Volvo VN Service Manual
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Volvo VN Service Manual

Volvo VN Service Manual

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See also: Operator's Manual
Service Manual
Trucks
177–500
Group
Preventive Maintenance
Basic Service
VN,VHD
PV776-TSP151476

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Table of Contents
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Summary of Contents for Volvo VN

  • Page 1 Service Manual Trucks 177–500 Group Preventive Maintenance Basic Service VN,VHD PV776-TSP151476...
  • Page 2 Greensboro, NC USA Order number: PV776-TSP151476 © 2001 Volvo Trucks North America, Inc., Greensboro, NC USA All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means, electronic, me- chanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc..

  • Page 3: Table Of Contents

    Contents General ....................3 Preventive Maintenance, General ............3 Safety Advice ..................7 Specifications ..................9 Engine ....................9 Transmission ..................12 Rear Axle ..................... 13 Tools ...................... 14 Special Tools and Special Equipment ..........14 Preventive Maintenance Inspection Bay ..........21 Design and Function ................

  • Page 5: General

    The pro- gram in this service manual covers all types of Volvo The driver is taking part in the continuous preventive VN/VHD vehicles with medium to high mileage and maintenance program by completing the required Daily sometimes high loads.
  • Page 6 For further information concerning component specifica- nance needs. tions see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, The “Driver Inspection Form” is also required by Publication Number 175–001, and any appropriate ven- Federal law.
  • Page 7 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.
  • Page 8 U.S. EPA Noise Control Regulations, at the Removing or rendering inoperative the cab tunnel or time it left the control of Volvo Trucks North America, Inc. hood noise insulating materials. This warranty covers this vehicle as designed, built and Removing or rendering inoperative any truck body equipped by Volvo Trucks North America, Inc., and is not...

  • Page 9: Safety Advice

    Group 177 General Safety Advice Never operate a diesel engine in an area where hy- Always chock the wheels before working under the drocarbon vapors (gasoline for example) are present vehicle to prevent it from rolling. Failure to do so can or are suspected to be present.

  • Page 11: Specifications

    Coolant tures and longer service intervals, make the choice of correct oil a hard task. The Volvo dealer, the engine The engine coolant protects the cooling system from manufacturer or the oil manufacturer has the expertise to freezing or boil over problems.
  • Page 12 175–001, and appropriate vendor literature. Maximum change intervals are 40,000 km (25,000 miles) if using oil that meets the Volvo Drain Specification (VDS). If the oil does not meet the requirements accord- ing to VDS, change intervals should be 24,000 km (15,000 miles).
  • Page 13 Supplemental coolant additives are recommended for all Detroit Diesel cooling systems. Antifreeze alone does not provide sufficient corrosion protection for heavy duty diesel engines. Note: The Detroit Diesel Engine is installed in earlier VN vehicles (from 1996–2000) only. CATERPILLAR ENGINES For further information concerning component specifica- tions see service information in Group 1, “Oil and Filter...

  • Page 14: Transmission

    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.

  • Page 15: Rear Axle

    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.

  • Page 16: Tools

    Special Tools and Special Equipment The following special tools are recommended for use in the preventive maintenance in- spection. 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.
  • Page 17 Group 177 Tools Special Tools (Continued) J-44302 J-443338 A/C Schrader Valve Core Removal Tool Oil Dipstick for A/C Compressor J-22610 J-43143 Drive Shaft Boot Camp Pliers Tie Strap Tensioner J-41610 J-44392 Feeler Gauge Set Fan Belt Tensioner Tool...
  • Page 18 Group 177 Tools Special Tools (Continued) PT 5900 9998142 Chip Vacuum Charge Air Cooler Pressure Tester J-38641-B J-44544 Diesel Fuel Hydrometer Ride Height Gauge 000700 Rim Flange Wear Gauge...
  • Page 19 Group 177 Tools Other Special Equipment J-42397-A 1089953 J-23600-B Coolant Pressure Test Adapter Bulb Removal Tool Belt Tension Gauge J-38460-ADigital Inclinometer J-36795 Tandem Axle Calipers 3093472 9996791 Timken Wheel End Play Gauge Spring Pin Socket...
  • Page 20 Group 177 Tools Other Special Equipment (Continued) 9998691 3947553, 3949521, 3946522, 3949523 Oil Filter Nipple Installer Kit Terminal and Shim Kits J-44701 J-44778, J-44779 Battery Tester Kit Driveshaft U-Joint and Yoke Kits...
  • Page 21 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. PC tool-package J-43939, 9 pin Diagnostic adapter (for VN vehicles...
  • Page 22 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. J-25300-D 1089953...

