Service Manual Trucks Group 177–500 Preventive Maintenance Basic Service VN,VHD PV776-TSP151476
Foreword The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to December 2001. The products are under continuous development. Vehicles and components produced after the above date may therefore have different specifications and repair methods. When this is believed to have a significant bearing on this manual, supplementary service bulletins will be issued to cover the changes. The new edition of this manual will update the changes.
Contents General .................................................................................................... 3 Preventive Maintenance, General ........................................................... 3 Safety Advice ......................................................................................... 7 Specifications ......................................................................................... 9 Engine ..............................................................................
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Group 177 General General Preventive Maintenance, General Introduction Maintenance Coverage This manual describes inspection and lubrication requirements during the Basic Service of Volvo VN/VHD vehicles. The purpose for doing the preventive maintenance is to ensure that the vehicle is safe and roadworthy over its full lifetime. There is no firm maintenance program that will apply to all operations.
Group 177 Program Structure This maintenance program has been based on the progress in vehicle technology and increases in oil quality to simplify the maintenance. For simplified scheduling, the program has tied maintenance to logical time or mileage limits that make it easy to anticipate needed servicing. For the majority of onhighway operators, the 24,000 km (15,000 miles) or 4 months schedule can be used with little change. It is important that the scheduled intervals are followed as limits.
Group 177 General Other Inspection There are additional service points that are carried out at specific mileage or time intervals. These are not part of the Preventive Maintenance Basic time. They should be scheduled as an adjustment or repair job carried out at the same time as the Preventive Maintenance, and are listed in this document as reminders only.
Group 177 General 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, to all applicable U.S. EPA Noise Control Regulations, at the time it left the control of Volvo Trucks North America, Inc.
Group 177 General Safety Advice Never operate a diesel engine in an area where hydrocarbon vapors (gasoline for example) are present or are suspected to be present. Hydrocarbon vapors can enter the air intake and make the engine overspeed, causing severe damage and/or explosion or fire. Serious personal injury or death can occur. Always chock the wheels before working under the vehicle to prevent it from rolling.
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Group 177 Specifications Specifications Engine General For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” Publication Number 175–001, and any appropriate vendor literature. In a modern diesel engine it is very important to have regular oil changes.
Group 177 VOLVO ENGINES Note: It is not recommended to mix synthetic oils with petroleum based oils. For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature. Maximum change intervals are 40,000 km (25,000 miles) if using oil that meets the Volvo Drain Specification (VDS).
Group 177 Specifications DETROIT DIESEL ENGINES For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature. The use of fuels with a sulfur content above 0.5% by weight will require more frequent oil changes. Refer to Detroit Diesel Publications for details.
Group 177 Specifications Transmission Includes Volvo, Eaton Fuller, Meritor, and Allison HD Transmissions For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature.
Group 177 Specifications Rear Axle Includes Volvo, Arvin Meritor, and Eaton Dana Rear Axles For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature.
Group 177 Tools Tools Special Tools and Special Equipment The following special tools are recommended for use in the preventive maintenance inspection. Special tools can be ordered through Volvo Special Tools program in the parts ordering system or already from Kent-Moore by calling (800) 328–6657. (Kent-Moore tools are preceded by a J.) Please refer to the specific tool number when ordering.
