Volvo VN Series Service Manual
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Volvo VN Series Service Manual

Volvo VN Series Service Manual

Preventive maintenance annual service, group 17
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Service Manual
Trucks
17
Group
Preventive Maintenance
Annual Service
VN, VHD VERSION
From build date 11.2002 to 12.2006
PV776-20177637

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Table of Contents
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Summary of Contents for Volvo VN Series

  • Page 1 Service Manual Trucks Group Preventive Maintenance Annual Service VN, VHD VERSION From build date 11.2002 to 12.2006 PV776-20177637...
  • Page 2 Repl: This Service Manual replaces Manual 17 “Preventive Maintenance Annual Service” (10.2002) Publication no. PV776–TSP176307. © 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 ................ 3 Safety Advice ..................6 Specifications ..................7 Engines ....................7 Transmissions ..................9 Rear Axle ....................9 Suspension ..................10 Tools ...................... 11 Special Tools and Special Equipment ..........11 Preventive Maintenance Inspection Bay ..........14 Design and Function ................

  • 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 mileages and sometimes maintenance program by completing the required Daily high loads.
  • Page 6 Group 1, “Oil and law. The use of this inspection report makes the driver Filter Change Intervals for Volvo Components,” publication a part of the maintenance program and places direct number 175-60, “Approved Oils Lists, Volvo Components”.
  • Page 7 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 8: 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 9: 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 10 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 11: Transmissions

    Includes Volvo, Eaton Fuller, Meritor, and Allison HD Transmissions For further information concerning component specifications see service information in Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number 175-60, “Approved Oils Lists, Volvo Components”, Publication Number 175–61, and appropriate vendor literature.

  • Page 12: 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 13: 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 14 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 15 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 16: 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 17: Design And Function

    Valve Adjustment Interval 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.
  • Page 18 W4002519 Fig. 2: Volvo Clutch Slave Cylinder 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 19: Power Take-Off

    175-60, “Approved Oils Lists, Volvo Components”, Publication Number 175–61, and appropriate vendor literature. Volvo PTO’s mount directly to the transmission and do not need separate oil fill and check. Make sure there is extra oil filled in the transmission for the PTO volume.

  • Page 20: Driveshaft

    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 21: 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 22: 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 23: 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 24: Chassis

    Chassis Springs and Suspension 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. Lubricate spring pins using a lithium-based grease with EP additives and the consistency of NLG1 No.2.

  • Page 25: Cab

    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 26 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 27: Preventive Maintenance

    Group 177 Preventive Maintenance Preventive Maintenance Check Oil Level in Automatic Transmission 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 Checks in Cab Chassis Lubrication...
  • Page 28 Group 177 Preventive Maintenance Engine Compartment External Checks Check Tightness on Servo Pump, Oil Lines and Function Check of External Lamps Steering Gear Check Rear View Mirrors and Reflectors Check Sound Baffles for Engine Function Check of Wipers and Washers Front Suspension, Steering System Check Check Headlamps Check Steering Linkage...
  • Page 29 Group 177 Preventive Maintenance Checks Beneath the Vehicle Checks Beneath the Vehicle Check Height Regulation for Air Suspension Check Stroke Length on Slack Adjusters, Brake Levers, and Brake Drums Check Chassis Frame and Crossmembers Check Load Sensing Valve Check Central Lubrication System Check Brake Chambers and Mounting Brackets Check Compressed Air Lines and Hoses Check Rear Wheel Bearings...
  • Page 30 Group 177 Preventive Maintenance Note: The values seen from cab and backwards are noted in the squares below Brake Linings - measured Right thickness in mm (in.) Left Brake Levers, Slack Right Adjusters, and Brake Drums - measured stroke in mm (in.) Left Notes on wear pattern on Right...

  • Page 31: Reception

    Group 177 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: Lubrication

    Group 177 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 177 Preventive Maintenance W1000189 The numbers in the lubrication Grease Coolant chart correspond with the Hub Oil Aut. Transm. Fluid numbered notes on page 32 and 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 177 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: Chassis Lubrication

    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 Group 177 Preventive Maintenance Brake Cams For further information concerning brake cams see service information in Group 5, “Q Plus LX500 and MX500 Cam Brakes Literature”, and appropriate vendor literature. There is one grease fitting on each cam for front and rear wheel brakes.
  • Page 38 Group 177 Preventive Maintenance 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. The grease fitting is located on the right side of the bell housing.

