Volvo D11F Operator's Manual And Maintenance Instructions
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Volvo D11F Operator's Manual And Maintenance Instructions

Volvo D11F Operator's Manual And Maintenance Instructions

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OPERATOR'S MANUAL
VEHICLE MAINTENANCE
VN,VHD
Volvo d11f and d13f engines
Volvo Trucks. Driving Success.
R

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  • Page 1 OPERATOR'S MANUAL VEHICLE MAINTENANCE VN,VHD Volvo d11f and d13f engines Volvo Trucks. Driving Success.

  • Page 3: Table Of Contents

    General Engine Information ......39 Engine Overview, D11F and D13F Left Side View ..39 Engine Overview, D11F and D13F Right Side View .
  • Page 4 Service Check List ....... . . 111 Preventive Maintenance ......112 Service Charts .

  • Page 5: Foreword

    Preventive Maintenance Service Manual and must not be regarded as such. 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.

  • Page 6: Warning Label Information

    In the event that a label is damaged or missing the label must be replaced. Contact your authorized Volvo Truck dealer for assistance regarding Warning and Advisory labels.

  • Page 7: General Information

    If you are not the original owner of this vehicle, please notify us about the change in ownership at the address below or through an authorized Volvo Truck dealer. This is the only way we will be able to contact you if necessary.
  • Page 8 Illustrations are used for reference only and may differ slightly from the actual vehicle, however, key components addressed in this manual are represented as accurately as possible. Volvo Trucks North America reserves the right to make changes at any time or to change specifications or design without notice and without incurring obligation.

  • Page 9: Exhaust And Noise Emissions

    General Information EXHAUST AND NOISE EMISSIONS General 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 its sale and delivery to the...
  • Page 10 Volvo Trucks North America recommends that you retain all receipts covering maintenance of your vehicle, but Volvo Trucks North America. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance listed in other manuals which were supplied with your vehicle.
  • Page 11 State of California) Volvo Trucks North America warrants the Emission Control Systems on each new VOLVO diesel engine in a new VOLVO truck to comply with all State of California emissions regulations applicable at the time of manufacture of the...
  • Page 12 General Information PROCEDURES FOR HANDLING EMISSIONS CONTROL SYSTEM WARRANTY The following engine components are covered by the supplemental emissions control system warranty policy as required by the California Code of Regulations. Turbocharger Assembly VGT Actuator Control Valve Charge Air Cooler Unit Injectors Engine Wiring Harness Electronic Control Module...
  • Page 13 Repairs by VOLVO Dealers, Sub-Dealers and Service Dealers Repairs covered by the California Emission Control Systems Warranty will be performed by any authorized VOLVO repair facility at his place of business with no charge for parts and labor (including diagnosis), using VOLVO parts for any part of the emission control systems covered by this warranty and found defective.
  • Page 14 The vehicle owner is responsible for the performance of all required maintenance specified in this manual. VOLVO will not deny a warranty claim solely because there is no record of maintenance; however, VOLVO may deny a warranty claim if failure to perform required maintenance results in the failure of a warranted part.
  • Page 15 General Information Customer Assistance Volvo Trucks North America wishes to assure that the California Emission Control Systems Warranty is properly administered. In the event that owners do not receive the warranty service to which they believe they are entitled under the California Emission Control Systems Warranty, they should contact Volvo Trucks North America Warranty Administration, (336) 393-2000.
  • Page 16 General Information CALIFORNIA EMISSION CONTROL SYSTEMS SERVICE RECORD CALIFORNIA EMISSION CONTROL SYSTEMS SERVICE RECORD DATE KM\MILES __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__ __/__/__...
  • Page 17 All warranty periods are calculated from the data-in-service of the new vehicle. The repair or replacement of defective parts will be made without charge for the cost of parts and, if repairs are made at an authorized Volvo Trucks North America. dealership, there will be no charge for labor.
  • Page 18 General Information ENGINE GASEOUS EMISSIONS CONTROL SYSTEM WARRANTY FEDERAL EMISSION REQUIREMENTS The following engine components are covered by the supplemental emissions control system warranty policy as required by the Federal emissions regulations. Turbocharger Assembly VGT Actuator Control Valve Charge Air Cooler Unit Injectors Engine Wiring Harness Electronic Control Module...
  • Page 19 Normal maintenance, such as cleaning ash from the filter at regular maintenance intervals, is not covered by the emission warranty. In response to customer requests, Volvo Trucks North America may build vehicles with engines supplied by other manufacturers, including, but not limited to, Cummins.