  • Page 23: Preventive Maintenance Inspection Bay

    Group 177 Tools Preventive Maintenance Inspection Bay Location Equipment Preventive Maintenance is logically carried out at the Inspection bay equipment should be specifically as- same time as lubrication of the vehicle. It is then natural signed to that bay and not be shared with the rest of the to use a bay with a grease pit to be assigned and shop.

  • Page 25: Design And Function

    General For further information concerning component specifica- tions see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature. 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.
  • Page 26 Group 177 Design and Function Other Clutch Slave Cylinder A slave cylinder for any non-Volvo clutch has a wear in- dicator. 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 operat- ing range again.

  • Page 27: Power Take-Off

    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.

  • Page 28: Brakes

    Brake Cams and Slack Adjusters For further information concerning component specifica- tions see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature. Lubricate the brake cam bushings using a lithium based grease with EP additives and consistency NLGI No.

  • Page 29: Steering System

    Steering Linkage and Knuckles For further information concerning component specifica- tions see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature. Lubricate the Steering shaft and drag link. Lubricated the tie rod.

  • Page 30: Hubs

    Steering System For further information concerning component specifica- tions see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175–001, and appropriate vendor literature. A darkened fluid indicates a steering system that is run- ning hotter than normal and the fluid is overheated.

  • Page 31: 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 appropri- ate vendor literature. Lubricate spring pins using a lithium based grease with EP additives and the consistency of NLG1 No.2.

  • Page 32: Cab

    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 appropri- ate vendor literature. In regular over-the-road operations the T-Ride should follow the normal lubrication schedule.

  • Page 33: Preventive Maintenance

    Group 170 Preventive Maintenance Preventive Maintenance Basic Service Including Lubrication and Oil Change Date: Model: Reg. No.: Time: Vehicle Identification Number: Engine: Dealer Code: Transmission Name: Rear Axle: √ = Correction not needed X = Corrected without comment N = Not relevant or applicable Lubrication, Oil and Fluid Level Check Cab Checks Chassis Lubrication...
  • Page 34 Group 170 Preventive Maintenance Checks Beneath the Vehicle Engine Compartment Checks Check the Oil Cooler and Transmission for Leak- Check Alternator Mounting and Electrical Connec- tions Check Retarder for Leakage Check Drive Belts Check Drive Shaft, Universal Joints, Sliding Joints Check Radiator Fan, Fan Shroud and Fan Ring and Support Bearings with Rubber Seal...
  • Page 35 Group 170 Preventive Maintenance Comments...
  • Page 36 Group 170 Preventive Maintenance Reception When the customer drops off the vehicle, the service re- ception starts the paperwork and prepares the forms needed for the preventive maintenance. Ask the cus- tomer about problems that have been noticed while driving the vehicle. Ask questions that will make the job easier for the technician to find problem sources: —...
  • Page 37 Group 170 Preventive Maintenance Lubrication Make sure that grease fittings are cleaned off before fill- cept lubrication due to damage or internal stoppage, ing grease. Dirt on the fitting that is not cleaned off is replace with a new fitting. pushed into the part with the new grease.