Group 177 Tools Special Tools (Continued) J-44302 A/C Schrader Valve Core Removal Tool J-443338 Oil Dipstick for A/C Compressor J-22610 Drive Shaft Boot Camp Pliers J-43143 Tie Strap Tensioner J-41610 Feeler Gauge Set J-44392 Fan Belt Tensioner Tool 15
Group 177 Tools Special Tools (Continued) PT 5900 Chip Vacuum 9998142 Charge Air Cooler Pressure Tester J-38641-B Diesel Fuel Hydrometer J-44544 Ride Height Gauge 000700 Rim Flange Wear Gauge 16
Group 177 Tools Other Special Equipment J-42397-A Coolant Pressure Test Adapter 1089953 Bulb Removal Tool J-38460-ADigital Inclinometer J-36795 Tandem Axle Calipers 3093472 Timken Wheel End Play Gauge 9996791 Spring Pin Socket J-23600-B Belt Tension Gauge 17
Group 177 Tools Other Special Equipment (Continued) 18 9998691 Oil Filter Nipple Installer Kit 3947553, 3949521, 3946522, 3949523 Terminal and Shim Kits J-44701 Battery Tester Kit J-44778, J-44779 Driveshaft U-Joint and Yoke Kits
Group 177 Tools VCADS Pro Tools The following hardware is used to operate VCADS Pro. The tools can be ordered from Volvo Trucks North America; please refer to the specific tool number when ordering.
Group 177 Tools Lighting System, Special Tools The tools listed below are used to complete maintenance on the Lighting System for Volvo Trucks. They may be obtained from Volvo or, where indicated, from Kent Moore at (800) 328-6657.
Group 177 Tools Preventive Maintenance Inspection Bay Location Equipment Preventive Maintenance is logically carried out at the same time as lubrication of the vehicle. It is then natural to use a bay with a grease pit to be assigned and equipped for Preventive Maintenance. If a pit is not available, a regular workshop bay can be used, with jacks added to the necessary equipment. Inspection bay equipment should be specifically assigned to that bay and not be shared with the rest of the shop.
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Group 177 Design and Function Design and Function Clutch General For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature. Hydraulic fluid in the clutch system collects moisture from the air and will eventually hold enough moisture to affect the metal surfaces in the system unless removed.
Group 177 Design and Function Other Clutch Slave Cylinder A slave cylinder for any non-Volvo clutch has a wear indicator. When the indicator is out of the operating range, it is time to adjust the clutch. To get the slave cylinder throw into the accepted range, adjust the clutch plate until the indicator is in the operating range again.
Group 177 Design and Function Power Take-off Volvo PTO For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature. Volvo PTO’s mount directly to the transmission and do not need separate oil fill and check. Make sure there is extra oil filled in the transmission for the PTO volume.
Group 177 Brakes Brake Cams and Slack Adjusters For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature. Lubricate the brake cam bushings using a lithium based grease with EP additives and consistency NLGI No. 2. Fill grease until old grease has been pushed out past the seal and new grease can be seen flowing.
Group 177 Design and Function Steering System Steering Linkage and Knuckles For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature. Lubricate the Steering shaft and drag link. Lubricated the tie rod.
Group 177 Steering System For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature. A darkened fluid indicates a steering system that is running hotter than normal and the fluid is overheated. Troubleshoot the reason for overheating and change fluid.
Group 177 Design and Function Chassis Springs and Suspension Note: For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate vendor literature. Lubricate spring pins using a lithium based grease with EP additives and the consistency of NLG1 No.2.
Group 177 T-Ride Equalizer Beam Note: For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate vendor literature. In regular over-the-road operations the T-Ride should follow the normal lubrication schedule. It is extremely important that the equalizer beam is well lubricated in any off-road or on/off-road operation.
Group 170 Preventive Maintenance Preventive Maintenance Basic Service Including Lubrication and Oil Change Date: Model: Reg. No.
Group 170 Preventive Maintenance Checks Beneath the Vehicle Engine Compartment Checks 36 Check Alternator Mounting and Electrical Connections 37 Check Drive Belts 38 Check Radiator Fan, Fan Shroud and Fan Ring with Rubber Seal 39 Check Radiator, Hoses and Pipes 40 Check Engine and Engine Driven Power Take-Off for Leaks 41 Check Fuel Pipes and Lines 42 Check for Exhaust Leakage 43 Check Intercooler Pipes and Hoses 44 Check A/C Compressor Mounting 45 Check A/C Hoses, Fittings, Switches,
Group 170 Preventive Maintenance Comments 33
Group 170 Preventive Maintenance Reception When the customer drops off the vehicle, the service reception starts the paperwork and prepares the forms needed for the preventive maintenance. Ask the customer about problems that have been noticed while driving the vehicle.
