Volvo VHD 2001 Operator's Manual
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Volvo VHD 2001 Operator's Manual

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Operator's Manual
Maintenance and Engine
VH D

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Summary of Contents for Volvo VHD 2001

  • Page 1 Operator's Manual Maintenance and Engine VH D...
  • Page 2 The National Highway Traffic Safety Administration (NHTSA) and Volvo Trucks North America, Inc. should be informed immediately if you believe that the vehicle has a defect that could cause a crash, in- jury or death.

  • Page 3: Table Of Contents

    Contents General Information ......1 Oil Sampling ........70 Information For the Owner ....1 Severe Service Schedule for VHD-Series ........... 74 Safety Information ......... 3 General and Check-Chart ....74 Proper Maintenance Procedure ..... 3 Maintenance Categories ...... 78 Injury Prevention ........
  • Page 4 Warning Label Information IMPORTANT Before driving this vehicle, be certain that you have read and that you fully understand each and every step of the driving and han- dling information in this Operator’s Manual. Be certain that you fully understand and follow all safety warnings. IT IS IMPORTANT THAT THE FOLLOW- NOTE! A note defines an operating proce- ING INFORMATION CONCERNING...

  • Page 5: General Information

    If there are questions on the maintenance Establish a Preventive Maintenance Pro- and performance of your vehicle, please gram with the help of your local Volvo discuss them with your Volvo Truck dealer. Truck dealer. A Preventive Maintenance Your authorized dealer is required to have...
  • Page 6 It contains important operational and safety information that is needed by all drivers and owners of this vehicle. This Maintenance Manual covers all Volvo vehicles manufactured by Volvo Trucks North America, Inc., including the whole chassis and all Volvo manufactured compo- nents.

  • Page 7: Safety Information

    Safety Information Proper Maintenance Procedure During Maintenance • Whenever performing maintenance or re- Before servicing your vehicle, apply pair, attach a DO NOT OPERATE or the parking brakes and adequately similar warning label or sign to the ignition chock the wheels in order to prevent key or prominently displayed on the instru- unintended vehicle movement.
  • Page 8 Safety Information • • Report all problems in a timely man- When starting an engine after repairs ner before they threaten the safety of have been made to the fuel or injection operating the vehicle. system, prepare equipment for shutting off the engine intake air and/or fuel •...
  • Page 9 Asbestos Information NOTE! The Volvo engine and replacement parts for it shipped from the factory are as- bestos 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 as- bestos fibers can create serious health risks,...

  • Page 10: Injury Prevention

    Safety Information Injury Prevention Burn Prevention Engine Parts WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot en- gine and/or fluid can cause serious burns. W0001525 Do not touch any part of the engine while it is hot.
  • Page 11 Safety Information Coolant To prevent personal injury, do not climb up on the engine to remove the filler cap. Use a suitable, properly positioned ladder to reach up to the cap. At normal operating temperature, the engine coolant is very hot and under pressure.
  • Page 12 Safety Information Oils WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot en- gine and/or fluid can cause serious burns. Hot oil can cause severe burns. Do not al- low hot oil to contact the skin. When changing oil, wear protective gloves.
  • Page 13 Safety Information Fire or Explosion Prevention The diesel engine will operate on any fuel which enters the cylinder, whether it is from the injectors or from the air in- take system. Therefore, if any solvent is W0001526 used to flush out the air cleaner element, the engine may overspeed during start-up.
  • Page 14 Safety Information Do not service any part of the fuel sys- tem while smoking or in the presence of flames, sparks or hot surfaces. Failure to follow these precautions can result in W0001527 fire, which can cause serious injury or death.
  • Page 15 Starting Aids Do not use ether or similar starting aids in a Volvo or any other engine with start help. The Volvo engine is equipped with a preheater. Introduction of ether or other combustible material in the intake manifold could cause a fire or explosion,...
  • Page 16 Safety Information Respiratory Hazard Prevention Exhaust gases contain carbon monoxide. Always run the engine outdoors or use a properly vented exhaust hose. Prolonged or excessive exposure may cause serious illness or death. W0001523 WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.
  • Page 17 Safety Information Crushing or Cutting Prevention 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 W0001524 movement and can cause serious per- sonal injury or death.
  • Page 18 Safety Information Wear protective glasses when striking ob- jects to avoid injury to your eyes. Chips or other debris can fly off objects that are struck. Make sure no one can be injured by flying debris before striking any object. W0001528 Climbing Up and Down Always have three limbs (one foot and...

  • Page 19: Engine Damage Prevention

    Make provisions for shutting off the engine intake air or fuel supply to stop the engine if there is an overspeed on start-up after performing repair or maintenance on it. Always consult the proper Volvo Service Manual before any repair is attempted.
  • Page 20 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 at- tached the tag before starting.

  • Page 21: Electric System Damage Prevention

    Safety Information Electric System Damage Prevention Electric and Electronic Systems Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the flammable vapor mix- ture of hydrogen and oxygen to explode. To prevent potential sparks from igniting W0001526 combustible gases produced by some bat-...
  • Page 22 See the vehicle Op- erator’s Manual for correct procedures. The Volvo D12 engine uses high voltage to the electronic unit injectors. DO NOT come in contact with the unit injector terminals while the engine is running.

  • Page 23: Reporting Safety Defects

    Contact 01 (800) 90 94 900 Volvo Trucks de Mexico by calling 91 (5) 259–3011 or by writing to: Volvo Trucks de Mexico, S.A. de C.V., Prol. Paseo de la Reforma 600, 1er.

  • Page 24: General Engine Design Information

    General Engine Design Information Engine Overview D7 W2002703 Fuel filters (secondary) Coolant filter Turbocharger Electronic injection pump Exhaust pressure governor (EPG) Hand fuel primer pump Coolant drain connection...
  • Page 25 General Engine Design Information W2002702 Engine electronic control unit 11. By-pass oil filter (EECU) 12. Full-flow oil filter Oil fill cap 14. Starter motor 10. Oil dipstick...

  • Page 26: Engine Overview, D12

    General Engine Design Information Engine Overview, D12 W0001846 Oil Fill Cap Fuel Filter (secondary) Starter Motor Oil Dipstick Engine Electronic Control Unit (EECU)
  • Page 27 General Engine Design Information W0001847 Coolant Drain Connection 14. Full-Flow Oil Filters 10. Exhaust Pressure Governor 15. Air Compressor (EPG) 16. Coolant Filter 11. VEB Control Unit 17. Coolant Radiator 12. Turbocharger 18. Charge Air Cooler 13. By-Pass Oil Filter...

