OPERATOR'S MANUAL VEHICLE MAINTENANCE VN,VHD Volvo d11f and d13f engines Volvo Trucks. Driving Success.
USA22978.bk.book Page i Wednesday, July 9, 2008 9:09 AM Table of Contents i Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Warning Label Information . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Information for the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exhaust and Noise Emissions . . . . . . . . . . . . . . . . . . . . . . . .
USA22978.bk.book Page ii Wednesday, July 9, 2008 9:09 AM ii Table of Contents Service Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Service Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Scheduled Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Repair Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USA22978.bk.book Page 1 Wednesday, July 9, 2008 9:09 AM Foreword 1 FOREWORD DO NOT Remove this manual from the vehicle. It contains important operational and safety information that is needed by all drivers and owners of this vehicle. This manual contains information concerning the safe operation of your vehicle. It is extremely important that this information is read and understood before the vehicle is operated.
USA22978.bk.book Page 2 Wednesday, July 9, 2008 9:09 AM 2 Foreword WARNING LABEL INFORMATION IMPORTANT: Before driving this vehicle, be certain that you have read and that you fully understand each and every step of the driving and handling information in this Operator's Manual. Be certain that you fully understand and follow all safety warnings. It is extremely important that this information is read and understood before the vehicle is operated.
USA22978.bk.book Page 3 Wednesday, July 9, 2008 9:09 AM General Information 3 INFORMATION FOR THE OWNER GENERAL INFORMATION If there are questions on the maintenance and performance of your vehicle, please discuss them with your Volvo Truck dealer. Your authorized dealer is required to have trained mechanics, special tools and spare parts to fully service your vehicle. If necessary, your dealer will contact Volvo Trucks North America or other manufacturers for any assistance.
USA22978.bk.book Page 4 Wednesday, July 9, 2008 9:09 AM 4 General Information This Maintenance Manual covers all Volvo vehicles manufactured by Volvo Trucks North America, including the whole chassis and all Volvo manufactured components. For specific maintenance information on vendor components, manufactured by, for example: Cummins, Fuller, Meritor, etc., see the respective manufacturer's service and maintenance literature.
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USA22978.bk.book Page 6 Wednesday, July 9, 2008 9:09 AM 6 General Information CALIFORNIA EMISSION CONTROL SYSTEMS WARRANTY Warranty coverage is subject to change without notice. Contact your Volvo Truck dealer for the current warranty statement. The California Air Resources Board and Volvo Trucks North America are pleased to explain the California emission control system warranty on your new motor vehicle engine.
USA22978.bk.book Page 7 Wednesday, July 9, 2008 9:09 AM General Information 7 If you have any questions regarding your warranty rights and responsibilities, you should contact the Volvo Trucks North America Warranty Department at P. O. Box 26115, Greensboro, NC 27402-6115, or the California Air Resources Board at 9480 Telstar Avenue, El Monte, California 91731.
USA22978.bk.book Page 8 Wednesday, July 9, 2008 9:09 AM 8 General Information PROCEDURES FOR HANDLING EMISSIONS CONTROL SYSTEM WARRANTY The following engine components are covered by the supplemental emissions control system warranty policy as required by the California Code of Regulations. a. Turbocharger Assembly b. VGT Actuator Control Valve c. Charge Air Cooler d. Unit Injectors e. Engine Wiring Harness f. Electronic Control Module g. EGR Mixer h. EGR Cooler i. EGR Control Valve j.
USA22978.bk.book Page 9 Wednesday, July 9, 2008 9:09 AM General Information 9 The emission warranty for the diesel particulate filter covers defects in workmanship only. Normal maintenance, such as cleaning ash from the filter at regular maintenance intervals, is not covered by the emission warranty. In response to customer requests, Volvo Trucks North America may build vehicles with engines supplied by other manufacturers, including, but not limited to, Cummins.
USA22978.bk.book Page 10 Wednesday, July 9, 2008 9:09 AM 10 General Information In the event that damage results from unauthorized adjustments to any emission control system components, as evidenced by settings other than as specified, or broken fastener seals, the cost of repairing such damage WILL NOT BE COVERED under warranty. 3.
USA22978.bk.book Page 11 Wednesday, July 9, 2008 9:09 AM General Information 7. 11 Customer Assistance Volvo Trucks North America wishes to assure that the California Emission Control Systems Warranty is properly administered. In the event that owners do not receive the warranty service to which they believe they are entitled under the California Emission Control Systems Warranty, they should contact Volvo Trucks North America Warranty Administration, (336) 393-2000.
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USA22978.bk.book Page 13 Wednesday, July 9, 2008 9:09 AM General Information 13 GASEOUS EMISSION CONTROL SYSTEMS WARRANTY For emission control systems information on engines other than VOLVO, refer to the engine vendor’s publications.
USA22978.bk.book Page 14 Wednesday, July 9, 2008 9:09 AM 14 General Information ENGINE GASEOUS EMISSIONS CONTROL SYSTEM WARRANTY FEDERAL EMISSION REQUIREMENTS The following engine components are covered by the supplemental emissions control system warranty policy as required by the Federal emissions regulations. a. Turbocharger Assembly b. VGT Actuator Control Valve c. Charge Air Cooler d. Unit Injectors e. Engine Wiring Harness f. Electronic Control Module g. EGR Mixer h. EGR Cooler i.
USA22978.bk.book Page 15 Wednesday, July 9, 2008 9:09 AM General Information 15 The emission warranty for the diesel particulate filter covers defects in workmanship only. Normal maintenance, such as cleaning ash from the filter at regular maintenance intervals, is not covered by the emission warranty. In response to customer requests, Volvo Trucks North America may build vehicles with engines supplied by other manufacturers, including, but not limited to, Cummins.