Group 170 Preventive Maintenance Lubrication Make sure that grease fittings are cleaned off before filling grease. Dirt on the fitting that is not cleaned off is pushed into the part with the new grease. Always fill grease to the point where old grease and contaminants are forced out from the part and only new grease comes out. If grease cannot be filled so old grease is forced out or if new grease exits without pushing old grease out, note this on the form for repair.
Group 170 Preventive Maintenance 1 Chassis Lubrication Note: For VN vehicles only. Front Axle Steering Knuckles Note: For further information concerning the steering system refer to Function Group 6. Volvo:Two grease fittings on each side: one on the top knuckle cover (fill with grease until the old grease is forced out past the top seal), one on the bottom cover (fill with grease until the old grease is forced out past the bottom seal).
Group 170 Preventive Maintenance Steering Linkage Note: Greasable drag links are also available as an option. 1 Lubricate the Steering shaft and drag link. 2 Lubricated the tie rod. TRW steering gears have a seal at the sector shaft that needs greasing with a hand gun every 4 months or more often if the weather and road conditions are severe.
Group 170 Preventive Maintenance Slack Adjusters Note: For further information refer to literature in Function Group 5. There is one grease fitting per slack adjuster. Fill with grease until old grease is forced out past the splined center and adjustment pawl area, and only uncontaminated grease is visible. Front Spring Pins Note: For further information refer to literature in Function Group 7. 1 Raise the front end of the truck up with a jack.
Group 170 Preventive Maintenance Clutch Bearing and Cross Shaft The Volvo Clutch Release Bearing is sealed for life and does not need lubrication. However, the cross shaft must still be lubricated. Vendor clutch cross shafts and release bearings need to be lubricated. The cross shaft bearings are remotely lubricated by a hose. The grease fitting is located on the right side of the bell housing. Grease the release bearing — but do not overgrease.
Group 170 Preventive Maintenance Fifth Wheel Note: For further information refer to Function Group 9. Lubricate the plate pivot points and slide mechanism. Apply a heavy coat of grease on top of the plate.
Group 170 Preventive Maintenance 2 Cab Lubrication Lubricate Door Locks 1 Grease door locks with white lithium grease as needed. 2 Clean excess grease off of the painted areas of the door. 3 Clean and lubricate scissor latch at the base of the cone receptacle with white lithium grease. Steering Gear Note: For further information refer to literature in Function Group 6 TRW and Sheppard steering gears may have severe weather seals at input shaft or sector shaft that need greasing.
Group 170 Preventive Maintenance 3 Change Engine and Oil Filters For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate vendor literature. Change engine oil and filters. If required by customer, take a sample of the oil for analysis. Note: Make sure the oil type is correct and has the correct viscosity.
Group 170 Preventive Maintenance Oil Filters 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. CAUTION Use only the engine manufacturer’s oil filter for replacement. Use of an oil filter not built to specification could result in severe damage to bearings, crankshaft, etc. as a result of unfiltered oil entering the lubrication system.
Group 170 Preventive Maintenance Check Oil Level In Manual Transmission 4 For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate vendor literature. Note: Synthetic oil is not recommended for the Volvo transmissions. Volvo: See specifications for conventional oil and filter change intervals.
Group 170 Preventive Maintenance 5 Check Oil Level in Automatic Transmission 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. Note: For further information refer to “Transmission” page 12.
Group 170 Preventive Maintenance Cold Check: Note: The fluid level rises as its temperature rises. Do not fill above the Cold Run band if the transmission fluid is below normal operating temperatures. 46 1 The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made. 2 Run the engine for at least one minute. Apply service brake.
