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Volvo D12, Operator'S Manual

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Maintenance

99

WHAT IS COVERED BY THE EMISSION WARRANTY

The following is a list of the items that are considered a part of the Emission Control Sys-
tems and are covered by the Emission Warranty when installed as original equipment by
Volvo Trucks North America, Inc. on vehicles which were built to conform to Environ-
mental Protection Agency and California Air Resources Board regulations

IMPORTANT - This may not include expendable maintenance items. Emission related
parts requiring scheduled maintenance are warranted until their first scheduled replacement
point.

I.

Fuel Injection System

II. Air Induction System

A. Intake Manifold

B. Turbocharge System

C. Charge Air Cooler (Intercooler)

III. Exhaust Manifold

IV. Miscellaneous Items Used in Above Systems

A. Hose, clamps, fittings and tubing

B. Pulleys, belts and idlers

C. Vacuum, temperature, and time sensitive valves and switches

D. Mounting hardware, sealing gaskets and PVC (if applicable)

THIS CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT IN NO WAY

REPLACES, MODIFIES, ALTERS OR SUPERSEDES THE TRUCK WARRANTY CER-

TIFICATE, ITS TERMS AND CONDITIONS, AND ITS

LIMITATIONS AND EXCLUSIONS.

BE CERTAIN YOU READ AND UNDERSTAND ALL WARRANTIES WHICH

ACCOMPANIED YOUR VEHICLE.

NOTE! Warranty coverage is subject to
change without notice. Contact your Volvo
Truck dealer for the current warranty
statement.

Summary of Contents for D12

Page 1: ...Operator s Manual Maintenance and Engine VHD ...

Page 2: ...ant 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 Inc should be informed immediately if you believe that the vehicle has a defect that could cause a crash in jury or death Contact NHTSA by calling the ...

Page 3: ...cification 51 Fuel Additives 55 Alternative Fuels 58 Oil System 59 Engine Oil 59 Oil Sampling 70 Severe Service Schedule for VHD Series 74 General and Check Chart 74 Maintenance Categories 78 Heavy Duty Service Schedule for VHD Series 84 General and Check Chart 84 Maintenance Categories 89 Maintenance 95 Engine Maintenance 95 Flushing Cooling System D7 121 Flushing Cooling System D12 124 Turbo and...

Page 4: ...etc which is essential to the proper operation of the ve hicle CAUTION A caution label directs the operator s attention to unsafe practices where per sonal injury is not likely but property damage could occur The caution label is in black type on a white background with a black border WARNING A warning label directs the operator s attention to unsafe practices which could result in personal injury...

Page 5: ...y or even death Information in this manual refers to Volvo components and Volvo drivetrain Informa tion concerning non Volvo engines and or drivetrains can be obtained by contacting the respective manufacturer Establish a Preventive Maintenance Pro gram with the help of your local Volvo Truck dealer A Preventive Maintenance Program makes it possible to maximize the amount of time your vehicle is u...

Page 6: ...ls for specific components for example Volvo engine Cummins engine Eaton transmis sion etc contain important information to be able to operate this vehicle safely They contain 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 specifica tions contained in this manual are based upon t...

Page 7: ...y cause serious illness or death Before servicing your vehicle apply the parking brakes and adequately chock the wheels in order to prevent unintended vehicle movement If the service procedure requires the parking brakes to be released recheck to en sure that the wheels are adequately chocked to prevent all forward and or rearward movement Do not use combustible substances in or around the engine ...

Page 8: ...OT attempt repairs you do not understand or have the proper tools for When starting an engine after repairs have been made to the fuel or injection system prepare equipment for shutting off the engine intake air and or fuel supply to stop the engine in case there is an overspeed on start up Start the engine only from the driver seat Never operate the starter motor across the starter terminals or t...

Page 9: ... Volvo engine and replacement parts for it shipped from the factory are as bestos 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 as bestos fibers can create serious health risks including death Fluid Penetration Always use a piece of paper or cardboard when checking for a leak Es caping fluid under hig...

Page 10: ...gine hood or cab if you see or hear steam or coolant escap ing from the engine compartment Wait until steam or coolant cannot be seen or heard any longer before raising the hood or cab Do not remove the coolant fill cap if the coolant in the surge tank is boiling Also do not remove the cap while the engine and radiator are still hot Scalding fluid and steam may be blown out under pressure if the c...

Page 11: ...olant can turn into steam Any contact with hot coolant or steam can cause severe burns The radiator and all heating system and radiator lines and hoses contain hot coolant WARNING Coolant may be combustible Coolant leaked or spilled onto hot surfaces or electrical components can cause a fire Clean up coolant spills immediately Verify coolant level only by the markings on the expansion tank Open th...

Page 12: ...g around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion WARNING Battery posts terminals and related accessories contain lead and lead com pounds chemicals known to the State of California to cause cancer and reproduc tive harm Wash hands after handling Battery electrolyte contains acid and can cause injury Avoid contact with the skin and eyes Wash hands a...

Page 13: ... intake system and could cause the engine to over speed with possible serious damage to the engine and bodily injury or property damage W0001526 Excessive heat may cause the pressur ized components of the air conditioned system to explode Never weld solder steam clean or use a gas torch near any part of the air conditioning system Se vere injury or death may occur from an explosion Do not pressure...

Page 14: ...ea WARNING Do not store fuel containers in the vehi cle They may leak explode and cause or feed a fire Empty or full they present a hazard that may lead to burns in the event of a fire Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized personnel Store oily rags or other flammable material in a protective container in a safe place Remove all flammable ...

Page 15: ...vo or any other engine with start help The Volvo engine is equipped with a preheater Introduction of ether or other combustible material in the intake manifold could cause a fire or explosion resulting in severe property damage se vere personal injury or death DO NOT use ether or other combustible starting aids on engines that have a heater element or other heating devices installed in the intake ...

Page 16: ...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 W0001523 Poisonous Substances Coolant is toxic risk of poisoning Do not drink coolant Use proper hand pro tection when handling Keep coolant out of reach of children and animals Failure to follow these precautions can cause se rious illness or death Co...

Page 17: ...y injured Support equipment and components prop erly when working beneath them Never attempt adjustments while the engine is running unless otherwise specified for the service procedure To help prevent an acci dent caused by moving parts work carefully around them Guards covers and shields should be in place whenever main tenance is not being performed Keep objects away from moving fan blades They...

Page 18: ...he cab or the area behind the cab Failure to follow this warning can result in serious per sonal injury or death DO NOT climb up on or jump off from the engine or stand on components that cannot support your weight Use an adequate lad der or scaffolding suitably situated Do not use top of engine or cowling ledge as foothold when reaching on top of cab Clean steps handholds and areas of the ve hicl...

Page 19: ...lly around them DO NOT disable or bypass automatic alarm shutoff circuits They are provided to prevent personal injury and engine damage The diesel engine will operate on any fuel which enters the cylinder whether it is from the injectors or from the air in take system Therefore if any solvent is used to flush out the air cleaner element the engine may overspeed during start up Engine damage and s...

Page 20: ...t 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 batter ies to start the engine as this could bypass the engine neutral start system as well as damage the electrical and electronic sys tem Always start the engine according to the required engine starting procedure de scribed in this operator ...

Page 21: ...r eye protection when work ing around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion Grounding Practices Proper grounding for vehicle and engine electrical and electronic systems is neces sary for proper vehicle and engine performance and reliability Improper grounding will result in uncontrolled and unreliable electrical paths Uncontrolled engine electri...

Page 22: ...als while the engine is running An electric shock can cause an involun tary muscle spasm and cause balance loss and falls leading to severe personal injury or death This engine is equipped with monitoring features that may cause reduced power or shutdown under certain conditions The power output monitoring and idling fea tures can only be programmed and or changed with electronic service tools and...

Page 23: ... S Department of Transport Washington DC 20590 1 800 424 9393 Canada Refer consumer complaints to Volvo Trucks Canada Inc or to the Transport Canada Department of Public Complaints Recalls and Investigations 1 905 795 1555 Mexico Volvo Trucks of Mexico S A de C V should be informed immediately if you be lieve the vehicle has a defect that could cause a crash injury or death Contact Volvo Trucks de...

Page 24: ...ne Design Information Engine Overview D7 W2002703 1 Fuel filters secondary 2 Turbocharger 3 Exhaust pressure governor EPG 4 Coolant drain connection 5 Coolant filter 6 Electronic injection pump 7 Hand fuel primer pump ...

Page 25: ...General Engine Design Information 21 W2002702 8 Engine electronic control unit EECU 9 Oil fill cap 10 Oil dipstick 11 By pass oil filter 12 Full flow oil filter 14 Starter motor ...

