Operator's Manual Maintenance and Engine VH D
Foreword This manual contains information concerning the safe operation of your vehicle. It is extremely important that this information is read and understood before the vehicle is operated. This manual also contains a considerable amount of information concerning the vehicle, such as vehicle identification, Preventive Maintenance recommendations and a log for your service records. Please keep this in the vehicle at all times.
Contents General Information ............................. 1 Information For the Owner ................... 1 Safety Information ................................. 3 Proper Maintenance Procedure ............. 3 Injury Prevention ................................... 6 Engine Damage Prevention ................. 15 Electric System Damage Prevention .. 17 Reporting Safety Defects .................... 19 General Engine Design Information . Engine Overview D7 ........................... Engine Overview, D12 ........
Warning Label Information IMPORTANT Before driving this vehicle, be certain that you have read and that you fully understand each and every step of the driving and handling information in this Operator’s Manual. Be certain that you fully understand and follow all safety warnings. IT IS IMPORTANT THAT THE FOLLOWING INFORMATION CONCERNING LABELS IS READ, UNDERSTOOD AND ALWAYS FOLLOWED.
General Information 1 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 Volvo Trucks North America or other manufacturer for any assistance. Establish a Preventive Maintenance Program with the help of your local Volvo Truck dealer.
2 General Information Do Not Remove this manual from the vehicle. It contains important operational and safety information that is needed by all drivers and owners of this vehicle. This Maintenance Manual covers all Volvo vehicles manufactured by Volvo Trucks North America, Inc., including the whole chassis and all Volvo manufactured components. Specific maintenance information on vendor components, manufactured by, for example: Cummins, Detroit Diesel, Fuller, Meritor, etc.
Safety Information 3 Proper Maintenance Procedure During Maintenance Whenever performing maintenance or repair, attach a DO NOT OPERATE or similar warning label or sign to the ignition key or prominently displayed on the instrument panel. • Before servicing your vehicle, apply the parking brakes and adequately chock the wheels in order to prevent unintended vehicle movement.
4 Safety Information • Report all problems in a timely manner before they threaten the safety of operating the vehicle. • Do not work on the engine while it is running. • Tag the vehicle with the DO NOT OPERATE sign. Make sure other protective locks and covers are in their proper place. • Disconnect the batteries whenever performing any repairs or before servicing the electrical system. • DO NOT use high amperage electronic starting devices for jump-starting the engine.
Safety Information Compressed Air and Water Compressed air can cause personal injury. When using compressed air for cleaning, wear a protective face shield, protective clothing and protective shoes. Pressurized water could cause particles and/or hot water to be sprayed in your direction and cause personal injury. The maximum air pressure must be below 30 psi (200 kPa) for cleaning purposes. Asbestos Information NOTE! The Volvo engine and replacement parts for it shipped from the factory are asbestos free.
6 Safety Information Injury Prevention Burn Prevention Engine Parts WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or fluid can cause serious burns. Do not touch any part of the engine while it is hot. Allow the engine to cool before any repair or maintenance is performed on the engine. WARNING Do not raise the engine hood or cab if you see or hear steam or coolant escaping from the engine compartment.
Safety Information Coolant To prevent personal injury, do not climb up on the engine to remove the filler cap. Use a suitable, properly positioned ladder to reach up to the cap. At normal operating temperature, the engine coolant is very hot and under pressure. If pressure is relieved rapidly in a hot cooling system, the hot coolant can turn into steam. Any contact with hot coolant or steam can cause severe burns. The radiator and all heating system and radiator lines and hoses contain hot coolant.
8 Safety Information Oils WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or fluid can cause serious burns. Hot oil can cause severe burns. Do not allow hot oil to contact the skin. When changing oil, wear protective gloves. Batteries WARNING Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion.
Safety Information Fire or Explosion Prevention The diesel engine will operate on any fuel which enters the cylinder, whether it is from the injectors or from the air intake system. Therefore, if any solvent is used to flush out the air cleaner element, the engine may overspeed during start-up. Engine damage and severe injury and/or death from burns or explosion can occur. The engine should not be operated in an area where combustible gases are suspected to be in the air.
10 Safety Information Do not service any part of the fuel system while smoking or in the presence of flames, sparks or hot surfaces. Failure to follow these precautions can result in fire, which can cause serious injury or death. All fuels, most lubricants and some coolant mixtures are flammable. Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes is extremely explosive. Do not smoke while refueling or when in a refueling area.
Safety Information Exhaust heat shields may be installed to protect oil or fuel carrying lines and pipes from hot exhaust parts. To protect from pipe or seal failure, install heat shields correctly. Provide adequate and proper waste oil disposal. Always dispose of waste liquids according to Federal and local regulations. Oil and fuel filters should be properly installed and housing covers tightened to the proper torque when being changed.
12 Safety Information Respiratory Hazard Prevention Exhaust gases contain carbon monoxide. Always run the engine outdoors or use a properly vented exhaust hose. Prolonged or excessive exposure may cause serious illness or death. WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.
Safety Information Crushing or Cutting Prevention Before working on a vehicle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. Do not work near the fan with the engine running or the ignition in the ON position. The engine fan can engage at any time without warning. Anyone near the fan when it turns on could be seriously injured.
14 Safety Information Wear protective glasses when striking objects to avoid injury to your eyes. Chips or other debris can fly off objects that are struck. Make sure no one can be injured by flying debris before striking any object. W0001528 Climbing Up and Down Always have three limbs (one foot and 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.
Safety Information Engine Damage Prevention Before Starting the Engine 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. Inspect engine for potential hazards. Make sure all protective guards and covers are properly installed if an engine needs to be started to make adjustments or checks.
16 Safety Information Engine Starting DO NOT start the engine or move any of the controls or disengage the parking brake if the warning tag “DO NOT OPERATE” is attached to the ignition key or located on the dash. Check with the person who attached the tag before starting. Make sure no one is working on or close to the engine or components driven by the engine before starting it. Always make an inspection of the engine before and after starting.
Safety Information 17 Electric System Damage Prevention Electric and Electronic Systems Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the flammable vapor mixture of hydrogen and oxygen to explode. To prevent potential sparks from igniting combustible gases produced by some batteries, attach the negative (-) terminal last when hooking up and remove the negative terminal first after the engine has started.
18 Safety Information Electronic Engine Control System Tampering with the electronic system installation can be dangerous and could result in personal injury or death and/or engine damage. It is very important to take the proper precautions with the electrical and electronic system when charging the batteries, jump-starting or performing electric welding on the vehicle. See the vehicle Operator’s Manual for correct procedures. The Volvo D12 engine uses high voltage to the electronic unit injectors.
Safety Information 19 Reporting Safety Defects USA The National Highway Traffic Safety Administration (NHTSA) and Volvo Trucks North America should be informed immediately if you believe that the vehicle has a defect that could cause a crash, injury or death. Contact NHTSA by calling the Auto Safety Hotline at 1 (800) 424–9393 (or 366–0123 in the Washington, DC area) or by writing to: NHTSA, U. S. Department of Transport, Washington, DC 20590.
20 General Engine Design Information Engine Overview D7 W2002703 1. Fuel filters (secondary) 5. Coolant filter 2. Turbocharger 6. Electronic injection pump 3. Exhaust pressure governor (EPG) 7. Hand fuel primer pump 4.
General Engine Design Information W2002702 8. Engine electronic control unit (EECU) 9. Oil fill cap 10. Oil dipstick 11. By-pass oil filter 12. Full-flow oil filter 14.
22 General Engine Design Information Engine Overview, D12 W0001846 1. Oil Fill Cap 4. Fuel Filter (secondary) 2. Starter Motor 5. Oil Dipstick 3.
General Engine Design Information W0001847 9. Coolant Drain Connection 10. Exhaust Pressure Governor (EPG) 11. VEB Control Unit 12. Turbocharger 13. By-Pass Oil Filter 14. Full-Flow Oil Filters 15. Air Compressor 16. Coolant Filter 17. Coolant Radiator 18.
24 General Engine Design Information Typical Engine Compartment Overview W2003478 1. Oil fill cap 2. Intake air heater 3. Engine Electronic Control Unit (EECU) 4. Coolant surge tank 5.
General Engine Design Information 25 W2003479 6. Engine air filter 7. Coolant fill cap 8. Radiator 9. Airfilter restriction gauge 10. Oil dipstick 11.
