a filter cartridge a water separation bowl and may have a fuel heater built in The secondary fuel filter is located on the left hand side below the engine electronic control unit EECU The filter is a spin on filter D11F and D13F Engine Mounted Fuel Filters D13F shown D11F similar 1 Secondary Fuel Filter 2 Primary Fuel Filter with Water Separator ...

Page 60: ... container Always dispose of fuel according to Federal or local regulations Take the drained fuel and water to a recycle or waste management center The filters are an important part of the fuel system Always replace the filters at the recommended intervals and use the recommended filter types for the best engine operation and service life Change the fuel filters at every oil change Drain the prima...

Page 61: ...and tighten or replace them as necessary ENGINE OIL General Keep the engine oil at the proper level and change it at the recommended intervals Always replace the oil filters at the same time as when the oil is changed Oil Quality Volvo Trucks North America recognizes engine oils that meet or exceed the standards given by American Petroleum Institute API for the oil classifications listed in this m...

Page 62: ...ls for more frequent oil changes For the correct oil change interval see Oil Capacity Tables and Viscosity Charts on page 108 For additional information about oil change intervals see your Volvo Truck dealer Also refer to Bulletin 175 60 Oil and Filters Volvo Components For a complete list of approved oils see your Volvo Truck dealer Also refer to Bulletin 175 61 Approved Oils Volvo Components Oil...

Page 63: ...mium Plus The use of synthetic oils does not permit the extension of the recommended oil change intervals Oil Viscosity The viscosity grade defines the thickness of the oil The oil must be thin enough at low temperatures for easy cold starts and thick enough to protect at high temperatures An oil is not fully defined until both the API quality classification and the viscosity grade are specified C...

Page 64: ...iquids are not necessary and may even harm the engine Using oils to the quality standards recommended in this manual makes the use of extra oil additives unnecessary as these oils already contain a balanced treatment of additives Oil Consumption Once the engine is stopped check the oil level daily If the engine has just been stopped and it is warm wait approximately five minutes to allow the oil t...

Page 65: ...se the proper tools and keep away as far as possible Raise the elbow so the forearm is parallel to the ground to prevent oil running down the arm causing burns Always dispose of all lubricants motor oil coolant gear box oils etc and filters according to Federal or local regulations Used oil disposed of in nature or waterways contaminates our drinking water and kills wildlife Prolonged contact with...

Page 66: ...t the same stringent requirements may cause unsatisfactory results 1 Coat the filter gasket with oil 2 Install the filter and turn it by hand until the gasket makes contact with the sealing surface 3 Manually turn the filter an additional 3 4 to one full turn Checking Oil Level DO NOT let the oil level fall below the marking on the dipstick DO NOT overfill so the level is above the upper marking o...

Page 67: ...filter is monitored by a pressure restriction gauge mounted on the air filter housing The gauge may be connected to the instrumentation to give a telltale signal when the air filter needs to be changed see the vehicle Operator s Manual A manual gauge needs to be inspected regularly Replace the filter according to the gauge or after a maximum of two years whichever comes first Optional extra filter...

Page 68: ...64 Maintenance and Service ...

Page 69: ...rticulate matter is collected by a filter where it is eventually oxidized using a regeneration process During the regeneration process the temperature of the exhaust will be elevated DO NOT park the vehicle with the exhaust outlet near flammable objects such as trees awnings etc that could be damaged by elevated exhaust temperatures When regeneration occurs an indicator lamp on the instrument pane...

Page 70: ...elf clear of all hot engine parts and or fluids A hot engine can cause serious burns All engine belts should be checked at each service point Inspect for cracked or frayed material All belts have automatic belt tensioners to keep the correct tension without adjustment Drive Belts ...

Page 71: ...Maintenance and Service 67 A drive belt routing label is located on the vehicle frame rail Drive Belt Routing Label Drive Belt Routing Label Location ...

Page 72: ...s to oil flow Check for unusual noise or vibration If any faults are detected do not operate the engine until the cause is determined and repaired Cleaning Charge Air Cooler and Radiator Package Always wear eye protection when cleaning radiator charge air cooler and condenser Failure to follow this recommendation may result in eye injury Periodically inspect the front of the radiator charge air co...

