Volvo VN 2002 Service Manual
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Volvo VN 2002 Service Manual

Volvo VN 2002 Service Manual

Group 17, preventive maintenance, basic service, from build date 11.2002 to 12.2006
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Service Manual
Trucks
17
Group
Preventive Maintenance
Basic Service
VN, VHD VERSION2
From build date 11.2002 to 12.2006
PV776-20178991

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Summary of Contents for Volvo VN 2002

  • Page 1 Service Manual Trucks Group Preventive Maintenance Basic Service VN, VHD VERSION2 From build date 11.2002 to 12.2006 PV776-20178991...
  • Page 2 Repl: This Service Manual replaces Manual 17 “Preventive Maintenance Basic Service” (10.2002) Publication no. PV776–TSP176304. © 2007 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, mechanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc.

  • Page 3: Table Of Contents

    Contents General ....................3 Preventive Maintenance, General ............3 Safety Advice ..................7 Specifications ..................9 Engine ....................9 Transmission ..................11 Rear Axle, Lubrication ................. 11 Suspension ..................12 Tools ...................... 13 Special Tools and Special Equipment ..........13 Preventive Maintenance Inspection Bay ..........

  • Page 5: General

    The program in this service manual covers all types of Volvo VN/VHD and The driver is taking part in the continuous preventive VT vehicles with medium to high mileage and sometimes maintenance program by completing the required Daily high loads.
  • Page 6 Group 1, “Oil and maintenance needs. Filter Change Intervals for Volvo Components,” publication The “Driver Inspection Form” is also required by Federal number 175-60, “Approved Oils Lists, Volvo Components”.
  • Page 7 Group 177 General Other Inspection There are additional service points that are carried out at specific mileage or time intervals. These are not part of the Preventive Maintenance Basic or Annual time. They should be scheduled as an adjustment or repair job carried out at the same time as their respective Preventive Maintenance, and are listed in this document as reminders only.
  • Page 8 U.S. EPA Noise Control Regulations, at the Removing or rendering inoperative the cab tunnel or hood time it left the control of Volvo Trucks North America, Inc. noise insulating materials. This warranty covers this vehicle as designed, built and Removing or rendering inoperative any truck body equipped by Volvo Trucks North America, Inc., and is not...

  • Page 9: Safety Advice

    Group 177 General Safety Advice You must read and understand the precautions and guidelines in Service Information, Groups 1-9, “General Safety Practices” before performing any of these procedures. Ask your supervisor for training, If you are not properly trained and certified in any of these procedures. WARNING DANGER Clean up fuel spills immediately.

  • Page 11: Specifications

    To be able to run the cooling system as long choice of correct oil a hard task. The Volvo dealer, the as 2 years between coolant changes, there must be a engine manufacturer or the oil manufacturer has the replenishment of additives as they are used up.
  • Page 12 Publication Number 175–61, and appropriate vendor literature. Maximum change intervals are 40,000 km (25,000 miles) if using oil that meets the Volvo Drain Specification -2 (VDS -2) . If the oil does not meet the requirements according to VDS, change intervals should be 24,000 km (15,000 miles) or 4 months for basic service and 96,000 km (60,000 miles) or 12 months for annual service.

  • Page 13: Transmission

    Includes Volvo, Eaton Fuller, Meritor, and Allison HD Transmissions For further information concerning component specifications see service information in Service Bulletins, “Oil and Filter Change Intervals for Volvo Components,” and “Approved Oils Lists, Volvo Components”, Function Group 1, and any appropriate vendor literature.

  • Page 14: Suspension

    Group 177 Specifications Suspension For further information refer to all Volvo Suspension literature and appropriate vendor literature. U-Bolt Tightening Note: Some vehicles are equipped with huck u-bolts on the rear suspension when produced. These u-bolts are not reusable. It is not necessary, nor is it recommended to re-torque them.