  • Page 20: Noise Emissions

    Volvo Trucks North America was designed, built and equipped to conform, at the time it left the control of Volvo Trucks North America, with all applicable U.S. EPA Noise Control Regulations.

  • Page 21: Tampering With Noise Control System

    General Information Tampering with Noise Control System Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...
  • Page 22 General Information Regulatory Compliance Acts that constitute tampering with the Noise Shielding and Insulation Devices: Removing or rendering inoperative the engine and/or transmission noise deadening panels, shields or insulating materials. Removing or rendering inoperative the cab-tunnel or hood noise insulating materials.

  • Page 23: Exhaust System

    General Information Exhaust System Hot engine! Avoid all movable parts or hot engine parts, exhaust gases, and/or fluids. A hot engine, exhaust, and/or fluids can cause burns. Maintenance Make sure the exhaust system is intact. Inspect for damage, misalignment and/ or leakage.
  • Page 24 General Information Engine Control, EGR and Fuel Systems Acts that constitute tampering with Engine Control, EGR and Fuel Systems: Removing rendering inoperative, or modifying the engine control system such as the ECU, EGR system components, or fuel system components, in order to allow the engine to operate outside of the manufacturer's specifications is not allowed and violates both warranty and legislation.

  • Page 25: Label Information

    General Information LABEL INFORMATION VT Shown, VN and VHD Similar 1. Transmission Type and Gear Pattern This information is located in the visor. 2. VIN/GAWR Located in the door frame “B” pillar. 3. VIN/Major Components Located in the door frame “B” pillar.

  • Page 26: Fuse And Relay Location

    General Information FUSE AND RELAY LOCATION Always replace fuses and circuit breakers with the same current/ amperage. Increasing fuse or circuit breaker rating may result in electrical circuit overheating and possible fire. On sleeper models equipped with fluorescent lighting, there is a 3 AMP maximum fuse located in the lighting fixture.
  • Page 27 General Information The fuse relay panel is located under the top cover of the dash board. The vehicle has an electrical center located in the middle of the dash under the top cover. Since the function of some fuses or relays may change for the vehicle application, refer to the list of functions that is attached beneath each panel.

  • Page 28: Safety Information

    Safety Information PROPER MAINTENANCE PROCEDURE SAFETY INFORMATION Before working on a vehicle, set the parking brakes, place the transmission in neutral, and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. Exhaust gases contain carbon monoxide.

  • Page 29: During Maintenance

    DO NOT attempt repairs you do not understand. If you do not have the proper tools/knowledge to perform the repairs correctly, Volvo recommends contacting your nearest Volvo Truck dealer for all necessary repairs. When starting an engine after repairs have been made to the fuel or...

  • Page 30: Asbestos Information

    200 kPa (30 psi) for cleaning purposes. Asbestos Information The Volvo engine and replacement parts for it shipped from the factory are asbestos free. Volvo recommends the use of only genuine Volvo spare parts. Never use any parts that contain or are thought to contain asbestos. Exposure to asbestos fibers can create serious health risks, including death.
  • Page 31 Safety Information DO NOT raise the engine hood if you see or hear steam or coolant escaping from the engine compartment. Wait until steam or coolant cannot be seen or heard any longer before raising the hood. DO NOT remove the coolant fill cap if the coolant in the surge tank is boiling.
  • Page 32 Safety Information To prevent personal injury, do not climb up on the engine to remove the filler cap. Use a suitable, properly positioned ladder to reach the cap. At normal operating temperature, the engine coolant is very hot and under pressure. If pressure is relieved rapidly in a hot cooling system, the hot coolant can turn into steam.

  • Page 33: Speed Restrictive Tires

    Safety Information Speed Restrictive Tires Operating a vehicle equipped with speed restrictive tires in excess of their stated rating may result in tread separation and/or blowout resulting in the loss of steering control and possible collision. Serious personal injury or death could occur.
  • Page 34 Contact your nearest Volvo Truck dealer for any necessary air conditioning testing or repairs. All fuels, most lubricants and some coolant mixtures are flammable. Diesel fuel is flammable.

  • Page 35: Starting Aids

    Safety Information DO NOT expose the engine to flames, driving over burning ground. DO NOT weld or flame cut on or around pipes or tubes that contain flammable fluids. Exhaust heat shields may be installed to protect oil or fuel carrying lines and pipes from hot exhaust parts.