Page 73: ...ne from the back of the core Air pressure should not exceed 200 kPa 30 psi for radiator and charge air cooler cores The use of a fin comb is also a good tool to loosen bugs and dirt from the fins If dirt cannot be cleaned off with this procedure consult your Volvo Truck dealer Cleaning Charge Air Cooler and Radiator typical radiator shown Inspect the charge air cooler for cracks at every inspectio...

Page 74: ...eanliness when working in the fuel system If dirt is mixed in with the fuel after it is filtered it will cause damage to the injectors Dirt can also cause air leakages that rob the engine of power Failure to change the primary fuel filter at the recommended intervals could result in reduced power 1 Open the drain valve and drain off some fuel into a container Remove the filter cartridge together w...

Page 75: ...or example cleaning or replacing fuel filter elements 앫 The engine is new or rebuilt When priming the system movement of the primer pump should be as up and down as possible Avoid putting any side load on the pump or causing a binding condition Failure to follow these instructions could prematurely damage the primer When the fuel system is empty 200 or more pump strokes may be needed to properly p...

Page 76: ... the primer pump in an up and down pumping motion Avoid putting any side load on the pump or causing a binding condition 3 Lock the hand primer pump by retracting it into the housing and turning it clockwise 4 Start the engine and run it at an increased idle speed for approximately 5 minutes to remove any remaining air in the system 5 Check the fuel system for leaks ...

Page 77: ...n below is displayed in the status icon bar When the operator chooses draining and the engine fulfils the conditions for draining the icon shown below is displayed in the status icon bar TRANSMISSION CLUTCH AND REAR AXLE MAINTENANCE Transmission Always dispose of oil according to Federal or local regulations Used oil disposed of in nature or waterways contaminates our drinking water and kills wild...

Page 78: ...e consistently high change oil more often or install an oil cooler With lengthy or continuous driving at altitudes of more than 2 000 m 6 000 feet above sea level more frequent oil changes will be necessary Clutch Check the fluid level in the clutch fluid reservoir The fluid level should be between the level marks on the reservoir If fluid needs to be added use brake fluid DOT 4 1 Clutch Fluid Res...

Page 79: ...ion and maintenance of the driveshaft may be required Contact your local authorized Volvo Truck dealer Rear Axle Checking and Draining Differential Oil Check the oil level through the top plug The oil should be level with the hole Add oil if necessary Drain oil through the bottom plug Oil should be drained immediately after driving while it is still hot Also check the rear axle ventilation for blo...

Page 80: ...ith the front wheels pointing straight ahead turn the steering wheel until the front wheel starts moving Then turn the steering wheel the other way until the front wheel moves Play should not be more than 25 mm 1 inch at the rim of the steering wheel If the steering play is excessive check the steering linkage for looseness wear etc Make necessary repairs before driving the vehicle ...

Page 81: ...every 240 000 km 150 000 miles Change filter every year or more often if necessary If the fluid has darkened it indicates that the power steering system is running hotter than normal and the fluid is overheating Take the vehicle to a Volvo Truck dealer for troubleshooting the overheating and to have the fluid changed 1 Engine Oil Fill Tube 2 Engine Oil Dipstick 3 Power Steering Fluid Reservoir ...

Page 82: ...effort to correct excessive push rod stroke as this condition indicates that a problem exists with the automatic adjuster installation of the automatic slack adjuster or problems related to components of the foundation brakes These conditions will not be corrected by manually adjusting the automatic slack adjusters Manual adjustment of automatic slack adjusters is a dangerous practice that could r...

Page 83: ...e from air tanks by pulling the drain valve lanyard or pull cord The tanks should be checked for condensation fluid even if an automatic drain valve is installed It is very important that the air system is kept clean If sludge or oil is found in the drainage or an excessive amount of fluid is drained out of the tanks see your authorized Volvo Truck dealer Air Dryers Air dryers have a regeneration ...

Page 84: ...rotection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion Disconnecting battery cables when vehicle is equipped with power door locks will result in automatic locking of doors When using a pressure washer to clean the vehicle do not direct the spray at electrical components in the engine compartment such as the alternator starter and co...