26 General Engine Design Information Engine Features Feature • VECTRO II - Volvo Engine Electronics System • • VECTRO II Diagnostics • Two-Piece Piston and Optimized Compression Ratio (D12) • Standard Exhaust Brake • Optional Volvo Engine Brake (VEB) (D12 only) • Optional Pre-Heater Element Air-to-Air Charge Air Cooler Benefit • • • • • • • • • • • • • • • • • • • • • • Cylinder Liners with Plateau Honing • Electronically Controlled Fuel Injection • Engine-Mounted Fan Ring Engine-Dri
General Engine Design Information 27 VECTRO II Parameter Values, D7 Parameter Default Value Minimum Value Maximum Value 2500 800 Low Idle Low Idle High Idle High Idle 87 (140) 30 (48) 87 (140) Yes 87 (140) 30 (48) 30 (48) 30 (48) RSL RSL No No - - No 5 1 40 Yes - - High Idle 2500 High Idle 600 550 800 PTO: • • Maximum engine speed, r/min Resume speed Road Speed Limit (RSL): • Value RSL (technical), mph (km/h) Cruise Control (CC): • • • CC enable (yes/no) Maximum Vehicle
28 General Engine Design Information VECTRO II Parameter Values, D12 Parameter Default Value Minimum Value Maximum Value 1200 800 Low Idle Low Idle High Idle High Idle 87 (140) 30 (48) 87 (140) Yes 87 (140) 30 (48) 30 (48) 30 (48) RSL RSL No No - - No 5 1 40 Yes - - High Idle 1200 High Idle 600 500 650 PTO: • • Maximum engine speed, r/min Resume speed Road Speed Limit (RSL): • Value RSL (technical), mph (km/h) Cruise Control (CC): • • • CC enable (yes/no) Maximum Vehicl
General Engine Design Information 29 Engine Variants, D7 Power Output Options D7C-275 D7C-300 Output, net , @ 2,200 r/min 275 hp (205 kW) 300 hp (224 kW) Torque, net1, @ 1,400 r/min 800 lb-ft (1,085 Nm) 950 lb-ft (1,288 Nm) Governed speed 2,200 r/min 2,200 r/min 1 1 Net output according to ISO 1585 and SAE J1349.
30 General Engine Design Information Engine Variants, D12 Power Output Options D12C-345 D12C-385 D12C-425 D12C-465 Output, net , @ 1,700 r/min 345 hp (250 kW) 385 hp (279 kW) 425 hp (309 kW) 465 hp (338 kW) Torque, net1, @ 1,200 r/min 1,255 lb-ft (1,700 Nm) 1,365 lb-ft (1,850 Nm) 1,475 lb-ft (2,000 Nm) 1,625 lb-ft (2,200 Nm) Governed speed 2,000 r/min 2,000r/min 2,000r/min 2,000r/min 1 1 Net output according to ISO 1585 and SAE J1349.
General Engine Design Information 31 Engine Data Fill in the blanks for future reference: Vehicle Identification Number (VIN) [ ................................................................................ ] Engine Model [ ..................................................................................................................... ] Engine Serial Number [ ....................................................................................................... ] Engine Power Output [ .............
32 Engine Storage Engine Storage If the vehicle needs to be parked for a period (more than 30 days), make sure to protect it as follows: 1 Drain the engine of its used oil. 2 Fill up to the proper level with oil of the recommended quality and viscosity. 3 Fill up the fuel tanks with the recommended grade of fuel. 4 Run the engine for two minutes around 1000 r/min. Shut the engine down. Do not drain the oil after this run. 5 Check the engine air filter and, if necessary, change it.
Engine Storage Starting Engine After an Extended Shutdown Before working on a vehicle, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. If an engine has been sitting unused for more than a week or if an oil change has been performed, it is recommended that the oil pressure is established before starting the engine.
34 Cooling System General Coolant Information General WARNING Do not raise the engine hood or cab if you see or hear steam or coolant escaping from the engine compartment. Wait until steam or coolant cannot be seen or heard before raising the hood or cab. Do not remove the coolant fill cap if the coolant in the surge tank is boiling. Also, do not remove the cap while the engine and radiator are still hot. Scalding fluid and steam may be blown out under pressure if the cap is taken off too soon.
Cooling System Recommended coolant consists of a 50/50 mixture of antifreeze and clean water. Never run the engine with only water. Regardless of the season, the coolant should always contain at least 40 to 60 percent ethylene glycol (antifreeze). The antifreeze also contains anti-corrosion agents that the cooling system needs to stay functional. NOTE! Do not use a winterfront for the cooling system. See the Operator’s Manual, Engine Start and Operation, for more information.
36 Cooling System Keep the radiator (including charge air cooler) and the frontal area free from bugs, dirt, leaves, etc. (see page 127 for cleaning information). Always keep the coolant level above the min. mark on the coolant expansion tank. Inspection of the whole cooling system is important. Check for swollen or deteriorated heater and radiator hoses, loose hose clamps and connections, and radiator leaks. W2003475 Do not work near the fan with the engine running.
Cooling System 37 W2002697 1. 2. 3. 4. Thermostat Housing Radiator Surge Tank Coolant Cap A well functioning and maintained cooling system is as important to the engine as performing regular oil changes or using good fuel. To get the best result it is very important to use quality products and to service the system at the right intervals. Please read this section carefully.
38 Cooling System Coolant consists of clean water and antifreeze. This mixture should never be less than 40% antifreeze and 60% clean water or more than 60% antifreeze and 40% clean water. Mix the antifreeze and water to the required concentration before adding to the cooling system. NOTE! Do not mix different products, such as regular antifreeze and extended life antifreeze. W2003082 NOTE! Volvo Trucks North America, Inc. does not recommend the use of antifreeze based on propylene glycol.
Cooling System The main purpose of coolant is to transport heat from the hot parts of the engine to the radiator and to protect the cooling system from corrosion. In addition to this, the coolant must: • • • • • Protect against pitting and cavitation erosion damage of the water pump and cylinder liners. Protect against freezing and boiling. Prevent formation of scale, sludge deposits and clogging. Be harmless to polymer materials and seals in the coolant system.
40 Cooling System Water Specification CAUTION Volvo Trucks North America, Inc. does not recommend using plain water in the cooling system. Water alone is corrosive at engine operating temperatures and does not provide adequate boiling protection. The engine may develop corrosion and cavitation problems in engine and radiator, and the boiling point of the coolant is lowered compared with a proper antifreeze/water mixture. The warranty is not valid when using only water in the cooling system.
Cooling System Additives Additives are part of most antifreeze and should be tested for and added to all coolant mixtures using normal antifreeze. If extended life coolant is used, the additives are in the product when mixed. Both types need to have additives added to after a time. Additives help prevent rust, scale and mineral deposits from forming. Additives also protect metals from corrosion, prevent water pump and cylinder liner cavitation and contain anti-foaming agents.
42 Cooling System Antifreeze General CAUTION Coolant is toxic; risk of poisoning. Do not drink coolant. Use proper hand protection when handling. Keep coolant out of reach of children and animals. Failure to follow these precautions can cause serious illness or death. CAUTION Never add coolant to a hot or overheated engine. Engine damage can result. Allow the engine to cool first. Use of recycled antifreeze or coolant by filtration is not approved by Volvo Trucks North America, Inc.
Cooling System Antifreeze or premixed coolant meeting the standards ASTM D 3306 or ASTM D 4656 are primarily for automotive gasoline engines, containing high levels of silicate, and are unacceptable for heavy duty diesel engines. Recommended antifreeze meeting the ASTM D 4985 standard is a low silicate ethylene glycol based antifreeze for heavy duty diesel engines. Standard antifreeze requires an initial charge of supplement coolant additives (SCA) when filling new coolant.
44 Cooling System Regular Coolant Change Interval Replace the coolant every 250,000 miles (400,000 km), 4,000 hours or every two years, whichever comes first. Coolant SCA level must be tested at least twice per year or whenever coolant loss occurs. For maximum coolant system efficiency, test the system every 25,000 to 30,000 miles (40,000 to 56,000 km) depending on engine oil change interval or every 1,000 hours or maximum every 6 months (whichever comes first). The SCA level must be between 1.
Cooling System 45 Standard Antifreeze Testing General Coolant SCA level must be tested at least twice per year and whenever coolant loss occurs. For maximum coolant system efficiency, test the system every 25,000 to 30,000 miles (40,000 to 56,000 km), depending on the oil change interval, or every 1,000 hours or every 6 months (whichever comes first). Use liquid SCA and pre-charged coolant filters to maintain a 1.5 to 3.0 SCA units per gallon (0.4 to 0.8 units per liter) concentration in the coolant.
46 Cooling System Testing Procedure Run the engine to operating temperature. After the engine has reached operating temperature, move the heater controls (on dash and in sleeper) to full heat and run the engine for 10 more minutes. EXAMPLE Step 1 Desired 2.3 units recom- SCA level per gallon mended level 1.53.0 units per gallon Subtract: WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or can cause serious burns.