Group 170 Preventive Maintenance Hot Check: Note: The fluid must be hot to insure an accurate check. The fluid level rises as the temperature increases. 1 Operate the transmission in Drive (D) range until normal operating temperature is reached: • • sump temperature 71–93 C (160–200 F) converter-out temperature 82–104 C (180–220 F) 2 Park the vehicle on a level surface and shift to Neutral (N). Apply the parking brake and chock the wheels. Allow the engine to idle (500–800 rpm).
Group 170 Preventive Maintenance 6 Check Oil Level in PTO (Power Take-Off) Note: For further information refer to Function Group 4. For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate vendor literature. Power Take-Off Volvo PTO Volvo PTOs mount directly to the transmission and do not need separate oil fill or checks.
Group 170 Preventive Maintenance 7 Check Oil Level in Retarder For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate vendor literature. To ensure the correct oil level in the retarder the oil level should be checked when the retarder is warm.
Group 170 Preventive Maintenance 9 Check Oil Level in Front Drive Axle Note: For further information refer to Function Group 6. Checking and Draining Oil WARNING 1 Level/Fill Plug 2 Drain Plug Serious burns can result from contact with a hot engine or engine oil. Take precautions when draining the oil. Wear gloves and let the engine cool down before draining.
Group 170 Preventive Maintenance 10 Check Oil Level in Rear Drive Axle Note: For further information refer to Function Group 6. Checking and Draining Oil WARNING 1 Level/Fill Plug 2 Drain Plug Serious burns can result from contact with a hot engine or engine oil. Take precautions when draining the oil. Wear gloves and let the engine cool down before draining. Check the oil level through the top plug. The oil should be level with the hole. Add oil if necessary. Drain oil through the bottom plug.
Group 170 Preventive Maintenance 12 Check Oil Level in Power Steering Note: For further information refer to Function Group 6. For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate vendor literature. Darkened fluid indicates that the power steering system is running hotter than normal and overheating the fluid.
Group 170 Preventive Maintenance 15 Check Oil Level in Clutch Fluid Reservoir Note: For further information refer to Function Group 4. For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate vendor literature. Check that the fluid level is in even with the LEVEL line below the filler neck of the fluid reservoir.
Group 170 Preventive Maintenance 18 Check Air Dryer Air Dryers For further information refer to Function Group 5. For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate vendor literature. Air Dryers have internal maintenance systems that clean out the accumulated moisture frequently and can therefore work with long maintenance intervals.
Group 170 Preventive Maintenance Cab 19 Check Warning and Control Lamps For further information refer to Function Group 8. For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate vendor literature. Check all indicators on the instrument cluster. Turn the ignition on. Wait until the instrument cluster has gone through the start-up cycle.
Group 170 Preventive Maintenance 20 Check for Fault Codes in the Vehicle Electronic Control Unit The instruments and engine control units, are always included in the system. Other included control units depend on the vehicle variant, legal requirements, and the vehicle specifications.
Group 170 Preventive Maintenance 21 Check for Fault Codes in the Engine Electronic Control Unit Use Service Information in Function Group 23 as a reference. When reading fault codes perform the following: • • • The engine is off. 1 Read on the instrument cluster display that no fault codes are saved in the ECU. The parking brake is applied. The starter key is in the drive position (I). Note: Fault codes can also be traced using a diagnostic program run through a PC.
Group 170 Preventive Maintenance 23 Check for Fault Codes in Transmission Note: Use Service Information in Function Group 4 as a reference. To complete the Fault Code Check for Transmission perform the following: 1 Check that no fault codes for the Transmission are displayed in the instrument cluster. 2 Write down any fault codes require correction. Note: Fault codes can also be traced using a diagnostic program run through a PC. Note: Refer to pertinent VCADS Pro Tool documentation.
Group 170 Preventive Maintenance 25 Check Retarder Control Ensure that the control’s steps are well-defined and that the control stops in the set position. 26 Check Sealing on Main Brake (Service) To perform the check of the Main Brake Seal perform the following: 1 Start engine. 2 Charge the Compressed Air System to 7.5 bar (109 psi). 3 Shut off engine. 4 Release the parking brake. 5 Apply the foot pedal for a minimum of five minutes. Use a pedal jack whenever appropriate.
