Foreword This manual contains information concerning the operation and function of the Volvo Link System. The information in this manual applies to vehicles built January 2010 and later. Please keep this manual in the vehicle at all times. Note: Illustrations in this manual are used for reference only and may differ slightly from the actual vehicle. However, key components addressed in this document are represented as accurately as possible.
Contents INTRODUCTION............................................................................................................1 .......................................................................................................................................1 ADVISORY LABEL DEFINITIONS (IN HANDBOOK)........................................1 INFORMATION FOR THE OWNER.......................................................................2 EMISSIONS CONTROL COMPLIANCE....................................
Panel D.....................................................................................................................60 Panel E .....................................................................................................................61 Tachometer...............................................................................................................64 Upper Tell-Tales.......................................................................................................
Pre-Trip Inspection Quick List ..............................................................................199 New Vehicle Break-In............................................................................................211 HOOD OPERATION.............................................................................................213 SAFETY BELTS....................................................................................................230 Safety Restraint VN 430, VN 630, VN 670 ................
Aftertreatment DEF Tank Level - Driver Warning & Inducement........................373 Aftertreatment DEF Quality - Driver Warning & Inducement ..............................374 Misfilling Diesel or Aftertreatment DEF Tanks.....................................................375 SCR Tampering - Driver Warning & Inducement .................................................376 Warranty and Maintenance ....................................................................................
Safety 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 handling information in this manual. Be certain that you fully understand and follow all safety warnings. IT IS IMPORTANT THAT THE FOLLOWING INFORMATION BE READ, UNDERSTOOD AND ALWAYS FOLLOWED.
INTRODUCTION 1 ADVISORY LABEL DEFINITIONS (IN HANDBOOK) Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this manual. Information accented by one of these signal words must be observed to minimize the risk of personal injury to service personnel, or the possibility of improper service methods which may damage the vehicle or cause it to be unsafe.
2 INTRODUCTION INFORMATION FOR THE OWNER If there are questions on the maintenance and performance of your vehicle, please discuss them with your Volvo Truck dealer. Your authorized dealer is required to have trained mechanics, special tools and spare parts to fully service your vehicle. If necessary, your dealer will contact the manufacturer for any assistance. In addition to this operators manual, there may be additional instruction/operators manuals supplied by component manufacturers.
INTRODUCTION 3 DO NOT Remove this operators manual from the vehicle. It contains important operational and safety information that is needed by all drivers and owners of this vehicle. Note: Illustrations in this manual are used for reference only and may differ slightly from the actual vehicle; however, key components addressed in the manual are represented as accurately as possible.
4 INTRODUCTION W0036011
INTRODUCTION 5 EMISSIONS CONTROL COMPLIANCE Exhaust and Noise Emissions General USA The Federal Clean Air Act, Section 203 (a) (3), states the following concerning the removal of air pollution control devices or modification of a certified engine to a non-certified configuration: CAA, Section (a) (3) (A) prohibits any person to remove or render inoperative any (emission control) device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
6 INTRODUCTION B5 Approval For Volvo US 10 Certified Products Volvo engines are certified to comply with U.S. EPA and California emissions standards based upon the use of test fuels with specifications established by these regulatory agencies. Alternative fuels, including biodiesel, that are not substantially similar to the required test fuels may adversely affect engine emissions compliance and may impact the performance of certain emissions aftertreatment components.
INTRODUCTION 7 Air is always present inside the fuel tanks, entering mainly through the tank ventilation. With the air being heated and cooled, condensation is formed and water is mixed in the fuel. To avoid condensation when the vehicle is parked for longer periods, fill the tanks up to 95% of capacity. Do not fill more than that, as the fuel needs to have room for expansion during the heat of the day. For additional information about fuel, refer to the Operator’s Manual Vehicle Maintenance.
8 INTRODUCTION ENGINES OTHER THAN VOLVO: For specific information on engines other than VOLVO, refer to the engine vendor’s publications. Noise Emissions Volvo Trucks North America warrants to the first person who purchases this vehicle for purposes other than resale and to each subsequent purchaser, that this vehicle as manufactured by Volvo Trucks North America was designed, built and equipped to conform, at the time it left the control of Volvo Trucks North America, with all applicable U.S.
INTRODUCTION 9 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; or (2) the use of the vehicle after such device or element of design has been removed or rende
10 INTRODUCTION • Removal of transmission noise shields. Noise Shielding and Insulation Devices Maintenance Ensure sound shielding and insulating devices are intact. Inspect components for damage. Primary system components requiring noise related inspection include the hood, engine compartment insulating materials (including hood insulation, bulkhead insulation, doghouse insulation, etc.) splash shields, cab skirts, fender shields, and body panels.
INTRODUCTION 11 WARNING Hot engine! Avoid all movable parts or hot engine parts, exhaust gases, and/or fluids. A hot engine, exhaust, and/or fluids can cause burns. Maintenance Make sure the exhaust system is intact. Inspect for damage, misalignment and/or leakage. Primary system components requiring noise related inspection include exhaust manifold, turbocharger, and all exhaust system (rigid and flexible) piping. Closely check the system for exhaust leaks.
12 INTRODUCTION Engine Control, EGR and Fuel Systems Acts that constitute tampering with Engine Control, EGR and Fuel Systems: Removing rendering inoperative, or modifying the engine control system such as the ECU, EGR system components, or fuel system components, in order to allow the engine to operate outside of the manufacturer’s specifications is not allowed and violates both warranty and legislation.
INTRODUCTION 13 VEHICLE DATA Identification and Labels It is extremely important that the correct vehicle model and serial number are given whenever replacement parts or service literature are ordered. Using these numbers, as well as giving the major component model and serial numbers, will prevent delay and errors in obtaining the correct material. Space is given on the rear inside cover of this manual for noting the main component model and serial numbers.
14 INTRODUCTION Three labels are located in the rear inside frame of the driver side door frame. These labels should not be removed. W8003115 Note: To deter tampering with the original build information, the information on the label will be destroyed if the label is removed. If for any reason a label is damaged, contact your authorized Volvo Truck dealer for a replacement. Vehicle Order The Vehicle Order is a complete and detailed record of all data pertaining to the assembly of the vehicle.
INTRODUCTION 15 Vehicle Identification Label The VIN is shown on the Vehicle Identification label. The VIN includes the vehicle make, model series, weight class, engine model, where the vehicle was built and the vehicle serial number. This label also shows the truck model designation, major component model and serial number, cab model and serial number, cab and chassis paint colors, and color numbers.
16 INTRODUCTION CAUTION To maintain compliance with emission regulations, engine settings should not be changed from those specified on the engine information label. In compliance with Federal and California emission requirements, an engine information label is affixed to all Volvo diesel engines. This label, which is located on the cylinder head cover at the front of the engine, gives basic engine identification information (engine model, serial number, etc.
INTRODUCTION 17 Clean Idle Engines The California Air Resources Board (ARB) requires that any engines having tamper-resistant software which limits the time at which the engine can idle at speeds above low idle (550 – 700 rpm). At speeds above low idle, and without a PTO engaged, idle time will be limited to five minutes, after which the engine will revert back to low idle.
18 INTRODUCTION Component Labels The Volvo engine serial number is located on the front left side of the cylinder block. The serial number can also be found on the certification label on the valve cover. The axle model and serial number is located on the front left side of the forward drive axle and the front right side of the rear drive axle. It is also located on the front right side of the single axle.
INTRODUCTION 19 SERVICE LITERATURE To order a single Service Manual or a Service Manual Set for your vehicle, contact your authorized Volvo Truck dealer. In order to handle the request correctly, you must give the model, year and VIN (last six digits of VIN only). For VIN location, see “Identification and Labels”, page 13. Service Manual prices will vary depending on the make and model of engine in the vehicle. (A Cummins engine manual is included in your introductory owner’s package).
20 INTRODUCTION SERVICE ASSISTANCE Your authorized Volvo Truck dealer is trained and equipped to perform expert service on your Volvo vehicle. Your dealer has direct access to Volvo Trucks North America for technical help, parts or service information. There is also a direct number to Volvo Action Service (VAS), staffed 24 hours a day, if you are in need of assistance. The number to the Customer Support Center is: 1 (800) 528–6586 [or (800) 52–VOLVO]. Also on the internet: www.vas.volvo.
INTRODUCTION 21 REPORTING SAFETY DEFECTS United States If you believe that your vehicle has a defect which could cause a crash, injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA), in addition to notifying Volvo Trucks North America. If NHTSA receives similar complaints, it may open an investigation and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
22 INTRODUCTION EVENT DATA RECORDING DEVICES Your Volvo vehicle is equipped with a device generally referred to as an "event data recorder" or "EDR." Please note that while the term "event data recorder" is typically used throughout the motor vehicle industry, not every EDR is the same; i.e., they do not all record the same data elements. The EDR on your Volvo vehicle records vehicle speed, engine rpm, time and date, plus a variety of pedal and switch positions, both before and after an "event.
SAFETY INFORMATION 23 GENERAL SAFETY INFORMATION Operating the Vehicle DANGER Never try to operate or work on this vehicle while under the influence of alcohol. Your reflexes can be affected by the smallest amount of alcohol. Drinking and operating this vehicle can lead to an accident, causing serious personal injury or death. WARNING All items within the cab must be secured before the vehicle is set in motion. This includes, but is not limited to, drinks, clothes, books, televisions, etc.
24 SAFETY INFORMATION Operating in Bobtail Mode CAUTION When operating bobtail, be certain that glad hands, trailer air hoses, electrical cable and connectors are properly stowed and secure. Do not allow them to rub or chafe on other components. Depending on customer specification, some tractors may be equipped with a bobtail air brake proportioning valve which automatically redistributes the braking force between front and rear axles when not hooked up to a semitrailer (bobtail operation).
SAFETY INFORMATION 25 DANGER DO NOT exceed the load rating of the tires or the vehicle weight ratings. Overloading may result in tire failure causing loss of vehicle control, leading to an accident resulting in severe personal injury or death. This vehicle has been designed and assembled for a maximum gross vehicle weight rating (GVWR) and a maximum front and rear axle weights rating (FAWR and RAWR).
26 SAFETY INFORMATION VORAD® COLLISION WARNING SYSTEM The Eaton® VORAD® computerized Collision Warning System constantly monitors vehicles ahead with a front end-mounted radar and in a blind spot area with an optional side-mounted radar. The Collision Warning System warns the driver of potentially dangerous situations by activating visual and audible alerts. DANGER The Eaton® VORAD® Collision Warning System is intended solely as an aid for an alert and conscientious professional driver.
SAFETY INFORMATION 27 ADVISORY LABELS Throughout this book you will find paragraphs labeled Danger, Warning, Caution, Note and Service Hint. Danger, Caution and Warning labels are also found in various locations on the vehicle to alert drivers, operators and service technicians to situations which can cause personal injury or equipment damage. The labels shown are applicable to the VN model chassis at the time of publication and are representative of what can be typically found.
28 SAFETY INFORMATION CAB ENTRY AND EXIT General DANGER DO NOT stand on the steps or any other part of the vehicle while it is in motion. The steps and the back of cab access deck plates are only for entering/exiting the vehicle and not for riding on. Failure to heed this warning can result in serious personal injury or death. DANGER Steps are designed to be slip resistant and to provide a stable surface for entering or exiting the cab. However, accumulation of ice, dirt, lubricants, etc.
SAFETY INFORMATION 29 W8003120 VN
30 SAFETY INFORMATION W8003127 VN without Fairings
SAFETY INFORMATION 31 General Entry Guidelines WARNING To avoid personal injury due to a slip and/or fall, observe the following guidelines. BE SURE TO FOLLOW ALL OF THESE INSTRUCTIONS BEFORE ENTERING OR EXITING THE CAB OR THE AREA BEHIND THE CAB. 1 Always have three limbs (one foot and two hands or two feet and one hand) in contact with the vehicle at all times when entering or exiting the cab or the area behind the cab.
32 SAFETY INFORMATION 14. Make sure your safety belt is disconnected before exiting the cab. 15. Make sure the safety belt is fully retracted and out of the way prior to entering or exiting the cab. 16. DO NOT put your foot on any surface that does not have slip resistant, selfcleaning material. If there is no step material, the surface may be slippery and you may fall. 17.
SAFETY INFORMATION 33 Driver Side Entry/Exit WARNING On vehicles without side fairings or cab panels, always make sure that the battery box cover is securely fastened before stepping up. Failure to fasten the cover may lead to a fall and personal injury. Open the door. Place any hand-carried items on the cab floor. Grasp the right grab handle with your right hand and the left grab handle with your left hand. Put the right foot fully on the bottom step and pull yourself up to the opening.
34 SAFETY INFORMATION Passenger Side Entry/Exit Open the door. Place any hand-carried items on the cab floor. Grasp the left grab handle with your left hand and the right grab handle with your right hand. Put the left foot fully on the bottom step and pull yourself up to the opening. W8003117 Slide hands up on the handles, if necessary. Put the right foot on the top step and step up. Step into the cab with the left foot first. To exit, reverse the process.
SAFETY INFORMATION 35 Behind the Cab Access WARNING Be careful when entering the back-of-cab area with dirty or wet soles. Wearing shoes with soles that are dirty or wet increases the chance of slipping or falling. When trailer air and electrical connections can not be coupled from the ground, Federal Regulations require commercial carriers to provide back-of-cab access steps, grab handles and plates. Depending on what option is chosen, grab handles are available in many variations.
36 SAFETY INFORMATION Grasp the grab handle to the left with both hands. Put the left foot onto the bottom step and pull yourself up. Put the right foot on the top step and step onto the deck plate with the left foot. W8003122 WARNING Always perform trailer hook-ups while standing on the ground. DO NOT climb on top of fuel tanks or frame rails to hook up or disconnect trailer air lines and electrical cord. Use only the metal, slip resistant steps provided to prevent a slip and fall injury.
SAFETY INFORMATION 37 Stand on the ground when connecting the air and electrical connections to the trailer.
38 SAFETY INFORMATION ENTERING SLEEPER FROM SEAT Standard Gear Lever CAUTION When moving from the driver seat to the sleeper section, follow this procedure: Be careful when standing to your feet in the seat area, headroom is limiting. • • • Make sure the parking brakes are set. • Place the left hand on the steering wheel and the right hand on the top of the gear lever. • • Move the right foot out to the middle of the floor.
SAFETY INFORMATION 39 W4001391
40 SAFETY INFORMATION SAFETY EQUIPMENT Safety triangles and fire extinguishers are available as optional equipment. The fire extinguisher should be located by the base of the driver seat, between the seat and the door. W1000176 Note: Always store the warning triangles in the box after use.
SAFETY INFORMATION 41 Warning Triangles, Day Cab The warning triangles are stored in a box that is strapped behind the passenger seat.
42 SAFETY INFORMATION Sleeper Cab The warning triangles are stored in a box, which is inside the exterior luggage compartment.
SAFETY INFORMATION 43 SAFETY BELT SYSTEM The safety belt system is the main restraint application in the vehicle. All vehicles are equipped with this system. For additional information on the safety belt system refer to “SAFETY BELTS”, page 230. The safety belt system monitors the safety belt latch and vehicle speed. When the vehicle is started the safety belt telltale displays in the cluster. The icon remains on whenever the vehicle is stationary and the safety belt is unbuckled.
44 SAFETY INFORMATION SRS AIRBAG The SRS airbag is intended to supplement — not replace — the standard safety belt. The airbag is not deployed when the truck is hit from behind, from the side or if it rolls over. For best protection, sit in a normal, upright position. Always wear the safety belt. For added safety, the vehicle may be equipped with an airbag or SRS (Supplemental Restraint System) as a supplement to the standard three-point anchored safety belt.
SAFETY INFORMATION 45 The inflatable airbag is folded into the center of the steering wheel. It inflates in the event of a serious collision above a certain level, where the angle of impact, crash severity, speed and nature of the object involved in the collision all play a part in whether or not the airbag is activated. W8003129 The system consists of a gas generator surrounded by the inflatable airbag.
46 SAFETY INFORMATION W8003119 If the control unit detects a sufficiently violent deceleration (collision), the system is activated. The gas generator triggers and fills the bag with a nontoxic gas within a few hundredths of a second. During a collision, after the bag is full, gas flows out through two holes in the weave. These holes are large enough to let the airbag collapse slowly, gently catching the driver.
SAFETY INFORMATION 47 If a problem develops in the system, the CHECK tell-tale will come on together with the SRS tell-tale. W3005170 Warning Labels The label attached to the left-hand sun visor shows the year and month when an authorized Volvo Truck dealer should be contacted for a specific inspection and for a possible replacement of the airbag. This is done to guarantee the function of the airbag after the indicated date. Replace the label when replacing the airbag module.
48 SAFETY INFORMATION Steering shafts and steering wheel should not be removed, adjusted or replaced without following the proper work procedure. Failure to do so can damage the SRS system, which can result in malfunction of the SRS. A warning label is located on the upper steering shaft. T8006842 There is also a label on the inside of the windshield that indicates the inclusion of an airbag to the vehicle safety features.
SAFETY INFORMATION 49 When equipped with an airbag, a label with the correct procedure for protecting small children and protecting the driver is attached to the left-hand, overhead storage lid or back of sun visor. W8002741 WARNING Never attempt to repair any part of the SRS system. Any interference with the system may cause it to malfunction and result in serious injury or death. Work on the system may only be carried out by an authorized Volvo Truck dealer.
50 SAFETY INFORMATION General Information When is the Airbag Deployed The airbag is only deployed during a head-on collision, where the vehicle hits a fixed or heavy object with sufficient force. The SRS system registers both the force of the collision and the internal forces caused by the collision. The control unit determines if the collision is sufficiently violent for the airbag to be deployed. Note: The SRS system is only activated once in a collision.
SAFETY INFORMATION 51 When is the Airbag not Deployed Not all frontal collisions activate the SRS system. In a collision with a soft object (a snow drift or bush for example, or a hard or fixed object at low speed), there is no need for the SRS system to be activated. The airbag is usually not inflated in response to side-on collisions, impacts from the rear or if the vehicle overturns. The extent of damage to the vehicle is no measure of how well the SRS system works.
52 INSTRUMENTS AND CONTROLS CAB INTERIOR W8003838 1 Instrument Cluster 4 Brake Pedal 2 Cab Climate Control Panel 5 Clutch Pedal (if equipped) 3 Accelerator Pedal 6 Steering Column Tilt Control Pedal
INSTRUMENTS AND CONTROLS 53 INSTRUMENT PANEL Tell-Tales A tell-tale is a display that indicates the actuation of a device, a correct or defective condition, or a failure to function. The operator should become familiar with these symbols in order to recognize and react (if necessary) to the indicated condition. Tell-tale symbols are shown in the instrument panel illustrations on the following pages. Colors To promote visual recognition internationally, specific colors for tell-tales have been established.
54 INSTRUMENTS AND CONTROLS Panel Arrangement Your view from the driver seat should look something like the illustrations shown. The layout is designed to provide the operator with a good view of the gauges and controls (which are placed so they are within easy reach). The instrument panel, as shown in the following drawing, is broken down into several main sections. For easy identification we refer to them, from left to right, as Panels A, B, C, D, E and F (where necessary).
