OPERATOR’S MANUAL VHD New Roads.
Foreword 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. This manual also contains a considerable amount of information concerning the vehicle, such as vehicle identification, Preventive Maintenance recommendations and a log for your service records. Please keep this in the vehicle at all times.
Contents General Information ............................. 1 Information For the Owner ................... 1 General Safety Information .................. 3 Modifications to Vehicle ....................... 7 Exhaust and Noise Emissions ............... 8 Vehicle Data ........................................ 16 Vehicle Access ...................................... Cab Doors and Door Lock ................. Cab Entry and Exit ............................. Hood ...................................................
Stereo/Radio ...................................... 188 Communication Equipment .............. 189 Fuel Economy Driving ...................... 190 Fuel Economy ................................... 190 Engine Start and Operation ............. Starting the Engine ........................... Cold Weather Start and Operation ... Engine Operation .............................. Cruise Control ................................... Fuel Tank(s) ...................................... 197 197 202 209 218 220 General .
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. IT IS IMPORTANT THAT THE FOLLOWING INFORMATION CONCERNING LABELS BE READ, UNDERSTOOD AND ALWAYS FOLLOWED.
General Information 1 Information For the Owner 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 the manufacturer for any assistance. In addition to this Operator’s Manual, there may be additional instruction/operator’s manuals supplied by component manufacturers.
2 General Information 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 Operator’s Manual covers Volvo VHD-series vehicles manufactured by Volvo Trucks North America, Inc.
General Information General Safety Information Operating the Vehicle Every vehicle, including heavy duty vehicles, has blind spots. The size of blind spots varies from driver to driver and from situation to situation. As a skilled, professional driver, you are in the best position to avoid accidents in turns, lane changes or other maneuvers. Volvo Trucks North America, Inc.
4 General Information Operating In Bobtail Mode Tractors are equipped with a bobtail air brake proportioning valve which automatically redistributes the braking force between front and rear axles when not hooked up to a semitrailer (bobtail operation). When operating in bobtail mode, the rear brake chambers receive reduced or proportional brake air pressure. When the tractor is towing a trailer, the rear brake chambers will receive full (normal) brake pressure.
General Information Do Not Overload This vehicle has been designed and assembled for a maximum gross vehicle weight rating (GVWR) and a maximum front and rear axle weights rating (FAWR and RAWR). The actual rating for this vehicle can be found on the label attached to the door frame on the driver’s side. If any of these three ratings is exceeded and overloading occurs, instability, poor handling, failure of parts and accelerated wear can occur.
6 General Information Reporting Safety Defects USA The National Highway Traffic Safety Administration (NHTSA) and Volvo Trucks North America, Inc. should be informed immediately if you believe that the vehicle has a defect that could cause a crash, injury or death. Contact NHTSA by calling the Auto Safety Hotline at 1 (800) 424–9393 (or 366–0123 in the Washington, DC area) or by writing to: NHTSA, U. S. Department of Transportation, Washington, DC 20590.
General Information 7 Modifications to Vehicle Chassis Frame Frame side rails are heat treated. No welding is permitted because structural failure may result. Do not drill through either top or bottom flanges. A warning label is also attached to the frame for information. Drilling is permitted in the frame web in accordance with a specified hole spacing pattern. Consult a Volvo Truck dealer to obtain approved hole spacing dimensions or refer to the Frame Rail and Cross Member Service Manual.
8 General Information Exhaust and Noise Emissions General USA The Federal Clean Air Act, Section 203 (a) (3), states the following concerning the removal of air pollution control devices or modification of a certified engine to a noncertified configuration: “The following acts and the causing thereof are prohibited: (3) For any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this part pri
General Information 9 California Emission Control Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Volvo Trucks North America , Inc. (VTNA) are pleased to explain the emission control system warranty on your vehicle. In California, new motor vehicles must be designed, built and equipped to meet the State’s stringent anti-smog standards. Volvo Trucks North America, Inc.
10 General Information EMISSION CONTROL SYSTEM WARRANTY Volvo Trucks North America, Inc. WARRANTS TO THE ORIGINAL OWNER, AND EACH SUBSEQUENT OWNER, OF A NEW TRUCK POWERED BY A VOLVO DIESEL ENGINE THAT THE EMISSION CONTROL SYSTEM OF YOUR TRUCK: 1 Is designed, built and equipped so as to conform at the time of sale to all regulations of the U.S.
General Information 11 The emissions control parts covered by this Emission Control System Warranty are listed under "What Is Covered by the Emissions Warranty." You are responsible for the performance of all required maintenance on your new Volvo engine, including maintenance or repairs needed due to severe operating conditions. Volvo Trucks North America, Inc. will not deny a warranty claim solely because you have no record of maintenance. However, Volvo Trucks North America, Inc.
12 General Information WHAT IS COVERED BY THE EMISSION WARRANTY The following is a list of the items that are considered a part of the Emission Control Systems and are covered by the Emission Warranty when installed as original equipment by Volvo Trucks North America, Inc. on vehicles which were built to conform to Environmental Protection Agency and California Air Resources Board regulations IMPORTANT - This may not include expendable maintenance items.
General Information Noise Emissions Volvo Trucks North America, Inc. warrants to the first person who purchases this vehicle for purposes other than resale and to each subsequent purchaser, that this vehicle as manufactured by Volvo Trucks North America, Inc. was designed, built and equipped to conform, at the time it left the control of Volvo Trucks North America, Inc., with all applicable U.S. EPA Noise Control Regulations.
14 General Information Tampering with Noise Control System Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has been removed
General Information Fuel System Removing or altering engine speed programming 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 damaged or loose portions of shields or skirts.
16 General Information Vehicle Data Identification and Labels It is extremely important that the correct vehicle model and serial number are given whenever replacement parts or service literature are ordered. Using these numbers, as well as giving the major component model and serial numbers, will prevent delay and errors in obtaining the correct material. Space is given on the rear inside cover of this manual for noting the main component model and serial numbers.
General Information 17 Identification and Certification Labels There are two labels that are located on the rear, lower face of the driver side door frame. These should be part of the vehicle at all times. The VIN is shown on the Vehicle Identification label. The VIN includes the vehicle make, model series, weight class, engine model, where the vehicle was built and the vehicle serial number.
18 General Information Components The Volvo D12 engine serial number is located on the rear, left side of the cylinder block. There is also a label on the engine electronic control unit that shows the engine serial number. W0001529 The Volvo D7 engine serial number is located 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.
Vehicle Access 19 Cab Doors and Door Lock The cab door is unlocked with the same key used for the ignition lock. Keys can be made to fit only one vehicle or all the vehicles in a fleet of Volvos. A tool for changing bulbs in the instrument cluster is included on the keychain. W0001231 The key fits in the door lock either way. Insert the key and turn it 1/4 turn counterclockwise to unlock or clockwise to lock the door. Key code on tag of keychain NOTE! The vehicle is delivered with 2 identical keys.
20 Vehicle Access The door has a position lock that enables the door to remain open in two different positions. An indented bar is holding the door at approximately 30 and in the fully open position at approximately 85 . To close the door from the inside, place the hand in the handhold 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.
Vehicle Access 21 Cab Entry and Exit General WARNING To avoid personal injury due to a slip and/or fall, observe all the guidelines explained in this section marked Cab Entry and Exit. Wearing shoes with soles that are dirty or wet increases the chance of slipping and falling. Be careful when entering the cab with dirty or wet soles. WARNING Do not stand on the steps or any other part of the vehicle while it is in motion.
22 Vehicle Access General Entry Guidelines To avoid personal injury due to a slip and/or fall, observe the following guidelines. 1 2 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. Be certain you have a firm handhold and/or stable foot position before transferring weight to that position.
Vehicle Access 23 Driver Side Entry/Exit Open the door. Place any hand-carried items on the cab floor. Grasp the right grab handle with your right hand and the left grab handle with your left hand. Put the right foot fully on the bottom step and pull yourself up to the opening. Slide hands up on the handles, if necessary. Put the left foot on the top step and step up. Step into the cab with the right foot first. To exit, reverse the process.
24 Vehicle Access Behind the Cab Entry When trailer air and electrical connections can not be coupled from the ground, Federal Regulations require commercial carriers to provide back-of-cab access steps, grab handles and plates. Depending on what option is chosen, grab handles are available in many variations. In each case, make sure to 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 area behind the cab.
Vehicle Access Stand on the ground when connecting the air and electrical connections to the trailer.
26 Vehicle Access Hood The hood is locked down by two latches, one on each side of the back end of the hood. The latches are operated by a handle on the bottom edge of the dashboard. Pull the bottom of the handle out to release hood. The hood will be raised about two inches off its resting position and remain there. Make sure the hood can be opened fully without hitting anything. Stand sideways in front of the hood with feet in line with the vehicle.
Vehicle Access 27 Manual Hood Opening In the event of a malfunction in the hood opening mechanism, the hood latches can be manually operated through an 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. Remove the cover plate. W8002389 The hood latch can now be accessed through the hole. Operate the latch manually by pushing the lever in towards the engine. Do the same on the other side.
28 Pre-Trip Inspection and Daily Maintenance General Before working on or inspecting a vehicle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. Safety is the most important and obvious reason for doing a pre-trip inspection. Federal and state laws require inspection done by the driver. Federal and state inspectors also inspect commercial vehicles.
Pre-Trip Inspection and Daily Maintenance 29 Pre-Trip Inspection Quick List W1000145 Inspect the vehicle in a circular manner as shown in the illustration. Numbers between parentheses in the list, refer to pages in this manual where component function and necessary inspection is explained in greater detail. Approaching the Vehicle Step 1: Left Side Of the Cab • Check under the vehicle for oil, fuel, coolant leaks or other signs of damage.
30 Pre-Trip Inspection and Daily Maintenance Step 1: Left Side Of the Cab (cont.) Lights and Reflectors Left Front Brake • Condition of brake drum. With brakes released, look for a noticeable gap between lining and drum (This check cannot be made if dust covers are in place). 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. • • Condition of brake air hose.
Pre-Trip Inspection and Daily Maintenance 31 W1000145 Step 3: Right Side Of Cab Area (cont.) Under Hood, Right Side Right Front Suspension • Check condition of coolant and heater hoses. • • Check condition of fan drive belts. • Check fuel separator sight glass and drain if necessary. Check for leaks. • Check wiring harnesses for signs of damage. • Check air filter with brackets and hoses for loose connections or damage. Check filter gauge, if mounted on the filter.
32 Pre-Trip Inspection and Daily Maintenance Condition of Visible Components Suspension • • Rear of engine: not leaking. • Transmission: not leaking. If equipped with oil cooler, check for leaks or that air-to-air cooler is not blocked. Check condition of springs (leaf or air), spring hangers, shackles and Ubolts. • Axle alignment. • • Check drive shaft. Brakes • Frame and cross members: no bends, cracks or breaks. • Air tubing and electrical wiring: secured against snagging and chafing.
Pre-Trip Inspection and Daily Maintenance 33 W1000145 Step 7: Coupling System Area Fifth Wheel • • • Securely mounted to the frame. 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.
34 Pre-Trip Inspection and Daily Maintenance Brakes Left Fuel Tank(s) • Condition of brake drums. With brakes released, look for a noticeable gap between lining and drum (This check cannot be made if dust covers are in place). • Securely mounted and not damaged or leaking. • Fuel lines secure and not leaking. Check that shut-off valves are open. • Condition of brake hoses: check for any chafing. • Tank(s) full of fuel. Cap on and secure. • Check brake chamber mounting bolts and brackets.
Pre-Trip Inspection and Daily Maintenance 35 W1000145 In the Cab • Check steps and grab handles for looseness or breakage ( page 22). Also, clean them if there is any substance that makes them slippery, which makes cab entry/exit hazardous. • Check climate control and defroster ( page 168). If equipped, check mirror heater. • Check condition of warning triangles, fire extinguisher and flares ( page 62). • Adjust the seat ( page 180). Check mirror adjustment. • Start the engine.
36 Pre-Trip Inspection and Daily Maintenance Hooking Up To Trailer Hook-up Preparation • Check kingpin and mounting plate on trailer, free from wear, bends or damage. • Chock trailer wheels. Fifth Wheel Or Trailer Hitch • No visible space between fifth wheel and trailer ( page 273). • Locking jaws around the shank and not the head of kingpin ( page 273). • Release lever properly seated and safety latch/lock engaged ( page 274).