  • Page 15: Tools

    Special Tools and Special Equipment The following special tools are recommended for use in the preventive maintenance inspection. Special tools can be ordered through the Volvo Special Tools program in the parts ordering system or directly from Kent-Moore by calling (800) 328–6657.
  • Page 16 Group 177 Tools Other Special Equipment W0001985 W7000708 J-36795 J-38460-A Tandem Axle Calipers Digital Inclinometer W0001843 J-44701 3093472 Battery Tester Kit Timken Wheel End Play Gauge...
  • Page 17 Group 177 Tools VCADS Pro Tools The following hardware is used to operate VCADS Pro. The tools can be ordered from Volvo Trucks North America; please refer to the specific tool number when ordering. W5001142 C0000285 1 PC tool-package 5 J-43939, 9 pin Diagnostic adapter (for vehicles built...

  • Page 18: Preventive Maintenance Inspection Bay

    Tools Lighting System, Special Tools The tools listed below are used to complete maintenance on the Lighting System for Volvo Trucks. They may be obtained from Volvo, or where indicated, from Kent Moore at (800) 328-6657. J-25300-D Headlight Aiming Kit (Kent Moore)

  • Page 19: Design And Function

    Distance C is set when the clutch is new. During wear of clutch, the distance will decrease. Readjustment should not be needed before it is time to reface the clutch disc. Fig. 2: Volvo Clutch Slave Cylinder...
  • Page 20 Group 177 Design and Function Other Clutch Slave Cylinder A slave cylinder for any non-Volvo clutch has a wear indicator. When the indicator is out of the operating range, it is time to adjust the clutch. To get the slave cylinder throw into the accepted range, adjust the clutch plate until the indicator is in the operating range again.

  • Page 21: Power Take-Off

    “Approved Oils Lists, Volvo Components”, Function Group 1, and any appropriate vendor literature. Volvo PTO’s mount directly to the transmission and do not need separate oil fill and check. Make sure there is extra oil filled in the transmission for the PTO volume.

  • Page 22: Brakes

    Brake Cams and Slack Adjusters For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175-60, “Approved Oils Lists, Volvo Components”, Publication Number 175–61, and appropriate vendor literature.

  • Page 23: Steering System

    Steering System Steering Linkage and Knuckles For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175-60, “Approved Oils Lists, Volvo Components”, Publication Number 175–61, and appropriate vendor literature.

  • Page 24: Hubs

    Design and Function Steering System For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175-60, “Approved Oils Lists, Volvo Components”, Publication Number 175–61, and appropriate vendor literature.

  • Page 25: Chassis, Lubrication

    Springs and Suspension For further information concerning component specifications see service information in Service Bulletins, “Oil and Filter Change Intervals for Volvo Components,” and “Approved Oils Lists, Volvo Components”, Function Group 1, and any appropriate vendor literature. Lubricate spring pins using a lithium based grease with EP additives and the consistency of NLG1 No.2.

  • Page 26: Cab, Lubrication

    These vehicles do not require lubrication. For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175-60, “Approved Oils Lists, Volvo Components”, Publication Number 175–61, and appropriate vendor literature.
  • Page 27 Group 177 Design and Function Hood Hood lock lever (front latch) is coated with teflon and should not need any conventional lubrication. If the mechanism is working hard or binds, try cleaning first. Clean and lubricate the scissor latch at the base cone receptacle with white grease.

