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Volvo VAH 2013, Operator'S Manual, Page: 111 / 175

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Volvo VAH 2013 Operator'S Manual Download Page 111

Operator's Manual Vehicle Maintenance

VN, VHD 107

Turbocharger and Charge Air Cooler

DANGER

If oil leaks internally from the turbocharger to the engine intake, the oil acts as a
fuel. Watch for excessive exhaust 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 over speed. Loss of control of vehicle may lead to an accident causing severe
personal injury or death.

WARNING

DO NOT remove, attach, or tighten turbocharger air intake ducting while the engine
is operating, or operate the engine while the ducting is removed. Working around
the turbocharger with the ducting removed may cause severe personal injury.

Visually inspect turbo mountings, intake and exhaust ducting and connections for
leaks on a daily basis. Check oil inlet and outlet for leaks or signs of restrictions 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.

Summary of Contents for VAH 2013

Page 1: ...Volvo Trucks Driving Success R OPERATOR S MANUAL VEHICLE MAINTENANCE VN VHD VAH Volvo d11H d13H AND D16H engines ...

Page 2: ......

Page 3: ... Overview D16H Right Side View 49 Engine Storage 50 Engine Storage 50 Maintenance and Service 51 Maintenance Hazards 51 Engine Components Service Schedules 51 Cooling System 68 Fuel System 73 Engine Oil 86 Engine Air Filter 94 Exhaust Aftertreatment System 96 Fan and Auxiliary Drive Belts 104 Turbocharger and Charge Air Cooler 107 Fuel System Service 110 Transmission Clutch and Rear Axle Maintenan...

Page 4: ...Literature 168 Service Assistance and Manuals 168 ...

Page 5: ...on to the new customer 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 Group North America LLC should be informed immediately if you believe that the...

Page 6: ...ctices which could result in serious personal injury or death The danger label is in white type on a black background with a black border WARNING A warning label directs the operators 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 CAUTION A caution label directs the oper...

Page 7: ... even death Information in this manual refers to VOLVO components and VOLVO drivetrain For information regarding the Cummins engine contact Cummins directly For detailed information on 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 possib...

Page 8: ...ssible VOLVO Trucks North America reserves the right to make changes at any time or to change specifications or design without notice and without incurring obligation General USA USA The Federal Clean Air Act Section 203 a 3 states the following concerning the removal of air pollution control devices or modification of a certified engine to a non certified configuration CAA Section a 3 A prohibits...

Page 9: ...aw for Emission Control which adheres to EPA regulations No changes should be made that render any or all of the emissions control devices inoperative Should the owner operator wish to make any changes to the emission control devices check with the state authority before making any such changes Federal Emission Requirements This section covers the requirement of the United States Clean Air Act whi...

Page 10: ...erson engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines following its sale and delivery to the ultimate purchaser or 4 Any person who operates a fleet of motor vehicles following its sale and delivery to the ultimate purchaser Note For specifics of the prohibited vehicle engine modifications refer to the VOLVO Bodybuilder documentatio...

Page 11: ...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 Note Not covered by the Emissions Control Syst...

Page 12: ...t DPF Assembly with Aftertreatment Diesel Oxidation Catalyst DOC Aftertreatment Doser Diffuser Pipe Aftertreatment Doser Mounting Fuel lines to Aftertreatment Doser Aftertreatment Fuel Shutoff Valve Aftertreatment Fuel Pressure Sensor Discharge Recirculation Valve DRV Heat Mode Discharge Recirculation Valve DRV Solenoid Engine Turbocharger Compressor Bypass Actuator Heat Mode Engine Turbocharger C...

Page 13: ...arger to Aftertreatment System 21 Data Link Connector DLC Engine Gaseous Emissions Control System Warranty The emission warranty for the diesel particulate filter and SCR Systems covers defects in workmanship only Normal maintenance such as cleaning ash from the filter at regular maintenance intervals and cleaning the Aftertreatment fuel injector on Diesel Oxidation Catalyst DOC DPF systems is not...

Page 14: ...eral and Canadian emissions regulations applicable at the time of manufacture of the engine and to be free from defects in material and workmanship under normal use and service up to 60 months or 160934 km 100 000 miles whichever occurs first provided that all maintenance requirements are followed as described in this manual All warranty periods are calculated from the date in service of the new v...

Page 15: ...r Note For specifics of the prohibited vehicle engine modifications refer to the VOLVO Body Builders documentation California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and VOLVO Trucks North America are pleased to Explain the emission control system warranty on your 2013 2014 vehicle In California new motor vehicle engines must be d...

Page 16: ...ime Owner s Warranty Responsibilities As the motor vehicle engine owner you are responsible for the performance of the required maintenance listed in this manual VOLVO recommends that you retain all receipts covering maintenance of your vehicle but VOLVO cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance listed in other m...

Page 17: ...16 Aftertreatment Diesel Particulate Filter DPF with Aftertreatment Diesel Oxidation Catalyst DOC Aftertreatment Doser Diffuser Pipe Aftertreatment Fuel Doser Mounting Fuel lines to Aftertreatment Fuel Doser Aftertreatment Fuel Doser Air Supply Regulator Aftertreatment Fuel Shutoff Valve Aftertreatment Fuel Pressure Sensor Engine Exhaust Gas Temperature EGT Sensor Aftertreatment DPF Intake Tempera...

