Volvo VN Service Manual
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Volvo VN Service Manual

Volvo VN Service Manual

Rustproofing cab group 182–500
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Service Manual
Trucks
182–500
Group
Rustproofing Cab
VN, VHD
PV776-TSP144735

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Summary of Contents for Volvo VN

  • Page 1 Service Manual Trucks 182–500 Group Rustproofing Cab VN, VHD PV776-TSP144735...
  • Page 2 Greensboro, NC USA Order number: PV776-TSP144735 © 2000 Volvo Trucks North America, Inc., Greensboro, NC USA All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means, electronic, me- chanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc..

  • Page 3: Table Of Contents

    Contents General ....................3 Rustproofing Information ............... 3 Specifications ..................5 Cavity Wax ..................... 5 Tools ......................7 Rustproofing, Special Equipment ............7 Design and Function ................9 Rustproofing Cab ................... 9 Service Procedures ................11 General Work Procedures ..............11 Rust Prevention, Inspection ..............

  • Page 5: General

    This manual covers information and procedures for rust- bodyshop that repaired the cab will warrant the repair proofing all types of cabs for the VN and VHD series. All area to cover any future rust and/or structural problems information needed for carrying out the work procedure stemming from the repair.

  • Page 7: Specifications

    Group 18 Rustproofing Specifications Specifications Cavity Wax Type ............................Solventborne, semi-firm Drying time ............................... 24 h (fully dry) Application temperature ........................above 18 C (70 Minimum wax coating thickness ......................10 m (0.0004 in.) Heat resistance ..........................max. 100 C (212 Tested lifetime ............................

  • Page 9: Tools

    Group 18 Rustproofing Tools Tools Rustproofing, Special Equipment The equipment can be ordered from Air Power, Inc., P.O.Box 773, 520 Apperson Dr., Salem, VA 24153, Ph. (800) 848–1011. W0001585 VRS-100 Cavity Wax Spray Kit (takes a 5 gallon pail) Cavity Wax Order in 5 gallon pails from: Order aerosol spray cans (for spot treatment) from: Wax, type 74–104S...

  • Page 11: Design And Function

    Group 18 Rustproofing Design and Function Design and Function Rustproofing Cab General W1000098 In production, the cab is treated against rust with several coats of primer and paint over a surface preparation pro- cedure. This gives very good initial rust coverage. In some areas, rust protection is added on top of the paint to increase the rust protection (see shaded areas in the illustration).
  • Page 12 Group 18 Rustproofing Design and Function Application Rust is iron oxide (Fe ). Rust forms in the presence of water (H O) on an unprotected iron surface or where the primer and top coat is damaged. Cavity wax works on the principle that if air and moisture cannot reach the material surface, there cannot be any oxidation of the material.

  • Page 13: Service Procedures

    Group 18 Rustproofing Service Procedures Service Procedures General Work Procedures 1821-06-02-01 Rust Prevention, Inspection Before beginning rust protection inspection, read about warranty information under “Rustproofing Information” PERSONAL INJURY HAZARD! Before working on a page 3, basic information under “General Work Proce- vehicle, set the parking brakes, place the transmission dures”...
  • Page 14 Group 18 Rustproofing Service Procedures W8001379 If the vehicle is equipped with me- Torx 25 chanical window regulators, remove the crank. Lift the vinyl cover in the wide end and push it to the side. Re- move the screw. W1000112 Remove the lower part of the door 16 mm socket, rear grab handle.
  • Page 15 Group 18 Rustproofing Service Procedures Disconnect the electrical connectors Torx 25 for the electrical equipment in the door panel. Remove the door panel. W8001381 Remove the three bolts and three 14 mm socket, screws holding the panel to the door. Torx 25 W1000091 Inspect the inside, lower half of the...
  • Page 16 Group 18 Rustproofing Service Procedures W1000095 W1000093 Remove plastic plugs along the inside mirror, Sleeper cabs only: mirror, of the bottom rail. Inspect for signs of flashlight Open luggage door. Locate the vent in flashlight rust on the inside of the bottom rail. In- the rear end of door frame.