  • Page 38: Chassis Lubrication

    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...
  • Page 39 Group 170 Preventive Maintenance Steering Linkage Note: Greasable drag links are also available as an op- tion. Lubricate the Steering shaft and drag link. 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.
  • Page 40 Lower the jack so that the front axle hangs free. Note: Volvo only uses Chevron Grease EP #2. Then thoroughly grease through the grease fitting until the lubricant emerges past the bushing seals, cleaning out all contaminants.
  • Page 41 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.
  • Page 42 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.

  • Page 43: Cab Lubrication

    Group 170 Preventive Maintenance Cab Lubrication Lubricate Door Locks Grease door locks with white lithium grease as needed. Clean excess grease off of the painted areas of the door. 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 Func- tion Group 6...

  • Page 44: Change Engine Oil And Filters

    Change Engine and Oil Filters For further information concerning component specifica- tions see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate ven- dor literature. Change engine oil and filters. If required by customer, take a sample of the oil for analysis.
  • Page 45 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 in- jury or death.

  • Page 46: Check Oil Level In Manual Transmission

    Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate ven- dor literature. Note: Synthetic oil is not recommended for the Volvo transmissions. Volvo: See specifications for conventional oil and filter change intervals.

  • Page 47: Check Oil Level In Automatic Transmission

    12. For further information concerning component specifica- tions see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate ven- dor literature. Transmission fluid cools, lubricates, and transmits hy- draulic power.
  • Page 48 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. 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.
  • Page 49 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. Operate the transmission in Drive (D) range until normal operating temperature is reached: • sump temperature 71–93 C (160–200 •...

  • Page 50: Check Oil Level In Pto (Power Take-Off)

    Publication Number 175-001, and any appropriate ven- dor literature. Power Take-Off Volvo PTO Volvo PTOs mount directly to the transmission and do not need separate oil fill or checks. Make sure there is extra oil filled in the transmission for the PTO volume. CAUTION...

  • Page 51: Check Oil Level In Retarder

    Check Oil Level in Retarder For further information concerning component specifica- tions see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate ven- dor literature. To ensure the correct oil level in the retarder the oil level should be checked when the retarder is warm.

  • Page 52: Check Oil Level In Front Drive Axle

    Drain Plug For further information concerning component specifica- tions see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate ven- dor literature. Check the oil level through the top plug. The oil should be level with the hole.

  • Page 53: Check Oil Level In Rear Drive Axle

    Note: Also check the rear axle ventilation for blockage. Blockage can cause extreme pressure in the axle and create leaks. Check Oil Level in Hydraulic Axle Lift Not applicable in VN/VHD vehicles.

  • Page 54: Check Oil Level In Power Steering

    The front wheel hubs are lubricated with several types of oil. It is acceptable to use either synthetic or petroleum based oils (Synthetic oils are not recommended for Volvo Axles). Change the Hub lubricant during routine hub mainte- nance.

  • Page 55: Check Coolant Freeze Protection And Coolant Level (Check Sca Level)

    Note: For further information refer to Function Group 4. For further information concerning component specifica- tions see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate ven- dor literature.

  • Page 56: Check Air Dryer

    For further information refer to Function Group 5. For further information concerning component specifica- tions see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components, All Models”, Publication Number 175-001, and any appropriate ven- dor literature.
  • Page 57 Note: For VN/VHD vehicles with the Traction Control System (TCS) five ’chuffs’ occur for each valve. If the vehicle is equipped with a Volvo engine, the engine preheater indicator stays on three to four seconds. If the coolant temperature is over 50...
  • Page 58 Group 170 Preventive Maintenance Check for Fault Codes in the Vehicle Elec- tronic Control Unit The instruments and engine control units, are always included in the system. Other included control units de- pend on the vehicle variant, legal requirements, and the vehicle specifications.