Page 18: ...t DEF Tank Temperature Sensor Aftertreatment DEF Level Sensor Aftertreatment DEF Heated Lines Aftertreatment DEF Quality Sensor 19 Instrument Cluster Repair of microprocessor OBD MIL Real Time Clock Aftertreatment DEF Tank Gauge and Aftertreatment DEF Tank Low Level Indicator 20 Exhaust Gas Piping from Turbocharger to Aftertreatment System 21 Data Link Connector DLC ...

Page 19: ...n 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 replacement part within the limitations of paragraphs 3 and 4 in this section An emergency condition exists under this section if after 30 days repairs have not been completed or parts are not yet available VOLVO will reimburse the owner for s...

Page 20: ...nance records should be transferred to subsequent owners if the vehicle is sold 6 Items Not Covered by the Emission Control Systems Warranty Malfunctions caused by misuse improper adjustments modification alteration tampering disconnection improper or inadequate maintenance and use of improper diesel fuel Damage resulting from accident acts of nature or other events beyond the control of VOLVO Tru...

Page 21: ...XCLUSIONS TO THIS WARRANTY APPEAR ON THE FOLLOWING PAGES THESE LIMITATIONS AND EXCLUSIONS ARE IMPORTANT AND MUST BE READ AND UNDERSTOOD This warranty applies to new 92 92 vehicles certified to the requirements of 40 CFR part 1037 92 92 7UXFNV reserves the right to make any changes in design or make additions to or upon its products without incurring any obligations to install the same changes on v...

Page 22: ...nt tires installed on this vehicle at the factory were certified to the U S EPA Greenhouse Gas GHG and NHTSA Fuel Efficiency regulations Replacement of these tires should be with a tire of equal or lower rolling resistance levels TRRL or Crr Please consult your tire supplier s for appropriate replacement tires Maintaining a GHG certified tire In order to maintain the certified rolling resistance o...

Page 23: ...fication Engine Vehicle Wire Harness Only circuits specifically connected to other emission related components Instrument Cluster Repair of microprocessor Real Time Clock Only where they are part of the certified emission controls See youU 92 92 Dealer for coverage identification Sensors Ambient Air Temperature Sensor Engine Coolant Temperature Sensor Engine Speed Sensor Transmission Speed Sensor ...

Page 24: ...onents Highway Tractors Only Chassis Fairings Ground Effect Extensions Roof Deflectors Cab Side Deflectors Adjustable Roof Extensions Side Deflector Extensions Bumper Deflectors A pillar Deflectors 60 Months or 160934 km 100 000 Miles whichever occurs first Air Conditioning Components Only those vehicles certified as Tractors according to the requirements of Chapter 40 of the Code of Federal Regul...

Page 25: ...rol Log page 163 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 additional log s...

Page 26: ...erature modulated cooling fan system Removal of the cooling fan shroud Removal or rendering inoperative of the air cleaner or air intake in line silencer Removal of the sound deadening material from the hood or cab tunnel Removal or rendering inoperative of the engine speed governor so as to allow engine speed to exceed the manufacturers specifications Removal of splash shields located inside the ...

Page 27: ... engine fan can engage 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 recirc...

Page 28: ...xhaust system fasteners brackets and clamps for damage and tightness Regulatory Compliance Acts that constitute tampering 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 compon...

Page 29: ...filter filter housings ducts etc Engine Control EGR and Fuel Systems Acts that constitute tampering with Engine Control EGR and Fuel Systems Removing rendering inoperative 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 manufacturers specifications is not allowed and violates both warranty...

Page 30: ...VHD Similar 1 Transmission Type and Gear Pattern and Exhaust Aftertreatment Systems EATS This information is located in the visor 3 VIN Major Components Located in the door frame B pillar 2 VIN GAWR Located in the door frame B pillar 4 Vehicle Noise Emission Located in the door frame B pillar ...

Page 31: ...AUTION On sleeper models equipped with fluorescent lighting there is a 3 AMP maximum fuse located in the lighting fixture W3035176 The fuse relay panel is located under the hood of the vehicle The vehicle has an electrical center located under the hood on the driver s side of the vehicle near the steering shaft Since the function of some fuses or relays may change for the vehicle application refer...

Page 32: ...28 Operator s Manual Vehicle Maintenance VN VHD W3032984 ...

Page 33: ...se Prolonged or excessive exposure may cause serious illness or death DANGER Never operate the engine in an area where hydrocarbon vapors gasoline for example are present or are suspected to be present 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 DANGER Never try to opera...

Page 34: ...t having sufficient training correct service literature and the proper tools Failure to follow this could lead to personal injury or making your vehicle unsafe WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm ...

Page 35: ...overs and guards are in place and properly secured Never put maintenance fluids into glass containers since glass containers can break Report all problems in a timely manner before they threaten the safety of operating the vehicle DO NOT work on the engine while it is running Make sure protective locks and covers are in their proper place DO NOT use high amperage electronic starting devices for ju...

Page 36: ...nformation Note The VOLVO engine and replacement parts for it shipped from the factory are asbestos 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 DANGER Always use a piece of paper or cardboard when checking for a leak E...

Page 37: ...fore raising the hood 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 cap is taken off too soon which can cause personal injury and damage to engine components W0001525 DO NOT touch any part of the engine while it is hot Allow the eng...