Page 26: ...22 General Engine Design Information Engine Overview D12 W0001846 1 Oil Fill Cap 2 Starter Motor 3 Engine Electronic Control Unit EECU 4 Fuel Filter secondary 5 Oil Dipstick ...

Page 27: ...n 23 W0001847 9 Coolant Drain Connection 10 Exhaust Pressure Governor EPG 11 VEB Control Unit 12 Turbocharger 13 By Pass Oil Filter 14 Full Flow Oil Filters 15 Air Compressor 16 Coolant Filter 17 Coolant Radiator 18 Charge Air Cooler ...

Page 28: ...General Engine Design Information Typical Engine Compartment Overview W2003478 1 Oil fill cap 2 Intake air heater 3 Engine Electronic Control Unit EECU 4 Coolant surge tank 5 Output from charge air cooler ...

Page 29: ...General Engine Design Information 25 W2003479 6 Engine air filter 7 Coolant fill cap 8 Radiator 9 Airfilter restriction gauge 10 Oil dipstick 11 Turbocharger ...

Page 30: ...aust Brake Efficient Braking on Grades Superior Temperature Control at Idle Quick Warm Up Optional Volvo Engine Brake VEB D12 only Exceptional Engine Braking Even at Low Engine Speed Optional Pre Heater Element Excellent Startability down to as Low as 15 F 25 C Minimum Smoke and Odor After Start No Fuel Dilution of Oil in Cylinder Due to Complete Combustion Less Engine Wear Cylinder Liners with Pl...

Page 31: ... h Yes 87 140 30 48 30 48 30 48 RSL RSL Differentiated Speed Limiter Yes No Transmission With Overdrive yes no No No Idle Timeout Yes No Time Before Shutdown if yes minutes No 5 1 40 External Engine Protection Yes No Yes Standstill Maximum Engine Speed Maximum Engine Speed r min High Idle 2500 High Idle Idle Adjustment Engine Idle Speed r min 600 550 800 NOTE This parameter listing is not com plet...

Page 32: ...m h Yes 87 140 30 48 30 48 30 48 RSL RSL Differentiated Speed Limiter Yes No Transmission with Overdrive yes no No No Idle Timeout Yes No Time Before Shutdown if yes minutes No 5 1 40 External Engine Protection Yes No Yes Standstill Maximum Engine Speed Maximum Engine Speed r min High Idle 1200 High Idle Idle Adjustment Engine Idle Speed r min 600 500 650 NOTE This parameter listing is not com ple...

Page 33: ...rimary fuel filter and Volvo spin on secondary fuel filters Exhaust pressure governor EPG Electronically controlled fuel injection One Volvo full flow and one Volvo by pass oil filters Electronic engine diagnostics system Intake air preheater element Thermostatically controlled fan 100 Ampere alternator Base Warranty 2 years or 250 000 miles parts and labor For covered components see the warranty ...

Page 34: ...lter Exhaust pressure governor EPG Electronically controlled fuel injection Double Volvo full flow and one Volvo by pass oil filters Thermostatically controlled oil cooler Electronically controlled unit injectors Overhead camshaft Electronic engine diagnostics system On off fan clutch 110 Ampere alternator Base Warranty 2 years or 250 000 miles parts and labor For covered components see the warran...

Page 35: ... Number VIN Engine Model Engine Serial Number Engine Power Output Engine Low Idle Speed Engine Full Load Speed Engine Full Torque Primary Fuel Filter P N Secondary Fuel Filter P N Oil Filter P N Full Flow Oil Filter P N By pass Air Cleaner Element P N Coolant Filter P N Fan Drive Belt Set P N Alternator Belt P N ...

Page 36: ... 1000 r min Shut the engine down Do not drain the oil after this run 5 Check the engine air filter and if nec essary change it 6 Check the coolant for proper levels of antifreeze and inhibitor SCA protec tion Service as necessary 7 Clean the exterior of the engine 8 Seal all engine openings using a wa terproof vaporproof and strong tape To return an engine preserved in this man ner can be done in ...

Page 37: ...ranking the engine without fuel delivered to the cylinders Let an experienced technician carry out the following 1 Separate the in line fuse feeding the engine electronic control unit The fuse is located in the battery box 2 Use the starter to turn the engine over until the oil pressure registers on the oil gauge CAUTION Do not crank the engine for more than 30 seconds at a time wait two minutes a...

Page 38: ...ack to a problem in the cooling system Always make sure that the coolant level is above the min mark on the surge tank 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 warn ing functions See page 122 or page 124 for information on how to change the coolant Coolant is toxic risk of ...

Page 39: ... for more infor mation NOTE Do not mix regular antifreeze into coolant mixed with extended life antifreeze The extended life properties can not be maintained with much reduced service in terval as a result Engine design requires the thermostat in the engine during summer and winter Cor rect engine temperature should be a minimum of 165 F 75 C with a properly functioning thermostat WARNING Coolant ...

Page 40: ...an sion tank Inspection of the whole cooling system is important Check for swollen or deterio rated heater and radiator hoses loose hose clamps and connections and radiator leaks Do not work near the fan with the en gine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seriously injured Before turning on the ignition be sure that no one is...

Page 41: ...oling system consists of a liquid that is pumped by a gear driven coolant pump that keeps the flow through the engine to the radiator The radiator gives off heat to the air as it passes through and air flow is helped by the engine fan For a quick warm up of the engine a thermostat regu lates the flow of coolant Coolant is toxic risk of poisoning Do not drink coolant Use proper hand pro tection whe...

Page 42: ...se of antifreeze based on propylene glycol W2003082 Coolant consisting of an antifreeze solu tion in water should be used year round to provide freeze and boil over protection as well as providing a stable environment for seals and hoses The solution needs to be tested for proper additive levels at regular intervals see page 45 for testing SCA lev els unless extended life antifreeze is used Adjust...

Page 43: ...avitation erosion damage of the water pump and cylinder liners Protect against freezing and boiling Prevent formation of scale sludge de posits and clogging Be harmless to polymer materials and seals in the coolant system Maintain its liquid properties in cold climates Coolant should consist of these three com ponents Clean water Additives Antifreeze Glycol See the following pages for proper han d...

Page 44: ...ng system Use clean water in the coolant mixture DO NOT use hard tap water or salt softened tap water in the cooling system If clean water is not available using distilled water is ideal Water specification should be Parts per Million Grains per Gallon pH Value Chlorides maximum 40 2 34 Sulfates maximum 100 5 8 Silica maximum 20 1 17 Iron maximum 0 10 0 0058 Manganese maximum 0 05 0 0029 Total dis...

Page 45: ...any time the additive goes below the rec ommended level For extended life coolant mixture this means an extender package added halfway through the coolant lifetime Nitrites or nitrite and molybdate additives protect the cylinder liner from cavitation erosion Nitrites deplete over time creating the need for SCA s or extender Other coolant additives also deplete and need re placement A too low conce...

Page 46: ...ll produce a sufficient base antifreeze Cor rectly inhibited to meet the ASTM D4985 standard it can be regarded as a new coolant which is fully accepted Antifreeze additives not only protect the cooling system from freezing but also against corrosion and cylinder liner pitting Antifreeze typically comes in one of two glycol types ethylene or propylene Propy lene antifreeze is NOT recommended for u...

Page 47: ... use of SCA to be added to the coolant to bring it up to the recommended SCA level when the coolant is initially filled or replaced Water and antifreeze should generally be filled as a 50 50 mixture The mixture should never be less than 40 antifreeze and 60 clean water or more than 60 an tifreeze and 40 clean water Mix the antifreeze water to the required concentra tion before adding to the coolin...

Page 48: ...l used coolant to a recycling or waste collec tion center Coolant Filter Change Intervals The charged coolant filter contains 8 units of SCA that are released slowly over time to maintain the recommended level during operation Change coolant filter after the first 30 days or 6 000 miles 10 000 km Thereafter Change the coolant filter at every other oil change when running 10 000 to 15 000 mile 16 0...

Page 49: ...after replace ment The SCA level will deplete over time so it is important that the SCA level is tested regularly and maintained The Volvo pre charged filter is designed to slowly release the SCA to help maintain the rec ommended level during operation NOTE Only change the filter after testing shows depleted SCA in the cooling system Do not exceed the 3 0 units per gallon 0 8 units per liter conce...

Page 50: ...n 0 8 units per liter Do not replace the coolant filter until further testing at the next oil change indicates that the level has dropped below 2 3 units per gallon 0 6 units per liter CAUTION SCA levels deplete during normal opera tion and when coolant is added because of low coolant level SCA levels should be maintained at the middle of the rec ommended interval Unit per gallon 1 5 LOW 2 3 MID 3...