USA22978.bk.book Page 16 Wednesday, July 9, 2008 9:09 AM 16 General Information ENGINES OTHER THAN VOLVO For specific information on engines other than VOLVO, refer to the engine vendor’s publications.
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USA22978.bk.book Page 18 Wednesday, July 9, 2008 9:09 AM 18 General Information Regulatory Compliance Acts that constitute tampering with the Noise Shielding and Insulation Devices: Removing or rendering inoperative the engine and/or transmission noise deadening panels, shields or insulating materials. Removing or rendering inoperative the cab-tunnel or hood noise insulating materials.
USA22978.bk.book Page 19 Wednesday, July 9, 2008 9:09 AM General Information 19 Exhaust System Hot engine! Avoid all movable parts or hot engine parts, exhaust gases, and/or fluids. A hot engine, exhaust, and/or fluids can cause burns. Maintenance Make sure the exhaust system is intact. Inspect for damage, misalignment and/ or leakage. Primary system components requiring noise related inspection include exhaust manifold, turbocharger, and all exhaust system (rigid and flexible) piping.
USA22978.bk.book Page 20 Wednesday, July 9, 2008 9:09 AM 20 General Information Engine Control, EGR and Fuel Systems Acts that constitute tampering with Engine Control, EGR and Fuel Systems: Removing rendering inoperative, or modifying the engine control system such as the ECU, EGR system components, or fuel system components, in order to allow the engine to operate outside of the manufacturer's specifications is not allowed and violates both warranty and legislation.
USA22978.bk.book Page 21 Wednesday, July 9, 2008 9:09 AM General Information 21 LABEL INFORMATION VT Shown, VN and VHD Similar 1. Transmission Type and Gear Pattern This information is located in the visor. 2. VIN/GAWR Located in the door frame “B” pillar. 3. VIN/Major Components Located in the door frame “B” pillar. 4. Vehicle Noise Emission Located in the door frame “B” pillar.
USA22978.bk.book Page 22 Wednesday, July 9, 2008 9:09 AM 22 General Information FUSE AND RELAY LOCATION Always replace fuses and circuit breakers with the same current/ amperage. Increasing fuse or circuit breaker rating may result in electrical circuit overheating and possible fire. On sleeper models equipped with fluorescent lighting, there is a 3 AMP maximum fuse located in the lighting fixture.
USA22978.bk.book Page 23 Wednesday, July 9, 2008 9:09 AM General Information 23 The fuse relay panel is located under the top cover of the dash board. The vehicle has an electrical center located in the middle of the dash under the top cover. Since the function of some fuses or relays may change for the vehicle application, refer to the list of functions that is attached beneath each panel.
USA22978.bk.book Page 24 Wednesday, July 9, 2008 9:09 AM 24 Safety Information PROPER MAINTENANCE PROCEDURE SAFETY INFORMATION Before working on a vehicle, set the parking brakes, place the transmission in neutral, and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. Exhaust gases contain carbon monoxide. Always run the engine outdoors or use a properly vented exhaust hose.
USA22978.bk.book Page 25 Wednesday, July 9, 2008 9:09 AM Safety Information 25 During Maintenance Remove key from ignition while working on vehicle or engine. DO NOT allow unauthorized personnel on, around or in the vehicle when maintenance or repair is being performed. 앫 When operating the engine in an enclosed area, vent the exhaust to the outside. 앫 Before servicing your vehicle, apply the parking brakes and adequately chock the wheels in order to prevent unintended vehicle movement.
USA22978.bk.book Page 26 Wednesday, July 9, 2008 9:09 AM 26 Safety Information Compressed Air and Water Compressed air can cause serious personal injury. When using compressed air for cleaning, wear a protective face shield, protective clothing and protective shoes. Pressurized water could cause particles and/or hot water to be sprayed in your direction and cause personal injury. The maximum air pressure must be below 200 kPa (30 psi) for cleaning purposes.
USA22978.bk.book Page 27 Wednesday, July 9, 2008 9:09 AM Safety Information 27 DO NOT raise the engine hood if you see or hear steam or coolant escaping from the engine compartment. Wait until steam or coolant cannot be seen or heard any longer before raising the hood. DO NOT remove the coolant fill cap if the coolant in the surge tank is boiling. Also, do not remove the cap while the engine and radiator are still hot.
USA22978.bk.book Page 28 Wednesday, July 9, 2008 9:09 AM 28 Safety Information To prevent personal injury, do not climb up on the engine to remove the filler cap. Use a suitable, properly positioned ladder to reach the cap. At normal operating temperature, the engine coolant is very hot and under pressure. If pressure is relieved rapidly in a hot cooling system, the hot coolant can turn into steam. Any contact with hot coolant or steam can cause severe burns.
USA22978.bk.book Page 29 Wednesday, July 9, 2008 9:09 AM Safety Information 29 Speed Restrictive Tires Operating a vehicle equipped with speed restrictive tires in excess of their stated rating may result in tread separation and/or blowout resulting in the loss of steering control and possible collision. Serious personal injury or death could occur. Always maintain proper air pressure and never exceed the tire ratings.
USA22978.bk.book Page 30 Wednesday, July 9, 2008 9:09 AM 30 Safety Information DO NOT service any part of the fuel system while smoking or in the presence of flames, sparks or hot surfaces. Failure to follow these precautions can result in fire, which can cause serious injury or death. DO NOT store fuel containers in the vehicle. They may leak, explode and cause or feed a fire. Empty or full, they present a hazard that may lead to burns in the event of a fire.