  • Page 29: Preventive Maintenance

    Group 170 Preventive Maintenance Preventive Maintenance Check Oil Level in Manual Transmission Including Lubrication and Oil Change Date: Model: Reg. No.: Time: Vehicle Identification Number: Engine: Dealer Code: Transmission Name: Rear Axle: √ = Correction not needed X = Corrected without comment N = Not relevant or applicable Lubrication, Oil and Fluid Level Check Cab Checks...
  • Page 30 Group 170 Preventive Maintenance Engine Compartment Checks Checks Beneath the Vehicle Check Alternator Mounting and Electrical Check Retarder for Leakage Connections Check Drive Shaft, Universal Joints, Sliding Joints Check Drive Belts and Support Bearings Check Radiator Fan, Fan Shroud and Fan Ring Check Sealing of Rear Axle and Hub Reduction with Rubber Seal Gear...
  • Page 31 Group 170 Preventive Maintenance Reception When the customer drops off the vehicle, the service receptionist starts the paperwork and prepares the forms needed for the preventive maintenance. Ask the customer about problems that have been noticed while driving the vehicle. Ask questions that will make the job easier for the technician to find problem sources: —...
  • Page 32 Group 170 Preventive Maintenance Lubrication Make sure that grease fittings are cleaned off before filling grease. Dirt on the fitting that is not cleaned off is pushed into the part with the new grease. Always fill grease to the point where old grease and contaminants are forced out from the part and only new grease comes out.
  • Page 33 Group 170 Preventive Maintenance W1000189 The numbers in the lubrication Grease Coolant chart correspond with the Hub Oil Aut. Transm. Fluid numbered notes on page 32 aand page 33. Read these notes Engine Oil Man. Transm. Oil before selecting a lubricant. Hydraulic Oil Rear Axle Oil Steering Fluid...
  • Page 34 T-Ride & B-Ride bogie beam (48k-70k suspension): Use a lithium based grease with EP Note: Always grease a Volvo front axle with the wheels additives to specification API NLGI No. 2. Make sure on the ground. the grease purges out of both the outer and inner Note: To grease non-Volvo axles, they are typically seals.
  • Page 35 Group 170 Preventive Maintenance Rear axle: Check the oil level in the differential by Fifth wheel: The fifth wheel and slider assemblies removing the fill/level plug in the housing. The oil should always be re-lubricated after steam cleaning should be level with the bottom of the fill/level plug or at least every 15,000 miles (24,000 km).
  • Page 36 Front Axle Steering Knuckles Volvo: Two grease fittings on each side-one on the top knuckle cover (fill with grease until the old grease is forced out past the top seal), one on the bottom cover (fill with...
  • Page 37 Preventive Maintenance Steering Linkage Steering shaft and draglink are lubed for life. Tie-rod for Volvo front axles are lubed for life. Meritor and Eaton front axle tie-rods need to lubricated. Fill tie-rod end with grease until old grease is forced out past the rubber boot and only uncontaminated grease is visible.
  • Page 38 5 After the check and/or service has been completed, lower the vehicle. Clutch Bearing and Cross Shaft Volvo clutch is sealed for life and does not need lubrication. Vendor clutch cross shafts and release bearings need to be lubricated. The cross shaft bearings are remotely lubricated by a hose.
  • Page 39 An ungreased U-joint bearing will fail after a short time. If vehicle is equipped with a PTO that has a driveshaft, lubricate its U-joints. Volvo T-Ride & B-Ride Note: Some vehicles are equipped with newer versions of the T-Ride & B-Ride Suspensions that use conical bushings.
  • Page 40 Group 170 Preventive Maintenance Fifth Wheel Note: For further information refer to Function Group 9. Lubricate the plate pivot points and slide mechanism. Apply a heavy coat of grease on top of the plate.
  • Page 41 Group 170 Preventive Maintenance Cab Lubrication Lubricate Door Locks Hood lock lever (front latch) is coated with teflon and should not need any conventional lubrication. If the mechanism is working hard or binds, try cleaning first. Clean and lubricate the scissor latch at the base cone receptacle with white lithium grease once per year.
  • Page 42 Change Engine and Oil Filters For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175-60, “Approved Oils Lists, Volvo Components”, Publication Number 175–61, and appropriate vendor literature.
  • Page 43 Group 170 Preventive Maintenance Oil Filters CAUTION Use only the engine manufacturer’s oil filter for replacement. Use of an oil filter not built to specification could result in severe damage to bearings, crankshaft, etc. as a result of unfiltered oil entering the lubrication system.
