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Volvo VNL, Operator'S Manual

The Volvo VNL is a remarkable commercial truck designed for heavy-duty transportation needs. To ensure optimal performance and maintenance, make sure to download the free Volvo VNL Service Manual from manualshive.com. This comprehensive manual encompasses all the necessary instructions and guidelines for maintenance, ensuring a smooth and efficient operation of your Volvo VNL.

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182

Heating and Air Conditioning

Air Vents

A

Closed

B

Open

C

Lateral Air Flow

D

Vertical Air Flow

When heating the cab, all vents should be
closed. However, the vents on the outer
parts of the dash can be used for defrosting
the cab door windows. When operating the
air conditioning, all air vents should be
completely open and the air flow directed
upward.

W8001150

Summary of Contents for VNL

Page 1: ...Operator s Manual VNL and VNM ...

Page 2: ... 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 VTNA should be informed imme diately if you believe that the vehicle has a defect that could cause a crash injury or death Contact NHTSA by calling the...

Page 3: ...ng Light Switches 104 Right Switch Cluster 106 Pneumatic Switch Cluster 110 Optional Switch Cluster 112 Miscellaneous Switches 113 Graphic Display 114 Graphic Display Overview 114 Graphic Display Controls 115 Graphic Display Telltales 117 Information and Stop Messages 118 Information Telltale 119 Stop Telltale 126 Acknowledge Information and Stop Messages 130 Main Menu Set Up Mode 132 Main Menu Sy...

Page 4: ...eration 249 Engine Operation 256 Cruise Control 265 Fuel Tank Cap s 267 Clutch and Transmission 269 Clutch 269 Folding Gear Lever option 270 Brakes 272 Brakes 272 Electrical System 292 Electrical System 292 Power Steering 309 General 309 Axles and Wheels 311 Axles 311 Wheels 313 Fifth Wheel Instructions 316 Fifth Wheel General Information 316 Fifth Wheel 319 Fifth Wheel Slider option 320 Unlocking...

Page 5: ...ote defines an operating proce dure practice condition etc which is essential to proper operation of the vehicle 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 unsaf...

Page 6: ... possible to maximize the amount of time your vehicle is up and run ning resulting in longer component life This makes for a safer vehicle by reducing any mechanical failures due to poor mainte nance practices Various truck warranty coverage plans con tingent on application and weight class are available Please contact an authorized Volvo Truck Dealer for complete details Replacement warranty cert...

Page 7: ...ch identifies the cab type This manual together with manuals 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 s...

Page 8: ...s and other visibility enhancement devices will eliminate all blind spots in every situation The safe operation of this vehicle is up to you Because of your special preferences needs and circumstances you may want to add extra mirrors and or other visibility en hancement devices If so you should contact an authorized Volvo Truck dealer to obtain those parts which best fit your own personal needs an...

Page 9: ...ing a trailer the rear brake chambers will receive full normal brake pressure NOTE When operating bobtail be certain that glad hands trailer air hoses electrical cable and connectors are properly stowed and secure Do not allow them to rub or chafe on other components WARNING When operating bobtail the brake system on the vehicle reduces the possi bility of rear wheel brake lockup except on full pe...

Page 10: ...rcumstances should the pub lished GVWR FAWR and or RAWR be exceeded Failure to observe these pre cautions can lead to the loss of vehicle control resulting in a crash causing seri ous personal injury or death Do not exceed the load rating of the tires or the vehicle weight ratings Over loading may result in tire failure causing loss of vehicle control leading to an ac cident resulting in severe pe...

Page 11: ... 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 Mexico by calling or by w...

Page 12: ...ly and tight ened to the specified torque if necessary W7000519 WARNING Do not weld on any part of the frame or drill holes in the top or bottom flanges Serious structural damage could occur Frame Alterations Under no circumstances can the frame be cut and an extension piece added to in crease the wheelbase The only alteration allowed is wheel base shortening where the only change in the frame rail ...

Page 13: ...ions 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 the USA...

Page 14: ...n 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 recei...

Page 15: ...s 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 suck par...

Page 16: ...n your 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 Tr...

Page 17: ...oint 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...

Page 18: ... applicable 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 wh...

Page 19: ...rchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Air Intake System Removing or rendering inoperative the air cleaner or intake piping Engine Cooling Fan Removing or rendering inoperative the fan clutch Removing the fan sh...

Page 20: ...tering engine speed pro gramming so as to allow engine speed to exceed manufacturer s specifications Inner Fender Shields and Cab Skirts Removing shields or skirts Cutting away parts of shields skirts or dam aged or loose portions of shields or skirts ...

Page 21: ...icle Identification label located in the door opening on the driver s side see next page The 8 digit chassis number is em bossed into the bottom flange right hand side of the frame rail and the top flange left hand side of the frame rail 42 inches 1065 mm back from the front edge of the frame rail The use of this number is very helpful when ordering parts for your vehicle W0001995 Vehicle Order The V...

Page 22: ...paint colors and color numbers On the upper part of the door frame is the Certification label showing the axle and load ratings for the vehicle as it was built Do not exceed these ratings by overloading NOTE To deter tampering with the origi nal build information the information on the label will be destroyed if label is removed If for any reason a label is dam aged contact your Volvo Truck dealer ...

Page 23: ... the cylinder block There is also a label on the engine elec tronic control unit that shows the engine serial number W0001529 The Volvo D7 engine serial number is lo cated on the rear left side of the cylinder block There is also a label on the rear valve cover that shows the engine serial number W2002707 ...

Page 24: ...odel and serial number is located on the right side of the transfer gear housing on the tandem front axle It is lo cated on the left side of the differential housing on the tandem rear axle and on the right side of the single axle W4000894 ...

Page 25: ...ace A new key can be made if the keys are lost The door locks are mechanically or electri cally operated The lock is activated by either the key from the outside or the door lock handle from the inside With mechani cal locks only one door can be locked unlocked at a time With electrical locks both doors will be locked unlocked by operating either the key or the inner door lock handle on either sid...

Page 26: ...old and pull the door in To lessen the chance of being thrown from the vehicle in case of an accident always lock the door and wear the safety belt while driving Failure to do so can cause serious personal injury or death if involved in an accident W8001854 CAUTION Do not shut the door by pushing on the door panel Hard pushing may distort the metal in the door panel To close the door from the outs...

Page 27: ...passenger should exercise caution when entering or exiting the cab Use the steps and grab handles to safely get in and out of the cab to prevent injuries related to a slip and fall Steps are designed to be slip resistant and to provide a stable surface for entering or exiting the cab However ac cumulation of ice dirt lubricants etc on the steps can make entering or exit ing hazardous Always make s...

Page 28: ...the curved surface of the fuel tanks They may be slippery from snow mud ice water spilled fuel or other slippery substances 8 If a step is mounted to the top of the battery box be certain that the battery box cover is properly fastened before stepping 9 Do not jump from the cab or from the steps to the ground 10 Always face the cab when entering or exiting 11 Do not hold anything in your hands whe...

Page 29: ...r hands WARNING On vehicles without side fairings al ways make sure that the battery box cover is securely fastened before step ping up Failure to fasten the cover may lead to personal injury W0001223 Passenger Side Entry Exit Open the door Place any hand carried items on the cab floor Grasp the left grab handle with your left hand and the right grab handle with your right hand Put your left foot f...

Page 30: ...tering or exiting the area behind the cab WARNING Wearing shoes with soles that are dirty or wet increases the chance of slipping or falling Be careful when entering the back of cab area with dirty or wet soles W8001363 Grasp the grab handle to the left with both hands Put the left foot onto the bottom step and pull yourself up Put the right foot on the top step and step onto the deck plate with t...

Page 31: ... parking brakes are set Place the gear shift lever in a gear po sition toward the rear of the vehicle If equipped with an adjustable steering column move the steering wheel up and forward Place the left hand on the steering wheel and the right hand on the top of the gear lever Move the right foot out to the middle of the floor Lift the upper body supported by the hands on the steering wheel and the...

Page 32: ...the knob downward in a straight line W4001388 Twist the lever counterclockwise while holding pressure on the knob When releasing the pressure the springloaded lever will be pushed up out of the locked position W4001389 Lift and fold the gear lever straight back parallel with the seat It will come to rest in the folded position NOTE If the lever is not folded straight back it may not be able to tra...

Page 33: ... dash Move the right foot out to the middle of the floor Lift the upper body supported by the hands on the steering wheel and the dash and step out from the seat area When locking the gear lever in place again follow the procedure on page 271 Failure to lock the gear lever properly into place can cause loss of control of vehicle leading to serious personal in jury or death W4001391 ...

Page 34: ...e top To assist in opening and to hold the door open there are two compressed gas cylinders mounted on each door The door will swing up by it self when pulled out a short distance and then released If the light switch is set on automatic the light will come on when the door opens W8001073 Safety equipment and tow hooks are stored in the luggage compartments If equipped the sleeper heater and air c...

Page 35: ... from the hood Lift the hood until it is past the balance point Release the hood and let it complete the opening movement unaided Two restraint cylinders will engage during the last part of the opening The cylinders will slow and dampen the hood down to its resting position WARNING Make sure that no one is in the way of the hood when closing The hood could injure a person in the way while being lo...

Page 36: ...n opening in the wheelwell splash shield The opening is normally covered by a plate To access the opening remove the two screws using a T30 Torx screwdriver Re move the cover plate W8002389 The hood latch can now be accessed through the hole Operate the latch manu ally by pushing the lever in toward the engine Do the same on the other side W8000981 ...

Page 37: ...p list The report should list all defects or deficiencies dis covered by the driver Doing a pre trip inspection prepares for the end of work re port Starting on the next page are suggested guidelines to be used in performing truck tractor and trailer pre trip inspections De pending on the application of the vehicle being used these guidelines should be modified to include other necessary inspec tion...

Page 38: ...drain cocks Start the engine and let the air pres sure build up to normal page 273 Stop engine Switch on parking lights and four way flashers page 99 Apply parking brakes page 278 Release the hood latches page 30 Raise hood Step 1 Left Side Of the Cab Left Front Wheel Check condition of wheel rim Espe cially look for cracks missing lockrings bent or broken studs clamps or lugs Check condition of ti...

Page 39: ...ing tension Check wiper blades for any damage dead rubber and securement to arm Lights and Reflectors Lower hood and inspect parking clearance and identification lights on hood and cab They should be clean operating and of the proper color Reflectors clean and proper color Turn on headlights High and low beams should be operating and lenses clean If equipped check daytime run ning lights Left and rig...

Page 40: ...ed look for conspicuously dif ferent positions of the slack adjusters Condition of Front Axle and Steering Sys tem Right Side No loose worn bent damaged or missing parts Under Hood Right Side Check condition of coolant and heater hoses Check condition of fan drive belts Check engine and surrounding areas for coolant oil and fuel leaks Check fuel separator sight glass and drain if necessary Check f...

Page 41: ...k that both tires are of same type for example not mixed radial and bias type and that their circumferences are matched Check wheel bearing and hub no obvi ous leaking on outside or inside wheel Suspension Check condition of springs leaf or air spring hangers shackles and U bolts Axle alignment Brakes Condition of brake drums With brakes released look for a noticeable gap be tween lining and drum ...

Page 42: ...se Step 8 Left Saddle Tank and Left Rear Vehicle Wheels Area Dual Wheels One Or Two Axles Check condition of wheels and rims Especially look for cracks missing lockrings bent or broken spacers studs clamps or lugs Check condition of tires properly in flated 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 o...

Page 43: ...Drive shaft looks OK Exhaust system secure not leaking not touching wires fuel or air tubing Frame and cross members no bends cracks or breaks Air tubing and electrical wiring se cured against snagging and chafing Left Fuel Tank s Securely mounted and not damaged or leaking Fuel lines secure and not leaking Check that shut off valves are open Tank s full of fuel Cap on and secure Battery Area Open ...

Page 44: ... function page 269 If equipped check for clutch brake func tion Check windshield wipers and washers page 47 and horns including back up alarm if equipped Clean inside windshield door win dows and instruments Clean mirrors Check climate control and defroster page 174 If equipped check mirror heater Check condition of warning triangles fire extinguisher and flares page 68 Adjust the seat page 195 Chec...

Page 45: ... fifth wheel and trailer page 326 Locking jaws around the shank and not the head of kingpin page 326 Release lever properly seated and safety latch lock engaged page 327 Check all connections to dolly or trailer hitch and safety chains are se cured 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 wil...

Page 46: ...d against tangling snagging and chafing with sufficient slack for turns Step 10 Right 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 Wheel s Carrier or rack not damaged Spare wheel securely mounted in rack Tire and wheel condition adequate for a spare proper size properly inflated...

Page 47: ...Flexible air tubing not cracked cut crimped or otherwise damaged Se cured against tangling dragging and chafing Brakes Condition of brake drums With brakes released look for a noticeable gap be tween lining and drum This check cannot be made if dust covers are in place Condition of brake hoses check for any chafing Check brake chamber mounting bolts and brackets Check slack adjusters and chamber pus...

Page 48: ...eck wheel bearing and hub no obvi ous leaking on outside or inside wheel Suspension Condition of springs leaf or air spring hangers shackles and U bolts Axle alignment Condition of torque rod arms If equipped with sliding axles check position and alignment Look for dam aged worn or missing parts all locks present fully in place and locked Flexible air tubing not cracked cut crimped or otherwise da...

Page 49: ...de clearance lights clean op erating and proper color Reflectors clean and proper color Frame and Body Frame and crossmembers not bent cracked damaged or missing Proper placarding Body parts not damaged or missing Before Leaving the Parking Area Remove chocks from the wheels Test trailer hook up by slowly pulling while applying the trailer brakes with the trailer brake hand control valve Test the s...

Page 50: ...hicle movement and can cause serious personal injury or death Check coolant level in the coolant tank The level should be above the minimum mark shown on the side of the tank WARNING Do not remove the cap to the surge tank while the engine and radiator are still hot and under pressure Scalding fluid and or steam may be blown out under pressure if the cap is taken off too soon If the coolant level i...

