OPERATOR'S MANUAL MAINTENANCE AND ENGINE VN, 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 Safety Information ................................. 3 Proper Maintenance Procedure ............. 3 Injury Prevention ................................... 6 Engine Damage Prevention ................. 15 Electric System Damage Prevention ... 17 Reporting Safety Defects ..................... 19 Speed Restrictive Tires ........................ 20 Fuel Safety Reminders ........................
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 IMPORTANT THAT THE FOLLOWING INFORMATION CONCERNING LABELS IS 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 Volvo Trucks North America or other manufacturers for any assistance.
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 Maintenance Manual covers all Volvo vehicles manufactured by Volvo Trucks North America, Inc., including the whole chassis and all Volvo manufactured components. For specific maintenance information on vendor components, manufactured by, for example: Cummins, Fuller, Meritor, etc.
Safety Information 3 Proper Maintenance Procedure During Maintenance Whenever performing maintenance or repair, attach a DO NOT OPERATE or similar warning label or sign to the ignition key or make sure the label or sign is prominently displayed on the instrument panel. • DO NOT allow unauthorized personnel on, around or in the vehicle when maintenance or repair is being performed.
4 Safety Information • DO NOT wear loose clothing or jewelry that can catch or get snagged by parts or moving components on the engine. Also wear all protective equipment required by the job conditions, such as protective glasses, hearing protection, etc. • Make certain that all protective covers and guards are in place and secured. • Never put maintenance fluids into glass containers since glass containers can break.
Safety Information Compressed Air and Water DANGER Compressed air can cause personal injury. When using compressed air for cleaning, wear a protective face shield, protective clothing and protective shoes. Pressurized water could cause particles and/or hot water to be sprayed in your direction and cause personal injury. The maximum air pressure must be below 30 psi (200 kPa) for cleaning purposes.
6 Safety Information Injury Prevention Burn Prevention Engine Parts WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or fluid can cause serious burns. DO NOT touch any part of the engine while it is hot. Allow the engine to cool before any repair or maintenance is performed on the engine. WARNING DO NOT raise the engine hood or cab if you see or hear steam or coolant escaping from the engine compartment.
Safety Information Coolant To prevent personal injury, do not climb up on the engine to remove the filler cap. Use a suitable, properly positioned ladder to reach up to the cap. At normal operating temperature, the engine coolant is very hot and under pressure. If pressure is relieved rapidly in a hot cooling system, the hot coolant can turn into steam. Any contact with hot coolant or steam can cause severe burns. The radiator and all heating system and radiator lines and hoses contain hot coolant.
8 Safety Information Oils WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or fluid can cause serious burns. Hot oil can cause severe burns. DO NOT allow hot oil to contact the skin. When changing oil, wear protective gloves. Batteries WARNING Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion.
Safety Information Fire or Explosion Prevention DANGER The diesel engine will operate on any fuel which enters the cylinder, whether it is from the injectors or from the air intake system. Therefore, if any solvent is used to flush out the air cleaner element, the engine may over speed during start-up. Engine damage and severe injury and/or death from burns or explosion can occur. The engine should not be operated in an area where combustible gases are suspected to be in the air.
10 Safety Information DANGER DO NOT service any part of the fuel system while smoking or in the presence of flames, sparks or hot surfaces. Failure to follow these precautions can result in fire, which can cause serious injury or death. All fuels, most lubricants and some coolant mixtures are flammable. Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes is extremely explosive. DO NOT smoke while refueling or when in a refueling area.
Safety Information Exhaust heat shields may be installed to protect oil or fuel carrying lines and pipes from hot exhaust parts. To protect from pipe or seal failure, install heat shields correctly. Provide adequate and proper waste oil disposal. Always dispose of waste liquids according to Federal and local regulations. Oil and fuel filters should be properly installed and housing covers tightened to the proper torque when being changed.
12 Safety Information Respiratory Hazard Prevention DANGER Exhaust gases contain carbon monoxide. Always run the engine outdoors or use a properly vented exhaust hose. Prolonged or excessive exposure may cause serious illness or death. WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.
Safety Information Crushing or Cutting Prevention DANGER Before working on 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. WARNING DO NOT work near the fan with the engine running or the ignition in the ON position. The engine fan can engage at any time without warning. Anyone near the fan when it turns on could be seriously injured.
14 Safety Information Wear protective glasses when striking objects to avoid injury to your eyes. Chips or other debris can fly off objects that are struck. Make sure no one can be injured by flying debris before striking any object. W0001528 Climbing Up and Down DANGER 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.
Safety Information Engine Damage Prevention Before Starting the Engine DANGER Before working on 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. Inspect engine for potential hazards. Make sure all protective guards and covers are properly installed if an engine needs to be started to make adjustments or checks.
16 Safety Information Engine Starting DO NOT start the engine or move any of the controls or disengage the parking brake if the warning tag “DO NOT OPERATE” is attached to the ignition key or located on the dash. Check with the person who attached the tag before starting. Make sure no one is working on or close to the engine or components driven by the engine before starting it. Always make an inspection of the engine before and after starting.
Safety Information 17 Electric System Damage Prevention Electric and Electronic Systems Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the flammable vapor mixture of hydrogen and oxygen to explode. To prevent potential sparks from igniting combustible gases produced by some batteries, attach the negative (—) terminal last when hooking up and remove the negative terminal first after the engine has started.
18 Safety Information Electronic Engine Control System Tampering with the electronic system installation can be dangerous and could result in personal injury or death and/or engine damage. It is very important to take the proper precautions with the electrical and electronic system when charging the batteries, jump-starting or performing electric welding on the vehicle. See the vehicle Operator’s Manual for correct procedures.
Safety Information 19 Reporting Safety Defects USA The National Highway Traffic Safety Administration (NHTSA) and Volvo Trucks North America should be informed immediately if you believe that the vehicle has a defect that could cause a crash, injury or death. Contact NHTSA by calling the Auto Safety Hotline at 1 (800) 424-9393 or by writing to: NHTSA, U. S. Department of Transport, Washington, DC 20590. 1 (800) 424-9393 or 1 (888) 327-4236 Canada Refer customer complaints to Volvo Trucks Canada, Inc.
20 Safety Information Speed Restrictive Tires DANGER Operating a vehicle equipped with Speed Restrictive Tires in excess of their stated rating may result in tread separation and/or blowout resulting in the loss of steering control and possible collision. Serious personal injury or death could occur. Always maintain proper air pressure and never exceed the tire ratings.
General Engine Design Information Engine Overview, VN D12D (Volvo V-Pulse) Right Hand View W2004343 1. 2. 3. 4. 5. 6. 7. 8. 9. EPG Air Supply Line EGR Pipes Wiring Harness Rail EGR Cooler Vibration Damper Reed Valve Housing Mixing Chamber Pre-Heater (Optional) EGR Valves 1 and 2 10. 11. 12. 13. 14. 15. 16. Shutter Housing Block Heater Air Compressor Oil Filter Bypass Oil Filter Full Flow Oil Pan Heater (Optional) Fast Lube Oil Change System (FLOCS) Optional (VN only) 17. Coolant Filter 18.