Pre-Trip Inspection and Daily Maintenance 37 W0001919 NOTE! Refer to the trailer manufacturer’s manual for specific information on the trailer checks. Step 9: Trailer Front Area Spare Wheel(s) Air and Electrical Connections • Carrier or rack not damaged. • Spare wheel securely mounted in rack. • Tire and wheel condition adequate for a spare: proper size, properly inflated. • Glad hands properly mounted, free from damage and not leaking.
38 Pre-Trip Inspection and Daily Maintenance Step 11: Right Rear Trailer Wheel tween lining and drum (This check cannot be made if dust covers are in place). 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.
Pre-Trip Inspection and Daily Maintenance 39 W0001919 NOTE! Refer to the trailer manufacturer’s manual for specific information on the trailer checks. Step 13: Left Rear Trailer Wheels Area • If equipped with sliding axles, check position and alignment. Look for damaged, worn or missing parts, all locks present, fully in place and locked. • Flexible air tubing not cracked, cut, crimped or otherwise damaged. It should be secured against tangling, dragging and chafing.
40 Pre-Trip Inspection and Daily Maintenance Step 14: Left Side of Trailer Area Before Leaving the Parking Area Landing Gear or Dolly Area • • Remove chocks from the wheels. • Test the service brakes before leaving the parking area. • Test parking brakes by stopping on a 20% grade and applying the parking brakes. The parking brakes shall hold the combined vehicle and trailer without moving. • Fully raised; no missing or damaged parts. • • Crank handle present and secured.
Pre-Trip Inspection and Daily Maintenance 41 Daily Maintenance The following should be checked daily in addition to doing the pre-trip inspection of the truck or tractor and trailer. While checking the fluid levels, visually inspect hoses, pipes and their connections for signs of leakage. Inspect the ground under engine, transmission and rear axle(s) for signs of leakage. Before working on or inspecting a vehicle, set the parking brakes, place the transmission in neutral and block the wheels.
42 Pre-Trip Inspection and Daily Maintenance WARNING Keep yourself clear of all moving or hot engine parts. A hot engine can cause serious burns. Check oil level in the engine with the dipstick. The oil level should be between the minimum and maximum marks on the dipstick. Do not overfill! See the “Operator’s Manual, Maintenance and Engine” for correct types of oil used in Volvo engines.
Pre-Trip Inspection and Daily Maintenance 43 Check fluid level in the clutch fluid reservoir. Fluid level should be between the level marks on the reservoir. If fluid needs to be added, use brake fluid, DOT 4. W4000726 Check level in the windshield washer reservoir. If washer fluid needs to be added, use a commercially 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).
44 Pre-Trip Inspection and Daily Maintenance If the windshield needs an overall cleaning, use a long handled cleaning sponge and squeegee. Clean the side windows in the same way with a long handled sponge and squeegee. W8002766 Check all lights for proper function: • • • • • Headlights Daytime running lights Parking and marker lights Stoplights Turn signals W3004425 NOTE! Make sure that all fluid levels are at their proper levels. If the fluids are not at their proper levels, add as necessary.
Pre-Trip Inspection and Daily Maintenance 45 WARNING When draining 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.
46 Additional Safety Features Safety Belts General Safety belts must be properly worn at all times by the driver and all passengers while the vehicle is in motion even if the vehicle is equipped with a Supplemental Restraint System (SRS or air bag). Failure to do so can result in serious personal injury or death in the event of a collision. Fasten the safety belt before starting to drive.
Additional Safety Features 47 Safety belts must be worn by the driver and all passengers at all times. Before adjusting or fastening the safety belt, move the seat forward or rearward and adjust the seat height as necessary. Sit erect and adjust the seat cushion and seat back for a comfortable driving position. In the event of a collision, a correct driving position maximizes the effectiveness of the safety belt. There are both Federal and State laws governing the use of safety belts.
48 Additional Safety Features Operating the Safety Belt To fasten the safety belt, pull the belt out from the retractor and insert the latch into the buckle. Verify proper lock of the latch by pulling on the latch. Adjust the slack by pulling on the top part of the belt until the lower part, or the part that crosses the lap, is snugly adjusted. Release the top part and let the retractor pull the belt in.
Additional Safety Features 49 Inspection Failure to properly inspect and maintain the safety belts can cause serious personal injury or death. It is critical that any time a vehicle has been involved in an accident, the entire safety belt system must be replaced in the vehicle (which also includes the sleeper bunk restraints) if they were in use at the time of the accident. Failure to replace the safety belt system may result in serious injury or death.
50 Additional Safety Features The following maintenance guidelines detail how to inspect safety belts and tethers for cuts, fraying, extreme or unusual wear of the webbing, etc., and damage to the buckle, retractor, hardware or other factors which indicate that safety belt system replacement is necessary. Check the web wear at the buckle/latch area. The webbing must be closely examined to determine if there are any cuts, fraying or extreme wear in the webbing.
Additional Safety Features Check to make sure that the D-loop web guide is rotating properly. If the guide is not rotating properly, the webbing will pull at the wrong angle through the guide, accelerating 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.
52 Additional Safety Features The retractor web storage device is mounted on the B-pillar, just behind the door in the cab. The retractor is the heart of the safety belt system and can be damaged if abused, even unintentionally. Check the retractor web storage device operation to ensure that it is not locked and that it spools out and retracts the webbing properly. W8002481 If tethers are being used to anchor the safety belts to the floor, make sure that they are properly attached to the seat.
Additional Safety Features 53 Important Facts About Safety Belts in Heavy Trucks The high mileage associated with heavy trucks, the continual relative movement of the seat with the cab, the possible contact with the vehicle seat or other parts of the cab structure, and the potential exposure of this safety belt to severe environmental conditions make it crucial to inspect the seat belt system regularly.
54 Additional Safety Features Comfort Clip Operation When provided, the comfort clip is located on the shoulder strap just below the D-ring. When adjusting the comfort clip, the following procedure must be followed for proper adjustment: 1 Pull out only enough webbing to allow slight pressure to the shoulder and chest. Allow no more than a 1 in. (25 mm) slack when measured between the chest and the belt. 2 To activate the clip mechanism feature, lift the lever up to clamp the webbing in place.
Additional Safety Features SRS Airbag WARNING The SRS airbag is intended to supplement — not replace — the standard safety belt. The airbag is not deployed when the truck is hit from behind, from the side or if it rolls over. For best protection, sit in a normal, upright position. Always wear the safety belt. For added safety, the vehicle may be equipped with an airbag or SRS (Supplemental Restraint System) as a supplement to the standard three-point anchored safety belt.
56 Additional Safety Features SRS System The inflatable airbag is folded into the center of the steering wheel. It inflates in the event of a serious collision above a certain level, where the angle of impact, crash severity, speed and nature of the object involved in the collision all play a part in whether or not the airbag is activated. T8006849 The system consists of a gas generator surrounded by the inflatable airbag.
Additional Safety Features The SRS system is continually monitored by the control unit. A control unit is mounted on a bracket above the engine cover which detects deceleration. The control unit also contains a standby power unit which can supply the system with power for a short time, should the normal supply be broken. T8006857 If the control unit detects a sufficiently violent deceleration (collision), the system is activated.
58 Additional Safety Features Warning Labels The label attached to the left hand sunvisor shows the year and month when a Volvo Truck dealer should be contacted for a specific inspection and for a possible replacement of the airbag. This is done to guarantee the function of the airbag after the stated date. Replace the label when replacing the airbag module. Never attempt to make any adjustments to SRS components yourself.
Additional Safety Features Any queries concerning the SRS system should be directed to a Volvo Truck dealer. There is no maintenance required for the SRS system until the date stated on the warning label located on the left hand sunvisor. Never attempt to repair any part of the SRS system. Any interference with the system may cause it to malfunction and result in serious injury. Work on the system may only be carried out by an authorized Volvo Truck dealer.
60 Additional Safety Features General Information When is the airbag deployed? The airbag is only deployed during a headon collision, where the vehicle hits a fixed or heavy object with sufficient force. The SRS system registers both the force of the collision and the internal forces caused by the collision. The control unit determines if the collision is sufficiently violent for the airbag to be deployed. NOTE! The SRS system is only activated once in a collision.
Additional Safety Features Can the airbag be deployed accidentally? The complete SRS system is constructed so that the airbag only inflates in particular collision conditions. The SRS system has its 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.
62 Additional Safety Features Safety Equipment Safety triangles and fire extinguishers are available as optional equipment. The fire extinguisher should be located by the base of the driver seat, between the seat and the door. W1000071 Warning Triangles The warning triangles are stored in a box that is strapped to the back wall of the cab.
Additional Safety Features VORAD Collision Warning System The Eaton VORAD computerized Collision Warning System constantly monitors vehicles ahead with a front end mounted radar and in a blind spot area with an optional side mounted radar. The Collision Warning System warns the driver of potentially dangerous situations by activating visual and audible alerts. The Eaton VORAD Collision Warning System is intended solely as an aid for an alert and conscientious professional driver.
64 Instruments and Controls Dash Overview W8002383 1 2 3 4 5 6 7 8 9 10 Air Vents ( page 176) Diagnostic Test Connection Left Switch Cluster ( page 94) Headlight Switch ( page 98) Driving/Fog Lights - option ( page 99) Instrument Light Dimmer ( page 107) Climate Unit Control Panel ( page 168) Hood Latch Handle ( page 26) Pneumatic Switches ( page 104) Cigar Lighter ( page 107) 11 12 13 14 15 16 17 18 19 20 Ashtray Instrument Cluster, Left ( page 68) Instrument Cluster, Main ( page 76) Instrument Clus
Instruments and Controls 65 Instrument Cluster Overview W3004396 General Center Section The cluster is available in seven different configurations, with the speedometer either graded in mph or km/h. The cluster consists of three combined sections: The center section contains tachometer, speedometer and odometer. See page 76 for gauge information. In the lower part there is a central warning lamp and telltales for different vehicle functions. Please refer to page 79 for telltale information.
66 Instruments and Controls Telltale Overview 1 2 3 4 5 6 7 8 9 10 11 12 1 1 Engine Preheat ( page 72) Yellow INFO Light ( page 73) Red STOP Light ( page 74) No Charge ( page 75) Left Turn ( page 80) Fifth Wheel Lock ( page 80) Wheel Differential Lock ( page 80) Axle Differential Lock ( page 80) High Beam ( page 81) Safety Belt ( page 81) Parking Brakes ( page 81) Tractor ABS ( page 82) W3004406 13 14 15 16 17 18 19 20 21 22 Trailer ABS ( page 82) Air Suspension Level ( page 82) Mirror Heater ( page
Instruments and Controls Graphic Display Telltale Overview W3003534 1 2 3 4 5 6 7 8 9 Voltmeter ( page 156) Engine oil temperature ( page 153) Transmission oil temperature ( page 119) Preheating active ( page 72) Acknowledged warning ( page 124) Alarm clock on ( page 161) PTO engaged ( page 96) Cruise control engaged ( page 218) Airbag (SRS) ( page 57) 10 11 12 13 14 Coolant level ( page 120) Washer fluid level ( page 114) Engine airfilter clogged ( page 115) Too cold for engine brake ( page 240) Overh
68 Instruments and Controls Left Instrument Section A Pyrometer (option) (this page) B Engine Coolant Temperature ( page 69) C Engine Oil Pressure ( page 70) D Turbo Boost Pressure (option) ( page 71) E Graphic Display ( page 108) F Telltale Indicators ( page 71) W3003644 A — Pyrometer (option) An engine pyrometer system indicates the exhaust temperature, which helps the operator get the best efficiency from the engine. Variations in engine load can cause the exhaust temperature to vary.
Instruments and Controls B — Engine Coolant Temperature The gauge indicates engine coolant temperature. Normal operating temperature reading is 165 to 205 F (75 to 95 C) for the VOLVO engine. The temperature, under normal driving conditions, must be below the red sector. The temperature range for the coolant will vary depending on the type of engine, load, grade, ambient air temperature and operating conditions.
70 Instruments and Controls C — Engine Oil Pressure The gauge indicates oil pressure by a sensor directly connected to the engine lubrication system. Normal oil pressure is 30 to 70 psi (210 to 480 kPa) when the engine is at normal operating temperature. At idle speed, the pressure may drop to 5 to 20 psi (35 to 140 kPa). When first starting a cold engine, oil pressure may exceed 90 psi (620 kPa). The LED light in the lower right corner of the gauge lights up solid when the oil pressure is too low.