Page 85: ...at every major inspection Replace worn cables Check battery terminals for cracks Battery Terminals When disconnecting battery terminals always disconnect the ground terminal first When reconnecting always connect the ground terminal last Disconnecting battery cables may result in a loss of preset radio controls radio programming and require refreshing Lighting Using incorrect bulbs or lamps may re...

Page 86: ...ous personal injury or death can occur DO NOT use oil or grease on studs or nuts The tightening torque is affected and can lead to incorrect clamping loads between the rim and hub This could lead to a loss of the wheel Loss of vehicle control and serious personal injury or death can occur DO NOT install regrooved retreaded or repaired tires on the steering axle s They could fail unexpectedly and c...

Page 87: ...t the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death Wheels must be serviced only by a qualified technician DO NOT do this work yourself Inflated tires on wheels contain compressed air and if suddenly released do so with an explosive force resulting in serious personal i...

Page 88: ...tightening only normal inspection of nut tightness is needed Check front and rear wheel nut tightness with a torque wrench All disc wheels for Volvo vehicles have a tightening torque of 610 Nm 450 lb ft Tighten the nuts in the correct sequence Inspect bolts and nuts for signs of wear or cracks Make sure that the bolts are not bent This tightening check is particularly important when rims or brake ...

Page 89: ...flexing resulting in increased heat leading to tire failure and vehicle accident Remove stones lodged in ribs or in between double mounted wheels Check the tire pressure and leak test the valve stems Measure the tread depth The depth should not be less than 4 8 mm 6 32 inch on front tires and not less than 1 6 mm 2 32 inch on drive tires Most premium steer tires start with 14 2 mm 18 32 inch tread...

Page 90: ... new or retreaded tires Dual mounted wheels should always be of the same type and diameter maximal diameter difference allowed is 6 mm 1 4 in Volvo Trucks North America is committed to repair procedure 642 RP 642 American Tire Association ATA and The Maintenance Council TMC Representatives from Volvo Trucks North America actively participated along with twenty two companies in developing recommend...

Page 91: ... Typical Wear Patterns Incorrect Air Pressure A Air pressure too high gives rapid wear in the middle B Air pressure too low gives rapid shoulder wear Incorrect Camber Incorrect camber gives abnormal wear on one half of the tire ...

Page 92: ...ng arm defect Dual Wheel Mounting A Excessive road camber different types of tire different circumference or off center loading give faster wear on one tire B Air pressure too low mismatched rims for the tire type and dimension excess flexing in tire wall or different types of tires in inner and outer tires gives contact wear ...

Page 93: ...alance A Caster angle B Imbalance Also rapidly wears the mechanical parts of steering linkage kingpin and wheel bearing Cuts in the Tire Tread A Cuts B Flaking cuts C Rubber flaking Cuts are due to poor roads air pressure too high or incorrect tire type ...

Page 94: ...90 Maintenance and Service Spot Wear Sudden braking locking brakes or out of round brake drums give spot wear Feathered Edges Normal occurrence on non driving wheels on good roads and high mileage ...

Page 95: ...Maintenance and Service 91 Cupping Cupping is a normal occurrence that depends on the tread pattern the higher the load the greater the wear ...

Page 96: ...loss of vehicle control and serious personal injury or death The front wheel hubs can be filled with one of several types of oil Motor oil should be SAE 30 or 15W40 The oil can be either petroleum based or synthetic synthetic should not be used for the Volvo axle Axle oil API GL 5 SAE 75W 90 can also be used There are no set change intervals for hub lubrication The only requirement is that if the ...

Page 97: ...Maintenance and Service 93 Unitized Front Hubs The non tapered axle hubs are sealed with lubricant inside the hub and do not require lubrication Unitized Hubs Non Tapered Axle End ...

Page 98: ...94 Maintenance and Service Tapered Axle End ...

Page 99: ... are properly tightened The nuts may loosen up with time Severe roads and service will loosen them faster Loose U bolts can cause springs to break axle misalignment hard steering and abnormal tire wear Inspect the chassis for broken springs shocks loose or broken axle U bolts If any of these are found contact your local Volvo dealer The U bolt nuts must be retightened to the proper torque specific...

