Volvo VHD Service Manual Download

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Service Manual

Trucks

Group

177–500

Preventive Maintenance

Basic Service

VN,VHD

PV776-TSP151476

Summary of Contents for VHD

Page 1: ...Service Manual Trucks Group 177 500 Preventive Maintenance Basic Service VN VHD PV776 TSP151476 ...

Page 2: ... reference is made to an S R T The following levels of observations cautions and warnings are used in this Service Documentation Note Indicates a procedure practice or condition that must be followed in order to have the vehicle or component function in the manner intended Caution Indicates an unsafe practice where damage to the product could occur Warning Indicates an unsafe practice where person...

Page 3: ...pecial Tools and Special Equipment 14 Preventive Maintenance Inspection Bay 21 Design and Function 23 Clutch 23 Power Take off 25 Driveshaft 25 Brakes 26 Steering System 27 Hubs 28 Chassis 29 Cab 30 Preventive Maintenance 31 Basic Service 31 97 Additional Time Based Maintenance 97 99 Additional Mileage Based Maintenance 99 Feedback 1 ...

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Page 5: ...ance program realizes the investment made in the vehicle The difference between a poorly maintained vehicle and a well maintained vehicle will not show up until later mileage Good maintenance is necessary to assure the designed life expectancy of the vehicle and its individual components Maintenance Coverage There is no firm maintenance program that will apply to all operations A basic maintenance...

Page 6: ...n point Items noted as being faulty or in need of adjustment need to be shown to the customer and scheduled for repair There are many time and or mileage based ser vice items that are not listed on the form Look at the end of this document for a listing of additional compo nents that may need to be serviced depending on the mileage or time since last service Maintenance Records It is important to ...

Page 7: ...re carried out at specific mileage or time intervals These are not part of the Preventive Maintenance Basic time They should be scheduled as an adjustment or repair job carried out at the same time as the Preventive Maintenance and are listed in this document as reminders only 5 ...

Page 8: ...to any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur chaser 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 Noise Shields and Insulation Removing or rendering inoperative the engi...

Page 9: ... use caution Al ways have a firm hand hold and or stable foot position before transferring weight to that position Do not carry anything when entering or exiting Make sure the soles of your shoes and the cab steps are free from dirt grease oil or moisture before using the steps Failure to do so can result in a fall and serious personal injury or death may occur If using a jack and or jack stands c...

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Page 11: ...e been tested by a collaboration with engine and oil manufacturers Synthetic oil is offered as an alternative to the traditional petroleum based oil for the engines The ability of syn thetic oil to protect the engine is better than regular oil but its life is the same as for regular oil This is because of the combustion by products that contaminate the oil These contaminates will make the change i...

Page 12: ...re recommended for all Volvo cooling systems Antifreeze alone does not provide sufficient corrosion protection for heavy duty diesel en gines If the fuel has a sulfur content exceeding 0 5 by weight halve the indicated maximum mileage intervals Oil filters should always be changed when changing oil CUMMINS ENGINES For further information concerning component specifica tions see service information...

Page 13: ...fica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Caterpillar does NOT recommend an automatic exten sion of oil drain intervals with high quality oil low sulfur fuel and non severe duty driving Oil drain intervals can only be extended with an oil analysis program containing the following e...

Page 14: ...on Fuller Meritor and Allison HD Transmissions For further information concerning component specifications see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature 12 ...

Page 15: ...Arvin Meritor and Eaton Dana Rear Axles For further information concerning component specifications see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature 13 ...

Page 16: ...ordering system or already from Kent Moore by calling 800 328 6657 Kent Moore tools are preceded by a J Please refer to the specific tool number when ordering Special Tools J 42942 ABS Sensor Adjustment Tool Kent Moore J 42189 Airline Release Tool Kent Moore J 44399 Air System Tester J 44773 Airline Release Tool J 44769 Wheel Speed Sensor Extractor J 44966 Wheel Speed Sensor Remover for Heavy Duty...

Page 17: ...Tools Continued J 44302 A C Schrader Valve Core Removal Tool J 443338 Oil Dipstick for A C Compressor J 22610 Drive Shaft Boot Camp Pliers J 43143 Tie Strap Tensioner J 41610 Feeler Gauge Set J 44392 Fan Belt Tensioner Tool 15 ...