USA22978.bk.book Page 31 Wednesday, July 9, 2008 9:09 AM Safety Information 31 DO NOT expose the engine to flames, driving over burning ground. DO NOT weld or flame cut on or around pipes or tubes that contain flammable fluids. Exhaust heat shields may be installed to protect oil or fuel carrying lines and pipes from hot exhaust parts. To protect from pipe or seal failure, install heat shields correctly. Provide adequate and proper waste oil disposal.
USA22978.bk.book Page 32 Wednesday, July 9, 2008 9:09 AM 32 Safety Information Fire Extinguisher Anytime work is being done to the fuel system or any other area where flammable substances are being used, have a fire extinguisher available and know how to use it. Inspect and have it serviced as recommended on its instruction label. Respiratory Hazard Prevention Exhaust gases contain carbon monoxide. Always run the engine outdoors or use a properly vented exhaust hose.
USA22978.bk.book Page 33 Wednesday, July 9, 2008 9:09 AM Safety Information 33 Crushing or Cutting Prevention Before working on a vehicle, set the parking brakes, place the transmission in neutral and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. DO NOT work near the fan with the engine running or the ignition in the ON position. The engine fan can engage at any time without warning.
USA22978.bk.book Page 34 Wednesday, July 9, 2008 9:09 AM 34 Safety Information Climbing Up and Down Always have three limbs (one foot and two hands or two feet and one hand) in contact with the vehicle at all times when entering or exiting the cab or the area behind the cab. Failure to follow this warning can result in serious personal injury or death. DO NOT climb up on or jump off from the engine or stand on components that cannot support your weight.
USA22978.bk.book Page 35 Wednesday, July 9, 2008 9:09 AM Safety Information 35 Engine Starting DO NOT start the engine or move any of the controls or disengage the parking brake if the warning tag “DO NOT OPERATE” is attached to the ignition key or located on the dash. Check with the person who attached the tag before starting. Make sure no one is working on or close to the engine or components driven by the engine before starting it. Always make an inspection of the engine before and after starting.
USA22978.bk.book Page 36 Wednesday, July 9, 2008 9:09 AM 36 Safety Information ELECTRIC SYSTEM DAMAGE PREVENTION Electric and Electronic Systems Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the flammable vapor mixture of hydrogen and oxygen to explode.
USA22978.bk.book Page 37 Wednesday, July 9, 2008 9:09 AM Safety Information 37 Electronic Engine Control System The engine uses high voltage to the electronic unit injectors. DO NOT come in contact with the unit injector terminals while the engine is running. An electric shock can cause an involuntary muscle spasm and cause loss of balance and falls leading to severe personal injury or death.
USA22978.bk.book Page 38 Wednesday, July 9, 2008 9:09 AM 38 Safety Information REPORTING SAFETY DEFECTS USA The National Highway Traffic Safety Administration (NHTSA) and Volvo Trucks North America should be informed immediately if you believe that the vehicle has a defect that could cause a vehicle accident, injury or death. Contact NHTSA by calling the Auto Safety Hotline at 1 (888) 327-4236, by writing to NHTSA, U.S.
USA22978.bk.book Page 39 Wednesday, July 9, 2008 9:09 AM General Engine Information 39 ENGINE OVERVIEW, D11F AND D13F LEFT SIDE VIEW GENERAL ENGINE INFORMATION D13F Engine Shown, D11F Engine Similar 1. 2. 3. 4. 5. 6. Breather Tube Intake Manifold Air Compressor Power Steering Pump Fuel Pump Engine Electronic Control Unit (EECU) 7. Fuel Filter 8. Fuel/Water Separator 9. 10. 11. 12. 13. 14. 15. 16.
USA22978.bk.book Page 40 Wednesday, July 9, 2008 9:09 AM 40 General Engine Information ENGINE OVERVIEW, D11F AND D13F RIGHT SIDE VIEW D13F Engine Shown, D11F Engine Similar 17. Exhaust Manifold 18. Valve Cover 19. Engine Pre-Heater Element (Optional) 20. Thermostat Housing 21. Belt Tensioner 22. Coolant Pump 23. Coolant Filter ENGINE STORAGE 24. 25. 26. 27. 28. 29. 30.
USA22978.bk.book Page 41 Wednesday, July 9, 2008 9:09 AM Engine Storage 41 ENGINE STORAGE If the vehicle must be parked for a period (more than 30 days), protect it as follows: 1. Drain the engine oil. 2. Fill up to the proper level with oil of the recommended quality and viscosity. 3. Fill up the fuel tanks with the recommended grade of fuel. 4. Run the engine for two minutes around 1000 rpm. Shut the engine down. DO NOT drain the oil after this run. 5.
USA22978.bk.book Page 42 Wednesday, July 9, 2008 9:09 AM 42 Maintenance and Service MAINTENANCE HAZARDS Before working on or inspecting a vehicle, set the parking brakes, place the transmission in neutral and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. DO NOT attempt to repair or service this vehicle without having sufficient training, correct service literature and the proper tools.
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USA22978.bk.book Page 44 Wednesday, July 9, 2008 9:09 AM 44 Maintenance and Service COOLING SYSTEM General Coolant Information Coolant is toxic; risk of poisoning. DO NOT drink coolant. Use proper hand protection when handling. Keep coolant out of reach of children and animals. Failure to follow these precautions can cause serious illness or death. DO NOT raise the engine hood if you see or hear steam or coolant escaping from the engine compartment.