Page 51: ... damage may result if you do See the Operator s Manual Maintenance and Engine for correct types of oil used in Volvo engines CAUTION If the vehicle is equipped with an aero dynamic bumper do not step on or press in between the bumper and the wheel Breakage or damage may result W2002047 To add oil to the engine remove oil cap on the valve cover and fill through the hole CAUTION Make sure the oil add...

Page 52: ...y reputable washer fluid that has good cleaning capability and does not freeze in cold weather Total reservoir capacity is 3 3 gallons 12 5 liters An indicator will appear on the diagnostic display when there is approximately 1 4 gallons 5 3 liters re maining in the reservoir W8000985 Check that windshield wipers and washer are working properly The windshield washer spray should cover the windshiel...

Page 53: ...nge and squeegee W1000070 Check all lights for proper function Headlights Daytime running lights Parking and marker lights Stoplights Turn signals W3000953 NOTE Make sure that all fluid levels are at their proper levels If the fluids are not at their proper levels add as necessary Refer to the Engine and Maintenance Manual for information on what types of fluids are rec ommended for your Volvo vehicl...

Page 54: ...ing the air tanks do not look into the area of the draining air Dirt or sludge particles may be in the air stream that could cause eye injury Empty out the air tanks daily With the air system fully charged and with the engine shut off listen for air leaks W5000601 ...

Page 55: ...safety belt while the vehicle is moving may lead to an accident causing serious personal in jury or death Safety belt assemblies installed in this vehi cle meet FMVSS 209 Type 1 and Type 2 requirements They are recommended for all persons weighing over 50 lb 25 kg W8001834 A child restraint system should also be pro vided for each child weighing 50 lb 25 kg or less It should meet the requirements ...

Page 56: ...t of a collision a correct driving position maxi mizes the effectiveness of the safety belt There are both Federal and State laws gov erning the use of safety belts As laws differ from state to state make yourself fa miliar with the current rules W8001077 Tether straps are installed on all suspension type seats Tether straps help se cure the seat to the floor and are intended to restrain the seat a...

Page 57: ...t latch by pushing in the button release on the buckle W8001835 The buckle portion of the safety belt sys tem is different depending on the seat option chosen The National standard and comfort seat has a separate buckle that is attached to a floor anchor by a seat strap This seat strap is not adjustable and does not need to be adjusted The buckle for the seat is bolted to the seat floor W8001836 If ...

Page 58: ... bunk can result in severe per sonal injury or death The restraint netting can be used for secur ing loose articles Any loose articles that can shift in the cab during hard cornering or braking should be kept restrained W8000895 Fasten the restraint by connecting the buckle with the latch Make sure the belts are not twisted Test the latch connection by pulling on the belt If they come apart reconn...

Page 59: ...st the straps to form a tent over the bunk VN 660 upper bunk does not have the tenting feature W8002039 Safety Restraint VN 770 Connect the restraint to the back wall first The wall connectors are located in the stor age units Connect the lower part of the restraint to the lower buckles Connect the side tethers and adjust the straps to form a tent over the bunk NOTE The restraints for top and botto...

Page 60: ...safety belt systems should be replaced at least every five years Do not bleach or re dye the color web bing because it may cause a severe loss of belt strength This loss of strength could allow the safety belt to break under stress thus resulting in severe per sonal injury or death Check the belts buckles latch plates re tractors anchorages and guide loops to ensure that they are working properly L...

Page 61: ...re are any cuts fraying or extreme wear in the webbing Cuts fraying or excessive wear would indi cate the need for replacement of the safety belt system W8001406 The D loop web guide is an area where al most constant movement of the safety belt webbing occurs because of the relative movement between the seat and the cab This constant movement forms an area where wear will often occur The webbing m...

Page 62: ...pull at the wrong angle through the guide ac celerating wear W8002477 If equipped check the comfort clip for cracks or possible damage Make sure that it works properly Check the buckle by inserting the latch and verifying proper operation Determine if the latch plate is worn or deformed Check the buckle and latch casing for cracks or breakage W8001404 ...

Page 63: ...e safety belts to the floor make sure that they are properly attached to the seat Tethers must also be inspected for web wear and proper tightness of mounting hardware W8001387 All hardware for safety belt mounting points should be evaluated for corrosion All attachment points of the system should be checked for tightness of mounting hardware Check the web in areas exposed to ultra violet rays from...

Page 64: ...placed immediately regardless of the mileage Once replacement of the safety belt has been determined necessary be certain that it is replaced only with a Volvo original re placement safety belt See your authorized Volvo Truck dealer for replacement Your Volvo safety belt system has been devel oped and tested specifically for heavy trucks Replace it only with the exact same design that the vehicle w...

Page 65: ...2 To activate the clip mechanism feature lift the lever up to clamp the webbing in place NOTE When the safety belt is not in use the clip should be in the open position to allow the seat belt to retract to its proper position Also make sure that the adjust ment of the comfort clip does not interfere with the operation of the safety belt W8002388 Open position Always adjust the clip so that there i...

Page 66: ...of injury to the driver s face and upper part of the body Together with the safety belt the airbag helps prevent the driver from be ing thrown against the steering wheel windshield or other hard surfaces in the cab The Volvo SRS Airbag provides increased protection in frontal collisions where the vehicle collides with a fixed or heavy object with enough force to activate the sensors which then acti...

Page 67: ...ufficiently violent collision a control unit activates the gas generator ig nitor and the airbag inflates To cushion the impact the airbag deflates when com pressed This also releases some non toxic smoke into the cab The entire sequence from inflation to deflation of the airbag takes a few tenths of a second WARNING Never attempt to drive with a deployed airbag With the bag hanging out of the hub of t...

Page 68: ...has been filled gas flows out through two holes in the weave These holes are large enough to let the airbag col lapse slowly gently catching the driver T8006857 In the event of a problem in the SRS sys tem a telltale shows on the graphic display in the instrument cluster This telltale to gether with other telltales in the cluster also light up when the engine is started The telltale should go out af...

Page 69: ...f T8006843 Steering shafts and steering wheel should not be removed adjusted or replaced with out following the proper work procedure Failure to do so can damage the SRS sys tem to the point where it does not work any longer A warning label is located on the upper steering shaft T8006842 There is also a label on the inside of the windshield that indicates the inclusion of an airbag to the vehicle ...

Page 70: ...f the SRS system Any interference with the system may cause it to malfunction and result in serious injury or death Work on the system may only be carried out by an authorized Volvo Truck dealer To allow the SRS system to work as de signed Never drive an SRS system equipped vehicle with the hands on the steering wheel pad airbag module No objects accessory equipment or stickers may be placed on at...

Page 71: ...lvo Truck dealer Even if the vehicle can be driven after a collision it is not recommended to drive the truck with the airbag deployed Have an authorized Volvo Truck dealer change the components in the SRS system Only use original Volvo parts when re placing the SRS system components airbag safety belt etc When is the airbag not deployed Not all frontal collisions activate the SRS system In a coll...

Page 72: ... own diagnostic unit which continuously monitors the functioning of the system Make a habit of checking the SRS system telltale light when starting and driving the vehicle Heart of the Volvo safety system The three point anchored safety belt is the heart of the Volvo safety system The belt should be worn at all times The SRS system is intended as a supplement to the three point anchored safety bel...

Page 73: ...f the driver seat between the seat and the door Depending on the cab style the safety triangles are located in different places in the cab W1000071 Day Cab The warning triangles are stored in a box that is strapped to the back wall W0001372 Sleeper Cab The warning triangles are stored in a box that is strapped to the inner wall of the right side luggage compartment W1000139 ...

Page 74: ...ntain safe operation of the vehicle Operate a VO RAD equipped vehicle in the same safe manner as if VORAD was not installed The Eaton VORAD Collision Warning System is not a substitute for safe driv ing procedures nor will it compensate for any driver impairment such as drugs alcohol or fatigue The Eaton VORAD Collision Warning System may provide little or no warning for some hazards like alerts f...

Page 75: ...page 74 13 Instrument Cluster Main page 82 14 Instrument Cluster Right page 89 15 Trailer Hand Brake Control page 283 16 Tractor Parking Brake page 278 17 Trailer Air Supply page 278 18 Radio option page 233 19 Optional Switches page 112 20 Right Switch Cluster page 106 Operating Before driving this vehicle locate the in struments and controls and become thoroughly familiar with their operation Af...

Page 76: ...telltales in the lower part Please refer to page 77 for telltale information Center Section The center section contains tachometer speedometer and odometer See page 82 for gauge information In the lower part there is a central warning lamp and telltales for different vehicle functions Please refer to page 85 for telltale information Right Section The right section can include forward and rear axle...

Page 77: ...ock page 86 8 Axle Differential Lock page 86 9 High Beam page 87 10 Safety Belt page 87 11 Parking Brakes page 87 12 Tractor ABS page 88 13 Trailer ABS page 88 14 Air Suspension Level page 88 15 Mirror Heater page 88 16 Right Turn page 86 17 Transmission Temperature page 92 18 Check Transmission page 92 19 Traction Control System page 92 20 Wait to Start Not used 21 Transmission in Neutral page 92...

Page 78: ...knowledged warning page 130 6 Alarm clock on page 167 7 PTO engaged page 101 8 Cruise control engaged page 265 9 Airbag SRS page 63 10 Coolant level page 126 11 Washer fluid level page 120 12 Engine airfilter clogged page 121 13 Too cold for engine brake page 289 14 Overheating instrument cluster page 120 15 Engine preheat fault page 249 16 Engine oil pressure page 76 17 Coolant temperature page 75 ...

Page 79: ...ne pyrometer system indicates the exhaust temperature which helps the opera tor get the best efficiency from the engine Variations in engine load can cause the ex haust temperature to vary For example high exhaust gas temperature is the result of prolonged engine lugging or overfueling If the pyrometer reading shows that exhaust temperature exceeds normal reduce fuel to the engine until exhaust tem...

Page 80: ... should be checked for problems by your Volvo Truck dealer W3003769 The LED light in the lower right corner of the gauge lights up solid when coolant tem perature is excessive The temperature limit is dependent on the engine manufacturer electronic program Together with the gauge light the red 1STOP telltale will come on and the buzzer will also sound The engine is at risk and the engine con troll...

Page 81: ...program When the gauge light comes on the red 1STOP telltale starts blinking the buzzer sounds and the oil pressure symbol appears on the graphic dis play The engine is at risk and the engine controller may react by derating the engine power for example Bring the vehicle to a safe stop where the problem can be checked With very low oil pressure the red 1STOP telltale lights up solid The engine wil...

Page 82: ...ure should be the same at a given engine tem perature speed and load Turbo boost pressure will vary for different engines and vehicle models By monitoring the gauge the operator can avoid engine problems W3003631 F Telltale Indicators Left Section 1 Engine preheat telltale page 78 2 Caution telltale page 79 3 Stop telltale page 80 4 No Charge telltale page 81 W3003645 ...

Page 83: ... 50 seconds depending on coolant temperature and outside air temper ature On cold mornings the preheater will be on for the maximum 50 seconds When the ignition key has been turned to the pre heat position the preheater coils in the intake manifold are activated to warm the intake air Once the engine is started the preheater may be re engaged to assist in a quicker engine warm up See page 249 for ...

Page 84: ... page 120 When the telltale comes on stop at the first safe place where the problem can be checked When ignition is switched on the telltale goes out unless a defect is detected NOTE On vehicles equipped with a Volvo engine the telltale is on for 3 to 5 seconds after the ignition key switch is turned on See page 119 for a listing on related mes sages that trigger this telltale T3008860 ...

Page 85: ... the vehicle speed is zero the engine shuts down Another example is with excessive coolant temperature the engine will gradu ally reduce power output to 50 This telltale always activates the buzzer The engine may be started again after the key is turned off and then back on How ever it will only operate for 30 seconds unless the problem is resolved CAUTION If the problem is allowed to persist seri...

Page 86: ...s no output from the alternator such as when the engine is not running The No Charge telltale lights up dimly when there are several volts difference be tween the system voltage and the alternator output voltage The telltale shines brighter as the alternator output voltage drops For more information on the electrical sys tem see page 293 T3008832 ...

Page 87: ...ine Monitor the tachometer to guide correct gear shifting and to prevent engine overspeeding when descending steep grades Each engine has its ideal operating ranges for power and economy Read the engine manufacturer s manual to find out the best ranges for each engine CAUTION Always keep an eye on the tachometer during downhill runs Do not allow the engine to over speed Excessive engine over speed ...

Page 88: ...n electronic controller Reprogramming can be performed by your authorized Volvo Truck dealer The odometer is a Liquid Crystal Display LCD mounted in the lower speedometer face The odometer registers up to 999 999 9 miles or km The internal elec tronics will make distance conversions between miles and km automatically To be able to read the current mileage without turning the ignition on press any ...

Page 89: ...10 kPa or lower The buzzer will also sound when the telltale lights up When the pressure goes above 60 psi in both front and rear brake circuits the tell tale will automatically go out Air brake system pressure should be be tween 90 to 135 psi 620 to 930 kPa for normal operation The master warning tell tale comes on and the buzzer sounds when air pressure has dropped to 60 psi or lower If the air ...

Page 90: ...tale page 88 9 Anti Lock Brake System Trailer Telltale page 88 10 Air Suspension System Telltale page 88 11 Mirror Defroster Telltale page 88 12 Right Turn Telltale page 86 NOTE All telltales may not be used in all vehicles The telltale strip is located below the tachometer and speedometer A yellow cau tion telltale indicates that there is a system or component in the vehicle that requires the ope...

Page 91: ...on It will stay lit until the switch is turned to the off position again See the 5th wheel uncoupling section on page 333 for correct use W3000621 Wheel and Interaxle Differential Lock Telltales These telltales will light up yellow when the pneumatic switches for either the wheel or interaxle differential lock are turned on For the interaxle lock the telltale is acti vated by the switch For the wh...

Page 92: ...the vehicle is stationary and that the seat has been adjusted as required Do not at tempt to adjust the safety belt or seat while the vehicle is in motion For proper use of the safety belt see page 52 W3000625 Parking Brake Telltale The telltale lights up red when the parking brake valve knob is pulled out The day time running light DRL function is also dependent on the parking brake application A...