22 General Engine Design Information Engine Overview, VN D12D (Volvo V-Pulse) Left Hand View W2004380 19. Preheat Relay 20. Engine Breather Tube Crankcase Ventilation 21. Intake Manifold Pressure/Temperature Sensor 22. Fuel Pressure Inlet (injector fuel supply) 23. Coolant Temperature Sensor 24. Air Valve Unit (AVU) 25. Engine Speed Sensor 26. Fuel Return Connection 27.
General Engine Design Information Engine Overview, VHD D12D (Volvo V-Pulse) Right Hand View W2004344 1. 2. 3. 4. 5. 6. 7. 8. 9. EPG Air Supply Line EGR Pipes Wiring Harness Rail EGR Cooler Vibration Damper Reed Valve Housing Mixing Chamber Pre-Heater (Optional) EGR Valves 1 and 2 10. 11. 12. 13. 14. 15.
24 General Engine Design Information Engine Overview, VHD D12D (Volvo V-Pulse) Left Hand View W2004381 16. Preheat Relay 17. Engine Breather Tube Crankcase Ventilation 18. Intake Manifold Pressure/Temperature Sensor 19. Fuel Pressure Inlet (injector fuel supply 20. Coolant Temperature Sensor 21. Air Valve Unit (AVU) 22. Engine Speed Sensor 23. Fuel Return Connection 24.
General Engine Design Information 25 Engine Features Feature Benefit • VECTRO III - Volvo Engine Electronics System • • • • • • • • • • • Engine Brake Control Coolant Warmhold Temperature Differentiated Speed Control Road Speed Limiter RPM Limiter PTO Speed Setting Engine Protection Cruise Control Idle Speed Setting Idle Shutdown Performance Bonus • VECTRO III Diagnostics • Ease of Troubleshooting • Air-to-Air Charge Air Cooler • • • Superior Fuel Economy Peak Performance Low Process Temperat
26 General Engine Design Information Engine Features Continued Feature • Optional Pre-Heater Benefit • • Excellent Startability down to as Low as -15 F (-25 C) Minimum Smoke and Odor After Start No Fuel Dilution of Oil in Cylinder Due to Complete Combustion Less Engine Wear • • • Cylinder Liners with Plateau Honing • Optimized Oil Consumption • Engine-Mounted Fan Ring • Efficient Cooling with Low Parasitic Losses • Electronically Controlled Fuel Injection • • • Precise Control of Combust
General Engine Design Information 27 VECTRO III Customer Parameter Values, D12D Parameter Parameter Code Default Value Range Customer Password DX 000000 1–10 Alphanumeric characters Road Speed Limit (RSL) DP 68 30-87 Gear-Down Protection Enabled AJ NO Yes/No DV RSL-5 (RSL-10)-(RSL-3) AG YES Yes/No AI 65 Yes/No BK 30 30-87 AF No Yes/No RPM Limits in Top Gears AZP YES Yes/No Max.
28 General Engine Design Information VECTRO III Customer Parameter Values, D12D (Continued) Parameter Idle Shutdown Enabled • Idle Shutdown Timer (minutes) • Engine Load in PTO for Idle Shutdown (%) • Allow Permanent Idle Shutdown Override • Minimum Ambient for Idle Shutdown (%) • Maximum Ambient for Idle Shutdown (%) Parameter Code Default Value Range AL YES Yes/No AM 5 1-40 CMM 20 0–100 CMQ No Yes/No CMN No 0–60 CMO 120 70–120
General Engine Design Information Parameter Parameter Code Default Value Range Engine Protection Enabled AMQ YES Yes/No Coolant Warmhold Temp ( F) AZN 158 158 - 176 Performance Bonus Enabled ADZ No Yes/No AEB 3 1–5 BTR 3 1, 2 or 3 AEA Yes Yes/No ADX 7.0 5.0–10.
30 General Engine Design Information Engine Variants, D12D Power Output Options D12D-365 D12D-385 D12D-425 1 D12D-435 D12D-465 Output, net @ 1,800 rpm 365 hp 395 hp 425 hp 435 hp 465 hp Torque, net, @ 1,200 rpm 1,350 lb-ft (1,830 Nm) 1,450 lb-ft (1,965 Nm) 1,450 lb-ft (1,965 Nm) 1,550 lb-ft (2,101Nm) 1,650 lb-ft (2,237 Nm) Governed speed 1,900 rpm 2,000 rpm 2,100 rpm 1,900 rpm 2,000 rpm 2,100 rpm 1,900 rpm 2,000 rpm 2,100 rpm 1,900 rpm 2,000 rpm 2,100 rpm 1,900 rpm 2,000 rpm 2,100 rp
General Engine Design Information Engine Optional Equipment • Volvo Engine Brake — 350 hp braking power @ 2,300 rpm.
32 General Engine Design Information Engine Data Fill in the blanks for future reference: Vehicle Identification Number (VIN) [ ................................................................................ ] Engine Model [ .................................................................................................................... ] Engine Serial Number [ ....................................................................................................... ] Engine Power Output [ ..............
Engine Storage Engine Storage If the vehicle must be parked for a period (more than 30 days), protect it as follows: 1 Drain the engine oil. 2 Fill up to the proper level with oil of the recommended quality and viscosity. 3 Fill up the fuel tanks with the recommended grade of fuel. 4 Run the engine for two minutes around 1000 rpm. Shut the engine down. DO NOT drain the oil after this run. 5 Check the engine air filter and, if necessary, change it.
34 Engine Storage Starting Engine After an Extended Shutdown DANGER Before working on 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. If an engine has been sitting unused for more than a week or if an oil change has been performed, it is recommended that the oil pressure is established before starting the engine.
Cooling System 35 General Coolant Information General WARNING DO NOT raise the engine hood or cab if you see or hear steam or coolant escaping from the engine compartment. Wait until steam or coolant cannot be seen or heard before raising the hood or cab. DO NOT remove the coolant fill cap if the coolant in the surge tank is boiling. Also, DO NOT remove the cap while the engine and radiator are still hot. Scalding fluid and steam may be blown out under pressure if the cap is taken off too soon.
36 Cooling System Many engine failures can be traced back to a problem in the cooling system. Always make sure that the coolant level is above the min. mark on the surge tank. If the coolant level is allowed to go below the bottom of the tank, there is the risk of the engine shutting down. See the Operator’s Manual for more information on the warning functions. For information on how to change the coolant, see “Flushing Cooling System, D12D” page 96. DANGER Coolant is toxic; risk of poisoning.
Cooling System Recommended coolant consists of a 50/50 mixture of antifreeze and clean water. Never run the engine with water only. Regardless of the season, the coolant should always contain at least 40 to 60 percent ethylene glycol (antifreeze). The antifreeze also contains anti-corrosion agents that the cooling system needs to stay functional. Note: DO NOT use a winterfront for the cooling system. See the Operator’s Manual, Engine Start and Operation, for more information.
38 Cooling System Keep the radiator (including charge air cooler) and the frontal area free from bugs, dirt, leaves, etc. (see page 99 for cleaning information). Always keep the coolant level above the min. mark on the coolant expansion tank. Inspection of the whole cooling system is important. Check for swollen or deteriorated heater and radiator hoses, loose hose clamps and connections, and radiator leaks. DANGER DO NOT work near the fan with the engine running.