USA22978.bk.book Page 45 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 45 In addition to this, the coolant must: 앫 Protect against pitting and cavitation erosion damage of the water pump and cylinder liners. 앫 Protect against freezing and boiling. 앫 Prevent formation of scale, sludge deposits and clogging. 앫 Be harmless to polymer materials and seals in the cooling system. 앫 Maintain its liquid properties in cold climates.
USA22978.bk.book Page 46 Wednesday, July 9, 2008 9:09 AM 46 Maintenance and Service DO NOT use antifreeze formulated for automobile gasoline engines. These have a very high silicate content that will clog the radiator and leave unwanted deposits in the engine.
USA22978.bk.book Page 47 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 47 Never add coolant to a hot or overheated engine. Engine damage can result. Allow the engine to cool first. Additives Additives help prevent rust, scale and mineral deposits from forming. Additives also protect metals from corrosion, prevent water pump and cylinder liner cavitation and contain anti-foaming agents. Additives are depleted during normal engine operation and need to be replaced.
USA22978.bk.book Page 48 Wednesday, July 9, 2008 9:09 AM 48 Maintenance and Service Extended Life Coolant Change Interval Extended life coolant will test as out of additives (SCA), but SCA should not be added. Shortened engine life may be the result of adding SCA. Replace coolant every 960 000 km (600,000 miles), 12,000 hours or every four years, whichever comes first.
USA22978.bk.book Page 49 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 49 FUEL SYSTEM Fuel Safety Reminders A diesel engine will operate on any fuel which enters the cylinder, whether it is from the injectors or from the air intake system. Therefore, if any solvent is used to flush out the air cleaner element, the engine may over speed during start-up. Engine damage, severe personal injury or death from burns or explosion may occur. DO NOT mix gasoline or alcohol with diesel oil fuel.
USA22978.bk.book Page 50 Wednesday, July 9, 2008 9:09 AM 50 Maintenance and Service Diesel Fuel Specification Quality Diesel engines for 2007 and later model year vehicles are designed to operate only with Ultra Low Sulfur Diesel (ULSD) fuel. Use of fuel other than ULSD will reduce the efficiency and durability of the engine, permanently damage the advanced emission control systems, reduce fuel economy and possibly prevent the engine from running at all.
USA22978.bk.book Page 51 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 51 Fuel Sulfur Content Fuel sold for use in diesel-powered engines for 2007 and later model year vehicles may only contain a maximum sulfur content of 0.0015% by weight. This was done to reduce particle emissions in the exhaust. The use of ultra-low sulfur diesel fuel does not permit extension of engine oil change intervals or oil filter changes.
USA22978.bk.book Page 52 Wednesday, July 9, 2008 9:09 AM 52 Maintenance and Service Supplemental Fuel Enhancers Supplemental additives are not recommended because of a high risk of injection system problems or engine damage. There are many aftermarket products available today which are intended to be added by the customer. They generally increase operating cost without providing benefits.
USA22978.bk.book Page 53 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 53 Prohibited Additives The addition of gasoline to diesel fuel will create a serious fire hazard. Serious personal injury can result. The following additives are specifically NOT allowed and must NOT be mixed in with the vehicle diesel fuel: 앫 Gasoline — Adding gasoline to diesel fuel will reduce the cetane number and increase combustion temperature.
USA22978.bk.book Page 54 Wednesday, July 9, 2008 9:09 AM 54 Maintenance and Service Fuel Storage If fuel is stored on site: 앫 Keep storage tank covered to prevent water entry. 앫 DO NOT use a tank made of galvanized metal or any galvanized piping for diesel oil storage. Diesel will react with the zinc, forming solids that can clog fuel filters and cause engine damage. 앫 Fuel stored for a long time may oxidize and form solids, causing filtering problems. 앫 Keep the area around the fill cap clean.
USA22978.bk.book Page 55 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 55 Fuel Filters A primary fuel filter can be located on the engine or remote mounted on the frame rail. This filter consists of a filter cartridge, a water separation bowl and may have a fuel heater built in. The secondary fuel filter is located on the left hand side, below the engine electronic control unit (EECU). The filter is a spin-on filter. D11F and D13F Engine-Mounted Fuel Filters (D13F shown, D11F similar) 1.
USA22978.bk.book Page 56 Wednesday, July 9, 2008 9:09 AM 56 Maintenance and Service Chassis Mounted Primary Fuel Filter (Optional) For priming the fuel system, see “Priming the Fuel System” on page 71. Replacing Fuel Filters When draining the fuel filters, collect the waste in a fuel-safe container. Always dispose of fuel according to Federal or local regulations. Take the drained fuel and water to a recycle or waste management center. The filters are an important part of the fuel system.
USA22978.bk.book Page 57 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 57 Maintenance When draining the fuel tank, collect the waste in a fuel safe container. Take the drained fuel and water to a recycle or waste management center. Open the drain at the bottom of the fuel tank approximately every 50 000 km (30,000 miles) or 300 hours, to drain off any water and/or sediment. Yearly or at 200 000 km (120,000 miles), tighten all fuel tank mountings and brackets.
USA22978.bk.book Page 58 Wednesday, July 9, 2008 9:09 AM 58 Maintenance and Service DO NOT add extra oil additives. Additives such as break-in oils, top oils, graphitizers, and friction-reducing liquids are not necessary and can harm the engine. Oil Change Intervals The length of time an engine can operate before an oil change depends on the quality oil used, the type of fuel used, fuel consumption, engine oil consumption, vehicle application, level of dust in the air, and fuel consumption.
USA22978.bk.book Page 59 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 59 D11F and D13F Oil Filters (D13F shown, D11F similar) Synthetic Lubrication Synthetic oils are offered by some oil suppliers as an alternative to the traditional, petroleum based oils for engines. These oils may be used in Volvo engines, provided they meet the quality levels specified on the previous pages, that is: both VDS-4 and EO-O Premium Plus.