Page 93: ...m The vehicle can still be driven with a prob lem in the ABS However the ABS will not be operating and standard air braking is in effect For more information see page 285 The trailer ABS telltale is in effect for ve hicles manufactured after February 2001 W3000905 Air Suspension Telltale The telltale lights up amber when the sus pension leveling valve is activated As long as the switch is activate...

Page 94: ...page 92 W3004407 L M Forward Rear Drive Axle Oil Temperature option The gauges are connected to temperature senders installed in the axles Normal oper ating temperature range is up to 250 F 120 C If average oil temperature consis tently goes above 250 F 120 C more frequent oil changes are needed or an oil cooler could be installed CAUTION A sudden increase in oil temperature that is not caused by ...

Page 95: ...ion pressure from either the front rear or trailer circuit pressure The gauge will not register air pressure un til the foot brake pedal is depressed or the trailer hand brake is applied W3004302 O Air Suspension Pressure option Air gauges are directly connected to the air suspension system It will indicate the sus pension pressure in the air springs The pressure shown on the gauge is a crude indi...

Page 96: ...age 273 for more in formation There is a low air warning switch in each gauge If the pressure in a brake circuit air tank drops below approximately 60 psi 420 kPa the red indicator in the lower right corner of the gauge will light up and the master warning indicator and the buzzer will simultaneously come on If the air pressure is allowed to drop below 30 to 40 psi 205 to 275 kPa in both systems t...

Page 97: ...sion Temperature Telltale The Transmission Temperature Telltale is for the Allison WTEC III transmission The amber warning signal lights up and a buzzer sounds when the transmission tem perature is too high W3004305 Check Transmission Telltale The Check Transmission Telltale is for the Allison WTEC III transmission The red warning signal lights up to indicate a trans mission problem Depending on t...

Page 98: ...e brake system to transfer power to wheels with greater traction Under circumstances where all drive wheels are spinning the system sends a signal to the engine control unit to reduce power W3000962 The TCS includes a TCS mud snow switch for turning the system off to increase wheel spin This function may be desirable in deep snow or mud to keep the vehicle from bogging down To operate press in the...

Page 99: ...hen ap plying throttle do not increase engine speed before the transmission has engaged If the engine speed is too high the trans mission will not engage CAUTION When operating the vehicle on normal grades less than 4 a slight roll back can be experienced when the brake pedal is released and before the trans mission re engages NOTE When operating on severe grades more than 5 the transmission has a...

Page 100: ...and let it rest face down against the steering column so the bulbs are accessible CAUTION Do not let the cluster be in the face down position for more than maxi mum 15 minutes Damage to the gauges can occur by oil running out of them making the gauge reading inaccurate W3000842 Do not use any other tools for changing the bulbs than the correct tool Using a pair of pliers could easily cause a short...

Page 101: ...n counterclock wise and pull the bulb assembly out of the cluster Insert a new bulb into the tool and install it into the cluster Rotate the bulb a 1 4 turn clockwise and pull the tool off of the bulb assembly NOTE The telltale area in the right part of the instrument does not use all spaces for active telltales These bulbs can be used for spare bulbs Lift up the instrument cluster and fasten the ...

Page 102: ...e lever does not need to be moved to a locking position Move the lever partway off the normal position until a resistance is felt The turn signal is now activated and the lever will return to normal position when it is released The headlight flash function is activated by pulling the turn signal lever toward the steering wheel The high beam will stay on until the lever is released To change between...

Page 103: ...ry 10 seconds To shorten the interval time move the lever to normal wipe position and then to the interval position again when the next wiper pass is desired In this way the inter val can be programmed between 1 to 10 seconds between each pass W3003655 To operate the windshield washer pull the lever toward the steering wheel If washer fluid needs to be added use a commercially reputable washer fluid...

Page 104: ...m part of the switch The indicator light in the switch will flash in unison with the outside lights The hazard lights function independently from the ignition switch Activate this function only when the vehi cle is stopped where it might be a danger to other vehicles or to alert others of a problem that changes the traffic rhythm W3001350 Back Of Cab Light option Turn on the back of cab light by pre...

Page 105: ...ow beam headlights are on W3002306 Sleeper Overhead Lighting VN 770 This operates the fluorescent overhead lighting in the VN 770 sleeper cab It is lo cated so the light can be accessed without entering the sleeper section of the cab The switch works together with the switch on the sleeper control panel see page 204 Depending on the position of the other switch switching on the light may have to be...

Page 106: ...ged with a bypass valve operated by the switch This type of PTO can be in use while driving NOTE If your vehicle is equipped with Autoshift and a Detroit Diesel engine the PTO telltale may blink when Autoshift is on and the transmission shifts gears Transmission Mounted PTO The vehicle should be stopped before en gaging power take off Engage the PTO by depressing the clutch pedal and pressing in t...

Page 107: ...e running at low idle and the vehicle should be stopped or run ning at very low speed before engaging power take off Engage the PTO by press ing in the bottom part of the switch The PTO is now in operation and hydraulic flow can be regulated by the engine speed W3001993 ...

Page 108: ...peed To increase decrease engine speed 1 Press and release the SET or SET toggle switch to increase decrease speed in increments increment size depend on programmed value 2 Press and hold the SET or SET tog gle switch to increase decrease speed When the switch is released the en gine speed sets at current speed To resume engine speed 1 If the PTO function was interrupted resume set speed by pressi...

Page 109: ...lease the lever as soon as the beam change is made Hold ing the lever up makes the headlight flash function stay engaged W3000955 The headlight is combined into one aerody namic assembly The halogen bulbs are accessed from the rear of the assembly Headlights do not need to be checked for aim after bulb replacement For more infor mation on changing the headlight bulb see page 308 Daytime Running Lig...

Page 110: ...ed with the parking lights and the low beam headlights Driving lights are used with the high beam head lights Switching from low to high beam will automatically switch from fog lights to driving lights Driving and fog lights should be used when driving conditions require additional light ing The driving or fog lights should not be used in traffic where they might distract other drivers thereby crea...

Page 111: ...interrupts power to the marker lights when held down When released it will spring back to the ON position and re turn power to the marker lights W3001352 Traction Control Switch If the vehicle is equipped with a Traction Control System TCS there is a switch that can be used for increasing wheel spin This may be useful for decreasing the chances of getting bogged down when driving in heavy snow slu...

Page 112: ... speed retardation device such as Jake Brake C Brake Exhaust Brake etc is not intended to replace the service brake system on your vehicle nor intended to bring your vehicle to a stop A vehicle speed retardation device is only intended to retard the speed of your vehicle under certain conditions NOTE It is normal for there to be a slight delay in the application of a vehicle speed retardation devi...

Page 113: ...sion brake It works together with the exhaust brake to provide two levels of braking power The switch has three posi tions OFF LOW and HIGH With the switch in position LOW only the exhaust brake is engaged With the switch in posi tion HIGH both the exhaust brake and compression brake are activated For proper operation see page 290 W3002303 Jake Brake or C Brake Optional These engine brakes are sim...

Page 114: ...ectric heater element that is a part of the mirror glass The heater is self regulating and will keep a steady temperature after reaching operating temperature Both top and bottom mirrors are heated Turning the switch on activates a telltale in the instrument cluster The telltale will stay on until the switch is turned off W3003492 ...

Page 115: ...ng axle 4x2 or 6x4 or between axles on a 6x4 The differential lock elimi nates one wheel spin out on slippery surfaces and improves traction Each switch has a safety latch to prevent accidental en gagement When the lock is engaged a telltale lights up in the instrument cluster A differential lock should only be used on a slippery surface and not when driving on good road conditions If a differenti...

Page 116: ...light up when the switch is in the on position W3001341 Sliding Fifth Wheel The release must never be operated while the vehicle is operating on the road Fifth wheel position adjustment must only be done when stationary Damage to the fifth wheel trailer king pin and slider may occur if not operated properly and may lead to an accident causing serious personal injury or death Tractors with a sliding...

Page 117: ...use more radio equipment The opening is a standard DIN radio slot W3000973 Generic switches are available for auxiliary functions that are installed by the customer These should be located in the optional switch cluster and can be purchased from your local Volvo Truck dealer W3002419 The optional switch panel can be removed and a radio or a Volvo Road Relay can be installed W3002420 ...

Page 118: ...wo buttons for the electric city horn 2 located on the steering wheel spokes W8000947 Instrument Light Dimmer Switch The switch is a rheostat that controls the instrument light Instrument light is activated by the headlight switch Light in tensity can be varied from off to full brightness by turning the rheostat clockwise or counterclockwise W3000956 Cigar Lighter To operate the cigar lighter pres...

Page 119: ...unctions are accessed with the controls on the wind shield wiper lever and which actions are required by the driver when messages are automatically shown in the display The information which is accessible varies depending on whether the truck is in a driving or non driving mode Certain func tions are protected by a password and are not shown until the correct password has been entered Password pro...

Page 120: ...a setting operation 2 Select confirms a highlighted selec tion of a menu or character 3 Up arrow moves the cursor up Used when setting numerical values 4 Down arrow moves the cursor down Used when setting numerical values T3008810 Selecting a Menu 1 Using the up down buttons the cursor is moved to the particular menu which is then highlighted A down ar row in the lower right hand corner shows wheth...

Page 121: ...main menus each with sub menus that lists functions avail able There are two types of menus Those that are available when the vehicle is in motion and those that can only be accessed when stationary Several non driving sub menus are only accessible with a password The password protected menus are not cov ered in this manual see page 158 While the vehicle is stationary there are 4 menus in addition...

Page 122: ...ed warning page 130 6 Alarm clock on page 167 7 PTO engaged page 101 8 Cruise control engaged page 265 9 Airbag SRS page 63 10 Coolant level page 126 11 Washer fluid level page 120 12 Engine airfilter clogged page 121 13 Too cold for engine brake page 289 14 Overheating instrument cluster page 120 15 Engine preheat fault page 249 16 Engine oil pressure page 76 17 Coolant temperature page 75 ...

Page 123: ... 1INFO telltale T3008860 Stop Telltale Failure to take necessary action when the 1STOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur Bring the vehicle to a safe stop where the problem can be checked See page 126 for a listing of other telltales that are linked to the 1STOP telltale T...

Page 124: ... is also shown The telltales are described starting on page 120 text messages are described starting on page 123 and combined telltale and text messages are described starting on page 125 Important When this telltale lights up the indicated fault should be checked at the next stop T3008860 Information messages can be put on standby if other information needs to be ac cessed on the display See page...

Page 125: ... the vehicle is being driven T3008842 Instrument Cluster Overheating The symbol is shown when the temperature behind the instrument cluster is too high The instrument lighting becomes weaker and the indicators on the instrument show a minimal reading Lower the heat in the cab When the heat is reduced the instru ment functions will gradually be restored NOTE If the temperature is too high over a pr...

Page 126: ...ator s Manual Maintenance and Engine T3008843 Too Cold for Engine Brake Volvo Engine Only Position 2 of the engine brake should not be switched on until the engine has become warm over 110 F 45 C If position 2 is selected and the engine is too cold this symbol will be shown however VEB is not activated T3009355 Fault in Preheating See page 249 for more information on the Volvo engine preheater T30...

Page 127: ...re is a problem in the charging system It is shown with text information of the charging system sta tus The voltage is shown together with the message TOO HIGH See page 162 for more information T3008832 Engine Oil Temperature This telltale lights if the engine oil temper ature becomes too high It is shown with the text TOO HIGH The engine power is derated The temperature limit for activa tion vari...

Page 128: ...ormation text is shown on the display The text contains information on where the fault has occurred as well as the type of fault applies to the data link Factory installed equipment CHECK ENGINE NEXT STOP T3008860 Specific data link fault CHECK ENGINE DATA LINK T3008860 ...

Page 129: ...Not factory installed equipment The following can be shown if equipment has been added by a customer and con nected to the data link MID Message IDentifier controller To find more information on the data link diagnostic function see page 137 CHECK ERROR IN MID 142 T3008860 ...

Page 130: ...ssion oil temperature becomes too high the 1INFO telltale lights up automatically with the text HIGH This tell tale and text will come on when the oil temperature has been 210 F 100 C or above for 30 minutes or 250 F 120 C or above for 10 minutes NOTE If the temperature goes over 285 F 140 C a STOP message will be gener ated see page 129 T3008831 HIGH 225 F T3008860 Voltmeter The voltmeter value i...

Page 131: ...rtain telltales T3008861 Telltales Coolant Level Failure to take necessary action when the 1STOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur Bring the vehicle to a safe stop where the problem can be checked The telltale is shown if the coolant level is too low During check Pre trip...

Page 132: ...gauge lights up to gether with the telltale and the buzzer also sounds Depending on the engine manufac turer s program in the ECU the trip point may differ slightly for different engines W3003613 T3008861 Coolant Temperature Failure to take necessary action when the 1STOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in ...

Page 133: ... shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur Bring the vehicle to a safe stop where the problem can be checked Specific data link fault STOP DATA LINK BRAKES Factory fitted equipment STOP ENGINE FAILURE Not factory fitted equipment The following is shown if the customer has fitted equipment which is connected to the data link MID Message IDe...

Page 134: ...emperature of the transmission oil becomes too high the red 1STOP telltale is shown automatically with the text TOO HIGH This warning will come on when the oil temperature has been 285 F 140 C or above for over 30 seconds Failure to take necessary action when the 1STOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in per...

Page 135: ...tale and the symbol can be acknowledged using Esc This warning is acknowledged until the next time the ig nition key is turned to the start position Exceptions The message can be shown again if the fault is de activated and then becomes active again Example If the engine oil temperature be comes too high a message is activated automatically The driver acknowledges this message using Esc If the tem...

Page 136: ...wl edged fault message is shown If there is more than one message a down ar row is shown in the right hand corner 2 The up down buttons move the cursor between the current messages If an acknowledged fault message is still ac tive at the next occasion the ignition key is turned to the ON position this is shown as a non acknowledged message NO FAULTS is shown if there are no fault messages ...

Page 137: ... ID Password config Language MENU Set up mode Language This setting of language applies only until the ignition key switch is turned off To change the language permanently a pass word is required see page 116 1 To set the desired language press SE LECT when you are in the menu Set up mode Language 2 On the graphic display up to three dif ferent languages will now be shown Select the desired languag...