Cooling System Changing from Regular to Extended Life Coolant Drain the system of old coolant and dispose of properly. The cooling system should be flushed with clean water. If significant deposits are visible, use a reputable commercial cooling system flush designed for heavy duty diesel engines. For specific information over draining and flushing, See page 122 for D7 and page 124 for D12 engines. NOTE! Extended Life Coolant is not recommended by all engine manufacturers.
48 Cooling System 3 Use a reputable cleaner to clean the cooling system. Follow the recommendations that come with the cleaner. 4 Drain the cleaner and flush the cooling system with clean water. 5 Fill the cooling system with clean water and operate the engine until the coolant temperature has reached 120 to 150 F (50 to 65 C). 6 Drain the water and flush the cooling system with clean water.
Cooling System 49 Extended Life Coolant Change Interval Replace coolant every 300,000 miles (480,000 km), 6,000 hours or every four years, whichever comes first. A one-time extender package must be added to the cooling system after 150,000 miles (240,000 km), 3,000 hours or two years, whichever comes first. NOTE! Do not add supplement coolant additives (SCA) to extended life coolant. CAUTION Extended life coolant will test as out of additives (SCA), but SCA should not be added.
50 Fuel System Fuel Safety Reminders A diesel engine will operate on any fuel which enters the cylinder, whether it is from the injectors or from the air intake system. Therefore, if any solvent is used to flush out the air cleaner element, the engine may overspeed during startup. Engine damage, severe injury and/or death from burns or explosion may occur. Do not mix gasoline or alcohol with diesel oil fuel. This mixture can cause an explosion and result in severe personal injury or death.
Fuel System Diesel Fuel Specification Quality Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life and acceptable exhaust emission levels. Volvo engines are designed to operate on most diesel fuels commercially available today. Volvo Trucks North America, Inc. recommends the use of diesel oil fuel which meets the specification ASTM D975 (grades No. 2–D and No. 1–D). NOTE! The use of lighter fuels (grade No. 1–D) can reduce fuel economy.
52 Fuel System Fuel Filters NOTE! When draining the fuel filters, collect the waste in a fuelproof container. Always dispose of coolant according to Federal or local regulations. Take the drained fuel and water to a recycle or waste management center. For the Volvo engine, change the fuel filters at every other oil change when running the 15,000 mile (24,000 km) oil drain interval. Change the fuel filters every oil change when running the 25,000 mile (40,000 km) oil drain interval.
Fuel System Cetane Number Direct injected diesel engines require a minimum cetane number of 40 under normal starting conditions. Fuel with a higher cetane value may be required for high altitude or cold weather operation. Filtration Fuel should be clean and free of contamination. Clean fuels should have no more than 0.1% of sediment and water. If fuel is stored on site, make sure that: • Keep storage tank covered to prevent water entry.
54 Fuel System Fuel Pour Point Fuel pour point should be at least 10 F (6 C) lower than the lowest ambient temperature at which the engine must start and operate. Lower pour points of diesel fuel grade No. 1–D may be necessary in extremely cold weather. Fuel Cloud Point The cloud point should be below the lowest ambient temperature at which the engine must start and operate, to prevent the fuel filter elements from plugging with wax crystals. Fuel Viscosity Fuel viscosity must be kept above 1.
Fuel System Fuel Additives General Fuel additives are generally not recommended or needed for fuels listed earlier. Cetane improvers can be used as necessary. Biocides may be needed to eliminate microorganism growth in storage tanks. In cold conditions, treatment for water in the vehicle tanks may also be necessary. Consult your fuel supplier about the use of additives to prevent incompatibility among additives already in the fuel and the additives to be used.
56 Fuel System NOTE! Repair expenses resulting from malfunctions in the fuel system or with engine components when fuel enhancers have been used are not covered under warranty. Some fuel additives can be used to provide temporary relief but they do not replace good fuel handling practices. These products can be used: • Isopropyl Alcohol — Use 1 pint per 125 gallons (1/2 liter per 500 liters) of fuel for winter freeze-up protection. • Biocide — For treatment of microbe growth or “black slime.
Fuel System Prohibited Additives The following additives are specifically NOT allowed and must NOT be mixed in with the vehicle diesel fuel: Used Lubricating Oil: Volvo Trucks North America, Inc. does not recommend the use of any type of used lubricating oil as an extender in the diesel fuel. Used lubrication oil contains solids and acids from the combustion process that can severely corrode parts of the injection system, resulting in reduced power and higher maintenance cost over time.
58 Fuel System Alternative Fuels Alternative fuels can be of several different types. There are vegetable based fuels, aviation fuel and recycled petroleum based fuels that are used in combustion engines. These are in general not compatible with modern heavy duty over-the-road vehicle engines. The use of unauthorized fuels may compromise the levels of pollutants in the exhaust to the point where the engine does not meet the emission requirements.
Oil System Engine Oil General Keep the engine oil at the proper level and change it at the recommended intervals. Always replace the oil filters at the same time as when the oil is changed. Always follow the oil change intervals and use the oil types that are recommended by the engine manufacturers. Oil change intervals for Volvo engines are found on page 61. Viscosity and capacity tables can be found beginning on page 166.
60 Oil System Oil Quality Volvo Trucks North America, Inc. recognizes and recommends engine oils that meet or exceed the standards given by American Petroleum Institute (API) for the oil classifications listed in this manual. Only oils licensed to carry the API symbol should be used. Lubricants meeting API standards have provided maximum engine life when used together with the recommended oil and oil filter change intervals.
Oil System 61 Oil Change Intervals The length of time an engine is operated before an oil change depends on which quality oil is used, the type of fuel used, engine oil consumption, vehicle application, level of dust in the air, etc. The change intervals given in this manual are maximum intervals. If the vehicle is operating in heavy-duty operation, dusty or off-road conditions, using high sulfur fuels, etc., adjust the intervals down for more frequent oil changes.
62 Oil System Oil Change Intervals, Volvo D7 Engine For the D7 engine, there are three columns of different oil change intervals depending on what application the vehicle is used in. Always use the correct oil quality for your application and distance driven. For example, in longhaul transport, oil changes can be done every 15,000 miles (24,000 km) if the oil quality meets or exceeds both API CH-4 and VDS-2 quality standards.
Oil System 63 D7 Oil Change Intervals Type of Operation • • • • • Average fuel consumption is under 6.0 miles per gallon (over 4.0 liters per 10 km) Gross combined weight (GCW) is greater than 60,000 lb (27,000 kg) Idle time is 40% or higher Vehicle operates off road or in dusty areas Vehicle operates in inner city delivery • • • Average fuel consumption is over 6.0 miles per gallon (under 4.
64 Oil System Oil Change Intervals, Volvo D12 Engine For the D12 engine, there are three columns of different oil change intervals depending on what application the vehicle is used in. Always use the correct oil quality for your application and distance driven. For example, in longhaul transport, oil changes can be done every 25,000 miles (40,000 km) if the oil quality meets or exceeds both API CH-4 and VDS-2 quality standards.
Oil System 65 D12 Oil Change Intervals Type of Operation • • • • • Average fuel consumption is under 5.0 miles per gallon (over 4.7 liters per 10 km) Gross combined weight (GCW) is greater than 100,000 lb (45,000 kg) Idle time is 40% or higher Vehicle operates off road or in dusty areas Vehicle operates in inner city delivery • • • Average fuel consumption is between 5.0 and 6.5 miles per gallon (between 4.7 and 3.
66 Oil System Synthetic Lubrication Synthetic oils are offered as an alternative to the traditional, petroleum based oils for engines. These oils may be used in Volvo engines, provided they meet the quality levels specified on the previous pages, that is: API CG-4, CH-4, VDS or VDS-2. Product information about synthetic oil should be reviewed carefully. Their use does not permit an automatic extension on recommended oil change intervals.
Oil System 67 Oil Viscosity The viscosity grade defines the thickness of the oil. The oil must be thin enough at low temperatures for easy cold starts and thick enough to protect at high temperatures. An oil is not fully defined until both the API quality classification and the viscosity grade are specified. Choose the viscosity grade for the typical ambient temperature for the application. Multigrade oils have a broad range that suit operation in changing temperature.
68 Oil System Sulfur Level and TBN Oils are available with different levels of Total Base Number (TBN) to counteract high sulfur levels in fuel. TBN measures an oil’s alkalinity and ability to neutralize acid. Normally, the higher the fuel sulfur, the higher the TBN is needed. When US Federal fuel is used (sulfur less than 0.05%), a minimum TBN of 5 is highly recommended. Sulfur creates highly acidic pollutants in the oil that break down the additives at a higher rate.