  • Page 39: Cab Lubrication

    Group 177 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 40: Change Engine Oil And Filter

    Change Engine and Oil Filter 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 41 Group 177 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 42: Check Oil Level In Manual Transmission

    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. W4000768...

  • Page 43: Check Oil Level In Automatic Transmission

    Group 177 Preventive Maintenance Check Oil Level in Automatic Transmission Note: For further information refer to “Transmissions” page 9. Transmission fluid cools, lubricates, and transmits hydraulic power. Always maintain proper fluid level. If fluid level is too low, the torque converter and clutches do not receive an adequate supply of fluid and the transmission overheats.
  • Page 44 Group 177 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 45 Group 177 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 46: Check Oil Level In Pto, Power Take-Off

    Note: For further information refer to “Power Take-off” page 17. 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. Add: with single PTO 0.5 L (0.5 qt.)

  • Page 47: Check Oil Level In Retarder

    Group 177 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. T1006646 Level/Fill Plug Drain Plug Check Oil Level in Transfer Case Not applicable for VN/VHD and VT vehicles.

  • Page 48: Check Oil Level In Front Drive Axle

    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 49: Check Oil Level In Rear Drive Axle

    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 50: Check Oil Level In Hydraulic Lift Axle

    Check Oil Level in Power Steering 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 51: Check Oil Level In Hubs For Oil Lubricated Wheel Bearings

    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 52: Check Coolant Freeze Protection And Coolant Level

    Group 177 Preventive Maintenance Check Coolant Freeze Protection and Coolant Level WARNING Do not remove the cap to the coolant surge tank while the engine and radiator are still hot. Scalding fluid and steam may be blown out under pressure if the cap is removed too soon.

  • Page 53: Check Air Dryer

    Group 177 Preventive Maintenance 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. Eventually the drying medium fills up and needs replacement. Change the cartridge when the medium is filling up more than usual.

  • Page 54: Cab

    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 55: Check Fault Codes In The Vehicle Electronic Control Unit

    Group 177 Preventive Maintenance Check for Fault Codes in the Vehicle Electronic Control Unit The instruments, vehicle ECUs and engine ECUs, 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 56: Check Fault Codes In The Engine Electronic Control Unit

    Group 177 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 57: Check Fault Codes In Transmission

    Group 177 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 58: Check Engine Control In Cab

    Group 177 Preventive Maintenance Check Engine Control in Cab Check engine controls and performance while moving through the gears. Accelerator pedal should work smoothly and without any hesitation in engine response. Engine should accelerate smoothly and without hesitation, misses or surges. Also, check the exhaust through the mirrors for excessive smoke during acceleration.

  • Page 59: Start Engine And Check Of Starter Element And Preheater

    Make sure the wiring is properly routed and securely clamped. Volvo Engine Preheater Inspect the Volvo engine preheater for correct function. The ignition switch has a position in between the normal run position and the start position that engages the pre-heater.

  • Page 60: Check Pressure Regulator's Disconnection And Connection Pressure

    Group 177 Preventive Maintenance Check Pressure Regulator’s Disconnection and Connection Pressure Pump the brake pedal while observing the air gauges. As the air pressure is lowering, verify the compressor governor cut-in pressure and the low air warning switches cut-in pressure. Check that both indicator lights in the lower right corner and the Master Warning indicator lights up and make sure the buzzer sounds.

  • Page 61: Check Sealing On Main Brake Circuit (Service)

    Group 177 Preventive Maintenance Check Sealing on Main Brake Circuit (Service) To perform the check of the Main Brake Seal perform the following: 1 Start engine. 2 Charge the Compressed Air System to 750 kPa (7.5 bar). 3 Shut off engine. W5000582 4 Release the parking brake.

  • Page 62: Check Parking Brake And Blocking Valve

    Group 177 Preventive Maintenance Check Parking Brake and Blocking Valve Check the parking brake and blocking valve holding power by engaging direct gear, not allowing the engine speed to go above 1000 rpm and attempt to drive off with the parking brake still applied.