  • Page 28: Typical Engine Compartment Overview

    General Engine Design Information Typical Engine Compartment Overview W2003478 Oil fill cap Coolant surge tank Intake air heater Output from charge air cooler Engine Electronic Control Unit (EECU)
  • Page 29 General Engine Design Information W2003479 Engine air filter Airfilter restriction gauge 10. Oil dipstick Coolant fill cap 11. Turbocharger Radiator...

  • Page 30: Engine Features

    General Engine Design Information Engine Features Feature Benefit • • VECTRO II - Volvo Engine Engine Brake Control (D12) • Electronics System Differentiated Speed Control • Road Speed Limiter • PTO Speed Setting • Cruise Control • Idle Speed Setting •...

  • Page 31: Vectro Ii Parameter Values, D7

    Engine Idle Speed, r/min NOTE! This parameter listing is not com- Parameters can be changed with a Pro-Link plete. Contact your Volvo Truck dealer for tool or with a VCADS Pro tool. These are a complete listing. available at your Volvo Truck dealer.

  • Page 32: Vectro Ii Parameter Values, D12

    Engine Idle Speed, r/min NOTE! This parameter listing is not com- Parameters can be changed with a Pro-Link plete. Contact your Volvo Truck dealer for tool or with a VCADS Pro tool. These are a complete listing. available at your Volvo Truck dealer.
  • Page 33 Base Warranty: 2 years or 250,000 • Electronically controlled fuel injection miles; parts and labor (For covered components, see the warranty certifi- • One Volvo full-flow and one Volvo by- cate) pass oil filters • Electronic engine diagnostics system Engine Optional Equipment •...

  • Page 34: Engine Variants, D12

    Thermostatically controlled oil cooler • Electronically controlled unit injectors Engine Optional Equipment • • Volvo Engine Brake — 350 hp brak- Engine oil pan heater ing power @ 2,300 r/min. • Side-mounted oil fill tube • Engine direct-mounted PTO — output •...

  • Page 35: Engine Data

    General Engine Design Information Engine Data Fill in the blanks for future reference: Vehicle Identification Number (VIN) [ ................] Engine Model [ ........................] Engine Serial Number [ ....................... ] Engine Power Output [ ......................] Engine Low Idle Speed [ ..................... ] Engine Full Load Speed [ ....................

  • Page 36: Engine Storage

    Engine Storage Engine Storage If the vehicle needs to be parked for a pe- riod (more than 30 days), make sure to protect it as follows: Drain the engine of its used oil. Fill up to the proper level with oil of the recommended quality and viscos- ity.
  • Page 37 Engine Storage Starting Engine After an Extended Shutdown 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 per- sonal injury or death.

  • Page 38: Cooling System

    Cooling System General Coolant Information General WARNING Do not raise the engine hood or cab if you see or hear steam or coolant escap- ing from the engine compartment. Wait until steam or coolant cannot be seen or heard before raising the hood or cab. Do not remove the coolant fill cap if the coolant in the surge tank is boiling.
  • Page 39 Cooling System Recommended coolant consists of a 50/50 mixture of antifreeze and clean water. Never run the engine with only water. Re- gardless of the season, the coolant should always contain at least 40 to 60 percent ethylene glycol (antifreeze). The antifreeze also contains anti-corrosion agents that the cooling system needs to stay functional.
  • Page 40 Cooling System Keep the radiator (including charge air cooler) and the frontal area free from bugs, dirt, leaves, etc. (see page 127 for cleaning information). Always keep the coolant level above the min. mark on the coolant expan- sion tank. Inspection of the whole cooling system is important.
  • Page 41 Cooling System W2002697 Thermostat Housing Level Sensor Radiator Heater Element Surge Tank Coolant Filter Coolant Cap Coolant Pump A well functioning and maintained cooling system is as important to the engine as per- forming regular oil changes or using good Coolant is toxic;...
  • Page 42 NOTE! Do not mix different products, such as regular antifreeze and extended life antifreeze. W2003082 NOTE! Volvo Trucks North America, Inc. does not recommend the use of antifreeze based on propylene glycol. Coolant, consisting of an antifreeze solu- tion in water, should be used year-round to...
  • Page 43 Cooling System The main purpose of coolant is to transport heat from the hot parts of the engine to the radiator and to protect the cooling system from corrosion. In addition to this, the coolant must: • Protect against pitting and cavitation erosion damage of the water pump and cylinder liners.

  • Page 44: Water Specification

    Water base/acid level 5.5 to 9 If you are not sure of the quality of the wa- ter in your area, contact your Volvo Truck dealer, your local water department, agri- cultural agent or an independent laboratory to analyze the water.

  • Page 45: Additives

    Cooling System Additives Additives are part of most antifreeze and should be tested for and added to all coolant mixtures using normal antifreeze. If extended life coolant is used, the additives are in the product when mixed. Both types need to have additives added to after a time. Additives help prevent rust, scale and min- eral deposits from forming.