Page 51: ...e manufacturers Contact other manufacturers for their cur rent recommendations 1 WARNING Do not remove the cap to the coolant surge tank while the engine and radiator are still hot Scalding fluid and or steam may be blown out under pressure if the cap is taken off too soon Drain the coolant into a suitable container Make sure the heater tem perature controls and valves are open NOTE Always dispose...

Page 52: ...un til the coolant temperature has reached 120 to 150 F 50 to 65 C 8 Drain the water and flush the cooling system with clean water 9 Fill the cooling system with pre mixed Extended Life Coolant Check the specifications section for refill quantity 10 Attach label P N 3969338 to the coolant surge tank to indicate that the system is now filled with Extended Life Coolant The label can be or dered from...

Page 53: ...ld the system become contaminated with regular coolant exceeding 10 of the system s total capacity or if SCA is added to the system either drain the system and refill with new extended life coolant or maintain the system as for regular coolant Continue treating with SCA and change the coolant at the intervals recommended for regular coolant Coolant Filter Do not use a filter that contains SCA In s...

Page 54: ...result in severe per sonal injury or death WARNING If a fuel leak is detected stop the engine immediately The vapors from hot fuel are highly flammable which may result in a fire Do not remove the fuel tank cap near an open flame Diesel fumes are com bustible and can cause an explosion of fire resulting in severe personal injury or death WARNING Do not store fuel containers in the vehi cle They ma...

Page 55: ... Fill the tank after completing driving for the day NOTE When draining the fuel tank col lect the waste in a fuelproof container Take the drained fuel and water to a recycle or waste management center Open the drain at the bottom of the fuel tank approximately every 30 000 miles 50 000 km or 300 hours to drain off any water and or sediment Yearly or at 120 000 miles 200 000 km tighten all fuel tan...

Page 56: ...the fuel system see page 134 for D12 and page 136 for D7 engines or the engine manufacturer s opera tor s manual for other engines W2001067 Fuel Sulfur Content Fuel sold after 1994 for highway use can only contain a maximum sulfur content of 0 05 by weight This was done to reduce particle emissions in the exhaust The sulfur content for off highway use con tinues to be specified at a maximum of 0 5...

Page 57: ...iesel will react with the zinc forming solids that can clog fuel filters and cause engine dam age Fuel stored for a long time may oxi dize and form solids causing filtering problems Keep the area around the fill cap clean Tilt the tank slightly toward the drainplug area so water and sediment can be easily drained Generally fuel contamination occurs as the result of improper fuel handling The most ...

Page 58: ... tremely cold weather Fuel Cloud Point The cloud point should be below the lowest ambient temperature at which the engine must start and operate to prevent the fuel filter elements from plugging with wax crystals Fuel Viscosity Fuel viscosity must be kept above 1 4 cSt at 100 F 38 C to provide adequate fuel system lubrication The viscosity also has an effect on the atomization of the fuel when it ...

Page 59: ...patibility among additives already in the fuel and the addi tives to be used Supplemental Fuel Enhancers CAUTION Supplemental additives are not recom mended because of a high risk of injection system problems or engine damage There are many aftermarket products avail able today which are intended to be added by the customer They generally increase operating cost without providing benefits Included...

Page 60: ...er warranty Some fuel additives can be used to provide temporary relief but they do not replace good fuel handling practices These prod ucts can be used Isopropyl Alcohol Use 1 pint per 125 gallons 1 2 liter per 500 liters of fuel for winter freeze up protection Biocide For treatment of microbe growth or black slime Follow man ufacturer s instruction for treatment ...

Page 61: ...l Used lubrication oil contains solids and acids from the combustion process that can severely corrode parts of the injection sys tem resulting in reduced power and higher maintenance cost over time Gasoline WARNING The addition of gasoline to diesel fuel will create a serious fire hazard Adding gasoline to diesel fuel will re duce the cetane number and increase combustion temperature If a tank co...

Page 62: ...se are in general not compatible with modern heavy duty over the road vehicle engines The use of unauthorized fuels may compro mise the levels of pollutants in the exhaust to the point where the engine does not meet the emission requirements This would make the vehicle illegal to drive on public roads DO NOT use any kind of alternative fuel unless specifically authorized by Volvo Trucks North Amer...

Page 63: ...d on page 61 Viscosity and capacity tables can be found beginning on page 166 Other engine manufacturers have different policies regarding their products and should be con sulted if a different change interval is desired Contact your Volvo Truck dealer for more information For information on synthetic oil see page 66 W1000077 NOTE Always dispose of oil according to Federal or local regulations Use...

Page 64: ...il is required for normal oil intervals Normal grade engine oils for all engines in vehicles produced by Volvo Trucks North America Inc must meet or exceed the API classifications CG 4 or CH 4 VDS and VDS 2 are Volvo oil standards See page 61 for interval recommendations for Volvo engines See each other engine manufacturer s Operator s Manual for infor mation on when and how to change the oil Oils...

Page 65: ...tc ad just the intervals down for more frequent oil changes NOTE Oil filters should always be changed when changing oil Oil Filters Always change oil filters when changing the oil There may be two or three filters on the engine one of which is a bypass filter This should be changed at the same time as the regular full flow filter s CAUTION Use only the engine manufacturer s oil filter for replacem...

Page 66: ...d oil that is defined by the API classifications For oils that meet both API CH 4 and VDS 2 which are required for model year 2000 and 2001 Volvo en gines there is a list that is periodically updated For the complete list see your Volvo Truck dealer The list is contained in the Technical Service Information refer to TSI 175 001 Oil and Filter Change Inter vals Depending on the seasonal temperature...

Page 67: ...is over 7 0 miles per gallon un der 3 5 liters per 10 km Gross combined weight GCW is less than 45 000 lb 20 000 kg On highway op eration only Higher Oil Qualities Oil Quality VDS 2 plus CH 4 VDS 2 plus CH 4 VDS 2 plus CH 4 Mileage Months Hours Fuel Usage 10 000 miles 16 000 km 4 250 1 500 gallons 5 700 liters 12 000 miles 19 000 km 4 300 1 800 gallons 6 800 liters 15 000 miles 24 000 km 4 400 2 2...

Page 68: ...oil that is defined by the API classifications For oils that meet both API CH 4 and VDS 2 which are required for model year 2000 and 2001 Volvo en gines there is a list that is periodically updated For the complete list see your Volvo Truck dealer The list is contained in the Technical Service Information binders refer to TSI 175 001 Oil and Filter Change Intervals Depending on the seasonal temper...

Page 69: ...mption is over 6 5 miles per gallon un der 3 6 liters per 10 km Gross combined weight GCW is less than 80 000 lb 36 000 kg On highway op eration only Higher Oil Qualities Oil Quality VDS 2 plus CH 4 VDS 2 plus CH 4 VDS 2 plus CH 4 Mileage Months Hours Fuel Usage 12 000 miles 19 000 km 4 300 2 500 gallons 9 500 liters 15 000 miles 24 000 km 4 400 3 000 gallons 11 500 liters 25 000 miles 40 000 km 4...

Page 70: ... some ways compared with petroleum based oils but its lifetime in the engine is the same This is because of the combustion by products that contaminate the oil These contaminates will make the change inter vals the same as for petroleum based oils The use of synthetic oils does not permit the extension of the recommended oil change intervals Synthetic oils offer improved low tempera ture flow prop...

Page 71: ...oose a monograde oil if the temperature is holding steady over a long period of time Volvo Trucks North America Inc recom mends the viscosities shown in the viscosity temperature table for Volvo en gines See page 167 for vendor engines Choosing an oil with a lower viscosity can help improve the fuel economy However if this is done make sure the upper tempera ture limit is not exceeded Also with lo...

Page 72: ...ximum of 0 05 by weight for No 2 D diesel fuel For fuels that have a sulfur content of 0 5 by weight and above Volvo Trucks North America Inc recommends that oil change intervals are cut in half so a shorter mileage is run between oil changes Oil Additives CAUTION Extra oil additives must not under any circumstances be added to any oil used A shortened engine life may be the re sult Using oils to ...

Page 73: ...gine in a heavy operation may get only 5 mpg fuel consumption and another gets over 8 mpg the oil consumption will vary in different applications To determine normal oil consumption it is therefore important to establish what is normal for your engine in your application Establish a record of oil usage and compare with other vehicles in your fleet There are two methods that are frequently used Mil...

Page 74: ...f clear of all hot engine parts and or fluids A hot en gine and or can cause serious burns Samples should be taken when the oil is warm and well mixed to be certain that the sample is representative of all the oil in the engine Samples can be taken by having a sampling valve installed on the engine or sampling through the oil dipstick tube Follow the instructions in the sampling package closely A ...