Page 18: ...Group 177 Tools Special Tools Continued PT 5900 Chip Vacuum 9998142 Charge Air Cooler Pressure Tester J 38641 B Diesel Fuel Hydrometer J 44544 Ride Height Gauge 000700 Rim Flange Wear Gauge 16 ...

Page 19: ...l Equipment J 42397 A Coolant Pressure Test Adapter 1089953 Bulb Removal Tool J 23600 B Belt Tension Gauge J 38460 ADigital Inclinometer J 36795 Tandem Axle Calipers 3093472 Timken Wheel End Play Gauge 9996791 Spring Pin Socket 17 ...

Page 20: ...ools Other Special Equipment Continued 9998691 Oil Filter Nipple Installer Kit 3947553 3949521 3946522 3949523 Terminal and Shim Kits J 44701 Battery Tester Kit J 44778 J 44779 Driveshaft U Joint and Yoke Kits 18 ...

Page 21: ...ica please refer to the specific tool number when ordering 7 1 PC tool package 2 9998555 Communication interface unit 3 9812331 Extension cable 4 J 43999 6 pin Diagnostic adapter for VN vehicles prior to 1999 5 J 43939 9 pin Diagnostic adapter for VN vehicles built from January 1999 6 9998496 Pressure gauge 7 9998495 Air Pressure Hose 19 ...

Page 22: ...the Lighting System for Volvo Trucks They may be obtained from Volvo or where indicated from Kent Moore at 800 328 6657 J 25300 D Headlight Aiming Kit Kent Moore 1089953 Lamp Removal Tool Volvo J 42395 Rheostat Removal Tool Kent Moore 20378326 Fuse Puller Tool Volvo J 43244 Relay Puller Tool Kent Moore 20 ...

Page 23: ...ight unless inspecting in the frame Equipment Inspection bay equipment should be specifically as signed to that bay and not be shared with the rest of the shop The floor equipment should have floor space for storage in between using them and tools should be hung on boards or stored in a cabinet for easy overview and access Install mirrors in four corners of the bay so one person can do a lighting ...

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Page 25: ...and the piston 1a in the master cylinder Thus the pedal will always have a play regard less of the clutch adjustment The correct play is adjusted with the upper adjusting screw 1b in the pedal carrier Fig 1 Clutch Volvo Clutch Slave Cylinder Slave cylinder stroke A is 29 1 mm 1 14 0 04 in The clutch pedal throw 2 Figure 1 gives the stroke The lower adjusting screw 2a limits the pedal throw and the...

Page 26: ...tor is out of the operating range it is time to adjust the clutch To get the slave cylinder throw into the accepted range adjust the clutch plate until the indicator is in the operat ing range again 1 Slave Cylinder 2 Mounting Bolts 3 Clutch Clevis Pin 4 Clutch Master Cylinder and Reservoir Found on the Bulkhead in the Engine Coupling 24 ...

Page 27: ... 2 Driveshaft For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Use a lithium based grease with EP additives with a consistency of NLGI No 2 Do not use conventional chassis grease The driveshaft U joints must be lubricated correctly for the...

Page 28: ...old grease has been pushed out past the splined shaft area and adjustment pawl and new grease can be seen flowing Air Dryers Air dryers have internal maintenance systems that clean out the accumulated moisture frequently and can there fore work with long maintenance intervals Eventually the drying medium will be filled up and the cartridge will need to be changed Change cartridge when there is mor...

Page 29: ... input shaft and at the sector shaft that need greasing with a hand gun ev ery 4 months or more often if the weather and road conditions are severe No axial movement is allowable when 100 lbs of hand pressure is applied Use hand pressure only do not check using pliers wrenches or any other tools For all VHD Axle Back models the steering shaft U joints should be inspected to see that the plastic ca...

Page 30: ...g system that is run ning hotter than normal and the fluid is overheated Troubleshoot the reason for overheating and change fluid Hubs Oil Lubricated Hubs For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Hubs are generally oil lubricated a...