Page 100: ... load off high wear and lower lifetime will occur because grease is not able to reach the contact surfaces If the vehicle is being driven in severe climates with a lot of wet slushy highly dusty roads or in off road service increase the frequency of spring bushing lubrication Grease Fittings Rubber Bushings Rubber bushings are used for extended service life If your vehicle is equipped with rubber ...

Page 101: ...op arm with white grease annually On wet and salted roads road spray can enter the door lock key cylinder Lubricate the cylinder with liquid graphite annually or more often if necessary The door hinge pins are treated at manufacturing and then sealed No lubrication is necessary To keep the door rubber moldings and seals around the windows in good working order and to prevent them from freezing shu...

Page 102: ...rk or binds the latch should be cleaned before greasing Rust Protection The rust protection applied when the cab was produced is adequate for normal use and service If an extension of the cab rust protection is desired or if the vehicle is used in a severe application it is recommended that cavity wax is re applied every 3rd year ...

Page 103: ...eat on the bunk support The filter should be checked after 19 200 km 12 000 miles more often in dusty conditions Replace the filter as necessary To inspect or to change the filter open the luggage storage lid and pull out the filter Paint and Brightwork Care Cab When using a pressure washer to clean the vehicle do not direct the spray at electrical components in the engine compartment such as the ...

Page 104: ...At the end of the cold season thoroughly flush away all collected dirt from the chassis Stainless Steel Stainless steel will rust if exposed to salt for too long Wash frequently especially during the cold season to remove salt laden snow and ice If rust appears wash the surface and use a rubbing compound to remove the rust Apply a coat of wax as a finish do not wax parts that get hot such as exhau...

Page 105: ... by oil ice cream shoe polish grease etc use a clothing fabric stain remover Plastic The plastic in the upholstery can be cleaned with a soft cloth and mild soap solution Alcntera Suede Like Material Suede like upholster can be cleaned with a soft cloth and mild soap solution Leather Care Volvo s Leather upholstery is manufactured with a protectant to repel soiling Over time sunlight grease and di...

Page 106: ...16 000 km 10 000 miles or less All lubricating points are found on the chassis lubrication chart on the next page Lubricating Grease Use grease with a lithium base with EP additives and a consistency of NLGI No 2 Care should be taken not to use any grease other than one with EP additives for the driveshaft DO NOT use any solid lubricants such as graphite copper or molybdenum disulfide Lubrication ...

Page 107: ...Maintenance and Service 103 Lubrication Chart The numbers in the lubrication chart correspond with the numbered notes on Lubrication Chart Notes on page 104 Read these notes before selecting a lubricant ...

Page 108: ...ster and brake cam Use a lithium based grease with EP additives to specification API NLGI No 2 If the brake cam seal does not purge make sure the inner seal does not purge into the brake drum and onto the brake linings 3 Steering gear Use a lithium based grease with specification API NLGI No 2 Only use a hand operated grease gun The high pressure from an air operated grease gun will damage the sea...

Page 109: ...No 2 Volvo axles may use a greased for life tie rod No provisions for adding grease are available 7 Brake fluid and clutch reservoir Check the fluid level in the reservoir Add brake fluid if necessary Use only DOT 4 brake fluid in the clutch release system Mixing DOT 4 brake fluid with petroleum based oil will cause seal damage which will cause leakage 8 Clutch bearing linkage Use a lithium based ...

Page 110: ...cation 12 Coolant Add coolant if necessary Only use pre mixed clean water and antifreeze in a 50 50 mix Add only the same type antifreeze extended life or standard 13 Steering assist cylinder If equipped use a lithium based grease with EP additives to specification API NLGI No 2 to grease both ball joints 14 Power steering fluid Check the fluid in the reservoir with the dipstick Add oil if necessa...

Page 111: ...y Most rear differentials have a large screw and nut protruding from the housing The screw and nut hold the thrust plate shoe against the ring gear and are not to be confused with the fill level plug 21 Fifth wheel The fifth wheel and slider assemblies should always be re lubricated after steam cleaning or at least every 24 000 km 15 000 miles A heavy coating of grease is recommended on the fifth ...