Instruments and Controls 71 D — Turbo Boost Pressure (option) The gauge indicates intake manifold pressure on the engine. The pressure is generated by the turbo. Boost pressure should be the same at a given engine temperature, speed and load. Turbo boost pressure will vary for different engines and vehicle models. By monitoring the gauge, the operator can avoid engine problems.
72 Instruments and Controls 1 — Engine Preheat Telltale The amber telltale will light when the intake manifold preheater is operating. The heater is used for better cold starts. Operation time of the heater can vary in several steps from 0 to 50 seconds depending on coolant temperature and outside air temperature. On cold mornings, the preheater will be on for the maximum 50 seconds.
Instruments and Controls 2— 1INFO Telltale 1 The yellow INFO telltale lights up to indicate a control system or component malfunction. In some cases, the engine power may be derated (see page 114). 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.
74 Instruments and Controls 3— 1STOP Telltale Failure to take necessary action when the STOP 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. 1 1 STOP telltale lights up red to alert The the operator that a severe problem has been detected and in some cases a preventive action may be taken by the engine electronics to protect the engine.
Instruments and Controls 4 — No Charge Telltale The No Charge telltale lights up red when a problem exists in the charging system or when there is no output from the alternator, such as when the engine is not running. T3008832 The No Charge telltale lights up dimly when there are several volts difference between the system voltage and the alternator output voltage. The telltale shines brighter as the alternator output voltage drops. For more information on the electrical system, see page 245.
76 Instruments and Controls Main Instrument Section G Tachometer ( this page) H Speedometer ( page 77) J Master Warning Telltale ( page 78) K Warning Telltales ( page 79) W3003643 G — Tachometer The tachometer is electrically driven by a signal from the engine. 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.
Instruments and Controls 77 H — Speedometer and Odometer The speedometer is driven by the vehicle’s electronic system. Recalibration of the speedometer can be made to compensate for tire size changes or other changes in the vehicle driveline. This is done by reprogramming the engine or transmission 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.
78 Instruments and Controls J — Master Warning Telltale The Master Warning Telltale and buzzer alerts of a dangerous situation. Air pressure is low and the remaining air volume may not be enough for repeated braking. The emergency brakes may engage, causing a wheel lock-up, loss of vehicle control and become a hazard to following vehicles. Bring the vehicle to a controled stop.
Instruments and Controls 79 K — Warning Telltales, Center Section W3003646 1 Left Turn Telltale ( page 80) 2 Fifth Wheel Lock Telltale ( page 80) 3 Wheel Diff. Lock Telltale ( page 80) 4 Interaxle Diff.
80 Instruments and Controls Left and Right Turn Telltales This lights up green when the turn signal is activated and blinks in time with the outside turn signal lamps. An audible signal also sounds in time with the telltale. A single short beep is heard when the telltale lights up. W3000903 5th Wheel Lock Telltale This telltale will light up yellow when the pneumatic switch for the 5th wheel slide lock is turned on. It will stay lit until the switch is turned to the off position again.
Instruments and Controls High Beam Telltale Any time the high beams are activated, by the high/low beam switch or the high beam flash switch, the telltale lights up blue. For information on switching high/low beam, see page 91. W3001303 Safety Belt Telltale The telltale lights up red each time the ignition is turned on to remind the driver to fasten the safety belt. It stays lit for 10 seconds and then goes out automatically.
82 Instruments and Controls ABS Telltale, Tractor and Trailer The telltale lights up amber if the AntiLock Brake System (ABS) senses a problem under the following conditions: 1 2 The system will go through its self test when the ignition switch is turned on and the telltale should continue to be on. The light should go out when the vehicle speed reaches over approximately 7 mph (11 km/h). If the telltale stays on at higher speed, there is a problem with the ABS.
Instruments and Controls 83 Right Instrument Section L Forward Drive Axle Oil Temperature (option) ( this page) M Rear Drive Axle Oil Temperature (option) ( this page) N Fuel Level Gauge ( page 84) O Application Air Pressure (option) ( page 84) OR Air Suspension Pressure (option) ( page 84) P Front Brake System Air Pressure ( page 85) Q Rear Brake System Air Pressure ( page 85) R W3004407 Warning Telltales ( page 86) L & M — Forward & Rear Drive Axle Oil Temperature (option) The gauges are
84 Instruments and Controls N — Fuel Level Gauge The gauge is connected to a sending unit in the fuel tank. There is only one sender even if the vehicle is equipped with dual tanks. W3003628 O — Application Air Brake Pressure (option) Air gauges are directly connected to the air brake system. They will indicate the brake application pressure from either the front, rear or trailer circuit pressure.
Instruments and Controls P & Q — Front and Rear Brake System Air Pressures The system air gauges are directly connected to the front and rear circuit tanks. The two gauges should register equal air pressure. Air brake system pressure should be between 90 to 135 psi (620 to 930 kPa) for normal operation. The pointers in the two gauges should register equal air pressure.
86 Instruments and Controls R — Warning Telltales, Right Section 1 Transmission Temperature (this page) 2 Check Transmission (this page) 3 Traction Control System ( page 87) 4 Wait to Start (Not used) 5 Automatic Neutral ( page 88) 6 Water in Fuel (Not used) W3004416 Transmission 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 temperature is too high.
Instruments and Controls Traction Control System Telltale The amber telltale will blink only when the Traction Control System (TCS) mud/snow mode is engaged. At all other times, the TCS system operates in the background without indication. The system does not have an on/off switch. See page 238 for more information. W3000962 The TCS only operates at speeds lower than 25 mph (40 km/h).
88 Instruments and Controls Auto Neutral Telltale The Auto Neutral Telltale is for the Allison WTEC III transmission. The green indicator lights up when the transmission is in auto neutral. Auto neutral is activated just before the vehicle comes to a complete stop (less than 1.5 mph [2.5 km/h]). The gear is re-engaged shortly (1–2 seconds) after the brake pedal is released. Allow for the gear re-engagement when applying throttle; do not increase engine speed before the transmission has engaged.
Instruments and Controls Changing Telltale Bulbs In Cluster NOTE! Before beginning to work, make sure the vehicle ignition is switched OFF. If possible, adjust the steering column back. Remove the two screws at the top of the instrument cluster and fold the cluster out and let it rest face-down against the steering column so the bulbs are accessible. CAUTION W3000842 Do not let the cluster be in the face-down position for more than maximum 15 minutes.
90 Instruments and Controls A bulb change tool is included with the ignition keys on the keychain, or can be ordered from your Volvo Truck dealer under part number 1089953. Use only this tool to change bulbs in the instrument cluster. To remove bulb, insert tool onto the bulb assembly, rotate a 1/4 turn counterclockwise and pull the bulb assembly out of the cluster. W3000642 Insert a new bulb into the tool and install it into the cluster.
Instruments and Controls 91 Steering Column Switches Turn Signal/Headlight Beam Change The turn signal is activated by the lever under the left side of the steering wheel. If the vehicle is equipped with a cruise control, the controls for this are located on the turn signal lever. See page 218 for more information about the cruise control. The standard turn signal switch is not self cancelling. It must be manually returned to neutral position after making a turn.
92 Instruments and Controls Windshield Wiper/Washer The wiper/washer functions are operated by the same switch. The wipers have a normal and a fast speed which are activated by moving the lever down one or two positions. To let the wipers engage for one or two passes, lightly depress the lever until the wipers start and hold it there. The wipers return to the parking position when the lever is released. The interval wiper function is engaged by moving the lever up.
Instruments and Controls Transmission Retarder If the vehicle is equipped with an Allison HD or MD transmission, the retarder lever is located in front of the highbeam and windshield wiper/washer lever. You can move this lever to six different positions to set the level. The retarder on/off switch is located in the dash, in the right-most position in the auxiliary panel. See page 243 for more information.
94 Instruments and Controls Left Switch Cluster This switch cluster has only one switch position permanently filled. Other positions are for optional equipment. The standard switch is for the Hazard Lights. Other switches that can be located in this cluster are for Back of Cab Light, Headlight Flash, Power Take Off, Headlight/Snowplow Changeover, and Fresh Air Intake. W3002002 Hazard Lights The hazard or four-way warning circuit is activated by pressing in the bottom part of the switch.
Instruments and Controls Headlight Flash Switch (option) The headlight flash switch will momentarily turn the headlights off when pressed. The switch will return when released, turning headlights on again. This switch functions when either of Daytime Running Lights or low beam headlights are on.
96 Instruments and Controls Power Take Off There are two basic types of PTOs available: engine mounted and transmission mounted. The transmission mounted PTO is clutch dependent, which means that operation can be regulated by depressing or releasing the clutch pedal. This type of PTO should not be in use while driving. The engine mounted PTO is direct-mounted to the engine and is engaged with a bypass valve operated by the switch. This type of PTO can be in use while driving.
Instruments and Controls PTO Speed Adjustment Have the PTO engaged before adjusting the speed. For the PTO speed adjustment to function, the Cruise Control or idle adjust can not be active, brake and clutch pedals must be released, and vehicle speed must be under approximately 5 mph (8 km/h). To set engine speed: 1 Set the PTO/CC switch in the ON position. 2 Use the accelerator to increase engine speed. 3 Momentarily press the SET+ or SETswitch to set current engine speed.
98 Instruments and Controls Driving Light Switches Headlights The headlight switch controls parking lights and headlights. It is a two position rotary switch, turning on parking lights, cab marker lamps and taillights in the first position and turning on headlights in the second position. To change between high and low beam, pull the direction indicator lever all the way toward the steering wheel. When a slight clicking sound is heard, release the lever.
Instruments and Controls Driving and Fog Lights (option) Combinations of driving and fog lights can be mounted in standard locations in the aerodynamic bumper or from the underside of the steel bumper. These are operated by a switch next to the headlight switch. Fog and driving lights are wired so they are turned on only when the headlight switch is on. Fog lights are used with the parking lights and the low beam headlights. Driving lights are used with the high beam headlights.
100 Instruments and Controls Right Switch Cluster This switch cluster can hold up to six optional equipment switches. Planned functions are Marker Interrupt, Traction Control (TCS), Exhaust or Engine Brake and Heated Mirrors. W3000972 Marker Interrupt Switch The switch interrupts power to the marker lights when held down. When released, it will spring back to the ON position and return power to the marker lights.
Instruments and Controls 101 Exhaust/Engine Brake When operating your tractor bob-tail 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 may occur. WARNING A vehicle speed retardation device (such as “Jake Brake,” “C-Brake,” “Exhaust Brake,” etc.
102 Instruments and Controls Several types of engine brakes can be installed or are standard on certain engines. All are used to reduce wear on the vehicle brake linings. Exhaust Brake, Volvo Engine The exhaust brake is standard equipment on the Volvo engine. It provides braking effect to the rear wheels by trapping the exhaust in the engine. The switch for exhaust brake has two positions: ON and OFF. The exhaust brake is most effective at high engine speed (1 500 to 2 300 r/min).
Instruments and Controls Heated Mirror Switch (option) The vehicle can be equipped with heated mirrors. The switch turns on an electric 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.
104 Instruments and Controls Pneumatic Switch Cluster The pneumatic switch cluster can have up to four optional equipment switches. They regulate air flow directly to the following equipment: Differential Lock — Wheel and Interaxle, Air Suspension Level and Fifth Wheel Slide. To prevent accidental engagement, each switch has a latch that needs to be pressed down before the switch can be operated.
Instruments and Controls Suspension Level 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. Tractors with rear air suspension have a control for deflating the air springs. Use this when uncoupling from trailers. See page 276 for correct operation when uncoupling. W3001341 The switch has a safety latch to prevent accidental engagement.
106 Instruments and Controls Optional Switch Cluster The optional switch cluster can either be used for additional switches when the other clusters are used up or can be removed to house 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.
Instruments and Controls 107 Miscellaneous Switches Horn Switches Electric and air horns are standard equipment. They are both operated from the steering wheel. The air horn button (1) is located in the middle of the steering wheel. If the vehicle is equipped with an airbag (SRS), the airbag module can be pressed down anywhere around the edge to engage the air horn. There are two buttons for the electric city horn (2) located on the steering wheel spokes.
108 Graphic Display Graphic Display Overview T3010426 The display in the bottom left-hand corner of the instrument cluster presents operational information to the driver. The display menus and functions are selected with the controls on the right-hand side of the steering wheel. Certain information will be shown automatically (e.g. warning messages that need immediate attention). The display has a large number of main menus and sub-menus used for selecting the correct functions.