Page 31: ...ate spring pins using a lithium based grease with EP additives and the consistency of NLG1 No 2 Fill grease until old grease has been pushed out past the seal on both sides and new grease can be seen flowing If grease is not flowing through use a prybar to lever down the spring ends to open up for the grease to flow To perform this procedure the axle must be free hanging Refer to the proper Servic...

Page 32: ...any off road or on off road operation If there are other severe duty constraints for example driv ing in water lubricate more frequently up to once per day if necessary Note For further information on the T Ride Equalizer Beam Function Group 7 Rear Suspension T Ride Cab Doors Door lock mechanism should be greased once per year using white lithium grease Coat the door stop arm with grease every yea...

Page 33: ...Check Oil Level in Cab Tilt Pump If equipped 15 Check Fluid Level in Clutch Fluid Reservoir 16 Check Coolant Freeze Protection and Coolant Level Check SCA Level 17 Check Fluid Levels in Windshield Wiper and Headlamp Wiper Reservoirs 18 Check Air Dryer Cab Checks 19 Check Warning and Control Lamps 20 Check for Fault Codes in the Vehicle Electronic Control Unit Cab Checks 21 Check for Fault Codes in...

Page 34: ...kage Checks Beneath the Vehicle 52 Check the Oil Cooler and Transmission for Leak age 53 Check Retarder for Leakage 54 Check Drive Shaft Universal Joints Sliding Joints and Support Bearings 55 Check Sealing of Rear Axle and Hub Reduction Gear 56 Check Bearing Clearance in Pinion and Rear Axle Input Shaft 57 Check Exhaust Pipe Silencer or Particulate Filter 58 Check Springs and U Bolts 59 Check Cen...

Page 35: ...Group 170 Preventive Maintenance Comments 33 ...

Page 36: ...about problems that have been noticed while driving the vehicle Ask questions that will make the job easier for the technician to find problem sources Irregular tire wear Unusual noise Unusual vibration Leaks Other operation problems As the vehicle is approached check for signs of leakage general appearance body damage etc Walk around the vehicle Note on the PM inspection form if any leaks or prob...

Page 37: ...are forced out from the part and only new grease comes out If grease cannot be filled so old grease is forced out or if new grease exits without pushing old grease out note this on the form for repair If a fitting does not ac cept lubrication due to damage or internal stoppage replace with a new fitting Do not heat the part for better grease application where rubber or plastic parts are involved R...

Page 38: ...e bottom cover fill with grease until the old grease is forced out past the bottom seal Note Lubrication of the Volvo axle should be done with the wheels on the ground Front Axle Steering Knuckles Meritor and Eaton Raise the axle so the wheels are off the ground before attempting to grease the steering knuckles Two grease fittings on each side one on the top knuckle cover fill with grease until th...

Page 39: ...ther tools For all VHD Axle Back models the steering shaft U joints should be inspected to see that the plastic caps are intact Complete this inspection every 4 months A shorter inspection period interval may be required if the vehicle is operated under severe driving conditions For VHD Axle Forward models grease the steering shaft U joints every 4 months A shorter maintenance interval may be requ...

Page 40: ...the truck up with a jack 2 Place jack stands underneath the frame rails on both sides to relieve the suspension of any weight Lower the jack so that the front axle hangs free 3 Place jack stands underneath the frame rails on both sides to relieve the suspension of any weight Lower the jack so that the front axle hangs free 4 Note Volvo only uses Chevron Grease EP 2 Then thoroughly grease through t...

Page 41: ...de If a U joint cannot be fully greased note it on the form for further inspection CAUTION An ungreased U joint bearing will fail after a short time If vehicle is equipped with a PTO that has a driveshaft lubricate its U joints Volvo T Ride 1 Remove the pressure relief valve located at A and install a grease fitting 2 Remove the grease fitting at B 3 Fill with grease through A fitting until grease...

Page 42: ...roup 170 Preventive Maintenance Fifth Wheel Note For further information refer to Function Group 9 Lubricate the plate pivot points and slide mechanism Apply a heavy coat of grease on top of the plate 40 ...

Page 43: ...n and lubricate scissor latch at the base of the cone receptacle with white lithium grease Steering Gear Note For further information refer to literature in Func tion Group 6 TRW and Sheppard steering gears may have severe weather seals at input shaft or sector shaft that need greasing CAUTION Lubricate with a hand grease gun only High pressure grease application may unseat or damage seal 41 ...