Page 38: ...re is relieved rapidly in a hot cooling system the hot coolant 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 Verify coolant level only by the markings on the expansion tank Open the filler cap only after the engine is stopped and cooled down Remove the filler cap slowly to reliev...

Page 39: ...recommended Always wear protective glasses when working with batteries Speed Restrictive Tires DANGER Operating a vehicle equipped with speed restrictive tires in excess of their stated rating may result in tread separation and or blowout resulting in the loss of steering control and possible collision Serious personal injury or death could occur Always maintain proper air pressure and never excee...

Page 40: ...he air conditioned system to explode Some mixtures of R134a refrigerant can become combustible at elevated pressures Never weld solder steam clean or use a gas torch near any part of the air conditioning system Severe injury or death may occur from an explosion W0001526 DANGER DO NOT service any part of the fuel system while smoking or in the presence of flames sparks or hot surfaces Failure to fo...

Page 41: ...ed 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 material such as fuel oil and other substances before they accumulate on the engine DO NOT expose the engine to flames driving over burning ground DO NOT weld or flame cut on or around pipes or tubes that contain flamma...

Page 42: ...th defects and other reproductive harm W0001523 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 DANGER Coolant is toxic risk of poisoning DO NOT drink coolant Use proper hand protection when handling Keep coolant out of reach of children and animals Failure to follow these precautions can cause serious...

Page 43: ... engage at any time without warning Anyone near the fan when it turns on could be seriously injured W0001524 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 pr...

Page 44: ... Manual for proper 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 DANGER 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 ...

Page 45: ...er starting Diesel engine exhaust contains products of combustion which may be harmful to your health Always start and operate the engine in a well ventilated area 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...

Page 46: ... 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 property damage serious personal injury or death W0001484 ...

Page 47: ...ompartment for loose or 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 engi...

Page 48: ...ith the electrical and 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 electron...

Page 49: ...Canada Defect 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 men...

Page 50: ...hown D11H Engine Similar 1 Breather Tube 9 Fuel Filter 2 Intake Manifold 10 Hand Priming Pump 3 Air Compressor 11 Crankcase Ventilator 4 Power Steering Pump 12 Alternator 5 Fuel Pump 13 AC Compressor 6 Engine Control Module ECM 14 Alternator AC Compressor Belt 7 Fuel Filter 15 Fan Coolant Pump Belt 8 Fuel Water Separator 16 EGR Mixing Chamber ...

Page 51: ... View W2006035 D13H Engine Shown D11H Engine Similar 17 Exhaust Manifold 24 Venturi Pipe 18 Valve Cover 25 Oil Filters 19 Intake Air Heater IAH optional 26 Oil Pan 20 Thermostat 27 EGR Cooler 21 Belt Tensioner 28 Turbocharger 22 Coolant Pump 29 Starter Motor 23 Coolant Filter 30 EGR Valve ...

Page 52: ...el Water Separator 2 Intake Manifold 10 Fuel Filter 3 Air Compressor 11 Hand Priming Pump 4 Power Steering Pump 12 Alternator 5 Fuel Pump 13 AC Compressor 6 Crankcase Ventilator 14 Alternator AC Compressor Belt 7 Engine Control Module ECM 15 Fan Coolant Pump Belt 8 Fuel Filter 16 Venturi Pipe 17 EGR Mixing Chamber ...

Page 53: ...ne Overview D16H Right Side View W2006036 18 Exhaust Manifold 24 Coolant Filter 19 Valve Cover 25 Oil Filters 20 Intake Air Heater IAH 26 EGR Cooler 21 Thermostat 27 Oil Pan 22 Belt Tensioner 28 Starter Motor 23 Coolant Pump 29 Turbocharger 30 EGR Valve ...

Page 54: ...nks with the recommended grade of fuel 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 ...

Page 55: ...ad all safety information before working on the vehicle Refer to Proper Maintenance Procedure page 29 Engine Components Service Schedules Component Operation Km Miles Maximum Months Hours Fuel Filter D11 D13 and D16 Change Each oil change Water Separator D11 D13 and D16 Filter change Each oil change Air Filter US2010 Change At maximum restriction as indicated on gauge or 12 months Fuel Tank Ventil...

Page 56: ...just 200 000 125 000 or 12 months whichever comes first Drive Belts Pinnacle Highway Change 500 000 300 000 or 36 months whichever comes first Drive Belts VHD Euro 4 Vocational Change 240 000 150 000 or 12 months whichever comes first Accessory Drive Belt Pinnacle Highway Change 500 000 300 000 or 36 months whichever comes first Accessory Drive Belt VHD Euro 4 Vocational Change 240 000 150 000 or ...

Page 57: ...park Assisted System only Clean Vocational Application 240 000 150 000 miles or 4 500 hours whichever comes first Aftertreatment Hydrocarbon Doser If equipped D11 D13 and D16 Clean 240 000 150 000 or 4 500 hours whichever comes first Under certain conditions for example irregular fuel quality the fuel water separator filters may require more frequent replacement Valves must be adjusted whenever th...

Page 58: ...g through the pre trip inspection Remember that a careful pre trip inspection saves time by eliminating unscheduled stops for correcting a faulty item The following information has been provided by the American Trucking Association as developed by the D O T Office of Motor Carriers BMCS W0001230 VN ...