Page 138: ...wing diagram is shown on the graphic display with the particular setting highlighted The up down buttons move the cursor between the alternatives 2 Confirm the choice with SELECT 3 When km and C are chosen the following is shown on the graphic dis play with the particular setting highlighted The up down buttons move the cursor between the alternatives 4 Confirm the choice with SELECT Cancel setting ...

Page 139: ...ELECT AM PM is the 12 hour display AM morning and PM evening Cancel setting Press Esc in order to cancel the setting AM PM 24 h Contrast MENU Set up mode Contrast 1 Select the menu Contrast and the fol lowing diagram is shown on the graphic display The bar shows the particular setting in relation to max min contrast The up arrow increases the contrast The down arrow reduces the contrast 2 Confirm t...

Page 140: ...trument cluster light ing In this menu the display lighting can be altered in relation to the other instru ment cluster lighting 1 Select the menu Backlight and the following diagram is shown on the graphic display The bar shows the particular setting in relation to max min lighting the up arrow button increases the background lighting the down arrow button reduces the background lighting 2 Confirm...

Page 141: ...ons the setting switches between Normal and Re verse With the setting Normal the text is dark and the background light The setting Reverse makes the text light and the background dark This setting only applies when the headlights or parking lights are on 3 Confirm the choice with SELECT Cancel setting Press Esc in order to cancel the setting Night display Normal Reverse ...

Page 142: ...MENU Diagnostic Fault diagnostic A list of the vehicle s ECUs is shown in the menu Fault diagnostic Each ECU is identified by a MID number Message IDentifier In addition a menu for resetting all the fault codes is shown For a list of common fault codes see page 143 ABS Brakes MID 136 Instrument cluster center module MID 140 Info Display instrument cluster graphic display MID 234 SRS Airbag MID 232 C...

Page 143: ...ws the text Data transfer in progress please wait 4 No faults in the chosen system Press Esc to return to the previous menu No errors 5 Not responding to Non spec system Press Esc to return to the previous menu Non spec syst MID 127 Not responding 6 If the chosen system does not respond within 5 seconds the following mes sage is shown in this example the engine has been called Engine MID 128 Not r...

Page 144: ...w in the lower right hand corner is shown if there is more than one fault code The up down buttons move the cursor and the next fault code message is shown To reset codes a password must be entered see page 158 Engine Coolant temperature Value too high Active 6 1 I 2 If more than 20 fault codes messages are available for the chosen ECU the 21st message will be To see those messages that are not sh...

Page 145: ...3 When Numeric has been selected the fault codes are shown with numbers MID Identification of ECU PID Identification of parameter PPID Volvo unique identification of parameter SID Identification of component PSID Volvo unique identification of component FMI Identification of fault type MID 128 PID 110 FMI 0 Active 6 1 I 6 1 shows how many times the fault occurred since the last resetting If there is no ...

Page 146: ... the correct password has been entered resetting can be done in Reset all last in the list This resetting deletes only the fault codes for the chosen ECU 4 If more than 20 fault codes messages are available for the chosen ECU the 21st message will be To see those messages that are not shown earlier messages must be reset password restricted see page 158 Too many error messages ...

Page 147: ...r SRS airbag The following menu is shown Numeric Text Time stamp Reset 2 Select Time stamp and the following text message is shown Data transfer in progress please wait 3 The following is shown time stamp is presented as the number of hours the engine has been running Press Esc to return to the previous menu First X Last X 4 If the transfer should fail the follow ing message is shown First No data...

Page 148: ...ions Unit Satel lite GPS Cellular SRS SID Description 1 Driver Airbag Ign Loop PID code Description 62 Retarder inh status 71 Idle shutdown status 84 Road speed 91 Throttle pedal 100 Engine oil pressure 102 Boost pressure 105 Air inlet temperature 106 Air inlet pressure 108 Barometric pressure 110 Engine coolant temperature 111 Coolant level 127 Transmission oil psi 160 Main shaft speed 161 Input ...

Page 149: ... code Description 1 Injector 1 2 Injector 2 3 Injector 3 4 Injector 4 5 Injector 5 6 Injector 6 21 Engine position sensor 22 Timing sensor 25 Ext engine protection sig Transm SID code Description 1 C1 solenoid valve 2 C2 solenoid valve 3 C3 solenoid valve 4 C4 solenoid valve 5 C5 solenoid valve 6 C6 solenoid valve 7 Lockup solenoid valve 16 Neutral start output 18 Shift selector 1 27 Lockup clutch...

Page 150: ... 1 ASR valve 19 ABS dif 2 ASR valve 22 Speed signal input 23 Warning light bulb 24 ASR light bulb FMI code Description 0 Data valid but high 1 Data valid but low 2 Data erratic 3 Voltage shorted high 4 Voltage shorted low 5 Current low or open C 6 Current high or short C 7 Mech syst no respons 8 Abnormal freq or PW 9 Abnormal update rate 10 Abnormal change rate 11 Failure unknown 12 Bad device 13 ...

Page 151: ...hibitor Status Sole noid Valve 76 Brake Lamps Status Relay 77 Compressor Status Solenoid Valve 78 Interval Wiper Status Relay 79 Area Inhibitor Status Solenoid Valve 86 Engine Brake Torque Percent 109 EPG3 Drive Stage Failure 121 MTE Engine Compressor Control Output Failure 122 VCB Engine Compression Brake 123 EPG2 Start and Warmhold 124 EPG1 Engine Brake 125 EOL Enable Failure 195 Proprietary Dia...

Page 152: ...l the test Bulb Test MENU System diagnostic Cluster self test Bulb test 1 Select Bulb test 2 The telltale lamps light up for approx 5 seconds 3 Esc cancels the test and the menu Bulb test is shown again Changing Bulbs Changing the instrument cluster s telltale bulbs can be carried out from the rear side without the instrument cluster needing to be opened See page 95 for replacement information ...

Page 153: ...n return to zero This is only a check that they can move i e that the gauge functions 3 Esc cancels the test and the menu Gauge test is shown again Display test MENU System diagnostic Cluster self test Display test 1 Select Display test 2 The display goes out lights up goes out In the odometer display all seg ments are shown then off back on off again and back to the normal display 3 Esc cancels t...

Page 154: ...r rent sound is shown at the same time as the sound is activated With the up down buttons you can switch be tween the different sounds Three different sounds flasher indica tor reminder and caution are tested for 10 seconds The caution sound is connected to the red 1STOP telltale 3 Esc cancels the test and the menu Buzzer test is shown again ...

Page 155: ...ifier ABS Brakes MID 136 Instrument cluster center module MID 140 Display MID 234 SRS Airbag MID 232 Vehicle ECU MID 144 Engine MID 128 1 The up down buttons are used to move the cursor in the list 2 SELECT confirms the selection of an ECU 3 In the meantime the display shows the text Data transfer in progress please wait 4 The following text is presented SW The software part number MID 128 SW ID 031...

Page 156: ...move the cursor in the list HW ECU part number MID 128 HW ID VOLVO08192949P06 6 If there is a communication error the following is shown No data this ex ample shows HW ID but same text applies to SW ID except that HW is replaced by SW MID 128 HW ID No data ...

Page 157: ... required see page 158 Reset trip data Vehicle ID MENU Data log mode Vehicle ID 1 Select the menu Data log mode Vehi cle ID and the following text message is shown Data transfer in progress please wait 2 The fleet ID that is shown has been entered in the menu Press Esc to return to the previous menu Fleet ID XXX Chassis no XXX 3 If the transfer should fail the follow ing message is shown Operation ...

Page 158: ...menu Data log mode To tals 2 The menus that show Totals can be scrolled to using the up down but tons Total distance 406 7 mi NOTE If km and C has been selected the consumption is shown in liters Total fuel used 51 3 gal Total engine hours 7 3 h Total idle time 0 3 h ...

Page 159: ...hic Display Total PTO hours 0 5 h Total engine revolutions 1 220 100 r 3 If the transfer should fail the follow ing message is shown Cancel operation Press Esc in order to cancel the operation Operation failed ...

Page 160: ...t the menu Data log mode Trip 2 The information below can be scrolled to using the up down buttons Trip distance 203 5 mi NOTE If Miles and F has been se lected the consumption is shown in US gallons Trip fuel Avg 28 l 100 km Acc 57 0 gal Trip overrevs 0 8 h Trip uneconomy rev s 0 4 h ...

Page 161: ...ption is shown in liters Trip fuel uneconomy rev s 8 5 gal Trip average speed 67 4 km h Trip overspeed 0 2 h Trip engine hours 3 0 h Trip idle time 0 4 h NOTE If km and C has been se lected the consumption is shown in liters Trip idle fuel 2 5 gal Trip PTO hours 1 3 h ...

Page 162: ... C has been se lected the consumption is shown in liters Trip PTO fuel 20 4 gal Trip cruise 2 5 h 4 If the transfer should fail the follow ing message is shown Cancel operation Press Esc in order to cancel the operation Operation failed ...

Page 163: ...ac cess to the password configuration i e it is not possible to change the Owner password or the Workshop password with it The following menus are protected by pass word Default language Fleet limit r min Fleet limit speed Fleet fuel target Amperemeter calibration Fleet ID Reset applicable for several functions Status test Password config When the start key has been in stop posi tion for more than 6...

Page 164: ...ne oil temperature is shown as in the diagram If the sensor data for Temperature engine oil is not available the symbol is shown as well as the text NO DATA T3008830 185 F T3008830 NO DATA Information message Yellow 1INFO telltale If the engine oil temperature becomes too high an information message is shown au tomatically with the text HIGH At the same time the yellow 1INFO telltale un der the di...

Page 165: ...s shown as well as the text NO DATA T3008831 170 F T3008831 NO DATA Information message Yellow 1INFO lamp If the temperature of the transmission oil becomes too high an information message is shown automatically with the text HIGH At the same time the yellow 1INFO telltale under the display lights up Esc ac knowledges the information message For HIGH to display with the 1INFO tell tale the transmi...

Page 166: ...sage is shown automatically with the text TOO HIGH At the same time the red 1STOP telltale under the display lights up and the warning signal sounds Esc acknowledges the stop message For TOO HIGH to display with the 1STOP telltale the transmission oil tem perature must be 285 F 140 C for 30 seconds T3008831 TOO HIGH 285 F T3008861 ...

Page 167: ... too low below 9 5 V the instru ment cluster will lose power T3008832 13 1 V Information message Yellow 1INFO telltale If the battery charging voltage becomes too high the voltmeter s value is shown auto matically as well as the text TOO HIGH At the same time the yellow 1INFO tell tale under the display lights up T3008832 TOO HIGH 17 9 V T3008860 ...

Page 168: ...ar The ar row s position shows the value For a short time after resetting the following is shown instead of the average fuel consumption Instantaneous fuel consumption INST The value is presented numerically as well as in the form of a bar Target trip fuel consumption TAR GET The value is presented as an arrow un der the bar The arrow s position shows the value This value is pass word protected se...

Page 169: ...ns in the menu AVG INST to reach the menu LEG FUEL The following is shown in the menu LEG FUEL on the display The Leg fuel consumption amount of fuel used since the last resetting Empty XXX mi where XXX is the calculated range using the present in stantaneous consumption NOTE If km and C have been selected the consumption is shown in liters In the example below L will then be shown in stead of USg...

Page 170: ...onds after the last depressing of the button The alarm clock cannot be set while driv ing but the buzzer which sounds for the alarm call can be switched off see page 168 Clock MENU TIME DIST CLOCK Shows the current time To set the time for mat 12h or 24h see page 134 Setting 1 To set the clock press SELECT when you are in the menu TIME DISTANCE and the clock function will be shown 2 Set the hours ...

Page 171: ...l setting When setting hours Esc cancels the setting and the time is shown according to the pre vious setting Pressing Esc after setting the minutes or af ter setting the AM PM moves the cursor back to the previous selection Ignition key in the off position When the ignition key is in the OFF posi tion if setting the clock takes more than 30 seconds between pushing the buttons the time which has b...

Page 172: ...choice with SE LECT 4 Set the first digit in the minutes with the up down buttons Confirm the choice with SELECT 5 Set the second digit in the minutes with the up down buttons Confirm the choice with SELECT 6 Set the AM PM if the format is 12h with the up down buttons Confirm the choice with SELECT 7 Move the cursor to ON using the up down buttons Press SELECT A symbol is shown on the right in the gra...

Page 173: ...LECT control button is pressed Activate alarm clock without changing the time of the alarm call 1 The cursor is moved with the up down buttons to ON 2 SELECT activates the alarm clock and the symbol is shown on the graphic display Cancel setting Press Esc in order to cancel the setting ALARM 08 30 AM T3008833 CLOCK 08 00 AM ON OFF SET De activate the alarm clock 1 The cursor is moved with the up d...

Page 174: ...Con firm the choice with SELECT or press Esc in order to cancel the resetting RESET 1 2 PRESS SELECT FOR 1S Average speed MENU TIME DIST AVERAGE SPEED The average speed is calculated using the distance driven divided by the time the en gine has been running since the last resetting AVERAGE SPEED 55 4 mph Reset average speed 1 Press SELECT when the menu AV ERAGE SPEED is shown 2 A new text message w...

Page 175: ...e graphic display when driving A summary of these symbols is shown in the illustration under page 172 Under the display there are two lamps a yellow 1INFO telltale and a red 1STOP telltale that attract the driver s attention when necessary When the red stop tell tale lights up and the engine is running a warning signal is also activated Several messages may be active at the same time When a new me...

Page 176: ...ext stop T3008860 Stop message Failure to take necessary action when the 1STOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur Bring the vehicle to a safe stop where the problem can be checked In the event of serious faults the red 1STOP telltale lights up and a warning buzzer sounds i...

Page 177: ...3008840 Level washer fluid The washer fluid sym bol lights when the washer fluid is low T3008838 Warning trans mission oil temperature If the temperature of the transmission oil be comes too high an information message is shown automatically with the text HIGH It comes on when the transmission oil is 250 F 120 C or over for more than 10 min utes or 210 F 100 C or over for more than 30 minutes The tem...