Cooling System 39 W2004361 1. 2. 3. 4 5. To Transmission Cooler EGR Cooler Thermostat Housing Expansion or Surge Tank Coolant Cap A well functioning and maintained cooling system is as important to the engine as performing regular oil changes or using good fuel. To get the best result it is very important to use quality products and to service the system at the right intervals. Please read this section carefully.
40 Cooling System Coolant consists of clean water and antifreeze. This mixture should never be less than 40% antifreeze and 60% clean water or more than 60% antifreeze and 40% clean water. Mix the antifreeze and water to the required concentration before adding to the cooling system. Note: DO NOT mix different products, such as regular antifreeze and extended life antifreeze. W2003082 Note: Volvo Trucks North America, Inc. does not recommend the use of antifreeze based on propylene glycol.
Cooling System The main purpose of coolant is to transport heat from the hot parts of the engine to the radiator and to protect the cooling system from corrosion. In addition to this, the coolant must: • • • • • Protect against pitting and cavitation erosion damage of the water pump and cylinder liners. Protect against freezing and boiling. Prevent formation of scale, sludge deposits and clogging. Be harmless to polymer materials and seals in the coolant system.
42 Cooling System Water Specification CAUTION Volvo Trucks North America, Inc. does not recommend using plain water in the cooling system. Water alone is corrosive at engine operating temperatures and does not provide adequate boiling protection. The engine may develop corrosion and cavitation problems in engine and radiator, and the boiling point of the coolant is lowered compared with a proper antifreeze/water mixture. The warranty is not valid when using only water in the cooling system.
Cooling System Additives Additives are part of most antifreeze and should be tested for and added to all coolant mixtures using normal antifreeze. If extended life coolant is used, the additives are in the product when mixed. Both types need to have additives added to after a time. Additives help prevent rust, scale and mineral deposits from forming. Additives also protect metals from corrosion, prevent water pump and cylinder liner cavitation and contain anti-foaming agents.
44 Cooling System Antifreeze General DANGER Coolant is toxic; risk of poisoning. DO NOT drink coolant. Use proper hand protection when handling. Keep coolant out of reach of children and animals. Failure to follow these precautions can cause serious illness or death.
Cooling System Antifreeze or premixed coolant meeting the standards ASTM D 3306 or ASTM D 4656 are primarily for automotive gasoline engines, containing high levels of silicate, and are unacceptable for heavy duty diesel engines. Water and antifreeze should generally be filled as a 50/50 mixture. The mixture should never be less than 40% antifreeze and 60% clean water or more than 60% antifreeze and 40% clean water. Mix the antifreeze/water to the required concentration before adding to the cooling system.
46 Cooling System Regular Coolant Change Interval Replace the coolant every 250,000 miles (400,000 km), 4,000 hours or every two years, whichever comes first. Coolant SCA level must be tested at least twice per year or whenever coolant loss occurs. For maximum coolant system efficiency, test the system every 25,000 to 30,000 miles (40,000 to 56,000 km) depending on engine oil change interval or every 1,000 hours or maximum every 6 months (whichever comes first). The SCA level must be between 1.
Cooling System 47 Standard Antifreeze Testing General Coolant SCA level must be tested at least twice per year and whenever coolant loss occurs. For maximum coolant system efficiency, test the system every 25,000 to 30,000 miles (40,000 to 56,000 km), depending on the oil change interval, or every 1,000 hours or every 6 months (whichever comes first). Use liquid SCA and pre-charged coolant filters to maintain a 1.5 to 3.0 SCA units per gallon (0.4 to 0.8 units per liter) concentration in the coolant.
48 Cooling System Testing Procedure Run the engine to operating temperature. After the engine has reached operating temperature, move the heater controls (on dash and in sleeper) to full heat and run the engine for 10 more minutes. EXAMPLE Step 1 • Subtract: - Coolant 1.5 units test results per gallon = Required 0.8 units SCA per per gallon gallon increase Step 2 Cooling 13 US Use actual system gallons system capacity capacity Multiply x by: Required 0.
Cooling System Changing from Regular to Extended Life Coolant Drain the system of old coolant and dispose of properly. The cooling system should be flushed with clean water. If significant deposits are visible, use a reputable commercial cooling system flush designed for heavy duty diesel engines. For specific information on draining and flushing, see “Flushing Cooling System, D12D” page 96. Note: Extended Life Coolant is not recommended by all engine manufacturers.
50 Cooling System 3 Use a reputable cleaner to clean the cooling system. Follow the recommendations that come with the cleaner. 4 Drain the cleaner and flush the cooling system with clean water. 5 Fill the cooling system with clean water and operate the engine until the coolant temperature has reached 120 to 150 F (50 to 65 C). 6 Drain the water and flush the cooling system with clean water.
Cooling System 51 Extended Life Coolant Change Interval Replace coolant every 600,000 miles (960,000 km), 12,000 hours or every four years, whichever comes first. A one-time extender package must be added to the cooling system after 300,000 miles (480,000 km), 6,000 hours or two years, whichever comes first. CAUTION Extended life coolant will test as out of additives (SCA), but SCA should not be added. Shortened engine life may be the result of adding SCA.
52 Fuel System Fuel Safety Reminders DANGER A diesel engine will operate on any fuel which enters the cylinder, whether it is from the injectors or from the air intake system. Therefore, if any solvent is used to flush out the air cleaner element, the engine may over speed during start-up. Engine damage, severe injury and/or death from burns or explosion may occur. DANGER DO NOT mix gasoline or alcohol with diesel oil fuel.
Fuel System Diesel Fuel Specification Quality Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life and acceptable exhaust emission levels. Volvo engines are designed to operate on most diesel fuels commercially available today. Volvo Trucks North America, Inc. recommends the use of diesel oil fuel which meets the specification ASTM D975 (grades No. 2–D and No. 1–D). Note: The use of lighter fuels (grade No. 1–D) can reduce fuel economy.
54 Fuel System Fuel Filters Note: When draining the fuel filters, collect the waste in a fuel-proof container. Always dispose of coolant according to Federal or local regulations. Take the drained fuel and water to a recycle or waste management center. For the Volvo engine, change the fuel filters at every other oil change when running the 15,000 mile (24,000 km) oil drain interval. Change the fuel filters every oil change when running the 25,000 mile (40,000 km) oil drain interval.
Fuel System Cetane Number Direct injected diesel engines require a minimum cetane number of 40 under normal starting conditions. Fuel with a higher cetane value may be required for high altitude or cold weather operation. Filtration Fuel should be clean and free of contamination. Clean fuels should have no more than 0.1% of sediment and water. If fuel is stored on site, make sure that: • Keep storage tank covered to prevent water entry.
56 Fuel System Fuel Pour Point Fuel pour point should be at least 10 F (6 C) lower than the lowest ambient temperature at which the engine must start and operate. Lower pour points of diesel fuel grade No. 1–D may be necessary in extremely cold weather. Fuel Cloud Point The cloud point should be below the lowest ambient temperature at which the engine must start and operate, to prevent the fuel filter elements from plugging with wax crystals. Fuel Viscosity Fuel viscosity must be kept above 1.
Fuel System Fuel Additives General Fuel additives are generally not recommended or needed for fuels listed earlier. Cetane improvers can be used as necessary. Biocides may be needed to eliminate microorganism growth in storage tanks. In cold conditions, treatment for water in the vehicle tanks may also be necessary. Consult your fuel supplier about the use of additives to prevent incompatibility among additives already in the fuel and the additives to be used.