  • Page 36: Respiratory Hazard Prevention

    Safety Information Fire Extinguisher Anytime work is being done to the fuel system or any other area where flammable substances are being used, have a fire extinguisher available and know how to use it. Inspect and have it serviced as recommended on its instruction label.
  • Page 37 Anyone near the fan when it turns on could be seriously injured. Never attempt adjustments or repairs while the engine is running, see your authorized Volvo Truck dealer. Inspect the fan blade assembly before service for cracks or loose mounting before starting the engine.

  • Page 38: Engine Damage Prevention

    To help prevent an accident by moving parts, work carefully around them. DO NOT disable or bypass automatic alarm/shutoff circuits. They are provided to prevent personal injury and engine damage. Only properly trained and authorized Volvo Service Technicians may attempt repairs on this vehicle.

  • Page 39: Engine Starting

    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.

  • Page 40: Electric System Damage Prevention

    Safety Information ELECTRIC SYSTEM DAMAGE PREVENTION Electric and Electronic Systems Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating.

  • Page 41: Electronic Engine Control System

    Safety Information Electronic Engine Control System The engine uses high voltage to the electronic unit injectors. DO NOT come in contact with the unit injector terminals while the engine is running. An electric shock can cause an involuntary muscle spasm and cause loss of balance and falls leading to severe personal injury or death.

  • Page 42: Reporting Safety Defects

    Volvo Trucks de Mexico, S.A. de C.V. should be informed immediately if you believe the vehicle has a defect that could cause a vehicle accident, injury or death. Contact Volvo Trucks de Mexico by calling: 01 (800) 90 94 900 (within Mexico only) or 011-52-55-50-81-68-50, or by writing to: Volvo Trucks de Mexico, S.A.

  • Page 43: General Engine Information

    General Engine Information ENGINE OVERVIEW, D11F AND D13F LEFT SIDE VIEW GENERAL ENGINE INFORMATION D13F Engine Shown, D11F Engine Similar 1. Breather Tube 2. Intake Manifold 3. Air Compressor 4. Power Steering Pump 5. Fuel Pump 6. Engine Electronic Control Unit (EECU) 7.

  • Page 44: Engine Overview, D11F And D13F Right Side View

    General Engine Information ENGINE OVERVIEW, D11F AND D13F RIGHT SIDE VIEW D13F Engine Shown, D11F Engine Similar 17. Exhaust Manifold 18. Valve Cover 19. Engine Pre-Heater Element (Optional) 20. Thermostat Housing 21. Belt Tensioner 22. Coolant Pump 23. Coolant Filter ENGINE STORAGE 24.

  • Page 45: Engine Storage

    ENGINE STORAGE If the vehicle must be parked for a period (more than 30 days), protect it as follows: Drain the engine oil. Fill up to the proper level with oil of the recommended quality and viscosity. Fill up the fuel tanks with the recommended grade of fuel. Run the engine for two minutes around 1000 rpm.

  • Page 46: Maintenance And Service

    Maintenance and Service MAINTENANCE HAZARDS Before working on or inspecting a vehicle, set the parking brakes, place the transmission in neutral and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death.

  • Page 47: Engine Components, Service Schedules

    Maintenance and Service ENGINE COMPONENTS, SERVICE SCHEDULES Component Fuel Filter — All Engine Models Water Separator — All Engine Models Air Filter — US07 Air Filter — Euro 4 Coolant (Standard — All Engine Models Coolant (ELC) — All Engine Models Coolant Filter —...

  • Page 48: Cooling System

    Clean up coolant spills immediately. Volvo Trucks North America 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...
  • Page 49 Maintenance and Service 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 cooling system. Maintain its liquid properties in cold climates.
  • Page 50 Maintenance and Service DO NOT use antifreeze formulated for automobile gasoline engines. These have a very high silicate content that will clog the radiator and leave unwanted deposits in the engine. Freeze Protection Down To: -25° C (-13° F) -30° C (-22° F) -38°...
  • Page 51 Maintenance and Service Never add coolant to a hot or overheated engine. Engine damage can result. Allow the engine to cool first. Additives Additives help prevent rust, scale and mineral deposits from forming. Additives also protect metals from corrosion, prevent water pump and cylinder liner cavitation and contain anti-foaming agents.
  • Page 52 Maintenance and Service Extended Life Coolant Change Interval Extended life coolant will test as out of additives (SCA), but SCA should not be added. Shortened engine life may be the result of adding SCA. Replace coolant every 960 000 km (600,000 miles), 12,000 hours or every four years, whichever comes first.