Page 59: ...sing lock rings bent or broken studs missing clamps or lug nuts Check condition of tire properly inflated no serious cuts bulges tread wear or any signs of misalignment valve stem not touching wheel rim or brake drum valve cap in place Check wheel bearing and hub no obvious leaking on outside or inside wheel Verify correct oil level in hub Left Front Suspension Check condition of the springs leaf ...

Page 60: ...age Check air filter with brackets and hoses for loose connections or damage Check filter gauge if mounted on the filter Step 2 Front of Cab Area Condition of Windshield Check for damage and clean if dirty Check windshield wiper arms for proper spring tension Check wiper blades for any damage dead rubber and attachment to arm Lights and Reflectors Lower cab and inspect parking clearance and identi...

Page 61: ...overs are in place For additional information on the disc brake check refer to Disc Brake Check page 121 Condition of brake air hose check for any chafing Check brake chamber mounting bolts and bracket Check slack adjuster and chamber pushrod travel With brakes applied or released look for conspicuously different positions of the slack adjusters for proper brake adjustment Condition of Front Axle ...

Page 62: ... obvious leaking on outside or inside wheel Suspension Check condition of springs leaf spring hangers shackles and U bolts Axle alignment Brakes Condition of brake drums With brakes released look for a noticeable gap between lining and drum This check cannot be made if dust covers are in place For additional information on the disc brake check refer to Disc Brake Check page 121 Condition of brake ...

Page 63: ...pacers studs missing clamps or lug nuts Check condition of tires properly inflated no serious cuts bulges tread wear or any signs of misalignment valve stems not touching wheels rims or brake drums valve caps in place and no objects stuck between the wheels Check that both tires are of same type for example not mixed radial and bias type and that their circumferences are matched Check wheel bearin...

Page 64: ...ea Open the battery box Battery box securely mounted to vehicle Batteries secured against movement Battery cases not broken or leaking Battery cables free from damage Tops of batteries and terminals clean and free from foreign material If equipped replace battery lid and make sure it is securely fastened In the Cab Check steps and grab handles for looseness or breakage Also clean them if there is ...

Page 65: ...ase lever properly seated and safety latch lock engaged Check all connections to dolly or trailer hitch and safety chains are secured Check function of trailer air supply valve and trailer brakes Sliding Fifth Wheel Check that fifth wheel is not so far forward that the tractor frame will strike the landing gear during turns Note Refer to the trailer manufacturer s manual for specific information o...

Page 66: ...ings bent or broken spacers studs missing clamps or lug nuts Check condition of tires properly inflated no serious cuts bulges tread wear or any signs of misalignment valve stems not touching wheels rims or brake drums valve caps in place and no objects stuck between the wheels Check that both tires are of same type for example not mixed radial and bias type and that their circumferences are match...

Page 67: ...cured End gates free from damage properly secured in stake pockets Canvas or tarp if required properly latched down to prevent water damage tearing billowing or blockage of either mirrors or tail lights Rear doors securely closed latched or locked required security seals in place Underside guard in place not cracked bent or broken Step 13 Left Rear Trailer Wheels Area Dual Wheels One or Two Axles ...

Page 68: ...g Check brake chamber mounting bolts and brackets Check slack adjusters and chamber push rod travel With brakes applied or released look for conspicuously different positions of the slack adjusters Check spring brakes Step 14 Left Side of Trailer Area Landing Gear or Dolly Area Fully raised no missing or damaged parts Crank handle present and secured If power operated no air hydraulic leaks Spare ...

Page 69: ... while applying the trailer brakes with the trailer brake hand control valve Test the service brakes before leaving the parking area Test parking brakes by stopping on a 20 grade and applying the parking brakes The parking brakes shall hold the combined vehicle and trailer without moving ...

Page 70: ...nd and the units at normal operating temperature Components must be filled to the correct level DO NOT OVERFILL Note Oil and filter change intervals in this manual pertain to components built by VOLVO Truck For information concerning oil and oil filter change intervals for vendor components refer to the specific vendor component service literature During the First 5000 Kilometers 3000 Miles After ...

Page 71: ... rear axle alignment and adjust if the alignment is out of specifications Check steering knuckle to axle beam clearance Although this quality built vehicle has been inspected lubricated and adjusted at the VOLVO Trucks Assembly Plant an occasional air oil or coolant leak may develop Quick action to correct these minor items will prevent a major repair later Take the vehicle to the nearest VOLVO se...

Page 72: ... engine and radiator are still hot Scalding fluid and steam may be blown out under pressure if the cap is taken off too soon and can cause personal injury WARNING Coolant may be combustible Coolant leaked or spilled onto hot surfaces or electrical components can cause a fire Clean up coolant spills immediately CAUTION VOLVO Trucks North America does not recommend using plain water in the cooling s...

Page 73: ...n 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 operators manual for more information on the warning functions W2006041 Note Always dispose of coolant according to Federal or local regulations Take all used coolant to a recycling or waste collection center Coolant mixture co...

Page 74: ...rated heater and radiator hoses loose hose clamps and connections and radiator leaks DANGER DO NOT work near the fan with the engine 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 near the fan CAUTION Never add coolant to a hot or overheated engine Engine damage can ...