USA22978.bk.book Page 60 Wednesday, July 9, 2008 9:09 AM 60 Maintenance and Service Volvo Trucks North America recommends the viscosities shown in the viscosity/temperature table for Volvo engines. Oil Additives Extra oil additives must never be added to any engine oil used. Additives such as break-in oils, top oils, graphitizers, and friction reducing liquids are not necessary and may even harm the engine.
USA22978.bk.book Page 61 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 61 All diesel engines are designed to consume some oil, so it is normal to add oil periodically. An engine used in heavy-duty operation will consume more oil than one in normal operation. To assist you in measuring your oil usage please refer to the Fuel and Oil Record on “Fuel and Oil Record” on page 120. Oil Change A hot engine or engine oil can be dangerous.
USA22978.bk.book Page 62 Wednesday, July 9, 2008 9:09 AM 62 Maintenance and Service It is important to drain as much oil as possible. Try to change oil immediately after driving, when the oil is warm. Always replace the oil filters when changing oil. Oil Filters Change Hot oil can cause severe burns. DO NOT allow hot oil to contact the skin. When changing oil, wear protective gloves. Volvo-branded oil filters are designed to provide the proper level of filtration and protection for Volvo engines.
USA22978.bk.book Page 63 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 63 ENGINE AIR FILTER Continued operation with the gauge showing in the red may cause damage to the engine. Operating the engine with a damaged filter allows dust to pass directly into the engine, causing damage. Replace damaged or clogged filters. The engine air filter is monitored by a pressure restriction gauge mounted on the air filter housing.
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USA22978.bk.book Page 65 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 65 DIESEL PARTICULATE FILTERS (IF EQUIPPED) This vehicle is equipped with a 2007 emission compliant engine and may be equipped with an exhaust aftertreatment system which includes a Diesel Particulate Filter (DPF). The DPF reduces soot and particulate emissions into the atmosphere.
USA22978.bk.book Page 66 Wednesday, July 9, 2008 9:09 AM 66 Maintenance and Service FAN AND AUXILIARY DRIVE BELTS Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine can cause serious burns. All engine belts should be checked at each service point. Inspect for cracked or frayed material. All belts have automatic belt tensioners to keep the correct tension without adjustment.
USA22978.bk.book Page 67 Wednesday, July 9, 2008 9:09 AM Maintenance and Service A drive belt routing label is located on the vehicle frame rail.
USA22978.bk.book Page 68 Wednesday, July 9, 2008 9:09 AM 68 Maintenance and Service TURBOCHARGER AND CHARGE AIR COOLER If oil leaks internally from the turbocharger to the engine intake, the oil acts as a fuel. Watch for excessive exhaust smoke. DO NOT operate engine until problem is corrected. There is no way to regulate the engine speed if it runs on oil and it may over speed. Loss of control of vehicle may lead to an accident causing severe personal injury or death.
USA22978.bk.book Page 69 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 69 When using a pressure washer to clean the vehicle, do not direct the spray at electrical components in the engine compartment such as the alternator, starter and compressors. Water spray from pressure washers can damage electrical components. The simplest method to clean the package is to use air pressure or a water stream. This should be done from the back of the core.
USA22978.bk.book Page 70 Wednesday, July 9, 2008 9:09 AM 70 Maintenance and Service FUEL SYSTEM SERVICE Changing the Primary Fuel Filter To avoid potential fire hazard, DO NOT service any part of the fuel system while smoking or in the presence of flames, sparks, or hot surfaces, or when working on an operating engine. Failure to follow these precautions can result in fire.
USA22978.bk.book Page 71 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 71 Priming the Fuel System The fuel system will need to be bled if: 앫 The vehicle has run out of fuel. 앫 The engine has not been running for an extended period of time. 앫 Service work has been done on the fuel system, (tank, fuel lines, filters, valves, etc.) for example cleaning or replacing fuel filter elements. 앫 The engine is new or rebuilt.
USA22978.bk.book Page 72 Wednesday, July 9, 2008 9:09 AM 72 Maintenance and Service D11F and D13F Primer Pump (D11F shown, D13F similar) 1. Unlock the hand pump by turning the handle counterclockwise. 2. Prime the system by moving the primer pump in an up and down pumping motion. Avoid putting any side load on the pump or causing a binding condition. 3. Lock the hand primer pump by retracting it into the housing and turning it clockwise. 4.
USA22978.bk.book Page 73 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 73 Water In Fuel You can only drain the water in the fuel when there is a high water level in the fuel filter housing, the engine is not running, the vehicle is stationary and the parking brake is applied. When the water in fuel indicator activates, the cluster displays the water in fuel icon and the message “Water in Fuel, Drain at next stop.
USA22978.bk.book Page 74 Wednesday, July 9, 2008 9:09 AM 74 Maintenance and Service If the temperature reaches 140° C (285° F), stop the vehicle to let the temperature go down. See the vehicle Operator's Manual for information on the optional transmission temperature gauge. If the transmission oil temperatures are consistently high, change oil more often or install an oil cooler.
USA22978.bk.book Page 75 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 75 Driveshaft If the driveshaft universal joints are not lubricated properly, they can be damaged to the point of the driveshaft separating from the vehicle. Driveshaft separation may cause loss of control of the vehicle resulting in severe personal injury or death. Periodic inspection, lubrication, and maintenance of the driveshaft may be required. Contact your local authorized Volvo Truck dealer.