  • Page 46: Antifreeze

    Antifreeze typically comes in one of two glycol types, ethylene or propylene. Propy- lene antifreeze is NOT recommended for use in a Volvo engine. There is also regular and extended life antifreeze. If the vehicle is delivered with extended life coolant, there is a label attached to the surge tank.
  • Page 47 Cooling System Antifreeze or premixed coolant meeting the standards ASTM D 3306 or ASTM D 4656 are primarily for automotive gasoline en- gines, containing high levels of silicate, and are unacceptable for heavy duty diesel en- gines. Recommended antifreeze meeting the ASTM D 4985 standard is a low silicate ethylene glycol based antifreeze for heavy duty diesel engines.
  • Page 48 Cooling System Regular Coolant Change Interval Replace the coolant every 250,000 miles (400,000 km), 4,000 hours or every two years, whichever comes first. Coolant SCA level must be tested at least twice per year or whenever coolant loss occurs. For maximum coolant system effi- ciency, test the system every 25,000 to 30,000 miles (40,000 to 56,000 km) de- pending on engine oil change interval or...
  • Page 49 The SCA level will deplete over time so it is important that the SCA level is tested regularly and maintained. The Volvo pre-charged filter is designed to slowly release the SCA to help maintain the rec- ommended level during operation.
  • Page 50 Cooling System Testing Procedure EXAMPLE Run the engine to operating temperature. recom- Step 1 Desired 2.3 units After the engine has reached operating tem- SCA level per gallon mended perature, move the heater controls (on dash level 1.5- and in sleeper) to full heat and run the en- 3.0 units gine for 10 more minutes.
  • Page 51 Cooling System Changing from Regular to Extended Life Coolant Drain the system of old coolant and dis- pose of properly. The cooling system should be flushed with clean water. If sig- nificant deposits are visible, use a reputable commercial cooling system flush designed for heavy duty diesel engines.
  • Page 52 10 Attach label P/N 3969338 to the coolant surge tank to indicate that the system is now filled with Extended Life Coolant. The label can be or- dered from your Volvo Truck dealer W2002144 spare parts department. NOTE! When changing over from standard to extended life antifreeze, tighten all hose clamps and fasteners in the cooling system.
  • Page 53 Cooling System Extended Life Coolant Change Interval Replace coolant every 300,000 miles (480,000 km), 6,000 hours or every four years, whichever comes first. A one-time extender package must be added to the cooling system after 150,000 miles (240,000 km), 3,000 hours or two years, whichever comes first.

  • Page 54: Fuel System

    Fuel System Fuel Safety Reminders A diesel engine will operate on any fuel Do not remove the fuel tank cap near an which enters the cylinder, whether it is open flame. Diesel fumes are com- from the injectors or from the air intake bustible and can cause an explosion of system.

  • Page 55: Diesel Fuel Specification

    Fuel quality is an important factor in ob- taining satisfactory engine performance, long engine life and acceptable exhaust emission levels. Volvo engines are designed to operate on most diesel fuels commer- cially available today. Volvo Trucks North America, Inc. recommends the use of diesel oil fuel which meets the specification...
  • Page 56 Federal or local regulations. Take the drained fuel and water to a recycle or waste management center. For the Volvo engine, change the fuel filters at every other oil change when running the 15,000 mile (24,000 km) oil drain interval.
  • Page 57 Fuel System Cetane Number Direct injected diesel engines require a minimum cetane number of 40 under nor- mal starting conditions. Fuel with a higher cetane value may be required for high alti- tude or cold weather operation. Filtration Fuel should be clean and free of contami- nation.
  • Page 58 Fuel System Fuel Pour Point Fuel pour point should be at least 10 F (6 C) lower than the lowest ambient tem- perature at which the engine must start and operate. Lower pour points of diesel fuel grade No. 1–D may be necessary in ex- tremely cold weather.

  • Page 59: Fuel Additives

    Fuel System Fuel Additives General Fuel additives are generally not recom- mended or needed for fuels listed earlier. Cetane improvers can be used as necessary. Biocides may be needed to eliminate mi- croorganism growth in storage tanks. In cold conditions, treatment for water in the vehicle tanks may also be necessary.
  • Page 60 Fuel System NOTE! Repair expenses resulting from malfunctions in the fuel system or with en- gine components when fuel enhancers have been used are not covered under warranty. Some fuel additives can be used to provide temporary relief but they do not replace good fuel handling practices.
  • Page 61 NOT allowed and must NOT be mixed in with the vehicle diesel fuel: Used Lubricating Oil: Volvo Trucks North America, Inc. does not recommend the use of any type of used lubricating oil as an extender in the diesel fuel. Used lubrication oil...

  • Page 62: Alternative Fuels

    This would make the vehicle illegal to drive on public roads. DO NOT use any kind of alternative fuel unless specifically authorized by Volvo Trucks North America, Inc.

  • Page 63: Oil System

    Always follow the oil change intervals and use the oil types that are recommended by the engine manufacturers. Oil change inter- vals for Volvo engines are found on page 61. Viscosity and capacity tables can be found beginning on page 166. Other engine...
  • Page 64 Engines meeting the 2000 and 2001 emis- sions requirements operate under higher soot loading conditions than previous en- W1000147 gines. This has led Volvo to require a Typical API Symbol higher grade oil that meets both API CH-4 and VDS-2 quality standards for model year 2000 and 2001 Volvo engines.
  • Page 65 Oil System Oil Change Intervals The length of time an engine is operated before an oil change depends on which quality oil is used, the type of fuel used, engine oil consumption, vehicle application, level of dust in the air, etc. The change in- tervals given in this manual are maximum intervals.
  • Page 66 Engines meeting the 2000 and 2001 emissions requirements operate under higher soot loading conditions than previous engines. This has lead Volvo to require an oil that meets both API CH-4 and VDS-2 quality standards for model year 2000 and 2001 Volvo engines.
  • Page 67 Oil System D7 Oil Change Intervals • • • Type of Average fuel Average fuel con- Average fuel consumption is sumption is over consumption is Operation under 6.0 miles 6.0 miles per gal- over 7.0 miles per gallon (over lon (under 4.0 per gallon (un- 4.0 liters per 10 liters per 10 km)
  • Page 68 Engines meeting the 2000 and 2001 emissions requirements operate under higher soot loading conditions than previous engines. This has lead Volvo to require an oil that meets both API CH-4 and VDS-2 quality standards for model year 2000 and 2001 Volvo engines.
  • Page 69 Oil System D12 Oil Change Intervals • • • Type of Average fuel Average fuel Average fuel consumption is consumption is consumption is Operation under 5.0 miles between 5.0 and over 6.5 miles per gallon (over 6.5 miles per gal- per gallon (un- 4.7 liters per 10 lon (between 4.7...
  • Page 70 Synthetic Lubrication Synthetic oils are offered as an alternative to the traditional, petroleum based oils for engines. These oils may be used in Volvo engines, provided they meet the quality lev- els specified on the previous pages, that is: API CG-4, CH-4, VDS or VDS-2.
  • Page 71 Only choose a monograde oil if the temperature is holding steady over a long period of time Volvo Trucks North America, Inc. recom- mends the viscosities shown in the viscosity/temperature table for Volvo en- gines. See page 167 for vendor engines.
  • Page 72 0.05% by weight for No. 2–D diesel fuel. For fuels that have a sulfur content of 0.5% by weight and above, Volvo Trucks North America, Inc. recommends that oil change intervals are cut in half so a shorter mileage is run between oil changes.
  • Page 73 Oil System Oil Consumption Check the oil level daily with the engine stopped. If the engine has just been stopped and it is warm, wait approximately 20 min- utes to allow the oil to drain back to the oil pan before checking. Add oil as necessary. NOTE! Do not overfill.