  • Page 59: Check For Fault Codes In The Engine Electronic Control Unit

    Group 170 Preventive Maintenance Check for Fault Codes in the Engine Elec- tronic Control Unit Use Service Information in Function Group 23 as a refer- ence. When reading fault codes perform the following: • The engine is off. • The parking brake is applied. •...

  • Page 60: Check For Fault Codes In Transmission

    Group 170 Preventive Maintenance 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 per- form the following: Check that no fault codes for the Transmission are displayed in the instrument cluster.

  • Page 61: Check Retarder Control

    Group 170 Preventive Maintenance Check Retarder Control Ensure that the control’s steps are well-defined and that the control stops in the set position. Check Sealing on Main Brake (Service) To perform the check of the Main Brake Seal perform the following: Start engine.

  • Page 62: Check Gear Shift And Clutch Pedal

    Group 170 Preventive Maintenance Check Gear Shift and Clutch Pedal To perform a service check on the Gear Shift and Clutch Pedal complete the following: Move the gearshift to range and split gear positions. Listen to the sound when passing through neutral and checking the range gear.

  • Page 63: External Checks

    Group 170 Preventive Maintenance External Checks Function Check of External Lamps To perform a function check of the External Lamps per- form the following: Check all external lighting for functionality. Check that all lamps are in good condition. Check Mirrors and Reflectors To perform a function check of the mirrors and reflectors complete the following: Check that the rear view mirrors are in good work-...

  • Page 64: Function Check Of Wipers And Washers

    Group 170 Preventive Maintenance Function Check of Wipers and Washers Check the wiper arm tension and condition of the wiper blades. Check Battery Mounting, Connections and Fluid Levels To complete a function check of the battery mounting, and connections, complete the following: Inspect battery hold-downs for proper placement and tightness.

  • Page 65: Check Fuel Tank, Hoses, Pipes And Mounting Straps

    Group 170 Preventive Maintenance Check Fuel Tank, Hoses, Pipes and Mounting Straps To complete a service check of the fuel tank, hoses, pipes and mountings complete the following: Check the fuel tank mounts. Check the fuel tank straps and J-brackets and en- sure they are tight and that the tanks haven’t rotated.

  • Page 66: Check Water Seperator For Fuel System

    Group 170 Preventive Maintenance 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. Check the primary fuel filter. Write date and mileage on filter when changed. Check the secondary fuel filter.
  • Page 67 Group 170 Preventive Maintenance Check Tire Wear and Wheel Alignment Tire Wear For further information refer to Function Group 7. Examine each tire tread for unusual wear patterns. Refer to chart below for typical tread patterns. Measure tread depth. Check tire pressure and leak-test valve stems. Check the Rim Flange wear on Aluminum Wheels every time the tire is replaced.
  • Page 68 Wheel Alignment Check Total Wheel Alignment. For further information re- fer to Service Bulletin 601–006, “Wheel Alignment, Steer and Drive Axles, VN/VHD.” Note: For Total Vehicle Alignment, if A is less than B then a Toe In problem exists. Total Vehicle Alignment...
  • Page 69 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. Vertical Line Wheel Center Line Camber Angle(C - D)

  • Page 70: Engine Compartment Checks

    Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle. For further information on Noise Emis- sions refer to “Noise Emissions” page 6. To perform a function check of the Drive Belts complete the following: Check fan belts for correct tension.

  • Page 71: Check Radiator Fan, Fan Shroud And Fan Ring

    Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle. For further information on Noise Emis- sions refer to “Noise Emissions” page 6. Perform the Check of the Hubs and Pulleys as follows: Inspect fan blades for any damage.

  • Page 72: Check Radiator, Hoses And Pipes

    Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle. For further information on Noise Emis- sions refer to “Noise Emissions” page 6. Perform the Check of the Radiator, Hoses and Pipes as...

  • Page 73: Check Fuel Pipes And Lines

    Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle. For further information on Noise Emis- sions refer to “Noise Emissions” page 6. To perform a check of the exhaust system complete the following: Check the exhaust flex line for routing.