Oil System Oil Consumption Check the oil level daily with the engine stopped. If the engine has just been stopped and it is warm, wait approximately 20 minutes to allow the oil to drain back to the oil pan before checking. Add oil as necessary. NOTE! Do not overfill. Oil may be blown out through the crankcase breather tube if the level is too high. All diesel engines are designed to use some oil, so it is normal to add oil periodically.
70 Oil System Oil Sampling General Oil sampling is a good tool for determining the condition of the engine. The oil samples are taken regularly over the life of the engine and establishes a history of each specific engine. The sampling results “paint a picture” of normal wear. When results occur that are outside of the normal, it indicates that something is happening that needs investigating. It is important that regular sampling is done.
Oil System Sampling Examples A new engine has a tendency to indicate high iron (Fe), lead (Pb) and copper (Cu) content during breaking in. Any left-over particles from the manufacturing process (foundry sand, machining filings, etc.) increase wear at this stage. Wear at this point should not cause any alarm as higher wear particle values nearly always show up during the breaking in period.
72 Oil System Wear Particles The analysis values used for comparison with each other must always come from the same engine. The results must be evalued with the knowledge of where the particles originate from.
Oil System supplementary to maintenance. In the maintenance program, always: • • Select high quality oils. Follow the oil change interval recommendations. It is not recommended to disassemble an engine simply on the basis of the oil analysis values. Instead, use the values as an indicator that something unusual is happening. Combine the oil analysis with other diagnostic methods to further confirm what the unusual might be.
74 Severe Service Schedule for VHD-Series General and Check-Chart Severe Service is defined here for vehicles that typically do maintenance depending on the accumulated engine hours rather than distance travelled. This includes applications that operate on road surfaces made of concrete, asphalt, maintained gravel, crushed rock or hard packed dirt or similar surfaces for 90% of the time, and up to 10% of the time in muddy or sandy conditions.
Severe Service Schedule for VHD-Series 75 Heavy Refuse Application: Oil Field Application: Typical operations include grades over 20%, residential refuse and recycle pickup, commercial and industrial pickup, typically a high number of stops per mile. More than 10% operation in muddy or sandy conditions, or more than 20% off paved roads.
76 Severe Service Schedule for VHD-Series The table on the next page is a check-chart to keep track of performed services and can be used for planning service work also. The table is laid out with the maximum intervals in hours. There are also maximum intervals based on the calendar. Each maintenance interval should be carried out at the indicated accumulated hours or maximum every month and a half — whichever comes first.
Severe Service Schedule for VHD-Series 77 Severe Service Check-Chart Hours Service Interval 250 a 500 aA 750 a 1,000 aAB 1,250 a 1,500 aA 1,750 a 2,000 aABC 2,250 a 2.
78 Severe Service Schedule for VHD-Series Maintenance Categories Category a: Every 250 Hours or 1 1/2 Months Category A: Every 500 Hours or 3 Months (Whichever comes first) (Whichever comes first) 1 Perform the daily checks as described in the beginning of the vehicle Operator’s Manual. 1 Clean engine and chassis before inspection. 2 2 Change engine oil. (See page 116.) Do the maintenance points as described under Category a. 3 Change oil filters, both full-flow and bypass. (See page 117.
Severe Service Schedule for VHD-Series 14 15 Check wiper blades and wiper/washer operation. Check operation of heater, defroster and/or air conditioner. 79 Exterior 27 Turn on and check all exterior lights. Inspect exposed wiring. 28 Check the hood or cab lock-down latches for wear and alignment. 16 Using the tachometer, check and record the high and low engine idle speeds. 29 Check that the cab mounts are securely bolted to the frame and cab. Check the cab suspension for function.
80 41 Severe Service Schedule for VHD-Series Check condition of paint and overall appearance of vehicle. Steering and Suspension 51 Fuel System 42 Inspect fuel tanks for damage, leaks or corrosion. 43 Drain the fuel separator and clean the view glass. (See page 128.) 44 Inspect the fuel lines for signs of wear or chafing. Wheels and Tires 52 Check the tightness of all wheel nuts with a torque wrench. Check the tire tread depth. (See page 152.) 53 Inspect each tire for unusual wear patterns.
Severe Service Schedule for VHD-Series 62 Check the engine air filter restriction gauge. Change the filter if necessary. (See page 119.) 63 Check engine mounts. 64 Check crankcase breather or tube. (See page 118.) Road Test 65 Operate the clutch several times. Check for smooth engagement and operation of clutch brake. 66 While driving, apply brakes and check for even stopping and quick release. 67 Check the ABS function. 68 Check engine controls and performance.
82 Severe Service Schedule for VHD-Series Category B: Every 1,000 Hours or 6 Months (Whichever comes first) 1 Do the maintenance points as described under Category a and Category A. 2 Check the frame for lose bolts. If necessary, tighten M14 bolts to a torque of 150 ± 24 ft-lb (200 ± 33 Nm). 3 Drain water from the fuel tank. (See page 138.) 4 Remove corrosion from cable terminals and battery posts. Spray the area with a corrosion preventive. 5 Make sure all ground connections are secure.
Severe Service Schedule for VHD-Series 83 Category C: Additional Service Points 1 Do the maintenance points as described under Category a, A and B. 2 Change standard antifreeze every 4,000 hours. (See page 122 or page 124.) 3 4 5 Extended life antifreeze should have an extender package added at 3,000 hours and then changed at 6,000 hours. (See page 122 or page 124.) Check coolant thermostat function every 2,000 hours.
84 Heavy-Duty Service Schedule for VHD-Series General and Check-Chart Heavy-Duty Service is defined here for vehicles that typically travel an annual distance of maximum 65,000 miles (105,000 km) per year or less and operate under Heavy-Duty conditions. This include applications that travel primarily on freeways with some or frequent stop-and-go driving. Typical applications include: local transport with occasional freeway travel and a majority of stopand-go driving.
Heavy-Duty Service Schedule for VHD-Series 85 Heavy Line / Long Haul Application: Rescue Service Application: Typical operations include grades of maximum 12%, moving different types of freight in high mileage operations more than 65.000 miles (105,000 km) per year. Operation should be on normal highway surfaces of good to excellent concrete or asphalt. Greater than 30 miles between starting and stopping.
86 Heavy-Duty Service Schedule for VHD-Series The table on the next page is a check-chart to keep track of performed services and can be used for planning service work also. The table is laid out with the maximum intervals in distance. There are also maximum intervals based on the calendar. Each maintenance interval should be carried out at the indicated accumulated mileage or maximum every fourth month — whichever comes first.
Heavy-Duty Service Schedule for VHD-Series 87 Check-Chart for Vehicles with D7 Engine miles (km) X 1,000 Service Interval 12.5 (20) A 25 (40) A 37.5 (60) ABC 50 (80) A 62.5 (100) A 75 (120) ABC 87.5 (140) A 100 (160) A 112.5 (180) ABC 125 (200) A 137.5 (220) A 150 (240) ABC 162.5 (260) A 175 (280) A 187.5 (300) ABC 200 (320) A 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 miles (km) X 1,000 Service Interval 212.5 (340) A 225 (360) ABC 237.5 (380) A 250 (400) A 262.
88 Heavy-Duty Service Schedule for VHD-Series Check-Chart for Vehicles with D12, Cummins or Detroit Diesel Engines miles (km) X 1,000 Service Interval 15 (24) A 30 (48) A 45 (72) ABC 60 (96) A 75 (120) A 90 (144) ABC 105 (168) A 120 (192) A 135 (216) ABC 150 (240) A 165 (264) A 180 (288) ABC 195 (312) A 210 (336) A 225 (360) ABC 240 (384) A 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 miles (km) X 1,000 Service Interval 255 (408) A 270 (432) ABC 285 (456) A 300 (480) A 315
Heavy-Duty Service Schedule for VHD-Series 89 Maintenance Categories Category A: Every 12,000 miles (19,000 km) or 4 Months (For Vehicles with D7 Engine Using VDS-2 plus CH-4 oil) Every 15,000 miles (24,000 km) or 4 Months (For Vehicles with D12 Using VDS-2 plus CH-4 oil, Cummins or Detroit Diesel Engine) (Whichever comes first) 1 Perform the daily checks as described in the beginning of the vehicle Operator’s Manual. Road Test 10 Start engine; check starter motor. 2 Change engine oil.