  • Page 53: Fuel System

    Maintenance and Service FUEL SYSTEM Fuel Safety Reminders A diesel engine will operate on any fuel which enters the cylinder, whether it is from the injectors or from the air intake system. Therefore, if any solvent is used to flush out the air cleaner element, the engine may over speed during start-up.

  • Page 54: Diesel Fuel Specification

    ULSD fuel in diesel-powered vehicles is illegal and punishable with civil penalties. Use of fuel additives to compensate for the lower sulfur content is NOT recommended by Volvo Trucks North America. The proper selection of fuel is essential for good economy, performance and engine life.

  • Page 55: Fuel Additives

    Maintenance and Service Fuel Sulfur Content Fuel sold for use in diesel-powered engines for 2007 and later model year vehicles may only contain a maximum sulfur content of 0.0015% by weight. This was done to reduce particle emissions in the exhaust. The use of ultra-low sulfur diesel fuel does not permit extension of engine oil change intervals or oil filter changes.
  • Page 56 Maintenance and Service Supplemental Fuel Enhancers Supplemental additives are not recommended because of a high risk of injection system problems or engine damage. There are many aftermarket products available today which are intended to be added by the customer. They generally increase operating cost without providing benefits.

  • Page 57: Prohibited Additives

    If a tank contains a diesel fuel/ gasoline mixture, it should be drained and cleaned as soon as possible. Used lubricating oil — Volvo Trucks North America does not recommend the use of any type of used lubricating oil as an extender in the diesel fuel.

  • Page 58: Fuel Storage

    Maintenance and Service Fuel Storage If fuel is stored on site: Keep storage tank covered to prevent water entry. DO NOT use a tank made of galvanized metal or any galvanized piping for diesel oil storage. Diesel will react with the zinc, forming solids that can clog fuel filters and cause engine damage.

  • Page 59: Fuel Filters

    The secondary fuel filter is located on the left hand side, below the engine electronic control unit (EECU). The filter is a spin-on filter. D11F and D13F Engine-Mounted Fuel Filters (D13F shown, D11F similar) 1. Secondary Fuel Filter 2. Primary Fuel Filter with Water...

  • Page 60: Replacing Fuel Filters

    Maintenance and Service Chassis Mounted Primary Fuel Filter (Optional) For priming the fuel system, see “Priming the Fuel System” on page 71. Replacing Fuel Filters When draining the fuel filters, collect the waste in a fuel-safe container. Always dispose of fuel according to Federal or local regulations. Take the drained fuel and water to a recycle or waste management center.

  • Page 61: Oil Quality

    Always replace the oil filters at the same time as when the oil is changed. Oil Quality Volvo Trucks North America recognizes 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.

  • Page 62: Oil Filters

    For additional information about oil change intervals, see your Volvo Truck dealer. Also, refer to Bulletin 175-60, Oil and Filters, Volvo Components. For a complete list of approved oils, see your Volvo Truck dealer. Also, refer to Bulletin 175-61, Approved Oils, Volvo Components.

  • Page 63: Synthetic Lubrication

    Synthetic Lubrication Synthetic oils are offered by some oil suppliers as an alternative to the traditional, petroleum based oils for engines. These oils may be used in Volvo engines, provided they meet the quality levels specified on the previous pages, that is: both VDS-4 and EO-O Premium Plus.

  • Page 64: Oil Consumption

    Maintenance and Service Volvo Trucks North America recommends the viscosities shown in the viscosity/temperature table for Volvo engines. Oil Additives Extra oil additives must never be added to any engine oil used. Additives such as break-in oils, top oils, graphitizers, and friction reducing liquids are not necessary and may even harm the engine.

  • Page 65: Oil Change

    Maintenance and Service All diesel engines are designed to consume some oil, so it is normal to add oil periodically. An engine used in heavy-duty operation will consume more oil than one in normal operation. To assist you in measuring your oil usage please refer to the Fuel and Oil Record on “Fuel and Oil Record”...