INSTRUMENTS AND CONTROLS 55 INSTRUMENT PANEL GAUGE LAYOUT W3007473 Panel Arrangement
56 INSTRUMENTS AND CONTROLS Panel A W3007469 1 Light Control Panel 2 Instrument Cluster 3 Trailer Air Supply
INSTRUMENTS AND CONTROLS 57 4 Tractor Parking Brake Panel B W3007470
58 INSTRUMENTS AND CONTROLS 5. Inter-Wheel Differential Lock 6. Inter-Axle Differential Lock 7. VN: Idle Management Indicator Lamp (ISX ICON) or Optional Switch or Electronically Controlled Suspension (ECS) On/Off or Lift Axle #1 (Pusher) 8. VN: Optional Switch or Electronically Controlled Suspension (ECS) Up/Down 9. Auxiliary #1 10. VN: Auxiliary #2 or Temp-A-Start (TAS) Indicator Lamps 11. VN: Auxiliary #3 or Temp-A-Start (TAS) On/Off 12. Secondary Gauge Cluster 13. Secondary Gauge Cluster 14.
INSTRUMENTS AND CONTROLS 59 Panel C W3007471 30. 31. 32. 33. 34.
60 INSTRUMENTS AND CONTROLS Panel D W3007472 35. 36. 37. 38. 39.
INSTRUMENTS AND CONTROLS 61 Panel E W3007474 40. 41. 42. 43. 44. AC Inverter 120 V Optional Switch Optional Switch Power Outlet Microphone Before driving this vehicle, locate the instruments and controls, and become thoroughly familiar with their operation. After starting and when driving, ensure that the instrument readings are normal. Note: The instruments and controls shown were available for this vehicle at the time of publication.
62 INSTRUMENTS AND CONTROLS 1. Light Control Panel — For more information, please refer to “LIGHT CONTROL PANEL”, page 107 2. Instrument Cluster There are two instrument cluster levels available: High and Mid level. W3034025 High Level Cluster 1. 2. 3. 4. 5. 6. 7. 8. Tachometer Upper Tell-Tales Speedometer Front Brake Air Pressure Rear Brake Air Pressure Oil Pressure Aftertreatment DEF Tank Gauge Malfunction Indicator Lamp (MIL) 9. Driver Information Display (DID) 10. Fuel Level 11.
INSTRUMENTS AND CONTROLS 63 W3034026 Mid Level Cluster 1. 2. 3. 4. 5. 6. 7. Tachometer Upper Tell-Tales Speedometer Front Brake Air Pressure Rear Brake Air Pressure Oil Pressure Aftertreatment DEF Tank Gauge 8. Malfunction Indicator Lamp (MIL) 9. Driver Information Display (DID) 10. Fuel Level 11. Intake Manifold Pressure 12. Hill Start Assist 13.
64 INSTRUMENTS AND CONTROLS Tachometer The tachometer has two colored fields: green and red. Use the green field for normal driving (1000 to 1600 rpm). Use higher engine speeds for maximum engine brake performance. Never allow the engine to go into the red field (greater than 2200 rpm). To achieve maximum fuel economy, use the Performance Bonus Guide feature. This feature helps the driver find the most efficient operating range for the engine. See Performance Bonus Guide for more information.
INSTRUMENTS AND CONTROLS 65 If the pressure in a brake circuit air tank drops below approximately 420 kPa (65 psi), the red LED light in the lower left corner of the gauge will come on and the STOP tell-tale warning indicator comes on. In addition, the buzzer comes on if the vehicle starts to move at speed higher than 1.6 km/h (1 mph). If the vehicle is stationary, only the STOP tell-tale warning and red LED light appear.
66 INSTRUMENTS AND CONTROLS W3005171 Stop Tell-Tale W3003613 Oil Pressure Symbol Note: The engine will shut down within 30 seconds from when the red STOP tell-tale comes on. Pull off the road as soon as possible without creating a safety hazard.
INSTRUMENTS AND CONTROLS 67 Coolant Temperature Gauge The coolant temperature gauge indicates engine coolant temperature. The normal operating temperature for Volvo engines is 80 to 105°C (170 to 215°F). Under normal driving conditions, the temperature must be below the red sector. The temperature range for the coolant will vary depending on the type of engine, load, grade, ambient air temperature and operating conditions.
68 INSTRUMENTS AND CONTROLS Intake Manifold Pressure Gauge (High Level Cluster Only) The intake manifold pressure gauge indicates intake manifold pressure to the engine. The pressure generated by the intake manifold pressure should be the same at a given engine temperature, speed and load. Intake manifold pressure will vary for different engines and vehicle models. By monitoring the gauge, the operator can avoid engine problems.
INSTRUMENTS AND CONTROLS 69 Exhaust Pyrometer Gauge (High Level Cluster Only) The exhaust pyrometer gauge indicates the exhaust temperature, which helps the operator get the best efficiency from the engine. Variations in engine load can cause the exhaust temperature to vary. For example, high exhaust gas temperature is the result of prolonged engine lugging or over-fueling.
70 INSTRUMENTS AND CONTROLS T4015831 Interwheel Differential Lock When the lock is engaged, a telltale lights up in the instrument cluster. T3014470 Inter-Wheel Tell-Tale A differential lock should only be used on a slippery surface, NOT when driving on good road conditions. If a differential lock telltale is activated in the instrument cluster, do not make turns until the telltale has gone out.
INSTRUMENTS AND CONTROLS 71 6. Inter-Axle Differential Lock The inter-axle differential lock eliminates slipping between axles to improve traction. The switch has a safety latch to prevent accidental engagement. W3028391 When the lock is engaged, a tell-tale lights up in the instrument cluster. W3006119 Inter-Axle Tell-Tale A differential lock should only be used on a slippery surface, NOT when driving on good road conditions.
72 INSTRUMENTS AND CONTROLS 7. Idle Management Indicator Lamp (CUMMINS ISX ICON) For more information on this lamp, please refer to your vendor engine manual supplied with this vehicle. OR Electronically Controlled Suspension (ECS) (ON/OFF) For more information on this lamp, please refer to your vendor engine manual supplied with this vehicle. OR Lift Axle The vehicle may be equipped with auxiliary lift axles. The lift mechanism operates with air pressure.
INSTRUMENTS AND CONTROLS 73 OR
74 INSTRUMENTS AND CONTROLS Lift Axle The vehicle may be equipped with auxiliary lift axles. The lift mechanism operates with air pressure. Press the top part of the switch to raise the axle and press the lower part of the switch to lower the axle. For information about lift axles, refer to “AXLES”, page 342.
INSTRUMENTS AND CONTROLS 75 Optional Switch 9. Auxiliary Switches Generic switches are available for auxiliary functions that are installed by the customer. These switches can be purchased from your authorized Volvo Truck dealer. W3005502 Auxiliary Switch Auxiliary Switches Generic switches are available for auxiliary functions that are installed by the customer. These switches can be purchased from your authorized Volvo Truck dealer.
76 INSTRUMENTS AND CONTROLS W3005507 Tag Axle Auxiliary Switches Generic switches are available for auxiliary functions that are installed by the customer. These switches can be purchased from your authorized Volvo Truck dealer.
INSTRUMENTS AND CONTROLS 77 12. and 13.Secondary Gauge Cluster The secondary gauge is an optional feature, which is available only with the Mid and High level instrument clusters. The instrument cluster receives temperature information from the datalink and then passes the information to the secondary gauge for viewing. W3006081 Engine/Transmission Temperature Gauge W3006082 Front/Rear Axle Temperature Gauge 14.
78 INSTRUMENTS AND CONTROLS 15. Engine Brake Mode Select (ISX) For more information about the engine brake, see “Volvo Engine Brake (I-VEB)”, page 272. W3002303 OR I-Shift Hill Start Assist For more information on this feature, please refer to the I-Shift Transmission Manual supplied with your vehicle.
INSTRUMENTS AND CONTROLS 79 16. Fifth Wheel Touch Lock. release the locking mechanism. Once activated, the switch will not relock the fifth wheel kingpin locking mechanism. DANGER Activation of the kingpin lock release switch ONLY unlocks the kingpin latch mechanism. To relock the latch mechanism, you MUST pull forward and then back up to re-engage the kingpin lock mechanism. Failure to follow these instructions can result in separation of the trailer from the tractor causing personal injury or death.
80 INSTRUMENTS AND CONTROLS 17. Marker Interrupt Switch This switch interrupts power to the marker lights when held down. When released, it springs back to the ON position and returns power to the marker lights.
INSTRUMENTS AND CONTROLS 81 18. Secondary Gauge Cluster The secondary gauge is an optional feature, which is available only with the Mid and High level instrument clusters. The instrument cluster receives temperature information from the datalink and then passes the information to the secondary gauge for viewing.
82 INSTRUMENTS AND CONTROLS 19. Traction Control Shut-Off Switch (TCS) If the vehicle is equipped with a Traction Control System (TCS), the switch can be used to disable the traction control feature, and therefore increase wheel spin. This may be useful for decreasing the chances of getting bogged down when driving in heavy snow, slush or muddy conditions. Refer to Volvo Exhaust Brake for more information. W3001336 Traction Control Switch 20.
INSTRUMENTS AND CONTROLS 83 21. Fifth Wheel Slide Switch DANGER The release must never be operated while the vehicle is operating on the road. Fifth wheel position adjustment must only be done when stationary. Damage to the fifth wheel, trailer kingpin and slider may occur if not operated properly and may lead to an accident, causing serious personal injury or death.
84 INSTRUMENTS AND CONTROLS OR Engine Air Control Switch The engine fresh air control switch controls air flow to the engine air cleaner. In the normal OFF position, air is pulled through the side hood vent, and into the air cleaner. In the ON position, air is pulled from within the engine compartment into the air cleaner. This feature is useful for keeping out cold air or snow for example, when using a snow plow. W3005380 Engine Air Control Switch 22.
INSTRUMENTS AND CONTROLS 85 29. Trailer Hand Brake Control The trailer hand brake control engages the trailer brakes. For information about the trailer hand brake control, refer to “Trailer Brake Hand Control”, page 288. 30. Passenger Window Control Switch or Optional Switch The trailer hand brake control engages the trailer brakes. For information about the trailer hand brake control, refer to “Trailer Brake Hand Control”, page 288. 31.
86 INSTRUMENTS AND CONTROLS Draining Procedure Note: If the engine is started before draining is complete, the process is interrupted. 1 Stop the vehicle. 2 Apply the parking brake. 3 Turn off the engine. 4 Place a container under the water separator. 5 Turn the ignition key counterclockwise to the "Radio, Accessories" position. 6 If the vehicle is equipped with a Mid Instrument Cluster, press the Water-In-Fuel Drain Switch.
INSTRUMENTS AND CONTROLS 87 33. Sleeper Fan Speed Switch The sleeper fan switch located in the dash, controls the sleeper fan speed. The switch in the sleeper control module performs the same function as the dash switch. Press the top part of the switch to increase the fan speed, press the lower part to decrease fan speed. W3005382 Sleeper Fan Speed Switch Snow Plow Lamps Vehicles specified with this option have the following: • • • • Turn ON low beam snow plow head lamps.
88 INSTRUMENTS AND CONTROLS W3005382 Sleeper Fan Speed Switch 34.
INSTRUMENTS AND CONTROLS 89 OR Optional Switch 35. Back of Cab Light Switch (Optional) To activate the back of cab light, press the bottom part of the switch. The light will stay on until the switch is turned to the OFF position. Back of cab lights are available as a flush-mounted light in the middle of the cab rear wall or as a high-mounted light on the side of the cab. W3001355 Back of Cab Light Switch 36. Optional Switch 37.
90 INSTRUMENTS AND CONTROLS 38. Sleeper Overhead Bunk Lamp This switch operates the overhead lighting in the VN sleeper cabs. It is situated on the left-hand side of the dash to allow access to the switch without entering the sleeper section of the cab. Press the bottom of the switch to turn the light ON, press the top of the switch to turn the light OFF. The switch works together with the switch on the sleeper control panel.
INSTRUMENTS AND CONTROLS 91 41. Microphone The microphone is located above the driver in the headliner. It is available on the Mid-Level radio with Blue Tooth/Hands free option. This is what is used to talk into when the phone is connected to the truck. For more information on the microphone, please refer to the Radio Manual that is supplied with the vehicle. DASH SWITCHES Power Take-Off (PTO) There are two basic types of PTOs available: engine-mounted and transmission-mounted.
92 INSTRUMENTS AND CONTROLS W3005510 Engine-Mounted PTO, VN The engine should be running at low idle and the vehicle should be stopped or running at very low speed before engaging power take-off. Engage the PTO by depressing the locking tab and at the same time, depressing the main part of the switch. The PTO is now in operation and hydraulic flow can be regulated by the engine speed.
INSTRUMENTS AND CONTROLS 93 PTO Speed Adjustment Engage the PTO before adjusting the speed. For the PTO speed adjustment to function, the Cruise Control or idle adjust cannot be active, brake and clutch pedals must be released, and vehicle speed must be under approximately 8 km/h (5 mph). To set engine speed: 1 Set the PTO/CC switch in the ON position. 2 Depending on configuration, the engine speed may automatically be selected when the PTO dash switch is activated (Volvo engines only).
94 INSTRUMENTS AND CONTROLS To increase/decrease engine speed: 1 Volvo engines: Press and release the SET+ or SET- toggle switch to increase/decrease speed in increments (increment size depends on programmed value). 2 Cummins engines: Press and hold the SET+ or SET- toggle switch to increase/decrease speed. When the switch is released, the engine speed sets at current speed. To deactivate PTO speed function. Set the PTO/CC switch to the OFF position. or 2. Depress the service brake pedal. or 3.
INSTRUMENTS AND CONTROLS 95 W3005433 Volvo Engine Brake I-VEB The Volvo Engine Brake (I-VEB) works together with the variable geometry turbocharger to provide retarding horsepower at low engine rpm. The I-VEB is standard equipment on the Volvo 16F engine and optional on the 13F and 11F engines. The I-VEB has a six position control located on the steering column, just forward of the wiper stalk.
96 INSTRUMENTS AND CONTROLS Cummins ISX Intebrake Standard: Two dash switches control the 3-level engine brake; the left dash switch controls ON/OFF, the right dash switch controls LOW/MED/HIGH.
INSTRUMENTS AND CONTROLS 97 Optional: A 6-level retarder stalk switch mounted to the right of the steering column. An ON/OFF switch at the end of the stalk lever enables/disables the engine brake.
98 INSTRUMENTS AND CONTROLS CLIMATE CONTROL SYSTEMS There are two different air conditioning systems. Depending on your vehicle, you will have one of these two air conditioning units installed: 1 Electronic Climate Control (EEC) 2 Manual Climate Control (MCC) Note: For both climate control systems (ECC and MCC), after a pre-determined number of "vehicle starts" the climate unit will recalibrate the door positions, which may take several seconds before the airflow returns to the selected distribution mode.
INSTRUMENTS AND CONTROLS 99 Recirculation Press recirculation to circulate the air in the cab. Only a small amount of air is taken directly from outside. The light in the button comes on when the button is pressed for air recirculation. Temperature Control Settings ECC Maximum Cold Setting The temperature knob should be set to the far left. The fan speed knob should be set to AUTO and the air distribution knob should be on AUTO. Maximum Heat Setting The temperature knob should be set to the far right.
100 INSTRUMENTS AND CONTROLS Mist and Ice Removal DANGER DO NOT attempt to drive with the windshield covered by mist, or fog or frost. The visibility is reduced, which could lead to an accident causing severe personal injury or death. 1 Turn knob to defrost. 2 Rotate the temperature knob to add heat as necessary. 3 Set the fan speed knob to maximum (the extreme right). Use these instructions to keep the windshield clear at all times.
INSTRUMENTS AND CONTROLS 101 ECC Air Distribution W8003067 1 Temperature Sensor CAUTION The temperature sensor shown in the illustration, detects the temperature in the cab. DO NOT cover the sensor, and DO NOT place warm objects, like coffee makers or refrigerators, close to the sensor. Always allow the dashboard vents (see arrows in illustration) to remain open.
102 INSTRUMENTS AND CONTROLS AIR CONDITIONING MANUAL CLIMATE CONTROL (MCC) One difference in the Manual Climate Control unit is the AC ON button. W8003066 1 AC ON button turns the air conditioning ON. 2 Temperature Control Knob 3 Fan Speed Knob 4 Recirculation Button 5 Air Distribution Knob Note: The LED light is green when the AC button is depressed. When the AC ON button is NOT depressed and the compressor or AC is heard, this is not a fault in the system.
INSTRUMENTS AND CONTROLS 103 Recirculation Press recirculation to circulate the air in the cab. Only a small amount of air is taken directly from outside. The light in the button comes on when the button is pressed for air recirculation. Temperature Control Settings MCC Move the knob to the blue bar for cool air to circulate in the cab, and to the red bar for warm to hot air to circulate in the cab. Select the desired fan speed starting from 1 to 4. "0" is not a fan speed.
104 INSTRUMENTS AND CONTROLS MCC Air Distribution W8003110 Always allow the dashboard vents (see arrows in illustration) to remain open. Irrespective of how the air distribution is set, a small amount of air will always come from the dashboard vents to ensure the temperature in the cab is correct. Note: Floor Mode: Unheated air is leaked to the panel vent to balance the heat rising from the floor.
INSTRUMENTS AND CONTROLS 105 If at any time there is any question whether fumes are entering the cab, determine the cause of the fumes and have it corrected as soon as possible. If the vehicle must be driven under these conditions, drive only with all windows open. Protect against carbon monoxide entry into the cab. Keep the engine exhaust system, cab and cab ventilation system properly maintained.
106 INSTRUMENTS AND CONTROLS SLEEPER CLIMATE UNIT The sleeper cabs have an A/C and heater unit that is located in the passenger side luggage compartment. The sleeper unit operates from the same heater and air conditioning supply as the main unit. The heater can be operated independently from the main unit as long as the engine is running.
INSTRUMENTS AND CONTROLS 107 LIGHT CONTROL PANEL Exterior lighting is controlled through the light control panel. The rotary knob controls the parking lights, headlights, and the optional fog and driving lights. The panel also has a dimmer control switch and hazard switch.
108 INSTRUMENTS AND CONTROLS Fog and Driving Lights Fog and driving lights are wired so they are turned on only when the headlight control is on. Fog lights are used with the low beam headlights. Driving lights are used with the high beam headlights. Switching from low to high beam will automatically switch from fog lights to driving lights. Driving and fog lights should be used when driving conditions require additional lighting.
INSTRUMENTS AND CONTROLS 109 W3005274 VNL Fog and Driving Lights
110 INSTRUMENTS AND CONTROLS SLEEPER CONTROL PANEL (SLEEPER MODELS ONLY) The sleeper control module is located behind the driver’s seat. It provides precise temperature control to the sleeper unit. There are separate temperature and fan control systems for the sleeper and the cab area. The driver can control the fan speed in the sleeper using a control switch on the dash. Also, radio controls are available.
INSTRUMENTS AND CONTROLS 111 W3030107 1 Panel in VN 730 ,780 and 2 Panel in VN 430, 630, 670 Note: High Sleeper or Basic Sleeper Control Panel are NOT cab model dependent This dual control usage provides optimum comfort to the driver and passenger (if any) in both compartments.