Page 75: ...s The charged coolant filter contains 8 units of SCA that are released slowly over time to maintain the recommended level during operation Consult engine service manual for proper SCA level and change intervals Extended Life Coolant Change Interval CAUTION Extended life coolant will test as out of additives SCA but SCA should not be added Shortened engine life may be the result of adding SCA Note ...

Page 76: ...VN VHD Extended Life Coolant Filter Change Interval WARNING Hot engine Keep clear of all hot engine parts and fluids A hot engine and fluids can cause serious burns CAUTION DO NOT use a filter that contains SCA Damage to components can result ...

Page 77: ... DO NOT mix gasoline or alcohol with diesel oil fuel This mixture can cause an explosion and result in severe personal injury or death DANGER 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 WARNING If a fuel leak is detected stop the engine immediately The vapors from hot fuel are highly...

Page 78: ...tic 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 Note The use of lighter fuels grade No 1 D can reduce fuel economy Note Euro 4 Engines Ultra Low Sulfur Diesel ULSD fuel with a maximum sulfur content of 15 ppm is required to meet emission certification for Euro 4 emission engines Using a...

Page 79: ...nation 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 eliminate microorganism growth in storage tanks In cold conditions treatment for water in the vehicle tanks may also be necessary Consult your fuel supplier about the...

Page 80: ...e Cetane improvers Emission control additives Detergents Combustion improvers Smoke suppressants Cold weather flow improvers Note 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 Th...

Page 81: ...an extender in 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 combu...

Page 82: ...io fuel used in the blend conforms to ASTM D6751 and B1 to B5 blends conform to ASTM D975 and B6 to B20 blends conform to ASTM D7467 Customers will need to utilize oil sampling to establish appropriate drain interval s for their application s Fuel Storage If fuel is stored on site Keep storage tank covered to prevent water entry DO NOT use a tank made of galvanized metal or any galvanized piping f...

Page 83: ...nted on the frame rail This filter consists 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 control module ECM The filter is a spin on filter W2006058 D11H and D13H Engine Mounted Fuel Filters D13H shown D11H similar ...

Page 84: ...80 Operator s Manual Vehicle Maintenance VN VHD W2006061 D16H Engine Mounted Fuel Filters ...

Page 85: ...te in a fuel safe 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 chang...

Page 86: ...in off any water and or sediment Yearly or at 200 000 Km 120 000 mi tighten all fuel tank mountings and brackets Check all hoses pipes and lines to and from the fuel tank At the same time inspect tank and connections for any signs of leakage Make sure that hoses and lines are not resting on or touching shafts couplings hot surfaces or sharp areas Since all machinery vibrates and moves to a certain...

Page 87: ...lable tank mounted or stanchion exhaust bracket mounted Attached to the fuel tank support bracket is the fuel tank ventilation filter The purpose of this component is to filter out contaminants that can enter the fuel tank from the vent lines This filter should be replaced in conjunction with the vehicle air filter every 12 months 1 Fuel Tank Ventilation Filter ...

Page 88: ...ank vent lines and mounted on the stanchion exhaust bracket at the right side of the truck This is for extremely dusty applications For both single or dual tank applications the vent lines will run from the tank vent fittings to the fuel tank ventilation filter This filter should be replaced in conjunction with the vehicle air filter every 12 months W2069496 ...

Page 89: ...or bowl while the engine is running Note Drain the filter water trap daily Change the fuel water separator filter at every oil change or when the fuel reaches the top of the filter W2080277 1 Drain Valve ELEMAX Filter SEEING IS BELIEVING The patented clear cover allows the user to know when not to change the filter Fuel level rises as the filter media becomes contaminated the fuel filter doesn t n...

Page 90: ... ULSD fuel EO O Premium Plus oils exceed the new API service category CJ 4 CAUTION DO NOT add extra oil additives Additives such as break in oils top oils graphitizers and friction reducing liquids are not necessary and can harm the engine Oil Change Intervals The length of time an engine can operate before an oil change depends on the quality oil used the type of fuel used fuel consumption engine...

Page 91: ...r This should be changed at the same time as the full flow filter s CAUTION VOLVO branded oil filters are designed to provide the proper level of filtration and protection for VOLVO engines Filters that do not meet the same stringent requirements may void engine warranty W2006059 D11H and D13H Oil Filters D13H shown D11H similar ...

Page 92: ...88 Operator s Manual Vehicle Maintenance VN VHD W2006060 D16H Oil Filters ...

Page 93: ... oil quality that determines the useful engine oil life and therefore the 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 Choose the v...

Page 94: ...in 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 to drain back to the oil pan before checking Add oil as necessary Note DO NOT overfill engine with oil All diesel engines are designed to consume some oil so it is normal to add oil periodically...

Page 95: ...t 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 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 For information on the type of oil recommended for your engine see Oil...

Page 96: ... VOLVO branded oil filters are designed to provide the proper level of filtration and protection for VOLVO engines Filters that do not meet 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 ...

Page 97: ...pstick DO NOT overfill so the level is above the upper marking on the dipstick This could lead to excessive oil temperature and or poor crankcase breather performance Ensure that the vehicle is parked on level ground before checking the oil level Wait five minutes after shutting off the engine then proceed with checking oil W2056443 ...

Page 98: ...ngine air 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 Operators 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 ext...