Page 178: ...s limit is set in the engine ECU T3008830 Air filter clogged The symbol is shown when the air filter sen sor is restricted T3008843 Too cold for en gine brake VEB Volvo engine only Position 2 on the switch must not be en gaged before the engine has reached operational temperature If position 2 is engaged and the engine is too cold this symbol is shown and a signal sounds when en gine braking is carr...

Page 179: ...ith the switch marked aut It allows all functions of the previous systems plus the ability to main tain the temperature in the cab as set by the driver The desired temperature is selected by the combination of the temperature con trol setting and the fan speed W8001004 The air conditioning only operates when the engine is running Best performance from the air conditioning is achieved when all wind...

Page 180: ...stem to change fan speed with changing temperatures Adjust the fan speed to the desired air flow Fan speed must be selected to meet either heating or cooling needs For the heater only and manual air conditioning variants of the climate system settings of tempera ture and air flow must be adjusted as often as necessary to accommodate changing temperatures outside and inside the cab The ATC system is ...

Page 181: ...e control in the leftmost position all air is directed out through the vents in the dash With the control in the middle position most air is directed out through the floor vents and the cab door window vents A small flow is directed out through the vents in the dash This mix is approximately 80 20 With the control in the right most position most air is directed out through the front dash vents to th...

Page 182: ...Heating and Air Conditioning 177 W8001078 ...

Page 183: ...e cab It can be used to heat up or cool down cab temperature quickly or to close intake from letting in odors etc with the intake air In the middle position there will be a 20 addition of fresh air to the 80 of recirculated air This position is well suited for use when the air conditioning is engaged so a minimum of warm or cooled air is lost through the evacuation vents while fresh air is still a...

Page 184: ...g and the fan speed For the ATC version the tempera ture is automatically maintained to where the control was set If needed the control can be moved to a new setting without turning the ATC off Using the heater on days when the outside temperature is low but there is direct sun light heating through the windows the air distribution control should be set in the center position air directed to the fl...

Page 185: ...utton is pressed the fan speed control must be set on 1 through 4 for the air conditioning to start If the air conditioning button is pressed when the fan speed control is set on 0 the air conditioning will not start To set the air conditioning temperature ad just the temperature control and fan speed until the desired temperature air flow has been reached If the cab temperature needs adjusting the...

Page 186: ...o have to be adjusted increasing or decreasing air flow to achieve correct cab temperature To use the ATC let the system run in the manual mode until the cab temperature has stabilized at a desirable temperature Then press the aut button to engage the auto matic control unit To set a new desired temperature simply slide the temperature control to a higher or lower setting and the system will mainta...

Page 187: ... Vertical Air Flow When heating the cab all vents should be closed However the vents on the outer parts of the dash can be used for defrosting the cab door windows When operating the air conditioning all air vents should be completely open and the air flow directed upward W8001150 ...

Page 188: ...ning For the air conditioning to operate the engine must be running the air condi tioning button must be pressed in and the fan control must be set at least for speed 1 on the main control panel W8002333 Air is taken from the sleeper area through a filter in the lower bunk support wall and heated or cooled in the underbunk unit Outlet air can be directed with the vents in the side walls the illustr...

Page 189: ...C the fan switch must be at least on speed 1 or the ATC button on the main control panel in the dash The ATC control unit for the sleeper climate system will keep the temperature output to where the tempera ture control was set However the fan speed may also have to be adjusted in creasing or decreasing air flow to achieve correct cab temperature The air conditioning works together with the heater ...

Page 190: ...ld not be used during rain while washing the vehicle or other cir cumstances where water may enter the cab while the vent is open To prevent leaks make sure the handle rollers are on the top center part of the cams W8001146 The VN 770 is equipped with 4 hinged side windows in the sleeper area The VN 660 has only the upper windows Do not force the window crank mechanism in the fully open position T...

Page 191: ...cer birth defects or other reproductive harm To allow for proper operation of the vehicle ventilation system keep the inlet grille at the base of the windshield clear of snow ice leaves and other obstructions at all times Do not park the vehicle and let the engine run or idle for more than 10 minutes with the ventilation system control switch in the off position Even with the ventilation sys tem o...

Page 192: ...a new filter after maximum 70 000 miles 110 000 km or earlier if driving in dusty conditions A clogged filter decreases the efficiency of the air conditioning system W8002474 If the vehicle is equipped with a sleeper heater A C there is a filter for the recircu lating air This is located behind the passenger seat on the bunk support The fil ter should be checked and cleaned after 40 000 miles 64 000 km...

Page 193: ...ldup of dangerous levels of CO which may lead to unconsciousness and later death WARNING The parking heater is a very hot object Do not touch the heater when it is in op eration or shortly thereafter Touching a heater may cause burns to exposed skin CAUTION The heater air cab inlet is located in the bunk wall in front of the heater Do not attempt to put small items or store flat items between the b...

Page 194: ...r is operated by a combined timer for the heater and a clock with built in alarm See page 225 for information to set the clock and alarm T8007012 Thermostat To be able to regulate the temperature in the sleeper while the parking heater is op erating there is a thermostat for setting the desired temperature It is located in the sleeper panel close to the timer clock The thermostat control range is ...

Page 195: ...ect function ap pears in the window Display Mode Symbols The three symbols illustrated below can be shown on the display Symbol showing that the alarm function is selected See page 225 for information to operate clock alarm Symbol shows that the parking heater is on See page 191 for information on direct and rapid start Symbol shows that the time delay start of the parking heater is on See page 19...

Page 196: ...er use the MODE button to switch between functions until the direct start symbol appears Press the SET button The hour digits start to flash Press the up button to set the number of hour the parking heater should operate Only complete hours or 0 59 minutes can be set The letter h ap pears after the indicated hour digit Accept the indicated time by pressing SET The display will show ON meaning that ...

Page 197: ...the SET button Set the minute digits the same way as the hour digits were set Accept the delay minutes by pressing the SET button The display will change to ON This means that the heater is ready to start when the set time has been reached If the heater is not to be started with the time delay press one of the up or down buttons and OFF is now displayed To alternate between ON and OFF press the up...

Page 198: ... the heater will not restart Overheat shut down will occur if there is a restriction of the heating air flow that is blocked inlet or outlet The automatic overheat switch will reset once the heater has cooled down The blower motor is checked on start up and every 4 minutes Shut down will occur if the blower does not start or maintain proper speed If any of these events should occur the unit should ...

Page 199: ...ed on the label are Slow Green Normal Fast Green Low system voltage 1 Red Blink Loss of refrigerant 2 Red Blinks Overcharge blockage or fan failure 3 Red Blinks Open or shorted clutch or circuit 4 Red Blinks Open pressure switch or circuit The air conditioning system is under pressure The possibility of an explosion is possible if serviced incorrectly A qualified technician should perform any servi...

Page 200: ...ide and also a fixed seat Each of the seats are described on the pages that follow All adjustments are to be made while the operator is seated and the vehicle is stationary Do not adjust the seat posi tion while driving the vehicle Failure to follow this warning can result in loss of vehicle control which can result in seri ous personal injury or death in the event of a crash Before adjusting or fa...

Page 201: ... fore or aft to a new position 4 Ride height adjustment Push the up per part of the switch up to increase ride height Push the lower part of the switch to deflate the airbag and lower the ride height 5 Lumbar support adjustment Push the upper part of the switch to inflate the support for a firmer support Push the lower part of the switch to deflate the support 6 Cushion rear tilt Rotate the lever to g...

Page 202: ...Lumbar support adjustment Push the upper part of the switch to inflate the upper part of the 3 chamber support Push the lower part to deflate it 11 Back rest side support Push the upper part of the switch to inflate the sup port Push the lower part to deflate it 12 Seat cushion side support Push the upper part of the switch to inflate the support Push the lower part to deflate it 13 Front seat cushion a...

Page 203: ...t of the seat cushion 3 Ride height adjustment Push or pull the control to change ride height 4 Lift the lever up to adjust the top part of the seat back 5 Push the lever down to adjust the whole backrest 6 The lumbar support is adjusted by turning the knob clockwise for firming and counterclockwise for slackening the support 7 The angle of the armrest is adjusted with the dial control on the under...

Page 204: ...d justed with control 1 Push the control button forward or backward The total seat adjustment movement is approximately 7 5 in 190 mm The seat cushion position in relation to the back rest 2 is adjusted with control 2 Push the control button forward or back ward The total cushion adjustment movement is approximately 3 0 in 75 mm The seat cushion front tilt is adjusted with control 3 Press or lift ...

Page 205: ...whole back rest angle is adjusted with control 5 Push the bottom part of the but ton forward or backward The back rest can be adjusted through 15 degrees of move ment The upper back rest angle is adjusted with control 6 Push the top part of the button forward or backward The upper back rest can be adjusted through 15 degrees of movement W8001830 ...

Page 206: ... cushion On the sides of the back rest there are cushions 4 for the side support of the back Both cushions are controlled by con trol 4 Move the control forward to inflate or rearward to deflate cushions Seat Heater There are two heater elements 5 in the seat One in the seat cushion and one in the lower part of the back rest They are oper ated by the switch 5 on the side panel The elements are regul...

Page 207: ...cushion up W8001386 No Passenger Seat option Using a temporary passenger seating without the benefit of proper seat mounting and safety belt can in the event of a loss of control of the vehicle cause serious personal injury or death In vehicles with no passenger seat installed Do not let a passenger ride on temporary seating This is against the law and can be very dangerous ...

Page 208: ...ated by the switch or be set to come on when the door opens The lens is red so the light is used to alert oncoming traffic from the rear that the door is open It is also used during night driving to light up the floor area and steps without distracting the operator with a glaring light W3000974 The door switch operates all door activated lights The switch is located in the rear part of the door fram...

Page 209: ...ture There are overhead fluorescent lights in the VN 610 VN 660 and VN 770 W3002425 The fluorescent overhead lights can be op erated from the sleeper panel switch W3001351 For the VN 770 model there is also a switch for the overhead fluorescent light in the left hand switch cluster on the dash This switch can be reached from outside the cab door to enable the light to be turned on without having to c...

Page 210: ...0 and an incandes cent light over the table in the VN 660 There is a switch in the sleeper panel on the driver side wall W3002332 A sleeper panel light is provided for the VN 770 model The light is located in the upper part of the panel and is operated by a switch located on the panel W3002334 ...

Page 211: ...al injury CAUTION Do not overload the cab suspension Make sure the weight distribution is equal in the cab Total load for the cab suspension in the daycab VN 420 VN 610 and VN 660 is 800 lb 360 kg with driver and passenger included To tal load for the cab suspension in the VN 770 is 1 000 lb 455 kg with driver and passenger included Overloading the suspension leads to poor ride and low ered drivin...

Page 212: ...during driving The top drawer also has a key lock so it can be used to store documents There is also a pull out writing tablet in the top part of the cabinet The drawer cabinet load limits are 9 5 lb 4 3 kg for the top drawer and 14 5 lb 6 5 kg each for the two lower drawers The drawer cabinet is substituted for a re frigerator when this option is chosen The clothes hanger cabinet does not have a ...

Page 213: ...Remove heavy items from top of the bunk before opening W8002021 The VN 610 front overhead roof storage offers extra storage for smaller items Load limits are 3 lb 1 5 kg for the side com partments and 5 lb 2 5 kg for the center compartment W8001096 The VN 660 front overhead roof storage is the same as for the VN 770 Load limits for the right and left sections are 5 lb 2 5 kg for upper shelf and 15...

Page 214: ...or the side openings and 11 lb 5 kg for the center opening The smaller top and under upper bunk storage load limit is 3 lb 1 5 kg for the outer openings and 11 lb 5 kg for the center opening W8001858 The driver side storage upper part can be either a pantry type cabinet with doors see illustration or an open cabinet with netting covering the storage openings not illus trated The pantry has an opti...

Page 215: ...assenger side storage upper part is prepared for TV and video There is also general storage above There is an optional 120 V electrical connection available for accessories Load limits are 5 lb 2 5 kg for the top shelf 15 lb 7 kg for the upper shelves and 33 lb 15 kg for the TV shelf W8001862 The passenger side storage bottom part is a clothes cabinet It is equipped with doors that latch closed wh...

Page 216: ... hatch under the outer bunk cushions The hatches are secured with a rubber cord To open the hatch loosen the cord and pull up the hatch with it On the VN 660 there is a velcro strap to hold the lid in the open position W8001873 In the front part of the cab roof there is ad ditional storage Load limits for the right and left sections are 5 lb 2 5 kg for upper shelf and 15 lb 7 kg for lower shelf Lo...

Page 217: ...while releasing the latches Failure to support the bunk may lead to the bunk falling without control causing personal injury The upper bunks for the VN 610 660 and 770 are also hinged and can be raised out of the way The VN 610 and VN 660 use the safety bunk harness latch for holding the bunk up The VN 770 has latches on both sides of the wall that hold the bunk in position To release the latches ...

Page 218: ...t all times when entering or exiting the upper bunk Failure to follow this procedure can lead to a fall and cause severe per sonal injury or death Start the climb by grabbing the grabhandles with both hands Place the right foot on the bunk bottom to the right of the cabinet and the left foot on the upper step as shown Put both feet on the upper step and move the right hand to the upper bunk for su...

Page 219: ...l ways a footstep available located in the passenger side cabinet Place the left foot on the footstep while holding on to the grab handle illustrated below Hold on to the handle in the middle of the bunk front edge and pull up into the bunk W8001886 The grab handle for upper bunk access is located on the cabinet W8001910 ...

Page 220: ... ladder falling out causing injury to leg or foot An upper bunk ladder is also available This is stored in its collapsed position be hind the passenger side cabinet To release the ladder unsnap the lock straps Support the ladder so it does not fall out unaided W8001888 The ladder unfolds out to provide a conve nient climb to the upper bunk W8001887 ...

Page 221: ...n the ladder is folded out lift the outer leg and guide it into the catch that is lo cated on the upper bunk W8001890 Lower the leg down and place the peg into the hole at the bottom Test the ladder by pulling on it before climbing up W8001889 WARNING When folding the ladder back into stor age position make sure fingers are out of the way If fingers are on the inside section of the upright pole they...

Page 222: ...in the bunk with the bunk restraint attached Failure to follow these instructions may result in severe personal injury or death in the event of a sudden stop or accident An advisory label is attached on the rear face of the driver side cabinet W8001898 To raise the table remove the cushions from the bunk and put them to the sides W8001891 Release the latch by pulling the handle un derneath the tab...