  • Page 63: Check Bogie Lift

    Group 177 Preventive Maintenance Check Bogie Lift Check the bogie lift by pressing the air suspension levelling switch. Verify function by watching the chassis being lowered. Verify that the telltale indicator lights up on the instrument cluster. Check Brake Pedal and Foot Brake Valve Letting the engine run at low idle, depress the brake pedal to full brake pressure (depress pedal only once so the compressor does not start loading again).

  • Page 64: External Checks

    Group 177 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 operation. 2 Check that all lamps are in good condition. W3005266 Check Rear View Mirrors and Reflectors To perform a function check of the mirrors and reflectors, complete the following:...

  • Page 65: Function Check Of Wipers And Washers

    Group 177 Preventive Maintenance Function Check of Wipers and Washers Check the wiper arm tension and condition of the wiper blades. W3004393 Check Headlamps Check alignment and output of headlights. Check Air Filter for Ventilation System For further information concerning component specifications see service information in Group 8 and appropriate vendor literature.

  • Page 66: Check Refrigerant Reservoir, Condenser, Pipes And Hoses

    Group 177 Preventive Maintenance If equipped, check the bunk unit air filter — located behind the passenger seat on bunk support. The bunk unit air filter should be inspected at regular intervals, approximately every 112,654 km (70,000 miles). The filter should be changed after 160,934 km (100,000 miles).

  • Page 67: Check Cab, Hood, Doors, Step Panels And Cab Suspension

    Note: The restraint cylinders are oil-filled and work like shock absorbers. Note: Volvo recommends the Upper & Lower Step Panel Bushings be replaced every 150,000 miles. For more information see your Volvo Truck Dealer. Check hood lock cables for function and condition. Make sure they are not fraying.

  • Page 68: Check Batteries - Dirt, Leakage, Attachment

    Group 177 Preventive Maintenance Check Batteries - Dirt, Leakage, Attachment, Specific Gravity of Battery Acid, Fluid Level, Connections and Battery Box 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 tightness.

  • Page 69: Check Fuel Tank, Hoses, Pipes, Venting And Mounting

    Group 177 Preventive Maintenance Check Fuel Tank, Hoses, Venting and Mounting 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 70: Draining Of Fuel Tank (Dirt, Water)

    Check Fuel Water Seperator for Fuel System, Draining of Condensation 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 71: Check Tire Wear

    Group 177 Preventive Maintenance Check Tire Wear Tire Wear 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. W7001270 W1000062...

  • Page 72: Engine Compartment Checks

    Group 177 Preventive Maintenance Engine Compartment Checks CAUTION When using a pressure washer to clean the vehicle, do not direct the spray at electrical components in the engine compartment such as the alternator, starter and compressors. Water spray from pressure washers can damage electrical components.

  • Page 73: Check Drive Belts

    Group 177 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 74: Check Air Compressor

    Group 177 Preventive Maintenance Check Air Compressor 1 Increase the air pressure until it is 585 kPa (85 psi). Time the air pressure build time from that point with the engine at full speed. The pressure should reach 690 kPa (100 psi) in 25 seconds or less. Verify that the governor cutout is at 900 ±...

  • Page 75: Check Engine Mounting

    Group 177 Preventive Maintenance Check Engine Mounting To perform a check of the engine mounting complete the following: • Check all brackets, bolts and other engine mounting parts for dirt, wear, and damage. W2001414 Check Radiator Mounting To perform a check of the radiator mounting, complete the following: •...

  • Page 76: Check Radiator Fan, Bearing Tolerance, Bolt

    Group 177 Preventive Maintenance Check Radiator Fan, Bearing Tolerance, Bolt Unions, 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.

  • Page 77: Check Radiator, Hoses, Pipes And Air Flow

    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 5. Perform the check of the radiator, hoses and pipes as...

  • Page 78: Check Intercooler, Hoses, Pipes And Air Flow

    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 Tightness of Engine and PTO For further information refer to Group 4.