USA22978.bk.book Page 76 Wednesday, July 9, 2008 9:09 AM 76 Maintenance and Service STEERING AND BRAKES MAINTENANCE Steering System Excessive play in the steering system is checked by turning the steering wheel while the engine is stopped. With the front wheels pointing straight ahead, turn the steering wheel until the front wheel starts moving. Then, turn the steering wheel the other way until the front wheel moves. Play should not be more than 25 mm (1 inch) at the rim of the steering wheel.
USA22978.bk.book Page 77 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 77 Power Steering Fluid Reservoir The power steering fluid reservoir is filled with Automatic Transmission Fluid (ATF) Dexron® III for the power steering system. Change fluid every 240 000 km (150,000 miles). Change filter every year or more often if necessary. If the fluid has darkened, it indicates that the power steering system is running hotter than normal and the fluid is overheating.
USA22978.bk.book Page 78 Wednesday, July 9, 2008 9:09 AM 78 Maintenance and Service Brake System DO NOT use replacement parts anywhere in the brake system unless it conforms exactly to original specifications. A nonconforming part in your vehicle's brake system could cause a malfunction, leading to loss of control of the vehicle resulting in severe personal injury or death.
USA22978.bk.book Page 79 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 79 Air Tanks Drain the air system tanks at the recommended intervals. If condensation accumulates, moisture can enter the brake system air valves, causing corrosion or clogging. The safety of the brake system could be compromised, leading to an accident causing severe personal injury or death. When draining the air tanks, DO NOT look into the area of the draining air.
USA22978.bk.book Page 80 Wednesday, July 9, 2008 9:09 AM 80 Maintenance and Service ELECTRICAL SYSTEM MAINTENANCE Battery Care Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion.
USA22978.bk.book Page 81 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 81 The electrolyte level on maintenance free batteries cannot be checked. Periodically, the condition and the state-of-charge of each battery should be checked by a Volvo Truck dealer. Maintenance free batteries DO NOT require any attention other than keeping them clean and firmly clamped in place in their respective trays. Keep the cable connections clean and tight.
USA22978.bk.book Page 82 Wednesday, July 9, 2008 9:09 AM 82 Maintenance and Service TIRES, WHEELS AND HUB MAINTENANCE Wheel Safety Information DO NOT attempt to repair wheels or tires unless you are trained and equipped to do so. Wheel and tire assemblies cannot be worked on without proper tools and equipment. Failure to follow this may lead to serious personal injury or death. Failure to properly torque-tighten the wheel nuts can result in the breakage of wheel studs and the subsequent loss of wheels.
USA22978.bk.book Page 83 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 83 DO NOT install tires with a load rating that is less than stated on the Certification Label in the door frame. The tire could be unintentionally overloaded, leading to an accident, causing serious personal injury or death. DO NOT use mismatched tires on the same axle. Always use the same type (radial or bias ply) or size.
USA22978.bk.book Page 84 Wednesday, July 9, 2008 9:09 AM 84 Maintenance and Service Wheel Nut Tightening Failure to properly torque-tighten the wheel nuts can result in the breakage of wheel studs and the subsequent loss of wheels. This can lead to loss of vehicle control and serious personal injury or death. After the initial tightening, retightening must be made within the first 800 km (500 miles). After the first retightening, only normal inspection of nut tightness is needed.
USA22978.bk.book Page 85 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 85 Tire Inflation and Wear DO NOT operate the vehicle with under-inflated tires. Always keep your tires inflated to the manufacturer's recommendation. Increased flexing in the tire sidewall produces heat. The heat can build to the point of blowing the tire out causing an accident. Check tire pressure when the tire is cool. Never bleed the air from hot tires. Increased tire pressure measured in a hot tire is normal.
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USA22978.bk.book Page 87 Wednesday, July 9, 2008 9:09 AM Maintenance and Service Typical Wear Patterns Incorrect Air Pressure A. Air pressure too high gives rapid wear in the middle. B. Air pressure too low gives rapid shoulder wear. Incorrect Camber Incorrect camber gives abnormal wear on one half of the tire.
USA22978.bk.book Page 88 Wednesday, July 9, 2008 9:09 AM 88 Maintenance and Service Incorrect Toe and Axle Alignment A. Incorrect toe-in B. Incorrect toe-out C. Out-of-line axle D. Steering arm defect Dual Wheel Mounting A. Excessive road camber, different types of tire, different circumference or off-center loading give faster wear on one tire. B.
USA22978.bk.book Page 89 Wednesday, July 9, 2008 9:09 AM Maintenance and Service Incorrect Caster and Imbalance A. Caster angle B. Imbalance Also rapidly wears the mechanical parts of steering linkage, kingpin and wheel bearing. Cuts in the Tire Tread A. Cuts B. Flaking cuts C. Rubber flaking Cuts are due to poor roads, air pressure too high or incorrect tire type.
USA22978.bk.book Page 90 Wednesday, July 9, 2008 9:09 AM 90 Maintenance and Service Spot Wear Sudden braking, locking brakes or out-of-round brake drums give spot wear. Feathered Edges Normal occurrence on non-driving wheels on good roads and high mileage.
USA22978.bk.book Page 91 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 91 Cupping Cupping is a normal occurrence that depends on the tread pattern; the higher the load, the greater the wear.
USA22978.bk.book Page 92 Wednesday, July 9, 2008 9:09 AM 92 Maintenance and Service Front Wheel Hubs Failure to keep wheel bearings properly adjusted and lubricated may result in accelerated tire wear, poor handling and, in extreme cases, wheel separation from the hub or from the spindle resulting in loss of vehicle control and serious personal injury or death. The front wheel hubs can be filled with one of several types of oil. Motor oil should be SAE 30 or 15W40.