58 Fuel System Note: Repair expenses resulting from malfunctions in the fuel system or with engine components when fuel enhancers have been used are not covered under warranty. Some fuel additives can be used to provide temporary relief but they do not replace good fuel handling practices. These products can be used: • Isopropyl Alcohol — Use 1 pint per 125 gallons (1/2 liter per 500 liters) of fuel for winter freeze-up protection. • Biocide — For treatment of microbe growth or “black slime.
Fuel System Alternative Fuels Alternative fuels can be of several different types. There are vegetable based fuels, aviation fuel and recycled petroleum based fuels that are used in combustion engines. These are in general not compatible with modern heavy duty over-the-road diesel engines. The use of unauthorized fuels may compromise the levels of pollutants in the exhaust to the point where the engine does not meet the emission requirements. This would make the vehicle illegal to drive on public roads.
60 Oil System Engine Oil General Keep the engine oil at the proper level and change it at the recommended intervals. Always replace the oil filters at the same time as when the oil is changed. Always follow the oil change intervals and use the oil types that are recommended by the engine manufacturers. Oil change intervals for Volvo engines are found on page 62 and page 63. Viscosity and capacity tables can be found beginning on page 142.
Oil System 61 Oil Quality Volvo Trucks North America, Inc. recognizes and recommends engine oils that meet or exceed the standards given by American Petroleum Institute (API) for the oil classifications listed in this manual. Only oils licensed to carry the API symbol should be used. Lubricants meeting API standards have provided maximum engine life when used together with the recommended oil and oil filter change intervals.
62 Oil System Oil Change Intervals The length of time an engine is operated before an oil change depends on which quality oil is used, the type of fuel used, engine oil consumption, vehicle application, level of dust in the air, etc. The change intervals given in this manual are maximum intervals. If the vehicle is operating in heavy-duty operation, dusty or off-road conditions, using high sulfur fuels, etc., adjust the intervals down for more frequent oil changes.
Oil System Oil Change Intervals, Volvo D12D Engine For the D12D engine, there are three columns of different oil change intervals depending on what application the vehicle is used in. Always use the correct oil quality for your application and distance driven. For example, in long haul transport, oil changes can be done every 25,000 miles (40,000 km) if the oil quality meets or exceeds both VDS-2 and EO-N Premium Plus. For oils meeting VDS-2 and CI-4 oil change intervals is met at 19,000 miles (30,000 km).
64 Oil System Synthetic Lubrication Synthetic oils are offered as an alternative to the traditional, petroleum based oils for engines. These oils may be used in Volvo engines, provided they meet the quality levels specified on the previous pages, that is: VDS-2, API CI-4, EO-N Premium Plus. Product information about synthetic oil should be reviewed carefully. Their use does not permit an automatic extension on recommended oil change intervals.
Oil System 65 Oil Viscosity The viscosity grade defines the thickness of the oil. The oil must be thin enough at low temperatures for easy cold starts and thick enough to protect at high temperatures. An oil is not fully defined until both the API quality classification and the viscosity grade are specified. Choose the viscosity grade for the typical ambient temperature for the application. Multigrade oils have a broad range that suit operation in changing temperature.
66 Oil System Sulfur Level and TBN Oils are available with different levels of Total Base Number (TBN) to counteract high sulfur levels in fuel. TBN measures an oil’s alkalinity and ability to neutralize acid. Normally, the higher the fuel sulfur, the higher the TBN is needed. Sulfur creates highly acidic pollutants in the oil that break down the additives at a higher rate. The sulfur content in low-sulfur fuel has been regulated to a maximum of 0.05% by weight for No. 2–D diesel fuel.
Oil System Oil Consumption Once the engine is stopped, check the oil level daily. If the engine has just been stopped and it is warm, wait approximately five minutes to allow the oil to drain back to the oil pan before checking. Add oil as necessary. Note: DO NOT overfill. Oil may be blown out through the engine breather tube if the level is too high. All diesel engines are designed to use some oil, so it is normal to add oil periodically.
68 Service Schedules VN, VHD Note: Use the information in the table below to determine the operating condition and usage applicable to your vehicle. HEAVY DUTY SEVERE DUTY • • • • For Cummins information: refer to Cummins literature in the introductory package inside your vehicle. • Average fuel consumption is over 4.7 liters per 10 km (under 5.0 miles per gallon) Gross combined weight (GCW) is greater than 45,000 kg (100,000lb.
Service Schedules VN, VHD Note: Once you determine the applicable operating condition for your vehicle, use the TYPE OF OPERATION 69 information in the table below to perform preventive maintenance.
70 Service Schedules VN, VHD TYPE OF OPERATION Check Air Dryer CHECK / CHANGE BASIC (4 MONTHS) X CHECK / CHANGE ANNUAL (12 MONTHS) X X Valve Adjustment ADDITIONAL SERVICE Check Warning and Control Lamps X X Check Fault Codes displayed in the vehicle Instrument Cluster X X Check Air Compressor’s Function and Condition X X Check Hinges, Doorstops, Locks and Sealing Strips X X Check External Lamps X X Check Rear view Mirrors and Reflectors X X Function Check of Wipers and Washers X X
Service Schedules VN, VHD TYPE OF OPERATION CHECK / CHANGE BASIC (4 MONTHS) CHECK / CHANGE ANNUAL (12 MONTHS) Check BatteriesDirt, Leakage, Attachment, Specific Gravity of Battery Acid, Fluid Level Connections and Battery Box X X Check Fuel Tank, Hoses, Pipes Venting and Mounting X X Check Fuel Water Separator for the Fuel system, Draining of Condensation.
72 Service Schedules VN, VHD TYPE OF OPERATION CHECK / CHANGE BASIC (4 MONTHS) CHECK / CHANGE ANNUAL (12 MONTHS) Check Mounting for Front and Rear Axle X X Check Chassis Frame and Crossmembers X X Check Compressed Air Lines and Hoses X X Check Rear Wheels and Bearings X X Check Brake Linings X X Check Brake Cylinders, Levers and Forks X X ADDITIONAL SERVICE
Maintenance 73 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 non-certified 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 prior to
74 Maintenance California and EPA 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 new 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.
Maintenance 75 MANUFACTURER’S WARRANTY COVERAGE This warranty is applicable for a period of five years, 250,000 miles or 6,250 hours of operation, whichever first occurs. If an emission-related part of your vehicle is defective, the part will be repaired or replaced by Volvo Trucks North America, Inc. This is your emission control system DEFECTS WARRANTY.
76 Maintenance 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 2 Is designed, built and equipped so as to conform at the time of sale to all regulations of the U.S.
Maintenance 77 In case of an emergency, where an authorized Volvo Trucks North America, Inc. dealer is not available, repairs may be performed at any available service establishment or by the owner, using any equivalent replacement parts and Volvo Trucks North America, Inc.
78 Maintenance WHAT IS NOT COVERED BY THE EMISSION WARRANTY This warranty does not cover: 1 2 3 4 5 6 7 Malfunctions in any part caused by any of the following: misuse, abuse, improper adjustments unless performed by a Volvo Trucks North America, Inc. dealer, modifications, alterations, tampering, disconnection, improper or inadequate maintenance, or use of fuels not recommended for the engine as described in the owner’s manual.