  • Page 66: Oil Filters Change

    When changing oil, wear protective gloves. Volvo-branded oil filters are designed to provide the proper level of filtration and protection for Volvo engines. Filters that do not meet the same stringent requirements may cause unsatisfactory results. Coat the filter gasket with oil.

  • Page 67: Engine Air Filter

    Maintenance and Service ENGINE AIR FILTER Continued operation with the gauge showing in the red may cause damage to the engine. Operating the engine with a damaged filter allows dust to pass directly into the engine, causing damage. Replace damaged or clogged filters. The engine air filter is monitored by a pressure restriction gauge mounted on the air filter housing.
  • Page 68 Maintenance and Service...

  • Page 69: Diesel Particulate Filters (If Equipped)

    Regenerations that are stopped and never restarted at a later time, however, will require that the vehicle be taken to an authorized Volvo Truck dealer to have the regeneration manually started.

  • Page 70: Fan And Auxiliary Drive Belts

    Maintenance and Service FAN AND AUXILIARY DRIVE BELTS Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine can cause serious burns. All engine belts should be checked at each service point. Inspect for cracked or frayed material.
  • Page 71 Maintenance and Service A drive belt routing label is located on the vehicle frame rail. Drive Belt Routing Label Drive Belt Routing Label Location...

  • Page 72: Turbocharger And Charge Air Cooler

    Over time, there may be a build-up of dirt, mud, insects, etc., between the radiator and charge air cooler. Inspect for build-up and contact your authorized Volvo Truck dealer, if necessary. Over time, dirt and insects will accumulate between the fins of the radiator, air conditioning condenser and charge-air-cooler.
  • Page 73 200 kPa (30 psi) for radiator and charge air cooler cores. The use of a fin comb is also a good tool to loosen bugs and dirt from the fins. If dirt cannot be cleaned off with this procedure, consult your Volvo Truck dealer. Cleaning Charge Air Cooler and Radiator (typical radiator shown) Inspect the charge air cooler for cracks at every inspection.

  • Page 74: Fuel System Service

    Maintenance and Service FUEL SYSTEM SERVICE Changing the Primary Fuel Filter To avoid potential fire hazard, DO NOT service any part of the fuel system while smoking or in the presence of flames, sparks, or hot surfaces, or when working on an operating engine. Failure to follow these precautions can result in fire.

  • Page 75: Priming The Fuel System

    Maintenance and Service Priming the Fuel System The fuel system will need to be bled if: The vehicle has run out of fuel. The engine has not been running for an extended period of time. Service work has been done on the fuel system, (tank, fuel lines, filters, valves, etc.) for example cleaning or replacing fuel filter elements.
  • Page 76 Maintenance and Service D11F and D13F Primer Pump (D11F shown, D13F similar) Unlock the hand pump by turning the handle counterclockwise. Prime the system by moving the primer pump in an up and down pumping motion. Avoid putting any side load on the pump or causing a binding condition.

  • Page 77: Water In Fuel

    Maintenance and Service Water In Fuel You can only drain the water in the fuel when there is a high water level in the fuel filter housing, the engine is not running, the vehicle is stationary and the parking brake is applied. When the water in fuel indicator activates, the cluster displays the water in fuel icon and the message “Water in Fuel, Drain at next stop.”...
  • Page 78 Maintenance and Service If the temperature reaches 140° C (285° F), stop the vehicle to let the temperature go down. See the vehicle Operator's Manual for information on the optional transmission temperature gauge. If the transmission oil temperatures are consistently high, change oil more often or install an oil cooler.
  • Page 79 Driveshaft separation may cause loss of control of the vehicle resulting in severe personal injury or death. Periodic inspection, lubrication, and maintenance of the driveshaft may be required. Contact your local authorized Volvo Truck dealer. Rear Axle Checking and Draining Differential Oil Check the oil level through the top plug.

  • Page 80: Steering And Brakes Maintenance

    Maintenance and Service STEERING AND BRAKES MAINTENANCE Steering System Excessive play in the steering system is checked by turning the steering wheel while the engine is stopped. With the front wheels pointing straight ahead, turn the steering wheel until the front wheel starts moving. Then, turn the steering wheel the other way until the front wheel moves.

  • Page 81: Power Steering Fluid Reservoir

    If the fluid has darkened, it indicates that the power steering system is running hotter than normal and the fluid is overheating. Take the vehicle to a Volvo Truck dealer for troubleshooting the overheating and to have the fluid changed.