USA22978.bk.book Page 93 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 93 Unitized Front Hubs The non-tapered axle hubs are sealed with lubricant inside the hub and do not require lubrication.
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USA22978.bk.book Page 95 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 95 CHASSIS MAINTENANCE Springs This work is best performed by a Volvo Truck dealer or other service outlet having the proper equipment. The spring package is fastened to the axle beam with U-bolts. It is important that the U-bolt nuts are properly tightened. The nuts may loosen up with time. Severe roads and service will loosen them faster.
USA22978.bk.book Page 96 Wednesday, July 9, 2008 9:09 AM 96 Maintenance and Service Spring Bushings When lubricating the springs, lift the axle off of the floor, suspend the frame with axle stands and lower the axle. The spring bushings are now in the position where grease can be added to the contact surfaces. If the spring bushings are greased without taking the load off, high wear and lower lifetime will occur because grease is not able to reach the contact surfaces.
USA22978.bk.book Page 97 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 97 CAB MAINTENANCE Doors The door lock mechanism should be greased annually using white grease. Lubricate the door lock cylinder with liquid graphite annually, or more often in climates with a lot of snow and salt on the roads. Coat the door stop arm with white grease annually. On wet and salted roads, road spray can enter the door lock key cylinder.
USA22978.bk.book Page 98 Wednesday, July 9, 2008 9:09 AM 98 Maintenance and Service Hood The hood latch mechanism should be greased with white grease yearly. If the mechanism is hard to work or binds, the latch should be cleaned before greasing. Rust Protection The rust protection applied when the cab was produced is adequate for normal use and service.
USA22978.bk.book Page 99 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 99 Cab Air Filter Air going into the cab passes a filter located on the right, front side of the cab. Remove the filter and check it every 19 200 km (12,000 miles). The filter should not be cleaned and reused. Replace with a new filter as necessary. Change the filter more often if driving in dusty conditions. A clogged filter decreases the efficiency of the air conditioning system.
USA22978.bk.book Page 100 Wednesday, July 9, 2008 9:09 AM 100 Maintenance and Service DO NOT aim the water jet directly at door and window seals or door locks. If locks are filled with water, use compressed air to clean the water out and then apply liquid graphite. Be especially careful of leaving water in locks or around seals during freezing weather. Apply a coat of wax regularly. This will help the paint and other surfaces keep their luster.
USA22978.bk.book Page 101 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 101 Never use steel wool to clean chrome. Pieces of the steel wool break off and can create rust stains on the surface. Aluminum Unprotected aluminum surfaces will form an oxide layer if not maintained. This is especially important during the cold season when roads are salted or in coastal areas where the salt level in the air is high. Clean with steam or high pressure water. Use a mild detergent if the dirt is heavy.
USA22978.bk.book Page 102 Wednesday, July 9, 2008 9:09 AM 102 Maintenance and Service LUBRICATION Chassis Lubrication Before working on or servicing a vehicle, set the parking brakes, place the transmission in neutral and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death.
USA22978.bk.book Page 103 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 103 Lubrication Chart The numbers in the lubrication chart correspond with the numbered notes on “Lubrication Chart Notes” on page 104. Read these notes before selecting a lubricant.
USA22978.bk.book Page 104 Wednesday, July 9, 2008 9:09 AM 104 * Maintenance and Service Grease Automatic Transmission Fluid Hub Oil Manual Transmission Oil Engine Oil Rear Axle Oil Steering Fluid Brake Fluid Auxiliary Axle(s) Coolant Hydraulic Oil Windshield Washer Fluid Lubrication Chart Notes 1. Spring hanger: Use a lithium-based grease with specification API NLGI No. 2.
USA22978.bk.book Page 105 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 4. Draglink and steering shaft: Use a lithium-based grease with specification API NLGI No. 2. 5. Kingpin, upper and lower: Use a lithium-based grease with specification API NLGI No. 2. 105 Always grease a Volvo front axle with the wheels on the ground. Non-Volvo axles are typically greased with the wheels on the ground. Consult with the axle manufacturer for the latest recommendation. 6.
USA22978.bk.book Page 106 Wednesday, July 9, 2008 9:09 AM 106 Maintenance and Service Ensure that grease purges out of all four seals of the U-joints. 10. PTO/Hydraulic reservoir: If equipped, consult with the PTO manufacturer for the latest recommendation. 11. T-Ride bogie beam (48k-70k suspension): If equipped, use a lithium-based grease with EP additives to specification API NLGI No. 2. Make sure the grease purges out of both the outer and inner seals.
USA22978.bk.book Page 107 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 107 18. Automatic and manual transmission: 앫 Automatic transmission: Use Dexron® III automatic transmission fluid. See the manufacturer's operator manual for intervals and quantity. 앫 Manual transmission: Use a mineral or synthetic oil. Check oil level periodically. Level should be to the bottom of the inspection hole. 19. Auxiliary axle(s): If equipped, use a lithium-based grease with specification API NLGI No. 2.
USA22978.bk.book Page 108 Wednesday, July 9, 2008 9:09 AM 108 Maintenance and Service OIL CAPACITY TABLES AND VISCOSITY CHARTS Use the information in the table below to determine the operating condition and usage applicable to your vehicle. D11F and D13F Engine Oil and Filter Change Intervals Medium Heavy Severe Very Severe Fuel Consumption (mpg) more than 6.0 more than 4.7 more than 3.7 more than 2.