Maintenance 79 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.
80 Maintenance THIS EMISSIONS PERFORMANCE WARRANTY STATEMENT IN NO WAY REPLACES, MODIFIES, ALTERS OR SUPERSEDES THE TRUCK WARRANTY CERTIFICATE, ITS TERMS AND CONDITIONS, AND ITS LIMITATIONS AND EXCLUSIONS. BE CERTAIN YOU READ AND UNDERSTAND ALL WARRANTIES WHICH ACCOMPANIED YOUR VEHICLE. Note: Warranty coverage is subject to change without notice. Contact your Volvo Truck dealer for the current warranty statement.
Maintenance 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.
82 Maintenance Noise Control System, Operator Inspection and Maintenance Requirements A Noise Control System Maintenance Log is located in “Noise Control Log” page 89. This log should be used to document all Noise Control System related maintenance, whether the maintenance results from a specific noise control system inspection, or a deficiency identified during another general maintenance event. If additional log space is needed, further entries may be added on a separate sheet of paper.
Maintenance 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 or rendered
84 Maintenance Noise Shielding and Insulation Devices Make sure sound shielding and insulating devices are intact. Inspect components for damage. Primary system components requiring noise related inspection include the hood, engine compartment insulating materials (including hood insulation, bulkhead insulation, doghouse insulation, etc.) splash shields, cab skirts, fender shields, and body panels. Inspect all related fasteners, brackets, and clamps for damage and tightness.
Maintenance Cooling System WARNING DO NOT work near the fan with the engine running or the ignition in the ON position. The engine fan can engage at any time without warning. Anyone near the fan when it turns on could be seriously injured. Visually inspect cooling system components for damage, and/or misalignment. Primary system components requiring noise related inspection include fan blades, fan clutch, fan shroud, fan ring, and recirculation shields.
86 Maintenance Exhaust System Make sure the exhaust system is intact. Inspect for damage, misalignment and/or leakage. Primary system components requiring noise related inspection include muffler body, exhaust manifold, turbocharger, and all exhaust system (rigid and flexible) piping. Closely check the system for exhaust leaks. Special attention should be given to all welds, seams, gaskets, support points, clamps, couplings and connections.
Maintenance Air Intake/Air Induction System Make sure the air intake system is intact. Inspect components for damage, misalignment and/or leakage. Primary system components requiring noise related inspection include the air cleaner housing, air cleaner element, turbocharger, charge air cooler and intake manifold. Also inspect all ducts, pipes, hoses, tubing and elbows used to interconnect the system.
88 Maintenance Engine Control, EGR and Fuel Systems Acts that constitute tampering with Engine Control, EGR and Fuel Systems: Removing rendering inoperative, or modifying the engine control system such as the ECU, EGR system components or the fuel system components, in order to allow the engine to operate outside of the manufacturer’s specifications is not allowed and violates both warranty and legislation.
Maintenance Noise Control Log NOISE CONTROL SYSTEM MAINTENANCE LOG DATE MILEAGE MAINTENANCE PERFORMED MAINTENANCE FACILITY 89
90 Maintenance Maintenance Hazards DANGER 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. DANGER DO NOT attempt to repair or service this vehicle without having sufficient training, correct service literature and the proper tools. Failure to follow this could lead to personal injury or death, or making your vehicle unsafe.
Maintenance 91 Oil Change DANGER 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. WARNING A hot engine or engine oil can be dangerous. Serious burns can result from contact with a hot engine or oil. Take precautions when draining the oil. Wear gloves or let the engine cool down before draining.
92 Maintenance Oil Filters DANGER 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. WARNING Hot oil can cause severe burns. DO NOT allow hot oil to contact the skin. When changing oil, wear protective gloves.
Maintenance Checking Oil Level Note: DO NOT let the oil level fall below the lower marking on the dipstick. DO NOT overfill so the level is above the upper marking on the dipstick. Wait five minutes after shutting off the engine before checking the oil level. This gives the oil time to drain back to the oil pan. Crankcase Air Breather CAUTION If the Crankcase Breather tube is not maintained on a regular basis, it will become plugged.
94 Maintenance Engine Air Filter DANGER 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. The engine air filter is monitored by a pressure restriction gauge mounted on the air filter housing.
Maintenance 95 Fan Drive Belts DANGER 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. WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or can cause serious burns. All engine belts should be checked at each service point. Inspect for cracked or frayed material.
96 Maintenance Flushing Cooling System, D12D Draining Cooling System DANGER 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. WARNING W2003947 DO NOT remove the cap to the coolant surge tank while the engine and radiator are still hot and under pressure.
Maintenance Flushing Cooling System Before filling, flush out the system thoroughly with clean water. Before flushing out the radiator, remove the lower radiator hose to allow a quicker and more efficient draining. When flushing the radiator, keep the water pressure low so the radiator tubes are not damaged. W2003948 Filling Cooling System Always use a pre-mixed solution of 50/50 clean water and antifreeze. DO NOT fill system with water and then add antifreeze.
98 Maintenance Turbo and Charge Air Cooler General WARNING DO NOT remove, attach or tighten turbocharger air intake ducting while the engine is operating, or operate the engine while the ducting is removed. Working around the turbo with the ducting removed may cause severe personal injury. Visually inspect turbo mountings, intake and exhaust ducting and connections for leaks on a daily basis. Check oil inlet and outlet for leaks or signs of restrictions to oil flow. Check for unusual noise or vibration.
Maintenance 99 Cleaning Charge-Air-Cooler and Radiator Package Over time, dirt and insects will accumulate between the fins of the radiator, air conditioning condenser and charge-air-cooler. The reduced air flow reduces the heat transfer from the components to the air. This increases the load on the fan and air conditioning compressor and can result in engine overheating and other performance related problems, such as high fuel consumption, etc.
100 Maintenance Replacing Fuel Filters General The filters are an important part of the fuel system. Always replace the filters at the recommended intervals and use the recommended filter types for the best engine operation and service life. A primary fuel filter is located on the outer right, inside front wheel or outer left frame rail, behind the cab. This filter consists of a filter cartridge, a water separation bowl and may have a fuel heater built in.
Maintenance Fuel System Service Changing the Primary Fuel Filter DANGER 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. The standard primary filter is manufactured by Racor. Use only the 30 micron (red coded) element. Failure to do so could result in reduced power.
102 2 Maintenance Separate the filter and the bowl. Note: Always dispose of fuel according to Federal or local regulations. Take all waste fuel to a recycling or waste collection center. 3 Clean and dry the bowl. Attach it to a new filter. Use new seals at both bowl and filter head joint. Install both on the filter head in the vehicle. CAUTION Never fill filter with fuel before installing. Contaminated fuel causes accelerated wear to fuel system components.
Maintenance Changing the Secondary Fuel Filter DANGER 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. 1 WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or can cause serious burns. Clean around the fuel filter.
104 3 Maintenance Wet the seal on the new filter with clean engine oil or fuel. 4 CAUTION Never fill filter with fuel before installing. Contaminated fuel causes accelerated wear to fuel system components. Spin on the new filter onto the filter head until it fully contacts the seal (no side movement evident). Tighten an additional 1/2 to 3/4 turn by hand. DO NOT overtighten! 5 To eliminate air from the filter, operate the primer pump to draw fuel and fill the filter.