112 INSTRUMENTS AND CONTROLS Sleeper Controls Sleeper Control Panel, High W3030106 1 Display Screen: Displays selected information. 2 On/Off button 3 Radio Forward Scan/Search/Next Track 4 Radio Power 5 Menu/Snooze Button: This button allows you to adjust settings in the display screen and activate the clock’s snooze option. 6 Fan Speed Control and Battery Protection Override Switch: This can be controlled from the sleeper control module or from the dash rocker switch.
INSTRUMENTS AND CONTROLS 113 9 Fuses 10 Panic button 11 LED: Only used for low voltage conditions. 12 Overhead Lamp Switch: This can be controlled from the sleeper control module or from the dash rocker switch. 13 Mode Switch: Changes mode of radio 14 Radio Reverse Scan/Search/Next Track 15 Set button 16 Increment/Decrement Knob: Use this knob to adjust the Volume level.
114 INSTRUMENTS AND CONTROLS Sleeper Control Panel, Basic W3030078 1 Overhead Lamp Switch: This can be controlled from the sleeper control module or from the dash rocker switch. 2 Speaker: Sounds when the alarm or timer goes off, or when entering battery protection mode. 3 Display Screen: Displays selected information. 4 Menu/Snooze Button: This button allows you to adjust settings in the display screen and activate the clock’s snooze option.
INSTRUMENTS AND CONTROLS 115 Set Clock To set the clock for the Sleeper Control Panel, perform the following: 1 Press the SET button. 2 To set the clock to either ’12’ or ’24’ hour increments, use the “+” or “-” knob. 3 Press the SET button. 4 To set the clock Hour, use the “+” or “-” knob. 5 Press the SET button. 6 To set the clock Minute, use the “+” or “-” knob. 7 Press the SET button to confirm settings. Once the clock is set to the desired time, the clock displays.
116 INSTRUMENTS AND CONTROLS Dimmer To adjust the backlighting brightness level, perform the following: 1 Press the MENU button. 2 Press the SET button. 3 Use the “+” or “-” knob to adjust the brightness level. 4 Press the SET button to confirm settings. Once the backlighting brightness is set to the desired level, the display goes back to the clock. Note: After 7 seconds of inactivity the display returns to clock. Press the MENU button to restart.
INSTRUMENTS AND CONTROLS 117 Setting Alarm Time To set the alarm time, perform the following: 1 Press the MENU button twice. 2 Press SET button. 3 Use the “+” or “-” knob to adjust the hour value. 4 Press SET to accept the set hour. 5 Use the “+” or “-” knob to adjust the minute value. 6 Press the SET button to confirm settings. Once the alarm time is set the display returns to the clock and the Alarm icon is illuminated. Note: After 7 seconds of inactivity the display returns to clock.
118 INSTRUMENTS AND CONTROLS Setting the Sleeper Control Panel Heat Control Value to Auto Auto Set a time in the future to automatically turn ON. Will remain ON until manually turned OFF. To set the Sleeper Control Panel heater to Auto, perform the following: 1 Press the MENU button three times. The Heat icon blinks. The heat control value displays either as OFF, Auto or Cycle depending on the previous setting. 2 Press the SET button,Heat is displayed. 3 Use “+” or “-” to chose Auto.
INSTRUMENTS AND CONTROLS 119 Setting the Sleeper Control Panel Heat Control Value to Cycle Cycle Set a cycle time to continuously cycle between ON/OFF To set the Sleeper Control Panel heater to Cycle, perform the following: 1 Press the MENU button three times. The Heat icon blinks. The heat control value displays either as OFF, Auto or Cycle depending on the previous setting. 2 Press the SET button,Heat is displayed. 3 Use “+” or “-” to chose Cycle. 4 Press the SET button, ON/OFF is displayed.
120 INSTRUMENTS AND CONTROLS Setting Sleeper Control Panel Timer To set the Sleeper Control Panel Timer, perform the following: 1 Press the MENU button four times. The TIMER icon blinks. 2 Press the SET button. 3 To set the Timer minutes, use the “+” or “-” knob. 4 Press the SET button. 5 To set the Timer seconds, use the “+” or “-” knob. 6 Press the SET button to confirm settings. Once the Timer is set to the desired time, the display goes back to the clock and the TIMER icon is shown.
INSTRUMENTS AND CONTROLS 121 Turning the Lamp Timer ON/OFF Lamp Timer Turns interior lamps off after a set time. To turn the Lamp Timer On/Off for the Sleeper Control Panel, perform the following: 1 Press the MENU button six times. The Lamp Icon flashes. 2 Press ON/OFF. 3 Press the SET button to confirm settings. The Lamp Timer is turned On/Off, and the display returns to the clock. The Lamp icon toggles between On/Off accordingly. Note: After 7 seconds of inactivity the display returns to clock.
122 INSTRUMENTS AND CONTROLS MISCELLANEOUS CAB EQUIPMENT Cup Holders and Trash Compartment There is a trash bin holder at the lower part of the dash. To open, press the top part of the lid in and the lid will fold out. To close, press the lid in until the latch closes. There are also two dash-mounted cup holders convenient to the driver and passenger. Trash bin: (Removable), Located below the 12 V power outlet.
INSTRUMENTS AND CONTROLS 123 Sleeper cup holder: Located on the left lower tower cabinet, for the bottom bunk. There is another cup holder located on the left upper tower cabinet for the upper bunk.
124 INSTRUMENTS AND CONTROLS Curtains Curtains are available for all the sleeper cabs to ensure privacy and to darken the cabin from outside light. Various configurations are available. Curtains can cover the whole windshield area or go across the sleeper opening. When the curtains are not in use, they are stored out of the way and held in place with velcro straps.
INSTRUMENTS AND CONTROLS 125 STEERING COLUMN Ignition Switch The ignition switch is located on the right side of the steering column just under the steering wheel. Standard equipment is a normal ignition switch. Note: The vehicle is delivered with 2 identical keys. If more keys are needed, order them through your authorized Volvo Truck dealer. The ignition positions are: • • • • A — Radio, Accessories B — Off C — Drive D — Start The key can only be removed when in the B or Off position.
126 INSTRUMENTS AND CONTROLS Windshield Wiper/Washer Note: Make sure the ignition is in the Off position to avoid draining the battery. The wiper/washer functions are operated by the same lever. The wipers have normal and fast speeds which are activated by moving the lever down one or two positions. To let the wipers engage for a few passes, lightly depress the lever until the wipers start and hold it there. The wipers return to the parking position when the lever is released.
INSTRUMENTS AND CONTROLS 127 ADJUSTABLE STEERING COLUMN DANGER DO NOT try to make adjustments to the steering wheel while the vehicle is moving. Never operate the vehicle with the steering wheel adjusted to its uppermost position (exiting cab position). Make all adjustments before starting the vehicle, to prevent loss of vehicle control, which can cause personal injury or death. The adjustment device is operated by a pedal on the left side of the floor.
128 INSTRUMENTS AND CONTROLS STEERING WHEEL CONTROLS Left-Hand Controls • Marker Interrupt (Bottom) • Headlamp Interrupt (Top) When either switch is pressed, the corresponding lights toggle from their current state. If OFF they change to ON and if ON they change to OFF. When pressed for more than 3 seconds, the lights revert automatically to the initial state. W3005294 Right-Hand Controls • Radio controls Press +, up or -, down to change the radio volume.
INSTRUMENTS AND CONTROLS 129 MISCELLANEOUS SWITCHES Horn Switches Electric and air horns are standard equipment. They are both operated from the steering wheel or center pad. The airbag can be pressed down anywhere around the edge to engage the air horn.
130 INSTRUMENTS AND CONTROLS INTERIOR LIGHTS The cab is equipped with separate and combined interior and reading lights in various locations in the cab. The front seat overhead lights can be turned on at any time using the switch in the fixture. This is a three-way switch, pressing the lamp turns the light ON, OFF or the light comes on with the door being opened. When the switch is in the middle position, the light does not turn on, even when the door is opened.
INSTRUMENTS AND CONTROLS 131 Interior Lights Chart Number Description 1 Overhead Dome Lamp 1 Overhead Dome/Spot Lamp connected to door 2 Door Courtesy Lamp 3 Dome Lamp — Sleeper 4 Reading Lamp under bunk storage 5 Reading Lamp 6 Overhead Lamp — Short 7 Overhead Lamp — Long 8 Overhead Dome/Spot Lamp Note: To prevent short service lift, DO NOT touch the glass surface of the replacement bulb. WARNING The lamp assemblies may get warm to the touch. DO NOT cover the lamps with any object.
132 INSTRUMENTS AND CONTROLS The red courtesy light comes on when the door is opened. The lens is red to alert oncoming traffic from the rear that the door is open. It is also used during night driving to light up the floor area and steps without distracting the driver with a glaring light. CAUTION DO NOT use sleeves of any kind over bulbs in the interior lamps. The bulbs may over heat causing damage to the fixture including possible fire.
INSTRUMENTS AND CONTROLS 133 The door latch has an internal switch that operates all door-activated lights.
134 INSTRUMENTS AND CONTROLS Fresh Air Vent A. Closed B. Open C. Vertical Air Flow D. Lateral Air Flow T0008094 When heating the cab, all vents should be closed. However, the vents on the outer parts of the dash can be used for defrosting the cab door windows. When operating the air conditioning, all air vents should be completely open and the air flow directed upward. DANGER DO NOT breathe the engine exhaust gas. It contains carbon monoxide, which has no color or odor.
INSTRUMENTS AND CONTROLS 135 CAB VENTILATION, SLEEPER In sleeper versions (except the VN 780 and VN 730) there is a fresh air vent located on each cab side wall. It opens to two positions so the air flow can be regulated. W8003135 The vent also opens toward the front or toward the rear. This can be used for forcing air into the cab (open toward the front) or for venting air out of the cab (open toward the rear).
136 INSTRUMENTS AND CONTROLS W8003823 1 VN 780 and VN 670 Vent Window 2 VN 780 Hinged Side Window The VN 730 is equipped with two hinged side windows in the sleeper area. DO NOT force the window crank mechanism in the fully open position. The mechanism can be damaged if you try to open the window beyond the stop position. CAUTION Make sure the windows are closed before washing the cab. Water can enter the cab through the window opening.
INSTRUMENTS AND CONTROLS 137 12 Volt Power Outlets CAUTION DO NOT connect a device with a current rating in excess of 10 amps or the amount labeled. There are a number of 12 V outlets that can be accessed in the cab. There is a power outlet on the sleeper control panel. The outlet is covered by a cap that is pulled out for access. W3005298 The outlet is made for 12 V accessory-type plug.
138 INSTRUMENTS AND CONTROLS 12 Volt Locations There is an optional power outlet in the driver and passenger side cabinets. Accessories for this cabinet will have ON/OFF switches of their own. The cabinet 12 V outlets are made for 12 V accessory-type plugs.
INSTRUMENTS AND CONTROLS 139 W3005500 VN 780, VN 730
140 INSTRUMENTS AND CONTROLS Inverter Switch 12 V DC to 120 V AC DANGER When parked on wet ground, avoid using an external power source to connect the cab power plug. Water is a conductor of electricity. In wet conditions, electrical shock can occur which can result in personal injury or death. This switch turns ON the optional power inverter, located near the battery compartment.
INSTRUMENTS AND CONTROLS 141 W3005980 This is a typical setup with a factory-installed inverter.
142 INSTRUMENTS AND CONTROLS Note: A tripped circuit is usually an indication of a fault in the circuit, or of an appliance being supplied with power. Every effort should be made to identify and correct any fault that exists. 120 Volt System and Outlets DANGER When parked on wet ground, avoid using an external power source to connect the cab power plug. Water is a conductor of electricity. In wet conditions, electrical shock can occur which can result in personal injury or death.
INSTRUMENTS AND CONTROLS 143 W3005284 Power goes through a circuit breaker box located on the front wall in the driver side luggage compartment. On the right is an ON/OFF switch and on the left is the ground fault circuit interrupter. The controls may also be reached from inside the cab through the hatch under the mattress or cushion.
144 INSTRUMENTS AND CONTROLS W3005967
INSTRUMENTS AND CONTROLS 145 From the breaker box in the VN 780 and 730, power goes to the three outlets as a standard feature. In the VN 670 and 630 models, the outlet on the driver side lower bunk box is standard, and the tower cabinet middle compartments (1) each have an optional outlet.
146 INSTRUMENTS AND CONTROLS W3005343 120 Volt System Wiring, VN 670, VN 630
INSTRUMENTS AND CONTROLS 147 W3005342 120 Volt System Components, VN 670, VN 630 1 120 Volt Outlet 2 External 120 Volt Receptacle 3 Circuit Breaker Box
148 INSTRUMENTS AND CONTROLS Cigar Lighter To operate the cigar lighter, press the center in until it stays in. The heating element will heat up and pop the lighter out when it is ready for use. The ash tray is located next to the cigar lighter. W3005271 The cigar lighter socket is optimized for use with cigar lighter heating element. This socket should not be used as an auxiliary 12 V power supply because there are many aftermarket power plugs available, with different dimensions.
INSTRUMENTS AND CONTROLS 149 PARKING HEATER (OPTIONAL, SLEEPER MODELS ONLY) DANGER DO NOT fuel the vehicle or handle flammable liquids in the vicinity of an operating parking heater. The fuel vapors can be ignited, causing an explosion or fire resulting in severe personal injury or death. DANGER DO NOT store flammable items close to the parking heater or put items on top of it. Flammable items should not be closer than 50 mm (2 inches).
150 INSTRUMENTS AND CONTROLS Fuel Parking Heater Note: The parking heater is not available if the vehicle is equipped with a sink. A fuel heated parking heater is available as an option. It is located in the left-hand luggage compartment. The heater provides automatically regulated heat that is distributed through its own vents into the sleeper section of the cab.
INSTRUMENTS AND CONTROLS 151 ANTENNAS General 3 Radio AM/FM 1 Multiband 4 TV Antenna 2 Multiplexer (Rami) Multiband Antenna There are antennas mounted on the top of the mirror brackets for wideband reception. They receive or send signals for radio, CB and telephone. Each antenna carries multiple wire windings that work together with mirror bracket devices to cover the needs of many uses. If the antenna is damaged, replace it only with a multiband type antenna.
152 INSTRUMENTS AND CONTROLS Antenna Multiplexer W3005509 1 Cellular Phone Antenna Cable 2 Radio Antenna Cable Connection 3 Phone Cable Connection 4 CB Radio Antenna Cable Connection Communication signals that travel to and from the antennas go through the antenna multiplexer. It is standard in the VN 670 and VN 780, and optional on other models. Coaxial cables for the cellular phone, CB radio and radio are included in the multiplexer system — all using the same set of antennas.
INSTRUMENTS AND CONTROLS 153 The multiplexer is accessed through the lower dash panels. Cable routing is as shown in the illustration above. Use only genuine Volvo replacement parts for this multiplexer system; standard antennas will give unsatisfactory performance. The windings in the antennas are specific to this system: different sections of the antenna are used for the cellular phone, radio and CB. Note: The location of the CB may vary.
154 INSTRUMENTS AND CONTROLS W0002361 There is an optional television speaker available, located in the top of the sleeper switch panel. Beside the speaker, there is a jack for headphones. This is provided for silent viewing of the TV. When the headset jack is plugged in, the speaker is cut out. Note: The TV prep kit is optional. TV Antenna CAUTION DO NOT pierce or drill through the headliner. The TV antenna may be damaged. The TV antenna for the VN 780, VN 730 and VN 830 is standard equipment.
INSTRUMENTS AND CONTROLS 155 COMMUNICATION EQUIPMENT CB Radio There is an optional platform provided for a CB radio on top of the dash. The unit is held in place with a strap which can accommodate a variety of sizes. W3006382 The CB radio can also be mounted in the overhead storage. See "STORAGE COMPARTMENTS" “STORAGE COMPARTMENTS”, page 156.
156 INSTRUMENTS AND CONTROLS Telephone There is room on the dash for a mobile telephone. This can be hooked up to the multiplex box. If the vehicle is delivered with a multiplex box, the connecting end of the telephone coaxial cable should be located at the lower dash cover. Note: The panel must be removed to access the cable.
INSTRUMENTS AND CONTROLS 157 To prevent the television and microwave oven from moving when the vehicle is driven, the strap in the storage area should be tight around the unit. Position the strap across the front corners of the unit. Periodically, check that the strap is tight and retighten as necessary.
158 INSTRUMENTS AND CONTROLS Front Overhead Storage There are two configurations of overhead storage compartments mounted over the windshield: five openings with nets, or CB radio, switch panel, and three openings with nets. The storage compartments have a maximum storage weight limit of approximately 1.1 kg (2.5 lb.) per opening or a total of 5.6 kg (12.5 lb.) evenly distributed.
INSTRUMENTS AND CONTROLS 159 W8003821 CB Radio, Switch Panel and Three Openings with Nets
160 INSTRUMENTS AND CONTROLS There are two configurations of forward overhead shelves at the front of the sleeper: without cabinets or with cabinets. The storage compartments have a maximum storage weight limit of approximately 3.6 kg (8 lb.) per section.
INSTRUMENTS AND CONTROLS 161 W8003793 Forward Overhead Shelf with Cabinets
162 INSTRUMENTS AND CONTROLS VN 780 Storage W8003805 1. 3 kg (6.6 lb.) 2. 3 kg (6.6 lb.) 3. 4 kg (8.8 lb.) 4. 15 kg (33.1 lb.) with TV, 6 kg (13 lb.) without TV 5. Hang Rod (Standard) 9 kg (19.8 lb.) 6. (Standard) 18 kg (39.6 lb.) 7. 3 kg (6.6 lb.)8.3 kg (6.6 lb.) 9. 4 kg (8.8 lb.) 10. 15 kg (33.1 lb.) with TV, 6 kg (13 lb.) without TV 11. 4 kg (8.8 lb.) 12. 5 kg (9.9 lb.) 13. 6 kg (13.2 lb.) 14. 6 kg (13.2 lb.) 15. 45 kg (99 lb.) with refrigerator, 6.5 kg (14 lb.
INSTRUMENTS AND CONTROLS 163 VN 780 Bunk Storage W8003157 1 Storage Bins 2 Storage Compartment 3 Storage Compartment 4 Exterior Side Storage Compartment
164 INSTRUMENTS AND CONTROLS VNL 730 Storage W0002358 1. 6 kg (13 lb.) without refrigerator, 45 kg (99 lb.) equally distributed with 78 L refrigerator 2. 6 kg (13 lb.) without refrigerator, 45 kg (99 lb.) equally distributed with 78 L refrigerator 3. 4 kg (8.8 lb.) 4. 15 kg (33.1 lb.) Note: Do not load the sink, if equipped. 5. 6. 7. 8. 9. 3 kg (6.6 lb.) 3 kg (6.6 lb.) 13.6 kg (30 lb.) 10 kg (22 lb.) on hanger rod 9 kg (19.8 lb.
INSTRUMENTS AND CONTROLS 165 W8028486 Load Limits
166 INSTRUMENTS AND CONTROLS 1. 5 kg (9.9 lb.) with 44 L refrigerator 2. 4 kg (8.8 lb.) if shelf, 5 kg (9.9 lb.) if refrigerator 3. 15 kg (33.1 lb.) 4. 3 kg (6.6 lb.) 5. 13.6 kg (30 lb.) 6. 10 kg (22 lb.) on hanger rod W8028487 Load Limits 1. 15 kg (33 lb) with 44 L refrigerator 2.