Page 75: ...cles from the manufacturing process foundry sand machining filings etc in crease wear at this stage Wear at this point should not cause any alarm as higher wear particle values nearly always show up dur ing the breaking in period Wait to see whether the second and third oil analyses give any indication that the particle levels have changed to any extent ...

Page 76: ...nkshaft bearing shells 20 Sn Tin Surface layer of sliding bearings 20 Cr Chrome Piston rings valve rod 10 Al Aluminum Pistons 10 Ni Nickel Layer between the surface and copper layers on a sliding bearing 5 Si Silicon Sand dirt etc 20 Insolubles Carbonized oil combustion particles soot 1 8 by weight Water Coolant liquid condensation water 0 1 by weight Fuel Dilution Incomplete combustion 3 0 by wei...

Page 77: ... engine simply on the basis of the oil analy sis values Instead use the values as an indicator that something unusual is happen ing Combine the oil analysis with other diagnostic methods to further confirm what the unusual might be For more information about oil intervals and oil sampling evaluation it is available in the Technical Service Information group 175 at your Volvo Trucks dealer ...

Page 78: ...ter the lubrication schedule should be changed to lubricate exposed lubrication points as often as every day For example if the vehicle is used off road driving through deep stand ing water the lubrication schedule should be changed to lubricate exposed lubrication points as often as every day Off Road Application Any vehicle that operates more than 10 in sandy or muddy conditions Heavy Haul Appli...

Page 79: ... end dump transfer dump hopper trailer combination Michigan special gravel trains and frameless dumps Oil Field Application Typical operations include grades of maxi mum 12 moving oil production related materials supplies and tools between job sites or movement of processing equipment and laboratories on the job site highpow ered engines low mileage operation 100 loading one way and empty return m...

Page 80: ...r typical applications If the schedule does not fit your application make modifications based on your experience of your application Your Volvo Trucks dealer is also equipped to help you optimize the maintenance to suit your vehicle and application the best When the interval hours or calendar time are reached refer to the check sheet to see what service categories need to be done Carry out each st...

Page 81: ...3 14 000 a A B C 3 2 250 a 3 8 250 a 3 14 250 a 3 2 00 a A 3 8 500 a A 3 14 500 a A 3 2 750 a 3 8 750 a 3 14 750 a 3 3 000 a A B 3 9 000 a A B 3 15 000 a A B 3 3 250 a 3 9 250 a 3 15 250 a 3 3 500 a A 3 9 500 a A 3 15 500 a A 3 3 750 a 3 9 750 a 3 15 750 a 3 4 000 a A B C 3 10 000 a A B C 3 16 000 a A B C 3 4 250 a 3 10 250 a 3 16 250 a 3 4 500 a A 3 10 500 a A 3 16 500 a A 3 4 750 a 3 10 750 a 3 ...

Page 82: ...sis before in spection 2 Do the maintenance points as de scribed under Category a 3 Change primary see page 129 and secondary see page 131 fuel filters 4 Visually inspect the component and all fluid pipes hoses seals gaskets and connection points on engine transmis sion and rear axle s for exterior signs of leakage 5 If using standard antifreeze in the en gine cooling system check the SCA level of...

Page 83: ...on filters Change if necessary Exterior 27 Turn on and check all exterior lights Inspect exposed wiring 28 Check the hood or cab lock down latches for wear and alignment 29 Check that the cab mounts are se curely bolted to the frame and cab Check the cab suspension for function 30 Check condition of air hoses and pipes See page 148 31 Check frame rails for cracks and dam age Note if there are any ...

Page 84: ...r operation mount ing and adjustment See page 146 Steering and Suspension 51 Check condition of air springs if ap plicable Wheels and Tires 52 Check the tightness of all wheel nuts with a torque wrench Check the tire tread depth See page 152 53 Inspect each tire for unusual wear pat terns See page 153 54 Check tire inflation Check for leaks in the valves See page 154 Engine Compartment 55 Visually...

Page 85: ... 69 Shifting through the gears check the transmission for smoothness of opera tion 70 Listen for unusual noises Make sure the vehicle is riding smoothly and is free from roughness or excess vibra tion 71 Check for excessive free play in the steering wheel Turning operation should be smooth and free of rough spots Check for vibration in the steer ing wheel or column 72 Check exhaust brake and or en...

Page 86: ...ront and rear wheel bearings See page 154 14 Check rear suspension springs mounts and U bolts See page 155 15 Check shock absorber mountings and for signs of leakage 16 Examine all rims for cracks Inspect for rust streaks around the nuts See page 152 17 Inspect coolant pump engine fan and fan hub for wear Test the function of the fan engagement 18 Pressure check cooling system Inspect for leaks in...

Page 87: ...anged at 6 000 hours See page 122 or page 124 4 Check coolant thermostat function ev ery 2 000 hours 5 Pressure test injectors or adjust height Volvo D7 Every 12 months or 2 000 hours Volvo D12 No recommendation Cummins Every 21 months or 3 800 hours Detroit Diesel Every 21 months or 3 800 hours 6 Check and adjust valves on the engine Volvo Every 12 months or 2 000 hours Cummins Every 21 months or...

Page 88: ...icate exposed lubrication points as often as every day Construction Application Typical operations include movement of material to and from job sites grades less than 20 only use one retarder and a relatively high number of starts stops Op eration on road surfaces made of concrete asphalt maintained gravel crushed rock and hard packed dirt or other similar sur face for 90 of the time and up to 10 ...

Page 89: ...al Typically GCWR for this application is less than 88 000 lb 40 metric tons Opera tion on road surfaces made of concrete asphalt maintained gravel crushed rock and hard packed dirt or similar surfaces Vehicle types are Ambulance aerial plat form or ladder truck Tanker truck pumper truck emergency service or utility body Rescue Service Application Typical operations include specialized vehi cles f...

Page 90: ... for typical applications If the schedule does not fit your application make modifications based on your experience of your application Your Volvo Trucks dealer is also equipped to help you optimize the maintenance to suit your vehicle and application the best When the interval mileage or calendar time are reached refer to the check sheet to see what service categories need to be done Carry out ea...

Page 91: ... A 3 450 720 A B C 3 62 5 100 A 3 262 5 420 A B C 3 462 5 740 A 3 75 120 A B C 3 275 440 A 3 475 760 A 3 87 5 140 A 3 287 5 460 A 3 487 5 780 A B C 3 100 160 A 3 300 480 A B C 3 500 800 A 3 112 5 180 A B C 3 312 5 500 A 3 512 5 820 A 3 125 200 A 3 325 520 A 3 525 840 A B C 3 137 5 220 A 3 337 5 540 A B C 3 537 5 860 A 3 150 240 A B C 3 350 560 A 3 550 880 A 3 162 5 260 A 3 362 5 580 A 3 562 7 900 ...

Page 92: ... 60 96 A 3 300 480 A 3 540 864 A B C 3 75 120 A 3 315 504 A B C 3 555 888 A 3 90 144 A B C 3 330 528 A 3 570 912 A 3 105 168 A 3 345 552 A 3 585 936 A B C 3 120 192 A 3 360 576 A B C 3 600 960 A 3 135 216 A B C 3 375 600 A 3 615 984 A 3 150 240 A 3 390 624 A 3 630 1 008 A B C 3 165 264 A 3 405 648 A B C 3 645 1 032 A 3 180 288 A B C 3 420 672 A 3 660 1 056 A 3 195 312 A 3 435 696 A 3 675 1 080 A B...

Page 93: ...eck all telltale and warning indica tors in instrument cluster See Operator s Manual 9 Check lights before going on road test Road Test 10 Start engine check starter motor 11 Operate the clutch several times Check for smooth engagement and op eration of clutch brake 12 Check parking brake hold 13 While driving apply brakes and check for even stopping and quick release Check ABS function 14 Check e...

Page 94: ...ed and that there are no signs of breakage 39 Check pedal carrier play 40 Check door alignment weather strip ping and mirrors 41 Check all safety equipment 42 Check all lamps lights wires and trailer light cord for function 43 Check trailer air hoses exhaust stack deck plates and air fairings 44 Check frame and all brackets for loose bolts and signs of cracks If necessary tighten M14 bolts to a to...

Page 95: ...ge 152 58 Check tire pressure Check tire tread for unusual wear pattern Measure tread depth See page 153 59 Check wheel hubs for leaks and proper oil level See page 154 60 Check wheel bearing clearance Brakes 61 Drain air tanks If a lot of condensate is drained check air dryer See page 145 62 Measure thickness of brake linings See page 146 63 Check slack adjuster throw and opera tion See page 146 ...