Maintenance Bleeding the Fuel System DANGER 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. The fuel system will need to be bled if: • • The tank has been emptied of fuel. • Service work has been done on the fuel system, for example cleaning or replacing fuel filter elements. • The engine is new or rebuilt.
106 Maintenance Bleeding the D12D Engine Note: Prior to bleeding the engine, make sure the key is in the ignition in the “ON” mode (engine is stopped) and the parking brakes are applied. Once the 4 minute bleeding process is complete, you can start the engine. To bleed the D12D engine simply press or push the fuel priming activation switch located on the right hand side of the steering column, in the dash. This is a non-locking switch, which when pressed, sends a signal to the Vehicle ECU (VECU).
Maintenance Draining Water from the Fuel Tank DANGER 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. Water accumulates in the fuel tank in the process of air entering the tank and water vapor condensating. This water will collect in the bottom of the tank and should be emptied out regularly.
108 Maintenance Transmission and Rear Axle Maintenance Transmission General Transmissions should not be operated consistently at temperatures above 250 (120 C). F If the temperature reaches 285 F (140 C), stop the vehicle to let the temperature go down (see the vehicle Operator’s Manual for information on the optional transmission temperature gauge). Operating temperatures above 250 F (120 C) increase the lubricant’s rate of oxidation and shorten its effective life.
Maintenance Oil Quality CAUTION Use only the specified type of single weight oils. DO NOT use multigrade oils or EP gear oils (for example axle lube oil such as GL-5 gear oils) as they may damage components. Monograde motor oils or transmission oil type API GL-1 are recommended for transmissions. Choose the correct viscosity for the outside temperature the vehicle will be operated in. See page 142 for the beginning of viscosity charts.
110 Maintenance DriveShaft DANGER If the driveshaft universal joints are not lubricated properly, they can be damaged to the point of the driveshaft separating from the vehicle. Driveshaft separation may cause loss of control of the vehicle resulting in severe personal injury or death. Note: RPL drivelines are not greaseable. Note: Make sure grease is purging from all four ends of the universal joint. If the universal joint can not be properly lubricated, replace it.
Maintenance 111 Checking and Draining Oil Check the oil level through the top plug 1. The oil should be level with the hole. Add oil if necessary. Drain oil through the bottom plug 2. Oil should be drained immediately after driving while it is still hot. WARNING Hot oil can cause severe burns. DO NOT allow hot oil to contact the skin. When changing oil, wear protective gloves. Note: Also check the rear axle ventilation for blockage. A blockage can cause overpressure in the axle and start oil leaks.
112 Maintenance Steering and Brakes Maintenance Steering System Excessive play in the steering system is checked by turning the steering wheel while the engine is stopped. With the front wheels pointing straight ahead, turn the steering wheel until the front wheel starts moving. Then, turn the steering wheel the other way until the front wheel moves. Play should not be more than 1 in. (25 mm) at the rim of the steering wheel.
Maintenance Steering Linkage Wear Check Wear is checked by gripping the linkage, tie rod or draglink, close to the ball joint and moving the seat of the ball axially. If there is a larger movement, remove the vehicle from service and have the linkage replaced before driving. Inspection Station Criteria The joint should not move more than maximum 1/8 in. (3mm) measured with hand pressure only.
114 Maintenance Brake Safety Information Note: The brake system is a critical vehicle safety system. For your safety and for those around you, follow the recommended preventive maintenance checks. If any problems occur, have them investigated immediately by an authorized service facility. DANGER Failure to properly maintain the brake system can result in compromised brake efficiency and may lead to loss of control of the vehicle resulting in severe personal injury or death.
Maintenance 115 Air Tanks 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. Air tanks should be drained daily. Make sure the drain cocks close properly after draining. Empty moisture from air tanks by pulling the drain valve lanyard or pull cord. The tanks should be checked for condensation fluid, even if an automatic drain valve is installed.
116 Maintenance Brake Slack Adjusters and Cam DANGER Before checking the slack adjusters, 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. To check the slack adjusters for proper throw, use a breaker bar to lever the slack adjuster out. Measure the distance of the travel. It should not exceed 1 to 1 1/4 in. (25 to 30 mm) for a 6 in.
Maintenance 117 Brake Linings DANGER Before measuring the brake linings, 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. Measure the brake lining thickness. If the brakes are equipped with backing plates, measure through the inspection holes in the plate. Reline the brake shoes if the lining thickness is 1/4 in. (6 mm) or less at the middle of the shoe.
118 Maintenance Check Valves Follow the procedure below to check out the air tank check valves at least once a year. This is to see if air pressure is maintained in the tanks when the air pressure is depleted in the supply tank (wet tank). Note: The check valves should be checked at least once per year. 1 2 3 4 5 6 Chock the rear wheels. Let the compressor build up air pressure to the governor cut-off. Bleed the air pressure from the supply tank (wet tank).
Maintenance 119 Front and Rear Brake System Air Pressure Air pressure in the two circuits is monitored by two pressure gauges on the right side of the instrument panel. The gauge for the secondary (front) brake circuit is marked with an “F” within a symbol and The gauge for the primary (rear) brake circuit is marked with an “R” within a symbol. The two pointers should register equal or nearly equal pressure.
120 Maintenance Electrical System Maintenance Battery Care WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. The electrolyte level on maintenance free batteries cannot be checked. Periodically, the condition and the state-of-charge of each battery should be checked by a Volvo Truck dealer.
Maintenance 121 Note: The illustration refers to the information in the VN interior lights table that follows. WARNING Using bulbs or lamps other than those specified may result in failures that could lead to a fire or a vehicle accident caused by improper lighting.
122 Maintenance Interior Lights VN, VHD Chart Number Bulb Volvo Number Bulb Number Maximum Wattage Rating 8 Overhead Dome/Spot Lamp 85107036 946777 Dome: 577 Spot: 50082 18W 10W 9 Control Panel Lamp 3132931 193 (T-3) 4.
Maintenance 123 Exterior Lights, VNM Bulb Volvo Number Number Maximum Wattage Rating High/Low Beam 3098653 9007 9007 55W 65W Driving lights 85103971 886 50W Fog Lights 3946923 H3-55 62W Front Turn Lamp 85104039 3157AK 28W Front Parking Light 85104039 194NA 3.
124 Maintenance Exterior Lights, VNL Bulb Volvo Number Number Maximum Wattage Rating High/Low Beam 85104041 85104040 H11 HB3 55W 65W Driving lights 85103971 886 50W Fog Lights 85103970 896 50W Front Turn Lamp 85104039 3157AK 28W/8W001 Front Parking Light 85107045 194NA 3.8W Marker Front Side 3132932 194 3.