90 Heavy-Duty Service Schedule for VHD-Series In the Shop Yard Exterior 22 Check function of pneumatic controls. 38 23 Check steering column adjustment function, if equipped. Inspect steps and grabhandles. Make sure they are properly fastened and that there are no signs of breakage. 39 Check pedal carrier play. 24 Check horns. 40 25 Record engine low idle. Check door alignment, weather stripping and mirrors. 26 Check low air warning switches. (See page 148.
Heavy-Duty Service Schedule for VHD-Series 91 Check rear suspension torque rods, hangers and brackets for looseness or cracks. Check springs for broken leaves or wear and cracks on air springs. Brakes 61 Drain air tanks. If a lot of condensate is drained, check air dryer. (See page 145.) 52 Inspect rear shock absorbers for leaks. 62 53 Check rear tandem axle components as the front tandem axle. Check interaxle driveshaft. Measure thickness of brake linings. (See page 146.
92 Heavy-Duty Service Schedule for VHD-Series Engine Compartment 72 73 74 75 76 Visually inspect the component and all fluid pipes, hoses, seals, gaskets and connection points on engine, transmission and rear axle(s) for exterior signs of leakage. Inspect all hoses for cracking, cuts, tightness, routing, chafing and evidence of leaks. Inspect steel-braided lines for wear and rust. Inspect clamps for tightness and insulation. Check radiator package mounts and shroud molding.
Heavy-Duty Service Schedule for VHD-Series 93 Category B: Annually 1 Check headlight aim and adjust if necessary. 2 Remove wheels and brake drums on all wheels. Inspect all wheel brake components and parts for signs of wear, warping and cracks. 3 Check function of tractor protection valve. 4 Check for spring pin wear. (See page 156.) 5 Measure wear in steering knuckles. 6 Measure wear in steering linkage. 7 Check wheel toe-in. 8 Check tandem axle alignment.
94 Heavy-Duty Service Schedule for VHD-Series Category C: Additional Service Points 1 Do the maintenance points as described under Categories A and B. 2 Standard antifreeze should be changed every 4,000 hours. (See page 122 or page 124.) 3 Extended life antifreeze should have an extender package added at 3,000 hours and then changed at 6,000 hours. (See page 122 or page 124.) 4 Check coolant thermostat function every 2,000 hours.
Maintenance 95 Engine Maintenance Exhaust 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 noncertified configuration: “The following acts and the causing thereof are prohibited: (3) For any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this part p
96 Maintenance California Emission Control Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Volvo Trucks North America , Inc. (VTNA) are pleased to explain the emission control system warranty on your vehicle. In California, new motor vehicles must be designed, built and equipped to meet the State’s stringent anti-smog standards. Volvo Trucks North America, Inc.
Maintenance 97 EMISSION CONTROL SYSTEM WARRANTY Volvo Trucks North America, Inc. WARRANTS TO THE ORIGINAL OWNER, AND EACH SUBSEQUENT OWNER, OF A NEW TRUCK POWERED BY A VOLVO DIESEL ENGINE THAT THE EMISSION CONTROL SYSTEM OF YOUR TRUCK: 1 Is designed, built and equipped so as to conform at the time of sale to all regulations of the U.S.
98 Maintenance The emissions control parts covered by this Emission Control System Warranty are listed under "What Is Covered by the Emissions Warranty." You are responsible for the performance of all required maintenance on your new Volvo engine, including maintenance or repairs needed due to severe operating conditions. Volvo Trucks North America, Inc. will not deny a warranty claim solely because you have no record of maintenance. However, Volvo Trucks North America, Inc.
Maintenance 99 WHAT IS COVERED BY THE EMISSION WARRANTY The following is a list of the items that are considered a part of the Emission Control Systems and are covered by the Emission Warranty when installed as original equipment by Volvo Trucks North America, Inc. on vehicles which were built to conform to Environmental Protection Agency and California Air Resources Board regulations IMPORTANT - This may not include expendable maintenance items.
100 Maintenance EPA Emissions Performance Warranty YOUR WARRANTY RIGHTS AND OBLIGATIONS The U.S. Environmental Protection Agency (EPA) and Volvo Trucks North America, Inc. (VTNA) are pleased to explain the emissions performance warranty on your vehicle. In compliance with section 207(b) of the Clean Air Act, VTNA must warrant the emission control system on your vehicle for the periods of time listed listed below, provided there has been no abuse, neglect or improper maintenance of your vehicle.
Maintenance 101 OWNER’S WARRANTY RESPONSIBILITIES As the vehicle owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Volvo Truck North America, Inc (VTNA) recommends that you retain all receipts covering maintenance on your truck, but VTNA cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
102 Maintenance EMISSION CONTROL SYSTEM WARRANTY Volvo Trucks North America, Inc. WARRANTS TO THE ORIGINAL OWNER, AND EACH SUBSEQUENT OWNER, OF A NEW TRUCK POWERED BY A VOLVO DIESEL ENGINE THAT THE EMISSION CONTROL SYSTEM OF YOUR TRUCK: 1 Is designed, built and equipped to conform at the time of sale to all regulations of the U.S.
Maintenance 103 The emissions control parts covered by this Emission Control System Warranty are listed under "What Is Covered by the Emissions Warranty." You are responsible for the performance of all required maintenance on your new Volvo engine, including maintenance or repairs needed due to severe operating conditions. VTNA will not deny a warranty claim solely because you have no record of maintenance.
104 Maintenance WHAT IS NOT COVERED BY THE EMISSION WARRANTY This warranty does not cover: 1 2 3 4 5 6 7 Malfunctions in any part caused by any of the following: misuse, abuse, improper adjustments unless performed by a VTNA dealer, modifications, alterations, tampering, disconnection, improper or inadequate maintenance, or use of fuels not recommended for the engine as described in the owner’s manual. Damage resulting from accident, acts of nature or other events beyond the control of VTNA.
Maintenance 105 WHAT IS COVERED BY THE EMISSION WARRANTY The following is a list of the items that are considered a part of the Emission Control Systems and are covered by the Emission Warranty when installed as original equipment by VTNA on vehicles which were built to conform to Environmental Protection Agency regulations. IMPORTANT - This may not include expendable maintenance items. Emission related parts requiring scheduled maintenance are warranted until their first scheduled replacement point. I.
106 Maintenance Noise Emissions Volvo Trucks North America, Inc. 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, Inc. was designed, built and equipped to conform, at the time it left Volvo Trucks North America, Inc’s control, with all applicable U.S. EPA Noise Control Regulations.
Maintenance Tampering with Noise Control System Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has been removed or rendered
108 Maintenance Cooling System Removing or rendering inoperative cooling system components (such as the temperature modulated fan clutch, fan shroud, fan ring, recirculation shields, etc.). Exhaust System Removing or rendering inoperative exhaust system components (such as the muffler, pipes, clamps, etc.). Air Intake System Removing or rendering inoperative air intake/induction system components (filter, filter housings, ducts, etc.).
Maintenance Noise Control System, Operator Inspection and Maintenance Requirements Before 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. A Noise Control System Maintenance Log is located in “Noise Control Log” page 114.
110 Maintenance Exhaust System Make sure the exhaust system is intact. Inspect for damage, misalignment and/or leakage. Primary system components requiring noise related inspection include muffler body, exhaust manifold, turbocharger, and all exhaust system (rigid and flexible) piping. Closely check the system for exhaust leaks. Special attention should be given to all welds, seams, gaskets, support points, clamps, couplings and connections.
Maintenance Air Intake/ Air Induction System Make sure the air intake system is intact. Inspect components for damage, misalignment and/or leakage. Primary system components requiring noise related inspection include the air cleaner housing, air cleaner element, turbocharger, charge air cooler and intake manifold. Also inspect all ducts, pipes, hoses, tubing and elbows used to interconnect the system.
112 Maintenance Cooling System WARNING Do not work near the fan with the engine running or the ignition in the ON position. The engine fan can engage at any time without warning. Anyone near the fan when it turns on could be seriously injured. Visually inspect cooling system components for damage, and/or misalignment. Primary system components requiring noise related inspection include fan blades, fan clutch, fan shroud, fan ring, and recirculation shields.
Maintenance Sound Shielding and Insulation Devices Make sure 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. Inspect all related fasteners, brackets, and clamps for damage and tightness.
114 Maintenance Noise Control Log NOISE CONTROL SYSTEM MAINTENANCE LOG DATE MILEAGE MAINTENANCE PERFORMED MAINTENANCE FACILITY
Maintenance Maintenance Hazards 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. Do not attempt to repair or service this vehicle without having sufficient training, correct service literature and the proper tools. Failure to follow this could lead to personal injury or death, or making your vehicle unsafe.