  • Page 74: Oil Sampling

    Oil System Oil Sampling General Oil sampling is a good tool for determining the condition of the engine. The oil sam- ples are taken regularly over the life of the engine and establishes a history of each specific engine. The sampling results “paint a picture”...
  • Page 75 Oil System Sampling Examples A new engine has a tendency to indicate high iron (Fe), lead (Pb) and copper (Cu) content during breaking in. Any left-over particles from the manufacturing process (foundry sand, machining filings, etc.) in- crease wear at this stage. Wear at this point should not cause any alarm as higher wear particle values nearly always show up dur- ing the breaking in period.
  • Page 76 Oil System Wear Particles The analysis values used for comparison — Oil and filter system total volume with each other must always come from the — Oil volume when taking sample same engine. The results must be evalued — Oil consumption with the knowledge of where the particles —...
  • Page 77 Combine the oil analysis with other diagnostic methods to further confirm what the unusual might be. For more information about oil intervals and oil sampling evaluation, it is available in the Technical Service Information, group 175, at your Volvo Trucks dealer.

  • Page 78: Severe Service Schedule For Vhd-Series

    Severe Service Schedule for VHD-Series General and Check-Chart Severe Service is defined here for vehicles that typically do maintenance de- pending on the accumulated engine hours rather than distance travelled. This includes applications that operate on road surfaces made of concrete, asphalt, maintained gravel, crushed rock or hard packed dirt or similar surfaces for 90% of the time, and up to 10% of the time in muddy or sandy conditions.
  • Page 79 Severe Service Schedule for VHD-Series Heavy Refuse Application: Oil Field Application: Typical operations include grades of maxi- Typical operations include grades over mum 12%, moving oil production related 20%, residential refuse and recycle pickup, materials, supplies and tools between job commercial and industrial pickup, typically sites or movement of processing equipment a high number of stops per mile.
  • Page 80 If the schedule does not fit your application, make modifications based on your experience of your application. Your Volvo Trucks dealer is also equipped to help you optimize the maintenance to suit your vehicle and application the best. When the interval hours or calendar time are reached, refer to the check-sheet to see what service categories need to be done.
  • Page 81 Severe Service Schedule for VHD-Series Severe Service Check-Chart Hours Service Interval Hours Service Interval Hours Service Interval 6,250 12,250 6,500 12,500 6,750 12,750 a A B a A B a A B 1,000 7,000 13,000 1,250 7,250 13,250 1,500 7,500 13,500 1,750 7,750...

  • Page 82: Maintenance Categories

    Severe Service Schedule for VHD-Series Maintenance Categories Category a: Category A: Every 250 Hours or 1 1/2 Months Every 500 Hours or 3 Months (Whichever comes first) (Whichever comes first) Perform the daily checks as described Clean engine and chassis before in- in the beginning of the vehicle Opera- spection.
  • Page 83 Manual) 36 Check pinion bearing for wear. 22 Check that all safety equipment are NOTE! The Volvo forward tandem present and in good working order. axle pinion is designed with a large bearing clearance. 23 Check operation of all windows and doors.
  • Page 84 Severe Service Schedule for VHD-Series 41 Check condition of paint and overall Steering and Suspension appearance of vehicle. 51 Check condition of air springs (if ap- plicable). Fuel System Wheels and Tires 42 Inspect fuel tanks for damage, leaks or corrosion.
  • Page 85 Severe Service Schedule for VHD-Series 62 Check the engine air filter restriction free from roughness or excess vibra- gauge. Change the filter if necessary. tion. (See page 119.) 71 Check for excessive free play in the 63 Check engine mounts. steering wheel.
  • Page 86 Severe Service Schedule for VHD-Series Category B: Every 1,000 Hours or 6 Months (Whichever comes first) Do the maintenance points as de- 15 Check shock absorber mountings and scribed under Category a and Category for signs of leakage. 16 Examine all rims for cracks. Inspect Check the frame for lose bolts.
  • Page 87 Do the maintenance points as de- Pressure test injectors or adjust height: scribed under Category a, A and B. • Volvo D7: Every 12 months or Change standard antifreeze every 2,000 hours. 4,000 hours. (See page 122 or page •...

  • Page 88: Heavy-Duty Service Schedule For Vhd-Series

    Heavy-Duty Service Schedule for VHD-Series General and Check-Chart Heavy-Duty Service is defined here for vehicles that typically travel an annual distance of maximum 65,000 miles (105,000 km) per year or less and operate under Heavy-Duty conditions. This include applications that travel primarily on freeways with some or frequent stop-and-go driving.
  • Page 89 Heavy-Duty Service Schedule for VHD-Series Heavy Line / Long Haul Application: Rescue Service Application: Typical operations include grades of maxi- Typical operations include specialized vehi- mum 12%, moving different types of cles for rapid acceleration to crash sites freight in high mileage operations more away from fire hydrant hookups, grades of than 65.000 miles (105,000 km) per year.
  • Page 90 If the schedule does not fit your application, make modifications based on your experience of your application. Your Volvo Trucks dealer is also equipped to help you optimize the maintenance to suit your vehicle and application the best. When the interval mileage or calendar time are reached, refer to the check-sheet to see what service categories need to be done.
  • Page 91 Heavy-Duty Service Schedule for VHD-Series Check-Chart for Vehicles with D7 Engine miles Service Interval miles Service Interval miles Service Interval (km) (km) (km) X 1,000 X 1,000 X 1,000 12.5 212.5 412.5 A B C (20) (340) (660) A B C (40) (360) (680)
  • Page 92 Heavy-Duty Service Schedule for VHD-Series Check-Chart for Vehicles with D12, Cummins or Detroit Diesel Engines miles Service Interval miles Service Interval miles Service Interval (km) (km) (km) X 1,000 X 1,000 X 1,000 A B C (24) (408) (792) A B C (48) (432) (816)