  • Page 79: Check Fuel Lines On Engine

    Group 177 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 80: Check A/C Compressor Mounting

    Group 177 Preventive Maintenance Check A/C Compressor Mounting To perform a check of the A/C compressor mounting, complete the following: 1 Check A/C compressor mounts for secureness and cracks. 2 Inspect the compressor exterior for leaks. Check A/C Pipes and Hoses To perform a check of the A/C hoses, fittings, switches, and wires, complete the following: 1 Inspect A/C hoses and pipes for signs of abrasion...

  • Page 81: Check Air Pipe Between Air Intake And Turbo

    Group 177 Preventive Maintenance Check Air Pipe between Air Intake and Turbo To perform a check of the air pipe between the air intake and turbo, complete the following: • Check the air pipe etween the air intake and turbo for wear, damage, and cracks.

  • Page 82: Check Pump Coupling For Injection Pump (Electronic Engines Not Applicable)

    Group 177 Preventive Maintenance Check Pump Coupling for Injection Pump (Electronic Engines Not Applicable) To perform a check of the pump coupling for the injection pump, complete the following: • Check the pump coupling is in good condition and clean. There must be no traces of oil or other impurities.

  • Page 83: Front Suspension, Steering System Checks

    Group 177 Preventive Maintenance Front Suspension, Steering System Checks Check Steering Linkage To perform a check of the servo pump and steering gear, complete the following: 1 Check the steering shaft, drag link, and tie-rod. Inspect for damage or external wear. 2 Check joints for play by manually pushing and pulling each ball stud.
  • Page 84 Group 177 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 85: Check Front Shock Absorbers, Springs And U Bolts

    Group 177 Preventive Maintenance Check Front Shock Absorbers, Springs and U bolts To perform a check of the front shock absorbers, complete the following: 1 Check the rubber mounting bushings for wear or damage. 2 Disconnect the lower end and work the shock absorber by hand to see that the outer tube is not striking or rubbing against the fluid reservoir tube.

  • Page 86: Check Steering Knuckle Bearing

    Group 177 Preventive Maintenance Check Steering Knuckle Bearing To perform a check of the steering knuckle bearing, complete the following: • Check the steering knuckle bearing for excessive dirt, wear, or damage. W6000869 Check Front Wheel Bearings To perform a check of the front wheel bearing clearance, complete the following: •...

  • Page 87: Check Front Wheels

    Group 177 Preventive Maintenance Check Front Wheels To perform a check of the front wheels, complete the following: 1 Inspect the hub and tires for excessive dirt, wear or damage. 2 Check the tire pressure to ensure proper tire inflation. Refer to the appropriate vendor literature for information concerning tire inflation.

  • Page 88: Checks Beneath The Vehicle

    Group 177 Preventive Maintenance Checks Beneath the Vehicle Check Tightness, Bearing Clearance and Ventilation on the Front Drive Axle To perform a check of the sealing on the front drive axle, complete the following: • Check the hub for excessive dirt, wear, or damage. •...

  • Page 89: Check Clutch Wear

    Group 177 Preventive Maintenance Check Clutch Wear For information on clutch maintenance and inspection see information on pages page 15 and page 16. Check Transmission’s Pneumatic and Mechanical Control System To perform a check of the transmission’s pneumatic and mechanical control system, complete the following: 1 Check the top of the transmission.

  • Page 90: Check Tightness On Transmission, Transfer Case

    Group 177 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 91: Check Ventilation For Transmission, Transfer Case

    Group 177 Preventive Maintenance Check Ventilation for Transmission, Transfer Case, and Power Take-Off To complete a check of the ventilation for the transmission, transfer case and power take off, complete the following: • Check that the air flow is free through the core for the transmission, transfer case and power take off.

  • Page 92: Check Sound Baffle For Gearbox

    Group 177 Preventive Maintenance Check Sound Baffle for Gearbox Not applicable to VN/VHD and VT vehicles. Check Transfer Case’s Mounting Not applicable for the VN/VHD and VT vehicles. Check Drive Belt for Power Steering Not Applicable for the VN/VHD and VT vehicles.

  • Page 93: Check Drive Shaft Universal Joints, Sliding Joints And Support Bearings

    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 94: Check Rear Drive Axle Ventilation

    Group 177 Preventive Maintenance Check Bearing Clearance in Pinion and Rear Axle Input Shaft To perform a check of the bearing clearance in the pinion and rear axle, complete the following: 1 Use a dial indicator to check bearing clearance in the pinion and rear axles.