  • Page 74: Check Intercooler Pipes And Hoses

    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 Emis- sions 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.

  • Page 75: Check A/C Hoses, Fittings, Switches, And Wires

    Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for Cab Climate Control Unit any Volvo vehicle. For further information on Noise Emis- sions refer to “Noise Emissions” page 6. To perform a check of the A/C Hoses, Fittings, Switches,...

  • Page 76: Front Suspension, Steering System Checks

    Group 170 Preventive Maintenance Front Suspension, Steering System Checks Check Gaiters/Plastic Covers and clear- ance for Ball Joints Note: For further information refer to literature in Func- tion Group 6. To perform a check of the Gaiters/Plastic Covers and clearance for the Ball Joints complete the following: Check that all Gaiters/Plastic Covers are undam- aged.

  • Page 77: Check Steering Shaft Joint, Hoses And Pipes For Power Steering

    Group 170 Preventive Maintenance Check Steering Shaft Joint, Hoses an Pipes for Power Steering Note: For further information refer to literature in Func- tion Group 6. To perform a check of the Steering Shaft Joint, Hoses and Pipes for Power Steering perform the following: Check the Steering Shaft Joint for leaks, cracks and other damage.

  • Page 78: Checks Beneath The Vehicle

    Group 170 Preventive Maintenance Checks Beneath the Vehicle Check Sealing on Front and Rear Drive Axle Note: For further information refer to literature in Func- tion Group 7. To perform a check of the sealing on the Front and Rear Drive Axles complete the following: •...

  • Page 79: Check Gearbox, Transfer Case, And Power Take

    Group 170 Preventive Maintenance Check Gearbox, Transfer Case, and Power Take-Off Mounting and Sealing Note: For further information refer to literature in Func- tion Group 2. To perform a check of the Gearbox, Transfer Case, and Power Take-Off complete following: •...
  • Page 80 Group 170 Preventive Maintenance Check Retarder Sealing To perform a check of the Retarder Sealing complete the following: • Check the Retarder Sealing for any cracks or leaks.

  • Page 81: Check Drive Shaft, Universal Joints, Sliding Joints And Support Bearings

    Check rear axle pinion bearing for wear and leaks past the seal. Note: The Volvo CT EV87 front tandem gear input shaft has a large play for the input shaft bearing. This is nor- mal and does not have any damaging effect on the transfer gear-during rotation, the shaft is balanced so that the clearance is insignificant.

  • Page 82: Check Sealing Of Rear Axle And Hub Reduction Gear

    Group 170 Preventive Maintenance Check Sealing of Rear Axle and Hub Re- duction Gear Note: For further information refer to literature in Func- tion Group 7. To perform a check of the Sealing on the Rear Axle and Hub Reduction Gear complete the following: On the Rear Axle, inspect around the mating sur- faces for leaks past the gasket.

  • Page 83: Check Exhaust Pipe, Silencer, Or Particulate Filter

    Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle. For further information on Noise Emis- sions refer to “Noise Emissions” page 6. To perform a check of the exhaust pipe, Silencer or Par- ticulater complete the following •...

  • Page 84: Check Central Lubrication System

    Group 170 Preventive Maintenance Check Central Lubrication System Not applicable to VN/VHD vehicles. Check Air Suspension and Air Springs Note: For further information refer to literature in Func- tion Group 7. To perform a check of the Air Suspension and Air...

  • Page 85: Check Rear Wheel Bearing Clearance

    Group 170 Preventive Maintenance Check Rear Wheel Bearing Clearance Note: For further information refer to literature in Func- tion 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.).

  • Page 86: Check Brake Linings

    Group 170 Preventive Maintenance Check Brake Linings Note: For further information refer to literature in Func- tion 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 manufac- turer’s specifications for minimum lining thickness.