  • Page 93: Maintenance Categories

    Heavy-Duty Service Schedule for VHD-Series Maintenance Categories Category A: Every 12,000 miles (19,000 km) or 4 Months (For Vehicles with D7 Engine Using VDS-2 plus CH-4 oil) Every 15,000 miles (24,000 km) or 4 Months (For Vehicles with D12 Using VDS-2 plus CH-4 oil, Cummins or Detroit Diesel Engine) (Whichever comes first) Perform the daily checks as described Road Test...
  • Page 94 Heavy-Duty Service Schedule for VHD-Series In the Shop Yard Exterior 22 Check function of pneumatic controls. 38 Inspect steps and grabhandles. Make sure they are properly fastened and 23 Check steering column adjustment that there are no signs of breakage. function, if equipped.
  • Page 95 Heavy-Duty Service Schedule for VHD-Series 51 Check rear suspension torque rods, Brakes hangers and brackets for looseness or 61 Drain air tanks. If a lot of condensate cracks. Check springs for broken is drained, check air dryer. (See page leaves or wear and cracks on air 145.) springs.
  • Page 96 Heavy-Duty Service Schedule for VHD-Series Engine Compartment 77 Change primary (see page 129) and secondary (see page 131) fuel filters as 72 Visually inspect the component and all recommended. fluid pipes, hoses, seals, gaskets and connection points on engine, transmis- 78 Check clutch fluid level.
  • Page 97 Inspect fan for cracks and ment. damage. Inspect water pump for wear 18 If equipped with a Volvo engine, and leaks. check function of engine preheater. 11 Change power steering filter. (See page 143.) 12 Remove the cab fresh air filter after...
  • Page 98 (See page 122 or page 124.) Check coolant thermostat function ev- ery 2,000 hours. Pressure test injectors or adjust height: • Volvo D7: Every 12 months or 2,000 hours. • Volvo D12: No recommendation. • Cummins: Every 21 months or 3,800 hours.

  • Page 99: Maintenance

    Maintenance Engine Maintenance Exhaust Emissions General The Federal Clean Air Act, Section 203 (a) delivery of the vehicle to the ultimate pur- (3), states the following concerning the re- chaser, and, in addition, no manufacturer or moval of air pollution control devices or dealer may make take such action after sale modification of a certified engine to a non- and delivery of the vehicle to the ultimate...
  • Page 100 30 days. As the vehicle owner, you should also be aware that Volvo Trucks North America, Inc. may deny you warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 101 first placed in service. The emission control system of your new Volvo engine was designed, built and tested us- ing genuine Volvo parts, and the engine is certified as being in conformity with Federal and California emission control regulations.
  • Page 102 However, Volvo Trucks North America, Inc. may deny a warranty claim if your failure to perform required maintenance resulted in the failure of a warranted part. Receipts covering the performance of regular maintenance should be retained in the event questions arise con- cerning maintenance.
  • Page 103 The following is a list of the items that are considered a part of the Emission Control Sys- tems and are covered by the Emission Warranty when installed as original equipment by Volvo Trucks North America, Inc. on vehicles which were built to conform to Environ- mental Protection Agency and California Air Resources Board regulations IMPORTANT - This may not include expendable maintenance items.
  • Page 104 EPA Emissions Performance Warranty YOUR WARRANTY RIGHTS AND OBLIGATIONS The U.S. Environmental Protection Agency (EPA) and Volvo Trucks North America, Inc. (VTNA) are pleased to explain the emissions performance warranty on your vehicle. In compliance with section 207(b) of the Clean Air Act, VTNA must warrant the emission control system on your vehicle for the periods of time listed listed below, provided there has been no abuse, neglect or improper maintenance of your vehicle.
  • Page 105 As the vehicle owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Volvo Truck North America, Inc (VTNA) recommends that you retain all receipts covering maintenance on your truck, but VTNA cannot deny war- ranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
  • Page 106 first placed in service. The emission control system of your new Volvo engine was designed, built and tested us- ing genuine Volvo parts, and the engine is certified as being in conformity with federal emission control regulations.
  • Page 107 CUSTOMER ASSISTANCE Volvo Trucks North America, Inc. wishes to help assure that the Emission Control System Warranty is properly administered. In the event that you do not receive the warranty ser- vice to which you believe you are entitled under the Emission Control System Warranty, you should contact Volvo Trucks North America, Inc.
  • Page 108 Any parts replaced under warranty before the first re- quired replacement point are warranted for the remainder of the warranty period. Replacement items which are not genuine Volvo parts or not authorized by VTNA. Loss of time, inconvenience, loss of use of vehicle or engine, or commercial loss.
  • Page 109 Maintenance WHAT IS COVERED BY THE EMISSION WARRANTY The following is a list of the items that are considered a part of the Emission Control Sys- tems and are covered by the Emission Warranty when installed as original equipment by VTNA on vehicles which were built to conform to Environmental Protection Agency regu- lations.
  • Page 110 U.S. EPA Noise Control Regulations. This warranty covers this vehicle as de- signed, built and equipped by Volvo Trucks North America, Inc., and is not limited to any particular part, component or system of the vehicle manufactured by Volvo Trucks North America, Inc.
  • Page 111 Maintenance Tampering with Noise Control System Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;...
  • Page 112 Maintenance Cooling System Removing or rendering inoperative cooling system components (such as the tempera- ture modulated fan clutch, fan shroud, fan ring, recirculation shields, etc.). Exhaust System Removing or rendering inoperative exhaust system components (such as the muffler, pipes, clamps, etc.). Air Intake System Removing or rendering inoperative air in- take/induction system components (filter,...
  • Page 113 Maintenance Noise Control System, Operator Inspection and Maintenance Requirements Before inspecting a vehicle, set the park- ing brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious per- sonal injury or death.
  • Page 114 Maintenance Exhaust System Make sure the exhaust system is intact. In- WARNING spect for damage, misalignment and/or leakage. Primary system components re- Hot engine! Keep yourself clear of all quiring noise related inspection include moving parts or hot engine parts, ex- muffler body, exhaust manifold, tur- haust gases, and/or fluids.
  • Page 115 Maintenance Air Intake/ Air Induction System Make sure the air intake system is intact. Inspect components for damage, misalign- ment and/or leakage. Primary system components requiring noise related inspec- tion include the air cleaner housing, air cleaner element, turbocharger, charge air cooler and intake manifold.
  • Page 116 Maintenance Cooling System WARNING Do not work near the fan with the en- gine running or the ignition in the ON position. The engine fan can engage at any time without warning. Anyone near the fan when it turns on could be seri- ously injured.
  • Page 117 Maintenance Sound Shielding and Insulation Devices Make sure sound shielding and insulating devices are intact. Inspect components for damage. Primary system components re- quiring noise related inspection include the hood, engine compartment insulating mate- rials (including hood insulation, bulkhead insulation, doghouse insulation, etc.) splash shields, cab skirts, fender shields, and body panels.
  • Page 118 Maintenance Noise Control Log NOISE CONTROL SYSTEM MAINTENANCE LOG DATE MILEAGE MAINTENANCE MAINTENANCE PERFORMED FACILITY...
  • Page 119 Maintenance Maintenance Hazards Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death. Do not attempt to repair or service this vehicle without having sufficient train- ing, correct service literature and the...
  • Page 120 Maintenance Oil Change Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death. WARNING T1006392 A hot engine or engine oil can be dan-...
  • Page 121 Maintenance Oil Filters Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death. WARNING W2003480 Hot oil can cause severe burns.
  • Page 122 Maintenance Checking Oil Level NOTE! Do not let the oil level fall below the lower marking on the dipstick. Do not overfill so the level is above the upper marking on the dipstick. Wait five minutes after shutting off the en- gine before checking the oil level.
  • Page 123 Maintenance Engine Air Filter Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death. The engine air filter is monitored by a pres- W2003507 sure restriction gauge mounted on the air...
  • Page 124 Maintenance Fan Drive Belts Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death. WARNING W2001070 Hot engine.