  • Page 82: Brake System

    Maintenance and Service Brake System DO NOT use replacement parts anywhere in the brake system unless it conforms exactly to original specifications. A nonconforming part in your vehicle's brake system could cause a malfunction, leading to loss of control of the vehicle resulting in severe personal injury or death. DO NOT release the parking brake or attempt to move the vehicle until brake air pressure in both circuits is at least 690 kPa (100 psi).

  • Page 83: Air Tanks

    Volvo Truck dealer Dryer manufacturers recommend changing the cartridge every 2 to 3 years but the intervals need to be adjusted for vehicle application. In some climates, the cartridge may have to be changed every year. See your authorized Volvo dealer.

  • Page 84: Electrical System Maintenance

    Maintenance and Service ELECTRICAL SYSTEM MAINTENANCE Battery Care Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion.
  • Page 85 The electrolyte level on maintenance free batteries cannot be checked. Periodically, the condition and the state-of-charge of each battery should be checked by a Volvo Truck dealer. Maintenance free batteries DO NOT require any attention other than keeping them clean and firmly clamped in place in their respective trays.

  • Page 86: Tires, Wheels And Hub Maintenance

    Maintenance and Service TIRES, WHEELS AND HUB MAINTENANCE Wheel Safety Information DO NOT attempt to repair wheels or tires unless you are trained and equipped to do so. Wheel and tire assemblies cannot be worked on without proper tools and equipment. Failure to follow this may lead to serious personal injury or death.
  • Page 87 Maintenance and Service DO NOT install tires with a load rating that is less than stated on the Certification Label in the door frame. The tire could be unintentionally overloaded, leading to an accident, causing serious personal injury or death. DO NOT use mismatched tires on the same axle.

  • Page 88: Wheel Nut Tightening

    800 km (500 miles). 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 lb-ft). Tighten the nuts in the correct sequence. Inspect bolts and nuts for signs of wear or cracks.
  • Page 89 Maintenance and Service Tire Inflation and Wear DO NOT operate the vehicle with under-inflated tires. Always keep your tires inflated to the manufacturer's recommendation. Increased flexing in the tire sidewall produces heat. The heat can build to the point of blowing the tire out causing an accident.
  • Page 90 Dual mounted wheels should always be of the same type and diameter (maximal diameter difference allowed is 6 mm [1/4 in.]). Volvo Trucks North America is committed to repair procedure 642 (RP 642), American Tire Association (ATA) and The Maintenance Council (TMC).
  • Page 91 Maintenance and Service Typical Wear Patterns Incorrect Air Pressure Air pressure too high gives rapid wear in the middle. Air pressure too low gives rapid shoulder wear. Incorrect Camber Incorrect camber gives abnormal wear on one half of the tire.
  • Page 92 Maintenance and Service Incorrect Toe and Axle Alignment Incorrect toe-in Incorrect toe-out Out-of-line axle Steering arm defect Dual Wheel Mounting Excessive road camber, different types of tire, different circumference or off-center loading give faster wear on one tire. Air pressure too low, 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.
  • Page 93 Maintenance and Service Incorrect Caster and Imbalance Caster angle Imbalance Also rapidly wears the mechanical parts of steering linkage, kingpin and wheel bearing. Cuts in the Tire Tread Cuts Flaking cuts Rubber flaking Cuts are due to poor roads, air pressure too high or incorrect tire type.
  • Page 94 Maintenance and Service Spot Wear Sudden braking, locking brakes or out-of-round brake drums give spot wear. Feathered Edges Normal occurrence on non-driving wheels on good roads and high mileage.
  • Page 95 Maintenance and Service Cupping Cupping is a normal occurrence that depends on the tread pattern; the higher the load, the greater the wear.
  • Page 96 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.
  • Page 97 Maintenance and Service Unitized Front Hubs The non-tapered axle hubs are sealed with lubricant inside the hub and do not require lubrication. Unitized Hubs, Non-Tapered Axle End...
  • Page 98 Maintenance and Service Tapered Axle End...

  • Page 99: Chassis Maintenance

    Maintenance and Service CHASSIS MAINTENANCE Springs This work is best performed by a Volvo Truck dealer or other service outlet having the proper equipment. The spring package is fastened to the axle beam with U-bolts. It is important that the U-bolt nuts are properly tightened. The nuts may loosen up with time.