Page 44: ...block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death WARNING Serious burns can result from contact with a hot en gine or engine oil Take precautions when draining the oil Wear gloves and let the engine cool down before draining CAUTION Prolonged contact with the used engine oil may be harmful Use rubber gloves when handling use...

Page 45: ...ed oil entering the lubrication system Note Always dispose of oil according to Federal and lo cal regulations Used oil disposed of inappropriately can contaminate nature waterways community drinking wa ter and kills wildlife Install new filters as follows Coat the filter gasket with oil Install the filter and turn it by hand until the gasket makes contact with the sealing surface Then turn the fil...

Page 46: ... conventional oil and filter change intervals Ensure that the filter cover is se cure after changing the filter Fuller See specifications for conventional oil and filter change intervals Synthetic lubricant No initial oil change is neces sary See specifications for the conventional oil and filter change intervals Meritor See specifications for conventional oil and filter change intervals Synthetic...

Page 47: ...nd clutches do not receive an adequate supply of fluid and the transmission overheats If the level is too high the fluid aerates caus ing the transmission to shift erratically and overheat Fluid may be expelled through the breather or dipstick tube when the fluid level is too high Transmission fluid check 1 Clean all dirt from around the end of the fluid fill tube before removing the dipstick Do n...

Page 48: ...rse R to clear the hydraulic system of air Then shift to Neutral N and allow the engine to idle 500 to 800 rpm 3 With the engine running remove the dipstick from the tube and wipe clean 4 Insert the dipstick into the tube and remove Check the fluid level reading Repeat the check procedure to verify reading 5 If the fluid level is within the COLD RUN band the transmission may be operated until the ...

Page 49: ...e 82 104 C 180 220 F 2 Park the vehicle on a level surface and shift to Neu tral N Apply the parking brake and chock the wheels Allow the engine to idle 500 800 rpm 3 With the engine running remove the dipstick from the tube and wipe clean Insert the dipstick into the tube and remove 4 Check the fluid level reading Repeat the check pro cedure to verify the reading 5 If the fluid level is not withi...

Page 50: ...at exchanger should be installed when using PTO continuously over 15 minutes at a time or with a continuous power output over 55 C W O 75 hp Without heat exchanger the oil can overheat and cause damage to the transmission If the application has a pump that is installed separately or a blower with a driveshaft connection the driveshaft U joints need to be greased at every maintenance inter val or m...

Page 51: ...Intervals for Volvo Components All Models Publication Number 175 001 and any appropriate ven dor literature To ensure the correct oil level in the retarder the oil level should be checked when the retarder is warm 1 Level Fill Plug 2 Drain Plug 8 Check Oil Level in Transfer Case Remove the level filler plug and check that the oil level reaches up to the edge of the filler hole 49 ...

Page 52: ...ng For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components All Models Publication Number 175 001 and any appropriate ven dor literature Check the oil level through the top plug The oil should be level with the hole Add oil if necessary Drain oil through the bottom plug Drain oil immediately after driving t...

Page 53: ...hen draining the oil Wear gloves and let the engine cool down before draining Check the oil level through the top plug The oil should be level with the hole Add oil if necessary Drain oil through the bottom plug Drain oil immediately after driving the vehicle so that the oil is hot Note Also check the rear axle ventilation for blockage Blockage can cause extreme pressure in the axle and create lea...

Page 54: ...nformation concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components All Models Publication Number 175 001 and any appropriate ven dor literature Front Wheel Hubs Failure to keep wheel bearings properly adjusted can result in accelerated tire wear poor handling and in extreme cases wheel separation from the hub or from the spindle ...

Page 55: ...ARNING Do not remove the cap to the coolant surge tank while the engine and radiator are still hot Scalding fluid and steam may be blown out under pressure if the cap is removed too soon CAUTION Ensure that the coolant is not a long life product SCA cannot be added to this type of coolant Draw coolant for testing Adjust coolant as necessary and change the filter if needed Supplement coolant additi...

Page 56: ...rs have internal maintenance systems that clean out the accumulated moisture frequently and can there fore work with long maintenance intervals Eventually the drying medium fills up and needs replacement Change the cartridge when the medium is filling up more than usual This service rate varies upon the application Dryer manufacturers recommended changing cartridge every two to three years but int...