  • Page 44 Check Oil Level In Manual Transmission For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175-60, “Approved Oils Lists, Volvo Components”, Publication Number 175–61, and appropriate vendor...
  • Page 45 Note: For further information refer to “Transmission” page For further information concerning component specifications see service information in Service Bulletins, “Oil and Filter Change Intervals for Volvo Components,” and “Approved Oils Lists, Volvo Components”, Function Group 1, and any appropriate vendor literature.
  • Page 46 Group 170 Preventive Maintenance Cold Check: Note: The fluid level rises as its temperature rises. Do not fill above the Cold Run band if the transmission fluid is below normal operating temperatures. 1 The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made.
  • Page 47 Group 170 Preventive Maintenance Hot Check: Note: The fluid must be hot to insure an accurate check. The fluid level rises as the temperature increases. 1 Operate the transmission in Drive (D) range until normal operating temperature is reached: • sump temperature 71–93 C (160–200 F) •...
  • Page 48 Note: For further information refer to page 19. Power Take-Off Volvo PTO Volvo PTOs mount directly to the transmission and do not need separate oil fill or checks. Make sure there is extra oil filled in the transmission for the PTO volume.
  • Page 49 Group 170 Preventive Maintenance Check Oil Level in Retarder To ensure the correct oil level in the retarder the oil level should be checked when the retarder is warm. Check Oil Level in Transfer Case Not applicable for VN/VHD and VT vehicles. Level/Fill Plug Drain Plug...
  • Page 50 Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175-60, “Approved Oils Lists, Volvo Components”, Publication Number 175–61, and appropriate vendor literature. Note: Synthetic oil is not recommended for the Volvo transmissions.
  • Page 51 Filter Change Intervals for Volvo Components,” publication number 175-60, “Approved Oils Lists, Volvo Components”, Publication Number 175–61, and appropriate vendor literature. Note: Synthetic oil is not recommended for the Volvo transmissions. Note: Independent shift units require an lubrication check, independent of the axle lubrication check.
  • Page 52 The suggested types are SAE 30 or 15W40. It is acceptable to use either synthetic or petroleum based oils (Synthetic oils are not recommended for Volvo Axles). Axle oils API GL-5 and SAE 75W-90 are acceptable as well.
  • Page 53 Group 170 Preventive Maintenance Check Oil Level in Clutch Fluid Reservoir Note: For further information refer to “Clutch” page 17. Check fluid level in the clutch fluid reservoir. Refer to lubrication chart on page 31. Replace clutch fluid every year to prevent corrosion problems in the system due to trapped moisture.
  • Page 54 Group 170 Preventive Maintenance Check Fluid Levels in Windshield Wiper and Headlamp Wiper Reservoirs Check fluid level in the washer fluid container regularly. Add if necessary. Check Air Dryer Air Dryers Air Dryers have internal maintenance systems that clean out the accumulated moisture frequently and can therefore work with long maintenance intervals.
  • Page 55 Note: For vehicles with the Traction Control System (TCS) five ’chuffs’ occur for each valve. If the vehicle is equipped with a Volvo engine, the engine preheater indicator stays on three to four seconds. If the coolant temperature is over 50...
  • Page 56 Group 170 Preventive Maintenance Check for Fault Codes in the Vehicle Electronic Control Unit The instruments and engine control units, are always included in the system. Other included control units depend on the vehicle variant, legal requirements, and the vehicle specifications. The control units are: •...
  • Page 57 Group 170 Preventive Maintenance Check for Fault Codes in the Engine Electronic Control Unit Use Service Information in Function Group 23 as a reference. When reading fault codes perform the following: • The engine is off. • The parking brake is applied. •...
  • Page 58 Group 170 Preventive Maintenance Check for Fault Codes in Transmission Note: Use Service Information in Function Group 40 as a reference. To complete the Fault Code Check for Transmission perform the following: 1 Check that no fault codes for the Transmission are saved in the Vehicle ECU.
  • Page 59 Group 170 Preventive Maintenance Check Retarder Control Ensure that the control’s steps are well-defined and that the control stops in the set position. Check Sealing on Main Brake (Service) To perform the check of the Main Brake Seal perform the following: 1 Start engine.