Page 96: ...gnment Check the function of the belt tensioner or mea sure the belt tension See page 120 76 Test coolant Adjust additives as nec essary change filter if necessary If equipped with long life coolant do not add additives See page 45 77 Change primary see page 129 and secondary see page 131 fuel filters as recommended 78 Check clutch fluid level 79 Check windshield washer fluid 80 Check engine air f...

Page 97: ...steering filter See page 143 12 Remove the cab fresh air filter after 60 000 miles 96 000 km or at least once per year and clean in a soap so lution Dry and reinstall Change filter after third use or maximum 240 000 miles 385 000 km 13 Remove inlet air hose to the turbo Check turbo shaft for wear Check hose and inside turbo for signs of oil leakage past the shaft seals 14 Check starter motor curre...

Page 98: ...e added at 3 000 hours and then changed at 6 000 hours See page 122 or page 124 4 Check coolant thermostat function ev ery 2 000 hours 5 Pressure test injectors or adjust height Volvo D7 Every 12 months or 2 000 hours Volvo D12 No recommendation Cummins Every 21 months or 3 800 hours Detroit Diesel Every 21 months or 3 800 hours 6 Check and adjust valves on the engine Volvo Every 12 months or 2 00...

Page 99: ...ations such as reprogramming of the fuel system so the engine will exceed the certified horsepower or torque or re moving the mufflers are examples of illegal changes Changes should not be made to a certified engine that would result in an engine that does not match the configuration of an en gine model that is currently certified to meet Federal Standards Canada The same conditions that apply in ...

Page 100: ...an emission related part of your vehicle is defective the part will be repaired or replaced by Volvo Trucks North America Inc This is your emission control system DEFECTS WARRANTY OWNER S WARRANTY RESPONSIBILITIES As the vehicle owner you are responsible for the performance of the required maintenance listed in your owner s manual Volvo Trucks North America Inc recommends that you re tain all rece...

Page 101: ... parts however will not be covered under the war ranty except in an emergency situation A part not being available or a repair not being completed within 30 days also constitutes an emergency Use of replacement parts which are not of equivalent quality may impair the effectiveness of emission control systems If other than Volvo parts are used for maintenance owner should obtain assurances that suc...

Page 102: ...r vehicle owner s manual If you need additional assistance or information concerning the Emission Control System Warranty contact Volvo Trucks North America Inc Warranty Adminis tration 336 393 2000 WHAT IS NOT COVERED BY THE EMISSION WARRANTY This warranty does not cover 1 Malfunctions in any part caused by any of the following misuse abuse improper adjustments unless performed by a Volvo Trucks ...

Page 103: ... I Fuel Injection System II Air Induction System A Intake Manifold B Turbocharge System C Charge Air Cooler Intercooler III Exhaust Manifold IV Miscellaneous Items Used in Above Systems A Hose clamps fittings and tubing B Pulleys belts and idlers C Vacuum temperature and time sensitive valves and switches D Mounting hardware sealing gaskets and PVC if applicable THIS CALIFORNIA EMISSION CONTROL WA...

Page 104: ...arranty provisions apply to all vehicles sold in all U S states and territories regardless of whether a state has enacted state warranty provisions that differ from the fed eral provisions Where a warrantable condition exists VTNA will repair your vehicle at no cost to you in cluding diagnosis parts and labor any emission control device or system which causes a vehicle to fail an EPA approved emis...

Page 105: ...ed maintenance You are responsible for presenting your vehicle to a VTNA dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Claim procedures are outlined in the Volvo Service Operations Manual As the vehicle owner you should also be aware that VTNA may deny you warranty cover age if your vehicle or a part has failed due ...

Page 106: ...ual and may elect to use parts other than Volvo parts for such maintenance replacement or repair without invalidating this warranty the cost of such services or parts however will not be covered under the warranty except in an emergency situation A part not being available or a repair not being completed within 30 days also constitutes an emergency Use of replacement parts which are not of equival...

Page 107: ...ays or shorter time limit required by state local or federal law or for reasons not attributable to the vehicle owner or events beyond the control of VTNA shall result in VTNA being responsible for repairing the vehicle free of charge to the vehi cle owner CUSTOMER ASSISTANCE Volvo Trucks North America Inc wishes to help assure that the Emission Control System Warranty is properly administered In ...

Page 108: ...endable maintenance items such as filters hoses belts oil thermostat and coolant made in connection with scheduled maintenance services once these parts have been replaced Any parts replaced under warranty before the first re quired replacement point are warranted for the remainder of the warranty period 4 Replacement items which are not genuine Volvo parts or not authorized by VTNA 5 Loss of time...

Page 109: ...ir first scheduled replacement point I Fuel Injection System II Air Induction System A Intake Manifold B Turbocharge System C Charge Air Cooler Intercooler III Exhaust Manifold IV Miscellaneous Items Used in Above Systems A Hose clamps fittings and tubing B Pulleys belts and idlers C Vacuum temperature and time sensitive valves and switches D Mounting hardware sealing gaskets and PVC if applicable...

Page 110: ...licable U S EPA Noise Control Regulations This warranty covers this vehicle as de signed built and equipped by Volvo Trucks North America Inc and is not limited to any particular part component or system of the vehicle manufactured by Volvo Trucks North America Inc Defects in design as sembly or in any part component or system of the vehicle as manufactured by Volvo Trucks North America Inc which ...

Page 111: ... acts presumed to constitute tampering are the acts listed Noise Shields and Insulation Removing or rendering inoperative the en gine and or transmission noise deadening panels shields or insulating materials Removing or rendering inoperative the cab tunnel or hood noise insulating materials Removing or rendering inoperative any truck body mounted sound insulation com ponents and or shields cab or...

Page 112: ...a ture modulated fan clutch fan shroud fan ring recirculation shields etc Exhaust System Removing or rendering inoperative exhaust system components such as the muffler pipes clamps etc Air Intake System Removing or rendering inoperative air in take induction system components filter filter housings ducts etc ...

Page 113: ...ise control system inspec tion or a deficiency identified during another general maintenance event If additional log space is needed further entries may be added on a separate sheet of paper Store these additions with the main log to preserve a comprehensive record It is recommended that copies of all noise emissions related maintenance invoices be retained The following Noise Control System in sp...

Page 114: ...k ets and clamps for damage and tightness Check integrity of internal muffler baffling by revving the engine through normal oper ating speeds Excessive rattling sounds or very loud operation indicates a failure within the muffler Repair or replace components as required See local dealer for Service Information in Group 177 500 Preventive Maintenance Basic Service VN VHD and Group 177 501 Preventiv...

Page 115: ...ipes hoses tubing and elbows used to interconnect the system Special attention should be given to all welds seams gaskets support points clamps couplings and connections Inspect all intake system fasteners brack ets and clamps for damage and tightness Repair or replace components as required See local dealer for Service Information in Group 177 500 Preventive Maintenance Basic Service VN VHD and G...

Page 116: ...s fan clutch fan shroud fan ring and recircula tion shields Check fan blades fan ring fan shroud and recirculation shields for any damage Verify that fan blades clear the fan ring Inspect all related fasteners brackets and clamps for damage and tightness Con firm operation of temperature modulated fan clutch Repair or replace components as required See local dealer for Service Information in Group...

Page 117: ...od insulation bulkhead insulation doghouse insulation etc splash shields cab skirts fender shields and body panels Inspect all related fasteners brack ets and clamps for damage and tightness Repair or replace components as required See local dealer for Service Information in Group 177 500 Preventive Maintenance Basic Service VN VHD and Group 177 501 Preventive Maintenance Annual Service VN VHD for...

Page 118: ...114 Maintenance Noise Control Log NOISE CONTROL SYSTEM MAINTENANCE LOG DATE MILEAGE MAINTENANCE PERFORMED MAINTENANCE FACILITY ...

Page 119: ...not attempt to repair or service this vehicle without having sufficient train ing correct service literature and the proper tools Failure to follow this could lead to personal injury or death or mak ing your vehicle unsafe CAUTION Prolonged contact with used engine oil may be harmful Use rubber gloves when handling used oil Wash skin thoroughly if it comes in contact with used oil NOTE Read all th...

Page 120: ...66 for quanti ties and viscosities or refer to other engine manufacturer s operator s manual WARNING When draining the oil use the proper tools and keep away as far as possible Raise the elbow so the forearm is paral lel to the ground to avoid oil running down the arm causing burns It is important to drain as much oil as pos sible Try to change oil immediately after driving when the oil is warm Al...

Page 121: ...eplacement Use of an oil filter not built to specification could result in severe damage to bearings crankshaft etc as a result of unfiltered oil entering the lubrication system NOTE Always dispose of oil filters ac cording to Federal or local regulations Used oil disposed of in nature or water ways contaminates our drinking water and kills wildlife Install new filters as follows Coat the filter g...