Page 57: ...ontrolled gauges go to half range full range and then back to rest three times Press the down and SET buttons again for testing the di agnostic display The display alternates between light and dark If any defects are noted cite them on the checklist Return the diagnostic display to the clock by pressing the MODE button five times To perform the ABS chuff test turn the ignition off Press down the f...

Page 58: ...tor Control Unit SRS Airbag Control Unit Anti Theft Control Unit Ensure the engine is switched off during the service check and the starter key is in the drive position I The control lever on the right hand side of the wheel is used to communicate and display any fault codes on the instrument s driver information display 1 Read any fault codes by using the control lever and display These fault cod...

Page 59: ...saved in the ECU Note Fault codes can also be traced using a diagnostic program run through a PC Note Refer to pertinent VCADS Pro Tool documentation 22 Check for Fault Codes in the ABS anti lock brakes Note Use Service Information in Function Group 59 as a reference To complete the Fault Code Check for ABS perform the following 1 Check that no fault codes are saved in the ABS ECU 2 Write down any...

Page 60: ...o be traced using a diagnostic program run through a PC Note Refer to pertinent VCADS Pro Tool documentation 24 Function Check of Parking Heater Check the heater and ensure that the exhaust is not blocked or leaking Fumes from the exhaust can cause personal injury or death If the vehicle is equipped with a parking heater start the vehicle and run the parking heater for fifteen minutes to perform a...

Page 61: ...ke Seal perform the following 1 Start engine 2 Charge the Compressed Air System to 7 5 bar 109 psi 3 Shut off engine 4 Release the parking brake 5 Apply the foot pedal for a minimum of five minutes Use a pedal jack whenever appropriate 6 Use a Dual Pressure Gauge to ensure that the pres sure drop doesn t exceed 10 bar 1 57 psi per minute 7 Listen for air leaks 8 Disconnect the Dual Pressure Gauge ...

Page 62: ...ar positions Listen to the sound when passing through neutral and checking the range gear The control lamp should light up when the high split gear is engaged 2 Check on the automatic transmission that the en gine can only be started when the gear selector is in neutral N 3 Check that there is no excessive play in the gearshift 4 Check that the gear stick gaiter fits tightly and is not cracked 60 ...

Page 63: ... 2 Check that all lamps are in good condition 29 Check Mirrors and Reflectors To perform a function check of the mirrors and reflectors complete the following 1 Check that the rear view mirrors are in good work ing condition and remain in position when set 2 Check the attachments for the rear view mirrors and ensure they are functional 3 Check the reflectors for functionality and that none are mis...

Page 64: ...roper placement and tightness 2 Make sure the connections are free from corrosion 3 Inspect cables for proper length chafing and proper routing 4 Check terminals for tightness and cracks 5 Remove any corrosion from cable ends and battery posts 6 After cleaning spray corrosive preventive on posts terminals and general area around them 7 Ensure that the battery ground connections from the engine to ...

Page 65: ...ckets and en sure they are tight and that the tanks haven t rotated 3 Inspect the fuel tank brackets for cracks 4 Check the fuel lines for proper routing wear and leaks Note Ensure that the fuel lines are not routed too close to the exhaust system 33 Check Fuel Tank Ventilation Filter To complete a service check of the fuel tank ventilation filter complete the following 1 Inspect the tanks for dam...

Page 66: ...r further information refer to Function Group 2 Note If the filter is not being changed drain the water separator 1 Check the primary fuel filter 2 Write date and mileage on filter when changed 3 Check the secondary fuel filter 4 Write date and mileage on filter when changed 64 ...

Page 67: ... patterns 2 Measure tread depth 3 Check tire pressure and leak test valve stems 4 Check the Rim Flange wear on Aluminum Wheels every time the tire is replaced Note Be advised the main causes of tire wear are faulty air pressure incorrect toe adjustment and incor rect drive tire alignment or thrust angles which causes pushing or scrubbing of the steer tires Feathered edges of the tires is and early...

Page 68: ...t Rear Tandem Alignment Wheel Alignment Check Total Wheel Alignment For further information re fer to Service Bulletin 601 006 Wheel Alignment Steer and Drive Axles VN VHD Note For Total Vehicle Alignment if A is less than B then a Toe In problem exists 66 ...