  • Page 60 Group 170 Preventive Maintenance Check Gear Shift and Clutch Pedal To perform a service check on the Gear Shift and Clutch Pedal complete the following: 1 Move the gearshift to range and split gear positions. Listen to the sound when passing through neutral and checking the range gear.
  • Page 61 Group 170 Preventive Maintenance External Checks Function Check of External Lamps To perform a function check of the External Lamps perform the following: 1 Check all external lighting for functionality. 2 Check that all lamps are in good condition. W3005266 Check Mirrors and Reflectors To perform a function check of the mirrors and reflectors complete the following:...
  • Page 62 Group 170 Preventive Maintenance Function Check of Wipers and Washers Check the wiper arm tension and condition of the wiper blades. W3004393 Check Batteries - Dirt, Leakage, Attachment, Specific Gravity of Battery Acid, Fluid Level, Connections and Battery Note: Batteries on U.S. vehicles are maintenance free. To complete a function check of the battery mounting, connections and fluid levels complete the following: 1 Inspect battery hold-downs for proper placement and...
  • Page 63 Group 170 Preventive Maintenance Check Fuel Tank, Hoses, Pipes and Mounting Straps To complete a service check of the fuel tank, hoses, pipes and mountings complete the following: 1 Check the fuel tank mounts. 2 Check the fuel tank straps and J-brackets and ensure they are tight and that the tanks haven’t rotated.
  • Page 64 Check Water Separator for Fuel System For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175-60, “Approved Oils Lists, Volvo Components”, Publication Number 175–61, and appropriate vendor literature.
  • Page 65 Group 170 Preventive Maintenance Check Tire Wear and Wheel Alignment Tire Wear For further information refer to Function Group 7. 1 Examine each tire tread for unusual wear patterns. Refer to chart below for typical tread patterns. 2 Measure tread depth. 3 Check tire pressure and leak-test valve stems.
  • Page 66 Group 170 Preventive Maintenance Wheel Alignment Check Total Wheel Alignment. For further information refer to Service Bulletin, “Wheel Alignment, Steer and Drive Axles, VN/VHD,” Function Group 6. Note: For Total Vehicle Alignment, if A is less than B then a Toe In problem exists. Total Vehicle Alignment Rear Tandem Alignment...
  • Page 67 Acceptable differences depends upon wheel base. Vehicle Thrust Angle Camber The Camber is set by the axle manufacturer to Volvo specifications and is not adjustable. 1 Vertical Line 2 Wheel Center Line 3 Camber Angle(C - D)
  • Page 68 Group 170 Preventive Maintenance Engine Compartment Checks Check Alternator Mounting and Electrical CAUTION Connections When using a pressure washer to clean the vehicle, • Check the alternator mounting for wear or damage. do not direct the spray at electrical components in the engine compartment such as the alternator, starter and •...
  • Page 69 Group 170 Preventive Maintenance Check Drive Belts DANGER Ensure that the engine cannot be started while working around the fan area. Failure to do so may result in serious personal injury or death. For further information refer to Function Group 2 and appropriate vendor literature.
  • Page 70 Group 170 Preventive Maintenance Check Radiator Fan, Fan Shroud and Fan Ring with Rubber Seal DANGER Ensure that the engine cannot be started while working around the fan area. Failure to do so may result in serious personal injury or death. Perform the check of the radiator fan as follows: 1 Inspect fan blades for any damage.
  • Page 71 Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle. For further information on Noise Emissions refer to “Noise Emissions” page 6. Perform the Check of the Radiator, Hoses and Pipes as...
  • Page 72 Group 170 Preventive Maintenance Check Fuel Lines on Engine To complete a check of the fuel pipes and fuel lines, complete the following: 1 Check that the hose and pipe fittings for the fuel lines don’t leak. 2 Check that the fuel lines do not leak or chaff. Check for Exhaust Leakage To perform a check of the exhaust system, complete the following:...
  • Page 73 Air pressure should not exceed 30 psi (200 kPa) for radiator and charge-air-cooler cores. The use of fin comb is also a good tool to loosen bugs and dirt from the fins. Note: If the dirt cannot be cleaned off, consult your Volvo Truck dealer. Check A/C Compressor Mounting...
  • Page 74 Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle. For further information on Noise Emissions refer to “Noise Emissions” page 6. To perform a check of the A/C Hoses, Fittings, Switches,...