  • Page 100: Spring Bushings

    Maintenance and Service Spring Bushings When lubricating the springs, lift the axle off of the floor, suspend the frame with axle stands and lower the axle. The spring bushings are now in the position where grease can be added to the contact surfaces. If the spring bushings are greased without taking the load off, high wear and lower lifetime will occur because grease is not able to reach the contact surfaces.

  • Page 101: Cab Maintenance

    Maintenance and Service CAB MAINTENANCE Doors The door lock mechanism should be greased annually using white grease. Lubricate the door lock cylinder with liquid graphite annually, or more often in climates with a lot of snow and salt on the roads. Coat the door stop arm with white grease annually.

  • Page 102: Rust Protection

    Maintenance and Service Hood The hood latch mechanism should be greased with white grease yearly. If the mechanism is hard to work or binds, the latch should be cleaned before greasing. Rust Protection The rust protection applied when the cab was produced is adequate for normal use and service.
  • Page 103 Maintenance and Service Cab Air Filter Air going into the cab passes a filter located on the right, front side of the cab. Remove the filter and check it every 19 200 km (12,000 miles). The filter should not be cleaned and reused. Replace with a new filter as necessary. Change the filter more often if driving in dusty conditions.

  • Page 104: Stainless Steel

    Maintenance and Service DO NOT aim the water jet directly at door and window seals or door locks. If locks are filled with water, use compressed air to clean the water out and then apply liquid graphite. Be especially careful of leaving water in locks or around seals during freezing weather.

  • Page 105: Leather Care

    Suede-like upholster can be cleaned with a soft cloth and mild soap solution. Leather Care Volvo's Leather upholstery is manufactured with a protectant to repel soiling. Over time, sunlight, grease and dirt can break down the protection. Staining, cracking, scuffing, and fading can result.

  • Page 106: Lubrication

    Maintenance and Service LUBRICATION Chassis Lubrication Before working on or servicing a vehicle, set the parking brakes, place the transmission in neutral and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death.

  • Page 107: Lubrication Chart

    Maintenance and Service Lubrication Chart The numbers in the lubrication chart correspond with the numbered notes on “Lubrication Chart Notes” on page 104. Read these notes before selecting a lubricant.
  • Page 108 Maintenance and Service Grease Hub Oil Engine Oil Steering Fluid Auxiliary Axle(s) Hydraulic Oil Lubrication Chart Notes 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.
  • Page 109 Kingpin, upper and lower: Use a lithium-based grease with specification API NLGI No. 2. Always grease a Volvo front axle with the wheels on the ground. Non-Volvo axles are typically greased with the wheels on the ground. Consult with the axle manufacturer for the latest recommendation.
  • Page 110 Maintenance and Service Ensure that grease purges out of all four seals of the U-joints. 10. PTO/Hydraulic reservoir: If equipped, consult with the PTO manufacturer for the latest recommendation. 11. T-Ride bogie beam (48k-70k suspension): If equipped, use a lithium-based grease with EP additives to specification API NLGI No. 2. Make sure the grease purges out of both the outer and inner seals.
  • Page 111 Maintenance and Service 18. Automatic and manual transmission: Automatic transmission: Use Dexron fluid. See the manufacturer's operator manual for intervals and quantity. Manual transmission: Use a mineral or synthetic oil. Check oil level periodically. Level should be to the bottom of the inspection hole. 19.

  • Page 112: Oil Capacity Tables And Viscosity Charts

    OIL CAPACITY TABLES AND VISCOSITY CHARTS Use the information in the table below to determine the operating condition and usage applicable to your vehicle. D11F and D13F Engine Oil and Filter Change Intervals Engine Operating Condition Fuel Consumption (mpg) Fuel Consumption (L/100 KM)
  • Page 113 Maintenance and Service 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 RS23-185 RT40-145/160, front tandem RT40-145/160, rear tandem RT 46–160 front RT 46–160 rear Select viscosity from the table above.
  • Page 114 Maintenance and Service Eaton Single 23080, 23105, 26105 and 30105Eaton Tandem DS405, DD405, DDH44 and DS462 For oil change intervals, see the manufacturer's operator's manual Capacity 23080 23105 and 26105 DD404, front tandem DD404, rear tandem DS404, front tandem DS404, rear tandem 19 liters (20 quarts) 26.5 liters (28 quarts)

  • Page 115: Service Check List

    Steering Hydraulic System Fluid type Change interval Hubs Oil Type Motor oil API CD or CE, SAE 30, 15W40 or synthetic Gear oil API GL5, SAE 75W90 SERVICE CHECK LIST Service Check List Automatic Transmission Fluid (ATF) Dexron Every 240 000 km (150,000 miles) or every 12 months Temperature Minimum: -25°...