Page 99: ...Operator s Manual Vehicle Maintenance VN VHD 95 W2003946 W2003945 ...

Page 100: ...n experience surface temperatures as high as 350 C 662 F It is important to verify the temperature at which the material or substance in or associated with the body can ignite If it is possible for the material or substance to fall or leak from the body take steps to prevent them from contacting or collecting on the DPF or SCR Failure to do so may result in fire It is important to note that additi...

Page 101: ...n to safer substances before being released to the atmosphere Some of the ash remains but takes a long time to reach the point where ash clogs the filter Cleaning a filter so it can continue to function is called regeneration Either system uses high heat to break down the chemical properties Depending on vehicle usage the engine is equipped with a passive or active regeneration system In passive r...

Page 102: ... hydrocarbon HC released The injected fuel will increase the EGT by oxidation of hydrocarbon An aftertreatment diesel oxidation catalyst DOC is mounted upstream of the aftertreatment diesel particulate filter DPF This elevated temperature is needed for the aftertreatment selective catalytic reduction SCR system and DPF The HC system shall be governed by the engine control module ECM The dosing sys...

Page 103: ...he exhaust stream into harmless gases Modern diesels already use exhaust aftertreatment systems called diesel particulate filters to control emissions of another pollutant soot also known as particulate matter or PM SCR works by injecting Diesel Exhaust Fluid DEF into the exhaust steam after the DPF DEF is a safe simple solution of water and urea DEF works with the heat of the exhaust and a cataly...

Page 104: ...gine The vertical SCR catalyst also comes in two different sizes one for the D11 D13 engines and larger size for the D16 engine The VOLVO SCR system is simple and effective with few components It consists of a Aftertreatment DEF tank positioned near the standard diesel tank plus a Aftertreatment DEF pump Aftertreatment DEF Dosing unit and SCR catalyst The advantage of using DEF is that it enables ...

Page 105: ...a is a compound of nitrogen that turns to ammonia when heated It is used in a variety of industries perhaps most commonly as a fertilizer in agriculture The fluid is not flammable nor is it dangerous when handled normally However it is highly corrosive to metal particularly copper and aluminium Read the separate section concerning the handling of DEF solution Only use approved DEF fluid W3036787 ...

Page 106: ...illed Diesel Exhaust Fluid DEF If urea solution comes into contact with the skin rinse with plenty of water and remove contaminated clothing If urea solution comes into contact with the eyes rinse for several minutes and call for medical help if necessary If inhaled breathe fresh air and call for medical help if necessary Do not allow the DEF solution to come into contact with other chemicals The ...

Page 107: ...ely vehicle power will be reduced to derate mode Refill the DEF tank when refilling the fuel tank the engine will resume normal power Note DEF tanks are sized for a two to one fuel to DEF ratio in order to meet US 2010 requirements Diesel Exhaust Fluid DEF Availability DEF will be available in 2 5 gallon containers 55 gallon drums 275 gallon IBC and in bulk storage for fleet locations truck stops ...

Page 108: ...ngine 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 W2006045 Drive Belts A drive belt routing label is located on the vehicle frame rail ...

Page 109: ...Operator s Manual Vehicle Maintenance VN VHD 105 W2005874 Drive Belt Routing Label ...

Page 110: ...106 Operator s Manual Vehicle Maintenance VN VHD W2005875 Drive Belt Routing Label Location ...

Page 111: ...dent causing severe personal injury or death WARNING DO NOT remove attach or tighten turbocharger air intake ducting while the engine is operating or operate the engine while the ducting is removed Working around the turbocharger with the ducting removed may cause severe personal injury Visually inspect turbo mountings intake and exhaust ducting and connections for leaks on a daily basis Check oil...

Page 112: ...educed air flow reduces the heat transfer from the components to the air This increases the load on the fan and air conditioning compressor and can result in engine overheating and other performance related problems such as high fuel consumption etc CAUTION When using a pressure washer to clean the vehicle do not direct the spray at electrical components in the engine compartment such as the alter...

Page 113: ...e Air Cooler and Radiator typical radiator shown Inspect the charge air cooler for cracks at every inspection DO NOT operate the vehicle with a damaged or broken charge air cooler To do so would void the warranty and the engine will not meet emission regulation requirements ...

Page 114: ...ant to maintain high cleanliness 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 filt...

Page 115: ... for example cleaning or replacing fuel filter elements The engine is new or rebuilt CAUTION 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 Note When the fuel system is empty 200 or more pump strokes may be needed ...

Page 116: ...system by moving 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 117: ...d When the water in fuel indicator activates the cluster displays the water in fuel icon and the message Water in Fuel Drain at next stop W3004309 When the operator chooses draining and the engine fulfils the conditions for priming the icon shown below is displayed in the status icon bar T3019229 When the operator chooses draining and the engine fulfils the conditions for draining the icon shown b...

Page 118: ...ntly at temperatures above 120 C 250 F Operating temperatures above 120 C 250 F increase the lubricants rate of oxidation and shorten its effective life If the temperature reaches 140 C 285 F stop the vehicle to let the temperature go down See the vehicle Operators Manual for information on the optional transmission temperature gauge If the transmission oil temperatures are consistently high chang...

Page 119: ...lutch 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 W2006043 1 Clutch Fluid Reservoir 3 Brake Valve 2 Windshield Washer Fluid Fill ...