Page 112: ...vy Severe Very Severe Fuel Consumption mpg more than 6 0 more than 4 7 more than 3 7 more than 2 0 Fuel Consumption L 100 KM less than 39 less than 50 less than 64 less than 120 Engine Oil and Filter Change Interval km miles 50 000 31 000 40 000 25 000 30 000 18 000 15 000 9 000 Clutch system fluid DOT 4 brake fluid according to SAE J 1703 Replacement interval Every 24 months For oil quality and o...

Page 113: ... these outside temperatures but the axle sump temperature MUST NEVER EXCEED 120 C 250 F For oil change intervals see the manufacturer s operator s manual Capacity RS23 160 19 liters 20 quarts RS23 185 22 5 liters 23 5 quarts RT40 145 160 front tandem 14 liters 15 quarts RT40 145 160 rear tandem 12 liters 13 quarts RT 46 160 front RT 46 160 rear approximately 18 liters 19 quarts approximately 16 li...

Page 114: ...S462 For oil change intervals see the manufacturer s operator s manual Capacity 23080 19 liters 20 quarts 23105 and 26105 26 5 liters 28 quarts DD404 front tandem DD404 rear tandem 14 5 liters 15 5 quarts 13 liters 14 quarts DS404 front tandem DS404 rear tandem 14 5 liters 15 5 quarts 13 liters 14 quarts ...

Page 115: ...type Automatic Transmission Fluid ATF Dexron lll Change interval Every 240 000 km 150 000 miles or every 12 months Oil Type Temperature Motor oil API CD or CE SAE 30 15W40 or synthetic Minimum 25 C 15 F Maximum No limit Gear oil API GL5 SAE 75W90 Minimum 40 C 40 F Maximum No limit ...

Page 116: ...NTHS CHECK CHANGE ANNUAL 12 MONTHS ADDITIONAL SERVICE Check Warning and Control Lamps X X Check Fault Codes displayed in the vehicle Instrument Cluster X X Check Air Compressor s Function and Condition X X Check Hinges Doorstops Locks and Sealing Strips X X Check External Lamps X X Check Rear View Mirrors and Reflectors X X Function Check of Wipers and Washers X X Check Headlamps X X Check Hood At...

Page 117: ...ing of Condensation X X Check Tire Wear X X Chassis Lubrication X X Cab Lubrication X X Check Oil Level in hubs for Oil Lubricated Wheel Bearings X X Check Oil in Front Drive Axle X X Check Exhaust Leakage X X Check Air Dryer X X Check Steering Linkage X X Check Front Shock Absorbers X X Check Front Wheels and Bearings X X Check Rear Spring Bolts X X TYPE OF OPERATION CHECK CHANGE BASIC 4 MONTHS C...

Page 118: ... Level in ManualTransmission If Applicable X X Check Oil in Retarder X X Check Oil Level in Power Steering X X Check Air Cleaner X X Check Fluid Level in Clutch Fluid Reservoir X X Check Coolant Level X X Check Fluid Levels in Windshield Wiper Reservoirs X X Check Transmission Oil Cooler hoses and Connections for leaks X X TYPE OF OPERATION CHECK CHANGE BASIC 4 MONTHS CHECK CHANGE ANNUAL 12 MONTHS...

Page 119: ...every 2 500 hours whichever comes first Check Drive Belts X X Check Radiator Fan Bearing Tolerance Bolt Unions Fan Cover and Fan Ring with Rubber Seal X X Check Turbocharger X X Check Discharge Lines and Hoses X X TYPE OF OPERATION CHECK CHANGE BASIC 4 MONTHS CHECK CHANGE ANNUAL 12 MONTHS ADDITIONAL SERVICE ...

Page 120: ...r a service appointment This gives the dealer time to schedule the correct equipment and provide a trained technician to service the vehicle 앫 Setting an appointment can decrease vehicle downtime 앫 When in for service at an authorized Volvo Truck dealer ask for outstanding safety related recalls that relate to the vehicle This service is available only at an authorized Volvo Truck dealership It is...

Page 121: ...eduled Service Date Preventive Maintenance See local Volvo Truck dealer for Service Information in group 17 Preventive Maintenance Basic Service and group 17 Preventive Maintenance Annual Service Work Completed Date Mileage ...