Page 122: ...inutes after shutting off the en gine before checking the oil level This gives the oil time to drain back to the oil pan Crankcase Air Breather CAUTION If the crankcase breather is not main tained on a regular basis it will become plugged When plugged excessive crankcase pressure buildup may cause crankshaft seal leakage Check and clean the crankcase ventilation system at every annual service ...

Page 123: ...gularly The filter should be replaced according to the gauge or after a maximum of two years whichever comes first Extra filter insert should be changed with every third main air filter CAUTION Continued operation with the gauge showing in the red may cause damage to the engine Operating the engine with a damaged filter allows dust to pass di rectly into the engine causing damage Replace damaged o...

Page 124: ... fluids A hot en gine and or can cause serious burns All engine belts should be checked at each service point Inspect for cracked or frayed material Most belts have automatic belt tensioners to keep the correct tension without adjustment Some belts are still ad justed with an adjusting mechanism to get the correct tension Check with your dealer to get the correct tension value for the dif ferent b...

Page 125: ...d antifreeze use a coolant filter containing the additives necessary for replenishing the used up ad ditives If using extended life antifreeze the coolant filter should be empty Do not in stall additive type filters on an engine filled with extended life type coolant See page 45 for information on coolant testing and page 44 for standard coolant or page 49 for extended coolant change intervals W20...

Page 126: ...fluid and or steam may be blown out un der pressure if the cap is taken off too soon WARNING Hot engine Keep yourself clear of all hot engine parts and or fluids A hot en gine and or can cause serious burns W2003079 1 Remove system fill cap 2 Open drain cocks located in the bot tom of the radiator and on the block You may have to use special tool 9996049 for quick connect fittings 3 Open the drain...

Page 127: ...ot fill sys tem with water and then add antifreeze A mixture with less than 35 antifreeze does not give adequate corrosion protection Concentrations of antifreeze above 60 does not give added freeze protection The system is self venting 1 Fill the system with clean coolant through the fill neck in the middle of the surge tank The fill rate is not to exceed 2 gpm 8 L min The engine should not be ru...

Page 128: ... and or steam may be blown out un der pressure if the cap is taken off too soon WARNING Hot engine Keep yourself clear of all hot engine parts and or fluids A hot en gine and or fluid can cause serious burns W2002059 1 Remove system fill cap 2 Open drain cocks located in the bot tom of the radiator or on the bottom radiator hose and on the block You may have to use special tool 9996049 for quick c...

Page 129: ... not fill sys tem with water and then add antifreeze A mixture with less than 35 antifreeze does not give adequate corrosion protection Concentrations of antifreeze above 60 does not give added freeze protection The system is self venting 1 Fill the system with clean coolant through the fill neck in the middle of the surge tank The fill rate is not to exceed 2 gpm 8 L minute The en gine should not...

Page 130: ...e detected do not operate the engine until the cause is deter mined and repaired If oil leaks internally from the tur bocharger to the engine intake the oil acts as a fuel Watch for excessive ex haust smoke Do not operate engine until problem is corrected There is no way to regulate the engine speed if it runs on oil and it may overspeed Loss of con trol of vehicle may lead to an accident causing ...

Page 131: ...to do so can result in un expected vehicle movement and can cause serious personal injury or death WARNING Always wear eye protection when clean ing radiator charge air cooler and condenser Failure to follow this recom mendation may result in eye injury The simplest method to clean the package is to use air pressure or a water stream This should be done from the back of the core Air pressure shoul...

Page 132: ...tridge a water separation bowl and may have a fuel heater built in W2001067 The secondary fuel filter is located on the left side under the control unit on D12 and on the left front side on the D7 engine The filter is contained in a disposable cartridge W2001079 Fuel Filter Change Intervals Filter change intervals should be tied to the oil change intervals Depending on the oil change intervals and...

Page 133: ... so could re sult in reduced power To replace the primary fuel filter element 1 To avoid potential fire hazard do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces or when working on an operating engine Failure to follow these precautions can result in fire To guard against burns from direct contact with hot fuel wear adequate protective clot...

Page 134: ...he vehicle CAUTION Never fill filter with fuel before in stalling Contaminated fuel causes accelerated wear to fuel system components 4 To eliminate air from the filter operate the primer pump to draw fuel and fill the filter 5 Do not work on or near the fan with the engine running The fan is of an auto matic on type and can be engaged without warning Fingers tools and equipment can be damaged if ...

Page 135: ...s Clean around the fuel filter This is important if dirt mixes with the fuel from this filter it will end up in the injection system 2 To avoid potential fire hazard do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces or when working on an operating engine Failure to follow these precautions can result in fire To guard against burns from dir...

Page 136: ...ly no side movement evident Tighten an additional 1 2 to 3 4 turn by hand Do not overtighten 5 To eliminate air from the filter operate the primer pump to draw fuel and fill the filter 6 Do not work on or near the fan with the engine running The fan is of an auto matic on type and can be engaged without warning Fingers tools and equipment can be damaged if the fan turns on when you do not expect i...

Page 137: ...ressure preparation Service work has been done on the fuel system for example cleaning or replacing fuel filter elements The engine is new or rebuilt NOTE It is very important to maintain high cleanliness when working in the fuel system If dirt is mixed in with the fuel af ter the filters it will cause damage to the injectors Dirt can also cause air leakages that rob the engine of power ...

Page 138: ...d or fluids A hot engine and or can cause serious burns Clean well around the bleed nipples on the fuel filter head and the cylinder head 2 To avoid potential fire hazard do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces or when working on an operating engine Failure to follow these precautions can result in fire To guard against burns fro...

Page 139: ...ad bleed nipple Connect the plastic hose to the nipple Open the bleed nipple with an 11 mm wrench and pump the hand primer un til clean air free fuel flows out of the hose Tighten the nipple while fuel is still flowing 5 Do not work on or near the fan with the engine running The fan is of an auto matic on type and can be engaged without warning Fingers tools and equipment can be damaged if the fan...

Page 140: ... cause serious burns Clean well around the bleed nipple on the fuel filter head 2 Make sure the ignition is ON The fuel system is not activated with the igni tion key switch off 3 To avoid potential fire hazard do not service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces or when working on an operating engine Failure to follow these precautions can r...

Page 141: ...flowing 4 Remove the hose and install the pro tection cap on the nipple 5 Do not work on or near the fan with the engine running or the ignition in the ON position The fan is of an automatic on type and can be engaged without warn ing Fingers tools and equipment can be damaged if the fan turns on when you do not expect it Start the engine and run it at an in creased idle speed for approximately 5 ...

Page 142: ...e kept high when the vehicle is parked Al ways fill up the tank at the end of the trip to minimize the amount of air in the tank Do not service any part of the fuel sys tem while smoking or while in the presence of flames sparks or hot sur faces Failure to follow these precautions can result in fire NOTE When draining the fuel tank col lect the waste in a fuelproof container Take the drained fuel ...

Page 143: ...above 250 F 120 C increase the lubricant s rate of oxidation and shorten its effective life If the transmission oil temperatures are consistently high change oil more often or install an oil cooler With lengthy or contin uous driving at altitudes of more than 6 000 ft 2 000 m above sea level more frequent oil changes will be necessary NOTE Always dispose of oil according to Federal or local regula...

Page 144: ...cosity for the outside temperature the vehicle will be operated in See page 166 for the beginning of viscosity charts If using synthetic base oils the change in terval goes up to 250 000 miles 400 000 km or 500 000 miles 800 000 km if us ing the manufacturer approved brand of oil filled from the factory Oil Filter Oil filters should be changed at the same time as the oil Also make sure that mag ne...

Page 145: ...four ends of the univer sal joint If the universal joint can not be properly lubricated replace it Rear Axle General NOTE Most rear axles today are run with a synthetic base oil The Volvo rear axles are an exception Do not use a synthetic base oil in Volvo rear axles Seals will de teriorate and leaks will develop Rear axles should not be operated if the oil temperature exceeds 250 F 120 C Choose t...

Page 146: ... oil to contact the skin When changing oil wear protective gloves NOTE Also check the rear axle vetilation for blockage A blockage can cause over pressure in the axle and start oil leaks T0008128 Hub Reduction If the axle is equipped with hub reduction when changing oil each hub must be emp tied separately Turn the wheel until the drain plug 2 is its lowest position Re move plug and drain Fill oil...

Page 147: ...ring fluid reservoir is filled with Automatic Transmission Fluid ATF Dexron III for the power steering system Change fluid every 150 000 miles 240 000 km 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 ...