Page 120: ...n lubrication 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 ventilati...

Page 121: ...topped With 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 in 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 W6001506 ...

Page 122: ...steering system Change fluid every 240 000 Km 150 000 mi Change the 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 W2064870 1 Maximum Level 2 Minimum Level ...

Page 123: ...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 result in serious consequences This practice gives th...

Page 124: ...tem 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 system that cleans out the accumulated moisture but eventually the drying medium will reach the end of its useful life See your authorized VOLVO Truck dealer Effective mid September 2008 all VOLVO ch...

Page 125: ... be found via a visual search For additional instructions on locating the lining wear indicator reference the brake manufacturer s service information The two main brake manufacturer s found on VOLVO vehicles are Meritor and Bendix Service documentation for each maker can be found at their main internet site Meritor http www meritor com customer northamerica default aspx Bendix http www bendix com...

Page 126: ... Vehicle Maintenance VN VHD W5082347 Brake Pad Wear Indicator 1 New Condition 2 25 Wear 3 50 Wear 4 75 Wear Note If the brake pad wear indicator shows 75 or more wear then the pads require further inspection or replacement ...

Page 127: ... pressure washer to clean the vehicle do not direct the spray at electrical components in the engine compartment such as the alternator starter and compressors Water spray from pressure washers can damage electrical components The electrolyte level on maintenance free batteries cannot be checked Periodically the condition and the state of charge of each battery should be checked by a VOLVO Truck d...

Page 128: ...y 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 ...

Page 129: ...a fuse connections All ground stud connections Electrical pneumatic pass thru connections All alternator connections All starter connections Intake preheater and preheater relay connections Electrical power inverter connections EFRC Ground studs on the cab firewall All connections should be cleaned and free of previously applied inhibitors oil dirt dust or other contaminants prior to application A...

Page 130: ...nd serious personal injury or death can occur DANGER 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 DANGER DO NOT install regrooved retreaded or repaired tires on the steering axle s They could fa...

Page 131: ...ing the wheels 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 death DANGER 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 resulti...

Page 132: ...first retightening 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 ft lb 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 o...

Page 133: ...ay cause side wall 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 W7001270 Measure the tread depth The depth should not be less than 4 8 mm 6 32 in on front tires and not less than 1 6 mm 2 32 in on drive tires Most premium steer tires start with ...

Page 134: ...eels 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 recommended practice 642 entitled Total Vehicle ...

Page 135: ...31 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 T1006457 Incorrect Camber Incorrect camber gives abnormal wear on one half of the tire T1006458 ...

Page 136: ... Steering arm defect T1006459 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 137: ...ator s Manual Vehicle Maintenance VN VHD 133 T1006718 Incorrect Caster and Imbalance A Caster angle B Imbalance Also rapidly wears the mechanical parts of steering linkage kingpin and wheel bearing T1006460 ...

Page 138: ...Tread A Cuts B Flaking cuts C Rubber flaking Cuts are due to poor roads air pressure too high or incorrect tire type T1006720 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 T1006720 ...

Page 139: ... Vehicle Maintenance VN VHD 135 Spot Wear Sudden braking locking brakes or out of round brake drums give spot wear T1006721 Feathered Edges Normal occurrence on non driving wheels on good roads and high mileage T1006722 ...

Page 140: ...136 Operator s Manual Vehicle Maintenance VN VHD Cupping Cupping is a normal occurrence that depends on the tread pattern the higher the load the greater the wear T1006723 ...

Page 141: ...ulting in 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 th...

Page 142: ...Operator s Manual Vehicle Maintenance VN VHD Unitized Front Hubs The non tapered axle hubs are sealed with lubricant inside the hub and do not require lubrication W1000213 Unitized Hubs Non Tapered Axle End ...

Page 143: ...Operator s Manual Vehicle Maintenance VN VHD 139 W1000212 Tapered Axle End ...

Page 144: ...U bolt nuts 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 torq...

Page 145: ...ng the 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 W7000449 Grease Fittings Rubber Bushings Rubber bushings are used for extended service life If your vehicle is equipp...

Page 146: ...door stop 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 freez...

Page 147: ...d to work or binds the latch should be cleaned before greasing W8003841 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 148: ... filter more often if driving in dusty conditions A clogged filter decreases the efficiency of the air conditioning system W8003189 If the vehicle is equipped with a sleeper heater A C system there is a filter for recirculating air It is located behind the passenger seat on the bunk support The filter should be checked after 19 200 Km 12 000 mi more often in dusty conditions Replace the filter as ...

Page 149: ...Apply a coat of wax regularly This will help the paint and other surfaces keep their luster If the surface gets dull use a restoring cleaner specially designed for this Clean off all tar spots and tree sap before waxing Chassis Keep the chassis free from buildup of dirt Make sure the chassis is cleaned before the maintenance inspections to help spotting leaks etc As salt can be part of the road sl...

Page 150: ...move rust spots use a non abrasive chrome cleaner and apply a coat of wax as a finish do not wax parts that get hot such as exhaust pipes etc Note Never use steel wool to clean chrome Pieces of the steel wool break off and can create rust stains on the surface Aluminum Unprotected aluminum surfaces will form an oxide layer if not maintained This is especially important during the cold season when ...