  • Page 17: Rust Prevention, Retreatment (Complete Cab)

    Group 18 Rustproofing Service Procedures 1821-09-02-02 Rust Prevention, Retreatment (Complete Cab) Daycab Before beginning rust prevention retreatment, read about warranty information under “Rustproofing Information” page 3, basic information under “General Work Proce- dures” page 11, material under “Specifications” page 5, application techniques under “Application”...
  • Page 18 Group 18 Rustproofing Service Procedures W1000101 Remove the door switch for the interior Torx 25, light. Insert the application wand in Cavity wax through the switch hole forward into spray kit the bottom rail cavity. The total length should be inserted. Fully depress the spray gun trigger, then slowly pull the application wand back out from the bottom rail at the...
  • Page 19 Group 18 Rustproofing Service Procedures W8001379 If the vehicle is equipped with me- Torx 25 W1000104 Remove the side repeater lamp lens Philips, chanical window regulators, remove and base. Coat the cavity behind the Torx 25, the crank. Lift the vinyl cover in the lamp.
  • Page 20 Group 18 Rustproofing Service Procedures Lift the upholstery away from the door. Torx 25 Disconnect the electrical connectors for the electrical equipment in the door panel. Remove the door panel. Note the position of wiring that may be Torx 25 taped to the cover plate.
  • Page 21 Group 18 Rustproofing Service Procedures W8001379 If equipped, install the window regula- Torx 25 tor handle. W8001382 Lift the door upholstery into place. Connect all electrical connectors. In- stall the door upholstery and secure with the “christmas tree” fasteners. W8001398 Install the door handle knob.

  • Page 22: Rust Prevention, Retreatment (Complete Cab)

    Group 18 Rustproofing Service Procedures 1821-09-02-02 Rust Prevention, Retreatment (Complete Cab) Sleeper Cab Before beginning rust prevention retreatment, read about warranty information under “Rustproofing Information” page 3, basic information under “General Work Proce- dures” page 11, material under “Specifications” page 5, application techniques under “Application”...
  • Page 23 Group 18 Rustproofing Service Procedures W1000103 Insert the application wand in through the switch hole rearward into the bot- tom rail cavity. The total length should W1000101 Remove the door switch for the interior Torx 25, be inserted. light. Insert the application wand in Cavity wax through the switch hole forward into spray kit...
  • Page 24 Group 18 Rustproofing Service Procedures W8001398 Remove the knob on the door by Torx 10 pulling the rubber plug out with a scriber. Remove the screw. W8001380 Using a small, flatblade screwdriver, carefully remove the six plugs in the door panel. W8001379 If the vehicle is equipped with me- Torx 25...
  • Page 25 Group 18 Rustproofing Service Procedures W1000105 Coat the lower door cavity with cavity Cavity wax wax up to 50 mm (2 in.) from the spray kit bottom. With the application wand in- serted in the door cavity, move the wand as necessary to ensure com- plete coverage.
  • Page 26 Group 18 Rustproofing Service Procedures W8001379 If equipped, install the window regula- Torx 25 tor handle. W8001382 Lift the door upholstery into place. Connect all electrical connectors. In- stall the door upholstery and secure with the “christmas tree” fasteners. W8001398 Install the door handle knob.
  • Page 27 Group 18 Rustproofing Service Procedures W1000108 Coat the lower luggage compartment W1000106 hatch cavity with cavity wax up to Open luggage door. Remove the com- Torx 25, 50 mm (2 in.) from the bottom. With partment light switch from the C-pillar. Cavity wax the application wand inserted in the Insert the application wand in the...

  • Page 29: Feedback

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

  • Page 31: Operation Numbers

    Operation Numbers 1821-06-02-01 Rust Prevention, Inspection ......11 1821-09-02-02 Rust Prevention, Retreatment (Complete Cab) ....15, 20...
  • Page 32 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-TSP144735 (1 000) 8.2000 © Volvo Trucks North America, Inc., 2000...

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