INSTRUMENTS AND CONTROLS 167 VNL 730 Bunk Storage W8028488 Load Limits 1. Storage Compartment 2. Storage Compartment 3.
168 INSTRUMENTS AND CONTROLS VN 670, 630, 430 W8028489 Load Limits 1. 2. 3. 4.
INSTRUMENTS AND CONTROLS 169 SLEEPER BUNKS General Upper and lower bunks are available in the VN 780, 730, 670 and 630 models. The lower bunk is standard while the upper bunk is optional. The VN 430 are equipped with one lower bunk. The bunks for the VN 670, 630, 430 cover the luggage compartment. They are hinged for access to luggage from inside of the cab. To gain access, release the latch mechanism and lift by the edge of the bunk platform.
170 INSTRUMENTS AND CONTROLS and hold the bunk properly. For more information on bunk safety restraints, see “Safety Restraint VN 430, VN 630, VN 670 ”, page 238. W8028490 1 Cushions: These can be moved and placed to the side.
INSTRUMENTS AND CONTROLS 171 VN 780 Sleeper Upper Bunk DANGER Always have three limbs (one foot and two hands or two feet and one hand) in contact with the floor, bunk or step at all times when entering or exiting the upper bunk. Failure to follow this procedure can lead to a fall and cause severe personal injury or death. WARNING Support the bunk with one hand while releasing the latches. Failure to support the bunk may lead to the bunk falling without control, causing personal injury.
172 INSTRUMENTS AND CONTROLS W8028491 1 Upper Bunk 2 Upper Bunk in Lowered Position 3 Release/Pull Strap 4 Upper Bunk in Raised Position
INSTRUMENTS AND CONTROLS 173 VNL 730 Sleeper Bunk DANGER Always have three limbs (one foot and two hands or two feet and one hand) in contact with the floor, bunk or step at all times when entering or exiting the upper bunk. Failure to follow this procedure can lead to a fall and cause severe personal injury or death.
174 INSTRUMENTS AND CONTROLS The VNL 730 can be equipped with a single 53-inch lower bunk, or a 42-inch lower bunk and an upper bunk. For information on bunk safety restraints, see “Safety Restraint VN 430, VN 630, VN 670 ”, page 238.
INSTRUMENTS AND CONTROLS 175 The 42-inch bunk cushions cover the luggage compartment. They can be moved for access to luggage from inside the cab. W8028524 1 Cushions: These can be moved for access to the luggage compartment. 2 Cushions: These can be moved and placed to the side.
176 INSTRUMENTS AND CONTROLS The upper bunk is hinged and can be raised out of the way. The bunk is supported by a strut on each side in the raised and lowered positions. Use the handle in the middle of the bunk to raise and lower it.
INSTRUMENTS AND CONTROLS 177 VN 670, 630 42-Inch Sleeper Bunk W8028526 VN 670, 630 Lower Bunk WARNING Support the bunk with one hand while releasing the latch. Failure to support the bunk may lead to the bunk falling without control, causing personal injury.
178 INSTRUMENTS AND CONTROLS W8028527 VN 670, 630 Lower and Upper Bunks
INSTRUMENTS AND CONTROLS 179 VN 670 Optional Fold Down Step In the VN 670 sleeper there is an option on the passenger side which offers a fold down step. See illustration.
180 INSTRUMENTS AND CONTROLS VN 670 W8028529 Moveable Cushions in Lower Bunk
INSTRUMENTS AND CONTROLS 181 VN 430 Sleeper Bunk W8028530 1 Bunk 2 Bunk Restraints 3 Lower Bunk Restraint Attachment Buckles 4 Tenting Buckles
182 INSTRUMENTS AND CONTROLS Upper Bunk Access VN 780 DANGER Always have three limbs (one foot and two hands or two feet and one hand) in contact with the floor, bunk or step at all times when entering or exiting the upper bunk. Failure to follow this procedure can lead to a fall and cause severe personal injury or death. WARNING Support the ladder with one hand while releasing the lock straps. Failure to support the ladder may lead to the ladder falling out, causing injury to leg or foot.
INSTRUMENTS AND CONTROLS 183 W8028531 1.Ladder in Down Position 2.Retainer 3.Grab Handle (on Optional Fixed Bunk, Grab Handle is Not Available) 4.Ladder (Stored) 5.Cabinet Grab Handle 6.
184 INSTRUMENTS AND CONTROLS VN 780, VNL 730, VN 670 OFFICE DANGER Do not sit at the table when the vehicle is moving. It is intended for use only when the vehicle is parked. Passengers should be in the passenger seat wearing the safety belt or in the bunk with the bunk restraint attached. Failure to follow these instructions may result in severe personal injury or death in the event of a sudden stop or accident. To raise table, remove the cushions from the bunk, place them to the sides.
INSTRUMENTS AND CONTROLS 185 W8003158
186 INSTRUMENTS AND CONTROLS SLEEPER COMPARTMENT SINK A built-in sink is available as optional equipment in some sleeper models. It is located on the left side, in the cabinet behind the driver. The sink is mounted in the drawer space. To pull out, grasp the drawer lip and release the latch. Pull out until the faucet can be raised without hitting the cabinet. CAUTION Never run the pump without water in the freshwater tank. The pump may be damaged if run dry.
INSTRUMENTS AND CONTROLS 187 To operate the water pump, there is a combined valve and switch in the knob (see arrow in illustration) on the base. Turn the knob slightly toward you to start the pump; see arrow in illustration. Turn the knob further to increase water flow. When the knob is turned fully back to rest position, the pump will stop. CAUTION Make sure the pump is turned off before pushing the drawer in. If the pump continues to deliver water, overflowing water can flood the cab floor.
188 INSTRUMENTS AND CONTROLS It is not recommended to keep unused water in the tank for over one month. Clean and refill as necessary. W8002168 CAUTION USE POTABLE DRINKING WATER ONLY. Verify with the supplier of any water prior to filling the fresh water tank that it is potable to avoid contamination of the tank. In the event that non-potable or contaminated water enters the fresh water tank, it should be drained and the tank should be cleaned out with a good commercial cleaner/disinfectant.
INSTRUMENTS AND CONTROLS 189 CAUTION Fresh water and waste water tanks must be drained if the vehicle is not being used and the outside temperature is below freezing. Also drain the hose from the pump to the faucet. Failure to drain the system may result in component damage due to water forming ice. To fill the fresh water tank, unscrew the fill hose from the elbow fitting and remove the fill cap (5) from the tank. The fill hose is connected to a hose with a garden hose-type fitting.
190 INSTRUMENTS AND CONTROLS When the tank is full, reinstall the fill hose on the elbow fitting. Do not tighten more than finger tight. Make sure that the valve handle is fully open (1) to allow venting. If the valve is left in any of the closed positions (2), the pumped out water may generate an under-pressure in the tank, interfering with the pump operation. Note: The valve positions are shown as viewed from inside the cab.
INSTRUMENTS AND CONTROLS 191 Waste Water Tank When the water is drained from the sink, it is collected in a waste water tank behind the fresh water tank. Waste water tank volume is 19 liters (5 gallons). The tank is fastened to the floor with a strap that can be easily opened for tank removal. Before removing the waste water tank, loosen the strap around the tank and unscrew the drain hose from the inlet cap.
192 OPERATION PRE-TRIP INSPECTION AND DAILY MAINTENANCE DANGER Before working on or inspecting 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 personal injury or death. Safety is the most important and obvious reason for doing a pre-trip inspection. Federal and state laws require inspection performed by the driver. Federal and state inspectors also inspect commercial vehicles.
OPERATION 193 Switch/Circuit Status Check The Switch/Circuit Status check tests the functionality of the switches and their corresponding circuits. To start the check the driver must turn the individual switches on/off. As the switches turn on/off, the cluster updates the DID to show switch option being tested and it’s status. Note: The Hazard and High/Low Switches are momentary switches and return to the OFF position when released during testing. 1. The initial Pre-Trip screen displays.
194 OPERATION Exterior Light Inspection Check The Exterior Light Inspection check repeatedly turns all exterior lights on/off for the vehicle. This allows the operator to start the test, exit the vehicle and do a visual check that all exterior lighting is functioning properly. The following exterior lights are cycled through the check: • • • • • • Parking Hazard Turn signals (left and right) High/Low beam headlights Brake Fog/Driving (Optional) 1.
OPERATION 195 2. The Test Started screen displays. You can stop the test by pressing ’ESC’ on the stalk or by starting the ignition. W3035557 Once the test is started all exterior lights flash on and off so that you can perform a visual check.
196 OPERATION Air Leakage Check The Air Leakage check allows the driver to accurately measure the amount of air pressure drop in the front and rear brake air systems. After selecting this test from the DID, you are prompted to apply the service brake for 60 seconds. After applying and holding the service brake for 60 seconds, the DID will display the amount of pressure drop in the brake system.
OPERATION 197 2. When the system is ready to be checked, the following screen displays. Press Enter to begin the test. W3035566 Press and hold the brake pedal for 60 seconds. If the brake pedal is not pressed and held for 60 seconds the following warning screen displays. W3035571 3. Once the brake pressure test is completed the pressure leak test results are displayed.
198 OPERATION W3035574
OPERATION 199 Take your time going through the pre-trip inspection. Remember that a careful pre-trip inspection saves time by eliminating unscheduled stops for correcting a faulty item. The following information has been provided by the American Trucking Association as developed by the D.O.T. Office of Motor Carriers (BMCS). Pre-Trip Inspection Quick List W0001230 VN Pre-Trip Inspection Quick List Inspect the vehicle in a circular manner.
200 OPERATION • Raise cab so belts can be checked Step 1: Left Side of the Cab Left Front Wheel • Check condition of wheel rim. Especially look for cracks, missing lockrings, bent or broken studs, missing clamps or lug nuts. • Check condition of tire: properly inflated, no serious cuts, bulges, tread wear or any signs of misalignment; valve stem not touching wheel, rim or brake drum; valve cap in place. • Check wheel bearing and hub: no obvious leaking on outside or inside wheel.
OPERATION 201 Engine Compartment, Right Side • Check condition of coolant and heater hoses. • Check condition of fan drive belts. • Check engine and surrounding areas for coolant, oil and fuel leaks. • Check fuel separator sight glass and drain if necessary. Check for leaks. • Check wiring harnesses for signs of damage. • Check air filter with brackets and hoses for loose connections or damage. Check filter gauge, if mounted on the filter.
202 OPERATION • Check condition of tire: properly inflated, no serious cuts, bulges, tread wear or any signs of misalignment; valve stem not touching wheel, rim or brake drum; valve cap in place. • Check wheel bearing and hub: no obvious leaking on outside or inside wheel. Verify correct oil level in hub. Right Front Suspension • Check condition of spring, spring hangers, shackles, U-bolts: no cracks, breaks or shifting. • Shock absorber condition. Right Front Brake • Condition of brake drum.
OPERATION 203 • Check drive shaft. • Exhaust system: secure, not leaking, not touching wires, fuel or air tubing. • Frame and cross members: no bends, cracks or breaks. DPF/SCR check hoses and fittings for leaks. • Air tubing and electrical wiring: secured against snagging and chafing. Step 5: Right Rear Vehicle Area Dual Wheels, One or Two Axles • Check condition of wheels and rims. Especially look for cracks, missing lockrings, bent or broken spacers, studs, missing clamps or lug nuts.
204 OPERATION • Check that air tubing and electrical lines are properly secured to the frame with no damage or chafing. Lights and Reflectors • Tail lights, brake lights and turn signal lights: operating, clean and proper color. Step 7: Coupling System Area Fifth Wheel • Securely mounted to the frame. • No missing or damaged parts. • Check that trunnion and plate are properly lubricated. Sliding Fifth Wheel • Mechanism not worn, bent, damaged or parts missing. • Properly lubricated.
OPERATION 205 Suspension • Check condition of springs (leaf or air), spring hangers, shackles and U-bolts, no cracks, breaks or shifting. Brakes • Condition of brake drums. With brakes released, look for a noticeable gap between lining and drum. (This check cannot be made if dust covers are in place.) • Condition of brake hoses: check for any chafing. • Check brake chamber mounting bolts and brackets. • Check slack adjusters and chamber push rod travel.
206 OPERATION In the Cab • Check steps and grab handles for looseness or breakage. Also, clean them if there is any substance that makes them slippery, which makes cab entry/exit hazardous. • Start the engine. If equipped, check that exhaust rain cap opens when accelerating engine. • Check gauges and tell-tale light function. See the Instruments and Controls section. • Check function of low air warning. • Check clutch function. If equipped, check for clutch brake function.
OPERATION 207 Sliding Fifth Wheel • Check that fifth wheel is not so far forward that the tractor frame will strike the landing gear during turns. Note: Refer to the trailer manufacturer’s manual for specific information on the trailer checks. Step 9: Trailer Front Area Air and Electrical Connections • Glad hands properly mounted, free from damage and not leaking. • Trailer cord receptacle properly mounted, free of damage; plug properly seated and safety catch engaged to prevent accidental disconnect.
208 OPERATION • Body parts not damaged or missing. Step 11: Right Rear Trailer Wheel Dual Wheels, One or Two Axles • Check condition of wheels and rims. Especially look for cracks, missing lockrings, bent or broken spacers, studs, missing clamps or lug nuts. • Check condition of tires: properly inflated, no serious cuts, bulges, tread wear or any signs of misalignment; valve stems not touching wheels, rims or brake drums; valve caps in place and no objects stuck between the wheels.
OPERATION 209 • Rear clearance, identification and tail lights clean, operating and proper color. • Reflectors clean and proper color. Cargo Securement • Cargo properly blocked, braced, tied, chained, etc. • Tailboard up and properly secured. End gates free from damage, properly secured in stake pockets. • Canvas or tarp (if required) properly latched down to prevent water damage, tearing, billowing or blockage of either mirrors or tail lights.
210 OPERATION • Condition of brake drums. With brakes released, look for a noticeable gap between lining and drum. (This check can not be made if dust covers are in place.) • Condition of brake hoses: check for any chafing. • Check brake chamber mounting bolts and brackets. • Check slack adjusters and chamber push rod travel. With brakes applied or released, look for conspicuously different positions of the slack adjusters. • Check spring brakes.
OPERATION 211 • Test the service brakes before leaving the parking area. • Test parking brakes by stopping on a 20% grade and applying the parking brakes. The parking brakes shall hold the combined vehicle and trailer without moving. New Vehicle Break-In To ensure many years of reliable, trouble-free operation, the following break-in procedures are recommended: Note: Oil change, filter change and chassis lubrication are no longer required at the 3,000-mile vehicle break-in interval.
212 OPERATION • Observe the instruments often, and shut down the engine at the first sign of any abnormal readings. • Report all leaks, loose fasteners, unusual noises, etc., to the service representative at the nearest Volvo dealership so they can be checked and corrected. • Check the spring clip torque (U-bolts). (On REYCO suspensions, also check equalizer nut torque.) • On chassis equipped with AIRTEK™ front axle air suspensions, retorque the U-bolts.
OPERATION 213 HOOD OPERATION WARNING Avoid tilting the hood under high or gusty wind conditions. Failure to follow this recommendation may result in the hood unexpectedly closing, which can cause personal injury. WARNING Make sure that no one is in the way of the hood when opening or closing. The hood could injure a person under the hood. Opening the Hood The hood is locked down by two latches, one on each side of the back end of the hood The hood release handle is at the bottom of the steering column.
214 OPERATION Make sure the hood can be opened fully without hitting anything. There are two methods for opening the hood. 1. Stand in front of the hood with feet in line with the vehicle. Place feet well apart and grasp the recessed handle in the front part of the hood. Transfer the body weight by leaning away from the hood. Lift the hood until it is past the balance point. Release the hood and let it complete the opening movement unaided.
OPERATION 215 2. Stand at the rear fender edge on the driver side of the vehicle. Lift the hood from under the fender, push the hood forward, release the hood and let it complete the opening movement unaided. W8003546 Two restraint cylinders will engage during the last part of the opening. The cylinders will slow and dampen the hood down to its resting position.
216 OPERATION Closing the Hood To close the hood, stand with feet well apart, place hands along the front edge of the hood. Bend the knees and let the leg muscles do the work when lifting. Raise the hood up to the halfway point. Carefully guide the hood down with enough speed that the hood latches lock the hood in place when it comes to its normal resting position.
OPERATION 217 Hood Latch (Optional) VNM 200 Day Cab, Short Fairing The VNM Day cab hood is opened by unlocking and releasing both sides of the latch located underneath the left and right-hand side panels. See illustration.
218 OPERATION CHASSIS FAIRING/STEPS OPEN AND LOCKED POSITIONS WARNING Always check security of fairing and steps before use. Ensure that the fairing is completely closed and the handles are in the locked position to prevent injury from slip and fall. The chassis fairing on the VN vehicle folds up and down for battery and air tank access. CAUTION DO NOT open fairing while the cab door is open. This can result in paint damage on the fairing.
OPERATION 219 W5001359 W5001358 1 Unlocked Position 2 Locked Position
220 OPERATION Closing and Locking Fairing WARNING Make sure the fairing/steps are locked into position. Failure to lock fairing/steps could result in personal injury due to slip and fall. To close and lock the fairings: Use your fingers to pull the handles to the unlocked position (1) as indicated in the illustration. Push with your palms against the fairings (2). Once the fairing is closed, make sure both handles are returned to the locked position.
OPERATION 221 Securing the Fairing/Step Make sure the handle is rotated to the locked position. Pull on the fairing/step to ensure the fairing/step is locked into position. See illustration.
222 OPERATION LUGGAGE COMPARTMENT WARNING Always place heavy objects in the luggage compartment. Sudden stops or sudden turns could cause personal injury if heavy objects fall from overhead storage shelves. To gain access to the luggage compartments, there is a pull-ring connected to the lock, located at the lower rear corner of the cab door opening, on each side (not shown). Pull ring to unlock the door. The lock has a safety latch that will hold the door in place, even if the door is not fully locked.
OPERATION 223 The door swings out from the bottom on hinges mounted on the top. To assist in opening and to hold the door open, there are two compressed gas cylinders mounted on each door. The door will swing up by itself when pulled out a short distance and then released. Manually switch the luggage lamp ON. Switch lamp OFF before closing door. W8003123 Safety equipment and tow hooks are stored in the luggage compartments.
224 OPERATION CAB DOORS AND DOOR LOCK DANGER To lessen the chance of being thrown from the vehicle in case of an accident, always lock the doors and wear the safety belt while driving. Failure to do so can cause serious personal injury or death if involved in an accident. The cab doors can be unlocked and locked with the same key used for the ignition lock. There is also a keyless remote entry available. Keys can be made to fit only one vehicle or all the vehicles in a fleet of Volvo vehicles.
OPERATION 225 Note: The vehicle is delivered with two identical keys. If more keys are needed, order them through your authorized Volvo Truck dealer. The door locks are mechanically or electronically operated. The lock is activated by either the key from the outside or the door lock handle from the inside. With mechanical locks, only one door can be locked and unlocked at a time.