  • Page 95: Check Exhaust Pipe And Silencer

    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 5. To perform a check of the exhaust pipe, silencer or particulater, complete the following •...

  • Page 96: Check Rear Shock Absorbers

    Group 177 Preventive Maintenance Check Rear Shock Absorbers For further information refer to 761-002, “Shock Absorbers, Front and Rear.” To perform a check of the rear shock absorbers, complete the following: • Check the rear shock absorbers for excessive dirt, wear, or damage.

  • Page 97: Check Bogie Lift Or Lift Axle

    Group 177 Preventive Maintenance Check Bogie Lift or Lift Axle To perform a check of the bogie lift or lift axle, complete the following: 1 Check the lift axle for excessive wear and damage. 2 Check the lift axle air lines for leaks or cracks. 3 Check the lift axle springs for wear or damage.

  • Page 98: Check Rear Suspension Level Sensors And Leveling Valves

    Group 177 Preventive Maintenance Check Rear Suspension Level Sensors and Leveling Valves To perform a check of the air bellow, level sensors and level valves for the air suspension, complete the following: 1 Check the air spring for wear and cracks. 2 Check the level valve for proper operation.

  • Page 99: Check Central Lubrication System

    Group 177 Preventive Maintenance Check Central Lubrication System Not applicable for VN/VHD and VT vehicles. Check Compressed Air Lines and Hoses For further information refer to 560-660, “Compressed Air Brakes, All Models.” To perform a check of the compressed air lines and hoses, complete the following: •...

  • Page 100: Check Rear Wheel Bearings

    The wheel hubs are lubricated with several types of oil. It is acceptable to use either synthetic or petroleum based oils (synthetic oils are not recommended for Volvo Axles). Hubs are generally oil-lubricated. There are no set oil change intervals. Change oil when the hub is removed for...

  • Page 101: Check Rear Wheels

    Group 177 Preventive Maintenance Check Rear Wheels Tire Wear For further information, refer to Service Information, 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. W7001270 4 Check the Rim Flange wear on Aluminum Wheels every time the wheel is replaced.

  • Page 102: Check Brake Linings

    Group 177 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 103 Group 177 Preventive Maintenance Check Brake Slack Adjusters and Cam DANGER Before checking the slack adjusters, 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 104: Check Load Sensing Valve

    Group 177 Preventive Maintenance Check Load Sensing Valve Not applicable for VN/VHD & VT vehicles. Check Brake Chambers and Mounting Brackets To perform a check of the brake chambers and mounting brackets, complete the following: 1 Inspect the brake chambers and mounting brackets for wear and damage.

  • Page 105: Test Driving

    Group 177 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 106: Check During Test Driving

    Group 177 Preventive Maintenance 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. Wheel Brake Application and Release W5000617 DANGER To do the brake test safely, make sure 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 107 Group 177 Preventive Maintenance Check ABS System DANGER To do the brake test safely, make sure 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 brake test in traffic may lead to an accident, personal injury or death.
  • Page 108 If the engine is equipped with an exhaust brake (Volvo only) or an engine brake, VEB, check the effectiveness of the retarding force when the brake is engaged.
  • Page 109 Group 177 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 110 Group 177 Preventive Maintenance Check Instruments and Gauges Check all instruments and gauges for proper function. If possible, check the odometer against a measured mile. 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.

  • Page 111: Check After Test Driving

    Group 177 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 112 Group 177 Preventive Maintenance Check Horns Sound both the air horn (1) and the electrical horn (2). Each should have a strong, even tone. W6001502...
  • Page 113 Group 177 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 114 Group 177 Preventive Maintenance Check Compressor Loading Raise the air pressure until it is 585 kPa (85 psi). Time the air pressure build time from that point with the engine at full speed. The pressure should reach 690 kPa (100 psi) in 25 seconds or less.

  • Page 115: Finish

    Group 177 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 fluids levels. Make sure there are no signs of leakage after changing oils or filters.

  • Page 116: 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 117 Group 177 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 118: 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 120 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 PV776-20177637 (700) 2.2007 © Volvo Trucks North America, Inc., 2007...

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