Graphic Display 109 Graphic Display Controls If the vehicle is in motion, use the display controls carefully. Do not lose road concentration. Be familiar with operation of the controls. Shifting concentration to operating the controls can lead to losing control of the vehicle and may result in serious personal injury or death. The controls for the graphic display are located on the windshield wiper lever on the right-hand side of the steering wheel.
110 Graphic Display Changing Settings 1 The up/down buttons increase or reduce the set values (e.g. hours and minutes in the adjacent example). 2 Pressing SELECT confirms the choice. 3 If there are several settings to change in the same menu, the cursor is moved to the next setting using the up/down buttons (e.g. the selection between ON, OFF and SET in the adjacent example). 4 Esc moves the highlight to the previous number or selection, if there are any, otherwise the setting is cancelled.
Graphic Display 111 Graphic Display Telltales W3003534 1 2 3 4 5 6 7 8 9 Voltmeter ( page 156) Engine oil temperature ( page 153) Transmission oil temperature ( page 119) Preheating active ( page 72) Acknowledged warning ( page 124) Alarm clock on ( page 161) PTO engaged ( page 96) Cruise control engaged ( page 218) Airbag (SRS) ( page 57) 10 11 12 13 14 Coolant level ( page 120) Washer fluid level ( page 114) Engine airfilter clogged ( page 115) Too cold for engine brake ( page 240) Overheating, ins
112 Graphic Display Information and Stop Messages 1 1 The information and stop messages work INFO or STOP telltogether with the tales below the Graphic Display. If the engine is running, the buzzer will sound at STOP telltale comes on. any time the 1 Information Telltale 1 NOTE! When the yellow INFO telltale lights up, the indicated fault should be checked at the next stop. T3008860 1 See page 113 for a listing of other telltales INFO telltale.
Graphic Display Information Telltale General 1 The yellow INFO telltale lights up when an abnormal status is detected by an electronic control unit. A telltale or text, or both, are shown in the display in addition INFO telltale. For certain telltales, to the a reference value is also shown. 1 The telltales are described starting on page 114, text messages are described starting on page 117 and combined telltale and text messages are described starting on page 119.
114 Graphic Display Telltales 1 The yellow INFO lights up and a telltale is shown in the graphic display, describing in what component the problem has occurred: Airbag The airbag (SRS) is described on page 57. T3008842 CAUTION The vehicle should be taken to an authorized Volvo Truck dealer immediately if the SRS telltale stays on or lights up when the vehicle is being driven. Instrument Cluster Overheating The symbol is shown when the temperature behind the instrument cluster is too high.
Graphic Display Air Filter Blocked (option) When the telltale lights, the engine air filter is blocked. A blocked filter will cause higher fuel consumption and black smoke. To replace air filter, see the Operator’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]).
116 Graphic Display Transmission Oil Temperature This telltale lights when the transmission oil temperature is too high. It is shown with a text information about the temperature. See page 119 for more information. T3008831 Charging System This telltale lights when there is a problem in the charging system. It is shown with text information of the charging system status. The voltage is shown together with the message TOO HIGH. See page 156 for more information.
Graphic Display Text 1 The yellow INFO telltale lights up and information text is shown on the display.
118 Graphic Display Data link broken: CHECK DATA LINK BROKEN T3008860 Not factory installed equipment: The following can be shown if equipment has been added by a customer and connected to the data link: CHECK ERROR IN MID (Message IDentifier) = controller To find more information on the data link diagnostic function, see page 131.
Graphic Display Telltale + Text 1 The yellow INFO telltale lights up and information text together with a value is shown on the display. The text contains information on where the fault has occurred and the value will show how much above or below the limit the current conditions are: Transmission Oil Temperature 1 If the transmission oil temperature becomes too high, the INFO telltale lights up automatically with the text HIGH.
120 Graphic Display Stop Telltale 1 In the event of a serious fault, the red STOP telltale lights up and the buzzer sounds (if the engine is on). In addition to STOP telltale, a symbol or text, or the both, are shown in the display. A reference value is also shown for certain telltales. 1 T3008861 Telltales Coolant Level Failure to take necessary action when the STOP telltale is on, can ultimately result in automatic engine shutdown and loss of power steering assist.
Graphic Display Engine Oil Pressure Failure to take necessary action when the STOP 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. 1 This symbol is shown when the engine oil pressure is too low. The LED in the gauge lights up together with the telltale and the buzzer also sounds.
122 Text Graphic Display 1 The red STOP telltale lights up and information text flashes on the display. The buzzer sounds if the engine is running. The text includes information about where the fault has occurred: Failure to take necessary action when the STOP 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.
Graphic Display Telltale + Text 1 The red STOP telltale lights up and information text together with a value is shown on the display. The text contains information on where the fault has occurred and the value will show how much above or below the limit the current conditions are: Warning, temperature transmission oil 1 If the temperature of the transmission oil becomes too high, the red STOP telltale is shown automatically with the text TOO HIGH.
124 Graphic Display Acknowledge Information and Stop Messages By pressing Esc, the display with the fault message is reset and the graphic display returns to the same status as before the error occurred. An acknowledged fault message is shown as a symbol on the right in the graphic display window. All types of fault messages can be acknowledged. Acknowledged but active messages are shown again when the ignition key is turned to the start position.
Graphic Display Recall An acknowledged fault message can be recalled, i.e. be shown on the graphic display again. MENU: FAULTS? 1 SELECT confirms the choice of the menu FAULTS? The last acknowledged fault message is shown. If there is more than one message, a down arrow is shown in the right-hand corner. 2 The up/down buttons move the cursor between the current messages.
126 Graphic Display Main Menu: Set-Up Mode The menu Set-up mode has 14 sub-menus where 6 are not protected by passwords and 8 are protected by passwords. • • • • • • Language Mi/ F/USgal or km/ C Clock format Contrast Backlight Night display Password is required: (see page 152) • • • • • • • Default language Fleet limit: r/min Fleet limit: speed Fleet fuel target Odometer setting Fleet ID Password config.
Graphic Display 127 Miles/ F/USgal or km/ C MENU: Set-up mode, Mi/ F/USgal or km/ C NOTE! If miles and Fahrenheit are chosen, the fuel consumption is shown in US gallons. If kilometers and Celsius are chosen, the consumption is shown in liters. 1 Select the menu Set-up mode, Mi/ F/USgal or km/ C and the following 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.
128 Graphic Display Clock format MENU: Set-up mode, Clock format 1 2 Select the menu Set-up mode, Clock format and the following diagram is shown on the graphic display (with the particular setting highlighted): AM/PM 24 h The up/down buttons move the cursor between the alternatives. Confirm the choice with SELECT. AM/PM is the 12 hour display (AM = morning and PM = evening). Cancel setting Press Esc in order to cancel the setting.
Graphic Display Backlight MENU: Set-up mode, Backlight NOTE! This setting affects the display brightness when the headlights or parking lights are on. When the exterior lights are off, the brightness on the display is constant. The graphic display brightness is controlled by the dimmer rheostat setting (which also controls the other instrument cluster lighting). In this menu, the display lighting can be altered in relation to the other instrument cluster lighting.
130 Graphic Display Night display MENU: Set-up mode, Night display 1 Select the menu Night display and the following diagram is shown on the display: 2 With the up/down buttons the setting switches between Normal and Reverse. 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.
Graphic Display Main Menu: System Diagnostic The menu System diagnostic has 3 submenus which are not protected by a password, and 1 sub-menu which is protected by a password. • • • Fault diagnostic Cluster self test Part number Password required: (see page 152) • Status test Fault Diagnostic 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).
132 Graphic Display 1 The up/down buttons are used to move the cursor in the list. 2 SELECT confirms the selection of ECU or Reset all. 3 During the time that each respective ECU is being called, the display shows the text: Data transfer in progress please wait 4 No faults in the chosen system: Press Esc to return to the previous menu. 5 No errors Not responding to Non spec. system: Non spec. syst Press Esc to return to the previous menu.
Graphic Display 133 Fault codes are shown 1 If there is a fault code or codes the following is shown, for example: Engine Coolant temperature Line 1: Identification of ECU Line 2: Identification of parameter/component Value too high Line 3: Fault type identification Active 6 ”6 1” shows how many times the fault has been registered since the last resetting. If no information is available for how many times the fault code has been registered, only Active is shown (the fault remains).
134 Graphic Display Numeric or text 1 Press SELECT when there are fault codes and the following menu is shown. Select numeric or text format (the function Reset will only be shown when the correct password has been entered; see page 152): Numeric Text Time stamp Reset 2 When Text has been selected, the fault codes are shown according to step no. 1, page 133.
Graphic Display The arrow 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 is shown. If 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.
136 Graphic Display Time stamp 1 To show the time when the fault code was set for the first and latest occasion respectively, press SELECT when the particular fault code is presented (does not apply to ABS brakes or SRS airbag).
Graphic Display 137 Common Fault Codes MID Messages Supported (with text) MID code Description 128 PID code Description 62 Retarder inh status Engine 71 Idle shutdown status 130 Transmission 84 Road speed 136 ABS 91 % Throttle pedal 140 Instrument 100 Engine oil pressure 144 Cab Controller 102 Boost pressure 232 SRS (Airbag) 105 Air inlet temperature 106 Air inlet pressure 108 Barometric pressure 110 Engine coolant temperature 111 Coolant level 127 Transmission oil p
138 Graphic Display Common SID code Description Transm.
Graphic Display Brake SID code Description FMI code 139 Description 1 ABS snsr axle 1 L 0 Data valid, but high 2 ABS snsr axle 1 R 1 Data valid, but low 3 ABS snsr axle 2 L 2 Data erratic 4 ABS snsr axle 2 R 3 Voltage shorted high 5 ABS snsr axle 3 L 4 Voltage shorted low 6 ABS snsr axle 3 R 5 Current low or open C 7 ABS valve axle 1 L 6 Current high or short C 8 ABS valve axle 1 R 7 Mech syst no respons 9 ABS valve axle 2 L 8 Abnormal freq or PW 10 ABS valve axle 2
140 Graphic Display PPID (Proprietary Parameter ID) PPID Code Description 69 Buffered Idle Switch 70 Pedal Switches, Supply 71 Cruise Control and Retarder, Supply Switch 72 Accelerator Pedal and Retarder, Supply Sensors 73 Accelerator Control 2 and Primary Tank, Supply Sensors 75 Range Inhibitor, Status Solenoid 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 Perce
Graphic Display Cluster Self-Test MENU: System diagnostics, cluster selftest Four sub-menus are available: • • • • Bulb test Gauge test Display test Buzzer test Cancel Test Press Esc in order to cancel the test. Bulb Test MENU: System diagnostic, Cluster selftest, 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.
142 Graphic Display Gauge test MENU: System diagnostics, Cluster selftest, Gauge test 1 Select Gauge test. 2 The pointers move back and forth a few times, between the end positions. They stop at the mid-point of the gauge before the test is complete, then 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 selftest, Display test 1 Select Display test.
Graphic Display Buzzer test MENU: System diagnostic, Cluster selftest, Buzzer test 1 Select Buzzer test. 2 On the display, the name of the current sound is shown at the same time as the sound is activated. With the up/down buttons you can switch between the different sounds. Three different sounds (flasher indicator, reminder and caution) are tested for 10 seconds. 1 The caution sound is connected to the red STOP telltale. 3 Esc cancels the test and the menu Buzzer test is shown again.
144 Graphic Display Part number MENU: System diagnostics, Part number A list of the vehicle’s electronic control units (ECUs) is shown in the menu Part number. Each ECU is identified by a MID number (Message IDentifier). • • • • • • 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.
Graphic Display 5 6 The up/down buttons are used to move the cursor in the list.
146 Graphic Display Main Menu: Data Log Mode (Volvo Engine Only) Menu Data log mode has 4 sub-menus where 3 are not protected by passwords and 1 is protected by a password. • • • Vehicle ID Totals Trip data Password required: (see page 152) • Reset trip data Vehicle ID MENU: Data log mode, Vehicle ID 1 Select the menu Data log mode, Vehicle 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.
Graphic Display Totals MENU: Data log mode, Totals 1 Select the menu Data log mode, Totals. 2 The menus that show Totals can be scrolled to using the up/down buttons. 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.
148 Graphic Display Total PTO hours 0.5 h Total engine revolutions 1 220 100 r 3 If the transfer should fail, the following message is shown: Operation Cancel operation Press Esc in order to cancel the operation.