226 OPERATION With electronic locks, to lock both doors from inside the cab, push the door lock handle forward on either door. The handle will stay in place, indicating the door is locked. Either door can be unlocked without opening the door by moving the door lock handle to the middle position. Each door must be unlocked individually from inside the cab. To unlock the doors using the key, insert the key in either door look. Turn the key to the unlock position to unlock that door.
OPERATION 227 W8003116 To close the door from the outside, place the hand flat against the door lock area and push the door shut. CAUTION DO NOT shut the door by pushing on the door panel. Hard pushing may distort the metal in the door panel.
228 OPERATION Power Door Locks (Optional) Press button 2 to lock both doors or unlock the passenger door. In the event of a power failure the electrical lock system reverts back to a mechanical functioning system. W8003087 Central Locking The central locking is operated using a remote control. There is no alarm in this unit. The central locking unit provides a means for the driver to electronically control the vehicle’s door locks, for increased personal safety and driver comfort.
OPERATION 229 Heated Rear View Mirrors (Optional) Press button 1 once to start electric heating for 15minutes. The indicator light in the button flashes. The heating is on for 15minutes. Hold button 1 in for longer than 1second to start electric heating. The indicator light in the button comes on. The heating remains on until the engine is switched off. Heater will run at 100% capacity for the first 30 minutes, after which it reduces to 75% capacity.
230 OPERATION Power Windows (Optional) Open Window (Auto-Down) 1 Depress the down position (2) on the button for 1second. 2 Release the button. 3 The window opens. The window stops when it is completely open, when the down position (2) on the button is depressed again or when the up position (1) on the button is depressed. Make small adjustments with short pushes on the button. Close Window Depress the up position (1) on the button until the window is completely closed.
OPERATION 231 Safety belt assemblies installed in this vehicle meet FMVSS 209, "Type 1" and "Type 2" requirements. They are recommended for all persons weighing over 25 kg (50 lb.).
232 OPERATION A child restraint system should also be provided for each child weighing 25 kg (50 lb.) or less. It should meet the requirements of FMVSS 213, "Child Restraint System." Carefully read and follow all manufacturer’s instructions on installation and use. Be certain the child remains in the restraint system at all times while the vehicle is in motion. W8002741 Safety belts must be worn by the driver and all passengers at all times.
OPERATION 233 Operating the Safety Belt To fasten the safety belt, pull the belt out from the retractor and insert the latch into the buckle. Verify proper lock of the latch by pulling on the latch. Adjust the slack by pulling on the top part of the belt until the lower part, or the part that crosses the lap, is adjusted to fit "snug." Release the top part and let the retractor pull the belt in.
234 OPERATION The buckle portion of the safety belt system is different depending on the seat option chosen. The National Standard and Comfort seat has a separate buckle that is attached to a floor anchor by a seat strap. This seat strap is not adjustable, and does not need to be adjusted. Comfort Clip Operation When provided, the comfort clip is located on the shoulder strap just below the D-ring.
OPERATION 235 Always adjust the clip so that there is a maximum of 25 mm (1 inch) of slack between the belt and chest (about two fingers width). If a larger slack is allowed, the effectiveness of the safety belt is decreased in the event of a collision.
236 OPERATION Sleeper Safety Restraint DANGER Always use the safety restraint when the vehicle is in motion. Failure to do so not only may cause severe injuries or death to the passenger in the event of an accident, but also poses a danger of injuries to other occupants of the vehicle. DANGER Anytime the vehicle is in motion, a passenger using the sleeper bunk should be strapped in using the safety restraint.
OPERATION 237 Fasten the restraint by connecting the buckle with the latch. Make sure the belts are not twisted. Test the latch connection by pulling on the belt. If they come apart, reconnect and test again. If the connection cannot be made, replace the belt before using the bunk for sleeping during driving. To loosen the restraint, press the red release button on the latch. Restraints should be properly stored when not used.
238 OPERATION Safety Restraint VN 430, VN 630, VN 670 The restraint has latches in one end and buckles in the other so it can only be installed one way. Connect the restraint to the back wall and the buckles on the floor. Connect the side tethers and adjust the straps to form a "tent" over the bunk (VN 670 upper bunk does not have the "tenting" feature).
OPERATION 239 W8003169 Upper Bunk W8003170 Lower Bunk
240 OPERATION Safety Restraint VN 730 Connect the restraint to the back wall first. The wall connectors are located on the back wall. Connect the lower part of the restraint to the lower buckles. Connect the side tethers and adjust the straps to form a "tent" over the bunk. Note: The restraints for top and bottom bunks are different. Each belt can only be installed to the correct bunk.
OPERATION 241 W8028593 42-Inch Lower Bunk
242 OPERATION W8028594 Upper Bunk
OPERATION 243 Safety Restraint VN 780 Connect the restraint to the back wall first. The wall connectors are located in the storage units. Connect the lower part of the restraint to the lower buckles. Connect the side tethers and adjust the straps to form a "tent" over the bunk. Note: The restraints for top and bottom bunks are different. Each belt can only be installed to the correct bunk.
244 OPERATION Inspection DANGER Failure to properly inspect and maintain the safety belts can cause serious personal injury or death. DANGER It is critical that any time a vehicle has been involved in an accident, the entire safety belt system must be replaced in the vehicle (which also includes the sleeper bunk restraints) if they were in use at the time of the accident. Failure to replace the safety belt system may result in serious injury or death.
OPERATION 245 Check the belts, buckles, latch plates, retractors, anchorages, and guide loops to ensure that they are working properly. Look for loose/damaged parts (without disassembling) that could keep the restraint system from working properly. If the safety belt, retractor and hardware were in use during a collision, they must be replaced. The restraint system anchorage fasteners must be replaced if necessary.
246 OPERATION The D-loop web guide is an area where almost constant movement of the safety belt webbing occurs because of the relative movement between the seat and the cab. This constant movement forms an area where wear will often occur. The webbing must be closely examined to determine if there are any cuts, fraying or extreme wear in the webbing. Cuts, fraying or excessive wear would indicate the need for replacement of the safety belt system.
OPERATION 247 Check the buckle by inserting the latch and verifying proper operation. Determine if the latch plate is worn or deformed. Check the buckle and latch casing for cracks or breakage.
248 OPERATION The retractor web storage device is mounted on the B-pillar, just behind the door in the cab. The retractor is the heart of the safety belt system and can be damaged if abused, even unintentionally. Check the retractor web storage device operation to ensure that it is not locked and that it spools out and retracts the webbing properly. W8002481 If tethers are being used to anchor the safety belts to the floor, make sure that they are properly attached to the seat.
OPERATION 249 W8001387
250 OPERATION All hardware for safety belt mounting points should be evaluated for corrosion. All attachment points of the system should be checked for tightness of mounting hardware. Check the web in areas exposed to ultraviolet rays from the sun or extreme dust or dirt. If the original color of the web in these areas is extremely faded, the physical strength of this web may have deteriorated. If this condition exists, replace the safety belt system.
OPERATION 251 SEATS, GENERAL Several seats can be used in the vehicles. If the seat installed in the vehicle is not explained in this section, see your authorized Volvo dealer. Before adjusting or fastening the seat belt, move the seat forward or rearward and adjust the seat height as necessary. Sit erect and adjust the seat cushion and seat back to obtain a comfortable driving position. DANGER All adjustments are to be made while the operator is seated and the vehicle is stationary.
252 OPERATION NATIONAL STANDARD SEAT Seat Adjustments W8002745 National Standard Seat 1 Backrest Tilt: By rotating the round handle, the backrest recline angle can be adjusted within 12 degrees. 2 Cushion Front Tilt and Length: Pulling the handle up and out adjusts the tilt and length of the seat cushion. Support your body weight with your feet while adjusting. 3 Fore and Aft Movement: Press the lever sideways to unlock the seat. Move seat fore or aft to a new position.
OPERATION 253 NATIONAL COMFORT SEAT Some National Comfort seats are equipped with a BackCycler® feature. Some National Comfort seats have a swivel mount. Seat Adjustments W8002744 National Comfort Seat 1.Seat Adjustment Fore and Aft 2.Isolator Lock 3.Cushion Tilt 4.Ride Height Adjustment 5.Lumbar Support Adjustment 6.Recliner Tilt 7.
254 OPERATION Bostrom Comfort Seat Some Bostrom Comfort seats have a swivel mount. W8002744 National Comfort Seat 1.Seat Adjustment Fore and Aft 2.Isolator Lock 3.Dampening Adjustment 4.Cushion Tilt 5.Ride Height Adjustment 6.Lumbar Support Adjustment 7.Recliner Tilt 8.
OPERATION 255 PASSENGER SEATS National Bench Seat The bench passenger seat has the option for a two-man storage seat. The base of the seat is a storage box that is accessed by lifting the seat cushion up.
256 OPERATION National Toolbox Seat The toolbox passenger seat has an optional accessible or non-accessible toolbox in the base of the seat. If the toolbox is an option, the storage box is accessed by lifting the seat cushion up. Note: There is a release latch behind the seat.
OPERATION 257 Bostrom Toolbox Seat W8003851 Bostrom Toolbox Seat 1 Seat Cushion Release Lever The toolbox passenger seat has an optional accessible or non-accessible toolbox in the base of the seat. If the toolbox is an option, the storage box is accessed by lifting the seat cushion up. Note: There is a release latch behind the seat.
258 OPERATION No Passenger Seat (Optional) WARNING Using a temporary passenger seating without the benefit of proper seat mounting and safety belt can, in the event of a loss of control of the vehicle, cause serious personal injury or death. In vehicles with no passenger seat installed, DO NOT let a passenger ride on temporary seating. This is against the law and can be very dangerous.
OPERATION 259 ENGINE OPERATION General Proper operation, driving techniques and maintenance are key factors in obtaining the maximum life and economy from a modern turbocharged diesel engine. This section has operational information about the components that make up the engine. When changing gears, avoid lugging to extend engine life. When the engine is operating at full throttle and maximum governed speed cannot be reached or maintained, the engine is lugging.
260 OPERATION This vehicle is equipped with an exhaust aftertreatment system which virtually eliminates exhaust smoke. Exhaust vapor may be visible during a cold start. If exhaust smoke is visible during engine operation, this indicates a problem with the exhaust aftertreatment system. Take the vehicle to an authorized Volvo Truck dealer immediately. IMMOBILIZER FEATURE Volvo Engines Only The Immobilizer Feature is used to prevent the engine from starting.
OPERATION 261 If the vehicle has not been placed in the Immobilizer Mode during the previous key-off, the driver will be able to start the vehicle as normal. After the password is entered (at shutdown) "Security Mode Active" is displayed.
262 OPERATION CONTROL AWARENESS FEATURE Volvo Engines Only Volvo engine and transmission. In addition, it provides a mechanical safety to the existing Power Take-Off (PTO) functionality. • Parameters are set in VCADS. If the vehicle exceeds the maximum vehicle speed for the corresponding PTO mode, a message appears on the DID screen as shown: W3006376 WARNING Do NOT exceed PTO maximum vehicle speed or the PTO may be damaged.
OPERATION 263 FUEL ECONOMY DRIVING General The absolute fuel consumption (counted in liters per 100 kilometers or miles per US gallon) is determined by a large number of circumstances which can be related to one of the following main areas: • • • • Build specification and equipment Service and maintenance External environment Driving habits Due to these factors, fuel consumption can vary considerably within what is called "normal fuel consumption.
264 OPERATION Tires Heavy duty threaded tires increase rolling resistance considerably. For long haul, choose a smoother, ribbed type tire. Choose a lugged type tire only when the added traction in mud and snow is needed. The number of wheels (axles) has a direct effect on the rolling resistance and, thereby, the fuel consumption. For volume and/or low weight transports, the use of a 4x2 instead of a 6x4 should be considered.
OPERATION 265 Brakes Dragging brakes increase fuel consumption. They should be checked regularly. It is important that the release action of the air valves is fast and that the moving parts of the wheel brakes are checked for good adjustment and operation. Axles An axle out of alignment increases rolling resistance. Regularly check the front wheel alignment and axles on both the tractor and trailer/semi-trailer.
266 OPERATION External Environment Under unfavorable conditions, the external environment can have a negative effect on fuel consumption. This can be broken down into two main groups: weather and wind, and the nature of the roads. Rain, snow, icy conditions and headwinds have a large negative impact on fuel economy, as do hilly roads and uneven road surfaces. Headwinds Headwinds have a large negative impact on fuel consumption. With tailwinds, fuel saving is only marginal.
OPERATION 267 Driving Habits The way in which a vehicle is being driven is the one factor which has the greatest influence on fuel consumption. Correct driving saves fuel and reduces vehicle wear. To achieve optimal running economy, the driver should always remember to: • • • • Start the engine correctly (especially important in winter season). Maintain an even and correct speed. Keep the engine at its optimum speed range. Use the correct uphill and downhill driving technique.
268 OPERATION Air Tanks All air tanks on the vehicle should be drained daily. Empty any moisture from air tanks by pulling the drain valve wire or by opening the drain cocks and allowing the air pressure to drain completely. Make sure the drain cocks close properly after draining. During draining the tanks should be checked for condensation fluid even if an automatic drain valve is installed. WARNING When draining the air tanks, do not look into the area of the draining air.
OPERATION 269 Trucks with automated Meritor Transmission: Drain the transmission air supply tank located on the right-hand rail daily to check for contamination, water, oil, etc. Charging Air to Another Vehicle DANGER 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 personal injury or death.
270 OPERATION CRUISE CONTROL DANGER DO NOT use the cruise control in heavy traffic, with ice/snow on the road or during other unfavorable conditions. This may lead to a loss of vehicle control, causing a vehicle crash, personal injury or death. Engaging W3002499 To engage and set desired speed: 1 Set the cruise control switch to ON. 2 When the desired vehicle speed has been reached, momentarily press in the SET+ or SET- switch on the end of the lever. 3 To increase speed, press the SET+ switch.
OPERATION 271 Note: The cruise control cannot be engaged at speeds below approximately 30 km/h (18 mph). Disengaging The cruise control is disengaged if the brake is depressed, or if the cruise control switch is set to OFF. If the ignition key is turned back to the accessories position (I), the cruise control system will automatically be disengaged. If configured, the cruise control will remain engaged if the clutch pedal is depressed for short durations (to allow shifting while in cruise control).
272 OPERATION Note: Read the Eaton VORAD Collision Warning System Driver Reference Manual before taking a vehicle equipped with VORAD out on the road. CAUTION On vehicles equipped with Eaton VORAD SmartCruise, cruise control is disengaged in the event the SmartCruise system fails to operate. You must stop the truck, turn the ignition off and on, and activate the control twice in order for the cruise control to operate.
OPERATION 273 BRAKE OPERATION Brake Safety Information DANGER DO NOT inspect or adjust parts or components in the brake system without setting the parking brake, placing the transmission in neutral and securely chocking the wheels. If the vehicle is not secured to prevent uncontrolled vehicle movement, it could roll and cause severe personal injury or death. DANGER DO NOT use replacement parts anywhere in the brake system unless it conforms exactly to original specifications.
274 OPERATION DANGER DO NOT operate the vehicle when there is a malfunction in the compressed air system. An air brake system with leaks or other malfunctions may prevent the brake system from operating properly. The vehicle should not be operated until the system is repaired and all brake circuits are working properly. Failure to repair the system can lead to loss of control of the vehicle resulting in severe personal injury or death. DANGER The brake system is a critical vehicle safety system.
OPERATION 275 DANGER Automatic slack adjusters MUST NOT be manually adjusted in an effort to correct excessive push rod stroke, as this condition indicates that a problem exists with the automatic adjuster, installation of the automatic slack adjuster or problems related to components of the foundation brakes. These conditions will not be corrected by manually adjusting the automatic slack adjusters.
276 OPERATION DANGER Never release or drive a truck that has a brake discrepancy — no matter how minor — until it has been repaired or corrected. Failure to repair brake discrepancies can result in compromised brake efficiency and may lead to loss of control of the vehicle resulting in severe personal injury or death. Air pressures in the two circuits are monitored by two pressure gauges on the right side of the instrument cluster.
OPERATION 277 W3006936 W3006937 Gauge 1 and Gauge 2 Before operating the vehicle, check the air gauges which indicate air pressure. They should not register less than 420 kPa (65 psi).
278 OPERATION Both circuits are piped into a dual brake valve, which simultaneously applies front and rear axle service brakes during each brake application. In the event of a failure in either one of the circuits, the other circuit becomes the emergency circuit for applying the brakes. W5001486 1 Clutch Fluid Reservoir 2 Windshield Washer Fluid Fill 3 Brake Valve DANGER The Master Warning Tell-Tale and buzzer alerts of a dangerous situation.
OPERATION 279 W3005171 Master Warning Tell-Tale An important feature of the brake system is that an automatic spring brake application does not take place as a result of an air loss in only one of the two circuits. In this case, brake control remains in the foot brake valve. In each air pressure gauge, there is a warning light connected to a low pressure switch that comes on if air pressure goes below 420 kPa (60 psi). At the same time, the buzzer will sound and the main warning tell-tale will come on.
280 OPERATION Foot Brake Valve The foot brake valve is directly connected to the brake pedal. The valve gives a progressive output against the pedal travel. This allows better control of the pressure in the first half of the pedal travel. In the last half of the pedal travel, the pressure output increase is faster. The foot brake valve applies the service brakes, incorporating both the primary and secondary air systems.
OPERATION 281 1 The best possible stop will be made when the first brake application is as firm as the speed and road condition permit. Then, ease off as the speed is reduced. Never apply the brakes lightly at first and increase the pressure as the speed diminishes. 2 DO NOT fan the brake pedal. Fanning gives poor brake performance and wastes air. 3 The air brake is designed so that when the brake pedal is fully depressed, an emergency application results.
282 OPERATION Parking Brake/Trailer Supply Valves Trucks/Tractors may have two air control valves on the instrument panel: • • Trailer Supply (red octagonal knob) System Park (yellow diamond knob) W5001116 The System Park valve knob (yellow) should be pushed in first, after sufficient air pressure is built up (apply foot brake to prevent vehicle from rolling). The Trailer Air Supply valve knob may then be pushed in.
OPERATION 283 On vehicles equipped with the standard two valve system, the operation of one valve together with the other permits the operator to select the desired functions described below: Red Valve (Trailer Air Supply) Yellow Valve (System Park) Function (Mode) Out Out System Park In Out Trailer Charge In In Normal Running Out In Bobtail Parking Brake Release VN models have engines equipped with engine electronic control units (EECU).
284 OPERATION There is also an engine shut-down device in the EECU that shuts down the engine after a pre-programmed time in order to save fuel. This is activated when the yellow parking brake knob is pulled out. Therefore, some drivers park and release the parking brakes using only the red knob to keep the engine running. It is then easily overlooked that in a vehicle parked with both the yellow and red knobs activated, only the red knob is pushed in by habit.
OPERATION 285 Spring Brake for Parking DANGER Never leave the vehicle without being certain the parking brakes are set or that other precautions are taken to prevent the vehicle from rolling. Failure to do so can result in serious personal injury or death. DANGER Before working on or inspecting 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 personal injury or death.
286 OPERATION W5001430 The parking brake spring tension is sufficient to hold a fully loaded vehicle on maximum grades permitted on modern highways, provided the brake drums and linings are in good condition and the brakes are properly adjusted. CAUTION DO NOT use the spring parking brakes if the service brakes are hot, such as after descending a steep grade. Also, do not use the spring parking brakes during freezing temperatures if the wheel brakes are wet.