Page 148: ... the parking brake or at tempt to move the vehicle until brake air pressure in both circuits is at least 100 psi 690 kPa Failure to follow this pro cedure may lead to uncontrolled vehicle movement and cause severe personal in jury or death Drain the air system tanks at the recom mended intervals If condensation accumulates moisture can enter the brake system air valves causing corro sion or cloggi...

Page 149: ... If sludge or oil is found in the drainage the air compressor should be checked for proper operation If an excessive amount of fluid is drained out of the tanks even when drained daily have the system checked for possible prob lems with the air dryer W5001203 Air Dryers Air dryers have a regeneration system that cleans out the accumulated moisture but eventually the drying medium will be filled up...

Page 150: ...exceed 3 4 to 1 in 20 to 25 mm for a 5 1 2 in slack ad juster Also make sure that the length of the slack adjuster is the same on an axle W5000613 Brake Linings Before measuring the brake linings set the parking brakes place the transmis sion in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death Measure the brake l...

Page 151: ...leed the air pressure from the supply tank wet tank 4 Check the air pressure gauges on the instrument panel to see if the pressure is maintained in both primary and sec ondary air tanks 5 Any bleed off from one or both of the tanks indicates a defective check valve replace valve 6 Repressurize the system and remove the wheel chocks WARNING To prevent personal injury always drain the air supply fro...

Page 152: ... pointers the operator is forewarned in the event of a pressure drop in either or both of the circuits and also may readily identify the specific circuit Before operating the vehicle check the air gauges which indicate air pressure They should not register less than 105 psi 725 kPa Maximum pressure at any time should not exceed 150 psi 1035 kPa W3000609 Air Tubing and Hoses All compressed air tubi...

Page 153: ...ep the cable con nections clean and tight Check the battery state of charge indicators periodically to determine battery condition Check for worn cables at every major in spection Replace worn cables Check battery terminals for cracks When disconnecting battery terminals al ways disconnect the ground terminal first When reconnecting always connect the ground terminal last W3002368 WARNING Always w...

Page 154: ...k up Lamp 1156 25 W Cab Marker Lamp w o sunvisor 67 10 W Driving Lamp Spotlight H9420 50 W Fog Lamp H9415 37 5 W Instrument Telltale Lamps 3919844 Volvo 1 5 W Door Courtesy Lamp 67 10 W All Overhead Dome Spot Lamp 1156 dome 67 spot 25 W 10 W Side Repeater 1156 25 W Turn Signal Parking Lamp front 3357 amber 25 8 W Turn Signal and Stop Lamp Parking rear 1157 25 8 W ...

Page 155: ...i cle control and serious personal injury or death can occur Do not install regrooved retreaded or re paired tires on the steering axle s They could fail unexpectedly and cause the loss of vehicle control leading to seri ous personal injury or death Do not use mismatched wheel compo nents If they do not exactly match the original design specifications they may cause failure or separation leading t...

Page 156: ...se ness steel rims Inspect all types of rims for cracks Cracks can appear in many places but typically radiate out from where a load is applied Inspect closely around wheelnuts handholes and inside circumference W7000445 Wheel Nut Tightening After the initial tightening retightening must be made within the first 500 miles 800 km After the first retightening only normal inspection of nut tightness ...

Page 157: ...ce the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious per sonal injury or death WARNING Check tire pressure when the tire is cool Never bleed the air from hot tires Increased tire pressure measured in a hot tire is normal Low pressures may cause side wall flexing resulting in increased heat leading to tire failure Measu...

Page 158: ... Wheel Hubs 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 hub is opened the lubricant must be changed Failu...

Page 159: ...ter Loose U bolts can cause springs to break axle misalignment hard steering and abnormal tire wear Do not operate the vehicle if the U bolts are loose If the U bolts are loose the axle is not properly secured to the sus pension This could cause loss of control of the vehicle leading to an accident re sulting in personal injury or death The U bolt nuts need to be retightened to the proper torque b...

Page 160: ... off high wear and lower lifetime will occur because of no grease reaching the contact surfaces If the vehicle is being driven in severe cli mates with a lot of wet slushy highly dusty roads or in off road service increase the frequency of spring bushing lubrication W7000449 T Ride Equalizer Beams The Volvo T Ride suspension has equalizer beams between the tandem axles The beam bushing needs to be...

Page 161: ...ey cylinder Lubricate the cylinder with liquid graphite annually or more often if necessary The door hinge pins are treated at manufac turing 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 shut dur ing the cold season occasionally spray on a silicone compound W8000949 Hood The hood la...

Page 162: ...b passes a filter lo cated on the right front side of the cab Remove the filter and clean with an air gun no more than 20 psi pressure after 40 000 miles 64 000 km in dusty conditions as often as every 10 000 miles 16 000 km Make sure the air stream is directed from the inside out The filter should not be cleaned and reused more than once Replace with a new filter after maximum 70 000 miles 110 00...

Page 163: ...sen dirt The use of steam or high pressure water will help in removing loose dirt Wash the surface with a sponge using a lot of water to flush away dirt Dry the surface with a towel or chamois Do not wait until it is dry as dry dusting will scratch the surface Apply a coat of wax regularly This will help the paint and other surfaces keep their luster If the surface gets dull use a restor ing clean...

Page 164: ...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 exhaust pipes etc NOTE Never...

Page 165: ...me Pieces of the steel wool breaks off and give rust stains on the surface Aluminum Unprotected aluminum surfaces will form an oxide layer if not maintained This is es pecially important during the cold season when roads are salted or in coastal areas where the salt level in the air is high Clean with steam or high pressure water Use a mild detergent if the dirt is heavy Rinse well Clean aluminum ...

Page 166: ...stency of NLGI No 2 The No 2 consistency is suitable for most temperatures Use NLGI No 1 or No 0 for extremely low temperatures 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 Procedure Make sure the grease fittings are cleaned off before filling grease Dirt on...

Page 167: ...ote 15 Clutch cylinder fluid Note 5 U Joint 1 Note 13 Automatic transmis sion Note 16 Manual transmission Note 6 U Joint 1 Note 13 Auxiliary axle s Note 17 U Joint 1 Note 13 Rear axle Note 7 Slack adjuster brake Cam 4 Note 9 T Ride bogie beam 2 Note 14 Slack adjuster brake Cam 4 Note 9 Rear axle Note 7 W1000146 Grease Coolant Hub Oil Aut Transm Fluid Engine Oil Man Transm Oil Hydraulic Oil Rear Ax...

Page 168: ... level with the in spection hole Add if necessary See page 169 for oil types 8 Use a lithium based grease with speci fication API NLGI No 2 When lubricating the 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 posi tion where grease can be added to the contact surfaces 9 Use a lithium based grease with speci fication AP...

Page 169: ...d inner seals If necessary adjust the lubrication schedule to include greasing the bogie bearing as often as daily in applica tions where the bogie runs in corrosive conditions or is submerged in water 15 Use a lithium based grease with EP additives to specification API NLGI No 2 Do not over grease the throwout bearing as grease may get into the clutch 16 Use Dexron III Automatic Transmis sion flu...

Page 170: ...high and low on dipstick 7 0 quarts 6 5 liters W1000144 1 Only completely synthetic and or VDS VDS 2 oils 2 Only VDS 2 oils Volvo Engine D12 For oil change intervals see page 61 First oil and filter change After 1 month or 6 000 miles 10 000 km Capacity including filters D12 service 37 quarts 35 liters Oil volume be tween high and low on dipstick 7 5 quarts 7 0 liters W1000144 1 Only completely sy...

Page 171: ...h and low on dipstick 7 9 quarts 6 5 8 5 liters ISX service 41 quarts 39 liters ISX oil volume between high and low on dipstick 8 9 5 quarts 7 5 9 liters W2002132 Cooling System Capacity VHD D12 39 liters 9 8 US gal VHD D7 36 liters 9 5 US gal approximate volumes Clutch Hydraulic System Clutch system fluid brake fluid accord ing to DOT 4 SAE J 1703 Replacement inter val every two years ...

Page 172: ...acturer s Operator s Manual Approximate Capacity MD3560P 5 speed MD3060P 5 speed 19 0 quarts 18 0 liters HD4060P 5 speed HD4560P 5 speed 39 0 quarts 37 0 liters Oil drain plug torque 18 24 ft lb 25 32 Nm W1000143 1 Arctic as defined by MIL L 46167B NOTE Fluid may require change sooner than listed intervals depending on operating condi tions Fluid must also be changed whenever there is evidence of ...