USA22978.bk.book Page 109 Wednesday, July 9, 2008 9:09 AM Maintenance and Service 109 Meritor Single RS23, 25, 26 and 30, Meritor Tandem RT40, 44 and 46 For oil change intervals, see the manufacturer's operator's manual Capacity RS23-160 19 liters (20 quarts) RS23-185 22.5 liters (23.
USA22978.bk.book Page 110 Wednesday, July 9, 2008 9:09 AM 110 Maintenance and Service Eaton Single 23080, 23105, 26105 and 30105Eaton Tandem DS405, DD405, DDH44 and DS462 For oil change intervals, see the manufacturer's operator's manual Capacity 23080 19 liters (20 quarts) 23105 and 26105 26.5 liters (28 quarts) DD404, front tandem DD404, rear tandem 14.5 liters (15.5 quarts) 13 liters (14 quarts) DS404, front tandem DS404, rear tandem 14.5 liters (15.
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USA22978.bk.book Page 112 Wednesday, July 9, 2008 9:09 AM 112 Service Check List PREVENTIVE MAINTENANCE Once you determine the applicable operating condition for your vehicle, use the information in the table below to perform preventive maintenance.
USA22978.bk.book Page 113 Wednesday, July 9, 2008 9:09 AM Service Check List CHECK / CHANGE BASIC (4 MONTHS) CHECK / CHANGE ANNUAL (12 MONTHS) Check Batteries-Dirt, Leakage, Attachment, Specific Gravity of Battery Acid, Fluid Level Connections and Battery Box X X Check Fuel Tank, Hoses, Pipes Venting and Mounting X X Check Fuel Water Separator for the Fuel system, Draining of Condensation.
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USA22978.bk.book Page 116 Wednesday, July 9, 2008 9:09 AM 116 Service Charts SCHEDULED SERVICES The vehicle had a pre-delivery inspection before being delivered to you, the customer. Regular maintenance inspections should be continued. The maintenance program and lubrication intervals that are listed in this manual may not suit your operation. Contact your nearest Volvo Truck dealer, who can help with designing a maintenance program that works in your application.
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USA22978.bk.book Page 118 Wednesday, July 9, 2008 9:09 AM 118 Service Charts REPAIR RECORD Keep track of repairs being made. This helps over the lifetime of the vehicle to spot trends that can be used to alter maintenance schedules, for example. Repair Record Date 1/1/07 Mileage 24816 Work Order or Invoice No.
USA22978.bk.book Page 119 Wednesday, July 9, 2008 9:09 AM Service Charts 119 TIRE RECORD Tire Record Date 1/1/07 Type Front Type Rear Low pro 22.5 Mich X2A Low pro 22.5 Mich XDA Notes (Tire Pressure, Tread Depths) All tires within 105 - 108 psi Tread Depth, Front 12/32, Rear 10/32.
USA22978.bk.book Page 120 Wednesday, July 9, 2008 9:09 AM 120 Service Charts FUEL AND OIL RECORD Keeping track of the fuel and oil consumption gives a record of what is normal for the vehicle. This can be compared with other vehicles in the same service application to indicate what is normal fuel and oil consumption for a certain application. Keep a record of how much fuel was filled between oil fill up or oil change. Accumulated Date Mileage 1/1/07 24816 Fuel Qty. (Gallon) 4166 Oil Qty. 36 SAE No.
USA22978.bk.book Page 121 Wednesday, July 9, 2008 9:09 AM Literature ENGINE DATA Consult your authorized Volvo Truck dealer.
USA22978.bk.book Page 122 Wednesday, July 9, 2008 9:09 AM 122 Literature SERVICE ASSISTANCE AND MANUALS Your Volvo Truck dealer is trained and equipped to perform expert service on your Volvo vehicle. Your dealer has direct access to Volvo Trucks North America for technical help, parts or service information. Volvo Action Service (VAS), provides on-call assistance. For help, contact VAS directly: 24 hours a day at 1 (800) 528-6586 or 1 (800) 52-VOLVO. Also on the internet: www.vas.Volvo.com.
USA22978.bk.book Page 123 Wednesday, July 9, 2008 9:09 AM Index 123 A Air Dryer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Air Filter, Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Air Filter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Air Tank Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Alternative Fuels . . . . . . . .
USA22978.bk.book Page 124 Wednesday, July 9, 2008 9:09 AM 124 Index Engine Overview, D11F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 40 Engine Overview, D13F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 40 Engine Shut-Down System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Engine, Before Starting. . . . . . . . . . . . . . . . . . . . . .
USA22978.bk.book Page 125 Wednesday, July 9, 2008 9:09 AM Index 125 N Noise Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 O Oil Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Oil Change Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Oil Consumption . . . . . . . .
USA22978.bk.book Page 126 Wednesday, July 9, 2008 9:09 AM 126 Index T Tires, Wheels and Hubs Maintenance . . . . . . . . . . . . . . . . . . . . . . . .82 Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Turbocharger and Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . .68 U U-bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Unitized Front Hubs . . . . . . . . . . . . . . . . . . .
1-800-52-VOLVO Volvo Action Service (VAS) Support Center If you need assistance on the road or if you need service repairs, contact the VAS support center. VAS is available 24 hours per day, 7 days per week at 1-800-528-6586. Please report the specific nature of the service problem to the Volvo Customer Support Specialist, who will answer your questions and arrange for the assistance you need.
Volvo Trucks North America P.O. Box 26115 Greensboro, NC 27402-6115 Volvo Trucks Canada, Ltd. 5600A Cancross Court, Mississauga, Ontario L5R 3E9 http://www.volvotrucks.volvo.com PV776-21012002 07.2008 © Volvo Group North America, Inc. 2008. All Rights Reserved.