OPERATION 287 There are several ways to determine if the parking brakes have been set. By pulling out the yellow knob: • • • • • An audible rush of air will be heard when the parking brake knob is pulled. The air exhausts from the park brake valve itself and from the spring brake chambers on the rear axle(s). A black ring around the base of the yellow control knob will be seen. The engine will stall if an attempt is made to set the vehicle in motion.
288 OPERATION Trailer Brake Hand Control DANGER The trailer hand brake control is not a parking brake valve and must not be used as one. This brake is not designed to hold the vehicle stationary. Failure to follow these instructions can result in the unintentional movement of the vehicle and may cause personal injury or death. DANGER DO NOT use the trailer brake hand control as a parking brake. The brakes could release and the vehicle could roll, causing a vehicle accident, personal injury or death.
OPERATION 289 W5001442 The "121" Brake Standard This manual refers occasionally to "121" brakes. Although some operators believe "121" only applies to vehicles equipped with anti-lock devices, the "121" standard applies to all vehicles that are capable of on-highway operation. The "121" is a Federal requirement also covering alterations or changes to parts or systems related to the "121" standard once the vehicle has been placed in service.
290 OPERATION ANTI-LOCK BRAKING SYSTEM (ABS) The vehicle has a standard brake system, equipped with an electronic speed monitoring and control system, Anti-lock Braking System (ABS). ABS monitors wheel speed continuously but is not involved in controlling the wheel speed unless there is an emergency. In normal braking applications, the standard air brake system is in effect. WARNING For proper ABS operation, DO NOT change tire sizes.
OPERATION 291 The ABS control unit contains a self-testing program that is engaged each time the ignition is turned on. The operator can verify the testing by listening for the ABS modulator valves actuating twice in series. To increase the sound, hold down the foot brake pedal when the ignition is turned on.
292 OPERATION VOLVO ENHANCED STABILITY TECHNOLOGY Some vehicles are equipped with Volvo Enhanced Stability Technology (VEST). VEST is an advanced stability control system designed to provide both roll stability and under- and over-steer correction in a wide variety of driving conditions. VEST continuously monitors a variety of vehicle parameters and sensors (including steering angle sensor) to determine whether the vehicle is reaching critical stability threshold.
OPERATION 293 W3000962 The TCS includes a switch to turn off the function. When the switch is in the OFF position, the TCS operates normally to increase traction if the drive wheels begin spinning. When the switch is pressed once, the TCS tell-tale in the instrument cluster blinks continuously, indicating that the TCS is in mud/snow mode. W3001336 The mud/snow mode increases available traction on soft surfaces like snow, slush or mud by slightly increasing the allowable wheel spin.
294 OPERATION Tire Pressure System (If Equipped) The tire pressure/temperature sensor is attached to each wheel with a stainless steel tire strap and is located in line with the wheels valve stem. This self powered sensor is responsible for transmitting the tire cavity pressure and temperature to the system via a radio frequency sign that is received by the system antenna. 1.
OPERATION 295 Air Pressure Monitoring and Alert The air pressure of each programmed tire can monitored by the operator via the DID. The system monitors tire air pressure in all cab tires independently and alerts the operator of low tire pressures in two stages; 1. Low Pressure Alert — The low pressure alert is triggered when tire pressure is 8% below it’s “Set Point”. The operator is alerted by an amber warning telltale light/buzzer that is displayed in the instrument cluster.
296 OPERATION Tire Temperature Monitoring and Alert The cavity air temperature of each programmed tire can monitored by the operator via the DID. The system monitors cavity air temperature in all cab tires independently and alerts the operator when any of these tire cavity temperature reaches 77°C (170°F). The operator is alerted by a red flashing telltale light/buzzer that is displayed in the instrument cluster.
OPERATION 297 VEHICLE SPEED RETARDING DEVICES DANGER When operating a tractor bobtail (without a trailer) or on slippery roads, the engine brake switch must be in the "OFF" position. Failure to follow this instruction can result in loss of vehicle control and serious personal injury or death. Note: The vehicle ABS will automatically turn off the vehicle speed retarding device, IF one of the sensed rear wheels is locking up as a result of vehicle speed retarding device operation.
298 OPERATION STARTING THE ENGINE Start Procedure Note: For cold weather starting, see “COLD WEATHER OPERATION”, page 306. These starting and operating procedures should be followed for all engines. For more detailed information about design and function on a non-Volvo engine, read the operator’s manual from the engine manufacturer. Note: Before starting the engine, see "Instruments and Controls" section for detailed information on how the gauges and tell-tales work.
OPERATION 299 1. Before starting the engine, perform the engine pre-trip inspection and daily maintenance checks in on “PRE-TRIP INSPECTION AND DAILY MAINTENANCE”, page 192. 2. Make sure the parking brakes are engaged. 3. Place the transmission in neutral or depress the clutch pedal. CAUTION DO NOT crank the engine for more than 30 seconds at a time; wait two minutes after each try to allow the starter to cool. Failure to follow these instructions could cause starter damage.
300 OPERATION W3006933 6. When the engine has started, it takes a while to send lubricating oil to all bearings and shafts, and between pistons and liners. Wait for the oil pressure gauge to settle at a normal level, then bring engine speed up gradually. Increase speed as it warms up. Check all gauges during warm-up. 7. During warm-up, apply load gradually until the oil temperature reaches 60°C (140°F). To move a loaded vehicle, the minimum coolant temperature must be approximately 50°C (120°F).
OPERATION 301 Engine Overspeed This vehicle is equipped with a diesel engine and should not be operated in an area with a concentration of hydrocarbon vapors (for example gasoline or diesel fuel fumes). Be especially cautious of low-lying or closed-in areas. The vapors may be drawn into the engine through the air intake and cause the engine to overspeed. Hot carbon and other sparks may come from the exhaust system, and cause an explosion and fire.
302 OPERATION If the engine coolant temperature is above 50°C (122°F), the vehicle is stationary (engine running; accelerator released; parking brake on) and the PTO not engaged, the engine low idle speed can be adjusted with the use of the cruise control function. W3002499 1 Set the cruise control switch to the ON position. 2 Depress the foot brake pedal. Hold it down during the entire procedure. 3 Move the cruise control switch to the RESUME position and hold it there for four seconds.
OPERATION 303 Idle Shutdown Timer The idle shutdown timer can be programmed to shut the engine down after a specific engine idling time. This programming cannot be changed by the operator, but can be done using special tools. Contact your authorized Volvo Truck dealer for details.
304 OPERATION Downhill Operation CAUTION DO NOT exceed engine manufacturer’s recommended maximum engine speed. Engine damage can occur. If equipped with an engine or exhaust brake, DO NOT exceed 2300 rpm. On a downgrade, do not coast with the clutch pedal depressed or the transmission in neutral. Select a gear that does not allow the engine speed to exceed the engine manufacturer’s maximum engine speed recommendation. Use the engine or exhaust brake and/or the service brakes to control the vehicle speed.
OPERATION 305 Stopping the Engine Allow the engine to slow down and idle for 3 to 5 minutes before shutting it off. This allows the turbo to slow down and the cooling system to dissipate the engine heat. Switch the engine off by turning the ignition key to the B, or OFF, position. CAUTION Shutting off an engine immediately after high speed or full load operation can damage the turbo and cause heat stress in the engine. Always let the engine idle for 3 to 5 minutes before shutting it off.
306 OPERATION COLD WEATHER OPERATION Volvo Engine Cold Start Note: These cold start instructions are for Volvo engines only. For other engine makes, see the manufacturer’s handbook. DANGER DO NOT use ether or other combustible starting aids on any Volvo engine. Introduction of ether or similar starting aids could cause a fire or explosion resulting in severe property damage, serious personal injury or death. Note: Volvo engines have a unique cold start feature.
OPERATION 307 T3008841 If necessary, once the engine has started, the preheater will reengage (post heating) for the same length of time as the preheat time. Engines Without Preheater Engines not equipped with a preheater may, depending on coolant temperature, take longer to start. If this should happen, DO NOT release the ignition key until the engine has started (while still observing the 30 second maximum cranking time).
308 OPERATION Cold Weather Operation If the engine is in good mechanical condition and the necessary preparations are taken for cold weather operation, ordinary cold weather will not cause difficulty in starting or loss of efficiency. Cold weather operation does require changes in operating practices, maintenance procedures, lubrication and fuel. Additions to the vehicle, such as heated fuel filters, fuel tank heater, engine block heater, winterfront, etc., can make winter operation easier.
OPERATION 309 For cold weather operation, follow these recommendations: • When starting the engine in temperatures below 15°C (5°F), use engine lubricants of lower viscosity. See the Operator’s Manual Vehicle Maintenance for additional information. • When the temperature is below freezing, make sure the concentration of antifreeze in the coolant is sufficient to prevent freezing. Refer to the Operator’s Manual Vehicle Maintenance for additional information.
310 OPERATION Engine Block Heater (Optional) An electric engine block heater can be installed for keeping the coolant hot when the vehicle is parked. The heater is mounted through the side of the engine block with the heater coils in the coolant jacket. The heater does not interfere with normal operation and can be permanently installed. The heater runs on 120 V and has an easily accessible plug, located beside the driver side door. The plug will hook up to a normal extension cable.
OPERATION 311 Oil Pan Heater (Optional) Oil pan heaters aid low temperature starting by improving oil flow to critical parts in the engine. This helps prevent engine wear. They are similar to block heaters and are wired into the same plug as the engine coolant heater. Fuel Heater Filter (Optional) If running in very cold weather, a heated fuel filter should be added. A number of different fuel heaters are available as options. They are electrically heated and regulated by a thermostat or coolant heated.
312 OPERATION Fuel Tank Heater (Optional) An in-tank fuel heater is also available. In-tank heaters use hot engine coolant to warm the fuel. This prevents wax formation in the fuel during cold season operation. These heaters are thermostatically controlled and will automatically raise the fuel temperature to an optimum level. Winterfront Volvo Trucks North America does not recommend the use of winterfronts, shutters or any other shield in front of the grille or radiator package under normal circumstances.
OPERATION 313 FIFTH WHEEL INSTRUCTIONS Fifth Wheel General Information DANGER Always have all fifth wheel maintenance and repairs done by a qualified technician. An incorrect repair can cause the trailer to separate from the tractor causing an accident with serious personal injury or death. Things to think about with trailer hook-up: • • • • • • Check the load distribution between axles. Always chock the trailer wheels. Grease the plate unless it is a low lube or no lube top plate.
314 OPERATION If the fifth wheel is equipped with a sliding mounting, follow the advisory labels attached to the component. Also, read the literature provided by the manufacturer. DANGER Always keep the fifth wheel plate well lubricated to prevent binding between the tractor and trailer. A binding fifth wheel could cause erratic steering and loss of vehicle control that may result in serious personal injury or death.
OPERATION 315 W9000242 Open — This is the position the fifth wheel is in after the trailer is uncoupled. The jaw is open and the operating rod is now dropped down and can be freely moved around. The safety latch is rotated toward the rear of the fifth wheel. This is the position the fifth wheel must be in when being coupled to a trailer.
316 OPERATION Fifth Wheel Slider (Optional) Open — This is the position the fifth wheel is in after the trailer is uncoupled. The jaw is open and the operating rod is now dropped down and can be freely moved around. The safety latch is rotated toward the rear of the fifth wheel. This is the position the fifth wheel must be in when being coupled to a trailer. Fifth Wheel Slider (Optional) The fifth wheel comes standard with an air operational slider.
OPERATION 317 Unlocking the Fifth Wheel Always check out the entire fifth wheel before attempting to couple to a trailer (ASF fifth wheel is shown). • • If not lubricated properly, add grease to the top of the fifth wheel plate. • If using a sliding fifth wheel, make sure the slide locking plungers are in a locked position. Make sure the mounting of the fifth wheel to the frame is tight and in good condition.
318 OPERATION Using a slight upward motion, pull the operating rod out until the operating rod shoulder is outside the fifth wheel operating slot. W9000202 When the shoulder of the operating rod is outside of the operating slot, raise the operating rod handle to its maximum upward position.
OPERATION 319 Release the operating rod. The upper shoulder of the operating rod should now be in contact with the plate casting above the operating slot. The fifth wheel is now in the lockset position and a trailer can be coupled. W9000274 Trailer Coupling Procedures DANGER It is important that the operating procedures contained in this manual are fully understood and closely followed. Failure to properly couple the tractor and trailer can result in their separation, causing death and property damage.
320 OPERATION Using the following procedures, inspect the equipment before coupling to a trailer: Make sure the fifth wheel is properly lubricated and the jaw is in the open position. W9000659 WARNING If the jaw is not in the open position, use a pry bar to rotate the jaw to the open position. The lock is spring loaded. Keep hands away to avoid injury. Use a pry bar to open the fifth wheel jaw, if necessary.
OPERATION 321 Make sure the plate is tilted downward to the proper position at the rear. W9000236 Make sure the mounting of the fifth wheel to the tractor frame is tight and in good condition. Make sure the plate is tilted downward to the proper position at the rear. If using a sliding fifth wheel, make sure the slide locking plungers are fully engaged.
322 OPERATION Chock the trailer wheels. Use two chocks (both on the front and rear of the wheel) on both sides of the trailer. Back up close to the trailer, centering the kingpin on the throat of the fifth wheel, and STOP. Note: For tractors with air ride suspension, make sure the suspension control switch is in the "RIDE" position (switch pushed in at the top) and the air springs are inflated. W3001341 Connect the air brake lines and the electrical power cord.
OPERATION 323 CAUTION Attempting to couple with the trailer at an improper height could result in a false or improper couple and cause damage to the tractor, fifth wheel and trailer. Check to see that the trailer is at the proper height for coupling. The leading edge of the trailer plate should initially contact the fifth wheel top plate surface about 200 mm (8 in.) behind the pivot point as the tractor backs under the trailer. Raise or lower the trailer landing gear as required to obtain this position.
324 OPERATION As an initial check, pull forward to test the completeness of the coupling. W9000237 A direct visual check is required to ensure proper coupling. Several types of improper couplings will pass the initial pull test. Sound is not reliable. Do not take for granted that you are properly coupled. Get out of the cab and look.
OPERATION 325 Make sure the trailer kingpin is in the jaw slot and that the jaw is closed behind the pin. The kingpin should not overhang the fifth wheel or be caught in the grease groove. To verify that the kingpin is actually in the fifth wheel slot and the jaw is closed, the pin must be visually inspected from the rear. Use a flashlight if necessary.
326 OPERATION W9000240 Make sure the operating rod is fully retracted, the safety latch is positioned above the handle, and the latch swings freely. If the fifth wheel is equipped with a manual secondary lock, check to see that it is properly engaged. Note: If you cannot get a proper coupling, repeat this procedure. DO NOT use any fifth wheel which fails to operate properly. W9000180 Check the kingpin to fifth wheel clearance by moving the tractor backward and forward with the trailer brakes set.
OPERATION 327 Trailer Uncoupling Procedures For Tractors With Air Ride Suspension Set the system park brake on the tractor. Set the trailer brakes by pulling out the trailer air supply knob. W5001433 Chock the trailer wheels. Use two chocks (one on the front and one on the rear of the wheel) on both sides of the trailer. Wind down the landing gear until it touches the ground and then give it a few extra turns in low gear. Do not raise the trailer off of the fifth wheel.
328 OPERATION Disconnect the light cord and air brake lines. Use the dummy air couplings to keep foreign material from entering the brake lines. Unlock the fifth wheel. Note: If the operating rod is too difficult to pull, back the tractor up slightly to relieve any kingpin load against the fifth wheel jaw. W9000275 Release the tractor park brakes and pull the tractor away from the kingpin about 300 mm (12 in.) and STOP. Do not allow the fifth wheel to leave the underside of the trailer.
OPERATION 329 W9000239 Select the "UNCOUPLE" position (push down the latch and press in the bottom part of the switch) on the suspension control switch to deflate the air springs.
330 OPERATION Wait about 30 seconds for the air springs to deflate. W9000238 With the suspension lowered, pull clear of the trailer and immediately select the "RIDE" position (press the top part of the switch in) on the suspension control. This restores the suspension to operating height. CAUTION The vehicle must never be driven with the air springs deflated. Damage to air suspension parts will occur if springs are not inflated properly.
OPERATION 331 After the trailer is uncoupled, the fifth wheel will be in the open position. The operating rod will drop and can be moved around freely.
332 OPERATION Operating the Fifth Wheel Slider CAUTION The trailer must be stopped and the trailer brakes locked, or damage to the tractor and/or trailer may result from uncontrolled sliding of the fifth wheel. Stop the tractor and trailer in a straight line on level ground. Lock the trailer brakes by pulling out the Trailer Supply knob. Release the slide locking plungers by moving the switch to the "UNLOCK" position (press down the latch and push in the bottom part of the switch).
OPERATION 333 W9000205 Slowly drive the tractor forward or backward to position the fifth wheel. After sliding the fifth wheel to the desired position, engage the slide locking plungers by moving the cab switch to the "LOCK" position (press in the top part of the switch).
334 OPERATION CAUTION DO NOT operate the vehicle if the plungers are not fully engaged and the trailer landing gear is not fully retracted. Doing so may cause damage to the tractor, trailer and landing gear. Visually check to see that the slide plungers are fully engaged. It may be necessary to leave the trailer brakes locked and to move the tractor slightly to engage the slide plungers into the rail. Wind up the trailer landing gear to its fully retracted position.
OPERATION 335 Clutch DANGER General Before starting the engine, set the parking brakes and place the transmission in neutral. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury and death. DO NOT allow the clutch to slip excessively. This would cause excessive heat to be generated and the clutch will be damaged and bring on premature failure. As soon as the vehicle is moving, remove the foot from the pedal for complete clutch engagement.
336 OPERATION PERFORMANCE BONUS FEATURE Description • • The Performance Bonus Feature is a tool used to promote driver efficiency. • The reward of higher RSL increases driver productivity and income. It also promotes increased driver and fuel efficiency. This feature rewards the driver with a higher Road Speed Limit (RSL) only if the performance targets set by the fleet management are achieved. Targets are set based upon fuel economy, idle time or a combination of both, or by the Sweet Spot Indicator.
OPERATION 337 Rolling Buffer The "rolling buffer" is set to measure distance driven. The buffer may be set at a short or long distance. A short buffer results in a faster reward, (or loss of reward) which provides driving fuel economy training to the driver, permitting the driver easy memory of the input to the buffer during this short period of time. A long buffer setting allows for the daily activities to "smooth out". In this case the reward is based on weekly/monthly activity.
338 OPERATION W3028721 Performance Bonus Guide Volvo Engines Only The Performance Bonus Guide is an aid that provides comprehensive feedback to the driver about the optimum engine operating range during a trip. If adhered to, this results in improved fuel efficiency. Icons in the Driver Information Display (DID) guide drivers to the most efficient engine operating range for any given engine load and speed. This is referred to as the engine’s "Sweet Spot".
OPERATION 339 Status Symbols Meaning Engine Operating in the Sweet Spot Mode. Fuel consumed in this mode will count 100% toward the Sweet Spot Percentage. W3006755 Engine Operating in a less efficient area of the Sweet Spot Mode. Fuel consumed in this mode will count 50% toward the Sweet Spot Percentage.