Graphic Display 149 Trip data (Volvo engine only) MENU: Data log mode, Trip data 1 Select 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 selected, 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.
150 Graphic Display NOTE! If km and C has been selected, the consumption 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 selected, the consumption is shown in liters. Trip idle fuel 2.5 gal Trip PTO hours 1.
Graphic Display NOTE! If km and C has been selected, the consumption is shown in liters. Trip PTO fuel 20.4 gal Trip cruise 2.5 h 4 If the transfer should fail, the following message is shown: Operation failed Cancel operation Press Esc in order to cancel the operation.
152 Graphic Display Main Menu: Password Input Certain functions are password protected and there are two password levels for the display (it is also possible to select not to protect functions with password, which can be done by a Volvo Truck dealer): 1 Workshop password 2 Owner password The two passwords give the user access to all password protected functions, with one exception: The workshop password does not give access to the password configuration, i.e.
Graphic Display Main Menu: Gauge When the menu GAUGE has been selected, you switch between the various sub-menus with the up/down buttons. • • • TEMPERATURE, ENGINE OIL TEMPERATURE, TRANSMISSION OIL (Option) VOLTMETER Temperature, engine oil MENU: GAUGE, TEMPERATURE ENGINE OIL The engine 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.
154 Graphic Display Temperature, transmission oil (option) MENU: GAUGE, TEMPERATURE, TRANSMISSION OIL The transmission oil temperature is shown as in the diagram. T3008831 170 F T3008831 NO DATA T3008831 HIGH 250 F NOTE! The temperature display starts showing only at approximately 150 F (65 C). If the sensor data for Transmission oil temperature is not available, the symbol is shown as well as the text NO DATA.
Graphic Display 155 1 Stop message Red STOP telltale If the temperature of the transmission oil becomes too high, a flashing stop message is shown automatically with the text TOO STOP HIGH. At the same time the red telltale under the display lights up and the warning signal sounds. Esc acknowledges the stop message. 1 T3008831 TOO HIGH 285 F 1STOP telltale, the transmission oil temperature must be 285 F (140 C) for 30 For TOO HIGH to display with the seconds.
156 Graphic Display Voltmeter MENU: GAUGE, VOLTMETER The battery/charging voltage is shown as in the diagram. If the battery/charging voltage becomes too low (below 9.5 V), the instrument cluster will lose power. 1 13.1 V T3008832 Information message Yellow INFO telltale If the battery/charging voltage becomes too high, the voltmeter’s value is shown automatically as well as the text TOO HIGH. INFO tellAt the same time the yellow tale under the display lights up. 1 T3008832 TOO HIGH 17.
Graphic Display 157 Main Menu: Fuel Economy (option) Menu FUEL ECONOMY has 2 submenus: • • AVG/INST LEG FUEL FUEL ECONOMY is chosen and then the up/down buttons are used in order to change between the available sub-menus. AVG/INST Fuel Economy MENU: FUEL ECONOMY, AVG/INST For setting metric or English value displays, see page 126. The following is shown on the display: • • • Average trip fuel consumption (AVG): The value is presented numerically and as an arrow above the bar.
158 Graphic Display Reset fuel economy 1 Press SELECT in the menu AVG/INST. 2 A new text message in the form of a question is shown: RESET FUEL DATA? Press SELECT to reset. RESET FUEL DATA? PRESS SELECT FOR 1S When the leg’s fuel consumption is reset, the average fuel consumption will also be reset. Leg Fuel MENU: FUEL ECONOMY, LEG FUEL Press the up/down buttons in the menu AVG/INST to reach the menu LEG FUEL.
Graphic Display Main Menu: Time/Distance Menu TIME/DIST has 4 sub-menus. • • • • CLOCK ALARM CLOCK TRIPMETER AVERAGE SPEED NOTE! Menu TIME/DIST is available even when the ignition key is in the off position. It is activated by keeping one of the control buttons on the wiper stalk pressed down for at least 1 second. The menu remains active for 30 seconds after the last depressing of the button.
160 Graphic Display 4 Set the second digit in the minutes with the up/down buttons. Confirm the choice with SELECT. 5 Set the AM/PM (if the time format is 12h) with the up/down buttons. Confirm the choice with SELECT. Cancel setting When setting hours, Esc cancels the setting and the time is shown according to the previous setting. Pressing Esc after setting the minutes or after setting the AM/PM, moves the cursor back to the previous selection.
Graphic Display 161 Alarm clock MENU: TIME/DIST, ALARM CLOCK Setting the alarm clock: 1 To set the alarm clock, press SELECT when the menu ALARM CLOCK is shown in the menu TIME/DIST. 2 Move the cursor to SET using the up/down buttons. Press SELECT. ALARM 08:30 AM CLOCK 08:00 AM ON OFF SET If the speed during the setting exceeds 5 mph (8km/h), the function is cancelled and the graphic display returns to the last active display in the ON position. 3 Set the hours with the up/down buttons.
162 Graphic Display Ignition key in the off position When the ignition key is in the OFF position, if setting the alarm clock takes more than 30 seconds, the time which has been entered then applies. Switch off the alarm clock When the alarm clock goes off, the word ALARM flashes, the current time is shown and a warning signal sounds. The alarm is switched off after 60 seconds or when the up, down, Esc or SELECT control button is pressed.
Graphic Display 163 Tripmeter MENU: TIME/DIST, TRIPMETER TRIP On the display in the menu TRIPMETER the distance driven for Leg 1 and Leg 2 are shown. #1 43.6 mi #2 507.3 mi Reset tripmeter 1 Press SELECT in the menu TRIPMETER. 2 A new text message with a question about the resetting of the tripmeter is shown. The up/down buttons move the cursor between Leg 1 and Leg 2. Confirm the choice with SELECT or press Esc in order to cancel the resetting.
164 Graphic Display Main Menu: FAULTS? General When a fault occurs a fault message is shown on the graphic display. There are two types of fault messages: 1 Information messages 2 Stop messages The stop message is always more urgent than information messages. Any information and stop messages as well as the associated symbols are shown automatically on the graphic display when driving. A summary of these symbols is shown in the illustration under page 166.
Graphic Display 1 Information message The yellow INFO telltale lights up when an abnormal state or a risk situation is indicated. In addition to the telltale, a symbol or text is shown on the graphic display at the same time. For certain symbols, a measurement value is also shown. T3008860 NOTE! In the event of a warning for low air pressure no message is shown on the graphic display, the LED in the gauge lights up instead (together with the master warning telltale [see page 78]).
166 Graphic Display Information symbols 1 The yellow INFO telltale lights up and a symbol is shown on the graphic display: Airbag For airbag (SRS system) information, see page 57. Warning, transmission oil temperature T3008842 Overheating, instruments The symbol will be shown when the temperature in the instrument cluster exceeds 92 C (198 F). The instrument lighting becomes weaker and the gauges show the minimum reading.
Graphic Display Too cold for engine brake (VEB) (Volvo engine only) Warning, temperature engine oil If the engine oil temperature becomes too high, a stop message is shown automatically with the text TOO HIGH. The engine output is reduced. The temperature limit which activates this warning varies for different engines. This limit is set in the engine ECU. T3008830 Air filter, clogged The symbol is shown when the air filter sensor is restricted.
168 Heating and Air Conditioning General Three levels of the cab climate systems are available. They can be identified by the appearance of the control panel. The basic system is a heater and defroster unit only. The heater unit has a rating of at least 40 000 Btu. W8001116 The manually operated heating and air conditioning unit is controlled from the same panel as the heater system, with the addition of a switch for turning the air conditioning system on (button with the snowflake symbol).
Heating and Air Conditioning 169 Climate Unit Main Control Panel Fan Speed Control The fan has four speeds and can also be shut off. With the fan control in the 0 position, air still flows out of the dash vents if the vehicle is moving at highway speeds and if the Fresh Air Control is set for outside air intake. If the Fresh Air Control is set for full recirculation, the fan has to be on for air to flow out the dash vents.
170 Heating and Air Conditioning Air Distribution Control The air distribution control is used to direct the air flow to either the dash vents, floor vents or defroster vents. The lever has detentes in the outer and middle positions so that it can be set without looking at the panel. The air flow for the three major settings are described below. Any setting outside of the detented positions will be a mix of the air flows that depends on how far from the detented position the lever is.
Heating and Air Conditioning 171 W8001078
172 Heating and Air Conditioning Fresh Air Control The top slide lever is the Fresh Air/Recirculation Control. The settings can be anywhere from full fresh air intake to only recirculated air. Settings can be chosen anywhere in between to give the desired flow of air. In the leftmost position, the fresh air inlet is closed. All air is recirculated within the 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.
Heating and Air Conditioning 173 Temperature Control The bottom slide lever is the Temperature Control which operates the coolant control valve. In the leftmost position the flow of coolant is shut off by the control valve, which means no heat from the climate unit. The heat will increase the further to the right the control is moved. The temperature control should be used as a thermostat, together with the fan speed, to “dial” in the desired temperature when using the air conditioning.
174 Heating and Air Conditioning A/C Control When the vehicle is equipped with air conditioning, the control panel has a button for engaging the air conditioning compressor. This button is marked with a snowflake symbol. When the A/C is engaged, the green LED light in the button is on. When the air conditioning button is pressed, the fan speed control must be set on 1 through 4 for the air conditioning to start.
Heating and Air Conditioning 175 A/C Automatic Control When the vehicle is equipped with Automatic Temperature Control (ATC), the control panel has a button, marked with aut, for engaging the electronic control unit. When ATC is engaged, the green LED light in the button is on. The ATC air conditioning works with the coolant control valve as a “thermostat,” making automatic adjustments with input from sensors for air output and for air inside of the cab.
176 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.
Heating and Air Conditioning 177 Cab Ventilation Ventilation Guidelines If at any time there is any doubt that exhaust fumes are entering the cab, have the cause of the fumes determined and corrected as soon as possible. If the vehicle must be driven under these conditions, drive only with all windows open. Protect against carbon monoxide entry into the cab. Keep the engine exhaust system, cab and cab ventilation system properly maintained.
178 Heating and Air Conditioning Cab Air Filter Air going into the cab passes a filter located on the right, front side of the cab. Remove the filter and clean with an air gun (no more than 20 psi pressure) after 40 000 miles (64 000 km), (in dusty conditions as often as every 10 000 miles [16 000 km]). Make sure the air stream is directed from the inside out. The filter should not be cleaned and reused more than once.
Heating and Air Conditioning 179 A/C Diagnostic Module Problem Codes The diagnostic module has two LED lights (one green and one red) which indicate if a system problem has been detected. If a problem is detected, a fault code or “blink” code is activated to identify the condition.
180 Seats General Several different seats can be used in the vehicles. If the seat installed in the vehicle is not explained in this section, look for the seat manufacturer’s manual in the Owner’s Package. On the driver’s side there is a standard seat and an upgrade that includes adjustable air cushions for lumbar and thigh-back support, arm rests and a frame cover. The passenger side can have the same type of seat as on the driver’s side and also a fixed seat.
Seats 181 National Standard Seat Adjustments 1 Backrest tilt: By rotating the round handle, the backrest recline angle can be adjusted within 12 degrees. 2 Cushion front tilt and length: Pulling the handle up and out adjusts the tilt and length of the seat cushion. NOTE! Support body weight with your feet while adjusting. 3 Fore and aft movement: Press the lever sideways to unlock the seat. Move seat fore or aft to a new position.
182 Seats Volvo Standard Seat Adjustments 1 Fore and aft movement: Press the control down to unlock the seat cushion. Move seat cushion fore or aft to a new position. 2 Cushion front tilt: Push the control down and adjust the tilt 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.
Seats National Stationary Seat For the passenger side, there is the option of a stationary seat. The base of the seat is a storage box that is accessed by lifting the seat cushion up. A bench seat for two passengers is also available. 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.
184 Cab Interior Interior/Reading Lights Front Of Cab The cab is equipped with separate and combined interior and reading lights in various locations in the cab. The front seat overhead lights can be turned on at any time using the switch in the fixture. By turning the switch the other way, the light will be activated by the cab door switches. Any time the door is opened, the light will come on.
Cab Interior 185 Storage Compartment CAUTION Heavy objects must be stored secured to the floor. Storage compartments are designed for lighter personal effects only. In the event of a collision, heavy, unsecured objects in overhead storage can come loose and cause severe personal injury or death to the driver or passengers. Do not overload the cab suspension. Make sure the weight distribution is equal in the cab. Total load for the cab suspension is 800 lb (360 kg), with driver and passenger included.