Page 122: ...de This helps over the lifetime of the vehicle to spot trends that can be used to alter maintenance schedules for example Repair Record Date Mileage Work Order or Invoice No Dealer Notes 1 1 07 24816 XXX XXX Basic Preventive Maintenance oil filter and lube chassis ...

Page 123: ...Charts 119 TIRE RECORD Tire Record Date Type Front Type Rear Notes Tire Pressure Tread Depths 1 1 07 Low pro 22 5 Mich X2A Low pro 22 5 Mich XDA All tires within 105 108 psi Tread Depth Front 12 32 Rear 10 32 ...

Page 124: ...le This can be compared with other vehicles in the same service application to indicate what is normal fuel and oil consumption for a certain application Keep a record of how much fuel was filled between oil fill up or oil change Date Accumulated Oil Qty SAE No Notes Mileage Fuel Qty Gallon 1 1 07 24816 4166 36 15W 40 Low 2 quarts ...

Page 125: ...ial Number Engine Power Rating Primary Fuel Filter Part Number Secondary Fuel Filter Part Number Oil Filter Part Number Full Flow Oil Filter Part Number By pass Air Cleaner Element Part Number Coolant Filter Part Number Fan Drive Belt Part Number Accessory Drive Belt Part Number Diesel Particulate Filter Part Number If Equipped Diesel Oxidation Catalyst Part Number If Equipped ...

Page 126: ...assistance VAS can arrange for load forwarding or equipment rental 앫 Personal Assurance Trained staff for handling any vehicle problems 앫 Uptime Assurance VAS will locate the nearest service provider and guarantee payment so you can get on the road as soon as possible 앫 Price Assurance VAS audits service and parts billing to ensure guaranteed labor rates and preferred parts pricing for Volvo compo...

Page 127: ...al Regular 47 Coolant System 44 Coolant Water Specification 44 Crushing Prevention 33 Cutting Prevention 33 D Diesel Particulate Filters 65 Driveshaft Maintenance 75 E Electric Grounding Practices 36 Electric System Precautions 36 Electronic System Precautions 37 Emissions Control Compliance 5 Engine Air Filter 63 Engine Components Service Schedules 43 Engine Damage Prevention 34 Engine Data Notes...

Page 128: ...Prevention 29 Fuel Additives 51 Fuel Cetane Number 51 Fuel Enhancers 52 Fuel Filter Replacement 56 Fuel Filter Replacement Primary 70 Fuel Filters 55 Fuel Quality 50 Fuel Safety Information 49 Fuel Storage 54 Fuel Sulfur Content 51 Fuel System Priming 71 Fuel Alternative 53 Fuses 22 H Hubs Front 92 I Injury Prevention 26 L Lubrication Chart 102 M Maintenance Hazards 42 Maintenance Safety Precautio...

Page 129: ...r s Information Package 4 P Power Steering Fluid Reservoir 77 R Radiator Package Cleaning 68 Relay Center 22 Respiratory Hazard Prevention 32 Roadside Assistance 122 Rubber Bushings 96 S Safety Defects Reporting 38 Safety Information Brakes 78 Selling Vehicle 3 Service Assistance 122 Service Charts 116 Service Manuals 122 Speed Restrictive Tires 29 Spring Bushings 96 Spring Maintenance 95 Steering...

Page 130: ... T Tires Wheels and Hubs Maintenance 82 Transmission Oil 73 Turbocharger and Charge Air Cooler 68 U U bolts 95 Unitized Front Hubs 93 V Vendor Component Information 3 Volvo Action Service 122 W Water In Fuel 73 ...

Page 131: ...or if you need service repairs contact the VAS support center VAS is available 24 hours per day 7 days per week at 1 800 528 6586 Please report the specific nature of the service problem to the Volvo Customer Support Specialist who will answer your questions and arrange for the assistance you need Volvo Action Service VAS Support Center 1 800 52 VOLVO ...

Page 132: ...ica P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 5600A Cancross Court Mississauga Ontario L5R 3E9 http www volvotrucks volvo com PV776 21012002 07 2008 Volvo Group North America Inc 2008 All Rights Reserved ...

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