Page 223: ...egs with the holes in the back wall W8001892 Push the table firmly into the holes Make sure the latches have caught properly by pulling out on the table W8001894 When the table is in place put the cushions in place to form a seat and backrest W8001895 ...

Page 224: ...ull the handle underneath the tabletop to release the latches Lower the table to its resting position Place the seat cushions toward the walls and then position the backrest cushions as illustrated W8001896 Press down on the cushions in the middle to form a mattress W8001897 ...

Page 225: ... there is a com bined valve and switch in the knob 1 on the base Turn on the 12V switch on the sleeper switch panel to the left of the tower cabinet then turn the knob slightly to start the pump Turn the knob further to increase water flow When the knob is turned fully back to rest position the pump will stop CAUTION Make sure the pump is turned off before pushing the drawer in If the pump con tinu...

Page 226: ... USE POTABLE DRINKING WATER ONLY Verify with the supplier of any water prior to filling the fresh water tank that it is potable to avoid contamination of the tank In the event that non potable or contaminated water enters the fresh water tank it should be drained and the tank should be cleaned out with a good commercial cleaner disinfectant The tank should also be tested for purity prior to being u...

Page 227: ...the fill hose is inserted in the water reservoir open the valve slowly to fill The valve is fully open when the handle is parallel with the hose W8002167 When the tank is filled reinstall the fill hose on the elbow fitting Do not tighten more than finger tight Make sure that the valve handle now is fully open 1 to allow venting If the valve is left in any of the closed positions 2 the pumped out water m...

Page 228: ...e floor with a strap that can be easily opened for tank removal Before removing the waste water tank loosen the strap around the tank and un screw the drain hose from the inlet cap Carry the tank to an approved dump station and empty by removing the inlet cap and tilting the tank up to let the waste water drain Flush the tank with fresh water Replace the inlet cap strap the tank into the cab and at...

Page 229: ...lock or alarm func tion are described on page 190 T8007012 Display Mode Symbols To set the clock or to set the alarm use the MODE button to switch be tween functions The three symbols illustrated below can be shown on the display Symbol showing that the alarm function is selected Symbol for the parking heater See page 189 for information Symbol for the parking heater See page 189 for information ...

Page 230: ...button The time can either be set as an AM PM or 24 hour mode To go from the 24 hour mode to the AM PM mode continue to press one of the arrow buttons until the new mode is shown Accept the hour by pressing the SET button The minute digits will now start to flash Set the minute by pressing the up or down arrow button Accept the minute by pressing the SET button The clock is now set ...

Page 231: ... either the alarm ON or alarm OFF This is alternated by pressing one of the arrow buttons To accept the alarm ON or OFF press the SET button The mode now returns to clock function If the alarm is set a solid bell symbol appears in the display If no alarm is set only the time will be displayed When the clock reaches the set time for alarm and providing the alarm was set a buzzer sounds intermittent...

Page 232: ...ard every 50 seconds The detector battery is monitored automati cally When the voltage is too low to ensure proper function a short signal is heard every 45 seconds To check the bat tery hold down the function button for approximately 5 to 10 seconds If the bat tery is functional the alarm sounds as long as the button is pressed The battery lasts for 1 to 2 years Its lifes pan depends on the numbe...

Page 233: ... the windows should be closed to prevent water from en tering the cab The windows also serve as emergency es cape exits In the event of an emergency kick the window open and climb out W8001473 The windows are operated with a knob that is turned clockwise or counterclockwise to open or close the window Do not force the window crank mechanism in the fully open position The mechanism can be damaged t...

Page 234: ...rmally are folded up To use fold down the base and fold up the support W8001881 There is also a cup holder in the middle of the dash To open press the top part of the lid in and the lid will fold out To close press the lid in until the latch closes There are also two cupholders molded into the engine cover W8001875 ...

Page 235: ...eld area or go across the sleeper opening W8001877 When the curtains are not in use they are stored out of the way and held in place with velcro straps W8001880 Covers for the VN 660 are to be stored in a rolled up position in the opening behind the cabinet The covers for the VN 770 side windows are stored behind the backrest cushions All covers are put on with snap buttons that are on the cover a...

Page 236: ...over the needs of many uses If the antenna is damaged replace it only with a multiband type antenna A regular antenna does not have the wiring necessary to give good reception for all uses W3001997 TV Antenna For the VN 770 the TV antenna is stan dard equipment It is mounted to the inside of the headliner connected with a coaxial cable to the cabinet VN 610 and VN 660 antenna is accessible in the ...

Page 237: ...ptional on other models Coaxial cables for the cellular phone CB radio and radio are included in the multi plexer system all using the same set of antennas The multiplexer is accessed through the lower dash panels Cable routing is as shown in the illustration above Use only genuine Volvo replacement parts for this multiplexer system standard antennas will give unsatisfactory performance The wind i...

Page 238: ...tant features built into the unit Take the time to read the manufacturer s manual to be able to operate functions such as ra dio wake up alarm snooze function and theft deterrent coding W3002006 CD Changer A CD changer is available for VN 660 and VN 770 It is located in the passenger side overhead storage The power amp is located in the same storage There can be 4 to 9 speakers in the cab The subw...

Page 239: ...e There is room on the dash for a mobile telephone This can be hooked up to the multiplex box If the vehicle is delivered with a multiplex box the connecting end of the telephone coaxial cable should be located at the lower dash cover W3002427 Road Relay The Road Relay is an engine communica tion tool that allows the driver to have fuel consumption time and mileage readouts and also programmed rem...

Page 240: ...a pre installed antenna The TV should be installed in the passenger side cabinet where there is a standard 12 V connection or an optional 120 V connection To prevent the TV set from moving when the vehicle is driven the strap in the TV storage area should be clamped tight around the set If the strap comes loose from the buckle thread it as illustrated Ad just the strap so it is tight around the se...

Page 241: ... optional television speaker available located in the top of the sleeper switch panel Beside the speaker there is a jack for headphones This is provided for silent viewing of the TV When the headset jack is plugged in the speaker is cut out W3002431 ...

Page 242: ...Fuel consump tion can vary from over 10 mpg 20 L 100 km when driving empty on a nice and dry summer road to 3 5 mpg 70 L 100 km while driving with maximum permitted GVW with vehicle and trailer on a hilly and slushy winter road Build Specification and Equipment Whenever a vehicle is used for transporta tion its build specification equipment and gross vehicle weight have a decisive effect on both fue...

Page 243: ...nd cab to the trailer superstructure the better the airflow With better airflow the engine has to pro duce less power to push the air to the side especially at higher speeds There are partial and full air fairing pack ages available that should cover most vehicle specifications and applications With flatbed trailers using tarpaulins to cover the load make sure the cover is tied down well and presents ...

Page 244: ...Use the recommended preventive maintenance PM program that Volvo Trucks North America Inc has developed for the vehicles This ensures optimal en ergy efficiency from all components that are important to fuel consumption Tires If the tire pressure is too low the rolling resistance increases and thereby increases the fuel consumption The overall economy is also affected as tire wear increases conside...

Page 245: ...of an axle or wheel out of alignment is uneven tire wear Check the tires often Engine Faulty or incorrectly adjusted engine com ponents increase fuel consumption The list below gives some typical components that can influence fuel consumption Blocked on the outside charge air cooler radiator package Faulty thermostats Blocked fuel filter Blocked air intake filter Faulty injectors Dirty turbo charger ...

Page 246: ...ain Snow and Road Surface A wet road surface increases rolling resis tance and thereby fuel consumption Slush will increase consumption even more In certain cases the surface structure of the road can also have a negative effect on fuel consumption Gradients A hilly road with many bends demands a higher output from the engine The differ ence between flat straight roads and hilly winding roads can a...

Page 247: ...ine at its optimum speed range Use the correct uphill and downhill driving technique Starting the Engine Start the engine according to the instruc tions in the Operator s Manual of the engine manufacturer for a Volvo engine see page 245 A proper start especially during the cold season saves fuel and re duces engine wear Sluggish lube oil in the engine makes cold starting more difficult Therefore it...

Page 248: ... driving Refer to each engine manufacturer s opera tor s manual for information on the engine s optimum operating range Hill Driving Technique Use the inertia of the vehicle to go over the crest of a hill under reduced power Use gravity to help with acceleration when go ing down the hill Build up speed before reaching the next uphill High Speed With increasing speed comes an increasing wind resist...

Page 249: ...d information on how the gauges and telltales work Do not use ether or similar starting aids in a Volvo or other engine with a pre heater 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 Never operate the starter without first pl...

Page 250: ... Failure to follow these instructions could cause starter damage NOTE Some starters are equipped with an optional thermostat If over cranking occurs the thermostat breaks the electrical circuit to the starter mo tor until the motor has cooled Turn on the ignition with the switch key see page 248 for ignition switch information Some telltales will light up in a routine check that shows that bulbs a...

Page 251: ... be shut down immediately Failure to stop the engine may cause major engine damage When the engine has started it takes a while to send lubricating oil to all bearings and shafts and between pis tons and liners Wait for the oil pressure gauge to settle at a normal level then bring engine speed up grad ually Increase speed as it warms up Check all gauges during warm up 7 During warm up apply load g...

Page 252: ...bo to slow down and the cooling system to dissipate the engine heat Switch the engine off by turning the igni tion key to the O or OFF position CAUTION Shutting off an engine immediately after high speed or full load operation can damage the turbo and cause heat stress in the engine Always let the engine idle for 3 to 5 minutes before shutting it off ...

Page 253: ...ruck au thorized dealer The keys are laser cut and require a special machine for copy ing available through your Volvo Truck dealer Record the key code and keep in a secure place A new key can be made using the key code if the keys are lost W3000976 The ignition positions are O Off I Radio Accessories II Drive II 1 2 Preheat Volvo engine only III Start The ignition switch has a restart inhibitor l...

Page 254: ...n resulting in severe property damage se vere personal injury or death NOTE Volvo engines have a unique cold start feature Depending on the ambient temperature the engine cranks two to four turns without injecting fuel This provides cleaner combustion at start up and pro motes longer engine life To avoid excessive exhaust smoke when starting a cold engine the intake air should be warmed up by usin...

Page 255: ...e engaged to assist in faster engine warm up To re engage turn the key to the preheat position and the preheater will en gage The starter will not engage as the start position is locked out Engines Without Preheater Engines not equipped may depending on coolant temperature take longer to start If this should happen do not release the igni tion key until the engine has started while still observing...

Page 256: ...ad and follow the manufacturer s in structions regarding its use handling and storage Many starting fluids are sold in capsules or pressure cans and improper usage can be dangerous resulting in ex plosion personal injury or death Ether allows combustion with lower cylin der temperatures A hand held spray can for injecting ether through the engine air intake system will usually provide quick startin...

Page 257: ...correct accessories and information about installation If satisfactory engine temperature is not maintained increased engine wear will result in higher maintenance cost Acces sories should be designed to be easily disconnected when switching to driving in warmer weather so they do not affect the operation of the engine For cold weather operation follow these recommendations When starting the engin...

Page 258: ...gradually bring it up to operating temperature before operating at high engine speeds or full load After start ing and before moving the vehicle run the engine at 800 to 1000 r min for 3 to 5 min utes Operate at partial engine load until the coolant temperature reaches 165 F 75 C Engine Block Heater option An electric engine block heater can be in stalled for keeping the coolant hot when the vehic...

Page 259: ...r a heated fuel filter should be added A number of different fuel heaters are available as op tions They are electrically heated and regulated by a thermostat They are typi cally built into the primary fuel filter housing W2001067 Fuel Tank Heater option An in tank fuel heater is also available In tank heaters use hot engine coolant to warm the fuel This prevents wax formation in the fuel during col...

Page 260: ...ses coolant and inlet manifold temperatures must also be care fully monitored and controlled CAUTION Failure to remove the winterfront when temperatures go above 15 F 25 C could cause severe damage to engine charge air cooler and or loss of fuel economy If a winterfront is used it must conform to these specifications The grille coverage should be such that airflow through to the charge air cooler is...

Page 261: ...to downshift the transmission as the vehicle goes into the grade Acceler ating to the governed engine speed will give additional power at approximately the same road speed For shifting instructions see the transmission manufacturer s Opera tor s Manual Always start moving the load in a gear low enough so that the engine can be acceler ated to the governed speed Then shift to the next gear as the e...

Page 262: ...ary to obtain the engine speed transmission gear combination which will prevent smok ing Excessive smoke indicates wasted fuel which creates carbon deposits in the engine and turbocharger This causes excessive en gine wear and oil consumption Excessive smoke not only pollutes the atmosphere but can also cause shortened exhaust system life Engine Break In Engines used in the VN series are run on dy...

Page 263: ...nding on the engine manufacturer See the engine op erator s manual for more information When the shut down is activated the telltales come on and the buzzer is also ac tivated From that time it will take 30 seconds before the engine shuts down In this time period find a safe place to pull off of the road After the engine has been shut down by the system the override will allow a restart of the engi...

Page 264: ...sent shut the engine off immediately if any abnormalities are experienced Do not leave it unattended 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 severe injury and or death from burns ...

Page 265: ...Avoid excessive idling If the vehi cle is parked for more than 5 minutes stop the engine An engine can burn from 0 75 to 1 5 gallons 3 to 5 5 liters of fuel per hour while idling During long engine idling periods the engine coolant tempera ture may fall below the normal operating range Incomplete combustion of fuel dur ing the warm up period can cause dilution of the oil in the crankcase formation...

Page 266: ...ed cannot be increased above the maximum allowed by the engine manufacturer 5 The idle speed is adjusted down with the SET switch Each time the SET switch is pressed momentarily the idle speed will decrease approx 10 r min the speed cannot be adjusted below the low idle set by the engine manu facturer By continuously pressing the switch engine speed will ramp up SET or down SET 6 When the desired ...

Page 267: ...idle shutdown feature is enabled the engine will shut down at the set time under the following conditions These are the standard choices when the vehicle is delivered For more information about other customer adaptation choices contact your Volvo Truck dealer after a specific engine idling time This programming cannot be changed by the operator however it can be changed using special tools For veh...