116 Maintenance Oil Change 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. WARNING T1006392 A hot engine or engine oil can be dangerous. Serious burns can result from contact with a hot engine or oil. Take precautions when draining the oil. Wear gloves or let the engine cool down before draining.
Maintenance 117 Oil Filters 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. WARNING Hot oil can cause severe burns. Do not allow hot oil to contact the skin. When changing oil, wear protective gloves. W2003480 D12 Oil Filters CAUTION Use only the engine manufacturer’s oil filter for replacement.
118 Maintenance Checking Oil Level NOTE! Do not let the oil level fall below the lower marking on the dipstick. Do not overfill so the level is above the upper marking on the dipstick. Wait five minutes after shutting off the engine before checking the oil level. This gives the oil time to drain back to the oil pan. Crankcase Air Breather CAUTION If the crankcase breather is not maintained on a regular basis, it will become plugged.
Maintenance 119 Engine Air Filter 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. The engine air filter is monitored by a pressure restriction gauge mounted on the air filter housing.
120 Maintenance Fan Drive Belts 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. WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or can cause serious burns. All engine belts should be checked at each service point. Inspect for cracked or frayed material.
Maintenance Flushing Cooling System, D7 Coolant Filter WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or fluid can cause serious burns. When using standard antifreeze, use a coolant filter containing the additives necessary for replenishing the used-up additives. If using extended life antifreeze, the coolant filter should be empty. Do not install additive type filters on an engine filled with extended life type coolant.
122 Maintenance Draining Cooling System 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. WARNING Do not remove the cap to the coolant 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.
Maintenance 123 Flushing Cooling System Before filling, flush out the system thoroughly with clean water. Before flushing out the radiator, remove the lower radiator hose to allow a quicker and more efficient draining. When flushing the radiator, keep the water pressure low so the radiator tubes are not damaged. W2003080 Filling Cooling System Always use a pre-mixed solution of 50/50 clean water and antifreeze. Do not fill system with water and then add antifreeze.
124 Maintenance Flushing Cooling System, D12 Draining Cooling System 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. WARNING Do not remove the cap to the coolant surge tank while the engine and radiator are still hot and under pressure.
Maintenance 125 Flushing Cooling System Before filling, flush out the system thoroughly with clean water. Before flushing out the radiator, remove the lower radiator hose to allow a quicker and more efficient draining. When flushing the radiator, keep the water pressure low so the radiator tubes are not damaged. W2002057 Filling Cooling System Always use a pre-mixed solution of 50/50 clean water and antifreeze. Do not fill system with water and then add antifreeze.
126 Maintenance Turbo and Charge Air Cooler General Do not remove, attach or tighten turbocharger air intake ducting while the engine is operating, or operate the engine while the ducting is removed. Working around the turbo with the ducting removed may cause severe personal injury. Visually inspect turbo mountings, intake and exhaust ducting and connections for leaks on a daily basis. Check oil inlet and outlet for leaks or signs of restrictions to oil flow. Check for unusual noise or vibration.
Maintenance 127 Cleaning Charge-Air-Cooler and Radiator Package Over time, dirt and insects will accumulate between the fins of the radiator, air conditioning condenser and charge-air-cooler. The reduced air flow reduces the heat transfer from the components to the air. This increases the load on the fan and air conditioning compressor and can result in engine overheating and other performance related problems, such as high fuel consumption, etc.
128 Maintenance Replacing Fuel Filters General The filters are an important part of the fuel system. Always replace the filters at the recommended intervals and use the recommended filter types for the best engine operation and service life. A primary fuel filter is located on the outer, right or left frame rail behind the cab. This filter consists of a filter cartridge, a water separation bowl and may have a fuel heater built in.
Maintenance Fuel System Service Changing the Primary Fuel Filter 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. The standard primary filter is manufactured by Racor. Use only their 30 micron (red coded) element. Failure to do so could result in reduced power.
130 2 Maintenance Separate the filter and the bowl. NOTE! Always dispose of fuel according to Federal or local regulations. Take all waste fuel to a recycling or waste collection center. 3 Clean and dry the bowl. Attach it to a new filter. Use new seals at both bowl and filter head joint. Install both on the filter head in the vehicle. CAUTION Never fill filter with fuel before installing. Contaminated fuel causes accelerated wear to fuel system components.
Maintenance Changing the Secondary Fuel Filter 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. 1 WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or can cause serious burns. Clean around the fuel filter.
132 3 Maintenance Wet the seal on the new filter with clean engine oil or fuel. 4 CAUTION Never fill filter with fuel before installing. Contaminated fuel causes accelerated wear to fuel system components. Spin on the new filter onto the filter head until it contacts the seal fully (no side movement evident). Tighten an additional 1/2 to 3/4 turn by hand. Do not overtighten! 5 To eliminate air from the filter, operate the primer pump to draw fuel and fill the filter.
Maintenance Bleeding the Fuel System The fuel system will have to be bled if: • • The tank has been emptied of fuel. • Service work has been done on the fuel system, for example cleaning or replacing fuel filter elements. • The engine is new or rebuilt. The engine has not been running for some time. (See also page 33 for oil pressure preparation). NOTE! It is very important to maintain high cleanliness when working in the fuel system.
134 Maintenance Bleeding D12 Engine 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. 1 WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or can cause serious burns. Clean well around the bleed nipples on the fuel filter head and the cylinder head.
Maintenance 135 Remove the protection cap from the filter bleed nipple. Connect a transparent 5/16 in. (8 mm) plastic hose to the nipple. Open the nipple with an 11 mm wrench and pump the hand primer until clean, air-free fuel flows out of the hose. Tighten the bleed nipple while fuel is still flowing. 3 Remove the hose and install the protection cap on the nipple. 4 Remove the protection cap from the cylinder head bleed nipple. Connect the plastic hose to the nipple.
136 Maintenance Bleeding D7 Engine 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. 1 WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or fluid can cause serious burns. Clean well around the bleed nipple on the fuel filter head. 2 Make sure the ignition is ON.
Maintenance 137 Remove the protection cap from the filter bleed nipple. Connect a transparent 5/16 in. (8 mm) plastic hose to the nipple. Open the nipple with an 11 mm wrench and pump the hand primer until clean, air-free fuel flows out of the hose. Tighten the bleed nipple while fuel is still flowing. 4 Remove the hose and install the protection cap on the nipple. 5 W2003174 Do not work on or near the fan with the engine running or the ignition in the ON position.
138 Maintenance Draining Water from the Fuel Tank 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. Water accumulates in the fuel tank in the process of air entering the tank and water vapor condensating. This water will collect in the bottom of the tank and should be emptied out regularly.
Maintenance 139 Transmission and Rear Axle Maintenance Transmission General Transmissions should not be operated consistently at temperatures above 250 F (120 C). If the temperature reaches 285 F (140 C), stop the vehicle to let the temperature go down (see the vehicle Operator’s Manual for information on the optional transmission temperature gauge). Operating temperatures above 250 F (120 C) increase the lubricant’s rate of oxidation and shorten its effective life.
140 Maintenance Oil Quality WARNING Use only the specified type of single weight oils. Do not use multigrade oils or EP gear oils (for example axle lube oil such as GL-5 gear oils) as they may damage components. Monograde motor oils or transmission oil type API GL-1 are recommended for transmissions. Choose the correct viscosity for the outside temperature the vehicle will be operated in. See page 166 for the beginning of viscosity charts.
Maintenance DriveShaft If the driveshaft universal joints are not lubricated properly, they can be damaged to the point of the driveshaft separating from the vehicle. Driveshaft separation may cause loss of control of the vehicle resulting in severe personal injury or death. Make sure grease is purging from all four ends of the universal joint. If the universal joint can not be properly lubricated, replace it. Rear Axle General NOTE! Most rear axles today are run with a synthetic base oil.
142 Maintenance Checking and Draining Oil Check the oil level through the top plug (1). The oil should be level with the hole. Add oil if necessary. Drain oil through the bottom plug. Oil should be darined immediately after driving while it is still hot. WARNING Hot oil can cause severe burns. Do not allow hot oil to contact the skin. When changing oil, wear protective gloves. T0008128 NOTE! Also check the rear axle vetilation for blockage.
Maintenance 143 Steering and Brakes Maintenance Steering System Excessive play in the steering system is checked by turning the steering wheel while the engine is stopped. With the front wheels pointing straight ahead, turn the steering wheel until the front wheel starts moving. Then, turn the steering wheel the other way until the front wheel moves. Slack should not be more than 1 in. (25 mm) at the rim of the steering wheel. If the slack is excessive, check the steering linkage for looseness, wear, etc.