Group 170 Preventive Maintenance 27 Check Gear Shift and Clutch Pedal To perform a service check on the Gear Shift and Clutch Pedal complete the following: 60 1 Move the gearshift to range and split gear positions. Listen to the sound when passing through neutral and checking the range gear. The control lamp should light up when the high split gear is engaged. 2 Check, on the automatic transmission, that the engine can only be started when the gear selector is in neutral (N).
Group 170 Preventive Maintenance External Checks 28 Function Check of External Lamps To perform a function check of the External Lamps perform the following: 1 Check all external lighting for functionality. 2 Check that all lamps are in good condition. 29 Check Mirrors and Reflectors To perform a function check of the mirrors and reflectors complete the following: 1 Check that the rear view mirrors are in good working condition and remain in position when set.
Group 170 Preventive Maintenance 30 Function Check of Wipers and Washers Check the wiper arm tension and condition of the wiper blades. 31 Check Battery Mounting, Connections and Fluid Levels To complete a function check of the battery mounting, and connections, complete the following: 1 Inspect battery hold-downs for proper placement and tightness. 2 Make sure the connections are free from corrosion. 3 Inspect cables for proper length, chafing and proper routing.
Group 170 Preventive Maintenance 32 Check Fuel Tank, Hoses, Pipes and Mounting Straps To complete a service check of the fuel tank, hoses, pipes and mountings complete the following: 1 Check the fuel tank mounts. 2 Check the fuel tank straps and J-brackets and ensure they are tight and that the tanks haven’t rotated. 3 Inspect the fuel tank brackets for cracks. 4 Check the fuel lines for proper routing, wear and leaks.
Group 170 Preventive Maintenance 34 Check Water Separator for Fuel System For further information refer to Function Group 2. Note: If the filter is not being changed, drain the water separator. 64 1 Check the primary fuel filter. 2 Write date and mileage on filter when changed. 3 Check the secondary fuel filter. 4 Write date and mileage on filter when changed.
Group 170 Preventive Maintenance 35 Check Tire Wear and Wheel Alignment Tire Wear For further information refer to Function Group 7. 1 Examine each tire tread for unusual wear patterns. Refer to chart below for typical tread patterns. 2 Measure tread depth. 3 Check tire pressure and leak-test valve stems. 4 Check the Rim Flange wear on Aluminum Wheels every time the tire is replaced.
Group 170 Preventive Maintenance Wheel Alignment Check Total Wheel Alignment. For further information refer to Service Bulletin 601–006, “Wheel Alignment, Steer and Drive Axles, VN/VHD.” Note: For Total Vehicle Alignment, if A is less than B then a Toe In problem exists.
Group 170 Preventive Maintenance Thrust Measure and compare thrust for both the left and right side of the vehicle. Acceptable differences depends upon wheel base. Vehicle Thrust Angle Camber The Camber is set by the axle manufacturer to Volvo specifications and is not adjustable.
Group 170 Preventive Maintenance Engine Compartment Checks 36 Check Alternator Mounting and Electrical Connections For further information refer to Function Groups 2 and 3. 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.
Group 170 Preventive Maintenance 38 Check Radiator Fan, Fan Shroud and Fan Ring with Rubber Seal For further information refer to literature in Function Group 2. Ensure that the engine cannot be started while working around the fan area. Failure to do so may result in serious personal injury or death. Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle. For further information on Noise Emissions refer to “Noise Emissions” page 6.
Group 170 Preventive Maintenance 39 Check Radiator, Hoses and Pipes Note: For further information refer to literature in Function Group 2. WARNING Do not remove the cap from the coolant surge tank while the engine and radiator are still hot. Scalding fluid and steam may be blown out by pressure if the cap is removed while the engine and radiator are hot. Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle.