Page 151: ...ction Staining cracking scuffing and fading can result CAUTION DO NOT use gasoline naphtha or similar cleaning agents on the plastic or leather since these can cause damage Take extra care when removing stains such as ink or lipstick since the coloring can spread Use solvents sparingly Too much solvent can damage the seat padding Start from the outside of the stain and work toward the center Sharp...

Page 152: ...d be every 16 000 Km 10 000 mi 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 Lubr...

Page 153: ...Operator s Manual Vehicle Maintenance VN VHD 149 Lubrication Chart W1055585 ...

Page 154: ...o be removed if equipped Note Always grease a VOLVO front axle with the wheels on the ground Note To grease non VOLVO axles they are typically greased with the wheels on the ground Consult with the axle manufacturer for the latest recommendation 2 Slack adjuster Do not grease till 1st scheduled maintenance interval Note See Manufactures Specifications for specific grease Adjust according to the sp...

Page 155: ...n the clutch release system Mixing DOT 4 brake fluid with petroleum based oil will cause seal damage which will cause leakage 9 Clutch bearing linkage Use a lithium based grease with EP additives to specification API NLGI No 2 Note Inspection cover removal is necessary Lubricate according to Eaton s lubrication document and reinstall the inspection cover See http www roadranger com for the latest ...

Page 156: ...el should be to the bottom of the inspection hole I Shift transmission With the vehicle level the oil should be between the maximum and minimum levels on the sight glass Only use VOLVO approved oils Refer to function group 1 for the approved oils list 20 Auxiliary axle s If equipped with auxiliary lift axles use a lithium based grease with specification API NLGI No 2 Also lubricate the Brake Cams ...

Page 157: ...24 000 15 000 450 hours 16 000 10 000 300 hours D16H Engine Oil and Filter Change Intervals Engine Operating Condition Med ium Heavy 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 mi 42 L 44 quart oil capacity standard in VNL 56 00...

Page 158: ...nance VN VHD Eaton Fuller Transmission 9 10 13 15 and 18 speed For oil quality and oil change intervals see the manufacturers operators manual Capacity 9 speed 12 0 liters 13 5 quarts 10 13 15 and 18 speed 13 0 liters 14 0 quarts W1000179 ...

Page 159: ...5 liters 23 5 quarts RT40 145 160 front tandem 14 liters 15 quarts RT40 145 160 rear tandem 12 liters 13 quarts RT 46160 front RT 46160 rear approximately 18 liters 19 quarts approximately 16 liters 17 quarts W4000881 Select viscosity from the table above Temperatures refer to stable ambient temperature readings There is no upper limit to these outside temperatures but the axle sump temperature MU...

Page 160: ...4 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 Steering Hydraulic System Fluid type Automatic Transmission Fluid ATF Dexron lll Change interval Every 240 000 Km 150 000 mi or every 12 months Hubs Oil Type Temperature Motor oil API CD or CE SAE 30 15W40 or synthetic Minimum 25 C 15 F Maxim...

Page 161: ...ON CHECK CHANGE BASIC 4 MONTHS 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 Compressors 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 He...

Page 162: ... Battery Box X X Check Fuel Tank Hoses Pipes Venting and Mounting X X Check Fuel Water Separator for the Fuel system Draining 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 Abs...

Page 163: ... X Check Chassis Frame and Crossmembers X X Check Rear Wheels and Bearings X X Check Brake Linings X X Check Brake Cylinders Levers and Forks X X Check Oil Level in Manual Transmission 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 ...

Page 164: ...eck Transmission Oil Cooler hoses and Connections for leaks X X Valve Adjustment X REQUIRED Once a year every 209 000 Km 130 000 mi or 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 ...

Page 165: ...dvance and arrange for a service appointment 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 VOLVO Truck dealer ask for outstanding safety related recalls that relate to the vehicle This service is available only at an authorized VOLVO Truck...

Page 166: ...162 Operator s Manual Vehicle Maintenance VN VHD Work Completed Scheduled Service Date Date Mileage ...

Page 167: ...Operator s Manual Vehicle Maintenance VN VHD 163 Noise Control Log NOISE CONTROL SYSTEM MAINTENANCE LOG DATE MILEAGE MAINTE NANCE PER FORMED MAINTE NANCE FA CILITY ...

Page 168: ...ce VN VHD Repair Record Keep track of repairs being made 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 ...

Page 169: ...Operator s Manual Vehicle Maintenance VN VHD 165 Tire Record Tire Record Date Type Front Type Rear Notes Tire Pressure Tread Depths ...

Page 170: ...cord of what is normal for the vehicle 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 Accumulated Date Mileage Fuel Qty Gallon Oil Qty SAE No Notes ...

Page 171: ...l Engine Serial 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 172: ...ce If you need roadside assistance VAS can arrange for load forwarding or equipment rental 2 Personal Assurance Trained staff for handling any vehicle problems 3 Uptime Assurance VAS will locate the nearest service provider and guarantee payment so you can get on the road as soon as possible 4 Price Assurance VAS audits service and parts billing to ensure guaranteed labor rates and preferred parts...

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Page 175: ... Group North America LLC P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 5600A Cancross Court Missisauga Ontario L5R 3E9 http www volvotrucks com PV776 English 07 2013 Volvo Group North America LLC 2013 ...

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