  • Page 75 Group 170 Preventive Maintenance Front Suspension, Steering System Checks Check Gaiters/Plastic Covers and clearance for Ball Joints Note: For further information refer to literature in Function Group 6. To perform a check of the Gaiters/Plastic Covers and clearance for the Ball Joints complete the following: 1 Check that all Gaiters/Plastic Covers are undamaged.
  • Page 76 Group 170 Preventive Maintenance Ball Joint CAUTION Do not use a wrench or other object to apply leverage when inspecting sockets. Applying leverage can give skewed results, and damage components. 1 Clean the joints and mating parts to be inspected with a clean dry rag.
  • Page 77 Group 170 Preventive Maintenance Check Steering Shaft Joint, Hoses and Pipes for Power Steering Note: For further information refer to literature in Function Group 6. To perform a check of the Steering Shaft Joint, Hoses and Pipes for Power Steering perform the following: 1 Check the Steering Shaft Joint for leaks, cracks and other damage.
  • Page 78 Group 170 Preventive Maintenance Checks Beneath the Vehicle Check Sealing on Front and Rear Drive Axle Note: For further information refer to literature in Function Group 7. To perform a check of the sealing on the Front and Rear Drive Axles complete the following: •...
  • Page 79 Group 170 Preventive Maintenance Check Slack in Mechanical Linkage for Clutch For information on clutch maintenance and inspection see information on pages page 17 and page 18 • Check Shift Tower for proper mechanical linkage. 1 Slave Cylinder 2 Mounting Bolts 3 Clutch Clevis Pin 4 Clutch Master Cylinder and Reservoir...
  • Page 80 Group 170 Preventive Maintenance Check Tightness on Transmission, Transfer Case, and Power Take-off including check of lines To perform a check of the tightness of the transmission, transfer case, and power take off complete following: • Visually check the transmission for secureness and any worn or broken clamps, bolts, or other securing devices.
  • Page 81 Group 170 Preventive Maintenance Check Retarder Sealing Not applicable for the VN/VHD and VT vehicles.
  • Page 82 7 Check rear axle pinion bearing for wear and leaks past the seal. Note: The Volvo CT EV87 front tandem gear input shaft has a large play for the input shaft bearing. This is normal and does not have any damaging effect on the transfer gear-during rotation, the shaft is balanced so that the clearance is insignificant.
  • Page 83 Group 170 Preventive Maintenance Check Sealing of Rear Axle and Hub Reduction Gear To perform a check of the sealing on the rear axle and hub reduction gear, complete the following: 1 On the rear axle, inspect around the mating surfaces for leaks past the gasket.
  • Page 84 Note: This check is also considered Noise Emissions Control Maintenance, which is required maintenance for any Volvo vehicle. For further information on Noise Emissions refer to “Noise Emissions” page 6. To perform a check of the exhaust pipe, silencer or particulater, complete the following •...
  • Page 85 Group 170 Preventive Maintenance Check Central Lubrication System Not applicable to VN/VHD vehicles and VT. Check Air Suspension and Air Springs Note: For further information refer to literature in Function Group 7. To perform a check of the Air Suspension and Air Springs complete the following: 1 Check suspension torque rods and the top shock absorber mounts for wear and looseness.
  • Page 86 Group 170 Preventive Maintenance Check Rear Wheel Bearing Clearance Note: For further information refer to literature in Function Group 7. To perform a check of the rear wheel bearing clearance complete the following: • Check wheel bearings with a dial indicator. Bearing axial clearance should be within 0.04 to 0.12 mm (0.001 to 0.005 in.).
  • Page 87 Group 170 Preventive Maintenance Check Brake Linings DANGER Before measuring the brake linings, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death.
  • Page 88 Group 170 Preventive Maintenance Check Brake Disc and Calipers Note: Not applicable for VN,VHD and VT vehicles. To perform a check of the brake discs and calipers, complete the following: 1 Remove the wheel. 2 Inspect the brake discs and calipers for signs of wear or damage.
  • Page 89 Group 170 Preventive Maintenance Test Driving Check After Start Note: Some vehicles are equipped with TEMP-A-START (TAS), which can be readily identified by a dash mounted switch with a TAS indicator. Vehicles equipped with this option will perform an engine shutdown if the engine is left idling for 10 minutes, or a dash shutdown if the key switch is left in the ignition position for 10 minutes with the engine running.