144 Maintenance Brake Safety Information The brake system is a critical vehicle safety system. For your safety and for those around you, follow the recommended preventive maintenance checks. If any problems occur, have them investigated immediately by an authorized service facility. Failure to properly maintain the brake system can result in compromised brake efficiency and may lead to loss of control of the vehicle resulting in severe personal injury or death.
Maintenance 145 Air Tanks WARNING When draining the air tanks, do not look into the area of the draining air. Dirt or sludge particles may be in the air stream that could cause eye injury. Air tanks should be drained daily. Make sure the drain cocks close properly after draining. Empty moisture from air tanks by pulling the drain valve wire. The tanks should be checked for condensation fluid, even if an automatic drain valve is installed. It is very important that the air system is kept clean.
146 Maintenance Brake Slack Adjusters and Cam Before checking the slack adjusters, set the parking brakes, place the transmission in neutral and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. To check the slack adjusters for proper throw, use a breaker bar to lever the slack adjuster out. Measure the distance of the travel. It should not exceed 1 to 1 1/4 in. (25 to 30 mm) for a 6 in.
Maintenance 147 Check Valves Before working on or inspecting the 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. Follow the procedure below to check out the air tank check valves at least once a year. This is to see if air pressure is maintained in the tanks when the air pressure is depleted in the supply tank (wet tank).
148 Maintenance Air System Pressure Air pressures in the two circuits are monitored by two pressure gauges on the right side of the instrument panel. The gauge for the primary (rear) brake circuit is marked with an “R” within a symbol and the gauge for the secondary (front) brake circuit is marked with an “F” within a symbol. The two pointers should register equal or nearly equal pressure.
Maintenance 149 Electrical System Maintenance Battery Care WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. The electrolyte level on maintenance free batteries cannot be checked. Periodically, the condition and the state-of-charge of each battery should be checked by a Volvo Truck dealer.
150 Maintenance Bulb Replacement List Bulb Number Max. Rating Headlamp, Hi/Low Beam Insert 2C1 45/60 W Headlamp, Hi Beam Insert 1C1 60 W Back-Of-Cab Lamp 1156 25 W Back-up Lamp 1156 25 W Cab Marker Lamp (w/o sunvisor) 67 10 W Driving Lamp (Spotlight) H9420 50 W Fog Lamp H9415 37.5 W Instrument Telltale Lamps 3919844 (Volvo) 1.
Maintenance 151 Tires, Wheels and Hub Maintenance Wheel Safety Information Do not attempt to repair wheels or tires unless you are trained and equipped to do so. Wheel and tire assemblies cannot be worked on without proper tools and equipment. Failure to follow this may lead to serious personal injury or death. Do not use mismatched wheel components.
152 Maintenance Wheels Before checking the wheels, 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. Wheels must be serviced only by a qualified technician. Do not do 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.
Maintenance Failure to properly torque-tighten the wheel nuts can result in the breakage of wheel studs and the subsequent loss of wheels. Loss of vehicle control and serious personal injury or death can occur. This check tightening is particularly important when rims or brake drums are newly painted. Paint can flake off from these surfaces, causing the nuts to lose their grip and the wheel to loosen. 153 W7000774 8 and 10–stud wheelnut tightening sequence.
154 Maintenance Do not operate the vehicle with underinflated tires. Always keep your tires inflated to the manufacturer’s recommendation. Increased flexing in the tire sidewall produces heat. The heat can build to the point of blowing the tire out causing an accident and lead to serious personal injury or death. W7000437 Remove stones lodged in ribs or in between double-mounted wheels. Check the tire pressure and leak-test the valve stems.
Maintenance 155 Chassis Maintenance Springs NOTE! This work is best performed by a Volvo Truck dealer or other service outlet having the proper equipment. The spring package is fastened to the axle beam with U-bolts. It is important that the U-bolt nuts are properly tightened. The nuts may loosen up with time. Severe roads and service will loosen them faster. Loose Ubolts can cause springs to break, axle misalignment, hard steering and abnormal tire wear.
156 Maintenance Spring Bushings 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. When lubricating the springs, lift the axle off of the floor, suspend the frame with axle stands and lower the axle. The spring bushings are now in the position where grease can be added to the contact surfaces.
Maintenance 157 Cab Maintenance Doors The door lock mechanism should be greased annually using white grease. Lubricate the door lock cylinder with liquid graphite annually, or more often in climates with a lot of snow and salt on the roads. Coat the door stop arm with white grease annually. On wet and salted roads, roadspray can enter the door lock key cylinder. Lubricate the cylinder with liquid graphite annually or more often if necessary.
158 Maintenance Rustprotection The rustprotection applied when the cab was produced is adequate for normal use and service. If an extension of the cab rustprotection is desired or if the vehicle is used in a severe application, it is recommended that cavity wax is re-applied every 3rd year. Cab Air Filter Air going into the cab passes a filter located on the right, front side of the cab.
Maintenance Lacquer and Brightwork Care Paint Cab Wash all exterior painted surfaces frequently to remove dirt. It is especially important to wash off salt-laden snow and ice during the cold season. A mild detergent can be used but avoid strong detergents. NOTE! Do not aim the water jet directly at door and window seals or door locks. If locks are filled with water, use compressed air to clean the water out and then apply liquid graphite.
160 Maintenance Chassis Keep the chassis free from buildup of dirt. Make sure the chassis is cleaned before the maintenance inspections to help spotting leaks, etc. As salt can be part of the road sludge during the cold season, remove buildup of snow and ice so it does not promote corrosion. At the end of the cold season, thoroughly flush away all collected dirt from the chassis. Stainless Steel Stainless steel will rust if exposed to salt for too long.
Maintenance Chrome Chromed surfaces will rust if they are not protected. This is especially important during the cold season when roads are salted or in coastal areas where the salt level in the air is high. Clean chrome surfaces with clean water. If the surface has heavy dirt or tar spots, use a tar remover. To remove rust spots, use a non-abrasive chrome cleaner and apply a coat of wax as a finish (do not wax parts that get hot, such as exhaust pipes, etc.). NOTE! Never use steel wool to clean chrome.
162 Maintenance Lubrication, VHD Chassis Lubrication Before working on or servicing 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. General lubrication includes lubricating all the grease fittings in the drivetrain, front and rear suspensions, power steering, and front axle, using a grease gun. Grease the chassis every 15,000 miles (24,000 km).
Maintenance 163 Lubrication Chart Spring hanger (2) Coolant level Note 8 Slack adjuster & brake Note 1 Steering assist cylin- cam (4) Note 9 Steering gear (1) der. Note 18 Power steering fluid Note 10 Kingpin, upper & lower (4) Note 2 Wheel bearings Note 11 Tierod (2) Note 3 Engine oil & filter Note 12 Spring hanger (4) Note 4 Note 8 Clutch bearing and linkage. Clutch cylinder fluid Note 15 U-Joint (1) Note 5 Automatic transmis- Note 13 sion.
164 Maintenance Lubrication Chart Notes 1 Add if necessary. Only use pre-mixed clean water and antifreeze in a 50/50 mix. Add only the same type antifreeze, that is: extended life or standard. 2 Check the fluid in the reservoir with the dipstick. Add if necessary. Use ATF Dexron® III. Change fluid every 150,000 miles (240,000 km). Change filter every year. 3 4 Use a lithium based grease with specification API NLGI No. 2.
Maintenance 12 Use a lithium based grease with specification API NLGI No. 2. NOTE! Volvo axles may use a greased-for-life tierod. No provisions for adding grease are available. 13 Use a lithium based grease with EP additives to specification API NLGI No. 2. NOTE! Make absolutely sure that grease purges out of all four seals of the U-joint. 14 Use a lithium based grease with EP additives to specification API NLGI No. 2. Make sure the grease purges out of both the outer and inner seals.
166 Maintenance Viscosity and Capacity Tables Volvo Engine D7C For oil change intervals, see page 61 First oil and filter change After 1 month or 6,000 miles (10,000 km) Capacity (including filters) D7C service 22 quarts (21 liters) Oil volume between high and low on dipstick 7.0 quarts (6.5 liters) W1000144 1 Only completely synthetic and/or VDS/VDS-2 oils. 2 Only VDS-2 oils.
Maintenance 167 Cummins Engine ISM For oil change intervals, see the manufacturer’s Operator’s Manual Capacity (including filters) ISM, service 39 quarts (37 liters) ISM, oil volume between high and low on dipstick 7-9 quarts (6.5-8.5 liters) ISX, service 41 quarts (39 liters) ISX, oil volume between high and low on dipstick 8-9.5 quarts (7.5-9 liters) Cooling System Capacity* VHD, D12 ......... 39 liters (9.8 US gal.) VHD, D7 ........... 36 liters (9.5 US gal.