Page 268: ...missible if the vehicle is cresting the top of a hill However extended operation at en gine speeds below the maximum torque range usually 1100 to 1200 r min will raise exhaust temperature and cylinder pres sure This can lead to reduced engine life Downhill Operation CAUTION Do not exceed engine manufacturer s recommended maximum engine speed Engine damage can occur If equipped with an engine or ex...

Page 269: ...An engine will produce excessive exhaust smoke at high altitude unless a lower gear is used Shift gears as needed to avoid ex cessive exhaust smoke Closely monitor the gauges during high al titude operation The thinner ambient air reduces the efficiency of the engine cooling system Engine overheat or cylinder dam age could occur if the engine is operated at full load for extended periods at high al...

Page 270: ...ly press in the SET or SET switch on the end of the lever 3 If the speed needs to be increased press the SET switch The vehicle speed will increase as long as the SET switch is pressed speed will not increase above the maximum pro grammed speed Release when the desired speed has been reached 4 If the speed needs to be decreased press the SET switch The vehicle speed will decrease as long as the SE...

Page 271: ...uise speed is re tained in the memory When the cruise control switch is pushed to the RESUME position the vehicle resumes the previously set speed providing vehicle speed is ex ceeding approximately 10 mph 15 km h when the switch is pressed Acceleration Momentary acceleration such as for over taking another vehicle does not interrupt cruise control operation After overtaking release accelerator an...

Page 272: ...ion of the vehicle 5 to 8 psi The thermal relief feature is large enough to limit tank pressure to a safe level even when the remaining fuel is boiling in the tank but not so large as to dump fuel un necessarily The thermal relief should respond as much as possible to fuel tem perature rather than flame temperature These features are also available on the op tional lockable fuel tank cap WARNING On...

Page 273: ... the tanks up to 95 of capacity Do not fill more than that as the fuel needs to have room for expansion dur ing the heat of the day Do not carry extra fuel containers in the cab Fuel containers full or empty may leak explode or give added fuel to a fire Failure to follow this precaution may lead to a fire and serious personal injury or death Do not smoke while fueling the vehicle The glow from the ci...

Page 274: ...h is fully engaged heat and wear does not affect it Do not shock load the drive line through rapid engagement of the clutch Extreme care should be taken when driving heavy loads up hills Always use the lowest gear when starting out under adverse conditions When operating a vehicle equipped with a clutch brake the clutch pedal should not be depressed more than halfway to the floor while shifting exc...

Page 275: ...o can result in un expected vehicle movement and can cause serious personal injury or death Make sure the parking brakes are set To release the gear lever pull the lever in toward the seat and press on the knob downward in a straight line W4001388 Twist the lever counterclockwise while holding pressure on the knob When releasing the pressure the springloaded lever will be pushed up out of the lock...

Page 276: ...ance W4001390 Locking Gear Lever To lock the gear lever in place move it from the folded position forward until it is upright Press down on the knob and twist clockwise until the knob is lined up straight Make sure that the gear lever is securely locked in position before taking the ve hicle on the road Failure to do so can cause loss of control over the vehicle leading to an accident with serious...

Page 277: ...erious personal injury or death Do not operate the vehicle when there is a malfunction in the compressed air sys tem An air brake system with leaks or other malfunctions may prevent the brake system from operating properly The vehicle should not be operated until the system is repaired and all brake cir cuits are working properly Failure to repair the system can lead to loss of control of the vehi...

Page 278: ...that use a single set of brake controls Each circuit is supplied by its own compressed air tank Both air tanks receive compressed air from the same supply tank wet tank and are charged with equal pressure The two cir cuits are interconnected for the parking brake system Air pressures in the two circuits are moni tored by two pressure gauges on the right side of the instrument cluster The primary r...

Page 279: ...he vehicle to a controled stop Failure to follow these precautions can result in loss of braking control and serious personal injury or death can occur as a result of a vehicle accident An important feature of the brake system is that an automatic spring brake application does not take place as a result of an air loss in only one of the two circuits In this case brake control remains in the foot b...

Page 280: ...rake Valve The foot brake valve is directly connected to the brake pedal The valve gives a pro gressive output against the pedal travel This allows better control of the pressure in the first half of the pedal travel In the last half of the pedal travel the pressure output increase is faster The foot brake valve applies the service brakes incorporating both the primary and secondary air systems The...

Page 281: ...air controlled braking of this vehicle Failure to observe these precautions can result in loss of brakes loss of vehicle control vehicle accident and serious personal injury or death 1 The best possible stop will be made when the first brake application is as firm as the speed and road condition permit Then ease off as the speed is reduced Never apply the brakes lightly at first and increase the pres...

Page 282: ...al and set the parking brake before shutting down the engine 6 When descending a long grade do not use the service brakes too long or too often The brakes may overheat and lose their effectiveness 7 Before descending a steep grade the transmission should be shifted into a lower gear and the vehicle speed re duced Other speed retardation devices should also be used if available en gine brakes retar...

Page 283: ...Supply valve knob may then be pushed in The Trailer Air Supply valve knob and Sys tem Park valve knob will automatically pop out if the system pressure both front and rear circuits drops to 25 to 35 psi 170 to 240 kPa The tractor protection valve will then close the tractor spring brakes will apply and the trailer emergency system will be activated On vehicles equipped with the standard two valve ...

Page 284: ... may result in overheated brakes and damaged wheel hubs WARNING Continual dragging of the brakes will cause brakes to overheat This may lead to wheel end fire To avoid overheating make sure both parking brake knobs are pushed in before driving off W5001114 If the yellow knob is pulled out and the red knob is pushed in a condition is created where the trailer parking brakes are not ap plied and only...

Page 285: ...tivated when the yellow parking brake knob is pulled out There fore some drivers park and release the parking brakes using only the red knob to keep the engine running It is then easily overlooked that in a vehicle parked with both the yellow and red knobs activated only the red knob is pushed in by habit W5001117 Incorrect Parking or Driving Position ...

Page 286: ...60 psi 420 kPa before the park ing brake may be released The parking brake spring tension is suffi cient to hold a fully loaded vehicle on maximum grades permitted on modern highways provided the brake drums and linings are in good condition and the brakes are properly adjusted CAUTION Do not use the spring parking brakes if the service brakes are hot such as after descending a steep grade Also do ...

Page 287: ...the parking brake knob is pulled The air exhausts from the park brake valve itself and from the spring brake chambers on the rear axle s A black ring around the base of the yellow control knob will be seen There will be a fluctuation in the air pressure gauge needles You will not be able to pull the knob out any further Do not attempt in any way to disassem ble or tamper with the spring brake chamb...

Page 288: ...y a full application of the foot brake valve To supply air to the trailer brakes to slow the trailer down pull the valve handle down The farther the handle is pulled down the more air pressure is applied to the trailer brakes Releasing the self returning handle releases the trailer brakes W5001035 Air Tanks WARNING When draining the air tanks do not look into the area of the draining air Dirt or s...

Page 289: ...r any repair facility to make any part or component inoperative when it is required for 121 compliance Charging Air To Another Vehicle There are many methods which may be used to charge the air system of another ve hicle Vehicles equipped with the standard two valve system trailer supply and parking brake must use the following pro cedure when using the emergency trailer air line as an auxiliary a...

Page 290: ...nto the electronic control unit Installing different sized tires could re sult in a reduced brake force leading to longer stopping distances or accidents There is a sensor installed in each wheel on a monitored axle The sensors transmit in formation to the electronic control unit ECU The ECU interprets the signals and calculates wheel speed wheel retardation and a vehicle reference speed If the ca...

Page 291: ...f testing program that is engaged each time the ignition is turned on The operator can verify the testing by listening for the ABS modulator valves actuating twice in series To increase the sound hold down the foot brake pedal when the ignition is turned on The self test is not finished and the telltale will stay on until the vehicle has started to move The wheel speed sensors are tested when the v...

Page 292: ...nd gives the operator greater vehicle control W3000962 The TCS includes a switch to turn of the function When the switch is in the OFF position the TCS operates normally to in crease traction if the drive wheels are spinning When the switch is pressed once the TCS telltale in the instrument cluster blinks continuously indicating that the TCS is in mud snow mode The mud snow mode increases availabl...

Page 293: ...xhaust Brake etc is not intended to bring the vehicle to a stop A vehicle speed retar dation device is only intended to retard the vehicle speed under certain condi tions NOTE If a Volvo engine is equipped with a Volvo Engine Brake the brake will not operate with full power until the engine coolant temperature has reached 110 F 45 C NOTE It is normal for there to be a slight delay in the applicati...

Page 294: ...st brake is operated by a two position switch in the right hand switch cluster For the exhaust brake to function the following must be in effect The switch is ON Accelerator and clutch pedals are fully released Engine speed exceeds 1 100 r min When the cruise control is engaged the ex haust brake automatically engages if the selected cruise speed is exceeded by ap proximately 5 mph 8 km h The exha...

Page 295: ...compression brake are acti vated For the engine brake to function the following must be in effect The switch is ON Vehicle speed over 7 5 mph 12 km h Engine temperature over 110 F 43 C Accelerator and clutch pedals are fully released Engine speed over 1 100 r min When the cruise control is engaged the en gine brake automatically engages if the selected cruise speed is exceeded by ap proximately 5 ...

Page 296: ...er is selected with the right switch which has three positions LOW MED and HIGH for Cummins M11 only LOW and HIGH For the exhaust brake to function the fol lowing must be in effect The switch is ON Vehicle speed over 7 5 mph 12 km h Engine temperature over 110 F 43 C Accelerator and clutch pedals fully re leased Engine speed exceeding 1100 r min When the cruise control is engaged the ex haust brak...

Page 297: ...While static electric ity is not normally dangerous to humans it can seriously damage electronic cir cuits and components Circuit boards mounted in the instrument cluster for example may not fail immediately after being hit with a static discharge Rather they may work for a while and then fail for no apparent reason Therefore al ways work with proper grounding straps and antistatic mats around ele...

Page 298: ...xpose batteries or the areas around them to sparks or flames The battery area may contain an explo sive gas mixture that can ignite causing an explosion leading to serious personal injury or death 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 to prev...

Page 299: ...ings batteries can be checked through the access door For full access the fairing needs to be removed To remove the fairing remove the two hex bolts in the corners of the step and the four screws to the cab The whole panel can now be removed W8001362 ...

Page 300: ...on the box before fastening the latches Faulty in stallation may cause the cover to shift when the steps are used which may lead to a fall causing serious personal injury or death W3002421 There may be three or four batteries in stalled Always make sure the batteries are fastened properly in the box When disconnecting battery terminals al ways disconnect the main ground terminal first When reconnec...

Page 301: ...80 Connect the jumper cables to the positive or hot terminal first and ground terminal last When disconnecting the cables dis connect the ground terminal first Connect the jumper cable clamps to the discharged battery first and to the booster battery last Avoid creating sparks by making all con nections quickly and firmly Do not permit vehicles to touch each other when jump starting Do not attempt to ...

Page 302: ... system with out the proper tools and training Repair work to the electrical system must always be done by trained professionals Your Volvo Truck dealer has the right tools and trained technicians Jump Starting the Engine If the batteries are discharged to the point where they do not have enough stored en ergy to start the engine they should be recharged using a low charge current not to exceed 16...

Page 303: ...ely after being hit with a static discharge Rather they may work for a while and then fail for no apparent reason Therefore always work with proper grounding straps and antistatic mats around electronic components Welding CAUTION Welding on the vehicle can damage the electrical system or components due to the high voltage and current spikes that normally occur when welding It is preferable to avoi...

Page 304: ... negative and positive battery cables Disconnect the negative cable first Reconnect the positive cable first Disconnect engine starter ground from the chassis This connection is located outside the left hand frame rail in the engine compartment Disconnect the power harness and ve hicle interface harness at the engine electronic control unit EECU If the vehicle is equipped with systems that have thei...

Page 305: ...electronic component during the welding procedure After finishing welding and the welded areas having cooled inspect wiring and components for possible shorts or damage In the event of a short circuit excessive current will be drawn when the batteries are reconnected causing more damage to the electrical system CAUTION Do not weld on the engine or engine components Welding on the engine or componen...

Page 306: ...60 seconds At the end of the alarm the monitor discon nects circuits to protect the batteries When the batteries are charged either through the vehicle alternator or a connected battery charger the monitor will automatically re store power to the disconnected circuits Disconnected circuits are connected to fuse positions F15 through 35 These circuits are primarily feeding the sleeper area and head...

Page 307: ...t of functions that is attached to the underside of each panel All fuses and relays are accessible under the top cover W3002514 Fuses are standard Reset breakers are avail able as an option for some circuits If a fuse continues to melt or disconnect the circuit has a malfunction and must be repaired If a breaker disconnects the ignition or main switch must be switched off before the breaker resets...

Page 308: ...over on the dash W3002526 One type of fuse in the new electrical cen ter are termed mini fuses and require a puller tool to remove from the fuse block The puller tool is part of the Owner s Pack age To order a new puller specify part number 20378326 W3002525 Mini fuse puller tool ...

Page 309: ...ripped wire ends are used make sure there are no wire strands that can bridge between the studs The red stud is the positive terminal and the black stud is the ground terminal Power from the studs must not exceed a 10 amp draw Before connecting any elec trical accessory make sure it is made for 12 V operation W3002001 The top tray is available as a CB mount with a strap to hold different size radi...

Page 310: ...g On the panel is also a cigar lighter that can be used for an additional 12 V outlet W3002430 In the VN 770 sleeper there are the same panel mounted outlets as for the VN 610 as well as outlets in the cabinets For the driver side cabinet the two outlets are switched The switch is located on the sleeper control panel and is used for switching off a refrigerator if the vehicle is parked for a longe...

Page 311: ...al injury or death resulting from electrical shock can occur in wet conditions To hook up the service there is a socket 1 lower illustration located under the driver side door If the vehicle is equipped with an engine heater the socket for cab power is on the bottom W3001996 Power goes through a breaker box 2 lo cated on the front wall in the driver side luggage compartment On the right is an ON O...

Page 312: ...Electrical System 307 From the breaker box power goes to three outlets One is on the driver side bunk box 4 There is one outlet in each tower cabi net in the middle compartment 3 and 5 W3002367 ...