  • Page 116: Preventive Maintenance

    PREVENTIVE MAINTENANCE Once you determine the applicable operating condition for your vehicle, use the information in the table below to perform preventive maintenance. TYPE OF OPERATION Check Warning and Control Lamps Check Fault Codes displayed in the vehicle Instrument Cluster Check Air Compressor's Function and...
  • Page 117 Service Check List TYPE OF OPERATION Check Batteries-Dirt, Leakage, Attachment, Specific Gravity of Battery Acid, Fluid Level Connections and Battery Box Check Fuel Tank, Hoses, Pipes Venting and Mounting Check Fuel Water Separator for the Fuel system, Draining of Condensation. Check Tire Wear Chassis Lubrication Cab Lubrication...
  • Page 118 TYPE OF OPERATION Check Mounting for Front and Rear Axle Check Chassis Frame and Crossmembers Check Rear Wheels and Bearings Check Brake Linings Check Brake Cylinders, Levers and Forks Check Oil Level in Manual Transmission (If Applicable) Check Oil in Retarder Check Oil Level in Power Steering...

  • Page 119: Service Charts

    TYPE OF OPERATION Valve Adjustment Check Drive Belts Check Radiator Fan, Bearing Tolerance, Bolt Unions, Fan Cover and Fan Ring with Rubber Seal Check Turbocharger Check Discharge Lines and Hoses SERVICE CHARTS Service Charts CHECK / CHECK / CHANGE CHANGE BASIC ANNUAL (4 MONTHS)

  • Page 120: Scheduled Services

    Regular maintenance inspections should be continued. The maintenance program and lubrication intervals that are listed in this manual may not suit your operation. Contact your nearest Volvo Truck dealer, who can help with designing a maintenance program that works in your application.
  • Page 121 Service Charts Preventive Maintenance (See local Volvo Work Completed Truck dealer for Service Information in group 17, "Preventive Maintenance Scheduled Basic Service" and group 17, Service "Preventive Maintenance Annual Date Service”) Date Mileage...

  • Page 122: Repair Record

    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. Date Mileage 1/1/07 24816 Service Charts Repair Record Work Order or Invoice Dealer Basic Preventive Maintenance:...

  • Page 123: Tire Record

    TIRE RECORD Type Date Front Low pro 1/1/07 22.5 Mich Service Charts Tire Record Type Rear Notes (Tire Pressure, Tread Depths) Low pro All tires within 105 - 108 psi Tread 22.5 Mich Depth, Front 12/32, Rear 10/32.

  • Page 124: Fuel And Oil Record

    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.

  • Page 125: Literature

    ENGINE DATA Consult your authorized Volvo Truck dealer. Fill in the blanks for future reference Vehicle Identification Number (VIN) Engine Model Engine Serial Number Engine Power Rating Primary Fuel Filter Part Number Secondary Fuel Filter Part Number Oil Filter Part Number, Full Flow...

  • Page 126: Service Assistance And Manuals

    Volvo vehicle. Your dealer has direct access to Volvo Trucks North America for technical help, parts or service information. Volvo Action Service (VAS), provides on-call assistance. For help, contact VAS directly: 24 hours a day at 1 (800) 528-6586 or 1 (800) 52-VOLVO. Also on the internet: www.vas.Volvo.com. VAS offers: Delivery Assurance —...

  • Page 127: Index

    Index Air Dryer Maintenance ........79 Air Filter, Cab .
  • Page 128 Engine Overview, D11F ....... 39 Engine Overview, D13F ....... 39 Engine Shut-Down System.
  • Page 129 Index Noise Emissions ........16 Oil Additives .
  • Page 130 Vendor Component Information ......3 Volvo Action Service........122...
  • Page 131 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.
  • Page 132 Volvo Trucks North America P.O. Box 26115 Greensboro, NC 27402-6115 Volvo Trucks Canada, Ltd. 5600A Cancross Court, Mississauga, Ontario L5R 3E9 http://www.volvotrucks.volvo.com PV776-21012002 07.2008 © Volvo Group North America, Inc. 2008. All Rights Reserved.

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