186 Cab Interior Cup Holders 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.
Communication and Entertainment 187 Antennas Multiband Antenna There are antennas mounted on the top of the mirror brackets for wideband reception. They receive or send signals for radio, CB and telephone. Each antenna carries multiple wire windings that work together with mirror bracket devices to cover 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.
188 Communication and Entertainment Communications signals that travel to and from the antennas go through the antenna multiplexer. Coaxial cables for the cellular phone, CB radio and radio are included in the multiplexer 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.
Communication and Entertainment 189 Communication Equipment CB Radio There is an optional platform provided for a CB radio on top of the dash. The unit is held in place with a strap which can accommodate a variety of sizes. For electrical hook-up, see page 255. The CB Radio can also be permanently mounted directly above the radio. When the optional switch panel is removed, a DIN standard radio mount is available. W8001876 Telephone There is room on the dash for a mobile telephone.
190 Fuel Economy Driving Fuel Economy General The absolute fuel consumption (counted in miles per US gallon or liters per 100 kilometers) is determined by a large number of circumstances which can be related to one of the following main areas: 1 Build specification and equipment 2 Service and maintenance 3 External environment 4 Driving habits Due to these factors, fuel consumption can vary considerably within what is called “normal fuel consumption.
Fuel Economy Driving Driveline Combination Engine, transmission and final drive must be selected in such a way that the engine can operate within the economic speed range at normal driving speed. This range is defined as where the engine makes the best use of the energy content of the diesel fuel. A poorly selected rear axle ratio, which results in the engine speed being constantly above the optimum speed, will increase fuel consumption.
192 Fuel Economy Driving Gross Vehicle Weight The gross vehicle weight of a vehicle combination has a large impact on the rolling resistance. Accessories As a rule, accessories such as roof rack, advertising signs, bug screens, exposed air horns, etc., have a negative effect on fuel consumption. Service and Maintenance A modern heavy-duty vehicle requires regular and preventive maintenance to ensure that all its components function as they should.
Fuel Economy Driving Axles An axle out of alignment will increase rolling resistance. Regularly check the front wheel alignment and axles on both the tractor and trailer/semi-trailer. If they are correct, there will be less rolling resistance and, therefore, lower fuel consumption. A good sign of an axle or wheel out of alignment is uneven tire wear. Check the tires often. Engine Faulty or incorrectly adjusted engine components increase fuel consumption.
194 Fuel Economy Driving External Environment Under unfavorable conditions, the external environment can have a negative effect on fuel consumption. This can be broken down into two main groups: weather and wind; and the nature of the roads. Rain, snow, icy conditions and headwinds have a large negative impact on fuel economy, as do hilly roads and uneven road surfaces. Headwinds Headwinds have a large negative impact on fuel consumption. With tailwinds, fuel saving is only marginal.
Fuel Economy Driving Driving Habits The way in which a vehicle is being driven is the one factor which has the greatest influence on fuel consumption. Correct driving saves fuel and reduces vehicle wear. To achieve optimal running economy, the driver should always remember to: • • • • Start the engine correctly (especially important in winter season) Maintain an even and correct speed Keep the engine at its optimum speed range Use the correct uphill and downhill driving technique.
196 Fuel Economy Driving Avoid High Engine Speeds High engine speeds mean high fuel consumption. Jerky driving also increases fuel consumption when the vehicle is constantly accelerated and slowed down. Avoid a higher consumption by steady, even driving. Refer to each engine manufacturer’s operator’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.
Engine Start and Operation Starting the Engine Start Procedure NOTE! For cold weather starting, see page 202. These starting and operating procedures should be followed for all engines. For more detailed information about design and function on a non-Volvo engine, read the Operator’s Manual from the engine manufacturer. NOTE! Before starting the engine, see “Instruments and Controls” (starting on page 64) for detailed information on how the gauges and telltales work.
198 Engine Start and Operation 1 Before starting the engine, perform the engine pre-trip inspection and daily maintenance checks in “Pre-Trip Inspection and Daily Maintenance” starting on page 28. 2 Make sure the parking brakes are engaged. 3 Place the transmission in neutral or depress the clutch pedal. 4 CAUTION Do not crank the engine for more than 30 seconds at a time; wait two minutes after each try to allow the starter to cool. Failure to follow these instructions could cause starter damage.
Engine Start and Operation 5 Turn the key on to the start position. Release key as soon as the engine has started. For the Volvo engine, the preheater can be engaged to help starting in cold temperatures. For switch function, see page 201. 6 CAUTION If at start-up, or thereafter, the oil pressure gauge indicates any drop in oil pressure, the engine must be shut down immediately. Failure to stop the engine may cause major engine damage.
200 Engine Start and Operation Stopping the Engine Allow the engine to slow down and idle for 3 to 5 minutes before shutting it off. This allows the turbo to slow down and the cooling system to dissipate the engine heat. Switch the engine off by turning the ignition 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.
Engine Start and Operation 201 Ignition Switch The ignition switch is located on the right side of the steering column just under the steering wheel. Standard equipment is a normal ignition switch. A steering wheel lock is available as an option. When the key is removed it actuates a detente pin that prevents the steering shaft from turning. NOTE! The vehicle is delivered with 2 identical keys. If more keys are needed, order them through your Volvo Truck authorized dealer.
202 Engine Start and Operation Cold Weather Start and Operation Volvo Engine Cold Start NOTE! These cold start instructions are for Volvo engines only. For other engine makes, see the manufacturer’s handbook. Do not use ether or similar starting aids in a Volvo or any other engine with start help. The Volvo engine is equipped with a preheater.
Engine Start and Operation Coolant Temperature Preheater Engagement Time (seconds) Above +120 F (50 C) 0 Above +50 F (10 C) Between +4 F (-15 C) and +50 F (10 C) 0 25 ± 2 to 50 ± 2 Below +4 F (-15 C) 50 When the engine has started, the preheater may be re-engaged to assist in faster engine warm-up. To re-engage, turn the key to the preheat position and the preheater will engage. The starter will not engage as the start position is locked out.
204 Engine Start and Operation Ether Start Do not use ether or similar starting aids in a Volvo or any other engine with start help. The Volvo engine is equipped with a preheater. Introduction of ether or other combustible material in the intake manifold could cause a fire or explosion, resulting in severe property damage, severe personal injury or death. W0001484 Do not breathe the ether fumes. Breathing ether fumes could result in personal injury or death.
Engine Start and Operation Cold Weather Operation If the engine is in good mechanical condition and the necessary preparations are taken for cold weather operation, ordinary cold weather will not cause difficulty in starting or loss of efficiency. Cold weather operation does require changes in operating practices, maintenance procedures, lubrication and fuel. Additions to the vehicle, such as heated fuel filters, fuel tank heater, engine block heater, winterfront, etc. can make winter operation easier.
206 Engine Start and Operation • During cold weather, give more attention to the condition of the batteries. Test them frequently to ensure sufficient power for starting. A dead battery may freeze. • Fuel cloud point is the temperature at which wax crystals become visible, which is generally above the pour point of the fuel. To keep the fuel filter elements from plugging with wax crystals, the cloud point should be no higher than the lowest ambient temperature at which the engine must start.
Engine Start and Operation 207 Oil Pan Heater (option) Oil pan heaters aid low temperature starting by improving oil flow to critical parts in the engine. This helps prevent engine wear. They are similar to block heaters and are wired into the same plug as the engine coolant heater. Fuel Heater Filter (option) If running in very cold weather, a heated fuel filter should be added. A number of different fuel heaters are available as options. They are electrically heated and regulated by a thermostat.
208 Engine Start and Operation Winterfront Volvo Trucks North America, Inc. does not recommend the use of winterfronts, shutters or any other shield in front of the grille or radiator package under normal circumstances. Today’s electronically controlled engines are designed to operate in cold temperatures without a winterfront. These devices, if not used properly, can cause higher exhaust temperatures, power loss, excessive fan usage, failure of the charge-air-cooler and a reduction in fuel economy.
Engine Start and Operation Engine Operation General Proper operation, driving techniques and maintenance are key factors in obtaining the maximum life and economy from a modern turbocharged diesel engine. This section has operational information about the components that make up the engine. For the best operation economy, see “Fuel Economy” page 190. When changing gears, avoid lugging to extend engine life.
210 Engine Start and Operation The operator should understand the operating characteristics of the engine the vehicle is equipped with. Modern diesel engines have maximum torques at much lower engine speeds than in the past. As such, these engines are designed to perform satisfactorily at a lower speed. New transmissions with wide ratio steps between gears demand the use of these engines.
Engine Start and Operation Engine Shut-Down System Failure to take the necessary precautions when the INFO or STOP telltales are on, can ultimately result in automatic engine shut-down and the loss of power steering. Vehicle crash can occur.
212 Engine Start and Operation Engine Overspeed This vehicle is equipped with a diesel engine and should not be operated in an area with a concentration of hydrocarbon vapors (for example gasoline or diesel fuel fumes). Be especially cautious of low-lying or closed-in areas. The vapors may be drawn into the engine through the air intake and cause the engine to overspeed. Hot carbon and other sparks may come from the exhaust system, and cause an explosion and fire.
Engine Start and Operation Idling All engines in the VHD models are electronically governed engines. The idle speed is pre-programmed from the manufacturer. Low idle speed is adjustable within certain limits (for most engines between 600 to 750 r/min). See page 214 for more information. The common belief that idling a diesel engine causes no engine damage is wrong. Idling produces sulfuric acid, which breaks down the oil and eats into bearings, rings, valve stems and engine surfaces.
214 Engine Start and Operation Low Idle Adjustment If the engine coolant temperature is above 122 F (50 C), the vehicle is stationary (engine running; accelerator released; parking brake on) and the PTO not engaged, the engine low idle speed can be adjusted with the use of the cruise control function. W3002499 1 2 3 4 5 6 7 Set the cruise control switch to the ON position. Depress the foot brake pedal. Hold it down during the entire procedure.
Engine Start and Operation Idle Shutdown Timer The idle shutdown timer can be programmed to shut the engine down after a specific engine idling time. The program can not be changed by the operator but requires a special tool (Pro-Link) that connects to the engine electronic control unit. This is available at your Volvo Truck dealer.
216 Engine Start and Operation Uphill Operation For best performance, allow engine speed to reach the bottom of the rated torque range before downshifting. Continue to downshift in this manner until a gear is reached that will maintain the desired speed. Continue to operate at the rated torque if the vehicle will make it to the top without a downshift. Begin upshifting as the grade of the hill decreases and the engine begins to accelerate above 1600 r/min.
Engine Start and Operation High Altitude Operation Engines lose power when operated at high altitude because the air is too thin to allow burning as much fuel as at sea level. For naturally aspirated engines, this loss is about 3 percent per 1000 feet (300 m) increase in altitude above sea level. Most turbocharged engines are rated for higher altitudes and will not lose as much power as a naturally aspirated engine. An engine will produce excessive exhaust smoke at high altitude unless a lower gear is used.
218 Engine Start and Operation Cruise Control Do not use the cruise control in heavy traffic, with ice/snow on the road or during other unfavorable conditions. This may lead to a loss of vehicle control, causing a vehicle crash and can result in personal injury or death. Engaging The cruise control switches are located on the turn signal lever. To engage and set desired speed: 1 Set the cruise control switch to ON.
Engine Start and Operation Disengaging The cruise control is disengaged if the brake or clutch pedal is depressed, or if the cruise control switch is set to OFF. If the ignition key is turned back to the accessories position (R), the cruise control system will automatically be disengaged. Resuming Vehicle Speed The previously selected cruise speed is retained in the memory.
220 Engine Start and Operation Fuel Tank(s) Tank Cap Do not remove the fuel tank cap near an open flame. Diesel fuel vapors are combustible and can cause an explosion or fire, resulting in severe personal injury or death. The fuel tank caps have a pressure and a thermal relief function built into the cap. These functions are designed to avoid fuel spills in the event of an accident.
Engine Start and Operation Fueling Air is always present inside the fuel tanks, entering mainly through the tank ventilation. With the air being heated up and cooled down, condensation is formed and water is mixed in the fuel. To avoid condensation when the vehicle is parked for longer periods, fill the tanks up to 95% of capacity. Do not fill more than that, as the fuel needs to have room for expansion during the heat of the day. Do not carry extra fuel containers in the cab.