Page 69: ...e and compare thrust for both the left and right side of the vehicle Acceptable differences depends upon wheel base 1 Vertical Line 2 Wheel Center Line 3 Camber Angle C D Camber The Camber is set by the axle manufacturer to Volvo specifications and is not adjustable 67 ...

Page 70: ...lts Ensure that the engine cannot be started while work ing around the fan area Failure to do so may result in serious personal injury or death Note This check is also considered Noise Emissions Control Maintenance which is required maintenance for any Volvo vehicle For further information on Noise Emis sions refer to Noise Emissions page 6 To perform a function check of the Drive Belts complete t...

Page 71: ... Inspect fan blades for any damage 2 Ensure there is enough clearance between the fan blade tips and the fan ring in the shroud Note The minimum clearance is 3 mm 0 12 in at any point around the fan ring 3 Loosen the belts and rotate the fan hub assembly Check for roughness and binding in the bearings Check that the end play does not exceed 1 5 mm 1 16 in 4 Check fan clutch for lining wear or air ...

Page 72: ...out Note Air pressure should not exceed 2 bar 30 psi for the radiator and charge air cooler cores Note If there is damage to the cooling fins straighten them out so air can flow freely 3 Check for fluid leaks on or around the engine Note Inspect the mating surfaces auxiliary compo nent attaching areas and hookup hoses and pipes 4 Pump up pressure in the relief valve with the heater controls open t...

Page 73: ...p 2 Note This check is also considered Noise Emissions Control Maintenance which is required maintenance for any Volvo vehicle For further information on Noise Emis sions refer to Noise Emissions page 6 To perform a check of the exhaust system complete the following 1 Check the exhaust flex line for routing 2 Ensure that nothing that is affected by heat is near the exhaust flex line 3 Check for si...

Page 74: ...ission regulation requirements The best method to clean the package is to use air pres sure or water stream Clean from the back of the core Air pressure should not exceed 30 psi 200 kPa for radi ator and charge air cooler cores The use of fin comb is also a good tool to loosen bugs and dirt from the fins Note If the dirt cannot be cleaned off consult your Volvo Truck dealer 44 Check A C Compressor...

Page 75: ...f to soon Note This check is also considered Noise Emissions Control Maintenance which is required maintenance for any Volvo vehicle For further information on Noise Emis sions refer to Noise Emissions page 6 To perform a check of the A C Hoses Fittings Switches and Wires complete the following 1 Pump up to where the relief valve releases heater controls should be open at 75 kPa 11 psi Leave under...

Page 76: ...Pump and Steering Gear Note For further information refer to literature in Func tion Group 6 To perform a check of the Servo Pump and Steering Gear complete the following 1 Check the steering shaft drag link and tie rod In spect for damage or external wear 2 Check joints for play by manually pushing and pulling each ball stud 3 Check the steering gear for leakage around the seal areas and hydrauli...

Page 77: ...er to literature in Func tion Group 6 To perform a check of the Steering Shaft Joint Hoses and Pipes for Power Steering perform the following 1 Check the Steering Shaft Joint for leaks cracks and other damage 2 Check the hoses for the Power Steering for leaks 3 Check the pipes for the Power Steering for cracks and other damage 75 ...

Page 78: ...mplete the following Check hub for leakage around front and rear drive axle shaft flange 1 Slave Cylinder 2 Mounting Bolts 3 Clutch Clevis Pin 4 Clutch Master Cylinder and Reservoir 50 Check Slack in Mechanical Linkage for Clutch Note For further information refer to literature in Func tion Group 4 To perform a check of the slack in the mechanical link age for the Clutch complete the following Che...

Page 79: ...y leaks 52 Check the Oil Cooler and Transmission Mounting and Sealing Note For further information refer to literature in Func tion Group 2 To perform a check of the Oil Cooler and Transmission complete the following 1 Check the top of the transmission Inspect the top covers for leakage shift lever for leakage and wear Inspect lower shift boot condition 2 On the Oil Cooler check the coolant lines ...