  • Page 90 Group 170 Preventive Maintenance Check Instruments and Gauges Check all instruments and gauges for proper function. If possible, check the odometer against a measured mile. Check Safety Restraints Note: For further information refer to literature in Function Group 8. DANGER A damaged safety belt, whether visibly damaged or not, could result in serious personal injury or death in the event of an accident.
  • Page 91 Group 170 Preventive Maintenance Check Horns Sound both the air horn (1) and the electrical horn (2). Each should have a strong, even tone. Check During Test Driving Check Clutch Operation During driving, check for smooth operation and engagement when shifting gears. Look for uneven engagement and/or unusual noise.
  • Page 92 Group 170 Preventive Maintenance Wheel Brake Application and Release Note: For further information refer to literature in Function Group 5. DANGER To do the brake test safely, ensure there are no other vehicles within 300 yards when testing, or perform the test in a off-road area where there is no traffic.
  • Page 93 Group 170 Preventive Maintenance Check ABS System DANGER To do the brake test safely, ensure there are no other vehicles within 300 yards when testing, or perform the test in a off-road area where there is no traffic. Performing a brake test in traffic may lead to an accident, and cause personal injury or death.
  • Page 94 If the engine is equipped with an exhaust brake (only on Volvo) or an engine brake, check the effectiveness of the retarding force when the brake is engaged. Engine Brake (D12)
  • Page 95 Group 170 Preventive Maintenance Check Transmission Operation Check the transmission for smooth operation through the gear pattern. Listen for any unusual noise during shifting. Check for excessive play in the shift lever. Drive vehicle in all gears and listen for any unusual differences in sound between the gears.
  • Page 96 Group 170 Preventive Maintenance Check Heater and Air Conditioning Check function of heater and air conditioning. Operate the controls and let the fan run on all speeds. Note: In the summertime, the shut-off valves for the heater may be closed for the season. Open valves before testing heater.
  • Page 97 Group 170 Preventive Maintenance Check After Test Driving Note: Some vehicles are equipped with TEMP-A-START (TAS), which can be readily identified by a dash mounted switch with a TAS indicator. Vehicles equipped with this option will perform an engine shutdown if the engine is left idling for 10 minutes, or a dash shutdown if the key switch is left in the ignition position for 10 minutes with the engine running.
  • Page 98 Group 170 Preventive Maintenance Engine Low Idle Record the engine low idle speed. Listen for idling problems such as surging, missing or unusual noise. See each engine manufacturer’s specification for correct idle speed. Record low and high oil pressure. Check Low Air Warning Switches Pump the brake pedal while observing the air gauges.
  • Page 99 Group 170 Preventive Maintenance Check Compressor Loading Raise the air pressure until it is 5.8 bar (85 psi). Time the air pressure build time from that point with the engine at full speed. The pressure should reach 6.9 bar (100 psi) in 25 seconds or less.
  • Page 100 Group 170 Preventive Maintenance Finish Drive Vehicle; Check Fluids Drive the vehicle around the block to settle the oil and to verify any points that were found during the inspection. Check all fluid levels. Make sure there are no signs of leakage after changing oils or filters.

  • Page 101: Additional Time Based Maintenance

    Volvo Engine For information on valve adjustment intervals see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175-60. For information on valve clearance check and adjustment refer to Service Information, Group 2. Every:...
  • Page 102 Group 170 Preventive Maintenance Every: Two to Three Years Air Dryers The exchange interval of the air dryer cartridge is heavily dependent on how often the compressor cycles off and on and if the climate is hot and moist or cool and dry. Do not use a dryer cartridge for more than three years.

  • Page 103: Additional Mileage Based Maintenance

    Regular oil change intervals when petroleum oil is used are at every 80,000 km (50,000 miles). See specification section for oil types and viscosities. Every: 120,000 km (75,000 miles) Volvo Transmission Regular oil change intervals for Volvo transmissions are at every 120,000 km (75,000 miles)
  • Page 104 Volvo Trucks North America, Inc. P.O. Box 26115, Greensboro, NC 27402-6115 Volvo Trucks Canada, Ltd. 5600A Cancross Court, Mississauga, Ontario L5R 3E9 http://www.volvotrucks.volvo.com PV776-20178991 (700) 2.2007 © Volvo Trucks North America, Inc., 2007...

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