Maintenance 125 Bulb Replacement List, VHD Exterior Lights VHD Bulb Volvo Number Number Maximum Wattage Rating High/Low Beam 3131227 3132904 H5001–18522 H5006-18523 50W 35W Fog Lights 39416923 H3-55 62W Front Turn Lamp 3132941 1157NA 24W Left/Right Turn/Stop Rear 3132940 1157 28W/8W Front Parking Light 3132940 1157 28W/8W Side Repeater Lamp 965826 1156 28W Brake Lights 3132939 1156 28W Parking Rear Lights 3132940 1157 28W/8W Cab Marker Light 3132929 67 8W Trailer Ma
126 Maintenance Tires, Wheels and Hub Maintenance Wheel Safety Information DANGER DO NOT attempt to repair wheels or tires unless you are trained and equipped to do so. Wheel and tire assemblies cannot be worked on without proper tools and equipment. Failure to follow this may lead to serious personal injury or death. DANGER Failure to properly torque-tighten the wheel nuts can result in the breakage of wheel studs and the subsequent loss of wheels.
Maintenance 127 Wheels DANGER Before checking the wheels, 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. DANGER Wheels must be serviced only by a qualified technician. DO NOT do this work yourself. Inflated tires on wheels contain compressed air and if suddenly released, do so with an explosive force, resulting in serious personal injury or death.
128 Maintenance Wheel Nut Tightening After the initial tightening, retightening must be made within the first 500 miles (800 km). After the first retightening, only normal inspection of nut tightness is needed. Check front and rear wheel nut tightness with a torque wrench. All disc wheels for Volvo vehicles have a tightening torque of 610 Nm (450 ft-lb). Tighten the nuts in the correct sequence. For spoke wheels, check the manufacturer’s specifications. Inspect bolts and nuts for signs of wear or cracks.
Maintenance 129 Tire Inflation and Wear DANGER Before checking the tires, 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. WARNING Check tire pressure when the tire is cool. Never bleed the air from hot tires. Increased tire pressure measured in a hot tire is normal.
130 Maintenance Front Wheel Hubs The front wheel hubs can be filled with one of several types of oil. Motor oil should be SAE 30 or 15W40. The oil can be either petroleum based or synthetic (synthetic should not be used for the Volvo axle). Axle oil, API GL-5, SAE 75W-90, can also be used. There are no set change intervals for hub lubrication. The only requirement is that if the hub is opened, the lubricant must be changed.
Maintenance Chassis Maintenance Springs Note: This work is best performed by a Volvo Truck dealer or other service outlet having the proper equipment. The spring package is fastened to the axle beam with U-bolts. It is important that the U-bolt nuts are properly tightened. The nuts may loosen up with time. Severe roads and service will loosen them faster. Loose U-bolts can cause springs to break, axle misalignment, hard steering and abnormal tire wear.
132 Maintenance Spring Bushings DANGER 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. When lubricating the springs, lift the axle off of the floor, suspend the frame with axle stands and lower the axle. The spring bushings are now in the position where grease can be added to the contact surfaces.
Maintenance 133 T-Ride Equalizer Beams The Volvo T-Ride suspension has equalizer beams between the tandem axles. The beam bushing needs to be lubricated at the normal lube intervals for normal highway driving. If the vehicle is being driven in severe climates with a lot of wet, slushy, highly dusty roads, or in off-road service, increase the frequency of lubrication. If driving in severe duty, where water may enter the bushing, daily lubrication may be necessary.
134 Maintenance Hood The hood latch mechanism should be greased with white grease yearly. If the mechanism is hard to work or binds, the latch should be cleaned before greasing. W8001132 Rustprotection The rustprotection applied when the cab was produced is adequate for normal use and service. If an extension of the cab rustprotection is desired or if the vehicle is used in a severe application, it is recommended that cavity wax is re-applied every 3rd year.
Maintenance Paint and Brightwork Care Cab Wash all exterior painted surfaces frequently to remove dirt. It is especially important to wash off salt-laden snow and ice during the cold season. A mild detergent can be used but avoid strong detergents. Note: DO NOT aim the water jet directly at door and window seals or door locks. If locks are filled with water, use compressed air to clean the water out and then apply liquid graphite.
136 Maintenance Chassis Keep the chassis free from buildup of dirt. Make sure the chassis is cleaned before the maintenance inspections to help spotting leaks, etc. As salt can be part of the road sludge during the cold season, remove buildup of snow and ice so it does not promote corrosion. At the end of the cold season, thoroughly flush away all collected dirt from the chassis. Stainless Steel Stainless steel will rust if exposed to salt for too long.
Maintenance Aluminum Unprotected aluminum surfaces will form an oxide layer if not maintained. This is especially important during the cold season when roads are salted or in coastal areas where the salt level in the air is high. Clean with steam or high pressure water. Use a mild detergent if the dirt is heavy. Rinse well. Clean aluminum surfaces with warm water. If the surface has heavy dirt or tar spots, use a tar remover. To prevent spotting, wipe aluminum surfaces dry after washing.
138 Maintenance Lubrication Chart W1000189 The numbers in the lubrication chart correspond with the numbered notes on page 140 and page 141. Read these notes before selecting a lubricant. * Grease Coolant Hub Oil Aut. Transm. Fluid Engine Oil Man. Transm.
Maintenance 139 Lubrication VN, VHD Chassis Lubrication DANGER Before working on or servicing 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. General lubrication includes lubricating all the grease fittings in the drivetrain, front and rear suspensions, power steering, and front axle, using a grease gun. Grease the chassis every 15,000 miles (24,000 km).
140 Maintenance Lubrication Chart Notes 1 Note: To grease non-Volvo axles, they are typically greased with the wheels on the ground. Consult with the axle manufacturer for the latest recommendation. Spring hanger: Use a lithium based grease with specification API NLGI No. 2. When lubricating the left and right sides of the front springs, lift the axle off of the floor, suspend the frame with axle stands and lower the axle.
Maintenance 141 Lubrication Chart notes Continued. 12 Coolant level: Add coolant if necessary. Only use pre-mixed clean water and antifreeze in a 50/50 mix. Add only the same type antifreeze, that is: extended life or standard. 13 Steering assist cylinder: Use a lithium based grease with EP additives to specification API NLGI No. 2 to grease both ball joints. 14 Power steering fluid: Check the fluid in the reservoir with the dipstick. Add oil if necessary. Use ATF Dexron® III.
142 Maintenance Viscosity and Capacity Tables Volvo Engine D12D For oil change intervals, see page 62 and page 63 First oil and filter change After 1 month or 6,000 miles (10,000 km) Capacity (including filters) D12 service 37 quarts (35 liters) Oil volume between high and low on dipstick 7.5 quarts (7.0 liters) W1000144 Cooling System Capacity* VN, D12D ......... 43.5 liters (11.50 US gal.) VHD, D12D ...... 39 liters (10.30 US gal.
Maintenance 143 Fuller Transmission 9,10, 13, 15 and 18–speed For oil change intervals, see the manufacturer’s Oparator’s Manual Capacity: 9-speed .............. 13.5 quarts (12.0 liters) 10, 13, 15 and 18-speed ............ 14.0 quarts (13.0 liters) W1000179 Allison Automatic Transmission For oil change intervals, see the manufacturer’s Operator’s Manual. Approximate Capacity: MD3560P 5-speed MD3060P 5-speed 19.0 quarts (18.0 liters) HD4060P 5-speed HD4560P 5-speed 39.0 quarts (37.