340 OPERATION Symbol Meaning Performance Bonus Guide (shows Sweet Spot Percentage [Large Symbol]) W3006755 Driving Mode The Sweet Spot Status icons are displayed at the bottom left of the DID screen. The Sweet Spot symbol is displayed at the top of the screen underneath Fuel Data. The Sweet Spot percentage page is displayed in the Fuel Data menu. The DID shows the screen with Sweet Spot Trip Data Percentage.
OPERATION 341 If Performance Bonus is enabled, and the Sweet Spot percentage target is a chosen condition, the DID also displays the Sweet Spot target percentage in parenthesis. W3028762 The Performance Bonus Guide is a standard feature for all Volvo engines on vehicles equipped with the mid or high level instrument cluster. Performance Bonus does not work with the basic instrument cluster.
342 OPERATION AXLES Differential Locks DANGER DO NOT drive on dry, paved surface with the differential locks engaged. The vehicle will strive to maintain a straight line. Taking a curve with the differential locks engaged may cause an accident, leading to serious personal injury or death. CAUTION Never operate the vehicle with the differentials locked any longer than is necessary, as this places a great strain on the axles and may cause rapid tire wear.
OPERATION 343 W3001991 The differential lock should be used on icy or slippery surfaces. As soon as the slippery surface has been passed, the differential lock should be disengaged. Differential locks must not, under any circumstances, be engaged when in a wheel-spin situation. Engage the locks ahead of the slippery area. If already slipping, stop the wheels, engage the locks and then continue.
344 OPERATION CAUTION DO NOT rely on gauges to determine axle pressure. Weight must be verified on scales, and pressure in the air springs should then be adjusted accordingly. Regulators for adjusting the air spring pressure are located on the outside of the cab, below the rear corner of the driver side door. Regulators are operated by turning the knob counterclockwise for lowering pressure, and clockwise for increasing pressure.
Volvo, US10 Emissions Solution 345 Exhaust Aftertreatment System W2029933 1. Selective Catalytic Reduction (SCR) Catalyst 2. Aftertreatment DEF Dosing Unit 3. Aftertreatment Diesel Particulate Filter (DPF) 4.
346 Volvo, US10 Emissions Solution Safety Information Volvo utilizes the use of a Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) to meet EPA2010 emissions. The system is designed to require very little driver interface to maintain correct operation. The technology utilizes a passive regeneration; requiring no fuel to be injected to clean the DPF. In EPA2007 an active regeneration (fuel was injected) was required to clean out the DPF producing very high exhaust outlet temperatures.
Volvo, US10 Emissions Solution 347 Exhaust Aftertreatment System Components and Operation Selective Catalytic Reduction (SCR) Selective Catalytic Reduction (SCR) is an emissions-reduction technology with the ability to deliver near-zero emissions of nitrogen oxides (NOx), a smog-causing pollutant and greenhouse gas. SCR’s performance has been proved in millions of miles of real-world truck operations in other countries, as well as in long-term field tests in the U.S.
348 Volvo, US10 Emissions Solution W2031651 1. Diesel Engine 2. Aftertreatment DEF Tank 3. Aftertreatment DEF Pump 4. Aftertreatment DEF Dosing Unit 5. Aftertreatment Diesel Particulate Filter (DPF) 6. Selective Catalytic Reduction (SCR) Catalyst 7.
Volvo, US10 Emissions Solution 349 System Operation 1 Diesel engine optimized for high performance, low particle emissions and low fuel consumption. 2 Aftertreatment DEF tank 3 The Aftertreatment Control Module (ACM) continuously monitors and adjusts the Aftertreatment DEF pump pressure in response to current engine load conditions. 4 DEF is injected into the exhaust gases in between the Aftertreatment DPF (5) and the SCR catalyst (6). 5 Aftertreatment Diesel Particulate Filter (DPF).
350 Volvo, US10 Emissions Solution W2055492 Horizontal SCR, full sive W2055493 Horizontal SCR, compact sive CAUTION Do not put diesel fuel in the Aftertreatment DEF tank. Diesel fuel, if sprayed into the hot exhaust along with the DEF, could ignite explosively causing a fire resulting in personal injury or damage to the exhaust system.
Volvo, US10 Emissions Solution 351 W3036787 Diesel Exhaust Fluid (DEF) Diesel Exhaust Fluid (DEF) is a reactant that’s key to the SCR process. It’s a nontoxic, aqueous solution of urea and ultra-pure water. Urea is a compound of nitrogen that turns to ammonia when heated. The fluid is non flammable, and is not dangerous when handled as recommended. However, it is highly corrosive to certain metals, espically copper and brass. Read the separate section concerning the handling of DEF solution.
352 Volvo, US10 Emissions Solution Diesel Exhaust Fluid (DEF) Handling When handling DEF solution, it is important that electrical connectors to be connected or well encapsulated, otherwise there is a risk that the DEF will cause oxidation that cannot be removed. Water or compressed air do not help, since DEF quickly oxidizes certain metal.
Volvo, US10 Emissions Solution 353 Diesel Exhaust Fluid (DEF) Availability DEF will be available in 2.5-gallon containers, 55-gallon drums, 275 gallon IBC and in bulk storage for fleet locations, truck stops and dealerships. All major truck stops, dealers and distributors will carry DEF. DEF will freezes to a "slush" type consistency at –11 degrees C (12 F), but not to a solid, so just as with diesel fuel, stored DEF needs to be protected from extended periods of severe cold.
354 Volvo, US10 Emissions Solution Aftertreatment Diesel Particulate Filter (DPF) W2030326 CAUTION Use of diesel fuel other than ULSD and engine oils other than EO-O Premium Plus (or VDS-4), will adversely affect performance, efficiency and durability of the Aftertreatment DPF system and the engine, to the point where the engine may not run at all. Manufacturer’s warranties can also be rendered void due to usage of improper fuel. Unapproved fuel additives (including engine oil) are NOT permitted.
Volvo, US10 Emissions Solution 355 The exhaust Aftertreatment system virtually eliminates exhaust smoke. White Exhaust vapor (water condensation) may be visible during a cold start. If black exhaust smoke is visible during engine operation, this indicates a problem with the exhaust Aftertreatment system. Take the vehicle to an authorized Volvo Truck dealer immediately.
356 Volvo, US10 Emissions Solution Aftertreatment Control Module (ACM) W2029917 The ACM controls the following components in the exhaust Aftertreatment system: • • • • • • Aftertreatment DEF Dosing Unit Aftertreatment DEF Tank Heater Valve Aftertreatment DEF Line Heaters Aftertreatment DEF Pump Aftertreatment DEF Return Valve Aftertreatment DEF Tank Level Sensor The ACM also monitors the following values in the exhaust Aftertreatment system: • • • • • • Aftertreatment DEF Dosing Absolute Pressure Aft
Volvo, US10 Emissions Solution 357 Exhaust Aftertreatment System Operation The stalk switch control lever is used to interact with the Driver Information Display (DID) in the center of the instrument cluster. The lever is located on the right-hand side of the steering wheel. W3005262 1 Esc or Escape button is used to return to the previous menu or display. 2 ↵ or Enter button is used to display a list of menus, open a menu, and select the highlighted area.
358 Volvo, US10 Emissions Solution Aftertreatment Menu 1 The Aftertreatment system menu is in the DID. Press the Esc button to display the main menus in the DID. 2 Use the up and down buttons on the stalk switch to scroll to the Aftertreatment menu. 3 Press the ↵ button to select the Aftertreatment menu. W3007527 The Aftertreatment menu has two submenus: Request Parked REGEN and ATS status.
Volvo, US10 Emissions Solution 359 Aftertreatment DPF Regeneration CAUTION During the Parked Regeneration, the exhaust gas temperature will be elevated. DO NOT park the vehicle with the exhaust outlet near flammable objects such as trees, awnings, etc. that could be damaged by elevated exhaust gas temperatures. CAUTION If the vehicle is PARKED in a location that may be hazardous when a parked Regeneration begins (i.e.
360 Volvo, US10 Emissions Solution There are two types of Aftertreatment DPF Regeneration: Passive regeneration and Parked regeneration. Passive Regeneration occurs when the exhaust gas within the aftertreatment system is hot enough to burn soot without injecting additional fuel into the DPF system. On chassis equipped with a US07 aftertreatment system, DPF”s needed an active regeneration, that includes this injection of fuel.
Volvo, US10 Emissions Solution 361 The Aftertreatment DPF Regeneration system is self-monitoring. When the Aftertreatment Diesel Particulate Filter is becoming full and Aftertreatment DPF regeneration is needed, the Aftertreatment DPF Regeneration Needed icon on the instrument cluster illuminates and the message ."Parked REGEN Needed" is displayed. To return to the main menu, press the Esc button on the stalk switch.
362 Volvo, US10 Emissions Solution If the vehicle has not had a parked REGEN completed after the “Parked REGEN Needed” screen displays the vehicle must be stopped. Perform the parked REGEN now. The vehicle will also be in Engine Derate. W3055326 Parked REGEN Required Now Engine in Derate If the vehicle is driven when the “Soot Level High” screen displays. The REGEN is needed immediately.
Volvo, US10 Emissions Solution 363 If a parked REGEN is not done when the” Soot Level High” displays the “Soot Level Critically High” screen displays. W3055333 Soot Level Critically High When the ATS Service DID and the Stop Light illuminates screen displays stop the vehicle immediately and perform a Parked Regen. If that Parked Regen doesn’t work take the vehicle immediately to a service center for ATS.
364 Volvo, US10 Emissions Solution The High Exhaust System Temperature (HEST) Icon comes on when the vehicle temperature becomes excessive. The Icon also comes on during the REGEN. W3007444 High Exhaust System Temperature (HEST) Icon Note: It is important to perform a Regeneration when required to avoid engine problems.
Volvo, US10 Emissions Solution 365 If the conditions are not met and a parked REGEN is attempted the “Parked REGEN Conditions Not Met Check Menu Status” screen displays. W3055181 Parked REGEN Conditions Not Met Scroll to the Aftertreament menu in the Driver information Display (DID) and select “ATS Status” to determine why the Regeneration did not initiate.
366 Volvo, US10 Emissions Solution If the Aftertreatment DPF Regeneration Required icon is flashing, the Aftertreatment Diesel Particulate Filter is over full. Maintain uninterrupted highway speed for a passive Aftertreatment DPF Regeneration Required or move the vehicle to a safe location and initiate a parked Aftertreatment DPF Regeneration.
Volvo, US10 Emissions Solution 367 Refer to the Exhaust Aftertreatment System Information sun visor label for additional Aftertreatment DPF information. W8056652 Exhaust Aftertreatment System (ATS) Status The ATS status submenus provide information about the conditions required for performing a parked DPF Regeneration. The status can be OK (regeneration allowed), Check (regeneration not allowed) or N/A (not applicable). When ATS Status is selected, the following submenus are available.
368 Volvo, US10 Emissions Solution To perform a parked Regeneration, the accelerator pedal (AP) must not be depressed, the transmission must be in the neutral position and the vehicle speed must not be zero. W3054889 To perform a parked Regeneration, the park brake must be engaged and there can be no active Diagnostic Trouble Codes (DTC) codes.
Volvo, US10 Emissions Solution 369 Temporary lockout prevents performing a parked DPF Regeneration when it is not needed. Permanent lockout prevents performing a parked Regeneration when a condition exists that requires vehicle service. Take the vehicle to a Volvo Truck dealer. A minimum engine temperature (ECT) of 35°C (95°F) is required for parked DPF Regeneration. W3054884 When Disable REGEN is selected in the Cancel REGEN submenu, regeneration is inhibited.
370 Volvo, US10 Emissions Solution Driver Warnings and On Board Diagnostics (OBD) On Board Diagnostics (OBD) Beginning with your US 2010 compliant Vehicle, On Board Diagnostics (OBD) is introduced. This is very similar to the On Board Diagnostics (OBD) system that has been required on passenger cars for many years. On Board Diagnostics (OBD) is a system that monitors the functions of emissions related components and alert the vehicle operator to any detected need for an emission related repair.
Volvo, US10 Emissions Solution 371 Instrument Cluster Icons Aftertreatment icons are displayed on the instrument cluster. There are three Aftertreatment icons: • • • Parked Aftertreatment DPF Regeneration Required High Exhaust System Temperature (HEST) Aftertreatment DEF Tank Low Level Indicator The Aftertreatment DPF Regeneration Required icon flashes when the Diesel Particulate Filter is full or overfull and regeneration is needed..
372 Volvo, US10 Emissions Solution The Aftertreatment DEF Tank Low Level Indicator icon illuminates when the fluid level is low. It also Flashes when the level becomes critically low.
Volvo, US10 Emissions Solution 373 Aftertreatment DEF Tank Level - Driver Warning & Inducement Aftertreatment DEF tanks are sized to have no less than two times the diesel fuel tank mileage or hour range The vehicle instrument cluster has a Aftertreatment DEF Tank Level Gauge Triggers Aftertreatment DEF Tank Low Level Indicator Amber Warning Lamp Inducement >12% Aftertreatment DEF Tank Level Gauge (>16% DEF Remaining) None None None None None None 25% torque reduction None 8 km/h (5 mph) Road S
374 Volvo, US10 Emissions Solution Aftertreatment DEF Quality - Driver Warning & Inducement Triggers Aftertreatment DEF Tank Low Level Indicator Amber Warning Lamp Good DEF Quality None None Poor DEF Quality DTC Initial Detected None Inducement None None W2029417 Poor DEF Quality DTC Initial Detected + 10 hours None Poor DEF Quality DTC Initial Detected + 20 hours Diesel Fuel Refueling >15% None Temporary Exit from 8 km/h (5 mph) Inducement None 25% torque reduction W2029417 8 km/h (5 mph
Volvo, US10 Emissions Solution 375 Misfilling Diesel or Aftertreatment DEF Tanks Although diesel fuel and Aftertreatment DEF caps are clearly labeled and filler necks and nozzles are different accidents can happen. Contamination of fluids by- misfilling of diesel or DEF in the wrong tank may result in vehicle malfunction.
376 Volvo, US10 Emissions Solution SCR Tampering - Driver Warning & Inducement 1. Disconnected Aftertreatment DEF tank level sensor 2. Blocked Aftertreatment DEF line or dosing unit 4. Disconnected Aftertreatment DEF pump 5. Disconnected SCR wiring harness 3. Disconnected Aftertreatment DEF dosing unit 6.
Volvo, US10 Emissions Solution 377 Warranty and Maintenance Exhaust Aftertreatment System Maintenance The vehicle must be taken to an authorized Volvo Truck dealer to remove the ash from the Aftertreatment Diesel Particulate Filter and clean the Aftertreatment Doser. Emissions Maintenance 1.
378 Volvo, US10 Emissions Solution Engine Maintenance Intervals Component Operation Interval Fuel Filter Change Every oil change. Under certain conditions (for example, irregular fuel quality), the fuel/water separator filters may require more frequent replacement.
Volvo, US10 Emissions Solution 379 Engine Gaseous Emission Control Systems WARRANTY MAINTENANCE Note: For emission control systems information on engines other than Volvo, refer to the engine vendor’s publication GASEOUS EMISSION CONTROL SYSTEMS WARRANTY Volvo Trucks North America.
380 Volvo, US10 Emissions Solution Emissions Control System Warranty The following engine components are covered by the supplemental emissions control system warranty policy as required by the Federal code of emission regulations.
Volvo, US10 Emissions Solution 381 • • EGR Differential Pressure Ambient Air Temperature (AAT) • • Aftertreatment DEF Tank Heater • Aftertreatment DEF Tank Temperature Sensor • • Aftertreatment DEF Level Sensor 18 SCR • Aftertreatment Selective Catalytic Reduction (SCR) Catalyst • Aftertreatment Diesel Exhaust Fluid (DEF) Pump • • • • Aftertreatment DEF Dosing Absolute Pressure Sensor • Aftertreatment DEF Return Valve Aftertreatment DEF Dosing Valve Aftertreatment DEF Tank Aftertreatment
382 Volvo, US10 Emissions Solution TAMPERING WITH GASEOUS EMISSION CONTROL SYSTEMS PROHIBITED The Federal Clean Air Act prohibits the removal or rendering inoperative of any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with Federal Emission Regulations by: 1 Any person prior to its sale and delivery to the ultimate purchaser, or 2 Any manufacturer or distributor after its sale and delivery to the ultimate purchaser, or 3 Any person engaged in the busi
Volvo, US10 Emissions Solution 383 OWNER’S WARRANTY RESPONSIBILITIES: As the motor vehicle engine owner, you are responsible for the performance of the required maintenance listed in this manual. Volvo Trucks North America. recommends that you retain all receipts covering maintenance of your vehicle, but Volvo Trucks North America.
384 Volvo, US10 Emissions Solution Qualifications and Limitations: Not covered by the Emissions Control Systems Warranty: • Malfunctions caused by misuse, improper adjustments, modification, alteration, tampering, disconnection, improper or inadequate maintenance and use of improper diesel fuel or DEF. • Damage resulting from accident, acts of nature or other events beyond the control of Volvo Trucks North America.
Volvo, US10 Emissions Solution 385 Emissions Control System Warranty The following engine components are covered by the supplemental emissions control system warranty policy as required by the California code of regulations.
386 Volvo, US10 Emissions Solution 17 Sensors: • • • • • • • • • • Crankshaft Position (CKP) Camshaft Position (CMP) Engine Coolant Temperature (ECT) Intake Manifold Air Temperature Intake Manifold Pressure (IMP) EGR Temperature Aftertreatment Outlet NOx Aftertreatment Intake NOx EGR Differential Pressure Ambient Air Temperature (AAT) 18 SCR • Aftertreatment Selective Catalytic Reduction (SCR) Catalyst • Aftertreatment Diesel Exhaust Fluid (DEF) Pump • Aftertreatment DEF Dosing Absolute Pressure Se
Volvo, US10 Emissions Solution 387 Oil Change Intervals The length of time an engine can operate before an oil change depends on the quality oil used, the type of fuel used, fuel consumption, engine oil consumption, vehicle application, level of dust in the air, and fuel consumption. The change intervals given in this manual are maximum intervals. If the vehicle is operating in heavy-duty operation, dusty or off-road conditions, etc., reduce the intervals for more frequent oil changes.
388 MAINTENANCE AND LUBRICATION DAILY MAINTENANCE DANGER Before working on or inspecting 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 personal injury or death. CAUTION Engines equipped with automatic start systems can start automatically. An alarm sounds before automatic start. Failure to turn off ignition before working on fan or belts can result in personal injury.
MAINTENANCE AND LUBRICATION 389 TOWING PROCEDURE General WARNING If a vehicle with air suspension is lifted by the rear frame member, there is a risk that the air springs will separate from the spring plates. When towing has been completed, DO NOT under any circumstances use your hands to reposition the air springs. There is a great risk that your hand will be caught between spring and plate causing personal injury. WARNING WARNING Vehicles with air fairings are tall.
390 MAINTENANCE AND LUBRICATION T0006670 The vehicle may now be towed. It is recommended that a wrecker with a lift bar is used since the service brakes will not function. The system must be filled with air to release the parking brake or follow the mechanical spring brake caging procedures on “Caging Spring Brake Chambers”, page 396. Note: The power steering does not function when towing a vehicle with a disabled engine.