  • Page 125: Flushing Cooling System, D7

    Maintenance Flushing Cooling System, D7 Coolant Filter WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot en- gine and/or fluid can cause serious burns. When using standard antifreeze, use a coolant filter containing the additives necessary for replenishing the used-up ad- ditives.
  • Page 126 Maintenance Draining Cooling System Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death. WARNING Do not remove the cap to the coolant surge tank while the engine and radiator...
  • Page 127 Maintenance Flushing Cooling System Before filling, flush out the system thor- oughly with clean water. Before flushing out the radiator, remove the lower radiator hose to allow a quicker and more efficient draining. When flushing the radiator, keep the water pressure low so the radiator tubes are not damaged.

  • Page 128: Flushing Cooling System, D12

    Maintenance Flushing Cooling System, D12 Draining Cooling System Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death.
  • Page 129 Maintenance Flushing Cooling System Before filling, flush out the system thor- oughly with clean water. Before flushing out the radiator, remove the lower radiator hose to allow a quicker and more efficient draining. When flushing the radiator, keep the water pressure low so the radiator tubes are not damaged.

  • Page 130: Turbo And Charge Air Cooler

    Maintenance Turbo and Charge Air Cooler General Do not remove, attach or tighten tur- bocharger air intake ducting while the engine is operating, or operate the engine while the ducting is removed. Working around the turbo with the ducting re- moved may cause severe personal injury.
  • Page 131 The use of a fin comb is also a good tool to loosen bugs and dirt from the fins. If dirt can not be cleaned off with this pro- cedure, consult your Volvo Truck dealer. Inspect the charge-air-cooler for cracks at every inspection. Do not operate the vehicle with a damaged or broken charge-air- cooler.

  • Page 132: Replacing Fuel Filters

    Maintenance Replacing Fuel Filters General The filters are an important part of the fuel system. Always replace the filters at the recommended intervals and use the recom- mended filter types for the best engine operation and service life. A primary fuel filter is located on the outer, right or left frame rail behind the cab.

  • Page 133: Fuel System Service

    Maintenance Fuel System Service Changing the Primary Fuel Filter Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death.
  • Page 134 Maintenance Separate the filter and the bowl. NOTE! Always dispose of fuel ac- cording to Federal or local regulations. Take all waste fuel to a recycling or waste collection center. Clean and dry the bowl. Attach it to a new filter. Use new seals at both bowl and filter head joint.
  • Page 135 Maintenance Changing the Secondary Fuel Filter Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death.
  • Page 136 Maintenance Wet the seal on the new filter with clean engine oil or fuel. CAUTION Never fill filter with fuel before in- stalling. Contaminated fuel causes accelerated wear to fuel system components. Spin on the new filter onto the filter head until it contacts the seal fully (no side movement evident).
  • Page 137 Maintenance Bleeding the Fuel System The fuel system will have to be bled if: • The tank has been emptied of fuel. • The engine has not been running for some time. (See also page 33 for oil pressure preparation). •...
  • Page 138 Maintenance Bleeding D12 Engine Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death. WARNING Hot engine.
  • Page 139 Maintenance Remove the protection cap from the filter bleed nipple. Connect a transpar- ent 5/16 in. (8 mm) plastic hose to the nipple. Open the nipple with an 11 mm wrench and pump the hand primer until clean, air-free fuel flows out of the hose.
  • Page 140 Maintenance Bleeding D7 Engine Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death. WARNING Hot engine.
  • Page 141 Maintenance Remove the protection cap from the filter bleed nipple. Connect a transpar- ent 5/16 in. (8 mm) plastic hose to the nipple. Open the nipple with an 11 mm wrench and pump the hand primer until clean, air-free fuel flows out of the hose.
  • Page 142 Maintenance Draining Water from the Fuel Tank Before working on or inspecting a vehi- cle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in un- expected vehicle movement and can cause serious personal injury or death.

  • Page 143: Transmission And Rear Axle Maintenance

    Maintenance Transmission and Rear Axle Maintenance Transmission General Transmissions should not be operated con- sistently at temperatures above 250 F (120 C). If the temperature reaches 285 F (140 C), stop the vehicle to let the tempera- ture go down (see the vehicle Operator’s Manual for information on the optional transmission temperature gauge).
  • Page 144 Maintenance Oil Quality WARNING Use only the specified type of single weight oils. Do not use multigrade oils or EP gear oils (for example axle lube oil such as GL-5 gear oils) as they may damage components. Monograde motor oils or transmission oil type API GL-1 are recommended for trans- missions.
  • Page 145 NOTE! Most rear axles today are run with a synthetic base oil. The Volvo rear axles are an exception. Do not use a synthetic base oil in Volvo rear axles. Seals will de- teriorate and leaks will develop. Rear axles should not be operated if the oil temperature exceeds 250 F (120 C).
  • Page 146 Maintenance Checking and Draining Oil Check the oil level through the top plug (1). The oil should be level with the hole. Add oil if necessary. Drain oil through the bottom plug. Oil should be darined immediately after driving while it is still hot. WARNING Hot oil can cause severe burns.