144 Maintenance Volvo Tandem CTEV87 and RT3210 Oil type: Petroleum based oil ...................... API-GL5, MIL-PRF-2105E First oil change After one month or 6,000 miles (10,000 km) Normal oil change interval .............. every 12 month or 75,000 miles (120,000 km) Synthetic lubricant ............ NOT USED Capacity: CTEV87 front tandem, EV87 ................. 21.0 quarts (20.0 liters) rear tandem ....... 9.5 quarts (9.0 liters) RT2610 front tandem ...... 24.5 quarts (23.
Maintenance 145 Meritor Single RS23, 25, 26 and 30 Meritor Tandem RT40, 44 and 46 For oil change intervals, see the manufacturer’s Operator’s Manual Capacity: RS23-160 .......... 20 quarts (19 liters) RS23-185 .......... 23.5 quarts (22.5 liters) RT40-145, front tandem RT40-145, rear tandem 15 quarts (14 liters) 13 quarts (12 liters) W4000881 1) Select viscosity from the table above. Temperatures refer to stable ambient temperature readings.
146 Maintenance Steering Hydraulic System Fluid type ..........
Literature Service Assistance and Manuals Your Volvo Truck dealer is trained and equipped to perform expert service on your Volvo vehicle. Your dealer has direct access to Volvo Trucks North America, 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.
148 Literature To order a single Service Manual or a Service Manual Set for your vehicle, contact your authorized Volvo Truck dealer. In order to process the request correctly, please give the model, year and VIN (last six digits of VIN). For VIN location, refer to the General Information section, under Vehicle Data, in the VN/VHD Operator’s Manual. Service Manual prices will vary depending on the make and model of engine in the vehicle.
Service Charts 149 Scheduled Services The vehicle had a pre-delivery inspection before being delivered to you, the customer. Regular maintenance inspections should be continued. The maintenance program and lubrication intervals that are listed in this manual may not suit your operation. Contact your nearest Volvo dealer, who can help with designing a maintenance program that works in your application. For regular service or maintenance, call the dealer in advance and arrange for a service appointment.
Date Mileage Scheduled Service Date Vehicle Age at Service Service Charts Preventive Maintenance (See local dealer for Service Information in group 17, "Preventive Maintenance Basic Service VN, VHD VERSION2" and group 17, "Preventive Maintenance Annual Service VN, VHD VERSION2.
Work Completed Date Mileage Preventive Maintenance (See local dealer for Service Information in group 17, "Preventive Maintenance Basic Service VN, VHD VERSION2" and group 17, "Preventive Maintenance Annual Service VN, VHD VERSION2.
152 Service Charts Repair Record Keep track of repairs being made. This helps over the lifetime of the vehicle to spot trends that can be used to alter maintenance schedules, for example.
Repair Record Date Mileage Work Order or Invoice No.
154 Repair Record Mileage Work Order or Invoice No.
Repair Record Date Mileage Work Order or Invoice No.
156 Repair Record Mileage Work Order or Invoice No.
Service Charts 157 Tire Record Tire Hints Hints on How to Avoid Unnecessary Tire Wear • • • • • • • • Maintain correct tire pressure Check the tire pressure when the tires are cold Check that valve caps are not missing Keep the wheels balanced Tire wear increases with speed Overloading not only decreases tire life but also creates a hazard Incorrect front end alignment causes increased wear Unnecessary tire rotation may cause excessive wear Note: A cold weather initial driving period will increase the
158 Service Charts Typical Wear Patterns Incorrect Air Pressure A Too high air pressure gives rapid wear in the middle. B Too low air pressure gives rapid shoulder wear. T1006457 Incorrect Camber Incorrect camber gives abnormal wear on one half of the tire. T1006458 Incorrect Toe and Axle Alignment A Incorrect toe-in. B Incorrect toe-out.
Service Charts 159 Dual Wheel Mounting A Excessive road camber, different types of tire, different circumference or off-center loading gives faster wear on one tire. B Too low air pressure, mismatched rims for the tire type and dimension, excess flexing in tire wall, or different types of tires in inner and outer tires gives contact wear. T1006718 Incorrect Caster and Imbalance A Caster angle. B Imbalance. Also rapidly wears the mechanical parts of steering linkage, kingpin and wheel bearing.
160 Service Charts Spot Wear Sudden braking, locking brakes or out-of-round brake drums gives spot wear. T1006721 Feathered Edges Normal occurrence on non-driving wheels on good roads and high mileage. T1006722 Cupping Cupping is a normal occurrence that depends on the tread pattern; the higher the load, the greater the wear.
Service Charts 161 AXLE LOAD/TIRE PRESSURE Axle Load lb (kg) Recommended tire pressure psi (kPa) W1000109
162 Service Charts Tire Record Size Ply Rating Make Type Serial No.
Service Charts 163 Tire Record Date Installed Date Removed Mileage At Installation At Removal Tire Mileage Notes
164 Service Charts Tire Record Size Ply Rating Make Type Serial No.
Service Charts 165 Tire Record Date Installed Date Removed Mileage At Installation At Removal Tire Mileage Notes
166 Service Charts Tire Record Size Ply Rating Make Type Serial No.
Service Charts 167 Tire Record Date Installed Date Removed Mileage At Installation At Removal Tire Mileage Notes
168 Service Charts Fuel and Oil Record Keeping track of the fuel and oil consumption gives a record of what is normal for the vehicle. This can be compared with other vehicles in the same service application to indicate what is normal fuel and oil consumption for a certain application.
Date Mileage Filled Fuel Qty. Oil Qty. SAE No.
Mileage Filled Fuel Qty. Oil Qty. SAE No.
Date Mileage Filled Fuel Qty. Oil Qty. SAE No.
Mileage Filled Fuel Qty. Oil Qty. SAE No.
Date Mileage Filled Fuel Qty. Oil Qty. SAE No.
Mileage Filled Fuel Qty. Oil Qty. SAE No.
Date Mileage Filled Fuel Qty. Oil Qty. SAE No.
Index 177 Index Emissions Control Compliance ...... 73 Engine Air Filter ............................. 94 Engine Damage Prevention ............. 15 Engine Data Notes .......................... 32 Engine Features .............................. 25 Engine Monitoring Systems ........... 18 Engine Oil Change .......................... 91 Engine Oil Filters ............................ 62 Engine Oil, General ........................ 60 Engine Optional Equipment ........... 31 Engine Overview, D12D .............
178 Index Fuel Viscosity ................................. 56 Fuel, Alternative ............................. 59 R Radiator Package, Cleaning ............ 99 Rear Axle Oil ................................ 110 Respiratory Hazard Prevention ....... 12 Roadside Assistance ..................... 147 Rubber Bushings ........................... 132 G General Coolant Information .......... 39 General Engine Design Information ..................................... 21 General Information .........................
1-800-52-VOLVO Volvo Action Service (VAS) Support Center If you need assistance on the road or if you need service repairs, contact the VAS support center. VAS is available 24 hours per day, 7 days per week at 1-800-528-6586. Please report the specific nature of the service problem to the Volvo Customer Support Specialist, who will answer your questions and arrange for the assistance you need.
Volvo Trucks North America, Inc. P.O. Box 26115 Greensboro, NC 27402-6115 Volvo Trucks Canada, Ltd. 5600A Cancross Court, Mississauga, Ontario L5R 3E9 http://www.volvotrucks.volvo.com PV776-20707967 (USA) 07.2004 © Volvo Trucks North America, Inc.