Group 170 Preventive Maintenance 41 Check Fuel Pipes and Lines Note: For further information refer to literature in Function Group 2. To complete a check of the fuel pipes and fuel lines complete the following: 1 Check that the hose and pipe fittings for the fuel lines don’t leak. 42 Check for Exhaust Leakage Note: For further information refer to literature in Function Group 2.
Group 170 Preventive Maintenance 43 Check Intercooler Pipes and Hoses Note: For further information refer to literature in Function Group 2. Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle. For further information on Noise Emissions refer to “Noise Emissions” page 6. WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with debris or fluids.
Group 170 Preventive Maintenance 45 Check A/C Hoses, Fittings, Switches, and Wires Note: For further information refer to literature in Function Group 2. WARNING Do not remove the cap to the coolant surge tank while the engine and radiator are still hot. Scalding fluid and steam may be blown out under pressure if the cap is taken off to soon. Cab Climate Control Unit Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle.
Group 170 Preventive Maintenance Front Suspension, Steering System Checks 46 Check Gaiters/Plastic Covers and clearance for Ball Joints Note: For further information refer to literature in Function Group 6. To perform a check of the Gaiters/Plastic Covers and clearance for the Ball Joints complete the following: 1 Check that all Gaiters/Plastic Covers are undamaged. 2 Check joints for play by manually pushing and pulling each ball stud.
Group 170 Preventive Maintenance 48 Check Steering Shaft Joint, Hoses an Pipes for Power Steering Note: For further information refer to literature in Function Group 6. To perform a check of the Steering Shaft Joint, Hoses and Pipes for Power Steering perform the following: 1 Check the Steering Shaft Joint for leaks, cracks and other damage. 2 Check the hoses for the Power Steering for leaks. 3 Check the pipes for the Power Steering for cracks and other damage.
Group 170 Preventive Maintenance Checks Beneath the Vehicle 49 Check Sealing on Front and Rear Drive Axle Note: For further information refer to literature in Function Group 7. To perform a check of the sealing on the Front and Rear Drive Axles complete the following: • Check hub for leakage around front and rear drive axle shaft flange. 50 Check Slack in Mechanical Linkage for Clutch Note: For further information refer to literature in Function Group 4.
Group 170 Preventive Maintenance 51 Check Gearbox, Transfer Case, and Power Take-Off Mounting and Sealing Note: For further information refer to literature in Function Group 2. To perform a check of the Gearbox, Transfer Case, and Power Take-Off complete following: • • • Visually check the Gearbox for any leaks. Visually check the Transfer Case for any leaks. Visually check the PTO and attached hoses for any leaks.
Group 170 Preventive Maintenance 53 Check Retarder Sealing To perform a check of the Retarder Sealing complete the following: • 78 Check the Retarder Sealing for any cracks or leaks.
Group 170 Preventive Maintenance 54 Check Drive Shaft, Universal Joints, Sliding Joints and Support Bearings Note: For further information refer to literature in Function Group 4. To perform a check of the driveshaft, Universal Joints, Sliding Joints and Support Bearings complete the following: 1 Check transmission output shaft bearing for wear. Move the flange up and down; bearing play should not be larger than 1.5 mm (1/16 in.). 2 Check for oil leaks past the transmission output shaft seal.
Group 170 Preventive Maintenance 55 Check Sealing of Rear Axle and Hub Reduction Gear Note: For further information refer to literature in Function Group 7. To perform a check of the Sealing on the Rear Axle and Hub Reduction Gear complete the following: 1 On the Rear Axle, inspect around the mating surfaces for leaks past the gasket. 2 Check brake chamber and air tubing condition. 3 Check Hub Reduction Gear for any leaks or cracked sealant.
Group 170 Preventive Maintenance 57 Check Exhaust Pipe, Silencer, or Particulater Filter Note: For further information refer to literature in Function Group 2. Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle. For further information on Noise Emissions refer to “Noise Emissions” page 6.