Page 80: ...Group 170 Preventive Maintenance 53 Check Retarder Sealing To perform a check of the Retarder Sealing complete the following Check the Retarder Sealing for any cracks or leaks 78 ...

Page 81: ...3 Check driveshaft U joints and slip joint for play There should exist no noticeable play in the U joint bearings The slip joint radial play maximum is 0 18 mm 0 007 in 4 The driveshaft tube should be straight and have no damage or missing weights Remove any build up of foreign material such as undercoating concrete etc 5 Check the torque of driveshaft bolts 170 Nm 125 10 ft lb 6 Check center bear...

Page 82: ... for leaks past the gasket 2 Check brake chamber and air tubing condition 3 Check Hub Reduction Gear for any leaks or cracked sealant 56 Check Bearing Clearance in Pinion and Rear Axle Input Shaft Note For further information refer to literature in Func tion Group 7 To perform a check of the Bearing Clearance in the Pin ion and Rear Axle complete the following 1 Use a dial indicator to check beari...

Page 83: ...on the cylinder heads at the intake and exhaust manifolds and at the flanges exhaust pipe s Silencer or Particulate Filter Check if there is exhaust leakage at the jointing clamp for the front exhaust pipe 58 Check Springs and U Bolts To perform a check of the Springs and U bolts complete the following 1 Check the springs for damaged or broken leaves 2 Check the spring bushing location in the spri...

Page 84: ...efer to literature in Func tion Group 7 To perform a check of the Air Suspension and Air Springs complete the following 1 Check suspension torque rods and the top shock absorber mounts for wear and looseness 2 Inspect all spring hanger torsion leaves and sus pension fasteners to the axle 3 Inspect all air springs for wear and cracks 4 Check ride height of air suspension 82 ...

Page 85: ...ck wheel bearings with a dial indicator Bearing axial clearance should be within 0 04 to 0 12 mm 0 001 to 0 005 in 62 Check Front Wheel Bearing Clearance Note For further information refer to literature in Func tion Group 7 To perform a check of the front wheel bearing clearance complete the following Check wheel bearings with a dial indicator Bearing axial clearance should be within 0 04 to 0 12 ...

Page 86: ...the inspection holes in the backing plates See each manufac turer s specifications for minimum lining thickness 64 Check Brake Cylinders Levers and Forks Note For further information refer to literature in Func tion Group 5 To perform a check of the Brake Cylinders Levers and Forks complete the following 1 Remove the wheel and brake drums 2 Inspect the brake cylinders levers and forks for signs of...

Page 87: ...te For further information refer to literature in Func tion Group 5 To perform a check of the brake lever slack adjuster and brake drums travel complete the following 1 Remove the wheel and brake drums 2 Inspect brake lever for signs of wear or damage 3 Check the slack adjuster throw and operation Note Maximum throw allowed is 5 1 2 in slack ad juster 25 30 mm 1 1 1 4 in 6 in slack adjuster 20 25 ...

Page 88: ...m 1 2 to 1 in from the floor while engaging a gear There should be no grating of the engagement teeth when the clutch brake is engaged Check Parking Brake and Clutch Slip Note For further information refer to literature in Func tion Groups 4 and 5 Check for parking brake holding power and also for clutch slippage by engaging direct gear not allowing the engine speed to go above 1000 rpm and attemp...

Page 89: ... Group 8 Failure to properly inspect and maintain the safety belts can cause serious personal injury or death A damaged safety belt whether visibly damaged or not could result in serious personal injury in the event of an accident The safety belt system should be re placed every five years 1 Check the belts buckles latch plates retractors an chorages and guide loops to ensure that they are working...

Page 90: ...en testing or perform the test in a off road area where there is no traffic Per forming a brake test in traffic may lead to an accident and cause personal injury or death During the first part of driving check the wheel brakes Check for even application and release Make sure the vehicle does not pull to the side when the brakes are ap plied and that the noise is not generated while braking Whether...

Page 91: ...y lead to an accident and cause personal injury or death Check the ABS system by attempting to lock up the wheels during hard braking The vehicle should come to a controlled stop Brake from a speed of 50 to 55 km h 30 to 35 mph Make a full brake application Note The rear wheels may lock intermittently while driv ing unloaded under 30 km h 20 mph even when equipped with ABS brakes This is normal in...