  • Page 147: Steering And Brakes Maintenance

    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 148 Maintenance Brake Safety Information The brake system is a critical vehicle Drain the air system tanks at the recom- safety system. For your safety and for mended intervals. If condensation those around you, follow the recom- accumulates, moisture can enter the mended preventive maintenance checks.
  • Page 149 Maintenance Air Tanks WARNING When draining the air tanks, do not look into the area of the draining air. Dirt or sludge particles may be in the air stream that could cause eye injury. Air tanks should be drained daily. Make sure the drain cocks close properly after draining.
  • Page 150 Maintenance Brake Slack Adjusters and Cam Before checking the slack adjusters, set the parking brakes, place the transmis- sion in neutral and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. To check the slack adjusters for proper throw, use a breaker bar to lever the slack adjuster out.
  • Page 151 Maintenance Check Valves Before working on or inspecting the ve- Compressed air components can separate hicle, set the parking brakes, place the violently during disassembly if air pres- transmission in neutral and block the sure is present. Before servicing any part wheels.
  • Page 152 All compressed air tubing and hoses need regular inspection. Check for signs of wear and that the routing is not near parts that can cause damage. Have any damaged tubing or hoses re- placed by your local Volvo Truck dealer. W3000838...

  • Page 153: Electrical System Maintenance

    Periodically, W3002368 the condition and the state-of-charge of WARNING each battery should be checked by a Volvo Truck dealer. Maintenance free batteries do Always wear eye protection when work- not require any attention other than keeping ing around batteries to prevent the risk them clean and firmly clamped in place in...
  • Page 154 Cab Marker Lamp (w/o sunvisor) 10 W Driving Lamp (Spotlight) H9420 50 W Fog Lamp H9415 37.5 W Instrument Telltale Lamps 3919844 (Volvo) 1.5 W Door Courtesy Lamp 10 W All Overhead Dome/Spot Lamp 1156 (dome) 25 W 67 (spot) 10 W...

  • Page 155: Tires, Wheels And Hub Maintenance

    Maintenance Tires, Wheels and Hub Maintenance Wheel Safety Information Do not attempt to repair wheels or tires Do not use mismatched wheel compo- unless you are trained and equipped to nents. If they do not exactly match the do so. Wheel and tire assemblies cannot original design specifications, they may be worked on without proper tools and cause failure or separation leading to an...
  • Page 156 Check front and rear wheel nut tightness with a torque wrench. All disc wheels for Volvo vehicles have a tightening torque of 450 ft-lb (610 Nm). Tighten the nuts in the correct sequence. For spoke wheels, check the manufacturer’s specifications. Inspect bolts and nuts for signs of wear or cracks.
  • Page 157 Maintenance Failure to properly torque-tighten the wheel nuts can result in the breakage of wheel studs and the subsequent loss of wheels. Loss of vehicle control and seri- ous personal injury or death can occur. W7000774 8 and 10–stud wheelnut tightening This check tightening is particularly impor- sequence.
  • Page 158 Motor oil should be SAE 30 or 15W40. The oil can be either petroleum based or synthetic (synthetic should not be used for the Volvo axle). Axle oil, API GL-5, SAE 75W-90, can also be used.

  • Page 159: Chassis Maintenance

    Maintenance Chassis Maintenance Springs NOTE! This work is best performed by a Volvo Truck dealer or other service outlet having the proper equipment. The spring package is fastened to the axle beam with U-bolts. It is important that the U-bolt nuts are properly tightened. The nuts may loosen up with time.
  • Page 160 T-Ride Equalizer Beams The Volvo T-Ride suspension has equalizer beams between the tandem axles. The beam bushing needs to be lubricated at the normal lube intervals for normal highway driving.

  • Page 161: Cab Maintenance

    Maintenance Cab Maintenance Doors The door lock mechanism should be greased annually using white grease. Lubri- cate 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 162 Maintenance Rustprotection The rustprotection applied when the cab was produced is adequate for normal use and service. If an extension of the cab rust- protection is desired or if the vehicle is used in a severe application, it is recommended that cavity wax is re-applied every 3rd year.
  • Page 163 Maintenance Lacquer and Brightwork Care Paint Wash all exterior painted surfaces fre- quently to remove dirt. It is especially important to wash off salt-laden snow and ice during the cold season. A mild detergent can be used but avoid strong detergents. NOTE! Do not aim the water jet directly at door and window seals or door locks.
  • Page 164 Maintenance Chassis Keep the chassis free from buildup of dirt. Make sure the chassis is cleaned before the maintenance inspections to help spotting leaks, etc. As salt can be part of the road sludge during the cold season, remove buildup of snow and ice so it does not pro- mote corrosion.
  • Page 165 Maintenance Chrome Chromed surfaces will rust if they are not protected. This is especially important dur- ing the cold season when roads are salted or in coastal areas where the salt level in the air is high. Clean chrome surfaces with clean water. If the surface has heavy dirt or tar spots, use a tar remover.

  • Page 166: Lubrication, Vhd

    10,000 miles (16,000 km) or less. NOTE! Always grease a Volvo front axle with the wheels on the ground. All lubricating points are found on the chassis lubrication chart on the next page.
  • Page 167 Maintenance Lubrication Chart Spring hanger (2) Coolant level Note 8 Note 1 Slack adjuster & brake Steering assist cylin- cam (4) Note 9 der. Note 18 Steering gear (1) Power steering fluid Note 10 Note 2 Kingpin, upper & lower (4) Wheel bearings Note 11 Note 3...
  • Page 168 Use a mineral or synthetic oil. Check fication API NLGI No. 2. oil level periodically. Level should be NOTE! Always grease a Volvo front to the bottom of the inspection hole. axle with the wheels on the ground. See page 166 for oil types.
  • Page 169 Maintenance 12 Use a lithium based grease with speci- fication API NLGI No. 2. NOTE! Volvo axles may use a greased-for-life tierod. No provisions for adding grease are available. 13 Use a lithium based grease with EP additives to specification API NLGI No.