Group 170 Preventive Maintenance 59 Check Central Lubrication System Not applicable to VN/VHD vehicles. 60 Check Air Suspension and Air Springs Note: For further information refer to literature in Function Group 7. To perform a check of the Air Suspension and Air Springs complete the following: 82 1 Check suspension torque rods and the top shock absorber mounts for wear and looseness. 2 Inspect all spring hanger, torsion leaves and suspension fasteners to the axle.
Group 170 Preventive Maintenance 61 Check Rear Wheel Bearing Clearance Note: For further information refer to literature in Function Group 7. To perform a check of the rear wheel bearing clearance complete the following: • Check wheel bearings with a dial indicator. Bearing axial clearance should be within 0.04 to 0.12 mm (0.001 to 0.005 in.). 62 Check Front Wheel Bearing Clearance Note: For further information refer to literature in Function Group 7.
Group 170 Preventive Maintenance 63 Check Brake Linings Note: For further information refer to literature in Function Group 5. To perform a check of the Brake Linings complete the following: • Measure the brake lining through the inspection holes in the backing plates. See each manufacturer’s specifications for minimum lining thickness. 64 Check Brake Cylinders, Levers and Forks Note: For further information refer to literature in Function Group 5.
Group 170 Preventive Maintenance 65 Check Brake Disc and Calipers Note: For further information refer to literature in Function Group 5. To perform a check of the brake discs and calipers complete the following: 1 Remove the wheel. 2 Inspect the brake discs and calipers for signs of wear or damage. 66 Check Brake Levers, Slack Adjusters, and Brake Drums Travel Note: For further information refer to literature in Function Group 5.
Group 170 Preventive Maintenance Test Driving 67 Check After Start Check Clutch Operation Note: For further information refer to literature in Function Group 4. Read through the road test section to become familiar with what needs to be checked before taking the vehicle on the road. Do not read while operating the vehicle-loss of vehicle control may occur. Start the test drive by checking clutch pedal play and clutch operation. Clutch pedal play should be 4 to 10 mm (0.15 to 0.40 in.
Group 170 Preventive Maintenance Check Instruments and Gauges Note: For further information refer to literature in Function Group 3. Check all instruments and gauges for proper function. If possible, check the odometer against a measured mile. Check Safety Restraints Note: For further information refer to literature in Function Group 8. Failure to properly inspect and maintain the safety belts can cause serious personal injury or death.
Group 170 Preventive Maintenance Check Horns Note: For further information refer to literature in Function Group 8. Sound both the air horn (1) and the electrical horn (2). Each should have a strong, even tone. 68 Check During Test Driving Check Clutch Operation Note: For further information refer to literature in Function Group 4. During driving check for smooth operation and engagement when shifting gears. Look for uneven engagement and/or unusual noise.
Group 170 Preventive Maintenance Check ABS System Note: For further information refer to literature in Function Group 5. To do the brake test safely, ensure there are no other vehicles within 300 yards when testing, or perform the test in a off-road area where there is no traffic. Performing a brake test in traffic may lead to an accident, and cause personal injury or death. Check the ABS system by attempting to lock up the wheels during hard braking. The vehicle should come to a controlled stop.
Group 170 Preventive Maintenance Check Engine Controls and Performance Note: For further information refer to literature in Function Group 3. Check engine controls and performance while moving through the gears. Accelerator pedal should work smoothly and without any hesitation in engine response. Engine should accelerate smoothly and without hesitation, misses or surges. Also check the exhaust through the mirrors for excessive smoke during acceleration.
Group 170 Preventive Maintenance Check Transmission Operation Note: For further information refer to literature in Function Group 4. Check the transmission for smooth operation through the gear pattern. Listen for any unusual noise during shifting. Check for excessive play in the shift lever. Drive vehicle in all gears and listen for any unusual differences in sound between the gears. Check Cruise Control Note: For further information refer to literature in Function Group 3.
Group 170 Preventive Maintenance Check Heater and Air Conditioning Note: For further information refer to literature in Function Group 8. Check function of heater and air conditioning. Operate the controls and let the fan run on all speeds. Note: In the summertime, the shut-off valves for the heater may be closed for the season. Open valves before testing heater.