Page 92: ...ine Brakes Note For further information refer to literature in Func tion Group 3 When operating a tractor bobtail without a trailer or on slippery roads the engine brake switch must be in the OFF position Failure to follow these instructions can result in loss of vehicle control and serious personal injury or death If the engine is equipped with an exhaust brake only on Volvo or an engine brake ch...

Page 93: ...uld engage and disengage smoothly Make sure the engine does not surge when in cruise control mode Check the resume accelerate and coast functions Verify that the cruise control is disengaged by the off switch clutch operation and brake application Check Steering System Note For further information refer to literature in Func tion Group 6 On the highway the steering should operate precisely and wit...

Page 94: ...her information refer to literature in Func tion Group 8 Check function of heater and air conditioning Operate the controls and let the fan run on all speeds Note In the summertime the shut off valves for the heater may be closed for the season Open valves be fore testing heater 92 ...

Page 95: ...ge ment by listening to the lock mechanism operating and that the telltale indicator lights up on the instrument clus ter If equipped with air suspension levelling switch operate the switch Verify function by watching the chassis being lowered Verify that the telltale indicator lights up on the instrument cluster Make sure the lock function of each switch works so that the switch can not be engage...

Page 96: ...ing switches should close at a minimum pressure of 420 kPa 60 psi Check Manifold Dash Valve Note For further information refer to literature in Func tion Group 8 Start the manifold dash valve check by pulling out the yellow knob Parking At the same time the red knob Trailer air supply should also pop out Press both knobs in Note The gauges should only be used for general refer ence Gauge accuracy ...

Page 97: ...he air release from the air dryer through the door or window Check Wipers and Washer Note For further information refer to literature in Func tion Group 9 Check the windshield wipers and washer from inside the cab Wipers should operate smoothly and without any binding in the sweep Listen for any unusual noise The blades should clear the swept area without leaving streaks or missing any spots Check...

Page 98: ...during the inspection Check all fluid levels Make sure there are no signs of leakage after changing oils or filters Clean Clean all areas that have been dirtied during the test drive As a courtesy to the customer be especially care ful about making sure the cab area is as clean or cleaner than when the vehicle came into the shop Attach a new maintenance sticker 96 ...

Page 99: ...ects moisture from the air and will eventually hold enough moisture to affect the metal surfaces in the system unless removed Drain fluid by removing the lid for the fluid container and then drain through the bleed fitting on the clutch slave cylinder into a container Use bleeder tool 999 6928 to refill the hydraulic system with new fluid Use fluid to specification DOT 4 Fan Hubs Check clutch lini...

Page 100: ...ake Slave Piston Lash If the engine is equipped with an engine compression brake adjust the slave piston lash after the engine valves are adjusted Make the adjustment with the en gine stopped Refer to the Caterpillar Service manual for adjustment information Every Four Years Caterpillar Long Life Coolant Change At every fourth year or 6000 hours of operation change coolant if Long life coolant is ...

Page 101: ... Lash Injector Preload Do an initial check on engine valve clearance and injec tor preload between 19 000 and 96 000 km 12 000 and 60 000 miles Ad just if necessary Every 120 000 km 75 000 miles Volvo Transmission Regular oil change intervals for Volvo transmissions are at every 120 000 km 75000 miles See specification section for oil types and viscosities Volvo Rear Axle Regular oil change interv...

Page 102: ...ecific information refer to Cummins Service Manual Every 240 000 km 150 000 miles Steering System Fluid Change Change steering system hydraulic fluid every 240 000 km 150 000 miles Use Dexron II or Dexron IIl If the fluid is very dark in color there may have been heat problems in the system Note on the inspection form for follow up Every 385 000 km 240 000 miles Cab Fresh Air Filter Change Change ...

Page 103: ...ur opinions and experience when using this manual would be greatly appreciated If you have any comments or suggestions make a copy of this page write down your comments and send them to us either via telefax or mailing directly to the address listed below To Volvo Trucks North America Inc Dept 516 Service Publications 7900 National Service Road P O Box 26115 Greensboro NC 27402 6115 USA Fax 336 39...

Page 104: ...th 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 TSP151476 700 12 2001 Volvo Trucks North America Inc 2001 ...

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