  • Page 87: Check Brake Disc And Calipers

    Group 170 Preventive Maintenance Check Brake Disc and Calipers Note: For further information refer to literature in Func- tion Group 5. To perform a check of the brake discs and calipers com- plete the following: Remove the wheel. Inspect the brake discs and calipers for signs of wear or damage.

  • Page 88: Test Driving

    (0.15 to 0.40 in.), which is the clearance between the pedal plunger and the piston in the master cylinder. On VN/VHD vehicles with clutch brake, check function by depressing clutch pedal to within 6 to 12 mm (1/2 to 1 in.) from the floor while engaging a gear.
  • Page 89 Group 170 Preventive Maintenance Check Instruments and Gauges Note: For further information refer to literature in Func- tion 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 Func- tion Group 8.

  • Page 90: Check During Test Driving

    Group 170 Preventive Maintenance Check Horns Note: For further information refer to literature in Func- tion Group 8. Sound both the air horn (1) and the electrical horn (2). Each should have a strong, even tone. Check During Test Driving Check Clutch Operation Note: For further information refer to literature in Func- tion Group 4.
  • Page 91 Group 170 Preventive Maintenance Check ABS System Note: For further information refer to literature in Func- tion 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. Per- forming a brake test in traffic may lead to an accident, and cause personal injury or death.
  • Page 92 If the engine is equipped with an exhaust brake (only on Volvo) or an engine brake, check the effectiveness of the retarding force when the brake is engaged. Engine Brake (D12)
  • Page 93 Group 170 Preventive Maintenance Check Transmission Operation Note: For further information refer to literature in Func- tion 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 dif- ferences in sound between the gears.
  • Page 94 Group 170 Preventive Maintenance Check Heater and Air Conditioning Note: For further information refer to literature in Func- tion Group 8. Check function of heater and air conditioning. Operate the controls and let the fan run on all speeds. Note: In the summertime, the shut-off valves for the heater may be closed for the season.

  • Page 95: Check After Test Driving

    Group 170 Preventive Maintenance Check After Test Driving Check Pneumatic Switches Note: For further information refer to literature in Func- tion 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 Note: If vehicle air pressure is below approximately 720 kPa (75 psi), pneumatic switches will not function.
  • Page 96 Group 170 Preventive Maintenance Engine Low Idle Note: For further information refer to literature in Func- tion Group 3. Record the engine low idle speed. Listen for idling prob- lems such as surging, missing or unusual noise. See each engine manufacturer’s specification for correct idle speed.
  • Page 97 Group 170 Preventive Maintenance Check Compressor Loading Note: For further information refer to literature in Func- tion 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 en- gine at full speed.

  • Page 98: Finish

    Group 170 Preventive Maintenance 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.

  • Page 99: Additional Time Based Maintenance

    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.
  • Page 100 Group 170 Every: Three Years Caterpillar: Engine Valves and In- Caterpillar: Engine Compression jector Preload Brake Slave Piston Lash If the engine is equipped with an engine compression Engine valve lash adjustment is checked and, if neces- brake, adjust the slave piston lash after the engine sary, adjusted every third year.

  • Page 101: Additional Mileage Based Maintenance

    Volvo Transmission Volvo Rear Axle Regular oil change intervals for Volvo transmissions are Regular oil change intervals for Volvo rear axle is at ev- at every 120,000 km (75000 miles). See specification section for oil types and viscosities. 120,000 km (75,000 miles). See specification section for...
  • Page 102 Group 170 Every: 190,000 km (120,000 miles) Detroit Diesel: Engine Valve Clear- Cummins: Overhead Set Adjust- ance and Injector Height ment Check valve clearance and injector height. Adjust each Check valve clearance and injector adjustment. Adjust as necessary. For specific information refer to Detroit each as necessary.

  • Page 103: Feedback

    If you have any comments or suggestions, make a copy of this page, write down your comments and send them to us, either via telefax or mailing directly to the address listed below. From Volvo Trucks North America, Inc................Dept. 516 Service Publications ................
  • Page 104 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., 2001...

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