222 Clutch and Transmission Clutch General Before starting the engine, set the parking brakes and place the transmission in neutral. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury and death. Do not allow the clutch to slip excessively. This would cause excessive heat to be generated and the clutch will be damaged and bring on premature failure. As soon as the vehicle is moving, remove the foot from the pedal for complete clutch engagement.
Brakes 223 Brakes Brake Safety Information Do not inspect or adjust parts or components in the brake system without setting the parking brake, placing the transmission in neutral and securely chocking the wheels. If the vehicle is not secured to prevent uncontrolled vehicle movement, it could roll and cause severe personal injury or death. Do not use replacement parts anywhere in the brake system unless it conforms exactly to original specifications.
224 Brakes Do not release the parking brake or attempt to move the vehicle until brake air pressure in both circuits is at least 100 psi (690 kPa). Failure to follow this procedure may lead to uncontrolled vehicle movement and cause severe personal injury or death. Never release or drive a truck that has a brake discrepancy — no matter how minor — until it has been repaired or corrected.
Brakes 225 Both circuits are piped into a dual brake valve, which simultaneously applies front and rear axle service brakes during each brake application. In the event of a failure in either one of the circuits, the other circuit becomes the emergency circuit for applying the brakes. W5000923 The Master Warning Telltale and buzzer alerts of a dangerous situation. Air pressure is low and the remaining air volume may not be enough for repeated braking.
226 Brakes Brake System Controls The air compressor, governor, pressure regulator valve and reservoirs are control devices. Their function is to build up, maintain and control air pressure in the reservoirs. This is so that pressure is held constant between the minimum and maximum range established for air brake operation. The brake valve, quick release valve, brake chambers and slack adjusters are application devices.
Brakes From the operator’s viewpoint, operating the foot brake valve of a vehicle equipped with air brakes differs very little from the operation of a conventionally braked vehicle. Because the operation of the brake pedal requires scarcely more effort than depressing the average throttle pedal, air brakes are naturally much easier to control.
228 Brakes 4 In making a stop or a slow-down, allow the transmission to remain in gear with the throttle closed, disengaging the clutch only when engine idling speed is reached. 5 When parking the vehicle, place the transmission in neutral 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.
Brakes 229 Parking Brake/Trailer Supply Valves Trucks/Tractors may have two air control valves on the instrument panel: • • Trailer Supply (red octagonal knob) System Park (yellow diamond knob) The two air control valves are interconnected and interacting. The System Park valve supplies and controls the Trailer Air Supply valve. The System Park valve knob (yellow) should be pushed in first, after sufficient air pressure is built up (apply foot brake to prevent vehicle from rolling).
230 Brakes Parking Brake Release VHD models have engines equipped with engine electronic control units (EECU). These have two features that may impact the brake system. One is the anti-stall device in the EECU which senses torque demand and automatically controls the engine to compensate and maintain speed. On tractors equipped with parking brakes on only one axle, the anti-stall device keeps the engine from stalling, allowing the driver to pull away with the brakes dragging.
Brakes There is also an engine shut-down device in the EECU that shuts the engine down after a pre-programmed time in order to save fuel. This is activated when the yellow parking brake knob is pulled out. Therefore, 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.
232 Brakes Spring Brake For Parking Never leave the vehicle without being certain the parking brakes are set or that other precautions are taken to prevent the vehicle from rolling. Failure to do so can result in serious personal injury or death. The parking brake mechanism uses spring pressure as a separate power medium to apply the service brakes on the driving axles. The parking brake is released by the same compressed air source used to apply the service brakes.
Brakes There are several ways to determine if the parking brakes have been set. By pulling out the yellow knob: • • • • • An audible rush of air will be heard when 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. The engine will stall if an attempt is made to set the vehicle in motion.
234 Brakes Trailer Brake Hand Control The trailer hand brake control is not a parking brake valve and must not be used as one. This brake is not designed to hold the vehicle stationary. Failure to follow these instructions can result in the unintentional movement of the vehicle and may cause personal injury or death. The hand control valve for the trailer brakes engages the trailer brakes independently from the vehicle brakes.
Brakes The “121” Brake Standard This manual refers occasionally to “121” brakes. Although some operators believe “121” only applies to vehicles equipped with anti-lock devices, the “121” standard applies to all vehicles that are capable of on-highway operation. The “121” is a Federal requirement also covering alterations or changes to parts or systems related to the “121” standard once the vehicle has been placed in service.
236 Brakes Antilock Braking System (ABS) The vehicle has a standard brake system, equipped with an electronic speed monitoring and control system, Antilock Braking System (ABS). ABS monitors wheel speed continuously but is not involved in controlling the wheel speed unless there is an emergency. In normal braking applications, the standard air brake system is in effect. WARNING For proper ABS operation, do not change tire sizes.
Brakes During emergency or reduced-traction stops, fully depress the foot brake pedal until the vehicle comes to a safe stop. DO NOT PUMP the brake pedal. With the brake pedal fully depressed, the ABS will control all wheels to provide steering control and a reduced braking distance. Although the ABS improves vehicle control during emergency braking situations, the operator still has the responsibility to change driving styles depending on the existing traffic, road and/or weather conditions.
238 Brakes Traction Control System (TCS) (option) The Traction Control System (TCS) uses the same wheel sensors as the ABS to determine if one set of drive wheels is spinning much more rapidly than the wheel set on the other side. If the TCS determines that a wheel is spinning (with vehicle speed below 25 mph [40 km/h]), it operates the brake system to apply some brake force to stop the spinning wheel(s). This puts the drive power over to the stationary wheel(s).
Brakes Vehicle Speed Retardation Devices 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 this instruction can result in loss of vehicle control and serious personal injury or death. WARNING A vehicle speed retardation device (such as a “Jake-Brake,” “C-Brake,” “Exhaust Brake,” etc.) is not intended to bring the vehicle to a stop.
240 Brakes Volvo Exhaust Brake The exhaust brake is standard on the Volvo D12 engine. It is used to reduce wear on the brake linings. The exhaust brake is most effective at high engine speeds (1500 to 2300 r/min). The exhaust brake is automatically disengaged if the engine speed drops to or below 1100 r/min. The exhaust brake works by containing the exhaust gases in the exhaust manifold, thereby making the engine work against the back pressure. This provides a retarding force on the drive wheels.
Brakes 241 Volvo Engine Brake (option) The Volvo Engine Brake (VEB) has a higher braking effect than the exhaust brake. The engine brake is most effective at high engine speeds (1500 to 2300 r/min). It is automatically disengaged if engine speed drops below 1100 r/min. The engine brake function is operated by one switch in the right hand switch cluster. It works together with the exhaust brake to provide two levels of braking power. The switch has three positions: OFF, LOW and HIGH.
242 Brakes Jake-Brake Or C-Brake The Jake-Brake or C-Brake is optional equipment for Cummins, and Detroit engines. These engine brakes are similar in operation. Three power levels are available by engaging 2, 4, or 6 cylinders when braking (for Cummins M11, only two power levels are available). It is operated by two switches in the right hand switch cluster. It works together with the exhaust brake to provide two levels of braking power. The left switch is the ON/OFF switch.
Brakes 243 Transmission Retarder The Transmission Retarder is an option with Allison HD and MD transmissions. It is activated by an on/off switch in the auxiliary panel and is controlled by a stalk switch mounted in front of the wiper switch. You can set 6 different levels with the stalk switch. W3004428 Do not use the retarder on wet or slippery roads. The retarder may cause vehicle to slide and cause an accident which could result in injury or death.
244 Electrical System Electrical System General Safety Guidelines WARNING Failure to repair a malfunction in the electrical system can result in serious damage due to vehicle fire. Always let an experienced electrical technician perform repairs. Always determine the source of the fault; do not just treat the symptoms. WARNING Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion.
Electrical System 245 Charging System An alternator with an integrated regulator is used to supply power to the vehicle electrical system. The charging system voltage should be checked periodically to prevent overcharging or undercharging the batteries and to detect any voltage drop in the wiring. W8002769 Battery Box The battery cover may also be a base for the cab steps. To remove the cover, unhook the two rubber latches and lift the cover up and out.
246 Electrical System There may be three or four batteries installed. Always make sure the batteries are fastened properly in the box. When disconnecting battery terminals, always disconnect the main ground terminal first. When reconnecting, always connect the main ground terminal last. W3002368 WARNING Battery posts, terminals and related accessories contain lead compounds, chemicals known to the state of California to cause cancer and reproductive harm. Wash hands after handling.
Electrical System 247 Battery Jump Starting and Charging To access the batteries on a vehicle equipped with side fairings, open the fairing access cover. On the second battery from the front there are special, longer posts installed to accept jumper cables.
248 Electrical System Charging the Battery High voltage machines that are used for work on the vehicle can do damage to the electrical system, especially to its electronic components. Welding or quick-charging machines subject the wiring to excessive voltage, which may often result in damage to electrical and electronic components anywhere on the vehicle. CAUTION Attempting to work on electronic components without proper equipment can damage internal parts with static electricity.
Electrical System Electronic Components CAUTION Electronic circuits and components are designed to sense voltage differences smaller than 1 volt. While static electricity is not normally dangerous to humans, it can seriously damage electronic circuits and components. Circuit boards mounted in the instrument cluster 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.
250 Electrical System CAUTION If there are other ground cables connected to the battery (such as engine ECU, etc.), disconnect those ground cables first, then remove the main battery ground cable. Electronic modules may be damaged when additional grounds are connected/disconnected without the main battery ground connected. Disconnect the main battery ground last.
Electrical System • Attach the welder ground cable as close to the weld area as possible (6 inches or less from the place being welded). • Do not connect the welder ground cable to the EECU or its cooling plate. • Welding cables should not be allowed to lay on, near or cross over any electrical wiring or electronic component during the welding procedure. • After finishing welding and the welded areas having cooled, inspect wiring and components for possible shorts or damage.
252 Electrical System Battery Protection System (option) An electronic battery monitor (“Battery Lifeguard”) may be installed in the electrical center. This monitor will disconnect certain circuits if it senses that the battery voltage falls under a safe charging level. Before disconnecting, the monitor will sound a loud and distinct alarm, alternating long and short beeps, for approximately 60 seconds. At the end of the alarm, the monitor disconnects circuits to protect the batteries.
Electrical System 253 Electrical Center W8000923 The electrical center is located in the middle of the dash. All the relays and fuses in the cab are collected here. The cover panels are fastened with screws that can be turned with a coin. Since the function of some fuses or relays may change for the vehicle application, refer to the list 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.
254 Electrical System The fuses and relays are all accessible under the top cover on the dash. W3002526 One type of fuse in the new electrical center are termed “mini-fuses” and require a puller tool to remove from the fuse block. The puller tool is part of the Owner’s Package. To order a new puller, use part number 20378326.
Electrical System 255 Power Studs On the passenger side of the dash are power studs for a CB hook-up. These studs are standard equipment. For a proper hookup, use fork type connectors on the wires or use “banana” plugs. CAUTION If stripped wire ends are used, make sure there are no wire strands that can bridge between the studs. W3002001 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.
256 Power Steering General The power steering consists of an integrated gear and hydraulic power cylinder, and a power steering pump with fluid container. The pump, driven by the engine, provides hydraulic pressure to the power steering. If the engine is not working, the steering is only manual. With the power steering not working, the effort required to turn the steering wheel is much greater than with power assist. If the power steering assist fails, bring the vehicle to a safe stop.
Power Steering 257 Periodically check the power steering fluid reservoir and keep it filled to the proper level with the recommended fluid. See the “Operator’s Manual, Maintenance and Engine” for more information. There is also a filter inside the reservoir that needs to be changed every 12 months. W6001428 Adjustable Steering Column (option) The steering column is fixed as standard. An adjustable steering column is available as an option.
258 Axles and Wheels Axles Differential Locks The drive axle(s) may be equipped with differential locks. The single drive axle will only have a wheel differential lock. With tandem drive axles, there could be both wheel differential locks and an inter-axle differential lock. CAUTION Never operate the vehicle with the differentials locked any longer than is necessary as this places a great strain on the axles and may cause rapid tire wear. The differential lock should be used on icy or slippery surfaces.
Axles and Wheels Engaging the differential locks must always be done in the following way (see page 104 for switch location): 1 2 3 4 Depress the clutch pedal. Wait for the drive wheels to stop spinning Engage the differential lock Engage a suitable gear Carefully release the clutch pedal W3001991 Do not drive on dry, paved surface with the differential locks engaged. The vehicle will strive to maintain a straight line.