Page 173: ...tandem 9 5 quarts 9 0 liters RT2610 front tandem 24 5 quarts 23 0 liters rear tandem 20 quarts 19 0 liters hub reduction each hub1 3 7 quarts 3 5 liters RT3210 front tandem 29 5 quarts 28 0 liters rear tandem 24 5 quarts 23 0 liters hub reduction each hub1 3 2 quarts 3 0 liters 1 Fill each hub before filling the rear axle W4000880 1 For very hard or continuous op eration above an altitude of 6 000...

Page 174: ...res refer to sta ble ambient temperature readings There is no upper limit to these outside temperatures but the axle sump temperature MUST NEVER EXCEED 250 F 120 C Eaton Single 23080 23105 26105 and 30105 Eaton Tandem DS405 DD405 DDH44 and DS462 For oil change intervals see the manu facturer s Operator s Manual Capacity 23080 20 quarts 19 liters 23105 and 26105 28 quarts 26 5 liters DD404 front ta...

Page 175: ...id ATF Dexron lll Change interval every 150 000 miles 240 000 km Hubs Oil type1 Temperature Motor oil API CD or CE SAE 30 15W40 or synthetic Minimum 15 F 25 C Maximum No limit Gear oil API GL5 SAE 75W90 Minimum 40 F 40 C Maximum No limit 1 For axles with hub reduction see page 169 ...

Page 176: ...rwarding or equipment rental Personal Assurance Trained staff for handling any vehicle problems Uptime Assurance VAS will locate the near est service provider and guarantee payment so you can get on the road as soon as possible Price Assurance VAS audits service and parts billing to ensure guaranteed labor rates and preferred parts pricing for Volvo compo nents There are also five regional offices...

Page 177: ...l help you locate the manual s you need To be able to handle the order correctly you must give the model year and VIN for VIN location see the vehicle Opera tor s Manual Prices for a Service Manual Set vary de pending on what model of vehicle and what engine it is Billing will be done through the nearest Volvo Truck dealer Name Company Address CSZ Province Postal Code Vehicle Model Telephone Fax M...

Page 178: ...nge for a service ap pointment This gives the dealer time to schedule the correct equipment and provide a trained technician to service the vehicle Setting an appointment can decrease vehicle downtime When in for service at an authorized dealer ask for outstanding safety related recalls that relate to the vehicle This service is available only at an authorized dealership NOTE It is strongly recomm...

Page 179: ...ileage Preventive Maintenance See local dealer for Service Information in Group 177 500 Preventive Maintenance Basic Service VN VHD and Group 177 501 Preventive Maintenance Annual Service VN VHD Sched uled Service Date Vehicle Age at Service ...

Page 180: ...ileage Preventive Maintenance See local dealer for Service Information in Group 177 500 Preventive Maintenance Basic Service VN VHD and Group 177 501 Preventive Maintenance Annual Service VN VHD Sched uled Service Date Vehicle Age at Service ...

Page 181: ...Service Charts 177 Repair Record Keep track of repairs beeing made This helps over the lifetime of the vehicle to spot trends that can be used to alter maintenance schedules for example ...

Page 182: ...178 Service Charts Repair Record Date Mileage Work Order or Invoice No Dealer Notes ...

Page 183: ...Service Charts 179 Repair Record Date Mileage Work Order or Invoice No Dealer Notes ...

Page 184: ...180 Service Charts Repair Record Date Mileage Work Order or Invoice No Dealer Notes ...

Page 185: ...Service Charts 181 Repair Record Date Mileage Work Order or Invoice No Dealer Notes ...

Page 186: ...182 Service Charts Repair Record Date Mileage Work Order or Invoice No Dealer Notes ...

Page 187: ...balanced Tire wear increases with speed Overloading not only decreases tire life but also creates a hazard Incorrect front end alignment causes increased wear Unnecessary tire rotation may cause excessive wear NOTE A cold weather initial driving period will increase the life of new or retreaded tires Dual mounted wheels should always be of the same type and diameter maximal di ameter difference al...

Page 188: ...s rapid wear in the middle B Too low air pressure gives rapid shoul der wear T1006457 Incorrect Camber Incorrect camber gives abnormal wear on one half of the tire T1006458 Incorrect Toe and Axle Alignment A Incorrect toe in B Incorrect toe out C Out of line axle D Steering arm defect T1006459 ...

Page 189: ...e and dimension excess flexing in tire wall or different types of tires in inner and outer tires gives contact wear T1006718 Incorrect Caster and Imbalance A Caster angle B Imbalance Also rapidly wears the mechanical parts of steering linkage kingpin and wheel bearing T1006460 Cuts in the Tire Tread A Cuts B Flaking cuts C Rubber flaking Cuts are due to poor roads air pressure too high or incorrec...

Page 190: ... of round brake drums gives spot wear T1006721 Feathered Edges Normal occurrence on non driving wheels on good roads and high mileage T1006722 Cupping Cupping is a normal occurrence that de pends on the tread pattern the higher the load the greater the wear T1006723 ...

Page 191: ...Service Charts 187 AXLE LOAD TIRE PRESSURE Axle Load lb kg Recommended tire pressure psi kPa W1000109 ...

Page 192: ...188 Service Charts Tire Record Size Ply Rating Make Type Serial No ...

Page 193: ...Service Charts 189 Tire Record Mileage Date Installed Date Removed At Installation At Removal Tire Mileage Notes ...

Page 194: ...190 Service Charts Tire Record Size Ply Rating Make Type Serial No ...

Page 195: ...Service Charts 191 Tire Record Mileage Date Installed Date Removed At Installation At Removal Tire Mileage Notes ...

Page 196: ...192 Service Charts Tire Record Size Ply Rating Make Type Serial No ...

Page 197: ...Service Charts 193 Tire Record Mileage Date Installed Date Removed At Installation At Removal Tire Mileage Notes ...

Page 198: ...ping track of the fuel and oil consumption gives a record of what is normal for the ve hicle 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 ...

Page 199: ...Service Charts 195 Filled Date Mileage Fuel Qty Oil Qty SAE No Notes ...

Page 200: ...196 Service Charts Filled Date Mileage Fuel Qty Oil Qty SAE No Notes ...

Page 201: ...Service Charts 197 Filled Date Mileage Fuel Qty Oil Qty SAE No Notes ...

Page 202: ...198 Service Charts Filled Date Mileage Fuel Qty Oil Qty SAE No Notes ...

Page 203: ...Service Charts 199 Filled Date Mileage Fuel Qty Oil Qty SAE No Notes ...

Page 204: ...200 Service Charts Filled Date Mileage Fuel Qty Oil Qty SAE No Notes ...

Page 205: ...Service Charts 201 Filled Date Mileage Fuel Qty Oil Qty SAE No Notes ...

Page 206: ...202 Service Charts Filled Date Mileage Fuel Qty Oil Qty SAE No Notes ...

Page 207: ...Service Charts 203 Filled Date Mileage Fuel Qty Oil Qty SAE No Notes ...

Page 208: ...204 Service Charts Filled Date Mileage Fuel Qty Oil Qty SAE No Notes ...

Page 209: ...Service Charts 205 Filled Date Mileage Fuel Qty Oil Qty SAE No Notes ...

Page 210: ...206 Service Charts ...

Page 211: ...kcase Breather 118 Crushing Prevention 13 Cutting Prevention 13 D DriveShaft Maintenance 141 E Electric Grounding Practices 17 Electric System Precautions 17 Electronic System Precautions 18 Emissions Control Compliance 95 Engine Air Filter 119 Engine Compartment Overview 24 Engine Damage Prevention 15 Engine Data Notes 31 Engine Features 26 Engine Monitoring Systems 18 Engine Oil Change 116 Engin...

Page 212: ... Oil Sampling General 70 Oil Sampling Taking 70 Oil Sulfur Level 68 Oil System 59 Oil Total Base Number TBN 68 Oil Viscosity 67 Oil Synthetic 66 Owner Information General 1 Owner s Information Package 2 P Power Steering Reservoir 143 R Radiator Package Cleaning 127 Rear Axle Oil 141 Respiratory Hazard Prevention 12 Roadside Assistance 172 S Safety Defects Reporting 19 Safety Information 3 Safety I...

Page 213: ...stance the group for technical and parts support is available 24 hours per day 7 days per week at 1 877 978 6586 This assistance is available to help you with solving technical issues and parts issues regarding the Volvo Heavy Duty VHD model vehicle A trained Volvo VHD Specialist for Technical and Parts Support will give you the assistance you need to resolve your problem 1 800 52 VOLVO 1 877 97 V...

Page 214: ... America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 6490 Vipond Drive Mississauga Ontario L5T 1W8 http www volvotrucks volvo com PV776 TSP20 154789 5000 10 2001 Volvo Trucks North America Inc 2001 ...

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