Page 313: ...ling back at the same time Turn the lock ring counterclockwise and remove Pull out the bulb W3002422 NOTE When removing the new bulb from the box do not touch the glass with fingers or anything that may put grease on the glass surface Install the bulb and line up with the loca tion tab by turning it and then push it in until fully seated Install the lock ring Push the terminal back on Check that th...

Page 314: ...safe stop Do not drive the vehicle until correct ing the cause of the problem Do not drive the vehicle without power assisted steering When the power assist has failed the effort to turn the steering wheel is much greater especially in sharp turns or at low speeds This can cause an accident and lead to serious personal injury or death While operating the vehicle avoid ruts and obstructions which c...

Page 315: ...Steering Column option The steering column is fixed as standard An adjustable steering column is available as an option The adjustment device is op erated by a pedal on the left side of the floor To make adjustments depress the pedal and move the steering column to the desired position and then release the pedal Do not try to make adjustments to the steering wheel while the vehicle is mov ing Make a...

Page 316: ...ces a great strain on the axles and may cause rapid tire wear The differential lock should be used on icy or slippery surfaces As soon as the slippery surface has been passed the differ ential lock should be disengaged Differential locks must not under any cir cumstances be engaged when in a wheel spin situation Engage the locks ahead of the slippery area If already slip ping stop the wheels engag...

Page 317: ...n and the differential locks engaged the vehicle will be understeered and therefore will tend to drive straight in a curve If the locks must be used on good traction surface drive cau tiously and do not exceed 25 mph 40 km h Disengage the locks as soon as possible When the differential locks are disengaged the couplings may be under tension Disen gage the locks by returning the switch to the OFF p...

Page 318: ...Wheel Nuts Failure to properly torque tighten the wheel nuts can result in the breakage of wheel studs and the subsequent loss of wheels Loss of vehicle control and seri ous personal injury or death could occur Check tighten all wheel nuts after the first 50 to 100 miles 80 to 160 km and the first 50 to 100 miles 80 to 160 km after each tire service This applies to both sin gle and dual wheels in co...

Page 319: ...side wall flexing re sulting in increased tire heat This may cause premature tire failure W7000437 Tires and wheels must be serviced only by a qualified technician Do not attempt to perform this work yourself Inflated tires on wheels contain compressed air and if suddenly released do so with an explosive force Serious personal injury or death can occur For specific information and warranty on rims and...

Page 320: ...r proper servicing Watch carefully for oil leaks and listen for unusual noises These are indications of worn bearings bad seals or misadjusted bearings These are problems which must be corrected as soon as possible Failure to keep wheel bearings properly adjusted may result in accelerated tire wear poor handling and wheel separa tion from the vehicle Failure to properly maintain bearings can ultim...

Page 321: ... Grease the plate No grease on the plate will produce heavy steering Verify visually that coupling has oc curred Verify visually that plungers have locked on slider Check for slack between the 5th wheel and the trailer kingpin Always have all fifth wheel maintenance and repairs done by a qualified techni cian An incorrect repair can cause the trailer to separate from the tractor caus ing an accident...

Page 322: ...earshift in neutral and chock trailer wheels Lower trailer landing gear to ground Disconnect air electric lines to tailer To release the fith wheel kingpin lock push the switch up This will release the locking mechanism Once acti vated the switch will not relock the fifth wheel kingpin locking mecha nism Release parking brake and drive trac tor 12 inches away from the kingpin Deflate air suspension b...

Page 323: ...n the Owner s pack age W9000183 If the fifth wheel is equipped with a sliding mounting follow the advisory labels at tached to the component Also read the literature provided by the manufacturer W9000185 Always keep the fifth wheel plate well lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause erratic steering and loss of vehicle control that may result in ...

Page 324: ...heel is in when uncoupling the trailer To achieve the lockset position the operating rod is pulled out with a slight upward mo tion The operating rod shoulder will catch on the plate casting The safety latch is ro tated toward the rear of the fifth wheel W9000242 Open This is the position the fifth wheel is in after the trailer is uncoupled The jaw is open and the operating rod is now dropped down a...

Page 325: ... axles The air operated slider takes the work out of adjusting the tractor for various trailer loads The fifth wheel portion is easily ad justed even with a fully loaded trailer connected Movement between the adjustable saddle plate and the stationary base plate rail can result in wear causing longitudinal latitu dinal and vertical slack Field repairs can be made to reduce this slack for additional...

Page 326: ... mounting of the fifth wheel to the frame is tight and in good condition If using a sliding fifth wheel make sure the slide locking plungers are in a locked position The following instructions are for preparing the fifth wheel for coupling to a trailer Rotate the safety latch toward the rear of the fifth wheel W9000180 Using a slight upward motion pull the op erating rod out until the operating rod sh...

Page 327: ...ot raise the oper ating rod handle to its maximum upward position W9000242 Release the operating rod The upper shoul der of the operating rod should now be in contact with the plate casting above the op erating slot The fifth wheel is now in the lockset position and a trailer can be coupled W9000274 ...

Page 328: ...procedures inspect the equipment before coupling to a trailer Make sure the fifth wheel is properly lubri cated and the jaw is in the open position W8001449 WARNING If the jaw is not in the open position use a pry bar to rotate the jaw to the open position The lock is spring loaded Keep hands away to avoid injury Use a pry bar to open the fifth wheel jaw if necessary W8001450 Make sure the plate is ...

Page 329: ...ngaged W9000205 Chock the trailer wheels Use two chocks both on the front and rear of the wheel on both sides of the trailer W9000263 Back up close to the trailer centering the kingpin on the throat of the fifth wheel and STOP NOTE For tractors with air ride suspen sion make sure the suspension control switch is in the RIDE position switch pushed in at the top and the air springs are inflated W30013...

Page 330: ...hind the pivot point as the tractor backs under the trailer Raise or lower the trailer landing gear as required to obtain this position WARNING Attempting to couple with the trailer at an improper height could result in a false or improper couple and cause dam age to the tractor fifth wheel and trailer and possible personal injury Back under the trailer keeping the trailer kingpin centered in the t...

Page 331: ...the pin The kingpin should not overhang the fifth wheel or be caught in the grease groove To verify that the kingpin is actually in the fifth wheel slot and the jaw is closed the pin must be visually inspected from the rear Use a flashlight if necessary W9000181 Make sure the trailer bed is resting on the top surface of the fifth wheel plate and that there is no visible gap between the fifth wheel and ...

Page 332: ...ctor backward and for ward with the trailer brakes set If the clearance appears excessive more than 1 8 in 3 mm or if the jaw does not lock the fifth wheel should be inspected by a qualified technician before proceeding Wind up the trailer landing gear trailer support to its fully retracted position Fold down or remove the crank handle and place it in the crank handle holder Check the air brake line...

Page 333: ...wheels Use two chocks one on the front and one on the rear of the wheel on both sides of the trailer W9000263 Wind down the landing gear until it touches the ground and then give it a few extra turns in low gear Do not raise the trailer off of the fifth wheel Fold down or remove the crank handle and place it in the crank handle holder NOTE In poor ground conditions it may be necessary to provide a ...

Page 334: ...back the tractor up slightly to re lieve any kingpin load against the fifth wheel jaw W9000275 Release the tractor park brakes and pull the tractor away from the kingpin about 12 in 300 mm and STOP Do not allow the fifth wheel to leave the underside of the trailer W9000239 Select the UNCOUPLE position push down the latch and press in the bottom part of the switch on the suspension control switch to ...

Page 335: ...p part of the switch in on the suspension control This restores the suspension to operating height CAUTION The vehicle must never be driven with the air springs deflated Damage to air suspension parts will occur if springs are not inflated properly W8001459 After the trailer is uncoupled the fifth wheel will be in the open position The op erating rod will drop and can be moved around freely W9000203 ...

Page 336: ...se two chocks both on the front and rear of the wheel on both sides of the trailer W9000263 Wind down the landing gear until it touches the ground and then give it a few extra turns in low gear Do not raise the trailer off of the fifth wheel Fold down or remove the crank handle and place it in the crank handle holder NOTE In poor ground conditions it may be necessary to provide a stable base for th...

Page 337: ...o difficult to pull back the tractor up slightly to re lieve any kingpin load against the fifth wheel jaw W9000275 Release the tractor park brakes and slowly drive the tractor out from under the trailer Let the trailer slide down the fifth wheel and pickup ramps W9000239 After the trailer is uncoupled the fifth wheel will be in the open position The op erating rod will drop and can be moved around fre...

Page 338: ...on level ground Lock the trailer brakes by pulling out the Trailer Supply knob Release the slide locking plungers by mov ing the switch to the UNLOCK position press down the latch and push in the bot tom part of the switch W3001346 Check to see that both of the slide plungers have released If the plungers do not come out lower the landing gear to relieve the pressure on the plungers Lowering the l...

Page 339: ...Do not operate the vehicle if the plungers are not fully engaged and the trailer landing gear is not fully retracted Doing so may cause damage to the trac tor trailer and landing gear loss of trailer and personal injury Visually check to see that the slide plungers are fully engaged It may be nec essary to leave the trailer brakes locked and to move the tractor slightly to engage the slide plunger...

Page 340: ...ust be removed if the vehicle is to be towed at speeds over 25 mph 40 km h or for a long distance Openings should be covered to prevent loss of oil and entry of dirt and grit Where oil lubricated bearings are used openings should be thor oughly sealed with metal discs and new gaskets before towing WARNING If a vehicle with air suspension is lifted by the rear frame member there is a risk that the ...

Page 341: ...raised up behind the wrecker does not exceed the maximum allowed height for local underpasses Failure to follow this instruction may lead to per sonal injury and vehicle damage The vehicle may now be towed It is rec ommended that a wrecker with a lift bar is used since the service brakes will not func tion The system must be filled with air to release the parking brake or follow the me chanical spr...

Page 342: ... wrecker lift bar under the front axle use the tow eyes supplied with the vehicle The front tow eyes are used as a point at the front of the vehicle where the vehicle can be pulled Do not use the tow eyes for raising the front of the vehicle the tow eyes can break Do not crawl under a vehicle sus pended by tow eyes Failure to follow these instructions can result in serious personal injury or death...

Page 343: ...eing used W8000934 When the vehicle is located properly lift the front and locate the lift bar under the front axle and secure Using the front axle for towing minimizes the possibility for damage to the vehicle body frame and sus pension NOTE When the drive shaft or axle shafts are reinstalled make sure the nuts are tight ened to the correct torques Also make sure the axle shafts are installed in ...

Page 344: ...prevent the vehicle from rolling Failure to do so can result in unexpected vehicle movement and serious personal injury or death can occur Remove the plastic plug in the front end of the chamber Remove the screw from the holder in the side of the brake chamber In sert the screw into the front hole and push in until it bottoms Screw into the cylinder so at least 4 to 6 threads have entered W5000643...

Page 345: ...nut This compresses the brake chamber spring and releases the parking brake Do not attempt in any way to disassem ble or tamper with the spring brake chamber If the force stored on the spring is suddenly released it can cause serious personal injury or death W5000644 ...

Page 346: ...istance The num ber to the Customer Support Center is 1 800 528 6586 or 800 52 VOLVO Also on the internet www vas volvo com VAS can offer Delivery Assurance If you have a breakdown VAS can arrange for load forwarding 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 ...

Page 347: ...IN For VIN location see page 16 Current prices for a Service Manual Set are 350 00 for vehicles with a Volvo engine and 300 00 for vehicles with a Cummins or Detroit Diesel engine manuals have to be ordered separately from the manufac turer If complete wiring schematics are needed they can be ordered for 150 00 Billing will be done through the nearest Volvo Truck dealer NOTE Prices subject to chan...

Page 348: ...laints 6 CB Radio 234 CD Changer 233 Change Bulbs In Instrument 95 Cigar Lighter 113 Clock Alarm Sleeper 226 Clock Sleeper 224 Clutch and Transmission 269 Clutch Operation 269 Cold Weather Operation 252 Collision Warning System VO RAD 69 Comfort Clip 60 Communication and Entertainment231 Coolant Temperature Gauge 75 Cruise Control 265 Cup Holders 229 Curtains 230 D Daily Maintenance Checks 45 Dash...

Page 349: ...ension Pressure 90 Gauge Brake Application Pressure 90 Gauge Brake System Air Pressure 91 Gauge Coolant Temperature 75 Gauge Drive Axle Oil Temperature89 Gauge Fuel Level 90 Gauge Oil Pressure 76 Gauge Pyrometer 74 Gauge Turbo Boost Pressure 77 General Information 1 Graphic Display 114 Graphic Display Controls 115 Graphic Display Overview 114 Graphic Display Telltales 117 H Headlight Bulb Changing...

Page 350: ...19 Road Relay 234 Roadside Assistance 341 S Safety Belt Replacement 59 Safety Belt Telltale 87 Safety Belts 50 Safety Defects Reporting 6 Safety Equipment 68 Safety Guidelines Electrical Sys tem 292 Safety Guidelines Fifth Wheel 318 Safety Information Brakes 272 Seat National 196 Seat Stationary 202 Seat Volvo 199 Seats 195 Selling Vehicle 1 Service Assistance 341 Service Information 341 Service M...

Page 351: ...lant 75 Tire Inflation 314 Towing Information General 335 Towing Procedures 337 Traction Control System TCS 287 Trailer Brake Hand Control 283 Trailer Coupling Procedures 323 Trailer Supply Valve 278 Trailer Uncoupling 328 Turbo Boost Pressure Gauge 77 Turn Signal 97 TV Antenna 231 U Uphill Operation 263 V Vehicle Access 20 Vendor Component Information 1 Ventilation 185 Voltmeter 125 Volvo Action S...

Page 352: ...our Truck Was Delivered By If you need breakdown assistance contact the VAS Support Center for towing or repair VAS is available 24 hours per day 7 days per week at 1 800 528 6586 A Volvo Customer Support Specialist will answer your questions or arrange for the assistance you need Volvo Action Service VAS Support Center 1 800 52 VOLVO ...

Page 353: ... 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 154796 4 000 4 2001 Volvo Trucks North America Inc 2001 ...

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