  • Page 170: Viscosity And Capacity Tables

    Maintenance Viscosity and Capacity Tables Volvo Engine D7C For oil change intervals, see page 61 First oil and filter After 1 month or change 6,000 miles (10,000 km) Capacity (including filters) D7C service 22 quarts (21 liters) Oil volume be- 7.0 quarts (6.5...
  • Page 171 Maintenance Cummins Engine ISM For oil change intervals, see the manu- facturer’s Operator’s Manual Capacity (including filters) ISM, service 39 quarts (37 liters) ISM, oil volume 7-9 quarts between high and (6.5-8.5 liters) low on dipstick ISX, service 41 quarts (39 liters) W2002132 ISX, oil volume 8-9.5 quarts...
  • Page 172 Maintenance Fuller Transmission 9,10, 13, 15 and 18–speed For oil change intervals, see the manu- facturer’s Oparator’s Manual Capacity: 9-speed ....13.5 quarts (12.0 liters) 10, 13, 15 and 18- 14.0 quarts speed ....(13.0 liters) W4000879 Allison Automatic Transmission For oil change intervals, see the manu- facturer’s Operator’s Manual.
  • Page 173 Maintenance Volvo Tandem CTEV87 and RT3210 Oil type: Petroleum based API-GL5, MIL- oil ...... PRF-2105E First oil change After one month or 6 000 miles (10 000 km) Normal oil change every 12 month or interval ....75 000 miles...
  • Page 174 Maintenance Meritor Single RS23, 25, 26 and 30 Meritor Tandem RT40, 44 and 46 For oil change intervals, see the manu- facturer’s Operator’s Manual Capacity: RS23-160 ..20 quarts (19 liters) RS23-185 ..23.5 quarts (22.5 liters) RT40-145, front 15 quarts W4000881 tandem (14 liters)
  • Page 175 Maintenance Steering Hydraulic System Fluid type ..Automatic Trans- mission Fluid ® (ATF) Dexron Change interval every 150,000 miles (240,000 km) Hubs Oil type Temperature Motor oil API Minimum: -15 F CD or CE, SAE (-25 C) 30, 15W40 or Maximum: No limit synthetic Gear oil API...

  • Page 176: Literature

    Personal Trained staff for handling Assurance any vehicle problems. There is also a direct number to Volvo Ac- tion Service (VAS), staffed 24 hours a day, Uptime VAS will locate the near- if you are in need of assistance. The num-...
  • Page 177 To order a single Service Manual or a Ser- vice Manual Set for your vehicle, you should contact your authorized Volvo Truck dealer or fax a request to the Volvo Truck North America, Inc. publications warehouse (Fax: (336) 668–3625). They will help you locate the manual(s) you need.

  • Page 178: Service Charts

    Regular maintenance inspections should be continued. The maintenance program and lu- brication intervals that are listed in this manual may not suit your operation. Contact your nearest Volvo dealer, who can help with designing a maintenance program that works in your application.
  • Page 179 Service Charts...
  • Page 180 Service Charts...

  • Page 181: Repair Record

    Service Charts Repair Record Keep track of repairs beeing made. This helps over the lifetime of the vehicle to spot trends that can be used to alter maintenance schedules, for example.
  • Page 182 Service Charts...
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  • Page 187: Tire Record

    Service Charts Tire Record Tire Hints Hints on How to Avoid Unnecessary Tire Wear • Maintain correct tire pressure • Check the tire pressure when the tires are cold • Check that valve caps are not missing • Keep the wheels balanced •...
  • Page 188 Service Charts Typical Wear Patterns Incorrect Air Pressure Too high air pressure gives rapid wear in the middle. Too low air pressure gives rapid shoul- der wear. T1006457 Incorrect Camber Incorrect camber gives abnormal wear on one half of the tire. T1006458 Incorrect Toe and Axle Alignment Incorrect toe-in.
  • Page 189 Service Charts Dual Wheel Mounting Excessive road camber, different types of tire, different circumference or off- center loading gives faster wear on one tire. Too low air pressure, mismatched rims for the tire type and dimension, excess flexing in tire wall, or different types of tires in inner and outer tires gives contact wear.
  • Page 190 Service Charts Spot Wear Sudden braking, locking brakes or out-of- round brake drums gives spot wear. T1006721 Feathered Edges Normal occurrence on non-driving wheels on good roads and high mileage. T1006722 Cupping Cupping is a normal occurrence that de- pends on the tread pattern; the higher the load, the greater the wear.
  • Page 191 Service Charts AXLE LOAD/TIRE PRESSURE Axle Load Recommended tire pressure lb (kg) psi (kPa) W1000109...
  • Page 192 Service Charts Tire Record Size Ply Rating Make Type Serial No.
  • Page 193 Service Charts Tire Record Mileage Date Date Tire Notes Installed Removed Mileage At Installation At Removal...
  • Page 194 Service Charts Tire Record Size Ply Rating Make Type Serial No.
  • Page 195 Service Charts Tire Record Mileage Date Date Tire Notes Installed Removed Mileage At Installation At Removal...
  • Page 196 Service Charts Tire Record Size Ply Rating Make Type Serial No.
  • Page 197 Service Charts Tire Record Mileage Date Date Tire Notes Installed Removed Mileage At Installation At Removal...

  • Page 198: Fuel And Oil Record

    Service Charts Fuel and Oil Record Keeping track of the fuel and oil consumption gives a record of what is normal for the ve- hicle. 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 199 Service Charts...
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  • Page 211: Index

    Index Index Electric Grounding Practices . . . 17 Air Dryer Maintenance ..145 Electric System, Precautions . . . 17 Air Filter, Cab ..158 Electronic System Precautions . . 18 Air Filter, Engine .
  • Page 212 Oil Sample Recommendations . . 72 Vendor Component Information . 1 Oil Sample Wear Particles ..72 Volvo Action Service ..172 Oil Sampling, General ..70 Volvo D12 Oil Capacity ..166 Oil Sampling, Taking .
  • Page 213 7 days per week at 1-877-978-6586. This assistance is available to help you with solving technical issues and parts issues regarding the Volvo Heavy Duty (VHD) model vehicle. A trained Volvo VHD Specialist for Technical and Parts Support will give you the assistance you need to resolve your problem.
  • Page 214 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-TSP20 154789 (5000) 10.2001 © Volvo Trucks North America, Inc. , 2001...

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