Group 170 Preventive Maintenance 69 Check After Test Driving Check Pneumatic Switches Note: For further information refer to literature in Function Group 8. If vehicle is equipped with a pneumatic 5th wheel sliding release, operate release mechanism while listening through door or have a helper check the function. Verify that the telltale indicator on the instrument cluster lights up. Note: If vehicle air pressure is below approximately 720 kPa (75 psi), pneumatic switches will not function.
Group 170 Preventive Maintenance Engine Low Idle Note: For further information refer to literature in Function Group 3. Record the engine low idle speed. Listen for idling problems such as surging, missing or unusual noise. See each engine manufacturer’s specification for correct idle speed. Record low and high oil pressure. Check Low Air Warning Switches Note: For further information refer to literature in Function Group 8. Pump the brake pedal while observing the air gauges.
Group 170 Preventive Maintenance Check Compressor Loading Note: For further information refer to literature in Function Group 5. Raise the air pressure until it is 5.8 bar (85 psi). Time the air pressure build time from that point with the engine at full speed. The pressure should reach 6.9 bar (100 psi) in 25 seconds or less. Verify that the governor cutout is at 9 ± .34 (130 ± 5 psi). Listen for unusual noises from the compressor while it is running under load and unloaded.
Group 170 Preventive Maintenance 70 Finish Drive Vehicle; Check Fluids Drive the vehicle around the block to settle the oil and to verify any points that were found during the inspection. Check all fluid levels. Make sure there are no signs of leakage after changing oils or filters. Clean Clean all areas that have been dirtied during the test drive. As a courtesy to the customer, be especially careful about making sure the cab area is as clean or cleaner than when the vehicle came into the shop.
Group 170 Additional Time Based Maintenance Every: Year Volvo Engine Adjust valves on the VE D7C and the D12 engine every 12 months, regardless of mileage. Preadjust the D7C engine initially at 6 to 8 months. Preadjust the D12 at 3 months. See engine manual for specifications and procedures. Every: Two Years Engine Coolant Caterpillar: Coolant Extender Added Engine coolant needs to be changed every two years unless the maximum mileage has been reached before that.
Group 170 Every: Three Years Caterpillar: Engine Valves and Injector Preload Caterpillar: Engine Compression Brake Slave Piston Lash Engine valve lash adjustment is checked and, if necessary, adjusted every third year. At the same time, adjust the injector preload. Refer to the Caterpillar Service Manual for correct procedure. If the engine is equipped with an engine compression brake, adjust the slave piston lash after the engine valves are adjusted. Make the adjustment with the engine stopped.
Group 170 Additional Mileage Based Maintenance Every: 80,000 km (50,000 miles) Eaton Fuller and Meritor Transmissions Regular oil change intervals when petroleum oil is used are at every 80,000 km (50,000 miles). See specification section for oil types and viscosities. Every: 96,000 km (60,000 miles) Caterpillar: Initial Valve Lash/Injector Preload Do an initial check on engine valve clearance and injector preload, between 19,000 and 96,000 km (12,000 and 60,000 miles). Adjust if necessary.
Group 170 Every: 190,000 km (120,000 miles) Detroit Diesel: Engine Valve Clearance and Injector Height Cummins: Overhead Set Adjustment Check valve clearance and injector height. Adjust each as necessary. For specific information refer to Detroit Diesel Service Manual. Check valve clearance and injector adjustment. Adjust each as necessary. For specific information refer to Cummins Service Manual.
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Volvo Trucks North America, Inc. P.O. Box 26115, Greensboro, NC 27402-6115 Volvo Trucks Canada, Ltd. 6490 Vipond Drive, Mississauga, Ontario L5T 1W8 http://www.volvotrucks.volvo.com PV776-TSP151476 (700) 12.2001 © Volvo Trucks North America, Inc.