MAINTENANCE AND LUBRICATION 391 Towing Instructions DANGER DO NOT use the tow eyes for raising the front of the vehicle; the tow eyes can break. DO NOT crawl under a vehicle suspended by tow eyes. Failure to follow these instructions can result in serious personal injury or death. W9000752 Fig. Fig. 2 DO NOT lift or tow vehicle as shown in this illustration.
392 MAINTENANCE AND LUBRICATION CAUTION If the vehicle becomes disabled, it is very important to tow it properly. Failure to do so can cause damage to the frame and body parts. Follow the instructions below to avoid damage. In the event that the vehicle cannot be reached to place the wrecker lift bar under the front axle, use the optional tow eyes. The front tow eyes are used as a point at the front of the vehicle where the vehicle can be pulled.
MAINTENANCE AND LUBRICATION 393 The tow eyes are held in place when mounted on the front of the vehicle by tractor pins. These pins are stored in the tow eye mounting holes when not being used. If the vehicle is equipped with the optional rock guard installed, insert the lock pin into the tow hook from the opposite side during installation.
394 MAINTENANCE AND LUBRICATION If the vehicle is equipped with the optional rock/stone guard installed, the driver will have to insert the lock pin into the tow hook from the opposite side during installation. W9000751 When the vehicle is located properly, lift the front and locate the lift bar under the front axle and secure. Using the front axle for towing minimizes the possibility for damage to the vehicle body, frame and suspension.
MAINTENANCE AND LUBRICATION 395 Note: When the driveshaft or axle shafts are reinstalled, make sure the nuts are tightened to the correct torques. Also make sure the axle shafts are installed in the proper sides, with the left shaft in the left side and the right shaft in the right side. Towing Pintle DANGER DO NOT exceed the maximum towing capacity of the pintle hook system (4,000 lb.). Exceeding the maximum towing capacity may result in vehicle accident, serious injury or death.
396 MAINTENANCE AND LUBRICATION Caging Spring Brake Chambers DANGER Always start by chocking the wheels to prevent the vehicle from rolling. Failure to do so can result in unexpected vehicle movement and serious personal injury or death can occur. DANGER DO NOT attempt in any way to disassemble or tamper with the spring brake chamber. If the force stored on the spring is suddenly released, it can cause serious personal injury or death.
MAINTENANCE AND LUBRICATION 397 W5001430
398 MAINTENANCE AND LUBRICATION Towing Procedure — AIRTEK® Suspension ®HENDRICKSON recommends that a vehicle equipped with a STEERTEK axle be towed using the following methods for ON HIGHWAY or ON ROADWAY applications. Methods listed are in order of preference.
MAINTENANCE AND LUBRICATION 399 CAUTION DO NOT tow the vehicle from the axle. Towing the vehicle by the axle will cause scarring and resultant damage to the axle and void warranty. When lifting a vehicle with an under lift boom, care must be taken not to damage the engine’s oil pan. It may also be necessary to remove the front fairing. This is an alternative method for towing the vehicle, but it requires SPECIAL forks (see illustration showing designated lift points).
400 MAINTENANCE AND LUBRICATION W7001301 Towing Vehicle From Rear Method This method is preferred when the proper equipment is not available to perform the wheel lift method or the axle fork method, and is necessary for wreckers not equipped with an under lift system. Spring Eye and Hanger Lift Method This method is permitted for under lift equipped units. Caution must be taken not to damage the leaf spring (see illustration for proper installation).
MAINTENANCE AND LUBRICATION 401 Off Roadway Towing Method WARNING When a truck is disabled and equipped with a STEERTEK axle, care must be taken to ensure there is no damage to the suspension when towing the vehicle. The use of a tow strap is necessary to tow a disabled truck into a repair facility. The tow straps should be connected to the tow hooks provided by the manufacturer at the front of the bumper.
402 MAINTENANCE AND LUBRICATION W7001304 Chains are not acceptable for Off roadway towing.
MAINTENANCE AND LUBRICATION 403 ENGINE OIL LEVEL CHECK CAUTION Make sure the oil added is the same type of oil that is in the engine. The wrong type of oil could accelerate wear on engine if not suited for application. Check the oil level in the engine with the dipstick. The oil level should be between the minimum and maximum marks on the dipstick DO NOT overfill! To add oil to the engine, remove cap from right-side oil fill and fill through the hole.
404 MAINTENANCE AND LUBRICATION Clutch Fluid Check Check the fluid level in the clutch fluid reservoir. The fluid level should be between the level marks on the reservoir. If fluid needs to be added, use brake fluid, DOT 4.
MAINTENANCE AND LUBRICATION 405 Engine Maintenance Intervals Components Operation Intervals Water Seperator Filter Change Every oil change. Under certain conditions (for example, irregular fuel quality), the fuel/water seperator filters may require more frequent replacement.
406 MAINTENANCE AND LUBRICATION POWER STEERING, GENERAL The VN power steering consists of an integrated gear. There is also a power steering pump with fluid container. The pump, driven by the engine, provides hydraulic pressure to the power steering. If the engine is not working, the steering is only manual. With the power steering not working, the effort required to turn the steering wheel is much greater than with power assist. If the power steering assist fails, bring the vehicle to a safe stop.
MAINTENANCE AND LUBRICATION 407 Windshield Washer Reservoir Check level in the windshield washer reservoir. If washer fluid needs to be added, use a commercially reputable washer fluid that has good cleaning capability and does not freeze in cold weather. Windshield Washer Capacity Model VN Reserve 6.35 liters (1.5 gallons) Total Capacity 13.70 liters (3.
408 MAINTENANCE AND LUBRICATION COOLING SYSTEM Coolant Level Check WARNING DO NOT remove the cap to the surge tank while the engine and radiator are still hot and under pressure. Scalding fluid and/or steam may be blown out under pressure if the cap is taken off too soon. CAUTION Add only premixed coolant made up of 50% clean water and 50% antifreeze. See the Operator’s Manual Vehicle Maintenance for more detailed information. Check coolant level in the coolant tank. The tank should be full.
MAINTENANCE AND LUBRICATION 409 CAB Air going into the cab passes a filter located on the right, front side of the cab. Remove the filter and check it every 19,200 km (12,000 miles). W8003189 The filter should not be cleaned and reused. Replace with a new filter as necessary. Change the filter more often if driving in dusty conditions. A clogged filter decreases the efficiency of the air conditioning system. If the vehicle is equipped with a sleeper heater-A/C, there is a filter for recirculating air.
410 MAINTENANCE AND LUBRICATION HEADLIGHTS Changing Headlight Bulb Note: To prevent short service life, DO NOT touch the glass surface of the replacement bulb. VNM Instructions The headlight bulb can be accessed from the rear of the headlight assembly. Raise the hood and remove the cover. Remove the terminal from the back of the bulb by bending up the lock tabs and pulling back at the same time. Turn the lock ring counterclockwise and remove. Pull out the bulb.
MAINTENANCE AND LUBRICATION 411 VNL Instructions The headlight bulb can be accessed from the rear of the headlight assembly. Raise the hood. In early production vehicles, remove the bulb cover by turning clockwise. In later production vehicles, the cover can be removed in the normal counterclockwise direction. Note: In some cases, the cover seal may stick to the housing, which makes removal difficult. Use special tool 85104355 to assist in removal. Contact your authorized Volvo dealer for the tool.
412 MAINTENANCE AND LUBRICATION ROOF EXTENDER The roof extender increases fuel economy. The extender is adjustable to five positions which are shown in the illustration and in the graphs. The vehicle is delivered with the extender or deflector lowered or down, which is the transport position, see A in illustration. W8003470 To set the extender to normal riding position, measure points H and G, then select positions 1 through 5 in the rod as determined by the adjustment chart.
MAINTENANCE AND LUBRICATION 413 Note: For 630 and 670 vehicle models, the frame height must be measured. See F in illustration. If F measures 266 mm (10-1/2 inches), subtract 17 mm (5/8-inch) from the value determined for H.
414 MAINTENANCE AND LUBRICATION W8003473 VN 630/670 Roof Extender Adjustment Chart
MAINTENANCE AND LUBRICATION 415 FRONT BUMPER/LICENSE PLATE MOUNTING CAUTION DO NOT cover the opening in the front bumper with a license plate. Covering this hole will restrict airflow to the lower portion of the radiator. This can cause the engine to overheat, which can damage the engine. When placing the license plate on the vehicle, make sure the opening in the bumper is not covered.
416 MAINTENANCE AND LUBRICATION Multiple License Plate Mounting Install multiple license plates as shown.
MAINTENANCE AND LUBRICATION 417 VORAD License Plate Mounting Install multiple license plates as shown. W8003371 Fig. Fig. 3 VN 1 Install license plates below this edge.
418 MAINTENANCE AND LUBRICATION MODIFICATIONS TO VEHICLE Chassis Frame WARNING DO NOT weld on any part of the frame or drill holes in the top or bottom flanges. Serious structural damage could occur. Frame side rails are heat treated. No welding is permitted because this can result in structural failure. DO NOT drill through either top or bottom flanges. A warning label is also attached to the frame for information.
MAINTENANCE AND LUBRICATION 419 Frame rail and cross member nuts and bolts should be checked periodically and tightened to the specified torque if necessary. Frame Alterations Under no circumstances can the frame be cut and an extension piece added to increase the wheelbase. The only alteration allowed is wheel base shortening, where the only change in the frame rail is a new hole pattern drilled for the new location of the rear suspension.
420 MAINTENANCE AND LUBRICATION WHEELS General Due to the size, equipment needed and the procedures used to change wheels, this should be done through the Volvo Truck dealer. By having an expert technician perform this procedure, personal injury and property damage may be avoided. Note: When replacing the wheel equipment or tires, use the same size wheels or tires as originally manufactured. Changing the tire or wheel size will affect brake performance.
MAINTENANCE AND LUBRICATION 421 W7001270 Inflating Tires DANGER Tires and wheels must be serviced only by a qualified technician. DO NOT attempt to perform this work yourself. Inflated tires on wheels contain compressed air and if suddenly released, do so with an explosive force. Serious personal injury or death can occur. CAUTION Never bleed the air from hot tires. Increased tire pressure measured in a hot tire is normal.
422 MAINTENANCE AND LUBRICATION W2002684 For specific information and warranty on rims and tires, contact the tire manufacturer’s distributor. Check tires for abnormal wear. Also, check the tread depth. Wheel Bearing Adjustment DANGER Failure to keep wheel bearings properly adjusted may result in accelerated tire wear, poor handling and, in extreme cases, wheel separation from the hub or from the spindle. It is important that wheel bearings are checked and adjusted regularly.
MAINTENANCE AND LUBRICATION 423 For reliable operation and adequate service life, the wheel bearings must be properly adjusted and checked during the service period. Loose wheel bearings could cause premature tire wear and possibly affect vehicle handling. See your authorized Volvo Truck dealer for proper servicing. Watch carefully for oil leaks and listen for unusual noises. These are indications of worn bearings, bad seals or misadjusted bearings.
424 MAINTENANCE AND LUBRICATION BATTERY Battery Box Access for Jump Start DANGER When inspecting or cleaning batteries, never smoke or expose batteries (or the areas around them) to spark or flames. The battery area may contain an explosive gas mixture that can ignite, causing an explosion, leading to serious personal injury or death. WARNING Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion.
MAINTENANCE AND LUBRICATION 425 The battery cover may also be a base for the cab steps. To remove the cover, unhook the two rubber latches and lift the cover up and out. This applies to the vehicle models without fairings. W3005334 There may be up to four batteries installed. Always make sure the batteries are fastened properly in the box.
426 MAINTENANCE AND LUBRICATION Battery Jump Starting and Charging DANGER DO NOT attempt to jump-start a vehicle equipped with Delco Maintenance Free batteries if the test indicator is light yellow. Replace the battery instead. Jump-starting may cause battery to explode causing skin burns from acid or serious personal injury or death. WARNING Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion.
MAINTENANCE AND LUBRICATION 427 W3005322 Connect the jumper cables in the following sequence: • • • • Good battery positive, Dead battery positive, Dead battery negative, Disconnect the cables in the reverse order. Avoid creating sparks by making all connections quickly and firmly. DO NOT permit vehicles to touch each other when jump starting.
428 MAINTENANCE AND LUBRICATION Battery to Battery Charging High voltage machines that are used for work on the vehicle can do damage to the electrical system, especially to its electronic components. Welding or quick-charging machines subject the wiring to excessive voltage, which may result in damage to electrical and electronic components anywhere on the vehicle.
MAINTENANCE AND LUBRICATION 429 Battery, Low State of Charge If the batteries are discharged to the point where they do not have enough stored energy to start the engine, they should be recharged using a low charge current, not to exceed 14.5 to 15.0 volts. If the vehicle needs to be started immediately, use a starting batteries charger. Note: If the voltage power is exceeded, this can cause damage to the lighting system and bulbs. DO NOT use battery chargers with very high "boosting" capability.
430 MAINTENANCE AND LUBRICATION CAUTION If there are other ground cables connected to the battery (such as engine ECU, transmission ECU, etc.), disconnect those wires in the sequence shown, then remove the main battery ground cable. Electronic modules may be damaged when their ground(s) are connected/disconnected with the main battery ground disconnected. Therefore, disconnect the main battery ground last or when installing, connect the main ground first.
MAINTENANCE AND LUBRICATION 431 The vehicle is equipped with systems that have their own electronics, including vehicle ECU (VECU), ABS, air bag (SRS), gauge cluster and some transmissions. Disconnect each ECU at its electrical connectors. W8003198 Disconnect the power harness (engine electronic control unit [EECU]) and vehicle interface harness at the battery. W8003199 Disconnect the electrical connections at the negative side of the battery.
432 MAINTENANCE AND LUBRICATION Reposition or shield any parts that would be damaged by high temperatures during welding. W8003200 Complete the battery cable removal by removing the positive cable last. • Attach the welder ground cable as close to the weld area as possible (6 inches or less from the place being welded). • DO NOT connect the welder ground cable near any electronic module, such as the EECU or its cooling plate.
MAINTENANCE AND LUBRICATION 433 Battery Voltage Protection System The vehicle is equipped with a battery protection system. The vehicle detects when the batteries are excessively discharged and will flash the indication light and sound an audible alarm. Should the battery voltage remain low for an additional 30 seconds the indication light and alarm rate increases (fast flash). This indicates that some circuits will be disconnected in 30 seconds to maintain engine starting capacity.
434 MAINTENANCE AND LUBRICATION W3030711 Battery Protection Data Flow from LVD Note: Pressing the fan speed button over rides for approximately 10 minutes, enabling all loads. When the batteries are charged, either through the vehicle alternator or a connected battery charger, the monitor will automatically restore power to the disconnected circuits. Unless the batteries are held at an elevated voltage for several hours, they will only develop a "surface" charge.
MAINTENANCE AND LUBRICATION 435 W3030520 In situations where there is a short or overcurrent (over 100 Amps), the battery voltage protection system will initiate a different audible and visual alarm. The alarms are activated at a series of three 30 second intervals. If the short or overcurrent situation is not resolved by the final alarm series, the LVD shuts down in order to protect the vehicle lectrical system. If the system is shut down, you must perform a battery disconnect to reset the system.
436 MAINTENANCE AND LUBRICATION ELECTRICAL General Safety Guidelines WARNING Failure to repair a malfunction in the electrical system can result in serious damage due to vehicle fire. Always let an experienced electrical technician perform repairs. Always determine the source of the fault; do not just treat the symptoms. WARNING Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion.
MAINTENANCE AND LUBRICATION 437 CAUTION Attempting to work on electronic components without proper equipment can damage internal parts with static electricity. CAUTION Today’s vehicles contain a high number of electronic devices. It is very important to exercise caution when working on a modern electrical system, charging batteries or jump starting the engine. To minimize the risk of any damage to the electronic components, follow the procedures below when work is being done to the electrical system.
438 MAINTENANCE AND LUBRICATION CAUTION DO NOT weld on the engine or engine components. Welding on the engine or components mounted on the engine can cause serious damage to the engine ECU. Note: DO NOT work on the electric system without proper tools and training. Repair work to the electrical system must be done by trained professionals. Your authorized Volvo Truck dealer has the right tools and trained technicians.
MAINTENANCE AND LUBRICATION 439 Electrical Center WARNING Failure to repair a malfunction in the electrical system may result in a vehicle fire and personal injury. WARNING Always replace fuses and circuit breakers with the same current/amperage rating. Using larger fuse or circuit breaker ratings may result in electrical circuit overheating and possibly fire. The vehicle has an electrical center located in the middle of the dash under the top cover.
440 MAINTENANCE AND LUBRICATION The cover panels are fastened with screws. Most relays and fuses are accessible from under the top cover. Since the function of some fuses or relays may change for the vehicle application, refer to the list of functions that is attached beneath each panel. W3007220 Additional relays are located in the left-hand luggage compartment, attached to the sleeper harness. Note: These relays have limited optional sleeper functions.
MAINTENANCE AND LUBRICATION 441 Additional fuses are located in the Sleeper Control Panel. W3007222 Sleeper Control Panel Fuses Fuses are standard. Reset breakers are available as an option for some circuits. If a fuse continues to blow or disconnect, the circuit has a malfunction and must be repaired. If a breaker trips, the ignition or main switch must be switched off before the breaker resets. One type of fuse in the electrical center is termed "mini-fuse.
442 MAINTENANCE AND LUBRICATION CB Power Studs CB Studs are available either in the overhead storage compartment, or on the dash. W3005282 The red stud is the positive terminal and the black stud is the ground terminal. For a proper hook-up, use fork-type connectors on the wires or use "banana" plugs. CAUTION If stripped wire ends are used, make sure there are no wire strands that can bridge between the studs.
MAINTENANCE AND LUBRICATION 443 Before connecting any electrical accessory, make sure it is made for 12 V operation. This circuit is fused at 20 A maximum, or optional circuits are fused at higher amps (30 A). DO NOT overload this circuit. CAUTION DO NOT connect a device with a current rating in excess of the amount specified on the fuse and relay panels. The dash top tray or the overhead radio shelf is available with an optional CB mount power strap to hold different size radios securely in place.
444 METRIC CONVERSIONS METRIC CONVERSIONS Note: Use all tools on the fasteners they were made to be used on. Use metric tools on Sl metric units only. Never try to use metric tools on U.S. standard fasteners or U.S. standard tools on Sl metric units. CAUTION Potential external/internal thread mismatch condition(s) may occur with certain metric thread-inch thread fastener combinations, and with fastener combinations involving incompatible metric fastener systems.
METRIC CONVERSIONS 445 SI to U.S. Conversions 25.4 millimeters = 1 inch 1.61 kilometers = 1 mile .473 liter = 1 pint (U.S. liquid) .946 liter = 1 quart (U.S. liquid) .01639 liter = 1 cubic inch 1.3558 Newton meters = 1 pound-foot .746 kilowatt = 1 horsepower 6.895 kilopascals = 1 pound/square inch (1.8 x degrees Celsius) + 32 = degrees Fahrenheit .83267 Imperial gallon = 1 gallon (U.S. liquid) U.S. to SI Conversions .03937 inch = 1 millimeter .6214 mile = 1 kilometer 2.
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