168 Maintenance Fuller Transmission 9,10, 13, 15 and 18–speed For oil change intervals, see the manufacturer’s Oparator’s Manual Capacity: 9-speed .............. 13.5 quarts (12.0 liters) 10, 13, 15 and 18speed ................. 14.0 quarts (13.0 liters) W4000879 Allison Automatic Transmission For oil change intervals, see the manufacturer’s Operator’s Manual. Approximate Capacity: MD3560P 5-speed MD3060P 5-speed 19.0 quarts (18.0 liters) HD4060P 5-speed HD4560P 5-speed 39.0 quarts (37.
Maintenance 169 Volvo Tandem CTEV87 and RT3210 Oil type: Petroleum based oil ...................... API-GL5, MILPRF-2105E First oil change After one month or 6 000 miles (10 000 km) Normal oil change interval .............. every 12 month or 75 000 miles (120 000 km) Synthetic lubricant .................... NOT USED Capacity: CTEV87 front tandem, EV87 ................. 21.0 quarts (20.0 liters) rear tandem ....... 9.5 quarts (9.0 liters) RT2610 front tandem ...... 24.5 quarts (23.
170 Maintenance Meritor Single RS23, 25, 26 and 30 Meritor Tandem RT40, 44 and 46 For oil change intervals, see the manufacturer’s Operator’s Manual Capacity: RS23-160 .......... 20 quarts (19 liters) RS23-185 .......... 23.5 quarts (22.5 liters) RT40-145, front tandem RT40-145, rear tandem 15 quarts (14 liters) 13 quarts (12 liters) W4000881 1) Select viscosity from the table above. Temperatures refer to stable ambient temperature readings.
Maintenance Steering Hydraulic System Fluid type ..........
172 Literature Service Assistance and Manuals Your 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, Inc. 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.
Literature To order a single Service Manual or a Service Manual Set for your vehicle, you should contact your authorized Volvo Truck dealer or fax a request to the Volvo Truck North America, Inc. publications warehouse (Fax: (336) 668–3625). They will help you locate the manual(s) you need. To be able to handle the order correctly, you must give the model, year and VIN (for VIN location, see the vehicle Operator’s Manual).
174 Service Charts Scheduled Services The vehicle had a pre-delivery inspection before being delivered to you, the customer. Regular maintenance inspections should be continued. The maintenance program and lubrication intervals that are listed in this manual may not suit your operation. Contact your nearest Volvo dealer, who can help with designing a maintenance program that works in your application. For regular service or maintenance, call the dealer in advance and arrange for a service appointment.
Date Mileage Work Completed Preventive Maintenance (See local dealer for Service Information in Group 177-500 Preventive Maintenance Basic Service VN, VHD and Group 177-501 Preventive Maintenance Annual Service VN, VHD).
Date Mileage Work Completed Preventive Maintenance (See local dealer for Service Information in Group 177-500 Preventive Maintenance Basic Service VN, VHD and Group 177-501 Preventive Maintenance Annual Service VN, VHD).
Service Charts Repair Record Keep track of repairs beeing made. This helps over the lifetime of the vehicle to spot trends that can be used to alter maintenance schedules, for example.
Date Mileage Work Order or Invoice No.
Date Mileage Work Order or Invoice No.
Date Mileage Work Order or Invoice No.
Date Mileage Work Order or Invoice No.
Date Mileage Work Order or Invoice No.
Service Charts 183 Tire Record Tire Hints Hints on How to Avoid Unnecessary Tire Wear • • • • • • • • Maintain correct tire pressure Check the tire pressure when the tires are cold Check that valve caps are not missing Keep the wheels balanced Tire wear increases with speed Overloading not only decreases tire life but also creates a hazard Incorrect front end alignment causes increased wear Unnecessary tire rotation may cause excessive wear NOTE! A cold weather initial driving period will increase the
184 Service Charts Typical Wear Patterns Incorrect Air Pressure A Too high air pressure gives rapid wear in the middle. B Too low air pressure gives rapid shoulder wear. T1006457 Incorrect Camber Incorrect camber gives abnormal wear on one half of the tire. T1006458 Incorrect Toe and Axle Alignment A Incorrect toe-in. B Incorrect toe-out.
Service Charts 185 Dual Wheel Mounting A Excessive road camber, different types of tire, different circumference or offcenter loading gives faster wear on one tire. B Too low air pressure, mismatched rims for the tire type and dimension, excess flexing in tire wall, or different types of tires in inner and outer tires gives contact wear. T1006718 Incorrect Caster and Imbalance A Caster angle. B Imbalance. Also rapidly wears the mechanical parts of steering linkage, kingpin and wheel bearing.
186 Service Charts Spot Wear Sudden braking, locking brakes or out-ofround brake drums gives spot wear. T1006721 Feathered Edges Normal occurrence on non-driving wheels on good roads and high mileage. T1006722 Cupping Cupping is a normal occurrence that depends on the tread pattern; the higher the load, the greater the wear.
Service Charts 187 AXLE LOAD/TIRE PRESSURE Axle Load lb (kg) Recommended tire pressure psi (kPa) W1000109
188 Service Charts Tire Record Size Ply Rating Make Type Serial No.
Service Charts 189 Tire Record Date Installed Date Removed Mileage At Installation At Removal Tire Mileage Notes
190 Service Charts Tire Record Size Ply Rating Make Type Serial No.
Service Charts 191 Tire Record Date Installed Date Removed Mileage At Installation At Removal Tire Mileage Notes
192 Service Charts Tire Record Size Ply Rating Make Type Serial No.
Service Charts 193 Tire Record Date Installed Date Removed Mileage At Installation At Removal Tire Mileage Notes
194 Service Charts Fuel and Oil Record Keeping track of the fuel and oil consumption gives a record of what is normal for the vehicle. This can be compared with other vehicles in the same service application to indicate what is normal fuel and oil consumption for a certain application.
Date Mileage Fuel Qty. Oil Qty. Filled SAE No.
Date Mileage Fuel Qty. Oil Qty. Filled SAE No.
Date Mileage Fuel Qty. Oil Qty. Filled SAE No.
Date Mileage Fuel Qty. Oil Qty. Filled SAE No.
Date Mileage Fuel Qty. Oil Qty. Filled SAE No.
Date Mileage Fuel Qty. Oil Qty. Filled SAE No.
Date Mileage Fuel Qty. Oil Qty. Filled SAE No.
Date Mileage Fuel Qty. Oil Qty. Filled SAE No.
Date Mileage Fuel Qty. Oil Qty. Filled SAE No.
Date Mileage Fuel Qty. Oil Qty. Filled SAE No.
Date Mileage Fuel Qty. Oil Qty. Filled SAE No.
206 Service Charts
Index 207 Index A B C D E Air Dryer Maintenance . . . . 145 Air Filter, Cab . . . . . . . . 158 Air Filter, Engine . . . . . . 119 Air Tank Draining . . . . . . 145 Allison Transmission Oil Capacity168 Alternative Fuels . . . . . . . . 58 Antifreeze Information, General . 42 Antifreeze Standard . . . . . . . 42 Antifreeze/Water Mixture . . . . 38 Battery Maintenance . . . Brake Maintenance Checks Brake System Pressure . . Bulb Replacement List . . Burn Prevention . . . . . . . . . . . . . . .
208 Index Fuel Quality . . . . . Fuel Safety Information Fuel Storage . . . . . Fuel Sulfur Content . . Fuel System . . . . . Fuel System, Bleeding Fuel Viscosity . . . . Fuel, Alternative . . . G H I L M O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 . 50 . 53 . 52 . 50 133 . 54 . 58 Oil Total Base Number (TBN) Oil Viscosity . . . . . . . . Oil, Synthetic . . . . . . . Owner Information, General . Owner’s Information Package P R General Coolant Information . . .
VHD Technical and Parts Support Group If you need technical assistance, the group for technical and parts support is available 24 hours per day, 7 days per week at 1-877-978-6586. This assistance is available to help you with solving technical issues and parts issues regarding the Volvo Heavy Duty (VHD) model vehicle. A trained Volvo VHD Specialist for Technical and Parts Support will give you the assistance you need to resolve your problem.
Volvo Trucks North America, Inc. P.O. Box 26115 Greensboro, NC 27402-6115 Volvo Trucks Canada, Ltd. 6490 Vipond Drive, Mississauga, Ontario L5T 1W8 http://www.volvotrucks.volvo.com PV776-TSP20 154789 (5000) 10.2001 © Volvo Trucks North America, Inc.