260 Axles and Wheels Auxiliary Lift Axle Before raising or lowering any of the auxiliary axles, be certain no one can be trapped by the axle movement. Failure to do so can result in a person being trapped between the wheel and the body, or between the wheel and the ground, resulting in serious personal injury or death. W3004429 Vehicles may be equipped with auxiliary lift axles. The lift mechanism operates with air pressure.
Axles and Wheels 261 Wheels General Due to the size, equipment needed and the procedures used to change wheels, this should be done through the Volvo Truck dealer. By having an expert technician perform this procedure, personal injury and property damage may be avoided. NOTE! When replacing the wheel equipment or tires, use the same size wheels or tires as originally manufactured. Changing the tire or wheel size will affect brake performance.
262 Axles and Wheels Inflating Tires Always check inflation pressures when the tires are cool, using an accurate tire pressure gauge. Check the pressures at regular intervals. CAUTION Never bleed the air from hot tires. Increased tire pressure measured in a hot tire is normal. Lower than recommended pressures may cause side wall flexing resulting in increased tire heat. This may cause premature tire failure. W7000437 Tires and wheels must be serviced only by a qualified technician.
Axles and Wheels 263 Wheel Bearing Adjustment For reliable operation and adequate service life, the wheel bearings must be properly adjusted and checked during the service period. Loose wheel bearings could cause premature tire wear and possibly affect vehicle handling. See your Volvo Truck dealer for proper servicing. Watch carefully for oil leaks and listen for unusual noises. These are indications of worn bearings, bad seals or misadjusted bearings.
264 Fifth Wheel Instructions Fifth Wheel General Information The standard fifth wheel is manufactured by ASF. Other fifth wheels available as options are Holland and Fontaine. Things to think about with trailer hook-up: • Check the load distribution between axles. • • Always chock the trailer wheels. • Verify visually that coupling has occurred. • Verify visually that plungers have locked on slider. • Check for slack between the 5th wheel and the trailer kingpin. Grease the plate.
Fifth Wheel Instructions 265 Safety Information Follow the instructions on the advisory labels attached to the various manufacturers’ fifth wheels. An operator’s manual from the manufacturer is supplied with each fifth wheel and is provided in the Owner’s package. W9000183 If the fifth wheel is equipped with a sliding mounting, follow the advisory labels attached to the component. Also, read the literature provided by the manufacturer.
266 Fifth Wheel Instructions Locked — This is the position that the fifth wheel will be in with a trailer hooked up. In the locked position, the operating rod is retracted and the safety latch will freely swing back and forth. W9000180 Lockset — This is the position the fifth wheel is in when uncoupling the trailer. To achieve the lockset position, the operating rod is pulled out with a slight upward motion. The operating rod shoulder will catch on the plate casting.
Fifth Wheel Instructions 267 Fifth Wheel Slider (option) The fifth wheel comes standard with an air operational slider. To remain within legal weight limits, this feature allows the driver to distribute the load easily on the axles. The air operated slider takes the work out of adjusting the tractor for various trailer loads. The fifth wheel portion is easily adjusted, even with a fully loaded trailer connected.
268 Fifth Wheel Instructions Unlocking the Fifth Wheel Always check out the entire fifth wheel equipment before attempting to couple to a trailer (ASF fifth wheel is shown): • If not lubricated properly, add grease to the top of the fifth wheel plate. • Make sure the 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.
Fifth Wheel Instructions 269 When the shoulder of the operating rod is outside of the operating slot, raise the operating rod handle to its maximum upward position. W9000242 Release the operating rod. The upper shoulder of the operating rod should now be in contact with the plate casting above the operating slot. The fifth wheel is now in the lockset position and a trailer can be coupled.
270 Fifth Wheel Instructions Trailer Coupling Procedures This procedure covers vehicles with and without air suspension. Failure to properly couple the tractor and trailer can result in their separation, causing death and property damage. It is important that the operating procedures contained in this manual are fully understood and closely followed.
Fifth Wheel Instructions 271 Make sure the mounting of the fifth wheel to the tractor frame is tight and in good condition. If using a sliding fifth wheel, make sure the slide locking plungers are fully engaged. 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.
272 Fifth Wheel Instructions Connect the air brake lines and the electrical power cord. Make sure that any slack in the lines is supported so that the brake lines do not become entangled. Set the trailer brakes by pulling out the Trailer Supply control on the dashboard. W5000713 Check to see that the trailer is at the proper height for coupling. The leading edge of the trailer plate should initially contact the fifth wheel top plate surface about 8 in.
Fifth Wheel Instructions 273 CAUTION A direct visual check is required to ensure proper coupling. Several types of improper couplings will pass the initial pull test. Sound is not reliable. Do not take for granted that you are properly coupled. Get out of the cab and look. W9000286 Failed trailer coupling Make sure the trailer kingpin is in the jaw slot and that the jaw is closed behind the pin. The kingpin should not overhang the fifth wheel or be caught in the grease groove.
274 Fifth Wheel Instructions Make sure the operating rod is fully retracted, the safety latch is positioned above the handle and the latch swings freely. If the fifth wheel is equipped with a manual secondary lock, check to see that it is properly engaged. NOTE! If you cannot get a proper coupling, repeat this procedure. Do not use any fifth wheel which fails to operate properly. Check the kingpin to fifth wheel clearance by moving the tractor backward and forward with the trailer brakes set.
Fifth Wheel Instructions 275 Trailer Uncoupling Procedures For Tractors With Air Ride Suspension: Set the system park brake on the tractor. Set the trailer brakes by pulling out the trailer air supply knob. W5000921 Chock the trailer 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.
276 Fifth Wheel Instructions Disconnect the light cord and air brake lines. Use the dummy air couplings to keep foreign material from entering the brake lines. Unlock the fifth wheel. NOTE! If the operating rod is too difficult to pull, back the tractor up slightly to relieve 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.
Fifth Wheel Instructions 277 Wait about 30 seconds for the air springs to deflate. W9000238 With the suspension lowered, pull clear of the trailer and immediately select the “RIDE” position (press the top 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.
278 Fifth Wheel Instructions For Tractors Without Air Ride Suspension: Set the system park brake on the tractor. Set the trailer brakes by pulling out the trailer air supply knob. W5000921 Chock the trailer wheels. Use 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.
Fifth Wheel Instructions 279 Disconnect the light cord and air brake lines. Use the dummy air couplings to keep foreign material from entering the brake lines. Unlock the fifth wheel. NOTE! If the operating rod is too difficult to pull, back the tractor up slightly to relieve 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.
280 Fifth Wheel Instructions Operating the Fifth Wheel Slider WARNING The trailer must be stopped and the trailer brakes locked, or damage to the tractor and/or trailer may result from uncontrolled sliding of the fifth wheel. Stop the tractor and trailer in a straight line on level ground. Lock the trailer brakes by pulling out the Trailer Supply knob. Release the slide locking plungers by moving the switch to the “UNLOCK” position (press down the latch and push in the bottom part of the switch).
Fifth Wheel Instructions 281 Slowly drive the tractor forward or backward to position the fifth wheel. After sliding the fifth wheel to the desired position, engage the slide locking plungers by moving the cab switch to the “LOCK” position (press in the top part of the switch). W8001459 WARNING 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 tractor, trailer and landing gear.
282 Emergency Information Towing Procedure General CAUTION The driveshaft must be removed before towing the vehicle. Failure to remove the driveshaft may result in damage to the transmission. Remove the drive shaft from the rear axle before moving the vehicle, unless it only needs to be moved a small distance for safety reasons. When the transmission is driven from the rear wheels without the engine running, there is no lubrication in the transmission.
Emergency Information 283 WARNING Do not tow a vehicle backwards when equipped with roof air fairings. The fairings act as an air scoop and may break off. Failure to follow this warning may lead to personal injury and vehicle damage. WARNING Vehicles with air fairings or large superstructures are tall. Make sure that the total height of the vehicle, when it is raised up behind the wrecker, does not exceed the maximum allowed height for local underpasses.
284 Emergency Information Towing Instructions WARNING If the vehicle becomes disabled, it is very important to tow it properly. Failure to do so can cause damage to the frame and body parts. Follow the instructions below to avoid damage. In the event that the vehicle cannot be reached to place the wrecker lift bar under the front axle, use the tow hooks in the front of the vehicle. The front tow hooks are used as a point at the front of the vehicle where the vehicle can be pulled.
Emergency Information 285 Caging Spring Brake Chambers The parking spring brake chambers may be released mechanically if there is no compressed air available. Always start by chocking the wheels to prevent the vehicle from rolling. Chocking the wheels is important since you have to work under the vehicle. Failure to do so can result in unexpected vehicle movement and serious personal injury or death can occur.
286 Emergency Information Install the washer and nut. Tighten the nut. This compresses the brake chamber spring and releases the parking brake. Do not attempt in any way to disassemble 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.
Service Information 287 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, Inc. for technical help, parts or service information. There is also a direct number to Volvo Action Service (VAS), staffed 24 hours a day, if you are in need of assistance. The number to the Customer Support Center is: 1 (800) 528–6586 [or (800) 52–VOLVO]. Also on the internet: www.vas.volvo.
288 Service Information To order a single Service Manual or a Service Manual Set for your vehicle, you should contact your authorized Volvo Truck dealer or fax a request to the Volvo Truck North America, Inc. publications warehouse [Fax: (336) 668–3625]. They will help you locate the manual(s) you need. To be able to handle the order correctly, you must give the model, year and VIN (for VIN location, see page 16). Current prices for a Service Manual Set is $350.
Index 289 Index A B C ABS Telltale . . . . . . . . . . 82 Acknowledge Information and Stop Messages . . . . . . . . . . 124 Additional Safety Features . . . 46 Air Conditioning . . . . . . . 168 Air Filters, Cab . . . . . . . 178 Air Suspension Gauge . . . . . 84 Air Suspension Telltale . . . . . 82 Air Tanks . . . . . . . . . . 234 Airbag . . . . . . . . . . . . 55 Alternator . . . . . . . . . . 245 Antenna Multiplexer . . . . . 187 Antennas . . . . . . . . . .
290 F G H Index Engine Serial Number Location, Volvo Engine . . . . . . . . Engine Shut-Down System . . Engine Start and Operation . . Engine Start Procedure . . . . Engine Stopping . . . . . . . Entering Behind Cab . . . . . Entering the Cab . . . . . . . Ether Start . . . . . . . . . . Exhaust Brake . . . . . . . . . 18 211 197 197 200 . 24 . 23 204 101 Fastening Safety Belt . . . . Fifth Wheel Instructions . . . Fifth Wheel Lock Telltale . . Fifth Wheel Slider . . . . .
Index P R S Parking Brake . . . . . . . Parking Brake Telltale . . . Parking Spring Brake . . . . Power Outlets, 12 V . . . . Power Steering . . . . . . . Power Steering, General . . . Power Studs . . . . . . . . Pre-Trip Inspection and Daily Maintenance . . . . . . . . Preheater Telltale . . . . . . Pressure Gauge, Oil . . . . Pressure Gauge, Turbo Boost PTO Speed Adjustment . . . Pyrometer Gauge . . . . . . . . . . . . . 229 . 81 232 255 256 256 255 . . . . . . . . . . . . Radio . . . . . . . . .
292 Index Trailer Supply Valve . . . Trailer Uncoupling . . . . Transmission Retarder . . Turbo Boost Pressure Gauge Turn Signal . . . . . . . U V . . . . . . . . . . 229 275 243 . 71 . 91 Uphill Operation . . . . . . . 216 Vehicle Access . . . . . . . . . 19 Vendor Component Information . 1 Voltmeter . . . . . . . . . . 119 Volvo Action Service . . . . . 287 Volvo Standard Seat . . . . . 182 Volvo Trucks North America Contacts . . . . . . . . . . . .
VHD Technical and Parts Support Group If you need technical assistance, the group for technical and parts support is available 24 hours per day, 7 days per week at 1-877-978-6586. This assistance is available to assist you with solving technical issues and parts issues regarding the Volvo Heavy Duty (VHD) model vehicle. A trained Volvo VHD Specialist for Technical and Parts Support will give you the assistance you need to resolve your problem.
Volvo Trucks North America, Inc. P.O. Box 26115, Greensboro, NC 27402-6115 Volvo Trucks Canada, Inc. 6490 Vipond Drive, Mississauga, Ontario L5T 1W8 http://www.volvotrucks.volvo.com Volvo Trucks North America, Inc.
